A133 6141 31 Enq Rev0 PDF

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Table of Contents
Document Number Rev. Document Title Page
Number
A133-086-VV-MR- A ENQUIRY DOCUMENT 4
6141-31-RFQ
A133-086-VV-MR- A CS VESSELS (UPTO 25 THK) 78
6141
A133-086-16-46-DS- B DEBUTANIZER OVERHEAD RECEIVER (86-C-27) 82
3018
A133-086-16-46-DS- B DEBUTANIZER OVERHEAD RECEIVER (86-C-27) SHEET 2 83
3018A2
A133-086-16-46-DS- B CLOSED BLOWDOWN DRUM (86-C-51) 84
3029
A133-086-16-46-DS- B CLOSED BLOWDOWN DRUM (86-C-51) SHEET 2 85
3029A2
A133-086-16-46-DS- B CLOSED BLOWDOWN DRUM (86-C-51) SHEET 3 86
3029A3
A133-086-16-46-DS- B COKER UNIT FEED SURGE DRUM 86-C-21 87
3012
A133-086-16-46-DS- B COKER UNIT FEED SURGE DRUM 86-C-21 SHEET 2 88
3012A1
A133-087-16-46-DS- B SAND FILTER FOR NAPHTHA+DSO (87-C-08) 89
3008
A133-087-16-46-DS- B SAND FILTER FOR NAPHTHA+DSO (87-C-08) SHEET 2 90
3008A2
A133-087-16-46-DS- B SAND FILTER FOR TREATED LPG (87-C-09) 91
3009
A133-087-16-46-DS- B SAND FILTER FOR TREATED LPG (87-C-09) SHEET 2 92
3009A2
A133-086-16-46- A VDR FOR VDR COMPILATION 93
VDR-6141
A133-086-16-46-UR- A UNIT RATES FOR ADDITION AND DELETION 97
6141
A133-16-46-TQS- A TECHNICAL QUESTIONAIRE 104
A133-16-46-TR-6141 A INSTRUCTIONS TO VENDOR/ TECHNICAL REQUIREMENTS 106
A133-16-46-LL-6141 A LIST OF ATTACHMENTS 115
A133-16-46-SS-6141 A SCOPE OF WORK AND SUPPLY 121
INDVSD052 0 Recommended Weld edge Preparation for But welds 126
INDVSD007 0 Detail of Skirt Base for Vessel & column 127
INDVSD045 0 Support For Internal distributor pipes 128
INDVSD002 0 Manway Davit (for vertical manhole) 129
44NC-4600-0000- 0 General specification for PMI at vendor's works 130
V.02-0100-A4
7-12-0030 4 Name plate for small equipment. 137
INDVSD024 Model 0 Nozzle projection 138
(1)
44NC 4600 0 COMPLIANCE STATEMENT 139
(Compliance
Statement)
44NC-4600- A Quality management system 140
000/N.02/0040/A4
Annesure 1 to V
INDVSD050 0 LIFTING LUG FOR HORIZONTAL VESSELS 146
44NC-4600-0000- 1 General Specification for Painting 147
V.02-0111-A4
INDVSD020 0 Name Plate Bracket 192
INDVSD064 0 Inlet deflector baffle 193
INDVSD046 0 Support For Internal feed pipes 194
INDVSD043 0 Ladder Rungs Inside Vessels and columns 195
Page 1 of 434
Table of Contents
Number
INDVSD022 0 INSULATION SUPPORT FOR VESSELS (HOT) 196
INDVSD058 0 INSULATION SUPPORT FOR HORIZONTAL VESSELS 197
INDVSD033 0 Vortex Breakers (Flush Type Nozzles) 198
INDVSD009 0 SADDLE SUPPORT FOR HORIZONTAL VESSELS 199
7-12-0019 5 Vortex breakers. 206
INDVSD030 0 Internal plate flange 207
INDVSD080 0 Earthing lug 208
44NC-4600-0000- 0 General Spec for Materials 209
V.02-0114
INDVSD012 0 Minimum Nozzle Wall Thickness 226
44NC-4600-0000- 0 Standard Specification for BQ plates 227
V.02-0117-A4
INDVSD040 0 Standard Bolt hole Orientation 232
INDVSD003 0 Manway Davit (for Horizntal manhole) 233
INDVSD006 0 Detail of skirt Opening for vessel & column 234
44NC-4600-0000- 0 GENERAL NOTES CS KCS VESSELS 235
V.02-0164
INDVSD018 0 Reinforcing Plates for Nozzles (C.A. 3mm) 236
INDVSD047 0 Support For Internal feed pipes 237
INDVSD021 0 Name plate for vessel 238
44NC 4600 (Drawing 0 DRAWING TITLE SAMPLE 239
Title Sample)
INDVSD019 0 R. PAD FOR NOZZLES (C.A. - 1.5MM) 240
INDVSD048 0 Lifting lug top head type 241
INDVSD034 0 Vortex Breakers (Nozzle with internal Projection) 242
44NC-4600- A Quality management system 243
000/N.02/0040/A4
44NC-4600-0000- 0 Supp spec for CS vessels 250
V.02-0120-A4
INDVSD051 0 Typ.nozzle flange to neck joint 255
INDVSD049 0 LIFTING LUG FOR VERTICAL VESSELS 256
44NC-4600-0000- A JOB SPECIFICATION - VESSELS 257
V.02-0141-A4
INDVSD004 0 Detail of Vessel/column Top davit 280
INDVSD062 Model 0 Fire proofing support 281
(1)
INDVSD001 0 Generl tolerances for pressure vessels 282
44NC-4600-0000- 0 LICENSOR SPECIFICATION 285
V.02-0101-A4
44NC-4600- B Standard grating (Type I & II) & staircase tread details (Sheet 1 of 326
0000/S.01/0008/A4 8)
(Sheet 1 of 8)
0000/S.01/0008/A4 8)
(Sheet 2 of 8)
0000/S.01/0008/A4 8)
(Sheet 3 of 8)
0000/S.01/0008/A4 8)
(Sheet 4 of 8)
0000/S.01/0008/A4 8)
(Sheet 5 of 8)
0000/S.01/0008/A4 8)
(Sheet 6 of 8)
Page 2 of 434
Table of Contents
Number
0000/S.01/0008/A4 8)
(Sheet 7 of 8)
0000/S.01/0008/A4 8)
(Sheet 8 of 8)
44NC-4600- B Circular platform for hot vessels (Sheet 1 of 6) 334
0000/S.01/0011/A4
(Sheet 1 of 6)
0000/S.01/0011/A4
(Sheet 2 of 6)
0000/S.01/0011/A4
(Sheet 3 of 6)
0000/S.01/0011/A4
(Sheet 4 of 6)
44NC-4600- B Circular platform for hot vessels ( For E>100mm) (Sheet 5 of 6) 338
0000/S.01/0011/A4
(Sheet 5 of 6)
0000/S.01/0011/A4
(Sheet 6 of 6)
44NC-4600- B Circular platform for cold vessels (Sheet 1 of 4) 340
0000/S.01/0012/A4
(Sheet 1 of 4)
0000/S.01/0012/A4
(Sheet 2 of 4)
0000/S.01/0012/A4
(Sheet 3 of 4)
0000/S.01/0012/A4
(Sheet 4 of 4)
6-68-0001 4 Standard specification civil and structural works - general scope. 344
44NC-4600- B Specification for Structural Steelwork 348
0000/C.02/0015/A4
44NC-4600- B Standard ladder & cage typical details for step through ladder 366
0000/S.01/0009/A3 (Sheet 1 of 2)
(Sheet 1 of 2)
44NC-4600- B Standard ladder & cage typical details for step through ladder 367
0000/S.01/0009/A3 (Sheet 2 of 2)
(Sheet 2 of 2)
A133-086-16-48- A SOR FOR LADDER & PLTF FOR 87-C-08 & 87-C-09 368
SOR-6141
A133-086-16-48- A SOQ FOR LADDER & PLTF FOR 87-C-08 & 87-C-09 371
SOQ-6141
A133-086-16-48- A SOW FOR LADDER & PLTF FOR 87-C-08 & 87-C-09 374
SOW-6141
44NC-4600- B Specification for Miscellaneous 381
0000/C.02/0025/A4
44NC-4600- 1 GENERAL SPECIFICATION FOR SHOP AND FIELD PAINTING 387
0000/V.02/0111/A4
A133-00-000--ITP- A INSPECTION AND TEST PLAN (JOB SPECIFIC) 432
015A
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0Regd. Office: Engineers India Bhawan, 1-Bhikaiji Cama Place, New Delhi-110066, India
Phone No. : 00 91 11 26762121 ; Fax No. : 00 91 11 26191714, 26167664
REQUEST FOR QUOTATION (RFQ)-(INDIGENOUS / FOREIGN / GLOBAL)
(e-Tendering)
Date: 27.12.2013
M/s Client Chennai Petrochemical Corporation Limited
For Limited Enquiry Only:
The Suppliers to whom this RFQ is Project Coker Block of Resid Upgradation Project at Manali
issued are only required to quote. Refinery, Chennai
RFQ No. RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31
Item CS VESSELS ( UPTO 25 THK)
Category II
Due Date 16.01.2014 [Up to 1200 Hrs. (IST)]
UNPRICED BID OPENING: At 1400 Hrs.(IST) on final bid due date
(In case the bid due date happens to fall on Holiday, the next working day
shall be deemed to be due date)
PRE-BID MEETING Not required
PRICED BID OPENING : TIME & VENUE SHALL BE INTIMATED LATER
Gentlemen,
1. Chennai Petroleum Corporation Limited (CPCL), a subsidiary of Indian Oil Corporation Limited has
existing Refinery Facilities at Manali, Chennai, Tamil Nadu (India). The present capacity of CPCL at Manali
Refinery is 9.5 MMTPA. CPCL is currently implementing a Revamp of existing units to increase the crude
processing capacity by 1 MMTPA to take the overall complex capacity to 10.5 MMTPA unit.
Chennai Petroleum Corporation Limited (CPCL) has awarded the work of Resid Upgradation Project-
Coker Block to Engineers India Limited (EIL) and EIL is the CONTRACTOR for this Project.
2. Bids are requested for the captioned item in complete accordance with enquiry documents and its
attachments.
3. The complete RFQ can be downloaded from the EIL website (http://tenders.eil.co.in) or e-tender site of
EIL's ASP (Authorized service provider) https://www.tenderwizard.com/eil or from CPP portal
http://eprocure.gov.in/cppp.
4. Bidders are invited under single stage two part system in e-tendering portal
(https://www.tenderwizard.com/eil) in accordance with the instructions and terms & conditions enclosed
with this RFQ Covering letter.
Bids should be submitted separately in two parts as follows:
Part-I: The techno-commercial Part consisting of following:
i) Offer Covering letter (in bidder’s letter head)
RFQ No. RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31 Page 1 of 9

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ii) Techno-commercial compliance to the RFQ terms & Conditions.
iii) Duly filled-in, signed & stamped Annexure I to Prefilled ATC giving basic details on
transportation charges, taxes/ duties etc.
iv) Bank Certified Mandate Form as per Annexure-II to Prefilled ATC, duly signed and
stamped with the Banker’s certification alongwith cancelled cheque.
v) Unpriced copy of Price Schedule (Uploaded as Excel file on

https://www.tenderwizard.com/eil), clearly indicating ‘Q’ in place of prices and ‘NQ’ for
not quoted items.
vi) Unpriced copy of unit rate for addition/ deletion in the format enclosed with MR/RFQ
indicating “ Q “ .
vii) Unpriced copy of schedule of rates for structural component in format enclosed with
MR/RFQ indicating “Q” in place of Prices.
viii) Technical Compliance/ datasheets/ documents, required as per Material Requisition.
ix) List of Commissioning spares (vendor’s recommended) and Special Tools & tackles
(vendors recommended), included in the quoted prices of main items.
Part-II: PRICED BID
Containing only prices filled in the prescribed price schedule excel format and other formats
provided in the RFQ Document, consisting of the following priced documents:
i) Prices in Price Schedule Format (only as per the Excel format uploaded on E-tendering
website https://www.tenderwizard.com/eil).
ii) Priced copy of unit rate for addition/ deletion, in the format enclosed in the MR/RFQ.
iii) Priced copy of schedule of rates for structural component in the format enclosed in the
MR/RFQ
Note:
a) Bidders are required to have a VALID digital signature of class IIIB issued by C.C.A. (Controller
of certifying authority, India) for participation in e-tendering.
b) A Ready Reckoner for e-tendering is available on e-tendering website

(https://www.tenderwizard.com/eil) under the Link “Latest Format/Circular/Manual”. Bidders to
click on the link to download the same. Bidders to follow the instructions given in the same for
uploading their e-bids in e-tendering website.
c) Deviations to terms and conditions, presumptions etc shall not be stipulated in Price part of bid
and price bids shall not contain any stapled slips. In case of any conditions stipulated in price
bids or the price bid containing any stapled slips, the bids of such bidders shall be summarily
rejected and shall not be considered for further evaluation. Evaluation shall be carried out
excluding such bidder(s.)
5. Offers received through Fax / Telex / Telegraphic / E-Mail / hard form (other than the documents
specifically required in hard form) shall not be considered.

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6. EIL will open the bids received online at their office, at the specified date and time given in the RFQ or
extended date, if any.
The bidders who have submitted their bid will be able to view online the name & status of all the bidders at
their respective windows, after unpriced bid opening by EIL.
Similarly, all technically and commercially acceptable bidders will be advised of date and time of online
priced bid opening. Aforesaid Bidders, will be able to view online the price sheets of other techno-
commercially acceptable bidders at their respective windows, after priced bid opening by EIL.
7. Please furnish your response to our RFQ either through EIL’s website http://tenders.eil.co.in or by
sending email/fax to EIL as per Proforma of Reply/ Acknowledgement Letter enclosed, by the pre-bid
meeting.
If not bidding, please return enquiry documents along with regret letter within the due date with reason(s)
of not participating in the RFQ.
The bidders should respond to this enquiry either by submitting their bids or by explaining the reason for
non-submission of the offer. In case there is no response either way continuously, the bidder shall
be liable for suitable action including review of their enlistment with EIL for that particular item.
8. Offer Validity : Offer shall be valid for 3 Months from the final / extended bid due date.
9. PAYMENT TERMS
Indigenous Supplier:
For Supply: As per clause No. 1.1.1 (vi) of Instruction to Bidders
For Mandatory spares, all consumables and First fill of lubricants, quoted separately as per MR : As per
clause No. 1.1.2 of Instruction to Bidders.
For other scope of MR: As per Instruction to Bidders
10. Delivery Period :

Supply :
Indigenous Supplier:
09 Months on FOT Site basis. The date of receipt of material at site shall be considered as the date of
delivery.
11. Price Reduction Schedule: As per clause No. 12.1 & 12.4 of Instruction to Bidders.
12. Repeat Order is not applicable for this RFQ.
13. Contact Persons for this RFQ are:
Mrs. Rekha Choudhary–Asst. General Manager (C&P)–Phone: 91-11-26763457, E-mail:

r.choudhary@eil.co.in
Mrs. Shalini Tiwari Arora (C&P) – Phone: 91-11-26763790, E-mail: shalini.tiwari@eil.co.in
* Please specify Ref. No. (i.e. RFQ No.) in all correspondence
THIS IS NOT AN ORDER Very truly yours,
(REKHA CHOUDHARY)
Asst. General Manager (C&P)
Enclosures :

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 Techno-Commercial Compliance To Bid Requirement
 Price Schedule (for Indian Bidders, as applicable) – uploaded on e-tendering portal
(www.tenderwizard.com/EIL) as excel file
Standard Commercial Documents Containing:
 Forms & Formats

 Reply/ Acknowledgement letter
 Proforma of Letter of Authority Rev.0
 Format for Bidders’ Pre-bid Queries
 Exceptions and Deviations (Commercial)
 Format for Present/ Concurrent Commitments
 Special Commercial Notes to RFQ
 Instructions to Bidders (ITB)
 Instructions to Bidders for e-Tendering
 General Purchase Conditions ( For Indian Bidder)
 Agreed Terms & Conditions (For Indian Bidder)
 Terms & Conditions for Reverse Auction
Material Requisition
 MR No. A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 Rev A

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REPLY/ACKNOWLEDGEMENT LETTER
FAX Nos. : 00-91-11-26191714, 26167664

SELF ADDRESSED FAX
(PLEASE REFAX TO EIL WITHIN TEN DAYS OF RECEIPT OF RFQ)
Engineers India Limited

Engineers India Bhawan,
nd
EI Annexe, 2 Floor,
1-Bhikaiji Cama Place,
New Delhi – 110066
Attn. : Ms. Rekha Choudhary – Asst. General Manager (C&P)

RFQ No. : RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31
Item : CS VESSELS ( UPTO 25 THK)
Bid Due Date : 16.01.2014 [Up to 1200 Hrs. (IST)]
Project : Coker Block of Resid Upgradation Project at Manali Refinery of M/s CPCL, Chennai
Dear Sirs,
We acknowledge with thanks receipt of your above cited RFQ alongwith enclosures. We undertake that the
contents of the above RFQ shall be kept confidential including all the drawings, specifications and documents
and the said documents shall be used only for the purpose, for which they are intended.
Further, our response is as under:- (Bidders to put a tick , as applicable).
1. We will submit the bid within due date.
2. We regret to submit our offer/quote because of the following reasons:
a. _____________________________________________________
b. _____________________________________________________
Thanking you,
Very truly yours,

Name of Bidder :
Bidder’s Address :
Contact Person :
Bidder’s Phone No. :
Bidder’s Fax No. :
Bidder’s E-mail No. :
Bidder’s Ref. No. & Date :
Page 1 of 1
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PROFORMA OF LETTER OF AUTHORITY FOR ATTENDING PRE-BID CONFERENCE
No. Date:
To,
ENGINEERS INDIA LIMITED
1, Bhikaiji Cama Place
R.K. Puram,
New Delhi 110066(India)
Attn . Ms. Rekha Choudhary, Asst. General Manager (C&P)
Dear Sirs,
We……………………………………..hereby authorise following representatives (s) to attend the Pre-Bid

Meeting against your RFQ No.: ……………………………………. for Item
…………………………………….……………
1. Name & Designation ………………………………Signature …………………………..
2. Name & Designation ……………………………… Signature …………………………
We confirm that we shall be bound by all and whatsoever our representative (s) shall commit.
Yours faithfully,
Signature ……………………………
Name & Designation ……………….
For & on behalf of ………………….
Note :
This Letter of Authority should be on the letter head of the bidder and should be signed by a person
competent and having the power of attorney to bind the bidder.
Page 1 of 1
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TECHNO-COMMERCIAL COMPLIANCE TO BID REQUIREMENT
RFQ No. : _____________________________

Item : ______________________________
We hereby agree to fully comply with, abide by and accept without variation, deviation or reservation
to all technical, commercial and other conditions whatsoever of the RFQ documents and Amendment/
Addendum to the RFQ Documents, if any, for subject RFQ.
SIGNATURE OF BIDDER : _______________________
NAME OF BIDDER : _______________________
COMPANY SEAL : _______________________
Page 1 of 1
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FOR BIDDERS’ QUERIES
RFQ No. : RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31

SL. REFERENCE OF RFQ DOCUMENT BIDDER'S QUERY EIL'S REPLY

NO.
PART/ Page Clause Subject
VOL. No. No.
NOTE: The Pre-Bid Queries may be sent on fax numbers 0091-11-26187664 and also by e-mail to concern person of EIL.
SIGNATURE OF BIDDER : ___________________________
NAME OF BIDDER : ___________________________
Page 1 of 1
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EXCEPTIONS AND DEVIATIONS
RFQ No. : RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31

SL.NO REF. OF RFQ DOCUMENT SUBJECT DEVIATIONS

DOCUMENT
PAGE NO. CLAUSE NO.
NOTE: This shall be submitted separately for Commercial & Technical Sections.

NAME OF BIDDER : _______________________
COMPANY SEAL : _______________________
Page 1 of 1
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PRESENT COMMITMENTS AS ON …………………………………..
(Due Date for submission of Bid)
RFQ No. : RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31

FULL POSTAL DATE OF

SCHEDULE %AGE EXPECTED
ADDRESS OF COMMEN-
SR. DESCRIPTION VALUE OF DELIVERY/ COMP. DATE OF
CLIENT & NAME OF CEMENT OF REMARKS
NO. OF THE ITEM ORDERS COMPLETION AS ON SUPPLY
OFFICER-IN- SUPPLY/
PERIOD DATE /COMPLETION
CHARGE WORK
NAME OF BIDDER : _______________________
COMPANY SEAL : _______________________
Page 1 of 1
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1. Bids complete in all respects should be successfully Submitted online on or before the bid due date
and time specified above.
2. Technical specifications should be strictly as per the material requisition attached.
3. As Purchaser intends to contract directly with suppliers of the goods for which bids are invited, the
bids should be prepared by the suppliers and submitted directly. Purchaser reserves the right to
reject offers made by intermediaries.
4. The bidder shall bear all costs associated with the preparation and submission of its bid, and the
Purchaser shall in no case be responsible or liable for these costs regardless of the conduct or
outcome of the bidding process.
5. Bidders who are enlisted with EIL are required to quote as per their capabilities registered with EIL.
6. EIL reserves the right to use in-house information for assessment of bidder’s capability for
consideration of bid.
7. EIL reserve the right to make any changes in the terms and conditions of purchase and to reject
any or all the bids.
8. The order, if placed will be issued by EIL.
9. Net Worth of the Bidder shall be positive as per the immediate preceding year’s Audited financial
results. Bidder is therefore requested to furnish the latest Audited Financial Statement including
Profit & Loss Account.
In case, the bidder’s Net Worth is negative, their bid shall not be evaluated further. However
this criteria will not be applicable for Indian Central Public Sector Undertaking/Enterprises.
10. Purchaser reserves the right to allow purchase preference to Central Public Sector
Undertakings/enterprises, as admissible under prevailing policy of Government of India.
11. Preference to MSEs
Deleted (Not Applicable)
12. In case any bidder is found to be involved in cartel formation, his bid will not be considered for
evaluation / placement of order. Such bidder will also be debarred from bidding in future.
13. In case a supplier seeks any suo-moto price increase subsequent to the bid due date and which is
not as a result of any change in scope of supply or terms and conditions, the bid of such a supplier
shall be rejected for the items in which such suo-moto increase is sought.
14. FRAUDULENT PRACTICES
The Owner requires that Bidders/ Vendors/ Contractors observe the highest standard of ethics
during the award/ execution of Contract. "Fraudulent Practice" means a misrepresentation of facts
in order to influence the award of a Contract to the detriment of the Owner, and includes collusive
practice among bidders (prior to or after bid submission) designed to establish bid prices at artificial
non-competitive levels and to deprive the owner of the benefits of free and open competition.
a) The owner will reject a proposal for award if it determines that the bidder recommended for
award has engaged in fraudulent practices in competing for the Contract in question.
Bidder is required to furnish the complete and correct information/ documents required for
evaluation of their bids. If the information/ documents forming basis of evaluation is found to
be false/ forged, the same shall be considered adequate ground for rejection of bids and
forfeiture of Earnest Money Deposit.
b) In case, the information/ document furnished by the Bidder/ Vendor/ Contractor forming basis
of evaluation of his bid is found to be false/ forged after the award of the contract, Owner shall
have full right to terminate the contract and get the remaining job executed at the risk & cost of
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such Bidder/ Vendor/ Contractor without any prejudice to other rights available to Owner under
the contract such as forfeiture of CPBG/ Security Deposit, withholding of payment etc.
c) Incase, this issue of submission of false documents comes to the notice after execution of
work, Owner shall have full right to forfeit any amount due to the Bidder/ Vendor/ Contractor
along with forfeiture of CPBG/ Security Deposit furnished by the bidder/vendor/ contractor.
d) Further, such bidder/ vendor/ contractor shall be put on Blacklist/ Holiday/ Negative List of
owner debarring them from future business with Owner for a time period, as per the prevailing
policy in EIL.
15. Submission of authentic documents is the prime responsibility of the bidder. Wherever EIL has
concern or apprehension regarding the authenticity/correctness of any document, EIL reserves a
right of getting the document cross verified from the document issuing authority.
16. SPECIAL INSTRUCTIONS TO FOREIGN BIDDERS

a) The bidder must ascertain and confirm along with supporting documents in the bid, if any
Customs Duty exemption / waiver is applicable to the products being supplied by him under
any multi-lateral / bi-lateral trade agreement between India and bidder's country.
b) The bidder shall be liable to provide all documentation to ensure availment of the exemption /
waiver. In case' the bidder defaults on this due to any reason, whatsoever, he shall be liable to
bear the incremental Customs Duty applicable, if any.
c) Any Customs Duty applicability on account of any change in the bi-lateral / multi-lateral
agreement shall be to bidder's account.
d) Documentation to be furnished for availing the exemption / waiver of Customs Duty shall be
specifically listed in the Letter of Credit also as the pre-requisite for release of payment against
shipping documents and this documentation shall necessarily form a part of shipping
documents
e) COMPLIANCE TO REQUIREMENT OF PAN NO. , TAX RESIDENCY CERTIFICATE AND
FORM NO.10F
It is mandatory for the foreign supplier/contractor/consultant to furnish the following information
in case his receipts are subject to tax deduction at source in India:
i) PAN No.
As per the Indian Income Tax requirements failing which the
Supplier/Contractor/Consultant shall be responsible for any additional tax deduction at
source as per the provisions of the Indian Income Tax Act/Rules and the same shall be
deducted from the payment made to supplier/contractor/consultant
ii) Tax Residency Certificate (TRC)

TRC containing prescribed particulars as per the enclosed Annexure-A from the
Government of foreign country in order to claim the benefits of DTAA as per the Indian
Income Tax requirements failing which the relief under DTAA will not be available and
consequently the higher rate of withholding tax @25% will be applicable and deducted
from the payment made to supplier/contractor/consultant (i.e., non-resident taxpayer).
The TRC shall be duly verified by the Government of the country of which the assessee
claims to be a resident for the purposes of tax.
iii) Form 10F

In additional to TRC, bidder in order to claim the benefits of DTAA shall also submit
additional information in form no. 10F (enclosed as Annexure-A). Form 10F has to be
signed & verified by the assessee himself.
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If some information is already contained in TRC, the bidder shall not be required to
provide that information in Form no. 10F but even then Form no. 10F is required to be
provided by the bidder.
However, the bidder may write Not Applicable in the relevant column in case that
information is already contained in TRC.
The above shall be furnished before release of any payment or within one month of the
release of Order, whichever is earlier.
Failing submission of the above information, any additional tax liability on purchaser, will be
deducted from the payment due to the supplier.
17. SHIFTING OF ORDER
Based on the lowest evaluated item wise prices out of the techno-commercial acceptable
bidders, the shifting of order shall be carried out provided the following conditions are met:
a) Shifting shall be done only if shifting cost of each order is up to Rs.1, 00,000/-.
b) Shifting shall not be resorted to if the value is more than 25% of the total order value
of the recommendation (i.e. total order valued for MR/RFQ). However, this ceiling will
not be applicable where total order value of recommendation is up to Rs. 4, 00,000/-.
c) In case the order value on L1 bidder is more than Rs. 2, 00,000/- then shifting shall
not be resorted.
With above shifting the selected bidder for award will be deemed to be L1 bidder
18. CLARIFICATION REQUESTS FROM BIDDERS
A bidder may seek clarification regarding the bidding document provisions, bidding process and / or
rejection of his bid. EIL shall respond to such requests with in a reasonable time.
19. SETTLEMENT OF DISPUTE BETWEEN GOVT. DEPT./ PUBLIC SECTOR UNDERTAKING
In the event of any dispute or difference relating to the interpretation and application of the
provisions of the contracts, such dispute or difference shall be referred by either party for
Arbitration to the sole Arbitrator in the Department of Public Enterprises to be nominated by the
Secretary to the Government of India in-charge of the Department of Public Enterprises. The
Arbitration and Conciliation Act, 1996 shall not be applicable to arbitration under this clause. The
award of the Arbitrator shall be binding upon the parties to the dispute, provided, however, any
party aggrieved by such award may make a further reference for setting aside or revision of the
award to the Law Secretary, Department of Legal Affairs, Ministry of Law & Justice, Government of
India. Upon such reference the dispute shall be decided by the Law Secretary or the Special
Secretary/Additional Secretary, when so authorized by the Law Secretary, whose decision shall
bind the Parties finally and conclusively. The Parties to the dispute will share equally the cost of
arbitration as intimated by the Arbitrator.
20. PRE BID MEETING
DELETED
21. REVERSE AUCTION

EIL reserves the right to go in for reverse auction among the technically and commercially acceptable
bidders. The decision to conduct reverse auction or not, will be conveyed to short listed bidders prior
to opening of price bid. In view of this, the bidders must quote most competitive prices in the first
instance itself.
The methodology and terms & conditions applicable for reverse auctioning is enclosed with this RFQ.
Page 21 of 434
However please note that in case of Reverse Auction, Rebate offered on Total Evaluated Price of
item/Group shall be prorated for all quoted prices of particular Items / Groups, which were considered
for evaluation and accordingly ordering shall be carried out.
22. INTEGRITY PACT

The attached copy of the Integrity Pact shall be included in the Bid submitted by the bidder (to be
executed by the bidder for all RFQ of value Rs. 5 (Five) crore and above). In case a bidder does not
sign the Integrity Pact, his bid shall be liable for rejection.
INDEPENDENT EXTRNAL MONITORS (IEMS)
The following two Independent External Monitors (IEMs) have been appointed by EIL, in terms of
Integrity Pact (IP) which forms part of EIL Tenders / Contracts.
i) Dr. U. K. Sen
C-162, Belvedere Park,
DLF Phase 3, Gurgoan-122002
(email : uksen@hotmail.com)
ii) Shri P. R. Balasubramanian
th st
229, 9 A Main, 1 Block,
HRBR Layout, Kalyan Nagar,
Bangalore-560043
(email : prbalasubramanian@gmail.com)
Page 22 of 434
 INSTRUCTION TO BIDDERS (ITB)
Document No.
[ CPCL – LSTK ] A133-01- ITB Rev. 0
Page 1

1 PAYMENT TERMS
1.1 FOR INDIGENOUS BIDDERS:
1.1.1 Supply:
(i) Where the MR is for supply of materials and there is no Vendor Data
requirement (VDR) specified in the MR:
- 90% against despatch documents directly to EIL on pro-rata basis together
with full taxes, duties and transportation charges and on submission of
Performance Bank Guarantee valid for the 3 (Three) Months beyond
guarantee period.
- 10% on receipt and acceptance of last consignment of materials at site and
and on submission of E1/E2 Form (wherever applicable).
(ii) Where the MR is for supply of materials and calls for Vendor Data
requirement: (Without site work):
- 5% against approval of drawings, wherever required (identified in
Purchase Requisition) at least in Code-2 and manufacturing Schedule.
.
- 80% (85% in cases where drawing approval is not required) against
despatch documents directly to EIL on prorate basis together with full
taxes, duties and transportation charges and on submission of Performance
Bank Guarantee valid for the 3 (Three) Months beyond guarantee period.
- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in requisite

number of copies/sets/CDs as per VDR specified in Purchase Requisition.
- 10% on receipt and acceptance of goods/ materials at Site and on

submission of E1/E2 Form (wherever applicable).
(iii) Where the MR is for supply of materials and calls for Vendor Data
requirement: (With site work)
- 5% against approval of drawings, wherever required (identified in
Purchase Requisition) at least in Code-2 and manufacturing Schedule.
- 80% against dispatch documents directly to EIL on prorate basis together

guarantee period.
- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in

requisite number of copies/sets/CDs as per VDR specified in Purchase
Requisition.
T&C FOR ED COMMITTEE APPL- LSTK-A133  
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL- All rights reserved
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- 10%. on successful completion of Site Work and on submission of E1/E2
Form (wherever applicable).
Note: In case site is not available upto 6 (Six) months after receipt of all
supplies at site, the last 10% payment shall be released against submission
of additional Bank Guarantee of equivalent amount valid for 1 (One) year or
such extended period as may required.
(iv) Where the MR is for Packages (with significant Bought out item) and
calls for Vendor Data requirement: (Without site work)
- 5% on approval of drawings, wherever required (identified in Purchase
Requisition), in at least Code-2 and manufacturing schedule.
-10% against placement of sub-order for specified major raw material (to be
identified by PEM and PM before issue of enquiry) against submission of
equivalent Bank Guarantee.
- 70% against dispatch documents directly to EIL on prorate basis together with
full taxes, duties and transportation charges and on submission of
guarantee period.
- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in requisite number

of copies/sets/CDs as per VDR specified in Purchase Requisition.
- 10% on receipt and acceptance of goods/ materials at Site and on

submission of E1/E2 Form (wherever applicable).
(v) Where the MR is for Packages (with significant Bought out item) and
calls for Vendor Data requirement: (With site work)
.
-10% against placement of sub-order for specified major raw material (to be
identified by PEM and PM before issue of enquiry) against submission of
equivalent Bank Guarantee.
full taxes, duties and transportation charges and on submission of Performance
Bank Guarantee valid for the 3 (Three) Months beyond guarantee period and
on submission of Performance Bank Guarantee valid for the 3 (Three) Months
beyond guarantee period.
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
- 10% on successful completion of Site Work and on submission of E1/E2

Form (wherever applicable).
Note: In case site is not available up to 6 (Six) months after receipt of all
(vi) For Pumps, Compressors, Heat Exchangers, Columns and Vessels:

(Without site work)
- 15% against receipt and identification of specified major raw materials and
against submission of equivalent BG.
- 65% against dispatch documents directly to EIL on prorate basis together
Performance Bank Guarantee valid for 3 months beyond guarantee period
- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in
Requisition.
- 10% on receipt and acceptance of goods/ materials at Site on submission of
E1/E2 Form (wherever applicable).
Major Raw Material for payment against receipt & identification of raw
materials:
Columns and Vessels Plates and Forgings
Heat Exchangers : Plates, Forgings and Tubes
Pumps : Castings
Compressors : Castings / Forgings
(vii) For Pumps, Compressors, Heat Exchangers, Columns and Vessels:

(With site work)
- 15% against receipt and identification of specified major raw materials and
against submission of equivalent BG..
full taxes, duties and transportation charges and on submission of Performance
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Document No.
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
Bank Guarantee valid for 3 months beyond guarantee period

- 10% on successful completion of Site Work on submission of E1/E2 Form

(wherever applicable).
Note: In case site is not available upto 6 (Six) months after receipt of all supplies at
site, the last 10% payment shall be released against submission of additional Bank
Guarantee of equivalent amount valid for 1 (One) year or such extended period as
may required.
Major Raw Material for payment against receipt & identification of raw materials:
Columns and Vessels : Plates and Forgings
Heat Exchangers: Plates, Forgings and Tubes
Pumps : Castings
(viii) For all Site Fabricated Columns:

- 5% on approval of drawings, manufacturing schedule & QAP by TPIA.
- 15% after receipt of identified raw materials at fabrication yard and against
certification by TPIA against Hypothecation Bond.
- 50% on completion of fabrication in all respect, Third party inspection and

making completed column ready for hydro-testing.
- 10% after hydro-testing of completed column and against submission of

Performance Bank Guarantee for 10% of total order value valid for the
guarantee period plus 3 (Three) Months claim period.
- 20% after receipt of tax invoice along with taxes & duties and after submission of
final technical documentation and drawings as per Purchase Requisition and on
transportation of completed column from fabrication yard/ assembly yard to
erection site, delivery of column up to equipment foundation and handing over
to Engineer-in-charge at site.
Terms of Delivery shall be delivery of column up to equipment foundation and
handing over to Engineer-in-charge at site.
1.1.2 For supply of Mandatory Spares:

- 90% on dispatch of spares against direct delivery of dispatch documents to
PURCHASER.
- 10% on receipt and acceptance of materials at site and on submission of
EI/E2 FORM (wherever applicable).
1.1.3 Site Work:

- 90% against monthly progressive bills (based on agreed billing schedule) duly
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
certified by Engineer-in-charge.
- 10% on successful completion of site work and handing over of

goods/equipment at site.
1.1.4 Supervision of Erection, Testing & Commissioning

- 100% prorate against monthly bills to be submitted by seller duly certified by
Engineer-in-Charge.
1.1.5 Training
- 100 % on successful completion of Training duly certified by PURCHASER,
as per Purchase Requisition.
1.1.6 Annual Maintenance Contract (AMC):

- 100% payment shall be paid at the end of each half year of the contractual
year against quarterly progressive bills to be submitted by seller duly certified
by Site-in-Charge.
1.2 FOR FOREIGN BIDDERS

1.2.1 Supply:
(i) Where the MR is for supply of materials and there is no Vendor Data
requirement (VDR) specified in the MR (Without Site Work):
- 100% against shipping documents through irrevocable Letter of Credit
(ii) Where the MR is for supply of materials and calls for Vendor Data
requirement: (Without site work)
- 5% against approval of Drawings, wherever required (identified in Purchase
Requisition) in at least in Code-2 & manufacturing schedule through Wire
Transfer.
- 90% (95% in cases where drawing approval is not required) against shipping
documents through irrevocable Letter of Credit .
- 5% on receipt of Final/ As built Drawings/Documents/Data/Manual in

Requisition through wire transfer. .
(iii) Where the MR is for supply of materials and calls for Vendor Data
requirement: (With site work)

Requisition) at least in Code-2 & manufacturing schedule through Wire
Transfer.
- 80% against shipping documents through irrevocable Letter of Credit .
- 5% on receipt of Final/ As built Drawings/Documents/Data/Manual in requisite

number of copies/sets/CDs as per VDR specified in Purchase Requisition
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
through wire transfer.
- 10% on successful completion of Site Work through wire transfer.
Note: In case site is not available upto 6 (Six) months after receipt of all supplies
at site, the last 10% payment shall be released against submission of additional
Bank Guarantee of equivalent amount valid for 1 (One) year or such extended
period as may required.
(iv) Where the MR is for Packages (with significant Boughtout item) and
calls for Vendor Data Requirement: (Without site work)

Transfer.
- 10% against placement of sub orders for specified major raw materials, against
submission of equivalent bank guarantee through wire transfer.
- 80% against shipping documents through irrevocable Letter of Credit.

(v) Where the MR is for supply Packages (with significant Boughtout item)
and calls for Vendor Data Requirement: (With site work)

Transfer.
- 10% against placement of sub orders for specified major raw materials, against
submission of equivalent bank guarantee through wire transfer.
- 70% against shipping documents through irrevocable Letter of Credit.

Note: In case site is not available upto 6 (Six) months after receipt of all
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
(vi) For Pumps, Compressors, Heat Exchangers, Columns and Vessels:

(Without site work)
Transfer.
- 15% against receipt and identification of specified major raw materials against
submission of equivalent BG through wire transfer.
documents through irrevocable Letter of Credit.

Pumps : Castings
(vii) For Pumps, Compressors, Heat Exchangers, Columns and Vessels:

(With site work)
Transfer.
- 15% against receipt and identification of specified major raw materials against
submission of equivalent BG through wire transfer.
documents through irrevocable Letter of Credit.

Note: In case site is not available upto 6 (Six) months after receipt of all supplies at
site, the last 10% payment shall be released against submission of additional Bank
Guarantee of equivalent amount valid for 1 (One) year or such extended period as
may required.
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
Pumps : Castings
1.2.2 For supply of Mandatory Spares:

- 100% against shipping documents through Bank through irrevocable Letter
of Credit
1.2.3 Site Work:

- 90% against monthly progressive bills (based on agreed billing schedule)
duly certified by Engineer-in-charge.
- 10% on successful completion and handing over of goods/equipment at site..
1.2.4 Supervision of Erection, Testing & Commissioning:

- 100% prorate against monthly bills to be submitted by seller duly certified by
Engineer-in-Charge.
1.2.5 Training:
- 100% through Wire Transfer on successful completion of Training duly
certified by PURCHASER, as per Purchase Requisition (PR).
1.2.6 Annual Maintenance Contract (AMC):

-
100% payment shall be paid at the end of each half year of the contractual
year against quarterly progressive bills to be submitted by seller duly certified
by Site-in-Charge.
NOTES :
(i) Total Order value shall be as indicated in the Purchase Order.
(ii) All bidders are required to submit their acknowledgement of FOA and/or PO.
(iii) PRS, if applicable, shall be deducted from payment milestone subsequent to
dispatch of material. In case of clause no. 1.1.1 ( Viii) , i.e, Fabricated column
at site , PRS , if applicable, shall be deducted from milestone payment of
20%.
(iv) All foreign vendors having service components in their purchase order are
required to submit PAN (Indian I. Tax) and to provide TRC (Tax Residency
Certificate) from the Govt. of vendor’s country in order to claim the benefit of
DTAA, wherever applicable.
(v) In case of indigenous SUPPLIERs, wherever taxes/duties are separately
indicated, the order value shall be exclusive of taxes/duties. 100% payment
of taxes/duties shall be paid alongwith the payment released against
dispatch documents on receipt of Cenvatable (Duplicate Copy of Excise
Invoice)/vattable documents (wherever applicable).
Payment to indigenous SUPPLIERs shall be released through Electronic
Clearing System (ECS). In view of this, necessary details, such as name of
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
bank, bank account no. etc., duly attested by BIDDER’s bank must be
submitted along with the offer.
(vi) Status of bills after submission can be viewed on our website
http://www.engineersindia.com.
(vii) Foreign bidders are required to submit contract cum Performance Bank
Guarantee within 30 days of FOA/PO.
(viii) Irrevocable Letter of Credit for payment to Foreign SUPPLIERs shall be
established in favour of the supplier in a bank in his country, for an
appropriate amount (in line with Payment Terms). L/C shall be opened
within 45 days of receipt of acknowledgement of FOA/PO along with PBG
(wherever applicable). In case confirmed L/C is insisted by supplier, L/C
confirmation charges shall be to supplier’s account.
(ix) Payment to foreign SUPPLIERs against Site Work and Supervision/Training
shall be through wire transfer.
(x) All payments (other than through L/C) shall be released within 30 days of
receipt of invoice and all requisite documents, complete in all respects.
(xi) All bank charges of respective bankers shall be to respective account.
(xii) Seller shall submit Billing Schedule within three weeks after placement of
FOA/PO ( whichever is issued earlier ) for PURCHASER’s approval
(wherever applicable).
(xiii) Sellers requiring multiple despatches will restrict the number of despatches to
maximum three, unless agreed otherwise by Project Manager.
(xiv) All progressive advances to foreign as well as Indian bidders (except the
milestone payment against drawing approval) shall be against equivalent
bank guarantees. The progressive advances shall be paid through wire
transfer to foreign bidder.
(xv) Other than the payment terms given above, no other advance payments shall
generally be payable. However, if any Seller insists on advance payments, such
advance payment (other than the payment terms given in RFQ) shall be interest
bearing @ SBI PLR + 2% per annum (simple interest) on reducing balance, up to
delivery period and shall be released only against equivalent Bank Guarantee,
which shall be valid up to contractual delivery date plus three months. Interest shall
be adjusted while releasing the payment against despatch documents.
2 TERMS OF DELIVERY
2.1 INDIGENIOUS ENQUIRIES: Terms of delivery are FOT Project site on freight
prepaid & door delivery basis. The date of receipt of material at site shall be
considered as the date of delivery.
2.2 FOREIGN ENQUIRIES: Terms of delivery are FOB international sea port of exit
basis. The Date of On Board Bill of Lading shall be considered as date of
Delivery.
2.3 GLOBAL ENQUIRIES:
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
2.3.1 For Indigenous Suppliers: Terms of delivery are FOT Despatch point on
freight to pay basis. The date of LR/GR shall be considered as the date of delivery.
2.3.2 For Foreign Suppliers: Terms of delivery are FOB international sea port of
exit basis. The Date of On Board Bill of Lading shall be considered as date of
Delivery.
3 TRANSPORTATION
3.1 INDIGENOUS SUPPLIERS

Indigenous SUPPLIERs are required to dispatch the goods on door delivery basis
through any of the bank approved Transporters. Any deviation shall be subject to
prior approval of Project Manager.
3.2 FOREIGN SUPPLIERS

In case order is placed on FOB International port of exit basis, ocean transportation
from FOB Port of Exit to the designated Indian Port (CHENNAI) shall be arranged
through PURCHASER nominated freight forwarder. BIDDER shall arrange handing
over the material to nominated freight forwarder at the designated Port of Exit. The
BIDDER will be required to furnish firm cargo details containing weight, dimensions,
no. of packages, no. & type of containers required & Port of shipment. In case the
actual cargo dispatched exceeds the cargo details furnished, the extra freight
incurred by PURCHASER will be to SUPPLIER’s account.The marine freight
quoted should be kept valid for a period one month lesser to delivery period.
However, Vendor shall furnish the shipping details viz. Net/ Gross weight, Volume
of consignment, number of packages with dimensions at least two month before the
expiry of validity of Ocean Freight. In the event of any delay by Vendor, the quoted
Ocean Freight charges shall remain valid further for one month from the date of
furnishing the above details. EIL reserves the option to ask the bidder to arrange
shipment at the quoted freight rates.
4 CURRENCY OF QUOTE
4.1 FOREIGN SUPPLIERS
Foreign SUPPLIERs are required to submit prices only in USD. In case a foreign
SUPPLIER is sourcing part of equipment/ services from India, prices of such
equipment/ services shall be quoted in Indian Rupees only and terms & conditions
applicable to Indian portion shall be same as applicable to Indian Bidders.
4.2 INDIGENOUS SUPPLIERS
Indigenous SUPPLIERs are required to submit price in Indian Rupees.
5 ANNUAL MAINTENANCE CONTRCT (AMC)

The prices shall be asked for AMC, if required as per Material Requisition.
6 SINGLE POINT RESPONSIBILITY OF THE SUPPLIER
In case of MRs containing supplies as well site work, a single order, covering the
supply part as well site work, shall be placed. Split ordering will not be permitted.
In case, a foreign SUPPLIER requests for a separate order on his Indian sub-
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
SUPPLIER, the same shall not be accepted. However, payment to Indian sub-
SUPPLIER shall be released directly in Indian Rupees against invoices duly
certified by the Foreign SUPPLIER.
For this purpose, the Indian sub-SUPPLIER’s name, material and corresponding
price in Indian Rupees, shall be clearly spelt out in the purchase order on foreign
SUPPLIER.. In case a Foreign supplier sources supplies/ services within India, the
applicable terms & conditions shall be modified to the extent as per Annexure-1
enclosed.
7 GUARANTEE PERIOD
GUARANTEE PERIOD:
For all items having CDD up to Dec 2014 :
18 Months from the date of successful Commissioning or 36 Months from the
date of shipment, whichever is earlier.
For all items having CDD beyond Dec 2014 :
18 Months from the date of successful Commissioning or 30 Months from the
date of shipment, whichever is earlier.
8 PERFORMANCE BANK GUARANTEE (PBG)/(CPBG)

8.1 PBG shall be required @ 10% of total order value. However, PBG shall not be
required for orders upto Rs. Twenty Five (25) Lakhs (equivalent Foreign
currency in case of Foreign SUPPLIERs) in case of Pipes, Fittings, Flanges,
Gaskets and Fasteners in Limited enquiries. For all other cases, PBG shall not
be required for Orders upto Rs. Five (5) lakh (equivalent Foreign currency in
case of Foreign SUPPLIERs).
8.2 PURCHASER shall get all bank guarantees verified for authenticity from the
regional / controlling / branch office of the issuing bank before the same are
accepted.
8.3 In limited enquiries for purchasing, Indigenous suppliers shall be required to
submit the PBG while claiming the dispatch payment.
8.4 In all other cases, the PBG shall be required to be submitted within four weeks
of issue of FOA.
8.5 Performance Bank Guarantees shall be valid till expiry of guarantee period
plus 3 (Three) Months claim period after which the PBG shall be released.
8.6 Bank Guarantee(s) shall be issued through Indian Nationalised Bank/ Indian
Scheduled bank (other than Co-operative Banks) / Indian branches of foreign
banks registered with Reserve Bank of India as a scheduled foreign bank.
Bank Guarantee from Foreign banks will only be accepted if same is counter
signed by their Indian branch or by any scheduled Indian bank.
8.7 Bank Guarantee shall have a claim period of 3 (Three) Months after its expiry.
9 INDIAN TAXES/DUTIES
9.1 The prices shall be exclusive of all Indian taxes/duties applicable on finished
goods/services supplied directly to PURCHASER. The excluded taxes/duties
shall be payable extra at actuals against documentary evidence. Where
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
Purchase Order includes supply and site work, Purchase Order will be divided
into supply and service portion separately , no VAT on work contracts is
envisaged, however VAT on work contract on site work portion if applicable
shall be included in the bidder’s quoted price & no statuary variation is payable
on the same.
9.2 Entry Tax and Terminal taxes are presently not applicable. If applicable at a
later date, same shall be payable extra at actual on production of necessary
Documentary evidence. Road permit shall be issued to supplier by CPCL for
material consigned to CPCL.
9.3 All payments on account of Excise Duty, Service Tax, TNVAT on finished
goods shall be released on receipt of CENVATABLE ( Duplicate Copy of
Excise Invoice) /VATTABLE copy of corresponding invoice and documents
valid for availing CENVAT / VAT credit.
9.4 PURCHASER shall be able to avail 100% credit against TNVAT(i.e. VAT on
sale of finished goods). PURCHASER will not issue any concessional form for
TNVAT.
TN VAT on sale of goods shall not be loaded for evaluation.
9.5 EIL shall issue concessional form-C for central sales tax.
CST against inter state sale shall be loaded during evaluation at the applicable
rates.
9.6 Since Cenvat Credit shall be available against Excise Duty and Service Tax
(excluding service tax on freight) & the same shall not be considered for
comparison purpose.
9.7 Indigenous SUPPLIER’s shall issue E1/E2 form on quarterly basis within 60
days after completion of each quarter based on “C” form no. provided by
PURCHASER. PURCHASER will provide original “C” form in exchange of
original E1/E2 form.
Statutory Variations are eligible only on Service Tax, cenvatable excise duty,
and VAT amount for which input tax credit is available to the OWNER under
TNVAT Act subject to SUPPLIER producing documentary evidence for the
above . Statutory Variations are eligible on CST also.
Statutory variations on non-cenvatable excise duty and VAT amount for which
input tax credit is not available to the OWNER/PURCHASER under TN VAT
Act shall be to SUPPLIER’s account.
9.9 All non-cenvatable /non-vattable taxes/duties shall be considered for
evaluation.
9.10 All new taxes/duties/cess/levies notified after the last date of submission of
final price bid/price implication, but within contractual delivery /completion
period, shall be to EIL’s account. These shall be reimbursed against
documentary evidence.
However, in case of delay on account of supplier, any new or additional taxes
and duties imposed after contractual delivery shall be to supplier’s account.
10 CUSTOMS DUTY/EPCG LICENSE
10.1 OWNER is obtaining an EPCG license for this project. In view of this
concessional rate of Custom Duty shall be applicable to imports from foreign
BIDDER’s for the goods directly consigned to CPCL.
10.2 Indigenous BIDDER’s will be required to quote price considering only merit
rate of duty, for their built in import content, in their bid and evaluation shall be
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
done accordingly. No PAC/EC/INVALIDATION LETTER shall be issued to
Indigenous BIDDER’s.
11 FIRM PRICES
11.1 The prices shall be firm and fixed and not subject to any variation,
whatsoever. In case of Cables, variation in prices shall be admissible as per
IEEMA Price Variation Clause.
11.2 For 2 years O&M spares, prices shall be kept valid for a period of 2 years
from the date of order of main equipment along with annual % escalation ( to
be indicated by the bidder) for subsequent two years.
12 PRICE REDUCTION SCHEDULE
12.1 In case of MRs other than packages, Price Reduction Schedule shall be
@1/2% of value of delayed equipment/ item per week of delay or part thereof
subject to a maximum of 5% of total order value.
12.2 For packages and critical items, with or without site work, the Price Reduction
Schedule shall be @1/2% of total order value per week of delay or part
thereof subject to a maximum of 7.5% of total order value.
12.3 Wherever the supply period and site work are indicated as two separate
periods and notice of site readiness is required for site work, intervening
period, if any, shall be excluded, while calculating the price reduction for
delay.
Note : it shall be endeavor to split the period ,i,e., a separate period for supply
and site work.
12.4 Price reduction shall be effected in the Invoice value before presenting for
payment. The Purchaser reserves the right to cancel the Purchase Order for
any delay exceeding the period of maximum reduction and the Seller shall be
liable to all consequences thereof.
Deleted: ¶
¶
13 INSPECTION ¶
All items shall be inspected by a Third Party Inspection agency as follows:
13.1 INDIGENOUS BIDDER’s: CEIL shall be appointed as Third Party Inspection
for the indigenous materials & accordingly the charges for the same shall be borne
by EIL. The quoted price of Bidder shall be exclusive of TPI charges.
13.2 FOREIGN BIDDERs: The quoted price shall be inclusive of TPI charges
(out of M/s.Lloyds Register (Country of origin), M/s.Bureau Veritas(BV) and
M/s.TUV Nord)
Suppliers will be informed the following:
a) QAP will be approved by Third Party Inspection agency incorporating
requirements of ITP, Technical specifications and approved documents. Approval of
QAP will not be carried out by EIL.
b) The Inspection release note issued by the Third party inspection agency shall
clearly stipulate that materials/equipment have been inspected as per Code-1
approved drawings, wherever applicable and approved QAP.
c) Certification of final documents, wherever applicable, for release of final payment,

shall be carried out by Third Party Inspection Authority issuing the final inspection
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
certificate. 
14 GENERAL PURCHASE CONDITIONS

General Purchase Conditions including formats for advance bank guarantee and
Performance Bank Guarantee shall be as approved earlier by ED Committee for
LSTK Projects with modification based on these terms and conditions.
15 COMPREHENSIVE MARINE-CUM-ERECTION INSURANCE
Comprehensive Insurance (Transit/Marine cum storage, erection, till handing over
of equipment) shall be arranged by PURCHASER.
16 BASIS OF EVALUATION
16.1 WHERE ONLY INDIAN BIDS ARE UNDER COMPARISON
16.1.0 Bids shall be evaluated on the basis of landed cost at Site, including site
work, if any, all duties, taxes, transportation charges less Cenvatable Excise
duty, Cenvatable Service tax, Cenvatable Educational cess & Vattable
TNVAT (100% of TNVAT).
16.1.1 Cost of mandatory spares, if identified in the Material Requisition,
commissioning spares and special tools & tackles will be included for price
evaluation of bids, but cost of Spares for two years operation shall be
excluded.
16.1.2 AMC charges shall be considered for evaluation wherever AMC is required.
16.1.3 Supervision and Training charges shall be considered for evaluation
wherever supervision and training are required.
16.1.4 Commercial loading shall be considered for evaluation of bids.
16.1.5 Technical loading, if any, shall be considered for evaluation of bids.
NOTE :
- Site Work, wherever applicable, shall be considered for evaluation.
- In case freight charges are not quoted, estimated freight shall be taken from
EIL shipping dept. and loading shall be done with the same. In case of
ordering , bidder shall be asked to absorb the freight first. In case bidder
does not agree to absorb then negotiation shall be done with the bidder to
agree upto maximum of the freight with which loading has been done. If
bidder does not agree with this also, then refloating of MR shall be done.
16.2 WHERE ONLY FOREIGN BIDS ARE UNDER COMPARISON
16.2.1 Bids shall be evaluated on the basis of CFR (CHENNAI) prices including
third party inspection charges, stowage charges wherever applicable (as
quoted by BIDDERs), and considering sea freight as under:
(i) Packages/equipments/pipes & plates :
- Firm freight as quoted by BIDDER’s
(ii) Bulk items – piping (other than pipes) / instruments :
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- Firm freight as quoted by BIDDER’s.
In case, firm freight is not quoted by BIDDER ( For Bulk Items as well
as Packages/equipments/pipes & plates), freight shall be taken from
Transchart through shipping Dept. and loading shall be done with the
same. In case of ordering, transportation shall be done by the
Transchart only.
16.2.2 Cost of mandatory spares identified in the Material Requisition,
Commissioning Spares and special tools & tackles will be included for
evaluation of bids, but costs of Spares for two years operation shall be
excluded.
16.2.3 AMC charges shall be considered for evaluation wherever AMC is required.
16.2.4 Supervision (man days as indicated in MR as well as TBA ) and Training
charges shall be considered for evaluation, wherever, supervision and
training are required.
16.2.4 (i) Service tax on Reverse charge and withholding tax ( in case it is not
included in bidder’s price) basis, wherever applicable shall be added for bid
evaluation purpose only.
16.2.5 Commercial loading shall be considered for evaluation of bids.
16.2.6 Technical loading, if any, shall be considered for evaluation of bids.
16.2.7 For global enquiries, evaluation of offer shall be done considering foreign
exchange rate, on the date of priced bid opening. Deleted: i.e., 1 USD = Rs. 56.13.
Payment shall be made based on the Foreign Exchange Rate prevailing on

the date of making payment.
NOTE :
16.3 WHERE INDIAN AS WELL AS FOREIGN BIDS ARE UNDER

COMPARISON
16.3.1 INDIGENOUS BIDDERS:
(i) The evaluated price of indigenous BIDDERs shall be carried out on the
basis of landed cost at Site, as per clause 16.1 above.
(ii) Notional Loading of 1% for TPI charges shall be considered for
evaluation.
16.3.2 FOREIGN BIDDERS :
The evaluated price of foreign BIDDERs shall be on the basis of landed cost
at Site, including the following:
(i) Evaluation shall be done as per clause 16.2 above plus marine
insurance @ 1% of FOB Price.
(ii) L/C charges @ 1% of FOB price.
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Document No.
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
(iii) Landing Charges @ 1% of CIF Value i.e S.No. (i).
(iv) Custom clearance, Port Handling and Inland Freight (from Port of Entry
(CHENNAI) to CPCL project site) charges @ 3% of CIF value including
L/C Charges, i.e., S. No. (i) plus (ii).
(v) Landed Cost = S.No. (i) to (iv).
NOTE :
- Transit insurance for Indigenous and Foreign BIDDERs, will not be loaded..
16.4 GENERAL
16.4.1 Taxes and duties will be cost loaded as quoted by the bidder. However, if a
SUPPLIER states that taxes/duties are not applicable at present and will be
charged as applicable at the time of delivery then his bid shall be loaded by
the maximum rate of taxes/duties applicable at the time of evaluation of
Bids.
16.4.2 In case of pipes, if a foreign BIDDER has not quoted or not included
stowage charges, the same shall be loaded @ 10% of BIDDER’s quoted
Ocean Freight.
17 LOADING/REJECTION CRITERIA
Cost loading on account of deviations to commercial terms & conditions shall be

calculated on FOT Despatch Point price/ FOB price as under :
17.1 PERFORMANCE BANK GUARANTEE (PBG)
In case, Foreign SUPPLIER takes any deviation with respect to the amount or
period or validity of the performance bank guarantee, the offer shall be rejected.
Any other type of bond (e.g. indemnity bond ) is not acceptable in lieu of
Performance Bank Guarantee (PBG).
In case foreign bidder submit stand by Letter of Credit in lieu of CPBG, same shall
be accepted. Confirmation charges for the stand by Letter of Credit shall be to
seller’s account.
In case, Indian Supplier takes any deviation with respect to the amount or period or
validity of the performance bank guarantee, loading shall be done for the differential
amount and /or the differential period.
For differential period/amount loading, the following example will amplify the
methodology :
For differential period:
10% for differential period : 10% * differential period /total period ,i.e,
(guarantee period + claim period)
In case of Differential Amount
Amount offered by the Bidder : Loading

a) 10% : Nil
b) Less than 10% : Differential between the offered percentage
and 10%
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17.2 PRICE REDUCTION SCHEDULE (PRS)
17.2.1 PRICE REDUCTION SCHEDULE (APPLICABLE AS 1/2% DOV ~ 5% TOV)

FOR DELAYED DELIVERY:
(i) 1/2% of DOV up to maximum of 5% of No loading
TOV
(ii) 1/2% of DOV up to maximum of 5% of 2.5%
DOV
(iii) Other than the above 5%
17.2.2 PRICE REDUCTION SCHEDULE ( APPLICABLE AS 1/2% TOV ~ 7.5%

TOV FOR PACKAGES & CRITICAL ITEMS ONLY )
(i) 1/2% of TOV up to maximum
a of 7.5% of No loading
) TOV
(ii) 1/2% of TOV to x% ofb TOV (7.5-x)%
)
(iii) Other than the abovec 7.5%
)
NOTE: TOV – Total Order Value (FOT Despatch Pt. Price); DOV – Delayed Order
Value (FOT Despatch Pt. Price).
17.4 PRICE VARIATION

(i) Firm Prices : No Loading
(ii) In case of Price Variation : Loading by ceiling %age
Formula with ceiling offered
(iii) No formula and no ceiling : Offer shall be rejected
specified by the BIDDER
Note : In case the enquiry itself provides for price variation on account of
certain variables, offers seeking such variation shall not be loaded.
17.5 PAYMENT TERMS

Payment terms at variance with RFQ (which are not interest bearing), will not be
permitted. However, if a BIDDER insists on the same, these shall be loaded @ SBI
PLR+ 2% per annum (simple interest) for the relevant period as under:
(i) Advance against FOA / PO : 100% of the delivery period
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
(ii) Drawing approval : 80% of the delivery period
(iii) Order on sub Vendors : 75% of the delivery period
(iv) Receipt of raw material at Vendor’s works : 50% of the delivery period
(v) %age payment against dispatch : Interest for Three month
Documents instead receipt & acceptance
at Site (Specified in RFQ)
(vi) % age payment against dispatch : Interest for One month
document instead of Final document
as per Purchase Requisition
(Specified in RFQ)
(vii) %age payment against : Interest for Three month

receipt of material
at site instead acceptance of
material at site
(Specified in RFQ)
Notes to S. No. (vii) :

- Shall be applicable to indigenous bidders.
- Shall be against Additional BG of equivalent amount valid initially for 3
months plus claim period.
PBG shall be required along with the Dispatch documents, in cases where there is
no further milestone payment of 10% or more left.
17.6 DELIVERY
17.6.1 FOR IDENTIFIED CRITICAL EQUIPMENTS (TO BE IDENTIFIED BY THE
PROJECT):
Delivery/Completion period longer than required in enquiry shall be liable for
rejection..
17.6.2 FOR BALANCE ITEMS/EQUIPMENTS (OTHER THAN CRITICAL
EQUIPMENTS) :
(i) FOR ENQUIRIES WITH DELIVERY/COMPLETION PERIOD UPTO 6
MONTHS
Delivery/Completion period longer than required in enquiry shall be loaded
@ 1/2% per week up to a maximum of four (4) weeks. In case, a SUPPLIER
quotes delivery longer than four (4) weeks from required, the bid shall be
rejected. One (1) month shall be construed as equal to four (4) weeks for the
purpose of such evaluation.
(ii) FOR ENQUIRIES WITH DELIVERY /COMPLETION PERIOD BEYOND 6

MONTHS
Delivery/Completion period longer than required in enquiry shall be loaded
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@ 1/2% per week upto a maximum of six (6) weeks. In case, a SUPPLIER
quotes delivery longer than six (6) weeks from required, the bid shall be
rejected. One (1) month shall be construed as equal to four (4) weeks for the
purpose of such evaluation.
NOTE: In case under clause no. 2.1, indigenous bidder offers a deviation
against the terms of delivery basis, their bid shall be rejected.
17.7 OFFER VALIDITY:
In case a SUPPLIER offers shorter validity of the bid against RFQ requirement, the
bid shall be rejected.
18 INVOICING INSTRUCTIONS
For imported goods, The Invoices shall be billed to CPCL a/c EIL. Consignee on
the invoices and bill of lading issued by the foreign supplier shall be in the name of
CPCL, COKER BLOCK OF RESID UPGRADATION PROJECT, MANALI REFINERY, and
CHENNAI. For Indigenous Goods, the invoices shall be billed to EIL a/c CPCL.
However, the consignee in the tax invoices shall be CPCL A/C EIL, COKER BLOCK
OF RESID UPGRADATION PROJECT, MANALI REFINERY, CHENNAI to avail input
credit of Excise duty by CPCL.
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Document No.
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
Annexure I
TERMS & CONDITIONS FOR INDIAN SOURCED COMPONENTS / SERVICES BY FOREIGN BIDDER
Foreign bidder may source components / sub-supplies and services from India, if allowed as
per Material Requisition. For such sub-supplies / services ,Commercial Terms & Conditions of
the RFQ shall stand modified to the following extent:
1. PRICING:
1.1 Unit and total price on FOT Despatch Point basis including packing and forwarding
charges.
1.2 Details of Taxes and duties (rates) payable extra on the finished goods, applicable on
Indian sub-suppliers. Purchaser shall issue ‘C’ form for Concessional rate of Central sales
tax.
1.3 Separate and clear break-up of charges for inland transportation excluding Entry Tax &
Terminal Tax. Entry Tax and Terminal Tax, if applicable, shall be reimbursed at actuals by
EIL on submission of documentary evidence.
1.4 Materials if ordered against the RFQ/Bidding Document are required to be dispatched
on door delivery basis through a reliable bank approved Road Transport Company.
1.5 Transit insurance of Indian sub supplies shall be borne and arranged by the EIL.
2. CURRENCY OF QUOTE:
The quoted price of sub-supplies / services shall be in Indian Rupees only.
3. AWARD OF ORDER:
Foreign Principal shall be the single point responsible Vendor and separate order on
Foreign supplier and Indian sub-supplier / sub-contractor is not acceptable. Single
Purchase order shall be issued on the Foreign principal clearly indicating the sub-
supplier’s / sub-contractor’s name, material and corresponding price in Indian Rupees.
4. DELIVERY:
The delivery period for sub-supplies shall be on FOT site basis within specified delivery
period for Foreign bidder as per Terms of RFQ/Bidding document.
5. PRICE REDUCTION SCHEDULE:

PRS shall be applicable in totality on Foreign scope + Indian sourced component / Service
for delay in supply of goods/services either by Foreign principals or Indian counterpart.
6. PAYMENT TERMS:
6.1 Indian sub-supplies:
 90% through E-Payment with taxes and duties will be paid against receipt of Indian
sourced goods/material at project site.
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
 10% against receipt & Acceptance on delivery of main equipments by Foreign
principal and as well as Indian supplies at site as per Terms of bidding document.
Payment of Indian sub supplies/Services shall be released directly to Indian counterpart
against Invoices raised by Indian counterpart duly certified by Foreign principal.
6.2 Foreign principals: Payment terms of Foreign bidder shall be modified and 5% payment
out of payment against shipping documents through L/c shall be released after receipt
on delivery of main equipments by Foreign principal as well as Indian supplies at site as
per Terms of bidding document through wire transfer.
6.3 The payments shall be made after Adjustment of Price Reduction Schedule.
7. PERFORMANCE BANK GUARANTEE:

Foreign principal shall submit the performance bank guarantee for 10% of total order
value including value of Foreign portion and Indian sourced components / services
Page 43 of 434
INSTRUCTIONS TO BIDDERS FOR E-TENDERING
Bidders who wish to participate for RFQs/ Tenders which are uploaded on EIL’s Authorised service
provider’s website (i.e. www.tenderwizard.com/eil ) should follow the following instructions which
shall permit them to Search, View, Download and Submit their Electronic Bids online in a secure manner
ensuring confidentiality. These Instructions for E-Tendering shall be read in conjunction with various
instructions, wherever appearing with the RFQ/ Bidding Document. The conditions & instructions
mentioned here in under shall supersede and shall prevail over the conditions & instructions enumerated
elsewhere in the RFQ/ Bidding Document.
1) PARTICIPATION IN E-TENDERING, REQUEST FOR USER ID and PASSWORD:
To participate in E-Tendering, it is Mandatory to the Bidders have a user id and password on e-
tendering portal. Bidders are required to be registered on E-Tendering website to obtain user id &
password (password will be system generated). However for the tenders issued on limited basis,
bidders are already registered by EIL and after their registered, user id & password were
communicated to bidders at their e-mail id available in EIL. The bidders who are already registered
may contact to concern person of EIL to get their user id and password.
For tender issued on NIT/ Press advertisement basis, bidders are required to registered themselves
by using the link of registration provide on the home page of e-tendering website. The bidders are
required to fill the online registration form with all required details. The bidder should indicate correct
information including their e-mail since all system generated correspondences will be send on these e-
mail ids. Digital signature of class 3b individual or class 3 organization is a mandatory requirement for
e-tendering, right from log-in into the system. Hence, during registration, bidders shall fill the details
of their digital Signature (serial No.) to save time and avoid mapping of Digital Signature details to the
bidders user ID at the bid uploading stage. Otherwise, bidders are required to furnish their DC details
to EIL for mapping the same to their user id by Service provider. Once, the online registration form is
submitted with all required field and documents like pan card, registration or any other document of
company, the system will generate the user id and password for the bidder.
However, to use this user id, the bidders are required to get their user id enabled (activate) through
concerned engineer for the tender in EIL. Accordingly, after registration, bidder shall send a request to
EIL to activate their user id by providing user id and bid reference number.
Note : Bidders who are already registered in any earlier tender of EIL, need not to create new user id,
as the same user id can be used for all the tenders issued to them by EIL on this e-tendering portal.
User id and password are unique to each bidder and the bidder shall use the same to
view/download/participate in all e-tenders of EIL. Bidders are required to change the password during
their first login into the system. There will be single user id permission for each bidder in the system
for their company/Organization.
Bidders in their own interest are requested to register on e- tendering portal and upload/submit their
bid well in time. Bidders should avoid the last hour rush to the website for registration of user id &
password, enabling of user id and mapping of digital signature serial number etc. since this exercise
require activities from EIL & M/s Antares System (Service Provider) and needs time. In the event of
failure in bidder’s connectivity with EIL/Service Provider during the last few hours, bidder is likely to
miss the deadline for bid submission. Due date extension request due to above reason may not be
entertained.
EIL/EIL’s ASP will not be responsible for any delay/ non-availability of USER ID or Password or any last
minute request for enabling /resetting the same by the Bidders.
2) TRAINING & FAMILIARIZATION WITH E-TENDERING SYSTEM

The bidder should familiarize themselves with the e-tendering system and understood all formalities
related to e-tendering including log-in, system settings, downloading & uploading procedures. The
contact details of the concerned representatives from ASP and other helpdesk no.
Instructions To Bidders For E-Tendering Page 1 of 4

Page 44 of 434
3) VIEW AND DOWNLOAD E-TENDER
Bidders must go to E-Tendering website www.tenderwizard.com/eil and log-in using their user-id,
password and digital signature.
However, the open tenders can be viewed/ downloaded from the link “tender free view” provided on
the home page the website, without being log-in into the system.
4) DIGITAL SIGNATURE
Bidders cannot submit e-bids without having valid Digital Signature. The Digital Signature shall be
issued by C.A. (Certifying Authority) in India, in the name of a person authorized for E- Tendering on
behalf of his Company.
FOREIGN BIDDERS SHALL ALSO HAVE TO OBTAIN DIGITAL SIGNATURE FROM CERTIFYING
AUTHORITIES IN INDIA AS APPROVED BY CCA. DIGITAL SIGNATURE OBTAINED FROM FOREIGN
COUNTRIES ARE NOT ACCEPTABLE.
Note: In terms of Indian I.T Act 2000, only a digitally signed document will be considered as a valid
signed document.
5) BID DOCUMENT FEE/ EARNEST MONEY DEPOSIT/ INTEGRITY PACT, IF
APPLICABLE
Bidders are required to submit the Bid Document Fee, EMD (in the prescribed format), Integrity Pact,
as required as per RFQ in original as per the manner prescribed in the RFQ/ Bidding Document at the
time of bid submission in sealed envelope. However, bidders are required to upload the scanned copy
of both Bid Document fee as well as EMD on E- Tendering website along with the e-bid.
In case the bidder fails to submit the above in original physical form within the final bid due date &
time, his bid shall be rejected, irrespective of their status/ ranking in tender and notwithstanding the
fact that a copy of the same was earlier uploaded by the bidder.
Any bidder intends to modify their bid they should use “‘MODIFY” instead of “WITHDRAW“.
Caution : ONCE BID IS WITHDRAWN BY THE BIDDER WILLINGLY OR UNWILLINGLY , SYSTEM WILL
NOT ALLOW THEM TO RESUBMIT THEIR BID.
6) SUBMISSION OF BID :
Bidders are required to upload the bid along with all supporting documents & Priced part on the E-
Tendering website (www.tenderwizard.com/eil) only. However, documents required to be submitted
physically, viz., Bid Document Fee, EMD, etc., need to be submitted in a sealed envelope as per the
provisions of RFQ/ Bidding Document.
Bidders shall ensure that all the required documents are uploaded in time and failure to upload the
same before bid submission date & time is the sole responsibility of bidder. Under no circumstances,
EIL shall entertain any request for acceptance of bid documents in physical form or any other form,
which are required to be uploaded on E- Tendering Website.
Also bidders are suggested to check the uploaded documents to verify the uploaded documents are
opening correctly or not by clicking on the download link.
The bidders needs to submit prices on-line strictly as per the Price Schedule format provided in our E-
Tender.
Bidders can submit their Bids on-line only after digitally signing the bid/documents with the Digital
Signatures used for log-in.
The Authenticity of above digital signatures may be verified through authorized CA after bid opening
and in case the digital signature is not authorized/valid, the bid will be rejected. Bidder shall be
responsible for ensuring the validity of digital signatures and proper usage of the same by responsible
persons.

Page 45 of 434
No Late Bids after due date & time shall be permitted in E-Tendering website. The system time (IST)
being displayed on the E-Tendering website shall be final and binding on bidder and bids have to be
submitted by bidders considering this time only and not the time as per their location / country. Bidder
who intends to change the bid already submitted may change/revise the same on or before the
closing date & time of bid submission.
No Manual Bids shall be permitted. The offers submitted through E-tendering website shall only be
considered for evaluation.
Note:
i. Bidders are advised in their own interest to ensure that bids are uploaded in E- tendering
website well before the closing date and time of bid submission.
ii. No bid can be modified after the dead line for submission of bids.
iii. EIL shall not be responsible for any failure on the part of the bidder to follow the instructions.
iv. Inadvertently, if a document is uploaded in E- tendering website by the bidders, such
document can be deleted/detach by the Bidder and a new/modified document can be
uploaded digitally signed within the bid due date & time.
v. Bidders are requested to upload small sized documents preferably (upto 5 MB) at a time to
facilitate easy uploading into E- Tendering website. EIL does not take any responsibility in
case of failure of the bidder to upload the documents within specified time of Bid submission.
Bidder can upload any number of documents each below 5 MB in size.
vi. Wherever, the bidders are asked to upload the required document in Mandatory folders, the
bidders must upload the required document only in the Mandatory folders and other
documents can be attached in general documents section.
vii. Any bidder intends to modify their bid they should use “‘MODIFY” instead of “WITHDRAW“.
viii. Caution : ONCE BID IS WITHDRAWN BY THE BIDDER WILLINGLY OR UNWILLINGLY ,
SYSTEM WILL NOT ALLOW THEM TO RESUBMIT THEIR BID.
7) OPENING OF BIDS:
The unpriced bids shall be opened online, at the specified date and time given in the RFQ document
or extended otherwise. The price bids shall also be opened online on the date & time which will be
informed to all the techno-commercially qualified/ acceptable bidders in advance.
The bidders who have submitted their bid will be able to view online the name & status of all the
bidders at their respective windows, after unpriced bid opening by buyer. Similarly, the techno-
commercially acceptable bidders will be able to view online the price sheets of other techno-
commercially acceptable bidders (who qualify for the price bid only) at their respective windows, after
priced bid opening by buyer.
Wherever the composite bids are invited, the composite bids shall be opened accordingly.
8) LAST DATE FOR SUBMISSION / RECEIPT OF BIDS:
System does not allow for submission of bids beyond the deadline for bid submission. The system
time displayed on EIL’s ASP E-Tendering website shall be final and binding on the bidders for all
purposes pertaining to various events of the subject RFQ/ Bidding Document and no other time shall
be taken into cognizance.
9) GENERAL
i. The bidders may quote from their own offices/ place of their choice. Internet connectivity shall
be ensured by bidders on its own.
ii. Bidders agree to non-disclosure of trade information regarding the purchase, identity of EIL,
bid process, bid technology, bid documentation and bid details.
iii. EIL shall not have any liability to bidders for any interruption or delay in access to the site

Page 46 of 434
irrespective of the cause.
iv. EIL shall not be responsible for any indirect / consequential losses / damages, including but
not limited to systems problems, inability to use the system, loss of electronic information,
etc.
v. EIL decision on award of Contract shall be final and binding on all the Bidders.
vi. EIL reserves the right to prescribe different Security Devices for accessing and/or using E-
Tendering System or any part thereof, including but not limited to prescribing different
Security Device(s) for accessing and/or using different parts of E-Tendering System.
vii. EIL reserves the right to prescribe password(s) and Login ID(s) for the bidders and its
representatives as well as any combination and/or sequence of letters and/or numerals for the
password(s) and Login ID(s).
viii. The actions, failures, omissions and defaults of the bidder's representative(s) shall be
construed and be given legal effect as if they are the actions, failures, omissions and defaults
of the bidder and the bidder shall be fully responsible for all such matters.
ix. The bidder shall bear all costs and expenses in relation to its access and use of E-Tendering
System, including but not limited to the costs and expenses incurred in ensuring its continued
access and use of E-Tendering System.
x. EIL shall not be responsible or held liable under these Terms and Conditions for any loss or
damage that is caused to any party due to use or misuse of the E-Tendering System or
breach, by any party, of the Terms and Conditions mentioned herein.
xi. All Clarification/ correspondences including enabling of user ids, password re-set request,
mapping of DC details, etc, if any, will only be entertained from 0900 Hrs. (IST) to 1600 Hrs.
(IST) only, during the office working hours.
NOTE: A Ready Reckoner for e-tendering is available on e-tendering website

(www.tenderwizard.com/eil) under the Link “Vendor Help”. Bidders to click on the link “Vendor
Help- Detailed Help” to downloading the same. Bidders to follow the instructions given in the
same for uploading their e-bids in e-tendering website.

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Annexure-I to ITB for E-Tendering
Contact details of Authorized Service Provide (ASP)
ASP Name: M/s Antares Systems Limited, Bangalore
Address: # 24, 1st Floor, Sudha Complex

Near Havanoor Circle, 3rd Stage
4th Block, Basaveshwara Nagar
Bangalore - 560 079
Ph: 080-40482000
Fax No: +91-80-40482114
New Delhi Help Desk:

C-9, 1st Floor (Back Side)
New Krishna Park, Najafgarh Road, Vikaspuri
Near Janakpuri West Metro Station
New Delhi-110018
Ph No: 011-49424365
Fax No: +91-11-25618721
Contact Persons:
1. Mr. Santosh Srivastava
Contact no: 08800591739
Email: santoshkumar.s@antaressystems.com
2. Mr. Sachin
Contact no: 8401982112
Email: sachin.t@antaressystems.com
Help Desk Numbers:

1. Bangalore : 080-40482000
2. New Delhi : 011-49424365
08800 991865
3. Gujarat : 08401982112

Page 48 of 434
COKER BLOCK OF RESID UPGRADATION PROJECT
GENERAL PURCHASE CONDITIONS

(INDIGENOUS)
INDEX
PART – A: GENERAL PURCHASE CONDITIONS (INDIGENOUS)
1. DEFINITIONS 18. RECOVERY OF SUMS DUE

2. REFERENCE FOR DOCUMENTATION 19. CHANGES
3. CONFIRMATION OF ORDER 20. CANCELLATION
4. SALES CONDITIONS 21. PATENTS AND ROYALTY
5. COMPLETE AGREEMENT 22. CONTROL REGULATION
6. INSPECTION - CHECKING - TESTING 23. PERFORMANCE GUARANTEE
7. OFFICIAL INSTITUTIONAL TESTING 24. NON-WAIVER
8. OILS & LUBRICANTS 25. NON-ASSIGNMENT
9. SPARE PARTS 26. PART ORDER/REPEAT ORDER
10. TRANSIT RISK INSURANCE 27. SELLER’S DRAWINGS AND DATA REQUIREMENT
11.RESPECT FOR DELIVERY DATES 28. TECHNICAL INFORMATION
12. DELAYED DELIVERY 29 PROGRESS CHART AND EXPEDITING
13. DELAYS DUE TO FORCE MAJEURE 30. SERVICES OF SELLER’S PERSONNEL
14. REJECTION, REMOVAL OF REJECTED GOODS AND 31. SELLER’S LIABILITIES
REPLACEMENT 32. PURCHASER’S MATERIAL
15. TRANSFER OF PROPERTY FROM THE 33. HEADINGS
SELLER TO THE PURCHASER 34. ARBITRATION
16. PRICE 35. JURISDICTION
17. TERMS OF PAYMENT
PART – B: PACKING, MARKING, SHIPPING AND

DOCUMENTATION SPECIFICATION FOR INDIGENOUS
MATERIAL (Document No. 8-1843-0002 Rev. No. 0)
PART–C: PROFORMA OF BANK GUARANTEE

(PERFORMANCE)
PART–D: PROFORMA OF BANK GUARANTEE

ADVANCE (INDIGENOUS)
A133-01-GPC (Ind.)-R0
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PART – A: GENERAL PURCHASE CONDITIONS (INDIGENOUS)
1. DEFINITIONS: Purchase Order / Purchase Requisition number must

appear on order confirmation, correspondence,
The following expressions used in these General drawings, invoices, shipping notes, packing and/ or any
Purchase Conditions (GPC) and the Purchase shall documents or paper connected with the Order.
have the meaning indicated against each of these:
3. CONFIRMATION OF ORDER:
The PURCHASER / OWNER means Engineers India
Limited, a company incorporated in India having its The Seller shall acknowledge the receipt of the Fax of
registered office at Engineers India Bhawan, 1, Bhikaiji Acceptance (FOA) / Purchase Order (PO) within seven
Cama Place, RK Puram, New Delhi-110066 and shall days following the date of the FOA / Purchase Order
include its successors and assignees. and shall thereby confirm his acceptance of the FOA /
Purchase Order without any exceptions. This
“GOODS/MATERIALS”: Goods and/or materials shall acknowledgment will bear on both FOA / Purchase
mean any of the Articles, Materials, Machinery, Order and General Purchase Conditions
Equipment, Supplies, Drawings, Data and other
property and all services including but not limited to 4. SALES CONDITIONS:
design, delivery, installation, inspection, testing and
commissioning specified to complete the order. With Seller’s acceptance of provision of the Purchase
Order, he waives and considers as cancelled any of his
“SELLER”: Seller shall mean the Person, Firm or general sales conditions.
Corporation to whom the Fax of Acceptance / Purchase
Order is issued. 5. COMPLETE AGREEMENT:
“Contractual Delivery Date”: Contractual Delivery The terms and conditions of the Purchase Order shall
Date is the date on which goods shall be delivered constitute the entire Agreement between the parties
F.O.T dispatching point/destination in accordance with hereto. Changes will be binding only if the amendments
the terms of the Purchase Order. The contractual are made in writing and signed by an authorized
delivery date/period is inclusive of all the lead time for representative of the Purchaser.
engineering, procurement of raw materials,
manufacturing, inspection, testing packing and any 6. INSPECTION-CHECKING-TESTING:
other activities whatsoever required to be accomplished
for effecting the delivery at the agreed delivery point. The equipment, materials and workmanship covered by
the Purchase Order are subject to inspection and
“Procurement co-coordinators /Managers”: testing at any time prior to shipment and/or despatch
Purchaser’s authorized representative appointed as and to final inspection within a reasonable time after
procurement co-ordinators/ manager. arrival at the place of delivery. Inspectors shall have the
right to carry out the inspection and testing which will
“INSPECTORS”: Inspectors Inspectors deputed / include the raw materials at manufacturer’s shop, at
authorized by Purchaser including Third Party fabricator’s shop and at the time of actual despatch
Inspection Agency. before and after completion of packing.
CLIENT: client means Chennai Petroleum Corporation All tests, mechanical and others as specified in the
Limited. Purchase Requisition and particularly those required by
codes will be performed at Seller’s expenses and in
PROJECT: Resid Upgradation Project- Coker Block accordance with Inspector’s instructions. The Seller will
at Manali Refinery of Chennai Petroleum Corporation also bear the expenses concerning preparation and
Limited. rendering of tests required by Boiler Inspectorate or
such other statutory testing agencies or by Lloyds
PROJECT MANAGEMENT CONSULTANT” or Register of Shipping and Industrial Services as may be
“PMC” or “CONSULTANT” shall mean any person(s) required.
nominated by the OWNER as the Project
Management Consultant for the Project. The words The salaries and fees of Inspectors and their travelling,
“PROJECT MANAGEMENT CONSULTANT”, “PMC”& lodging and boarding expenses will not be borne by the
“CONSULTANT” are synonymous. M/s Jacobs Seller unless inspection becomes anfractuous due to
Engineering India Private Limited is the PMC for this any omission or commission on the part of the Seller.
Project. Before shipping or despatch, the equipment and/or
materials will have to be checked and stamped by
2. REFERENCE FOR DOCUMENTATION: Inspectors who are authorized also to forbid the use
A133-01-GPC (Ind.)-R0
and despatch of any equipment and/or materials which Inspectors to maintain Schedule and delay, if any, in
during tests and inspection fail to comply with the this process will not be taken into consideration as a
specification, codes and testing requirements. cause of Force Majeure.
The Seller shall: 8. OILS & LUBRICANTS:
- Inform Procurement Coordinator/Managers at The first filling of oils and lubricants, if any, required for
least eight days in advance of the exact place, every equipment shall be supplied inline with MR. The
date and time of rendering the equipment or Seller shall also recommend the quality / quantity of oils
materials for required inspection. and lubricants required for one-year continuous
operation.
- Provide free access as required to Inspectors
during normal and / or extended working hours 9. SPARE PARTS:
to Seller’s or his/its sub-Supplier’s works and
place at their disposal all useful means of The Seller must furnish item wise and priced list of
performing, checking, marking, testing, spare parts required for two years normal operation and
inspection and final stamping. maintenance of the equipment and prime movers also.
Even if the Inspections and tests are fully carried out, The Seller shall provide the necessary cross - sectional
Seller would not be absolved to any degree from his drawing to identify the spare parts numbers and their
responsibilities to ensure that all equipment and location as well as an inter-changeability chart.
material supplied comply strictly with requirements as
per agreement both during manufacturing, at the time of 10. TRANSIT RISK INSURANCE:
delivery, inspection, on arrival at site and after its
erection or start-up and guarantee period as stipulated The Purchaser against its/ Client’s Open General Policy
in Clause 23 herein. (The name of the Insurance Co. will be conveyed
subsequently) shall cover transit Risk Insurance. The
The Seller’s responsibility will not be lessened to any Seller shall advise the dispatch particulars to the
degree due to any comments made by Procurement Insurance Company under advice to the Procurement
Coordinators/Managers and Inspectors on the Seller’s Coordinators / Managers before shipment.
drawings or specifications or by inspectors witnessing
any chemical or physical tests. In any case, the 11. RESPECT FOR DELIVERY DATES:
equipment must be in strict accordance with the
Purchase Order and/or its attachments failing which the Time of delivery as mentioned in the Purchase Order
Purchaser shall have the right to reject the goods and shall be the essence of the agreement and no variation
hold the Seller liable for non-performance of contract. shall be permitted except with prior authorization in
writing from the Purchaser. Goods should be delivered
7. OFFICIAL INSTITUTIONAL TESTING: securely packed and in good order and condition at the
place and within the time specified in the Purchase
In addition to testing and inspection by Inspectors Order for their delivery. The Purchaser reserves the
mentioned above, Lloyds register Industrial services or right to defer the period of delivery in writing.
similar institutional agencies like Boiler-Inspectorate
may be assigned for official testing of all coded 12. DELAYED DELIVERY:
equipment. The Seller shall ensure that all Procedures
for preparation and Performance of test prescribed by The time and date of delivery of materials / equipment
such institution shall be complied scrupulously. as stipulated in the Order shall be deemed to be the
essence of the contract. In case of delay in execution
The Seller is required to send to such institutions as of the order beyond the date of delivery stipulated in the
may be designed by the Purchaser at least three sets of order or any extensions sanctioned, the Purchaser may
fabricated / manufactured drawings for each equipment at his option either:
and calculations. All manufacturer’s mill test certificates
and analytical reports from material laboratories in (i) Accept delayed delivery at prices reduced by as per
respect of all raw material and components employed Price Reduction Schedule Clause of RFQ.
shall have to be presented to such Institution’s
Inspectors in the number of copies required. Seller (ii) Cancel the order in part or full and purchase such
shall be responsible for any delay in submission of cancelled quantities from elsewhere on account and at
necessary certificates. The Seller shall maintain close risk and cost of the Seller, without prejudice to its right
liaison with Procurement Co-ordinators and Institution’s under (i) above in respect to goods delivered.
A133-01-GPC (Ind.)-R0
13. DELAYS DUE TO FORCE MAJEURE: The transfer of property shall be deemed to have taken
place as follows subject to the provisions herein
In the event of causes of Force Majeure occurring within contained:
the agreed delivery terms, the delivery dates can be
15.1 F.O.T. despatch point: On handing over the
extended by the Purchaser on receipt of application
equipment to the carrier against receipt and
from the Seller without imposition of penalty. Only
such receipt having been passed over to the
those causes which depend on natural calamities, wars
Purchaser.
and national strikes which have duration of more than
seven consecutive calendar days and Government Acts 15.2 Equipment sent freight/ carriage paid to the
and other direct legislative enforcement are considered
Refinery site: On receipt of goods at site.
the causes of Force Majeure.
15.3 Equipment erected by the Seller; on
The Seller must advise the Purchaser by a registered acceptance at job site.
letter duly certified by a local Chamber of Commerce or
15.4 Equipment commissioned by the Seller: On
statutory authorities, the beginning and the end of such
taking over by the Purchaser for regular
causes of delay immediately, but in no case later than
operation after test run at maximum capacity
10 days from the beginning and end of each cause of
for specified period satisfactorily performed.
such Force Majeure condition defined above.
16. PRICE:
The extension of time for completion of the work or any
part of the work or any operation(s) involved therein Unless otherwise agreed to in the terms of the
shall be the sole remedy of the Seller for any cause or Purchase Order, the price shall be:
event of delay and the Seller shall not be entitled in
addition to or in lieu of such extension to claim any a) Firm and not subject to escalation for any reasons
damages or compensation for extended stay or whatsoever till the execution of entire order even though
otherwise whether under the law governing contracts or it might be necessary for the order execution to take
quasi-Seller or any other relationship, and the Seller longer than the delivery period specified in the order.
hereby waives and disclaims any and all contrary rights.
b) Inclusive of adequate road worthy packing and
14. REJECTION, REMOVAL OF REJECTED forwarding charges upto effecting delivery at F.O.T.
GOODS AND REPLACEMENT: despatch point in all cases whenever F.O.T destination
delivery terms are agreed to but exclusive of transit
In case the testing and inspection at any stage by insurance.
Inspectors reveal that the equipment, material and
workmanship do not comply with the specification and c) Exclusive of Central/State Sales Tax, Excise Duty
requirements, the Seller at his/its own expense and risk and or such imposts which are leviable by law on sales
shall remove the same within the time allowed by the of finished goods to Purchaser and/or Octroi duty, if
Purchaser. The Purchaser shall be at liberty to dispose any, leviable at destination/ project site. The nature and
of such rejected goods in such a manner, as he may extent of such levies shall be shown separately.
think appropriate. In the event the Seller fails to remove
the rejected goods within the period as aforesaid, all 17. TERMS OF PAYMENT:
expenses incurred by the Purchaser for such disposal
shall be to the account of the Seller. The freight paid by Payment terms shall be as specified in the Inquiry /
the Purchaser, if any, on the inward journey of the Purchase Order.
rejected materials shall be reimbursed by the Seller to
the Purchaser before the rejected materials are Seller shall claim their invoice excluding Excise Duty.
removed by the Seller. The Excise Duty shall be released separately on receipt
of documents including Transporters copy of Invoice,
The Seller shall have to proceed with the replacement valid for availing CENVAT. In the event CPCL is not
of that equipment or part of the equipment at able to claim CENVAT, the amount of Excise Duty to
Purchaser’s stores / site, if so required by the that extent shall be recovered from the Seller.
Purchaser, without claiming any extra payment. The
time taken for replacement in such event will not be Seller shall ensure submission of proper documents for
added to the contractual delivery period. availing CENVAT/ VAT benefits of Service Tax/ VAT. In
case the documents are not found to be in order,
15. TRANSFER OF PROPERTY FROM THE amount of Service Tax/ VAT will be recovered from the
SELLER TO THE PURCHASER. Seller.
A133-01-GPC (Ind.)-R0
The Seller shall furnish to the Purchaser bank owned by the Seller.
guarantee / Cash Security. Bank Guarantee shall be
from a Scheduled/ Nationalized Bank in a form Upon receipt of the cancellation notice the Seller shall
approved by the Purchaser for an amount of 10% of the discontinue all work on the Purchase Order and matters
contract value as security for the due performance of all connected with it.
the Seller’s liability in terms of and/or in connection with
the contract. This security will be released after the The Purchaser in that event will be entitled to procure
expiry of the period of performance guarantee. the requirement in the open market and recover the
excess payment over the Vender’s agreed price, if any,
The financial settlement of Seller’s Invoice is liable to be from the Seller, reserving to itself the right to forfeit the
withheld in the event the Seller has not complied with security deposit, if any, made by the Seller against the
submission of drawing, data and such documentation contract. The Seller is aware that the said goods are
as called for in Purchase Order and/or as required required by the Purchaser for the ultimate purpose of
otherwise. material production and that non delivery may cause
loss of production and consequently loss or profit to the
18. RECOVERY OF SUMS DUE: Purchaser. In this event of the Purchaser exercising the
option to claim damages for non-delivery other than by
Whenever any claim against the Seller for payment of way of difference between the market price and the
sum of money arises out of or under the contract, the contract price, the Seller shall pay to the Purchaser, the
Purchaser shall be entitled to recover such sums from fair compensation to be agreed upon between the
any sum then due or which at any time thereafter may Purchaser and the Seller.
become due from the Seller under this or any other
contract with the Purchaser including right to encash the The provision of this clause shall not prejudice the right
PBG. In the event of encashment of PBG, the same of the Purchaser from invoking the provisions of clause
shall be re-stored to its original amount by the Seller “Delayed Delivery” as aforesaid.
and should this sum be not sufficient to cover the
recoverable amount, the Seller shall pay to the 21. PATENTS AND ROYALTIES:
Purchaser on demand the balance remaining due.
On acceptance of this order, the Seller will be deemed
19. CHANGES to have entirely indemnified the Purchaser and
Procurement Coordinators/Managers from any legal
The Purchaser has the option at any time to make action or claims regarding compensation for breach of
changes in quantities ordered or in specifications and patent rights which the Seller deems necessary to apply
drawings. If such changes cause an increase or for manufacturing the ordered equipment and/or
decrease in the price or in the time required for supply, materials or which can in any way be connected in the
an equitable, adjustment under this provision must be manufacture.
finalized within 10 days from the date when the change
is ordered. 22. CONTROL REGUALTIONS:
20. CANCELLATION: The supply, despatch and delivery of goods shall be

arranged by the Seller in strict conformity with the
The Purchaser reserves the right to cancel the statutory regulations including provision of Industries
Purchase Order or any part thereof and shall be entitled (Development and Regulation) Act, 1951 and any
to rescind the contract wholly or in part in a written amendment thereof as applicable from time to time.
notice to the Seller if: The Purchaser disowns any responsibility for any
irregularity or contravention of any of the statutory
i) The Seller fails to comply with the terms of this regulations in manufacture or supply of his stores
Purchase Order. covered by this order.
ii) The Seller fails to deliver the goods on time

23. PERFORMANCE GUARANTEE:
and/or replace the rejected goods promptly.
iii) The Seller becomes bankrupt or goes into The Seller shall guarantee that any and all materials
liquidation. used in execution of the Purchase Order shall be in
strict compliance with characteristics, requirements and
iv) The Seller makes a general assignment for specifications agreed upon and that the same shall be
the benefit of creditors. free from any defects. Checking of the Seller’s drawings
by Procurement Co-coordinators/ Managers and their
v) A receiver is appointed for any of the property approval and permission to ship or despatch the
A133-01-GPC (Ind.)-R0
equipment and materials guaranteed by Inspectors 27. SELLER’S DRAWING AND DATA
shall not relieve the Seller from any part of his/its REQUIREMENT:
responsibilities of proper fulfillment of the requirement.
The Seller will guarantee that all materials and The Seller shall submit drawings, data and
equipment shall be repaired or replaced as the case documentation in accordance with but not limited to
may be, at his own expense in case the same have what is specified in the requisition and/or in the Seller
been found to be defective in respect of materials, drawings and data form attached to the Purchase
workmanship or smooth and rated operation within Requisition and as called for in Clause 8, viz. Expediting
Guarantee Period as stipulated in the RFQ document. above. Types, quantities and time limits of submitting
this must be respected in its entirety failing which the
The guarantee period for the replaced parts shall be 18 Purchase Order shall not be deemed to have been
months starting from the date on which the executed for all purposes including settlement of
replacements are put in service or period as specified payment since the said submission is an integral part of
above in case of critical items, whichever is later. Purchase Order execution.
Acceptance by the Purchaser or Inspectors of any
equipment and materials or their replacement will not 28. TECHNICAL INFORMATION:
relieve the Seller of his/its responsibility concerning the
above guarantee. Drawings, specifications and details shall be the
property of the Purchaser and shall be returned by the
The Seller shall furnish a Bank Guarantee for 10% of Seller on demand. The Seller shall not make use of
total of total order value (as per proforma hereunder) to drawings and specifications for any purpose at any time
support Seller’s performance. This bank guarantee save and except for the purpose of the Purchaser.
shall remain in force for the entire period covered in
Performance Guarantee plus three months. The Seller shall not disclose the technical information
furnished to or gained by the Seller under or by virtue of
24. NON-WAIVER: or as a result of the implementation of the Purchase
Order to any person, firm or body or Corporate authority
Failure of the Purchaser / Procurement Coordinators/ and shall make all endeavours to ensure that the
Managers to insist upon any of the terms or conditions technical information is kept CONFIDENTIAL. The
incorporated in the Purchase Order or failure or delay to technical information imparted and supplied to the
exercise any rights or remedies herein or by law or Seller by the Purchaser shall at all times remain the
failure to properly notify Seller in the event of breach, or absolute property of the Purchaser.
the acceptance of or payment of any goods hereunder
or approval of design shall not release the Seller and 29. PROGRESS CHART AND EXPEDITING:
shall not be deemed a waiver of any right of the
Purchaser / Procurement Coordinators/Managers to The Seller shall submit to EIL within four (4) weeks from
insist upon the strict performance thereof or any of his the date of Fax Of Acceptance a BAR CHART showing
or their rights or remedies as to any such goods start and finish dates for various activities forming part
regardless of when goods are shipped received or of the execution of the order and identifying the delivery
accepted nor shall any purported oral modification or dates to this activity schedule. Seller shall update this
revisions of the order by Purchaser/ Procurement bar chart every fortnight showing the actual
Coordinators/Managers act as waiver of the terms performance of the activities and if and how the delivery
hereof. date has been affected thereby. Copies of the updated
bar chart will also be submitted for review of the
25. NON ASSIGNMENT: progress of the order.
The Seller without obtaining prior written consent of the Procurement Coordinator/Managers have been
Purchaser shall not assign the Purchase Order to any assigned to expedite both manufacture and shipment of
other agency. equipment and materials covered by the Purchase
Order. The Procurement Co-coordinator/ Managers
26. PART ORDER/ REPEAT ORDER shall have free access to Seller’s shop and/or sub-
Supplier’s shop at any time and they shall be provided
Seller hereby agrees to accept part order at Purchasers all the necessary assistance and information to help
option without any limitation whatsoever and also them perform their job.
accept repeat order(s) during a period of 6 months from
the date of original purchase order on same unit prices, In order to facilitate over-all execution of the order within
terms and conditions. the contractual delivery date, Seller shall furnish to
Procurement Coordinator / Manager within 4 weeks of
A133-01-GPC (Ind.)-R0
receipt of Purchase Order in required number of copies c) The Seller shall give a firm and binding list of
of documents / detailed drawings such as but not Purchasers issue of materials which shall be duly
limited to schedule/PERT chart, unpriced copies of sub reviewed & approved by EIL and the desired schedule
orders/sub contracts, phased program of itemize of its delivery to shop floor strictly in accordance with
manufacturing, testing and delivery and any other the sequence of fabrication vis-a-vis the contractual
information/documentation as may be called for by the delivery period.
Procurement Coordinators/Managers. All post order
correspondence shall be addressed to the DGM d) Unused materials or scrap from material supplied by
(Inspection), with a copy to the Project Manager, the Purchaser to the Seller shall be returned by the
Engineers India Ltd., New Delhi. Seller to the Purchaser or if the Purchaser so directs the
Seller may dispose of the same by sale or otherwise on
30. SERVICES OF SELLER’S PERSONNEL: such terms and conditions as the Purchaser may
stipulate and the Seller shall pay to the Purchaser the
Upon three week advance notice, the Seller shall sale proceeds of the material so disposed off by sale
depute the necessary personnel along with required deducting there from expenses incurred by the Seller on
Tools & Tackles to site for supervision of erection and such sale, the quantum of such deduction to be
start up of the equipment and train a few of the IOCL/ mutually agreed upon in advance between the
EIL’s personnel for the operation and maintenance of Purchaser and the Seller.
the equipment, if required by the Purchaser. The terms
and conditions for the services of the Seller shall be 33. HEADINGS:
mutually settled.
The headings of the conditions hereof shall not affect
31. SELLER’S LIABILITIES construction thereof.
The Seller’s workmen or employees shall under no 34. ARBITRATION:

circumstances be deemed to be in Purchaser’s
employment and the Seller shall hold himself Any dispute or difference between the parties hereof
responsible for any claims which they or their heirs, arising out of any notified claim of the SELLER included
dependents or personal representatives may have or in his final bill and /or arising out of any amount claimed
make for damages or compensation for anything done by the OWNER (whether or not the amount claimed by
or committed to be done in the course of carrying out of the OWNER or any part thereof shall have been
the work covered by this Purchase Order, whether deducted from the Final bill of the supplier or any
arising on Purchaser’s premises or elsewhere and amount paid by the OWNER to the SELLER in respect
agrees to Indemnify the Purchaser against any such of the work) shall be referred to arbitration in
claim or claims if made against the Purchaser and all accordance with the UNCITRAL Rules as adopted in
cost (as between attorney and client) of proceedings, India by the Arbitration & Conciliation Act, 1996.
suits or action which the Purchaser may incur or sustain
in respect of the same. The Seller shall also procure The venue of the arbitration shall be New Delhi.
and keep in force at his own cost comprehensive
automobile Liability insurance for adequate coverage in Notwithstanding the existence of any dispute or
respect of all his vehicle/s visiting or plying in project arbitration in terms hereof or otherwise, the Seller shall
premises. The Seller shall also be responsible for continue and be bound to continue and perform the
compliance of existing laws in respect of their workmen works to completion in all respects according to the
and employees.
Contract (unless the Contract or works be determined
32. PURCHASER’S MATERIAL by the Owner or by the Seller under the provisions of
the Contract), and the Seller shall remain liable and
a) Purchaser’s materials shall be delivered to the Seller bound in all respects under the Contract.
after the Seller submits the Bank Guarantee for
Indemnifying the full value thereof strictly in the manner 35. JURISDICTION
and as per Performa of Bank Guarantee approved by
the Purchaser. The Seller hereby agrees that the Court situated at New
Delhi alone shall have the jurisdiction to hear and
b) Wherever possible, the material shall be consigned determine all action and proceedings arising out of this
to goods depot to be specifically confirmed by Seller. contract.
The Seller at his responsibility and cost shall arrange
Loading/Unloading and any handling from the
destination.
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PROFORMA OF BANK GUARANTEE
(PERFORMANCE)
(On non-judicial stamp paper of appropriate value)
(For Indigenous Suppliers)
To
Engineers India Bhawan
1 Bhikaiji Cama Place
R.K. Puram
New Delhi – 110 066
Kind Att.: Head (LSTK-Finance)
RFQ NO.: _______________________
Dear Sirs,
In consideration of the Engineers India Limited, 1 Bhikaiji Cama Place, R.K. Puram, New Delhi-110066 (hereinafter
called – “the Purchaser” which expression shall include its successors and assigns having awarded
________________________________ work to M/s (Name) _______________________________________
(Constitution) ___________________________ (Address) _____________________________ (hereinafter referred
to as “the Supplier” which expression shall wherever the subject or context so permits include its successors and
assigns) a supply contract in terms inter-alia, of the Purchaser’s Letter No. ______________________ dated
__________ hereinafter referred to as the “Contract” and the general purchase conditions of the purchaser and upon
the condition of Supplier’s furnishing security for the Performance of the Supplier’s obligations and/or discharge of the
Supplier’s liabilities under and/or in connection with the said supply contract for a sum of Rs.
_______________________ only amounting to 10% (ten percent) of the total contract value.
We _______________________________________ (name) a body / corporate registered/constituted under the laws

of ___________________________ and having a Branch at ______________________ (Indian Branch Address)
(hereinafter called “the Bank” which expression shall include its successors and assigns) with the intent to bind the
Bank and its successors and assigns, hereby undertake to pay the Purchaser at __________________ (place) on
first demand in writing without protest or demur or proof or satisfaction or condition and without reference to supplier
any and all amounts from time to time demanded by the Purchaser from the Bank with reference to this
Guarantee/Undertaking upto an aggregate limit of Rs. _________________ (Rupees
___________________________ only).
AND THE BANK DOTH HEREBY FURTHER AGREE AS FOLLOWS:-
1. This Guarantee/Undertaking shall be a continuing Guarantee/Undertaking and shall remain valid and
irrevocable for all claims of the Purchaser and liabilities of the Supplier arising upto and until ___________
plus claim period of 3 months.
2. This Guarantee/Undertaking shall be in addition to any other guarantee or security whatsoever that the
Purchaser may now or at any time have in relation to the Supplier’s obligations liabilities under and/or in
connection with the said supply contract and the Purchaser shall have full authority to take recourse to or
reinforce this security in preference to the other security(ies) at its sole discretion, and no failure on the part
of the Purchaser in enforcing or requiring enforcement of any other security shall have the effect of releasing
the Bank from its full liability hereunder.
3. The Purchaser shall be at liberty without reference to the Bank and without affecting the full liability of the
Bank hereunder to take an other security in respect of the Supplier’s obligation and/or liabilities under or in
connection with the said supply contract and to vary the terms vis-à-vis the Supplier of the said supply
contract or to grant time and/or indulgence to the Supplier or to reduce or to increase or otherwise vary the
prices of the total contract value or to release or to forebear from enforcement of all or any of the obligations
of the Supplier under the said supply contract and/or the remedies of the Purchaser under any other
Guarantee(s) or Security(ies) now or hereafter held by the Purchaser and no such dealing(s), variation(s),
reduction(s) or other indulgence(s) or arrangement(s) with the Supplier or release or forbearance whatsoever
shall have the effect of releasing the Bank from its full liability to the Purchaser hereunder or of prejudicing
rights of the Purchaser against the Bank.
4. This Guarantee/Undertaking shall not be determined or affected by the liquidation or winding up, dissolution,
or change of constitution or insolvency of the Supplier or any change in the legal constitution of the Bank or
of the Purchaser.
A133-01-GPC (Ind.)-R0 Page 1 of 2
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5. Bank hereby waives all rights at any time inconsistent with the terms of this Guarantee/Undertaking and the
obligations of the Bank in terms hereof shall not be anywise affected or suspended by reasons of any dispute
or disputes having been raised by the Supplier (whether or not pending before any Arbitrator, Officer,
Tribunal or Court) or any denial of liability by the Supplier or any other order for Communication whatsoever
by the Supplier stopping or preventing or purporting to stop or prevent any payment by the Bank to the
Purchaser in terms hereof.
6. Notwithstanding anything contained herein:
(a) The Bank’s liability under this Guarantee/Undertaking shall not exceed Rs._____________ (In
figures) ______________________ (In words) ____________________________ only).
(b) This Guarantee/Undertaking shall remain in force upto _____________ and any extension(s)
thereof, if any; and
(c) The Bank shall be released and discharged from all liability under this Guarantee/Undertaking
unless a written claim or demand is issued to the Bank on or before _____________ plus 3 months
period or the date of expiry of any extension(s) thereof if this guarantee/undertaking has been
extended.
7. The Bank doth hereby declares that Shri ______________________ (name & designation of the person
authorized to sign on behalf of the Bank) is authorized to sign this Guarantee/Undertaking on behalf of the
Bank and to bind the Bank thereby.
Yours faithfully,
(Signature)
NAME & DESIGNATION

NAME OF THE BANK
NOTE
1. This Guarantee is required to be stamped as an agreement according to the Stamp Duty Act.
2. The Performance Bank Guarantee shall be strictly as per above proforma and shall be through Indian or
Foreign Branches of Indian Scheduled Banks (other than Cooperative Bank)/Nationalized Bank or Indian
Branches of Foreign Banks.
3. The bank shall provide details viz contact person, telephone number, fax number, e-mail address and
address of the Controlling/Regional Office of issuing bank for verification of authenticity of Bank Guarantee.
4. This Guarantee is required to be sent by Seller’s Bankers directly to the Head (LSTK-Finance), Engineers
rd
India Limited, EI Bhawan, 3 Floor, 1, Bhikaiji Cama Place, New Delhi-110066.
Page 64 of 434
PROFORMA OF BANK GUARANTEE
ADVANCE (INDIGENOUS)
(On non-judicial stamp paper of appropriate value)
To
1 Bhikaiji Cama Place
New Delhi – 110 066
Attn.: Head (LSTK-Finance)
Project ______________________
RFQ No. _____________________
Dear Sirs,
Engineers India Limited, 1, Bhikaiji Cama Place, New Delhi-110066 (hereinafter called – “the Purchaser” which
expression shall include its successors and assigns) has awarded M/s ____________________________________
(hereinafter called “The Supplier” which expression shall include its successors and assigns) the work of designing,
manufacturing, fabricating and supply of ______________________ in terms of a contract as constituted by Purchase
Order No. ____________________ dated _________________ issued by the Purchaser to the Supplier (hereinafter
called “The Contract” which expression include all the amendments and/or modifications of the Purchase Oder).
AND WHEREAS the Purchaser has agreed to advance the Supplier a sum of Rs._________________ (Rupees
_________________________________________________) hereinafter called “The Advance” as financial
assistance to the Supplier under the Contract on the condition, inter alia, that the advance shall be secured by a Bank
Guarantee as hereinafter appearing:
We ______________________________ Bank _____________________ a Bank incorporated/ constituted under the

laws of _____________________ and having it registered/principal office at _________________________________
(hereinafter called “The Bank” which expression shall include our successors and assigns) in consideration of the
aforesaid promises and at the request of the Supplier DO HEREBY bind ourselves and our successors and assigns,
and irrevocable undertake to pay the Purchaser on first demand in writing without protest or demur or proof or
condition and without reference to the Supplier any and all amounts at any time and from time to time claimed by you,
as due to you under or in respect of the said advance, and demanded by you from us, with reference to this
undertaking for an aggregate limit of Rs. _____________ (Rupees
___________________________________________).
AND, we, the Bank DO HEREBY further agree as follows:
(i) The Purchaser shall have the fullest liberty without reference to the Bank and without affecting in any way the
liability of the Bank under this Guarantee/Undertaking, at any time and/or from time to time to anywise vary
the Contract and/or any of terms and conditions thereof or of or relative to the advance and to extend time for
the performance of the Contract and/or repayment of the advance or to postpone for any time or from time to
time the obligations of the Supplier and to waive or postpone exercise of any of the rights available to the
Purchaser against the Supplier or to forebear from enforcing any of the terms or conditions of the Contract
and/or the advance or any security(ies) available to the Purchaser, AND the liability of the Bank shall remain
in full force and effect notwithstanding any exercise by the Purchaser of the liberty with reference to any or all
the matters aforesaid or by reason of time being given to the Supplier or any forbearance, waiver, act or
omission on the part of the Purchaser or any indulgence by the Purchaser to the Supplier or any other act,
matter or thing whatsoever which under the law relating to sureties would have the effect of releasing the
Bank from its liability hereunder or any part thereof, AND the BANK DOTH HEREBY waive all rights at any
time inconsistent with the terms of this Guarantee/Undertaking.
(ii) It shall not be necessary for the Purchaser to proceed against the Supplier before proceeding against the
Bank and this guarantee/undertaking shall be enforceable against the Bank as principal debtor
notwithstanding the existence of any other security for any indebtedness of the Supplier to the Purchaser
(including relative to the advance) and notwithstanding that any such security shall at the time when claim is
made against the Bank or proceedings taken against the Bank be outstanding or unrealized.
(iii) As between the Bank and the Purchaser for the purpose of this guarantee/undertaking the amount claimed
by the Purchaser from the Bank with reference to this guarantee/ undertaking shall be final and binding upon
the bank as to the amount payable by the Bank to the Purchaser hereunder.
Page 65 of 434
(iv) The liability of the Bank to the Purchaser under this guarantee/undertaking shall remain in full force and
effect notwithstanding the existence of any difference or dispute between the Supplier and the Purchaser,
the Supplier and the Bank and/or the Bank and the Purchaser, or otherwise howsoever touching or affecting
these presents or the liability of the Supplier to the Purchaser, and notwithstanding the existence of any
instructions or purported instructions of the Supplier or any other person(s) to the Bank not to pay or for any
cause withhold or defer payment to the Purchaser under these presents with the intent that notwithstanding
the existence of such difference, dispute or instruction, the Bank shall be and remain liable to make payment
to the Purchaser.
(v) This guarantee/undertaking shall not be affected by any change in the constitution of the Bank or that of the
Supplier or the Purchaser, or any irregularity in the exercise of borrowing powers by or on behalf of the
Supplier.
(vi) This guarantee/undertaking shall be valid for all claims/demands made by the Purchaser to or upon us upto
____________________ provided always that if for any reasons, the Supplier is unable to complete supplies
under the Contract, the Bank shall at the request of the Purchaser and without recourse to the Supplier
extend the validity of this guarantee/undertaking for a further period of six months. For the purpose of this
clause, the Purchaser’s statement that the Supplier is unable to complete supplies under the contract shall
be conclusive and final binding on us.
(vii) Notwithstanding anything contained herein:
(a) The Bank’s liability under this Guarantee/Undertaking shall not exceed Rs. _______ (Rupees
__________________________________only).
(b) This Guarantee/Undertaking shall remain in force upto ______________ and any extension(s)
thereof; and
(c) The Bank shall be released and discharged from all liability under this Guarantee/ Undertaking
unless a written claim or demand is issued to the Bank on or before ________ plus 3 months claim
period, or the date of expiry of any extension(s) thereof if this guarantee/undertaking has been
extended.
(viii) The Bank DOTH HEREBY declare that Mr. ______________ (name of the person signing on behalf of the
Bank) who is _____________ (his designation), is authorized to sign this guarantee/undertaking on behalf of
the Bank and to bind the Bank thereby.
Dated this ________________________ day of ______________
Yours faithfully,
For _____________________________________________
Signature ________________________________________
Name & Designation ________________________________
Name of the Branch ________________________________
NOTE
1. This Guarantee is required to be stamped as an agreement according to the Stamp Duty Act.
2. The Performance Bank Guarantee shall be strictly as per above proforma and shall be through Indian or
Foreign Branches of Indian Scheduled Banks (other than Cooperative Bank)/Nationalized Bank or Indian
Branches of Foreign Banks.
3. The bank shall provide details viz contact person, telephone number, fax number, e-mail address and
address of the Controlling/Regional Office of issuing bank for verification of authenticity of Bank Guarantee.
4. This Guarantee is required to be sent by Seller’s Bankers directly to the Head (LSTK-Finance), Engineers
rd
India Limited, EI Bhawan, 3 Floor, 1, Bhikaiji Cama Place, New Delhi-110066.
Page 66 of 434
JOB NO. A133
RESID UPGRADATION PROJECT – COKER BLOCK OF CPCL, CHENNAI
PRE-FILLED AGREED TERMS & CONDITIONS (FOR INDIGENOUS SUPPIERS)
BIDDER’s NAME : M/s._____________________________________________________________________________
RFQ No.: ________________________________________________________________________________________
Bidder’s Offer Ref. No. :____________________________________________________________________________
Tel No. : ____________________________________ Fax No.:_____________________________________________
Contact Person :________________________E-Mail:______________________Mobile No:_____________________
S. No. DESCRIPTION BIDDER’S CONFIRMATION

Quoted prices are on FOT despatch point basis inclusive of Packing &
a) Confirmed
Forwarding (P&F) charges.
Indicated
b) Specify Despatch Point in the enclosed Annexure – I
(Refer ANNEXURE – I)
Confirm that firm freight charges for transportation by road upto the
c) Project site including Service Tax & Education Cess, have been quoted in Confirmed
the price bid.
1 Confirm the freight charges for Recommended Spares for two years
d) normal operation & maintenance, if any, have been quoted extra in the Confirmed
Price Schedule separately.
Confirm the freight for all other supplies like mandatory spares
e) commissioning spares, tools and tackles etc., are included in freight for Confirmed
main equipment.
Marine-cum-erection insurance (MCE policy) shall be arranged by EIL and
f) Confirmed
therefore, the same shall not be included in the quoted prices.
Excise Duty + Education Cess: Indicated
a)
Tarrif sub heading no. (Refer ANNEXURE – I)
Present rate of Excise Duty + Education Cess payable extra against Indicated
b)
documentary evidence on finished products (including spares). (Refer ANNEXURE – I
Indicated
c) Maximum rate applicable (If present rate is nil or concessional)
2 (Refer ANNEXURE – I)
Clarify whether Excise Duty + Education Cess will be applicable on freight Indicated
d)
charges also. (Refer ANNEXURE – I)
Please indicate following break-up
Indicated
e) I) Cenvatable [Excise Duty + Educational Cess]
II) Non Cenvatable
Sales Tax:
Indicated
a) Sales tax payable extra Specify CST/ Tamilnadu VAT (TN VAT) on sale of
goods.
*In case of CST, C form shall be provided.
3 b)
In case of TN VAT, no concessional form shall be provided. TN VAT shall be Confirmed
reimbursed to bidder subject to submission of requisite documents
enabling owner to avail “INPUT CREDIT’ for the same.
EIL/CPCL shall avail credit of 100% of TN VAT on sale of goods. TN VAT shall
c) be reimbursed to bidder subject to submission of requisite documents Confirmed
enabling EIL/IOCL to avail ‘INPUT CREDIT’ for the same.
A133 ATC (IND)-REV 0 AUG13 PAGE 1 OF 7
Page 67 of 434
Clarify whether CST / TN VAT on sale of goods will be applicable on freight Indicated
d)
charges also. (Refer ANNEXURE – I)
Indigenous suppliers shall issue E1/E2 form on quarterly basis within 60
days after completion of each quarter based on “C” form no. provided by
e) Confirmed
PURCHASER. PURCHASER will provide original “C” form in exchange of
original E1/E2 form.
In case Excise Duty / CST / TN VAT are stated as not applicable on freight
charges presently, and if they are applicable at the time of delivery due to
4 Confirmed
any reasons other than statutory, the same will be borne by the Bidder.
Confirm compliance.
Only statutory variations, if any, in the present rate of Service Tax,
cenvatable excise duty, Central Sales Tax and VAT amount for which input
a) Confirmed
tax credit is available to the EIL under TN VAT Act etc. shall be to EIL’s
account subject to documentary evidence to be furnished by the bidder.
5 Statutory variations on non-cenvatable excise duty shall be to SUPPLIER’s
b) Confirmed
account.
However, any variation in Excise duty + Ed. Cess at the time of supplies for
c) any reasons, other than statutory, including variations due to turnover, Confirmed
shall be borne by bidder.
VAT on Works Contract:
Confirmed
a) Wherever site job is involved, bidders to quote their prices inclusive of TN
VAT on work contracts (if applicable).
Only single order covering complete scope of supply & services will be
6 b) issued (indicating supply and services portion separately). Order for supply Confirmed
and services shall not be split.
Any statutory variation on TN VAT on work contracts or change in rate of
c) TN VAT due to wrong assessment by supplier shall be to supplier’s Confirmed
account.
Service Tax:
a) Service Tax on freight charges shall be included in the quoted Freight Confirmed
Charges.
Percentage of Cenvatable Service Tax applicable extra on Site Work Indicated (Refer Annexure I)
Charges, , if applicable as per MR.
b)
Service tax shall be paid only against a cenvatable invoice issued in Confirmed
accordance with Service Tax rules.
Percentage of Cenvatable Service Tax applicable extra on Supervision Indicated (Refer Annexure I)
Charges, if applicable as per MR.
c)
7 Service tax shall be paid only against a cenvatable invoice issued in Confirmed
Percentage of Cenvatable Service Tax applicable extra on AMC Charges, if Indicated (Refer Annexure I)
applicable as per MR.
d)
Percentage of Cenvatable Service Tax applicable extra on Training Indicated (Refer Annexure I)
Charges, if applicable as per MR.
e)
Page 68 of 434
Entry Tax and Octroi:
Entry Tax / Octroi and Terminal Taxes are presently not applicable. If
8 a) applicable at a later date, same shall be payable extra at actual on Confirmed
production of necessary Documents/Invoices and information. Confirm
Compliance.
All new taxes/duties/cess/levies notified after the last date of submission
of final price bid/price implication, but within contractual delivery
/completion period, shall be to EIL’s account. These shall be reimbursed
a) against documentary evidence. Confirmed
9 However, in case of delay on account of supplier, any new or additional
taxes and duties imposed after contractual delivery shall be to supplier’s
account. Confirm compliance.
Any errors of interpretation of applicability of taxes/duties by bidders shall
b) Confirmed
be to bidders’ account.
Price Reduction Schedule:
a) Acceptance of applicable Price Reduction Schedule for delayed delivery as Confirmed
10 specified in RFQ.
In case of delay in delivery, bills shall be submitted after deducting price
b) Confirmed
reduction for delay.
Delivery Period / Completion Period:
11 Please confirm delivery/completion period as specified in RFQ Covering Confirmed
Letter.
Payment Terms:
a) Confirmed
Acceptance of applicable Payment terms as specified in RFQ.
Payment shall be released through Electronic Clearing System (ECS).
12 Furnished
In view of this, confirm that necessary details such as name of bank, bank
b) account no. etc. as per Mandate Form enclosed with RFQ, has been
furnished duly attested by your bank alongwith a cancelled cheque, along (Refer ANNEXURE – II)
with your offer (as per Annexure-II to ATC).
Part Order:
a) Confirmed
Acceptance of Part Order as per GPC (Indigenous).
13
Any charges quoted extra as lumpsum shall be applicable prorata on value
b) Confirmed
basis in the event of part order.
Repeat Order:
14 Acceptance of repeat order as per the clause specified in GPC (Indigenous), Confirmed
if applicable as per RFQ covering letter.
Performance Bank Guarantee:
a) Submission of Performance Bank Guarantee for 10% of total order value as Confirmed
15 per General Purchase Conditions (GPC)/ Instructions to Bidders.
Indemnity Bond/Corporate Guarantee in lieu of PBG shall not be
b) Confirmed
considered.
Guarantee :
16 Confirm acceptance of Guarantee period & terms as per Instruction to Confirmed
Bidders/General Purchase Conditions (Indigenous).
Firmness of prices:
17 The prices shall be firm and fixed and not subject to any variation, Confirmed
whatsoever.
Page 69 of 434
CIF Value of Built in Import Content and Import Duties:
a) In case of any Built-in import content considered in your offer, details of Confirmed
items to be furnished in Annexure-I.
Confirm that quoted prices are based on Merit rate of Customs duty, CVD,
b) Confirmed
Educational Cess and SAD as applicable.
18
Quoted prices shall remain firm and fixed on account of FE variation and
c) Confirmed
Custom Duty Variation, till complete execution of the order.
d) EIL shall not provide any import license. Noted
Quoted prices are after considering the benefit of CENVAT on CVD
e) Confirmed
including Edu. Cess.
Testing charges:
19 Confirm that quoted prices are inclusive of all testing charges as per Confirmed
Material Requisition.
Third Party Inspection charges:
a) Goods and services shall be subject to stagewise and final inspection by Confirmed
CEIL.
The TPI charges for Certification Engineers India Ltd. (CEIL) as TPI agency
20 b) Confirmed
shall be borne by EIL.
All built in import content shall be subject to inspection by TPI (out of M/s.
Lloyds Register (Country of origin), M/s.Bureau Veritas(BV) and M/s.TUV
c) Confirmed
Nord) for which charges are included in quoted price and no additional
charges shall be paid by EIL.
Validity:
a) Confirm that the Offer is valid for period as mentioned in RFQ covering Confirmed
letter from the bid due date/ extended due date.
21 For 2 years O&M spares, prices shall be kept valid for a period of 2 years
b) Confirmed
from the date of order of main equipment.
Confirm that Annual % escalation for subsequent two years beyond the
c) validity of 2 years for O&M spares have been quoted in format for prices Confirmed
for O&M spares.
Confirm acceptance in totality to the following :
 General Purchase Conditions (GPC) indigenous Confirmed
 Instructions to Bidders Confirmed
 Terms & Conditions for supervision of Erection, Testing & Confirmed
22
Commissioning (if applicable).
 Terms & Conditions for site work (if applicable). Confirmed
 Terms & Conditions for Annual Maintenance Contract (if applicable). Confirmed
 All other terms & conditions of RFQ covering letter. Confirmed
Confirm that you have furnished the following documents in the offer:
a) Integrity Pact Furnished
23
b) Solvency Certificate Furnished
c) Concurrent / Present Commitment Furnished
Page 70 of 434
Confirm the list, wherever required as per MR, has been submitted for
following :
a) Mandatory Spares (if specified in MR) Confirmed
b) Commissioning Spares (as included in main item) Confirmed
24
c) Special tools & tackles (if required) Confirmed
d) Recommended Spares for two years normal operation & maintenance (if Confirmed
required)
e) First fill of consumables, lubricant, etc Confirmed
Confirm that you have quoted strictly for items based on your registration
25 Confirmed
/ approval with EIL on the date of issue of RFQ.
Furnish Annual Report containing Balance Sheet & Profit & Loss Statement
26 Enclosed
for last one (01) years along with your unpriced offer.
Confirm that net worth of your company (bidder) during the last financial
27 Confirmed
year is positive.
Whether any of the Directors of Bidder is a relative of any Director of EIL
or the Bidder is a firm in which any Director of EIL or his relative is a
28 No
partner of the Bidder or a private company in which any Director of EIL is a
Director.
Please confirm you have not been banned or delisted by any Government
29 or Quasi Government agencies or PSUs. If you have been banned, then this Confirmed
fact must be clearly stated.
Deviations to Terms & Conditions shall lead to loading of prices or
30 Confirmed
rejection of offer as per Instructions to Bidders. Please confirm.
Printed terms and conditions, if any, appearing in quotation, shall not be
applicable in the event of order. In case of contradiction between the
31 Confirmed
confirmations given above and terms & conditions mentioned elsewhere
in the offer, the confirmation given herein above shall prevail.
BIDDER’S SIGNATURE & DATE : _______________________________

SEAL/ STAMP
Page 71 of 434
ANNEXURE – I TO PRE-FILLED AGREED TERMS & CONDITIONS (FOR INDIGENOUS SUPPIERS)
NAME OF BIDDER : _______________________________________________________________________
OFFER REFERANCE: ________________________________________________ DATED ________________
RFQ NO.: _______________________________________________________________________________
ITEM : ________________________________________________________________________________
PROJECT : RESID UPGRADATION PROJECT – COKER BLOCK OF CPCL, CHENNAI
1. Bidder confirms the following :DESPATCH POINT _________________________

2. Service Tax & Education Cess on Supervision Charges, if applicable. _________________________% EXTRA
3. Service Tax & Education Cess on Site Work Charges, if applicable. _________________________% EXTRA
4. Service Tax & Education Cess on AMC, if applicable.
5. Service Tax & Education Cess on Training, if applicable.

6. Rate of Excise Duty : Tariff Sub Heading No. ________________________________
7. Excise Duty + Education Cess _________________________% EXTRA
8. Maximum rate of Excise Duty applicable (If present rate is nil or
concessional) _________________________% EXTRA
9. Please indicate following break-up
a) Cenvatable [Excise Duty + Educational Cess] a) Cenvatable [ED+ Edu. Cess]________%
b) Non Cenvatable b) Non Cenvatable [ED+ Edu. Cess]____%
(In case bidder do not indicate anything, Excise Duty plus Edu. Cess
shall be considered as 100% cenvatable).
10. Excise Duty on freight charges (Tick one whichever is applicable). APPLICABLE
(In case no option is selected, ED on Freight Charges shall be
NOT APPLICABLE
considered to be not applicable)
11. Central Sales Tax against form ‘C’
_________________________% EXTRA
12. Tamilnadu VAT without concessional form.
(Applicable for supplies from TN State) _________________________% EXTRA
13. CST/TN VAT on freight charges (Tick one whichever is applicable). APPLICABLE
(In case no option is selected, CST/TN VAT on Freight Charges shall be
NOT APPLICABLE
considered to be not applicable)
14. Built-in import content in the offer (Tick one whichever is applicable).
APPLICABLE
(In case no option is selected, Buit-in import content shall be
considered to be not applicable) NOT APPLICABLE
15. Item detail of CIF Content
16.
(a) The bidder is a Micro or Small Enterprise under the Micro, Small & YES NO
Medium Enterprises Development Act, 2006.
(b) Documentary evidence required as per RFQ to avail preference to FURNISHED
MSEs.
(c) The MSEs is owned by SC/ST Entrepreneurs. YES NO

\
(d) Supporting documentary evidence with respect to MSEs is owned FURNISHED

by SC/ST Entrepreneurs as per RFQ to avail preference to MSEs
owned by SC/ST.
BIDDER’S SIGNATURE & DATE : _______________________________WITH SEAL/STAMP
Page 72 of 434
ANNEXURE - II TO AGREED TERMS & CONDITONS (INDIGINEOUS)
MANDATE FORM
1. Bidder Name :
2. Bidder Code: :
3. Address of the Bidder :

4. Particulars of Bank Account of Bidder :
a. Name of the Bank :

b. Name of the Branch and Address of the Branch :
c. Branch Code :
d. 9 – Digit MICR code Number of the Bank & Branch :

(As appearing in the MICR Cheque issued by the bank)
(Please do not give multicity cheque book code Number)
e. Type of account (Saving Bank, Current or Cash Credit) :

f. Account Number :
g. RGTS/ IFSC Code (11 digit) :

h. NEFT Code No. :
5. E-mail address of the Bidder :

6. Contact Person(s) of the Bidder :
I/ we declare that the particulars given above are correct and complete and I/ we accord our consent for
receiving all our payments through Electronic Mechanism.
____________________________________________________
(Signature and designation of the Authorised person(s) of Bidder)
Official seal of the Bidder

Place :
Date :
BANK CERTIFICATION
Certified that the particulars furnished above are correct as per our records.
Place :
Date :
______________________________________
Signature of the Authorised Official of the Bank
Bank’s Stamp
Page 73 of 434
Appendix ‐ A to ITB

Terms and conditions for Reverse Auction

1 Owner / Purchaser reserves the right to go in for reverse auction among the
technically and commercially acceptable bidders. The decision to conduct reverse
auction or not, will be conveyed to short listed bidders prior to opening of price bid.
In view of this, the bidders must quote most competitive prices in the first instance
itself.

2 Once the decision to conduct Reverse Auction is conveyed to the bidders, it will be
mandatory for the bidders to participate in Reverse Auction, failing which, the
bidder shall be liable for punitive action including but not limited to rejection of
offer, encashment of bid security, wherever applicable, etc. For this purpose, even
log‐in to the system shall be construed as participation.

3 Schedule for Reverse Auction

The Reverse Auction shall be scheduled for a duration of two hours. If a bidder
places a Bid in the last 5 minutes of scheduled closing time of the Auction, the
Auction time shall get extended automatically for another 5 minutes from the time
of the last Bid placed. In case, there is no Bid in the last 5 minutes of closing of the
Auction, the Auction shall be closed automatically without any extension.

The above provision shall apply to the bids in extended time also.
4 Auction process

- Each Bidder shall be assigned a Unique User Name & Password. The Bidders are
requested to change the Password and edit the information in the Registration
Page after the receipt of initial Password. All bids using the Login ID given to
the bidder will be deemed to have been submitted by the bidders. During the
auction, bidders will be referred by proxy names as B1, B2, B3, etc. and identity
will not be disclosed.
- The Reverse Auction shall be conducted based on the lowest evaluated price
out of all the techno‐commercially acceptable bidders, based on the prices
submitted along with the bid, as the opening price. The Bidder shall be able to
bid lower than the opening price in multiples of the decrement, but a Bidder
must always bid lower than the Lowest Bid.
- Only one bidder shall be at a particular position / rank, which means only one
L1.
Page 1 of 4
Page 74 of 434
- The Bidder shall be able to view the following on his screen along with the
necessary fields:

i) Opening Price.
ii) Leading Bid in the Auction, i.e., the lowest bid.
iii) Bid placed by him.
At no point of time will any bidder see the names of other bidders, or the
prices of bidders other than the lowest bid.

- A bidder can continue to revise his bid till the auction ends. However, the
Bidder cannot quote / Bid equal to the Leading / Lowest Bid. He must always
quote lower than the Leading / Lowest Bid.
- The evaluation criteria is based on Price alone. The Bidder who quotes the
lowest evaluated Price is determined as the lowest bidder.
- However, if Reverse Auction does not lead to any bid, EIL shall reserve the right
to award the job based on the lowest prices quoted in sealed envelope.
- Apart from the participating bidders, the Reverse Auction shall be visible, while
in progress to authorized officials of Owner / Purchaser, who are monitoring
the process.

5 Bid Price

The price shall be based on the scope, technical specifications and commercial
terms & conditions and other part of Bidding document agreed upto the date of
reverse auction.

The Opening Price and the Bid Decrement shall be displayed on the auction site at
the start of the auction. However, the bidders shall be able to view the auction
details, generally, 15 to 30 minutes before the start of actual auction.

6 Bid Decrement

Shall be 0.1% of the Opening Price. The bidder to lower the bid in multiples of the
bid decrement.

7 Bidding Currency

Bidding will be conducted in Indian Rupees (INR).

Page 2 of 4
Page 75 of 434
8 Bid Validity

The Bid Price submitted in the reverse auction shall be firm and valid for
acceptance for a period of 15 days from the date of reverse auction and shall not be
subject to any change whatsoever.

9 Bids once placed, binding on the Bidder

The bid of the bidder will be taken to be an offer to sell. Bids once submitted by
the bidder cannot be cancelled. The bidder is bound to sell the material/services at
the price that they bid. Should any bidder back out and not accept the order as per
the rates quoted, Owner / Purchaser reserves the right to take action as considered
appropriate, including encashment of bid security and placement on Holiday /
Negative list etc.

10 Lowest bid of a Bidder

During the process of reverse auction, the bidder may submit several bids. In case
the bidder submits such multiple bids, the lowest bid will be considered as the
bidder’s final offer to sell.

11 Submission of final prices by successful bidder
Successful bidder shall be required to submit the final prices, quoted during the
Reverse Auction in an appropriate format within two days of the completion of
Auction to EIL, duly signed and stamped as token of acceptance without any new
condition. However, in case the reverse auction is for a package, within 2 working
days after completion of the online event of Reverse Auction, the successful bidder
would submit their cost break down as per the price format for the final price
arrived at after reverse auction.

12 General

- The bidders may quote from their own offices/ place of their choice. Internet
connectivity shall have to be ensured by each agency on its own. In extreme
case of failure of internet connectivity, (due to unforeseen circumstances other
than power failure), communication shall have to be sent by fax/E‐mail/ phone
immediately. Owner / Purchaser shall extend the bidding time, in such a case,
appropriately (generally by half an hour) but not more than once per bidder.
- The Bidder, himself or any of his representatives, shall not involve in Price
manipulation of any kind directly or indirectly by communicating with other
bidder.

Page 3 of 4
Page 76 of 434
- The Bidder shall not divulge either his Bids or any other exclusive details of
Owner / Purchaser to any other party.

- Bidders agree to non‐disclosure of trade information regarding the purchase,
identity of EIL, bid process, bid technology, bid documentation and bid details.

- Owner / Purchaser can decide to extend, reschedule or cancel any Auction. No
bidder can claim any kind of compensation on account of the same.

- Owner / Purchaser shall not have any liability to Bidders for any interruption or
delay in access to the site irrespective of the cause.

- Owner / Purchaser shall not be responsible for any direct / indirect /
consequential losses / damages, on account of systems problems, inability to
use the system, loss of electronic information etc.

- Owner / Purchaser shall be at liberty to cancel the reverse auction process /
tender at any time, before ordering, without assigning any reason.

- Owner / Purchaser’s decision on award of Contract shall be final and binding on
all the Bidders.

Page 4 of 4
Page 77 of 434


 
  

   
    


        

        
  
 


 
 

 

     
     


 

  
Page 78 of 434
 



    
 













    
    

    

    
    
 
 




    
    
    
    
    
 

    
    
    
    
    
 
 
  


 
 
  






 
  
    
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 



    








 
  
    
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 




    
 

   
   
 
   

   

   
 
   
 


  
 
 

 

  


   
  
   
  
   
  
   
  
   
  

   

   
 
   














 
  
    
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 

NOZZLES AND CONNECTIONS GENERAL NOTES SPECIFICATIONS DESIGN DATA
MARK QTY
NOM.
SCH./THK
FLANGES PROJECTION PAD
SERVICE
UNLESS STATED OTHER WISE X DENOTES APPLICABLITY CODE ASME SEC. VIII DIV.1 2010+ADDENDA 2011
DIA CLASS TYPE FACING NOTE-4 WxT 1 ALL DIMENSIONS ARE IN MM UNLESS STATED OTHER WISE. WORKING PRESSURE (kg/cm2g) 13.9
INT:
SEE 2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. DESIGN PRESSURE (NOTE-11) (kg/cm2g) 16.8 EXT F.V. @ 190°C
1 1 600 22 THK. 300 WN RF 255X22 MANHOLE + B.F.+DAVIT 0
TOP/
DWG. 3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. WORKING TEMPERATURE ( C) 40
4 (A) FOR NOZZLES ON SHELL PROJECTIONS ARE REFERRED FROM VESSEL JACOBS SPECIFICATIONS DESIGN TEMPERATURE
0
( C) 85
7 1 80 160 300 WN RF 1525 55X22 VAPOR OUTLET TO 86-E-06 CENTER LINE TO FLANGE CONTACT FACE.
X GENERAL SPECIFICATION FOR PRESSURE VESSELS 44NC-4600-0000-V.02.-0101-A4 MDMT (0C) 18
8 1 200 80 300 WN RF 1525 95X22

VENTILATION NOZZLE + B.F. 4 (B) FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM HEAD T.L TO X GENERAL SPECIFICATION FOR SHOP & FIELD PAINTING 44NC-4600-0000-V.02.-0111-A4 CORROSION ALLLOWANCE (MM) 3 FOR SHELL 6 FOR BOOT
(NOTE-17) FLANGE CONTACT FACE. GENERAL SPECIFICATION FOR INSULATION 44NC-4600-0000-V.02.-0112-A4 TYPE OF HEAD 2:1 ELLIPSOIDAL
11 1 250 60 300 WN RF 1525 120X22 FEED FROM 86-E-15

5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER X GENERAL SPECIFICATION - MATERIAL SPECIFICATIONS 44NC-4600-0000-V.02.-0114-A4 JOINT EFFICIENCY SHELL/BOOT SHELL 1.0 HEAD/BOOT HEAD 1.0
CONSTRUCTION.
X STANDARD SPECIFICATION FOR BQ CS PLATES 44NC-4600-0000-V.02.-0117-A4 RADIOGRAPHY (NOTE-12 & 18) SHELL/BOOT SHELL FULL HEAD/BOOT HEAD FULL
12 1 100 120 300 WN RF 1525 55X22 FEED FROM 86-C-07

6 FLANGE GASKET FACE SHALL BE 125 AARH FINISH. X SUPPLEMENTARY SPECIFICATION FOR CS VESSELS 44NC-4600-0000-V.02.-0120-A4 POST WELD HEAT TREATMENT YES (COMPLETE VESSEL) (NOTE-16)
X JOB SPECIFICATION FOR PRESSURE VESSELS 44NC-4600-0000-V.02.-0141-A4 HEAT TREATMENT HEAD (AS PER SPEC.)
LIQUID BOTTOM OUTLET TO 86-G- 7 DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS PER OPERATING MEDIUM DEBUTANIZER OVERHEAD RECEIVER
17 1 200 80 300 WN RF 1410 60X22
09A/B ASME B16.5 AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER ASME B16.47 JACOBS STANDARDS SP. GRAVITY 0.530
SERIES `B' UNLESS SPECIFIED OTHERWISE.
18 1 50 XXS 300 WN RF
SEE
_ WATER LIQUID OUTLET TO 86-E-61
X GENERAL TOLERANCES FOR PRESSURE VESSELS IND VSD 001 WIND SPECIFICATION IS 875
DWG. 8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING ID OF X MANWAY DAVIT (FOR VERTICAL/HORIZONTAL MANHOLE) IND VSD 002/003 SEISMIC IS 1893 & SITE SPECTRA
50.8I/D NOZZLE PIPE. DETAIL OF VESSEL/COLUMN TOP DAVIT IND VSD 004 CAPACITY (M3) 33.1
33 1 _ 300 LWN RF 1525 _ SAFETY VALVE
(HOLD) 9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2 NOS. 40 x 6 THK DETAIL OF SKIRT OPENING FOR VESSEL & COLUMN IND VSD 006 PAINTING/CLEANING AS PER PAINTING JOB SPEC.
0
SEE _ FLATS 90 APART. DETAIL OF SKIRT BASE FOR VESSEL & COLUMN IND VSD 007 INSULATION THICKNESS (mm) NIL HOT COLD
35 1 50 160 300 WN RF UTILITY CONNECTION
DWG. 10 ALL INTERNALS SHALL BE SIZED TO PASS THROUGH NEAREST MANHOLE LEG SUPPORT FOR VERTICAL VESSEL (2 SHEETS) IND VSD 008 FIRE PROOFING YES NO
37 1
50
160 300 WN RF 1525
_
PRESSURE CONTROLLER
EASILY.
X SADDLE SUPPORT FOR HORIZONTAL VESSEL(7 SHEETS) IND VSD 009 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL / VERTICAL (AT TOP)
(HOLD) 11 2
VESSEL IS SUBJECTED TO STEAM OUT CONDITION OF 0.5 Kg/Cm (g) AT LUG SUPPORTS (2 SHEETS) IND VSD 010 PRESSURE (NEW & COLD) 21.84
45 50 SEE 1900C PIPE LEG SUPPORT IND VSD 011 INSPECTION BY EIL CIB X TPI
2 160 300 WN RF _ LEVEL GLASS / GAUGE
A-B (HOLD) DWG. 12 ALL NOZZLE FABRICATED FROM PLATES SHALL BE 100% RADIOGRAPHED. X MINIMUM NOZZLE WALL THICKNESS IND VSD 012
MATERIAL OF CONSTRUCTION
47
2
80
160 300 WN RF
SEE
55X22 LEVEL CONTROLLER
13 ALSO REFER 44NC-4600-00/V.02/0164/A3 FOR OTHER APPLICABLE NOTES. X REINFORCING PLATES FOR NOZZLES. (C.A. 3mm) IND VSD 018 (AS PER ASME / IS OR EQUIVALENT)
A-B (HOLD) DWG. 14 VENDOR SHALL INDICATE C.G OF EQUIPMENT IN FABRICATION DWGS. X NAME PLATE BRACKET IND VSD 020
45
2
50
XXS 300 WN RF
SEE
_ LEVEL GLASS / GAUGE
15 MANDATORY & COMISSIONING SPARES SHALL BE SUPPLIED BY FABRICATOR. X STANDARD NAME PLATE FOR VESSEL IND VSD 021 SHELL /BOOT SA 516 GR.60 *
C-D (HOLD) DWG. INSULATION SUPPORTS FOR VESSELS (HOT) IND VSD 022 REINFORCEMENT PAD/INSERT PLATE SA 516 GR.60
47
2
80
XXS 300 WN RF
SEE
16 HARDNESS OF BASE METAL, WELD & HAZ SHALL NOT EXCEED 200 BHN X STANDARD NOZZLE PROJECTION IND VSD 024 HEADS /BOOT HEAD SA 516 GR.60 *
C-D (HOLD) DWG. AFTER PWHT. LIFTING TRUNNIONS IND VSD 025 SHELL FLANGES -
SEE _ 17 MOUNT 2" VENT NOZZLE `50' ON THE BLIND FLANGE OF VENTILATION HANDHOLE WITH HINGED COVER IND VSD 029 NOZZLE FLANGES/LWN NOZZLES/BF SA 105 *
50 1 50 160 300 WN RF VENT (NOTE-17) NOZZLE-8.
DWG. STANDARD INTERNAL PLATE FLANGES IND VSD 030 NOZZLE NECK UPTO 300 NB SA 106 GR.B * (SEAMLESS)
18 FULL RADIOGRAPHY IMPLIES 100% RADIOGRAPHY OF ALL BUTT WELDS. VORTEX BREAKERS (FLUSH TYPE NOZZLES) IND VSD 033 NOZZLE NECK ABOVE 300 NB SA 516 GR.60 *
19 THE EQUIPMENT IS IN SOUR SERVICE. NACE MR 0103 REQUIREMENT X VORTEX BREAKERS (NOZZLE WITH INTERNAL PROJECTION) IND VSD 034 PIPE FITTINGS SA 234 GR. WPB *
TO BE METIN ADDITION TO REQUIREMENT AT CLAUSE 1.1 OF STANDARD DEMISTERS TYPE-I (VESSEL DIA<800mm) IND VSD 036 SPIRAL WOUND GASKET WITH SS 316L
SPECIFICATION OF 44 NC-4600-0000-V.02-0114-A4 STANDARD DEMISTERS TYPE-II(VESSEL DIA> 800mm) IND VSD 037 METAL WINDINGS AND NON ASBOSTOS
GASKET EXTERNAL
STANDARD DEMISTERS TYPE-III IND VSD 038 FILLER MATERIAL WITH SS 316L OUTER &
STANDARD DEMISTERS TYPE-IV IND VSD 039 INNER RING AS PER ASME B16.20
X STANDARD BOLT HOLE ORIENTATION IND VSD 040 GASKET INTERNAL -

EARTHING BOSS IND VSD 041 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7M / SA 194 GR.2HM
X LADDER RUNGS INSIDE VESSELS AND COLUMNS IND VSD 043 INTERNAL STUDS/BOLTS/NUTS -
FOUNDATION TEMPLATE (2 SHEETS) IND VSD 044 SKIRT/ SUPPORT IS 2062 Gr.B
SUPPORT FOR INTERNAL DISTRIBUTOR PIPES IND VSD 045 SKIRT/ SUPPORT BASE IS 2062 Gr.B
X SUPPORTS FOR INTERNAL FEED PIPE IND VSD 046/047 INTERNAL PARTS (WELDED) SA 516 GR.60 */SA 106 GR.B *
LIFTING LUG TOP HEAD TYPE IND VSD 048 INTERNAL PARTS (BOLTED) -
X LIFTING LUG FOR HORIZONTAL VESSEL IND VSD 050 CLIPS & ATTACHMENTS ((EXT.) DIRECTLY WELDED SA 516 GR.60
X TYP. NOZZLE FLANGE TO NECK JOINT IND VSD 051 CLIPS & ATTACHMENTS (EXT.) WELDED OVER PAD IS 2062 Gr.B
X RECOMMENDED WELD EDGE PREPARATION FOR BUTT WELDS IND VSD 052 PAD FOR EXTERNAL ATTACHMENTS SA 516 GR.60
ALLOY LINER DETAIL (2SHEETS) IND VSD 053 NAME PLATE SS 304
SUPPORT RING AND BOLTING BAR IND VSD 055 NAME PLATE BRACKET SA 516 GR.60
SUPPORT RING SIZES FOR PACKED TOWERS IND VSD 056 WRAPPER PLATE SA 516 GR.60
INSULATION SUPPORTS FOR VERTICAL VESSEL IND VSD 057 BRACKET SA 516 GR.60
MANWAY DAVIT
INSULATION SUPPORTS FOR HORIZONTAL VESSEL IND VSD 058 ALL OTHER PARTS IS 2062 Gr.B
FIRE PROOFING SUPPORT IND VSD 062 EARTHING LUGS IS 2062 Gr.B
INLET DEFLECTOR BAFFLE IND VSD 064 LIFTING LUGS IS 2062 Gr.B
X EARTHING LUG IND VSD 080
EIL REFERENCE DRAWINGS

NOZZLE ORIENTATIONS
LADDERS/PLATFORM CLEATS
PIPE SUPPORT CLEATS
DEMISTER DATA SHEET N.A
MONKEY LADDER N.A
* NACE (REFER NOTE-16 &19)
APPROVAL
PMC REVIEW
RECORDS
SOUR SERVICE (NACE MR0103)
PMC CONTROL CODE -V21

STATUTORY REGULATIONS
LICENSORS SPECIFICATION INDIAN BOILER REGULATIONS (IBR)
LICENSORS STANDARDS
FOUNDATION LOADING DATA (OPERATING CONDITION) HOLD UPS DEPARTMENT OF EXPLOSIVES, NAGPUR (CCOE)
TYPE
MAX MOMENT AT BASE (M)
MAX. SHEAR FORCE AT BASE (H) (kg) X NOZZLE ORIENTATIONS X SIZE OF NOZZLES 33,37,45A-D & 47A-D APPROXIMATE WEIGHT (kgs)
X NOZZLE ELEVATIONS(AS MARKED) X PIPE SUPPORT CLEATS
(kgm) (PER ITEM)
DBE _ _ X SLIDING/FIXED SUPPORT X LADDER/PLATFORM CLEATS ERECTION 14,200 OPERATING 32,500

DETAILS OF INTERNALS TRAY SUPPORT/BOLTING BARS
SEISMIC
PIPE DAVIT
MCE _ _ HYDROTEST(SHOP) 47,400 HYDROTEST ( FIELD ) 48,700
WIND _ _ NUMBER OF ITEMS : ONE
FILE NAME A133-086-16-46-DS-3018-B-1
DESIGN DATA fMtkbu MkVk

ENGINEERS INDIA LIMITED JOB NO: A133 UNIT - 86 DRAWING NUMBER REV
DEBUTANIZER OVERHEAD
CLIENT : M/s. CPCL
fMC;wVsukbtj vksojgsM fjlhoj A133-086-16-46-DS-3018 B
NEW DELHI B 24.09.2013 REVISED AND ISSUED FOR BIDS/ENGG. GCP SUU/PKP BBC RECEIVER
A 26.05.11 ISSUED FOR BIDS/ENGG. SBS AY/PP TG
PLANT : COKER BLOCK, CPCL
REV DATE REVISION BY CHECKED APPROVED
ITEM NO. 86-C-27 ÁbVe ua 86&lh&27 SHEET 1 OF 2
FORMAT NO.3-1646-0113 REV.1 (22.12.2009) A3-420 X 297
Page 82 of 434
Page 83 of 434
JOB NO.: A133 UNIT-86
CLIENT : M/S CPCL fMC;wVsukbtj
vksojgsM fjlhoj
MARK QTY
NOM.
SCH./THK
SERVICE
DIA CLASS TYPE FACING NOTE-4 WxT 1 ALL DIMENSIONS ARE IN MM UNLESS STATED OTHER WISE. WORKING PRESSURE (kg/cm2g) 0.1-1.7
INT:
SEE 2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. DESIGN PRESSURE (kg/cm2g) 3.5 EXT FV
C1 1 200 100 150 WN RF 95X18 INLET 0
TOP/
DWG. 3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. WORKING TEMPERATURE ( C) 40-180
SEE 4 (A) FOR NOZZLES ON SHELL PROJECTIONS ARE REFERRED FROM HORIZONTAL JACOBS SPECIFICATIONS DESIGN TEMPERATURE
0
( C) 200
C2 1 50 XXS 150 WN RF _ VENT WITH BLIND FLAGE
DWG. PLANE TO FLANGE CONTACT FACE.
C3 1 80 XXS 150 WN RF
SEE
_ VENT TO FLARE
4 (B) FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM VERTICAL PLANE X GENERAL SPECIFICATION FOR SHOP & FIELD PAINTING 44NC-4600-0000-V.02.-0111-A4 CORROSION ALLLOWANCE (MM) 6 (INT) 1.5 (EXT)
DWG. TO FLANGE CONTACT FACE. GENERAL SPECIFICATION FOR INSULATION 44NC-4600-0000-V.02.-0112-A4 TYPE OF HEAD 2:1 ELLIPSOIDAL
C4 1 50 XXS 150 WN RF
SEE
_ STEAM OUT/UC
5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER X GENERAL SPECIFICATION - MATERIAL SPECIFICATIONS 44NC-4600-0000-V.02.-0114-A4 JOINT EFFICIENCY SHELL 1.0 HEAD 1.0
DWG. CONSTRUCTION.
X STANDARD SPECIFICATION FOR BQ CS PLATES 44NC-4600-0000-V.02.-0117-A4 RADIOGRAPHY (NOTE-11 & 16) SHELL FULL HEAD FULL
C5-6 2 80 XXS 150 WN RF

SEE
55X18 LP STEAM/CW IN/OUT
DWG. 7 DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS PER ASME X JOB SPECIFICATION FOR VESSELS 44NC-4600-0000-V.02.-0141-A4 HEAT TREATMENT HEAD (AS PER SPEC.)
SEE B16.5 AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER ASME B16.47 OPERATING MEDIUM HYDROCARBON DRAINS
C7 1 50 XXS 150 WN RF
DWG.
_ SERVICE WATER SERIES `B' UNLESS SPECIFIED OTHERWISE. JACOBS STANDARDS SP. GRAVITY 0.6 - 1.0
A1 1 750 18 THK. 150 WN RF

SEE
350X18 HOUSING + B.F.
8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING ID OF X GENERAL TOLERANCES FOR PRESSURE VESSELS IND VSD 001 WIND SPECIFICATION IS 875
DWG. NOZZLE PIPE. X MANWAY DAVIT (FOR VERTICAL/HORIZONTAL MANHOLE) IND VSD 002/003 SEISMIC IS 1893 & SITE SPECTRA
SEE 9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2 NOS. 40 x 6 THK DETAIL OF VESSEL/COLUMN TOP DAVIT IND VSD 004 CAPACITY (M3) 51.6
A3 1 600 (H) 18 THK. 150 WN RF 250X18 HOUSING + B.F.
DWG. FLATS 900 APART. DETAIL OF SKIRT OPENING FOR VESSEL & COLUMN IND VSD 006 PAINTING/CLEANING AS PER PAINTING JOB SPEC.
50 SEE _ 10 ALL INTERNALS SHALL BE SIZED TO PASS THROUGH NEAREST EASILY DETAIL OF SKIRT BASE FOR VESSEL & COLUMN IND VSD 007 INSULATION THICKNESS (mm) NO HOT COLD
R1 1 XXS 300 WN RF THERMOCOUPLE MANHOLE.
(HOLD) DWG. LEG SUPPORT FOR VERTICAL VESSEL (2 SHEETS) IND VSD 008 FIRE PROOFING YES NO
50 SEE _ 11 FULL RADIOGRAPHY WHEN SPECIFIED SHALL IMPLY 100% RADIOGRAPHY OF SADDLE SUPPORT FOR HORIZONTAL VESSEL(7 SHEETS) IND VSD 009 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL / VERTICAL (AT TOP)
R4 1 XXS 300 WN RF PRESSURE TRANSMITTER ALL BUTT WELDS.
(HOLD) DWG. LUG SUPPORTS (2 SHEETS) IND VSD 010 PRESSURE (NEW & COLD) 4.55
50 SEE _ 12 VESSEL IS SUBJECTED TO STEAM OUT CONDITION OF 0.5 Kg/Cm2(g)/ FV AT PIPE LEG SUPPORT IND VSD 011 INSPECTION BY EIL CIB X TPI
R2-3 2 XXS 300 WN RF LEVEL TRANSMITTER
X MINIMUM NOZZLE WALL THICKNESS
0
(HOLD) DWG. 190 C IND VSD 012
A2 1
700
18 THK. 150 WN RF
SEE
350X18 HOUSING + B.F.
13 ALSO REFER 44NC-4600-00/V.02/0164/A3 FOR OTHER APPLICABLE NOTES. X REINFORCING PLATES FOR NOZZLES. (C.A. 3mm) IND VSD 018 (AS PER ASME / IS OR EQUIVALENT)
(HOLD) DWG. 14 VENDOR SHALL INDICATE C.G OF EQUIPMENT IN FABRICATION DWGS. X NAME PLATE BRACKET IND VSD 020
15 MANDATORY & COMISSIONING SPARES SHALL BE SUPPLIED BY FABRICATOR. X STANDARD NAME PLATE FOR VESSEL IND VSD 021 SHELL /BOOT SA 516 GR.60 *
INSULATION SUPPORTS FOR VESSELS (HOT) IND VSD 022 REINFORCEMENT PAD SA 516 GR.60
16 ALL NOZZLES FABRICATED FROM PLATES SHALL BE 100% RADIOGRAPHED. X STANDARD NOZZLE PROJECTION IND VSD 024 HEADS SA 516 GR.60 *
LIFTING TRUNNIONS IND VSD 025 SHELL FLANGES -
17 VESSEL IS CATHODICALLY PROTECTED (BY OTHERS). CLEATS FOR CATHODIC HANDHOLE WITH HINGED COVER IND VSD 029 NOZZLE FLANGES/LWN NOZZLES/B.F SA 105 *
PROTECTION AS SHOWN IN SHT. 3 OF 3 SHALL BE PROVIDED BY VENDOR.
X STANDARD INTERNAL PLATE FLANGES IND VSD 030 NOZZLE NECK UPTO 300 NB SA 106 GR.B * (SEAMLESS)
18 MOUNTING BLIND FLANGE FOR NOZZLE 'A3' WITH PUMP ASSEMBLY, 'PUMP VORTEX BREAKERS (FLUSH TYPE NOZZLES) IND VSD 033 NOZZLE NECK ABOVE 300 NB SA 516 GR.60 *
DISCHARGE NOZZLE, BOLTING & GASKET SHALL BE SUPPLIED BY PUMP VORTEX BREAKERS (NOZZLE WITH INTERNAL PROJECTION) IND VSD 034 PIPE FITTINGS SA 234 GR. WPB *
VENDOR.
STANDARD DEMISTERS TYPE-I (VESSEL DIA<800mm) IND VSD 036 SPIRAL WOUND GASKET WITH SS 316L
19 DESIGN DATE OF COOLING WATER COIL STANDARD DEMISTERS TYPE-II(VESSEL DIA> 800mm) IND VSD 037 METAL WINDINGS AND NON ASBESTOS
GASKET EXTERNAL
DESIGN PRESSURE (kg/cm2g) -10/FV STANDARD DEMISTERS TYPE-III IND VSD 038 FILLER MATERIAL WITH SS 316L OUTER &
INNER RING AS PER ASME B16.20
DESIGN TEMPERATURE (0C) - 225 STANDARD DEMISTERS TYPE-IV IND VSD 039
WORKING PRESSURE (kg/cm2g) - 4.6 X STANDARD BOLT HOLE ORIENTATION IND VSD 040 GASKET INTERNAL -
0
WORKING TEMPERATURE ( C) - 33 - 190 EARTHING BOSS IND VSD 041 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7M / SA 194 GR.2HM
TEST PRESSURE (kg/cm2g) - 15 LADDER RUNGS INSIDE VESSELS AND COLUMNS IND VSD 043 INTERNAL STUDS/BOLTS/NUTS SS 316L
SIZE OF COIL (MM) (HOLD) - 80 NB , SCH.XXS FOUNDATION TEMPLATE (2 SHEETS) IND VSD 044 SKIRT/ SUPPORT -
LENGTH OF COIL (m) - 90 SUPPORT FOR INTERNAL DISTRIBUTOR PIPES IND VSD 045 SKIRT/ SUPPORT BASE -
20 FABRICATOR SHALL DEVELOP COIL LAYOUT FOR SUBMERGED COIL LENGTH X SUPPORTS FOR INTERNAL FEED PIPE IND VSD 046/047 INTERNAL PARTS (WELDED) SA 516 GR.60 */SA 106. GR.B *
OF 90m (MIN). COIL SHOULD BE LOCATED AT MIN. DISTANCE FROM VESSEL LIFTING LUG TOP HEAD TYPE IND VSD 048 INTERNAL PARTS (BOLTED) SA 516 GR.60 */SA 106. GR.B *
BOTTOM. COIL SHOULD COVER FULL LENGTH OF VESSEL INCLUDING AREA
NEAR PUMP IMPELLER. SUPPORTS FOR COIL SUPPORTING SHALL BE X LIFTING LUG FOR HORIZONTAL VESSEL IND VSD 050 CLIPS & ATTACHMENTS ((EXT.) DIRECTLY WELDED SA 516 GR.60
DESIGNED AND DETAILED OUT BY FABRICATOR. QUOTED PRICE SHOULD X TYP. NOZZLE FLANGE TO NECK JOINT IND VSD 051 CLIPS & ATTACHMENTS (EXT.) WELDED OVER PAD IS 2062 Gr.B
INCLUDE THE SAME INCLUDING COIL SUPPORT. X RECOMMENDED WELD EDGE PREPARATION FOR BUTT WELDS IND VSD 052 PAD FOR EXTERNAL ATTACHMENTS SA 516 GR.60
21 THE EQUIPMENT IS IN SOUR SERVICE. NACE MR0103 REQUIREMENTS ALLOY LINER DETAIL (2SHEETS) IND VSD 053 NAME PLATE SS 304
TO BE MET IN ADDITION TO REQUIREMENTS AT CL.1.1 OF SUPPORT RING AND BOLTING BAR IND VSD 055 NAME PLATE BRACKET SA 516 GR.60
SPECIFICATION 44NC-4000-0000-V.02-0114-A4.
22 PRIMER AND FINISH PAINT SHALL BE DONE BY VENDOR AND SHALL BE AS INSULATION SUPPORTS FOR VERTICAL VESSEL IND VSD 057 LIFTING LUGS IS 2062 Gr.B
PER PAINTING SPECIFICATION. INSULATION SUPPORTS FOR HORIZONTAL VESSEL IND VSD 058 BRACKET SA 516 GR.60
MANWAY DAVIT
23 HARDNESS OF BASE METAL, WELDS & HAZ SHALL NOT EXCEED 200 BHN FIRE PROOFING SUPPORT IND VSD 062 ALL OTHER PARTS IS 2062 Gr.B
AFTER PWHT. INLET DEFLECTOR BAFFLE IND VSD 064
24 THE BOOT DIMENSION TO BE FINALISED BY CONSIDERING ATLEAST 300MM X EARTHING LUG IND VSD 080
LIQUID LEVEL AVAILABLE BETWEEN VESSEL BTL AND EYE OF IMPELLER.
25 STIFFENER RING SHALL NOT BE WELDEDTO SHELL TILL ALL THE FOULING EIL REFERENCE DRAWINGS
W.R.T. THE PIPING AND STRUCTURAL CLIPS ARE CLEARED / RESOLVED. NOZZLE ORIENTATIONS
LADDERS/PLATFORM CLEATS N.A. *NACE (REFER NOTE-21 & 23)
PIPE SUPPORT CLEATS N.A.
DEMISTER DATA SHEET N.A.
APPROVAL MONKEY LADDER N.A.
PMC REVIEW
RECORDS
@ EXCLUDING PUMP AND SAND OVER VESSEL

VESSEL SHALL BE LOCATED IN A RCC PIT & SAND
PACKED WITH VIBRO COMPRESSION WITH LEAN
CONCRETE TOP (100mm THK.) THE PIT SHALL
LICENSORS SPECIFICATIONS INDIAN BOILER REGULATIONS (IBR)
FOUNDATION LOADING DATA (OPERATING CONDITION) HAVE A MIN. CLEARANCE OF 2000mm (HOLD) HOLD UPS DEPARTMENT OF EXPLOSIVES, NAGPUR (CCOE)
ALL AROUND THE VESSEL SURFACE.
LICENSORS STANDARDS
TYPE
MAX. SHEAR FORCE AT BASE (H) (kg) X NOZZLE ORIENTATIONS X SIZE OF NOZZLES A3,R1-4 & A2 APPROXIMATE WEIGHT (kgs)
X NOZZLE ELEVATIONS(AS MARKED)
(kgm) (PER ITEM)
PIPE SUPPORT CLEATS
SUPPORT HEIGHT LADDER/PLATFORM CLEATS
DBE _ _ ERECTION 18,200 OPERATING @ 61,300
SEISMIC X DETAILS OF INTERNALS TRAY SUPPORT/BOLTING BARS
PIPE DAVIT
MCE _ _ VESSEL IS IN SOUR SERVICE HYDROTEST(SHOP) 69,800 HYDROTEST ( FIELD ) @ 69,800
FILE NAME A133-086-16-46-DS-3029-B-1

50

CLIENT : M/s. CPCL CLOSED BLOWDOWN DRUM DyksTM CyksMkmu Mªe A133-086-16-46-DS-3029 B
NEW DELHI B 30.09.2013 REVISED AND ISSUED FOR BIDS/ENGG. GCP SUU/PKP BBC
A 20.06.11 ISSUED FOR BIDS/ENGG. GCP AY/PKP TG
ITEM NO. 86-C-51 86&lh&51 SHEET 1 OF 3
FORMAT NO.3-1646-0113 REV.1 (22.12.2009) A3-420 X 297
Page 84 of 434
Page 85 of 434
JOB NO.: A133 UNIT - 86
CLIENT : M/S. CPCL
PLANT :
CATHODIC PROTECTION CLEAT (TOTAL 4NOS.)
Page 86 of 434
A133 UNIT - 86
M/S. CPCL
The drawing, design and details given below on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited, or used, except in the limited way permitted by written consent given by the lender

MARK QTY
NOM.
SCH./THK
SERVICE
DIA CLASS TYPE FACING NOTE-4 WxT 1 ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE STATED. WORKING PRESSURE (kg/cm2g) TOP 1.5 BOT _
INT:
SEE 2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. DESIGN PRESSURE (kg/cm2g) 7 EXT F.V. AT 190°C
1 1 600 16THK. 150 WN RF 250X16 MANHOLE + B.F.+DAVIT 0
TOP/
DWG. 3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. WORKING TEMPERATURE ( C) TOP 193 BOT _
0
( C) 250
7 1 80 160 150 WN RF 2120 55X16 VAPOR OUTLET TO BALANCE LINE CENTER LINE TO FLANGE CONTACT FACE.
8 1 200 80 150 WN RF 2120 85X16 VENTILATION NOZZLE +BF

4 (B) FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM HEAD T.L TO X GENERAL SPECIFICATION FOR SHOP & FIELD PAINTING 44NC-4600-0000-V.02.-0111-A4 CORROSION ALLLOWANCE (MM) 3
FLANGE CONTACT FACE. GENERAL SPECIFICATION FOR INSULATION 44NC-4600-0000-V.02.-0112-A4 TYPE OF HEAD 2:1 ELLIPSOIDAL
5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER GENERAL SPECIFICATION - MATERIAL SPECIFICATIONS 44NC-4600-0000-V.02.-0114-A4 JOINT EFFICIENCY SHELL 0.85 HEAD 1.0
11 1 350 16THK. 150 WN RF 2120 140X16 FEED FROM OSBL CONSTRUCTION.
X STANDARD SPECIFICATION FOR BQ CS PLATES 44NC-4600-0000-V.02.-0117-A4 RADIOGRAPHY (NOTE-17) SHELL SPOT HEAD FULL
17 1 350 16THK. 150 WN RF 2050 140X16 BOTTOM OUTLET TO 86-G-02A/B

6 FLANGE GASKET FACE SHALL BE 125 AARH FINISH. X SUPPLEMENTARY SPECIFICATION FOR CS VESSELS 44NC-4600-0000-V.02.-0120-A4 POST WELD HEAT TREATMENT NO
7 DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS PER X JOB SPEC. FOR VESSELS 44NC-4600-0000-V.02.-0141-A4 HEAT TREATMENT HEAD (AS PER SPEC.)
ASME B16.5 AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER ASME B16.47 OPERATING MEDIUM COKER UNIT FEED SURGE DRUM
20 1 200 (H) 80 150 WN RF 2120 85X16 RETURN FROM 86-G-02A/B SERIES `B' UNLESS SPECIFIED OTHERWISE. JACOBS STANDARDS SP. GRAVITY 0.930
31 1 80 160 150 WN RF 1970 55X16 DRAIN

NOZZLE PIPE. X MANWAY DAVIT (FOR VERTICAL/HORIZOTAL MANHOLE) IND VSD 002/003 SEISMIC IS 1893 & SITE SPECTRA
152.4 9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2 NOS. 40 x 6 THK DETAIL OF VESSEL/COLUMN TOP DAVIT IND VSD 004 CAPACITY (M3) 122.2
33 1 _ 150 LWN RF 2120 _ SAFETY VALVE
I/D (H) FLATS 900 APART. DETAIL OF SKIRT OPENING FOR VESSEL & COLUMN IND VSD 006 PAINTING/CLEANING AS PER PAINTING SPEC.
SEE _ 10 ALSO REFER 44NC-4600-0000-V02-0164 A3 FOR OTHER APPLICABLE NOTES. DETAIL OF SKIRT BASE FOR VESSEL & COLUMN IND VSD 007 INSULATION THICKNESS (mm) 45 HOT COLD
35 1 50 XXS 150 WN RF UTILITY CONNECTION
DWG. LEG SUPPORT FOR VERTICAL VESSEL (2 SHEETS) IND VSD 008 FIRE PROOFING YES NO
36 1 50 (H) 160 300 WN RF 2120

_
PRESSURE GAUGE
11 2
VESSEL IS SUBJECTED TO STEAM OUT CONDITION OF 0.5 Kg/Cm (g) AT X SADDLE SUPPORT FOR HORIZONTAL VESSEL(7 SHEETS) IND VSD 009 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL / VERTICAL (AT TOP)
1900C LUG SUPPORTS (2 SHEETS) IND VSD 010 PRESSURE (NEW & COLD) 9.1
45 SEE LEVEL GLASS/LEVEL 12 ALL NOZZLE FABRICATED FROM PLATES SHALL BE FULLY RADIOGRAPHED. PIPE LEG SUPPORT IND VSD 011 INSPECTION BY EIL CIB X TPI
2 50 (H) XXS 300 WN RF _
A-B DWG. CONTROLLER/BRIDLE 13 SURFACE PREPARATION AND PRIMER AND PRIMER SHALL BE AS PER JOB X MINIMUM NOZZLE WALL THICKNESS IND VSD 012
47
2 80 (H) 160 300 WN RF
SEE
SPECIFICATION 44NC-4600-000-V-02-0111-A4.
X REINFORCING PLATES FOR NOZZLES. (C.A. 3mm) IND VSD 018 (AS PER ASME / IS OR EQUIVALENT)
A-B DWG. 14 VENDOR SHALL INDIDATE C.G OF EQUIPMENT IN EACH FABRICATION X NAME PLATE BRACKET IND VSD 020
49
2 80 (H) 160 300 WN RF
SEE
55X16 LEVEL TRANSMITER
DRAWING. X STANDARD NAME PLATE FOR VESSEL IND VSD 021 SHELL SA 516 GR.70
A-B DWG. 15 MANDATORY AND COMMISIONNING SPARES SHALL BE SUPPLIED BY X INSULATION SUPPORTS FOR VESSELS (HOT) IND VSD 022 REINFORCEMENT PAD/INSERT PLATE SA 516 GR.70
50 1 50 160 150 WN RF
SEE _
VENT NOZZLE (NOTE-18)
FABRICATOR.
X STANDARD NOZZLE PROJECTION IND VSD 024 HEADS SA 516 GR.70
DWG. 16 PIPE TO PIPE, PIPE TO FLANGE PIPE TO FITTING & FITTING TO FLANGE JOINT LIFTING TRUNNIONS IND VSD 025 SHELL FLANGES -
SHALL BE WELDED WITH SAME TECHNIQUE USED FOR MAIN EQUIPMENT HANDHOLE WITH HINGED COVER IND VSD 029 NOZZLE FLANGES/LWN NOZZLES/B.F. SA 105
WELDING.
STANDARD INTERNAL PLATE FLANGES IND VSD 030 NOZZLE NECK UPTO 300 NB SA 106 GR.B (SEAMLESS)
17 WHEREVER FULL RADIOGRAPHY IS SPECIFIED SHALL IMPLY 100% X VORTEX BREAKERS (FLUSH TYPE NOZZLES) IND VSD 033 NOZZLE NECK ABOVE 300 NB SA 516 GR.70
RADIOGRAPHY OF ALL BUTT WELDS. VORTEX BREAKERS (NOZZLE WITH INTERNAL PROJECTION) IND VSD 034 PIPE FITTINGS SA 234 GR. WPB
18 VENT NOZZLE `50' SHALL BE MOUNTED ON BLIND FLANGE OF VENTILATION STANDARD DEMISTERS TYPE-I (VESSEL DIA<800mm) IND VSD 036 SPIRAL WOUND GASKET WITH SS 304 METAL
NOZZLE `8'. STANDARD DEMISTERS TYPE-II(VESSEL DIA> 800mm) IND VSD 037 WINDINGS AND GRAFOIL FILLER MATERIAL
GASKET EXTERNAL
STANDARD DEMISTERS TYPE-III IND VSD 038 WITH SS 304 INNER & OUTER RING AS PER
STANDARD DEMISTERS TYPE-IV IND VSD 039 ASME B16.20
X STANDARD BOLT HOLE ORIENTATION IND VSD 040 GASKET INTERNAL -

EARTHING BOSS IND VSD 041 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7 / SA 194 GR.2H
X LADDER RUNGS INSIDE VESSELS AND COLUMNS IND VSD 043 INTERNAL STUDS/BOLTS/NUTS SS 304L
FOUNDATION TEMPLATE (2 SHEETS) IND VSD 044 SKIRT/ SUPPORT IS 2062 Gr.B
SUPPORT FOR INTERNAL DISTRIBUTOR PIPES IND VSD 045 SKIRT/ SUPPORT BASE IS 2062 Gr.B
SUPPORTS FOR INTERNAL FEED PIPE IND VSD 046/047 INTERNAL PARTS (WELDED) SA 516 GR.70
LIFTING LUG TOP HEAD TYPE IND VSD 048 INTERNAL PARTS (BOLTED) SA 516 GR.70
X LIFTING LUG FOR HORIZONTAL VESSEL IND VSD 050 CLIPS & ATTACHMENTS ((EXT.) DIRECTLY WELDED SA 516 GR.70
X RECOMMENDED WELD EDGE PREPARATION FOR BUTT WELDS IND VSD 052 PAD FOR EXTERNAL CLIPS ATTACHMENTS SA 516 GR.70
ALLOY LINER DETAIL (2SHEETS) IND VSD 053 DEMISTER/GRID -
SUPPORT RING AND BOLTING BAR IND VSD 055 PIPE DAVIT -
INSULATION SUPPORTS FOR VERTICAL VESSEL IND VSD 057
X INSULATION SUPPORTS FOR HORIZONTAL VESSEL IND VSD 058
MANWAY DAVIT
BRACKET SA 516 GR.70
FIRE PROOFING SUPPORT IND VSD 062 ALL OTHER PARTS IS 2062 Gr.B
INLET DEFLECTOR BAFFLE IND VSD 064 SHELL STIFFENER RING SA 516 GR.70
X EARTHING LUG IND VSD 080 NAME PLATE SS 304
NAME PLATE BRACKET SA 516 GR.70
EIL REFERENCE DRAWINGS EARTHING LUGS IS 2062 Gr.B
NOZZLE ORIENTATIONS LIFTING LUGS IS 2062 Gr.B
LADDERS/PLATFORM CLEATS
PMC CONTROL CODE -V21 PIPE SUPPORT CLEATS
DEMISTER DATA SHEET NA
APPROVAL
PMC REVIEW
RECORDS
FOUNDATION LOADING DATA (OPERATING CONDITION) HOLD UPS
to the borrower for the intended use.
LICENSORS STANDARDS
TYPE
MAX. SHEAR FORCE AT BASE (H) (kg) X NOZZLE ORIENTATIONS X SIZE OF NOZZLES 20,33,36,45A-B,47A-B,49A-B APPROXIMATE WEIGHT (kgs)
X NOZZLE ELEVATIONS X PIPE SUPPORT CLEATS
(kgm) (PER ITEM)
DBE _ _ X FIXED/SLIDING SUPPORT X LADDER/PLATFORM CLEATS ERECTION 22,000 OPERATING 123,500

DETAILS OF INTERNALS PIPE DAVIT
SEISMIC
MCE _ _ HYDROTEST(SHOP) 146,000 HYDROTEST ( FIELD ) 150,400
FILE NAME A133-086-16-46-DS-3012-B-1

CLIENT : M/s. CPCL COKER UNIT FEED SURGE DRUM dksdj ;wuhV QhM ltZ Mªe A133-086-16-46-DS-3012 B
A 29.04.2011 ISSUED FOR BIDS/ENGG. SBS AB/PP TG
FORMAT NO.3-1646-0113 REV.1 (22.12.2009) A3-420 X 297
Page 87 of 434
Page 88 of 434
JOB NO.: A133 UNIT-86
CLIENT : M/S CPCL dksdj ;wuhV
MARK QTY
NOM.
SCH./THK
SERVICE
DIA CLASS TYPE FACING NOTE-4 WxT 1 ALL DIMENSIONS ARE IN MM. UNLESS STATED OTHER WISE WORKING PRESSURE (kg/cm2g) TOP 8.7 BOT _
INT:
2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. DESIGN PRESSURE (kg/cm2g) 18.5 EXT _
F 1 50 160 300 WN RF 1040 _ INLET 0
TOP/
3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. WORKING TEMPERATURE ( C) TOP 47 BOT _
0
( C) 67
B 1 50 160 300 WN RF 1040 _ BOTTOM OUTLET CENTER LINE TO FLANGE CONTACT FACE.
D 1 40 160 300 WN RF
SEE
_ DRAIN
DWG. FLANGE CONTACT FACE. GENERAL SPECIFICATION FOR INSULATION 44NC-4600-0000-V.02.-0112-A4 TYPE OF HEAD 2:1 ELLIPSOIDAL
5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER GENERAL SPECIFICATION - MATERIAL SPECIFICATIONS 44NC-4600-0000-V.02.-0114-A4 JOINT EFFICIENCY SHELL 1.0 HEAD 1.0
LG1,2 2 50 (H) 160 300 WN RF 1040 _ LEVEL GAUGE CONSTRUCTION.
MH1 1 600 18 THK. 300 WN RF SEE DWG. 200X18 MANHOLE+DAVIT+BF

7 DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS PER X JOB SPEC. FOR VESSELS 44NC-4600-0000-V.02.-0141-A4 HEAT TREATMENT HEAD (AS PER SPEC.)
ASME B16.5 AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER ASME B16.47 OPERATING MEDIUM SOLVENT+DSO
MH2 1 600 18 THK. 300 WN RF 1170 250X18 MANHOLE+DAVIT+BF SERIES `B' UNLESS SPECIFIED OTHERWISE. JACOBS STANDARDS SP. GRAVITY 0.730-0.780
V 1 50 160 300 WN RF
SEE
_ VENT
DWG. NOZZLE PIPE. X MANWAY DAVIT (FOR VERTICAL/HORIZONTAL MANHOLE) IND VSD 002/003 SEISMIC IS 1893 & SITE SPECTRA
UC 1 50 160 300 WN RF 1040 _ UTILITY CONNECTION

9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2 NOS. 40 x 6 THK X DETAIL OF VESSEL/COLUMN TOP DAVIT IND VSD 004 CAPACITY (M3) 10.9
FLATS 900 APART. X DETAIL OF SKIRT OPENING FOR VESSEL & COLUMN IND VSD 006 PAINTING/CLEANING AS PER PAINTING JOB SPEC.
SV 1
203.2
- 300 LWN RF
SEE
40X18 SAFETY VALVE
10 ALL FABRICATED NOZZLES FROM PLATES SHALL BE 100% RADIOGRAPHED. X DETAIL OF SKIRT BASE FOR VESSEL & COLUMN IND VSD 007 INSULATION THICKNESS (mm) NO HOT COLD
I/D (H) DWG. 11 VESSEL IS SUBJECTED TO STEAM OUT CONDITION OF 0.5Kg/Cm (g)
2
AT LEG SUPPORT FOR VERTICAL VESSEL (2 SHEETS) IND VSD 008 FIRE PROOFING (BY OTHERS) X YES NO
190°C. SADDLE SUPPORT FOR HORIZONTAL VESSEL(7 SHEETS) IND VSD 009 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL / VERTICAL (AT TOP)
SK1-4 4 100 80 AS PER JACOB'S STD. SKIRT VENT
12 SS SCREEN SHALL BE SUPPORTED WITH GRID (GRATING) AND SHALL BE LUG SUPPORTS (2 SHEETS) IND VSD 010 PRESSURE (NEW & COLD) 24.05
WIRED TO THE GRATINGS. MAXIMUM SIZE OF EACH OPENING AND % OPEN PIPE LEG SUPPORT IND VSD 011 INSPECTION BY EIL CIB X TPI
AO 1 600 I.D. 10 THK. AS PER JACOB'S STD. ACCESS OPENING AREA SHALL BE 0.025" (0.635MM) AND 23% RESPECTIVELY.
X MINIMUM NOZZLE WALL THICKNESS IND VSD 012
13 HARDNESS SURVEY OF WELD, HAZ & BASE METAL SHALL BE CARRIED OUT X REINFORCING PLATES FOR NOZZLES. (C.A. 3mm) IND VSD 018 (AS PER ASME / IS OR EQUIVALENT)
AFTER PWHT. HARDNESS SHALL NOT EXCEED 200 BHN. X NAME PLATE BRACKET IND VSD 020
14 ALL INTERNALS SHALL BE SIZED TO PASS THROUGH MANHOLE. X STANDARD NAME PLATE FOR VESSEL IND VSD 021 SHELL SA 516 GR.60
INSULATION SUPPORTS FOR VESSELS (HOT) IND VSD 022 REINFORCEMENT PAD SA 516 GR.60
15 ALSO REFER 44NC-4600-00/V.02/0164/A3 FOR OTHER APPLICABLE NOTES. X STANDARD NOZZLE PROJECTION IND VSD 024 HEADS SA 516 GR.60
16 VENDOR SHALL INDICATE C.G OF EQUIPMENT IN FABRICATION DWGS. HANDHOLE WITH HINGED COVER IND VSD 029 NOZZLE FLANGES/LWN NOZZLES/B.F. SA 105
(H) HOLD
17 MANDATORY & COMISSIONING SPARES SHALL BE SUPPLIED BY FABRICATOR. X STANDARD INTERNAL PLATE FLANGES IND VSD 030 NOZZLE NECK UPTO 300 NB SA 106 GR.B (SEAMLESS)
VORTEX BREAKERS (FLUSH TYPE NOZZLES) IND VSD 033 NOZZLE NECK ABOVE 300 NB SA 516 GR.60
18 FULL RADIOGRAPHY SPECIFIED SHALL IMPLY 100% RADIOGRAPHY VORTEX BREAKERS (NOZZLE WITH INTERNAL PROJECTION) IND VSD 034 PIPE FITTINGS SA 234 GR. WPB
19 SCREEN WITH GRID SUPPORT SHALL BE PROCURED FROM ONE OF THE NOZZLE INTERNAL BAFFLE (FOR INSTRUMENT) IND VSD 035 SPIRAL WOUND GASKET WITH SS 316 METAL
SUPPLIERS LISTED AT NOTE-21 & INSTALLED BY VESSEL FABRICATOR. STANDARD DEMISTERS TYPE-II(VESSEL DIA> 800mm) IND VSD 037 WINDINGS AND NON ASBESTOS FILLER
THE PROFILE WIRE SCREEN & GRID/GRID SUPPORT SYSTEM (INCLUDING GASKET EXTERNAL
STANDARD DEMISTERS TYPE-III IND VSD 038 MATERIAL WITH SS 316 OUTER & INNER
BEAMS , BEAM SEAT & SUPORT RING SHALL BE DESIGNED WITH FOLLOWING RING AS PER ASME B16.20
CONDITIONS: STANDARD DEMISTERS TYPE-IV IND VSD 039
X STANDARD BOLT HOLE ORIENTATION IND VSD 040 GASKET INTERNAL NON ASBESTOS
(i)THE WET SAND DENSITY SHALL BE CONSIDERED AS 1600 KG/M3. TAILING LUG IND VSD 042 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7 / SA 194 GR.2H
(ii)THE VESSEL IS FULL OF LIQUID OF DENSITY 780KG/CM3. X LADDER RUNGS INSIDE VESSELS AND COLUMNS IND VSD 043 INTERNAL STUDS/BOLTS/NUTS SS 316
(iii)THE PRESSURE DROP SHALL BE CONSIDERED AS 0.3 KG/CM2 FOR DIRTY FOUNDATION TEMPLATE (2 SHEETS) IND VSD 044 SKIRT/ SUPPORT SA 516 GR.60/IS 2062 Gr.B
SERVICE & 0.15 KG/CM3 FOR CLEAN CONDITION.(HOLD)
X SUPPORT FOR INTERNAL DISTRIBUTOR PIPES IND VSD 045 SKIRT/ SUPPORT BASE IS 2062 Gr.B
(iv)THE GRID SUPPORT RING SHALL BE MIN 20 THK SUPPORTS FOR INTERNAL FEED PIPE IND VSD 046/047 INTERNAL PARTS (WELDED) SA 516 GR.60
20 THE NOZZLE B SHALL BE ORIENTED UNDER THE BAFFLE X LIFTING LUG TOP HEAD TYPE IND VSD 048 INTERNAL PARTS (BOLTED) SS 316
21 SUPPLIERS OF PROFILE WIRE SCREEN (GRID):(HOLD) LIFTING LUG FOR HORIZONTAL VESSEL IND VSD 050 CLIPS & ATTACHMENTS ((EXT.) DIRECTLY WELDED SA 516 GR.60
A).JOHNSON SCREEN X TYP. NOZZLE FLANGE TO NECK JOINT IND VSD 051 CLIPS & ATTACHMENTS (EXT.) WELDED OVER PAD IS 2062 Gr.B
B).NAGAOKTA INTL. CORPORATION,JAPAN OR EQUIVALENT X RECOMMENDED WELD EDGE PREPARATION FOR BUTT WELDS IND VSD 052 PAD FOR EXTERNAL CLIPS ATTACHMENTS SA 516 GR.60
C).EUROSLOTS ALLOY LINER DETAIL (2SHEETS) IND VSD 053 DEMISTER/GRID -
22 DESIGN OF ALL INTERNALS SHALL BE CARRIED OUT AS CONSIDERING SUPPORT RING AND BOLTING BAR IND VSD 055 WEAR PLATE -
LOADS AS SPECIFIED IN NOTE-19 ABOVE.
X SUPPORT RING SIZES FOR PACKED TOWERS IND VSD 056 NAME PLATE SS 304
A).ALLOWABLE STRESSES IN BENDING SHALL BE 0.66 OF YIELD STRESS AT INSULATION SUPPORTS FOR VERTICAL VESSEL IND VSD 057 NAME PLATE BRACKET SA 516 GR.60
DESIGN TEMPERATURE. INSULATION SUPPORTS FOR HORIZONTAL VESSEL IND VSD 058 SUPPORT GRID SS 316
B)ALLOWABLE DEFLECTION OF BEAM SHALL BE L/360 X FIRE PROOFING SUPPORT IND VSD 062 BEAMS FOR GRID SS 316
23 ONE NO. MONKEY LADDER SHALL BE PROVIDED IN SKIRT AS PER ATTACHED X INLET DEFLECTOR BAFFLE IND VSD 064 WIRE MESH SS 316
SKETCH.
X EARTHING LUG IND VSD 080
24 ALL STAINLESS STEEL SURFACES SHALL BE PICKLED AND PASSIVATED AS BRACKET SA 516 GR.60
PER ASTM A380.PROCEDURE SHALL BE SUBMITTED FOR JACOBS REVIEW EIL REFERENCE DRAWINGS MANWAY/PIPE DAVIT
ALL OTHER PARTS IS 2062 Gr.B
NOZZLE ORIENTATIONS LIFTING LUGS SA 516 GR.60
LADDERS/PLATFORM CLEATS EARTHING LUGS IS 2062 Gr.B
PIPE SUPPORT CLEATS
X MONKEY LADDER A133-000-16-46-SK-01
APPROVAL
PMC REVIEW
RECORDS

LICENSORS STANDARDS
TYPE
MAX. SHEAR FORCE AT BASE (H) (kg) X NOZZLE ORIENTATIONS X SIZE OF NOZZLES "LG1-2 & SV" APPROXIMATE WEIGHT (kgs)
X NOZZLE ELEVATIONS (AS MARKED) X PIPE SUPPORT CLEATS
(kgm) (PER ITEM)
DBE 31300 4200 X SUPPORT HEIGHT X LADDER/PLATFORM CLEATS ERECTION 8100 OPERATING 28700
MCE 50800 6850 X PIPE DAVIT HYDROTEST(SHOP) 19000 HYDROTEST ( FIELD ) 29300
WIND 12900 2550 NUMBER OF ITEMS : ONE
FILE NAME A133-087-16-46-DS-3008-B-1

11

CLIENT : M/s. CPCL SAND FILTER FOR NAPHTHA+DSO lS.M fQYVj QWkj ukQFkk$Mh ,l vks A133-087-16-46-DS-3008 B
PLANT : COKER LPG CFC TREATING UNIT
FORMAT NO.3-1646-0113 REV.1 (22.12.2009) A3-420 X 297
Page 89 of 434
$ Mh ,l vks
Page 90 of 434
MARK QTY
NOM.
SCH./THK
SERVICE
DIA CLASS TYPE FACING NOTE-4 WxT 1 ALL DIMENSIONS ARE IN MM.UNLESS STATED OTHER WISE WORKING PRESSURE (kg/cm2g) TOP 14.8 BOT _
INT:
2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. DESIGN PRESSURE (kg/cm2g) 23 EXT _
F 1 80 160 300 WN RF 940 55X20 INLET 0
TOP/
3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. WORKING TEMPERATURE ( C) TOP 40 BOT _
0
( C) 85
B 1 80 160 300 WN RF 940 55X20 BOTTOM OUTLET CENTER LINE TO FLANGE CONTACT FACE.
X GENERAL SPECIFICATION FOR PRESSURE VESSELS 44NC-4600-0000-V.02.-0101-A4 MDMT (0C) (-) 27
D 1 40 160 300 WN RF
SEE
_ DRAIN
DWG. FLANGE CONTACT FACE. GENERAL SPECIFICATION FOR INSULATION 44NC-4600-0000-V.02.-0112-A4 TYPE OF HEAD 2:1 ELLIPSOIDAL
V 1 50 160 300 WN RF
SEE
_ VENT
5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER X GENERAL SPECIFICATION - MATERIAL SPECIFICATIONS 44NC-4600-0000-V.02.-0114-A4 JOINT EFFICIENCY SHELL 1.0 HEAD 1.0
DWG. CONSTRUCTION.
UC 1 50 160 300 WN RF 940 _ UTILITY CONNECTION

7 DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS PER X JOB SPEC. FOR VESSELS. 44NC-4600-0000-V.02.-0141-A4 HEAT TREATMENT HEAD (AS PER SPEC.)
ASME B16.5 AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER ASME B16.47 OPERATING MEDIUM LPG
LG1,2 2 50 (H) 160 300 WN RF 940 _ LEVEL GAUGE SERIES `B' UNLESS SPECIFIED OTHERWISE. JACOBS STANDARDS SP. GRAVITY 0.519
SV 1
101.6
- 300 LWN RF
SEE
_ SAFETY VALVE
I/D (H) DWG. NOZZLE PIPE. X MANWAY DAVIT (FOR VERTICAL /HORIZONTAL MANHOLE) IND VSD 002/003 SEISMIC IS 1893 & SITE SPECTRA
MH1 1 600 20 THK. 300 WN RF

SEE
230X20 MANHOLE+DAVIT+BF
9 NOZZLES 50NB AND BELOW SHALL BE STIFFENED WITH 2 NOS. 40 x 6 THK X DETAIL OF VESSEL/COLUMN TOP DAVIT IND VSD 004 CAPACITY (M3) 8.41
DWG. FLATS 900 APART. X DETAIL OF SKIRT OPENING FOR VESSEL & COLUMN IND VSD 006 PAINTING/CLEANING AS PER PAINTING JOB SPEC.
MH2 1 600 20 THK. 300 WN RF 1070 250X20 MANHOLE+DAVIT+BF

10 ALL FABRICATED NOZZLE FROM PLATE SHALL BE 100% RADIOGRAPHED. X DETAIL OF SKIRT BASE FOR VESSEL & COLUMN IND VSD 007 INSULATION THICKNESS (mm) NO HOT COLD
11 VESSEL IS SUBJECTED TO STEAM OUT CONDITION OF 0.5Kg/Cm (g)
2
AT LEG SUPPORT FOR VERTICAL VESSEL (2 SHEETS) IND VSD 008 FIRE PROOFING (BY OTHERS) X YES NO
190°C. SADDLE SUPPORT FOR HORIZONTAL VESSEL(7 SHEETS) IND VSD 009 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL / VERTICAL (AT TOP)
SK1-4 4 100 80 AS PER JACOB'S STD. SKIRT VENT
12 SS SCREEN SHALL BE SUPPORTED WITH GRID (GRATING) AND SHALL BE LUG SUPPORTS (2 SHEETS) IND VSD 010 PRESSURE (NEW & COLD) 29.9
WIRED TO THE GRATINGS MAXIMUM SIZE OF EACH OPENING AND % OPEN PIPE LEG SUPPORT IND VSD 011 INSPECTION BY EIL CIB X TPI
AO 1 600 I.D. 10 THK. AS PER JACOB'S STD. ACCESS OPENING AREA SHALL BE 0.025" (0.635MM) AND 23% RESPECTIVELY.
X MINIMUM NOZZLE WALL THICKNESS IND VSD 012
(H) HOLD
13 THE EQUIPMENT IS IN SOUR SERVICE. NACE MR0103 REQUIREMENT X REINFORCING PLATES FOR NOZZLES. (C.A. 3mm) IND VSD 018 (AS PER ASME / IS OR EQUIVALENT)
TO BE MET IN ADDITION TO REQUIREMENTS AT CL1.2 OF X NAME PLATE BRACKET IND VSD 020
SPECIFICATION 44NC-4000-0000-V.02-0114-A4.
X STANDARD NAME PLATE FOR VESSEL IND VSD 021 SHELL SA 516 GR.60 *@
14 ALL INTERNALS SHALL BE SIZED TO PASS THROUGH MANHOLE. INSULATION SUPPORTS FOR VESSELS (HOT) IND VSD 022 REINFORCEMENT PAD SA 516 GR.60 @
15 ALSO REFER 44NC-4600-00/V.02/0164/A3 FOR OTHER APPLICABLE NOTES. X STANDARD NOZZLE PROJECTION IND VSD 024 HEADS SA 516 GR.60 * @
16 VENDOR SHALL INDICATE C.G OF EQUIPMENT IN FABRICATION DWGS. HANDHOLE WITH HINGED COVER IND VSD 029 NOZZLE FLANGES/LWN NOZLES/B.F. SA 105 * @
X STANDARD INTERNAL PLATE FLANGES IND VSD 030 NOZZLE NECK UPTO 300 NB SA 106 GR.B * @ (SEAMLESS)
17 MANDATORY & COMISSIONING SPARES SHALL BE SUPPLIED BY FABRICATOR. VORTEX BREAKERS (FLUSH TYPE NOZZLES) IND VSD 033 NOZZLE NECK ABOVE 300 NB SA 516 GR.60* @
VORTEX BREAKERS (NOZZLE WITH INTERNAL PROJECTION) IND VSD 034 PIPE FITTINGS SA 234 GR. WPB * @
18 ALL WELD & HAZ SHALL BE IMPACT TESTED AT (-)270 C AND ACCEPTANCE NOZZLE INTERNAL BAFFLE (FOR INSTRUMENT) IND VSD 035 SPIRAL WOUND GASKET WITH SS 316L METAL
CRITERIA SHALL BE AS PER CODE STANDARD DEMISTERS TYPE-II(VESSEL DIA> 800mm) IND VSD 037 WINDINGS AND NON ASBESTOS FILLER
GASKET EXTERNAL
19 FULL RADIOGRAPHY WHEN SPECIFIED SHALL IMPLY 100% RADIOGRAPHY OF STANDARD DEMISTERS TYPE-III IND VSD 038 MATERIAL WITH SS 316L OUTER & INNER
ALL BUTT WELDS STANDARD DEMISTERS TYPE-IV IND VSD 039 RING AS PER ASME B16.20
20 HARDNESS SURVEY OF WELD, HAZ & BASE METAL SHALL BE CARRIED OUT X STANDARD BOLT HOLE ORIENTATION IND VSD 040 GASKET INTERNAL NON ASBESTOS
AFTER PWHT. HARDNESS SHALL NOT EXCEED 200 BHN. TAILING LUG IND VSD 042 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7M / SA 194 GR.2HM
21 SCREEN WITH GRID SUPPORT SHALL BE PROCURED FROM ONE OF THE X LADDER RUNGS INSIDE VESSELS AND COLUMNS IND VSD 043 INTERNAL STUDS/BOLTS/NUTS SS 316
SUPPLIERS LISTED AT NOTE-23 & INSTALLED BY VESSEL FABRICATOR. FOUNDATION TEMPLATE (2 SHEETS) IND VSD 044 SKIRT/ SUPPORT SA 516 GR.60/IS 2062 Gr.B
THE PROFILE WIRE SCREEN & GRID/GRID SUPPORT SYSTEM (INCLUDING
BEAMS , BEAM SEAT & SUPORT RING SHALL BE DESIGNED WITH FOLLOWING X SUPPORT FOR INTERNAL DISTRIBUTOR PIPES IND VSD 045 SKIRT/ SUPPORT BASE IS 2062 Gr.B
CONDITIONS: SUPPORTS FOR INTERNAL FEED PIPE IND VSD 046/047 INTERNAL PARTS (WELDED) SA 516 GR.60 * @
X LIFTING LUG TOP HEAD TYPE IND VSD 048 INTERNAL PARTS (BOLTED) SS 316
(i).THE WET SAND DENSITY SHALL BE CONSIDERED AS 1600 KG/M3. LIFTING LUG FOR HORIZONTAL VESSEL IND VSD 050 CLIPS & ATTACHMENTS ((EXT.) DIRECTLY WELDED SA 516 GR.60 @
(ii).THE VESSEL IS FULL OF LIQUID OF DENSITY 519 KG/CM .
3
(iii).THE PRESSURE DROP SHALL BE CONSIDERED AS 0.3 KG/CM
2
FOR DIRTY X RECOMMENDED WELD EDGE PREPARATION FOR BUTT WELDS IND VSD 052 PAD FOR EXTERNAL CLIPS ATTACHMENTS SA 516 GR.60 @
SERVICE & 0.15 KG/CM3 FOR CLEAN CONDITION.(HOLD) ALLOY LINER DETAIL (2SHEETS) IND VSD 053 DEMISTER/GRID -
(iv)THE GRID SUPPORT RING SHALL BE MIN 22 THK. SUPPORT RING AND BOLTING BAR IND VSD 055 PIPE DAVIT SA 106 GR.B/SA 53
22 THE NOZZLE "B" SHALL BE ORIENTED UNDER THE BAFFLE X SUPPORT RING SIZES FOR PACKED TOWERS IND VSD 056 WEAR PLATE -
23 SUPPLIERS OF PROFILE WIRE SCREEN (GRID): (HOLD) INSULATION SUPPORTS FOR VERTICAL VESSEL IND VSD 057 NAME PLATE SS 304
A).JOHNSON SCREEN INSULATION SUPPORTS FOR HORIZONTAL VESSEL IND VSD 058 NAME PLATE BRACKET SA 516 GR.60
B).NAGAOKTA INTL. CORPORATION,JAPAN X FIRE PROOFING SUPPORT IND VSD 062 SUPPORT GRID FOR SAND BED SS 304
C).EURO SLOTS X INLET DEFLECTOR BAFFLE IND VSD 064 BEAMS FOR GRID SS 304
D).OR EQUIVALENT X EARTHING LUG IND VSD 080 WIRE MESH SS 304
24 DESIGN OF ALL INTERNALS SHALL BE CARRIED OUT AS CONSIDERING BRACKET SA 516 GR.60
LOADS AS SPECIFIED IN NOTE-21 ABOVE. EIL REFERENCE DRAWINGS MANWAY DAVIT
ALL OTHER PARTS IS 2062 Gr.B
A).ALLOWABLE STRESSES IN BENDING SHALL BE 0.66 OF YIELD STRESS AT NOZZLE ORIENTATIONS LIFTING LUGS IS 2062 Gr.B
DESIGN TEMPERATURE. LADDERS/PLATFORM CLEATS EARTHING LUGS IS 2062 Gr.B
B)ALLOWABLE DEFLECTION OF BEAM SHALL BE L/360. PIPE SUPPORT CLEATS
25 ALL STAINLESS STEEL SURFACES SHALL BE PICKLED AND PASSIVATED AS MONKEY LADDER
APPROVAL PER ASTM A380. PROCEDURE SHALL BE SUBMITTED FOR JACOBS REVIEW * NACE + HIC ( REFER NOTE-13 & 20)
PMC REVIEW "@" IMPACT TESTED (REFER NOTE-18 & 26)
RECORDS 26 ENERGY VALUE AND IMPACT TEST TEMPERATURE FOR PLATES SHALL BE AS
PER TABLE A2.15 OF SA-20.

LICENSORS STANDARDS
TYPE MAX MOMENT AT BASE (M) (kgm) MAX. SHEAR FORCE AT BASE (H) (kg) X NOZZLE ORIENTATIONS X SIZE OF NOZZLES "LG1-2 & SV" APPROXIMATE WEIGHT (kgs)
X NOZZLE ELEVATIONS(AS MARKED) X PIPE SUPPORT CLEATS
(PER ITEM)
DBE 20500 3250 X SUPPORT HEIGHT X LADDER/PLATFORM CLEATS ERECTION 7,100 OPERATING 22,700
MCE 33500 5300

SOUR SERVICE (NACE MR 0103) X PIPE DAVIT HYDROTEST(SHOP) 15,600 HYDROTEST ( FIELD ) 25,400
WIND 8450 1950 NUMBER OF ITEMS : ONE
FILE NAME A133-087-16-46-DS-3009-B-1

11

SAND FILTER FOR TREATED LPG lSUM fQYVj QWkj VªhVsM ,yihth
NEW DELHI CLIENT : M/s. CPCL B 10.09.2013 REVISED AND ISSUED FOR ENGG./BIDS GCP SUU/PKP BBC
A133-087-16-46-DS-3009 B
PLANT : COKER LPG CFC TREATING UNIT
FORMAT NO.3-1646-0113 REV.1 (22.12.2009) A3-420 X 297
Page 91 of 434
Page 92 of 434
lSUM fQYVj QWkj
Document No.
VENDOR DATA REQUIREMENTS A133-086-16-46-VDR-6141
FOR Rev. A
CS VESSELS Page 1 of 4
VENDOR DATA REQUIREMENTS

FOR
CS VESSELS
A 20-DEC-2013 ISSUED FOR BIDS PB PKP BBC

Rev. Date Purpose Prepared by Checked by Approved by
No.
Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved
Page 93 of 434
Document No.
FOR Rev. A
VENDOR DATA REQUIREMENTS
The following drawings/documents marked " " shall be furnished by the bidder.
POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. RADIOGRAPHIC EXAMINATION REPORTS Vendor to store these
for 5 years.
WITH FILMS @.
2. CODE CERTIFICATES (INCLUDING Documents shall be
INSPECTION CERTIFICATE, HYDROSTATIC submitted within 1
TEST CERTIFICATE, LOCAL CODE week after final
REQUIREMENTS, RUBBING OF CODE inspection.
@.
STAMP AND NAME PLATE ETC.)
3. MATERIAL TEST CERTIFICATES Documents shall be
submitted within 1
week after final
inspection.
@.
4. DESTRUCTIVE AND NON-DESTRUCTIVE Documents shall be
submitted within 5 to 8
TEST REPORTS weeks of issue of PR.
@.
5. PACKING AND FORWARDING
INSTRUCTIONS
6. WELDING PROCEDURES AND Documents shall be
QUALIFICATION TEST REPORTS weeks of issue of PR.
@.
7. INSPECTION AND TESTING PLAN Documents shall be
weeks of issue of PR.
@.
8. GENERAL ARRANGEMENT DRAWING
INDICATING DESIGN DATA FABRICATED Documents shall be
EQUIPMENT WEIGHT, GENERAL NOTES, submitted within 3 to 5
NOZZLE SCHEDULE, DETAIL OF SHELL, weeks of issue of PR.
HEADS, SUPPORTING ARRANGEMENT, Plate cutting layout is
not required.
MAIN WELD SEAMS, NOZZLE ORIENTATION
PLAN, CUTTING LAYOUT ETC.
9. DETAIL OF NOZZLES, MANHOLES, Documents shall be
ACCESSORIES ETC weeks of issue of PR.
10. DETAIL OF INTERNAL DISTRIBUTOR. Documents shall be
weeks of issue of PR.
11. DETAIL OF EXTERNAL CLIPS SUCH AS Documents shall be
submitted highlighting
LADDER, PLATFORM, PIPE SUPPORT. areas of discrepency
or fouling, etc. within
10 to 15 weeks of
issue of PR.
12. DETAIL OF INSULATION, FIRE PROOFING Documents shall be
areas of discrepency
or fouling, etc.within 10
to 15 weeks of issue of
PR.
Page 94 of 434
Document No.
FOR Rev. A
POST ORDER
S. WITH WITH
BID
(FINAL)
13. DETAIL OF PIPE DAVIT Documents shall be
10 to 15 weeks of
issue of PR.
14. DETAIL OF LIFTING LUG,TRUNION AND Documents shall be
TAILING LUG ETC. areas of discrepency
10 to 15 weeks of
issue of PR.
15. CERTIFIED 'AS BUILT' DRAWINGS Documents approved
by inspector shall be
INCORPORATING ACTUAL DIMENSIONS submitted within 2
AND MATERIAL USED, DULY CERTIFIED BY weeks after dispatch of
THE INSPECTOR equipment.
@.
16. DATA FOLDER AS PER SPECIFICATION Documents approved
by inspector shall be
submitted within 2
weeks after dispatch of
equipment.
@.
17. HEAT TREATMENT PROCEDURE AND TIME Documents shall be
submitted within 1
TEMPERATURE CHARTS week after final
inspection.
@.
18. DETAIL OF INTERNAL DISTRIBUTOR AND Documents shall be
ITS SUPPORT,VORTEX BREAKERS, etc. areas of discrepency
or fouling, etc.within 8
to 10 weeks of issue of
PR.
19. DETAILS OF PACKING SUPPORT,
GRATINGS, AND GRATING SUPPORTS.
POST ORDER
S. WITH WITH
BID
(FINAL)
1. Assembly & Installation Details Documents shall be
submitted within 12 to
16 weeks of issue of
PR. Documents shall
be approved by EIL
before shipment. @
2. Hydrotest procedure & foundation monitoring Documents shall be
submitted within 12 to
procedure 16 weeks of issue of
PR. @
3. Erection drawings including weights, C.G. & Documents shall be
submitted within 1
slinging facilities, etc. week after final
inspection.
Documents shall be
approved by EIL
before shipment.
4. Detail of Structural Platforms etc. Documents shall be
or fouling, etc.
Page 95 of 434
Document No.
FOR Rev. A
Notes :
1. Quality requirements as mentioned in Job Specification of columns.
2. Refer 44NC-4600-0000/N.02/0040/A4+Annexure- I to V for quality management system
3. Bidder to submit 6 nos. hard copy of each drawing/document at drawing review stage along with soft copy in
eDMS. Final documentation shall be submitted in hard copy (15 prints) and soft (4 CDs/DVDs) in addition to
submission through EIL eDMS.
4. "TICK" denotes applicability.
5. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
6. All post order documents shall be submitted / approved through EIL eDMS portal.
7. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /
contractor / supplier during finalization of Document Control Index (DCI).
8. "@" indicates submission of documents to Inspection Agency.
9. Bill of Material shall form part of the respective drawing.
10. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
Page 96 of 434
DOCUMENT No.
UNIT RATES FOR
ADDITION/DELETION A133-16-46-UR-6141
Rev. A
Page 1 of 7
UNIT RATES
FOR
ADDITION/DELETION
PROJECT : COKER BLOCK (EPCC-1)

RESID UPGRADTAION PROJECT, CPCL, CHENNAI
OWNER : CHENNAI PETROLEUM CORPORATION LIMITED
PMC : JACOBS ENGINEERING INDIA PRIVATE LIMITED
CONTRACTOR : ENGINEERS INDIA LIMITED
JOB NO. : A133
A 19.12.2013 ISSUED FOR BIDS PB PKP BBC

Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 97 of 434
DOCUMENT No.
UNIT RATES FOR
Rev. A
Page 2 of 7
UNIT RATES FOR ADDITIONS/DELETIONS
1. Offer shall contain the sheets given below & the subsequent sheets for addition / deletion
of nozzles duly filled in, else offer will be rejected. Please note that the same EIL sheets
as given below shall be filled in and enclosed in the offer. Bidder shall not enclose his
own sheets.
2. It is understood that
a) The quoted price includes for the “HOLDS “details of which are indicated on
respective equipment Engineering Drawing.
b) The weights indicated on EIL Engineering Drawings do not form the basis for
offer, since these are approximations only.
c) Spares as included in clause no. 2.3 in Scope of Supply are quoted.
d) The rates to be quoted below shall be paid on finished weight basis only.
Description Price List (To be filled in by bidder)
1. Indicate charges for the following for future

addition/deletion with material as per scope of supply
defined in the material requisition :
i) External support clips per Kg. basis.
- IS: 2062 Gr.B

- SA-516 Gr. 60
- SA 516 Gr 70
- IS-2062 Gr.B with BQCS Mat.Pad
ii) Reinforcement pad for nozzle per Kg. Basis
- SA 516 Gr 70
- SA-516 Gr. 60
iii) Pipe davit per metre basis
- 100 NB Sch.80
- 150 NB Sch.40
- 150 NB Sch.80
- 200 NB Sch.40
- 200 NB Sch.80
- 250 NB Sch.40
- 250 NB Sch.80
- 300 NB Sch.40
- 300 NB Sch.80
iv) Tray support ring/bolting bar, seal pan support,

chimney tray support ring and its support,
packing support rings per kg.basis.
- SA-516 Gr.70
- SA-240 Gr.316
- SA-240 Gr.316L
Page 98 of 434
DOCUMENT No.
UNIT RATES FOR
Rev. A
Page 3 of 7
v) Change in skirt height/dimensions per Kg. Basis

- IS:2062 Gr.B
- SA-516 Gr. 60
- SA-516 Gr.70
vi) Change in pipe leg support per Kg. Basis

- SA-106 Gr.B
- SA-53
vii) Change in angle/beam leg support per Kg. Basis

- IS-2062 Gr.B
- SA-283 Gr.C
viii) Change in nozzle pipe lengths per Kg. basis
- SA-516 Gr.60
- SA-516 Gr.70
- SA-106 Gr B
- SA 516 Gr.60 (NACE)
- SA 516 Gr.60 (NACE + HIC)
- SA 106 Gr. B (NACE)
- SA 106 Gr. B (NACE + HIC)
ix) Change in self reinforced nozzle sizes per kg.
Basis
- SA-105
- SA-105 (HIC+NACE)
- SA-105+ SS 304L Weld Overlay
- SA -350 LF2 CL1
In case of change in size, vendor shall submit
design calculation, details and weights of the
previous size also for EIL review at the time of
extra claims.
x) Change in of pipe fitting per Kg. Basis
- SA 234 WPB
- SA 234 WPB + SS 410S WO
- SS 410S
- SS 316
- SA 234 WPB (NACE)
- SA 234 WPB (NACE + HIC)
xi) Change in quantity / change in size of LWN

Nozzle per Kg. Basis
- SA-105
- SA-105 + SS 410 S WO
- SA 105 (NACE)
- SA 105 (NACE + HIC)
xii) Change in Pressure parts (Shell, Dished heads,
Page 99 of 434
DOCUMENT No.
UNIT RATES FOR
Rev. A
Page 4 of 7

vacuum stiffeners,insert plate) per kg basis
- SA-516 Gr.60
- SA-516 Gr.60 + SS 410 S CLAD
- SA-516 Gr.70
- SA 516 Gr.60 (NACE)
- SA 516 Gr.60 (NACE + HIC) Impact
Tested
xiii) Change in internal plates per Kg. Basis
- SA-516 Gr. 60
- SA-516 Gr. 70
- SA 516 Gr.60 (NACE)
- SA-240 Gr. 304
- SA 240 Gr. 316
- SA 516 Gr.60 (NACE + HIC) Impact
Tested
xiv) Change in internal pipe per Kg. Basis
- SA-106 Gr. B
- SS 304
- SA 106 Gr. B (NACE)
- SA 106 Gr. B (NACE + HIC)
- SS 316
- SS 316 L
xv) Addition/ deletion of site seams per inch mean

circumference basis.
a) Carbon steel to carbon steel for following

thickness in Pressure Parts including rate for
local PWHT & box type hydrotest
- Up to 10 mm
- 11 mm to 20 mm
- 21 mm to 25 mm
Page 100 of 434
DOCUMENT No.
UNIT RATES FOR
Rev. A
Page 5 of 7
TABLE-1(A)
SCHEDULE OF RATES FOR ADDITION/DELETION OF NOZZLES
FLANGE MATERIAL :- SA 105

NOZZLE NECK MOC :- SA 106 Gr. B / SA 516 Gr. 60/SA 516 Gr. 70
ANSI B 16.5/ ANSI B 16.47 (SERIES B)

CLASS 150 (WN RF FLG.) CLASS 300 (WN RF FLG.) CLASS 600 (WN RF FLG.)
SL.NO. NOMINAL SIZE WITHOUT BLIND WITH BLIND WITHOUT BLIND WITH BLIND WITHOUT WITH BLIND REMARKS
NB FLANGE FLANGE FLANGE FLANGE BLIND FLANGE FLANGE
1 25
2 40
3 50
4 80
5 100
6 150
7 200
8 250
9 300
10 350
11 400
12 450
13 500
14 600
15 650
16 700
17 750
18 800
19 850
20 900
21 950
22 1050
23 1200
24 1350
25 1400
26 1450
27 1500
NOTES :-
1. MATERIAL SPECIFICATION FOR NOZZLE COMPONENTS SUCH AS NOZZLE NECK, FLANGE, REINFORCEMENT PAD, NOZZLE STIFFENER,
STUDS, NUTS AND GASKETS SHALL BE AS PER ENGINEERING DRAWING. NOZZLE REINFORCEMENT AND PROJECTION DETAIL SHALL
BE AS PER ATTACHED STANDARD. BIDDER SHALL NOTE THAT EXTRA CLAIM FOR INCREASE IN NOZZLE PROJECTION UPTO
100MM W.R.T ATTACHED STANDARD SHALL NOT BE PAYABLE.
2. SCOPE OF SUPPLY OF NOZZLE COMPONENTS SHALL BE AS PER MATERIAL REQUISITION.
3. THE RATES QUOTED SHALL INCLUDE SUPPLY OF NOZZLE NECK, FLANGE, STIFFENER, STUDS, NUTS AND GASKETS (WHEN SUPPLIED
WITH BLIND FLANGE) AND ASSOCIATED FABRICATION AND TESTING.
4. PRICES INDICATED ABOVE SHALL BE IRRESPECTIVE OF NOZZLE THICKNESS.NO EXTRA CLAIM ON THIS ACCOUNT WILL BE
ENTERTAINED AT A LATER DATE.
5. THE SCHEDULE OF RATES EXCLUDES COST OF REINFORCEMENT PAD
Page 101 of 434
DOCUMENT No.
UNIT RATES FOR
Rev. A
Page 6 of 7
TABLE-1(B)
FLANGE MATERIAL :- SA 105 (NACE + HIC) / SA 105 (NACE + HIC+ Impact Tested)
NOZZLE NECK MOC :- SA 106 Gr. B (NACE + HIC) / SA 106 Gr. B (NACE + HIC+ Impact tested) /SA 516 Gr. 60 (
NACE + HIC)/ SA 516 Gr. 60 (NACE + HIC +Impact tested)
1 25
2 40
3 50
4 80
5 100
6 150
7 200
8 250
9 300
10 350
11 400
12 450
13 500
14 600
15 650
16 700
17 750
18 800
19 850
20 900
9
21 9 950
22 1050
23 1200
24 1350
25 1400
26 1450
27 1500
NOTES :-
5. THE SCHEDULE OF RATES EXCLUDES COST OF REINFORCEMENT PAD.
Page 102 of 434
DOCUMENT No.
UNIT RATES FOR
Rev. A
Page 7 of 7
TABLE-1(C)
FLANGE MATERIAL :- SA 105 (NACE)

NOZZLE NECK MOC :- SA 106 Gr. B (NACE) /SA 516 Gr. 60 ( NACE)

1 25
2 40
3 50
4 80
5 100
6 150
7 200
8 250
9 300
10 350
11 400
12 450
13 500
14 600
15 650
16 700
17 750
18 800
19 850
20 900
9
21 9 950
22 1050
23 1200
24 1350
25 1400
26 1450
27 1500
NOTES :-
5. THE SCHEDULE OF RATES EXCLUDES COST OF REINFORCEMENT PAD.
Page 103 of 434
TECHNICAL COMPLIANCE SHEET DOCUMENT NO.
A133-16-46-TQS-6141
Rev A
Page 1 of 2
TECHNICAL COMPLIANCE SHEET

JOB NO. : A133
Rev. No Date Purpose Prepared by Checked by Approved by
Format No. EIL 1641-1924 Rev. 1 Copyrights EIL – All rights reserved
Page 104 of 434

TECHNICAL COMPLIANCE SHEET DOCUMENT NO.
A133-16-46-TQS-6141
Rev A
Page 2 of 2
THIS FORM MUST BE DULY FILLED-IN AND RETURNED WITH THE QUOTATION. QUOTATION WITHOUT
THIS FORM DULY FILLED-IN SHALL BE DEEMED AS INCOMPLETE AND NOT TO BE EVALUATED.
Sl. COMMENT/QUERY BIDDER’S CONFIRMATION/ ANSWER

No. (YES / NO)
1. Bidder to confirm that complete documents enclosed
with requisition have been received.
2a. Bidder to confirm their offer is in complete compliance to

requisition (A133-086-VV-MR-6141 Rev A), drawings,
standard & specifications attached /referred in this
requisition and the entire requirements are met with.
2b. If answer to S.No.2a. is “No”, confirm that list of
technical deviations if any, have been filled in Deviation
Schedule format attached with the material requisition.
Beside these deviations, confirm that the offer is in total
conformity with the Specification for all equipment.
Further note that deviation mentioned elsewhere except
the deviation format shall not be considered.
3. Bidder to confirm that following spares as per document

no. A133-16-46-SS-6141 have been considered &
included in their offer.
(i) Mandatory spares
(ii) Commissioning spares
BIDDERS SIGNATURE AND STAMP
Format No. EIL 1641-1924 Rev. 1 Copyrights EIL – All rights reserved
Page 105 of 434
DOCUMENT No.
INSTRUCTIONS TO BIDDERS A133-16-46-TR-6141
Rev. A
Page 1 of 9
INSTRUCTIONS TO BIDDERS

JOB NO. : A133

Rev. Prepared Checked
Date Purpose Approved by
No by by
Page 106 of 434
DOCUMENT No.
Rev. A
Page 2 of 9
Bidding Instructions
A) Category-II MR
1. Vendor to note that bid evaluation may be carried out without any post-bid correspondence.
2. Vendor shall furnish quotations only for those items (as per attached vendor list) which he
can supply strictly as per MR specifications including fulfillment of BQC criteria as per MR.
3. If the bid does not include complete scope, technical / performance data, proven track record
etc. required to be submitted with the bid, the offer shall be liable for rejection.
B) It is understood that
1. The quoted price includes for the “HOLDS” details of which are indicated on the Drg.
2. The weights indicated on EIL Engineering Drgs. do not form the basis for offer, since these
are approximations only.
3. Spares included in of doc. A133-16-46-SS-6141 are included in the quoted price.
4. Any decrease/ increase in weights shall be recovered/ paid as per Doc.No. A133-16-46-UR-
6141.
C) Transportation of equipment shall be governed by commercial conditions.
1. The equipment having length more than 20 m and / or forming ‘Gross vehicle weight
(Weight of equipment and the weight of vehicle clubbed together) more than 49 MT
shall be transported by Hydraulic axles only with compliance to all statutory norms of
authorities concerned.
Fabricator/transporter to check the requirements as per latest guidelines issued by

Ministry of surface Transport before shipping the equipment.
2. Prime mover of the vehicle to have GPS tracking system to monitor the movement of
consignment.
Technical Instructions
1. The shape of dished end/toricone, profile of conical reducer, knuckle radius, cone angle and
overall height shall be as per engineering drawing. Minimum thickness of shell, cone and
dished end shall be achieved taking into account thinning and scaling etc.
2. Dished ends and hot formed pressure parts shall have 10% or 2mm (whichever is higher)
allowance for scaling and thinning, in order to achieve minimum thickness specified on the
drawing.
3. a) Wherever hot forming and subsequent heat treatment is involved, adopted procedure shall
not impair the mechanical properties of the material beyond the limits specified in respective
material specification.
b) For low temperature equipment and hot formed parts, number of production coupons and
the tests thereon shall be as per requisition.
4. Post weld heat treatment and all non destructive testing like radiography, ultrasonic testing,
magnetic particle/dye penetrant examination etc. shall be conducted as per requisition.
Page 107 of 434
DOCUMENT No.
Rev. A
Page 3 of 9
5. The vessels shall be transported in single piece except for Burried vessel Tag no. 86-C-51.
6. Workmanship and materials, in bidder's scope of supply, shall be guaranteed.
7. Pickling and passivation of internal surfaces of stainless steel shall be carried out as per
ASTM A-380/Job specification no. A133-08-16-46-SP-11 as applicable as per respective
MDS. Procedure shall be furnished for approval/review.
8. For IBR vessels, approval of drawings, documents, stagewise inspection and final
certification of the equipment by Inspectorate of Boilers shall be included in bidder’s scope.
Complete design of equipment as per IBR shall be carried out by vendor.
9. For items which are to approved by CCOE,Nagpur ,approval of drawings, documents,

stagewise inspection and final certification of the equipment by Chief Controller of explosives
responsibility of bidder.
10. The main equipment shall not be subcontracted, however bought out items/ components can
be subordered or subcontracted to approved vendors/sub-contractors only. Refer commercial
section and attached vendor list for approved vendors for complete equipment, all raw
material and bought out components.
11. Demister /Agitator shall be procured from approved vendors only ( Refer vendor List attached
in commercial section)
12. Fabricator to supply template for checking the orientation of anchor bolts on foundation and to
ensure matching of base plate that is drilled in advance. The template for foundation shall be
box type and height of template shall be equal to anchor chair base ring, top ring, washer and
nuts. The schedule of supply of template at site shall be 8 weeks from FOA.
13. Gaskets used for hydrotesting of vessels shall be of the same specification as service
gaskets and the fabricator shall supply new gaskets for manholes and nozzles with blind
flanges apart from spares. Gaskets used for hydrotest shall not be used for actual hook up.
14. While transporting vessels, fabricator shall provide suitable type and no. of supports so that
no deformation of any part of the equipment takes place.
15. Fabricator shall exercise utmost care during fabrication so that no damage to any part of the
equipment occurs. Suitable type and no. of supports shall be provided for supporting the
vessels.
16. Fabricator shall also design and provide suitable stiffening arrangement at the base anchor
chair locations so that deformation/buckling of base and bottom zone does not occur at the
time of lifting while the vessels are being erected.
17. Fabricator shall design and provide lugs/trunnions for handling and assembly of vessel
sections.
18. Number of temporary attachments/cleats, lifting lug/trunnion used for site assembly should be
kept minimum. Temporary attachments / cleats shall be removed by fabricator after complete
execution of work if desired by engineer-in-Charge leaving 12mm from the shell & grinding of
all cut edge burrs.
19. If the equipment is to be transported via sea routes (marine transportation), the following shall
be provided by bidder and included in the quoted price:
Page 108 of 434
DOCUMENT No.
Rev. A
Page 4 of 9
After completion of all testing and inspection, the inside of complete equipment shall be
thoroughly drained and dried out. Equipment shall be completely dried by passing hot air for
sufficient time until no further increase in relative humidity of outgoing air is observed. After
drying, the equipment shall be purged and filled with dry N2 at 0.25 kg/cm 2. The equipment
section shall be provided with pressure gauge to monitor N2 pressure and ½ “ non-return
valve. All threaded holes other than tell tale holes for testing shall be suitably protected with
steel bar plugs. All nozzles not provided with blind flange shall be provided with steel covers,
temporary gaskets and bolts. All external surfaces shall be properly protected / covered
against sea environments.
20. Erection weight given in equipment data sheet is approximate. Vendor shall calculate the
actual equipment weight and furnish calculation. Erection weight furnished in vendor drawing
shall be based on fabricator’s calculation. Calculation of Centre of Gravity (C.G.) of the
equipment shall also be done by vendor and marked on the equipment & in the fabrication
GA drawing.
21. For internal distributor pipes, internal flanges shown are minimum required. It is vendor’s
responsibility to provide required number of flanges to ensure removability through nearest
manway.
22. For CS/LAS equipments:
All production welding shall be examined by RT. In case vendor want to perform UT by TOFD
technique in lieu of RT, the same is acceptable subject to the following:
a) Thickness of plate is greater than 38mm.
b) With Code Case 2235, Automated UT incorporating TOFD and pulse echo probes or
TOFD and Phased Array mounted on the same chassis that automatically traverses
along the joints to be inspected and displaying both results simultaneously on a single
screen may be considered in lieu of RT.
c) Calibration block of similar material/thickness shall be used. Calibration block shall have
suitable notches to simulate longitudinal as well as transverse cracks on outside and
inside surface. Setup should be capable of detecting defects on outside as well as
inside while scanning from one surface only.
d) The system that is proposed to be deployed in lieu of radiography shall be submitted

along with the track record prior to use for EIL review. The vendor shall demonstrate
successfully the capability of AUT machine and the defects evaluation in the same
screen during the site visit of EIL inspector/EIL representative. Based on which, the
approval of the parties and their AUT system shall be given.
e) Qualified NDT persons shall be deployed to perform UT.
23. Steel structure to be fabricated in modular forms including electroforged galvanized grating,
handrails, stairs, toe guard at vendor’s shop. Platforms shall be transported to site with
identification & match marking for assembly and erection at site. Installation and erection of
platform is excluded from bidder’s scope. Shot blasting, and primer shall also be completed
at shop for platform components as applicable.
General Instructions
Page 109 of 434
DOCUMENT No.
Rev. A
Page 5 of 9
1. Stage wise & final inspection of the vessel shall be by Third Party Inspection Agency
(Refer commercial documents for list of approved agencies). Fabrication shall not commence
before their approval except as noted at Sl. No. 2 & 3.
2. Raw material procurement may proceed prior to approval of vendor drawings on the basis of
Material Requisition and all testing and agency for testing shall be arranged by Vendor.
3. Shell rolling/welding and dished - head fabrication shall commence without awaiting
fabrication drawing approval. Inspection shall be carried out in accordance with Purchase
Requisition documents till approved fabrication drawings are available.
4. Material for shell, dished ends and skirt shall be considered as major raw material wherever
identification of major raw material is one of the payment milestones.
5. Purchase requisition shall be issued within two weeks of Fax of intent (FOI). Final nozzle
sizes (without any holds) shall be issued along with purchase requisition or latest within one
month of Fax of intent (FOI).
6. Nozzle orientation of the equipment shall be issued latest by mid of contractual delivery
period reckoned from date of issue of Fax of intent (FOI) .
7. Pipe support/structural clip details shall be issued latest by three months before contractual
delivery date.
8. Approved for construction (AFC) drawings of platforms shall be issued latest by three months
before contractual delivery date.
9. Minimum course width shall be 1 metre. Maximum no. of longitudinal seams shall be as
follows:
(a) vessels upto 2 metre diameter : 1 seam
(b) vessels from 2 metre upto 4 metre dia. : 2 seam
(c) vessels from 4 metre upto 6 metre dia. : 3 seam
(d) vessels from 6 metre upto 10 metre dia. : 9 seam
In any case, distance between two longitudinal seams shall not be less than 3 meters. .
10. If any discrepancy is found during design and fabrication stages, the fabricator shall inform
EIL immediately and shall obtain necessary clarification/approval before proceeding with that
portion of the job any further. EIL's review of fabricator's drawings and documents must not
be considered as a check and shall not relieve the fabricator of his responsibilities to supply
equipment as per requisition. Fabricator shall remain responsible for conflicts between his
drawings/documents and EIL drawings/documents.
11. English language and metric units shall be used in all documents. Drawings shall be prepared
in prescribed sizes as standardised by bureau of indian standards (BIS) and shall be
preferably in the sizes such as 210 x 297, 297 x 420, 420 x 597, 597 x 841, 841 x 1189 mm.
12. All fabricator's drawings submitted to EIL shall be based on purchase requisition and shall
bear reference number and revision of the corresponding EIL drawings. It shall indicate the
following in the lower right hand corner. All revisions shall be clearly marked by encircling
with revision marks.
Item Number
Owner name and logo. (attached with MR)
PMC name and logo. (attached with MR)
Page 110 of 434
DOCUMENT No.
Rev. A
Page 6 of 9
The document number

Contractor (EIL) name and logo (attached with MR)
Fabricator name
Purchase Order No.
Purchase requisition No.
Contractor Job reference number (i.e. A133)
The date and revision number of the document
The purpose of issue or revision of the document
The title of the document, including the Contract name
The project name
The unit number
The signature or initials of the persons who drafted, checked and approved the document
(for each revision)
Space for approval of each revision
13. Submission of required drawings/documents shall be the responsibility of fabricator. In the

event of fabricator's failure to meet this requirement, the supply of equipment shall be
considered as incomplete.
14. Preparation & Submission of Document Control Index (DCI):
a). Vendor shall prepare Document Control Index (list of those drawings, which are to be
submitted to EIL along with the submission dates for each drawing) within 15 days of
placement of FOI. Successful bidder to submit DCI (document control index) and all
the vendor data through vendor portal (http://edocx.eil.co.in:7001/vportal) and refer
general note-3 of Vendor data requirements document (Doc. No. A133-086-16-46-VDR-
6135). The detail guidelines for uploading the documents on vendor portal are
available on the site itself. Successful bidder to submit all the documents as
scheduled documents only.
b). Vendor to note that unscheduled documents (documents which are not listed in DCI)
shall not be accepted by EIL. All vendor drawings/documents shall be submitted as
scheduled document only.
15. All drawings shall be thoroughly checked and duly signed by fabricator. Unchecked drawings
and drawings without revisions clearly marked shall be returned without review. Successive
review of the same fabricator's drawing shall apply only to EIL's latest data sheet/comments
on the previous revision. Drawings and documents returned to fabricator for revision shall be
resubmitted preferably within ten days of receipt.
16. Dimensions of all flanges shall be as per ANSI B16.5 for nozzle sizes 24"NB and below and
as per ANSI B16.47 Series B for sizes greater than 24"NB, unless otherwise stated.
17. Fabrication drawings shall be submitted in following stages:
Stage-I
- General arrangement drawing indicating design data, fabricated equipment's weight,
general notes, nozzle schedule, detail of shell, heads, skirt/supporting arrangement, main
weld seams, nozzle orientation plan, cutting layout (in case of free issue material) etc.
- Detail of all nozzles, manholes, accessories etc.
- Bill of material for each item showing part size, quantity, material specification, scope of
supply and weight etc.
Page 111 of 434
DOCUMENT No.
Rev. A
Page 7 of 9
Stage-II
- Detail of internals such as tray support ring and bolting bar.
- Detail of internal distributor, demister support and packing support etc.
- Detail of external clips for ladder, platform, pipe support, insulation, fire proofing, pipe davit,
lifting lugs etc.
- Shell development drawing incorporating all attachments and weld seams.
- Bill of material for each item showing part size, quantity, material specification, scope of
supply and weight etc.
- Details of platforms including support beam, grating etc.
- In case of owner's free issue plate material, fabricator shall submit plate cutting diagram for
EIL's approval.
18. After receipt of order, fabricator shall submit to EIL, the planning of fabrication which shall
indicate the details and scheduled date of:
- Sub orders.
- Purchase of materials such as plates, pipes, forged flanges, bolting, gaskets, etc.
- Start of fabrication of dished ends and shell, welding of shell and heads.
- Welding of nozzles and external attachments such as cleats etc.
- Phased programme of shop/site fabrication of equipment section, shop assembly, testing

and despatch to site.
This planning shall be established to extend from purchasing of equipment components to the
end of fabrication and delivery of equipment.
19. All drawings shall be drawn in AUTOCAD R-14.No hand drawn drawings shall be accepted.
All residual calculations shall be computerised.
20. Documents and letters shall be furnished in electronic format. The software used shall be as
follows.
a) MS OFFICE 97 or above
b) ADOBE ACROBAT 4.0 & ABOVE
21. In case of owner's free issue plate material, fabricator shall tabulate each plate detail as per
following table:
Plate No./ Material Size of Plate Equipment Ref. Dwg. Part

Plate mark Specification Thk x Width x Length Number No. number and
(mm) x (M) x (M) qty.
Size of Plate Heat/ Plate Weight Used plate Burnout
Page 112 of 434
DOCUMENT No.
Rev. A
Page 8 of 9
Thk x Width x Length sample (Kgs.) weight (Kgs.) losses

(mm) x (M) x (M) number (Kgs.)
Returnable offcut Returnable offcut Non returnable scrap Remarks

size with sketch weight (Kgs.) weight (Kgs.)
Fabricator shall be allowed 2% burnout losses against the material consumed in case of
pressure vessels and 1% in case of storage tanks and spheres unless otherwise specified. In
general purchase conditions.all offcuts of width 800mm and perimeter 2400mm in carbon
steel materials and 150mm width and perimeter 1500mm in stainless steel materials shall be
returned to owner, unless otherwise specified. Returnable offcuts shall have original plate
markings transferred and duly stamped by inspector. All other non returnable scrap shall be
sold by fabricator on the basis of owner's instructions and approval.
22. Words “fabricator”, “vendor”, “contractor” appearing any where in the MR/Specifications/
Standards etc. shall be read as “bidder”.
23. Further to pt. No. 9 of General Instructions; Bidder to note that interference of nozzles
with circumferential seams is not acceptable. However, vendor to take suitable care to
avoid fouling of external/internal attachments with C-seams. Vendor to submit shell
development for checking above in the 1st submission.
24. Vendor shall note that the vendor drawing for the following standard components shall not be
reviewed by EIL. It shall be solely vendor's responsibility to ensure the correctness of these
drawings as per EIL Standards and Drawings. If any discrepancy / mistake is found at a later
date the vendor shall rectify the same at his time and cost.
- Manhole davit/ hinge arrangement & Ladder rungs

- Pipe Davit
- EIL Name plate, Manufacturer's Nameplate, Nameplate bracket
- Skirt (Pipe) opening details, Access Opening Details, Skirt vent.
- Lifting lugs (Standard Type)
- Fireproofing and Insulation Support
- Earthing lug
- Pipe support cleats and ladder and platform cleats (Fouling of external support cleats (if
any), shall be highlighted to EIL along with shell development drawing and suggestion for
resolution)
However, all these above listed drawing shall be submitted in a separate drawing for
information to EIL ensuring adherence to all the respective EIL Standards and Drawings.
Clarifications (if any) shall be obtained by Vendor from EIL before fabrication.
25. Standard Inspection and test plans are attached with requisition for guidance. Vendor shall
submit inspection test plans for the approval of visiting inspection engineer. Inspection shall
take care of all the requirements of specifications. Inspection engineer has the authority to
modify the plan depending on the criticality of the item.
26. In the event of conflict, most stringent requirement in following order of precedence shall
govern:
a) EIL Mechanical Data Sheet and MR requirements

b) EIL specifications and standards
c) Codes
Page 113 of 434
DOCUMENT No.
Rev. A
Page 9 of 9
However in event of conflict it shall be the duty of the Vendor to bring it to EIL’s attention for
resolution and resolve it before proceeding with the manufacture. EIL’s comments shall be
final and binding on vendor without any cost and delivery implications.
ADDITIONAL REQUIREMENTS:
1.0 The following formats are attached with the MR. The same shall be filled by vendor with
each transmittal, submitted to EIL for approval/review or records.
a) Compliance Statement: Any EIL/PMC comments shall be indicated on the

compliance statement sheet alongwith resolution.
2.0 Vendor shall furnish itemized price list for 2 years normal operation and maintenance
spares, if any.
3.0 Access to Client/TPIA/EIL/PMC shall be provided at all times for inspection at fabrication
yard during execution of the job.
4.0 FOR PRESERVATION AT SITE: Non stick/washable coating of approved make shall be
applied inside the complete equipment to protect/preserve the equipment. The coating shall
be completely removable by water. The coating shall be suitable for protecting the
equipment at least for 6 months.
Vendor to apply the coating before dispatching the equipment. Localized coating at location
of site seam to be performed at site.
5.0 SPIR form duly filled shall be furnished by vendor after code-2 approval of the drawings.
Page 114 of 434
LIST OF APPLICABLE DOCUMENT No.
SPECIFICATIONS AND A133-16-46-LL-6141
STANDARDS Rev. A
Page 1 of 6
LIST OF APPLICABLE
SPECIFICATIONS & STANDARDS

JOB NO. : A133

Date Purpose
No by by by
Page 115 of 434

STANDARDS Rev. A
Page 2 of 6
LIST OF APPLICABLE SPECIFICATIONS
[X] indicates applicability

Title Doc No. Shts. Rev
[ ] Engineering Design Basis Static 44NC-4600-0000- 49 1
Equipment. V.02-0001-A4
[X] General Specification For Positive 44NC-4600-0000- 7 0

Material Identification (PMI) at V.02-0100-A4
Vendor’s Works
[ ] Specification for positive material 44NC-4600- 7 2
identification (PMI) at site 00/X.02/005/A4
[X] General Specification For Pressure 44NC-4600-0000- 41 0

Vessels V.02-0101-A4
[ ] General Specification For Trays 44NC-4600-0000- 10 0

And Tower Internals ( Applicable for V.02-0107-A4
Welded Internal only)
[ ] General Specification For 44NC-4600-0000- 5 0

Fabrication Of Tower Internals V.02-0109-A4
[ ] General Specification For Knitted 44NC-4600-0000- 4 0

Wire Mesh Demister V.02-0110-A4
[X] General Specification For Shop and 44NC-4600-0000- 45 1

Field Painting V.02-0111-A4
[X] General Specification- Material 44NC-4600-0000- 17 0

Specification (Carbon equivalent V.02-0114-A4
issue)
[X] Standard Specification For BQ 44NC-4600-0000- 5 0

Carbon Steel Plates V.02-0117-A4
[] Standard Specification For Alloy 44NC-4600-0000- 8 0

Clad Vessels and Heat Exchangers V.02-0119-A4
[X] Supplementary Specification For 44NC-4600-0000- 5 0

Carbon Steel Vessels V.02-0120-A4
[] Standard Specification For Cladded 44NC-4600-0000- 5 0

Plates V.02-0121-A4
[] Packing, Marking and Shipping 44NC-4600-0000- 4 0

Specifications for Tray and Tower V.02-0124-A4
Internals
[] Job Specification for Column 44NC-4600-0000- 29 1

V.02-0140-A4
Page 116 of 434

STANDARDS Rev. A
Page 3 of 6

[X] Job Specification for Vessels 44NC-4600-0000- 23 A
V.02-0141-A4
[X] General Notes for CS/KCS Vessels 44NC-4600-0000- 1 1

V.02-0164-A3
[] General Notes for SS Clad Column/ 44NC-4600-0000- 1 1

Vessels V.02-0165-A3
[] Scope of work for Fabricated 44NC-4600-0000- 9 1

Equipment V.02-0172-A4
[X] Quality Management System 44NC-4600- 7+6 A

0000/N.02/0040/A4+
Annexure- I to V
[] Standard specification for Field 44NC-4600- 101 A1

(HSE) Activities 003/X.02/004/A4
NOTE: ANY DISCREPANCY BETWEEN VARIOUS APPLICABLE SPECIFICATIONS SHALL BE

BROUGHT TO EIL/PMC NOTICE. PRIOR WRITTEN APPROVAL SHALL BE OBTAINED
BEFORE PROCEEDING WITH THE JOB.
Page 117 of 434

STANDARDS Rev. A
Page 4 of 6
LIST OF APPLICABLE STANDARDS

[X] indicates applicability
[X] General Tolerances for Pressure Vessels

IND VSD 001 3 0
[X] Manway Davit (for Vertical Manhole) IND VSD 002 1 0

[X] Manway Davit (for Horizontal Manhole) IND VSD 003 1 0
[X] Detail of Vessel/Column Top Davit IND VSD 004 1 0
[ ] Top Davit Support Detail for Cold
IND VSD 005 2 0
Insulated Vessels
[X] Detail of Skirt Opening for Vessel &
IND VSD 006 1 0
Column
[X] Detail of Skirt Base for Vessel & Column IND VSD 007 1 0
[ ] Leg Support for Vertical vessel IND VSD 008 0

2
[X] Saddle Support for Horizontal Vessels IND VSD 009 0
7
[ ] Lug Supports IND VSD 010 2 0
[ ] Pipe Leg Support IND VSD 011 1 0
[X] Minimum Nozzle Wall Thickness IND VSD 012 1 0
[ ] Swing Stopper IND VSD 013 1 0
[ ] Carbon Steel Jacketed Nozzle
IND VSD 014 1 0
(Horizontal)
[ ] Stainless Steel Jacketed Nozzle
IND VSD 015 1 0
(Horizontal)
[ ] Carbon Steel Jacketed Nozzle (Vertical) IND VSD 016 1 0
[ ] Stainless Steel Jacketed Nozzle
IND VSD 017 1 0
(Vertical)
[X] Reinforcing Plates for Nozzles (C.A.
IND VSD 018 1 0
3mm)
[X] Reinforcing Plates for Nozzles (C.A.
IND VSD 019 1 0
1.5mm)
[X] Name Plate Bracket IND VSD 020 1 0
[X] Standard Name Plate for Vessel IND VSD 021 1 0
[X] Insulation Supports for Vessels (hot) IND VSD 022 1 0
[ ] Insulation Supports for Vessels (cold) IND VSD 023 1 0
[X] Standard Nozzle Projection IND VSD 024 1 0
[ ] Lifting Trunnions IND VSD 025 1 0
[ ] Light and Sight Glasses IND VSD 026 1 0
[ ] Sight Glass for Pressure Vessels
IND VSD 027 1 0
(300x50)
[ ] Manhole with Hinged Cover IND VSD 028 2 0
[ ] Handhole with Hinged Cover IND VSD 029 1 0
[X] Standard Internal Plate Flanges IND VSD 030 1 0
Page 118 of 434

STANDARDS Rev. A
Page 5 of 6
[ ] Details of self reinforced forged nozzles IND VSD 031 1 0

[ ] Screwed Coupling IND VSD 032 1 0
[X] Vortex Breakers (Flush Type Nozzles) IND VSD 033 1 0
[X] Vortex Breakers (Nozzle with Internal
IND VSD 034 1 0
Projection)
[ ] Nozzle Internal Baffle (for Instrument) IND VSD 035 1 0
[ ] Standard Demisters type-I (Vessel dia. <
IND VSD 036 1 0
800 mm)
[ ] Standard Demisters type-II (Vessel dia. >
IND VSD 037 2 0
800 mm)
[ ] Standard Demisters type-III IND VSD 038 1 0
[ ] Standard Demisters type-IV IND VSD 039 1 0
[X] Standard Bolt Hole Orientation IND VSD 040 1 0
[ ] Earthing Boss IND VSD 041 1 0
[ ] Tailing Lug IND VSD 042 1 0
[X] Ladder Rungs Inside Vessels and
IND VSD 043 1 0
Columns
[ ] Foundation Template IND VSD 044 2 0
[X] Support for Internal Distributor Pipes IND VSD 045 1 0
[X] Support for Internal Feed Pipe IND VSD 046 1 0
[X] Supports for Internal Feed Pipe IND VSD 047 1 0
[X] Lifting Lug Top Head Type IND VSD 048 1 0
[X] Lifting Lug for Vertical Vessel IND VSD 049 1 0
[X] Lifting Lug for Horizontal Vessel IND VSD 050 1 0
[X] Typ. Nozzle Flange to Neck Joint IND VSD 051 1 0
[X] Recommended Weld Edge Preparation
IND VSD 052 1 0
for Butt welds
[ ] Alloy Liner Details IND VSD 053

2
0
[ ] Pad Type Handholes with Cover Flange

IND VSD 054 1 0
ANSI Class 150# & 300#
[ ] Support Ring and Bolting Bar IND VSD 055 1 0
[ ] Support Ring Sizes for Packed Towers IND VSD 056 1 0
[ ] Insulation Supports for Vertical Vessel
IND VSD 057 2 0
[X] Insulation Supports for Horizontal Vessel IND VSD 058 1 0

[ ] Complementary Material Cold Insulation
(for Support Saddles of Horizontal Steel IND VSD 059 2 0
Vessels)
[ ] Manhole Cover with Trolley (450 to 600
IND VSD 060 1 0
dia.)
[ ] S.R. Nozzle Neck IND VSD 061 1 0
Page 119 of 434

STANDARDS Rev. A
Page 6 of 6
[X] Fire Proofing Support IND VSD 062 1 0

[ ] Pad Nozzles for Vessels IND VSD 063 1 0
[X] Inlet Deflector Baffle IND VSD 064 1 0
[ ] Packing, Marking & Shipping
Specifications for tray and tower IND VSD 079 1 0
internals
[X] Earthing Lug IND VSD 080 1 0
[X] Vortex Breaker 7-12-0019 5

1
[X] Name Plate for Small Equipment 7-12-0030 4
1
Page 120 of 434

DOCUMENT No.
SCOPE OF SUPPLY A133-16-46-SS-6141
Rev. A
Page 1 of 5
SCOPE OF SUPPLY

JOB NO. : A133

Date Purpose
No by by by
Page 121 of 434

DOCUMENT No.
Rev. A
Page 2 of 5
SCOPE OF SUPPLY
[X] Indicates applicability
The following materials will be supplied by
1. Owner
1.1 Boiler quality/low-alloy/stainless/clad steel plate conforming to specification

NIL for
[] Shell
[] Dished head/intermediate head/cone
[] Sump and sump head
[] Skirt
[] Manhole neck, nozzle neck 300 NB and above in carbon steel and 125 NB and above
in stainless steel
[] Reinforcement pad
[] Wrapper plate
[] Plate type flange
[] Internal piping
[] Tray support ring/bolting bar/seal pan welded to the vessel
[] Pad for external attachment (directly welded to shell)
[] Insulation support
[] Lifting lugs
[] Baffle
[] Demister support
1.2 [ ] Forged flange/matching blind flange
[] Pipe for nozzle neck
[] Pipe fitting
[] Gasket
1.3 [X] Foundation/anchor bolts
[X] Permanent instruments
Page 122 of 434

DOCUMENT No.
Rev. A
Page 3 of 5
[] Demister with grid, bolting and support beams
[X] Fire proofing and insulation
[X] Pump assembly with bolting
[] Agitator assembly with bolting
[] Tray/downcomer/seal pan /chimney tray not welded to the vessel
[] Brick lining
[] Refractory lining
[] Spray nozzles
[] Tower packing & associated internals including distributor (as indicated in respective
MDS), feed pipes, support grid / plates, retaining grid / bed limiters etc associated
with packing.
[ ] Light and sight glass assembly
[X] Thermowells
2. VENDOR
2.1 Boiler quality/low alloy/stainless steel/ clad steel / Monel plate conforming to
specification as indicated in respective vessel mechanical data sheets for :-
[X] Shell
[X] Dished head/intermediate head/cone / toricone.
[X] Sump and sump head
[X] Skirt (part)/ Anchor chair/ Base plate/Lug/ intermediate skirt
[X] Manhole neck, nozzle neck above 300 NB in carbon steel and 125 NB and above in
stainless steel & 350 NB and above and in clad steel shall be fabricated from clad
plate.
[X] Reinforcement pad / Insert plate
[X] Wrapper plate
[X] Plate type flange
[X] Internal piping
[ ] Tray support ring/bolting bar/seal pan and their supports welded to the vessel
[X] Pad for external attachment
[X] Fire proofing and insulation support
[ ] Saddle support/bracket/leg support
[X] Lifting lug/ trunions
Page 123 of 434

DOCUMENT No.
Rev. A
Page 4 of 5
[X] Baffle, vortex breaker, ladder rungs

[ ] Welded demister support ring
[X] Sand bed/Catalyst support ring, support beam
[ ] Wear plate / Retaining Plate
[ ] Welded trays/other internals welded with column.
[X] Vacuum stiffening rings, structural & Piping cleats (welded directly over shell / head)
[X] All welded support for packing, distributors, chimney trays, other internals etc
[X] All plate fabricated welded/removable attachments like manhole in partition baffle,
supporting members etc.
2.2 Structural steel section and plate conforming to IS:226/IS:2062 Gr.B / SA-283 Gr.C
for
[ ] Shell
[X] Skirt/anchor chair/base plate/saddle and bracket support
[ ] Internals
[X] Insulation support/fire proofing support over BQCS pad or on skirt (IS 2062 portion)
[ ] Flat cover
[ ] Manway flange/cover
[ ] Tailing lug in skirt portion /Trunion with BQCS pad
[X] Structural/Piping clips welded over BQCS pad or on skirt (IS 2062 portion)
[ ] Section for stiffeners for skirt base/anchor block
[ ] Leg supports and base plate
2.3 [X] Forged flanges / matching blind flange wherever shown
[X] Studs/bolts and nuts for manway/handholes/internal flanges /nozzles with matching
flange/shell flange, including jack bolts for manway
[X] Gasket for manway/handhole/internal flange/shell flange/ nozzles shown with blind
flanges
[X] Welding consumables and gases
[X] Wire meshes/SS Screen with grid (Profile type)/ SS distributor
[ ] Demister with SS grid and SS bolting
[ ] Agitator assembly with bolting
[ ] Pump assembly with bolting
Page 124 of 434

DOCUMENT No.
Rev. A
Page 5 of 5
[X] Seamless nozzle neck 300 NB and below in carbon steel & weld overlayed nozzles
[X] Internal piping, distributors, coupling and pipe fitting
[ ] Spray nozzle
[ ] Internal packing
[ ] Light and sight glass assembly with 4 sets of spare glasses for each size
[X] Self reinforced nozzles, LWN nozzles as applicable
[X] Davit/hinge assembly for manway.
[ ] Davit/hinge assembly for handhole.
[X] Pipe davit assembly for equipment
[X] Items covered in applicable standards
[X] All other metallic and non-metallic parts, consumables and gases not covered under
1 and 2 but required to complete fabricated equipments including inspection, testing
and supply of equipments as per this requisition
[ ] Design and supply of lifting trunion/lug for columns/ column sections
[X] Mandatory spares - 10% of fasteners (minimum two numbers for each size) and two
sets of gaskets for each nozzle shown with blind flange/for each shell flange/for all
internal flanges
[X] Commissioning spares - 10% of fasteners (minimum two numbers of each size) and
one set of gaskets for each nozzle shown with blind flange/for each shell flange/for
all internal flanges
[ ] Spares( demister) - 10% (min. 4 nos. Of each size/type) extra fasteners (bolts,nuts,
clamps, spacers etc.) as required for holding the demister
[X] The Monkey ladder inside the skirt.
[X] Still Well for Item tag-86-C-51
[X] Steam coil for Item Tag-86-C-51
[X] Supply of all materials, fabrication of all platforms, ladders, cage ladders,
hand railing, hot dip electroforged galvanized grating and other structural
works as per schedule of quantities attached with MR.
[X] Non stick/washable coating inside the equipment/equipment section.
[SPARES SPECIFIED AS ABOVE SHALL ONLY BE CONSIDERED. SPARES SPECIFIED

ELSEWHERE SHALL NOT BE TAKEN INTO CONSIDERATION.]
Page 125 of 434

Page 126 of 434
Page 127 of 434
Page 128 of 434
Page 129 of 434
Page 1 of 7
CHENNAI PETROLEUM CORPORATION LIMITED

CHENNAI, INDIA
CPCL REFINERY - RESID UPGRADATION PROJECT
PART : V
SECTION : 3.4
TITLE: GENERAL SPECIFICATION FOR POSITIVE MATERIAL

IDENTIFICATION (PMI) AT VENDOR’S WORKS
DOCUMENT NO. 44NC-4600-0000-V.02-0100-A4
Rev Issue Date Pages Rev Description Prepared Checked Approved

No.
By By By
0 09.03.2010 7 Issued as general specification MS CR CR
Page 130 of 434

CPCL, Chennai GENERAL SPECIFICATION FOR Part V Section 3.4
44NC-4600 PMI AT VENDOR’S WORKS Page 2 of 7
LSTK Doc. No. 44NC-4600-0000-V-02-0100-A4 Rev. 0
TABLE OF CONTENTS
1.0 SCOPE
2.0 DEFINITIONS
3.0 PMI EXAMINATION
4.0 ACCEPTABLE METHODS FOR PMI
5.0 EXTENT OF PMI EXAMINATION
6.0 RECORDING AND DOCUMENTATION
7.0 MARKING
8.0 ATTACHMENTS
8.1 TYPICAL POSITIVE MATERIAL IDENTIFICATION REPORT FORM – ALLOY STEEL BULK
MATERIAL
Page 131 of 434

1.0 SCOPE
1.1 This specification applies to the requirements for Positive Material Identification (PMI) to be
performed at vendor’s works on Metallic Alloy Materials procured either directly by Vendor or
indirectly through their sub-vendors. Any deviations from this specification must be approved by
Purchaser in the deviation / Waiver permit format. This specification shall also be read in
conjunction with positive material identification at site.
1.2 This Specification covers the procedures and methodology to be adopted to assure that the
chemical composition of alloy material is consistent with the material specification as specified in
purchase documents using alloy analyser at the time of final inspection before despatch.
1.3 The scope of this specification shall include but not limited to Positive Material identification (PMI) to
be performed on Alloy Piping Materials listed below :
However all grades of materials including stainless steel are subjected to PMI verification / test after
receipt at site.
− Alloy Steel Pipes

− Alloy steel plates
− Alloy steel large forgings
− Alloy Steel nozzle Flanges & Forgings
− Alloy Steel Fittings
− Alloy Steel Fasteners
− Alloy Cast & Forged Steel Valves
− Alloy Steel Instrumentation items (Control Valve, Safety Valves etc.)
− Equipment, Pipe & Fittings Welds.
− Gaskets (Ring Type Joints)
Following items shall be excluded from scope of PMI examination
− Gasket other than Ring Type Joints

− Valve internal Components
2.0 DEFINITIONS
2.1 Vendor : Any supplier or manufacturers on whom an order is placed for supply of referred piping
items. This definition shall also include any sub-vendor or manufacturers on whom a sub-order is
placed by the vendor.
2.2 Inspection Lot : A group of items offered for Inspection covered under same size, heat and heat
treatment lot.
2.3 Alloy Material : Any metallic material (including welding filler materials) that contains alloying
elements such as chromium, nickel, molybdenum, vanadium, etc which are intentionally added to
enhance mechanical or physical properties and/or corrosion resistance.
44NC-4600-0000-V.02-0100-A4 General spec for PMI-Vendor.doc
Page 132 of 434

3.0 PMI EXAMINATION
3.1 The Vendor shall submit a procedure of PMI to comply with the requirements of this Specification.
Approval of PMI procedure shall be obtained from Purchaser prior to commencing manufacturer /
inspection of product.
3.2 PMI examination of alloy materials is independent of any certification, markings of colour coding that
may exist and is aimed at verifying that the alloy used are as per specified grades.
3.3 The Vendor shall identify all incoming alloy materials and maintain full traceability of all alloy
materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to cutting
to ensure maintenance of identification on off-cuts.
3.4 The Vendor shall ensure that all materials are segregated and stored in separately identified
locations to prevent the mix-up of materials of different alloy specifications or alloy material with
carbon steel. Non-ferro-magnetic materials shall be segregated at all times from ferro – magnetic
materials.
3.5 PMI examination is subject to surveillance inspection by Vendor / Jacobs / Third Party Inspection
Agency / Purchaser as specified in Quality Assurance Plan.
4.0 ACCEPTABLE METHODS FOR PMI
4.1 The Method used for PMI examination shall provide a quantitative determination of the alloying
elements like Cr, Mo, Ni, V in Alloy Steel items. For Non-Ferrous alloys quantitative determination of
appropriate alloying elements shall be verified.
4.2 Instruments or methods used for PMI examination shall be of those that will provide quantitative,
recordable, elemental composition results for positive identification of alloying elements present.
4.3 The acceptable instrument for alloy analyser shall be either “Portable X-ray fluorescence” or “Optical
Emission Spectro Analyser” type capable of verifying the percentage of alloy elements within
specified range.
4.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current methods are
not acceptable for PMI examination.
4.5 The PMI instrument used shall have the sensitivity to detect the alloying elements in the specified
range.
4.6 Each analyser must be calibrated according to the manufacturer’s specification at the beginning and
end of each shift. Instrument must be checked against known standard for each alloy type to be
inspected during the shift.
4.7 Certified samples with full traceability of “known” alloy materials shall be available for use as a
random spot check on the instrument calibration.
4.8 The surface to be examined shall be prepared by light grinding or abrasive paper and solvent
cleaner. Evidence of arc burn resulting from examination shall be removed by light grinding or
abrasive paper.
Page 133 of 434

4.9 Alloy steel type joint gaskets shall only be inspected by using portable X-ray fluorescence
instrument.
4.10 Testing shall be done as per the procedures outlined by the manufactures of alloy analyser being
used. Modification of these procedures if any, must be approved by Purchaser.
4.11 The persons performing PMI shall demonstrate their capabilities to the satisfaction of
Owner/Jacobs/Third Party Inspection Engineer. If the vendor has qualified operator in his rolls, he
may perform the examination. Otherwise PMI examination shall be sub contracted to an
independent testing agency.
4.12 Whenever materials, items and welds are identified as not meeting requirements by the visiting
engineer a rejection note shall be issued. The above shall be marked with a red “R” pending
resolution.
5.0 EXTENT OF PMI EXAMINATION
Following sampling plans shall be applicable for PMI examination of various alloy items.
A. Flanges, Fittings, Valves, RTJ : 100%

Gaskets
B. Pipes,Plates,Forgings : 100% (for pipes, plates, Forgings procured
from traders).
10% random samples (minimum 2 Nos.)
drawn from each size/Heat/Lot (for
pipes,plates ,Forgings procured directly from
mills).
C. Tubes for heat transfer service : 100% (for tubes procured from traders).
Spot checking by sampling 1% of the tubes or
25 nos. whichever is less (for tubes procured
directly from mills.
D Fasteners :
Lot Size Sample Size

Upto 100 2% (Min 2)
101 to 500 1% (Min 3)
501 and above 0.5% (min 5)
6.0 RECORDING AND DOCUMENTATION
The results of PMI examination shall be recorded in the PMI Report Form as enclosed with this
specification.
Page 134 of 434

7.0 MARKING
7.1 All alloy materials tested by PMI shall be identified using either of the following methods by
indicating “AV”
a) Electro – etching
b) A low stress stamp marking
c) Hologram Sticker
d) Vibro – etching
e) Colour Coding
Location of markings will be near to vendor’s monogram, material specification, heat number / cast
number, welders stamp, etc as applicable.
8.0 ATTACHMENTS
As enclosed.
Page 135 of 434

PMI REPORT FORM – ALLOY BULK MATERIAL
ATTACHMENT 8.1
TYPICAL POSITIVE MATERIAL IDENTIFICATION REPORT : ALLOY STEEL
Page ….of ….
BULK MATERIALS
Project : Client : Job No. :
PMI Report No. : Vendor / Sub-Vendor :
Purchase Order No. : Testing Agency :

Purchase
PMI Location :
Requisition No.
Bulk Item Type (as per Requisition)
Material Specification / Grade :
Number of items in Lot :

Remarks
Requisition Item No. Description : Alloy Content Weight Percent
Accept/Reject
Cr. Mo Ni V
Source Age
Instrument Type / ID
Source dt.
Last Service Date :
PMI Examination Approved by
Witnessed by
by : Vendor
Company
Page 136 of 434

STANDARD No.
15i1WieditENIGNEERS
NAME PLATE
41gatafflegwiNDR LIMITED FOR 7-12-0030 Rev. 4
men 0E44E10139MR) (A Govt. of kidio Undertaking)
SMALL EQUIPMENT Page 1 of 1
1"1' 0
125
M IS NAME OF MANUFACTURER
DESIGNED BY I I OWNER I
cs,
ITEM NO. I I JOB NO. I rs,
, P.O. NO. I I YEAR OF FABRICATION I
(.1
D in CODES I INSPECTED BY I ,
IN N. I
DESIGN PRESSURE I I DESIGN TEMPERATURE I
CORROSION ALLOW. I I RADIOGRAPHY I
cs,
TEST PRESSURE I I EMPTY WEIGHT I
rs,
4,st- I
4" DATE OF TEST I
el
5R
4.50 HOLE 2
28 26 28
BRACKET
NAME /
PLATE
NOTES
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED.
ALL LETTERS, BLOCKS AND BORDERS SHALL BE RAISED POLISHED FACE.
BACKGROUND SHALL BE BLACK.
NAME PLATE SHALL BE TACK—WELDED TO THE BRACKET. WHERE NOT POSSIBLE
IT MAY BE RIVETTED.
NAME PLATE SHALL BE OF STAINLESS STEEL OF 2mm THICK.
BRACKET MATERIAL SHALL BE SAME AS SHELL MATERIAL.
4
3
31.08.2011
12.10.2006
REAFFIRMED AND REISSUED AS STANDARD
REAFFIRMED AND REISSUED AS STANDARD
POREL
POREL
A41
KT
RKG
A.D‘>)
kAAr914/1"/
KM / SC
AKM
DM
VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Page 137 of 434 Copyright EIL - All rights reserved
Format No. 8-00-0001-F4 Rev.0
Page 138 of 434
Page 139 of 434
ANNEXURE - I
QUALITY PLAN (Design Function) Document Number
Organisation DIVISION / Document Number
DEPARTMENT : Revision Number Sheet of
Reviewed by : (Signature, Name & Date)

Page 140 of 434
Approved by : (Signature, Name & Date)

GENERAL BASIC PROCESS DESIGN MATURITY Final All
Procedure / Verification Verification Reviewed Validated Validation Approval Records Generated
Activity module / Deliverable Work Ins. Performer By Method By By Method By
ANNEXURE - II
QUALITY PLAN (Project Services) Document Number

Page 141 of 434

GENERAL BASIC PROCESS SERVICE PERFORMANCE ANALYSIS All
Activity Description Procedure / Performer Reports / Outputs Sampling Acceptance Criteria By Records Generated
Work Ins. Basis
ANNEXURE - III
QUALITY PLAN (Procurement Function) Document Number

Page 142 of 434

GENERAL BASIC PROCESS FINAL APPROVAL All
Activity Module / Deliverable Procedure / Performer Reviewer (if any) Sampling Acceptance By Records Generated
Work Ins. Basis Criteria
ANNEXURE - IV
QUALITY PLAN (Construction Activities) Document Number

Page 143 of 434

GENERAL BASIC PROCESS FINAL APPROVAL All
Activity Module / Deliverable Procedure / Performer Records Maintained Sampling Acceptance Criteria Inspected Records Generated
Work Ins. Basis By
ANNEXURE V
QUALITY PLAN (Design Function)
(STRIKE WHICH EVER IS NOT APPLICABLE)
PROJECT _______________________ ORIGINATOR REF. __________________
JOB NO. ________________________ ORDER / CONTRACT NO. _______________

TO BE FILLED BY ORIGINATOR
ORIGINATOR : VENDOR / CONTRACTOR / JACOBS DEPARTMENT ______________________________________________
REQUIREMENT AS PER SPECIFICATION DESCRIPTION OF WAIVER / DEVIATION SOUGHT
Why the Waiver / Deviation is required ?
Contractual Implication if waiver / deviation is granted :

* Time taken shall be More / Less / No change
* Cost of item shall be More / Less / No change
* Performance requirement shall be Satisfied / Not Satisfied
Under present constraints, requested waiver / deviation is most optimum for the project and does not involve any security and
safety hazard
Date Signature
Contractor / Vendor(With Seal) / Jacobs
Decision on waiver / deviation with remarks, if any, on time / cost implications
(To be filled by the department / division in Jacobs responsible for conveying to the originator)
Signature : _________________________
Date : _____________
Name : _____________________________
WAIVER / DEVIATION REQUEST NUMBER
Page 144 of 434

OPINION FROM PMC
Date : __________ Signature : _________________

Name : ____________________
Department : ________________
FORWARDED TO ________________________ BY PROJECT DIRECTOR OF PMC

(PROJECT MANAGER)
Date : __________ Signature : _________________

Name : ____________________
FORWARDED TO __________________
(Target Resolution Div / Dept./Group)
Date : __________ Signature : ___________________

(PROJECT MANAGER)
Name : ____________________
DISPOSITION BY TARGET RESOLUTION DIV / DEPT / GROUP
Date : __________ Signature : _________________

Name : ____________________
FINAL DECISION OF PROJECT MANAGER ALONG WITH OVERALL REVIEW

(Client's decision required / not required)
Date : __________ Signature : _________________

Name : ____________________
OWNER'S DECISION, IF REQUIRED
Date : __________ Signature : _________________

Name : ____________________
WAIVER / DEVIATION REQUEST NUMBER
Page 145 of 434

Page 146 of 434
Page 1 of 45

CHENNAI, INDIA
PART : III
SECTION : B.12
TITLE: GENERAL SPECIFICATION FOR SHOP AND FIELD PAINTING
DOCUMENT NO. : 44NC-4600-0000-V.02-0111-A4
REV ISSUE DATE PAGES REV DESCRIPTION PREPARED CHECKED APPROVED

NO. BY BY BY

Revised as marked and issued
1 08.07.2010 45 SNK MS HSC
for FEED
Page 147 of 434

CPCL, Chennai GENERAL SPECIFICATION FOR Part III Section B.12
44NC-4600 SHOP AND FIELD PAINTING Page 2 of 45
LSTK Doc. No. 44NC-4600-0000-V.02-0111-A4 Rev. 1
TABLE OF CONTENTS
1.0 General
2.0 Scope
3.0 Codes & Standards
4.0 Equipment
5.0 Surface Preparation
6.0 Paint Materials
7.0 Paint Systems
7.1 Pre-erection / Pre-fabrication and shop priming for carbon steel, low temperature carbon
steel & low alloy steel, un-insulated and insulated steel structures, piping and equipment,
etc.,
7.2 Repair of pre-erection /fabrication and shop priming after erection / welding for carbon steel,
low temperature carbon steel & low alloy steel uninsulated and insulated items in all
environments.
7.3 Repair of all weld joints and damages of galvanized steel, carbon steel and alloy steel
structures, piping and equipment after erection on above ground / overhead areas at site.
8.0 Field paint system for normal corrosive environment (for carbon steel, low temperature
carbon steel and low alloy steel)
9.0 Field paint system for corrosive areas in plant (for carbon steel, low temperature carbon
steel and low alloy steel)
10.0 Field paint system for highly corrosive areas in plant (for carbon steel, low temperature
carbon steel and low alloy steel)external surfaces of piping & equipment
11.0 Field paint system for carbon steel storage tanks (internal & external) for all environment
and areas
12.0 Coating system for external side of underground carbon steel plant piping and tanks
13.0 Painting under insulation for (hot, cold & safety) Carbon Steel plant piping and tanks
14.0 Internal protection of Carbon Steel water boxes and tube sheets of cooler condensers
15.0 Field painting system for GI towers / Non-Ferrous tueb sheet
16.0 Shop & Field painting system for Effluent treatment plant
17.0 Storage
18.0 Color code for piping as per CPCL
19.0 Identification of vessels, piping, etc.,
20.0 Painting for civil defence requirements
21.0 Inspection and testing
22.0 Guarantee
23.0 Qualification criteria of painting contractor
Annexure-1 List of Recommended manufacturers

Annexure-2 Paint colour code for Piping & Equipment as given by CPCL
44NC-4600-0000-V.02-0111-A4 General Specification for Painting.doc
Page 148 of 434

1.0 GENERAL
1.1 These technical specifications shall be applicable for the work covered by the contract and
without prejudice to the various codes of practice, standard specifications, etc. It is understood
that Contractor shall carry out the work in all respects with the best quality of materials and
workmanship and in accordance with the best engineering practice and instructions of Engineer-
in-Charge.
1.2 1 Wherever it is stated in the specification that a specific material is to be supplied or a specific
work is to be done, it shall be deemed that the same shall be supplied or carried out by the
contractor. Any deviation from this standard without written deviation permit from appropriate
authority will result in rejection of job.
2.0 SCOPE
2.1 Scope of work covered in the specification shall include, without being limited to the following
2.1.1 This specification defines the requirements for surface preparation, selection and application of
paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures,
external & internal protection of storage tanks for all services. MS chimney without refractory
lining and flare lines etc. The items listed in the heading of tables of paint systems is indicative
only, however the contractor is fully responsible for carrying out all the necessary painting,
coating and lining on external and internal surfaces as per the tender requirement.
2.2 Extent of Work
2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting :
a. All un-insulated C.S & A.S equipment like columns, vessels, drums, storage tanks, heat
exchangers, pumps, compressors, electrical panels and motors etc., and tanks and
equipment in ETP plant.
b. All un-insulated carbon and low alloy piping fittings and valves (including painting of
identification marks), furnace, ducts and stacks.
c. All items contained in a package unit as necessary.
d. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders,
platforms, etc.
e. External surfaces of MS chimneys without refractory lining & flare lines.
f. Identification color bands on all piping as required including insulated aluminum clad,
galvanized, SS and nonferrous piping.
g. Identification lettering / numbering on all painted surfaces of equipment / piping insulated

aluminum clad, galvanized, SS and non-ferrous piping.
h. Marking / identification signs on painted surfaces of equipment / piping hazardous service.
i. Supply of all primers, paints and all other materials required for painting other than Owner’s
supply.
j. Over insulation surface of equipments and pipes wherever required.
k. Painting under insulation for carbon steel, alloy steel and stainless steel as specified. 1
Page 149 of 434

l. Repair work of damaged / pre-erection / fabrication shop primer and weld joints at field.
m. Internal surfaces of RCC tanks and structures in Effluent Treatment Plant.
2.2.2 The following surfaces and materials shall not require painting in general. However, if there are
any specific requirement by the Owner, the same shall be painted as per the relevant
specifications:
a. Un-insulated austenitic stainless steel

b. Plastic and / or plastic coated materials.
c. Non-ferrous materials like Aluminum, galvanized “piping”, “gratings” and “Handrails” etc.
except G.I. Tower.
2.3 Unless otherwise instructed final painting on pre-erection / shop primed pipes and equipments
shall be painted in the field, only after the mechanical completion, testing on systems are
completed as well as after completion of steam purging wherever required.
2.4 Changes and deviations required for any specific job due to clients requirements or otherwise
shall be referred to Jacobs for deviation permit.
3.0 CODES & STANDARDS
3.1 Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the
contract, the following codes and standards shall be followed for the work covered by the
contract.
Color coding Color coding inspection manual for piping issued by CPCL (Ref.
Annexure-2) 1
IS-101 Methods of test for ready mixed paints and enamels.
ASTM American standard test methods for paints and coatings.
ASA A 13.1-1981 Scheme for identification of piping systems: American National Standards
Institution.
3.2 Surface Preparation Standards
Following standards shall be followed for surface preparations
3.2.1 Swedish Standard – SIS-05 5900-1967 (surface preparation standards for painting steel surfaces)
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.
3.2.2 Steel Structures Painting Council, U.S.A (Surface Preparation Specifications (SSPC-SP).
3.2.3 British Standards (Surface Finish of Blast-Cleaned for Painting) BS-4232.
3.2.4 National Association of Corrosion Engineers, U.S.A (NACE).
3.2.5 Various International Standards equivalent to Swedish Standard for surface preparations are
given in Table-I.
3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of above standards
and codes at site.
Page 150 of 434

3.4 The paint manufacturer’s 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 recommended limit on time intervals between coats.
e. Suggested Quality assurance procedures.
4.0 EQUIPMENT
4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning, inspection
instruments, e.g. surface profile gauges, holiday detectors, pin hole detectors, dry film thickness
gauges, etc. and all equipments, scaffolding materials, shot blasting equipments like hooper, grit
etc & air compressors, etc., required to be used shall be suitable for the work and all in good
order and shall be arranged by the Contractor at site and in sufficient quantity. 1
4.2 Mechanical mixing shall be used for paint mixing operations in case of two pack systems except
that the Engineer-in-Charge may allow the hand mixing of small quantities at his discretion.
5.0 SURFACE PREPARATION, SHOP, COATING APPLICATION & REPAIR AND

DOCUMENTATION
5.1 General
5.1.1 In order to achieve the maximum durability, blast cleaning is considered the most desirable
method to achieve required profile however one or more of following methods of surface
preparation shall be followed, depending on conditions of steel surface and as instructed by
Engineer-in-Charge. Adhesion of the paint film to surface depends largely on the degree of
cleanliness and surface profile of the metal surface. Proper surface preparation contributes more
to the success of the paint protective system.
a) Manual or hand tool cleaning

b) Mechanical or power tool cleaning.
c) Blast cleaning. NO sand shall be used. Only grit blasting shall be allowed. 1
5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and dry
surface is obtained. The minimum acceptable standard in case of manual or hand tool cleaning
shall be St. 2 or equivalent, in case of mechanical or power tool cleaning it shall be St. 3 or
equivalent in case of blast cleaning it shall be Sa 2-1/2 OR equivalent as per Swedish Standard
SIS-055900-1967 or equivalent. Where highly corrosive conditions exist, then blast cleaning shall
be Sa 3 as per Swedish Standard.
Remove all other contaminants, oil, grease, etc. by use of an aromatic solvent prior to surface
cleaning.
5.1.3 Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such
cleaning or during humid weather conditions having humidity exceed 85%.
Page 151 of 434

5.1.4 Irrespective of the method of surface preparation, the first coat of primer must be applied by
airless spray gun on dry surface No brush shall be used except for touchup. This should be done
immediately and in any case within 4 hours of cleaning of surface. However, at times of
unfavorable weather conditions, the Engineer-In-Charge shall have the liberty to control the time
period, at his sole discretion and / or to insist on re-cleaning, as may be required, before primer
application is taken up. In general, during unfavorable weather conditions, blasting and painting
shall be avoided as far as practicable. 1
5.1.5 The external surface of RCC chimney to be painted shall be dry and clean. Any loose particle of
sand, cement, aggregate etc., shall be removed by scrubbing with soft wire brush if necessary
acid etching with 10-15% HCl solution for about 15 minutes shall be carried and surface must be
thoroughly washed with water to remove acid & loose particles then dry completely before
application of paint.
5.2 Procedure of Surface Preparation :
5.2.1 Blast Cleaning
5.2.1.1 Air Blast Cleaning
The surfaces shall be blast cleaned using one of the abrasives Al2O3 particles chilled cast iron or
malleable iron and steel at pressure of 7 Kg /cm2 at appropriate distance and angle depending of
nozzle size maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel
shall be in the form of shot or grit of size not greater than 0.055” maximum in case of steel and
malleable iron and 0.04” maximum in case of chilled iron. Compressed air shall be free from
moisture and oil. The blasting nozzles should be venturi style with tungsten carbide or boron
carbide as the materials for liners. Nozzles orifice may vary from 3/16” to ¾”. On completion of
blasting operation, the blasted surface shall be clean and free from any scale or rust and must
show a grey white metallic luster. Primer or first coat of paint shall be applied within 4 hours of
surface preparation. Blast cleaning shall not be done outdoors in bad weather without adequate
protection or when there is dew on the metal, which is to be cleaned. Surface profile shall be
uniform to provide good key to the paint adhesion (i.e. 35 to 50 microns). If possible vacuum
collector shall be installed for collecting the abrasives and recycling.
5.2.1.2 Water Blast cleaning
Environmental, health and safety problems associated with abrasive blast cleaning limit the
application of Air Blast Cleaning in many installations. In such case water blast cleaning is
resorted to.
Water Blast Cleaning can be applied with or without abrasive and high pressure water blasting.
The water used shall be inhibited with sodium chromate / phosphate. The blast-cleaned surface
shall be washed thoroughly with detergents and wiped with solvent and dried with compressed
air. For effective cleaning abrasives are used. The most commonly used pressure for high
pressure water blast cleaning for maintenance surface preparation is 3000 to 6000 psi at 35-45
lit/minute water volume and pressures upto 1000 psi and water volume at 45 lit/minute provide
maximum cleaning.
The water blast cleaned surface shall be comparable to SSPC-SP-12/nace No. 5. The operation
shall be carried out as per SSPC guidelines for water blast cleaning. The indicative values for
sand injection is :
Air : 300 to 400 Cu. Ft. / min

Water : 5-10 lit/min. with corrosion inhibitor
Sand : 200-400 lbs/hr.
Nozzle : 0.5 to 1” dia.
Page 152 of 434

Special equipments for water blast cleaning with abrasives, now available, shall be used.
5.2.2 Mechanical or Power Tool Cleaning
Power tool cleaning shall be done by mechanical striking tools, Chipping hammers, grinding
wheels or rotating steel wire brushes. Excessive burnish of surface shall be avoided as it can
reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be
removed by clean rags and / or washed by water or stream and thoroughly dried with compressed
air jet before application of paint.
5.2.3 Manual or hand tool cleaning
Manual or hand tool cleaning is used only where safety problems limit the application of other
surface preparation procedure and there is approach problem in certain areas and hence does
not appear in the tables of paint systems.
Hand tool cleaning normally consists of the following :
a. Hand descaling and / or hammering

b. Hand scraping
c. hand wire brushing
Rust, mill scale spatters, old coatings and other foreign matter, shall be removed by hammering,
scrapping tools, emery paper cleaning, wire brushing or combination of the above methods. On
completion of cleaning, loose material shall be removed from the surface by clean rags and the
surface shall be bushed, swept, dusted and blow off with compressed air/steam to remove all
loose matter. Finally the surface may be washed with water and dried for effective cleaning.
5.3 Non-compatible shop coat primer
The compatibility of finishing coat should be confirmed from the paint manufacturer. In the event
of use of primer such as zinc rich epoxy, inorganic zinc silicate etc., as shop coat, the paint
system shall depend on condition of shop coat. If the shop coat is in satisfactory condition
showing no major defect, the shop coat shall not be removed. However a non-compatible primer
shall have to be removed before application of compatible paint system for the environment. The
touch up primer and finishing coat(s) shall be identified for application by Engineer-in-Charge.
5.4 Shop coated (coated with primer & finishing coat) equipment should not be repainted unless paint
is damaged.
5.5 Shop primed equipment and surfaces will only be ‘spot cleaned’ in damaged areas by means of
power tool brush cleaning or hand tool cleaning and then spot primed before applying one coat of
field primer unless otherwise specified. If shop primer is not compatible with field primer then
shop-coated primer should be completely removed before application of selected paint system for
particular environment.
5.6 For Package units / equipment, shop primer should be as per the paint system given in this
specification. However, manufacturer’s standard can be followed after review.
5.7 Coating Procedure and Application
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious airborne elements
0
exists, when the steel surface temperature is less than 5 F above dew point when the relative
0
humidity is greater than 85% or when the temperature is below 40 F.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hrs. the same day.
Page 153 of 434

5.7.3 To the maximum extent practicable, each coat of material shall be applied as a continuous film
uniform thickness free of probes. Any spots or areas missed in application shall be recoated and
permitted to dry before the next coat is applied. Applied paint should have the desired wet film
thickness.
5.7.4 Each coat shall be in proper state of cure or dryness before the application of succeeding coat.
Material shall be considered dry for recoating when an additional coat can be applied without the
development of any detrimental film irregularities, such as lifting or loss of adhesion of the under
coat. Manufacturer instruction shall be followed for inter-coat interval.
5.7.5 When the successive coat of the same color have been specified, alternate coat shall be tinted,
when practical, sufficiently to produce enough contrast to indicate complete coverage of the
surface. The tinting material shall be compatible with the material and not detrimental to its
service life.
5.7.6 Deleted 1
5.7.7 Airless spray application shall be in accordance with the following procedure : as per steel
structure paint Manual Vol. 1 & Vol. 2 by SSPC, USA. Air less spray relies on hydraulic pressure
rather than air atomization to produce the desired spray. An air compressor or electric motor is
used to operate a pump to produce pressures of 1000 to 6000 psi, paint is delivered to the spray
gun at this pressure through a single hose within the gun, a single paint stream is divided into
separate streams, which are forced through a small orifice resulting in atomization of paint without
the use of air. This results in more rapid coverage with less over spray. Airless spray usually is
faster, cleaner, more economical and easier to use than conventional air spray.
Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint
from any container, including drums. The unit shall have inbuilt agitator that keep the paint
uniformly mixed during the spraying. The unit shall consist of inbuilt strainer. Usually very small
quantity of thinning is required before spray. In case of high build epoxy coating (two pack), 30:1
pump ratio and 0.020-0.023” tip size will provide a good spray pattern. Ideally fluid hoses should
not be less than 3/8” ID and not longer than 50 ft. to obtain optimum results.
In case of gun choking, de-choking steps shall be followed immediately.

5.7.8 Brush application of paint shall be in accordance with the following :
a. Brushes shall be of a style and quality that will enable proper application of paint.
b. Round or oval brushes are most suitable for rivets, bolts, irregular surface and rough or pitted
steel. Wide flat brushes are suitable for large flat areas, but they shall not have width over
five inches.
c. Paint shall be applied into all corners.
d. Any runs or sags shall be brushed out.
e. There shall be a minimum of brush marks left in the applied paint.
f. Surfaces not accessible to brushes shall be painted by spray, doubaers or sheepskin.
5.7.9 Manual application by sling (where 6 o’ clock position of pipe is not approachable)
A canvas strip (alternatively a tinplate strip) about 450mm wide and 1.5m long is held under the
pipe by two men holding this sling move it up and down and walk slowly forward while fresh
coating is poured on the pipe and they manipulate the sling so that an even coating is obtained all
round the bottom. This work shall be done very carefully and by experienced personnel. There
shall not be any formation of “Whiskers” and holes in the coating. The coating film shall be
inspected by mirror.
Page 154 of 434

5.7.10 For each coat the painter should know the WFT corresponding to the specified DFT and
standardize the paint application technique to achieve the desired WFT. This has to be ensured
in the qualification trial.
5.8 Drying of coated surfaces
5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be considered dry
for re-coating when another coat can be applied without the development of any film irregularities
such as lifting or loss of adhesion of undercoats. Drying time of the applied coat should not
exceed maximum specified for it as a first coat; if it exceeds the paint material has possibly
deteriorated or mixing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause checking, wrinkling, blistering
formation of pores, or detrimentally affect the conditions of the paint.
5.8.3 No drier shall be added to paint on the job unless specifically called for in the manufacturer’s
specification for the paint.
5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dry to
the fullest extent practicable.
5.9 Repair of damaged paint surface
5.9.1 Where paint has been damaged in handling and in transportation, the repair of damaged coating
of pre-erection / fabrication shall be as given below.
5.9.2 Repair of damaged inorganic zinc silicate primer after erection / welding.
Quickly remove the primer from damaged area by mechanical scrapping and emery paper to
expose the white metal. Blast clean the surface if possible. Feather the primer over the intact
adjacent surface surrounding the damaged area by emery paper.
0 0
5.9.3 Repair of damaged pre-erection and shop priming in the design temperature of –90 C to 400 C
• Surface preparation shall be done as per procedure 5.9.2
• One coat of F-9 shall be applied wherever damage was observed on pre-erection / pre-
fabrication / shop primer of inorganic zinc silicate coating (F-9).
5.10 Paint Application
5.10.1 Shop priming / pre-erection priming with F9 or F12 shall be done only on blasted surface.
5.10.2 Shop priming / pre-erection priming with F9 shall be done only with airless spray.
5.10.3 For large flat surface field painting shall be done by airless spray otherwise brush can be used.
5.11 Documentation
5.11.1 A written quality plan with procedure for qualification trials and for the actual work.
5.11.2 Daily progress report with details of weather conditions, particular of applications, no. of coats
and type of materials applied, anomalies, progress of work versus program.
5.11.3 Results of measurement of temperatures relative humidity, surface profile, film thickness, holiday
detection, adhesion tests with signature of appropriate authority.
5.11.4 Particulars of surface preparation and paint application during trials and during the work.
Page 155 of 434

5.11.5 Details of non-compliance, rejects and repairs.
5.11.6 Type of testing equipments and calibration.
5.11.7 Code and batch numbers of paint materials used.
Page 156 of 434

TABLE-1 (FOR CLAUSE 5.0)
SURFACE PREPARATION STANDARDS
VARIOUS INTERNATIONAL STANDARDS

(EQUIVALENT)
SR.
DESCRIPTION BRITISH REMARKS
NO. Swedish SSPC-
NACE STANDAR
Standard SP
USA D
SIS-05- USA
BS-4232
5900
1. Manual or hand tool ST.2 SSPC- -- -- This method is applied
cleaning. SP-2 when the surface is
exposed to normal
Removal of loose rust, atmospheric conditions
loose mill scale and loose when other methods
paint, chipping, scrapping, cannot be adopted and
standing and wire brushing. also for spot cleaning
Surface should have a faint during maintenance
metallic sheen. painting.
2. Mechanical or power tool ST. 3 SSPC- -- --
cleaning. SP-3
Removal of loose rust,
loose mill scale and loose
paint to degree specified by
power tool chipping,
descaling, sanding, wire
brushing and grinding, after
removal of dust, surface
should have a pronounced
metallic sheen.
3. Blast cleaning (air & water)
There are four common
grades of blast cleaning
3.1 White metal SA.3 SSPC- NACE First Where extremely clean
Blast cleaning to white SP-5 #1 Quality surface can be
metal cleanliness. expected for prolong
Removal of all visible rust. life of paint system.
Mill sale, paint & foreign
matter 100% cleanliness
with desired surface profile.
Page 157 of 434

3.2 Near white metal SA 2 ½ SSPC- NACE Second The minimum

SP-10 #2 Quality requirement for
chemically resistant
paint systems such as
epoxy, vinyl,
polyurethane based
and inorganic zinc
silicate paints, also for
conventional paint
systems used under
fairly corrosive
conditions to obtain
desired life of paint
system.
3.3 Commercial Blast SA 2 SSPC- No. 3 Third For steel required
Blast cleaning until at least SP-6 Quality to be painted with
two-third pf each element of conventional paints for
surface are is free of all exposure to mildly
visible residues with corrosive atmosphere
desired surface profile for longer life of the
paint systems.
3.4 Brush-off Blast SA 1 SSPC- No. 4
Blast cleaning to white SP-7
metal cleanliness, removal
of all visible rust, mill scale,
paint & foreign matter.
Surface profile is not so
important.
Page 158 of 434

6.0 PAINT MATERIALS
Paint manufacturers shall furnish the characteristics of all paints materials on printed literature
along with the test certificate for all specified characteristics given in this specification. All the paint
materials shall be on first quality and conform to the following general characteristics. As per the
tables 6.1, 6.2 and 6.3.
TABLE No. 6.1 PRIMERS
Sr.
Description P-2 P-4 P-6
No.
1. Technical Name Chlorinated rubber Etch primer / Epoxy zinc phosphate

Zinc Phosphate primer wash primer primer
2. Type and Single pack, air drying Two pack Two component polyamide
composition chlorinated rubber based polyvinyl butyral cured epoxy resin medium-
medium plasticised with resin medium pigmented with zinc
unsaponifiable plasticizer, cured with phosphate.
pigmented with zinc phosphoric acid
phosphate solution
pigmented with
zinc tetroxy
chromate
3. Volume Solids 40% 7-8% 40%

(approx.)
4. DFT (Dry Film 40-45µ 8-10µ 40-50µ

thickness) per
coat (approx.)
5. Theoretical 8-10 8-10 8-10

covering capacity
2
in M /coat/litre
(approx.)
6. Weight per liter in 1.3 1.2 1.4

kgs/liter (approx)
7. Touch dry at 30 minutes 2 hrs. After 30 min.

0
30 C (approx.)
0
8. Hard dry at 30 C 24 hrs. 24 hrs. 24 hrs.
(approx.)
9. Over coating Min: 8 hrs. Min: 4-6 hrs. Min.: 8 hrs.

interval (approx.) Max. : No limitations Max. : 24 hrs. Max. : 3-6 months
10. Pot life (approx) Not applicable Not applicable 8 hrs.

0
at 30 C for two
component paints
(approx.)
Page 159 of 434

TABLE No. 6.2 FINISH PAINTS
Sr. Description F-2 F-3 F-6A/F-6B F-7

No.
1. Technical Acrylic Chlorinated rubber Epoxy high High build coaltar

Name polyurethane based finish paint build finish paint epoxy coating.
finish paint
2. Type and Two-pack Single pack Two pack Two pack polyamide
composition aliphatic plasticized polyamine (F- cured epoxy resin
isocynate cured chlorinated rubber 6A) / polyamide blended with coaltar
acrylic finish based medium (F-6B) cured medium, suitably
paint with chemical and epoxy resin pigmented.
weather resistant medium suitably
pigments pigmented
3. Volume Solids 40% 40% 62% 65%

(approx.)
4. DFT (Dry Film 30-40µ 40-45µ 100-125µ 100-125µ

thickness) per
coat (approx.)
5. Theoretical 10-13 8-10 5-6 5.2-6.5

covering
capacity in
2
M /coat/litre
(approx.)
6. Weight per liter 1.3 1.2 1.4 1.5

in kg/liter
(approx)
7. Touch dry at 1 hr. 30 minutes 3 hrs. 4 hrs.

0
30 C (approx.)
8. Hard dry at Overnight 8 hrs. Overnight 48 hrs.

0
30 C (approx.)
9. Over coating Min : Overnight Min : Overnight Min : Overnight Min. : 24 hrs.
interval (12 hrs.) Max. : Unlimited Max : 5 days Max. : 5 days
(approx.) Max. : Unlimited
10. Pot life 6-8 hrs. Not applicable 4-6 hrs. 4-6 hrs.
(approx) at
0
30 C for two
component
paints (approx.)
Page 160 of 434

Sr. Description F-8 F-9 F-11 F-12

No.
1. Technical Name Self priming type Inorganic zinc Heat resistant Heat resistant silicone
surface tolerant silicate coating synthetic medium aluminum paint suitable
0 0
high build epoxy based on two pack upto 500 C / 550 C dry
coating (complete Aluminum paint temp.
rust control suitable upto
0
coating) 250 C dry temp.
2. Type and Two-pack epoxy A two pack air Heat resistant Single pack silicone resin
composition resin based drying self curing synthetic medium based medium with
suitable solvent based based two pack Aluminum flakes.
pigmented and inorganic zinc Aluminum paint
capable of silicate coating suitable upto
0
adhering to 250 C
manually
prepared surface
and old coating.
3. Volume Solids 72% 60% 25% 20%

(approx.)
4. DFT (Dry Film 100-125µ 65-75µ 20-25µ 20-25µ

thickness) per coat
(approx.)
5. Theoretical covering 6.0-7.2 8-9 10-12 8-10

capacity in
2
M /coat/litre
(approx.)
6. Weight per liter in 1.4 2.3 1.2 1.1

kg/liter (approx)
0
7. Touch dry at 30 C 3 hrs 30 minutes 3 hrs. 30 min
(approx.)
0
8. Hard dry at 30 C 24 hrs 12 hrs. 12 hrs. 24 hrs
(approx.)
9. Over coating interval Min : 10 hrs Min : 8 hrs at Min : 16 hrs Min. : 16 hrs
0
(approx.) Max. : 6 months 20 C & 50% RH Max : Unlimited Max. : Unlimited
Max. : Unlimited
10. Pot life (approx) at 90 min 4-6 hrs Not applicable Not applicable
0
30 C for two
component paints
(approx.)
0 0
11. Temperature - - 250 C 500 C
Resistance
Page 161 of 434

Sl. DESCRIPTION F-14 F-15 F-16

No
1 Technical name Polyamine cured Epoxy phenolic Ambient temperature curing Poly
coal tar epoxy coating Siloxane/ inorganic copolymer
based aluminium coating suitable
for under insulation coating of CS
and SS piping for high
temperature service
2 Type and Specially formulated Two pack ambient Amercoat 738 from Ameron
composition polyamine cured temperature curing Products, USA/ Berger 938 from
coal tar epoxy epoxy phenolic coating Berger Paints Ltd., Kolkata or
suitable for suitable for application Intertherm 751 CSA from Akzo
application under under insulation Nobel coating, Bangalore.
insulation
3 Volume Solids 70% 65% 60%

(approx.)
4 DFT (Dry Film 125 urn 75-100 urn 75-100 urn

thickness) per coat
(approx.)
5 Theoretical covering 5.5 6.5-8.5 6.0- 8.0

capacity in M2/ coat/
litre (approx.)
6 Weight per liter in 1.5 1.7 1.3
kg/ litre (approx.)
7 Touch dry at 30°C 4hrs 2 hrs 1hr
(approx.)
8 Hard dry at 30°C 168hrs(7days) 168 hrs (7 days) 12 hrs

(approx.)
9 Over coating Min. 6 hrs Min. 36 hrs Max. Min. 16 hrs Max. Not applicable
interval (approx.) Max.5 days 21 days
10 Pot life (approx.) at 4 hrs 1.5 hrs 1hr
30°C for two
component paints
(approx.)
11 Temperature -45°Cto150°C under -45°C to 150°C under Up to 400 deg. C for CS & SS
Resistance insulation insulation surfaces under insulation
0 0
F-14 Specially formulated polyamide cured Coal-tar epoxy suitable for –45 C to 125 C for application
under insulation.
0 0
F-15 Two pack ambient temperature curing epoxy phenolic coating suitable for –45 C to 125 C for
application under insulation.
F-16A Engineered polysiloxane coating : Amercoat 738 from Ameron Products, USA
F-16B Engineered poly siloxane coating : Berger 938 from Berger Paints Ltd., Kolkatta
Page 162 of 434

NOTES
1 Covering capacity and DFT depends on method of application. Covering capacity specified above
are theoretical. Allowing the losses during application, min. specified DFT should be maintained.
2. All primers and finish coats should be ambient temperature curing and air drying unless otherwise
specified.
3. All paints shall be applied in accordance with manufacturer’s instructions for surface preparation,
intervals, curing and application. The surface preparation, quality and workmanship should be
ensured.
4. Technical data sheets for all paints shall be supplied at the time of submission of quotations.
6.4 List of recommended Manufacturers
The paints shall conform to the specifications given above and best quality in their products range of
manufacturers listed in Annexure-I.
Page 163 of 434

7.0 PAINT SYSTEMS
The paint system should vary with type of environment envisaged in and around the plants. Three
types of environment as given below are considered for selection of paint system. The paint system
is also given for specific requirements.
PRIMERS & FINISH COATS COVERED IN TABLE NOS. 7.0 TO 15.0
PRIMERS
P-2 : Chlorinated rubber zinc phosphate primer
P-4 : Etch primer / wash primer
P-6 : Epoxy zinc phosphate primer
Finish Coats / Paints
F-1 : First quality corrosion resistant synthetic enamel
F-2 : Acrylic – Polyurethane finish paint
F-3 : Chlorinated rubber finish paint
F-6A : High build epoxy finish coating cured with polyamine hardner
F-6B : High Build epoxy finish coating cured with polyamide hardner
F-7 : High build coal tar epoxy coating
F-8 : Self priming surface tolerant high build epoxy coating
F-9 : Inorganic zinc silicate coating
F-11 : Heat resistant synthetic medium based aluminium paint
F-12 : Heat resistant silicone aluminium paint

0
F-14 : Specially formulated polyamine cured coal for epoxy coating suitable upto 150 C
F-15 : Epoxy phenolic coating
F-16A : Epoxy siloxane coating : Amercoat 738
F-16B : Epoxy siloxane coating Berger 938
Page 164 of 434

TABLE 7.1 : SHOP PRIMING, PRE-ERECTION / PRE-FABRICATION FOR STRUCTURES,

PIPING & EQUIPMENT ETC.
Materials : CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL,
STEEL
TYPE : UNINSULATED AND INSULATED
Sr. Design Surface Paint System Total DFT Remarks

0
No. Temperature in C Preparation in Microns
(min.)
7.1.1 -90 to 400 SSPC-SP-10 1 coat of F-9 65-75 No over coating is to be done
7.1.2 401 to 500 SSPC-SP-10 1 coat of F-12 40-50 Finish coat at site
TABLE 7.2 : REPAIR OF SHOP PRIMING, PRE-ERECTION / PRE-FABRICATION AFTER

ERECTION / WELDING FOR ITEMS IN ALL ENVIRONMENTS
Materials : CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL
Sr. Design Surface Preparation Paint System Total DFT in Remarks

No. Temperature Microns (min.)
0
in C
7.2.1 -90 to 400 SSPC-SP-3 (for repair only) 1 coat of F-9 65-75
SSPC-SP-10
7.2.2 401 to 500 SSPC-SP-3 (for repair only) 2 coats of F-12 40-50
SSPC-SP-10
TABLE 7.3 : REPAIR OF ALL WELD JOINTS AND DAMAGES FOR STRUCTURES, PIPING
AND EQUIPMENT AFTER ERECTION ON ABOVE GROUND OVERHEAD AREAS
AT SITE
Materials : GALVANIZED STEEL, CARBON STEEL AND ALLOY STEEL

0
in C
7.3.1 -14 to 80 SSPC-SP-3 1 coat of F-8 100
7.3.2 81 to 500 SSPC-SP-3 1 coat of F-12 20
Page 165 of 434

TABLE 8 : FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT IN OFFSITE

AREAS FOR STRUCTURES, PIPING, EQUIPMENT, FLARE LINES ETC. -
UNINSULATED
TYPE : UNINSULATED

No Temperat Preparation in Microns
. ure in 0C (min.)
Field Primer Finish paint
-90 to -15 SSPC-SP-10 Repair of None 65-75 No over coating to be

8.1 done. Follow repair
pre-fabrication
primer 1 coat of procedure only on
F-9 @ 65-75 µ damaged areas of
DFT/coat pre-erection / pre-
fabrication primer /
-14 to 60 SSPC-SP-10 Repair of 2 coats of F-3 225 Coating F-9 / F-12 shall
8.2
pre-fabrication @ 40 µ DFT/ be ambient
primer 1 coat of Coat 2x40=80 temperature curing
F-9 @ 65-75 µ type till operating
DFT/coat + 2 temperature is attained
coats of P-2 @ for full curing.
40 µ DFT/Coat
2x40=80
61 to 80 SSPC-SP-10 Repair of 1 coat of F- 245
8.3
pre-fabrication 6B@ 100 µ
primer 1 coat of DFT/Coat
F-9 @ 65-75 µ
DFT/coat + 2
coats of P-6 @
40 µ DFT/Coat
2x40=80
81 to 250 SSPC-SP-10 Repair of 3 coats of F-12 125
8.4
pre-fabrication @ 20 µ DFT/
primer 1 coat of Coat 3x20=60
F-9 @ 65-75 µ
DFT/coat
8.5 251 to SSPC-SP-10 Repair of 2 coats of F-12 105
400 pre-fabrication @ 20 µ DFT/
F-9 @ 65-75 µ
DFT/coat
8.6 401 to SSPC-SP-10 Repair as per 2 coats of F-12 80
500 7.2.2. @ 20 µ DFT /
Coat 2x20=40
NOTE 1 : For external surfaces of MS chimney with or without refractory lining 8.3, 8.4 and 8.5 shall
be followed.
NOTE 2 : For external surfaces of RCC chimney: 2 coats of F-6B @ 100µ DFT/Coat to obtain
2x100=200 µ DFT shall be applied after making surface preparation as per guidelines in
5.1.5. The DFT on concrete surfaces can be checked by Tool Gauge or by applying the
same coating system simultaneously on a carbon steel panel of 12"x12" size and measure
the DFT by normal Magnetic gauges/digital electronic gauges for ferrous surfaces.
Page 166 of 434

NOTE 3 : Wherever required S.No.8.3 shall be used for -14°C to 80°C and S.No.8.2 will be deleted.
TABLE 8 A : FIELD PAINT SYSTEM FOR CORROSIVE ENVIRONMENT IN PLANT AREA

Surface : Un-insulated
Note :
For all corrosive areas above ground where H2S, SO2 fumes or spillages of
acid/Alkali/Salt are likely to come in contact with surfaces such as external surfaces of
un-insulated columns, vessels, heat exchangers, blowers, piping, pumps, towers,
compressors, and structural steel etc.
Sl. Design Surface Paint System Total Remarks
No. Temperature Preparation DFT in
in °C Microns
(min.)
Field Primer Finish Paint
9.1 -90 to -15 SSPC-SP-10 Repair of pre- None 65-75 Repair of pre-erection /
fabrication primer pre-fabrication primer shall
1 coat of F-9 @ be done wherever damage
65-75µ DFT/coat is observed.
9.2 -14 to 80 SSPC-SP-10 Repair of pre- 1 coat of F- 245
fabrication primer 6A@ 100 µ
1 coat of F-9 @ DFT/coat +
65-75 µ DFT/coat 1 coatofF-2
+ 1 coats of P-6 @40u
@ 40 µ DFT/coat DFT/coat.
9.3 81 to 400 SSPC-SP-10 Repair of pre- 2 coats of 105

fabrication primer F-12@20
1 coat of F-9 @ µ DFT/coat
65-75 µ DFT/coat 2x20=40
9.4 401 to 500 SSPC-SP-10 Repair as per 2 coats of 80
7.2.2. F-12@20
µ DFT/coat
2x20=40
Page 167 of 434

TABLE 9 : FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE AREAS IN PLANT AREA
EXTERNAL SURFACES OF UNINSULATED COLUMNS, VESSELS, HEAT
EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS,
STRUCTURAL STEEL ETC.
Note : Exposed to spillage or fumes of HCL, H2SO4, salty water, water impingement,
chloride etc
Sl. Design Surface Paint System Total DFT Remarks
No. Temperature Preparation In
in°C Microns
(min.)
10.1 -90 to -15 SSPC-SP-10 Repair of pre- None 65-75 Repair procedure of
fabrication primer pre-erection/fabri
1c o at of F- 9 @ cation primer shall be
65-75u DFT/coat followed. No
overcoating is
allowed.
Surface preparation is
required only for
repairing of damaged
pre-erection/
fabrication primer.
10.2 -14 to 80 SSPC-SP-10 Repair of pre- 2 coats of F- 345

fabrication primer 6A @ lOOu
1c o at of F- 9 @ 65-DFT/Coat =
75u DFT/coat + 1 2x100=200 +
coats of P-6@ 40u 1coatofF-2
DFT/Coat @40u
DFT/coat.
10.3 81 to 400 SSPC-SP-10 Repair of pre- 2 coats of F- 105
fabrication primer 12@20u
1c o at of F- 9 @ DFT/Coat
65-75u DFT/coat 2x20=40
10.4 401 to 500 SSPC-SP-10 Repair as per 7.2.2. 2 coats of F- 80
12@20u
DFT/Coat
2x20=40
Page 168 of 434

TABLE 10 : PAINTING UNDER INSULATION FOR INSULATED (HOT, COLD & SAFETY) PIPING,
STORAGE TANKS AND EQUIPMENTS IN ALL ENVIRONMENT
Materials : CARBON STEEL, LOW ALLOY STEEL, LOW TEMPERATURE CARBON STEEL &
STAINLESS STEEL
Surface : Insulated
Paint System
Sr. Design Surface Field Primer Finish paint Total Remarks
No. Temperatur Preparation DFT in
0
e in C Microns
(min.)
9.1 Insulated carbon steel, low alloy steel and LTCS piping and equipment and tanks
9.1.1 -45 to 125 SSPC-SP-10 Repair of pre- 2 coats of F-14 315

fabrication primer @ 125 µ For other temperature
F-9 @ 65-75 µ DFT/coat = ranges no painting is
DFT. 2x125=250 OR 3 required under insulation
coats of F-15 =
3x80=240
9.1.2 Operating SSPC-SP-10 Repair of pre- 2 coats of F-12 105-115

temperature fabrication primer @ 20 µ DFT /
–45 to F-9 @ 65-75µ coat = 3x20 = 60
0
125 C but DFT.
design
temperature
0
126-400 C
9.2 Insulated stainless steel including Alloy-20 piping
9.2.1 Below 00C Aluminium sheeting with aluminium foil and “Chloride free mineral If the piping &
to all minus sealant coating barium chromate” shall be applied. equipments are already
temperature erected then surface
shall be prepared by
cleaning with emery
9.2.2 0 to 120 SSPC-SP-10 None 2 coats of F-14 @ 250 or
paper and wash / flush
(15-25µ surface 125 µ DFT / coat 240
with chloride free DM
profile) = 2x125 = 250 or 3
water followed by wiping
coats of F-15 =
with organic solvent.
3x80=240
All the coating materials
9.2.3 121 to 400 SSPC-SP-10 None 3 coats of F-12 60 for SS shall be free from
@20µ DFT /Coat = leachable chlorides.
3x20=60 or 1 coat
of Poly siloxane or
coating (F-16 A/B)
@ 75 microns
DFT/coat
9.2.4 401 to 600 SSPC-SP-10 None 2 coats of heat 40

resistant silicone
aluminium paint @
20 microns DFT /
coat = 2x20=40
9.3 No painting is required for insulated Monel, Incoloy and Nickel lines
Page 169 of 434

Page 170 of 434

Page 171 of 434

Page 172 of 434

TABLE 12.0 COATING SYSTEM FOR EXTERNAL SIDE OF UNDERGROUND CARBON STEEL
PLANT PIPING AND TANKS

No. Temp. °C Preparation DFT in µ
(min.)
12.1 Carbon steel plant piping (underground)

12.1.1 Yard coating
12.1.1.1 25 to 60 SSPC-SP-10 1 coat of 4 mm thick 4 mm CTE coating shall confirm
synthetic fast coaltar to 120/5 as per BS:4164
drying primer coating
type-B as per wrapping as
AWWA-C-203 per AWWA-
(1991) C-203 in 2
layers of
each 2 mm
thickness.
12.1.2 Over the Ditch Coating
12.1.2.1 25 to 60 SSPC-SP-10 1 coat of 2 layers of 4 mm
synthetic fast coal tar
drying primer based tape
type-B as per coating
AWWA-C-203
(1991)
12.2 Carbon plant piping (underground).

12.2.1 61 to 225 SSPC-SP-10 1CoatofF-15@ 75 2 Coat of F- 225 Cold and hot insulation
µ DFT/coat 15 @ 75 µ shall be provided
DFT/coat
µ DFT/coat 16@ 100µ shall be provided
DFT/coat
12.3 External side of un-insulated underground storage tanks:

12.3.1 -40 to 80 SSPC-SP-10 1CoatofF-9@ 65- 3 coats of 365
75 µ DFT/coat F-7 @100 µ
DFT/coat
3x100=300
12.3.2 81 to 180 SSPC-SP-10 1CoatofF-15@ 75 2 Coat of F- 225
µ DFT/coat 15 @ 75u
DFT/coat
12.3.3. 181 to 400 SSPC-SP-10 1CoatofF-9@ 65- 2 Coat of F- 215-225
75 µ DFT/coat 16 @ 75 µ
DFT/coat
2x75=150
Note: No Coating and Wrapping systems are available for underground high temperature services
Page 173 of 434

TABLE 13.0 PAINTING UNDER INSULATION FOR INSULATED (HOT, COLD & SAFETY) CARBON
STEEL, LOW ALLOY STEEL, LOW TEMPERTURE CARBON STEEL & STAINLESS STEEL
PIPING, STORAGE TANKS AND EQUIPMENTS IN ALL ENVIRONMENT.
Sl. Design Surface Paint system Total

(min.)
Primer Finish Paint
13.1 Insulated carbon steel, low alloy steel and LTCS piping and equipment & tanks
13.1.1 -45 to 125 SSPC-SP-10 Repair of 2 coats of F- 315 For other temperature ranges no
pre- 14 @125 µ painting is required under
fabricatio DFT/coat = insulation F-12 shall be ambient
n primer 2x125=250 temperature curing type till
F-9 @ 65- OR 3 coats of operating temperature is attained
75 µ DFT. F-15= for full curing. F-16 is completely
3x80=240 ambient temperature curing.
13.1.2 Operating SSPC-SP-10 Repair of 2 Coats of 125-135
temperature pre- F-12 @20 µ
-45 to 125°C fabricatio DFT/coat
but design n primer 3x20=60 (or)
temperature F-9 one coat of
126-400°C @65-75 µ Poly-siloxane
DFT coating @ 75
µ DFT/coat

13.2.1 Below 0°C to Aluminum sheeting with aluminum foil and If the piping & equipments are
all minus "Chloride free mineral sealant coating barium already erected than surface
temp. chromate" shall be applied. shall be prepared by cleaning with
emery paper and wash/flush with
chloride free DM water followed
by wiping with organic solvent. No
pre-erection primer to be applied.
F-12 shall be ambient temp
curing type till final curing is
obtained during operating temp.
F-16 is completely ambient temp
curing type.
13.2.2 0 to 120 SSPC-SP-10 None 2 coats of F- 250

(15-25 14@125 µ or
surface DFT/COAT 240
profile) 2x125=250 or
3 coats of F-15
= 3x80=240
Page 174 of 434

13.2.3 121 to 400 SSPC-SP-10 None 3 coats of F- 60-75

12@20 µ
DFT/COAT
3x20=60 or 1
coat of F-16 Poly
Siloxane coating
@ 75 microns
DFT/coat
13.2.4 401 to 600 SSPC-SP-10 3coatsofF-12@ 60
20 µ DFT/coat 60
13.2.5 Cyclic SSPC-SP-10 None 2 coats of DFT/coat 150

service-196 F-16 Poly
to 480 Siloxane coating
excepting - @ 75 µ DFT/coat
45 to 120 = 2x75=150
13.3 No painting is required for insulated Monel, Incoloy and Nickel lines.
Page 175 of 434

TABLE 14.0 INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF
COOLERS / CONDENSERS
Water boxes, channels, partition plates, end covers and tube sheets etc.
Sl. Design Surface Paint system Total DFT Remarks

No. Temperature Preparation in Microns
in°C (min.)
Primer Finish paint
14.1 Upto 80 SSPC-SP-10 1 coat of P-6 @ 2 coats of F-7 290 For C.S.
40 µ DFT/coat @125 µ
DFT/coat
2x125=250
14.2 Upto 80 Non SSPC-SP-3 1coatofP-4@ 8-1 2 coats of F-7 300 For non ferrous
ferrous and On DFT/coat. @125 µ surfaces
brass tube 1coat of P-6 @ DFT/coat
sheets 40 µ DFT/coat. 2x125=250
TABLE 15.0 FIELD PAINTING SYSTEM FOR GI TOWERS/NON-FERROUS TUBE SHEET

in°C (min.)
Primer Finish Paint
15.1 Upto 80 SSPS-SP-3 1 coat of P-4 @ 2 coats of F-2 130 Shade as per
8-10 µ DFT/coat @40 µ defence
+ 1 coat of P-6 @ DFT/coat Requirements.
40u DFT/coat 2x40=80
15.2 Upto 80 Non SSPS-SP-3 lcoatofP-4@8u 2 coats of F-7 300

ferrous and DFT/coat @125 µ
sheets 40u DFT/coat 2x125=250
Page 176 of 434

TABLE 16.0 SHOP & FIELD PAINTING SYSTEM FOR EFFLUENT TREATMENT PLANT
Sl. Design Temp. °C Surface Paint System Total DFT Remarks

No. Preparation in Microns
(min.)
Primer Finish Paint
16.1 -14 to 80(for SSPS-SP-10 1 3 coats of F- 365
C.S./M.S. items): coatofF-9 6A @100u
Screens, Walk way @ 65-75u DFT/coat
bridges, Baffles, Dual DFT/coat 3x100=300
media filters
(external) Vertical
pumps, piping in
treated effluent sump
and pump house,
external side lining of
Slop oil MS tank
16.2 -14 to 80(CS/MS SSPS-SP-10 1 2 coats of F- 265

Items) for Vertical coatofF-9 6A @100u
pump and piping in, @ 65-75u DFT/coat
Bio-sludge sump and DFT/coat.
pump, Filter feed
sump and pump,
Process sump,
Sanitary sump;
Transfer sump,
Sludge, MS Slop oil
tank internal,
scrapping
mechanism in
Clarifier, Screw pump
16.3 -14 to 80 deg.C :All Blast cleaning Epoxy Epoxy 3mm Epoxy screed lining
R.C.C. surfaces such t o SSPC- SP screed screed shall be used as per
as tanks, structures, guide lines and lining lining specific instructions
drains etc.) in Acid etching from Engineer-in-
Process sump, TPI with 10-15% Charge at site.
HCl acid
separator (Process
followed by
and Oil), Aeration thorough water
Tank, Transfer sump washing.
etc.
16.4 U p t o 6 0 d e g . C SSPC-SP-10 Rubber 4.5mm
C.S/M.S Dual media Lining
filters (Internal),
Chemical dosing
tanks(internal such
as DAP, Urea)
Page 177 of 434

17.0 STORAGE
1 All paints and painting materials shall be stored only in rooms to be arranged by
contractor and approved by Engineer-in-charge for the purpose. All necessary precautions
shall be taken to prevent fire. The storage building shall preferably be separate from adjacent
building. A signboard bearing the word "PAINT STORAGE - NO NAKED LIGHT - HIGHLY
INFLAMABLE" shall be clearly displayed outside.
18.0 PIPING COLOR CODE
The color code shall be followed as given in Annexure-II.
19.0 IDENTIFICATION OF VESSELS, PIPING ETC.: As per color coding given in

Annexure-II
20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS
20.1 Following items shall be painted for camouflaging if required by the client.
a. All columns
b. All tanks in off sites
c. Large Vessels
d. Spheres
20.2 Two coats of selected finishing paint as per defence requirement shall be applied in a
particular pattern as per 20.3 and as per the instructions of Engineer-In-Charge.
20.3 Method of Camouflaging
20.3.1 Disruptive painting for camouflaging shall be done in three colors in the ratio
of
5:3:2 (all matt finish).
Dark Green Light Green Dark Medium Brown

5: 3: 2
20.3.2 The patches should be asymetrical and irregular.
20.3.3 The patches should be inclined at 30 Deg.. to 60 Deg. to the horizontal.

20.3.4 The patches should be continuous where two surfaces meet at an angle.
20.3.5 The patches should not coincide with corners.
20.3.6 Slits and holes shall be painted in dark shades.
20.3.7 Width of patches should be 1 to 2 meters.
21.0 INSPECTION AND TESTING
21.1 All painting materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufactures as per specifications and
shall be accompanied by manufacturer's test certificates. Paint formulations without
certificates are not acceptable.
21.2 Engineer-In-Charge at his discretion may call for tests for paint formulations. Contractor
shall arrange to have such tests performed including batch-wise test of wet paints for
physical & chemical analysis. All costs there shall be borne by the contractor.
Page 178 of 434

21.3 The painting work shall be subject to inspection by Engineer-In-Charge at all times. In
particular, following stage-wise inspection will be performed and contractor shall offer the
work for inspection and approval of every stage before proceeding with the next stage. The
record of inspection shall be maintained in the registers. Stages of inspection are as
follows:
(a) Surface preparation

(b) Primer application
(c) Each coat of paint
In addition to above, record should include type of shop primer already applied on equipment
e.g. Red oxide zinc chromate or zinc chromate or Red lead primer etc.
Any defect noticed during the various stages of inspection shall be rectified by the contractor
to the entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, contractor shall be
responsible for making good any defects found during final inspection/guarantee
period/defect liability period as defined in general condition of contract. Dry film thickness (D
F T)) shall be checked and recorded after application of each coat and extra coat of paint
should be applied to make-up the DFT specified without any extra cost to owner, the extra
cost should have prior approval of Engineer-in-charge.
21.4 Primer Application
After surface preparation, the primer should be applied to cover the crevices, corners, sharp
edges etc. in the presence of inspector nominated by Engineer-In-Charge.
21.4.1 The shades of successive coats should be slightly different in color in order to ensure
application of individual coats, the thickness of each coat and complete coverage should
be checked as per provision of this specification. This should be approved by
Engineer-In-Charge before application of successive coats.
21.4.2 The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface profile in case
of sand blasting. Holiday detectors and pinhole detector and protector whenever required
for checking in case of immersion conditions.
21.4.2 Prior to application of paints on surfaces of chimneys, the thickness of the individual coat
shall be checked by application of each coat of same paint on M.S.test panel. The
thickness of paint on test panels shall be determined by using gauge such as
'Elkometer'. The thickness of each coat shall be checked as per provision of this
specification. This shall be approved by Engineer-In-Charge before application of paints on
surface of chimney.
21.4.3 At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert
technical service at site as and when required. This service should be free of cost and
without any obligation to the owner, as it would be in the interest of the manufacturer to
ensure that both surface preparation and application are carried out as per their
recommendations.
21.4.4 Final inspection shall include measurement of paint dry film thickness, Adhesion, Holiday
detection check of finish and workmanship. The thickness should be measured at as
many points/ locations as decided by Engineer-In-Charge and shall be within + 10% of the
dry film thickness, specified in the specifications.
Page 179 of 434

21.4.5 The contractor shall arrange for spot checking of paint materials for Sp.gr., glow time (ford
cup) and spreading rate.
22.0 GUARANTEE
22.1 The contractor shall guarantee that the chemical and physical properties of paint
materials used are in accordance with the specifications contained herein/to be
provided during execution of work.
22.2 The contractor shall produce test reports from manufacturer regarding the quality of the
particular batch of paint supplied. The Engineer-in-Charge shall have the right to test wet
samples of paint at random for quality of same, as per the paint materials specification.
Batch test reports of the manufacturer's for each batch of paints supplied shall be
made available by the contractor. The contractor shall stand guarantee for carrying
out the rectification/repair/re-painting of the defects/ failures of painting found during the
execution of painting job and till the expiry of the defect liability period of total project as
per the directions of the Engineer-in-Charge of CPCL/JE
23.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR
Painting contractor who is awarded the job under this standard must have necessary
equipments, machinery, tools and tackles for surface preparation, paint application and
inspection. The contractor mush have qualified, trained and experienced surface
preparator, paint applicator, inspector and supervisors. The contractor's supervisor,
inspector, surface preparator and paint applicator must be conversant with the
standards referred in this specification. The painting job shall be carried out by the approved
agencies of paint manufacturers and supervised by the approved paint manufacturers own
representative or paint manufacturer their scheme( supply and apply basis).
Page 180 of 434

ANNEXURE-I
LIST OF RECOMMENDED MANUFACTURERS
Indian Vendors
1. Asian Paints (I) Ltd., Mumbai

2. Berger Paints Ltd., Kolkata
3. Goodlass Nerolac Paints Ltd., Mumbai
4. Chemguard Coatings, Mumbai(For Ameron, USA Products only)
5. Chokugu Marine paints Pte. Ltd., Mumbai/Singapore
6. Shalimar Paints Ltd., Kolkata
7. Sigma Coatings, Mumbai.
8. CDC Carboline Ltd., Chennai
9. Premier products Ltd., Mumbai
10. Coromandel Paints & Chemicals Ltd., Visakhapatnam
11. Anupam Enterprises, Kolkata
12. Grand Polycoats, Vadodata
13. Bombay Paints Ltd., Mumbai
14. Akzo Nobel Coatings and Sealants Pvt. Ltd., Bangalore
15. Cipy Polyurethanes Pvt. Ltd., Pune
16. Gunjan Paints Ltd., Ahmedabad
17. Advance Paints Ltd., Mumbai
18. VCM Polyurethane Paints (for polyurethane paints only)
19. Jotun Paints, Chennai(Singapore)
20. Chembond Chemicals Ltd., Navi Mumbai
Foreign Vendors
1. Sigma Coatings, Singapore

2. Ameron, USA
3. Kansai Paints, Japan
4. Hempel Paints, USA
5. Valspar Corporation, USA
6. Akzo Nobel/International Coatings, UK
7. Jotun Paints, Singapore
For De-humidification equipment (on Rental Basis)
1. Technical Drying Equipment (Asia) Pvt. Limited, Gurgaon, Haryana
The following are approved vendors for speciality items (phosphating chemical) only.
1. Mark-chem Incorporated, Mumbai.
2. Chemtreat India Ltd., Navi Mumbai
Page 181 of 434

Annexure-II
Paint Color Code for Piping & Equipment given by CPCL Document No. 00-ES-100-004, Rev. 5
dated 24/12/2006 to Specification No.6782-0642-PT-L06 Rev.2
This section of the standard deals with the color coding to he given to in service piping for easy
identification bused on the liqui d contained in the line.
1. Where ever paint is required for piping external surfaces, the finish coat color shall be as follows
except for paragraph 2, Type of paint, surface preparation. DFT etc. shall he as per the
painting specification.
a) 1 lent resistant paint - Alum inn in

b) Other grades of paint - White or Al. in Color
Insulated and austenitic stainless steel lines will he having only color coding for fluid
discrimination as given in 3 below.
2. Fire water lines shall he painted " Red '" as per IS 536 through out the line.
3. All lines, in general, shall he provided with discrimination color coding mark over the final coat or
on the cladding / jacketing surface of insulated piping as mentioned in 1 above . as
well as on the surfaces on which any paint is not provided. The color coding shall be as per the
attachment to this standard and in the following manner. Color codes on Austenitic SS lines should
he done only wit chloride free paint suitable for application on stainless steel surfaces.
As far as possible, paint used for color bands should he of the same specification as the finish
coat. If for some reason a deviation is required for this, then enamel paint can be used over finish
coat after taking approval from the ‘engineer In - Charge'
3.1 The system of color coding shall consist o f a primary identification color band and other color
hand (s) superimposed on the primary band. All the bands shall be painted circumferential!;
around the line.
The primary color hand identifies the basic nature of the fluid carried in the line. The second and
the third color hands will identify the exact fluid carried in the line. The various primary color
bands included in t h i s standard are explained below:
Basic fluid Color of primary band
Water Sea Green

Steam Signal Red
Air Sky Blue
Gases Canary Yellow
Acids and acid producing, gases Dark Violet
Hydrocarbons Dark Grey
Alkalies Light Brown
Chemicals Light Orange
No identification required Black
Page 182 of 434

3.2 Painting of color bands
3.2.1 Primary colorblind / color band ( s ) (see Fig I) arc required to be located at
- battery limit points

- intersection points in the piping system
- start and terminal points
- at spec i lied intervals as given below
- specific points on the l i n e as directed by the "Engineer - In - Charge "
3.2.2 Primary color band shall he intermittently coated along respective lines with primary color
bands of 2V1 length with the following maximum center to center distance between two
adjacent color bands.
− 15 M for lines with in battery limits of respective units

− 50 M for lines on interconnecting pipe rack and in lower plateau
Center to center distances at lesser intervals may be given. if" so desired by unit head.
3.2.3 Sizing of II &. Ill color bund (s)
Size II color band I I I Color band

3" and below 100 mm 50 mm
> 3" upto ft" 200 mm 100 mm

> 6" upto 12" 300 mm 150 mm
> 12" 400 mm 200 mm
Page 183 of 434

SR CONTENTS Primary II Color Band 111 Color

NO Color Band Band
1 ALL KINDS OF WATER

Drinking water Sea green French Blue Signal rod
De-mineralized water Sea green Light Orange
Cooling water Sea green French blue
Boiler feed water Sea green Gulf Red
Condensate Sea green Light Brown
Quench water Sea green Dark grey Signal rod
Wash water Sea green Canary Yellow
Process water Sea green Light grey
Raw water ( from river } Sea green
Page 184 of 434

Fire water ( Full color, not band ) Fire red

2 STEAM
Very high pressure steam Signal Red Silver Grey
High pros sure steam Signal Red French Blue
Medium Pressure steam Signal Red Gulf Red
Low Pressure steam Signal Red Canary Yellow
Dilution steam/ Purge steam Signal Red Silver Grey Canary Yellow
3 AIR
Plant Air Sky Blue Silver Grey
Instrument Air Sky Blue French Blue
Process air ( ex: bitumen, Sky Blue Signal Red
Mereox)
Combustion air Sky Blue Canary Yellow

4 GASES
Hydrogen Canary Yellow Signal red French Blue
Nitrogen Canary Yellow Black
Flare gas Canary Yellow
Hydrogen sulfide/ Acid gas Canary Yellow Gulf Red
Fuel gas Canary Yellow Light Brown While
Regeneration gas Canary Yellow While Dark Violet
LPG (as gas) Canary Yellow Brilliant Green While
Propane ( as gas ) Canary Yellow Signal Red Black
Sulfur Dioxide Dark Violet Brilliant Green
Ammonia Dark Violet
Chlorine Dark Violet Signal Red
HCN Dark Violet Trench Blue
5 AC IDS
Sulfuric Acid Dark Violet Brilliant Green Light Orange

Nitric Acid Dark Violet French Blue Light Orange
1 Hydrochloric Acid Dark Violet Signal Red Light Orange
Acetic acid Dark Violet Silver Grey
6 LIQUID HYDROCARBONS
LPG ( as liquid ) Dark Grey Brilliant Green While

Naphtha. Dark Grey Brilliant Green
MS Dark Grey Sky Blue
Reformate Dark Grey While
SKO Dark Grey Light Brown
ATF Dark Grey Light Brown Sky Blue
USD Dark Grey Light Orange
FO Dark Grey Signal Red
LSHS / Low Sulfur fuel Dark Grey Signal Red Black
Bitumen Dark Grey Black
Page 185 of 434

Other Hydrocarbons not defined Dark Grey

Above
Crude Dark Grey Canary Yellow
7 ALKALIES Light Brown

8 CHEMICALS-GENERAL Light Orange
Sulfur Light Orange Black
9 All other items which do no Black

require individual identification
Surface Part Color Remarks

Tanks A.C. Grey
Spheres White
Vessels, drums, heat exchangers D.A. Grey
etc.
Furnace casing Silver
Machinery - Pumps. Silver
Compressors, blowers etc)
Steam Turbine Silver
Generator' Mfr. Std.
Motor Light grey ISC 631
Packaged dosing system Mfrs. Std
DG Set Mfrs. Std
Cable duct Silver
Instrument Panel
Instrument Panel including DCS Indoor
Cabinet Front Opaque Beige With leather lone
Other Neutral Grey With leather lone
sides Neutral Grey
Inside
Control Valve
C:S Body Light grey ISC 631
SS Body No paint
Low alloy body Canary Yellow ISC 309
Control Valve Actuators
Normally Brilliant Green ISC 221
Closed
Normally Open Signal Red \SC 537
Instruments. Transmitters Mfrs Sid
Page 186 of 434

Sr. No. Content Final Color ISC

No:
1 Gantry girder and monorail Brilliant Green 221
2 Stopper for gantry girder and monorail Signal Red 537
3 Pipe rack structural steel and trestle including that Dark Admiralty Grey 632
for equipment and platform
4 Chequered Plates Dark Admiralty Grey 632
Ladder rungs, verticals and cage Canary Yellow 309
6 Hand railing. middle rail, toe pi ale and Canary Yellow 309
vertical post
7 Platforms : Structural sled parts other Dark Admiralty Grey 632
than grating and hand railing
8 Staircase : Structural steel parts other Dark Admiralty Grey 632
than hand railing and steps using galvanized
9 Safety Gate Signal Red 537

10 Miscellaneous Structural Part Dark Admiralty Grey 632
Notes : 1) Wherever Dark Admiralty Grey is not available due to the nature of the final coat of
paint ( eg: Coal Tar epoxy in high H2S environments ) . Black can be used.
2) Canary Yellow for ladders etc. has been selected for visibility.
1. Equipment number shall be stenciled in black (after initial painting if any) on each vessel,
column, equipment, machinery till a visible location as directed by the "Engineer - in -
charge "'
Size of letters is as below:
− Column, vessel. exchanger, other stationary equipment : 150 mm height
− Pump. Compressor and other machinery including : 50 mm height HT

motors
Rotating equipment shall have tin arrow showing the direction of rotation painted on the
equipment.
In case of small auxiliary equipment in packaged unit, separate identification by stenciling is

not required as long as name plate or tag bearing item number is duly attached to the aux.
equipment.
2. Line number, service, source and destination shall be stenciled in black on respective
pipe lines at
− start and terminating points of line next to the color code
− battery limit points next to the color code,
Page 187 of 434

Additional stenciling of line numbers and service will be required and shall be provided on
the lines at the direction of “Engineer- In - Charge"
Sizing of letters shall be :
OD of pipe Height of letters
80- 150 mm 40 mm
150-250 mm 60 mm
> 250 mm 90 mm
Auxiliary piping in packaged units or on base plates of pumps / compressors wilh in the
scope of vendors do not need numbering at site.
However, an auxiliary line with operational significance (where it is referenced specifically in

the operation manual by a line number) shall he provided with a number by stenciling hi-
other suitable means.
3. The following details are to he painted on the Lank shell in black color, letter size 50 mm
high, at the entrance point of the staircase.
• Tank number
• Reference height
• Stile filling height
• Critical /one ( in ease of floating roof tanks only )
• Dale of commissioning
• Date of last cleaning
4. The following details are to be painted on the tank shell near the top landing platform of the
staircase, in letter size 50 mm high, black color.
• Sale filling height
• Critical zone ( in case of floating roof tanks only )
5. The following details shall he painted on the kink at 2!3 the height of the tank at a
location facing the road, from where normal approach lo the Tank is provided. In addition,
the same details shall be provided on two additional points in the lank 120 degrees apart.
Tank number
• Capacity
• Service.
The size of the above lettering shall be 500 mm for 20 M high tanks and 300 mm for
smaller tanks.
DGCA requirements for a l l shall be followed in addition to the above.
Page 188 of 434

1.0 The part of the standard covers the method of identification of STORED piping material by
color coding. This standard is applicable to storage during project Stage as well.
2.0 General guide lines of identification by color coding:
a) Piping shall be painted with one color or a combination of two color as
enclosed.
b) Color identification is not required on galvanized material and mm ferrous
material such as Copper. Aluminum etc. because of their peculiar color and
Page 189 of 434

Jacobs
character
e) Special items l i k e bellow, strainers, steam Imps etc. should be lagged and hence do
mil require color identification.
d) Color identification of Austenitic Stainless Steel is not desirable due to r i s k
of contamination from paint material.
e) Ends of piping to be welded shall not be painted. The color band shall start
2" from the pipe ends.
f) Width of color strips shall be 25 mm for .V nominal pipe dia and above. Secondary
color strip where required, shall be half the size of primary strips. For less than 3" size
color strip shall be 12 mm < 1/2") or maximum practical.
Carbon Steels
API 5L Gr B Pink Seamless

API 5L Gr B Pink / White Welded
A 106 Gr B Red [BR
A 106 Gr B Yellow Non IBR
Welded and seamless fittings Red IBR
Welded and seamless fittings Yellow Non IBR
Welded fittings Yellow / White Normalized
Miters Silver
Class 22 fittings Silver / Pink Stress relieved at s h o p
IS 3589- IS 12239 No Paint Non critical
Alloy Steels
P1, F1. WP1, WP1W etc. Green / Red
P12, F12, W12 etc Green / Yellow
P22, F22, WP22. etc Green / Silver
P11, F11, WP11 etc. Green / Orange
P5, F5, WP5 etc. Green / Blue
P9, F9, WR9 etc. Green / Pink
Page 190 of 434

Jacobs
Color ( In alphabetical order ) ISC No:

Black
Brilliant Green 221

Canary Yellow 309
Dark Grey 632
Dark Violet 796
Fire Red 536
French Blue 166
Golden Yellow 356
Gulf Red 473
Jasmine Yellow 397
Light Brown 410
Light Grey 631
Light Orange 557
Sea Green 217
Signal Red 537
Silver 110
Silver Grey 628
Sky Blue 101
White -
Page 191 of 434

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Page 205 of 434
STANDARD No.
BsICNEERS
WA LIMITS) VORTEX BREAKERS 7-12-0019 Rev. 5
Man VIRINVINOMPINI (A Govt. of Indio Undertaking)
Page 1 of 1
to
4=1
w
0 50
z
50 FOR NOZZLES UPTO 250 NB
AND 80 FOR NOZZLES ABOVE
250 NB
60 DRAIN HOLE FLUSH

WITH VESSEL WALL ---CLAD/WELD OVERLAYED NOZZLE
(TYP)
UNLINED NOZZLE (TYP.)
TYPE — 1A TYPE — 2A
FOR NOZZLE NB 100
3D0
60 DRAIN HOLE FLUSH

PLAN VIEW FOR
WITH VESSEL WALL 1B AND 2B
TYPE — 1B TYPE — 2B
FOR NOZZLE NB < 100
ALLOY / ALLOY CLAD/ CONCRETE LINED

VESSEL CARBON STEEL/LOW ALLOY STEEL ALLOY LINED
MATERIAL (NOTE-3b)
CORROSION
ALLOWANCE 1.5 3 4.5 6 — —
THICKNESS 't' 6 8 12 14 5 5
WELD SIZE 'W' 6 6 8 8 5 5
NOTES
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.
3.a) FOR ALLOY LINED VESSELS, THE BAFFLE MATERIAL SHALL BE SAME AS ALLOY LINING.
b) FOR CONCRETE LINED VESSELS, THE BAFFLE MATERIAL SHALL BE ALLOY AS SPECIFIED
IN ENGINEERING DRAWING.
REFER ENGINEERING DRAWING FOR DIMENSION 'B'.
DENOTES NOMINAL BORE SIZE OF SUBJECT NOZZLE.
5 30.07.2011 REAFFIRMED AND REISSUED AS STANDARD POREL KT DM

4 11.09.2006 REAFFIRMED AND REISSUED AS STANDARD POREL DNN AKM VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
No. by by Approved by
Page 206Rev.O
Format No. 8-00-0001-F4 of 434 Copyright EIL - All rights reserved
Page 207 of 434
Page 208 of 434
Page 1 of 17

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: GENERAL SPECIFICATION – MATERIAL SPECIFICATIONS

(Vessels, Heat exchangers, Tanks, Air Cooled Exchangers, Reactors, Columns)
DOCUMENT NO. 44NC-4600-0000-V.02-0114-A4
Rev Issue Pages Rev Description Prepared Checked Approved

No. Date By By By
Page 209 of 434

Jacobs
CPCL, Chennai Job specification Part V Section 3.4
44NC-4600 Material specifications Page 2 of 17
LSTK Doc. no.: 44NC-4600-0000-V.02-0114-A4 Rev. 0
TABLE OF CONTENTS
1.0 MATERIAL REQUIREMENTS FOR SOUR SERVICE
2.0 MATERIAL SPECIFICATION FOR PARTS OF C.S. EQUIPMENT
3.0 MATERIAL SPECIFICATION FOR PARTS OF C.S.(NACE/HIC) EQUIPMENT
4.0 MATERIAL SPECIFICATION FOR PARTS OF SS316L CLAD EQUIPMENT
5.0 MATERIAL SPECIFICATION FOR PARTS OF S.S. EQUIPMENT
6.0 MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (1¼Cr-1/2Mo) EQUIPMENT
7.0 MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (2 ¼ Cr-1 Mo) EQUIPMENT
8.0 MATERIAL SPECIFICATION FOR PARTS OF TANKAGES
9.0 MATERIAL SPECIFICATION FOR PARTS OF MONEL 400 CLAD EQUIPMENT
10.0 PICKLING & PASSIVATION PROCEDURE FOR SURFACE CLEANING ON MONELCLAD

SURFACE
11.0 MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL ( 1 ¼ Cr-1/2 Mo)
EQUIPMENT WITH SS 347 CLAD
12.0 MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL ( 2 ¼ Cr-1 Mo) EQUIPMENT
WITH SS 347 CLAD
13.0 MATERIAL SPECIFICATION FOR PARTS OF HIGH THICK (>50 MM) C.S. EQUIPMENT
44NC-4600-0000-V.02-0114-A4 General Spec for Materials.doc
Page 210 of 434

1. Introduction
Intention of this specification is to state minimum requirements for various materials to be used
for plant equipment.
In case of conflict with any of Licensor documents, requirements specified in Licensor documents
will govern.
In case of conflict with any of code requirements, stringent of the requirements specified herein
and code will govern.
1.1 SOUR SERVICE REQUIREMENTS (NACE MR 0103)
PLATES
− Carbon steel plates conforming to SA-516 Gr. 60 shall be supplied in normalised condition
− Carbon content ≤ 0.18%, Carbon equivalent (Ceq) ≤ 0.43%
− Hardness of plates shall be less than 200 BHN
− Cold deformation during forming / rolling shall be less than 5%
FORGINGS
− Carbon steel forging shall conform to SA-105 or equivalent
− Hardness of forging shall be less than 187 BHN
PIPES
− Seamless carbon steel pipes shall conform to SA-106 Gr. B and hardness shall not exceed
190 BHN.
− Cold deformation during forming / rolling shall be less than 5%
BOLTINGS
− Internal bolting and bolting exposed to H2S environment shall conform to SA 193 B7M/SA-
194 Gr. 2HM
1.2 SOUR SERVICE + HIC RESISTANT REQUIREMENTS
PLATES
− Carbon steel plates conforming to SA-516 Gr. 60 shall be supplied in normalised condition.
The steel shall be killed and shall conform to fine austenitic grain size as per SA-20.
− Carbon content ≤ 0.2%. Carbon equivalent (Ceq) ≤ 0.42% for t < 2” and 0.45% for t ≥ 2”
− Manganese content shall be less than 1.2%

Page 211 of 434

− Nickel content shall be less than or equal to 0.5 %
− Sulphur content shall be less than or equal to 0.002%
− Phosphorus content shall be less than or equal to 0.01%
Materials shall pass the NACE standard TM 0284 but using the acidified test solution specified
in NACE TM 0177 with:
Crack Length Ratio (CLR) ≤ 10%
− Hardness of plates shall be less than 200 BHN (22HRC)
− Through thickness tension testing of plates 25mm thick and above shall be carried out as per
SA-770, S-3 and minimum reduction area shall be 35%.
− Ultrasonic inspection of plates shall be carried out as follows :
a. Plates having thickness 16mm to 50mm (both inclusive) shall be examined ultrasonically
as per SA 435
b. For thicknesses above 50mm ultrasonic examination shall be carried out as per SA 578
and shall have acceptance standard of Level – 1
c. For quenched and tempered steel plates, ultrasonic examination shall be done after the
heat treatment of plates
− Cold deformation during forming/rolling shall be less than 5%
The steel shall be specially produced as HIC resistant steel at the specified HIC resistant
level, tested originally by the Steel Producer.
PIPES
− Seamless carbon steel pipes conforming to SA-106 Gr. B shall have following chemistry
requirement on product
− Hardness of pipes shall be limited to 190 BHN. Cold deformation < 5%
FORGINGS
− Carbon steel forging shall conform to SA-105 or equivalent
− Hardness of forging shall be limited to less than 187 BHN
WELD METAL : Welding consumables shall conform to ASME Section II Part C
BOLTINGS
Internal bolting and bolting exposed to H2S environment shall conform to SA 193 B7M/SA-194
Gr. 2HM

Page 212 of 434
1.3 HIC RESISTANT HIGH THICK FORGED CARBON STEEL
Carbon steel forging shall conform to SA-266 Gr.2 with the following requirements:
− Nickel content shall be less than or equal to 0.5 %
− Sulphur content shall be less than or equal to 0.01%
− Hardness of forging shall be limited to less than 187 BHN
The HIC resistance of these forgings shall be verified in the HIC test in accordance with NACE
TM-0284 but using the acidified test solution specified in NACE TM 0177. The acceptance
criteria of the material shall be as follows:
Crack Length Ratio (CLR) ≤ 10%
All licensor requirements shall be complied with. However in case of any contradiction
same to be resolved in consultation with the Owner/Jacobs/Licensor

Page 213 of 434
2. MATERIAL SPECIFICATION FOR PARTS OF CS EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 516 GR. 60/70
Reinforcement Pad/Pad for external Same as shell material
attachment
Nozzles & Pipes SA 106 Gr. B (Seamless) < 12” NB
“Same as shell material” for 12” NB and above

(with full radiography of weld joints)
Flanges SA 105
Fittings SA 234 WPB
Couplings SA 105
Gaskets As per Piping Material Specification

0
External Bolts & Nuts SA 193 Gr. B7/SA 194 Gr. 2H upto 343 C
0
*SA 193 Gr. B16/SA 194 Gr. 4 for temp. > 343 C
Internal Bolts & Nuts SS 304 / as specified in Process Data Sheet
Wrapper Plate Same as shell material
Skirt support for min. top 1m (Top 2m in case Same as shell material
0
of design temp. ≥ 400 C)
Skirt / Base Plate SA 283 Gr. C

0
Angle leg support / Pipe leg support / Bracket SA 283 Gr. C / SA 53 upto 343 C
0
Support / Saddle support Same as shell material for temp > 343 C
Welded internal parts Same as shell material
Removable Internal parts As specified in Process Data Sheet
External cleats (Directly welded to vessel) Same as shell material

0
External cleats with pad (same as shell/head SA 283 Gr. C upto 343 C
0
Material) Same as shell material for temp > 343 C
Internal Gaskets Non-asbestos
Tray support ring Same as shell material
Demister support Same as shell material
* MDS shall be referred for material of external bolts / nuts and in case of discrepancy between this
material specification and PMS, the same shall be referred to OWNER/Jacobs for clarification.
Page 214 of 434

3. MATERIAL SPECIFICATION FOR PARTS OF CS (NACE/HIC) EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 516 GR. 60 WITH
NACE/HIC REQUIREMENTS (See Note 1)
Reinforcement Pad / Pad for external Same as shell material / use self reinforced nozzles if
attachment required as per design
Nozzles & Pipes SA 106 Gr. B (Seamless) < 12” NB

“Same as shell material” for 12” NB and above (with full
radiography of weld joints)
Flanges SA 105
Fittings SA 234 WPB
Couplings SA 105

0
External Bolts & Nuts SA 193 Gr. B7M/SA 194 Gr. 2HM upto 343 C
0
Wrapper Plate SA 516 Gr. 60
Skirt support for min. top 1m (top 2m in case Same as shell material
0

0
Angle leg support / Pipe leg support / SA 283 Gr. C / SA 53 upto 343 C
0
Bracket Support / Saddle support Same as shell material for temp > 343 C

0
External cleats with pad (same as shell/head SA 283 Gr. C upto 343 C
0
Material) Same as shell material for temp > 343 C
material specification and PMS, the same shall be referred to OWNER/Jacobs for clarification
Note 1 : All materials shall comply with the requirement of Clause 1
Page 215 of 434

4. MATERIAL SPECIFICATION FOR PARTS OF SS316L CLAD EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 516 GR. 70 + SA 240 Gr.
316L CLAD (In case of a different SS cladding, the same shall be applicable )
Reinforcement Pad/Pad for external SA 516 Gr. 70
attachment
Nozzles & Pipes ** SA 106 Gr. B (Seamless) + SS 316L Weld overlay <
8” NB

Flanges SA 105 + SS 316L Weld overlay
Fittings SA 234 WPB + SS 316L Weld overlay
Couplings SA 105 + SS 316L Weld overlay

0
0
*SA 193 GR. B16/SA 194 Gr. 4 for temp. > 343 C
Skirt support for min. top 1m (top 2m in case SA 516 Gr. 70

0
design temp. ≥ 400 C)

0
0
support / Saddle support Same as shell material for temp > 343 C
Internal parts (Removable & welded both) Same as cladding alloy
External cleats (Directly welded to vessel) SA 516 Gr. 70
Tray support ring Same as cladding alloy material
Demister support Same as cladding alloy material
Vacuum Stiffeners SA 516 Gr. 70

** For smaller size if weld overlay is not possible in seamless pipe (3” NB & below) it shall be cut in
two pieces and after weld overlay & proper finish these two pieces shall be welded and weld
Seams shall be fully radiographed.
Page 216 of 434

5. MATERIAL SPECIFICATION FOR PARTS OF SS EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 240Gr.

304/304L/316L
Reinforcement Pad/Pad for external Same as shell material
attachment
Nozzles & Pipes SA 312 Type 304/304L/316L (seamless) upto 6”

NB
“Same as shell material” for above 6” NB
Flanges SA 182 F 304/304L/316L
Fittings SA 403 WP 304/304L/316L (Seamless)
Couplings SA 182 F 304/304L/316L

0
0
Internal Bolts & Nuts SS 304
Wrapper Plate Same as shell material
0

0
0
Support / Saddle support Same as shell material for temp > 343 C
Internal parts Same as shell material / As specified in Process

Data Sheet

0
External cleats (welded over pad ) SA 283 Gr. C for temp. <343 C
0
same as shell material for temp. ≥ 343 C
* MDS shall be referred for material of external bolts / nuts and in case of discrepancy between
this material specification and PMS, the same shall be referred to OWNER/Jacobs for
clarification.
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6. MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (1¼ Cr-1/2 Mo) EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 387GR. 11 Cl. 1

Reinforcement Pad/Pad for external attachment SA 387 Gr. 11 Cl. 2
Nozzles & Pipes SA 335 P 11 (seamless) < 16” NB

Flanges SA 182 F 11 Cl. 2
Fittings SA 234 WP 11 Cl. 2
Couplings SA 182 F 11 Cl. 2
0
0
Internal Bolts & Nuts SS 304 / As per Process data sheet
Skirt support for min. top 1m (top 2m in case of Same as shell material
0
design temp. ≥ 400 C)
Saddle support Same as shell material
Welded Internal parts Same as shell material
Removable Internals As specified in process data sheet
Vacuum Stiffeners Same as shell material
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7. MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (2 ¼ Cr-1 Mo) EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 387 Gr. 22 Cl. 2
Reinforcement Pad / Pad for external SA 387 Gr. 22 Cl. 2
attachment
Nozzles & pipes SA 335 P 22 (seamless) <12” NB.

Flanges SA 182 F 22
Fittings SA 234 WP 22
Couplings SA 182 F 22
External Bolts & Nuts *SA 193 Gr.B7 / SA 194 Gr. 2H upto 343°C
* SA 193 GR. B16/ SA 194 Gr.4 for temp. >343°C
Internal Bolts & Nuts SS 304 / as per Process Data Sheet
Skirt support for min. top 1m (top 2m in Same as shell material

case design temp. ≥400°C)
External cleats (Directly welded to Vessel) Same as shell material
Removable internals As specified in Process Data Sheet
Internal Gaskets Non-Asbestos.
Tray Support Rings Same as shell material
Demister Support Same as shell material
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8. MATERIAL SPECIFICATION FOR PARTS OF TANKAGES
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/BOTTOM AND ROOF PLATE IS SA 36 / IS

2062 Gr. B / SA 516 Gr.70 / SA 516 Gr. 60
Reinforcement Pad / Pad for external attachment Same as shell material
Nozzles Pipes upto 10” NB SA 106 Gr. B
Nozzle ≥ 12” NB and Man way necks Same as shell material
Nozzle Flanges SA 105
Man way Flanges Same as shell and roof material
Fittings SA 234 WPB
External Bolts & Nuts * SA 193 GR B7/SA 194 GR 2H
Internal Bolts & Nuts SS 304
Bolting for structures IS 1363/IS 1367
Structures IS 2062 Gr. B
Internal Same as shell material or as specified in Process

Data Sheet
Hand railing, Stairway, Platform IS 1239 Cl.1 as per standard / SA 53/IS2062 Gr.A/B
External cleats Same as shell material for temperature>343deg.C
Heating coil SA 106 Gr A/.B / As per Process Data Sheet
Wind girder Same as shell material
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9. MATERIAL SPECIFICATION FOR PARTS OF MONEL400 CLAD EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 516 Gr. 70 +

MONEL 400 CLADDING / WELD OVERLAY
Reinforcement Pad / Pad for external SA 516 Gr. 70
attachment
Nozzles & pipes ** SA 106 Gr. B + Monel 400 Weld overlay <8” NB.
Flanges SA 105 + Monel 400 Weld overlay
Fittings SA 234 WPB + Monel 400 Weld overlay
Couplings SA 105 + Monel 400 Weld overlay

0
0
Internal Bolts & Nuts MONEL 400
Skirt support for min. top 1m (top 2m in SA 516 Gr. 70

case of design temp. ≥400°C)
Saddle support SA 516 Gr. 70
External cleats SA 516 Gr. 70
Internal parts Monel 400 / As specified in Process Data Sheet.
Internal Gaskets Non-Asbestos.
Tray Support Rings Monel 400
Demister Support Monel 400
Vacuum Stiffeners SA 516 Gr. 70
** For small size if weld overlay is not possible in seamless pipe (3” NB & below) it shall be cut in two
pieces and after weld overlay and proper finish these two pieces shall be welded and weld seams
shall be fully radiographed.
Note : In case of Monel weld overlay ferrite content shall be checked and the same shall be limited
to 2.5% at the depth of 3 mm cladding.

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10. PICKLING & PASSIVATION PROCEDURE FOR SURFACE CLEANING ON MONEL CLAD
SURFACE
SURFACE CLEANING OF MONEL (SB 127) 400 CLAD SURFACE

1.0 The following pickling procedure shall be adopted for cleaning the internal surfaces of the
Monel cladding / weld overlay.
1.1 Swab with a solution made of
Water : 1 gal.
Nitric acid (42 D Be) : 1 gal.
Common Salt : 2 lb.
Temperature : 70-100°F (ambient)
Time : 5 Sec.
1.2 Rinse clean repeatedly with hot water (180°F)
1.3 Second swab with a solution with
Water : 1 gal.
Nitric acid (42 D Be) : 1 gal.
Temperature : 70-100°F (ambient)
Time : 5 Sec.
1.4 Neutralisation by swabbing 1-2% soda ash followed by hot water rinse.
1.5 Cleaning with saw dust or dry cloth cleaning
The procedure shall be pre-qualified before being employed on the vessel.
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11. MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (1¼ Cr-1/2Mo) EQUIPMENT
WITH SS347 CLAD
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 387 GR. 11 CL.1 + SS
347 CLAD
Reinforcement Pad/Pad for external SA 387 Gr. 11 Cl. 1
attachment
Nozzles & Pipes ** SA 335 P 11 (seamless) + SS347 Weld overlay <12” NB

Flanges SA 182 F 11 Cl. 2 + SS 347 Weld overlay
Fittings SA 234 WP 11 Cl. 1 + SS 347 Weld overlay
Couplings SA 182 F 11 Cl. 2 + SS 347 Weld overlay

0
0
Internal Bolts & Nuts SS 304 / as per Process Data Sheet
Skirt support for min. top 1m (top 2m in Same as shell material

0
case of design temp. ≥ 400 C)
Internal Gaskets As specified in Process Data Sheet
Vacuum Stiffners Same as shell material
* For smaller size if weld overlay is not possible in seamless pipe (3” NB & below) it shall be cut in two
* pieces and after weld overlay and proper finish these two pieces shall be welded and weld seams
shall be fully radiographed .

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12. MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (2¼ Cr-1 Mo) EQUIPMENT
WITH SS347 CLAD
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 387 GR. 22 CL.2 + SS
347 CLAD
Reinforcement Pad / Pad for external SA 387 Gr. 22 Cl. 2
attachment
Nozzles & Pies ** SA 335 P 22 + SS 347 Weld Overlay (seamless) <

12” NB.,“Same as shell material” for 12” NB and above
Flanges SA 182 F 22 + SS 347 Weld Overlay
Fittings SA 234 WP 22+ SS 347 Weld Overlay

0
0
0
Saddle Support Same as shell material
Internal Gaskets Non-Asbestos
Tray supporting Same as shell material
Demister Support Same as shell material
** For smaller size if welded overlay is not possible in seamless pipe (3” NB & below) it shall be cut in
two pieces and after weld overlay and proper finish these two pieces shall be welded and weld
seams shall be fully radiographed.
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13. MATERIAL SPECIFICATION FOR PARTS OF HIGH THICK (>50 MM) C.S. EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 516 Gr. 60 / 70 / SA
266 Gr.2
Pad for external attachment Same as shell material / SA516 Gr. 70
Pipes (Except for nozzles directly welded to SA 106 Gr. B (Seamless) < 12” NB.
vessels “Same as shell material” for 12” NB and above (with full
Flanges & SR Nozzles including integral type SA 350 GR. LF2

flanges
Fittings SA 234 WPB
External Bolts & Nuts * SA 193 GR. B7/SA 194 Gr. 2H upto 343°C
* SA 193 GR. B7/SA 194 Gr. 4 Temp. > 343°C
Wrapper Plate Same as Shell Material / SA516 Gr. 70
0
Saddle Support SA 283 Gr. C upto 343°C

Same as shell material for temp > 343°C
Welded internal parts ** Same as shell material / SA516 Gr. 70
External cleats with pad (same as shell / SA 283 Gr. C upto 343°C
head material Same as shell material / SA516 Gr.70 for temp > 343°C
Internal Gaskets Non-Asbestos
Tray support ring Same as shell material / SA516 Gr. 70
Demister Support Same as shell material / SA516 Gr. 70

material specification and MDS, the same shall be referred to OWNER/Jacobs for clarification.
* For welded internal parts of clad portions of equipment, refer to respective material specifications /
Mechanical Data sheet.
Page 225 of 434

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Page 1 of 5

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: STANDARD SPECIFICATION FOR BQ CARBON STEEL PLATES
DOCUMENT NO. 44NC-4600-0000-V.02-0117-A4
Rev No. Issue Date Pages Rev Description Prepared Checked Approved
By By By
0 09.03.2010 5 Issued as Standard specification MS CR CR
Page 227 of 434

CPCL, Chennai STANDARD SPECIFICATION FOR Part V Section 3.4
44NC-4600 BOILER QUALITY CARBON STEEL PLATES Page 2 of 5
CONTENTS
1.0 PURPOSE
2.0 GENERAL
3.0 TECHNICAL REQUIREMENTS
4.0 FINAL DOCUMENTS
5.0 PAINTING AND COATING
6.0 INSPECTION AUTHORITY
44NC-4600-0000-V.02-0117-A4 Standard Specification for BQ plates.doc

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1.0 PURPOSE
This specification covers requirements for carbon steel plates intended primarily for pressure
vessels / heat exchangers. The steel plates shall meet the requirements of ASME Section II
(latest). This is intended to supplement the minimum applicable requirements of the material
specification indicated in the purchase requisition.
2.0 GENERAL
2.1 Plates supplied to this specification shall conform to specification SA-20 with additional
requirements mentioned herein.
2.2 The tolerance on thickness of steel plates shall be positive only. Final Rolling shall be
lengthwise.
2.3 The plates shall be free from injurious defects and shall have workman like finish.
Reconditioning / repair of plates by welding shall not be permitted. Surface conditions shall
meet requirements of EN 10163 Class A Subclass 3.
3.1 All plates shall be supplied in normalised condition except when the applicable material
specifications require supply of plates in quenched and tempered condition.
3.2 a. One product analysis of each heat shall be carried out and reported. Chemical analysis
shall be as per applicable specification.
b. The carbon content for plates shall not exceed 0.23%.
Additionally, one of the following requirements for carbon equivalent based on heat
analysis, shall also be satisfied.
Ceq = C + Mn/6 ≤ 0.42 (Eqn. – 1)
Ceq = C + Mn/6 + ( Cr+Mo+V)/5 + ( Cu+Ni)/15≤ 0.45 (Eqn. – 2)
Equation – 1 shall be used when applicable material specification specified C and Mn

only.
Equation – 2 shall be used when applicable material specifies the above elements or
restricted chemical requirements are specified or supplementary requirements S19 and
S21 of SA-20 are specified in purchase requisition.
3.3 Ultrasonic Examination of Plates
a. Plates having thickness 16 mm to 50 mm (both inclusive) shall be examined

ultrasonically as per SA-435.
b. For thickness above 50 mm ultrasonic examination shall be carried out as per

SA-578 and shall have acceptance standard of level – B.
c. For quenched and tempered steel plates, ultrasonic examination shall be done after the
heat treatment of plates.
3.4 Simulated Heat Treatment of Test Coupons
The following heat treatment shall be conducted on the test coupons representative of heat-
treated plates before the specified mechanical testing like tensile, bend, impact tests, etc.

Page 229 of 434
These details shall also be recorded on the test certificates.
3.5 Heat Treatment Cycle for components as well as test coupons
For plates above 16 mm thickness : One normalising * + One stress relieving as per
intended for hot rolling / hot forming UCS-56 of ASME Sec. VIII Div. 1
Note: Any other special requirement shall be specified in purchase requisition.
* Recommended normalising cycle :
0 0
(I) Soaking temperature: 900 C to 1000 C
(ii) Holding time one hour per 25 mm thickness but shall not less than half an hour
(iii) Cooling in still air
3.6 If specified in the purchase requisition, charpy V-notch impact test as per supplementary
requirement S5 of specification SA-20 at temperature indicated in the purchase requisition shall
be conducted, for low temperature service.
3.7 If specified in the purchase requisition, plates shall meet the requirements of Indian Boiler
Regulations (IBR).
3.8 Additional requirements for high thickness plates
Plates of thickness 50 mm and above shall meet following additional requirements: -
a. Vacuum Degasing treatment as per the supplementary requirement S1 of specification

SA-20
b. Charpy V – notch impact test as per the supplementary requirement S5 of specification

SA 20.
0
i) Material meant to be used for design temperature warmer than 0 C, impact test
0
shall be carried out at minus 29 C and acceptance criteria for energy absorption
shall be as per Table A2.15 of SA-20.
ii) Acceptance criteria and test temperature for impact testing of non listed material of
Table A2.15 of SA-20 shall be as specified in purchase requisition.
c. Bend test as per the supplementary requirement S14 of specification SA-20.
d. Simulated heat treatment of test coupons for all plates as per Clause 3.4 mentioned
above.
4.0 FINAL DOCUMENTS
The supplier shall furnish 7 copies of the following certificates / documents inclusive of all tests
required as per specification duly certified by the Inspecting Authority before shipment of plates.
The actual values obtained shall be recorded in the test certificates / documents. Material
certificates shall conform to DIN 50049 Type 3.1 B/EN 10204 Type 3.1 B.
a. Chemical Analysis
b. Mechanical Tests

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c. Data of heat treatment i.e. initial temperature, heating rate, soaking temperature, cooling
rate, etc
d. Simulated Heat Treatment of Mechanical Test coupons (S3 of SA-20) at indicated Heat
Treatment Cycle (if specified in the requisition or whenever applicable)
e. Ultrasonic Examination (S8 or S12 of SA-20)
f. Charpy V-notch impact tests (S5 of SA-20 if specified in the requisition or whenever
applicable)
g. Bend test (S14 of SA 20 if specified in the requisition or whenever applicable)
h. Certification as per IBR (if specified in the requisition)
i. Date of manufacture (final rolling)
j. SSC and / or HIC tests (if specified in purchase requisition)
5.0 PAINTING AND COATING
No painting / coating of any kind is permitted on the steel plates, except stencil marking.
6.0 INSPECTION AUTHORITY
6.1 Material test certificate duly certified by Mill’s quality assurance / quality control department is
acceptable. However, if third party inspection is specified in requisition, all test certificates and
documents shall be duly certified by the third party.

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MANALI REFINERY
EPCC-1 : COKER BLOCK : DELAYED COKER UNIT & LPG CFC TREATING UNIT
PART : I
SECTION : 9
TITLE: QUALITY MANAGEMENT SYSTEM
DOCUMENT NO.: 44NC-4600-0000/N.02/0040/A4
A 03-May-10 7 Issued for FEED RB RPG BBD

Prepared Checked Approved
Rev No. Issue Date Pages Rev Description
By By By
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Jacobs
CPCL, Chennai QUALITY MANAGEMENT SYSTEM Part-I
LSTK – 1 : Coker Block Section-9.0
44NC-4600 Doc.no.: 44NC-4600-0000/N.02/0040/A4 Page 2 of 7
TABLE OF CONTENTS
1.0 INTRODUCTION 3
2.0 DEFINITIONS 3
3.0 SCOPE OF WORK BY CONTRACTOR 3
4.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS 4
5.0 CONFLICT 7
6.0 CONTRACTOR’S MANAGEMENT REVIEW 7
ANNEXURES
ANNEXURE – I : QUALITY PLAN FORMAT – DESIGN FUNCTIONS
ANNEXURE – II : QUALITY PLAN FORMAT – PROJECT SERVICES
ANNEXURE – III : QUALITY PLAN FORMAT – PROCUREMENT
FUNCTIONS
ANNEXURE – IV : QUALITY PLAN FORMAT – CONSTRUCTION
ACTIVITIES
ANNEXURE – V : QUALITY PLAN FORMAT – WAIVER / DEVIATION
REQUEST
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Jacobs
1.0 INTRODUCTION
This Quality Management System requirements are to be met by the LSTK Contractor during
execution of contracted Scope of Work.
It is preferred by Owner / PMC, that Contractor has a fully documented and certified (by a third
party, internationally accredited certification agency) quality system such as ISO 9001:2000.
2.0 DEFINITION
2.1 Owner – shall mean Chennai Petroleum Corporation Limited.
2.2 PMC – shall mean Project Management Consultant i.e. Jacobs.
2.3 Contractor
For the purpose of this specification, the work “Contractor” means the person(s), firm, company
or organisation who is either under the process of being contracted or contracted by Owner /
PMC for delivery of some products (Including service). The work is considered synonymous to
supplier, bidder or tenderer.
2.4 Quality Manager – Shall mean quality assurance manager dedicated to this project.
2.5 Third Party - Shall mean an independent organisation carrying out assessment on behalf of
Owner / PMC to assess Contractor’s compliance with quality system.
3.0 SCOPE OF WORK BY CONTRACTOR
3.1 Prior to the award of contract
The LSTK contractor shall provide a detail of plan for his total scope of work along with the Bid.
This is required to assure Owner / PMC that he has understood the work and has required
capabilities to carry out the work. Following documents are required to be submitted along with
the bid to enable assessment of above stated requirements,
3.1.1 Brief description of the quality system used by the contractor for carrying out the following
activities:
¾ Project management
¾ Licensor / Technology Slection
¾ Engineering
¾ Procurement including inspection and expediting
¾ Planning and controls
¾ Construction
¾ Commissioning
¾ Subcontracting
¾ Training
¾ Quality Management
3.1.2 Details indicating the plan for all activities, required to be done by the contractor, to accomplish
offered scope of work. These quality plans must be made on enclosed forms, complete in all
respects. The quality plans shall be assumed to be detailing contractors understanding and
planning for the contract / offered scope of work. It is the responsibility of the contractor to
ensure complete harmony between deliverables covered under quality plan(s) and other
documents of the contract.
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Jacobs
Applicable forms for quality planning are enclosed as Annexure-I to IV.
3.2 During / After the award of the Contract
3.2.1 Various documents submitted by the Contractor during the pre-award stage shall be finalised in
consultation with PMC / Owner. It shall be presumed that once an offer is made, the contractor
has understood the requirements given in this specification and agrees to comply with them in
totality unless otherwise categorically so indicated during pre-award stage by Owner / PMC.
3.2.2 Owner / PMC will review all the quality documents including quality manual and contractor is
obliged to incorporate all comments as per this specification.
3.2.3 It is obligatory on the contractor to obtain approval on every quality document (documents
demanded by this specification and / or in the quality plans) before using a particular document
for delivery of contracted scope of work.
3.3 During Job Execution
3.3.1 The LSTK contractor is expected to fully comply with all quality documents submitted and
finalised / agreed against the requirements of this specification. Approval of PMC / Owner on all
these documents shall be sought before start of work.
3.3.2 The LSTK contractor shall be producing sufficient quality records on controlled forms such that
requirements given in this specification can be objectively demonstrated..
3.3.3 The LSTK contractor shall facilitate PMC / Owner during quality audits / surveillance at his office
works / sites to demonstrate compliance to any / all requirements of this specification. PMC /
Owner may institute audits at its sole discretion.
3.3.4 The LSTK contractor shall discharge all responsibilities towards enforcement of this
specification on all the sub-contractors for any part of the work that is sub-contracted by the
contractor.
4.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS

4.1 The contractor shall nominate an overall in charge of the quality titled as “Quality Manager” for
the scope of work of agreed contract. The name of this person shall be duly intimated to PMC /
Owner and all subsequent changes in this shall also be duly intimated to PMC / Owner.
4.2 The LSTK contractor shall clearly establish the responsibilities and authorities of senior
functionaries such that PMC / Owner has total clarity about the concerned person depending
upon nature of the issue. The contractor shall provide adequate manpower and material
resources as per the agreed quality plans.
4.3 The contractor is required to review the contract at all appropriate stages to evaluate its
capability vis-à-vis contract scope of work. All major / critical aspects must be evaluated before
acceptance of the contract. It is expected that the contractor completely plans the contract scope
of work on quality plan formats such that no major variation is expected during delivery of
contract scope of work. Contractor shall plan the type of resources, including various work
methodology and strategies that are to be utilised for delivery of contract scope of work and form
the basis for the costing. The resources shall be planned and deployed based on good industry
practices and as per the job need.
4.4 The scope of the audit shall cover but not limited to the following areas of the project:
4.4.1 Engineering and design
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Jacobs
- Project specific procedures

- Requisitions for equipment and bulk materials .
- Requisitions for Construction sub-contracts.
- Drawings
- Documentation
- Calculations
- Design Verification & Reviews
- Vendor data and vendor calculations
- Constructability review
- Design Safety review
- Document Control
- Softwares to be used.
4.4.2 Procurement
- Enquiry documents for equipment / materials etc.

- Bids for equipment / materials and sub-contract selection, qualification of vendors and sub-
contractors.
- Approval of purchase requisitions of critical equipment as stated in the Contract by Owner /
PMC.
- Purchase Orders
- Inspection and test requirements.
- Contents of inspection reports
- ODC consignments and transportation.
- Packing requirements
- Completeness of manufacturer’s data, documentation requirements,
- Review of installation, pre-commissioning & commissioning documents including vendor
assistance whenever required.
- Documents and Data Control.
4.4.3 Construction / Pre-commissioning / Commissioning / Guarantee Run.
- QA / QC plans for all disciplines including PMI

- Fabrication, erection & Commissioning procedures
- Requirements for mechanical completion
- Handing over procedures and documentation.
- HSE requirements.
4.4.4 The quality requirements shall address the activities / procedures associated but not limited to
following personnel / disciplines.
- Home office activities
- Project team consisting of managers from various disciplines such as process, mechanical,
electrical, civil, instrument, procurement etc.
- All functional disciplines
- Site Construction etc.
4.5 All design activities, if any, performed during delivery of contract scope of work shall be so
controlled that the output is efficient and reliable. It is expected that during development of
design, the contractor shall take recourse to detailed checking, inter departmental reviews and
documented verification methods. Demonstrable objectives evidence for these measures shall
be retained. For all design activities (including verification and review), the contractor shall use
duly qualified personnel as per good industry practices
4.6 A system which assures that latest / required version(s) of the documents(s) are available at all
locations / point of use.
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4.7 In case the contractor decides to sub-contract any part of the contract scope of work (with in the
frame-work of main contract), the contractor shall ;
4.7.1 Evaluate the sub-contractor(s) before awarding them with any work.
4.7.2 Requirements of this specifications shall be enforced on sub-contracted agency also. No

relaxation shall be granted (after finalisation of main contract) on the requirements of this
specification. The contractor shall choose sub-contractor based on their capability to meet
requirements of this specification also.
In case, a sub-contractor may not have a system meeting requirements of this specification, the
contractor may lend his system to sub-contractor for the contract such that sub-contractor
effectively meets the requirements of this specifications.
4.8 All outputs delivered against the contract scope of work shall be suitably identified in such a
manner that either through identification or some other means, sufficient traceability is
maintained which permits effective resolution of any problem reported in the outputs. By this, the
intention is that when some problems are found in the outputs, the root cause can be traced
back through available marking on the output such that effective preventive action is feasible.
4.9 For all critical activities, contractor is expected to have documented methodologies that are to be
utilized for delivery of contract scope of work. Wherever it is difficult to fully inspect or verify the
output (special process), contractor shall pre-qualify the performers and methodologies.
4.10 All inspections carried out by the contractor’s surveillance / inspection staff shall be in conformity
to quality plans and / or inspection and test plans. All inspections results shall be duly
documented on controlled forms such that results are traceable to specific product, that was
inspected / tested. All inspections shall be carried out by duly qualified personnel as per industry
norms or applicable standards.
4.11 All Inspection, Measuring & Test Equipment (IMTE) shall be duly calibrated as per national,
international standards / codes and only duly calibrated and so certified IMTEs shall be utilised
for inspection / testing of contract scope of work.
4.12 All outputs / products delivered against contract scope of work shall be duly marked such that
their inspection / control status is clearly evident during all stages / period of the contract.
4.13 All non-conformities found by contractor’s inspection / surveillance staff shall be duly recorded
including their disposal action. Effective corrective and preventive action shall be implemented
by the contractor for all repetitive non-conformities.
4.14 All non-conformities found by PMC / Owner representative shall be duly recorded on a controlled
form. Such non-conformities shall be analyzed by the contractor and effective and appropriate
correction, corrective and preventive actions shall be implemented. Contractor shall intimate
PMC / Owner of all such corrective and preventive actions implemented by him. Effectiveness of
implemented corrective and preventive action shall be monitored till next two audits.
4.15 Contractor shall establish appropriate methodologies for safe and effective handling, storage,
preservation of various materials / inputs encountered during delivery of contract scope of work.
4.16 Contractor shall prepare sufficient records for various processes carried out by him for delivery
of contract scope of work such that requirement of this specification can be objectively
demonstrated. Various records produced during performance of any activity shall be specified in
the quality plans. In case PMC / Owner finds that enough objective / recording is not available for
any particular process, contractor shall be obliged to make additional records so as to provide
sufficient objective evidence. The decision of PMC / Owner shall be final and binding on such
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Jacobs
issues.
4.17 The contractor shall carry-out internal quality audit for the contract scope of work including this
specification after every three months. Audits shall be scehduled such that each element of
contractor’s quality system applicable to each major activity areas viz., design / engineering,
project management, procurement, construction and commissioning is audited. An independent
team having appropriate qualification shall be appointed for this purpose. The findings of such
assessment shall be duly recorded and appropriate corrective and preventive actions
established and acted upon, the complete report / copy of these shall be sent to PMC / Owner
for information / review.
4.18 The contractor shall institute second part audits on all subcontractors after every three months to
establish compliance to this specification. PMC / Owner reserves the right to nominate their
representatives during such audits. Records of findings and actions shall be maintained.
4.19. For all special, verification and critical processes, contractor shall deploy only qualified
performers. Wherever PMC / Owner find any deficiency, the contractor shall be obliged to impart
necessary training / qualifications to the performer(s) before any further delivery of work.
5.0 CONFLICT
In case of any conflict between the main contract and requirements given in this specification or
any document finalised based on this specification, the requirements / provisions of the main
contract shall prevail.
6.0 CONTRACTOR’S MANAGEMENT REVIEW
6.1 Management Review Meetings shall be carried out scheduled quarterly or on as needed basis at
sufficient intervals.
6.2 The Management shall address in these meetings the feed back received from audit findings,
non-conformities and the feed back from Owner / PMC.
6.3 There shall be total involvement and commitment by the Management to enhance Owner’s
satisfaction through continual improvement of the system and assurance of conformity to
Owner’s and applicable regulatory requirements.
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Page 1 of 5

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: SUPPLEMENTARY SPECIFICATION FOR CARBON STEEL

VESSELS
DOCUMENT NO. : 44NC-4600-0000-V-02-0120-A4
Rev No. Issue Date Pages Rev Description Prepared Checked Approved
By By By
0 09.03.2010 5 Issued as Standard specification MS CR CR
Page 250 of 434

CPCL, Chennai SUPPLEMENTARY SPECIFICATION FOR Part V Section 3.4
44NC-4600 CARBON STEEL VESSELS Page 2 of 5
TABLE OF CONTENTS
1.0 PURPOSE
2.0 DESIGN
3.0 ELECTRODES
4.0 FABRICATION
44NC-4600-0000-V.02-0120-A4 Supp spec for CS vessels.doc

Page 251 of 434
1.0 PURPOSE
This supplementary specification indicating additional requirements for fusion welded carbon steel
vessels shall form addenda to General Specification for Pressure Vessels No. 44MM-2800-00-
V.02-0101-A4
2.0 DESIGN
2.1 Reinforcement for nozzle openings shall be integral type when required by the applicable
codes/standards or when the nominal thickness of vessel part exceeds 50mm. Self-reinforcing
type nozzles of size 3” NB and above shall be `set in’ type.
2.2 Design calculations for self reinforced nozzles/self reinforced weld ends shall be submitted by
Vendor.
3.0 ELECTRODES
3.1 Electrodes conforming to following specification shall be used. In case of any deviation, prior
approval from Jacobs shall be obtained.
Sr. no. Material to be welded Electrode Specification
1. General Structure Welding : ASME IIC SFA 5.1 E-6013
2. Pressure Parts :
a. Steels with UTS upto 70,000 psi : ASME IIC SFA 5.1 E7016/ E7018
b. Steels with UTS upto 80,000 psi : ASME IIC SFA 5.5 E8016-X/
E8018-XX depending upon the alloy
element
c. Low temperature service

0 0
Below minus 0 C and upto minus 46 C : ASME IIC SFA 5.1 E7016-1/
Steels to A-516, A-537, A-333 Gr.6 and A-350 E-7018-1
LF2
3.2 All electrodes and fluxes shall be properly baked / dried as per manufacturer’s recommendation
before use.
3.2.1 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.
3.2.2 Only dry flux shall be used.
4.0 FABRICATION
4.1 Plate Forming
4.1.1 Forming of shell plates and heads shall be carried out by machine, either hot or cold, in such a
way so as to preserve the specified material properties and to produce a regular finish.

Page 252 of 434
4.1.2 Magnetic particle / Dye penetrant examination shall be carried out on the outside and inside
surfaces including edges of torispherical or elliptical heads in knuckle zone, after forming, for
detection of cracks.
4.2 Edge Preparation
4.2.1 The preparation of edges to be welded shall be done by machining, chipping, grinding, cold
shearing, Oxy-acetylene flame cutting or a combination of these.
4.2.2 Chipping shall be followed by grinding to a smooth and regular finish.
4.2.3 Oxy-acetylene flame cutting done in any circumstances shall be followed by machining or grinding
to eliminate any discoloration of material affected.
4.2.4 All welding edges shall be checked by Magnetic particle/Dye penetrant examination for detection
of cracks, laminations or segregations.
0
4.2.5 No welding shall be carried out when ambient temperature is less than 10 Celsius unless
preheating is carried out.
4.3 Heat Treatment
4.3.1 Heat treatment of formed parts shall be carried out as per following:
(a) Cold formed dished ends or knuckles up to 16 mm nominal thickness shall be stressed
relieved.
(b) Cold formed dished ends or knuckles above 16 mm nominal thickness shall be
normalised
(c) Hot formed dished ends or similar parts, which have not been uniformly heated in the
normalising range in the final stages of manufacturing shall be normalised.
(d) When the completed vessel involves post weld heat treatment, heat treatment
recommended in (a) above shall not be applicable.
4.3.2 Vessels in caustic service, amine or sour service shall be stress relieved.
4.4 Production Weld Tests
Production weld tests shall be applicable for vessels above 50 mm nominal thickness or when
required by the applicable code. The following shall apply:
a) Two production test plate coupons representative of one longitudinal and another
circumferential seam shall be provided for each procedure, position and thickness in
each vessel shell.
b) One production test plate representative of the weld seams shall be provided for each
procedure, position and thickness for welded dished ends/cones.
c) 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. Extra coupons shall be
preserved to take care of eventuality of retests.

Page 253 of 434
d) The tests mentioned below shall be carried out as per methods of testing in governing
codes:
(i) One transverse tension test
(ii) Two side bend tests with weld located in the centre of bend.
(iii) Hardness test on production test coupon weld & HAZ (The hardness value shall not
exceed 200 BHN)
(iv) Micro & macro examination of welds
(v) Charpy V notch tests on weld and HAZ.
a) For low temperature service impact test temperature shall be lowest of

minimum ambient temperature, design temperature and minimum design
metal temperature.
b) For vessel over 50 mm nominal thickness used for warmer service, the test
0
temperature shall be lower of 0 C or lowest ambient temperature of the site.
c) The acceptance criteria for energy absorption shall be as per Table A 2.15 of
SA 20 or the Design Code whichever is more stringent.
4.5 For vessels required to meet stress corrosive conditions (such as caustic service, H2S service,
amine, etc.), one Brinell hardness reading shall be taken on the inside of each shell section, head
longitudinal weld, circumferential weld and nozzle longitudinal weld after final post weld heat
treatment. The value shall be limited to the specified value as per requisition.

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Page 1 of 33

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: GENERAL SPECIFICATION FOR PRESSURE VESSELS
DOCUMENT NO. 44NC-4600-0000-V.02-0101-A4
Rev Issue Date Pages Rev Description Prepared Checked Approved

No.
By By By
Page 285 of 434

44NC-4600 PRESSURE VESSELS Page 2 of 41
TABLE OF CONTENTS
1.1 CODES
1.2 STATUTORY REQUIREMENTS
1.3 INTERNATIONAL REQUIREMENTS
2.0 DESIGN BASIS – GENERAL
3.0 DESIGN REQUIREMENTS – SPECIFIC APPLICATIONS
4.0 MATERIAL SPECIFICATION
5.0 SUPPLY
6.0 FABRICATION
7.0 NON DESTRUCTIVE TESTS
8.0 HEAT TREATMENT
10.0 PROTECTION AND DESPATCH
11.0 VENDOR’S GUARANTEES
TABLE – 1 DETAIL & WEIGHT OF COLUMN ATTACHMENTS
TABLE – 2 ALLOWABLE STRESS FOR COMBINED LOADING
TABLE – 3 MATERIAL SELECTION CHART
TABLE – 4 NOZZLE LOCAL LOADS
Page 286 of 434

1.1 CODES
The following applicable codes and laws of India and their applicable standards in their
latest edition including latest addenda shall be followed unless otherwise specified for the
design, fabrication, inspection and testing of Vessels, Columns, Reactors, Storage Tanks,
Steel Flare/ Vent Stacks :
ASME SEC. VIII DIV. 1 For Pressure Vessels
ASME SEC. VIII DIV. 2 For Pressure Vessels (as specified in bid package for
high shell wall thickness of equipment)
ASME SEC.V For non-destructive testing
ASME SEC. II Part A, B, C, D For material specification & allowable stresses
ASTM/ IS For material specification for Tanks
ASME Sec. IX For welding
ASME B 16.5 For flanges
ASME B 16.47 For large diameter flanges
ASME B 16.20 / For gaskets
ASME B1.1 For bolting specification
ASME B 16.28 For elbows & return bends
ASME SEC. VIII Div. 1 For workmanship of Vessels not categorised under
any other code
API 650 For Storage Tanks
API 620 For Low Pressure Storage Tanks
IS: 6533 For steel vent stacks etc
IS: 875/ Site Data For wind load consideration
IS: 1893/ Site Data For seismic design consideration
44NC-4600-0000-V.02-0101-A4 General Spec for Pressure vessels.doc
Page 287 of 434

IBR For steam producing, steam storage, catch water vessels,

condensate flash drums and similar vessels
SMPV Static and mobile pressure vessel (unfired) rules, 1981
1.2 STATUTORY REQUIREMENTS
National laws and statutory requirements such as of Indian Boiler Regulations and
requirements of Department of Explosives, Nagpur, India together with any local by-laws for
the state shall be complied with. Static and Mobile Pressure Vessel (SMPV) rules and
Petroleum rules, Directorate (OISD) etc. as applicable shall also be complied with.
1.3 INTERNATIONAL PUBLICATIONS
NACE MR 0103 Sulphide Stress Cracking Resistant Metallic Materials for Oil Field
Equipment
NACE MR 0284 Evaluation of Pipeline and Pressure Vessel Steel for Resistance
to Hydrogen Induced Cracking
NACE TM 0177 Laboratory Testing of Metals for Resistance to Sulphide Stress

Cracking in Hydrogen Sulphide Environment
NACE RP 0472 Methods & controls to prevent in service cracking of CS welds in

P1 materials in corrosive petroleum refining environments
WRC Bulletin # 107 Local Stresses in Spherical & Cylindrical Shells due to External
Loadings
WRC Bulletin # 297 Local Stresses in Cylindrical Shells due to External Loadings on
Nozzles
WRC Bulletin # 368 Stresses in intersecting Cylindrical Shells subject to pressure
Page 288 of 434

2.0 DESIGN BASIS – GENERAL
All equipment shall be designed in accordance with the latest design codes, and
applicable standards/ specifications. Design calculations shall be made considering all
loads for Erection, Operating and Hydrotest conditions (ref. Para.3.1.2)
2.1 SIZING OF EQUIPMENT
All equipment columns, clad/lined vessels, vessels (including thickness ≥ 50 mm), tanks,
bullets & all others vessels shall be sized on the basis of internal diameter only.
2.2 SHELL/HEAD THICKNESS
2.2.1 For columns of carbon and low alloy steel, minimum thickness shall be 8mm (including
corrosion allowance up to 3mm).
The minimum thickness of carbon and low alloy steel vessels shall be 6.0 mm (including
corrosion allowance not exceeding 3.0 mm) but shall not be less than calculated as per
following formula:
Wall thickness = Dia / 1000 + 1.5 + Corrosion Allowance, for Dia. less than 2400 mm.
Wall thickness = Dia / 1000 + 2.5 + Corrosion Allowance, for Dia. 2400 mm and more.
All dimensions are in mm. Above formula is applicable for both columns & vessels.
2.2.2 For columns of stainless steel and high alloy steel, minimum thickness shall be 5mm.
Corrosion allowance shall be added in this minimum thickness as specified in process
data sheet.
The minimum thickness of stainless steels & high alloy vessels shall be 3.0 mm but shall
not be less than calculated as per following formula:
Wall thickness = Dia / 1000 + 2.5 + Corrosion Allowance, for Dia. more than 1500 mm.
Corrosion allowance shall be added to minimum thickness as specified. Above formula is

applicable for both columns & vessels.
2.2.3 Tangent to tangent height (H) to diameter (D) ratio (H/D) greater than 5 shall be
considered as column and designed accordingly.
2.3 VESSEL END CLOSURES
2.3.1 2:1 semi-ellipsoidal dished end shall be used for pressure vessels unless otherwise
specified. Seamless dished ends shall be used for specific services as per process
licensor requirement.
2.3.2 Unless specified otherwise, hemispherical ends shall be used when the thickness of shell
exceeds 70 mm.
2.3.3 For atmospheric vessels, flat covers may be used.
Page 289 of 434

2.3.4 For vessels diameter < 600 mm, without any internals, pipe caps may be used.
2.3.5 Dished ends, after forming, shall be heat treated as per following applicable details:
a) For thickness ≤ 16mm

Dished ends with nominal thickness ≤ 16mm shall be stress relieved
b) For thickness > 16mm
Dished ends with nominal thickness > 16mm shall be normalized. Recommended
normalizing cycle:
0 0
• Soaking temperature: 900 C to 1000 C
• Holding time one 2.4 min per mm thickness but shall not less than half an
hour
• Cooling in still air
2.3.5 Vessels and columns with diameter up to 1000 mm shall be provided with 500 NB
manhole. Vessels and columns with diameter greater than 1000 mm and up to 1500
mm shall be provided with 500 NB manhole. However, if required, vessels and
columns with diameter above 1500 mm shall be provided with 600 NB manhole.
Trays and other column internals installation shall be given consideration in deciding the
size and location of manholes, hand holes or body flanges as the requirements may be at
the initial design itself.
High pressure reactor manholes i.e. HCGO/OHCU Reactor etc. shall be on I.D. basis.
Size shall be as per Licensor drawing.
2.3.6 All process vessels that have a manhole will also be specified to have a vessel vent to
provide ventilation for maintenance. This vessel vent will be located at the top, or a
minimum distance from top of vessel. Size of this vent shall be as follows.
Vessel capacity Length of (Horizontal Vent Nozzle Drain Ventilation

Vessel) (L) mm Nozzle Nozzle
V<6. 0 - 40 NB 40 NB -
6.0<V< 15 - 50 NB 40 NB -
V>15 - 50 NB 50 NB -
- 3000mm<L<4500 mm - 100 NB
- 4500mm<L< 7500 mm - 150NB
L>7500mm 200NB
Vertical vessel not having any nozzle on the top shall be provided with 50 NB nozzle for
conducting hydro test in vertical conditions.
All vent and drain lines of light Hydrocarbons like MS, naphtha, LPG, propylene, and H2
shall be provided with double isolation valves with end flanges as per OISD. Dia11/2 in
NB (40 NB) and above drain lines shall be provided with end flanges.
Page 290 of 434

2.3.7 If the equipment process data sheet indicates sour service (alkaline or wet H2S service),
the equipment materials, their testing, their post weld heat treatment and any other
recommendations of the NACE materials recommended by the licensor and pertinent
publications like NACE MR 175 shall be complied without exception.
2.4 DESIGN PRESSURE
Design pressure shall be calculated as per the following unless otherwise specified
elsewhere.
2.4.1 Design pressure = As per PDS
2.4.2 Design pressure shall be at the top of vertical vessel or at the highest point of horizontal
vessel.
2.4.3 The design pressure at any lower point shall be calculated by adding the highest operating
liquid head and any pressure drop within the vessel.
2.4.4 Equipment with steam out condition shall be designed for full vacuum condition.
2.4.5 Equipment operating under vacuum / partial vacuum shall be designed for an external
2
pressure of 1.055 kg/cm g (15 psi g)
2.4.6 Vessels shall be designed for steam out conditions if specified on process data sheet. For
steam out conditions equipment shall not be designed for Full vacuum.
2.4.7 Minimum design pressure shall be 3.5 kg/cm2 g for any equipment except API storage
tanks.
For vessels operating at ATM pressure minimum design pressure shall be ATM
2.4.8 All storage tanks shall be designed as per code considering full height & using specific
gravity 1.0 if not specified.
2.4.9 Pressure chambers of combination units in equipment shall be designed for testing
independently without pressure in the adjacent chamber in corroded condition.
2.5 DESIGN TEMPERATURE
2.5.1 Design temperature = As per PDS
2.5.2 Minimum Design Metal Temperature (MDMT) shall be lower of minimum atmospheric
temperature and minimum operating temperature encountered during operation.
Un-insulated vessels containing LPG and similar fluids shall be designed for maximum &
minimum temperature as recommended by SMPV rules.
Page 291 of 434

2.6 HYDRO TEST PRESSURE
2.6.1 Equipment shall be hydro tested in the fabricator’s shop as per applicable design code &
specification requirements. However care shall be taken that hydrostatic temperature shall
be at least 6 degree centigrade higher than critical exposure temperature (CET) for vessel
thickness up to 50 mm and minimum 17 degree centigrade higher than the CET where CET
id minimum design metal temperature (MDMT). However, if code requirement is found to be
stringent, than the same shall be followed.
2.6.2 All vertical vessels, columns and horizontal vessels (in full corroded condition) shall also be
designed for site testing of the equipment with water at the test pressure on the top of the
equipment considering 33% wind load.
2.6.3 All equipment foundation shall be designed and constructed for water full condition when
equipment is new with 33% wind load.
2.6.4 Open atmospheric vessels shall be tested by filling water up to the top curb angle.
2.6.5 Pressure chambers of combination units that have been designed to operate independently
shall be hydro tested to code test pressure as separate vessels i.e., each chamber shall be
tested without pressure in the adjacent chamber.
When pressure chambers of combination units have their common elements designed for
maximum differential pressure, the common elements shall be subjected to test pressure
equivalent to the differential pressure multiplied by a factor as per applicable design code.
Hydro test pressure shall be equal to 1.3 x design pressure x temperature correction factor
as specified in ASME SEC. VIII DIV.1 (Clause UG-99) at top of column unless specified
otherwise. If column is tested in horizontal position, hydro test pressure shall be increased
in order to take the effect of water head.
After taking precautions as suggested in para 2.21.5, an IBR equipment may be tested to
meet IBR’s hydrostatic test requirements.
2.6.6 Coils shall be hydro tested to code test pressure separately.
2.6.7 Unless otherwise specified in applicable design code allowable stress during hydro test in
tension shall not exceed 90% of yield stress point.
2.6.8 Storage tanks shall be tested as per applicable code.
2.7 CORROSION ALLOWANCE
2.7.1 Corrosion allowance shall be as per Process data sheet
2.7.2 No corrosion allowance for stainless steel columns & vessels shall be used unless
otherwise specified.
2.7.3 If it is agreed to develop the cladding by weld overlay method, then it shall be ensured to
have undiluted chemistry of the cladding upto specified thickness of cladding. Surface
texture requirement if applicable shall also be ensured.
Page 292 of 434

Cladding or lining thickness shall not be included in strength calculations.
2.7.4 For storage tanks, minimum corrosion allowance shall be as follows unless otherwise
specified:
Bottom plate : 1.5 mm,
First shell course : 3 mm,
Subsequent shell courses : 1.5 mm
Floating roof/fixed roof : 1.0 mm.
2.7.5 Corrosion allowance for nozzles including manholes shall be equal to that specified for the
vessel. No corrosion allowance is required for standard flange face.
2.7.6 Corrosion allowance for girth/ body flange faces shall be used equal to that specified for
vessel.
2.7.7 Corrosion allowance for support skirts of columns & vertical vessels shall be 1.5 mm
(minimum) unless specified otherwise.
2.8 Earthquake & Wind Considerations
2.8.1 Wind Consideration
Wind load for equipment including anchor chair shall be calculated on the basis of IS 875 / site
data for skirt supported equipments, storage tanks, spheres, flare stacks and air coolers.
a) Drag coefficient for cylindrical vessels shall be 0.7 minimum.
b) Drag coefficient for spherical vessel shall be 0.6 minimum considering:
K1 = Risk factor 1.0 (for 50 years life)

K2 = Terrain category Factor based on category 3 (for units) and factor based
on category 2 (for off sites)
K3 = Topography Factor based on site topography =1.0
Contingency factor of 1.1 shall be used on wind pressure
2.8.2 Earthquake Consideration:
For seismic design consideration of new equipments which are replaced on the existing old
foundation, Earthquake loads shall be calculated in accordance with IS: 1893- 1984/Site data.
For seismic design consideration of new equipments on totally new foundations (i.e. skirt
supported equipments, storage tanks, spheres and air coolers) Earthquake loads shall be
calculated in accordance with IS:1893 (Latest), if site specific acceleration spectra is not
specified in the project specification.
Page 293 of 434

2.9 TANK CAPACITY
Capacity shall be specified as Nominal capacity and stored capacity. Nominal capacity for
fixed roof tanks shall be volume of cylindrical shell.
Stored capacity for fixed roof tanks shall be equal to nominal capacity minus free board
volume (equivalent to 500mm of shell height) or location of fixing of lowest roof structure
member
Nominal capacity (also the stored capacity) for floating roof tanks shall be volume of cylindrical
shell minus free board volume. (Equivalent to minimum 1500mm of shell height)
Nominal capacity (also the stored capacity) for fixed cum floating roof tanks shall be volume of
cylindrical shell minus free board volume. (Equivalent to minimum 2500 mm of shell height).
2.10 SUPPORTS
2.10.1 Skirt supports shall be provided for all vertical vessels, columns and reactors. Small vertical
vessels may be supported on legs or brackets.
2.10.2 All Cr-Mo steel reactors shall be supported on skirts. Welding of external cleats on Cr-Mo steel
reactors shall be avoided wherever possible.
2.10.3 Skirt thickness
The minimum thickness for the skirts shall be greater of:
a. The thickness required by stress analysis with a minimum of 6 mm.
b. 30 mm or 1/3 of the vessel wall thickness whichever is lower.
Corrosion allowance of total 1mm minimum shall be considered for skirt unless otherwise
specified in the project specifications to achieve final thickness of skirt shell.
2.10.4 Columns with diameter 1000 mm & larger shall be self supported unless the process data
sheet indicates a guide supported design.
2.10.5 Columns with diameter less than 1000mm shall be supported by superimposed structure
around the column covering the entire height. Guy wires shall not be used to support any
equipment. Supporting of columns by superstructure require prior approval from Jacobs
2.10.6 In special cases, columns with diameter up to 1000mm and height not exceeding 10m
(including skirt height) can be self-supported and heights exceeding 10m shall be supported
by super imposed structure around the column covering the entire height.
2.10.7 Flare and vent stacks shall be supported structurally by superimposed structure around for
complete height.
2.10.8 Buried vessels shall be suitably anchored to prevent the uplift due to water table. Anchor bolts
shall have corrosion allowance of 6mm. Buried vessels shall be supported on concrete
saddles with bracket support at the centerline of the vessel.
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2.11 NOZZLE SIZE
Minimum nozzle size = 40 NB
Minimum nozzle size for clad vessels / columns = 80 NB
Safety valve nozzle = Based on I.D.
Self reinforced nozzle neck = Based on I.D.
2.12 Nozzles and manholes including self-reinforced type shall be “set in” type attached to vessel
with full penetration welds unless otherwise specified.
2.13 FLANGES
2.13.1 Nozzle flanges up to 600 NB shall be as be ASME / ANSI B16.5 and above 600 NB shall be
as per ASME / ANSI B 16.47 (SERIES ‘B’).
2.15.2 Nozzle flanges shall be welding neck flanges unless specified otherwise.
2.15.3 Slip on flanges shall not be used in Lethal, Hydrogen, Amine, Caustic, severe cyclic service,
sour service, HIC (Hydrogen induced cracking) service and corrosive service where corrosion
allowance is more than 3 mm.
2.14 INTERNALS
All removable internals shall be bolted type and bolting shall be SS type 304 unless specified
otherwise.
2.15 GASKETS
Service gaskets supplied shall not be used for hydro testing purpose. Gasket used for hydro
testing of equipment shall be of same specification as that of service gaskets for all nozzles,
manholes and body/girth flanges. Gasket seating face of flanges shall have finish as per
gasket specified.
2.16 COLUMN DAVIT
All columns and Vertical vessels with internals & safety valve shall be provided with pipe davit
as per Jacobs’s standard. Weight of the valve or item to be handled shall be advised for
selection of configuration.
2.17 Spares
2.17.1 Mandatory Spares
i) Vessels & Columns
Gaskets Two sets for each installed gasket.

Fastener 10% (Minimum two in each size) of installed fasteners
Page 295 of 434

Sight/Light Glass 4 sets for each installed glass

ii) Shell & tube Exchangers
Gaskets 400%
Bolting 20% (Min. 4 studs and 8 nuts per joint)
iii) Air coolers
a) 400% for gaskets (for headers & blinded flanges)
b) 200% gaskets for plugs
c) 20% plug
d) 100% belts
e) 20% (minimum 4) studs and nuts for each pair of cover header and nozzles
with blinded flange
f) 100% Bearings
g) One blade for each size / type of fan
h) 1 set of Diaphragm Actuator with positioner for each type of auto variable pitch
fan (for Moore fans) (Alternatively vendor recommended spares for his type of
auto variable pitch fans for make other than Moore).
Variable Speed Drives (If applicable)

(One set of spares for each rating of VSD)
Rectifier Control Module 1 Set

Thyristor module 1 Set
Inverter control unit 1 Set
IGBT driver card 1 Set
IGBT 10% with min. 1 No. for each rating of IGBT
PCB of each type 1 No.
All fuses (Power & Control) 20% or 1 Min for each rating of fuse.
Control cards One set
Power supply card One set / 1 No. of each type and rating
Relays 10% with min. 1 No. for each type of relay
Contactors 10% with min 1 No. for each rating of contactor
Man machine interface One set
CT / PT One No. for each type & rating
Cooling fans One set / 1 no. of each rating
Limiters & protection devices One set
Indicating lamps 20% with Min. 3 Nos
Induction Motors (If applicable)-37kW and above
Bearing set (DE & NDE) 1 no. for each type
Terminal studs / bushing assembly 1 no. for each type
External cooling fans 1 no. for each type
DE / NDE end shields 1 no. for each type
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2.17.2 Commissioning Spares:

i) Reactors and Columns :
Gaskets 100% (For Manways, Interconnecting Nozzles,
and nozzles with blind Flange).
Fasteners 10% (Minimum two in each size) of installed
fasteners.
ii) Shell & tube Exchangers 200% Gaskets
iii) Air Coolers
Plug/ Header Gaskets 30 % (Min 1 no) of Installed quantity)
Plugs 10%
Belts 50%
MP Connection for PG/TI
i) Shell & Tube : For Clad Exchangers

vessels
1 no. 50mm NB LWN nozzle with BF on each inlet/outlet nozzle.
If it is not possible to provide on inlet/outlet nozzle, then it shall
be provided on main shell/channel close to main nozzles
Others (Non Clad)

One no. 40NB nozzle with blind on each inlet / outlet. Rating
shall be same as process nozzle
ii) Air Cooler One on one of the inlet & one on one of the outlets of each
header, size 40NB nozzle with BF etc. If it is not possible to
provide on process nozzle then it shall be provided on header.
Rating shall be same as process nozzle.
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2.18 IMPORTANT CONSIDERATIONS
2.18.1 All vessels and columns shall be designed considering design pressure; maximum
operating liquid head and any pressure drop within the vessels/columns.
2.18.2 All columns and vessels shall be capable of withstanding water full condition during system
testing.
2.18.3 Vessels and columns shall be hydro tested at shop at pressure calculated as per applicable
code in new and cold condition.
2.18.4 Seismic design shall be carried out based on design requirement for earthquake.
2.18.5 Equipment covered under the purview of IBR (Indian Boiler Regulations) shall be designed
as per IBR regulations. However, design of components not covered in IBR Regulations
shall be designed in accordance with ASME SEC. VIII Div-1 by multiplying the allowable
stress at design temperature by 0.8667 (1.3/1.5 which is the ratio of minimum multiplying
factor for hydro test for ASME sec VIII div-1 and IBR). This way the equipment can be safely
tested to meet ASME as well as IBR requirements.
2.18.6 Detail stress analysis, local load analysis for loads due to piping and supported equipment
etc. shall be carried out for all equipment. Critical equipment shall be analysed by using
finite element analysis methods (FEM) as defined in job specifications & reports shall be
submitted for Jacobs review. For allowable nozzle loads refer Jacobs’s standard
specification attached with Bid package.
2.18.7 All nozzle necks, all nozzle flanges and blind flanges shall be of weld overlay construction
for clad equipment. Loose liners on nozzle necks and blind flanges are not permitted.
2.18.8 All vertical vessels and columns shall be provided with 2 lifting lugs/Lifting trunions. Lifting
lugs shall be designed with impact factor of two.
2.18.9 Mechanical design of self supporting Tall columns / tower shall be carried out for various
load combinations as per Clause 3.1
2.18.10 Material of various parts of equipment shall be selected as per table given in TABLE– 3
unless otherwise stated on process data sheets. In case the suggested basic material
system for equipment does not meet the temperature applicability requirement, it shall be
brought to the notice of Jacobs and clarification obtained at enquiry stage itself.
2.18.11 Local Stress analysis shall be carried out for nozzle to shell junction using maximum shear
stress theory for vessels and columns. Allowable stress intensity shall be as per ASME
SEC. VIII Div. 2 and non-destructive examinations shall be carried out for shell to nozzle
junction as per ASME SEC. VIII Div. 2.
2.18.12 Stress analysis of shell to skirt junction shall be carried out using maximum shear stress
theory for vessels and columns designed as per ASME Sec. VIII Div. 2. In case skirt shell
joint is of butt-welded construction, the same shall be 100% radiographed.
Page 298 of 434

2.18.13 All vessel, columns and tanks shall be provided with earthing bosses as per Jacobs’s
standard. Body flanges of equipment shall have provision to provide jumpers for earthing.
2.18.14 Permanent fixed ladders shall be provided inside the skirt of columns/vertical vessels for
inspection of dome / dished end.
2.18.15 ODC / Very heavy equipment shall require special considerations for handling,
transportation and erection by Contractor.
2.18.16 All equipment shall be painted as per Jacobs painting specification.
2.18.17 All equipment requiring insulation shall be provided with insulation support rings /cleats as
per Jacobs’s specifications.
3.0 DESIGN REQUIREMENTS-SPECIFIC APPLICATIONS
3.1 TALL COLUMNS
Mechanical design of self-supporting column and its anchorage block shall be carried out
considering combination of various loads.
3.1.1 Loadings:
The loadings to be considered in designing a self supporting column / tower shall include:
a. Internal and or external design pressure specified on process data sheets.
b. Self weight of column inclusive of piping, platforms, ladders, manholes, nozzles, trays,
welded and removable attachments, insulation and operating liquid etc. The weight of
attachments to be considered shall be as per Table–1
c. Other loadings as specified in UG-22 of ASME SEC. VIII Div. 1 wherever applicable
d. Seismic forces and moments shall be computed in accordance with design

requirement for earthquake. Unless otherwise specified importance factor and
damping coefficient shall be considered as 2 and 2% respectively.
e. Basic wind pressure and wind velocity (including that due to winds of short duration as
in squalls) for the computation of forces / moments and dynamic analysis respectively
shall be in accordance with site data for the project (Refer Clause 2.8 above).
Additional wind loading on column due to external attachments like platforms, ladders,
piping and attached equipment should be given due consideration.
f. Loadings resulting in localized and gross stresses due to attachment or mounting of

reflux / reboiler, condenser etc
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3.1.2. Loading condition
Analysis shall be carried out for following conditions:
(a) Erection condition: Column (uncorroded) erected on foundation without insulation,

platforms, trays, removable internals etc., but with welded
attachments plus full wind on column.
(b) Operating condition: Column in (corroded condition) under design pressure, including
welded items, trays, removable internals, piping, platforms,
ladder, reboiler mounted on column, insulation and operating
liquid etc., plus full wind on insulated column with all other
projections open to wind or earthquake forces.
(c) Test conditions Column (in corroded condition) under test pressure, filled with
water plus 50% of specified wind load on uninsulated column
including all attachments shall be considered.
Earthquake and wind shall be considered not acting concurrently.
3.1.3 Deflection of column:
Maximum allowable deflection at top of column shall be equal to total height (including skirt
height) of the column divided by 200 but shall not exceed 300 mm in any case.
3.1.3.1 If the deflection of column exceeds the above allowable limit, the thickness of skirt shall be
increased as first trial upto a maximum value equal to the column thickness and this exercise
shall be stopped if the deflection falls within allowable limit.
3.1.3.1 If the above step is inadequate, skirt shall be gradually flared to reduce the deflection. Flaring of
skirt shall be stopped if the deflection falls within limits or half angle of cone reaches maximum
limit of 9°.
3.1.3.3 If the above two steps prove inadequate in limiting the deflection within allowable limits, the
thickness of shell courses shall be increased one by one starting from bottom course above skirt
and proceeding upwards till the deflection falls within allowable limits.
3.1.3.4 For tall equipment fabricated from stainless steels and other exotic materials, it shall be
examined if an external guide will be helpful in controlling the required thickness such that the
equipment along with its guide structure cost is economical than a free standing design
3.1.4 Stress Limits
The stresses due to design pressure, weights, wind/seismic loads shall be combined using
maximum principal stress theory for ASME SECTION VIII Div.1. Thickness is accordingly
chosen to keep the stresses within limits as per Table-2.
3.1.5 Skirt support base
Base supporting including base plate, anchor chairs, compression ring, foundation bolting etc.,
shall be designed based on over-turning moment (greater of seismic or wind). Minimum size of
anchor bolts shall be M24.
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A minimum number of 8 foundation bolts shall be provided. Numbers of foundation bolts shall be
in multiple of four. Skirt thickness shall also be checked to anchor chair reaction forces.
Anchor bolts shall be so spaced that there is no interference between fixing arrangement, Anchor
bolt sleeves and trailing lug etc.
3.1.6 Dynamic analysis of column / Tower
Dynamic analysis of each column shall be carried out for stability under transverse wind induced
vibrations as per standard design practice and calculations for each column shall be submitted to
Jacobs for approval.
The recommended magnification factor for unlined towers / column shall be taken as 70 and
allowable dynamic amplitude shall be limited to tower diameter divided by 5.
4.0 MATERIAL SPECIFICATION
4.1 General
4.1.1 All materials and accessories required for the fabrication, inspection, testing etc. of the vessel
shall be supplied by the Vendor unless otherwise stated. Whenever some material is to be
supplied by the Owner, this shall be so indicated as Free Issue Material and the supplementary
specifications in this regard shall be complied with.
4.1.2 In addition to the requirements of materials as per material specifications, material shall also
meet the requirements mentioned in this specification and other specifications enclosed with the
requisition. All materials shall be certified for compliance with IBR requirements for the term(s)
so specified.
While procuring materials, Vendor shall stipulate additional requirements such as limits on
hardness, ultimate tensile strength (UTS), yield strength, chemical composition, heat treatment
and any other specific requirements to ensure that final requirement as per specification and
Code are met with.
4.1.3 All materials for pressure parts and parts welded to pressure parts including materials in the
scope of sub-vendors shall be accompanied with mill test certificates duly certified by a reputed
third party inspection agency. In the absence of mill test certificate the material shall get tested
from a reputed third party inspection agency like Jacobs, Lloyds, BV, DNV etc. and test results
shall be submitted in lieu of mill test certificate.
All cost towards such testing and inspection shall be borne by the Vendor. All materials shall be
inspected at Vendor’s and sub-vendor’s shop for verification prior to use on the job. The decision
of Authorized Inspector to accept or reject materials on the basis of such testing shall be final.
4.1.4 Wherever simulated heat treatment of test specimens is required as per code or specification,
the simulation cycle shall include one extra cycle of stress relieving for any eventuality of repair
at site by Owner during the life of the equipment.
0
4.1.5 The exchanger’s minimum design metal temperature (MDMT) shall be taken as 0 C or the
design temperature specified in drawing or datasheet whichever is lower, unless specified
otherwise in design basis or datasheets or drawings.
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All Carbon steel (CS), low temperature carbon steel (LTCS) and low alloy steel (LAS) materials for
0
pressure parts and attachments to pressure parts having MDMT below 0 C shall be impact tested.
The test temperature shall be minimum of MDMT and impact test temperature as specified in
applicable materials specification or as given in job specification whichever is lower. Unless
specified otherwise, impact values shall be more stringent of the values as per UG 84 or applicable
material specification
In addition to the tests done at the mill, one impact test (three specimens) per heat shall be repeated
after receipt of materials at vendor shop, with the test temperature same as given above.
If the test results do not meet the impact energy requirements given above, the material shall be
rejected.
4.1.6 PLATES
4.1.6.1 Pressure parts having thickness 16 mm to 50 mm (both inclusive) shall be ultrasonically tested as
per SA – 435.
4.1.6.2 Pressure parts having thickness greater than 50 mm shall be ultrasonically tested as per SA-578
Level B.
4.1.7 FORGINGS
Forgings to SA-105 and SA - 266 above 75 mm thickness, all tube sheet forgings and all forgings of
other materials except standard nozzle flanges up to 8” NB and small forgings shall be 100%
ultrasonically tested as per SA-388. Acceptance standard shall be as per para AM 203.2 of ASME
Section VIII Division 4.
4.1.8 PIPES
Pipes shall be seamless and sizes above 1 ½ “ NB shall be hot finished. Dimensions and
tolerances shall be in accordance with ANSI 36.10 or ANSI 36.19 applicable as per material
specification.
4.2 Specific material requirements (Pressure parts and parts welded to pressure parts)
4.2.1 CS AND LTCS MATERIALS
a) Carbon content shall not exceed 0.23%.
b) All plates shall be in normalized condition
c) Use of SA 515 of any grade is not permitted.
d) Plates above 50 mm thickness shall meet following additional requirements of SA- 20.
i) Vacuum treatment shall be as per the supplementary requirement S1. If vacuum degassing
is not reported in the test certificate, then through thickness tests as per SA 770 shall be
conducted and minimum reduction in area of 35% shall be ensured.
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ii) Charpy V-notch test shall be as per supplementary requirement S5. Test temperature shall
0 0 0
be minus 29 C for MDMT greater than or equal to 0 C. For MDMT less than 0 C refers
clause 4.1.5 above. Impact energy values shall be as per Para UG-84 of Code, or as per
applicable material specification, whichever is higher. Orientation of test bar shall be
transverse to rolling direction.
iii) Bend test as per supplementary requirements S14 of SA-20.
e) Unless specified otherwise in requisition or bid document. All CS materials specified, as HIC
tested shall meet the following requirements.
i) Carbon equivalent shall be restricted to 0.43% max. Nickel content shall be 0.2% max.
ii) Sulphur content shall be 0.002% max for plates and 0.01% for pipes and forgings.
iii) Hardness of plates and pipes shall not exceed 200 BHN, and that of forgings shall not
exceed 187 BHN.
iv) Plates shall be to SA 516 Gr. 60/70 only. The plates shall contain calcium or other rare
earth elements to create spherical inclusions instead of stringers. The plates shall be
tested in accordance with NACE TM-02-84 using the test solution of NACE TM-01-77.
The acceptance criteria shall be crack length ratio 10% maximum.
f) All LTCS and CS charpy plate material shall be to fine grain practice and the austenitic grain
size shall be measured and reported in the mill test certificate.
g) CS pipes shall be SA-106 Gr.B. LTCS pipes shall be seamless conforming to SA 333 Gr. 1 or 6
h) Non-standard forgings (SA 266, SA 350 etc.) shall be in normalized and tempered condition.
4.2.2 LAS MATERIALS
a) All LAS plates, pipes, forgings and fittings shall be in normalized and tempered condition. Use
of C-½ Mo materials is prohibited.
b) For 1-¼ Cr- ½ Mo materials the maximum room temperature tensile strength of all pressure
containing components, materials and welds shall be 100000 psi.
c) For LAS tubes (SA-199, 209 and 213) hardness test shall be performed on outside of the tubes
as per SA-450.
d) For LAS plates above 50 mm thickness, following supplementary requirements of SA-20 shall
also apply:
i) Vacuum treatment shall be as per supplementary requirement S1. If vacuum degassing

is not reported in the test certificates, then through thickness tests as per SA 770 shall be
conducted and minimum reduction in area of 35% shall be ensured.
ii) Charpy V-notch impact test as per supplementary requirement S5 with impact values as
0 0
per UG 84 of Code. Test temperature shall be lower of MDMT or -18 C (0 C for 5Cr- ½
Mo) whichever is lower. Orientation of test bar shall be transverse to the direction of
rolling.
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iii) Bend Test as per supplementary requirement S14.
4.2.3 SS AND OTHER HIGH ALLOY MATERIAL
a) All SS material (300 series) shall be in the solution heat treated (fully annealed) and pickled
condition. All stabilized grades of SS (SS 321, SS 347 etc.) shall be given stabilization heat
treatment, in addition to solution annealing.
b) All SS (300 series) plates shall be hot rolled and shall have No.1 finish on both sides.
c) SS (300 series) materials for all components shall be procured with the IGC test as per ASTM
A-262 (test shall be carried out, after the specified heat treatment and sensitization per
specification) with acceptable corrosion rate and practices as under.
i) For all services except nitric acid service, Practice E shall be followed Specimen after
exposure shall be bent as per requirements mentioned in A262 Practice E and shall be
inspected under magnification of 200X. The bent specimen shall be free of any cracks or
grain dropping. The microstructure shall be submitted to the Authorized Inspector for
approval.
ii) For Nitric acid service: Practice C with corrosion rate not greater than 25 mils per year.
iii) For straight chrome (13% Cr.) material, maximum carbon content shall not exceed
0.08%. Hardness of UNS No.S41000 and S41008 shall not exceed 75 RB and that of
S40500 shall not exceed 80 RB.
4.2.4 CLAD MATERIALS
a) Cladding shall be integrally and continuously metallurgically bonded to the base metal. All
clad plates shall be rolled-on or explosion bonded type.
b) Clad plates shall be ultrasonically examined from the cladding surface in accordance with SA-
578. Scanning shall be 100% of the plate surface. Acceptance standard shall be level B.
Clad plates shall meet the supplementary requirements of S7 of SA-578. All ultrasonic
testing shall be undertaken after specified heat treatment of clad plates.
c) Both base material and clad material shall meet the specification of the respective materials
as stipulated in this specification.
d) Alloy clad steel plates shall be as per SA 263 or SA 264 or SA 265. Bond between cladding
and the base metal shall be checked for a minimum strength of 14 kg/mm2 in shear for alloy
clad steel plates, by conducting shear test as per applicable material specification.
e) For copper alloy clad plates, the bond between cladding and base metal shall be checked for
a minimum strength of 10 kg/mm2 in shear by conducting shear test.
f) During tension test of clad plates the cladding shall be removed and the tensile properties of
the base material shall meet the Code material requirements.
g) For austenitic SS clad plates the SS surface shall be acid pickled as per ASTM A-380. For
Chromium steel clad surfaces the pickling shall be as per Vendor’s established procedure.
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The same shall be submitted to Owner /Jacobs for approval.
h) For all clad plates used in Hydrogen or H2S service with design temperature greater than 350
0
C, Hydrogen dis-bonding test shall be carried out. The test condition shall be representative
of the actual design conditions and the procedure shall be submitted to Authorized Inspector
for approval.
4.3 Non Pressure Parts
4.3.1 CS plates shall be minimum IS-2062 Gr. B/C or SA 283 Gr. C or equivalent. Pipes shall be to IS
1239 or SA 53 or equivalent.
0
4.3.2 Saddle material shall be same as that of shell for design temperature greater than 350 C.
4.4 Equivalent materials
The materials for various components in a vessel shall be as per Owner or Jacobs’s requirement.
This does not preclude use of equivalent or better materials. However, these deviations should be
clearly indicated in the prescribed format. If an equivalent material sought by the Vendor is to a
specification, other than IS or ASTM or ASME, it is necessary for the Vendor to submit the
specifications of the equivalent material with complete details in English for approval.
5.0 SUPPLY
Supply shall be in accordance with requisition or bid documents to which this specification is
attached. It shall, however, include the following:
5.3 Other accessories
5.3.2 Earthing lugs shall be provided on each vessel and shall be located in such a way as to avoid any
fouling with the exchanger foundation bolts at site.
5.3.3 Vendor to supply one set of torque wrenches for bolt size M45 (1¾“) to M56 (2¼”) and a set of bolt
tensioner device for bolt sizes greater than M56 (2¼”) in case these bolt sizes are being used in
exchangers covered in the requisition. BTD capacity shall be 40% more than the maximum load
required for hydro test condition. BTD pump shall be pneumatically and manually driven. Vendor
shall supply one pump unit, required load cells and 4 heads of each size. Torque values for
tightening the bolts shall be mentioned in the fabrication drawings.
5.3.4 Davits, if required, as per design basis or drawings, shall be provided.
5.3.5 Additions like cleats for piping, ladder, platform, insulation cleats etc. which may be required shall be
provided.
6.0 FABRICATION
6.1 Edge preparation
6.1.1 For CS, the preparation of edges for welding shall be done using machining, chipping, cold
shearing, oxy-acetylene flame cutting or a combination of these. Chipping or cold shearing shall be
followed by grinding to a smooth and regular surface. Oxy-acetylene flame cutting shall be followed
by machining or grinding to eliminate any discoloration of material affected.
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6.1.2 For LAS, the edges for welding shall be made by oxy-acetylene flame cutting or by machining. Cold
shearing may be used for cutting thickness up to 10 mm. Oxy-acetylene flame cutting shall be used
with preheat and shall be followed by machining or grinding to eliminate any discoloration of material
affected.
6.1.3 For austenitic SS, the edges shall be prepared using plasma arc; however, cold shearing may be
adopted for thickness up to 15 mm. In all cases the cut edges shall be ground back or machined
back by 2 to 3 mm.
6.1.4 All welding edges after cutting shall be Dye Penetrant (DP) or Magnetic Particle (MP) examined for
laminations, cracks or segregation. Additionally UST shall be carried out within twice the material
thickness of edge for LAS materials or when the service is low temperature or hydrogen or HIC.
6.1.5 The paragraphs NF7 and NF14 in part UNF of Code are mandatory. This applies to non-ferrous
cladding and weld overlay.
6.2 Rolling and dishing of plates
6.2.1 Rolling
Rolling for bending and forming of plates shall be in the longitudinal direction of the plates. This
direction shall be clearly marked on the plates.
Re-rolling after welding is not normally recommended. However, if for large diameter shells, re-
rolling of welded shell course is inevitable, procedure for re-rolling along with extent of non-
destructive tests (NDT) shall be submitted for approval of the Authorized Inspector.
All welds on the section to be re-rolled must be ground flush. After re-rolling all the welds on the re-
rolled section must be DP checked. Such welds shall then be subjected to radiography as required
by drawings and Code.
6.2.2 Dishing
All dished heads shall preferably be of single piece construction. However dished ends with one
chordal seam are acceptable for shells with diameter greater than 1 m. In such cases, the chordal
seam shall preferably be in the middle one-third of the blank.
Dished ends shall preferably be 2:1 ellipsoidal or tori-spherical (knuckle radius 15 % of the outside
diameter and crown radius 80% of outside diameter).
Dished heads shall be subjected to DP test on knuckle portions (both inside and outside) and weld
edges after heat treatment. Vendor to ensure adequacy of indicated thinning allowance for dished
head. If nominal thickness indicated is not adequate then the nominal thickness should be increased
accordingly, keeping minimum thickness as per equipment drawing.
A straight face of 38 mm or 3 times the nominal thickness of dished end, whichever is less shall be
provided. However, if larger straight face is specified, it shall be ensured.
6.3 Welding
6.3.1 All welding and weld overlays shall be done with electrodes, fillers and fluxes of reputed make with
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proven reproducibility of results. Brand names shall be specifically approved by Authorized

Inspector. For CS pressure parts, the electrodes shall be of low hydrogen type, IGC test as per
ASTM A262 Practice E shall be done for austenitic SS consumables, which are to be used in
application involving solution annealing.
Austenitic SS consumables of low carbon and stabilized grade shall also be IGC tested as per
ASTM A262 Practice E. Straight chrome materials shall be welded with electrode that produces an
austenitic chromium nickel weld deposit or a non-air hardening nickel –chromium-iron weld deposit.
6.3.2 All welding procedures shall be submitted for approval by Authorized Inspector giving all relevant
details. Welding qualification records shall indicate hardness values of weld metal. HAZ and parent
0
metal and also results of impact tests when design temperature are below 0 C or when specifically
indicated for materials being welded. No welding shall be undertaken until the welding procedure
and welder’s qualification have been approved by the Authorized Inspector.
All welding procedures and welders shall be qualified for the particular type of welding and material
in accordance with the ASME Section IX. Vendor shall be responsible for the quality of the welds
performed.
6.3.3 Pressure holding joints shall be full penetration welds. Root pass of single side welded joints shall
be done with GTAW process. Backing strip for single side welded joints is not permitted.
For LTCS materials both inside and outside of welds shall be ground flush or dressed smooth. All
internal welds in the shell shall be ground flush in order to insert and remove tube bundle. Also all
internal welds shall be ground flush to the extent of facilitating draining of complete equipment.
6.3.4 Longitudinal seams shall be staggered with the circumferential distance between the centers of
welds being at least 5 times the thickness of the thicker-plate. Weld seams shall be located so as to
avoid interference with weld seam of nozzles and external attachments.
6.3.5 Attachment to pressure part shall be of same quality as the pressure part. All LAS weld
attachments to pressure retaining component shall be with full penetration weld and ground to a
smooth concave contour.
External attachments like lugs, supports, etc. of CS shall not be welded directly to high alloy or
austenitic SS vessel components. These attachments should be of the same material as the vessel
components.
If this is not so, intermediate pad plates of the same material type as the vessel component may be
used. These pads shall be at least 100 mm wider and longer than the attachment and shall be at
least 5 mm thick. Welding of CS or LAS to austenitic SS shall be done with austenitic SS electrodes
or filler wire (AWS – ASTM – E 309L or E-309 Mo.L only).
Wrapper plates, reinforcing pads or stiffeners of higher thickness than specified can be used
provided there is no change in basic dimensions and with the approval from Jacobs.
6.3.6 When impact tests are required on material as per Code or specification the welds shall also be
qualified for impact test. In such case following special requirement shall apply to the welding
procedure qualification:
i) Qualification tests shall be made on plates of the ASME specification as specified for the
exchanger using welding electrodes of AWS or SFA specification and wire & flux of the
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specification and brand as are to be used on the job.
ii) Welding current and travel speed shall be considered essential variables in order to ensure
that production welding is substantially equivalent to the procedure qualification.
iii) Welded test plates shall be subjected to a total thermal cycle sequence similar to the finished
equipment. Specifically, test plates shall be held at intermediate and final stress relief
temperatures for approximately the same length of time as the finished exchanger. Final
cooling rate shall be approximate to that expected for the finished exchanger.
iv) Charpy V-notch impact tests shall be made on the weld and HAZ of the test plate for each
welding procedure to be qualified. Test procedure shall be as per UG 84 of Code. Test
temperature shall not be higher than MDMT. Impact energy requirements shall be as per
Table 2.15 of SA 20 of ASME Section II Part A or UG 84 of Code whichever is higher.
6.3.7 WELD OVERLAY
6.3.7.1 Weld deposit overlay shall be done by a qualified welding procedure and surface shall be properly
machined or ground flush after overlay. Minimum thickness of finished weld deposit shall be as
indicated in the drawings or specifications.
In case a higher deposition thickness and multiple weld layers are required to achieve the minimum
specified undiluted deposit metal, the same shall be done only after taking prior approval from
Jacobs.
Minimum thickness of undiluted finished weld overlay from top shall be 3 mm or as specified in the
drawings. For non-ferrous weld deposit, the iron dilution should be restricted to 2.5% (maximum) in
the finished undiluted layer (thickness defined above).
6.3.7.2 The weld overlay procedure shall be qualified on base metal of the same composition as the
exchanger component and meeting the requirements of ASME Section IX.
6.3.7.3 The weld overlay shall be relatively smooth with no notches and undercuts that would act as stress
raisers. All cracks, fissures and circular defects greater than 1/16” diameter shall be removed.
Repaired areas shall be DP checked.
Weld overlay shall be applied to base metal, which has been grit blasted and is smooth and clean
so as to ensure full bonding. Welding overlay cladding shall be applied after any normalizing but
before the post weld heat treatment (PWHT). The weld overlay shall consist of at least 2 layers.
6.3.9.4 The alloy cladding shall be cut back at all seams to permit back welding of the base metal. Weld
metal shall be ground flush and fully covered with the applicable weld deposit.
The weld joint in base plate shall be 100% DP tested for detection of cracks and flaws before
welding from clad side. The weld deposit shall be at least as thick as the cladding.
6.3.7.5 Shells, cones and dished heads formed from clad plates shall be UST after forming for a minimum
of 10% of the clad surface, including no less than one square feet in each 10 square feet or fraction
thereof.
Unbonded areas that cannot be encompassed by a 3“ diameter circle shall be repaired by weld
overlay. When repairs in excess of 5% of the total examined area are required, the complete
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exchanger shall be 100% UST.
Repaired areas and weld deposit overlay at weld seams shall be DP examined. UST shall be
repeated for dished heads after heat treatment. All UST shall be in accordance with SA 578 S6 for
spot examination and SA 578 S7 for 100% examination
6.3.7.6 All weld overlays shall be 100% DP examined in accordance with the method described in ASTM-E-
165. The barrier layer shall be 100% examined.
When the overlay involves multiple passes (layers) and the procedure uses an intermediate heat
treatment with cooling to room temperature prior to applying the subsequent layer, each layer shall
be examined.
Where overlay is to be machined such as for flange facing, machined surface shall be 100%
examined after PWHT. If 100% of overlay is examined prior to the final PWHT, overlay shall be spot
examined (not less than 10% of the surface) after heat treatment.
6.3.7.7 Samples of the weld overlay shall be taken to perform chemical analysis to the required depth as
specified. The number and location of samples shall be at the discretion of Authorized Inspector.
However, they shall be representative of each exchanger component for each type of welding
process. Report of this chemical analysis shall be submitted to Authorized Inspector for approval.
6.3.7.8 For all weld overlays used in hydrogen or H2S service with design temperature greater than 3500 C.
Hydrogen disbonding test shall be carried out. The test condition shall be representative of the
actual design conditions and the procedure shall be submitted to Authorized Inspector for approval.
6.4 Production test coupons (PTC) are required for CS welds above 50 mm thickness, for LAS welds
above 25 mm or when required by the Code. For PTC the following shall apply:
a) Two PTCs representative of one longitudinal and another circumferential seam shall be
provided for each procedure, position and thickness.
b) PTC shall be from material of the same heat and thickness as of parent metal. During and
after welding PTC shall be subjected to same heat treatment as and together with the course
they represent, extra PTC shall be preserved to take care of eventuality of retests.
c) The tests mentioned below shall be carried out as per methods of testing in Code:
i) One transverse tension test
ii) Two side bend tests with weld located in the center of bend
iii) One hardness test on PTC weld and HAZ. The acceptable limits are 200 BHN for CS, 225
BHN for P3 and P4 materials and 235 BHN for P5
iv) Micro and macro examination of welds

0
v) For CS, charpy V notch tests on weld and HAZ shall be carried out. For MDMT below 0 C,
0
impact test temperature shall be MDMT. For MDMT greater than or equal to 0 C, the test
0
temperature shall be 0 C. The acceptance criteria for impact energy shall be as per table a
2.15 of SA 20 of ASME Section II part A or UG – 84 of Code whichever is higher.
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vi) For LAS, charpy V notch tests on weld and HAZ shall be carried out for 25 mm thickness
and above or when specified in requisition. Test temperature and acceptance criteria shall
be as per clause 2.2.2 (d) (ii) above.
6.5 Hardness limitations
Hardness limitation for materials wherever specified on drawings or datasheets and LAS materials
shall be as per Jacobs Spec. 44NC-4600-0000-V.02-0110-A4-General Spec for hardness
requirements. Hardness limitation for tube to tubesheet welding shall be established on a mock-up
with simulation heat treatment. Hardness of straight chrome materials in the cold-formed state, HAZ
and welds shall not exceed 88 RB.
6.6 Nozzle flanges, nozzles and reinforcing pads
6.6.1 Flanges
Unless otherwise indicated, dimensions, drilling, facing and tolerance for nozzle flanges (and blind
covers if required) shall be as per ASME B 16.5 (for size up to 24” NB) and ASME B 16.47 series B
(for sizes above 24” NB) for the respective class. Weld overlays, wherever specified or required,
shall be in addition to the thickness as per these standards. Bolt holes on these nozzle flanges shall
straddle principal vertical and horizontal centerlines of equipment. If the component to which
nozzles are attached is subsequently stress relieved, it shall be Vendor’s responsibility to maintain
true gasket faces by machining or otherwise. If distortion expected is considerable, final machining
operation should be done after stress relieving; sufficient machining allowance for this purpose
should be available. Gaskets for flanges to ASME B16.5 and B16.47 shall be as per ANSI B16.20.
6.6.2 Nozzles
6.6.2.1 Nozzle pipes shall be attached to the vessel components by full penetration welds. Attachment
welds using only inner and outer fillet welds are not permitted. Unless otherwise indicated on the
datasheets or drawings, necks of all nozzles shall be flush with the inside of vessel component.
Inside corners of nozzle pipes at shell and channel inside diameter shall be radiused. All nozzles 2”
NB and below except long weld neck, shall have two stiffeners (40 mm x 6 mm) at right angles.
6.6.2.2 Whenever nozzle inside is required to be over-layed, these shall be done by weld overlay or
cladding. Minimum nozzle ID before weld depositing shall be 50 mm in such cases. Loose liners
are not acceptable.
6.6.3 Reinforcing pads and testing
Reinforcing pads whenever required as per drawings or Code shall be of the same material as the
vessel component to which it is welded. All reinforcing pads shall be provided with two 1/8” (3 mm)
0 2
NPT tapped holes located 180 apart for air soap solution test with a pressure of 1.25 kg/cm (g).
This test shall also be required to be carried out for slip on flanges.
Higher test pressure are not recommended because of accompanying risks and also because the
soap bubbles have a chance to blow off. Tell-tale holes in reinforcing pads shall be plugged with
hard grease unless otherwise indicated after the hydro test of the exchanger.
6.7 Bolts, studs etc. and tapped holes
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6.7.1 All inch bolting and threading shall conform to ANSI B 1.1 except for size 1” and above where it shall
be 8 threads per inch. Metric bolting and threading shall conform to ISO – R261 except for size
M24 and above, where it shall have 3 mm pitch.
6.7.2 Studs shall extend beyond the nut by about 10 mm and shall be threaded full length except when
square ends are required for use with bolt tensioner, in which case the extension shall be as per bolt
tensioner manufacturer’s recommendation. The studs for extended tubesheet and the studs for use
with connecting piece shall also have square ends. The extended portion of the stud shall be
provided with a suitable protection cap to avoid clogging / rusting of stud threads.
6.7.3 All nuts shall be of heavy series only and nut-seating faces shall be machined or spot faced.
6.7.4 Threads on external bolting, plugs etc. shall be lubricated with graphite grease for working
temperature unto 200 0C and with Molybdenum Disulphide for higher temperatures.
6.8 Assembly and handling
6.8.1 Vendor shall be responsible for taking adequate preventive measures to ensure the quality and
finish of materials and to avoid any rusting.
6.8.4 ‘T’ wherever indicated on drawings, denotes match mark for assembly and shall be punched on all
mating parts.
6.8.5 Lifting lugs shall be provided as per standard for lifting of channels, channel covers, shell covers,
test rings, test flanges etc.
6.9 De-scaling, pickling and passivation shall be done for all SS parts of vessels in accordance with
ASTM A-380. The Vendor shall supply details of the procedure for approval to the Authorized
Inspector.
6.10 Fabrication tolerances and finish
6.10.1 The dimensional tolerances shall be within the limits indicated on Jacobs’s drawings and standards.
Where tolerances are not specified, these shall be in accordance with the requirements of TEMA
and Code.
6.10.3 Finish of all machined components shall be minimum 12 microns (500 RMS) unless otherwise
indicated. Parts subjected to UT shall have minimum finish of 6 microns.
7.0 NON DESTRUCTIVE TESTS
7.1 All the NDT procedures shall be submitted to the Authorized Inspector for approval. For all NDT
activities, only qualified NDT technicians shall be deployed with the approval of Authorized
Inspector.
7.2 The extent of radiography shall be as specified on the datasheets or drawings or job specifications.
In no case it shall be less than that required in the Code.
7.3 Minimum extent of radiography shall be spot, unless full radiography is specified in the drawings or it
is required as per specification or Code. Spot radiography shall mean that at least 10% of the total
welded length must be radiographed. Further, all “T” joints must be radiographed and at least one
Page 311 of 434

Jacobs
shot must be taken on each longitudinal and circumferential seam. This requirement shall
supplement the ones specified in Code. The Authorized Inspector shall be consulted in marking the
area to be radiographed.
7.4 Full radiography when specified shall imply 100% radiography of all butt welds.
7.5 All nozzles fabricated from plate, irrespective of thickness of plate and radiography specified, shall
be 100% radiographed.
7.6 Weld seams of formed heads shall be 100% radiographed after forming and heat treatment, if any.
7.7 All nozzles to shell welds shall be DP or MP checked at the root run and final weld.
7.8 For LAS welds, radiography shall be done after final PWHT. All welds which cannot be fully
radiographed such as nozzle to shell weld etc. shall be 100% ultrasonically tested after final PWHT.
Regarding fillet welds and welds which can not be radiographed or ultrasonically tested (i.e. pass
partition plate to channel and floating head joint etc.), the root run shall be DP checked and the
welds should finally be MP checked after stress relieving.
7.9 All attachment welds shall be either DP or MP tested.
7.10 Acceptance standards for radiography shall be as per Code unless stated otherwise.
8.0 HEAT TREATMENT
8.1 PWHT shall, in general, be done as required by datasheets, drawings, specifications, Code etc.
PWHT when mentioned on the drawings shall be over and above the requirements of specifications
or Code. No welding or heating is permitted after PWHT operation.
All matching operations shall preferably be carried out after heat treatment (Also refer clause 4.6.1.
above). It shall be the responsibility of the Vendor to leave sufficient allowance for this purpose.
Vendor shall submit all the procedures for PWHT to Authorized Inspector for review.
8.3 Heat treatment of SS clad assemblies shall be at reduced temperature to avoid sensitization of SS
materials. The soaking time shall be increased accordingly as per Code.
8.4 Heat treatment of non-ferrous clad assemblies, if required, shall be performed with extra care, if
required at reduced temperatures to avoid differential thermal expansion. The soaking time in such
a case shall be increased accordingly as per Code.
8.5 Heat treatment of CS and LAS dished heads shall be as follows.
a) Stress Relieving for:
i) Cold formed dish heads unto 16 mm thick.
ii) Cold formed floating head cover up to 16 mm thick if fiber stretch exceeds 5%.
b) Normalizing for CS and normalizing and tempering for LAS:
Page 312 of 434

Jacobs
i) Hot formed dish head and floating head dish if not formed in normalizing range.
ii) Cold formed dish heads for thickness greater than 16 mm.
iii) Cold formed floating head dish above 16 mm thick.
This heat treatment need not be given if same heat treatment is given subsequently on sub-
assembly.
8.6 SS component shall be solution annealed in the following cases.
i) Cold formed dished heads with nominal thickness of 16 mm or above.
ii) Hardness value of dished heads after cold forming exceeds 235 BHN.
iii) Hot formed shells, cones, dished heads.
After any heat treatment on austenitic SS, IGC test shall be carried out as per clause 2.2.3 (c)
above.
8.8 For LAS materials, preheating procedure shall be established in the welding procedure and got
approved by the Authorized Inspector. Preheating by resistance or induction heating method is
preferred. Preheating shall extend uniformly to at least three times the thickness of joint but not less
than 50 mm on both sides of the weld. Temperature indicating crayons shall be used for
assessment of correct pre-heat temperature.
8.9 All Low Alloy Steel pressure containing welds shall be PWHT.
9.1 Inspection
9.1.1 The inspection shall be carried out by Authorized Inspector. The materials, fabrication and testing of
exchangers shall be open to inspection by the Authorized Inspector in addition to any inspection
required by the specified Code or by local authorities having jurisdiction over the installation.
9.1.2 Inspection shall be carried out both during fabrication and before delivery and also for sub-ordered
materials. If any, in addition to final inspection and certification by Authorized Inspector during the
course of manufacture, Authorized Inspector’s written approval shall be obtained by the Vendor at
various stages of fabrication. For this purpose, Vendor shall prepare his Quality Assurance Plan,
defining the stages of fabrication, hold points for his own inspection and that by the Authorized
Inspection or Code or statutory Authorities Inspection etc.
The Quality Assurance Plan shall be discussed with Authorized Inspector before start of job and
mutually agreed. The various stages of fabrication to be inspected (by Vendor or the Authorized
Inspector) shall include but not limited to the following.
a) Raw material identification and verification of mill test certificate.
b) Edge preparation for welding, including visual check for laminations
c) Alignment of longitudinal and circumferential seams
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d) Rolling tolerances on individual section
e) Alignment and fit up of section, nozzle setting and components.
f) Root pass clearance before welding and cleaning
g) Profile and thinning of dished ends and toriconical pieces after forming
h) Review of NDT reports and any other specified test such as for leak, corrosion and hardness.
i) Review of heat treatment charts.
j) Calibration records of measuring instruments.
k) Final visual and dimensional inspection
l) Witnessing of hydro test
m) Surface preparation, primer painting
9.1.3 The presence of the Authorized Inspector shall not modify or reduce the obligation of the Vendor to
carry out his own tests and control. Should any material and / or equipment be found not in
compliance with the requirements specified, the Authorized Inspector or his delegate shall be
entitled to irrevocably reject them, even if such non-compliance has not been evidenced in the
course of inspections and/or tests.
9.1.4 The Authorized Inspector will, at the time of initial visit, set up with the Vendor actual details of
inspection stages to be witnessed or carried out: the schedule of future visits and subsequent
inspection notices can be arranged between the Authorized Inspector and the Vendor.
9.1.5 The Vendor shall notify the Authorized Inspector sufficiently in advance of any fabrication operations
to permit him to arrive at the Vendor’s shop in time to witness the operations.
9.1.6 The Vendor shall provide to the Authorized Inspector, free access to his shops at all times. He shall
also supply all tools and tackles to the Authorized Inspector for carrying out the inspection. The
Vendor shall also arrange for similar facilities at this sub-contractor’s shops.
9.1.7 The Vendor must satisfy the Authorized Inspector that the welding procedures, welders, electrodes,
fluxes, welding wires etc. are in accordance with the requirements of the Code and specifications.
Further the welder’s qualification test must be carried out in the presence of the Authorized
Inspector.
9.1.8 Prior to final inspection, all slag, weld spatters, loose scale, dirt, grit, paint, grease, oil and other
foreign matter shall be removed in order to facilitate inspection. All reinforcing pads and slip on type
flange welds shall be pressure tested with air and soap solution before and after heat treatment (if
any) and before final hydro test.
9.1.9 A dimensional checking of equipment shall be carried out taking into account the tolerances shown
on job drawings and standards, design specification or Code; the more stringent values shall
govern. Dimensional checks are to be taken of the internal measurements of equipment together
with external ones and these are to be recorded on a copy of the drawings as being the “As Built”
dimensions.
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9.2 Hydrostatic tests
9.2.1 Hydrostatic tests shall be witnessed by the Authorized Inspector. When hydrostatic tests are
performed the indicating gauge shall be connected to the upper most parts of the equipment.
Testing water shall be clean potable water. Seawater shall not be used.
For SS equipment water used for these tests shall not contain more than 25 ppm chlorides.
0
Minimum metal temperature during hydrostatic tests shall be 20 C.
Test pressures shall be maintained for at least one hour. Shell and tube sides shall be tested
separately, unless otherwise mentioned on the drawing.
10.0 PROTECTION AND DESPATCH
10.1 After completion of all testing and inspection, the inside of complete equipment shall be thoroughly
drained and dried out. Equipment shall be completely dried by passing hot air for sufficient time
until no further increase in relative humidity of outgoing air is observed.
Dry out shall be done simultaneously on both shell and tube sides. After drying, the equipment shall
2
be purged and filled with dry N2 at 0.25 kg/cm . The equipment shall be provided with pressure
gauge to monitor N2 pressure, and a ½” non-return valve.
All threaded holes; other than tell tale holes for testing, shall be suitably protected with steel bar
plugs. All nozzles not provided with blind flange shall be provided with steel covers and temporary
gaskets and bolts adequate to maintain nitrogen pressure as above.
10.2 Shop painting
All CS and LAS external surfaces other than gasket faces and other machined surfaces shall be
given one coat of primer paint. Surfaces to be painted shall be prepared for painting by removing
loose mill scale, loose rust, oil, grease and other films or substances harmful to the adhesion of
paint by an approved method such as shot blast cleaning.
The surface shall be prepared to near white finish as per SSPC-SP-10 [SA 2 ½ Swedish standard
(SIS-05-5900)]. The shop primer shall be inorganic zinc silicate with 65-75 microns dry film
thickness, unless stated otherwise.
10.3 The equipment item number, Purchase Order (PO) number and Owner name and address shall be
painted in bold white paint letters written with stencil, on the vessel.
10.4 Dispatch of equipment
Vessels shall be securely anchored for dispatch in order to prevent any shifting and damage during
transportation. Expansion joints and bellows, wherever used shall be suitably protected against any
possible damage by providing tie bars before boxing up.
Packaging shall be suitable for rail or road transport and also sea worthy if transported by sea.
Spares shall be dispatched separately in a box and marked with PO number, item number and
Owner’s name and address.
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Sling mark identification shall be provided by Vendor on all vessels with respect to center of gravity
of the equipment.
No equipment shall be dispatched until a written clearance is obtained from Owner or Jacobs
regarding Piping Clips and Structural Cleats on individual equipment.
11.0 VENDOR’S GUARANTEES
The Vendor shall be completely responsible for the compliance to Code requirements, residual
design, detailing, fabrication, materials and workmanship of the exchangers as per the stipulations
of the requisition and its attachments. In this regard, it may be noted that review by Owner or
Jacobs shall not relieve the Vendor of his responsibility of meeting all requirements and ensuring
satisfactory performance of the equipment. Guarantee period shall be as per Purchase Condition of
Owner.
Page 316 of 434

TABLE – 1
DETAILS AND WEIGHT OF COLUMN ATTACHMENTS
1. Minimum Shape factor for shell (for wind load : 0.7

calculations) (Also refer para 2.8.1.1 for
column design)
2
2. Weight of trays (with liquid) to be considered : 120 kg / m
3. Weight of plain ladder : 15 kg / m
4. Weight of caged ladder : 37 kg / m
5. Equivalent projection to be considered for wind : 300 mm

load on caged ladder.
6. Distance of platform below each manhole : Approx. 1000 mm
7. Maximum distance between consecutive : 5000 mm

platforms
8. Projection of platform : 900 mm up to 1.0 m dia. Column and

1.2 m for column dia.>1m from column
insulation surface
9. Equivalent height of platform (for wind load : 1000 mm

computation)
2
10. Weight of platforms : 170 kg/m
Page 317 of 434

TABLE-2
ALLOWABLE STRESS FOR COMBINED LOADING
Vessel condition / temperature –type of Conditions

stresses
Erection Operating Test
New or corroded New Corroded Corroded
Temperature Ambient Design Ambient
Longitudinal KxSxE KxSxE 0.90 x Y.P. x E
Longitudinal compressive stress KxB KxB B
Where
S = Basic allowable tensile stress as per Clause UG 23(a) of ASME SEC.VIII Div.1
B = ‘B’ value calculated as per clause UG-23 (b)
E = Weld joint efficiency of circumferential weld, depending on extent of radiography
K = Factor for increasing basic allowable value when wind or seismic load is present
Y.P. = Yield point stress
Note: Allowable stresses in skirt to shell joint shall be as per following:
0.49S, if joint is shear type.
0.70S, if joint is compression type.
Page 318 of 434

Jacobs
TABLE- 3
MATERIAL SELECTION CHART
The following table gives general guidelines for material selection chart for various pressure parts / non
pressure parts of the equipment:
Design Plate Pipe (See Forging Bolts / Structural Interna Studs /
0
Temp. C note 8) Studs / attachment l pipes Bolts /
Nuts welded to Nuts
External pressure parts Internal
CRYOGENIC
From – SA240 SA312 SA182, Gr. F SA320, Gr.B8, 8C, 8T strain
254 up to Gr.304L, Type 304 304, 304L hardened
–195 304, 316, 304L, 316, 316, 347, SA 194 Gr.8, 8C, 8T
316L, 347 316L, 347 316L
(impact
tested)
Same as pressure parts
Above SA240, SA312, SA182 Gr.F SA320, Gr.B8, 8C, 8T strain
–195 up Gr.304L, Type 304, 304 F304L, hardened
to –80 304, 316, 304L, 316, F316L SA194 Gr.8, 8C, 8T
316L, 316L, 321,
321, 347. 347.
SA 353, SA333, SA522

553, Gr.A Gr.8
LOW TEMPERATURE
Above – SA203 SA 333 SA 350 SA 320 L7 SA 203 Gr.E SA333 SA193 Gr.B8
80 Gr.E Gr.3, 4 Gr. LF3 SA 194 Gr.3, 4 SA194 Gr.8
Up to – impact Gr.4 or Gr.7
60 tested
(see note-
1)
Above – SA537 SA333 SA350 SA320 L7 SA537 Cl.1 SA333 SA193, Gr.B8,
60 Cl.1 Gr.3 Gr.LF3 SA194 Gr.4 Gr.3 SA194 Gr.8
Up to – impact Or GR 7
45 tested
(see note-
1)
Above-45 SA516 SA333 SA350 SA320 Gr.L7 SA516 (in all SA333 SA193, Gr.B8,
upto –29 (All Gr.6 or Gr.LF2 SA194 Gr.4 grades) Gr.6 , SA194 Gr.8
grades) Gr.1 or Gr.7 1
impact
tested
(see note-
1)
Above SA516 SA106, SA105 / SA193 SA516 (in all SA106, SA-193, Gr.B8,
-29 upto (all Gr.B (see SA266 (see Gr.B7 grades) Gr.B SA194, Gr.8
0 grades) note 3) note 3) SA194
(See note Gr.2H
3)
Page 319 of 434

Design Plate Pipe (See Forging Bolts / Structural Internal Studs /

Temp. note 8) Studs / attachment pipes Bolts /
0
C Nuts welded to Nuts
External pressure parts Internal
INTERMEDIATE TEMPERATURE
Above 0 SA516 SA106 Gr.B SA105 SA193 B7 IS2062 (plates) SA106 Gr.B SA193
Upto (all grades) SA266 SA194 Gr.2H Gr.B8
343 SA194,Gr.
SA193 B7 Same as Same as 4
SA240 SA312 SA182 F SA194 Gr.2H Pressure parts Pressure
type 304L, TP304L, 304L, 316L, parts SA193,
316L, 321 316L, 321, 321 Gr.B8,
(see note A376 SA194
4) TP321 Gr.8
Above SA387 SA335, SA182 SA193 Gr.B7 Same as Same as SA193
343 Gr.11 Cl.1 / Gr.P11 Gr.F11 SA194 Gr.4 Pressure parts Pressure Gr.B8
upto Cl.2. parts SA194
427 SA-193, B7 Gr.8
SA240 SA312 type SA182F SA194 Gr.4 Same as
type 304L, 304L, 316L, 304L, 316L Pressure parts Same as
316L, 321 321,SA 376 321 Pressure SA193
(see note Type 321 parts Gr.B8
4) SA-194
Gr.8
ELEVATED TEMPERATURE
Above SA387 SA335 P11 SA182 SA193 Gr.B16 Same as Same as SA193
427 Up Gr.11, Cl.1/ SA335 P12 Gr.F11, SA194 Gr.4 Pressure parts Pressure Gr.B8.
to 538 Cl.2, SA182 parts SA194
SA387 Gr.F12 Gr.8
Gr.12, Cl.1/
Cl.2
Above SA240 SA312, SA182 F SA193 Same as Same as SA193

427 type 304, SA376 type 304, 316, 321 Gr.B16 Pressure parts Pressure Gr.B8.
Upto 316, 321, 304, 316, SA194 Gr.4 parts SA194
500 (See note 321 Gr.8
4).
Above SA387 SA335 P22 SA182 SA193 Gr.B5,

538 Gr.22 Cl.1/ Gr.F22, SA194 Gr.3
Upto Cl.2 SA387 SA336 Same as pressure parts
593 Gr.21, Cl.1/ Gr.F22
Cl.2
Above SA240, SA312/ SA182 Gr. SA193, Gr.B8

500 Gr.304H, SA376 304H, 316H, SA194, Gr.8
Upto 316H, Type 304H, 321H. (strain Same as pressure parts
815 321H 316H, hardened)
321H
Page 320 of 434

NOTES
1. Pressure vessel steel plates are purchased to the requirement of the standard ASME SA-20
which requires testing of individual plates for low temperature service. Carbon steel material is
ordered to meet the impact requirements of supplement S5, of standard ASME SA 20. Typical
material specification is as follows. SA516 Gr.60 normalised to meet impact requirements per
o
supplement S5 of SA 20 AT -50 F.
2. All permanent attachments welded directly to 9% nickel steel should be of the same material or
of an austentic stainless steel type which can not be hardened by heat treatment.
3. Check for impact testing requirement as per UCS-66 for coincident temperature and part
thickness.
4. Selection of stainless steel material shall be based on process recommendation / process

licensor.
5. This table is not applicable for atmospheric / low pressure storage tanks. Materials shall be
selected as per API 650 / API 620 as applicable.
6. Materials for caustic service, sour service, or sour service + HIC shall be selected based on
specific recommendation of process licensor & considering chemical composition, hardness,
Vacuum degassing requirements & heat treatment requirements.
7. Material for pressure vessels designed according to ASME SEC VIII DIV. 2 shall be given special
consideration as per code.
8. All pipes shall be of seamless construction.
9. Non-ferrous material and super alloys are not covered above and shall be selected based on
specific recommendation.
10. Material for vessel / column skirt shall be the same material as of vessel / column shell for upper
part with a minimum of 1000mm.
11. Materials used for IBR equipment shall meet all requirements of Indian Boiler Regulations.
Page 321 of 434

TABLE 4:
NOZZLE LOADING DATA FOR NOZZLES ON CYLINDRICAL SHELLS
2
(Not applicable for High Pressures > 75 kg/cm )
NOZZLE FORCES FLANGE RATING

SIZE AND
NB MOMENTS 150# 300# 600# 900# 1500# 2500#
1” FA (kg) 120 140 160 180 200 220
FL (kg) 120 140 160 180 200 220
FT (kg) 90 10.5 120 135 150 165
ML (kg.m) 7.8 9.1 10.5 11.7 13 14.5
MT (kg.m) 9 10.5 12 13.5 15 16.5
MC (kg.m) 6 7.5 8 9 10 10
1½” FA (kg) 180 210 240 270 300 330

FL (kg) 180 210 240 270 300 330
FT (kg) 135 158 180 203 225 248
ML (kg.m) 17.5 20.5 23 26 29 32
MT (kg.m) 20 24 27 30 34 37
MC (kg.m) 13.5 16 18 20 23 25
2” FA (kg) 240 280 320 360 400 440

FL (kg) 240 280 320 360 400 440
FT (kg) 180 210 240 270 300 330
ML (kg.m) 31 37 42 47 52 57
MT (kg.m) 36 42 48 54 60 66
MC (kg.m) 24 28 32 36 40 44
3” FA (kg) 360 420 480 540 600 660

FL (kg) 360 420 480 540 600 660
FT (kg) 270 315 360 405 450 495
ML (kg.m) 70 82 94 106 117 129
MT (kg.m) 81 95 108 122 135 148
MC (kg.m) 54 63 72 81 90 99
4” FA (kg) 480 560 640 720 800 880

FL (kg) 480 560 640 720 800 880
FT (kg) 360 420 480 540 600 660
ML (kg.m) 125 146 167 187 208 229
MT (kg.m) 144 168 192 216 240 264
MC (kg.m) 96 112 128 144 160 176
6” FA (kg) 720 840 960 1080 1200 1320

FL (kg) 720 840 960 1080 1200 1320
FT (kg) 540 630 720 810 900 990
ML (kg.m) 281 328 375 421 468 515
MT (kg.m) 324 378 432 486 540 594
MC (kg.m) 216 252 288 324 360 396
Page 322 of 434

8” FA (kg) 960 1120 1280 1440 1600 1760

FL (kg) 960 1120 1280 1440 1600 1760
FT (kg) 720 840 960 1080 1200 1320
ML (kg.m) 499 583 665 749 832 915
MT (kg.m) 576 672 768 864 960 1056
MC (kg.m) 384 448 512 576 640 704
10” FA (kg) 1200 1400 1600 1800 2000 2200

FL (kg) 1200 1400 1600 1800 2000 2200
FT (kg) 900 1050 1200 1350 1500 1650
ML (kg.m) 780 910 1040 1170 1300 1430
MT (kg.m) 900 1050 1200 1350 1500 1650
MC (kg.m) 600 700 800 900 1000 1100
12” FA (kg) 1440 1680 1920 2160 2400 2640

FL (kg) 1440 1680 1920 2160 2400 2640
FT (kg) 1080 1260 1440 1620 1800 1980
ML (kg.m) 1123 1310 1498 1685 1872 2060
MT (kg.m) 1296 1512 1728 1944 2160 2376
MC (kg.m) 864 1008 1152 1296 1440 1584
14” FA (kg) 1680 1960 2240 2520 2800 3080

FL (kg) 1680 1960 2240 2520 2800 3080
FT (kg) 1260 1470 1680 1890 2100 2310
ML (kg.m) 1530 1784 2038 2293 2548 2803
MT (kg.m) 1764 2058 2352 2646 2940 3235
MC (kg.m) 1176 1372 1568 1764 1960 2156
16” FA (kg) 1920 2240 2560 2880 3200 3520

FL (kg) 1920 2240 2560 2880 3200 3520
FT (kg) 1440 1680 1920 2160 2400 2640
ML (kg.m) 1997 2330 2663 2995 3328 3660
MT (kg.m) 2304 2688 3072 3456 3840 4224
MC (kg.m) 1536 1792 2048 2304 2560 2816
18” FA (kg) 2160 2520 2880 3240 3600 3960

FL (kg) 2160 2520 2880 3240 3600 3960
FT (kg) 1620 1890 2160 2430 2700 2970
ML (kg.m) 2527 2949 3370 3791 4212 4633
MT (kg.m) 2916 3402 3888 4374 4860 5346
MC (kg.m) 1944 2268 2592 2196 3240 3564
Page 323 of 434

20” FA (kg) 2400 2800 3200 3600 4000 4400

FL (kg) 2400 2800 3200 3600 4000 4400
FT (kg) 1800 2100 2400 2700 3000 3300
ML (kg.m) 3120 3640 4160 4680 5200 5720
MT (kg.m) 3600 4200 4800 5400 6000 6600
MC (kg.m) 2400 2800 3200 3600 4000 4400
22” FA (kg) 2640 3080 3520 3960 4400 4840

FL (kg) 2640 3080 3520 3960 4400 4840
FT (kg) 1980 2310 2640 2970 3300 3630
ML (kg.m) 3775 4405 5034 5663 6292 6921
MT (kg.m) 4356 5082 5808 6534 7260 7986
MC (kg.m) 2904 3388 3872 4356 4840 5324
24” FA (kg) 2880 3360 3840 4320 4800 5280

FL (kg) 2800 3360 3840 4320 4800 5280
FT (kg) 2160 2520 2880 3240 3600 3960
ML (kg.m) 4493 5242 5991 6739 7488 8237
MT (kg.m) 5184 6048 6912 7776 8640 9504
MC (kg.m) 3546 4032 4608 5184 5760 6336
26” FA (kg) 3120 3640 4160 4680 5200 5720

FL (kg) 3120 3640 4160 4680 5200 5720
FT (kg) 2340 2730 3120 3510 3900 4290
ML (kg.m) 5273 6152 7031 7909 8788 9667
MT (kg.m) 6084 7098 8112 9126 10140 11154
MC (kg.m) 4056 4732 5408 6084 6760 7436
28” FA (kg) 3360 3920 4480 5040 5600 6160

FL (kg) 3360 3920 4480 5040 5600 6160
FT (kg) 2520 2940 3360 3780 4200 4620
ML (kg.m) 6115 7135 8154 9173 10192 11211
MT (kg.m) 7056 8232 9408 10584 11760 12936
MC (kg.m) 4704 5488 6272 7056 7840 8624
30” FA (kg) 3600 4200 4800 5400 6000 6600

FL (kg) 3600 4200 4800 5400 6000 6600
FT (kg) 2700 3150 3600 4050 4500 4950
ML (kg.m) 7020 8190 9360 10530 11700 12870
MT (kg.m) 8100 9450 10800 12150 13500 14850
MC (kg.m) 5400 6300 7200 8100 9000 9900
Page 324 of 434

NOZZLE LOADING OF CYLINDRICAL, DISHED / FORMED END
Y
FA
FY=FA
MT
Z X
ML MC
FZ=FT FX=FL
FT FL
C Y L IN D R IC A L E N D S
FA
MB
Y MT
Z X
FR = RESU LTAN T
D IS H E D / F O R M E D E N D S
(NOTE: LOADS INDICATED IN THE TABLES TO BE CHECKED FOR BOTH POSITIVE AND NEGATIVE
CONDITIONS)
Page 325 of 434

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Page 343 of 434
STANDARD SPECIFICATION STANDARD SPECIFICATION No.
k5-1
1 ENGINEERS CIVIL & STRUCTURAL WORKS — 6-68-0001 Rev.4
$fgal idWg INDIA LIMITED GENERAL SCOPE
iir,73 Govt ol India Undenakinn) Page 1 of 4
41114) el I kiwi
Thr-4U 7-4 kitc111c-Ich chief
STANDARD SPECIFICATION
CIVIL AND STRUCTURAL WORKS
'Eirft.T
GENERAL SCOPE
REAFFIRMED AND REISSUED AS

Arro k
4 28.03.2013 AJS RS PKM SC DM
SPECIFICATION
REAFFIRMED AND REISSUED AS VC
3 26.02.2008 PKB PKM VK
SPECIFICATION
REAFFIRMED AND REISSUED AS
2 08.06.2001 DPN RPM SCJ MI
SPECIFICATION
1 02.03.1994 ISSUED AS STD. SPECIFICATION HM GPL AS
Standards Standards
Conimittee Bureau
Rev. Prepared Checked
No by by
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 344 of 434
,3`ilf-a_lt.-1. ENGINEERS
fgar felf54-' dg INDIA LIMITED CIVIL & STRUCTURAL WORKS — 6-68-0001 Rev.4
Mi-e (A Govt of India undenakm
GENERAL SCOPE Page 2 of 4
Abbreviations:
IS : Indian Standards
Structural Standards Committee
Convenor: Mr. P.K. Mittal
Members: Mr. S.Debnath

Mr. P.J. Singh
Mr. Rajanji Srivastava
Mr. Samir Das
Mr. V.S. Chhaya (Projects)
Mr. Ravindra Kumar (Constn)

Page 345 of 434
ENGINEERS
1 ar 16ifireg INDIA LIMITED CIVIL & STRUCTURAL WORKS — 6-68-0001 Rev.4
Hren ele,nre Jnurn) IA Govt of India Undertaking)
1 These specifications establish and define the material and constructional requirements for
CIVIL and STRUCTURAL WORKS.
2. Methods of measurements are indicated in these specifications; where not so specified, latest
revision of IS:1200 shall be applicable.
3. Providing and operating all necessary measuring and testing devices/ equipments including all
materials and consumables are included in the scope of work. No separate measurement or
payment for testing the quality of work and materials shall be made; rates quoted for various
items shall be deemed to include the cost of such tests which are required to ensure
achievement of specified quality.
4. All materials shall be of standard quality, manufactured by renowned concerns conforming to

Indian Standards or equivalent, and shall have IS mark as far as possible unless otherwise
approved by the Engineer-in-Charge. Vendor List attached in the Tender document shall be
followed. The Contractor shall get all materials approved by the Engineer-in-Charge prior to
procurement and use. The Contractor shall furnish manufacturer's certificates for the
materials supplied by him when asked for. Further to that he shall get the materials tested
from an approved test house if asked for by the Engineer-in- Charge. The cost for all the tests
and test certificates for the material procured by the Contractor shall be borne by the
Contractor. No separate payment shall be made for the testing. The Engineer-in-Charge shall
have the right to determine whether all or any of the materials are suitable. Any materials
procured or brought to site and not conforming to specifications and satisfaction of the
Engineer-in-Charge shall be rejected and the Contractor shall have to remove the same
immediately from site at his own expense and without any claim for compensation due to such
rejection.
5. Wherever referred to in the tender document, only the latest revision of Specifications, Codes
of Practice and other publications of Bureau of Indian Standards shall be applicable.
6. Wherever the Contractor executes civil and structural works involving buildings, equipment
foundations, supporting structures, pipe racks, etc., the following works are deemed to have
been included in the quoted rates for various works.
Marking of centre lines of foundations etc.
- Establishing layout and levels of foundations and superstructure etc., including

establishment of reference lines, bench marks on various floors, platforms etc.
- General upkeep of the plant site.
- Preparation of Fabrication drawings and getting approval from Engineer-in-Charge after

incorporating all the comments.
- Preparation of "As-Built" scheme of structural drawings indicating constructed details

including levels, centre lines, layouts, member sizes etc. complete.
7. The provisions of Schedule of Rates, specifications and drawings shall be read in conjunction
with each other and in case of conflict amongst them, clarification shall be obtained from the
Engineer-in-Charge whose decision shall be final and binding. However, the following
procedure may generally be followed:
- Description of items in schedule of rates shall be followed when provisions therein are
different from those in specifications.

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ei ENGINEERS
fg-aiiarreA
r taf51ft w INDIA LIMITED CIVIL & STRUCTURAL WORKS — 6-68-0001 Rev.4
varotre inland.° IA Govt of India Undertaking,
Where the description of item does not call for some specific requirement but the
same is given in specifications, the specifications shall be followed in addition to the
requirement given in description of item.
Where drawings call for requirements different from or additional to those given in
item description and specifications, the decision of the Engineer-in-Charge shall be
obtained as to what shall be followed.

Page 347 of 434
Page 1 of 18

MANALI REFINERY , CHENNAI
RESID UPGRADATION PROJECT
TITLE : STANDARD SPECIFICATION FOR
STRUCTURAL STEELWORK
DOCUMENT NO: 44NC-4600-0000/C.02/0015/A4
B 12/07/2010 18 Issued for Feed SAP BPS DPC
Issued for Client’s

A 19/04/2010 18 SAP PMP DPC
Comments and Approval
Rev No. Issue Date Pages Rev. Description Prepared Checked Approved
By By By
Page 348 of 434

CPCL-CHENNAI STANDARD SPECIFICATION
44NC – 4600 FOR STRUCTURAL STEEL WORKS Sheet 2 of 18
DOC NO: 44NC-4600-0000/C.02/0015/A4 Rev. B
CONTENTS
1.0 PURPOSE
2.0 SCOPE OF WORK
4.0 RELATED DOCUMENTATION
5.0 ATTACHMENTS
Secification for Structural Steelwork

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DOC NO: 44NC-4600-0000/C.02/0015/A4 Rev. B
1.0 PURPOSE
The purpose of this document is to state the requirements of material, workmanship and
construction procedure to be followed during the execution of structural steelworks.
2.0 SCOPE OF WORK
This specification covers the requirements for material, storage, fabrication, assembly,
testing/examination, transportation and erection of all types of bolted and welded structural steel
work for general fabrication work. Fabrication of structure shall also include fabricating .
a. Built up section / plate girders, made out of rolled section or by plates.

b. Compound section made out of rolled sections.
c. Castellated sections
d. Tubular sections
Preparation of fabrication drawings shall be made by contractor.

B Wide sections also can be used.
3.1 GENERAL
a. The requirements set forth in IS 800 for general construction in steel and IS 9595 cold formed
light sections are not allowed to be used. IS 806 for use of steel tubes in general building
construction for the design, fabrication and erection of structural steel for buildings shall be
followed for structural steel work, unless otherwise specified.
b. In cases of conflict between this specification and the above Indian Standards, this specification
shall govern conflict between design basis and job specification & this specification , the former
shall govern.
3.2 MATERIALS
3.2.1 Structural Steel
The Structural steel shall conform to IS:2062-2006 (Weldable quality) unless specified otherwise.
Carbon steel pipes shall conform to IS:1161-1998 of Grade YST-240 or higher , IS : 1239-2004
(PART-1). & IS :1239-Part 2 -1992.
Wide flange sections conforms to Is: 12278 whenever applicable shall be used.
3.2.2 Electrodes for metal arc welding
Covered electrodes for metal arc welding of structural steel shall conform to IS:814-2004.
Bare wire electrodes for submerged arc welding of structural steel shall conform to IS: 7280. The
combination of wire and flux shall comply with IS: 3613.
Filler rods and wires for gas welding shall conform to IS: 1278. Filler rods and bare electrodes for
gas shielded arc welding of structural steel shall conform to IS: 6419.
3.2.3 Bolts and Nuts

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Bolts and nuts (including lock nuts) shall conform to IS:1363-2002, IS:1364-2002 (property class -
4.6) , IS:1367-2002, IS:3460, IS:6623 and IS:6639 as applicable. Washers shall conform to
IS:5369, IS:5370, IS:5372, IS:5374, IS:6610 and IS:6649 as applicable.
High strength bolt shall conform to IS : 3757-1985.
3.2.4 Receipt and storing of materials
All sections shall be checked on receipt to ensure that they are free from surface defects such as
pitting, twists, cracks and laminations. They shall be arranged by grade and quality and by lot.
Every section shall be marked for identification and the manufacturers certificate for every lot
giving details of chemical analysis and mechanical characteristics shall be kept in record.
Welding wires and electrodes shall be segregated by quality and lots and stored inside a dry,
enclosed room as per recommendations of IS:9595. All care shall be taken to keep the
electrodes in perfectly dry condition to ensure weld metal soundness and satisfactory operations.
Manufacturers certificates for electrodes shall also be logged into the records.
Bolts, nuts and washers shall be sorted out by grade, type and diameter and the manufacturers
quality / test certificates shall be maintained for record purpose.
3.2.5 Material Testing
The contractor is required to provide manufacturers quality certificate for every item of material
supplied by him. In case such certificates are not available, the contractor shall at his own cost
carry out all such tests as are required by Owners / consultant at an approved Test House and
submit the test results for approval. The approval of such material shall however be entirely at
the discretion of the Owner / Consultant.
The Contractor shall ensure that all materials brought to site are duly approved. Rejected
materials shall not be used and shall be removed from site. Any material doubtful in quality for
which specific tests are to be carried out as per the instruction of Owner / Consultant, shall be
separately stacked and properly identified and shall not be used.
3.2.6 Storage and preparation
The storage yard for fabricated steel parts shall be prepared in advance and got approved by the
Owner / Consultant before the steel structures start arriving from the shop.
All materials shall be set at least 150 mm clear from ground on wooden or steel blocks for
protection against direct contact with the ground and to permit drainage of water.
Steps shall be taken to prevent warping of items during handling at all stages.
3.2.7 Deviations
Use of materials other than those specified above shall be allowed, with prior approval, only
where Contractor can prove technical advantage to the Owner.
3.3 FABRICATION DRAWINGS
Fabrication and erection shall be carried out based on drawings thoroughly checked, stamped
“Approved for Fabrication” and signed by the contractors own responsible engineer. Unchecked
and unstamped drawings shall not be used for purpose of proceeding with the work
B
The contractor shall directly issue to site / shop the fabrication and erection drawing in the correct
order, simultaneously submitting required copies (specified elsewhere)copies to Owner /
Consultant for their review. The Owner / Consultant shall at his sole discretion review part or
whole of all, some or none of the drawings.

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Review of drawings by Owner / Consultant shall in no way relieve the contractor of his
responsibility for correctness in the execution of the work, and the contractor shall be required to
modify / rectify the structure at any stage of the work in case owner / consultant bring to his
attention any mistake / omission in the fabrication drawing and the fabrication based on this
drawing or that the work does not conform to good engineering practice. All such modifications /
rectifications shall be made at no extra cost to the owner.
Fabrication drawings shall be drawn to scale and shall convey the information clearly and
adequately. Following information shall be furnished on such drawings :
– Reference to design drawing number (along with revision number) based on which fabrication
drawing has been prepared.
– Structural layout, elevations and sections (with distinct erection marking of all members).
– Framing plans, member sizes, orientation and elevations.
– Layout and detailing of rain water pipes and gutters showing all necessary levels, connections
and provisions wherever required.
– Detailing of shop / field joints, connections, splices for required strength and erection.
– Location, type, size and dimensions of welds and bolts.
– Shapes and sizes of edge preparation for welding.
– Details of shop and field joints / welds.
– Bill of materials / D.O.D Lists.
– Quality of structural steel, plates etc., welding electrodes, bolts, nuts and washers to be used.
– Erection assemblies identifying all transportable parts and sub-assemblies with special
erection instructions, if required.
– Method of erection and special precautions to be taken during erection as required.
The Contractor shall additionally ensure accuracy of the following and shall be solely responsible
for the same :
– Provisions for erection and erection clearances.

– Marking of members
– Cut length of members
– Matching of joints and holes.
– Provisions kept in the members for other interconnected members.
– Bill of materials / D.O.D Lists.
Connections, splices and other details where not shown on the design drawings shall be suitably
designed and shown on the fabrication drawings based on good engineering practice developing
full member strength. Design calculations for such connections/splices shall be submitted to the
Owner / Consultant, if called for.
Any substitution or change in section shall be allowed only when prior written approval of the
Owner / Consultant has been obtained. Fabrication drawings shall be updated incorporating all
such substitutions/changes by the Contractor at no extra cost.

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In case during execution of the work, the Owner / Consultant on review of drawings considers any
modifications/substitutions necessary to meet the design parameters/good engineering practice,
these shall be brought to the notice of the Contractor who shall incorporate the same in the
drawings and works without any extra cost to the Owner. The Contractor will be totally
responsible for the correctness of the detailed fabrication drawings and execution of the work.
Contractor shall incorporate all the revisions made in the design drawings during the course of
execution of work in his fabrication drawings and resubmit the drawings at no extra cost. All
fabrication shall be carried out only as per the final AFC drawings.
The Contractor shall supply two prints each of the final / as built drawings alongwith their
transparencies to Owner / Consultant for reference and record.
The contractor is required to update the fabrication drawings to include revisions made in design
drawings during the course of work at no extra cost. The Contractor shall also supply two prints
of as built drawings, along with their transparencies at no extra cost.
3.4 FABRICATION
3.4.1 General
All fabrication shall be done as per specifications, IS:800, IS:9595 and other relevant IS codes on
the basis of stamped and signed “Good for Construction” fabrication drawings.
The contractor shall prior to starting any fabrication ensure that the fabrication yard is levelled and
firm enough to take weight of structures and equipment.
Any defective fabrication or material pointed out at any stage shall be replaced by the contractor
free of cost.
3.5 FABRICATION PROCEDURE
3.5.1 Straightening
All materials shall be straight and free from twists. If straightening or flattening is necessary, it
shall be done by a process approved by the Owner / Consultant, and in a manner that will not
damage the material properties. Sharp kinks or bends shall be a cause for rejection. The
specified camber wherever necessary shall be provided.
Bending of rolled steel section and plates shall be done by Cold Process to shapes, as shown in
drawings.
Tolerance as per IS: 7215.
3.5.2 Clearance
The erection clearance for members having end cleats or plates shall not be more than 2 mm at
each end, whereas for other types of end connections it shall not be more than 3 mm at each
end. If for any reason a greater end clearance is required, suitable seating, approved by Owner /
Consultant shall be provided.
3.5.3 Cutting
Prior to cutting, all members shall be properly marked showing the requisite cut length / width,
connection provisions e.g., location and dimensions of holes, welds, cleats, etc. Marking for
cutting shall be done judiciously so as to avoid wastages or unnecessary joints as far as
practicable. Marking shall be done by placing the members on horizontal supports/pads in order
to ensure accuracy. Marking accuracy shall be limited to + 1 mm.

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Template shall be used for full scale layout incase of critical joints connection.
Cutting may be affected by shearing, cropping or sawing. Gas cutting by mechanically controlled
torch shall be permitted for mild steel. Hand flame cutting may be permitted subject to the
approval of the Owner / Consultant.
Except where the material is subsequently joined by welding, no loads shall be transmitted into
metal through a gas cut surface.
Shearing, cropping and gas cutting shall be clean, square, free from any distortion & burrs and
should the Owner / Consultant find it necessary, the edges shall be ground afterwards, to make
the same straight and uniform at no extra cost to the Owner.
Cutting tolerances shall be as follows :-
a. For member connected at both ends : ± 1 mm

b. Elsewhere : ± 3 mm
3.5.4 Holing
Holes for compound or built up section passing through more than one thickness shall preferably
be drilled after the members are assembled and tightly clamped or bolted together. In case the
thickness of metal for each component is less than 16 mm, the holes may be punched prior to
assembly provided the holes are punched 3 mm smaller in diameter than the required size and
reamed after assembly to the required diameter. Dynamically loaded structures shall not be
holed by punching. In case the material is not more than 12 mm thick and the connection is not a
splice, the hole may be punched full size except in holes for close tolerance bolts or barrel bolts.
Holes may be drilled in one operation through two or more parts and the burrs removed from
each part after drilling. Holes not drilled through all the thicknesses in one operation shall be
drilled to a smaller size and reamed out after assembly.
Holes for close tolerance bolts and barrel bolts shall be drilled through all the thicknesses in one
operation and subsequently reamed to size after firmly holding the parts together with the aid of
tacking bolts or clamps.
Finished holes for black bolts of high strength and high strength friction grip bolts shall not have a
diameter more than 2 mm the diameter of the bolt passing through them or as specified in
fabrication drawings.
Holes for bolts shall not be formed by gas cutting.
To facilitate the grouting, holes shall be provided in column base / seating plates exceeding
300 mm width for the escape of entrapped air.
To avoid accumulation of water inside column base or boxed type construction suitable
reverse U-type holes shall be provided at junction of base plate and column section in vertical
gusset plates to drain collected water out.
3.5.5 Bending
Bending of plates, flats and sections shall be carried out on bending rolls or in presses.
Cold process bending may be accepted when bending radius is equal to or more than
- 25 times member thickness for plates and flats.

- 25h or 25b for rolled steel beams and channels according to the bending plane.

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DOC NO: 44NC-4600-0000/C.02/0015/A4 Rev. B
- 45b for angle
where, h = section height

b = flange width
Accuracy of bending operations shall be checked by means of templates and the clearance
between member and template shall not be more than + 1 mm.
Bent member shall not have cracks or deep indentations from bending equipment.
3.5.6 Assembly
The component parts shall be aligned and assembled in such a fashion that they are not twisted
or damaged in any way and have the prescribed camber. The clamps, jigs and other fixtures
shall be placed so as to cause no imbalance which would result in twisting / incorrect positioning
of members. Due attention shall be paid to welding shrinkage and distortion.
3.5.7 Bolting
All turned and fitted bolts shall be parallel throughout the barrel within the tolerance of 0.125 mm,
unless otherwise specified and faces of heads and nuts bearing on steel work shall be machined.
All such bolts shall be provided with washers not less than 3 mm thick, so that when the nut is
tightened, it shall not bear the unthreaded body of the bolt and the threaded portion of the bolt
should not be within the thickness of the parts bolted together. The threaded portion of each bolt
shall project through the nut by at least one thread. Square tapered washers shall be provided for
all heads and nuts bearing on bevelled surface. Flat washers shall be circular in shape. The
bolts, nuts and washers, etc., shall be thoroughly cleaned and dipped in linseed oil.
The bolts shall be of Class I type conforming to the above specifications.
All nuts and bolts shall be tightened in a staggered pattern and where more than four bolts in any
joints they shall be tightened from centre to outwards. Every bolted connection shall have atleast
2 bolts.
3.5.8 Bracings
Guys wires and temporary bracing shall be used wherever necessary to withstand the loads due
to erection. Such members shall be left in place as long as may be required for safety.
3.5.9 Welding
a. General
Welding of steel shall be in accordance with IS:816-1969, IS:819, IS:1024, IS:1261, IS:1323 and
IS:9595-1996 as applicable. Welds shall be made only by Qualified Welding Operators who have
been previously qualified by tests by the Owner / Consultant. Evidence of welder’s qualification
tests shall be produced if required by the Owner / Consultant. Owner / Consultant may reject any
welder found not suitable during actual work.
Welding wire and electrodes shall be sorted separately by quantities and lots inside a dry and
enclosed room, and as per instruction given by the Owner / Consultant. Electrodes shall be low
hydrogen type.
Both the structural members and the welding operation / process shall be adequately protected
from rain, strong winds or snow during welding. The Contractor shall provide necessary
supervision to ensure that all welding is carried out in conformity with the specification and
relevant IS codes. The contractor shall make all necessary infrastructure available such as

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requisite number of welding sets, cutting and grinding equipment, test equipment and all
consumables as required.
b. Preparation of members for welding
Edge preparation of fusion faces for welding shall be carried out as per details given in IS: 9595
or as shown on drawings. All tolerances for such work shall be as per IS: 9595. The bevelling of
such faces shall be checked by the Owner / Consultant.
Surfaces to be welded shall be cleared to ensure that they are free from loose scales, slag, rust,
grease, paint and other foreign matter, and shall be maintained.
Preheating of members shall be necessary when the base metal temperature (based on ambient
temperature) is less than the temperature required for that welding procedure. The preheating
shall be done in such a manner that the part on which weld metal is to be deposited is above the
specified temperature for a distance of 75 mm on either side of the weld line. The temperature
shall be measured on the face opposite to the face being heated. In case access is limited to
only the face being heated, the source of heat shall be removed and sufficient time allowed to
elapse for heat equalisation prior to measurement. (1 minute per 25 mm of plate thickness).
Column splices and butt joints of compression members shall be accurately ground and close
butted over the entire section to ensure full contact for load transmission. The tolerance for such
work shall be maximum 0.2 mm. In the case of column bases and caps the ends of the section
along with connected gussets, stiffeners, angles, channels etc. shall be ground so as to ensure a
minimum contact area of 90%. The fitting of angles and channels should be sufficiently accurate
to limit the reduction in thickness on account of grinding to 2 mm. The ends of bearing stiffeners
shall be ground so as to fit tightly at both top and bottom. Slab bases and cap plates shall be
accurately ground over bearing surfaces to ensure minimum 90% contact area with columns.
c. Welding Processes
Any one or more of the following welding processes may be used.
i. Manual Metal Arc Welding Process.
ii. Submerged Arc Welding Process.
iii. Gas Metal Arc Welding Process.
iv. Flux cored Arc Welding Process.
Argon welding process shall be done where working in an existing working plant building. Where
welding operation is carried out in restricted working plant areas , it shall only be conducted only
if required by the Owner/consultant in specified areas. See Annexure 1 for details on Argon
welding.
The Contractor shall submit the welding procedure and the consumables proposed to be used to
the Owner / Consultant for approval. Combination of processes or electrodes may be permitted
only with the specific approval of the Owner / Consultant.
d. Approval & Testing of Welders
The Contractor shall satisfy the Owner / Consultant that the welders are suitable for the work
upon which they will be employed. For this purpose the welders shall have satisfied the relevant
requirements of IS: 7318. If the welders will be working to approved welding procedures, they
shall have satisfied the relevant requirements of IS: 7310.

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Adequate means of identification shall be provided to enable each weld to be traced to the welder
by whom it was made. The Contractor shall intimate the Owner / Consultant sufficiently in
advance, the commencement of tests, to enable him to be present to witness the same.
e. Approval and Testing of Welding Procedures
The Contractor shall carry out procedure tests in accordance with IS:7307 to demonstrate by
means of a specimen weld of adequate length on steel , that the welder can make welds with the
welding procedure to be used for the work to the complete satisfaction of the Owner / Consultant.
The test weld shall be as per weld details required for the actual work and should simulate the
work conditions likely to be encountered in the actual work in terms of sit up electrode condition
etc. The test weld shall be held at ambient temperature for a minimum period of 72 hours prior to
testing to IS: 7307
After establishing the welding method, the Contractor shall finally submit to the Owner /
Consultant for his approval of the welding procedure specification in standard format given in IS:
9595 before starting the fabrication.
f. Sequence of Welding
i. The direction of welding shall be from points relatively fixed with respect to each other
towards points having more flexibility.
ii. Welding shall be carried out continuously to completion with the required number of runs.
iii. For compound section splices, each component part shall be spliced prior to welding with
other component parts.
iv. Welds shall progress in a sequence that will balance the applied heat so as to reduce
distortion.
v. Joints having more shrinkage shall be welded prior to joints having less shrinkage.
vi. The sequence causing minimum distortion or shrinkage shall be chosen.
g. Welding Technique
The fusion faces shall be properly aligned and the gap set to the distance specified. The root
pass of butt joint shall be done such that full penetration is achieved as also complete fusion of
root edges.
On completing each run the weld and the parent metal shall be cleared by wire brushing and light
chipping to remove all slag and splatters. Visible defects if any such as cracks, cavities etc. shall
be removed to sound metal prior to depositing subsequent run of weld.
All full penetration butt welds shall be completed by gouging / chipping the back of the joint and
depositing a seal run of weld metal. Alternatively a backing strip shall be provided.
All care shall be taken to prevent any kind of movement, shock or vibration of components during
welding to prevent weld cracks.
h. Inspection and Testing of Welds

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The method of inspection shall be according to IS:822 and extent of inspection and testing shall
be in accordance with the relevant applicable standard or, in the absence of such a standard, it
shall be done as specified by the Owner / Consultant. Welds shall not be painted or otherwise
obscured until they have been inspected, approved and accepted.
The Owner / Consultant or his representative shall have access to the Contractor’s work at all
reasonable times and the Contractor shall provide him with all facilities necessary for inspection
during all stages of fabrication and erection with, but not limited to, the following objectives.
i. To check the conformity with the relevant standards and suitability of various welding
equipments and their performance.
ii. To witness / approve the welding procedure qualification.
iii. To witness / approve the welders performance qualification.
iv. To check whether shop/field welding being executed is in conformity with the relevant
specifications and codes of practice.
Inspection and testing of all fabricated structures shall be carried out by the Contractor by any, or,
a combination of all the following methods as directed by the Owner / Consultant and no separate
payment shall be made, unless otherwise mentioned, for inspection and testing of
welds/fabricated structures:
The various types of tests shall be :
i. Visual Inspection
100% welds shall be visually inspected to ascertain absence of the following defects.
- Surface cracks in weld or parent metal, or undercut, burning, overheating of parent metal.
- Blow holes, exposed porosity in the weld or unfused welds.
- Defects in the profile such as excessive convexity or concavity, unequal leg lengths
incompletely filled grooves, excessive penetration beeds, root grooves etc.
- Distortion due to welding and misalignment.
ii. Mechanical Tests
Tensile load test, bend tests, impact tests etc. shall be carried out as per the standard.
iii. Radiographic Testing
Radiographic examination shall be carried out only in special cases for random joints as
directed by the Owner / Consultant. The Contractor shall not be paid any extra for such
examination. The Contractor shall make necessary arrangement at his own expense for
providing the radiographic equipment, films and all other necessary materials required for
carrying out the examination. The tests shall be carried in the presence of the Owner /
Consultant by employing approved testing procedure in accordance with IS:822. The
Contractor shall fulfil all the statutory safety requirements while handling X-ray and Gamma-
ray equipment and provide the Owner / Consultant all the necessary facilities at site such as
dark room, film viewer etc., to enable him to examine the radiographs. When full strength
butt weld / full penetration bevelled weld shall be tested minimum 10% joints / length of weld
can be considered for testing.

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Iv Magnetic Particle / Dye Penetrator / Ultrasonic Tests
The examination shall be done at random as directed by the Owner / Consultant. Whenever
such tests are directed, the tests shall be carried out on joints chosen by owner / consultant .
The tests shall be carried out by employing approved testing procedure in accordance with
IS: 822.
i. Repair of Welds
No repair of defective welds shall be carried out without proper permission of the Owner /
Consultant and his approval for the corrective procedure.
Welds not complying with the acceptance requirements (as specified by IS codes & the Owner /
Consultant), as revealed during inspection & testing of welds or erection or in-situ condition, shall
be corrected either by removing & replacing or as follows :
a. Excessive convexity – Reduced to size by removal of excess weld metal.

b. Shrinkage cracks, cracks in - Defective portions removed down to sound metal and
parent plates and craters and rewelded.
c. Under cutting - Additional weld metal deposited.
d. Improperly fitted / - Welding removed & edges suitably prepared and parts
misaligned parts rewelded.
e. Members distorted by the heat - Member straightened by mechanical means or by
of welding careful application of limited amount of heat.
In removing defective parts of a weld, gouging, chipping, oxygen cutting or grinding shall not
extend into the parent metal to any substantial amount beyond the depth of weld penetration,
unless cracks or other defects exist in the parent metal. The weld or parent metal shall not be
undercut in chipping, grinding, gouging or oxygen cutting.
Any fabricated structure or its component which, in the opinion of Owner / Consultant, is defective
and/or beyond any corrective action shall be removed forthwith from the site as instructed by the
Owner / Consultant without any extra claim. The Owner reserves the right to recover any
compensation due to any loss arising out of such rejections.
3.5.10 Splicing
Splicing of built up / compound / latticed sections shall be done in such a fashion that each
component of the section is joined in a staggered manner.
Where no butt weld is used for splicing, the meeting ends of two pieces of joist/channel/built up
section shall be ground flush for bearing on each other and suitable flange and web splice plates
shall be designed and provided for the full strength of the flange / web of the section and welds
designed accordingly.
Where full strength butt weld is used for splicing (after proper edge preparation of the web and
flange plates) of members fabricated out of joist/channel/angles/built up section, additional flange
and web plates shall be provided, over and above the full strength butt welds, to have 40%
strength of the flange and web.
Where a cover plate is used over a joist/channel section the splicing of the cover plate and
channel/joist sections shall be staggered by minimum 500 mm. Extra splice plate shall be used
for the cover plate.
Prior approval shall be obtained by the Contractor for locations of splices where not shown on
design drawings. Only a single splice at approved locations shall be allowed for members up to a

Page 359 of 434
DOC NO: 44NC-4600-0000/C.02/0015/A4 Rev. B
length of 6 to 7 m. Maximum two numbers of splices shall be allowed for members exceeding
this length.
In case full strength butt weld is used to connect opposing ends at a joint, additional flange and
web splice plates shall be provided capable of carrying 20% strength of the flange and web.
3.6 SHOP ERECTION
The steel work shall be temporarily erected in the shop to determine the accuracy of the fit. The
extent of erection shall be either complete or as directed by Owner / Consultant.
3.7 INSPECTION AND TESTING OF STRUCTURES
Materials and workmanship at all times shall be subject to inspection by the Owner / Consultant.
All inspection as far as possible shall be made at the place of fabrication and the contractor shall
co-operate with the Owner / Consultant’s Inspector and permit access for inspection to all places
where work is being done. The contractor shall supply free to the Owner / Consultant all
necessary gauges and templates necessary for inspection. However, such inspection shall not
relieve the contractor of his responsibility to furnish satisfactory work.
Materials of workmanship, not conforming to provisions of the specifications, may be rejected at

any time when defects are found during the progress of work.
The contractor shall obtain approval from the Owner / Consultant of all fabricated items prior to
commencement of their erection. However, any such approval shall not absolve the Contractor
from his responsibility of correctness and workmanship of the entire work.
3.8 SHOP PAINTING
Refer Painting specification no 44NC-4600-00-V.02-0111-A4 however, primer application to steel

members which are to be fireproofed by vermiculite based material, shall be as per the vendor’s
specifications.
3.9 PACKING AND TRANSPORTATION
Loading and transportation shall be done in accordance with transport rules prevailing at that
location. Items shall be packed to protect them from damage / distortion. Small parts shall be
securely wired to their main members.
Loose items such as Bolts, nuts and washers shall be packed in crates.
3.10 FIELD ERECTION
Plant & Equipment
The suitability and capacity of all plant and equipment used shall be to the complete satisfaction
of the Owner / Consultant.
Storing & Handling
All steel work shall be so stored and handled at site so that the members are not subjected to
excessive stresses and any damage.
Setting Out
Prior to setting out of the steel work, the Contractor shall get himself satisfied about the
correctness of levels, alignment, location of existing concrete pedestals/columns/brackets and

Page 360 of 434
DOC NO: 44NC-4600-0000/C.02/0015/A4 Rev. B
holding down bolts/pockets provided therein. Any minor modification in the same including
chipping, cutting and making good, adjusting the anchor bolts etc., if necessary, shall be carried
out by the Contractor at his own expense. The positioning and levelling of all steel work including
plumbing of columns and placing of every part of the structure with accuracy shall be in
accordance with the drawings and to the complete satisfaction of the Owner / Consultant.
Tolerances
Tolerances for erection of steel work shall be in accordance with Table given below & IS:7215
whichever is more stringent.
ERECTION TOLERANCES
Tolerances allowed in the Erection of Structural Steel Buildings frames shall be as follows :
Component Description Variation allowed
Main Columns and Roof a) Shifting of column axes at

Posts foundation level with respect
to true axes.
- in Longitudinal direction + 5 mm
- in Lateral direction + 5 mm
b) Out of plumbness of column

axis from true vertical as
measured at the top.
- For a column up to + 25 mm or + H/1000
and ( whichever is less )
including 30 m ht.
- For a column greater than + 35 mm or + H/1200
30 m height ( whichever is less )
c) Deviation in straightness in
longitudinal and transverse + 10 mm or + H/1000
planes of column at any ( whichever is less )
point along the height.
d) For an individual column + 5 mm

deviation of any bearing or
resisting level from levels
shown on the drawings.
e) Difference in the erected + 5 mm

positions of adjacent pairs of
columns across the width of
the building prior to placing
of truss / beams with respect
to true distance.

Page 361 of 434
DOC NO: 44NC-4600-0000/C.02/0015/A4 Rev. B
f) For adjacent pairs of + 5 mm

columns either across the
width of building or
longitudinally, level diffe-
rence allowed between
bearing or seating level
supposed to be at the same
level.
Trusses a) Deviation at centre of span 1/250 of the height of truss

of upper chord member from in mm at centre of span or +
vertical plane running 15 mm whichever is less.
through centre of bottom
chord.
Component Description Variation allowed
b) Lateral displacement of top 1/1500 of span of truss in

chord at centre of span from mm or + 10 mm (whichever
vertical place running is less).
through centre of supports.
c) Lateral shift in location of + 10 mm

purlin from its true vertical
position.
d) Lateral shift in location of + 5 mm

purlin from true position.
e) Deviation in difference of + 1/1200 of span of truss in

bearing levels of truss from mm or + 20 mm (whichever
the true difference. is less)
Crane, Gantry, Girders and Shift in the centre line of crane rail + (half web thickness
Rails with respect to centre line of web of plus 2 mm)
gantry girder
Shift of alignment of crane rail w.r.t. + 5 mm

true axis of crane rail
Deviation in crane track gauge with

respect to true gauge
i) For gauge upto 15 m + 5 mm

ii) For gauge more than 15 m + 10 mm
Deviation in the crane rail level at + 10 mm

any point from true level
Difference in levels between crane

track rails (across the bay) at
i) Supports 15 mm
ii) Midspan 20 mm

Page 362 of 434
DOC NO: 44NC-4600-0000/C.02/0015/A4 Rev. B
Relative shift of crane rail surface 2 mm

(at a joining in plan and elevation)
3.11 SAFETY & SECURITY DURING ERECTION
The CONTRACTOR shall comply with IS: 7205 for necessary safety and adhere to safe erection
practices and guard against any hazardous as well as unsafe working conditions during all stages
of erection.
During erection, the steel work shall be securely bolted or otherwise fastened and when
necessary, temporarily braced/guyed to provide for all loads to be carried by the structure during
erection till the completion, including those due to the wind, erection equipment and its operation
etc., at no extra cost to the Owner. For the purpose of guying, the Contractor shall not use other
structure in the vicinity without prior written permission of the Owner / Consultant.
No permanent bolting or welding shall be done until proper alignment has been achieved.
Proper access, platform and safety arrangement shall be provided for working and inspection, (at
no extra cost to the Owner) whenever required.
3.12 FIELD CONNECTIONS
Field Bolting
Field bolting shall be carried out with the same care as required for shop bolting.
Field Welding
All field assembly and welding shall be executed in accordance with the requirements for shop
assembly and welding. Holes for all erection bolt – where removed after final erection shall be
plugged by welding. Alternatively, erection bolts may be left and secured.
3.13 GROUTING
Prior to positioning of structural columns/girders/trusses over the concrete

pedestals/columns/brackets, all laitance and loose material shall be removed by wire brushing
and chipping. The bearing concrete surfaces shall be sufficiently levelled, hacked with flat chisels
to make them rough, cleaned (using compressed air) and made wet for clean surface and excess
water removed . All pockets for anchor bolts shall also be similarly cleaned and any excess water
removed. Thereafter, the structural member shall be erected, aligned and plumbed maintaining
the base plates/shoe plates at the levels shown in the drawings, with necessary shims/pack
plates/wedges.
After final alignment and plumbing of the structure, the forms shall be constructed alround and
joints made tight to prevent leakage. Grouting (under the base plates/shoe plates including
grouting of sleeves & pockets) shall be done on dry cleaned concrete surface with non-shrink
2
grout having compressive strength (28 days) not less than 40 N/mm . Non shrink grout shall be
of free flow premix type and of approved quality and make. It shall be mixed with water in
proportion as specified by the manufacturer. Ordinary 1:2 cement/sand mortar grout with non-
shrink admixture in to the cement grout mix in shall be used only for small, isolated structures
e.g., operating platforms not supporting any equipment not exceeding 2 m heiht, pipe supports
not exceeding 1.5 m height, cross overs, & ladders. The thickness of grout shall be as shown on
the drawings but not less than 25 mm or more than 50 mm in any case.

Page 363 of 434
DOC NO: 44NC-4600-0000/C.02/0015/A4 Rev. B
The grout mixture shall be poured continuously (without any interruption till completion) by
grouting pumps from one side of the base plate and spread uniformly with flexible steel strips and
rammed with rods, till the space is filled solidly and the grout mixture carried to the other side of
the base plate.
The grout mixture shall be allowed to harden for a period as per manufacturer’s specification
decided by the Owner / Consultant. At the end of this period, the shims/wedges/pack plates may
be removed and anchor bolts tightened uniformly. The alignment of the structure shall now be
rechecked and if found correct, the voids left by the removal of shims/wedges/pack plates (if
removed) must be filled up with a similar mixture of grout. In case after checking, serious
misalignment is indicated, the grout shall be removed completely and fresh grouting done after
making appropriate correction of alignment.
3.14 PAINTING AFTER ERECTION
Painting shall be as per specification for structural steel painting
4.0 RELATED DOCUMENTATION
44NC-4600-00-V.02-0111-A4 - Painting specification
5.0 ATTACHMENTS
Annexure -1
ANNEXURE-1
TUNGSTEN INERT – GAS (ARGON ) ARC WELDING:

Page 364 of 434
DOC NO: 44NC-4600-0000/C.02/0015/A4 Rev. B
Material:
The essential components are

a. Welding power source designed to deliver AC or DC or tooth as required.
b. Welding torch with a tungsten electrode which is gas-cooled or water cooled.
c. Supply of argon gas
d. Controls
Tig Welding Machine:

DC type preferred mode comprising of gas hose assembly 5m long; remote control unit (10m) for current
control; earthing cable with damp assembly 5m long. Also tig torch and tungsten electrodes and also
pressure regulator cum flow meter for argon gas. The welding machine and its accessories shall be of
approved equivalent make.
Technical Requirements:-
a. The welding should be done by experienced and qualified Tungsten inert gas
(Argon) welder.
b. Starting the arc by touching the tungsten electrode to the work piece must be
avoided as it contaminates and wears out the electrode tip, and gives rise to
tungsten Inclusions in the weld deposit and thereby degrading the weld metal
properties.
c. Gas pre-flow is must for good quality fig welding, as it removes air from the torch
and gas hose before the arc strikes and ensures complete and perfected
shielding of the electrode and base metal even before the arc is struck and
during arc striking.
d. Joints to be welded should be free from paint grease oil, oxide film and scale
and free of sulphur lead.
e. While welding the welder must watch the puddle at all times to see that it is built
up to a uniform height and form a smooth bead with only traces of a ripple.
f. The welder must be careful to prevent the electrode from making contact with the
sides of the joints and molten puddle.
g. While welding with tungsten electrodes the arc tip should be only hot part of the
electrode, the remainder should be kept as cool as possible.
h. Electrodes should be kept in original package and kept clean; without broken electrodes.

Page 365 of 434
Page 366 of 434
Page 367 of 434
SCHEDULE OF RATES FOR ADDITION AND DELETION Document No.
FOR LADDER & PLATFORMS A133-086-16-48-SOR-6141
87-C-08 & 87-C-09 Rev No A
Page 1 of 3
DCU, EPCC-1, RESID UPGRADATION PROJECT

CPCL, MANALI, CHENNAI
SCHEDULE OF RATES FOR ADDITION AND DELETION
FOR
LADDER & PLATFORMS FOR
87-C-08 & 87-C-09
(STRUCTURAL)
(MR NO. A133-086-VV-MR-6141)
A 20.12.2013 ISSUED WITH MR

CDS VKG KK
Rev No Date Purpose Prepared by Reviewed by Approved by
Template No 5-0000-0001-T3 Rev 1

Page 368 of 434 Copyrights EIL – All rights reserved
87-C-08 & 87-C-09 Rev No A
Page 2 of 3
SL. RATES FOR ADDITION AND DELETION

NO. DESCRIPTION OF ITEMS UNIT
(In Indian Rupees/ UNIT)
FIGURES WORDS
STRUCTURAL
1. "Supplying, Fabricating, transporting fabricated items to site, unloading & storing bolted and/ MT
or welded STRUCTURAL STEEL WORKS of Grade E250A (confirming to IS:2062 at all
locations and levels) including all builtup sections/ compound sections made out of rolled
sections and/or plates/ bent plates in beams, brackets, bracings, ladders (with or without
cage), safety chain brackets, staircases and platforms of any shape and size (excluding
chequered plates/ gratings), on vertical and/ or horizontal equipments, in miscellaneous
valve operating platforms, pipe supports etc, cutting to required size, straightening/ bending
if required, edge preparation, cleaning, preheating, bolting/ welding of joints, (including
sealing the joints of box sections with continuous welding and plugging any open ends &
holes of box sections), finishing edges by grinding, including preparation and submission of
detailed fabrication drawings, preparing the surface for painting (SSPC-SP-10) and applying
pre-erection/ shop primer (1 coat of Inorganic Zinc Sulphate (F-9) coating @ 65-75 micron
DFT) as per Specification No. 44NC-4600-0000-V.02-0111-A4 after fabrication etc. all
complete as specified and directed. (SUPPLY OF ALL MATERIAL IN CONTRACTOR'S
SCOPE.)
2. Supplying and fabricating ELECTROFORGED GALVANISED GRATING TYPE-I MT

(purchased from approved manufacturer by the Contractor) conforming to Standard No.
44NC-4600-0000/S.01/0008/A4 (Sheet 1 of 8 to sheet 8 of 8) (in walkways, platforms, stair
treads etc.) including cutting to required size, shape, making holes, notches, openings of
required size, nosing, straightening if required, making the edges smooth, removing the
burrs, supplying manufacturer's supplied galvanised clamps, preparation and submission of
fabrication drawings, all complete as specified and directed (SUPPLY OF ALL MATERIALS
IN CONTRACTOR'S SCOPE).
3. Supplying, Fabricating, transporting fabricated items to site, unloading & storing 1050mm M
high HORIZONTAL HAND RAILING (for platforms, walkways, etc. or any other location as
directed) consisting of top rail with 32mm nominal diameter medium grade MS Tubes
conforming to IS:1239, mid rail with L50x50x6 & vertical posts (Maximum spacing 1200mm
c/c) with L90x90x8 confirming to IS:2062 (Grade A), including straightening if required,
cutting, bending, welding, bolting, cleaning, preparing the surface for painting (SSPC-SP-
10) and applying pre-erection/ shop primer (1 coat of Inorganic Zinc Sulphate (F-9) coating
Template NoPage
5-0000-0001-T3
369 of 434 Rev 1 Copyrights EIL – All rights reserved
87-C-08 & 87-C-09 Rev No A
Page 3 of 3
SL. RATES FOR ADDITION AND DELETION

NO. DESCRIPTION OF ITEMS UNIT
(In Indian Rupees/ UNIT)
FIGURES WORDS
@ 65-75 micron DFT) as per Specification No. 44NC-4600-0000-V.02-0111-A4 after
fabrication and submission of fabrication drawings etc., all complete as specified, shown
and directed. (SUPPLY OF ALL MATERIALS IN CONTRACTOR'S SCOPE). (Complete
handrail work shall be measured as length of top rail only and not length of each element
fixed).
_____________________________
(SIGNATURE OF THE BIDDER)
Template NoPage
5-0000-0001-T3
SCHEDULE OF QUANTITIES Document No.
FOR PLATFORMS & LADDER FOR A133-086-16-48-SOQ-6141
87-C-08 & 87-C-09 Rev No A
Page 1 of 3
DCU, EPCC-1, RESID UPGRADATION PROJECT

CPCL, MANALI, CHENNAI
SCHEDULE OF QUANTITIES
FOR
PLATFORMS & LADDER FOR
87-C-08 & 87-C-09
(STRUCTURAL)
(MR NO. A133-086-VV-MR-6141)
A 20.12.2013 ISSUED WITH MR

CDS VKG KK
Rev No Date Purpose Prepared by Reviewed by Approved by
Template No 5-0000-0001-T3 Rev 1

Page 371 of 434 Copyrights EIL – All rights reserved
87-C-08 & 87-C-09 Rev No A
Page 2 of 3
SL. NO. DESCRIPTION OF ITEMS UNIT QUANTITY
STRUCTURAL
1. "Supplying, Fabricating, transporting fabricated items to site, unloading & storing bolted and/ or welded
STRUCTURAL STEEL WORKS of Grade E250A (confirming to IS:2062 at all locations and levels) including all
builtup sections/ compound sections made out of rolled sections and/or plates/ bent plates in beams, brackets,
bracings, ladders (with or without cage), safety chain brackets, staircases and platforms of any shape and size
(excluding chequered plates/ gratings), on vertical and/ or horizontal equipments, in miscellaneous valve operating
platforms, pipe supports etc, cutting to required size, straightening/ bending if required, edge preparation, cleaning,
preheating, bolting/ welding of joints, (including sealing the joints of box sections with continuous welding and
plugging any open ends & holes of box sections), finishing edges by grinding, including preparation and submission
of detailed fabrication drawings, preparing the surface for painting (SSPC-SP-10) and applying pre-erection/ shop
primer (1 coat of Inorganic Zinc Sulphate (F-9) coating @ 65-75 micron DFT) as per Specification No. 44NC-4600-
0000-V.02-0111-A4 after fabrication etc. all complete as specified and directed. (SUPPLY OF ALL MATERIAL IN
CONTRACTOR'S SCOPE.)
1.1 EQUIPMENT NO. 87-C-08 MT 2.6
2. Supplying and fabricating ELECTROFORGED GALVANISED GRATING TYPE-I (purchased from approved
manufacturer by the Contractor) conforming to Standard No. 44NC-4600-0000/S.01/0008/A4 (Sheet 1 of 8 to sheet
8 of 8) (in walkways, platforms, stair treads etc.) including cutting to required size, shape, making holes, notches,
openings of required size, nosing, straightening if required, making the edges smooth, removing the burrs, supplying
manufacturer's supplied galvanised clamps, preparation and submission of fabrication drawings, all complete as
specified and directed (SUPPLY OF ALL MATERIALS IN CONTRACTOR'S SCOPE).
3. Supplying, Fabricating, transporting fabricated items to site, unloading & storing 1050mm high HORIZONTAL HAND
RAILING (for platforms, walkways, etc. or any other location as directed) consisting of top rail with 32mm nominal
diameter medium grade MS Tubes conforming to IS:1239, mid rail with L50x50x6 & vertical posts (Maximum
spacing 1200mm c/c) with L90x90x8 confirming to IS:2062 (Grade A), including straightening if required, cutting,
bending, welding, bolting, cleaning, preparing the surface for painting (SSPC-SP-10) and applying pre-erection/
shop primer (1 coat of Inorganic Zinc Sulphate (F-9) coating @ 65-75 micron DFT) as per Specification No. 44NC-
Template NoPage
5-0000-0001-T3
87-C-08 & 87-C-09 Rev No A
Page 3 of 3
SL. NO. DESCRIPTION OF ITEMS UNIT QUANTITY
4600-0000-V.02-0111-A4 after fabrication and submission of fabrication drawings etc., all complete as specified,
shown and directed. (SUPPLY OF ALL MATERIALS IN CONTRACTOR'S SCOPE). (Complete handrail work shall
be measured as length of top rail only and not length of each element fixed).
3.1 EQUIPMENT NO. 87-C-08 M 50
3.2 EQUIPMENT NO. 87-C-09 M 50
_____________________________
(SIGNATURE OF THE BIDDER)
Template NoPage
5-0000-0001-T3
TECHNICAL SPECIFICATIONS DOCUMENT No.
(CIVIL-STRUCTURAL) FOR A133-086-16-48-SOW-6141
Rev. A
87-C-08 & 87-C-09 Page 1 of 7
TECHNICAL SPECIFICATIONS
(SCOPE OF WORK/ SUPPLY
AND SPECIFIC REQUIREMENTS)
(CIVIL-STRUCTURAL)
FOR

87-C-08 & 87-C-09
(MR NO. A133-086-VV-MR-6141)
PROJECT : DCU, EPCC-1, RESID UPGRADATION PROJECT
OWNER : CHENNAI PETROLEUM CORPORATION LTD.
PMC : JACOBS ENGINEERING INDIA PVT.LTD.
LSTK CONTRACTOR : ENGINEERS INDIA LTD.
JOB NO. : A133
A 20.12.2013 ISSUED FOR MR

CDS VKG KK
Date Purpose
No by by by
Page 374 of 434
DOCUMENT No.
TECHNICAL SPECIFICATIONS A133-086-16-48-SOW-6141
(CIVIL-STRUCTURAL) FOR Rev. A
PLATFORM & LADDER FOR
87-C-08 & 87-C-09 Page 2 of 7
CONTENTS
SL TITLE PAGE
1. SCOPE OF WORK ......................................................................................................................... 3

2. SCOPE OF SUPPLY....................................................................................................................... 3
3. SPECIFIC REQUIREMENTS ........................................................................................................ 4
4. LIST OF SPECIFICATIONS, STANDARDS AND OTHER DOCUMENTS .............................. 4
5. PREAMBLE TO SCHEDULE OF QUANTITIES/ RATES .......................................................... 5
6. ADDENDUM TO SPECIFICATIONS ........................................................................................... 5
7. SCHEDULE OF QUANTITIES/ RATES....................................................................................... 7
Page 375 of 434
DOCUMENT No.
87-C-08 & 87-C-09 Page 3 of 7
1. SCOPE OF WORK
The scope of work under this contract shall include in general, but not limited to supply,
fabrication, transportation etc. for all relevant structural works (excluding erection at site) for
platforms (circular or any shape) on vertical vessels 87-C-08 & 87-C-09 in LPG CFC unit at
CPCL, Manali, Chennai including supply of all materials (as defined in scope of supply), tools
& tackles, labour, etc., as per the detailed scope of work, scope of material supply, schedule of
quantities, specifications, standards, drawings included in this Document (including
addendums/ amendments) and the directions of Engineer-in-charge and as per approved for
construction (AFC) drawings (including subsequent revisions) made available to the
successful bidder.
Major structural activities involved shall include but not be limited to the following :
1.1 Structural steel works with rolled steel or tubular/ hollow sections, including supply,
transportation, fabrication and preparation of detailed fabrication drawings for all types
of structures at all locations and heights.
1.2 For scope of other civil-structural works, refer Doc. No. A133-16-46-SS-6141 attached
elsewhere in the bid document.
Any other structural work, not specifically mentioned herein, but required for the
satisfactory and successful completion of the project as per directions of the Engineer-in-
Charge shall also be in the scope of the contractor.
2. SCOPE OF SUPPLY
2.1 Owner’s scope:
NIL.
2.2 Contractor’s scope:
2.2.1 All items consumables/ non consumables required to complete the job as per
Specifications, standards, drawings & instructions of Engineer-in-Charge.
2.2.2 All labor, tools tackles, plant machinery etc to complete the job.
2.3 Approved manufacturer/ vendor list for Electro-forged galvanized grating for use in
Structural works is as follows:
S. No. MANUFACTURER’S NAME PLACE

1. BHOLA RAM STEELS PVT. LTD. PATNA
2. GREATWELD STEEL GRATINGS PVT. LTD. PUNE
3. INDIANA GRATINGS PVT. LTD. MUMBAI
4. KANADE ANAND UDYOG PVT. LTD. MUMBAI
5. PINAX STEEL INDUSTRIES PVT. LTD. KOLKATA
6. VINFAB GRATINGS MUMBAI
Page 376 of 434
DOCUMENT No.
87-C-08 & 87-C-09 Page 4 of 7
3. SPECIFIC REQUIREMENTS
Note: In case of any contradiction between these Specific Requirements and Requirements/
Specification specified elsewhere in the tender document, the Specific Requirements given
below shall have precedence.
3.1 All works shall be done to the entire satisfaction of the Engineer-in-Charge/ TPI. Any
work not carried out in accordance with the instructions shall be dismantled and made
good without any extra cost and time implication to the owner.
3.2 Assembly & Shop erection of platforms as per specification shall be ensured before
supplying to site.
3.3 The contractor shall ensure proper co-ordination / co-operation with other agencies,
while working in the unit area, without affecting others work front areas.
4. LIST OF SPECIFICATIONS, STANDARDS AND OTHER DOCUMENTS
4.1 STANDARD SPECIFICATIONS:
SL. REV. NO. OF

SPECIFICATION NO. TITLE
NO. NO. SHEETS
1 6-68-0001 4 4 General Scope
2 44NC-4600-0000/C.02/0015/A4 B 18 Specification for Structural Steel
Works
3 44NC-4600-0000/C.02/0025/A4 B 6 Specification for Miscellaneous
Fabrication Work
4 44NC-4600-0000/V.02/0111/A4 1 45 General Specification for Shop & Field
painting
4.2 ENGINEERING STANDARDS:
SL. STANDARD REV. NO. OF

TITLE
NO. NO. NO. SHEETS
1 44NC-4600-0000/S.01/0008/A4 B 1 Standard grating (Type I & II) &
(SH1 OF 8) staircase tread details
Page 377 of 434
DOCUMENT No.
87-C-08 & 87-C-09 Page 5 of 7
9 44NC-4600-0000/S.01/0009/A3 B 1 Standard ladder & cage typical

(SH1 OF 2) details for step through ladder
10 44NC-4600-0000/S.01/0009/A3 B 1 Standard ladder & cage typical
(SH2 OF 2) details for step through ladder
11 44NC-4600-0000/S.01/0011/A4 B 1 Circular platform for hot vessels
(SH1 OF 6)
(SH2 OF 6)
(SH3 OF 6)
(SH4 OF 6)
(SH5 OF 6) (For E>100mm )
(SH6 OF 6)
17 44NC-4600-0000/S.01/0012/A4 B 1 Circular platform for cold vessels
(SH1 OF 4)
(SH2 OF 4)
(SH3 OF 4)
(SH4 OF 4) and hand rail details
5. PREAMBLE TO SCHEDULE OF QUANTITIES/ RATES
5.1. Prices for quantities of items mentioned in SOQ (Doc. No. A133-086-16-48-SOQ-6141)
shall be included in the quoted prices. Unit rate quoted against each SOR item (as per Doc.
No. A133-086-16-48-SOR-6141) shall be applicable for any addition and deletion during
execution of the project.
6. ADDENDUM TO SPECIFICATIONS
6.1. Payment terms for item for STRUCTURAL STEEL WORKS
6.1.1. The payment terms shall be read in conjunction with the Specification No. 44NC-4600-
0000/C.02/0015/A4.
6.1.2. Payment for structural steel works shall be made on the basis of admissible weight in
metric tons (determined as described in Clause 6.1.3 and 6.1.4) of the structure accepted
by the Engineer-in-Charge. The rate shall include supplying (as per supply conditions
given in the Tender) fabricating, testing/examining (excluding radiography only) of
bolted and/or welded structural steel works of all types (including all built up/compound
sections made out of rolled sections and/or plates) including all handling, transporting,
storing, straightening if required, cutting, edge preparation, preheating, bolting and
welding of joints (including sealing the joints of box sections with continuous welding),
finishing edges by grinding/machining as shown, preparation of fabrication drawings,
preparation and submission of as built drawings, preparing the surfaces for painting, and
Page 378 of 434
DOCUMENT No.
87-C-08 & 87-C-09 Page 6 of 7
applying the primer as specified after fabrication, etc. all complete for all the operations
mentioned in the foregoing clauses.
6.1.3. The weight for payment shall be determined from the fabrication drawings and
respective bill of materials prepared by the Contractor. The bill of materials shall be
checked and approved by the Engineer-in-Charge before making the payment. The
Contractor shall prepare full scale template in order to supplement/verify the actual
cutting dimensions where so directed by the Engineer-in-Charge. The weight shall be
calculated on the basis of BIS Hand Book wherever applicable. In case sections used are
different from BIS sections, then Manufacturers' Hand Book shall be adopted. No
allowance in weight shall be made for rolling tolerances.
6.1.4. Welds, bolts, nuts, washers, shims, pack plates, wedges, shop painting shall not be
separately measured. The quoted rate shall be deemed to include the same.
6.1.5. The rate shall include all expenses related to safety & security arrangements and all
plants & tools required for fabrication & transportation.
6.2. Payment terms for item for GRATINGS
0000/C.02/0025/A4.
6.2.2. Payment shall be made on the basis of admissible weight in metric tons (determined as
described in clause 6.2.4) of the gratings accepted by the Engineer- incharge.
6.2.3. The rate shall include supplying & fabricating M.S. gratings (purchased from approved
manufacturer) including transporting, handling, cutting to required size and shape,
making holes/notches/openings, smoothening the edges, fabricating clamps, preparing
detailed fabrication drawings, surface cleaning, removal of rust, scale, grease and
galvanising as required, all complete.
6.2.4. The weight for payment shall be determined from the fabrication drawings and
respective bill of materials prepared by the Contractor. The bill of materials shall be
checked and approved by the Engineer-incharge before making the payment. The
weight, shall be calculated on the basis of BIS Handbook as mentioned above. No
allowance in weight shall be made for rolling tolerances.
6.2.5. Welds, bolts, clamps, nuts and washers shall not be measured. The quoted rate shall be
deemed to include the same.
6.3. Payment terms for item for TUBULAR HAND RAILINGS
0000/C.02/0025/A4.
6.3.2. Payment shall be made on the basis of measured length in meters (m) of top rail only
(Horizontal and/or inclined lengths). The rate shall include preparation of fabrication
drawings, supply of all materials, handling, transporting, straightening if required,
cutting to required size, bending, welding, bolting, surface cleaning, removal of rust,
scale, grease and applying one coat of primer as per Specification no. 44NC-4600-
0000/V.02/0111/A4, after fabrication etc. all complete.
Page 379 of 434
DOCUMENT No.
87-C-08 & 87-C-09 Page 7 of 7
6.3.3. The rate shall include making suitable notches in floor plates/gratings for fixing the
vertical posts.
7. SCHEDULE OF QUANTITIES/ RATES
For schedule of quantities refer Document No. A133-086-16-48-SOQ-6141.

For schedule of rates refer Document No. A133-086-16-48-SOR-6141.
Page 380 of 434
Page 1 of 6

MANALI REFINERY , CHENNAI
RESID UPGRADATION PROJECT
TITLE : STANDARD SPECIFICATION FOR
MISCELLANEOUS FABRICATION WORK
DOCUMENT NO: 44NC-4600-0000/C.02/0025/A4
B 121/07/2010 06 Issued for Feed SAP BPS DPC
Issued for Client’s

A 19/04/2010 06 UJK PMP DPC
Comments and Approval
Rev. Rev. Description Prepared Checked Approved

Issue Date Pages
No. By By By
Page 381 of 434

44NC – 4600 FOR MISCELLANEOUS FABRICATION WORK Sheet 2 of 6
DOC NO: 44NC-4600-0000/C.02/0025/A4 Rev. B
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
Specification for Miscellaneous Fabrication Work

Page 382 of 434
DOC NO: 44NC-4600-0000/C.02/0025/A4 Rev. B
1.0 PURPOSE
The purpose of this standard is to define specifications to be followed for miscellaneous

fabrication work.
2.0 SCOPE
The work covered consists of providing & installing all miscellaneous metal work in strict
accordance with the specifications and the applicable drawings. The following work shall normally
be covered under the specifications.
a) Ladders & Rungs

b) Anchor Bolts
c) Sleeves
d) Access Openings in Roof & Air-Tight Hatch Covers
e) Metal Flashings
f) Steel Stairs & Cat Walks
g) Edge Protection Angles
h) M.S. Inserts
j) Hand Rails
k) Anchor Fasteners
l) M.S. Chequered plate
m) Grating
Work included under the Specifications shall be fabricated and installed by the contractor at the
proper time, and as rapidly as progress of the adjacent & connecting work will permit. Work to be
installed by the contractor shall be delivered when required. The contractor shall consult with the
various Agencies installing adjoining work, regarding the methods to be employed in connecting
the several materials. Holes and connections for the work of other trades shall be provided as
necessary. All work shall be erected and secured plumb and true to line, and finished smooth and
free from noticeable irregularities of file marks.
The contractor shall verify all measurements in the field, for the fabricated work to fit the actual
conditions at site. Before starting work, all adjoining work shall be examined. Application of
corrective measures to the adjoining work, may be necessary to make the work comply with the
specifications.
3.1 MATERIALS
The materials for fabrication work covered in the specifications shall be supplied by the
contractor. The M.S. materials shall conform to IS 2062 / IS 432 for tubular sections conform to
IS: 1161and IS:1239 (Part 1), IS : 1239 (Part 2) , for welding conform to IS: 814 , IS:816, IS :
9595 ,IS : 813.
3.2 LADDERS & RUNGS
Steel ladders with cage and rungs shall be provided and installed wherever indicated and as
detailed in the drawings. Necessary accessories, such as base plates, anchor bolts shall also be
provided.
3.3 ANCHOR BOLTS
Anchor bolts shall be made out of steel or iron rod, with pipe sleeves, bent ends or anchor plates
as shown and specified in drawings. Bolts shall be provided with hexagonal head, nuts &
washers. Bolts shall be provided with M.S. sleeves, wherever necessary for adjustment during

Page 383 of 434
DOC NO: 44NC-4600-0000/C.02/0025/A4 Rev. B
erection. The material shall conform to IS 2062 : 2006 Grade ‘B’ ( Fe 410 w ) E250 ( carbon 0.22
% maximum).
3.4 SLEEVES
Sleeves shall be fabricated out of M.S. sheets or YST 25 medium pipes or P.V.C. If load bearing,
they shall be fastened by anchor straps in concrete, and shall be placed at proper elevation as
shown in the drawings. The work shall include providing and fixing sleeves and sealing with
cement grout in manner approved by the owner / consultants.
3.5 ACCESS OPENINGS IN ROOF & AIR - TIGHT HATCH COVERS
These shall be provided in underground ducts & roofs as indicated in the drawings. Access
opening covers shall be of steel and painted as required. Air - tight hatches shall be gasketed
suitably.
3.6 METAL FLASHINGS
Metal flashings shall be installed at locations shown in the drawings to provide water-tight
protection. Exposed edges of all flashings shall be folded back 12 mm to provide stiffness. Cap
flashings shall be secured in metal reglects with the groove filled with caulking compound as
shown in the drawings. The materials of flashings will be either G.I., aluminium or copper as
specified.
3.7 STEEL STAIRS & CAT - WALKS
Steel stairs including cat - walks, wherever shown on the drawings shall be complete with
stringers, treads, risers, cat - walk framing, struts, hangers, bracing, chequered plates, toe plates,
railings and all fastenings and fittings. All work shall be shop fitted and assembled as far as
possible before erection. All work shall be erected square, plumb straight and true. Joints and
intersections shall be accurately fitted and securely braced or anchored.
3.8 EDGE- PROTECTION ANGLES
These shall consist of M.S. angle 50 x 50 x 6mm size with hold-fasts @ 200 mm minimum / c.c.
unless otherwise stated. Hold-fasts shall normally be 8mm M.S. rods approximately 150mm long,
bent to shape and welded within the flanges of the angles.
3.9 M.S.INSERTS
M.S. plate or pipe inserts in concrete or masonry shall be fixed at correct locations and elevations
shown in the relevant drawings. The fabrication of the inserts shall be done in the best applicable
methods to avoid distortion. Hold-fasts shall normally be fully welded unless otherwise specified.
Any parts such as bolts, which are integral part of the insert, shall be carefully handled during
fabrication to avoid damages to threads and shall be accurately positioned prior to and during
welding. The inserts shall be painted with anti –corrosive paint over primer on exposed surfaces
after placement. Any modifications after placement in concrete particularly with gas-cutting shall
be avoided.
3.10 HAND RAILS
This shall consist of M.S. angle / M.S. pipes and two runners at top and mid height of the post.
Wherever necessary, the plates shall be provided. The construction shall be welded type unless
otherwise specified. The vertical posts shall be M.S. angle 50x50x6 / 32 NB or 40 NB ‘B’ class
pipe or as specified in drawings and shall be placed at 1.5M max spacing unless otherwise

Page 384 of 434
DOC NO: 44NC-4600-0000/C.02/0025/A4 Rev. B
specified. The height shall be 1050 mm. The mid rail 32 NB or 25 NB B class pipe / structural
steel shall be welded as shown on the drawing and specified elsewhere.
Fabrication, in general, shall be as shown on the drawings and specified elsewhere. Toe plate of
100 x 6 M.S. flat shall be provided whenever called out. The handrail top shall be wooden or M.S.
pipe fixed as per detail drawing.
The painting of shop shall be done after usual surface preparation.
3.11 M.S.CHEQUERED PLATES
The material shall conform to IS 2062 / IS 3502 . The thickness of the chequered plate shall be
as specified in the drawings. The plates shall either be tack-welded / seal-welded to the
supporting structure or shall be fixed by the counter - sunk bolts, as required. The plate shall be
fixed in regular shapes and the intermediate joints shall be welded types. Care shall be taken to
avoid distortion of the plate while welding. The M.S. stiffening angle shall be specifically shown in
the relevant drawings. Openings and cuts shall be provided wherever necessary to allow service
piping and / or cables to pass through. Wherever necessary, vertical edge strips shall be
provided. The rate of chequered plates shall be deemed to include all the work necessary and as
described in the preceding lines and shall also cover one shop coat of red-oxide primer.
3.12 ANCHOR FASTNERS
These shall be of the best locally available make, and shall be approved by the Consultants
before using the same. The anchor fasteners type, diameter shall be as per the loading for
holding up minor / medium/ heavy structural works and equipments in concrete or masonry as
required. It shall be as per manufacture’s specification.
3.13 PREFABRICATED ELECTROFORGED GRATING
Grating shall be designed for min. 500 Kg load over 1 sq. m area or as desired by Owner /
Consultant.
Electroforged grating shall conform to BS 4592. The electroforged grating shall have hot dip
galvanized finish as per IS 2629 / ASTM 123 / BS 729. Minimum thickness of galvanizing shall
be 120 microns.
Flats / Twisted cross bars to be pressed and simultaneously resistance welded into solid bearing
flats to obtain perfectly homogeneous forged weld at every intersection without any air gaps to
give the grating panels high stability, maximum strength & optimum load distribution.
The entire manufacturing process shall be programmed & controlled to achieve forge weld that
provide incomparable resistance to twisting and bending distortions along with dimensional
accuracy.
The top surface of the grating should be non-skid / plain. Sprays for the galvanization shall be
used when grating are cut to form openings at site to return the galvanization.
The Vendor shall provide all necessary non-corrosive clamps, fixtures required as per connection
developed.
Strengthening at cutout location to be done in grating as per requirement.
It shall be electroplated or stainless steel depending on the location of usage as directed by

Owner / Consultant. Mechanical or chemical type shall be decided at designing state and all the
work done as per manufacture specification.

Page 385 of 434
DOC NO: 44NC-4600-0000/C.02/0025/A4 Rev. B
Product shall be guaranteed for a minimum life of 5 years.
3.14 FRP GRATING
FRP grating of minimum 30mm thick of Vinylester based resin material of approved make
shall be used where grating would be subjected to acid attack.
3.15 CAST - IRON GRATING
The grating shall be manufactured from grey cast - iron conforming to grade 15 of IS - 210. The
cast - iron grating shall conform to IS - 5961 and as specified on the drawing.

Page 386 of 434
Page 1 of 45

CHENNAI, INDIA
PART : III
SECTION : B.12
TITLE: GENERAL SPECIFICATION FOR SHOP AND FIELD PAINTING
DOCUMENT NO. : 44NC-4600-0000-V.02-0111-A4
REV ISSUE DATE PAGES REV DESCRIPTION PREPARED CHECKED APPROVED

NO. BY BY BY

Revised as marked and issued
1 08.07.2010 45 SNK MS HSC
for FEED
Page 387 of 434

TABLE OF CONTENTS
1.0 General
2.0 Scope
3.0 Codes & Standards
4.0 Equipment
5.0 Surface Preparation
6.0 Paint Materials
7.0 Paint Systems
7.1 Pre-erection / Pre-fabrication and shop priming for carbon steel, low temperature carbon
steel & low alloy steel, un-insulated and insulated steel structures, piping and equipment,
etc.,
7.2 Repair of pre-erection /fabrication and shop priming after erection / welding for carbon steel,
low temperature carbon steel & low alloy steel uninsulated and insulated items in all
environments.
7.3 Repair of all weld joints and damages of galvanized steel, carbon steel and alloy steel
structures, piping and equipment after erection on above ground / overhead areas at site.
8.0 Field paint system for normal corrosive environment (for carbon steel, low temperature
carbon steel and low alloy steel)
9.0 Field paint system for corrosive areas in plant (for carbon steel, low temperature carbon
steel and low alloy steel)
10.0 Field paint system for highly corrosive areas in plant (for carbon steel, low temperature
carbon steel and low alloy steel)external surfaces of piping & equipment
11.0 Field paint system for carbon steel storage tanks (internal & external) for all environment
and areas
12.0 Coating system for external side of underground carbon steel plant piping and tanks
13.0 Painting under insulation for (hot, cold & safety) Carbon Steel plant piping and tanks
14.0 Internal protection of Carbon Steel water boxes and tube sheets of cooler condensers
15.0 Field painting system for GI towers / Non-Ferrous tueb sheet
16.0 Shop & Field painting system for Effluent treatment plant
17.0 Storage
18.0 Color code for piping as per CPCL
19.0 Identification of vessels, piping, etc.,
20.0 Painting for civil defence requirements
21.0 Inspection and testing
22.0 Guarantee
23.0 Qualification criteria of painting contractor
Annexure-1 List of Recommended manufacturers

Annexure-2 Paint colour code for Piping & Equipment as given by CPCL
Page 388 of 434

1.0 GENERAL
1.1 These technical specifications shall be applicable for the work covered by the contract and
without prejudice to the various codes of practice, standard specifications, etc. It is understood
that Contractor shall carry out the work in all respects with the best quality of materials and
workmanship and in accordance with the best engineering practice and instructions of Engineer-
in-Charge.
1.2 1 Wherever it is stated in the specification that a specific material is to be supplied or a specific
work is to be done, it shall be deemed that the same shall be supplied or carried out by the
contractor. Any deviation from this standard without written deviation permit from appropriate
authority will result in rejection of job.
2.0 SCOPE
2.1 Scope of work covered in the specification shall include, without being limited to the following
2.1.1 This specification defines the requirements for surface preparation, selection and application of
paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures,
external & internal protection of storage tanks for all services. MS chimney without refractory
lining and flare lines etc. The items listed in the heading of tables of paint systems is indicative
only, however the contractor is fully responsible for carrying out all the necessary painting,
coating and lining on external and internal surfaces as per the tender requirement.
2.2 Extent of Work
2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting :
a. All un-insulated C.S & A.S equipment like columns, vessels, drums, storage tanks, heat
exchangers, pumps, compressors, electrical panels and motors etc., and tanks and
equipment in ETP plant.
b. All un-insulated carbon and low alloy piping fittings and valves (including painting of
identification marks), furnace, ducts and stacks.
c. All items contained in a package unit as necessary.
d. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders,
platforms, etc.
e. External surfaces of MS chimneys without refractory lining & flare lines.
f. Identification color bands on all piping as required including insulated aluminum clad,
galvanized, SS and nonferrous piping.
g. Identification lettering / numbering on all painted surfaces of equipment / piping insulated

aluminum clad, galvanized, SS and non-ferrous piping.
h. Marking / identification signs on painted surfaces of equipment / piping hazardous service.
i. Supply of all primers, paints and all other materials required for painting other than Owner’s
supply.
j. Over insulation surface of equipments and pipes wherever required.
k. Painting under insulation for carbon steel, alloy steel and stainless steel as specified. 1
Page 389 of 434

l. Repair work of damaged / pre-erection / fabrication shop primer and weld joints at field.
m. Internal surfaces of RCC tanks and structures in Effluent Treatment Plant.
2.2.2 The following surfaces and materials shall not require painting in general. However, if there are
any specific requirement by the Owner, the same shall be painted as per the relevant
specifications:
a. Un-insulated austenitic stainless steel

b. Plastic and / or plastic coated materials.
c. Non-ferrous materials like Aluminum, galvanized “piping”, “gratings” and “Handrails” etc.
except G.I. Tower.
2.3 Unless otherwise instructed final painting on pre-erection / shop primed pipes and equipments
shall be painted in the field, only after the mechanical completion, testing on systems are
completed as well as after completion of steam purging wherever required.
2.4 Changes and deviations required for any specific job due to clients requirements or otherwise
shall be referred to Jacobs for deviation permit.
3.1 Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the
contract, the following codes and standards shall be followed for the work covered by the
contract.
Color coding Color coding inspection manual for piping issued by CPCL (Ref.
Annexure-2) 1
IS-101 Methods of test for ready mixed paints and enamels.
ASTM American standard test methods for paints and coatings.
ASA A 13.1-1981 Scheme for identification of piping systems: American National Standards
Institution.
3.2 Surface Preparation Standards
Following standards shall be followed for surface preparations
3.2.1 Swedish Standard – SIS-05 5900-1967 (surface preparation standards for painting steel surfaces)
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.
3.2.2 Steel Structures Painting Council, U.S.A (Surface Preparation Specifications (SSPC-SP).
3.2.3 British Standards (Surface Finish of Blast-Cleaned for Painting) BS-4232.
3.2.4 National Association of Corrosion Engineers, U.S.A (NACE).
3.2.5 Various International Standards equivalent to Swedish Standard for surface preparations are
given in Table-I.
3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of above standards
and codes at site.
Page 390 of 434

3.4 The paint manufacturer’s 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 recommended limit on time intervals between coats.
e. Suggested Quality assurance procedures.
4.0 EQUIPMENT
4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning, inspection
instruments, e.g. surface profile gauges, holiday detectors, pin hole detectors, dry film thickness
gauges, etc. and all equipments, scaffolding materials, shot blasting equipments like hooper, grit
etc & air compressors, etc., required to be used shall be suitable for the work and all in good
order and shall be arranged by the Contractor at site and in sufficient quantity. 1
4.2 Mechanical mixing shall be used for paint mixing operations in case of two pack systems except
that the Engineer-in-Charge may allow the hand mixing of small quantities at his discretion.
5.0 SURFACE PREPARATION, SHOP, COATING APPLICATION & REPAIR AND

DOCUMENTATION
5.1 General
5.1.1 In order to achieve the maximum durability, blast cleaning is considered the most desirable
method to achieve required profile however one or more of following methods of surface
preparation shall be followed, depending on conditions of steel surface and as instructed by
Engineer-in-Charge. Adhesion of the paint film to surface depends largely on the degree of
cleanliness and surface profile of the metal surface. Proper surface preparation contributes more
to the success of the paint protective system.
a) Manual or hand tool cleaning

b) Mechanical or power tool cleaning.
c) Blast cleaning. NO sand shall be used. Only grit blasting shall be allowed. 1
5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and dry
surface is obtained. The minimum acceptable standard in case of manual or hand tool cleaning
shall be St. 2 or equivalent, in case of mechanical or power tool cleaning it shall be St. 3 or
equivalent in case of blast cleaning it shall be Sa 2-1/2 OR equivalent as per Swedish Standard
SIS-055900-1967 or equivalent. Where highly corrosive conditions exist, then blast cleaning shall
be Sa 3 as per Swedish Standard.
Remove all other contaminants, oil, grease, etc. by use of an aromatic solvent prior to surface
cleaning.
5.1.3 Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such
cleaning or during humid weather conditions having humidity exceed 85%.
Page 391 of 434

5.1.4 Irrespective of the method of surface preparation, the first coat of primer must be applied by
airless spray gun on dry surface No brush shall be used except for touchup. This should be done
immediately and in any case within 4 hours of cleaning of surface. However, at times of
unfavorable weather conditions, the Engineer-In-Charge shall have the liberty to control the time
period, at his sole discretion and / or to insist on re-cleaning, as may be required, before primer
application is taken up. In general, during unfavorable weather conditions, blasting and painting
shall be avoided as far as practicable. 1
5.1.5 The external surface of RCC chimney to be painted shall be dry and clean. Any loose particle of
sand, cement, aggregate etc., shall be removed by scrubbing with soft wire brush if necessary
acid etching with 10-15% HCl solution for about 15 minutes shall be carried and surface must be
thoroughly washed with water to remove acid & loose particles then dry completely before
application of paint.
5.2 Procedure of Surface Preparation :
5.2.1 Blast Cleaning
5.2.1.1 Air Blast Cleaning
The surfaces shall be blast cleaned using one of the abrasives Al2O3 particles chilled cast iron or
malleable iron and steel at pressure of 7 Kg /cm2 at appropriate distance and angle depending of
nozzle size maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel
shall be in the form of shot or grit of size not greater than 0.055” maximum in case of steel and
malleable iron and 0.04” maximum in case of chilled iron. Compressed air shall be free from
moisture and oil. The blasting nozzles should be venturi style with tungsten carbide or boron
carbide as the materials for liners. Nozzles orifice may vary from 3/16” to ¾”. On completion of
blasting operation, the blasted surface shall be clean and free from any scale or rust and must
show a grey white metallic luster. Primer or first coat of paint shall be applied within 4 hours of
surface preparation. Blast cleaning shall not be done outdoors in bad weather without adequate
protection or when there is dew on the metal, which is to be cleaned. Surface profile shall be
uniform to provide good key to the paint adhesion (i.e. 35 to 50 microns). If possible vacuum
collector shall be installed for collecting the abrasives and recycling.
5.2.1.2 Water Blast cleaning
Environmental, health and safety problems associated with abrasive blast cleaning limit the
application of Air Blast Cleaning in many installations. In such case water blast cleaning is
resorted to.
Water Blast Cleaning can be applied with or without abrasive and high pressure water blasting.
The water used shall be inhibited with sodium chromate / phosphate. The blast-cleaned surface
shall be washed thoroughly with detergents and wiped with solvent and dried with compressed
air. For effective cleaning abrasives are used. The most commonly used pressure for high
pressure water blast cleaning for maintenance surface preparation is 3000 to 6000 psi at 35-45
lit/minute water volume and pressures upto 1000 psi and water volume at 45 lit/minute provide
maximum cleaning.
The water blast cleaned surface shall be comparable to SSPC-SP-12/nace No. 5. The operation
shall be carried out as per SSPC guidelines for water blast cleaning. The indicative values for
sand injection is :
Air : 300 to 400 Cu. Ft. / min

Water : 5-10 lit/min. with corrosion inhibitor
Sand : 200-400 lbs/hr.
Nozzle : 0.5 to 1” dia.
Page 392 of 434

Special equipments for water blast cleaning with abrasives, now available, shall be used.
5.2.2 Mechanical or Power Tool Cleaning
Power tool cleaning shall be done by mechanical striking tools, Chipping hammers, grinding
wheels or rotating steel wire brushes. Excessive burnish of surface shall be avoided as it can
reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be
removed by clean rags and / or washed by water or stream and thoroughly dried with compressed
air jet before application of paint.
5.2.3 Manual or hand tool cleaning
Manual or hand tool cleaning is used only where safety problems limit the application of other
surface preparation procedure and there is approach problem in certain areas and hence does
not appear in the tables of paint systems.
Hand tool cleaning normally consists of the following :
a. Hand descaling and / or hammering

b. Hand scraping
c. hand wire brushing
Rust, mill scale spatters, old coatings and other foreign matter, shall be removed by hammering,
scrapping tools, emery paper cleaning, wire brushing or combination of the above methods. On
completion of cleaning, loose material shall be removed from the surface by clean rags and the
surface shall be bushed, swept, dusted and blow off with compressed air/steam to remove all
loose matter. Finally the surface may be washed with water and dried for effective cleaning.
5.3 Non-compatible shop coat primer
The compatibility of finishing coat should be confirmed from the paint manufacturer. In the event
of use of primer such as zinc rich epoxy, inorganic zinc silicate etc., as shop coat, the paint
system shall depend on condition of shop coat. If the shop coat is in satisfactory condition
showing no major defect, the shop coat shall not be removed. However a non-compatible primer
shall have to be removed before application of compatible paint system for the environment. The
touch up primer and finishing coat(s) shall be identified for application by Engineer-in-Charge.
5.4 Shop coated (coated with primer & finishing coat) equipment should not be repainted unless paint
is damaged.
5.5 Shop primed equipment and surfaces will only be ‘spot cleaned’ in damaged areas by means of
power tool brush cleaning or hand tool cleaning and then spot primed before applying one coat of
field primer unless otherwise specified. If shop primer is not compatible with field primer then
shop-coated primer should be completely removed before application of selected paint system for
particular environment.
5.6 For Package units / equipment, shop primer should be as per the paint system given in this
specification. However, manufacturer’s standard can be followed after review.
5.7 Coating Procedure and Application
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious airborne elements
0
exists, when the steel surface temperature is less than 5 F above dew point when the relative
0
humidity is greater than 85% or when the temperature is below 40 F.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hrs. the same day.
Page 393 of 434

5.7.3 To the maximum extent practicable, each coat of material shall be applied as a continuous film
uniform thickness free of probes. Any spots or areas missed in application shall be recoated and
permitted to dry before the next coat is applied. Applied paint should have the desired wet film
thickness.
5.7.4 Each coat shall be in proper state of cure or dryness before the application of succeeding coat.
Material shall be considered dry for recoating when an additional coat can be applied without the
development of any detrimental film irregularities, such as lifting or loss of adhesion of the under
coat. Manufacturer instruction shall be followed for inter-coat interval.
5.7.5 When the successive coat of the same color have been specified, alternate coat shall be tinted,
when practical, sufficiently to produce enough contrast to indicate complete coverage of the
surface. The tinting material shall be compatible with the material and not detrimental to its
service life.
5.7.6 Deleted 1
5.7.7 Airless spray application shall be in accordance with the following procedure : as per steel
structure paint Manual Vol. 1 & Vol. 2 by SSPC, USA. Air less spray relies on hydraulic pressure
rather than air atomization to produce the desired spray. An air compressor or electric motor is
used to operate a pump to produce pressures of 1000 to 6000 psi, paint is delivered to the spray
gun at this pressure through a single hose within the gun, a single paint stream is divided into
separate streams, which are forced through a small orifice resulting in atomization of paint without
the use of air. This results in more rapid coverage with less over spray. Airless spray usually is
faster, cleaner, more economical and easier to use than conventional air spray.
Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint
from any container, including drums. The unit shall have inbuilt agitator that keep the paint
uniformly mixed during the spraying. The unit shall consist of inbuilt strainer. Usually very small
quantity of thinning is required before spray. In case of high build epoxy coating (two pack), 30:1
pump ratio and 0.020-0.023” tip size will provide a good spray pattern. Ideally fluid hoses should
not be less than 3/8” ID and not longer than 50 ft. to obtain optimum results.
In case of gun choking, de-choking steps shall be followed immediately.

5.7.8 Brush application of paint shall be in accordance with the following :
a. Brushes shall be of a style and quality that will enable proper application of paint.
b. Round or oval brushes are most suitable for rivets, bolts, irregular surface and rough or pitted
steel. Wide flat brushes are suitable for large flat areas, but they shall not have width over
five inches.
c. Paint shall be applied into all corners.
d. Any runs or sags shall be brushed out.
e. There shall be a minimum of brush marks left in the applied paint.
f. Surfaces not accessible to brushes shall be painted by spray, doubaers or sheepskin.
5.7.9 Manual application by sling (where 6 o’ clock position of pipe is not approachable)
A canvas strip (alternatively a tinplate strip) about 450mm wide and 1.5m long is held under the
pipe by two men holding this sling move it up and down and walk slowly forward while fresh
coating is poured on the pipe and they manipulate the sling so that an even coating is obtained all
round the bottom. This work shall be done very carefully and by experienced personnel. There
shall not be any formation of “Whiskers” and holes in the coating. The coating film shall be
inspected by mirror.
Page 394 of 434

5.7.10 For each coat the painter should know the WFT corresponding to the specified DFT and
standardize the paint application technique to achieve the desired WFT. This has to be ensured
in the qualification trial.
5.8 Drying of coated surfaces
5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be considered dry
for re-coating when another coat can be applied without the development of any film irregularities
such as lifting or loss of adhesion of undercoats. Drying time of the applied coat should not
exceed maximum specified for it as a first coat; if it exceeds the paint material has possibly
deteriorated or mixing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause checking, wrinkling, blistering
formation of pores, or detrimentally affect the conditions of the paint.
5.8.3 No drier shall be added to paint on the job unless specifically called for in the manufacturer’s
specification for the paint.
5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dry to
the fullest extent practicable.
5.9 Repair of damaged paint surface
5.9.1 Where paint has been damaged in handling and in transportation, the repair of damaged coating
of pre-erection / fabrication shall be as given below.
5.9.2 Repair of damaged inorganic zinc silicate primer after erection / welding.
Quickly remove the primer from damaged area by mechanical scrapping and emery paper to
expose the white metal. Blast clean the surface if possible. Feather the primer over the intact
adjacent surface surrounding the damaged area by emery paper.
0 0
5.9.3 Repair of damaged pre-erection and shop priming in the design temperature of –90 C to 400 C
• Surface preparation shall be done as per procedure 5.9.2
• One coat of F-9 shall be applied wherever damage was observed on pre-erection / pre-
fabrication / shop primer of inorganic zinc silicate coating (F-9).
5.10 Paint Application
5.10.1 Shop priming / pre-erection priming with F9 or F12 shall be done only on blasted surface.
5.10.2 Shop priming / pre-erection priming with F9 shall be done only with airless spray.
5.10.3 For large flat surface field painting shall be done by airless spray otherwise brush can be used.
5.11 Documentation
5.11.1 A written quality plan with procedure for qualification trials and for the actual work.
5.11.2 Daily progress report with details of weather conditions, particular of applications, no. of coats
and type of materials applied, anomalies, progress of work versus program.
5.11.3 Results of measurement of temperatures relative humidity, surface profile, film thickness, holiday
detection, adhesion tests with signature of appropriate authority.
5.11.4 Particulars of surface preparation and paint application during trials and during the work.
Page 395 of 434

5.11.5 Details of non-compliance, rejects and repairs.
5.11.6 Type of testing equipments and calibration.
5.11.7 Code and batch numbers of paint materials used.
Page 396 of 434

TABLE-1 (FOR CLAUSE 5.0)
SURFACE PREPARATION STANDARDS
VARIOUS INTERNATIONAL STANDARDS

(EQUIVALENT)
SR.
DESCRIPTION BRITISH REMARKS
NO. Swedish SSPC-
NACE STANDAR
Standard SP
USA D
SIS-05- USA
BS-4232
5900
1. Manual or hand tool ST.2 SSPC- -- -- This method is applied
cleaning. SP-2 when the surface is
exposed to normal
Removal of loose rust, atmospheric conditions
loose mill scale and loose when other methods
paint, chipping, scrapping, cannot be adopted and
standing and wire brushing. also for spot cleaning
Surface should have a faint during maintenance
metallic sheen. painting.
2. Mechanical or power tool ST. 3 SSPC- -- --
cleaning. SP-3
Removal of loose rust,
loose mill scale and loose
paint to degree specified by
power tool chipping,
descaling, sanding, wire
brushing and grinding, after
removal of dust, surface
should have a pronounced
metallic sheen.
3. Blast cleaning (air & water)
There are four common
grades of blast cleaning
3.1 White metal SA.3 SSPC- NACE First Where extremely clean
Blast cleaning to white SP-5 #1 Quality surface can be
metal cleanliness. expected for prolong
Removal of all visible rust. life of paint system.
Mill sale, paint & foreign
matter 100% cleanliness
with desired surface profile.
Page 397 of 434

3.2 Near white metal SA 2 ½ SSPC- NACE Second The minimum

SP-10 #2 Quality requirement for
chemically resistant
paint systems such as
epoxy, vinyl,
polyurethane based
and inorganic zinc
silicate paints, also for
conventional paint
systems used under
fairly corrosive
conditions to obtain
desired life of paint
system.
3.3 Commercial Blast SA 2 SSPC- No. 3 Third For steel required
Blast cleaning until at least SP-6 Quality to be painted with
two-third pf each element of conventional paints for
surface are is free of all exposure to mildly
visible residues with corrosive atmosphere
desired surface profile for longer life of the
paint systems.
3.4 Brush-off Blast SA 1 SSPC- No. 4
Blast cleaning to white SP-7
metal cleanliness, removal
of all visible rust, mill scale,
paint & foreign matter.
Surface profile is not so
important.
Page 398 of 434

6.0 PAINT MATERIALS
Paint manufacturers shall furnish the characteristics of all paints materials on printed literature
along with the test certificate for all specified characteristics given in this specification. All the paint
materials shall be on first quality and conform to the following general characteristics. As per the
tables 6.1, 6.2 and 6.3.
TABLE No. 6.1 PRIMERS
Sr.
Description P-2 P-4 P-6
No.
1. Technical Name Chlorinated rubber Etch primer / Epoxy zinc phosphate

Zinc Phosphate primer wash primer primer
2. Type and Single pack, air drying Two pack Two component polyamide
composition chlorinated rubber based polyvinyl butyral cured epoxy resin medium-
medium plasticised with resin medium pigmented with zinc
unsaponifiable plasticizer, cured with phosphate.
pigmented with zinc phosphoric acid
phosphate solution
pigmented with
zinc tetroxy
chromate
3. Volume Solids 40% 7-8% 40%

(approx.)
4. DFT (Dry Film 40-45µ 8-10µ 40-50µ

thickness) per
coat (approx.)
5. Theoretical 8-10 8-10 8-10

covering capacity
2
in M /coat/litre
(approx.)
6. Weight per liter in 1.3 1.2 1.4

kgs/liter (approx)
7. Touch dry at 30 minutes 2 hrs. After 30 min.

0
30 C (approx.)
0
8. Hard dry at 30 C 24 hrs. 24 hrs. 24 hrs.
(approx.)
9. Over coating Min: 8 hrs. Min: 4-6 hrs. Min.: 8 hrs.

interval (approx.) Max. : No limitations Max. : 24 hrs. Max. : 3-6 months
10. Pot life (approx) Not applicable Not applicable 8 hrs.

0
at 30 C for two
component paints
(approx.)
Page 399 of 434

Sr. Description F-2 F-3 F-6A/F-6B F-7

No.
1. Technical Acrylic Chlorinated rubber Epoxy high High build coaltar

Name polyurethane based finish paint build finish paint epoxy coating.
finish paint
2. Type and Two-pack Single pack Two pack Two pack polyamide
composition aliphatic plasticized polyamine (F- cured epoxy resin
isocynate cured chlorinated rubber 6A) / polyamide blended with coaltar
acrylic finish based medium (F-6B) cured medium, suitably
paint with chemical and epoxy resin pigmented.
weather resistant medium suitably
pigments pigmented
3. Volume Solids 40% 40% 62% 65%

(approx.)
4. DFT (Dry Film 30-40µ 40-45µ 100-125µ 100-125µ

thickness) per
coat (approx.)
5. Theoretical 10-13 8-10 5-6 5.2-6.5

covering
capacity in
2
M /coat/litre
(approx.)
6. Weight per liter 1.3 1.2 1.4 1.5

in kg/liter
(approx)
7. Touch dry at 1 hr. 30 minutes 3 hrs. 4 hrs.

0
30 C (approx.)
8. Hard dry at Overnight 8 hrs. Overnight 48 hrs.

0
30 C (approx.)
9. Over coating Min : Overnight Min : Overnight Min : Overnight Min. : 24 hrs.
interval (12 hrs.) Max. : Unlimited Max : 5 days Max. : 5 days
(approx.) Max. : Unlimited
10. Pot life 6-8 hrs. Not applicable 4-6 hrs. 4-6 hrs.
(approx) at
0
30 C for two
component
paints (approx.)
Page 400 of 434

Sr. Description F-8 F-9 F-11 F-12

No.
1. Technical Name Self priming type Inorganic zinc Heat resistant Heat resistant silicone
surface tolerant silicate coating synthetic medium aluminum paint suitable
0 0
high build epoxy based on two pack upto 500 C / 550 C dry
coating (complete Aluminum paint temp.
rust control suitable upto
0
coating) 250 C dry temp.
2. Type and Two-pack epoxy A two pack air Heat resistant Single pack silicone resin
composition resin based drying self curing synthetic medium based medium with
suitable solvent based based two pack Aluminum flakes.
pigmented and inorganic zinc Aluminum paint
capable of silicate coating suitable upto
0
adhering to 250 C
manually
prepared surface
and old coating.
3. Volume Solids 72% 60% 25% 20%

(approx.)
4. DFT (Dry Film 100-125µ 65-75µ 20-25µ 20-25µ

thickness) per coat
(approx.)
5. Theoretical covering 6.0-7.2 8-9 10-12 8-10

capacity in
2
M /coat/litre
(approx.)
6. Weight per liter in 1.4 2.3 1.2 1.1

kg/liter (approx)
0
7. Touch dry at 30 C 3 hrs 30 minutes 3 hrs. 30 min
(approx.)
0
8. Hard dry at 30 C 24 hrs 12 hrs. 12 hrs. 24 hrs
(approx.)
9. Over coating interval Min : 10 hrs Min : 8 hrs at Min : 16 hrs Min. : 16 hrs
0
(approx.) Max. : 6 months 20 C & 50% RH Max : Unlimited Max. : Unlimited
Max. : Unlimited
10. Pot life (approx) at 90 min 4-6 hrs Not applicable Not applicable
0
30 C for two
component paints
(approx.)
0 0
11. Temperature - - 250 C 500 C
Resistance
Page 401 of 434

Sl. DESCRIPTION F-14 F-15 F-16

No
1 Technical name Polyamine cured Epoxy phenolic Ambient temperature curing Poly
coal tar epoxy coating Siloxane/ inorganic copolymer
based aluminium coating suitable
for under insulation coating of CS
and SS piping for high
temperature service
2 Type and Specially formulated Two pack ambient Amercoat 738 from Ameron
composition polyamine cured temperature curing Products, USA/ Berger 938 from
coal tar epoxy epoxy phenolic coating Berger Paints Ltd., Kolkata or
suitable for suitable for application Intertherm 751 CSA from Akzo
application under under insulation Nobel coating, Bangalore.
insulation
3 Volume Solids 70% 65% 60%

(approx.)
4 DFT (Dry Film 125 urn 75-100 urn 75-100 urn

thickness) per coat
(approx.)
5 Theoretical covering 5.5 6.5-8.5 6.0- 8.0

capacity in M2/ coat/
litre (approx.)
6 Weight per liter in 1.5 1.7 1.3
kg/ litre (approx.)
7 Touch dry at 30°C 4hrs 2 hrs 1hr
(approx.)
8 Hard dry at 30°C 168hrs(7days) 168 hrs (7 days) 12 hrs

(approx.)
9 Over coating Min. 6 hrs Min. 36 hrs Max. Min. 16 hrs Max. Not applicable
interval (approx.) Max.5 days 21 days
10 Pot life (approx.) at 4 hrs 1.5 hrs 1hr
30°C for two
component paints
(approx.)
11 Temperature -45°Cto150°C under -45°C to 150°C under Up to 400 deg. C for CS & SS
Resistance insulation insulation surfaces under insulation
0 0
F-14 Specially formulated polyamide cured Coal-tar epoxy suitable for –45 C to 125 C for application
under insulation.
0 0
F-15 Two pack ambient temperature curing epoxy phenolic coating suitable for –45 C to 125 C for
application under insulation.
F-16A Engineered polysiloxane coating : Amercoat 738 from Ameron Products, USA
F-16B Engineered poly siloxane coating : Berger 938 from Berger Paints Ltd., Kolkatta
Page 402 of 434

NOTES
1 Covering capacity and DFT depends on method of application. Covering capacity specified above
are theoretical. Allowing the losses during application, min. specified DFT should be maintained.
2. All primers and finish coats should be ambient temperature curing and air drying unless otherwise
specified.
3. All paints shall be applied in accordance with manufacturer’s instructions for surface preparation,
intervals, curing and application. The surface preparation, quality and workmanship should be
ensured.
4. Technical data sheets for all paints shall be supplied at the time of submission of quotations.
6.4 List of recommended Manufacturers
The paints shall conform to the specifications given above and best quality in their products range of
manufacturers listed in Annexure-I.
Page 403 of 434

7.0 PAINT SYSTEMS
The paint system should vary with type of environment envisaged in and around the plants. Three
types of environment as given below are considered for selection of paint system. The paint system
is also given for specific requirements.
PRIMERS & FINISH COATS COVERED IN TABLE NOS. 7.0 TO 15.0
PRIMERS
P-2 : Chlorinated rubber zinc phosphate primer
P-4 : Etch primer / wash primer
P-6 : Epoxy zinc phosphate primer
Finish Coats / Paints
F-1 : First quality corrosion resistant synthetic enamel
F-2 : Acrylic – Polyurethane finish paint
F-3 : Chlorinated rubber finish paint
F-6A : High build epoxy finish coating cured with polyamine hardner
F-6B : High Build epoxy finish coating cured with polyamide hardner
F-7 : High build coal tar epoxy coating
F-8 : Self priming surface tolerant high build epoxy coating
F-9 : Inorganic zinc silicate coating
F-11 : Heat resistant synthetic medium based aluminium paint
F-12 : Heat resistant silicone aluminium paint

0
F-14 : Specially formulated polyamine cured coal for epoxy coating suitable upto 150 C
F-15 : Epoxy phenolic coating
F-16A : Epoxy siloxane coating : Amercoat 738
F-16B : Epoxy siloxane coating Berger 938
Page 404 of 434

TABLE 7.1 : SHOP PRIMING, PRE-ERECTION / PRE-FABRICATION FOR STRUCTURES,

PIPING & EQUIPMENT ETC.
Materials : CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL,
STEEL

0
No. Temperature in C Preparation in Microns
(min.)
7.1.1 -90 to 400 SSPC-SP-10 1 coat of F-9 65-75 No over coating is to be done
7.1.2 401 to 500 SSPC-SP-10 1 coat of F-12 40-50 Finish coat at site
TABLE 7.2 : REPAIR OF SHOP PRIMING, PRE-ERECTION / PRE-FABRICATION AFTER

ERECTION / WELDING FOR ITEMS IN ALL ENVIRONMENTS

0
in C
7.2.1 -90 to 400 SSPC-SP-3 (for repair only) 1 coat of F-9 65-75
SSPC-SP-10
7.2.2 401 to 500 SSPC-SP-3 (for repair only) 2 coats of F-12 40-50
SSPC-SP-10
TABLE 7.3 : REPAIR OF ALL WELD JOINTS AND DAMAGES FOR STRUCTURES, PIPING
AND EQUIPMENT AFTER ERECTION ON ABOVE GROUND OVERHEAD AREAS
AT SITE
Materials : GALVANIZED STEEL, CARBON STEEL AND ALLOY STEEL

0
in C
7.3.1 -14 to 80 SSPC-SP-3 1 coat of F-8 100
7.3.2 81 to 500 SSPC-SP-3 1 coat of F-12 20
Page 405 of 434

TABLE 8 : FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT IN OFFSITE

AREAS FOR STRUCTURES, PIPING, EQUIPMENT, FLARE LINES ETC. -
UNINSULATED
TYPE : UNINSULATED

No Temperat Preparation in Microns
. ure in 0C (min.)
Field Primer Finish paint
-90 to -15 SSPC-SP-10 Repair of None 65-75 No over coating to be

8.1 done. Follow repair
pre-fabrication
primer 1 coat of procedure only on
F-9 @ 65-75 µ damaged areas of
DFT/coat pre-erection / pre-
fabrication primer /
-14 to 60 SSPC-SP-10 Repair of 2 coats of F-3 225 Coating F-9 / F-12 shall
8.2
pre-fabrication @ 40 µ DFT/ be ambient
primer 1 coat of Coat 2x40=80 temperature curing
F-9 @ 65-75 µ type till operating
DFT/coat + 2 temperature is attained
coats of P-2 @ for full curing.
40 µ DFT/Coat
2x40=80
61 to 80 SSPC-SP-10 Repair of 1 coat of F- 245
8.3
pre-fabrication 6B@ 100 µ
primer 1 coat of DFT/Coat
F-9 @ 65-75 µ
DFT/coat + 2
coats of P-6 @
40 µ DFT/Coat
2x40=80
81 to 250 SSPC-SP-10 Repair of 3 coats of F-12 125
8.4
pre-fabrication @ 20 µ DFT/
F-9 @ 65-75 µ
DFT/coat
8.5 251 to SSPC-SP-10 Repair of 2 coats of F-12 105
400 pre-fabrication @ 20 µ DFT/
F-9 @ 65-75 µ
DFT/coat
8.6 401 to SSPC-SP-10 Repair as per 2 coats of F-12 80
500 7.2.2. @ 20 µ DFT /
Coat 2x20=40
NOTE 1 : For external surfaces of MS chimney with or without refractory lining 8.3, 8.4 and 8.5 shall
be followed.
NOTE 2 : For external surfaces of RCC chimney: 2 coats of F-6B @ 100µ DFT/Coat to obtain
2x100=200 µ DFT shall be applied after making surface preparation as per guidelines in
5.1.5. The DFT on concrete surfaces can be checked by Tool Gauge or by applying the
same coating system simultaneously on a carbon steel panel of 12"x12" size and measure
the DFT by normal Magnetic gauges/digital electronic gauges for ferrous surfaces.
Page 406 of 434

NOTE 3 : Wherever required S.No.8.3 shall be used for -14°C to 80°C and S.No.8.2 will be deleted.
TABLE 8 A : FIELD PAINT SYSTEM FOR CORROSIVE ENVIRONMENT IN PLANT AREA

Note :
For all corrosive areas above ground where H2S, SO2 fumes or spillages of
acid/Alkali/Salt are likely to come in contact with surfaces such as external surfaces of
un-insulated columns, vessels, heat exchangers, blowers, piping, pumps, towers,
compressors, and structural steel etc.
No. Temperature Preparation DFT in
in °C Microns
(min.)
9.1 -90 to -15 SSPC-SP-10 Repair of pre- None 65-75 Repair of pre-erection /
fabrication primer pre-fabrication primer shall
1 coat of F-9 @ be done wherever damage
65-75µ DFT/coat is observed.
9.2 -14 to 80 SSPC-SP-10 Repair of pre- 1 coat of F- 245
fabrication primer 6A@ 100 µ
1 coat of F-9 @ DFT/coat +
65-75 µ DFT/coat 1 coatofF-2
+ 1 coats of P-6 @40u
@ 40 µ DFT/coat DFT/coat.
9.3 81 to 400 SSPC-SP-10 Repair of pre- 2 coats of 105

fabrication primer F-12@20
1 coat of F-9 @ µ DFT/coat
65-75 µ DFT/coat 2x20=40
9.4 401 to 500 SSPC-SP-10 Repair as per 2 coats of 80
7.2.2. F-12@20
µ DFT/coat
2x20=40
Page 407 of 434

TABLE 9 : FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE AREAS IN PLANT AREA
EXTERNAL SURFACES OF UNINSULATED COLUMNS, VESSELS, HEAT
EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS,
STRUCTURAL STEEL ETC.
Note : Exposed to spillage or fumes of HCL, H2SO4, salty water, water impingement,
chloride etc
No. Temperature Preparation In
in°C Microns
(min.)
10.1 -90 to -15 SSPC-SP-10 Repair of pre- None 65-75 Repair procedure of
fabrication primer pre-erection/fabri
1c o at of F- 9 @ cation primer shall be
65-75u DFT/coat followed. No
overcoating is
allowed.
Surface preparation is
required only for
repairing of damaged
pre-erection/
fabrication primer.
10.2 -14 to 80 SSPC-SP-10 Repair of pre- 2 coats of F- 345

fabrication primer 6A @ lOOu
1c o at of F- 9 @ 65-DFT/Coat =
75u DFT/coat + 1 2x100=200 +
coats of P-6@ 40u 1coatofF-2
DFT/Coat @40u
DFT/coat.
10.3 81 to 400 SSPC-SP-10 Repair of pre- 2 coats of F- 105
fabrication primer 12@20u
1c o at of F- 9 @ DFT/Coat
65-75u DFT/coat 2x20=40
10.4 401 to 500 SSPC-SP-10 Repair as per 7.2.2. 2 coats of F- 80
12@20u
DFT/Coat
2x20=40
Page 408 of 434

TABLE 10 : PAINTING UNDER INSULATION FOR INSULATED (HOT, COLD & SAFETY) PIPING,
STORAGE TANKS AND EQUIPMENTS IN ALL ENVIRONMENT
Materials : CARBON STEEL, LOW ALLOY STEEL, LOW TEMPERATURE CARBON STEEL &
STAINLESS STEEL
Surface : Insulated
Paint System
Sr. Design Surface Field Primer Finish paint Total Remarks
No. Temperatur Preparation DFT in
0
e in C Microns
(min.)
9.1 Insulated carbon steel, low alloy steel and LTCS piping and equipment and tanks
9.1.1 -45 to 125 SSPC-SP-10 Repair of pre- 2 coats of F-14 315

fabrication primer @ 125 µ For other temperature
F-9 @ 65-75 µ DFT/coat = ranges no painting is
DFT. 2x125=250 OR 3 required under insulation
coats of F-15 =
3x80=240
9.1.2 Operating SSPC-SP-10 Repair of pre- 2 coats of F-12 105-115

temperature fabrication primer @ 20 µ DFT /
–45 to F-9 @ 65-75µ coat = 3x20 = 60
0
125 C but DFT.
design
temperature
0
126-400 C
9.2.1 Below 00C Aluminium sheeting with aluminium foil and “Chloride free mineral If the piping &
to all minus sealant coating barium chromate” shall be applied. equipments are already
temperature erected then surface
shall be prepared by
cleaning with emery
9.2.2 0 to 120 SSPC-SP-10 None 2 coats of F-14 @ 250 or
paper and wash / flush
(15-25µ surface 125 µ DFT / coat 240
with chloride free DM
profile) = 2x125 = 250 or 3
water followed by wiping
coats of F-15 =
with organic solvent.
3x80=240
All the coating materials
9.2.3 121 to 400 SSPC-SP-10 None 3 coats of F-12 60 for SS shall be free from
@20µ DFT /Coat = leachable chlorides.
3x20=60 or 1 coat
of Poly siloxane or
coating (F-16 A/B)
@ 75 microns
DFT/coat
9.2.4 401 to 600 SSPC-SP-10 None 2 coats of heat 40

resistant silicone
aluminium paint @
20 microns DFT /
coat = 2x20=40
9.3 No painting is required for insulated Monel, Incoloy and Nickel lines
Page 409 of 434

Page 410 of 434

Page 411 of 434

Page 412 of 434

TABLE 12.0 COATING SYSTEM FOR EXTERNAL SIDE OF UNDERGROUND CARBON STEEL
PLANT PIPING AND TANKS

(min.)
12.1 Carbon steel plant piping (underground)

12.1.1 Yard coating
12.1.1.1 25 to 60 SSPC-SP-10 1 coat of 4 mm thick 4 mm CTE coating shall confirm
synthetic fast coaltar to 120/5 as per BS:4164
drying primer coating
type-B as per wrapping as
AWWA-C-203 per AWWA-
(1991) C-203 in 2
layers of
each 2 mm
thickness.
12.1.2 Over the Ditch Coating
12.1.2.1 25 to 60 SSPC-SP-10 1 coat of 2 layers of 4 mm
synthetic fast coal tar
drying primer based tape
type-B as per coating
AWWA-C-203
(1991)
12.2 Carbon plant piping (underground).

µ DFT/coat 15 @ 75 µ shall be provided
DFT/coat
µ DFT/coat 16@ 100µ shall be provided
DFT/coat
12.3 External side of un-insulated underground storage tanks:

12.3.1 -40 to 80 SSPC-SP-10 1CoatofF-9@ 65- 3 coats of 365
75 µ DFT/coat F-7 @100 µ
DFT/coat
3x100=300
12.3.2 81 to 180 SSPC-SP-10 1CoatofF-15@ 75 2 Coat of F- 225
µ DFT/coat 15 @ 75u
DFT/coat
12.3.3. 181 to 400 SSPC-SP-10 1CoatofF-9@ 65- 2 Coat of F- 215-225
75 µ DFT/coat 16 @ 75 µ
DFT/coat
2x75=150
Note: No Coating and Wrapping systems are available for underground high temperature services
Page 413 of 434

TABLE 13.0 PAINTING UNDER INSULATION FOR INSULATED (HOT, COLD & SAFETY) CARBON
STEEL, LOW ALLOY STEEL, LOW TEMPERTURE CARBON STEEL & STAINLESS STEEL
PIPING, STORAGE TANKS AND EQUIPMENTS IN ALL ENVIRONMENT.
Sl. Design Surface Paint system Total

(min.)
Primer Finish Paint
13.1 Insulated carbon steel, low alloy steel and LTCS piping and equipment & tanks
13.1.1 -45 to 125 SSPC-SP-10 Repair of 2 coats of F- 315 For other temperature ranges no
pre- 14 @125 µ painting is required under
fabricatio DFT/coat = insulation F-12 shall be ambient
n primer 2x125=250 temperature curing type till
F-9 @ 65- OR 3 coats of operating temperature is attained
75 µ DFT. F-15= for full curing. F-16 is completely
3x80=240 ambient temperature curing.
13.1.2 Operating SSPC-SP-10 Repair of 2 Coats of 125-135
temperature pre- F-12 @20 µ
-45 to 125°C fabricatio DFT/coat
but design n primer 3x20=60 (or)
temperature F-9 one coat of
126-400°C @65-75 µ Poly-siloxane
DFT coating @ 75
µ DFT/coat

13.2.1 Below 0°C to Aluminum sheeting with aluminum foil and If the piping & equipments are
all minus "Chloride free mineral sealant coating barium already erected than surface
temp. chromate" shall be applied. shall be prepared by cleaning with
emery paper and wash/flush with
chloride free DM water followed
by wiping with organic solvent. No
pre-erection primer to be applied.
F-12 shall be ambient temp
curing type till final curing is
obtained during operating temp.
F-16 is completely ambient temp
curing type.
13.2.2 0 to 120 SSPC-SP-10 None 2 coats of F- 250

(15-25 14@125 µ or
surface DFT/COAT 240
profile) 2x125=250 or
3 coats of F-15
= 3x80=240
Page 414 of 434

13.2.3 121 to 400 SSPC-SP-10 None 3 coats of F- 60-75

12@20 µ
DFT/COAT
3x20=60 or 1
coat of F-16 Poly
Siloxane coating
@ 75 microns
DFT/coat
13.2.4 401 to 600 SSPC-SP-10 3coatsofF-12@ 60
20 µ DFT/coat 60
13.2.5 Cyclic SSPC-SP-10 None 2 coats of DFT/coat 150

service-196 F-16 Poly
to 480 Siloxane coating
excepting - @ 75 µ DFT/coat
45 to 120 = 2x75=150
13.3 No painting is required for insulated Monel, Incoloy and Nickel lines.
Page 415 of 434

TABLE 14.0 INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF
COOLERS / CONDENSERS
Water boxes, channels, partition plates, end covers and tube sheets etc.
Sl. Design Surface Paint system Total DFT Remarks

in°C (min.)
Primer Finish paint
14.1 Upto 80 SSPC-SP-10 1 coat of P-6 @ 2 coats of F-7 290 For C.S.
40 µ DFT/coat @125 µ
DFT/coat
2x125=250
14.2 Upto 80 Non SSPC-SP-3 1coatofP-4@ 8-1 2 coats of F-7 300 For non ferrous
ferrous and On DFT/coat. @125 µ surfaces
sheets 40 µ DFT/coat. 2x125=250
TABLE 15.0 FIELD PAINTING SYSTEM FOR GI TOWERS/NON-FERROUS TUBE SHEET

in°C (min.)
Primer Finish Paint
15.1 Upto 80 SSPS-SP-3 1 coat of P-4 @ 2 coats of F-2 130 Shade as per
8-10 µ DFT/coat @40 µ defence
+ 1 coat of P-6 @ DFT/coat Requirements.
40u DFT/coat 2x40=80
15.2 Upto 80 Non SSPS-SP-3 lcoatofP-4@8u 2 coats of F-7 300

ferrous and DFT/coat @125 µ
sheets 40u DFT/coat 2x125=250
Page 416 of 434

TABLE 16.0 SHOP & FIELD PAINTING SYSTEM FOR EFFLUENT TREATMENT PLANT
Sl. Design Temp. °C Surface Paint System Total DFT Remarks

No. Preparation in Microns
(min.)
Primer Finish Paint
16.1 -14 to 80(for SSPS-SP-10 1 3 coats of F- 365
C.S./M.S. items): coatofF-9 6A @100u
Screens, Walk way @ 65-75u DFT/coat
bridges, Baffles, Dual DFT/coat 3x100=300
media filters
(external) Vertical
pumps, piping in
treated effluent sump
and pump house,
external side lining of
Slop oil MS tank
16.2 -14 to 80(CS/MS SSPS-SP-10 1 2 coats of F- 265

Items) for Vertical coatofF-9 6A @100u
pump and piping in, @ 65-75u DFT/coat
Bio-sludge sump and DFT/coat.
pump, Filter feed
sump and pump,
Process sump,
Sanitary sump;
Transfer sump,
Sludge, MS Slop oil
tank internal,
scrapping
mechanism in
Clarifier, Screw pump
16.3 -14 to 80 deg.C :All Blast cleaning Epoxy Epoxy 3mm Epoxy screed lining
R.C.C. surfaces such t o SSPC- SP screed screed shall be used as per
as tanks, structures, guide lines and lining lining specific instructions
drains etc.) in Acid etching from Engineer-in-
Process sump, TPI with 10-15% Charge at site.
HCl acid
separator (Process
followed by
and Oil), Aeration thorough water
Tank, Transfer sump washing.
etc.
16.4 U p t o 6 0 d e g . C SSPC-SP-10 Rubber 4.5mm
C.S/M.S Dual media Lining
filters (Internal),
Chemical dosing
tanks(internal such
as DAP, Urea)
Page 417 of 434

17.0 STORAGE
1 All paints and painting materials shall be stored only in rooms to be arranged by
contractor and approved by Engineer-in-charge for the purpose. All necessary precautions
shall be taken to prevent fire. The storage building shall preferably be separate from adjacent
building. A signboard bearing the word "PAINT STORAGE - NO NAKED LIGHT - HIGHLY
INFLAMABLE" shall be clearly displayed outside.
18.0 PIPING COLOR CODE
The color code shall be followed as given in Annexure-II.
19.0 IDENTIFICATION OF VESSELS, PIPING ETC.: As per color coding given in

Annexure-II
20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS
20.1 Following items shall be painted for camouflaging if required by the client.
a. All columns
b. All tanks in off sites
c. Large Vessels
d. Spheres
20.2 Two coats of selected finishing paint as per defence requirement shall be applied in a
particular pattern as per 20.3 and as per the instructions of Engineer-In-Charge.
20.3 Method of Camouflaging
20.3.1 Disruptive painting for camouflaging shall be done in three colors in the ratio
of
5:3:2 (all matt finish).
Dark Green Light Green Dark Medium Brown

5: 3: 2
20.3.2 The patches should be asymetrical and irregular.
20.3.3 The patches should be inclined at 30 Deg.. to 60 Deg. to the horizontal.

20.3.4 The patches should be continuous where two surfaces meet at an angle.
20.3.5 The patches should not coincide with corners.
20.3.6 Slits and holes shall be painted in dark shades.
20.3.7 Width of patches should be 1 to 2 meters.
21.1 All painting materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufactures as per specifications and
shall be accompanied by manufacturer's test certificates. Paint formulations without
certificates are not acceptable.
21.2 Engineer-In-Charge at his discretion may call for tests for paint formulations. Contractor
shall arrange to have such tests performed including batch-wise test of wet paints for
physical & chemical analysis. All costs there shall be borne by the contractor.
Page 418 of 434

21.3 The painting work shall be subject to inspection by Engineer-In-Charge at all times. In
particular, following stage-wise inspection will be performed and contractor shall offer the
work for inspection and approval of every stage before proceeding with the next stage. The
record of inspection shall be maintained in the registers. Stages of inspection are as
follows:
(a) Surface preparation

(b) Primer application
(c) Each coat of paint
In addition to above, record should include type of shop primer already applied on equipment
e.g. Red oxide zinc chromate or zinc chromate or Red lead primer etc.
Any defect noticed during the various stages of inspection shall be rectified by the contractor
to the entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, contractor shall be
responsible for making good any defects found during final inspection/guarantee
period/defect liability period as defined in general condition of contract. Dry film thickness (D
F T)) shall be checked and recorded after application of each coat and extra coat of paint
should be applied to make-up the DFT specified without any extra cost to owner, the extra
cost should have prior approval of Engineer-in-charge.
21.4 Primer Application
After surface preparation, the primer should be applied to cover the crevices, corners, sharp
edges etc. in the presence of inspector nominated by Engineer-In-Charge.
21.4.1 The shades of successive coats should be slightly different in color in order to ensure
application of individual coats, the thickness of each coat and complete coverage should
be checked as per provision of this specification. This should be approved by
Engineer-In-Charge before application of successive coats.
21.4.2 The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface profile in case
of sand blasting. Holiday detectors and pinhole detector and protector whenever required
for checking in case of immersion conditions.
21.4.2 Prior to application of paints on surfaces of chimneys, the thickness of the individual coat
shall be checked by application of each coat of same paint on M.S.test panel. The
thickness of paint on test panels shall be determined by using gauge such as
'Elkometer'. The thickness of each coat shall be checked as per provision of this
specification. This shall be approved by Engineer-In-Charge before application of paints on
surface of chimney.
21.4.3 At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert
technical service at site as and when required. This service should be free of cost and
without any obligation to the owner, as it would be in the interest of the manufacturer to
ensure that both surface preparation and application are carried out as per their
recommendations.
21.4.4 Final inspection shall include measurement of paint dry film thickness, Adhesion, Holiday
detection check of finish and workmanship. The thickness should be measured at as
many points/ locations as decided by Engineer-In-Charge and shall be within + 10% of the
dry film thickness, specified in the specifications.
Page 419 of 434

21.4.5 The contractor shall arrange for spot checking of paint materials for Sp.gr., glow time (ford
cup) and spreading rate.
22.0 GUARANTEE
22.1 The contractor shall guarantee that the chemical and physical properties of paint
materials used are in accordance with the specifications contained herein/to be
provided during execution of work.
22.2 The contractor shall produce test reports from manufacturer regarding the quality of the
particular batch of paint supplied. The Engineer-in-Charge shall have the right to test wet
samples of paint at random for quality of same, as per the paint materials specification.
Batch test reports of the manufacturer's for each batch of paints supplied shall be
made available by the contractor. The contractor shall stand guarantee for carrying
out the rectification/repair/re-painting of the defects/ failures of painting found during the
execution of painting job and till the expiry of the defect liability period of total project as
per the directions of the Engineer-in-Charge of CPCL/JE
23.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR
Painting contractor who is awarded the job under this standard must have necessary
equipments, machinery, tools and tackles for surface preparation, paint application and
inspection. The contractor mush have qualified, trained and experienced surface
preparator, paint applicator, inspector and supervisors. The contractor's supervisor,
inspector, surface preparator and paint applicator must be conversant with the
standards referred in this specification. The painting job shall be carried out by the approved
agencies of paint manufacturers and supervised by the approved paint manufacturers own
representative or paint manufacturer their scheme( supply and apply basis).
Page 420 of 434

ANNEXURE-I
LIST OF RECOMMENDED MANUFACTURERS
Indian Vendors
1. Asian Paints (I) Ltd., Mumbai

2. Berger Paints Ltd., Kolkata
3. Goodlass Nerolac Paints Ltd., Mumbai
4. Chemguard Coatings, Mumbai(For Ameron, USA Products only)
5. Chokugu Marine paints Pte. Ltd., Mumbai/Singapore
6. Shalimar Paints Ltd., Kolkata
7. Sigma Coatings, Mumbai.
8. CDC Carboline Ltd., Chennai
9. Premier products Ltd., Mumbai
10. Coromandel Paints & Chemicals Ltd., Visakhapatnam
11. Anupam Enterprises, Kolkata
12. Grand Polycoats, Vadodata
13. Bombay Paints Ltd., Mumbai
14. Akzo Nobel Coatings and Sealants Pvt. Ltd., Bangalore
15. Cipy Polyurethanes Pvt. Ltd., Pune
16. Gunjan Paints Ltd., Ahmedabad
17. Advance Paints Ltd., Mumbai
18. VCM Polyurethane Paints (for polyurethane paints only)
19. Jotun Paints, Chennai(Singapore)
20. Chembond Chemicals Ltd., Navi Mumbai
Foreign Vendors
1. Sigma Coatings, Singapore

2. Ameron, USA
3. Kansai Paints, Japan
4. Hempel Paints, USA
5. Valspar Corporation, USA
6. Akzo Nobel/International Coatings, UK
7. Jotun Paints, Singapore
For De-humidification equipment (on Rental Basis)
1. Technical Drying Equipment (Asia) Pvt. Limited, Gurgaon, Haryana
The following are approved vendors for speciality items (phosphating chemical) only.
1. Mark-chem Incorporated, Mumbai.
2. Chemtreat India Ltd., Navi Mumbai
Page 421 of 434

Annexure-II
Paint Color Code for Piping & Equipment given by CPCL Document No. 00-ES-100-004, Rev. 5
dated 24/12/2006 to Specification No.6782-0642-PT-L06 Rev.2
This section of the standard deals with the color coding to he given to in service piping for easy
identification bused on the liqui d contained in the line.
1. Where ever paint is required for piping external surfaces, the finish coat color shall be as follows
except for paragraph 2, Type of paint, surface preparation. DFT etc. shall he as per the
painting specification.
a) 1 lent resistant paint - Alum inn in

b) Other grades of paint - White or Al. in Color
Insulated and austenitic stainless steel lines will he having only color coding for fluid
discrimination as given in 3 below.
2. Fire water lines shall he painted " Red '" as per IS 536 through out the line.
3. All lines, in general, shall he provided with discrimination color coding mark over the final coat or
on the cladding / jacketing surface of insulated piping as mentioned in 1 above . as
well as on the surfaces on which any paint is not provided. The color coding shall be as per the
attachment to this standard and in the following manner. Color codes on Austenitic SS lines should
he done only wit chloride free paint suitable for application on stainless steel surfaces.
As far as possible, paint used for color bands should he of the same specification as the finish
coat. If for some reason a deviation is required for this, then enamel paint can be used over finish
coat after taking approval from the ‘engineer In - Charge'
3.1 The system of color coding shall consist o f a primary identification color band and other color
hand (s) superimposed on the primary band. All the bands shall be painted circumferential!;
around the line.
The primary color hand identifies the basic nature of the fluid carried in the line. The second and
the third color hands will identify the exact fluid carried in the line. The various primary color
bands included in t h i s standard are explained below:
Basic fluid Color of primary band
Water Sea Green

Steam Signal Red
Air Sky Blue
Gases Canary Yellow
Acids and acid producing, gases Dark Violet
Hydrocarbons Dark Grey
Alkalies Light Brown
Chemicals Light Orange
No identification required Black
Page 422 of 434

3.2 Painting of color bands
3.2.1 Primary colorblind / color band ( s ) (see Fig I) arc required to be located at
- battery limit points

- intersection points in the piping system
- start and terminal points
- at spec i lied intervals as given below
- specific points on the l i n e as directed by the "Engineer - In - Charge "
3.2.2 Primary color band shall he intermittently coated along respective lines with primary color
bands of 2V1 length with the following maximum center to center distance between two
adjacent color bands.
− 15 M for lines with in battery limits of respective units

− 50 M for lines on interconnecting pipe rack and in lower plateau
Center to center distances at lesser intervals may be given. if" so desired by unit head.
3.2.3 Sizing of II &. Ill color bund (s)
Size II color band I I I Color band

3" and below 100 mm 50 mm
> 3" upto ft" 200 mm 100 mm

> 6" upto 12" 300 mm 150 mm
> 12" 400 mm 200 mm
Page 423 of 434

SR CONTENTS Primary II Color Band 111 Color

NO Color Band Band
1 ALL KINDS OF WATER

Drinking water Sea green French Blue Signal rod
De-mineralized water Sea green Light Orange
Cooling water Sea green French blue
Boiler feed water Sea green Gulf Red
Condensate Sea green Light Brown
Quench water Sea green Dark grey Signal rod
Wash water Sea green Canary Yellow
Process water Sea green Light grey
Raw water ( from river } Sea green
Page 424 of 434

Fire water ( Full color, not band ) Fire red

2 STEAM
Very high pressure steam Signal Red Silver Grey
High pros sure steam Signal Red French Blue
Medium Pressure steam Signal Red Gulf Red
Low Pressure steam Signal Red Canary Yellow
Dilution steam/ Purge steam Signal Red Silver Grey Canary Yellow
3 AIR
Plant Air Sky Blue Silver Grey
Instrument Air Sky Blue French Blue
Process air ( ex: bitumen, Sky Blue Signal Red
Mereox)
Combustion air Sky Blue Canary Yellow

4 GASES
Hydrogen Canary Yellow Signal red French Blue
Nitrogen Canary Yellow Black
Flare gas Canary Yellow
Hydrogen sulfide/ Acid gas Canary Yellow Gulf Red
Fuel gas Canary Yellow Light Brown While
Regeneration gas Canary Yellow While Dark Violet
LPG (as gas) Canary Yellow Brilliant Green While
Propane ( as gas ) Canary Yellow Signal Red Black
Sulfur Dioxide Dark Violet Brilliant Green
Ammonia Dark Violet
Chlorine Dark Violet Signal Red
HCN Dark Violet Trench Blue
5 AC IDS
Sulfuric Acid Dark Violet Brilliant Green Light Orange

Nitric Acid Dark Violet French Blue Light Orange
1 Hydrochloric Acid Dark Violet Signal Red Light Orange
Acetic acid Dark Violet Silver Grey
6 LIQUID HYDROCARBONS
LPG ( as liquid ) Dark Grey Brilliant Green While

Naphtha. Dark Grey Brilliant Green
MS Dark Grey Sky Blue
Reformate Dark Grey While
SKO Dark Grey Light Brown
ATF Dark Grey Light Brown Sky Blue
USD Dark Grey Light Orange
FO Dark Grey Signal Red
LSHS / Low Sulfur fuel Dark Grey Signal Red Black
Bitumen Dark Grey Black
Page 425 of 434

Other Hydrocarbons not defined Dark Grey

Above
Crude Dark Grey Canary Yellow
7 ALKALIES Light Brown

8 CHEMICALS-GENERAL Light Orange
Sulfur Light Orange Black
9 All other items which do no Black

require individual identification
Surface Part Color Remarks

Tanks A.C. Grey
Spheres White
Vessels, drums, heat exchangers D.A. Grey
etc.
Furnace casing Silver
Machinery - Pumps. Silver
Compressors, blowers etc)
Steam Turbine Silver
Generator' Mfr. Std.
Motor Light grey ISC 631
Packaged dosing system Mfrs. Std
DG Set Mfrs. Std
Cable duct Silver
Instrument Panel
Instrument Panel including DCS Indoor
Cabinet Front Opaque Beige With leather lone
Other Neutral Grey With leather lone
sides Neutral Grey
Inside
Control Valve
C:S Body Light grey ISC 631
SS Body No paint
Low alloy body Canary Yellow ISC 309
Control Valve Actuators
Normally Brilliant Green ISC 221
Closed
Normally Open Signal Red \SC 537
Instruments. Transmitters Mfrs Sid
Page 426 of 434

Sr. No. Content Final Color ISC

No:
1 Gantry girder and monorail Brilliant Green 221
2 Stopper for gantry girder and monorail Signal Red 537
3 Pipe rack structural steel and trestle including that Dark Admiralty Grey 632
for equipment and platform
4 Chequered Plates Dark Admiralty Grey 632
Ladder rungs, verticals and cage Canary Yellow 309
6 Hand railing. middle rail, toe pi ale and Canary Yellow 309
vertical post
7 Platforms : Structural sled parts other Dark Admiralty Grey 632
than grating and hand railing
8 Staircase : Structural steel parts other Dark Admiralty Grey 632
than hand railing and steps using galvanized
9 Safety Gate Signal Red 537

10 Miscellaneous Structural Part Dark Admiralty Grey 632
Notes : 1) Wherever Dark Admiralty Grey is not available due to the nature of the final coat of
paint ( eg: Coal Tar epoxy in high H2S environments ) . Black can be used.
2) Canary Yellow for ladders etc. has been selected for visibility.
1. Equipment number shall be stenciled in black (after initial painting if any) on each vessel,
column, equipment, machinery till a visible location as directed by the "Engineer - in -
charge "'
Size of letters is as below:
− Column, vessel. exchanger, other stationary equipment : 150 mm height
− Pump. Compressor and other machinery including : 50 mm height HT

motors
Rotating equipment shall have tin arrow showing the direction of rotation painted on the
equipment.
In case of small auxiliary equipment in packaged unit, separate identification by stenciling is

not required as long as name plate or tag bearing item number is duly attached to the aux.
equipment.
2. Line number, service, source and destination shall be stenciled in black on respective
pipe lines at
− start and terminating points of line next to the color code
− battery limit points next to the color code,
Page 427 of 434

Additional stenciling of line numbers and service will be required and shall be provided on
the lines at the direction of “Engineer- In - Charge"
Sizing of letters shall be :
OD of pipe Height of letters
80- 150 mm 40 mm
150-250 mm 60 mm
> 250 mm 90 mm
Auxiliary piping in packaged units or on base plates of pumps / compressors wilh in the
scope of vendors do not need numbering at site.
However, an auxiliary line with operational significance (where it is referenced specifically in

the operation manual by a line number) shall he provided with a number by stenciling hi-
other suitable means.
3. The following details are to he painted on the Lank shell in black color, letter size 50 mm
high, at the entrance point of the staircase.
• Tank number
• Stile filling height
• Critical /one ( in ease of floating roof tanks only )
• Dale of commissioning
• Date of last cleaning
4. The following details are to be painted on the tank shell near the top landing platform of the
staircase, in letter size 50 mm high, black color.
• Sale filling height
• Critical zone ( in case of floating roof tanks only )
5. The following details shall he painted on the kink at 2!3 the height of the tank at a
location facing the road, from where normal approach lo the Tank is provided. In addition,
the same details shall be provided on two additional points in the lank 120 degrees apart.
Tank number
• Capacity
• Service.
The size of the above lettering shall be 500 mm for 20 M high tanks and 300 mm for
smaller tanks.
DGCA requirements for a l l shall be followed in addition to the above.
Page 428 of 434

1.0 The part of the standard covers the method of identification of STORED piping material by
color coding. This standard is applicable to storage during project Stage as well.
2.0 General guide lines of identification by color coding:
a) Piping shall be painted with one color or a combination of two color as
enclosed.
b) Color identification is not required on galvanized material and mm ferrous
material such as Copper. Aluminum etc. because of their peculiar color and
Page 429 of 434

Jacobs
character
e) Special items l i k e bellow, strainers, steam Imps etc. should be lagged and hence do
mil require color identification.
d) Color identification of Austenitic Stainless Steel is not desirable due to r i s k
of contamination from paint material.
e) Ends of piping to be welded shall not be painted. The color band shall start
2" from the pipe ends.
f) Width of color strips shall be 25 mm for .V nominal pipe dia and above. Secondary
color strip where required, shall be half the size of primary strips. For less than 3" size
color strip shall be 12 mm < 1/2") or maximum practical.
Carbon Steels
API 5L Gr B Pink Seamless

API 5L Gr B Pink / White Welded
A 106 Gr B Red [BR
A 106 Gr B Yellow Non IBR
Welded and seamless fittings Red IBR
Welded and seamless fittings Yellow Non IBR
Welded fittings Yellow / White Normalized
Miters Silver
Class 22 fittings Silver / Pink Stress relieved at s h o p
IS 3589- IS 12239 No Paint Non critical
Alloy Steels
P1, F1. WP1, WP1W etc. Green / Red
P12, F12, W12 etc Green / Yellow
P22, F22, WP22. etc Green / Silver
P11, F11, WP11 etc. Green / Orange
P5, F5, WP5 etc. Green / Blue
P9, F9, WR9 etc. Green / Pink
Page 430 of 434

Jacobs
Color ( In alphabetical order ) ISC No:

Black
Brilliant Green 221

Canary Yellow 309
Dark Grey 632
Dark Violet 796
Fire Red 536
French Blue 166
Golden Yellow 356
Gulf Red 473
Jasmine Yellow 397
Light Brown 410
Light Grey 631
Light Orange 557
Sea Green 217
Signal Red 537
Silver 110
Silver Grey 628
Sky Blue 101
White -
Page 431 of 434

APPENDIX - A
INDICATIVE INSPECTION & TEST PLAN** SHEET 1 OF 3

PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID
UPGRADATION PROJECT
DOC. NO: A133-00-000-ITP015A VENDOR :
EQUIPMENT / ITEM DESCRIPTION : PRESSURE VESSELS (ALLOY P.O. NO. :
STEEL, SS & CS – LT SERVICE) EQUIPMENT / ITEM TAG NO. : PR/PS NO. DRG. NO.
TEST & INSPECTION AS PER :
(CODES & SPECIFICATIONS) : EQUIPMENT INSPECTION CODE : A
A 1 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / PMC
C 2 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY THIRD PARTY
T INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY
I 3 WITNESS INSPECTION BY SUB VENDOR,VENDOR Rev.1
V 4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR /
I VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC
T
Y
1 H H X PRE-INSPECTION MEETING TO BE CONDUCTED AFTER ISSUE OF PO / PR
/ PS. AGENDA TO BE PREPARED BY LSTK CONTRACTOR
2 A A R X DETAILED INSPECTION & TEST PLAN AFTER ISSUE OF PO/PR/PS
(INCLUDING FOR BOUGHT – OUT ITEMS)
3 A R X INSPECTION & TEST PROCEDURES INCLUDING NDT / PWHT / WELD
REPAIR / HYDRO TEST / PAINTING / PICKLING & PASSIVATION
PROCEDURES, ETC.
4 A X PACKING PROCEDURE Rev.1
5 R R X Rev.1
6 A W X WELDING PROCEDURE SPECIFICATIONS AND PROCEDURE
QUALIFICATION RECORD INCLUDING WELD REPAIR PQRs.
7 A W X WELDERS’ QUALIFICATION / WELDERS PERFORMANCE RECORDS
8 H W X NEW PROCEDURES AND WELDERS QUALIFICATION
9 R R X WELDING CONSUMABLES BATCH CERTIFICATE
10 H W X RAW MATERIAL INSPECTION / IDENTIFICATION FOR ALL PRESSURE
PARTS / COMPONENTS W.R.T MILL / MANUFACTURER’S TCs.
11 R W X RAW MATERIAL IDENTIFICATION FOR NON-PRESSURE PARTS/
STRUCTURAL MATERIALS
12 R R X SUB-ORDER VERIFICATION FOR BOUGHT-OUT ITEMS VIZ FLANGES /
FORGINGS, FITTINGS, DISHED ENDS, BELLOWS, FASTENERS ETC.
13 H W X INSPECTION OF BOUGHT-OUT ITEMS AT MANUFACTURES, WORKS FOR
FLANGES, FITTINGS, FASTENERS, DISHED ENDS, EXPANSION BELLOWS
ETC.
14 W W X LONG-SEAM, CIRC-SEAM SET-UP CHECK FOR SHELLS, DISHED ENDS,
NOZZELS ETC
15 H W X IDENTIFICATIONS OF ALL BOUGHT OUT ITEMS AT FABRICATION SHOP
16 W W X NOZZLES ATTACHMENTS & INTERNALS FIT-UP CHECK ON SHELLS /
DISHED ENDS.
17 R W X ROOT RUN DP CHECK Rev.1
18 R W X DP CHECK AFTER BACK GOUGING OF WELD JOINTS Rev.1
Page 432 of 434

APPENDIX - A
INDICATIVE INSPECTION & TEST PLAN** SHEET 2 OF 3

PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID
UPGRADATION
PROJECT
DOC. NO: A133-00-000-ITP015A VENDOR :
EQUIPMENT / ITEM DESCRIPTION : PRESSURE VESSELS P.O. NO. :
(ALLOY STEEL, SS & CS – LT SERVICE) EQUIPMENT / PR/PS NO. DRG. NO.
ITEM TAG NO. :
TEST & INSPECTION AS PER :
(CODES & SPECIFICATIONS) : EQUIPMENT INSPECTION
CODE : A
A 1 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / PMC
C 2 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY THIRD PARTY
T INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY
I 3 WITNESS INSPECTION BY SUB VENDOR,VENDOR Rev.1
V 4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR /
I VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC
T
Y
19 R W X AIR TEST OF REINFORCING PADS Rev.1
20 H/R W X NDT (RT, UT, MT, PT, ETC, AS APPLICABLE.) EXAMINATION / NDT
CLEARANCE OF WELD JOINTS BEFORE PWHT/HYDROTEST Rev.1 H for
NDT clearance and RT film review
21 H W X VISUAL (INTERNALS & EXTERNAL) & DIMENSIONAL CHECK BEFORE
RELEASE FOR PWHT (IF APPLICABLE)
22 R W X PWHT CHART / RECORDS (IF APPLICABLE) Rev.1
23 H W X MECHANICAL TESTS OF COUPONS FOR TENSILE, HARDNESS, IMPACT
AS APPLICABLE
24 R W X HARDNESS CHECK OF BASE METAL, HAZ & WELD AFTER PWHT AND
ANY OTHER SUPPLIMENTATRY REQUIREMENT CHECK. FERRITE
CHECK OF WELD METAL WHEN SPECIFIED.(S.S.MATERIAL) Rev.1
25 H/W W X VISUAL (INTERNAL & EXTERNAL) & DIMENSIONAL CHECK BEFORE
RELEASE FOR HYDROTEST. NDT CHECKS AFTER PWHT WHEN
SPECIFIED. Rev.1
26 H W X HYDROSTATIC TEST. NDT CHECKS AFTER HYDROTEST WHEN
SPECIFIED. (WATER CHLORIDE PPM TO BE CHECKED FOR SS
EQUIPMENTS)
27 H W X FINAL INSPECTION INCLUDING NAME PLATE AND MARKING CHECK
28 R W X SURFACE PREPARATION / PAINTING CHECK. FERROXYLE TEST FOR SS
EQUIPMENT AFTER PICKLING & PASSIVATION. Rev.1
29 H R X FINAL DOCUMENTATION INCLUDING CERTIFICATION OF AS-BUILT
DRAWINGS AND STAMPING OF EQUIPMENT
30 W H X SPARES AND PACKING LIST CHECK. PACKING & LOADING OF
EQUIPMENT AS PER SHIPPING DRAWING Rev.1
31 H H INSPECTION RELEASE CERTIFICATE
LEGENDS : H – HOLD, W - WITNESS, R – REVIEW, A - APPROVAL, I - INFORMATION, X –
SUBMIT PO – PURCHASE ORDER, PR – PURCHASE REQUISITION, PS – PURCHASE
SPECIFICATION
** NOTE : THIS IS AN INDICATIVE INSPECTION AND TEST PLAN IDENTIFYING SCOPE OF
Page 433 of 434

INSPECTION /REVIEW OF DOCUMENTS AS A MINIMUM REQUIREMENT, DETAILED
INSPECTION AND TEST PLAN INDICATING ALL SPECIFIED REQUIREMENTS AFTER ISSUE OF
PO / PR TO BE GENERATED BY VENDOR AND SAME DULY APPROVED BY TPI A TO BE
SUBMITTED TO OWNER/PMC FOR APPROVAL.
* TPI A TO CARRY OUT INSPECTION AT SUB-VENDORS’ WORKS.
OWNER / PMC RESERVES RIGHT TO WITNESS INSPECTION OF ANY ITEM AT ANY
STAGE WHICH SHALL BE INDICATED ON QAP / INSPECTION & TEST PLAN AT THE
TIME OF APPROVAL AND SAME TO BE COVERED AS PART OF PURCHASE ORDER
CONDITION ISSUED BY CONTRACTOR.
Note : Following modification has been made from the original ITP attached with
Bid Document.
1. In activity :scope of Inspection LSTK contractor has been deleted
2. Activity 4: Shipping drawings of completed equipments has been deleted
3. Activity 5: Summary of all supplementary requirements as specified in the
order/PS/PR deleted
4. Activity 17: Root run DP has been modified as R for TPI
5. Activity 18: DP check after back gouging of weld joints has been modified as R
for TPI
6. Activity 19 : Air test of RF pad has been modified as R for TPI
7. Activity 20 : NDT clearance and RT film review has been modified as H and
balance as R for TPI
8. Activity 22 : PWHT chart review has been modified as R for TPI
9. Activity 24: Hardness check of base metal, weld and HAZ after PWHT been
modified as R for TPI
10. Activity 25 : Visual/dimensional inspection before Hydrotest has been modified as
H/W for TPI , H if not checked before, W if checked before PWHT.
11. Activity 28:Surface preparation painting /pickling etc has been modified as R for
TPI
12. Activity 30 : Spare parts and packing list check have been modified as W for TPI
13. Activities in respect of QAP / ITP and IRN /IC for categories will be as below:
For PMC category A : QAP/ITP approval by EPC , TPIA & PMC.
IRN/IC issued by TPIA and to be endorsed by PMC
Page 434 of 434

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Item CS VESSELS ( UPTO 25 THK)

PRE-BID MEETING Not required

PRICED BID OPENING : TIME & VENUE SHALL BE INTIMATED LATER

Bids should be submitted separately in two parts as follows:

Part-I: The techno-commercial Part consisting of following:

i) Offer Covering letter (in bidder’s letter head)

RFQ No. RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31 Page 1 of 9

v) Unpriced copy of Price Schedule (Uploaded as Excel file on

viii) Technical Compliance/ datasheets/ documents, required as per Material Requisition.

Part-II: PRICED BID

b) A Ready Reckoner for e-tendering is available on e-tendering website

RFQ No. RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31 Page 2 of 9

10. Delivery Period :

13. Contact Persons for this RFQ are:

Mrs. Rekha Choudhary–Asst. General Manager (C&P)–Phone: 91-11-26763457, E-mail:

* Please specify Ref. No. (i.e. RFQ No.) in all correspondence

THIS IS NOT AN ORDER Very truly yours,

RFQ No. RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31 Page 3 of 9

 Forms & Formats

RFQ No. RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31 Page 4 of 9

FAX Nos. : 00-91-11-26191714, 26167664

Engineers India Limited

Attn. : Ms. Rekha Choudhary – Asst. General Manager (C&P)

Further, our response is as under:- (Bidders to put a tick , as applicable).

1. We will submit the bid within due date.

2. We regret to submit our offer/quote because of the following reasons:

Very truly yours,

We……………………………………..hereby authorise following representatives (s) to attend the Pre-Bid

1. Name & Designation ………………………………Signature …………………………..

2. Name & Designation ……………………………… Signature …………………………

Name & Designation ……………….

For & on behalf of ………………….

RFQ No. : _____________________________

SIGNATURE OF BIDDER : _______________________

NAME OF BIDDER : _______________________

COMPANY SEAL : _______________________

RFQ No. : RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31

SL. REFERENCE OF RFQ DOCUMENT BIDDER'S QUERY EIL'S REPLY

SIGNATURE OF BIDDER : ___________________________

NAME OF BIDDER : ___________________________

RFQ No. : RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31

SL.NO REF. OF RFQ DOCUMENT SUBJECT DEVIATIONS

SIGNATURE OF BIDDER : _______________________

COMPANY SEAL : _______________________

RFQ No. : RC/ A1 3 3 - 0 8 6 - V V - M R - 6 1 4 1 /31

FULL POSTAL DATE OF

SIGNATURE OF BIDDER : _______________________

NAME OF BIDDER : _______________________

COMPANY SEAL : _______________________

16. SPECIAL INSTRUCTIONS TO FOREIGN BIDDERS

ii) Tax Residency Certificate (TRC)

iii) Form 10F

21. REVERSE AUCTION

22. INTEGRITY PACT

1.1 FOR INDIGENOUS BIDDERS:

- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in requisite

- 10% on receipt and acceptance of goods/ materials at Site and on

- 80% against dispatch documents directly to EIL on prorate basis together

- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in

T&C FOR ED COMMITTEE APPL- LSTK-A133  

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL- All rights reserved

- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in requisite number