Tender Sample

MECHANICAL PACKAGE –V
TECHNICAL SPECIFICATION
FOR
“Design , Supply, Fabrication, Erection, Testing & Commissioning of

Process, IBR, Utility and Piggable Piping, Equipment , Heat Exchangers,
Mini bulk/ Condensate recovery Tanks, Equipment Erection supplied by
global vendor, pumps , Electrical Tracing / Insulation of pipeline & tanks, ,
Structural Work and associated Misc. Mechanical works including
modification of existing facilities at IOCL Lube plant , Paharpur ,
Kolkata”
MECON Limited,
Bangalore
Doc. No. MEC/23RK/01/31/D2/ME/535/R00

INDIAN OIL CORPORATION LIMITED
MODERNIZATION OF LUBE OIL BLENDING PLANT AT
PAHARPUR,KOLKATA
`
MECHANICAL PACKAGE-V
TABLE OF CONTENTS
CHAPTER NO. DESCRIPTION

CHAPTER 1 SPECIAL INSTRUCTIONS TO BIDDERS
MECH. PKG.-V CHAPTER 2 TECHNICAL SPECIFICATION OF PIPING AND EQUIPMENT
CHAPTER- 3 TECHNICAL SPECIFICATION OF FIRE HYDRANT SYSTEM
CHAPTER -4 STANDARD TECHNICAL SPECIFICATIONS
CHAPTER -5 TECHNICAL DATA SHEETS
CHAPTER -6 TENDER DRAWINGS
LIST OF ANNEXURES (CHAPTER – 2)

ANNEXURE NO. DESCRIPTION PAGE NO.
01 LIST OF APPROVED VENDOR 71-79
02 LIST OF THIRD PARTY INSPECTION AGENCIES 80-80
03 ABBREVIATIONS & NOTATIONS 81-81
04 CODES & STD. TO BE FOLLOWED 82-82
05 PACKING LIST OF GLOBAL EQUIPMENT 83-91
LIST OF STANDARD TECHNICAL SPECIFICATIONS (CHAPTER – 4)
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SL. NO. DESCRIPTION TECHNICAL SPECIFICATION PAGE

NO. NO.
1 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/P/0002/ 1-10
ASSORTED PIPES R000
2 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/IGP/000 1-3
INTERNAL GEAR PUMPS 3/R000
3 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/HE/0004 1-9
SHELL AND TUBE HEAT /R000
EXCHANGERS(SUCTION HEATER)
4 TECHNICAL SPECIFICATION FOR BALL MEC/23RK/01/31/D1/ME/BV0005/ 1-14
VALVES R000
5 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/CV/0006 1-11
CHECK VALVES /R000
6 TECHNICAL SPECIFICATION FOR GATE MEC/23RK/01/31/D1/ME/GV/0007 1-8
& GLOBE VALVES /R000
7 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/ROSOV/ 1-8
ROV(REMOTE OPERATED SHUT OFF 0008/R000
VALVE) (PNEUMATICALLY OPERATED
TRIPLE OFFSET BUTTERFLY VALVE)
8 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/PA/0009 1-11
PNEUMATIC ACTUATOR FOR ROSOV /R000
9 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/F- 1-5

SEAMLESS FITTINGS & FLANGE (SIZE FIT/0010/R000
UPTO DN 400MM (16”) NB)
10 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/ST/0011/ 1-6
STEAM TRAPS R000
11 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/PSV/001 1-7
PRESSURE SAFETY VALVES 2/R000
12 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/GKT- 1-5
GASKETS, NUTS & BOLTS NT/0013/R000
13 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/EHT/001 1-12
ELECTRICAL HEAT TRACING 4/R000
14 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/PSV/001 1-7
PRESSURE SAFETY VALVES 5/R000
15 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/INSL/00 1-40
INSULATION 16/R000
16 TECHNICAL SPECIFICATION FOR NDT MEC/23RK/01/31/D1/ME/NDT/001 1-13
7/R000
17 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/IFT/0018 1-8
INSPECTION,FLUSHING ,TESTING OF /R000
PIPING SYSTEM
18 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/QMS/00 1-8
QUALITY MANAGEMENT SYSTEM 19/R000
REQUIREMENT
19 TECHNICAL SPECIFICATION FOR LT MEC/23RK/01/31/D1/ME/LTM/002 1-11
MOTORS 0/R000
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20 STANDARD TECHNICAL MEC/23RK/01/31/D1/ME/ST/0021/ 1-28

SPECIFICATION FOR R000
STORAGE TANKS
21 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/SP/P- 1-3
VERTICAL SUBMERSIBLE PUMPS FOR 0022/R000
LDO/HSD STORAGE TANKS
22 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/ST/PRS- 1-3
PRESSURE REDUCING STATION 0023/R000
23 TECHNICAL SPECIFICATION FOR PIPE MEC/23RK/01/31/D1/ME/STRL./0 1-23
STOCKADE STRUCTURAL WORKS 024/R000
24 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/LOBP./P 1-8
PAINTING AINTING/R000
24.1 SPECIFICATION FOR 100% SOLVENT ANNEXURE-A 1-1
FREE POLY URETHANE COATING
MATERIAL FOR EXTERNAL COATING
FOR UNDER GROUND PIPING .
24.2 SPECIFICATION FOR HIGH BUILD ANNEXURE-B 1-1
SOLVENT FREE LIQUID EPOXY
COATING MATERIAL FOR EXTERNAL
COATING OF UNDERGROUND PIPING
24.3 IOCL STD. PAINTING SPECIFICATION ANNEXURE-C 1-6
GLOBAL VENDORS DOCUMENT
25 PIPING MATERIAL SPECIFICATION (PMS)
25.1 PIPING FOR STEAM AND CONDENSATE PS-201 CL150 CS 1-4

25.2 PIPING FOR COMPRESSED AIR PS-202 CL150 CS 1-4
25.3 PIPING FOR PIGGABLE SERVICE PS-250 CL150 CS 1-3
25.4 PIPING FOR GENERAL SERVICE PS-251 CL150 CS 1-5
25.5 IDENTIFICATION CODES AND PS-275 1-7
DESCRIPTIONS FOR VALVES AND
PIPING COMPONENTS
26 GENERAL GUIDELINES FOR INSTALLATION OF PIGGABLE

PIPES,DEMISTER,PIGGABLE VALVES
26.1 GENERAL GUIDLINE FOR THE 1-2

INSTLLATION OF DEMISTER
INSTLLATION OF PIGGABLE PIPE
INSTLLATION OF PIGGABLE VALVES
27 BATCH BLEND BESSEL(BBV) PJ435-09-0975-01-001 1-64
ASSEMBLY AND PREMIX(PM)
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ASSEMBLY JOB SITE INSTALLATION

CONTRACTOR SCOPE OF WORK
DOCUMENT
LIST OF TECHNICAL DATA SHEETS (CHAPTER – 5)
SL. NO. DESCRIPTION TECHNICAL DATASHEET NO Page

No.
1 DATA SHEET FOR MANUAL BALL MEC/23RK/01/31/D1/ME/CA/BV 1-2

VALVE (BV-001A) -SW -001A/R00
VALVE (BV-001B) -THREADED -001B/R00
VALVES (BV-002) -002/R00
4 DATA SHEET FOR CHECK VALVE MEC/23RK/01/31/D1/ME/CA/CV 1-2
(CV-008) -008/R00
5 DATA SHEET FOR MANUAL GATE MEC/23RK/01/31/D1/ME/CA/GV- 1-3
VALVES (GV-009) 009/R00
DATA SHEET FOR MANUAL MEC/23RK/01/31/D1/ME/CA/GLV- 1-2
6 GLOBE VALVES (GLV-005) 005/R00
DATA SHEET FOR MANUAL MEC/23RK/01/31/D1/ME/CA/GLV- 1-2
7 GLOBE VALVES (GLV-003) 003/R00
DATA SHEET FOR MANUAL BALL MEC/23RK/01/31/D1/ME/GS/BV 1-2
8 VALVE (BV-007A) -007A/R00
9 VALVE (BV-007B) -007B/R00
10 VALVE (BV-009) -009/R00
DATA SHEET FOR TRIPLE 1-2
ECCENTRIC BUTTERFLY VALVE MEC/23RK/01/31/D1/ME/GS/BUV
11 (BUV-002)- FLANGED TYPE -ROV -002/R00
DATA SHEET FOR MANUAL GATE MEC/23RK/01/31/D1/ME/GS/GV- 1-3
12 VALVES (GV-002)-SOCKET WELD 002/R00
13 VALVES (GV-001B)-THREADED 001B/R00
14 VALVES (GV-003)-LARGER SIZE 003/R00
DATA SHEET FOR CHECK VALVES MEC/23RK/01/31/D1/ME/GS/CV- 1-2
15 (CV-003)- FLANGED 003/R00
DATA SHEET FOR MANUAL BALL MEC/23RK/01/31/D1/ME/PGS/BV- 1-2
16 VALVE (BV-007)-THREADED 007/R00
DATA SHEET FOR MANUAL BALL MEC/23RK/01/31/D1/ME/PGS/BV- 1-2
17 VALVES (BV-009)-FLANGED 009/R00
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MEC/23RK/01/31/D1/ME/LOP/PRV/R0 1-10
18 DATA SHEET FOR PRV/PIRV 0
DATA SHEET FOR MANUAL MEC/23RK/01/31/D1/ME/ST/CV- 1-2
19 CHECK VALVE (CV-002) 002/R00
DATA SHEET FOR CHECK VALVE MEC/23RK/01/31/D1/ME/ST/CV- 1-3
20 (CV-003) 003/R00
DATA SHEET FOR MANUAL GATE 1-3
21 VALVES (GV-002) MEC/23RK/01/31/ME/ST/GV-002/R00
DATA SHEET FOR MANUAL GATE MEC/23RK/01/31/D1/ME/ST/GV- 1-3
22 VALVE (GV-003)-SW 003A/R00
DATA SHEET FOR MANUAL GATE MEC/23RK/01/31/D1/ME/ST/GV- 1-3
23 VALVES (GV-003)-THD 003B/R00
MEC/23RK/01/31/D1/ME/ST/STRP- 1-2
24 DATA SHEET OF STEAM TRAP 0001 /R00
DATA SHEET OF Y-TYPE MEC/23RK/01/31/D1/ME/ST/Y-STR- 1-2
25 STRAINER 001/R00
DATA SHEET FOR PRESSURE 1-3
26 SAFETY VALVES MEC/23RK/01/31/D1/ME/GS/PSV/R00
DATA SHEET FOR BASKET MEC/23RK/01/31/D1/ME/LOB/BS- 1-1
27 STRAINER 0001/R00
28 DATA SHEET OF SUCTION HEATER
DATA SHEET OF SUCTION MEC/23RK/01/31/D1/ME/BO/HE- 1-4
28.1 HEATER-HE-0001 0001/R00
DATA SHEET OF HEAT MEC/23RK/01/31/D1/ME/BO/HE- 1-4
28.2 EXCHANGER HE-0004 0004/R00
28.3 HEATER HE-0006 0006/R00
28.4 HEATER HE-0014 0014/R00
28.5 HEATER HE-0007 0007/R00
29 DATA SHEET FOR MINI BULK TRANSFER PUMP
DATA SHEET FOR MINI BULK MEC/23RK/01/31/D1/ME/MB/P- 1-3
29.1 TRANSFER PUMP, P-0201 0201/R00
30 DATA SHEET FOR STEAM MEC/23RK/01/31/D1/ME/ST/CT- 1-3
CONDENSATE TRANSFER PUMP 0001/R00
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DATA SHEET FOR LDO/HSD MEC/23RK/01/31/D1/ME/LDO/LP- 1-3

31 TRANSFER PUMP 0001 /R00
DATA SHEET FOR PRESS. MEC/23RK/01/31/D1/ME/ST/PRV/000 1-3
32 REDUCING VALVE 1/R00
MEC/23RK/01/31/D1/ME/CA/ADT/000 1-1
DATA SHEET FOR AUTO DRAIN 1/R00
33 TRAP
34 3” PIGGABLE VALVE DATASHEET ------ 1-6
------ 1-5
35 4” PIGGABLE VALVE DATASHEET
LIST OF TENDER DRAWINGS (CHAPTER – 6)
SL. NO. DESCRIPTION DRAWING NO.
1 PROCESS FLOW DIAGRAM (PFD) PFD 001 TO 012

2 PIPING & INSTRUMENTATION DIAGRAM (PID) PID-001 TO PID-805
3 GENERAL ARRANGEMENT DRAWING FOR MINIBULK MEC/23RK/01/31/D5/ME/FP/
TANK WITHOUT STEAM COIL - TAG NO. T-0201/0202 533/R00/A3,SHEET 1 OF 2
& T-0204
TANK –WITHOUT STEAM COIL, TAG NO. T-0201/0202 533/R00/A3,SHEET 2 OF 2
& T-0204, LEG SUPPORT FOR MINIBULK TANK
5 GENERAL ARRANGEMENT DRAWING FOR MINIBULK
TANK- WITH STEAM COIL, TAG NO. T-0203/0205 & T- MEC/23RK/01/31/D5/ME/FP/
0206 534/R00/A3,SHEET 1 OF 2
TANK- WITH STEAM COIL TAG NO. T-0203/0205 & T- 534/R00/A3,SHEET 2 OF 2
0207,LEG SUPPORT FOR MINIBULK TANK
7 GENERAL ARRANGEMENT DRAWING FOR MEC/23RK/01/31/D5/ME/FP/
CONDENSATE TANK -5M3 535/R00/A3,SHEET 1 OF 1
8 GENERAL LAYOUT MEC/23RK/01/14/0001/R03
9 PIPERACK LAYOUT DRAWING MEC/23RK/01/31/D5/ME/PS/
536/R00/A1,SHEET 1 OF 2
10 PIPERACK LAYOUT DRAWING-SECTIONAL VIEW MEC/23RK/01/31/D5/ME/PS/
536/R00/A1,SHEET 2 OF 2
MEC/23RK/01/40/D2/ME/FW/
11 FIRE WATER PIPING NETWORK 671/R0/A0, SHEET 1 OF 1
MEC/23RK/01/40/D2/ME/FW/
12 WHEELED FIRE FIGHTING EQPT 672/R0/A1, SHEET 1 OF 1
13 UTILITY WATER PIPING NETWORK MEC/23RK/01/40/D2/ME/UW/
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675/R0/A0, SHEET 1 OF 1
14 EXISTING TANKS MODIFICATION DRWAINGS
MODIFICATION DWG. FOR EXISTING TANKS –T- MEC/23RK/01/31/D5/ME/MO
0104(BT-01)/T-0105(BT-02)/T-0120(BT-08)/T-0108(BT- D/536/R00/A1, SHEET 1 OF
14.1 09)/T-0115(BT-03)/T-0116(BT-04) 1
MEC/23RK/01/31/D5/ME/MO
MODIFICATION DWG. FOR EXISTING TANKS –T- D/537/R00/A1. SHEET 1 OF
14.2 0117(BT-05)/T-0111(BT-06) 1
15. GLOBAL VENDORS EQUIPMENT DRAWINGS (FOR REFRENCE ONLY)
15.1 BBV ASSEMBLY LAYOUT WITH DOSING TANK M17534

15.2 DRUM OVEN LAYOUT M-0003
15.3 GLOBAL VENDORS EQUIPMENT LAYOUT MEC/23RK/01/14/0001/R03
15.4 EDUCTORS
EDUCTORS-1 INSTALLATION DETAIL FOR FINISHED
15.4.1 PROTANK M-0010 SHEET 1 OF 3
EDUCTORS-2 INSTALLATION DETAIL FOR FINISHED M-0010 SHEET 2 OF 3
15.4.2 PROTANK
EDUCTORS-3 INSTALLATION DETAIL FOR FINISHED M-0010 SHEET 2 OF 3
15.4.3 PROTANK
15.5 PIGGABLE MANIFOLD 36X12 MATRIX 14992054
15.6 3” HLDV GAD 1414203013000
15.7 3” HLDV GAD 1414203013001
15.8 3” HLDV GAD 1414203013035
15.9 3” HLDV GAD 1414203013036
15.10 3” ILDV GAD 1414203013002
15.11 3” ILDV GAD 1414203013070
15.12 4” HLDV GAD 1414204013001
15.13 4” ILDV GAD 1414204023004
15.14 4” HLDV GAD 1414204143092
15.15 4” ILDV GAD 1414204153089
15.16 BBV ASSEMBLY STRUCTURE WL1717.00
15.17 DDU ASSEMBLY & TIE IN POINT 0701
15.18 DDU ASSEMBLY & TIE IN POINT 0702
15.19 DDU ASSEMBLY & TIE IN POIN 0703
15.20 DRUM OVEN SYSTEM M10
15.23 PPM DOSING SKID GAD. FMC-T-0301-SKID
15.24 SMB SKID POC-561 (2 NOS.)
15.25 SMB FABRICATION DRAWING PIP-151
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15.28 1 TON DOSING VESSEL T-0642 WL1707W_R3
15.29 4 TON DOSING VESSEL T-0612 WL1711.00_R3
15.30 4 TON DOSING VESSEL T-0622 WL1710_R3
15.31 5 TON BBV TAG V-0641 WL1706 R3
15.32 6 TON DOSING VESSEL T-0632 wL1709 R3
15.33 10 TON PREMIX TANKS TAGS T-0652 & T-0662 WL1712 R3
15.34 20T BBV V-0611 & V-0621 WL1713_R3
15.36 30 TON BBV TAG V-0631 WL1708 R3
15.37 PREMIX ASSEMBLY FRAME WL-1718.02 R3
15.38 PREMIX ASSEMBLY GENERAL LAYOUT WL1718 R3
15.39 BBV ASSEMBLY STRUCTURE FRAME WL1717.01 R0
15.40 BBV ASSEMBLY GENERAL LAYOUT WL 1717 R2
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CHAPTER-01
SPECIAL INSTRUCTIONS TO BIDDERS
SPECIAL INSTRUCTIONS TO BIDDERS
1.1 General
M/s. Indian Oil Corporation Limited (IOCL) intends to modernize its existing Lube Oil
Blending plant & facilities at Paharpur, Kolkata to enhance installed production capacity of
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the plant from 70,000 – 80,000 KLPA to 1,00,000 KLPA. The modern automated plant shall
able to cater to the present and future demands of lube oils of various grades by state- of
-art blending technology being supplied by M/s. FMC Technologies, USA . The automated
tank farm management system and bulk distribution facilities for Base Oils and Finished
lube Oil products through automated piggable manifolds to various destinations envisaged
in the plant like viz. barrel filling, small can filling & multi bays Tank Truck Filling stations
etc.. The modernization of the plant also envisaged allied facilities like modification of
existing Firefighting facilities network for proposed plant, construction of plant & non plant
buildings & utility services.
1.2 Compliance with this specification will not relieve the bidder of his responsibilities for
supplying the equipment / items of proper design, material and workmanship to meet the
specified operating/process requirements and also proper workmanship and performance of
the facilities under the contract.
1.3 The scope of work specified is indicative only and the bidder is required to carry out any
other scope as per the site requirement available under this tender’s meanings. Any
additional material, which are not specifically mentioned in the technical specifications, SOR
but are required to make the system complete in all respects for safe operation and
guaranteed performance, shall be included in the scope of work of the Bidder without extra
cost.
1.4 All materials supplied shall be new, of best quality and tested in accordance with the latest
version of the relevant Indian standards or relevant International standard & codes acceptable
to IOCL/ MECON. The bidder shall indicate make and grade of all bought out items for
approval of IOCL/ MECON.
1.5 No deviations/ exceptions from this specification shall be permitted without in written approval
of IOCL/MECON.
1.6 All moving parts of erection equipment, which can conceivably cause injury to the operator or
other authorized personnel within the vicinity of the working area, shall be suitably guarded.
Selection of equipment shall be made with the following in view:
a) Safety of personnel, c) Long life of equipment,

b) Uninterrupted operation, d) Easy maintenance
1.7 All drawings and instructions shall be in English language. Dimensions in drawings, technical
data, weights and quantities shall be in metric units.
1.8 SOR accompanying the tender document are indicative scope of work and issued for
tendering purpose only. Final working drawings will be furnished to the successful bidder.
Bidder shall design and prepare the required detailed drawings and site modifications drawings
during the course of execution for fabrication/erection. The preparation of all the fabrication
drawings of complete facilities shall be in the scope of Contractor.
1.9 The bidder is recommended to visit the site to get himself acquainted with prevailing site
conditions i.e., availability of water, power, approach road, existing civil & steel structures of
existing plant & proposed site locations , pipelines etc., before quoting for this tender. The
bidder shall be entirely responsible for provision of all such utilities. No delay shall be
entertained on this account.
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1.10 The bidder shall arrange water or procure water required for the work at his own cost.
Bidder shall ensure a timely and adequate supply of water to meet the schedule.
The bidder shall make his own arrangement for power required for carrying out the work at
his own cost. DG set of suitable capacity may be installed and operated by the bidder at his
own cost. IOCL shall not be responsible for power supply for site construction work .Bidder
shall also ensure proper supply of electricity to meet the schedule. All the electrical works
shall be carried out through Licensed Electrical personnel only.
1.11 For payment purpose against items of supply, fabrication and erection of steel of all types, the
weight shall be calculated based on section given in the standard steel tables and physical
verification whichever is less. The net fabricated dimensions edge to edge shall be taken into
account. The measurement shall exclude any allowance for wastage, weld metals etc.
1.12 Measurement of pipeline shall be taken for actual pipeline laid at site.
1.13 All fittings such as flanges, bends, elbows, tees, branch connections, reducers, full & half
coupling etc. shall be measured separately as per actual execution.
1.14 The installation of all inline instruments shall be paid as per installation rate of flanges indicated
in SOR.
1.15 All nuts & bolts, gaskets etc. as per the type & grades indicated in the PMS, required for flange
connection, equipment ends connection, nozzles, valves, manholes etc. shall be supplied by
the contractor and the cost of supply & erection of the same shall be included in their quote.
1.16 The contractor may be given old and new steel pipes available from the existing stock .The
contractor will have to clean and erect the same.
1.17 The above ground pipeline may pass through brick walls, Dyke walls etc., at some places.
The bidder shall dismantle the required portion of the structure for passing the line and also
make good the damaged surface of the structure to its original conditions. The bidder shall
also provide necessary pipe sleeve. The sleeves for Dyke wall shall be filled with bitumen
sand mixture without any extra cost.
1.18 The contractor shall supply all necessary skilled and unskilled personnel, cranes, hoists, tools
and tackles, instruments, safety implements & barriers and other accessories required for
assembly, erection, testing and commissioning of the system at his own cost .Contractor shall
provide Pre-OISD and OISD inspection assistance for demonstrating the firefighting and other
facilities and carrying out the modifications as suggested by the inspection team. The
contractor should extend commissioning assistance till the complete plant & facilities are
commissioned i.e. successful commissioning of Blenders system, Tank lorry gantry, existing &
new Tank farm pumping & transfer system, utility system etc.
1.19 Safe custody of all the equipment and materials is bidder’s responsibility till the same are
handed over to IOCL/MECON after completion of commissioning activities.
1.20 Successful bidder shall be agreeable to include any other jobs not covered in the tender but
required for the completion/ commissioning of the items covered under this tender. The
rates quoted shall be deemed to include all jobs required for completion/ commissioning.
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1.21 The Bidder shall give complete technical specification of the equipment / items offered and
general arrangement and schematic drawings for the approval of IOCL/MECON or his
representative, sufficiently in advance for the commencement of manufacturing. Such
approval, when accorded, shall however, not relieve the bidder of his responsibilities
towards satisfactory and trouble free performance of the installations. It is responsibility of
the bidder to submit the documents in proper order and getting it approved by
IOCL/MECON after incorporating comments, if any.
1.22 All the equipment / items under contractor’s scope of supply shall be shop tested according
to the relevant latest codes & standards. The particulars of the proposed tests shall be
submitted to IOCL/MECON for approval before conducting the tests. IOCL/MECON or their
representative shall be given full access to all the tests. The supplier shall inform
IOCL/MECON sufficiently in advance so that if IOCL/MECON desires, their representative
can witness the tests. All the certificates shall be submitted for the approval of IOCL/MECON
before clearance for dispatch of the equipment can be given.
1.23 The standard specification requirement, if superior to the technical specifications will prevail
over the technical specification. If the standard specification requirement is inferior to the
standards & codes requirement, then the ’Standards and codes will prevail. But in any case,
the contractor shall proceed after obtaining the necessary clarifications from the
purchaser/consultant.
1.24 The contractor shall be fully responsible for any residual engineering required due
to variation from the design drawings and documents enclosed with the tender, supply,
erection, testing, commissioning operation and maintenance of the system in his scope of
work for guaranteed performance.
1.25 The contractor shall carefully check the enclosed Technical Specifications and drawings
and shall satisfy himself to the suitability of the equipment, facilities and layout in totality
as given in the technical Specification, drawings & datasheets and shall take full
responsibility for the efficient operation and guarantee of the specified output of the
plant and equipment offered.
1.26 All norms pertaining to statutory authorities including electrical/ environment/pollution

control as shall be adhered in strict compliance with the National/ State/ Workplace Health
and Safety regulations and guidelines for the complete plant and equipment under the
contractor’s scope during the contract execution period.
1.27 The bidder shall be responsible for safe custody of all mandatory spares, spares required
during commissioning & guarantee tests, all materials/ equipment, drawings, catalogues till
handing over to IOCL/MECON.
1.28 It is understood that approval or release by IOCL/MECON does not include the checking for
drafting and other errors, but only review of basic concepts and general principles involved.
Approval does not relieve the contractor of responsibility for correctness of design, details
and dimensions.
1.29 The bidder shall furnish to IOCL/MECON the complete drawings, documents, test certificates,
etc. as indicated in this technical specification for approval / information and record.
1.30 The successful bidder shall execute the work as per drawings and technical specification of
this tender however, the bidder shall also execute the work based on the subsequent
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revision of the respective drawings during the execution time as per the site conditions and
statutory requirements.
1.31 Guarantee for the performance from the vendors for all the equipment / materials/ facilities
etc. shall be as per GCC.
1.32 Bidder shall procure & supply the materials/items in line with the respective “STANDARD
TECHNICAL SPECIFICATIONS “- Chapter-04 & “TECHNICAL DATA SHEETS- Chapter-05
enclosed with this tender.
1.33 The painting specification for above ground pipeline & all steel structure shall be as per the
ANNEXURE-C of Standard painting specification no. MEC/23RK/01/31/D1/ME/LOBP/
PAINTING/R000 of this tender.
1.34 The painting specification for underground pipeline shall be as per the ANNEXURE-A / B of
Standard painting specification no. MEC/23RK/01/31/D1/ME/LOBP/ PAINTING/R000 of this
tender.
1.35 List of approved make / vendors for various major items to be procured is enclosed in
ANNEXURE-01.
1.36 Items under contractor’s scope of supply shall be inspected by TPI agency before
dispatching to the site for execution. Contractor shall engage the TPI agency as
per the list of Third party inspection (TPI) agencies enclosed as ANNEXURE-02 and
shall include the cost towards engaging the TPI in their quote.
1.37 General abbreviation & notations used in this tender shall be as per ANNEXURE-03.
1.38 Codes & Std. to be followed as per ANNEXURE-04.
1.39 The detailed scope of work (SOW) pertaining to global vendor equipment and allied works for
complete blending system shall be as enumerated in the doc. no. PJ435-09-0975-01-001
furnished in this tender.
1.40 The tentative packing list of the global equipment indicated as ANNEXURE-05.
02.00 SITE CLEANING
02.01 The bidder shall take care to clean the working site from time to time for easy access to work
site and for safety. Working site should always be kept clean to the entire satisfaction of the
Engineer-in-charge.
02.02 Before handing over any work to the owner, the bidder in addition to other formalities to be
observed as detailed in the document shall clear the site to the entire satisfaction of Engineer-
in-charge.
03.00 CO-ORDINATION WITH OTHER AGENCIES
Work shall be carried out in such a manner that the work of other agencies operating at the
site is not hampered due to any action of the bidder. Proper co-ordination with other
agencies shall be the responsibility of the bidder. In case of any dispute, the decision of
Engineer-in-charge shall be final and binding on the bidder. All fronts may not be available
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at a time to the bidder; it is the responsibility of the bidder to plan the activities as per site
conditions, wherever fronts are available. However total work should be completed within
the specified time period.
04.00 SAFETY PRECAUTIONS AND HOT WORK
04.01 Bidder shall have to take all safety precautions for carrying out hot work in the premises after
obtaining hot work permit from site in charge at his own cost as directed by the Engineer-in-
charge. Necessary safety equipment such as safety belts, helmet, etc. and other safety
instruments are to be positioned by the bidder and the same shall be used by the work force
as per work requirement. The bidder has to enforce the same. No hot work is permitted
without issuance of hot work permit by location in charge at the existing location.
04.02 Safety distance as per CCOE rules and Oil Industry Safety Directorate shall be maintained
strictly.
04.03 The suitability and capacity of all equipment used for erection shall be up to the satisfaction
of the Engineer-in-charge.
05.00 ABILITY AND EXPERIENCE OF BIDDER
The bidder shall be capable of executing the entire scope of work, supply of the specified items
and erection work, within specified period. In this regard, the bidder shall submit a list of
various shop facilities, annual manufacturing/ fabrication capacity, manpower availability,
testing facilities and list of clients for whom similar jobs have been executed.
06.00 INCOMPLETE INFORMATION
Tenders with incomplete information are liable to be rejected. Hence, bidders are requested
to go through entire tender document and fulfill all the requirements.
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CHAPTER-02
TECHNICAL SPECIFICATION
OF
PIPING & EQUIPMENT
TECHNICAL SPECIFICATION OF PIPING & EQUIPMENT
1.00 GENERAL
The intent of this specification is to cover scope of design , engineering, residual

engineering ,supply, fabrication, erection, , painting, testing and commissioning of Piping &
Equipment as specified under scope of work (clause no. 02.00) and SOR of this tender.
This specification shall intend to cover the piping for process, pigged ,IBR & compressed air
,GI for water supply to plant & non plant buildings including the equipment being supplied by
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contractor as well as free issue to the contractor for assembly/installation in the propose
modernization of LOBP Kolkata. Details regarding items, which shall be supplied as free
issue items by the owner and items to be included in the scope of supply of the bidder are
also indicated in the SOR of the tender.
Specification of products being handled in the proposed modernization of Lube oil plants are
given below for general guidelines to the bidders.
Product Base Oil Additives Finished Product HSD LDO

Parameters Lube oil
V Viscosity, cst at ~14.1 cst to 420 cst ~3 cst to 13650 cst Variable ~2 to 5 ~1.8 to 5.0
400C & 1000C
Sp. Gravity ~0.8 cst to 0.905 cst ~0.947 cst to 114 cst ~0.90 ~0.87 ~0.85
01.01 Brief process description of new Lube Oil Plant facilities:
Base Oil of various grades is received from jetty through existing pig gable pipeline to the
Base Oils receipt manifold (Blend D) and further distributed to the respective existing Base
Oil storage tanks through dedicated pipelines. Various grades of additives being used in
bulk as well as in mini bulk and ppm quantity for manufacturing of the various grades and
quality of lube oils products. Additives are received through tankers for bulk requirements
and in Drums for minibulk & ppm dosing. Bulk additives are being unloaded from the tank
truck to the respective existing bulk additives storage tanks having in-built steam heating
coil arrangement. In the proposed modernization, some of the existing base oils & additives
tanks shall require to be modified and converted in to additive tanks for proposed
modernization so as to cater to the process requirements of additives and enable plant to
produce proposed rated throughput of 100000 KLPA. Base oil & additives from the
respective tanks will be transferred by a dedicated Positive displacement Gear pump to the
four numbers of Batch Blending Vessels (BBV- 01 / capacity-20MT,BBV-02/ capacity-
20MT,BBV-03/capacity-30MT,BBV-04/capacity-5MT) respectively through dedicated
dosing kettles and two numbers of Simultaneous Metered Blending (SMB-01/capacity-
100m3/hr. & SMB-02/capacity-70m3/hr.) through dedicated premix tanks .The complete
blending system is designed with state –of- art technology for the production of low volume
and high volume products in batch & bulk quantity as per the product formulations &
demands. The additives being viscous in nature, hence pre heating is essential to ease the
pumping of products prior to feeding to the blenders. The blenders are steam jacketed to
maintain the operating temp. of 500C for uniform blending. Three numbers of Drum Heating
Unit (DHU) & Drum Decanting Units (DDU) are also envisaged in the modernization plant
to facilitate the heating requirements of additives drums suitably to the desired operating
temp. of 500C to minimize the pressure drop during pumping and also enable for uniform
mixing in the blenders .The various grades of Finished products (lubes) from
aforementioned blenders(BBVs) & SMBs are being transferred to 36 Nos. of newly
constructed finished product tanks and 14 nos. of existing OHT ( Over Head Tank) and
existing vertical tanks .The products from the finished product tanks are being transferred by
dedicated gear pumps through pig gable lines to respective three filling destinations :
i. Tank Truck Lorry Filling (TTLF) station - 4 nos. of pigged lines for loading of various
finished products to tankers, 1 no. of non-pig gable line for direct loading of Base oil
from the Bulk storage tanks.
ii. 2nos. operation +1no. Spare - Barrel Filling station for drum filling.
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iii. 5 Nos. of pigged pipelines will be connected to the existing storage & overhead
tanks catering to the existing small can filling station requirements.
The entire plant will be operated & control automatically by PLC based system. To cater to
the utility requirements, Package boiler (1W+1S) - 02 nos. X 5 MT/hr. Capacity and Air
compressor - 03 Nos. X 600CFM x10 bar each are envisaged in the process plant.
The above brief description of modernization of LOBP is only for major distribution of piping
system and to have brief idea of the facilitates of proposed modernization plant .The GA
drawings of major piping system shall be furnished to the successful bidder before
execution of work.
02.00 SCOPE OF WORK
This specification covers the minimum requirements of supply, fabrication, erection, testing
and commissioning of above ground pipeline system, equipment, assembly and erection of
equipment, valves etc. The specification covers the scope of work of the bidder to be carried
out, general guidelines, codes, standards and general engineering practice to be followed
during supply, fabrication and erection of modernization of Lube Oil Blending Plant (LOBP),
Paharpur,Kolkata.
The scope of work shall be read in conjunction with Schedule of Rate (SOR), technical
specifications and datasheet enclosed with this tender document.
Contractor shall prepare detailed fabrication drawings based on the design drawing
provided by IOCL/MECON
02.01 The scope of work of the bidders shall include but not limited to the following:
a) Receiving free issue items from IOCL/stores, loading –unloading and transporting, shifting
as many times as per requirements of these items to the contractor’s store or work place.
b) Design , engineering, supply, handling, loading -unloading , transportation and storage ,

fabrication, erection ,installation, assembly ,alignment, cutting, edge preparation, fitting,
welding, painting, testing and commissioning , final handing over of complete pipeline
system at various elevations & destinations including connections to and from equipment
nozzles, welded / threaded / flanged pipelines system of modernization of LOBP , Kolkata.
The pipeline system shall include steel pipes of all sizes /MOC/ class or rating, fittings
(elbows, miter bends , non-standard bends as per piping requirements, tees,
expander/reducer, couplings, nipples etc.) ,manual/automatic valves ,ROSOV or
ROV/PRV/PIRV/PSV/TSV etc. , flanges ,strainers, expansion bellows, heat exchangers
,connections for field instruments, installation of all in-line instruments including Flow
meters, Control valves with Reducers / Expanders and matching flanges etc. along with
erection accessories, ,reinforcement pad, low point drain, high point vent , branch
connections etc., integration of new to existing facilities , necessary hook ups at various
elevations with the pipelines & equipment.
Note:
i) The qty. & sizes of steel pipes shall be supplied to the contractor as free issue by IOCL as per SOR.
ii) All pipeline connection from the pig gable manifold to Automatic Barrel filling machines (Old and New)
and hook with the existing storage tanks shall be in the scope of contractor.
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iii) The Battery limit of contractor for TTLF (Tank Truck Lorry Filling) gantry shall be limited to the upstream
flange of the Air Eliminator (Tag. No. U-0821/0822/0823/0824/0901/0902) of the tank lorry filling
pipeline as indicated PID. The supply and erection of Air Eliminator, PD meter, valves, Flow meter,
bottom loading arms, flexible hose with suitable matching end connections, inline instruments, cablings
etc. are in the scope of Instrumentation contractor. However, the supply and erection of
companion/matching flanges of the Air Eliminator shall be in scope of piping contractor. The pipeline
connection of compressed air line to the Base oil and finished product loading pipelines before and after the
air eliminator as per PID/ drawings shall be in the scope of piping contractor.
iv) The supply, fabrication & erection of instrument tapping point for gauges shall include –Tapping from main
header, welding of half coupling, small pipe piece, sockets/flange, isolation valve as per hook up drawings.
v) Instrumentation hook drawings shall be furnished to successful bidder.
vi) Inline instruments shall be supplied by IOCL as free issue items to piping contractor.
c) Design , engineering, supply, transportation, handling, fabrication, installation, erection,

alignment, cutting, edge preparation, fitting, welding , painting ,testing like DPT, radiography,
hydro testing etc. , commissioning , final handing over of complete IBR piping (steam and
condensate) system at various elevations & destinations including connections to and from
equipment nozzles (example – Heat exchanger , Pressure Reducing Station(PRS) ,
Boiler ,Condensate tank , pumps etc.) , welded / threaded / flanged pipelines etc. The IBR
pipeline system shall include IBR steel pipes of various sizes /MOC/ class or rating, fittings
(elbows of all dimensions, tees, expander/reducer, couplings, nipples etc.)
,manual/automatic valves ,TCV etc. ,flanges , steam traps, strainers, tapping connections
for field instruments, erection of in-line instruments including Flow meters, Control valves
with Reducers and Expanders, matching flanges, expansion loops etc. along with erection
accessories ,reinforcement pad, low point drain, high point vent , branch connections, etc.
as per GA drawings and specification. The scope of IBR piping work shall also include
preparation and submission of IBR drawings to the office of Directorate of Steam Boilers,
Kolkata through approved IBR contractor for obtaining approval of the drawings,
arrangement of Inspection of pipes, valves, fittings, and Instruments etc. at site by Boiler
Inspector, carrying out fabrication/erection of Steam Piping, steam coils as per approved
drawings, stage wise or complete inspection of steam pipeline system by Boiler Inspector,
Hydro testing of Steam Piping in presence of Boiler Inspector including necessary
Liaisoning work with the office of Directorate of Steam Boilers ,Kolkata to obtain the
required approvals and submission of 3 sets of hard copies of IBR approved “As Built
Drawings” to IOCL/MECON for reference and records.
Note:
i) The IBR piping system shall also include pipeline from the outlet flange of the package boiler to the inlet
flange of PRS/s located at various locations inside the plant , from PRS/s outlet flange to steam coil inlet
flange/connection of individual equipment and tanks , heat exchangers etc. ,steam condensate out let
from the equipment , tanks, Heat exchangers etc. to condensate recovery tank , condensate recovery
tanks to pump suction and discharge line tapping to boiler feed water header /tanks as per GA drawings.
ii) All weld joints of steam pipeline shall be radio graphed as per applicable IBR std.
iii) The construction /fabrication of civil/strl. supports of PRS , condensate tanks as applicable shall be in the
contractor’s scope.
d) Design ,engineering , supply, transportation, handling, fabrication, installation, erection,

alignment, cutting, edge preparation, fitting, welding, testing , painting and commissioning
and final handing over of complete Fire Hydrant system as per technical specification,
datasheet ,as per fire water piping network drawings no. MEC/23RK/01/40/D2/ME/
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FW/671/R0/A0 enclosed with this tender. The Fire Hydrant system shall comprise of fire
hydrant equipment, steel pipes of various sizes /MOC/ class or rating, fittings (elbows of all
dimensions, tees, expander/reducer, couplings, nipples etc.) ,manual/automatic valve
,flanges , inline strainers, expansion bellow, tapping connections for field instruments, in-
line instruments including Flow meters, Control valves, Reducers, Expanders, Matching
flanges, etc. along with erection accessories ,reinforcement pad, low point drain, high point
vent , branch connections etc., integration of new with the existing facilities and necessary
hook ups with existing facilities at various elevations for connections to and from equipment
nozzles, welded / threaded / flanged pipelines. The necessary modification of existing Fire
Water Network shall also be in the scope of bidder to complete the Fire hydrant system
requirement at the new LOBP, Kolkata.
Note:
i) The detail technical specification along with Technical datasheet for Complete Fire Hydrant system is
enclosed as CHAPTER-03 in this tender.
ii) Contractor shall also need to carry out all the necessary modifications of existing fire hydrant line as
required i.e cutting & rerouting of pipeline to the original condition for accommodating proposed civil
& steel structures during construction/erection of pipe pedestals ,pipe rack etc. in the existing as well
as proposed area and consider the cost in their quote. No extra payment shall be made for above
modifications work.
e) Shifting, loading – unloading ,transportation, handling, unpacking , residual engineering

,assembly, installation, fabrication ,erection, alignment , cutting , edge preparation , fitting,
welding , painting, testing and commissioning , final handing over of complete blending
system comprising of BBVs/SMBs/DDUs/DHUs/ conveyors system , associated pipelines ,
piggable manifold, Pig gable pipeline system and sleeves , 5D bends , piggable manifold ,
HLDVs (Head Line Distribution Valves) /ILDVs (Inline Distribution Valves),
automatic/manual valves, all RIO panels, electrical panels , associated cabling work ,
installation of cable trays, inst. Air lines etc. , all inline instruments including Flow meters,
Control valves, reducers and expanders with matching flanges etc. along with erection
accessories of ppm dosing skids and assemblies , structural platform , DDU/DHU
assemblies including respective structural as per document enclosed with this tender.
Erection and installation of Eductors inside the finished product tanks as per SOR and
drawings shall also be in the scope of bidder. The work shall be carried out as per the
specification, instruction and guidelines furnished by the Global equipment supplier with this
tender and instruction of Engineer in charge.
Note:
i) Shifting, loading unloading, transportation, handling, unpacking, assembly, installation, erection of all
the electrical & instrumentation panels and associated assemblies, piping , valves etc. pertaining to
complete blending system supplied by global vendor shall be in the scope contractor.
ii) The cabling work of unwired /pre wired connections/disassembled connections etc. to the respective
panels in complete for the blending system shall be in the scope of contractor.
iii) The assembly job site installation or Detail Scope of Work (SOW) pertaining to Global equipment is
detailed/enumerated in the document no. PJ435-09-0975-01-001, Sl. No. 27 of Chapter-4 of this
tender. Contractor shall be carried out the work with close compliance with the technical specification,
instruction and guidelines furnished in the document. by Global equipment supplier. Contractor shall
include the cost towards erection/installation /fixing/handling etc. of all panels , cable trays, respective
cabling and all allied work to complete the blending system in totality in their quote.
iv) Piggable pipe and sleeves, 5D bends, HLDVs/ILDVs, inline instruments, blenders and associated
structural platform & assemblies along with all miscellaneous accessories of BBVs - 4 Nos. , SMB
equipment-02 Nos. & assemblies along with all miscellaneous accessories, respective premix &
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dosing tanks with structural platform , DDU/DHU -3 Nos. each with assemblies along with
miscellaneous accessories like Electrical & instrumentation panels, respective cablings, roller
conveyors, prefabricated piping/valves etc. and associated assemblies/accessories , piggable manifold
and accessories , pumps , Eductors etc. shall be supplied by IOCL to the contractor as free issue
items.
v) Eductors shall be installed inside the 36 nos. of finished product tanks as per the SOR and the
schematic drawings. Eductors shall be supplied as free issue to contractor as per SOR.
vi) Supply & installation of matching flanges, fittings, SS 316 bolts – nuts & gaskets, consumables etc. for
pigged lines shall be in the scope of the contractor as per the technical specification enclosed with this
tender.
vii) GAD of equipment being supplied by the Global vendor is enclosed with the tender for reference.
viii) Supply and installation of anchor bolts for pumps, equipment etc. being supplied by global vendor shall
be under contractor scope and shall be paid as per item no. 660 of SOR.
ix) The tentative packing list of the equipment comprising of wt. of equipment, packing dimension, quantity
is indicated in ANNEXURE-5.
x) Blending system shall mean- BBVs/SMBs/ DDU/DHU/ Piggable manifolds/conveyors system / PPM
skids etc., associated prefabricated piping, valves ,steel structure, electrical & instrument panels
,cabling, cable trays etc. as indicated in the doc. No. PJ435-09-0975-01-001 in this tender.
f) Testing of complete piping system like Radiography, DP test including all requisite testing as
per codes and standards, flushing including low–point-drains, high point vents, fabrication of
spool pieces for in-line instruments, Supply & fabrication of necessary plated for blinds for
isolations of flanges , equipment , instruments etc., nuts –bolts & gaskets etc. ,enabling of
above testing, draining of complete pipe line system after hydro test, drying the pipeline with
compressed air etc. shall be in the scope of contractor.
Note:
i) After the completion of fabrication and radiography test successfully, pipelines shall have to be hydro
tested to the specified pressure and holding time as per specification. After performing hydro test
successfully, dewatering, removal of slush, internal cleaning, flushing and drying up of the pipe line
system with compressed air shall be carried out. In case any leak is observed during the tests,
contractor shall decant the water on his own cost to the satisfaction of Engineer In -Charge and repeat
the test till the leak is arrested. No extra payment shall be made to contractor for the same.
ii) All lines weld joint shall be 100% tested for Dye penetration. After the completion of root runs welding,
random radiography of 10% maximum or a minimum of 5 joints from each welder, whichever is more,
shall be carried out by contractor. In case of defects observed during 10% radiography of the weld
joints, repairs shall be carried out and radiography shall be taken after repairs at no extra cost to
contractor. In addition to this, for each joint recommended for repairs, two joints as advised by
Engineer-in-charge shall be subjected to Radiography and analyzed in order to investigate any
problems in the process.
g) Design, engineering, supply, erection, installation of all shims, wedges, packing plates,
inserts, anchor bolts etc. for alignment of equipment , structures ,pipeline system etc. shall
be in the scope of bidder. The final adjustment of foundation levels, dressing of foundation
surface , bedding and grouting of anchor bolts in to the constructed civil works, cutting and
patching up of the existing concrete structure as may be required for the erection of the
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equipment shall be in the scope of bidder. Any civil work if damage by the bidder during the
erection work, shall be rectified by the bidder at his own cost to the satisfaction of Engineer
In-charge.
h) Design , engineering, supply, fabrication , erection ,installation of structural pipe supports

including , steel support columns, shoes, guides, brackets, U-clamps, tie rods along with
fixtures etc. as per standards , drawings & specification and as directed by Engineer in-
charge.
i) Design, engineering, supply, fabrication, erection including preparation of fabrication

drawings, plate cutting diagrams, as-built drawings etc., procurement of material (Except
Free Issued MS Plates for shell & ends plate) like pipes for nozzles, dip pipe , product inlet
pipe , dip hatch etc. flanges ,gussets ,pad plate , structural leg support etc. as per tender
drawings , shifting, cutting, edge preparation, rolling, providing appurtenances, DPT,
Radiography, hydro-testing, insulation, calibration, painting etc. as per drawings , technical
specification and applicable codes and standards. The scope shall also include cleaning of
tank after testing, dewatering, removing slush, if any and lifting & placing of fabricated tanks
in position as per specification and drawings of the respective tanks. Appurtenance shall
mean welding of neck ring, seamless pipe for fabrication of nozzles for Inlet/Outlet , pump
recirculation , manholes with cover plate, TSV, provision for dip pipe , fill pipe , spare
nozzles, holding down arrangement, vent pipe , low drain point, temperature hatch, nozzle
for radar gauge etc. , reinforcement pad plate, stiffeners, wear plate, pipes for nozzles ,
product inlet , dip hatch etc., gusset, lifting lugs, SORF flanges with holes drilled as per
ANSI B 16.5, 150 lbs. rating, blind flange for spare nozzle including nuts -bolts , gaskets,
earthing boss etc. as per drawings .Supply , fabrication & installation of calibrated brass dip
rod graduated in cm on one side only with 3mm thick MS plate and lifting hook and brass
cap as per drawings and specification shall also be in the scope of bidder. Painting
(external surface, support structure etc.) of tanks shall be carried out as per the approved
painting specification.
Following tanks are under contractor’s scope of works:
i) 02 No. of Steam condensate recovery drum of nominal capacity: 5m 3

confirming to ASME SEC-VIII, DIV.-I (latest edition), dimension: 1.8 m x 2.5
m HT, Vertical cylindrical, Dish ends, Legs supports as per design drawings &
specification.
ii) 03 Nos. of Mini-bulk Additive dosing tank without steam coil of nominal
Capacity : 10m3 confirming to API 650 latest edition , dimension of tank:
2.0m Dia. x 4.0m Ht. (T-0201, T-0202, T-0204), Vertical cylindrical, conical
top & bottom without steam coils arrangement ,legs supported as per design
drawings & technical specification.
iii) 03 Nos. of Mini-bulk Additive dosing tank with steam coil of nominal
Capacity: 10m3 confirming to API 650, dimension: 2.0m Dia. x 4.0m Ht. (T-
0203, T-0205, and T-0206), Vertical cylindrical, conical top & bottom with
external limpet type steam coils arrangement, legs supported as per design
drawings & specification.
iv) Note:
i) Plate material: IS 2062 Gr.B.
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ii) Plate Materials for tanks Shell & Ends shall be supplied by IOCL as free issue item to contractor.
Supply of all other materials which are required to complete the fabrication of tanks in all respect like
nozzles , pipes , plates for gussets , RF pad plate etc. shall be in the contractor's scope of supply.
Incase of any additional requirement of MS plate for fabrication of tank , the supply of the plate shall be
covered under structural steel items of SOR for pipe stockades/racks ,Item Sl. No. .574
iii) MOC of pipe material for all purposes : ASTM A 106 Gr. B,. 40S/STD, Seamless, dimension as per
ASME B 36.10.
iv) MOC for steam coil pipe : ASTM A 106 Gr. B,. XS, Seamless, IBR quality, dimension as per ASME B
36.10.
v) MOC of leg support/cross braced/main rafter etc.: IS 2062 Gr. A.
vi) MOC of Gusset plate/central drum etc. :IS 2062 Gr. B
vii) All the steam coils butt weld joints shall be tested for 100% DPT and hydro tested.
viii) All Steam coil butt weld joints shall be radio graphed as per IBR std.
ix) All the applicable tests pertaining to steel tanks as per API 650 latest edition including stress relieved of
steam coil tanks shall be in the scope of contractor.
x) Mini bulk dosing tank /system may be fabricated at site or shop. In case of shop fabrication, no extra
payment shall be made for transportation, loading –unloading, testing etc. for above mentioned tanks.
xi) IOCL shall issue the plates as per plate cutting schedule prepared by fabricator and approved by
IOCL /MECON.
xii) The left over steel plates having area more than one square meter but less than full plate if any , can
be handed over to contractor provided IOCL declares it as unserviceable totally as per the discretion of
IOCL. An amount @25000/- MT shall be recovered from fabricators bill towards the cost of such plates.
balance plates having area less than one square meter will be the property of the contractor.
j) Design, engineering, supply, erection, installation, alignment, testing & commissioning of

pump as per type, specifications, and sizes indicated in data sheets and technical
specification. Scope of supply shall also include manufacture, inspection, insurance,
packing and delivery to project site. Material test certificates for physical and chemical
composition shall be furnished for all pumps to IOCL. Pumps shall be inspected as per
approved QAP and relevant codes & standards. The inspection of pumps shall be carried
out by the approved TPI agencies viz. M/s. IGIS (BV), Lloyds, RITES, PDIL, IRS, DNV as
per tender in compliance with relevant codes & standards at manufacturer's works. The
contractor shall include the cost towards engaging TPI in his quoted price for supply of
materials in his scope of supply. Contractor shall complete the work in all respect in
accordance with the piping GA drawing, specification, codes & standards, manufacturer’s
installation procedures, instructions manuals & direction of Engineer-In-Charge.
i) Rotary Positive Displacement Pump with Motor & Accessories for Mini-bulk
tanks, Capacity -4m3/hr. Head -12.2 kg/cm2(g) as per datasheet and technical
specification.
ii) 01 No. of HSD transfer pump- vertical Centrifugal HSD transfer pump with
Motors & Accessories - Vertical submersed Centrifugal type, Capacity: 20
m3/hr., Head -3kg/cm2 (g) as per datasheet and technical specification.
iii) 01 No. of LDO transfer pump with Motors & Accessories - Vertical submersed
Centrifugal type, Capacity : 20 m3/hr., Head -3kg/cm2(g)
iv) 04 Nos. of steam Condensate recovery pump with Motors & Accessories -
Centrifugal 10m3/hr., Head -4 kg/cm2.
Note:
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i) The piping work for the above shall include supply, fabrication, erection, testing &
commissioning of complete pipeline system including fittings, valves, inline equipment etc.
from the HSD/LDO/ Condensate /Mini additive dosing tanks to respective transfer pumps
suction and pump discharge flange to existing LDO/HSD Day tanks of respective products and
from the Day tanks outlet flange to DG/ Boiler fuel injection/ Boiler feed water/ header pipe
flange. For mini-bulk, pipeline shall be connected to the respective blenders as per PID and
piping GA drawings.
ii) Contractor shall procure the above specified pumps from the preferred pump vendors only.
k) Design, supply, fabrication, erection, installation , insulation , testing & commissioning ,

guarantee of complete Electrical Heat Tracing (EHT) system – Self-regulating type to
maintain operating temperatures at 50°C in the process pipelines as per PID and technical
specification. The work shall include complete design of the Electrical tracing system for the
process pipelines of various sizes ranging from 15 NB to 350 NB including inline valves,
flanges, Strainers etc., inline instruments like flow meter etc. including insulation as per
technical specification and SOR. IOCL shall provide incoming power cables to the panels at
designated point. The supply of panel , cabling, Distribution Boxes, Power Junction Boxes,
Tracer Connection Kits etc. , local Cable trays, Structural steel support for installation of field
panels, Canopy etc., laying of cables connection from the panels etc. shall be in the scope
of the contractor.
l) Design, engineering, supply and fixing of thermal insulation on steam/condensate pipeline

of various sizes, tanks, equipment – indigenous & foreign and modified tanks etc. as per
PID, drawings & Technical specification. The insulation shall be of Resin Bonded Rockwool,
as per IS 8183 for Mattresses & IS 9842 for Pre-form Pipe Section, with Aluminum
Cladding.
Note:
The rate shall include all the miscellaneous items required for fixing the insulation including TPI
charges for the supply & installation of the material.
m) Design , engineering , supply , fabrication , erection , testing & commissioning complete GI

pipeline for drinking /service water supply to plant & non plant building as per drawings
,technical specifications and SOR.
n) Testing and no load run of all mechanical equipment including rotary and static facilities
shall be scope of contractor.
o) Bidder shall supply at his own cost, all necessary resources like skilled & unskilled
personnel, cranes, hoist, tools & tackles, instruments, safety implements & barriers
including accessories required for assembly, erection, testing and commissioning of the
complete plant.
p) Supply ,fabrication & erection of pipe rack with associated platform, walkways, Ladders etc.
any incidental structural steel operating platforms, structural columns / posts, anchoring for
supporting pipes at all elevations, pipe supporting brackets from the walls /columns etc.
Anchor bolt required for supporting the pipes and for aforementioned purposes as per
drawings & specification shall be in contractor scope of supply.
q) Pre -OISD and OISD inspection assistance for demonstrating firefighting, process facilities
and carrying out the modifications as suggested by the inspection team shall be in the
scope of bidder.
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r) Modification of existing steel tanks of Base Oil tank, Additives tanks, Blending kettles, Over
Head Tanks (OHT) for finished product as per PID, drawings and SOR.
The modification work shall include design, engineering, preparation of fabrication drawing,
supply, fabrication and erection of requisite number of appurtenances in the existing tanks
for accommodating TFMS instruments and other process requirements as per PID &
drawings, blinding of unwanted nozzles, providing tank roof & roof supporting structure,
fabrication & erection of steam coils –external type as indicated in the drawing including
obtaining all necessary statutory IBR approvals, thermal insulation etc.
Bidder shall formulate the modification plan of above tanks as per the existing plant
production schedule in consultation with IOCL and approval from IOCL.
Note:
i) The modification work shown in the drawing is indicative & to assess the contractor to the extent of the
modification work to be under taken in the existing tanks. Contractor shall design, carryout detail
engineering, supply, fabrication and erection, testing, painting, insulation, integration etc., suit to the site
condition of the existing tanks.
ii) Contractor shall supply all the materials required for modification of existing tanks including steel plates,
steel structure, nozzle pipe, inlet pipes for product/dip hatch etc., flanges, blind flanges , nut bolts ,
gaskets, IBR quality pipes for steam coil , gusset plate , RF Pad plate, thermal insulation etc. and shall
ensure that that modification of tankage works is complete in all respect and meet the technical
requirements.
iii) Contractor shall dismantle the internals of the existing tanks, blinding of unwanted nozzles, modification
of existing nozzles to suit to the size as per requirements, existing steel & civil structure as required for
modification work of aforementioned tanks.
iv) The fabrication drawings prepared by the contractor shall get approved by IOCL/MECON prior to taking
up modification work.
v) All the steam coils butt weld joints shall be tested for 100% DPT and hydro tested.
vi) All Steam coil butt weld joints shall be radio graphed as per IBR std.
vii) The internal coils of existing tanks to be dismantled and new external type steam coil to be provided.
viii) MOC of plate material : IS 2062 Gr. B
ix) MOC of leg support/cross braced/main rafter etc.: IS 2062 Gr. A.
x) MOC of Gusset plate/central drum etc. :IS 2062 Gr. B
xi) MOC of pipe material for all purposes (process fluid) : ASTM A 106 Gr. B,. 40S/STD, Seamless,
dimension as per ASME B 36.10.
xii) MOC for steam coil pipe: ASTM A 106 Gr. B,. XS, Seamless, IBR quality, dimension as per ASME B
36.10.
s) Review of pipe line routing of existing plant, modification of existing tanks/kettles, steam coil
,collection of all technical inputs data /parameters/information of the site required for
carrying out design , engineering ,supply , fabrication , erection and integration of new
pipeline system to existing shall be in the scope of bidder. The number of the tanks in SOR
are indicative only and may change during the course of details engineering. Contractor
shall formulate the plan for modification of above tanks as per the existing plant production
schedule in consultation with IOCL and approval from IOCL.
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Note :
The integration of new pipeline system to existing one, tap -off of new to existing pipeline system,
modification of existing pipeline, tanks , blending kettles etc. , new pipe supports, anchoring of base plate of
supports etc. shall need to be under taken as per suit to site conditions.
t) Modification of existing Base Oils receipt manifold (Blend-D). The modification work shall
include design , engineering ,supply, fabrication , installation of pipeline , manual/automated
valves , fittings , flanges , coupling / half coupling, tapping for instrument , erection of in line
instruments , necessary supports etc. Bidder shall prepare detail fabrication drawing of the
modification to be under taken suit to the site conditions and submit to IOCL/MECON for
approval prior to commencing of work. Contractor shall formulate the plan for modification of
above as per the existing plant production schedule in consultation with IOCL and approval
from IOCL.
u) The integration of existing pipeline system to new pipeline system shall require modification
of existing pipelines , rerouting of new pipelines , dismantling of existing civil & steel
structures, repositioning/relocating of civil & steel structures to any extent to complete the
entire pipeline system as per suit to site conditions.
v) Dismantling of existing equipment, pipes, fittings, valves & accessories like tanks, pumps,
structures, heat exchanger or any other static equipment at site and transportation to the
owner’s storage/designated points. Unloading the equipment from any height ,unfixing of
foundation bolts ,demolishing of foundation , dismantling of pipes of various thickness,
MOCs etc. ,fittings, valves, inline instruments, steam trap, strainer, pipe supports ,pipe
racks, steel/ concrete structures and platform , unfixing of cleaning of debris , dismantling of
and shifting to the location/s identified by IOCL.
w) Receipt, unloading from trailer/trucks, shifting from client’s godown/store located inside the
premises, unpacking, assembling of sub-assemblies, checking of civil foundation, placing
equipment & frame on foundation, leveling and aligning. All connected systems to the
Equipment like – Lubrication system, heating /cooling system, vacuum system etc. with
accessories.
x) Cleaning, greasing, Oil charging, internal piping, structural work, anchoring equipment,
support as per specifications, drawings, instruction of equipment supplier and to the
satisfaction of Site In-charge.
y) Supply, erection of pipe scaffolding for hydro test, pneumatic test etc. as required shall be in
the scope of bidder at no extra cost to IOCL.
z) Materials handling equipment like chain pulley blocks, crane, hydra, forklift, electric winch
machine and all equipment and resources required for assembly, erection and installation of
Equipment at various elevations shall be in the scope of bidder. All the material handling
equipment used by the contractor should have valid test certificates approved by the
competent authorities.
aa) All consumables like cotton cloth, cleaner, de-greaser etc. and tools and tackles like water
level, spirit level, master level, straight edge, plumb with line dory, scale, drilling machine,
grinding machine, SS /MS shims, wedges, packing plates (machined wherever required)
etc. and assembly ,fabrication aids for all requirements shall be provided by bidder at no
extra cost to IOCL.
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bb) Design, supply, fabrication & erection of spool pieces, blinds, lugs, temporary gaskets and
other materials arrangements required for hydro testing & flushing of pipeline and piping
system.
cc) Mechanical completion of all such works in all respects as per the instructions of
Client/Consultant, specifications and drawings shall be carried out by bidder according to
drawings, datasheet, technical specification, PID, PFD, codes & standard and good
engineering practice.
dd) The contractor shall execute welding work by ARC / 100% TIG welding process as
applicable at locations specified in the drawings & by engineer – In charge at no extra cost
to IOCL.
ee) All the work shall include inspection of materials to be supplied by the contractor by the
approved TPI agencies as per approved QAP, codes & standards. The cost towards TPI for
above inspection shall be borne by the contractor and to be included in their quote.
ff) Any other material not enumerated above but required to execute & complete the job as per
the instructions of Client/Consultant within the scheduled time of completion shall be within
contractor’s scope & responsibility at no extra cost to IOCL.
F
03.00 SUPPLY OF FREE ISSUE ITEMS BY IOCL TO CONTRACTOR
The following items shall be issued by IOCL as free issue items to the contractor as per
SOR.
1. Internal Gear pump with motor, Base plate, accessories for Base Oil,
Additives, Finished product, BBVs, SMBs, PPM dosing skids.
2. Piggable pipelines and sleeves
3. 5D bends
4. Eductors for 36 Nos. of finished product tanks
5. Batch Blender Skids (BBVs) and miscellaneous items, structural platform etc.
6. Premix tanks and miscellaneous items, structural platform etc.
7. Dosing kettles
8. Simultaneous metered blending (SMBs) skids and accessories etc.
9. Piggable manifold- 1 No.,36 x12 matrix
10. Drum oven and accessories-3 Nos.
11. Roller Conveyors for drum ovens
12. Drum Decanting system and accessories-3 Nos.
13. PPM dosing skids-5 Nos.
14. Demisters-5 Nos.
15. Pigged HLDVs and ILDVs, distribution tees, Twin/three ways valves etc.
16. In line Instruments
17. Temp. Control Valves (TCV).
18. Flow control Valves (FCV)
19. Mass Flow Meters
20. PIRVs
21. PRVs
22. Automatic Ball valves
23. Inline strainers
24. Electrical /instrumentation panels, cable trays etc.
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25. BBVs/SMBs/ premix/DDU/DHU etc. prefabricated piping, valves etc.

26. Drawings/Documents like overall plot plan, GAD of major equipment being
supplied by Global vendor, piping material specifications, equipment and
pump datasheet and technical specifications.
The above free issue items is indicative only and shall be supplied to the bidder anywhere
within the project site (LOBP Kolkata) .Shifting, transportation of all the free issue items to the
construction site as per requirements shall be in the scope of the bidder.
Note:
i) GA Piping drawings, equipment drawings, support details etc. shall be furnished to successful bidder.
ii) Bidder shall include the cost to be incurred for the shifting & transportation of equipment, materials in their
quote.
03.01 CONTRACTORS SCOPE OF SUPPLY

The contractor shall supply the following items as per enclosed datasheet, specification &
SOR.
Estimated quantities of the items enlisted below are given in the Schedule of Rates (SOR)
enclosed in this tender.
i) Process pipes & Compressed Air pipes – All sizes /Grades/MOC/Rating or

Class
ii) IBR Pipes & flanges , Fittings with IBR certificates- All sizes
/Grades/MOC/Rating/ Class
iii) Complete fire hydrant system including pipes, fittings, valves equipment etc.
iv) GI pipeline & fitting for drinking/service water supply to plant and non- plant
building
v) Flanges- All sizes /Grades/MOC/Rating or Class
vi) Pipe fittings- Bends, Elbows, non std. elbow, Reducers, Tees, and Couplings
etc.
vii) Valves- Manual /Automated valves - Globe, Gate, Ball, Check
viii) ROV- Pneumatic Triple Eccentric Butterfly valve (Valve & Actuator)
ix) PRV/PSV-Press. Reducing Valve/Press. Safety valve
x) PRV/PIRV – Pressure regulating valve / Pressure indicator regulating valve
xi) LDO/HSD Vertical submersible transfer pumps
xii) Mini bulk transfer pumps, pneumatically operated drum decantation pumps,
steam condensate transfer pumps.
xiii) Compressed air system along with fixing arrangements on Base oil storage
tanks.
xiv) Inline T- type /Y-type Strainer, steam trap etc.
xv) Gaskets
xvi) Fasteners.
xvii) Steel flexible hose for HLDV/ILDV connection
xviii) Loading/Unloading hoses with couplers
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xix) Steel & rubber flexible hose

xx) Expansion bellow
xxi) Pre-fabricated/ site fabricated steel pipe supports , shoes, saddles, clamps,
guides, anchors, stops, clips, cradles, hangers, turn buckles, supporting
fixtures, brackets, fasteners, etc. as per drawings.
xxii) Steel structure such as support columns, platform, walkways, crossover,
stairs, gratings, ladders and hand railings etc.
xxiii) Structural steel for fabrication, erection of pipe racks, platform, walkway,
ladder & other miscellaneous items for erection.
xxiv) Mini bulk dosing tank-6Nos.
xxv) Steam condensate tanks-2 Nos.
xxvi) Complete Electric Heat tracing System
xxvii) PRS
xxviii) Basket strainers
xxix) Any other material not enumerated above but required to execute & complete
the job as per specifications, drawings, datasheet & instructions of
Client/Consultant within the scheduled time of completion shall be within
contractor’s responsibility at no extra cost to the client.
The above items are indicative only and shall be supplied by the bidder anywhere within the
project site (LOBP Kolkata) .All the materials being procured by the contractor shall be
inspected by TPI and the report shall be submitted to IOCL/MECON for review before
supplying to site.
03.02 CONDITIONS FOR ISSUE OF MATERIALS
Whenever any material is issued by Owner, following conditions for issue of material in
addition to other conditions specified in the contract shall be applicable:
1. Necessary indents shall have to be raised by the Bidder as per procedure laid
down by the Engineer-in-Charge from time to time, when he requires the above
material for incorporation in permanent works.
2. Materials shall be issued only for permanent works and not for temporary works,
enabling works etc. unless specifically approved by the Engineer-in-Charge and
the same shall not be taken into account for the purpose of materials
reconciliation.
3. The Bidder shall bear all other cost including lifting, carting from issue points to
work site/Bidder's store, custody and handling etc. and return of
surplus/serviceable materials to Owner's storage points to be designated by the
Engineer-in-Charge etc. No separate payment for such expenditure will be
made.
4. No material shall be allowed to be taken outside the plant without a gate pass.
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5. The Bidder shall be responsible for proper storage, preservation and watch &
ward of the materials.
04.0 BRIEF TECHNICAL SPECIFICATION OF SUPPLY OF MAJOR ITESMS FOR PIPING AND
RELATED ITEMS.
(This shall be read in conjunction with the enclosed Technical specification & Datasheet, PMS
and SOR)
04.01 FLANGES
i) Slip on flanges (as per SOR)

ii) Blind flanges (as per SOR)
iii) Weld neck flanges (as per SOR)
iv)
a) Flanges shall conform to ASME B 16.5 class 150 for size up to 600mm NB
and MSS-SP- 44 for sizes more than 600NB.
b) Flanges shall have 1.5mm raised face and serrated finish to 125 to 250
uAARH.
c) Material of flange shall conform to A105 up to 250mm NB and to IS 2002 Gr
2A above 250mm NB.
Note :
Flanges shall be supplied alongwith required nuts- bolts & gaskets as per PMS & technical specification.
Contractor shall include the cost of supply & installation of nuts-bolts & gasket in their quote.
4.2 BOLTS AND NUTS
- For process /compressed air /steam & condensate services/GI: Bolts and nuts shall
conform to A193 Gr B7 and A194 Gr 2H respectively. Washers (Machined steel Washers.)
shall conform to IS 2016-1967.
- For piggable pipeline , HLDV/ILDV flanges - SS316 studs bolts full threaded conforming to
A-193GRB8M and 2 Nos. of heavy Nuts – SS316 conforming to A-194 Gr 8M shall be
used.
Note:
The SS or CS nuts & bolts, as applicable in the plant, shall be provided along with the flanges. Bidder shall
include the cost of supply & installation of Nuts & bolts in their quote.
4.3 GASKETS
Gaskets shall conform to IS: 7719-75, Class20, metallic spiral wound gaskets for product lines
and metallic/spiral gaskets for tanks manholes.
Note :
Bidder shall include the cost towards supply & installation of gaskets requirements in their quote.
4.4 T-TYPE / Y- TYPE STRAINERS
i. Strainers shall be of 40 mesh.

ii. Strainers shall be of rating class 150.
iii. Strainers shall be with flanged ends to suit ANSI B16.5, #150, serrated finish to 125
to 250 AARH.
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iv. Vent and drain connections with valves shall be provided

v. The flow shall be IN to OUT for oil applications (filtration impurities are collected
inside the basket)
vi. Lifting lugs, handles, legs and other accessories shall be provided
vii. Maximum pressure drop across the strainers at maximum flow of the product shall
not exceed the following values :
viii. On the suction side – 0.05 kg/cm2
ix. Effective filtering area on the strainer shall be at least four times the inlet pipe cross
sectional area.
Required quantities are listed in SOR.
4.5 PIPE FITTINGS
i) The following types of pipefittings are required
a. Butt welded long radius elbows (90°)

b. Butt welded long radius elbows (45°)
c. Straight (equal) Tees
d. Reducing outlet Tees
e. Eccentric reducers
f. Concentric reducers
g. Short radius elbows conforming to ANSI B 16.28 shall be used where long
radius elbows cannot be used due to space restriction.
ii) The fittings shall be steel butt welding fittings conforming to ANSI B 16.9 ASTM A 234 WPB
Seamless, Std. Socket welded fittings conforming to ANSI B16.11shall be used for pipes OD
less than 50 mm and material of construction ASTM A 105, class 3000. The thickness of fitting
should match with pipe thickness.
4.6 UNLOADING HOSES WITH COUPLINGS
Synthetic flexible rubber hose 80mm nominal diameter and 6m length and 2.5 m length for oil
service (IS: 10733-1983 Type 2B) shall be embedded with GI wire cotton canvas plies and
copper wire for electrical continuity. Inside of the hose shall have smooth surface and shall be
resistant to the oil. Outer cover shall be resistant to abrasion. Hoses shall be provided with
flange coupling matching with railway wagon / tank truck outlet valves / unloading header
valves.
4.7 PIPES –IBR & NON IBR- CS,GI pipes
a) The pipes shall be supplied as per the technical specification & PMS
enclosed with this tender. This specification covers CS pipes plain /bevel ended
intended primarily for process piping, compressed air piping, and pipes for inline
instrument tapping for Petroleum product services. The pipes for petroleum products
shall conform to A106, Grade ‘B’ or ERW as indicated in technical specification & SOR.
b) TPI shall carry out inspection as per the scope of inspection detailed in Technical
specification and relevant standard for which all arrangements/ facilities shall be made
by successful bidder.
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c) GI pipe shall conform to the IS 1239Part-( Heavy grade GI) . The GI pipes shall be
supplied along with the necessary fittings like elbow, flanges , couplings etc. bidder
shall included the price of fittings in their quote.
d) Material and workmanship
i. The pipes shall be new and the best of its kind. All pipes and their
dimensions, tolerances, chemical composition, physical properties, heat
treatment, hydro test and other testing and marking shall conform to the
respective codes indicated against each category of pipes in the
schedule of quantity. Deviation (s) if any, shall be clearly highlighted in
the offer.
ii. All the materials used shall be free from injurious defects and surface
defects like scale, burns, fins, rusts, cracks and deformation etc. The
inside surface shall be free from weld spatter, foreign matter or other
obstruction. Reconditioning /repair of pipes by welding shall not be
permitted.
iii. Pipes having OD more than 50mm shall be supplied with bevelled ends
and less than 50mm with square ends.
iv. Necessary test certificates shall be submitted to IOCL/MECON for
checking compliance to specified grade of materials.
4.8 VALVES –MANUAL/AUTOMATIC
a) This specification covers the following types of valves as per standards mentioned against each
type, intended for different products of IOCL. Painting shall be suitable for Coastal area & in
line with std. painting specification of IOCL enclosed in the tender.
i. Gate valves
ii. Ball valves
iii. Globe valves
iv. Check valves
v. ROV- Pneumatic Triple Eccentric Butterfly valves
vi. Non return valves/Check valves
vii. Back pressure regulating valve ( PRV)
viii. Pressure Safety Valves ( PSV)
ix. Pressure relief valves (PRV)
i. GATE VALVE
The gate valves sizes ½” to 11/2” shall be of forged steel construction of class 800, socket
weld and shall conform to API 602 latest edition , outside screw and yoke type, bolted bonnet,
solid wedge, rising stem, renewable seat ring and hand wheel operated and for size 2” and
above shall be ASTM A 216 gr. WCB , conforming to API 600 latest edition. The valves shall
be suitable for both horizontal and vertical installation without any modification at site. End
connection shall be socket welded conforming to ANSI B16.11or flanged conforming to ANSI
B16.5 as per SOR. Testing of valves shall conform to API 598.
ii. BALL VALVES
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Ball valves sizes ½” to 11/2” shall be of forged steel construction of class 800 and shall
conform to API 602/ BS: 5351 . The valves shall be of Full bore type, handle operated with
anti-blow out stem, single piece construction with antistatic device and fire safe as per API 607
and for 2” and above shall conform to BS EN ISO 17292/API 6D. End connections shall be
Socket welded type conforming to ANSI B 16.11 or flanged conforming to ANSI B16.5 as per
SOR. Testing shall be as per BS: 6755-Part I.
iii. ROV –TRIPLE ECCENTRIC BUTTERFLY VALVES
Valve shall be forged steel construction of class 150 conform to API 609. End connection shall
be of flanged type confirming to ANSI 16.5. Testing of valves shall be as per API 598 latest
edition.
iv. NON RETURN VALVE/CHECK VALVE
Lift check valves for sizes ½” to 11/2” of forged steel construction of class 800 shall conform to
BS: 1868/IS15761 and 2” and above shall be cast steel ASTM A 216 Gr. WCB, conforming to
API 6D/BS 1868. End connections shall be of socket welded conforming to ANSI B16.11 or
flanged connection conforming to ANSIB 16.5 as per SOR. Testing of valves shall be as per
BS 6755 Part I.
v. GLOBE VALVE
Flanged type Globe valve shall conform to BS 1873. Face to face dimensions of flanged valves
shall confirm to ANSI B 16.10 to the extent covered. For valves not covered in the ANSI
specifications, Contractor shall furnish certified dimensional drawings. Flange dimensions of
steel, alloy steel and stainless steel flanged valves shall confirm to ANSI B 16.5 for sizes up to
24” and API 605 for size 26” and above Flange dimensions for cast iron flanged valves shall
confirm to ANSI B 16.1 for size up to 24” class 125 and API 605 with flat face for sizes
greater than 24”. Testing of valves shall be as per API 598.
b) INSPECTION AND TESTING
All the tests furnished below and as indicated in API 598 for gate valves, BS 6755 Part. I for
NRV and Ball valves shall be carried out for each valve.
a. Visual examination of all assembled valves for surface defects, if any.

b. Overall dimensional check for all valves.
c. Operation of all valves for easy opening and closing.
d. Shell test (hydrostatic) for all valves.
e. Seat and back seat test (hydrostatic) for all valves.
f. Low pressure (6.0 kg/cm2g) air seat test.
Fire safe test certificates from reputed testing agency shall be furnished for all the valves.
vi. PRESSURE REGULATING VALVES/ PRESSURE INDICATOR REGULATING VALVES

-PRV/PIRV
The Pressure regulating valve shall be of forged steel 150 class as per manufacturing
standard. The valve shall be designed to work as adjustable back pressure regulator. End
connections shall be of flanged type , RF conforming to ANSI B16.5. The actuator shall be of
self contained adjustable spring type.
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vii. PRESSURE SAFETY VALVE
Safety pressure relief valves shall be mounted on the product pipeline header between the
valves. These valves shall take care of the excess pressure developed in the header due to
rise in temperature of the product, if any, during daytime
viii. COMPRESSED AIR LINE CONNECTION FOR HLDV/ILDV AND OTHER OPERATION:
¾” dia. SS321 Corrugated metallic flexible hose over SS304 wire braided , one end
connecting to valve shall be ¾” NPT ( M) and other end matching with the connecting pipe.
ix. PRESSURE REDUCING STATION
Skid mounted ,Pressure reducing valves ,stop valves ,bypass valve/isolation stop
valve(piston valve-2Nos. ) strainers ,safety valves, Pressure sensor, Pressure Gauge,
Moisture separation with drain trap, all intermediate piping &welding, fitting along with
companion flanges ,Temp. gauges , Gasket Nut & bolts (IBR Certified).
x. ELECTRIC HEAT TRACING SYSTEM
Electrical heat tracing system – Self-regulating heating cables to maintain process

temperatures in the pipeline at 50°C for the process pipelines of various sizes ranging
from 15 NB to 350 NB including inline valves , flanges, inline equipment etc. , erection of
Panels, Cables, Cable Glands, Heat shrink for cables, field junction boxes, Power
connection Boxes, Glass tape, Support Brackets, GI Cable Trays, Pipe Strap, thermal
insulation , Warning Labels etc. for the complete system, as per technical specification.
xi. The following Piping Material Specification (PMS) shall be followed by the bidder for supply
of items indicated in SOR alongwith the technical specification ,datasheet , technical
document ,drawings enclosed with this tender:
i. PS-201 CL150 CS Piping for Steam and Condensate

ii. PS-202 CL150 CS Piping for Compressed Air
iii. PS-250 CL150 CS Piping for Pig gable Service
iv. PS-251 CL150 CS Piping for General Service
v. PS-275 Identification Codes and Descriptions for Valves &
Piping Components
vi. Drawings
vii. Technical document for the installation of piggable pipeline, demister ,
piggable valves ( HLDV/ILDV)
4.9 MAJOR EQUIPMENT UNDER SCOPE OF SUPPLY OF CONTRACTOR
a) Mini bulk tank :
i. 03 Nos. of Minibulk Additive Dosing tank without steam coil : Nominal Capacity -
10 m3 confirming to API 650 , dimension : 2.0m Dia. x 4.0m Ht. (T-0201, T-
0202, T-0204), Vertical cylindrical, conical top & bottom without steam coils
arrangement ,legs supported as per drawings & technical specification.
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ii) 03 Nos. Minibulk Additive Dosing tank with steam coil: Nominal Capacity -10 m3
confirming to API 650 , dimension : 2.0m Dia. x 4.0m Ht. (T-0203, T-0205, T-
0206),Vertical cylindrical, conical top & bottom with steam coils arrangement ,
legs supported as per specification & drawings. Supply of 50 NB, Sch. XS pipe
for steam coil is in the scope of bidder. The IBR pipe shall conform to ASTM A
106 GR.B, BE,SEAMLESS, dimensions as per ASME B 36.10, IBR Quality ,
50NB, Sch. XS.
b) 02 Nos. of Condensate Recovery Drum of nominal capacity :5m3 confirming to ASME

SEC-VIII, DIV.-I, dimension: 1.8 m x 2.5 m HT, Vertical cylindrical, Dish Ends , Legs
supports as per specification & drawings .
Note :
- For sl. no. a) & b) above , the plate Materials for Shell & ends shall be supplied by IOCL as free issue item
to contractor . Supply of all other materials which are required to complete the fabrication of tanks in all
respect ,as per drawings shall be under contractor's scope of supply.
-
- MOC of plate material : IS 2062 Gr.B.
c) Rotary Positive Displacement Pump with motor & accessories for Minibulk tanks as per
datasheet and technical specification.
i) P - 0201, Capacity - 4 m3/hr, 1200 kPa, Working Temp - Ambient, Viscosity of

Fluid - 85 cSt to 115 cSt @ 40deg C.
ii) P - 0202, Capacity - 4 m3/hr, 1200 kPa, Working Temp - Ambient, Viscosity of
iii) P - 0203, Capacity - 4 m3/hr, 1200 kPa, Working Temp - 50 deg C Viscosity of
Fluid - 2040 cSt @40 deg C and 170 cSt @ 100 deg C
iv) P - 0204, Capacity - 4 m3/hr, 1200 kPa, Working Temp - Ambient, Viscosity of
v) P - 0205, Capacity - 4 m3/hr, 1200 kPa, Working Temp - 50 deg C Viscosity of

Fluid - 9300 cSt @ 40 deg and 775 cSt @100 deg C.
vi) P - 0206, Capacity - 4 m3/hr, 1200 kPa, Working Temp - 50 deg C Viscosity of
Fluid - 100 cSt to 200 cSt @ 100 deg C.
d) HSD transfer pump with Motors & Accessories - Vertical submersed Centrifugal type,
Capacity: 20 m3/hr, head -3kg/cm2 (g) as per datasheet and technical specification.
e) LDO transfer pump with Motors & Accessories - Vertical submersed Centrifugal type,
Capacity: 20 m3/hr,head -3kg/cm2(g) as per datasheet.
f) Condensate recovery pump with Motors & Accessories - Centrifugal 10m3/hr, head -4
kg/cm2 as per datasheet.
g) Pneumatically operated drum decantation gear pump for minibulk doing system (Viscosity
of fluid - 6 cSt to 9300 cSt) as per datasheet.
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h) Suction heater at base oil tank outlet : Shell and tube type suction heater conforming to
design code ASME section VIII Div. 1/TEMA for continuous operation . The suction
heater shall be designed to maintain fluid outlet temp. 500C as per datasheet.
i) Suction heater for tank T-0001, fluid qty. 29700kg/hr, pump discharge
capacity : 30m3/hr.
ii) Suction heater for tank T-0004, fluid qty. 106680kg/hr, pump discharge capacity
: 120m3/hr.
iii) Suction heater for tank T-0006, fluid qty. 35880kg/hr, pump discharge capacity :
40m3/hr.
iv) Suction heater for tank T-0007, fluid qty. 104640kg/hr, pump discharge capacity
: 120m3/hr.
v) Suction heater for tank T-0014, fluid qty. 54360kg/hr, pump discharge capacity:
60m3/hr.
i) BASKET TYPE STRAINER FOR PUMP PROTECTION
Carbon steel flanged basket strainer shall be supplied as per data sheet and SOR. The filter
mesh shall be of SS304, 1000 microns. The ends flange conform to ANSI 16.5.
i) 80NB, Sch STD, 4 m3/hr,viscosity- 6 -5000cSt

ii) 100NB, Sch STD,30m3/hr, viscocity -50-500cSt
iii) 150NB, Sch STD,15m3/hr,viscosity -500-7500cSt
iv) 150NB, Sch STD,20m3/hr,viscosity -500-7500cSt
v) 200NB, Sch STD,15m3/hr,viscosity -500-7500cSt
vi) 150NB, Sch STD,40m3/hr,viscosity -25-350cSt
vii) 150NB, Sch STD,120m3/hr,viscosity -25-350cSt
viii) 150NB, Sch STD,90m3/hr,viscosity -25-350cSt
ix) 200NB, Sch STD,60m3/hr,viscosity -25-350cSt
x) 150NB, Sch STD,60m3/hr,viscosity -25-350cSt
xi) 150NB, Sch STD,30m3/hr,viscosity -25-350cSt
4.10 HOT INSULATION MATERIAL:
Supply and fixing of insulation for pipes of following grade -Resin Bonded Rockwool, as per
IS 8183/IS9842 Mineral wool, bulk density 100kg/m3 including 22 SWG Al. cladding ,self
tapping screws, ring wire ,stitching wire ,strengthening wire. Gal. steel hexagonal wire net
/performed pipe section or mat as per technical specification & SOR.
04.09.01 Application Specification:
a) Cleaning the surface to be insulated to remove dust, dirt, grease etc.

b) Fixing insulation material of required thickness, joints duly butted and laced
with 22swg G.I lacing wire.
c) Securing the insulation with the help of 20mm X 22 SWG Aluminum bands at
300mm center to center distance.
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d) Fabrication and fixing 22SWG Plain Aluminum sheet with proper grooves and
overlaps. The sheet joints shall be sealed with suitable sealant and it shall be
secured with self-tapping screws.
e) Further securing the sheet with the help of 20mm X 22 SWG Aluminum
bands at 450mm center to center distance.
4.10 STANDARD SPECIFICATION FOR SCAFFOLDING, PLATFORMS & LADDERS:
Normally only metal is to be used for scaffolding, platforms and ladders for construction,
erection and allied works at height. Scaffold should conform to provisions given in IS: 2750
– Specification for Steel Scaffoldings.
 A scaffold should be provided and maintained where work cannot safely be

done on or from the ground or from part of a building or other permanent
structure.
 Scaffolds should be provided with safe means of access. Ladders should be
secured against inadvertent movement.
 Every scaffold should be constructed, erected and maintained so as to
prevent collapse or accidental displacement when in use.
 Every scaffold and part thereof should be constructed such as not to cause
hazards for workers during erection and dismantling
 Scaffold is to be of suitable type and adequate for the job
 Every scaffold should be maintained in good and proper condition, and every
part should be kept fixed or secured so that no part can be displaced in
consequence of normal use.
Lifting appliances on scaffolds
When a lifting appliance is to be used on a scaffold the parts of the scaffold should be
carefully inspected to determine the additional strengthening and other safety measures
required
Prefabricated scaffolds
In the case of prefabricated scaffold systems, the instructions provided by the

manufacturers or suppliers should be strictly adhered to. Prefabricated scaffolds should
have adequate arrangements for fixing bracing.
Frames of different types should not be intermingled in a single scaffold. Scaffolding shall
be erected on firm and level ground.
Suspended scaffolds/boatswain’s chair
In addition to the requirements for scaffolds in general as regards soundness, stability and
protection against the risk of falls, suspended scaffolds should meet the following specific
requirements.
a. Platforms should be designed and built with dimensions that are compatible
with the stability of the structure as a whole, especially the length.
b. The number or anchorage should be compatible with the dimensions of the
platform.
c. The safety of workers should be safeguarded by an extra rope having a point
of attachment independent of the anchorage arrangements of the scaffold.
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d. The anchorage and other elements of support of the scaffold should be

designed and built in such a way as to ensure sufficient strength.
e. The ropes, winches, pulleys or pulley blocks should be designed, assembled,
used and maintained according to the requirements established for lifting
gear adapted to the lifting of persons according to national laws and
regulations.
f. Before use, the whole structure should be checked by a competent person.
g. Bamboo Scaffolding shall not be used.
4.12 TECHNICAL SPECIFICATION FOR STEEL STRUCTURALS FOR SUPPORTS,

PLATFORMS ETC.
a. All structural steel plates will conform to IS 2062 – 1999, Fe 410W, Grade A,
for thickness up to and including 20 mm and to IS 2062-1999 Fe 410W Grade
B for thickness above 20mm.
b. All structural steel rolled sections will conform to IS 2062 Fe 410W Grade A
c. All structural steel for hollow sections will conform to IS 4923 grade Yst 240.
d. Electrodes for mild steel will conform to IS 814 – 1991(ASME, BPV, and Sec. II
Part C). The electrodes will be chosen according to the welding procedure to
be adopted, and the quality of metal to be welded. The strength of the weld
metal will not be less than that of the parent metal.
e. Hexagonal head bolts will generally conform to the property class 4.6 as
specified in IS 1367 – (Part 3) – 1991 unless otherwise noted.
f. Bolts and nuts of property class 4.6 will conform to IS 1363 Part 3, - 2002
Size of permanent bolts will not be less than 16 mm
g. Minimum size of fillet weld will be as per recommendation of clause A –

2.1.8 of IS 9595 – 1996 except that leg size will not be lower than 6 mm.
However for nominal fillet weld as required, for example, between
chequered plates and their stiffeners or supporting members, the leg size
will not be less than 4 mm.
h. Steel tubes for structural purposes shall conform to IS: 1161-1998

(Gr Yst-210)
4.13 ERECTION OF STEEL STRUCTURES
a. Erection of structural of fabricated items.
b. Erection shall be carried out in accordance with IS: 800:1984 and other
relevant standards referred to therein.
c. For safe and accurate erection of structural steelwork, staging, temporary

support, false-work etc. shall be erected as required.
d. The fabricated materials received at erection site shall be verified with

respect to marking on the key plan/marking plan or shipping list.
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e. Any material found damaged or defective shall be stacked separately and the
damaged or defective portions shall be painted in distinct colour for
identification and the same shall be brought to the notice of the Purchaser.
f. Erection work shall be taken up after receipt of clearance from the purchaser.
g. For safety requirements during erection, provisions in IS: 7205:1974, IS:

7969:1975 and other relevant Indian standards shall be followed.
h. Erection shall be carried out with the help of maximum mechanization possible.
i. Prior to commencement of erection, all the erection equipment, tools, tackles,

ropes etc. shall be tested for their load carrying capacity. Such tests may be
repeated at intermediate stages also if considered necessary and frequent
visual inspection shall be done of all vulnerable areas and components to
detect damages or distress in the erection equipment, if any.
j. Following shall be taken care of during erection, whenever necessary:
 Temporary bracing, whenever required, shall be provided to sustain

forces due to erection loads and equipment etc. Erected parts of the
structures shall remain stable during all stages of erection when
subjected to the action of wind, dead weight and erection forces etc.
Specified sequence of erection of vertical and horizontal structural
members shall be followed.
 Erected members shall be held securely in place by bolts to take care of
dead load, wind load and erection load.
 All connections shall achieve free expansion and contraction of
structures wherever provided.
 No final bolting or welding of joints shall be done until the structure has
been properly aligned.
 For positioning beams, columns and other steel members, the use of
steel sledges is not permitted. Instrumental checking of correctness of
initial setting out of structures and adjustment of alignment shall be
carried out in sequence and at different stages as required. The final
leveling and alignment shall be carried out immediately after
completion of each section of a building.
 All structural members shall be erected with erection marks in the
same relative position as shown in the appropriate erection and shop
drawings.
 The contractor shall design, manufacture, erect and provide false-work,
staging temporary support etc. required for safe and accurate erection
of structural steelwork and shall be fully responsible for the adequacy
of the same.
 The Contractor shall also provide facilities such as adequate temporary
access ladders, gangways, tools & tackles, instruments etc.to
purchaser for his inspection at any stage during erection.
05.0 TECHNICAL SPECIFICATIONS FOR ERECTION, TESTING & COMMISSIONING
05.01 ERECTION OF EQUIPMENT
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This specification describes a general outline for the installation of the equipment like Heat
exchanger, BBVs, SMBs, premix tank, dosing tanks ,DDU/DHU , piggable manifold, all
electro mechanical drives etc. ,involved in the LOBP Paharpur , Kolkata. The field
circumstances shall be taken into consideration and methods suitable to the site conditions
shall be adopted in consultation with and concurrence of the erection supervisor, erection
manuals and instructions.
Note ; Supply of anchor bolts/foundation bolts of all the equipment supply by the contractor and
for fixing of free issue equipment by IOCL to the contractor like pumps, BBV/SMB/ DDU/DHU
/conveyor system , manifold etc. shall be under contractors scope.
05.01.01. Major activities involved in erection, testing & commissioning are enumerated below.
However, any other activity not mentioned but required for total work execution shall be
included in the scope of work of the bidder.
a. Receiving of equipment/ material, unpacking, storage, transporting the same to respective

erection site.
b. Safe custody of equipment/ material from time of receipt till these are installed and handed
over.
c. Cleaning, flushing and lubricating equipment / material before assembly, erection and
testing. Servicing, greasing, packing the supplied valves as required by IOCL/MECON
d. Checking of foundation levels, center lines, orientation, locations etc.
e. Carrying out minor leveling and alignment of equipment foundation and supports including
chipping of concrete foundation, if required.
f. Assembling, coupling, fitting, fixing, jointing, aligning various sections of equipment etc. by
welding /bolting etc. as per the drawings.
g. Servicing of anchor bolts.
h. Supply and fabrication of liner plates, shim plates.
i. Installing the equipment on foundation /structures/ platforms / walls/ columns as the case
may be in proper orientation.
j. Orienting and leveling the equipment including supply and fabrication of packing plates if
required.
k. Fixing and grouting of anchor bolts and base frame for pumps including supply of non-
shrink grouting mix.
l. Supply, Assembly, positioning, fixing of all accessories (platform, ladder, internals) on the
main equipment.
m. Providing temporary supports, scaffolding, staging around the equipment as required

during the construction, installation, and erection or testing. Removing the same after the
job completion and keeping the area clean. Wooden ladders are not acceptable.
Contractor shall use metallic ladders only.
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n. Protecting properly all installed and uninstalled equipment/ material from theft, damage,
pilferage and becoming a hazard to life and property. Protecting nozzles, flanges,
machined parts, and open pipe ends etc. by covering with plastic pipe caps/flange caps,
wooden blanks, etc.
o. Fabrication and erecting of all temporary or secondary supports, assemblies etc. that are
required for supporting, fixing equipment, pipes etc.
p. Cleaning of equipment (internal & external) before testing.
q. Testing of pipelines, equipment as per the requirement, specifications and standards.
r. Draining, emptying and cleaning the pipelines, equipment after testing and painting
providing necessary drain points.
s. Opening/closing manholes/ nozzles etc. as required during pre-commissioning.
t. The following jobs are also included under bidder’s scope for pumps, motors.(Fixing,
aligning of equipment shall be done only by skilled millwright fitter who will be approved
by MECON before commencement of such work in case felt necessary).
i. Servicing of coupling, stuffing box, and bearings.

ii. Installing of equipment / motor on the base frame.
iii. Checking the motor / equipment for free rotation.
iv. Aligning and coupling equipment with motor before piping and alignment after
piping.
v. Decoupling for testing motor.
vi. Recoupling of equipment with motor after testing.
vii. Hot alignment during trial run.
viii. Installation of mechanical seal and pump/ seal accessories to be carried out
under the supervision of manufacturer.
5.1.2 ERECTION OF PUMP SETS
i. The pumps shall be erected as per the procedure given in the erection manual of
the pump supplier. However the following guidelines shall be taken care of. The
pump base frame shall be erected on prepared foundation and leveled with shims
and wedges with the help of precision levels and other instruments. After leveling,
grouting of foundation bolts shall be completed. When tightening the foundation
bolts, the base plate levels should not get affected. Final level achieved should be of
the order of 0.05 mm per meter.
ii. The pump and driver shall be placed on their respective machined pads ensuring
that their feet make lull contact. Normally a 0.002 inch feeler strip should not pass
between the feet and the pad when the pump and motor are freely placed.
iii. The coupling if not supplied fitted with the pump and drive unit, should be
carefully fitted with a pusher or by means of heating in an oil bath of approximately
180 deg F. The coupling shall never be hammered onto the shaft as this may cause
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serious damage to bearings and mechanical seals. Run-out on a coupling after

fitment should be between 0.05 mm and 0.1 mm TIR. Before proceeding with any
alignment, the pump and driver bearings should be thoroughly cleaned and flushed
with recommended grade of lubricant and the individual units should be checked for
freeness of rotation. The coupling shall be aligned radially and angularly using two
dial gauges.
iv. Connection of suction and delivery pipes shall be made in such a manner that the
connection to the pump flanges does not develop any undue stress and the weight
of the pipes is not transmitted to the pump.
v. After completion of the pipe work, the pump set shall be grouted upto the flanges of
the base frame. Grouting should be filled from inside the base frame and all cavities
filled up. After the grout has set the alignment should be re-checked and compared
with the values recorded prior to grouting. Supply of grouting material and shims is in
bidder scope.
vi. During manual rotation, it shall be ensured that the shaft assembly moves freely and
no noise develops from bearings.
i) Before coupling the driver to the pump, it shall be ensured that the direction of
rotation of the motor corresponds to that of the pump (as indicated in its casings ).
Note: Anchor bolts for all the pumps under the scope of supply of contractor as well as pumps as free
issue to contractor shall be in contractors scope.
05.02 ERECTION OF PRODUCT PIPELINE
05.02.01 GENERAL
The handling, laying and welding of pipelines shall be carried out conforming to relevant
codes / standards unless otherwise stated in the specification given below.
There may be variation between dimensions shown in drawings and actually existing at
site due to minor variations in the location of equipment, inserts, structures, etc. To take
care of these variations “Field welds” shall be provided during piping fabrication. An extra
pipe length of 100 mm over and above the dimensions indicated in the drawings may be
left on one side of the pipe at each of the field welds. During erection, the pipe end with
extra length at each field weld, shall be cut to obtain the actual dimension occurring at site.
Isometrics, if supplied may have the field welds marked on them. However, it is the
responsibility of the contractor to provide adequate number of field welds. In any case no
extra claims will be entertained from the contractor on this account. Wherever errors /
omissions occur in drawings and Bills of materials it shall be the contractor’s responsibility
to notify the Engineer-in-charge prior to fabrication or erection.
Note:
1. Based on the site conditions, the routing of pipelines shown in the drawings may require
modifications. The bidder shall execute the work under his scope of work according to the
modifications as directed by the Engineer in charge.
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2. Piggable pipeline work shall be carried out as per the specification, instruction and guidelines
furnished by the Global equipment supplier and Engineer in charge.
5.2.2 ERECTION OF PIPE - ABOVE GROUND
i. All piping shall be routed and located as per final approved piping drawing
keeping in view the piping specifications. No deviations from the arrangement
shown shall be permitted without the written consent of IOCL/MECON.
ii. Above ground pipes shall be provided at minimum height of 300mm above
finish ground level to enable proper maintenance
iii. In general, pipelines shall be routed above ground. However, where road
crossing is involved as indicated in the layout drawing, the pipelines shall be
routed underground/culverts.
iv. Pipelines shall be routed in a multiple tiers with cable trays as per the structural
drawings of pipe rack enclosed with this tender.
v. All pipes work including IBR pipes shall be designed with sufficient flexibility to
prevent development of undesirable forces or movements at the point of
connection to equipment at anchorage or due to thermal expansion. Flexibility
shall be provided by change of direction or by use of bends, loops or offsets.
vi. Eccentric reducer (i.e on suction side of the pump etc.) the top of pipeline
should be maintained level.
vii. Where equipment has to be removed for maintenance ,the associated pipeline
should be self supporting .Hence ,valves etc. shall be provided with an adjacent
support.
viii. Location and design of pipe supports shown in General Arrangement drawings/
support drawings should be strictly adhered to. However, any change in the
location/s of pipe support/s, type, elevations etc. may be required during actual
execution, shall be approved by Engineer in charge. Pipe supports i.e.
restraints, such as guides, stops, anchors must be made in such a manner that
they will not contribute to the over stressing of a line, while protecting a weaker
or more sensitive component. E.g. pump.
ix. Span of support : The maximum span for various sizes of pipes is given
below:
Sl. Nominal pipe size Max. span in ‘m’

No. ( mm)
1. 25 2.13
2. 40 2.74
3. 50 3.05
4. 65 3.35
5. 80 3.66
6. 100 4.27
7. 150 5.18
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8. 200 5.79
9. 250 6.71
10. 300 7.01
11. 350 7.62
x. Flanged joint shall be used for connections to vessels, equipment,

flan300ged valves and also on suitable straight lengths of pipelines at
strategic points to facilitate erection and subsequent maintenance work.
However, as far as possible ,the flange joints to be kept minimum in the
pipeline to avoid probable leak due to failure of gasket.
xi. While fitting/ welding of matching flanges care shall be exercised to properly
align the pipes and to check the flanges for trueness, so that faces of the
flanges can be pulled up together without inducing any stress at the pipes and
equipment nozzles.
xii. All flange facings shall be true and perpendicular to the axis of pipe to which
they are attached to. Bolt holes of the flanges shall straddle the normal
centerlines unless different orientation is shown in the drawing.
xiii. Wherever a spectacle blind is to be provided, drilling and tapping for the
jackscrews in the flange shall be done before welding it to the pipe.
.
xiv. Anti-static jumpers shall be provided with 8 gauge copper wire at the flanged
joints in piping network to maintain electrical continuity. Piping shall be earthed.
xv. Flanged connections at the pumps, fittings, accessories, etc. shall be made in
such a way as not to induce any stress due to misalignment, excessive gap etc.
The final tightening shall be carried out when the machines are aligned
completely and specifically authorized by Engineer-in-Charge. Temporary
protection covers shall be provided at all flanged connections of pumps, until
the piping is finally connected.
xvi. Pipelines shall be laid sloping wherever shown in the drawings.
xvii. The contractor shall maintain slopes specified for various lines in the drawing.
Corrective action shall be taken by the contractor in consultation with Engineer-
in-charge wherever the contractor is not able to maintain the specified slope.
xviii. Vents and drains shall be provided on each line at the highest and lowest points
to release the trapped air during hydraulic testing and to drain out the test fluid
after testing. These openings shall be plugged and welded after the test.
xix. After the piping is erected in final position, it shall be cleaned, tested for
tightness and kept dry as described in the specification.
xx. All valves shall be provided with the operating handle/ lever/ wrench within easy
reach. Where necessary, operating platforms shall be provided.
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xxi. Installation of line mounted equipment / items like filters, strainers, sight
glasses, etc., including their supporting arrangements shall form part of piping
erection work and no separate payment shall be made for this work.
xxii. The bidder shall provide all required supports, anchors, saddles, hangers,
rollers, clamps, U-bolts, guides, spring supports, sway bracings, vibration
dampers etc. for aligning and controlling the pipe work. Supports shall prevent
under operating conditions, excessive stresses and excessive vibration of
supporting elements from possible resonance with imposed vibrations.
xxiii. Wherever additional flange joints/valve fittings are required, the same shall be
provided after taking approval of site engineer on drawings.
xxiv. All suitable hoisting tackles/ equipment should be used for speedy and safe
handling of pipes while laying the pipes on supports, specifically in case of
surface coated pipes. Such tackles/ equipment shall be provided with
cushioning material to avoid damage to the lining / coating of the pipes.
xxv. The inside of the pipes shall be cleaned of stones, sand, dirt, oil, grease etc.
thoroughly before laying. The cleaning process shall include removal of foreign
matter such as scale, sand, weld, spatter, cutting chips, etc. by wire brushes,
cleaning tools, etc. and blowing out with compressed air and / or flushing out by
potable water.
xxvi. Any equipment or section of pipeline containing liquid hydrocarbon in the

form of trapped volume shall be protected against excessive pressure
development due to rise in surrounding temperature, by installing thermal
relief valve. The discharge of thermal relief valve shall be transferred to
storage tanks or through blow down drain connected to a sump tank. The
pressure safety valve or other devices of sufficient capacity & sensitivity shall
be installed to ensure that normal operating pressure of the system does not
exceed by more than 10%.
5.2.3 ERECTION OF UNDER GROUND PIPE
i. All buried pipe work shall be laid with earth cover sufficient to avoid damage
from pressure of vibration caused by surface traffic. Minimum earth covering
over the pipe shall be 1200 mm with adequate protection ( sand cushion etc.)
from the finished ground level area in areas subject to temporary loads and
1000 mm from finished ground level in areas not subject to temporary loads.
Where the buried depth is less than these limits, permission from the Engineer
in charge shall be taken. All buried pipelines shall be provided with anti-
corrosion coating as specified.
ii. The excavation of trenches shall be so carried out that the digging of trenches
does not go far ahead of the pipe laying operations, so as to prevent risk of
landslide. All work shall be so organized that trench digging, pipe laying, testing
and back filling of trenches follow one another closely.
iii. All buried pipes shall be hydro tested before protective coating.
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iv. Where loose earth is met during excavation or where trench is very deep, side
walls shall be shored properly with timber or other means.
v. The trench shall be excavated to proper width (min. for single pipe 800mm) and
depth. In case of pipeline passing through existing RCC/ asphalt driveway,
contractor shall refill the excavated driveway and complete it to its original
finish. No additional claim for such shall be entertained.
vi. All underground pipelines crossing rail tracks or roads shall be through culverts
or Hume pipes as indicated in the drawings to suit the site.
vii. It should be ensured that while laying the pipes no foreign materials like stones,
sand, gunny bags, bits of welding rods, muck, weld materials etc. are left inside
the laid pipes. The contractor should ensure that the coating of the pipes are
not damaged while drawing the pipes through RCC pipes. If there is any
damage, it shall be rectified by the contractor at his cost.
viii. At the end of each day of work, the free ends of the laid pipes must be kept
properly sealed.
ix. Special care shall be taken to place the pipes in the trenches. If any damages
are caused during laying/ residual welding of pipes in trenches, floating of pipes
in water in trenches, it shall be the contractor's responsibility to get them
repaired and no claim whatsoever on this account shall be entertained by
MECON/ IOCL.
x. On completion of testing and painting of pipelines, the trenches shall be filled as

per specification. The entire responsibility lies with the contractor for taking care
of the pipes including lining/ coating of the pipes.
xi. Underground pipeline should be adequately protected to prevent corrosion.

Special paints viz. solvent free poly urethane /high build solvent free epoxy
coating to be used. This painting system should extend up to 300m beyond
underground portion as it climbs up. In the case of underground pipelines which
extend over large lengths, consideration should be given for providing cathodic
protection to the pipeline in order to prevent electrolytic corrosion.
xii. Factory made bends conforming to ASMEB 16.9 shall be used as far as
possible.
xiii. Branch connection of size below NPS 2 are not recommended in buried
pipeline section.
xiv. All branch connections from main header shall be provided with an isolation
valve located at a minimum possible distance from the main pipeline.
5.2.4 PIPE SLEEVES
Pipe sleeves shall be provided for pipes passing through foundations, walls, floors,
roofs etc. They shall be of sufficient size to permit the passage of flanges or fittings
assembled with the line. The annular space at the ends between the sleeve and the
pipe shall be sealed with cement concrete.
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All required operating platforms, valve stands, access ladders, handrails, pipe
crossovers etc. shall be erected after the piping has been installed. Structural steelwork
in connection with those items shall conform to the relevant Indian Standards for
structural steel work.
5.2.5 ERECTION OF VALVES
i. The valve spindle positions shall be marked in piping drawings and installed
accordingly. In no case valves shall be installed with the stem below the
horizontal.
ii. Check valve, Strainers etc. shall be installed in the correct sequence and in the
direction as shown in piping drawings.
iii. In case the direction of flow is not given on the valve body the same shall be
checked and the correct direction thereon shall be punched prior to their
installation.
iv. Before erection of valves, it shall be ensured that:
a) All grit and foreign matter are removed from the inside of the valves
before connecting the pipes.
b) All the faces are thoroughly cleaned and coated with a thin layer of
mineral grease.
c) It shall be ensured that adequate support is provided for the pipeline

and valve. The valve should never carry the weight of the pipeline.
Hangers or supports placed near the valve will provide better
supports.
d) The connecting pipeline should be cleaned and flushed of sediments,

sand and other foreign matter before installing the valves.
e) The valves should be tightly closed when being installed, to prevent

any foreign matter from getting in between the working parts of
valves.
f) The gasket shall be lubricated with graphite or other recommended

lubricant.
g) It shall be ensured that the joining material sits squarely between the
flanges of valves and pipelines without obstructing the waterway.
h) Valves and other appurtenances shall be so located that they are

easily accessible for operation, repairs and maintenance.
5.2.6 SUPPORTS, GUIDES AND ANCHORS
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Correct installation of supports, restraint guide at pumps and other equipment

maintaining clearances as per approved support drawing shall be ensured. The pipe
support shall conform to provision of ASME B 31.3 code for ASME Boilder & Pressure
Vessel code .
Supports are meant to hold the pipe in the desired position, taking care of thermal
expansion , beside the weight of the piping system without causing undue stress in
entire system.
5.2.7 BOLTS AND NUTS
Proper number and size of bolts and nuts as per drawings and specifications shall be
provided. Approved quality of grease mixed with graphite powder shall be applied
thoroughly on all the bolts and nuts during storage.
5.2.8 ASSEMBLY
The assembly of various piping components shall be done so that the completely
erected piping conforms to the requirements of the specification as well as the
arrangement and details shown in construction drawings.
All flanged joints shall be so fitted that the gasket contact faces bear uniformly on the
gasket and then made up with relatively uniform bolt stress.
Tightening of bolts in flanged joint shall be done in such a sequence that the gaskets
shall be properly compressed in accordance with the design principles applicable to the
types of gaskets used. All bolts shall extend completely through their nuts, but not more
than 15 mm.
06.00 WELDING SPECIFICATION FOR ABOVE GROUND PIPING
This specification shall be followed for the fabrication of all types of weld joints of above
ground process piping system, utility piping system and fire hydrant system of the plant.
a) The welding of pipe joints shall include all pipe joints of the butt welded and
socket weld type as indicated in the piping drawings, welding of flanges
(Slip on /WN/SORF) ,steel supports to pipes, welding of sub-assemblies,
welding of branch connections with or without reinforcing pads,
instrumentation tapping points from the header , connections for vents,
drain etc.
b) All welding work, equipment for welding, heat treatment, other auxiliary
functions, welding procedures and the welding personnel shall meet the
requirements stipulated in the latest editions of the following standards.
i Chemical Plant and Petroleum Refinery Piping - ANSI: B31.3

ii The Indian Boiler Regulations - I.B.R
iii Welding and Brazing Qualifications ASME Sec IX
iv Nondestructive examination ASME Sec. V
v Material Specifications: welding rods, Electrodes and filler metals
as per ASME SEC. II Part C or IS:814.
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Note :
Any approval granted by the Engineer-in-charge or Owner’s inspector, shall not relieve the Contractor
of his responsibilities and guarantee.
c) Before proceeding with welding, contractor shall submit for approval of site
engineer, type brand and size for each batch of consumables for use in each
class of piping.
d) Approval of electrodes shall be based on the successful result of Electrode

qualification test (EQT). EQT shall be conducted per ASME boiler and
pressure vessels code section II part C.
e) The pipes are to be welded are carbon steel, alloy steel and stainless steel,
GI. The contractor shall provide the manufacturer’s test certificates for heat
of the materials supplied by him.
f) The contractor shall provide, at his own expense, all the welding
consumables necessary for the execution of the job such as electrodes, filler
wires, oxygen, acetylene, argon etc., and these should bear the approval of
the Engineer-in- charge.
g) The welding electrodes and filler wires supplied by the Contractor shall
conform to the class specified in the welding specifications chart to be
submitted by the contractor. The materials shall be of the approved make as
per the preferred list enclosed in this tender. The contractor shall submit
batch test certificates from the electrode manufacturers, giving details of
physical and chemical tests carried out by them for each batch of electrode
to be used.
h) All electrodes shall be purchased in sealed containers and stored properly to

prevent deterioration. The electrodes removed from the containers shall be
kept in holding ovens at temperatures recommended by the electrode
manufacturer before they are consumed and such duration shall not exceed
the limits recommended by the electrode manufacturer. The electrodes shall
be handled with care to avoid any damage to the flux covering.
i) All low hydrogen type of electrodes shall be re-baked at 350 0 dig for 1 hour
minimum and stored in ovens kept at 80-1000C before use or as per the
recommendations of the electrode manufacturer shall be followed if available
j) The electrodes, filler wires and flux used shall be free from rust, oil, grease,
earth and other foreign matter which affect the quality of welding.
k) Tungsten electrodes used shall conform to SPA 5.12 specification.
l) The contractor shall provide sufficient number of welding and cutting

equipment, auxiliaries, and accessories of adequate capacities. The
equipment for performing the heat treatment (if applicable), including
transformer ,Thermo-couples, pyro-meters, automatic temperature recorders
with suitable calibration arrangements etc. shall be provided by the
Contractor at his own expense and these should bear the approval of the
Engineer-in-charge.
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m) Contractor shall make necessary arrangements at his own expense for

providing the radiographic equipment, radiographic films, and all the
equipment / materials required for carrying out the Dye-Penetrant Test (DPT)
and any other test required as per codes and standard for satisfactory and
timely completion of the job. Redoing of any work necessitated by faulty
equipment or operation used by the Contractor shall be done at his own
expense.
06.01 WELDING PROCESSES:
Welding of various materials under this specification shall be carried out using one or more
of the following processes with the approval of the Engineer-in- charge.
 Shielded Metal Arc Welding Process (SMAW)

 Gas Tungsten Arc Welding Process (GTAW).
The welding processes to be employed shall be as given in the welding specifications chart.
Automatic and semi-automatic welding processes shall be employed only with the express
approval of the Engineer-in-charge. The welding procedure adopted and consumables used
shall be specifically approved.
A combination of different welding processes could be employed for a particular joint only
after duly qualifying the welding procedure to be adopted and obtaining the approval of
Engineer-in-charge.
6.2 END PREPARATION
06.02.01 The edges to be welded shall be prepared to meet the joint design requirements by any
of the following methods recommended.
a) For Carbon Steel pipe, Gas cutting, machining or grinding methods shall be
used. After gas cutting, oxides shall be removed by chipping & grinding.
b) For Low Alloy Steels, Gas cutting, machining or grinding methods shall be
used. After cutting, machining or grinding shall be carried out on the cut
surface.
c) For alloy steels, Cupro-nickel, Nickel alloys, and Aluminum alloys, Plasma
cutting, machining or grinding methods shall be used. After plasma cutting,
cut surfaces shall be machined or ground smooth.
06.02.02 The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust,
oxides, sand, earth and other foreign matter and made complete dry before the welding
commences.
06.02.03 On completion of each weld run, craters, welding irregularities, slag etc., shall be
removed by grinding and chiseling. Wire brushes to be used for cleaning stainless steel
joints shall have stainless steel wires and the grinding wheels used for grinding
stainless steel shall be of suitable type. Separate grinding wheels and wire brushes
should be used for carbon steels and stainless steel.
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07.00 ALIGNMENT & SPACING
07.01 Components to be welded shall be aligned and spaced as per the requirements laid down in
applicable code. Special care must be taken to ensure proper fitting and alignment when the
welding is performed by GTAW process. Flame heating for adjustment and correction of
ends is not permitted unless specifically approved by the engineer-in-charge.
07.02 A wire spacer of suitable diameter may be used for maintaining the weld root Opening while
tacking, but it must be removed after tack welding and before laying the root bead.
07.03 For pipes of wall thickness 5mm and above, the ends to be welded shall be secured in
position with the aid of couplers; yokes and ‘C’ clamp to maintain perfect alignment. Yokes
shall be detached after the completion of weld, without causing any surface irregularity. Any
irregularity caused on the pipe surface must be suitably repaired to satisfaction of the
Engineer-in-charge.
07.04 Tack welds, for maintaining the alignment, of pipe joints shall be executed careful and shall
be free from defects. Defective tack welds must be removed prior to the actual welding of
the joints.
07.05 Tacks should be equally spaced. Minimum number of tacks shall be
2” tacks - for 2 “and smaller Dia. pipes

4” tacks - for 3” to 12” Dia. Pipes
6” tacks - for 14” and larger Dia. pipes
The tack welds shall be approximately 25mm long and well fused along with sides of end to the
bottom of "V" or groove.
07.06 Welding shall commence only after approval of fit-up by the Engineer – In – charge.
07.07. Welding shall be done in accordance with the approved welding procedure specification.
07.09. All welding machine , line up clamps , beveling machines and other equipment used for
welding work must be satisfactory and kept in good condition
07.10 When socket welded joints are specified, they shall be fabricated and assembles in
accordance with ANSI B 31.3.
07.11 During welding sections of pipe shall be adequately supported, so that the joints are
relieved of any strain.
07.12 all welding shall be supervised and records maintained to ensure that each weld could be
subsequently identified with the individual welder concerned.
07.13 Before welding pipes & pipes fittings, preheating using LPG torch shall be carried out
whenever called for in accordance with the applicable codes. Welding shall be continuous
and shall not be interrupted during pass.
07.14 welding surface shall be thoroughly cleaned so as to be dry and free from paint ,oil, rust
,scale and other material detrimental to weld quality . Each bead shall be cleaned of scale,
oxides, dirt, slag and other impurities before any succeeding weld passes are made.
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07.15 Cleats (if any) welded to the pipes for the joint fit up shall be removed by grinding only. In no
case removal of cleats by hammering is allowed.
07.16 all welds shall be marked by the welders according to numbers assigned to them by the
contractor, who will furnish the Engineer – in – charge with a record of all number assigned .
Should any welder leave during the course of the job, his stamp shall be void & not to be
duplicated on the job.
07.17 Proper identification of each & every joints shall be maintained by providing a unique
number to each joint. Nomenclature of each joint can be written over the pipe/fittings by
paint . No punch or steel stenciling shall be permitted .
08.00 RISER AND BRANCH CONNECTIONS
The end of the riser or branch connections and the openings in the line or header shall be
prepared by gas cutting or machining along templates lines to ensure accurate cutting and
proper fit up. After gas cutting the edge forming the pipes, opening shall be beveled so as to
permit welding completely around the joint for connections. Any rough gas cut edges shall be
cleaned and or removed by chipping or other mechanical means. The riser may be fitted inside
the opening in the header, or set in top. In the latter case the branch shall be beveled for
welding. It is preferable to have the riser at least one size smaller than the header but risers of
the same sizes as the header are permitted. The use of welding toes in such case is
recommended.
After beveling the work shall be assembled and checked as regards to matching of ends,
uniformity of spacing and bevel angle and any defects noted shall be corrected prior to
welding.
The joint shall be tack welded in manner similar to that required for ‘Pipe line joint’.
Where the riser is set in, the weld shall be thoroughly fused to both the beveled edge of the
header and to the sidewalls of the riser. Where the branch or riser is beveled for setting on top
of the opening care shall be exercised to penetrate well, metal shall be fused through at the
root. Where the riser is placed on top of the header it should be back welded on the inside,
wherever possible.
All set in connections shall be prepared so that the ends are at least flush with the inside wall of
the header.
In the case of an offset riser subjected to excessive stresses, knee braces gaskets shall be
used.
09.00 WELDING TECHNIQUE:
09.01 ROOT PASS
a) Root pass shall be made with electrodes / filler wires recommended in

the welding specification chart. For fillet welding, root welding shall be done with
consumables recommended for filler passes. The preferred size of the
electrodes is 2.5mm diameter but in any case not greater than 3.25mm .
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b) Upward technique shall be adopted for welding pipe held fixed with its
axis horizontal.
c) The root pass of butt joints should be executed so as to achieve full penetration
with complete fusion of the root edges. Weld projection inside the pipe shall be
as per applicable code. It shall be limited to 3mm maximum. When the
applicable code does not place any restriction.
d) Any deviation desired from the recommended welding technique and electrodes
indicated in the welding specification chart should be adopted only after
obtaining express approval of the Engineer – in – charge.
e) Welding shall be uninterrupted.
f) While the welding is in progress care should be taken to avoid any kind of
movement of the components, shocks, vibrations and stresses to prevent
occurrence of weld cracks.
g) Peening shall not be used.
09.02 JOINT COMPLETION
a) Joint shall be completed using the class of electrodes, recommended in the

welding specification chart. Size of the electrode shall not exceed 4mm in
diameter for stainless steel and alloy steels used for low temperature
applications.
b) Two weld beads shall not be started at the same point in different layers.
c) Butt joint shall be completed with a cover layer that would ensure good fusion at
the joint edges and a gradual notch free surface.
d) Each weld joint shall have a workmanship like finish. Weld identification mark
shall be stamped clearly at each joint, just adjacent to the weld. Metal stamping
shall not be used on thin pipe having wall thickness less than 3.5mm. Suitable
paint shall be used on thin wall pipes for identification.
e) Rust preventive / protective painting shall be done after the weld joint has been
approved.
f) The weld shall be thoroughly fused to both sides of the "V" or groove and
through the bottom of the joint. The pipes shall be welded with three runs of
weld. There shall be good fusion between each run and scale shall be
thoroughly removed from the surface of each bead or layer of scaling or
moderately peeling before the next one is applied. In the event of any cracks
occurring, tack welds shall be chipped out before welding is continued. Special
care shall be exercised to re melt the tack welds to fuse them with the weld.
g) Where the pipe can be turned, all welding shall be carried out in the down hand
position. The finished weld shall be uniform and of smooth finish. There shall be
no overlapping or excessive undercutting of the pipe at the edge of the weld.
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h) No painting shall be done until the weld joint has been approved.
i) All weld joints shall be free from adherent weld spatters slag, scarf, dirt or
foreign matter. This can be achieved by brushing. For stainless steel,
brushes with only stainless steel bristles should be used
10.00 INSPECTION AND TESTING
10.01 GENERAL
a) The owner’s inspector shall have free access to all concerned areas, where
the actual work is being performed. The contractor shall also provide the
Owner’s Inspector all means and facilities necessary to carry out inspection.
b) The owner is entitled to depute his own inspector to the shop or field where
prefabrication and erection of pipe lines are being done with (but not limited
to) the following objectives.
 To check the conformance to relevant standards and suitability of

various welding equipment and the welding performance.
 To witness the welding procedure qualification
 To witness the welder performance qualification
 To check whether shop/field welding being executed is in conformity
with the relevant specifications and codes of practice followed in
piping construction.
c) Contractor shall intimate sufficiently in advance the commencement of

qualification tests, welding works and acceptance tests to enable the
Owner’s inspector to be present to supervise them.
10.02 WELDING PROCEDURE QUALIFICATION / SPECIFICATION (WPQ/WPS)
Welding Procedure Qualification shall be carried out in accordance with the relevant
requirement of ASME Sec. IX latest edition or API 1104 latest edition and the job
requirements. The contractor shall submit the latest Welding Procedure Specifications as
per ASME Sec IX immediately after the receipt of the order in the approved format. Owner’s
inspector will review, check and approve the welding procedure submitted for his approval
immediately after completing the procedure qualification test. Standard tests as specified in
the code shall be carried out in all cases. On successful completion of procedure
qualification, welding procedure specification along with procedure qualification Record
( PQR) shall be finalized . It shall be the responsibility of the Contractor to carry out all the
tests required to the satisfaction of the Owner’s inspector. The procedure qualification test
shall be carried out by the Contractor at his own expense. A complete set of test results in
format shall be submitted to the owner’s inspector/EIC.
The intent of welding procedure qualification is to establish to demonstrate that welds with
suitable mechanical properties( like strength , ductility and hardness etc.) and soundness
can be made by procedure. The quality of welds shall be determined by nondestructive
/destructive testing ,as applicable as per above std. procedure. The production welding
adhere to the qualified WPS and where there is a change in any of the essential variables ,
the welding procedure must be re-established as a new procedure specification and must
be re-qualified.
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10.3 WELDER’S QUALIFICATION
a) The intent of welder Qualification Test ( WQT) is to determine the ability of

welders to make sound butt welds using previously qualified procedures .
Therefore, before any production welding is performed ,welders shall be
qualified to the requirements of ASME Sec. IX latest edition or API 1104
latest edition and of this specification.
b) Welders shall be qualified in accordance with the ASME Section - IX

requirements or other applicable codes. The owner’s inspector/EIC shall
witness the test and certify the qualification of each welder. It shall be the
responsibility of contractor to carry out qualification tests of welders.
c) The welders shall qualify for welding by performing tests on segments of pipe
of same diameter and specification as the pipe to be used in system
according to the applicable requirements of ASME Sec. IX latest edition or
API 1104 latest edition.
d) The specimen shall be cut out and tested using the testing methods
described in ASME Sec. IX latest edition or API 1104 latest edition and
contractor shall get these tests done as per direction of Engineering In –
charge.
e) A welder who has successfully completed the qualification test shall be

qualified within the limits of essential parameters described in the relevant
codes & std.. if any of essential variable are changed , the welder using the
new procedures shall be re-qualified.
f) The welders shall always have in their possession the identification card and
shall produce it on demand by the Owner’s inspector. It shall be the
responsibility of the Contractor to issue the identity cards after it has been
duly certified by the Inspector.
g) No welder shall be allowed to work without the possession of identity card.
h) If the welder is found to perform a type of welding in a position for which he is

not qualified, he shall be debarred from doing any further work. All welds
performed by an unqualified welder shall be cut and redone by a
qualified welder at the expense of the Contractor.
10.4 WELDING CONSUMABLES
The welding consumables used shall meet requirements of relevant codes and shall produce
a weld deposit, which is compatible in chemical analysis and similar in mechanical properties
to parent material. Normally ,the following electrodes are to be specified /used in pipe
fabrication , unless otherwise mentioned
Welding electrodes shall conform to ASME SEC. II Part C or IS:814 latest edition – covered
electrodes for manual metal arc welding of carbon and carbon manganese steel / American
welding society , AWS – A5.1- carbon steel covered arc welding electrodes – AWS
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classification nos. E6010/E6011/E6013/E7015/E7016/E7018 .The notation signifies the

following :
E- Electrode
60 ( first two numerals) : Tensile strength of the electrodes in PSI
1 ( 3rd Numeral) : The position for which the electrodes can be used . 1 indicated for all
positions .
10 ( last two numerals) : 10 indicates use of DC only .
10.05 VISUAL INSPECTION
Inspection of all welds shall be carried out as per the ANSI B 31.3 latest editions of the
applicable codes and specifications. All finished welds shall be visually inspected for
parallel and axial alignment of the work, excessive reinforcement, concavity of welds,
shrinkages cracks, inadequate penetration, unrepaired burn-through, under cuts,
dimensions of the weld, surface porosity and other surface defects. Undercutting adjacent to
the completed weld shall not exceed the limits specified in the applicable standard/code.
10.06 REPAIRS OF WELDS
a) Defects ascertained, through the inspection methods, which are beyond

acceptable limits shall be removed after the joint is completely radiographed by
the process of chipping and grinding.
b) When the entire joint is judged unacceptable, the welding shall be completely
cut and edges suitably prepared as per required alignment tolerances. The re
welded joint shall again be examined following standard practices.
c) No repair shall be carried out without prior permission of the Owner’s inspector.
d) Repairs and / or rework of defective welds shall be done in time to avoid

difficulties in meeting the construction schedules
10.07 RADIOGRAPHY FOR PIPING WORKS

i. Radiographic examination shall be carried out by approved agency arranged by the
contractor at his cost.
ii.The independent agency to be appointed by the contractor for radiographic inspection

shall be competent to carry out the job and shall have qualified personnel such as
radiographers , helpers etc. and shall comply necessary equipment and material such
as radiographic source camera, films , penetrometers , density meter, dark room screen
etc.
iii.Weld areas to be radiographed shall be designated by the Engineer-in-charge or his

representative. Overall 10% of the joints shall be radiographed for process , air and fuel
including drain line . Cost towards radiography of the pipelines shall be included in the
erection cost of pipeline.
iv.Steam pipeline & steam coil shall be radio graphed as per IBR std.
v.Steam pipeline & steam coils shall be hydro tested 1.5 times the max. operating
pressure.
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vi.Radiography for fire water lines is not mandatory.
vii.Radiographs of the welds shall be taken as soon as the welding of joint is completed. If
repairs are required they shall be carried out before continuing the other welds.
viii.Repeat radiography due to contractors fault or additional radiography necessitated due

to poor performance of contractor/welders shall be done at contractor's cost.
ix.Welds found faulty as a result of Radiographic, visual or other tests must be chipped off
to the satisfaction of the Engineer-in-Charge or his representative and welded as per
specifications and instructions. The welded portion shall be re-tested as per the
instructions of the Engineer-in-Charge or his representative. No claims for
compensation whatsoever shall be entertained on this account.
x.For each weld performed by a welder found unacceptable, two additional checks shall
be carried out on welds performed by the same welder. This operation is iterative and
that of the two additional welds for each weld deemed unsatisfactory shall be continued
till such time that two consecutive welds of satisfactory quality are found for every
defective weld.
xi.The contractor shall carry out these additional radiographic testing at his own expense.
To avoid the possibility of too many defective welds by a single welder remaining
undetected for a long period to time, the contractor shall promptly arrange for
radiographic examination so that there is no accumulation of defective joints.
xii.Radiographic examination shall be carried out by using Gama radiation. The

radiographic quality level required wire.
xiii.The welding engineer Quality Inspector shall have minimum ASNT level –II qualification
as per ASTM-E 1025 unless otherwise a higher or lower quality level is agreed upon
between IOCL/MECON and the Contractor. The welding engineer shall be conversant
with welding metallurgy as well as welding and weld testing practice in accordance with
relevant codes & stds and shall be able to determine the acceptability of welds by visual
& radiographic inspection/interpretation .
xiv.The radiographer employed shall have minimum ANST Level –I qualification and must
be fully familiar with radiographic equipment and methods including safety procedure
and thoroughly experience in the field of radiographic works . He should be aware of
rules & regulations of radiations protection as well as other relevant safety standards of
the country.
xv.The contractor shall offer all necessary facilities to the site engineer such as dark room
with controlled temperature viewer etc. for the examination of radiograph films.
xvi.If it is impossible to place the radiation source inside the pipe, the weld will be
inspected with the source on the outside. An overlap of at least 40mm at the ends of
each film shall be required to ensure that the first and last location increment
numbers are common to successive films and to establish that no part of a weld has
been omitted.
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xvii.All unexposed films shall be protected and stored properly as per the requirements of
API 1104 standard and ASTM E 94. The exposed and unexposed film shall be
protected from heat, light, dust and moisture. Sufficient shielding shall be supplied to
prevent exposure of film to damaging radiation prior to and following the use of the
film for radiographic exposure.
xviii.The welding Engineer of the agency carrying out radiographic examination shall submit
the radiographic films together with his findings ,reports and recommendation as to the
acceptability or otherwise of welds radiographed to the site in charge. The site in charge
decision as to the acceptability or other wise of the welds irrespective of the opinion or
advice tendered by welding engineer shall be final and binding upon the contractor.
xix.The procedure of radiographic examination shall be qualified to the entire satisfaction

of IOCL/MECON prior to use. It shall include but not be limited to the following
requirement.
 Add foil intensifying screen, at the rear of the film shall be used for all
exposures.
 Fine grain films shall be used.
 A densitometer shall be used to determine film density. The transmitted film
density shall be 2.0 and 3.5 throughout the weld. The unexposed base
density of the film shall not exceed 0.30.
 Radiographic identification system and documentation for radiographic
interpretation reports and their recording system.
xx. All the films submitted by contractor shall be the property of IOCL.
10.08 THIRD PARTY INSPECTION :
It must be noted that whenever, inspection notice is given to the third party for inspection of
materials, a copy will also be dispatched to IOC/MECON so that IOCL/MECON
representatives may join inspection if required. However, party is not absolved of his
responsibility of providing proper type and quality of materials including workmanship.
10.9 RADIOGRAPHIC INSPECTION
10.09.01GENERAL
Radiographic inspection of weld joints shall be conducted as per latest API 1104, the
radiographic requirement shall be as given below.
a. Radiography of first weld of each welder is to be done except that for pipe 100
mm and lower in nominal size, where radiography of first two welds of each
welder are to be done completely.
b. The radiographic procedure shall be approved by the Owner’s Inspector, the
procedure and quality of radiographic examination, limits of acceptability, repair
and removal of defects shall be as per API code 1104, ASTM E-94 and ASTM E-
142.
c. The contractor shall be responsible for carrying out radiography, rectification of
defects and re-radiography of welds repaired and rectified. He shall make
necessary arrangements for providing the equipment as well as Radiographic
film for the satisfactory and timely completion of the job.
d. Radiographic inspection of the welds shall be preferably made with X rays.
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Iridium 192 isotope or any other source may be used with the approval of the site
engineer.
e. The contractor shall fulfill all the statutory safety requirements in handling the X
ray or gamma ray equipment.
f. The details of the radiography shall be duly entered and signed by him in a
register and shall be submitted to the Owner’s Inspector for approval.
g. The contractor shall provide all necessary facilities to the inspector at site such
as darkroom with controlled temperature, viewer etc. for the examination of the
radiographic film at his own cost.
h. Interpretation of Radiographs film shall be done as per acceptable standards.
i. When the entire joint is unacceptable, the weld shall be cut completely and the
pipe ends shall be restored for re welding. After re weld the joint shall again be
radiographed.
j. No repair of welds shall be done without prior permission of the site engineer.
k. For each weld found unacceptable due to welder’s fault such as lack of fusion
and penetration, two additional checks should be carried out on welds performed
by the same welder whose joint was judged unacceptable originally. The
operation is progressive and the procedure of radio graphing two additional
welds for each weld deemed unsatisfactory shall be followed till such time two
consecutive satisfactory welds are obtained.
l. The contractor shall carry out these additional radiographs at his own expense.
10.0.02 EXAMINATION OF RADIOGRAPHS
The radiographic examination method employed shall be in accordance with the ASME
Boiler and Pressure Vessel Code Section V “Non Destructive Examination” Article 2.
The requirements of Article 2, Section V of ASME code are to be used only as a guide.
However, final acceptance of radiographs shall be based on the ability to see the prescribed
penetrometer image and the specified hole. Contractor will engage minimum one L-2
inspector at site for interpretation of radiographs which in-turn will be submitted to
IOCL/MECON for final interpretation.
10.08.03 DETERMINATION OF LIMITS OF DEFECTIVE WELDING
a. When a section of weld is shown by radiograph to be unacceptable under
aforementioned provisions or limits of the deficient welding are not defined by the
radiograph, two adjacent spots shall be examined by radiography.
b. However, if the original radiograph shows at least 75 MM of acceptable weld
between the defect and any one edge of the film, an additional radiograph need
not be taken of the weld on that side of the defect.
c. If the weld at either side of two adjacent sections fails to comply with the
requirements stipulated above, additional nearby spots shall be examined until
the limits of acceptable welding are determined or the fabricator may replace all
the welding performed by the welder on that joint.
d. If the welder is replaced, one radiograph should be taken at any selected
location on any other joint on which the same welder has welded.
e. If any of these additional spots fails to comply with the above requirements, the
limits of unacceptable welding shall be determined as specified for the initial
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section.
10.08.041 REPAIR OF DEFECTIVE WELDS
a. The defective weld shall be removed by chipping or melting out by thermal
gouging process from both sides of joint and re-welding. Only sufficient cutting out
of the defective joints, as is necessary to correct the defect, is required.
b. All repaired weld in joints shall be checked by repeating the original inspection
procedure and by repeating the hydrostatic testing / vacuum box testing method.
10.08.05 RECORD OF RADIOGRAPHIC EXAMINATION:
The fabricator shall make a record consisting of all films with their identification
marks and submit the same on completion of work.
10.08.06 RADIOGRAPHIC INTERPRETATION OF WELD JOINTS AS PER API 1104
Standard for welding pipelines and related facilities for pipe 2” OD. and above
CRACK Not acceptable

LACK OF ROOT PENETRATION / Individual defect shall not exceed 1” in
FUSION 12” weld length.
LACK OF SIDE WALL FUSION Shall not exceed 2” total length shall not
exceed 3” in weld length.
INTERNAL CONCAVITY Not acceptable
POROSITY Max. Dimension shall not exceed ½” in
12”weld length. Distribution of gas
pockets as per porosity chart given in
code.
BURN THROUGH Individual defect shall not exceed ¼”
SLAG INCLUSION Any elongated slag shall not exceed 2”
in length or 1/16” in width
Total length of such defect shall not exceed 2” in 12” weld length. Parallel slag lines shall be
considered as separate conditions if width of either exceeds 1/32”. Isolated slag inclusion
width shall not exceeds 1/8”. Total length of any isolated inclusion shall not exceed ½” in 12”
length of weld nor there did four isolate inclusion of width greater than 1/8” in this length.
Undercutting shall not exceed 1/32” in depth and 2” length under cutting adjacent to the
root bead shall not exceed 2” in length.
10.08.07DOCUMENTS TO BE SUBMITTED BY CONTRACTOR AS APPLICABLE (4 copies

each)
a. Electrode and Welding Consumable Qualification Record

b. Batch test Certificates, for the Electrodes used, obtained from the
Electrode Manufacturer.
c. Proposed Heat Treatment Procedure
d. Heat Treatment Charts
e. Weld joint hardness test results
f. Welding Procedure Specifications.
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g. Welding Procedure Qualification records

h. Welder Performance Qualification records immediately after conducting welder
qualification tests.
i. Radiography Procedure
j. Radiographic test Report along with Radiographs.
k. Residual Pipeline drawings, Isometric etc. giving all the details regarding the pipe
specifications, welded joints, joints radio graphed, joints heat treated, electrodes
used, welders identification number etc.
12.00 TFMS - PIPE SUPPORTS
Cement concrete pedestal with metal inserts shall be provided for structural support of pipeline
system of tank farm area including utility pipelines. The steel structural supports shall be
provided and erected on the inserts by the contractor as per drawings.
The heights of the supports shall be adjusted as per site conditions so as to suit the pipeline
gradient required. The underside of the pipe should have a minimum distance of 300mm from
the ground level. This enables easy maintenance of the pipelines and fittings. Special
consideration should be given to the control valves etc. in the pipe run.
Grade stakes set to correct levels shall be provided along the pipeline alignment at suitable
intervals for checking the levels of the pipe supports/ pipeline during construction of supports/
laying of pipelines.
Due care shall be taken while laying the pipeline on the supports. The contractor shall correct
any damage caused to supports. No claims whatsoever will be entertained by IOCL/MECON
on this account.
General guidelines for supports:
The contractor shall provide pipe supports on steel structures / concrete pedestals:
a) Near changes in direction, branch lines and particularly near valves

b) On pipe and not on valves, fittings or expansion joints
c) On pipe and not on sharp radius bends or elbows
d) On runs which do not require frequent removal for maintenance
e) As close as practical to heavy load concentrations such as vertical runs which do not
require removal for maintenance
f) As close as practical to heavy load concentrations such as vertical runs, branch
lines, heavy valves, separators, strainers etc. and as per direction of site engineer.
g) In establishing the location of pipe supports, the Contractor should be guided by two
requirements
h) The horizontal span must not be so long that sag in the pipe will impose an
excessive stress in the pipe wall
i) The pipeline must be pitched downward so that outlet of such span is lower than
maximum sag in the span in order to facilitate drainage.
13.00 FLUSHING OF PIPELINE
Flushing of all lines shall be done before pressure testing.
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a. Flushing shall be done by fresh potable water or dry compressed air, wherever
water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign
material.
b. In line instruments like control valves, orifice plates, Rota meter, safety valves
and other instruments like thermo wells, which may interfere with flushing, shall
not be included in flushing circuit.
c. The screens / meshes shall be removed from all permanent strainers before
flushing. Screens / meshes shall be reinstalled after flushing but before testing.
d. During flushing temporary strainers shall be retained. These shall be removed,

cleaned and reinstalled after flushing but before testing.
e. In case equipment such as column, vessel, exchanger etc. form part of a piping
circuit during flushing, this shall be done with the approval of Engineer – in –
charge. However, equipment thus included in circuit shall be completely drained
and dried with compressed air after flushing is completed.
f. During flushing discharged water / air shall be drained to the place directed by
the Engineer – in – charge. If necessary, proper temporary drainage shall be
provided by the contractor.
g. Care shall be taken during flushing so as not to damage / spoil work of other
agencies. Precautions shall also be taken to prevent entry of water / foreign
matter into equipment, electric motors, instruments, electrical installation etc. in
the vicinity of lines being flushed.
h. The contractor shall carry out all the activities required before, during and after
the flushing operation, arising because of flushing requirements, such as but not
limited to the following:
i. Removing of valves, specials, distance pieces, inline instruments and any

other piping part before flushing. The flanges to be disengaged for this
purpose shall be envisaged by the contractor and approved by the
Engineer – in - charge. These flanges shall be provided with temporary
gaskets at the time of flushing.
ii. After flushing is completed and approved, the valve distance pieces,
piping specials, etc. shall be reinstalled by the contractor with permanent
gaskets. However, flanges at equipment nozzles and other places where
isolation is required during testing, only temporary gaskets shall be
provided.
iii. Records in triplicate shall be prepared and submitted by the contractor for
each piping system for the flushing done.
14.0 TESTING
I) GENERAL:
a. Soundness of the welds shall be tested by means of hydrostatic tests. The test
shall be conducted only after fulfilling the requirements of visual inspection,
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radiography, etc., and when the entire work is certified by the engineer-in-
charge for performance of such testes.
b. This specification covers the hydrostatic testing of petroleum pipelines. It

recommends minimum procedure to be followed, equipment to be used and
conditions to be considered during the hydrostatic testing of pipelines.
c. Nothing in this recommended procedure should be considered as a fixed rule

for application without regard to sound engineering judgment. Certain
Governmental requirements may differ from the criteria set forth in this
recommended procedure and its issuance is not intended to
supersede/override such requirements.
II) EXTENT OF TESTING
With the exclusion of instrumentation, piping systems fabricated or assembled in the field shall
be tested irrespective of whether or not they have been pressure tested prior to site welding or
fabrication.
To facilitate the testing of piping systems, vessels and other equipment may be included in the
system with the prior approval of Engineer – in – charge if the test pressure specified is equal
to or less than that for the vessel and other equipment.
Pumps and other rotary equipment shall not be subjected to field test pressure.
Lines, which are directly open to atmosphere such as vents, drains, safety valves discharge
need not be tested, but all joints shall be visually inspected. Wherever necessary, such lines
shall be tested by continuous flow of fluid to eliminate the possibility of blockade. However,
such lines if provided with block valve shall be pressure tested up to the first block valves.
Seats of all valves shall not be subjected to a pressure in excess of the maximum cold working
pressure of the valve. Test pressure applied to valves shall not be greater than the
manufacturer’s recommendation nor less than that required by the applicable code. Where
allowable seat pressure is less than test pressure, test shall be made through an open valve.
Instruments in the system to be tested shall be excluded from the test by isolation or removals,
unless approved otherwise by the Engineer – in – charge.
Restrictions, which interfere with filling, venting and draining such as orifice plates etc. shall not
be installed unless testing is complete.
Control valves shall not to be included in the test system. Where bypasses are provided test
shall be performed through the bypass and / or necessary spool pieces shall be used in place
of the control valve.
Pressure gauges, which are part of the finished system, but cannot withstand test pressure,
shall not be installed until the system has been tested. Where piping systems to be tested are
directly connected at the battery limits to piping for which the responsibility rests with other
agencies, the piping to be tested shall be isolated from such piping by physical disconnection
such as valve or blinds.
III) GENERAL REQUIREMENT / TEST PREPARATION FOR TESTING
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Testing shall be carried out with permanent gaskets installed unless specified otherwise or
instructed by the Engineer – in – charge
No pressure test shall be carried out against closed valve unless approved by the Engineer –
in – charge.
The Engineer- in – charge shall be notified in advance by the contractor, of the testing
sequence and program me, to enable him to be present for witnessing the test.
Before testing, all piping shall be cleaned by flushing to make it free from dirt, loose scale
debris and other loose foreign materials.
All piping system to be hydrostatically tested shall be vented at the high points and the systems
purged of air before the test pressure is applied.
Wherever in the line any void exist due to any reasons, like absence of control valves, safety
valves check valves etc. it shall be filled with temporary spool pieces.
Water shall be introduced in the system from low point to avoid air pocket formation. Vents at
high point shall be left open and not to be closed until water flows out.
All joints welded, screwed or flanged shall be left exposed for examination during the test.
Before pressuring the lines, each weld joint shall be cleaned by wire brush to free it from rust
and any other foreign matter.
Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted

between the companion flanges. Minimum thickness of the blank shall be designed in
accordance with applicable design code.
Open ends of piping system where blanks cannot be used, such as pumps, compressors,
turbines or wherever equipment or pipe spool pieces have been removed or disconnected prior
to hydrostatic testing, shall be blinded off by using standard blind flanges of same rating as the
piping system being tested.
Pressure gauges used in testing shall be installed as close as possible to the lowest point in
the piping system to be tested, to avoid overstressing of any of the lower portions of the
system. For longer lines and vertical lines two or more pressure gauges shall be installed at
locations decided by the Engineer – in – charge.
For lines containing check valves any of the following alternatives shall be adopted for
pressure testing:
Wherever possible pressurize up- streamside of valve.
Replace the valve by a temporary spool pieces and reinstall the valve after testing.
Provide blind on valve flanges and test the upstream and downstream of the line separately
and remove the blind after testing. At these flanges, temporary gaskets shall be provided
during testing and shall be replaced by permanent gaskets subsequently.
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For check valves in lines 1 ½ “and below flapper or seat shall be removed during testing (if
possible). After completion of testing the flapper / seat shall be refitted.
Piping which is spring or counter weight supported shall be temporarily supported, where
the weight of the fluid would overload the support. Retaining pins for spring supports shall
be removed only after testing is completed and test fluid is completely drained.
When testing any piping system, air or steam of approximately 2 kg / cm2 g may be used as
preliminary test to detect missing gaskets etc. as this avoids the necessity of draining the
line to make repairs. However, steam shall not be used for this purpose, if the steam
temperature is more than the design temperature of the line.
For jacketed pipes testing of core pipes shall be done on individual pieces where the pipe is
continuously jacketed, before it is jacketed. The outer jacket shall be tested separately as a
system. For piping with discontinuous jacketing the core pipe and the jacket shall be tested
as separate continuous system.
IV) TESTING MEDIA, TEST PRESSURE AND TEST PRESSURE GAUGES
a) Testing Media
In general all pressure test shall be hydrostatic using iron free water, which is clean and free
of silt. Maximum chlorine content in water for hydrostatic testing for SS piping shall be 15 –
20 PPM.
Salt water shall not be used for hydrostatic testing under any circumstances.
Air shall be used for testing only if water would cause corrosion of the system or overloading
of supports etc. in special cases as directed by Engineer – in – charge.
b) Test Pressure
The hydrostatic / pneumatic test pressure shall be not be less than 1.5 times the maximum
operating pressure and shall be applied and maintained for at least four hours. Line
operating pressure varies from 2.5 bar to 10.5 bar. The water for testing shall be arranged
by the contractor. The testing shall be carried out in convenient section as approved by the
Engineer in charge. If some defect is noticed during the hydrostatic testing, the same shall
be brought to the notice of Engineer in charge. Joints if leaking shall be rectified as per the
welding specification and instruction of Engineer in charge to the satisfaction at no extra
cost to the owner.
The selection of the piping system for one individual test shall be based on the following:
Test pressure required as per piping drawing.
Maximum allowable pressure for the material of construction of piping.
Depending upon the above requirements and based on construction progress, maximum
length of piping shall be included in each test.
c) Test Pressure Gauge
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All gauges used for field testing shall have suitable range so that the test pressure of the
various systems falls in 40 % to 80 % of gauge scale range. Gauge shall be of a good
quality and in first class working condition.
Prior to the start of any test or periodically during the field test programme, all test gauges
shall be calibrated using a standard dead weight gauge tester or other suitable approved
testing apparatus. Any gauge showing an incorrect zero reading or error of more than +2%
of full scale range shall be discarded. The Engineer – in – charge shall check the accuracy
of master pressure gauge used for calibration.
d) Testing Procedure
Air Test
When testing with air, pressure shall be supplied by means of a compressor. The
compressor shall be portable type with a receiver, after cooler and oil separator.
Piping to be tested by air shall have joints covered with a soap and water solution so that
the joint can be examined for leaks.
All other details shall be same as per hydro testing procedure (specified above)
e) Completion of Testing
After the hydrostatic test has been completed, pressure shall be released in a manner and
at a rate so as not to endanger personnel or damage equipment.
All vents and drains shall be opened before the system is to be drained and shall remain
open till all draining is complete, so as to prevent formation of vacuum in the system. After
draining, lines / systems shall be dried by air.
After testing is completed the test blinds shall be removed and equipment / piping isolated
during testing shall be connected using the specified gaskets, bolts, and nuts. These
connections shall be checked for tightness in subsequent pneumatic tests to be carried out
by the contractor for complete loop / circuit including equipment ( except rotary equipment).
Pressure test shall be considered complete only after approved by the Engineer – in –
charge. Defects, if any, noticed during testing shall be rectified immediately and retesting of
the system / line shall be done by the contractor at his cost.
f) Test Records
Records in triplicate shall be prepared and submitted by the contractor for each piping system,
for the pressure test done.
14.01 HYDRAULIC TEST
The Contractor shall ensure that the pipelines have been thoroughly cleaned up by flushing
with clean water/ compressed air of any foreign matter inside the pipes and dried before taking
up for hydro test. The procedure adopted for cleaning shall be indicated by the bidder and
subject to approval by IOCL/MECON.
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All equipment materials, consumables including water and services required for
carrying out the pressure testing of piping system shall be provided by the contractor at
his own cost.
In case of buried pipes the trenches shall be kept free of water and the pipeline surfaces dry.
The pipeline shall be filled with water and the pressure built up by means of test pump with a
gauge to the specified pressure.
With the exclusion of instrumentation, piping systems fabrication or assembled in the shop /
factories shall be tested at the site, irrespective of whether or not they have been pressure
tested prior to site welding or fabrication.
The site – In – charge shall be notified in advance by the contractor of testing sequence /
Program me, to enable him to be present for witnessing the test.
All vents and other connections used as vents shall be left open while filling the line with test
fluid for complete removal of air. In all lines for pressurizing and depressurizing the system,
temporary isolating valves shall be provided if valve vents, drains do not exist in the system.
Open ends of piping system such as pumps or other equipment shall be isolated prior to
hydrostatic testing or blinded by temporary blind flange made out of 10mm thick MS plate.
Pressure shall be applied only after the system / line is ready and approved by the Engineer –
in – charge.
Pressure shall be applied by means of a suitable test pump or other pressure source, which
shall be isolated from the system, as soon as test pressure is reached and stabilized in the
system.
A pressure gauge shall be provided at the test pump discharge for guidance in bringing the
system to the required pressure.
The test pump shall be attended constantly during the test by an authorized person. The pump
shall be isolated from the system whenever the pump is to be left unattended.
Test pressure shall be maintained for a sufficient length of time to permit thorough inspection of
all joints for leakage or signs of failure. Any joint found leaking during a pressure test shall be
retested to the specified pressure after repair. Test pressure shall be maintained for a
minimum of three (04) hours.
The pump and the piping system to be tested are to be provided with separate pressure
indicating test gauge. These gauges are to be checked by the standard test gauge before each
pressure test.
Care shall be taken to avoid increase in the pressure due to temperature variation during the
test.
ii) Equipment for a hydrostatic test
Equipment for the hydrostatic test should be properly selected and in good working order.
Equipment affecting the accuracy of the measurements used to validate the specified test
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Pressure should be designed to measure the pressures to be encountered during the

Hydrostatic test.
Equipment for conducting the hydrostatic test may include the following:
a. A high volume pump capable of filling the line at minimum velocity of 2 km/h
b. A test medium supply line filter capable of ensuring a clean test medium.
c. An injection pumps to introduce corrosion inhibitors or other chemicals into the test
segment, if their use is required.
d. A meter or other comparable means of measuring line fill.
e. A variable speed positive displacement pump shall be capable of pressurizing the

line at specified test pressure. The pump should have a known volume per stroke
and should be equipped with a stroke counter (a constant speed pump having a
variable flow rate control may be used in lieu of the above if the liquid test medium
injected into the pipeline is measured during pressurization).
f. Portable tank, if required, capable of providing a source of liquid test medium.
g. A large diameter bourdon tube type pressure gauge with a pressure range and
increment divisions necessary to indicate anticipated test pressures.
h. A deadweight tester certified for accuracy and capable of measuring increments of

0.1 kg/cm2 (1.5psi).
i. Pressure gauge for recording pressure .This gauge should be deadweight tested
immediately prior to and after use.
j. Temporary manifolds and connections as necessary.
k. Equipment, materials and fluids needed to displace the test medium from the test
segment.
iii) Test Plan
The following factors should be considered in planning a hydrostatic test:
a. Maximum operating pressure anticipated through the life of the facility.

b. Location of pipe and other piping components in the test segment by size, wall
thickness, grade type and internal design pressure(s).
c. Shell pressure rating and location of pipeline valves, air vents and connections
to the segment.
d. Anticipated temperature of test medium, atmosphere and ground.
e. Source(s) of test medium and any inhibiting or other treating requirements
f. Locations and requirements for test medium disposal.
g. Profile and alignment drawing maps.
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h. Safety precautions and procedures.
iv) Test Procedures
A hydrostatic test procedure diagram with explanatory notes and data should be
prepared prior to testing and should indicate in a detailed fashion the following:
a. The length and location of the test segment(s).
b. Test medium to be used.
c. Procedures for cleaning and filling the line.
d. Procedures for the pressurization of test segment(s) including the locations of the
injection points and the specified minimum and maximum test pressures.
e. Minimum test duration for test segment(s).
f. Procedures for removal and disposal of test medium.
g. Safety precautions and procedures.
A specified test pressure is defined as the minimum test pressure, which should be
applied to the most elevated point in the test segment. A detailed analysis of the profile
to determine static and dynamic pressures while the pipeline is being tested should be
performed so that the pipeline will not be over pressurized at points, which are at low
elevations.
v) Line fill And Cleaning
The line fill operation should serve the dual function of cleaning the line and introducing the
necessary test medium into the test segment. Screens or filters should be installed in the test
medium supply line to control the contamination of the test medium by debris or sediment. The
quality and source of water should be determined. Water, which is not free of sediments and
may be injurious to the pipe, valves, equipment, etc., should not be used unless it is filtered.
The filling operation should be planned and executed in a manner, which prevents the infusion
of air into segment to permit the purging of trapped air.
vi) Pressurization
Personnel conducting the test should maintain continuous surveillance over the operation and
ensure that it is carefully controlled.
The test segment should be pressurized at a moderate and constant rate. When approximately
70% of the specified test pressure is reached, the pumping rate should be regulated to
minimize pressure variations and to ensure that increments of no greater than 1 kg/cm2 may be
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accurately read and recorded. Pipe connections should be periodically checked for leaks
during pressurization.
The pressure shall be maintained for a minimum period of 1 hour unless otherwise specified by
the client. The hydrostatic test shall be considered positive only if there is no drop in pressure
at the end of the specified period.
All welded and flange joints shall be inspected for leaks.
Leaky joints shall be repaired by chipping or gauging out such defects as required and re-
welded. The cut out of joints shall be just sufficient to correct the defects. After repairing the
leaky joints, the line shall be tested to prescribed pressure. No claims for expenditure incurred
by the contractor towards such repairs of defective work and testing shall be entertained.
vii) The Test Hold
When the test pressure is reached, pumping should be stopped and all valves and connections
to the line should be inspected for leakage, a period of conservation to the line should follow
during which test personnel verify that specified test pressure is being maintained at the line
pressure and temperature have stabilized. Upon the completion, the injection pump should be
disconnected of its connection to the pipelines and checked for leakage. Pressure should be
monitored and record continuously during the duration of the test.
viii) Displacement of test medium
Water should be completely drained off. Water should be disposed of at approved locations in
a manner that will cause minimal environment effects.
After test, the water shall be completely emptied out and the line shall be made free of water.
All underground piping shall be tested and ensured of no leakage at test pressure before filling
up trenches.
No painting shall be done at weld joints till the system is accepted in all respects.
19.00 DRAWINGS/ INFORMATION TO BE SUBMITTED WITH TENDER
The following drawings & documents in four copies shall be submitted along with the offer:
a. List of clients, for whom similar works were executed, with value of the jobs. Purchase
order / work order and completion certificate copies signed and stamped by the bidder.
b. List of deviations, if any.
c. Bar chart showing the time schedules and break up of different activities like design,
supply, erection, testing, painting and commissioning.
d. List of Erection and supervisory personnel with their qualification experience and
equipment available with the bidder for execution of the project.
20.0 DRAWINGS / DOCUMENTS TO BE SUBMITTED AFTER PLACEMENT OF ORDER BY

THE SUCCESSFUL BIDDER
The following drawings and documents shall be submitted by the successful bidder in 6
copies for approval/ information within the time stipulated.
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a) Detailed bar chart indicating time schedule for different activities like design,
procurement, inspection, erection, testing, painting, commissioning, etc.
b) Detail drawing of steam coils, pipe rack, TLF gantry, operating platforms,
crossovers, ladders, by superimposing on piping drgs. etc. along with fabrication
details.
c) Complete final bill of materials for fittings, steel structures, supports, fasteners,
and other accessories, for each area.
d) Specifications, makes and data sheets of valves, pipe fittings, paints, coating and
other accessories.
e) Quality Assurance Plan for manufacture / fabrication / erection/ testing,
inspection and test reports, radiographic films wherever applicable.
f) As built drawings.
g) Weekly/Monthly progress report.
21.0 PAINTING :
REFER PAINTING SPECIFICATION NO. MEC/23RK/01/31/D2/ME/

LOP/PAINTING/R00.
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ANNEXURE-01
LIST OF APPROVED MAKE / VENDORS FOR VARIOUS ITEMS
The approved vendor list is furnished here. All procurement of material/equipment shall be
adhered from these vendors only.
In case for any item there is no vendor mentioned in the approved vendor list the contractor
shall propose the name of the vendor along with complete credential, catalogue for the item,
past experience, statutory approval etc. which the contractor plans to procure from the
proposed vendor. The procurement activity will start only after the IOCL has approved the
new vendor. The decision of the IOCL/MECON shall be final and binding the contractor in
this regard. In case for any reasons the vendors mentioned in the approved vendor list are
unable to supply item / equipment then also the contractor will furnish all the details of the
proposed vendor.
1. STRUCTURAL STEEL
M/s. JINDAL
M/s. SAIL
M/s. TATA STEEL
M/s. RINL
M/s. VSP
M/s. IISCO
2. PAINTS (TO BE READ ALONG WITH MAKES GIVEN UNDER TENDER

SPECIFICATIONS)
M/s. ASIAN PAINTS

M/s. BERGER
M/s. NEROLAC
M/s. SHALIMAR
M/s. JENSON NICOLSON
M/s. BOMBAY PAINTS.
3. PIPES
a) SEAMLESS PIPES
M/s. PSL LIMITED

M/s. SWASTIK PIPES LIMITED
M/s. MAHARASHTRA SEAMLESS LTD.
M/s. INDIAN SEAMLESS LTD.
M/s. SAW PIPES ( SEAMLESS DIVISION)
M/s. RATNAMANI
M/s. KOBE STEEL INDIA LTD.
M/s. MAHALAXMI SEAMLESS LTD.
M/s.UNITED SEAMLESS TUBULAR PVT. LTD.
M/s. SURAJ LIMITED
b) ERW PIPES
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M/s. ZENITH BIRLA PVT. LIMITED

M/s. JINDAL PIPES LTD.
M/s. STEEL METAL TUBE INDIA LTD.
M/s. PSL LIMITED
M/s. SURYA PIPES
Or EQUIVALENT MAKE
4. PUMPS:
CENTRIFUGAL: LDO/HSD, CONDENSATE TRANSFER PUMP
M/s. AKAY INDUSTRIES, HUBLI

M/s. KSB PUMP, PUNE
M/s. SULZER PUMPS
M/s. KIRLOSKAR, , PUNE
Or EQUIVALENT MAKE
5. INTERNAL GEAR PUMP FOR MINI BULK TRANSFER :
M/s.TUSHACO PUMPS
M/s. ROTO PUMPS ,DELHI.
M/s DESMI INDIA LLP
M/s.UT PUMPS & SYSTEM PVT. LTD.
M/s. DELTA PD PUMPS
Or EQUIVALENT MAKE
6. PNEUMATIC DRUM DECANTATION PUMP FOR MINI BULK ADDITIVES
M/s. GRACO
M/s. MANDAR
M/s. JK FILL PACK
M/s JVG products
M/s. NEXT GEN ENGINEERING
Or EQUIVALENT MAKE
7. SUBMERSIBLE PUMP FOR LDO/HSD:
M/s. KSB,PUNE
M/s. CALAMA INDUSTRIES ,MUMBAI
M/s. CROMPTON AND GREAVES, MUMBAI
M/s. GRUNDFOSS,MUMBAI
M/s TUSHACO PUMPS
8. MOTORS:
M/s. BHARAT BIJLEE

M/s. CROMPTION GREAVES
M/s. SIEMENS
M/s. KIRLOSKAR ELECTRIC
9. SUCTION HEAT EXCHANGER FOR BASE OIL :
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M/s. KINAM ENGINEERING INDUSTRIES , AHMEDABAD

M/s. HRS PROCESS SYSTEM LTD.
M/s JITSON FILTER INDUSTRIES , KOLKATA
Or EQUIVALENT MAKE
10. PIPE FITTINGS:
M/s. ALLIANCE FORGE, MUMBAI

M/s. STEWARTS & LLOYDS OF INDIA LTD, CALCUTTA
M/s. BHARAT FORGE PRESS INDUSTRIES, BARODA
M/s. STEEL SAMRAT (I) LTD, MUMBAI.
M/s. SIVANANDA PIPE FITTINGS LTD, CHENNAI.
M/s. SUPER FORGE, MUMBAI.
M/s. GAYATRI FORGE PVT LTD, MUMBAI
M/s. PERFECTT SERVICES , CHENNAI
M/s. EBY , MUMBAI
M/s. ECHJAY INDUSTRIES , MUMBAI
M/s. TEEKAY TUBES , MUMBAI
M/s. M.S.FITTING
M/s. COMMERCIAL SUPPLYING AGENCY
11. FLANGES:
M/s. C. D. ENGG, CO, GHAZIABAD

M/s. CHAUDHARY HAMMER WORKS PVT. LTD, GHAZIABAD
M/s. GOLDEN IRON & STEEL WORKS, NEW DELHI
M/s. PUNJAB STEEL WORKS, NEW DELHI
M/s. STEEL SAMRAT (I) LTD, MUMBAI
M/s. AJAY FORGINGS, FARIDABAD.
M/s. STEWARTS & LLOYDS OF INDIA LTD, CALCUTTA.
M/s. SUPER FORGE, MUMBAI.
M/s. GAYATRI FORGE PVT LTD, MUMBAI.
M/s. PERFECTT SERVICES, CHENNAI.
M/s. ECHJAY INDUSTRIES, MUMBAI.
M/s. METAL FORGING, NEW DELHI.
M/s. CHOUDHARY HAMMER, GHAZIABAD.
12. GASKETS:
M/s. MADRAS INDUSTRIES PRODUCTS, CHENNAI.

M/s. IGP ENGR, CHENNAI.
M/s. UNI KLINGER
M/s. GOODRICH, CHENNAI.
M/s. VIRCAP SEALINGTECH PVT. LTD.. METROPOLITAN INDUSRIES, CALCUTTA.
M/s. SOUTHRN GASKET PRODUCTS, CHENNAI.
M/s. CHAMPION JOINTING PVT. LTD, MUMBAI.
M/s. HINDUSTAN COMPOSITES, MUMBAI.
13. BOLTS AND NUTS:
M/s.. BOMBAY TOOLS & HARDWARE MART, MUMBAI.

M/s. CONSOL ENGINEERING AND FATNERS INDUSTRIES, HOWRAH.
Page 73 of 91
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M/s. EBY INDUSTRIES, MUMBAI.

M/s. MODERN MECHANICAL INDUSTRIES, MUMBAI.
M/s. PACIFIC FORGING AND FATNERS PVT. LTD, MUMBAI.
M/s. DURG FASTNERS, LUDHIANA.
M/s. PRECISION AUTO ENGINEERS, LUDHIANA.
M/s. MAHAJAN, PUNE.
M/s. NIREKA ENGINEERING , KOLKATTA
M/s. PRECISION ENGINEERING INDUSTRIES , BARODA
M/s. FIX FIT FASTENERS, KOLKATTA.
M/s. PRECISION TAPS AND DIES, MUMBAI
M/s. GKW, MUMBAI.
M/s. ECH JAY
14. VALVES:
BALL, CHECK, GATE, GLOBE
M/s. L&T
M/s. AUDCO
M/s. PECO ENGINEERING
M/s. BHEL, TRICHY.
M/s. MICROFINISH
M/s. XOMOX
M/s. NITON
M/s. FOURESS ENGINEERING
M/s. B.D.K. ENGG. INDUSTRIES PVT. LTD, HUBLI.
M/s.. LEADER VALVES LIMITED, JALANDHAR.
M/s.. VALTECH INDUSTRIES, MUMBAI.
M/s. FLOWCHEM INDUSTRIES, AHMEDABAD.
M/s. TYCO VALVES & CONTROLS INDIA PVT LTD, NAVI MUMBAI.
M/s. SIGMA INDUSTRIES, MUMBAI
M/s. GM ENGINEERING
M/s. ADVANCE VALVE
15. ROSOV-BUTTERFLY VALVE WITH PNEUMATIC ACTUATOR
M/s. VIRGO VALVE& CONTROL PVT. LTD.

M/s. L&T VALVES
M/s. BRAY CONTROL INDIA PVT. LTD.
M/s. CRESCENT VALVES MANUFACTURING COMPANY
M/s. INTRAVALVE POONAWALLA LTD.
M/s. ADVANCE VALVES
a) PNEUMATIC ACTUATOR
M/s. TYCO – BIFFI,
M/s.METSO, BETTIS,
M/s.IL,
M/s.VIRGO,
M/s. EL-O-MATIC,
M/s. KEYSTONE
Page 74 of 91
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b) SOLENOID VALVE
M/s. ASCO,
M/s. NORGEN-HERION,
M/s. SCHRADER-SCHOVILL,
M/s..SAMSOMATIC
c) AIR FILTER REGULATOR

M/s. SHAVO-NORGREN,
M/s. PLACKA ,
M/s. SCHRADER-SCHOVILL,
M/s. NORGEN,
M/s. FESTO
Or EQUIVALENT MAKE
d) LIMIT SWITCHES
M/s. HONEYWELL,
M/s.P+F,
M/s.TELEMECHANIQUE,
M/s.SIEMENS
e) TUBING & FITTINGS

M/s PARKER,
M/s. SWAGELOK
Or EQUIVALENT MAKE
16. BACK PRESSURE REGULATING VALVES-PRV & PRESSURE RELIEF VALVE
M/s. EMERSON PROCESS MANAGEMENT CHENNAI PVT. LTD.

M/s. NIRMAL INDUSTRIAL CONTROL PVT. LTD.
M/s. VANAZ ENGINEERS LTD.
M/s FULFLOW , USA
17. PRESSURE SAFETY VALVE
M/s. KEYSTONE
M/S.FAINGER LESER
M/S.TYCO SANMAR
Or EQUIVALENT MAKE
18. STRAINER
M/s.. GREAVES LIMITED, NEW DELHI.

M/s. RAK DIN ENGINEERING, NEW DELHI.
M/s. MULTITEX FILTRATION ENGINEERS PVT. LTD, NEW DELHI.
M/s. CHEMPHARM INDUSTRIES (INDIA) LTD, GHAZIABAD.
M/s. GRAND PRIX (P) LTD, NEW DELHI.
M/s. INDUSTRIAL PIPING ENGINEERING, ALLAHABAD.
M/s. SUPERFLOW FILTERS PVT. LTD, MUMBAI.
M/s. J.N. MARSHAL & CO.
M/s. OTOKLI N FI LTERS OF INDIA LTD.
M/s. GREAVES COTTON & CO.
M/s. MULTITEX FILTRATION ENGG.
Page 75 of 91
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M/s. VARALL ENGINEERS.

M/s. VINUS INDUSTRIES
M/s. VIRA INDUSTRIES
M/s JITSAN,KOLKATA
19. THERMAL INSULATION
M/s. LLOYD INSULATIONS

M/s. LAPINUS ROCKWWOL
M/s. MINWOOL ROCK FIBRES
M/s. U P TWIGA FIBREGLASS
20. ELECTRICAL HEAT TRACING ( EHT) SYSTEM
M/s. PENTAIR THERMAL MANAGEMENT

M/s. THERMOPAD SYSTEM
M/s. THERMON
M/s. BARTEC
21. STEAM TRAP
M/s. PENNANT, PUNE.

M/s. PRECISION CONTROL, MUMBAI.
M/s. ENERJET.
M/s. FORBES MARSHALL, PUNE
Or EQUIVALENT MAKE
22. BASKET TYPE STRAINER
M/s. Filter concept pvt. Ltd.

M/s. ALECON Commercial pvt. Ltd..
M/s. JITSAN FILTER INDUSTRIES
Or EQUIVALENT MAKE
23. STEEL FLEXIBLE HOSE & NITRILE RUBBER HOSE
M/s. Hydroflex pipes pvt. Ltd.

M/s. GAYTRI INDUSTRIAL CORPORATION
M/s Momtaj rubber Industries
M/s. SIT FLEXIBLE HOSE PVT. LTD. VADODARA
Or EQUIVALENT MAKE
24. Y- TYPE STRAINER
M/s FORBES MARSHALL

M/s ALECON FILTERS,KOLKATA
M/s. M/s. VK valves ,
M/s. M/s. Mahavas Precision control
Or EQUIVALENT MAKE
25. PRESSURE REDUCING STATION
Page 76 of 91
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M/s FORBES MARSHALL ,

M/s. DARLING MUSSO
M/s. Mahavas Precision control
M/s Silson, Pune
M/s. VK valves
Or EQUIVALENT MAKE
26. WELDING ELECTRODES
M/s.ESAB India ltd.

M/s. Advani Orlekon
M/s.D & H Sechron Electrodes Ltd.
M/s.GEE Limited
M/s. Modi Arc Electrodes Co.
M/s. Honavar Electrodes Ltd.
27. PAINT MANUFACTURER
M/s Asian Paints India Ltd.

M/s Bombay Paints Ltd. Mumbai.
M/s Berger Paints India Ltd. Mumbai.
M/s Ameron / Goodlass Nerolac Paints Ltd. Mumbai.
M/s Jenson & Nicholson India Ltd. Kolkata.
M/s CDC Carboline, Chennai.
M/s Shalimar Paints Ltd. Mumbai.
M/s Solvo-Sol Paints (P) Ltd. Hyderabad.
M/s Grand Polycoats Company Pvt Ltd. Vadodara.
M/s. Sigma Coatings Mumbai
M/s. Akzo Noble coatings India Ltd., Bangalore or
28. FIRE PROTECTION SYSTEM
1. M/s. STEELAGE INDUSTRIES LTD.

2. M/s. AGNICE FIRE PROTECTION LTD.
3. M/s. VIJAY INDUSTRIES & PROJECTS LTD.
4 M/s. NEW FIRE ENGINEERS PVT. LTD.
5. M/s. MATHER & PLATT (INDIA) LTD.
6. M/s. RELIANCE FIRE PROTECTION SYSTEMS
7. M/s. AGNI CONTROLS

8. M/s. ZENITH FIRE SERVICES
28.1 FIRE PROTECTION SYSTEM
Sl No Item Description Preferred makes
Page 77 of 91
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1. Gate and NRV : Fouress, Audco, Kirloskar Brothers, KSB, Crescent

(Carbon Steel) Valves, BDK, Indian Valve(IVC), L&T, NECO, AV Valves,
XOMOS, Leader, KBL, BHEL, Fluid control equipment,
Steam & Mining, Virgo
2 Gate and NRV Kirloskar Brothers, Steam & Mining, IVPL, AV Valves,
(Cl) Shiv Durga, BDK, Fouress.
3 Butterfly valves : Audco, Fouress, Indian Valve, L&T, FISCHER, XOMOS,
TYCO Valves, JASH, AVC Engg, FLEX, Kirloskar
Brothers, Virgo, AL Saunders, steam & Mining, Keystone,
BDK, IVPL Nasik
4 Gunmetal gate, : Bombay metal, Leader, Levcon valves, Neta, Sant, zoloto,
Globe, Check valve Keystone, Samsons
5 Air Release Valve Shiva Durga, IVPL, IM Engineers, Steam & Mining,
Schroder Duncum, Fluid Line Valves.
6 Ball Valve Audco, KSB, AL Saunders, Xomox, Virgo, BDK, Virgo
7 Solenoid valves : Siets Rotex, Norgren, Schrader, Avcon, BS, REXROTH,

Sicmag, Scharder, NECO, Indfos, Eastern pneumatic,
Bluestar, Avcon, Asco
8 Strainer : Otoklin, superflo, Triveni, Sarojini Enterprises, Filteration

Engineers , Boll&Kirch, Imetrol, JPG, Plenty, Filter Mfg.
Ind., Purolator
9 Deluge Valves : Kidde India, Grinell / Tyco, HD Fire
10 Water Spray Nozzles : Reliable, ASCO, HD Fire, LAXMI SPRINKLER, Grinell /

Tyco, Fire Tech
11 Q.B. Detector : Reliable, ASCO, HD Fire, Grinell / Tyco
12 Portable Fire : VIPL / Kidde India, Steelage /Gunnebo/ Minimax, Zenith,

Extinguishers Kooverji Devshi, Safex, New Fire, Ace Fire
13 Steel Pipes (MS) : SAIL, ITC, BST. Jindal, Ajanta, Prakash Tubes, Zenith,
Gujrat Steel Tubes, TATA, Maharastra Seamless, Kalinga,
Surya, RSP, PSL, RINL, Ratnamani, IIsco, SAW
14 Steel Pipe Fittings : Tube Bends, Gujrat Infra pipes, MS Fittings, Tube
products, EBY Industries, Stewards&Lloyds, Heavy Metal
tubes, Nobel Tubes, Rajendra Mech. Ind., Vitrag, Poonam
Enterprices, N.L Hazra, Veketesh Udyog, Navkar, Reliable
Steel (Reliable pipes &tubes limited)
15 Water / Foam Monitor : Newage, HD Fire, FM/UL Listed
16 Fire Hydrant New Age Industries, Steelage Industires,

ASCO Strumech, Fire Tech
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17 Fire Hose New Age Industries, Steelage Industires,

ASCO Strumech, Fire Tech,
18 Foam System HD Fire, New Age Industries, Fire Tech
equipments
19 Foam Concentrate : Newage, KV Fire Chemicals, Integrated fire protection
20 RCC Pipes & Fittings SUR Industrial Pipes, Hind Ceramics, Indian Hume
Pipes, Daya Cuncrching.
Page 79 of 91
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ANNEXURE-02
LIST OF THIRD PARTY INSPECTION AGENCIES

1 M/s Projects & Development India Ltd.
Bengal Chemical Building, 1st Floor,
502, S.V.Savarkar Marg, Prabhadevi, Mumbai – 400025
2 M/s Loyd’s Register of Shipping.
Solitaire Corporate Park,Bldg. No 1, 4th Floor,
151 M. Vasanji Road, Chakala,
Andheri (East), MUMBAI – 400093
3 M/s Indian Register of Shipping
52 A, Adi Shankaracharya Marg,
Opp. Powai Lake, Powai, Mumbai – 400072
4 M/s Bureau Veritas Industrial Services (India) Pvt Ltd.
The Leela Galleria, 5th Floor,
Andheri Kurla Road, Andheri (E),MUMBAI – 400059
5 M/s Det Norske Veritas
Emgeen Chambers, 5th Floor,10, CST Road (Opp. Kalina University Campus)
Santacruz (East), MUMBAI – 400092
6 M/s Certification Engineers Intl. Ltd. (CEIL),
Great Eastern Chambers, 5th Floor, Sector II,
Belapur CBD, NAVI MUMBAI – 400614
7 M/s Directorate General of Supplies & Disposals (DGS&D)
1st Floor, Director of Quality Assurance,
Ayakar Bhawan Annexe, New Marine Lines,
Mumbai – 400020
8 M/s SGS India Ltd.
SGS House, 4B, Adi Shankaracharya Marg,
Vikhroli, Mumbai – 400083
9 M/s Rail India Technical & Economic Services
Western Region, Inspection Wing, 2nd Floor,
Churchgate Station Building, Churchgate, Mumbai – 400020
10 M/s UL India Pvt. Ltd.
205-209, 2nd Floor,Prestige Meridian – 1
29, MG Road,Bangalore - 560001
11 Indian Institute of Technology, Kanpur / Mumbai / Delhi / Chennai / Kharagpur /
Guwahati
12 Engineers India Limited
Note : Contractor shall engage any of above inspection agencies for carrying out
inspection of all the material being supplied by them.
Page 80 of 91
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ANNEXURE -03
ABBREVIATIONS & NOTATIONS
UNLESS OTHERWISE SPECIFIED FOLLOWING NOTATIONS/ ABBREVIATIONS SHALL

BE APPLICABLE TO DOCUMENT.
1. BBV : BATCH BLENDING VESSEL

2. SMB : SIMULTANEOUS METERED BLENDING
3. DHU : DRUM HEATING UNIT
4. DDU : DRUM DECANTATION UNIT
5. MM/mm : MILLIMETER
6. SQMM/sqmm/mm2 : SQUARE MILLIMETER
7. CM/cm : CENTIMETER
8. SQCM/Sqcm : SQUARE CENTIMETER
9. SFT/sft : SQUARE FEET
10. M/m/rm/RM : METRE / RUNNING METRE
11. SQM/sqm/m2/SM : SQUARE METRE
12. CUM/cum/m3 : CUBIC METRE
13. KG or kg : KILOGRAM
14. MT : METRIC TONNE
15. MS : MILD STEEL
16. DIA or dia or  : DIAMETER
17. NO (S) / Nos. / nos. : NUMBER(S)
18. PCC : PLAIN CEMENT CONCRETE
19. RCC : REINFORCED CEMENT CONCRETE
20. E-I-C : ENGINEER - IN – CHARGE
21. IS/BIS : INDIAN STANDARD
22. API : AMERICAN PETROLEUM INSTITUTE
23. LS : LUMPSUM
Page 81 of 91
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ANNEXURE -04
CODES / STANDARDS TO BE FOLLOWED
The codes & standards that governs the specifications, design , laying , welding , testing &
Commissioning of piping system of hydrocarbon industries are enumerated below:
Sl. Codes / Std. Description

No.
1. ASME B 31.3 Codes for pressure piping
2. ASME B 31.4 Codes for pressure piping for liquid petroleum
Transportation
3. ASME IX – Boiler & pressure Code for Welding & brazing
vessel
4. ASMEB 16.5 Pipe flanges & flanged fittings
5. ASME B 16.9 Factory made wrought steel butt welded
fittings
6. OISD-141 Design & construction requirement for
hydrocarbon pipelines
7. API-5L Specification for Petroleum line pipe
8. IS1239 & IS3589 Specification for water pipe line
9. IS 817 Welder qualification test
10 SFA 5.1 Specification for Carbon steel Electrodes for
shielded metal arc welding
11. API-1104/ASME, BPV Code, Non-Destructive Examination
Section V
12. ASME, BPV Code, Sec II ;Part C, Welding Rods, Electrodes and
Material Specification Filler
materials.
13. ASME, BPV Code, Section VIII Pressure Vessels
Page 82 of 91
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ANNEXURE -05
PACKING LIST (TENTATIVE) OF EQUIPMENT RECEIVED FROM GLOBAL VENDOR

AND TO BE INSTALLED AND COMMISSIONED BY SUCCESSFUL BIDDER.
1. PIGGABLE MANIFOLD
ITEM
NO. Qty. Unit DESCRIPTION

Piggable Manifold
Thirteen (13) Packages
39809 Net Kgs / 47765 Gross Kgs
194.5 m3

4400mmL*2270mmW*1900mmH--19m3
3850.00 Net Kgs / 4684.00 Gross Kgs
9 Ea XPM 4 X 12 3" ASI+PLSs+X1FVs
General Arrangement with PLS's and Support
P/N 14992055

4400mmL*2270mmW*1900mmH--19m3
1 Ea XPM 4 X 12 3" ASI+PLSs+X1FVs
XPM 4 X 12 3" ASI+PLSs+X1FVs+X2FVs
P/N 14992056

1700mmL*1220mmW*700mmH--1.5m3
3 Ea PLS-301 3" SCH40 ANSI 150 ASI+C 4V
P/N 1414203243073
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2. HLDV/ILDV
Thirty Six(36) Packages
8934 Net Kgs. / 12832 Gross Kgs.
60.46 m3
ITEM
NO. Qty. Unit DESCRIPTION
2260mmL*950mmW*750mmH--1.61m3
13 Ea HLDV-301 3" Sch40 ANSI 150 ASI+PS+C
P/N 1414203013000
H.S CODE: 84819010 Net Kgs: 69.00

2260mmL*950mmW*750mmH--1.61m3
6 Ea HLDV-304 3" SCH40 ANSI 150 ASI+C
P/N 1414203013001
H.S CODE: 84819010 Net Kgs: 65.00

2260mmL*950mmW*750mmH--1.61m3
4 Ea HLDV-304 3" SCH40 ANSI 150 ASI+C
P/N 1414203013001
H.S CODE: 84819010 Net Kgs: 58

2260mmL*1220mmW*750mmH--2.07m3
1 Ea ILDV-303 3" SCH40 ANSI150 ASI+PS+MV
P/N 1414203023002
H.S CODE: 84819010 Net Kgs: 58.00
HLDV-321 3" SCH40 ANSI 150 ASI+PS+EV
P/N 1414203013035
H.S CODE: 84819010 Net Kgs: 67.00

2260mmL*1050mmW*750mmH--1.78m3
4 Ea HLDV-401 4" Sch40 ANSI 150 ASI+PS+C
P/N 1414204013000
H.S CODE: 84819010 Net Kgs: 94.00

2260mmL*1050mmW*750mmH--1.78m3
1 Ea THLDV-414 4" SCH40 ANSI150 ASI+C
P/N 1414204143092
H.S CODE: 84819010 Net Kgs: 135.00
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2260mmL*1050mmW*750mmH--1.78m3
7 Ea TILDV-413 4" SCH40 ANSI150 ASI+PS+MV
P/N 1414204153089
H.S CODE: 84819010 Net Kgs: 122.00
3. DRUM OVEN/CONVEYOR SYSTEM

Forty five (45) Packages
25728 Net Kgs / 37740 Gross Kgs
200.4 m3
Description CM KG
Package 1 of 45
Drum Oven & Conveyor System #1 - 191.00 126.00 81.00 350.00 152.00 198.00
Part 1
1#Drum Conveyor line-1

Package 2 of 45
Part 2

Package 3 of 45
Part 3

Package 4 of 45
Part 4

Package 5 of 45
Part 5

Package 6 of 45
Part 6

Package 7 of 45
Part 7
Page 85 of 91
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Package 8 of 45
Part 8

Package 9 of 45
Part 9 0
Drum Heating-1

Package 10 of 45
Part 10 0
Drum Heating-2

Package 11 of 45
Part 11 0
Electric box

Package 12 of 45
Part 12
H# Elevator for 1# Drum Conveyor
line

Package 13 of 45
Part 13
G# Elevator for 2# Drum Conveyor

line

Package 14 of 45
Part 14 0
Escalator 1#

Package 15 of 45
Part 15
Escalator 2#

Package 16 of 45
Page 86 of 91
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Part 1

Package 17 of 45
Part 2

Package 18 of 45
Part 3

Package 19 of 45
Part 4

Package 20 of 45
Part 5

Package 21 of 45
Part 6

Package 22 of 45
Part 7

Package 23 of 45
Part 8

Package 24 of 45
Part 9 0
Drum Heating-1

Package 25 of 45
Part 10 0
Page 87 of 91
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Drum Heating-2

Package 26 of 45
Part 11 0
Electric box

Package 27 of 45
Part 12
line

Package 28 of 45
Part 13

line

Package 29 of 45
Part 14 0
Escalator 1#

Package 30 of 45
Part 15
Escalator 2#

Package 31 of 45
Part 1

Package 32 of 45
Part 2

Package 33 of 45
Part 3

Package 34 of 45
Page 88 of 91
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Part 4

Package 35 of 45
Part 5

Package 36 of 45
Part 6

Package 37 of 45
Part 7

Package 38 of 45
Part 8

Package 39 of 45
Part 9 0
Drum Heating-1

Package 40 of 45
Part 10 0
Drum Heating-2

Package 41 of 45
Part 11 0
Electric box

Package 42 of 45
Part 12
line

Package 43 of 45
Page 89 of 91
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Part 13

line

Package 44 of 45
Part 14 0
Escalator 1#

Package 45 of 45
Part 15
Escalator 2#
4. BBV /PREMIX ASSEMBLIES

Qty. Weight in
Description Package Size in mm Total wt. Kgs.
nos. Kgs.
BBV Assembly - Structural Members 5500*2200*2200 6 7000 42000

Premix Assembly - Structural Members 10000*2200*2200 1 8000 8000

BBV & Premix Tanks 2524x2524x2120 1 1470 1470
2524x2524x2120 1 1410 1410
2750x2750x2510 1 1800 1800
4130x4130x4700 1 8800 8800
3176x3176x3305 1 2875 2875
3176x3176x3305 1 2875 2875
3688x3688x4230 1 6088 6088
3688x3688x4230 1 6088 6088
1624X1624X1660 1 550 550
2700X2700X2550 1 3000 3000
Estimate 17 84956
5. SMB SKIDS/DDU SKIDS

Description Qty. Sizes in inch Wt. in Kgs.
Nos.
L W H
SMB SKID AND ASSEMBLIES 02 34’-4” 7’-4” 7’-6” 10206
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DDU SKID 03 9’-6” 7’-1/2” 6’-6” 2813
Page 91 of 91

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MECHANICAL PACKAGE –V

“Design , Supply, Fabrication, Erection, Testing & Commissioning of

Doc. No. MEC/23RK/01/31/D2/ME/535/R00

CHAPTER NO. DESCRIPTION

MECH. PKG.-V CHAPTER 2 TECHNICAL SPECIFICATION OF PIPING AND EQUIPMENT

CHAPTER- 3 TECHNICAL SPECIFICATION OF FIRE HYDRANT SYSTEM

CHAPTER -4 STANDARD TECHNICAL SPECIFICATIONS

CHAPTER -5 TECHNICAL DATA SHEETS

CHAPTER -6 TENDER DRAWINGS

LIST OF ANNEXURES (CHAPTER – 2)

LIST OF STANDARD TECHNICAL SPECIFICATIONS (CHAPTER – 4)

SL. NO. DESCRIPTION TECHNICAL SPECIFICATION PAGE

9 TECHNICAL SPECIFICATION FOR MEC/23RK/01/31/D1/ME/F- 1-5

20 STANDARD TECHNICAL MEC/23RK/01/31/D1/ME/ST/0021/ 1-28

GLOBAL VENDORS DOCUMENT

25 PIPING MATERIAL SPECIFICATION (PMS)

25.1 PIPING FOR STEAM AND CONDENSATE PS-201 CL150 CS 1-4

26 GENERAL GUIDELINES FOR INSTALLATION OF PIGGABLE

26.1 GENERAL GUIDLINE FOR THE 1-2

ASSEMBLY JOB SITE INSTALLATION

LIST OF TECHNICAL DATA SHEETS (CHAPTER – 5)

SL. NO. DESCRIPTION TECHNICAL DATASHEET NO Page

1 DATA SHEET FOR MANUAL BALL MEC/23RK/01/31/D1/ME/CA/BV 1-2

DATA SHEET FOR LDO/HSD MEC/23RK/01/31/D1/ME/LDO/LP- 1-3

LIST OF TENDER DRAWINGS (CHAPTER – 6)

SL. NO. DESCRIPTION DRAWING NO.

1 PROCESS FLOW DIAGRAM (PFD) PFD 001 TO 012

15. GLOBAL VENDORS EQUIPMENT DRAWINGS (FOR REFRENCE ONLY)

15.1 BBV ASSEMBLY LAYOUT WITH DOSING TANK M17534

15.27 SMB FABRICATION DRAWING PIP-153

SPECIAL INSTRUCTIONS TO BIDDERS

SPECIAL INSTRUCTIONS TO BIDDERS

a) Safety of personnel, c) Long life of equipment,

1.26 All norms pertaining to statutory authorities including electrical/ environment/pollution

1.38 Codes & Std. to be followed as per ANNEXURE-04.

02.00 SITE CLEANING

03.00 CO-ORDINATION WITH OTHER AGENCIES

04.00 SAFETY PRECAUTIONS AND HOT WORK

05.00 ABILITY AND EXPERIENCE OF BIDDER

06.00 INCOMPLETE INFORMATION

TECHNICAL SPECIFICATION OF PIPING & EQUIPMENT

The intent of this specification is to cover scope of design , engineering, residual

Product Base Oil Additives Finished Product HSD LDO

01.01 Brief process description of new Lube Oil Plant facilities:

02.00 SCOPE OF WORK

b) Design , engineering, supply, handling, loading -unloading , transportation and storage ,

v) Instrumentation hook drawings shall be furnished to successful bidder.

c) Design , engineering, supply, transportation, handling, fabrication, installation, erection,

d) Design ,engineering , supply, transportation, handling, fabrication, installation, erection,

e) Shifting, loading – unloading ,transportation, handling, unpacking , residual engineering

h) Design , engineering, supply, fabrication , erection ,installation of structural pipe supports

i) Design, engineering, supply, fabrication, erection including preparation of fabrication

Following tanks are under contractor’s scope of works:

i) 02 No. of Steam condensate recovery drum of nominal capacity: 5m 3

i) Plate material: IS 2062 Gr.B.

v) MOC of leg support/cross braced/main rafter etc.: IS 2062 Gr. A.

vi) MOC of Gusset plate/central drum etc. :IS 2062 Gr. B

j) Design, engineering, supply, erection, installation, alignment, testing & commissioning of

k) Design, supply, fabrication, erection, installation , insulation , testing & commissioning ,

l) Design, engineering, supply and fixing of thermal insulation on steam/condensate pipeline

m) Design , engineering , supply , fabrication , erection , testing & commissioning complete GI

viii) MOC of plate material : IS 2062 Gr. B

ix) MOC of leg support/cross braced/main rafter etc.: IS 2062 Gr. A.