Technical FF PRT C 20181016 171523 PDF

Dobhi-Durgapur-Haldia Pipeline Section alongwith spurlines under
JHBDPL Project
Fire Protection and Fire AlarmSystem for DDPL (Part-C)
(Document No : B035-001-81-41-FP-T-8106)
Page 1 of 851
Click on the Document Title to go to that section of the document
Table of Contents
Document Number Rev. Document Title Page
Number
B035-001-81-41-FP- A Fire Protection and Fire AlarmSystem for DDPL (Part-C) 5
T-8106
B035-001-83-41- G SCHEMATIC ARRANGEMENT OF PIPELINE FACILITIES 6
30001-G
B035-001-81-41- A SCOPE OF WORK & SUPPLY 7
SOW-8106
B035-001-81-41-SP- A ANY DOCUMENT TYPE SPECIFIC TO DEPT. 17
8106
B035-001-81-41-1- 2 ARCHITECTURAL DRAWINGS (PLANS ,ELEVATIONS 39
2101 ,SECTIONS ) OF SV STATION BUILDING
2103 ,SECTIONS ) OF IP STATION/ RT BUILDING
B035-001-81-41- 1 IP Station/Repeater Bldg. Door window details 41
12104
2105 ,SECTIONS ) OF GUARD ROOM
B035-001-81-41- A VENDOR DATA REQUIREMENT 43
VDR-8106
B035-001-81-41-LL- A LIST OF ATTACHMENTS 46
8106
B035-001-16-50- 0 SCOPE OF WORK- ELECTRICAL (FA SYSTEM) 52
SOW-8106
B035-000-16-50-SP- 1 JOB SPECIFICATION 63
0003
B035-001-16-50-VR- 0 VENDOR DATA REQUIREMENTS- FA SYSTEM 71
8106
B035-001-16-50- 0 TECHNICAL COMPLIANCE-FIRE PROTECTION AND FIRE 75
TCL-8106 ALARM SYSTEM
B035-000-16-50-DS- 4 DATA SHEET FA SYSTEM 78
0006
B035-001-16-50-VL- 0 VENDOR LIST- ELECTRICAL (FA SYSTEM) 83
8106
B035-001-16-50- 0 EQUIPMENT,CABLE,EARTHING & LIGHTNING PROTECTION 97
01102 LAYOUT- SV STATION (TYPICAL) CONTROL ROOM BULIDING
B035-001-16-50- 0 OVERALL LIGHTING, CABLE, EARTHING & FIRE ALARM 98
01105 LAYOUT- SV STATION-19A
B035-001-16-50- 2 EQUIP, CAB, EARTH, LIGHTINING PROTECTION LAYOUT OF 99
01130 IP/RT BUILDING
6-44-0012 4 Standard specification for fabrication and erection of piping 100
6-44-0013 5 Standard specification for inspection, flushing and testing of piping 115
systems.
6-44-0016 7 Standard specification for non destructive examination 124
requirements of piping
6-44-0051 6 Technical notes for pipes. 145
6-44-0052 7 Technical notes for valves. 155
6-44-0053 6 Technical notes for flanges, spectacle blinds and drip rings. 175
6-44-0054 6 Technical notes for butt welded, socket welded and screwed 182
fittings.
6-44-0056 5 Technical notes for gaskets. 191
6-44-0057 5 Technical notes for bolts and nuts. 196
6-44-0067 1 Technical notes for strainers 201
6-51-0051 8 Specification for medium and high voltage cables & accessories. 210
6-51-0052 6 Specification for communication and fire alarm cables. 220
6-51-0076 5 Specification for fire detection and alarm system. 230
6-51-0081 4 Specification for electrical equipment installation. 256
Page 2 of 851
Table of Contents
Number
6-51-0087 3 Specification for field inspection, testing and commissioning of 271
electrical installations
6-65-0006 3 Standard specification for earthwork for underground piping. 279
6-65-0030 5 Standard specification for fabrication and Laying of Underground 286
piping.
6-65-0035 3 Standard specification for misc. civil & structural works for U/G 297
piping & other civil works
6-66-0004 1 Standard specification for portable fire extinguisher 304
6-66-0012 4 Standard specification for standard post type fire hydrant (with or 309
without pumper connection)
6-66-0018 4 Standard specification for first aid hose reel 315
6-66-0047 4 Standard specification for hose cabinet. 319
6-66-0061 4 Standard specification for 50 kg. & 75 kg. capacity dry chemical 324
powder extinguisher.
6-66-0074 3 Standard specification for fire hydrant system. 329
6-68-0009 4 Standard specification - civil & structural works - brick masonary. 338
6-77-0001 4 Welding specification for fabrication of piping. 347
6-77-0005 4 Welding specification charts for piping classes. 387
6-78-0001 1 Specification for quality management system requirements from 417
bidders
6-78-0002 1 Specification for documentation requirement from contractors 424
6-78-0003 1 Specification for documentation requirement from suppliers 433
6-79-0011 2 Standard specification for tape coating for underground steel 442
pipelines
6-79-0020 0 Standard specification for surface preparation and protective 456
coating (new construction)
6-81-1052 3 ITP for communication & fire alarm cables 515
6-81-1076 3 ITP for fire detection & alarm system 522
6-82-0001 8 Standard specification for health, safety & environment (HSE) 529
management at construction sites
6-82-3100 0 Inspection & test plan (ITP) for civil, structural & architectural 619
works (item rate contracts - with categorization)
6-82-3200 0 Inspection & test plan (ITP) for mechanical works (item rate 683
contracts - with categorization)
6-82-6100 2 Standard QA plan construction division (item rate contracts) 788
7-44-0002 4 Abbreviations. 801
7-44-0003 4 Symbols of piping elements on drawings. 803
7-44-0032 4 Stub-in standard. 807
7-44-0033 5 Details of mitered elbow. 809
7-44-0303 6 T-strainer type-1 2"-4" (150CL RF, 300CL RF & RTJ, 600CL RF & 811
RTJ)
7-44-0304 6 `T' strainer type-1 6" to 24" ( 150# RF, 300# RF & RTJ, 600# RF 812
& RTJ)
7-44-0350 4 Vent & drains (on lines 1 1/2" & below). 813
7-44-0351 4 Vents and drains (on lines 2 and above). 814
7-44-0352 4 Orientation of orifice taps (class 600 & below. 815
7-44-0476 4 Welding of pipe with different thickness. 817
7-44-0477 4 Butt welding end preparation. 818
7-44-0478 4 Fillet weld details. 819
7-44-0479 4 Welding details for branch connections (not breaking into). 820
7-44-0480 4 Butt weld details (dimensions). 821
7-44-0481 4 Butt weld details (sequence of welds). 822
Page 3 of 851
Table of Contents
Number
7-44-0482 4 Welding detail for branch connections (stub in). 823
7-44-0483 4 Branch connection (breaking into). 824
7-44-0484 4 Branch connection (not breaking into). 825
7-44-0485 4 Method of cutting and dimensions of field manufactured concentric 826
reducers.
7-44-0486 4 Tolerances for fabrication. 827
7-44-0487 5 Method of cutting & dimensions of field manufactured eccentric 828
reducers.
7-44-0621 5 Low support sliding for bare & insulated pipe size 2" thru 36" type 829
L1 & L1A
7-52-0002 4 Instrument connection on pipes. 830
7-52-0041 4 Orifice plates and flanges dimensional details. 833
7-65-0001 3 Abbreviations, legends and equipment symbols. 847
7-65-0420 4 Installation details of fire water hydrant. 851
Page 4 of 851
TENDER No. B035-001-81-41-FP-T-8106
Page 5 of 851
SIZE LENGTH PIPELINE
S.NO. PART DESCRIPTION INSTALLATION
(INCH) (KM) AGENCY
DOBHI - DURGAPUR PIPELINE SECTION 1 A DOBHI - DURGAPUR MAINLINE SECTION 30 188.412 CORRTECH
2 B DOBHI - DURGAPUR MAINLINE SECTION 30 158.796 ILFS
(DOBHI DURGAPUR HALDIA PIPELINE PROJECT) 1 B FCI SINDRI

SPURLINES
12 9.378
ILFS
2 2 B MATIX CHEMICALS & FERTILIZERS 12 1.690
(OD 30"/24"/18"/12", DP: 92 KG/CM G, COATING: 3LPE (EXT)) 3 C CGS JAMSHEDPUR 12 122.946 G LIKHITA
4 D 18 6.150
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
DPL DURGAPUR
5 D SAIL DURGAPUR 12 5.190
MID EAST
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
6 D HFC DURGAPUR 24 6.626

7 D SAIL IISCO BURNPUR (ISP) 12 14.076
BIHAR JHARKHAND
SPREAD 1 PART A SPREAD 2
TOTAL SPURLINE LENGTH 166.418
BY OTHERS
PART B
STATE BOUNDARY
SPREAD 1
BY EIL
DAMODAR RIVER
JAMUNIYA RIVER
JAMUNIYA RIVER
JAMUNIYA RIVER
MATCHLINE A-A
CH. 363.509
SY-2
CH. 533.710
SY-1
IPS-5 (GAINRA)
CH. 534.000
CH. 533.071
CH. 475.529
CH. 492.500
CH. 511.344
CH. 361.478
CH. 385.405
CH. 407.905
CH. 430.918
CH. 457.610
CH. 483.200
CH. 498.800
CH. 519.100
CH. 527.880
CH. 472.555
CH. 347.928
CH. 424.113
CH. 445.679
CH. 469.172
CH. 475.305
CH. 530.377
TAP OFF CONNECTION FOR
CH. 423.115
CH. 529.199
BOKARO ANGUL SECTION
CH. 531.525
RAILWAY
RAILWAY
SV-19A
RAILWAY
NH-100
SV-27
SV-19
SV-20
SV-21
SV-22
SV-23
SV-24
SV-25
SV-26
NH-2
NH-2
NH-2
NH-2
CH. 533.680
SH
G
30" 30" 30"
CP CP CP CP CP
DURGAPUR HALIDA SECTION

CP
IPS-4 (DOBHI)
DOBHI DURGAPUR SECTION

JHARKHAND WEST BENGAL
CH. 345.080
SPREAD 1 PART B SPREAD 2
DAMODAR BANK CANAL

DAMODAR RIVER
MATCHLINE A-A
IPS-6 (DANDUA)
STATE BOUNDARY
RIGHT BANK CANAL

UTTALA RIVER
LEFT BANK CANAL

GARGA RIVER
SY-3
GOBAI RIVER
CH. 534.000
CH. 578.760
CH. 562.742
CH. 593.182
CH. 539.423
CH. 568.795
CH. 671.038
CH. 673.312
CH. 551.120
CH. 614.855
CH. 593.750
CH. 663.700
CH. 639.700
CH. 540.958
CH. 562.689
CH. 602.786
CH. 665.962
CH. 686.601
CH.648.365
CH.678.724
CH. 666.572
CH. 677.060
CH. 680.392
CH. 551.924
CH. 575.911
CH. 604.450
CH. 647.035
CH. 677.733
CH. 567.937
RAILWAY
RAILWAY
RAILWAY
RAILWAY
RAILWAY
IPS-7 (DURGAPUR)
NH-32
NH-60
SH-12
SH-14
SV-28
SV-29
SV-34
SV-30
SV-31
SV-32
SV-33
SH-5
SH-9
NH-2
SY-5 CH. 692.300
NOTE-6
30"
CH. 692.500
CP SY-6
CP CH. 0.00 CP CP CP
NOTE-5
CH. 0.00 CP
24"
CH. 0.00 CH. 0.00 12"
12"
SH-8 RAILWAY
SPREAD 2
RAILWAY CH. 6.450 12"
PART B
CH. 3.390
SPREAD 1
CH. 3.420
PART B
PART D
SPREAD 2
SV-1E DAMODAR RIVER DAMODAR VALLEY CORP. CANAL
STATE BOUNDARY WEST BENGAL
CH. 5.739 JHARKHAND CH. 18.100 CH. 8.910 RAILWAY CH. 0.299
SH
NOTE-5 CH. 3.820
12"
PART D
CH. 27.550 RAILWAY
SPREAD 1
DAMODAR SV-1F
SPREAD 1
RIVER RAILWAY CH. 4.391

CH. 9.725
MATIX FERTILISERS
RAILWAY
CH. 2.810
CH. 31.247 RAILWAY
CH. 5.918
CP SV-2E CH. 4.473 CH. 1.690
CH. 33.593 RAILWAY
NH-60A
CH. 10.075 DPL DURGAPUR
FCI SINDRI CH. 34.790 CH. 6.15 LINE PIPE DELIVERY LOCATION
G KASAI RIVER 18"
CH. 9.378
PART C
CH. 40.880
SH-5 SAIL IISCO (ISP) SY No. LOCATION
HFC DURGAPUR
WEST BENGAL
CH. 45.100
CH. 14.076 PART D
CP SV-3E NOTE-7 CH. 6.626
SY- 1
CH. 0.00
PIPELINE PARAMETERS CH. 53.016 NOTE-8 SPREAD 2 12" CH. 0.00
SPREAD 2
API 5L GR X 70 PSL2 KUMARI RIVER
PART D
S.NO. SIZE 3LPE THK (MM) CCW THK (MM) CA (MM)
WALL THICKNESS (MM) CH. 57.650
LINED CANAL SY- 2
1 30 12.5/ 14.8/ 18.5/ 20.6 2.8 120/ 100/ 80 0.5 CP SV-4E CH. 4.450
2 24 10.3/ 12.7/ 15.0/ 17.5 2.8 80 0.5 CH. 75.000 SY- 3
3 18 7.9/ 9.5/ 11.9/ 12.7 2.5 60 0.5 RAILWAY
4 12 6.4/ 7.1/ 8.7/ 9.5 2.5 50 0.5 STATE BOUNDARY CH. 75.270 SY- 4
NH-32
LIST OF HDD CH. 80.534 CH.86.950 SAIL DURGAPUR
SY- 5
JHARKHAND
S.NO. LINE NAME CROSSING SIZE WT LENGTH CHAINAGE

PART STATE
RAILWAY CP CH. 5.190
NAME (M) (KM) CH. 91.180
SPREAD 2
1 MAINLINE JAMUNIYA RIVER 30 14.8 500 475.529 A JHARKHAND CP

SV-5E SY- 6
CH. 92.450
2 MAINLINE DAMODAR RIVER 30 14.8 800 533.071 A JHARKHAND
CHANDIL CANAL
3 MAINLINE RIGHT BANK CANAL 30 18.5 500 666.572 B CH.97.470
NH-33 LEGENDS: NOTES:
4 MAINLINE DAMODAR RIVER 30 14.8 1500 671.038
CH. 100.976 1. ALL CHAINAGES INDICATED ARE IN KM.
5 MAINLINE 30 14.8 500 677.060 B SV-6E 2. LOCATIONS OF IP & SV STATIONS ARE INDICATIVE ONLY.
DT DESPATCH TERMINAL MAJOR RIVER (>100M WIDTH)
6 MAINLINE DAMODAR CANAL 30 14.8 500 680.392 B CH. 108.590 3. ALL SVS SHALL BE REMOTE OPERATED.
SPURLINES
RAILWAY RT RECEIPT TERMINAL MAJOR CANAL (HDD) 4. THE SCHEMATIC OF MAIN LINE & SPURLINES IS BASED ON SURVEY DATA AS PROVIDED BY CLIENT.
CH. 109.080 5. DAMODAR RIVER HDD SHALL BE EXECUTED VIA SEPARATE TENDER/ CONTRACT.
7 MATIX DAMODAR VALLEY
12 7.1 300 0.299 B SUBARNAREKHA RIVER
IPS INTERMEDIATE PIGGING STATION RAILWAY CROSSING
FERTILISERS CORP. CANAL 6. IPS-6 (DANDUA) OF DDPL MAINLINE SHALL BE TAP OFF LOCATION FOR BOTH CGS JAMSHEDPUR & FCI SINDRI
8 FCI SINDRI DAMODAR RIVER 12 7.1 1200 5.918 B WEST BENGAL
/JHARKHAND
CH. 112.280 SY STORAGE YARD (LINEPIPE) NATIONAL HIGHWAY(NH)/ SPURLINES. PART B & C INSTALLATION CONTRACTORS SHALL CO-ORDINATE AS PER THEIR SCOPE AT THIS
9 JSR SPURLINE CHANDIL CANAL 12 7.1 300 97.470 C JHARKHAND KHARKAI RIVER G WT WALL THICKNESS (IN mm) STATE HIGHWAY (SH) TERMINAL.
7.1 500 C JHARKHAND
CH. 122.746
PIG LAUNCHER/RECEIVER 7. LENGTH OF SAIL ISP SPURLINE STANDS INCREASED BY 225M DUE TO SHIFT OF TAP OFF LOCATION OF
10 JSR SPURLINE SUBARNAREKHA 12 112.280 CP CCW CONCRETE WEIGHT COATING SVS-31 OF DDPL MAINLINE. PIPELINE IN THIS STRETCH SHALL BE LAID PARALLEL TO DDPL MAINLINE
11 JSR SPURLINE KHARKAI RIVER 12 7.1 500 122.746 C JHARKHAND G
SECTIONALIZING VALVE (SV) STATION TO BE EXECUTED BY 8. LENGTH OF HFC DURGAPUR SPURLINE STANDS INCREASED BY 1186M DUE TO SHIFT OF TAP OFF LOCATION
12 SAIL ISP DAMODAR RIVER 12 7.1 1500 8.910
SY-4
CGS JAMSHEDPUR G SEPARATE HDD TENDER OF SVS-34 OF DDPL MAINLINE. PIPELINE IN THIS STRETCH SHALL BE LAID PARALLEL TO DDPL MAINLINE.
CH. 122.946 CP CATHODIC PROTECTION SYSTEM
13 SAIL DSP CANAL 12 7.1 300 4.450 D
PROJECT : DRAWING NO. REV.

ENGINEERS INDIA LIMITED SCHEMATIC ARRANGEMENT OF
CLIENT : GAIL (INDIA) LTD. B035-001-83-41-30001 G
PIPELINE FACILITIES
Page 6 of 851
NEW DELHI
JOB NO : B035 REV. DATE REVISION BY CHK APPROVED APPROVED
SCOPE OF WORK & SUPPLY DOCUMENT No.
FOR FIRE PROTECTION & FIRE B035-001-81-41-SOW-8106
ALARM SYSTEM Rev. A
(STRUCTURAL) Page 1 of 10
SCOPE OF WORK & SUPPLY

(STRUCTURAL)
FOR
FIRE PROTECTION SYSTEM
FOR
DOBHI- DURGAPUR PIPELINE SECTION
TENDER No. B035-001-81-41-FP-T-8106

( PART -C )
PROJECT : DOBHI - DURGAPUR - HALDIA -

PIPELINE PROJECT
OWNER : GAIL
CONSULTANT : ENGINEERS INDIA LIMITED
JOB NO. : B035
A 24.09.18 ISSUED FOR TENDER AKS RS VG

Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 7 of 851
FOR FIRE PROTECTION & FIRE
ALARM SYSTEM B035-001-81-41-SOW-8106
(STRUCTURAL) Rev. A
Page 2 of 10
Contents
1.0 SCOPE OF WORK .................................................................................................................... 3
2.0 SCOPE OF SUPPLY ................................................................................................................. 6
3.0 LIST OF ATTACHMENTS ........................................................................................................ 6
4.0 SPECIFICATIONS: .................................................................................................................... 6
5.0 STANDARDS:............................................................................................................................. 8
6.0 APPROVED VENDOR LIST: ................................................................................................... 9
7.0 JOB SPECIFICATION: .............................................................................................................. 9
8.0 SCHEDULE OF RATES: .......................................................................................................... 9
9.0 ARCHITECTURAL DRAWINGS : .......................................................................................... 10
Page 8 of 851
(STRUCTURAL) Rev. A
Page 3 of 10
1.0 SCOPE OF WORK

The scope of Work & Supply for Fire Protection and fire alarm tender shall include
supply, of all materials, consumables, tools, tackles, machinery, equipments,
arranging of manpower, construction/ installation, fabrication, erection, painting,
supervision, testing and commissioning (wherever applicable) at following locations
of DDHPL Project” as per detailed Scope of work, Schedule of Rates, approved
Drawings, Documents, Specifications, relevant Codes, Standards and direction of
Engineer-in-Charge.
Detailed Work shall be carried out at following locations :
1. IPS-6
2. SV-30
3. SV-31
4. SV-32
5. SV-33
6. SV-34
7. IPS-7
8. RT SAIL IISCO
9. RT HFC-DURGAPUR
10. RT DPL DURGAPUR
11. RT SAIL DURGAPUR
12. RT MATRIX FERTILISERS
CONTRACTOR shall visit the site for familiarization of actual condition to

quantify/ assess the job himself before quoting rates. No extra claim at a later
date shall be entertained due to the non-familiarization of site.
1.1 DETAILED SCOPE OF WORK
1.1.1 Supply and installation of first aid firefighting equipments/extinguishers as per OISD-
226 and PNGRB including supply of related brackets, nuts, bolts, rain shed (for
outdoor installation) transportation to site including supply of all related material etc.
all complete as per standards, specifications, drawings, codes and direction of
Engineer-in-charge.
1.1.2 Design, supply of all materials, installation, fabrication, testing and Commissioning,
puff test, performance guaranteeing of total flooding (below false floor + main room +
above false ceiling) centralised Clean Agent Fire Extinguishing System as per
specifications & NFPA-2001(latest addition) and schedule of rate attached for Control
room building at Dhobi- Durgapur- Haldia Pipeline project.[Refer Job specification
Doc. B035-001-81-41-SP-8106 Architectural drawings of Control room building
i.e. Plan, Elevation & Section shall be given to successful bidder)
Page 9 of 851
(STRUCTURAL) Rev. A
Page 4 of 10
1.1.3 Providing Firewater piping Network System: Supplying, fabrication and erection
of required size C.S. pipes (as per PMS, to be laid partly above ground and
underground), Isolation/ Drain/ Vent valves (Carbon Steel as per VMS), bends,
elbows, flanges, gaskets, nut and bolts etc., as required, providing firefighting
accessories, anti-corrosive tape coating for underground firewater piping and painting
on above ground pipes, piping within firewater pump house etc., including supply of
all consumables, tools, machinery required all complete as per drawings, standards,
specifications and direction of Engineer-in-Charge. The details scope of work shall be
as follows:
a) Supply of piping materials (as described in Cl. 1.1.3.b below) and pipe support
materials (as described in Cl. 1.1.3.d) and all other necessary piping materials
including its transportation from CONTRACTOR’s storage point/OWNER’s
storage point/ workshop/ warehouse to work site for complete Firewater piping
including supply of all other material for providing RCC sleepers, supports,
including providing machinery, tool, tackles, labours consumable, non-
consumables as required to complete the job.
b) Piping materials include the following but is not limited to the same
i. Pipes (All sizes and schedules)
ii. Flanges (All sizes, types and Pressure ratings)
iii. Fittings (All sizes, types and schedules)
iv. Valves (All sizes, types and ratings)
v. Gaskets (All sizes, types and ratings)
vi. Studs, Nuts or M/c Bolts (all types)
c) Fit up, Shop & field fabrication, transportation and erection of piping in
accordance with documents listed under Cl. 1.2 i.e. 'BASIS OF WORK' including
erection/ installation / laying of all piping materials enumerated above.
d) Fabrication and erection of pipe supports like shoe, saddle, guide, stops anchors,
clips, cradles, supporting fixtures, brackets, cantilevers, struts, tee-posts etc.
e) Radiography, stress relieving, dye penetration, magnetic particle test etc., as per
specification 6-44-0016.
f) Painting of complete above ground piping system and supports including supply
of all materials, consumables.
g) Flushing and testing of all piping systems as per standard specification for
inspection, flushing and testing of piping systems. (Specification No. 6-44-0013).
Drying by compressed air, cardboard blasting, flushing with water/ air, draining as
required.
1.1.4 Underground Piping Works: Supplying, laying and jointing of required size C.S.
pipes (as per PMS), wrapping coating of underground pipes, and supply and
installation of isolation/drain/vent valves (as per VMS), spectacle blind, funnel,
reducer, bends, elbows, flanges, gaskets, nut and bolts etc. as required.
1.1.5 Supply and Installation of Hose box chamber (Type-II) including all items inside
the chamber as per Specifications, including transportation of material , all Civil
works and supply of all material including cement etc.
Page 10 of 851
(STRUCTURAL) Rev. A
Page 5 of 10
1.1.6 Supply and Installation of Stand post type fire hydrant ( Double outlet) including
transportation, fixing of nuts, bolts, washers, gasket needed for fixing the
equipment with matching flange, welding etc. complete as per drawings,
specification and direction of Engineering In-Charge.
1.1.7 Design, Engineering, Supply, Erection, Fabrication, Testing and Commissioning

of "Deluge Valve " assembly actuated by (a) Quartzoid Bulb Detection (QBD)
system (on Water line) through Deluge valve (in automatically operation mode),
(b) Manual remote operation through Solenoid Valve (in remote operation mode)
and (c) local Manual operation including providing T-Strainer, deluge valve,
solenoid valve, self actuated pressure control valve, gate valve, ball valve, non
return valve, filter, pressure transmittal, pressure instrument, pressure gauge, vent
valve, restricted orifice (RO) including matching flange, tubing for actuation,
fittings, control/signal cables/cabling (for panel, between junction box & control
panel located at control building), control panel & local control panel/junction box,
instruments & instrumentation works, electrical works, associated piping
confirming to PMS, and painting etc. all complete within the battery limit as per
technical data sheets, drawings, codes and directions of Engineer-in-Charge.
1.1.8 Supply and Installation of medium velocity spray nozzles with fixing arrangement,
testing etc. all complete as per specification , drawings, data sheet and direction of
Engineer In-Charge.
1.1.9 Supply and Installation of Restricted orifice plate Including manufacturing,

delivery all complete as per direction of Engineer In-Charge.
1.1.10 Brick Masonry works in sub-structure and super-structure for all depths and all
heights in platforms and plastering works etc. as per specifications
1.1.11 Collection of debris, surplus/ unserviceable earth and disposal of same for all lead
inside the plant boundary limit including transportation, loading, unloading, clearing
of site etc. all complete as per specifications and direction of Engineer-in-charge
.
Any other Works, not specifically mentioned herein, but required for the
satisfactory and successful completion of the project as per directions of the
Engineer-in-Charge shall also be in the scope of the CONTRACTOR.
1.2 BASIS OF WORKS
The complete piping work shall be carried out in accordance with the following:
a. Approved for construction' drawings, hook-ups and sketches issued by

EIL to the CONTRACTOR- Plans and/or Isometrics.
b. Drawings, sketches and documents prepared by CONTRACTOR duly

approved by Engineer-in-charge.
c. EIL specifications/Documents as below:

i. Process and Instrumentation Diagram.
ii. Piping Material Specification
iii. Piping Support Indices (Only in offsite), if supports are not shown
in piping plan.
iv. Standard Specification of Non-Destructive Requirement of Piping
(6-44-0016)
Page 11 of 851
(STRUCTURAL) Rev. A
Page 6 of 10
v. Welding Specification Chart for Piping Classes

vi. Standard Specification for pressure testing of erected piping
system (6-44-0017)
vii. Welding Specification for fabrication of Piping Any other EIL or
other specification attached with Piping Material Specification or
special conditions of contract (such as standard for dimensional
tolerances etc.)
viii. Procedure for storage, preservation and positive identification of
materials at CONTRACTOR’s works/ stores.
ix. Hook-up drawings.
x. Specific requirements of Owner/Engineer-in-charge.
2.0 SCOPE OF SUPPLY
2.1 OWNER’S SCOPE OF SUPPLY
NIL
2.2 CONTRACTOR’S SCOPE OF SUPPLY
Procurement and supply of all materials (consumables / non-consumables) including

all tools, tackles and labors required for the completion of the works shall be in the
scope of the CONTRACTOR.
3.0 LIST OF ATTACHMENTS
CONTRACTOR shall carry out all works strictly in accordance with the drawings /
documents / specifications indicated in subsequent paragraphs.
4.0 SPECIFICATIONS:
Sl. Specification Rev. No. of

Title of Document
No No No. Sheets
1 6-66-0004 Standard Specification for Portable Fire

0 5
Extinguisher
Standard specification for 50 Kg & 75 kg
2 6-66-0061 3 5 Capacity Dry Chemical Powder (DCP)
Extinguisher
3 6-44-0012 Standard specification for fabrication and
4 15
erection of piping.
4 6-44-0013 Standard specification for inspection, flushing

4 9
and testing of piping.
5 6-44-0016 Standard Specification for nondestructive

7 21
examination requirement of piping.
6 6-44-0051 6 10 Technical notes for pipes.
Page 12 of 851
(STRUCTURAL) Rev. A
Page 7 of 10
7 6-44-0052 7 12+8 Technical notes for valves.
8 6-44-0053 Technical notes for flanges, spectacle blinds

6 7
and drip rings.
9 6-44-0054 Technical notes for but welded , socket

6 9
welded and screwed fittings.
10 6-44-0056 4 5 Technical notes for gaskets.
11 6-44-0057 4 5 Technical notes for bolts and nuts.
12 6-44-0067 1 9 Technical notes for strainers.
13 6-65-0006 Standard specification for earthwork for

3 7
Underground piping.
14 6-65-0030 Standard specification for fabrication and

4 11
laying of underground piping.
Standard Specification for Misc. Civil &
15 6-65-0035 3 7 Structural works for U/G piping and other civil
works.
Standard specification for stand post type
16 6-66-0012 3 5 hydrant ( with and without pumper connection
)
17 6-66-0018 3 4 Standard specification for first aid hose reel
18 6-66-0047 3 5 Standard specification for house cabinet
19 6-66-0074 3 9 Standard specification for fire hydrant system
20 6-68-0009 Standard specification - civil & structural

4 9
work- brick masonry
21 6-77-0001 4 40 Welding specification for fabrication of piping
22 6-77-0005 Welding specification charts for piping

4 30
classes.
23 6-78-0001 Specification for quality management system

1 7
requirement from bidders.
24 6-78-0002 Specification for documentation requirement

1 9
from contractors.
25 6-78-0003 Specification for documentation requirement

1 9
from suppliers.
Standard Specification for corrosion
26 6-79-0011 1 15 protection tape coating for underground steel
piping.
27 6-79-0020 Surface preparation and protective coating (
0 59
New Construction )
Standard specification for health, safety and
28 6-82-0001 7 90 environment ( HSE) management at
construction site.
Page 13 of 851
(STRUCTURAL) Rev. A
Page 8 of 10
Inspection and test plan ( ITP) for civil ,

29 6-82-3100 0 64 structural & architectural works ( item rate
contract with categorization)
Inspection and test plan ( ITP) for mechanical
30 6-82-3200 0 105 works ( item rate contract with categorization
)
30 6-82-6100 Standard Quality Assurance plan-
2 13
Construction division ( Item rate contract )
5.0 STANDARDS:
Sl. Standard Rev. No. of

Title of Document
No No No. Sheets
1 7-65-0001 Abbreviation , legends and equipment

3 4
symbols.
2 7-65-0420 3 1 Installation details of fire water hydrant
3 7-44-0002 4 2 Abbreviations
4 7-44-0003 4 4 Symbols of piping elements on drawings
5 7-44-0032 4 2 Stub-in standard
6 7-44-0033 5 2 Details of Mitered elbow

T-type Strainer Type-I (Dia. 2” to Dia. 4”)
7 7-44-0303 5 1 150CL RF, 300CL RF & RTJ, 600CL RF &
RTJ).
T-type Strainer Type-I (Dia. 6” to Dia. 24”)
8 7-44-0304 6 1 "(150# RF, 300# RF and RTJ, 600# RF and
RTJ).
Vent & drains (on lines 1 ½” and below).
9 7-44-0350 4 1
Vents and Drains (on line 2” and above)
10 7-44-0351 4 1
Orientation of orifice taps (class 600 & below)
11 7-44-0352 4 2
Welding of pipe with different thickness
12 7-44-0476 4 1
Butt welding end preparation
13 7-44-0477 4 1
Fillet welds details
14 7-44-0478 4 1
Welding details of Branch connections.
15 7-44-0479 4 1
Page 14 of 851
(STRUCTURAL) Rev. A
Page 9 of 10
Butt welding Details

16 7-44-0480 4 1
Butt weld details. (sequence of welds)

17 7-44-0481 4 1
Welding Detail. Of Branch connections (Stub-
18 7-44-0482 4 1 in)
Branch connection (breaking into).
19 7-44-0483 4 1
Branch Connection (not breaking into)
20 7-44-0484 4 1
Method of cutting and dimensions of field

21 7-44-0485 4 1
manufactured concentric reducers.
22 Tolerance of fabrication.
7-44-0486 4 1
23
Method of cutting & dimensions of field
7-44-0487 5 1
manufactured eccentric reducers.
Low support sliding for bare & insulated
24 7-44-0621 5 1
pipe size 2" thru 36" type L1 & L1A
Instrument connections on piping
25 7-52-0002 4 3
Orifice plates and flanges dimensional details
26 7-52-0041 4 14
6.0 APPROVED VENDOR LIST:
Sl. No. of
Document Number Rev. No. Title of Document
No Sheets
1 B035-001-81-41-LL-8106 0 6 Vendor list ( Structural U/G )
7.0 JOB SPECIFICATION:
Sl. Rev. No. of Title

Standard No.
No. No. Sheets
Job specification for Clean
1. B035-001-81-41-SP-8106 A 22
Agent System
8.0 SCHEDULE OF RATES:
Refer SOR No.
1. B035-001-81-41-FP-SOR-8106, Rev-0 ( Part-C)
Page 15 of 851
(STRUCTURAL) Rev. A
Page 10 of 10
9.0 ARCHITECTURAL DRAWINGS :
Sl. No Drawing Number Rev. No. Title of Drawing
1 B035-001-81-41- 12101 SV Station Building (Typical)

2
Plans, Elevations & Sections
IPS Building / Receipt Terminal /
2 B035-001-81-41- 12103 1 Despatch Terminal (Typical)
Ground Floor Plans & Sections
IPS Building / Receipt Terminal /
3 B035-001-81-41- 12104 1 Despatch Terminal (Typical)
Terrace Plans & Sections
4 B035-001-81-41- 12105 GUARD Room (Typical)
0
Plans, Elevations & Sections
Page 16 of 851
SPECIFICATION No.
JOB SPECIFICATION FOR B035-001-81-41-SP-8106
CLEAN AGENT SYSTEM Rev A
Page 1 of 22
JOB SPECIFICATION
FOR
CLEAN AGENT SYSTEM
FOR
DOBHI - DURGAPUR - PIPELINE SECTION
TENDER NO. B035-001-81-41-FP-T-8106

( PART- C)
PROJECT : DOBHI - DURGAPUR - HALDIA - PIPELINE

PROJECT
OWNER : GAIL
CONSULTANT : ENGINEERS INDIA LIMITED
JOB NO. : B035
A 24.09.18 ISSUED FOR BIDS AKS RS VG

Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
Page 17 of 851
SPECIFICATION No.
Page 2 of 22
CONTENTS
1.0 SCOPE ............................................................................................................................................ 4
2.0 CODES AND STANDARDS ......................................................................................................... 6
3.0 DESIGN REQUIREMENTS .......................................................................................................... 7
4.0 MATERIALS OF CONSTRUCTION .......................................................................................... 15
5.0 INSPECTION AND TESTING .................................................................................................... 16
6.0 VENDOR DATA REQUIREMENTS .......................................................................................... 16
7.0 MANDATORY SPARES ............................................................................................................. 16
8.0 RECOMMENDED SPARES ........................................................................................................ 17
9.0 SCOPE OF SUPPLY .................................................................................................................... 17
ANNEXURE - I ......................................................................................................................................... 18
Page 18 of 851
SPECIFICATION No.
Page 3 of 22
Abbreviations:
AC Alternate Current.
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
CRCA Cold Rolled Cold Annealed
F&G Fire and Gas.
FM Factory Mutual
LED Light Emitting Diode
LOAEL Lowest Observable Adverse Effect Level
LPC Loss Prevention Council
NFPA National Fire Protection Association
NOAEL No Observable Adverse Effect Level
OEM Original Equipment Manufacturer
PESO Petroleum Explosive Safety Organization
(Formerly known as CCOE)
PVC Poly Vinyl Chloride
RCC Reinforced Cement Concrete
SRR Satellite Rack Room
SMPV Static and Mobile Pressure Vessels
TAC Tariff Advisory Committee
UL Underwriters Laboratory
V Volts.
Vds Verband Der Sachversicherer
Page 19 of 851
SPECIFICATION No.
Page 4 of 22
1.0 SCOPE
The scope of work envisaged under Fire Protection and fire alarm tender covers the
Clean Agent system protection for the Dhobi Durgapur Pipeline Section as per
specifications, drawings, codes, standards and good engineering practice etc. complete.
The contractor shall be responsible to complete the entire work in all respects and any
other work necessary to complete the job whether specifically mentioned or not in the
scope of work.
Contractor’s scope shall include design, supply of all materials, installation, fabrication,
testing and Commissioning, puff test, performance guaranteeing of total flooding (below
false floor + main room + above false ceiling) centralised total flooding Clean Agent Fire
Extinguishing System as per this specification & NFPA-2001(latest addition). Clean
Agents to be considered are IG-541, IG-100, IG-55 and IG-01 as per NFPA-2001 for Fire
Protection of various risks. The list of various buildings ( IPS Building / Receipt terminal /
despatch Terminal and SV - Station ) for which the Clean agent system to be provided
along with the risks is listed below:-
1. IPS-6
2. SV-30
3. SV-31
4. SV-32
5. SV-33
6. SV-34
7. IPS-7
8. RT SAIL IISCO
9. RT HFC-DURGAPUR
10. RT DPL DURGAPUR
11. RT SAIL DURGAPUR
12. RT MATRIX FERTILISERS
Page 20 of 851
SPECIFICATION No.
Page 5 of 22
I. TABLE - 1 : IPS Building / Receipt Terminal / Despatch terminal (Typical)
RISK VOLUME
S.
RISK DESCRIPTION (MINIMUM)
No.
(cum)
Telecom & Scada room (Main room + False ceiling
1 RISK -1 182
+ False floor)
Control Room (Main room + False ceiling+ False
2 RISK -2 318
Flooring )
RISK -3 UPS Room (Main room + False ceiling+ False
3 127
Flooring )
4 RISK -4 Electrical room (Main room) 207
5 RISK -5 Battery room (Main room) 181
II. TABLE -2 : SV-Station (Typical)
RISK VOLUME
S.
RISK DESCRIPTION (MINIMUM)
No.
(cum)
1 RISK -1 Battery room (Main room) 162
2 RISK -2 Electrical room (Main room) 243
Instrument / Scada room (Main room + False
3 RISK -3 153
ceiling + False floor)
Clean agent shall also be provided in the cable trenches. Volume of clean agent
required for cable trenches shall be added to the risk volume as mentioned in
Table-1 & Table 2 above.
The actual net volume of the risk shall be calculated based on the Architectural,
Structural & Electrical drawings of the building by the bidder. However, the risk
volume given in Clause 1.0 shall be considered as minimum (i.e. Equivalent
number of main and stand-by cylinders shall be provided as minimum).
1.1 BIDDER shall design the system to meet the minimum requirements of total
flooding fire extinguishing Clean Agent system as per NFPA-2001 and having
design concentration as specified at 70ºF (21ºC) for the single largest risk area of
the control room/ SRR to be protected.
1.2 The system design shall be total flooding and Clean Agent requirement shall
correspond to the single largest risk area of Control Room/SRR to be protected.
1.3 No deviation from specification will be acceptable.
1.4 System supplied and software for design calculation shall be approved by
UL/FM/Vds/LPC. All the equipment’s shall be approved by UL/FM/Vds/LPC.
Cylinders along with cylinder valve assemblies shall also be PESO approved in
addition to UL/FM/Vds/LPC approval.
Page 21 of 851
SPECIFICATION No.
Page 6 of 22
1.5 Clean Agent system to be provided shall meet the requirements of NFPA-2001
(Latest). Hence any thing specified as “Mandatory” in NFPA-2001, although not
specifically mentioned in this specification, shall form part of this specification.
1.6 The system shall be designed based on the single largest risk area of the Control
Room/ SRR to be protected. However, the grouping of cylinders shall be made in
such a way that discharge takes place corresponding to the volume of the risk
under fire.
1.7 The system shall include electrically actuated automatic Clean Agent Fire
Extinguishing System complete with filled up Clean Agent cylinders, cylinder
rack, manifolds, pressure reducing devices, cylinder valves, directional valves,
pipes, discharge nozzles, bracket supports, hangers and such other fittings as
necessary for complete installation of the system, including chipping of existing
RCC / brick walls / cutting of steel plates etc. or removal & re-fixing of false
ceiling and false floor of risk areas, fixing fasteners and other activities required to
install the system.
1.8 The system shall also comprise of the different modes of operation, actuation and
cancellation facility etc. with necessary local control panel as per specification.
1.9 Operating devices and Local control panel shall be provided as per Clause 3.7
and Clause 3.8 respectively.
1.10 The bidders shall provide 100% Clean Agent filled standby cylinders. (i.e. A
reserve bank of Clean Agent filled cylinders with manifold, directional valves and
automatic change over to any of the two banks after actuation of main cylinders
to be provided in each risk area i.e. 100% reserve.)
1.11 The bidder shall very clearly mention in his offer that he has considered total
flooding centralised system with directional valves and have also offered 100%
standby cylinders.
1.12 The design requirements as given in Clause 3.0 shall be met.
1.13 The material of construction shall be as per Clause. 4.0.
1.14 Bidder shall furnish valid collaboration certificate with OEM (if applicable) in his
bid.
1.15 Bidder shall submit valid certificates of agencies who have approved/ listed the
system design , design concentration, equipment’s/ components offered.
2.0 CODES AND STANDARDS

The latest editions of the following codes, specification and regulations has been used
for the detailed design and specification of Clean Agent system
a. NFPA 2001: National Fire Protection Association, (Latest)
Page 22 of 851
SPECIFICATION No.
Page 7 of 22
(Standard on Clean Agent fire extinguishing system)

b. Clean Agent manufacturer’s recommendations
c. SMPV Rules, PESO Nagpur (For Storage cylinders)
3.0 DESIGN REQUIREMENTS
3.1 System Design

Design requirement shall be as given below.
3.1.1 System
The centralised system shall be designed to protect the single largest risk area (volume
wise) of all the three portions simultaneously i.e. main room + above false ceiling +
below false floor/ in trenches. Volume for main room, above false ceiling and below false
floor/ trenches shall be calculated based on the relevant Architectural , Structural and
Electrical drawings.
3.1.2 System Operation

The system shall comprise of the following mode of operation and actuation and
cancellation facility etc. with necessary control panel:
System operation shall be possible by the following means:
a. Automatically due to fire detection in the protected area.
b. Operation of manual release push button located adjacent to protected risk.
c. By operating manual lever provided on electrical/ manual control head on pilot
cylinder
d. By push button actuation at Clean Agent control panel, in manual mode for each risk
Automatic/ manual mode selection shall be provided for all risks individually from clean
agent control panel.
The Clean Agent shall be discharged / actuated automatically after an adjustable time
delay based on the detection signal received. The delay shall be minimum 30 seconds;
however it shall be adjustable from 30 to 120 seconds. In the local control panel of Clean
Agent system, there shall be one hooter, which shall operate once the gas is released.
During time delay, there shall be a pre-discharge alarm (audio + visual). Hooter shall
follow the alarm once the gas is discharged.
3.1.3 Clean Agent Gas & its grouping/distribution
Page 23 of 851
SPECIFICATION No.
Page 8 of 22
The quantity of Clean Agent gas provided shall be sufficient to protect the single largest
risk with 100% standby. The system for every individual risk shall have its own
distribution piping, nozzles, alarm, and actuation system, etc.
Suitable combination of cylinders shall be made to cater to all the risk areas individually.
Both main and standby cylinders shall be permanently connected to the distribution
piping through manifold and arranged for easy and auto changeover.
Since the system is designed for the largest risk and there are several risk areas varying
in size in a particular building, the system shall permit the use of required no. of cylinders
for any individual risk involved so that the concentration of gas in that risk area does
not exceed the NOAEL specified.
3.1.4 Gas properties & its discharge characteristics

Physical properties of Inert Gas Agents shall meet the requirements of NFPA-2001.
FOLLOWING PROPERTIES OF AGENTS SHALL BE USED AS FIRE EXTINGUISHING

AGENTS (Shall be as per NFPA-2001 latest edition)
AGENT
AGENT
CONTAINE
NAME OF GAS
CONTAINER
R
CHARGING DESIGN
FORMULA CHARGING
PRESSURE CONCENTRATION
PRESSURE
NOAEL%
0 0
AT 70 F (21
AT 1300F
C)
(550 C)
N2 (50%)
IG-55 43 4350 psig 5222 psig (*) Design
AR (50%)
Concentration for
N2 (52%) type of clean agent
IG-541 AR (40%) 43 4503 psig 5359 psig selected shall be in
CO2 (8%) accordance to
IG-100 N2 (100 %) 43 4061 psig 4754 psig approval taken from
UL/ FM/ Vds/ LPC
IG-01 AR (99.9%) 43 4510 psig 5402 psig (Follow NFPA

clause no. 5.4)
Page 24 of 851
SPECIFICATION No.
Page 9 of 22
(*) Or higher % /quantity of volume as specified by Clean Agent manufacturer for

Clean Agent system. However the maximum discharge concentration shall not
exceed No Adverse Effect Level (NOAEL).
The agent discharge shall be substantially completed within a time period as per clause
no. 5.7.1.1 of NFPA-2001 for IG-541, IG-55, IG-100 and IG-01. For inert gases the
measured discharge time is considered to be the time when the measuring device starts
to record reduction of oxygen until the design oxygen reduction level is achieved.
The minimum oxygen concentration shall be as per NFPA-2001 for NOAEL.
3.2 System Flow Calculations

System flow calculations shall be performed using A CALCULATION METHOD LISTED
OR APPROVED BY THE AUTHORITY HAVING JURISDICTION (i.e. UL/FM/Vds/LPC).
The system design shall be within the manufacturers listed limitations.
BIDDER shall also provide sufficient measure/ (like properly designed fire rated louvers
etc.) facilities in the risk areas to dissipate over pressurisation due to release of Clean
Agent and also provide calculation in support of same for each protected area.
Approval certificate of software from the UL/FM/Vds/LPC etc. shall be submitted

along with the offer.
3.3 Clean Agent Quantity

Minimum design concentration of Clean Agent gas shall be based on greater of the
design concentration as specified in NFPA-2001 or the design concentration for which
the vendors clean agent system is listed/ approved, for Class “C” fire as per cl. No.
5.4.2 of NFPA-2001 at 700 F by volume for Clean Agent fire extinguishing system based
on approved / listed flow calculation method.
Clean Agent concentration requirement and quantity shall be computed as per NFPA-
2001 considering the volume of the hazard as specified.
3.4 Clean Agent Storage Cylinders

The Clean Agent storage cylinders shall be designed as per ASME code for boiler &
pressure vessels section-VIII OR as per IS 7285 Part 2 to hold Clean Agent at ambient
temperatures. Cylinder shall be of approved type and freshly imported/ manufactured.
Minimum design level pressure of storage cylinder shall be as per Clause 4.1.4 and
Table A-4.1.4.1 of Annexure-A to NFPA-2001.
Page 25 of 851
SPECIFICATION No.
Page 10 of 22
The design pressure for cylinder shall be suitable for the maximum pressure developed
at 1300 F (550 C).
The cylinders shall be charged to a fill density or super pressurisation (super
pressurisation means the addition of a gas to fire suppression agent cylinder necessary
to achieve the pressure required for proper system operation) within the range specified
in the manufacturers listed manual.
BIDDER shall select the capacity of cylinder based on the storage space available and
for better replacement and inter changeability. The BIDDER shall preferably select the
capacity of cylinder keeping in view the filling ratio as per NFPA 2001.
The cylinder shall be seamless, brand new (date of manufacturing of cylinders shall not
be older than 1 year from the date of bid opening) never retested and month & year of
manufacture shall be latest (or as specified in the requisition).
Each cylinder shall have a permanent name plate, specifying the agent, tare and gross
weight in addition to the pressurisation level, nominal agent volume.
Cylinder shall bear the mark of manufacturer, serial number, test certificate issued by
authority having jurisdiction and shall be duly approved by competent authority
providing approval of the system i.e. UL/ FM/ Vds/ LPC. A reliable means of
indication shall be provided to determine the pressure in refillable cylinders. PESO
Approval of the cylinders along with cylinder valve is a must irrespective of the
country of Origin. Cylinder shall conform to the requirement of NFPA 2001 and shall be
compatible with the engineered system being provided along with design analysis.
Cylinders without approval shall not be accepted.
Each cylinder shall have pressure relief valve to protect the cylinders against excess
pressure conditions.
Pressure gauges with isolation valves on manifold shall be provided.
Automatic means such as check valve shall be provided to prevent agent loss if the
system is operated when any cylinders are removed for maintenance.
Layout of Cylinders:
Clean Agent cylinders shall be arranged in the following manner:
i) In a battery of cylinders manifold together, leading to distribution piping and discharge
nozzles for the risk to be protected, including below false floor and above false ceiling
Page 26 of 851
SPECIFICATION No.
Page 11 of 22
spaces, along with a reserve battery of Clean Agent filled cylinders with manifold and
directional valves, including arrangement for automatic change over to any of the two
banks after actuation of main cylinders to be provided in each risk area i.e. 100%
reserve.
ii) The cylinder storage racks shall be provided for main as well as for reserve cylinders.
iii) The manifold cylinders referred above shall be securely mounted on the floor and
suitably supported in a rack with provision for convenient individual servicing, according
to the manufacturers installation manual. Such servicing shall be possible without
shutting down the system.
A space marked as cylinder location on the drawing will be made available to the
Contractor for placing Clean Agent Cylinders and Piping Manifold. Contractor shall
accommodate the storage of Gas Cylinders and Manifold Piping in the space provided
and confirm the adequacy of space (along with technical bid).
3.5 Piping, Fittings and Discharge Nozzles
3.5.1 Piping & Fittings
3.5.1.1 Seamless CS pipe as per ASTM A106 GR. B shall be provided as per the requirements
specified in clause 4.2.1 of NFPA-2001. Pipe thickness calculation shall be as per ASME
B31.1 power piping code. Normally welded joints shall be provided. Threaded pipes, if
used, shall have threads in joints and fittings conforming to ANSI B1.20.1.
3.5.1.2 Pipe fittings shall be provided as per clause no. 4.2.3 of NFPA-2001.
3.5.1.3 All CS Studs, Bolts and Nuts shall be Hot Dip Galvanised as per ANSI A153 for
corrosion resistance.
3.5.1.4 The Pressure Reduction device shall be easily identifiable.
3.5.1.5 The Clean Agent piping layout shall be such that the pipes of one risk shall not pass
through that of another risk.
3.5.1.6 All Valves shall be approved for intended use. The Gaskets, O-Rings and other Valve
material shall be compatible to the Clean Agent.
3.5.1.7 The Clean Agent piping and nozzles shall have to be planned clearing following facilities
coming on its route, in the areas where protection is being envisaged.
a. The beams and ribs which criss-cross the ceiling. The Clean Agent piping shall be
routed considering clearing structural beams / columns or any other facilities coming
in the areas where Clean Agent system is being envisaged. All necessary civil works
Page 27 of 851
SPECIFICATION No.
Page 12 of 22
including taking support from Structural steel members, blast resistant RCC walls or
breaking brick walls for routing the piping, installing pressure relief vent etc. and
making them good, shall be in the scope of work of contractor.
b. Path of AC ducts.
c. Cabling in false flooring.
d. Light fittings, detectors etc.
3.5.1.8 If required, the exposed piping works shall be camouflaged to match with the interior of
the protected room.
3.5.2 Discharge Nozzles

Discharge nozzles shall conform to Cl.4.2.5 of NFPA 2001 and shall be of Brass and
shall be FM/UL approved. Discharge nozzles used in the system shall be listed for the
use intended for discharge characteristics. The selection of nozzle orifice shall be such
discharge time required to achieve 95% of the minimum design concentration for flame
extinguishment as per clause no. 5.7.1.1 of NFPA-2001. Each nozzle shall be
permanently marked to identify the manufacturer as well as type and size of the orifice
along with tag / part number, orifice code, or other suitable marking as specified by the
authority having jurisdiction.
3.6 Painting
Painting and colour scheme of pipelines, Clean Agent storage cylinders, supports etc.
shall be as specified in the Specification for Shop and Field Painting attached with the
Bid.
3.7 Operating Devices

a. Operating devices shall include Clean Agent releasing devices or valves, discharge
controls and shut down equipment necessary for successful performance of the system.
b. Electric Supply: The purchaser shall supply 240 V ± 6%, 50 Hz ± 3% single phase power
supply at a convenient point. Converter if required to convert to any other operating
voltage shall be in contractor’s scope.
c. The automatic Clean Agent system shall be of robust design and shall not be readily
rendered inoperative easily. The Clean Agent system shall be designed to function
properly for the temperature range specified in NFPA-2001.
d. The Clean Agent cylinders shall be mounted on front and firmly supported in brackets in
a manner that they will not be easily subjected to mechanical, chemical or other damage,
which would render the system inoperative.
Page 28 of 851
SPECIFICATION No.
Page 13 of 22
e. In addition to Automatic actuation, there shall be a normal manual control for actuation,
which shall be located so as to be conveniently and easily accessible at all times
including the time of fire. This control shall cause the complete system to operate in its
normal fashion.
f. Manual controls shall not require a pull of more than 40 lb nor a movement of more than
14 inches to secure operation. Each remote manual control for activation shall be located
not more than 4 feet above the floor.
g. Weight of Clean Agent shall be monitored by Pressure Transmitter along with local
pressure indicator for each cylinder. All local pressure indicators in a bank of cylinders
(main / stand by) shall be connected in a signal loop and shall give a common
indication/signal of loss of pressure in that particular bank in the Control Panel for Clean
Agent system located inside Control Room. Contractor's scope of supply includes
complete system, interconnecting cables and installation of all equipments and
accessories.
h. Contractor shall also provide sufficient measure (like properly designed fire rated louvers
etc.) facilities in the risk areas to dissipate over pressurisation due to release of clean
agent and also provide calculation in support of the same for each protected area.
3.8 Local Control Panel for Clean Agent System
3.8.1 The local control panel shall be free standing, floor mounted type and shall be suitable
for both auto and manual operation. The panel shall be made out of minimum 16 gauge
CRCA sheets. Doors and covers shall be made out of 14 gauge CRCA sheets. The
panel shall be naturally ventilated, totally enclosed, dust and vermin proof, with IP-41
enclosure as a minimum.
The Clean Agent system shall be actuated automatically by the signal received from the
fire alarm & detection system and shall provide feedback to the fire alarm & detection
system for actuation of clean agent system for each zone. Fire alarm & detection system
shall be separate system from clean agent system and Main Fire alarm panel shall be a
separate panel from clean agent Control Panel. Fire alarm & detection system, after
detecting the fire in the protected area/ zone, shall provide an actuating signal to Clean
Agent control panel, which in turn shall energise the solenoid valve to trigger the
dumping operation in the respective protected area / zone. Necessary control / interlock
cabling between Fire Alarm & Detection system and Clean Agent system panel, for each
protected area / zone for command & feeder using multi-core 2.5mm2, Cu conductor
Page 29 of 851
SPECIFICATION No.
Page 14 of 22
XLPE insulated flame retardant low smoke (FRLS) cable, shall be provided by the Clean
Agent Vendor. The interface point with fire alarm & detection system shall be located in
room where the control panel for clean agent system is to be installed.
The control panel shall be located either just outside the entry/ exit gate of main control
room or in cylinder room or any other place as decided by owner at the time of detailed
engineering.
However, control panel shall be equipped with adequate rating battery charger and
VRLA battery with 24 hour back up, for efficient operation of the system during mains
power failure. Battery sizing shall be done considering end cell voltage as 1.75V
3.8.2 Control panel shall be provided with all alarms, indicators, caution/sign board and relays/
control switches meeting all the requirements of NFPA-2001 and shall include but not be
limited to the following:
a) i) Two alarms and one fault indicator lamp for each zone to be protected.
ii) Combination of alarm silence and alarm off switch.
iii) Combination of fault silence and trouble lamp switches.
iv) Alarm test switch
v) Alarm re-set switch.
b) The system shall have a positive warning device by sounding alarm to alert
personnel of the impending discharge and also a positive indication to show that
the system has actuated. Two numbers potential free contacts shall be provided
for owner’s use, one contact for indication of start of dumping operation and other
contact for indication of end of dumping operation.
c) Alarm indicating failure of supervised devices of equipment shall give prompt and
positive indication of any failure and shall be distinctive from alarm indicating
operation of hazardous conditions.
d) One number potential free contact for owner’s use shall be provided for each
protected area/zone for indicating the actuation of dumping operation in the
respective area.
e) Provision for receiving auto actuation command through potential free contacts
from owner’s fire alarm & detection system shall be provided for each protected
area/zone for imitating dumping operation in the respective protected area/ zone.
Page 30 of 851
SPECIFICATION No.
Page 15 of 22
f) All indication lamps shall be LED type with minimum size of 10 mm.
g) Following alarms (through contacts) are required to be provided to purchaser
RTU system for centralized monitoring purpose:
a) System Actuation alarm
b) System Inhibit/Fault Alarm
c) Clean agent Cylinder Weight loss alarm
3.8.3 Warning and instruction signs at entrance to and inside protection areas shall be
provided.
3.8.4 A Control Box shall be provided for manual control at the exit doors of each risk area,
comprising of abort switch and Auto/Manual Push buttons for Clean Agent release
3.8.5 Automatic/ manual mode selection shall be provided for all risks individually from clean
agent control panel. Selector switches for selection of Main/Reserve cylinders shall be
provided for all risks individually from clean agent control panel.
3.8.6 Potential free contacts shall be provided from the Clean Agent Control Panel to shut off
the fire dampers / louvers and Air Conditioning System.
3.8.7 Supervision of automatic systems shall be provided and shall include electrical
supervision of the actuating device and the wiring connecting the actuation device and
the detection system.
3.8.8 Operating instructions shall be displayed on a name plate fitted permanently on the
Clean Agent skid.
3.8.9 Clean Agent extinguishing system shall incorporate a pre-discharge alarm with a time
delay, sufficient to allow personnel evacuation prior to discharge. The delay shall be
minimum 30 seconds. However it shall be adjustable from 30 to 180 seconds.
4.0 MATERIALS OF CONSTRUCTION

The material of construction shall be as per this specification for the items specified. For
other items, the materials of construction used in the system shall be in accordance with
NFPA-2001 or as specified by the equipment manufacturer for the intended use (if the
same is not specified in NFPA-2001). The material of construction shall be
UL/FM/Vds/LPC approved. The approval of the same shall be submitted at the time of
bid submission.
Page 31 of 851
SPECIFICATION No.
Page 16 of 22
5.0 INSPECTION AND TESTING
Approval of Installation
Only listed or approved equipment and devices shall be used in the systems i.e. all
equipments & devices shall be approved by UL/FM/Vds/LPC. The complete system shall
be tested to meet the approval of Owner.
In order to determine that the system has been properly installed and will function as
specified, the following tests shall be performed:
The approval of installation shall be subject to satisfying the requirements of
Clause 7 of NFPA-2001.
a. A thorough visual inspection of the installed system and hazard area. The piping,
operational equipment and discharge nozzles shall be inspected for proper size and
location. The locations of alarms and manual emergency releases shall be
confirmed. The hazard area shall be inspected closely for un-closable openings and
sources of agent loss. The supplier shall furnish the composition certificate of Clean
Agent satisfying the requirements of Table 4.1.2(b) for IG Agent Quality
requirements of NFPA-2001. Filling certificate should be provided specifying from
which original Clean Agent drum the gas has been taken and which cylinder is filled.
b. A check of labeling of devices for proper designations and instructions. Name plate
data on the storage cylinders shall adhere to specifications.
c. A test for mechanical tightness of the piping shall be conducted as per NFPA-2001
d. The cylinder along with cylinder valve assembly shall be PESO, Nagpur
approved in addition to listing/ approval by UL/FM/Vds/LPC.
e. A flow test (puff test) using nitrogen shall be performed on the piping network to
verify that flow is continuous and that the piping and nozzles are unobstructed as per
NFPA-2001.
6.0 VENDOR DATA REQUIREMENTS

Refer VDR documents attached with the bid.
7.0 MANDATORY SPARES

The bid must include in the quoted price for the following mandatory spares to be
supplied with the Clean Agent system:
Page 32 of 851
SPECIFICATION No.
Page 17 of 22
1. Clean Agent Cylinders Minimum one or 5% of total cylinder (i.e. main

cylinders + 100% standby cylinders), whichever is
more, shall be supplied with filled in Clean Agent gas.
These are in addition to 100% standby filled up
cylinder
2. Automatic and Manual One of each type/ size used in the
release system system supplied
3. Cylinder Valve with One of each type / size used in the systems supplied.
safety pressure relief
device
4. Clean Agent Nozzles 10% of total nozzles used in each size / type with
minimum drill holes.
5. Clean Agent Release 10% of total used of each type etc.
Push Buttons
Spares for two years AMC shall be separately quoted in a separate envelope.
8.0 RECOMMENDED SPARES

In addition to above mandatory spares, Contractor must recommend list of spares
required for 2 years trouble free operation, with unit rates and quantity, along with the
offer.
9.0 SCOPE OF SUPPLY
9.1 OWNER'S SCOPE OF SUPPLY

Nil
9.2 CONTRACTOR'S SCOPE OF SUPPLY

All items required for completing the job as per Bid requirement including all materials,
tools, tackles, and labors etc. including mandatory spares.
Page 33 of 851
SPECIFICATION No.
Page 18 of 22
ANNEXURE - I
TECHNICAL DATA SHEETS DETAILS TO BE FURNISHED BY THE BIDDER ALONG

WITH THE OFFER
(Data sheets shall be filled in separately for each clean agent as per NFPA-2001)
Legend V: Vendor to furnish data/details
1.0 Type of system : V

Total flooding centralised system
(Mention name of agent & manufacturer)
Formulation of gas : V
Normal Charging Pressure (psig) : V
Name of OEM : V
2.0 Design code/standard to which design/

manufacture/ testing conforms. : NFPA-2001- (Latest)
3.0 System designed to protect the largest

or total risk in the building as specified. : Largest risk
3.1 Risk name/volume / Agent Container : Refer scope of work/job spec.

Charging Pressure
3.2 Design Concentration (Refer Clause 3.1.4) : V
3.2.1 Amount of gas required. (Attach separate

sheet, if required).(List out gas supplied,
number of cylinders etc. for working and
Standby requirements, risk wise.) : V
3.3 Clean agent Cylinder Details (Seamless)

a) Manufacturer : V
b) Design Code : NFPA-2001
c) Capacity : V
Page 34 of 851
SPECIFICATION No.
Page 19 of 22
d) Gas Holding Capacity (Kg) : V
e) Total Number supplied (main + stand by) : V
f) Approving Agency : FM/UL/LPC/Vds/PESO
g) Approval by PESO (YES/NO) : V
h) Working pressure (kg/cm2g) : V
i) Design Pressure (kg/cm2g) : V
3.4 Pipes, valves and fittings.

a) Material for Construction
i. Pipes : As per spec
ii. Fittings : As per spec
iii. Valves : As per spec

b) Design Code
i. Pipes : As per NFPA
ii. Fittings : As per NFPA
iii. Valves : As per NFPA
iv. Type of joints : As per NFPA

c) Hydraulic test Pressure of
manifold/ supply lines(kg/cm2g) : As per NFPA
d) Directional Valve
i. Test Pressure (kg/cm2) : V
ii. Approved by FM/UL/Vds/

LPC (Yes/No) : V
e) Discharge Nozzles
i. Number Supplies : V

LPC (Yes/No) : V
f) Pressure Gauge
i. Make : V
ii. Pressure Range : V
iii. Approved by FM/UL/Vds/

LPC (Yes/No) : V
g) Pressure Reducer
Page 35 of 851
SPECIFICATION No.
Page 20 of 22
i. Approved by FM/UL/Vds/
LPC (Yes/No) : V
h) Cylinder along with cylinder valve
i. Make : V

LPC (Yes/No) : V
iii. PESO Approval (Yes/No) : V
k) Cylinder valve actuator

i. Approved by FM/UL/Vds/
LPC (Yes/No) : V
3.5 Painting and colouring of pipeline, nozzles,

Cylinder supports included : V
3.6 Operating Devices

3.6.1 Signal from the Clean Agent Control
Panel for shuttering off the air handling
unit and damper closing. : V
3.6.2 Push Button Station

i. Type : V
ii. Manufacturer : V
iii. Model, numbers offered : V
iv. Overall dimensions : V
3.6.3 Control Cables

i. Manufacturer : V
ii. Code/ Standard : V
iii. Type : V
iv. Size : V
v. Rating : V
3.7 Main Control Panel
Page 36 of 851
SPECIFICATION No.
Page 21 of 22
i. Manufacturer : V
ii. Mounting Detail : V
iii. Number of entries : V
iv. Sheet Thickness : V
v. Cable Entry : V
vi. Total heat load predicted for air

conditioning. : V
vii. No. of AC/DC feeders and their

rating. : V
3.7.1 Additional Requirements for Control Panel

a) Whether housing all the necessary
printed card circuits, board cards,
relays indicating lamps, push buttons,
switches, etc. for the efficient
operation of the system,
(Yes/No). : V
b) Input power supply requirement for

operation of panel. (AC/DC Volts) : V
c) Panel Signal Voltage (AC/DC Volts) : V
d) Type of battery and AH of the battery : V
e) Charger rating : V
f) Interconnecting cabling between

battery and panel. : V
g) Power supply unit incorporated in

the panel. (Yes/No). : V
h) Audio visual alarm on panel provided

for Battery low conditions (Yes/ no) : V
i) Change over from AC Main supply

to standby power supply fully
automatic in either direction (Yes/No). : V
j) Following push buttons provided
Page 37 of 851
SPECIFICATION No.
Page 22 of 22
i) Alarm : V
ii) Reset : V
iii) Test (Yes/ No) : V
k) Audio visual indication for AC
supply failure provided (Yes/No). : V
l) Pilot lamp for system supply

failure provided (Yes/No). : V
m) Dual tone hooter for fire/fault alarm

Provided & range of the same : V
n) Painting (External/Internal) : V
4.0 Material of Construction selected in

accordance with NFPA-2001 (Yes/No) : V
5.0 Inspection and Testing

a) Visual inspection of installed : V
system & hazard area.
b) Check of labelling of devices. : V
c) Check for mechanical tightness of

piping & associated equipments : V
d) Non-destructive operational tests for all

devices included. : V
e) Test with N2 gas for all risks (YES/No) : V
6.0 Confirmation regarding the available space

For cylinders (main+ standby) (YES/No) : V
7.0 Confirmation that Main, Standby and : V

Mandatory Spare Cylinders shall be
supplied full of gas.
Page 38 of 851
B035-001-81-41-12101
REF. DWG. NO. REFERENCE DRAWING TITLE
SCHEDULE OF FINISHES
A-EXTERNAL :-
500 HIGH R.C.C. PLAIN CEMENT PLASTER WITH EXTERIOR ACRYLIC EMULSION PAINT
PARAPET WALL AS/APPROVED DESIGN.
WATER PROOFING
AS/TENDER SPECS. WATER PROOFING
4mm thk APP MODIFIED REINFORCED BITUMINOUS MEMBRANE
1000 HIGH R.C.C. R.C.C. SLAB AS/STRL.
WATERPROOFING OVER RCC SLAB AS/SPECIFICATIONS NOTES :-
PARAPET WALL
500
WATER PROOFING B-INTERNAL 1. DIMENSIONS, CO-ORDINATES, LEVELS
AS/TENDER SPECS. A. ALL DIMENSIONS ARE IN MILLIMETRES.
ROOM/AREA FLOORING WALLS CEILING B. DRAWING IS NOT TO BE SCALED FOR ANY MISSING DIMENSION.
R.C.C. SLAB AS/STRL.
FIRE FIGHTING HEAVY DUTY CEMENT PLASTER CEMENT C. ALL LEVELS & CO-ORDINATES ARE IN METRES.
2400
750 WIDER.C.C. GUTTER STAIRCASE
ROOM, ELECTRICAL FLOORING WITH OIL BOUND PLASTER WITH
D. LEVEL 100.00 CORRESPONDS TO TOP OF APPROACH/ACCESS ROAD
ROOM DISTEMPER OIL BOUND
1000
DISTEMPER NEAR THE BUILDING ENTRY, CROSS REFERENCE TO STRUCTURAL
30 DRAWING SHALL BE MADE.
E. PLINTH LEVEL OF THE BUILDING SHALL BE SAME THROUGHOUT
1000
750 CHEMICAL & CHEMICAL CEMENT
BATTERY ROOM UNLESS SPECIFICALLLY INDICATED.
20 ABRASION RESISTANT EPOXY PLASTER WITH
RESISTANT EPOXY DADO UPTO F. LOCATION/ORIENTATION/CO-ORDINATES OF THE BUILDING SHALL BE
OIL BOUND
FALSE CEILING COATING OVER 2500mm HEIGHT & DISTEMPER CROSS-CHECKED WITH STRUCTURAL AND GENERAL CIVIL DRAWINGS.
CLEAR
4000
INSTRUMENT/SCADA ROOM HEAVY DUTY OIL BOUND IN CASE OF ANY MIS-MATCH THE SAME SHALL BE GOT RESOLVED
3000
900 1200
10 FLOORING DISTEMPER ABOVE BEFORE CONSTRUCTION.
2. FLOOR
izLrqr vkjs[k ,oa blesa fufgr fMt+kbu bathfu;LkZ bafM;k fyfeVsM dh LkaifRr gSA ;s ek= m/kkj fn, x, gSa vkSj m/kkjdrkZ us ;g Li"V Lke>kSrk fd;k gS fd u rks mUgsa iqu% eqfnzr fd;kk tk,xk] u udy dh tk,xh]
u m/kkj fn, tk,axs] u iznf'kZr fd, tk,axs vkSj u gh Lkhfer vkSj futh iz;ksx ds vykok budk dksbZ vU; iz;ksx gksxk vkSj ;g iz;ksx m/kkj nsus okys }kjk m/kkjdrkZ dks fyf[kr :i esa nh xbZ Lkgefr Lks gksxk A
100.450 100.450 A. FINISHED FLOOR LEVEL OF WC/BATH CUBICLES, DRINKING WATER

INSTRUMENT/ FALSE FLOORING CEMENT PLASTER ALUMINIUM
F.F.L 100.00 100.00 F.F.L 1
450
(WITH HIGH WITH PLASTIC PANEL FALSE AREA, PANTRY / KITCHEN SHALL BE 12MM LESS THAN ADJOINING
600
A.R.L. A.R.L. SCADA TELECOM
ROOM PRESSURE EMULSION PAINT CEILING AREAS AND SHALL HAVE PROPER SLOPE FOR FLOOR DRAINAGE.
LAMINATE) B. FLOOR OF CABLE CELLAR, AC PLANT/AHU, BATTERY ROOM SHALL
FALSE FLOORING
2000 6000 6000 2000 2000 6000 6000 2000 HAVE PROPER SLOPE FOR FLOOR DRAINAGE.
STAIRCASE KOTA STONE CEMENT PLASTER CEMENT C. REFERENCE SHALL BE MADE TO RELEVANT DRAWINGS BEFORE
C B A A B C FLOORING WITH PLASTIC PLASTER WITH

C B A A B C STARTING FLOORING WORKS. TRENCHES/CUT OUTS IN FLOOR
EMULSION PAINT PLASTIC
SHALL BE PROVIDED IN ACCORDANCE WITH RELEVANT ELECTRICAL/
EMULSION
PAINT INSTRUMENTATION/PED/STRUCTURAL//EQUIPMENT DRAWINGS.
ELEVATION E2 ELEVATION E4 SECTION B-B SECTION A-A VERANDAH, KOTA STONE EXTERIOR ACRYLIC EXTERIOR
3. WALL
RAMP & STEPS FLOORING EMULSION PAINT ACRYLIC A. THICKNESS OF ALL BRICK MASONRY WALLS (EXCEPT WC/BATH
EMULSION CUBICLES) SHALL BE 230MM IF NOT SPECIFICALLY INDICATED.
PAINT B. INTERNAL PARTITION WALLS OF WC/BATH CUBICLE SHALL
BE 2500MM HIGH FROM FLOOR LEVEL.
C. ALL OTHER WALLS SHALL BE UPTO ROOF/ROOF BEAM IF NOT
SPECIFICALLY INDICATED.
D. CUT-OUTS/OPENINGS FOR CABLES/DUCTS ETC. SHALL BE PROVIDED
AS/PER PED/STRUCTURAL/EQUIPMENT, CABLE, DUCTING DRAWINGS.
4. CABLING/CONDUITS
A. ALL CONDUITS SHALL BE CONCEALED TYPE EXCEPT IN AREAS CONCEALED
BY FALSE CEILING AND SHALL BE LAID AS PER RELEVANT DRAWINGS.
B. IN CASE OF CONDUITS CONCEALED IN ROOF/BEAM/FLOOR, THEY
SHALL BE LAID BEFORE CASTING.
5. FINISHING
A. IN CASE OF ANY CONFLICT WITH TENDER/PACKAGE, THE SAME
SHALL BE GOT RESOLVED BEFORE PROCUREMENT AND EXECUTION.
100.450 100.450 SCHEDULE OF DOORS AND WINDOWS

100.00 F.F.L 100.00 F.F.L
A.R.L. A.R.L. LINTEL
TYPE OPENING SIZE FRAME SIZE DESCRIPTION NOS.
LEVEL
PRESSED STEEL DOOR DOUBLE SHUTTER WITH
4000 7000 7000 6000 4000 4000 6000 7000 7000 4000 SD1 1500 X 2700 1480 X 2690 2700 PRESSED STEEL FRAME AS PER EIL STD. WITH 02
2 LOUVERS AT BOTTOM
28000 28000 POWDER COATED ALUMINIUM GLAZED DOUBLE
AL1 1500 X 2700 1480 X 2690 2700 SHUTTER DOOR WITH 6mm TH. TOUGHENED 02
GLASS AS PER EIL STD
POWDER COATED ALUMINIUM GLAZED SINGLE
1 2 3 4 5 6 6 5 4 3 2 1 AL3 1000 X 2100 0980 X 2090 2100 SHUTTER DOOR WITH 6mm TH. TOUGHENED 02
ELEVATION E1 ELEVATION E2 W1 1200 X 1200 1180 X 1180 2100

POWDER COATED ALUMINIUM GLAZED WINDOW
WITH 6.0mm THK TOUGHENED GLASS, PARTLY
FIXED/PARTLY OPENABLE TYPE AS/EIL STD.
08

W2 1200 X 1200 1180 X 1180 2100 WITH 6.0mm THK TOUGHENED GLASS, PARTLY 05
FIXED/PARTLY LOUVERED TYPE AS/EIL STD.
W3 1200 X 1200 1180 X 1180 2100 WITH 6.0mm THK TOUGHENED GLASS, FIXED 03
TYPE AS/EIL STD.
POWDER COATED ALUMINIUM GLAZED
V2 3650 X 600 3630 X 580 2100 VENTILATOR AS/EIL STD. WITH 6 MM TH. 02
TOUGHENED GLASS , FIXED TYPE
1 2 3 E2 4 5 6 1 2 3 4 5 6 NOTE :-
28000 28000 ALL GLAZED DOOR (FAN LIGHT), WINDOWS & VENTILATORS
4000 7000 7000 6000 4000 4000 7000 7000 6000 4000 SHALL BE PROVIDED WITH ALUMINIUM GRILL.
UP
LOCATION, NO. OF AC SHALL BE AS PER MED DRAWING.
STEPS
B TREAD-300
A RISER-150
A B
3X3 NOS.100 DIA
RAMP GI PIPE SLEEVE
100.000
A.R.L. (SLOPE 1:8) 1000MM HIGH RAILING
C C
VERANDAH
100.450
2000
2000
250 Ø EXHAUST FAN 4 NOS.100 DIA 2NOS.50 DIA

360 F.F.L. EQ EQ 230
EQ EQ GI PIPE SLEEVE 1200 EQ 1200 GI PIPE SLEEVE
W3 W1 W1 EQ EQ
AL1
B AL2 2000 3665
B
W2 W2
SD1 SD1 AL1
1500 2 18.09.18 REVISED AND RE-ISSUED FOR CONSTRUCTION BR PD NK
4NOS.150 DIA 1500
SLOPE 1:80
SLOPE 1:80
SLOPE 1:80
SLOPE 1:80
20 UP GI PIPE SLEEVE 20 1 17.04.18 ISSUED FOR CONSTRUCTION BR PD NK
8000
8000
1 21 0 29.12.17 ISSUED FOR CONSTRUCTION BR PD NK

CAP
ELECTRICAL ROOM BATTERY

C 12.12.17 CLIENT'S COMM. INCORPORATED & REISSUED FOR ENGG BR PD NK
INSTRUMENT/ ROOM
E4
6000
6000
TRENCH/ SLEEVE AS /ELECTRICAL B 14.07.17 ISSUED FOR ENGINEERING MLT PD NK

SCADA ROOM DWG A 17.04.17 ISSUED FOR TENDER MLT PD NK
AC FC
FIRE FIGHTING RM.
E2 11
FF UD
11
REV. DATE REVISIONS BY CHKD APPD PEM/PC
10 DC-DC 30
CNVT.
1500
FLOOR TRAP DN 1000 MM WIDE

STAIRCASE W3 W3 W1 W1 W1 W1 W2 W2 W2 W1 W1 STAIRCASE AL3 SUNSHADE ABOVE
SINK
A A
V2
EQ EQ EQ EQ V2
EQ EQ
STAIRS AS/STRL. DESIGN
(FROM GROUND TO ROOF)
350 350 350 350 350
450 Ø EXHAUST FAN
350 350 540 350
xsy ¼bafM;k½ fyfeVsM
WIDTH=1500
450 Ø EXHAUST FAN
3X3 NOS.100 DIA SUN SHADE PROJ. ABOVE WIDTH=1500 750MM WIDE RCC GUTTER GAIL
GAIL (INDIA) LIMITED
TREAD =300 GI PIPE SLEEVE
750MM WIDE RCC GUTTER ABOVE TREAD =300 1000MM HIGH RCC PARAPET WALL
RISER =150 RISER =150
RAILING-S.S.RAILING,1000 HIGH 160 Ø PVC RAIN WATER PIPE RAILING-S.S.RAILING,1000 HIGH
160 Ø PVC RAIN WATER PIPE /kksch nqxkZiqj gfYn;k DHOBI - DURGAPUR HALDIA
E1 EMBEDDED IN CONC. (TYP.) EMBEDDED IN CONC. (TYP.) ikbZiykbu izkstsDV PIPELINE PROJECT
A B A B ,l oh LVs'ku fcfYMax SV STATION BUILDING
(fof'k"V ) (TYPICAL)
GROUND FLOOR PLAN TERRACE PLAN vk;kstuk] n`'; ,oa dkV PLANS, ELEVATIONS & SECTIONS
SCALE JOB NO. UNIT DIVN. DEPT. DWG. NO. REV.
1:100 B 0 3 5 0 0 1 8 1 4 1 1 2 1 0 1 2
Page 39 of 851
3-1641-0501 REV.2 A1-841x594
B035-001-81-41-12103
B035-001-81-41-12104TERRACE PLAN & ELEVATIONS
SCHEDULE OF FINISHES
A-EXTERNAL :-
PLAIN CEMENT PLASTER WITH EXTERIOR ACRYLIC EMULSION PAINT AS/APPROVED DESIGN.
WATER PROOFING NOTES :-
4mm thk APP MODIFIED REINFORCED BITUMINOUS MEMBRANE WATERPROOFING 1. DIMENSIONS, CO-ORDINATES, LEVELS
OVER RCC SLAB AS/SPECIFICATIONS A. ALL DIMENSIONS ARE IN MILLIMETRES.
500 HIGH R.C.C. B. DRAWING IS NOT TO BE SCALED FOR ANY MISSING DIMENSION.
PARAPET WALL B-INTERNAL C. ALL LEVELS & CO-ORDINATES ARE IN METRES.
WATER PROOFING
AS/TENDER SPECS. ROOM/AREA FLOORING WALLS CEILING D. LEVEL 100.00 CORRESPONDS TO TOP OF APPROACH/ACCESS ROAD
R.C.C. SLAB AS/STRL. FIRE FIGHTING HEAVY DUTY CEMENT PLASTER CEMENT PLASTER NEAR THE BUILDING ENTRY, CROSS REFERENCE TO STRUCTURAL
1000 HIGH R.C.C. ROOM/ CLEAN AGENT FLOORING WITH OIL BOUND WITH OIL BOUND DRAWING SHALL BE MADE.
500
PARAPET WALL ROOM, ELECTRICAL DISTEMPER DISTEMPER
WATER PROOFING ROOM E. PLINTH LEVEL OF THE BUILDING SHALL BE SAME THROUGHOUT
AS/TENDER SPECS. UNLESS SPECIFICALLLY INDICATED.
CHEMICAL & ABRASION CHEMICAL RESISTANT CEMENT PLASTER F. LOCATION/ORIENTATION/CO-ORDINATES OF THE BUILDING SHALL BE
R.C.C. SLAB AS/STRL. BATTERY ROOM RESISTANT EPOXY EPOXY DADO UPTO WITH OIL BOUND CROSS-CHECKED WITH STRUCTURAL AND GENERAL CIVIL DRAWINGS.
2400
STAIRCASE 600 WIDE R.C.C. GUTTER COATING OVER HEAVY 2500mm HEIGHT & OIL DISTEMPER
BOUND DISTEMPER IN CASE OF ANY MIS-MATCH THE SAME SHALL BE GOT RESOLVED
DUTY FLOORING
BEFORE CONSTRUCTION.
1000
ABOVE
2. FLOOR
30
R1 A. FINISHED FLOOR LEVEL OF WC/BATH CUBICLES, DRINKING WATER
SCADA TELECOM FALSE FLOORING CEMENT PLASTER ALUMINIUM PANEL AREA, PANTRY / KITCHEN SHALL BE 12MM LESS THAN ADJOINING
1000
ROOM, CONTROL (WITH HIGH WITH PLASTIC FALSE CEILING AREAS AND SHALL HAVE PROPER SLOPE FOR FLOOR DRAINAGE.
20
ROOM, UPS PRESSURE LAMINATE) EMULSION PAINT AND UNDERDECK B. FLOOR OF CABLE CELLAR, AC PLANT/AHU, BATTERY ROOM SHALL
4500
ROOM INSULATION
4000
FALSE CEILING HAVE PROPER SLOPE FOR FLOOR DRAINAGE.
CERAMIC TILES CERAMIC TILES DADO ALUMINIUM PANEL
TELECOM CORRIDOR ENGINEER'S ROOM TOILET, PANTRY C. REFERENCE SHALL BE MADE TO RELEVANT DRAWINGS BEFORE
3000
900 1200
10 450 FLOORING UP TO 2100MM FALSE CEILING
& SCADA ROOM STARTING FLOORING WORKS. TRENCHES/CUT OUTS IN FLOOR

TYP. HEIGHT & OIL BOUND
100.600 100.600 DISTEMPER ABOVE SHALL BE PROVIDED IN ACCORDANCE WITH RELEVANT ELECTRICAL/
F.F.L 1 FALSE FLOORING INSTRUMENTATION/PED/STRUCTURAL//EQUIPMENT DRAWINGS.
600
100.00 F.F.L
100.00 VITRIFIED TILE CEMENT PLASTER ALUMINIUM PANEL
A.R.L. ENGINEERS ROOM 3. WALL
800
A.R.L. WITH PLASTIC FALSE CEILING AND
,I/C ROOM
EMULSION PAINT UNDERDECK A. THICKNESS OF ALL BRICK MASONRY WALLS (EXCEPT WC/BATH
6000 2500 2350 3500 INSULATION CUBICLES) SHALL BE 230MM IF NOT SPECIFICALLY INDICATED.
6000 2500 2350 3500 CEMENT PLASTER ALUMINIUM PANEL
LOBBY/ VITRIFIED TILE B. INTERNAL PARTITION WALLS OF WC/BATH CUBICLE SHALL
CORRIDOR WITH PLASTIC FALSE CEILING BE 2500MM HIGH FROM FLOOR LEVEL.
E D C B A E D C B A EMULSION PAINT C. ALL OTHER WALLS SHALL BE UPTO ROOF/ROOF BEAM IF NOT
CEMENT PLASTER CEMENT PLASTER SPECIFICALLY INDICATED.
STAIRCASE KOTA STONE
FLOORING WITH PLASTIC WITH PLASTIC D. CUT-OUTS/OPENINGS FOR CABLES/DUCTS ETC. SHALL BE PROVIDED
SECTION A-A SECTION B-B EMULSION PAINT EMULSION PAINT

4. CABLING/CONDUITS
KOTA STONE EXTERIOR ACRYLIC EXTERIOR ACRYLIC
VERANDAH,
RAMP & STEPS FLOORING EMULSION PAINT EMULSION PAINT R1 A. ALL CONDUITS SHALL BE CONCEALED TYPE EXCEPT IN AREAS CONCEALED
CEMENT PLASTER CEMENT PLASTER B. IN CASE OF CONDUITS CONCEALED IN ROOF/BEAM/FLOOR, THEY
DOCUMENATION VITRIFIED TILE
WITH PLASTIC WITH OIL BOUND SHALL BE LAID BEFORE CASTING.
ROOM
EMULSION PAINT DISTEMPER 5. FINISHING
SCHEDULE OF DOORS AND WINDOWS

LINTEL
TYPE OPENING SIZE FRAME SIZE DESCRIPTION NOS.
LEVEL
PRESSED STEEL DOOR DOUBLE SHUTTER WITH
SD1 1500 X 2700 1480 X 2690 2700 PRESSED STEEL FRAME AS PER EIL STD. WITH 02
LOUVERS AT BOTTOM
POWDER COATED ALUMINIUM GLAZED DOUBLE
AL1 2000 X 2700 1980 X 2690 2700 SHUTTER DOOR WITH 6mm TH. TOUGHENED 01
1 2 3 3' 4 4' 5 6 7 8 9 10
E2 AL2 1500 X 2700 1480 X 2690 2700
POWDER COATED ALUMINIUM GLAZED DOUBLE
SHUTTER DOOR WITH 6mm TH. TOUGHENED 05
A B c GLASS AS PER EIL STD

POWDER COATED ALUMINIUM GLAZED SINGLE
33000 AL3 1000 X 2100 0980 X 2090 2100 SHUTTER DOOR WITH 6mm TH. TOUGHENED 04
STAIRS AS/STRL. DESIGN GLASS AS PER EIL STD
(FROM GROUND TO TERRACE) 4000 3450 1825 1725 2275 1725 4000 4000 3000 4000 3000 35mm THICK FLUSH DOOR SHUTTER FACED WITH
D1 0900x2100 0880x2090 2100 03
WIDTH=1500 1MM THK. LAMINATION ON BOTH SIDE WITH
TREAD =300 600 WIDE RCC GUTTER STEEL FRAME AS/EIL STD.
RISER =150 300 Ø EXHAUST FAN 350 1200 EQ 1200 EQ 1200 350 350 1200 550 1200 350 725 1200 725
1000 HIGH R.C.C. 35mm THICK FLUSH DOOR SHUTTER FACED WITH
RAILING-S.S.PIPE,1000 HIGH TYP. D2 0800x2100 0780x2090 2100 1MM THK. LAMINATION ON BOTH SIDE WITH 02
PARAPET WALL
V2 V1 V1 W1 W1 W3 W3 W3 W3 W3 W3 W3 W3 TEAK WOOD FRAME AS/EIL STD.
E WATER PROOFING
AS/TENDER SPECS. POWDER COATED ALUMINIUM GLAZED WINDOW
1350 1500
1100
300 Ø EXHAUST FAN WITH 6.0mm THK TOUGHENED GLASS, PARTLY

1250
STAIRCASE WC R.C.C. SLAB AS/STRL.

W1 1200 X 1200 1180 X 1180 2100
FIXED/PARTLY OPENABLE TYPE AS/EIL STD.
12
D2
4000 5725 POWDER COATED ALUMINIUM GLAZED WINDOW
10 D2 WITH 6.0mm THK TOUGHENED GLASS, PARTLY 03
11 W2 1200 X 1200 1180 X 1180 2100
FEMALE
1000
FIXED/PARTLY LOUVERED TYPE AS/EIL STD.
MALE
TOILET FIRE FIGHTING TELECOM & SCADA CONTROL ROOM
6000
TOILET UPS ROOM POWDER COATED ALUMINIUM GLAZED WINDOW

FC W3 1200 X 1200 1180 X 1180 2100 WITH 6.0mm THK TOUGHENED GLASS, FIXED 08
FC ROOM/ AC FC ROOM AC FC
FF UD
AC FC
TYPE AS/EIL STD.
FF UD FF UD
CLEAN AGENT
1000
2 NOS.100 DIA 2 NOS.150 DIA POWDER COATED ALUMINIUM GLAZED
D1 D1 2100 02
1
ROOM GI PIPE SLEEVE GI PIPE SLEEVE V1 1200 X 0600 1180 X 0580 VENTILATOR AS/EIL STD., WITH 6mm TH.
2170 TOUGHENED GLASS, FIXED/LOUVERED TYPE.
UP
1800
FC R1 FALSE CEILING BOTTOM POWDER COATED ALUMINIUM GLAZED

AL2 V2 3650 X 0600 3630 X 0580 OF VENTILATOR AS/EIL STD., WITH 6mm TH. 02
PANTRY D1 AL2 AL2 AL2 TELECOM &
3000
3000
BEAM TOUGHENED GLASS, FIXED TYPE.
D SCADA ROOM CORRIDOR LOBBY VERANDAH
AL3
6 NOS.150 DIA 4 NOS.150 DIA
2100MM WIDE CORRIDOR 100.600
14350
VERANDAH GI PIPE SLEEVE GI PIPE SLEEVE

NOTE :-
2600
2 NOS.100 DIA
FALSE FLOORING F.F.L
FC
100.600 AL1 GI PIPE SLEEVE
100.00
2 A.R.L. ALL GLAZED DOOR (FAN LIGHT), WINDOWS & VENTILATORS
F.F.L. R1 230 TYP.
SD1 SHALL BE PROVIDED WITH ALUMINIUM GRILL.
C AL3 AL3 AL3
800
STEPS SINK 6000 2600 2500 3250
FT LOBBY LOCATION, NO. OF AC SHALL BE AS PER MED DRAWING.
1050
TREAD-300 4 NOS.100 DIA SD1

UP
2500
RISER-150
GI PIPE SLEEVE
100.00 E D C B A
A.R.L. AL1
ENGINEER'S DOCUMEN I/C ROOM 1 18.09.18 ELECTRICAL COMMENTS INCORP. & RE-ISSUED FOR CONSTRUCTION BR PD NKP
BATTERY ELECTRICAL
B ROOM -TATION 0 27.02.18 ISSUED FOR CONSTRUCTION BR PD NKP
ROOM
450 Ø EXHAUST FAN ROOM
TRENCH/ SLEEVE AS /ELECTRICAL AC FC
UD
ROOM
AC FC
UD SECTION C-C C 08.12.17 CLIENT'S COMM. INCORPORATED & REISSUED FOR ENGG BR PD NKP
DWG B 14.07.17 ISSUED FOR ENGINEERING MLT PD NKP
3250
A 23.06.17 ISSUED FOR BIDS MLT PD NKP
A VERANDAH REV. DATE REVISIONS BY CHKD APPD PEM/PC

1050
W2 W2 W2 W1 W1 W1 W1 W1 W1 W1 W1 W1 100.600
F.F.L.
A
2000
160 Ø PVC RAIN WATER PIPE 750 1200 EQ 1200 EQ 1200 750 3X4 NOS.100 DIA RAMP
EMBEDDED IN CONC. (TYP.) GI PIPE SLEEVE (SLOPE 1:8)
450 Ø EXHAUST FAN 2000mm WIDE
450 MM WIDE SUN SHADE

(2 Nos) B
100.00
A.R.L. PROJ ABOVE xsy ¼bafM;k½ fyfeVsM
STEPS
PROJ. ABOVE
RCC GUTTER ABOVE
E1 TREAD-300
RISER-150
GAIL
UP
c /kksch nqxkZiqj gfYn;k DHOBI - DURGAPUR HALDIA

ikbZiykbu izkstsDV PIPELINE PROJECT
आई पी एस बिल्डिंग, रिसीप्ट टर्मिनल IPS BUILDING/ RECEIPT TERMINAL/

GROUND FLOOR PLAN व डिस्पच
ै टर्मिनल ( fof'k"V) DESPATCH TERMINAL (TYPICAL)
Hkwry Iyku ,oa dkV GROUND FLOOR PLAN & SECTION
1:100 B 0 3 5 0 0 1 8 1 4 1 1 2 1 0 3 1
Page 40 of 851
3-1641-0501 REV.2 A1-841x594
B035-001-81-41-12104
B035-001-81-41-12103GROUND FLOOR PLAN & SECTIONS
NOTES :-
1. ALL DIMENSIONS ARE IN MILLIMETRES.

2. FOR OTHER NOTES REFER DRAWING NO. B035-001-81-41-12103
4000 3450 1825 1725 2275 1725 4000 4000 3000 4000 3000
1 2 3 3' 4 4' 5 6 7 8 9 10
ELEVATION E1
3000 4000 3000 4000 4000 1725 2275 1725 1825 3450 4000
10 9 8 7 6 5 4' 4 3' 3 2 1
ELEVATION E2
1 2 3 3' 4 4' 5 6 7 8 9 10
A B
33000
(FROM GROUND TO TERRACE) 4000 3450 1725 1825 2275 1725 4000 4000 3000 4000 3000
WIDTH=1500
TREAD =300
RISER =150
RAILING-S.S.PIPE,1000 HIGH
V2
E
STAIRCASE AL3
DN
SLOPE 1:80
SLOPE 1:80
SLOPE 1:80
SLOPE 1:80
6000
1500
D RIDGE LINE
NOTE :-
14350
TERRACE ALL GLAZED DOOR (FAN LIGHT), WINDOWS & VENTILATORS

2600
SHALL BE PROVIDED WITH ALUMINIUM GRILL.
C
2500
A
SLOPE 1:80
SLOPE 1:80
SLOPE 1:80
SLOPE 1:80
B
1 18.09.18 REVISED AND RE-ISSUED FOR CONSTRUCTION BR PD NK
0 27.02.18 ISSUED FOR CONSTRUCTION BR PD NK
3250
A 08.12.17 ISSUED FOR ENGINEERING BR PD NK
160 Ø PVC RAIN WATER PIPE

EMBEDDED IN CONC. (TYP.)
B xsy ¼bafM;k½ fyfeVsM
600MM WIDE RCC GUTTER GAIL
1000MM HIGH RCC PARAPET WALL
/kksch nqxkZiqj gfYn;k DHOBI - DURGAPUR HALDIA
आई पी एस बिल्डिंग, रिसीप्ट टर्मिनल IPS BUILDING/ RECEIPT TERMINAL/

TERRACE PLAN व डिस्पच
ै टर्मिनल ( fof'k"V) DESPATCH TERMINAL (TYPICAL)
Nr dk Iyku ,oa n`'; TERRACE PLAN & ELEVATIONS
1:100 B 0 3 5 0 0 1 8 1 4 1 1 2 1 0 4 1
Page 41 of 851
3-1641-0501 REV.2 A1-841x594
B035-001-81-41-12105
CAT LADDER
AS/STRL.
NOTES :-
1. DIMENSIONS, CO-ORDINATES, LEVELS
A. ALL DIMENSIONS ARE IN MILLIMETRES.
B. DRAWING IS NOT TO BE SCALED FOR ANY MISSING DIMENSION.
C. ALL LEVELS & CO-ORDINATES ARE IN METRES.
D. LEVEL 100.00 CORRESPONDS TO TOP OF APPROACH/ACCESS ROAD
NEAR THE BUILDING ENTRY, CROSS REFERENCE TO STRUCTURAL
DRAWING SHALL BE MADE.
E. PLINTH LEVEL OF THE BUILDING SHALL BE SAME THROUGHOUT

UNLESS SPECIFICALLLY INDICATED.
100.000 100.000 F. LOCATION/ORIENTATION/CO-ORDINATES OF THE BUILDING SHALL BE
A.R.L. A.R.L. CROSS-CHECKED WITH STRUCTURAL AND GENERAL CIVIL DRAWINGS.
IN CASE OF ANY MIS-MATCH THE SAME SHALL BE GOT RESOLVED
4000 3000 3000 4000 BEFORE CONSTRUCTION.
2. FLOOR
A. FINISHED FLOOR LEVEL OF WC/BATH CUBICLES, DRINKING WATER

C B A A B C AREA, PANTRY / KITCHEN SHALL BE 12MM LESS THAN ADJOINING
AREAS AND SHALL HAVE PROPER SLOPE FOR FLOOR DRAINAGE.
B. FLOOR OF CABLE CELLAR, AC PLANT/AHU, BATTERY ROOM SHALL
ELEVATION E2 ELEVATION E4 HAVE PROPER SLOPE FOR FLOOR DRAINAGE.
C. REFERENCE SHALL BE MADE TO RELEVANT DRAWINGS BEFORE

STARTING FLOORING WORKS. TRENCHES/CUT OUTS IN FLOOR

500 HIGH R.C.C. PARAPET WALL SHALL BE PROVIDED IN ACCORDANCE WITH RELEVANT ELECTRICAL/
INSTRUMENTATION/PED/STRUCTURAL//EQUIPMENT DRAWINGS.
WATER PROOFING AS/TENDER SPECS.
3. WALL
R.C.C. SLAB AS/STRL. A. THICKNESS OF ALL BRICK MASONRY WALLS (EXCEPT WC/BATH
CAT LADDER CUBICLES) SHALL BE 230MM IF NOT SPECIFICALLY INDICATED.
500
CAT LADDER AS/STRL. B. INTERNAL PARTITION WALLS OF WC/BATH CUBICLE SHALL
AS/STRL. BE 2500MM HIGH FROM FLOOR LEVEL.
C. ALL OTHER WALLS SHALL BE UPTO ROOF/ROOF BEAM IF NOT
SPECIFICALLY INDICATED.
D. CUT-OUTS/OPENINGS FOR CABLES/DUCTS ETC. SHALL BE PROVIDED
4. CABLING/CONDUITS
GUARD ROOM TOILET WC A. ALL CONDUITS SHALL BE CONCEALED TYPE EXCEPT IN AREAS CONCEALED
3000
B. IN CASE OF CONDUITS CONCEALED IN ROOF/BEAM/FLOOR, THEY
SHALL BE LAID BEFORE CASTING.
5. FINISHING
100.300
F.F.L.
100.000 100.000 100.000 SCHEDULE OF DOORS & WINDOWS
A.R.L. A.R.L. A.R.L.
TYPE OPENING FRAME LINTEL DESCRIPTION NOS.
4000 SIZE SIZE LEVEL
4000
AL11000 x 2100 0980 x 2090 2100 POWDER COATED ALUMINIUM GLAZED 02
SINGLE SHUTTER DOOR WITH 6mm TH.
TOUGHENED GLASS AS PER EIL STD
1 1' 2 2 1' 1 A B C
35mm THICK BLOCK BOARD FLUSH DOOR
D1 0800 x 2100 0780 x 2090 2100 SHUTTER FACED WITH 1 MM LAMINATED 02
ELEVATION E1 ELEVATION E3 SECTION B-B BOTH SIDE WITH PRESSED STEEL FRAME
POWDER COATED ALUMINIUM GLAZED 03
W1 1500 x 1200 1480 x 1180 2100
WINDOW WITH 6.0mm THK TOUGHENED
GLASS, PARTLY FIXED/ PARTLY OPENABLE
E3 TYPE AS/EIL STD.
B V1 0750 x 0600 0730 x 0580 2100

POWDER COATED ALUMINIUM GLAZED 02
3100 900 VENTILATOR WITH 6.0mm THK TOUGHENED
GLASS, LOUVERED TYPE AS/EIL STD.
3100 900
V1 V1 SCHEDULE OF FINISHING
A-EXTERNAL :-
C C (a)-PLASTER/PAINTING
1200 PLAIN CEMENT PLASTER WITH EXTERIOR ACRYLIC EMULSION PAINT AS/APPROVED DESIGN.
1000
1000
(b)-WATER PROOFING
1200
BATH 4mm thk APP MODIFIED REINFORCED BITUMINOUS MEMBRANE WATERPROOFING OVER RCC SLAB AS/SPEC.
WC 1000 B-INTERNAL :-
D1 D1 ROOM/AREA FLOORING WALLS CEILING REMARKS
500 HIGH R.C.C. PARAPET WALL
CAT LADDER CAT LADDER GUARD ROOM VITRIFIED TILES 12 MM THK. CEMENT
WATER PROOFING AS/TENDER SPECS. FLOORING PLASTER WITH OIL 6mm THK. CEMENT
AS/STRL. AS/STRL. BOUND DISTEMPER PLASTER WITH OIL
4000
4000
AL1 100.000 R.C.C. SLAB AS/STRL. BOUND DISTEMPER

VERANDAH
CERAMIC TILES CERAMIC TILES DADO

TOILET A.R.L. TOILET
FLOORING UPTO 2100 MM HEIGHT
500
VERANDAH KOTA STONE
STEP UP FLOORING
R-150
T-300 LEGEND:
E2 DW AL1 ARL = TOP OF APPROACH ROAD LEVEL
450 FFL = FINISHED FLOOR LEVEL
B B GUARD ROOM
750
750
TERRACE
3000
3000
3000
GUARD ROOM
E4 0 01.01.18 ISSUED FOR CONSTRUCTION BR PD NK
W1 100.300 W1 C 14.12.17 CLIENT'S COMM. INCORPORATED & REISSUED FOR ENGG BR PD NK

F.F.L. 100.300 B 14.07.17 ISSUED FOR ENGINEERING MLT PD NK
A A 100.000 F.F.L. A 23.06.17 ISSUED FOR COMMENTS MLT PD NK
A.R.L. REV. DATE REVISIONS BY CHKD APPD PEM/PC
750
750
W1 4000
A A
600
1 1' 2
900 500
4000
B 500 900 160 Ø PVC RAIN WATER PIPE
4000 SECTION A-A GAIL
500 HIGH R.C.C. PARAPET WALL
E1 /kksch nqxkZiqj gfYn;k DHOBI - DURGAPUR HALDIA
1 1' 2 1 1' 2
xkMZ :e GUARD ROOM
( fof'k"V ) (TYPICAL)
vk;kstuk] n`'; ,oa dkV PLANS, ELEVATIONS & SECTIONS
GROUND FLOOR PLAN TERRACE PLAN SCALE JOB NO. UNIT DIVN. DEPT. DWG. NO. REV.
1:50 B 0 3 5 0 0 1 8 1 4 1 1 2 1 0 5 0
Page 42 of 851
3-1641-0501 REV.2 A1-841x594
VENDOR DATA REQUIREMENTS Document No.
B035-001-81-41-VDR-8106
FOR Rev. A
VENDOR DATA REQUIREMENTS FOR
CLEAN AGENT Page 1 of 3
VENDOR DATA REQUIREMENTS

FOR
VENDOR DATA REQUIREMENTS FOR CLEAN
AGENT
A 24-SEP-2018 ISSUED FOR TENDER RS VG VG

Rev. Date Purpose Prepared by Checked by Approved by
No.
Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved
Page 43 of 851
B035-001-81-41-VDR-8106
FOR Rev. A
The following drawings/documents marked " " shall be furnished by the bidder.
POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. List of clause wise deviations, if any, to the
specifications in the deviation format.
2. Indian/International standards to which the
offered system/equipment conform.
3. DCI including all the documents
4. Catalogues/Brochures giving technical
particulars and details of operation/
maintenance of the offered elements/ system.
5. Certificates of agencies who have accorded
approval for the system design, design
concentration, software elements/components
offered.
6. Collaboration certificate with OEM (if
applicable )
7. All the documents for meeting the Bidder
qualification Criteria.
8. Protected room/area layouts as reconfirmation
regarding the area being provided with Clean
Agent system).
9. Confirmation regarding the available space for
cylinders as given in the bid drawing.
10. Calculation of clean Agent Quantity / cylinders
offered for various areas as per specification
11. Availability of gas, spare parts, refilling facilities
in India
12. Details of source of Clean Agent to be procured
shall be submitted along with the offer.
13. Filled-in Technical Data Sheet as per attached
Specificatiosn B035-001-81-41-SP-8106, REV-
A
14. List of Mandatory and Recommended spares
as per B035-001-81-41-SP-8106, REV-A
15. Hydraulic Calculation
16. PFD, P&ID and GA Drawing
17. Testing and inspection procedure
18. Data sheet of cylinder and other components
19. System description and write-up
20. Battery and charger sizing calculations
21. GA and schematic design of Control Panel
Page 44 of 851
B035-001-81-41-VDR-8106
FOR Rev. A
POST ORDER
S. WITH WITH
BID
(FINAL)
22. Functional write up of control panel including
battery charger
23. Operating and maintenance manual
24. GA and design calculation for pressure release
vent / louvers
25. Firm commitment and agreement with backup
consultant for design, supply, engineering,
construction, testing and commissioning etc. (
furnish certificate )
26. Piping GA Drawing
Notes :
1. "TICK" denotes applicability.
2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
3. All post order documents shall be submitted / approved through EIL eDMS portal.
4. Final documentation shall be submitted in hard copy (Six prints) and soft ( two CDs/DVDs ) in addition to
submission through EIL eDMS.
5. Refer - 6-78-0001: Specification for quality management system from Bidders.
6. Refer - 6-78-0002: Specification for documentation requirements from Contractors.
7. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.
8. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
9. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /
contractor / supplier during finalization of Document Control Index (DCI).
10. "@" indicates submission of documents to Inspection Agency.
11. Bill of Material shall form part of the respective drawing.
Page 45 of 851
Suppliers List for FIRE PROTECTION AND Date :24/09/2018 14:58:57
Page 1 of 6
Sr No Supplier Supplier Name Country Holiday Description

Code
Item Code : 05AA Description : FIRE EXTINGUISHERS
Approved Suppliers
1 F202 FIRE SAFETY DEVICES PVT. LIMITED INDIA
2 B027 BRIJBASI HI-TECH UDYOG INDIA
3 M719 MINIMAX GmbH & Co.KG GERMANY
4 I205 INTIME FIRE APPLIANCES PVT LTD INDIA
5 I212 INTEGRATED FIRE PROTECTION PVT. LTD. INDIA
6 U185 UNITED FIRE EQUIPMENTS PVT. LTD. INDIA
7 S060 SAFEX FIRE SERVICES LTD. INDIA
8 N052 NITIN FIRE PROTECTION INDUSTRIES LTD INDIA
9 S081 SUPREMEX EQUIPMENTS INDIA
10 G165 GUNNEBO INDIA LIMITED INDIA
11 B033 BHARAT ENGG. WORKS INDIA
12 V072 VIMAL FIRE CONTROLS PVT LTD INDIA
13 K181 KANADIA FYR FYTER PVT. LTD. INDIA
14 Z001 ZENITH FIRE SERVICES (INDIA) PVT. LTD. INDIA
066053057050
Copyrights EIL - All rights reserved

066053057050
Page 46 of 851
Page 2 of 6

Code
Item Code : 05AC Description : CLEAN AGENT SYSTEM
Approved Suppliers
1 N075 NEW FIRE ENGINEERS (P) LTD INDIA
2 M275 MX SYSTEMS INTERNATIONAL PVT. LTD. INDIA
3 T206 TYCO FIRE & SECURITY INDIA PVT. LTD INDIA
4 N539 NOHMI BOSAI LTD JAPAN
5 3639 CHETAN CORPORATION INDIA
7 3702 ADN FIRE SAFETY PVT LTD INDIA
8 C356 CHETAN ENGINEERS INDIA
9 S003 SIEMENS LIMITED INDIA
10 U095 NOHMI BOSAI (INDIA) PRIVATE LIMITED INDIA
066053057050

066053057050
Page 47 of 851
Page 3 of 6

Code
Item Code : 05AD Description : DELUGE VALVE
Approved Suppliers
1 F115 FIRETECH EQUIPMENTS & SYSTEM PVT. LTD. INDIA
3 H091 HD FIREPROTECT PVT. LTD. INDIA
066053057050

066053057050
Page 48 of 851
Page 4 of 6

Code
Item Code : 05AQ Description : LANDING VALVES
Approved Suppliers
3 U185 UNITED FIRE EQUIPMENTS PVT. LTD. INDIA
4 N215 NEWAGE FIRE PROTECTION INDUSTRIES P LTD INDIA
5 V078 VENUS PUMP & ENGINEERING WORKS INDIA
7 3646 SUKAN EQUIPMENTS PVT. LTD. INDIA
8 S313 SHAH BHOGILAL JETHALAL & BROTHERS INDIA
9 N214 NEWAGE FIREFIGHTING CO,LTD. INDIA
10 A077 ASCO STRUMECH PVT.LTD. INDIA
066053057050

066053057050
Page 49 of 851
Page 5 of 6

Code
Item Code : 05AS Description : SPRAY NOZZLE- FIRE FIGHTING
Approved Suppliers
1 S621 STRAHMAN VALVES INC. UNITED STATES
On Holiday
1 S619 SPRAYING SYSTEMS CO. UNITED STATES DORMANT (NOT TO BE
CONSIDERED)
066053057050

066053057050
Page 50 of 851
Page 6 of 6

Code
Item Code : 05BB Description : WATER MONITOR
Approved Suppliers
3 V072 VIMAL FIRE CONTROLS PVT LTD INDIA
5 S313 SHAH BHOGILAL JETHALAL & BROTHERS INDIA
8 A738 AKRON BRASS COMPANY UNITED STATES
9 N214 NEWAGE FIREFIGHTING CO,LTD. INDIA
10 S081 SUPREMEX EQUIPMENTS INDIA
066053057050

066053057050
Page 51 of 851
DOCUMENT No.
SCOPE OF WORK FOR FIRE
DETECTION AND ALARM B035-001-16-50-SOW-8106
SYSTEM (ELECTRICAL) Rev. 0
Page 1 of 10
GAIL (India) LIMITED
SCOPE OF WORK & JOB SPECIFICATION

FOR
FIRE DETECTION AND ALARM SYSTEM
FOR
DOBHI DURGAPUR PIPELINE SECTION (DDPL)
(ELECTRICAL)
TENDER NO: B035-001-81-41-FP-T-8106
PROJECT : DOBHI DURGAPUR HALDIA PIPELINE
OWNER : M/S. GAIL
CONSULTANT : ENGINEERS INDIA LTD.
JOB NO : B035
0 19-09-2018 ISSUED WITH TENDER AR ANPS ANPS

Rev Prepared Checked Approved
. Date Purpose
by by by
No
Page 52 of 851
DOCUMENT No.
Page 2 of 10
CONTENTS
1.0 SCOPE OF WORK (ELECTRICAL)
2.0 SCOPE OF SUPPLY (ELECTRICAL)
3.0 SCOPE OF DESIGN & ENGINEERING
4.0 JOB SPECIFICATION
5.0 FIRE DETECTION & ALARM SYSTEM VENDOR
6.0 APPROVED VENDOR LIST FOR ELECTRICAL ITEMS
8.0 RECOMMENDED O & M SPARES
ANNEXURE – A: COMMITMENT LETTER FORMAT
Page 53 of 851
DOCUMENT No.
Page 3 of 10
1.0 SCOPE OF WORK (ELECTRICAL)
A new 30” diameter pipeline has been envisaged from Dobhi to Haldia via Durgapur
(DDHPL) by GAIL under JHBDPL Project. The scope of work envisaged under this
Tender covers the Fire alarm system for a part of the Dhobi - Durgapur -Haldia Pipeline
Project as per specifications, drawings, codes, standards and good engineering practice
etc. complete. The contractor shall be responsible to complete the entire work in all
respects and any other work necessary to complete the job whether specifically
mentioned or not in the scope of work.
The DDHPL Project shall be implemented in following two parts:
i. Dobhi – Durgapur Pipeline (DDPL)
ii. Durgapur Haldia Pipeline (DHPL)
Scope of this tender is limited to some part of Dobhi-Durgapur Pipeline (DDPL) section
only.
Following SV / IP / RT stations for which analogue addressable Fire Alarm System

shall be considered for some part of the Dobhi - Durgapur Pipeline (DDPL) section :
SL. NO. SV STATION IP STATION RT

1. SV-30 IPS-6 SAIL IISCO
2. SV-31 IPS-7 HFC DURGAPUR
3. SV-32 DPL DURGAPUR
4. SV-33 SAIL DURGAPUR
5. SV-34 MATIX FERTILISERS
For better understanding CONTRACTOR is advised also to refer Schematic

Arrangement of Pipeline Facilities (Dwg. No. B035-001-83-41-30001, Rev. G) attached
elsewhere in the Tender.
2.0 SCOPE OF SUPPLY (ELECTRICAL)
a) Design, Engineering, Supply, installation, testing and commissioning of Fire alarm

system as per attached datasheet B035-002-16-50-DS-0006, standard specification 6-
51-0076, standard specification for communication and fire alarm cable 6-51-0052. Fire
alarm panel (FAP) shall be analogue addressable type with addressable detectors.
b) Complete scope including supply and installation of analogue addressable Fire alarm
panel with mimic, Repeater panel (to be provided in Guard room of the SV/IP station),
Electrical Siren (roof-top type), Hand operated siren, addressable detectors (including
detectors in areas of control room building, guard room, cable trench), heat sensing
cables for cable trench inside CR building, response indicators, exit signs, electronic
horn, break glass type manual call points, junction boxes, required cabling/wiring etc. is
in the scope of Contractor.
Page 54 of 851
DOCUMENT No.
Page 4 of 10
c) Fire alarm panel (FAP) shall be complete with power supply unit (VRLA battery and
charger/ power supply panel). Bidder shall include supply of battery stands (if
applicable); all cables between power supply units (Battery Chargers and battery banks)
to FAP. Price for the same shall be included in the quoted price of FAP.
d) The distance between the farthest Manual Call Point/detectors and FAP has been
considered as approximately 250m for SV / IP station and max. 400m for RT for
calculating the complete loop length. Contractor shall ensure and confirm suitability of
the offered fire alarm system for the above.
e) The vendor shall supply all necessary additional equipment (even if not specified) for
safe and satisfactory operation of the system and price of the same shall be included in
the basic price.
f) Batteries supplied by the Contractor shall be suitable for panel mounting. In case the
same is not possible than suitable battery stand and inter-connecting
cables/connectors/lugs etc. shall be supplied by the Contractor. Batteries shall be sized
for minimum End cell voltage of 1.8 V/cell. An overall ageing factor of 0.8 and a
temperature correction factor corresponding to minimum temperature of 10ºC shall be
considered for battery sizing.
g) Battery back-up time for FAP and Repeater panel shall be considered in line with EIL
specification 6-51-0076.
h) The following shall be noted w.r.t various equipments supplied by the Contractor:
- Multi-sensor addressable detectors for safe area shall be as per IS-2189 and
NFPA-72 (Latest Edition).
- Exit signs, hooters etc. shall be provided as per IS: 2189 and NFPA-72 (Latest
Edition).
- Control relay modules for tripping of AC system / exhaust fans shall be provided.
- The loop cabling for wiring detectors and BGUs shall be class A, fault tolerant
type as per NFPA 72.
- Necessary Input/output modules for receiving signals to/from separate clean
agent system shall be provided within the fire alarm panel (FAP).
i) Cable glands and lugs shall be supplied with all equipment. Provide single compression
cable glands for all indoor equipment. Weather-proof double compression gland shall be
provided for all outdoor equipment located in safe area and flameproof double
compression gland shall be provided for all flameproof equipment.
j) Wiring shall be done using 2-pair, 1.5 mm2 copper conductor twisted pair, PVC insulated
cables for indoor installations. Wiring for manual call points and other items located in
the plant/outdoor area shall be done using 2-pair, 1.5 mm2, annealed tinned Copper
conductor twisted pair, PVC insulated, PVC inner sheathed, overall screened, armoured
and overall PVC sheathed cables.
k) Only estimated quantities are indicated in SOR. Unit rates quoted against each SOR
item shall be applicable for any addition and deletion.
l) Installation, Testing & commissioning of complete system is in Contractor scope. The FA

system Contractor / vendor shall submit all necessary installation details/ instruction
details/ precautions to be taken care by the installation contractor / main Contractor
during installation of the FA equipment. Whenever felt necessary by the FA system
Page 55 of 851
DOCUMENT No.
Page 5 of 10
vendor, necessary co-ordination /association with the Contractor for Terminal Works
Tender (i.e. Building Works) at the installation stage shall be also ensured by him for
smooth commissioning.
m) Services of OEM of FA system shall be availed by the Contractor for testing and
commissioning of FA system.
n) Required potential free contacts / transducer shall be provided as per attached SCADA
I/O list (Doc. No. B035-000-16-50-SP-0003) for Fire alarm system.
o) Bidder to furnish with BID overall dimensions for the offered FAP including the
space required for the batteries (if the same are to be installed outside the panel)
& Battery charger.
p) Following facilities related to Fire alarm & detection system are coming for different SV /
IP /RT stations:
SL. Control Guard DG Remarks

NO. Room Room Room
Building Building Building
(6m x 6m )
A SV Stations   NA In SV station FA system
(Typical) for Electrical Room,
Battery Room,
Telecom/SCADA Room
and Clean Agent Room
of Control Room Building
shall be considered as a
minimum.
In Guard Room Building
only repeater panel with
inbuilt buzzer shall be
considered.
B IP Stations   NA In IP station FA system

for Electrical Room,
Battery Room, Telecom/
SCADA Room, Control
Room, UPS Room, Fire
Fighting Room /Clean
Agent Room, Engineer’s
Room, Documentation
Room, I/C Room , Pantry
and Lobby & corridor of
Control Room Building
shall be considered as a
minimum.
In Guard Room Building
only repeater panel with
inbuilt buzzer shall be
considered.
Page 56 of 851
DOCUMENT No.
Page 6 of 10
C RT / CRT   NA Same as IP Station
NOTES :
1. All MCP shall be safe area outdoor type as per 6-51-0076 and following nos. of
MCP shall be considered for each SV Station / IP Station / RT:
a. 1 no. at exit of Control Room Building (outdoor type)
b. 1 no. at exit of Guard Room Building (outdoor type)
c. 1 no. for Outdoor area.”
2. Maximum distance between Control Room Building to Guard Room shall be

considered as 60 Meters for each SV station and 120 Meters for each IP / RT
station.
q) Work shall be carried out with best workmanship in conformity to the tender
specifications, approved drawings and instructions, from time to time, of owner or its
authorized representative/Engineer-in-charge.
r) The job includes repairing of all civil works damaged during installation of electrical
facilities.
s) The scope of work under this contract shall be inclusive of breaking of walls and floors,
and chipping of concrete foundations necessary for the installation of equipment,
materials, and making good of the same.
t) Miscellaneous works (civil works, co-ordination, etc.): All related civil works shall be
included in the scope of the Contractor.
u) Supporting arrangement / stands for Fire alarm panels, Clean agent panels, as required,
shall also to be considered by Contractor. However, the same shall be finalized based
on location of above panels during detailed engineering without any cost and time
implication to the Owner.
3.0 SCOPE OF DESIGN & ENGINEERING
3.1 Complete Design, Engineering, Supply, installation, testing and commissioning of Fire
Alarm system, repeater panel including field equipments are in scope of Contractor.
3.2 Contractor to furnish with BID overall dimensions for the offered Fire alarm panel (FAP)
including the space required for the batteries (if the same are to be installed outside the
panel) & Battery charger.
3.3 Fire alarm layout drawings of building /stations in Autocad format shall be prepared and
submitted by Contractor during detail engineering along with detailed FA block diagram
and functional design specification for Owner’s review.
3.4 Contractor shall furnish / submit the vendor drawings / documents as per Vendor Data
requirement (Electrical) attached with tender.
Page 57 of 851
DOCUMENT No.
Page 7 of 10
3.5 Contractor shall also prepare As-built drawings and submit as part of final
documentation.
3.6 Please note that there is no separate item in SOR related to design requirements of
various electrical equipments to be supplied by Contractor. All prices related to design
and engineering shall be included in the relevant SOR item for supply.
4.0 JOB SPECIFICATION
4.1 Site Condition
A. Max/Min Temperature : 50 / 02 0C
B. Relative Humidity : 95%
C. Equipment design temperature (IS 9676) : * 450C
D. Soil Resistivity : As per Soil Analysis report

E. Min. temp. for battery sizing : 100C
F. Altitude above mean sea level : Less than 1000M above
G. Weather : Dry, dust storms in summer,
humid / heavy rain fall during
monsoon
4.2 Area Classification
Electrical / Control room building at all stations shall be located in safe area. All the
electrical equipment to be located in hazardous area Zone 1 or Zone 2, Gas Group
IIA/IIB and Temp. Class T3, based on respective area classification drawing as per IS
5572, Indian Petroleum Rules and as shown in the respective equipment specification/
particular specification, shall be flameproof type. All Electrical equipment for hazardous
areas shall be selected as per IS-5571.
4.3 Job Specific Requirement
a) One spare loop (in addition to as required) shall be considered for Fire Alarm
Panel for each location.
b) Electrical operated siren for diametrical range of 2 kms. The same shall be suitable for
single phase (i.e. SPN) input power supply.
c) The Hand Operated Siren used for firefighting & general purposes shall comply to
IS: 6026 (latest edition)
a) The shape, components, material, design and construction shall comply with
IS:6026.
b) It shall have Siren body inbuilt disc and handle, guard & portable stand.
c) The Siren shall have a minimum. range of 1.6 Kms.
Page 58 of 851
DOCUMENT No.
Page 8 of 10
d) Workmanship
e) The performance test & QAP requirements are as per IS
f) The markings shall have the manufacturers name, trademark, date of
manufacture, etc as per IS and based on PTR
d) There will be interlocks to shut off the exhaust fans and tripping of A/C system in case of
Fire detection. The fire signal from first detector will operate the audio-visual alarm
whereas on confirmation of fire signal from the other detector the ventilation/air
conditioning system shall be switched off automatically. Appropriate tripping relays and
their contacts shall be provided by the Contractor for this purpose considering zone wise
operation, partitions in cable gallery/ basement and number of fans/ system operating in
the electrical rooms/battery room/SCADA room.
e) Potential free contacts (Relay modules) shall be made available for each zone for
tripping of respective ventilation/air conditioning system. Location of above relay module
shall be finalized during detailed engineering stage. Contractor to consider all
accessories such as cabling/ wiring, contact multiplication etc. as required to achieve the
system requirement. Contact of auxiliary relays shall be made available in relay auxiliary
panel of the above mentioned places and shall be suitable to wire directly in PDB/starter
panel control circuit.
f) Necessary interface between FA system and clean agent system shall be considered by
Fire Alarm system vendor and shall also coordinate the same with clean agent Vendor.
For details refer Clean Agent system scope (Doc. No. B035-001-81-41-SP-8101).
However, FA system and Clean agent system shall be two separate system/Panel.
g) For cable trench and false flooring area suitable type detectors shall be considered by
Contractor.
h) Heat sensing cables for cable trench area inside Control Room (CR) building shall be
considered in addition to detectors.
5.0 FIRE DETECTION & ALARM SYSTEM VENDOR
5.1 Main bidder shall offer Fire Detection and Alarm System from any one of the following
vendors only:
a. New Fire Engineer(s) Pvt. Ltd.
b. Tyco Fire and Security India Pvt. Ltd.
c. Honeywell Inc.
d. Honeywell Automation India Ltd.
e. Edward International
5.2 Bidder shall clearly indicate in their offer the Vendor(s) for FA system considered by
them.
5.3 Deviations / exceptions / clarifications against tender technical specification shall be

limited to only those which are as per agreed MOUs between EIL and FA system
vendors. Deviation/exceptions over and above the MOU shall render Bidder's offer liable
for rejection.
5.4 Bidder shall submit the “COMMITMENT LETTER” from minimum one or more Fire
Alarm system vendor(s) selected from the approved vendor list as per FA system
datasheet / Scope of Work (Electrical) attached with Tender, confirming that FA system
Page 59 of 851
DOCUMENT No.
Page 9 of 10
Vendor will supply the said FA system to the Main Bidder in the event of award. Bidder
to confirm that commitment letter(s) have been submitted along with the BID.
In case the above mentioned “COMMITMENT LETTER” is not submitted along

with the bid, Bidder’s offer will be rejected.
6.0 APPROVED VENDOR LIST FOR ELECTRICAL ITEMS
For list of acceptable makes of Electrical equipment / items, refer Vendor List –
Electrical (Doc. No. B035-001-16-50-VL-8106) attached the tender document.
The bid must include in the quoted price for the following mandatory spares to be
supplied with the Fire Alarm system:
Sl. No. Equipment / Item Mandatory Spare

1. Fire Alarm System 1) All cards- 1 No. of each type
(for each SV / TOP / 2) Power fuses- 20% for each rating OR 1 no. (min.)of
IP / RT Station) each rating, whichever is more
3) Control fuses / MCB-10 Nos. of each rating & type
4) Terminal blocks- 20 Nos
5) Fire Detectors- 1% of total installed capacity of each
type OR 1 no.(min.) of each type, whichever is more
6) Glass for Break Glass Boxes/ Manual call point- 5 % of
each type OR 1 No. (min.) of each type, whichever is
more
8.0 RECOMMENDED O&M SPARES
In addition to above mandatory spares, BIDDER must recommend list of spares

required for 2 years trouble free operation, with unit rates and quantity, along with the
offer for Fire Alarm system. These items shall be optional for purchaser / Client.
Spares for two years AMC shall be separately quoted in a separate envelope.
Sr. No. Description Document. No. Revision

A. SPECIFICATION
1. Specification for medium and high 6-51-0051 Rev-8
voltage cables & accessories.
2. Specification for communication and fire 6-51-0052 Rev-6
alarm cables.
Page 60 of 851
DOCUMENT No.
Page 10 of 10
3. Specification for fire detection and fire 6-51-0076 Rev-5

alarm system.
4. Specification For Electrical Equipment Rev-4
6-51-0081
Installation
5. Specification for field inspection, testing 6-51-0087 Rev-3
and commissioning of electrical
installations
B. INSPECTION AND TEST PLANS
1. Inspection & test plan for 6-81-1052 Rev-3
communication & fire alarm cables
2. Inspection & test plan for fire detection 6-81-1076 Rev-3
& alarm system
C. DATA SHEETS
1. Data Sheet For Fire Alarm System B035-000-16-50-DS-0006 Rev-4
2. SCADA IO List For Electrical B035-000-16-50-SP-0003 Rev-1
Parameters
D. MISCELLANEOUS DOCUMENTS
1. Vendor Data requirement – FA System B035-001-16-50-VDR-8106 Rev-0
2. Vendor List – Electrical Items B035-001-16-50-VL- 8106 Rev-0
E. TECHNICAL COMPLIANCE
1. Technical Compliance (Electrical) B035-001-16-50-TCL-8106 Rev-0
F. DRAWINGS
1. Equipment, Cable, Earthing and B035-001-16-50-01130 Rev-1
Lightning Protection Layout of IPS
Building / Receipt Terminal/
Despatch Terminal (Typical)
2. Equipment, Cable, Earthing and B035-001-16-50-01102 Rev-0

Lightning Protection Layout of SV
Station (Typical) - Control Room
Building
NOTES:
1. Contractor to note that all cabling (including supply & laying) & other electrics for
the fire alarm system shall be supplied along with the package and no separate
payment shall be admissible for the same. Owner shall provide only single point
power supply for the same.
Page 61 of 851
Dobhi-Durgapur-Haldia ANNEXURE – A
Pipeline Project TO
EIL Job. No. – B035 SCOPE OF WORK (ELECTRICAL)
(DOC. No. B035-001-16-50-SOW-8106)
COMMITMENT LETTER
RFQ No.:
We M/S ..…………………………….................... (*) hereby confirm that Fire

Alarm System part of subject RFQ shall be designed, engineered, supplied,
tested and commissioned by us in the event of award of subject tender to
M/S…………………………………………………(**).
Deviations / exceptions / clarifications against tender technical specification,

model nos. offered and agreements made shall be as per our agreed MOU with
EIL.
.
……………………………..(*) ………………………………(**)
Signed for and on behalf of Authorised signatory iFor and on behalf of Authorised signatory
FA System Vendor of Main Bidder
Name : Name :
Date : Date :
* FA System Vendor
** Ma i n B i d d e r o f S u b j e c t R F Q
Page 62 of 851
DOCUMENT No.
SCADA I/O LIST FOR B035-000-16-50-SP-0003
ELECTRICAL PARAMETERS Rev. 1
Page 1 of 7
DOBHI - DURGAPUR - HALDIA PIPELINE PROJECT

(DDHPL)
SCADA I/O LIST

FOR
ELECTRICAL PARAMETERS
CLIENT’S COMMENT INCORPORATED & ISSUED WITH

1 14.03.2018 SS AR ANPS
TENDER
0 27.02.2018 REVISED & ISSUED WITH TENDER AR ANPS ANPS
A 28.07.2017 ISSUED WITH TENDER AR ANPS ANPS

Date Purpose
No by by by
Page 63 of 851
SCADA I/O LIST REV. NO. 01
FOR
SCADA I/O LIST - SV STATION
MONITORING( DIGITAL ANALOG NOS. DIGITAL STATUS DESCRIPTION ANALOG DESCRIPTION

SL.
LOAD TAG. FROM TO DESCRIPTION M)/ CONTROL OF TAG NO. ALARM ALARM
NO. INPUT OUTPUT INPUT OUTPUT CONTACT OPEN CONTACT CLOSE RANGE
(C ) SIGNAL (LOW) (HIGH)/TRIP
1 FIRE ALARM SYSTEM SCADA FIRE DETECTION ALARM M 1 - - - 1 FA FIRE DETECTED NORMAL OPERATION - - -
FIRE DETECTION - FIRE DETECTECTION - ELEC.
2 FIRE ALARM SYSTEM SCADA M 1 - - - 1 FA-ELECT-RM NORMAL OPERATION - - -
ELECTRICAL ROOM ROOM
FIRE DETECTION -TELCOM FIRE DETECTECTION -
3 FIRE ALARM SYSTEM SCADA M 1 - - - 1 FA-TEL-RM NORMAL OPERATION - - -
/ SCADA ROOM TELECOM ROOM
FIRE DETECTION - FIRE DETECTECTION -
4 FIRE ALARM SYSTEM SCADA M 1 - - - 1 FA-BAT-RM NORMAL OPERATION - - -
BATTERY ROOM BATTERY ROOM
FAULT IN FIRE DETECTION FAULT IN FIRE
5 FIRE ALARM SYSTEM SCADA M 1 - - - 1 FA-F NORMAL OPERATION - - -
SYSTEM DETECTECTION SYSTEM
FA & CLEAN CLEAN AGENT GAS CLEAN AGENT GAS
6 FIRE ALARM SYSTEM SCADA M 1 - - - 1 CA-PRL-CM NORMAL OPERATION - - -
AGENT RELEASED - CMN RELEALESED
SYSTEM
CLEAN AGENT CYLINDER CLEAN AGENT CYLINDER
7 FIRE ALARM SYSTEM SCADA M 1 - - - 1 CA-LKG NORMAL OPERATION - - -
WEIGHT LOSS BY LEAKAGE WEIGHT LOSS BY LEAKAGE
CLEAN AGENT GAS CLEAN AGENT GAS
8 FIRE ALARM SYSTEM SCADA RELEASED ELECTRICAL M 1 - - - 1 CA-PRL-ER RELEASED ELECTRICAL NORMAL OPERATION - - -
ROOM ROOM
CLEAN AGENT GAS
CLEAN AGENT GAS
9 FIRE ALARM SYSTEM SCADA RELEASED TELECOM M 1 - - - 1 CA-PRL-TR NORMAL OPERATION - - -
RELEASED TELECOM ROOM
ROOM
CLEAN AGENT GAS
CLEAN AGENT GAS
10 FIRE ALARM SYSTEM SCADA RELEASED BATTERY M 1 - - - 1 CA-PRL-BR NORMAL OPERATION - - -
RELEASED BATTERY ROOM
ROOM
8 SOLAR SYSTEM SCADA SOLAR ARRAY -1 START C - 1 - - 1 AR1-ST SOLAR ARRAY-1 START N.A. - - -
9 SOLAR SYSTEM SCADA SOLAR ARRAY-1 STOP C - 1 - - 1 AR1-STP SOLAR ARRAY-1 STOP N.A. - - -
10 SOLAR SYSTEM SCADA SOLAR ARRAY-1 RESET C - 1 - - 1 AR1-RST SOLAR ARRAY-1 RESET N.A. - - -
11 SOLAR SYSTEM SCADA SOLAR ARRAY -1 START C - 1 - - 1 AR2-ST SOLAR ARRAY-2 START N.A. - - -
12 SOLAR SYSTEM SCADA SOLAR ARRAY-1 STOP C - 1 - - 1 AR2-STP SOLAR ARRAY-2 STOP N.A. - - -
13 SOLAR SYSTEM SCADA SOLAR ARRAY-1 RESET C - 1 - - 1 AR2-RST SOLAR ARRAY-2 RESET N.A. - - -
14 SOLAR SYSTEM SCADA SOLAR ARRAY -1 CURRENT M - - 1 - 1 SAC-AR1 ARRAY-1 CURRENT - * * *
15 SOLAR SYSTEM SCADA SOLAR ARRAY -2 CURRENT M - - 1 - 1 SAC-AR2 ARRAY-2 CURRENT - * * *

BATTERY CHARGING BATTERY -1 CHARGING
16 SOLAR SYSTEM SCADA
CURRENT - 01
M - - 1 - 1 BCC-1
CURRENT
- * * *
BATTERY CHARGING BATTERY -2 CHARGING
17 SOLAR SYSTEM SCADA
CURRENT- 02
M - - 1 - 1 BCC-2
CURRENT
- * * *
JOB. NO. - B035 PROJECT ; DOBHI -DURGAPUR-HALDIA PIPELINE Page 1 of 7
Page 64 of 851
FOR

SL.
18 BATTERY ISOLATED SCADA BATTERY-1 ISOLATED M 1 - - - 1 S-BAT-ISO BATTERY-1 DISCONNECTED CONNECTED - - -
19 BATTERY ISOLATED SCADA BATTERY-2 ISOLATED M 1 - - - 1 S-BAT-2-ISO BATTERY-2 DISCONNECTED CONNECTED - - -
BATTERY DEEP BATTERY DEEP

20 SCADA M 1 - - - 1 S-BAT-DD BATTERY DEEP DISCHARGED NORMAL OPERATION - - -
DISCHARGED DISCHARGED
FAULT ON SOLAR PANEL / SOLAR PANEL/ARRAY-01
21 SOLAR PANEL FAULT SCADA M 1 - - - 1 AR1-F NORMAL OPERATION - - -
ARRAY - 01 FAULT
FAULT ON SOLAR PANEL / SOLAR PANEL/ARRAY-02
22 SOLAR PANEL FAULT SCADA M 1 - - - 1 AR2-F NORMAL OPERATION - - -
ARRAY - 02 FAULT
SOLAR CONTROLLER FAULT ON SOLAR SOLAR CONTROLLER-01

23 SCADA M 1 - - - 1 SC1-F NORMAL OPERATION - - -
SOLAR FAULT CONTROLLER - 01 FAULT
SYSTEM
SOLAR CONTROLLER FAULT ON SOLAR SOLAR CONTROLLER-02
24 SCADA M 1 - - - 1 SC2-F NORMAL OPERATION - - -
FAULT CONTROLLER - 02 FAULT
25 ARRAY FAULT SCADA ARRAY FAULT M 1 - - - 1 SA-F ARRAY FAULT NORMAL OPERATION - - -
26 ARRAY FAULT SCADA ARRAY-2-FAULT M 1 - - - 1 SA-2-F ARRAY FAULT NORMAL OPERATION - - -
SOLAR CONTROL CKT. SOLAR CONTROL CKT. SOLAR CONTROL CKT.

27 SCADA M 1 - - - 1 SCC-F NORMAL OPERATION - - -
FAULT FAULT FAULT
BUS VOLTAGE OF 24V

28 24V DCDB SCADA
DCDB
M - - 1 - 1 24-DCDB-V - - 0-24V * -
BUS VOLTAGE OF MAIN BUS VOLTAGE OF 48V

29
DCDB
SCADA
DCDB
M - - 1 - 1 48-DCDB-V - - 0-48V * *
30 BATTERY VOLTAGE SCADA BATTERY VOLTAGE -01 M - - 1 - 1 S-BAT-1-V - - * * *
31 BATTERY VOLTAGE SCADA BATTERY VOLTAGE-02 M - - 1 - 1 S-BAT-2-V - - * *

32 LOAD CURRENT SCADA LOAD CURRENT -24V M - - 1 - 1 S-LC-24V - - * * *
33 LOAD CURRENT SCADA LOAD CURRENT -48V M - - 1 - 1 S-LC-48V - - * * *
GRID CHARGER-1
S-GRD-CHGR-1- INCOMING PHASE TO GRID INCOMING PHASE TO
34 GRID CHARGER-1 SCADA INCOMING PHASE M 1 - - - 1 - - -
IC CHGR.-1 AVAILABLE GRID CHGR.-1 OFF
HEALTHINESS
GRID CHARGER-2
HEALTHINESS
GRID CHARGER-3
HEALTHINESS
96/48V DC-DC 96-48V DC-DC 48V DC-DC CONVERTER
37 SCADA M 1 - - - 1 48-DC-DC-F HEALTHY - - -
CONVERTER CONVERTER FAILED FAILED
Page 65 of 851
FOR

SL.
96/24V DC-DC 96-24V DC-DC 48V DC-DC CONVERTER
38 SCADA M 1 - - - 1 24-DC-DC-F HEALTHY - - -
CONVERTER CONVERTER FAILED FAILED
39 GRID STATUS MV SWITCHBOARD SCADA GRID POWER AVAILABLE M 1 - - - 1 GRID-ON GRID POWER AVAILABLE GRID OFF - - -
DOOR OF TELECOM
40 DOOR STATUS SCADA DOOR STATUS M 1 - - - 1 DST-CLOSED DOOR CLOSED DOOR OPEN - - -
/SCADA ROOM
41 SPARES M 4 - - - 4 - - - - - -
42 SPARES M - - 2 - 2 - - - 4-20mA - -
43 SPARES C - 2 - - 2 - - - - - -
NOTES
1. ALL DIGITAL OUTPUTS FROM SCADA SHALL BE POTENTIAL FREE CONTACT, WHICH WILL MOMENTARYILY CLOSED FOR 2 SECONDS FOR ACTIVATION OF CORRESPONDING DIGITAL OUTPUT COMMAND.
2. ALL ANALOG SIGNALS TO SCADA SHALL BE THROUGH 4-20MA TRANDUCERS.
3. VALUES SPECIFIED UNDER ANALOG SIGNAL DETAILS ARE BASED ON AVAILABLE INFORMATION. EXACT VALUES BASED ON ORDER EQUIPMENT SHALL BE INFORMED LATER.
Page 66 of 851
SCADA I/O LIST
SCADA I/O LIST - IP STATION
MONITORING( DIGITAL ANALOG DIGITAL STATUS DESCRIPTION ANALOG DESCRIPTION

SL. NOS. OF
LOAD TAG. FROM TO DESCRIPTION M)/ CONTROL TAG NO. ALARM ALARM
NO. INPUT OUTPUT INPUT OUTPUT SIGNAL CONTACT OPEN CONTACT CLOSE RANGE
(C ) (LOW) (HIGH)/TRIP
1 FIRE ALARM SYSTEM SCADA FIRE DETECTION ALARM M 1 - - - 1 FA FIRE DETECTED NORMAL OPERATION - - -
FIRE DETECTECTION - ELEC.
2 FIRE ALARM SYSTEM SCADA FIRE DETECTION -ELECTRICAL ROOM M 1 - - - 1 FA-ELECT-RM NORMAL OPERATION - - -
ROOM
FIRE DETECTION -TELCOM / SCADA FIRE DETECTECTION - TELECOM
3 FIRE ALARM SYSTEM SCADA M 1 - - - 1 FA-TEL-RM NORMAL OPERATION - - -
ROOM ROOM
FIRE DETECTECTION - CONTROL
4 FIRE ALARM SYSTEM SCADA FIRE DETECTION -CONTROL ROOM M 1 - - - 1 FA-CR-RM NORMAL OPERATION - - -
ROOM
FIRE DETECTECTION - BATTERY
5 FIRE ALARM SYSTEM SCADA FIRE DETECTION -BATTERY ROOM M 1 - - - 1 FA-BAT-RM NORMAL OPERATION - - -
ROOM
FAULT IN FIRE DETECTECTION
6 FA & FIRE ALARM SYSTEM SCADA FAULT IN FIRE DETECTION SYSTEM M 1 - - - 1 FA-F NORMAL OPERATION - - -
SYSTEM
CLEAN
7 AGENT FIRE ALARM SYSTEM SCADA CLEAN AGENT GAS RELEASED - CMN M 1 - - - 1 CA-PRL-CM CLEAN AGENT GAS RELEALESED NORMAL OPERATION - - -
SYSTEM
CLEAN AGENT CYLINDER WEIGHT CLEAN AGENT CYLINDER WEIGHT
8 FIRE ALARM SYSTEM SCADA M 1 - - - 1 CA-LKG NORMAL OPERATION - - -
LOSS BY LEAKAGE LOSS BY LEAKAGE
CLEAN AGENT GAS RELEASED CLEAN AGENT GAS RELEASED
9 FIRE ALARM SYSTEM SCADA M 1 - - - 1 CA-PRL-ER NORMAL OPERATION - - -
ELECTRICAL ROOM ELECTRICAL ROOM
10 FIRE ALARM SYSTEM SCADA M 1 - - - 1 CA-PRL-TR NORMAL OPERATION - - -
TELECOM ROOM TELECOM ROOM
CLEAN AGENT GAS RELEASED BATTERY CLEAN AGENT GAS RELEASED
11 FIRE ALARM SYSTEM SCADA M 1 - - - 1 CA-PRL-BR NORMAL OPERATION - - -
ROOM BATTERY ROOM
12 FIRE ALARM SYSTEM SCADA M 1 - - - 1 CA-PRL-CR NORMAL OPERATION - - -
CONTROL ROOM CONTROL ROOM
13 DG AMF PANEL SCADA DG POWER ON M 1 - - - 1 DG- ON ON OFF - - -
14 DG AMF PANEL SCADA DG FAILED TO START M 1 - - - 1 DG-F FAILED TO START NORMAL - - -
15 DG AMF PANEL SCADA DG FAULT M 1 - - - 1 DG-FLT FAULT HEALTHY - - -

DG SET
16 DG CHARGER SCADA DC SYSTEM STATUS M 1 - - - 1 DG-DCV HEALTHY NOT HEALTHY - - -
17 DG TANK SCADA FUEL LEVEL M - - 1 - - DG-FUELL - - 4-20mA YES -
18 DG VOLTAGE SCADA VOLTAGE M - - 1 - - DG-VOLT - - 4-20mA YES -
JOB. NO.- B035 PROJECT-DHOBI DURGAPUR PIPELINE Page 4 of 7
Page 67 of 851
SCADA I/O LIST
SCADA I/O LIST - IP STATION

SL. NOS. OF
19 UPS SCADA I/C VOLTAGE PHASE-1 M - - 1 - 1 UPS-PH1-V - - * * *

22 UPS SCADA I/C CURRENT PHASE-1 M - - 1 - 1 UPS-PH1-A - - * * *
25
UPS
UPS SCADA BATTERY CHARGING VOLTAGE M - - 1 - 1 BCH-V - - * * *
26 SYSTEM UPS SCADA BATTERY CHARGING CURRENT M - - 1 - 1 BCH-C - - * * *
27 UPS SCADA UPS BYPASS FREQ. OUT OF RANGE M 1 - - - 1 BYPASS-OUT
28 UPS SCADA UPS COMMON ALARM M 1 - - - 1 UPS-CMN
29 UPS SCADA UPS INVERTER OVER LOAD M 1 - - - 1 UPS-OL
30 UPS SCADA UPS LOAD ON BY PASS M 1 - - - 1 BY-PASS BYPASS-ON BYPASS-OFF - - -
31 UPS SCADA UPS LOW BATTERY M 1 - - - 1 UPS-BAT-LW LOW BATTERY HEALTHY - - -
32 UPS SCADA UPS OUTPUT VOLTAGE M - - 1 - 1 UPS-OP-V - - * * *
33 UPS SCADA UPS OUTPUT CURRENT M - - 1 - 1 UPS-OP-A - - * * *
34 230/48V RECTIFIER SCADA 230-48V RECTIFIER FAILED M 1 - - - 1 48-RCF-F 48V RECTIFIER FAILED HEALTHY - - -
35 230/24V RECTIFIER SCADA 230-24V RECTIFIER FAILED M 1 - - - 1 24-RCF-F 24V RECTIFIER FAILED HEALTHY - - -
GRID
36 MV SWITCHBOARD SCADA GRID POWER AVAILABLE M 1 - - - 1 GRID-ON GRID POWER AVAILABLE GRID OFF - - -
STATUS
DOOR DOOR OF TELECOM

37 SCADA DOOR STATUS M 1 - - - 1 DST-CLOSED DOOR CLOSED DOOR OPEN - - -
STATUS /SCADA ROOM
DOOR DOOR OF CONTROL

38 SCADA DOOR STATUS M 1 - - - 1 DST-CLOSED DOOR CLOSED DOOR OPEN
STATUS ROOM
39 SPARES M 4 - - - 4 - - - - - -
40 SPARES M - - 2 - 2 - - - 4-20mA - -
41 SPARES C - 2 - - 2 - - - - - -
NOTES
JOB. NO.- B035 PROJECT-DHOBI DURGAPUR PIPELINE Page 5 of 7
Page 68 of 851
SCADA I/O LIST
SCADA I/O LIST - CONSUMER RECEIPT TERMINAL (CRT)

SL. NOS. OF
NORMAL
1 FIRE ALARM SYSTEM SCADA FIRE DETECTION ALARM M 1 - - - 1 FA FIRE DETECTED - - -
OPERATION
FIRE DETECTION - FIRE DETECTECTION - NORMAL
2 FIRE ALARM SYSTEM SCADA M 1 - - - 1 FA-ELECT-RM - - -
ELECTRICAL ROOM ELEC. ROOM OPERATION
FIRE DETECTION -TELCOM FIRE DETECTECTION - NORMAL
3 FIRE ALARM SYSTEM SCADA M 1 - - - 1 FA-TEL-RM - - -
/ SCADA ROOM TELECOM ROOM OPERATION
4 FIRE ALARM SYSTEM SCADA M 1 - - - 1 FA-CR-RM - - -
CONTROL ROOM CONTROL ROOM OPERATION
5 FIRE ALARM SYSTEM SCADA M 1 - - - 1 FA-BAT-RM - - -
BATTERY ROOM BATTERY ROOM OPERATION
FAULT IN FIRE
FAULT IN FIRE DETECTION NORMAL
6 FIRE ALARM SYSTEM SCADA M 1 - - - 1 FA-F DETECTECTION - - -
SYSTEM OPERATION
SYSTEM
FA & CLEAN CLEAN AGENT GAS CLEAN AGENT GAS NORMAL
7 FIRE ALARM SYSTEM SCADA M 1 - - - 1 CA-PRL-CM - - -
AGENT RELEASED - CMN RELEALESED OPERATION
SYSTEM CLEAN AGENT
CLEAN AGENT CYLINDER NORMAL
8 FIRE ALARM SYSTEM SCADA M 1 - - - 1 CA-LKG CYLINDER WEIGHT - - -
WEIGHT LOSS BY LEAKAGE OPERATION
LOSS BY LEAKAGE
NORMAL
9 FIRE ALARM SYSTEM SCADA RELEASED ELECTRICAL M 1 - - - 1 CA-PRL-ER RELEASED ELECTRICAL - - -
OPERATION
ROOM ROOM
NORMAL
10 FIRE ALARM SYSTEM SCADA RELEASED TELECOM M 1 - - - 1 CA-PRL-TR RELEASED TELECOM - - -
OPERATION
ROOM ROOM
NORMAL
11 FIRE ALARM SYSTEM SCADA RELEASED BATTERY M 1 - - - 1 CA-PRL-BR RELEASED BATTERY - - -
OPERATION
ROOM ROOM
NORMAL
12 FIRE ALARM SYSTEM SCADA RELEASED CONTROL M 1 - - - 1 CA-PRL-CR RELEASED CONTROL - - -
OPERATION
ROOM ROOM
13 DG AMF PANEL SCADA DG POWER ON M 1 - - - 1 DG- ON ON OFF - - -
14 DG AMF PANEL SCADA DG FAILED TO START M 1 - - - 1 DG-F FAILED TO START NORMAL - - -
15 DG AMF PANEL SCADA DG FAULT M 1 - - - 1 DG-FLT FAULT HEALTHY - - -

DG SET
16 DG CHARGER SCADA DC SYSTEM STATUS M 1 - - - 1 DG-DCV HEALTHY NOT HEALTHY - - -
17 DG TANK SCADA FUEL LEVEL M - - 1 - - DG-FUELL - - 4-20mA YES -
18 DG VOLTAGE SCADA VOLTAGE M - - 1 - - DG-VOLT - - 4-20mA YES -
JOB. NO.- B035 PROJECT - DHOBI DURGAPUR PIPELINE Page 6 of 7
Page 69 of 851
SCADA I/O LIST
SCADA I/O LIST - CONSUMER RECEIPT TERMINAL (CRT)

SL. NOS. OF

BATTERY CHARGING
25 UPS SCADA
VOLTAGE
M - - 1 - 1 BCH-V - - * * *
BATTERY CHARGING
26 UPS SCADA
CURRENT
M - - 1 - 1 BCH-C - - * * *
UPS BYPASS FREQ. OUT
27 UPS SCADA M 1 - - - 1 BYPASS-OUT
OF RANGE
UPS
28 UPS SCADA UPS COMMON ALARM M 1 - - - 1 UPS-CMN
UPS INVERTER OVER
29 UPS SCADA M 1 - - - 1 UPS-OL
LOAD
30 UPS SCADA UPS LOAD ON BY PASS M 1 - - - 1 BY-PASS BYPASS-ON BYPASS-OFF - - -
31 UPS SCADA UPS LOW BATTERY M 1 - - - 1 UPS-BAT-LW LOW BATTERY HEALTHY - - -
32 UPS SCADA UPS OUTPUT VOLTAGE M - - 1 - 1 UPS-OP-V - - * * *
33 UPS SCADA UPS OUTPUT CURRENT M - - 1 - 1 UPS-OP-A - - * * *
230-48V RECTIFIER
34 230/48V RECTIFIER SCADA M 1 - - - 1 48-RCF-F 48V RECTIFIER FAILED HEALTHY - - -
FAILED
230-24V RECTIFIER
35 230/24V RECTIFIER SCADA M 1 - - - 1 24-RCF-F 24V RECTIFIER FAILED HEALTHY - - -
FAILED
GRID POWER
36 GRID STATUS MV SWITCHBOARD SCADA GRID POWER AVAILABLE M 1 - - - 1 GRID-ON GRID OFF - - -
AVAILABLE
DOOR OF TELECOM
37 DOOR STATUS SCADA DOOR STATUS M 1 - - - 1 DST-CLOSED DOOR CLOSED DOOR OPEN - - -
/SCADA ROOM
DOOR OF CONTROL
38 DOOR STATUS SCADA DOOR STATUS M 1 - - - 1 DST-CLOSED DOOR CLOSED DOOR OPEN
ROOM
39 SPARES M 4 - - - 4 - - - - - -
40 SPARES M - - 2 - 2 - - - 4-20mA - -
41 SPARES C - 2 - - 2 - - - - - -
NOTES
JOB. NO.- B035 PROJECT - DHOBI DURGAPUR PIPELINE Page 7 of 7
Page 70 of 851
Document No.
VENDOR DATA REQUIREMENTS B035-001-16-50-VDR-8106
FOR Rev. 0
FIRE ALARM SYSTEM Page 1 of 4

FOR
FIRE ALARM SYSTEM
0 20-SEP-2018 ISSUED WITH TENDER SS AR ANPS

Rev. Date Purpose Prepared by Checked by Approved by
No.
Page 71 of 851
Document No.
FOR Rev. 0
The following drawings/documents marked " " shall be furnished by the bidder.
COMMUNICATIONFIRE ALARM CABLES
POST ORDER
S. WITH WITH
BID
(FINAL)
1. Schedule of Vendor Documents
2. Data Sheets (Duly filled-in)
3. Dimensional Drawings : Cross sectional views
of cables
4. Dimensional Drawings : Crossectional view of
accessories
5. Test Records
6. Inspection & Test Plan (ITP) -For review by Refer Note-'*'
Inspection Dept.
7. Type Test Certificate for similar cables
8. Data Books/ Manuals : Installation Manual
9. Data Books/ Manuals : Operating/ Maintenance
Manual
10. Data Books/ Manuals : Catalogues/ Brochures
11. Equipment storage procedure at site
FIRE DETECTION AND ALARM SYSTEM
POST ORDER
S. WITH WITH
BID
(FINAL)
1. Schedule of Vendor Documents
2. Confirmation of Technical Compliance
3. Dimensional Drawings : GA Drawings for
Panels, Battery, Charger, UPS
4. Dimensional Drawings : Installation plan/
Mounting Details/ Cable cut-out details
5. Dimensional Drawings : Sectional View
Drawing
6. Dimensional Drawings : G.A. drawings of all
devices e.g. (Detectors, Call stations, Hooters,
Siren, Exit signs, Response indicators etc)
7. Dimensional Drawings : Cubicle arrangement
drawing
8. Dimensional Drawings : Mimic diagram
Page 72 of 851
Document No.
FOR Rev. 0
POST ORDER
S. WITH WITH
BID
(FINAL)
9. Dimensional Drawings : Battery rack
arrangement drawing
10. Dimensional Drawings : Name plate drawings
11. Dimensional Drawings : Bill of material
12. Electrical Wiring Drawings : Block and Logic
Diagrams
13. Electrical Wiring Drawings : Control Schematics
14. Electrical Wiring Drawings : Wiring Diagram
and Terminal Details
15. Electrical Wiring Drawings : Interconnection
Diagrams
16. Performance Curves of battery
17. Test Records
18. Inspection & Test Plan (ITP) -For review by Refer Note-'*'
Inspection Dept.
19. Calculations for : Selected quantity & location
of detectors
20. Calculations for : Battery Sizing
21. Calculations for : UPS, Battery charger sizing
22. Calculations for : System cable selection
23. Statutory approval certificate
24. Type Test Certificates for similar equipment
25. List of Commissioning Spares
26. List of Mandatory Spares
27. List of Maintenance Spares
28. List of Special Tools & Tackles
29. Data Books/ Manuals : Installation Manual
30. Data Books/ Manuals : Operating/ Maintenance
Manual
31. Data Books/ Manuals : Catalogues/ Brochures
32. Equipment storage procedure at site
33. Typical FA system Layout of Control Room
Building of for SV station / IP Station / RT
34. Commitment Letter(s) from FA System
Vendor(s) as per Technical Compliance
(Electrical)
35. Data Sheets ( duly filled-in)
Notes :
1. "TICK" denotes applicability.
2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
Page 73 of 851
Document No.
FOR Rev. 0
3. All post order documents shall be submitted / approved through EIL eDMS portal.
4. Final documentation shall be submitted in hard copy (Six prints) and soft ( two CDs/DVDs ) in addition to
submission through EIL eDMS.
5. Refer - 6-78-0001: Specification for quality management system from Bidders.
6. Refer - 6-78-0002: Specification for documentation requirements from Contractors.
7. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.
8. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
9. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /
contractor / supplier during finalization of Document Control Index (DCI).
10. "@" indicates submission of documents to Inspection Agency.
11. Bill of Material shall form part of the respective drawing.
12. Also refer other department's VDR :-
13. Structures
14. '*' indicates the following:
a. Equipments whose ITP is attached with Contract -ITP for respective equipment shall be followed. Therefore,
no ITP is to be furnished for review for those equipments.
b. Equipments whose ITP is not attached with Contract-Manufacturer's ITP shall be submitted by Packager/
Vendor/Contractor to respective Regional Procurement Office (RPO) near to manufacturer's works for approval
by EIL Inspection.
15. All technical details and documents furnished with bids shall be treated as data for engineering. These shall
however be subject to Purchasers review after order placement and bidder shall comply to MR/Tender
requirements without any cost & time implication to EIL/Owner.
16. '*' indicates the following:
a. Equipments whose ITP is attached with Contract -ITP for respective equipment shall be followed. Therefore,
no ITP is to be furnished for review for those equipments.
b. Equipments whose ITP is not attached with Contract-Manufacturer's ITP shall be submitted by Packager/
Vendor/Contractor to respective Regional Procurement Office (RPO) near to manufacturer's works for approval
by EIL Inspection.
17. All technical details and documents furnished with bids shall be treated as data for engineering. These shall
however be subject to Purchasers review after order placement and bidder shall comply to MR/Tender
requirements without any cost & time implication to EIL/Owner.
18. Fire Alarm system and Clean agent system shall be two separate systems. This VDR is applicable for only
Fire Alarm system.
19. Bidder shall submit the Commitment Letter from minimum one or more Fire Alarm system vendor(s)
selected from the approved vendor list as per FA system datasheet / Scope of Work (Electrical)attached with
Tender confirming that FA system Vendor will supply the said FA system to the Main Bidder in the event of
award.
Page 74 of 851
TECHNICAL COMPLIANCE DOC. NO.
(ELECTRICAL) B035-001-16-50-TCL-8106
FIRE PROTECTION AND FIRE ALARM Rev 0
SYSTEM TENDER
Page 1 of 3
TECHNICAL COMPLIANE
(ELECTRICAL)
FOR
FIRE PROTECTION AND FIRE ALARM
SYSTEM TENDER
(DOBHI-DURGAPUR PIPELINE SECTION)
TENDER NO: B035-001-81-41-FP-T-8106
PROJECT : DOBHI-DURGAPUR HALDIA PIPELINE
OWNER : M/S. GAIL
JOB NO : B035
Bidder’s Signature and

Stamp
0 19.09.2018 ISSUED WITH BID PACKAGE AR ANPS ANPS

Date Purpose
No by by by
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved
Page 75 of 851
(ELECTRICAL) B035-001-16-50-TCL-8106
SYSTEM TENDER
Page 2 of 3
BIDDER’S CONFIRMATION /
S.NO COMPLIANCE STATEMENT / QUERY
ANSWER
1. Vendor for Fire detection and alarm (FA) system has

been selected from the list of approved Vendors given
under clause no. 5.0 of Scope of Work (Electrical) [Doc.
no. B035-001-16-50-8106] and Cl. no. "H" of
Purchaser's data of FA System Datasheet (Doc. No.
B035-000-16-50-DS-0006) only.
Bidder to confirm compliance and indicate the proposed

Vendor for FA system.
2. Bidder shall submit the “COMMITMENT LETTER” from

minimum one or more Fire Alarm system vendor(s)
selected from the approved vendor list as per FA
system datasheet / Scope of Work (Electrical) attached
with Tender, confirming that FA system Vendor will
supply the said FA system to the Main Bidder in the
event of award.
Bidder to confirm that commitment letter(s) have been

submitted along with the BID.
In case the above mentioned “COMMITMENT LETTER”

is not submitted along with the bid, Bidder’s offer will be
rejected.
3. Offered FA system shall be strictly as per as per agreed

MOUs between EIL and FA system vendors.
Deviation/exceptions / clarifications over and above the
mutually agreed and signed MOU shall render Bidder's
offer liable for rejection.
4. The scope of work shall be complete in all respects as

specified in the tender document and all other
equipment, materials and work not explicitly mentioned
but nevertheless required to fulfil the functional
requirements shall be deemed to be included in the
scope of Bidder with no additional cost and times
implication to the Owner.
5. Deviations, if any, from the applicable specifications

and codes have been duly consolidated at one place.
(Under Exceptions / Déviations List Form).
Any deviations/ deletions / corrections made by the
Contractor elsewhere will not be taken cognisance of
and all such deviations shall deem to have been
withdrawn by the Bidder.
6. Makes of various electrical equipment the equipment
and components supplied shall be as per Vendor List
(B035-001-16-50-VL-8106) given in the in the bid
document. Bidder to confirm compliance.
7. Detailed offers from the sub-vendors for various
equipment is not required to be furnished in the
Bidder’s offer at this stage. If any such details are
furnished by the Bidder in their proposal, these shall
not be reviewed or taken cognisance of at this stage.
These details shall be treated as preliminary and for
reference and record purpose only and shall not be
contractually binding. Confirm compliance.
Page 76 of 851
(ELECTRICAL) B035-001-16-50-TCL-8106
SYSTEM TENDER
Page 3 of 3
8. All data and documents required to be submitted with

the BID as per Vendor Data Requirement (doc. No.
B035-001-16-50-VDR-8106) have been furnished.
9. Confirm that Mandatory spares as per clause no 7.00
of of Scope of Work (Electrical) [Doc. no. B035-001-
16-50-8106] have been included in Bidder’s offer.
10. Confirm that Fire Alarm system shall be ordered by the
successful Bidder only after :
a) Review / Approval of the Purchase requisition by
Owner/ EIL for FA system.
11. Confirm that Operation and Maintenance spares

required for the two years of normal operation for all
system and equipment along with unit prices and
quantities as recommended by the equipment
manufacturer have been quoted.
12. Confirm that commissioning spares, as required for
offered system and equipment, have been included in
the proposal.
13. Confirm that Special Tools and Tackles, as required
for each equipment, have been included in the
proposal.
14. Bidder has furnished the indicative FA system layout
for following buildings along with BID:
a. Control Room Building of SV Station
b. Control Room Building of IP Station / RT
Confirm compliance.
NOTE
1. The above technical compliance shall be duly filled-in, signed & stamped and submitted by
bidder along with their offer. Bidder’s offer is liable for rejection in case the technical
compliance is not submitted with the offer.
Page 77 of 851
Datasheet No.
DATA SHEET
B035-000-16-50-DS-0006
FIRE ALARM SYSTEM
Rev. No. 4
(ANALOGUE ADDRESSABLE TYPE)
Page 1 of 5
PURCHASER'S DATA
(to be filled by the Purchaser)
A Site Conditions
1 Ambient Temperature 2 Relative humidity 96 %
- Maximum : 46 °C 3 Altitude <1000 m above mean sea level
- Minimum : 5 °C 4 Atmosphere Dusty, Humid & corrosive
- Design : 45 °C
B Area classification
1 Buildings Safe Area
2 Plant units Hazardous area (Zone-2, gas group IIA/IIB, T3)
C General Data
1 Max. Distance from Fire Alarm 250 Meter for SV Station
Panel to the farthest field device 400 Meter for IP/RT Station
2 Cable entries for Break Glass 2 Nos. from Bottom
Units
3 Cable entries for Fire alarm Panel √Bottom/ Top
4 Cable entries for Repeater Panel √Bottom/ Top
5 Integration with Existing Fire Req./Not Req.√
Alarm System
6 Integration with following Systems:
a Public Alarm Announcement Req./Not Req.√ c Plant Data Network Req./Not Req.√
System(Public address system) d ISDN telephone exchange Req./Not Req.√
b Paging and Plant Comm. System Req./Not Req.√ e Fire Suppression System √ Req./Not Req.
( Clean Agent)
7 Area to be covered by FA system Refer Scope Doc.
D Power supply
1 Input power (Voltage/Frequency) See note 3 & 4 4 Temperature for battery sizing 10 °C
2 Battery type VRLA 5 Ageing factor 0.8
3 Duration for battery sizing (*Clause 5.2) As per 6-51-0076
E Type of fire alarm system

1 Conventional Not Required
2 Microprocessor based Required (see note -1)
analogue addressable
F Specific requirements for Fire Suppression
1 Status signals, alarms & Refer cl. No. 9
shutdown signal requirements 0f 6-51-0076
a Selector switches for clean agent/ √Req./Not Req. g Fire water pump running indications NA
CO2 supply h Fire water pump start push buttons NA
b Automatic signal for clean agent/ √Req./Not Req. i Control for sirens Required
CO2 supply j Controls & signals to various NA
c Manual push button for discharge Required control rooms
of clean agent/CO2 k Repeat alarm signal to mimic panel Required
d Clean agent/CO2 discharge inhibit Required l Repeat alarm signal to repeat Required
push-buttons alarm panel
e Deluge valve activation/test push- NA m Status of battery condition Required
buttons and activated status lamps
f Shutdown signals (potential free Required
contacts for air handling units)
G Siren
a Control for Sirens (Motorized) Automatic / Auto- c Hand operated Siren √Req./Not Req.
Manual √ d Location During detail Eng.
b Location Control Room
H Vendor of fire alarm system New Fire Engineer(s) Pvt. Ltd. / Tyco Fire & Security India Pvt. Ltd. /
/ Honeywell Inc./ Honeywell Automation India / Edward International
(Bidder to indicate the make offered) [ see note18 & 19]
REFERENCE EIL SPECIFICATION : 6-51-0076

4 19-09-2018 Updated & Reissued for BIDs AR ANPS ANPS
3 18-07-2018 Updated & Reissued for BIDs AR ANPS ANPS
2 24-04-2018 Revised & Issued for BIDs AR ANPS ANPS
1 19-04-2018 Issued for BIDs AR ANPS ANPS
0 04-04-2018 Issued for BIDs DK AR ANPS
Rev. No. Date Purpose Prepared By Checked By Approved By
Format No: EIL-1650-2027 Rev. 2 Copyrights EIL - All rights reserved
Page 78 of 851
Datasheet No.
DATA SHEET B035-000-16-50-DS-0006
FIRE ALARM SYSTEM Rev. No. 4
Page 2 of 5
PURCHASER'S DATA
(to be filled by the purchaser)
A NOTES
1 This data sheet is applicable for fire alarm system for SV & IP Stations/ RT / TOP+DT . Fire alarm syatem shall be
microprocessor based analogue addressable type.
2 Complete scope including supply and installation of Fire alarm panel, Repeater panel ( to be provided in Guard room of the
SV/IP station), Siren, all detectors (including detectors in areas of control room building, cable trench ), heat sensing cables (
for cable trench inside CR building) response indicators, exit signs, electronic horn, break glass type manual call points (one
in Control Room Building exit door, one in Guard room exit door and one in outdoor safe area), junction boxes, required
cabling/wiring etc. is in the scope of respective Fire alarm system vendor.
3 Electrical operated Fire siren (2km. Dia. range) shall be supplied as part of fire alarm system and shall be suitable for 240V
AC supply.
4 Hand Operated Fire siren (1.6km. Dia. range) shall be supplied one per station as part of fire alarm system.
5 Single point normal power supply shall be made available at 240V±10%, 50Hz±3%, SPN AC for Fire Alarm
Panel for battery charging and siren power supply. All further distribution shall be done by FA Vendor.
6 Another 24V DC for Fire alarm panel critical load (logical cards, detectors, exit sign, hooter etc.)
7 Separate zones shall be considered above false ceiling, below false ceiling and below false flooring / trench (as
applicable).
8 Mimic shall be provided on the Fire alarm panel / repeater panel.
9 The Fire alarm panel/ system shall provide potential free contacts for the signals as
specified in clause no. 9.2 of specification no. 6-51-0076 (whichever applicable). Minimum 2NO+2NC contacts shall be
provided for each of these signals. In case additional contacts are required for any of the signals during detailed engineering,
the same shall be provided by the Vendor /contractor without any cost implication.
10 Required input/output status through SCADA system to Control Room Building through potential free contact shall be provided
in Fire alarm system for SCADA interface as per SCADA I/O List for Electrical parameters (Doc. No. B035-000-16-50-SP-
0003).
11 All initiating contacts in required numbers (rooms and area wise), interlocks, controls etc. shall be provided as a
part of Fire alarm system.
12 Minimum 1NO+1NC contact shall be provided in fire alarm panel/system for 1 no. digital monitoring signal (DI signal)
for 'FIRE DETECTED' in Repeater Station.
13 Fire alarm system layout drawing for areas where clean agent flooding is required shall be developed FA system
supplier in coordination with Clean agent system vendor. Indicative fire alarm layout for Control room building of SV / IP
/RT station shall be furnished by Contractor along with offer.
14 Required separate zones shall be considered Fire alarm system for BGU, detector (in cable trench etc.)
in electrical fire alarm layouts. Clean agent flooding shall not be initiated in case of fire detection through these
detectors/BGUs. (i.e. in trenches) and only status/alarm shall be initiated.
15 Fire alarm system shall have suitable interlocks with ACs and exhaust fans system for control room building.
16 Necessary interface / interlocks in fire alarm panel shall be considered for Clean Agent system (separate system)
& its separate Control panel as per Job specofication for Clean Agent System (Doc.No. B035-001-81-41-SP-8106).
17 One spare loop (in addition to as required) shall be considered for Fire Alarm Panel for each location.
18 The list of EIL approved Vendors for FA system has been given under cl. no. "H" of Purchaser's data of Fire
Alarm System datasheet. Bidder shall indicate the make(s) of FA system considered by them in their offer
from above list only.
19 Deviations / exceptions / clarifications against tender technical specification shall be limited to only those
which are as per agreed MOUs between EIL and FA system vendors. Deviation/exceptions over and above
the MOU shall render Bidder's offer liable for rejection.
20 Heat sensing cables for cable trench area inside Control Room building shall be considered complete with all
necessary modules (as required) for interfacing of heat sensing cables with addressable Fire Alarm Panel.
Format No: EIL-1650-2027 Rev. 2 Copyrights EIL - All rights reserved
Page 79 of 851
Datasheet No.
DATA SHEET B035-000-16-50-DS-0006
Page 3 of 5
MANUFACTURER'S DATA
Part-2
(to be filled by the Vendor)
A Make, type and model no. of following items
Make Type/Model No. Dimensions
1 Heat detectors
a Safe area
b Hazardous area
2 Ionisation type smoke detectors
a Safe area
b Hazardous area
3 Photoelectric type detectors
a Safe area
b Hazardous area
4 Linear beam smoke detectors
a Safe area
5 BreakReq
Glass Units
a uire
Safe area
b Hazardous area
6 Ultra-voilet Flame detectors
a Safe area
b Hazardous area
7 I/R Detectors
a Safe area
b Hazardous area
8 Heat Sensing cables
Detector unit for heat sensing cable
9 Response Indicators
10 Fault Isolators
11 Exit Signs
12 Hooters
a Hooter acknowledge boxes
13 Manual break glass boxes
14 Halon/ CO2 release/ Inhibit switches
15 Siren
B Genaral Data
1 Exit Signs Self-Luminous/ Backlit
2 Max. Distance from Fire Alarm 300-400 Meter
Panel to Detector/ BGU
C Conventional Fire Alarm System

1 Central fire alarm panel
a Make & model no. f Mimic Integral/Non-integral
b No. of zones g LED size
c Operating voltage & power h LED arrangement
consumption i LED arrangement basis
d Ingress protection IP-41
e Dimensions (LXDXH)mm
2 Siren
a Siren range e Siren Actuation Automatic/ Automatic
b Output kW/ db at 1 meter as well as Manual
c Voltage V f Power Supply Normal/ Emergency
Phase Phase
Frequency Hz
d Starter for siren (IP-55) Required/Not-required
3 Mimic panel (if non-integral)
a Make & model no. c Mounting Floor mounting/Wall mounting
b Operating voltage ISSUED FOR BIDS d Dimensions (LXWXH)mm
4 Zonal fire alarm panel
a Make & model no. d Dimensions (LXDXH)mm
b Operating volt & power cosumption e No.of zones
c Mounting Floor mounting / Wall mounting f Max. No. of devices per zone
Format No: EIL - 1650-2027 Rev. 2 Copyrights EIL - All rights reserved
Page 80 of 851
Datasheet No.
DATA SHEET B035-000-16-50-DS-0006
Page 4 of 5
6 Repeat alarm panel
a Make & model no. d Dimensions (LXDXH)mm
b Operating Voltage & e LEDs arranged in a matrix
power consumption f LEDs arranged on graphic mimic
c Mounting
D Microprocessor Based Fire Alarm System

1 Central fire alarm panel (CFAP)
a Make & model no. h Processor Redundancy
b Memory capacity (refer cl. No. 5.3.1.28 of
c No. of Inputs EIL spec 6-51-0076)
d Nos. of programmable outputs i Ingress protection :IP-41
e Scanning speed j Dimensions (LXDXH)
f Operating volt & power consumption
g Software used
2 Video Display Unit (VDU)
a Make & model no.
b Locations
c VDU screen size
d VDU type / colour
e Dimensions (LXDXH)
3 Printer
a Make & model no. d Speed & size
b Quantity e Dimensions (LXDXH)
c Locations
4 Data gathering cum fire alarm panel (DGFAP)
a Make & model no. f Scan frequency for devices
b Max.and min.number of loops g Operating voltage & power
c Number of devices in each consumption
anlogue loop h Ingress protection :IP-41
d Event history storage processing i Communication protocol
e Number of programmable outputs
5 Repeat alarm panel
a Make & model no. c Display
b Operating voltage & d Ingress protection :IP-41
power consumption e Dimensions (LXDXH)mm
6 Integration with following Plant Comm. Systems:
a Public Alarm Announcement Yes/ No c Plant Data Network Yes/ No
system(Public address system) d ISDN telephone exchange Yes/ No
b Paging and Plant Comm. Yes/ No e Fire Suppression system Yes/ No
system
E Battery bank & charger details

1 Battery DGFAP CFAP Zonal Panel
a Make
b Type & model no.
f AH rating
d No. of cells
e Voltage per cell
f End cell voltage
g Dimensions (LXDXH)mm
2 Charger/ UPS Charger UPS
a Make
b Type/model no.
c Rating Amp KVA
d Dimensions (LXDXH)mm
Page 81 of 851
Datasheet No.
DATA SHEET B035-000-16-50-DS-0006
Page 5 of 5
F Power Requirements
a DGFAP( Watts)
b Zonal Fire Alarm Panels ( Watts)
c Total Fire Alarm system ( Watts)
G Communication Protocol
a Signal Loop
b Data Highway
H Cables
1 Recommended cable / wire size & Type
(Conventional Fire Alarm System)
a Between zonal panel & detectors,
break glass units.
b Between CFAP & Zonal panel
c Between CFAP & Repeat alarm panel
d Between zonal panel & repeat alarm
panel
2 Recommended cable / wire size & Type
(Microprocessor based Fire Alarm System)
a Between DGFAP & detectors 1.5mm2 Cu/
b Between CFAP & DGFAP
c Between CFAP & Zonal panel
d Between CFAP & Repeat alarm panel
f Between DGFAP & Repeat alarm panel
g Between Zonal panel & Repeat alarm panel
3 Cable Resistance (Max. per loop)
4 Cable capacitance (Max. per loop)
I Details of equipment certification/approval for hazardous

area application
Equipment MCP Heat Ionisation Optical detector Others

Detector detector
MR item no.
Explosion protection class
(as applicable)
Type reference no.
Reference no.& date of CMRI/
other test
certificates of recognised test
authority
Reference no.& date of CCOE
approval certificate
Reference no.& date of DGFALSI
approval certificate
Reference no.& date of DGMS
BIS License No. & date
Page 82 of 851
VENDOR LIST Document No.
FOR B035-001-16-50-VL-8106
ELECTRICAL ITEMS Rev. 0
Page 1 of 14
VENDOR LIST
FOR
ELECTRICAL ITEMS
(DOBHI-DURGAPUR PIPELINE SECTION)
TENDER NO: B035-001-81-41-FP-T-8106
PROJECT : DOBHI DURGAPUR HALDIA PIPELINE
OWNER : M/S. GAIL
JOB NO : B035
0 19-09-2018 Issued with Tender SS AR ANPS

Rev. Checked Approved
Date Purpose Prepared by
No by by
Page 83 of 851
VENDOR LIST Document No.
FOR B035-001-16-50-VL-8106
ELECTRICAL ITEMS Rev. 0
Page 2 of 14
NOTES:
1. Vendor may procure material from any of approved vendors listed below. However current
validity and range of approval as per enlistment letter, workload, stability and solvency need to
be verified by the Vendor before placement of order.
2. For equipments/components other than the above, vendor shall submit past track record for the
proposed sub-vendors and obtain written approval from Owner / EIL before placing order.
Page 84 of 851
Suppliers List for FA Tender(DDPL-B035) Date :19/09/2018 16:39:08
Page 1 of 12

Code
Item Code : 13HC Description : BATTERIES-LEAD ACID (VRLA)
Approved Suppliers
1 N216 NED ENERGY LIMITED INDIA
2 E149 EXIDE INDUSTRIES LTD. INDIA
3 A209 AMARA RAJA BATTERIES LTD INDIA
4 H132 HBL POWER SYSTEMS LTD INDIA
065057051048

065057051048
Page 85 of 851
Page 2 of 12

Code
Item Code : 13OC Description : CABLES-MEDIUM VOLTAGE-POWER-PVC/XLPE
Approved Suppliers
1 3669 KEI INDUSTRIES LIMITED INDIA
2 H060 HAVELLS INDIA LTD INDIA
3 G156 GEMSCAB INDUSTRIES LTD INDIA
4 3722 POLYCAB WIRES PVT LTD INDIA
7 S025 SRIRAM CABLES PVT LTD INDIA
8 K190 KEC INTERNATIONAL LTD-SILVASSA (F-R133) INDIA
9 3602 Special Cables Pvt. Ltd. INDIA
10 K082 KEI INDUSTRIES LIMITED INDIA
11 U003 UNIVERSAL CABLES LTD INDIA
12 T124 TORRENT POWER LIMITED INDIA
13 A132 ASSOCIATED FLEXIBLES & WIRES [P] LTD INDIA
14 C145 CORDS CABLE INDUSTRIES LTD INDIA
15 P254 POLYCAB WIRES PVT LTD INDIA
16 F013 FINOLEX CABLES LTD. INDIA
065057051048

065057051048
Page 86 of 851
Page 3 of 12

Code
Item Code : 13OE Description : CABLES-FIRE ALARM AND COMMN.
Approved Suppliers
1 3724 CORDS CABLE INDUSTRIESLTD. INDIA
2 K082 KEI INDUSTRIES LIMITED INDIA
3 C145 CORDS CABLE INDUSTRIES LTD INDIA
4 D012 DELTON CABLES LIMITED INDIA
5 3669 KEI INDUSTRIES LIMITED INDIA
6 C019 CMI LIMITED INDIA
7 E063 ELKAY TELELINKS LTD.- INDIA
065057051048

065057051048
Page 87 of 851
Page 4 of 12

Code
Item Code : 14AB Description : AUX. RELAYS
Approved Suppliers
1 A392 GE T&D INDIA LIMITED INDIA
2 A200 ABB INDIA LTD (BANGALORE) INDIA
3 3642 M/S JVS ELECTRONICS PVT LTD INDIA
065057051048

065057051048
Page 88 of 851
Page 5 of 12

Code
Item Code : 14CD Description : CONTACTORS
Approved Suppliers
1 L103 LARSEN & TOUBRO LTD-AHMEDNAGAR INDIA
3 A200 ABB INDIA LTD (BANGALORE) INDIA
4 S450A SCHNEIDER ELECTRIC INDIA P LTD-HYDERABAD INDIA
5 G147 GE INDIA INDUSTRIAL PVT LTD INDIA
065057051048

065057051048
Page 89 of 851
Page 6 of 12

Code
Item Code : 14CF Description : CONTROL SWITCHES / SELECTOR SWITCHES
Approved Suppliers
2 K143 KAYCEE INDUSTRIES LTD. INDIA
3 H142 HOTLINE SWITCHGEAR & CONTROLS INDIA
4 A392 GE T&D INDIA LIMITED INDIA
5 R159 RELIABLE ELECTRONIC COMPONENTS PVT LTD INDIA
6 S373 SWITRON DEVICES INDIA
065057051048

065057051048
Page 90 of 851
Page 7 of 12

Code
Item Code : 14FA Description : FUSES
Approved Suppliers
2 I013 NOVATEUR ELECTRICAL & DIGITAL SYSTEMS P INDIA
4 C194 COOPER BUSSMAN INDIA PVT LTD INDIA
065057051048

065057051048
Page 91 of 851
Page 8 of 12

Code
Item Code : 14MA Description : MCB
Approved Suppliers
1 S450 SCHNEIDER ELECTRIC INDIA PVT LTD INDIA
2 I168 INDIANA CURRENT CONTROL LTD INDIA
3 S393 STANDARD ELECTRICALS LTD INDIA
4 H060 HAVELLS INDIA LTD INDIA
6 3726 NOVATEUR ELECTRICAL & DIGITAL SYSTEMS PVT. INDIA
LTD.
7 L071 LEGRAND (INDIA) PVT. LTD (FORM. M-006) INDIA
8 A372 ABB INDIA LTD INDIA
065057051048

065057051048
Page 92 of 851
Page 9 of 12

Code
Item Code : 14MB Description : MCCB
Approved Suppliers
3 L001C LARSEN & TOUBRO LTD-POWAI INDIA
5 A200B ABB INDIA LTD INDIA
065057051048

065057051048
Page 93 of 851
Page 10 of 12

Code
Item Code : 14MC Description : METERS
Approved Suppliers
1 A028A AUTOMATIC ELECTRIC LTD. INDIA
2 M239 MECO INSTRUMENTS PVT LTD INDIA
3 N130 NIPPEN ELECTRICAL INSTRUMENTS CO. INDIA
4 R042 RISHABH INSTRUMENTS PVT LTD INDIA
5 S141 SECURE METERS LIMITED INDIA
065057051048

065057051048
Page 94 of 851
Page 11 of 12

Code
Item Code : 14PB Description : PUSH BUTTON AND INDICATING LAMPS
Approved Suppliers
1 S365 SHRI TULSI SWITCHGEARS PVT LTD INDIA
2 H142 HOTLINE SWITCHGEAR & CONTROLS INDIA
3 E173 ESSEN DEINKI INDIA
4 L001C LARSEN & TOUBRO LTD-POWAI INDIA
5 P291 PRECIFINE PRODUCTS PVT. LTD. INDIA
8 T166 TEKNIC ELECTRIC (I) PVT. LTD. INDIA
065057051048

065057051048
Page 95 of 851
Page 12 of 12

Code
Item Code : 14TA Description : TIMERS
Approved Suppliers
1 E151 ELECTRONIC AUTOMATION PVT LTD INDIA
065057051048

065057051048
Page 96 of 851
B035-001-16-50-01102
800 B035-001-81-41-12101-1 SV-STN. (TYP.) CONTROL ROOM BUILDING PLAN,ELE,& SEC.
7-51-0022,0102,0103,0116 EIL ELECTRICAL STANDARDS
SOLAR CHARGER NOTES :-
50
1000
300
600
100 300
1200
1 2 3 4 5 6
28000
4000 7000 7000 6000 4000 1 2 3 4 5 6
UP 28000
4000 7000 7000 6000 4000
RAMP
100.000
A.R.L. (SLOPE 1:8)
1000MM HIGH RAILING
C C
VERANDAH
2000
2000
100.450
CLP-1L
PP-1P
LP-1L
F.F.L.
B B
FAP
PDB
CAP
SLOPE 1:80
SLOPE 1:80
SLOPE 1:80
SLOPE 1:80 SLOPE 1:80

CPPSM
20 UP 20
INSTRUMENT/
8000
1 21
SCADA ROOM BATT. RACK-1
BATT. RACK-2
DCDB-2
AC FC
GRID CHGR.
6000
6000
FF UD ELECTRICAL ROOM FIRE FIGHTING RM.
11 10 11
DCDB-1
DC-DC DC-DC 30
STAIRCASE CNVT. SOLAR CHGR. CNVT.
DN
BATTERY ROOM STAIRCASE
A A
SUN SHADE PROJ. ABOVE
750MM WIDE RCC GUTTER ABOVE
WIDTH=1500 160 Ø PVC RAIN WATER PIPE 750MM WIDE RCC GUTTER
TREAD =300 EMBEDDED IN CONC. (TYP.)
1000MM HIGH RCC PARAPET WALL
RISER =150
RAILING-S.S.RAILING,1000 HIGH
TERRACE PLAN EMBEDDED IN CONC. (TYP.)
EARTHING LAYOUT
LIGHTNING PROTECTION LAYOUT
1 2 3 4 5 6 1 2 3 4 5 6
28000 28000
4000 7000 7000 6000 4000 4000 7000 7000 6000 4000
UP UP
3X3 NOS.100 DIA

RAMP RAMP GI PIPE SLEEVE
100.000 100.000
A.R.L. (SLOPE 1:8) 1000MM HIGH RAILING A.R.L. (SLOPE 1:8) 1000MM HIGH RAILING
C C
VERANDAH VERANDAH
2000
2000
4 NOS.100 DIA 2NOS.50 DIA

100.450 100.450
CLP-1L
CLP-1L
GI PIPE SLEEVE GI PIPE SLEEVE
PP-1P
PP-1P
200
LP-1L
LP-1L
3000 F.F.L. 200 F.F.L.
200
800
200 200 170
B B
800 750
1020
FAP
FAP
1200 800 800
420 800
PDB BATTERY ROOM BP/AR ANPS
1200
F PDB 0 05.08.18 ISSUED FOR CONSTRUCTION MK
CAP
CAP
4NOS.150 DIA B 04.08.18 RE-ISSUED FOR COMMENTS RMC AR ANPS
CPPSM
CPPSM
20 UP F 20 UP GI PIPE SLEEVE
0 F AR ANPS
8000
8000
1 75 1 A 16.04.18 ISSUED FOR COMMENTS RA

F
BATT. RACK-1
BATT. RACK-2
BATT. RACK-1
BATT. RACK-2
1200
DCDB-2
DCDB-2
INSTRUMENT/ F INSTRUMENT/
GRID CHGR.
GRID CHGR.
AC FC AC FC
6000
6000
ELECTRICAL ROOM
4000
FIRE FIGHTING RM. ELECTRICAL ROOM FIRE FIGHTING RM.

3600
SCADA ROOM FF UD F SCADA ROOM FF UD
A
F
200
F F F
11 10 11 10
DCDB-1
DCDB-1
1200
2000
DC-DC DC-DC F 1200 DC-DC DC-DC

STAIRCASE CNVT. SOLAR CHGR. CNVT. STAIRCASE CNVT. SOLAR CHGR. CNVT.

750
750
BATTERY ROOM
200
A
2170 800 1000 800 1000
A GAIL
750 1000 1275 800 2000 800 1000 600
STAIRS AS/STRL. DESIGN 200 200 200 STAIRS AS/STRL. DESIGN
A
450 Ø EXHAUST FAN
(FLP IIC TYPE) (FROM GROUND TO ROOF) /kksch nqxkZiqj gfYn;k DHOBI - DURGAPUR HALDIA
WIDTH=1500
TREAD =300
450 Ø EXHAUST FAN
SUN SHADE PROJ. ABOVE WIDTH=1500
TREAD =300
3X3 NOS.100 DIA
GI PIPE SLEEVE
750MM WIDE RCC GUTTER ABOVE
RISER =150 RISER =150
RAILING-S.S.RAILING,1000 HIGH 160 Ø PVC RAIN WATER PIPE
EMBEDDED IN CONC. (TYP.)
RAILING-S.S.RAILING,1000 HIGH bZfDoiesaV dscy vjfFkax ,oe~ EQPTUIPMENT, CABLE, EARTHING AND
EQUIPMENT LAYOUT rfMr izfrj{kk O;oLFkk vkjs[k LIGHTNING PROTECTION LAYOUT
SV STATION (TYPICAL)
,loh LVs'ku fu;a=.k Hkou CONTROL ROOM BUILDING
CABLE TRENCH LAYOUT SCALE JOB NO. UNIT DIVN. DEPT. DWG. NO. REV.
"NOT TO SCALE, ASK IF IN DOUBT" 1:100 B 0 3 5 0 0 1 1 6 5 0 01 1 0 2 0
Page 97 of 851
3-1641-0501 REV.2 A1-841x594
B035-001-16-50-01105
N
(REFER
T o H ar
NOTE N
ha
1000V Po
dA
Ro
s p
w
h
wer
a
Li
l t
Ro
e
m i
w
d
t
O.11) Line
L
R
i
o
m i
ad
t
419.638
PBM-19A
Pond
Tree
N
To M
adgar
BA
TH
a
W
TO C
DW IL
ET
AH
ND
RA
GU
VE
AR
D
RO
OM
11
ST
AI
RC
SE A
20
10
UP
1
220
IN
VP
A
SC STRU
AD M
E
OM
RO NT/
owe
r Li
ne
EL
EC
TR
RA
IC
OP
E
(SL MP
AL
1:
8)
RO
OM
VE
RA
ND
AH
FR
BA
UP
TT
O
RY E
RO
OM
M
FIR
EF
IG
HT
D
IN
G
RM
.
O
BH
AREA
PANEL
SOLAR
Ro
u
Li
m
it
PI
(R PE
ER L
TE
OU INE
D)
Ro
u
Li
m
it
TO
D
U
RG
A
700
PI
100 150 450

PU
(P PE
R
RO L
SE
D)
PO INE
500
100 100 100 100 100
SCALE
REV. DATE
NOTES :-
GAIL
REF. DWG. NO.
JOB NO.
|ksHkh & nqxkZiqj
UNIT
ikbiykbZu ifj;kstuk
REVISIONS
DIVN.
BILL OF MATERIAL
SV STATION-19A
DEPT.
BY

REFERENCE DRAWING TITLE
3-1641-0501 REV.2
DWG. NO.
PIPELINE PROJECT
DOBHI - DURGAPUR
OVERALL LIGHTING, CABLE, EARTHING & FIRE ALARM LAYOUT
REV.
A1-841x594
CHKD APPD PEM/PC
Page 98 of 851
B035-001-16-50-01130
800 REF. DWG. NO. REFERENCE DRAWING TITLE
B035-000-81-41-12103-1 IPS BUILDING/ RECEIPT TERMINAL/ DESPATCH TERMINAL (TYPICAL)
GROUND FLOOR PLAN & SECTION
IPS BUILDING/ RECEIPT TERMINAL/ DESPATCH TERMINAL (TYPICAL)
B035-000-81-41-12104-1 TERRACE PLAN & ELEVATIONS
7-51-0022,0102,0103,0116 EIL ELECTRICAL STANDARDS
PDB
1000
50
FALSE CEILING NOTES :-
1000
(MIN.)
600
300
1000 900
UPS
ROOM
1800
3000
UPS
1850
900
1000
300
600 100.000
800
A.R.L
FALSE FLOORING
300
4000
100
1200
1 2 3 3' 4 4' 5 6 7 8 9 10
1 2 3 3' 4 4' 5 6 7 8 9 10
33000 33000
(FROM GROUND TO TERRACE) 4000 3450 1825 1725 2275 1725 4000 4000 3000 4000 3000 4000 3000 2275 1725 2275 1725 4000 4000 3000 4000 3000
WIDTH=1500
TREAD =300
RISER =150
E E
WC
STAIRCASE STAIRCASE
DN
10
B B
UPS PANEL
11
FEMALE
TOILET
FIRE FIGHTING AC FC TELECOM & SCADA CONTROL ROOM

6000
6000
FC
SLOPE 1:80
FF UD
SLOPE 1:80
SLOPE 1:80
SLOPE 1:80
ROOM/ ROOM AC FC
MALE CLEAN AGENT ROOM 2 NOS.100 DIA 2 NOS.150 DIA
FF UD
TOILET FC AC FC
1 GI PIPE SLEEVE FF UD GI PIPE SLEEVE
PANTRY FC UPS ROOM
UP
6 NOS.150 DIA
F
CAP
GI PIPE SLEEVE
D D
4 NOS.150 DIA
2100MM WIDE CORRIDOR
14350
14350
VERANDAH GI PIPE SLEEVE
2600
2600
2 NOS.100 DIA
100.600 FC
PP-1P
A
LP-1L
F.F.L.
GI PIPE SLEEVE BATT.
MCCB
C PP-2P C
STEPS
TREAD-300 4 NOS.100 DIA
UP GI PIPE SLEEVE
2250
RISER-150 FAJB
2500
1200
CPPSM
F CLP-1L
100.00 LOBBY
SLOPE 1:80
SLOPE 1:80
SLOPE 1:80
A.R.L. BATT. RACK-1 PDB
F
FAP
BATTERY F DOCUMENTA I/C ROOM B

B AC FC ENGINEER'S
ELECTRICAL
A
UD AC FC
ROOM 1200 ROOM -TION ROOM UD
ROOM
BATT. RACK-2 F F F F
3500
ACDB
3250
RCF DCDB-2 RCF DCDB-1

1200
F 2 1 VERANDAH
SINK
WR-01 100.600
F.F.L.
A A
160 Ø PVC RAIN WATER PIPE EMBEDDED IN RAMP

3X4 NOS.100 DIA (SLOPE 1:8)
CONC. (TYP.)
450 MM WIDE SUN SHADE GI PIPE SLEEVE 100.00
A.R.L.
PROJ. ABOVE
RCC GUTTER ABOVE STEPS
TREAD-300
RISER-150
UP
TERRACE PLAN
LIGHTNING PROTECTION LAYOUT
CABLE TRENCH LAYOUT
1 2 3 3' 4 4' 5 6 7 8 9 10 1 2 3 3' 4 4' 5 6 7 8 9 10

33000 33000
(FROM GROUND TO TERRACE) 4000 3450 1825 1725 2275 1725 4000 4000 3000 4000 3000 4000 3450 1825 1725 2275 1725 4000 4000 3000 4000 3000
WIDTH=1500
TREAD =300 300 Ø EXHAUST FAN
RISER =150 300 Ø EXHAUST FAN
E E
WC WC
750
1000 900
STAIRCASE STAIRCASE
10
UPS 10
UPS PANEL
UPS PANEL
11 ROOM TELECOM & SCADA 11
FEMALE
FEMALE
TOILET
TOILET
3200
FIRE FIGHTING AC FC ROOM CONTROL ROOM FIRE FIGHTING AC FC TELECOM & SCADA CONTROL ROOM
6000
6000
FC FC
FF UD FF UD
ROOM/ AC FC AC FC ROOM/ AC FC ROOM AC FC
MALE CLEAN AGENT ROOM FF UD FF UD MALE CLEAN AGENT ROOM
FF UD FF UD
TOILET FC TOILET FC
1 1
PANTRY FC 600 PANTRY FC
UP 200 UP UPS ROOM
1820
F
CAP
CAP
800
D D
200
2100MM WIDE CORRIDOR 2100MM WIDE CORRIDOR

14350
14350
VERANDAH VERANDAH
2600
2600
100.600 BATT. MCCB 100.600

PP-1P
PP-2P
LP-1L
CLP-1L
FC FC
PP-1P
PP-2P
LP-1L
CLP-1L
F.F.L. 1640 F.F.L.
200 200 200
FAJB
C C 2 05.09.18 REVISED & RE-ISSUED FOR CONSTRUCTION MK BP/AR ANPS
1070
STEPS STEPS
800 900
600 1770 FAJB

800
TREAD-300 2080 TREAD-300

1100
RISER-150 UP BATTERY ROOM RISER-150 UP 1 08.08.18 ISSUED FOR CONSTRUCTION MK BP/AR ANPS
2500
2500
CPPSM
CPPSM
F 3000 LOBBY LOBBY 0 10.04.18 ISSUED FOR CONSTRUCTION
800
100.00 100.00 PDB RA AR ANPS

750 1000 750
A.R.L. BATT. RACK-1 PDB A.R.L. BATT. RACK-1

200
F REV. DATE REVISIONS BY CHKD APPD PEM/PC
FAP
FAP
F ENGINEER'S I/C ROOM I/C ROOM

800
AC FC DOCUMENTA BATTERY ELECTRICAL AC FC ENGINEER'S DOCUMENTA

B B
ELECTRICAL UD AC FC UD AC FC
2050
450 Ø EXHAUST FAN 200 ROOM -TION ROOM UD

ROOM ROOM ROOM -TION ROOM UD
(FLP IIC TYPE) ROOM
BATT. RACK-2 F F F BATT. RACK-2
ACDB
F
ACDB
3250
3250
2400
750 4500
600
RCF DCDB-2 RCF DCDB-1

800
F 2 1 VERANDAH RCF-2 DCDB-2 RCF-1 DCDB-1 VERANDAH

1650
SINK
WR-01 100.600 SINK
WR-01 100.600
1370 800 1200 800 1200
200
F.F.L. F.F.L.

A 200 A
200 200 200
160 Ø PVC RAIN WATER PIPE EMBEDDED IN

CONC. (TYP.)
450 Ø EXHAUST FAN
880 RAMP
(SLOPE 1:8)
RAMP
(SLOPE 1:8)
GAIL
450 MM WIDE SUN SHADE 100.00 100.00
A.R.L. A.R.L.
PROJ. ABOVE
RCC GUTTER ABOVE STEPS
TREAD-300
RISER-150
STEPS
TREAD-300
RISER-150
/kksch nqxkZiqj gfYn;k DHOBI - DURGAPUR HALDIA PIPELINE
UP UP ikbZiykbu izkstsDV PROJECT
EQUIPMENT LAYOUT bZfDoiesaV dscy vjfFkax ,oe~ EQPTUIPMENT, CABLE, EARTHING AND
EARTHING LAYOUT rfMr izfrj{kk O;oLFkk vkjs[k LIGHTNING PROTECTION LAYOUT
आई पी एस बिल्डिंग , रिसीप्ट टर्मिनल IPS BUILDING/ RECEIPT TERMINAL/
व डिस्पच
ै टर्मिनल DESPATCH TERMINAL (TYPICAL)
"NOT TO SCALE, ASK IF IN DOUBT" 1:125 B 0 3 5 0 0 1 1 6 5 0 0 1 1 3 0 2
Page 99 of 851
3-1641-0501 REV.2 A1-841x594
STANDARD SPECIFICATION STANDARD SPECIFICATION No.
~zit4 ENGINEERS FOR FABRICATION AND
$1g-ar 0154- g w INDIA LIMITED ERECTION OF PIPING
6-44-0012 Rev. 4
1.~ cYrTK M13,4.1 Ift Govt of Incha Unclertaking)
Page 1 of 15
STANDARD SPECIFICATION FOR

FABRICATION AND ERECTION OF
PIPING
REVISED AND ISSUED AS STANDARD

4 30.07.14
SPECIFICATION AK ATD SC
3 31.03.09
SPECIFICATION RN VKB SC ND
PMI REQT. INCLUDED AND ISSUED AS
2 05.06.03
STANDARD SPECIFICATION RN DM BN SKG
REAFFIRMED AND ISSUED AS STD.
1 15.09.98 SH BRB NS AS
SPECIFICATION
0 14.04.93 ISSUED AS STANDARD SPECIFICATION AKG BPV GRR AS
Standards Standards
Rev. Committee Bureau
Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 100 of 851

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEEFZS
RLJI £;Mes o INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1~1 C-1,9,1, 051 3W1,) (A Govt ol Indo Undertakngt
OF PIPING Page 2 of 15
Abbreviations:
A.S. : Alloy Steel

ASME : American Society of Mechanical Engineers
C.I. : Cast Iron
C.S. : Carbon Steel
HMTD : Heat & Mass Transfer Division
IBR Indian Boiler Regulations
LTCS : Low Temperature Carbon Steel
NACE : National Association of Corrosion Engineers
NB Nominal Bore
NDT : Non Destructive Testing
P&ID : Piping and Instrumentation Diagram
PMI Positive Material Identification
S.S. Stainless Steel
SMMS : Specialist Material & Maintenance Services
Piping Standards Committee
Convenor : Mr. R. Nanda
Members : Mr. M. Ismaeel

Mr. Amrendra Kumar
Mr. G. Balaji
Mr. K.J. Harinarayanan (HMTD)
Mr. P P Lahiri / Mr. S. Ghoshal (SMMS)
Mr. S. Mukherjee (Construction)
Mr. K.V.K. Naidu (Projects)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved
Page 101 of 851

zig ENGINEERS
OgLar INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1>ffeR IA Tool ol Ind2 Undertakin)
CONTENTS
1.0 SCOPE 4
2.0 SCOPE OF WORK OF CONTRACTOR .4
3.0 BASIS OF WORK 7
4.0 FABRICATION 8
5.0 ERECTION 11
Page 102 of 851

ENGNEERS
fffl it—
eg INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
.1"2-, 21,1,1,
151,41,411 IA Govt of India Undertalong)
1.0 SCOPE
This specification covers general requirements of fabrication and erection of above ground
and trench piping systems at site. The specification covers the scope of work of Contractor,
basis of work to be carried out by Contractor and standards, specifications and normal
practice to be followed during fabrication and erection by the Contractor.
2.0 SCOPE OF WORK OF CONTRACTOR
Generally the scope of work of Contractor shall include the following:
2.1 Transportation of required piping materials (as described in C1.2.1.1), pipe support (material
as described in Cl. 2.3) and all other necessary piping materials from Owner's storage point
or Contractor's storage point (in case of Contractor's scope of supply) to work site/shop
including raising store requisitions for issue of materials in the prescribed format &
maintaining an account of the materials received from Owner's stores.
2.1.1 Piping materials include the following but not limited to the same.
a. Pipes (A11 sizes and schedule)
b. Flanges (A11 sizes, types & Pressure ratings).
c. Fittings (All sizes, types and schedule)
d. Valves (A11 sizes, types and Ratings)
e. Gaskets (All sizes, types & Ratings)
f. Bolts, Nuts or M/C Bolts (All types)
g. Expansion Joint/Bellows (All types)
h. Specialty items like online filters, ejectors, sample coolers, steam traps, strainers, air
traps, springs, silencers, snubbers, steam and condensate manifolds, injection nozzles,
MOVs, sight glass, spray nozzles, integrated steam traps, hoses, hose couplings, etc.
i. Online instruments like control valve, orifice flange, rotameter, safety valves,
restriction orifice, rupture disc, de-super heaters, corrosion probes, annubar, magnetic
flow meter, ultrasonic flow meter, Coriolis mass flow meters, venturi PG/PT/ Flow
transmitter, ejectors, static mixers, flame arrestors, thermal flow switches, pre-
fabricated hook-ups etc.
j. Shut Down Valves with and without fire box.
2.2 Shop & field fabrication and erection of piping in accordance with documents listed under
C1.3.0 i.e. 'BASIS OF WORK' including erection of all piping materials enumerated above.
2.3 Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors, clips,
cradles, hangers, turn-buckles, supporting fixtures, bracket cantilevers, struts, tee-posts
including erection of spring supports, sway braces, dummy pipes, corrosion pads/protection
shields, low friction pads, clamps, special support, expansion bellows, steam and condensate
manifolds supports etc. Corrosion Pads/Protection shields, stiffeners and stiffening rings, if
not covered in the specifications/standards, shall be of the same material as of parent pipes.
Page 103 of 851

ENGINEEFZS
dg INDIA LIMITED
Odi FABRICATION AND ERECTION 6-44-0012 Rev. 4
.R27T 0,
1 J~1,
A
GoN of Ind,a Underta«.9) OF PIPING Page 5 of 15
2.4 Site fabrication of Piping items
Site fabrication of Piping items shall include but not be limited to the following
2.4.1 Fabrication of piping specials like special radius bends, reducers, mitres etc.
2.4.2 Fabrication of plain and threaded nipples from pipes as required during erection.
2.4.3 Fabrication of swage nipples as and when required.
2.4.4 Fabrication of odd angle elbow like 60°, 30° or any other angle from 90°/45° elbows as and
when required.
2.4.5 Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when required.
2.4.6 Fabrication of stub-in connection with or without reinforcement.
2.4.7 Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven/different
thickness wherever required.
2.4.8 Fabrication of circular pipe for steam rings, fire water lines, utility lines.
2.4.9 Threading of all small bore piping as per piping material specifications.
2.4.10 Drilling on blind flange for inserting / joining small bore lines.
2.4.11 Fabrication and welding of reinforcement pads at branch pipe locations wherever required.
2.4.12 Equipment nozzle reinforcement with pads, jacket & stiffeners wherever required.
2.4.13 Fabrication of injection nozzles as per details provided wherever required.
2.4.14 Fabrication of chain operation arrangement for valves, wherever required. A11 material
required for this modification shall be supplied by Contractor.
2.4.15 Fabrication and erection in position of funnels required for OWS/ SS/ Condensate blow
down system as per direction of Engineer-in-charge.
2.4.16 Grinding/ finishing of uneven surfaces/ joints after welding. Internal grinding of welds of
orifice flanges to render smooth surface.
2.4.17 Tapping and drilling of holes in flanges, blind flanges, piping connections for jack screw, if
required.
2.4.18 Providing bird screens at the outlet of lines open to atmosphere.
2.5 Modifications like providing additional cleats, extension of stem of valve, locking
arrangement of valves etc. as and when required.
2.6 Piping isometrics for main process/utility lines shall be provided to the Contractor.
Preparation of miscellaneous small bore isometrics with bill of materials for process and
utility lines (up to 11/2" size) like instruments & pump flushing / cooling, sample connection,
purging, pump casing vents & drains, pump Base plate drains, control valve drains / vent to
flare, instrument drains & vents, steam tracing (non-IBR) from steam supply stations up to
condensate recovery station, and lines specified as field routed within the Unit battery limit
Page 104 of 851

ry s ENGINEERS
Ogz-drr 2fal-egI INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1.1r7R Crt-LISTC 2/513,721,) IA Govl o■ Indu UnclettakIng)
as and when required are in Contractor's scope of work. Approval for these isometrics
prepared by the Contractor shall be taken from Engineer-in-charge before erection.
Small bore piping isometrics given by Owner shall be rechecked by Contractor before
erection and installation.
2.7 Obtaining approval for drawings prepared by Contractor from statutory authority, if
required.
2.8 Spun concrete lining of the inside of pipes 3" NB & above including fittings and flanges as
required in accordance with specification.
2.9 Rubber lining inside pipes, fittings, flanges as and when required, in accordance with
specification.
2.10 Radiography, stress relieving, dye penetration, magnetic particle test etc. as required in
specification.
2.11 Performing PMI using alloy analyzers as per `Standard Specification for Positive Material
Identification at Construction Sites, 6-82-0002'.
2.12 Casting of concrete pedestals and Fabrication and erection of small structures/ platforms for
pipe supports and valve operation / attending some instruments, spectacle blinds etc.,
providing brackets, modification / extension of platforms, providing additional platforms /
ladders for improving / providing accessibility.
2.13 Providing insert plates with anchor fasteners in concrete structures / paved floors and repair
of platform gratings around pipe openings and providing suitable members for support
under the platform grating.
2.14 Making material reconciliation statement and return of Owner's supply left over materials to
Owner's storage.
2.15 Flushing and testing of all piping systems as per standard specification for inspection,
flushing and testing of piping systems (Specification No. 6-44-0013). The accessories
required for blinding the line like flange, blind flange, gasket (all sizes, type and rating),
stud-bolts, flexible hoses etc. are to be arranged by the Contractor. During flushing the
discharged water / air shall be drained / routed as directed by the Engineer — In Charge.
2.16 Contractor shall prepare welding specifications for all weld joints where dissimilar welding
will be performed, and obtain approval from EIL.
2.17 Contractor to ensure meeting all requirements for carrying out work in shutdown/running
plant.
2.18 Pickling (as and when applicable) as per Job specification(s) for chemical cleaning of CS
suction piping of compressors, SS Piping, Weldments etc, as applicable.
2.19 Chemical Cleaning/ Hydro jet cleaning as per marked-up P&IDs with supply of chemicals,
consumables, DM water, equipments, boilers, coupons, tools & tackles and other testing
equipments required for the same.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved
Page 105 of 851

■31 ENGINEERS
FABRICATION AND ERECTION
ar 1.1W1 <9,741 451 ,1,1~)
INDIA LIMITED 6-44-0012 Rev. 4
in Govt ot India Undertaloow
3.0 BASIS FOR WORK
3.1 The complete piping work shall be carried out in accordance with the following:
3.1.1 "Approved for Construction" drawings and sketches issued by EIL to the Contractor - Plans
and/or Isometrics.
3.1.2 "Approved for Construction" drawings and sketches issued by Turn-key bidders to the
Contractor - Plans and/or Isometrics.
3.1.3 Approved Process Licensor's standards and specifications.
3.1.4 Drawings, sketches and documents prepared by Contractor duly approved by Engineer-in-
Charge (such as isometrics of small bore piping and offsite piping etc.).
3.1.6 EIL specifications/documents as below:
a. Process and Instrument Diagram.
b. Job Piping Materials Specification (****-6-44-0005). **** denotes job number.
c. Piping support, engineering standards.
d. Line list
e. Piping support indices (only in offsite), if supports are not shown in plan.
f. Job specification of Non-destructive Requirement of Piping (****-6-44-0016)
g. Job Welding Specification Charts for Piping Classes (****-6-77-0005)
h. Job Welding specification for fabrication of piping (****-6-77-0001).
i. Any other EIL or OTHER specifications attached with Piping Material Specification
or special condition of contract (such as standard for cement lining of pipe, standard
ofjacketed piping, standard for steam tracing, Dimensional Tolerances etc.)
j. Standard specification for positive material identification (PMI) at construction sites,

6-82-0002
k. Standard Spec for application of torque & hydraulic bolt tension for flange joints (6-
76-0002) and its addendum, if any.
3.1.7 Following codes, standards and regulations
a. ASME B 31.3 Process Piping
b. ASME Sec. VIII Code for unfired pressure vessel.
c. IBR Regulations
d. ASME Sec. IX Qualification standard for welding and brazing

procedures, welders, brazers and welding and
brazing operators.
Page 106 of 851

ENGINEERS
Og-ar fa2es
I è-117R C4c,7>r, ,Lq .~11
INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
IA Govt 01 India UndetaMing)
e. NACE Std. Code for Sour Services material requirements

MR-0175/MR0103/Job spec(NACE), as applicable
Note : A11 codes referred shall be latest edition, at the time of award of contract.
3.2 Deviations
Where a deviation from the "Basic of Work" and approved job procedure described above is
required or where the basis of work does not cover a particular situation, the matter shall be
brought to the notice of Engineer-in-Charge and the work carried out only after obtaining
written approval from him in each case.
4.0 FABRICATION
4.1 Piping Material
Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system
shall be strictly as per the "Piping Material Specification" for the "Pipe Class" specified for
that system. To ensure the above requirement, all piping material supplied by the Owner /
Contractor shall have proper identification marks as per relevant standards / EIL
specifications / Licensors specification. Contractor shall provide identification marks on left
over pipe lengths wherever marked up pipe lengths have been fabricated/erected. Material-
traceability is to be maintained for A.S., S.S., NACE, LTCS, material for Hydrogen service
and other exotic materials by way of transferring heat number, etc. (hard punching) as per
approved procedure. This shall be in addition to colour coding for all piping materials to
avoid mix-up.
For the purpose of common understanding the construction job procedure, to be submitted
by the Contractor, shall include proposal for
- Maximizing prefabrication, inspection and testing at fabrication shop with minimum

field joints.
- Positive material identification, handling, storage & preservation.
4.2 Dimensional Tolerances
Dimensional tolerances for piping fabrication shall be as per EIL Standard No. 7-44-0486.
The Contractor shall be responsible for working to the dimensions shown on the drawings.
However, the Contractor shall bear in mind that there may be variations between the
dimensions shown in the drawing and those actually existing at site due to minor variations
in the location of equipments, inserts, structures etc. To take care of there variations "Field
Welds" shall be provided during piping fabrication. An extra pipe length of 100 mm over
and above the dimensions indicated in the drawing may be left on one nide 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.
4.3 IBR Piping
4.3.1 Contractor shall obtain approval for the piping systems falling under purview of IBR from
the statutory Indian Boiler Regulations (IBR) authority of the state where the plant is
Page 107 of 851

ENGINEERS
5gU Offl— g
1.1WR Govt of UnOettaking)
situated. The Owner shall provide documentation for the IBR System. The Contractor shall
carry out the fabrications, erection and testing of this piping as per requirements of Indian
Boiler Regulations and to the entire satisfaction of the Local Boiler Inspector. The
Contractor shall also get the approval of IBR inspector for all fabrication and testing done
by him at his own cost. All certificates of approval shall be in proper IBR forms.
4.3.2 IBR Package for residual, field routed and site modified steam lines shall be prepared by the
Contractor. IBR approval for the same shall be in Contractor's scope, at his own cost.
4.4 Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In general,
joining of lines 2" and above in process and utility piping shall be accomplished by butt-
welds. Joining of lines 1-1/2" and below shall be by socket welding/butt welding/threaded
joints as specified in "Piping Material Specifications". However, in piping 1-1/2" and below
where socket welding/ threaded joints are specified butt - welds may be used with the
approval of Engineer-in-Charge for pipe to pipe joining in long runs of piping. This is only
applicable for non-galvanized piping without lining.
Flange joints shall be used at connections to Vessels, Equipment's, Valves and where
required for ease of erection and maintenance as indicated in drawings.
4.5 Butt Welded and Socket Welded Piping
End preparation, alignment and fit-up of pipe pieces to be welded, welding, pre-heating,
post-heating and heat treatment shall be as described in the Job welding specification
(****-6-77-0005) and NDT specification (****-6-44-0016).
4.6 Screwed Piping
In general, Galvanized piping shall have threads as per IS:554 or ANSI B2.1 NPT as
required to match threads on fittings, valves etc. All other piping shall have threads as per
ANSI B2.1, tapered unless specified otherwise.
Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed.
Threading of pipes shall be done preferably after bending, forging or heat treating
operations. If this is not possible, threads shall be gauge checked and chased after welding
heat treatment etc.
During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly
cleaned of cuttings, dirt, oil or any other foreign matter. The male threads shall be coated
with thread sealant and the joint tightened sufficiently for the threads to seize and give a
leakproof joint. Threaded joints to be seal-welded shall be cleaned of all foreign matter,
including sealant and made up to full thread engagement before seal welding.
4.7 Flange Connections
All flange facings shall be true and perpendicular to the axis of pipe to which they are
attached. Flanged bolt holes shall straddle the normal centerlines unless different orientation
is shown in the drawing.
Wherever jack screws are to be provided, drilling and tapping for the jack screws in the I
flange, shall be done as per EIL Standard before welding it to the pipe.
4.8 Branch Connections
Page 108 of 851

■
31 ENGINEERS
fg-r;Ir fa2e5 INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
14.2R ar a,
W,7,1~1) IA GoN of Indo Underfaon9)
Branch connections shall be as indicated in the piping material specifications. For end
preparation, alignment, spacing, fit-up and welding of branch connections refer welding
specifications. Templates shall be used wherever required to ensure accurate cutting and
proper fit-up.
For all branch connections accomplished either by pipe to pipe connections or by using
forged tees the rates quoted for piping shall be inclusive of this work.
Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc.
4.9 Bending
Bending shall be as per ASME B31.3 except that corrugated or creased bends shall not be
used.
Cold bends for lines 1-1/2" and below, with a bend radius of 5 times the nominal diameter
shall be used as required in place of elbows wherever allowed by piping specifications.
Bending of pipes 2" and above may be required in some cases like that for headers around
heaters, reactors etc.
The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles,
bulges, flat spots and other serious defects. They shall be true to dimensions. The flattening
of a bend, as measured by the difference between the maximum and minimum diameters at
any cross-section, shall not exceed 8% and 3% of the nominal outside diameter, for internal
and external pressure respectively.
4.10 Forging and Forming
Forging and forming of small bore fittings, like reducing nipples for piping 1-1/2" and
below, shall be as per ASME B 31.3.
4.11 Mitre Bends and Fabricated Reducers
The specific application of welded mitre bends and fabricated reducers shall be governed by
the Piping Material Specifications. Reducers shall be fabricated as per directions of
Engineer-in-Charge. The radiographic requirements shall be as per Material Specifications
for process and utility systems and NDT Specification for steam piping under IBR,
radiographic requirements of IBR shall be complied with.
4.12 Cutting and Trimming of Standard Fittings & Pipes
Components like pipes, elbows, couplings, half-couplings etc. shall be cut / trimmed / edge
prepared wherever required to meet fabrication and erection requirements, as per drawings
and instructions of Engineer-in-Charge. Nipples as required shall be prepared from straight
length piping.
4.13 Galvanized Piping
Galvanized carbon steel piping shall be completely cold worked, so as not to damage
galvanized surfaces. This piping involves only threaded joints and additional external
threading on pipes may be required to be done as per requirement.
Page 109 of 851

ENGINEERS
r Êtral
fg--a,- -g
e INDIA LJMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
oloo,r1.,om, IA Go, ol lnO. Undellaking)
4.14 Jacketed Piping
The Jacketing shall be done in accordance with EIL Specification or Licensors specification
as suggested in material specification or special condition of contract.
Pre-assembly of jacketed elements to the maximum extent possible shall be accomplished at

shop by Contractor. Position of jump-over and nozzles on the jacket pipes, fittings etc. shall
be marked according to pipe disposition and those shall be prefabricated to avoid damaging
of inner pipe and obstruction of jacket space. However, valves, flow glasses, in line
instruments or even fittings shall be supplied as jacketed.
4.15 Shop Fabrication / Prefabrication
The purpose of shop fabrication or pre-fabrication is to minimize work during erection to

the extent possible. Piping spool, after fabrication, shall be stacked with proper
identification marks, so as facilitate their withdrawal at any time during erection. During this
period all flange (gasket contact faces) and threads shall be adequately fabricated by coating
with removable rust preventive. Care shall also be taken to avoid any physical damage to
flange faces and threads.
4.16 Miscellaneous
4.16.1 Contractor shall fabricate miscellaneous elements like flash pot, seal pot, sample cooler,
supporting elements like turn-buckles, extension of spindles and interlocking arrangement of
valves, operating platforms as required by Engineer-in-Charge.
4.16.2 Spun Concrete Lining
The work of inside spun concrete lining of pipes and specials of diameter 3" and above shall
be done as per material specifications and special condition contract.
4.16.3 Fabrication of pipes from plate
Pipes shall be fabricated at site as and when required as per the specifications and the actual
Piping Material Specification.
5.0 ERECTION
5.1 Cleaning of Piping before Erection
Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and
outside by suitable means. The cleaning process shall include removal of all foreign matter
such as scale, sand, weld spatter chips etc. by wire brushes, cleaning tools etc. and blowing
with compressed air/or flushing out with water. Special cleaning requirements for some
services, if any, shall be as specified in the piping material specification or isometric or line
list. S.S jacketed piping requiring pickling shall be pickled to remove oxidation and
discolouring due to welding.
5.2 Piping Routing
No deviations from the piping route indicated in drawings shall be permitted without the
consent of Engineer-in-Charge.
Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the drawings
shall be strictly followed as these clearances may be required for the free expansion of
Page 110 of 851

ENGINEERS
$1gul8M--eg INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
1.117R +1,13,70,) (A Govt ol roma Undertalong)
piping / equipment. No deviations from these clearances shall be permissible without the
approval of Engineer-in-Charge.
In case of fouling of a line with other piping, structure, equipment etc. the matter shall be
brought to the notice of Engineer-in-Charge and corrective action shall be taken as per his
instructions.
5.3 Cold Pull
Wherever cold pull is specified, the Contractor shall maintain the necessary gap, as
indicated in the drawing. Confirmation in writing shall be obtained by the Contractor from
the Engineer-in-Charge, certifying that the gap between the pipes is as indicated in the
drawing, before drawing the cold pull. Stress relieving shall be performed before removing
the gadgets for cold pulling.
5.4 Slopes
Slopes specified for various lines in the drawings / P&ID shall be maintained by the
Contractor. 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.
5.5 Expansion Joints / Bellows
Installation of Expansion Joints/Bellows shall be as follows:
5.5.1 Al1 Expansion joints / Bellows shall be installed in accordance with the specification and
installation drawings, supplied to the Contractor.
5.5.2 a. Upon receipt, the Contractor shall remove the Expansion Joints/ Bellows from the
case(s) and check for any damage occurred during transit.
b. The Contractor shall bring to the notice of the Engineer-in- Charge any damage done
to the bellows / corrugations, hinges, tie-rods, flanges/ weld ends etc.
c. Each Expansion Joint / Bellow shall be blown free of dust / foreign matter with
compressed air or cleaned with a piece of cloth.
5.5.3 a. For handling and installation of Expansion Joints, great care shall be taken while
aligning. An Expansion Joints shall never be slinged from bellows corrugations/
external shrouds, tie / rods, angles.
b. An Expansion Joints / Bellow shall preferably be slinged from the end pipes / flanges
or on the middle pipe.
5.5.4 a. All Expansion Joints shall be delivered to the Contractor at "Installation length",
maintained by means of shipping rods, angles welded to the flanges or weld ends or
by wooden or metallic stops.
b. Expansion Joints stop blocks shall be carefully removed after hydrostatic testing.
Angles welded to the flanges or weld ends shall be trimmed by saw as per
manufacturer's instructions and the flanges or weld ends shall be ground smooth.
5.5.5 a. The pipe ends in which the Expansion Joint is to be installed shall be perfectly aligned
or shall have specified lateral deflection as noted on the relevant drawings.
b. The pipe ends / flanges shall be spaced at a distance specified in the drawings.
Page 111 of 851

■31 ENGINEERS
r 02-
$1g-a,ffum eg INDIA LIMITED FABRICATION AND ERECTION 6-44-0012 Rev. 4
IA Go, ol Underlaking)
5.5.6 The Expansion Joint shall be placed between the mating pipe ends / flanges and shall be
tack welded/bolted. The mating pipes shall again be checked for correct alignment.
5.5.7 Butt-welding shall be carried out at each end of the expansion joint. For flanged Expansion
Joint, the mating flanges shall be bolted.
5.5.8 After the Expansion Joint is installed the Contractor shall ensure that the mating pipes and
Expansion Joints are in correct alignment and that the pipes are well supported and guided.
5.5.9 The Expansion Joint shall not have any lateral deflection. The Contractor shall maintain
parallelism of restraining rings or bellows convolutions.
5.5.10 Precautions
a. For carrying out welding, earthing lead shall not be attached with the Expansion Joint.
b. The Expansion bellow shall be protected from arc weld spot and welding spatter.
c. Hydrostatic Testing of the system having Expansion Joint shall be performed with
shipping lugs in position. These lugs shall be removed after testing and certification
is over.
5.6 Flange Connections
While fitting up mating 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 together, without
inducing any stresses in the pipes and the equipment nozzles. Extra care shall be taken for
flange connections to pumps, turbines, compressors, cold boxes, air coolers etc. The flange
connections to these equipments shall be checked for misalignment, excessive gap etc. after
the final alignment of the equipment is over. The joint shall be made up after obtaining
approval of Engineer-in-Charge.
Hydraulic bolt tensioning & torque tensioning shall be performed on flange joints as per the
requirements specified in "Standard Specification for application of Torque & Hydraulic
Bolt Tension for flange joints," 6-76-0002 and its addendum, if any.
Temporary protective covers shall be retained on all flange connections of pumps, turbines,
compressors and other similar equipments, until the piping is finally connected, so as to
avoid any foreign material from entering these equipments.
The assembly of a flange joint shall be done in such a way that the gasket between these
flange faces is uniformly compressed. To achieve this, the bolts shall be tightened in a
proper sequence. A11 bolts shall extend completely through their nuts but not more than 1/4".
Steel to C.I. flange joints, if any, shall be made up with extreme care, tightening the bolts
uniformly after bringing flange flush with gaskets with accurate pattern and lateral
alignment.
5.7 Vents and Drains
High point vents and low point drains shall be provided as per the instructions of Engineer-
in-Charge, even if these are not shown in the drawings. The details of vents and drains shall
be as per piping material specifications / job standards.
Page 112 of 851

ENGINEERS
Og'-ar Ofd i gw
2,22F1? 461 34.--,1
IA Govt of Ind‘a Undenak,n9)
5.8 Valves
Valves shall be installed with spindle / actuator orientation / position as shown in the layout
drawings. In case of any difficulty in doing this or if the spindle orientation / position is not
shown in the drawings, the Engineer-in-Charge shall be consulted and work done as per his
instructions. Care shall be exercised to ensure that globe valves, check valves, and other uni-
directional valves are installed with the "Flow direction arrow "on the valve body pointing
in the correct direction. If the direction of the arrow is not marked on such valves, this shall
be done in the presence of Engineer-in-Charge before installation.
Fabrication of stem extensions, locking arrangements and interlocking arrangements of

valves (if called for), shall be carried out as per drawings/ instructions of Engineer-in-
Charge.
5.9 Instruments
Installation of in-line instruments such as control valve, orifice flange, rotameter, safety
valves, restriction orifice, rupture disc, de-super heaters, corrosion probes, annubar,
magnetic flow meter, ultrasonic flow meter, Coriolis mass flow meters, venturi PG/PT/
Flow transmitter, ejectors, etc. and Shut Down Valves with fireboxes shall form a part of
piping erection work.
Fabrication and erection of piping upto first block valve / nozzle / flange for installation of
offline Instruments for measurement of level, pressure, temperature, flow etc. shall also
form part of piping construction work. The limits of piping and instrumentation work will be
shown in drawings / standards / specifications. Orientations / locations of take-offs for
temperature, pressure, flow, level connections etc. shown in drawings shall be maintained.
Flushing and testing of piping systems which include instruments mentioned above and the
precautions to be taken are covered in flushing, testing and inspection of piping (EIL Spec.
6-44-0013). Care shall be exercised and adequate precautions taken to avoid damage and
entry foreign matter into instruments during transportation, installation, testing etc.
5.10 Line Mounted Equipments / Items
Installation of line mounted items like filters, strainers, steam traps, air traps,
desuperheaters, ejectors, samples coolers, mixers, flame arrestors, light glasses etc
including their supporting arrangements shall form part of piping erection work.
5.11 Bolts and Nuts
The Contractor shall apply molycoat grease mixed with graphite powder (unless otherwise
specified in piping classes) all bolts and nuts during storage, after erection and wherever
flange connections are broken and made-up for any purpose whatsoever. The grease and
graphite powder shall be supplied by the Contractor within the rates for piping work.
5.12 Pipe Supports
Pipe supports are designed and located to effectively sustain the weight and thermal effects
of the piping system and to prevent its vibrations. Location and design of pipe supports will
be shown in drawings for lines 2" NB & above. For lines 11/2"NB & below Contractor
shall locate and design pipe supports in line with EIL Stds. In case of IBR Lines 1 1/2"NB &
below only indicative supporting shall be provided & detailing of such supports is in
Contractor's scope. Contractor shall obtain approval of Engineer - in - Charge on drawings
prepared by Contractor, before erection. However, any extra supports desired by Engineer-
in-Charge shall also be installed.
Page 113 of 851

ENGINEERS
1~1 ,i,cmtJ9-0,-.1) IA Govt of InOla Undertaxng)
No pipe shoe / cradle shall be offset unless specifically shown in the drawings.
Hanger rods shall be installed inclined in a direction opposite to the direction in which the
pipe move during expansion.
Preset pins of all spring supports shall be removed only after hydrostatic testing and
insulation is over. Springs shall be checked for the range of movement and adjusted if
necessary to obtain the correct positioning in cold condition. These shall be subsequently
adjusted to hot setting in operating condition. The following points shall be checked after
installation, with the Engineer-in-Charge and necessary confirmation in writing obtained
certifying that:
- A11 restraints have been installed correctly.

- Clearances have been maintained as per support drawings.
- Insulation does not restrict thermal expansion.
- A11 temporary tack welds provided during erection have been fully removed.
- All welded supports have been fully welded.
Page 114 of 851

ENGINEERS INSPECTION, FLUSHING AND
rif
INDIA UMITED 6-44-0013 Rev. 5
IA GPM of In Undettalting) TESTING OF PIPING SYSTEMS Page 1 of 9
trrftrr fiwrz4 P-Faqur, ~r air

ttqui 1-11vich fq-raftr

INSPECTION, FLUSHING AND
TESTING OF PIPING SYSTEMS
REAFFIRMED & ISSUED AS STANDARD

5 31.07.18 PK frS7
1 MI RKT
SPECIFICATION
REVISED & ISSUED AS STANDARD
4 01.07.13 UK SH RN ATD DM
SPECIFICATION
3 27.08.07 RN ATD DM VC
SPECIFICATION
PMI REQT. INCLUDED AND ISSUED AS
2 05.06.03
STANDARD SPECIFICATION RN DM BN SKG
REAFFIRMED AND ISSUED AS STD.
1 15.09.98 SH BRB NS AS
SPECIFICATION
Standards Standards
Prepared Checked
No by by
Approved by
Page 115 of 851

STANDARD SPECIFICATION STANDARD SPECIFICATION
ENGINEERS FOR INSPECTION, FLUSHING No.
if INDIA LIMITED
) IA Gore of India Undertaking) AND TESTING OF PIPING 6-44-0013 Rev. 5
SYSTEMS Page 2 of 9
Abbreviations:
ASME : The American Society of Mechanical Engineers
IBR : Indian Boiler Regulations
PMI : Positive Material Identification
ppm Parts per million
SS Stainless Steel
Convenor : Mr. M. Ismaeel
Members : Mr. Amrendra Kumar

Mr. G. Balaji
Mr. Udayan Chakravarty
Mr. K.J. Harinarayanan (S&ME)
Mr. S. Ghosal (Process-2)
Mr. G.K. Iyer (Projects)
Mr. Pankaj Kumar Rai (Construction)
Mr. S. C. Maity (Structural)
Page 116 of 851

daaeieldik
r- ENGINEERS FOR INSPECTION, FLUSHING No.
51&.41 kitiReglilir INDIA LIMITED 6-44-0013 Rev. 5
1.11OPI rRONVotratItooll (A Govt of Mr Undertaking) AND TESTING OF PIPING
SYSTEMS Page 3 of 9
CONTENTS
1.0 SCOPE 4
2.0 REFERENCES 4
3.0 INSPECTION 4
4.0 FLUSHING 4
5.0 PRESSURE TESTING 5
Page 117 of 851

31 ENGINEERS FOR INSPECTION, FLUSHING No.
feVieg
I 4.11VI 212Mre J,10,71)
INDIA LIMITED
(A Govt of Intha Undertaking) AND TESTING OF PIPING 6-44-0013 Rev. 5
SYSTEMS Page 4 of 9
1.0 SCOPE
This specification covers the general requirements for inspection, flushing and testing of piping
systems. However, testing of steam lines falling under IBR shall also be governed by Indian
Boiler Regulations.
Flushing and testing of all piping systems shall be witnessed by the Engineer-In-Charge.
2.0 REFERENCES
ASME B31.3 Process Piping
6-82-0002 Standard Specification for Positive Material Identification

(PMI) at Construction Sites
3.0 INSPECTION
During various stages and after completion of fabrication and erection, the piping system shall
be inspected by the Engineer-In-Charge to ensure that:
Proper piping material has been used.
PMI has been performed as per EIL specification '6-82-0002'.
Piping has been erected as per drawings and instructions of Engineer-In-Charge.
All supports have been installed correctly.
Test preparations mentioned in this specification have been carried out.
4.0 FLUSHING
Flushing of all lines shall be done before pressure testing.
Flushing shall be done by 'fresh potable water' or by 'dry compressed air wherever water
flushing is not desirable to clean the pipe of all dirt, debris or loose foreign material.
Required pressure for water flushing shall meet the fire hydrant pressure or utility water
pressure. For air flushing, the line/system shall be pressurized by compressed air at the required
pressure which shall be 3.5 kg/cm2 g maximum. The pressure shall then be released by quick
opening of a valve, already in line or installed temporarily for this purpose. This procedure
shall be repeated as many times as required till the inside of the pipe is fully cleaned.
In line instruments like control valves, orifice plates, rotameters, safety valves and other
instruments like thermowells which may interfere with flushing shall not be included in flushing
circuit.
The screens/meshes shall be removed from all permanent strainers before flushing.
Screens/meshes shall be reinstalled after flushing but before testing.
During flushing temporary strainers shall be retained. These shall be removed, cleaned and
reinstalled after flushing, but, before testing.
Page 118 of 851

ENGINEERS FOR INSPECTION, FLUSHING No.
Eit5teg TOY INDIA LIMITED 6-44-0013 Rev. 5
0., maw ret amen) (A Govl of Inch. Undenak.9) AND TESTING OF PIPING
SYSTEMS Page 5 of 9
In case any 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, equipments thus
included in the circuit shall be completely drained and dried with compressed air after flushing
is completed.
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.
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 equipments, electric
motors, instruments, electrical installations etc. in the vicinity of lines being flushed.
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:
Dropping 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.
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.
Records in triplicate shall be prepared and submitted by the contractor for each piping system
for the flushing done in the proforma provided/approved by the Engineer-in-Charge.
5.0 PRESSURE TESTING
Pressure testing, in general shall be as per clause 345 of ASME B31.3, unless otherwise
specified, herein. Lines carrying highly hazardous/poisonous fluids must have a sensitive leak
test. For IBR lines, ÌBR Regulations' shall also be followed.
5.1 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 equipments 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 vessels and other equipments.
Pumps, compressors and other rotary equipments 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 blockage. However, such lines
if provided with block valve shall be pressure tested up to the last block valve.
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.
Page 119 of 851

Ill6ki ENGINEERS No.
Ifgar lapteg FOR INSPECTION, FLUSHING
eIiikorenalJnonal IA Govt of India Undertaking) AND TESTING OF PIPING
SYSTEMS Page 6 of 9
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, draining such as orifice plates etc. shall not be
installed unless testing is complete.
Control valves shall not be included in the test system. Where bypasses are provided test shall
be performed through the bypass and/or necessary spool 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.
5.2 General Requirements / Test Preparation for Testing
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 programme, to enable him to be present for witnessing the test. The Contractor shall be
fully responsible for making arrangements with the local boiler inspector to witness the tests for
steam lines falling under IBR. IBR certificates for these tests shall be obtained in the relevant
IBR forms and furnished to the Engineer-in-Charge.
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 systems 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 exists due to any reasons, like absence of control valves, safety
valves, check valves etc. it shall be filled with temporary spools.
All joints welded, screwed or flanged shall be left exposed for examination during the test.
Before pressurizing 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 spools have been recovered 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.
Page 120 of 851

ENGINEERS
1=g-ar idOles INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 5
cleans' 0,13ER7.1) (A Govt of India UnOeflaking)
TESTING OF PIPING SYSTEMS Page 7 of 9
For lines containing check valves any of the following alternatives shall be adopted for
pressure testing:
Whenever possible pressurize up-stream side of valve.
Replace the valve by a temporary spool 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.
For check valves in lines P/2" and below flapper or seat shall be removed during
testing (if possible). After completion of testing the flapper/seat shall be refitted.
Gas lines when hydrostatically tested shall be provided with additional temporary supports
during testing as directed by the Engineer-in-Charge.
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/ cm2g 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 systems.
5.3 Testing Media, Test Pressure and Test Pressure Gauges
5.3.1 Testing Media
In general all pressure tests shall be hydrostatic using iron free water, which is clean and free
of silt. Maximum chloride content in water for hydrostatic testing for SS piping shall be 15-
20 ppm.
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.
If operating fluid in the line is much lighter than testing fluid, the additional weight of testing
fluid may render piping supports (as designed) inadequate. This will call for additional
temporary supports. The typical examples are flare and vapor lines. It is preferable that
hydrostatic testing is avoided in such systems and instead pneumatic testing may be specified.
Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene, methanol etc.
shall be used as the testing medium, with due consideration to the hazards involved. These test
fluids shall be specified in the line list given to the contractor.
Format No. 8-00-0001-F1 Rev. 0 Copyright DL — All rights reserved
Page 121 of 851

ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ir 056
fg-zwren INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 5
rf eme m..r.row)
TESTING OF PIPING SYSTEMS Page 8 of 9
5.3.2 Test Pressure
The hydrostatic/ pneumatic test pressure shall be as indicated in the line list or as per the
instruction of Engineer-in-Charge.
The selection of the piping system for one individual test shall be based on the following:
Test pressure required as per line list.
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.
5.3.3 Test Pressure Gauge
All gauges used for field testing shall have suitable range so that the test pressure of various
systems falls in 35% to 65% of gauge scale range. Pressure gage dial shall be minimum of 150
mm. Size of Bourdon shall not be less than 75% of nominal diameter of dial 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. Calibration certificate shall be furnished for the pressure
gages.
5.4 Testing Procedure
5.4.1 Hydrostatic 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 isolation valves shall be provided if valved vents, drains do not exist in the system.
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 pump discharge for guidance in bringing the system
to the required pressure.
The 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 not less than 10minutes. Test
pressure shall be released only after physical checking of all the joints and attachments are
completed, to permit thorough inspection of all joints and connections for leakage or signs of
failure. Any joint found leaking during a pressure test shall be retested to the specified
pressure after repair.
The pump and the piping system to be tested are to be provided with separate pressure
indicating test gauges.
Page 122 of 851

ENGINEERS
fsral
(11W!
acs
1731,1,1.11
INDIA LIMITED INSPECTION, FLUSHING AND
TESTING OF PIPING SYSTEMS
6-44-0013 Rev. 5
Page 9 of 9
Care shall be taken to avoid increase in the pressure due to temperature variation during the
test.
5.4.2 Pneumatic 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
joints can be examined for leaks.
All other details shall be same as per hydrotesting procedure (specified above).
5.5 Completion of Testing
After the hydrostatic test has been completed, pressure shall be released by opening the vents,
in a manner and at a rate so as not to endanger personnel or damage equipments.
All vents 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. In services like dry air, ethylene etc., small traces of water
can cause problem. For such lines hot air drying is to be done after hydro-test.
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 equipments (except rotary equipments).
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.
5.6 Test Records
Records in triplicate shall be prepared and submitted by the contractor for each piping system,
for the pressure test done in the proforma provided/approved by the Engineer-in-Charge.
Records shall also be submitted for the PMI undertaken as per EIL Std. Specification No.
6-82-0002.
Page 123 of 851

ENGINEERS FOR NON DESTRUCTIVE
0`-ar 2Ws INDIA LIMITED
IA Govt of indo Undertaking)
EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
9igrki41 aTteik:r~ trftur

aTr-
g~ra#

NON DESTRUCTIVE EXAMINATION
REQUIREMENTS OF PIPING
7 28.01.14 REVISED & ISSUED AS STD. SPECIFICATION PsgoyUK àH K N SC
6 20.10.10 REVISED & ISSUED AS STD. SPECIFICATION RN ATD SC DM ND
5 23.07.07 REVISED & ISSUED AS STD SPECIFICATION RN ATD DM VC
4 15.01.02 ISSUED IN CONFORMITY WITH STD PMS REV-4 RN AKG BN GRR
3 18.04.95 ISSUED IN CONFORMITY WITH STD PMS REV-2 MP AKG NS AS

Standards Standards
Committee Bureau
Rev. Prepared Checked
No by by
Approved by
Page 124 of 851

k31 ENGINEERS FOR NON DESTRUCTIVE
fgW la2"
4,1R 2320,12 ,151,1QPI
INDIA LIMITED
IP Govt of lntlia Undertakmg) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
Abbreviations:
AS Alloy Steel
ASTM : American Society for Testing & Materials
CS Carbon Steel
DP/LP : Dye/Liquid Penetrant
MP Magnetic Particle
PMS : Piping Material Specification
SS Stainless Steel

Mr. Amrendra Kumar
Mr. G. Balaji
Mr. Ajay Shrivastava
Mr. G.K. Iyer (Construction)
Page 125 of 851

ENQNEERS FOR NON DESTRUCTIVE
$"g-alaWs INDIA LIMITED
1.11,n 21~ fuLttivn.t, IA Govt of lorlo Unclertalong) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
CONTENTS
1.0 GENERAL 4
2.0 VISUAL EXAMINATION 4
3.0 NON DESTRUCTIVE EXAMINATION 6
4.0 TABLE-1 (with applicable Notes to Table-1) 7
Page 126 of 851

51g, ;
131
2[41
e
_g ENGINEERS FOR NON DESTRUCTIVE
I ~71 0.100,0 0/1300.0 A Go. 01 0100 Unde1101000 ) EXAMINATION REQUIREMENTS
1.0 GENERAL
1.1 Scope
This specification covers the general requirements for non destructive examination of
shop & field fabricated piping.
1.2 Related Codes & Engineering Standards
Referred codes / standards are as follows. Latest editions of the Codes/Standards referred
to shall be followed.
a) ASME Boiler & Pressure Vessel Codes, Section V & VIII (Div.1) including
addenda.
b) ASME B31.3
c) ASME B16.5
d) ASME B16.34
e) Standard Piping Material Specification, 6-44-0005
f) Welding Specification Charts for Piping Classes, 6-77-0005
g) Standard Specification for Fabrication & Erection of Piping 6-44-0012
h) ASTM EIO
i) Welding Specification for Fabrication of Piping, 6-77-0001
j) Design Guide for Radiography Requirements, 8-77-0010
k) Indian Boiler Regulations (IBR)
2.0 VISUAL EXAMINATION
2.1 Weld shall be visually inspected wherever accessible in accordance with the following
requirements:
a) Internal misalignment 1.5 mm or less
b) Cracks or lack of fusion not permitted
c) Incomplete penetration Depth shall not exceed the Lesser of 0.8mm or 0.2
times thickness of thinner component joined by
butt-weld. The total length of such imperfections
shall not exceed 38 mm in any 150 mm of weld
length.
d) Surface porosity and not permitted

exposed slag inclusions
(For nom. wall thickness
4.7 mm and less)
Page 127 of 851

2f5le'g w
1~1 a-1,cnr1.,.TRIs.
INDIA LIMITED
I A Govt of Incha Undettaiong1 EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
e) Concave root surface For single sided welded joints, concavity of the
root surface shall not reduce the total thickness
(Suck up) of joint, including reinforcement, to less than the
thickness of the thinner of the components being
joined.
Weld ripples irregularities 2.5 mm or less.
Lack of uniformity in bead 2.5 mm or less.

width
Lack of uniformity of leg 2.5 mm or less.

length
Unevenness of bead 2.0 mm or less.
Weld undercutting 0.8 mm or 1/4 thickness of thinner components

joined by butt weld, whichever is less. (shall be
smooth finished)
Overlap 1.5 mm or less
Bead deflection 2.5 mm or less
External weld reinforcement and internal weld protrusion (when backing rings are
not used) shall be fused with and shall merge smoothly into the component
surfaces. The height of the Lesser projection of external weld reinforcement or
internal weld protrusion from the adjacent Base material surface shall not exceed
the following limits:
Wall thickness of thinner Weld reinforcement or internal weld protrusion

component joined by butt (mm) max
weld (mm)
6.4 and under 1.6

Over 6.4 -12.7 3.2
Over 12.7 -25.4 4.0
Over 25.4 4.8
n) Throat thickness of fillet welds:
Nominal thickness of the thinner component x 0.7 or more.
o) Flattening
Flattening of a bend, as measured by difference between the nominal outside

diameter and minimum or maximum diameter at any cross section shall not
exceed 5 % of the nominal outside diameter of pipe.
P) Reduction of wall thickness
Reduction of wall thickness of a bend, as measured by difference between the

nominal thickness and minimum thickness shall not exceed 10 % of the nominal
wall thickness of pipe.
Page 128 of 851

$'1g-af la2es INDIA LIMITED 6-44-0016 Rev. 7
IA Govl ol Indo Undertalfing) EXAMINATION REQUIREMENTS
2.2 Welds having any of imperfections which exceed the limitations specified in various
clauses of 2.1 shall be repaired by welding, grinding or overlaying etc. Number of times
of repair welding for the same weld, however shall conform to applicable notes to Table
1- Note 6(b)b.5.
3.0 NON DESTRUCTIVE EXAMINATION
3.1 The type and extent of weld examination shall be in accordance with Table-1. A11 visual
and supplementary methods of girth weld examination shall be in accordance with ASME
B31.3 & the requirements of this standard specification.
3.2 Welds between dissimilar materials shall be examined by method & to the extent required
for the material having the more stringent examination.
Page 129 of 851

■
311 ENGINEEFZS FOR NON DESTRUCTIVE
22— eg INDIA LIMITED 6-44-0016 Rev. 7
■
~1,-xcrwan,rem) 1A Gov1 of Irwha Undellaiong) EXAMINATION REQUIREMENTS
4. TABLE-1 (with applicable notes)
TABLE 1 : CLASS, TYPE & EXTENT OF WELD EXAMINATION
INSPECTION CLASS: 1
INSPN. SERVICE MATERIAL P.NO. TEMP. PRESS. APPLICABLE TYPE OF TYPE OF WELD EXAMINED
CLASS (NOTE 3) DEG.0 CLASS PIPING EXAMINATION
B16.5/ CLASS
B16.34 GIRTH SOCKET ATTACH- FAB. FAB.
BUTT WELD MENT BRANCH WELDS
WELD (NOTE 2) WELD WELD OF
(NOTE 1) MITRES /
REDUC.
1 2 3 4 5 6 7 8 9 10 11 12 13
I CATEGORY 'D' CARBON 1 0 A3A, A3Y,

FLUID STEEL TO J2A, J3A,
SERVICE 186 A4Y, A5Y
AUSTENIC 8 - 29 150# A3K a)

UPTO 100% 100% 100% 100% 100%
S.S. TO VISUAL
186 10 55
KG/CM2
HDPE - 20 A1Z, A4Z,
TO ASZ. b)
--- 5°o 10%
50 LP (NOTE 4, 6,9,) —
CURPO 34 - 29
NICKEL TO
60
REMARKS FOR ABOVE TABLE :
1. LP TEST NOT APPLICABLE TO NON-METALLIC CLASSES.
2. MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
Page 130 of 851

Og-ar fddi-eg
I .R71,,,crt +1,1344.11
INDIA LIMITED
IA GoA Ot incha Undmi.kIn9) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTD.)
INSPECTION CLASS: II
INSPN. SERVICE MATERIAL P. TEM PRESS. APPLICABLE TYPE OF TYPE OF WELD EXAMINED
CLASS (NOTE 3) NO. P. CLASS PIPING EXAMINATION
DEG. B16.5/ CLASS
C B16.34 GIRTH SOCKET ATTACH FAB. FAB.
BUTT WELD -MENT BRANCH WELDS
WELD (NOTE 2) WELD WELD OF
(NOTE 1) MITRES/
REDUC.
1 2 3 4 5 6 7 8 9 10 11 12 13
II a) ALL SERVICES
COVERED UNDER CARBON 1 - 29 I50# TO AIA, BIA, DIA
INSPECTION STEEL TO 600# A6A, B6A,
CLASS-I, BUT, 427 A7A, A8A,
EXCEEDING A9A, B9A, D9A,
CATAGORY 'D' AIOA, AllA,
PR /T EMP A13A, BI3A,
LIMITATIONS. A15A, A20A,
A32A, B32A.
b) ALL SERVICES
OTHER THAN a) 100% I 00% 100% 100% 100%
THOSE COVERED VISUAL
UNDER
INSPECTION b)
CLASS-I BUT RADIOGRAPHY 5% --- --- 20%
NON-TOXIC, NOT (NOTE 5,6)
SUBJECTED TO
SEVERE CYCLIC c)
CONDITIONS. MP / LP (NOTE --- 5% -- 5% 20%
4,6,10,11)
c) TOXIC, NON-
LETHAL & LTCS -45 A4A, B4A, D4A d)
FLAMMABLE. TO HARDNESS NOTE 7 NOTE 7 NOTE-7 NOTE-7 NOTE-7
204
d) FLAMMABLE /
NON FLAMMABLE
& TOXIC / NON-
TOXIC; NOT
SUBJECT TO
SEVERE CYCLIC
CONDITIONS
AUSTENITIC 8 -29 AlK, BIK,DIK,

STAINLESS TO A6K, B6K,
STEEL 500 AlM, B1M,B3M,
AlN, 131N, B6N,
1. EXTENT OF HARDNESS TEST FOR Al 1A IS 100%..
2. MITRES & FABR1CATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
3. NOTE- 7 FOR HARDNESS IS NOT VALID FOR P. NO. 8.
Page 131 of 851

ENGINEEFZS FOR NON DESTRUCTIVE
1~71 C.1~21,61~) IA Govt Undertffitvv31 EXAMINATION REQUIREMENTS
INSPECTION CLASS: III
INSPN. SERVICE MATERIAL P. TEMP. PRESS. APPLICABLE TYPE OF TYPE OF WELD EXAMINED
CLASS (NOTE 3) NO. DEG.0 CLASS PIPING EXAMINATION
B16.5/ CLASS
B16.34 GIRTH SOCKET ATTACH FAB. FAB.
WELD (NOTE 2) WELD WELDS OF
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
III FIRE WATER CARBON I - 29 150# A33A, A33Y, a) 100% 100% 100%
100% 100%
AND IBR STEEL (FIRE TO TO VISUAL
SERVICES. WATER) 427 600#
b)
10% -- --- 50%
CARBON A2A, B2A, RADIOGRAPHY
STEEL (IBR) D2A. (NOTE 5,6)
c) 10%. --- 10% ---

LP / MP (NOTE
4,6,11)
d) NOTE 7 NOTE 7
NOTE 7 NOTE 7 NOTE 7
HARDNESS
FOR IBR SERVICE A2A, B2A & D2A NOTE- 8 IS ALSO APPLICABLE.
3. FOR A33A & A33Y FIRE WATER SERVICE, NOTE-12 IS ALSO APPLICABLE.
Page 132 of 851

$1g-ar 2a-eg INDIA LIMITED 6-44-0016 Rev. 7
1.11Z71 2.1~ LIA 3,121.41 IA Govl o7 Indo Undertaking) EXAMINATION REQUIREMENTS
INSPECTION CLASS: III (CONTD.)
B16.5/ CLASS
B16.34
GIRTH SOCKET ATTACH FAB. FAB.
(NOTE 1) MITRES /
REDUC.)
I 2 3 4 5 6 7 8 9 10 11 12 13
III ALL GENERAL C - 0.5 Mo

(CONTD) SERVICES STEEL. 3 a) 100% 100% 100% 100% 100%
EXCEPT THOSE 0.5 Cr _ 0.5 mo VISUAL
SUBJECT TO STEEL
SEVERE b)
ABOVE 150# 20% --- --- --- 50%
CYCLIC I TO 3 Cr Mo. 4 5A A1D, B1D, D1D RADIOGRAPHY
CONDITIONS. ' -29 TO (NOTE 5,6)
STEEL. BlE
600#
c)
C - 0.5 Mo 3 LP / MP (NOTE --- 20% --- 20% ---
STEEL (IBR). 4,6,11)
I - 3 Cr Mo 4,5A D2D d)
STEEL (IBR) HARDNESS NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7
FOR IBR SERVICE D2D NOTE- 8 IS ALSO APPLICABLE.
Page 133 of 851

$'1 gar 22- eg INDIA LIMITED
IHRn e,cnr, 451 IA Govl ol Incha Undenakbng) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
III ALL GENERAL 3 5 Ni STEEL 9B - 80 150# 100% 100% 100% 100% 100%
a)
(CONTD) SERVICES TO TO
VISUAL
EXCEPT THOSE 120 600#
SUBJECT TO
b)
SEVERE 10% --- -- 50%
RADIOGRAPHY
CYCLIC
(NOTE 5,6)
CONDITIONS.
c)
10% --- 10% --
LP / MP (NOTE
4,6,10,11)
d)
NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7
HARDNESS
REMARKS FOR ABOVE TABLE:
1. NOTE- 7 FOR HARDNESS IS NOT VALID FOR P. NO. 9B.
Page 134 of 851

Offleg INDIA LIMITED 6-44-0016 Rev. 7
(~, ofrovt IA Govl of loOla Undenalmg) EXAMINATION REQUIREMENTS
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
III ALL GENERAL ALUMINIUM 21 ALL 150#

(CONTD) SERVICES & TO
EXCEPT THOSE ALUMINIUM 25
SUBJECT TO BASE ALLOY a)
100% 100% 100% 100% 100%
SEVERE CYCLIC VISUAL
CONDITIONS. COPPER & 31
COPPER
BASE ALLOY
b) 20% --- --- -- 50ò
RADIOGRAPHY
(NOTE 5,6)
ALUMINIUM 35
BRONZE
-- 20% --- 20% ---

c)
LP / MP (NOTE
OTHER NON -- 4,6,10,11)
FERROUS
ALLOYS
Page 135 of 851

.311 L.1 ENGINEERS FOR NON DESTRUCTIVE
22-eg
1,117",r-fraw a.,~1)
INDIA LIMITED
IA Govt o11n0ia Undellakong) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
B16.5/ CLASS
B16.34 GIRTH SOCKET ATTACdFAB. FAB.
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
III SPECIAL CARBON 1 ALL 150# A16A, B16A,

(CONTD) SERVICES STEEL TO D16A, a) 100% 100% 100% 100% 100%
(NACE, 600# A19A, B19A, VISUAL
CAUSTIC) D19A
b)
RADIOGRAPHY 20% --- --- 50%
(NOTE 5,6)
c)
CARBON 150# A5A, B5A Lp / mp -- 20% 10% 20% --
SPECIAL STEEL TO (NOTE
SERVICES 300# 4,6,10,11,13)
( 0, H)
d) NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7

HARDNESS
SPECIAL AUSTENITIC 8 150# -

SERVICES STAINLESS TO
(NACE, STEEL 600#
CAUSTIC)
EXTENT OF HARDNESS TEST FOR CLASSES A5A & B5A IS 10% & FOR CLASSES A 1 6A, B 16A, D16A, A 1 9A, B19A & D19A IT
IS 100%.
Page 136 of 851

71n ENGINEEFZS FOR NON DESTRUCTIVE
fg-ar faae5
lèvRN JOtTolt
INDIA LIMITED
IA Govt ot Indo Undettalong) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
INSPECTION CLASS: IV
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
I 2 3 4 5 6 7 8 9 10 11 12 13
IV ALL SERVICES CARBON I ALL ABOVE E1A, F1A, a) 100%

100% 100% 100% 100%
OTHER THAN STEEL 600# E9A, F9A, VISUAL
SPECIAL E19A, Fl9A
SERVICES (O,H) b)
RADIOGRAPHY 100%
CARBON E2A, F2A. 100% --- - ---
(NOTE 5,6)
STEEL (IBR)
c)
LP / MP
100% 10% 100%
(NOTE 4,6,10,11) ---
d) NOTE 7
NOTE 7 NOTE 7 NOTE 7 NOTE 7
HARDNESS
1. FOR IBR SERVICE E2A & F2A NOTE- 8 IS ALSO APPLICABLE.
2. EXTENT OF HARDNESS TEST FOR CLASSES El 9A, FI9A IS 100% .
Page 137 of 851

IA Govt 01 inolta Undettaktog) EXAMINATION REQUIREMENTS
INSPECTION CLASS: IV (CONTD.)
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 11 12 13
IV ALL GENERAL C - 0 5 Mo 3 ALL ABOVE

(CONTD) SERVICES. STEEL 600# a)
100% 100% 100% 100% 100%
VISUAL
5 Cr - 9 Cr Mo 5B 150# TO A4F, A4G, B3F,
STEEL 600# B4F, B4G.
b)
100% --- --- -- 100%
RADIOGRAPHY
(NOTE 5,6)
13 Cr (TYPE- 6 ALL --
410 SS)
c)
--- 100% 1 0% 100% --
KILLED 1 UPTO ABOVE -- LP / MP
CARBON - 45 600# (NOTE 4,6,10,11)
STEEL
4,5A ALL F2D d)

I TO 3 Cr NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7
STEEL (IBR) HARDNESS
FOR IBR SERVICE F2D NOTE- 8 IS ALSO APPLICABLE..
MITRES & FABRICATED REDUCERS ARE PERMITTED ONLY IF SPECIFIED IN PMS.
Page 138 of 851

fg-ar dj-eg
1.1,771 ?:1721512" L151,1-05-41,
INDIA LIMITED
Iff GON of Incha Uncleflak,ng) EXAMINATION REQUIREMENTS
6-44-0016 Rev. 7
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
1 2 3 4 5 6 7 8 9 10 I1 12 13
SPECIAL CARBON 1 ALL ABOVE D5A, E5A, FSA 100%

IV SERVICES (O, H) STEEL 300#
(CONTD)
SERVICES 0 5 TO 9 CR 3, ALL ALL
SUBJECT TO Mo STEEL 4, —
100%
SEVERE CYCLIC 5A,
CONDITIONS 5B
SPECIAL 135D, D5D,
SERVICES D5E, ESE
(NACE, O, H, 100% 100% 100% 100%
VISUAL
CAUSTIC)
SERVICES 13 CR 6 —
SUBJECT TO STEEL b)
SEVERE CYCLIC (TYPE RADIOGRAPHY
CONDITIONS 410SS) 100% -- --- ---
(NOTE 5,6) NOTE 7
SERVICES 3 5 NI 9B —
SUBJECT TO STEEL c)
SEVERE CYCLIC LP / MP
CONDITIONS. --- 100% 10% 100%
(NOTE
SPECIAL — 4,6,10,11,13)
SERVICES
(NACE, O, H,
CAUSTIC) d)
NOTE 7 NOTE 7 NOTE 7 NOTE 7
SPECIAL NI ALLOYS 41, — HARDNESS
SERVICES 42,
(NACE, O, H, 43
CAUSTIC)
45 —
ALL SERVICES
1. NOTE-7 FOR HARDNESS IS NOT VALID FOR P.NO.9B.
2. EXTENT OF HARDNESS TEST FOR CLASS D5A, E5A AND F5A IS 10%.
Format No. 8-00-0001-F1 Rev. 0 Copyright — All rights reserved
Page 139 of 851

ENQNEERS FOR NON DESTRUCTIVE
IA GoA of Indo Underlakong) EXAMINATION REQUIREMENTS
B16.5/ CLASS
(NOTE 1) MITRES /
REDUC.)
I 2 3 4 5 6 7 8 9 10 11 12 13
SERVICES AUSTENITIC
IV SUBJECT TO STAINLESS 8 ALL ALL --
(CONTD) SEVERE STEEL
CYCLIC a)
CONDITIONS 100% 100% 100% 100% 100.%0
VISUAL
LOW TEMP. BELOW 150# A2K, B2K,
SERVICE - 45 300# & D2K
600# b)
100% - -- -- 100%
RADIOGRAPHY
GENERAL ALL ABOVE -- (NOTE 5,6)
SERVICES 600#
c)
-- 100% 10% 100%
HIGH TEMP. > 500 ALL B4K, BSK LP / MP (NOTE
SERVICES 4,6,10,11)
SPECIAL ALL ALL B5M d)

- -
SERVICES (0,H) HARDNESS -
Page 140 of 851

fèrffleg INDIA LIMITED 6-44-0016 Rev. 7
Ivozn ASI Ja-4.1) IA Govt of Incha Undertaking) EXAMINATION REQUIREMENTS
Applicable Notes to Table-1
Branch welds shall consist of the welds between the pipe & reinforcing element (if any),
nozzles & reinforcing element and the pipe & nozzle under the reinforcing element.
Reinforcing element to be interpreted as pads, saddles, weldolets, sockolets etc.
2. Seal welds of threaded joints shall be given the same examination as socket welds.
3. Unless specifically stated, all materials shall be for "Non-IBR" service.
4. Magnetic Particle & the Liquid Penetrant method of examination shall be in accordance
with Section V of the ASME Boiler and Pressure Vessel Code, Article VII and VI
respectively. The entire area of the accessible finished weld surface shall be examined.
Selected root runs, subject to a maximum of 10%, before finished weld, may also be
examined, at the discretion of the engineer-in-charge.
a) Wherever MP / LP testing is specified, either MP or LP test may be used. But

wherever only MP test is specified, LP method of examination may be used only
if MP examination is impracticable in the field as concurred by EIL site-in charge.
b) "Random 5%" of Liquid Penetrant / Magnetic Particle test shall mean testing, by
applicable test, one weld for each twenty welds or less made by the same welding
procedure. "Random 10%" shall mean testing, by applicable test, one weld for
each ten welds or less made by the same welding procedure. Similarly "Random
20%" shall mean testing, by applicable test, one weld for each five welds or less
made by the same welding procedure.
c) When Liquid Penetrant examination is specified, the surface shall be free of

peened discontinuities.
d) Inspection shall be performed in the welds excluding those for which radiography
has been done.
e) Girth weld, branch weld, attachment weld & socket weld of 3-1/2% Ni steel shall
be Liquid Penetrant tested only when welded with austenitic material where MP
test has been specified.
5. Radiography:
a) "Random 5%, 10% or 20% radiography" shall mean examining not less than one
from each 20 welds or less in case of "Random 5% radiography", 10 welds or less
in case of "Random 10% radiography", one from each five welds or less in case of
"Random 20% radiography" made by the same welding procedure. Irrespective of
percentage, no. of welds to be radiographed shall be minimum 1. However first
two welds made by each welder shall also be radiographed in case of "Random
radiography". Welds selected for examination shall not include flange welds and
shall be radiographed for their entire length. However, where it is impossible or
impracticable to examine the entire weld length of field welds for either random
or 100% radiography, and if the same impossibility is agreeable to EIL site-in-
charge, then a single 120 deg. exposure of the weld length may be given a
Magnetic Particle test or Liquid Penetrant test. However in such cases for
ferro-magnetic materials, only MP test shall be acceptable for classes higher than
600#.
b) In-process examination shall not be substituted for any required radiographic

examination.
Page 141 of 851

,31 ENGINEERS FOR NON DESTRUCTIVE
fgzTr g INDIA LIMITED 6-44-0016 Rev. 7
,~n a,rort a,~) IA Govt ol Incha Undettak.g) EXAMINATION REQUIREMENTS
c) Number of radiography per one circumferential weld shall be as per ASME Sec.V
Articles 2 and 22.
6. When radiography or other non destructive inspection is specified, acceptance criteria for
repairs or defects shall be as follows:
a) In case of 1 00eY0 examination, any unacceptable weld shall be repaired and

reinspected.
b) If required random examination reveals a defect requiring repair, then:
b. 1 Two additional examinations of same type shall be made of the same kind
of item (if welded joint, then by the same welding procedure or operator
or both).
b.2 If the group of items examined as required by b.1 above is acceptable, the
items requiring repair shall be repaired or replaced and reexamined as
required and all items represented by this additional examination shall be
accepted.
b.3 If any of the items examined as required by b.1 above reveals a defect
requiring repair, two further comparable items shall be examined for each
defective item found by examination.
b.4 If all the items examined as required by b.3 are acceptable, the items
requiring repair shall be repaired or replaced and reexamined as required,
and all items represented by this further examination shall be accepted.
b.5 Number of times repair welding could be done for the same weld before
acceptance shall be as follows:
Material No. of times repair welding is allowed
C.S. upto 300 # 3 or less
C.S. above 300 # 2 or less
Killed steel 2 or less
Low alloy steel 2 or less
Austenitic S.S. 2 or less
3.5 Ni steel 2 or less
Al & Al base alloy 2 or less
Cu & Cu base alloy 2 or less
Others 2 or less
b.6 Welds not found acceptable for allowed number of times of repair as per
b.5 above shall be replaced and reexamined.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — AII rights reserved
Page 142 of 851

Ilf ENGINEERS FOR NON DESTRUCTIVE
$Rz-1~1ir2TlQT7 +151~1) INDIA LIMITED 6-44-0016 Rev. 7
IA GoA ol Intha UndeAolongI EXAMINATION REQUIREMENTS
b.7 If any of the items examined as required by b.4 above reveals a defect
requiring repair, all items represented by these examinations shall be
either :
- repaired or replaced and reexamined as required.
- fully examined and repaired or replaced as necessary, and

reexamined as necessary.
7. Hardness Test:
a) Hardness test shall be in accordance with ASTM specification E10.

Hardness tests of the heat affected zone shall be made at a point as near as
practicable to the edge of the weld. One test per weld shall be performed.
b) Hardness test where specifically called out in Table-1 of this specification

or in PMS, shall be carried out irrespective of thickness and to the extent
(%age) as mentioned therein.
c) A11 welds which are given heat treatment shall be hardness tested.
Hardness test shall be performed after final heat treatment.
d) A minimum of 10% of welds, hot bends, and hot formed components in

each furnace heat treated batch and 100% of those which are locally heat
treated shall be hardness tested.
e) Hardness test requirement not covered in this specification shall be as per

ASME B31.3.
f) The hardness limit applies to the weld and heat affected zone. Following
hardness values shall be maintained:
Base Metal Group Maximum

Hardness
(BHN/RC)
CS 238BHN/RC22
CS (NACE) , Caustic, 200BHN

Amine, H2
Cr Upto 2% 225BHN
Cr 2.25%-10% 241BHN
18/8 SS (NACE) RC22
g) In case hardness values are mentioned in both Welding Specification

Charts for Piping Classes, (6-77-0005) & table given in Note-7(f), the
lower of the two values shall be applicable.
8. For IBR service lines, following IBR requirements shall apply in addition to the notes 4, 5, 6,
7, 12 and Table 1. In case of conflict between above notes and these requirements, the more
stringent ones shall apply. IBR piping shall be erected of IBR inspector approved material and
Page 143 of 851

/01 ENGINEERS FOR NON DESTRUCTIVE
OgL
ar 2e5 INDIA LIMITED 6-44-0016 Rev. 7
■awrt vtevort tol,rosvi) IA Govt of InO. Uneef taking) EXAMINATION REQUIREMENTS
construction procedure. Erected piping shall be hydrotested, inspected and approved by IBR
inspector.
a) Piping over 102 mm (4") bore:
10')/0 of welds made by each welder on a pipeline with a minimum of two welds per
welder, selected at random, shall be subjected to radiography.
b) Piping 102 mm (4") bore and under, but not less than 38 mm (1-1/2") bore:
Two percent of welds made by each welder on a pipeline with a minimum of one weld
per welder, selected at random, shall be subjected to radiography or may be cut for
visual examination and tests.
c) Piping less than 38 mm (1.5") bore:
Special tests are not normally required but 2% of welds by each welder on a pipe line
may be cut out from the pipeline for the visual examination and bend tests.
d) Retests:
If any test specimen is unsatisfactory, two further weld specimens for retests shall be
selected from the production welds and subjected to tests. In the event of failure of
any retest specimens, the production welds carried out by this welder subsequent to
the previous test shall be given special consideration.
9. For fabricated fittings LP test shall be done on the final pass of welding only, in addition to
visual examination.
10. For mitres and fabricated reducers, LP / MP test shall be done on root pass in addition to
radiography applicable to circumferential joint of respective piping class.
11. For branch connections, LP/MP test shall be done on root pass and final pass.
12. 10% of the butt weld joints shall be radiographed, however, 50% of these butt weld joints
shall be field weld joints.
13. All joints including butt weld joints for Al 6A, B16A and D16A classes shall be wet
fluorescent magnetic particle tested. Percentage of wet fluorescent magnetic particle testing of
butt weld joints shall be 100% and this testing shall be in addition to radiography.
14. For lined specs, testing (MP/LP/Radiography etc.) shall be performed before lining.
Page 144 of 851

STANDARD SPECIFICATION No.
ENGINEERS TECHNICAL NOTES FOR
5fg-ar I~-3
dg INDIA LIMITED PIPES 6-44-0051 Rev. 6
IA GoN of Indo Undeflakng)
Page 1 of 10
lebri ch i•JA
TECHNICAL NOTES
FOR PIPES

6 25.09.14
SPECIFICATION SH' K ATD(‘'\:' SC
5 31.12.13
SPECIFICATION UK SH AK RN SC
4 04.07.08
SPECIFICATION RN SC DM VC
3 15.03.00 RN BRB NS AS
SPECIFICATION
HYDROTEST & I.G.C. TEST CLAUSES
2 04.04.94 AKG BPV GRR AS
REVISED
Standards Standards
Committee Bureau
No by by
Approved by
Page 145 of 851

INDIA LIMITED PIPES 6-44-0051 Rev. 6
rivvottt.1.5trool, IA Govt ot Intha Undertalfing)
Page 2 of 10
Abbreviations:

API American Petroleum Institute
ASTM American Society for Testing & Materials
BHN Brinell Hardness Number
BIS Bureau of Indian Standards
E.FS.W Electric Fusion Weld
E.R.W Electric Resistance Weld
HAZ Heat Affected Zone
HIC Hydrogen Induced Cracking
IGC Inter Granular Corrosion
IS Indian Standard
LT Low Temperature
MR Material Requisition
NACE MR National Association of Corrosion Engineers : Material Requirement
NB Nominal Bore
NPT Nominal Pipe Thread
PR Purchase Requisition
SMYS Specified Minimum Yield Strength
SS Stainless Steel

Mr. Amrendra Kumar
Mr. G. Balaji
Page 146 of 851

$;fgW 2154- INDIA LIMITED PIPES 6-44-0051 Rev. 6
1+fV7R rwnrt ,151,70541, IA Govl of lodia Undeftalong)
Page 3 of 10
CONTENTS
1.0 GENERAL 4
2.0 IBR PIPES 6
3.0 ACCEPTABLE DEVIATIONS 7
4.0 HYDROSTATIC TEST 7
5.0 MARKING AND DESPATCH 10
6.0 REFERENCES 10
Page 147 of 851

2f5le'g INDIA LIMITED
IA Govl ol lnaia Undertakog)
PIPES 6-44-0051 Rev. 6
Page 4 of 10
1.0 GENERAL
1.1 A11 pipes and their dimensions, tolerances, chemical composition, physical properties, heat
treatment, hydrostatic test and other testing and marking requirements shall conform to the
latest codes and standards specified in the material requisition (MR). Supplier shall strictly
comply with MR/PR stipulations and no deviations shall be permitted. Post Order
Concession/Deviation Permit 5-0000-0180-F1 as mentioned in Cl. 5.18 of Specification for
Quality Management System Requirements from Bidders (6-78-0001) is not applicable.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the applicable material
specifications. Test reports shall also be furnished for any supplementary tests as specified in
the MR & Clauses 1.10 & 1.11.
1.2.2 Material test certificates (physical property, chemical composition & heat treatment report)
shall also be furnished for the pipes supplied.
1.2.3 PMI shall be performed as per the scope and procedures as defined in the spec for PMI at
Supplier's Works (6-81-0001).
1.2.4 Refer to specification nos. 6-81-0002 and 6-81-0003 for Inspection & Test plans for welded
pipes and seamless pipes respectively.
1.3 Manufacturing Processes
1.3.1 Steel made by acid Bessemer process shall not be acceptable.
1.3.2 A11 longitudinally welded pipes should employ only automatic welding.
1.4 Pipe shall be supplied in single or double random length of 4 to 7 and 7 to 14 meters
respectively.
1.5 a. Seamless and E.R.W. pipes shall not have any circumferential seam joint in a random
length. However, in case of E.FS.W pipe, in one random length one welded
circumferential seam of same quality as longitudinal weld is permitted. This weld
shall be at least 2.5 m from either end. The longitudinal seams of the two portions
shall be staggered by 90°. Single random length in such cases shall be 5 to 7 m.
b. Unless otherwise mentioned in the respective material code, E.FS.W pipes < 36" shall
not have more than one longitudinal seam joint and E.FS.W pipes 36" shall not
have more than two longitudinal seam joints.
1.6 Pipe with screwed ends shall have NPT external taper pipe threads conforming to
ASME/ANSI B1.20.1 up to 1.5" NB & IS 554 for 2" to 6" NB.
Page 148 of 851

INDIA LIMITED PIPES 6-44-0051 Rev. 6
wlrrT t,vcrtV ItISOIstt ) IA Govt ol Intlia Gott000k,o9)
Page 5 of 10
1.7 Pipe with beveled ends shall be in accordance with ASME B16.25. Weld contours shall be as
follows:
Material Wall Thickness Weld Contour

Up to 22 mm Figure 2 Type A
Carbon Steel (Except
Low Temp. Carbon Steel) > 22 mm Figure 3 Type A
Up to 10 mm Figure 4
Alloy Steel,
Stainless Steel & > 10 mm & Up to 25 mm Figure 5 Type A
Low Temp. Carbon Steel
> 25 mm Figure 6 Type A
1.8 Galvanized pipes shall be coated with zinc by hot dip process conforming to IS 4736 / ASTM
A 153.
1.9 All austenitic stainless steel pipes shall be supplied in solution annealed condition. All types
of 321 or 347 stainless steel pipes shall be in a stabilized heat treated condition. Stabilizing
heat treatment shall be carried out subsequent to the normal solution annealing. Soaking time
& holding temp. for stabilizing heat treatment shall be 4 hrs & 900°C respectively.
1.10 I.G.C. Test for Stainless Steels
1.10.1 For all austenitic stainless steel pipes inter-granular corrosion test shall have to be conducted
as per following:
ASTM A262 Practice "B" with acceptance criteria of "60 mils/year (max.)".
OR
ASTM A262 Practice E with acceptance criteria of no cracks at 20X magnification and
microstructure to be observed at 250X magnification shall ensure the absence of any cracks/
fissures. When testing is conducted as per practice 'E' photograph of microstructure shall be
submitted for record.
1.10.2 When specifically asked for in MR for high temperature application of some grades of
austenitic stainless steel (eg.SS 309, 310, 316, 316H etc.) ASTM A262 Practice "C" with
acceptance criteria of "15 mils/year (max.)" shall have to be conducted.
1.10.3 For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shall be drawn from each
solution annealing lot; one set corresponding to highest carbon content and the other set
corresponding to the highest pipe thickness.
All welded pipes indicated as `CRY0' & `LT' in MR shall be impact tested per requirement
& acceptance criteria of ASME B31.3. The impact test temperature shall be -196°C & -45°C
for stainless steel and carbon steel respectively unless specifically mentioned otherwise in
MR.
1.12 NACE/HIC Requirements
1.12.1 Pipes under "NACE" category and those designated as "HIC1" shall meet the requirements
given in NACE MR-0103 unless mentioned otherwise.
1.12.2 Pipes made from plates and designated as "HIC1" shall meet the HIC requirements of EIL
specification 6-79-0013 unless mentioned otherwise.
Page 149 of 851

`51
1 ENGINEEFZS TECHNICAL NOTES FOR
5fga 02-eg INDIA LIMITED PIPES 6-44-0051 Rev. 6
1.11UR ertcnt ,TR,1-4.1) Ift Govt of UnciertaNingf
Page 6 of 10
1.13 Specified heat treatment for carbon steel and alloy steel and solution annealing for stainless
steel pipes shall be carried out after weld repairs. Number of weld repairs at the same spot
shall be restricted to maximum two by approved repair procedure.
1.14 For black or galvanized pipes to IS 1239, the minimum percentage of elongation shall be
20%.
1.15 All 1Cr-V2Mo and 11/4Cr-1/4Mo seamless pipes shall be normalised and tempered.
1.16 For all welded alloy steel pipes with mandatory requirement of heat treatment and
radiography, radiography shall be performed after heat treatment.
1.17 For Hydrogen service pipes following special requirements shall also be met:
1.17.1 All carbon steel pipes having wall thickness 9.53 mm (0.375") and above shall be normalised.
Cold drawn pipes shall be normalised after the final cold draw pass for all thicknesses.
1.17.2 All alloy steel (Cr-Mo) pipes shall be normalised and tempered. The normalising and
tempering shall be a separate heating operation and not a part of the hot forming operation.
The maximum room temperature tensile strength shall be 100,000 psig.
1.17.3 For carbon steel Pipes, hardness of weld and HAZ shall be 200 BHN (max.). For alloy steel
Pipes, hardness of weld and HAZ shall be 225 BHN (max.).
1.17.4 For all austenitic stainless steels, the weld deposit shall be checked for ferrite content. A
Ferrite No.(FN) not less than 3% and not more than 10% is required to avoid sigma phase
embrittlement during heat treatment. FN shall be determined by Ferritescope prior to post
weld heat treatment.
1.17.5 For all Carbon steel and Alloy steel pipes with wall thickness over 20mm, Charpy-V Notch
impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section
VIII, Div-1 for weld metal and base metal from the thickest item per heat of material and per
heat treating batch. Impact test specimen shall be in complete heat treated condition and
accordance with ASTM A370. Impact energies at 0°Celsius shall average greater than 27J (20
ft-lb) per set of three specimens, with a minimum of 19J (15 ft-lb).
1.18 For dual grades of SS where specified, chemical composition and mechanical properties of
both grades specified shall be ensured.
2.0 IBR PIPES
2.1 IBR Documentation
2.1.1 Pipes under purview of IBR shall be accompanied with IBR certificate original in Form III-A
duly approved and countersigned by IBR authority/local authority empowered by the Central
Boiler Board of India(Photocopy of the original certificate duly attested by the local boiler
inspector where the supplier is located is the minimum requirement for acceptance) or Form
III-D [for well known pipe manufacturers as per IBR] signed by Manufacturer's authorized
representative. Well known pipe manufacturers, as recognized by IBR, shall submit a duly
attested copy of Form XVI-G along with Form
2.1.2 For materials 11/4Cr - V2Mo (ASTM A335 Gr.P11 / A691 Gr.11/4Cr), 21/4Cr - 1Mo (ASTM
A335 Gr.P22 / A691 Gr.21/4Cr) & 9Cr -1Mo-V (A335 Gr.P91/A691 Gr.91), Form III-A
approved by IBR shall include the tabulation of Et, Sc & Sr values for the entire temperature
range given below. Et, Sc & Sr values shall be such that throughout the temperature range
Page 150 of 851

$R-ar 22-eg
1.177, rrmrr an s~›
INDIA LIMITED
IA Govt ot India Undertalfingt
PIPES 6-44-0051 Rev. 6
Page 7 of 10
E,/ 1.5
Sr / 1.5 SA
Sc
where ,
SA Allowable stress at the working metal temperature.

Yield point (0.2% proof stress at the working metal temperature)
S, The average stress to produce elongation of 1%(creep) in 100000 hrs at the
working metal temperature.
Sr The average stress to produce rupture in 100000 hrs at the working metal
temperature and in no case more than 1.33 times the lowest stress to produce
rupture at this temperature.
SA (psi)
Temp(°F)
500 600 650 700 750 800 850 900 950 1000 1050 1100
Material
A335 Gr.P11 17200 16700 16200 15600 15200 15000 14500 12800 9300 6300 4200 2800
A691 Gr.11/4Cr 18900 18300 18000 17600 17300 16800 16300 15000 9900 6300 4200 2800
A335 Gr.P22 /
17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
A691 Gr.21/4Cr
A335 Gr.P91/
28100 27700 27300 26700 25900 24900 23700 22300 20700 18000 14000 10300
A691 Gr.91
Note : SA values shall be as per the latest edition prevai ing.
2.2 For carbon steel pipes under IBR the chemical composition shall conform to the following:
Carbon (max) 0.25%

Others (S, P, Mn) As prescribed in IBR.
The chemical composition as indicated in this clause is not applicable for pipes other than IBR
services.
3.0 ACCEPTABLE DEVIATIONS
3.1 Pipes to IS 3589 Gr.410 are acceptable in place of IS 3589 Gr.330.
3.2 Pipes of Grades SS317 of corresponding material are acceptable in place of Grades SS316 or
SS316(2.5 Mo min.).
3.3 Pipes of Grades SS317L of corresponding material are acceptable in place of Grades SS316L
or SS316L(2.5Mo min.).
3.4 Seamless pipes are acceptable in place of welded pipes except in the case of welded
SS321/SS321H pipes with nominal thickness greater than 9.53mm.
4.0 HYDROSTATIC TEST
4.1 A11 pipes shall be hydrostatically tested.
Page 151 of 851

~_le7 ENGINEERS TECHNICAL NOTES FOR
• e5 INDIA LIMITED
IA Govt of Incha Undertalting)
PIPES 6-44-0051 Rev. 6
Page 8 of 10
4.2 The mill test pressure shall be as follows:
4.2.1 Seamless, E.R.W. & Spiral Welded
a) Carbon Steel
Material Std. Test Pressure Std.
ASTM A106 Gr.B ASTM A530
API 5L Gr.B, Seamless API 5L
API 5L, E.R.W. API 5L
API 5L, Spiral API 5L
ASTM A333 Gr.3 & 6, Seamless ASTM A530
ASTM A333 Gr.3 & 6, E.R.W. ASTM A530
b) Seamless Alloy Steel
ASTM A335 Gr.P1, P12, P11, P22, P5, P9 ASTM A530
ASTM A268 TP 405, TP410 ASTM A530
c) Seamless Stainless Steel

ASTM A312 Gr.TP 304, 304L, 304H, 316, ASTM A999
316L, 316H, 321, 347
d) Seamless Nickel Alloy
ASTM B161 UNS No. 2200 ASTM B161
e) Welded Nickel Alloy
ASTM B725 UNS No. 2200,4400 ASTM B725
Page 152 of 851

0141
-eg INDIA LIMITED
IA Govt of Indo UnclertaNngt
PIPES 6-44-0051 Rev. 6
Page 9 of 10
4.2.2 Electric Fusion Welded
a) Carbon Steel & Alloy Steel E.FS.W (16" & above)

API 5L Gr.B P = 2ST/D
ASTM A671 Gr.CC65, 70 (C1.32) S = 90% of SMYS
ASTM A672 Gr.C60, 65, 70 (CI.12,22) Except for API 5L Gr.B
ASTM A671 Gr.CF60, 65, 66, 70 (C1.32) S = 85% of SMYS
ASTM A691 Gr.V2Cr, 1Cr, 11/4Cr, 21/4Cr, For API 5L Gr.B
SCr, 9Cr (C1.42) T = Nominal Wall Thickness
D = O.D of Pipe
b) Stainless Steel E.FS.W (2" to 6")
The hydrostatic test pressure in kg/cm2 for the following materials shall be as given
below :
Material Gr.1 :ASTM A312 TP 304 / 304H / 316 / 316H / 321 / 347 welded.
Material Gr.2 :ASTM A312 TP 304L / 316L welded.
Size Pipe Schedule : 10S Pipe Schedule : 40S Pipe Schedule : 80S
Material Material Material Material Material Material
Gr. 1 Gr.2 Gr.1 Gr.2 Gr.1 Gr.2
2" 100 80 155 130 230 190
3" 80 60 155 130 230 190
4" 80 50 155 130 230 190
6" 65 35 90 75 155 130
c) Stainless Steel E.FS.W (8" and above).

ASTM A358 TP 304L, 304, 304H, 316L, P = 2ST/D
316, 316H, 321, 347 (Classes 1, 3 & 4) S = 85% of SMYS
T = Nominal Wall Thickness
D = O.D of Pipe
ASTM A358 TP 304L, 304, 304H, 316L, P = 2ST/D
316, 316H, 321, 347 (Classes 2 & 5) S = 72% of SMYS
T = Nominal Wall Thickness
D = 0.D of Pipe
4.2.3 Carbon Steel Pipes to BIS Standards

IS 1239 IS 1239
IS 3589 IS 3589
4.3 Hydrostatic pressure testing shall be performed using iron free water, which is clean and free
of silt. Maximum chloride content in water for hydrostatic testing for SS piping shall be 50
ppm.
Page 153 of 851

OrcRes
1
.1,P+,,
M11 J457,01/
INDIA LIMITED
IA GoN ol India UnclettaMing)
PIPES 6-44-0051 Rev. 6
Page 10 of 10
5.0 MARKING AND DESPATCH
5.1 All pipes shall be marked in accordance with the applicable codes, standards and
specifications. In addition the purchase order number, the item code & special conditions like
"IBR", "CRY0", "NACE", "H2" etc. shall also be marked.
5.2 Pipes under "IBR","CRY0", "NACE" & "H2" shall be painted with one circumferential
stripe of colour red, light purple brown, canary yellow & white respectively for easy
identification. Width of stripe shall be 12mm for pipe sizes lens than 3" and 25mm for pipes
3" and above.
5.3 Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc, lead
or copper which cause corrosive attack on heating.
5.4 Pipes shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.
5.5 Pipes shall be protected from rust & corrosion.
5.6 Rust preventive used on machined surfaces to be welded shall be easily removable with a
petroleum solvent and the same shall not be harmful to welding.
5.7 Both ends of the pipe shall be protected with the following material:
Plain end Plastic cap

Bevel end Wood, Metal or plastic cover
Threaded end Metal or plastic threaded cap
5.8 Pipes may be provided with plastic push-fit type end caps/ steel caps without belt wire.
5.9 Steel end protectors to be used on galvanized pipes shall be galvanized. Plastic caps can also
be used as end protectors for galvanised pipe ends.
6.0 REFERENCES
6.1 6-81-0001: Specification for Positive Material Identification (PMI) at Supplier's Works.
6.2 6-81-0002: Inspection & test plan for welded pipes.
6.3 6-81-0003: Inspection & test plan for seamless pipes.
6.4 6-79-0013: Material requirements for carbon steel components used in sour service for
petroleum refinery environments
Page 154 of 851

ENGINEERS TECHNICAL NOTES
fg0j1 fetWeg INDIA LIMI TED FOR VALVES 6-44-0052 Rev. 7
(A Govt of India Undertaking)
Page 1 of 12
vilcni rd uAluiii*
TECHNICAL NOTES FOR VALVES
7 13.07.17
REVISED AND ISSUED AS STANDARD 01/4
SPECIFICATION ‘ )t.144<-1 MI RN
6 04.08.10
SPECIFICATION RN ATD SC DM ND
5 04.07.08 RN SC DM VC
SPECIFICATION
4 15.11.00 RN BRB NS MI
SPECIFICATION
3 04.04.94 ISSUED IN LINE WITH GENERAL REVISION AKG NS GRR AS
Standards Standards
Committee Bureau
No by by
Approved by
Page 155 of 851

taleg
ailErf t-recnr11513‘grai
INDIA LIMITED
FOR VALVES 6-44-0052 Rev.7
Page 2 of 12
Abbreviations:
AARH : Arithmetic Average Roughness Height

ASTM : American Society for Testing & Materials
BGO Bevel Gear Operator
BHN Brinnel Hardness Number
BS • British Standard
BVIS ▪ Bureau Veritas Industrial Services
BW • Butt Weld
CAT • Category
CEIL • Certification Engineers International Limited
CS Carbon Steel
DFT Dry Film Thickness
DNV Det Norske Veritas
DP Dye-Penetrant
eDMS : Electronic Document Management System
IS Indian Standard
LT • Low Temperature
LTCS • Low Temperature Carbon Steel
MOV • Motor Operated Valve
MP • Magnetic Particle
MR • Material Requisition
NDT • Non Destructive Testing
PMI • Positive Material Identification
PO Purchase Order
RFQ Request for Quotation
SCRD : Screwed
SS Stainless Steel
SW Socket Weld
Convenor : Mr M. Ismaeel

Mr. G. Balaji
Mr. S. Ghoshal (Process-2)
Mr. Pankaj Kumar Rai (Construction)
Page 156 of 851

1f lots
Igar 0151-e-G INDIA LIMITED
tole,r rievore tri.ltrovn) (A Govt of India Undertaking)
Page 3 of 12
CONTENTS
1.0 GENERAL 4
2.0 DOCUMENTATION 4
3.0 DESIGN AND CONSTRUCTION 5
4.0 OPERATION 9
5.0 INSPECTION AND TESTING 9
6.0 RADIOGRAPHY OF CAST VALVES 10
7.0 IBR CERTIFICATION 11
8.0 MARKING 11
9.0 DESPATCH 11
10.0 ATTACHMENTS 12
11.0 REFERENCES 12
Page 157 of 851

LIIdel ENGINEERS TECHNICAL NOTES
$1gziT tif4leg INDIA LIMITED FOR VALVES 6-44-0052 Rev.7
MIRFC eleax, 45134115-41) IA Govt of Ind ia Undertaking)
Page 4 of 12
1.0 GENERAL
1.1 Vendor shall supply valves in accordance with the valve specification sheets along with
auxiliaries, if any, such as gear operator, bypasses, drains, locking arrangements etc. wherever
specified in the specification sheets, subject notes and other enclosures to the material
requisition (MR).
1.2 Vendor shall quote in strict accordance with the valve data / specification sheets, subject
technical notes and all other enclosures to the MR. For 'Cat-I valves', no deviations
whatsoever shall be accepted. Post Order Waiver/ Deviation format 5-0000-0180-F1 as
mentioned in Cl. 5.17 of specification for Quality Management System Requirements from
Bidder (6-78-0001) is not applicable for Cat-I valves. For Cat-II Valves, if exceptions/
deviations become absolutely must, the same shall be requested as explained in clause 2.3.6
giving reasons for seeking such exceptions/ deviations.
1.3 All codes and standards for manufacture, testing, inspection etc. shall be of latest editions as
on issue date of RFQ.
2.0 DOCUMENTATION
2.1 All document submissions to EIL shall be through EIL eDMS.
2.2 For 'Cat-I' valves, no documents shall be submitted with the offer.
2.3 For 'Cat-IF valves, vendor shall submit the following documents with the offer:
2.3.1 Manufacturer's complete descriptive and illustrative catalogue / literature.
2.3.2 Detailed dimensioned cross section drawing with parts / material lists, weight etc.
2.3.3 Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator,
motor, extension bonnet, extended stems with stands, bypass etc. giving major salient
dimensions.
2.3.4 One copy of the valve specification sheets signed as "Accepted" by the manufacturer.
Deviations, if any shall be marked as applicable on the valve specification sheet.
2.3.5 If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve
specification sheets as "Regret" or "No Deviation".
2.3.6 For 'CAT-II' valves, if there is any deviation, the same shall be listed clausewise.
2.3.7 On failure to submit documents as specified in clauses 2.1.1 to 2.1.6 above, the offer is likely
to be rejected.
2.4 The following documents shall be submitted through eDMS of EIL after placement of the
order:
2.4.1 For Cat-I valves to manufacturers' standard specified in MR/valve specification sheet,
detailed dimensioned cross section drawing with parts, materials, weight, etc. shall be
submitted for records/information.
Page 158 of 851

laffaad ENGINEERS TECHNICAL NOTES
$/fg-ar kites INDIA LIMITED FOR VALVES 6-44-0052 Rev.7
(Merl e4tax,...13,63.0 (A Govt of India undertaking)
Page 5 of 12
2.4.2 For 'Cat-II' valves, Vendor shall submit for review drawings mentioned in clauses 2.1.2 &
2.1.3 before start of manufacture. No other drawings shall be submitted for review.
2.4.3 Test report shall be supplied for all mandatory tests as per the applicable code. Test reports
shall also be furnished for any supplementary tests as specified in clauses 3.13, 3.14 & 3.15.
2.4.4 Material test certificates (physical properties, chemical composition & heat treatment report)
of the pressure containing parts shall be furnished for the valves supplied. Material test
certificates for the other parts shall also be furnished for verification during inspection.
2.5 In addition to submissions through EIL eDMS, Catalogues/Drawings shall be in submitted in

hard copies (6 sets) and soft copies (2 CDs/DVDs) along with delivery for Purchaser's record
for all categories/types of valves.
3.0 DESIGN AND CONSTRUCTION
3.1 Valve shall be designed, manufactured, tested, inspected and marked as per the manufacturing
standards, design codes and standards indicated in the respective valve specification sheets.
Any conflict between the requisition, enclosures, specification sheets and referred standards/
codes shall be brought to the notice of the purchaser for clarifications and resolution, before
proceeding with the manufacture. The purchaser's decision shall be final and binding to the
vendor. The drawings submitted for review shall not include any deviations except as
communicated in writing in Deviation permits. The Drawings shall be reviewed only for
design and construction features.
3.2 All flanged valves shall have flanges integral (except forged valves) with the valve body.
Flange face finish shall be normally specified in the valve specification sheet as 125 AARH
etc. The interpretation for range of face finish shall be as follows:
Stock Finish : 1000 p. in AARH max.

125 AARH : Serrations with 125 to 250 p in AARH
63 AARH : 32 to 63 p. in AARH
33 For all weld end valves with bevel end as per ASME B 16.25, the contour of bevel shall be as
follows:

Carbon Steel (Except Upto 22 mm Figure 2 Type A
Low Temp. Carbon Steel)
Alloy Steel, Upto 10 mm Figure 4
Stainless Steel &
Low Temp. Carbon Steel > 10 mm & Upto 25 mm Figure 5 Type A
Valve ends shall match thickness of the connecting pipe. Sloping of inside contour of valves
shall be done wherever necessary to achieve this.
Page 159 of 851

r..11 feitReg
411M eiecnte J,,RfrA
INDIA LIMITED
IA Govt or India Undertaking)
Page 6 of 12
3.4 For flanged valves with ring joint flanges the hardness shall be as follows:
Flange Material Min. Hardness of Groove (BHN)

Carbon Steel 140
1% Cr to 5% Cr, 9% Cr 150
Type 304, 316, 321, 347 160
Type 304L, 316L 140
3.5 Following requirements for check valves shall be met over and above the valve specification
sheet requirements:
3.5.1 Unless specified otherwise in the data sheet all check valves 3" & above (except in 900#,
1500# & 2500# rating) shall have a drain boss at location "G" (Refer Fig.No.1 of ASME
B16.34) where pocket is formed in valve body. A tapped drain hole with plug shall be
provided as per ASME B 16.34. Threads shall be as per ASME B 1.20.1 (Taper) NPT.
3.5.2 For heavy check valves, provisions shall be available for lifting by way of lugs, eye bolts and
other such standard devices.
3.6 If an overlay weld-deposit is used for the body seat ring seating surface, the corrosion
resistance of the seat ring base material shall be at least equal to the corrosion resistance of the
material of the shell.
3.7 Following valve bypass requirements shall be met:
3.7.1 By-pass requirement for Gate valves shall be as follows unless otherwise mentioned.
ASME 150 Class On sizes 26" and above

3.7.2 The by-pass piping arrangement shall be such that clearance between main valve body and by-
pass assembly shall be the minimum possible for layout reasons. Vendor shall follow the
sketch enclosed in Specification No. 6-44-0052-Al.
3.7.3 By-pass valve shall be a globe valve. The sizes shall be as under:
On main valve 4" 1/2"

On main valve 6" to 8" 3/4"
On main valve 10" & above 1"
By-pass piping shall be of same metallurgy as main valve. The by-pass piping, fittings and
valve tag numbers shall be as specified in Specification No. 6-44-0052-A2. In case details of
by-pass arrangement for any Valve tag number is missing, Vendor shall bring the same to
notice of EIL and provide by-pass as per details specified.
3.7.4 Vendor shall supply the by-pass valve duly tested and fitted to the main valve. Valves with
by-pass shall have the direction of flow marked on the main valve. By-pass attachment to the
Page 160 of 851

, 31 ENGINEERS TECHNICAL NOTES
Ogell ttfaeg INDIA LIMITED
IA Govt of India Undertaking)
Page 7 of 12
main valve body shall not be screwed. All fillet welds for by-pass installation shall be 100%
examined by DP/MP test and Butt-weld joints shall be 100% examined by radiography.
3.8 Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of
casting but not vice-versa.
3.9 Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However,
integral stem of cast material is acceptable for Plug valves.
3.10 Stelliting / hardfacing by deposition, shall be minimum 1.6 mm.
3.11 Renewable seat rings shall be seal welded for valves of size 3" and above to prevent loosening
in service.
3.12 For Low Temperature & Cryogenic valve requirements, refer Specification.No.6-44-0052-A3
unless otherwise specified.
3.13 For Hydrogen service valve requirements, refer Specification.No.6-44-0052-A4 unless

otherwise specified.
3.14 Valves under `NACE' category shall meet the requirements specified in MR-0103 unless
3.15 For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall be conducted
as per the following:
3.15.1 ASTM A262 Practice 'B' with acceptance criteria of '60 mils/year (max.)' for all materials -
forged, rolled, wrought and casting.
Or
ASTM A262 Practice È' with acceptance criteria of 'No cracks as observed from 20X
magnification' for all materials other than castings. 'Microscopic structure to be observed
from 250X magnification' in addition.
austenitic stainless steel (eg. SS309, 310, 316, 316H etc.) ASTM A262 Practice 'C' with
acceptance criteria of ' 15 mils/year (max.)' shall be conducted.
3.15.3 For the IGC test as described in Clauses 3.15.1 & 3.15.2, two sets of samples shall be drawn
from each solution annealing lot. One set shall correspond to the highest Carbon content and
the other to the highest pressure rating. When testing is conducted as per practice È',
photograph of the microscopic structure shall be submitted for record.
3.16 All types of 321 or 347 stainless steel valves shall be in a stabilised heat treated condition.
Stabilising heat treatment shall be carried out subsequent to the normal solution annealing.
Soaking temperature and holding time for stabilising heat treatment shall be 900°C and 4
hours respectively.
3.17 Spiral wound bonnet gaskets are to be provided with inner/outer ring except when
encapsulated gaskets type body-bonnet joints are employed. Outer ring may be avoided in
case of non-circular spiral wound gasket used in 150# valve provided the outermost layer of
spiral touches the bolts ascertaining the centering.
3.18 All Stainless Steel Castings shall be solution heat treated.
Page 161 of 851

101 tGI J ENGINEERS TECHNICAL NOTES
Ogen EtOleg S INDIA LIMITED
IrkRer eteakeott3tratTO (A Govt of India Undertaking)
Page 8 of 12
3.19 Only normalized and tempered material shall be used in the following specifications :
Castings A217 Gr.WC1, A217 Gr.WC4, A217 Gr.WC5, A217 Gr.WC6, A217
Gr.WC9, A217 Gr.C5, A217 Gr.C12
Forgings : A182 Gr.F11 C1.2, A182 Gr.F12 C1.2
3.20 Ball / Plug / Butterfly Valves
3.20.1 As a prequalification, fire safe test as per API 607 / API 6FA / BS EN ISO 10497 (Supersedes
BS 6755 Part II) shall be carried out on soft seated ball, plug & butterfly valves and also on
lubricated plug valves The test shall be witnessed and certified by a third party inspection
agency like Lloyds, BVIS, DNV or EIL/ CEIL unless otherwise specified. The vendor has to
submit test certificate for the particular design of the valve offered, if fire safe design is
required as per the Valve Material Specification sheet..
3.20.2 Each valve shall be supplied with a lever / wrench except for gear operated / motor operated
valves.
3.20.3 Soft-seated ball, plug & butterfly valves shall be supplied with antistatic devices.
3.20.4 BW / SW end ball valves shall have a 100 mm long seamless pipe nipple welded to each end
of the valve. Nipples are to be welded prior to assembling Teflon seats / seals. Specifications
of the nipples shall be as indicated in the MR.
3.20.5 The face-to-face dimensions of all ball valves shall be same as those of gate valves of the
corresponding ANSI class (except 10" onwards in Class 150 where the face-to-face
dimensions shall be as per API 6D long pattern).
3.20.6 The ball of ball valve shall not protrude outside the end flanges of valve.
3.20.7 Ball valves shall be of floating ball/trunnion mounted type as per following:
150# 8" & below Floating ball

10" & above Trunnion mounted
300# 4" & below Floating ball

6" & above Trunnion mounted
600# 1.5" & below Floating ball

& above 2" & above Trunnion mounted
3.20.8 Unless otherwise specified in the data sheets, bore of all reduced bore ball valves shall be
limited to one size lower than the nominal bore.
3.21 The MOVs are to be installed in an open area and the actuators shall be suitable for all
weather conditions. The testing of complete assemblies of MOVs along with the actuators
shall be done by the supplier at his works.
3.22 Ends of flanged valves of 22" size shall match corresponding flanges to MSS-SP44 unless
3.23 Yoke material shall be same as bonnet material where maximum temperature specified is
more than 427°C.
Page 162 of 851

/gar Ea&
(ORR MEW MI 3‘17.3)
INDIA LIMITED
(A Govt. of India undertaking,
Page 9 of 12
4.0 OPERATION
4.1 Gear operation shall be provided as under:
Valve Type Class Size Requiring Gear-Operator

Gate Valve, Globe Valve & 150 Class 12" and larger
Diaphragm Valve 300 Class 12" and larger
600 Class 10" and larger
Ball Valve / Plug Valve 150 Class 6" and larger
(Other than pressure balance 300 Class 6" and larger
plug valves)
Butterfly Valve 150, 300 Class 6" and larger
For sizes lower than these ranges, hand wheel / lever / wrench shall be provided. For pressure
balance plug valves manufacturer's recommendation shall be acceptable provided the
requirements specified in clause 4.6 are met.
4.2 Gear operator shall be provided, with position indicators for open / close positions and with
limit stops. (Limit stops are not applicable for gate and globe valves).
4.3 Where gear operator is not called for as per Clause 4.1 but vendor recommends a gear
operator, the same shall be highlighted.
4.4 Gear operator shall be so designed as to operate effectively with the differential pressure
across the closed valve equal to the cold non-shock pressure rating.
4.5 Ball, plug and butterfly valves, shall have "Open" position indicators with limit stops.
4.6 Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on
either side. Effort to operate shall not exceed 35 Kg at handwheel periphery. However, failing
to meet the above requirements, vendor shall offer gear operated valve and quote as per clause
4.3.
5.1 Every valve shall be subjected to all the mandatory tests and checks called in the respective
codes / data sheet by EIL inspection or any third party as approved by the purchaser. For IBR
valves refer clause 7.0.
5.2 Every valve, its components and auxiliaries must be subjected to all the mandatory tests and
checks called for in the respective codes, data sheets etc. by the manufacturer.
5.3 Though the extent of inspection shall be as under, exact extent with hold points shall be
decided by EIL regional inspection office and recorded in the form of inspection plan. In case
of third party inspection, the inspection plan shall be approved by the purchaser.
Page 163 of 851

Reie?(7
ENGINEERS
-A TECHNICAL NOTES
Ogelf idaeg INDIA LIMITED
eIreel ,too e MI OW.) IA Govt of India Undertaking)
Page 10 of 12
Forged Valves:
1. Visual and dimensional inspection.

2. Review of material test certificates.
3. Any mandatory or supplementary test.
4. Hydrostatic test on 10% valves selected on random basis.
5. Strip check is required for 1% of total ordered quantity of Gate & Globe valves (min. 1
No.) for each Valve sheet no., however, strip check is not required for CS/ Brass/ Bronze
material valves with 13% Cr/ Brass/ Bronze trims.
Cast Steel Valves:
1. Visual and dimensional inspection.

2. Review of material test certificates.
3. Review of radiographs/radiographic reports or any other NDT tests wherever applicable
as per data sheet.
4. Any mandatory or supplementary test.
5. Hydrostatic test 100% for body, 10% other test.
6. Strip check is required for 1% of total ordered quantity of Gate & Globe valves (min. 1
No.) for each Valve sheet no., however, strip check is not required for CS/ Brass/ Bronze
material valves with 13% Cr/ Brass/ Bronze trims.
Samples for strip check shall be selected at random and shall generally be in the highest
size in the lot.
5.4 In case of motor operated or actuator operated valves, functional / operational checks as per
the requirements of the specifications shall be made on each valve.
6.0 RADIOGRAPHY OF CAST VALVES
6.1 Valve castings shall undergo radiographic examination as specified below.
Material Rating Size Range Radiography

All 150# 24" and below NIL**
26" and above* 100%
300# 16" and below NIL**
18" and above 100%
600# & above All sizes 100%
* No radiography is required for valves of size 26" and above in cooling water service.
**For sizes 24" & below in 150# and 16" & below in 300#, radiography percentage if
specifically mentioned in individual valve material spec sheet shall govern.
Radiography specified as random 10% or 20% etc. in the respective valve data sheet implies
10% or 20% etc. of number of valves ordered against each item number with a minimum of
one valve against each item.
Page 164 of 851

rn~r el ENGINEERS TECHNICAL NOTES
fEff5teg INDIA LIMITED
(A Govt of India Unclertalcing)
Page 11 of 12
6.2 Radiography procedure, areas of casting to be radiographed shall be as per ASME B 16.34 and
acceptance criteria shall be as per ASME B 16.34 Annexure-B. However for areas of casting
to be radiographed for types of valves not covered in ASME B 16.34, vendor shall radiograph
castings in line with ASME B 16.34.
6.3 For random radiography wherever specified in individual data sheets, the sampling shall be
per size of the quantity ordered for each foundry.
6.4 Radiography wherever specified in the data sheets or as per clause 6.1 shall be done by X-ray /
'y-ray to get the required sensitivity.
7.0 IBR CERTIFICATION
7.1 For valves described "IBR", valves shall be in accordance with the latest IBR (Indian Boiler
Regulation) including the requirements specified in the specification.
7.2 For SW / BW end carbon steel valves under IBR, the chemical composition shall conform to
the following:
Carbon (Max) 0.25%

Others (S, P, Mn) As per IBR
7.3 Valves coming under the purview of "IBR"(Indian Boiler Regulations) shall each be
individually accompanied by IBR certificate original in Form III-C duly approved by IBR
authority / local authority empowered by the Central Boiler Board of India. Photocopy of
original certificate duly attested by the local boiler inspector where the supplier is located is
the minimum requirement for acceptance.
7.4 All "IBR" valves shall be painted red in body-bonnet / body-cover joint.
8.0 MARKING
8.1 Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the
standard referred in specification sheet as applicable. Vendor's name, valve rating, material
designation, nominal size, direction of flow (if any) etc. shall be integral on the body.
8.2 Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely
attached to the valve body.
8.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead
8.4 Carbon Steel / Alloy Steel valves shall be painted with one coat of inorganic zinc silicate
(minimum DFT 65 to 75 microns).
9.0 DESPATCH
9.1 Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.
9.2 Valves shall be protected from rust, corrosion and any mechanical damage during
transportation, shipment and storage.
Page 165 of 851

,511faeieì Lfth ENGINEERS TECHNICAL NOTES
Q41 k1Rs INDIA LIMITED FOR VALVES 6-44-0052 Rev.7
Page 12 of 12
9.3 Rust preventive on machined surfaces to be welded shall be easily removable with a
petroleum solvent or shall not be harmful to welding.
9.4 Each end of valve shall be protected with the following materials:
Flange Face Wood or Plastic Cover

Bevelled End Wood or Plastic Cover
SW & SCRD. End Plastic Cap
9.5 End protectors of wood / plastic to be used on flange faces shall be attached by at least three
bolts and shall not be smaller than the outside diameter of the flange. However, plastic caps
for SW & SCRD end valves shall be press fit type.
9.6 End protectors to be used on bevelled end shall be securely and tightly attached.
9.7 For special service valves additional requirement for despatch shall be as prescribed in data
sheet.
10.0 ATTACHMENTS
6-44-0052-A 1 Bypass Piping Arrangement
6-44-0052-A2 Specifications for Bypass Piping, Fittings and Valves
6-44-0052-A3 Special Requirements for Low Temperature and

Cryogenic Valves
6-44-0052-A4 Special Requirements for Hydrogen Service Valves
11.0 REFERENCES
6-78-0001 Specification for Quality management system

requirements from bidders
6-78-0003 Specification for documentation requirements from

suppliers
6-81-0001 Specification for Positive Material Identification

(PMI) at Supplier's Works
6-81-0004 Inspection and Test plan for Valves
Page 166 of 851

1514-zA ENGINEERS BYPASS PIPING
51guttf54- ag
INDIA LIMITED
(4.,,,,,N,L15,78..) (A Govt of India Undertaking)
ARRANGEMENT 6-44-0052-Al Rev.7
Page 1 of 1
BYPASS PIPING ARRANGEMENT

L7
(minimum)
Bevel Gear
Operator (BGO)
L6
L5
L4
300 mm
(approx.)
Globe valve
for BOO valves
L3 as per spec.
sht. indicated
in the MR.
ote-8
150 mm
(approx.)
for non-BOO valves
L2 Pipe bend
Flow
L1
(minimum possible)
NOTES :
1. The orientation & location of handwheel of bevel gear operator & the bypass arrangement
shall be strictly as per this sketch.
2. The bypass connection ends shall be socket welded upto 600# and butt welded for 900#
and above rating.
3. The bypass arrangement shall be properly clamped to & supported by the body of the
main valve.
4. Basic design of bypass shall be to MSS-SP-45.
5. Material of bypass pipe & 90° elbows shall be same or equivalent to the body material as
indicated in Specification No. 6-44-0052-A2.
6. This sketch is applicable for both BGO & NON-BGO Valves.
7. Vendor shall furnish dimensions Ll to L8.
8. Stem shall not be horizontal in the case of CRYO Valves
Page 167 of 851

ENGINEERS SPECIFICATIONS FOR BYPASS
INDIA LIMITED PIPING, FITTINGS AND VALVES 6-44-0052-A2 Rev.7
I etecnie ref 34ore) (A Govt of India Undertaking)
Page 1 of 3
SPECIFICATIONS FOR BYPASS PIPING, FITTINGS AND VALVES
Bypass
Class (Main Valve Sht.no.) Pipe Fittings Valve
Sht.no.
A1A(51301), A3A(51321),
A9A(51301), A10A(51301), ASTM A106 Gr.B (SMLS) ASTM A105
Al 1A(51301), A33A(51301), 0.5"-0.75": S160 0.5"-0.75": SW 6000# 52001
B1A(51401), B9A(51401), 1.0"-1.5" : XS 1.0"-1.5" : SW 3000#
D1A(51501), D9A (51501)
ASTM A106 Gr.B (SMLS) ASTM A105
A6A(51301), B6A(51401) 0.5"-0.5" : XXS 0.5"-0.5" : SW 9000# 52001
0.75"-1.5": S160 0.75"-1.5": SW 6000#
A13A(51301), B13A(51401) 52001
0.5"-1.5" : XXS 0.5"-1.5" : SW 9000#
ASTM A106 Gr.B (SMLS)- IBR ASTM A105 - IBR
A2A(51302), B2A(51402), 52002
0.5"-0.75": S160 0.5"-0.75": SW 6000#
D2A (51502) 1.0"-1.5" : SW 3000#
1.0"-1.5" : XS
ASTM A350Gr.LF2-
ASTM A333 Gr.6 (SMLS)- LT
A4A (51303), B4A (51403), LT
0.5"-0.75": S160 52003
D4A (51503) 0.5"-0.75": SW 6000#
1.0"-1.5" : XS
1.0"-1.5" : SW 3000#
ASTM A106 Gr.B (SMLS) -H2 ASTM A105 - H2
A5A (51304), BSA (51404), 52004
0.5"-0.75": S160 0.5"-0.75": SW 6000#
D5A (51504)
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
A7A (51307) 0.5"-0.75" : S160 0.5"-0.75": SW 6000# 52007
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
ASTM A106 Gr.B (SMLS) -
ASTM A105 - NACE
Al6A (51311), B16A (51411), NACE
0.5"-0.5" : SW 9000# 52011
D16A (51511) 0.5"-0.5" : XXS
0.75"-1.5": SW 6000#
0.75"-1.5": S160
A19A (51313), B19A (51413),
0.5"-0.75" : 5160 0.5"-0.75": SW 6000# 52013
D19A (51513) 1.0"-1.5" : SW 3000#
1.0"-1.5": XS
ASTM A234 Gr.WPB/
ASTM A106 Gr.B (SMLS)
ElA (51601), FlA (51701) ASTM A105 52101
0.5"-1.5" : S160
0.5"-1.5" : BW, S160
ASTM A234 Gr.WPB/
ASTM A106 Gr.B (SMLS) - IBR
E2A (51602), F2A (51702) ASTM A105 - IBR 52102
1.5 : S160
0.5"-"
0.5"-1.5" : BW, S160
ASTM A234 Gr.WPB/
ASTM A106 Gr.B (SMLS) - H2
E5A (51604), F5A (51704) ASTM A105 - H2 52104
0.5"-1.5" : S160
0.5"-1.5" : BW, S160
ASTM A106 Gr.B (SMLS) ASTM A234 Gr.WPB/
0.5"-1.5" : SCH XXS ASTM A105
E9A (51605), F9A (51705) 52105
0.5"-1.5" : BW, SCH
XXS
ASTM A106 Gr.B (SMLS) ASTM A234 Gr.WPB/
0.5"-1.5" : SCH XXS ASTM A105
E19A (51613), F19A (51713) 52113
0.5"-1.5" : BW, SCH
XXS
Page 168 of 851

01 el ENGINEERS SPECIFICATIONS FOR BYPASS
Page 2 of 3
Bypass
Sht.no.
ASTM A106 Gr.B ;(SMLS) ASTM A105
A5Y (51384), A33Y (51384) 0.5"-1.5" : S160 ' 0.5"-1.5" : SW 6000# 52085
4
ASTM A182
ASTM A335Gr.P11(SMLS)
MD (51330), BM (51430), Gr.F11C1.2
0.5"-0.75" : S160 52030
D1D (51530) 0.5"-0.75": SW 6000#
1.0"-1.5": XS
1.0"-1.5" : SW 3000#
ASTM A335Gr.P11 (SMLS) - ASTM A182
IBR Gr.F11C1.2 - IBR
D2D (51531) 52031
0.5"-0.75" : S160 0.5"-0.75": SW 6000#
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
ASTM A182
ASTM 335Gr.P11(SMLS)- H2
Gr.F11C1.2 - H2
B5D (51432), D5D (51532) 0.5"-0.75" : S160 52032
0.5"-0.75": SW 6000#
1.0"-1.5": XS
1.0"-1.5" : SW 3000#
ASTM A182
ASTM A335Gr.P22(SMLS) 0.5"-
Gr.F22C1.3
BlE (51433) 0.75" : S160 52033
0.5"-0.75": SW 6000#
1.0"-1.5": XS
1.0"-1.5" : SW 3000#
ASTM A182
ASTM A335Gr.P22(SMLS) - H2
Gr.F22C1.3 - H2
D5E (51534) 0.5"-0.75" : S160 52034
0.5"-0.75": SW 6000#
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
ASTM A335 Gr.P5(SMLS) ASTM A182 Gr.F5
A4F (51336), B4F (51436) 0.5"-0.75" : S160 0.5"-0.75": SW 6000# 52036
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
B3F (51436) ASTM A335 Gr.P5(SMLS) ASTM A182 Gr.F5
52036
0.5"-1.5" : XXS 0.5"-1.5" : SW 9000#
ASTM A335 Gr.P9(SMLS) ASTM A182 Gr.F9 52039
A4G (51339), B4G (51439) 0.5"-0.75: SW 6000#
0.5"-0.75" : S160
1.0"-1.5": XS 1.0"-1.5" : SW 3000#
ASTM
ASTM A335 Gr.P11 (SMLS) - A234Gr.WP11C1.1/
F2D (51731) IBR A182 Gr.F11C1.2 - 52131
0.5"-1.5" : S160 IBR
0.5"-1.5" : BW, S160
ASTM
ASTM A335 Gr.P22(SMLS) -
A234Gr.WP22C1.1/
H2 52134
E5E (51634) A182 Gr.F22C1.3 - H2
0.5"-0.75" : S160
0.5"-0.75" : BW, S160
1.0"-1.5": XS
1.0"-1.5" : BW, XS
ASTM A312 TP304(SMLS) ASTM A182 Gr.F304
A1K (51345), A3K (51345), 0.5"-1.5" : SW 3000# 52045
0.5-0.75" : 80S
B1K (51445), D1K (51545)
1.0"-1.5": 40S
ASTM A312 TP304(SMLS) - ASTM A182 Gr.F304
A2K (51346), B2K (51446), CRY() - CRYO
52046
D2K (51546) 0.5"-0.75" : 80S 0.5"-1.5" : SW 3000#
1.0"-1.5": 40S
ASTM A182
ASTM A312 TP304H (SMLS)
B4K (51448), B5K (51448) Gr.F304H 52048
0.5"-1.5" : 80S
0.5"-1.5": SW 3000#
Copyright EIL — All rights reserved

Format No. 8-00-0001-F1 Rev. 0
Page 169 of 851

dl ENGINEERS SPECIFICATIONS FOR BYPASS
(anen eienne aA 3vpRil (A Govt of India Undertaking)
Page 3 of 3
Bypass
Sht.no.
ASTM A182
ASTM A312 TP304L (SMLS)
Gr.F304L
Gr.
A6K (51350), B6K (51450) 0.5"-0.75" : 80S 52050
0.5"-1.5": SW 3000#
1.0"-1.5": 40S
AIM (51361), B1M (51461) 0.5"-0.75" : 80S 0.5"-1.5": SW 3000# 52061
1.0"-1.5": 40S
ASTM A312 TP316H (SMLS) - ASTM A182
H2 Gr.F316H - H2
B5M (51462) 52062
0.5"-0.75" : 80S 0.5"-1.5": SW 3000#
1.0"-1.5": 40S
B3M (51463) 0.5"-0.75" : 80S 0.5"-1.5": SW 3000# 52063
1.0"-1.5": 40S
ASTM A182
ASTM A312 TP 316L (SMLS)
Gr.
Gr.F316L
A1N (51366), 131N (51466) 0.5"-0.75" : 80S 52066
0.5"-1.5": SW 3000#
1.0"-1.5": 40S
ASTM A182
ASTM A312 TP316L (SMLS) Gr.F316L
B6N (51471) 0.5"-0.75" : 80S 0.5"0.5"-1.5": SW 52071
1.0"-1.5": 40S 3000#
Page 170 of 851

SPECIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
iH6i ENGINEERS
51g-zufM5Veg INDIA LIMITED LOW TEMPERATURE & 6-44-0052-A3 Rev.7
own ,limiwre Mn .3P011) (A Govt of Me Undertaking)
CRYOGENIC VALVES Page 1 of 2
SPECIAL REQUIREMENTS FOR LOW TEMPERATURE & CRYOGENIC VALVES
1.0 SCOPE
All valves of Low Temperature Carbon Steel (LTCS) and all grades of austenitic SS
(CRYO) material are categorized as cryogenic valves. All these valves shall have
extended bonnet as per BS 6364 except check valves.
Following qualification criteria shall be met by the valve vendors to quote valves for
cryogenic services:
2.0 QUALIFICATION CRITERIA
i) Both cryogenic test (clause 2.1) and reference list (clause 2.2) together shall be
considered for vendor qualification and vendor shall furnish the same, along with his
offer.
ii) Vendors who do not have cryogenic test reports and reference list covering valves of
all sizes, materials and ratings required by MR, should confirm / furnish the following
for consideration of their offer:
a. Evidence of having conducted successfully at least one cryogenic test as per

BS 6364. Test certificate shall be furnished with the offer.
b. Vendor shall confirm to conduct cryogenic test per clauses 2.1 & 2.3 for the
remaining valves not later than 12 weeks from the date of purchase order.
c. Vendor shall also furnish reference list for valves supplied for non-cryo
service if reference list referred in 2.2.1 does not cover all the sizes of MR.
Offers of vendors who do not comply with above requirements would be rejected.
2.1 Cryogenic Test
Vendors to furnish copies of cryogenic test certificate for tests conducted as per details
given below:
2.1.1 Test shall be as per BS 6364.
2.1.2 Test temperature, unless specifically called for otherwise in the individual MR,
shall be -45°C for LTCS and -196°C for all grades of austenitic stainless steel.
2.1.3. Tests carried out on a particular size of one type of valve, pressure rating and
material shall qualify all sizes equal to and below the test valve size for the
same type, pressure rating and material. In case of austenitic SS any one grade
would qualify for all other grades of austenitic SS.
2.1.4. Tests should have been witnessed and certified by any one of the following
third party inspection agencies; M/s Lloyd, BV, DNV, TUV or EIL/ CEIL.
2.1.5. Cryogenic test need not be conducted for every order. Test conducted
previously and witnessed by inspection agencies listed above shall be
considered acceptable and need not be repeated.
Page 171 of 851

Gil ENGINEERS
eiC1 SPECIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
Ogeg tameg INDIA LIMITED
eieEDIZ an 3.7.1) IA Govt of India Undertaking)
LOW TEMPERATURE &
CRYOGENIC VALVES
6-44-0052-A3 Rev.7
Page 2 of 2
2.2 Reference List
Vendor shall furnish reference list for valves supplied for cryogenic service indicating the
name of client, year of supply, size, material, pressure rating, type of valve and quantity.
2.3 Post Order Testing Procedure
2.3.1. Before conducting post order testing, vendor shall submit the following for
approval:
a. Test procedure (as per BS 6364).

b. Cross-section drawing of the valve with material of construction.
c. Schematic of test rig (as per BS 6364) with complete details.
2.3.2. Test has to be conducted irrespective of the service on largest size for each type of
valve and for each material and class rating. Vendor shall offer one, two or three
valves for selection of test valve by inspector depending upon whether quantity of
largest valve in the order is one, two or three and more than three respectively.
In the event of failure of the test valve to meet the specification requirements, the
vendor shall conduct test on two more valves. These two valves which pass test
successfully, are of lower size, then the qualification will be valid only to sizes
upto which test has been conducted successfully.
2.3.3. In case of non-conductance of cryogenic test(s) within 12 weeks or failure in the

test(s) conducted after receipt of order, the owner reserves the right to invoke any
of the provisions of the purchase order including cancellation of the purchase
order at the risk and cost of vendor.
3.0 Bonnet extension, wherever specified in the valve sheet to BS 6364 shall be for "non
cold box application" unless otherwise specified in the MR. Even if not called for in
valve sheet, valves indicated as "LT" or "CRYO" shall be supplied with bonnet
extension.
4.0 Bonnet and Gland extension joints shall be of butt welded/integrally cast construction. I
5.0 Repair welding procedure for austenitic stainless steel valves in "CRYO" service shall
have to be qualified for impact test as per ASME B31.3. Minimum acceptable impact
energy shall be 20 J or lateral expansion of 0.38 mm at temperature of -196°C.
6.0 Wherever impact test of SS studs / nuts is called for in the data sheet, the impact value
shall be 27 J at the intended service temperature specified in the data sheets.
Page 172 of 851

‘31 ENGINEERS SPECIAL REQUIREMENTS FOR
Ogelftlf5teg INDIA LIMITED HYDROGEN SERVICE VALVES 6-44-0052-A4 Rev.7
OMR e9eeR2,1313‘10.1) (A Govt of India Undertaking)
Page 1 of 2
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE
1.0 GENERAL
1.1 These requirements are applicable for valves used in Hydrogen service. These are in
addition to the requirements described in "Technical Notes for Valves" Spec. No. 6-44-
0052, and shall be read in conjunction with this specification.
1.2 All cast valve flanges & bodies with flange rating of Class 900 or greater shall be
examined in accordance with paragraphs 7.2 through 7.5 of Appendix-VII of ASME
SEC-VIII, DIV.1, regardless of casting quality factor.
1.3 Body / bonnet / cover joints & stuffing box of all valves shall have low emission. One
valve per metallurgy, per rating, per size shall be helium leak tested as per ASME Sec.V,
Subsection A, Article 10 (Detector Probe Technique), Appendix IV at a minimum of
25% of the allowable (rated) cold working pressure. Selection of valves for helium leak
test shall be at random. Test duration shall be as follows:
Test Duration in Minutes

Pressure Class
Nominal Size
Upto 300 600 800 & 900 1500 2500
Upto 2" 3 6 9 12 12
3" to 6" 6 9 12 15 18
8" to 16" 9 9 12 15 18
18" to 24" 9 12 15 18 21
The valve shall show no leakage. No leakage is defined as a total leakage rate of less than
0.0001 ml/s of helium.
2.0 Only normalized and tempered material shall be used in the following specifications:
Castings A217 Gr.WC1, A217 Gr.WC4, A217 Gr.WC5, A217 Gr.WC6, A217
Gr.WC9, A217 Gr.C5, A217 Gr.C12
Forgings A182 Gr.F11 C1.2
3.0 CS & AS VALVES
3.1 Bend test and Magnetic Particle inspection of the entire surface of body and bonnet
casting shall be in accordance with ASTM A217. Supplementary requirement S3 & S4
evaluation of magnetic particle, inspection shall be in accordance with MSS-SP-53
except that no linear discontinuities shall be allowed.
3.2 The Brinell hardness of heat treated casting shall not exceed 200 BHN for carbon steel &
225 for alloy steel.
3.3 Repair to defective casting shall be outlined in writing to the purchaser before repair
starts. Repair method to be approved prior to welding.
3.4 Casting shall be preheated to a minimum of 400°F prior to welding and all Chromium-
Molybdenum alloys shall be postweld heat treated after welding is complete. Stress
relieving is essential for welds.
Page 173 of 851

t3t
77.1) ENGINEERS SPECIAL REQUIREMENTS FOR
fell5reg
(7
Oge.il INDIA LIMITED HYDROGEN SERVICE VALVES 6-44-0052-A4 Rev.7

Page 2 of 2
3.5 Carbon steel shall be normalised and alloy steels shall be normalised & tempered.
3.6 Dye Penetrant test of welds shall be in accordance with ASTM B165 Procedure B-2.
Interpretation as per Appendix-8 of ASME-VIII Div. 1.
3.7 The tensile stress for AS shall be less than 100,000 psi.
3.8 Charpy V-notch impact testing is to be done for valve material (average 20 ft-lb for set of
3 [minimum value 15 ft-lb] at 30°F).
3.9 For radiography and acceptance criteria for valve castings, refer Cl. 4.2.
4.0 SS VALVES
4.1 Valve casting shall be in solution heat treated and pickled condition.
4.2 Critical body and bonnet casing section typically defined by ASME B 16.34 shall be
radiographed and shall meet ASTM E446 (upto 2" thick) Category A, B & CA Level 2,
Category CB, OC & CD Level 3, Category D, B & F Level 0. For wall thickness 2" to
4.5" comparable plates of ASTM E186 shall be used. ASTM E94 and ASTM E142 shall
be used for recommended practice & controlling quality of radiography as guide. The
entire surface of all castings shall be dye-penetrant inspected after pickling.
4.3 Welds shall be 100% radiographed and evaluated in accordance with paragraph 344.5 of
ASME B31.3 with a minimum casting quality factor of 0.95. Dye Penetration test shall
be as per ASTM E165 Procedure B-2, Interpretation as per Appendix-8 of ASME-VIII
Div.l.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — An rights reserved
Page 174 of 851

TECHNICAL NOTES FOR STANDARD SPECIFICATION No.
, k31 ENGINEERS FLANGES, SPECTACLE BLINDS
$'1g-af INDIA LIMITED 6-44-0053 Rev. 6
237,1,
17 ,
151 ,R,A) IA GoN of Inda Undeflakng) AND DRIP RINGS Page 1 of 7
• •
4ct-cb(Net cs)(Yi
41
f- n1 CfrielChr FU I 1T
TECHNICAL NOTES FOR FLANGES,

SPECTACLE BLINDS AND DRIP RINGS
i
6 25.09.14 REVISED & ISSUED AS STD SPECIFICATION SH AK
/RN ATNNo SC
5 31.12.13 REVISED & ISSUED AS STD SPECIFICATION UK SH AK RN SC
4 04.07.08 REVISED & ISSUED AS STD SPECIFICATION RN SC DM VC
3 01.11.00 REVISED & ISSUED AS STD SPECIFICATION RN BRB NS MI
2 04.04.94 I.G.C. TEST CLAUSE REVISED AKG BPV GRR AS
Standards Standards
Committee Bureau
No by by
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL—All rights reserved
Page 175 of 851

ENGINEERS
5gar fa2eg INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 6
1.1r, vomooJosnytt IA Govt ot InO. Undellakoog)
AND DRIP RINGS Page 2 of 7
Abbreviations:
AARH Arithmetic Average Roughness Height

AWWA American Water Works Association
IS Indian Standard
MSS Manufacturer's Standardization Society

Mr. Amrendra Kumar
Mr. G. Balaji
Page 176 of 851

k31•-1 ENGINEERS
$gt-LIE IM2-- INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 6
1.41,1c,,DrO0,
13OO,-.0 11, Tool ol InO. Undonok■o9)
CONTENTS
1.0 GENERAL 4
2.0 IBR REQUIREMENTS 6
5.0 REFERENCES 7
Page 177 of 851

ENQNEERS
$fg-z1
- f d2-
'
1 dg INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 6
.117,1 rfrforr onJO'SOff in Go■ft of Indo Uncleflak,o9)
1.0 GENERAL
1.1 All items, their dimensions, tolerances, chemical composition, physical properties, heat
treatment and testing etc. shall conform to the latest codes and standards specified in the
requisition. Supplier shall strictly comply with MR/PR stipulations and no deviations shall be
permitted. Post Order Concession/Deviation Permit 5-0000-0180-F1 as mentioned in Cl. 5.18
of Specification for Quality Management System Requirements from Bidders (6-78-0001) is
not applicable.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications. Test reports shall also be furnished for any supplementary tests as specified in
the requisition & Clauses 1.11, 1.12 & 1.15.
1.2.2 Material test certificates (physical property, chemical composition & heat treatment report)
shall also be furnished for the flanges supplied.
1.2.3 Positive Material Identification (PMI) shall be performed as per the scope and procedures as
defined in the `Specification for Positive Material Identification (PMI) at Supplier's Works'
(No. 6-81-0001).
1.2.4 Refer to specification no. 6-81-0006 for Inspection and Test plans for flanges, spectacle blinds
& drip rings.
1.3 Ends of weld neck flanges shall be beveled to suit the schedule / thickness of matching pipe,
as specified in the requisition.
1.4 Bevel end details for welding neck flanges shall be as per ASME B16.25. Contour of bevel
end shall be as follows:
Stainless Steel &
Low Temp. Carbon Steel
> 10 mm & Upto 25 mm Figure 5 Type A
1.5 Bore of socket weld flanges & reducing blind flanges shall suit the outside diameter and
schedule / thickness of matching pipe.
1.6 Bore of slip on flanges shall suit the outside diameter of matching pipe.
1.7 Flange face finish shall be normally specified in the requisition as serrated finish, 125 AARH
etc. The interpretation for range of face finish shall be as follows:
Stock Finish 1000 1.1 in AARH max.
Serrated Finish/125 AARH Serrations with 125 to 250gin AARH
63 AARH 32 TO 63 µ in AARH
Page 178 of 851

+31 ENGINEERS
$'g-arWes INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 6
1.41771 051 A Gol ol ind. Undenak.9) AND DRIP RINGS Page 5 of 7
1.8 Galvanized flanges shall be coated with zinc by hot dip process conforming to IS 4736 /
ASTM A153.
1.9 Ends of screwed flanges unless otherwise specified shall have taper threads as per
ASME/ANSI B1.20.1 (upto 1.5" NB) & IS 554 (for 2" to 6" NB).
1.10 For ring joint flanges, blinds and spacers the hardness shall be as follows:
Flange Material Min. Hardness of Groove (BHN)

Carbon Steel 140
1% Cr to 5%, 9% Cr 150
Type 304, 316, 321, 347 160
Type 304L, 316L 140
1.11 For ring joint flanges, blinds and spacers, the hardness shall be recorded in the test report.
1.12.1 Flanges, blinds, drip rings under "NACE" category and those designated as "HIC1" shall meet
the requirements given in NACE MR-0103 unless otherwise specified.
1.12.2 Flanges, blinds, drip rings made from plates and designated as "HIC1" shall meet the HIC
requirements of EIL Specification 6-79-0013 unless otherwise specified.
1.13 All austenitic stainless steel flanges shall be supplied in solution annealed condition.
1.14 I.G.C. Test for Stainless Steels:
1.14.1 For all austenitic stainless steel flanges, blinds, drip rings & Fig.8 flanges intergranular
corrosion test shall have to be conducted as per following:
ASTM A262 Practice `B' with acceptance criteria of "60 mils/year (max.)".
OR
1.14.2 When specifically asked for in requisition for high temperature application of some grades of
austenitic stainless steel (like SS309, 310, 316, 316H etc.) ASTM A262 Practice 'C' with
acceptance criteria of "15 mils/year" shall have to be conducted.
1.14.3 For the IGC test as described in 1.14.1 & 1.14.2 two sets of samples shall be drawn from each
solution treatment lot; one set corresponding to highest carbon content and the other
corresponding to the highest rating / thickness.
1.15 All types of 321 or 347 stainless steel flanges shall be in a stabilized heat treated condition.
Stabilizing heat treatment shall be carried out subsequent to the normal solution annealing.
Soaking temperature and holding time for stabilizing heat treatment shall be 900 C and 4
hours respectively.
Page 179 of 851

t31 ENGINEERS
$gelE f22e5 1NDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 6
el,ntetvrst,,cmt IA Govt ot Indo Undertaltng)
1.16 For dual grades of SS where specified, chemical composition and mechanical properties of
1.17 AWWA C207 flanges shall be hub type.
1.18 Dimensions for handle projection for Spacers & Blinds shall be as specified in EIL Std. 7-44-
0166.
1.19 Flanges of 22" size shall be as per MSS-SP44 unless otherwise specified
1.20 All 1Cr-V2Mo and 11/4Cr-'/2Mo flanges shall be normalised and tempered.
1.21 Ring Joint Fig-8 Flanges, Spacers & Blinds shall be female type only.
1.22 The handle for spacers & blinds for classes 900# & above shall be designed by the vendor.
The handle may be integral or attached to the line blank / spacer by welding. In case of
attachment by welding heat treatment & welding shall be in accordance with B31.3.
1.23 For Hydrogen service following special requirements shall also be met:
a. All carbon steel flanges having wall thickness 9.53 mm and above shall be normalised.
The normalising heat treatment shall be a separate heat treatment operation and not a part
of the hot forming operation.
b. All alloy steel (Cr-Mo) flanges shall be normalised and tempered. The normalising and
tempering shall be a separate heat treatment operation and not a part of the hot forming
operation.
c. For all carbon steels and alloy steels with wall thickness over 20mm, Charpy-V Notch
impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section
VIII, Div-1 per heat of material and per heat treating batch. Impact test specimen shall be
in accordance with ASTM A370. Impact energies at 0 C shall average greater than 27J (20
ft-lb) per set of 3 specimens, with a minimum of 19J (15ft-lb).
2.0 IBR REQUIREMENTS
2.1 IBR Documentation
2.1.1 Flanges coming under the purview of IBR (Indian Boiler Regulations) shall be accompanied
with IBR Certificate original in Form III C duly approved and countersigned by IBR
authority/ local authority empowered by Central Boiler Board of India. Photocopy of original
certificate duly attested by the local boiler inspector where the supplier is located is the
minimum requirement for acceptance.
Carbon (max) 0.25%
Others (S, P, Mn) • As prescribed in IBR.
services.
3.1 Blind Flanges and Spacers & Blinds if specified as plate materials are acceptable in forging
materials also in the corresponding material grades.
Page 180 of 851

ENGINEERS
faaes
1.117,
1217-,5W.13tt0.11
INDIA
IA
LIMITED FLANGES, SPECTACLE BLINDS
Govt ol Indo Undertakingt
AND DRIP RINGS
6-44-0053 Rev. 6
Page 7 of 7
3.2 Flanges/Spectacle Blinds/Drip rings of Grades SS317 of corresponding material are

acceptable in place of Grades SS316 or SS316(2.5Mo min.).
3.3 Flanges/Spectacle Blinds/Drip rings of Grades SS317L of corresponding material are

acceptable in place of Grades SS316L or SS316L(2.5Mo min.).
4.1 A11 items shall be legibly and conspicuously stamped in accordance with the requirements of
applicable ASME, API and MSS Standards. In addition, EIL item code, purchase order
number & special conditions like "IBR", "CRY0", "NACE" "H2" etc. shall also be stamped.
4.2 A11 items coming under the purview of "IBR", "CRYO" , "NACE" & "H2"(hydrogen) shall
be painted with one stripe of colour red, light purple brown, canary yellow & white
respectively for easy identification. Width of stripe shall be 25mm and it shall be painted
longitudinally across the complete thickness of flange other than hub.
4.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead
4.4 All items shall be dry, clean and free from moisture, dirt and loose foreign materials of any
kind.
4.5 All items shall be protected from rust, corrosion and mechanical damage during
4.6 Rust preventive on machined surfaces to be welded shall be easily removable with a
4.7 Each end of flange shall be protected with the following materials:
Flange face Wood, metal or plastic cover

Bevelled end Wood, metal or plastic cover
Threaded end Plastic plug
Socket welding end Plastic cover or plug
4.8 Each size of flanges, blinds, etc. shall be supplied in separate packagings marked with the
purchase order number, item code number, material specification, size and rating.
5.0 REFERENCES
6-81-0001 Specification for Positive Material Identification (PMI) at Supplier's

Works.
6-81-0006 Inspection & test plan for flanges, spectacle blinds & drip rings
6-79-0013 Material requirements for carbon steel components used in sour

service for petroleum refinery environments
7-44-0162 Standard for Spacers & Blinds 26" (150CL, 300CL & 600CL FF)
7-44-0164 Standard for Spacers & Blinds 26" (For AWWA Flanges)
7-44-0166 Dimensions for Handle projection for Spacers & Blinds 1/2"-24"
Page 181 of 851

TECHNICAL NOTES FOR BUTT STANDARD SPECIFICATION No.
ENGINEERS WELDED, SOCKET WELDED
,,cnf1,151,Pqd,,) IA Govt ol Intha UnooOok,o9) AND SCREWED FITTINGS Page 1 of 9
-rEFW1 rc-R dcb-ilcb1
TECHNICAL NOTES FOR BUTT

WELDED, SOCKET WELDED AND
SCREWED FITTINGS
6 25.09.14 REVISED AND ISSUED AS STD SPECN

SH .AK jRN ATD4 SC
5 31.12.13 REVISED AND ISSUED AS STD SPECN UK SH AK RN SC
4 04.07.08 REVISED AND ISSUED AS STD SPECN

RN SC DM VC
3 15/03/00 REVISED AND ISSUED AS STD SPECN RN BRB NS AS
HYDROTEST AND I.G. TEST CLAUSE

2 04/04/94 AKG BPV GRR AS
REVISED
Standards Standards
Comm ittee Bureau
No by by
Approved by
Page 182 of 851

TECH. NOTES FOR BUTT STANDARD SPECIFICATION No.
ENG1NEERS
fg-;fr Êtfai INDIA LIMITED WELDED, SOCKET WELDED 6-44-0054 Rev. 6
1.12R ,,c»,.13,70.1/
AND SCREWED FITTINGS Page 2 of 9
Abbreviations:

CS Carbon Steel
DP Dye Penetrant
IS Indian Standard
LT Low Temperature
MSS Manufacturer's Standardisation Society
NB Nominal Bore
PO Purchase Order
SMYS Specified Minimum Yield Strength
SS Stainless Steel

Mr. Amrendra Kumar
Mr. G. Balaji
Page 183 of 851

7tn ENGNEERS
5tgu faaeg
1.17,1 ,rcnr1,1111.~1/
INDIA LIMITED WELDED, SOCKET WELDED
AND SCREWED FITTINGS
6-44-0054 Rev. 6
Page 3 of 9
CONTENTS
1.0 GENERAL 4
2.0 IBR REQUIREMENTS 8
5.0 REFERENCES 9
Page 184 of 851

k71 ENGINEERS
Og'-ar 22-'dg INDIA LIMITED WELDED, SOCKET WELDED 6-44-0054 Rev. 6
G" Unde""g) AND SCREWED FITTINGS Page 4 of 9
1.0 GENERAL
1.1 Chemical composition, physical properties, tests, dimensions and tolerances, heat treatment
and marking shall conform to the applicable latest codes / standards / specifications as
specified in the material requisition (MR). Supplier shall strictly comply with MR/PR
stipulations and no deviations shall be permitted. Post Order Concession/Deviation Permit 5-
0000-0180-F1 as mentioned in Cl. 5.18 of Specification for Quality Management System
Requirements from Bidders (6-78-0001) is not applicable.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the material specifications. Test
reports shall also be furnished for any supplementary tests as specified in the MR, Clauses
1.7.8, 1.9, 1.10 & 1.11. Material test certificates (physical properties, chemical composition &
heat treatment report) shall also be furnished for fittings supplied.
1.2.2 Positive Material Identification (PMI) shall be performed as per scope and procedures defined
in the Specification for Positive Material Identification (PMI) at Supplier's Works (6-81-
0001).
1.2.3 Refer to specification no.6-81-0005 for Inspection and Test plan for forged, seamless and
welded fittings.
1.3 All fittings shall be seamless in construction unless otherwise specified. If fittings are
specified as welded, the same shall conform to clause 1.7.
1.4 Outside diameters and wall thickness (unless otherwise mentioned) of butt welded fittings
shall be in accordance with ASME B36.10 and ASME B36.19 as applicable.
1.5 For reducing butt weld fittings having different wall thicknesses at each end, the greater wall
thickness of the fitting shall be employed and inside bore at each end shall be matched with
the specified inside diameter.
1.6 Beveled ends for all fittings shall conform to ASME B16.25. Contour of bevel shall be as
follows:


Stainless Steel &
1.7 Welded Fittings
1.7.1 A11 welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm.
Welds shall be ground smooth at least 25 mm from the ends.
Page 185 of 851

ENGINEERS
INDIA LIMITED WELDED, SOCKET WELDED 6-44-0054 Rev. 6
1.11,1 051~,
(A G" "d" Unde"''') AND SCREWED FITTINGS Page 5 of 9
1.7.2 For fittings made out of welded pipe, the welded pipe shall be double welded type & shall be
manufactured with the addition of filler metal.
1.7.3 Welded tees shall not be of fabricated (stub-in) type.
1.7.4 All welded fittings shall be normalized & 100% radiographed by X-ray on all welds made by
fitting manufacturers & also on the parent materials.
1.7.5 Welded pipes employed for manufacture of fittings shall be made by automatic welding only.
1.7.6 Specified heat treatment for carbon steel & alloy steel fittings shall be carried out again after
weld repairs.
1.7.7 Irrespective of the material code requirement, all welded fittings indicated in the MR as
"Cryo"& "LT" shall meet impact test requirements of ASME B3I .3. The impact test
temperature shall be -196°C & -45°C for stainless steel & carbon steel respectively unless
specifically mentioned otherwise in the MR.
1.8 Stainless Steel Fittings
1.8.1 All stainless steel fittings shall be supplied in solution heat treated condition.
1.8.2 Solution annealing for stainless steel fittings shall be carried out again after weld repairs.
1.8.3 For all stainless steel fittings Inter Granular Corrosion (IGC) test shall have to be conducted as
per the following:
ASTM A 262 Practice "B" with acceptance criteria of "60 mils/year (max.)".
Or
austenitic stainless steel (eg. SS309, 310,316,316H etc.) ASTM A 262 Practice "C" with
acceptance criteria of "15 mils/year" shall have to be conducted.
1.8.5 For the IGC test as described in Clauses 1.8.3 & 1.8.4, two nets of samples shall be drawn
from each solution treatment lot, one set corresponding to the highest carbon content and other
set to the highest fitting thickness.
1.8.6 For dual grades of SS where specified, chemical composition and mechanical properties of
1.9.1 Fittings under "NACE" category or those designated as "HIC1" shall meet the requirements of
NACE MR-0103 unless otherwise specified.
1.9.2 Fittings made from plates and designated as "HIC1" shall meet the HIC requirements of EIL
specification 6-79-0013 unless otherwise specified.
1.10 Thickness/schedule lower or higher than specified for the finished product shall not be
accepted.
Page 186 of 851

ENQNEERS TECH. NOTES FOR BUTT STANDARD SPECIFICATION No.
k31
5g"arfaidles INDIA LIMITED WELDED, SOCKET WELDED 6-44-0054 Rev. 6
°Rna" Unde"«ng) AND SCREWED FITTINGS Page 6 of 9
For manufacturing of elbows from pipes, same size of pipe as that of elbow shall be used and
the nominal wall thickness of the starting pipes shall have positive tolerance only. However,
where the manufacturer has an established automatic/semi-automatic process for the
manufacture of elbows, the starting pipe may be permitted to be of Iower size with higher
schedule as required. Starting pipe of higher size than that of the elbow shall not be permitted.
1.11 The gasket contact surfaces of stub ends shall be flat with face finish specified in the
requisition. Interpretation on the specified face finish is as follows:
125 AARH Serrations with 125 to 250 µ in AARH
1.12 Seamless stub ends shall not have any welds on the body. Stub ends shall be long pattern type.
1.13 Galvanized fittings shall be coated with zinc by hot dip process conforming to IS 4736 /
ASTM A153.
1.14 Threaded ends shall have NPT taper threads in accordance with ASME/ANSI B1.20.1 up to
1.5" NB & IS 554 from 2" to 6" NB.
1.15 Unless and otherwise specified in the MR, all socket welded and screwed fittings shall be in
accordance with ASME B16.11 to the extent covered in the specification except for unions
which shall be in accordance with MSS-SP-83.
1.16 Special fittings like weldolet, sockolet, sweepolet, latrolet, elbolet etc., the dimensions of
which are not covered in ASME, MSS-SP & EIL Standards, shall be as per manufacturer's
std. Contours of these fittings shall meet the requirements of ASME B31.3. Manufacturer shall
submit drawings / catalogues of these items for records after acceptance of offer.
1.17 Length of all long half couplings shall be 100 mm unless otherwise specified in the MR.
1.18 For reducers to manufacturers' standard, length of reducer shall not be less than 0.7D where D
is the outside diameter of the larger end.
1.19 All seamless pipes employed for manufacturing of fittings shall be required to have undergone
hydrostatic test to ASTM A 530. Welded pipes employed for manufacture of fittings shall be
tested as given below :
Welded Pipe Employed For Manufacture Of Welded Fittings. Test Criteria
ASTM A671 Gr. C65,70 (C1.32) P=2ST/D

ASTM A672 Gr. C60,65,70 (C1.12, 22) S = 90% of SMYS.
ASTM A671 Gr. CF60,65,70,66 (C1.32) T = Nom. Wall Thickness
ASTM A691 Gr. 1/2Cr, 1Cr, 11/4Cr, 21/4Cr, 5Cr, 9Cr (C1.42), D = 0.D. of Pipe.
91 (C1.42)
API 5L P=2ST/D
ASTM A358 TP 304, 304L, 304H, 318, 318L, 318H, 321, S = 85% of SMYS.
347 (C1.1, 3, 4) T = Nom. Wall Thickness
D = 0.D. of Pipe.
ASTM B725 ASTM B725
ASTM B517 ASTM B517
ASTM B514 ASTM B514
1.20 The bevel ends of all butt weld fittings shall undergo 100% MP / DP test.
Page 187 of 851

Odie`g cw INDIA LIMITED

ENGINEEFZS
WELDED, SOCKET WELDED
Ii 1.177, 2:12.72 ,151~)
Unde"") AND SCREWED FITTINGS
6-44-0054 Rev. 6
Page 7 of 9
1.21 Abbreviations for ends of swages and nipples shall be as follows:

PBE Plain Both Ends
TBE Threaded Both Ends
TOE Threaded One End
TSE Threaded Small End
TLE Threaded Large End
1.22 All types of SS321 or SS347 fittings shall be in stabilized heat treated condition. Stabilizing
heat treatment shall be carried out subsequent to normal solution annealing. Soaking
temperature and holding time for stabilizing heat treatment shall be 900°C and 4 hours
respectively.
1.23 For Hydrogen service fittings following special requirements shall also be met:
a. All carbon steel fittings having wall thickness 9.53 mm (0.375") and above shall be
normalised. Cold drawn fittings shall be normalised after the final cold draw pass for all
thicknesses. In addition, fittings made from forgings shall have Carbon- 0.35 % max. and
Silicon- 0.35 % max. The normalising heat treatment shall be a separate heating operation
and not a part of the hot forming operation
b. All alloy steel (Cr-Mo) fittings shall be normalised and tempered. The normalising and
tempering shall be a separate heating operation and not a part of the hot forming
operation. The maximum room temperature tensile strength shall be 100,000 psi.
c. For carbon steel fittings, hardness of weld and HAZ shall be 200 BHN (max.). For alloy
steel fittings, hardness of weld and HAZ shall be 225 BHN (max.).
d. For all austenitic stainless steels, the weld deposit shall be checked for ferrite content. A
Ferrite No.(FN) not lens than 3% and not more than 10% is required to avoid sigma phase
embrittlement during heat treatment. FN shall be determined by Ferritescope prior to post
weld heat treatment.
e. For all Carbon steel and Alloy steel fittings with wall thickness over 20mm, Charpy-V
Notch impact testing shall be carried out in accordance with paragraph UG-84 of ASME
Section VIII, Div-1 for weld metal and base metal from the thickest item per heat of
material and per heat treating batch. Impact test specimen shall be in complete heat treated
condition and accordance with ASTM A370. Impact energies at 0°Celsius shall average
greater than 27J (20 ft-lb) per set of three specimens, with a minimum of 19J (15 ft-lb).
1.24 For all welded alloy steel fittings with mandatory requirements of heat treatment and
radiography, radiography shall be performed after heat treatment.
1.25 All 1Cr-0.5Mo & 1.25Cr-0.5Mo fittings shall be normalized and tempered. All 2.25Cr- 1 Mo,
5Cr-0.5Mo, 9Cr- 1 Mo & 9Cr- 1 Mo-V welded fittings shall be normalized and tempered.
1.26 Fitting material as per ASTM A234 Gr.WP5/WP9/WP91, wherever specified, shall be as per
'Cl.lt, unless otherwise specified.
1.27 Materials designated as structural steel grades like IS 2062, SA 36 etc. or similar specification
are not permitted for manufacture of fittings.
Page 188 of 851

ENGINEERS
Ofaj- egIw INDIA LIMITED
I MTA <7,7.1,711,~
'flnd" Unde"")
6-44-0054 Rev. 6
Page 8 of 9
2.0 IBR REQUIREMENTS
2.1 IBR Documentation Required
2.1.1 Fittings under the purview of "IBR" (Indian Boiler Regulations) shall be accompanied with
original IBR certificate in Form III-C duly approved and countersigned by IBR authority /
local authority empowered by Central Boiler Board of India. Photocopy of the original
certificate duly attested by the local boiler inspector where the supplier is located is the
minimum requirement for acceptance.
2.1.2 For materials 11/4Cr - 1/2Mo (ASTM A 234Gr.WP11 & ASTM A234 Gr.WP11W) & 21/4Cr -
1Mo (ASTM A 234 Gr.WP22 & ASTM A234 Gr. WP22W) & 9Cr-lMo-V (A234 Gr.WP91/
A234Gr.WP91W),where fittings are manufactured from pipe, Form III-C approved by IBR
shall include the tabulation of Et, Sc, & Sr values for the entire temperature range given below.
Et, S„ & Sr values shall be such that throughout the temperature range
Et / 1.5
S, / 1.5 SA
Sc
SA Allowable stress at the working metal temperature.

E, Yield point (0.2% proof stress at the working metal temperature)
Sc The average stress to produce elongation of 1%(creep) in 100000 hrs at
the working metal temperature.
Sr The average stress to produce rupture in 100000 hrs at the working metal
temperature and in no case more than 1.33 times the lowest stress to
produce rupture at this temperature.
SA (psi)
Temp( F) 500 600 650 700 750 800 850 900 950 1000 1050 1100
Material
A234Gr.WP11/ 21700 20900 20500 20100 19700 19200 18700 13700 9300 6300 4200 2800
A234Gr.WP11W
A234Gr.WP22 / 17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
A234Gr.WP22W
A234Gr.WP91/
28100 27700 27300 26700 25900 24900 23700 22300 20700 18000 14000 10300
A234Gr.WP91W
Note : SA values shall be as per the latest edition prevailing.
Carbon (max) 0.25%

Others (S, P, Mn) As prescribed in IBR.
services.
3.1 Seamless fittings are acceptable in place of welded fittings, however, welded fittings are not
acceptable in place of seamless fittings. Forged fittings are acceptable in place of wrought
Page 189 of 851

ENGINEERS
aje- g
51g-ar fa INDIA LIMITED
IA
5" °"'" Un0en'''9)
6-44-0054 Rev. 6
Page 9 of 9
fittings. However, wrought seamless fittings are acceptable in place of forgings only in case of
swages.
3.2 Fittings of Grades SS317 of corresponding material are acceptable in place of Grades SS316
or SS316(2.5Mo min.).
3.3 Fittings of Grades SS317L of corresponding material are acceptable in place of Grades
SS316L or SS316L(2.5Mo min.).
4.1 Each fitting shall be legibly and conspicuously stamped in accordance with the requirements
of applicable standards along with special condition like "IBR", "Cryo", "NACE" and "H2"
etc.
4.2 Steel die marking with round bottom punch may be permitted on body of butt weld CS &
lower alloy steel fittings, but for SS & higher alloy steel fittings, the same should be marked
by electro-etching only.
4.3 Paint or ink for marking shall not contain any harmful metals or metal salts such as Zinc, Lead
or Copper which causes corrosive attack on heating.
4.4 Fittings shall be dry, clean and free of moisture, dirt and loose foreign materials of any kind.
4.5 Fittings shall be protected from rust, corrosion and mechanical damage during transportation,
shipment and storage.
4.6 Rust preventive used on machined surfaces to be welded shall be easily removable with a
4.7 Fittings coming under the purview of "IBR", "CRYO" , "NACE" & "H2"(hydrogen) shall be
painted with one circumferential stripe of colour red, light purple brown, canary yellow &
white respectively for easy identification. Width of stripe shall be 12mm for sizes less than 3"
and 25mm for sizes 3" and above. Stripe shall be located centrally for elbows, diagonally for
caps, at the larger end for reducing fittings, longitudinally for couplings and at one end near to
the bevel/socket/screwed end for other fittings.
4.8 Each end of fitting shall be protected with a wood, metal or plastic cover.
4.9 Each size of fitting shall be supplied in separate packaging marked with the purchase order
number, item code number, material specification, size and schedule / thickness / rating. For
small quantities, fittings of different sizes may be packed in separate packing size-wise and
there packing may be packed in a bigger package/ container clearly identifying the contents.
5.0 REFERENCES
6-81-0001 : Specification for Positive Material Identification (PMI) at

Supplier's Works
6-81-0005 Inspection & test plan for forged, seamless and welded
fittings
6-79-0013 Material requirements for carbon steel components used in

sour service for petroleum refinery environments
Page 190 of 851

Igar Rai dg
Imwn rircvre Lr5, JEnsm)
INDIA LIMITED
GASKETS 6-44-0056 Rev. 5
Page 1 of 5
Trrkzke fff
achi en dui 'Jig'
TECHNICAL NOTES
FOR GASKETS

5 30.03.18 PK SH MI
SPECIFICATION
4 21.03.13 UK SH RN ATD DM
SPECIFICATION
3 23.07.07
SPECIFICATION RN ATD DM VC
2 15.06.98 SH BRB BN AS
SPECIFICATION
1 30.12.92 AKG BPV GRR AS
SPECIFICATION
Standards Standards
Committee Bureau
Rev. Prepared
Date Purpose Checked by Convenor Chairman
No by
Approved by
Page 191 of 851

of ei ENGINEERS TECHNICAL NOTES FOR
41litiffAeu INDIA LIMITED GASKETS 6-44-0056 Rev. 5
mart eleartartairtkortio A Govt of India undertaking)
Pa•e 2 of 5
Abbreviations:
AARH : Average Arithmetic Root Height
BHN : Brinnel Hardness Number
CS Carbon Steel
MR : Material Requisition
RTJ : Ring Type Joint

Mr. G. Balaji
Mr. Mr. S. Ghosal (Process-2)
Mr. Pankaj Kr. Rai (Construction)
Page 192 of 851

dafaeJel. ENGINEERS TECHNICAL NOTES FOR
$1?-ar 2151--e-g. INDIA UMITED
oda, etecerer, ,011.:1) IA Goer at India Undertaking)
GASKETS 6-44-0056 Rev.5
Page 3 of 5
CONTENTS
1.0 GENERAL 4
2.0 REFERENCES 5
Fermat No. 8-00-0001-F1 Rev. 0 Copyright ER. — All rights reserved
Page 193 of 851

el ENGINEERS TECHNICAL NOTES FOR
rge.irial511-ez WA LIMITED GASKETS 6-44-0056 Rev. 5
1.2n rzazre IAIJAUFAII IA Gout 01 Indla UndeltaMAg/
Page 4 of 5
1.0 GENERAL
1.1 All gaskets shall conform to the codes/standards and specifications given in the
requisition. Supplier shall strictly comply with MR/PR stipulations and no deviations shall
be permitted.
1.2 Process of manufacture, dimensions and tolerances not specified in requisition shall be in
accordance with the requirements of the manufacturer's standards.
1.3 Testing
1.3.1 Test reports shall be supplied for all mandatory tests for gaskets as per the standards
specified in the requisition.
1.3.2 Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of
test reports on samples.
1.3.3 For Spiral wound material following shall be furnished:
a. Manufacturer's test certificate for filler material and spiral material as per the relevant
material specifications.
b. Manufacturer's test certificate for raw materials and tests for compressibility/ seal-
ability & recovery as per the relevant material specifications.
1.3.4 PMI shall be performed as per the scope and procedures defined in the Specification for
PMI at Supplier's Works (6-81-0001) for ring type joint gaskets.
1.3.5 Refer Specification no 6-81-0008 for 'Inspection & Test Plan for Gaskets'.
1.4 Fail face gaskets shall have bolt holes punched out.
1.5 Filler material for spiral wound gaskets shall not have any colour or dye.
1.6 All spiral wound gaskets shall be supplied with Outer ring. Material of the outer ring shall
be CS unless otherwise specified in the MR.
1.7 For spiral wound gaskets, material of Inner Compression ring shall be same as Spiral Strip
material. Inner rings shall be provided for all Spiral Wound Gaskets.
1.8 Hardness of metallic RTJ gaskets shall not exceed the values specified below ;finless
otherwise specified in MR:
Ring Gasket Material Maximum Hardness (BM)
Soft Iron 90
Carbon steel 120
5 Cr. '/2 Mo 130
Type 304, 316, 321, 347 140
Type 304L, 316L 120
Page 194 of 851

ligar tiW-g- VIY INDIA LIMITED GASKETS 6-44-0056 Rev. 5
+ea, ,vm IA Govt of India Undenalong)
Page 5 of 5
Inconel UNS N06625 200
Incoloy UNS N08825 190
Duplex SS UNS NO32205, NO31803 230
1.9 Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.
1.10 Gaskets of different types and sizes shall be placed in separate shipping containers and
each container clearly marked with the size, rating, material specification and item code.
1.11 All items shall be inspected and approved by EIL Inspector or any other agency
authorized by EIL.
1.12 Any additional requirements specified in the requisition, shall be fully complied with.
1.13 Non-metallic ring gaskets as per ASME B 16.21 shall match flanges to ASME B 16.5 upto
24" and to ASME B16.47B above 24" unless specified otherwise.
1.14 Spiral wound gasket as per ASME B 16.20 shall match flanges to ASME B 16.5 upto 24"
and to ASME B16.47B above 24" unless specifically mentioned otherwise.
1.15 The following abbreviations have been used in the Material Requisition for Spiral Wound
Gaskets
(1) Inner Ring

(0) •. Outer Ring
GRAFIL : Grafoil Filler
1.16 Specialties mentioned in item description like "IBR", "LT", "HIC1", "H2", etc. shall be
ignored.
2.0 REFERENCES
6-81-000i Specification for Positive Material Identification (PMI) at Supplier's

Works
6-81-0008 Inspection & Test Plan for Gaskets
6-78-0001 Specification for Quality Management System Requirements from

Bidders
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserver;
Page 195 of 851

t31 el ENGINEERS TECHNICAL NOTES FOR
11-4-ar tlf5reg INDIA LIMITED BOLTS AND NUTS 6-44-0057 Rev. 5
oren eirergem.,,m) (A Govt of 11101.3 Undettaung) Page 1 of 5
7•11 r--R "RA111 Tqi fffq

achl 4) ulql
TECHNICAL NOTES
FOR BOLTS AND NUTS

5 30.03.18 PK MI >RN
SPECIFICATION
REVISED & ISSUED AS STANDARD RN ATD DM
4 21.03.13 UK SH
SPECIFICATION
3 23.07.07
SPECIFICATION RN ATD DM VC
2 15.06.98 SH BRB BN AS
SPECIFICATION
REVISED & ISSUED AS STANDARD AS
1 30.12.92 AKG BPV GRR
SPECIFICATION
Standards Standards
Committee Bureau
No by by
Approved by
Page 196 of 851

oga fadleg
1.12n 2.1i4M172
INDIA LIMITED
(A Govt of India UnOettalung)
BOLTS AND NUTS 6-44-0057 Rev. 5
Page 2 of 5
Abbreviations:
ASME : The American Society of Mechanical Engineers
ASTM : The American Society for Testing and Materials
SS Stainless Steel

Mr. G. Balaji
Mr. Mr. S. Ghosal (Process-2)
Mr. Pankaj Kr. Rai (Construction)
Page 197 of 851

iti&reYENGINEERS TECHNICAL NOTES FOR
ligar laWg
?.re
INDIA LIMITED
IA Go, of India Undertaking)
BOLTS AND NUTS 6-44-0057 Rev. 5
Page 3 of 5
CONTENTS
1.0 GENERAL 4
3.0 REFERENCES 5
Page 198 of 851

tWg INDIA LIMITED BOLTS AND NUTS 6-44-0057 Rev. 5
lawn eikkaire aft,pgr,q) IA Govt of India undertaking)
Page 4 of 5
1.0 GENERAL
1.1 The process of manufacture, heat treatment, chemical & mechanical requirements and
marking for all stud bolts, m/c bolts, jack screws & nuts shall be in accordance with the
codes/standards and specifications given in the requisition. The applicable identification
symbol in accordance with the material specification shall be stamped on each bolt and
nut. Supplier shall strictly comply with MR/PR stipulations and no deviations shall be
permitted.
1.2 Testing
1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications.
1.2.2 Material test certificate shall also be furnished. (Heat Analysis, Product Analysis and
Mechanical Requirement)
1.2.3 PMI shall be performed as per the scope and procedures defined in the Specification for
PMI at Supplier's Works (6-81-0001).
1.2.4 Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM A453
bolting material irrespective of the temperature.
1.2.5 Refer Specification no 6-81-0007 for 'Inspection & Test Plan for Bolting Material'.
1.3 All bolting shall be as per ASME B 18.2.1 for studs, M/c bolts and jackscrews and ASME
B18.2.2 for nuts.
1.4 Threads shall be unified (UNC for up to 1" dia and 8UN for > 1" dia) as per ASME B1.1 I
with class 2A fit for studs, M/c bolts and jackscrews and class 2B fit for nuts.
1.5 Stud bolts shall be threaded full length with two heavy hexagonal nuts unless otherwise
specified. Length tolerance shall be in accordance with the requirement of Table D2 of
Annexure-D of ASME B 16.5.
1.6 The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be
made by the hot forged process and stamped as per respective material specification.
1.7 Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end shall be
rounded.
1.8 Each size of studs & m/c bolts with nuts and jackscrews shall be supplied in separate
containers marked with size and material specifications. `CRY0' shall be marked
additionally in case `CRY0' is specified in the requisition.
1.9 All items shall be inspected and approved (stage-wise) by EIL inspector or any other
agency authorized by EIL.
1.10 The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.
1.11 All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed
condition unless specified otherwise in the material specification.
1.12 Any additional requirements specified in the requisition shall be fully complied with.
1.13 Stud bolts, nuts & jackscrews shall be impact tested wherever specified in the material
specification and also where the material specification is indicated as "CRYO". For S.S.
Page 199 of 851

151fMTRA ENGINEERS TECHNICAL NOTES FOR
$41-dMr
I aiR elea, ■ 754,17,41
INDIA LIMITED BOLTS AND NUTS 6-44-0057 Rev. 5
IA Go of India underlalong)
Page 5 of 5
nuts and bolts minimum impact energy absorption shall be 27 Joules and test temperature
shall be -196°C unless mentioned otherwise. For other materials impact energy and test
shall be as per respective code.
1.14 Bolts/nuts of material of construction B7M/2HM shall be 100% Hardness tested as per
supplementary requirement S3 of ASTM A193.
1.15 When specified as galvanized, the studs, M/C bolts and nuts shall be 'hot dip zinc coated'
in accordance with requirements of 'class C' of ÀSTM A 153'. As an alternative, electro-
galvanizing as per IS 1573, 'Service Grade Number 2' is also acceptable.
1.16 All Stud Bolts of Bolt diameter size 1" and above shall be provided with three nuts
irrespective of whatever has been specified elsewhere in the MR.
1.17 Bolting shall be protected by non-corrosive oil or grease before dispatch to prevent
rusting.
1.18 For stud bolt diameters not covered in ASTM A320, mechanical properties shall match
the values specified for the matching grades and stud bolt diameters in ASTM A193.
1.19 In cases where the lengths of Stud/Machine bolts specified in the MR are not multiples of
0.25", the length supplied shall be equal to the specified length rounded up to the next
higher 0.25".
1.20 All Specialties mentioned in item description like "IBR", "LT", "H2", etc. other than
"CRYO" & "NACE" shall be ignored.
2.1 'Nuts' to ASTM A194Gr.7 are acceptable in place of ASTM A194Gr.4.
2.2 Stud Bolts to ASTM A453 Gr.660 CLB are acceptable in lieu of ASTM A453 Gr.660 I
CI.A and vice versa.
3.0 REFERENCES
6-81-0001 Specification for Positive Material Identification (PMI) at Supplier's

Works
6-81-0007 Inspection & 'rest Plan for Bolting Material
6-78-0001 Specification for Quality Management System Requirements from

Bidders
Format No. 8-00-0001-F1 Rev. 0 Copyright EIS—All rights reserved
Page 200 of 851

k31 ENGINEERS TECHNICAL NOTES FOR
6-44-0067 Rev. 1
$gU1812 -g INDIA LIMITED STRAINERS
IA GoA ot Indta Undeflakng)
Page 1 of 9
RYI
ch 1-1 ch u I 41
TECHNICAL NOTES FOR

STRAINERS

1 23.09.2014 SH ,RN D SC
SPECIFICATION
0 29.06.2009 ISSUED AS STANDARD SPECIFICATION PK RN SC ND
Standards Standards
Com m ittee Bureau
No by by
Approved by
Page 201 of 851

IM2— g INDIA LIMITED STRAINERS 6-44-0067 Rev. 1
aIIZ, rlecnW ast aamnl lA Govt ol Indo Undertakng)
Page 2 of 9
Abbreviations:

AISI American Iron and Steel Institute
BW Butt Weld
DP Dye Penetrant
FLGD Flanged
FN Ferrite Number
H2 Hydrogen
MOC Material of Construction
NACE National Association of Corrosion Engineers
SCRD Screwed
SW Socket Weld
UNC Unified Coarse
WN Weld Neck

Mr. Amrendra Kumar
Mr. G. Balaji
Page 202 of 851

tg'-ar2f51-
dg INDIA LIMITED
IA Govt of Indo UndellaMing)
STRAINERS 6-44-0067 Rev. 1
Page 3 of 9
CONTENTS
1.0 PURPOSE & SCOPE 4

2.0 DESIGN & CONSTRUCTION 4
3.0 DOCUMENTATION 7
4.0 SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE 7
5.0 TESTING & INSPECTION 8
6.0 ACCEPTABLE DEVIATIONS 8 I
7.0 MARKING & DESPATCH 8
8.0 ATTACHMENTS FOR MR 9
9.0 REFERENCES 9
Page 203 of 851

t-11 ENGINEERS TECHNICAL NOTES FOR
Og-ar a;es
1~1 tY,CD11,613~
INDIA LIMITED
in Govt of Indu Unclellalong)
Page 4 of 9
1.0 PURPOSE & SCOPE
This specification covers the design and construction, IBR requirements, documentation,
testing, inspection, marking and despatch requirements for Strainers. Vendor shall supply
Strainers in accordance with the technical notes and details specified in the Data Sheet for
strainers. Supplier shall strictly comply with MR/PR stipulations and no deviations shall be
permitted. Post order Concession/ Deviation format 5-0000-0180-F1 as mentioned in Cl. 5.18
of Specification for Quality Management System Requirements from Bidders (6-78-0001) is
not applicable.
2.0 DESIGN & CONSTRUCTION
2.1. All codes and Standards for manufacture, testing and inspection etc. shall be of latest editions.
2.2 The material of construction shall be as per the data sheet; for parts not mentioned in the data
sheet, vendor shall guarantee the material used for the service conditions specified.
For flanged strainers, MOC of end flanges shall correspond to the material specified in the
Data sheet.
For welding of dissimilar materials required for strainer assembly, welder qualification
procedure shall be done prior to welding.
2.3 The material composition, physical properties, heat treatment, mandatory test reports,
dimensions and tolerances shall confirm to the applicable codes/ standards/specifications as
specified in the requisition.
2.4 Design shall be based on EIL Std 7-44-0300 for temporary strainers, EIL Stds 7-44-0303/0304
for T-type permanent strainers and Manufacturer's std. for Y-type strainers.
2.5 Dimension Standards for various components are as follows:
Body - ASME B16.9/B16.11

Flanges - ASME B16.5/B16.47 Series B
Gaskets - ASME B16.20/B16.21
Bolts & Nuts - ASME B18.2.1 & B 18.2.2 respectively
2.6 Ends of body shall either be Flanged, BW, SW or Screwed as specified in the data sheet.
2.6.1 The ends for strainers shall correspond to the following standards:
FLGD ASME B16.5/B16.47 Series B

BW ASME B16.25
SW ASMEB16.11
SCRD ASME B16.11
2.6.2 Bevel end details for BW strainers shall be as per ASME B16.25. Contour of bevel end shall
be as follows:

Low Temp. Carbon
Steel) > 22 mm Figure 3 Type A
Page 204 of 851

INDIA LIMITED STRAINERS 6-44-0067 Rev. 1
1.41Q, 2:17.77 ffil,m++1) IA Gov, 01 lrMia Under,ak,n9)
Page 5 of 9

Stainless Steel &
2.7 Flange face finish shall be normally specified in the strainer data sheet. The interpretation for
range of face finish shall be as follows:
Stock Finish 1000 p in AARH max.

Serrated/Smooth Finish/125AARH Serrations with 125 to 250 p in AARH
Extra Smooth Finish/63 AARH 32 TO 63 µ in AARH
2.8 For strainers with ring type joint flanged ends the hardness shall be as follows:
Flange Material Min. Hardness of Max. Gasket

Groove (BHN) Hardness (BHN)
Carbon Steel 140 90
1% Cr to 5% Cr, 9% Cr 150 130
Type 304, 316, 321, 347 160 140
Type 304L, 316L 140 120
2.9 For strainers with flanged ring type joint ends, the hardness shall be recorded in the test report.
2.10 Ends of screwed strainers unless otherwise specified shall have taper threads as per
ASME/ANSI B1.20.1 (upto 1.5" NB) & IS 554 (for 2" to 6" NB).
2.11 All 2" and higher size Y type strainers shall be provided with 3/4" screwed plug for drain
connection. For less than 2" this shall be 1/2" size.
For Y type, SW end Strainers (size 1.5" & below) to MNF'STD, blind end is also acceptable
with threaded plug cover instead of flanged end. In this case, plug shall be of forged material
equivalent to body material.
2.12 For Y type strainers, cast strainers with integrally cast flanges and with end cover / blind
flange in cast/forged construction is acceptable.
2.13 For flanged end strainers, weld-on flanges (WN) are acceptable.
2.14 Pressure drop calculations shall be furnished by vendor along with the offer, wherever
specified in the data sheet.
2.15 Stainless Steel Strainers
2.15.1 All Austenitic Stainless Steel items shall be supplied in solution annealed condition.
2.15.2 For all Austenitic Stainless Steel items Inter-granular Corrosion Test shall be conducted as per
following:
Page 205 of 851

ENGINEEFZS TECHNICAL NOTES FOR
Og-ar faaes
1~, c.wen/C ,151,370M)
INDIA LIMITED
Ift Govt of InOla Undettakong)
Page 6 of 9
ASTM A 262 Practice 'B' with acceptance criteria of `60mils/year (max.)'

OR
ASTM A262 Practice E with acceptance criteria of no cracks at 20X magnification
and microstructure to be observed at 250X magnification shall ensure the absence of
any cracks/ fissures. When testing is conducted as per practice 'E' photograph of
microstructure shall be submitted for record.
2.15.3 When specifically asked for in MR for High Temp. application of some grades of Austenitic
Stainless Steel (like SS 309, 310, 316H etc.) ASTM A 262 practice 'C' with acceptance criteria
of "15mils/year" shall be conducted.
2.15.4 All types of SS321 or SS347 material shall be in stabilized heat treated condition. Stabilizing
heat treatment shall be carried out subsequent to normal solution annealing. Soaking
temperature and holding time for stabilizing heat treatment shall be 900 °C and 4 hours
respectively.
2.16 IBR Requirements
2.16.1 For SW / BW end carbon steel strainers under IBR, the chemical composition shall conform to
the following :
Carbon (Max) 0.25%

Others (S, P, Mn) As per IBR regulations
2.16.2 Strainers coming under the purview of "IBR" (Indian Boiler Regulations) shall each be
individually accompanied by original IBR certificate in Form duly approved by IBR
authority / local authority empowered by the Central Boiler Board of India. Photocopy of
original certificate duly attested by the local boiler inspector where the supplier is located is
the minimum requirement for acceptance.
2.17 In case of T-type strainer, body construction shall be `Seamless' unless otherwise specified in I
the data sheet.
2.18 Welded Tees shall not be of fabricated (Stub-in) type.
2.19 Strainers with welded body shall be in normalized condition & 100 percent radiographed by
X-ray.
2.20 All alloy steel strainers with welded body construction shall be normalized and tempered &
100 percent radiographed by X-ray.
2.21 Weld joints shall be stress relieved as per the requirement specified in the Strainer MR
Attachment..
2.22.1 Strainines under "NACE" category or those designated as "HIC1" shall meet the requirements
of NACE MR-0103 unless otherwise specified.
2.22.2 Strainers made from plates and designated as "HIC1" shall meet the HIC requirements of EIL
specification 6-79-0013 unless otherwise specified.
2.23 Strainers of Hydrogen service category shall meet the requirements as specified in clause 4.0
below.
2.24 Galvanized strainers shall be coated with zinc by hot dip process conforming to IS 4736 / I
ASTM A153.
Page 206 of 851

Og-arld2- g INDIA LIMITED
IA Govt of InOta Unclettakingt
Page 7 of 9
2.25 Gaskets
2.25.1 Non-metallic gaskets shall conform to B16.21 (corresponding to B16.5) up to 24" and B16.21
(corresponding to B16.47 Series `B') beyond 24", unless otherwise specified.
2.25.2 Spiral wound gaskets shall conform to B16.20.
2.25.3 Ring type and spiral wound gasket shall be self-aligning type.
2.25.4 Ring Joint gasket shall Octagonal type and shall conform to B16.20.
2.26 Bolting
2.26.1 All bolts shall conform to B18.2.1, nuts to B18.2.2. Reference shall also be made to B16.5 for
studs.
2.26.2 Threads shall be unified (UNC for upto 1"dia and 8UN for > 1"dia) as per ANSI B.1.1 with
class 2A fit for studs and M/C bolts and class 2B fit for nuts.
2.26.3 Nuts for Bolts & Studs shall be the American Standard Hexagon Heavy Series.
3.0 DOCUMENTATION
3.1 No documents shall be submitted with the offer.
3.2 Detailed dimensioned cross section drawing with parts, materials, weight, etc. shall be
submitted through EIL eDMS for records/information.
4.0 SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE
4.1 Method of Manufacture
4.1.1 All carbon steel strainers having wall thickness 9.53 mm and above shall be normalized.
Carbon content shall be limited to .35% max. and Silicon .35% max. The normalizing heat
treatment shall be a separate heat treatment operation and not a part of the hot forming
operation. Normalizing shall be done after final cold draw pass for all thicknesses if cold
drawn.
4.1.2 All alloy steel (Cr-Mo) strainers shall be normalized and tempered. The normalizing and
tempering shall be a separate heat treatment operation and not a part of the hot forming
operation. The maximum room temperature tensile strength shall be 100,000 psig.
4.2 Impact Test
4.2.1 For all carbon steels and alloy steels with wall thickness over 20 mm, Charpy-V Notch impact
testing shall be carried out in accordance with paragraph UG-84 of ASME Section VIII, Div-1
per heat of material and per heat treating batch. Impact test specimen shall be in accordance
with ASTM A370. Impact energies at 0° C shall average greater than 27J (20 ft-lb) per set of 3
specimens, with a minimum of 19J (15ft-lb).
4.3 For all austenitic stainless steels, the weld deposit shall be checked for ferrite content. A
ferrite No (FN) not lens than 3% and not more than 10% is required to avoid sigma phase
embrittlement during heat treatment. FN shall be determined by ferritescope prior to post weld
heat treatment.
4.4 Hardness of weld and HAZ shall be 200 BHN (max) for carbon steel and 225 BHN (max) for
alloy steel.
Page 207 of 851

, ENGINEERS TECHNICAL NOTES FOR
sig-ar rircortom.3oor.o
INDIA LIMITED
in Govt ol indLe Undenak,o9)
Page 8 of 9
5.0 TESTING & INSPECTION
5.1 A11 strainers shall be hydrostatically tested at the lower of twice the design pressure and 1.5
times the class rating as per ASME B16.5 at ambient temperature.
5.2 All BW joints shall be 100% Radiographed and Fillet welds shall be 100% DP/MP checked.
5.3 Positive Material Identification (PMI) shall be performed as per the scope and procedures as
defined in the `Specification for Positive Material Identification (PMI) at Supplier's Works'
(No. 6-81-0001).
5.4 All welded Tees indicated in the MR as "Cryo" & "LT" shall meet Impact test requirements of
ASME B31.3. The Impact test temperature shall be (-)196°C & (-)45°C for Stainless Steel &
Low Temperature Carbon Steel respectively unless otherwise mentioned in the MR.
5.5 The stage wise inspection of non-IBR Strainers shall be done by EIL inspector before
despatch. EIL/Client's authorized representatives reserve full right to witness stagewise
inspection of all mandatory/applicable supplementary tests. However, for IBR items, the
tests/inspection shall be by IBR authority.
5.6 Material Test Certificates (Physical Properties, Chemical Composition and heat Treatment
Report) shall also be furnished.
5.7 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications/requisition. Test reports shall also be furnished for hydrotest and other
supplementary tests as specified in the requisition.
5.8 Refer Specification 6-81-0133 for Inspection & Test Plan for Strainers.
6.1 Following alternative body materials are acceptable :
AISI 420/AISI 410/A743 Gr.CA40/A743 Gr.CA15 in lieu of ASTM A105.

A182 F22 in lieu of A182 F11.
AISI 420/A182 Fl 1 in lieu of A182 F1.
6.2 Cast strainers with integrally cast flanges are also acceptable in lieu of equivalent forged
material. All castings offered in place of forgings shall be radiographed.
6.3 Forgings of equivalent material shall be acceptable in place of castings.
6.4 In the case of T type strainers, `Seamless' body is acceptable in place of "Welded" body.
`Welded' body shall not be acceptable in place of `Seamless'.
7.0 MARKING & DESPATCH
7.1 Each Strainer shall be legibly & conspicuously stamped on the body, in accordance with the
requirements of applicable standards along with special condition like IBR, CRYO, NACE,
H2 etc. Vendor shall also mark on the body the Location/Tag No. and Line Number
mentioned in MR attachment.
7.2 A11 items shall be dry, clean and free from moisture, dirt and loose foreign material of any
kind.
Page 208 of 851

2-1 ENGINEERS TECHNICAL NOTES FOR
$'g-a r laWs INDIA
1.1RA. vivaxt As..AlcA.1>
LIMITED
IA Govt 01 Ind. Undellaking)
Page 9 of 9
7.3 All items shall be protected from rust, corrosion, and mechanical damage during
7.4 Rust preventive, on machined surfaces to be welded, shall be easily removable with a
petroleum solvent or shall not be harmful to welding.
7.5 Paint or ink for marking shall not contain any harmful metal or metallic salts such as Zinc,
Lead or Copper which causes corrosive attack on heating.
7.6 Strainers under "IBR", "CRYO", "NACE" & "H2" shall be painted in Red, Light Purple,
Canary Yellow and sea green strips respectively for easy identification. Width of strip shall be
25 mm. Strainers coming under the purview of "IBR", "CRYO" , "NACE" &
"H2"(hydrogen) shall be painted with one circumferential stripe of colour red, light purple
brown, canary yellow & white respectively for easy identification. Width of stripe shall be
12mm for sizes less than 3" and 25mm for sizes 3" and above. Stripe shall be located one end
near to the bevel/socket/screwed/flanged end.
7.7 After testing, one coat of inorganic zinc silicate (minimum DFT 65 to 75 microns) shall be
applied as primer over the external surface for carbon steel / alloy steel strainers.
7.8 Each end of strainer shall be protected with the following materials :
Flange Face Wood or Plastic Cover

Bevelled End Wood or Plastic Cover
SW & SCRD End Plastic Cap
End protectors of wood / plastic to be used on flange faces shall be attached by at least three
bolts and shall not be smaller than the outside diameter of the flange. However plastic caps
for SW & SCRD end strainers shall be press fit type. End protectors to be used on beveled end
shall be securely and tightly attached.
8.0 ATTACHMENTS FOR MR
Format No.3-1643-0093: Data Sheet for Strainers
9.0 REFERENCES
6-81-0001 Specification for PMI at Supplier's Works
6-81-0133 Inspection and Test Plan for Strainers
6-78-0001 Specification for Quality Management System Requirements

from Bidders
Page 209 of 851

SPECIFICATION STANDARD SPECIFICATION No.
42:E4
/ati= ENGINEERS FOR
ei 051,1s3,41 (A Govt of India Undettakingf
MEDIUM AND HIGH VOLTAGE
CABLES AND ACCESSORIES Page 1 of 10
TR-714 74 d'ucl
c;c1(1 "On a#R:rft7
Fri 1-49-4r
SPECIFICATION
FOR
CABLES & ACCESSORIES

8 20/01/17 MKS BRB SRN
SPECIFICATION
REVISDANU STDAR
7 01/04/16 RG MKS BRB RN
SPECIFICATION
REVISDANU STDAR
6 11,704/11 PS ANPS UAP DM
SPECIFICATION
REVISDANU STDAR
5 20/04/09 PB UAP JMS ND
SPECIFICATION
REVISDANU STDAR
4 15/03/0 RKM AAN VPS SKG
SPECIFICATION
StandardsCommitteeC Standards
Bureau
Rev. Prepared Checked onvenor
Date Purpose Chairman
No by by
Approved by
Page 210 of 851

ei ENGINEERS FOR
tilire g INDIA LIMITED 6-51-0051 Rev. 8
IA Govt al India Unde[taking) MEDIUM AND HIGH VOLTAGE
Abbreviations:
ASTM American Society for Testing and Materials

BS British Standard
CEA Central Electricity Authority
DGMS Director General of Mines and Safety
EPR Ethylene Propylene Rubber
FR Flame Retardant
FRLS Flame Retardant Low Smoke
FS Fire Survival
HR PVC Heat Resistant Polyvinyl Chloride
ICEA Insulated Cable Engineers Association
IEC International Electro technical Commission
IS Indian. Standards
NEMA National Electrical Manufacturers Association
PVC Polyvinyl Chloride
UV Ultra Violet
XLPE Cross linked Polyethylene
Electrical Standards Committee
Convener: Mr. B.R:Bhogal

Members: Ms. S. Anand
Mr. Parag Gupta
Mr. M. K. Sahu
Ms. N S Bhattacharya
Mr. Saeed Akhtar (Inspection)
Ms. N.P. Guha (Projects)
Page 211 of 851

(31 eit4ENGINEERS FOR
Igzu kif5i-eg INDIA LIMITED
GOVT c/I InAjA UnderIAA ,A9) MEDIUM AND HIGH VOLTAGE
6-51-0051 Rev. 8
CONTENTS
1.0 SCOPE 4
2.0 STANDARDS 4
3.0 GENERAL CONSTRUCTION 5
4.0 CABLE ACCESSORIES 7
5.0 INSPECTION, TESTING AND ACCEPANCE 8
6.0 PACKING AND DESPATCH 10
Page 212 of 851

ENGINEERS FOR
tg-ar tameg
eit'aNt e61.390.3)
INDIA LIMITED
(A Govt of India Undertaking) MEDIUM AND HIGH VOLTAGE
6-51-0051 Rev. 8
1.0 SCOPE
This specification along with data sheets covers requirements for design, manufacture, testing
at works and supply of Fire survival Medium voltage cables and Flame Retardant Low Smoke
Medium & High Voltage cables and cable jointing / terminating accessories for medium and
high voltage systems.
2.0 STANDARDS
2.1 The cables and cables jointing & terminating accessories shall comply with the latest edition
of the following standards as applicable:
IS: 209 Specification for zinc.

IS: 1554 PVC insulated (heavy duty) electric cables.
IS: 3961(Pt-2) : Recommended current ratings for cables: Part - 2 PVC Insulated and
PVC sheathed heavy-duty cables.
IS: 3975 Mild steel wires, strips and tapes for armouring of cables.
IS: 5831 PVC insulation and sheath of electric cables.
IS: 6380 Specification for elastomeric insulation and sheath of electric cables.
IS: 7098 Cross-linked polyethylene insulated PVC sheathed cables.
IS: 8130 Conductors for insulated electric cables and flexible cords.
IS: 10418 Drums for electric cables.
IS: 10462 (Pt-1): Fictitious calculation method for determination of dimensions of
protective coverings of cables: Part - I Electrometric and thermo-
plastic insulated cables.
IS: 10810 Methods of test for cables:
Part 41: Mass of zinc coating on steel armour
Part 58: Oxygen index test
Part-61: Flame retardant test
Part-62:Fire resistance test for bunched cables.
Part-63: Measurement of Smoke density of Electric cables
under fire conditions
IS: 13573 Joints and terminations for polymeric cables for working voltages
from 6.6kV up to and including 33kV.
IEC: 60331-21: Tests for electric cables under fire conditions circuit integrity —
Pro:..edure..; and r..:q1; ,,m-ients - Cables of rated voltage up and
including 0.6/1.0kV.
IEC: 60332-1 Test of the fire behaviour on single core or single cable (flame
retardancy)
IEC: 60332-3 : Tests of the fire behaviour on bunched cables (reduced flame
propagation)
IEC: 61034 Measurement of smoke density of cables burning under defined
condition
NEMA-WC70 : Standard for non shielded power cables rated 2000V or less for
the distribution of electrical energy.
NEMA-WC53 : Standard test methods for extruded dielectric power, control,
instrumentation and portable cables for test.
ASTM-G-1 54 : Standard practice for operating fluorescent light apparatus for UV
exposure of non metallic materials.
ASTM-D-2863 : Measurement of minimum oxygen concentration to support candle
like combustion of plastics
BS: 7846 Electric cables- 600/1000V armoured fire resistant cables having
thermosetting insulation and low emission of smoke and corrosive
gases when affected by fire.
Page 213 of 851

k.11 el ENGINEERS FOR
g-ar QCs INDIA LIMITED
6-51-0051 Rev. 8
I 41R7I ,flecrAt +.1,3c10..1) Govt of In&. Uodettak ,N)
2.2 The cables and accessories shall also conform to the provisions of CEA Regulations and other
statutory regulations, as applicable.
2.3 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent one shall prevail. However, Owner's decision in this regard will be
final and binding.
3.0 GENERAL CONSTRUCTION
3.1 The cables shall be suitable for laying in trays, trenches, ducts, and conduits and for
underground-buried installation with uncontrolled backfill and possibility of flooding by water
and chemicals.
3.2 Outer sheath of all cables shall be black in colour and the minimum value of oxygen index
shall be 29% at 27 ± 2 ° C. In addition suitable chemicals shall be added into the PVC
compound of the outer sheath to protect the cable against rodent and termite attack. However,
for earthing cables; colour of outer sheath shall be green.
3.3 All cables covered in this specification shall be Flame Retardant Low Smoke (FRLS) or Fire
Survival (FS). The outer sheath of FRLS cables shall possess flame propagation properties
meeting requirements as per IS-10810 (Part-62) category AF. FRLS cable shall be identified
by indenting, embossing or printing the appropriate legend i.e. 'FRLS, Category — C2'
throughout the cable length. FRLS properties shall be as per IS:10810 Part 61 & 62, IEC-
60332 Part 1 & Part 3, IEEE-383, IEC-61034, IEC-60754 Part 1, ASTM-D-2863.
3.4 Sequential marking of the length of the cable in metres shall be provided on the outer sheath at
every one metre. The embossing/engraving shall be legible and indelible.
3.5 The overall diameter of the cables shall be strictly as per the values declared by the
manufacturer in the technical information subject to a maximum tolerance of ±2 mm up to
overall diameter of 60mm and ±3mm for beyond 60mm.
3.6 PVC/ Rubber end caps shall be supplied free of cost for each drum with a minimum of eight
per thousand metre length. In addition, ends of the cables shall be properly sealed with caps to
avoid ingress of water during transportation and storage.
3.7 The joints in armour wire/strips shall be made by brazing or welding and any surface
irregularities shall be removed. A joint in any wire/strip shall be at least 300mm. from the
nearest joint in any wire/strip in the complete cable.
3.8 The cables meant to be used in mining area under the jurisdiction of DGMS shall satisfy the
following
(a) "DGMS CERTIFIED" to be embossed at outer sheath at regular interval.

(b) Cables to be used in Mines shall have copper conductor only.
(c) The resistance of armour shall not exceed that of the conductor as specified in IS-8130
by more than 33%. To satisfy this, substitution of galvanised steel wire/strip in
armouring by the required number of tinned copper wires/strips is permissible.
(d) For mining cables, the size and type of armour shall be such that the combined
conductance of armour shall be equivalent to 75 percent of the conductance of the
largest conductor of the cable.
Page 214 of 851

ENGINEERS FOR
051-eG INDIA
INDIA
LIMITED 6-51-0051 Rev. 8
(A Gov( al India Undet(aking) MEDIUM AND HIGH VOLTAGE
3.9 Medium Voltage Cables
3.9.1 All power/control cables for use on medium voltage systems shall be heavy-duty type,
650/1100V grade with aluminium/ copper conductor, PVC/XLPE (as mentioned in datasheet /
Material requisition) insulated, inner-sheathed, armoured/ unarmoured and overall PVC
sheathed. XLPE insulated cables shall meet the requirement specified in IS-7098 (Part-1).
3.9.2 The conductors shall be solid for conductor of nominal area up to and including 6mm 2 and
stranded beyond 6mm 2. Conductors of nominal area less than 16 mm 2 shall be circular only.
Conductors of nominal area 16 mm 2 and above may be circular or shaped as per IS 8130.
Cables with reduced neutral conductor shall have sizes as per Table 1 of IS 1554 (Part-1).
3.9.3 The core insulation shall be with PVC/XLPE compound applied over the conductor by
extrusion. PVC compound shall conform to the requirements of type 'C compound as per IS:
5831. The thickness of insulation and the tolerance on thickness of insulation shall be as per
Table 2 of IS: 1554 (Part-1). Control cables having 6 cores and above shall be identified with
prominent and indelible Arabic numerals on the outer surface of the insulation. Colour of the
numbers shall contrast with the colour of insulation with a spacing of maximum 50 mm
between two consecutive numbers. Colour coding for cables up to 5 cores shall be as per
Indian standard.
3.9.4 The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC
conforming to the requirements of Type ST-2 PVC compound as per IS: 5831. The minimum
thickness of inner sheath shall be as per Table-4 of IS: 1554 (Part-1). Single core cables shall
have no inner sheath.
3.9.5 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables intended for use on AC system, the armouring shall be of non-thagnetic
material. For multicore cables, the armour shall be by single round galvanised steel wires
where the calculated diameter below armouring does not exceed 13 mm and by galvanised
steel strips where this dimension is greater than 13 mm. Requirement and methods of tests for
armour material and uniformity of galvanisation shall be considered as per IS - 3975 and IS -
10810 (Part 41). The dimensions of armour shall be considered as per method (b) of IS - 1554
(Part -1). For single core cables, the armour shall be with H4 grade hard drawn aluminium
round wire of 2.5 mm diameter.
3.9.6 The outer sheath for the cables shall be applied by extrusion and shall be formulated for lower
smoke and shall be of PVC compound conforming to the requirements of type ST-2
compound as per IS: 5831. The minimum and average thickness of outer sheath for
unarmoured cables and minimum thickness of outer sheath for armoured cables shall be as per
Table-7 of IS: 1554 (Part -1).
3.9.7 If heat resisting PVC cables are specified in the data sheet, it shall be possible to continuously
operate the cable at a maximum conductor temperature of 85°C under full load condition and
160°C under short-circuit condition.
3.9.8 For XLPE insulated cables, it shall be possible to continuously operate the cable at a
maximum conductor temperature of 90°C under full load condition and 250°C under short-
circuit condition.
3.9.9 The fire survival cables shall meet the following additional requirements :
i) The insulation shall be of EPR or equivalent material with glass mica tape below or
above insulation.
ii) The cables shall meet requirement of circuit integrity test for a minimum period of 3
hours at maximum temperature of 950 0 C.
Page 215 of 851

ENGINEERS
N FOR
oge.n Emeg
(ailvA ofrowe an A)
INDIA LIMITED
IA Govt of India Unde MEDIUM AND HIGH VOLTAGE
6-51-0051 Rev. 8
3.10 High Voltage Cables
3.10.1 Power cables from 3.3kV and up to and including 33kV systems shall be Aluminium/ Copper
conductor, XLPE insulated, sheathed, armoured/ unarmoured and overall PVC sheathed.
3.10.2 The conductors shall be stranded and compacted circular for all cables.
3.10.3 All cables rated 3.8/ 6.6kV and above shall be provided with both conductor screening and
insulation screening. The conductors shall be provided with non-metallic extruded semi
conducting screen.
3.10.4 The core insulation shall be with cross linked polyethylene insulating compound dry cured,
applied by extrusion. It shall be free from voids and shall withstand all mechanical and
thermal stresses under steady state and transient operating conditions. It shall conform to the
properties given in Table-1 of IS: 7098 (Part -2).
3.10.5 The insulation screen shall consist of non-metallic extruded semi-conducting compound in
combination with a non-magnetic metallic copper screen. The copper screen for all the three
cores together shall be capable of carrying the single line to ground fault current value and the
duration specified in the data sheet. For single core cable, copper screen provided shall be
capable of carrying the single line to ground fault current value and the duration specified in
the data sheet.
3.10.6 The conductor screen, XLPE insulation and insulation screen shall all be extruded in one
operation by 'Triple Extrusion' process to ensure perfect bonding between the layers. The core
identification shall be by coloured strips or by printed numerals.
3.10.7 The inner sheath shall be applied over the laid up cores by extrusion and shall conform to the
requirements of type ST 2 compound of IS: 5831. The extruded inner sheath shall be of
uniform thickness. In case of single core cables, there shall be extruded inner sheath between
insulation metallic screen and armouring.
3.10.8 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables intended for use on AC system, the armouring shall be of non-magnetic
material. For multicore cables, the armour shall be by galvanised steel strips. Requirement and
methods of tests for armour material and uniformity of galvanisation shall be as per IS - 3975
and IS -10810 (Part 41). The dimensions of armour shall be as per method (b) of IS - 7098
(Part -2). For single core cables, the armour shall be with H4 grade hard drawn aluminium
round wire of 2.5 mm diameter.
3.10.9 The outer sheath of the cables shall be applied by extrusion over the armouring and shall be of
PVC compound conforming to the requirements of Type ST 2 compound of IS: 5831. The
minimum and average thickness of outer sheath for unarmoured cables and minimum
thickness of outer sheath for armoured cables shall be as per IS: 7098 (Part-2).
3.10.10 The thickness of the insulation, inner sheath shall be governed by values given in Table-4 and
Table-5 of IS: 7098 (Part -2).
4.0 CABLE ACCESSORIES
4.1 The termination and straight through jointing kits for use on the systems shall be suitable for
the type of cables offered as per this specification and shall meet requirements of IS 13573.
4.2 The accessories shall be supplied in kit form. Each component of the kit shall carry the
manufacturer's mark of origin.
Page 216 of 851

err ta-eg
ENGINEERS FOR
eiecnie 0,1347.0 IA Govt of India Undeltaiong) MEDIUM AND HIGH VOLTAGE
4.3 The kit shall include all stress grading, insulating and sealing materials apart from conductor
fittings and consumable items. An installation instruction sheet shall also be included in each
kit.
4.4 The contents of the accessories kit including all consumable shall be suitable for storage
without deterioration at a temperature of 45° C, with shelf life extending to more than 5 years.
4.5 Terminating Kits
The terminating kits shall be suitable for termination of the cables to an indoor switchgear or
to a weatherproof cable box of an outdoor mounted transformer/ motor. For outdoor
terminations, weather shields/ sealing ends and any other accessories required shall also form
part of the kit. The terminating kits shall be from one of the makes/ types mentioned in the
data sheet.
4.6 Jointing Kits
The straight through jointing kits shall be suitable for installation on overhead trays, concrete
lined trenches, and ducts and for underground burial with uncontrolled backfill and possibility
of flooding by water and chemicals. These shall have protection against any mechanical
damage and suitably designed to be protected against rodent and termite attack. The inner
sheath similar to that provided for cables shall be provided as part of straight through joint.
The jointing kits shall be from one of the makes/ types mentioned in the data sheet.
5.0 INSPECTION, TESTING AND ACCEPTANCE
The cables shall be tested and inspected at the manufacturer's works. Manufacturer shall
furnish all necessary information concerning the raw material supply to EIL/ Owner's
inspectors. The inspector shall have free access to the manufacturer's works for the purpose of
inspecting the process of manufacture in all its stages and will have the power to reject any
material, which appears to be of unsuitable description or of unsatisfactory quality. For HV
cables, the vendor shall give at least 2 weeks advance notice to the purchaser, regarding the
date of testing to enable purchaser's representative to witness the tests.
5.1 Cables
5.1.1 After completion of manufacture of cables and prior to despatch, the cables shall be subjected
to type, routine, acceptance and special tests as detailed below. The test reports for all cables
shall be got approved from the Engineer before despatch of the cables.
5.1.2 All routine tests, acceptance tests, type tests and additional type tests for improved fire
performance shall be carried out as listed in IS: 1554 (Part-1) and IS: 7098 (Part-2) on PVC
and XLPE insulated cables respectively.
5.1.3 The test requirements for PVC insulation and sheath of cables shall be as per latest revision of
IS: 5831.
5.1.4 Test for Resistance to Ultra Violet Radiation: This test shall be carried out as per ASTM-G-53
or ASTM-G-154 on outer sheath. The retention value of tensile strength and ultimate
elongation after the test shall be minimum 60 % of tensile strength and ultimate elongation
before the test. Test certificates with respect to this test (not older than one year) from
recognised testing laboratory to be furnished for review by EIL before despatch clearance of
cables. In case test certificates are not available, test is to be conducted by vendor at his own
cost in any recognised test laboratory or in house testing laboratory, before despatch clearance
Page 217 of 851

ENGINEERS FOR
Ogeji t115ieg INDIA LIMITED 6-51-0051 Rev. 8
1.12PI 2:12M2 .710.1) A Coot 04 India Undertaking) MEDIUM AND HIGH VOLTAGE
of cables. Sampling for this test is to be done randomly once for each order, provided outer
sheath remains same.
5.1.5 Acceptance tests as per IS-1554 (Part-1) and IS-7098 (Part-2) and the following special tests
to be performed on the cables as per sampling plan for all cables. However these tests are
required to be witnessed by EIL/ Owner for HV cables.
a. Accelerated water absorption test for insulation as per NEMA-WC-70. (For PVC
insulated cables) and as per NEMA-WC-53 (for XLPE/ EPR insulated cables). Test
certificates with respect to this test (not older than one year) from recognised testing
laboratory to be furnished for review by EIL before despatch clearance of cables. In case
test certificates are not available, test is to be conducted by vendor at his own cost in any
recognized test laboratory or in house testing laboratory, before despatch clearance of
cables. Sampling for this test is to be done randomly once for each order, provided type of
insulation remains same.
b. Dielectric Retention Test: The dielectric strength of the cable insulation tested in
accordance with NEMA-WC-70 at 75 ± 1° C shall not be less than 50 % of the original
dielectric strength. (For PVC insulated cables). Test certificates with respect to this test
(not older than one year) from recognised testing laboratory to be furnished for review by
EIL before despatch clearance of cables. In case test certificates are not available, test is
to be conducted by vendor at his own cost in any recognized test laboratory or in house
testing laboratory, before despatch clearance of cables. Sampling for this test is to be done
randomly and once for each order.
c. Oxygen Index Test: The test shall be carried out as per IS-10810 (Part 58). Sampling to
be done for every offered lot/size as per sampling plan.
d. Flammability Test: The test shall be carried out on finished cable as per IS-10810 (Part 61
& 62). Sampling for these tests is to be done randomly once for each order, provided
outer sheath remains same. The acceptance criteria for tests conducted shall be as under:
Part-61-The cable meets the requirement if there is no visible damage on the test
specimen within 300 mm from its upper end
Pan-62-The maximum extent of the charred portion measured on the test ample should
not have reached a height exceeding 2.5 m above the bottom edge of the burner at the
front of the ladder.
e. Test for rodent and termite repulsion property shall be done by analysing the property by
chemical method.
5.1.6 Following tests shall be carried out to prove FRLS property of the cable.
a. Critical oxygen index as per ASTM-D-2863 i.e. Determination of % of oxygen required

for combustion at room temperature of FRLS sheath which shall remain as 29%(min.)
b. Temperature index as per ASTM-D-2863 i.e. to determine at what temperature normal

oxygen content of 29% in air will support combustion of FRLS sheath which shall remain
as 250°C.
c. Halogen acid gas emission as per IEC-60754 Part 1 i.e. to determine the % of release of
hydrochloric acid gas from the FRLS sheath under fire which shall be 20% (max.)
Page 218 of 851

/-1 ENGINEERS FOR
015teg INDIA LIMITED 6-51-0051 Rev. 8
Myer, vleotte 41,1J4ZeM (A Govt of Ind. Under!Moog) MEDIUM AND HIGH VOLTAGE
d. Smoke Density Test shall be as per ASTM D - 2843 and Smoke Density Rating of FRLS
Sheath shall be 60% (max.).
5.1.7 The test for circuit integrity for fire survival cables shall be carried out as per lEC-60331
(Part-21).
5.2 Cable Accessories
Type tests should have been carried out to prove the general qualities and design of a given
type of termination/ jointing system as per IS-13573. The type test certificates from
independent testing laboratory shall be submitted before despatch.
6.0 PACKING AND DESPATCH
6.1 Cables shall be despatched in non-returnable steel drums of suitable barrel diameter, securely
packed, with the take-off end fully protected against mechanical damage. Ferrous parts used
shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit
or storage.
6.2 On the flange of the drum, necessary information such as project title, manufacturer's name,
type, size, voltage grade of cable, length of cable in metres, drum no., cable code, BIS
certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum
with suitable instructions to show the direction of rotation of the drum.
6.3 Cables shall be supplied in drum lengths as follows:
6.3.1 MV Cables
- Multicore Power cables upto 6 mm 2 1000 m
Multicore Power cables from 10 mm 2 up to 500 mm 2 500 m
Single Core Power cables upto 630 mm 2 1000 m
Control cables upto 61 cores 1000 m
6.3.2 HV Power Cables Upto 11kV Grade
Three Core cables upto 400 mm 2 500 m

Single Core cables upto 100 mm 2 1000 m
Single Core cables above 400 mm 2 and upto 1000 mm 2 750 m
6.3.3 HV Power Cables Above 11kV Grade and upto 33kV Grade
Three Core cables upto 300 mm 2 grade 350 m

Single Core cables upto 400 mm 2 1000 m
Single Core cables above 400 mm 2 and upto 1000 mm2 500 m
However exact drum lengths shall be finalised during order execution. A tolerance of ± 3 %
shall be permissible for each drum. However overall tolerance on each size of cable shall be
limited to ±2%.
Page 219 of 851

SPECIFICATION FOR STANDARD SPECIFICATION No.
1151-adft ENGINEERS COMMUNICATION AND 6-51-0052 Rev. 6
5g7 Raitg W INDIA LIMITED
A CON nos unoenoingi FIRE ALARM CABLES Page 1 of 10
Tiwg at{ afT9. clam

* -Wu
SPECIFICATION
FOR
COMMUNICATION AND
FIRE ALARM CABLES
taL
6 01/04/16 RG MKS BRB RN
SPECIFICATION
5 27/04/11 PS ANPS UAP DM
SPECIFICATION
4 25/04/08 ANPS UAP JMS VC
SPECIFICATION
3 21/03/03 UAP AAN VPS SKG
SPECIFICATION
2 05/05/97 NS VPS SG AS
SPECIFICATION
Standards Standards
Committee Bureau
Prepared Checked
Rev. Date Purpose Convenor Chairman
by by
Approved by
Page 220 of 851

ENGINEERS
fanINDIA LIMITED COMMUNICATION AND 6-51-0052 Rev. 6
0417, E9701701J(10.9) co.. OI ima UndertaltrIgl
FIRE ALARM CABLES Page 2 of 10
Abbreviations:
ASTM : American Society for Testing and Materials

BS British Standard
DOT Department of Telecommunications (Government of India)
FR Flame Retardant
FRLS Flame Retardant Low Smoke
FS Fire Survival
HR PVC : Heat Resistant Polyvinyl Chloride
IEC International Electro technical Commission
IEEE Institute of Electrical and Electronics Engineers
IS Indian Standards
LF Low Frequency
NEMA : National Electrical Manufacturers Association
PE Polyethelene
PO Purchase Order
UV Ultra Violet
VDE Verband Deutscher Elecktrotechniker
Convener: Mr. B.R. Bhogal

Mr. Parag Gupta
Mr. M. K. Sahu
Ms. N. S. Bhattacharya
Mr. Saeed Akhtar (Inspection)
Page 221 of 851

E NGINEERS
sgar INDIA LIMITED COMMUNICATION AND 6-51-0052 Rev. 6
IA Govt of India Underlakim FIRE ALARM CABLES Page 3 of 10
CONTENTS
1.0 SCOPE 4
2.0 CODES AND STANDARDS 4
3.0 SITE CONDITIONS 5
4.0 TECHNICAL REQUIREMENTS FOR NON JELLY FILLED CABLES 5
5.0 TECHNICAL REQUIREMENTS FOR JELLY FILLED CABLES 7
6.0 INSPECTION, TESTING AND ACCEPTANCE 9
Page 222 of 851

arae.1 SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGNEERS
ar INDIA LIMITED COMMUNICATION AND 6-51-0052 Rev. 6
(A Go.t of Incla Undertalong)
1.0 SCOPE
The intent of this specification is to define the requirements for design, manufacture and
supply of Flame Retardant Low Smoke type and Fire Survival type PVC sheathed cables for
use in plant communication and fire alarm systems and jelly filled telecommunication cables.
The equipment shall comply with the requirements of the latest revision of the following
standards:
2.1 BIS and other Standards
ASTM D-883 Standard terminology relating to plastics.

ASTM-D-2863 Measurement of minimum oxygen concentration to support
candle like combustion of plastics
ASTM-G-154 Standard practice for operating fluorescent light apparatus for
UV exposure of non-metallic materials.
IEC: 60331-21 Tests for electric cables under fire conditions circuit integrity —
Procedures and requirements — Cables of rated voltage up and
including 0.6/1.0kV.
ASTM D-924 Standard test method for dissipation factor (or power factor)
and relative permittivity (dielectric constant) of electric
insulating liquids.
BS-6234 Specification for polythene insulation and sheath of electric
cables.
IS-694 PVC insulated cables for working voltages upto and including
1100V.
IS-1554 (Part 1) PVC insulated (heavy duty) electric cables (Part-1 for working
voltages up to and including 1100V).
IS-5831 PVC insulation and sheath of electric cable.
IS-8130 Conductors for insulated cables and flexible cords.
IS-9938 Recommended colour for PVC insulation for LF wires and
cables.
IS-10418 Drums for electric cables.
IS-10462 (Part 1) Fictitious calculation method for determination of dimensions
of protective coverings of cables (Part-1: Elastomeric and
thermoplastic insulated cables).
IS-10810 (Part 58) Methods of test for cables (Part 58: Oxygen index test).
IS-10810 (Part 61) Methods of test for cables (Part 61: Flame retardant test)
IS-10810 (Part 62) Methods of test for cables (Part 62: Fire resistance test for
bunched cables).
IS-12444 Continuously cast and rolled electrolytic copper wire rods for
electrical conductors.
2.2 DOT Standards
GR/WIR-06/03 Specification for cable - switchboard (Screened and

Unscreened) - Generic requirements.
GR/CUG-01/03 Specification for solid polythene insulated fully filled,
polythene sheathed underground telecom cables.
2.3 In case of imported cables, standards of the country of origin shall be applicable, if these
standards are equivalent to or stringent than the applicable Indian standards.
2.4 The cables shall also conform to the provisions of the CEA Regulations and other statutory
regulations currently in force in the country.
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Itilfazre ENGINEERS
COMMUNICATION AND
sig-(41EMeg, INDIA LIMITED 6-51-0052 Rev. 6
IP Govl of India Undeptakingi
2.5 In case Indian standards are not available for any material, standards issued by IEC/ BS/ VDE/
IEEE/ NEMA or equivalent agency shall be applicable.
2.6 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent one shall prevail. However, Owner's decision in this regard will be
final and binding.
3.0 SITE CONDITIONS
Cables shall be suitable for installation in following conditions:
i. Above ground in open-air locations (trays/ ducts) in tropical, humid and corrosive
atmosphere prevalent in refineries/ petrochemical plants with severe weathering and
exposure to solar radiation.
ii. Directly buried in underground trenches, conduits with uncontrolled back-fill and
possibility of flooding by water and chemicals.
iii. Design ambient air temperature of 40°C/ ground temperature of 30°C.
4.0 TECHNICAL REQUIREMENTS FOR NON JELLY FILLED CABLES
4.1 Non jelly filled communication and fire alarm cables shall in general conform to the
requirements of DOT specification GR/WIR-06/03.
4.2 Conductors
4.2.1 The size of conductor shall be as per job requirement.
4.2.2 The conductors shall consist of annealed, high conductivity solid copper wire, smoothly
drawn, circular in cross-section, uniform in quality, free from defects and uniformly coated
with pure tin and shall conform to Cl. 3.0 of DOT specification GR/WIR-06/03.
4.3 Insulation
4.3.1 The core insulation shall be with PVC compound applied over the conductor by extrusion.
4.3.2 PVC insulation shall meet the following requirements:
Conductor Diameter Thickness of Insulation

Type of Insulation
(Area) (Minimum)
Up to 0.5mm (0.2mm 2) 0.18 mm
Above 0.5mm (0.2mm2) &
0.26 mm
up to 0.71mm (0.4mm 2)
Above 0.71mm (0.4mm 2) &
0.31 mm
up to 0.9mm (0.63mm2)
Above 0.9mm (0.63mm 2) & Type-A or B as per IS-5831
0.39 mm
up to 1.12mm (1mm 2)
Above 1.12mm (1mm2) &
0.58 mm
up to 1.38mm (1.5mm2)
1.78mm (2.5mm2) 0.71 mm
2.26mm (4mm2) 0.80 mm
4.3.3 The colours used for insulation shall conform as nearly as practicable to the standard colours
as per IS-9938. The wire insulation shall have colours in accordance with Table-2 of DOT
specification GR/WIR-06/03. The applied colour shall neither have deleterious effect on the
electrical, mechanical or ageing properties of basic insulation nor shall get damaged by any
friction etc.
4.3.4 For single pair cables, the colour shall be incorporated in the insulation.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL -All rights reserved
Page 224 of 851

lata_Jes,;,
ENGINEERS
COMMUNICATION AND
411447IT Rift W INDIA LIMITED 6-51-0052 Rev. 6
IA Goo of ham Ur,*ltakingi
4.3.5 For multi pair cables, cores shall have uniform pattern of continuous spiral (Pitch not
exceeding 25mm) to facilitate easy identification. This may be done by the application of one
or more coloured strips on a base colour or by direct extrusion.
4.3.6 Alternately, colouring may consist of concentric coloured rings or dots or dashes on the base
colour. The coloured rings, dots or dashes shall have a width of not less than 1.0mm and shall
be repeated along the length of the insulation at an interval not less than 15mm and not more
than 25mm.
4.3.7 The dots or dashes shall be applied on diametrically opposite sides of the insulation, so that all
colours are visible when the insulation is viewed from any side.
4.4 Twisting
The two insulated conductors of a pair shall be uniformly twisted with a suitable right hand
lay, which shall not exceed 80mm.
4.5 Core Formation
The core formation shall conform to Cl. 6.0 of DOT specification no. GR/WIR-06/03.
4.6 Screen
4.6.1 The cables shall be provided with overall screen. The screen shall be of aluminium tape with
minimum thickness of 0.04mm. The overlap shall be minimum 3mm for cables up to 50 pair &
minimum 6mm for cables above 50 Pair. The screen shall be backed by an outer protective
layer of 0.13mm PVC tape or other non-hygroscopic material lapped applied longitudinally or
helically with overlap.
4.6.2 The cables shall be provided with a drain wire. Drain wire shall have a minimum cross-section
of 0.5mm2, shall be composed of multistrand bare tinned annealed copper conductor. The drain
wire shall be in continuous contact with the aluminium side of the overall screen. The drain
wire resistance including screen shall not exceed 30 ohm/km.
4.7 Ripcord
A non-metallic ripcord of suitable quality shall be laid longitudinally under the inner sheath &
screen. The ripcord when pulled shall cut through the sheath and strip the core.
4.8 Inner Sheath
4.8.1 An extruded inner sheath of type ST2 PVC, as per IS-5831, with minimum thickness as per
Table-4 of IS-1554 (Part-1) shall be applied over the laid up core, by extrusion to fit closely on
it.
4.8.2 The inner sheath shall be as circular as possible. It shall be possible to remove the inner sheath
without damage to the insulation.
4.8.3 When one or more layers of non-hygroscopic tape is helically applied over the laid up cores, as
a binder, the thickness of such tape(s) shall not be construed as a part of the inner sheath.
4.9 Armour
4.9.1 The cables shall be provided with armouring, made of hot dip galvanised steel wire /strip over
the inner sheath.
4.9.2 The armour shall be by means of 1.4mm thick round wires for cables with under armour
diameter upto 13mm. For cables with an under armour diameter above 13mm, the armour shall
either be of steel strip or round wire with thickness as per IS-1554 (Part-1).
4.10 Outer Sheath
4.10.1 The cables shall be provided with an extruded PVC sheath for external protection. The PVC
shall be type ST2 PVC, as per IS-5831.
Page 225 of 851

OPZIET ENGINEERS
$igirr Weg INDIA LIMITED COMMUNICATION AND 6-51-0052 Rev. 6
IA Own al India Urvierlaking)
4.10.2 All cables covered in this specification shall be flame retardant low smoke (FRLS). The other
sheath shall be with oxygen index 29% at 27+2 °C and possess flame retardant low smoke
properties meeting the requirements of IS 10810 Part-62 category - AF. In addition, suitable
chemicals shall be added to the PVC compound of the outer sheath to protect the cable against
rodent and termite attack.
4.10.3 The thickness of outer sheath shall be as per IS-1554 (Part 1).
4.10.4 The outer sheath shall fit tightly on the armour and shall be applied in such a manner that no
undue residual strain is left in the material.
4.10.5 The outer sheath shall be red in colour for cables to be used for fire alarm system, grey in
colour for cables to be used for telephone & communication system and black in colour for all
other functions.
4.10.6 Sequential marking of the length of the cable, in meters, shall be provided on the outer sheath
at every one meter. The marking shall be legible and indelible by suitable method.
4.10.7 The overall diameter of the cables shall be strictly as per the values declared in the data sheet,
subject to a maximum tolerance of +2mm.
4.11 The fire survival cables (if specified in data sheet) shall meet the following additional
requirements:
i) The insulation shall be of EPR or equivalent material with glass mica tape below or above
insulation.
ii) The cables shall meet requirement of circuit integrity test for a minimum period of 3
hours at maximum temperature of 950 ° C.
iii) Vendor shall have the test certificate for circuit integrity test as per IEC: 60331-21.
4.12 Cable Capacitance
4.12.1 The core to core capacitance of the cables shall not exceed 100nF/km at I kHz.
4.12.2 The core to screen capacitance for the screened cables shall not exceed 250nF/km at IkHz.
5.0 TECHNICAL REQUIREMENTS FOR JELLY FILLED CABLES
5.1 Jelly filled telecom cables shall in general conform to the requirements of DOT specification
GR/CUG-01/03.
5.2 Conductors
5.2.1 The conductors shall consist of annealed, high conductivity solid copper wire, smoothly
drawn, circular in cross-section, uniform in quality, free from defects and uniformly coated
with pure tin and shall conform to Cl. 3.0 of DOT specification GR/CUG-01/03.
5.3 Insulation
5.3.1 Each conductor shall be insulated with insulating grade PE conforming to Cl. 4.0 of DOT
specification GR/CUG-01/03.
5.4 Twisting
The two insulated conductors of a pair shall be uniformly twisted with a suitable right hand
lay, which shall not exceed 150mm.
5.5 Core Formation
The core formation shall conform to Cl. 6.0 of DOT specification GR/CUG-01/03.
5.6 Filling Compound
5.6.1 The cable core shall be filled with a suitable stable water resistant compound, which shall be
compatible with the insulation, binders and tapes used in the cable.
Page 226 of 851

151M2Te? ENGINEERS
$€-L it INDIA COMMUNICATION AND 6-51-0052 Rev. 6
W IA Cal of India undertaking)
5.6.2 It shall be homogeneous and uniformly mixed material containing an anti-oxidant.

5.6.3 The compound shall not obscure the identification of the colour of the insulation of the
conductors.
5.6.4 It shall not contain dirt, metallic particles or other foreign matter.
5.6.5 The compound shall be readily removable from the insulated conductors by wiping.
5.6.6 It shall be free from any unpleasant odour and shall have no toxic or dermatic hazards.
5.6.7 The flash point of the compound shall not be less than 200°C.
5.6.8 The volume resistivity measured at 100°C shall not be less than 10 1° ohm-cm.
5.6.9 The permittivity at 1 MHz tested as per ASTM D-924 shall not be greater than 2.3 at 20°C.
5.7 Core Wrapping
At least one closed helical or longitudinal application of a nonhygroscopic and nonwicking
polyester tape or tape of any other suitable material shall be provided over the cable core.
5.8 Screen
5.8.1 The cables used for telephone system shall be provided with overall screen. The screen shall
be of aluminium tape with minimum thickness of 0.2mm. The overlap shall be minimum 3mm
for cables having maximum diameter over inner sheath < 30mm & minimum 6mm for cables
having maximum diameter over inner sheath 30mm. The screen shall be coated with 0.05
mm nominal thickness polythene/copolymer on both sides. The thickness of the composite
tape shall be 0.3mm ± 15%.
5.8.2 The aluminium tape shall be electrically continuous through out the length of the cable.
5.9 Inner Sheath
5.9.1 The inner sheath shall be as circular as possible and free from pinholes and other defects. It
shall be possible to remove the inner sheath without damage to the insulation.
5.9.2 The inner sheath shall be of polythene conforming to type 03C or HO3C of BS 6234 and shall
contain a suitable antioxidant system. The material shall be virgin as per ASTM D-883 and
meet the requirements of Cl. 10.1 of DOT specification no. GR/CUG-01/03.
5.9.3 The thickness of inner sheath shall conform to Table-6 of DOT specification no. GR/CUG-
01/03.
5.9.4 The maximum diameter over inner sheath shall conform to Table-7 of DOT specification no.
GR/CUG-01/03.
5.10 Armour
5.10.1 The cables shall be provided with bedding and armour over the inner sheath.
5.10.2 The bedding shall consist of two close helical lappings of polythene or polypropylene tape.
Each tape shall be applied with a minimum of 5% overlap.
5.10.3 The armour shall be made of hot dip galvanised steel tape of thickness as per Table-8 of DOT
specification GR/CUG-01/03 .
5.11 Outer Sheath
5.11.1 The external protection shall consist of a polythene sheath conforming to the material
specification defined in Clause 5.9 above.
5.11.2 The thickness of outer sheath shall conform to Table-9 of DOT specification GR/CUG-01/03.
5.11.3 The outer sheath shall be as circular as possible and free from pinholes and other defects.
5.11.4 Colour of outer sheath shall be grey.
Page 227 of 851

ENGINEERS
51g2:8 Eiareg VW INDIA LIMITED COMMUNICATION AND 6-51-0052 Rev. 6
5.11.5 The maximum diameter over outer sheath shall conform to Table-7 of DOT specification
GR/CUG-01/03.
5.12 Cable Capacitance
The average mutual capacitance of the pairs measured at 800 to 1000Hz shall be 52 ± 3 nF/km.
However, the mutual capacitance of individual pairs shall be within the limits of 52 ± 4.5
nF/km.
6.1 The cables shall be tested and examined at the manufacturer's works. All the materials
employed in the manufacture of the cable shall be subjected to examination, testing and
approval by EIL/ Owner. Manufacturer shall furnish all necessary information concerning the
supply to EIL/ Owner's inspectors. The inspector shall have free access to the manufacturer's
works for the purpose of inspecting the process of manufacture in all its stages and will have
the power to reject any material, which appears to be of unsuitable description or of
unsatisfactory quality.
6.2 The following acceptance tests shall be conducted on the completed jelly filled cables as per
the test procedures given in DOT specification GR/CUG-01/03 and this specification:
i. Measurement of diameter of conductor, over inner sheath & over outer sheath.
ii. Measurement of thickness of insulation, inner sheath, screen, armour & outer sheath.
iii. Measurement of resistance of conductor.
iv. Measurement of resistance unbalance.
v. Continuity check & measurement of resistance of Poly-al tape.
vi. Colour coding.
vii. Conductor continuity test.
viii. Mutual capacitance test.
ix. Capacitance unbalance test.
x. Cross talk test.
xi. Attenuation test.
xii. Insulation resistance test.
xiii. Dielectric strength test.
xiv. Drip test.
xv. Armour galvanisation test.
xvi. Conductor annealing test.
xvii. Measurement of drum length.
6.3 Following tests shall be carried out to prove FRLS property of the cable.
a. Critical oxygen index as per ASTM-D-2863 i.e. Determination of % of oxygen required

for combustion at room temperature of FRLS sheath which shall remain as 29% (min.)
b. Temperature index as per ASTM-D-2863 i.e. To determine at what temperature normal

oxygen content of 29% in air will support combustion of FRLS sheath which shall remain
as 250°C.
c. Halogen acid gas emission as per IEC-60754 Part 1 i.e. To determine the % of release of
hydrochloric acid gas from the FRLS sheath under fire which shall be 20% (max.)
d. Smoke Density Test shall be as per ASTM D - 2843 and Smoke Density Rating of FRLS
Sheath shall be 60% (max.).
6.4 The test for circuit integrity for fire survival cables shall be carried out as per IEC-60331 (Part-
21).
6.5 The following tests shall be conducted on the completed non jelly filled cables as per the test
procedures given in DOT specification GR/WIR-06/03 and this specification:
Page 228 of 851

$.reel ENGINEERS
S'frar EI9e6 INDIA LJMITED COMMUNICATION AND 6-51-0052 Rev. 6
Gori of hula Undenaking)
6.5.1 Acceptance tests
i. Measurement of diameter of conductor, over inner sheath & over outer sheath.
ii. Measurement of thickness of insulation, inner sheath, screen, armour & outer sheath.
iii. Measurement of resistance of conductor.
iv. Colour coding.
v. Conductor continuity test.
vi. Mutual capacitance test.
vii. Capacitance unbalance test.
viii. Insulation resistance test.
ix. High voltage test.
x. Armour galvanisation test.
xi. Conductor annealing test.
xii. Measurement of drum length.
6.5.2 Special Tests
The non jelly filled cables shall also be subjected to following special tests.
i. Oxygen index test as per IS-10810 (Part 58).

ii. Flammability test on finished cable as per IS-10810 (Part 61 & 62).
The special test shall be conducted on one sample from each lot. The sample will be selected
by the inspector.
7.1 Cables shall be dispatched in non-returnable steel drums of suitable barrel diameter, securely
packed, with the take-off end fully protected against mechanical damage.
7.2 On the flange of the drum, necessary information such as project title, manufacturer's name,
type, size, length of cable in meters, drum no., cable code, BIS certification mark, gross
weight, 'Owner's particulars', 'P.O. numbers' etc., shall be printed. An arrow shall be printed
on the drum with suitable instructions to show the direction of rotation of the drum.
7.3 The drum lengths for cables shall be as below:
Upto 50 pairs 1000 meters

Above 50 pairs & upto 100 pairs 500 meters
Above 100 pairs As per job requirement (subject to max.
length of 500 meters)
7.4 A tolerance of ± 5% shall be permissible for each drum. However overall tolerance on each
size of cable shall be limited to ± 2%.
7.5 For non jelly filled cable, PVC/ rubber end caps shall be supplied free of cost for each drum
with a minimum of eight per thousand meter length. In addition, ends of the cables shall be
properly sealed, with caps, to avoid ingress of moisture/ water during transit and storage.
7.6 For jelly filled telephone cables, the ends of the cable shall be sealed by thermo shrinkable end
caps of adequate wall thickness. Alternately ends may be sealed by enclosing them in rubber
or PVC caps of wall thickness not less than 1.8mm. The caps shall be secured to the outer
sheath with hose clips or ties or black adhesive tape or heat shrinkable sleeves.
7.7 The cables may be stored outdoors for long periods before installation. The packing shall be
completely suitable for outdoor storage, in areas with heavy rains and high ambient
temperature.
Page 229 of 851

ENGINEERS FOR
faffi-6 INDIA LIMITED 6-51-0076 Rev. 5
1.1771,i2ON, 451,1sa-1, (A Govi of Indo Undertakm)
FIRE DETECTION AND
ALARM SYSTEM Page 1 of 26
31-F-9 (iJA
~aia1-11 varr Fri
'trrcr9-r
SPECIFICATION
FOR
FIRE DETECTION
AND
ALARM SYSTEM
154'1/41
1‘‘
5 24.09.2014 REVISED & ISSUED AS SPECIFICATION S\41
4 14.05.2009 REVISED & ISSUED AS SPECIFICATION MKS AKS JMS ND
3 24.12.2003 REVISED & ISSUED AS SPECIFICATION AKS/RCS AAN VPS SKG

2 24.04.1997 NS VPS SG ASONI
SPECIFICATION
1 12.03.1991 ISSUED AS STANDARD SPECIFICATION RR VPS SG
Standards Standards
Committee Bureau
No by by
Approved by
Page 230 of 851

ENGINEERS FOR
1if612-eg
NT7R c731,1,7■ M)
INDIA LIMITED
in Govl of India Undeftak.q, FIRE DETECTION AND
6-51-0076 Rev. 5
Abbreviations
IS Indian Standard
BIS Bureau of Indian Standards ITU-T International
BASEEFA British Approvals Service for Telecommunication
Electrical Equipment in Union- (Telecom)
Flammable Atmosphere LCD Liquid Crystal Display
BGU Break glass unit LED Light Emitting Diode
CCE Chief Controller of Explosives LPC Loss Prevention Council
CFAP Central Fire Alarm Panel LIFO Last In First Out
CIMFK Central Institute of Mines and MCP Manual call point
Fuel Research (formerly MR Material Requisition
known as CMRI) Ni-Cd Nickel Cadmium (battery)
CPU Central Processing Unit NFPA National Fire Protection
CRCA Cold Rolled Cold Annealed Association
DGFAP Data Gathering cum Fire NEMA National Electrical
Alarm Panel Manufacturers Association
EEPROM Electrically Erasable PCB Printed Circuit Board
Programmable Read Only PESO Petroleum and Explosive
Memory safety organization
ERTL Electronic Regional Test PO Purchase Order
Laboratory RF Radio Frequency
FAT Factory Acceptance Tests SAT Site Acceptance Tests
FDD Floppy Disk Drive SOE Sequence Of Event
FM Factory Mutual SMF Sealed Maintenance Free
FRP Fibre Reinforced Plastic SPN Single phase and neutral
FO Fibre Optic TPN Three phase and neutral
GUI Graphic User Interface TAC Tariff Advisory Committee
HDD Hard Disk Drive UL Under Writers Laboratory
HMI Human Machine Interface UPS Uninterrupted Power Supply
HVAC Heating Ventilation Air VRLA Valve Regulated Lead Acid
Conditioning (battery)
IEC International Electro-technical VdS Verband der Sachversicherer
Commission e.V.
IEEE Institute of Electrical and WP Weather Proof
Electronics Engineers ZFAP Zonal Fire Alarm Panel
ISDN Integrated Service Digital
Network
Convenor: Mr. B.R. Bhogal

Mr. P. Gupta
Mr. M.K. Sahu
Mr. A.K. Chaudhary (Inspection)
Ms. N.P.Guha (Projects)
Page 231 of 851

ENGINEERS FOR
IND1A LIMITED 6-51-0076 Rev. 5
• INIP9 ,I,O,■11151,7,141501, IA Govt ot lnrha Undertaking) FIRE DETECTION AND
CONTENTS
1.0 SCOPE 4
3.0 GENERAL REQUIREMENTS 5
4.0 DEFINITIONS 5
5.0 SYSTEM AND SITE CONDITIONS 6
6.0 FIRE ALARM SYSTEM DESCRIPTION 8
7.0 CONVENTIONAL FIRE ALARM SYSTEM 9
8.0 MICROPROCESSOR BASED FIRE ALARM SYSTEM 11
9.0 INTEGRATION WITH VARIOUS PLANT SYSTEMS 15
10.0 PANEL CONSTRUCTION (CFAP, DGFAP, ZFAP, REPEATER) 16
11.0 CABLE AND CABLE ACCESSORIES 17
12.0 AUTOMATIC FIRE DETECTORS AND ACCESSORIES 18
13.0 FIELD DEVICES FOR HAZARDOUS AREA 23
14.0 ENGINEERING REQUIREMENTS 24
15.0 INSPECTION, TESTING AND ACCEPTANCE 25
17.0 INSTALLATION AND COMMISSIONING 25
18.0 TRAINING 26
Page 232 of 851

, ■31 ENGINEERS FOR
$g-ar INDIA LIMITED
fA GoN of lndN UnciertakoN) FIRE DETECTION AND
6-51-0076 Rev. 5
1.0 SCOPE
1.1 The intent of this specification is to define the functional and design requirements for an
Integrated Fire Alarm System for industrial plants and buildings. This specification covers the
requirements for selection, design and engineering, manufacture, testing at vendor's works,
supply and installation, testing at site and commissioning unless otherwise stated.
1.2 The Integrated Fire Alarm System shall be conventional or micro processor based analogue
addressable system comprising BGUs, detectors; conventional or microprocessor based Fire
Alarm panels and associated equipment detailed hereunder and in Project data sheets/
drawings.
2.1 The fire alarm system and the components used shall conform to the latest edition of the
following Codes/Standards, other relevant Indian Standards and International Standards as
applicable.
IS -5 Colours for ready Mixed Paint & Enamels.

IS — 513 Specification for cold rolled low carbon steel sheets and strips
IS — 1646 Code of practice for fire safety of buildings (general): Electrical
Installations
IS — 2175 Specification for heat sensitive fire detectors for use in automatic fire
alarm system
IS — 2189 Code of practice for selection; installation and maintenance of automatic
fire detection and alarm system.
IS — 3034 Code of practice for fire safety of Industrial buildings: Electrical
generating and distributing stations.
IS — 5469 Code of practice for the use of semi-conductor junction devices
(Applicable parts)
IS — 12459 Code of practice for fire safety in cable runs
IS/IEC 60079-0 General requirements for electrical apparatus for explosive gas
atmosphere
IS/IEC 60079-11 Specification for Intrinsically safe electrical apparatus and circuits
IS/IEC 61241-14 Electrical apparatus with protection of enclosure for use in the presence
of combustible dust
NFPA 72 National Fire Alarm code
LPC Loss prevention council recommendations.
BS — 5839 Specifications for manual call points. Part — 2
BS-EN 50081-1/2 EMC (Electromagnetic compatibility test)
BS-EN 50082-1/2 EMC (Electromagnetic compatibility test)
2.2 Standards of country of origin shall be applicable if these standards are equivalent or more
stringent than the applicable Indian Standards in case of imported equipment.
2.3 Equipment shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by
IEC/BS/VDE/IEEE/NEMA/UL/FM/VdS or equivalent agency shall be applicable.
Page 233 of 851

$blll , -i ENGINEERS FOR
Og-ar IM2- g
I èfiWY 2.12,W M1 .ffl.1 I
INDIA LIMITED
IA Govt of Inda Undeftak,ogt FIRE DETECTION AND
6-51-0076 Rev. 5
2.5 In case of any contradiction between various referred standards/specifications/data sheet and
statutory regulations, the most stringent requirement shall govern and decision of owner in
this regard shall be final.
3.0 GENERAL REQUIREMENTS
3.1 Offered equipment shall be brand new with established state of the art technology and having
proven field track record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment for at least 10 years from the date of supply. The spares shall be available
ex-stock with the vendor.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/spares to enable the end user to place order for spares and services.
3.4 Vendor shall be responsible for design & engineering and manufacturing of the complete
system and equipment to fully meet the intent and requirements of this specification and
attached data sheets.
3.5 All equipment and accessories required for completeness of the system, whether specifically
mentioned or not but considered essential for satisfactory performance, shall be included by
the vendor as part of the offered system.
3.6 The system integrator shall coordinate with the manufacturers of various bought-out items
associated with the system as required, and shall freely and readily supply all technical
information as and when asked for.
3.7 All equipment required to be located in hazardous areas shall have test certificates issued by
recognized independent test house such as CIMFR, ERTL, BASEEFA, UL, FM or equivalent.
Indigenous equipment shall conform to Indian standards and shall be certified by Indian
testing agencies. Equipment (indigenous & imported) shall also have valid statutory approvals
e.g. PESO, DGMS as applicable for the specified location. Indigenous flameproof equipment
shall also have valid BIS license and marking as required by statutory authority.
4.0 DEFINITIONS
4.1 CFAP
It is the main or central fire alarm panel located in fire station or in disaster management
control room, which receives inputs from automatic and manual Fire alarm devices and
supplies power to detection and notification devices along with sub-systems where applicable.
CFAP provides interface with telephone exchange, plant' s public address system etc. and has
features, such as provision to activate plant-wide sirens. CFAP is supported by mimic/
graphical display for geographical depiction of alarms either on panel or HMI.
4.2 DGFAP
It is a Microprocessor based fire alarm panel, designed for use with addressable fire alarm
system. It has alphanumeric LCD displays along with LED displays for fire/ fault
conditions. It also includes loop cards (for field devices), I/O (input/ output) cards for
interface with other equipment e.g. exit signs and hooters. It functions as fire alarm panel
located centrally to population of fire detectors distributed over an area for optimizing and
limiting the loop lengths.
Page 234 of 851

ENGINEERS FOR
$1gzu fd2-
eg INDIA LIMITED 6-51-0076 Rev. 5
(A GoN ol india Underla(fing) FIRE DETECTION AND
4.3 ZFAP
It is a fire alarm panel for conventional fire alarm system. This is functionality similar to
what is provided for DGFAP. This has LEDs for fire/ fault annunciations.
4.4 Repeater Panel
It is similar to distributed fire alarm panels (DGFAP/ ZFAP) but will not have Zone card/
Loop card for field devices. These are provided at manned locations and are configured to
acquire information about the fire/ fault of selected zones from DGFAP/ ZFAP and
annunciate.
4.5 Integrated Fire Alarm System
It signifies a comprehensive fire alarm system comprising all the distributed fire alarm panels
(DGFAP, ZFAP, repeater panels etc) having integration with CFAP for fire/ fault monitoring
of total plant/ buildings. It provides audio/ visual alarm building/plant-wide having provisions
for connectivity with telephone exchange and public address system. It shall provide
interfaces with fire protection system and other systems like pressurization systems, air
conditioning, clean agent system, water spray system, Fire & Gas detection system etc. via
potential free contacts.
4.6 System Architecture
System architecture is line diagram defining the connectivity of DGFAPs, repeater and
CFAP. This also specifies various system requirements such as redundancy, communication
protocol, communication hardware, cable requirement, work station and programming tools.
4.7 Data High Way
This term is meant to define the communication path between DGFAPs, CFAP and other
network components in microprocessor based fire alarm system. Physical media for Data
highway can be FO cable or twisted pair copper conductor, screened cable.
4.8 Field Devices
Devices such as detectors, BGUs, exit Signs, hooters, siren etc. are termed as field devices.
4.9 Hazardous Area
An area in which an explosive gas/ dust atmosphere is present, or likely to be present in
quantities such as to require special protection for the construction, installation and use of
electrical apparatus.
4.10 Signal Loop (Signaling Circuit)/Signaling Line Circuit
A circuit or path between any combination of circuit interfaces, control units, or transmitters
over which multiple system input signals or output signals, or both are carried.
4.11 Notification Appliance Circuit
A circuit or path directly connected to notification appliances (eg. Bell, horn, speaker, strobe,
printer etc.)
4.12 Zone
A defined area within protected premises. A zone may define an area from which a signal
can be received, an area to which a signal can be sent or an area in which a form of control
can be executed.
5.0 SYSTEM AND SITE CONDITIONS

A11 equipment shall be designed to operate with power supply and site conditions as specified
below:
5.1 Site Conditions

The offered equipment shall be capable of operating continuously and maintaining its
guaranteed performance at the site ambient conditions indicated in data sheet.
Page 235 of 851

ENGINEERS FOR
IA Govt ol Indra Undertatong) FIRE DETECTION AND
Unless specified otherwise, fire alarm panels along with associated hardware shall be suitable
for installation and operation in a closed building/ room with restricted ventilation. Unless
otherwise defined, a design ambient temperature of 40°C and an altitude not exceeding
1000M above mean sea Level shall be considered for all equipment. For battery sizing,
minimum ambient temperature shall be considered as 10°C.
5.2 Input Power Supply
5.2.1 Primary power supply will be provided by Owner at 240V, 50Hz, SPN at one point to each
Fire Alarm Panel. Suitable power distribution to various signaling and notification devices
shall be included in the vendor' s scope. For microprocessor based system, 240V, 50Hz, SPN
power supply to remotely located Repeater panel and sub-system, if any, shall be provided by
the Owner on the basis of actual system configuration and requirements. For conventional
Fire Alarm system, power supply to ZFAP, repeater panel and remotely located strobe etc.
shall be planned and provided by the vendor.
5.2.2 For siren, power supply shall be made available by Owner preferably at 110/230V AC supply.
5.2.3 Unless otherwise specified, secondary power supply for fire alarm panels shall be through
battery provided by the vendor. This shall have sufficient capacity to operate the fire alarm
system under quiescent load (system operating in a non-alarm condition) i.e. to operate a local
central station or proprietary Fire alarm system for a minimum of 24 hours. At the end of that
period, this shall be capable of operating all alarm notification devices used for evacuation
and to direct aid to the location of emergency for 5 minutes.
The secondary power supply for in-building fire emergency voice/alarm communication
service shall be capable of operating the system under quiescent load for a minimum of 24
hours and then be capable of operating the system during a fire and other emergency
conditions for 15 minutes at maximum connected load.
The secondary power supply capacity required shall include all power supply loads that are
not automatically disconnected upon the transfer to secondary power supply.
Battery sizing shall consider the maximum quantity of detector/equipment that can be
connected in the loops, as well as 5 hooters and 5 exit signs per loop in DGFAP. Battery
sizing calculations shall be reviewed during detailed engineering and there shall be no
cost/time implication for providing adequately sized batteries and chargers of approved rating
during the order execution. Separate battery charger shall be provided incase battery charger
part of the DGFAP cannot cater to the boost charging requirement of battery.
An overall ageing factor of 0.8 and a temperature correction factor corresponding to

minimum temperature of 10°C shall be considered for battery sizing.The battery calculations
shall include a 10 percent safety margin to the calculated amp-hour rating.
Operation on secondary power shall not affect the required performance of a fire alarm
system or supervising station facility. The system shall produce the same alarm, supervisory
and trouble signals and indications.
Page 236 of 851

ENGINEERS FOR
ia2e5 INDIA LIMITED 6-51-0076 Rev. 5
IA Govl at Intlia Undertahngi FIRE DETECTION AND
The switch-over from primary source to secondary source, in the event of mains failure, shall
be automatic. Battery shall be Ni-Cd/VRLA/ SMF type as specified in the datasheet. Suitable
adequately rated battery charger shall be supplied as a part of secondary power source. Quick
charging of the battery from fully discharged state shall be attainable in 10-14 hours except
VRLA batteries, which shall follow the charging cycle according to supplier's
recommendations.
6.0 FIRE ALARM SYSTEM DESCRIPTION
6.1 General
Fire alarm system, under this specification, is envisaged to provide fire monitoring in
industrial plants and buildings. The system shall be designed to detect incipient fires, smoky
fires and flaming fires and generate audio/ visual alarm on detection of smoke or fire.
The system shall consist of automatic fire detectors and break glass units. Automatic fire
detectors shall work on the principle of sensing of smoke, heat or infrared / ultraviolet rays.
Depending on type of smoke, optical or ionization type detectors shall be used. Detectors
shall generally be provided in plant/ buildings. BGUs shall be provided at exit doors of the
buildings, exit routes of industrial plants and along service roads surrounding protected areas.
Number of detectors and break glass units shall be decided as per guidelines given in
applicable codes and standards.
For conventional FA system, Plant/ building shall be divided into fire monitoring zones. In
defining zones, care shall be taken to ensure that location of fire can be easily identified. No
two buildings shall be combined to form one zone. Detectors and BGUs at these buildings
and plants shall be connected to CFAP, ZFAP. These panels shall continuously monitor the
state of these devices. On sensing fire condition, an audio/ visual alarm shall be initiated
identifying the zone where fire is detected. Panels shall continuously monitor the health of the
cabling and in case of short circuit or open circuit fault alarm shall be activated. Fire alarm
panels shall also have powered outputs for switching on exit signs and hooters as specified in
data sheet/ drawings. Further, panels shall provide required output for interfacing with the
Owner's systems such as air conditioning system or pressurization system or fire protection
systems.
Alarms, if specified, shall be relayed to repeater panel provided in buildings like control
rooms/ administrative buildings to provide zone wise annunciation. In addition facility shall
be provided to actuate siren/ hooter.
For integrated fire alarm system where plant-wide large numbers of fire alarm panels are
envisaged, these panels shall be integrated to CFAP, which shall be located in fire station,
disaster management control room or in administrative control room of the building as per the
job requirements. The connectivity shall be achieved using data high way or dedicated cable
connection from each fire alarm panel to CFAP. In conventional system Mimic at CFAP shall
be provided for fire/ fault annunciation depicting geographical location in addition to the text/
LED on the CFAP. This will be in the form of graphics available at HMI in microprocessor
based system. If defined, CFAP shall have provision for automatic and manual actuation of
plant-wide siren as per operator's choice. Interface with other systems such as telephone
exchange/ plant's public address system shall be provided for communication required for
disaster management.
6.2 Conventional / Addressable fire alarm systems
6.2.1 Fire alarm system shall be conventional fire alarm system or addressable microprocessor
based fire alarm system as specified in data sheet. Conventional fire alarm system shall have
Page 237 of 851

ENGINEERS FOR
$'Igz:1[015/kg INDIA LIMITED 6-51-0076 Rev. 5
It-oWt eKmrl ,151,7-4,
41) (A Govt ot Ind. UneettakIng) FIRE DETECTION AND
conventional field devices/ equipment and microprocessor based system shall have
addressable type field devices.
Conventional fire alarm system shall generally comprise but not be limited to the following
equipment used in conjunction with conventional automatic fire alarm detectors and BGUs as
a minimum.
• CFAP with/ without mimic (as per data sheet)

• ZFAPs
• Repeater Fire Alarm Panel
• Sirens and starters/Siren control panels
• Hooters & exit sign in buildings
• Interface with Owner' s systems
• Any other hardware as required to render system complete
6.2.2 Microprocessor based fire alarm system shall generally comprise but not be limited to the
following equipment used in conjunction with addressable automatic detectors and
addressable BGUs as a minimum.
• CFAP consisting of computer based graphic work station and engineering station.
• Multi loop DGFAPs
• Sirens and starters/siren control panels
• Hooters & exit sign
• Interface with Owner' s systems
• Data Highway
[Copper/ FO cable data highway complete with redundant architecture for
communication, hardware including communication port, switches, processor and power
supply.]
• Any other hardware/ Software required for rendering system complete.
6.2.3 As specified in data sheet, the system shall be provided with siren/s to be located at a suitable
location/s in the plant and it shall be actuated manually and automatically as selected by
operator from CFAP/ DGFAP located at fire station/ other buildings.
7.0 CONVENTIONAL FIRE ALARM SYSTEM
7.1 Design Features
7.1.1 System shall be modular and facilitate future extension / modification. Panel design and
component selections shall be done for future extension up to 10% of specified zones or one
zone whichever is maximum in each panel. 10% spare zone cards subject to minimum of 1
shall be provided. The design of common facility and hardware shall be provided for
required future extension of zones.
7.1.2 PCBs shall have watchdog feature for self-diagnostic. Each PCB shall have LED for
annunciating card failure. Following self-diagnostic features may be considered as minimum.
• Open circuit detection
• Short circuit detection
• Earth fault detection
• Power supply failure e.g. low battery voltage, main incoming supply fail
• System faults (PCB failure)
Page 238 of 851

ENGINEERS FOR
$`2Z[1214-
.1,-172M esi-t-T-r, GoN of rtmla Unde,taking) FIRE DETECTION AND
7.1.3 Logic of operation shall be built on "Fail safe" feature i.e. NC contact of field devices shall be
considered as healthy condition and NO as fire condition. 1 NO+ 1 NC contact of output
relays shall be wired to terminal block for interface with Owner' s other equipment.
7.1.4 It shall be possible to test lamps, hooters, flasher circuit, and carry out functional tests etc
through common "Test" push button.
7.1.5 The circuit shall be so designed that silencing of the current alarm by ACCEPT push button
shall not prevent annunciation of subsequent fire alarm received from any other location.
7.1.6 Signal-to noise ratio shall be high to avoid spurious actuation due to noise induced in the field
wiring because of proximity with power cables. Cables for field devices shall be multicore
copper conductor, unscreened, armoured, copper conductor FRLS cable. If required noise
filters shall be provided at fire alarm panel.
7.1.7 Detectors and BGUs shall be wired through 1.5 mm2 multi-core, Copper conductors, PVC
insulated, armoured FRLS cable. Limiting distance from fire alarm panel to last
detector/BGU shall not be less than 2 km or as specified in data sheet whichever is
maximum.
7.1.8 LEDs shall be provided for fire/ fault visual annunciation on the panel front. LED shall also
be provided for Power supply healthy, Battery backup ON, Battery/ Charger status.
7.1.9 If zone is protected with clean agent/ CO2 system, the detectors and BGUs of the zone shall be
wired in cross-zones by providing minimum two signaling circuits in a zone. The last device
in each circuit shall be provided with end of line resistor of suitable value as per circuit design
to facilitate cable open circuit and short circuit detection.
7.1.10 Scheme for FIRE/ FAULT annunciation for CFAP/DGFAP, Zonal Fire Alarm Panel, Repeat
Alarm Panel shall be as per the following.
System condition AUDIO VISUAL
NORMAL OFF OFF

FIRE ON (tone 1) Flasher ON, Fire LED Steady ON
Accept OFF Flasher steady, Fire LED steady ON
Reset OFF Flasher OFF, Fault LED OFF
FAULT ON (tone 2) Flasher OFF, Fault LED Steady ON
Accept OFF Flasher OFF, Fault LED Steady ON
Reset OFF Flasher OFF, Fault LED OFF
7.1.11 Fire alarm panels including repeater panels and CFAP shall be certified/ approved by
applicable approving agency of country of origin as required.
7.2 Zonal Fire Alarm Panel
7.2.1 ZFAP shall consist of number of zones as specified in data sheet. Detectors/ BGUs/ heat
sensing cables etc shall be connected zone wise in signaling circuits. It shall monitor fire/
fault condition of the zone. ZFAP shall be located indoor in safe area.
7.2.2 ZFAP shall be free-standing, floor mounting vertical panel consisting of audio/visual
annunciation with Alarm Accept, Test and Reset Push Buttons, Auto/Manual control of
hooters provided in buildings. Provision to actuate siren shall be provided if specified in data
sheet. Circuit shall be designed to provide annunciation if any detector in a zone senses fire.
7.2.3 Audio/ Visual indication and annunciation shall be as per clause 7.1.8.
Page 239 of 851

ENGINEEFZS FOR
Ogzrr Offl- g K1Sii,
Mvem ,frortmJ,
INDIA LIMITED
IA Govl of Incha Underlakog) FIRE DETECTION AND
6-51-0076 Rev. 5
7.2.4 ZFAP shall have required interface hardware where integration with CFAP/ repeater panel is
envisaged as per data sheet.
7.2.5 Output contacts (1NO+1NC) shall be provided for interface with Owner' s systems as per
clause 9.0 of this specification.
7.2.6 Input power supply and battery backup for ZFAP shall be as per data sheet and as per clause
5.2 of this specification.
7.3 Repeat Alarm Panel-Conventional
7.3.1 Repeat fire alarm panel shall be provided for repetition of fire/fault annunciation of
CFAP/ZFAP. Depending on the size Repeat Fire Alarm panel may be floor mounting type or
wall mounting type. The display shall be similar to CFAP/ZFAP.
7.3.2 Where required, input power supply from Owner shall either be 240V or 110V, 1 phase,
50Hz. It shall be possible to select supply either 240V or 110V at site without modifying or
adding additional equipment in the panel.
7.4 Central Fire Alarm Panel
7.4.1 CFAP shall receive inputs from automatic and manual fire alarm devices and supply power to
detection, notification and communication devices. Fire and fault annunciation for each Zone
or group of zones at ZFAP shall be repeated at CFAP.
7.4.2 CFAP shall be in vertical panel construction or desk type construction as per datasheet having
controls such as Accept, Test and Reset Push Buttons, Auto/Manual control of siren etc.
7.4.3 Unless otherwise specified in the data sheet, CFAP shall have mimic to display geographical
location of fire. Mimic shall form an integral part of the CFAP and shall be located at the top
of the panel. When separate mimic panel is specified, it shall either be wall mounting or
freestanding floor mounted type. Two LEDs shall be provided for each zone on mimic panel
for display of fire alarm. Mimic panel shall be powered by CFAP. Mimic made out of plastic
stickers shall not be acceptable.
7.4.4 Input supply and battery backup for CFAP and MIMIC shall be as per data sheet and as per
clause 5.2 of this specification.
7.4.5 Battery charger provided in the CFAP/ ZFAP shall be modular mounted on a draw out
chassis. Charger module shall be located on the front allowing withdrawal with the help of
handle bars for maintenance.
8.0 ANALOGUE ADDRESSABLE FIRE ALARM SYSTEM
8.1 Design Feature
8.1.1 Unless otherwise specified Microprocessor based FA system shall be analog addressable type.
The system shall be integrated as per `system architecture' indicated in data sheets/ drawings.
8.1.2 Fire alarm system shall be designed consistent with state of the art technology. A11 fire alarm
panels including repeater panel shall be networked through data high way. The system
supplied shall not pose any limitation for future expansion by way of networking of fire alarm
panels, data transfer, parameterization of addressable field devices, graphic displays etc.
8.1.3 The system shall be modular and shall facilitate future extension/ modification. Panel design
and component selections shall be done for future extension up to 10% of specified number of
loops or one loop whichever is maximum in each panel. The design of common facility and
hardware shall be provided for required future extension.
Page 240 of 851

ENGINEERS FOR
1:?-2:[[ 112-&g
NIV, 2,12 ■751,05.71
INDIA LIMITED
in GoN oi India lindettahmg) FIRE DETECTION AND
6-51-0076 Rev. 5
8.1.4 PCBs shall have watchdog feature for self-diagnostic. Each PCB shall have LED for
annunciating card failure. Following self-diagnostic features shall be considered as minimum
for the system.
i) Open loop detection
ii) Short circuit detection
iii) Earth fault detection
iv) Power supply failure e.g. low battery voltage, main incoming supply fail
v) System faults (PCB failure)
8.1.5 Unless specified otherwise in data sheet, system architecture shall have minimum redundancy
indicated below at DGFAP & CFAP, however not limited to the same.
i) Redundant at processor level (communication processor and I/O card processor)
ii) Redundant communication port
iii) Redundant data highway cable. (For data highway ring topology will be
preferred)
iv) Redundant microprocessor
v) Redundant work station/ HMI (engineering station+ operator' s station)
vi) Redundant power supply card at all fire alarm panels (but with non-redundant
battery backup)
8.1.6 Data highway shall be using Fibre optic or twisted pair shielded copper cable as specified in
data sheets. Whether specified or not, data highway shall include all necessary hardware such
as modem, repeaters, network switches/ hubs etc including power supply system as required
to suit the length of data highway.
8.1.7 The communication shall be peer to peer between various DGFAPs, repeater Panels, CFAP
and other system components connected on fire alarm system data highway.
8.1.8 Any fault in Analogue detector addressable loop (signaling loop/ circuit), notification
appliance circuit and data highway shall not impair communication, i.e. Communication/ flow
of analogue signal shall be possible from either end.
8.1.9 The loop cabling for wiring detectors and BGUs shall be class A, fault tolerant type as per
NFPA 72.
8.1.10 Fire alarm logic shall be programmable type. The logic for zone protected with clean agent
system/ CO2, shall be programmed to provide output for actuation after ensuring that there is
no false alarm using alarm verification feature. Similarly logic to switch ON sounders.
Beacon and hooters shall be programmable type. Exit sign shall remain ON all the time.
8.1.11 The logic shall be so programmed that it will ensure silencing of the current alarm by
ACCEPT push button & shall not prevent annunciation of subsequent fire alarm received
from any other location.
8.1.12 Signal-to noise ratio shall be high to avoid spurious actuation due to noise induced in the field
wiring because of proximity with power cables. Unless other wise specified, fire alarm cables
laid in buildings shall be twisted pair, screened and unarmoured and shall be laid in conduits
while cable laid outdoor in plant shall be twisted pair, screened and armoured. If required
noise filters shall be provided at fire alarm panel.
8.1.13 Unless specified otherwise in data sheet, the minimum number of detectors/ BGUs/
addressable devices in a signal loop shall be 120.
Page 241 of 851

ENGINEERS FOR
fgar 22e5
(~1 C1,7,1, 0,13,10.11
INDIA LIMITED
IA Govt of Indo Undertakingt FIRE DETECTION AND
6-51-0076 Rev. 5
8.1.14 Unless specified otherwise in data sheet, conductor size of loop cable shall be 1.5sqmm
copper. The allowable signal loop length shall not be less than 2 km.
8.1.15 DGFAP and repeater panel shall have backlit alphanumeric LCD display to provide addresses
and status of each field device. In addition LEDs shall be provided for fire/ fault visual
annunciation. LED shall also be provided for Power supply healthy, Battery backup ON,
Battery/ Charger status.
8.1.16 Fire station shall be provided with redundant PC(s) with monitors for operator's work
station and for engineering station. Any of the two should be possible to configure as
engineering station for programming off line. After Programming, the engineering station
will be connected to network as online operator's workstation. Programming shall also
allow activating Siren from the keyboard in manual mode as per operator's choice.
8.1.17 All field devices such as detectors and BGUs shall be addressable type. If available in
vendor' s design, hooters and exit signs may also be connected in addressable loop. Fault
isolators shall be provided to minimize outage of number of detectors/ BGUs in case of loop
cable fault. For hazardous area flame proof equipment shall be used. As far as possible, the
use of intrinsically safe field devices in hazardous area should be avoided. If unavoidable, due
care shall be taken care in design to avoid signal distortion and thus the mal-operation due to
cable capacitance and inductance.
8.1.18 System shall provide adequate EEPROM size to store minimum of 200 events fire/ fault. The
event shall be stored in LIFO structure. All events shall be time stamped. DGFAP shall have
real time clock for event time stamping.
8.1.19 Software access for either Zone programming or access to plant/ building graphic on monitor
shall be password protected. For viewing status of various field devices e.g. fire and fault
status password protection shall not be given.
8.1.20 All Fire alarm panels including repeater panels and CFAP shall be certifieci/ approved by an
international approving agency/ approving agency of country of origin as applicable.
8.2 Data Gathering Cum Fire Alarm Panel (DGFAP)
8.2.1 DGFAP shall have basic design features as per clause 8.1 above. Number of signal loops in
each DGFAP shall be as defined in the data sheet/ drawings/ MR. Number of loops shall be
basic part of main PCB and should not be extended by providing external electronic devices.
LCD display and annunciation scheme shall be as per clause 7.1.10.
8.2.2 It shall be possible to change the reference value of detector sensitivity either manually or
automatically as required during the operation to avoid false alarms prior to detector
maintenance.
8.2.3 DGFAP shall have serial port for communication to data highway. It should be possible to
communicate all the information to CFAP/ FA system work station located with fire marshal.
The protocol of communication shall preferably be open protocol.
8.2.4 In the event of non-availability of data highway, DGFAP shall work as stand alone intelligent
panel monitoring fire in the zones connected to it.
8.2.5 It shall be possible to configure DGFAP to access data of any other DGFAP and display as
per the operation requirement to be finalized during engineering/ commissioning.
Page 242 of 851

ENGINEERS FOR
rii 2W5 INDIA LIMITED
IA ol Indo Undertakmq) FIRE DETECTION AND
6-51-0076 Rev. 5
8.2.6 Where specified in MR/ data sheet, it shall be possible to interface with existing fire alarm
system consisting of conventional zone detectors and BGUs with end of line resistor as a part
of retrofitting.
8.2.7 DGFAPs shall have output relays to provide interface with Owner' s system defined in
clause 9.0 as minimum.
8.3 Repeat Alarm Panel
Repeat fire alarm panel shall be provided for repetition of fire/fault annunciation of
CFAP/DGFAP. Depending on the size repeat Fire Alarm panel may be floor mounting type or
wall mounting type. The display shall be similar to CFAP/ZFAP.
These panels shall be without loop cards and shall be connected to data highway through
serial communication. Panels shall have programming facility to inhibit the display of
information that is not required in a particular repeater panel.
8.4 CFAP with PC Based Monitoring Station or Work station
8.4.1 Vendor shall supply CFAP similar to DGFAP along with PC based work stations. Application
software shall be installed in PC as Graphic User Interface. The graphic shall include
geographical display of locations of various plant areas including locations of
addressable detectors and BGUs. The navigation between various graphic pages shall be user
friendly. Screen shall have defined area to display the latest fire or fault alarm and shall also
have facility to pop up the graphic displaying the location of fire event.
Where specifically indicated CFAP shall include network PC based monitoring station based
on vendor' s system design directly connected to data highway with other peripherals such as
network switches/ controller (HUB).
8.4.2 Unless stated otherwise, CFAP shall have all the features and facilities of the DGFAPs. It
shall monitor the status of each addressable field device indirectly from the DGFAPs
connected on data highway.
8.4.3 Engineering workstation shall be used for programming off-line. After programming, the
changed parameters shall be down loaded to other PC to work in synchronism as normal
operation. This station shall also have one laser printers connected to PCs working as
engineering printer.
8.4.4 The monitoring station/work station shall be equipped to display the overall plot plan showing
all MCPs along the unit roads. The display shall have three levels of penetration, which
permits zooming on to any process unit/area or any building. Further one may zoom into
specific rooms of the building and view the detectors below the false floor, above the false
ceiling or in the room cavity. The CFAP shall also display the location of fire/ fault when
such an event occurs.
8.4.5 Unless specified otherwise, adequately rated UPS with bypass shall be provided for the
workstations and printers of CFAP. Battery backup shall be sized as per criteria given under
5.2. Only normal supply shall be made available at one point by Owner at the location of
central fire alarm panel. Where both CFAP and PC based work stations are provided the
battery back up time for the UPS shall be 30 min. Battery back-up to CFAP shall be as per
clause 5.2.
8.4.6 It shall be possible to actuate plant-wide siren in auto/ manual mode. Unless other wise
specified, manual actuation shall be done from keyboard of workstation. Auto actuation shall
be through software logic, which shall be finalized with end user during implementation.
Page 243 of 851

ENGINEERS FOR
1. gz-JE INDIA LIMITED 6-51-0076 Rev. 5
~~~,~ )
M3.747.1 IA GoA o Unctertatong) FIRE DETECTION AND
Auto/Manual selection shall be provided at operator's work station. The actuation signal
under manual mode selection shall be communicated serially to DGFAP to which siren starter
is connected. Siren starters shall be hardwired to DGFAP.
8.4.7 The minimum requirements for the PC and other peripherals shall be as stated below:
* Industrial type Latest generation PC
* DVD-RW
* Mouse and keyboard
* 29 Inch coloured LED monitor
* Engineering laserjet coloured printer with 8 PPM
*Application software supporting graphics with no limitation on number of graphics, events,

alarms, number of field devices as required for any large plant like refinery, petrochemical
complex or large multistory building.
8.4.8 It shall be possible to provide multilevel access of fire alarm system. Read only access shall
not require password protection. Access for programming and access for controls from
keyboard shall be password protected. The levels of password protection shall be agreed with
plant operators at the time of commissioning of system.
8.4.9 Printer
Printer options shall include graphic laser printer. Printer used in the system shall provide real
time records of the system events and provide system reports on demand, and shall be
microprocessor controlled, high speed, read only (RO).
9.0 INTEGRATION WITH VARIOUS PLANT SYSTEMS
9.1 Fire Alarm System shall have required hardware to have interface with following plant
systems as specified in data Sheet via potential free contacts.
i) Public Alarm Announcement system
ii) Paging and plant communication systems
iii) Plant data network
iv) ISDN telephone exchange
v) Fire suppression system
vi) Clean agent system
vii) Fire & Gas detection system
9.2 Where ZFAP is required to carry out fire suppression functions, it shall be provided with the
following interfaces with fire suppression system unless specified otherwise.
i) Automatic signal for release of clean agent/CO2 release for protected area and
RELEASE audio/ Visual alarm for evacuation.
ii) Selector switches for primary or secondary clean agent/CO2 supply for each protected
area.
iii) Manual push button for discharge of clean agentlCO2 in each protected area. The
actual release of clean agent/ CO2 shall however be delayed by 30sec after the alarm.
iv) Clean agent/CO2 Discharge inhibit push button for each protected area.
v) Deluge valve activation push buttons, deluge valve test push buttons and deluge valve
activated status lamps.
vi) Firewater pumps start push buttons.
vii) Firewater pumps running indications.
Page 244 of 851

ENGINEERS FOR
fülf54-
in Govt of Inda Unclerlaking) FIRE DETECTION AND
viii) Shutdown signals to various air-handling units/Pressurization system relative to the

zone of fire.
10.0 PANEL CONSTRUCTION (CFAP, DGFAP, ZFAP, REPEATER)
10.1 All fire alarm Panels shall be free standing, floor mounting type unless specified otherwise
and shall be fabricated out of minimum 2mm thick CRCA sheets and doors shall be
fabricated out of minimum 1.6mm CRCA sheets. The panel shall be naturally ventilated in
IP-41 enclosure protection as minimum.
The colour shade of final paint shall be 536 as per IS: 5, unless otherwise specified.
10.2 Equipment Mounting
10.2.1 All apparatus, display screen, instruments and indicating lamps mounted on the panel front
shall be flush mounting type. The external cabling shall not be terminated directly on the base
connector of PCBs but shall be terminated on separate terminal block. Further connection to
PCBs shall be as per manufacturer's standard. Routine calibration, adjustments, programming
and operation shall be accessible from the front of the panel without opening the door.
External cabling shall preferably be done from the rear.
10.2.2 Power supply system including VRLA battery bank shall be mounted inside the panel.
10.2.3 Doors shall be provided with pistol grip handle with lock. Lamps shall be provided inside the
panel to provide adequate light for maintenance of equipment.
10.2.4 Cable entry shall be from bottom unless otherwise specified in the data sheet. Terminal strip
shall be provided for incoming / outgoing cables.
10.3 Wiring and Terminals
10.3.1 Wiring within the panel shall be harnessed in slotted plastic raceways enclosed with cover.
Control connections shall be done with 660V grade PVC insulated wires having stranded
copper conductors. 1.5mm2 size of wire shall normally be used for circuits with control fuse
rating of 10A or less. Control wiring for electronic circuits shall be through ribbon cable or
through copper wire minimum of 0.5mm dia. Panels shall be supplied completely pre-wired,
such that only field termination shall be required at site before it is energized.
10.3.2 PCBs for identical functions shall be interchangeable. PCBs shall be plug in type having
pin/edge connectors. PCBs shall be suitable for use in tropical, humid and dusty environment.
These shall be protected with anti fungus treatment.
10.3.3 Cables shall be terminated on terminal blocks. Clamp type terminals shall be of spring-
loaded, stacking type, mounted on rails. Terminals shall be sized to accept, as a minimum
2.5mm2 cross section conductors. Not more than one conductor shall be terminated on the
outgoing nide of each terminal. At least 20 % spare terminals shall be provided in each panel
for termination of spare cores of cables.
10.4 Earthing
A common earth bar of minimum 25 mm x 3 mm. copper or equivalent aluminum shall be

provided throughout the length of the panel. All non-current carrying metallic parts of the
panel-mounted equipment shall be earthed. Flexible jumpers shall connect all doors and
movable parts to the earth bus. Two numbers earth lugs shall be provided outside the panel.
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, ENGINEERS FOR
$1g2-122--e-g INDIA LIMITED 6-51-0076 Rev. 5
1~1,i,c7›,..14-4.3, (A Govt of Intha Untle,tOk(o9) FIRE DETECTION AND
10.5 Name Plates / Warning plates
10.5.1 All nameplates for panel shall be engraved out of 3 ply (black-white- black) lamicoid sheets
or anodized aluminum. Back-engraved Perspex sheet nameplates will also be acceptable.
Engraving shall be done with square groove cutters. Hard paper or self-adhesive plastic tape
nameplates shall not be acceptable.
10.5.2 Labels shall be provided for every component on the cards, connecting wires as well as for
the terminals in the terminal strip inside the panel. Wiring diagram shall be pasted inside the
panel door as required for termination and maintenance.
10.5.3 Special warning plates shall be provided on all removable covers or doors giving access to
energized metallic parts above 24 volts.
10.6 Painting
10.6.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust,
grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of
acid. The undersurface shall be made free from all imperfections before undertaking the
finishing coat.
10.6.2 After preparation of the undersurface, the panel shall be powder coated. The colour shade of
final paint shall be as approved by the Owner. The finished panels shall be dried in dust free
atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, run-off
paint etc.
10.6.3 All unpainted steel parts shall be zinc passivated or suitably treated to prevent rust-corrosion.
Moving elements shall be greased.
11.0 CABLE AND CABLE ACCESSORIES
11.1 Supply and laying of FA cables shall be as per the requirement specified in the MR/data
sheet. Vendor shall provide JBs for detectors, BGUs, exit signs, hooters etc.
11.2 Where supply and installation of field cabling is excluded from vendor' s scope, terminations
of all cables (supplied by both vendor/ Owner) at both ends shall be in vendor' s scope.
11.3 Bidder, as a part of integration and selection of fire alarm equipment, shall furnish detailed
specifications for loop/zone cables, data highway cables, cables for hooter/exit signs etc
giving details such as type of cables, number of pais, size of cable, inductance and
capacitance data, number of fibres/ connectors etc.
11.4 Data Highway Cables
11.4.1 Unless specified otherwise, vendor shall supply Copper cable/ FO type data highway cable to
suit system design and equipment specification. Copper cables, if supplied, shall be of
adequate size, twisted pair, PVC insulated, overall screened, PVC inner sheathed, armoured,
FRLS type PVC outer sheathed as the minimum requirement. Fibre Optic cables, if supplied,
shall be armoured, overall FRLS PVC outer sheathed and shall be as per ITU-T
recommendation as a minimum.
11.4.2 Vendor shall supply and install all hardware and cabling accessories as per data high way
design including modems, repeaters etc as part of the Fire Alarm system. Modems/ repeaters
shall be powered by the supply provided for DGFAPs / CFAP.
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k-71 ENGINEERS FOR
$'2-al OW5 INDIA LIMITED 6-51-0076 Rev. 5
>31,
- IA GoN of Indo undertakng) FIRE DETECTION AND
11.5 Cable Glands / Accessories
11.5.1 A11 cable glands/ lugs/ connectors as required for the equipment shall be included in vendor's
scope and shall be supplied along with the system, irrespective of whether installation is to be
performed by vendor or not.
11.5.2 All the cable glands for outdoor application shall be weatherproof, nickel-plated brass and
double compression type, whereas those for indoor application shall be single
compression type.
11.5.3 Cable glands for hazardous area equipments shall be flameproof, weatherproof and nickel-
plated brass double compression type.
12.0 AUTOMATIC FIRE DETECTORS AND ACCESSORIES
12.1 General Specifications
12.1.1 Detectors for conventional fire alarm system shall be conventional type. End of line resistor
shall be provided at the last detector in the zone. Detectors for microprocessor based
Analogue addressable FA system shall be addressable type. Detectors shall be plug-in type
and shall have twist lock action fitting. Multi-colour LEDs provided on the detectors shall
indicate Normal and Alarm state. Essential features of detectors are indicated as below.
12.1.2 Detectors shall be supplied with mounting bases. Mounting base shall be identical for all type
of detectors except special application detectors such as linear beam detectors etc. for
installation as well as cable connection. Detector housing (body and cover) shall be made up
of damage resistant, fire resistant polycarbonate and shall be suitable for either surface or
recess mounting. Detector base shall be mounted on Junction boxes having terminals for
cable termination. Where installation is included in vendor's scope, all necessary installation
materials shall also be included in vendor's scope.
12.1.3 Detectors shall be suitable for storage at ambient condition specified in data Sheet.
12.1.4 All detectors shall be on the approved list of LPC, UL / FM/ equivalent international
approving agency as applicable.
12.1.5 A11 detectors shall be suitable for operation at DC power supply extended from fire alarm
panel.
12.1.6 The addressable detectors shall be continuously monitored to measure changes in their
sensitivity due to the environment (dirt, dust, temperature, humidity etc.). These detectors
shall give an advance indication to the panel regarding the need for maintenance. The
analogueue reading rent by the detectors shall be sensed and if there is a rapid increase, an
alarm shall be generated. However, if there is a gradual increase in the analogueue reading, a
maintenance alert shall be generated by the fire alarm panel. It shall be possible to generate
maintenance reports from the fire alarm panel. For the addressable detectors two-wire
operation shall be possible.
12.1.7 All addressable detectors shall have selectable settings for pre-alarm and alarm and preferably
have the facility to set the sensitivity and address from the fire alarm panel.
12.1.8 Break glass units for microprocessor based fire alarm system shall be addressable type.
Each device shall have its own address module.
Page 247 of 851

ENGINEERS FOR
"gZir faW5 INDIA LIMITED 6-51-0076 Rev. 5
cof,ost.3~)
23-, IA Govt of Indo Undertatongt FIRE DETECTION AND
12.1.9 All addressable detectors shall be suitable for installation using fault tolerant wiring (class-A,
style - 6 wiring as per NFPA72). T- Tapping shall not be permitted in the case of such wiring.
12.1.10 All detectors must have insect screen to prevent insect entry and cause false alarm.
12.1.11 All field devices shall be from the latest generation in the manufacturer's range of products.
Commonly used field devices are listed below. The specification given shall be considered as
minimum requirements.
12.2 Heat Detectors
12.2.1 Heat detectors shall use negative temperature coefficient thermisters for sensing and for
reference. The detector shall be designed to give a response that depends on both absolute
temperature and rate of rise in temperature.
12.2.2 The rate of rise element shall be carefully calibrated to ignore any normal fluctuation in
temperature, but to respond quickly when the temperature rise is 9°C or more per minute.
12.2.3 The fixed temperature feature should be entirely independent of the rate of rise element. The
operating temperature of fixed temperature element should be factory set at 57° C ± 5° C.
12.2.4 The detector shall be self-restoring type ensuring repeated use and easy maintenance.
12.3 Multi Sensor (Detector)
12.3.1 Multi sensor shall have combined & individual features of smoke detector and thermal sensor
(heat detector). Smoke activity shall be monitored by photoelectric sensing technology in a
single detector / base assembly. Heat detection shall be fixed with selectable rate of rise
settings. Multi sensor detectors shall be able to generate multiple alarm signals from any of
the sensors (smoke or heat) employed in design independently or in combination. Detectors
shall be analogueue addressable.
12.3.2 The detector shall be able to sense incipient fire by detecting the presence of visible and
invisible products of combustion like wood, paper, ammonia processing paper, cloth, PVC,
bakelite, nylon, foam, acrylic, thermocol, Photo film, nylon, polyester, painted sheets, Teflon,
leather etc.
12.3.3 The sensitivity of the detector shall not vary with change in ambient temperature, humidity,
pressure or permissible voltage variation. Its performance shall not be affected by an air
current of 5 m/sec. It shall have an inbuilt arrangement such that puffs of smoke or hot air
pockets do not inadvertently trigger the alarm. The detector shall be protected against dust
accumulation/ ingress. It shall have insect resistant screen to prevent nuisance alarms.
12.3.4 In recess above ceiling designed to handle return air for HVAC, it shall be ensured that
detectors are compatible to air velocity. Where air velocity is expected to be too high for the
detectors to function normally, smoke guard/ baffle shall be used as per requirement.
12.4 UV Flame Detector
12.4.1 UV flame detectors shall work on the principle of a vacuum photodiode tube to detect the UV
radiation that is produced by a flame.
12.4.2 UV flame detectors shall respond to ultraviolet rays of a flame. The detector shall not be
actuated by artificial lights, sunlight incident through a windowpane or welding arc. False
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ENGINEERS FOR
fta[ fa25 INDIA LIMITED 6-51-0076 Rev. 5
iA GoN ot Indla Undertaking) FIRE DETECTION AND
alarm check circuit shall be incorporated to prevent false alarm due to intermittent flash or
lightning.
12.5 IR Detectors
12.5.1 IR detectors shall work on the principle of a single wavelength infrared flame detector using
one of several different photocell types to detect the infrared emissions in a single wave
length band that are produced by a flame.
12.5.2 IR detectors shall react to the infrared rays of a flame. It should be sensitive enough to detect
smoky fires in which flame is hardly recognizable. The detector should not react to extremely
glaring artificial light or direct sunlight. The detector shall be completely solid-state type.
12.5.3 Where specified combination UV-IR detector shall be used.
12.6 Linear Beam Detector
12.6.1 Linear beam detector shall work on the principle of obscuration of infrared light beam by
particles of smoke. The scnsitivity shall be such as to enable operation at 30% to 50%
obscuration.
12.6.2 Linear beam detector shall consist of transmitter and receiver. Linear beam detector shall be
suitable for application in high roofed locations (10 m & above) such as warehouses,
pressurization room, transformer room (if required) etc. The detector shall, preferably, be
powered from the loop signal itself. However, if external power supply is required the same
shall be explicitly stated by the vendor, which shall be covered ander common power supply
for the fire alarm panel and devices connected with it.
12.7 Heat Sensing Cables
Heat sensing cable shall be analogueue type. It shall consist of four copper conductors, each
covered with a colour coded, negative temperature co-efficient material. The cores shall be
twisted together and protected by an outer sheath of high temperature, flame retardant PVC
insulation. External mechanical protection shall be provided over the sensor cables. Vendor
shall provide control unit for each 100 m length of the sensor cable.
12.8 Break Glass Unit (BGU)
12.8.1 Manual break glass unit shall be fabricated out of 14-gauge cold rolled sheet steel.
Alternately the break glass unit may be made of die cast aluminum alloy such as LM6. It shall
have IP-55 enclosure and weatherproof construction suitable for outdoor installation. The
break glass unit shall have a minimum dimension of 100x100x8Omm.
12.8.2 The box shall be fabricated in such a way it can be mounted flush to the wall or on the surface
without any modification. Two nos. 19 mm knockouts shall be provided at the bottom of the
box to facilitate cable / conduit entry. The glass shall cover at least 30cm 2 area and shall have
a thickness not exceeding 2mm.
12.8.3 The box shall have a push button element kept in pressed condition by a glass sheet fitted in
the front of the box.
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ENGINEERS FOR
fgzir fais INDIA LIMITED
Govt of India Undertalongt FIRE DETECTION AND
6-51-0076 Rev. 5
12.8.4 The enclosure shall be painted with fire red colour (shade 536 of IS-5) epoxy painting and an
inscription " Break Glass in case of Fire", shall be painted in white letters or riveted on the
enclosure by a steel nameplate. A suitable nickel-plated brass hammer, duly chained to the
box with stainless steel chain shall be provided with each box for breaking the glass. Each
box shall have a distinct identification number boldly painted on it.
12.8.5 One No. blanking plug shall be provided for 5% of the total quantity of MCPs. MCPs for
outdoor installation shall be complete with FRP canopy.
12.8.6 Hazardous area Break Glass Units shall meet the requirement of clause 13.0 of this
specification.
12.9 Response Indicator
12.9.1 If specified in the data sheet, response indicators shall be provided suitable for wall/ ceiling
mounting. Response indicator shall be provided where the detector is located either above
false ceiling or below false floor or where detectors are not directly visible. The response
indicators shall be connected to the detectors directly and shall be complete with terminal
blocks suitable to accept cables with up to 1.5mm2 copper conductor. In the normal state of
detector, the LED shall flicker, but in the event the detector goes into alarm condition, the
LED shall glow steadily. LEDs shall be red in colour with 5mm dia. as a minimum.
12.9.2 Use of Response indicators in addressable system is not envisaged unless otherwise specified
in data sheet.
12.10 Exit Signs
12.10.1 Exit signs shall be fabricated out of 1.6mm thick cold rolled sheet steel. This shall be suitable
for wall mounting or suspension from ceiling. Exit signs suspended from the ceiling shall
have text/ direction printed on both the side of exit sign.
12.10.2 Fire exit shall be displayed by means of 5mm dia LEDs or backlit text. It shall be powered
from the fire alarm panel. Exit sign shall operate on DC power supply.
12.10.3 The exit sign shall be either in red letters on white background or white letters on green
background.
12.10.4 Where specified in data sheet, self-luminous exit sign shall be provided.
12.11 Hooters
12.11.1 The unit shall consist of solid-state circuitry on a printed circuit board, a loudspeaker and a
flashing lamp housed in a weatherproof dust tight, wall mounting type enclosure. The hooter
shall, at least, have 102 db (A) output measured at 1-meter distance. The unit shall be
powered from the fire alarm panel and operate on DC power. In the event of fire, the hooter
shall raise pulsating audio alarm and the lamp shall start flashing.
12.12 Flashing Lights (Beacon)
12.12.1 The unit shall consist of solid-state circuitry on a printed circuit board and a red-capped
incandescent lamp and audio unit housed in a dust tight, wall/ ceiling mounting type
enclosure. It shall derive power from the DGFAP/ ZFAP and shall operate on DC supply.
12.12.2 Flashing lights shall be installed in the enclosed areas where clean agent/ CO2 is to be
released. In the event a signal for clean agent/CO2 release is given, the lamp shall start
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ENGINEERS FOR
faWs INDIA LIMITED
IA boN llnOeftakngi FIRE DETECTION AND
6-51-0076 Rev. 5
blinking with a warning sound enabling operating personnel to evacuate the area. The audio
unit (hooter) shall have 102 db (A) output measured at 1-meter distance.
12.13 Clean Agent / CO2 Release and Inhibit Switches
12.13.1 This unit is required to be provided at the exit of the protected buildings/ rooms. lf specified,
this unit is integrated with DGFAP/ ZFAP. This shall consist of pull type release and inhibit
switches clean agent / CO2 . The unit shall be fabricated out of 2mm thick cold rolled sheet
steel suitable for wall mounting. Switches shall be pulled to release or inhibit clean agent
CO,.
Release switches shall have inscription:
"PULL TO RELEASE CLEAN AGENT / CO2"
And inhibit switches shall have inscription:
"PULL TO INHIBIT CLEAN AGENT / CO2".
12.14 Zener Barrier
12.14.1 Preterably flameproof (Ex 'd. ) equipment that does not require the use of Zener barrier shall
be used. When necessary, intrinsically safe (Ex 'i') detectors and BGUs, Zener barriers shall
be provided. These shall be located in unclassified/ non-hazardous areas.
12.14.2 Normally not more than 10 detectors shall be connected to one zener barrier. However vendor
shall indicate maximum number of detectors/ BGUs that can be connected to one Zener
barrier without compromising on working of loop/ zone. Vendor shall also indicate the
maximum loop length from zener barrier considering 1.5 mm2 copper conductor screened
cable.
12.14.3 In case loop length permits, zener barrier shall be located at DGFAP itself, else it shall he
located in safe area nearest to the detector/ BGU.
12.14.4 Wherever zener barriers are provided in safe area outside the Zonal panel or DGFAP, these
shall be housed in their own enclosure with IP-55 degree of protection as a minimum.
12.15 Fault Isolator
12.15.1 Fault isolator shall be installed, if specified in the data sheet.
12.15.2 Fault isolator shall be designed to provide short circuit protection to an addressable detector
loop. lt shall be possible to wire the fault isolator at any point in the detector loop.
12.15.3 On occurrence of a fault (short circuit), the isolator shall cut power to all devices installed
between the two isolators minimizing the outage of all the detectors in a loop.
12.15.4 The fault isolator shall have the capability to continuously check the faulted side of the loop
to determine if the fault still exists. On rectification of the fault, the isolator shall
automatically reset itself.
12.15.5 Fault isolator modules shall be housed in a enclosure having IP-55 degree of protection as a
minimum. If located in hazardous area, it shall also be tested and approved for use in area
classification defined in the data sheet.
12.16 Sirens
12.16.1 Sirens shall be industrial type with minimum 2.5 km unidirectional range (i.e. 5 km
diametrical range) against the wird direction.
Format No 8-00-0001-F1 Rev. 0 Copyright EIL. All rights reserved
Page 251 of 851

k31 ENGINEERS FOR
$ig-ar fafs INDIA LIMITED 6-51-0076 Rev. 5
1~1 217,,,,,51,3,
1,711 IA Govt ol India Undertalongt FIRE DETECTION AND
12.16.2 The decibel level of the siren shall, at least be 132db(A) at 1 meter, to meet the audibility
requirement for the above range. Unless otherwise specified, Sirens shall operate preferably at
110/230V AC supply. Sirens shall be housed in weatherproof enclosure. Starter shall be DOL
and shall be housed in a separate IP55 enclosure suitable for installation indoor/ outdoor.
12.16.3 The siren shall provided with five tones suitable for various conditions as follows
i) SMALL FIRE: No siren
ii) MAJOR FIRE: A wailing siren for two minutes.
iii) DISASTER: Same type of siren as in case of Major Fire but the same will be sounded
for three times at the interval of one minutes i.e.(wailing siren 2min + gap 1 min +
wailing siren 2min + gap l min + wailing siren 2min) total duration of Disaster siren
to be eight minutes.
iv) ALL CLEAR (For fere): Straight run siren for two minutes.
v) TEST: Straight run siren for two minutes at frequency atleast once a week.
12.16.4 The siren controller shall be as below
i) The operation of siren shall be in Manual mode with single button operation through
Push Buttons — 5 Nos. mounted on the control desk for tone selection.
ii) The siren shall be initiated with a single pulse from the Push Button. The logic shall
be such that first Push Button pressed shall be accepted till the completion of cycle of
that particular siren tone.
iii) One no Push Button shall be provided for EMG STOP in case the siren tone is
required to be stopped mid way.
12.16.5 The operation of the siren shall also be possible in Auto mode. The programming for the same
shall be possible from the DGFAP/CFAP.
13.0 FIELD DEVICES FOR HAZARDOUS AREA
13.1 Hazardous area is classified as Zone 1/ Zone 2, gas group IIA/ IIB or IIC, temperature class
T3 (200 °C) as specified in data sheet. The field devices shall be suitable for installation in
hazardous area as per specified area classification.
13.2 Field devices such as detectors, BGUs, fault isolators, Beacons, hooters etc for use in
hazardous area, if specified in the data sheet, shall have flame proof enclosure conforming to
IS/IEC 60079. All equipment for hazardous area installation shall be complete with flame
proof weather proof cable glands as specified in clause 11.5.
13.3 Equipment, which cannot have flameproof construction, shall be intrinsically safe in design
and shall be used with Zener barriers located in safe area.
13.4 Equipment that are tested / certified by a recognized test laboratory of country of origin shall
only be offered. The vendor shall possess valid test certificate issued by a recognized
independent test house such as CIMFR/ BASEEFA/ UL/ FM or Equivalent for the offered
equipment.
Page 252 of 851

ENGINEERS FOR
laWs- INDIA LIMITED 6-51-0076 Rev. 5
,r1d1., undettak ,l, FIRE DETECTION AND
Page 24 of 26
ALARM SYSTEM
13.5 All equipment (indigenous or imported) shall have valid statutory approval as applicable for
the specified hazardous location from PESO or any other applicable statutory authority. All
indigenous flameproof equipment shall also have valid BIS license and corresponding
marking as required by statutory authority.
13.6 A separate name plate shall also be provided on each equipment to indicate details of testing
agency, test certificate number with date, statutory approval number with date, approval
agency, BIS license number with date, applicable gas group, temperature class etc. The name-
plate shall be riveted/ fixed with screws and not pasted. ln case above information are
embossed on the enclosure, the same need not be repeated.
14.0 ENGINEERING REQUIREMENTS
Unless specified otherwise, vendor shall design entire fire alarm system including design of
system architecture with details of integration, cabling requirement and protocol selection etc.
Vendor's scope shall also include basic design and preparation of layouts for fire alarm
system for plant/ buildings if specified in the data sheet/ purchase documents.
14.1 Conventional Fire Alarm System
i) For conventional fire alarm system, Owner shall provide typical block diagram. On
this basis, vendor shall prepare detailed drawing giving various system component
details. The design and engineering shall include sizing and selection of various
equipment such as fire alarm panels, batteries, battery chargers, field equipments,
siren/ siren starter etc. including preparation of General Arrangement drawings of
various equipment.
ii) The layout engineering for buildings shall include the drawings showing location of
BGU/ Detector and other field devices, cable schedules, interconnection diagram.
equipment installation drawings etc as minimum.
14.2 Addressable Fire Alarm System
i) Vendor shall develop a system architecture based on Owner's requirement showing

details of various network elements such as DGFAP, CFAP, Work station,
networking hardware, redundancy, protocols, data highway etc. including the
maximum permissible loop length and length of data highway.
ii) The design and engineering shall include sizing and selection of various equipment
such as fire alarm panels, batteries, battery chargers, field equipment, siren/ siren
starter etc. including preparation of General Arrangement drawings of various
equipment.
iii) The layout engineering for buildings shall include the drawings showing location of
BGU/ Detector and other field devices, cable schedules, interconnection diagram,
equipment installation drawings etc. as minimum.
iv) The "Cause & effect" diagram of the system shall be developed by vendor during
detail engineering, in consultation with client.
v) The parameterization facilities of various field devices along with the geographic
mimic, annunciation, text messages etc shall be available on the fire alarm panel.

Page 253 of 851

ENGINEERS FOR
fg-a,,
r la2es, INDIA LIMITED 6-51-0076 Rev. 5
IA Govt of Incla Undertaking) FIRE DETECTION AND
15.1 All the equipment shall be tested to the defined specifications as per mutually agreed test
plan/ FAT procedure, which shall be submitted and got approved from Owner at least one
month before inspection. EIL/ Owner' s inspectors shall witness all the tests.
15.2 During manufacture, the equipment shall be subject to inspection as per agreed inspection
plan to assess the progress of work and to ascertain that the quality controls are being
maintained. Vendor shall provide all necessary assistance and information concerning the
supply to ELL/Owner's inspectors.
15.3 Tests shall be carried out at the vendor's works under his care and expense and Owner
shall be informed at least 4 weeks in advance regarding this.
15.4 FAT shall include simulation of operational field conditions and test for functional adequacy
besides all routine and acceptance tests specified by applicable codes and standards.
15.5 For bought out items, the routine and acceptance tests shall be conducted at the respective
equipment manufacturer' s works.
15.6 At the time of inspection, vendor shall produce original of all the type test certificates, test
and approval certificates for hazardous area equipment from testing and approving authority
and any other certificates as required from statutory authority for the review of inspectors.
15.7 Vendor shall submit a SAT procedure for EIL/ Owner' s approval. All equipment and
systems shall be tested at site as per the approved SAT procedure
15.8 SAT shall be conducted by vendor after the entire fire alarm system is installed and inter
connected by cables. These tests shall establish the operational correctness of the system.
Vendor shall rectify deficiencies noticed during SAT with no commercial implication to
Owner including replacement of system components and supply of new component for
making system successfully operational.
All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for selected mode of
transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polythene sheets
before being placed in crates to prevent damage to finish. Crates shall have skid bottom for
handling. Special notations such as 'Fragile', 'This side up', 'Center of gravity', 'Weight' etc.,
shall be clearly marked on the package together with Tag nos., Purchase order Nos. etc.
The equipment may be stored outdoors for long periods before erection. The packing shall be
completely suitable for outdoor storage in areas with heavy rains/ high ambient temperature.
17.0 INSTALLATION AND COMMISSIONING
Where installation of the system is included in the scope of the vendor, vendor shall arrange
all necessary manpower and equipment required for the same. Commissioning of the
complete system is to be carried out by vendor in all cases irrespective of whether the
installation was performed by vendor or not. All tools, test equipment etc. for the successful
commissioning of the system shall be arranged by the vendor at his own cost. Only the
cabling specifically excluded from vendor's scope shall be installed by others. However,
termination at panels for Owner' s cables shall be done by the vendor.

Page 254 of 851

2_Jt4 ENGINEERS FOR
5fgu INDIA LIMITED
in Govl ol maga UndeOakingi FIRE DETECTION AND
6-51-0076 Rev. 5
18.0 TRAINING
Vendor shall provide comprehensive training on various operation and maintenance aspects
of the Fire Alarm system as agreed during ordering at manufacturer's works. Vendor shall
also provide training on various operation and maintenance aspects to Owner's engineers at
site.
Page 255 of 851

r"_11
1 Reig ENGINEERS ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
$'g?;ir INDIA LIMITED
IA Govt of Ilioia Undertakingt INSTALLATION Page 1 of 15
fqxja `CID Tzrp-ir9r NfffhT
SPECIFICATION FOR
ELECTRICAL EQUIPMENT
INSTALLATION
4 21.05.14 REAFFIRMED & ISSUED AS SPECIFICATION FA SA BRB SC
3 25.04.08 REVISED & ISSUED AS SPECIFICATION RKS SSM JMS VC
2 28.02.03 REVISED & ISSUED AS SPECIFICATION HKM RSG VPS SKG
REVISED & ISSUED AS STANDARD RR VPS SG AS

1 26.08.97
SPECIFICATION
0 28.08.81 ISSUED AS STANDARD SPECIFICATION RR RR SGG
Standards Standards
Committee Bureau
No by by
Approved by
Page 256 of 851

ENGINEERS
$11gui&W- eg INDIA LIMITED 6-51-0081 Rev. 4
rycnrc ~I) IA Govt of India Undeffoloogf INSTALLATION Page 2 of 15
Abbreviations:
AC Alternating Current
ACDB AC Distribution Board
AL Aluminium
CCoE Chief Controller of Explosives
CD Compact Disc
CIMFR Central Institute of Mining and Fuel Research
CT Current Transformer
CTC Carbon Tetrachloride
CU Copper
DC Direct Current
DCDB DC Distribution Board
DGMS Directorate General of Mines and Safety
Ex(d) Flameproof
FRP Fibre Reinforced Plastic
HV High Voltage
IR Insulation Resistance
IS India Standard
LV Low Voltage
HMI Human Machine Interface
MV Medium Voltage
OISD Oil Industry Safety Directorate
OSR Oil Surge Relay
OTI Oil Temperature Indicator
PF Power Factor
PI Polarisation index
PRV Pressure relief Valve
PT Potential Transformer
SLD Single Line Diagram
UPS Uninterrupted Power Supply
VRLA Valve Regulated Lead Acid
WTI Winding Temperature Indicator
Convener: Mr. B.R. Bhogal

Mr. Parag Gupta
Mr. M. K. Sahu
Mr. A.K. Choudhury (Inspection)

Page 257 of 851

‘3-1R_Jt4
1 ENGINEERS ELECTRICAL EQUIPMENT
orrrn c,craddaJnadfan IA Govt of India Undeftalong) INSTALLATION Page 3 of 15
CONTENTS
1.0 SCOPE 4
3.0 INSTALLATION OF EQUIPMENT 4
4.0 EQUIPMENT COMMISSIONING 14
5.0 LIST OF CONSTRUCTION EQUIPMENT 14

Page 258 of 851

ENGINEERS
$11g-a 22-g INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
aiT7ii CRI dYtn. (A Govt of lochA UnderfAk(.9) INSTALLATION Page 4 of 15
1.0 SCOPE
This specification defines the requirements for the installation, field inspection, testing and
commissioning of electrical equipment, forming part of electrical power distribution and
utilisation system, including Communication and Fire alarm system.
2.1 The work shall be carried out in the best workmanlike manner in conformity with this
specification, EIL Installation Standards, layout drawings and to the following specifications/
codes of practice of Bureau of Indian Standards and OISD standards.
SP-30 (BIS) National Electrical Code.

IS:7816 Guide for testing Insulation resistance of rotating machines.
IS:10028 (Part-2) Code of practice for selection, Installation and maintenance of
transformers; Part 2 : Installation.
OISD 137 Inspection of Electrical Equipment.
OISD 147 Inspection and safe practices during electrical installations
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:
a. CEA Regulations.
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by CCoE/DGMS (as applicable).
d. The petroleum rules (Ministry of Industry Government of India).
e. Any other regulations laid down by central/state/local authorities and Insurance
agencies.
3.0 INSTALLATION OF EQUIPMENT
Prior to start of installation of the electrical equipment, Contractor shall verify that equipment
and complete materials have been received. Handling, shifting to required site location,
installation, testing and commissioning of all electrical equipment shall be done by contractor
with utmost care. Manufacturer's instructions and the requirements given in their technical
manuals shall be strictly adhered. The substation/switchgear room wherein the equipment
shall be installed shall be kept clean, dry and free from all debris. Panel floor cutouts not in
immediate use shall be suitably covered to avoid any mishap. When handling the switchboard
panels, care shall be taken to observe the correct lifting arrangements and to make sure that
slings are attached to the manufacturer's designated lifting points,where applicable. No parts
shall be subjected to undue strains or sudden stresses which could cause damage to the
equipment.
The lifting position mark indicated on packing casing shall be adhered to strictly, for keeping
it in required vertical position.
Contractor shall check and report to the Engineer-in-charge about any damaged item and / or
missing component for getting the same replaced as per specifications. During installation, all
accessories and loose items shall also be inspected by the contractor before their
assembly/mounting.

Page 259 of 851

ENGINEERS
Otait INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
1~,.r2",1,77 ,1713,21,) (A Govt ol InOla Undedalong) INSTALLATION Page 5 of 15
3.1 Switchboards and Bus Ducts
3.1.1 The term switchboard here includes all HV / MV/ LV switchboard panels, motor control
centers, power and lighting distribution boards, UPS panels, ACDB, Battery charger panels,
DCDB etc.
The switchboard panels shall be handled with care, avoiding any impact to the equipment.
Dragging of the panels directly on floor shall be avoided. Roller bars may be used for shifting
of panels. Use of a crane and trailer shall be made for handling of equipment. The
switchboard panels shall be properly supported on the truck or trailer by means of ropes to
avoid any chance of tilting. The switchboards shall be lifted after ensuring that panel supports,
nuts and bolts are all intact and tightened. While lifting the panels in packed conditions,
utmost care shall be taken to avoid any damage to insulators, bushings, metering and
protective equipment and if specified in the tender document tyre mounted hydraulic trolley
shall be used.
The panels shall be preferably kept inside the packing cases till foundations are ready. Proper
rain/sun/dust protection shall be ensured till switchboards are installed.
3.1.2 The switchboard panels shall be installed on prepared foundations or floor cutouts. Steel base
channels shall be welded to inserts provided in floor slab. Cross members shall be provided at
the junctions of each shipping section and other places as required.. It shall be ensured that the
base plate level of HV switchboard shall match with the finished floor level.
The foundation pockets and the grouted bolts shall be cured for a minimum period of 48
hours. Proper level of base frames shall be maintained throughout and shall be checked with
water level/spirit level. Steel Shims shall be provided below base frame wherever required.
3.1.3 The switchboard panels shall be taken out from the packed cases and shifted one by one to
their proper place. Al1 the panels shall be assembled, aligned and leveled. Alignment of
panels shall be checked in both longitudinal and lateral directions. It shall be ensured that
panel to panel coupling bolts, bus bar links etc. fit properly without any strain on any part. No
new holes for jointing of the panels other than those recommended by the vendor shall be
drilled. No gaps shall be left between the panels. Gap if any found between panels shall be
suitably sealed using sealing compound or T-profile. The lifting, racking in and out operation
of the breaker and all other motions shall be free from any obstruction.
The panels shall be checked for correct vertical position using Plumb line and spirit levels.
The switchboard panels shall be tack welded at suitable intervals to base channel.
After erection of switchboard panels, all uncovered portions of floor cutouts shall be covered
with 6 mm thick removable chequered plates finished with floor level. The design of the
chequered plates shall be such that the maximum allowable deflection is L/200 (where L is the
span of the chequered plates in meters) for a live load of 500 kg./sq. meters.
Additional stiffer shall be provided at the bottom if required. Suitable lifting arrangements
shall be provided for chequered plates. The chequered plates shall be painted with a coat of
red oxide zinc chromate primer after proper surface preparation as per specifications. Where
specified, panels' cutouts provided for future use shall be filled with lean concrete.
3.1.4 After completion of Installation of switchboards, all the cubicles, switchboard components
such as switches, starters, CT and PT chambers, bus bar chamber shall be cleaned and
checked for tightness of all the components.
Vacuum circuit breakers shall be checked for integrity of bottle seals. A11 loosely supplied
items shall be fitted up. Bus bar sections or links shall be inserted and where specified, of high
Copyright EIL All rights reserved

Page 260 of 851

ENGINEERS
Ordie'g INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
eivavv'dv~) IA Govt of Intha Undertaking) INSTALLATION Page 6 of 15
voltage equipment shall be insulated. Interconnection wiring between shipping sections shall
be done by contractor.
All the wiring connections shall also be checked. Contact resistance of all bus bar joints and
contactors shall be checked. Insulator shall be checked for any damage. All the starters,
switches, contacts shall be cleaned with CTC where required.
A11 the moving parts shall be checked for easy and free movement. Hinges of panel doors
shall be lubricated to give free and noise less movement. A11 openings shall be kept
completely closed to avoid ingress of any foreign particles inside the panel.
Functional scheme verification of individual feeder shall be carried out and minor wiring
modifications in the panel wiring, if required shall be done as per the directions of Engineer-
in-charge. Special attention shall be paid to CT circuits' polarity, wiring continuity and
correctness in the protection as well as measurement circuits. Auto transfer scheme shall be
simulated and verified. During the course of scheme verification tests, defective components
if any shall be taken out, after bringing to the notice of Engineer-in-charge. The same shall be
replaced by component supplied by owner.
3.1.5 Where switchboard is damp or having a low IR value due to damaged insulators/
bushings/any other insulated parts, or any other reason, the entire switchboard shall be dried-
up according to the instruction of the Engineer-in-charge for the IR value to improve to a safe
level for commissioning. Care shall be taken to protect the surrounding insulation from direct
local heating during the drying up process.
3.1.6 All the metering instruments, protective relays and other relays and contactors shall be tested
as per manufacturer's recommendations and according to the instructions of the Engineer-in-
charge. Protection relays shall be inserted and connected and settings adjusted as required by
the Engineer- in- charge
3.1.7 All moving parts, of closing/tripping mechanism, racking in and racking out mechanism,
spouts and shutter closing mechanism shall be checked for proper operation. A11 the auxiliary
contacts of breaker shall be checked-up, cleaned and contact pressure measured.
3.1.8 All the control wiring, PTs, bushings, bus bars, other live parts of switchgear, incoming and
outgoing cables shall be meggered.
3.1.9 Electrical simulation tests shall be carried out for all the protective, alarm and annunciation
relays and external interfaces to ascertain proper functioning.
3.1.10 Safety insulation mats of approved make and of required voltage grade shall be provided in
the sub-station.
3.1.11 Pre-Commissioning Check List

Before commissioning any switchboard, following points shall be checked and ensured for
safe energising of the switchboard:
i. That the installation of equipment to be commissioned is complete in all respects with

its auxiliaries and all other mounting including earthing. Openings in floor within and
outside panels have been sealed off. All cover and door gaskets are intact to make the
enclosure vermin proof.
ü. That all the metering instruments have been checked and found in working order.
Indicating lamps are healthy and are in correct position. All power and control fuses
are of proper rating.

Page 261 of 851

ENGINEERS
g INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
(A GoV1 ol Ind. Unde(l.k,n91 INSTALLATION Page 7 of 15
iii. That the polarity test and ratio test of all the PTs and CTs is complete and phase
sequence of CTs conforms to the correct vector group connections. Wiring continuity
and correctness are ensured in the protection and measurement circuits. Polarity of
D.C. supply for all the circuits is correct.
iv. That the high voltage tests of incoming and outgoing cables have been conducted and
results are satisfactory.
v. That all the protective relays including both conventional and microprocessor based
numerical relays and thermal overload relays/electronic motor protection relays have
been tested for secondary injection tests. (Primary injection tests shall be carried out
for differential protection, Restricted Earth fault protection at full / reduced current to
ensure correctness of complete wiring). Relay settings, status indications, fault
annunciations, data logging, display of switchboard SLDs shall be verified from HMI
in case the same is provided.
vi. That IR Value has been recorded for bus bars, circuit breaker, incoming and outgoing
cables, control wiring and potential transformers. Where required joint resistance of
bus bars have been recorded and found to be satisfactory. All the surroundings and
panels have been cleaned and temporary earth leads have been removed.
vii. Following tests shall be ensured for all CTs
- Insulation resistance test
Ratio test through primary injection
Polarity test
Knee point voltage for class PS CTs
viii. Following tests shall be ensured for all PTs
Insulation resistance test
Ratio test through primary injection
- Polarity test
ix. Following tests shall be ensured for all breakers
- Insulation resistance test
- Breaker closing, opening sequence using 3 pole timers
- High voltage test both in open and close condition for HV breaker
Contact resistance of all three poles using 100A DC Kit
x. Following tests shall be ensured for all meters
- Calibration of meters
Functional verification and settings
xi. Following tests shall be ensured for all relays
Secondary injection test
- Relay settings
Timing check with timers
- Any other test recommend by the supplier
xii. Following tests shall be ensured for all bus bars
- Tightness of all nuts/bolts using Torque wrench
IR value
- Contact resistance using 100A DC Kit
- Cleaning of bus bar chamber using vacuum cleaner
- Conducting jelly shall be applied on AL/CU joints as per manufacturer's
recommendations
- HV test in case of HV switchboard

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k31naf t IENGINEERS
$1gzir INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
1~7tYleaHt an .3~1 Ift Govt of Incha Undertaking) INSTALLATION Page 8 of 15
xiii Following tests/Checks shall also be performed on the switchboards

Functional verification of individual feeders including all spare feeders
Simulation test for under voltage tripping of related feeders such as motor
feeder, capacitor feeders etc
Verification of control supply schemes
Stability test for all differential protections
Simulation test for bus auto/manual change over scheme
Checks for all panel illuminations, indicating lamps, sockets
All upstream and down stream interlocks
3.1.12 Bus Ducts
The bus ducts as per issued drawings will be supplied in parts and all the parts shall be
assembled and the bus bar connections shall be made at site. The insulators in bus ducts shall
be inspected for any possible damage during transit and the defective ones shall be replaced.
The insulators shall be cleaned. Contact surface of bus bars, bus bar bolts and nuts shall be
thoroughly cleaned. Petroleum jelly shall then be applied and bolted connection made. The
bus duct enclosure shall be checked for earth continuity and then earthed at two places. The
bus duct shall be properly supported between switchgear and transformer. The opening in the
wall where the bus duct enters the switchgear room shall be completely sealed to avoid rain
water entry. Expansion joints, flexible connections etc. supplied by the manufacturer of the
bus duct shall be properly connected. The bus duct levelling shall be checked with spirit level
and pendulum weight.
Pre-commissioning check list
Before commissioning any bus duct, following points shall be checked and ensured for safe
energising of the bus ducts
All joints are tightened using torque trench

Cleaning of bus duct chamber with vacuums cleaner
Silica gel breather shall be connected if supplied. If required, silica gel shall be
reactivated as per the instruction of engineer in charge.
Space heater circuit shall be checked and tripping through thermostat shall be ensured
Contact resistance shall be measured for all phases/neutral using 100A DC kit
High voltage test in case of HV bus ducts
3.2 Transformers
Transformers on receipt at site shall be unloaded by means of crane or lifting devices of

adequate capacity. All lifting lugs shall be used to avoid unbalanced lifting and undue
stresses on lugs. Lifting lugs if any provided for partial lifting (e.g. for active part,
conservator) etc. shall not be used for lifting complete transformer. Parts other than those
identified for lifting of the transformer shall not be used for lifting. While slinging, care shall
be taken to avoid slings touching other parts.
3.2.1 Before lifting transformer, it shall be ensured that all cover bolts are tightened fully. In case
when it is necessary to use jacks for lifting, projections provided for the purposes of jacking
shall be used . Lifting jacks shall not be used under the valves or radiator tubes. For
transporting transformers from stores to site, the transformers shall be loaded on a suitable
capacity truck or trailer. The transformers shall be properly supported by steel ropes and
stoppers on the trailer to avoid tilting of the transformers in transit due to jerks and vibrations.
At no instance, the transformer shall be kept on bare ground. Where it is not possible to
Page 263 of 851

k5-1
1 ENGINEERS
Og-LITI&2eg INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
aiWn 4,
1 .3~1/ (A Govt ol Indla Undertaking) INSTALLATION Page 9 of 15
unload the transformer directly on a foundation, it shall be unloaded on a properly built

wooden sleeper platform. A transformer shall never be left without putting stoppers to the
wheels.
3.2.2 Transformers shall be examined, for any sign of damage in transit. Particular attention shall
be given to the following in this regard.
i. Dents on tank wall or cooling tubes, radiators

ü. Damage to protruding parts like valves, sight glass etc.
Loosening of bolts due to vibration in transit.
iv. Cracked or broken bushings.
v. Oil leakage particularly along welds.
If any thing adverse is noted, the same shall be brought to the notice of Engineer- in- charge.
3.2.3 Contractor shall examine the transformer base, oil pit, fire walls and foundations made by the
civil contractor. It shall be ensured that oil spills can not propagate along cable trenches. Any
discrepancy noted will be brought to the notice of Engineer- in- charge. Transformers shall be
placed on channels or rails over concrete foundations. The transformers shall be levelled,
aligned and checked for free movement on the channels or rails. Stoppers shall be provided to
the transformers immediately to prevent any movement. Normally transformers upto 1000
kVA rating shall be received duly fitted with radiator tubes, conservator tanks, valves, wheels
and other accessories. While the transformers of above 1000 kVA rating may be supplied with
loose accessories. All the accessories like radiators, cooling fans, valves, conservator tanks,
explosion vent pipe, bushings and other devices which are supplied in different packages
shall be checked for any transit damage and cleaned thoroughly before fixing on the
transformer. All loosely supplied parts shall be assembled as per manufacturer's instruction
manuals/ drawings and documents. All the connections for CTs bushings and other wiring
shall be checked for tightness and correctness before replacing the lid or tightening all the
bolts. Gravels shall be filled in the transformer bay, soak pit as per requirement.
3.2.4 Topping of transformer with oil
Before topping up with oil, transformer shall be fitted with all accessories such as valves,
gauges, thermometers etc. Oil samples shall be taken from each drum and tested for
determination of dielectric strength. Any sign of leakage of the barrel or of its having been
opened shall be recorded and reported. It is necessary to filter the oil before the transformers
are filled. It shall be ensured in oil filling operation that no air pockets are left in the tank and
that no dust or moisture enters the oil. All air vents shall be opened. Oil shall be filled
through a streamline oil filter using metal hose. To prevent aeration of the oil, the transformer
tank shall be filled through the bottom drain valve. In a transformer with conservator tank, the
rate of oil flow shall be reduced when the level is almost upto the bottom of the main cover to
prevent internal pressure from rupturing the pressure relief-pipe diaphragm. Sufficient time
shall be allowed for the oil to permeate the transformers and also for the locked -up air
bubbles to escape. Any air accumulation in the buchholz relay shall be released.
3.2.5 Transformer Oil
i. Sample of oil from the transformer shall be taken from the bottom of the tank.
ii. Testing of Oil

For dielectric test, the oil shall be tested as described in IS: 335. The oil shall also be
tested for acidity in accordance with the methods prescribed.
3.2.6 Drying out of the transformers, if required, shall be carried out and record maintained in
accordance with IS: 10028. Normally a streamline filter shall be used for drying-up. IR value

Page 264 of 851

01 ENGINEERS
ogur 015:1&g INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
14~ ,le'crn( 0,1 3,121,1) (A Govt of India Undettakingi
INSTALLATION Page 10 of 15
versus time of both windings along with OTI/WTI and filtrations machine temperature curve
for IR value Vs time shall also be plotted and recorded during the drying-up process.
Precautions when drying
i. The maximum sustained temperature to which transformer oil may be subjected shall
be limited to 80° C.
ü. The transformer shall be carefully monitored throughout the drying out process and
all observations shall be carefully recorded.
Drying out shall be continued so that the insulation resistance as prescribed in the
standard code of practice is attained and the value remains constant for more than 12
hours. However, a minimum number of cycles shall be done for each transformer as
found necessary by the Engineer-in-charge. Generally a Megger reading of 2
megohms / kV at 60° C temperature. with a 5 kV Megger may be a rough indication
for stopping the dehydration.
3.2.7 The following work on transformers shall be performed by the contractor if specifically called
for:
i. Before finally commissioning the transformer it may sometimes be desired to run it

for a few hours on short-circuit, applying a low voltage, approximately equal to the
impedance voltage of the transformer. During this process, regular readings of the
insulation resistance of the winding to earth and winding to winding and temperature
against time shall be recorded.
ü. Testing of radiator tubes for any leakage and rectifying these by welding / brazing.
3.2.8 Pre-commissioning Check List
Before commissioning of any transformer, the following points shall be checked for safe
energisation of the transformer:
i. All the accessories have been fixed properly and transformer body and neutral are
properly earthed. The transformer dehydration is over and results are satisfactory and
approved by the Engineer-in-charge. In case transformers are idle for more than one
month after dehydration, transformer oil has been given at least two circulations.
ü. Oil level, in the transformer conservator tank and all the bushings is upto the marked
point and the oil has been tested for dielectric strength and acidity.
Silicagel is in reactivated condition. The breather pipe is clear from any blocking and
contains oil upto the proper level.
iv. The explosion vent diaphragm does not have any dents. Accumulation of any oil and
air had been released.
v. Operation of off-load and on-load tap changers on all the tap positions is satisfactory.
The mechanical parts of the on-load tap changer are lubricated. Motor IR value has
been taken and found satisfactory. Tap position mechanical indicator on the
transformer and tap position indication meter on the control panel are reading the
same tap positions. Tap changer limit switches are operating satisfactorily on the
maximum and minimum tap positions. On-load tap changer contact pressure and
resistance is as per manufacturers recommendations. Oil level of tap changer tank is
upto the required level and oil has been tested for dielectric strength. The tap setting
on which the off load tap switch is locked shall be recorded. Generally the off-load
tap switch shall be kept on nominal tap.
Page 265 of 851

ENGINEERS
51gzuc-wert -"dg
2a1ams..) INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
(A Govt of India Unde(tak,ngj INSTALLATION Page 11 of 15
vi. Buchholz relay has been tested and checked up for any friction in the movement, and
floats are free. All the other protective relays, alarm and annunciation relays have
been tested.
vii. Metering equipment has been tested and polarity test of PT's and transformer winding
is satisfactory. Phase sequence and connections have been checked for proper vector
group.
viii. Ratio test and winding resistance on all the tap positions is satisfactory.
ix. Gaps of arcing horns for the bushings where provided are in order and earth
connections for the surge diverters have been checked.
x. Winding and oil temperature thermometer pockets contain oil and the winding and oil
temperature settings on dial gauges are in order.
xi. Transformers fitted with fans for forced air cooling have been checked up for starting
and stopping of the fans both in manual and auto mode and air-displacement has been
verified.
xii. Simulation tests for all external interface connection alarm, annunciation and trip
circuits have been checked and are in order.
xiii. Insulation resistance of all the control circuits and IR value of the transformer
windings and all the incoming and outgoing cables have been checked.
xiv. Valves in the cooling system and valve between the buchholz relay and the
conservator tank are in open position.
xv. Setting of all the protective relays is at the desired value and DC Trip supply is
healthy.
xvi. Magnetic, current and magnetic balance test have been conducted
xvii Simulation test for WTI,OTI,PRV,OSR
xviii Settings of WTI/OTI as per the instruction of the manufacturer
xix Earth resistance value for the neutral earthing
3.2.9 Observations after Commissioning
After switching on the transformer the following points shall be observed and recorded.
i. The inrush magnetizing current and no-load current.

ü. Alarm, if any, or if any relay flag has operated.
Voltage and current on all the three phases.
iv. Transformer hum or abnormal noise.
v. Circulation of oil and leakages.
vi. Record current, voltage, cooling air temperature, winding temperature and oil
temperature readings, hourly for 24 hours.
vii. Cable end boxes for any over-heating.
3.3. HV and MV MOTORS
3.3.1 All the motors generally would be erected by the mechanical contractor.
3.3.2 Electrical contractor shall keep the motor space heater energised as per the directions of
Engineer-in-charge. Electrical contractor shall measure the insulation resistance of motor
windings and PI in case of HV motors. Insulation resistance of the motors shall be measured
between the winding of the machine and its frame by means of a 500 / 1000 V Meggar in case
of 415 V motors. A minimum value of 1 megohm for 415 V motors shall be considered a safe
value. In case of lower I.R. Value, the insulation value shall be improved by any of the
following methods as directed by the Engineer-in-charge.

Page 266 of 851

ENGINEERS
Og'zIr faf-Zs
ei2LIW ,
R13,,g1,
11)
INDIA LIMITED
IA Govt ot Intha Undertakmg
INSTALLATION
6-51-0081 Rev. 4
Page 12 of 15
i. Blowing hot air from external source.

ii. Putting the motor in oven.
iii. Placing heaters or lamps around and inside after making suitable guarding and
covering arrangements so as to conserve the heat.
In case the insulation is low, the following method of drying has to be adopted, after
consultation with Engineer-in-charge. During drying the temperature rise of winding shall not
exceed the permissible value for the class of insulation used.
i. By locking the motor so that it can not rotate and then applying such a low voltage to
the stator terminals so as to pass full load current in the stator keeping the stator
winding temperature below 90° C . In this case a close watch shall be kept for any
possible overheating and I.R. Values vs. temperature shall be plotted and heating
continued till I.R. value becomes steady.
ü. By blasting hot air from external source, Maximum temperature of winding while
drying shall be 70° C to 80° C (thermometer) or 90° C to 95° C by resistance
method. Heating shall be done slowly first till steady temperature of winding is
reached after 4 to 5 hours, and for large machines after 10 hours. A record has to be
kept for drying process, with half an hour readings and, till steady temperature is
reached. In case it is essential, the drying process can be supplemented by blower.
3.3.3 It shall be ensured that the motor leads are correctly connected in the terminal box, as
indicated in the `Name Plate'. The covers of all terminal boxes shall be properly fixed, the
gaskets intact. The control circuit shall be tested for proper functioning as per circuit diagram.
3.3.4 In case of synchronous machines, slip rings and brush gear shall be polished and brushes shall
be fixed in their holders with clearance and pressure as recommended by the manufacturers.
3.3.5 Before commissioning, the ventilation and cooling system of the motor must be inspected. In
case of motor with forced ventilation the air inlet shall be examined to ensure that it is free
from moisture and any foreign material. It shall also be ensured that recommended flow and
pressure of air is available to produce the required cooling effect.
3.3.6 The motor control gear shall also be carefully examined, the over-load settings may be
reduced or time lags bypassed from protective gear to ensure rapid tripping of switchgear in
event of faults. The direction of rotation of a new motor specially of large capacity , and phase
sequence of supply shall be kept in view while joining and connecting to the motor terminals
3.3.7 Finally the motor shall be started on no-load after decoupling, and shall be allowed to run for
a minimum period of 4 hours, or for a time as instructed by Engineer-in-charge. Attention
shall be given to the proper running of the bearings, vibration or unusual noises if any.
Voltage, starting current, no load current, stator winding and bearing temperature shall be
recorded after every 1 hour during this test. Direction of rotation shall be checked and
recorded. Normally the motors run in clockwise direction as viewed from the driving end
with reference to the phase sequence R, Y, B.
3.3.8 After switching off the motor, the insulation resistance of the motor shall be recorded under
hot and cold conditions.
3.3.9 If the no load test run is found satisfactory, the motor shall be allowed to run for 8 hours and
all readings shall be recorded.
3.3.10 The following work on motors, may be performed by the contractor if specifically called for.

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31 ENGINEERS
ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
$'fgu Offleg INDIA LIMITED
1.2T (A Govt of India Untleltakmgl INSTALLATION Page 13 of 15
i. The proper level of bearing oil has to be checked. The condition of grease in bearings
shall be checked and in case it is necessary, complete replacement of bearing with
specified grade of grease after proper cleaning of the bearing shall have to be done.
Wherever external greasing facility exists, the condition of grease may be checked by
pumping some new grease of specified grade at start. If the grease coming out is
deteriorated grease shall be replaced.
ü. All the motors, motor exciter set and induction generators directly coupled or coupled
through reduction gears shall be checked for abnormal vibration, if any Large rated
HV motors with journal type bearings are liable to get damaged from shock, rough
handling during transit. Any minor defect in a race or roller may give rise to
considerable amount of vibration and noise. Contractor shall check and bring to the
attention of Engineer-in-charge any defect noticed in this regard.
Due care shall be taken to avoid any damage to bearing insulation wherever provided.
3.4. Batteries/Battery charger
Battery (Lead acid, Nickel Cadmium or VRLA type as specified) shall be erected on stands
and insulators supplied by the manufacturer of the batteries. The installation shall be done as
per the layout drawings and manufacturer's instructions. Electrolyte if required / as applicable
shall be filled as per manufacturer's instructions. Interrow connections shall be made with the
leads supplied by the manufacturer. Functional check shall be done on the battery charger
including battery charging and discharging, recharging as per the recommendation of the
manufacturer.
3.5. Neutral Earthing Resistor
The neutral earthing resistor shall be inspected for any damage to the resistor grid and other
components. The resistor shall be levelled and installed. All covers etc. shall be checked for
tightness to ensure that the enclosure of the resistor is dust, vermin and weatherproof.
Earthing conductors shall be taken from the out end terminal of the resistor, for connection to
earth electrodes and to the main grid. Check such as IR, operation of space heater, earth
resistance shall be done before the commissioning.
3.6 Welding Receptacles
The welding receptacles shall be erected on steel/concrete structures as per the drawings. In
isolated places a separate support shall be fabricated and installed.
3.7 Push Button/Control Stations
The push buttons / control stations shall be installed near to the motors to be controlled.
Individual channel supports shall be installed as per EIL standard. If control stations for
hazardous areas are to be supplied by contractor, these shall be of Ex (d) type, tested by
CIMFR and approved by CCoE or other applicable certifying authorities. All outdoor push
buttons / control stations shall preferably have integral canopies for additional weather
protection. The canopy shall be made of 2 mm thick galvanized sheet steel or FRP where
these are not integral with the equipment.
3.8 Gang operated Isolators/outdoor Disconnectors
The isolators shall be transported to site in the dismantled condition. All the insulators may be
also supplied loose. The contractor shall inspect, clean, assemble and install the isolator on the
base structure previously fabricated, erected and levelled by him. The operating mechanism

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31 ENGINEERS
5ga. 22-- g INDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
Govt of Incha Undertalongt INSTALLATION Page 14 of 15
shall be installed on the structure and connected to the isolator poles. The operating
mechanism shall be tested by slowly bringing the isolator to the closed position and carrying
out the necessary adjustment as per the manufacturer's instructions. The earthing switches,
frames and operating handle etc. shall be earthed.
3.9 Contractor shall provide the following items in substation, as per CEA Regulations.
3.9.1 Fire buckets filled with clean dry sand and ready for immediate use for extinguishing fires and
fere extinguisher (carbon dioxide, dry chemical extinguisher etc.) suitable for dealing with
electric fires shall be conspicuously marked and kept.
3.9.2 First aid boxes containing ointments and medicines for immediate treatment of injuries (As
prescribed by Indian Red Cross Society or equivalent).
3.9.3 Instructions of restoration of persons suffering from electric shock in English, Hindi and Local
language of the district shall be affixed in a conspicuous place.
3.9.4 Danger boards (HV., MV.) shall be provided on transformer bay gate, switchboards, entrance
to switchgear room and at other places as required by Engineer-in-charge.
3.10 The Communication system and Fire alarm system panels and equipment shall be installed
complying to manufacturer's instructions. The location of field station (call back station unit,
break glass unit, telephone set etc.) shown on the drawing are indicative. The exact location
shall be decided at site by contractor in consultation with Engineer-in-charge. Correct type of
equipment with regard to hazardous protection as specified on drawing shall be adhered to by
contractor, for installation.
4.0 EQUIPMENT COMMISSIONING
4.1 Field inspection, testing and commissioning of the complete electrical installation shall be
carried out as per EIL specification no. 6-51-0087.
After the equipment is installed properly in accordance with drawings and specifications,
contractor shall carry out all pre-commissioning checks and tests as per EIL format in the
presence of Engineer-in-charge and test readings shall be recorded and furnished to EIL in
triplicate.
4.2 All equipment layout drawings shall be marked by the Contractor for "AS BUILT STATUS"
and two sets of hard copies shall be submitted to EIL.
5.0 LIST OF CONSTRUCTION EQUIPMENT
The contractor shall have all necessary construction equipment, tools and tackles and testing
instruments to carry out the erection works and to commission the system as specified. These
shall include but not be limited to the following, and these shall be brought to site by
contractor before the start of work.
5.1 Equipment
i. Portable grinder.
ü. Portable welding machine.
üi Portable gas cutting / welding set.
iv. Pipe threading machine.
v. Pipe bending machine (hydraulic).
Page 269 of 851

ENGINEERS
$11g-a [R6 UINDIA LIMITED ELECTRICAL EQUIPMENT 6-51-0081 Rev. 4
(.T-rn an,ram IA Govt or Indo Undertaking) INSTALLATION Page 15 of 15
vi. Portable drill machine suitable to take up drilling for different sizes as per
requirement.
vii Dewatering pump sets (diesel driven).
viii. Power Hacksaw.
ix. Conduit dye set.
x. Hydraulic crimping machine with round/hexagonal dye set.
xi. Hand crimping tool.
xii. Portable electric blowers, vacuum cleaners.
xiii. Miscellaneous items such as slings, pulleys, tarpaulins, wooden sleepers, ladders. etc.
as required.
xiv. Safety belts, safety goggles, and gloves.
xv. Separate tool kit for each Electrician.
xvi. Hydraulic/Hand held grease gun
5.2 Test Instruments
i. Insulation tester 1000 V hand driven.

ü. Insulation tester 2500 V motor/hand driven.
Insulation tester 5000 V motor/hand driven
iv. Phase sequence indicator.
v. Earth Resistance tester.
vi. Single phase variac
vii. 3 phase variac of adequate capacity.
viii. Secondary and primary injection testing kit.
ix. Multimeter, both analogue and digital
x. Portable Ammeters, Wattmeters, P.F. meters.
xi. Portable Voltmeters.
xii. Clip on meters of different ranges.
xiii. Tacho-meter.
xiv. Kelvins double bridge for measurement of very low resistance.
xv. D.C. high -pot test kit.
xvi. A.C. high -pot test kit.
xvii. Oil filtration machine of adequate capacity.
xviii. Lux Meter to measure illumination levels.
xix. Breaker timing 3 pole kit
xx. Timers
xxi. 100A DC milli volt drop(Contact resistance) kit
xxii. Vibration measuring Instrument
xxiii. Thermo meters

Page 270 of 851

SPECIFICATION FOR FIELD SPECIFICATION No.
ENGINEERS INSPECTION, TESTING AND
gfga faWs INDIA LIMITED 6-51-0087 Rev. 3
lair,i237,15,2,131,05.) IA Govt of Indla Undertalong)
COMMISSIONING OF
ELECTRICAL INSTALLATIONS Page 1 of 8
-ftw #f-~
PiRkurr, -crftwr
SPECIFICATION
FOR
FIELD INSPECTION, TESTING
AND
COMMISSIONING OF ELECTRICAL
INSTALLATIONS

3 10.6.14
SPECIFICATION AKG SA BRB *". SC
2 03.03.09
SPECIFICATION RKS NS JMS ND
1 14.07.03 HKM RSG VPS SKG
SPECIFICATION
0 02.08.01 ISSUED AS STANDARD SPECIFICATION UAP RR VPS MI
Standards Standards
Committee Bureau
No by by
Approved by
Page 271 of 851

k31 ENGINEERS INSPECTION, TESTING AND
laW5 INDIA LIMITED 6-51-0087 Rev. 3
iairerf r-freA, asl,~7,) A GoN of Indla Undeltaking) COMMISSIONING OF
Abbreviations:
AC Alternating Current
AFC Approved for Construction
CCOE Chief Controller of Explosives
DC Direct Current
DCS Distributed Control System
DGMS Director General for Mines and Safety
ECS Electrical Control Station
GI Galvanized Iron
HV High Voltage
IS Indian Standard
MV Medium Voltage
OISD Oil Industry Safety Directorate
Convenor: Mr. BR Bhogal

Mr. Parag Gupta
Mr. M.K. Sahu
Mr. A.K. Chaudhary (Inspection)
Page 272 of 851

ENG1NEERS
fawres, INDIA LIMITED
IA Govt ol Ind. Undertaiong)
INSPECTION, TESTING AND
COMMISSIONING OF
6-51-0087 Rev. 3
CONTENTS
1.0 SCOPE 4
3.0 FIELD INSPECTION, TESTING AND COMMISSIONING 4
4.0 RECORDS 8
Page 273 of 851

k`51
12..itq ENGINEERS INSPECTION, TESTING AND
$'1gz:IT ft- s INDIA LIMITED 6-51-0087 Rev. 3
I.R77 c`F,1,4, CA3PC1171) IA Govt of India Undertalong) COMMISSIONING OF
1.0 SCOPE
This specification covers the requirements for the field inspection, testing and commissioning
of Electrical Equipment and Installation, forming part of electrical power distribution and
utilisation system.
2.1 The field inspection, testing and commissioning of electrical equipment shall be carried out in
line with this specification and the latest edition of following Indian Standards and OISD
standards.
SP-30(BIS) National Electrical Code.

IS 1255 Code of practice for installation and maintenance of power cables up
to & including 33 kV rating.
IS-7816 Guide for testing Insulation resistance of rotating machines.
IS 10810(Part 43) Method of Test for cables; Part 43 Insulation resistance.
IS 10810(Part 45) Method of Test for cables; Part 45 High voltage test.
IS 12729 HV Switchgears
OISD 137 Inspection of Electrical Equipment.
OISD 147 Inspection and safe practice during electrical installation.
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of
the following as applicable:
a. CEA Regulations
b. Regulations laid down by CEA / Electrical Inspectorate.
c. Regulations laid down by Tariff Advisory Committee/Loss prevention council.
d. Regulations laid down by CCoE/DGMS (as applicable).
e. The petroleum rules (Ministry of Industry, Government of India).
f. Any other regulations laid down by central / state / local authorities / insurance
agencies
3.0 FIELD INSPECTION, TESTING AND COMMISSIONING
3.1 Contractor shall carry out complete field inspection, testing and commissioning of electrical
equipment as per Inspection & Test plans.
3.2 Before the completed installation or an addition to the existing installation is put into service,
inspection / pre-commissioning checks and tests shall be carried out by contractor. In the
event of defects being found out, the same shall be rectified and the installation retested as
applicable.
3.3 The pre-commissioning inspection among other requirements shall include visual inspection,
checking the workmanship of the installation, the rating of equipment, safety clearances, sizes
of cables installed, conformance to the AFC document, soundness of switchgear bus
connections, wiring properly dressed and labeled, sealing of unused cable entries, checking of
all safety interlocks, control/interface functions as per requirement etc.
3.4 Visual inspection for soundness of bus bar connections of busducts, terminal connections of
equipment/motor shall be carried out. It shall be ensured that no foreign materials are present
inside busduct and equipment terminal boxes. After the visual inspection, all the covers of
terminal boxes, inspection chambers shall be refitted with gaskets, bolts & nuts as per
equipment manufacturer's instructions.
Page 274 of 851

k31 ENGINEERS INSPECTION, TESTING AND
Og-ar 2f5:1- g
~srz as,:ror.)
(~1
INDIA LIMITED
(A GoN cd InEia Und<rlAk(A9) COMMISSIONING OF
6-51-0087 Rev. 3
3.5 Pre-commissioning tests shall include but not be limited to the following:
Continuity test for each winding and power and control circuits.
Insulation test for each winding and power and control circuit
High voltage test for cables
- Dielectric strength test on transformer oil.
- Checking the correctness of wiring schemes, control circuit interlocks for intended
functioning.
- Verification of phase sequence.

Testing of all types of relays/releases for required operation.
- Testing of measuring instruments for proper functioning.
- Earth continuity test for all circuits.
Checking of safety features for correctness of operation, etc.
Checking of all wired interface contacts (analogue, digital input/output contacts) for DCS
and ECS interface, at panel and equipment terminal chambers as applicable.
(Electrical contractor shall co-ordinate with other agencies involved for the above and
provide support services for checking interfaces of electrical equipment and the intended
functioning)
Earth resistance measurement for each earth electrode, and the earthing system as a whole.
Lighting installation shall be tested for correct illumination levels, with fittings installed.
Fittings shall be operated only with specified type of a lamp or tube.
3.6 After the above tests and inspection are completed, control circuits shall be tested for correct
operation under all operating combinations and proved correct before applying power to
main circuit.
3.7 Plant Communication, Fire alarm detection and telephone system shall be checked for correct
operation and intended function.
3.8 A close visual inspection of electrical equipment in hazardous areas shall be made to ensure
that equipment is suitable for the classified zone and gas group and correctly installed, with all
covers, bolts, nuts and hardwares intact and there is no physical damage mark seen on the
enclo sure
3.9 Site Acceptance Test procedure for specific equipment shall be furnished by the respective
equipment vendor. The contractor shall provide necessary assistance to the equipment vendor
to perform Site acceptance testing to enable the equipment vendor to perform the same.
3.10 All pre-commissioning checks and tests shall be carried out as per the directions of Engineer-
in-charge. In addition to the equipment manufacturer's instructions, pre-commissioning check
requirements shall also be complied. All tests shall be carried out by contractor in the presence
of EIL/Owner' s representatives
3.11 The contractor shall bring to site all required tools, tackles, and testing instruments for
carrying out field testing. Contractor shall use only calibrated measuring and test instruments
and shall maintain valid calibration records.
Page 275 of 851

$tigzrr
IN■fn
fa2es INDIA LIMITED
IF GoN of lndN Underfakrogf COMMISSIONING OF
6-51-0087 Rev. 3
3.12 The Insulation Resistance test values for various electrical equipment shall be as below:
3.12.1 Cables
The insulation resistance test values for cables shall be as per following table:
Rated voltage of the Cable DC Test Voltage in Volts Minimum Insulation

resistance in Mega ohms
Lighting and power circuit
250 1
wiring
650/1100V grade cables 1,000 10
1,900/3,300V grade cables 1,000 200
3,800/6,600V grade cables 1,000 200
6,350/11,000V grade cables 5,000 200
8,700/15,000V grade cables 5,000 200
12,700/22,000V grade cables 5,000 200
19,000/33000V grade cables 5,000 200
3.12.2 IIV, MV and Miscellaneous Switchboards
The insulation resistance test values for the switchboards shall be as per following table:
Rated voltage of the DC Test Voltage in Volts Minimum Insulation

Switchboard resistance in Mega ohms
33,000V 5,000 200
11,000V 5,000 200
6,600V 1,000 200
3,300V 1,000 200
415V 1,000 100
240V 500 10
110V 500 10
3.12.3 Generators and Motors
3.12.4 The insulation resistance test values for the Generators and Motors shall be as per following
table:

Generators and Motors resistance in Mega ohms at
40 °C
11,000V 5,000 120
6,600V 1,000 80
3,300V 1,000 50
415V 1,000 15
240V 500 12
Page 276 of 851

I f ~5)
irr0n twor,on
INDIA LIMITED
in Govt ol IndU Undertalong) COMMISSIONING OF
6-51-0087 Rev. 3
3.12.5 Transformers
3.12.6 The insulation resistance test values for the Transformers shall be as per following table:

Transformers resistance in Mega ohms at
40 °C
Up to 600V 1,000 100
601 to 5000V 2,500 1,000
5001 to 15,000V 5,000 5,000
15001 to 35,000V 5,000 10,000
3.12.7 It shall be ensured that during insulation tests, electronic devices and components that are
liable to get damaged on applied test voltage shall be disconnected from circuit. The
instructions of equipment/panel manufacturer shall be followed strictly in this regard.
3.13 High-voltage Testing
3.13.1 DC high voltage test shall be conducted as per following table on all HV feeder cables and
also on 1100 V grade cables where straight through joints have been made.
Rated Voltage of TEST VOLTAGE (kV) BETWEEN Duration

Cable (kV) (Minutes)
U. / U* Any Conductor and Metallic Conductor to Conductor
Sheath/ Screen/Armour (For Unscreened Cables)
0.65/1.1 3 3 5
1.9/3.3 5 9 5
3.3/3.3 9 9 5
3.8/6.6 10.5 18 5
6.6/6.6 18 18 5
6.35/11 18 30 5
11/11 30 30 5
12.7/22 37.5 - 5
19/33 60 - 5
*U. : Phase Voltage
U : Line Voltage
The cable cores must be discharged on completion of DC high voltage test and cable shall be
kept earthed until it is put into service.
DC test voltage for old cables shall be 1.5 times rated voltage or less depending on the age of
cables, repair work or nature of jointing work carried out, etc. In any case, the test voltage
shall not be less than the rated voltage.
Page 277 of 851

mar faZ5 INDIA LIMITED
l aiWn 23~ ag,o.) IA Gosn of Intha Undertakog) COMMISSIONING OF
6-51-0087 Rev. 3
3.13.2 AC high voltage test shall be conducted as per following table on all HV Switchboards.
Rated Voltage Rated 1 Min. Power Frequency Withstand Voltage Duration in

(rms Value in (rms Value in kV) Minutes
kV)
U To Earth, Between Across the Isolating
Poles and Across Open Distance
Switching Device
3.6 10 12 1
7.2 20 23 1
12 28 32 1
24 50 60 1
36 70 80 1
72.5 140 160 1
The withstand voltage values across the isolating distances are valid only for switching
devices, where the clearance between open contacts is designed to meet the safety
requirements specified for disconnectors.
3.14 All protective relays including thermal overload relays shall be tested by secondary injection
current. Primary injection tests shall be carried out for differential protection, restricted earth
fault protection at full/reduced current to ensure correctness of complete wiring.
3.15 Before energizing any equipment, `COMMISSIONING CLEARANCE FORM' as per

standard format shall be duly filled in by contractor and submitted to EIL/owner.
3.16 It shall be ensured that the electrical inspectorate approval is available before energizing the
equipment
4.0 RECORDS
Contractor shall keep up-to-date records of all activities carried out and test results. Field
inspection / test reports shall be submitted to EIL / Owner by the contractor in bound volumes
(triplicate copies).
Page 278 of 851

OOZE'?ift -
" ENGINEERS
og eg fd51egW, INDIA LIMITED
elvasetmagmo(A Govt d n Undertak.9)
EARTHWORK FOR UNDER
GROUND PIPING
STANDARD SPECIFICATION
No.
6-65-0006 Rev. 3
Page 1 of 7
Irma. trrectrr t wrzi

ReR
fgrffbi
FOR EARTHWORK
FOR UNDERGROUND PIPING
REVISED AND ISSUED AS STD.

3 23.05.11 ALOK RK VK DM
SPEC.
REVISED AND ISSUED AS STD.
2 16.02.06 SKC NK VDS VJN
SPEC
REAFFIRMED & ISSUED AS STD.
1 30.09.96 SM PCS MMK A SONI
SPEC
0 13.6.83 ISSUED AS STD. SPEC. UCJ RPB RCPC AK
Standards GM Standards
Committee (Engg) Bureau
No by by
Approved by
Page 279 of 851

ENGINEERS STANDARD SPECIFICATION FOR No.
If arOfte 056
g INDIA LIMITED EARTHWORK FOR UNDER 6-65-0006 Rev. 3
n elenkenaanorkl/ IllGovt of India Undertaking)
GROUND PIPING Page 2 of 7
Abbreviations:
IS India Standard
RCC : Reinforced Cement Concrete
U/G : Underground
General Civil Standards Committee
Convener: Mr. R. B. Bhutda
Members: Mr. Vipan Goel

Mr. D.C. Brahma
Mr. R.K. Sharma
Mr. S. K. Naskar
Mr. Raju Chutani
Mr. P.K. Mittal (Strl)
Mr. A.T. Dharmik (Piping)
Mr. U.A. Patro (Electrical)
Mr. J. K. Joshi (Environment)
Mr. M.P. Jain (Projects)
Page 280 of 851

ENGINEERS STANDARD SPECIFICATION FOR No.
Mf INDIA LIMITED EARTHWORK FOR UNDER 6-65-0006 Rev. 3
IA Govt or India Undertaking)
CONTENTS
1.0 SCOPE 4
2.0 CODES & STANDARDS 4
3.0 MATERIAL 4
4.0 EARTHWORK IN EXCAVATION FOR TRENCHES / PITS FOR PIPELINES 4
5.0 BACKFILLING AND COMPACTION 6
6.0 TRANSPORTATION OF SURPLUS EARTH 7
7.0 PAYMENT 7
Page 281 of 851

STANDARD S PECIFICATION
ENGINEERS STANDARD SPECIFICATION FOR No .
iaeag
)+11e7. (9217R70173,10.1)
INDIA LIMITED
Govt of India Undertaking)
EARTHWORK FOR UNDER 6-65-0006 Rev. 3
IA
1.0 SCOPE
This specification deals with earthwork in trenches and pits (for valves, manholes, catch pits
etc.) for underground piping.
2.0 CODES & STANDARDS
IS: 783 Code of practice for laying of RCC pipes.
IS: 1200 (Part-I) Method of measurement of building and civil engineering works.
IS: 3764 Excavation work — code of safety.
NOTE:- Latest Edition of all Codes and Standards shall be followed.
3.0 MATERIAL
All workmanship and materials shall conform to the provisions of IS: 1200 (Part-1) and IS:
3764.
4.0 EARTHWORK IN EXCAVATION FOR TRENCHES / PITS FOR PIPELINES
4.1 Excavation
Plant, machinery and equipments for excavation shall be selected and deployed to provide
optimum mechanisation in excavation of trenches and pits. The selection for excavation and
earth movement machinery etc. shall take into account type of materials to be excavated,
method of excavation, prevailing weather conditions and type of transport to be used.
The excavation of area of cut shall be so timed that the bottom level is not exposed to the
deteriorating influence of the weather for longer duration.
Excavation and earth moving equipment shall be deployed such that minimum damage is
caused to the natural sub-soil structure of exposed formations.
The monitoring of soil deformations, ground water levels during and possibly after
construction work shall be taken into consideration.
In the event, when excavation works are carried out in the vicinity of structures of any
importance, the above monitoring shall be carried out within a distance, from the edge of the
excavation of 5 to 15 times the excavation depth, depending upon the subsoil conditions and
the stability of the neighboring structures.
4.2 Trenching work shall be carried out in all classes of soil including soft rock and excluding
hard rock and shall be for all depths.
4.3 The trench shall be cut true to the line and level as per drawings.
4.4 If the trench is excavated below the required level than that indicated in the drawing, the extra
depth shall be filled with concrete 1:5:10 or approved equivalent materials, as directed by the
Engineer-in-Charge, at no extra cost to the owner.
4.5 In case of pressure piping, the trench shall be excavated generally as to provide a cover of
1000 mm or dia of pipe whichever is more. In case of gravity sewers/ pipes, the trench shall
be excavated to conform to invert levels as per drawings. However in certain cases, the pipes
may run at shallower levels or at deeper levels depending upon drawing, site condition etc.
Page 282 of 851

1611faeleift
- ENGINEERS STANDARD SPECIFICATION FOR No.
5` ar &Wig W' INDIA LIMITED
g EARTHWORK FOR UNDER 6-65-0006 Rev. 3
RWOW O. M30.1)undertakm
GROUND PIPING
IA Govt of /We
Page 5 of 7
No rebate for lesser excavations, nor extra payment due to deeper excavations, shall be
admissible in those cases where pipeline laying rates are inclusive of earthwork items. The
rates quoted shall be deemed to cover all works connected with trenching, whether trenches
are with single pipeline or have multiple pipelines in common trenches including road cutting
and making good the same.
4.6 The width of the trench shall be sufficient to give free working space of personnel,
equipment, supports and ancillaries on each side of the pipe. The free working space shall
conform to IS: 783. Generally it shall not be less than 150 mm on either side or 1/3 dia of
outer diameter of the pipe, whichever is greater.
4.7 When pipelines are running parallel, whether the trenching shall be individual or common,
shall be decided by the Engineer-in-Charge and such decision shall be final and binding on
the contractor. No extra shall be payable for common excavations.
4.8 All earthwork involved in excavations of all types of manholes, catch pits, valve chambers,
inspection chambers, chambers for instrumentation tapping etc., which are coming on the
alignment of U/G piping or as defined by drawing as a part of U/G piping work, shall be paid
extra under Earth work in excavation, back filling and removal of surplus earth etc. under
relevant clauses of the SOR.
4.9 Aspects such as variations in the soil conditions and the geological structure, depth of
excavation, the existence of ground water and surface water, the type and extent of
excavation, the topography of site, the proximity of items such as roads, buildings and buried
services, construction traffic and activities near the excavation eg. stock piling shall be taken
into account when determining whether the sides of excavation should be free standing,
sloping or temporary supported.
Suitable drainage and / or dewatering system like Well Point method / Bore well method etc.
shall be provided to prevent or limit ingress of surface or sub surface water into excavation.
Serviceable materials intended for reuse should be used as soon as possible after excavation
otherwise they should be stock piled at a location beyond 1.5m from the top edge of the
excavation or beyond a distance equal to the depth of the excavation whichever is higher at a
location approved by the Engineer-in-charge. If excavated serviceable material is not possible
to be stacked within the limits specified above, due to some constraint, it shall be stacked
away at a location approved by Engineer-in-Charge and paid separately under relevant item.
Areas used for temporary stockpiling of excavated material shall be kept clean and orderly,
with excavated material kept by the side of road to avoid traffic movement. Excavated areas
shall be restored to their original condition before completion of works.
All types of shoring and strutting, wherever necessary, shall be adopted to with hold the face
of earth or cutting in slope, as per site requirements and direction of Engineer-in-Charge.
Supports shall be maintained such that the integrity of the sides of the excavation is not
impaired.
4.10 Any obstacle encountered during excavation shall be reported immediately to the Engineer-
in-Charge and shall be dealt with as instructed.
4.11 The contractor shall maintain all excavated trenches and pits, in a dry and trim condition.
4.12 Necessary barricading and protection of slopes against slips due to traffic movement shall be
provided to the satisfaction of Engineer-in-Charge. Necessary warning flags and lights shall
be provided to caution traffic in the areas where trenches and/ or pits are provided.
Page 283 of 851

1,5-ifaeley ftENGINEERs
, STANDARD SPECIFICATION FOR No.
INDIA LIMITED
Ogar 51-e W Govt of India Underlakm) EARTHWORK FOR UNDER 6-65-0006 Rev. 3
(AAPA ?WW1' =JAW) (A
4.13 In case of road cutting, all road material i.e. metal etc., shall be taken out carefully and kept
separately for reuse and road work shall be redone up to the original level, as it was prior to
cutting the road, with the excavated road materials after laying and testing of the pipeline,
within 10 days from the date of starting this work, at the cost of the contractor. The contractor
shall provide suitable warning signs and barricades to prevent accidents.
Contractor shall also provide reasonable bye pass at his own cost when a road is cut for laying
pipeline. Tankage dykes cut due to laying of the pipes, shall be redone conforming to the
original specifications, by the Contractor at his own cost. Secondary dykes, to take care of
any eventuality during construction, shall be provided by the Contractor at his own cost.
4.14 Dewatering shall be done in advance of the installation of the pipe to allow adequate
inspection of padding of the bottom, if required. Dewatering shall be continued throughout
during installation and backfilling.
The trench shall follow the gradient of pipeline as specified in the drawing. The contractor
shall keep the trench in good condition, until the pipe is laid and tested. No extra claim shall
be entertained due to its caving or setting down, either before or after the pipe is laid.
In case, pipe is lowered in caved trench and backfilled before being inspected by the
Engineer-in-Charge, the Contractor shall re-excavate the trench for inspection and backfill it
at his own cost.
5.0 BACKFILLING AND COMPACTION
Backfilling
Trenches shall be back filled with suitable materials which should be compacted to the same
degree or better as the surrounding soils.
5.1 The soil used should be selected and approved by Engineer-in-Charge. Suitable material can
be extracted from available excavated material. The soil should be free from rubbish, grass,
organic matter, stones, building waste and Black Cotton Soil etc. It should be free from clods
and hard lumps. In case good soil is not available from excavated material for back filling,
trench shall be filled back with locally available coarse sand upto 30 cm. thick above the pipe
and rest of trench shall be filled back with excavated soil upto required level.'
5.2 The filling should commence only after approval of Engineer-in-Charge is obtained and after
the structures or pipes to be buried are tested and approved. Otherwise, if required, contractor
shall uncover buried portion and refill at his own cost.
Temporary excavation supports should be removed as back filling and compaction proceeds,
such that unacceptable movement of the supported ground does not occur.
Voids caused by extracted supports should be filled and compacted.
5.3 Filling should be done in layers. Each layer should be not more than 15 cm thick when loose
and should be well rammed, with necessary watering, to obtain at least 90% of maximum
laboratory dry density.
Compaction trials should be carried out on each soil type to be placed in backfill, in order to
confirm the type of machine and number of passes required to obtain optimum compaction
for given soil moisture contents. These trials should also be used to determine the variability
of the proposed fill material for different weather conditions.
Page 284 of 851

ENGINEERS STANDARD SPECIFICATION FOR No .
Igar 251-eg INDIA LIMITED EARTHWORK FOR UNDER 6-65-0006 Rev. 3

of India undenakm)
eiMIVOA3a0F,1) IA Govt
5.4 Care must be exercised to protect cables, pipes, joints, and other features from damage due to
backfilling and consolidation.
5.5 Filling should extend up to the level of original ground surface or as per drawing or as
directed by Engineer-in-Charge. The finished surface should be properly trimmed and
dressed. The adjoining area should be cleaned and no heaps of surplus earth should be left
out.
6.0 TRANSPORTATION OF SURPLUS EARTH
Unserviceable materials and serviceable materials not intended for re-use shall be removed
from the work site and disposed off at a location as approved by Engineer-in-charge.
The surplus earth is generated due to pipe laying, valve chambers, and manhole construction
etc. Surplus earth is also generated due to voids in the back filled volume of earth. The
removal of surplus earth shall include excavation, loading, transportation, dumping, stacking
or spreading, as per the directions of Engineer-in-charge.
7.0 PAYMENT
7.1 Unless specifically stated in the schedule of rates, no separate payment for earthwork in
excavation, backfilling, transportation, dewatering etc. shall be admissible and the payment
for the same is deemed to have been included in the relevant items of the contract.
7.2 In case payment for earthwork is specified separately in the Schedule of Rates, the payment
shall be based on the actual quantity of excavation, backfilling and transportation done, taking
into consideration the slopes authorised by the Engineer-in-Charge for excavation, volume of
backfilling calculated on the basis of excavation reduced by the volume of pipes.
7.3 In cases where hard rock excavation is involved, the matter shall be referred to Engineer-in-
Charge, before proceeding with the work.
Page 285 of 851

No.
ENGINEERS FOR
Igar Eleft
lawn ewer? enjorten)
INDIA LIMITED
FABRICATION AND LAYING OF 6-65-0030 Rev. 5
UNDERGROUND PIPING Page 1 of 11
prrras 1.W441 LAisic;kii aft(

*uNER -ffrw Fail4111
FOR
FABRICATION AND LAYING OF
UNDERGROUND PIPING
r Itor
a
-V
RAJA RK
5 06.07.18 REAFFIRMED & ISSUED AS STD. SPEC. LP Ve
SRIVASTAVA TRIVEDI
4 20.05.13 REAFFIRMED & ISSUED AS STD. SPEC. RBT RKS RBB DM

Standards Standards
Committee Bureau
No by by
Approved by
Page 286 of 851

5I ENGINEERS STANDARD SPECIFICATION No.
s`ge.JI
(win'
tifWdu
-mow)
ewcn,r
INDIA LIMITED
(A G.4 of butia Undertak.9)
FOR FABRICATION AND LAYING 6-65-0030 Rev. 5
OF UNDERGROUND PIPING
Page 2 of 11
Abbreviations:
ANSI AMERICAN NATIONAL STANDARDS INSTITUTE
dia. DIAMETER
IS INDIAN STANDARD
Kg/cm2/minute KILOGRAME/SQUARE CENTIMETRE/MINUTE
m METRE
mm MILLIMETRE
CS CARBON STEEL
Structural Standards Committee:
Convenor: Mr. Rajanji Srivastava
Members: Mr. Anurag Sinha

Mr. VK Panwar
Mr. Samir Das
Mr. Amitabh Kishore
Mr. Gyasuddin
Mr. Charanjeet Singh (Projects)
Mr. Ravindra Kumar (Construction)
Page 287 of 851

el ENGINEERS STANDARD SPECIFICATION No.
WA LIMITED FOR FABRICATION AND LAYING 6-65-0030 Rev. 5
I MI I IA Govt of India Undettakingj
Page 3 of 11
CONTENTS
1.0 SCOPE 4
3.0 FABRICATION 4
4.0 LAYING OF UNDERGROUND PIPING 5
5.0 INSPECTION 8
6.0 TESTING 8
7.0 RECORDS 10
8.0 PAYMENT 10
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell — All rights reserved
Page 288 of 851

ENONEERS STANDARD SPECIFICATION No.
(awn eRzwolojt.rm)
IA Govt o India Undertalong)
Page 4 of 11
1.0 SCOPE
This specification covers the technical requirements for the execution of Piping Fabrication,
Assembly and Laying of the underground pipe work defined here under, for water pipe lines.
i) Fabrication and erection of underground piping systems from piping materials

supplied by Owner in accordance with this specification and applicable drawings and
standards.
ii) Testing and flushing.
iii) Coating of under ground piping.
iv) Fabrication and erection of drain assemblies.
Underground piping systems shall be fabricated, installed, flushed, and tested in accordance
with this specification and applicable codes, drawings and standards. Any deviation from the
specification and drawings shall be permitted only after obtaining the written approval of the
Engineer-in-Charge.
ANSI B31.3 Chemical Plant and Petroleum Refinery Piping.
6-65-0006 Standard specification for earth work for U/G piping.
6-44-0012 Standard specification for fabrication and erection of piping.
6-77-0001 Welding specification for the fabrication of piping
6-77-0005 Welding specification charts for piping classes
6-79-0011 Standard specification for corrosion protection tape coating for underground
steel piping
NOTE: - Latest Edition of all Codes and Standards shall be followed.
3.0 FABRICATION
3.1 The contractor shall fabricate all the pipe work in conformity with the Standard Specification
for Erection of Piping, Specification no. 6-44-0012 and requirements of relevant general
arrangement drawings. Where specific details of fabrication are not indicated on the drawings
or not specified in the specification, fabrication and erection shall be done in accordance with
ANSI B 31.3.
3.2 The contractor shall be responsible for working to the exact dimensions as shown on the
drawings, irrespective of individual tolerances permissible. Where errors and / or omissions
occur on the drawings, it shall be the contractor's responsibility to notify the Engineer-in-
Charge, prior to fabrication or erection. Dimensional tolerance for fabrication shall be as per
EIL standard.
Page 289 of 851

ENGINEERS STANDARD SPECIFICATION No.
idadg INDIA LIMITED FOR FABRICATION AND LAYING
..me:R.5,,011.3‘105.1) IA Govt of India undertakingl 6-65-0030 Rev. 5
Page 5 of 11
4.0 LAYING OF UNDERGROUND PIPING
4.1 Laying
4.1.1 The Contractor shall lay the underground piping in accordance with the following clauses and
as per the piping arrangement drawings issued during the course of construction. Corrosion
protection tape coating of the underground lines shall be in accordance with Standard
Specification no. 6-79-0011.
4.1.2 The Contractor shall be responsible for correct layout and gradient of the line. Errors, if any,
shall be rectified by the Contractor at his own cost.
4.2. Trenching
4.2.1 The trench shall be cut according to the drawing, true to the line, levelled with the help of
sight rails provided at every 30 m, at change of direction / gradient and at any suitable
distance, as directed by Engineer-in-Charge.
4.2.2 If the trench is excavated below the required level as indicated in the drawing, the extra depth
shall be filled with concrete 1:5:10 or approved equivalent material, as directed by the
Engineer-in-Charge, at no extra cost to owner.
4.2.3 The trench shall be excavated so as to provide an average cover of 1000 mm or equal to the
diameter of the largest pipe to be laid in the trench, whichever is greater or as shown in
drawings. The average cover will be reckoned from top of the pipe of the largest diameter to
be laid in the trench, to the finished grade level. The width of the trench shall be sufficient to
give free working space on each side of the pipe. The free working space shall conform to
specifications. Generally it shall not be less than 150 mm on either side or 1/3 of dia of pipe,
whichever is greater.
4.2.4 No excavated material shall be deposited within 1.5 meters from the excavated trench.
4.2.5 In case of road cutting, all materials i.e. metal, bricks etc., shall be taken out carefully and kept
separately for reuse. Road work shall be redone up to the original level and profile with the
excavated road materials, after laying and testing of the pipe line, within 10 days from the date
of starting the work, at the cost of the contractor. The contractor shall provide suitable slings
and barricades to prevent accidents. He shall also provide reasonable by-pass at his own cost
when a road is cut for laying pipeline.
4.2.6 During excavation, if some obstacle is met with, the same shall be reported to the Engineer-in-
Charge and dealt with as instructed by him.
4.2.7 The contractor shall do dewatering, shoring, strutting / timbering if required or do whatever
might be required to excavate the trench, install the pipe in it and backfill the trench, in
accordance with the specifications, at no extra cost to the Owner. Dewatering shall be done in
advance of the laying of the pipe, to allow adequate inspection of padding of the bottom, if
required. Dewatering shall be continued throughout during laying of the pipe and backfilling
of the trench.
4.2.8 In muddy / slushy ground, the bed shall be provided with a layer of sand or lean concrete as
directed by the Engineer-in-Charge.
4.2.9 The trench shall follow the gradient of pipeline as specified in the drawing. The contractor
shall keep the trench in good condition, until the pipe is laid and tested. No extra claim shall
be entertained due to its caving or settling down, either before or after the pipe is laid. All
Page 290 of 851

Riren two, ...tovvq) IA Govt ol ■ nolia Undertalung)
Page 6 of 11
materials to shore the trench, in order to prevent caving, shall be furnished and removed by the
Contractor, at no extra cost to the Owner.
4.2.10 In case pipe is lowered in caved trench and back filled before being inspected by the Engineer-
in-Charge, the Contractor shall re-excavate the trench for inspection and backfill it at his own
cost.
4.3 Lowering & Laying
4.3.1 The pipe shall be lowered by mechanical method when the trench is ready and bottom of the
trench is graded as per required pipe laying conditions and specifications.
4.3.2 By Machine
The shop coated pipe already transported to the pipe laying site in convenient length of pipe
assembly, near the trench after hydrostatic testing, shall be placed on clean square cut skids
suitably spaced, so as to keep the pipe away from touching the ground. The pipe may be
lowered down in the trench by the launcher cranes with sufficient care, to protect the coating
of the pipeline.
At tie in welds and other site fabrications, the contractor shall clean, prime, coat and wrap
manually.
Also short sections of pipelines, which are impracticable to shop-treat, may be hand treated,
but only after obtaining prior written approval of the Engineer-in-Charge.
4.3.3 By Hand
Only in unavoidable circumstances and after obtaining approval of Engineer-in-Charge, the

pipe may be lowered with the help of tripods and chain pulley blocks into the trench.
However, if in the opinion of the Engineer-in-Charge, the temperature condition does not
allow direct lowering, then the pipes shall be set down on clean square cut skids. The skids
shall be so spaced as to keep the pipe away from touching the ground.
4.4 Method & Time of Lowering Pipe
4.4.1 Under favorable temperature conditions and using methods, which will not damage the
coating, the pipe may be lowered into the trench.
4.4.2 Pipes previously set on skids, because of unfavorable temperature conditions, shall be lowered
into the trench normally in the cool of the morning and only when the temperature of the pipes
is below the softening point of the coating materials.
4.4.3 All skid marks and other places of damage shall be thoroughly examined to ensure proper
patching where necessary, before the pipe is finally lowered into the trench.
4.5 Handling Coated Pipe
4.5.1 Coated pipe shall not be placed in trench, until cave-in plugs, hard clods, stones, skids and
welding rods etc. have been removed from there. Where the trench has a hard or jagged
bottom, sufficient fine dirt or stand shall be placed therein, before the pipe is lowered.
4.5.2 Coated pipe shall not be handled or moved by means of cable or chains or by prying with
skids or bars. It shall be tied and lowered by using belts of a standard width and design, for the
size of pipe being handled.
Page 291 of 851

ENGINEERS
q_i STANDARD SPECIFICATION No .
51&41 acs' l INDIA LIMITED FOR FABRICATION AND LAYING
IA Govt India Ondenakingi 6-65-0030 Rev. 5
Page 7 of 11
4.5.3 Coated pipe shall not be dragged along the ground or otherwise handled in a manner that will
be detrimental to the coating.
4.5.4 Despite all precautions taken during handling of coated pipes, if the coating gets damaged,
same shall be recoated by Contractor at site, at his own cost, as per directions of Engineer-in-
Charge.
4.6 Lining up & Welding
4.6.1 The ends of the pipeline shall be kept securely closed, to prevent entry of any foreign material/
moisture, after lowering into the trench.
4.6.2 Before making joints the pipe shall be laid carefully, so as to be perfectly aligned, in both plan
and profile and the end closures provided shall be removed.
4.6.3 Tie-in shall be made in the coolness of the morning or when the ambient temperature is not
exceeding 29°C or softening temperature of the coating material, whichever is less. All
bevelling, aligning and welding shall be in accordance with the welding specification given in
the tender.
4.6.4 Free access shall be provided for the welding of the circumferential joints by increasing the
width and depth of the trench at these points. There should be no obstruction to the welder
from any side, so that good welded joint is obtained.
4.7 Testing & Coating
The completed system shall then be tested as per clause 6.0 and the field welded joints coated
as per specification 6-79-0011.
4.8 Back Filling
4.8.1 After testing and inspection of the pipeline to the entire satisfaction of the Engineer-in-Charge,
the trench shall be back filled with the excavated material. No trench shall be back filled
without the approval of the Engineer-in-Charge.
4.8.2 Backfilling with the excavated material shall be done in layers of 200 mm, well watered and
rammed to avoid any settling afterwards.
4.8.3 The Contractor shall place soil over the trench to such a height as well as in opinion of the
Engineer-in-Charge, to provide adequately for future settlement of the trench backfill.
If due to exigencies of the work, some portion of the pipeline is backfilled without approval of
the Engineer-in-Charge, the Engineer-in-Charge shall have the right to order uncovering of the
pipe for examination and the cost of such uncovering shall be borne by the Contractor.
4.8.4 The backfill material shall be free from stone pieces.
4.8.5 When the trench has been dug through roads, all backfill shall be thoroughly compacted. In
certain cases, special compaction methods may be required by the Engineer-in-Charge. This
shall be done by the contractor at no extra cost to the Owner.
4.8.6 When the trench has been dug through unlined ditches, the backfill shall be thoroughly
compacted in 150 mm layers for a distance of 1.5m beyond the outside banks of the ditch on
either side. The banks of the ditch shall also be compacted in 150mm layers, at no extra cost to
the Owner.
Page 292 of 851

fdai
eg INDIA LIMITED FOR FABRICATION AND LAYING 6-65-0030 Rev. 5
t.r1rt' eliera2451.34e.rt (A Govt d India Undertaking)
Page 8 of 11
4.8.7 After the roads have been already graded, and if they are trenched or otherwise disturbed by
the Contractor during laying of the pipe lines, the contractor shall restore the road to its
original level and condition. In the event the Contractor is required to place extra fill, gravel,
or other special materials, it shall be done by him without any extra cost to the Owner.
4.9 Clean up of Surroundings
4.9.1 As soon as the backfill is completed, the contractor shall immediately clean up the adjoining
area by removing all surplus and defective material and dispose off all refuge such as spurs,
sheet-iron and broken skids and surplus excavated earth etc., at his own cost, to the entire
satisfaction of the Engineer-in-Charge.
4.9.2 The earth on both sides of the pipeline trench, which has been disturbed during the
construction of the pipe line, shall be smoothened and left in a condition to the entire
satisfaction of Engineer-in-Charge.
5.0 INSPECTION
5.1 General
5.1.1 Owner's inspector shall have free access to all places where the work is being done or any
other thing and place concerned with the work.
5.1.2 Owner is entitled to send his own inspector to field or shops, where prefabrication and
erection of pipe lines are being done, with the following functions but not limited to:
i) To check that the welding performance and welding equipment used on the job are
suitable and conform to relevant standards.
ii) To supervise welding procedure qualification.
iii) To supervise welder performance qualification.
iv) To check whether welding is conforming to relevant specification and the practice
followed is in accordance with good pipeline construction practice.
v) To check any other performance to ensure quality of work.
5.1.3 Contractor shall notify sufficiently in advance the commencement of qualification tests,
welding work and acceptance tests, to enable the Owner's Inspector to supervise the same.
5.1.4 Contractor shall provide all the facilities to Owner's Inspector, necessary for carrying out his
work, at no extra cost to the Owner.
5.1.5 Approval from the Owner's Inspector shall not relieve the contractor partially or fully of his
responsibilities and guarantees under this contract.
6.0 TESTING
6.1 General
6.1.1 The field test pressure shall not be less than the greatest of the following:
a) 1.5 times the maximum sustained operating pressure.
b) 1.5 times the maximum pipeline static pressure, and

Page 293 of 851

INDIA LIMITED FOR FABRICATION AND LAYING
6-65-0030 Rev. 5
elierw?dojaCI.,1) IA Gavt of India lindeltalung)
Page 9 of 11
c) Sum of the maximum sustained operating pressure or the maximum pipeline static
pressure and the maximum calculated surge pressure.
The field test pressure shall, wherever possible be not less than two thirds of the work
test pressure, and shall be applied and maintained for at least four hours.
Where the field test pressure is less than two-thirds the works test pressure, the period of
test shall be increased to at least 24 hours. The test pressure shall be gradually raised at
the rate of nearly 1.0 kg/cm 2/minute.
6.1.2 The testing shall be carried out in convenient section as approved by the Engineer-in-charge.
The joints of the pipe, connecting the testing sections, shall be 100% radiographed.
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 specifications and
instructions of Engineer-in-Charge and tested to his satisfaction, at no extra cost to the Owner.
6.1.3 The Engineer-in-Charge shall be notified in advance by contractor of all testing. The
hydrostatic testing / flushing of all the piping shall be carried out by the Contractor, at his own
cost.
6.1.4 Contractor shall make his own arrangements for flushing, at suitable points, as per the
instructions of the Engineer-in-Charge. Any extra work / modification on this account shall be
done by the Contractor at his own cost.
6.2 Test Medium
Construction water shall generally be used as the testing medium, for the hydrostatic testing of
piping system.
6.3 Cleaning
All systems shall be cleaned and flushed free of all dirt, debris or loose foreign material, after
testing.
6.4 Temporary Blinds
Open ends of piping systems, such as at pumps or wherever equipment has been removed or
disconnected prior to hydrostatic testing, or at termination point of piping branch connections,
shall be blinded off by temporary blind flange, made out of 10 mm thick CS plate.
6.5 Venting
All piping systems and equipment shall be properly vented, to remove air from system, during
filling.
6.6 Pressurizing
6.6.1 Pressure shall be applied by means of a suitable test pump, which shall not be connected to the
system until ready to test. A pressure gauge shall be provided at the pump discharge for
guidance in bringing the system to required pressure. The pump shall be attended to constantly
during the test, by an authorised operator. The pump shall be disconnected, after the pressure
test is completed.
Page 294 of 851

5d17=4Z:Eq ENGINEERS STANDARD SPECIFICATION No.
tiOlft
rwore al4,1011M)
INDIA LIMITED
IA Govt of India UndertakIng)
FOR FABRICATION AND LAYING
6-65-0030 Rev. 5
Page 10 of 11
6.6.2 The test pressure is to be maintained for sufficient time, to permit complete inspection of the
system under test, but in no case shall the time be less than ten minutes. Test shall be
considered complete only when approval is given by the Engineer-in-Charge.
6.7 Test Gauges
Contractor's own test gauge shall be installed as close as possible to the lowest point in the
system being tested. Prior to installation, the test gauge shall be checked against a standard
gauge or calibrated with the aid of a dead weight tester. Calibration of test gauges shall be the
responsibility of the contractor.
6.8 Draining
6.8.1 All lines and equipments shall be completely drained after the hydrostatic test of the system
has been completed. High point vents shall be open to prevent excessive vacuum and permit
complete draining.
6.8.2 If it becomes necessary to leave a system filled with the testing medium for any abnormal
length of time, suitable arrangement such as venting shall be made to provide for possible
liquid expansion with change in ambient temperatures.
7.0 RECORDS
Records in triplicate shall be made for each piping system as follows:
7.1 In case of underground piping, layouts giving actual elevations of pipeline as laid.
7.2 Test certificates containing date of test, identification of the piping system, test fluid used, test
pressure and approval of Owner's Inspector.
7.3 Certificates for flushing containing flushing medium used, identification of the piping system,
date of flushing & approval by Owner's Inspector.
8.0 PAYMENT
8.1 Payment for piping shall be based on linear measurements, calculated on the basis of the
execution drawings. The length shall be measured along the center lines of pipes, center lines
of bends and elbows, tees, reducers and flanged joints. All types of valves shall be excluded
from this measurement. Branch connections shall be measured from the outer surface of the
header.
The payment shall be made on per metre basis of piping work laid, measured to the nearest
centimeter. The unit rates for the underground piping shall be inclusive of earthwork in
excavation, backfilling, compaction, disposal of surplus earth and coating and wrapping
including supply of materials.
All piping attachments, such as couplings, nipples, thermowells etc., shall be installed by the
Contractor as part of piping work and no separate payment shall be made for such work.
However, extension on such attachments such as vents and drains will be measured and paid as
applicable for the respective size and category of piping / valves.
Fabrication of mitre bends, concentric and eccentric reducers fabricated from pipes supplied by
owner & fabrication of flanges from plates supplied by owner, will be paid at respective unit
rates. However, erection of these items will be along with piping of the respective size and no
separate payment will be made for erection.
The reducers will be measured and paid along with the piping of large diameter.
Page 295 of 851

Ogell 015Eleg
Imo,
INDIA LIMITED FOR FABRICATION AND LAYING 6-65-0030 Rev. 5
(AGO of India Undettalungl
Page 11 of 11
No separate payment will be made for making pipe to pipe branch connection and crosses, with
or without reinforcing pads. The unit rates for piping are deemed to include all such work.
Fabrication, installation and removal of temporary spool pieces etc. to aid contractor's work
such as fabrication, erection, flushing and testing etc. will neither be measured nor paid
separately. The same is deemed to be included in the unit rates for piping. Payment for carrying
out radiographic examination shall be based on linear length of the welded joint radiographed.
Repeat radiography / additional radiography required due to contractor's faults / poor
performance of his welders and defective films etc., shall be done at contractor's own cost.
8.2 The payment clause(s) as described in the clause no. 8.1 shall not be referred / applicable for
LSTK Jobs
Page 296 of 851

ENGINEERS MISCELLANEOUS CIVIL &
1812--gw'INDIA LIMITED 6-65-0035 Rev. 3
IA Govt of India Undertalongt
STRUCTURAL WORKS FOR U/G
PIPING & OTHER CIVIL WORKS Page 1 of 7
r* , icsfR r
14-PETW
fqr-4e6T fur wpf,
fur chNT
f-4r-4-4rr
FOR
MISC. CIVIL & STRUCTURAL WORKS
FOR
U/G PIPING & OTHER CIVIL WORKS
3 25.06.14 REVISED & ISSUED AS STD. SPEC. '" 6s VM SC
2 16.04.09 REVISED & ISSUED AS STD. SPEC. GS RKS NK ND
1 30.10.97 REVISED & ISSUED AS STD. SPEC. SKC PCS MMK A SONI
0 31.3.82 ISSUED AS STD. SPEC. RB RSG

Standards Standards
Comm ittee Bureau
No by by
Approved by
Page 297 of 851

g1-11 22eg INDIA LIMITED 6-65-0035 Rev. 2
lv■Ien ~TsPOWI3OfOvI) GOvt of India Undellakino) STRUCTURAL WORKS FOR U/G
Abbreviations:
C. I. Cast Iron
ERC : Electrical Road Crossings
IRC : Instrumentation Road Crossings
IS Indian Standards
LSTK : Lump Sum Turn Key
M. S. : Mild Steel
PVC : Poly Vinyl Chloride
SCRC : Street Communication Road Crossing
U/G : Under Ground
Convener: Mr. R.B. Bhutda

Mr. R.K. Sharma
Mr. S. K. Naskar
Mr. Vinod Mahajan
Mr. Amitabh Kishore
Mr. Rajan ji Srivastava (Structural)
Mr. Harish Chandra (Piping)
Mr. B. R. Bhogal (Electrical)
Mr. Praveen Goel (Environment)
Mr. V S Chhaya (Projects)
Page 298 of 851

02-e- g INDIA LIMITED
(M177 292e1Ream.3~) IA Govt o1 India Undellaking) STRUCTURAL WORKS FOR U/G
6-65-0035 Rev. 2
CONTENTS
1.0 SCOPE 4
3.0 EARTHWORK & BACKFILLING 5
4.0 PLAIN AND REINFORCED CEMENT CONCRETE 5
5.0 BRICK WORK 5
6.0 CEMENT PLASTERING 5
7.0 RUNGS 5
8.0 CHEQUERED PLATES & STRUCTURAL STEEL WORKS 5
9.0 C.I. MANHOLE FRAME AND COVER 6
10.0 VENT PIPES FOR MANHOLES 6
11.0 FUNNELS, CLEAN OUTS, PLUGS 6
12.0 BRICK BAT FILL 6
13.0 PAYMENT 6
Page 299 of 851

x'_7-112-1t4 xj, ENGINEERS MISCELLANEOUS CIVIL &
g_ji fffilegWINDIA LIMITED 6-65-0035 Rev. 2
m3aas.)
1.11E,, 21~, IA Govt of India Undedak.g) STRUCTURAL WORKS FOR U/G
1.0 SCOPE
This specification covers the material and construction details for various civil works as
given below:
(a) A11 Earthwork except for Site Grading and U/G Piping.
(b) Plain and Reinforced Cement Concrete work in Culverts, ERC/IRC/SCRC, Pipe-
way Bridges, Catch pits, Clean outs, Manholes, Pipe supports, Water
monitors/Hydrant pedestals, Thrust block, valve pits etc.
(c) Brick work for various structures such as Drains, Septic Tank, Soak Pit, Manholes,
Catch basins, Valve chambers, Instrument tapping chambers, Flushing chambers,
etc.
(d) Plastering for the above structures as applicable.
(e) Manhole frames, Manhole covers, Ladders, Rungs etc. for the above structures as
applicable.
(t) Miscellaneous steel structure work such as Ladders, Platforms, Chequered plate
covers, Gratings etc.
The work shall include supply of various materials as per relevant standards required for the
execution of work except for those items designated as Owner' s scope of supply in the
special conditions of contract or elsewhere in the contract documents. Contractor shall
transport material from Owner' s stores, which are a part of owner's scope of supply.
A11 materials not fully specified herein and which may be used for the completion of WORK
shall be of quality, as approved by the Engineer-in-charge. Engineer-in-charge shall have the
right to determine whether all or any of the materials offered or delivered for the execution
of WORK are suitable for the purpose. CONTRACTOR shall give the samples of material
to the Engineer-in-Charge and get it approved before procurement and use.
IS: 458 Pre cast concrete pipes (with and without reinforcement)
IS: 4985 Unplasticized PVC Pipes for Potable Water Supplies
IS: 1239 Mild steel tubes, tubulars and other wrought steel fittings
IS: 1726 Cast Iron Manhole covers and frames
IS: 1786 High strength deformed steel bars and wires for concrete reinforcement
IS: 2062 Steel for general structural purposes
IS: 3502 Steel chequered plates
IS: 5455 Specification for Cast Iron steps and manholes.
Page 300 of 851

gRzit4,, ENGINEERS MISCELLANEOUS CIVIL &
2."111=1P' INDIA LIMITED 6-65-0035 Rev. 2
~IRE' M"7.1) IA Govt of Inoie undertaking) STRUCTURAL WORKS FOR U/G
3.0 EARTHWORK & BACKFILLING
Refer EIL Standard Specification No. 6-68-0003.
4.0 PLAIN AND REINFORCED CEMENT CONCRETE
Refer EIL Standard Specification No.6-68-0004.
5.0 BRICK WORK
Refer EIL Standard Specification No. 6-68-0009.
6.0 CEMENT PLASTERING
6.1 Materials
The specifications for cement, sand and water shall be as given in EIL Standard Specification
No. 6-68-0002.
6.2 Cement mortar shall be of grade and thickness as specified in drawing or as directed by the
Engineer-in-Charge, if not specified. The surface on which plastering is to be done shall be
thoroughly cleaned from dust, dirt, oil, etc. It should be washed properly and watered for 4
hours before plastering. The joints of brickwork shall be raked out to a depth of at least 12mm
when plastering has to be done. On cement concrete surface, the surface shall be scarified by
lines with trowel when it is still green or hacked, if concrete is hard as directed by Engineer-
in-Charge.
6.3 Plaster shall not in any case, be thinner than specified. It shall have uniform specified
thickness. Any extra thickness of plaster done by contractor will not be paid for. When smooth
finishing is required, the cement plaster shall be floated over with neat cement within 15
minutes of the application of the final coat.
During the process of plastering, all corners shall be rounded to a radius of 25mm unless
6.4 The plaster shall be protected from Sun and rain by such means as per the approval of
Engineer-in-Charge. The plaster shall be cured for 7 days.
6.5 Construction joint shall be kept in plastering work at places approved by Engineer-in-Charge.
7.0 RUNGS
7.1 Materials
The rungs for valve pits / manholes shall be of Tor Steel conforming to IS: 1786 and to the
shape and size as shown in drawings. Rungs shall be coated with 2 coats of approved
bituminous paint.
8.0 CHEQUERED PLATES & STRUCTURAL STEEL WORKS
8.1 Materials
8.1.1 Chequered plates shall be 6mm thick (7mm or more chequered plates shall conform to IS:
3502). Steel for chequered plate shall conform to IS: 2062 and shall be clearly rolled and free
from harmful surface defects such as crack, surface flaws etc. The plate shall be cut to shape
and fixed to the bearing members as shown in relevant drawings and as directed by Engineer-
Page 301 of 851

!&.1t4
k3i
r-- ENGINEERS MISCELLANEOUS CIVIL &
$1g-ar 2154egW INDIA LIMITED
1.11VR 2~17013~) (A Govt of Indo Undertalmg) STRUCTURAL WORKS FOR U/G
6-65-0035 Rev. 2
in-Charge. The edges shall be made smooth, no burrs or gagged ends shall be left. The plates
may be spliced with prior consent of the Engineer-in-Charge. But in that case, care should be
taken so that there is continuity in the pattern of the plates between the portions. Lifting
arrangements shall be provided including lifting rods.
8.1.2 Grating shall be fabricated out of M.S flats, angles and rounds etc., as per drawings and as
approved by Engineer-in-Charge. Steel for grating plates shall conform to IS: 2062 of general
weldable quality and shall be clearly rolled and shall be free from harmful surface defects.
9.0 C.I. MANHOLE FRAME AND COVER
9.1 Materials
C I manhole frame and covers shall conform to IS: 1726 with size and grade as shown in
drawings.
10.0 VENT PIPES FOR MANHOLES
10.1 Materials
These shall be black steel tube conforming to IS: 1239 medium grade or as specified in
drawings/ Piping Material Specification. The pipe bends shall be embedded in 1:3:6 grade
cement concrete or as shown in drawing.
10.2 A11 pipes shall be 25mm clear of wall or column with steel holder bat clamp, as per
instructions of the Engineer-in-Charge. All holes in walls and column shall be made good by
1:2:4 grade cement concrete. All pipes and clamps shall be painted with two coats of paints of
approved make.
11.0 FUNNELS, CLEAN OUTS, PLUGS
11.1 Materials
These shall be fabricated from M.S Plates, pipes, chequered plates, rounds, angles etc., to be
supplied by the contractor and painted with 2 coats of anticorrosive paint of approved make.
The fabrication shall be in accordance with the approved drawings.
12.0 BRICK BAT FILL
12.1 Materials
The brickbats used as filling in valve pits shall be from common burnt clay building bricks
of size ranging from 27mm to 37mm. Sample of brickbats used shall be got approved from
Engineer-in-charge.
12.2 The compaction of the layer of brickbat shall be proper so that brickbat are not disturbed
and do not sink in the soil.
13.0 PAYMENT
13.1 Cement Plastering
13.1.1 Payment for plastering shall be made on basis of the area of surface plastered, measured
before plastering. A11 measurements shall be separately made for each face of walls.
Page 302 of 851

Ogzrr ffieg
1.1T27I C,12,1W 01~1)
INDIA LIMITED
IA Govt of India undertax.ng) STRUCTURAL WORKS FOR U/G
6-65-0035 Rev. 2
13.1.2 The rate of plastering shall include cost of scaffolding, swings, cleaning the surface, raking
out joints, hacking concrete surfaces, etc. needed for carrying the work and shall cover the
extra labour for plastering the jambs, sills, and soffits or opening except for plastering bands,
cornices and skirting upto 30 cm width.
13.2 Rungs
Payment for rungs shall be made per number and the rate shall include supply and fixing,
finishing the wall etc. complete.
13.3 Chequered Plates & Structural Steel Works
Payment shall be made on the basis of weight of MS gratings / chequered plate and supporting
frame including hold fast. The rate shall include supply of all necessary steel materials
including cutting to size, fabricating, smoothening edge, if necessary, transporting and fixing
at all positions and providing lifting arrangements. Full deductions shall be made for all
openings above 30mm square and the rate shall include making of opening of all sizes and
supplying and painting 2 coats of anticorrosive paint over a coat of red oxide zinc chromate
primer. The exposed surface of grating and frame shall be painted with two thick coats of coal
tar. The rate shall include providing and laying MS grating and frame, breaking and making
good existing concrete/ brick masonry surface if necessary, finishing, painting etc. complete
with all labour and materials. Payment shall be made on number basis.
13.4 CI Manhole Frame and Cover
Payment for Manhole Frame and cover shall be made per number and rate shall include
supply and fixing etc. complete.
13.5 Vent Pipes for Manholes
Payment shall be made on running meter basis and the rate shall include supply of all
materials, cutting, edge preparation, jointing by welding, fixing in concrete block, cutting of
walls or concrete and making good the same, painting with 2 coats of anticorrosive paint of
approved make, necessary scaffolding etc. complete.
The rate shall also include excavation and backfilling if any.
13.6 Funnels, Clean Outs, Plugs
Payment for these items shall be made on weight basis and rate shall include fabrication,
erection, welding, jointing and painting etc. all complete.
13.7 Brick Bat Fill
The payment for brickbats fill shall be made on m2 basis, as shown in drawing and the rate
shall include supply, laying, compacting etc. complete, with all materials & labour.
13.8 The payment clause(s) as described in the clause no. 13.1, 13.2, 13.3, 13.4, 13.5, 13.6 & 13.7
shall not be referred / applicable for LSTK Jobs.
Page 303 of 851

ENGINEERS FOR PORTABLE FIRE 6-66-0004 Rev. 1
tilWrez
I WTI 29RSI1E,1513%,..1)
INDIA LIMITED
IA Govt of Una..lond) EXTINGUISHER Page 1 of 5
mcbR
afravrmw f4-4r
FOR
PORTABLE FIRE EXTINGUISHER
24.08.18 REVISED & ISSUED AS STD. SPEC. GRAVGYAS

SINGH
0-} RS RKT
0 19.08.10 ISSUED AS STANDARD SPECIFICATION AS RKS RBB ND

Standards Standards
Committee Bureau
No by by
Approved By
Page 304 of 851

t311 el ENGINEERS FOR PORTABLE FIRE 6-66-0004 Rev. 1
weg INDIA LIMITED
A Govt of Me UncleItakng) EXTINGUISHER
I WM e12,
612 0117711
Page 2 of 5
Abbreviations:
MS MILD STEEL
IS INDIAN STANDARD
PESO PETROLEUM EXPLOSIVE SAFETY ORGANISATION
Structural Standards Committee

Mr. VK Panwar
Mr. Samir Das
Mr. Amitabh Kishore
Mr. Gyasuddin
Mr. Charanjit Singh (Proj.)
Mr. Ravindra Kumar (Const.)
Page 305 of 851

laRge? 86
5 '11 til
eg, G
INDIMITFD
(A Got 01 Indi. Undedak.g)
FOR PORTABLE FIRE
EXTINGUISHER
6-66-0004 Rev. 1
Page 3 of 5
CONTENTS
1.0 SCOPE 4
3.0 MATERIAL OF CONSTRUCTION & BASIC REQUIREMENT 4
4.0 APPROVALS 4
5.0 COLOR & MARKING 4
6.0 ACCESSORIES 5
7.0 INSPECTION 5
Page 306 of 851

Ion el ENGINEERS FOR PORTABLE FIRE 6-66-0004 Rev.
tsar felf5teg INDIA LIMITED EXTINGUISHER
1.112T1 2.21,92 41313P47.11 Govt of India Undertaking) Page 4 of 5
1.0 SCOPE
This standard lays down requirements regarding material, shape, construction, method of
operation, performance and tests of portable fire extinguisher of Carbon Dioxide type, Dry
Chemical Powder type Fire Extinguisher.
The extinguisher shall be supplied along with respective extinguishing media duly charged.
IS: 5 Colours for ready mixed paints and enamels

IS: 2932 Enamel, synthetic, exterior; a) undercoating, b) finishing - specification
IS: 4308 Dry Chemical Powder for Fighting B and C Class Fires
IS: 4947 Specification for gas cartridges for use in fire extinguishers
IS: 14609 Dry Chemical Powder for Fighting A, B, C Class Fires
IS: 15222 Carbon dioxide as the extinguishing media for fire protection - Specification
IS: 15683 Portable Fire Extinguishers, Performance and Construction — Specification
Note: Latest Edition of all standard documents shall be followed
3.0 MATERIAL OF CONSTRUCTION & BASIC REQUIREMENT
3.1 CARBON DIOXIDE TYPE:-
3.1.1 Extinguisher shall be portable high pressure type with capacities 2 / 4.5 Kg as per requirement.
3.1.2 Requirement of performance, construction, and test shall comply with IS: 15683.
3.1.3 Carbon dioxide of 99.5% purity used as extinguishing media shall comply with IS: 15222 with
maximum fill density shall not exceed 0.667Kg/l.
3.1.4 Extinguishers shall have concave base, material for extinguisher body shall be either steel
conforming to IS: 7285 or aluminum confirming to IS: 4947 and discharge valve shall be of hand
wheel / key / lever operated type conforming to IS: 3224
3.2 DRY CHEMICAL POWDER TYPE:
3.2.1 Extinguisher shall be portable low pressure Cartridge type with capacities 1 / 2 / 4 / 6 /per
requirement based on fire rating.
3.2.2 Requirement of performance, construction, and test shall comply with IS: 15683.
3.2.3 Dry powder conforming to IS: 14609, I.S. 4308 and Of IS: 4861 shall be used for charging the
extinguishers.
3.2.4 Material for extinguisher body shall be carbon steel conforming IS: 513 with no vertical joints on
the body. Discharge nozzle, valve assembly shall be SS-316 or brass confirming to IS: 6912.
3.2.5 Carbon di oxide gas cartridge shall be ISI marked as per IS: 4947
4.0 APPROVALS
Carbon di oxide extinguisher and valve shall have approval from PESO, Government of India,
Nagpur.
5.0 COLOR & MARKING
The color of extinguisher bodies shall be Red conforming to shade no.536 or 538 of IS: 5. Paint
shall conform to IS: 2932. Each extinguisher shall be clearly and permanently marked with the
information specified in IS: 15683, along with IS certification mark and purchaser's name.
Page 307 of 851

k3iia.itAi ENGINEERS FOR PORTABLE FIRE 6-66-0004 Rev. 1
fawag INDIA LIMITED
(A Govt of India Undertaking) EXTINGUISHER Page 5 of 5
6.0 ACCESSORIES
Each extinguisher shall be supplied with MS bracket, screws and spanner as may be necessary.
The details of the bracket shall be submitted with the offer.
7.0 INSPECTION
Owner's / EIL's authorized representative shall have access at all reasonable times to vendor's
works where Extinguishers are being manufactured and/or tested. Vendor shall arrange for all
tests and inspection facilities for checking material, design and fabrication, workmanship,
finish, performance (operating performance and performance required for test fires), and testing
as per IS: 15683.
8.0 INFORMATION REQUIRED FROM VENDOR
8.1 Following information shall be furnished by the vendor along with the supply of extinguisher:
Instruction book(s) - Instruction book(s) for guidance of the user including both the
operating and normal maintenance procedures shall be supplied. The book(s) shall include
an itemized and illustrated part list/spare parts list giving reference number of all the
wearing parts.
Approval certificate from PESO as described in clause 4.
Page 308 of 851

lafaziel" eft,
' ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
511g-af lai5teg W1 INDIA LIMITED STAND POST TYPE FIRE HYDRANT
otre,t IA Govt of India Undertakong)
6-66-0012 Rev. 4
Page 1 of 6
"ftER 3f-WR aTPT

irocti air TERW feitr
(-cpirK TrrEr aTzgr fay trizrK

STAND POST TYPE FIRE HYDRANT
(WITH OR WITHOUT PUMPER
CONNECTION)
4 26.06.18 REVISED & ISSUED AS STD. SPEC.

Cam"
GAURAV
SINGH
,/f
GYAS RS
AN/01
RKT
3 23.05.11 REVISED AND ISSUED AS STD. SPEC. ALOK RKS RBB DM
2 22.12.05 REVISED & REISSUED AS STD. SPEC. SKC NK VDS VJN
1 15.02.98 REVISED & ISSUED AS STD. SPEC. VEDA SM MMK ASONI
0 31.03.82 ISSUED AS STD. SPEC. RB HVR RCPC

Standards Standards
Committee Bureau
No by by
Approved By
Format No. 8-00-0001-F1 Rev. 0 Copyright El L — All rights reserved
Page 309 of 851

ENGINEERS
5Sz1r tifkg
MT', rieamecn1J0L10:0
INDIA LIMITED
(A Govt
STAND POST TYPE FIRE 6-66-0012 Rev. 4
01 India U0000010091
HYDRANT Page 2 of 6
Abbreviations:
FM Factory Mutual
IS Indian Standard
MS Mild Steel
UL Underwriters Laboratories

Mr. VK Panwar
Mr. Samir Das
Mr. Amitabh Kishore
Mr. Gyasuddin
Page 310 of 851

ENGINEERS
INDIA LIMITED STAND POST TYPE FIRE 6-66-0012 Rev. 4
1.112A cleave ) IA Govt Al Inde Undeddlong)
HYDRANT Page 3 of 6
CONTENTS
1.0 SCOPE 4
3.0 MATERIAL 4
4.0 DESCRIPTION 4
5.0 WORKMANSHIP AND FINISH 4
6.0 TESTING 4
7.0 PAINTING 5
8.0 MARKING 5
9.0 INSPECTION 5
10.0 VENDOR's DRAWING AND DATA REQUIREMENT 5
11.0 APPROVAL 5
ANNEXURE-I (SCOPE DRAWING FOR SUPPLY OF HYDRANTS) 6
Page 311 of 851

ei ÊNGINEERS
iajteg •■■•./ INDIA LIMITED STAND POST TYPE FIRE 6-66-0012 Rev. 4
IA Goo of India Undeltakmg)
HYDRANT Page 4 of 6
1.0 SCOPE
This standard lays down the requirements of codes and standards, type, shape, dimensions,
material and test for vertical stand post type fire hydrant (with or without pumper connection)
to be installed on fire water main. The Hydrant shall normally be supplied without pumper
connection unless otherwise specifically mentioned in the Data sheet/ Material Requisition.
IS: 902 Suction hose couplings for fire fighting purposes.

IS: 903 Fire hose delivery couplings, branch pipe.
IS: 5290 Specification for Landing Valves.
ANSI B16.5 Pipe Flanges and Flanged Fittings.
NOTE:- Latest Edition of all Codes and Standards shall be followed.
3.0 MATERIAL
All material shall be as given in Job Specific Data Sheet provided along with this specification
in the Material Requisition.
4.0 DESCRIPTION
4.1 The hydrant shall be stand post type. The vertical post shall be of 100 mm diameter with two
horizontal hydrant arms, each 75 mm diameter, on which independent Landing valve shall be
fixed. Landing valve shall comply to IS: 5290, Type A.
4.2 Outlet of the landing valve shall be provided with instantaneous female coupling with blind
cap & chain as per IS 5290
4.3 For hydrant assembly with pumper connection, the vertical post shall have 100 mm outlet as
pumper connection and provided with a blind cap. The 100mm outlet shall have round male
threads, conforming to IS: 902 and blind cap shall be provided with four fixing lugs and 500
mm long SS-chain.
4.4 All flanges for landing valve connection shall have all dimensions conforming to
ANSI.B.16.5, 150 lbs rating, Flat Face, Slip On type. Base flange of stand post shall be as per
job specific Piping Material Class as mentioned in datasheet.
4.5 Job specific requirements shall be as per Data Sheet enclosed in Bid / Requisition document.
4.6 Refer Annexure-I for scope details for supply of Hydrants
5.0 WORKMANSHIP AND FINISH
All parts shall have good workmanship and finish. All warps and sharp edges shall be
removed. The waterways shall have smooth finish.
6.0 TESTING
Each hydrant assembly shall be satisfactorily tested for water tightness, hydrostatic test and
flow test as per IS 5290.
Hydrant assembly with Landing valves closed shall be satisfactorily tested and proved water
tight, under a hydraulic pressure of 21.0 kg/cm 2. The pumper connection shall be kept closed
during testing in case the same is provided on hydrant assembly.
Page 312 of 851

fs~t idDleg
NIVR ereElge ■751,3■IOSSO
INDIA LIMITED
(A Goo of Indo Undeitaking)
STAND POST TYPE FIRE 6-66-0012 Rev. 4
HYDRANT Page 5 of 6
7.0 PAINTING
The stand post and its arms shall be painted as specified in Job Specific Data Sheet attached
with this specification.
8.0 MARKING
Each hydrant shall be clearly and permanently marked with the following:
a) Manufacturers name or trade mark.

b) Year of Manufacture.
c) Purchaser name.
d) BIS certification marking on landing valve and couplings.
9.0 INSPECTION
Owner's / EIL's authorized representative or as mentioned in data sheet shall have access at all
reasonable times to vendor's works where Stand Post Hydrants and Landing Valves are being
manufactured and/or tested. Vendor shall arrange for all tests and inspection facilities for
checking material, design and construction, hydraulic performance, workmanship, finish and
hydrostatic testing. Any shortcoming pointed out shall be rectified to the satisfaction of the
inspectors. All consumables i.e. water etc. shall be arranged by vendor at his own cost.
10.0 VENDOR's DRAWING AND DATA REQUIREMENT
Vendor shall furnish drawings for review, prior to fabrication of Hydrant assembly as per
Vendor Data Requirement.
11.0 APPROVAL
Vendor shall furnish valid BIS certificate approval letter.
Page 313 of 851

51/Zir 16i15 INDIA LIMITED STAND POST TYPE FIRE 6-66-0012 Rev. 4
1442A e`f ,Pre 451.344541, (A Govt of India Undettakingt
HYDRANT Page 6 of 6
ANNEXURE-I
(SCOPE DRAWING FOR SUPPLY OF HYDRANTS)
CAP AS PER ASTM A-105 ..AP AS PER ASTM A -"CD
ANSI B 16.5 ANSI 3 16.5
3" FLANGE AS PER 63 MM DELIVERY CUTLETS 3" FLANGE AS PER

63 NN DEUVERY CUTLETS
ANSI 816.5 1 50 it RATING WITH INSTANTANEOLS ANSI 1316.5 150 RATING
WITH INSTANTANEOUS 5.0. FF (ASTM A-105)
COUPLING \ 5.0. FF (ASTM A-1135) COUPLING
AS PER 15:9D3 AS PER 15.903
Ai
HYDRANT VALVE
(IS:5290-T"PE-A)
S5304 CAP AND CHAIN
,
4
Ijii II
HYDRANT VALVE
(IS:5290-TYPE-A)
55304 CAP AND CHAIN,
a
1 .1 I
,
waa
Till
ppp :
' 1 04" POST

4" POST FIRE FIGHT!
FIRE FIGHT!
VENDOR'S SCOPE OF SUPPLY 11 PBS (REFER DATASHEET) VENDOR'S SCOPE CF SUPPLY 111 PM (REFER DATASHEET;
4" FLANGE AS '-'ER

BY THEIR
4" FLANGE AS PER
PINS (REFER DATASHEET)
D •• Ai, PBS (REFER DATASHEET)
04" 150 L6TION 04" ISOLATION
VA V
VALVE LIN
TYP. DETAILS TYP. DETAILS

OF HYDRANT ASSEMBLY OF HYDRANT ASSEMBLY
WITHOUT PUMPER CONNECTION WITH PUMPER CONNECTION
4" PUMPER CONNECTION
04" POST
(PBS AS PER DATASHEETr-
FIRE FIGHTI LY
VENDOR'S SCOPE OF SUPPLY
55304 CAP AND CHAIN
B SS304 CAP AND CHAIN

4" FIANCE AS PER
VAL PINS (REFER DATASHEET)
TYP. DETAILS
OF HYDRANT ASSEMBLY
WITH PUMPER CONNECTION
(VIEW C - C )
Page 314 of 851

1511:4-zre ENGINEERS STANDARD SPECIFICATION
$figzir OW-eg INDIA LIMITED STANDARD SPECIFICATION No.
1.41271 IA Govt of India Undertaong)
FOR FIRST AID HOSE REEL 6-66-0018 Rev. 4
Page 1 of 4
3114f1W *men tfAh lte fry

1-4-4-4r
FOR
FIRST AID HOSE REEL
GAURAV
4 26.06.18 REVISED & ISSUED AS STD. SPEC. GYAS RS RKT
SINGH
3 23.05.11 REVISED & REISSUED AS STD. SPEC ALOK RKS RBB DM
2 12.01.06 REVISED & REISSUED AS STD. SPEC SKC NK VDS VJN
1 21.11.96 REVISED & ISSUED AS STD. SPEC NK PCS MMK A SONI
0 31.03.82 ISSUED AS STD. SPEC. RB KP HVR RCPC

Standards Standards
Rev. C
Committee Bureau
Prepared Checked
No by by
Approved By
Page 315 of 851

150-4:Ek ENGIEERS
N STANDARD SPECIFICATION No.
seal INDIA LIMITED FOR 6-66-0018 Rev. 4
,..e,,29iwt1713.40.1) IA Govt of India Uncleflakong)
FIRST AID HOSE REEL
Page 2 of 4
ABBREVIATIONS:
IS Indian Standard

Mr. VK Panwar
Mr. Samir Das
Mr. Amitabh Kishore
Mr. Gyasuddin
Format No. 8-00-0001-F1 Rev. 0 Copyright El L — All rights reserved
Page 316 of 851

,31faq_Je? LIMB STANDARD SPECIFICATION No.
$1gz-ir 16104GS INDIA TED FOR 6-66-0018 Rev. 4
(A Gout of India undertakm
FIRST AID HOSE REEL
Page 3 of 4
CONTENTS
1.0 SCOPE 4
3.0 MATERIAL, CONSTRUCTION AND TEST 4
4.0 SIZE 4
5.0 HYDRAULIC PERFORMANCE 4
6.0 MARKING 4
9.0 APPROVAL 4
Page 317 of 851

15151ZIEg ENGINEERS STANDARD SPECIFICATION No.
Igar ElOteg INDIA LIMITED
(wen netere ne sewn) IA Govt of India Undertaking)
FOR 6-66-0018 Rev. 4
FIRST AID HOSE REEL
Page 4 of 4
1.0 SCOPE
This specification covers the requirements regarding material, constructional details and test for
Floor/Wall mounted First Aid Hose Reel, intended for installation within process units / buildings as
emergency fire fighting equipment.

IS : 884 First-Aid hose reel for fire-fighting.
NOTE: Latest Edition of all Codes and Standards shall be followed.
3.0 MATERIAL, CONSTRUCTION AND TEST

Material, Construction, tests and all other requirements shall conform to IS: 884, Type-A Hose Reel,
except as mentioned in the Data Sheet of Hose Reel attached with Bids / Requisition.
4.0 SIZE
House reel tubing length shall be 40 m with internal bore 25 mm or as specified in data sheet.
5.0 HYDRAULIC PERFORMANCE

5.1 First Aid hose reel shall be capable of discharging not less than 24 Ipm at the reel inlet pressure of
7 kg/cm2 g.
5.2 The horizontal range of water jet shall not be less than 6.0 m at the reel inlet pressure of 7 kg/cm2g.
6.0 MARKING
Each hose reel shall be clearly and permanently marked with the following information along with
Purchaser's name.
a) Manufacturer's name or Trade Mark

b) Year of Manufacture
c) Length and size of tube carried on hose reel.
d) Type of Reel.
e) BIS certification mark on house reel tubing

Owner's / EIL's authorized representative as mentioned in data sheet shall have access at all
reasonable times to vendor's works where Hose Reels are being manufactured and/or tested. Vendor
shall arrange for all tests and inspection facilities for checking material, design and construction,
hydraulic performance, workmanship, finish and hydrostatic testing. Any shortcoming pointed out
shall be rectified to the satisfaction of the inspectors. All consumables i.e. water etc. shall be arranged
by vendor at his own cost.

Vendor shall furnish drawings and data for review, prior to fabrication of Hydrant assembly as per
Vendor Data Requirement.
9.0 APPROVAL
Vendor shall furnish valid BIS certificate.
Format No. 8-00-0001-Fl Rev. 0 Copyright EIL —All rights reserved
Page 318 of 851

ENGINEERS FOR
cif INDIA LIMITED 6-66-0047 Rev. 4
I ) (A Govt of India Undertaking) HOSE CABINET Page 1 of 5
*-1-44- Hvich Far,14-kil

HOSE CABINET
4 26.06.18 GAURAV
REVISED & ISSUED AS STD. SPEC. GYAS RS
SINGH
3 JAY
21.01.2013 REAFFIRMED AND ISSUED AS STD. SPEC. RC RBB DM
KUMAR
2 26.12.07 REVISED AND REISSUED AS STD. SPEC. GAURAV PPC NK VC
1 20.06.97 REVISED AND REISSUED AS STD. SPEC. NK PCS MMK A.SONI

ISSUED AS STD. SPEC.
0 31.03.82 RB HVR
RECOMPOSED IN AUG. 95
Standards Standards
Prepared Checked
No by by
Approved By
Page 319 of 851

15Mad
INDIA LJMITED FOR
1g7 fit5rg, IA Govt of India UndenakIng)
HOSE CABINET
6-66-0047 Rev. 4
Page 2 of 5
Abbreviations:
GI Galvanised Iron
IS Indian Standard
MS Mild Steel
mm Millimeter

Mr. VK Panwar
Mr. Samir Das
Mr. Amitabh Kishore
Mr. Gyasuddin
Page 320 of 851

ISift:Eq(ft, ENGINEERS
Ogaf Piez voi INDIA LIMITED FOR 6-66-0047 Rev. 4
1.1171 mow onJaam) IA Govt of WM Undertaking)
HOSE CABINET Page 3 of 5
CONTENTS
1.0 SCOPE 4
3.0 DESIGN REQUIREMENTS 4
4.0 MATERIAL 5
5.0 PANTING 5
6.0 MARKING 5
7.0 TESTING 5
8.0 INSPECTION 5
Page 321 of 851

ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
INDIA LIMITED FOR 6-66-0047 Rev. 4

17.1RR eiTa57245■ 070,71, IA Govf of India Undertaking)
1.0 SCOPE
1.1 This specification covers the general requirements regarding the Design requirement,
Material, Construction, Painting and Marking of Hose cabinet and fire fighting equipments
contained in the cabinets.
1.2 The Hose cabinet shall be supplied along with all the fire fighting equipments contained in it.
IS: 5 Colors for Ready Mix Paints and Enamels

IS: 636 Non-Percolating flexible fire fighting delivery hose
IS: 903 Fire Hose Delivery Couplings, Branch Pipe, Nozzles and Nozzle Spanner
IS: 2871 Branch pipe, universal, for fire fighting purposes
NOTE: Latest Edition of all Codes and Standards shall be followed.
3.1 Hose cabinet shall be of two types, Type-I and Type-II, to accommodate delivery hose and jet
nozzle with branch pipe or universal branch pipe.
3.2 Type I Hose Cabinet
3.2.1 It shall be suitable to accommodate one Type B firefighting delivery hose (Reinforced rubber
lined, non-Percolating with elastomeric outer coating applied as reinforcement conforming IS
636) of size 63 mm 15 meter long with ends couplings, one jet nozzle with branch pipe or one
universal branch pipe.
3.2.2 It shall be capable of being mounted on wall. Necessary hangers and bracket for hose, nozzle
and branch pipe or universal branch pipe shall be provided, with the cabinet.
3.2.3 It shall be provided with single panel glass door
3.3 Type II Hose Cabinet
3.3.1 It shall be suitable to accommodate two Type B firefighting delivery hoses (Reinforced
rubber lined, non-Percolating with elastomeric outer coating applied as reinforcement
conforming IS 636) of size 63 mm, 15 meter long with end couplings, one jet nozzles with
branch pipe and one universal branch pipes.
3.3.2 It shall be of self-supporting type, suitable for outside installation. Necessary hangers and
brackets for hose, nozzle and branch pipe or universal branch pipe shall be provided within the
cabinet.
3.3.3 It hall be provided with double panel glass door.
3.4 Both the types shall be provided with handle type lock, a small recess to keep cabinet key
under glass cover, a small hammer secured to the cabinet with a chain to break key glass
cover.
Page 322 of 851

el ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
OgeliWeg INDIA LIMITED FOR 6-66-0047 Rev. 4

011i, eV-Mr, ,151, (A Goof of India Unclettalonm
4.0 MATERIAL
4.1 Cabinet shall be made Of 18 gauge MS sheet suitably welded with single/double MS door
frame glass covered. 3mm Glass with rubber gomet shall be securely fitted to the door frame
in a standard manner.
4.2 Door shall be provided with standard handle Mortise type lock.
4.3 Hammer shall be of MS with GI chain.
4.4 Suitable size angle iron posts shall be provided to support type II cabinet.
4.5 Delivery hose shall be either of the following type
a) Type B Reinforced rubber lined hose to I.S. 636
4.6 End couplings, jet nozzle and branch pipe shall conform to I.S. 903.
4.7 Universal branch pipe shall conform to I.S. 2871.
5.0 PAINTING
The hose cabinet shall be painted with 3 coats of anticorrosive fire red paint conforming to
shade no. 536 of IS: 5 from outside and white paint from inside. The paint shall conform to IS:
2932.
6.0 MARKING
6.1 Each cabinet shall be clearly and permanently marked with following.
a) The words Hose Cabinet-Type I or II

b) Instructions for use.
6.2 Each equipment in the cabinet shall be marked with BIS certification mark and purchaser's
name.
7.0 TESTING
All equipments being supplied with Hose Cabinet shall be tested as per relevant IS test
requirements.
8.0 INSPECTION
Owner's / EIL's authorised representative shall have access at all reasonable times to vendor's
works where Hose Cabinets and equipments being supplied with Hose Cabinet, are being
manufactured and/or tested. Vendor shall arrange for all tests and inspection facilities for
checking material, design and construction, hydraulic performance, workmanship, finish and
hydrostatic testing. Any shortcoming pointed out shall be rectified to the satisfaction of the
inspectors.
Vendor shall furnish drawings and data as per "Vendor's drawings and Data Requirements" for
information and records.
Page 323 of 851

ENGINEERS FOR 50KG & 75KG. CAPACITY
Igar tifWleg INDIA LIMITED 6-66-0061 Rev. 4
INKref URON2 (A Scott of Mad undertaiong)
DRY CHEMICAL POWDER
EXTINGUISHER Page 1 of 5
50 Alito n9:11 75 *R11) kiTrffT *

ttil~l~l 41351 afrffumw -41 iiirich
FOR
50 KG. & 75 KG. CAPACITY DRY
CHEMICAL POWDER EXTINGUISHER
GAURAV
4 24.08.18 REVISED & ISSUED AS STD. SPEC. GYAS RS RKT
SINGH
3 06.07.10 REVISED AND ISSUED AS STD. SPEC. AS RKS RBB ND
2 29.04.08 REVISED AND ISSUED AS STD. SPEC. GAURAV RKS NK VC
1 25.6.99 REVISED AND ISSUED AS STD. SPEC. RC PCS MMK AS
0 18.1.93 ISSUED AS STANDARD SPECIFICATION RB MMK RPB RNS

Standards Standards
Committee Bureau
No by by
Approved By
Page 324 of 851

ENGINEERS 50KG & 75KG. CAPACITY DRY
II•DIA LIMITED 6-66-0061 Rev. 4
(A Govt of India Undertaking) CHEMICAL POWDER
Abbreviations:
DCP DRY CHEMICAL POWDER
IS INDIAN STANDARD
OISD OIL INDUSTRY SAFETY DIRECTORATE
PESO PETROLEUM EXPLOSIVE SAFETY ORGANISATION

(Formerly known as CCOE)

Mr. VK Panwar
Mr. Samir Das
Mr. Amitabh Kishore
Mr. Gyasuddin
Page 325 of 851

a faRegNW glithINDIA
ENGINEERS LIMITED 50KG & 75KG. CAPACITY DRY
5 6-66-0061 Rev. 4
iwzrr evarrallasam) IA Govt Inda undertaiong) CHEMICAL POWDER
CONTENTS
1.0 SCOPE 4
3.0 DESIGN REQUIREMENTS 4
4.0 MATERIAL OF CONSTRUCTION 4
5.0 SAFETY CLIP 4
6.0 COLOUR AND MARKING 5
7.0 TESTING INSPECTION AND APPROVALS 5
8.0 INFORMATION REQUIRED FROM VENDOR 5
Page 326 of 851

ENGINEERS 50KG & 75KG. CAPACITY DRY
*igen iaales INDIA UMITED 6-66-0061 Rev. 4
iifErrt 2.107617 3,
10.1) (A Govl of Inda UndertaMtng) CHEMICAL POWDER
1.0 SCOPE
This specification lays down the requirements regarding material, shape, construction,
chemical charges, anticorrosive treatment, painting, test, safety, reliability and performance
for trolley mounted dry powder fire extinguishers of capacities 50 kg and 75 kg.
IS: 16018 Specification for performance and construction of wheeled fire

Extinguisher
OISD-GDN-115 Guidelines on Fire Fighting, Equipment and Appliances in Petroleum

Industry
Note: - Latest Edition of all standard documents shall be followed.
3.1 Fire extinguisher shall be as per IS: 16018.
3.2 The method of expulsion of dry powder shall be by means of pressure produced from
compressed or liquefied gas from gas cylinder attached to the body and suitably mounted on
trolley.
3.3 Propellant for cartridge operated wheeled fire extinguisher shall be CO2 gas type and having
maximum dew point of -55°C.Gas cartridge shall conform to IS 4947 in all aspects.
3.4 Chemical content for Dry chemical powder used as extinguishing media shall cover more than
50% of Mono ammonium phosphates of total composition of the extinguishing powder,
and shall comply with IS 14609, with maximum fill density as specified in IS: 16018.
3.5 The recommended capacity with filling tolerance/ Nominal charge of the dry powder
extinguisher when filled for the various capacities shall be as under:
Nominal Size (Kg) Dry Powder content (Kg. minimum.)
50 50 ±2% by mass
75 75±2% by mass
4.0 MATERIAL OF CONSTRUCTION
4.1 The material of for construction of various parts of Fire Extinguisher shall be as per
IS: 16018.
4.2 The body shall be cylindrical made up of welded Low carbon steel (Mild steel) / stainless
Steel. The welding of cylinder shall conforming to requirements of IS 9595.
4.3 All internal and external surface of the body shall be completely coated with an anti corrosive
Material. Thickness of the coating shall be measured as per IS: 3203. Testing of anti-corrosive
Treatment shall be complying with IS: 10658.
5.0 SAFETY CLIP
Safety Clip should be provided to prevent accidental actuation of piercing mechanism.
Page 327 of 851

OIPP_A ENGINEERS 50KG & 75KG. CAPACITY DRY
eirS INDIA LIMITED 6-66-0061 Rev. 4
imam maw =awn) IA Govt d India Undertaking) CHEMICAL POWDER
6.0 COLOUR AND MARKING
Each extinguisher shall be painted fire red confirming to shade No. 536 of IS 5. Each
extinguisher shall be clearly and permanently marked with the information specified in IS:
16018 along with the BIS certification mark, operating instruction and purchaser's name.
7.0 TESTING INSPECTION AND APPROVALS
Each fire extinguisher shall be complying with test requirement specified in IS: 16018
Wheeled fire extinguishers intended for use on class ABC fires shall be tested for 6A and
144B fire rating system as specified in IS 15683.
A clearance/approval certificate from the PESO, Nagpur shall be submitted for each gas
cartridge supplied with the DCP extinguishers.
EIL or its authorised representatives shall have access at all reasonable times to the
manufacturer's works where the extinguishers are being manufactured or being tested.
8.0 INFORMATION REQUIRED FROM VENDOR
8.1 The vendor shall furnish the following information along with the offer and for approval prior
to fabrication.
General arrangement of trolley mounted extinguisher showing plan and elevation.

Fabrication details and plate thickness calculation for pressure vessel.
Catalogues for all bought out items with Model No. If any.
8.2 Following information shall be furnished by the vendor along with the supply of extinguisher:
- Instruction book(s) - Instruction book(s) for guidance of the user including both the
operating and normal maintenance procedures shall be supplied. The book(s) shall
include an itemized and illustrated part list/spare parts list giving reference number of
all the wearing parts.
- Duly approved final drawings listed in clause 8.1.
A clearance/approval certificate from PESO as described in clause 7.
Page 328 of 851

k31 ENGNEERS FOR 6-66-0074 Rev. 3
$ig-af 02-dg
' INDIA LIMITED
IA Govt of Intha Undertak,ngi
FIRE HYDRANT SYSTEM
Page 1 of 9
31f19' tnq 4-11.1ch "F~T

FIRE HYDRANT SYSTEM
3 25.06.14 REAFFIRMED AND ISSUED AS STD. SPEC. DCB cf.RBB SC
2 19.02.10 REVISED AND ISSUED AS STD. SPEC. ALOK SKN RBB ND
1 15.07.98 REVISED AND ISSUED AS STD. SPEC. RC PCS MMK AS
0 13.09.88 ISSUED AS STANDARD SPECIFICATION NK NK HVR RCPC

Standards Standards
Comm ittee Bureau
No by by
Approved by
Page 329 of 851

ENGINEERS FOR
fda- g INDIA LIMITED 6-66-0074 Rev. 3
Nr2,1 c.
1,051.2 71, .3,7057.1, IA Go, of Undertaking) FIRE HYDRANT SYSTEM
Page 2 of 9
Abbreviations:
BIS Bureau of Indian Standard
EOT : Electric Overhead Travelling Crane
HOT : Hand operated Overhead Travelling Crane
NB Nominal Bore
NPSH : Net Positive Suction Head
OISD : Oil Industry Safety Directorate
P&ID : Piping and Instrumentation Diagram
TAC : Tariff Advisory Committee
Convener: Mr. R.B. Bhutda

Mr. R.K. Sharma
Mr. S. K. Naskar
Mr. Vinod Mahajan
Mr. Amitabh Kishore
Mr. Rajan ji Srivastava (Structural)
Mr. Harish Chandra (Piping)
Mr. B. R. Bhogal (Electrical)
Mr. Praveen Goel (Environment)
Mr. V S Chhaya (Projects)
Page 330 of 851

..i ENGINEERS FOR
gaf Wes INDIA LIMITED 6-66-0074 Rev. 3
IA Govt of Indo Undertalfing) FIRE HYDRANT SYSTEM
Page 3 of 9
CONTENTS
1.0 SCOPE 4
2.0 DESIGN CODES AND STANDARDS 4
3.0 FIRE WATER STORAGE 4
4.0 PUMPING SYSTEM 5
5.0 HYDRANT SYSTEM DISTRIBUTION NET WORK 7
6.0 INSTRUMENTATION WORKS 8
7.0 ELECTRICAL WORKS 8
8.0 PAINTING 8
9.0 RADIOGRAPHY 9
10.0 DRAWINGS AND DOCUMENTS 9
11.0 STATUTORY APPROVALS 9
Page 331 of 851

ENGINEERS FOR
eg
$fgU f&M— INDIA LIMITED 6-66-0074 Rev. 3
co,ortanJotrot, Itt Govt of mala Undertatongt FIRE HYDRANT SYSTEM
Page 4 of 9
1.0 SCOPE
This standard covers the technical requirements for design, supply fabrication, erection, testing and
commissioning of fire hydrant system for protection of various facilities in the plant area.
The hydrant system shall generally consist of following facilities:
a. Fire water storage.
b. Pumping system.
c. Fire water distribution network.
d. Controls for automatic operation of the system.
2.0 DESIGN CODES AND STANDARDS

a. Fire protection manual Part II (Hydrant System) of TAC.
b. IS Codes for fire fighting appliance and accessories.
c. Hydraulic institute guide lines.
d. OISD-116, 117.
3.0 FIRE WATER STORAGE

3.1 Basic Requirements
3.1.1 The total water requirement shall be stored in any of the following manner.
a. Minimum two above ground steel storage tanks covered or uncovered as per Job Data Sheet
each meeting half the total requirements.
b. A ground level RCC uncovered reservoir with attached sump and pump house for installing
horizontal centrifugal pumps with flooded suction. The reservoir shall have two equal
compartments.
c. An underground RCC uncovered reservoir and pump sump having two equal compartments,
with sump and pump house for installing vertical pumps.
3.1.2 The tank / reservoir shall be provided with manhole vent pipes, inlet pipe scour pipe and overflow
connections. The scour/overflow pipe shall be connected to the nearest drain.
3.1.3 The tank / reservoir shall have float type level indicator with sliding pointer and scale to indicate
the water level in the tank.
3.1.4 The design, construction, erection and testing of the reservoir shall be done as per drawings, design
data and specifications enclosed.
3.1.5 The length, breadth and depth of suction sump shall be decided with following considerations.
a. Number of pumps to be connected.
b. Pump capacity.
c. Minimum holding capacity should not be less than 5 minutes.
d. Pump NPSH requirements.
e. Pump submergence requirements.
f. Piping arrangement requirements.
g. To meet hydraulic institute requirements.
Page 332 of 851

ENGINEERS FOR
5Igw faW5
,,enrt ces1 ,isnol
INDIA LIMITED
in GoN of Undertafongf FIRE HYDRANT SYSTEM
6-66-0074 Rev. 3
Page 5 of 9
3.1.6 The general arrangement showing the relative location of fire water storage and pumping facilities
shall be as per job drawings.
4.0 PUMPING SYSTEM

4.1 Basic Requirements
4.1.1 Pumps
Horizontal or Vertical Mains/Standby/Jockey pumps shall be provided as per Job Data Sheet.
Diesel driven and electric driven pumps shall be provided as per Job Data Sheet. Jockey pumps
shall be electric driven with emergency power supply. Electric driven pumps shall be fed from
separate Sub-Station through a dedicated cable trench as per TAC requirement. The pumps shall
start sequentially with pressure drop in the network. Jockey pumps shall keep the network
pressurized. The automatic sequential operation of main pumps shall be as per job P&ID. Diesel
engine shall be provided with battery start-up system.
4.1.2 Pump House Building
i) A pump house building shall be provided near the fire water storage to house the fire water
pumps.
ii) The pump house shall be sized to accommodate pumps, drives, pipe fittings and other
accessories required for pumping system and provide adequate rain protection to the
equipment and accessories. The pump house size shown in the bid drawings shall be
considered as min. requirement and may be increased by the bidder if required.
iii) The pump house shall be covered with RCC slab at top and enclosed all side with brick wall.
iv) Suitable arrangement shall be provided for drainage to nearby drain by gravity. The floor
shall be sloped towards the drain.
v) A monorail with chain pulley block of suitable capacity or HOT/EOT crane as required shall
be provided in the pump house longitudinally for maintenance purpose. Provision shall be
made to load the equipment from the pump house directly on a truck with the help of the
monorail and chain pulley block or HOT/EOT crane.
vi) The height of the pump house shall be decided such that sufficient clearance is available
when any equipment is being carried by chain pulley block over other pumps and drives in
the pump house.
vii) RCC cable trenches (covered steel trays in case of pumps mounted on sump slab) shall be
provided for Electrical and Instrumentation cabling in the pump house.
viii) The building shall be designed, constructed, and finished as per enclosed design and
construction specification. The selection of materials shall be done as per structural design
basis.
ix) The building shall be provided with adequate lighting as per enclosed design and
construction specifications.
4.1.3 Pump House Piping
i) Pump house piping shall be done in accordance with the piping and instrumentation drawing
and specification enclosed and also with all fittings, specials.
ii) Gate valves shall be provided Inside pump house and instruments shall be provided as
required. The piping detailing and layout shall be done as per sound engineering practice and
meeting requirements of TAC.
iii) The pumps shall be spaced with adequate clearance for operation and maintenance.
iv) All equipment shall be accessible for operation and maintenance. A clear space for walk way
of minimum 1.0m wide shall be available for easy access to all equipments, controls,
Page 333 of 851

ENGINEERS FOR
22-eg
>fr2R 2422,12 .7,4AM
INDIA LIMITED
IA Go. of India UndenakIngl FIRE HYDRANT SYSTEM
6-66-0074 Rev. 3
Page 6 of 9
instruments for operation, maintenance and repair etc. Necessary platforms, and ladders,
stair case shall be provided for approach to equipments, instruments and controls wherever
required.
v) Necessary covers, railings etc. for personnel safety shall be provided judiciously wherever
required.
vi) The pump house piping shall be done in such a way that flooded suction is available to the
pump as per TAC requirements. The layout shall meet the NPSH requirements of the pump.
vii) Adequate submergence shall be provided to prevent vortex formation on the suction inlet.
viii) The location and orientation of the pumps and their suction and discharge connection shall
be so planned as to meet hydraulic institute guidelines.
ix) The suction piping shall be detailed in such a way that there would be no possibility of any
air being trapped. For this reason eccentric reducers with flat side at top shall be used and
vertical loops shall be avoided. The water entry to pump nozzle shall be smooth and
uniform. The bends shall be minimised in the suction piping. Any bend should not be placed
immediately before the pump nozzle. If a bend in the suction piping is unavoidable, a
straight length of atleast four times the suction pipe diameter shall be provided after the
bend. Similar straight length shall be provided in case of inline strainers, valves etc. before
the pump nozzle.
x) Expansion bellows shall be provided on suction piping of 300MM NB or higher, wherever
required, as per P&ID.
xi) The pump suction should have a bell mouth entry. The bell mouth dia. shall be 1.5 to 1.8
times the dia. of suction pipe. The bottom clearance below the bell mouth shall be about half
the diameter of the bell mouth.
xii) The discharge side piping shall be detailed such that in case of sudden start and stop of pump
water hammer generated is taken care of.
xiii) Pipe supports shall be provided such that it shall be possible to remove any component of
pump, valves, strainers etc. without disturbing the rest of piping.
xiv) No loads should be transferred to the pump nozzles. Rigid supports shall be provided close
to the pump suction and discharge nozzles.
xv) All valves of dia. 8" and above size shall be provided with separate bottom supports so that
no load is transferred to the rest of the piping.
xvi) Fire water pumps and their drives shall conform to the enclosed specs, and data sheets. The
operator philosophy shall be as per piping and instrumentation diagram drawing.
4.1.4 Operators Room and Battery Room
An operator's room shall be provided within the pump house building. The operator room shall be
sized to accommodate the following facilities.
a. Seating requirements for two operators.
b. Control panel.
The operator room size shown in the bid drawings shall be considered only as a minimum
requirement. Vendor shall increase the same if required.
A battery room of adequate size shall be provided within the pump house for storing spare
batteries. The size of the battery room shown in drawing is min. requirement and may be increased
if required by the bidder.
Page 334 of 851

x71IIi1J~
~ ENGINEERS FOR
5gu£;125etvotrv .7,1721.1)
INDIA LIMITED
IA Govt of Incha Unclertaitogf FIRE HYDRANT SYSTEM
6-66-0074 Rev. 3
Page 7 of 9
i) A laboratory sink with water supply connection a battery charger unit and exhaust fan shall
be provided in the battery room. Acid proof tiles shall be provided on flooring and upto 1.0m
height on wall on all sides.
ii) Overall building design shall be such that standard grid system for structural design can be
developed. The building shall be designed as per enclosed design specs.
iii) The control room and battery room bldg. shall be constructed of Brick wall and RCC roof
and cement concrete granolithic flooring. Necessary doors and windows shall be provided so
that natural ventilation and lighting area shall not be less than one tenth of the floor area.
iv) External brick wall shall be min. 250 mm brick and intemal partition walls shall be 1/2 brick
thick.
v) The building shall be provided with dry distemper and white wash finished on inside
surfaces and weather proof snowcem wash on external surface.
vi) The plaster on intemal walls shall be minimum 12 mm thick for fair surface and 15 mm
thick for rough surface in cement mortar 1:6. Plaster on external walls shall be minimum
18mm thick in cement mortar 1:6.
vii) RCC roof slab of the building shall be treated with a six layer self finished bitumen felt
water proofing treatment over cement concrete slab in scope and finish with Pea gravel or
alternative water proofing of approved type.
viii) All windows and ventilators shall be conforming to IS: 1038 or IS: 1361 or 1081 with min
4mm thick glass.
ix) Ventilator shall be provided with bird mesh of suitable design.
x) All doors shall be min. 1.0m wide and 2.1m high with teak wood frame and panel/flush
doors shutters. Toilet doors shall be 0.75m wide and 2.1m high. The sizes of doors shall be
decided as per dimensions of critical equipment or panel.
xi) Adequate lighting shall be provided as per enclosed design and construction specifications.
The spillage from battery room shall be treated in neutralisation pit before disposal into nearest
storm water drain.
5.0 HYDRANT SYSTEM DISTRIBUTION NET WORK

5.1 System Design
5.1.1 The hydrant system has been envisaged to protect various hazardous and non hazardous facilities
as per layout drawing.
5.1.2 Hydrants shall be placed around process units/ tankages/ spheres area @30 m of perimeter.
Hydrants shall be placed @45 m c/c around utilities. Adequate coverage of equipments inside unit,
utilities, offsite shall be ensured.
5.1.3 Water cum foam monitors shall be provided around hydrocarbon storage tanks. Long range
monitors shall be provided to adequately cover the area at ground Level and higher elevations.
Isolation valves shall be provided in the network considering maintenance/isolation of network.
5.1.4 The fire water network of carbon steel as per Piping material specification shall be buried around
process units, pressurized storages and under road crossings. The network shall be above ground at
all other places on concrete sleepers. The fire water piping shall be cement lined carbon steel (As
per PMS) for sea water service.
5.1.5 The hydrant system net work sizing and pump house piping sizing shall be excluded from the
scope of bidder. This shall be based on single fire or two major fires to be fought simultaneously as
per complex requirement. This data is made available to the bidder in the Fire water layout
drawing and pump house and storage P&ID drawing. The bidder shall follow this data for
development of the piping layout for execution purpose.
Page 335 of 851

tll ENGINEERS FOR
$fg-ar22-eg INDIA LIMITED
Govt of Incha Underta.g) FIRE HYDRANT SYSTEM
6-66-0074 Rev. 3
Page 8 of 9
5.2 System Testing

The bidder shall arrange to demonstrate the availability of water as per design flow and required
pressure at the farthest end and major water consuming locations as per design requirements.
The bidder shall design the operation of the pumping system as mentioned in the drawing and
specifications. The operation of the pumps shall be demonstrated by the bidder for automatic
operation system conditions.
The system shall be deemed to be complete after the above tests are conducted to the satisfaction
of the owner by the bidder.
5.3 Construction Requirements
The fire water lines shall be generally laid above ground except around process units, road
crossings or at other places indicated in the drawings, in accordance with tender specifications.
The above ground line shall be laid on RCC pipe sleepers. The clearance between the
bottom of pipe and the finished grade level shall be kept between 300mm & 500mm. Necessary
expansion Ioops shall be provided on fire water line to take care of thermal stresses.
The underground pipes shall be provided with tape coating as per the specifications. The
excavation, backfilling, laying etc. for underground pipes shall be as per relevant specifications.
In open areas a minimum clear cover of 1.0m shall be provided above the buried line. At road
crossings a minimum of 1500mm (between road top and pipe top levels) shall be provided. NP4
class RCC pipe sleeves of one higher size than the fire water pipe shall be provided at road
crossings if required due to non-availability of required minimum cover or due to any other reason.
Fire water lines under RCC paved areas shall be laid in RCC pipe trenches filled with sand and
tape coated with removable covers. The width of the trench shall be adequate to permit
accessibility for installation and maintenance etc.
The necessary isolation valves, hydrants, monitors, and blind flanges etc. shall be provided on the
fire water lines as shown in the layout drawing. The valves and blind flanged ends of underground
water lines shall be installed in pits as per the drawing. The installation of hydrants and monitors
etc. shall also be as per the relevant drawing.
The fire water connections to various facilities as indicated in the drawings shall be provided from
the fire hydrant network.
The complete water distribution network shall be tested at hydrostatic pressure of 1.5 times design
pressure for a period of at least 4 hours. The procedure and other details of testing shall be as per
the specifications.
The testing of all other items/equipment systems shall be as per relevant specifications.
6.0 INSTRUMENTATION WORKS

A11 instrumentation works for control and auto operation shall be done as shown in the piping and
instrumentation diagram and enclosed specifications for instrumentation works. Plant air and
instrument air as required shall be supplied to contractor at the battery limit.
Restricted Orifice shall be as per TAC requirement.
7.0 ELECTRICAL WORKS

All electrical works shall be done in accordance with enclosed specification for electrical works,
and inputs as per battery limit parameters.
8.0 PAINTING
The above ground fire water piping shall be painted with fire red paint conforming to shade No.
536 of IS: 5 as per job painting specification. All other equipment and structures shall be painted in
accordance with relevant specifications.
Page 336 of 851

ENGINEEFZS FOR
fg-ar 2fàj-g
cwcort of,afoo.
INDIA LIMITED
(A Govf of InO. UndertaM,ogj FIRE HYDRANT SYSTEM
6-66-0074 Rev. 3
Page 9 of 9
9.0 RADIOGRAPHY
Vendor shall perform radiographic inspection of all types of piping joints subject to following
scope including providing all necessary equipments and whatsoever else required to perform the
work as per specification and instruction of the Engineer-in-Charge.
At least 10% of all welded joints shall be radiographed and shall be found in order. At least 50% of
welded joints selected for radiography shall be field joints.
10.0 DRAWINGS AND DOCUMENTS

The drawings enclosed with the tender document are for tender purpose only and are indicative of
general requirements and scope of work.
Contractor shall prepare detailed drawings and calculations to explain all salient features of their
design and submit along with their offer failing which the offer shall be liable for rejection.
Final construction shall be done as per approved construction drawings released during course of
execution of the work to be prepared by the contractor and approved by owner/EIL.
The cost of such design, calculation, documents and drawings to be furnished shall be included in
the price quoted for the work. The term `drawing' in the detailed specification shall imply the
drawing prepared by the contractor and approved by EIL.
Advance certified final drawings/calculation submitted by the Contractor shall be reviewed by
Owner/EIL. During such review, the Engineer-in-Charge may suggest certain comments
necessitating some modification in these documents. The contractor shall incorporate all such
modifications.
11.0 STATUTORY APPROVALS

Documents and drawings as required by TAC accredited agency complete in all respects shall be
prepared and submitted by the Contractor well ahead of time so that the actual
construction/commissioning of the work is not delayed for want of the approval/inspection by the
concerned authorities. The bidder shall give assistance and co-operation to the inspection
authorities for inspection work at various stages.
Any change/addition required to be made to meet the requirements of the statutory authorities shall
be carried out by the Contractor. The inspection and acceptance of the work by statutory
authorities shall, however, not absolve the Contractor from any of these responsibilities under this
contract.
Page 337 of 851

1512-ael c ENGINEERS CIVIL & STRUCTURAL WORKS 6-68-0009 Rev. 4
$iaei(lafaeg
iafen ewowasiJoorm
INDIA LIMITED
BRICK MASONRY
(A Go. of India UnciertakIng)
Page 1 of 9
7117W
fedff thwcIlltlich
CIVIL & STRUCTURAL WORKS
BRICK MASONRY
REVISED & REISSUED AS STANDARD

AL cs....9✓
4 10.03.16 MK AJS RS S CHANDA
SPECIFICATION
3 14.05.10 YPC PKM SC N DUARI
SPECIFICATION
2 06.04.00 REAFFIRMED & ISSUED SBJ SKP SCJ MI
Standards Standards
Rev. Prepared Checked Committee Bureau
No Date Purpose by by Convenor Chairman
Approved by
Page 338 of 851

ENGINEERS
INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0009 Rev. 4
(A Go. of Ind. Undertakm
BRICK MASONRY Page 2 of 9
Abbreviations:
BIS : Bureau of Indian Standards
IS Indian Standards
Members : Mr. Anurag Sinha

Mr. J K Bhagchandani
Mr. S K Naskar
Mr. V K Panwar
Mr. Charanjit Singh (Projects)
Mr. Ravindra Kumar (Construction)
Page 339 of 851

ENGINEERS
INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0009 Rev. 4
(A Gan of Incio Unclertaiong)
CONTENTS
1.0 SCOPE 4
2.0 REFERENCES 4
3.0 MATERIAL 4
5.0 CONSTRUCTION PROCEDURE .5
6.0 PAYMENT 8
Page 340 of 851

01fReit1ENGINEERS ,
CIVIL & STRUCTURAL WORKS

Oaeir Rift WINDIA LIMITED 6-68-0009 Rev. 4
laaan d"°0.0 Ginn of India Undertakag)
1.0 SCOPE
This specification establishes the materials, dressing, laying, joining, curing, workmanship
etc. for brick masonry works. Brick masonry shall also comply with all the requirements of
IS: 2212.
2.0 REFERENCES
2.1 BIS Codes
S.No. IS No. Title
1. IS:2212 Brick works- code of practice
2. IS: 2250 Code of practice for preparation and use of Masonry mortars
3. IS: 2750 Specification for Steel Scaffoldings
2.2 EIL specifications
6 68 0002 : Materials
- -
3.0 MATERIALS
Refer EIL Specification No. 6 68 0002. - -
4.1 Cement Mortar
Cement mortar shall meet the requirements of IS:2250 and shall be prepared by mixing
cement and sand by volume. Proportion of cement and sand shall be 1:6 (1 part of cement
and 6 parts of sand), or as directed by the Engineer-in-Charge/shown on the drawing, for
brick masonry of one brick thickness or more, while 1:4 cement mortar (1 part of cement
and 4 parts of sand) shall be used for brick masonry of half brick thickness. The sand being
used for mortar shall be sieved. The mortar shall be used as soon as possible after mixing
and before it has begun to set and in any case within initial setting time of cement after
water is added to the dry mixture. Mortar unused for more than initial setting time of
cement, shall be rejected and removed from the site of work.
4.1.1 Proportioning
The unit of measurement for cement shall be a bag of cement weighing 50 Kg and this shall
be taken as 0.035 cubic metre. Sand shall be measured in boxes of suitable size on the basis
of its dry volume. In case of damp sand, its quantity shall be increased suitably to allow for
bulkage.
4.1:2 Mixing
The mixing of mortar shall be done in a mechanical mixer operated manually or by power.
The Engineer-in-Charge may, however, permit hand-mixing as a special case, taking into
account the magnitude, nature and location of work. The Contractor shall take the prior
permission of Engineer-in-Charge, in writing, for using hand-mixing before the
commencement of work.
Page 341 of 851

ENGINEERS
*Ige..8 RA& INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0009 Rev. 4
eIWAIV AA3AMAI IA Gov of India UndertalAng)
4.1.2.1 Mixing in Mechanical Mixer
Cement and sand in specified proportions, by volume, shall be thoroughly mixed dry in a
mixer. Water shall then be added gradually and wet mixing continued for atleast one minute.
Care shall be taken not to add more water than that which shall bring the mortar to the
consistency of stiff paste. Wet mix from the mixer shall be unloaded on water-tight masonry
platform, made adjacent to the mixer. Platform shall be atleast 150 mm above the levelled
ground to avoid contact of surrounding earth with the mix. Size of the platform shall be such
that it shall extend atleast 300mm alround the loaded wet mix area. Wet mix, so prepared,
shall be utilised within initial setting time of cement after addition of water. Mixer shall be
cleaned with water each time before suspending the work.
4.1.2.2 Hand Mixing
The measured quantity of sand shall be levelled on a clean water-tight masonry platform and
cement bags emptied on top. The cement and sand shall be thoroughly mixed dry by being
turned over and over, backward and forward, several times till the mixture is of uniform
colour. The quantity of dry mix which can be consumed within initial setting time of cement
shall then be mixed with just sufficient quantity of water to bring the mortar to the
consistency of stiff paste.
5.0 CONSTRUCTION PROCEDURE
5.1 Soaking of Bricks
Bricks shall be soaked in water before use for a period that is sufficient for the water to just
penetrate the whole depth of bricks as well as to remove dirt, dust and sand. Proper soaking
of bricks shall prevent the suction of water from the wet mortar as otherwise mortar will dry
out soon and crumble before attaining any strength. The bricks shall not be too wet at the
time of use as they are likely to slip on mortar bed and there will be difficulty in achieving
the plumbness of wall as well as proper adhesion of bricks to mortar. The period of soaking
shall be determined at site by a field test by immersing the bricks in water for different
periods and then breaking the bricks to find the extent of water penetration. The least period
that corresponds to complete soaking, will be the one, to be allowed for in the construction
work.
The soaked bricks shall be stacked over a clean place, wooden planks or masonry platforms
to avoid earth, dirt being smeared on them. It shall be ensured that at the time of laying of
soaked bricks, they are skin dry.
5.2 Laying
5.2.1 Brick Work (one or more brick thickness)
Brick work (one or more brick thickness) shall be laid in English Bond unless otherwise
specified. Half or cut bricks shall not be used except when needed to complete the bond. In
no case the defective bricks shall be used.
A layer of average thickness of 10mm of cement mortar shall be spread on full width over a
suitable length of lower course or the concrete surface. In order to check and achieve
uniformity in masonry, the thickness of bed joints shall be such that four courses and three
joints taken consecutively shall measure equal to four times the actual thickness of the brick
plus 30mm. Each brick with frog upward, shall be properly bedded and set in position by
gently tapping with handle of trowel or wooden mallet. Its inside faces shall be buttered with
Page 342 of 851

ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
*laza 251eg
1.1771 ele.l =JCR./
INDIA LIMITED CIVIL & STRUCTURAL WORKS
IA GON of Inds UnOeffakfo9)
BRICK MASONRY
6-68-0009 Rev. 4
Page 6 of 9
mortar before the next brick is laid and pressed against it. After completion of the course, all
vertical joints shall be filled from top with mortar.
All brick courses shall be taken up truly plumb; if battered, the batter is to be truly
maintained. All courses shall be laid truly horizontal and vertical joints shall be truly
vertical. The level and verticality of work in walls shall be checked up at every one metre
interval.
The masonry walls of structures shall be carried up progressively, leaving no part one metre
lower than the other. If this cannot be adhered to, the brick work shall be raked back
according to bond (and not left toothed) at an angle not more than 45 degrees but raking
back shall not start within 60 cm of a corner. In all cases returns, buttresses, counter forts,
pillars etc. shall be built up carefully course by course, and properly bonded with the main
walls. The brick work shall not be raised more than fourteen (14) courses per day.
At the junction of any two walls, the bricks shall at each alternate course, be carried into
each of the respective walls so as to thoroughly unite the work.
The courses at the top of plinth and sills, at the top of the wall just below the soffit of the
roof slab or roof beam and at the top of the parapet, shall be laid with bricks on edge. Brick
on edge course shall be so arranged as to tightly fit under the soffit of the roof beam or roof
slab, restricting the mortar layer thickness upto 12mm. However, any gap between the
finished brick work and soffit of roof slab/beam shall be suitably sealed with the mortar.
5.2.2 Brick Work (half brick thickness)
For brick walls of half brick thickness, all courses shall be laid with stretchers. Wall shall be
reinforced with 2 nos. - 6mm diameter for steel reinforcement bars, placed at every fourth
course. The reinforcement bars, shall be straightened and thoroughly cleaned. Half the
mortar thickness for the bedding joint shall be laid first and for steel reinforcement, one on
each face of the wall, shall be embedded, keeping a side cover of 12mm mortar.
Subsequently, the other half of the mortar thickness shall be laid over the reinforcement
covering it fully.
The reinforcement bars shall be carried at least 150mm into the adjoining walls or RCC
columns. In case the adjoining wall being of half brick thickness, the length of bars shall be
achieved by bending the bars in plan. During casting of reinforced concrete columns, 6mm
dia. for steel reinforcement bar shall be placed at every fourth course of brick masonry. At
the junction of two walls, the brick shall, at each alternate course, be carried into each of the
respective walls so as to thoroughly unite the work. The brick masonry work shall not be
raised more than 14 courses per day.
Brick course under the soffit of beam or slab, shall be laid by restricting the mortar thickness
to 12mm. However, any gap between the finished brickwork and soffit of slab/beam, shall
be suitably sealed with the mortar.
5.2.3 Cavity Walls
Brick work in cavity walls shall be similar to general brickwork. It shall consist of one wall
of one or more brick thickness while the other wall shall be of half brick thickness at a clear
gap of 50mm. The brick work on either side of cavity shall conform to the specifications
already as stated in Cl. No. 5.2.1 and 5.2.2. At the base of the cavity wall, the walls shall be
solidly constructed upto 300mm above the ground level. The cavity wall shall be terminated
300mm below the soffit of roof slab/beam and the courses over this shall be continued as
solid brickwork.
Page 343 of 851

,31nrae_.1 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
tif5itu INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0009 Rev. 4
INR"eRtasr7 43,710570 (A Govt of India Under along)
Cavity should be continuous and free from obstructions. Mortar droppings shall be
prevented from falling down the cavity by the use of laths or by hayhands which shall be
drawn up the cavity as the work proceeds. Any mortar which may unavoidably fall on the
wall-ties, shall be removed daily and temporary openings shall be provided to permit the
daily removal of mortar droppings from the bottom of the cavity.
The outer and inner leaves shall be tied by means of wall ties. Ties shall be of for steel bars
of 8mm dia. 200 mm long with hooks at both the ends. These shall be placed not more than
750mm c/c horizontally and not more than 300mm vertically, and staggered. Additional ties
shall be provided near the openings. There shall at least, be 5 ties per square metre of surface
area of the wall. Ties shall be given a bituminous coat before placement, to protect them
from corrosion.
In order to keep the cavity dry, air slots shall be provided in the cavity walls at bottom as
well as top to the extent of 50 sq.cm area of vents to every 2.0 sq.metre area of the wall.
5.2.4 Circular Brick Work
The detailed specification for brick work covered under clauses 5.2.1 & 5.2.2 shall also
apply for circular brickwork. Bricks forming skew backs, shall be dressed or cut so as to
give proper radial bearing. Defects in dressing of bricks shall not be covered up by
extravagant use of mortar, nor shall the use of chips etc. be permitted.
The circular brick work shall be carried up from both ends simultaneously and keyed in the
centre. The bricks shall be flushed with mortar and well pressed into their positions so as to
squeeze out a part of their mortar and leave the joints thin and compact. All joints shall be
full of mortar and thickness of joints shall be between 5mm and 15mm.
5.3 Jointing
Joints shall be restricted to a width of 10mm with brickwork of any classification. All bed
joints shall be normal to the pressure upon them i.e. horizontal in vertical walls, radial in
circular brick masonry and at right angles to the face in the battered retaining walls. The
vertical joints in alternate courses shall come directly one over the other and shall be truly
vertical. Care shall be taken that all the joints are full of mortar, well flushed up. In case no
pointing is to be done, cement mortar shall be neatly struck as the work proceeds. The joints
in faces which are to be plastered or pointed shall be squarely raked out to a depth of 12mm
while the mortar is still green. The rake joints shall be brushed to remove loose particles.
After the day's work, the faces of the brick work shall be cleaned on the same day with wire
brush and all mortar droppings removed.
5.4 Curing
Green work shall be protected from rain or any other running water or accumulated water
from any source, by suitable means. Masonry work, as it progresses, shall be kept
thoroughly wet by sprinkling water at regular intervals, on all faces. Curing shall be done
after 24 hours of completion of day's work as per IS:2212.
5.5 Staging/Scaffolding
5.5.1 Staging/scaffolding shall be properly planned and designed by the Contractor. Use of only
steel tubes is permitted for staging/scaffolding. Design of staging/scaffolding shall be
submitted for approval of the Engineer-in-Charge, before commencement of work.
Single scaffolding having one set of vertical support, shall be used and other end of the
horizontal scaffolding member shall rest in a hole provided in the header course. The
Page 344 of 851

ENQNEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
$11g-aImiot
r f&151-'eg INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0009 Rev. 4
Aornfoom,y,moso '"Go. of India Undertaktng)
support shall be sound and strongly clamped with the horizontal pieces over which the
scaffolding planks shall be fixed. The holes left in the masonry work for supporting the
scaffolding shall be filled and made good with plain cement concrete of grade 1:2:4 during
plastering. Suitable access shall be provided to the working platform area. The scaffolding
shall be strong enough to withstand all loads likely to come upon it and shall also meet the
requirements specified in IS:2750.
Double scaffolding shall be provided for pillars less than one metre in width or for the first
class masonry or for a building having more than two storeys.
Following measures shall also be considered during erection of the scaffolding/ staging:
a) Sufficient sills or underpinnings, in addition to base plates, shall be provided,

particularly, where scaffoldings are erected on soft grounds.
b) Adjustable bases to compensate for uneven ground shall be used.
c) Proper anchoring of the scaffolding/staging at reasonable intervals shall be provided in

each direction with the main structure wherever available.
d) Horizontal braces shall be provided to prevent the scaffolding from rocking.
e) Diagonal braces shall be provided continuously from bottom to top between two
adjacent rows of uprights.
f) The scaffolding/staging shall be checked at every stage for plumb line.
g) Wherever the scaffolding/staging is found to be out of plumb line, it shall be dismantled

and re-erected afresh. Efforts shall not be made to bring it in line with a physical force.
h) All nuts and bolts shall be properly tightened and care shall be taken that all the
clamps/couplings are firmly tightened to avoid slippage.
i) Erection work of a scaffolding/staging, under no circumstance shall be left totally to

semiskilled or skilled workmen and shall be carried out under the supervision of
Contractor's technically qualified civil engineer.
5.5.2 For smaller works or works in remote areas wooden ballies may be permitted for
scaffolding/staging by the Engineer-in-Charge at his sole discretion. The contractor must
ensure the safety and suitability of such works as described under clause 5.5.1 above.
5.6 Embedment of Fixtures
All fixtures, pipes, conduits, holdfasts of doors and windows etc. required to be built in
walls, shall be embedded in plain cement concrete block of grade 1:2:4, at the required
positions, as the work proceeds.
6.0 PAYMENT
This clause shall apply to Item Rate tender only.
6.1 General
The payment of brick masonry shall be inclusive of all labour, material, scaffolding/staging
sampling and testing, soaking of bricks, laying of bricks, raking of joints, cutting of bricks,
providing recesses and making rectangular or round openings, sealing the gap between brick
Page 345 of 851

15dfRele-1 grim ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
4igelt faWeg INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0009 Rev. 4
IA GoA Ind* Undertaking)
masonry and soffit of beam/slab with and including cement mortar, curing, making of
masonry platform for unloading the wet mix, embedding the fittings/fixtures including
providing PCC (1:2:4) etc, all as specified for all heights and depths. Deduction for
rectangular or circular openings, shall be done as per relevant BIS Codes.
6.1.1 Payment for brick masonry works of one or more brick thickness, including circular
brickwork, shall be made on cubic metre basis of the work done.
6.1.2 Payment for half brick masonry work shall be made on square metre basis on the area of
work done and shall also include the cost of supplying and fixing of reinforcement bars in
position.
6.1.3 Payment for forming the cavity shall be in square metres and shall include the cost of laying
of bitumen coated for steel ties in position, labour required for keeping the cavity clear,
providing air slots etc.
Page 346 of 851

011 ENGINEERS WELDING SPECIFICATION FOR
$tg INDIA LIMITED 6-77-0001 Rev. 4
...ARITA I iA Govt of Incha Ifficlertakong) FABRICATION OF PIPING
Page 1 of 40
‘-r91,:k111 * fffq f4F-InkkrT
WELDING SPECIFICATION FOR

FABRICATION OF PIPING
ft (.
4 8/07/14 P CHOWDHARY S GHOSAL P P LAHIRI S CHANDA
SPECIFICATION
3 28/12/07 MPJ VRK VRK VC
SPECIFICATION
REVISED TO INCLUDE CHECK
2 08/02/32 GC RN TVD
RADIOGRAPHY
1 15/05/98 MPJ TVD JRP AS
SPECIFICATION
ISSUED AS STANDARD
0 31/07/87 TVD TVD JRP AK
SPECIFICATION
Standards Standards
Date Purpose Prepared by Checked by
No Convenor Chairman
Approved by
Page 347 of 851

ENGINEERS
WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
$t&.1( fatMeg > INDIA LIMITED
1.~ "WIWS MI,R.S. I
•
Govt ot Undeftak.3)
FABRICATION OF PIPING Page 2 of 40
ABBREVIATIONS
ASNT American Society for Nondestructive Testing
AWS American Welding Society
AUT Automated Ultrasonic Testing
BPVC Boiler & Pressure Vessel Code
CFH Cubic Feet per Hour
DWDI Double Wall Double Image
DWSI Double Wall Single Image
GTA Gas Tungsten Arc
GTAW Gas Tungsten Arc Welding
IQI Image Quality Indicator
NDT Non Destructive Testing
PQR Procedure Qualification Record
RT Radiographic Testing
SMAW Shielded Metal Arc Welding
SWSI Single Wall Single Image
UTS Ultimate Tensile Strength
Welding Standards Committee
Convenor : Mr. P. P. Lahiri (SMMS)
Members : Mr. R.Nanda(Piping)

Mr. S.Ghosal (SMMS)
Mr. K. Anjaneyulu (SED)
Mr. D. Jana (Construction)
Mr. R.K. Singh (Inspection)
Mr. Raj Kishore (Pipeline)
Page 348 of 851

ENGINEERS
INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
54,41 I ∎A rX.
Page 3 of 40
CONTENTS
1.0 GENERAL 4
2.0 APPLICABLE CODES & STANDARDS 4
3.0 BASE METAL 5
4.0 WELDING CONSUMABLES 5
5.0 SHIELDING & PURGING GAS 5
6.0 EQUIPMENTS & ACCESSORIES 6
7.0 WELDING PROCESS 6
8.0 EDGE PREPARATION 6
9.0 ALIGNMENT & SPACING 7
10.0 WEATHER CONDITIONS 7
11.0 WELDING TECHNIQUE 7
12.0 HEAT TREATMENT 8
13.0 CLEANING OF THE WELD JOINT 10
15.0 REPAIRS OF WELDS 14
16.0 DOCUMENTS TO BE SUBMITTED BY CONTRACTOR (4 COPIES EACH) 14
EXHIBIT — A: ELECTRODE QUALIFICATION TEST RECORD 16
EXHIBIT — B: STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION 20
EXHIBIT-D: FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) 24
EXHIBIT — E: FORMAT FOR MANUFACTURER'S RECORD FOR WELDER OR WELDING
OPERATOR QUALIFICATION TESTS 27
EXHIBIT — F: RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD FOR PIPE
WELDING 29
EXHIBIT — G: WELDER'S IDENTIFICATION CARD 30
EXHIBIT — H: TYPE OF SOURCE AND FILMS TO BE USED FOR RADIOGRAPHY 31
EXHIBIT — I: AUTOMATED ULTRASONIC TESTING 32
Page 349 of 851

ENGINEERS
$vg 22egL INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
Go.i ol trxt. Undenalong>
1.??7 ".5.,151,1,77141
Page 4 of 40
1.0 GENERAL
This specification shall be followed for the fabrication of all types of welded joints of piping
system within the battery limits of the plant. This specification shall be used in conjunction with
Welding Specification Charts.
The welded pipe joints shall include the following:
a) A11 pipe joints, longitudinal butt welds, circumferential butt welds and socket welds.
b) Attachments of forgings, flanges and other supports to pipes.
c) Welded manifold headers and other sub-assemblies.
d) Welded branch connections with or without reinforcing pads.
e) Join,ts in welded/fabricated piping components.
f) The attachments of smaller connections for vents, drain drips and other instrument tappings.
Any approval granted by the Engineer-in-Charge or Owner's inspector, shall not relieve the
Contractor of his responsibilities and guarantee.
This specification shall not be applicable for welding of pipelines for transportation of liquid
petroleum , gas and other similar products in on shore and off shore.
2.0 APPLICABLE CODES & STANDARDS

A11 welding work, equipments for welding, heat treatment, other auxiliary functions and the
welding personnel shall meet the requirements of the latest editions of the following accepted
standards and procedures unless otherwise specified in the Welding Specification Chart and the
Technical Notes attached thereof. In the case of conflicting requirements, the requirements
mentioned in Welding Specification Chart/Technical Notes shall be applicable.
i) ASME B31.3: Process Piping, ASME Code for Pressure Piping, B31
ii) ASME Boiler & Pressure Vessel Code, Sec II Part C: Specifications for Welding Rods,
Electrodes and Filler metals.
iii)ASME Boiler & Pressure Vessel Code, Section V: Non destructive examination.
iv) ASME Boiler & Pressure Vessel Code, Section IX: Welding and Brazing Qualifications.
v) The Indian Boiler Regulations I.B.R.
vi) 6-44-0016: Standard Specification for Non-Destructive Examination Requirements of

Piping.
vii) 6-77-0005: Welding Specification charts for Piping Classes.
viii) API 582: Welding Guidelines for the Chemical, Oil, and Gas Industries.
In the event of any differences due to the additional requirements mentioned in this
specification, over and above those obligatory as per codes, this specification shall be binding.
Page 350 of 851

,31
-1f4zre? ENGINEERS
92e INDIA LIMITED
t. Go, d indu ltneipd*mg)
117,I :151 ,11,1,33.1
3.0 BASE METAL

3.1 In general, use of carbon steel, alloy steel and stainless steel is envisaged. The details of the
material specifications are given in the Welding Specification Chart.
3.2 The Contractor shall provide the manufacturer's test certificates for every batch of the
materials supplied by him.
4.0 WELDING CONSUMABLES

4.1 The Contractor shall provide, at his own expense, all the welding consumables necessary for
the execution of the job such as electrodes, filler wires, argon etc. and these should bear the
approval of the Engineer-in-Charge.
4.2 The welding electrodes and filler wires supplied by the Contractor shall conform to the class
specified in the Welding Specification Chart. The materials shall be of the make approved by
the Engineer-in-Charge.
4.3 Electrode qualification test records should be submitted as per the Exhibit-A (attached) in
respect of the electrodes tested by the Contractor, for obtaining the approval of the Engineer-
in-Charge. It shall record the minimum test results required for classification of welding
consumables as per ASME Section II part C.
4.4 The Contractor shall submit batch test certificates from the electrode manufacturers.
4.5 A11 electrodes shall be purchased in sealed containers and stored properly to prevent
deterioration. The electrodes removed from the containers shall be kept in baking ovens at
temperatures recommended by the electrode manufacturer. "Out of the oven time" of
electrodes, before they are consumed, 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.
4.6 All low hydrogen type of electrodes and others, shall be baked as per manufacturers
recommendation and stored in holding ovens at temperature recommended by the
manufacturer.
4.7 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.
5.0 SHIELDING & PURGING GAS

5.1 Argon gas used in GTA welding for shielding purposes shall be minimum 99.995% pure. The
purity of the gas shall be certified by the manufacturer. The rate of flow for shielding
purposes shall be established through procedure qualification tests.
5.2 Argon gas with a purity level of minimum 99.995% shall be used for purging.
5.3 When GTAW process alone or a combination of GTAW and SMAW processes is
recommended for the production of a particular joint, the purging shall be maintained during
the root pass and for the first filling pass to minimize oxidation on the inner side of th,; pipe,
unless otherwise specified in Welding Specification Chart.
5.4 Initial purging shall be maintained for sufficient period of time so that at least 4-5 times the
volume between the dams is displaced, in order to completely remove the entrapped air. In no
case should the initial purging period be less than 10 minutes. High gas pressure should be
avoided.
Page 351 of 851

~e? ENGINEERS
$#@LI1 22eg INDIA LIMITED
(A Go,1 o■ indta udeftak.nw
5.5 After initial purging, the flow of the backing gas should be reduced to a point where only a
slight positive pressure prevails.
5.6 Gas backing (purging) is not required for socket type of welded joints.
5.7 Dams, used for conserving inert gas during purging, shall be removed after completion of the
welding, and shall be accounted for. Wherever, removal of dams is not possible after welding,
use of water-soluble dams should be made.
6.0 EQUIPMENTS & ACCESSORIES

6.1 A11 the equipment for performing the heat treatment, including transformers, thermocouples,
pyro-meters, automatic temperature recorders (with suitable calibration arrangement etc.) shall
be provided by the Contractor at his own expense along with certificate traceable to national
/international standard.
6.2 Contractor shall make necessary arrangements at his own expense, for providing the
radiographic equipments, radiographic films, processing equipment all other darkroom
facilities and all the equipments/materials required for carrying out the dye-penetrant/magnetic
particle test/ultrasonic testing.
7.0 WELDING PROCESS

7.1 The welding processes to be employed are given in the Welding Specification Chart.
7.2 In addition to Shielded Metal Arc Welding Process (SMAW) and Gas Tungsten Arc Welding
Process (GTAW), Welding of various materials under this specification may be carried out
using one or more of the following processes with the approval of the Engineer-in-Charge.
Gas Metal Arc Welding (GMAW)

Flux Cored Arc Welding (FCAW)
Submerged Arc Welding (SAW)
7.3 The Welding procedure could be employed for a particular joint only after duly qualifying the
welding procedure to be adopted.
8.0 EDGE PREPARATION

8.1 General
The edges to be welded shall be prepared to meet the joint design requirements by any of the
following methods recommended:
(a) Carbon Steel

Gas cutting, machining or grinding methods shall be used. After gas cutting, oxides
shall be removed by chipping or grinding.
(b) Low Alloy Steels (containing up to 5% Chromium).

Gas cutting, machining or grinding methods shall be used. After gas cutting,
machining or grinding shall be carried ozit on the cut surface.
(c) High alloy steel (> 5% Chromium) and stainless steels, nickel alloys:
Plasma cutting, machining or grinding methods shall be used. After plasma cutting,
cut surfaces shall be machined or ground smooth.
Page 352 of 851

k31 ENGINEERS
$1gar 02-"
dg INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
lA Gni, Unelmtaiang)
Page 7 of 40
8.2 Cleaning
(a) The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust,
oxides, sand, earth and other foreign matter. The ends shall be completely dry before
the welding commences.
(b) On completion of each run, craters, welding irregularities, slag etc., shall be removed
by grinding and chiseling. Wire brushes used for cleaning stainless steel joints shall
have stainless steel wires and the grinding wheels used for grinding stainless steel
shall be of a suitable type. Separate grinding wheels and wire brushes should be used
for carbon steels and stainless steels.
9.0 ALIGNMENT & SPACING

9.1 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.
9.2 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.
9.3 For pipes of wall thickness 5 mm and above, the ends to be welded shall be secured in position
with the aid of couplers, yokes and 'C' clamps, 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 the satisfaction of the
Engineer-in-Charge.
9.4 Tack welds, for maintaining the alignment, of pipe joints shall be made only by qualified
welders using approved WPS. Since the tack welds become part of the final weldment they
shall be executed carefully and shall be free from defects. Defective tack welds must be
removed prior to the actual welding of the joints.
9.5 Tacks should be equally spaced. Minimum number of tacks shall be:
3 tacks - for 2 1/2" and smaller dia. pipes.

4 tacks - for 3" to 12" dia. pipes.
6 tacks - for 14" and larger dia. pipes.
9.6 Welding shall commence only after approval of fit-up by the Engineer-In-Charge.
10.0 WEATHER CONDITIONS

10.1 The parts being welded and the welding personnel should be adequately protected from rain
and strong winds. In the absence of such a pritection no welding shall be carried out.
10.2 During field welding using GTAW process, particular care shall be exercised to prevent any
air current affecting the welding process.
11.0 WELDING TECHNIQUE

11.1 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 2.5 mm
diameter (12 SWG) but in any case not greater than 3.25 mm (10 SWG).
Page 353 of 851

~:Te? ENGINEERS
.g
$ wINDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
(A Govt ot ,rtdo Undettalono
(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 3mm max. 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.
11.2 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 4 mm in diameter for
stainless steels 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 joints shall be completed with a cover layer that would affect good fusion at the
joint edges and a gradual notch free surface.
(d) Each weld joint shall have a workmanship like finish. Weld identification work 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.
11.3 Dissimilar Welds
Where welds are to be produced between carbon steels and alloy steels, preheat and post weld
heat treatment requirements shall be those specified for corresponding alloy steels and filler
wire/electrodes shall correspond to ER70S-2 or E-7016/7018 type. For welds between two
dissimilar Cr-Mo low alloy steels, preheat and post weld heat treatments shall be those
specified for higher alloy steel and electrodes used shall correspond to those specified for steel
of lower alloy content. For carbon steel or alloy steel to stainless welds, use of filler
wire/electrodes E/ER-309/ERNiCr-3/E Ni Cr Fe-3/ENiCrMo-3 shall be made. The welding
procedure, electrodes/filler wires to be used shall be approved by the Engineer-in-Charge.
12.0 HEAT TREATMENT

12.1 Preheating
(a) No welding shall be performed without preheating the joint to 10°C (50°F) when the
ambient temperature is below 10 degree.
Page 354 of 851

t.31 ENQNEERS
IC:Wg
1.1177,iveYDT± 3.11,10.T311
A no, 1d Indu Unt1Prtak.)
Page 9 of 40
(b) Preheating requirements for the various materials shall be as per the Welding
Specification Chart attached.
(c) Preheating shall be performed using resistance or induction heating methods.

Preheating by gas burners, utilizing oxy-acetylene or oxy-propane gas mixtures, with
neutral flame may also be carried when permitted by the Engineer-in-Charge.
(d) Preheating shall extend uniformly to at least three times the thickness of the joint, but
not lens than 25 mm, on each sides of the weld.
(e) Preheating temperature shall be maintained over the whole length of the joint during
welding. Temperature recorders shall be provided by the Contractor to record the
temperature during alloy steel welding. For carbon steel piping, preheat temperature
shall be ensured by use of temperature indicating crayons, pyrometers or other suitable
means.
12.2 Post Heating
In case of alloy steel materials such as Cr-Mo steels, if the post weld heat treatment is not
performed immediately after welding, the weld joint and adjacent portion of pipe, at least 50
mm on either side of weld, shall be uniformly heated to 300°C. This temperature shall be
maintained for half an hour minimum, and then wrapped with mineral wool before allowing it
to cool to room temperature. If the Post Heating temperature specified in the Welding
Specification Charts exceeds 300°C, the same shall be followed. Similarly, if the welding
specification chart specifies post-heat time, the same shall be applicable. Post weld heat
treatment as specified in the Welding Specification Chart shall be carried out later on.
12.3 Post Weld Heat Treatment (PWHT )
(a) Post weld heat treatment, wherever required for joints between pipes, pipes and
fittings, pipe body and supports shall be carried out as per the welding specification
chart, applicable codes standards and the instructions of the Engineer-in-Charge. In
this regard procedure qualification to be done before carrying out PWHT in
production welds
(b) The Contractor shall submit for the approval of the Engineer-in-Charge, well before
carrying out actual heat treatment, the details of the post weld heat treatment
procedure as per Exhibit B attached, that he proposes to adopt for each of the
materials/assembly/part involved.
(c) Post weld heat treatment shall be done in a furnace or by using an electric resistance or
induction-heating equipment, as decided by the Engineer-in-Charge.
(d) While carrying out local post weld heat treatment, technique of application of heat
must ensure uniform temperature attainment at all points of the portion being heat-
treated. Care shall be taken to ensure that width of heated band over which specified
post weld heat treatment temperature attained is at least that specified in the relevant
applicable standards/codes. Control of temperature shall be done using
microprocessor/computer controlled system. The desired time-temperature cycle shall
be entered into the microprocessor/computer.
(e) Throughout the cycle of heat treatment, the portion outside the heated band shall be
suitably wrapped under insulation so as to avoid any harmful temperature gradient at
the exposed surface of pipe. For this purpose temperature at the exposed surface
should not be allowed to exceed 50% of the peak temperature.
Page 355 of 851

k31 ENGINEERS
$stga. t INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
1.11WS ",
(1,77 2191~70 (A Gom. of Indo Undertalong)
(f) The temperature attained by the portion under heat treatment shall be recorded by
means of thermocouple pyrometers. Adequate number of thermocouples should be
attached to the pipe directly at equally spaced location along the periphery of the pipe
joint. The minimum number of thermocouples attached per joint shall be 1 up to 6"
dia., 2 up to 10" dia. and 3 for 12" dia. and above. However, the Engineer-in-Charge
can increase the required number of thermocouples to be attached if found necessary.
(g) Automatic temperature recorders, which have been suitably calibrated, shall be
employed for measuring & recording temperature. The time-temp graph shall be
submitted to Engineer-in-Charge immediately on completion of Stress Relieving
Cycle The calibration record of each recorder should be submitted to the Engineer-in-
Charge prior to starting the heat treatment operations and his approval should be
obtained.
(h) Manufacturer's test certificate shall be submitted for the thermocouples materials and
record shall be maintained by the Contractor.
Immediately on completion of the Heat Treatment, the Post Weld Heat Treatment
charts/records along with the hardness test results on the weld points, wherever
required as per the Welding Specification Chart, shall be submitted to Engineer-in-
Charge for his approval.
(i) Each weld joint shall bear a unique identification number, which shall be maintained
in the piping sketch to be prepared by the Contractor. The weld joint identification
number should appear on the corresponding post weld heat treatment charts. The
chart containing the identification numbers and piping sketch shall be submitted to the
Engineer-in-Charge in suitable folders.
13.0 CLEANING OF THE WELD JOINT

All weld joints shall be free from adherent weld spatters slag, swarf, dirt or foreign matter.
This can be achieved by brushing. For stainless steels, brushes with only stainless steel
bristles shall be used.

14.1 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 accord 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 is in progress for (but not limited to) the
following objectives:
i) To check the conformance to relevant standards and suitability of various

welding equipments and the welding performance.
ii) To witnes„ the welding procedure qualification.
iii) To witness the welder performance qualification.
iv) To check whether shop/field welding being executed is in conformity with the
relevant specifications and codes of practice followed in piping construction.
Page 356 of 851

ot ENGINEERS
IMf5tg INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
Gou ■nau 11,d.rtak■ nT
I 4,11,77 of
Page I I of 40
(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, as decided by the Engineer-In-Charge.
14.2 Welding Procedure Qualification
Welding procedure qualification shall be carried out in accordance with the applicable
requirements of ASME Sec. IX latest edition and/or other applicable codes and the job
requirements. The contractor shall submit the welding procedure specification in format as per
Exhibit-C (attached) immediately after the receipt of the order. Owner's inspector will review,
check and approve the welding procedure submitted and shall release the procedure for
qualification tests. The procedure qualification test shall be carried out by the Contractor at
his own expense. A complete set of test results in the format as per Exhibit-D attached) shall
be submitted to the Owner's inspector for his approval immediately after completing the
procedure qualification test and at least 2 weeks before the commencement of actual work.
Standard test as specified in the code shall be carried out in all cases. In addition to these tests,
other tests like macro/micro examination, hardness tests, dye penetrant examination, charpy V-
notch, Corrosion tests, impact tests etc. shall be carried out on specimens depending upon the
type of base material, operating conditions and requirements laid down in the detailed
drawings and specifications. It shall be the responsibility of the Contractor to carry out all the
tests required to the satisfaction of the Owner's inspector.
14.3 Welder's Qualification
(a) Welders shall be qualified in accordance with the ASME Section-IX or other
applicable codes. The Owners inspector reserves the right to witness the test and
certify/approve the qualification of each welder separately. Only those welders who
have been approved by the Owner's Inspector shall be employed for welding.
Contractor shall submit the welder qualification test reports in the format as per
Exhibit-E (attached) and obtain express approval before commencement of work.
It shall be the responsibility of
Contractor to carry out qualification tests of welders. For welding of the steam piping,
falling under the purview of Indian Boiler Regulations, only those welders with IBR
Certification, qualified by Boiler Inspectorate, and acceptable to the local Boiler
Inspector authority shall be employed.
(b) The welders shall always have in their possession, an identification card containing
information contained in Exhibit-G and shall produce it on demand by the Engineert-
In-Charge or his representative. It shall be the responsibility of the Contractor to issue
the identify cards after it has been duly certified by the, owner's Inspector.
(c) No welder shall be permitted to work without the possession of the identify card.
(d) If a welder is found to perform a type of welding or in a position for which he is not
qualified, he shall be debarred from doing any further work. All welds performed by
an unqualified welder shall be cut and redone by a qualified welder at the expense of
the Contractor
14.4 Visual Examination
Visual Examination of all welds shall be carried out as per the 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, shrinkage 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.
Page 357 of 851

ENGINEERS
INDIA L1MITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
INRf "Mlfi?1,12 .10,1,311 Go,1 d inda Undertak.91 FABRICATION OF PIPING
Page 12 of 40
14.5 Radiographic Examination
(a) The Radiographic Examination procedures to be adopted shall be submitted by the

contractor as per Exhibit-F and shall be got approved from the Owner's Inspector
prior to employment. A person qualified to ASNT Level-II or ASNT Level-III in
Radiographic testing shall prepare the procedure. The Radiography Procedure shall be
established to demonstrate that the required sensitivity can be consistently achieved
under the most unfavorable parameters (e.g. source to film distance, geometric
unsharpness, thickness etc.). The radiographic technique and procedure adopted shall
conform of the requirements mentioned in Article 2 as well as Article 22 of ASME
Sec.V. The IQI sensitivity obtained shall be equal to or better than the requirements
mentioned in Article 2 of ASME Sec.V. Source nide penetrameter shall be used in
establishing radiographic procedure/ technique. The acceptance criteria shall be as per
the relevant codes of Fabrication and over riding requirements if mentioned else where
in the technical specifications of the contract. The Contractor shall be responsible for
carrying out Radiography; rectification of defects and re-radiography of welds
repaired/rectified at his cost.
(b) The extent of Radiography shall be as per specifications to be supplied to the
Contractor. For welds between dissimilar materials, the extent of Radiographic
Examination shall be the more stringent of the two recommended for the materials
being welded. Wherever random Radiography is called for, in a particular piping
class, the dissimilar materials weld joints shall essentially be included.
(c) Type of Radiation source and film to be used shall be as per Exhibit-H for carrying out
radiographic examination. However if specifications (as given else where in the
contract) for some critical material require usage of X-Radiation, then Radiography
shall be done using X-Rays only.
(d) The Contractor shall fulfill all the statutory and owner's safety requirements while
handling X-ray and Gamma-ray equipments.
(e) In case of random radiography, the joints for Radiography shall be selected by the
Owner's Inspector and the Radiography shall be performed in his presence, if he
instructs the contractor to do so. The contractor shall furnish all the radiographs, to the
Owner's Inspector immediately after processing along with evaluation by a person
qualified to ASNT Level-II in Radiographic testing, inline with Article 2 of ASME
Sec.V. The certificate of ASNT/ISNT Level II qualification of the NDT personnel
shall be submitted to owner's inspector for his approval prior to start ofjob.
(f) The Contractor shall provide the Owner's Inspector, all the necessary facilities at site
such as a dark room with controlled temperature, illuminator (viewer) suitable for
varying densities, a duly calibrated electronic densitometer with batteries, magnifying
glass, tracing papers, ruler, marking pencils etc. to enable him to review the
radiographs.
(g) Where random radiography is specified, the first weld of each welder shall be
completely radiographed. In the case of pipe of size 6" and below, the first two welds
shall be completely radiographed.
(h) 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
the of 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.
(i) 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
Page 358 of 851

■
31 ENGINEERS
$1g-zir 2ffl-eg INDIA UMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
(4,7757, IA Govt t>f IrWit IlrOwtalonW
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.
(1) Contractor shall quote rates for X-ray as well as Gamma Ray for joints indicated to be
radiographed by X-ray in Table of Exhibit-H.
14.5.1 Check shots
(a) Owner / Engineer- in- charge or his representative shall select 5% of the total joints
radiographed on a day for check shots. Contractor shall carry out check shots as
directed.
(b) Weld profiles of check shots shall be compared with weld profile observed in the
earlier Radiographs. In the event of any one variation in the check shots and earlier
Radiographs, contractor shall re-shoot the entire lot of joints radiographed by
particular Radiography agency on the particular date. All the re-shot films shall be
compared with the originally submitted films.
14.6 Liquid Penetrant and Magnetic Particle Examination
(a) Whenever such tests are specified, the tests shall be carried out on joints chosen by the
Owner's inspector, as per ASME Section V article 6 and 7 respectively. The tests are
to be performed by a person possessing a valid ASNT/ISNT Level-II qualification in
the method being used.
(b) For austenitic stainless steels and other nonmagnetic materials, liquid (dye) penetrant
test shall be carried out. For carrying out this test, the materials shall be brought
within a temperature limit of 15° to 50°C.
14.7 Automated Ultrasonic examination (AUT)
(a) Automated ultrasonic testing (AUT) can be used in substitution of radiographic

examination when permitted by ASME B31.3 code case 181 shall require prior
approval of Engineer-in-charge as detailed in EXHIBIT-I.
(b) The automated ultrasonic testing (AUT) procedure to be adopted shall be submitted by
the CONTRACTOR as per EXHIBIT-I and get it approved from EIL/OWNER.
(c) The CONTRACTOR shall make all the arrangements for the Automated Ultrasonic
Testing of work at his expense. The CONTRACTOR shall furnish all the reports to the
EIL/OWNER, immediately after examination together with the corresponding
interpretation reports on the approved format. The details of the AUT reports along
with the joint identification number shall be duly entered in a register and signed by
the CONTRACTOR and submitted to the EIL/OWNER for approval. The
EIL/OWNER will review all the Automatic Ultrasonic Testing records of welds and
inform the CONTRACTOR to those welds, which are unacceptable. The decision of
the COMPANY shall be final and binding in this regard.
(d) In addition, Radiography examination shall be carried out when in the opinion of
EIL/OWNER, Radiography inspection is required to confirm or clarify defects
indicated by Automated Ultrasonic examination. Repaired welds and transition spool
piece weld joints shall be additionally examined by radiography if it is examined by
automated ultrasonic testing.
(e) The automated ultrasonic testing system used for inspecting welds shall be approved by
EIL/OWNER.
Page 359 of 851

ENGINEERS
$12_.11 INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
1.??, 2A41,72 I A Govt of INA43 Undertaloog)
14.8 Hardness Test
Hardness requirements for welds shall be as per the Welding Specification Chart/Non
Destructive Examination Specification attached elsewhere in the contract. Hardness testing
shall be carried out by Vickers Hardness Tester during welding procedure qualification and
shall be cross sectional. For production welds, hardness testing shall be carried out by portable
digital hardness testers. Poldi hardness tester shall not be permitted. Contractor shall produce
documentary evidence/calibration certificate to the Owner's Inspector and obtain approval of
the hardness testing equipment.
14.9 Proof Tests
Hydrostatic and pneumatic tests shall be performed as per the requirements laid down by
respective flushing and Testing specification/applicable codes to demonstrate the soundness of
the welds. The tests shall be conducted after fulfilling the requirement of visual examinations
radiography etc., and after the entire work has been certified by the Owner's inspector to be fit
for being subjected to such tests.
15.0 REPAIRS OF WELDS

(a) No repair shall be carried out without prior permission of the Owner's inspector.
(b) Repairs and/or work of defective welds shall be done in time to avoid difficulties in
meeting the construction schedules.
(c) 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. The repaired welds shall be subjected, as a minimum requirement to the
same testing and inspection requirements as the original weld.
(d) The number of times repair welding can be permitted for the same weld shall be
governed by the standard specification, 6-44-0016.
(e) When the entire joint is judged unacceptable, the welding shall be completely cut and
edges suitably prepared as per required alignment tolerances. The rewelded joint shall
again be examined following standard practices.
16.0 DOCUMENTS TO BE SUBMITTED BY CONTRACTOR (4 COPIES EACH)
(a) Electrode and Welding Consumable Qualification Records as per Exhibit-A, for the
Welding Consumables tested and approved for the work.
(b) Batch Test Certificates, for the Electrodes used, obtained from the Electrode
Manufacturers.
(c) Proposed Heat Treatment Procedure as per Exhibit-B.
(d) Heat Treatment Charts.
(e) Weld joint hardness test results.
(f) Welding Procedure Specifications as per Exhibit-C immediately after receipt of the
order.
(g) Welding Procedure Qualification records as per Exhibit-D.
Page 360 of 851

ENGINEERS
IA Go, ■.4 lnda UntWialong
HIR7f
(h) Welder Performance Qualification records as per Exhibit-E immediately after

conducting Welder Qualification Tests.
(i) Radiography Procedure as per Exhibit-F and other NDT procedures.
Radiographic test Report along with Radiographs and other NDT reports.
(k) Piping Sketch (Isometric) giving all the details regarding the pipe specifications,
welded joints, joints radiographed magnetic particle, tested, ultrasonic tested,
penetrant tested, joints heat treated, WPS used, welders identification number, etc.
Page 361 of 851

IMWg. INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4

IA Govt d indo Undertahang)
EXHIBIT — A: ELECTRODE OUALIFICATION TEST RECORD
Date:
Test started on:
Test completed on:
A: DETAILS
CONTRACTOR
Tested at (Site name)
Code of Reference (used for testing)
Special Requirements (if any)
S1. Classificat Size of Batch Manufacturer Intended for Remarks

No. ion of electrode no. name/brand/date welding in
electrode of manufacture position
B: All-weld Tensile Test

Base Material used
Buttering used : Yes/No
Pre-heat temperature
Inter-pass temperature
Post weld heat treatment details
Visual examination
Radiographic examination results
Tensile test results
Sheet 1 of 4
Page 362 of 851

ENGINEERS
fax INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
■A GAA ol ind“, UndeAak■N»
Page 17 of 40
S1.No. Batch no./ Size of Current UTS YS % elongation

identification electrode & Remarks
no. polarity
As Actual As Actual As Actual

per per per
code code code
C. Impact Test Results
Test Temperature Notch in
Type of Specimens (Charpy) Size of Specimens
S1.No. Batch no./ Size of Current Impact value Remarks

identification electrode &
no. polarity
As per 1 2 3 4 5 Average
code,
max./avg.
i
I
Sheet 2 of 4
Page 363 of 851

frc ENGINEERS
1.'7,1",?ffirt del".■ (A Govi 01 inda Undenak.g) FABRICATION OF PIPING Page 18 of 40
D. Chemical Analysis Results

Batch no./ Size of Current % % % % % % % % % others Remarks
identification electrode &
SI.No.
no. polarity C Mn Si P S Cr Ni Mo V
As per
code
Actual
As per
code
Actual
E. Fillet Weld Test Results
Base Materials
Batch no./ Size of Current Macro Fracture Remarks
Welding Visual
identification electro &
Sl. no. de polarity position
No.
Horizontal
Vertical
Overhead
Horizontal
Vertical
Overhead
F. Other Test Results
1. Transverse tensile test
In combination with
Base material used
Position of welding
Preheat temperature
Post weld heat treatment
Radiography
Sheet 3 of 4
Page 364 of 851

,41 ENGINEERS
$1g- 1122- INDIA LIM1TED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
Go, Q1 Intlu Ilnd.°0».ng} FABRICATION OF PIPING
Page 19 of 40
Identification No. U.T.S. Fracture in Remarks
2. Guided Bend Test
Position Identification No. Root, Face or Side Bend Remarks
G. Any other tests
H. Conclusions
PREPARED BY REVIEWED BY APPROVED BY

(CONTRACTOR) (CONTRACTOR) (EIL/OWNER)
Sheet 4 of 4
Page 365 of 851

71 ENGINEERS
$424T181~~INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
(A Govt d unenak.no
Page 20 of 40
EXHIBIT — B: STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION
LSTK CONTRACTOR
Name of the Heat treater
Name of the Project
Specification /Reference No.
Line no./Joint No.
1. General Details Other Details
Name of the Type of Heating : Elec. Res./

Equipment : Induction
(Tick mark applicable method)
Maximum Permissible Temp at

Uncovered Parent Metal
Width of heated band

Width of Insulation
Material : No. of Themo couples (dia wise)
Type of Thermo couples
3. Heat Treatment Cycle Details
Charging Temp ° C
Rate of heating ° C /Hr.
Soaking Temperature, ° C
Soaking Time, Hrs.
Rate of Cooling ° C /Hr.
Method of Cooling
4. Other details, if any
Page 366 of 851

ENGINEERS
$agzu f81W-g INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
EXHIBIT — C: FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS)
Company Name By
Welding Procedure Specification No. Date Supporting PQR No. (S)
Revision No. Date
Welding Process (es) Type (s)

(Automatic, Manual, Machines or Semi Auto)
JOINTS
Joint Design
Backing (Yes) (No)
Backing Material (Type)
Sketches Production Drawings. Weld Symbols Written
Description should show the general arrangement of the parts to be welded. Where applicable, the
root specing and the details of weld groove may be specified.
(At the option of the Manufacturer sketches may be attached to illustrate joint design weld layers and
bead sequence e.g. for notch toughness procedures, for multiple process procedures, etc.)
BASE METALS
P.No. Group No. to P. No. Group No.
OR
Specification type and grade

to Specification type and grade
OR
Chem. Analysis and Mech. Prop.

to Chem. Analysis and Mech. Prop.
Thickness Range :
Base Metal : Groove Fillet
Deposited Weld Metal : Groove Fillet
Pipe Dia Range : Groove : Fillet
Other
SHEET IOF 3
Page 367 of 851

■31 ifFr", ENGINEERS
Ofjt- g INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
I .AM ,.11,7175T7 I A GA41 of india Unde~n0
Page 22 of 40
FILLER METALS
F.No. Other
A.No. Other
Spec. No. (SFA)
AWS No. (Class)
Size of filler metals
(Electrodes, Cold Wire, Hot Wire etc.)

Electrode-Flux (Class)
Flux Trade Name
Consumable Inset
Each base metal/filler metal combination should be recorded individually.
WPS NO. Rev.
POSITIONS: POSTWELDED HEAT TREATMENT
Position (s) of Groove Temperature Range
Welding Progression : UP Down Time Range
Position (s) of Fillet
PREHEAT GAS
Shielding Gas (es)
Preheat Temp. Min. Percent Composition (mixtures)
Interpass Temp. Max. Flow Rate

Gas Backing
Preheat Maintenance Trailing Shielding Gas Composition
ELECTRICAL CHARACTERISTICS
Current AC or DC Polarity
Amps (Range) Volts (Range)
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below).
Tungsten Electrode Size and Type

(Pure Tungsten, 2% Ceriated, etc)
Mode of Metal Transfer for GMAW
(Spray arc, short circuiting arc, etc.)
Electrode Wire feed speed range
SHEET 2 OF 3
Format No. 8-00-0001-F1 Rev. 0 Copyright E1L — All rights reserved
Page 368 of 851

ENGINEERS
A Govl of Incka Undwuk.gi
TECHNIQUE
String or Weave Bead

Orifice or Gas Cup Size
Initial and Interpass Cleaning (Brushing, Grinding, etc.)
Method of Back Gouging

Oscillation
Contact Tube to Work Distance
Multiple or Single Pass (per side)
Multiple or Single Electrodes
Travel Speed (Range)
Peening
Other
Filler Metal Current Travel

eld Volt
Process Speed Others
Layer(s)
er(s) Type Amp. Range
Class. Dia. Range
Polarity Range
e.g. Remarks,
Comments, Hot
wire Addition,
Technique Torch
Angle, etc.
SHEET 3 OF 3
Page 369 of 851

d-2:1-g
fflf= ENGINEERS
(A Govt crt inch Undeft )
Page 24 of 40
EXHIBIT-D: FORMAT FOR PROCEDURE QUALIFICATION RECORD (POR)

RECORD OF ACTUAL CONDITIONS USED TO WELD TEST COUPON
Company Name
Procedure Qualification Record No. Date
WPS No.
Welding Process (es)

Types (Manual, Automatic, Semi-Auto)
JOINTS
Groove Design of Test Coupon
(For combination qualification the deposited weld metal thickness shall be recorded for each Filler metal or process weld)
BASE METALS POSTWELD HEAT TREATMENT

Material Sepc. Temperature
Type of Grade Time
P.No. to P.No. Other
Thickness of Test Coupon
Diameter of Test Coupon
Other
FILLER METALS GAS

Weld Metal Analysis A No. Type of Gas/Gases
Size of Filler Metal Composition of Gas Mixture
Filler Metal F.No. Other
SFA Specification
AWS Classification
Other
POSITION ELECTRICAL CHARACTERISTICS

Position of Groove Current
Weld Progression (Uphill, Downhill) Polarity
Other Amps.
Tungsten Electrode Size
Other
PREHEAT TECHNIQUE
Phreheat Temp. Travel Speed
Interpass Temp. String or Weave Bead
Oscillation
Multipass or Single Pass (per side)
Single or Multiple Electrodes
Other
SHEET 1 OF 3
Page 370 of 851

ENGINEERS
101?n,4,151,1,1,,..43■ A Gos1
TENSILE TEST
Specimen Width Thickness Area Ultimate total Ultimate tensile Type &
No. force, kgf stress, location of
Kgf/mm2 failure
GUIDED BEND TESTS
TOUGHNESS TESTS
Lateral Exp. Drop Weight

Specimen Notch Notch Test Impact
No. Location Type Temp. Value No
% Shear Mils Break
Break
FILLET WELD TEST
Result - Satisfactory : Yes No Penetration into Parent Metal : Yes No.

Marco - Results
SHEET 2 OF 3
Page 371 of 851

ENGINEERS
$°gelf 22egW.' INDIA IJMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
3~1 fA Govt oi intl o UndefIak.g)
OTHER TESTS
Type of Test
Deposit Analysis
Other
Welder' s Name Clock No. Stamp No.

Test Conducted by Laboratory Test No.
We certify that the statements in this record are correct and test welds were prepared, welded and
tested in accordance with the requirements of Section IX of the ASME Code.
Date Manufacturer
By
(Detail of record of tests are illustrative only and may be moulded to conform to the type and number
of tests required by codes and specifications).
SHEET 3 OF 3
Page 372 of 851

01
'12—Jt4 ENGINEERS
$
11g-
ar f&1 51e
— g INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
t. Go, ol Ind4. Iln<1.1fflong)
1.17R ,P4244,
Page 27 of 40
EXHIBIT — E: FORMAT FOR MANUFACTURER'S RECORD FOR WELDER OR

WELDING OPERATOR QUALIFICATION TESTS
Welder Name Check No. Stamp. No.
Using WPS No. Rev.
The above welder is qualified for the following ranges
Variable Record Actual Values Qualification Range

Used in Qualification
Process
Process Type
Backing (metal,
Weld metal, flux, etc)
Material Spec. to to
Thickness
Groove
Fillet
Diameter
Groove
Fillet
Filler Metal
Spec. No.
Class
F. No.
Position
Weld Progression
Gas Type
Electrical Characteristics
Current
Polarity
SHEET 1 OF 2
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reserved
Page 373 of 851

ENGINEERS
INATY ("AWAR 1161 30~1 (A Govt of india Unclefla~
Guided Bend Test Results
Type and Fig. No. Result
Radiographic Test Results

For alternative qualification of groove welds by radiography
Radiographic Results
Fillet Weld Test Results

Fracture Test (Describe the location, nature and size of any crack or tearing of the specimen_
Length and Per Cent of Defects inches
Macro Test - Fusion
Appearance - Fillet Size (ing) x Convexity or Concavity
Test Conducted by Laboratory - Test No.
We certify that the statements in this record are correct and that the test welds were prepared.
Welded and tested in accordance with the requirements of Section IX of the ASME Code.
Date Organization
By
(Details of record tests are illustrative only and may be modified to conformation to the type & number
of tests required by the Code).
Note: Any essential variables in addition to those above shall be recorded.
SHEET 2 OF 2
Page 374 of 851

ENGINEERS
Go, oi ,n(). Ilndpflffiong, FABRICATION OF PIPING
Page 29 of 40
EXHIBIT — F: RADIOGRAPHIC PROCEDURE QUALIFICATION

RECORD FOR PIPE WELDING
1. Location
2. Date of Testing
3. Name of the LSTK CONTRACTOR/Agency
4. Material: Carbon steel/Alloy Steel/Stainless Steel
4 A. Technique: DWSI/SWSI/DWDI
5. Diameter & Thickness:
6. Type of Weld Joint:
7. Radiation Source:
8. Intensifying Screens/Lead Screens:
9. Geometric Relationship:
10. Limit of Film Coverage:
11. Film Type and Make:
12. Exposure Time:
13. Processing:
14. Density:
15. Sensitivity:
16.* Type of penetrameter:

(Source side)
17.* Type of penetrameter:

(Film side)
Signature of LSTK CONTRACTOR/Agency with Seal
Approval of OWNER/ PMC's Inspector
Ref. Para regarding recommended practice on placement of penetrameters Article 22, SE 142,
ASME Sec. V.
For "Random Radiography" lines placement of penetrameters as per Article 2, ASME, Sec. V
is permitted.
Page 375 of 851

ENGINEERS
$42L11 INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
.4.197f ~15r71,34~7.11 IA GoN of india UndortalOng)
EXHIBIT — G: WELDER'S IDENTIFICATION CARD
1. Name:
2. Identification:
Photograph
3. Date of Testing:
4. Process
5. Thickness range
6. Diameter range
7. P. No.
8. Date of approval of welding
9. Position(s)
Approved by: Employer's Signature with Seal
Page 376 of 851

k31 ENGINEERS
$1g-ar 22-eg INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
( A Go, oI indk, l}n~lak■Flg)
Page 31 of 40
EXHIBIT — H: Type of Source and Films to be used for RADIOGRAPHY
NOMINAL WALL
SHOP WELDED JOINTS IN-SITU WELDS
THICKNESS (T) IN mm
SOURCE FILM : CEN Class SOURCE FILM : CEN Class
T > 19 A11 Materials Gamma Ray ' C5 Gamma Ray C5
8 < T < 19 Carbon Gamma Ray Gamma Ray
C4 C4
Steel
A11 other Gamma Ray Gamma Ray
C3 C3
materials
<8 Carbon Steel
Other than C3/C1
Gamma Ray C3 Gamma Ray
Inspection
Class IV *
A11 other X-ray with C4 or Equivalent to be
materials and used. Gamma Ray (Se 75 Source
Carbon Steel only) with C3/C2 Equivalent may be
of Inspection allowed only if in the assessment of
X-Ray C4
Class IV * the owner's inspector, Joints are
inaccessible for X-ray equipment
and radiographic sensitivity is
achieved.
Note: Integral to above table
1) Films slower than the above may have to be used, if required radiographic sensitivity is not
achieved consistently.
* Piping classes where 100% RT is specified. Refer Std. Spec. No. 6-44-0016
COMPARISON OF FILMS FROM DIFFERENT MANUFACTURERS
CEN Classification KODAK AGFA FUJI

CX D8 ---
C5 AA400 D7 IX100
C4 T200 D5 IX80
C3 MX125 D4 IX50
C2 M100 D3 ---
Cl DR50 D2 IX25
--- SR** --- ---
** Special films, extremely fine grain & very high resolution
Page 377 of 851

~Zr& rEr") ENGINEERS
041f INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
Govt ot Indo UndertalonW
1.11W■ ~115rf ffit "PAI tA
EXHIBIT — I: AUTOMATED ULTRASONIC TESTING (AUT)
1.0 INTRODUCTION
2.0 REFERENCE DOCUMENTS
3.0 AUT SYSTEM
4.0 COUPLANTS
5.0 CALIBRATION/DEMONSTRATION BLOCK
6.0 CALIBRATIONS
7.0 PROCEDURE
8.0 TRAINING AND QUALIFICATION
9.0 EVALUATION AND ACCEPTANCE CRITERIA
Page 378 of 851

(31 ENGINEERS
A ewu c ndMUndert.long)
1.0 INTRODUCTION
The specification shall be applicable for Automated Ultrasonic Testing (AUT) system or Semi-
Automated Ultrasonic Testing suitable for full penetration butt welds of piping. The system
shall incorporate Phased array probes and Time of Flight Diffraction (TOFD) probes plus pulse
echo probes. The procedure shall evaluate the performance of Phased Array Ultrasonic
examination instruments and system. This specification is intended to be used on thickness of
13.0 mm and greater. Lesser thicknesses may be tested using the standard practice if the
technique can be demonstrated to provide adequate protection on mockups of the same wall
thickness and geometry.

The latest edition with addendum of the following standards shall be referred here:
a) ASME B31.3 — Process piping
b) ASME B31 Case 181-2. 2012 Use of alternative Ultrasonic Examination Acceptance
Criteria in ASME B31.3
c) ASME Section V- Non Destructive Examination (Latest edition)
d) ASNT SNT-TC-1A - Recommended Practice for Personnel Qualification and Certification

in Nondestructive Testing
3.0 AUT SYSTEM
3.1 Instrument Requirement

The ultrasonic examination shall be performed using a system employing automated/ semi-
automated scanning with computer based data and analysis abilities.
The instrument shall be capable of real-time sectorial scan (also called an S-scan) image during
scanning to assure that proper data has been collected, generating and displaying sectorial-scan
image, which can be stored and recall for subsequent review.
The system shall provide an adequate number of examination channels to ensure the complete
volumetric examination of the weld through the thickness in one circumferential scan.
The evaluation zones should be of maximum 2.0mm height. The instrument linearity should be
such that the accuracy is within 5%.
Each examination channel should be selective for pulse-echo or through transmission mode gate
position and length for a minimum of two gates and gain.
TOFD techniques & B-scan mapping should be available to improve characterization.

Recording thresholds should be selectable to display signals between 0 and 100% of full screen
height for simple amplitude and transit time recording and it should be from 0 to 100% for B-
scan or mapping type recording of data. Two recordable signals output per gate should be
available being either analog or digital and representative of signal height and time of flight.
Measuring distance accuracy of circumferential weld shall be within 1.0 cm from zero (0)
position.
Electronic noise shall be lower than acoustical noise in all channels for the probes and
sensitivities to be used during inspection. The signal to noise ratio for each channel during
examination shall be at least > 20 dB for shear waved probes.
The Contractor shall provide the detail information of the equipment like model, trade name,
software used to the OWNER/EIL.
Page 379 of 851

ENGINEERS
Ogl_JE fdt&I-g INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
iNt?Pf k.R+151?,12,1,R1r. A Govt Undertak.g)
3.2 Probes
The phased array search unit frequency shall be between 1 MHz and 10 MHz depending on
material type and thickness. The Contractor shall provide the detail information of the probe
frequency, no. of elements, size, pitch etc. to the OWNER/EIL.
3.3 Wedge
Phased array wedges shall be of a design to accommodate phased array search unit. Nominal
refracted-wedge angles shall be possible from 35 to 75 degrees to ensure 100 % coverage of the
weld and heat affected zone. The Contractor shall provide the detail information of the wedge
to the OWNER/EIL.
3.4 Encoder
The encoder shall be capable of permitting a scan resolution of 1.0mm as minimum.
4.0 COUPLANT
The couplant shall be obtained by using a medium suitable for the purpose. It shall be suitable
for the temperature used. The couplant, including additives, shall not be detrimental to the
material being examined. Couplants used on nickel base alloys shall not contain more than 250
ppm of sulfur. Couplants used on austenitic stainless steel shall not contain more than 50 ppm of
halides (chlorides plus fluorides).A method should be employed to determine that constant
coupling is achieved during examination. An examination of the test piece with its surface
wiped dry should produce a record showing an absence of the couplant recording signal.
The same couplant shall be used during calibration and examination.
5.0 CALIBRATION/DEMONSTRATION BLOCK
5.1 Calibration/Demonstration Block Material
5.1.1 Material selection

The material from which the qualification and calibration blocks are fabricated shall be of the
same product form and material specification or equivalent P-number grouping as one of the
materials being examined.
5.1.2 Heat treatment

The calibration and qualification blocks shall receive at least the minimum tempering treatment
required by the material specification for the type and grade. If the calibration and qualification
blocks contains welds other than cladding, and the component weld at the time of the
examination has been heat treated, the block shall receive the same heat treatment.
5.1.3 Reflectors
a) Calibration blocks reflectors: Side drilled holes shall be used to confirm adequate sensitivity
settings.
b) Demonstration blocks reflectors: Surface and sub-surface notches
5.1.4 Quality of calibration and demonstration blocks

Prior to fabrication, the block material shall be completely examined with a straight beam
search unit. Areas that contain an indication exceeding the remaining back-wall reflection shall
be excluded from the beam paths required to reach the various calibration reflectors.
5.1.5 Cladding
When the component material is clad, the block shall be clad by the same welding procedure as
the production part. It is desirable to have component materials, which have been clad before
the dropouts, or prolongations are removed. When the cladding is deposited using an automatic
welding process, and, if due to block size, the automatic welding process is impractical,
deposition of clad may be by the manual method.
Page 380 of 851

k31 ENGINEERS
$1gZIE~g INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
A Go.t ei IntlU Undeftaing)
5.1.6 Surface roughness of calibration and demonstration blocks

The roughness of the Demonstration and calibration surfaces of the blocks shall be
representative for the scanning surface of the components to be examined.
5.2 Calibration Blocks
5.2.1 Standard block

IIW VI calibration block or V2 or equivalent calibration block are a recognized test reference
for sweep range scale, index point of shear wave transducer, and refracting angle.
5.2.2 Calibration reference block

Reference block shall be made with notch and side-drilled hole as per ASME Section V article
4, Fig.T-434.2.1 and Fig.T-434.3 and shall be used for gain calibration and construction of
reference curves. The reference calibration block shall be a section of pipe of the same nominal
and schedule and normally be manufactured from the actual material examined and have
approved dimensions.
5.2.3 Non-piping Calibration block

The basic calibration block configuration and reflectors shall be as shown in ASME Section V
article 4, Fig.T-434.2.1. The block size and reflector locations shall be adequate to perform
calibrations for the beam angles used.
5.2.4 Piping Calibration block

The basic calibration block configuration and reflectors shall be as shown in ASME Section V
article 4, Fig.T-434.3. The block size and reflector locations shall be adequate to perform
calibration for the beam angles used.
5.2.5 Block Curvature

The block curvature shall be as per ASME Section V article 4.
5.3 Demonstration Block
5.3.1 Preparation
A demonstration block shall be prepared by welding or, provided the acoustic properties are
similar, the hot isotactic process (HIP) may be used.
5.3.2 Thickness
The demonstration block shall be within 25% of the thickness to be examined. For welds
joining two different thickness of material, demonstration block thickness shall be based on the
thinner of the two materials.
5.3.3 Weld joint configuration

The demonstration blocks weld joint geometry shall be representative of the production joints
details.
5.3.4 Flaw location

Unless specified otherwise by the referencing Code Section, the demonstration block which
three EDM notches oriented and major groove faces. The flaws shall be located at or adjacent to
the blocks groove faces as follows:
(a) One surface flaw on the side of the block representing the component O.D. surface
(b) One surface flaw on the side of the block representing the component I.D. surface
(c) One subsurface flaw
When the scan plan to be utilized subdivides a weld into multiple examination zones, a
minimum of one flaw per zone is required.
Page 381 of 851

~Zie? ENG1NEERS
fM2-èg IND1A L1MITED
Govt uldia Undenakmg)
I N1WItIe.,7,7 t1,1,127.1 A
Page 36 of 40
5.3.5 Flaw Size

Demonstration block flaw sizes shall be based on the demonstration block thickness and
shall be no larger than that specified by the referencing Code Section.
(a) Maximum acceptable flaw height for material less than 1 in. (25 mm) thickness, or
(b) 0.25 aspect ratio acceptable flaw for material equal to or greater than 1 in. (25 mm)
thickness based on the demonstration block
5.3.6 Single I.D. / O.D. flaw alternative

When the demonstration block can be scanned from both major surfaces during the qualification
scan [e.g., joint I.D. and O.D. have a similar detail, diameter of curvature is greater than 20 in.
(500 mm), no cladding or weld overlay present, etc.], then only one surface flaw is required.
5.3.7 One-sided exams

When, due to obstructions, the weld examination can only be performed from one side of the
weld axis, the demonstration block shall contain two sets of flaws, one set on each side of the
weld axis. When the demonstration block can be scanned from both sides of the weld axis
during the qualification scan(e.g., similar joint detail and no obstructions), then only one set of
flaws is required.
6.0 CALIBRATION
6.1 General Calibration Requirements

1) Ultrasonic system: Calibration
Calibration shall be performed for complete ultrasonic system and shall be done prior to
examination in the desired thickness range.
2) The surface condition of the calibration block shall be similar to that on which production
test will be performed with respect to the surface geometry and cladding.
3) Same couplant shall be used for calibration as well as production testing.
4) Contact wedges, if used, shall be same for the calibration as well as for the production
testing.
5) Any control, which affects instrument linearity (e. g. Filters, reject, or clipping), shall be in
the same position for calibration, calibration checks, instrument linearity checks and
examination.
6) Focal-Law: The focal law to be used during the examination shall be used for calibration.
7) Beam Calibration
All individual beams used in the examination shall be calibrated to provide measurement of
distance and amplitude correction over the sound path employed in the examination. This
shall include applicable compensation for wedge sound path variations and wedge
attenuation effects.
8) The maximum temperature difference between test blocks and examination surface shall not
exceed 14°C.
6.2 PA Instrument Linearity

The following requirements shall be met at intervals not to exceed one year or prior to first use
thereafter.
1) Screen height linearity: The PAUT equipment's screen height linearity shall be evaluated in
accordance with Mandatory Appendix I of ASME Sect. V, Art.4.
2) Amplitude control linearity: The PAUT equipment's amplitude control linearity shall be
evaluated in accordance with Mandatory Appendix II of ASME Sect. V, Art.4 for each pulse-
receiver circuit
3) Equipment linearity shall be such that accuracy of indicated amplitude or time is ±5% of
actual full scale amplitude or time.
Page 382 of 851

ENGINEERS
$1g-a. fa2g INDIA LIMITED
IA Co, VI Ind. Unel.t.,,■ no,
Illri 3,405,41i
Page 37 of 40
6.3 Phased array system calibration

Calibration shall be performed from the surface of the calibration block which corresponds to
the component surface to be examined. System calibration shall include the complete ultrasonic
system. Screen distance calibration shall be at least 1-1/2 "veepaths"(also known as skip) for the
minimum angle that will be used during the examination.
The system shall be calibrated for velocity and wedge delay calibration, sensitivity calibration,
Time Corrected Gain (TCG) calibration. Encoder calibration and confirmation of sensitivity.
The system shall require re-calibration due any of the following conditions:
1) Search unit transducer or wedge change.
2) Search unit cable or length change.
3) Ultrasonic instrument change.
4) Change in examination personnel.
5) Change in type of power source.
7.0 PROCEDURE
7.1 Safety
At first, safety supervisor or technician should be confirmed regarding safety matters before
starting examination. Those are included mainly of scaffolding, ladder, lighting, electric
conditions and personnel safety equipments have been checked by themselves as followed
Project Safety Regulation. If there is not clear for safety questions for personnel, equipment and
examination, the technician has right to stop his job whenever.
7.2 A detailed Automated Ultrasonic examination procedure shall be prepared and qualified for each
wall thickness and joint geometry to be examined prior to the start of any NDT work. Repair
procedure shall be separately qualified for each joint geometry. The procedure as a minimum
shall include the following:
Scope; equipment; probe type and details; surface preparation, cleaning and couplant; technique
sheet for each technique specified (number of techniques to be sufficient to cover all type of
joints to be covered by the procedures scope); material; weld material (if different); sketch
showing joint configuration, beam coverage; extent of scan; scanning pattern; material thickness
and curvature; calibrations and frequency; means of setting and scanning sensivity Ievels and
DAC curves; flaw location and size evaluation; acceptance criteria; reporting format; operator
qualifications.
7.3 Lamination Check

A-UT shall be performed using a device employing automatic computer based data acquisition.
The straight beam material examination (T-472 of Section V, Article 4) for reflectors that could
interfere with the angle beam examination shall be performed:
a) Manually,
b) As part of a previous manufacturing process, or
c) During the A-UT examination provided detection of there reflectors is demonstrated.
d) The coverage shall be included minimum 100mm from centerline of welding.
7.4 Examination Coverage

The required volume of the weld and base material to be examined shall be scanned using a
linear scanning technique with an encoder. Each linear scan shall be parallel to the weld axis at
a constant standoff distance with the beam oriented perpendicular to the weld axis.
The ultrasonic examination area shall include the volume of the weld, plus the lesser of 25mm
(1 in.) or "t" on each side of the weld.
Page 383 of 851

~2d
- ig ENGINEERS
2Wg INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
14~ "..;1157,39KNI GoN otIndo Untlertak■ng)
A documented examination strategy or scan plan shall be provided, showing transducer

placement, movement, and component coverage, that provides a standardized and repeatable
methodology for weld acceptance. The scan plan shall also include ultrasonic beam angle used,
beam directions with respect to weld centerline, and pipe volume examined for each weld. The
documentation shall be made available to the owner's Inspector.
7.5 Examination side

Basically shall be examined on the both sides of welding line axis but can be examined from
one side in case of another side is not available access under full coverage volume condition.
7.6 Surface condition

The contact surface shall be cleaned of weld spatter, dirt, pitting, rust and/or any other
impurities or roughness that will interfere with the free movement of the ultrasonic transducers
or would prevent adequate transmission of ultrasound. Prior to inspection the NDT technician
shall judge the suitability of the surface and when required remedial action shall be taken.
7.7 Scanning
1) The search unit shall be maintained at a fixed distance from the weld axis by a fixed
guide or mechanical means.
2) The examination angle(s) for E-scan and range of angles for S-scan shall be appropriate for
the joint to be examined.
3) Scanning speed shall be such that data drop-out is less than 2 data lines per inch (25mm) of
the linear scan length and that there arr no adjacent data line skips.
4) For E-scan techniques, overlap between adjacent active apertures (i.e., aperture incremental
change) shall be a minimum of 50% of the effective aperture height.
5) For S-scan techniques, the angular sweep incremental change shall be a maximum of 1 deg or
sufficient to assure 50% beam overlap.
6) When multiple linear scan are required to cover the required volume of weld and base
material, overlap between adjacent linear scans shall be a minimum of 10% of the effective
aperture height for E-scan or bean width for S-scan
7) Each scan shall have an overlap of minimum 1 in. (25 mm) - (in case of re-acquisition of
missing or poor data line etc.)
8) TOFD channel
The TOFD gate start will be set 1 1.1.Sec before the arrival of the lateral wave and should
extend up to the first back wall echo to achieve full cover of wall thickness.
7.8 Data Recording

A-scan data shall be recorded in an unprocessed form with on threshold, at a minimum
digitization rate of five times the examination frequency, and recording increments of a
maximum of
a) 0.04 in. (1 mm) for material < 3 in. (75 mm) thick
b) 0.08 in. (2 mm) for material > 3 in. (75 mm) thick
7.9 Reflectors Transverse to the Weld Seam

As an alternate to line scanning, a manual angle beam examination may be performed for
reflectors transverse to the weld axis. Manual angle beam UT shall be accordance with manual
ultrasonic examination procedure based on (T-472 of Article 4, ASME Sec V).
Page 384 of 851

ENGINEERS
$1g-ar1~--g INDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
dorr, 151.3.0.1, IA Go, ol Und.■,11.ng>
Page 39 of 40
7.10 Re-examination
1) Re-examination for repaired welds shall follow the same condition (same examination
method, same acceptance criteria) as for the original weld.
2) The additional testing shall be extent a length at least equal to 1 in.(25 mm) from the both
end of repaired area.
3) Additional NDT methods of UT and MT shall be carried out to make ensure for the repaired
area
8.0 TRAINING AND QUALIFICATION
All Inspectors of the EIL/OWNER (EIL/OWNER) shall be imparted training at the

CONTRACTOR's cost. The inspector shall be provided complete awareness and
knowledge regarding the equipment, limitations, capabilities complete range, method of
operation, calibration, scanning, including development of suitable procedure, training on
variables effecting the system performance and interpretation of results.
The Ultrasonic lead operator performing the examination shall be qualified in accordance with
the EIL/OWNER's written practice, ASNT-TC-1A, ASME B31 Case 181-1. The minimum
qualification of AUT operator who analyze and interpret the collected data shall be a ASNT
Level II or III.
Only qualified UT personnel trained in the use of the equipment and who have demonstrated the
ability to properly acquire examination data, shall conduct production scan.
Scanner technician, Band setter, scribe line technician shall have sufficient experience and
capabilities to perform their duties to the satisfaction of AUT operator.
9.0 EVALUATION AND ACCEPTANCE CRITERIA
9.1 Evaluation
9.1.1 Data analysis criteria
Reflectors exceeding the limits in either a) or b) below, as applicable, shall be investigated to
determine whether the indications originates from a flaw or is a geometric indication in
accordance with Para. 9.1.3 (Flaw sizing) below.
a) For amplitude-based techniques, the location, amplitude, and extent of all reflectors that
produce response greater than 20% of the reference level shall be investigated.
b) For non amplitude-based techniques, the location and extent of all images that have an
indicated length greater than the limits, as applicable, shall be investigated.
9.1.2 Geometric
Ultrasonic indications of geometric and metallurgical origin shall be classified as follows:
1) Indications that are determined to originate from the surface configurations(such as

weld reinforcement or root geometry) or variations in metallurgical structure of materials (such
as cla-Iding to base metal interface) may be classified as geometric indications, and
a) Need not be characterized or sized.

b) Need not be compared
c) Location shall be recorded
2) The following steps shall be taken to classify an indication as geometric:
Page 385 of 851

51
12_.1t4'"ENGINEERS
OW-g WINDIA LIMITED WELDING SPECIFICATION FOR 6-77-0001 Rev. 4
I /11?7( ",(75,7 (151.YATI711 (A Go,1 ot tnOka Undettatong)
a) Interpret the area containing the indication;

b) Plot and verify the indication coordinate, provide a cross-sectional display showing the
indication position and surface discontinuity such as root or counter bore; and
c) Review fabrication or weld preparation drawings.
3) Altematively other NDE methods or techniques may be applied to classify an indication

as geometric (e.g. altemative UT beam angles, radiography, ID and/or OD profiling).
9.1.3 Flaw sizing

The dimensions of the flaw shall be determined by the rectangle that fully contains the area of
the flaw.
Flaw Sizing - Reflectors determined to be flaws shall be sized in accordance with a procedure
demonstrated to size similar flaws at similar material depths. A flaw may be sized by manually
analysis the data using sizing techniques that have been demonstrated on the calibration block.
The dimension of the flaw shall be determined by the size of the rectangle that fully contains the
,area of the flaw.
9.1.4 Flaw evaluation

Flaws shall be evaluated for acceptance using the applicable criteria of ASME B31 Case 181-2.
9.2 Acceptance criteria

Weld quality shall be judged on the basis of the acceptability criteria mentioned in ASME
B31 Case 181-2.
Page 386 of 851

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SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
ENGINEERS MANAGEMENT SYSTEM 6-78-0001 Rev. 1
lakgINDIA LIMITED REQUIREMENTS FROM
mren ewaire mjvam) (A Gavt at India Undertaking)
BIDDERS Page 1 of 7
64)(11 Chrlf qui ciall -51-04ff

u tea aliikrrat t ?drift'
SPECIFICATION FOR QUALITY

MANAGEMENT SYSTEM
REQUIREMENTS FROM BIDDERS
QMS QMS
1 12.03.15 General Revision Standards Standards MPJ SC
Committee Committee

QMS QMS
0 04.06.09 Issued as Standard Specification Standards Standards SCT ND
Committee Committee
Standards Standards
Committee Bureau
Rev. Checked
Date Purpose Prepared by Convener Chairman
No by
Approved by

Page 417 of 851

ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
INDIA LIMITED SYSTEM 6-78-0001 Rev. 1

lft2 (AG'"ind'Undelt6ung) REQUIREMENTS FROM BIDDERS Page 2 of 7
Abbreviations:
CV Curriculum Vitae
ISO International Organization for Standardization
PO Purchase Order
QA Quality Assurance
QMS Quality Management System
QMS Standards Committee
Convener: Mr. M.P. Jain
Members: Mr. A.K. Chaudhary (Insp.)

Mr. S.K. Kaul (C&P)
Mr. R.K. Trivedi (Engg.)
Mr. Tilak Raj (Projects)
Mr. Vinod Kumar (CQA)

Page 418 of 851

Igar llks INDIA LIMITED SYSTEM 6-78-0001 Rev.
Oiren
'A
Govt
At ' nth' Und"k"V) REQUIREMENTS FROM BIDDERS Page 3 of 7
CONTENTS
Clause Title Page

No.
1.0 SCOPE 4
2.0 DEFINITIONS 4
3.0 REFERENCE DOCUMENTS 4
4.0 QUALITY MANAGEMENT SYSTEM — GENERAL 4
5.0 QUALITY SYSTEM REQUIREMENTS 4
6.0 AUDITS 7
7.0 DOCUMENTATION REQUIREMENTS 7
Page 419 of 851

el ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.

$1g-zg faReg INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1
own 120.2 .I J40.9) IA GOVt of India Undertaking) REQUIREMENTS FROM BIDDERS Page 4 of 7
1.0 SCOPE
This specification establishes the Quality Management System requirements to be

met by BIDDER for following purpose:
• QMS requirements to be met by suppliers/contractors after award of work/

during contract execution.
2.0 DEFINITIONS
2.1 Bidder
For the purpose of this specification, the word "BIDDER" means the person(s), firm,
company or organization who is under the process of being contracted by EIL /
Owner for delivery of some products (including service). The word is considered
synonymous to supplier, contractor or vendor.
2.2 Project Quality Plan
Document tailored from Standard Quality Management System Manual of BIDDER,

specifying how the quality requirements of the project will be met.
2.3 Owner
Owner means the owner of the project for which services / products are being
purchased and includes their representatives, successors and assignees.

6-78-0002 Specification for Documentation Requirements from
Contractors
6-78-0003 Specification for Documentation Requirements from Suppliers
4.0 QUALITY MANAGEMENT SYSTEM — GENERAL
Unless otherwise agreed with EIL / Owner, the BIDDER proposed quality system
shall fully satisfy all relevant requirements of ISO 9001 "Quality Management
Systems — Requirements." Evidence of compliance shall be current certificate of
quality system registration to ISO 9001 or a recent compliance audit recommending
registration from a certification agency. The quality system shall provide the
planned and systematic control of all quality related activities for execution of
contract. Implementation of the system shall be in accordance with BIDDER'S
Quality Manual and PROJECT specific Quality Plan.
5.0 QUALITY SYSTEM REQUIREMENTS

5.1 BIDDER shall prepare and submit for review / record, Project Quality Plan / Quality
Assurance Plan for contracted scope / job. The BIDDER'S Quality Plan shall
address all of the applicable elements of ISO 9001, identify responsible parties
within BIDDER'S organization, for the implementation / control of each area,
reference the applicable procedures used to control / assure each area, and verify
the documents produced for each area. The Project Quality Plan shall necessarily
define control or make reference to the relevant procedures, for design and
engineering, purchase, documentation, record control, bid evaluation, inspection,
production/manufacturing, preservation, packaging and storage, quality control at

Page 420 of 851

INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1

(A Gavt of India undertaking' REQUIREMENTS FROM BIDDERS Page 5 of 7
construction site, pre-commissioning, commissioning and handing over (as

applicable) in line with contract requirement and scope of work.
5.2 BIDDER shall identify all specified or implied statutory and regulatory requirements
and communicate the same to all concerned in his organization and his sub
contractor's organization for compliance.
5.3 BIDDER shall deploy competent and trained personnel for various activities for
fulfillment of PO / contract. BIDDER shall arrange adequate infrastructure and work
environment to ensure that the specification and quality of the deliverable are
maintained.
5.4 BIDDER shall do the quality planning for all activities involved in delivery of order.
The quality planning shall cover as minimum the following:
Resources
Product / deliverable characteristics to be controlled.
Process characteristics to ensure the identified product characteristics are
realized
Identification of any measurement requirements, acceptance criteria
Records to be generated
Need for any documented procedure
The quality planning shall result into the quality assurance plan, inspection and test
plans (ITPs) and job procedures for the project activities in the scope of bidder.
These documents shall be submitted to EIL/Owner for review/approval, before
commencement of work.
5.5 Requirements for sub-contracting / purchasing of services specified in contract /

tender shall be adhered to. In general all outsourced items will be from approved
vendors of EIL. Wherever requirements are not specified, or approved sub vendors
do not exist, the sub-contractor shall establish and maintain a system for purchasing
/ sub-contracting to ensure that purchased product / service conforms to specified
requirements. Criteria for selection of sub-contractor, evaluation, re-evaluation,
maintenance of purchasing data and verification of purchased product (sub-
contractor services), constitute important components of this requirement.
5.6 BIDDER shall plan and carry production and service provision under controlled
conditions. Controlled conditions shall include, as applicable
the availability of information that describes the characteristics of the product

the availability of work instructions
the use of suitable equipment
the availability and use of monitoring and measuring devices
the implementation of monitoring and measurement
the implementation of release, delivery and post-delivery activities
5.7 BIDDER shall validate any processes for production and service provision where
resulting output cannot be verified by subsequent monitoring and measurement.
This includes any process where deficiencies become apparent only after the
product is in use or service has been delivered.
5.8 BIDDER shall establish a system for identification and traceability of product /
deliverable throughout product realization. Product status with respect to inspection
and testing requirements shall be identified.

Page 421 of 851

ei ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
lge.ji id5fez INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1

Oren erRRIZ .71.1.113,70 IA Govt of India undettaking) REQUIREMENTS FROM BIDDERS Page 6 of 7
5.9 BIDDER shall identify, verify, protect and safeguard EIL / Owner property (material /
document) provided for use or incorporation into the product. If any Owner / EIL
property is lost, damaged or otherwise found to be unsuitable for use, this shall be
reported to the EIL / Owner.
5.10 BIDDER shall ensure the conformity of product / deliverable during internal
processing and delivery to the intended destination. Requirements mentioned in the
tender shall be adhered to.
5.11 BIDDER shall establish system to ensure that inspection and testing activities are
carried out in line with requirements. Where necessary, measuring equipments
shall be calibrated at specified frequency, against national or international
measurement standards; where no such standard exists, the basis used for
calibration shall be recorded. The measuring equipments shall be protected from
damage during handling, maintenance and storage.
5.12 BIDDER shall ensure effective monitoring, using suitable methods, of the processes
involved in production and other related processes for delivery of the scope of
contract.
5.13 BIDDER shall monitor and measure the characteristics of the product/deliverable to
verify that product requirement has been met. The inspection (stage as well as
final) by BIDDER and EIL / Owner personnel shall be carried out strictly as per the
ITPs forming part of the contract. Product release or service delivery shall not
proceed until the planned arrangements have been satisfactorily completed, unless
otherwise approved by relevant authority and where applicable by Owner / EIL.
5.14 BIDDER shall establish and maintain a documented procedure to ensure that the
product which does not conform to requirements is identified and controlled to
prevent its unintended use or delivery
5.15 All non-conformities (NCs) / deficiencies found by the BIDDER'S inspection /

surveillance staff shall be duly recorded, including their disposal action shall be
recorded and resolved suitably. Effective corrective and preventive action shall be
implemented by the BIDDER so that similar NCs including deficiencies do not recur.
5.16 All deficiencies noticed and reported by EIL / Owner shall be analyzed by the
BIDDER and appropriate corrective and preventive actions shall be implemented.
BIDDER shall intimate EIL / Owner of all such corrective and preventive action
implemented by him.
5.17 BIDDER should follow the standards, specifications and approved drawings.
Concessions/Deviations shall be allowed only in case of unavoidable circumstances.
In such situations Concession/deviation request must be made by the BIDDER
through online system of EIL eDMS. URL of EIL eDMS is
http://edocx.eil . co . in/vportal.
5.18 BIDDER shall have documented procedure for control of documents.
5.19 All project records shall be carefully kept, maintained and protected for any damage
or loss until the project completion, then handed over to EIL / Owner as per contract
requirement (Refer Specification Nos. 6-78-0002 - Specification for Documentation
Requirements from Contractors and 6-78-0003 - Specification for Documentation
Requirements from Suppliers), or disposed as per relevant project procedure.
Page 422 of 851


ei MANAGEMENT SYSTEM
IftJr
kif51ft. INDIA LIMITED 6-78-0001 Rev. 1
wirer riraxem3Tmil (A Goof of India UndertakIngi
REQUIREMENTS FROM BIDDERS Page 7 of 7
6.0 AUDITS
BIDDER shall plan and carry out the QMS audit for the job. Quality audit programme
shall cover design, procurement, construction management and commissioning as
applicable including activities carried out by sub-vendors and sub-contractors. This
shall be additional to the certification body surveillance audits carried out under
BIDDER'S own ISO 9001 certification scheme.
The audit programmes and audit reports shall be available with bidder for scrutiny
by EIL / Owner. EIL or Owner's representative reserves the right to attend, as a
witness, any audit conducted during the execution of the WORKS.
In addition to above EIL, Owner and third party appointed by EIL/Owner may also
perform Quality and Technical compliance audits. BIDDER shall provide assistance
and access to their systems and sub-contractor / vendor systems as required for this
purpose. Any deficiencies noted shall be immediately rectified by BIDDER.
7.0 DOCUMENTATION REQUIREMENTS
BIDDER shall submit following QMS documents immediately after award of work
(Within one week) for record / review by EIL / Owner.
Organization chart (for complete organization structure and for the project)
Project Quality Plan/Quality Assurance Plan
Job specific Inspection Test Plans, if not attached with PR
Job Procedures
Inspection/Test Formats
In addition to above QMS documents, following documentation shall be maintained

by the BIDDER for submission to EIL / Owner on demand at any point of time during
execution of the project.
Quality Manual
Certificate of approval for compliance to ISO: 9001 standard
Procedure for Control of Non-conforming Product
Procedure for Control of Documents
Sample audit report of the QMS internal and external audits conducted during
last one year
Customer satisfaction reports from at least 2 customers, during the last one
year
Project QMS audit report
Technical audit reports for the project
Corrective action report on the audits
Documents as specified above are minimum requirements. BIDDER shall submit

any other document/data required for completion of the job as per EIL/Owner
instructions.
Page 423 of 851


101 ENGINEERS DOCUMENTATION
g
** el!2RAfi'aA
IAIRON
g
Meavow INDIA LIMITED
IA GoN. Of India Undeftakingi
REQUIREMENTS FROM
6-78-0002 Rev. 1
CONTRACTORS Page 1 of 8
-4-4-<R1 51(t)01
tr-g 1-4-4vr
SPECIFICATION FOR
DOCUMENTATION REQUIREMENTS
FROM CONTRACTORS
QMS QMS
1 12.03.15 General Revision Standards Standards MPJ SC
Committee Committee
QMS QMS
Committee Committee
Standards Standards
Prepared Checked Committee Bureau
Rev.
Date Purpose by by Convener Chairman
No
Approved by
Page 424 of 851

SPECIFICATION FOR STANDARD SPECIFICATION
k311 ei ENGINEERS DOCUMENTATION No.
51g-a 015teg INDIA LIMITED 6-78-0002 Rev. 1
1.1FA 2IETIN

IA Govt of India undertaking) REQUIREMENTS FROM
Abbreviations:
DCI - Document Control Index

eDMS - Electronic Document Management System
FOA - Fax of Acceptance
HOD - Head of Division / Department
IC - Inspection Certificate
IRN - Inspection Release Note
ITP - Inspection and Test Plan
LOA - Letter of Acceptance
MOU - Memorandum of Understanding
QMS - Quality Management System
URL - Universal Resource Locator

Mr. S.K. Kaul (C&P)

Page 425 of 851


adaelei m,4 ENGINEERS DOCUMENTATION No.
$1fgar 051ft INDIA UMITED
Merl evensmaR3sTWIl (A Govt of India UndertakIng) REQUIREMENTS FROM 6-78-0002 Rev. 1
CONTENTS
Clause Title Page

No.
1.0 SCOPE 4
2.0 DEFINITIONS 4
Attachments
Format for completeness of Final Documentation Format No. 3-78-0004
Page 426 of 851

k391-4elei TEED ENGINERS DOCUMENTATION No.
INDIA EL IMITED 6-78-0002 Rev. 1
lit15reg, IA Govt al India Undertaking) REQUIREMENTS FROM
1.0 SCOPE
This specification establishes the Documentation Requirements from Contractors
All documents/data against the Tender / Contract shall be developed and submitted
to ElUOwner by the contractor for review / records, in line with this specification.
2.0 DEFINITIONS
2.1 Contractor
For the purpose of this specification, the word "CONTRACTOR" means the
person(s), firm, company or organization who is under the process of being
contracted by EIL / Owner for delivery of some products and services. The word is
considered synonymous to bidder, supplier or vendor.
2.2 Owner

from Bidders
4.1 Documents/Data to be submitted by the Contractor
4.1.1 The contractor shall submit the documents and data against the Tender/Contract as
per the list specified in respective Tender/Contract.
4.1.2 Review of the contractor drawings by EIL would be only to review the compatibility
with basic designs and concepts and in no way absolve the contractor of his
responsibility/contractual obligation to comply with Tender/Contract requirements,
applicable codes, specifications and statutory rules/regulations. Any error/deficiency
noticed during any stage of manufacturing/execution/installation shall be promptly
corrected by the contractor without any extra cost or time, whether or not comments
on the same were received from EIL during the drawing review stage.
4.1.3 Unless otherwise specified, submission of documents for Review/Records shall

commence as follows from the date of Fax of Intent / Letter of Intent/ Fax of
Acceptance (FOA)/ Letter of Acceptance (LOA):
QMS - 1week
Drawing/Document Control Index - 2weeks
Other Documents/Drawings - As per approved Drawing/Document Control
Index/Schedule
4.1.4 Documents as specified in Tender/Contract are minimum requirements. Contractor

shall submit any other document/data required for completion of the job as per
EIL/Owner instructions.

Page 427 of 851

ei ENGINEERS No.
acs INDIA LIMITED
DOCUMENTATION
REQUIREMENTS FROM 6-78-0002 Rev. 1
4.2 Style and Formatting
4.2.1 All Documents shall be in ENGLISH language and in M.K.S System of units.
4.2.2 Before submitting the drawings and documents, contractor shall ensure that the
following information are properly entered in each drawing:
Tender Number
Name of Equipment / Package
Equipment / Package Tag No.
Name of Project
Owner
Main Contractor (if work is sub-contracted)
Drawing / Document Title
Drawing / Document No.
Drawing / Document Revision No. and Date
4.3 Review and Approval of Documents by Contractor
4.3.1 The Drawing/Documents shall be reviewed, checked, approved and duly

signed/stamped by contractor before submission. Revision number shall be changed
during submission of the revised contractor documents and all revisions shall be
highlighted by clouds. Whenever the contractor require any sub- contractor drawings
to be reviewed by EIL, the same shall be submitted by the contractor after duly
reviewed, approved and stamped by the contractor. Direct submission of sub-
contractor's drawings without contractor's approval shall not be entertained.
4.4 Document Category
4.4.1 Review Category
Following review codes shall be used for review of contractor Drawings/Documents:
Review Code 1 No comments. Proceed with manufacture/

fabrication/ Construction as per the document.
Review Code 2 Proceed with manufacture/ fabrication/
Construction as per commented document.
Revised document required
Review Code 3 Document does not conform to basic
requirements as marked. Resubmit for review
R Document is retained for Records. Proceed with
manufacture/ fabrication
V Void
4.5 Methodology for Submission of Documents to EIL/Owner
4.5.1 Document Control Index (DCI)

Contractor shall create and submit Document Control Index (DCI) for review based on
PO/PR/MR along with schedule date of submission of each drawing/document on EIL
eDMS. The DCI shall be specific with regard to drawing/document no. and the exact
title. Proper sequencing of the drawings/documents should be ensured in schedule
date of submission.

Page 428 of 851


ENGINEERS DOCUMENTATION No.
tra /A Govt of India Undertaking) REQUIREMENTS FROM
4.5.2 Submission of Drawings/Documents

Drawings/documents and data shall be uploaded on the EIL eDMS Portal. The detail
guidelines for uploading documents on EIL eDMS Portal are available on following
URL
http://edocx.ei Lco. i n/vporta I
4.5.3 Statutory Approvals

Wherever approval by any statutory body is required to be taken by Contractor, the
Contractor shall submit copy of approval by the authority to EIL.
4.5.4 Details of Contact Persons of Contractor
After placement of order contractor shall assign a Project Manager for that order. The
details are to be filled online through the portal. The details include e-mail address,
mailing address, telephone nos., fax nos. and name of Project Manager. All the system
generated emails pertaining to that order shall be sent to the assigned Project
Manager.
4.5.5 Schedule and Progress Reporting
Contractor shall submit monthly progress report and updated procurement,
engineering and manufacturing status (schedule vs. actual) every month. First report
shall be submitted within 2 weeks from FOA/LOA. In case of exigencies, EIL/Owner
can ask for report submission as required on weekly/fortnightly/adhoc basis depending
upon supply status and contractor shall furnish such reports promptly without any price
implication. Format for progress report shall be submitted by the contractor during
kick off meeting or within one week of receiving FOA/LOA, whichever is earlier.
4.5.6 Quality Assurance Plan/Inspection and Test Plan

Inspection and test plans attached if any, to the tender are generic and indicative only.
Immediately after receipt of the order, contractor shall submit within one week of
receiving FOA/LOA, job specific ITPs based on the indicative ITPs. Further, contractor
shall also submit Quality Assurance Plan for project activities in the scope of contract,
starting from manufacturing to handing over/ commissioning, these plans shall
cover/identify the activities, relevant procedure, if any, code of conformance,
resources for performance and checking/monitoring, approval requirements and
authority, records to be generated and audit scope by EIL/Owner.
For EPCC/LSTK/Package contracts, the contractor shall prepare a list of items/
equipments and their inspection categorization plans for all items included in the scope
of supply immediately after receipt of order and obtain approval for the same from EIL.
The items shall be categorized into different categories depending upon their criticality
for the scope of inspection of TPIA and/or EIL.
4.5.7 Inspection Release Note (IRN)/ Inspection Certificate (IC)

Contractor shall ensure that all documents viz. documents reviewed, manufacture's
test certificate etc., mentioned in Inspection Release Note(IRN), issued by EIL/third
party against the materials supplied by contractor., are sent to EIL along with the IRN.
IRN/ IC shall be issued by EIL Inspector/ third party inspection agency only after all
the drawings/documents as per DCI are submitted and are accepted under review
code-1 & code R. Material/Equipments dispatch from contractor's/sub vender's works
shall not commence till above condition is met.
Page 429 of 851

Ogof IOM 0,1.I
INDIA LIMITED
(A Govt W Indio Undertalung) REQUIREMENTS FROM 6-78-0002 Rev. 1
Note: Non fulfilling above requirement shall result into appropriate penalty or with-
holding of payment as per conditions of Tender/Contract.
4.6 Final Documentation

4.6.1 As built Drawings
Shop/Site changes made by contractor after approval of drawings under 'Code 1' by
EIL and deviations granted through online system , if any, shall be marked in hard
copies of drawings which shall then be stamped 'As-built' by the contractor. These
'As-built' drawings shall be reviewed and stamped by EIL Inspector/Site
engineer/TPIA also. Format for completeness of final documents (Format No. 3-78-
0004) is attached with this specification. Contractor shall prepare scanned images
files of all marked — up 'As — built' drawings. Simultaneously contractor shall
incorporate the shop/site changes in the native soft files of the drawings also.
4.6.2 As built Final Documents
As built final documents shall be submitted as listed in Tender/Contract.
4.6.3 Packing/Presentation of Final Documents
Final Documents shall be legible photocopies in A4, A3 size only. Drawings will be
inserted in plastic pockets (both sides transparent, sheet thickness minimum 0.1 mm)
with an extra strip of 12 mm wide for punching so that drawings are well placed.
Final Documentation shall be bound in hard board plastic folder(s) of size 265 mm x
315 mm (10 1 /2 inch x 12 1 /2 inch) and shall not be more that 75 mm thick. It may be of
several volumes and each volume shall have a volume number, index of volumes and
index of contents of that particular volume. Where numbers of volumes are more,
90mm thickness can be used. Each volume shall have top PVC sheet of minimum
0.15 mm thick duly fixed and pressed on folder cover and will have 2 lever clips. In
case of imported items documents, 4 lever clip shall also be accepted. All four corners
of folders shall be properly metal clamped. Indexing of contents with page numbering
must be incorporated by contractor. Spiral/Spico bound documents shall not be
acceptable. As mentioned above, books should be in hard board plastic folders with
sheets punched and having 2/4 lever clips arrangement.
Each volume shall contain on cover a title block indicating Tender No., name of project,
name of customer, package equipment tag no. & name (if applicable). Each volume
will have hard front cover and a reinforced spine to fit thickness of book. These spines
will also have the title printed on them. Title shall include also volume number (say 11
of 15) etc.
4.6.4 Submission of Soft copies

Contractor shall submit to EIL, the scanned images files as well as the native files of
drawings/documents, along with proper index.
In addition to hard copies, contractor shall submit electronic file (CD-ROM) covering
soft copies of all the final drawings and documents, all text documents prepared on
computer, scanned images of all important documents (not available as soft files), all
relevant catalogues, manuals available as soft files (editable copies of drawings/text
documents, while for catalogues/manuals/proprietary information and data PDF files
can be furnished).
All the above documents shall also be uploaded on the EIL eDMS portal.

Page 430 of 851

laraeles ENGINEERS DOCUMENTATION No.
Ogell 22-eg W INDIA LIMITED 6-78-0002 Rev. 1
(A Govt of India Undertaking) REQUIREMENTS FROM
4.6.5 Completeness of Final Documentation

Contractor shall get the completeness of final documentation verified by EIL/TPIA and
attach the Format for Completeness of Final Documentation (Format No. 3-78-0004)
duly signed by EIL or TPIA as applicable to the document folder.
Page 431 of 851

COMPLETENESS OF FINAL
fEr) ENGINEERS DOCUMENTATION
$afg7:11 tel5leg
Men eRali• 4,30.0
INDIA LIMITED
(A Gort of hula Undertakog)
COMPLETENESS OF FINAL DOCUMENTATION
Name of Supplier/Contractor
Customer
Project
EIL's Job No.
Purchase Order No./
Contract No.
Purchase Requisition No./

Tender No. Rev. No. :
Name of the Work/

Equipment
Tag. No.
Supplier's/ Contractor's
Works Order No.
Certified that the Engineering Documents/ Manufacturing & Test Certificates submitted by the
supplier are complete in accordance with the Vendor Data Requirements of Purchase
Requisition.
Signature Signature
Date Date
Name Name
Designation Designation
Department Department
Supplier/Contractor EIL/TPIA
arTilittl/APPROVED
gTffTeR/ Sig
eilegiltk
tvi . ...........
.....
4/ Name: ......... .. . ......
..................
f4-41--/ Date: ..... ••••••• .... ......
Format No. 3-78-0004, Rev. 1/ 12.03.2015 Copyright EIL — All rights reserved
Page 432 of 851


∎31 ENGINEERS DOCUMENTATION
ligar lafgesW INDIA LIMITED 6-78-0003 Rev. 1
(411W1 292,51V MIJ‘10571) Govt o India Undertalongj
REQUIREMENTS FROM
SUPPLIERS Page 1 of 8
affr irewufat 74ER

*mat t feitu
SPECIFICATION FOR
DOCUMENTATION REQUIREMENTS
FROM SUPPLIERS
C)(415----2
QMS QMS
1 12.03.15 General Revision Standards Standards SC
Committee Committee
QMS QMS
Committee Committee
Standards Standards
Comm ifte Bureau
Date Purpose Convener Chairman
No by by
Approved by
Page 433 of 851

(t,ft. ENGINEERS
1i laWGNIIY INDIA LIMITED
ogire, efiTIWAnowAl (A Govt of Into Undertaking(
DOCUMENTATION
REQUIREMENTS FROM
No.
6-78-0003 Rev. 1
Abbreviations:
DCI - Document Control Index

eDMS - Electronic Document Management System
FOA Fax of Acceptance
HOD Head of Division / Department
IC Inspection Certificate
IRN Inspection Release Note
ITP Inspection and Test Plan
LOA Letter of Acceptance
MOU Memorandum of Understanding
PO Purchase Order
QMS Quality Management System
TPIA Third Party Inspection Agency
URL Universal Resource Locator

Mr. S.K. Kaul (C&P)
Page 434 of 851


ei ENGINEERS DOCUMENTATION No.
Oaez idiWIeg INDIA LIMITED 6-78-0003 Rev. 1
011E71 ewaxedaagem)

(A Govt of India Undertaking) REQUIREMENTS FROM
CONTENTS

Clause Title Page
No.
1.0 SCOPE 4
2.0 DEFINITIONS 4
Attachments
Format for completeness of Final Documentation Format No. 3-78-0004

Page 435 of 851

dol ENGINEERS DOCUMENTATION No.
5'gzir tlf5ltu INDIA LIMITED 6-78-0003 Rev. 1
I.VOM (A Govt of Intha Undertakongt REQUIREMENTS FROM
1.0 SCOPE
This specification establishes the Documentation Requirements from Suppliers.
All documents/data against the PO / PR / MR shall be developed and submitted to
EIL/Owner by the suppliers for review / records, in line with this specification.
2.0 DEFINITIONS
2.1 Supplier
For the purpose of this specification, the word "SUPPLIER" means the person(s),
firm, company or organization who is under the process of being contracted by EIL /
Owner for delivery of some products (including service). The word is considered
synonymous to bidder, contractor or vendor.
2.2 Owner

from Bidders
4.1 Documents/Data to be Submitted by the Supplier
4.1.1 The Supplier shall submit the documents and data against the PO/PR/MR as per the
list given in respective PO/PR/MR.
4.1.2 Review of the supplier drawings by EIL would be only to review the compatibility with
basic designs and concepts and in no way absolve the supplier of his
responsibility/contractual obligation to comply with PR requirements, applicable
codes, specifications and statutory rules/regulations. Any error/deficiency noticed
during any stage of manufacturing/execution/installation shall be promptly corrected
by the supplier without any time and cost implications, irrespective of comments on
the same were received from EIL during the drawing review stage or not.
4.1.3 Unless otherwise specified, submission of documents for Review/Records shall

commence as follows from the date of Fax of Intent / Letter of Intent/ Fax of
Acceptance (FOA)/ Letter of Acceptance (LOA):
QMS - 1 week
Drawing/Document Control Index - 2 weeks
Other Documents/Drawings - As per approved Drawing/Document Control
Index/Schedule
4.1.4 Documents as specified in PO/PR/MR are minimum requirements. Supplier shall

submit any other document/data required for completion of the job as per EIL/Owner
instructions.

Page 436 of 851

'7f 11 INDIA LIMITED 6-78-0003 Rev. 1
I OfiTt cYeawlnn (A Govt of India UndenakIngi REQUIREMENTS FROM
4.2 Style and Formatting
4.2.1 All Documents shall be in ENGLISH language and in M.K.S System of units.
4.2.2 Before forwarding the drawings and documents, contractor shall ensure that the
following information are properly mentioned in each drawing:
Purchase Requisition Number
Name of Equipment / Package
Equipment / Package Tag No.
Name of Project
Client
Drawing / Document Title
Drawing / Document No.
Drawing / Document Revision No. and Date
43 Review and Approval of Documents by Supplier
4.3.1 The Drawing/Documents shall be reviewed, checked, approved and duly

signed/stamped by supplier before submission. Revision number shall be changed
during submission of the revised supplier documents and all revisions shall be
highlighted by clouds. Whenever the supplier require any sub-supplier drawings to be
reviewed by EIL, the same shall be submitted by the supplier after duly reviewed,
approved and stamped by the supplier. Direct submission of sub-supplier's drawings
without contractor's approval shall not be entertained.
4.4 Document Category
4.4.1 Review Category
Following review codes shall be used for review of supplier Drawings/Documents:
Review Code 1 No comments. Proceed with manufacture/

fabrication as per the document.
Review Code 2 Proceed with manufacture/fabrication as per
commented document. Revised document
required.
Review Code 3 Document does not conform to basic
requirements as marked. Resubmit for review
R Document is retained for Records. Proceed
with manufacture/fabrication.
V Void
4.5 Methodology for Submission of Documents to EIL/Owner
4.5.1 Document Control Index (DCI)
Supplier shall create and submit Document Control Index (DCI) for review based on
PO/PR/MR along with schedule date of submission of each drawing/document on EIL
eDMS. The DCI shall be specific with regard to drawing/document no. and the exact
title. Proper sequencing of the drawings/documents should be ensured in schedule
date of submission.

Page 437 of 851


r1.7
-14 ENGINEERS DOCUMENTATION No.
51g-a feff5leg INDIA LIMITED 6-78-0003 Rev. 1
1.17,124ifflsrefloJOORI1 IA GUN. of India Undertaking, REQUIREMENTS FROM
4.5.2 Submission of Drawings/Documents

Drawings/documents and data shall be uploaded on the EIL eDMS Portal as per DCI.
The detail guidelines for uploading documents on EIL eDMS Portal are available on
following URL
http://edocx.eil.co.in/vportal
4.5.3 Statutory Approvals
Wherever approval by any statutory body is required to be taken by Supplier, the

Supplier shall submit copy of approval by the authority to EIL.
4.5.4 Details of Contact Persons of Supplier
After placement of order supplier shall assign a Project Manager for that order. The
details are to be filled online through the portal. The details include e-mail address,
mailing address, telephone nos., fax nos. and name of Project Manager. All the system
generated emails pertaining to that order shall be sent to the assigned Project
Manager.
4.5.5 Schedule and Progress Reporting
Supplier shall submit monthly progress report and updated procurement, engineering
and manufacturing status (schedule vs. actual) every month, beginning within 2 weeks
from FOA/LOA. In case of exigencies, EIL/Owner can ask for report submission as
required on weekly/fortnightly/adhoc basis depending upon supply status and supplier
shall furnish such reports promptly without any price implication. Format for progress
report shall be submitted by the Supplier during kick off meeting or within one week of
receiving FOA/LOA, whichever is earlier.
4.5.6 Quality Assurance Plan/Inspection and Test Plan

Inspection and test plans (ITP) attached if any, to the MR/PR are to be followed.
However for cases wherein ITPs have not been attached with MR/PR, Supplier shall
submit within one week of receiving FOA/LOA, the Quality Assurance Plan for
manufacturing, covering quality control of critical bought out items/materials,
inspection & testing at various stages of production, quality control records and site
assembly & testing as may be applicable to the specific order and obtain approval
from concerned Regional procurement Office of EIL/third party inspection agency, as
applicable.
For Package equipment contracts, the supplier shall prepare a list of items/
equipments and their inspection categorization plan for all items included in the scope
of supply immediately after receipt of order and obtains approval for the same from
EIL. The items shall be categorized into different categories depending upon their
criticality for the scope of inspection of TPIA and/or EIL.
4.5.7 Inspection Release Note (IRN)/ Inspection Certificate (IC)
IRN/ IC shall be issued by EIL Inspector/ third party inspection agency on the basis of
successful inspection, review of certificates as per specifications & agreed quality plan
(as applicable) and only after all the drawings/documents as per DCI are submitted
and are accepted under review code-1 or code R. Supplier shall ensure that necessary
documents/manufacturing and test certificates are made available to EIL/TPIA as and
when desired.

Page 438 of 851

Ogell 0151jeg INDIA LIMITED 6-78-0003 Rev. 1
1.127, owtore o43frosso IA Govt of India Unclettalong) REQUIREMENTS FROM
Note: Non fulfilling above requirement shall result into appropriate penalty or with-
holding of payment as per conditions of PO/PR/MR.
4.5.8 Transportation Plan

Transportation Plan for Over Dimensional Consignments (ODC), if any, shall be
submitted within 2 weeks of receiving FOA/LOA, for approval. Consignment with
parameters greater than following shall be considered as over dimensional.
Dimensions: 4 meters width x 4 meters height x 20 meters length
Weight : 32 MT
4.6 Final Documentation

4.6.1 As Built Drawings
Shop changes made by Supplier after approval of drawings under `Code 1' by EIL and
deviations granted through online system , if any, shall be marked in hard copies of
drawings which shall then be stamped 'As-built' by the supplier. These 'As-built'
drawings shall be reviewed and stamped by EIL Inspector/ TPIA also. Supplier shall
prepare scanned images files of all marked — up 'As — built' drawings. Simultaneously
Supplier shall incorporate the shop changes in the native soft files of the drawings
also.
4.6.2 As Built Final Documents
As built final documents shall be submitted as listed in PO/PR/MR.
4.6.3 Packing/Presentation of Final Documents
Final Documents shall be legible photocopies in A4, A3 size only. Drawings will be
inserted in plastic pockets (both sides transparent, sheet thickness minimum 0.1 mm)
with an extra strip of 12 mm wide for punching so that drawings are well placed.
Final Documentation shall be bound in Hard board Plastic folder(s) of size 265 mm x
315 mm (101 /2 inch x 12 1 /2 inch) and shall not be more that 75 mm thick. It may be of
several volumes and each volume shall have a volume number, index of volumes and
index of contents of that particular volume. Where number of volumes are more,
90mm thickness can be used. Each volume shall have top PVC sheet of minimum
0.15 mm thick duly fixed and pressed on folder cover and will have 2 lever clip. In
case of imported items documents, 4 lever clip shall also be accepted. All four corners
of folders shall be properly metal clamped. Indexing of contents with page numbering
must be incorporated by supplier. Spiral/Spico bound documents shall not be
acceptable. As mentioned above, books should be in hard board plastic folders with
sheets punched and having 2/4 lever clips arrangement.
Each volume shall contain on cover a Title Block indicating package Equipment Tag
No. & Name, PO/Purchase Requisition No., Name of Project and Name of Customer.
Each volume will have hard front cover and a reinforced spine to fit thickness of book.
These spines will also have the title printed on them. Title shall include also volume
number (say 11 of 15) etc.
4.6.4 Submission of Soft Copies
Supplier shall submit to EIL, the scanned images files as well as the native files of
drawings/documents, along with proper index.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL—AIL rights reserved
Page 439 of 851

(L:ED'D ENGINEERS No.
lig ar idf5les
I MT
C,'
INDIA UMITED
riernfO7IJOCFAI IA Govt of India Undertaking)
DOCUMENTATION
REQUIREMENTS FROM 6-78-0003 Rev. 1
In addition to hard copies, Supplier shall submit electronic file (CD-ROM) covering soft
copies of all the final drawings and documents, all text documents prepared on
computer, scanned images of all important documents (not available as soft files), all
relevant catalogues, manuals available as soft files (editable copies of drawings/text
documents, while for catalogues/manuals/proprietary information and data, PDF files
can be furnished).
All the above documents shall also be uploaded on the EIL eDMS portal.
4.6.5 Completeness of Final Documentation
Supplier shall get the completeness of final documentation verified by EIUTPIA and
attach the Format for Completeness of Final Documentation (Format No. 3-78-0004)
duly signed by EIL Inspector or TPIA as applicable to the document folder.

Page 440 of 851

COMPLETENESS OF FINAL
fEr) ENGINEERS DOCUMENTATION
$afg7:11 tel5leg
Men eRali• 4,30.0
INDIA LIMITED
(A Gort of hula Undertakog)
COMPLETENESS OF FINAL DOCUMENTATION
Name of Supplier/Contractor
Customer
Project
EIL's Job No.
Purchase Order No./
Contract No.
Purchase Requisition No./

Tender No. Rev. No. :
Name of the Work/

Equipment
Tag. No.
Supplier's/ Contractor's
Works Order No.
Certified that the Engineering Documents/ Manufacturing & Test Certificates submitted by the
supplier are complete in accordance with the Vendor Data Requirements of Purchase
Requisition.
Signature Signature
Date Date
Name Name
Designation Designation
Department Department
Supplier/Contractor EIL/TPIA
arTilittl/APPROVED
gTffTeR/ Sig
eilegiltk
tvi . ...........
.....
4/ Name: ......... .. . ......
..................
f4-41--/ Date: ..... ••••••• .... ......
Format No. 3-78-0004, Rev. 1/ 12.03.2015 Copyright EIL — All rights reserved
Page 441 of 851

STANDARD SPECIFICATON FOR STANDARD SPECIFICATION NO.
ENGINEERS TAPE COATNG FOR
iiLlf INDIA LIMITED 6-79 -0011 Rev. 2
• eiemre as1 iA Gov, of India Undeaak,ng) UNDERGROUND STEEL
PIPELINES Page 1 of 14
VFW *az! Liwictrwil Vireff

. 1:1-MW 1-
41-44rr

TAPE COATING FOR
UNDERGROUND STEEL PIPELINES
REVISED & ISSUED AS

2 09.08.18 SM SS SG RKT
REVISED & ISSUED AS
1 16.08.12 SS RC PPL DM
0 09.06.03 ISSUED AS STANDARD SPEC. GVS GS KKS SKG

Standards Standards
Date Purpose Prepared by Checked by Convener Chairman
No
Approved by
Page 442 of 851

Oge.n Eateg INDIA LIMITED 6-79-0011 Rev. 2
taw?, evemre nn0anml IA Govt of India Undertaking) UNDERGROUND STEEL
Abbreviations:
ASTM American Society for Testing and Materials

AWWA American Water Works Association
DFT Dry Film Thickness
ISO International Organization for Standardization
SSPC Steel Structure Painting Council
For the purpose of this specification, the following definitions shall apply:
OWNER : Owner is the party that initiates the project and ultimately pays for its design
& construction.
PMC : Owner's authorized agent/consultant to act for the owner. PMC is the party,
which carries out management of the project.
MANUFACTURER : The party which manufactures and/or supplies the tape coating materials
and services to perform the duties specified by owner/PMC.
Materials & Coating Standards Committee
Convener : Mr. S.Ghosal
Members : Mr. Deepak Gupta (Projects)

Mr. M. Ismaeel (Piping)
Mr. K.J Harinarayanan (SME)
Mr. D.C. Brahma (Structural)
Mr. R. Muthu Ramalingam (SCM)
Mr. Divyajyot Singh (Construction)
Mr. Naveen Parashar (Projects)
Mr. Satya Sridhar (Process-2)
Page 443 of 851

I elecnft ) (A Govt of India Undeftaiong) UNDERGROUND STEEL
CONTENTS
1.0 SCOPE 4
4.0 DOCUMENTATION 4
5.0 MATERIALS 5
6.0 SURFACE PREPARATION 8
7.0 APPLICATION OF PRIMER 8
8.0 TAPE COATING SYSTEM AND APPLICATION 8
9.0 FIELD JOINT COATING AND REPAIR OF DAMAGED COATING 9
10.0 INSPECTION AND TESTING FOR QUALITY ASSURANCE 9
11.0 PROTECTION OF COATED PIPES AGAINST UV DEGRADATION 11
12.0 COAL TAR TAPE WIDTH 11
ANNEXURE-I 12
Page 444 of 851

(prol) ENGINEERS TAPE COATNG FOR
Ifgar
,alre'er fdaeg
efecrwl.,17F.3)
INDIA LIMITED
(A Govt of ndo Undellaking) UNDERGROUND STEEL
6-79-0011 Rev. 2
1.0 SCOPE
This specification covers the requirement for materials, surface preparation, application,
inspection, repairs and handling for external corrosion protection of underground carbon steel
pipelines, field joints and coating repair with service temperature upto 60°C using coal tar tape
coating.
The latest edition of the following standards and documents shall apply:
2.1 AWWA C-203: Coal tar protective coatings and linings for steel water pipelines
2.2 SIS 05-5900: Pictorial surface preparation standard for painting steel surface ISO 8501:1988
2.3 SSPC-SP: The Society for Protective Coatings surface preparation specifications :
SSPC-SP1: Solvent cleaning

SSPC-SP3: Power tool cleaning
SSPC-SP10: Near white metal blast cleaning
2.4 BS 4164: British Standard Specification for coal tar based hot applied coating materials for
protecting iron and steel including a suitable primer
3.1 Equipments and accessories required for tape coating shall be in good operating conditions.
Adequacy of equipments and accessories shall be ensured by EPCC Contractor and Certified.
3.2 Necessary arrangements for power supply and other utilities shall be made for completion of
the job.
3.3 Necessary testing and inspection facilities as required by this standard shall be developed at
site and shall be approved by the PMC/OWNER.
3.4 Protective tapes and other materials brought to site shall be as per the specifications of this
standard and should be approved by the PMC/OWNER.
Field and laboratory tests as given in this standard shall be carried out for each batch of primer
and tape.
3.5 All work shall be carried out in accordance with this specification and shall be phase wise
approved by PMC/OWNER. Any working procedure developed from this specification shall
be approved in advance by the Engineer-In-Charge (EIC).
3.6 Manufacturers recommended/ Trained supervisor and skilled applicator shall be engaged by
the contractor for application, inspection and quality assurance.
3.7 Applicator shall possess copy of reference documents and test procedure appearing in this
standard, which are required for field application.
4.0 DOCUMENTATION
The following documentation is required:
Page 445 of 851

Oar INDIA LIMITED 6-79-0011 Rev. 2
(111271,2MIZ 431.140,41) UNDERGROUND STEEL
4.1 Before Starting-Up of the Work
A quality plan with procedures for qualification trials and for the actual work shall be made.
The quality plan shall include a time table for the various activities, with a description of
coating materials to be used, their application, qualification of personnel involved in the work,
responsibilities and lines of communications, details of equipment and their calibration,
proposed hold points for PMC/OWNER inspection and endorsement and the detailed
procedures for the testing and inspection. Documented evidence that the requirements of this
specification have been met during production shall be shown.
4.2 During Execution of Coating Job
• Daily progress reports on application of tape coating materials with details on weather
conditions
• Results of comparison of surface cleanliness, surface profile on blast cleaned surface,
tape coating thickness, holiday detection and adhesion tests
• Particulars of surface preparation, priming and tape application; no. of wraps
• Details of non-compliance, rejects and repairs
• Types of testing equipments and calibration
• Code and batch numbers of coating materials used
• Field tests on primers and tape coat
• Progress of work as per scheduled program.
5.0 MATERIALS
5.1 General Requirements
5.1.1 Manufacturer's test certificates shall be produced and examined by the PMC/OWNER for all
materials, proposed to be used for tape coating as per this standard.
5.1.2 All materials brought to site for tape coating shall be suitably marked and identifiable with the
following information:
Manufacturer's name
Type of material and code
Batch number
Date of manufacturing
Technical datasheet for each type of material
Shelf life
Manufacturer's quality control test certificates with actual results of each batch.
5.1.3 Materials without manufacturer's test certificates and identification marks shall not be
accepted and used.
5.1.4 Test certificate from competent/recognized Govt. laboratory/in the laboratory of

internationally reputed certifying agencies like, Lloyds registrars, DNV (Det Norske Veritas),
BV (Bureau Veritas) on the properties of materials quoted by the manufacturer in the technical
data sheet shall also be submitted along with the technical data sheet of the products. Any
recent past certificate can also be submitted
5.1.5 Each batch of primer and tape shall be tested in the field by the procedure as given in this
standard. PMC/OWNER will review the field test data before use of the materials.
Page 446 of 851

,--, STANDARD SPECIFICATON FOR STANDARD SPECIFICATION NO.
ENGINEERS
0g-a fail& _
1.112n eitaxt M1,12.3)
INDIA LIMITED
IA Govt of India Undettak,o9)
TAPE COATNG FOR
UNDERGROUND STEEL
6-79-0011 Rev. 2
5.2 Characteristics and Functional Requirements of Coating Materials
5.2.1 Coal tar tapes
Materials for coal tar tape coating shall conform to the following specifications. The
following are the salient features of coal tar tape coating materials.
5.2.1.1 Primer
The primer shall be type B as specified in AWWA C-203. Following are the main
characteristics:
Type Fast drying, synthetic, chlorinated rubber-synthetic
plasticizer-solvent based
Drying time (tack free) 15 minutes (approx.) (ASTM D1640)
Flash point > 23°C (ASTM D93/D3941)
Volatile matter (105-110°C) percent 75 (maximum) (ASTM D2369)
by mass
Viscosity, on FORD CUP NO. 35-60 seconds (ASTM D1200)
4 (4mm nozzle) at 23°C
DFT 25 microns/coat (minimum)
Coverage (Theoretical) 10 M2/Lit/Coat
Coverage (Practical) @ 25 microns 6 M2/Lit/Coat (minimum) (ASTM D344)
DFT coat
Application properties By brush/ spray should produce an effective bond
between metal and subsequent coaltar tape
Adhesion test ( after 72 hours) The primer shall be tested after applying tape
coating as per AWWA C-203.
5.2.1.2 Coal tar tape
The tape shall be coal-tar component supported on fabric of inorganic fibres.
a) Raw coal tar pitch
The coal tar (hard pitch) which shall have the following salient properties:
Characterization Values Standard

Softening point °C 65 121 ASTM D36
Specific gravity 1.30±0.05 ASTM D71
Ash content, % 0.5 Max. ASTM D2415
Physical state Solid at ambient temperature
b) Fabric
Type: The fabric shall be a thin, flexible, uniform mat or tissue composed of glass
fibers in an open structure bonded with a suitable resinous inert material compatible
with coal tar.
Weight (min) g/m2 40

Thickness (min.) mm 0.3
Breaking load in the longitudinal direction: 2.28KN/m (min.)
Page 447 of 851

STANDARD SPECIFICATON FOR
afaelt4 ENGINEERS TAPE COATNG FOR
STANDARD SPECIFICATION NO.
tlf4leg
riecrat any,
INDIA LIMITED
(A GON of India Undertaking) UNDERGROUND STEEL
6-79-0011 Rev. 2
Porosity When related to pressure difference across the sample, the glass fibre
fabric shall have porosity of not less than 0.6mm and not more than
1.9mm of water at an average air velocity of 61m/minute (1m/sec.)
Temperature The fabric shall be unaffected under load in hot coal tar at 288°C for
resistance one minute. It shall not shrink length wise or width wise.
Pliability test No cracking shall take place when bent over a mandrel of 3mm radius
through 90° arc at a uniform speed of approximately 2 seconds after
immersing in water for 10 to 15 minutes.
Note (1) : Manufacturer's test data in the laboratory are required for the above properties on
the materials supplied.
c) Physical properties of coal tar tape
Property Requirement Test method

Min. Max.
Service temperature ( °C) - 60
Tape thickness mm 2.0 2.5 AWWA C-203

Weight average (kg/sq.m/mm) 1.25 - ASTM D146
Breaking strength in longitudinal 0.7 AWWA C-203

direction kN/m
Adhesion AWWA C-203.
Insoluble content % by wt in 93 minimum (procedure given in ANNEXURE-I)
petrol
d) Physical properties of coal tar component in the finish tape
Property Requirement Test method

Min. Max.
Softening point ( °C) 65 121 ASTM D36
Penetration at 25°C/100g/ 1 9 ASTM D5/BS-4164
10 mm/5 sec
Filler % 20 35 ASTM D 2415 or AWWA C-203
e) Filler
Characteristics Requirement Test Method

Fineness: % w/w, minimum Shall pass through ASTM D1366
mesh size of 75
microns
Loss on ignition at 800° C, w/w 10 ASTM D1208
max.
1) Field Tests
Few test methods given in ANNEXURE-I are mainly applicable during field
application.
Page 448 of 851

ir ta
5'1g-e.AZ -eg INDIA LIMITED 6-79-0011 Rev. 2
,,ea,(e..3qM-A, (A Go4 of India Unde(taA,A9) UNDERGROUND STEEL
6.0 SURFACE PREPARATION
6.1 All oil, grease on the pipe metal surface shall be thoroughly removed by flushing with a
suitable solvent (such as xylene or 1,1,1 trichloroethylene) and wiping with clean rags. The
solvent cleaning shall be as per SSPC-SP-1. If required detergent cleaning shall be done
before or after solvent cleaning.
6.2 The degreased pipe metal surface shall be blast cleaned to Sa21/2 of SIS -05-5900 or SSPC-SP-
10 with a surface profile of 30-50 microns trough to peak. Blasted surface that rusts before
priming shall be cleaned by wire brushing or shall be re-blasted. Priming shall be done within
4 hours of completion of blast cleaning. Otherwise total re-blasting may be necessary.
7.0 APPLICATION OF PRIMER
One coat of primer shall be applied on blast cleaned surface by brush or spray to achieve
complete wetting of the surface as recommended by the manufacturer. In case the surface is
wet during application of primer, the surface should be made dry. The primer shall be allowed
to become touch dry prior to tape application. Primer and tape shall be supplied by the same
manufacturer.
8.0 TAPE COATING SYSTEM AND APPLICATION
8.1 Tape Coating System
(a) One coat of fast drying synthetic primer by brush or spray after surface preparation to
provide complete wettability of the surface.
(b) One layer of coal tar tape coating with 2 mm thickness on the surface of primed pipe
after touch dry.
(c) Second coat of fast drying synthetic primer by brush or spray on 1st layer of tape
coating to provide complete wettability of the surface for application of 2nd layer of
tape.
(d) 2nd layer of coal tar tape coating with 2 mm thickness on the surface of primed pipe
after touch dry.
8.2 Application Method
Tape application should follow primer application as soon as the primed pipe surface is touch
dry. The primer and tape application should not be done in case of dusty/windy weather or
during rain. Primed surface should not be kept exposed to atmosphere for very long duration.
The tape shall be wrapped in accordance with the manufacturer's recommendations in a

manner that shall meet the adhesion and holiday detection requirement of this standard. In
any event, there shall be a minimum of 12.5 mm overlap per single wrap.
The applied coating system shall be as follows:
(a) In application, care shall be taken that there are no air pockets or bubbles beneath tape
and the tape shall be in intimate contact with the primed steel.
(b) Manufacturer recommended/trained supervisor and skilled applicator shall be engaged
for tape application.
Page 449 of 851

ENGINEERS
fg-ar vareg
ervoveak.orark0
INDIA LIMITED
(A Govt India Undertaking)
TAPE COATNG FOR
UNDERGROUND STEEL
6-79-0011 Rev. 2
9.0 FIELD JOINT COATING AND REPAIR OF DAMAGED COATING
9.1 Field Joint Coating on Exterior Welds
The exterior joints shall be cleaned and surface preparation by blast cleaning to Sa2'/2 finish of
SIS-05-5900/SSPC-SP-10 as given in clause 6.0. The coating materials shall be same as
applied on as main pipeline. The tape coating material applied on field weld joints shall
overlap at least 75 mm the main pipe coating on each side of the field joint to form a
continuous external coating free of defects. The coating inspection for quality assurance shall
be as given in clause 10.0.
9.2 Repair of Damaged Tape Coating
9.2.1 Damages, flawed areas and holidays: Areas that are damaged, flawed or contain holidays shall
be repaired using the tape coating materials applied on main pipeline and made by the same
manufacturer. In no case, shall damaged areas be repaired by applying additional tape over
loose damaged tape where the damage goes down to the metal or where the bond of the tape
has been destroyed.
9.2.2 Repair of tape: Repair shall be made by removing the applied tape coating from the area
around the holiday. The surface preparation shall be done as per clause 6.0 of this
specification and then repair the area by using the same system of primer and hot applied tape
as was used for the original wrapping as given in clause 8.0. When completed, the area shall
be re-tested following the method of electrical inspection described in clause 10.8.
10.0 INSPECTION AND TESTING FOR QUALITY ASSURANCE
The following stage wise inspection and testing shall be carried out at manufacturers end/at
site by the OWNER or by OWNER's representative third party inspection agency. Petrol test
as per Clause No. 5.2.1.2 c) and Section 2.3 of ANNEXURE-I shall be conducted at site under
the supervision of EIC.
10.1 Fast Drying Synthetic Primer Materials
The physical properties of primer are given in clause 5.2.1.1.The test procedure given is in
Annexure-1
10.2 Tape Coating
As per 5.2.1.2 (b), (c), & (d), the procedure is given in ANNEXURE-I.
10.3 Measurement of Pipe thickness (in case of coating refurbishment)
10.4 Surface Preparation
• Blast cleaning equipment for nozzle type, size, safety gauges, working condition, and
pressure at the tip of the gun.
Abrasive type, hardness to provide required profile size and cleanliness.
Measurement of surface profile and comparing cleanliness with visual standards of
ISO 8501.
10.5 Measurement of pitting depth area of pitted portion, inspection of weld filling and grinding
and patch plate welding, welding of replaced pipe if any.
10.6 Checking of condition of concrete saddles, rubber padding and end seals wherever required.
Page 450 of 851

09faelc4 Ir30•4) ENGINEERS TAPE COATNG FOR
err 02ft w ow) INDIA LIMITED
linen eveoverfsLetrark) (A Gov! of India Undertaking) UNDERGROUND STEEL
6-79-0011 Rev. 2
10.7 Inspection of Primer after Application
• Checking for drying time to be touch dry, tack free drying and hard drying of primer.
Dry film thickness (DFT) shall be checked on metal panel separately.
10.8 Inspection of Tape Coating after Application
•
Visual inspection for uniformity without any wrinkles and irregularities and
overlapping width as per specifications
•
Adhesion test as per AWWA C-203
•
High voltage holiday detection test for pinholes as per AWWA C-203.
10.8.1 Visual
The coated pipes including field joint coating shall be visually inspected for cracks, trapped
air, uniformity, damage etc. Any repair arising out of visual inspection will be decided by
PMC/OWNER.
10.8.2 Thickness
Thickness has to be measured with a caliper with caliper surfaces of at least 20mm diameter,
on 5 tape pieces with an edge length of at least 50mm taken from 5 different coils. The
measuring pressure should be 0.5 N/m2. The measuring accuracy should be within 0.1 mm.
10.8.3 Adhesion Test
a) Adhesion tests shall be made to determine the proper bond between the tape and the
primed pipe. One test per section (of upto 10 meter length) shall be carried out
initially afterwards adhesion test is to be done as per the advice of PMC/OWNER.
Repair required due to adhesion testing shall be decided by the PMC/OWNER.
b) Temperature of the tape and pipe to be tested shall be between 10°C and 27°C. If
required cold water shall be poured over the test area to bring down the temperature to
with in the above range. The coating shall be allowed to set at ambient temperature
for 72 hrs.
• A test area shall be selected where the tape is smooth for 150 mm in the
longitudinal direction of the tape.
Two knife cuts of 150 mm long and 50 mm apart shall be made through the tape.
• A flat blade shall be used to pry up 50 mm of the fabric.
The 50 mm flap of fabric shall be grasped firmly in one hand and shall be pulled
with a quick motion in the direction of the remaining 100 mm of the 150 mm
knife cut.
The adhesion is satisfactory if (i) the tape tears at the point of stripping or (ii) the
fabric strips from the underlying tape component, leaving no more than 10% or
less of the primer or bare metal exposed.
c) Adhesion between tape to tape can be tested following similar procedure as in (b).
This should preferably be done on a test panel.
10.8.4 High voltage holiday detection test
• All tape coated pipes and joints shall be tested with an approved high voltage holiday
detector preferably equipped with an audio visual signaling device to indicate any
faults, holes, breaks or conductive particles in the protective coating.
Page 451 of 851

Ogar tt5teg INDIA LIMITED 6-79-0011 Rev. 2
WWI twant Jg215.0 UNDERGROUND STEEL
• The applied output voltage of the holiday detector shall have a spark discharge of
thickness equal to at least twice the thickness of the coating to assure adequate
inspection voltage and compensate for any variation in coating thickness. The
electrode shall be passed over the coated surface at approximately half the spark
discharge distance from the coated surface only one time at the rate of approximately
10 to 20 meters per minutes. The edge effects shall be ignored. Excessive voltage shall
be avoided as it tends to induce holidays in the coated surface thereby giving erroneous
readings.
While selecting test voltages, consideration shall be given to the tolerance on coating
thickness and the voltage should be selected on the basis of maximum coating
thickness likely to be encountered during testing of a particular pipe.
Thickness of Coating (mm) Test Voltage (Max.) (kV)

2 10
3 12
4 15
The electrical equipment used to test tape coating shall be a portable, low amperage,
adjustable-voltage, pulse type holiday detector. It shall be furnished with a'coil spring
electrode or a suitable brush type electrode. The primary input wattage shall not be
higher than 20 W, and the minimum pulse at crest voltage shall be 20 per second.
11.0 PROTECTION OF COATED PIPES AGAINST UV DEGRADATION
When the coated pipes are required to be left out exposed to sun light for more than a week
before back filling the trench, the coated pipe shall be protected with white coloured water
emulsion latex paint. The water emulsion latex paint to be used must be stabilized, pigmented
dispersion of water-insoluble film forming, high molecular wt. Synthetic polymeric materials
in water. After application and drying the paint must be able to produce a film that adheres to
the coal tar tape coating is white in colour, water resistant and able to withstand exterior
exposure without degradation for a minimum of 90 days.
12.0 COAL TAR TAPE WIDTH
The width of coal tar tape coating for various pipe sizes shall be as follows:
Pipe Size Tape Width

(Nominal Bore) (mm)
80 100/125
100 100/125/166
150 125/166/200
200 125/166/200/250
250 166/200/250/333
300 166/200/250/333
>300 333
Page 452 of 851

er ENGINEERS TAPE COATNG FOR
$fg-ar faareg INDIA LIMITED 6-79-0011 Rev. 2
1.11R71 X 05,) UNDERGROUND STEEL
ANNEXURE-I
TEST METHODS
1.0 PRIMER (fast drying chlorinated rubber based synthetic primer)
1.1 Test method for volatile content (refer ASTM D2369 for full details)
Procedure:
A specimen sample of primer 0.50± 0.10 gms is weighed into a tared aluminum foil dish into
which add 3 ml of solvent toluene technical grade and disperse completely. Heat the above
sample in the forced draft oven for 60 mins. at 110°C ± 5°C. Remove the dishes from the
oven place immediately in desicator, cool to room temperature and weigh. Calculate %
volatile matter (V) by using the following formula:
V = (W2-W1) x 100
S
Where, W2 - Weight of dish + Specimen

WI - Weight of dish + Specimen after heating
S - Specimen wt.
1.2 Test method for viscosity by ford cup no. 4 (refer ASTM D1200 for full details)
The efflux time of primer is determined by ford cup no.4. The cup is cleaned thoroughly by
solvent toluene and a soft brush. Fill the cup with the primer to full level by holding the
orifice with a rubber stopper or finger pull the stopper away and simultaneously start the timer
and measure the time until the first break of primer in the orifice. Measure the temperature of
the fluid in the efflux stream. It shall be reported the efflux time in seconds at a measured
temperature.
1.3 Test method for drying time (refer ASTM D1640 for full details)
Apply the primer by brush on clean glass/clean mild steel panels of suitable sizes and measure
the drying time at a normal room temperature and 50% relative humidity with the coated
panels on horizontal position:
a) Set-to-touch time: Lightly touch the test film with the tip of clean finger and
immediately place the finger tip against a piece of clean clear glass. Observe if any
coating is transferred to the glass. The film is set- to- touch where it still shows a
tacky condition, but none of it adheres to the finger.
b) Dust free time: The coating film is considered to have dried dust free when the
cotton fibres can be removed by blowing lightly over the surface of film.
c) Tack free time: The film is considered free from after tack when the test paper drops
of the test film within 10 seconds.
2.0 COAL TAR TAPE
2.1 Test Method for Relative Density of Tape (refer ASTM D71for full details)
Page 453 of 851

004) ENGINEERS TAPE COATNG FOR
e-g 4,w)- INDIA LIMITED
lfgar fa5i- UNDERGROUND STEEL
6-79-0011 Rev. 2
The test sample is suspended from a thin wire and weighed first in air, then in water at 25°C in
a glass beaker. The relative density is calculated from these weights.
Relative density of tape sample at 25°C = A
(A-B)
Where, A = Weight of specimen in air in mg.

B = Weight of specimen in water at 25°C in mg.
2.2 Test Method for Adhesion of Tape Coating in Laboratory (AWWA C-203)
Clean a section of 2 inch dia steel pipe of 2 ft length or a flat steel panel of 2 inch x 6 inch
prime the cleaned metal and apply a 2 inch width of tape as per manufacturer's
recommendations. The coating shall be allowed to set at room temperature for 72 hrs. after
the test sample has completely set, grasp one end of the tape and pull it off by hand. The
coating is considered to have satisfactory adhesion if [1] the fabric tears at the point of
stripping or (2) the fabric strips from the under lying coating material leaving no more than
approximately 10% or less of the primer or bare metal exposed.
2.3 Test Method for % Wt Loss in 24 hrs Immersion of Tape in Petrol
Samples as described below for this test shall be drawn at random in presence of EIC at site
from the lot delivered to site.
Test Method: Cut 2 tape samples from the same batch weighing accurately 100gms each with
same dimensions (wt. A) and put this sample in a clean and dry 600 ml capacity glass beaker.
Pour 550 ml of standard quality petrol (gasoline) into the glass beaker in v-shape form so that
the tape sample gets totally immersed in petrol. The level of petrol shall be about 5 cm above
the tape sample.
Cover the mouth of the beaker with two layers of thick polyethene sheets and tie these
polyethene sheets with a rubber band around the mouth of the glass beaker. Allow the beaker
to stand at room temperature for 24 hrs without any disturbance. No stirring is to be done.
Take the tape sample out of the beaker after 24 hrs and spread it on blotting papers on a table.
Allow it to dry in the air for 4 hrs weigh the tape accurately again (wt. B)
% Loss in wt. = ( A-B) X 100

A
% Insoluble = 100 - % Loss in wt.
The above test shall simultaneously be carried out with 3 more tape samples selected at
random and the average result shall be taken.
The indicative loss for coal tar tape in petrol shall be 7% maximum.
2.4 Standard Test Method for Relative Density of Solid Hard Pitch of Coal (refer ASTM
D71 for full details).
This test is applicable for testing at manufacturer's end.
2.4.1 Summary of Test Method
The sample is suspended from a thin wire and weighed, first in air, then submerged in water at
25°C. The relative density is calculated from these weights.
Page 454 of 851

ENGINEERS
lea Of-Zs
riemv...3q05.0
INDIA LIMITED
(A GAN of 'Ado Undettak,n9)
TAPE COATNG FOR
UNDERGROUND STEEL
6-79-0011 Rev. 2
Relative density of sample at 25°C = A

A-B
Where A = Weight of specimens in air in mg.
Weight of the specimen in water at 25°C in mg.
2.4.2 Procedure
Tare the balance with a piece of 0.127, (5 ml) nichrome wire or mono-filament nylon line
sufficiently long to reach from the hook on the pan. Support to the saddle when the latter is in
position across the pan. Attach the test specimen to the wire or line so that it is suspended 20
to 30 mm above the straddle when the other end of the wire is attached to the hook.
Weigh the suspended specimen to the nearest 1 mg and record this weight as "A". Fill a 400
or 600m1 beaker two thirds full with freshly boiled distilled water containing a small amount
of detergent. About 100 mgs of Alconox detergent to 200 ml of water has been found
satisfactory. Adjust the temperature of water to 25±2°C and maintain this temperature during
the remainder of the test. Place the beaker with water on the saddle with the specimen, still
suspended, and fully submerged. Weight the immersed specimen to the nearest 1 mg and
record this weight as "B".
Repeat the determination with the second test specimen.
2.4.3 Report
Report the average of two determinations to the third place, unless the individual values differ
by more than 0.005. In this case, repeat the determinations.
Page 455 of 851

siitaet5 (Cr) ENGINEERS FOR SURFACE PREPARATION NO. 6-79-0020
Keg INDIAN.LIMITED
RI AQFIV CA , IA GOO Of Undeflangl AND PROTECTIVE COATING Rev. 0
PAGE 1 OF 59
tin a K4
1-49-br
(7q. Wu! tg)
FOR
SURFACE PREPARATION
AND PROTECTIVE COATING
(NEW CONSTRUCTION)
6-44-0004 REV. 3 REVISED, RE-

0 30.08.12 NUMBERED 8 ISSUED AS STANDARD A.SRIDHAR R.CHAUDHURY P.P.LAHIRI D.MALHOTRA
SPECIFICATION
Standards Standards
Rev. Prepared Committee Bureau
No Date Purpose by Checked by Convenor Chairman
Approved by
Page 456 of 851

02-zieLa ENGINEERS NO. 6-79-0020
$1?-eir la Me ear INDIA LIMITED FOR SURFACE PREPARATION
HIM eknillcIAJAA.M IA GNI al India LInderlaIm9/ AND PROTECTIVE COATING Rev. 0
PAGE 2 OF 59
Abbreviations:
AS Alloy Steel
CS Carbon Steel
DFT : Dry Film Thickness
DM De-mineralized
GI Galvanized Iron
ID Internal Diameter
IRN Inspection Release Note
MS Mild Steel
NB Nominal Bore
OD Outside Diameter
SS Stainless Steel
TSAC : Thermally Sprayed Aluminium Coating
WFT : Wet Film Thickness
SMMS Standards Committee
Convener : Mr. P.P. Lahiri
Members : Mr. A. Amin (SMMS)

Mr. R. Chaudhury (SMMS)
Mr. S. Ghosal (SMMS)
Mr. G.S. Hegde (SMMS)
Mr. P. Saha (SMMS)
Mr. R Nanda (Piping)
Mr. Raj Kishore (Pipeline)
Mr. A.K. Gupta (HMTD)
Mr. S. Mukharjee (Construction)
Mr. A.R. Purushottam (POSD)
Mr. R. Muthulingam (Inspection)
Mr. M.P. Jain (Projects)
Page 457 of 851

OfteituvaNEERs STANDARD SPECIFICATION STANDARD SPECIFICATION
FOR SURFACE PREPARATION NO. 6-79-0020
laiReedi INDIA LIMITED Rev. 0
PIM FRW ZIRJR140 IA Go.4 ei India unden.lono AND PROTECTIVE COATING PAGE 3 OF 59
CONTENTS
SL. DESCRIPTION PAGE

NO NO.
1.0 General 4
2.0 Scope 4
3.0 Reference Codes & Standards 6
4.0 Equipment 7
5.0 Surface Preparation, Shop Primer,Coating Application & Repair and Documentation 7
6.0 Paint Materials 16
7.0 Coating Systems 21
8.0 Coating System for Gratings, Rolling & Stationery Ladders, Spiral Stairways and
Hand Rails in All Location 23
9.0 Coating System for Offsite Area (Inland Plants) 24
10.0 Coating System For Unit Areas as well as DM, CPP, Cooling Tower of Inland Plants
and for All Areas (Unit, Offsite, DM, CPP, etc.) of Coastal Plants 25
11.0 Coating System for Effluent Treatment Plant (ETP) 27
12.0 External Coating Systems for Uninsulated Carbon Steel and Low Alloy Steel Storage
Tanks (For All Plant Locations, Coastal or Inland) - All Process Units & Off-Sites 28
13.0 Internal Coating Systems for Carbon Steel and Low Alloy Storage Tanks - All
Process Units & Off-Sites 30
14.0 Coating Systems for External Side of Underground Carbon Steel Plant Piping and
Underground Vessels 32
15.0 Coating Under Insulation (Coastal Or Inland Plants) All Units Areas & Off-Sites 33
16.0 Coating System for Carbon Steel Components of Coolers / Condensers (Internal
Protection) for Fresh Water Service 34
17.0 Coating System (Internal Protection) for Galvanized or Non Ferrous or Stainless
Steel/ Duplex Stainless Steel Components of Coolers/ Condensers for Fresh Water
Service 35
18.0 Storage 35
19.0 Colour Code 35
20.0 Identification of Vessels, Piping etc 42
21.0 Painting for Civil Defence Requirements 42
22.0 Quality Control, Inspection and Testing 42
23.0 Guarantee 46
24.0 Qualification Criteria of Painting Contractor/Sub-Contractor 46
25.0 Qualification/Acceptance Criteria for Paint Coating System 46
26.0 Method of Sampling & Dispatch for Laboratory Testing 48
Annexure-I Specification For TSAC 50
Page 458 of 851

StilMziet- ENONEERS
Oar iiiRtg Ter INDIA LIMITED Rev. 0
own ARAW/INJOSA) /A Govt a htha Unden•ingi AND PROTECTIVE COATING PAGE 4 OF 59
1.0 GENERAL
1.1 This technical specifications shall be applicable for the work covered by the contract, and
without prejudice to the provisions of various international codes of practice, standard
specifications etc. It is understood that contractor shall carry out the work in all respects with
the best quality of materials and workmanship and in accordance with the best engineering
practice and instructions of Engineer-In-Charge.
1.2 Wherever it is stated in the specification that a specific material is to be supplied or a specific
work is to be done, it shall be deemed that the same shall be supplied or carried out by the
contractor.
Any deviation from this standard without written deviation permit from appropriate
authority will result in rejection of job.
1.3 This specification coven the requirement for protective coating for new construction.
2.0 SCOPE
2.1 Scope of work covered in the specification shall include, without being limited to the
following.
2.1.1 This specification defines the requirements for surface preparation, selection and application
of primers and paints on external surfaces of equipment, vessels, machinery, piping, ducts,
steel structures, external & internal protection of storage tanks for all services and chimneys
if any. The items listed in the heading of tables of paint systems is indicative only, however,
the contractor is fully responsible for carrying out all the necessary painting, coating and
lining on external and internal surfaces as per the tender requirement.
2.2 Extent of Work
2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting:
All uninsulated Carbon Steel & Alloy Steel equipments like vessels, Columns, storage
Tanks, Exchangers if any, parts of boilers etc.
All uninsulated carbon steel and low alloy plant and related piping, fittings and valves
(including painting of identification marks), furnace ducts and stacks.
All insulated parts of vessels, boilers, chimneys, stacks, piping and steam piping and if
any other insulated items present.
All items contained in a package unit as necessary.
All structural steel work, pipe, structural steel supports, walkways, handrails, ladders,
platforms etc.
Flare lines, external surfaces of MS chimney with or without refractory lining and
internal surfaces of MS chimney without refractory lining. (If present)
Page 459 of 851

0a-zetaENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
51gar fatilegW INDIA WIRD Rev. 0
laiRrIMENVOIMBIll (A GoN ot India undertaiongi AND PROTECTIVE COATING PAGE 5 OF 59
Identification of colour bands on all piping as required including insulated aluminium

clad, galvanized, SS and nonferrous piping.
Identification lettering/ numbering on all painted surfaces of equipment/piping insulated

aluminium clad, galvanized, SS and non-ferrous piping.
Marking / identification signs on painted surfaces of equipment/piping including

hazardous service.
Supply of all primers, paints and all other materials required for painting (other than
Owner supplied materials)
Over insulation surface of equipments and pipes wherever required.
Painting under insulation for carbon steel, alloy steel and stainless steel as specified.
Painting of pre-erection/fabrication and Shop primer.
Repair work of damaged pre-erection/ fabrication and shop primer and weld joints in the
field/site before and after erection as required.
All CS Piping, equipments, storage tanks and internal surfaces of RCC tanks in ETP
plant.
Quality control, testing and inspection during all stages of work (surface preparation,
application of coating and testing of furnished coating).
2.2.2 The following surfaces and materials shall not require painting in general. However, if there
is any specific requirement by the owner, the same shall be painted as per the relevant
specifications:
Uninsulated austenitic stainless steel.
Plastic and/or plastic coated materials
c. Non-ferrous materials like aluminum, Cu-Ni alloy, galvanized steel.
2.3 Documents
2.3.1 The contractor shall perform the work in accordance with the following documents issued to
him for execution of work.
Bill of quantities for piping, equipment, machinery and structures etc.
Piping Line List.
c. Painting specifications including special civil defence requirements.
2.4 Unless otherwise instructed, final paint coating (i.e., application of field primer,
wherever required, intermediate and top coats) on pre-erection/ shop primed
Page 460 of 851

151fraeLA ENGINEERS
Itgar 'Matt INDIA umnB) FOR SURFACE PREPARATION NO. 6-79-0020
(NM Fletifie Maga,/ IA Gobi al India uncienaton9/ AND PROTECTIVE COATING Rev. 0
PAGE 6 OF 59
equipments shall be applied at site, only after all welding, testing on systems are
completed as well as after completion of steam purging wherever required .
2.5 Changes and deviations required for any specific job due to clients requirement or otherwise
shall be referred to E1L for deviation permit.
3.0 REFERENCE CODES & STANDARDS
3.1 Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the
contract, latest editions of the following codes and standards are applicable for the work
covered by this contract.
IS-5 : Colour coding

RAL DUTCH : International Standard for colour shade (Dutch Standard)
IS-101 : Methods of test for ready mixed paints and enamels
IS-2379 : Indian Standard for Pipe line identification-colour code
ISO-12944 : Corrosion Protection of steel Structures by Protective Paint
System
ASTM-Vol 6.01&6.03 : American standard test methods for Paints and Coatings.
ANSI A 13.1 : Scheme for identification of piping systems: American
National Standards Institution
SSPC : Steel Structures Painting Council
3.2 Surface Preparation Standards
The latest editions of any of the following standards shall be followed for surface
preparation:
3.2.1 ISO 8501-1 / SIS-05 59 00: ISO standard for Preparation of steel substrates before
application of paints and related products. This standard contains photographs of the various
standards on four different degrees of rusted steel and as such is preferable for inspection
purpose by the Engineer-In-Charge.
3.2.2 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP).
3.2.3 National Association of Corrosion Engineers, U.S.A., (NACE).
3.2.4 Various International Standards equivalent to Swedish Standard for surface preparations are
given in Table-I.
3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of above standards
and codes at site.
3.4 The paint manufacturer's instructions shall be followed as far as practicable at all times for
best results. Particular attention shall be paid to the following:
Instructions for storage to avoid exposure as well as extremes of temperature.
Surface preparation prior to painting shall be followed as per Table 8.0 to 16.0 of
this standard shall be followed.
Page 461 of 851

oga1511teTa
naleuw ENONEERS
INDIA umn-ED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
Men KROP7m3R6311 IA GOY/ India Undatalang/ AND PROTECTIVE COATING
PAGE 7 OF 59
Mixing and thinning.
Application of paints and recommended limit on time intervals in between coats.
4.0 EQUIPMENT
4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning and all
equipments, scaffolding materials, shot & grit blasting equipments & air compressors etc.
required to be used shall be suitable for the work and all in good order and shall be arranged
by the contractor at site and in sufficient quantity. The manufacturer's test certificates / data
sheets for all the above items shall be reviewed by Engineer-in-charge at site before start of
work.
4.2 Mechanical mixer shall be used for paint mixing operations in case of two pack systems
except that the Engineer-In-Charge may allow the hand mixing of small quantities at his
discretion in case of specific requirement for touch up work only.
5.0 SURFACE PREPARATION, SHOP PRIMER COATING APPLICATION & REPAIR

AND DOCUMENTATION
5.1 General
5.1.1 In order to achieve the maximum durability, one or more of following methods of surface
preparation shall be followed, depending on condition of surface to be painted and as
instructed by Engineer-In-Charge. Adhesion of the paint film to surface depends largely on
the degree of cleanliness of the metal surface. Proper surface preparation contributes more to
the success of the paint protective system.
Abrasive blast cleaning
Mechanical or power tool cleaning
5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and
dry surface is obtained. Unless otherwise specified, surface preparation shall be done as per
provisions of relevant tables given elsewhere in this specification. The minimum acceptable
standard, in case of thermally sprayed metal coatings, in case of mechanical or power tool
cleaning it shall be St. 3 or equivalent. In case of blast cleaning it shall be Sa 2-1/2 as per
Swedish Standard SIS-055900 (latest edition) or SSPC-SP or ISO 8501-01.Blast cleaning
shall be Sa 3 as per Swedish Standard in case thermally sprayed metal coatings.
Before surface preparation by blast cleaning, the surface shall be degreased by aromatic
solvent to remove all grease, oil etc.
5.1.3 Irrespective of whether external or internal surface to be coated, blast cleaning shall not be
performed where dust can contaminate surfaces undergoing such cleaning or during humid
weather conditions having humidity exceed 85%. In case of internal coating of storage tanks,
dehumidifier shall be used, to control humidity level below 60%. Dehumidifier should
depress the dew point of air in the enclosed space, sufficient enough so as to maintain it 3°C
Page 462 of 851

Oa ft ENGINEERS STANDARD SPECIFICATION
FOR SURFACE PREPARATION
NO. 6-79-0020
Og a 'Meg INDIA LIMITED
Rev. 0
MON FIXOW COIORFM /A Govt kW Undertaking) AND PROTECTIVE COATING PAGE 8 OF 59
below the metal substrate temperature during centre period of blasting and coating
application. During the interval time between application of primer coat and subsequent
intermediate and top coats or between blast cleaning completion and start of application of
primer coat, dehumidifier unit should be in continuous operation to ensure that no
condensation occurs on substrate.
Dehumidifier should be able to maintain grain drop (moisture removal) at the rate of 25
grains per pound of air per hour. Dehumidifier should have capacity of at least 2 air changes
per hour of the enclosed space. All necessary psychometric data should be collected by
contractor for the given site conditions before starting operation of dehumidifier to ensure
that desired values of dew point, moisture content in enclosed scope is achieved.
Dehumidification to be maintained round the clock for surface preparation and painting till
the total coating application is over.
Dehumidifier shall not be stopped under any condition till the entire blasted surface is primed
to the satisfaction of the technical representative of the paint manufacturer interested with
quality assurance for the work. In case the dehumidifier breaks down in middle of the job, the
same shall be replaced at the risk and the cost of the contractor and the entire unfinished
work shall be repeated.
5.1.4 The Engineer in-charge shall have the right to disallow usage of dehumidifier if the
performance is not meeting the specified requirements. Under such circumstances the
contractor shall remove the equipment and replace the same with another equipment to
provide satisfactory results without any additional cost to the owner.
5.1.5 Irrespective of the method of surface preparation, the first coat of primer must be applied by
airless spray/ air assisted conventional spray if recommended by the paint manufacturer on
dry surface. This should be done immediately and in any case within 4 hours of cleaning of
surface. However, at times of unfavorable weather conditions, the Engineer-In-Charge shall
have the liberty to control the time period, at his sole discretion and/or to insist on re-
cleaning, as may be required, before primer application is taken up. In general, during
unfavorable weather conditions, blasting and painting shall be avoided as far as practicable.
5.1.6 The external surface of R.C.C. chimney to be painted shall be dry and clean. Any loose
particle of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush.
Acid etching with 10-15% HCL solution for about 15 minutes shall be carried and surface
must be thoroughly washed with water to remove acid & loose particles and then dried
completely before application of paint.
5.2 Procedure for Surface Preparation
5.2.1 Air Blast Cleaning with abrasives
The surfaces shall be blast cleaned using one of the abrasives like angular chilled cast iron or
steel grit, copper slag or Nickel slag, Al 203 particles at pressure of 7kg/cm 2 at an appropriate
distance and angle depending of nozzle size maintaining constant velocity and pressure.
Chilled cast iron or steel shall be in the form of shot or grit of size in the range of G16 — G42
conforming to SSPC AB I and 5250 grade size of steel shots (maximum) to obtain a desired
surface profile of 35-50 microns trough to peak. For all other abrasives, size shall be in the
Page 463 of 851

aielMENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Iguemegwir INDIA LIMITED Rev. 0
Men AMR =MOM (A GS of India UndedaIngl AND PROTECTIVE COATING PAGE 9 OF 59
range of G16 — G24. The combination of steel grits and shots shall be normally in the ratio of
3:1. The quality of abrasives shall be free from contaminants and impurities and shall meet
the requirements of SSPC AB I . Compressed air shall be free from moisture and oil. The
blasting nozzles should be venturi style with tungsten carbide or boron carbide as the
materials for liners. Nozzles orifice may vary from 3/16" to %". On completion of blasting
operation, the blasted surface shall be clean and free from any scale or rust and must show a
grey white metallic luster. Primer/first coat of paint shall be applied within 4 hours of surface
preparation. Blast cleaning shall not be done outdoors in bad weather without adequate
protection or when there is dew on the metal, which is to be cleaned. Surface profile shall be
uniform to provide good key to the paint adhesion (i.e. 35 to 50 microns). If possible
vacuum collector shall be installed for collecting the abrasives and recycling.
5.2.2 Mechanical or Power Tool Cleaning
Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding
wheels or rotating steel wire- brushes. Excessive burnish of surface shall be avoided as it can
reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be
removed by clean rags and /or washed by water or steam and thoroughly dried with
compressed air jet before application of paint.
5.3 Non-Compatible Shop Coat Primer
For equipments on which application of total protective coating (Primer + Intermediate + top
coat) is carried out at shop, compatibility of finish coat with primer should be checked with
paint manufacturer. If the shop coat is in satisfactory condition showing no major defect upon
arrival at site, the shop coat shall not be removed.
5.4 Shop coated equipments (coated with Primer & Finishing coat) should not be repainted unless
paint is damaged. Repair shall be carried out as per Table 7.2 of paint systems depending
upon compatibility of paint.
5.5 Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas by means
of power tool brush cleaning or hand tool cleaning and.then spot primed before applying one
coat of field primer unless otherwise specified. If shop primer is not compatible with field
primer then shop coated primer should be completely removed before application of selected
paint system for particular environment.
5.6 For Package units/equipment, shop primer should be as per the paint system given in this
specification. However, manufacturer's standard can be followed after review.
As mentioned in section 2.4, all coating application at field (field primer, intermediate and
top coat) on equipments, structures, piping, etc, shall be carried out only after its erection and
all welding, testing, steam purging (wherever carried out) have been completed.
5.7 Coating Procedure and Application
All paint coatings shall be applied by airless spray excepting at the following special
cases where application can be carried out by brush subject to suitability of the
application of the paint product by brush.
Spot repair
Stripe coating on edges
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — MI rights reserved
Page 464 of 851

samzEift. ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
51?eg faitegW: INDIA LIMITED Rev. 0
MUT fIRIVOIMIPM (A Ga.( al Oda undenakm AND PROTECTIVE COATING PAGE 10 OF 59
- Small bore parts not suitable for spray application.

Irregular surfaces such as sharp edges, welds, small brackets, and interstices may stripe
coated to ensure specified DFT is achieved. Paint manufacturer recommendation
should be followed before deciding for brush application.
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious airborne elements
exists, when the steel surface temperature is less than 5°F above dew point when the relative
humidity is greater than 85% or when the temperature is below 40°F and when the
ambient/substrate temp is below the paint manufacturer's recommended temperature of
application and curing. De-humidifier equipment shall be used to control RH and Dew point.
The paint application shall not be done when the wind speed exceeds 20km per hour.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hrs the same day.
5.7.3 To the maximum extent practicable, each coat of material shall be applied as a continuous
film uniform thickness free of probes. Any spots or areas missed in application shall be
recoated and permitted to dry before the next coat is applied. Applied paint should have the
desired wet film thickness.
5.7.4 Each coat shall be in proper state of cure or dryness before the application of succeeding
coat. Material shall be considered dry for recoating when an additional coat can be applied
without the development of any detrimental film irregularities, such as lifting or loss of
adhesion of the under coat. Manufacturer instruction shall be followed for inter coat interval.
5.7.5 When the successive coat of the same colour have been specified, alternate coat shall be
tinted, when practical, sufficiently to produce enough contrast to indicate complete coverage
of the surface. The tinting material shall be compatible with the material and not detrimental
to its service life and shall be recommended by the original paint manufacturer.
5.7.6 Airless spray application shall be in accordance with the following procedure: as per steel
structure paint Manual Vol.1 & Vol.2 by SSPC, USA, Air less spray relies on hydraulic
pressure rather than air atomization to produce the desired spray. An air compressor or
electric motor is sued to operate a pump to produce pressures of 1000 to 6000 psi. paint is
delivered to the spray gun at this pressure through a single hose within the gun, a single paint
stream is divided into separate streams, which are forced through a small orifice resulting in
atomization of paint without the use of air. This results in more rapid coverage with less over
spray. Airless spray usually is faster, cleaner, more economical and easier to use than
conventional air spray.
Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks
paint from any container, including drums. The unit shall have in built agitator that keep the
paint uniformly mixed during the spraying. The unit shall consist of in built strainer. Usually
very small quantity of thinning is required before spray. In case of high build epoxy coating
(two pack). 30:1 pump ratio and 0.020-0.023" tip size will provide a good spray pattern.
Ideally fluid hoses should not be less than 3/8" ID and not longer than 50 ft to obtain
optimum results.
In case of gun choking, de-choking steps shall be followed immediately.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —AI rights reserved
Page 465 of 851

ada INGINEERS
#ar1512-
epeow INDIA umirED
NO. 6-79-0020
OfferleIRPRIM3aqi/ IA Gov1 a/ India UnclettSagl AND PROTECTIVE COATING Rev. 0
PAGE 11 OF 59
5.7.7 Brush application of paint shall be in accordance with the following:
Brushes shall be of a style and quality that will enable proper application of paint.
Round or oval brushes are most suitable for rivets, bolts, irregular surface, and
rough or pitted steel. Wide flat brushes are suitable for large flat areas, but they
shall not have width over five inches.
Paint shall be applied into all corners.
Any runs or sags shall be brushed out.
There shall be a minimum of brush marks left in the applied paint.
Surfaces not accessible to brushes shall be painted by spray, doubers, or sheepkin.
5.7.8 For each coat the painter should know the WFT corresponding to the specified DFT and
standardize the paint application technique to achieve the desired WFT. This has to be
ensured in the qualification trial.
5.8 Drying of Coated Surfaces
5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be considered
dry for re-coating when another coat can be applied without the development of any film
irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat
should not exceed maximum specified for it as a first coat; if it exceeds the paint material has
possibly deteriorated or maxing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause chalking, wrinkling,
blistering formation of pores, or detrimentally affect the conditions of the paint.
5.8.3 No drier shall be added to paint on the job unless specifically called for in the manufacturer's
specification for the paint.
5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dry
to the fullest extent practicable.
5.9 Spot Repair of Damaged Primer
5.9.1 Where pre erection shop primer has been damaged at isolated localized spots during handling
and transportation, or after erection / welding, the repair of damaged coating of pre-erection /
pre-fabrication or shop primer shall be done as given below and as per the Table 7.2 of this
specification.
5.9.2 Repair of damaged inorganic zinc silicate pre-erection / pre-fabrication or shop primer
(F9) after erection / welding in the design temperature of -90°C to 400°C and damaged
silicone aluminium (F-12) pre-erection / pre-fabrication or shop primer after erection /
welding for design temperature range of 401 — 550 °C.
Surface Preparation: Quickly remove the primer from damaged area by mechanical scraping
and emery paper conforming to SSPC-SP-3 to expose the white metal. Blast clean the
Page 466 of 851

0R-4:Aft ENGINEERS
Siga tilaiegel INDIA LIMITED Rev. 0
11412712013Valgarff / IA Gott of Ha undertaking) AND PROTECTIVE COATING PAGE 12 OF 59
surface, if possible. Feather the primed surface over the intact adjacent surface surrounding
the damaged area by emery paper.
Primer coating: One coat of F-9 shall be applied wherever damage was observed on pre-
erection / pre fabrication or shop primer of inorganic zinc silicate coating (F-9). Similarly
one coat of F-12 shall be applied wherever damage observed on pre-erection / pre-
fabrication shop primer of silicone aluminium (F-12).
5.9.3 Wherever if damaged areas are found extensive and spread over large areas, then entire pre-
erection / pre-fabrication or shop primer shall be removed by blasting to achieve SSPC-SP-
10 then entire blasted surface shall be primed again with F-9 or F-12 as applicable for the
intended design temp. (See note under table 7.2).
5.10 Paint Application
5.10.1 Shop priming/pre-erection priming with F9 or F12 shall be done only on blasted surface
(SSPC-SP-10)
5.10.2 Shop priming / pre-erection priming with F9 or F 12 shall be done only with airless spray.
5.10.3 Assessment of Painting Requirement
The paint system to be applied for a specific job shall be arrived at sequentially as given
below:
- Identify the environment from area classification details and chose the appropriate table.
- Identify the design temperature from the technical documents
- Identify the specific field paint system and surface preparation requirement from the above
identified table and temperature range.
- Identify the shop priming requirement from Table 7.1 based on compatibility of the above
paint system.
- Identify the need of repair of shop primer and execute as per Table 7.2.
5.11 Documentation / Records
5.11.1 A written quality plan with procedure for qualification trials and for the actual work
including test and inspection plan & procedure for approval before start of work.
5.11.2 Daily progress report with details of weather conditions, particular of applications, no of
coats and type of materials applied, anomalies, progress of work versus program.
5.11.3 Results of measurement of temperatures relative humidity, surface profile, film thickness,
holiday detection, adhesion tests with signature of appropriate authority.
5.11.4 Particulars of surface preparation and paint application during trials and during the work.
Page 467 of 851

02zielt. ENGINEERS
I@Tif WeVITIV INDIA LIMITED Rev. 0
INIPPIFIRINVMMICID (A Gov of Inda Underliong) AND PROTECTIVE COATING PAGE 13 OF 59
5.11.5 Details of non-compliance, rejects and repairs.
5.11.6 Type of testing equipments and calibration.
5.11.7 Code and batch numbers of paint materials used.
The coating applicator must maintain a job record consisting of all the information as per
5.11.2 -5.11.7 above as well as the approved procedure of work (5.11.1 above). The job
record consisting of information as required in accordance to 5.11.2 — 5.11.7 shall be entered
on daily basis and should be daily signed by Engineer-in-charge.
Page 468 of 851

1515036a ENGINEERS
KiegW WA LIMITED FOR SURFACE PREPARATION NO. 6-79-0020
l aildleRzer7013Rdill Cdd d India Underldm9) AND PROTECTIVE COATING Rev. 0
PAGE 14 OF 59
TABLE-1 (FOR CLAUSE 5.0)
SURFACE PREPARATION STANDARDS
VARIOUS INTERNATIONAL
SI. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
Manual or hand tool
cleaning
Removal of loose rust, loose ST.2 SSPC-SP-2 --

1 mill scale and loose paint,
chipping, scrapping, This method is
standing and wire brushing. applied when the
Surface should have a faint surface is exposed to
metallic sheen normal atmospheric
Mechanical or power tool conditions when
cleaning other methods cannot
be adopted and also
Removal of loose rust loose ST.3 SSPC-SP-3 -- for spot cleaning
mill scale and loose paint to during maintenance
2 degree specified by power painting.
tool chipping, de-scaling,
sanding, wire brushing and
grinding, after removal of
dust, surface should have a
pronounced metallic sheen.
Dry abrasive Blast cleaning
3
There are four common
grades of blast cleaning
White metal
Blast cleaning to white metal Where extremely

cleanliness. Removal of all clean surface can be
3.1 . SA 3 SSPC-SP-5 NACE#1
visible rust. Mill scale, paint expected for prolong
& foreign matter 100% life of paint system.
cleanliness with desired
surface profile.
Near white metal The minimum
requirement for
Blast cleaning to near white chemically resistant
metal cleanliness, until at paint systems such as
least 95% of each element of epoxy, vinyl,
surface area is free of all polyurethane based
visible residues with desired and inorganic zinc
3.2 SA 21/4 SSPC-SP-10 NACE#2 .
surface profile. silicate
licate paints, also
for conventional paint
systems used under
fairly corrosive
conditions to obtain
desired life of paint
system.
Page 469 of 851

Isdozesk -r ENGINEERS
fatalegwv INDIA mem FOR SURFACE PREPARATION NO. 6-79-0020
laiRn FRaW !N W) GoA a/ India Undenaly.91 AND PROTECTIVE COATING Rev. 0
PAGE 15 OF 59
VARIOUS INTERNATIONAL
SI. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
Commercial Blast For steel required to
be painted with
Blast cleaning until at least conventional paints
two-third of each element of for exposure to
3.3 SA 2 SSPC-SP-6 NO.3
surface area is free of all mildly corrosive
visible residues with desired atmosphere for longer
surface profile. life of the paint
systems.
Brush-off Blast
Blast cleaning to white metal

3.4 cleanliness, removal of all SA 1 SSPC-SP-7 NO.4
visible rust, mill scale, paint
& foreign matter. Surface
profile is not so important
Page 470 of 851

15illtea ENGINEERS
Itgai Bakst INDIA map FOR SURFACE PREPARATION NO. 6-79-0020
Men eiMEORMCFM (A Govt of India Undertalung) AND PROTECTIVE COATING Rev. 0
PAGE 16 OF 59
6.0 PAINT MATERIALS
Paint manufacturers shall furnish the characteristics of all paints materials on original printed
literature, alongwith the test certificate for all specified characteristics given in this
specification. All the paint materials shall be of first quality and conform to the following
general characteristics as per the tables 6.1, 6.2, 6.3 and 6.4.
PAINT MATERIALS
TABLE No. 6.1 PRIMERS
SI. DESCRIPTION P-2 P-4 P-6 P-7

No.
Chlorinated Etch Epoxy zinc ZINGA,
rubber Zinc primer/wash phosphate primer LOCKTITE or
1 Technical name
Phosphate primer. primer ZRC
cold galvanizing
Single pack, air Two pack Two component One pack
drying chlorinated polyvinyl butyral polyamine cured Synthetic Resin
rubber based resin medium epoxy resin based zinc
medium cured with medium, galvanizing
2 Type and composition plasticised with phosphoric acid pigmented with containing min
unsaponifiable solution zinc phosphate. 92% of electrolytic
plasticizer, pigmented with zinc dust of
pigmented with zinc tetroxy 99.95% purity.
zinc phosphate. chromate.
3 Volume Solids % 40±3 10±1 50±1 37%
DFT (Thy Film
4 thickness) per coat in 40-45 8-10 40-50 40-50p
microns
Theoritical covering
5 8-10 8-10 8-10 4m2/kg
capacity in M2/coat/ litre
Weight per litre in
6 1.3±0.05 1.2±0.05 1.4±0.05 2.67 kg at 15°C
kgs/litre
Touch dry at 30°C
7 30 minutes 2 hrs. After 30 min. 10 minutes
(minimum)
Hard dry at 30°C
8 8 hrs. 24 hrs. 8 hrs 24 hrs.
(maximum.)
9 Overcoating interval Min.: 8 hrs Min: 4-6 hrs. Min.:Shrs. Min.:4 hrs
Pot life at 30°C for two Not
10
component paints Applicable
Not applicable 6 - 8 hrs. Unlimited
Temperature (Resistance 60 °C NA 80°C 50°C
11
(minimum) Dry service Dry service Dry service Dry service
Page 471 of 851

15ifiziEgftENIONEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
star taRegWINDIA LIMITED
011iTIF01112451W1, (A GM al Se Undertab19) AND PROTECTIVE COATING Rev. 0
PAGE 17 OF 59
PAINT MATERIALS
TABLE No. 6.2 FINISH PAINTS
SI. DESCRIPTION F-2 F-3 F-6A/I3 F-6C F-7

No
Acrylic Chlorinated
1 Technical name Polyurethane rubber based Epoxy-High
. Build Solvent less High build coal
finish paint finish paint coati ng epox coating tar
coating.
epoxy
Single pack F-6A Two-pack Two pack, Two

plasticised Aromatic amine cured pack
with polyamide
Two-pack chlorinated cured epoxy resin Amine
aliphatic rubber based medium suitably Adduct; cured epoxy
2 Type and isocynate medium with resin blended
composition pigmented. with
cured acrylic chemical and F-6B: polyamide catalyzed
epoxy resin
coaltar
finish paint. weather cured epoxy resin suitably medium,
resistant .
medium suitably pigmented suitably
pigments. pigmented pigmented
3 Volume Solids % 40 ± 3 38±2 60±3 99+1 65±3
DFT (Dry Film
4 thickness) per coat in 30-40g 30-40 100-125g 200-500 100-125g
microns
5 capacity in 11-15 11-15 5-6 2-3 5.2-6.5
M2/coat/litre
6 Weight per liter in 1.15±0.03 1.150.03 1.41+0.03 1.40+0.03 1.40±0.03
kgs/litre
7 Touch dry at 30°C 30 minutes 30 minutes. 3 hrs. 3 hrs. 4 hrs.
Hard dry at 30°C
(max) 16 hrs
8 hrs 48 hrs
8 Full cure at 30°C (for 8 hrs 16 hrs
immersion/ high 5 days
5 days
temperature service)
9 Over-coating
at 30°C
interval Min.12 hrs. Min.: Min.: Overnight Min.: 8 hrs. Min.: 24 hrs
Overnight Max.: 5 days Max.: 48 hrs. Max.: 5 days.
Pot life (approx.) at
10 30°C for two 6-8 hrs. ot 4-6 hrs 30 minutes
applicable 4-6 hrs.
component paints
Temperature 120°C(Diy
Resistance 80 °C 60 °C service), 125°C
11 (minimum) Dry service Immersion 80°C 50°C Immersion
min service Dry service
(Immersion service
service)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — NI rights reserved
Page 472 of 851

ogesOwes
kveg
ENGINERS
INDIA Limo) FOR SURFACE PREPARATION NO. 6-79-0020
Wien diereer eagatale deort d India Undertaking) AND PROTECTIVE COATING Rev. 0
PAGE 18 OF 59
PAINT MATERIALS
SI.
DESCRIPTION F-8 F-9 F-11 F-12
No
Self priming type Heat resistant
Heat resistant
surface tolerant synthetic medium
silicone
high build epoxy Inorganic zinc based two pack
1 Technical name Aluminium paint
coating (complete silicate coating Aluminium paint
suitable upto
rust control suitable upto
500 ° C dry temp.
coating). 250°C dry temp.
A two pack air
Two pack epoxy drying self curing
resin based solvent based
Heat resistant
suitable inorganic zinc Single pack
synthetic medium
pigmented and silicate coating with silicone resin
based two pack
2 Type & composition capable of minimum 80% zinc based medium
Aluminium paint
adhering to content on dry film. with Aluminium
suitable upto
manually The final cure of flakes.
250°C.
prepared surface the dry film shall
and old coating. pass the MEK rub
test.
3 Volume Solids % 7813 60±3 3810.03 2012
DFT (Dry Film
4 thickness) per coat in 100-125 65-75p 15-20g 15-20g
microns
5 capacity in M2/coat/ 6.0-7.2 8-9 10-12 8-10
litre
Weight per liter in
6 1.4110.03 2.310.03 0.95±0.03 1.0010.03
kgs/litre
Touch dry at 30°C
7 3 hrs. 30 minutes. 3 hrs. 30 minutes.
(maximum)
Hard dry at 30°C
(maximum) 24 hrs 12 12 hrs 24 hrs
8 Full cure 30°C (for
immersion thigh 5days NA NA NA
temperature service)
Mb. 12 hrs . at 20°C
Mm.:
9 Over-coating interval Min.: 10 hrs 24 lin Mb.: 24 hrs
& 50 % RH
Pot life at 30°C for two
10 90 minutes. 4-6 hrs. Not applicable Not applicable
component paints
Temperature 80 °C 400 °C 250°C 500°C
11
Resistance (minimum) Dry service Dry service Dry service Dry service
Page 473 of 851

ate ENGINEERS
azir Wear INDIA LIMITED
Rev. 0
NOM MN ?AMMO (A GS of kola tAlerlicing) AND PROTECTIVE COATING PAGE 19 OF 59
PAINT MATERIALS
SI. F-16
DESCRIPTION F-14 F-15 F-17
No
Ambient temperature
curing Poly Siloxane
Two-component Two component
coating/High build
Epoxy phenolic solvent free type
cold applied inorganic
coating cured with high build epoxy
copolymer based
Polyamine cured Polyamine adduct phenolic/novalac
1 Technical name aluminium coating
coal tar epoxy hardner system epoxy phenolic
suitable for under
(primer + . coating cured with
Insulation coating of
intermediate coat Polyamine adduct
CS and SS piping for
+ finish paint) hardner system
high temperature
service.
Two pack ambient Two component
Specially
temperature curing Amercoat 738 from solvent free type
formulated
epoxy phenolic PPG Protective & high build epoxy
polyamine cured
coating system Marine Coatings or phenolic/novalac
2 Type & composition coal tar epoxy
suitable for Intertherm 751 CSA of epoxy phenolic
suitable for
application under International (Akzo coating cured with
application under
insulation of Nobel). Note: 6 Polyamine adduct
insulation
CS/SS piping hardner system
3 Volume Solids % 70±3 70±3 60±2 98-100
DFT (Dry Film
4 thickness) per coat in 100-125 75-100 75-100 125- 150
microns
5 capacity in M2/coat/ 5-8 4-5 7.0- 9.0 6.5 - 8
litre
Weight per liter in
6 1.4540.03 1.650.03 1.3 1.7
kgs/litre (mix paint)
Touch dry at 30°C
7 4 hrs 3 hrs 1 hr 2 hrs
(maximum)
Hard dry at 30°C
(maximum) 24 hrs 24 hrs 16 hrs 24 hrs
8 Full cure 30°C (for
immersion Thigh 168 hrs (7 days) 168 hrs (7 days) - 168 hrs (7 days)
temp. service)
Over-coating interval Min. 6 hrs Min. 36 hrs Min.16 hrs Min. 16 hrs
9
Max.S days Max.21 days Max. Not applicable Max.21 days
Pot life at 30°C for
10 two component 4 hrs 4-6 hrs 1 hr 1 hr
paints
Temperature upto 400 °C for C.
Resistance Steel & S. Steel for
-45°C to 150°C
-45°C to 125°C Intertherm 751 CSA
under insulation & -45°C to 150°C for
11 under insulation upto 480 °C for C.
immersion immersion service
And immersion Steel & upto 600 °C
(Note: 5)
for S. Steel for
Amercoat 738
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell. —All rights reserved
Page 474 of 851

0151-43-eta ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Igtlf Emegw INDIA LIMIIID Rev. 0
IMWIFIRMFM WD IA Gobi of Incl. Unded*V AND PROTECTIVE COATING PAGE 20 OF 59
NOTES (for tables 6.1 to 6.4):
Covering capacity and DFT depends on method of application. Covering capacity

specified above are theoretical. Allowing the losses during application, min specified
DFT should be maintained.
All primers and finish coats should be cold cured and air drying unless otherwise
specified.
All paints shall be applied in accordance with manufacturer's instructions for surface
preparation, intervals, curing and application. The surface preparation, quality and
workmanship should be ensured. In case of conflict between this specification and
manufacturer's recommendation, the same shall be clarified through EIL SMMS
department.
Technical data sheets for all paints shall be supplied at the time of submission of
quotations.
F-15: Two-component Epoxy phenolic coating cured with Polyamine adduct hardner
system (primer + intermediate coat + finish paint) suitable upto 225°C (Intertherm 228
from M/s Akzo Nobel Coatings India Pvt Ltd. Bangalore). For all other companies, the
temperature resistance shall be a maximum of 150°C.
F-16: Ambient temperature curing epoxy poly siloxane Coating or high build cold
applied inorganic co-polymer based aluminium coating.
Amercoat 738 from PPG Protective & Marine coatings. Mumbai, is suitable up to
480°C for CS surfaces and 600°C for SS surfaces.
Intertherm 751 from Akzo Nobel Coatings India Pvt Ltd. Bangalore, Inorganic co-
polymer cold applied Aluminium spray coating is suitable upto 400°C of CS & SS
surfaces.
Page 475 of 851

fit ENGINEERS
ligar ta2eg e INDIA LIMITED
i
Rev. 0
1 11101.124112=3WRI■ IA Gen a/ Ind4a Undertalng) AND PROTECTIVE COATING PAGE 21 OF 59
7.0 COATING SYSTEMS
The coating system should be selected based on the Plant location as given below:
Classification based on Plant Location:
a) Plant located in Inland area (more than 50 km from coast);

Environment Classification — Industrial
For offsite areas: Table 9.0 to be followed
For all unit areas including DM,CPP and Cooling Tower: Table 10.0 to be
followed
b) Plant located on sea coast or within 50 km from sea coast;

Environment classification- Industrial marine
- For offsite area, as well as all unit area including DM, CPP, Cooling Tower:
Table 10.0 to be followed
c) For external surface of above ground tanks, table 12.0 to be followed for all
locations (Inland or coastal)
Notes:
Coating systems (Primers, Finish Paints etc.) based on Area

classification/environments/Applications are tabulated in Table 8.0 to Table 17.0
Primers & Finish paints covered in Tables 8.0 to 17.0 are listed in Table 7.1.
3. Repair of Pre-Erection/Pre-Fabrication & Shop priming after erection/ welding shall be

done as per Table 7.2.
Page 476 of 851

el ENGINEERS NO. 6-79-0020
Raft
litaimeneRanuoim INDIA LIMITED
IA GNI d Undertakng)
AND PROTECTIVE COATING Rev. 0
PAGE 22 OF 59
TABLE 7.1: LIST OF PRIMERS & FINISH COATS COVERED IN TABLE NOS. 8 to 18.0
PRIMERS
P-2 Chlorinated rubber zinc Phosphate Primer
P-4 Etch Primer/Wash Primer
P-6 Two component Epoxy Zinc Phosphate Primer cured with polyamine hardener
Single pack, cold galvanizing compounds containing minimum 92% electrolytic zinc in dry film.
P-7
make ZINGA, LOCKTITE (of HENKEL) or ZRC
FINISH COATS / PAINTS

F-2 Two component Acrylic — Polyurethane finish paint
F-3 Chlorinated Rubber finish paint
F-6A High Build Epoxy finish coating cured with polyamine hardener
F-6B High Build Epoxy finish coating cured with polyamide hardener
F-6C Solvent less Epoxy Coating cured with poly amine hardener
F-7 High. build Coal Tar epoxy coating cured with polyamine hardener
F-8 Self priming surface Tolerant High Build epoxy coating. cured with polyamine hardener
F-9 Two component Inorganic Zinc Silicate coating
F-11 Heat resistant synthetic medium based Aluminium paint
F-12 Two component Heat resistant Silicone Aluminium paint.
F-14 Specially formulated coal tar epoxy coating. cured with polyamine hardener
F-15 Two component Epoxy phenolic coating cured with Polyamine adduct hardener system
Engineered Epoxy poly Siloxane Coating or high build cold applied inorganic co-polymer based
F-16
aluminium coating
Two component solvent free type high build epoxy phenolic/novalac epoxy phenolic coating cured
F-17
with Polyamine adduct hardener system
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — NI rights reserved
Page 477 of 851

latrazieLre ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
lgaf Efieg NDIA LIMITED
Rev. 0
lageR21201701JMAI (A Govt Lea Undertakin) AND PROTECTIVE COATING PAGE 23 OF 59
TABLE 7.2 REPAIR OF PRE-ERECTION/PRE-FABRICATION OR SHOP PRIMER

AFTER ERECTION/WELDING
For all un-insulated CS, LTCS & low allow steel items in all Environments
Total DFT
SI. Surface Coating System in Microns Remarks
No.
Design Temp. in °C Preparation
(min.)
7.2.1 -90 to 400 SSPC-SP-3 1 coat of F-9 65-75 See note
below and
7.2.2 401 to 550 SSPC-SP-3 1 coat of F-12 20 clause 5.9.3
NOTES
1 The application and repair of pre-erection/pre-fabrication or Shop Primer given in above tables
shall be done for all the items to be painted. In case the damages of primer are severe and spread
over large area, entire primer shall be removed by blasting to achieve SSPC-SP-10 and surfaces
to be primed again with F-9 or F-12 as applicable.
TABLE 8.0 COATING SYSTEM FOR GRATINGS, ROLLING & STATIONERY

LADDERS, SPIRAL STAIRWAYS AND HAND RAILS IN ALL LOCATION
Design
SI. Total DFT
No.
Temp. in Coating System in Microns (min.)
°C
Hot Dip Galvanizing to 80-85 microns (600-610
80 microns of finish coat
gm/m2)as per IS 4759, 2629, 4736, 2633 +
8.1 Up to 60 (excluding the thickness of
1 coat of P-6 @ 40u DFT/coat + 1 coat of F-2 @ 40
)
microns DFT/coat
NOTES:
1 No galvanized specimen shall have thickness less than 80 microns.
2 Repair of the damaged area of galvanized coatings due to welding during erection shall be
carried out as per recommended practice IS 11759 using cold galvanizing spray process.
Organic Paint systems are not acceptable for repair.
3 After repair of damaged galvanized coating by Cold Galvanized, the repaired area shall be top
coated with paint system as given in Table 8.0 above (i.e., 1 coat of P-6 @ 40g DFT/coat + 1
coat of F-2 @ 40g DFT/coat).
4 Approved Cold Galvanizing manufacturers are ZINGA, LOCKTITE or Z.R.C.
Page 478 of 851

PlitiegaENONIEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Oga ft W INDIA UMITED Rev. 0
lam mewl:limn.) IA Gal of w. undmanno AND PROTECTIVE COATING PAGE 24 OF 59
TABLE 9.0 COATING SYSTEM FOR OFFSITE AREA (INLAND PLANTS)

For external surfaces of Un-insulated & aboveground (atmospheric exposure)
Structures, Piping, Vessels, Equipments, Pumps, etc. (Note-1); (For Carbon Steel,
LTCS & Low Alloy Steel). See Note Below*
Surface Coating System Total Final

Design
SI. Preparation & (Post-erection / Field) DFT
Temp. in Remarks
No. Pre-erection/Shop in Microns
°C Primer Finish Coat
Primer (min.)
SSPC-SP-10; No over-
9.1 -90 to -15 lcoat of F-9 @ None None 65-75 coating to be
65-75p DFT/coat done on
SSPC-SP-10; F-9 as it will
I coat of F-2 @
9.2 -14 to 60 1 coat of F-9 @ None 105-115 lead to mud
40p DFT/coat cracking.
65-75p DFT/coat
SSPC-SP-10;
1 coat of F-2 @
9.3 61 to 80 lcoat of F-9 @ None 105-115
40g DFT/coat
65-75g OFT/coat
2 coats of F-11
SSPC-SP-10;
20p
9.4 81 to 250 I coat of F-9 @ None 105
DFT
@/coat;
65-75p DFT/coat
(2x20=40)
2 coats of F-12
SSPC-SP-10;
@ 20p
9.5 251 to 400 1 coat of F-9 @ None 105-115
DFT/coat
65-75p DFT/coat F-12 shall be
(2x20=40)
ambient
SSPC-SP-10; 2 coats of F-12 temperature
9.6 401 to 550 lcoat of F-12 @ None @20g DFT/coat 60 curing type
20g DFT/coat (2x20=40)
* Flare line within unit or offsite areas shall be coated as per Clause 10.3 of Table 10.0, but
having finish coat of 2 coats of F-12.
NOTES:
1 The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The Contractor is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated through his scope of work as per tender document.
2 If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not
be repeated again in the field. In case the damages of primer are severe and spread over large
areas, the engineer-in-charge may decide & advise re-blasting and priming again. Repair of pre-
fabrication/pre-erection primer, if required, shall be done as per Table 7.2.
3 In case of Paint systems as per SI. Nos. 9.5 and 9.6, the color bands shall be applied over the
Aluminum paint as per the Color coding requirement for specific service of piping given in
Clause 19.0.
4 All coating system including surface preparation, primer, and finish coat for piping shall be done
at field only.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —NI rights reserved
Page 479 of 851

15Naeg a- ENGNEERS
NO. 6-79-0020
5litaf talateltli INDIA LMTED
Rev. 0
eRternorni IA God al Indo Undenalogl AND PROTECTIVE COATING
PAGE 25 OF 59
TABLE 10.0 COATING SYSTEM FOR UNIT AREAS AS WELL AS DM, CPP,
COOLING TOWER OF INLAND PLANTS AND FOR ALL AREAS (UNIT,
OFFSITE, DM, CPP, etc.) OF COASTAL PLANTS
For external surfaces of un-insulated and above ground (atmospheric exposure)

structures, piping, vessels, equipments, external surface of MS chimney/stacks,
RCC chimney, internal surface of MS chimney without refractory lining, towers,
columns, pumps, compressors, blowers etc. of carbon steel, LTCS & low alloy
steels (note-1)
Surface Preparation & Coating System Total DFT

Design Pre-erection/Shop (Post-erection / Field) in
SI. Remarks
Temp. in °C Primer Microns
No. Primer Finish Coat
(min.)
SSPC-SP-10; No over-
10.1 -90 to -15 lcoat of F-9 @ None None 65-75 coating to be
65-75g DFT/coat done on
F 9 as it will
2 coats of F-6A lead to mud
@ 100 g cracking.
DFT/coat + 1
SSPC-SP-I 0; 1 coat of P-6
coat of F-2 @ 345_355 F-12 shall
10.2 -14 to 80 lcoat of F-9 @ @ 40 p
4 0p DFT/coat; be ambient
65-75p DFT/coat DFT/coat
(2x100 + 40= temperature
240) curing type
c) Finish coat
including
2 coats of F-12 primer
SSPC-SP-10; @ 20p compatible
10.3 81 to 400 lcoat of F-9 @ None DFT/coat 105-115 with finish
65-75p DFT/coat 2x20=40 coat (i.e. field
primer) shall
be applied at
site only.
Finish
2 coats of F-12 coating is not
SSPC-SP-10; permitted at
@ 20p
10.4 401 to 550 lcoat of F-12 @ None 60 equipment
DFT/coat;
20p DFT/coat manufacture
(2x20=40)
shop.
NOTES:
The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The Contractor is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated through his scope of work as per tender document.
If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall not
be repeated again in the field. In case the damages of primer are severe and spread over large
Page 480 of 851

ail-ileaENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
Eififtw INDIA LIMITED
imprriWREM3001411 (A GS of In& Undertalargl
AND PROTECTIVE COATING
NO. 6-79-0020
Rev. 0
PAGE 26 OF 59
areas, the engineer-in-charge may decide & advise re-blasting and priming again. Repair of pre-
fabrication/pre-erection primer, if required, shall be done as per Table 7.2.
For external surface of MS chimney with or without refractory lining and for internal surface
without refractory lining, paint system as per 10.3 above shall be followed.
For external surface of RCC Chimney, 2 coats of F-6 @ 10012 DFT/coat to obtain total DFT of
200 p. shall be applied after proper surface preparation as per guidelines in 5.1.6.
In case of paint systems as per SI. Nos. 10.3 and 10.4, the colour bands shall be applied over the
Aluminum paint as per the Color coding requirement for specific service of piping given in
Clause 19.0.
All coating system including surface preparation, primer, finish coat for piping shall be done at
site/field only.
Page 481 of 851

OWIETte. ENONEERS
1ga fa2e3 WV INDIA LIMITED Rev. 0
Olen eiROIMMICR)A GM a/ Incia Undertalong) AND PROTECTIVE COATING PAGE 27 OF 59
TABLE 11.0 COATING SYSTEM FOR EFFLUENT TREATMENT PLANT (ETP)
Coating System Total

SI. Design Temp. DFT in
Surface Preparation Remarks
No. in °C Primer Finish Coat Microns
(min.)
For Extemal Surfaces of C.S./M.S. items: Screens, Walk way bridges, Baffles, Dual media filters,
11.1 Vertical pumps, piping in treated effluent sump, bio sludge pump, Screw pump and pump house, CS
tanks, sumps and vessels.
2 coats of
F-6A @100g
DFT/coat + 1
1 coat of F-9
coat40g
of F-2 @
-14 to 80 SSPS-SP-10 @ 65-75g 305-315 -
DFT/coat
DFT/coat;
(2x100+40=2
40)
For Internal Surfaces of CS/MS Items: Bio-sludge sump, Fil er feed sump, Process sump, Sanitary
11.2
sump, Transfer ump, Sludge, Slop oil tank, scrapping mechanism in Clarifier
3 coats of
1 coat of F-9
F-6A @100g
-14 to 80 SSPS-SP-10 @ 65-75g 365-375 Note:1
DFT/coat
DFT/coat.
(3x100=300)
All R.C.C./concrete surfaces exposed to effluent water / liquid such as tanks, structures, drains etc. in
11.3 Process sump, TPI separator (Process and Oil), Aeration Tank and Transfer sump etc.
Epoxy screed
lining shall be
Blast cleaning to SSPC-SP
applied as per
guide lines and Acid
specific
-14 to 80 etching with 10-15% HCI Epoxy Screed lining 3mm
manufacturer
acid followed by thorough
and Engineer-
water washing.
in-Charge
instructions
C.S/M.S Dual media filters (Internal), Chemical dosing tanks(intemal such as Di-Ammonium
11.4
Phosphate (DAP) and Urea
Natural
Rubber lining
shall be
Natural Rubber Lining applied as per
Up to 60 SSPC-SP-10 (As per IS 4682, Part 1) 4.5mm specific
manufacturer
and Engineer-
in-Charge
instructions
NOTES
1. The paint /coating manufacturers shall provide their Quality control test certificate of coating
materials (F-6A) for immersion service of the exposed effluent given in 11.2.
Page 482 of 851

azdZICS ENGNEERS
Oa' 111e W INDIA LIMITED Rev. 0
(02,121POIRCOMWM (A Sort el In& Undeftm g ) AND PROTECTIVE COATING PAGE 28 OF 59
TABLE 12.0 EXTERNAL COATING SYSTEMS FOR UNINSULATED CARBON STEEL

AND LOW ALLOY STEEL STORAGE TANKS (For all plant locations, coastal
or inland)
All Process Units & Off-sites
Total
Surface Coating system (Field) DFT
SI. Design Temp. Preparation (see note 1 below) in Remarks
No. in °C (Field)
Microns
Primer Finish Coat (min.)
All external surfaces of shell, wind girders, appurtenances, roof tops of all above ground tank including top
12' 1 . of external and internal floating roof and associated external structural works.
side
F-6 should
2 coats of F-6A @
lcoat of F-9 @ 65-75p be suitable
100p DFT /coat + 1
SSPC-SP-10 DFT/coat + lcoat of P-6 for
12.1.1 -14 to 80 coat of F-2 @ 40p 345-355
@ 40p DFT/ coat ; occasional
DFT/ coat;
water
immersion
1 coat of F-15 primer @ 1 coat of F-15 finish

SSPC-SP-10 80p DFT/ coat + 1 coat coat @80p DFT/ coat +
12.1.2 81 to 150 280 -
of F-15 intermediate lcoat of F-2 @ 40p
coat @ 80p DFT/coat ; DFT/ coat;
2 coats of F-12 @20 p

105
DFT/ coat
lcoat of F-9 @ 65-75p or or
12.1.3 151 to 500 SSPC-SP-10 -
DFT/coat 115
1 coat of F-16 @ 50 p
DFT / coat
12.2 External surfaces of bottom pla e (soil side) for all storage tanks.
F-7 should
be suitable
for
SSPC-SP-10 1 coat of F-9 @ 3 coats of F-7@ 100p 365_375 immersion
12.2.1 -14 to 80
65-75p DFT/ coat DFT/coat (3x100=300) service of
the
products
given
1 coat of F-15 primer @
80p DFT/ coat + 1 coat
SSPC-SP-10 1 coat of F-15 finish
12.2.2 81 to 150 of F-15 intermediate 240 -
coat @ 80p DFT/ coat
coat @ 80p DFT/coat ;
(80+80=160)
1 coat of F-16 @ 125 p 1 coat of F-16 @ 125 p
12.2.3 151 to 550 SSPC-SP-10 250 -
DFT /coat DFT /coat
12.3 For underside of the bottom plate (in case tank is not lifted during PWHT) (see Note 2c)
Page 483 of 851

5Rizth ft ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
1@U Elffleg NDIA LIMITED
Rev. 0
leiarr FIROIMIWII IA Gut d India Undedalung) AND PROTECTIVE COATING PAGE 29 OF 59
For CS Products
SSPC SP-6 from
JOTUN or
Commercial
Blast HI-TEMP
2 coats of inert
-180 to 650 1 coat of inert polymeric coatings or
12.3.1 polymeric matrix 350-400
For SS matrix coating @ 125 u SK
coating @ 125 Ft
SSPC SP-1 FORMULA
with non- TIONS are
chloride
chlo recommend
solvent ed.
NOTES
All paint coating application including primer for tankage shall be carried out at field after
erection and completion of all welding.
For underside of bottom plate :

Painting shall be carried out before laying of bottom plate for tanks with Non-Post Weld
Heat Treatment (PWHT).
For tanks with PWHT, painting shall be carried out after PWHT.
c) In case tank is not lifted during PWHT then painting shall be applied before laying of bottom
plate, clause no. 12.3.1 shall be followed.
Caution: PWHT temperature shall not exceed 650°C.
Page 484 of 851

151fizieta ENCINEERS
Oga tiRegs INDIA LMTED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
INF 212(INVINMER) (A Gout of kb Undettiong) AND PROTECTIVE COATING
PAGE 30 OF 59
TABLE 13.0 INTERNAL COATING SYSTEMS FOR CARBON STEEL AND LOW ALLOY
STORAGE TANKS
All Process Units & Off-sites
Coating system (Field) Total

Surface DFT
SI. Design Preparation (see note 1 below)
in Remarks
No. Temp. in °C (Field) Microns
Primer Finish Coat
(min.)
CRUDE OIL, ATF, TURPENTINE OIL, LUBRICAT NG OIL AND VEGETABLE OIL
Underside of floating roof, internal surface of cone roof, inside of bottom plate, Internal surfaces of Shell
13.1
- including wetted and free board height, oil side surfaces of deck plates, oil side surfaces of pon oons,
roof structures, structural steel, ladders and other CS internals
1 coat of F-15
intermediate coat @
13.1. 1 coat of F-15 primer a -
-14 to 90 SSPC-SP-10 — 800 DFT/coat + 1 coat 240-300
1 800 DFT/ coat
of F-15 finish coat @
80p DFT/ coat,
PETROLEUM PRODUCTS & INTERMEDIATES like LDO, HSD , GAS OIL, FEEDS of
FCC-PC, FCC-LCO, VGO-HDT, ISOM, DHDT, REFORMATE, DCU, NHT & GASOLINE,
NAPHTHA, ISOMERATE AND KEROSENE.
13.2
Underside of Floating roofs, internal surface of cone roof, inside of bottom plate, internal surfaces of
Bare shell for full height, underside of floating roof, oil side surfaces of deck plates, oil side surfaces of
pontoons, support structures and ladders etc.
13.2. I coat of F-9 @
-14 to 45 SSPC-SP-10 - 75 Note 2
I 75 0 DFT/coat
1 coat of F-15
intermediate coat @
13.2. 1 coat of F-15 primer @
46 to 90 SSPC-SP-10 80p DFT/coat + 1 coat 240-300 -
2 80p DFT/ coat
of F-15 finish coat @
800 DFT/ coat;
POTABLE AND FIRE WATER
13.3 All internal surfaces, accessories and roof structures of Cone and Dome roof tanks
2 Coats of F-6A @
13.3. 1 Coats of P-6 @ Note-4
-14 to 60 SSPC-SP-10 1000 DFT/ Coat; 300-350
1 100 0 DFT/coat;
(2x100=200)
DE-MINERALIZED (DM) WATER
2 coats of F-6C @
13.4. 1 Coats of P-6 @
-14 to 60 SSPC-SP-i0 200p DFT/ coat; 400-450 -
1 1000 DFT/coat;
(2x200=400)
1 coat of F-15
intermediate coat @
13.4. 1 coat of F-15 primer @ 800 DFT/coat + 1 coat
61 to150 SSPC-SP-10 240-300
2 800 DFT/ coat of F-15 finish coat @
800 DFT/ coat;
(80+80=160)
HYDROCHLORIC ACID (HCI) 10 %
13.5
All internal surfaces, accessories and roof structures of Cone and Dome roof tanks
13.5. 4.5 mm -
-14 to 60 SSPC-SP-10 None Natural Rubber Lining
1
Page 485 of 851

ofteiftENGINEERS
ogaiEgRegewr INDIA um-rED FOR SURFACE PREPARATION NO. 6-79-0020
114M MK,'"UMR0 IA GS of Undertaiong) AND PROTECTIVE COATING Rev. 0
PAGE 31 OF 59
AGGRESSWE SOLVENTS LIKE HEXANE, HEXENE, BENZENE, XYLENE AND TOLUENE

13.6. 1 coat of F-9 @ 75p

-14 to 65 SSPC-SP-10 --- 75
1 DFT/ coat
ETHYLENE GLYCOL (EG) TANKS

13.7 Internal shell-full height, bottom plate, underside of roof and all accessories
3 coats of vinyl
chloride co-polymer
13.7. AMERCOAT 23 @ 225 -
All SSPC-SP-10 None
1
75p /Coat;
(3x75=225)
13.8 Inside pontoon and inside of double deck of all floatingroofs
13.8. 1 coat of F-8 @ 100p 1 coat of F-8 @ 100p
- 14 to 80 SSPC-SP-3 200
1 DFT/coat DFT/coat
WET SLOPS, AMINE soluCons, SOUR WATER , WATER DRAW OFF
13.9
1 coat of F-15
intermediate coat @
13.9. 1 coat of F-15 primer @ 80p DFT/coat + 1 coat
-14 to 90 SSPC-SP-]0 240
1 80p DFT/ coat of F-15 finish coat @
80p DFT/ coat;
(80+80=160)
VACUUM RESIDUE, FUEL OIL , DRY SLOP, BITUMEN AND OTHER HIGH TEMPERATURE
HYDROCARBON LIQUIDS
13.10 Underside of floating roof, internal surface of cone roof, bottom plate, inside of bare shell — including
wetted and non wetted surfaces, oil side surfaces of deck plates, oil side surfaces of pontoons, roof
structures, structural steel and ladders
1 coat of F-17
intermediate coat @
13.10 1 coat of F-17 primer 125p DFT/coat + 1 coat 375 .. N.. _
Up to 150°C SSPC-SP-10 ote:3
.1 @ 125p DFT/ coat of F-17 finish coat
@125p DFT/ coat.
(125+125=250)
ALKALIS UP TO 50 % CONCENTRATION
13.11
2 Coats of F-6 A @
13.11 1 coat of F-15 primer
mer @
Up to 60°C SSPC-SP-10 100p DFT/coat; 280-100 -
1 80p DFT/ coat
(2x100=200)
NOTES
I. All paint coating application including primer shall be carried out after erection and completion
of all welding work at site.
F-6A should be suitable and resistant for immersion service for the respective Hydrocarbons.
This system can be used where maximum operating temperature is below 150°C and design
temperature is upto 200°C. Cases of operating temperature > 150°C are not covered in this spec,
such cases shall be covered in the job specifications.
4 F-6 A shall be suitable for drinking water service and should have competent authority
certification.
Page 486 of 851

ateaftINGINEERS
Igar fitileuW WA LIMITED Rev. 0
Iiik717421191PONAZIPI) IA GM al Ma Undslasn91 AND PROTECTIVE COATING PAGE 32 OF 59
TABLE 14.0 COATING SYSTEMS FOR EXTERNAL SIDE OF UNDERGROUND

CARBON STEEL PLANT PIPING AND UNDERGROUND VESSELS
Surface Coating system (Field) Total Final

Design Preparation
SI. Surface DFT
Temp. in & Remarks
No. Preparation & Finish Coat in Microns
°C Shop Primer
(min.)
min.)
14.1 Underground carbon steel plant piping
I layer of coaltar tape

The primer
coating @ 2mm +1
DFT is not
coat of synthetic fast
SSPC-SP-10; measurable.
drying primer 25 @u
Reconciliation
OFT/ coat + 1 layer of
14.1.1 25 to 65 --- 1 coat of synthetic 4 mm primer shall
coal tar tape coating @
fast drying primer be done by
2mm /layer as per
25 @it DFT/ coat coverage of
EIL Standard
maximum 10
Specification No
sq.m/litre
6-79-0011
SSPC-SP-10; 1 coat of F-17

intermediate coat @
14.2.1 66 to 150 --- 1 coat of F-17 125u DFT/coat + I 375 -
primer @ 125u coat of F-17 finish
DFT/ coat coat @125u DFT/ coat
SSPC-SP-10;
1 coat of F-16 finish
14.2.2 151 to 400 ---
1 coat of F-I6 250 -
coat @125u DFT/ coat
primer @l25µ
DFT/ coat
14.3 External side of un-insulated underground storage vessels
SSPC-SP-10;
I coat of F-9 3 coats of F-7 @ 100u

14.3.1 -40 to 80 -- 365-375 -
@ DFT/coat
65-75u DFT/
coat
SSPC-SP-10;
I coat of F-17
intermediate coat @
1 coat of F-17
14.3.2 81 to 150 --- 125u DFT/coat + 1 375 -
primer @
coat of F-17 finish
125u DFT/
coat @12512 DFT/ coat
coat
SSPC-SP-10;
I coat of F-16 1 coat of F-16 finish

143.3 151 to 400 --- 250 -
primer @ coat @125u DFT/ coat
125u DFT/
coat
Page 487 of 851

azosfillteifitENONEERS
eies INDIA utsiTED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
IMIPWd3,0111 IA GOA d loan Undeglaan9) AND PROTECTIVE COATING
PAGE 33 OF 59
TABLE 15.0 COATING UNDER INSULATION (COASTAL OR INLAND PLANTS). ALL

UNITS AREAS & OFF-SITES
For insulated Piping, Equipments, Storage vessels, tanks, Columns etc of Carbon
Steel, LTCS, Low Alloy Steel & Stainless Steels

Surface
(Post-erection / Field) Final
Preparation &
SI. Design DFT
Pre- Remarks
No. Temp. in °C Primer/ in
erection/Shop Finish Coat
Intermediate Microns
Primer
(min.)
15.1 Carbon steel, LTCS and low Alloy steel Piping
SSPC-SP-10; 2 coats of F-15 @
1 coat of F-15 @
15.1.1 -45 to 120 'coat of F-15 @ 75p DFT/coat; 225- 250 -
75p DFT/coat
75p DFT/coat (2x75= 150)
SSPC-SP-10; 2coat of F-I2 @
15.1.2 121-540 'coat of F-12 @ None 20p DFT/coat; 60 -
20p DFT/coat (2x20=40)
15.2 Carbon steel, LTCS and low Alloy steel - Storage vessels, Reactors, Columns & Equipments
SSPC-SP-10; 2 coats of F-15 @
1 coat of F-15 @
15.2.1 -45 to 120 'coat of F-15 @ 75p DFT/coat; 225- 250 -
75p DFT/coat
75p DFT/coat (2x75= 150)
Temporary oil
based varnish Thermally Sprayed Aluminium coating
121 to 540 coating to be (TSAC)
15.2.2 - -
provided for Refer ANNEXURE-I
transport and
storage
153 Stainless Stee (SS) including Alloy-20 piping (Note:2)
For CS
SSPC SP-6 Products from
Commercial Blast JOTUN or HI-
1 coat of inert 2 coats of inert
-180 to Zero TEMP coatings or
15.3.1 polymeric matrix polymeric matrix 350-400
For SS SK
coating @ 125 p coating @ 125 p
SSPC SP-1 with FORMULATIONS
non-chloride are recommended.
solvent
If the piping &
equipments are
already erected
then surface shall
SSPC-SP-10
1 coat of F-15 be prepared by
(15-25p surface 1 coat of F-15
cleaning with
15.3.2 0 to 125 profile) intermediate coat finish coat@ 80 240
emery paper and
1 coat of F-15@ @80 p DFT/coat p DFT/coat; wash/flush with
80 p DFT/coat
chloride free DM
water followed by
wiping with
organic solvent
SSPC-SP-10 Not recommended
1 coat of F-16 @
15.3.3 126 to 400 1 coat of F-16 @ None 250 for operating
125 0 DFT/coat
125 g DFT/coat temperature
Page 488 of 851

laizEtha ENGINEERS FOR SURFACE PREPARATION
NO. 6-79-0020
Glg a tiOtegmv INDIA UNITED Rev. 0
1011PFT 21R077 ttUatf 0 IA Govl of Yea Undetlicingi AND PROTECTIVE COATING PAGE 34 OF 59
SSPC SP-10; between

I coat of
1 coat of 60 - 120 °C
15.3.4 401 to 600
Amercoat 738@
None Amercoat 738@ 250
125 it DFT/coat 125 g DFT/coat
15.4 Coating system for Cyclic Service of Carbon Steel, LTCS, Low Alloy Steel & Stainless Steel
SSPC-SP-10 Apcothem EPN
(15-25g surface 1 coat of F-15 1 coat of F-15 200 of M/s Asian
15.4.1 - 40 to 150 profile) intermediate coat finish coat @ 240 Paints Ltd
1 coat of F-15 @ @ 80g DFT/coat 80m DFT/coat; OR
80 p DFT/coat Equivalent
For CS
Products from
SSPC SP-6
JOTUN or HI-
Commercial Blast 1 coat of inert 2 coats of inert
-180 to 650 TEMP coatings or
15.4.2 For SS polymeric matrix polymeric matrix 350-400
SK
SSPC SP-1 with coating @ 125 g coating @ 125 g FORMULATIONS
non-chloride are recommended.
solvent
15.5 No painting is required for insulated Monel, Incoloy and Nickel lines.
NOTES
"Cyclic Service" is characterized by rapid temperature fluctuation.

The blast cleaning abrasives for SS and Alloy steel surfaces shall be Aluminium oxide
grits/shots or garnet.
3. In case of overlapping of temperature ranges as mentioned in 15.4.1 and 15.4.2, clause 15.4.1
shall be followed.
TABLE 16.0 COATING SYSTEM FOR CARBON STEEL COMPONENTS OF COOLERS /

CONDENSERS (INTERNAL PROTECTION) FOR FRESH WATER SERVICE
Fresh Water boxes, channels, partition plates, end covers and tube sheets etc.

Surface Preparation Final DFT
SI. Design (Post-erection / Field)
& Pre-erection/Shop Remarks
No. Temp. in .C in Microns
Primer Primer Finish paint (min.)
1 coat of F-15 2 coats of F-15 @
16.1 Up to 80 °C SSPC-SP-10 240
@ 80 microns 80p DFT/coat;
1 coat of Glass
Fibre Reinforced
16.2 80 to 140 SSPC-SP-10 1500 -
Novolac epoxy of
1.5 mm DFT
Format No. 8-00-0001-Fl Rev. 0 Copyright EIL - All rights reserved
Page 489 of 851

laitairiENONEERS
5fgaitameni, INDIA umiTED FOR SURFACE PREPARATION NO. 6-79-0020
MR" eleanSFM (A Gm 0/ India Undertiongi AND PROTECTIVE COATING Rev. 0
PAGE 35 OF 59
TABLE 17.0 COATING SYSTEM (INTERNAL PROTECTION) FOR GALVANIZED OR

NON FERROUS OR STAINLESS STEEL/ DUPLEX STAINLESS STEEL
COMPONENTS OF COOLERS/ CONDENSERS FOR FRESH WATER
SERVICE
Coating System Total Final

Surface Preparation
SI. Design (Post-erection / Field) DFT Remarks
& Pre-erection/Shop in Microns
No. Temp. in °C
Primer Primer Finish paint
(min.)
1 coat of F-15 @ 1 coat of F-15 @
17.1 Up to 80 Sweep Blasting 160 -
80g DFT/coat; 80g DFT/coat;
I coat of Glass
Fibre Reinforced
17.2 80 to 140 Sweep Blasting --- 1500 -
Novolac epoxy of
1.5 mm DFT
18.0 STORAGE
18.1 All paints and painting materials shall be stored only in rooms to be arranged by contractor
and approved by Engineer-in-charge for the purpose. All necessary precautions shall be
taken to prevent fire. The storage building shall preferably be separate from adjacent
building. A signboard bearing the word "PAINT STORAGE - NO NAKED LIGHT -
HIGHLY INFLAMABLE" shall be clearly displayed outside. Manufacturer's
recommendation shall be followed for storage of paint materials.
19.0 COLOUR CODE
The following colour coding system shall be followed. However alternate colour coding may
also be followed as per Owner's colour coding practice/scheme.
19.1 IDENTIFICATION
The system of colour coding consists of a ground colour and secondary colour bands
superimposed over the ground colour. The ground colour identifies the basic nature of the
service and secondary colour band over the ground colour distinguishes the particular service.
The ground colour shall be applied over the entire length of the un-insulated pipes. For
insulated lines ground colour shall be provided as per specified length and interval to identify
the basic nature of service and secondary colour bands to be painted on these specified length
to identify the particular service. Above colour code is applicable for both unit and offsite
pipelines.
Page 490 of 851

,S RS STANDARD SPECIFICATION STANDARD SPECIFICATION
0?atitatuvoy INDIA LIMITED
Rev. 0
Sifflirel3qtall IA Govt d Irda Undenkr9) AND PROTECTIVE COATING PAGE 36 OF 59
COLOUR CODING
SR. SERVICE RECOMMNDED COLOUR FOR RAL COLOUR CODE

No. PAINT SYSTEM
BASE BAND
COLOUR COLOUR
HYDROCARBON LINES (UNINSULATED)
1 CRUDE SOUR Dark Admiralty grey with 1 orange band 7012 2011
2 CRUDE SWEET Dark Admiralty grey with I red band 7012 3001
3 LUBE OILS Dark Admiralty grey with 1 green band 7012 6010
4 FLARE LINES Heat Resistant Aluminium 9006
5 LPG Orange with 1 oxide red band 2011 3009
6 PROPYLENE Orange with 2 blue bands 2011 5013
7 NAPTHA Orange with 1 green band 2011 6010
8 M.S. Orange with 1 dark admiralty grey band 2011 7012
9 AV.GASOLINE (96 RON) Orange with 1 band each of green, white 2011 6010 9010 3001
and red bands
10 GASOLINE (regular, leaded) Orange with 1 black band 2011 9005
11 GASOLINE (premium, Orange with 1 blue band 2011 5013
leaded)
12 GASOLINE (white) Orange with 1 white band 2011 9010
13 GASOLINE (Aviation Orange with 1 red band 2011 3001
100/130)
14 GASOLINE (Aviation Orange with 1 purple band 2011 4006
115/145)
15 N-PENTANE Orange with 2 blue bands 2011 5013
16 DIESEL OIL (White) Oxide red with 1 white band 3009 9010
17 DIESEL OIL (Black) Oxide red with 1 yellow band 3009 1023
18 KEROSENE Oxide red with 1 green band 3009 6010
19 HY.KEROSENE Oxide red with 2 green bands 3009 6010
20 DISUFIDE OIL (EX- Oxide red with 1 black band 3009 9005
MEROX)
21 M.T.0 Oxide red with 3 green bands 3009 6010
22 DHPPA Oxide red with 2 white bands 3009 9010
23 FLUSHING OIL Oxide red with 2 black bands 3009 9005
24 LAB FS Oxide red with 2 dark admiralty grey 3009 7012
bands
25 LAB RS Oxide red with 3 dark admiralty grey 3009 7012
bands
26 LAB (Off. Spec) Oxide red with 1 light grey band 3009 7035
27 N-PARAFFIN Oxide red with 1-blue band 3009 5013
28 HEAVY ALKYLATE Oxide red with red band 3009 3001
29 BLOW DOWN, VAPOR Off white / Aluminum with 1-Brown 9006 8004
LINE band
30 SLOWDOWN Off white / Aluminum with 2 brown 9006 8004
bands
31 A.T.F. Leaf brown with 1 white band 8003 9010
32 TOULENE Leaf brown with 1 yellow band 8003 1023
33 BENZENE Leaf brown with 1 green band 8003 6010
34 LAB PRODUCT Leaf brown with 1 blue band 8003 5013
35 FUEL OIL Black with 1 yellow band 9005 1023
Page 491 of 851

ogegOfrae
liftENGINEERS NO. 6-79-0020
gaituw INDIA umn-ED FOR SURFACE PREPARATION
INIMMER1101MOR0 IA GOA d India Undedakingl AND PROTECTIVE COATING Rev. 0
PAGE 37 OF 59
36 FULE OIL (Aromatic rich) Black with 2 yellow bands 9005 1023
37 ASPHALT Black with 1 white band 9005 9010
38 SLOP AND WASTE OILS Black with 1 orange band 9005 2011
39 SLOP AROMATICS Black with 2 orange bands 9005 2011
CHEMICAL LINES
40 TRI-SODIUM PHOSPHATE Canary yellow with 1 violet band 1012 5000

41 CAUSTIC SODA Canary yellow with 1 black band 1012 9005
42 SODIUM CHLORIDE Canary yellow with 1 white band 1012 9010
43 AMMONIA Canary yellow with 1 blue band 1012 5013
44 CORROSION INHIBITOR Canary yellow with 1 Aluminum band 1012 9006
45 HEXAMETA PHOSPHATE Canary yellow with 2 black bands 1012 9005
46 ACID LINES Golden Yellow with 1 red band 1004 3001
47 RICH AMINE Canary yellow with 2 blue bands 1012 5013
48 LEAN AMINE Canary yellow with 3 blue bands 1012 5013
49 SOLVENT Canary yellow with 1 green band 1012 6010
50 LCS Canary yellow with 1 smoke grey 1012 7031
WATER LINES
51 RAW WATER Sky blue with 1 black band 5015 9005

52 INDUSTRIAL WATER Sky blue with 2 signal red band 5015 3001
53 TREATED WATER Sky blue with 1 oxide red band 5015 3009
54 DRINKING WATER Sky blue with 1 green band 5015 6010
55 COOLING WATER Sky blue with 1 light brown band 5015 1011
56 SERVICE WATER Sky blue with 1 signal red brown 5015 3001
57 TEMPERED WATER Sky blue with 2 green bands 5015 6010
58 DM WATER Sky blue with 1 aluminum band 5015 9006

59 DM WATER ABOVE 150°F Sky blue with 2 black bands 5015 9005
60 SOUR WATER Sky blue with 2 yellow bands 5015 1013

61 STRIPPED WATER Sky blue with 2 blue bands 5015 5013
62 ETP TREATED WATER Sky blue with 2 oxide red bands 5015 3009
FIRE PROTECTION SYSTEM (ABOVE GROUND)
63 FIRE WATER FOAM & Post office red 3002

EXTINGUISHERS
AIR & OTHER GAS LINES (UNINSULATED)
64 SERVICE MR Sea green with 1 signal red band 6018 3001

65 INSTRUMENT AIR Sea green with 1 black band 6018 9005
66 NITROGEN Sea green with 1 orange band 6018 2011
67 FREON Sea green with 1 yellow band 6018 1023
68 CHLORINE Canary yellow with 1 oxide band 1012 3009
69 SO2 Canary yellow with 2 white bands 1012 9010
70 H2S Orange with 2 red oxide bands 2011 3009
71 GAS (Fuel) Orange with 1 aluminum band 2011 9006
72 GAS (Sour) Orange with 2 aluminum bands 2011 9006
Page 492 of 851

ogatimever
ol
gra14 ENGINEERS
NA UNITED FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
1 4*Vi MeRnm agara) (AGutsneauncleilaking) AND PROTECTIVE COATING PAGE 38 OF 59
73 GAS (Sweet) Orange with 2 signal red band 2011 3001

74 HYDROGEN Orange with 1 light green band 2011 6021
STEAM AND CONDENSATE LINES (UNINSULATED)
75 HP STEAM Off white / Aluminum with 1 yellow band 9006 1023

76 MP STEAM Off white / Aluminum with 1 red band 9006 3001
77 MLP STEAM Off white / Aluminum with 1 orange band 9006 2011
78 LP STEAM Off white / Aluminum with 1 light green 9006 6021
band
79 CONDENSATE Sky blue with 1 white band 5015 9010
80 CONDENSATE ABOVE Sky blue with 3 oxide red band 5015 3009
150°F .
81 BFW Sky blue with 2 red bands 5015 3001
Note: For all insulated steam lines, the colour coding shall be follow as given for un insulated lines with the
specified length of color bands.
INSULATED HYDROCARBON PIPING
82 IFO SUPPLY 1Black ground colour with 1 yellow band

9
9005 1023
in centre
83 IFO RETURN Black ground colour with 1 green band in 9005 6010
centre
84 HPS Black ground colour with 1 red band in 9005 3001
centre
85 BITUMEN Black ground colour with 2 red bands in 9005 3001
centre
86 CLO Black ground colour with 1 brown band 9005 8004
in centre
87 VB TAR Black ground colour with 2 brown bands 9005 8004
in centre
88 VR AM (BITUMEN / VBU 1 Black ground colour with 1 blue band 9005 5013
FEED) in centre
89 VR BH 1 Black ground colour with 2 blue bands 9005 5013
in centre
90 VAC. SLOP 1 Black ground colour with 1 white band 9005 9010
in centre
91 SLOP 1 Black ground colour with 1 orange band 9005 2011
in centre
92 CRUDE SWEET 1 Dark admiralty grey ground colour with 7012 3001
1 red band in centre
93 CRUDE OUR 1 Dark admiralty grey ground colour with 7012 2011
1 orange band in centre
94 VGO / HCU 1 Oxide red ground colour with 2 steel 3009 7011
grey bands in centre
95 OHCU BOTOM / FCCU 1 Oxide red ground colour with 2 steel 3009 7011
FEED grey bands in centre
UNINSULATED EQUIPMENTS, TANKS AND STRUCTURES
96 HEATER STRUCTURE Steel grey 7011

97 HEATER CASING Heat resistant aluminium 9006
98 VESSELS & COLUMNS Aluminium 9006
Page 493 of 851

15ilfraq t ENGINEERS
igeg Eveglief INDIA um iTED FOR SURFACE PREPARATION NO. 6-79-0020
INA/ 2ROWMACNI) IA Cal el India Undertaking) AND PROTECTIVE COATING Rev. 0
PAGE 39 OF 59
99 HYDROGEN BULLETS Pink 3014

100 LPG VESSELS Oxide red 3009
101 SO2 VESSEL Canary yellow 1012
102 HEAT EXCHANGER Heat resistant aluminium 9006
103 FO TANK AND HOT Black 9005
TANKS
104 ALL OTHER TANKS Aluminum / Off white 9006
105 CAUSTIC / AMINE / ACID Golden yellow 1004
TANKS
106 SOUR WATER Sky Blue 5015
107 OUTER SURFACE IN Heat resistant aluminum 9006
BOILER HOUSE
108 COMPRESSORS AND Dark admiralty grey 7012
BLOWERS
109 PUMPS Navy blue 5014
110 MOTORS & SWITCH GEAR Bluish green 5024
111 HAND RAILING Signal red 3001
112 STAIRCASE, LADDER Black 9005
AND WALKWAYS
113 LOAD LIFTING Leaf brown 8003
EQUIPMENT AND
MONORAILS ETC
114 GENERAL STRUCTURE Black 9005
PIPES AND FITTINGS OF ALLOY STEEL AND SS MATERIAL IN STORE
115 IBR Signal red 3001

116 9Cr-lMo Verdigris green 6021
117 5Cr-0.5Mo Satin blue 5012
118 2 1,4 Cr-1 Mo Aircraft yellow 1026
119 1,,4Cr- 1/2 Mo Traffic Yellow 1023
120 SS-304 Dark blue grey 5008
121 SS-316 Dark violet 4005
122 SS-321 Navy blue 5014
SAFETY COLOUR SCHEMES
123 DANGEROUS Black and alert orange band 9005 2008

OBSTRUCTION
124 DANGEROUS OR Alert orange 2008
EXPOSED PARTS OF
MACHINERY
Note: All LPG service PSVs shall be painted Deep Blue.
All drains & Vents shall be painted in Main line colour.

The colour code scheme is for identification of piping service group, It consists of a ground
colour and 1 / 2 colour bands.
19.2 Ground Colour

On uninsulated pipes, the entire pipe has to be painted in ground colour., and on metal cladded
insulated lines, minimum 2M long portion should be painted.
Page 494 of 851

el ENGNERS NO. 6-79-0020
lazir faiatowNDIAumn-ED FOR SURFACE PREPARATION
O
7R W ,a MOM g
IA God d Ada Undertakin / AND PROTECTIVE COATING Rev. 0
PAGE 40 OF 59
19.3 Colour Bands

Location of colour bands:
At Battery Limits
Intersection points & change of direction points in piping
Midway of piping section, near valves, across culverts
At 50 M interval on long stretch pipes
At starting and termination points.
Minimum width:
NB Width
3" and below 75 mm
Above 3" to 6" NB X 25 MM II! Note:
Above 6" to 12" NB X 18 MM For insulated pipes, NB indicates
Above 12" NB X 15 MM OD of the insulation
Sequence :
Colour bands shall be arranged in sequence showing Table above and the sequence follows the
direction of flow. The width of the l st Band to 2nd band is 4:1,
!!! Note : Wherever deemed required by Process Department or Safety, pipes handling hazardous
substances will be given hazard marking of 30 mm wide diagonal stripes of Black and Golden Yellow
as per IS : 2379.
19.4 Special Camouflage Painting for Uninsulated Crude and Product Storage Tanks.
Paint specification shall be as per standards.
Camouflage painting scheme for Defense requirement in irregular patches will be applied with
3 colours
Dark Green Light green Medium Brown

5 3 2
The patches shall be irregular and asymmetrical and inclined at 30 to 60 Degrees.
Patches should be continuous at surface meeting lines / points.
Slits / holes shall be painted in dark green shade.
Width of patches shall be 1 to 2 meters.
19.5 Identification Markings on Equipment / Piping
Equipment tag Numbers shall be Stenciled / neatly painted using normal 'Arial' Lettering
Style on all equipment and piping (Both insulated & uninsulated) after completion of all paint
works. Lettering colour shall be either BLACK or WHITE, depending upon the background,
so as to obtain good contrast.
Page 495 of 851

02zieLft ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
NO. 6-79-0020
-
IgZIT gate* WA LIMITED FOR SURFACE PREPARATION

IMEAMIIInM 3AIFAI IA GoN d India Undeoliongl AND PROTECTIVE COATING Rev. 0
PAGE 41 OF 59
Operations Group shall specify location.
Sizes shall be:

Columns, Vessels, Heaters: 150 mm
Pumps and other M/c 50 mm
Piping OD / 2 with Maximum 100 MM.
Storage Tanks (As per Drawings)
19.6. Colour Coding for Control Valve
Carbon steel body - Light grey
Alloy steel body - Canary yellow
Stainless steel body - Natural
The actuator of the Control valve shall be painted as :
Direct action (open on air failure) valves - Green
Reverse acting (close on air failure 1 valves - Red
The painting Status shall be comprehensively updated every 6 months for compliance
19.7 Colour Coding for Structural & Others
SI Item Color Indicative

No
1 Pipe rack structurals Dark Admiraltry Grey
2 Chequered Plate ( Both faces) Black
3 Grating Black
4 Ladder Rungs & Railing Vertical Posts Black
5 Hand Rail, Middle rail, Toe Plate Signal Red
6 Ladder Verital Posts Signal Red
7 Building Structurals, Steel Columns; brackets,
beams, bracings, roof trusses, purlings, side Dark Admiratry Grey
girts, louvers, stringers
8 OverHead Monorail Signal Red
9 Gantry Girder & Monorail Dark Green
10 Monorail Stopper Plates Signal Red.
11 Coke Cutting System Signal red
12 EOT / HOT Cranes Canary Yellow
13 Transformers, & Battery room structurals Dark Admiraltry Grey
14 Electrical Motors Dark Blue
Page 496 of 851

OWES ENGINEERS STANDARD SPECIFICATION
NO. 6-79-0020
Sga €10e3W INDIA LIMITED
a
Rev. 0
PRA panne an) IA Govt Crl hda Undertakng ) AND PROTECTIVE COATING PAGE 42 OF 59
20.0 IDENTIFICATION OF VESSELS, PIPING ETC
20.1 Equipment number shall be stencilled in black or white on each vessel, column, equipment &
machinery (insulated or uninsulated) after painting. Line number in black or white shall be
stencilled on all the pipe lines of more than one location as directed by Engineer-In-Charge;
Size of letter printed shall be as below:
Column & Vessels 150mm (high)

Pump, compressor & other machinery 50mm (high)
Piping 40-150 mm
20.2 Identification of Storage Tanks
The storage tanks shall be marked as detailed in the drawing.
21.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS
21.1 Following items shall be painted for camouflaging if required by the client.
All Columns
All tanks in Offsites
Large Vessels
Spheres
21.2 Two coats of selected finishing paint as per defense requirement shall be applied in a
particular pattern as per 20.3 and as per the instructions of Engineer-In-Charge.
21.3 Method of Camouflaging
21.3.1 Disruptive painting for camouflaging shall be done in three colours in the ratio of 5:3:2 (all
matte finish).
Dark Green Light Green Dark Medium Brown

5 3 2
21.3.2 The patches should be asymmetrical and irregular.
21.3.3 The patches should be inclined at 30° to 60° to the horizontal.
21.3.4 The patches should be continuous where two surfaces meet at an angle.
21.3.5 The patches should not coincide with corners.
21.3.6 Slits and holes shall be painted in dark shades.
21.3.7 Width of patches should be 1 to 2 meters.
22.0 QUALITY CONTROL, INSPECTION AND TESTING
22.1 All painting materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufactures as per specifications and shall be
Page 497 of 851

OPzEtt, ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
NO. 6-79-0020
laatuilir INDIA UMITED
1142710IROW WWI/ IA Gait pi India Uadettiong)
AND PROTECTIVE COATING Rev. 0
PAGE 43 OF 59
accompanied by manufacturer's test certificates. Paint formulations without certificates are

not acceptable (see section 24.0).
22.2 The contractor must produce Test Certificate from Pre Qualified Paint Manufacturer for
various tests as detailed out in section 25.1 of this document, for each batch & for each
category of product. The Engineer-in-Charge shall have the right to test wet samples of paint
from each batch at random for verifying quality of paint supplied. Contractor shall arrange to
have such tests, when called for by Engineer-in-Charge, performed at his cost any one of the
independent laboratories listed in the 25.1 of this document.
Samples for the test will be drawn at random in presence Engineer-in-Charge or his
representations. Following tests to be carried out if called for by Engineer-in-Charge:
Specific Gravity
- % solids by weight (% zinc content in case of inorganic or organic zinc primer)
Drying time (touch dry & full curing)
- Adhesion
Flexibility
- Hardness
Storage stability (pot life)
Test methods for above tests shall be as per relevant ASTM or ISO Standard.
22.3 The painting work shall be subject to inspection by Engineer-In-Charge at all times. In
particular, following stage-wise inspection will be performed and contractor shall offer the
work for inspection and approval of every stage before proceeding with the next stage. The
record of inspection shall be maintained in the registers. Stages of inspection are as follows:
Surface preparation
Primer application
(c) Each coat of paint
During surface preparation, following tests are to be carried out:
Test for absence oil & grease after degreasing before blasting as per procedure given in
sec 6.7 of Annexure-I of this specification (specification for thermally sprayed
Aluminium Coating).
Tests for surface finish of blasted surface shall be done by visual inspection using SSPC-
VISI. Clear cellophane tape test as per ISO 8502-3 shall be used to confirm absence of
dust on blasted surface. Checks shall be done on each component atleast once per 200 m2
of blasted surface and minimum of 3 checks per shift.
Test for presence of soluble salt as per method ISO 8502-9. Maximum allowable salt
content shall be considered 20 mg/m 2 (2 mg/cm 2). Checks shall be done on each
component atleast once per 200 m2 of blasted surface and minimum of 3 checks per shift.
In case salt exceeds specified limit, the contaminated surface shall be cleaned by method
as per Annexure-C of IS 12944-4 (water cleaning). After cleaning surface shall be
retested for salt after drying.
Blast profile measurement — This shall be done as described in sec 6.2 of Annexure-I of
this specification (Specification for thermally sprayed Aluminium).
Test for blasting Media and Blasting air- this shall be done as described in sec 6.6 of
Annexure-I of this specification (Specification for thermally sprayed Aluminium).
Page 498 of 851

w ENGINEERS
161daelela,
Ogzir tapeg NDR FOR SURFACE PREPARATION NO. 6-79-0020
Rev. 0
Mien FIRM WWI) LID
IA Gad of Nu Uncle/01V AND PROTECTIVE COATING PAGE 44 OF 59
In addition to above, record should include type of shop primer already applied on equipment
e.g. zinc silicate, or zinc rich epoxy, or zinc phosphate.
Any defect noticed during the various stages of inspection shall be rectified by the contractor
to the entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, contractor shall be responsible
for making good any defects found during final inspection/guarantee period/defect liability
period as defined in general condition of contract. Dry film thickness (DFT) shall be checked
and recorded after application of each coat and extra coat of paint should be applied to make-
up the DFT specified without any extra cost to owner, the extra coat should have prior
approval of Engineer-in-charge.
22.4 Primer Application
After surface preparation, the primer should be applied to cover the crevices, corners, sharp
edges etc. in the presence of inspector nominated by Engineer-In-Charge.
22.5 The shades of successive coats should be slightly different in colour in order to ensure
application of individual coats, the thickness of each coat and complete coverage should be
checked as per provision of this specification. This should be approved by Engineer-In-
Charge before application of successive coats.
22.6 The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface profile in case
of sand blasting. Holiday detectors and pinhole detector and protector whenever required for
checking in case of immersion conditions.
22.7 Prior to application of paints on surfaces of chimneys, the thickness of the individual coat
shall be checked by application of each coat of same paint on M.S.test panel. The thickness of
paint on test panels shall be determined by using gauge such as 'Elkometer'. The thickness of
each coat shall be checked as per provision of this specification. This shall be approved by
Engineer-In-Charge before application of paints on surface of chimney.
22.8 At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert
technical service at site as and when required. This service should be free of cost and without
any obligation to the owner, as it would be in the interest of the manufacturer to ensure that
both surface preparation and application are carried out as per their recommendations. The
contractor is responsible to arrange the same.
22.9 Final inspection of finished coating shall consist of measurement of:

Paint dry film thickness (DFT),
Adhesion, and,
3) Holiday detection check as well as for finish and workmanship.
1) Coating DFT measurement shall be as per ISO 2808. Type II electromagnetic gauges
should be used for ferrous substrates. DFT gauge calibration, number of measurement
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — M rights reserved
Page 499 of 851

agraes STANDARD SPECIFICATION STANDARD SPECIFICATION
ENGINEERS NO. 6-79-0020
azit ta5tegWV INDIA LIMITED FOR SURFACE PREPARATION
ilMweg awo (A GM of Inda Undertalcmg) AND PROTECTIVE COATING Rev. 0
PAGE 45 OF 59
shall be as per SSPC-DA 2. Measured DFT shall be within + 10% of the dry film
thickness, specified in the specifications.
Adhesion of the primer to the steel substrate and intercoat adhesion of the subsequent
coat(s) after curing for at least a week after application of the topcoat shall be examined by
a knife test in accordance with ASTM D 6677. For the knife test, if the rating is better than
8, the adhesion is considered acceptable. The adhesion is destructive and tested areas shall
be repaired afterward using the spot repair procedure. Alternatively, the applicator may
perform the adhesion test on a steel coupon coated using the same surface preparation and
coating application procedure as the work piece. Adhesion testing shall be carried out for
each component at least once per 200 m2 (2000 ft2) of coated surface.
Holiday testing shall be conducted in accordance with NACE SP 0188. For immersion
services, 100% of coated area shall be inspected for holidays. For atmospheric exposure,
10% of coated area which must include weld seams, corners and edges to be holiday
tested. Voltage at which test is to be carried out will depend upon DFT of coating being
tested and shall be as per NACE SP 0188. Any holiday is unacceptable and should be
marked and repaired immediately.
22.10 The contractor shall arrange for spot checking of paint materials for Specific gravity, glow
time (ford cup) and spreading rate.
22.11 Final Inspection of coating system
A final inspection shall be conducted prior to the acceptance of the work. The coating
contractor and the facility owner shall both be present and they shall sign an agreed inspection
report. Such reports shall include:
General
Names of the coating contractor and the responsible personnel
Dates when work was performed
Coating Materials
- Information on coating materials being applied
- Condition of coating materials received
Environmental Conditions
- Weather and ambient conditions
- Coating periods
Surface Preparation
Condition of surface before preparation
Tools and methods used to prepare surface
Condition of surface after preparation
Coating Application
- Equipment used
- Mixing procedure prior to application
- Coating application techniques used
Page 500 of 851

15i1frita ENGINEERS STANDARD SPECIFICATION
NO. 6-79-0020
V_IF INDIA UNITED Rev. 0
le FROWCPWO (A Gpi of Irda usertakm9) AND PROTECTIVE COATING
PAGE 46 OF 59
Testing
Type and calibration of inspection instruments used
Type of quality control tests performed, and results
23.0 GUARANTEE
23.1 The contractor shall guarantee that the chemical and physical properties of paint materials used
are in accordance with the specifications contained herein/to be provided during execution of
work.
24.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR/SUB-CONTRACTOR
Painting contractor who is awarded any job for EL, Projects under this standard must have
necessary equipments, machinery, tools and tackles for surface preparation, paint application
and inspection. The contractor mush have qualified, trained and experienced surface
preparator, paint applicator, inspector and supervisors. The contractor supervisor, inspector,
surface preparator and paint applicator must be conversant with the standards referred in this
specification.
25.0 QUALIFICATION/ACCEPTANCE CRITERIA FOR PAINT COATING SYSTEM
25.1 Pre-Qualification of Paint Coating Manufacturer and his Products
Paint Coating manufacture meeting the following requirements shall be considered for supply
of their products. Contractor is advised to select coating manufacturer. Only after obtaining
prequalification from EL for the manufacturer based on following requirements. Even those
manufacturers, whose names are appearing elsewhere in the tender document, under the list of
"EIL's Recommended or Approved Vendors", will also be required to meet the following
prequalification requirements.
Manufacturer should have been in continuous business of paint coating formulation and
manufacturer for at least past 5 years.
Manufacturer should posses past experience of supplying his products to hydrocarbon

processing industry or offshore platforms in the past 5 years.
- Coating manufacturer should have supplied at least 10000 litre of an individual product
to hydrocarbon processing industry or offshore platform.
The manufacturer's manufacturing procedure & QA/QC system shall meet ISO 9001
requirements and preferably should posses ISO 14000 certificate.
The Quality control set up should be manned by qualified paint technologists whose bio
data should be sent along with quality control organization chart.
Pre-Qualification Testing:
Manufacturer should have got his products tested at least one time in last 3 years at a
reputed independent laboratory for the following test items. Test certificates which are
more than 3 years old will not be considered.
Page 501 of 851

OFEET STANDARD SPECIFICATION STANDARD SPECIFICATION
ENONEERS NO. 6-79-0020
Iariaffleg41, INDIA UNITED FOR SURFACE PREPARATION
iwnewa.mgarm IA Gart Inda Undertaar0 AND PROTECTIVE COATING Rev. 0
PAGE 47 OF 59
Test Test Method

Specific gravity ASTM D 1475
Dipping properties ASTM D 823
Film characteristics -
Solids content by weight ASTM D 2369
Drying time ASTM D 1640
Flexibility ASTM D 1737/ D 522
Hardness ASTM D 3363
Adhesion ASTM D 2197
Abrasion resistance ASTM D 968/ D 1044
DFT/coat As per SSPC guidelines
Storage Stability ASTM D 1849
Resistance to moisture vapour permeability for 2000 hrs ASTM D 2247
Cyclic Test for the duration of 4200 h (25 cycles a 168 ISO 7253, ASTM G53
hours)
% Zn in Dry film for Inorganic Zinc -
Silicate primer
Chemical Resistance test ASTM D 543
- 10% & 40% NaOH (applicable only for F-6 & F-15)
- 10% H2SO4 (applicable only for F-6 & F-15)
- 10 % Nitric Acid test (applicable only for F-6 & F-15)
- Benzene / Toluene (applicable only for F-6 & F-15)
- Kerosene (applicable only for F-6 & F-15)
- Sea water (applicable only for F-6 & F-15)
- MIBK test (applicable only for F-6 & F-15)
Resistance to water using water immersion (applicable ASTM D 870
only for F6-, F-7, F-8, F-14 & F-15)
Dry Heat Resistance test
(applicable only for F-9, F-6A/B, F-2, F-15, F-16,
polysiloxane, heat resistance Al silicone)
Thermal shock resistance test ASTM D2485 - 91
(only for F-9, F-6, polysiloxane)
Each coating product to be qualified shall be identified by the following
An infrared scan (fingerprint), for Part A and B, each component as per ASTM
D 2621
Specific gravity of Base and curing agent (Ref. ISO 2811)
3) Ash content (ASTM D1650), volatile and non-volatile matters (ISO 3251) of each
component
The identification shall be carried out on the batch, which is used for the Pre-
qualification testing. Pre-qualification of the products shall be carried out at an
independent laboratory.
Test shall be carried out at any one of the following laboratories and tests to be witnessed &
certified by third party inspection agency (TUV, BV, DNV).
Page 502 of 851

000:eftENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
siges eg W: WA LIMITED
Rev. 0
men eeteRtel3AARI (A God d( Undell/A1A) AND PROTECTIVE COATING PAGE 48 OF 59
IICT, Hyderabad
HBTI, Kanpur
DMSRDE, Kanpur
BIS Laboratories
UICT, Matunga, Mumbai
RITES, Kolkata
PDIL, Sindri
NTH, Kolkata
Contractor shall furnish to EIL for approval/ acceptance of all necessary

documents/information including test certificates to prove that the paint manufacturers, from
whom he intends to procure paint products, meet the various requirements for fulfilling the
pre-qualification criteria as given under section 25.1 above. The paint manufacturer shall be
qualified and approved for supply after review/assessment of the submission made by the
contractor.
25.2 Information to be furnished during delivery of coating system:
Contractor along with delivery of paint material has to furnish following information from
paint manufacturer to EIL for acceptance/approval of products.
Batch test certificates (Batch Testing)
Along with delivery to site of the paint products from pre-qualified coating manufacturer.
Contractor has to produce test certificate from paint manufacturer for each batch and for
each category of product for the following test items. Test to be witnessed & certified
by third party inspection agency. All test results must mention clearly the batch no. and
category of product tested. Tests to be conducted for following properties:
Infrared scan for Part A and B, each component

- Specific Gravity
- % solids by weight (% zinc content in case of inorganic or organic zinc primer)
Product information sheet/ technical data sheet for each category of product.
26.0 METHOD OF SAMPLING & DISPATCH FOR LABORATORY TESTING

(Pre-Qualification tests (sec. 25.1), Batch testing (sec. 25.2) and Inspection testing (sec.
22.0))
26.1 Samples of coating materials should be submitted to the Govt. laboratory in sealed containers
with batch no. and test certificate on regular format of manufacturer's testing laboratory. The
sampling shall be certified and sealed by a certifying agency.
26.2 All test panels should be prepared by Govt. testing agency coloured photographs of test
panels should be taken before and after the test and should be enclosed along with test report.
Sample batch no. and manufacturer's test certificate should be enclosed along with the
report. Test report must contain details of observation and rusting if any, as per the testing
code.
Page 503 of 851

Oftieta ENGINEERS
Tif Ell5leg4TV WA LIMITED Rev. 0
Mien a21017 ./L7RIM IA GM of India Undeddimal AND PROTECTIVE COATING PAGE 49 OF 59
26.3 Manufacturers should intimate the company, details of sample submitted for testing, name of
Govt. testing agency, date, contact personnel of the govt. testing agency. At the end of the
test the manufacturer should submit the test reports to the company for approval.
26.4 Coating systems for panel test shall be decided after discussion with EIL
Page 504 of 851

151Rat ENGINEERS
71E1071ft%, INDIA LIMITED
NO. 6-79-0020
11;4 Rev. 0
MM.'MOWS° g
IA GM India Underlim ) AND PROTECTIVE COATING PAGE 50 OF 59
ANNEXURE-I
SPECIFICATION FOR THERMALLY SPRAYED ALUMINIUM (TSA) COATING
1.0 SCOPE
The following sections outlines the requirement of supply, application and testing of thermally
sprayed aluminum coatings (TSAC) for corrosion protection of insulated carbon steel piping
and equipments with design temperature not exceeding 540 ° C.
2.0 ITEMS TO BE THERMALLY SPRAYED
Steel Structures/equipments to be protected by TSAC shall be as per Tables 15.0 of this

standard specification. Structures, components thermally sprayed shall not have any uncoated
area or shall not be in mechanically connected by flanges etc to any uncoated bare steel work.
Such adjacent areas to TSA coated areas, if not coated by TSA shall have suitable paint
coating system as per the standard specification.
3.0 TSAC REQUIREMENTS
3.1 Surface Preparation
All the parts to be sprayed shall be degreased according to SSPC-SP 1. The absence of oil and
grease after degreasing shall be tested by method given elsewhere in the specification (Refer
Sec. 6.7). Thereafter the surface to be abrasive blasted to white metal finish as per NACE
1/SSPC-SP 5 for marine and immersion service. Using SSPC VIS 1, it is to be visually
assessed that the blast cleaned surface meets requirement of SSPC-SP 5. Thereafter clear
cellophane tape test as per ISO 8502-3 shall be used to confirm absence of dust on the blasted
surface Finally blasted surface shall be tested for presence of soluble salts as per method ISO
8502-9. Maximum allowable salt content shall be considered 50mg/m 2 . (5 micrograms/cm2)
.In case salt content exceeds specified limit. The contaminated surface shall be cleaned by
method as per Annex C of IS 12944-4 (Water Cleaning). After cleaning the surface shall be
retested for salt content after drying. Testing shall be carried out at least on each component,
once per 200 m2 and a min of 3 times per shift during progress of work.
The blasting media shall be either chilled iron or angular steel grit as per SSPC-AB-3 of mesh
size G-16 to G-40. Copper, Nickel slag, Garnet or Aluminum Oxide as abrasives will also be
suitable having mesh size in the range of G16 to G24 (10-30 mesh), conforming to SSPC-AB-
1. Mesh size shall be required as appropriate to the anchor tooth depth profile requirement and
blasting equipment used. The blasted surface should be having angular profile depth not less
than 65 microns with sharp angular shape but shall not exceed 85 microns. The profile depth
shall be measured according to NACE standard RP 0287 (Replica Tape) or ASTM D 4417
method B (Profile depth gauge).
For manual blasting one profile depth measurement shall be taken every 10-20 m 2 of blasted
surface.
Surface preparation shall be completed in one abrasive blast cleaning operation wherever
possible.
Page 505 of 851

agraift ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
$1g a fifReall INDIA UNITED Rev. 0
(NMI MIRMIARI/ (A Gout al lita Underlakin3) AND PROTECTIVE COATING PAGE 51 OF 59
If rust bloom (visual appearance of rust) appears on the blast cleaned surface before thermal
spraying, the affected area shall be reblasted to achieve specified degree of cleanliness after
which only thermal spraying shall commence.
Air blasting pressure at nozzle shall be normally maintained at 100 psi. Air pressure and
media size should be reduced and adjusted to preclude damage/distortion to thin gauge
materials. Blasting time on work piece should be adjusted to only clean the surface and cut
required anchor tooth with minimum loss of metal. Blast angle should be as close to
perpendicular as possible but in no case greater than ± 30 ° from perpendicular to work
surface. Blasting media must be free of debris, excessive fines, and contaminants such as
NaCI and sulfur salts (Ref. SEC 6.0 of this Spec). Blast cleaning shall not be performed when
the surfaces to be blasted are wet or less than 5°C above dew point temperature or when the
relative humidity in the vicnicity of the work is greater than 90%.
3.1.1 Blasting Equipment
The TSAC applicator shall use mechanical (centrifugal wheel) or pressure pot blast cleaning
equipment and procedures. Suction blasting equipment shall not be used. Sec 6.6.2 shall be
used to validate clean and dry air.
3.1.2 Feed Stock
The feed stock shall be in the form of wire. The feed stock shall be 99.5% aluminum of
commercial purity grade, its composition shall be in accordance with requirement of BS 1475
or ASTM B833 or ISO 209-1 type Al (wrought aluminum and aluminum alloys, wire). Wire
shall be supplied in protective wrapping indicating batch number and other details.
3.1.3 Thickness Requirement
The nominal thickness of finished TSAC shall be 250 microns having minimum value of 225
microns at low thickness areas (valleys) and not more than 275 microns at peak areas.
The finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge
(Magnetic Gauge).
3.1.4 Coating Bond Strength Requirement
The TSAC coating shall have a minimum individual tensile-bond strength value of 1000 psi
for flame sprayed and 1500 psi for arc sprayed coating with an average of 2000 psi for arc
sprayed coatings. Minimum tensile bond strength should be achieved by proper anchor tooth
profile of blasted surface, laying down the TSA thickness in multiple passes and carrying out
TSA application under controlled environment
3.1.5 Porosity
All thermally sprayed metallic coatings will have porosity. For thermally sprayed aluminum
coatings porosity shall not exceed 15% of total surface area for flame sprayed coating and 8%
for arc spray coating.
Page 506 of 851

lafteleENIONEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
es iiptew INDI A umn-ED FOR SURFACE PREPARATION NO. 6-79-0020
(MRPI FRaRVINJWMil IA GO. Dna Wean) AND PROTECTIVE COATING Rev. 0
PAGE 52 OF 59
4.0 THERMAL SPRAY APPLICATION PROCEDURE
Items in the atmospheric zone to be coated by TSA shall be applied by either Flame
spray or Arc spray method only. For coating under insulation, application shall be by
arc wire method.
4.1 Equipment Set Up
4.1.1 Thermal spray equipment shall be set up calibrated, operated (1) according to manufacturer
instructions/technical manuals and also TSAC applicators refinement thereto and (2) as
validated by Procedure Qualification (Sec 7.0 of this specification).
4.1.2 Spray Parameters
Spray parameters (see 4.1.3 below) and thickness of each crossing pass shall be set and shall
be validated with bend test (See 6.5 of this Spec).
4.1.3 Spray Parameters
Spray Parameters Method of Application

Arc wire Spray Flame Wire Spray
Arc voltage 27 V -
Air pressure 80 psi 80 psi
NACE-1 white metal /
Steel surface cleanliness NACE-1 white metal
or Near white metal
Steel surface profile 75 microns (minimum) 75 microns (min.)
Arc current 250-280A -
Coating thickness 225 microns (nominal) 225 microns(Nominal)
Coating adhesion > 1500 psi (Total coating),see 3.1.4 >1000 psi
Coating porosity Less than 8% Less than 15%.
Spray distance (spray Gun 5-7"
6-8"
work piece)
Spray Pass width 40mm 20 mm
The above parameters to be validated with a bend test by the contractor before start of work
(for details of bend test see Sec 6.5 of this Spec).
4.2 Post Blasting Substrate Condition and Thermal Spraying Period.
4.2.1 The steel surface temperature shall be at least 5°C above dew point of ambient air temperature.
Steel substrate surface temperature shall be recorded by with a contact pyrometer.

Thermal spraying should commence within 15 minutes from the time of completion of blasting
4.2.2 Holding Period
Time between the completion of final anchor tooth blasting and completion of thermal
spraying of blasted surface should be no more than four hours. If within this period rust bloom
appears Sec 4.4.1of this specification will apply.
Format No. 8-00.0001-F1 Rev. 0 Copyright EIL — All rights reserved
Page 507 of 851

az
dzieft ENGINEERS NO. 6-79-0020
1&11€151erilV INDIA LIMITED FOR SURFACE PREPARATION
imerreRaRtitM11711 IA Gat al InCia UNIeltaking) AND PROTECTIVE COATING Rev. 0
PAGE 53 OF 59
4.3 Pre-Heating
For flame spraying, the initial starting area of 1-2 square feet to be preheated to approx.120°C
to prevent condensation of moisture in the flame on the substrate. For arc spraying the
preheating is not required.
4.4 Thermal Spraying
Spraying should commence only after validation of equipment set up by procedure

qualification test and spray parameter validation tests described in Sec 7.0 and 6.5
respectively. Thermal spraying must commence within 15 minutes from the time of
completion of blast cleaning
The specified coating thickness shall be applied in several crossing passes. The coating bond
strength is greater when the spray passes are kept thin. Laying down an excessively thick spray
pass increases the internal stresses in TSAC and decreases the bond strength of total TSAC.
The suitable thickness for crossing passes shall be determined by procedure qualification test
described in Sec 7.0 of this specification.
For manual spraying, spraying to be done in perpendicular crossing passes to minimize thin
spots in coating. Approx. 75-100 microns of TSAC shall be laid down in each pass.
The surface geometry of the item or area to be sprayed should be inspected before application.
The spraying pass and sequence shall be planned according to following.
Maintain Gun as close to perpendicular as possible and within ± 30° from perpendicular to
the substrate.
Maintain nominal standoff distance and spray pass width as given below:
Spray pass width

Spray method Standoff (Inches)
(Inches)
Arc Wire 6-8 1 'A( 40mm )
Flame wire 5-7 %( 20mm )
4.4.1 Rust Bloom (Visual appearance of rust or Discoloration)
If Rust bloom appears on the blasted surface before thermal spraying, the affected area shall be
reblasted to achieve the specified level of cleanliness.
If Rust bloom in form of discoloration, or any blistering or a degraded coating appears at any
time during application of TSAC, then spraying shall be stopped and acceptable sprayed area
shall be marked off. The unsatisfactory areas shall be repaired to the required degree of surface
cleanliness and profile.
Blast the edges of the TSAC to provide for 2-3" feathered area overlap of the new work into
existing TSAC.
Then apply TSAC to the newly prepared surfaces and overlap the existing TSAC to the extent
of feathered edge so that overlap is a consistent thickness.
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell. —AI rights reserved
Page 508 of 851

latazidie ENGINEERS FOR SURFACE PREPARATION
NO. 6-79-0020
sigtaReW INDIA LIMITED Rev. 0
2174WZAJWIRD .
(A Go .4 Inda Undedalungl AND PROTECTIVE COATING PAGE 54 OF 59
4.4.2 Masking
Masking all those parts and surfaces which are not required to be thermally sprayed as
instructed by purchaser should be inspected by applicator to ensure that they are properly
marked and covered by purchaser.
Complex geometries (flanges, valve manifolds, intersections) shall be masked by applicator to

minimize overspray i.e. TSAC applied outside spray parameters (primarily gun to substrate
distance and spray angle).
4.4.3 TSAC Finish
The deposited TSAC shall be uniform without blisters, cracks, loose particles, or exposed steel
as examined with 10 X magnification.
5.0 SEALER
Sealant shall be applied after satisfactory application of TSAC and completion of all testing
and measurements of the finished TSAC as per Sec 6.0 of this specification.
For shop workSealer shall be applied immediately after thermal spraying and for field work
sealer shall be applied within 8 hours. The sealcoat shall be thin enough to penetrate into the
body of TSAC.
The sealant shall be Silicone Alkyd Aluminium paint having DFT not more than 35-40 micron.
Typically seal coat shall be applied at a spreading rate resulting in theoretical 38 microns DFT.
The seal coat shall be applied in accordance with SSPC-PA 1 and the paint manufacturer
instruction for sealing.
6.0 TESTING AND MEASUREMENT SCHEDULE
6.1 Surface Finish
That the blasted cleaned surface meets the required criteria (NACE 1/SSPC-SP 5) shall be
visually inspected using SSPC-VIS 1. The clear cellophane-tape test as per ISO 8502-3 shall
be used to confirm absence of dust or foreign debris on the cleaned surface. Checks shall be
done on each component at least once per 200 m2 of blasted surface and minimum of 3 checks
per shift.
6.2 Blast Profile Measurement: (In-Process testing during actual production before application
of TSA coating)
The angular profile depth measurement shall be done by profile tape as per method NACE
Standard RP 0287 or ASTM D 4417 method B (Profile depth gauge micrometer). Spot
measurement shall be carried out every 15m 2 of blasted surface. At each spot three
measurements shall be taken over an area of 10 cm 2 and average of measurements to be
recorded and reported.
If profile is <65 microns blasting shall continue till grater than 65 microns depth profile is
achieved.
Page 509 of 851

Oftela ENGINEERS STANDARD SPECIFICATION
NO. 6-79-0020
felliteCe INDIA LIMITED Rev. 0
awn maw nem) (A Gem al inda Underlikog AND PROTECTIVE COATING PAGE 55 OF 59
6.3 TSAC Thickness (In-Process Testing For finished coating during regular production)
6.3.1 TSAC finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge.
6.3.2 For flat surfaces, measurements shall be taken along a straight measurement line, one
measurement line for every 15 m2 of applied TSAC shall be selected along which 5
measurements to be taken at 25 mm internal and average to be reported.
6.3.3 For curved surface or complex geometry, 5 measurements shall be taken at a spot measuring
10 cm2 in area. One spot to be taken for every 15 m2 of applied TSAC area.
6.3.4 The TSAC thickness in surface changes or contour changes, welds and attachments shall be
also measured and reported.
6.3.5 If TSAC is less than specified minimum thickness, apply additional TSAC until specified
thickness range is achieved.
6.3.6 All locations and values of TSAC thickness measurements shall be recorded in Job Record
(JR).
6.4 Tensile Bond Testing (In-Process testing for finished coating during regular production)
Tensile Bond strength of the TSAC finish coat shall be determined according to
ASTM D 4541 using a self-aligning adhesion tester.
One measurement shall be made every 50 m2. If tensile bond at any individual spot
is less than 1000 psi for flame sprayed coating and 1500 psi for arc sprayed coating
the degraded TSAC shall completely removed and reapplied.
The tensile bond portable test instrument to be calibrated according to ASTM C 633
6.5 Bend Tests
Bend test shall be carried out at beginning of each work shift. Bend tests shall also be
conducted on sample coupons before start of thermal spraying work to qualify the following as
mentioned earlier in this specification.
To qualify spray parameters and thickness of each crossing pass.
6.5.1 Test Procedure
Five corrosion control steel coupons each of dimension 50 mm x 150 mm x 1.3 mm

thk. to be prepared.
Surface shall be prepared by dry abrasive blast cleaning as per this specification.
TSAC shall be applied as per specified thickness range. TSAC should be sprayed in
crossing passes laying down approx. 75-100 microns in each pass.
TSAC applied coupons shall be bent 180 ° around a 13 mm diameter mandrel.
Page 510 of 851

g,, STANDARD SPECIFICATION STANDARD SPECIFICATION
(gal etiregw ENGINEERS
INDIA LMTED FOR SURFACE PREPARATION NO. 6-79-0020
1411MeRePWW) IA Govt al India Undertiong) AND PROTECTIVE COATING Rev. 0
PAGE 56 OF 59
e) Bend test shall be considered passed if on bend radius there is
- No cracking or spalling or lifting by a knife blade from the substrate

- Only minor cracking that cannot be lifted from substrate with a knife blade.
Bend test fails if coating cracks with lifting from substrate.
6.6 Tests for blasting media, blasting air
6.6.1 Blasting Media (For every fresh batch of media and one random test during blasting)
Blasting Media shall be visually inspected for absence of contamination and debris using 10 X
magnification.
Inspection for the absence of oil contamination shall be conducted using following
procedure :
Fill a small clean 200 ml bottle half full of abrasive.
Fill the bottle with potable water, cap and shake the bottle.
Inspect water for oil film/slick. If present, the blasting media is not to be used.
Soluble salt contamination if suspected shall be verified by method ASTM D 4940. If

present, media to be replaced.
c) Clean blasting equipment, especially pot and hoses, and then replace blasting media
and retest.
6.6.2 Test for Blasting Air (Once Daily before start of blasting and once at random during blasting)
The air for blasting shall be free from moisture and oil. The compressor air shall be checked
for oil and water contamination per ASTM D 4285.
6.7 Test for presence of oil/grease and contamination
The steel substrate after degreasing as per SSPC-SP 1 shall be tested as per following
procedure to validate absence of oil and grease contamination.
Visual inspection - Continue degreasing until all visible signs of contamination are removed.
Conduct a solvent evaporation test by applying several drops or a small splash of residue-free
trichloromethane on the suspect area especially pitting, crevice corrosion areas or depressed
areas. An evaporation ring formation is indicative of oil and grease contamination.
Continue degreasing and inspection till test is passed.
7.0 TSAC APPLICATOR QUALIFICATION
Following tests to be carried out as part of procedure qualification test for the applicator.
Thickness measurement
Coating bond strength
Porosity test
Page 511 of 851

loi
rif&JelitENIGINERS
gtIf WegNEW INDIA LIMITED Rev. 0
MDR [111,3M11/ IA Gael d hdia Underlain)) AND PROTECTIVE COATING PAGE 57 OF 59
Bend strength
TSAC applicator's surface finishing and application process and equipment set up, calibration
and operation shall be qualified by application of TSA on a reference sample which shall be
used as a comparator to evaluate the suitability of application process. Only that applicator will
be permitted to carry out the work when test specimens coated by the applicator meets the
desired requirements as cited below.
The sample shall be made of a steel plate measuring approx. 18"x 18" x Vo" thick. If the actual
work is less than 1/4" thick then the sample to be made from material of representative
thickness.
The surface preparation, TSAC application shall be made with actual field equipments and
process/spray parameters and procedures as per the specification. The depth profile of blasted
surface, TSAC coating thickness for each cross pass and total thickness range shall be as per
specification.
The surface preparation and thermal spraying shall be carried out in representative
environmental conditions spraying with makeshift enclosure.
7.1 After application of coating, thickness and tensile bond measurements shall be made in
following manner.
Divide the sample piece into four quadrants.
Measure thickness along the diagonal line of each quadrant.
Four each quadrant five in-line thickness measurements at 1" interval shall be done
using SSPC-PA 2 type 2 fixed probe gauge. Thus a total of four "five in line"
thickness measurements to be done for the whole sample.
One tensile bond measurement using ASTM D 4541 type III or IV portable self
aligning test instrument to be done at centre of each quadrant. Total of 4 measurements
for the sample.
One porosity evaluation test by Metallographic examination shall be conducted to

demonstrate the achievement of porosity within the limits specified. Sample shall be
prepared for Metallographic examination as per ASTM E — 3.
The procedure shall be considered qualified if thickness and tensile-bond strength and
porosity values meet the specification requirement.
7.2 Bend test: Bend test shall be carried out as detailed at sec. 6.5 of this specification.
Applicators thermal spray equipment set-up, operation and procedure of application including
in-process QC checkpoints adopted during procedure qualification as described above should
be always subsequently followed during entire duration of work.
8.0 DOCUMENTATION
The following information shall be provided by TSAC applicator before award of work.
Page 512 of 851

S ilOzeift ENONEERS
f
NO. 6-79-0020
gaf 215leg e INDIA WAITED
li ir
Rev. 0
1411PMFIRFROMPI) IA &vet Incha Undertaang/
AND PROTECTIVE COATING PAGE 58 OF 59
TSAC application process consisting of equipment capabilities and their technical

parameters, feed stock material and source of procurement.
Detailed application procedure and in-process quality control check points for (a)
surface preparation (b) thermal spraying (c) seal coats.
Type and specification of instruments to be deployed for measurement of blast profile

depth, TSAC thickness and tensile bond.
Paint manufacturer data sheet for the selected sealing coat to be applied.
9.0 RECORDS
The TSAC applicator shall maintain job record to record production and QC
information. All the results of the tests and quality control checks shall be entered in
the record for each component/part thermally sprayed. All the result of tests
(thickness, tensile bond, bend tests) and other validation tests (e.g. procedure
qualification test, test for surface cleanliness after abrasive blasting, test for
cleanliness of abrasives and air) shall also be recorded and duly signed by owner.
All the information mentioned in Sec 8.0 above should also form part of the Job
record.
Any modification affected after procedure qualification in the procedure, QC, spray
parameter, equipment spec to the original information (submitted before award of the
work) must also form part of Job record.
10.0 WARRANTY
The TSAC applicator shall warrant the quality of material used by providing the purchaser
with a certificate of materials used to include
Spray feed stock: Alloy type/designation, Lot Number, wire diameter, chemical
analysis, name of supplier, manufacturer.
Sealant: Name of manufacturer, application data sheet.
11.0 SAFETY
The TSAC applicator shall follow all safety procedures required by the purchaser/owner.
Owner shall also give compliance requirement to be followed by applicator. The applicator
shall follow all appropriate regulatory requirements.
This specification shall apply in case of conflict between specification and following
applicable standards:
Page 513 of 851

(3i1tael4t ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION
5gaia2egwiNDIA umn-ED FOR SURFACE PREPARATION NO. 6-79-0020
t
Wen FRaW ',AMER) IA Govi al India Undeltalang l AND PROTECTIVE COATING Rev. 0
PAGE 59 OF 59
AWS C. 2.17 Recommended Practice for Electric arc Spray.

ASTM C 633 Test Method for Adhesive/Cohesive Strength of Flame Sprayed Coatings.
ASTM D 4285 Method for indicating Oil or Water in Compressed Air.
ASTM D 4417 Test Method for Field Measurement of Surface Profile of Blasted Steel.
BS 2569 Specification for Sprayed Metal Coating.
NACE Standard RP Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel
0287 Surfaces Using a Replica Tape.
Test method for Pull-Off Strength of Coating Using Portable Adhesion
ASTM D 4541
Testers.
Guide for the Protection of Steel with Thermal Spray Coatings of
ANSI/AWS C2.18
Aluminum, Zinc and Their Alloys and Composites.
NACE No. 12/AWS Specification for the application of thermal spray coatings (Metallizing) of
C2.23M/SSPC-CS aluminum, zinc, and their alloys and composites for the corrosion
23.00 protection of steel.
The inspection of coatings and linings: A Handbook of Basic practice for
SSPC Publication
Inspectors, Owners, and Specifiers.
SSPC-AB 1 Mineral and Slag Abrasives.
SSPC-AB 3 Ferrous Metallic Abrasives.
SSPC-PA 1 Shop, Field, and Maintenance Painting of Steel.
SSPC-PA 2 Measurement of Dry Coating Thickness with Magnetic Gages.
NACE No. 1/SSPC- White Metal Blast Cleaning.
SP 5
NACE No. 2/SSPC- Near —White Metal Blast Cleaning.
SP 10
Guide and Reference Photographs for Steel Surfaces Prepared by Dry
SSPC-VIS 1
Abrasive Blast Cleaning.
Page 514 of 851

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Page 528 of 851

ENGINEERS HEALTH, SAFETY &
6-82-0001 Rev. 7
4Igsirfal51-ag
lawn erexer7traaarnart
INDIA LIMITED
IA Govt of India Undertakengt
ENVIRONMENTAL
MANAGEMENT AT Page 1 of 90
CONSTRUCTION SITES
ui TETF 117
1:4744, laTkir LitircRui
Hlich RIF1411-1
STANDARD SPECIFICATIONFOR
HEALTH, SAFETY&ENVIRONMENTAL
(HSE)MANAGEMENT AT
CONSTRUCTION SITES
■
Leip>.,,e
uuto4,
0 1
7 31/01/2017
REVISED & UPDATED AS
6 26/02/2014
REVISED & UPDATED SM DJ RKD SC
5 19/12/2012 REVISED & UPDATED SM SM RKD DM
4 13/02/2008 REVISED & UPDATED AS RK SCB VC
3 17/07/2007 REVISED & UPDATED AS MPJ VNP VC
2 11/08/2005 REVISED & UPDATED MPJ MPJ VNP VJN
Standards Standards
Committee Bureau
Rev Date Purpose Prepared by Checked by Convenor Chairman
Approved by
Page 529 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 2 of 90
Abbreviations:
AERB : Atomic Energy Regulatory Board

ANSI : American National Standards Institute
BARC : Bhabha Atomic Research Centre
BS : British Standard
EIL : Engineers India Limited
BPCL : Bharat Petroleum Corporation Limited
ELCB : Earth Leakage Circuit Breaker
EPC : Engineering, Procurement and Construction
EPCC : Engineering, Procurement, Construction and Commissioning
ESI : Employee State Insurance
GCC : General Conditions of Contract
GM : General Manager
GTAW : Gas Tungsten Arc Welding
HOD : Head of Department
HSE : Health, Safety & Environment
HIRAC : Hazard, Identification Risk Assessment & Control
OISD : Oil Industry Safety Directorate
HV : High Voltage
IS : Indian Standard
IE : Indian Electricity
LOTO : Lock Out & Tag Out
LPG : Liquefied Petroleum Gas
LSTK : Lump Sum Turn Key
MV : Medium Voltage
PPE : Personal Protective Equipment
RCM : Resident Construction Manager or Site-in-Charge, as applicable
SCC : Special Conditions of Contract
SLI : Safe Load Indicator
TBT : Tool Box Talks
Construction Standards Committee
Convenor : Sh. T K Sen, ED(Construction)
Members : Sh. Amitava Pal, CGM (C)

Sh. S N Bhatnagar, GM (C)
Sh. M K Garg, GM (C)
Sh. A K Mishra, GM(C)
Sh. Janak Kishore, DGM (P)
Sh. Rajeev Jain, DGM (C&P)
Sh. Udayan Chakravarthy, AGM (Piping)
Sh. Ravindra Kumar, AGM (C)
Sh. Sunil Dahiya, AGM (C)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – Al rights reserved
Page 530 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
CONTENTS
CLAUSE TITLE PAGE NO.

1.0 Scope 5
2.0 References 5
3.0 Requirement of Health, Safety and Environmental (HSE) 5
Management System to be complied by Bidders
3.1 Management Responsibility 5
3.1.1 HSE Policy & Objective 5
3.1.2 Management System 5
3.1.3 Indemnification 6
3.1.4 Deployment & Qualification of Safety 6
Personnel
3.1.5 Implementation, Inspection& Monitoring 8
3.1.6 Behavior Based Safety 9
3.1.7 Awareness 9
3.1.8 Fire prevention & First-Aid 9
3.1.9 Documentation 10
3.1.10 Audit 10
3.1.11 Meetings 11
3.1.12 Intoxicating drinks & drugs and smoking 11
3.1.13 Penalty 11
3.1.14 Accident/Incident investigation 14
3.2 House Keeping 14
3.3 HSE Measures 15
3.3.1 Construction Hazards 15
3.3.2 Accessibility 16
3.3.3 Personal Protective Equipment’s (PPEs) 16
3.3.4 Working at height 17

3.3.5 Scaffoldings 19
3.3.6 Electrical installations 19
3.3.7 Welding/Gas cutting 21
3.3.8 Ergonomics and tools & tackles 22
3.3.9 Occupational Health 23
3.3.10 Hazardous substances 23
3.3.11 Slips, trips & falls 23
3.3.12 Radiation exposure 23
3.3.13 Explosives/Blasting operations 24
3.3.14 Demolition/Dismantling 24
3.3.15 Road Safety 24
3.3.16 Welfare measures 26
3.3.17 Environment Protection 26
3.3.18 Rules & Regulations 26
Contd. to page 4 …
Page 531 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
3.3.19 Weather Protection 27

3.3.20 Communication 27
3.3.21 Confined Space Entry 27
3.3.22 Heavy Lifts 28
3.3.23 Key performance indicators 28
3.3.24 Unsuitable Land Conditions 29
3.3.25 Under Water Inspection 29
3.3.26 Excavation 29
3.4 Tool Box talks 30
3.5 Training & Induction Programme 30
3.6 Additional safety requirements for working Inside a running 31
3.7 Self Assessment and Enhancement 33
3.8 HSE Promotion 33
3.9 LOTO for isolation of energy source 33
4.0 Details of HSE Management System by Contractor
4.1 On Award of Contract 33
4.2 During Job Execution 33
4.3 During short listing of the sub-contractors 35
5.0 Records 35
Appendices
1. Standards/Codes on HSE Appendix-A
2. Details of First AID Box Appendix-B
3. Types of Fire Extinguishers & their Appln. Appendix-C
4. Indicative List of statutory Acts & Rules Appendix-D
5. Construction Hazards and their mitigation Appendix-E
6. Training subjects / topics Appendix-F
7. Construction Power Board ( typ) Appendix-G
8. List of HSE procedures Appendix-H
Attachments (Reporting Formats)
I Safety Walk through Report HSE-1 Rev.0
II Accident/Incident Report HSE-2 Rev.0
III Suppl. Accident/Incident Investigation Report HSE-3 Rev.0
IV Near Miss Incident Report/Dangerous occurrence HSE-4 Rev.0
V Monthly HSE Report HSE-5 Rev.0
VI Permit for Working at height HSE-6 Rev.0
VII Permit for Working in Confined Space HSE-7 Rev.0
VIII Permit for Radiation work HSE-8 Rev.0
IX Permit for Demolishing/ Dismantling HSE-9 Rev.0
X Daily Safety Checklist HSE-10 Rev.0
XI Housekeeping assessment & compliance HSE-11 Rev.0
XII Inspection of temporary electrical booth / HSE-12 Rev.0
installation
XIII Inspection for scaffolding HSE-13 Rev.0
XIV Permit for erection / modification & dismantling of HSE-14 Rev.0
scaffolding
XV Permit for heavy lift/critical erection HSE-15 Rev.0
XVI Permit Energy Isolation & De-Isolation HSE-16 Rev 0
XVII Permit for Excavation HSE-17 Rev 0
XVIII Environmental Aspect Impact Register HSE-18 Rev 0
XIX HIRAC Register HSE-19 Rev 0
Page 532 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
1.0 SCOPE
This specification establishes the Health, Safety and Environment (HSE) management
requirement to be complied by Contractors/ Vendors including their sub-contractors/ sub-
vendors during construction.
This specification is not intended to replace the necessary professional judgment needed to
design & implement an effective HSE system for construction activities and the contractor is
expected to fulfill HSE requirements in this specification as a minimum. It is expected that
contractor shall implement best HSE practices beyond whatever are mentioned in this
specification.
Requirements stipulated in this specification shall supplement the requirements of HSE

Management given in relevant Act(s)/ legislations, General Conditions of Contract (GCC),
Special Conditions of Contract (SCC) and Job (Technical) Specifications. Where different
documents stipulate different requirements, the most stringent shall apply.
2.0 REFERENCES
The document should be read in conjunction with following:
- General Conditions of Contract (GCC)

- Special Conditions of Contract (SCC)
- Building and other construction workers Act,
- Indian Factories Act
- Job (Technical) specifications
- Relevant International/ National Codes (refer Appendix-A for standards/codes on HSE)
- Relevant State & National Statutory requirements.
- Operating Manuals Recommendation of Manufacturer of various construction Machineries
- Occupation Health and Safety Management System (OHSAS 18001:2007) and
Environmental Management System (ISO 14001:2004).
3.0 REQUIREMENTS OF HEALTH, SAFETY & ENVIRONMENTAL (HSE)

MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS
3.1 Management Responsibility
3.1.1 HSE Policy & Objectives
The Contractor should have a documented and duly approved HSE policy &objectives to
demonstrate commitment of their organization to ensure health, safety and environmental
aspects in their line of operations.
HSE Policy of the contractor shall be made available to Owner / EIL at the place of execution of
specific contract works, as a valid document.
3.1.2 Management System
The HSE management system of the Contractor shall cover the HSE requirements &
commitments to fulfill them, including but not limited to what have been specified under
clauses 1.0 and 2.0 above. The Contractor shall obtain the approval of its site specific HSE Plan
from EIL / Owner prior to commencement of any site works. Corporate as well as Site
management of the Contractor shall ensure compliance of their HSE Plan at work sites in its
entirety in true spirit.
Page 533 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
3.1.3 Indemnification
Contractor shall indemnify & hold harmless, Owner/EIL & their representatives, free from any
and all liabilities arising out of non-fulfillment of HSE requirements or its consequences.
3.1.4 Deployment & qualifications of Safety personnel
The Contractor shall designate/deploy various categories of HSE personnel at site as indicated
below in sufficient number. In no case, deployment of safety Supervisor / Safety Steward shall
substitute deployment of Safety Officer / Safety Engineer what is indicated in relevant statute of
BOCW Act i.e. deployment of safety officer/Safety Engineer is compulsory at project site. The
Safety supervisors, Safety stewards/Observer etc. Would facilitate the HSE tasks at grass root
level for construction sites and shall assist Safety Officer /Engineers.
Contractor shall appoint safety personnel as given below for every work shift (As per table
point):
Safety Observer/ Steward: Contractor shall depute one Safety Observer/Steward for
every 100 workers and additionally thereon.
Safety Supervisor: In addition to above, contractor shall depute one Safety
Supervisor for every 250 workers and additionally thereon.
Safety Engineer: In addition to above, one safety engineer/ officer for
every 1000 workers and additionally thereon.
Requirement of Safety Personnel for every shift

No. of Workers
deployed Safety Observer/
Safety Supervisor Safety Engineer/ Officer
Steward
1- 50
One
51-100
101-150 One
Two
151-200
201-250
Three
251-300 One
301-350
Four
351-400 Two
401-450
Five
451-500
Up to 1000 Ten Four
Up to 2000 Twenty Eight Two
In case any of the safety personnel leave the contractor the same shall be intimated to the
owner/ Consultant/ EIL. The contractor shall recruit new personnel and fill up the vacancy.
a) Safety Steward/Observer
As a minimum, he shall possess class XII pass certificate and trained in fire-fighting as
well as in safety/occupational health related subjects, with minimum two year of practical
experience in construction work environment and should have adequate knowledge of the
local language spoken by majority of the workers at the construction site.
Page 534 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
b) Safety Supervisor
As a minimum, he shall possess a recognized graduation Degree in Science (with Physics
& Chemistry) or a diploma in Engg. or Tech. with minimum Two years of practical
experience in construction work environment and should possess requisite skills to deal
with construction safety & fire related day-to-day issues.
c) Safety Officer / Safety Engineer
Safety officer/Engineer Should Possess following Qualification &Experience:
(i) Recognized degree in any branch of Engg. or Tech. or Architecture with practical
experience of working in a building or other construction work in supervisory
capacity for a period of not less than two years, or possessing recognized diploma in
any branch of Engg. or Tech with practical experience of working in a building or
other construction work in supervisory capacity for a period of not less than five
years.
(ii) Recognized degree or diploma in Industrial safety
(iii) Preferably have adequate knowledge of the language spoken by majority of the
workers at the construction site.
Alternately
(i) Person possessing Graduation Degree in Science with Physics & Chemistry and
degree or diploma in Industrial Safety (from any Indian institutes recognized by
AICTE or State Council of Tech. Education of any Indian State) with practical
experience of working in a building, plant or other construction works (as Safety
Officer, in line with Indian Factories Act, 1958) for a period of not less than five
years, may be considered as Safety Officer.
d) HSE In-Charge
In case there is more than one Safety Officer at any project construction site, one of them,
who is senior most by experience (in HSE discipline), may be designated as HSE In-
Charge. Duties & responsibilities of such person shall be commensurate with that of
relevant statute and primarily to coordinate with top management of Client and contractors.
In case the statutory requirements i.e. State or Central Acts and / or Rules as applicable like
the Building and Other Construction Workers’ Regulation of Employment and Conditions
of Service- Act,1996 or State Rules (wherever notified), the Factories Act, 1948 or Rules
(wherever notified), etc. are more stringent than above clarifications, the same shall be
followed.
Contractors shall ensure physical availability of safety personnel at the place of specific
work location, where Hot Work Permit is required/granted. No work shall be started at any
of the project sites until above safety personnel & concerned Site Engineer of Contractor
are physically deployed at site. The Contractor shall submit a HSE Organogram clearly
indicating the lines of responsibility and reporting system and elaborate the responsibilities
of safety personnel in their HSE Plan.
The Contractor shall verify & authenticate credentials of such safety personnel and furnish
Bio-Data/Resume/Curriculum Vitae of the safety personnel as above for EIL/Owner’s
approval, at least 1 month before the mobilization. The Contractor, whenever required,
shall arrange submission of original testimonials/certificates of their Safety personnel, to
EIL/Owner (for verification/scrutiny, etc.)
Page 535 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
Imposition / Realization of penalty shall not absolve the Contractor from his/ her
responsibility of deploying competent safety officer at site.
Adequate planning and deployment of safety personnel shall be ensured by the Contractor
so that field activities do not get affected because of non-deployment of competent &
qualified safety people in appropriate numbers.
3.1.5 Implementation, Inspection/ Monitoring
 The Contractor shall be fully responsible for planning, reporting, implementing and
monitoring all HSE requirements and compliance of all laws & statutory requirements.
 The Contractor shall also ensure that the HSE requirements are clearly understood &
implemented conscientiously by their site personnel at all levels at site.
 The Contractor shall ensure physical presence of their field engineers / supervisors, during
the continuation of their contract works / site activities including all material transportation
activities. Physical absence of experienced field engineers / supervisors of Contractor at
critical work spot during the course of work, may invite severe penalization as per the
discretion of EIC, including halting / stoppage of work.
 Contractor shall furnish their annual Inspection Plan, with regard to project issues /subjects,
frequency and performers to EIL/Owner.
 The Contractor shall regularly review inspection report internally and implement all
practical steps / actions for improving the status continuously.
 The Contractor shall ensure important safety checks right from beginning of works at every
work site locations and to this effect format No: HSE-10 “Daily Safety Check List” shall be
prepared by field engineer & duly checked by safety personnel for conformance.
 The Contractor shall carry out inspection to identify various unsafe conditions of work
sites/machinery/equipment’s as well as unsafe acts on the part of
workmen/supervisor/engineer while carrying out different project related works.
 Adequate records for all inspections shall be maintained by the Contractor and the same
shall be furnished to EIL/Owner, whenever sought.
 The Contractor shall not carry-out work by engaging single worker anywhere without any
supervisor anytime during day or night.
 To demonstrate involvement/commitment of site management of Contractor, at least one
Safety Walk through in a month shall be carried out by Contractor’s head of site (along
with his area manager/field engineers) and a report shall be furnished to EIL/Owner as per
format No: HSE-1” Safety walk through report” followed by compliance for unsatisfactory
remarks.
 As a general practice lifting tools/ tackles, machinery, accessories etc. shall be inspected,
tested and examined by competent people (approved by concerned State authorities) before
being used at site and also at periodical interval (e.g. during replacement, extension,
modification, elongation/ reduction of machine/parts, etc.) as per relevant statutes. Hydra,
cranes, lifting machinery, mobile equipment’s / machinery / vehicles, etc. shall be
inspected regularly by only competent / experienced personnel at site and requisite records
for such inspections shall be maintained by every contractor. Contractor shall also maintain
records of maintenance of all other site machinery (e.g. generators, rectifiers, compressors,
cutters, etc.) & portable tools/equipment’s being used at project related works (e.g. drills,
abrasive wheels, punches, chisels, spanners, etc.).The Contractor shall not make use of
arbitrarily fabricated ‘derricks’ at project site for lifting / lowering of construction
materials.
 Site facilities /temporary. installations, e.g. batching plant, cement godown, DG-room,
temporary electrical panels/distribution boards, shot-blasting booth, fabrication yards, etc.
and site welfare facilities, like labour colonies, canteen/pantry, rest-shelters, motor
cycle/bicycle-shed, site washing facilities, First-aid centers, urinals/toilets, etc. should be
periodically inspected by Contractor (preferably utilizing HR/Admn. personnel to inspect
site welfare facilities) and records to be maintained.
Page 536 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
3.1.6 Behaviour Based Safety
 The contractor shall develop a system to implement Behaviour-Based Safety (BBS)

through which work groups can identify, measure and change the behaviours of employees
and workers towards construction safety aspects.
 The BBS process shall include the following:
- Identify the behaviours critical to obtaining required safety performance.
- Communicate the behaviours and how they are performed correctly to all
- Observe the work force and record safe/at risk behaviours. Intervene with workers to
give positive reinforcement when safe behaviours are observed. Provide
coaching/correction when at risk behaviours are observed
- Collect and record observation data
- Summarize and analyze observation data
- Communicate observation data and analysis results to all employees
- Provide recognition or celebrate when safe behaviour improvements occur
- Change behaviours to be observed or change activators or change consequences as
appropriate.
- Communicate any changes to workforce
 Contractor through its own HSE committee shall implement the above process.
 The necessary procedures and Monthly reporting formats shall be developed by the
contractor for approval by EIL/ Owner.
 The HSE committee of contractor shall observe individual’s behavior for safe practices
adapted for utilization/ execution of work for following as a minimum:-
- PPE
- Tools & equipment
- Hazard Identification & control
- House keeping
- Confined space entry
- Hot works
- Excavation
- Loading & unloading
- Work At height
- Stacking & storage
- Ergonomics
- Procedures
3.1.7 Awareness and Motivation
 The Contractor shall promote and develop awareness on Health, Safety and Environmental
protection among all personnel working for the Contractor.
 Regular awareness programs and fabrication shop/work site meetings atleast on monthly
basis shall be arranged on HSE activities to cover hazards/risks involved in various
operations during construction.
 Contractor to motivate & encourage the workmen & supervisory staff by issuing/ awarding
them with tokens/ gifts/ mementos/ monetary incentives/ certificates etc.
 Contractor shall assess & recognize the behavioral change of its site engineers / supervisors
periodically and constantly motivate / encourage them to implement HSE practices at
project works.
3.1.8 Fire prevention & First-Aid
 The Contractor shall arrange suitable First-aid measures such as First Aid Box (Refer
Appendix-B for details), stand-by Emergency Vehicle. Additionally separate ambulance
with trained personnel/nurse (male) to administer First Aid shall be provided by the
Contractor beyond deployment of 400 workmen during day/night working hours.
Page 537 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
 The Contractor shall arrange installation of fire protection measures such as adequate
number of steel buckets with sand & water and adequate number of appropriate portable
fire extinguishers (Refer Appendix-C for details) to the satisfaction of EIL/Owner.
 The Contractor shall deploy trained supervisory personnel / field engineers to cater to any
emergency situation.
 The Contractor shall arrange EMERGENCY MOCK DRILL like fire, bomb threat, gas
leakage, earth quake, etc. at each site at least once in three months, involving site workmen
and site supervisory personnel & engineers. The Contractor shall maintain adequate record
of such fire drills at project site
3.1.9 Documentation
The Contractor shall evolve a comprehensive, planned and documented system covering the
following as a minimum for implementation and monitoring of the HSE requirements and the
same shall be submitted for approval by owner/EIL.
- HSE Organogram
- Site specific HSE Plan
- Safety Procedures, forms and Checklist. Indicative list of HSE procedures is attached as
Appendix :H
- Inspections and Test Plan
- Risk Assessment & HIRAC for critical works.
- HIRAC Register as per Format no: HSE-19 to identify, assess, analyze & mitigate the
construction hazards& incorporate relevant control measures before actually executing site
works.
- Environmental Aspect Impact Register as per Format no: HSE-18 (identify, assess, analyze
& mitigate the environmental impact & incorporate relevant control measures).
- Legal Register to identify and comply to all applicable HSE related legal requirements.
The monitoring for implementation shall be done by regular inspections and compliance of the
observations thereof. The Contractor shall get similar HSE requirements implemented at his
sub-contractor(s) work site/office. However, compliance of HSE requirements shall be the
responsibility of the Contractor. Any review/approval by EIL/Owner shall not absolve
contractor of his responsibility/liability in relation to fulfilling all HSE requirements.
3.1.10 Audit
The Contractor shall submit an Audit Plan to EIL/Owner indicating the type of audits and
covering following as minimum:
 Internal HSE audits regularly at least on quarterly basis by engaging internal qualified
auditors (viz safety officers/ Construction personnel having 5 years experience in
construction safety and Lead Auditor Course : OSHA 18001certification).
 External HSE audits regularly at least on every six months by engaging qualified external
auditors (viz safety officers/ Construction personnel having 10years experience in
construction safety and Lead Auditor Course: OHSAS 18001certification).
All HSE shortfalls/ non-conformances on HSE matters brought out during review/audit, shall be
resolved forthwith (generally within a week) by Contractor& compliance report shall be
submitted to EIL/ Owner.
In addition to above audits by contractor, the contractor’s work shall be subjected to HSE audit
by EIL/ Owner at any point of time during the pendency of contract. The Contractor shall take
all actions required to comply with the findings of the Audit Report and issue regular
Compliance Reports for the same to OWNER/ EIL till all the findings of the Audit Report are
fully complied.
Failure to carry-out HSE Audits& its compliance (internal & external) by Contractor, shall
invite penalization.
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3.1.11 Meetings
 The Contractor shall ensure participation of his top most executive at site (viz. Resident
Construction Manager / Resident Engineer/ Project Manager / Site-in-Charge) in Safety
Committee/HSE Committee meetings arranged by EIL/ Owner usually on monthly basis or
as and when called for. In case Contractor’s top most executive at site is not in a position
to attend such meeting, he shall inform EIL/ Owner in writing before the commencement of
such meeting indicating reasons of his absence and nominate his representative – failure to
do so may invite very stringent penalization against the specific Contractor, as deemed fit
in Contract. The obligation of compliance of any observations during the meeting shall be
always time bound. The Contractor shall always assist EIL/Owner to achieve the targets
set by them on HSE management during the project implementation.
 In addition, the Contractor shall also arrange internal HSE meetings chaired by his top most
executive at site on weekly basis and maintain records. Such internal HSE meetings shall
essentially be attended by field engineers / supervisors (& not by safety personnel only) of
the Contractor and its associates. Records of such internal HSE meetings shall be
maintained by the Contractor for review by EIL/ Owner or for any HSE Audits.
 Agenda of internal HSE meeting should broadly cover: -

a) Confirmation of record notes /minutes of previous meeting
b) Discussion on outstanding subjects of previous points / subjects, if any
c) Incidents / Accidents (of all types) at project site, if any
d) Current topics related to site activities / subjects of discussion
e) House keeping
f) Behavioral Safety
g) Information / views / deliberations of members / site, sub-contractors
h) Report from Owner / Client
i) Status of Safety awareness, Induction programs & Training programs
The time frame for such HSE meeting shall be religiously maintained by one and all.
3.1.12 Intoxicating drinks & drugs and Smoking

 The Contractor shall ensure that his staff members & workers (permanent as well casual)
shall not be in a state of intoxication during working hours and shall abide by any law
relating to consumption & possession of intoxicating drinks or drugs in force.
 The Contractor shall not allow any workman to commence any work at any locations of
project activity who is/are influenced / effected with the intake of alcohol, drugs or any
other intoxicating items being consumed prior to start of work or working day.
 Awareness about local laws on this issue shall form part of the Induction Training and
compulsory work-site discipline.
 The Contractor shall ensure that all personnel working for him comply with “No-Smoking”
requirements of the Owner as notified from time to time. Cigarettes, lighters, auto ignition
tools or appliances as well as intoxicating drugs, dry tobacco powder, etc. shall not be
allowed inside the project / plant complex.
 Smoking shall be permitted only inside smoking booths exclusively designated &
authorized by the Owner/EIL.
3.1.13 Penalty
The Contractor shall adhere consistently to all provisions of HSE requirements. In case of non-
compliances and also for repeated failure in implementation of any of the HSE provisions,
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EIL/Owner may impose stoppage of work without any cost & time implication to the Owner
and/or impose a suitable penalty.
The amount of penalty to be levied against defaulted Contractor shall be up to a cumulative
limit of
2.0% (Two percent) of the contract value for Item Rate or Composite contracts with an overall
ceiling of 1, 00, 00, 000 (Rupees One crore)
0.5% (Zero decimal five percent) of the contract value for LSTK, OBE, EPC, EPCC or Package
contracts with an overall ceiling of 10, 00.00.000 (Rupees ten crores)
This penalty shall be in addition to all other penalties specified elsewhere in the contract. The
decision of imposing stop-work-instruction and imposition of penalty shall rest with
EIL/Owner. The same shall be binding on the Contractor. Imposition of penalty does not make
the Contractor eligible to continue the work in unsafe manner.
The amount of penalty applicable for the Contractor on different types of HSE violations is
specified below:
Sl.
Violation of HSE norms Penalty Amount
No.
1. For not using personal protective equipment Rs.500/- per day/ Item / Person.
(Helmet, Shoes, Goggles, Gloves, Face shield,
Boiler suit, etc.)
2. Working without Work Permit/Clearance Rs.20,000/- per occasion
3 Execution of work without deployment of requisite Rs.5,000/- per violation per day
field engineer / supervisor at work spot
4. Unsafe electrical practices (not installing ELCB, Rs.10,000/- per item per day.
using poor joints of cables, using naked wire without
top plug into socket, laying wire/cables on the roads,
electrical jobs by incompetent person, etc.)
5. Working at height without full body harness, using Rs.10,000/- per case per day.
non-standard/ rejected scaffolding and not arranging
fall protection arrangement as required, like hand-
rails, life-lines, Safety Nets etc.
6. Unsafe handling of compressed gas cylinders (No Rs.500/- per item per day.
trolley, jubilee clips double gauge regulator, and not
keeping cylinders vertical during storage/handling,
not using safety cap of cylinder).
7. Use of domestic LPG for cutting purpose / not using Rs.3,000/- per occasion.
flash back arresters on both the hoses/tubes on both
ends.
8. No fencing/barricading of excavated areas / Rs.3,000/- per occasion.
trenches.
9. Not providing shoring/strutting/proper slope and not Rs.5,000/- per occasion.
keeping the excavated earth at least 1.5M away from
excavated area.
10. Non display of scaffold tags, caution boards, list of Rs.1,000/- per occasion per day
hospitals, emergency services available at work
locations.
11. Traffic rules violations like over speeding of Rs.2,000/- per occasion per day
vehicles, rash driving, talking on mobile phones
during vehicle driving, wrong parking, not using seat
belts, vehicles not fitted with reverse horn / warning
alarms / flicker lamps during foggy weather.
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Sl.
No.
12. Absence of Contractor’s RCM/ SIC or his Rs.10,000/- per meeting.
nominated representative (prior approval must be
taken for each meeting for nomination) from site
HSE meetings whenever called by EIL/Owner&
failure to nominate his immediate deputy (in the site-
organogram) for such HSE meetings.
13. Failure to maintain HSE records by Contractor Rs.10,000/- per month.
Safety personnel, in line with approved HSE
Plan/Procedures/Contract specifications.
14. Failure to conduct daily site safety inspection (by Rs.10,000/- per occasion.
Contractor’s safety engineers/safety officers),
internal HSE meeting, internal HSE Awareness/
Motivation Program, Site HSE Training and HSE
audit at predefined frequencies (as approved in HSE
Plan).
15. Failure to submit the monthly HSE report by 5th of Rs.10,000/- per occasion and Rs.
subsequent month to Project’s Engineer-in-Charge/ 1,000/- per day of further delay.
Owner
16. Poor House Keeping Rs.5,000/- per occasion per
subject
17. Failure to report &follow up accident (including Rs.20,000/- per occasion
Near Miss) reporting system within specific time-
frame.
18. Degradation of environment (not confining toxic Rs.10,000/- per occasion
spills, spilling oil/ lubricants onto ground)
19. Not medically examining the workers before Rs.5,000/- per occasion per
allowing them to work at height / to work in worker
confined space / to work in shot-blasting / to work
for painting / to work in bitumen or asphalt works,
not providing ear muffs while allowing them to work
in noise polluted areas, made them to work in air
polluted areas without respiratory protective devices,
etc.
20. Violation of any other safety condition as per job Rs.5,000/- per occasion
HSE plan / work permit and HSE conditions of
contract (e.g. using crowbar on cable trenches,
improper welding booth, not keeping fire
extinguisher ready at hot work site, unsafe rigging
practices, non-availability of First-Aid box at site,
not providing dead man handle switch for blasting,
whiplash arrestor for the compressor line, not using
hood with respiratory devices by blaster for
shot//grit blasting, etc.)
21. Penalty for non-deployment of ambulance in case of Rs.3,000/- per day
man-power more than 400 or not providing
dedicated emergency vehicle in case of man-power
less than 400.
22. Failure to carry-out Safety audit in time (internal & Rs.20,000/- per occasion
external), close-out of identified shortfalls of
Observations of Safety Aspects(OSA), etc.
23. Carrying out sand blasting instead of grit/shot Rs.50,000/- per day
blasting.
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Sl.
No.
24. Failure to deploy adequately qualified and Rs.10,000/- per day per Officer
competent Safety Officer
25. Utilization of hydra/back-hoe loader for material Rs.25,000/- per occasion
shifting or any other unauthorized /unsafe lifting
works
26. Any Fatal Accident Rs.10,00,000/- per fatality
26. Any violation not covered above To be decided by EIL/Owner.
 The Contractor shall make his field engineers/supervisors fully aware of the fact that they
keep track with the site workmen for their behavior and compliance of various HSE
requirements. Safety lapses / defects of project construction site shall be attributable to the
concerned job supervisor / engineer of the Contractor, (who remains directly responsible
for safely executing field works). For repeated HSE violations, concerned job supervisor /
engineer shall be reprimanded or appropriate action, as deemed fit, shall be initiated (with
an information to EIL & Owner) by the concerned Contractor.
Contractor shall initiate verbal warning shall be given to the worker/employee during his first
HSE violation. A written warning shall be issued on second violation and specific training shall
be arranged / provided by the Contractor to enhance HSE awareness/skill including feedback on
the mistakes/ flaws. Any further violation of HSE stipulations by the erring individuals shall call
for his forthright debar from the specific construction site. A record of warnings for each
worker/employee shall be maintained by the Contractor, like by punching their cards / Gate
passes or by displaying their names at the Project entry gate. Warnings, penalizations,
appreciations etc. shall be discussed in HSE Committee meetings by site Head of the
Contractor.
3.1.14 Accident/ Incident investigation
All accidents/incidents shall be informed to EIL/Owner at least telephonically by Contractor

immediately and in writing within 24 hours on Format No. HSE-2 as applicable, by Contractor.
Thereafter, a Supplementary Accident/Incident investigation Report on Format No. HSE-3 shall
be submitted to EIL/Owner within 72 hours. Near Miss incident(s), Dangerous
accidents/incident shall also be reported on Format No. HSE-4 within24 hours. The accident/
incident shall be investigated by a team of Contractor’s senior Site personnel (involving Site-in-
Charge or at least by his deputy) for establishing root-cause and recommending corrective &
preventive actions. Findings shall be documented and suitable actions taken to avoid
recurrences shall be communicated to EIL/Owner. Owner/EIL shall have the liberty to
independently investigate such occurrences and the Contractor shall extend all necessary help
and cooperation in this regard. EIL/Owner shall have the right to share the content of this report
with the outside world.
3.2 House Keeping
The Contractor shall ensure that a high degree of housekeeping is maintained and shall ensure
inter-alia; the followings:
a) All surplus earth and debris are removed/ disposed-off from the working areas to
designated location(s).
b) Unused/ surplus cables, steel items and steel scrap lying scattered at different places within
the working areas are removed to identify location(s).
c) All wooden scrap, empty wooden cable drums and other combustible packing materials,
shall be removed from work place to identified location(s).
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d) Roads shall be kept clear and materials like pipes, steel, sand, boulders, concrete, chips and
bricks etc. shall not be allowed on the roads to obstruct free movement of men &
machineries.
e) Fabricated steel structural, pipes & piping materials shall be stacked properly for erection.
f) Water logging on roads shall not be allowed.
g) No parking of trucks/trolleys, cranes and trailers etc. shall be allowed on roads, which may
obstruct the traffic movement.
h) Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the working
areas.
i) Trucks carrying sand, earth and pulverized materials etc. shall be covered while moving
within the plant area/ or these materials shall be transported with top surface wet.
j) The contractor shall ensure that the atmosphere in plant area and on roads is free from
particulate matter like dust, sand, etc. by keeping the top surface wet for ease in breathing.
k) At least two exits for any unit area shall be assured at all times – same arrangement is
preferable for digging pits / trench excavation / elevated work platforms/ confined spaces
etc.
l) Welding cables and the power cable must be segregated and properly stored and used. The
same shall be laid away from the area of movement and shall be free from obstruction.
m) Schedule for upkeep/ cleaning of site to be firmed up and implemented on regular basis.
The Contractor shall carry-out regular checks (minimum one per fortnight) as per format No:
HSE-11 for maintaining high standard of housekeeping and maintain records for the same. The
Contractor shall provide supervisor for housekeeping exclusively for management of day-to-day
housekeeping activities.
3.3 HSE Measures
3.3.1 Construction Hazards
The Contractor shall ensure identification of all Occupational Health, Safety & Environmental
hazards in the type of work he is going to undertake and enlist mitigation measures. Contractor
shall carry out HIRAC specifically for high risk jobs/critical jobs like
a) Working at height (+2.0 Mts height) for cold (incl. colour washing, painting, insulation
etc.) & hot works.
b) Work in confined space,
c) Deep excavations &trench cutting (depth > 2.0 mts.)
d) Operation & Maintenance of Batching Plant.
e) Shuttering / concreting (in single or multiple pour) for columns, parapets & roofs.
f) Erection & maintenance of Tower Crane.
g) Erection of structural steel members / roof-trusses / pipes at height more than 2.0 Mts. with
or without crane.
h) Erection of pipes (full length or fabricated) at height more than 2.0 Mts. height with Crane
of 100T capacity.
i) All lifts using 100T Crane plus mechanical pulling.
j) All lifts using two cranes in unison (Tandem Lifting).
k) Any lift exceeding 80% capacity of the lifting equipments (hydra, crane etc.).
l) Laying of pipes (isolated or fabricated) in deep narrow trenches – manually or
mechanically.
m) Maintenance of crane / extension or reduction of crane-boom on roads or in yards.
n) Erection of any item at >2.0 Mts. height using 100T crane or of higher capacity
o) Hydrostatic test of pipes, vessels & columns and water-flushing.
p) Radiography jobs (in-plant & open field)
q) Work in Live Electrical installations / circuits
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r) Handling of explosives & Blasting operations

s) Demolishing/ dismantling activities
t) Welding/ gas cutting jobs at height (+2.0 Mts.)
u) Lifting/placing roof-girders at height (+2.0 Mts.)
v) Lifting & laying of metallic / non-metallic sheet over roof/structures.
w) Lifting of pipes, gratings, equipments/ vessels at heights (+2.0 Mts) with & without using
cranes
x) Calibration of equipment, instruments and functional tests at yards / work-sites.
y) Operability test of Pump, Motors (after coupling) & Compressors.
z) Cold or Hot works inside Confined Space.
aa) Transportation & shifting of ODC consignments into project areas.
bb) Working in “charged/Live” elect. Panels
cc) Stress Relieving works (Electrically or by Gas-burners).
dd) Pneumatic Tests
ee) Card board blasting
ff) Chemical cleaning
And take feedback from EIL/Owner. The necessary HSE measures devised shall be put in to
place, prior to start of an activity &also shall be maintained during the course of works, by the
Contractor. Copies of such HIRAC shall be kept available at work sites by the Contractor to
enable all concerned carrying out checks / verification.
A list of typical construction hazards along with their effects & preventive measures is given in
Appendix-E.
3.3.2 Accessibility
 The Contractor shall provide safe means of access(in sufficient numbers)& efficient exit to
any working place including provisions of suitable and sufficient scaffolding at various
stages during all operations of the work for the safety of his workmen and EIL/Owner.
 The Contractor shall implement use of all measures including use of “life line”, “fall-
arresters”, “retractable fall arresters”, “safety nets” etc. during the course of using all safe
accesses& exits, so that in no case any individual remains at risk of slip & fall during their
travel.
 The access to operating plant / project complex shall be strictly regulated. Any person or
vehicle entering such complex shall undergo identification check, as per the procedures in
force / requirement of EIL/Owner.
 Accessibility to ‘confined space’ shall be governed by specific system / regulation, as
established at project site.
3.3.3 Personal Protective Equipment (PPEs)
 The Contractor workmen shall be permitted entry inside the project premises only with
proper PPEs.
 The Contractor shall ensure that all their staff, workers and visitors including their sub-
contractor(s) have been issued (records to be kept) & wear appropriate PPEs like nape strap
type safety helmets preferably with head &sweat band with ¾” cotton chin strap (made of
industrial HDPE), safety shoes with steel toe cap and antiskid sole, full body harness (CЄ
marked and conforming to EN361), protective goggles, gloves, ear muffs, respiratory
protective devices, etc. All these gadgets shall conform to applicable IS Specifications/ CE
or other applicable international standards. The Contractor shall implement a regular
regime of inspecting physical conditions of the PPEs being issued / used by the workmen
of their own & also its sub-agencies and the damaged / unserviceable PPEs shall be
replaced forthwith.
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 Owner/EIL may issue a comprehensive color scheme for helmets to be used by various
agencies. The Contractor shall follow the scheme issued by the owner/EIL and shall choose
any colour other than white (for Owner) or blue (for EIL) All HSE personnel shall
preferably wear dark green band on their helmet so that workmen can approach them for
guidance during emergencies. HSE personnel shall preferably wear such dresses with
fluorescent stripes, which are noticeable during night, when light falls on them.
 Florescent jackets with respective company logo to be worn by the contractor workmen
with different color coding for categories like supervisor and workmen
 For shot blasting, the usage of protective face shield and helmets, gauntlet and protective
clothing is mandatory. Such protective clothing should conform relevant IS Specification.
 For off-shore jobs/contracts, contractor shall provide PPEs (new) of all types to EIL &
Owner's personnel, at his (contractor's) cost. All personnel shall wear life jacket at all time.
 An indicative list of HSE standards/codes is given under Appendix-A.
 Contractor shall ensure procurement & usage of following safety equipment’s/ accessories
(conforming to applicable IS mark / CE standard) by their staff, workmen & visitors
including their subcontractors all through the span of project construction / pre-
commissioning/ Commissioning:-‘
a. PPEs (Helmet with company name/logo, Spectacle, Ear-muff, Face shield, Hand
gloves, Safety Shoes, Gum boot)
b. Barricading tape / warning signs
c. Rechargeable Safety torch (flame-proof)
d. Safety nets (with tie-chords)
e. Fall arresters
f. Portable ladders (varying lengths)
g. Life-lines (steel wire-rope, dia not less than 8.0 mm)
h. Full body harness (double lanyard)
i. Lanyard
j. Karabiner
k. Retractable fall arresters (various length)
l. Portable fire extinguishers (DCP type) – 5 kg capacity
m. Portable Multi Gas detector
n. Sound level meter
o. Digital Lux meter
p. Fire hoses & flow nozzles
q. Fire blankets / Fire retardant cloth (with eyelets)
3.3.4 Working at height
 The Contractor shall issue permit for working (PFW) at height after verifying and
certifying the checkpoints as specified in the attached permit (Format No. HSE-6). He
shall also undertake to ensure compliance to the conditions of the permit during the
currency of the permit including adherence of personal protective equipment’s.
Contractor’s Safety Officer shall verify compliance status of the items of permit document
after implementation of action is completed by Contractor’s execution / field engineers at
work site. HIRAC for specific works at height duly commented by EIL/Owner, shall be
kept attached with particular Permit for Work (PFW) at site for ready reference & follow-
up.
 Such PFW shall be initially issued for one single shift or expected duration of normal work
and extended further for balance duration, if required. EIL/Owner can devise block-permit
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system at any specific area, in consultation with project specific HSE Committee to specify
the time-period of validity of such PFW or its renewal. This permit shall be applicable in
areas where specific clearance from Owner’s Operation Deptt./ Safety Deptt. is not
required. EIL / Owner’s field Engineers/ Safety Officers/ Area Coordinators may verify
and counter sign this permit (as an evidence of verification) during the execution of the job.
 All personnel shall be medically examined & certified by registered doctor, confirming
their ‘medical fitness for working at height. The fitness examination shall be done once in
six months.
 In case work is undertaken without taking sufficient precautions as given in the permit,
EIL/ Owner Engineers may exercise their authority to cancel such permit and stop the work
till satisfactory compliance/rectification is arranged made. Contractors are expected to
maintain a register for issuance of permit and extensions thereof including preserving the
used permits for verification during audits etc.
 The Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems by his
workers. Fall arresters are to be used while climbing/descending tall structures or vessels /
columns etc. These arresters should lock automatically against the anchorage line,
restricting free fall of the user. The device is to be provided with a double security opening
system to ensure safe attachment or release of the user at any point of rope. In order to
avoid shock, the system should be capable of keeping the person in vertical position in case
of a fall.
 The Contractor shall ensure that Full body harnesses conforming EN361 and having
authorized CЄ marking is used by all personnel while working at height. The lanyards and
life lines should have enough tensile strength to take the load of the worker in case of a fall.
One end of the lanyard shall be firmly tied with the harnesses and the other end with life
line. The harness should be capable of keeping the workman vertical in case of a fall,
enabling him to rescue himself.
 The Contractor shall provide Roof Top Walk Ladders for carrying out activities on sloping
roofs in order to reduce the chances of slippages and falls.
 The Contractor shall ensure that a proper Safety Net System is used wherever the hazard of
fall from height is present. The safety net, preferably a knotted one with mesh ropes
conforming to IS 5175/ ISO 1140 shall have a border rope & tie cord of minimum 12mm
dia. The Safety Net shall be located not more than 6.0 meters below the working surface
extending on either side upto sufficient margin to arrest fall of persons working at different
heights.
 In case of accidental fall of person on such Safety Net, the bottom most portion of Safety
Net should not touch any structure, object or ground.
 Grade separators shall be provided in Pipe-rack/Tech-structures to arrest falling objects like
welding spatters, welding rods, nuts, bolts, tools etc. and to facilitate U/G and A/G works
simultaneously.
 Beam Clamps may be used for construction of localized temporary working platforms,
sheds for welding booths etc. at height in all types of steel structure due to faster
installation and requirement of less scaffolding materials.
 Hanging Platform, manufactured by Standard HSE equipment vendors must be
encouraged for painting of Buildings etc.
 All the tools used at height (like spanner, screw driver etc.) shall be provided with securing
arrangement like back-pack/waist pouch to prevent accidental slippage from worker hand.
 The Contractor shall install temporary lightening arrester in tall structures during
construction to save human life and to avoid damage to equipments & machineries
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 The Contractor shall ensure positive isolation while working at different levels like in the
pipe rack areas. The working platforms with toe boards & hand rails shall be sufficiently
strong & shall have sufficient space to hold the workmen and tools & tackles including the
equipment’s required for executing the job. Such working platforms shall have mid-rails, to
enable people work safely in sitting posture.
3.3.5 Scaffoldings& Barricading

 Suitable steel scaffoldings only shall be provided to workmen for all works that cannot be
safely done from the ground or from solid construction except such short period work that
can be safely done using ladders or certified (by 3rd party competent person) man-basket.
When a ladder is used, an extra workman shall always be engaged for holding the ladder.
 The Contractor shall ensure that the scaffolds used during construction activities shall be
strong enough to take the designed load. Main Contractor shall always furnish duly
approved construction-design details of scaffold & SWL (from competent designers) free
of charge, before they are being installed / constructed at site. Owner/EIL reserves the right
to ask the Contractor to submit certification and or design calculations from his Head
office/ Design/ Engineering expert regarding load carrying capacity of the scaffoldings.
 All scaffolds shall be inspected by a competent Scaffolding Inspector of the Contractor. He
shall paste a GREEN tag (duly signed by competent Scaffolding Inspector) on each
scaffold found safe and a RED tag (duly signed by competent Scaffolding Inspector) on
each scaffold found unsafe. Scaffolds with GREEN tag only shall be permitted to be used
and Scaffolds with RED ones shall immediately be made inaccessible. Work being found
continuing on scaffolds with RED tag shall be considered unauthorized work by Contractor
and may invite penalization from EIL/Owner. For every 120-125 m2 /m3 area / volume or
its parts there of minimum one TAG shall be provided.
 The Contractor shall ensure positive barricading (indicative as well as protective) of the
excavated, radiography, heavy lift, high pressure hydrostatic & pneumatic testing and other
such areas. Sufficient warning signs shall be displayed along the barricading areas.
 Scaffolding shall be constructed using foot seals or base plates only.
3.3.6 Electrical installations
 All electrical installations/ connections shall be carried out as per the provisions of latest
revision of following codes/standards, in addition to the requirements of Statutory
Authorities and IE/applicable international rules& regulations:
- OISD STD 173 : Fire prevention & protection system for electrical installations
- SP 30 (BIS) : National Electric Code
 All electrical installations shall be approved by the concerned statutory authorities.
 All temporary electrical installations/ facilities shall be regularly checked by the licensed/
competent electricians of the Contractor and appropriate records shall be maintained in
format no: HSE-12” Inspection of temporary electrical booth/ installation at project
construction site”. Such inspection records are to be made available to EIL/Owner,
whenever asked for.
3.3.6.1 The Contractor shall meet the following requirements:

a. Shall make Single Line Diagram (SLD) for providing connection to each equipment’s &
machinery and the same (duly approved by EIL/Owner) shall be pasted on the front face of
DBs (distribution boards) or JBs (Junction boxes) at every site. (A typical Switch Board
Sketch is attached as Appendix -G).
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b. Ensure that electrical systems and equipment including tools & tackles used during
construction phase are properly selected, installed, used and maintained as per provisions
of the latest revision of the Indian Electrical/ applicable international regulations.
c. Shall deploy qualified & licensed electricians for proper & safe installation and for regular
inspection of construction power distribution system/points including their earthing. A
copy of the license shall be submitted to EIL / Owner for records. Availability of at least
one competent (ITI qualified) / licensed electrician (by State Elec. authorities) shall be
ensured at site round the clock to attend to the normal/emergency jobs.
d. All switchboards / welding machines shall be kept in well-ventilated & covered shed/ with
rain shed protection. The shed shall be elevated from the existing ground level to avoid
water logging inside the shed. Installation of electrical switch board must be done taking
care of the prevention of shock and safety of machine.
e. No flammable materials shall be used for constructing the shed. Also flammable materials
shall not be stored in and around electrical equipment / switchboard. Adequate clearances
and operational space shall be provided around the equipment.
f. Fire extinguishers and insulating mats shall be provided in all power distribution centers.
g. Temporary electrical equipment shall not be employed in hazardous area without obtaining
safety permit.
h. Proper housekeeping shall be done around the electrical installations.
i. All temporary installations shall be tested before energizing, to ensure proper earthing,
bonding, suitability of protection system, adequacy of feeders/cables etc.
j. All welders shall use hand gloves irrespective of holder voltage.
k. Multilingual (Hindi, English and local language) caution boards, shock treatment charts and
instruction plate containing location of isolation point for incoming supply, name &
telephone No. of contact person in emergency shall be provided in substations and near all
distribution boards / local panels.
l. Operation of earth leakage device shall be checked regularly by temporarily connecting

series test lamp (2 bulbs of equal rating connected in series) between phase and earth.
ELCB tester /test meter shall be used for testing ELCBs
m. Regular inspection of all installations at least once in a month. (Ref. Format HSE-12).
3.3.6.2 The following features shall also be ensured for all electrical installations during construction
phase by the contractor:
 Each installation shall have a main switch with a protective device, installed in an
enclosure adjacent to the metering point. The operating height of the main switch shall not
exceed 1.5 M. The main switch shall be connected to the point of supply by means of
armoured cable.
 The outgoing feeders shall be double or triple pole switches with fuses / MCBs. Loads in a
three phase circuit shall be balanced as far as possible and load on neutral should not
exceed 20% of load in the phase.
 The installation shall be adequately protected against overload, short circuit and earth
leakage by the use of suitable protective devices. Fuses wherever used shall be HRC type.
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Use of rewirable fuses shall be strictly prohibited. The earth leakage device shall have an
operating current not exceeding 30 mA.
 All connections to the hand tools / welding receptacles shall be taken through proper
switches, sockets and plugs.
 All single phase sockets shall be minimum 3 pin type only. All unused sockets shall be
provided with socket caps.
 Only 3 core (P+N+E) overall sheathed flexible cables with minimum conductor size of 1.5
mm2 copper shall be used for all single phase hand tools.
 Only metallic distribution boxes with double earthing shall be used at site. No wooden
boxes shall be used.
 All power cables shall be terminated with compression type cable glands. Tinned copper
lugs shall be used for multi-strand wires / cables.
 Cables shall be free from any insulation damage.
 Minimum depth of cable trench shall be 750 mm for MV & control cables and 900 mm for
HV cables. These cables shall be laid over a sand layer and covered with sand, brick & soil
for ensuring mechanical protection. Cables shall not be laid in waterlogged area as far as
practicable. Cable route markers shall be provided at every 25 M of buried trench route.
When laid above ground, cables shall be properly cleated or supported on rigid poles of
atleast 2.1 M high. Minimum head clearance of 6 meters shall be provided at road
crossings.
 Underground road crossings for cables shall be avoided to the extent feasible. In any case
no underground power cable shall be allowed to cross the roads without pipe sleeve.
 All cable joints shall be done with proper jointing kit. No taped/temporary joints shall be
used.
 An independent earthing facility should preferably be established within the temporary

installation premises. All appliances and equipment shall be adequately earthed. In case of
armoured cables, the armour shall be bonded to the earthing system.
 All cables and wire rope used for earth connections shall be terminated through tinned
copper lugs.
 In case of local earthing, earth electrodes shall be buried near the supply point and earth
continuity wire shall be connected to local earth plate for further distribution to various
appliances. All insulated wires for earth connection shall have insulation of green colour.
 Separate core shall be provided for neutral. Earth / Structures shall not be used as a neutral
in any case.
 ON/OFF position of all switches shall be clearly designated / painted for easy isolation in
emergency.
3.3.7 Welding/ Grinding/ Gas cutting
 Contractor shall ensure that flash back arrestors conforming to BS:6158 or equivalent are
installed on all gas cylinders as well as at the torch end of the gas hose, while in use.
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 All cylinders shall be mounted on trolleys and provided with a closing key. Empty & filled-
up gas cylinders shall be stored separately with TAG, protecting them from direct sun or
rain. Minimum 2 nos. of Portable DCP type fire extinguishers (10 kg) shall be maintained
at the gas cylinder stores. Stacking & storing of compressed gas cylinders shall be arranged
away from DG set, hot works, Elect. Panels / Elec. boards, etc.
 The burner and the hose placed downstream of pressure reducer shall be equipped with
Flash Back Arrester/ Non Return Valve device.
 The hoses for acetylene and oxygen cylinders must be of different colours. Their
connections to cylinders and burners shall be made with a safety collar.
 At end of work, the cylinders in use shall be closed and hoses depressurized.
 Cutting of metals using gases, other than oxygen &acetylene, shall require written
concurrence from Owner.
 Grinding activity shall not be carried out in confined spaces without a valid work permit.
 All grinding/cutting machines shall be guarded and fitted with Dead-Man switch and this
shall not be bypassed any time.
 All welding/grinding machines shall have effective earthing at least at distinctly isolated
two points.
 In order to help maintain good housekeeping, and to reduce fire hazard, live electrode bits
shall be contained safely and shall not be thrown directly on the ground.
 The hoses of Acetylene and Oxygen shall be kept free from entanglement & away from
common pathways / walkways and preferably be hanged overhead in such a manner which
can avoid contact with cranes, hydra or other mobile construction machinery.
 Hot spatters shall be contained / restricted appropriately (by making use of effective fire-
retardant cloth/fabric) and their flying-off as well as chance of contact with near-by
flammable materials shall be stopped.
 The Contractor shall arrange adequate systems & practices for accumulation / collection of
metal & other scraps and remnant electrodes and their safe disposal at regular interval so as
to maintain the fabrication and other areas satisfactorily clean & tidy.
 All gas cylinders must have a cylinder cap on at all times when not in use.
3.3.8 Ergonomics and tools & tackles
 The Contractor shall assign to his workmen, tasks commensurate with their qualification,
experience and state of health.
 All lifting tools, tackles, equipment, trailers, trucks/dumpers, accessories including cranes
shall be tested periodically by statutory/competent authority for their condition and load
carrying capacity. Valid test & fitness certificates from the applicable authority shall be
submitted to Owner/EIL for their review/acceptance before the lifting tools, tackles,
equipment, trailers, trucks/dumpers, accessories and cranes are used.
 Load testing of Cranes must be made mandatory after each modification/alteration of crane
configuration/change in boom length.
 The contractor shall not be allowed to use defective equipment or tools not adhering to
safety norms.
 Contractor shall arrange non-sparking tools for project construction works in operating
plant areas / hydrocarbon prone areas.
 Wherever required the Contractor shall make use of Elevated Work Platforms (EWP) or
Aerial Work Platforms (mobile or stationary) to avoid ergonomical risks and workmen
shall be debarred to board such elevated platform during the course of their shifting/
transportation.
 Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes (while in use)
to minimize overloading risk. SLI shall have capability to continuously monitor and display
the load on the hook, and automatically compare it with the rated crane capacity at the
operating condition of the crane. The system shall also provide visual and audible warnings
at set capacity levels to alert the operator in case of violations.
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 The contractor shall be responsible for safe operations of different equipment’s mobilized
and used by him at the workplace like transport vehicles, engines, cranes, mobile ladders,
scaffoldings, work tools, etc.
 The Contractor shall arrange periodical training for the operators of hydra, crane,
excavator, mobile machinery, etc. at site by utilizing services from renowned
manufacturers
3.3.9 Occupational Health
 The contractor shall identify all operations that can adversely affect the health of its
workers and issue & implement mitigation measures.
 For surface cleaning operations, sand blasting shall not be permitted even if not explicitly
stated elsewhere in the contract.
 To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc Welding
shall not contain Thorium.
 Appropriate respiratory protective devices (hood with respiratory devices) shall be used to
protect workmen from inhalation of air borne contaminants like silica, asbestos, gases,
fumes, etc.
 Workmen shall be made aware of correct methods for lifting, carrying, pushing & pulling
of heavy loads. Wherever possible, manual handling shall be replaced by mechanical lifting
equipment’s.
 For jobs like drilling/demolishing/dismantling where noise pollution exceeds the specified
limit of 85decibels, ear muffs shall be provided to the workers.
 To avoid work related upper limb disorders (WRULD) and backaches, Display Screen
Equipment’s' workplace stations shall be carefully designed & used with proper sitting
postures. Power driven hand-held tools shall be maintained in good working condition to
minimize their vibrating effects and personnel using these tools shall be taught how to
operate them safely & how to maintain good blood circulation in hands.
 The Contractor shall arrange health check-up (by registered medical practitioner) for all the
workers at the time of induction. Health check may have to be repeated if the nature of duty
assigned to him is changed necessitating health check or doubt arises about his wellness.
EIL/Owner reserves the right to ask the contractor to submit medical test reports. Regular
health check-ups are mandatory for the workers assigned with Welding, Radiography,
Blasting, Painting, Heavy Lift and Height (>2m) jobs. All the health check-ups shall be
conducted by registered Medical practitioner and records are to be maintained by the
Contractor.
 The Contractor shall arrange Medical Camps at regular intervals at work sites and labor
colonies to assess health condition of workers.
 The Contractor shall ensure vaccination of all the workers including their families, during
the course of entire project span.
3.3.10 Hazardous substances

 Hazardous, inflammable and/or toxic materials such as solvent coating, thinners, anti-
termite solutions, water proofing materials shall be stored in appropriate containers
preferably with lids having spillage catchment trays and shall be stored in a good ventilated
area. These containers shall be labeled with the name of the materials highlighting the
hazards associated with its use and necessary precautions to be taken. Respective MSDS
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(Material Safety Data Sheet) shall be made available at site & may be referred whenever
problem arises.
 Where contact or exposure of hazardous materials are likely to exceed the specified limit or
otherwise have harmful effects, appropriate personal protective equipment’s such as
gloves, goggles/face-shields, aprons, chemical resistant clothing, respirator, etc. shall be
used.
 The work place shall be checked prior to start of activities to identify the location, type and
condition of any asbestos materials which could be disturbed during the work. In case
asbestos material is detected, usage of appropriate PPEs by all personnel shall be ensured
and the matter shall be reported immediately to EIL/ Owner.
3.3.11 Slips, trips & falls
The contractor shall establish a regular cleaning and basic housekeeping programme that covers
all aspects of the workplace to help minimize the risk of slips, trips & falls. The contractor shall
take positive measures like keeping the work area tidy, storing waste in suitable containers &
harmful items separately, keeping passages, stairways, entrances & exits especially emergency
ones clear, cleaning up spillages immediately and replacing damaged carpet/ floor tiles, mats &
rugs at once to avoid slips, trips & falls.
 Grating removal permit system should be implemented during construction phase. So that after
permanent gratings are installed on platforms and tech structure floors; removal of any gratings
for whatever purpose (including for lifting piping material etc.) is required to be sanctioned by
signed permit by HSE officers of both contractor and Engineer-in-charge. The spot where
gratings are removed shall be hard-barricaded during course of work. The removed gratings
shall be re-installed immediately after completion of work or at the time of cessation of work
every day whichever is earlier and the permit shall be closed on daily basis. A register shall be
maintained for recording all the grating removal permits and their closure shall be monitored on
daily basis.
3.3.12 Radiation exposure
 All personnel exposed to physical agents such as ionizing & non-ionizing radiation,
including ultraviolet rays or similar other physical agents shall be provided with adequate
shielding or protection commensurate with the type of exposure involved.
 For Open Field Radiography works, requirements of Bhabha Atomic Research Centre
(BARC)/ Atomic Energy Regulatory Board (AERB) shall be followed.
 The Contractor shall implement an effective system of control (as described in the AERB
regulations) at site for handling radiography-sources & for avoiding its misuse & theft.
 The contractor shall generate the Format No: HSE-8 “Permit for radiation work” before
start of work.
 In case the radiography work has to be carried out at day time, suitable methodology to be
used so that other works, people are not affected.
3.3.13 Explosives/Blasting operations
 Blasting operations shall be carried out as per latest Explosive Rules (Indian/ International)
with prior permission. The Contractor shall obtain license from Chief Controller of
Explosives (CCoE) for collection, transportation, storage of explosives as well as for
carrying out blasting operations.
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 The Contractor shall prepare exclusive method statement (in cognizance with statutory
requirements) for diffusing unfired explosives, if any, at project site before carrying out
actual task. Nowhere blasting shall be carried out by the Contractor or its agency without
the involvement of competent supervisor and licensed blaster / shot blaster.
3.3.14 Demolition/ Dismantling
 The contractor shall adhere to safe demolishing/ dismantling practices at all stages of work
to guard against unsafe working practices.
 The contractor shall disconnect service lines (power, gas supply, water, etc.)/ make
alternate arrangements prior to start of work and restore them, if required as directed by
EIL/ Owner at no extra cost.
 Before carrying out any demolition/dismantling work, the contractor shall take prior
approval of EIL/Owner and generate the Format No.HSE-9. For revamp jobs in operating
plants where location of underground utilities is not known with certainty, the contractor
shall depute an experienced engineer for supervision and shall make adequate arrangements
for fire-fighting & First-Aid during the execution of these activities.
 The Contractor shall arrange approved HIRAC / Method Statement for the specific
demolition / dismantling task and corresponding action plan commensurate with hazards /
risks associated therein. In no case any activity related to demolition / dismantling shall be
carried out by the Contractor without engaging own supervision / field engineer.
3.3.15 Road Safety
 The Contractor shall ensure adequately planned road transport safety management system.
 The vehicles shall be fitted with reverse warning alarms & flashing lights / fog-lights and
usage of seat belts shall be ensured.
 The Contractor shall also ensure a separate pedestrian route for safety of the workers and
comply with all traffic rules & regulations, including maintaining speed limit of 20 KMPH
or indicated by owner for all types of vehicles / mobile machinery. The maximum
allowable speed shall be adhered to.
 In case of an alert or emergency, the Contractor must arrange clearance of all the routes,
roads, access. The Contractor shall deploy sufficient number of traffic controllers at project
site routes / roads/ accesses, to alert reversing movement of vehicles & machinery as well
as pedestrians.
 Dumpers, Tippers, etc. shall not be allowed to carry workers within the plant area and also
to & from the labour colony to & from project sites.
 Hydras shall only be allowed for handling the materials at fabrication/ storage yards and in
no case shall be allowed to transport the materials over project / plant roads.
 The Contractor shall not deploy any such mobile machinery / equipment, which do not
have competent operator and / or experienced banks-man/ signal-man. Such machinery/
equipment shall have effective limit-switches, reverse-alarm, front & rear-end lights etc.
and shall be maintained in good working order.
 The Contractor shall not carry-out maintenance of vehicles / mobile machinery occupying
space on project / plant roads and shall always arrange close supervision for such works.
 For pipeline jobs, the contractor shall submit a comprehensive plan covering transportation,
loading / unloading of pipes, movement of side booms, movement of vehicles on the ROW,
etc.
 Contractor shall arrange/ install visible road signs, diversion boards, caution boards, etc. on
project roads for safe movement of men and machinery.
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3.3.16 Welfare measures

Contractor shall, at the minimum, ensure the following facilities at work sites:
 A crèche at site where 10 or more female workers are having children below the age of 6
years.
 Adequately ventilated / illuminated rooms at labour camps & its hygienic up-keeping.
 Reasonable canteen facilities at site and in labour camps at appropriate location depending
upon site conditions. Contractor shall make use of “industrial” variety of LPG cylinder &
satisfactory illumination at the canteens. Necessary arrangement for efficient disposal of
wastes from canteens & urinals /toilets shall also be made and regular review shall be made
to maintain the ambience satisfactorily hygienic &shall also comply with all applicable
statutory requirements.
 Adequately lighted & ventilated Rest rooms at site (separate for male workers and female
workers).
 Provision for suitable mobile toilets to be made available by Contractor for remote/scattered
job locations.
 Urinals, Toilets, drinking water, washing facilities, adequate lighting at site and labour
camps, commensurate with applicable Laws/ Legislation.
3.3.17 Environment Protection
Contractor shall ensure proper storage and utilization methodology of materials that are
detrimental to the environment. Where required, Contractor shall ensure that only the
environment friendly materials are selected and emphasize on recycling of waste materials, such
as metals, plastics, glass, paper, oil & solvents. The waste that cannot be minimized, reused or
recovered shall be stored and disposed of safely. In no way, toxic spills shall be allowed to
percolate into the ground. The contractor shall not use the empty areas for dumping the wastes.
Contractor to submit Environmental Aspect Impact Register detailing the list of activities in his
scope, the respective environmental impact and the actions taken to minimize the impact.
Environmental Aspect Impact Register to be prepared as per Format HSE-18 and to be updated
and maintained till job completion.
The contractor shall strive to conserve energy and water wherever feasible.
The contractor shall ensure dust free environment at workplace by sprinkling water on the
ground at frequent intervals. The air quality parameters for dust, poisonous gases, toxic releases,
harmful radiations, etc. shall be checked by the contractor on daily basis and whenever need
arises.
The contractor shall not be allowed to discharge chemicals, oil, silt, sewage, sullage and other
waste materials directly into the controlled waters like surface drains, streams, rivers, ponds. A
discharge plan suggesting the methods of treating the waste before discharging shall be
submitted to EIL/Owner for approval.
For pipeline jobs, top soil shall be stacked separately while making ROW through fields. This
fertile soil shall be placed back on top after backfilling.
For offshore construction barges, arrangements shall be made for safe disposal of human, food
& other wastes and applicable laws in this regard shall be followed.
3.3.18 Rules & Regulations
All persons deployed at site shall be knowledgeable of and comply with the environmental laws,
rules & regulations relating to the hazardous materials, substances and wastes. Contractor shall
not dump, release or otherwise discharge or disposes off any such materials without the express
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authorization of EIL/Owner. An indicative list of Statutory Acts & Rules relating to HSE is
given under Appendix-D.
3.3.19 Weather Protection

Contractor shall take appropriate measures to protect workers from severe storms, rain, solar
radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses, Sun
screen lotions, respirators, dust masks, etc. and rearranging/ planning the construction activities
to suit the weather conditions. Effective arrangement (without creating inconvenience to project
facilities & permanent installations) for protecting workmen from hailstorm, drizzle in the form
of temporary shelter shall be made at site.
3.3.20 Communication
All persons deployed at the work site shall have access to effective means of communication so
that any untoward incident can be reported immediately and assistance sought by them.
All health & safety information shall be communicated in a simple & clear language easily
understood by the local workforce.
For information to all, typical subjects that should be communicated are: -
Inside the company (Top to down)

a. Quality Policy
b. HSE Policy contents
c. Environment Policy
d. HSE Objectives
e. Safety Cardinal Rules
f. HSE Target – reached or missed
g. Praises & Warnings to personnel for HSE Management
h. Safety Walk Through Reports and safety defects / shortfalls (by management)
i. HSE Audit results
j. Revised Statutory Health & Safety provisions, if any
k. H & S publicity
l. Suggestions
Inside the Company (Bottom to up)

a. Complaints
b. Compliances on safety defects / shortfalls
c. Suggestions
d. Proposals for changes & improvements
e. HSE Reports (including near-miss reports)
3.3.21 Confined Space Entry

The contractor shall generate a work permit (Format No. HSE -7) before entering a confined
space. People, who are permitted to enter into confined space, must be medically examined &
certified by registered doctor, confirming their ‘medical fitness for working in confined space’.
All necessary precautions mentioned therein shall be adhered to. An attendant shall be
positioned outside a confined space for extending help during an emergency. Effective
communication shall be maintained between personnel in confined space and outside by
combination of visual/voice or portable radio. Compressed gas cylinders shall not be taken into
confine space. Entry Register for confined space to be maintained with the name and time of
entry/exit. All appropriate PPEs and air quality parameters shall be checked before entering a
confined space. It shall be ensured that the piping of the equipment which has to be opened is
pressure- free by checking that blinds are in place, vents are open and volume is drained. Inside
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confined space works, only electrical facilities/ installations of 24V shall be permitted.
Contactor shall ensure usage of safe & suitable arrangement of oxygen supply for individual
workmen (during the course of work in confined space), if oxygen concentration is found to be
less than 19.5% (v/v) there.
3.3.22 Heavy Lifts

 The contractor shall submit detailed rigging studies plan for EIL/ Owner approval prior to
lifting equipment which cannot be erected with a crane of approx. 100 MT capacity due to
constraints of its dimensions, location of foundation height, approach & weight.
 Contractor shall generate the format no:HSE-15 “Permit for heavy lift/critical erection”
 The Safe Working Load (SWL) and manufacturer’s serial numbers shall be clearly marked
on the slings and the lifting gears, either by tagging, stamping, engraving or embossing.
 Prior to actual lifting activities, contractor shall check the validity of the crane inspection
certificate issued by statutory/ competent authority. This requirement shall also apply to all
rigging equipment’s utilized for the job.
 The contractor shall, at all times, be responsible for all rigging activities.
 The Contractor shall ensure medical fitness of all workmen who are engaged / involved in
erection of equipment’s, vessels etc. and such fitness checks shall be carried-out every six
months interval with the help of a registered medical practitioner & record shall be
maintained
 Adequate safety measures such as positive barricading, usage of appropriate PPEs, permit
to work, etc. shall be taken during all heavy or critical lifts.
 For lifting any material (irrespective of shape, size or volume), at any height, it is always
advisable to prepare a Plan of Erection (PoE) taking into consideration hazards & risks
associated therein – this can enable people to put their own experiences of various natures
& side-by-side establish a practical method for risk-free erection / lifts. The contractor shall
prepare PoE & shall document the same, when risks are identified as “medium” or “high”
and the same shall be approved by its competent / qualified engineer.
3.3.23 Key Performance Indicators
The contractor shall measure an activity in both leading & trailing indicators for statistical and
performance measurement. The activities pertaining to key performance indicators are covered
in Monthly HSE Report (Format No. HSE-5). The contractor shall try to achieve a statistically
fair record and strive for its continual improvement.
Leading Indicators viz :-
- Number of Safety Inductions carried-out at site (for workmen & staff members)
- Number of HSE inspections carried out
- Number of “Safety Walk Through” carried-out by site-head.
- Number of HSE shortfalls / lapses identified per contractor& closed-out in time.
- Number of Safety Meetings conducted (in-house / with contractors)
- Number of HSE Audits made (internal & external) vis-à-vis non conformances raised
- Number of HSE Awareness / Motivational program conducted by contractors
- Number of HSE Trainings conducted at site for supervisors & workmen
- Study of Near miss case reported
- Encouragements / Awards / Recognitions to workmen, job supervisors & field engineers.
- Suggestions for improvement
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Trailing Indicators viz :-
- Calculation of HSE statistics viz frequency rate, severity rate, LTA free manhours, etc.
- Analysis of incidents / accidents (nature, severity, types etc.)
- Study of Incident / Accident with respect to :-
 Variety
 Period of the year / project span
 Timings of the incident / accident
 Age profile of victims
 Body parts involved
 Penalty levied for causing incident / accident
3.3.24 Unsuitable Land Conditions

Contractor shall take appropriate measures and necessary work permits/clearances if work is to
be done in or around marshy areas, river crossings, mountains, monuments, etc. The Contractor
shall make right assessment and take all necessary action for developing work areas to make
them safe & suitable for crane operations or other vehicular movement before carrying out any
project related activity / operation. Contractor shall take all necessary actions to make the
surroundings of its site establishments (site office, stores, lay-down area etc.) work-worthy
safe and secure.
3.3.25 Under Water Inspection
Contractor shall ensure that boats and other means used for transportation, surveying &
investigation works shall be certified seaworthy by a recognized classification society. It shall
be equipped with all life saving devices like life jackets, adequate fire protection arrangements
and shall posses communication facilities like cellular phones, wireless, walkie-talkie. All
divers used for seabed surveys, underwater inspections shall have required authorized license,
suitable life saving kit. Number of hours of work by divers shall be limited as per regulations.
EIL/ Owner shall have the right to inspect the boat and scrutinize documents in this regard.
3.3.26 Excavation
The Contractor shall obtain permission from competent authorities prior to excavation wherever
required.
The Contractor shall locate the position of buried utilities (water line, cable route, etc.) by
referring to project / plant drawing / in consultation with EIL/Owner. The Contractor shall start
digging manually to locate the exact position of buried utilities & thereafter use mechanical
means.
The Contractor shall keep soil heaps at least 1.5 M away from edge or a distance equal to depth
of pit (whichever is more).
All excavated pits greater than 10 Sq.M plan area and depth more than 1.5M shall have at least
two access routes for ingress and egress. Also, additional access routes shall be provided such
that distance between any two access routes shall not be more than 20M.
The Contractor shall maintain sufficient “angle of repose” during excavation – shall also
provide slope or suitable bench as decided by EIL / Owner.
The Contractor shall arrange “battering” or “benching” wherever required for preventing
collapse of edge of excavations.
The Contractor shall identify & arrange de-watering pump or well-point system to prevent earth
collapse due to heavy rain / influx of underground water.
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The Contractor shall arrange protective fencing/ barricading with warning signal around
excavated pits, trenches, etc. along with minimum 2 (two) entries, exits/ escape ladders.
The Contractor must avoid “underpinning” / under-cutting to prevent collapse of chunk of earth
during excavation
The Contractor shall use “stoppers” to prevent over-run of vehicle wheels at the edge of
excavated pits/ trenches.
The Contractor shall arrange strengthening of “shoring” & “strutting” proactively to avoid
collapse of earth/ edges due to vehicular movement in close proximity of excavated areas/ pits/
trenches, etc.
3.4 Tool Box Talks (TBT)
Contractor shall conduct daily TBT with workers prior to start of work and shall maintain
proper record of the meeting. A suggested format is given below. The TBT is to be conducted
by the immediate supervisor of the workers
The Contractor shall conduct TBT before start of every morning or evening shift or night shift
activities, for alerting the workers on specific hazards and their appropriate dos & don’ts. The
Contractor shall provide sufficient rests to the site workmen and their foremen to avert fatigue
& thereby endangering their lives during the course of site works.
TOOLBOX TALK RECORDING SHEET

Date & Time
Work Location
Subject (Nature of work)
Presenter
Hazards involved
Precautions to be taken
Worker's Name Signature Section
Remarks, in any
The topics during TBT shall include
- Hazards related to work assigned on that day and precautions to be taken.

- Any forthcoming HSE hazards/events/instruction/orders, etc.
The above record can be kept in local language, which workers can read. These records shall be
made available to EIL/ Owner whenever demanded.
3.5 Training & Induction Programme
 Initial induction of workers into Construction oriented activities and appraising them about
the methodology of works and how to carry-out safely and the same should not be inter
mixed with Tool Box Talks or HSE Training. In this regard careful action should be made
& maintained for imparting HSE induction to every individual, irrespective of his
task/designation/level of employment, whereas, HSE Training should be imparted to
specific person/group of people who are to carry-out that specific task more than once – for
example, Riggers must be trained for working at heights, welders must be trained for work
in confined space, fitters/carpenters, mesons must be trained for work at heights, etc.
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 Contractor shall conduct Safety induction programme on HSE for all his workers and
maintain records. The Gate Pass shall be issued only to those workers who successfully
qualify the Safety induction programme.
 The Contractor shall brief the visitors about the HSE precautions which are required to be
taken before their proceeding to site and make necessary arrangements to issue appropriate
PPEs like Aprons, hard hats, ear-plugs, goggles & safety shoes etc., to his visitors. The
Contractor shall always maintain relevant acknowledgement from visitor on providing him
brief information on HSE actions.
 Contractor shall ensure that all his personnel possess appropriate training to carry out the
assigned job safely. The training should be imparted in a language understood by them and
should specifically be trained about
- Potential hazards to which they may be exposed at their workplace

- Measures available for prevention and elimination of these hazards
The topics during training shall cover, at the minimum: -
- Why safety should be considered during work - explanation

- Education about hazards and precautions required
- Employees’ duties & responsibilities
- Emergency and evacuation plan
- HSE requirements during project activities
- Fire fighting and First-Aid
- Use of PPEs
- Occupational health issues – dos & don’ts
- Local laws on intoxicating drinks, drugs, smoking in force
- Common environmental subjects – lighting, ventilation, vibration, smoke/fumes etc.
 Records of the training shall be kept and submitted to EIL/ Owner.
 The Contractor shall make regular program for conducting Safety Training on various
topics related to various activities & their safe-guarding utilizing experienced persons /
outside agency / faculty. A program for Safety Training (indicative list as per Appendix –F)
shall be furnished by the Contractor in its HSE Plan.
 For offshore and jetty jobs, contractor shall ensure that all personnel deployed have
undergone a structured sea survival training including use of lifeboats, basket landing, use
of radio communication etc. from an agency acceptable to Owner/EIL.
3.6 ADDITIONAL SAFETY REQUIREMENTS FOR WORKING INSIDE A RUNNING

PLANT
As a minimum, the contractor shall ensure adherence to following safety requirements while
working in or in the close vicinity of an operating plant:
a) Contractor shall obtain permits for Hot work, Cold work, Excavation and Confined Space
from Owner in the prescribed format.
b) The contractor shall monitor record and compile list of his workers entering the operational
plant/unit each day and ensure & record their return after completing the job.
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c) Contractor’s workers and staff members shall use designated entrances and proceed by
designated routes to work areas only assigned to them. The workers shall not be allowed to
enter units' area, tanks area, pump rooms, etc. without work authorization permit.
d) Work activities shall be planned in such a way so as to minimize the disruption of other
activities being carried out in an operational plant/unit and activities of other contractors.
e) The contractor shall submit a list of all chemicals/toxic substances that are intended to be
used at site and shall take prior approval of the Owner.
f) Specific training on working in a hydrocarbon plant shall be imparted to the work force and
mock drills shall be carried out for Rescue operations/First-Aid measures.
g) Proper barricading/cordoning of the operational units/plants shall be done before starting

the construction activities. No unauthorized person shall be allowed to trespass. The height
and overall design of the barricading structure shall be finalized in consultation with the
Owner and shall be got approved from the Owner.
h) Care shall be taken to prevent hitting underground facilities such as electrical cables,
hydrocarbon piping during execution of work.
i) Barricading with water curtain shall be arranged in specific/critical areas where

hydrocarbon vapors are likely to be present such as near horton spheres or tanks.
Positioning of fire tenders (from owner) shall also be ensured during execution of critical
activities.
j) Emergency evacuation plan shall be worked out and all workmen shall be apprised about
evacuation routes. Mock drill operations may also be conducted.
k) Flammable gas test shall be conducted prior to any hot work using appropriate measuring
instruments. Sewers, drains, vents or any other gas escaping points shall be covered with
flame retardant tarpaulin.
l) Respiratory devices shall be kept handy while working in confined zones where there is a
danger of inhalation of poisonous gases. Constant monitoring of presence of
Gas/Hydrocarbon shall be done.
m) Clearance shall be obtained from all parties before starting hot tapping, patchwork on live
lines and work on corroded tank roof.
n) Positive isolation of line/equipment by blinding for welding/cutting/grinding shall be done.

Closing of valve will not be considered sufficient for isolation.
o) Welding spatters shall be contained properly and in no case shall be allowed to fall on the
ground containing oil. Similar care shall be taken during cutting operations.
p) The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust pipe
and got it approved from Safety Department of the Owner.
q) Plant air should not be used to clean any part of the body or clothing or use to blow off dirt
on the floor.
r) Gas detectors should be installed in gas leakage prone areas as per requirement of Owner's
plant operation personnel.
s) Experienced full time safety personnel shall be exclusively deployed to monitor safety
aspects in running plants.
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3.7 Self Assessment and Enhancement

The contractor shall develop a method of check & balance through self assessment &
enhancement techniques and shall explore the opportunities for continual improvement in the
HSE system.
3.8 HSE Promotion

The contractor shall encourage his workforce to promote HSE efforts at workplace by way of
organizing workshops/ seminars/ training programmes, celebrating HSE awareness weeks
&National Safety Day, conducting quizzes & essay competitions, distributing pamphlets,
posters & material on HSE, providing incentives for maintaining good HSE practices and
granting incentives / bonus for completing the job without any lost time accident.
3.9 Lock Out and Tag Out (LOTO) for Isolation of Energy Source
 Contractor shall follow the LOTO/ Isolation procedure of owner for all energy source
isolations installed/under purview by/of owner i.e. “Brown field”
 For all the other energy source (not under purview of client/owner) i.e. “Green field”
Contractor shall develop a system to ensure the isolation of equipments, pipelines, Vessel,
electrical panels from the energy source covering following as minimum:-
- Identification of all energy source viz electrical, mechanical, hydraulic, pneumatic,

chemical, thermal, gravitational, radiation and other forms of stored or kinetic
energy.
- Establishing the energy isolation devices viz: manually operated electrical circuit
breakers, disconnection switches, blind flanges, etc.
- Installation of Lock Out devices for preventing the inadvertent release of stored
energy and Tag Out devices (“Danger”, “Do Not operate” or Do not Remove” tags)
to indicate that testing, maintenance or servicing is underway and the device cannot
be operated until the tag out device is removed.
- Lock Out and Tag out log book
- Permit for isolation and de-isolation of energy source as per format NO: HSE-16
- Availability of competent persons like experienced operators at substations, pump
house, units, etc, supervisors etc.
 Contractor shall ensure that all the sources are locked out and tagged properly before giving
clearance to start the job.
 After the completion of job, contractor shall ensure all tools and tackles are removed and
nobody is present in the working area and signing on LOTO log book.
 Only on confirmation of above the contractor will remove their lock and tag from the
isolation points and give instructions for energizing the same. Only the person carrying out
the task shall himself carry the key for the lock in /Lock out.
4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR

4.1 On Award of Contract
The Contractor shall submit a comprehensive Health, Safety and Environmental Plan or
programme for approval by EIL/Owner prior to start of work. The Contractor shall participate in
the pre-start meeting with EIL/Owner to finalize HSE Plans which shall including the
following:
- HSE policy & Objectives
- Job procedure to be followed by the Contractor for construction activities including
handling of equipment’s, scaffolding, electric installations, etc. describing the risks
involved, actions to be taken and methodology for monitoring each activity. Indicative list
of procedures is enclosed as Annexure-H
- EIL/Owner review/audit requirement.
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- Organization structure along with responsibility and authority, on HSE activities.

- Administrative & disciplinary steps involving implementation of HSE requirements
- Emergency evacuation plan/ procedures for site and labour camps
- Procedures for reporting & investigation of accidents and near misses.
- HSE Inspection
- HSE Training programmes at project site
- HSE Awareness programmes, at project site
- Reference to Rules, Regulations and statutory requirements.
- HIRAC
- Environment Aspect Impact Register
- Legal Register
- HSE documentation viz reporting, analysis & record keeping.
4.2 During Job Execution

Contractor shall implement approved Health, Safety and Environment management programme
including but not limited to as brought out under para 3.0. Contractor shall also ensure:
 to arrange workmen compensation insurance, registration under ESI Act, third party
liability insurance, registration under BOCW Act etc., as applicable.
 to arrange all HSE permits before start of activities (as applicable), like permits for hot
work, working at heights (Refer Format No. HSE-6), confined space (Refer Format No.
HSE-7), Radiation Work Permit (Refer Format No. HSE-8), Demolishing/ Dismantling
Work Permit (Refer Format No. HSE-9), Permit for erection/modification & dismantling of
scaffolding (Refer Format No:HSE-14),Permit for heavy lift/critical erection (Refer Format
No:HSE-15) ,Permit for energy Isolation & De-isolation” (HSE-16) ,storage of chemical
/explosive materials & its use and implement all precautions mentioned therein. In this
regard, requirements of Oil industry Safety Directorate Standard No. Std-105 "Work
Permit Systems” shall be complied with while working in existing Oil or Gas processing
plants. List of the persons involved shall be maintained as annexure to the work permit
issued for a particular activity.
 to submit, timely, the completed checklist on HSE activities in Format No.HSE-1, Monthly
HSE report in Format No.HSE-5 (use of web based package (www.eil.co.in/conthse) is
compulsory wherever the facility is available else a hard copy is to be submitted), accident/
incident reports, investigation reports etc. as per EIL/Owner requirements. Compliance of
instructions on HSE shall be done by Contractor and informed urgently to EIL/Owner.
 that his top most executive at site attends all the Safety Committee/HSE meetings arranged
by EIL/Owner and carries out safety walk regularly. Only in case of his absence from site
that a second senior most person shall be nominated by him, in advance, and
communicated to EIL/Owner for performing the above tasks.
 display at site office and at prominent locations HSE Policy, caution boards, list of
hospitals, emergency services available, safety signs like Men at work, Speed Limits,
Hazardous Area, various do’s & don’ts, etc.
 provide posters, banners for safe working to promote safety consciousness.
 identify, assess, analyze & mitigate the construction hazards& incorporate relevant control
measures before actually executing site works. (HIRAC = Hazard Identification, Risk
Analysis and Control).
 identify, assess, analyze & mitigate the environmental impact & incorporate relevant
control measures through Environmental Aspect Impact Register
 Identify and comply to all applicable HSE related legal requirements by preparing and
maintaining a Legal register
 arrange testing, examination, inspection of own as well as borrowed construction
equipment’s / machinery (stationary &mobile) before being used at site and also at
periodical interval, through own resources and also by 3rd party competent agencies (as
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deemed fit in statutes). Records of such test, examination etc. shall be maintained & shall
be submitted to EIL/Owner as & when asked for.
 carryout audits/ inspection (internal & external) at his works as well as sub-contractor
works as per approved HSE plan/ procedure/ programme & submit the compliance reports
of identified shortfalls for EIL/Owner review.
 arranging HSE training for site workmen (of his own & sub-contractors) through internal or
external faculty at periodical intervals.
 Assistance& cooperate during HSE audits by EIL/Owner or any other 3rd party and submit
compliance report.
 Generate & submit of HSE records/report as per this specification.
 apprise EIL/Owner on HSE activities at site regularly.
 carry-out all dismantling activities safely, with prior approval of EIL/Owner representative.
 The Contractor shall ensure that “Hot works” and painting works do not continue at the
same place / location at project site for which chance or probability of “fire” incident
exists.
4.3 During Short Listing of the Sub-Contractors

The contractor shall review the HSE management system of the sub-contractors in line with the
requirements given in this specification. The contractor shall be held responsible for the
shortcomings observed in the HSE management system of the sub-contractor(s) during
execution of the job.
5.0 RECORDS
At the minimum, the contractor shall maintain/ submit HSE records in the following reporting
formats:
Safety Walk Through Report HSE-1
Accident/ Incident Report HSE-2
Supplementary Accident/ Incident Investigation report HSE-3
Near Miss Incident Report HSE-4
Monthly HSE Report HSE-5
Permit for working at height HSE-5
Permit for working in confined space HSE-7
Permit for radiation work HSE-8
Permit for demolishing/ dismantling HSE-9
Daily Safety checklist HSE-10
Housekeeping Assessment & compliance HSE-11
Inspection of temporary electrical booth/installation HSE-12
Inspection for scaffolding HSE-13
Permit for erection/modification &dismantling of scaffolding HSE-14
Permit for heavy lift/critical erection. HSE-15
Permit for Energy isolation and de-isolation. HSE-16
Permit for Excavation HSE-17
Inspection reports of Equipment/tools/tackles *
Report of Toolbox talks As indicated in
specification
PPE issue report/register *
Site inspection reports *
Training records *
(*) The formats shall be developed in consultation with EIL/Owner.
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APPENDIX-A
(Sheet 1 of 2)
A. IS CODES ON HSE
SP: 53 Safety code for the use, Care and protection of hand operated tools.
IS: 838 Code of practice for safety & health requirements in electric and gas welding
and cutting operations
IS: 1179 Eye & Face precautions during welding, equipment etc.
IS: 1860 Safety requirements for use, care and protection of abrasive grinding wheels.
IS: 1989 (Pt -II) Leather safety boots and shoes
IS: 2925 Industrial Safety Helmets
IS: 3016 Code of practice for fire safety precautions in welding & cutting operation.
IS: 3043 Code of practice for earthing
IS: 3764 Code of safety for excavation work
IS: 3786 Methods for computation of frequency and severity rates for industrial injuries
and classification of industrial accidents
IS: 3696 Safety Code of scaffolds and ladders
IS: 4083 Recommendations on stacking and storage of construction materials and
components at site
IS: 4770 Rubber gloves for electrical purposes
IS: 5121 Safety code for piling and other deep foundations
IS: 5216 (Pt-I) Recommendations on Safety procedures and practices in electrical works
IS: 5557 Industrial and Safety rubber lined boots
IS: 5983 Eye protectors
IS: 6519 Selection, care and repair of Safety footwear
IS: 6994 (Pt-I) Industrial Safety Gloves (Leather & Cotton Gloves)
IS: 7293 Safety Code for working with construction Machinery
IS: 8519 Guide for selection of industrial safety equipment for body protection
IS: 9167 Ear protectors
IS: 11006 Flash back arrestor (Flame arrestor)
IS: 11016 General and safety requirements for machine tools and their operation
IS: 11057 Specification for Industrial safety nets
IS: 11226 Leather safety footwear having direct moulded rubber sole
IS: 11972 Code of practice for safety precaution to be taken when entering a sewerage
system
IS: 13367 Code of practice-safe use of cranes
IS: 13416 Recommendations for preventive measures against hazards at working place
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APPENDIX-A
(Sheet 2 of 2)
B. INTERNATIONAL STANDARDS ON HSE
Safety Glasses : ANSI Z 87.1, ANSI ZZ 87.1, AS 1337, BS 2092,

BS 1542, BS 679, DIN 4646/ 58311
Safety Shoes : ANSI Z 41.1, AS 2210, EN 345
Hand Gloves : BS 1651
Ear Muffs : BS 6344, ANSI S 31.9
Hard Hat : ANSI Z 89.1/89.2, AS 1808, BS 5240, DIN 4840
Goggles : ANSI Z 87.1
Face Shield : ANSI Z 89.1
Breathing Apparatus : BS 4667, NIOSH
Welding & Cutting : ANSI Z49.1
Safe handling of compressed:P-1 (Compressed Gas Association Gases in cylinders 1235

Jefferson Davis Highway,
Arlington VA 22202 - USA)
Full body harness : EN-361
Lanyard : EN-354
Karabiner : EN-362 and EN-12275
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APPENDIX-B
DETAILS OF FIRST AID BOX
------------------------------------------------------------------------------------------------------------------------
SL. DESCRIPTION QUANTITY
NO.
------------------------------------------------------------------------------------------------------------------------
1. Small size Roller Bandages, 1 Inch Wide (Finger Dressing small) 6 Pcs.
2. Medium size Roller Bandages, 2 Inches Wide (Hand & Foot Dressing) 6 Pcs.
3. Large size Roller Bandages, 4 Inches Wide (Body Dressing Large) 6 Pcs.
4. Large size Burn Dressing (Burn Dressing Large) 4 Pkts.
5. Cotton Wool (20 gms packing) 4 Pkts.
6. Antiseptic Solution Dettol (100 ml.) or Savlon 1 Bottle
7. Mercurochrome Solution (100 ml.) 2% in water 1 Bottle
8. Ammonia Solution (20 ml.) 1 Bottle
9. A Pair of Scissors 1 Piece
10. Adhesive Plaster (1.25 cm X 5 m) 1 Spool
11. Eye pads in Separate Sealed Pkt. 4 pcs.
12. Tourniqut 1 No.
13. Safety Pins 1 Dozen
14. Tinc. Iodine/ Betadin (100 ml.) 1 Bottle
15. Polythene Wash cup for washing eyes 1 No.
16. Potassium Permanganate (20 gms.) 1 Pkt.
17. Tinc. Benzoine (100 ml.) 1 Bottle
18. Triangular Bandages 2 Nos.
19. Band Aid Dressing 5 Pcs.
20. Iodex/Moov (25 gms.) 1 Bottle
21. Tongue Depressor 1 No.
22. Boric Acid Powder (20 gms.) 2 Pkt.
23. Sodium Bicarbonate (20 gms.) 1 Pkt.
24. Dressing Powder (Nebasulf) (10 gms.) 1 Bottle
25. Medicinal Glass 1 No.
26. Duster 1 No.
27. Booklet (English& Local Language) 1 No. each
28. Soap 1 No.
29. Toothache Solution 1 No.
30. Vicks (22 gms.) 1 Bottle
31. Forceps 1 No.
32. Note Book 1 No.
33. Splints 4 Nos.
34. Lock 1 Piece
35. Life Saving/Emergency/Over-the counter Drugs As decided at site
-----------------------------------------------------------------------------------------------------------------
Box size: 14" x 12" x 4"
-----------------------------------------------------------------------------------------------------------------
Note : The medicines prescribed above are only indicative. Equivalent medicines can also be used.
A prescription, in this regard, shall be required from a qualified Physician.
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APPENDIX-C
TYPE OF FIRES VIS-À-VIS FIRE EXTINGUISHERS
Fire
Extinguisher
Multi-purpose
Fire Water Foam CO2 Dry Powder
(ABC)
Originated from can control can control

  minor surface 
paper, clothes, wood minor surface
fires fires
Inflammable liquids
like alcohol, diesel,     
petrol, edible oils,
bitumen
Originated from
gases like LPG,     
CNG, H2
Electrical fires     
LEGEND : : CAN BE USED
: NOT TO BE USED
Note: Fire extinguishing equipment must be checked atleast once a year and after every use by an
authorized person. The equipment must have an inspection label on which the next
inspection date is given. Type of extinguisher shall clearly be marked on it.
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APPENDIX-D
List of Statutory Acts & Rules Relating to HSE
- The Indian Explosives Act and Rules

- The Motor Vehicle Act and Central Motor Vehicle Rules
- The Factories Act and concerned Factory Rules
- The Petroleum Act and Petroleum Rules
- The Workmen Compensation Act
- The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules
- The Indian Electricity Act and Rules
- The Indian Boiler Act and Regulations
- The Water (Prevention & Control & Pollution) Act
- The Water (Prevention & Control of Pollution) Cess Act
- The Mines & Minerals (Regulation & Development) Act
- The Air (Prevention & Control of Pollution) Act
- The Atomic Energy Act
- The Radiation Protection Rules
- The Indian Fisheries Act
- The Indian Forest Act
- The Wild Life (Protection) Act
- The Environment (Protection) Act and Rules
- The Hazardous Wastes (Management & Handling) Rules
- The Manufacturing, Storage & import of Hazardous Chemicals Rules
- The Public Liability Act
- The Building and Other Construction Workers (Regulation of Employment and Condition of service)
Act
- Other Statutory Acts like EPF, ESIS, Minimum Wage Act.
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APPENDIX-E (Sheet 1 of 12)
CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES
TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
(A) Falling into pit Personal injury Provide guard rails/ barricade with warning
EXCAVATION signal.
Provide atleast two entries/ exits.
Pit Excavation Provide escape ladders.
upto 3.0m Earth Collapse Suffocation/ Provide suitable size of shoring and strutting, if
Breathlessness required.
Buried Keep soil heaps away from the edge equivalent to
1.5m or depth of pit whichever is more.
Don't allow vehicles to operate too close to
excavated areas. Maintain atleast 2m distance
from edge of cut.
Maintain sufficient angle of repose. Provide
slope not less than 1:1 and suitable bench of 0.5m
width at every 1.5m depth of excavation in all
soils except hard rock.
Battering/benching the sides.
Contact with Electrocution Obtain permission from competent authorities,
buried electric Explosion prior to excavation, if required.
cables Locate the position of buried utilities by referring
Gas/ Oil to plant drawings.
Pipelines Start digging manually to locate the exact
position of buried utilities and thereafter use
mechanical means.
Pit Excavation Same as above Can cause Prevent ingress of water.
beyond 3.0m plus drowning situation Provide ring buoys.
Flooding due to Identify and provide suitable size dewatering
excessive rain/ pump or well point system.
underground
water
Digging in the Building/Structure Obtain prior approval of excavation method from
vicinity of may collapse local authorities.
existing Building/ Loss of health & Use under-pining method.
Structure wealth Construct retaining wall side by side.
Movement of May cause cave-in Barricade the excavated area with proper lighting
vehicles/ or slides. arrangements.
equipment’s close Persons may get Maintain at least 2m distance from edge of cut
to the edge of cut. buried. and use stop blocks to prevent over-run.
Strengthen shoring and strutting.
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APPENDIX-E: (Sheet 2 of 12)
CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)
TYPE OF EFFECT OF
HAZARD HAZARD
Narrow deep Same as above May cause severe Battering/ benching of sides.
excavations for plus injuries or prove Provide escape ladders.
pipelines, etc. Frequent cave-in fatal
or slides
Flooding due to May arise drowning Same as above plus
Hydro- static situation Bail out accumulated water.
testing Maintain adequate ventilation.
Rock by Improper May prove fatal Ensure proper storage, handling & carrying of
excavation handling of explosives by trained personnel.
blasting explosives Comply with the applicable explosive acts &
rules.
Uncontrolled May cause severe Allow only authorized persons to perform
explosion injuries or prove blasting operations.
fatal Smoking and open flames are to be strictly
prohibited.
Scattering of Can hurt people Use PPE like goggles, face mask, helmets etc.
stone pieces in
atmosphere
Rock excavation Entrapping of May cause severe Barricade the area with red flags and blow siren
by blasting persons/ animals. injuries or prove before blasting.
(Contd.) fatal
Misfire May explode Do not return to site for atleast 20 minutes or
suddenly unless announced safe by designated person.
Piling Work Failure of pile- Can hurt people Inspect Piling rigs and pulley blocks before the
driving beginning of each shift.
equipment
Noise pollution Can cause deafness Use personal protective equipments like ear
and psychological plugs, muffs, etc.
imbalance.
Extruding Can hurt people Barricade the area and install sign boards.
rods/casing Provide first-aid.
Working in the Can cause Keep sufficient distance from Live-Electricity as
vicinity of 'Live- electrocution/ per IS code.
Electricity' Asphyxiation Shut off the supply, if possible.
Provide artificial/rescue breathing to the injured.
(B) Air pollution by May affect Wear respirators or cover mouth and nose with
CONCRETING cement Respiratory System wet cloth.
Handling of Hands may get Use gloves & other PPE.
ingredients injured
Protruding Feet may get Provide platform above reinforcement for
reinforcement injured movement of workers or provide end caps for
rods. protection on reinforcement bars.
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APPENDIX-E : (Sheet 3 of 12)
TYPE OF EFFECT OF
HAZARD HAZARD
Earthing of Can cause Ensure earthing of equipments and proper
electrical electrocution/ functioning of electrical circuit before
mixers, asphyxiation commencement of work.
vibrators, etc.
not done.
Falling of Persons may get Use hard hats.
materials from injured Remove surplus material immediately from work
height place.
Ensure lighting arrangements during night hours.
Continuous Cause tiredness of Insist on shift pattern.
pouring by same workers and may Provide adequate rest to workers between
gang lead to accident. subsequent pours.
Revolving of Parts of body or Allow only mixers with hopper.
concrete mixer/ clothes may get Provide safety cages around moving motors.
vibrators entrapped. Ensure proper mechanical locking of vibrator.
Super-structure Same as above Shuttering/props Avoid excessive stacking on shuttering material.
plus may collapse and Check the design and strength of shuttering
Deflection in prove fatal material before commencement of work.
props or Rectify immediately the deflection noted during
shuttering concreting.
material
Passage to work Improperly tied and Ensure the stability and strength of passage
place designed before commencement of work.
props/planks may Do not overload and stand under the passage.
collapse
(C) Curtailment and Persons may get Use PPE like gloves, shoes, helmets, etc.
REINFORCE- binding of rods injured Avoid usage of shift tools.
MENT Carrying of rods Workers may get Provide suitable pads on shoulders and use safety
for short injured their hands gloves.
distances/at and shoulders. Tie up rods in easily liftable bundles.
heights Ensure proper staging.
Checking of Rods may cut or Use measuring devices like tape, measuring rods,
clear distance/ injure the fingers etc.
cover with hands
Hitting projected Persons may get Use safety shoes and avoid standing
rods and injured and fell unnecessarily on cantilever rods.
standing on down Avoid wearing of loose clothes.
cantilever rods.
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TYPE OF EFFECT OF
HAZARD HAZARD
Falling of material May prove fatal Use helmets.
from height Provide safety nets.
Transportation of Protruded rods may Use red flags/lights at the ends.

rods by trucks/ hit the persons Do not protrude the rods in front of or by the side
trailers of driver's cabin.
Do not extend the rods 1/3rd of deck length or
1.5m whichever is less.
(D) Welding radiates Radiation can Use specified shielding devices and other PPE of
WELDING invisible damage eyes and correct specifications.
AND GAS ultraviolet and skin. Avoid thoriated tungsten electrodes for GTAW.
CUTTING infra-red rays
Improper Explosion may occur Move out any leaking cylinder.
placement of Keep cylinders in vertical position.
oxygen and Use trolley for transportation of cylinders and
acetylene cylinders chain them.
Use flashback arrestors.
Leakage/ cuts in May cause fire Purge regulators immediately and then turn off.
hoses Never use grease or oil on oxygen line
connections and copper fittings on acetylene
lines.
Inspect regularly gas carrying hoses.
Always use red hose for acetylene & other
fuel gases and black for oxygen.
Opening-up of Cylinder may burst Always stand back from the regulator while
cylinder opening the cylinder.
Turn valve slowly to avoid bursting.
Cover the lug terminals to prevent short
circuiting.
Welding of tanks, Explosion may occur Empty & purge them before welding.
container or pipes Never attach the ground cable to tanks, container
storing flammable or pipe storing flammable liquids.
liquids Never use LPG for gas cutting.
Page 572 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
TYPE OF EFFECT OF
HAZARD HAZARD
(E) Ionizing Radiations may react Ensure Safety regulations as per BARC/AERB
RADIOGRAPHY radiation with the skin and can before commencement of job.
cause cancer, skin Cordon off the area and install Radiation warning
irritation, dermatitis, symbols.
etc. Restrict the entry of unauthorized persons.
Wear appropriate PPE and film badges issued by
BARC/AERB.
Transportation Same as above Never touch or handle radiography source with
and Storage of hands.
Radiography Store radiography source inside a pit in an
source exclusive isolated storage room with lock and
key arrangement. The pit should be approved by
BARC/AERB.
Radiography source should never be carried
either in passenger bus or in a passenger
compartment of trains.
BARC/AERB has to be informed before source
movement.
Permission from Director General of Civil
Aviation is required for booking radio isotopes
with airlines.
Loss of Radio Same as above Try to locate with the help of Survey Meter.
Isotope Inform BARC/AERB (*)
(F) Short circuiting Can cause Use rubberized hand gloves and other PPE.
ELECTRICAL Electrocution or Fire Don't lay wires under carpets, mats or door ways.
INSTALLATION Allow only licensed electricians to perform on
AND USAGE electrical facilities.
Use one socket for one appliance.
Ensure usage of only fully insulated wires or
cables.
Don't place bare wire ends in a socket.
Ensure earthing of machineries and equipments
Do not use damaged cords and avoid temporary
connections.
Use spark-proof/ flame proof type field
distribution boxes.
(*) Atomic Energy Regulatory Board (AERB),

Bhabha Atomic Research Centre (BARC)
Anushaktinagar, Mumbai – 400 094
Page 573 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
TYPE OF EFFECT OF
ACTIVITY
HAZARD HAZARD
PREVENTIVE MEASURES
Do not allow open/bare connections.
Provide all connections through 30mA ELCB.
Protect electrical cables/equipments from water
and naked flames.
Check all connections before energizing.
Overloading of Bursting of system Display voltage and current ratings prominently
Electrical can occur which with 'Danger' signs.
System leads to fire Ensure approved cable size, voltage grade and
type.
Switch off the electrical utilities when not in use.
Do not allow unauthorized connections.
Ensure proper grid wise distribution of Power.
Improper laying Can cause Do not lay unarmoured cable directly on ground,
of overhead and electrocution and wall, roof of trees.
underground prove fatal Maintain atleast 3m distance from HT cables.
transmission All temporary cables should be laid atleast 750
lines/cables mm below ground on 100 mm fine sand
overlying by brick soling.
Provide proper sleeves at crossings/ inter-
sections.
Provide cable route markers indicating the type
and depth of cables at intervals not exceeding
30m and at the diversions/ termination.
(G) Small fires can Cause burn injuries In case a fire breaks out, press fire alarm system
FIRE become big ones and may prove fatal and shout "Fire, Fire".
PREVENTION and may spread Keep buckets full of sand & water/ fire
AND to the extinguishing equipment near hazardous locations
PROTECTION surrounding Confine smoking to 'Smoking Zones' only.
areas Train people for using specific type of fire
fighting equipments under different classes of
fire.
Keep fire doors/ shutters, passages and exit doors
unobstructed.
Maintain good housekeeping and first-aid boxes
(for details refer Appendix-B).
Don't obstruct assess to Fire extinguishers.
Do not use elevators for evacuation during fire.
Maintain lightening arrestors for elevated
structures.
Stop all electrical motors with internal
combustion.
Page 574 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
TYPE OF EFFECT OF
HAZARD HAZARD
Move the vehicles from dangerous locations.
Remove the load hanging from the crane booms.
Remain out of the danger areas.
Improper It may not Ensure usage of correct fire extinguisher meant
selection of Fire extinguish the fire for the specified fire (for details refer Appendix-
extinguisher C).
Do not attempt to extinguish Oil and electric
fires with water. Use foam cylinders/ CO2/ sand
or earth.
Improper storage Same as above Maintain safe distance of flammable substances
of highly from source of ignition.
inflammable Restrict the distribution of flammable materials
substances to only min. necessary amount.
Construct specifically designed fuel storage
facilities.
Keep chemicals in cool and dry place away from
heat. Ensure adequate ventilation.
Before welding operation, remove or shield the
flammable material properly.
Store flammable materials in stable racks,
correctly labeled preferably with catchment
trays.
Wipe off the spills immediately.
Short circuiting Same as above Don't lay wires under carpets, mats or door
of electrical Can cause ways.
system Electrocution Use one socket for one appliance.
Use only fully insulated wires or cables.
Do not allow open/bare connections.
Provide all connections through 30mA ELCB.
Ensure earthing of machineries and equipments.
(H) Crossing the Personal injury Obey speed limits and traffic rules strictly.
VEHICULAR Speed Limits Always expect the unexpected and be a
MOVEMENT (Rash driving) defensive driver.
Use seat belts/ helmets.
Blow horn at intersections and during
overtaking operations.
Maintain the vehicle in good condition.
Do not overtake on curves, bridges and slopes.
Adverse weather Same as Above Read the road ahead and ride to the left.
condition Keep the wind screen and lights clean.
Do not turn at speed.
Recognize the hazard, understand the defense
and act correctly in time.
Page 575 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
TYPE OF EFFECT OF
HAZARD HAZARD
Consuming Same as above Alcohol and driving do not mix well. Either
alcohol before choose alcohol or driving.
and during the If you have a choice between hitting a fixed
driving object or an on-coming vehicle, hit the fixed
operation object.
Quit the steering at once and become a passenger.
Otherwise take sufficient rest and then drive.
Do not force the driver to drive fast and round the
clock.
Do not day dream while driving.
Falling objects/ May prove fatal Ensure effective braking system, adequate
Mechanical visibility for the drives, reverse warning alarm.
failure Proper maintenance of the vehicle as per
manufacturer instructions.
(I) Bursting of May cause injury Prepare test procedure & obtain EIL/ Owner's
PROOF TESTING piping and prove fatal approval.
(HYDROSTATIC/ Collapse of Provide separate gauge for pressurizing pump
PNEUMATIC tanks and piping/equipment.
TESTING) Tanks flying off Check the calibration status of all pressure
gauges, dead weight testers and temperature
recorders.
Take dial readings at suitable defined intervals
and ensure most of them fall between 40-60% of
the gauge scale range.
Provide safety relief valve (set at pressure
slightly higher than test pressure) while testing
with air/ nitrogen.
Ensure necessary precautions, stepwise increase
in pressure, tightening of bolts/nuts, grouting, etc.
before and during testing.
Keep the vents open before opening any valve
while draining out of water used for hydro-testing
of tanks.
Pneumatic testing involves the hazard of released
energy stored in compressed gas. Specific care
must therefore be taken to minimize the chance
of brittle failure during a pneumatic leak test.
Test temperature is important in this regard and
must be considered when the designer chooses
the material of construction.
Page 576 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
TYPE OF EFFECT OF
HAZARD HAZARD
A pressure relief device shall be provided, having
a set pressure not higher than the test pressure
plus the lesser of 345 KPa (50 psi) or 10% of the
test pressure.
The gas used as test fluid, if not air, shall be
nonflammable and nontoxic.
(J) Person can fall May sustain severe Provide guard rails/barricade at the work place.
WORKING AT down injuries or prove Use PPE like full body harness, life line, helmets,
HEIGHTS fatal safety shoes, etc.
Obtain a permit before starting the work at height
above 3 meters.
Fall arrest and safety nets, etc. must be installed.
Provide adequate working space (min. 0.6 m).
Tie/weld working platform with fixed support.
Use roof top walk ladder while working on a
slopping roofs.
Avoid movement on beams.
May hit the Keep the work place neat and clean.
scrap/material Remove the scrap immediately.
stacked at the
ground or in
between
Material can fall May hit the workers Same as above plus
down working at lower Do not throw or drop materials or equipment
levels and prove from height i.e. do not bomb materials.
fatal All tools to be carried in a tool-kit Bag or on
working uniform.
Remove scrap from the planks.
Ensure wearing of helmet by the workers
working at lower levels.
(K) Suffocation/ Unconsciousness, Use respiratory devices, if reqd.
CONFINED drowning death Avoid over crowding inside a confined space.
SPACES Provide Exhaust fans for ventilation
Do not wear loose clothes, neck ties, etc.
Fulfill conditions of the permit.
Page 577 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
TYPE OF EFFECT OF
HAZARD HAZARD
Check for presence of hydrocarbons, O2 level.
Obtain work permit before entering a confined
space.
Ensure that the connected piping of the
equipment which is to be opened is pressure free,
fluid has been drained, vents are open and piping
is positively isolated by a blind flange.
Presence of Inhalation can pose Same as above plus

foul smell and threat to life Check for hydrocarbon and Aromatic compounds
toxic before entering a confined space.
substances Depute one person outside the confined space for
continuous monitoring and for extending help in
case of an emergency.
Ignition/ flame Person may sustain Keep fire extinguishers at a hand distance.
can cause fire burn injuries or Remove surplus material and scrap immediately.
explosion may occur Do not smoke inside a confined space.
Do not allow gas cylinders inside a confined
space.
Use low voltage (24V) lamps for lighting.
Use tools with air motors or electric tools with
max. voltage of 24V.
Remove all equipments at the end of the day.
(L) Failure of load Can cause accident Avoid standing under the lifted load and within
HANDLING lifting and and prove fatal the operating radius of cranes.
AND moving Check periodically oil, brakes, gears, horns and
LIFTING equipment’s tyre pressure of all moving machinery.
EQUIPMENTS Check quality, size and condition of all chain
pulley blocks, slings, U-clamps, D-shackles, wire
ropes, etc.
Allow crane to move only on hard, firm and
leveled ground.
Allow lifting slings as short as possible and
check gunny packings at the friction points.
Do not allow crane to tilt its boom while moving.
Install Safe Load Indicator.
Ensure certification by applicable authority.
Page 578 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
TYPE OF EFFECT OF
HAZARD HAZARD
Overloading of Same as above Safe lifting capacity of derricks and winches
lifting written on them shall be got verified
equipments The max. safe working load shall be marked on
all lifting equipment’s
Check the weight of columns and other heavy
items painted on them and accordingly decide
about the crane capacity, boom and angle of
erection
Allow only trained operators and riggers during
crane operation.
Overhead Can cause Do not allow boom or other parts of crane to
electrical wires electrocution and come within 3m reach of overhead HT cables.
fire Hook and load being lifted shall preferably
remain in full visibility of crane operators.
(M) Person can fall Person May sustain Provide guard rails for working at height.
SCAFFOLDI- down severe injuries and Face ladder while climbing and use both hands.
NG, prove fatal Ladders shall extend about 1m above landing for
FORMWORK easy access and tying up purpose.
AND Do not place ladders against movable objects and
LADDERS maintain base at 1/4 unit of the working length of
the ladder.
Suspended scaffolds shall not be less than 500
mm wide and tied properly with ropes.
No loose planks shall be allowed.
Use PPE, like helmets, safety shoes, etc.
Failure of Same as above Inspect visually all scaffolding materials for
scaffolding stability and anchoring with permanent
material structures.
Design scaffolding for max. load carrying
capacity.
Scaffolding planks shall not be less than 50x250
mm full thickness lumber or equivalent. These
shall be cleated or secured and must extend over
the end supports by at least 150mm and not more
than 300mm.
Don't overload the scaffolds.
Do not splice short ladders to make a longer one.
Vertical ladders shall not exceed 6m.
Material can Persons working at Remove excess material and scrap immediately.
fall down lower level gets Carry the tools in a tool-kit bag only.
injured Provide safety nets.
Page 579 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
TYPE OF EFFECT OF
HAZARD HAZARD
(N) Personal Can cause injury or Do not take rest inside rooms built for welding
STRUCTU- negligence and casualty machines or electrical distribution system.
RAL danger of fall Avoid walking on beams at height.
WORKS Wear helmet with chin strap and full body
harness while working at height.
Use hand gloves and goggles during grinding
operations.
Cover or mark the sharp and projected edges.
Do not stand within the operating radius of
cranes.
Lifting/ slipping Same as above Do not stand under the lifted load.
of material Stack properly all the materials. Avoid slippage
during handling.
Control longer pieces lifted up by cranes from
both ends.
Remove loose materials from height.
Ensure tightening of all nuts & bolts.
(O) Erection/ Can cause injury Do not stand under the lifted load.
PIPELINE lowering failure Do not allow any person to come within the
WORKS radii of the side boom handling pipes.
Check the load carrying capacity of the lifting
tools & tackles.
Use Safe Load Indicators (SLI)
Use appropriate PPEs.
Other Same as above Wear gum boots in marshy areas.
Allow only one person to perform signaling
operations while lowering of pipes.
Provide night caps on pipes.
Provide end covers on pipes for stoppage of pigs
while testing/ cleaning operations.
(P) Pollution in Can cause personal Ensure the blasting is done in enclosed shed.
GRIT neighboring injury Keep safe distance while blasting operations.
BLASTING area, hit by grits Wear positive pressure blast hood or helmet
and high with view-window, ear-muff/plug, gloves,
pressure air overall or leather coat /apron, rubber shoes.
Page 580 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
APPENDIX-F
TRAINING SUBJECTS / TOPICS

(For contractors’ personnel)
1. The Law & Safety – Statutory Requirement / Applicable statutes / Duties of employer / employee
2. Policy & Administration – Why HSE? / Duties & Responsibilities of Safety Personnel at project
site / Effect of incentive on accident prevention
3. HSE & Supervision – Duties of Supervisor / HSE integrated supervision/ Who should be held
responsible for site accidents?
4. Safety Budget / Cost of Accidents – Direct costs / Indirect costs
5. Hazard Identification / Type of hazards / HIRAC
6. Behavioural Safety & Motivation
7. Housekeeping – Storage / Stacking / Handling of materials / Hydra handling
8. Occupational Health in Construction sector
9. Personal Protective Equipments – Respiratory & Non- respiratory
10. Electricity & Safety – ELCB / Fuse / Powered tools / Project illumination
11. Handling of Compressed Gas – Transportation / Storage / FBAs / Fire prevention
12. Machine Safety – Machine guarding / Maintenance
13. Transportation – Hazards & risks in transp. of materials / ODC consignments
14. Cranes & Other Lifting machinery – Legal requirements vis-à-vis essential safety requirements.
15. Communication – HSE Induction/ TBTs/ Safety Committee/ Safety meeting/ Safety propaganda/
Publicity.
16. Excavation – Risks & Dangers / Safety measures
17. Working at Heights – Use of ladder / Work on roofs / Scaffolds / Double harness lanyards / Life-
line / Fall arrester / Safety Nets / Floor openings
18. Hazards in Welding & important safety precautions
19. Gas Cutting – Hazards & safety measures
20. Fire prevention & fire protection
Page 581 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
APPENDIX - G
CONSTRUCTION POWER BOARD (typ.)
Page 582 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
APPENDIX-H
LIST OF PROCEDURES (MINIMUM) TO BE FORMING PART OF HSE PLAN:-
A. HSE Management Procedures:
 HSE Risk Management (including HIRA)

 HSE Legal Compliance and Other Requirements
 HSE Objectives & Performance
 HSE Training and Competence (including Induction)
 HSE Motivation &Award Scheme
 HSE Audits
 HSE Meetings
 HSE Sub Contractor Management
 HSE Emergency Management
 HSE Incidents Reporting and Management
 HSE Reports
 HSE Management System Review
 HSE Change Management
 HSE procedure for Behaviour based Safety
 First Aid & Management
 Roles, Responsibility, Accountabilities and Authorities
B. Job procedures/ Safe Operating procedures
 Setting Up Site & Signages

 Handling of Electrical Appliances
 Working at Height
 Confined Space Entry
 Permit to Work (including hot works)
 Housekeeping
 Lifting Operations
 Transportation of Materials including Manual Handling
 Compressed Air Tools and Units
 Earthmoving Operations & excavation
 Scaffolding
 Fire Prevention/ Protection
 Hazardous Substance Handling & Storage
 Radiation Hazard
 Personal Protective Equipment
Page 583 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
FORMAT NO. : HSE-1 REV 0

(Sheet 1 of 6)
SAFETY WALK-THROUGH REPORT
(Name & signature of walk through performer to be inserted at the bottom of each page)
Project : _____________ Report no. : ___________
Date : _____________ Contractor : ___________
Inspection by :_____________ Owner : ___________
Frequency : Monthly Job no. : ___________
Note : Write ‘NA’ wherever the item is not applicable

Non
SL. Satisfactory/
ITEM satisfactory/ Remarks Action
NO. Yes
No
1. HOUSEKEEPING
a) Waste containers provided and used
b) Sanitary facilities adequate and Clean
c) Passageways and Walkways Clear
d) General neatness of working areas
e) Other
2. PERSONNEL PROTECTIVE EQUIPMENT
a) Goggles; Shields
b) Face protection
c) Hearing protection
d) Foot protection
e) Hand protection
f) Respiratory Masks etc.
g) Full body harness conforming to CЄ, EN 361
h) Hard hat (HDPE)
i) Other
3. EXCAVATIONS/ OPENINGS
a) Openings properly covered or barricaded
b) Excavations shored
c) Excavations barricaded
d) Overnight lighting provided
e) Other
Safety walk-through performer (Name & Signature) …………………………………………….
Page 584 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 2 of 6)
Non
SL. Satisfactory/
NO. Yes
No
4. WELDING & GAS CUTTING
a) Gas cylinders chained upright
b) Cables and hoses not obstructing
c) Screens or shields used
d) Flammable materials protected
e) Live electrode bits contained properly
f) Fire extinguisher (s) accessible
g) Other
5. SCAFFOLDING & BARRICADING
a) Fully decked platforms
b) Guard and intermediate rails in place
c) Toe boards in place
d) Adequate shoring
e) Adequate access
f) Positive barricading for critical activities
g) Installation of warning signs
h) Other
6. LADDERS
a) Extension side rails 1 m above
b) Top of landing
c) Properly secured
d) Angle + 700 from horizontal
e) Other
Safety walk-through performer (Name & Signature) ……………………………………………..
Page 585 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 3 of 6)
Non
SL. Satisfactory
ITEM satisfactory Remarks Action
NO. / Yes
/No
7. HOISTS, CRANES AND DERRICKS
a) Condition of cables and sheaves OK
b) Condition of slings, chains, hooks and eyes

O.K.
c) Inspection and maintenance log-books
maintained
d) Outriggers used
e) Reverse horn installed / active / coupled with

gear
f) Signs/barricades provided
g) Signals observed and understood
h) Qualified operators
i) Other
8. MACHINERY, TOOLS AND EQUIPMENT
a) Proper instruction
b) Safety devices
c) Proper cords
d) Inspection and maintenance
e) Other
9. VEHICLE AND TRAFFIC
a) Rules and regulations observed
b) Inspection and maintenance
c) Licensed drivers
d) Other
Safety walk-through performer (Name & Signature) …………………………………
Page 586 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 4 of 6)
Non
SL. Satisfactory
NO. / Yes
/No
10. TEMPORARY FACILITIES
a) Emergency instructions posted
b) Fire extinguishers provided
c) Fire-aid equipment available
d) Secured against storm damage
e) General neatness
f) In accordance with electrical requirements
g) Other
11. FIRE PREVENTION
a) Personnel trained & instructed to make use

of facility
b) Fire extinguishers checked periodically &
record maintained
c) No smoking in Prohibited areas.
d) Fire Hydrants not obstructed
e) Regular fire drill conducted
12. ELECTRICAL
a) Use of 3-core armored cables everywhere
b) Usage of 'All insulated' or 'double-insulated'

electrical tools
c) All electrical connection are routed through
ELCB
d) Natural Earthing at the source of power
(Main DB)
e) Continuity and tightness of earth conductor
f) Effective covering of junction boxes, panels

and other energized wiring places
g) Ground fault circuit interrupters provided
h) Prevention of tripping hazards maintained
f) DCP extinguishers arranged & licensed

electrician engaged at site
Safety walk-through performer (Name & Signature) …………………………………………
Page 587 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
AT CONSTRUCTION SITE Page 60 of 90

(Sheet 5 of 6)
Non
SL. Satisfactory/
NO. Yes
No
14. HANDLING AND STORAGE OF
MATERIALS
a) Safely stored or stacked
b) Passageways clear / free from obstructions
c) Fire fighting facility in place
15. FLAMMABLE GASES AND LIQUIDS
a) Containers clearly identified / protected from
fire
b) Safe storage & transportation arrangement
made
c) Fire extinguishers positioned nearby
d) Facilities kept away from electric spark, hot
spatters & ignition source.
16. WORKING AT HEIGHT
a) Approved Erection plan and work permit in
place
b) Safe access, Safe work platform & Safety
nets provided
c) Life lines, Fall arrester, Full body harness
with double lanyards used;
d) Health Check record available for workers
going up?
e) Protective handrails arranged around floor
openings
17. CONFINED SPACE
a) Work Permit obtained from requisite
authority
b) Test for toxic gas and sufficient availability
of oxygen conducted & status
c) Supervisor present at site & at least one
person outside the confined space for
monitoring deputed
d) Availability of safe means of entry, exit and
ventilation (register for entry & exit
maintained)
e) Fire extinguisher and first-aid facility
ensured
f) Lighting provision made by using 24V Lamp
g) Proper usage of PPEs ensured
18. RADIOGRAPHY
a) Proper storage and handling of source as per
BARC/ AERB guidelines (authorized
radiographer available)
b) Work permit obtained
Safety walk-through performer (Name & Signature)…………………………………………
Page 588 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 6 of 6)
Non
SL. Satisfactory
NO. / Yes
/No
c) Cordoning of the area done
d) Use of appropriate PPE's ensured
e) HSE training to workers/supervisors
imparted during the fortnight (indicate topic)
f) Minimum occupancy of workplace ensured
19. HEALTH CHECKS
a) All Workers medically examined and found

be fit for working at heights (slinging,
rigging, painting etc.)
in confined space
in excavation / trenching
in shot blasting
b) Availability of First Aid box with contents
c) Proper sanitation at site, office and labour
camps
d) Arrangement of medical facilities.
e) Measures for dealing with illness at site &
labour camps.
f) Availability of Potable drinking water for
workmen & staff.
g) Provision of crèches for children.
h) Stand by vehicle / ambulance available for

evacuation of injured
20. ENVIRONMENT
a) Chemical and Other Effluents properly

disposed
b) Cleaning liquid of pipes disposed off
properly
c) Seawater used for hydro-testing disposed off
as per agreed procedure
d) Lubricant Waste/ Engine oils properly
disposed
e) Waste from Canteen, offices, sanitation etc.
disposed properly
f) Disposal of surplus earth, stripping materials,
Oily rags and combustible materials done
properly
g) Green belt protection
Safety walk-through performer (Name & Signature) …………………………………………
Page 589 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 1 of 3)
ACCIDENT / INCIDENT REPORT
(To be submitted by Contractor after every Incident / Accident within 24 hours to EIL/ Owner)
Report No.: ____________________________ Date: ______________________

Project site: ____________________________ Name of work: _______________________
Contractor’s name: ________________ Contractor’s Job Engineer (name) ________
Non-disabling injury (Non- Hospitalized but resumed duty before end of 48 hrs
LTA)
Disabling injury (other LTA) Hospitalized & failed to resume duty within next 48 hrs
Fatal (LTA): Death / Expiry
First Aid case (non LTA) Resume duty after first aid
Name of the injured: _______________________ Father's name of victim: _________________

Sub Contractor’s Name: ……………………………………………………………………………….
Gate Pass No.: ……….. Age: _____Yrs. Victim’s medical fitness exam. (Pre-empl.) date: ______
Date & time of Accident / Incident: _______________________________________________

Names of Witnesses: (1) ________________ (2) ___________________ (3) ________________
Profession of victim:
Bar bender Carpenter Meson
Fitter Helper Gas cutter
Grinder Welder Electrician
Driver Rigger M/c. operator
Engineer Manager Other/ specify
Qualification
No formal education Non-Matriculate Matriculate
Graduate Post- grad Other/specify
Job Experience
NIL Less than 2 yrs 2-5 yrs
5-10 yrs 11-15 yrs 15 years and above
Location where the incident happened: ___________________________________________

______________________________________________________________________________
Page 590 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 2 of 3)
Activity / Works that were continuing during incident / accident: -

Excavation Demolition Concrete carrying
Concrete pouring Transportation of materials Transportation of
(manually) materials (mechanically)
Work on or adjacent to water Work at height (+2.0 mts) Scaffold preparation
Scaffold dismantling Piling works Welding
Grinding Gas-cutting Pipe fit-ups & fabrication
Structural fabrications Machine works Hydro-testing works
Electrical works Erection activities Other/specify
What exactly the victim was doing just before the incident / accident? ..........................................
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
Nature of injury:
Bruise or Contusion Abrasion (superficial wound) Sprains or strains
Cut or Laceration Puncture or Open wound Burn
Inhalation of toxic or Absorption Amputation
Poisonous fumes or gases
Fracture Other/specify
Parts of body involved in incident / accident

Head Face Eyes
Throat Arm (above wrist) Hand (including wrist)
Fingers Truck (Abdomen / Back / Throat
Chest / Shoulder)
Leg (above ankle) Foot (incl. ankle) Toes
Multiple Other/specify
Accident type:
Struck against Struck by Fall from Elevation
Fall on same level caught in caught under
caught in between Rubbed or abraded Contact with (Electricity)
Contact with (Temp./ Contact with chemicals or Vehicle accident

extremes) oils
Other/specify
Page 591 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 3 of 3)
Medical Aid provided:- (indicate specific aids / treatment etc.)

………………………………………………………………………………………………………….
…………………………………………………………………………………………………………..
-------------------------------------------------------------------------------------------------------------------------
Actions taken to prevent recurrence of similar incident / accident: ………………………………
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
……………………………………………………………………………………………………………
………………………………………………………………………………………………………...
__________________________________________________________________________________
Intimation to local authorities (Dist. Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ………………………………………………………………………………………..
Safety Officer Site Head / Resident Construction Manager

(Signature and Name) (Signature and Name)
Stamp of Contractor
To : Owner
: RCM/Site-in-charge EIL (3 copies)
Divisional Head (Constn.) through RCM

Project Manager, EIL, through RCM
Page 592 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 1 of 5)
SUPPLEMENTARY INCIDENT / ACCIDENT INVESTIGATION REPORT

TICK THE APPROPRIATE ONE AS APPLICABLE (furnish within 72 hours)
Supplementary to Incident / Accident Report No: ______ (Copy enclosed)
Report No.: ____________________________ Date: ______________________
Project site: ____________________________ Name of work: _______________________
Contractor’s name: ________________ Contractor’s Job Engineer (name) ________
Non-disabling injury (Non- Hospitalized but resumed duty before end of 48 hrs
LTA)
Disabling injury (other LTA) Hospitalized & failed to resume duty within next 48 hrs
Fatal (LTA): Death / Expiry
First Aid case (non LTA) Resume duty after first aid
Name of the injured: _______________________ Father's name of victim: _________________

Sub Contractor’s Name: ……………………………………………………………………………….
Gate Pass No.:……….. Age: _____Yrs. Victim’s medical fitness exam. (Pre-empl.) date: ______
Date & time of Accident / Incident: _______________________________________________

Names of Witnesses: (1) ________________ (2) ___________________ (3) ________________
Profession of victim:
Bar bender Carpenter Meson
Fitter Helper Gas cutter
Grinder Welder Electrician
Driver Rigger M/c. operator
Engineer Manager Other/specify
Qualification
No formal education Non-Matriculate Matriculate
Graduate Post- grad Other/specify
Job Experience
NIL Less than 2 yrs 2-5 yrs
5-10 yrs 11-15 yrs 15 years and above
Location where the incident happened: ___________________________________________

______________________________________________________________________________
Page 593 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 2 of 5)
Activity / Works that were continuing during incident / accident: -
Excavation Demolition Concrete carrying
Concrete pouring Transportation of materials Transportation of
(manually) materials (mechanically)
Work on or adjacent to water Work at height (+2.0 mts) Scaffold preparation
Scaffold dismantling Piling works Welding
Grinding Gas-cutting Pipe fit-ups & fabrication
Structural fabrications Machine works Hydro-testing works
Electrical works Erection activities Other/specify
What exactly the victim was doing just before the incident / accident? ..........................................
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
Particular of tools & tackles being used and condition of the same after incident/accident:
…………………………………………………………………………….........................................
………………………………………………………………………………………………………
Description of Incident/Accident (How the incident was caused):

……………………………………………………………………………………….
………………………………………………………………………………………………………
………………………………………………………………………………………………………
Nature of injury:
Bruise or Contusion Abrasion (superficial wound) Sprains or strains
Cut or Laceration Puncture or Open wound Burn
Inhalation of toxic or Absorption Amputation
Poisonous fumes or gases
Fracture Other/specify
Parts of body involved in incident / accident

Head Face Eyes
Throat Arm (above wrist) Hand (including wrist)
Fingers Truck (Abdomen / Back / Throat
Chest / Shoulder)
Leg (above ankle) Foot (incl. ankle) Toes
Multiple Other/specify
Page 594 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 3 of 5)
Accident type:
Struck against Struck by Fall from Elevation
Fall on same level caught in caught under
caught in between Rubbed or abraded Contact with (Electricity)
Contact with (Temp./ Contact with chemicals or Vehicle accident

extremes) oils
Other/specify
Name & Designation of person who provided First-Aid to the victim: …………………………………
Name & Telephone number of Hospital where the victim was treated _________________________
Mode of transport used for transporting victim – Ambulance / Private car / Tempo / Truck / Others
How much time taken to shift the injured person to Hospital ________________________________
In case of FATAL incident, indicate clearly the BOCW Registration No. of the victim/ Company
……………………………………………………………………………………………
Comments of Medical Practitioner, who treated / attended the victim/injured (attached / described
here) _____________________________________________________________________
What actions are taken for investigation of the incident, please indicate clearly – (Video film /
Photography / Measurements taken etc. ………………………………………………………………..)
Immediate cause (Please tick the right applicable) –

Hazardous methods or Poor housekeeping Inadequate or improper
procedures inadequately PPE
guarded
Environmental hazards improper illumination/ Working on dangerous
(excess noise/ space Moving on oval surface equipment
constraint/ inadequate
ventilation)
Page 595 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 4 of 5)
Failure to secure Horse-play Failure to use PPE
Inattention to surroundings Improper use of hands & By-passing safety devices

body-parts
Unsafe mixing or placement Bypassing standard Failure in communication
of tools & tackles procedures
Operating without authority Improper use of equipment drug or alcoholic
or tools & tackles influence
excessive haste Others(specify)
Basic cause
Over confidence Impulsiveness over-exertion

Faulty judgement or poor Failing to keep attention Nervousness & Fear
understanding constantly
Fatigue Defective vision Ill health or sickness
Slow reaction Others(specify)
Root cause
Inadequate Engg Improper Design Inadequate Planning &

organization
Inadequate knowledge Inadequate skill Inadequate training
Inadequate supervision Improper work procedure Inadequate compliance
with standard
Substandard performance Inadequate maintenance Improper inspection
Others(specify)
Loss of man days and impact on site works, (if any) –
Remarks from Contractor’s Safety Officer/ Engineer –
Was the victim performing relevant tasks for which he was engaged /employed? Yes / No
Was the Supervisor present on work-site during the incident? Yes / No
Have the causes of incident rightly identified? Yes / No
Cause of Accident was_____________________________________________________________
Page 596 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

(Sheet 5 of 5)
Remedial measures recommended by Safety Officer of Contractor for avoiding similar incident in
future :
……………………………………………………………………………………………………………
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
…………………………………………………………………………………………………….……
………………………………………………………………………………………………………….
Intimation to local authorities (Dist. Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ………………………………………………………………………………………..
………………………………………………………………………………………………………….
Safety Officer Site Head / Resident Construction Manager

Stamp of Contractor
To : Owner
: RCM / Site-in-charge of EIL (3 copies)
Project Manager EIL, through RCM
Page 597 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
NEAR MISS INCIDENT/ DANGEROUS OCCURRENCE SUGGESTED PROFORMA

(to be submitted within 24 hours)
 Near Miss : Human injury escaped & no damage to property, equipment or interruption to work.
 Dangerous Occurrence: Damage to property, equipment or interruption of work, but not
resulting in personal injury/ illness, e.g. Fire incident, collapse of structure, crane failure, etc.
Report No.: _________________
Name of Site: _________________________ Date: ______________________
Name of work: __________________________ Contractor: __________________
__________________________________________________________________________________
Incident reported by :
Date & Time of Incident :
Location :
__________________________________________________________________________________
Brief description of incident
__________________________________________________________________________________
Probable cause of incident
__________________________________________________________________________________
Suggested corrective action
__________________________________________________________________________________
Steps taken to avoid recurrence Yes No
To : Owner
: RCM/Site-in-charge EIL (3 copies)

Project Manager EIL, through RCM
Page 598 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

MONTHLY HEALTH, SAFETY & ENVIRONMENTAL (HSE) REPORT
(To be submitted by each Contractor)
Actual work start Date: _______________ For the Month of: __________________
Project: ____________________________ Report No: ________________________
Name of the Contractor: ______________ Status as on : ______________________
Name of Work : _____________________ Job No : __________________________
(Contractor in consultation with EIL shall generate the reports through web based
package(www3.eil.co.in/eilhse)only.
UPTO
THIS
ITEM PREVIOUS CUMULATIVE
MONTH
MONTH
1) Average number of Staff & Workmen
(average daily headcount, not man days)
2)Total Man-hours worked
3) Number of Induction programmes conducted
4) Number of HSE meetings organized at site
5) Number of HSE awareness programmes conducted at site
6) Number of Tool Box Talks conducted
7) Number of Lost Time Accidents (LTA) Fatal
Other LTA
8) Number of Loss Time Injuries (LTI) Fatalities
Other LTI
9) Number of Non-Loss Time Accidents
10) Number of First Aid Cases
11) Number of Near Miss Incidents
12) No. of unsafe acts/ practices detected
13) No. of disciplinary actions taken against staff/ workmen
14) Man-days lost due to accidents
15) LTA Free man-hours i.e. LTA free man-hours counted from the
Last LTA (enter date: ……….)
16) Frequency Rate (No. of LTA per 2 lacs man-hours worked)
17) Severity Rate (No. of man days lost per 2 lacs man-hours worked)
18) Loss Time Injury Frequency (No. of LTI per 2 lacs man-hours
worked)
19) No. of activities for which HIRAC completed
20) No. of incentives/ awards given
21) No. of occasions on which penalty imposed by EIL/ Owner
22) No. of Audits conducted
23) No. of pending NCs in above Audits
24) Compensation cases raised with Insurance
25) Compensation cases resolved and paid to workmen
26) No of Vehicular Accident cases
27) No of fire/Explosion cases
28) Whether workmen compensation policy taken Yes No
29) Whether workmen compensation policy is valid Yes No
30) Whether workmen registered under ESI Act, as applicable Yes No
31) Whether HIRAC Register prepared and updated Yes No
32) Whether Environment Aspect Impact Register prepared and Yes No
updated
33) Whether Legal Register prepared and updated Yes No
Remarks, if any
Date:
Prepared by Safety Officer Approved by Site Head / Resident Construction Manager
To : - OWNER
- RCM EIL (2 copies)
Page 599 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7

PERMIT FOR WORKING AT HEIGHTS (ABOVE 2.0 METER)
(In duplicate to be issued daily for site and for office)
Permit No…………….. Name of Main Contractor…………………………
Name of work executing agency / sub agency / vendor ……………………………………………….…...
Date……………… Exact Location of work……………………………………
Nature of work …………………………………….. Duration of work (from) ………… (to) ……….......
Number of workers covered within this permit ……………………………………………………………
(List enclosed with name & gate pass numbers.)
Sl. Status of compliance

Items / Subjects
No. (Yes / No)
1 Work areas / Equipments inspected
2 Work area cordoned off
3 Adequate lighting is provided
4 Precautions against public traffic taken
5 Concerned persons in & around have been alerted & cautioned
Hazards / risks involved in routine / non-routine task assessed and control
6
measures have been implemented at specific task
7 ELCB provided for electrical connection & found working
8 Ladder safely attached / fixed
9 Scaffoldings are checked and TAGs are found used correctly
10 Working platforms are provided and are found sound /safe for use
Safe access & egress arrangements (e.g. ladders, fall arresters, life-lines etc.)
11
are satisfactorily incorporated
a. Openings on platform / floors are effectively cordoned / covered
12
b. Safety Nets are provided wherever required
Use of following safety gadgets by people working at area under this permit, is
checked and found satisfactory -
Safety helmet
13 Safety harness (full body) with double lanyard
Safety Shoes
Safety gloves
Safety goggles
14 Housekeeping of work area found satisfactorily tidy / clean & clear
Adequate measures have been taken for works being continued at the ground
15
level, when simultaneous works are permitted overhead at that very location.
16 Materials are not thrown from heights on to ground
17 Medical examination of workers are made & found satisfactory
Responsible job engineer / supervisor found physically present at work spot for
18
overall administration of work as well as safety of people.
Above items have been checked & compliance has been found in place. Hence work is permitted to
start / continue at the above-mentioned location. Work shall not start till identified lapses are rectified.
Additional Precautions, if any …………………………………………………………….

……………………………………………………………………………………………..
Work Permit issued by Verification By

Contractor Engineer/ RCM Contractor Safety Officer
AT THE END OF THE DAY/WORK:

All works at height are completed & workmen have returned safely from work location at (time)
………….. (date) ……………
(Sig. Contractor Engineer)
Page 600 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
CONFINED SPACE ENTRY PERMIT

Project site ____________________________ Sr. No. _________________________
Name of the work _______________________ Date ___________________________
Name of Contractor _____________________ Nature of work ___________________
Exact location of work ___________________
Safety Requirements POSITIVE ISOLATION OF THE VESSEL IS MANDATORY

(A) Has the equipment been ?
Y NR Y NR Y NR
 Isolated from  water flushed &/or  radiation sources
power/steam/air steamed removed
 isolated from liquid or  Man ways open &  proper lighting
gases ventilated provided
 depressurized &/or  cont. inert gas flow 
drained arranged
 blanked/ blinded/  adequately cooled 
disconnected
(B) Expected Residual Hazards
 lack of O2  combustible gas/ liquid  H2S / toxic gases
 corrosive chemicals  pyrophoric iron / scales  electricity / static
 heat/ steam / frost  high humidity  ionizing radiation
  
(C) Protection Measures
 gloves  ear plug / muff  goggles / face shield
 protective clothing  dust / gas / air line mask  personal gas alarm
 grounded air duct/ blower/  attendant with SCBA/air  rescue equipment/
AC mask team
 Fire fighting arrangements  safety harness & lifeline  communication
equipment
  
Authorization / Renewal (It is safe to enter the confined space)
Signature Time Signature
No. of Contractor's Contractor's From To Workman
Name of persons
persons Supervisor Safety
allowed
allowed Officer
Permit Closure :
(A) Entry  was closed  stopped  will continue on .................
(B)  Site left in a safe condition  Housekeeping done
(C) Multilock  removed  key transferred

 Ensured all men have come out  Man-ways barricaded
Remarks, if any:
Page 601 of 851

HEALTH, SAFETY &
6-82-0001 Rev. 7
RADIATION WORK PERMIT
Project : Sr. No. :

Name of the work : Date :
Name of site contractor : Job No. :
Location of work :
Source strength :
Cordoned distance (m) :
Name of Radiography agency : Approved by Owner/EIL
No. of workers engaged :

The following items have been checked &compliance shall be ensured during currency of the
permit:
S. No. Item description Done

Safety regulations as per BARC/AERB ensured while source in use/in transit & during
storage
Area cordoned off / safe working platform provided
Lighting arrangements for working during nights ensured
Warning signs/ flash lights installed
Cold work permit taken (if applicable)
PPEs like film badges, dosimeters used
Additional precautions, if any ______________________________________________________
(Radiography Agency’s BARC/AERB authorized Supervisor)
Permission is granted.
Permit is valid from ___________ AM/PM ____________ Date to ___________ AM/PM _________
Date
(Signature of permit issuing authority of site contractor)

Name: Designation: Date:
Permit renewal:
Sign. of issuing
Additional precautions
Permit extended upto authority with date
required, if any
(of site contractor)
Date Time
Work completed/ stopped/ area cleared at ________ Hrs of Date ______________

(Sign. of permit issuing authority)
Name & Signature of site contractor:
Page 602 of 851

HEALTH, SAFETY & 6-82-0001 Rev. 7
AT CONSTRUCTON SITE Page 75 of 90

DEMOLISHING/DISMANTLING WORK PERMIT
Project : Sr.No. :
Name of contractor : Job No. :
Name of sub-contractor : No. of workers to be engaged:

Line No./ Equipment No./ Structure to be dismantled :

Location details of dismantling/ demolition with sketch : (clearly indicate the area)
The following items have been checked &compliance shall be ensured during currency of the
permit:
S. Item description Done Not

No. Applicable
Services like power, gas supply, water, etc. disconnected
Dismantling/ Demolishing method reviewed & approved
Usage of appropriate PPEs ensured
Precautions taken for neighbouring structures
First-Aid arrangements made
Fire fighting arrangements ensured
Precautions taken for blasting
(Contractor’s Supervisor) (Contractor’s Safety Officer)
Permission is granted.
(Permit issuing authority)
Name :
Date :
Completion report :
Dismantling/ Demolishing is completed on _____________ Date at ____________ Hrs.
Materials/ debris transported to identified location Tagging completed (as applicable)
Services like power, gas supply, water, etc. restored
(Permit issuing authority)
CONTRACTOR’s NAME
Page 603 of 851

HEALTH, SAFETY & ENVIRONMENTAL
6-82-0001 Rev. 7
MANAGEMENT
DAILY SAFETY CHECKLIST

(To make use of before start of day’s work)
Project : Sr. No. :

Description of Job decided to perform : -
 Use of PPE / Safety Gadgets
Sl. Compliance Sl. Compliance

PPEs PPEs
No (Yes / No) No (Yes / No)
1 Safety Helmets 6 Face Shield
2 Safety Shoes 7 Full body harness
3 Hand Gloves 8 Fall Arrest System
4 Dust Musk 9 Safety net
Horizontal life-line made
5 Safety Goggles 10 of steel wire, (dia not
less than 8.0 mm.)
(Serial No. 1 & 2 are compulsory for everyone. Specify & ensure use of other safety gadgets as required for the job)
 Identify following important unsafe conditions: -
Sl. No Conditions Yes / No

1 Access to work site / emergency escape clear
2 Soil / Loose earth kept away from excavated pit / slope / ladder provided
Electrical wire / welding lead lying entangled on ground / welding m/c. booth
3
accessible
4 Elevated work platform / open ends are protected
Ground area cordoned off before lifting works or erection at height / ground
5
area checked & cordoned-off before start of height works
Structural members / erected pipes / wooden boards/pieces etc. are safely
6 anchored at heights and are not likely to fall down on people when working
beneath
Rope ladders tied-up on tall steel structures, long before are removed to get
7
rid of their use
8 Any Other
 Indicate actions taken, if status of any of the above items is found “No”
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
 Specific Safety guidelines / precautions, if any (communicated thro’ TBT)

……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
 Above conditions and PPE compliances are checked by undersigned and correct status are
indicated after verification
Inspected by Verification By
Contractor Engineer Contractor Safety Officer
Page 604 of 851

6-82-0001 Rev. 7
MANAGEMENT

(Sheet 1 of 2)
HOUSEKEEPING ASSESSMENT& COMPLIANCE
Project : Sr. No. :
Name of contractor : Fortnightly
Sl. Satisfactory/ Non-

No.
Subjects of Review Remarks Action
Yes satisfactory/ No
1. Cleanliness at the Main entry / access of site
2. Ground condition / floor areas free from water-
logging / oil spillage
3. Ground & elevated floors free from rubbish /
wastes / accumulated debris / scraps.
4. Manholes / openings are covered / fenced
5. Trenches are barricaded / walkways are in place
6. Drains are cleaned / not choked / not occupied
by dumped materials
7. Sufficient CAUTION boards / instructions
displayed
8. Construction machinery are maintained &
parked in orderly manner.
9. Movement of site people are not obstructed
because of dumping / storing of construction
materials
10. Access/ egress to Electrical Distribution Boards/
Panels clear from wires / cables / earth-strips etc.
11. Electrical panel rooms / sheds / MCC / Control
rooms / Substations etc. are clean & tidy and not
used for storing dress / clothes, tiffin-box or
bicycles.
12. Passage behind Elec. panels are free for access
13. Fire extinguishers / fire-buckets are accessible
without any difficulty.
14. Stair-steps, platforms & landings are clear & tidy
15. Sheds / rooms & work areas have got sufficient
illumination as well as ventilation.
16. Cables / Wires / welding leads are routed /
hanged appropriately & are not creating unsafe
condition.
17. Stacking / storing of insulation materials or their
packing.
18. Removal or cleanliness of left-over sand,
concrete, brick-bats, insulation-materials, excess
earth, wastes etc.
19. Storing / stacking of sand, metal chips, re-bars,
steel pipes, valves, fittings etc.
20. One escape route at ground & minimum two
escape routes at elevation available.
Page 605 of 851

6-82-0001 Rev. 7
MANAGEMENT

(Sheet 2 of 2)
Sl. Satisfactory/ Non-
No.
Subjects of Review Remarks Action
Yes satisfactory/ No
21. Captions / Posters / Slogans on various safety
instructions are displayed legibly in local
language
22. Cable trenches are water-free or regular
arrangement for taking out accumulated water
exists.
23. Windows of rooms / offices are regularly
cleaned
24. Facilities for cycle sheds, drinking water,
washing, rest-rooms etc. are maintained in tidy
manner.
25. Toilet, Urinals, Canteen / kitchen / pantry etc.
are maintained & free from obnoxious smell.
26. Construction tools / tackles are stored
systematically - the items are tagged / tested /
certified by competent third party.
27. Sufficient numbers of Dust-bins / Waste-bins
found at site and are regularly emptied.
Additional remarks, if any -

………………………………………………………………………………………………………………
………………………………………………………………………………………………………………
……………………………………
Page 606 of 851

6-82-0001 Rev. 7
MANAGEMENT
INSPECTION OF TEMPORARY ELECTRICAL BOOTH / INSTALLATION

Project : Sr. No. :
Sub Station No:/Booth No Location:
SL
SUBJECTS OBSERVATION (YES /NO) ACTION TAKEN
NO
Switchboards installed properly are in order and
1
protected from rain & water-logging.
Adequate illumination provided for switchboard
2 operation during night hours & the lamps are protected
from direct human contact.
Voltage ratings, DANGER signs, Shock-Treatment-
3
Chart displayed in the installation / booth
Fire extinguisher (DCP or CO2) & Sand Bucket kept in
4
close vicinity of Switchboards
Valid License & Competent Electrician / Wireman
5 available & name/ license no. displayed at booth /
installation.
General housekeeping in & around booth / installation
6
found in order.
7 Cable-route-markers for U/G cables provided.
Monthly inspection report of Electrical hand tools
8
available in booth / installation.
9 Insulated Mat provided in front of Elec. Panels.
10 Rubber hand gloves available/ used by Electricians
Availability of CAUTION boards for shutdown & / or
11
repairing works.
All incoming & outgoing feeders have proper MCCB /
12
HRC fuses / Switches.
Switchboards “earthed” at two distinctly isolated
13
locations.
Switchboards have adequate operating space at the front
14
face & at the rear face too.
15 All connections provided through 30mA ELCB.
16 Testing records of all ELCBs available at site
17 Only industrial type plugs & sockets are used.
Temporary connections are 3-core double insulated &
18 free from cuts & joints and 3rd core is earthed at both
ends
Socket boards are properly mounted on stand &
19
protected from water ingress.
Electrical equipments operating above 250V have two
20
earthing / double earthing.
All incoming / outgoing cables are properly glanded &
21
terminated with “lugs”.
22 Switch-boards are of industrial variety / type.
Sketch for installation / connection (SLD) made &
23
pasted& other safety labels/display boards
24 Labeling of incoming / outgoing feeders made.
25 All hand lamps are protected from direct contact.
26 All electrical cable / joints are in safe condition
Page 607 of 851

6-82-0001 Rev. 7
MANAGEMENT

(Sheet 1 of 2)
INSPECTION FOR SCAFFOLDING
Project : Sr. No. :
Sl. Actions
Description Yes No N.A
No taken
1 Whether work permit is obtained to take up work at height above 1.5 Mts?
Whether atmospheric condition is “stormy” or “raining” and works at
2
heights have been permitted?
3 Whether steel pipes scaffoldings are used for units /off-site areas?
Whether scaffolding has been erected on rigid/firm/leveled surfaces /
4 ground? Whether “foot-seals” or “base-plates” are used beneath the up-
rights (vertical steel pipes)
Whether scaffold construction is as per IS specification with toe-board and
5
hand-rails (top-rail as well as mid-rail)?
Whether distance between two successive up-rights are less than 2.5 Mts
6 (height of scaffold & load carrying capacity governs the distance between
two uprights)
Whether all uprights are extended at least 900 mm above the top most
7
working platform (to enable fitting of handrails)?
Whether vertical distance of two successive ledgers is satisfactory?
8
(varying between 1.3 Mts. To 2.1 Mts)
Whether the peripheral areas of working at height are cordoned-off? (for
9
avoiding accident to people arising out of dropped / deflected materials)
10 Whether platform is provided? Is it safely approachable?
Whether end of scaffold platform / board are extended beyond transoms?
11
(125mm to 150 mm)
Whether CE / IS approved quality and worthy conditioned full-body safety
12 harness (with double lanyard & karabiners) are used while working at
heights?
Whether life-line of safety harness is anchored to an independent secured
13
support capable of withstanding load of a falling person?
Whether the area around the scaffold is cordoned off to prohibit the entry of
14
unauthorized person / vehicle?
Whether clamps used are of good condition, of adequate strength and free
15
from defects?
16 Whether ladder is placed at secured and leveled surface?
17 Whether water-pass and oil-spills are avoided around the scaffold structure?
18 Whether ladder is extended 1.5mts. above the landing point at height?
19 Whether more than one access/egress provided to the scaffold?
Whether ladder used are of adequate length and overlapping of short
20
ladders avoided?
Whether metallic ladders are placed much away from near-by electrical
21
transmission line?
22 Whether rungs of ladder are inspected and found in good order?
23 Whether fall-arresters provided on both the access/egress routes?
Whether diagonal (cross) bracings are provided at regular interval on the
24
scaffold?
Whether working platform on the scaffold has been made free from “jolt”
25
or “gap”?
Whether tools or materials are removed after completion of the day’s job at
26
heights?
Whether a valid Permit for Work (PFW) is obtained before taking up work
27
over asbestos or fragile roof?
28 Whether sufficient precaution is taken while working on fragile roof?
Page 608 of 851

6-82-0001 Rev. 7
MANAGEMENT
(Sheet 2 of 2)
Sl. Actions
Description Yes No N. A
No taken
Whether provision is made to arrange duck ladder, crawling board for
29
working on fragile roof?
Whether scaffold has been inspected by qualified civil engineers prior to
30
their use?
Whether the scaffolding has been designed for the load to be borne by the
31
same?
Whether the erection and dismantling of the scaffolding is being done by
32
trained persons and under adequate supervision?
Whether safety net with proper working arrangement and life-line has
33
been provided?
Whether TAGS (Green for acceptable and Red for incomplete/unsafe
34
scaffolds) are used on scaffolds?
Whether sufficient illumination is provided in and around the scaffold
35
and access?
Whether emergency rescue / response arrangements are made in place
36
Page 609 of 851

6-82-0001 Rev. 7
MANAGEMENT

(sheet 1 of 2)
PERMIT FOR ERECTION / MODIFICATION & DISMANTLING OF SCAFFOLDING
Project : Sr. No. :
Nature of activities : Duration: From………To…………
SL. NOT
SUBJECTS / ITEMS DONE REMARKS
No. DONE
Specific task of Erection / Modification / Dismantling of scaffolds,
1 identified & TAGGED accordingly (before as well as after carrying-
out jobs).
People engaged in doing the job are identified & are certified by Job Names to be
2
Engineer of Main Contractor as experienced / trained. noted
Concerned persons are alerted by the Job Engineer of Main Contractor
3 in connection with possible hazards & what the workmen MUST do /
MUST not do.
Verification by Job Engineer of Main Contractor made for confirming
that all persons permitted to carry-out the jobs are making use of
4
Helmet, Safety Shoes, Goggles, Gloves & Double lanyard safety
harness and other relevant PPEs.
5 Area of work is effectively cordoned-off / barricaded / illuminated.
For taking-up / lowering down Scaffolding members / clamps /
couplings etc. appropriate ropes / pulleys/ chains etc. have been
6
arranged for use (not to throw any item) & the same have been
verified as “fit for purpose”.
Items / members of scaffold, being lowered are removed from the area
7
& stacked correctly.
Ropes, chains, pulley blocks etc. being used for lifting or lowering
scaffold items, are inspected by the Job Engineer & their certifications
8
as well as physical conditions have been found O.K, before signing
this PERMIT.
Safety Net / Life-line / Fall Arresters etc. are arranged in position and
9 Job Engineer has found working conditions favourable for activities to
start.
Scaffold erection or dismantling tasks are being supervised by
10
Experienced Engineer / Competent person.
Only competent & experienced people have been selected / engaged in
11
Scaffolding erection, modification or dismantling tasks.
Adequate & effective actions for traffic and movement of people
12
around the cordoned-off area taken to avoid inadvertent incident
13 Working platforms are protected with handrails & toe-boards.
14 Access & Exit (for reach & escape) are safe for use by people.
Tools, tackles to be used for above jobs are verified by job Engineers
15 of Main contractor as genuinely good and tied-up at height (to prevent
their fall).
16 Site important Telephone Nos. are made known to everyone
SOP (Safe Operating Procedure) for the specific task is made &
17
followed too.
18 Emergency vehicle has been arranged at work locations.
 This permit for work shall be available at specific work location all the time.
 After completion of work, permit shall be returned to safety cell of main contractor, without fail.
 This Permit shall be issued maximum upto (Monday to Sunday).
 Additional Precautions, if any
…………………………………………………………………………………………………………………
 ACCORD OF PERMISSION (to be ticked) - YES ( ) / NO ( )
Page 610 of 851

6-82-0001 Rev. 7
MANAGEMENT

(sheet 2of 2)
Everyday Site working conditions & performance of workmen shall be assessed / checked by Contractor
Site Engr. and Safety Officer shall verify the same.
Name / Sign. MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY

Site
Engr.
Safety
Off.
Page 611 of 851

6-82-0001 Rev. 7
MANAGEMENT
PERMIT FOR HEAVY LIFT / CRITCAL ERECTION
Project : Sr. No. :

Nature of activities : Duration: From………To…………
Location of work : Name /Type of crane :
Equipment/Structure to be erected: Wt. of equipment/ structure to be erected :
SL. COMPLIANCE STATUS
Description of Item
NO. Remarks
Yes No Not applicable
Is the crane type suitable for lift or as per erection
1
procedure?
Is the crane have the correct number of counterweights
2
fitted?
Availability of Load Certification of crane from
3
authorized agency.
Is the load chart of crane available in carne cabin/or with
4
Crane operator?
Is the device to check the Wind speed in crane is working?
5
Is the safety features in crane are working?
Availability of Load certification of slings and other
6
accessories from authorized agency
Availability of Licensee/certificate for crane operator from
7
authorized agency.
8 Availability of approved HIRAC for the subject activities.
9 Availability of approved erection/rigging procedures.
Availability of temporary gratings/ platforms for critical
10
lifting(as applicable)
11 Tool Box conducted before erection?
12 Has the area been cordoned off?
13 Are the authorized persons during erection are identified?
Does each person identified for erection understand their
14
roles and responsibilities?
Is the ground on which crane will rest or outrigger support
15
are correct?
16 Is hard stand requirement (if any) complied?
Is the communication system (viz. walkie talkies, etc. are
17
working properly?
If more than one crane is lifting the load, is an
18
Intermediate rigger will supervise the lift?
If there is other obstruction within the operating radius of
19 the crane, have correct precautions been taken to prevent
collision?
20 All the persons are wearing the requisite PPE?
Inspected & Issued by Verification By

Contractor Engineer/RCM Contractor Safety Officer
Page 612 of 851

6-82-0001 Rev. 7
MANAGEMENT
PERMIT FOR ENERGY ISOLATION & DE-ISOLATION
Project : Sr. No. :

ENERGY ISOLATION PERMIT
 Clearance required from: ……... Hrs ……… Date To ……….. Hrs ……………. Date
 Name of equipment/ energy source etc. ………………………………………………………………….
 Nature of job to be done: ………………………………………………………………………………….
 Area: …………………………. Location: …………………………………………………………………..
PERMIT VALIDATION PERFORMING AUTHORITY

I hereby authorize the …………..personnel (performer) The work and precautions will be carried out under my
to isolate the above equipment/energy source from all overall responsibility.(Testing/execution engineer)
sources of power and handover the equipment/energy
source for maintenance/repair.
Signature: Date:
Issuing authority Name:
Area –Incharge/RCM
Signature: Date:
Name:
SAFETY PRECAUTIONS FOR CLEARANCE NORMALISING AFTER CLEARANCE

1. Notify workers of intent to de- energize 1. Notify workers of intent to re- energize
2. Obtain lock, tag or locking/tagging devices 2. Conduct visual inspection to confirm that the
3. Shut down, de-energize, dissipate any danger zone is clear of workers
residual energies. 3. Conduct visual inspection to confirm that tools,
4. Apply lock ,tag and locking and/or tagging equipment’s danger zone is clear of workers
devices 4. Reposition the safety devices (interlocks,
5. *Any other job specific precautions valves, guards, covers, sensors, as applicable, etc.)
6. Verify effectiveness of lockout by 5. *Any other job specific normalizing details
attempting to restart. 6. Remove lock, tag and locking and/or tagging
7. Proper PPE is ensured devices.
7. Re-energize.
I certify that the energy source mentioned above is 8. Confirm system is operating properly & safely.
isolated from all sources and is safe to start the work. I certify that the energy source mentioned above is
isolated from all sources and is safe to start the work.
Tag No: …… Lock No: ………….
Tag No: …… Lock No: ………….
Issuing authority Issuing authority
Area –Incharge /RCM Area –Incharge /RCM
Signature: Date: Signature: Date:
Name: Name:
(*to be included by contractor in consultation with (*to be included by contractor in consultation with
EIL/owner) EIL/owner)
ENERGY DE-ISOLATION PERMIT
PERMIT VALIDATION PERFORMING AUTHORITY
I hereby authorize the …………..personnel (performer) I hereby certify that the equipment/energy source
to de- isolate the above equipment/energy source from mentioned above has been de-isolated and is ready for
all sources of power and handover the equipment/energy normal operation. (Testing/execution engineer)
source for normal operation..
Issuing authority Signature: Date:

Area –Incharge/RCM Name:
Signature: Date:
Name: Countersigned by Issuing authority
Page 613 of 851

6-82-0001 Rev. 7
MANAGEMENT
PERMIT FOR EXCAVATION (depth 2m and above)

(Sheet 1of 2)
Project : Sr. No. :
Job Description : Location:
Size of excavation :
COMPLIANCE STATUS
SL.
Description of Item Not Remarks
NO. Yes No
applicable
1 Suitable and sufficient risk assessments and method statements
has been carried to ensure that the work shall be undertaken in
accordance with specification and standard.
2 Are plans/details of underground services available and the
same has been reviewed?
3 Has survey done to locate the services/obstacles etc.
4 Has the live services (electrical, water line, air line, telephone
line, etc.) has been disabled for carrying out the job.
5 Is adequate barriers/ fences to protect the excavation are in
place?
6 Is Adequate warning signs are in place?
7 Is Assessment of ground conditions done and remedial action (if
any) taken?
8 Safe access / egress (e.g. ramp / steps / ladders etc.) provided for
site workmen & supervisors.
9 Is the excavation work being undertaken in proximity of
structure, etc.? If Yes, it’s effect is considered?
10 Availability of competent person for supervising the excavation
work?
11 Adequate safe arrangement to prevent collapse of edges (e.g.
shoring / strutting / benching / sloping etc.) made at site.
12 Hard barricades (at least 1.0M away from edge & for excavation
near site access roads) with warning signs/caution boards are
provided
13 Accumulation / passage-ways of water at periphery of
excavation / trench stopped/ restricted.
14 Is the equipment being used for excavation has been checked for
adequacy and is in good working condition having all the safety
features?
15 Age & fitness of workmen ensured by medical test before
engagement in job?
16 Arrangement of Monitoring of possible oxygen deficiency or
obnoxious gases done & action taken?
PERMIT GRANTED - Yes / No
Name & Signature of Site Engr. Name & Signature of Safety Officer
Contractor (Initiator) Contractor (Issuing authority)
Page 614 of 851

6-82-0001 Rev. 7
MANAGEMENT
PERMIT FOR EXCAVATION

(Sheet 2of 2)
NOTES: -
1. Slopes or benches for excavation beyond 2.0M depth shall be designed & approved by Contractor’s site
head.
2. Excavated earth to be kept at least 1.5M away from edges.
3. Safety helmets, Safety shoes or gum-boots, gloves, goggles, Face shield, Safety Harness shall be essential
PPEs.
4. Permit shall be made in duplicate and original shall be available at site of work.
5. Permit shall be issued for maximum one week only (Monday to Sunday).
6. After completion of works, permit shall be closed & preserved for record purpose.
GRANT OF PERMIT AND EXTENSIONS
Issuing authority
Initiator (site Review by EIL /
Sl. Validity period Working Time (Safety Officer
Engr. of Main Owner (Remarks
No. From ____To ____ From _____To _____ of Main
Contractor) with date
Contractor)
1.
2.
3.
4.
5.
6.
7.
Additional safety instructions if any: -

1.
2.
3.
Page 615 of 851

Page 616 of 851
STANDARD SPECIFICATION FOR HEALTH, SAFETY & STANDARD SPECIFICATION No.

ENVIRONMENTAL MANAGEMENT 6-82-0001 Rev. 7
FORMAT NO. : HSE-18 REV 0 (Sheet 1of 2)
IDENTIFICATION OF ENVIRONMENTAL ASPECTS, IMPACT ASSESSMENT AND CONTROL MEASURES
Risk Signific
Environmental Environment Control Consequences Gaps/
S. No Activity N/A/E Level ant
Aspect Impact Measures Recommendations
A B C D E F G Yes/No

Page 617 of 851

(Sheet 2 of 2)
INITIAL ENVIRONMENT REVIEW TECHNIQUE
WP = Water LC = Land DNR = Depletion of

Environmental Impacts AP = Air Pollution NP = Noise Pollution
Pollution Contamination Natural Resources
Legal and other

Scale Quantity (A) Occurrence (B) Severity of Impact (C) Detection (D) Control (E)
requirements (F)
Available & effective at In compliance or not
1 Negligible Very Rare Negligible visual impact Immediately
place applicable
Once a month or Causes Discomfort or Has in-built Secondary
2 Low Within 1 hour
less Nuisance control
3 Moderate Once a day Resource Depletion Within 8 hours Needs human Intervention
Several times a Affects Aquatic Life, flora, Mechanism in place but

4 High Within 24 hours
Day fauna or global issue not reliable
Absent or no effective
5 Excessive Continuous Human health effect More than 24 hours Not in compliance
control
Risk Level - G : A x B x C x D x Ex F
Aspects with score of 100 and above are considered as significant.

Also, Irrespective of the score, all legal noncompliance’s to be considered as significant
Condition
N NORMAL
A ABNORMAL
E EMERGENCY

Page 618 of 851

FORMAT NO. : HSE-19 REV 0 HIRAC
RECOMENDED
CONTROL
DESIRED CONTROLS &
RISK IDENTIFICATION RISK ASSESSMENT ACTIONs TO ACTION BY REMARKS
EXISTING GAPS, IF ANY
REDUCE THE
RISK LEVEL
S. Activity Activity Hazards Condition Associate Desired Control Gaps If Any Probabil Impact Risk Risk
No. type (N/AN/E) d Risk Measures ity (P) (I) R= P*I Classifi
(R/NR) cation
Likelihood – Possibility of occurrence of risks based on present gaps (technological / operational / competence / measurement and monitoring);
UL: Unlikely, L: Likely, VL: Very Likely, FR: Frequent, C: Continuous
Impact –
SI: Slight Injury, MI: Minor Injury, MJ: Major Injury, SF: Single Fatality, MF: Multiple Fatalities
Level of consequence – Refer Guidance criteria for this i.e. possible degree of damage;
Condition- N: Normal, AN: Abnormal, E-Emergency
Activity Type: R- Routine, NR- Non Routine
RISK –
L: Low Risk, M: Moderate Risk, H: High Risk

INSPECTION & TEST PLANS STANDARD SPECIFICATION No.
ENGINEERS CIVIL, STRUCTURAL &
INDIA LIMITED 6-82-3100 Rev 0
• I elc•cr,W 051,44.1, IA Govt of indla Undertakmg) ARCHITECTURAL WORKS Page 1 of 64
furqw,
kTt) ct) f9Tivur titkcrur
(3Trzlift)
($147cbui *ira
INSPECTION & TEST PLAN (ITP) FOR

CIVIL, STRUCTURAL &
ARCHITECTURAL WORKS
(ITEM RATE CONTRACTS-WITH
CATEGORIZATION)
0 14.01.2014 ISSUED AS STANDARD SPECIFICATION

SM DJ RKD SC
Standards Standards
Rev. Prepared Checked Committee Bureau
Date Purpose by Convenor Chairman
No by
Approved by
Page 619 of 851

INSPECTION & TEST PLAN STANDARD SPECIFICATION No.
CIVIL, STRUCTURAL & 6-82-3100 Rev 0
ARCHITECTURAL WORKS Page 2 of 64
Abbreviations:
AFC : Approved For Construction

BM : Bench Mark
CI : Cast Iron
CPT : Cone Penetration Test
GI : Galvanised Iron
IRC : Indian Road Congress
JB : Junction Box
MS : Mild Steel
MPT : Magnetic Particle Testing
PCC : Plain Cement concrete
PQR : Procedure Qualification Record
PT : Penetration Testing
PVC : Poly Vinyl Chloride
PWHT : Post Weld Heat Treatment
RF : Reinforcement
SPT : Standard Penetration Test
U/G : Under Ground
WBM : Water Bound Macadam
WPS : Welding Procedure Specification
Convenor: Mr. RK Das ,ED (Construction)
Members : Mr. M Natarajan, GM (C&P)

Mr M Deshpande, GM(Construction)
Mr. Rakesh Nanda, GM (Piping)
Mr. Janak Kishore, DGM (P)
Mr S.Mukherjee, DGM (Constn)
Mr D Jana, AGM (Constn)
Page 620 of 851

CONTENTS
S. DOCUMENT ISSUE PAGE

DESCRIPTION
NO NO. DATE NO.
SECTION A
ITPS FOR CIVIL WORKS
1. Land and Topographical survey 3101 Rev 0 14.01.2014 6
2. Soil Investigation 3102 Rev 0 14.01.2014 7
3. Site Grading 3103 Rev 0 14.01.2014 8
4. Excavation 3104 Rev 0 14.01.2014 9
5. Backfilling 3105 Rev 0 14.01.2014 10
6. Underground Piping (RCC/CI) 3106 Rev 0 14.01.2014 11
7. WBM Roads 3107 Rev 0 14.01.2014 12
8. Black Topping(Premix Carpeting) 3108 Rev 0 14.01.2014 13
9. Tank Pads 3109 Rev 0 14.01.2014 14
10. Micro Grading 3110 Rev 0 14.01.2014 15
11. Under Ground Piping (Carbon 3140 Rev 0 14.01.2014 16
ITPS FOR STRUCTURAL WORKS
12. Plain cement concrete 3141 Rev 0 14.01.2014 22
13. RCC(Substructure) 3142 Rev 0 14.01.2014 23
14. RCC(Super structure) 3143Rev 0 14.01.2014 24
15. Flooring/Pavement 3145 Rev 0 14.01.2014 25
16. Brick Work 3146 Rev 0 14.01.2014 26
17. Structural Works 3147 Rev 0 14.01.2014 27
18. Piling works 3148 Rev 0 14.01.2014 28
ITPS FOR ARCHITECTURAL WORKS
19. Antitermite Treatment 3171 Rev 0 14.01.2014 29
20. Plastering 3172 Rev 0 14.01.2014 30
21. Doors and Windows 3173 Rev 0 14.01.2014 31
22. Painting (building works) 3174 Rev 0 14.01.2014 32
23. Sanitary fittings 3175 Rev 0 14.01.2014 33
24. Water proofing 3176 Rev 0 14.01.2014 34
25. False Flooring and False ceiling 3177 Rev 0 14.01.2014 35
26. Under Deck Insulation 3178 Rev 0 14.01.2014 36
27. Roofing Accessories 3179 Rev 0 14.01.2014 37
28. Lighting works (Non plant 3199 Rev 0 14.01.2014 38
SECTION B
FORMATS FOR CIVIL/STRUCTURAL/ARCHITECTURAL WORKS 40
SECTION C
FORMATS FOR UNDERGROUND PIPING WORKS 55
Page 621 of 851

SECTION - A
Page 622 of 851

GENERAL NOTE
The enclosed ITP's shall be followed for the works to be performed by the contractor. The
provisions indicated for stagewise inspection by EIL/Owner are the minimum and the Engineer-In-
Charge may decide to increase Hold Points/ Witness Points. Activities for which ITP's are not
given, contractor to develop and get the same approved by EIL/Owner well before start of the work.
Contractor to submit required reporting formats and job procedures for each activity listed in ITP's
and submit to EIL/Owner for approval, well before commencement of the activity. If the contractor
has to deviate from the given ITP for a valid reason, he shall obtain prior written approval of
EIL/Owner. Contractor to carry out 100% examination of all activities.
LEGEND
HP : Hold Point ;
A point which requires witnessing/inspection/verification and acceptance by Owner/EIL

before any further processing is permitted.
The Contractor shall not process the activity/item beyond a Hold Point without written
approval by Owner/EIL except where prior written permission for further processing is
available.
W : Witness Point ;
An activity which requires witnessing/inspection/verification by Owner/EIL when the

activity is performed.
After proper notification has been provided (notification modalities and period shall be
finalized before hand), the Contractor is not obliged to hold further processing if
Owner/EIL is not available to witness the activity or does not provide comments before
the date notified. Basis of acceptance shall be as per relevant technical specification.
Rw : Review of Contractor’s documentation.
S : Surveillance Inspection by Owner/ EIL.

Monitoring or making observations to verify whether or not material/items or services
conform to specified requirements. Surveillance activities may include audit, inspections,
witness of testing, review of quality documentation & records, personnel qualifications,
etc.
WC : 100% Examination by Contractor.
Responsibility for execution of the inspection/testing is with the Contractor; Owner/EIL only
verifies examination or testing done by the Contractor at important stages
Page 623 of 851

ITP NO.: 3101 Rev 0
LAND & TOPOGRAPHICAL SURVEY
Sl. Records to be submitted/

Activity Contractor EIL
No. Format No.
1 Boundary markings and submission of WC S Yes

drgs./sketches
2 a) Review of calibration certificates of WC HP Yes/ Format C1
instruments/ testing equipments
b) Field calibration, if any WC W Yes/
3 Block levels, contour plans, establishing WC W Format C2

permanent bench marks with ref. to Survey
of India B.Ms. by check levels and
submission of relevant drgs. & records
4 Protection of control points, permanent WC S -

bench marks and regular rechecking
5 Submission of Master plan showing WC S Yes

monuments, structures exposed rocks,
weirs, water works, ponds, underground
services if crossing that area, etc.
INSPECTION & TEST DOCUMENTS
Review Test and Inspection Documents WC Rw Yes
Page 624 of 851

ITP NO.: 3102 Rev 0
SOIL INVESTIGATION

No. Format No.
1. Positioning of test location WC S -

2. a) Review of calibration certificates of WC HP Yes /Format C1
b) Field calibration, if any WC W Yes
3. Boring & sampling WC S -
4. In-situ testing (SPT, CPT, Plate load test, WC S/Rw Yes
Soil Resistivity, Block vibration test, etc.)
5. Lab testing (as applicable) WC W/Rw Yes
6. Monitoring of water level WC S -
Page 625 of 851

ITP NO.: 3103 Rev 0
SITE GRADING
Records to be
Sl.
Activity Contractor EIL submitted/
No.
Format No.
CAT A CAT B
1. Clearing and stripping of soil including WC S -
disposal of unsuitable material -
2 a) Review of calibration certificates of WC HP HP Yes/Format C1
b) Field calibration, if any WC S - Yes
3. Taking and plotting of initial levels at WC HP HP Yes

specified intervals for cutting as well as
filling areas
4. Classification (Levels of strata) and WC S - Yes
testing of filling soil for suitability
including preparation of Lead Charts to
filling/disposal areas.
5. Proper warning of explosions, misfires WC - S -
and storage of explosive materials (As
applicable).
6. Breaking up of clods, lumps, etc. at the WC S - -
time of filling and compaction.
7. Identification and suitability of borrow WC S/Rw - Yes
areas for filling soil/murrum including
verification of payments for royalty, etc.
8. Compaction test for earth filling in WC W/Rw - Format C3
specified layers including finished areas.
9. Verification of final finished grade levels. WC HP HP Yes
10. Computation of Earth works. WC W W Yes
11. Record of tree cuttings, stacking of
blasted rocks and other quarry materials WC S S Yes
including handing over to Owner
12. Preparation of “As built drawings WC Rw Rw Yes
13. Removal of Surplus earth/excavated WC S - -
material and leveling in disposal areas.
14. Resolutions of obstacles/hindrances WC S - -
Review Test and Inspection Documents WC Rw Rw Yes
CAT A: All fillings

CAT B: All cuttings.
Page 626 of 851

ITP NO.: 3104 Rev 0
EXCAVATION
Records to be
Sl.
No.
Format No.
CAT A CAT B
1. a) Review of calibration certificates of WC HP HP Yes
b) Field calibration, if any WC W W Yes/Format C1
2. Layout checking WC S S Format C2
3. Taking initial levels WC W W Yes
4. Slopes of excavation, benching, WC S S -
overburden, shoring & strutting (in case of
deep excavation)
5. Check for sub-soil water, dewatering WC S S -
requirements as per specifications.
6. Bottom level of excavation and WC S S -
compaction
7. Stacking of different type of soils WC S S -
separately
8. List of obstacles encountered (cables, WC S S Yes
pipes, conduits, etc)
9. Barricading of excavated pits for safety & WC S S -
protection from rain
FOR HARD ROCK
1 Obtaining license from district authorities WC Rw Rw Yes

for undertaking blasting operations
2 Storing of explosive materials as per WC S S -
explosive rules
3 Prominent display of red flags around the WC S S -
area to be blasted
4 Check the dimensions of bore holes WC S S -
5 Stacking of hard rock for useable/non WC S S Yes
useable including handing over to owner
CAT A : Equipment foundations, Plant buildings, Technological structures, pipe racks, etc.
CAT B : Non Plant buildings, Boundary walls, wing walls, manholes, drains, pipe culverts ,bridges,
etc
Page 627 of 851

ITP NO.: 3105 Rev 0
BACK FILLING
Records to be
Sl.
No.
Format No.
CAT A CAT B
1. Selection of materials/selected earth WC W S Format C4, C5
2. Check for treatment of soil, if any WC S S Yes
3. a) Review of calibration certificates of WC HP HP Yes /Format C1
b) Field calibration, if any WC W W Yes
4. Filling in specified layers, consolidating, WC S S -
watering.
5. Compaction tests for layers WC W/Rw S/Rw Format C3
6. Filling to required levels WC S S -
CAT A : Equipment foundations, Plant buildings, Technological structure, Pipe racks, etc.
CAT B : Non Plant buildings, pipe racks ,Boundary walls, wing walls, manholes, drains, pipe culverts,
bridges etc.
Page 628 of 851

ITP NO.: 3106 Rev 0
UNDERGROUND PIPING (RCC/ CI)
Records to be
Sl.
No.
Format No.
CAT A CAT B
1. Incoming Material Contractor to check all free issue materials and maintain
a) Owner’s supply records of MIV for material issued by owner/EIL
b) Contractors supply WC Note -1 Format M2
2. Adequate slope, benching in excavation WC S - -
for safety purposes (if required)
3. a) Review of calibration certificates of WC Rw Rw Yes/ Format C1
4. Layout, line & level WC S S Format C2
5. Laying & jointing, grouting at WC S - -
manholes/chambers
6. Check for supports/ firm bed/ sub soil WC S - -
water level
7. Testing for leakages by blocking pipe WC W W -
ends
8. Hydro-testing and other tests, Removal of WC HP HP Format C6
blockages, Cleaning & flushing of
system
9. Backfilling in layers WC Rw Rw Format C3
10. Check for MS rungs in proper position, WC S S -
inlet/outlet pipe levels in manholes
11. Preparation of “As-built drawings” WC Rw Rw Yes
INSPECTION & TEST
DOCUMENTS
NOTE: 1) For Incoming material Inspection please refer ITP no: 6-82-1010
CAT A: Main plant buildings, Utilities , offsites, etc.
CAT B: Non plant buildings, , technological buildings admn. Buildings, Gate house, security
rooms, etc
Page 629 of 851

ITP NO.: 3107 Rev 0

WBM ROADS
Records to be
Sl.
No.
Format No.
CAT A CAT B
2. WC W W Yes
Layout checking including Road
crossings and taking initial levels
3. Approval of source & checking/testing of WC NOTE 1 NOTE 1 Format C4
materials (wherever required) Format C5
4. Filling (if any), compaction, providing WC W/Rw W/Rw Format C3
cambers in sub-base including levels
5. Spreading metal to required thickness, WC S - Yes
line & levels, dry rolling including
spreading of screening material
6. Check for camber and levels over WC S S -
metalling
7. Spreading murrum/ sand, watering and WC S - -
rolling
8. Checking thickness after each layer and WC S S Yes
rectification thereof (if any)
9. Checking quantity of aggregate by WC W W Yes
excavation of trial pits as per IRC Code
INSPECTION & TEST
DOCUMENTS
NOTE : 1) For Incoming material Inspection please refer ITP no: 6-82-1010
CAT A: Roads subjected to heavy loading, connected to main highway, main plant roads, etc
CAT B: Balance Roads
Page 630 of 851

ITP NO.: 3108 Rev 0
BLACK TOPPING (PREMIX CARPETING) & BITUMINOUS MACADAM (BM)

No. Format No.
CAT B
1. Approval of source of materials(aggregate, WC Note 1 Format C4
bitumen, etc)
2. a) Review of calibration certificates of WC HP Yes /Format C1
3. Surface preparation & check for WC - -
camber/level
4. Checking/ testing of material wherever WC W Format C5, Yes

required
5. Tack coat application WC - -
6. Laying of Premix carpeting/ BM including WC S Yes
rolling
7. Application of Seal coat WC - Yes
8. Check for camber and levels WC S -
9. Check for bitumen temperature and WC S -

consumption
10. Thickness check (random)of Premix WC S Yes
carpet/ BM
11. Removal of surplus earth WC - -
12. Berm preparation WC - -

13. Final Inspection WC W Yes
CAT B: All works
Page 631 of 851

ITP NO.: 3109 Rev 0
TANK PADS
Records to be
Sl.
No.
Format No.
CAT A CAT B
1. Approval of source of materials WC NOTE 1 NOTE 1 Format C4
2. Stripping the area WC - - -
3. a) Review of calibration certificates of WC HP HP Yes/ Format C1
4. Layout and marking of ground level WC S - Format C2
5. Excavation to required level, compaction WC W S -
of sub-base
6. Checking/ testing of materials WC W S Format C5
7. Filling selected materials in specified WC S - -

layers, rolling, watering
8. Compaction tests WC W/Rw Rw Format C3
9. Gravel filling under annular ring with WC W S Yes

compaction and adding graded filler
material (As applicable)
10. Anti-corrosive layer, consolidation WC S - -

11. Premix carpeting on side slopes WC S S -
12. Preparation of “As-built drawing” for WC Rw Rw Yes
erection
13. Check for settlement of pads during WC W S Yes
hydro testing of tanks
INSPECTION & TEST
DOCUMENTS
CAT A: All Site fabricated steel storage tanks for process fluid /Hydrocarbon, floating roof tanks
having capacity more than 600cum or 10m dia and 8 m height.
CAT B: Site fabricated steel storage tanks for Raw water, Fire water, waste water, DM water, etc. and
all tanks not covered under “CAT A”
Page 632 of 851

ITP NO.: 3110 Rev 0
MICRO GRADING

No. Format No.
CAT B
1. a) Review of calibration certificates of WC HP Yes/ Format C1
b) Field calibration, if any WC - Yes
2. Taking initial levels WC S Yes
3. Clearing/ Removal of extra soil, debris, WC S Yes

etc. from site by transportation
4. Taking final levels WC S Yes
5. Verification of gradient of ground WC S -
6. Finishing of ground surface by hand WC S -

compactor/ Roller (As applicable)
7. Final inspection WC W Yes

CAT B: All works
Page 633 of 851

ITP NO.: 3140 Rev 0
FOR UNDERGROUND PIPING (CARBON STEEL) (Sheet 1 of 6)
Records to be
Sl.
No
Format No.
CAT A CAT B
A.
PRIOR TO FABRICATION
Incoming Material Contractor to check all free issue materials and maintain
1
c) Owner’s supply records of MIV for material issued by owner/EIL
d) Contractors supply WC Note -1 Format M2
2. Welding Filler Material
Approval/Qualification
i) Review of Manufacturer's WC Yes

Test Certificates/ other Rw Rw
documents
ii)Testing, if any WC Rw Rw Yes
3. WPS/PQR
WC HP HP Yes
i) Review of proposed Procedure
ii) Testing WC HP HP Yes
iii) Approval of Final WPS/PQR WC HP HP Yes
4. Welder Performance Qualification Test WC Yes

W W
4a. WC W W Yes
Certification & approval of welders
5. NDT Procedure Qualification
WC Rw Rw Yes
i) Review of proposed Procedure
WC Rw Rw Yes
ii) Testing
WC HP HP Yes
iii) Approval of NDT procedure
Preparation of sketches from General WC Rw - Yes
6.
Arrangement drawings
7. Joint numbering WC Rw - Yes
8. Approval of colour coding scheme WC Rw - Std spec
Monitoring of colour coding on pipes & WC S -
9.
fittings
B.
FABRICATION (SHOP & FIELD)
Material as per piping class (check w.r.t. WC Format P1
1. W
approved colour coding procedure)
i) Fit-up check WC S Rw
ii) Dimensional check WC S Rw
Page 634 of 851

ITP NO.: 3140 Rev 0
Records to be
Sl.
No
Format No.
CAT A CAT B
2. Pre-heat (if any) WC S Yes
S
Check for purity of purging/shielding Gas WC S
3
(if any)
Purging (if any) WC S
4.
Shielding rate (if any) WC S - --
5.
6. Baking of Electrodes WC S - Yes
7. WC S --
Inter-pass cleaning & Temperature check.
Visual check of completed welds WC Format P2
8. - For welds with Random W S
Radiography
-For welds with 100% Radiography WC Format P2
S S
PT/MPT WC S - Yes
9.
Radiography marking (for Random WC Format P3
W W
10. Radiography)
Radiography Interpretation WC W W Format P4

11.
HYDROSTATIC/ PNEUMATIC
C.
TESTING
Procedure Review WC HP HP Yes

1.
Correctness of Testing arrangements WC S - ---

2.
Calibration of Pressure Gauges WC - - Format C1

3.
R.F. Pad testing, if any WC HP W --
4.
Scrutiny of test packs for Mechanical & WC Annex-1, Format
HP HP P5, UG1
5. NDT Clearance (Refer Annexure-1)
Air/Water Flushing (preliminary) WC S -

6. S
Addition of corrosion inhibitors, if WC Yes

HP HP
6a. required – Approval of make & quality
Page 635 of 851

ITP NO.: 3140 Rev 0
Records to be
Sl.
No
Format No.
CAT A CAT B
7. WC S S Format P6
Pneumatic/ Hydrostatic testing
8. Draining of water & Air drying WC S S Format P6
D.
LAYING
1. WC S - Yes
Trench excavation and levels
2. WC S - -
Cleaning of pipe surface
Approval of wrapping/coating material Note 1 Note 1 Yes
WC
3 manufacturers
Approval of agency for wrapping & Rw Rw Yes

4. WC
coating
Sample test of coating materials in Rw Rw Yes

5. WC
approved laboratory
Procedure qualification for wrapping & HP HP Yes

6. WC
coating
Application of primer WC S S --
7.
Coal tar temperature WC S - ---
8.
Coating & wrapping WC S S ---
9.
Check Thickness of coating (if S - Yes
WC
10. applicable)
Calibration of Holiday tester WC HP HP Format C1

11.
Holiday testing WC W W Yes
12.
WC HP S/Rw Yes
13. Peel test
CAT A: All pressure lines, Fire Water line, Cooling Water line, etc.
CAT B: Balance Works
Page 636 of 851

ITP NO.: 3140 Rev 0
Records to be
Sl.
No
Format No.
CAT A CAT B
14. Lifting arrangement WC S - Yes
Lowering (levels & orientation of S - --

15. WC
branches)
Checking of wrapping & coating for S S --

16. damages during lowering, their repair, WC
Holiday Testing, etc.
17. Back filling & compaction WC S - Yes
18. Location, Brickwork, plaster of valve pit WC - - Yes
19. Top cover & Finish of valve pit WC S S --
E. SYSTEM COMPLETION
1. Tie in joints (Refer Annexure-2) WC Annex-2 Annex-2
Scrutiny of test packs for system testing Annex-1 Annex-1

2. WC
(Refer Annexure-1)
3. System testing WC HP S/Rw Format UG2
INSPECTION & TEST

DOCUMENTS
WC Rw Rw Yes
Review Test and Inspection Documents
CAT A: All pressure lines, Fire Water line, Cooling Water line, etc.
CATB: Balance Works
Page 637 of 851

ITP NO.: 3140 Rev 0
ANNEXURE – 1
Sl.
No.
CAT A CAT B
A. MECHANICAL COMPLETION RECORD
(U/G Piping)
1. Clearance for flushing & testing WC Rw Rw

1a. Mechanical clearance
- Conformity with drawing WC HP Rw
- Material as per Specification WC Rw Rw
1b. Welding & NDT clearance
- Material as per Specification WC Rw Rw
- Fit-up check record WC Rw Rw
- Visual check of completed welds WC Rw -
- PT/MPT WC Rw Rw
- Radiography WC Rw Rw
- PWHT & hardness WC Rw Rw
- RF pad testing WC Rw Rw
2. Flushing & Pressure testing HP HP
WC
3. Coating & wrapping
- Surface preparation WC Rw -
- Primer application WC Rw Rw
- Coating, wrapping & peel test WC Rw -
- Holiday check WC Rw Rw
4. Laying
- Trench leveling WC Rw Rw
- Lowering & checking for damages in Rw Rw

WC
wrapping & coating, their repair,
Holiday testing, etc.
- Backfilling WC Rw Rw
CAT B: All pressure lines, Fire Water line, Cooling Water line, etc.
CAT C: Balance works
Page 638 of 851

ITP NO.: 3140 Rev 0
ANNEXURE – 2
TIE-IN
Sl.
No.
A. FIT UP WC W
B. ROOT RUN DP WC W
C. FINAL RUN DP WC W
D. RADIOGRAPH REVIEW WC HP
E. PWHT HARDNESS WC Rw
F. RF PAD TESTING WC HP
G. CLEANING & PRIMING WC S
H. COATING, WRAPPING WC W
I. PEEL TEST WC HP
J. HOLIDAY TESTING WC HP
K. CHECKING FOR ANY DAMAGE IN WRAPPING WC W
& COATING AFTER LOWERING,
THEIR REPAIR HOLIDAY TESTING, ETC.
L BACK FILLING WC S
For CAT A as well as CAT B
Page 639 of 851

ITP NO: 3141 Rev 0
PLAIN CEMENT CONCRETE

No. format no.
CAT B
1. a) Review of calibration certificates of WC Rw Yes /Format C1

instruments/ testing
equipments
b) Field calibration, if any WC S/Rw Yes
2. Checking of layout and materials, WC S Format C2, C3, C5, C7

compaction of sub -grade
3. Mix proportion WC S -
4. Check for shuttering, dewatering if any. WC - Yes
5. Concreting with proper compaction WC - -
6. Checking of top level of PCC WC Rw Yes
7. Curing WC - -
CAT B : All works
Page 640 of 851

ITP NO: 3142 Rev 0
REINFORCED CEMENT CONCRETE ( SUBSTRUCTURE)

Records to be
Sl.
No.
Format No.
CAT A CAT B
1 Approval of source of materials WC HP HP Format C4
2. Approval of agency for providing Ready WC HP HP Yes
Mixed Concrete (RMC), as applicable
4. Checking of layout & condition of PCC/ WC S S Yes
leveling course
5. Incoming material checking WC NOTE 1 NOTE 1 Yes
6. Design of mix &establishment of strength WC HP HP Yes
at site by trial mix
7. Check for line & level of shuttering WC S S
including its condition, quality and
rigidity.
8. Check for sub-soil water & dewatering WC S S -
arrangement, if any
9. Reinforcement & covers to reinforcement WC S S
10. Inserts, Anchor bolts and pipe sleeves, WC S S -
pockets, dowels, etc.
11. Pour Card WC W W Yes
12. Check for obstacles encountered WC S S Format C8, C9
(Electrical conduits, pipe lines, etc.)
13. Concreting, ,compaction & finishing WC W S/Rw Yes
14. Casting of cubes WC S S Yes
15. Curing WC S S
16. Testing of cubes WC W W Format C10
17. Removal of shuttering WC S - -
18. Check for water tightness, rendering, if WC S S -
any
19. Preparation of As-built drawings WC Rw Rw Yes
INSPECTION & TEST
DOCUMENTS
CAT A: Critical foundations of equipments i.e compressors, reactors, columns, stacks, Unit Pipe
racks, plant buildings and other equipment foundations with RCC Quantity > 250 Cum, tank
foundations
CAT B: Non critical pipe racks(branch pipe, offsite pipe rack, etc) non plant buildings ,pipe sleepers,
manhole, catch pit, pipe culverts ,bridges other equipment foundations not covered in CAT A, and
balance works
Page 641 of 851

ITP NO: 3143 Rev 0
REINFORCED CEMENT CONCRETE (SUPER STRUCTURE)

Records to be
Sl.
No.
Format No.
CATA CATB
2. Approval of agency for providing Ready Mixed WC HP HP Yes

Concrete (RMC), as applicable
3. a) Review of calibration certificates of instruments/ WC HP HP Yes
testing equipments
b) Field calibration, if any WC Rw Rw Format C1
4. Checking of layout WC S S Yes

5. Incoming material inspection WC Note 1 Note 1 Format C5, C7
6. Design of mix &establishment of strength at site by trial WC HP HP Yes

mix
7. Check for line & level of shuttering and scaffolding/ WC S S --
vertical bracing including hoisting arrangements.
8. Reinforcement & covers to reinforcement WC S S -
9. Inserts, bolts, pipe sleeves, MS rungs, concealed WC S S Yes

electrical conduits, fan hooks, dowels, etc. including
welding if any
10. Pockets/ openings WC S S --
11. Expansion joints, if any WC S S -
12. Check for water stops, slopes, stoppers, if any WC S S -
13. Pour Card WC W W Format C8, C9
14. Quality Records of RMC like Delivery Ticket WC Rw Rw Yes

Information, if applicable
15. Concreting, testing, compaction & finishing WC W S Yes
16. Casting of cubes WC S S Yes

17. Curing WC S S -
18. Testing of cubes WC W W Format C10

19. Removal of formwork/ staging WC S - -
20. Verification of dimensions viz AFC drawings and WC S S -

tolerances
21 Check for water tightness, rendering, if any WC S S --
22 Preparation of As built drawing . WC Rw Rw Yes-
INSPECTION & TEST DOCUMENTS Yes
CAT A: Super structure of foundations for Critical equipments ie compressors, reactors, columns, stacks,
foundations, Slabs of plant and non plant buildings, tank foundations, Unit Pipe racks, plant buildings and super
structure of any other equipment, etc.
CAT B: not covered in category A Non critical pipe racks (branch pipe, offsite pipe rack, etc) non plant
buildings other than slab, catch pit and balance works, pipe sleepers, pipe culverts, bridges, manhole etc
Page 642 of 851

ITP NO: 3145 Rev 0
RCC PAVEMENT/FLOORING

No. Format No.
CAT B
1. Approval of source of materials WC Rw Format C4
2 Approval of agency for providing Ready Mixed WC HP Yes

Concrete (RMC), as applicable
. 3. a) Review of calibration certificates of instruments/ WC HP Yes
testing equipments
b) Field calibration, if any WC S Format C1
4. Layout checking/ excavation of all new foundations WC - Yes
5. Incoming material inspection WC NOTE 1
6. Design of mix &establishment of strength at site by WC HP Yes

trial mix
7. Check for proper back filling/compaction/ completion WC S Format C3, Yes
of sub - Structure works
8. Check for proper arrangements for vacuum dewatering WC W -
flooring including all accessories as per specification
(as applicable)
9. Check for edges of shuttering, alternate panels WC - -
10. Check for slopes, thickness of flooring WC S -
11. Shuttering, reinforcement (as applicable) WC - -
12. Check for expansion joints/ Construction joints WC S -
13. Check for concealed pipe embedment, earthing, if any WC - -
14. Check for dividing strips, as applicable WC S -
15. Concreting, finishing, etc WC S Format C8, C9
16. Quality Records of RMC like Delivery Ticket WC Rw Yes

Information
17. Concreting, testing, finishing, test cubes WC W Yes
18. Checking for line, levels, slopes, joints, thickness of WC S -

flooring viz. AFC drawings
19 Curing WC S -
20 Grinding & polishing, as applicable WC S -
21 Testing of concrete cubes (as applicable) WC W Format C10
22 Testing of vacuum dewatering flooring (as applicable) WC W/Rw Yes
23 Preparation of “As Built Drawings” WC Rw Yes
CAT B: All works.
Page 643 of 851

ITP NO: 3146 Rev 0
BRICK MASONARY
Records to be
Sl.
No.
Format No.
CAT A CAT B
1. a) Review of calibration certificates of WC Rw Rw Yes/ Format C1
b) Field calibration, if any WC Rw Rw Yes
2. Incoming material inspection WC Note 1 Note 1
3. Cleaning of surface WC - - -
4. Wetting/soaking of bricks WC S S -
5. Cement mortar proportion WC S S -
6. Staging & scaffolding WC - - -
7. Hacking of adjacent concrete surface WC S -
8. Check for bond/closers, thickness of WC S - -

joints .
9. Line, level & plumb WC S S -
10. Raking out joints, keys in brick work, if WC S -

any
11. Check for placement of Reinforcement WC S S -

bars in case of partition brick work
12. Embedment of fixtures WC S S -
13. Curing WC - - -
14. Preparation of 'As Built' Drawings WC Rw Rw Yes
INSPECTION & TEST

DOCUMENTS
CAT A: Load bearing walls

CAT B: Balance works
Page 644 of 851

ITP NO: 3147 Rev 0

STRUCTURAL STEEL WORKS
S. Records to be
No submitted/
A PRE – FABRICATION ACTIVITIES
1. a) Review of calibration certificates of instruments/ testing WC HP HP Yes/ Format
equipments C1
2. Incoming material inspection WC Note 1 Note 1 Yes
3. Welding Filler material approval/ qualification
a) Manufacturing test certificates/ documents WC Rw Rw Yes
b) Testing, if any WC W W Yes
4. WPS/ PQR WC HP HP Yes
5. Welders performance qualification WC W W Yes
6. Layout checking WC S - Yes
7. Welding equipment and accessories WC S - -
8. Preparation and approval of Fabrication drawings WC Rw Rw Yes
B FABRICATION ACTIVITIES
1 Materials as per design drawing WC Rw Rw Format C12
2 Check straightness and non-warping of members WC S S Format C12
3 Dimensional and fit-up checks including provision of slopes WC S S Format C12

for deflection wherever required
4 Visual check for welding WC S S Format C12
5 Grinding including surface preparation for painting and WC S S Format C12
application of primer
6 Checking paint as per specs, shelf-life, etc. WC S S Yes
7 Application of specified paint, painting thickness, etc. WC S S Format C12
C FIELD ERECTION ACTIVITIES

1 Lifting arrangements including test certificates of lifting WC S /Rw S/Rw Yes
tackles
2 Correctness of location WC S - Format C12
3 Orientation of bracing, lugs WC S - -
4 Alignment & levels WC S - Format C12
5 Field welding (if any) WC S S Format C12
6 Grouting WC S S Format C12
7 Finishing coat of paint, thickness of paint etc. WC S S Format C12
8 Preparation of As-built drawings WC Rw Rw Yes
CAT A: Steel structures pertaining to equipments ie compressors, reactors, columns, Unit Pipe racks, stacks, Technological
structures.
CAT B: Steel structures of Non critical pipe racks (branch pipe, offsite pipe rack, etc) non plant buildings , walkways,
platforms , etc
Page 645 of 851

ITP NO: 3148 Rev 0

PILING WORKS
Records to be
Sl.
No.
Format No.
CAT A CAT B
2 Approval of agency for providing Ready WC HP HP Yes
Mixed Concrete (RMC), if applicable
3 a) Calibration certificate of measuring & WC HP HP Yes/ Format C1
testing equipments/ instruments
b) Field calibration, if any WC W S Yes
4 Layout and ground level WC S S Yes
5 Incoming material inspection WC Note 1 Note 1

6 Design of mix &establishment of strength WC HP HP Yes
at site by trial mix
7 Driving of piles & check for set point WC S S -
8 Check for depth of bore and lowering of WC S - -
cage measuring
9 Check for cage reinforcement, its length, WC S S -
overlaps
10 Pour Card WC HP HP Format C8, C9
11 Quality records of RMC like Delivery WC Rw Rw Yes
Ticket Information, if applicable
12 Concreting, WC W S Yes
13 Casting of cubes/Testing WC W W Format C10
14 Check for cut off level of concreting & WC S - Yes
quantity of concrete poured
15 Lifting of casing pipe WC S S -
16 Pile load tests (lateral/vertical/cyclic/pull WC W Rw Yes
out)
17 Submission of pile load test report WC Rw Rw Yes
INSPECTION & TEST
DOCUMENTS
CAT A: Critical foundations of equipments ie compressors, reactors, columns, stacks, Technological

structures, Unit Pipe racks, plant buildings and other equipment foundations ,.
CAT B: Non critical pipe racks (branch pipe, offsite pipe rack, etc) non plant buildings
Page 646 of 851

ITP NO: 3171 Rev 0
ANTITERMITE TREATMENT

No. Format No.
CAT B
1. Testing of material & spraying devices WC HP & Yes
including personal protective equipments Note 1
like facemask, gloves, shoes, etc.
2. Preparation of surface for taking dosage of WC - -

emulsion by ramming of each layer of soil
by roding the earth at specified intervals
3. Backfilling and compaction in specified WC S Format C3

layers along with application of emulsifier
along the sides of masonry & RCC
structures
4 Compaction of top surface for taking WC - -

dosage of emulsifier by roding the earth at
specified intervals for the entire floor area
before concreting
5 Check for consumption of emulsifier WC S Yes

utilized

CAT B: All works
Page 647 of 851

ITP NO: 3172 Rev 0
PLASTERING
Records to be
Sl.
No.
Format No.
CAT A CAT B
1 Calibration of testing equipments WC Rw Format C1
2. Checking/ testing of materials WC W Format C5, C7
3 Check for completeness of all hidden jobs WC - - -

like piping, conduiting, etc.
4 Check for grading of sand, Mix WC S S -

proportion
5. Sample preparation for finish and its WC W S -

approval
6. Neeru application on plaster (as WC S - -

applicable)
7. Hacking and cleaning the surface, WC - - -

removing loose particles, wetting the
surface
8 Checking of plaster thickness, plumb & WC S - Yes

even surface
9 Check for grooves, openings, rounding WC - - -

off the corners, hollowness in plaster
10 Curing WC S S -
INSPECTION & TEST
DOCUMENTS
CAT A: Area requiring special finish
CAT B: Balance works.
Page 648 of 851

ITP NO.: 3173 Rev 0
DOORS, WINDOWS AND VENTILATORS
Records to be
Sl.
No.
Format No.
CAT A CAT B
2. Calibration of testing equipments WC HP HP Yes
3. Check for sections & dimensions WC S - Yes
4. Line, level & plumb WC - - -
5 Section joinery details WC Rw - -
6 Grouting with lugs/ dash fasteners WC - -
7 Check for fixtures & fittings WC S S Yes
8 Check for thickness & type of glazing WC - - Yes
9 Check for rubber gasket, anodizing (as WC - - -

applicable)
10 Brand/ shade of paints, no. of coats WC S Rw -

including surface preparation
11 Final inspection WC HP HP Yes
INSPECTION & TEST

DOCUMENTS
CATA: Main plant buildings
Page 649 of 851

ITP NO.: 3174 Rev 0
PAINTING (BUILDING WORKS)
Records to be
Sl.
No.
Format No.
CAT A CAT B
1. Completion of surface preparation WC - - -
3. Confirmation of colour, shade & brand WC HP HP -
4. Check for number of coats and thickness WC S S Yes
5 Curing, if any WC S - -
INSPECTION & TEST
DOCUMENTS
CAT A: Main plant buildings, Major non plant building (viz: Administrative building, Training center
etc
Page 650 of 851

ITP NO. : 3175 Rev 0
SANITARY FITTINGS
Records to be
Sl.
No.
Format No.
CAT A CAT B
2. Checking of sample (as applicable) WC S - Yes
3. Check completeness of finishing works WC S - -
w.r.t. line, level & position
4. Check proper fixing of the sanitary WC S - -
fittings to give aesthetic appeal
5 Check for leakage WC S Rw -
INSPECTION & TEST
DOCUMENTS
CAT B: Main plant buildings, Major non plant building (viz: Administrative building, Training center
etc)
Page 651 of 851

ITP NO. : 3176 Rev 0
WATER PROOFING (ROOF)

No. Format No.
CAT B
1. Approval of materials WC HP Format C4
2. a) Calibration certificate of measuring & WC HP Yes/ Format C1

testing equipments/application
instruments (if applicable)
3 Surface preparation for screeding/ water WC W -

proof plastering
4. Mix proportion, thickness of screeding/ S Yes

WC
plastering & slope towards rain water pipes
5. Formation of groove at specified height on - -
WC
parapet wall
6. Incoming material inspection, no. of coats, Note 1 Yes
WC
application procedure and consumption.
7. Termination of material in groove on S -
WC
vertical plane
8. Check for hollowness, bubbles in water S -
WC
proofing, if any
9. Conducting a sample of water proofing test S/Rw
by flooding the area for specified interval WC
(as applicable)
10 Cleaning of surface WC - --
11 Submission of Guarantee in the requisite Yes
WC
Performa Rw
CAT B: All works
Page 652 of 851

ITP NO: 3177 Rev 0
FALSE FLOORING AND FALSE CEILING

No. Format No.
CAT B
FALSE FLOORING
1. Manufacturers Test Certificate WC Rw Yes

2. Incoming material inspection WC Note 1 Yes
3. Cleaning base floor WC - -
4. Painting base floor with Polyurethane WC S Yes
based paint (as specified)
5. Check for installation of grid framework WC S -
6 Proper line, level & layout WC S -

7 Final inspection WC HP Yes
FALSE CEILING
1. Manufacturers Test Certificate WC Rw Yes
3. Surface preparation of panel boards WC - -
4. Proper line, level & cut-outs WC S -
5. Painting of panel boards WC S Yes
CAT B: All works.
Page 653 of 851

ITP NO.: 3178 Rev 0
UNDER DECK INSULATION

No. Format No.
CAT B
1. Incoming material checking including WC Note 1 Yes
density
2. Checking of adhesive, fasteners for WC S Yes
anchorage
3. Fixing of scaffolding, ladders, platforms WC S -
4 Fixing of under-deck insulation with WC - -
adhesive
5 Fixing of dash fasteners at defined spacing WC - -
6 Finishing WC S -

CAT B: All works.
Page 654 of 851

ITP NO.: 3179 Rev 0
ROOFING ACCESSORIES
Records to be
Sl.
No.
Format No.
CAT A CAT B
1. Incoming material inspection WC Note 1 Note 1 Yes
2. Ensure proper sequence of sheeting WC W
3. Check for mitring, overhang, laps, etc. WC S - -
4. Slopes line, level of sheets, barge boards, WC S - -
ridges & gutters, overhang
of sheets
5 Bolting by drilling only, length of bolts, WC S - -
nos., anodizing and type of washers
6 Check for slopes of rain gutters, down WC S - -
take pipes, north lighting curves/ supports
for gutters
7 Check for leakage/ passing of light WC S - -
8. Final inspection WC W W Yes
INSPECTION & TEST -
DOCUMENTS
2) Fixing arrangement need to be reviewed with respect to contract specifications.
CAT A: Important structures (e.g Compressor House, Ware house ,workshop and Pump house
etc.),main plant buildings, etc
CAT B: Balance works.
Page 655 of 851

ITP NO.: 3199 Rev 0
LIGHTING WORKS (NON PLANT BUILDINGS)

No. Format No.
CAT B
1. Prepare detailed conduit layout diagram as WC W Yes
per the approved electrical drawing
2. Provide GJ/PVC sleeves in columns/beams WC S -
at identified locations to facilitate laying of
conduit on later date.
4. Ensure that the conduit is laid in line with WC S -
execution drawings & provide pull-wires
as per requirement.
5. Check correctness of drop/JB locations WC S -
6. Check threaded joints are proper WC S -
7. Ensure all JB/Fan box are properly stuffed WC S -
with jute
8. Ensure conduits are properly tied to WC S -
reinforcement bars to prevent floating
during concrete
9. Ensure proper supporting of conduit WC S -
lengths wherever required
10. Ensure adequate chasing depth for conduit WC S -
portion coming inside brick walls
11. Check workmanship towards joints and WC S -
presence of any foreign material inside the
conduits
12. Ensure wiring material is inspected at site WC W Yes
before use
13. Ensure correctness of lighting wire size WC S -
and no. of wires as per the drawing in each
conduit portion
14. Preparation of "As Built" drgs. WC Rw Yes
CAT B: All works
Page 656 of 851

SECTION - B
Page 657 of 851

FORMATS
FOR
CIVIL, STRUCTURAL &
ARCHITECTURAL WORKS
Page 658 of 851

CONTENTS
S. DESCRIPTION FORMAT ISSUE PAGE

NO NO. DATE NO.
FORMATS FOR CIVIL, STRUCTURAL & ARCHITECTURAL WORKS
1. Record of calibration of Measuring/Testing C1 Rev.1 14.01.2014 42

equipments
2. Surveying and Layout record C2 Rev.1 14.01.2014 43
3. Test report for determination of dry density & C3 Rev.1 14.01.2014 44
moisture content of sand/soil
4. Record of approval of source(s) for aggregates C4 Rev.1 14.01.2014 45
5. Sieve analysis report C5 Rev.1 14.01.2014 46
6. Underground piping – test report (RCC/CI) C6 Rev.1 14.01.2014 47
7. Cement testing result report C7 Rev.1 14.01.2014 48
8. Pour card (I) – Programme of concreting C8 Rev.1 14.01.2014 49
9. Pour card (II) – Observation during concreting C9 Rev.1 14.01.2014 50
10. Crushing strength testing results of concrete C10 Rev.1 14.01.2014 51
cubes
11. Water absorption, crushing strength & C11 Rev.1 14.01.2014 52
efflorescence testing results of bricks
12. Structural fabrication & erection sheet C12 Rev.1 14.01.2014 53
Page 659 of 851

Page 660 of 851

FORMAT NO. : C1 REV 0

RECORD OF CALBIRATION OF MEASURING/TESTING EQUIPMENTS
Project : Job No. :
Client : Contractor :
Name of Work :
Accepted
Next
Sl. Model Certificate Calibrated Calibration Calibration
Name of Equipment/Apparatus Remarks
No. No. No. By Date Contractor EIL
Due on
Theodolite
Levels
Steel measurement tapes
Cross staff
Distomat
All balances
Weigh Batcher
Cube testing Machine
Pressure Gauges
Dial gauges
Dead weight tester
Vernier caliper/ screw gauge
Holiday tester
Universal Testing Machine
Charpy V-notch Impact testing machine
Hardness Testing Machine
Various Digital and Analog meters
Variable current, voltage and resistance
generators
Temperature/ Pressure Recorders
Temperature gauges including RTDs
Thermocouples
Vibration probes
Decibel-meter
Any other


SURVEYING AND LAYOUT RECORD
Project : Job No :
Name of Work :
1. Reference Drawing :
2. Reference Grid Pillars :
3. Reference Bench Mark/Reduced Level :
4. Co-ordinates :
5. Reduced Level :
6. Closing error, if any :
7. Layout Sketch :
________________ _____ _________

( CONTRACTOR ) ( EIL ) ( CLIENT )
Date :
Page 661 of 851

Page 662 of 851


TEST REPORT FOR DETERMINATION OF DRY DENSITY & MOISTURE CONTENT OF SAND/SOIL
Project : Job No :
Name of Work :
Location : Layer No :
S. Description Relation Test Nos: Remarks
No. 1 2 3 4 5 6
1. Wt. of mould + wt. of wet soil/sand W1 gm
2. Wt. of mould W2 gm
3. Wt. of wet soil/sand (W1 – W2) gm
4. Volume of mould V cc
5. Density of wet soil/sand Dw = (W1 – W2)/V gm/cc
6. Wt. of wet sample taken Ww gm
7. Wt. of sample after drying Wd gm
8. Moisture Content Mc = (Ww – Wd)/wdx100%
(or directly by moisture meter)
9. Dry density Dd = Dw/(1+Mc) gm/CC
10. Laboratory Max dry density gm/cc
11. Degree of Compaction %
12. Required degree of compaction %
13. Optimum Moisture Content (OMC) %
_____________________________ ________________ _____

( TESTED BY/LAB-IN-CHARGE ) ( CONTRACTOR ) ( EIL )
Date :


RECORD OF APPROVAL OF SOURCE(S) FOR
AGGREGATES ,SOIL
Project : Job No :
Name of Work :
1. Reference :
2. Material :
3. Location of Source :
4. Approx. distance from the site :
5. Physical Properties
a) Colour (as applicable) :

b) Shape (as applicable) : Rounded/Irregular
c) Texture (as applicable) : Glossy/Smooth/Granular
6. Tests conducted at :
7. Code of Conformance :
8. Test Report Reviewed : Satisfactory/Un-satisfactory
9. Remarks : The source is approved/not approved
10. Explanation if any :
Enclosures : a) Reviewed Test Reports

b) Request of contractor, if available
COMMITTEE MEMBERS :
APPROVED : i) EIL :
ii) Client :
Signature of the contractor :
Date :
Place :
Page 663 of 851

Page 664 of 851


SIEVE ANALYSIS REPORT
Project : Job No : Name of Work :
Client : Date : Contractor :
Wt. of Sample taken : Date on which sample taken :
FINE AGGREGATE
S. No. Sieve Size Weight Retained (gm) Percentage Retained Cumulative % Passing Fineness Zone Remarks
% Retained Modulus (As per IS:383)
1. 4.75mm
2. 2.36mm
3. 1.18mm
4. 600 u
5. 300 u
6. 150 u
7. Pan
COARSE AGGREGATE/ROAD METAL Wt. of Sample taken :

Passed/ Failed Remarks
(As per IS:383/EIL Spec 6-64-0018)
1. 125mm
2. 90mm
3. 80mm 90-45 (Gr-I),
4. 63mm 63-45 (Gr-II),
5. 53mm 13.2mm (screening) for
6. 45mm
7. 40mm road work
8. 22.4mm
9. 20mm
10. 16mm 40mm down for PCC
11. 13.2mm
12. 12.5mm 20mm down for RCC
13. 11.2mm
14. 10mm
15. 5.6mm
16. 4.75mm
17. 2.36mm
18. 180 u
________________________ _______________ ____
(TEST BY/LAB-IN-CHARGE) (CONTRACTOR) (EIL)

Page 665 of 851


UNDERGROUND PIPING-TEST REPORT (RCC/CI)
Project : Job No :
Name of Work :
1. Reference Drawing :
2. Location :
3. Line Designation :
4. Type of Pipe & System :
5. Specification :
6. Dia of Pipe :
7. Gradient :
8. Type of Manhole :
9. Test (s) Conducted :
10. Date of Testing :
11. Remarks, if any :
______________ ___ _______

CONTRACTOR EIL CLIENT
Date :


CEMENT TESTING RESULT REPORT
Project : Job No :
Name of Work :
Brand of Cement : Consignment No. :
Wt. of sample taken : Sample Collected on :
Room Temperature :
A. CONSISTENCY
Trial Wt. of Wt. of % of Water Reading Consistency Remarks
No. Cement Water on
(gm) Added Indicator
(gm) (mm)
B. SETTING TIME
Trial Wt. of Wt. of W/C Time Time Initial Final Setting Remarks
No. Cement Water Ratio Recorded Recorded Set Set Time
(gm) Added When At set
(gm) Water
Added
C. FINENESS
Trial No. Wt. of Cement Retained on % Retained Remarks
90 µ IS sieve
Sample Used in gm
D. COMPRESSIVE STRENTH
Cube Size : 7.06X7.06X7.06 cm
Trial Mix Date of Age of Crushing Crushing Crushing Remarks
No. Proportion Testing Specimen Surface Load Strength
Casting Area (Cm2) (Kg) (Kg/Cm2)
______________________________ ________________ _____

( TESTED BY )/LAB-IN-CHARGE ( CONTRACTOR ) ( EIL )
Date :
Page 666 of 851


POUR CARD-I (PROGRAMME OF CONCRETING)
Contractor : Client :
Name of work :
1. Reference document :
2. Type of structure : Location :
3. Levels From : To :
4. Grade of concrete/ Approved Design Mix
5. Brand name, Grade and Consignment no. of cement
6. Estimated volume of concrete :
7. Quantity of cement required :
8. Reinforcement checking details :
No. Dia.
Length
a) Laps
b) Separators
c) Chairs
d) Any other
Remarks
9. Pre pour inspection details Checked NA

a) Survey/ Layout
b) Sub soil compaction
c) Completion of underground works
d) Cleanliness
e) Cover to reinforcement
f) Anchor bolts/Insert plates
g) Sleeves/ pockets
h) Water stops
i) Formwork
j) Slopes
k) Construction/ Expansion joints
l) Admixtures
m) Any other
Remarks
10. Clearance for Electrical/ Mechanical Electrical Mechanical

works required/ not required :
11. The above structure is finally inspected on at AM/PM and found/ not found
satisfactory for concreting.
Remarks, if any
(Contractor) (EIL) (Client/ Owner)

Name Name Name
Designation Designation Designation
Date Date Date
Page 667 of 851


POUR CARD-II (OBSERVATIONS DURING CONCRETING)
Contractor : Client :
Name of work :
1. a) Quality of coarse aggregates
Satisfactory Not satisfactory
b) Quality of fine aggregates

c) Bulkage of sand taken into account

Yes No
2. Quality of water
3. Machinery mobilization Nos. Stand by

a) Mixture machine
b) Ready mixed concrete dumpers
c) Vibrators
d) Pumps
e) Hoists
4. Pour start time : AM/PM ; Date :
5. Slump
6. W/C Ratio
8. Type of weather
Normal Abnormal
Details of abnormality :
(Precautions taken for <50C and >400C, rainy season)
10. Number of cubes taken & Cube identification number/marks :
11. Quantity of concrete poured :
12. Pour completion time : AM/PM ; Date :
13. Curing method :
Traditional Curing compound
Blankets/ foils/ gunny bags Others (specify)
14. Period for removal of form work :

15. Any defect(s) observed during concreting :
(Contractor) (EIL) (Client/ Owner)

Name Name Name
Designation Designation Designation
Date Date Date
Page 668 of 851

Page 669 of 851


CRUSHING STRENGTH TESTING RESULTS OF CONCRETE CUBES
Project : Job No :
Name of Work :
Grade of Concrete : Type of Cement :
W/C Ratio : Max. size of Aggregate :
Cube Id. Type & Date of Age Dimensions of Cube Vol. Wt. Unit Surface Crushing Crushing Remarks
No. Mark Location (days) of of WT. Area Load Strength
on of Structure Cube Cube (Kg/m3) (Cm2) (Kg) (Kg/Cm2)
Casting Testing L B H
cube (m3) (Kg)
(Cm) (Cm) (Cm)
_____________________________ ________________ _____

( TESTED BY)/LAB-IN-CHARGE (CONTRACTOR ) ( EIL )

Page 670 of 851


DIMENSIONAL, WATER ABSORPTION, CRUSHING STRENGTH & EFFLORESCENCE TESTING RESULTS
OF BRICKS
Project : Job No :
Name of Work :
S. Frog Wt.of oven Absorption Wt. of wet % of Water Efflorescence Size Crushing Crushing Crushing Remarks
No. Mark Period Brick Absorption Observed of Brick Surface Load Strength
Dried Brick (hr) (gm) After Drying (L X B X H) Area (Kg) (Kg/Cm2)
(gm) Cm (Cm2)
NOTE : i) Water absorption shall not be more than 20% by its dry weight. Bricks should be soaked in cold water for 24 hrs.
ii) Code of conformance shall be IS:3495 (for conducting tests) and IS:5454 (for collecting samples)
____________________________ _____________ ___

(TESTED BY/LAB-IN-CHARGE) CONTRACTOR EIL
Date :

Page 671 of 851


STRUCTURE FABRICATION & ERECTION SHEET
Project : Job No :
Name of Work :
Reference Drawing : Location/Coordinates/Grids :
Layout Clearance obtained : Yes/ No
Cleaning & Final

Material & Erection Fit Alignment & Field Grouting
S. Shop Fit up Shop welding primer Painting &
Item No. Dimensional up leveling welding clearance Remarks
No. painting thickness
clearance Con EIL Con EIL Con EIL Con EIL Con EIL Con EIL Con EIL Con EIL
Abbreviations:
Con : Contractor's signature with date

SECTION - C

Page 672 of 851


FORMATS
FOR
UNDERGROUND PIPING WORKS
Page 673 of 851

CONTENTS
S.NO DESCRIPTION FORMAT ISSUE PAGE

NO. DATE NO.
FORMATS FOR UNDERGROUND PIPING WORKS
1. Daily fit up inspection & traceability report P1 Rev.1 14.01.2014 57

2. Weld visual inspection report P2 Rev.1 14.01.2014 58
3. Radiography offering report P3 Rev.1 14.01.2014 59
4. Radiography interpretation report P4 Rev.1 14.01.2014 60
5. Piping hydrostatic test release record P5 Rev.1 14.01.2014 61
6. Piping hydrostatic test acceptance record P6 Rev.1 14.01.2014 62
7. Linewise record UG1 Rev.1 14.01.2014 63
8. U/G piping system testing record UG2 Rev.1 14.01.2014 64
Page 674 of 851

FORMAT NO. : P1 REV 0

DAILY FIT UP INSPECTION & TRACEABILITY REPORT
Project : Job No :
Name of Work:
Report No. : Date :
Sl. Joint Inch Manufacturers

Service/Line No. Dia. Type Clearance Remarks
No. No. Mtr. Heat No.
TOTAL TOTAL
INCH DIA. INCH
MTR.
Total Inch Previous Till Date

Diameter
Meter
G – Butt Weld S – Socket Weld B – Branch Weld M – Mitre Weld
(CONTRACTOR) (EIL)
Page 675 of 851


WELD VISUAL INSPECTION REPROT
Project : Job No :
Name of Work :
Report No. : Date :
WPS No. :
Visual
Sl. Joint
Service/Line No. Dia. Type Welder No. Inspection Remarks
No. No.
Clearance
Total inch Dia
WORK LOAD =
PREVIOUS =
TILL DATE =
% PROGRESS =
G - BUTT WELD
S - SOCKET WELD
B - BRANCH WELD
M - MITRE WELD
_____________ ______________
CONTRACTOR EIL
Page 676 of 851


RADIOGRAPHY OFFERING REPORT
Project : Job No :
Name of Work :
Report No. : Date :
Sl. Radiography Accepted R.A.

Service/Line No. Dia. Joint No. Welder No.
No. No. Date Bill No.
_____________________ ______________
CONTRACTOR EIL
Page 677 of 851


RADIOGRAPHY INTERPRETATION REPORT
Project : Job No :
Name of Work :
Radiography Technique : SWSI/DWSI/DWDI
Source : Ir192 , X-Ray , Cobalt 60
Film Type & Make :
IQI : Date :
Radiography Procedure No. :
Sl. Service/ Joint Welder Radiography Joint Status

Dia. Segment Results
No. Line No. No. No. No. A/R/H
SWSI - SINGLE WALL SINGLE IMAGE

DWSI - DOUBLE WALL SINGLE IMAGE
DWDI - DOUBLE WALL DOUBLE IMAGE
A - ACCEPTED
R - REPAIR
H - HOLD
S/C - SURFACE CHECK
RT - RETAKE
_____________ _______________
CONTRACTOR EIL
Page 678 of 851


PIPING HYDROTESTATIC TEST RELEASE RECORD
Project : Job No :
Name of Work :
Plan : ________________________________ Date : _______________________________
Loop No : ____________________________ Area : _______________________________
REF P & ID No. : _____________________
INCH MTR : _________________________
From ________________ To _____________
Line No. (s) Isometric No. (s) P&ID No. (s)
Test Medium : Test Duration : Design/Test Pressure :

Test Pressure Gauge No. Range Calibration Certificate No.: Gauge Calibration Date:
Items to check Accept Witness

Contractor EIL
Field Installation Checklist Prior to Hydrostatic test Signed
Punch list Prepared Yes No
Pre – Hydrostatic test Punch items Cleared
Accessibility to Inspection/Witness Locations
Capacity of pressurizing pump checked
Cordon off area for high pressure testing, as required
Pre-hydrostatic test flushing carried out
IBR/Others test Witnessing Required Yes No
System Released for Pressure Testing :
Contractor : EIL:
Sign : Name : Sign : Name :

Date : Date :
Designation : Designation:
Page 679 of 851


PIPING HYDROSTATIC TEST ACCEPTANCE RECORD
ACTIVITY Date Time

Water Filling and Venting started at
Water Filling Completed
Vents Closed
Isolation of Pressurizing pump
Test completed at :
- Water drained
- Air
- Temp Blinds Removed
- Checked for reinstallation of
a. Valves
b. Others
- Cold setting of spring supports carried out
Contractor : EIL :
Sign : Sign:
Date : Date:
Name : Designation Name: Designation:
Reviewed by EIL Area Coordinator :

Sign:
Date:
Name: Designation:
Page 680 of 851

Page 681 of 851

FORMAT NO. : UG1 REV 0

LINEWISE RECORD
Project : Job No :
Name of Work:
Plant : % Radiography :
Loop No. :
Fitup Radiography Stress Hydro- Clearance date for

Date
Sl. Clea- Welder Relieve Hard- static
Dia. Jt. No Type of Cleaning Coating Trench Lowering Remarks
No. rance No. Result Chart ness test Holiday
Welding No. & & Level Back-
Date & Date No. Date Checking
Priming Wrapping Checking Filling
_____________ ______________
CONTRACTOR EIL
Date :

INSPECTION & TEST PLAN STANDARD SPECIFICATION No:
FOR CIVIL, STRUCTURAL & 6-82-3100 Rev 0
FORMAT NO. : UG2 REV 0

U/G PIPING SYSTEM TESTING RECORD
ACTIVITY Date Time

Air/Water Filling and Venting started at
Water Filling Completed/Air pressure achieved
Vents Closed (for water testing)
Isolation of Pressurizing pump/compressor
Visual Test/Soap Bubble check completed at :
- Water drained/Air depressurized
- Drying, if applicable
a. Valves
b. Others
Contractor : EIL :
Sign : Sign:
Date : Date:
Reviewed by EIL Area Coordinator :

Sign:
Date:
Name: Designation:
Page 682 of 851

■
31 ENG1NEERS INSPECTION & TEST PLANS
INDIA LIMITED M ECHANICAL WORKS 6-82-3200 Rev 0
urra
i rirooft'am~.0 IA GoN ol lnOo Undertalong) Page 1 of 105
c;fzicbcti chNT
fatqur .cRIkcrur (3~)
(147cmui ki•ircm)
INSPECTION & TEST PLAN (ITP)

FOR MECHANICAL WORKS
(ITEM RATE CONTRACTS-WITH
CATEGORIZATION)
0 14.01.2014 ISSUED AS STANDARD SPECIFICATION

SM DJ RKD SC
Standards Standards
Comm ittee Bureau
No by by
Approved by
Format No. 8-00-0001-F1 Rev 0 Copyright EIL — All rights reserved
Page 683 of 851

INSPECTION & TEST PLAN
MECHANICAL WORKS 6-82-3200 Rev 0
Page 2 of 105
Abbreviations:
A/G : Above Ground

AFC : Approved For Construction
AS : Alloy Steel i.e. Cr-Mo steels like A335 Gr P11, P5, P9,P22,etc.
CFB : Ceramic Fibre Blankets
CS : Carbon Steel
CSO : Car Seal Open
FD : Free Draught
GAD : General Arrangement Drawings
HIC : Hydrogen Induced Cracking
I/S : Inner Side
ID : Induced Draught
LO/ LC : Lock Open/ Lock Close
MRIR : Material Receipt Inspection Report
MT : Magnetic Particle Testing
NACE : National Association of Corrosion Engineers
NRV : Non Return Valve
O/S : Outer Side
ODC : Over Dimension Consignment
PQR : Procedure Qualification Record
PT : Penetrant Testing
PWHT : Post Weld Heat Treatment
RF : Reinforcement
RT : Radiographic Testing
SS : Stainless Steel like A312 TP 304, 316, 321, 304L, 316L, 316Mo, etc.
SSCC : Sulphide Stress Corrosion Cracking
TSR : Tray Support Ring
UDFC : Under Down Flow Clearance
WPS : Welding Procedure Specification
Convenor: Mr. RK Das, ED (Construction)
Members : Mr. M Natarajan, GM (C&P)

Mr M Deshpande, GM(Construction)
Mr. Janak Kishore, GM (P)
Mr. Rakesh Nanda, GM (Piping)
Mr S.Mukherjee, DGM (Constn)
Mr D Jana, AGM (Constn)
Format No. 8-00-0001-F1 Rev 0 Copyright EIL – All rights reserved
Page 684 of 851

Page 3 of 105
CONTENTS
S.NO DESCRIPTION DOCUMENT NO. ISSUE PAGE

DATE NO.
SECTION – A
ITPs FOR MECHANICAL WORKS
1. Above Ground Piping 6 – 82 - 3210 Rev 0 14.01.2014 5
2. Installation of Column Internals 6 – 82 - 3220 Rev 0 14.01.2014 16
3. Fired Heaters (Fabrication & Erection) 6 – 82 - 3230 Rev 0 14.01.2014 18
4. Refractory & Insulation Works (Fired 6 – 82 - 3240 Rev 0 14.01.2014 22
Heaters)
5. Equipment Erection (Static) 6 – 82 - 3250 Rev 0 14.01.2014 28
6. Equipment Erection (Rotary) 6 – 82 - 3260 Rev 0 14.01.2014 31
7. Crane (EOT/HOT) 6 – 82 - 3270 Rev 0 14.01.2014 34
8. Storage Tanks 6 – 82 - 3280 Rev 0 14.01.2014 35
SECTION – B
FORMATS FOR MECHANICAL WORKS 41
Page 685 of 851

Page 4 of 105
GENERAL NOTE
The enclosed ITP’s shall be followed for the works to be performed by the contractor. The
provisions indicated for stagewise inspection by EIL/Owner are the minimum and the Engineer-In-
Charge may decide to increase Hold Points/ Witness Points. Activities for which ITP’s are not
given, contractor to develop and get the same approved by EIL/Owner well before start of the work.
Contractor to submit required reporting formats and job procedures for each activity listed in ITP’s
and submit to EIL/Owner for approval, well before commencement of the activity. If the contractor
has to deviate from the given ITP for a valid reason, he shall obtain prior written approval of
EIL/Owner. Contractor to carry out 100% examination of all activities.
LEGEND
HP : Hold Point ;
A point which requires witnessing/inspection/verification and acceptance by Owner/EIL

before any further processing is permitted.
The Contractor shall not process the activity/item beyond a Hold Point without written
approval by Owner/EIL except where prior written permission for further processing is
available.
W : Witness Point :
An activity which requires witnessing/inspection/verification by Owner/EIL when the

activity is performed.
After proper notification has been provided (notification modalities and period shall be
finalized before hand), the Contractor is not obliged to hold further processing if
Owner/EIL is not available to witness the activity or does not provide comments before
the date notified. Basis of acceptance shall be as per relevant technical specification.
Rw : Review of Contractor’s documentation.
S : Surveillance Inspection by Owner/ EIL.

Monitoring or making observations to verify whether or not material/items or services
conform to specified requirements. Surveillance activities may include audit, inspections,
witness of testing, Review of quality documentation & records, personnel qualifications,
etc.
WC : 100% Examination by Contractor.
Responsibility for execution of the inspection/testing is with the Contractor; Owner/EIL

only verifies examination or testing done by the Contractor at important stages
Page 686 of 851

Page 5 of 105
ITP NO: 3210 REV 0

ABOVE GROUND PIPING
(sheet 1of 11)
Records to be
Sl.
Activity Contractor EIL Submitted/
No
Format No.
CAT A CAT B
A. PRIOR TO FABRICATION
1. Incoming Material Contractor to check all free issue materials and

a) Owner’s supply maintain records of MIV for material issued by
owner/EIL
b) Contractors supply WC Note -1 Format M2
2. Welding Filler Material Approval/Qualification Format M3, M4

a) Review of Manufacturer’s Test WC* HP* HP*
Certificates/Documents & Sampling
b) Laboratory Testing, if any WC HP HP Format M3, M4
3. WPS/PQR
a) Review of proposed procedure WC HP HP Format M5
b) Welding of Test Coupons and subsequent WC HP HP Format M6
testing
c) Approval of final WPS/PQR WC HP HP Format M5,M6

4. Welder performance Qualification WC Rw Rw Format M7
5. Certification & approval of welders. WC HP HP Format M8

6. NDT Procedure Qualification
i) Review of proposed procedure WC HP HP Yes
ii) Witnessing of Proposed Procedure Testing WC HP HP Yes
iii) Approval of Qualified Procedure WC HP HP Yes
7. Review of Joint numbering in Isometrics (Big & WC HP S Yes

Small bore)/Sketches
8. Lines where Isometrics not available WC Rw Rw Yes
a) Preparation of sketches
b) Joint Numbering in sketches WC HP Rw
9. Material traceability & Transfer of Heat Nos. WC HP S Format M9
* a) Notwithstanding any other tests/documentation required for qualification/approval of filler

metals :
i) For Alloy Steel & Stainless Steel welding filler metals, chemical analysis to be carried
out for every batch.
ii) For Low Temperature Services piping, Impact testing to be carried out for every
batch of the filler metal, to be witnessed by PMC/owner
b) For NACE filler metals, corrosion tests like HIC, SSCC, etc. to be carried out for every batch.
However, HIC/SSCC tests done earlier & duly witnessed by a reputed third party, will be
acceptable.
Page 687 of 851

Page 6 of 105
ITP NO: 3210 REV 0

ABOVE GROUND PIPING
(sheet 2 of 11)
Records to be
Sl.
No.
Format No.
CAT A CAT B
B. FABRICATION /ERECTION
1. Material as per piping class (check w.r.t. WC W S Format M10
approved colour coding procedure), Fit-up check
a) Dimensional checks WC W S
b) Fit-up check for butt joints and socket joints WC W S
c) Fit-up checks for branch joints WC W S
2. Pre-heat (if any) WC S --
3. Certificate of purity of purging/shielding Gas (if WC S -- Yes
any)
4. Purging rate (if any) and arrangement WC S --
5. Shielding rate (if any) WC S --
6. Baking of Electrodes WC S --
7. Inter-pass cleaning & Temperature check. WC S --
8. Visual Examination of completed welds having
a) Random Radiography WC W S Format M11
b) 100% Radiography WC S --- Format M11
9. a)Monitoring of PWHT Cycle WC S --
b) Review of Time – Temperature graph WC Rw Rw Yes
10. Hardness Check WC S -- Format M12
a) For CS material
b)For AS Materials WC W S Format M12
11. a) PT/MT (Branch Joints) WC W S Format M13,
b)PT /MT (Others) WC W S Format M13,
M14
12. a)Identification of Joints for Radiography (for WC S -- Format M15
Random Radiography only)
b)Check shot for radiography WC HP HP Format M15
13. Review of Radiographs interpreted by the WC HP W Format M16
Contractor
b) For Alloy Steel/SS Piping WC HP W Format M16
14 Check shot for Radiography WC W Rw Format M16
15 Surface cleaning and primer application WC W S Format M17
16 Lifting arrangement (for critical piping only) WC S Rw Yes
17 Test certificates for lifting tackles WC S Rw Yes
18 Location and orientation of Branch connections WC S Rw Annex-1
19 Provision of Inst. Tappings WC HP W Annex-1
20 Provision of vents and drains WC Rw Rw Annex-1
21 Correctness of type of supports, Anchors, Guides WC HP W Annex-1
22 Correctness of gaskets/ fasteners WC W S Annex-1
23 Correctness of valves WC HP W Annex-1
(NRV, Gate, Globe, control Valves etc), steam
traps and their direction of flow.
a) C.S. piping
24 b) A.S. Piping, S.S Piping, NACE piping WC HP W Annex-1
25 Provision of cold pull, if any. WC HP W Annex-1
Page 688 of 851

Page 7 of 105
ITP NO: 3210 REV 0

ABOVE GROUND PIPING
(sheet 3 of 11)
Records to be
Sl.
No.
Format No.
C PROOF TESTING CAT A CATB
1. Procedure Review (Refer Annexure -2) WC HP Rw Annex-2
2. Correctness of Testing arrangements. (Refer WC S -- Annex-2
Annex-2)
3. Check all valves kept open and confirm that WC W S Annex-2
testing is not done against closed valve seat
4. Isolation of equipments, control valves, WC W S Annex-2
Instruments, bellows. Removal of flappers from
5. Scrutiny of test packs for Mechanical & NDT WC HP W Annex-I,
Clearance Format M21
6. Positive Material Identification as per WC Rw -- Format M18
specification after completion of installation.
7. Preparation of Punch list .(Refer Annex-3) WC W W Annex-3
8. Review of Punch List prepared by Contractor WC Rw Rw Annex-3
9. Liquidation of check list, if applicable.(Refer WC HP HP Annex-3
Annex-3)
10. a) Review of Calibration certificates of pressure WC HP W Format M1
Gauges
11. b) Field Calibration, if any WC S -- Yes
12. Air/Water Flushing (preliminary) WC S S ---
13. Visual inspection of all weld joints for leak WC HP W ----
during Pneumatic/ Hydrotesting
14. Draining of Water & Air Drying (Refer WC W S Annex-2
15. Removal of temporary blinds/supports.(Refer WC W S Annex-2
Annex-2)
16. Pickling of system, if required WC W S Format M19
17 Boxing up including reinstallation of flappers of WC S -- Annex-2
check valves
18 Review of Records of fasteners & gaskets WC Rw Rw Yes
19 Torque tightening/ tensioning of flange joints, WC W S Yes **
wherever applicable
20 System testing WC HP Format M20
21 Setting of spring supports WC HP Annex-2
22 Modification of Tested lines.(Refer Annexure - WC Rw Rw Annex-4
4))
2) Pre-commissioning activities such as chemical cleaning, card board blasting,
system testing are not covered by these ITP’s. The contractor shall develop ITP’s
for such activities and obtain Owner/ PMC/ Licensor’s approval.
** Refer Procedure for Identification and Boxing up of flange joints not subjected to hydrostatic test
at site No. 5-7700-0120, enclosed elsewhere in the contract.
CAT A: All services involving hydrogen and hydrogen bearing fluid., , all SS, AS,NACE,LTCS ,clad
Inconel, piping ,SHP/HP Steam piping. All CS piping for process lines all Steam lines under
purview of IBR and excluding category Jacketed piping.
CAT B, Piping for “D” class fluid, Non IBR portion of condensate & steam lines
Page 689 of 851

Page 8 of 105
ITP NO: 3210 REV 0

ABOVE GROUND PIPING
(sheet 4 of 11)
ANNEX – 1
Checklist for Mechanical Clearance - A/G Piping
Project : ______________________________ Report No : ____________________________
Plant/Unit : ____________________________ Date : ________________________________
Contractor : ___________________________ Area : ________________________________
Loop No : ____________________________ INCH MTR : __________________________
Line No (Isometric No.) Rev. GAD No. Rev. P&ID No. Rev.
Items to be checked Accept Remarks

Contractor
1. Installation checked as per Isometric w.r.t.
CONFIGURATION : Route, plumb, elevation,
Clearance for thermal
expansion/ insulation
BRANCH : Location, angle, orientation,
type, RF pad, etc.
STEAM TRAP : Direction
2. Installation checked as per GAD w.r.t.
CONFIGURATION : Route, clearance for thermal
expansion/insulation
3. Installation checked as per P&ID
4. Isometrics completed for ( enclosed ):
a. Joint Numbering (Shop & Field Welds)
b. Spool Numbering
c. As-built routing & dimensions
5. Valves(Check Rating, Gaskets, Flow Direction, Nos
Sheet No., Tag No., Spindle direction, CSO
LO/LC, Damage, etc)
Gate Valves
Globe Valves
Check Valves
Control Valves Tag Nos.:
Safety Valves Tag Nos.:
Any other valves :
6. Strainers : Check for clearance, flow direction,

elements
FORMAT NO: ____________________ ( Sht 1/4 )
Page 690 of 851

Page 9 of 105
ITP NO: 3210 REV 0
ABOVE GROUND PIPING

(sheet 5 of 11)
Item to check Accept Remarks

Contractor
7. Flanged Joints
Total Nos.
Check for type of flange
Check for Rating
Check for Alignment, (proper gap & parallelity
Check for Correct Studs & nuts – dia., length, Material, uniform
protrusion of studs, anti seize compound
Check for correct gasket ( type, size, spec., thickness, etc.)
Torque values used for tightening
8. Seal Welding of Screwed Connections (if Required)
9. Vents/Drains as per Dwg and Provision of additional high point
Vents and/or low point Drains, if reqd.
10. Reinforcement pads as per piping class
11. Orifice Flanges :
Check for Tag No., tapping orientation, tap valve, jack screw,
straight run length of upstream & downstream
12. Local Gauges : Check for accessibility
13. Slope (When Applicable)
14. Supports
a) Guides, Cross Guides, Trunnion, etc.
i) Check for correct type, material & dimension
ii) Check welding
iii) Check for vent hole on pads (if applicable)
iv) Check offset for thermal expansion
v) Check clearance of guide
vi) Check U bolt for slide support
b) Spring Support
c) Verify tag no. and check details as per data
sheet/spring set
d) Check for locking arrangement and any
damage
during transit, etc.
e) Check for completeness of installation as per drg.
Including welding of mounting cleat/ bracket
iv) Check for locking during installation and pressure test
c) Bracket Support & Inserts with Anchor Fasteners :
i) Check for members dimensions and materials
ii) Check for welding
iii) Check for bolting
iv) Check for appearance/ damage
FORMAT NO: ____________________ ( Sht 2/4 )
Page 691 of 851

Page 10 of 105
ITP NO: 3210 REV 0
ABOVE GROUND PIPING

(sheet 6 of 11)

Contractor
15. Vents/ Drains :
- As per drg.
- Orientation of valve handles
- Clearance for hose
- Requirement of additional vents/ drains (highest/lowest pt.)
16. Earthings :
a) Check for location
b) Check for dimension of lug welding
17. Joists History sheets enclosed for :
17.1 Material Traceability as per Procedure No:__________
(refer enclosed suggested Format)
17.2 Fit ups checked
17.3 NDT Complete (Radiography, MT, PT)
17.4 Stress Relieving & Hardness check complete
17.5 Positive Material Identification (PMI)
Checked for Removal/Blinding-off of:
a. Control, Safety and Check Valves
b. In-Line Instruments
c. Rupture Discs
d. Equipment Nozzles
e. Others
18. Supports and Weld/Flanged/Screwed connections free from
insulation or other coverage`
19. Checked Installation of (Indicate Location in Drawings)
a. Temporary Blinds/Spades
b. Temporary Strainers
c. Temporary Dummy-Spools
d. Temporary Gaskets
e. Others
20. Expansion Bellows -
a) Checks prior to installations
- Physical damages
- Transit locks are intact
- Dimensions as per drgs.
b) Check during installation
- Parallelity of mating flanges
- Face to face dimension of mating flanges
- Concentricity of mating flanges
- No stress on expansion bellows
- Record
FORMAT NO: ____________________ ( Sht 3/4 )
Page 692 of 851

Page 11 of 105
ITP NO: 3210 REV 0
ABOVE GROUND PIPING

(sheet 7 of 11)

Contractor
c) Isolation during pressure tests
- Bellow mfg. recommendations on isolation of
bellow during pr. Test to be followed
- If recommended expn. Bellow to be dropped during
pr. Test.
21. Cleanliness Internally and Externally
22. Rotating Equipment Final Alignment Checked with piping
23. Removal of unwanted construction supports
24. Instrument tapings provided as per Drawing
25. Physical-Walk-Through – The – Line, checked for gross
irregularities including physical damages, unwanted tacks,
arc strikes, spatters and space for thermal expansion.
Other :
Remarks
Reviewed by Contractor (minimum one level higher than checker)

Name : Designation :
Date :
EIL
Sign :
Date :
Name : Designation :
FORMAT NO: ____________________ ( Sht 4/4 )
Page 693 of 851

Page 12 of 105
ITP NO: 3210 REV 0
ABOVE GROUND PIPING

(sheet 8 of 11)
ANNEX – 2
Piping Hydro Test Release Record – A/G Piping
Project : ______________________________ Report No : __________________________
Plan : ________________________________ Date : _______________________________
Contractor : ___________________________ Area : _______________________________
Loop No : ____________________________ REF P & ID No. : _____________________
INCH MTR : _________________________
From ________________ To _____________
Line No. (s) Isometric No. (s) P&ID No. (s)
Test Medium : Test Duration : Design/Test Pressure :

Test Pressure Gauge No. Range Calibration Certificate No.: Gauge Calibration Date:
Items to check Accept Witness

Contractor EIL
Field Installation Checklist Prior to Hydrotest Signed
Punch list Prepared Yes No
Pre – Hydrotest Punch items Cleared
Accessibility to Inspection/Witness Locations
Capacity of pressurizing pump checked
Cordon off area for high pressure testing, as required
Pre-hydrotest flushing carried out
IBR/Others test Witnessing Required Yes No
System Released for Pressure Testing :
Contractor : EIL:
Sign : Name : Sign : Name :

Date : Date :
Designation : Designation:
FORMAT NO: ____________________ ( Sht 1/2 )
Page 694 of 851

Page 13 of 105
ITP NO: 3210 REV 0
ABOVE GROUND PIPING

(sheet 9 of 11)
Piping Hydro Test Record – A/G Piping

ACTIVITY Date Time
Water Filling and Venting started at
Water Filling Completed
Vents Closed
Isolation of Pressurizing pump
Test completed at :
- Water drained
- Air
a. Control & Safety vales
b. On line Instruments
c. Rupture disks
d. Deblinding
e. Others
- Cold setting of spring supports carried out
- Test Result Acceptable Not Acceptable
Contractor : EIL :
Sign : Sign:
Date : Date:
FORMAT NO: ____________________ ( Sht 2/2 )
Page 695 of 851

Page 14 of 105
ITP NO: 3210 REV 0
ABOVE GROUND PIPING

(sheet 10 of 11)
ANNEX – 3
Punchlist
Project : _____________________________ Report No : ______________________________
Plan : _______________________________ Date : ___________________________________
Contractor : __________________________ Area : ___________________________________
Loop No : ___________________________ REF P & ID No. : _________________________
Description : _________________________________________________________________________
Ref Document : _____________________________________________________________________
Punch Prio Description of Punch Location Prepared Action Due Completion

Item rity Items By By date Acceptance
No.
Priority: 1. Needed for pressure test 2. Needed for commissioning 3. Needed for start up 4. Needed for
plant acceptance
Contractor : EIL :
Sign : Sign :
Date : Date :
Name : Designation : Name : Designation :
FORMAT NO: ____________________ Sh. 1/1
Page 696 of 851

Page 15 of 105
ITP NO: 3210 REV 0

ABOVE GROUND PIPING (sheet 11 of 11)
ANNEXURE-IV
Indicative format for Authorizing/Recording of Modification of Piping Joints after Mechanical clearance /NDT
Clearance/ Hydro Testing /Pneumatic Testing of pressure Test Packages/Loops in piping jobs.
Job No. : Unit No.: Report No: Date:
Pressure Test Package No.:
Owner/Client :
PMC : System Name/No. :
Contractor : Previous Hydrotest Date :
Drawing No :
Line No. :
Joint Nos. to be modified (attach sketch) :
Size & type of joint :
New Joint Nos. :
Deleted Joint Nos. :
Modification Joint Nos. :
Reason for Modification :
A) Proposed checks/NDT / Testing after Modification

1. Fit up and Traceability. :
2. PMI Checks : Mark ‘√’ in box as necessary
3. MPI Test : PT (root/final) : RT :
4. PWHT/Hardness : Required. : Not Required. :
5. Hydrotesting : Pneumatic Test :
Authorized Signatory (note-1)
Name
Signature
Date
B) Proposal Accepted by EIL ( note-2)
Area Co-ordinator Welding/ NDT Incharge
Name
Signature
Date
Clearance/Acceptance after modifications (All Supporting Documents enclosed)

Mechanical clearance : Contractor Mech. Signature. EIL Mech. Signature.
NDT Clearance : Contractor QA/QC. Signature. EIL Welding/NDT Signature.
Testing Acceptance : Contractor Mech. Signature. EIL Mech. Signature.
Final acceptance after Modification
Contractor EIL
Name
Signature
Date
Note: 1. Authorized signatory(*): RCM/ Site In charge of execution agency

2. RCM/SIC of EIL may seek opinion of Engineering , prior to acceptance of proposal from
contractor as necessary.
Page 697 of 851

Page 16 of 105
ITP NO: 3220 REV 0
COLUMN INTERNALS
Records to be
Sl.
No.
Format No.
CAT A
INSTALLATION OF COLUMN INTERNALS
A. Before Installation
1. Internal Installation Procedure including WC Rw Yes

identification of confined space hazards &
mitigation thereof
2. Material inspection WC HP Note-1
3. Level check on TSRs WC S Format M49
4. Check for downcomer clearance and Tray WC S Format M49

clearance
5. Distance between TSRs WC S Format M49
B. After Installation - Check for
1. Exit weir height WC S Format M49
2. UDFC WC S Format M49
3. Tightness of bolts WC S Format M49
4. Orientation and tightness of clamps WC S Format M49
5. Provision of lock nuts/seal plates WC HP Format M49
Page 698 of 851

Page 17 of 105
ITP NO: 3220 REV 0
COLUMN INTERNALS
Records to be
Sl.
No.
Format No.
CAT A
6. Correctness of installation of WC HP** Format M49

shimming/bolting for top downcomer
7. Correctness of gasketing (if any) WC S Format M49
8. Tray to tray distance and level of trays WC S Format M49
9. Leak testing of seal pans as applicable WC S Format M49
10. Damaged, missing valves and valve WC S Format M49

movements for valve trays
11 Fitting of proper valve combination WC S Format M49
12 Damage to deck components WC S Format M49
13 Level and alignment of inlet weir and exit WC S Format M49

weir
14 Check for slots on tray components to be WC S Format M49
fully
15 Covered WC S Format M49
16 Gaps at downcomer ends WC S Format M49
17 Removal of temporary plugs after testing WC S Format M49
18 Cleaning of all trays & inside of equipment WC* HP Format M49
19 Certification of installation by Vendor’s WC* HP** Format M50

representative ,Final boxing up, if any.
* 100% Check for All activities by Vendor Representative pertaining to material receipt,
identification, pre-installation checks and installation to be carried out in the presence of Vendor’s
representative and duly certified and documented for submission as final document
** By Owner/Process Licensor
CAT A: All works
Page 699 of 851

Page 18 of 105
ITP NO: 3230 REV 0

FIRED HEATERS
(sheet 1 of 4)
Records to be
Sl.
No.
Format No.
CAT A
1. Incoming Material Contractor to check all free issue materials and
c) Owner’s supply maintain records of MIV for material issued by
owner/EIL
d) Contractors supply WC Note -1 Format M2
2. Welding Filler Material Approval/Qualification
a) Review of Manufacturer’s Test WC Yes

Certificate/Documents HP*
b) Laboratory testing, if any
Format M3, M4
i) Carbon Steel WC Rw
ii) Alloy Steel/Stainless Steel WC W Format M3, M4
3. WPS/PQR
a) Review of proposed Procedure WC HP Format M5
b) Welding of Test Coupons and subsequent

testing
i) Carbon Steel WC W Format M6
ii) Alloy Steel/Stainless Steel WC W Format M6
iii) All other materials including NACE CS, CS Format M5, M6

WC W
for H2 Service
c) Approval of final WPS/PQR WC HP
4. Welder performance Qualification Test WC S Format M7
5. Certification & Approval of welders before WC Format M8

HP
deployment on job
6. i) NDT Procedure Qualification Yes
a) Review of proposed Procedure WC HP Yes
b) Witnessing of Proposed Procedure WC Yes

Testing W
c) Approval of Qualified Procedure WC HP Yes

7. Joint Numbering for coils/ pressure parts WC S Yes
B. FABRICATION
STEEL WORK
1. Materials as per AFC drawing WC S Yes
2. Dimensional check WC S Yes
3. Fit-up check WC S Yes
* Notwithstanding any other tests/documentation required for qualification/approval of filler metals:
i) For Alloy Steel & Stainless Steel welding filler metals, chemical analysis to be carried out for
very batch.
ii) For NACE filler metals, corrosion tests like HIC, SSCC, etc. to be carried out for every batch.
However, HIC/SSCC tests done earlier & duly witnessed by a reputed third party, will be
acceptable.
Page 700 of 851

Page 19 of 105
ITP NO: 3230 REV 0

FIRED HEATERS
(sheet 2 of 4)
Records to be
Sl.
No.
Format No.
CAT A
Weld Visual Inspection WC W Yes
4. Radiography, as applicable Yes
a) RT Marking (for random/spot radiography WC S Yes
only)
b) RT Interpretation WC W Yes
5. Completion of structures as per AFC WC W Yes
6 dSurface
i cleaning for primer painting WC W Format M17
7 Primer Coating as applicable * * Format M17
C COIL WORK
1. a)Material as per specification (check w.r.t. WC W Yes
approved colour coding procedure)
b)Dimensional checks WC S ---
c)Fit-up check for butt joints and socket WC S Format M10
joints
d)Fit-up checks for branch joints WC S Format M10
2. Pre-heat (if any) WC S ---

3. Certificate of purity of purging/shielding WC S Yes
4. G (if rate) (if any) and arrangement
Purging WC S ---
5. Shielding rate (if any) WC S ---
6. Baking of Electrodes WC S ---
7. Inter-pass cleaning & Temperature check WC S
Visual check of completed welds having WC S Format M11
8.
a) For Random Radiography
b) 100% Radiography WC S Format M11
9. a)Monitoring of PWHT Cycle WC S
b)Review of Time – Temperature graph WC HP
10 Hardness Check
(i) For C.S. Coils WC S Format M12
(ii) For A.S. Coils WC W Format M12
11. PT/MT WC W Format M13,
M14
Radiography marking (for Random WC Format M15
12. W
Radiography only)
13. Radiography Interpretation/ Review WC HP Format M16
a)For Random Radiography
b) 100% Radiography WC HP Format M16
14. Check Shot for Radiography, if applicable WC W Format M16
15. Clearance for Hydrostatic testing WC HP Format M21
16. Positive Material Identification for base WC HP Format M18
material and welds, as applicable
17. Hydrostatic testing WC HP Format M22
Page 701 of 851

Page 20 of 105
ITP NO: 3230 REV 0

FIRED HEATERS
(sheet 3 of 4)
Records to be
Sl.
No
Format No.
D. ERECTION CAT A
Review of foundation check as per AFC WC HP
1.
drawing
Lifting arrangements WC Rw Yes
2.
Test certificates for lifting tools and tackles WC Rw Yes
3.
Lifting of radiant section columns and their WC S Yes
4.
alignment
WC S Yes
5. Bottom plate fit-up & welding
WC S Yes
6. Radiant shell courses fit-up & welding
WC S Yes
7. Weld visual inspection
Review of radiographs interpreted by the WC W Yes
8
contractors
9 Cutout ----
a) Marking for burners, sight doors, WC S
soot blowers
WC S
b) Marking for balance cut outs
WC S
c) Cutting
10. Coil erection in Radiant section ----

WC S
a) Fixing of coil support castings
WC S
b) Clearance for erection of coil
c) Alignment of completed coil work WC W

11 Assembly and erection of convection box
a) Erection procedure Review WC S Yes
b) Structural including plate work WC S

c) End tube sheets and intermediate
WC S
tube sheets with support brackets
d) Clearance of coil erection WC W
e) Erection of box (If applicable) WC W
Check Shot for radiography for coil field Format M15,
12. WC W
joints, if applicable M16
13. Clearance for Hydro test WC HP Format M23
14. Hydro test for field Joint WC HP Format M23
Page 702 of 851

Page 21 of 105
ITP NO: 3230 REV 0

FIRED HEATERS
(sheet 4 of 4)
Records to be
Sl.
No
Format No.
CAT A
15. Erection, fit-up & welding of stack
a) Erection procedure WC Rw Yes
b) Erection WC W
c) Alignment WC W
Erection Fit-up, welding of ducts and its WC S Yes

16.
support structural
17. Radiography, as required on steel work
WC HP Yes
a) RT Marking
WC W Yes
b) RT Interpretation
18. FD & ID Fan WC Note 4 Yes

19 Installation of auxiliary equipment
a) Burner along with ignition system WC W Yes
and transformer
b) Soot blower alongwith sequential WC W
control panel and electrical wirings
c) Damper with control panel and WC W
winch
d) Air pre-heater (cast, glass, plate) and WC W
steam air heater
WC W
e) Skin thermocouples
Erection of all platforms. Ladders, Hand WC S Yes
20.
rails & miscellaneous structures
WC Note 3
21. Insulation/ refractory lining
WC Note 2
22. Final Painting
23 Liquidation of checklist WC HP Format M26

24 Final inspection and acceptance WC HP
Yes
Review of Test and Inspection documents WC Rw
2) For cleaning & painting, please refer ITP No. 3301
3) For Insulation, please refer ITP No. 3305
4) For Rotary Equipment, please refer ITP No. 2160
CAT A : All works
Page 703 of 851

Page 22 of 105
ITP NO: 3240 REV 0
REFRACTORY & INSULATION WORKS- FIRED HEATER

(sheet 1of 6)
Records to be
Sl.
No.
Format No.
CAT B
A. RADIANT SECTION
1. Radiant shell
Fixing of Ceramic fibre blanket
i) Material inspection Format M2
- Manufacturing test certificates WC Rw Yes

- Testing, if any WC W ---
ii) Clearance for hot work WC HP Yes
iii) Marking of studs WC S Yes
iv) Welding of studs with approved WC S Yes
WPS&PQR
v) Surface cleaning WC S Yes
vi) Check for individual layers of WC W Yes
ceramic
vii) Check for overlap of ceramic blanket WC S Yes
viii) Fixing of speed fix washer and cup WC S Yes
lock
ix) Cleaning and final inspection WC HP Yes
2. ARCH PLATE

iii) Marking of studs/anchors WC S Yes
iv) Welding of studs/anchors with approved WC S Yes

WPS&PQR
vi) Check for individual layers of ceramic Yes
Fibre blankets (CFB) modules and SS WC S
foils
vii) Check for overlap of CFB and modules WC S Yes
viii) Cleaning and final inspection WC HP Yes
Page 704 of 851

Page 23 of 105
ITP NO: 3240 REV 0

(sheet 2 of 6)
Records to be
Sl.
No.
Format No.
CAT B
3. FLOOR PLATE
Laying of castable/fire bricks

ii) Surface cleaning WC S Yes
iv) Check Shelf life prior to application WC W Yes
v) Check for undulations on floor WC S Yes

vi) Check for castable mix WC W Yes
vii) Check for proper compaction WC S Yes
viii) Check for thickness of castable WC S Yes
ix) Curing WC S Yes

x) Cleaning after laying of castable WC S Yes
xi) Check for cracks and repair WC W Yes
xii) Fixing of tar paper, if applicable WC S Yes
xiii) Cleaning and final inspection WC HP Yes

B. CONVECTION SECTION
1)CONVECTION WALLS
Laying of castable
- Testing, if any - Manufacturing test WC W Yes

certificates
Page 705 of 851

Page 24 of 105
ITP NO: 3240 REV 0

(sheet 3 of 6)
Records to be
Sl.
No.
Format No.
CAT B
iv) Welding of studs/anchors with WC S Yes
approved WPS & PQR
v) Surface cleaning WC W Yes
vi) Check for undulations on wall WC S Yes
vii) Check for castable mixing WC W Yes
viii) Check for proper compaction WC S Yes
ix) Check for thickness of castable WC S Yes
x) Curing WC S Yes
xi) Cleaning after laying of castable WC S Yes
xii) Check for cracks and repair WC W Yes

2) END TUBESHEETS
Laying of castable
- Testing, if any WC W Yes

approved WPR & PQR
vi) Check for castable mixing WC W Yes

vii) Check for proper compaction WC S Yes
viii) Check for thickness of castable WC S Yes
ix) Curing WC S Yes
x) Cleaning after laying of castable WC S Yes
xi) Check for cracks and repair WC W Yes
xii) Cleaning and final inspection WC HP Yes

Page 706 of 851

Page 25 of 105
ITP NO: 3240 REV 0

(sheet 4 of 6)
Records to be
Sl.
No.
Format No.
CAT B
3) BREECHING PLATE
Laying of castable
d WPR & PQR WC S Yes
v) Surface cleaning
vi) Check for undulations on plate WC S Yes
x) Curing WC S Yes
4) HEADER BOX
Laying of castable
approved WPR & PQR
WC S Yes
v) Surface cleaning
vi) Check for undulations on box WC S Yes

x) Curing WC S Yes
Page 707 of 851

Page 26 of 105
ITP NO: 3240 REV 0

(sheet 5 of 6)
Records to be
Sl.
No.
Format No.
CAT B
xiv) Surface cleaning WC S Yes
xv) Check for undulations on box WC S Yes
xvi) Check for castable mixing WC W Yes
xvii) Check for proper compaction WC S Yes
xviii) Check for thickness of castable WC S Yes
xix) Curing WC S Yes
xx) Cleaning after laying of castable WC S Yes
xxi) Check for cracks and repair WC W Yes
xxii) Cleaning and final inspection WC HP Yes

C STACK
Laying of castable

approved WPR & PQR
vi) Check for undulations on stack shell WC S Yes
x) Curing WC S Yes
Page 708 of 851

Page 27 of 105
ITP NO: 3240 REV 0

(sheet 6 of 6)
Records to be
Sl.
No.
Format No.
CAT B
D HOT AIR DUCT

ii) Clearance for insulation WC HP Format M24
iii) External Surface cleaning WC S Format M24
iv) Provide spacer rings/anchors WC S Format M24
v) Check for thickness of the mineral wool WC S Format M24
insulation
vi) Check for staggering of joints in WC S
insulation Format M24
vii) Check for providing expansion joints WC W Format M24
viii) Overlapping of metal sheet as per WC S Format M24
specification
ix) Overlap on joints for aluminium WC W Format M24
sheeting as per specifications
x) Sealing aluminium sheeting WC S Format M24
Final inspection & acceptance WC HP Format M25
E INSPECTION & TEST DOCUMENTS
CAT B: All works.
Page 709 of 851

Page 28 of 105
ITP NO: 3250 REV 0

EQUIPMENT ERECTION (STATIC)
(sheet 1of 3)
Records to be
Sl.
No
Format No.
CAT A CAT B
1. BEFORE ERECTION
a. Review of foundation acceptance report WC HP Rw
b. Incoming Material Contractor to check all free issue materials and

e) Owner’s supply maintain records of MIV for material issued by
owner/EIL
f) Contractors supply WC Note -1 Format M2
c. Readiness for erection
i) Centre line marking on equipment WC S -- Format M27

and foundation
ii) Level of foundation (shims/ packing WC S -- Format M27

with marking to be prepared &
kept ready)
iii) Correctness of no. & size of WC S -- Format M27

Foundation bolts
iv) Hole dia and no. of holes in base/ WC S -- Format M27

structure of equipment columns
v) Matching equipment base bolt holes WC S -- Format M27

with actual
foundation bolt layout
vi) Marking orientation WC S -- Format M27
vii) Checking the threads of bolts & nuts WC S -- Format M27
viii) Chipping & roughening of WC S -- Format M27

foundation
d. Outside cleaning, coating/wrapping, WC HP W

painting
(for underground equipment only)
Page 710 of 851

Page 29 of 105
ITP NO: 3250 REV 0

(sheet 2 of 3)
Sl.
No
CAT A CAT B CAT C
2. ERECTION SCHEMES FOR CRITICAL EQPTS
a.Review of rigging procedure WC HP --
3. SAFETY TEST
a .Load test of cranes, lifting beams, slings and WC Rw Rw Rw

shackles, length and dia. of sling & condition of wire
rope by competent authority
4. DURING ERECTION
a. Orientation to be checked WC S -- --
b. Placement of packing as per AFC drg WC S -- --
c. Placement of Main & trailing crane as per approved WC S -- --

rigging procedure
d. Orientation of equipment as per AFC drg WC S -- --
5. AFTER ERECTION
a. Tightening of Bolts and Providing washers WC S -- --
b. Leveling and Alignment of equipments WC HP W --
c. Corresponding requirement elevation & WC S -- --

distance between nozzles in special cases
d. Cleaning of Sleeves before grouting WC S -- --
e. Grouting WC S -- --
i) Acceptance of Specified grouting materials WC HP Rw Rw
ii) Placement of grouting WC S -- --
iii) Curing of grout WC S -- --
f. Final tightening of bolts WC S -- --
Page 711 of 851

Page 30 of 105
ITP NO: 3250 REV 0

(sheet 3 of 3)
Sl.
No
CAT A CAT B
6. PACKED EQUIPMENTS
1. Before Installation
a. Identify the material, check thickness, WC S --

dimensions, no. and angle of fingers of
packing rings
2. During Installation
a. Degreasing and cleaning of packing material WC S --
b. Check packing support plate WC S --
c. Check for stacked or dumped packing as per WC S --

specifications
d. Check for nesting WC S --
e. Check that packings are touching bed limiter WC S --
Review Test and Inspection Documents WC Rw Rw
CAT A Process columns & Reactors ( including internals ), Mounded Bullets, ODC’s or Any special type
of equipment ( Project specific) Vessels & exchangers above 5 T, Hoppers /bins ,Incinerators, combustion
chamber, Boilers
CAT B Seal pots All vessels/exchangers Up to 5T
Page 712 of 851

Page 31 of 105
ITP NO: 3260 REV 0

EQUIPMENT ERECTION ROTARY
(sheet 1of 3)
Sl.
Activity Contractor* EIL
No
CAT A CAT B
1. PRE – ERECTION ACTIVITIES
a. Review of foundation acceptance report WC HP Rw
b. Material Supply
- Owner's supply including templates, if any WC Rw Rw
- Contractor's supply & check testing, if any WC Note-1 Note-1
c. Readiness for erection
i. Level of foundation (shims/packing with markings to WC W --

be prepared & kept ready)
ii. Marking/Centre line of foundation & equipment WC W --
iii. No./dia./length of anchor bolts, depth WC W --

of pockets, verticality of pockets
iv. Chipping, roughing & cleaning of pockets/top of WC HP W

foundation
v. Acceptance of grouting materials as per WC HP Rw

specifications/ Manufacturer’s recommendations
2. LIFTING TACKLES
a. Certificate from competent authority WC Rw --
b. Load test of Cranes/Lifting beams/slings/ shackles/ WC Rw --

Wire ropes, etc. for weight of equipments to be
handled
3. VISUAL INSPECTION OF EQPT.

TAG/IDENTIFICATION NO.
a. For any damage WC S --
b. Free shaft rotation WC S --
4. Drilling & Tapping, holes in the base plate of eqpt. (if WC S --

reqd.)
5. Approval of Rigging procedure WC HP Rw
* Inspection by Vendor/Manufacturer for all critical equipments

Page 713 of 851

Page 32 of 105
ITP NO: 3260 REV 0

(sheet 2of 3)
Sl.
No
CAT A CAT B
a. Level/elevation of base frame WC S --
b. Checking of foundation bolts (for S --

WC
location, threading, greasing, etc.)
c. Checking orientation of equipment WC S --
d. Placement of Crane(s), if applicable WC S --
e. Elevation/level of equipment and placement of

shims/packings as per AFC drawings WC S --
f. Distance between couplings WC S --
g. Rough alignment of equipment WC S --
h. Availability of Vendor’s engineer at site WC S --

(For critical equipments
i. Cleaning of pockets/ grouting of foundation bolts’ HP --
WC
pockets/base frame
j. Erection of auxiliary equipment/ Accessories WC S --
k. Final alignment of equipment WC S --
WC W W
- Without piping
HP W
- With piping (After tightening the flange bolts) WC
WC S --
l. All protection & safety guards installation
Page 714 of 851

Page 33 of 105
ITP NO: 3260 REV 0
(sheet 3 of 3)
Sl.
No
CAT A CAT B
7. POST ERECTION ACTIVITIES
a. Curing of grout WC
S --
b. Auxiliary connections to be mounted on eqpts as per WC S --

drawing
WC S --
c. Final tightening of bolts
d. Chemical cleaning of equipment parts/ connected S --
WC
piping
e. Boxing up of equipment & connected piping WC S --
f. Log book maintenance (For rotating of shaft and any

other activity to be performed as per vendor’s WC --
recommendations) S
g. No load run of motors WC HP W
WC HP W
h. Re-coupling of motor & reconfirmation of alignment
Review Test and Inspection Documents WC S --
* Inspection by Vendor/Manufacturer for all critical equipments
NOTE : 1)For Incoming material Inspection please refer ITP no: 6-82-1010
CAT A : Compressors, Pumps Turbines & Diesel Engines, Rotary Driers or Any special type of equipment (
Project specific) , Fans & Blowers, Conveyors & Material handling Equipment
CAT B : Metering & Dosing Pumps, non critical pumps/blowers , any other items etc
Page 715 of 851

Page 34 of 105
ITP NO: 3270 REV 0
INSTALLATION/ERECTION & TESTING OF CRANES (EOT/HOT)
Sl.
No.
CAT A CAT B
1. BEFORE ERECTION
a. Execution scheme of equipment foundation WC Rw
b. Materials supply WC Note-1 Note-1
c. Readiness for erection WC W --
i. Structural steel girder span centre to centre WC W --
& elevation difference
ii. Check centre to centre distance of rails, WC W --
gaps, elevations, crab wheels distances
iii. Check buffer stops WC W --
2 a. Erection and assembly of components like WC S --
LT, Crane Girders, Crab, Platforms, etc.
b. Review of hoist ropes and assembly of hook WC S --
blocks
3. a. Electrical installation, testing & no load test WC S --
of motors
b. Coupling of motors to drivers WC S --
4 NO LOAD TEST
a. Winding & unwinding test WC W --
b. Traversing test WC W --
c. Traveling test WC W --
5. LOAD TEST
a. Winding & unwinding test WC HP W
b. Traversing test WC HP W
c. Traveling test WC HP W
d. Load & over load testing WC HP W
e. Deflection of girder WC HP W
CAT A: Special purpose M/C viz. Pot tending M/c All EOT cranes with capacity 10T and above
CAT B: All EOT /HOT cranes with capacity below 10T
Page 716 of 851

Page 35 of 105
ITP NO: 3280 REV 0

STORAGE TANKS
(sheet 1 of 5)
Records to be
Sl.
No
Format No.
CAT A CAT B
1. Review Acceptance Report of the tanks WC HP Rw

foundation
2. Incoming Material WC Note-1 Note-1
3. Welding Filler Material WC* HP HP
Approval/Qualification
a)Review of Manufacturer’s Test Yes
Certificate/Documents
b) Laboratory testing, if any
i) Carbon Steel WC HP -- Format M3, M4
ii) Alloy Steel/Stainless Steel WC HP -- Format M3, M4
iii) Low Temperature Services WC HP -- Format M5
4. WPS/PQR
a) Review of proposed procedure WC HP HP Format M6
b) Testing Format M6
i) Carbon Steel WC Rw Rw Format M5, M6
ii) Alloy Steel/Stainless Steel WC HP HP Format M7
c) Approval of Final WPS/PQR WC HP HP Format M8
5. a) Welder performance Qualification WC HP HP
Test
b) Certification & approval of welders WC HP HP Yes
6. NDT Procedure Qualification ---
i) Review of proposed procedure WC HP HP Yes
ii) Witnessing of the proposed procedure WC HP HP Yes
testing
iii) Approval of Qualified Procedure WC HP HP ---
7. Review of Joint numbering in drawings WC HP HP Yes
8. Review fabrication, erection, testing WC HP HP
Procedures for job
B. FABRICATION/ERECTION
BOTTOM
1. Blast cleaning & painting of underside WC HP S
of bottom plates
* Notwithstanding any other tests/documentation required for qualification/approval of filler metals :
i) For Alloy Steel & Stainless Steel welding filler metals, chemical analysis to be carried
out for every batch.
ii) For Low Temperature application, Impact testing to be carried out for every batch of
the filler metal, to be witnessed by PMC/Owner.
iii) For NACE filler metals, corrosion tests like HIC, SSCC, etc. to be carried out for
every batch. However, HIC/SSCC tests done earlier & duly witnessed by a reputed third party,
will be acceptable.
Page 717 of 851

Page 36 of 105
ITP NO: 3280 REV 0
STORAGE TANKS
(sheet 2 of 5)
Records to be
Sl.
No
Format No.
CAT A CATB
2. Plate lay out, overlap and fit up WC S --
3. Sequence of welding WC S --
Size and positioning of backing plate S --

4. WC
for annular plates
5. Baking of electrodes WC S --
6. Inter-pass cleaning WC W --
7. WC W S
Visual check of welding
PT/MT/NDT of annular plate butt W S
WC
8 welds and bottom plate butt welds (As
applicable)
Vacuum box test for bottom plate W S
9. WC
welding
SHELL
Shell course alignments and fit-up of W S
1. WC
vertical and circumferential joints
before welding
a) Check Shell diameter, circularity, W S
2. WC
perpendicularity, straight edge before
welding.
b) Check Shell diameter, circularity, W S
WC
perpendicularity straight edge after
welding,
Visual check of welding and Back WC S -
3
chipping
4. WC S -
Inner side welding visual check
5. Location, size, alignment and fit-up of WC HP HP
nozzles & other openings
6. R.F. Pads fit-up/welding WC S -
PWHT of shell, RF pads, Nozzles, WC HP W

7
manholes, etc. (As applicable)
8. Radiography marking (for Random WC HP W
radiography only)
9. Curb angle and Wind girders fit- WC S Rw
up/welding
Page 718 of 851

Page 37 of 105
ITP NO: 3280 REV 0

STORAGE TANKS
(sheet 3 of 5)
Records to be
Sl.
No
Format No.
CAT A CATB
10. PT/MT of nozzles, wind girders and WC W S
other attachments (as applicable)
11. RF pads pneumatic test WC HP W
12. WC W S
Shell to bottom fit up
13. Shell to bottom I/S welding root run WC W S
visual/Oil chalk test
Shell to bottom O/S welding visual and W S
14. WC
PT
15. WC S --
Fabrication and erection of stair ways
16. Cleats welding for insulation WC S --
17. Review of radiographs interpreted by WC HP Rw

the contractors
FIXED ROOF
1. Blast cleaning and painting Roof W S
WC
Structure, underside of Roof plates
2. Location and Welding of Roof supports WC S --
Alignment and welding of Roof S --

3. WC
structures
4. Plate layout, overlap and fit-up WC S --
5. Visual check of roof welds WC S --
6. Location, size and alignment of roof WC W S

nozzles, man-holes vents, etc.
7. PWHT (as applicable)
i) Procedure Review WC HP Rw
ii) PWHT cycle monitoring WC W --
iii) Time-Temp Chart Review WC HP Rw
RF pads fit-up & Welding WC S --
8.
9. RF pad pneumatic testing WC HP S

PT/MT of Nozzles, vents & other WC W S
10.
attachments
Welding of Roof plate with shell/ curb WC S --
11.
angle
Page 719 of 851

Page 38 of 105
ITP NO: 3280 REV 0

STORAGE TANKS
(sheet 4 of 5)
Records to be
Sl.
No
Format No.
CAT A CATB
FLOATING ROOF
Temporary staging spacing and levels S --

WC
1.
Plate layout, overlap, fit-up/welding WC S --

2.
Availability of approved calculations HP --
WC
3. for design of buoys
WC S --
4. Buoys fabrications
5. Vacuum testing of roof-plate welds WC W --
6. Location of sleeve supports WC S --
7. Pad plate welding with roof and sleeve WC S --

support
8. Fixing and welding of Buoys WC S --
Initial – lift WC S --
9.
Supports fixing through sleeves WC S --
10.
Seal welding of support sleeves from S --
WC
11. beneath after dewatering
Air test of Buoys WC S --

12.
Pontoon welding
13.
Location, fixing and welding of man W --
WC
14. holes, drains etc
Shell to pontoon clearance WC HP --

15.
Seal fixing WC HP --
16.
Floating Roof Testing, as required e.g. WC HP --
17.
flooding etc
Page 720 of 851

Page 39 of 105
ITP NO: 3280 REV 0

STORAGE TANKS
(sheet 5 of 5)
Records to be
Sl.
No
Format No.
CAT A CATB
C.
TESTING
Correctness of testing arrangements S --
1. WC
especially size of blind
flanges/vents/drains/ temporary piping
Mechanical / Inspection clearances WC HP HP
2.
Earthing of ladder & shell WC HP W
3.
Settlement readings during water filling WC HP Rw
4.
Hammer test WC HP W
5.
Air pressure test WC HP W
6.
Vacuum test WC HP W
7.
Roof collapsibility test in case of WC HP W
8.
floating roof tanks
Calibration of tanks from Statutory WC Rw Rw
9.
authorities
INSPECTION & TEST
DOCUMENTS
NOTE : 1) For Incoming material Inspection please refer ITP No: 6-82-1010
2) For cleaning & painting, please refer ITP No. 3301
3) For Insulation, please refer ITP No. 3305
CAT A: All Site fabricated steel storage tanks for process fluid /Hydrocarbon, floating roof,
tanks having capacity 600cum or 10m dia and 8 m height.
CAT B: Site fabricated steel storage tanks for Raw water, Fire water, waste water, DM water,
etc. and all tanks not covered under “CAT A”
Page 721 of 851

Page 40 of 105
SECTION - B
Page 722 of 851

Page 41 of 105
FORMATS
FOR
MECHANICAL WORKS
Page 723 of 851

Page 42 of 105
CONTENTS

NO NO. DATE NO.
FORMATS FOR MECHANICAL WORKS
1. Record of Calibration of Measuring/Testing M-1 Rev 0 14.01.2014 44

Equipments
2. Incoming Material Inspection Report M-2 Rev 0 14.01.2014 45
3. Electrode Qualification Test report M-3 Rev 0 14.01.2014 46
4. Inspection Report - Filler Material Manufacturer’s M-4 Rev 0 14.01.2014 49
works
5. Format for Welding Procedure Specification (WPS) M-5 Rev 0 14.01.2014 50
6. Suggested format for procedure Qualification record M-6 Rev 0 14.01.2014 52
(PQR)
7. Suggested format for manufacturer’s record of M-7 Rev 0 14.01.2014 54
welder or welding operator qualification tests
8. Welder’s identification card M-8 Rev 0 14.01.2014 55
9. Material Traceability Report M-9 Rev 0 14.01.2014 56
10. Daily Fit-up inspection report M-10 Rev 0 14.01.2014 57
11. Daily Welding inspection report M-11 Rev 0 14.01.2014 58
12. Hardness test record M-12 Rev 0 14.01.2014 59
13. Liquid penetrant examination report M-13 Rev 0 14.01.2014 60
14. Magnetic particle examination report M-14 Rev 0 14.01.2014 61
15. Radiography offering report M-15 Rev 0 14.01.2014 62
16. Radiography interpretation report M-16 Rev 0 14.01.2014 63
17. Daily Painting report M-17 Rev 0 14.01.2014 64
18. Positive material identification (PMI) report M-18 Rev 0 14.01.2014 65
19. Pickling above ground piping certificate M-19 Rev 0 14.01.2014 66
20. System completion report above ground piping M-20 Rev 0 14.01.2014 67
21. Line wise record M-21 Rev 0 14.01.2014 68
22. Shop Hydro test report for Coil (Heater) M-22 Rev 0 14.01.2014 69
23. Mechanical completion record (Heater) M-23 Rev 0 14.01.2014 70
24. Inspection check sheet – daily inspection record of M-24 Rev 0 14.01.2014 71
insulation
25. Inspection check sheet – installation acceptance M-25 Rev 0 14.01.2014 72
certificate for insulation
26. Erection check list M-26 Rev 0 14.01.2014 73
27. Execution scheme M-27 Rev 0 14.01.2014 74
28. Heat exchangers/horizontal vessels Record M-28 Rev 0 14.01.2014 76
29. Columns/Reactors/Vessels Record M-29 Rev 0 14.01.2014 77
30. Machinery Alignment record M-30 Rev 0 14.01.2014 78
31. Permissible tolerance for traveling Rail M-31 Rev 0 14.01.2014 79
32. Test and inspection record – crane M-32 Rev 0 14.01.2014 80
33. Sequence of welding for bottom plates & shell of the M-33 Rev 0 14.01.2014 82
tanks
34. Tank bottom/floating roof inspection record M-34 Rev 0 14.01.2014 83
Page 724 of 851

Page 43 of 105

NO NO. DATE NO.
FORMATS FOR MECHANICAL WORKS
35. Tank shell development drawing with radiographic M-35 Rev 0 14.01.2014 84
spot location
36. Inspection record for tank fabrication M-36 Rev 0 14.01.2014 85
37. Inspection Record for Tank fabrication M-37 Rev 0 14.01.2014 86
38. Inspection Record for checking roundess of tank M-38 Rev 0 14.01.2014 87
39. Inspection Record for checking perpendicularity of M-39 Rev 0 14.01.2014 88
tank
40. Openings/Attachments inspection record M-40 Rev 0 14.01.2014 89
41. Radiography Offering report M-41 Rev 0 14.01.2014 90
42. Radiography Interpretation report M-42 Rev 0 14.01.2014 91
43. Fixed Roof tank inspection record M-43 Rev 0 14.01.2014 92
44. Buoy/Pantoon inspection report M-44 Rev 0 14.01.2014 93
45. Certificate of pressure tests for tanks M-45 Rev 0 14.01.2014 94
46. Floating roof tank tolerance record M-46 Rev 0 14.01.2014 95
47. Tank settlement record M-47 Rev 0 14.01.2014 96
48. Manufacturer’s certification for tank Built to API M-48 Rev 0 14.01.2014 97
Standard 650
49. Installation reporting format for column internals M-49 Rev 0 14.01.2014 98
50. Installation review check list M-50 Rev 0 14.01.2014 104
Page 725 of 851

Page 726 of 851

Page 44 of 105
FORMAT NO. : M-1 REV 0

RECORD OF CALIBRATION OF MEASURING/TESTING EQUIPMENTS
Report No. : ______________
Date : ______________
Project : __________________________________ Name of work : __________________________

Client : __________________________________ Job No. : __________________________
Consultant : ___________________________________
Contractor : ___________________________________
Work order No. : ___________________________________
Make/ Calibration Calibration Next Accepted

Sl. Test Equipment Model No./ Calibrated
Range Certificate No./ Validity Calibration Remarks
No. Description Sr. No. by Contr. EIL
Date Period & Date Due Date
Note : Ensure measuring/test equipment is sent to laboratory prior to expiry of present certificate
_________________ _____________
CONTRACTOR EIL

Page 727 of 851

Page 45 of 105
Format No: M: 02 REV 0

INCOMING MATERIAL INSPECTION REPORT
Report No. :
Date :
Project : Unit : Name of Work :

Contractor : Consultant : Job No. :
Work order No. : P.O. No. & Date : LR No. :
MTC No./
IRN No. Heat/
Sl. SOR Item Material Date of Qty. Qty. Manufacturer/ Ref. Invoice/ Observation/Remarks/
with Date/ Batch
No. No. description/Tag no Receipt Received Accepted Vendor Challan No. Storage Instruction
Field,Lab No.
test,etc
Notes :
INSPECTION ACTIVITY AT SITE (Tick as applicable)

1. Quantity verified and found in order 2. Material condition appears to be good 3. Heat/Batch/Tag No. mentioned on the material
4. Color coding done as applicable 5. Site identification mark on material 6. Correlation w.r.t. IRN/MTC/Lab Tests report
7. TC verification w.r.t. IRN/Spec/QAP, etc. 8. Check forVendor/Source approval 9. Special Requirement if any.
Based on above, materials are accepted.

________________ ______________
Contractor Field Engineer Contractor RCM/Site Incharge
______________ ____________________
EIL Field Supervisor EIL Lead Engineer/Area coordinator/Spread Incharge
(countersigned)

Page 46 of 105

ELECTORDE QUALIFICATION TEST REPORT
(Sheet 1 of 3)
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

Name of Work : _________________________
Job No. : _________________________ Work order No. : ______________________
Site _________________________________ Test started on _____________________
Sponsoring Contractor _________________ Test completed on ___________________
_____________________________________ H.O. Reference _____________________
Manufacturer __________________________ Date of approval ____________________
Brand Name ___________________________ Batch No./Size ______________________
Ref. Code _____________________________ IS/AWS Classification _______________
Colour code ___________________________
All Weld Test
Base material used _____________________
Buttering used Yes/No
Preheat temp. _________________________

Interpass temp. ________________________
Postheat temp/time ____________________
Visual Inspection _____________________
Radiographic result : Gr.I/Gr.II/Not required (As per ASME Sec II Part C)
Mechanical Test Results
UTS YS % Elongation
Size of Current
Identification Kgs/mm2 Kgs/mm2 Gauge length
Electrode AC/DC
Code Actual Code Actual Code Actual
UTS = Ultimate tensile strength YS = Yield strength
Page 728 of 851

Page 47 of 105
(Sheet 2 of 3)
o
IMPACT TEST RESULTS : C
Size of I
Identi- Current Cooling I1 I2 I3 I4 I5 Code
Elect- Average
fication AC/DC Medium Kgf-m Kgf-m Kgf-m Kgf-m Kgf-m Kgf-m
rode Kgf-m
CHEMICAL ANALYSIS RESULTS

WELD PAD/FILLER WIRE
Size
Iden- Curr- C Mn P S Si Ni Cr Mo V Cu Co/Nb
of % As per
tifi- ent.
Elec- Code
cation AC/DC
trode
% As per
Actual
Code/Act
FILLET WELD TEST RESULT
Size of Current F H V OH
Identification
Electrode AC/DC Flat Horizontal Vertical Over Head
Macro Examinations Result ____________________
Procedure Test Result

Material __________________________________
Pipe/Plate Size______________________________ Position ____________________
In combination if any (ELECTRODE)__________ Current : ____________AC/DC
Preheat temp. _______________________________
Post heat temp/time _________________________
Visual Examination Result ____________________ Radiographic Examination
Dye Penetrant/Magnetic Particle Testing Result ________________

Result ____________________________________
Page 729 of 851

Page 48 of 105
(Sheet 3 of 3)
TENSILE AND BEND TEST RESULT
Tensile Tests Kg/mm2 Bend Tests

Actual
Position Identification Code F1/S1 F2/S2 R1/S3 R2/S4
T1 T2
Impact Test Results ________________ oC
Identification : _____________________
I
I1 I2 I3 I4 I5 Code requirements
Location average
Kgf-m Kgf-m Kgf-m Kgf-m Kgf-m Kgf-m
Kgf-m
WELD
HAZ
POSITION TEST AS PER IS-814 (M.S. ELECTRODES ONLY)
Material ________________________
Plate size ________________________
Visual __________________________ Radiography Result ________________
Identification _____________________
Tensile Test Bend Tests Impact Tests

T-kg/mm2 I1 I2 I3 I
Posi- Identifi- Code
F1 F2 R1 R2 Kgf-m Kgf-m Kgf-m ave-
tion cation Code Actual Kgf-m
-oC -oC -oC rage
1G
2G
3G
4G
Special Remarks for approval ___________________________

Encl 1)
2)
Strike whichever is not applicable
Suffix indicates specimen number.
Index
T = Tensile Test
S = Side Bend
F = Face Bend Witnessed by Approved by
R = Root Bend
I = Impact Test
Page 730 of 851

Page 49 of 105

INSPECTION REPORT - FILLER MATERIAL
MANUFACTURER’S WORKS
Report No. : __________
Date : __________
Project : _________________________ Unit : ______________________

Name of Work : _________________________
1. Date of visit _____________________ 2. By __________________________
3. Manufacturer ____________________ 4. Ref. _________________________
5. Location ________________________ 6. Person contacted _______________
7. Brand name of electrode/Filler wire/Bare electrode __________________________________
8. Specification _________________________ 9. Classification __________________
10. Current I.S. approval available: (Yes/No) Valid upto_________________________________
11. Testing laboratory: Available/Not available
12. Testing facilities: A) Mechanical i) Tensile _______________________

Including Machining ii) Bend _________________________
iii) Impact ________________________
B) Chemical elements ______________________________________
13. Qualified chemists: Available/No available
If yes Name _________________________________________________________________
14. Quality control procedure: Suitable/Unsuitable

( copy enclosed for ready reference )
15. Qualified quality control personal: Available/No available
16. Raw material supplier _________________________________________________________
17. List of approvals _____________________________________________________________
18. List of users _________________________________________________________________
19. Remarks ____________________________________________________________________
To
Manager of Construction
Through RCM/Site In-charge Signature
Page 731 of 851

Page 50 of 105

FORMAT FOR WELDING PROCEDURE SPECIFICATIONS(WPS)
(Section IX, ASME Boiler and Pressure Vessel Code)
(Sheet 1 of 2)
Report No. : __________
Date : __________
Project : _________________________ Unit : ______________________

Name of Work : _________________________ Contractor : ______________________
Company Name ______________________________ By _________________________________

Welding Procedure Specification No. ________ Date ________Supporting PQR No.(s) ___________
Revision No. _____________________ Date _______________________
Welding Process(es) __________________________ Type(s) ______________________________
(Automatic, Manual, Machine or Semi-Auto)
JOINTS (QW-402) Details :

Joint Design __________________________________
Backing (Yes) _______________ (No.) ____________
Backing Material (Type) ________________________
Sketches, Production Drawings, Weld Symbols or Written Description should
show the general arrangement of the parts to be welded. Where applicable,
the root spacing and the details of weld groove may be specified.
(At the option of the Mfgr., sketches may be attached to illustrate joint design,
weld layers and bead sequence, e.g. for notch toughness procedures, for
multiple process procedures. etc.
*BASE METALS (QW-403)
P.No. _________ Group No. ____________to P.No. __________Group No. ____________________
OR
Specification type and grade ___________________________________________________________ to
Specification type and grade _________________________________________________________
OR
Chem. Analysis and Mech. Prop. _____________________________________________________
Thickness Range :
Base Metal : Groove ___________________________ Fillet ________________________________
Deposited Weld Metal
Pipe Dia. Range : Groove _______________________ Fillet ________________________________
Other _____________________________________________________________________________
*FILLER METALS (QW-404)

F.No. _________________________________ Other ______________________________________
A.No. _________________________________ Other ______________________________________
Spec. No. (SFA) ____________________________________________________________________
AWS No. (Class) ____________________________________________________________________
Size of filler metals __________________________________________________________________
__________________________________________________________________
(Electrode, Cold Wire, Hot wire etc.)
Electrode-Flux (Class) _______________________________________________________________
Flux Trade Name ___________________________________________________________________
Consumable Insert __________________________________________________________________
* Each base metal-filler metal combination should be recorded individually.
Page 732 of 851

Page 51 of 105
(Sheet 2 of 2)
POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407)

Position(s) of Groove ______________________ Temperature Range _______________________
Welding Progression : Up _______ Down ______ Time Range _____________________________
Position(s) of Fillet ________________________
PRHEAT (QW-406) GAS (QW-408)

Preheat Temp. Min. _______________________ Shielding Gas(es) _________________________
Interpass Temp. Max. ______________________ Percent Composition (mixtures) ______________
Preheat Maintenance ______________________ ________________________________________
(Continuous or special heating where applicable Flow Rate _______________________________
should be recorded) Gas Backing _____________________________
Trailing Shielding Gas Composition __________
ELECTRICAL CHARACTERISTICS (QW-409)

Current AC or DC _________________ Polarity ___________________
Amps (Range) _________________ Volts (Range) _________________
(Amps and volts range should be recorded for each electrode size,
position, and thickness, etc. This information may be listed in a tabular
form similar to that shown below.)
Tungsten Electrode Size and Type ______________________________________________________
(Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW ______________________________________________________________________
(Spray arc, short circuiting arc, etc.)
Electrode wire feed speed range ________________________________________________________
TECHNIQUE (QW-410)
String or Weave Bead ________________________________________________________________
Orifice or Gas Cup size _______________________________________________________________
Initial and Interpass Cleaning (Brushing, Grinding etc.) _____________________________________
__________________________________________________________________________________
Method of Back Gouging _____________________________________________________________
Oscillation _________________________________________________________________________
Contact Tube to Work Distance ________________________________________________________
Multiple or Single Pass (per side) _______________________________________________________
Multiple or Single Electrodes __________________________________________________________
Travel Speed (Range) ________________________________________________________________
Peening ___________________________________________________________________________
Other _____________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Filler Metal Current Travel

Weld Volt
Process Type Amp Speed Other
Layer(s) Class Dia. Range
Polar. Range Range
e.g.
Remarks, Comments
Hot Wire Addition
Technique
Torch Angle
Etc.
Page 733 of 851

Page 52 of 105

SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION
RECORD (PQR)
(Sheet 1 of 2)
Report No. : __________
Date : __________
Project : _________________________ Unit : ______________________

Name of Work : _________________________
Company Name ____________________________________________________________________
Procedure Qualification Record No. _________________________ Date _______________________
WPS No. __________________________________________________________________________
Welding Process(es) _________________________________________________________________
Type (Manual, Automatic, Semi-Auto) __________________________________________________
JOINTS (QW-402)
Groove Design Used

BASE METALS (QW-403) POSTWELD HEAT TREATMENT (QW-407)
Materials Spec. ___________________________ Temperature _____________________________
Type or Grade ____________________________ Time ___________________________________
P. No.______________ to P.No. _____________ Other ___________________________________
Thickness _______________________________ ________________________________________
Diameter ________________________________ ________________________________________
Other ___________________________________
________________________________________ GAS (QW-408)
________________________________________ Type of Gas or Gases ______________________
________________________________________ Composition of Gas Mixture ________________
Other ___________________________________
________________________________________
FILLER METALS (QW-404) ELECTRICAL CHARACTERISTICS

Weld Metal Analysis A No._________________ (QW-409)
Size of Electrode__________________________ Current _________________________________
Filler Metal F No. _________________________ Polarity _________________________________
SFA Specification_________________________ Amps. _____________ Volts ________________
AWS Classification _______________________ Other ___________________________________
Other ___________________________________ ________________________________________
________________________________________
POSITION (QW-405) TECHNIQUE (QW-410)

Position of Groove ________________________ Travel Speed _____________________________
Weld Progression (Uphill, Downhill) __________ String or Weave Bead ______________________
Other ___________________________________ Oscillation _______________________________
________________________________________ Multipass or Single Pass (per side) ___________
Single or Multiple Electrodes ________________
PREHEAT (QW-406) Other ___________________________________
Preheat Temp. ____________________________ ________________________________________
Interpass Temp. __________________________ ________________________________________
Other ___________________________________ ________________________________________
________________________________________ ________________________________________
Page 734 of 851

Page 53 of 105
(Sheet 2 of 2)
Ultimate Ultimate Character of

Specimen
Width Thickness Area Total Load Unit Stress Failure &
No.
lb. psi Location
Guided Bend Tests (QW-160)
Type and Figure No. Results
Toughness Test (QW-170)
Specimen Notch Notch Test Impact Lateral Exp. Drop Weight

No. Location Type Temp. Values % shear M/s Break No. Break
Fillet Weld Test (QW-180)
Results-Satisfactory : Yes________ No _____ Penetration into Parent Metal : Yes _______ No _____
Type and Character of Flt: Micro ______________________ Macro-Results ____________________
Other Tests
Type of Test _______________________________________________________________________

Deposit Analysis ____________________________________________________________________
Other _____________________________________________________________________________
………………………………………………………………………………………………………….....
Welder’s Name _____________________ Clock No. ________________ Stamp No. _____________

Tests conducted by: _____________________________ Laboratory Test No ____________________
We certify that the statements in this record are correct and that the test welds were prepared, welded
and tested in accordance with the requirements of Section IX of the ASME Code.
Manufacturer _________________________
Date ______________________________ By _________________________________
(Details of record of tests are illustrative only and may be modified to conform to the type and number of test required by the Code.)
Page 735 of 851

Page 54 of 105

SUGGESTED FORMAT FOR MANUFACTURER’S
RECORD OF WELDER OR WELDING OPERATOR
QUALIFICATION TESTS
Report No. : __________
Date : __________
Project : _________________________ Unit : ______________________

Welder Name _____________ Check No. ___________ Stamp No. ________________________
Welding Process ________________________________ Type ___________________________________
In accordance with Welding Procedure Specification (WPS) __________________________________________
Backing (QW-402) __________________________________________________________________________
Material (QW-403) Spec. ________to ____________of P No. ____________to P No._____________________
Thickness ______________________ Dia _____________________________________
Filler Metal (QW-404) Spec.No. ______________ Class No. ___________ F. No. ____________________
Other ______________________________________________________________________________
Position (QW-405) (1G, 2G, 6G) _______________________________________________________________
Gas (QW-408 type) __________________________ % Composition __________________________________
Electrical Characteristics (QW-409) Current Polarity _________________________________
Weld Progression (QW-410) ___________________________________________________________________
Other _____________________________________________________________________________________
For Information Only

Filler Metal Diameter and Trade Name __________________________________________________________
Submerged Arc Flux Trade Name ______________________________________________________________
Gas Metal Arc Welding Shield Gas Trade Name ___________________________________________________
Guided Bend Test Results QW-462.2(a), QW-462.3(a), QW-462.3(b)
Type and Fig No. Fault
Radiographic Test Results (QW-305)

For alternative qualification of grove welds
Radiographic Results:
Fillet weld test Results (QW-462.4(a), QW-462.4(b))
Fracture Test (Describe the location nature arrange of any check ring of the specimen)
Length and per cent of defects __________________ inches __________________%

Macro Test-Fusion ___________________________________________________________________________
Appearance-Fillet size: deg __________in. x________in. Convexity _________ in. or concavity __________in.
__________________________________________________________________________________________
Test conducted by _____________________________ Laboratory – Test No. ______________________
We certify that the statements in this record are correct and that the test welds were prepared, welded and tested
in accordance with the requirements of Sections IX of the ASME Code
Organization _________________________
Date :_____________________ by __________________________________
(Detail of record of tests are illustrative only and may be modified to conform to the type and number of tests
required by the Code)
Note : Any essential variables in addition to those above shall be recorded.
Page 736 of 851

Page 55 of 105

WELDER’S IDENTIFICATION CARD
Report No. : __________
Date : __________
Project : _________________________ Unit : ______________________

NAME :
Identification :
Date of Testing :
Plate/Pipe size :
Welding process :
Filler material
Classification :
Position :
Qualified to weld :
Valid until :
WELDING ENIGNEER
____________________ ___________________________________
(NAME & DATE ) EMPLOYERS SIGNATURE WITH SEAL
DETAILS OF QUALIFICATIONS :
BACKSIDE OF IDENTITY CARD
Sr. Qualified EIL

WPS/PQR No. Date of Test Remarks
No. On Signature
Page 737 of 851

Page 738 of 851

Page 56 of 105

MATERIAL TRACEABILITY REPORT
Project : ___________________________________ Job No. : _____________ Report No. : _________________________________
Contract No. : __________________________________ Date : ___________________________________
Contractor : ___________________________________
S. Line/ Heater Area Dia. Joint Spool Piping Manufacturer Material Heat/ Colour Verified Remarks
No. No. No. No. No. Component Batch Code Sub- Contractor EIL/
No. Contractor Owner*
* As per approved Inspection & Test Plans (ITPs)
NOTE : A sketch of the spool may be enclosed.
(Sub-Contractor) (Contractor) (EIL) (Owner)

Page 57 of 105

DAILY FIT-UP INSPECTION REPORT
(FOR ABOVE GROUND PIPING/HEATER)
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

Sl. Joint Type Inspection

Line/Heater No. Area No. Dia Inch Metre Remarks
No. No. (*) Clearance
TOTAL TOTAL
INCH DIA. INCH MTR
TOTAL INCH DIA. =

PREVIOUS =
TILL DATE =
TOTAL IN MTR. =
PREVIOUS =
TILL DATE =
(*)
G - BUTT WELD
S - SOCKET WELD
B - BRANCH WELD _____________ ______________
M - MITRE WELD CONTRACTOR EIL
Format No. 8-00-0001-F1 Rev 0
Page 739 of 851

Page 58 of 105

DAILY WELDING INSPECTION REPORT
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

Sl. Jont Type Inspection

Heater/Line No. Area No. Dia Welder No. Remarks
No. No. (*) Clearance
Total
Inch Dia.
(*)
G = BUTT WELD
S = SOCKET WELD TOTAL IN DIA. =
B = BRANCH WELD PREVIOUS =
M = MITRE WLED TILL DATE =
_____________ ______________
CONTRACTOR EIL
Page 740 of 851

Page 741 of 851

Page 59 of 105

HARDNESS TEST RECORD
Report No. : __________________
Date : __________________
Project : _______________________________ Unit : ________________________

Name of Work : _______________________________ Contractor : ________________________
Job No. : _______________________________ Work order No. : ________________________
Stress Hardness Diameter After Impression B.H.N.

Line No./ Weld Joint
Relief Bar Bar Job Observation Remarks
Equipment No. No. 0 00 180
Chart No. Factor 0 1800 00 1800
______________ __________________
CONTRACTOR EIL

Page 60 of 105

LIQUID PENETRANT EXAMINATION REPORT
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

__________________________________________________________________________________
Item Name/No. Drg. No.
__________________________________________________________________________________
Part Name Method of Colour Application No. Material

Examination Contrast
Solvent
Removal
__________________________________________________________________________________
EXAMINATION DETAIL
Surface Temperature
& Penetrant Time ______________ oC ____________ Minute
__________________________________________________________________________________
Penetrant
Remover
Developer
__________________________________________________________________________________
Sketch Line No. Joint No. Type Size
__________________________________________________________________________________
______________ ________________
CONTRACTOR EIL
Format No. 8-00-0001-F1 Rev 0
Page 742 of 851

Page 61 of 105

MAGNETIC PARTICLE EXAMINATION REPORT
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

__________________________________________________________________________________
Name of Item Drg. No.
__________________________________________________________________________________
Item No.
__________________________________________________________________________________
Joint No.
__________________________________________________________________________________
1. Test Condition
Tester Type : ________________ Magnetizing Type : Not Remained
Method : Prod. Remained
Coil Exami. Medium Dry White

Wet Brown
Fluorescent
Magnetizing Current A Standard JIS A type
Magnetizing Time Sec. Surface Condition Surface Temp.
2. Acceptance Observations
3. Sketch
4. Result
Remarks
______________ ________________
CONTRACTOR EIL
Page 743 of 851

Page 62 of 105

Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

TO
______________________
______________________
______________________
Please arrange to radiograph the following welds and submit the results with in 24 hours
positively.
Radio-
Sl. Heater/Line Accepted
Area Dia Joint No. Welder No. graphy Remarks
No. No. Date
No.
______________
EIL
Page 744 of 851

Page 63 of 105

Name of Work: ____________________________ Report No. : ________

Radiography Technique : SWSI/DWSI/DWDI Date : _____________
Source IR 192, X RAY, COBALT CO Project :___________
Film Type & Name : __________________________ Contractor : ________
IQI : _______________________________________
Radiography Procedure No. _____________________
Sl. Heater/ Area Dia Joint Welder Radio- Segment Results Joint Status
No. Line No. No. No. No. graphy No. A/R/H (*)
SWSI - SINGLE WALL SINGLE IMAGE, DWDI - DOUBLE WALL DOUBLE IMAGE
DWSI - DOUBLE WALL SINGLE IMAGE
(*) A - ACCEPTED, R - REPAIR, H - HOLD
_____________ ____________
CONTRACTOR EIL
Page 745 of 851

Page 746 of 851

Page 64 of 105

DAILY PAINTING REPORT
Name of Work : Report No.
Contractor : Date
Drawing No. Location
Specification No. Procedure
Job Description :
Daily weather record :
Time Relative Humidity Ambient temperature Surface temperature Dew point temperature Weather condition
Surface preparation
a) Method
Blasting Power tool Hand clean Solvent Emery cloth Other
b) Blasting details
Abrasive Sand Grit Shot Certificate No.
c) Surface standard
SIS 05 5900 SA-2 ½ Others Profile Micron Result : Accepted /Rejected
Painting material and application method : Painting System - Temp. Range -
Material brand Manufacturer Certificate No. Batch No. Shelf life upto Shade/ Colour Application
Primer (Base/Hardener)
Intermediate-1st coat
Intermediate-2nd coat
Finish -1st coat
Finish -2nd coat
Painting Inspection Record :
Area/Joint Wet Film Thickness Dry Film Thickness Holiday Visual
Item Coating Layer Acceptance
From To Measurements 1,2,3… Avg. Reqd Measurements 1,2,3… Avg. Reqd Testing Inspection
Primer
Intermediate-1st coat
Intermediate-2nd coat
Finish -1st coat
Finish -2nd coat
Identification colour band & direction marker : Accepted/ Not Accepted

NOTE: All blasting and coating materials shall be approved by the Owner. All measuring and testing equipments shall have valid calibration certificate and shall adhere to relevant specifications.
(Contractor) (EIL)

Page 65 of 105

POSITIVE MATERIAL IDENTIFICATION (PMI)
REPORT
Report No: __________
Name of work : ____________________
Contractor : ______________________ Date of PMI : _____________________
Project : _________________________ Inspection Agency : ________________
Location : ________________________ PMI Agency : _____________________
Job No.: _________________________ PMI Equipment Model : _____________
Line No. /ISO Drg. No : ______________ Make & Serial No.: ________________
/Heater No./Drawing No
Result
Sr. Material Material
Part Identification (Accepted/Rejected/
No. As per Drg./spec as per PMI
Retest)
________________ ______________ __________________ ______________

(PMI AGENCY) (TPI AGENCY) (CONTRACTOR) (EIL/OWNER )
Page 747 of 851

Page 66 of 105

PICKLING ABOVE GROUND PIPING CERTIFICATE
Report No. : __________

Date : __________
Project : _________________________ Unit/Plant : ______________________

SYSTEM :________________________________
LOOP/LINE NOS :_________________________ LOOP SKETCH - ATTACHED
PICKLING DONE DURING : ________________ TEST RESULTS – ATTACHED
CERTIFICATE
Certified that the pickling of the above system has been carried
out successfully as per specification and the system is preserved
with …………….. gas at …………. kg/cm2 pressure
_____________ ________ _______

Page 748 of 851

Page 67 of 105

SYSTEM COMPLETION REPORT ABOVE
GROUND PIPING
Report No. : __________
Date : __________
Project : _________________________ Unit/Plant : ______________________

System : _____________________________ Area : ____________________________

Loop Nos. : ___________________________ Unit : ____________________________
Ref. P&ID No. : _______________________ Test Reports – Enclosed
The above system has been cleaned/flushed/tested as per the

requirement of drawings and specifications and cleared for
operation.
_____________ ________ _______

Page 749 of 851

Page 68 of 105

LINE WISE RECORD
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

HEATER/LINE NO. ……………… % RADIOGRAPHY ______
Radio-
Joint graphy Stress
Sl. Type Area Welder Date of DPT/
Dia. No. Relieving BHN Remarks
No. (*) No. No. Welding MPT
(**) Resol. Chart No.
No.
Date
(*)
G - BUTT WELD
S - SOCKET WELD (**) Joint No. are to be posted from the daily
B - BRANCH WELD fit up reports
M - MITRE WELD Where ever lso,s are not available
_________________ _____________
CONTRACTOR EIL
Page 750 of 851

Page 751 of 851

Page 69 of 105

SHOP HYDRO TEST REPORT FOR COIL (HEATER)
Name of Work : _________________________________________ Report No : ________________________
Project : ________________________________________________ Date : _____________________________
Plant : __________________________________________________ Contractor : _________________________
Sketch Coil No.

X- X- X- Test Medium : ______________________
C- C- C-
W- W- W- Test Pressure : _______________________
J- J- J-
J- J- J-
W- W- W -
C- C- C -
X- X - X-
Acceptance By
Item
Contractor EIL
Cleared for Hydro/Pneumatic Testing
Air Blowing and Flushing
Pneumatic/Hydrostatic Testing
Dewatering and Drying
Cleared for Erection

Legend : J – Joint No, W – Welder No., C – Stress Relief Chart No., X – X-Ray No.
CONTRACTOR EIL

Page 70 of 105

MECHANICAL COMPLETION RECORD (HEATER)
Name of work : ___________________ Report No. : ____________________

Project : _________________________ Date : _________________________
Plant : ___________________________ Area : _________________________
Contractor : _______________________ Ref P&ID No. : __________________
__________________________________________________________________________________
Loop No. : ___________________ Inch Mtr. _________________
From_________ To _________
Line Nos. : ___________________
Clearance by
Sl.
Activity Check Contractor EIL
No.
Sign Date Sign Date
1. Clearance for flushing and testing.
1.1 Mechanical clearance

- Conformity to drawings
- Provision of Inst. Tappings
- Provision of Vent & Drains
- Correctness of gaskets and fastners
- Correctness of type of support
anchors, guides, etc.
- Correctness of valves
- Provision of cold pull
- Isolation of equipment, CV, Insts,
Bellows, etc.
1.2 Welding and NDT clearance

- Material as per piping class
- Fit up checks
- Visual check of completed welds
- LPT/ MPT checks
- Radiography clearance
- PWHT & Hardness clearance
- Preparatory arrangements for
flushing/testing
2.0 Flushing and testing

Medium ______________
Pressure ______________ KG/CM2
3.0 Draining and drying
4.0 Pickling
5.0 Box up
Remarks : ISO/Loop sketches duly filled in data (Jt. No. W. No. XR No. Sr. chart No.) shall be
enclosed for item (1)
_________________ _____________
CONTRACTOR EIL
Page 752 of 851

Page 71 of 105

INSPECTION CHECK SHEET –
DAILY INSPECTION RECORD OF INSULATION
(HOT & COLD)
Report No. : __________
Date : __________
Project : _________________________ Unit : ______________________

Item No. / Equip. No. / Line No. ________________________________________________________
Surface Preparation : Visual Acc./Not Acc.

Fixing of Support Ring/ Lugs & Spacing : Acc./Not Acc.
Surface Area
Length
Thickness
Sl. Visual Insulated
Activity & Item No. of Remarks
No. Inspection
Insulation
From To SA(m2)
1. Lagging of Insulation
materials
2. Sheeting/Cladding work
3. Miscellaneous
a) Inspection Window
b) Valve boxes
c) Flange covers
d) Expansion joint
e) SS Foil for SS
Piping
f) Wooden Support
g) Vapour Barrier
h) Vapour Sealant
i) Others
_________________ _____________
CONTRACTOR EIL
Page 753 of 851

Page 72 of 105

INSPECTION CHECK SHEET –
INSTALLATION ACCEPTANCE CERTIFICATE FOR
INSULATION
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

SHEET_________ OF _________
Result
Insulation Items Remarks
Contractor EIL
Quality control after installation
Hot Insulation
(Visual & position of seam to

prevent water penetration)
Cold Insulation
(Visual & Sealing)
_________________ _____________
CONTRACTOR EIL
Page 754 of 851

Page 73 of 105

ERECTION CHECK LIST
Name of work : _________________ Report No: __________________

Project : _______________________ Date : ______________________
Plant : _________________________ Page : _______ of _____________
Contractor : ____________________ P & ID Ref. No. : _____________
Loop No: ______________________ Test Pack No: ________________
Line Nos.: ______________________
ACTION TAKEN
SL. REMARKS DESCRIPTION OF ERROR RECHECK AND
CONTRACTOR'S
NO. FOUND AND ACTION TO BE TAKEN ACCEPTED, DATE
SIGN & DATE
CHECKED BY
REMARKS:
_________________ _____________
CONTRACTOR EIL
Page 755 of 851

Page 74 of 105
FORMAT NO. : M-27 REV 0 (Sheet 1of 2)

EXECUTION SCHEME
NAME OF WORK : REPORT NO :
PROJECT : EXECUTION SCHEME DATE :
PLANT : DATE OF CHECKING :

FOR FOUNDATIONS
CONTRACTOR :
FDN NO: DRG NO:
PCD / BCD ______________
GROUT THK ____________
( ) TOP OF BOLT
( ) TOP OF CONCRETE
PITCH
CIRCLE
DIA (PCD)
BOLT HT.
DESCRIPTION AS PER DRG ACTUAL DEVIATION REMARKS

N
C/L CO-ORDINATES
E
EL. TOP OF CONCRETE
NO. OF BOLTS & SIZE
HEIGHT OF BOLTS
PCD OF BOLTS
POCKET CLEARING
FDN. ROUGHENING
EL. TOP OF GROUT
Remarks :
____________ _____________
CONTRACTOR EIL
Page 756 of 851

Page 75 of 105
FORMAT NO. : M-27 REV 0 (Sheet 2 of 2)

EXECUTION SCHEME
Details for pocket (applicable in case of epoxy or special grout)
Sl Identifcation Dimension Actual *Volume *Volume Variation in Remarks

no of pocket as per executed of grout of grout as volume of
drawing dimension as per per actual grout if nay
drawing
* To be filled by grouting execution agency as per actuals
Page 757 of 851

Page 76 of 105

HEAT EXCHANGERS/HORIZONTAL VESSELS
RECORD
Report No. :
Date :
Name of Work : _______________________ Service : ________________________

Eqpt. Type & No: ______________________ Location : _______________________
Client : ______________________________ Unit/Area : ______________________
Project : _____________________________ Manufacturer : ____________________
Contractor : ___________________________
Length/Height : _______________ Diameter : __________ Weight : ______
Vender Drg. No: ________________________
Date With Date With

Check Items Result Check Items Result
Signature Signature
1. Foundations/ Co- 6. Alignment
ordinates
2. Anchor Bolts & Nuts 7. Grouting
3. Name Plate 8. Sliding Plate Arrangement
4. Setting of Centre Line 9. Greasing of Bolts/Nuts
5. Erected on
( mm) DWG DIM'N
T.L. SLOPE T.L.

* *
* *
* *
FIX
NOZZLE SLIDE
(CHANNEL)
X C/L OF
PEDESTAL
G.L.
NOZZLE NO. SIZE DRG. ELV. ACTUAL ELV DRG. DIM 'X' ACTUAL DIM 'X'
NOTES : Deviations on the above dimensions shall be intimated all concerned
REMARKS :
Approvals Signatures Designation Date

Contractor
EIL
Client
Page 758 of 851

Page 77 of 105

COLUMNS/REACTORS/VESSELS RECORD
Report No. :
Date :
Name of Work : _______________________ Services : ______________________
Eqpt. No: _____________________________ Location : ______________________
Client : _______________________________ Area/Unit : _____________________
Project : ______________________________ Manufacturers : _________________
Contractor : ___________________________
Length/Height : ______________ Dia Meter : _____________ Weight : ___________
Vendor Drg No.: ________________
DATE WITH DATE WIT

CHECK ITEMS REMARKS CHECK ITEMS REMARKS
SIGNATURE SIGNATURE
1. FOUNDATION/ 5. VERTICAL
CO-ORDINATES ALIGNMENT
2. ANCHOR BOLTS & 6. BASE ALIGNMENT
NUTS
3. SETTING OF 7. GROUTING
CENTRE LINES
WITH TEMPLATE 8.
IF REQUIRED.
4. ERECTED ON 9.
00 (….)mm
NOZZLE NO. SIZE DRG. ELV. ACTUAL ELV.
1
2700 0
4 2 90
(….)mm (….)mm
3
1800 (….)mm
VERTICAL
A
B
G.L.
Approvals Signatures Designation Date

Contractor
EIL
Client
Page 759 of 851

Page 78 of 105

MACHINERY ALIGNMENT RECORD
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

1) Equipment No. : _____________________________________________________________

2) Manufacturer : ______________________________________________________________
3) Drive : HP/RPM : ___________________________________________________________
4) Weight in M.T. : _______________________ 7) Type of Coupling : _________________
5) Erected on : ___________________________ 8) Distance Between As/Drg. Actual
6) Aligned & Grouted on : _________Qty _________ Coupling Halves (D)
Without Piping With Piping

Angular
Concentricity Parallelism Concentricity Parallelism
Position
A B A B A B A B
0o
90o
180o
270o
Tolerances As per Data Sheet/Manual : -

Recoupling of motor and reconfirmation of alignment Checked
Result :-
Approvals Signature Designation Date
Contractor
EIL
Client
Page 760 of 851

Page 761 of 851

Page 79 of 105
FORMAT NO. : M-31 REV 0 Report No. : _________________

PERMISSIBLE TOLERANCE FOR TRAVELLING RAIL Date : ________________________
Name of work : ______________
CHECK ITEM TOLERANCE AT INSTALLATION CHECK METHOD TRUTH DATUM
Straight Degree Base Line By Transit
Left mm or
For Total Length ------------------------- Piano Wire
< + 5 mm Right mm
Span
Max. Value -------------------------
SPAN CHECK EVERY 5 m (At two ends of the girders diagonal
distance should also be checked)
By Steel Tape Scale (JIS Fat Class)
< + 5 mm
Max. Value mm
-------------------------- Distance
Min. value mm
Elevation difference Span By Transit
For wheel base length
between rails Difference
< SPAN x 1
Max Value mm
----------
------------------------
1000
Inclination Max. value (Railway) By Transit
< 1 Left mm
---------- --------------------------
1000 Check Every 10 m Right mm
-------------------------
Joint Difference By steel tape scale
< 0.5 mm
Joint gap By steel tape scale

< 2 mm
Crane Span
REMARKS : The Span should be measured by steel tape scale stretching with < 20 mm ---------- 7 kg
> 20 mm ---------- 10 kg
(CONTRACTOR) (EIL)

Page 80 of 105

TEST AND INSPECTION RECORD – CRANE
Report No. : __________
Date : __________
Project : _________________________
(Sheet 1 of 2)
No Load 0Ton Rated Load Ton 125% Load Ton

Speed Volt Ampere Speed Volt Ampere Speed Volt Ampere
(m/mm) (V) (A) (m/mm) (V) (A) (m/mm) (V) (A)
Upper
Hoisting
Lowering
Right
Traversing
Left
Front
Travelling
Back
Hoisting Traversing Travelling

Item Name Lowering Upper
(m/min.) (m/min) (m/min.) (m/min.)
1. Maintenance Shop Crane
2. Warehouse Crane
3. Emergency Generator Crane
4. Propane Compressor Crane
5. B.O.G. Compressor Crane
6. Return Gas Blower Crane
7. Sea Water Pump Crane
8. Air Compressor Crane
Page 762 of 851

Page 81 of 105
(Sheet 2 of 2)
Span
Trolley
Runway
Runway girder
girder
Load
Piano wire
Guide rule
* Setting Side
of wirght
Allowable Deflection
Rated Test
Item Name of Girder
Load (Ton) Result (m/m)
(m/m) (Drive or Non drive)*
1. Maintenance Shop Crane
2. Warehouse Crane
3. Emergency–Generator Crane
4. Propane Compressor Crane
5. B.O.G. Compressor Crane
6. Return Gas Blower Crane
7. Sea Water Pump Crane
8. Air Compressor Crane
_________________ _____________
CONTRACTOR EIL
Page 763 of 851

Page 82 of 105

SEQUENCE OF WELDING FOR BOTTOM PLATES & SHELL OF THE TANKS
1. All the short seams shall be

welded first starting from
centre and proceed
outwards
2. Then all the long seams shall 200 mm
be welded starting from
middle and proceed outwards
3. Joggled Portion when shell
erection is to be carried out
shall be welded first and then
tested before shell erection.
10 10 10 Curb angle
TYPICAL BOTTOM PLATE ARRGT
Last Vertical WITHOUT ANNULAR PLATE
11 11 11 11 Seam
8 8 8 Last Horizontal
Seam
9 9 9 Penultimate
6 6 6 vertical seam
7 7 7 7
4 4 4
5 5 5 5 2nd vertical seam
2 2 2 1st horizontal seam
3 3 3 1st vertical seam
1 1 1
SHELL WELDING SEQUENCE
_______________ _____________
CONTRACTOR EIL
TYPICAL BOTTOM PLATE ARRGT

WITH ANNULAR PLATE
Page 764 of 851

Page 765 of 851

Page 83 of 105

TANK BOTTOM/FLOATING ROOF INSPECTION RECORD
Report No. : _______________________
Date : _______________________
Project : ____________________________________ Unit : ___________________________

Name of Work : ______________________________ Contractor : ___________________________
Job No. : ____________________________________ Work order No. : ___________________________
SHORT SEAMS LONG SEAMS

Fit Up Welding Fit Up Welding
Jt. Jt.
Visual Vacuum Remarks Visual Vacuum Remarks
No. Cont. EIL No. Cont. EIL
Cont. EIL Cont. EIL Cont. EIL Cont. EIL
_________________ _____________
CONTRACTOR EIL

Page 766 of 851

Page 84 of 105
FORMAT NO. : M-35 REV 0 Report No. _____

TANK SHELL DEVELOPMENT DRAWING WITH RADIOGRAPHIC SPOT LOCATION (AS BUILT) Date : __________
Name of work : ____
1800 900 00 2700 1800
EIL Job No :
H5 Tank No. :
V23 V22 V21 V25 V24 Ref. Drg. No. :
P/Th…
Fab. Code :
H4
P/Th… V17 V16 V20 V19 V18 Capacity :
Tank Height :
H3 Tank Dia :
P/Th… V13 V12 V11 V15 V14
H2
P/Th… V7 T-T2-W-X-
V8 T-H1-W-X- V6 V10 V9
T1
H1 T4 T2 T-V1-W-X-
P/Th… V2 M V5 V4 N V3
V1
NOTE :- SHELL TO BOTTOM PLATE TEST
Contractor EIL
T - Stands for tank number
V - Stands for vertical seam 1) Fit Up ___________ ____
X - Stands for X-ray number 2) Welding (Inside)
W - Stands for welder’s number a) Visual ___________ ____
H - Stands for Horizontal seam b) Oil chalk ___________ ____
<T-T< - Stands for in between Tee joints 3) Welding (Outside)
M - Stands for manhole a) Visual ___________ ____
N - Stands for nozzle b) D.P. ___________ ____
4) Curb Angle/Wind
Girders (as per details ___________ ____
given in Const./QA/RF/ST/5A)
5) Openings (as per details ___________ ____
given in Const./QA/RF/ST/5A)

Page 85 of 105

INSPECTION RECORD FOR TANK FABIRCATION
(VERTICAL JOINTS)
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

First Side Back Second Side

Fit-up
Welding Chip Welding
Check
Course Vertical Welder Check Check Check
Remarks
No. Joint No. No.

V1
V2
V3
1
V4
V5
V6
V7
V8
V9
2
V 10
V 11
V 12
V 13
V 14
V 15
3
V 16
V 17
V 18
V - Vertical Joint
_________________ _____________
CONTRACTOR EIL
Page 767 of 851

Page 768 of 851

Page 86 of 105

INSPECTION RECORD FOR TANK FABIRCATION (HORIZONTAL JOINTS)
Report No. : _________________________
Date : _________________________
Project : __________________________________________ Unit : __________________________
Name of Work : ____________________________________ Contractor : __________________________
Job No. : __________________________________________ Work order No. : __________________________
Fit-up First Side Welding Back Chip Second Side

Joint Check Welder Detail Check Check Welding Check
Remarks
NO.
0 – 90 90 – 180 180 – 270 270 - 0
H1
H2
H3
H4
H5
H6
H7
H8
H - Horizontal Joint
(CONTRACTOR) (EIL)

Page 769 of 851

Page 87 of 105
FORMAT NO. : M-38 REV 0 Report No : ___________________

INSPECTION RECORD FOR CHECKING ROUNDESS OF TANK Date : ________________________
Name of work : ________________
Tank No. : _____________________ CONTRACT CLAUSE
Dia : _____________________ A template one metre long shall be used representing the are of a circle with
Height : _____________________ theoretical dia. of the tank. When the centre of this template is applied at
No of courses : _____________________ right angle to a vertical joint, max. gap shall not be more than …………… 1M
R+1/2D
N 00
h
W 2700 E 900
l
0 0
0 90 1800 2700 3600
N E S W N
1800 S
Course No. No. of N-E 00-900 No. of E-S 900-1800 No. of S-W 1800-2700 No. of W-N 2700-3600
Weld 1 2 3 4 5 6 7 8 Weld 1 2 3 4 5 6 7 8 Weld 1 2 3 4 5 6 7 8 Weld 1 2 3 4 5 6 7 8 REMARKS
Joints Joints Joints Joints
NOTE : Readings should be taken as shown in the sketch indicating the maximum deviation in each shell plate.
(CONTRACTOR) (EIL)

Page 770 of 851

Page 88 of 105
FORMAT NO. : M-39 REV 0 Report No. : ____________

INSPECTION RECORD FOR CHECKING PERPENDICULARITY OF TANK Date : _________________
Name of work: ______________
Tank No. : _____________________ CONTRACT CLAUSE
Dia : _____________________ Difference in perpendicularity between top & bottom shall not be more than …………. mm per metre of height. When one
Height : _____________________ metre straight edge or template is applied at right angles to a horizontal joint, maximum gap shall not be more than …..
No of courses : _____________________
Contractor : _____________________
N 00
h
0 0
W 2700 E 90
l
00 900 1800 2700 3600
N E S W N
1800 S
N-E 00-900 E-S 900-1800 S-W 1800-2700 W-N 2700-3600

Course No. REMARKS
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
NOTE : The straight edge shall be moved on the horizontal weld joint and any variation in respect to the specified tolerance shall be highlighted. Minimum three
readings shall be taken for each full length plate
_____________________ ________________
CONTRACTOR EIL

Page 89 of 105

OPENINGS/ATTACHMENTS INSPECTION RECORD
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

Openings Fit-Up Welding PWHT D.P. Test

(Nozzles),
Sl. Attachments
Contra- Contra- Contra- Contra- Remarks
No. - Curb Angle EIL EIL EIL EIL
ctor ctor ctor ctor
- Wind Girders
- RF Pads
_________________ _____________
CONTRACTOR EIL
Page 771 of 851

Page 90 of 105

(FOR TANK WELDS)
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

To
___________________
___________________
___________________
Please arrange to radiograph the following welds and submit the results within 24 hrs.
positively.
Sl. Radiography Spot Acceptance

Welder No. Radiography No. Remarks
No. Identification Date
______________
EIL
Page 772 of 851

Page 91 of 105

(FOR TANK WELDS)
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

SOURCE IR 192, X RAY, COBALT CO DATE : _____________

FILM TYPE & MAKE : _____________________
IQI : ____________________
Sl. Radiography Spot Radiography

Welder No. Segment Results Remarks
No. Identification No.
_____________ _____________
CONTRACTOR EIL
Page 773 of 851

Page 92 of 105

FIXED ROOF TANK INSPECTION RECORD
Report No. : __________
Date : __________
Project : _________________________ Unit : ______________________

SHORT SEAMS LONG SEAMS

Jt. Fit-up Welding Jt. Fit-up Welding
Remarks Remarks
No. Cont. EIL Cont. EIL No. Cont. EIL Cont. EIL
_________________ _____________
CONTRACTOR EIL
Page 774 of 851

Page 775 of 851

Page 93 of 105

BUOY/PANTOON INSPECTION RECORD
Report No. : __________
Date : __________
Project : _________________________ Unit : ______________________

SHELL TO BOTTOM/SLEEVE (BUOY/PANTOON) OTHER ATTACHMENTS

Fit Up Welding Fit Up Welding
Jt. Jt.
Visual Oil Chalk Air Test Visual D.P. Test Remarks
No. Cont. EIL No. Cont. EIL
Cont. EIL Cont. EIL Cont. EIL Cont. EIL Cont. EIL
_________________ _____________
CONTRACTOR EIL

Page 94 of 105

CERTIFICATE OF PRESSURE TESTS FOR TANKS
Report No. : __________

Date : __________
Project : _________________________ Unit : ______________________

Write N.A. when not applicable
SIGNATURE OF SIGNATURE OF EIL

TYPE OF TEST
CONTRACTOR WITH DATE WITH DATE
Hammer Test
Water Height _______________
Fixed Roof Test

Air Pressure ______________
Vacuum Test
Vacuum ____________________
Floating Roof Test

As Per _________________
Additional Test if Any
This is to certify that the subject tank was tested at the above pressures in the presence and to
the satisfaction of EIL/Client
_____________ ______________
CONTRACTOR EIL
Page 776 of 851

Page 777 of 851

Page 95 of 105
FORMAT NO. : M-46 REV 0 Report No : _______________

FLOATING ROOF TANK TOLERANCE RECORD (PONTOON CLEARNACE) Date : _______________________
Tank No. : _____________________ CONTRACT CLAUSE Name of work : _______________
Dia : _____________________ C = A tolerance of 40 mm will be allowed on the clearance originally
Height : _____________________ provided for the tank shells
No of courses : _____________________ ‘c’ CLEARANCE
Dia of pontoon : _____________________
``
N 00
h DECK TOP
W 2700 E 900
l
0 0
0 90 1800 2700 3600 BOTTOM
0
N E S W N
180 S
N-E 00-900 E-S 900-1800 S-W 1800-2700 W-N 2700-3600
Course No. REMARKS
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Top
1 Center
Bottom
Top
2 Center
Bottom
Top
3 Center
Bottom
Top
4 Center
Bottom
Top
5 Center
Bottom
Top
6 Center
Bottom
Top
7 Center
Bottom
Top
8 Center
Bottom
NOTE : The gauge plate shall be run through the interior periphery of the tank in order to check the required tolerances. However reading shall be recorded at eight points on each quadrant of the shell and besides this any variation in respect of
the specified tolerances shall be highlighted.
(CONTRACTOR) (EIL)

Page 778 of 851

Page 96 of 105

TANK SETTLEMENT RECORD
TANK NO. _________________________

Report No. : __________
Date : __________
Project : _________________________ Unit : ______________________

Height of Water Location of Observation (*)

Date of Time of
During Remarks
Observation Observation 1 2 3 4 5 6 7 8 9 10
Observation
(*) No. of Locations area to be decided on the basis of Diameter of the Tank and Specifications/Codes
_________________ _____________
CONTRACTOR EIL

MECHANICAL WORKS 6-82-3200 Rev. 0
Page 97 of 105

MANUFACTURER’S CERTIFICATION FOR
TANK BUILT TO API STANDARD 650
Report No. : __________
Date : __________
Project : _________________________ Unit :

______________________
To _______________________________________________________________________________
(Name & address of purchaser)
__________________________________________________________________________________
We hereby certify that the tank constructed for you at
__________________________________________________________________________________
(Location)
and described as follows: _____________________________________________________________

(Serial or contract number, size (diameter x height), capacity,
__________________________________________________________________________________
description of tank, i.e., floating roof or fixed roof)
meets all applicable requirements of API Standard 650 ______________________________________
Edition, _______________________________ Revision and Appendix ________________________
dated ___________________________________________ including the design, materials,

fabrication, and erection.
The tank is further described on the attached as built data sheet dated __________________________
_____________________________
Manufacturer
______________________________
Authority Representative
_______________________________
Date
Page 779 of 851

Page 98 of 105
(Sheet 1 of 6)
INSTALLATION REPORTING FORMAT FOR
COLUMN INTERNALS (BEFORE INSTALLATION)
Report No. : __________
Date : __________
DISTANCE BETWEEN TRAY SUPPORT RING (BETWEEN CONSECUTIVE TRAYS)
Contractor: Name of Work:

COLUMN NO.: VENDOR DWG. NO.:
SERVICE: JOB NO.:
PLANT: CLIENT:
TRAY NO.:
DWG. DIMENSION:
A
B
AS BUILT DIMENSION C
AT POINT D
E
F
DIMENSION TO BE TAKEN FROM TOP TO TOP OF TSR WITH POINTS MARKED ON THE SAME
ORIENTATION FOR ALL TRAYS MINIMUM AT FOUR POINTS UPTO 2000 Φ & MINIMUM SIX
POINTS ABOVE 2000 Φ
2. LOCATION OF BOLTING BAR
TRAY NO.
G1 ACTUAL
DIMENSION
G2 ACTUAL
DIMENSION
G3 ACTUAL
DIMENSION
G4 ACTUAL
DIMENSION
G5 ACTUAL
DIMENSION
G6 ACTUAL
DIMENSION
G7 ACTUAL
DIMENSION
G8 ACTUAL
DIMENSION
INATALLATION ENGINEER IN-CHARGE.........................................

CONTRACTOR......................... (SIGNATURE)
(SIGNATURE) NAME:
NAME: DATE:
DATE:
Notes:
(1) This format shall be filled for all the Trays by installation Contractor and counter checked by Engineer
In‐Charge.
(2) Tolerance on various drawing dimensions shall be as per applicable drawing / standard.
Page 780 of 851

Page 99 of 105

COLUMN INTERNALS (BEFORE INSTALLATION)
(Sheet 2 of 6)
PLANT: CLIENT:
DISTANCE BETWEEN TRAY SUPPORT RING (BETWEEN CONSECUTIVE TRAYS)

3. LEVEL READING:
LEVEL TSR REF. (TRAY /
AT INTERNAL)
REF. POINT
A
B
C
D
E
F
G
H
I
J
K
L
M
N
LEVEL AT A, B, C ,D.... AKEN WITH WATER TUBE WITH “A” AS REFERENCE POINT MINIMUM AT
FOUR POINTS UPTO 2000 Φ & MINIMUM SIX POINTS ABOVE 2000 Φ. MINIMUM 3 POINTS PER TSR
SEGMENTS SHALL BE SELECTED
INATALLATION ENGINEER IN-CHARGE.........................................

CONTRACTOR......................... (SIGNATURE)
(SIGNATURE) NAME:
NAME: DATE:
DATE:
Notes:
In‐Charge.
Page 781 of 851

Page 100 of 105

COLUMN INTERNALS (AFTER INSTALLATION)
(Sheet 3 of 6)

SERVICE: JOB NO.:
PLANT: CLIENT:
TRAY NO.:
DWG. A1, A3, A4, A5, A7, A8
A
DIMENSION: A2, A6
A1
A2
A3
HEIGHT OF EXIT WEIR (FROM TOP
A4
OF TRAY DECK TO TOP OF WEIR)
A5
(mm)
A6
A7
A8
DWG. B1, B3, B4, B5, B7, B8
B
DIMENSION: B2, B6
B1
B2
UNDER DOWNFLOW CLEARANCE
B3
(DISTANCE BETWEEN
B4
DOWNCOMER BOTTOM & TRAY
B5
DECK / RECESSED SEAL PAN
B6
PLATE) (mm)
B7
B8
DWG. C1, C3, C4, C5, C7, C8
C
DIMENSION: C2, C6
C1
C2
C3
HORIZONTAL DISTANCE BETWEEN
C4
DOWNCOMER PLATE & RECESSED
C5
SEAL PAN (mm)
C6
C7
C8
INSTALLATION CONTRACTOR......................... ENGINEER IN-CHARGE.........................................

(SIGNATURE) (SIGNATURE)
NAME: NAME:
DATE: DATE:
Notes:
In‐Charge.
Page 782 of 851

Page 101 of 105

(Sheet 4 of 6)

SERVICE: JOB NO.:
PLANT: CLIENT:
TRAY NO.:
DWG. D1, D3, D4, D5,D7, D8
D
DIMENSION: D2, D6
D1
D2
UNDER DOWNFLOW CLEARANCE D3
(DISTANCE BETWEEN D4
DOWNCOMER PLATE & SEAL PAN) D5
(mm) D6
D7
D8
DWG. E1, E3, E4, E5, E7, E8
E
DIMENSION: E2, E6
E1
E2
CLEAR DISTANCE BETWEEN E3
DOWNCOMER PLATE & SEAL PAN E4
(mm) B5
E6
E7
E8
INATALLATION CONTRACTOR......................... ENGINEER IN-CHARGE.........................................

NAME: NAME:
DATE: DATE:
Notes:
In‐Charge.
Page 783 of 851

Page 102 of 105

(Sheet 5 of 6)
SERVICE: JOB NO.:
PLANT: CLIENT:
CHECK THE FOLLOWING TRAY No.
CHECK EACH BOLT FOR TIGHTNESS

CHEAK ORIENTATION, PROPOER MARK (TYPE) AND
TIGHTNESS OF EACH CLAMP
CHECK PROVISION OF LOCK NUTS AND SEAL PLATES
WHEREEVER SPECIFIED
CHECK EACH TOP DOWNCOMER PIECE FOR CORRECT
INSTALLATION OF SHIMMING INCLUDING TACK
WELDING / BOLTING
CHECK SEAL WELDING / GASKETING WHEREEVER
APPLICABLE
CHECK LEAK TESTING OF SEAL PANS RECESSED
SEAL PAN, CHIMNEY TRAYS, DISTRIBUTOR, DRAW-
OFF BOXES ETC. AS PER DRAWING
CKECK OVERLAPING OF DECKS
CHECK FOR DAMAGED, MISSING VALVES AND
VALVE MOVEMENT FOR ALL VALVES FOR VALVE
TRAYS
CHECK FOR FITTING OF PROPER VALVE
COMBINATION (MR2, MR6, ETC.)
CHECK FOR NOTICEABLE DAMAGE TO DECK
COMPONENTS
CHECK LEVELNESS AND ALLIGNMENT OF INLET
WEIR AND EXIT WEIR AND ADJUST IF NECESSARY
CHECK BEAM AND CLIPS ARE PROPERLY FITTED
CHECK THAT TRAY MANWAY CAN BE OPENED FROM
TOP AS WELL AS FROM BOTTOM
CHECK THAT ALL SLOTS ON TRY COMPONENTS ARE
FULLY COVERED
CHECK THAT GAPS AT DOWNCOMER ENDS AND
OTHER PLACES ARE WITHIN SPECIFIED LIMITS
CHECK ORIENTATION IN CASE OF RIPPLE WAYS
FOR LATTICE GIRDERS, CHECK THE LEVELLNESS OF
PRIMARY MEMBERS AND COMPLETENESS OF
WELDING OF ALL THE BRACINGS AND SECONDARY
MEMBERS
CHECK TEMPORARY PLUGS WHEREEVER PROVIDED
FOR TESTING HAVE BEEN REMOVED
CHECK THAT TRAYS HAVE BEEN CLEARED OFF ALL
FOREIGN MATERIALS
INATALLATION CONTRACTOR......................... ENGINEER –INCHARGE…………………
NAME: NAME:
DATE: DATE:
Notes:
In‐Charge.
Page 784 of 851

Page 103 of 105

(Sheet 6 of 6)
SERVICE: JOB NO.:
PLANT: CLIENT:
CHECK THE FOLLOWING BED NO:
CHECK THAT MULTIBEAM SUPPORT PLATE SITS PROPERLY

ON THE TSR WITH NO UNDESIRED GAPS, ALL SPACINGS
AND GAPS ARE EVENLY DISTRIBUTED ACCROSS THE
VESSEL DIAMETER
CHECK FOR PROPER LEVELLING OF TOP BED AND GAP
BETWEEN TOP OF BED AND BED LIMITER (NO GAPS
PREFERRED, MAXIMUM GAP AT FEW LOCATIONS NOT O
EXCEED ONE PACKING SIZE)
CHECK LEVELNESS FOR DISTRIBUTOR / REDISTRIBUTORS /
FLASH GALLERIES / SPRAY HEADER. SAME TO BE WITHIN
TOLERANCE SPECIFIED IN DRAWINGS / STANDARDS AND
TO BE RECORDED IN SHEET ONE.
FLASH GALLERIES / SPRAY HEADERS ARE PROPERLY
CLAMPED / BOLTED
FLASH GALLERIES (IF REQUIRED) ARE PRPERLY
GASKETTED AS SPECIFIED IN DRAWINGS
CHECK LEAK TIGHTNESS OF THE DISTRIBUTOR /
REDISTRIBUTOR / FLASH GALLERIES (IF REQUIRED), TO BE
ENSURED BY FILLING WATER AND CHECKING LEAKAGES
FROM GASKETTED JOINTS
FOR CHIMNEY COLLECTOR TRAY, DRAW OFF BOXES,
WHEREEVER APPLICABLE CHECK COMPLETENESS OF SEAL
WELDING, GASKETTING, PROPER FITNMENT OF VAPOUR
RISER COVERS AND REVIEW RECORD FOR LEAK TESTING.
FOR SPRAY NOZZLE DISTRIBUTOR CHECK FOR:
i) HYDROTEST FOR SPRAY HEADER
ii) CLOGGING OF SPRAY NOZZLES, BY RUNNING PUMP, IF
FEASIBLE
iii) CHECK TIP DISTANCE FROM TOP OF THE BED (TO BE
WITHIN 25 mm)
iv) CHECK GASKET AT FLANGE JOINT, THREAD SEALANT
AT THREADED JOINTS
v) ANY OBSTRUCTION IN THE UNIFORM SPRAY PATTERN
REVIEW OF PROPER ORIENTATION OF VARIOUS TOWER
INTERNALS LIKE BED LIMITER WRT DISTRIBUTOR /
REDISTRIBUTORS, AS PER DETAIL SHOWN IN RESPECTIVE
DRAWINGS
CHECK TEMORAY PLUGS WHERE EVER PROVIDED HAVE
BEEN REMOVED AFTER TESTING.
INATALLATION CONTRACTOR......................... ENGINEER IN-CHARGE...................................

NAME: NAME:
DATE: DATE:
Notes:
In‐Charge.
Page 785 of 851

Page 104 of 105

INSTALLATION REVIEW CHECK LIST
Report No. : __________
Date : __________
(Sheet 1 of 2)
TRAY INSTALLATION REVIEW CHECKLIST
Sl. Description Remarks

1. Review of filled formats for tray levelness and other tray installation data Formats to be
completed by Contractor and duly certified for 100% checking by sites.
If any dimension is out of permissible tolerances, specialist to review and suggest remedial
action, in consultation with HO (if required)
2 Provide clarification to site on any matter w.r.t. installation of trays and tower internals.
3 Random check minimum 25% of trays (subject to minimum two trays per set) (Trays
selected shall be true representative)
 EWII & Adjustability (permissible deviation =1 mm)
 UDFC (permissible deviation = 3, D/C bottom piece to rest on D/C bracket.
 Gap at deck joints (max. gap – 3 mm at deck joint, 5 mm at EW location)
 Overlapping of tray decks (no overlapping allowed)
 Valve movement, missing & damaged valves (check approx. 5% of valves)
 For bubble cap trays, check skirt height & locknuts on caps (check approx 5% caps)
 Check plugging of holes in case of sieve trays
 Noticeable damage in internal components, wooden hammers to be used in case
flattening is required
 Chord heights (acceptable limit= (Col. ID/200 I 4)
 Check inlet weir/inlet seir scale plate at respective location
 Check for proper fitting of gaskets for gasketed deck components.
 Also check whether same has been leak tested or not. Also check that drain holes are
open unless specified otherwise in the drawings.
 Light and heavy valves combination adopted at right place
 Check provision of lock nuts wherever specified
 For ripple trays, check relative orientation of trays
 For cartridge trays, check the top tray of each bundle orientation and removal of lifting
box.
 Check the provision of anti jump baffle wherever specified
 Check for seal plates on receassed seal pans
 Check temporary plugs wherever provided has been removed after testing
4 For chimney/collector tray, draw-off boxes, wherever applicable, check completeness of
seal welding, gasketting, proper fitment of vapour riser covers and review record for leak
testing
5 Check arrangement for proper feeding and liquid withdrawal
Reflux of top tray
 Reflux at top tray
 Transition arrangement from one tray to other
 Intermediate feed including direction/angle of vapour and liquid slots.
 Feed from bottom most seal pan to partitioned column bottom
 Vapour/reboiler return,if flush ,should be parallel to down comer of bottom most tray.
 Location/orientation of withdrawl nozzle.Also check provision of vortex breaker.
 Drain & vents holes wherever provided in the feed system shall be clear and open
6 List out all discrepancies in a punch list for individual column
Signature:
Date: Name:
Page 786 of 851

Page 105 of 105

INSTALLATION REVIEW CHECK LIST
(Sheet 2 of 2)
Report No. : __________
Date : __________
TOWER INTERNAL INSTALLATION REVIEW CHECKLIST
Sl. Description Remarks

1. Review site record for levelness for distribution/redistributors/flash galleries/spray
header. Same to be within tolerance specified in the drawing/ standards
2 Check that the distributor/redistributors/flash galleries/spray headers are properly

clamped/bolted.
3 Check that the distributor/redistributors/flash galleries(if required) are properly

gasketed as specified in the drawing.
4 Review site record of leak tightness of the distributors/redistributors/flash

gallery(if required), to be ensured by filling water and checking leakages from
gasketted joints.
5 For chimney/collector tray wherever applicable, check, if possible, completeness

of seal welding, gasketting, proper fitment of vapour riser covers and review
record for leak testing.
6 For spray nozzle distributor check for
i) Hydrotest record for spray header

ii) Clogging of spray nozzles, by running pump, if feasible
ii) Sample check tip distance from top of the bed (to be within ± 25 mm).
iii) Check proper gasket fitment at flange joint, thread sealant at threaded joints.
Any obstruction in uniform spray pattern
7. Review of proper orientation of various lower internals like bed limiter w.r.t.
Distributor/redistributors, as per detail shown in respective drawings is mandatory.
Signature:
Date: Name:
Page 787 of 851

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Page 788 of 851

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Page 800 of 851

STANDARD No.
ENGINEERS
INDIA LIMITED ABBREVIATIONS 7-44-0002 Rev. 4
Page 1 of 2
API AMERICAN PETROLEUM INSTITUTE FAB. FABRICATED

ANSI AMERICAN NATIONAL STDS. INSTITUTE FF FLAT FACE
ASME AMERICAN SOCIETY OF MECHANICAL ENGINEERS FFL FINISHED FLOOR LEVEL
ASTM AMERICAN SOCIETY FOR TESTING AND MATERIALS FGL FINISHED GRADE LEVEL
AWWA AMERICAN WATER WORKS ASSOCIATION FHY. FIRE HYDRANT
AG ABOVE GROUND FLR FLOOR
ANC. ANCHOR FLGD FLANGED
BBE BEVEL BOTH ENDS FLG. FLANGE
BE BEVEL ENDS FS FORGED STEEL
BF BLIND FLANGE FTG FITTING
B/L BATTERY LIMIT FDN FOUNDATION
BLDG BUILDING FCN FIELD CHANGE NOTE

BLE BEVEL LARGE END FSD FLAT SIDE DOWN
BOM BILL OF MATERIAL FSU FLAT SIDE UP
BOP BOTTOM OF PIPE FW FIELD WELD
B&S BELL & SPIGOT GALV. GALVANIZED
BS EN BRITISH STANDARD EUROPEAN NORM GPM GALLONS PER MINUTE
BSE BEVEL SMALL END GR. GRADE

BTU BRITISH THERMAL UNIT HDR HEADER
BW BUTT WELD HOR. HORIZONTAL
CFM CUBIC FEET PER MINUTE HC HOSE COUPLING

CENTRELINE HEX. HEXAGONAL
CL
CAT CATALYST HP HIGH PRESSURE OR HORSE POWER
CI CAST IRON HS HOSE STATION
COL. COLUMN HPP HIGH POINT OF PAVEMENT
CONN. CONNECTION ID INSIDE DIAMETER
CONC. CONCENTRIC INS. INSULATION/INSULATED
CPLG COUPLING INST INSTRUMENT
CS CARBON STEEL OR COLD SPRING INV. INVERT
CSO CAR SEALED OPEN ISBL INSIDE BATTERY LIMIT
CSC CAR SEALED CLOSED IH HOT INSULATION

IS SAFETY INSULATION
CR. CHROME
IT STEAM TRACED
DC DRAIN CONNECTION
IE ELECTRICAL TRACED
DCN DESIGN CHANGE NOTE
IC COLD INSULATION
DF DRAIN FUNNEL
DIA. DIAMETER LB POUND
LC LOCK CLOSED
DIM. DIMENSION
LF LARGE FEMALE
DISCH. DISCHARGE
DN DIAMETER NOMINAL LJ LAP JOINT
LM LARGE MALE
DWG DRAWING
LO LOCK OPEN
ECC. ECCENTRIC
LR LONG RADIUS
EL. ELEVATION
LT LARGE TONGUE
ELB. ELBOW
LW LAP WELD
EOL. ELBOLET
LWN LONG WELDING NECK
EXH. EXHAUST
EWSS EYE WASH & SAFETY SHOWER
4 31.07.13 REVISED & ISSUED AS STANDARD f()/U K SH RN ATDAA DM

3 15.11.08 REAFFIRMED & ISSUED AS STANDARD AC RN DM VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright E IL - All rights reserved
Page 801 of 851
STANDARD No.
ENGINEERS
ABBREVIATIONS
f
If a ofe.
,a1reR c-lecnie Jtig.1)
INDIA LIMITED
7-44-0002 Rev. 4
Page 2 of 2
M&F MALE & FEMALE SO SLIP ON
MI MALLEABLE IRON SOL. SOCKOLET
MOV MOTOR OPERATED VALVE SP. GR SPECIFIC GRAVITY
MOLY OR MO MOLYBDENUM SR SHORT RADIUS
MR MATERIAL REQUISITION SS STAINLESS STEEL
MTO MATERIAL TAKE OFF ST STEAM TRAP

MS MILD STEEL STN STATION
MSS MANUFACTURER'S STANDARD SOCIETY STM STEAM
MH MANHOLE STD STANDARD
NPT NATIONAL PIPE THREAD SW SOCKET WELD
NPS NOMINAL PIPE SIZE SWG SWAGE NIPPLE / STD WIRE GAGE
NPSH NET POSITIVE SUCTION HEAD STA STEAM TRAP ASSEMBLY
NIP. NIPPLE TOG TOP OF GRATING
NTS NOT TO SCALE TEMP. TEMPERATURE
OD OUTSIDE DIAMETER TL TANGENT LINE
P&ID PIPING AND INSTRUMENTATION DIAGRAM TO L. THREADOLET
PC.MK PIECE MARK T&C THREADED & COUPLED
PE PLAIN END THRD THREADED
PBE PLAIN BOTH ENDS T&G TONGUE & GROOVE
PL PLATE TBE THREADED BOTH ENDS
PLTF. PLATFORM TLE THREADED LARGE END
PS PIPE SUPPORT TSE THREADED SMALL END
PSE PLAIN SMALL END TOS TOP OF STEEL
PRESS. PRESSURE TOE THREADED ONE END
PSI POUNDS PER SQUARE INCH TYP. TYPICAL
POE PLAIN ONE END UC UTILITY CONNECTION
PSIG POUNDS PER SQUARE INCH GAUGE VC VENT CONNECTION
RAD OR R RADIUS VERT. VERTICAL
RED. REDUCER VF VENDOR FURNISHED
RF RAISED FACE WAFL WAFER LUGGED
R/L RANDOM LENGTH WP WORKING PRESSURE,WORKING POINT
REF. REFERENCE U INVERT LEVEL OF PIPE
RPM REVOLUTIONS PER MINUTE V BOTTOM LEVEL OF THE PIPE
RTJ RING TYPE JOINT V CENTRELINE ELEVATION OF PIPE
SH SPRING HANGER WN WELD NECK
SHT. SHEET WT WEIGHT
SCH. SCHEDULE WOL. WELDOLET
SCRD SCREWED WLD WELD
SC SAMPLE CONNECTION XS EXTRA STRONG
SG SIGHT GLASS XXS DOUBLE EXTRA STRONG
SMLS SEAMLESS
NOTE :
1. FOR ABBREVIATIONS RELATED TO CIVIL ENGINEERING/UNDERGROUND PIPING WORK,

REFER CIVIL ENGINEERING STANDARD 7-65-0001.
A'
4 31.07.13 REVISED & ISSUED AS STANDARD UK 7 RN ATD DM
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 802 of 851
STANDARD No.
k31 ENGINEERS SYMBOLS OF PIPING
$'1g-allaW5 INDIA LIMITED 7-44-0003 Rev. 4
1.1127, 21~ C151"1.) IA Govt of india Undertaking)
ELEMENTS ON DRAWINGS
Page 1 of 4
DESCRIPTION FLANGED SCREWED WELDED SOCKET WELD

(NOTE-1)
J
90' ELBOW _
—To-ii-- —1.
ELBOW 111---
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)
MITERED BEND 45' I\
45' ELBOW
-,/ k6\
45' ELBOW
(TURNED UP) 3-1 3i _...° • -.0 le
45' ELBOW •• C.
(TURNED DOWN) KC I C---- .1 C—P--
TEE
EQUAL/UNEQUAL —II T n- i 1- i •i• u Is
TEE - •-,•—•
(OUTLET UP) —11-&
11—
TEE ■
(OUTLET DOWN) --1, t — I •
_. el ■
._., .
_ . JL
l•
CROSS --II I II---- _I .• -.-
CONCENTRIC REDUCER --1H 1111■ 11119 --
ECCENTRIC REDUCER --lhl --1---1 —41 , —31+
DEAD END _._1

11 1 —{)
LATERAL %
— II / II— i /I • 7/. .1 7(I.
SIGHT GLASS —HO • --•<»—
UNION ------------ /--""-"-- —•Iii•—

—I I—
HALF COUPLING ~ ~
111
FULL COUPLING --F --4i 1+—
HOSE COUPLING ~
il [ 4[
4 01.09.14 REAFFIRMED & ISSUED AS STANDARD = /AK 7RN /ATDSC

3 29.06.09 REAFFIRMED & ISSUED AS STANDARD PK RN SC ND
Prepared Checked Stds. Committee Stds. Bureau
Rev.
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
Page 803 of 851

STANDARD No.
ENGINEERS SYMBOLS OF PIPING
$'gzIrfêWs INDIA LIMITED 7-44-0003 Rev. 4
Govt of Uodedak,t,g) ELEMENTS ON DRAWINGS
Page 2 of 4
FLANGED SCREWED WELDED SOCKET WELD

DESCRIPTION (NOTE)
GATE VALVE —1>< __H>.<-.-- —4><•—•
(PLAN) —1>11--
GATE VALVE H' —1. ::i*
(ELEVATION)
GLOBE VALVE ----4>•1
1—
(PLAN) —1><I1— -----*(1— --°-->(--°—
GLOBE VALVE
(ELEVATION) 1 Z
ANGLE VALVE
PLAN) I>0 01-- OCF— cici--
ANGLE VALVE --.1. 11— —- -±■:ZT-°—
(ELEVATION) -T-
CHECK VALVE - ,■--
-9...—.N.,,
(PLAN OR ELEVATION)
ANGLE STOP CHECK .,--
VALVE (PLAN) 031— 0 3:—e-- 0 3'''—
ANGLE STOP CHECK -4<ii--
VALVE (ELEVATION) T
PLUG VALVE
(PLAN) —1011—
PLUG VALVE
(ELEVATION) —1>kij— ----> --•-*-9—
BALL VALVE ---101 •[)0(-.-- ----4)C(.—
(PLAN) ---1 [)C11 I— ---
BALL VALVE
(ELEVATION) --I [ ( (1 1— --[) 11
— ----•-* -...— —{)k.--
NEEDLE VALVE —{1.2)‹
(PLAN OR ELEVATION) —1>I<H- * ----•->i<-*— .---
RELIEF VALVE
(PLAN) .CA .C °25 C 4) C "--
RELIEF VALVE
(ELEVATION) 0> A
T
ll- 03 AI
CONTROL VALVE
—10 CO lip 0 Iti • .111.......0
GLOBE TYPE (PLAN)
CONTROL VALVE
GLOBE TYPE (ELEV) 1Y4 4 .Y4 9 .% c .7. C
C ONTROL VALVE
BUTTERFLY TYPE(PLAN) --1 0 F- 11/1 151
CONTROL VALVE
BUTTERFLY TYPE(ELEV) ___I I ..'
SOLENOID OPERATED II I
_.4> Ij<_<.__ I
VALVE (PLAN OR ELEV) —1><:11--- --->i<1— —4>l<l•—
BUTTERFLY VALVE
(PLAN OR ELEVATION) —I /1( 1F--
4 01.09.14 REAFFIRMED & ISSUED AS STANDARD „PFSH /ATD SC

Checked Stds. Committee Stds. Bureau
Rev. Prepared
No. by by
Approved by
Page 804 of 851

STANDARD No.
7-44-0003 Rev. 4
144Wrf 2T?a51..No.1)
INDIA LIMITED ELEMENTS ON DRAWINGS
IA Govt of iodia Undertak,o9)
Page 3 of 4
DESCRIPTION FLANGED SCREWED WELDED SOCKET WELD

(NOTE- 1 )
DIAPHRAGM VALVE —4 ".—

—117NH-- 1". —.1^1-.—
(PLAN OR ELEVATION)
3-WAY PLUG VALVE --11.11-- --.-1:::21--.--
(PLAN OR ELEVATION) -r ----r*— -- --
4-WAY PLUG VALVE
(PLAN OR ELEVATION) --11—
1>X1
—4.
—
EXPANSION JOINT --I1
-.— —E12.--
ANGLE CONTROL VALVE A
1
-
,.
CHAIN OPERATING
VALVE (TYP) *-1->}
:-
i
GEAR OPERATED VALVE ai 1-4 INDICATES
BEVEL PINION
(BEVEL GEAR) PLAN 1 LOCATION
i
GEAR OPERATED VALVE 4 2 1-4 INDICATES
(SPUR GEAR) PLAN PINION
3 LOCATION
MOTOR OPERATING •
VALVE • (3 $ Cl>
-r
STEAM TRAP —i —..--U —i-U I.
1—
i li— .. i \,, i .1
Y-STRAINER
SYMBOL
T
DESCRIPTION SYMBOL DESCRIPTION
,
SLIP-ON FLANGE
I
1 STUB - IN
(WITH OR WITHOUT REINF)
WELDNECK FLANGE .
SCREWED FLANGE I 1
STUB - IN I1--
(SADDLE REINF)
SOCKET WELD FLANGE .1
R.P.
SPACER i
1) STUB - IN WITH REINF
(IN PLAN) —=
SPACER BLIND
SPECTACLE FIG. 8
(BLIND) INSULATED
(EINES 12" AND BELOW)
SPECTACLE FIG. 8
(OPEN) 11
4 01 .09.1 4 REAFFIRMED & ISSUED AS STANDARD /ATD SC

Rev.
No. by by
Approved by
Page 805 of 851

STANDARD No.
IA Govt of India Undeffaloo9) ELEMENTS ON DRAWINGS
Page 4 of 4
DESCRIPTION SYMBOL DESCRIPTION SYMBOL
INSULATED
CONICAL STRAINER F--..
[1---' (EINES 14" & ABOVE)
E-- --!
3-
T-TYPE STRAINER STEAM TRACED

~ '- ö-- —-
T-STRAINER
--111 —<p---
DRIP-RING WELDOLET
NOTES :
1. WELD DOTS NOT TO BE SHOWN ON PIPING G.A.Ds.
2. FOR SYMBOLS/LEGENDS RELATED TO CIVIL ENGINEERING/UNDERGROUND PIPING WORK,
REFER CIVIL ENGINEERING STANDARD 7-65-0001.
4 01.09.14 REAFFIRMED & ISSUED AS STANDARD ~SH /ATCk4s

No. by by
Approved by
Page 806 of 851

STANDARD No.
ENGINEERS
INDIA LIMITED STUB-IN STANDARD 7-44-0032 Rev. 4
IA Govt of India Undertalong)
Page 1 of 2
NOTES:—
DIMENSIONS GIVEN ARE ONLY MINIMUM

REQUIREMENTS FOR STUB—IN CONNECTIONS. %?
ALL FABRICATION SHALL BE DONE AS D
PER ISOMETRIC SHEETS.
1 (WITHOUT REINFORCEMENT)
C 1 (WITH REINFORCEMENT)
kA
D d A C B D d A C B D d A C B D d A C B
2" 2" 110 150 110 16" 12" 310 460 370 26" 12- 310 460 520 32" 12" 310 460 580
3" 2" 120 150 130 14" 320 490 380 14" 320 490 520 14" 320 490 580
3" 140 190 140 16" 360 530 400 16" 360 530 520 16" 360 530 580
4" 2" 130 150 130 18" 2" 150 180 360 18" 380 590 560 18" 380 590 620
3" 140 190 150 3" 160 210 360 20" 420 640 560 20" 420 640 620
4" 160 220 160 4" 180 240 370 24" 470 750 620 24" 470 750 680
6" 2" 120 160 180 6" 220 300 370 26" 500 800 660 26" 500 800 720
3" 140 190 180 8" 240 340 390 28" 2" 150 180 500 28" 520 850 750
4" 160 220 200 10" 280 400 400 3" 160 210 510 30" 550 900 780
6" 180 280 200 12" 310 460 410 4" 170 240 520 32" 570 950 810
8" 2" 120 160 210 14" 320 490 420 6" 220 300 520 36" 2" 150 180 610
3" 140 190 260 16" 360 530 430 8" 240 340 520 3" 160 210 620
4" 160 220 240 20" 18" 380 590 440 10" 280 400 520 4" 170 240 620
6" 200 280 240 2" 150 180 390 12" 310 460 540 6" 220 300 620
8" 220 330 240 3" 160 210 400 14" 320 490 540 8" 240 340 620
10" 2" 120 160 250 4" 180 240 400 16" 360 530 540 10" 280 400 620
3" 140 190 260 6" 220 300 400 18" 380 590 580 12" 310 460 640
4" 160 220 270 El" 240 340 420 20" 420 640 580 14" 320 490 640
6" 200 280 280 10" 280 400 420 24" 470 750 640 16" 360 530 640
8" 220 330 280 12" 310 460 440 26" 500 800 680 18" 380 590 680
10" 270 400 300 14" 320 490 440 28" 520 850 710 20" 420 640 680
12" 2" 120 160 250 16" 360 530 460 30" 2" 150 180 530 24" 470 750 740
3" 140 190 260 18" 380 590 480 3" 160 210 540 26" 500 800 760
4" 160 220 270 20" 420 640 500 4" 170 240 540 28" 520 850 790
6 200 290 280 2" 150 180 450 6" 220 300 540 30" 550 900 810
8" 220 330 280 24" 3" 160 210 460 8" 240 340 540 32" 570 950 840
10" 270 400 320 4" 170 240 470 10" 280 400 540 36" 620 1050 910
12" 300 450 330 6" 220 300 470 12" 310 460 560
14" 2" 130 170 310 8" 240 340 480 14" 320 490 560
3" 150 200 320 10" 280 400 480 16" 360 530 560
4" 160 230 330 12" 310 460 500 18" 380 590 600
6" 210 290 330 14" 320 490 500 20" 420 640 600
8" 220 330 340 16" 360 530 520 24" 470 750 660
10" 270 400 360 18" 380 590 540 26" 500 800 700
12" 300 460 370 20" 420 640 560 28" 520 850 720
14" 320 490 380 24" 470 750 600 30" 550 900 760
16" 2" 150 180 330 26" 2" 150 180 480 32" 2" 150 180 760
3" 160 210 340 3" 160 210 490 3" 160 210 550
4" 180 240 350 4" 170 240 500 4" 170 240 560
6" 220 300 350 6" 220 300 500 6" 220 300 560
8" 240 340 360 8" 240 340 500 8" 240 340 560
10" 280 400 360 10" 280 400 500 10" 280 400 560
4 01.09 14 REAFFIRMED & ISSUED AS STANDARD 713-VSH AK RN /ATD

No. by by
Approved by
Page 807 of 851

STANDARD No.
ENGINEERS
g-a[ fafardg2.FRFROSI 3f1?1,1)
INDIA LIMITED
IA Govt of InOia Undertakingt
STUB-IN STANDARD 7-44-0032 Rev. 4
Page 2 of 2
NOTES: —
DIMENSIONS GIVEN ARE ONLY MINIMUM
REQUIREMENTS FOR STUB— IN CONNECTIONS.
THESE ARE BASED ON ASME B16.9 FLANGES
FOR SIZES UPTO 24"NB & ASME B16.47B
FOR SIZES 26" & ABOVE. ALL FABRICATION
SHALL BE DONE AS PER ISOMETRIC SHEETS. (WITHOUT REINFORCEMENT)
(WITH REINFORCEMENT)
D d A C B D d A C B D d A C B D d A C B
2" 2" 180 220 180 16" 12" 450 600 500 26" 12" 450 600 650 32" 12" 480 630 710
3" 2" 200 230 200 14" 460 630 520 14" 460 630 660 14" 490 660 720
3- 220 270 220 16" 500 670 540 16" 500 670 670 16" 530 700 730
4" 2" 210 240 220 18" 2" 310 340 430 18" 520 730 720 18" 550 760 780
3" 220 270 230 3" 320 370 440 20" 560 780 720 20" 590 810 780
4" 240 300 250 4" 340 400 450 24" 610 890 790 24" 640 920 850
6- 2" 220 260 250 6" 380 460 470 26" 640 940 800 26" 670 970 860
3" 240 290 260 8" 400 500 500 28» 2" 300 330 570 28" 690 1020 900
4" 260 320 280 10" 440 560 520 3- 310 360 580 30" 720 1070 940
6" 280 380 300 12" 470 620 540 4" 320 390 610 32" 740 1120 980
Er 2- 230 260 280 14" 480 650 560 6" 370 450 620 36- 2" 330 360 680
3" 250 300 300 16" 520 690 580 8" 390 490 630 3" 340 390 700
4" 270 330 320 18" 540 750 600 10" 430 550 640 4" 350 420 710
6" 300 390 340 20- 2" 310 350 460 12- 460 610 670 6" 400 480 720
8" 330 440 350 3" 320 380 480 14" 470 640 680 8" 420 520 730
10" 2- 240 280 320 4" 340 410 490 16" 510 680 690 10" 460 580 740
3" 260 310 340 6" 380 470 500 18" 530 740 740 12" 490 640 770
4- 280 340 350 8" 400 510 530 20- 570 790 740 14" 500 670 780
6" 320 400 380 10" 440 570 550 24" 620 900 810 16" 540 710 790
8" 340 450 390 12" 480 620 570 26" 650 950 820 18" 560 770 840
10" 390 520 420 14" 490 650 580 28" 670 1000 860 20" 600 820 840
12" 2" 260 300 350 16" 520 700 600 30" 2" 310 340 600 24" 650 930 910
3" 280 330 380 18" 540 750 640 3" 320 370 620 26" 680 980 900
4" 290 360 390 20" 580 810 670 4" 330 400 630 28- 700 1030 940
6" 330 420 410 24" 2" 320 350 570 6" 380 460 640 30" 730 1080 970
8" 350 460 420 3" 330 380 540 8" 400 500 650 32" 750 1130 1010
10" 400 530 440 4" 340 410 560 10" 440 560 660 36" 800 1230 1080
12" 430 580 460 6" 390 470 570 12" 470 620 690
14" 2" 270 310 380 8" 410 510 590 14" 480 650 700
3" 290 340 400 10" 450 570 600 16" 520 690 710
4" 300 370 410 12" 480 630 630 18" 540 750 760
6" 350 430 430 14" 490 660 650 20" 580 800 760
8" 360 470 450 16" 530 700 660 24" 630 910 830
10" 410 540 480 18" 550 760 700 26" 660 960 840
12" 440 600 500 20" 590 810 720 28" 680 1010 870
14" 460 630 520 24" 640 920 770 30" 710 1060 920
16" 2" 230 320 400 26" 2" 290 320 550 32" 2" 320 350 620
3" 310 350 420 3" 300 350 570 3" 330 380 640
4" 330 380 440 4" 310 380 590 4" 340 410 650
6" 370 440 450 6" 360 440 600 6" 390 470 660
8" 380 480 470 8" 380 480 610 8" 410 510 670
10" 420 540 480 10" 420 540 620 10" 450 570 680
4 01.09.14 REAFFIRMED & ISSUED AS STANDARD SH /AK /RN /ATD\sk)4 SC

No. by by
Approved by
Page 808 of 851

STANDARD No.
ENGINEERS`-ifs it4 DETAILS OF MITERED
1at felOrdg INDIA LIMITED
Iffre eirone d)7 5IIRIIM (A Govt of India Undertaking)
ELBOW 7-44-0033 Rev. 5
Page 1 of 2
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5 01.07.15 REAFFIRMED & ISSUED AS STANDARD "SH 4eAK RN SC

4 10.07.10 REAFFIRMED & ISSUED AS STANDARD PK RN SC DM ND
No. by by
Approved by
Format No. 8 - 00 - 0001 - F4 Rev.O Copyright EIL - All rights reserved
Page 809 of 851

STANDARD No.
ENGINEERS DETAILS OF MITERED
Oge.11
(
Oa MI3ERTPR)
INDIA LIMITED
(A Govt. of India Undertaking)
ELBOW 7-44-0033 Rev. 5
Page 2 of 2
FOR FIGURES
REF.EIL STANDARD NO.7-44-0033(SHT.1 OF 2)
'L' FOR TYPE—I TYPE—II TYPE—Ill

PIPE FF OR RF 'R' IDENTICAL PIPE
SIZE FOR ALL TYPES SIZE
150# 300# A B C D A B C D A B C D
38" 1572 1640 1448 800 600 400 848 517 388 259 1060 384 288 192 1160 38"
40" 1653 1722 1524 842 631 421 893 544 408 273 1116 404 303 202 1221 40"
42" 1733 1805 1600 884 663 442 937 572 429 286 1171 424 318 213 1282 42"
44" 1813 1890 1676 926 694 463 982 599 449 299 1227 445 333 222 1343 44"
46" 1898 1975 1753 968 726 484 1027 626 470 313 1283 465 349 233 1404 46"
48" 1978 2053 1829 1010 758 505 1071 653 490 327 1339 485 363 243 1465 48"
50" 2059 2140 1905 1052 789 526 1116 681 510 340 1395 505 379 253 1526 50"
52" 2138 2224 1981 1094 821 547 1160 708 531 354 1450 525 394 263 1587 52"
54" 2219 2297 2057 1136 852 568 1205 735 551 367 1506 546 409 273 1648 54"
56" 2301 2402 2134 1178 884 589 1250 762 572 381 1562 566 424 283 1710 56"
58" 2385 2485 2210 1220 915 610 1295 790 592 395 1618 586 440 293 1770 58"
60" 2465 2558 2286 1263 947 631 1339 817 613 408 1673 606 455 303 1831 60"
5 01.07.15 REAFFIRMED Sc ISSUED AS STANDARD 3SH RN SC

No. by by
Approved by
Page 810 of 851

NOM SCH C DEHG P
STIFFENER OG 0 150CL 300CL 300CL 600CL 600CL
+0 RF RF RTJ RF RTJ
L., _2
40, STD 154 160 168 170 171 51
2" 80, XS 152 158 166 168 169 48 58 8 6 6X6
owit 160 149 155 163 165 166 40
L
XXS 147 153 163 164 35
1115111IS 40, STD 177 183
161
190 192 198 61
IMI• ■■ ••••IIIM
MM••••MM SEE DETAIL-1 1 -
194
MMXIINI•••••////w
MWV.11./WW/N/ 2/2 80, XS 175 181 190 196 57 64 8 6 6X6..
WIMIRIM”../Mr
\*Ilw
160 172 179 192 188 194 51
40, STD 194 204 211 213 214 76
80, XS 192 202 209 211 212 72 64 8 6 6X6
160 189 198 206 208 209 64
XXS 185 194 202 204 205 54
40, STD 232 242 250 264 266 100

80, XS 229 239 247 261 263 95 64 8 6 6X6
4- 120 227 237 245 259 261 89
AS PER MESH SPECIFICATION 160 224 234 242 256 258 83
231 239
(NOTE 1) XXS 221 253 255 75
DETAIL-1
MESH SPECIFICATIONS (NOTE-1)

STIFFENER OG MESH OPEN MESH -
SERVICE OPENING (IN)
SPECIFICATION AREA% DESIGNATION
LOW
VISCOCITY 0.097 8 MESH 22 SING 62.2 TYPE 4
EQUAL TEE (MATERIAL & o<y< 2
THICKNESS AS PER SPEC.) MIDIUM
VISCOSITY 0.111 7 MESH 21 SING 60.3 TYPE 3
2 Sy 8
E HIGH
VISCOSITY 0.202 4 MESH 18 SING 65.3 TYPE 2
1> 8
GASOLINE, 0.053 TYPE 5
EQUAL SECTION FRAME ATTACHED BY PROPANE
14 MESH 26 SWG 55.1
INTERMITTENT WELD SIZE P
WATER 0.053 14 MESH 26 SWG 55.1 TYPE 5
BLIND FLANGE (MATERIAL PRESSURE
RATING & FACING AS PER SPEC.)
NOTES:-
1. THE MESH SPECIFICATIONS AS GIVEN IN THE TABLE ARE TO BE USED WHEN STRAINER
IS INTENDED TO BE USED AS PERMANENT STRAINER. IN CASE OF TEMPORARY STRAINER
THE MESH SPECIFICATION SHALL BE AS FOLLOWS:
FOR LINES UPTO 2 1/2"—
S.S STD. STOCK MESH 0.047" DIA WIRE X0.203 SQ.CLEAR OPENING-65.9 % OPEN AREA
FOR LINES 3"& ABOVE —
3/4"0
SCREWED S.S STD. STOCK MESH 0.08" DIA WIRE X0.253 SQ.CLEAR OPENING— 57.6 % OPEN AREA.
PLUG 2. MATERIAL AS PER LINE SPECIFICATION.
WELD NECK FLA GE (MATERIAL, PRESSURE 3. 3/4"0 SCREWED PLUG FOR DRAIN CONNECTION SHALL BE PROVIDED.
PCD (NO. OF BOLTS & BOLT DIMENSIONS RATING & FACING AS PER SPEC.)
& MATERIAL TO SU!T SPEC.)
6 22.03.18 REAFFIRMED AND ISSUED AS STANDARD .51T`V

SH MI
t•44Y
RN STANDARD No.
lagiaddakENGNERs 5 28.03.13 REVISED AND ISSUED AS STANDARD UK SH RN ATD DM T-STRAINER TYPE-1 2"-4"
oft tiolegmy ism LIMITED
emeiVirlagalio (A Govt. of India Undertaking)
Rev.
Date Purpose
Prepared Checked Stds. Committee
Convenor
Stds. Bureau
Chairman (150CL RF,300CL RF AND RTJ, 600CL RF AND RTJ)
7-44-0303 Rev. 6
No. by by Page 1 of 1
Approved by
Page 811 of 851

FLAT BAR-A NOM SCH
H C J FLAT BAR SQ
BAR
0 150# 300# 300# 600# 600# 150# 300# 300# 600# 600#
A
AS PER MESH SPEC. RF RF RTJ RF RTJ RF RF RTJ RF RTJ
(NOTE-1) 40 308 318 331 343 349 151 131 121 131 144 156 162
C/2 304 314 327 339 345 143 123 129 139 152 164 170
15X5 10X5 10X5 7 8 10X10
120 301 311 324 336 342 137 117 133 143 156 168 174
FLAT BAR—A FLAT BAR—A 160 297 307 321 332 338 129 109 139 149 162 174 180
XXS 293 303 316 328 334 122 102 144 154 167 179 185
FLAT BAR—D 20-30 382 391 404 420 425 203 183 129 138 151 167 172
40-60 378 387 400 416 421 197 177 132 141 154 170 175
8- 80 376 386 399 415 420 192 172 137 147 160 176 181 15X5 10X5 10X5 7 8 10X10
120 370 380 393 409 414 180 160 146 156 169 185 190
XXS-160 366 376 389 405 410 171 151 154 164 177 193 198
FLAT BAR—D \ FLAT BAR —E 141 154 182 188
20-30 446 462 475 503 509 256 216 125
Hi-9 40 444 460 473 501 508 253 213 127 143 156 184 191
60 441 457 470 498 504 246 206 133 149 162 190 196
SECTION-A FILTER DETAIL SECTION-B
10" 80 439 455 468 496 502 241 201 137 153 166 194 200 15X5 20X10 20X5 7 14 10X10
120 432 448 461 489 495 228 188 147 163 176 204 210
FLAT BAR—A
m.. •• .•• • •. 160 482 488 214 174 215 221
20 523 539 552 571 577 310 270 132 148 161 180 186
30 521 537 550 569 575 305 265 137 153 166 185 191
STD-40 519 535 548 567 573 302 262 139 155 168 187 193
12" XS-60 515 531 544 563 569 294 254 145 161 174 193 199 15X5 20X10 20X5 8 14 12X12
PERSPECTIVE VIEW 512 528 541 560
80 566 287 247 151 167 180 199 205
120 504 520 533 552 558 271 231 163 179 192 211 217
160 544 550 255 215 224 230
10 577 593 606 621 627 341 291 148 164 177 192 198
----- BLIND FLANGE (MATERIAL PRESSURE 20 575 591 604 619 625 338 288 150 166 179 194 200
FLAT BAR—A RATING & FACING AS PER SPEC.) 14" 30-40 572 588 601 616 623 332 282 155 171 184 199 206 15X5 25X10 25X6 10 16 12X12
P.C.D.NO.OF BOLTS, BOLT D'MN. XS 570 586 599 614 620 328 278 158 174 187 202 208
& MATERIAL TO SUIT SPEC.) 60 584 597 612 618 324 274 177 190 205 211
80 580 608 614 316 266 183 196 211 217
PLAN VIEW 593
10 628 647 660 686 691 392 332 135 154 167 193 198
SQ.BAR M 20 627 646 659 685 690 389 329 138 157 170 196 201
16" 30 625 644 657 683 688 386 326 140 159 172 198 203 20X5 30X12 30X7 10 16 14X14
XS-40 641 654 680 685 379 319 165 178 204 209
60 676 681 371 311 210 215
80 671 676 361 301 218 223
10 704 724 737 755 761 443 373 146 166 179 197 203
20 703 722 735 753 759 440 370 149 168 181 199 205
STD 701 720 733 751 757 437 367 151 170 183 201 207
18" 30 700 719 732 750 756 433 363 155 174 187 205 211 16 14X14
20X5 35X12 35X7 10
XS 698 717 730 748 754 430 360 157 176 189 207 213
OUTSIDE INTERMITTENT 40 747 753 427 357 215
3/4"95 209
OUTSIDE INTERMITENT SCREWED WELD 60 743 749 419 349 216 222
WELD SECTION —C c12 PLUG
10 773 790 805 825 832 493 413 153 170 185 205 212
C 216
MESH SPECIFICATION(NOTE-1) STD-20 769 787 802 822 829 487 407 156 174 189 209
WELD NECK FLANGE (MATERIAL PRESSURE
SERVICE STRAINER OPENING MESH OPEN MESH RATING Sc FACING AS PER SPEC.) 20" XS-30 766 784 799 819 826 480 400 162 180 195 215 222 20X5 40X15 40X8 11 20 14X14
SIZE NOM.(IN) (IN) SPECIFICATION AREA % DESIGNATION 816 476 396 217 224
40 823
EQUAL TEE (MATERIAL &
LOW 6" 0.097 8MESH 22SWG 60.2 TYPE 4
THICKNESS AS PER SPEC.)
SECTION-D 60 811 818 464 384 227 234
VISCOSITY 132 148 164 190 1 HV
940
do NI A.USOOS1A
0 < )) < 2 8-AND ABOVE 0.111 7MESH 21SWG 60.3 TYPE 3 10 882 898 914 949 594 504
STD-20 879 895 937 946 588 498 136 152 168 194 203
MEDIUM 6- 0.111 7MESH 21SWG 60.3 TYPE 3 911
110
VISCOSITY 876 892 908 934 943 582 492 141 157 173 199 208 20X5 45X15 45X8 11 20 14X14
24" XS
2 < pc a 8 -AND ABOVE 0.202 4MESH 18SWG 65.3 TYPE 2
30 932 941 579 489 201 210
HIGH 6" 0.202 4MESH 18SWG 65.3 TYPE 2
928 937 572 482 206 215
VISCOSITY 40
y> 8 8-AND ABOVE 0.269 3MESH 16SWC 65.2 TYPE 1 NOTES:-
1. THE MESH SPECIFICATION AS GIVEN IN THE TABLE IS TO BE USED NI HEN STRAINER IS INTENDED TO BE USED AS PERMANENT STRAINER IN CASE OF TEMPORARY STRAINER
GASOLINE e AND 8" 0.053 14MESH 26SWG 55.1 TYPE 5 THE MESH SPECIFICATIONS SHALL BE AS FOLLOWS: FOR LINE UPT02 V 2" —5.5 STD. STOCK MESH 0.07" DIA WIRE X0.203 SQ.CLEAR OPENING-65.9% OPEN AREA
PROPANE 10-AND ABOVE 0.087 8MESH 22SWG 60.2 TYPE 4 FOR LINES 3"& ABOVE S.S.STD. STOCK MESH 0.08" DIA WIRE X0.25 3 SQ.CLEAR OPENING— 57.6% OPEN AREA.
WATER 6" ABOVE 7MESH 21SWG 60.3
2 MATERIAL AS PER LINE SPECIFICATION
0.115 TYPE 3
3. 3/4"0 SCREWED PLUG FOR DRAIN CONNECTIO SHALL BE PROVIDED
6 30/03/2017 Revised and Issued as Standard PK .per MI el%N

T STRAINER TYPE-1 STANDARD No.
Viliaadak
— ENGINEERS 5 05/09/2011 Revised and Issued as Standard SH RN ATD DM
6"-24" (150# RF, 300# RF AND RTJ, 7-44-0304 Rev. 6
f IFIeUW
R MIA UM r r EEO Rev. Prepared Checked Stds. Committee Stds. Bureau
(A Govt. of India Undertaking) Date Purpose Convenor Chairman 600# RF AND RTJ)
No. by by Page 1 of 1
Approved by
Page 812 of 851

STANDARD No.
ENGINEERS VENTS AND DRAINS
Ogar (411UR efraf12 t1513g4»411
INDIA LIMITED
(f> Govt of Incha Undertalong)
(ON LINES 1 1/2" AND BELOW) 7-44-0350 Rev. 4
Page 1 of 1
TYPE TYPE
TEE EQUALLI,
VC1 REDUCING o DC1
PLUG 3/4" u"
(TYP)o
r, 3/4"
VF1 TEE EQUAL REDUCING DF1
VP1 \ ON LINE 3/4"-1 1/2" DP1
ON LINE 3/4"-1 1/2"

EQUAL TEE
o
VC2 3/4" DC2
RED
VF2 EQUAL TEE DF2
3/4" lon
VP2 DP2
_L_L
ON LINE 1"-1 1/2"
ON LINE 3/4"-1 1/2"
TEE EQUAL
VC3 REDUCING DC3
3/4"(NOTE 2) ON LINE 1"- 1 1/2"
3/4 "4 (NOTE 2)
VF3 TEE EQUAL DF3
DC7
REDUCIN
VP3 DP3
DF7
ON LINE 3/4"-1 1/2"
DP7 ON LINE 3/4""-1 1/2"
DC4
DF4
VC4
DP4
VF4
200
VP4
ON LINE 1"-1 1/2" TEE EQUAL/

ON LINE 1.
-1 1/2"
REDUCING
3/4" • \
(NOTE 2) X 3/4" in
!(NOTE 2) N
VF5 TEE EQUAL/

TEE EQUAL
REDUCING _ DC5
REDUCINIG (NOTE 2) 3/4"
VP5 • •• DF5
ON LINE 3/4"-1 1/2"
ON LINE 3/4"-1 1/2"
ON LINE 3/4"- 1 1/2"
VF6 DC8
(NOTE 2) x 3/4"
DF8
VP6 RED.
FITTING
FITTING DP8 TO FITTING
TO FITTING EQUAL TEE
DC6
VENT ON LINE 1"- 1 1/2" DF6

ON LINE 1"- 1 1/2"
4 01.09.14 REAFFIRMED & ISSUED AS STANDARD v< RN / AT4k--{ • SC

No. by by
Approved by
Page 813 of 851

STANDARD No.
ENGINEERS VENTS AND DRAINS
gz;11. fafZs INDIA LIMITED (ON LINES 2" AND ABOVE) 7-44-0351 Rev. 4
2s17astg erti.rftotfit A Govt of Incha Undeltak,og)
Page 1 of 1
TYPE VENT DRAIN TYPE
V1 D1
VP 1 DP1
D2
V2
D3
DP3
V3
VP3
D4
V4
D5
V5
NOTES :
MIN.
1. DIMENSIONS INDICATED ARE VALID FOR 75mm (MAX) INSULN.
THICKNESS. FOR HIGHER INSULATION THICKNESS INCREASE (NOTE 2)
DC9
DIMENSION AS REQUIRED
DF9
2. VALVES TO BE PROVIDED SHALL BE SIMILAR TO LINE ISOLATION DP9
VALVE (LATE, BALL OR PLUG VALVE ETC., WITH FLGD, SW OR SCR'D
ENDS) UNLESS OTHERWISE SPECIFIED IN PMS.
BRANCH—OFFS LIKE HALF CPLG(SW OR SCR'D)/SOCKOLET/WELDOLET
& END CONNECTIONS LIKE CAP/PLUG/FLANGE & BLIND FLANGE
SHALL BE AS PER PIPING MATERIAL SPECIFICATIONS.
3. VENTS/DRAINS CAN BE PROVIDED ON FLAT SIDE OF

ECCENTRIC REDUCER ON SIZES 4" & ABOVE
4. LEGEND V=VENT, D=DRAIN, C=CAP, F= FLANGE, P=PLUG DC10
5. PLUGGED END OF VALVE OR FITTING SHALL BE THREADED 3/4" (NOTE 2) DF1 0

DP10
it
150
4 01.09.14 REAFFIRMED & ISSUED AS STANDARD d9.9vSH `>RN / ATD SC

No. by by
Approved by
Page 814 of 851

STANDARD No.
ENGINEERS ORIENTATION OF ORIFICE
INDIA LIMITED TAPS 7-44-0352 Rev. 4
A Govt of India Undertakingt
(CLASS 600 & BELOW) Page 1 of 2
FOR LIQUID OR STEAM LINES FOR GAS LINES FOR VERTICAL LINES
DETAIL— 0 DETAIL— 0 DETAIL— 0
1/2- 1/2- 1 i
■ ' 1. ' 0111
l■ 1
1 ■
,,
ill
• - 1
1
1 /2"
1 /2"
0:1011
P1F1 14:
05
* FOR STEAM & CONDENSIBLES, LOWER
0 BLOCK VALVE SHALL BE RAISED TO
5 THE LEVEL OF THE UPPER BLOCK VALVE
FOR LIQUID LINES ON PIPE RACK FOR STEAM & GAS LINES ON PIPE RACK
FOR TAPS ON PIPE RACK
WITH OPERATING TEMP > = O'C & LIQUID LINES WITH TEMP BELOW 0.0
NOTE-5 NOTES-5
DETAIL— ® <000 DETAIL— 0 1/2- .
. DETAIL— (6)
..,... ORIF1 P T
1D 1D/2
.
1/2-80k
" 441)4° 1- INST. 1
1/2” 3/4..A
V PIPING Y 3/4-
4 i iioNs
■
„00%
.1,2. ,r FLOW
DETAIL— 0 DETAIL—
1/2-.
,ki/2- i
P..
P 410 LINE FLANGES
PER.SPEC.
" ORIENTATON OF TAPS SHALL BE
.. LIQUID UNES WITH OPERATING TEMP. >= O'C :
4 ►•1/2. 45' FROM VERTICAL DOWNWARDS
0..
1/2" 00410 STEAM, GAS & LIQUID LINES WITH OP.TEMP < O'C :
45' FROM VERTICAL UPWARDS
INSTRUMENT SCOPE PIPING SCOPE
A. ORIFICE FLANGES ASSEMBLY WITH BOLTS/NUTS AND GASKETS A. TAPPING NIPPLE, COUPLINGS AND VALVES
B. IMPULSE LINE STARTING AFTER THE TAPPING VALVE
NOTES :
1. ORIFICE FLANGES IN HORIZONTAL LINES SHALL BE PREFERED.
2. TAPS SHALL BE ORIENTED TO SUIT LOCATION OF INSTRUMENT.
3. TAPS ON PIPE LINES INSTEAD OF ORIFICE FLANGES SHALL BE GENERALLY USED FOR 16" & ABOVE (DETAIL-6) UNLESS
OTHERWISE SPECIFIED. IN WHICH CASE FLANGES SHALL BE SAME AS LINE FLANGES AND SHALL BE IN PIPING SCOPE.
4. IN CASE OF VERTICAL LINES FLOW SHALL BE UPWARDS FOR LIQUIDS CONTAINING VAPOUR & DOWNWARDS FOR WET
GASES & STEAM.
5. THE ORIENTATION OF TAPPING IN CASE OF DETAILS 4 & 5 SHALL BE AS FOLLOWS:
FOR LIQUID LINES WITH OPERATING TEMPERATURE >= O'C :
4,8 &16 BOLT FLANGE — AT 45' TO VERTICAL POINTING DOWNWARDS
12 BOLT FLANGE — AT 60' TO VERTICAL POINTING DOWNWARDS
20 BOLT FLANGE — AT 54' TO VERTICAL POINTING DOWNWARDS.
FOR LIQUID LINES WITH OPER. TEMP. < O'C AND STEAM AND GAS LINES :
4,8 & 16 BOLT FLANGE — AT 45' TO VERTICAL POINTING UPWARDS,
12 BOLT FLANGE — AT 60' TO VERTICAL POINTING UPWARDS
20 BOLT FLANGE — AT 54' TO VERTICAL POINTING UPWARDS.
6. DETAILS 4 & 5 SHALL NOT BE USED FOR PRE—FABRICATED HOOK—UPS.
7. FOR CLEARANCE REQUIREMENT AROUND ORIFICE FLANGE REFER EIL STD. 7-44-0504
8. FOR DETAILS OF ORIFICE TAPPINGS AND ORIENTATION, REFER EIL STD. 7-52-0005.
4 21.10.14 REVISED & ISSUED AS STANDARD r\P'r SH ÂK "RN /ATDIxe-) SC

3 29.06.09 REVISED & ISSUED AS STANDARD PK RN SC
No. by by
Approved by
Page 815 of 851

STANDARD No.
ORIENTATION OF ORIFICE
ENGINEERS
5gzir 11lait?R envvrtrttcnt.nrcnc-0
INDIA LIMITED
IA Govt of Inclia UnclertakIng)
TAPS 7-44-0352 Rev. 4
(CLASS 900 & ABOVE) Page 2 of 2
FOR LIQUID OR STEAM LINES FOR GAS LINES FOR VERTICAL LINES
DETAIL — 0 DETAIL — 0 DETAIL— C)

40 4 4 I. 3/4" h
• , h 1 0114
3/4" 1. 1
3/4" /
000,11 s 400111111i3/4" • , I. 11 0000mm•N
400 3 4" 01111
3/4" '--
eblO
P IF'1°.f • 4
II45
* FOR STEAM & CONDENSIBLES, LOWER
IC/41‘ "
«. BLOCK VALVE SHALL BE RAISED TO
rif
5 GOf, THE LEVEL OF THE UPPER BLOCK VALVE
FOR LIQUID LINES ON PIPE RACK FOR STEAM & GAS LINES ON PIPE RACK
FOR TAPS ON PIPE RACK
WITH OPERATING TEMP > = O'C & LIQUID LINES WITH TEMP BELOW O'C
; NOTE-5 3/4" -..I. NOTES-5

DETAIL— ® DETAIL— 0 .,
• ...
%..
.. ••■\ 4,00 DETAIL— 0 Rin P T
3/4» ., 1D 1D 2
INST.
vi PIPING V
.004
' .,
3/4" 3/4" A„ ■ 3/4"
0014 .
■
.
AL.
.' 3/4" -
FLOW 01 I 11013
3/4",, ,,,,,, 3/4,
g;
DETAIL— 0 DETAIL— ® No...4' N. 1
.k
UNE FLANGES
• PER.SPEC.
ORIENTATON OF TAPS SHALL BE
.0. -■.. ,„,3/4" o
UQUID LINES WITH OPERATING TEMP. >= O'C :
45* FROM VERTICAL DOWNWARDS
3/4 4, •'''. STEAM, GAS Ec LIQUID UNES WITH OP.TEMP < CYC
45 FROM VERTICAL UPWARDS
INSTRUMENT SCOPE PIPING SCOPE
A. ORIFICE FLANGES ASSEMBLY WITH BOLTS/NUTS AND GASKETS A. TAPPING NIPPLE, COUPLINGS AND VALVES
B. IMPULSE LINE STARTING AFTER THE TAPPING VALVE
NOTES :
1. ORIFICE FLANGES IN HORIZONTAL LINES SHALL BE PREFERED.
2. TAPS SHALL BE ORIENTED TO SUIT LOCATION OF INSTRUMENT.
3. TAPS ON PIPE LINES INSTEAD OF ORIFICE FLANGES SHALL BE GENERALLY USED FOR 16" & ABOVE (DETAIL-6) UNLESS
OTHERWISE SPECIFIED. IN WHICH CASE FLANGES SHALL BE SAME AS LINE FLANGES AND SHALL BE IN PIPING SCOPE.
4. IN CASE OF VERTICAL LINES FLOW SHALL BE UPWARDS FOR LIQUIDS CONTAINING VAPOUR & DOWNWARDS FOR WET
GASES & STEAM.
5. THE ORIENTATION OF TAPPING IN CASE OF DETAILS 4 & 5 SHALL BE AS FOLLOWS:
FOR LIQUID LINES WITH OPERATING TEMPERATURE >= O'C :
4,8 &16 BOLT FLANGE — AT 45' TO VERTICAL POINTING DOWNWARDS
12 BOLT FLANGE — AT 60' TO VERTICAL POINTING DOWNWARDS
20 BOLT FLANGE — AT 54' TO VERTICAL POINTING DOWNWARDS.
FOR LIQUID LINES WITH OPER. TEMP. < O'C AND STEAM AND GAS LINES :
4,8 & 16 BOLT FLANGE — AT 45' TO VERTICAL POINTING UPWARDS,
12 BOLT FLANGE — AT 60' TO VERTICAL POINTING UPWARDS
20 BOLT FLANGE — AT 54' TO VERTICAL POINTING UPWARDS.
6. DETAILS 4 & 5 SHALL NOT BE USED FOR PRE—FABRICATED HOOK—UPS.
7. FOR CLEARANCE REQUIREMENT AROUND ORIFICE FLANGE REFER EIL STD. 7-44-0504
8. FOR DETAILS OF ORIFICE TAPPINGS AND ORIENTATION, REFER EIL STD. 7-52-0005.
4 21.10.14 REVISED & ISSUED AS STANDARD /AK RN /ATI)* SC

3 29.06.09 REVISED & ISSUED AS STANDARD PK RN SC
Rev. Pre pared Checked Stds. Committee Stds. Bureau
No. by by
Approved by
Page 816 of 851

STANDARD No.
ENGINEERS WELDING OF PIPE WITH
fg-ar Of54-eg
Mri rirmle 3.10,,1)
INDIA LIMITED
,A DIFFERENT THICKNESS
7-44-0476 Rev. 4
Page 1 of 1
PERMITTED MISALIGNMENT
OF 1.5mm
30' MAX
THICKER PIPE TAPER BORED TO ALIGN
(AS PER ASME B31.3)
4 31.07.13 REAFFIRMED & ISSUED AS STANDARD kry UK 'SH Vii RN ATD DM

3 15.11.08 REAFFIRMED Sc ISSUED AS STANDARD AC RN DM VC
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright E IL - All rights reserved
Page 817 of 851
STANDARD No.
ENGINEERS BUTT WELDING
5g-211 926 INDIA LIMITED
IA Govt of India Undertakng)
END PREPARATION 7-44-0477 Rev. 4
Page 1 of 1
0.8-2.4mm
END PREPARATION FOR MITRE BEND
37 1/2421/2' 20-+21/2'
=22mm MAX.
1.6+0.8mm
(A) WALL THICKNESS 5-22mm INCLUSIVE

(AS PER ASME B31.3)
1
1 0'± 2 /2' 1
20'2/2'
OVER22mm
1-1.61-0.8mm
(B) WALL THICKNESS OVER 22mm
(AS PER ASME B31.3)
NOTES :
1. SQUARE ENDS MAY BE USED FOR WALL THICKNESS LESS THAN 5mm
.+5'
2. PIPE ENDS SUPPLIED WITH BEVEL ANGLE OF 30 _cy NEED NOT BE BEVELED FURTHER.
4 23.09.14 REAFFIRMED & ISSUED AS STANDARD AK RN /AT

Rev.
No. by by
Approved by
Page 818 of 851

STANDARD No.
ENGINEERS FILLET WELD DETAILS
t~f exow zolJoor44) IA Govt of Incha UndertakIngt
Page 1 of 1
FrAa
X MIN.
ElE1
X MIN. X MIN.
t OR 6.4mm WHICHEVER 1.6mm APPROX.

IS SMALLER
SLIP ON FLANGE SOCKET WELDED FLANGE
X MIN. = 1.4t OR THE THICKNESS OF HUB, WHICHEVER IS SMALLER.

t = PRESSURE DESIGN THICKNESS.(NOT CONSIDERING CORROSION ALLOWANCE AND MANUFACTURING
TOLERANCE.)
t=PRESSURE DESIGN THICKNESS
1.6mmAPPROX.
SOCKET WELDING FITTINGS
Cx (MIN)=1.25t BUT NOT LESS THAN 3.2mm
FILLET WELD DETAILS

(AS PER ASME B31.3)
4 01.09.14 REAFFIRMED & ISSUED AS STANDARD \*,(1 SH IC7 K V-^N /ATD) SC .-

No. by by
Approved by
Page 819 of 851
WELDING DETAIL FOR STANDARD No.
ENGINEERS
faigleg W INDIA LIMITED
MreM elecnreill5101?1,N) Govt of India Undertaking)
BRANCH CONNECTIONS 7-44-0479 Rev. 4
(NOT BREAKING INTO) Page 1 of 1
RECOMMENDED MIN 45' RECOMMENDED MIN 45'
0.8-2.4mm
45'
V '$ A's tc(min)
1.6 to 3.2mm
1.6 to 3.2mm
tc: MINIMUM OF 0.7T & 6.4mm
SECTION X AT CROTCH OF
RIGHT ANGLE BRANCH
SECTION Y AT FLANK
0.5T min tc(min)

45'
min.
VENT HOLE 10mm0
1.6 to 3.2mm
tc: MINIMUM OF 0.7T dc 6.4mm
DETAIL FOR REINFORCED BRANCH
0.8-2.4mm
0.8-2.4mm
1.6 to 3.2mm
1.6-3.2mm
45'MIN
SECTION W AT FLANK OF SECTION Q AT BACK OF SECTION Z AT CROTCH OF

EQUAL BRANCH SLOPING BRANCH SLOPING BRANCH
NOTES :-
1. THIS TYPE IS TO BE USED WHEN BRANCH IS EQUAL TO OR ONE SIZE SMALLER THAN MAIN PIPE.
2. REFER STANDARD 7-44-0484 FOR DIMENSIONAL DETAILS.
4 01.07.15 REAFFIRMED & ISSUED AS STANDARD SH RN 'SC

3 10.07.10 REAFFIRMED & ISSUED AS STANDARD PK SC DM ND
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights resery
Page 820 of 851

STANDARD No.
ENGINEERS BUTT WELD DETAILS
fafaitg
ramie anJvms+1
INDIA LIMITED
to Govt of India Undertaking)
( DIMENSIONS) 7-44-0480 Rev. 4
Page 1 of 1
371/2*-1-21/2'
OR —0
0.8-1.6 mm 1.6 mm 1.6 mm
•••
•• ••••
A ■
X MAX 0.8-2.4 mm
1.6-3.2 mm
4.8 mm < t < 19.1 mm

X MAX = 1.5 mm FOR PIPES 2" AND BELOW
3.0 mm FOR PIPES ABOVE 2"
4 31.07.13 REAFFIRMED & ISSUED AS STANDARD t)p• UK 511,,r--/SH ✓ RN ATD14\.n DM

No. by by
Approved by
Page 821 of 851
STANDARD No.
ENGINEER.S BUTT WELD DETAILS
faijiles
(.„„,rr rrrmir
C57.5,
10.1)
INDIA LIMITED
( A Govt of India Undertaking)
( SEQUENCE OF WELDS) 7-44-0481 Rev. 4
Page 1 of 1
1.6 mm
0.8-1.6 mm
1.6+0.8 mm
FAPPROX. 1.6 —3.2 mm
STANDARD 'V' BEVEL

BUTT JOINT
APPROX.3mm
SEQUENCE OF WELDS
4.8 mm < t < 19.1 mm
4 31.12.13 REAFFIRMED & ISSUED AS STANDARD > 'CJK

3 15.1 1.08 REAFFIRMED & ISSUED AS STANDARD AC RN
No. by by
Approved by
Page 822 of 851

WELDING DETAIL FOR STANDARD No.
ENGINEERS
k.31
1Ufa2a5 INDIA LIMITED BRANCH CONNECTIONS 7-44-0482 Rev. 4
I ~f 27221517 C151.1,44.1) IA Govl of India UndertakIng)
(STUB IN) Page 1 of 1
RECOMMENDED MIN 45' RECOMMENDED MIN 45'
NOTES :
›—tc(min) 1. THIS TYPE IS TO BE USED WHEN

BRANCH IS MORE THAN ONE SIZE
SMALLER OF MAIN PIPE.
2. FOR LINES COMING UNDER THE
PURVIEW OF IBR RECOMMENDED
1.6 TO 3.2 mm MIN. ANGLE SHALL BE 60').
SECTION X AT CROTCH OF RIGHT SECTION Y AT FLANK

ANGLE BRANCH
tc=MIN OF 0.7t & 6.4mm
0.5T (min) tc(min)
VENT HOLE lOmmg>
z
•
tc(min.)
1.6 to 3.2mm
1.6 to 3.2mm E 1.6 to 3.2mm
SECTION Q AT BACK OF SECTION Z AT CROTCH OF

SLOPING BRANCH SLOPING BRANCH
4 31.12.13 REAFFIRMED & ISSUED AS STANDARD *ryUK yN"4

,7 H RN SC
No. by by
Approved by
Page 823 of 851

STANDARD No.
ENGNEERS e..1 BRANCH CONNECTION
ligar051-eg INDIA LIMITED 7-44-0483 Rev. 4
MM.! riemie OW1170 (A Govt of India Undertaking) (BREAKING INTO)
Page 1 of 1
A=2d
10 0 TAPPED HOLE
FOR TESTING
0 MAIN PIPE
2 VENT HOLES 0 3mm

(PLUG BY WELD AFTER WELDING OF PAD)
SYMBOL ON GADS SYMBOL ON ISOMETRICS
REINFORCEMENT PAD REINF.PAD

0 X THK. REINF. PAD
0 X THK.\
PLAN (SINGLE LINE) PLAN (DOUBLE LINE)
NOTES :-
1. THIS TYPE IS TO BE USED WHEN BRANCH IS MORE THAN ONE SIZE SMALLER THAN MAIN
PIPE
2. THE REINFORCING PLATE SHALL BE OBTAINED FROM PIPE SPOOL OF THE SAME SCHEDULE
AND DIAMETER OF MAIN PIPE UNLESS OTHERWISE STATED
3. THE REINFORCEMENT PAD CALCULATIONS SHALL BE MADE IN ACCORDANCE WITH ASME 831.3
OR IBR AS APPLICABLE
4. ALSO SEE STANDARD 7-44-0484
5. REFER STANDARD 7-44-0482 FOR WELDING DETAILS.
4 01.07.15 REAFFIRMED & ISSUED AS STANDARD j SH ,.- RN SC

No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - At rights reserved
Page 824 of 851

STANDARD No.
k31ifoJ i ENGINEERS BRANCH CONNECTION
fai5teg INDIA LIMITED
14Ireef riecole C1513WR) IA Govt of India Undertaking)
(NOT BREAKING INTO) 7-44-0484 Rev. 4
Page 1 of 1
10 0 TAPPED HOLE
FOR TESTING
2 VENT HOLES 0 3mm PLUG BY

WELD AFTER WELDING OF PAD
REINF. PAD
0 x THK.
SYMBOL ON ISOMETRICS
NOTES :
1. THIS TYPE IS TO BE USED WHEN BRANCH IS EQUAL TO OR ONE SIZE SMALLER THAN MAIN PIPE
2. THE REINFORCEMENT PAD SHALL BE OBTAINED FROM PIPE SPOOL OF THE SAME SCHEDULE AND
DIAMETER AS MAIN PIPE UNLESS OTHERWISE STATED.
3. THE REINFORCEMENT PAD CALCULATION SHALL BE MADE IN ACCORDANCE WITH ASME 831.3 OR
IBR AS APPLICABLE.
4. ALSO SEE STANDARD 7-44-0483
5. REFER STANDARD 7-44-0479 FOR WELDING DETAILS.
4 01.07.15 REAFFIRMED & ISSUED AS STANDARD SH fv,AK ,/ RN SC

No. by by
Approved by
Page 825 of 851

METHOD OF CUTTING AND DIMENSIONS STANDARD No.
k31 2i ENGINEERS
ggU fajles w INDIA LIMITED OF FIELD MANUFACTURED 7-44-0485 Rev. 4
laiWf 212Z1512M.D.Isn.i)
iA G°""nd'a Undeda"g) CONCENTRIC REDUCERS
Page 1 of 1
LENGTH OF REDUCER
NUMBER OF ANGLE SIZE OF LENGTH CIRCUMFERENCE

DIFFERENCE
PIECES TO BE BETWEEN CUT OUT OF OF D1 MINUS
IN DIAMETER
D1 - D2 CUT OUT CUT OUTS REDUCER CIRCUMFERENCE OF D2.
X Y
1 .
1" 2 180' 1 1/2,. D1 3 /8
1 .
2" 3 120' .,
- 1/4.. D1 6 /4
1 .
3" 3 120' 3" D1 9 /2
4" 4 90' 3" D1 12 1/2"

3
5" 4 90' 4" D1 15 /4"
3
6" 4 90' 4 3/4. D1 18 /4"
3 .
7" 6 60' 3 /4 D1 22"
8" 6 60' 4 1/4" 1.1XD1 25"
9" 6 60' 4 3/4. 1.1XD1 28 1/4"

i, .
10" 8 45' 4" 1.1XD1 31 / 2
3 /4.. 3 ..
12" 8 45' 4 1.1XD1 37 /4
1 .
14" 10 36' 4 /2 1.1XD1 44"
1 . 1 .,
16" 12 30' 4 /4 1.1XD1 50 /4
18" 12 30' 4 3/4. 1.1XD1 56 1/2"

1 . 3 .
20" 12 30- 5 /4 1.1XD1 62 /4
NOTES:-
1. CUT OUT REQUIRED NUMBER OF PIECES IN ACCORDANCE WITH TABLE. HEAT & BEND ENDS
OF PIPE TO CONFORM WITH DIAMETER D2. WELD ALL AROUND.
2. RADIOGRAPHY SHALL BE PERFORMED IN ACCORDANCE WITH REQUIREMENTS OF INDIVIDUAL PIPING CLASSES.
4 31.12.13 REAFFIRMED & ISSUED AS STANDARD <540/UK SH ,RN SC

Rev. Prepared Stds. Committee Stds. Bureau
No. by
Approved by
Page 826 of 851

STANDARD No.
01 ENGINEERS TOLERANCES FOR
r 02eg
$'1g-a(44WR 23~1d50tn.)
INDIA LIMITED
IA Govt of Incha Undertaking) FABRICATION
7-44-0486 Rev. 4
Page 1 of 1
SECTION
A t3mm. MAX: FROM INDICATED DIMENSIONS FOR FACE TO FACE

CENTER TO FACE LOCATION OF ATTACHMENTS ETC. TOLERANCE
CAN NOT BE ADDED.
B ±1.5mm MAX. LATERAL TRANSLAT1ON IN ANY DIRECTION FROM

THE INDICATED POSITION.
C +1.5mm MAX. ROTATION FROM THE INDICATED POSITION MEASURED

AS SHOWN.
CO
D ±1mm MAX. OUT OF ALIGNMENT FROM THE INDICATED POSITION
MEASURED ACROSS ANY DIAMETER AS SHOWN.
E FLATI-ENING, MEASURED AS DIFFERENCE BETWEEN THE MAX.

AND MIN. OD AT ANY CROSS SECTION.
—3% MAX: FOR PIPE WITH EXTERNAL PRESSURE.
8% MAX: FOR PIPE WITH INTERNAL PRESSURE.
(_)
t•-""
4 31.12.13 REAFFIRMED & ISSUED AS STANDARD UK SH Ayl /R N SC
W
No. by by
Approved by
Page 827 of 851

METHOD OF CUTTING AND STANDARD No.
ENGINEERS
$1g-ar fa(Zs INDIA LIMITED DIMENSIONS OF FIELD 7-44-0487 Rev. 5
MANUFACTURED ECC. REDUCERS Page 1 of
E
11
6
10
5
4
9
2
8r-
1
7 0.866E
3xA
SIDE VIEW END VIEW
....................................
....................................
....................................
COMPLETED REDUCER
A = 1/8 OF SMALL PIPE CIRCUMFERENCE.

B = 3/12 DIFFERENCE BETWEEN CIRCUMFERENCES.
C = 2/12 DIFFERENCE BETWEEN CIRCUMFERENCES.
D = 1/12 DIFFERENCE BETWEEN CIRCUMFERENCES.
E = 1.5 x 0.D. OF LARGER PIPE.
NOTES
1. REDUCER SHALL BE FABRICATED OUT OF LINE PIPE.

2. ALL WELDS SHALL BE RADIOGRAPHED AS PER THE
PIPING CLASS NDT REQUIREMENTS.
3. THE DIFFERENCE BETWEEN D1 & D2 SHALL NOT BE
MORE THAN 20" NOMINAL BORE.
5 23.09.14 REVISED & ISSUED AS STANDARD MSH AK krARN /ATD X-N,PC) SC

No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - AII rights reserved
Page 828 of 851

STANDARD No.
LOW SUPPORT SLIDING
INGNEERS FOR BARE AND INSULATED PIPE 7-44-0621 Rev. 5
ORM. MIA LIMITED
Mel elelliMAIIINO (A Govt. of India Undertaking)
SIZE 2" THRU. 36" TYPE - Ll AND LlA Page 1 of 1
NO M. PIPE D IA
CUT TO REQUIRED LENGTH AT SITE

DO NOT CUT THROUGH ELBOW OR PIPE)
PROTECTION SHIELD
K (SEE VIEW A-A AND REF. NOTE-4)
A
LJ-
LL
0
A 0
D1 (TYP.) 0 0
In
LL
LL
0 0
10 DIA. TELL TALE z 0
HOLE (TYP.) 0 -C
LLI
CC 0
I I 0
0
z
0
VIEW A-A rx
INSERT PLATE ExExT(TYP)

; SLIDING PLATE BxBxT(TYP) t
.1 '///\\' • / ;,\\ \ N
L1-1- H/M L1A-2-H/M

TYPE TYPF
SIZE NO. SIZE NO.
HFIGHT LOCATION OF MATERK HFIGHT LOCATION OF_MATERIAL
TRANSITION (NOTE-2) TRANSITION (NOTE-2)
SYMBOL SYMBOL
D1 B T c E K
SIZE NO. D (NOTE-3) (NOTE-4)
(NOTE-5)
2' 70
1 2' 540/105 150 10 250 160
3' 115
4' 137
2 3 S40/10S 200 10 300 190
6' 174
a" 205
3 10' 4' 540/105 200 12 262 300 215
12' 287
14' 388
4 6' S40/105 250 12 350 270
16' 418
5 18' 8' S40/10S 300 12 454 400 320
20' 554
6 10' S40/10S 350 12 450 375
24' 815
26' 875
7 30' 12' S20/105 400 16 800 500 425
NOTES:- 36' 950
1. INSERT AND SLIDING PLATE MATERIAL SHALL BE CARBON STEEL WHERE DESIGN TEMP. IS > 343'C WITH h < 200MM, SLIDING PLATE
MATERIAL SHALL BE EQUIVALENT TO PIPE MATERIAL
2. DIMENSION LOCATES THE POINT OF MATERIAL TRANSITION ON THE SUPPORT. THE STUB MATERIAL SHALL BE EQUIVALENT TO THAT OF UNE PIPE AND
THE LOWER SUPPORT PIPE SHALL BE CARBON STEEL MINIMUM VALUE OF M SHALL BE 'INSULATION THICKNESS+25MM."
A. FOR CARBON STEEL(CS) UNE PIPE, THE ENTIRE SUPPORT PIPE SHALL BE CS, THAT IS M=0.
B. FOR ALLOY STEEL(AS) OR STAINLESS STEEL(SS) UNE-PPE, SUPPORT PIPE SHALL CONSIST OF THE FOLLOWING -
- FOR h LESS THAN OR EQUAL TO 500MM, ENTIRE SUPPORT PIPE MATERIAL SHALL BE EQUNALENT TO THAT OF UNE PIPE, THAT IS M=h.
- FOR h GREATER THAN 500MM, SUPPORT PIPE SHALL BE COMPOSITE WITH MAANSULABON THK.+25MM OR 100MM, WHICHEVER IS GREATER.
3. IN CASE SIZE AND/OR SCH. OF SUPPORT PIPE (1)1) LISTED IN THE TABLE IS NOT AVAILABLE, USE NEXT HIGHER SIZE AND/OR NEAREST HIGHER
THICKNESS AVAILABLE.
4. PROTECTION SHIELD (LENGTH-K MM) CUT FROM UNE-PIPE OR EQUNALENT PLATE SHALL BE PROVIDED ON HORIZONTAL UNE AS FOLLOWS -
A. FOR 150# AND 300# CLASS PIPING
CS AND AS ONES - 10" AND ABOVE
SS ONES - 2' AND ABOVE
B. FOR 600# AND HIGHER CLASS PIPING
CS, AS AND SS ONES - 10' AND ABOVE
5. DIMENSION 'C' IS TO BE MODIFIED IF OTHER THAN 1.50 RADIUS ELBOWS ARE USED.
6. IN CASE CALCULATED h EXCEEDS THE MAX. VALUE, PEDESTAL SHALL BE RAISED ACCORDINGLY.
5 11.08.2016 REAFFIRMED AND ISSUED AS STANDARD SH MI S2 RN

4 27.06.2011 REAFFIRMED AND ISSUED AS STANDARD RSB • ATD VKB DM
No. by by
Approved by
Page 829 of 851
patuasai sp.i6p — ii3 1q6uAdoo
0*A821Ld- 1.000-00-9ON wwioj
Page 830 of 851

Aq penoiddv
z
CD
a
CD
m
cr m
P `)
0.
c
a SD gu
0 w
7 0
= coa
C a
O
CO
7
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O
C1311SSI3NCINVCI3SIA31:1
0
2
z z
NJ
agnssial ONVCl3SIA321
O
zz
C)
W
0311SSI32i aNYCI3SIA3e1
0
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V
m
m
-a
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Cl)
C)
C)
cn
0
0
0
C
z
z
z
z
ti"AON Z000-ZS-L S3cIld NONOIIO3NNOO
'oN ativaNVIS
0 00 rn J. 1,1
11
113131AI MOTH
Cb
t21
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0.A91:I L3- L.000-00-9*clisl)et.uioj

V /A Z E3 rn ■
,; c: 65 v /A V /A V /A
CA 0, -q
■ • > .-4 PO tTi CA 0, cl, 0, CA 0, V
ci, 0,
CD
CD c
o on '-' a cc rr o c, o c, c, c, o c,
4t , 4k c,
4t o
4k o c> CD CD CD
4t 4t 4t 4t 4L
..... .-
1":! :',,.: w 2,,'
. uo .,■'
;7;7 ;.1'7
. .11 :37:
on on -1 CA .1 "Irl LO
-ri r) n r- n
n
r r- p0
r- . r- .
CD CD X CD 70 CD CD 70
C7 C7 C7 C7 u 0 C7
'A" FLGD
P P * * • * *
A" SCRD*
PROCESS
CONNECTION
...
2" FLGD.
::37
,
." ,■'0 1:".- . 1
''-!
''. W ';',7
, 7
3 3
on C4 n1 cn "< -in. nn GO
r) (-) r- n 2 r- . r- . n
r- Pc C) 7o ,,, 70
CD C7 0 CJ 0 --3 C)
VALVE
C)
'A" FLGD
* * • * ...-, 0
'A" SCRD*
.- .-
;:r. ;;F: w ,":3: u'.3 w w
,',7, Z.7
.. .3: 1
LO Ln n1 LO hl nn nn
nn "T1 n r) ,-. r) r- . , , t-
r-
c) r"
C 70 ,
0 x 4
C C) C)
2" FLGD
P P :.- P C7 C7
'A" SCRD
T
'A" SCRD
C) P
WHERE PIPINGCLASS RECOMMENDS
CONNECTION
FIRST BLOCKINSTRUMENTS
SCRDCONNECTION ..
-- -.
3 4, .":,:f.3 Qa ;.„.:' ;;;.7
. 3
7.7
;:',7 ::...7 .3 l'.̀
.
'
.
I. Go Go ' on " Ln „ 3 1
r-
P, p ,1 -,1 r) (-, -1
r- il (::J c E E P:, El
c) c
P P 1..- P 0 u a • P„ u
__
2" FLGD.
t! ...! :37
LO C4 vu ...‹ . 3 3 l'' ,;,Z
!..,',.
r- 1` P2 2 P P. P. cc on a
C) aa 65 0 tr- cn C 0 C C
Y2" SW
%" BW
VALVE
P -3 0 CI c
'A" FLGD
P l'
-'i C
INSTRUMENT CONNECTION ON PIPES
... ...
;.. .c ..;‹ ^': ;;;Z, W. ,,;.r w w w ua La ;')..7.
cn cn -n un -n .-1 .:1 .11 ce,
n (..) r- () r- r- r- r a ()
r- r" 7s pD3 C) xi C) C) C) C) C) 20
2" FLGD
0 C) C7 C7 C7 C7 :7 0 C7 C) V Z7
'A" SCRD
'A" SCRD
'A" SCRD
C7 P
'ING CLASS RECOMMENDS
CONNECTION
FIRST BLOCK INSTRUMENTS
BW # CONNECTION
..- --
:;"‹ 1",
! .
"3:,
'
. (J'i '33! w Is: ;:37 ;:',,.'
3 ;73'-
,
t137, 1 „ 3 :
nn ,, .., nn nn
-n n1 'f=";
r r r r r r =" c4
c)
c) c c
r0
c c o c) i,-i x c)
2" FLGD.
0
'A" FLGD
Puuoc) *uu
'" SCRD*
P P
PROCESS
'A" SCRD**
CONNECTION
'
,.;‹ ;-...,: 1-;,..-, .,.'3 "Ea

,..< .
,,.-: ';'....t...3 .■.373 1".. 3 ::,3: ;1"!
3
.11 .71 `11'T1 nn nn nn a a
t- r- r r" nn r 2r' r r a r r r-
c.) c) c),c2,C)cncc)c)c)c)c)
FIRST
BLOCK
c
'A" FLGD
A" FLGD
c :.--, C7 .-.- C7 C7 0 0 C) C7
'A" FLGD
p
CD
CD
NJ
0
- --
." ;.',.7. ;.,u. ;.;,-, L'..! t'f< '"i. w L., 3.,..t L..) ::;.7
.
„ nn C n1 ni=1 -.6 h6 -.6 ,,
h,
.noN Z000-Z9-L
n1 ,-, r (-.) r' r-

'(e'2) r-- r- r- ,
.oN a avaNvis
r c) C) c c C) C) x
.1
2" FLGD
c-) C7 p C7 ? C7 Z7 C7 C7 p
'A" SCRD
'A" SCRD
'A" SCRD
0 P
CONNECTI
Copyright EIL — All rightsreserved

INSTRUMENTS
ON
WHERE PIPINGCLASS RECOMME NDS
FLGDCONNECTION
VALVE
Page 831 of 851

▪
'0 Oa -4 ON to 41. Lo t,
..) --
C
lewiod
(.01 4:a. L.)
<5>
ORIFICE
(FLGD ) <5>
+ + * 4t * "Iv . .; > "11
FLOW METER
FLOW METER
ORIFICE (DIA-
THERMOWELL
* X'-'-rO
PHGRAMSEAL)
+
SEAL PRESSURE
rrI '-3 CM'X
c4 .,„
cn > E.-;) "il >
DIAPHGRAM SEAL
/A V
FLOWMETER ++
TYPEOF
INSTRUMENTS <5>
c:r"rn ; Z cs O,
XJ .-< C, CD
[DP INSTRUMENTS <5>

DIAPHGRAM SEAL D.P.
(-) (./) > V) H>OZ
— , _ r, r, C, C,
# 009 <
INSTRUMENTS
0'AO/AL3-1000-00-8
#009
7r ii 0 --] CA m = -1 ' -7.,. 12 -4 xt 4k
AVERAGINGPITOT TUBE
DIAPHGRAM(CHEMICAL)
_PRESSUREINSTRUMENTS
PRESSUREINSTRUMENTS
rZ,..,-1:1 cliF5S2c4=
INSTRUMENTS (SCRD.) <5>

r; Z ni r-
0r- rl c Po C) rrl .5
mH r)._,°7JmCHn
-, -r., ----
:C '0 >H z ..- .e■
. 1):',.! l'iZ.! ,7,.
,
H3,2r1-Jmr44
r, 2 z r- c) ..4 po
m cnm - e-,HHrZC c) r) (-)
> ,1 r- cn - cn z cD P.
z c) 'z' 'd PC
m,2rHu,r,-, c) x)
0
3" FLGD
3" FLGD.
3" FLGD.
'A" SCRD*
PROCESS
*
3/4" SCRD**
%"SW/BW#
c) ,_ n(-) 24=z 0 a
IT' ,...., .n C: r- m , -1 > H
r- crl
CONNECTION
CY.° '-2- P,.-lS 2, ;:rz

H2 , u mcz3,mc
HcA „...-t.,4„..m .-3 _
OH u 7:,==1'4>pc :.', 1-,:z.! ,;z ,' ,;z
4po z rri - - En rri, ..:
cA
cn (4 0 -cl H
m= m m
-orri c zz, r- aa Ca
-tlz HcA P'' 0
VALVE
3" FLGD 6a
3" FLGD.
3/4" SCRD*
*
3/4"SW/BW#
OH P V V
FIRST BLOCK
(4,
(BY INST)
z r-n1 0
CLADDED PIPES
(n r- Z (4
Y>rcxr) 4c4Mm -
r q m >n -3 ,;;Z: 7. t...,.■
m M2Z"-j= cn ^ri
cn xJ -000 m
n ,-ri r) r
c ...›....,
(4. r- XI 0
—3 C.) 0
WHERE PIPING CLASS SPECIFIES
3" FLGD
3" FLGD
3" FLGD
3 " FLGD
'A" SCRD
V2" SCRD
,-,
SCRD.
>2=-7
'A" SCRD.
-t, z o m2 P P 5?
r
CONNECTION
poz,
INSTRUMENTS
F i
0, cA rn - r)
U 700H H
-to ,r
‹ c4 > -
c,, m z g
a c ,.-
cr X 0 t-r1 C/)
H rri til0H I ' 0
Xi 0 ..n > P:J
C
3" FLGD
3" FLGD
3" FLGD
o
3" FLGD
3" FLGD
3" FLGD
3" FLGD
> .:J'
'A" SCRD*
...
PROCESS
K C c., ct' h
tri 0
rri H (4
:c
Z --
CONNECTION
H cn cn >
0 t-
r r-
> :',..'
.-3
1A
o 5' r
: vi
O . . .
?:' z v)
= < `-0 oa
VALVE
3"FLGD
3" FLGD
m
3/4" FLGD
a
1 1/4"FLGD
'A" SW/BW
'A" SW/BW
CD 7y
' " SW/BW
r
FIRST BLOCK
<
(BY INST)
rrl rn
< c
S3dId NO NO1133NNO3IN3IN I11:11SNI
rn
CI =
,...,
r r1 ....
CEMENT LINED PIPES
X w0 C: ,.."7 .■
's7. .,7
rrl PO > ..,z :. .1
(n C) r- Cl) CA cn . .
H <n (-) n n
e P zJ zi
5 c
3" FLGD
3" FLGD
3" FLGD
WHERE PIPING CLASSSPECIFIES
'A" SCRD
0 0
3" FLGD+
ti, c 0
0, p c
INSTRUMENTS
.< CO .-
'-'
K 0 n1
m-i K
r) 2 m
z
x --
0 !
-3 „Z .1:
1A
-1
.11
z P r,
F--)' 0 r” c)
> 0 c)
1" FLGD
1" FLGD
3" FLGD
3" FLGD
0
3" FLGD.
r- 0
PROCESS
0
' " FLGD
C)
n >
CONNECTION CONNECTION
o c.)
z t-1-1
X H
ul
n u, --.
H = "r1
O > . '
,
1 ' t-'
?c1 r- r
r-
VALVE
C
1" FLGD
1" FLGD
3" FLGD
I" FLGD
0
3" FLGD.
cc
(BY INST)
1 'A" FLGD
m 0
FIRST BLOCK
2 up
rn
-0 Ca
za 0
2 Ca
C)
..;Z
n
-nau Z000-Z9-L
0 -,1 C . .
C)
.oN auvaNvis
RUBBER/TEFLON LINED PIPES
-c, r- x
C)
3" FLGD
WHERE PIPINGCLASS SPECIFIES
3" FLGD
'"SCRD
'A" SCRD
3" FLGD.
'A" SCRD
3" FLGD+
C C
INSTRUMENTS
pamasai spAi IIV—113114 6pAdo0

CONNECTION
Page 832 of 851

ORIFICE PLATES AND FLANGES STANDARD No.
ei
‘31 ENGINEERS
gz:Iii&Pieg INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 4
MR" erWa5", 3q0570 IA Govt of India Undertaking)
DETAILS Page 1 of 14
SEE DETAIL - Y SEE DETAIL - X
m
INLET FACE
WELDED AND
SMOOTH
GROUND 45° ± 2° SMOOTHED
WHEN REQD.
SHARP EDGE MUST NOT

REFLECT LIGHT WHEN
'G' (VEND VIEWED WITHOUT
IF REQD. MAGNIFICATION
GLOSSED
'G' (DRAIN)
IF REQD.
A SECTION Z-Z
INLET
d
DETAIL - X DETAIL - Y
NB
ASME CLASS- - - RF
CONCENTRIC SQUARE EDGED ORIFICE PLATE

l) • 12Fie
4 28.03.17 REVISED & REISSUED tNir Manoj/RS MN RN
AY.'
wir
3 30-05-11 REVISED & REISSUED Manoj RG RP/JMS DM
No. by by
Approved by
Fnrmat Nn R-nn-0001-F4 Rev 0 ennvrinht Fll - All rinhts rpsArvpd
Page 833 of 851

ENGINEERS
INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 4
(NWT 2:17851ZMI,3q0A) (A Govt of India Undertalong)
INLET FACE
WELDED AND
SMOOTH GROUND
45° * 2°
SMOOTHED
WHEN REQD.
ALTERNATE VENT
LOCATION SHARP EDGE MUST NOT
G (VENT)
REFLECT LIGHT WHEN
IF REQD.
VIEWED WITHOUT
MAGNIFICATION
GLOSSED
•
Atv
SECTION Z-Z
(D-d)
E- 0.01 D
ECCENTRIC ORIFICE PLATE

,911
4 28.03.17 REVISED & REISSUED Manoj/RS MN
3 30-05-11 REVISED & REISSUED Manoj RG
d' I'S
RP/JMS
RN
DM
No. by by
Approved by
Format No R - n0 - 0001 - F4 Rev n Crinvrinht Fll - All rinhts reserved
Page 834 of 851

faZit4 ,-,ft ENGINEERS
en fagtegW INDIA LIMITED
(WM ereokedx3eib-e) (A Govt of India Undertaking)
DIMENSIONAL 7-52-0041 Rev. 4
Z•
U)
co INLET FACE
WELDED AND
SMOOTH GROUND
SMOOTHED
G (VENT)
IF REQD. 45° t 2°
WHEN REQD. SHARP EDGE MUST NOT
REFLECT LIGHT WHEN
VIEWED WITHOUT
MAGNIFICATION
GLOSSED
A SECTION Z-Z
F = 0.98D
SEGMENTAL ORIFICE PLATE

4 28.03.17 REVISED & REISSUED Manoj/RS eRN
No. by by
Approved by
Format No R-n0-0001-F4 RPV n Convrinht Fll - All rinhts nacmvad
Page 835 of 851

ISRTA ENGINEERS
Oe..11214ieg INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 4
(PPM peatfreatiafkeet IA Govt of India Undertaking)
(NOTE-2)
SEE DETAIL - Y SEE DETAIL -X
INLET FACE
WELDED AND
SMOOTH GROUND
SMOOTHED
OPTIONAL VENT HOLE
INSIDE RADIUS
1 SEE DEAT1L -A
OF PIPE LESS
1 mm (3/64")
LO
LL
0
-
0
0
0
DI
A SECTION Z-Z
F = 1.5d BUT NOT GREATER THAN INTERNAL PIPE DIA "D"
INLET RADIUS - r
(TOLERANCE
MATL- - - - ± 0.01 r)
d
DETAIL - Y
DETAIL - X
NB
ASME CLASS- - - RF
TAG NO.- - - -
EQUAL TO r
DETAIL - A
QUADRANT EDGE ORIFICE PLATE

NOTES :-
1. DIMENSIONS A,B,C ARE SAME AS FOR SQUARE EDGE ORIFICE PLATES.
2. 'W SHALL NOT BE LESS THAN 2.54 mm AND SHALL NOT EXCEED 0.1 D WHERE THE RADIUS 'r . OF THE
UPSTREAM PROFILE EQUALS OR EXCEEDS 0.1D (WHERE IS THE CASE WHEN 8? 0.571 OR m 0.325),
'W SHALL BE REDUCED FROM 'r' TO 0.1D BY REMOVING METAL FROM THE UPSTREAM FACE.
4 28.03.17 REVISED & REISSUED Manoj/RS MN RN

3 30-05-11 REVISED & REISSUED Manoj RG P/JMS DM
No. by by
Approved by
Format Nn R-00-0001-F4 Rev Convrioht Fll - All rinhts reserved
Page 836 of 851

ENGINEERS
IOW! 2122152 27513,11:1P0 (A Govt of India Undertaking)
z r---1(NOTE-3)
SEE DETAIL - Y SEE DETAIL -X
INLET FACE
WELDED AND
SMOOTH GROUND
SMOOTHED
OPTIONAL VENT HOLE
2 mm
I
INSIDE RADIUS
SEE DEATIL - A
OF PIPE LESS
1 mm (3/64")
2
V
U-
A SECTION Z-Z
INLET
MATL- - - -
d
DETAIL - X DETAIL - Y
NB
TAG NO.- - - -
ASME CLASS- - - RF
0.084d ± 0.003d
0.021d ± 0.003d
0.105d MAX
0.1 D MAX
CONICAL ENTRANCE ORIFICE PLATE
DETAIL - A
NOTES :-
1. DIMENSIONS A,B,C ARE SAME AS FOR SQUARE EDGE ORIFICE PLATES.
2. DIMENSION-d SHALL NOT BE LESS THAN 0.25" AND NOT GREATER THAN 0.316D.
3. DIMENSION- W SHALL BE GENERALLY SAME AS FOR SQUARE EDGE ORIFICE PLATES AND
SHALL NECESSARILY CONFORM TO FOLLOWING;
W SHALL NOT EXCEED 0.1D WHERE D IS THE INTERNAL DIAMETER OF UPSTREAM PIPE

No. by by
Approved by
Fnrmat Nn R-On-00111-F4 Rev 0 r.nnvrinht Fll - All rinhts rPSAIVACI
Page 837 of 851

ENGINEERS
( ALL RATING AS PER ASME CLASS)
RATING 125 TO 2500

A ± 0.40
< 315° C > 315° C
NB RATING T T
+0 +0
125 250
400 600 900 1500 2500 W TOLER. - 0.25 W TOLER. - 0.25
mm (") 150 300
25 (1) 66.7 73.0 73.0 73.0 79.4 79.4 85.7 3.18 0.51 6.35
40 (11/2) 85.7 95.3 95.3 95.3 98.4 98.4 117.5 3.18 +0.12 0.76 6.35
50 (2) 104.8 111.1 111.1 111.1 142.9 142.9 146.1 3.18 0.79 6.35
80 (3) 136.5 149.2 149.2 149.2 168.3 174.6 196.9 3.18 -0.25 0.79 6.35
100 (4) 174.6 181.0 177.8 193.7 206.4 209.6 235.0 3.18 1.59 6.35
150 (6) 222.3 250.8 247.7 266.7 288.9 282.6 317.5 3.18 1.59 6.35 ± 0.25
200 (8) 279.4 308.0 304.8 320.7 358.8 352.4 387.4 6.35 3.18 9.52
250 (10) 339.7 362.0 358.8 400.1 435.0 435.0 476.3 6.35 SEE 3.18 9.52 SEE
300 (12) 409.6 422.3 419.1 457.2 498.5 520.7 549.3 6.35 N OT E 3.18 9.52 NOTE
-2 2
350 (14) 450.8 485.8 482.6 492.1 520.7 577.9 6.35 ± 0.25 3.18 9.52
400 (16) 514.4 539.8 536.6 565.2 574.7 641.4 6.35 6.35 9.52
450 (18) 549.3 596.9 593.7 612.8 638.2 704.9 9.52 9.52 12.7
500 (20) 606.4 654.1 647.7 682.6 698.5 755.7 9.52 9.52 12.7
550 (22) 660.4 704.9 701.7 733.4 9.52 9.52 12.7
600 (24) 717.6 774.7 768.4 790.6 838.2 901.7 9.52 9.52 12.7
-0
B + 10 C±0.4
RATING RATING R
NB
125 250 125 TO 600 TO
mm (") 400 600 900 1500 2500
150 300 400 2500
25 (1)
100
40 (1 1/2) 100 (D-G)
88 88 88 30 R-
50 (2) 100 2
114
80 (3)
100 (4) 114 127
100
150 (6)
88 100 100 158
200 (8) 127
114 40
250 (10) 165
114 140
300 (12) 177
350 (14) 114 114
127 152
400 (16)
450 (18) 100 50
140 177
500 (20) 127 127 127
550 (22) 144
600 (24) 40 140 140 165 203
d G
LEGEND:-
<d TOLER.
FROM I TO TOLER.
D - INTERNAL DIAMETER OF THE PIPE
FROM TO ± 0.05
< 6.350 0.007 NB - NOMINAL BORE.
< 25.400 - -
6.350 9.525 0.013 d - ORIFICE BORE DIAMETER.
25.400 88.900 2.38
9.526 12.700 0.015 DIMENSIONS IN mm UNLESS OTHERWISE
88.901 104.775 3.18
12.701 15.875 0.020 SPECIFIED.
104.776 127.000 3.97
15.876 19.050 0.023 NOTE :-
127.001 152.400 4.76
19.051 22.225 0.025
152.401 171.450 5.56 1. FOR BIDIRECTIONAL FLOW BEVELLING SHALL NOT BE
22.226 25.400 0.030 PROVIDED.
171.451 190.500 6.35
25.401 31.750 0.036
190.501 212.725 7.14 2. VALUES OF T SHOWN IN THIS STANDARD ARE
31.751 38.100 0.043
212.726 234.950 7.94 VALID FOR THE CORRESPONDING 'W AND d/D
38,101 44.450 0.051 (11) BETWEEN 0.25 AND 0.70 INCL WHEN THE
234.951 254.000 8.73
44.451 127.000 0.064 VALUES ARE NOT SHOWN AND FOR II < 0.25
254.001 276.225 9.53
0.0005 AND R > 0.70, T SHALL BE CALCULATED EVERY
> 127.000 276.226 295.275 10.32
xd TIME AND SHALL NOT BE HIGHER THAN THE
295.276 317.500 11.11 SMALLER OF THE VALUES RESULTING FROM
317.501 336.550 11.91 THE FOLLOWING RATIOS :-
> 336.550 - 12.70
d8 D -8 d
ORIFICE PLATE DIMENSIONS /
4 28.03.17 REVISED & REISSUED i\sr Manoj/RS MN

No. by by
Approved by
Format No R-no-nn01-F4 RPV n Corwrioht Fll - All rinhts rpsprvart
Page 838 of 851

ENGINEERS
litarIa5leg INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 4
Riker (A Govt of India Undertaking)
ENGAGEMENT OF THREADS OF PLUG

SHALL BE AS PER ASME B 1.20.1
PLUG MATERIAL SHALL BE
SAME AS FLANGE MATERIAL.
SECTION A-A
1/2" NPT
OR AS SPECIFIED
B
SEAT MACHINED
25.4 MINUS
FOR NUT SUPPORT
DETAIL A
TAPER MAX. 90°
SECTION B-B
DETAIL - A
BEVEL FOR WALL THICKNESS (S) BEVEL FOR WALL THICKNESS (S)
0.19 INCH TO 0.88 INCH INCLUSIVE. GREATER THAN 0.88 INCH.
7° MAX
0
10±1
7* MAX
37.5° ± 2.5° 37.5° ± 2.5 °
CO
1 4 ---I 0.25' MIN.

0.06 "± 0.03 " 0.06"± 0.03 "
WELD NECK, RAISED FACE ORIFICE FLANGE

4 28.03.17 REVISED & REISSUED ManoyRS MN RN
No. by by
Approved by
Format No R-00-0001-F4 ReW 0 ennviinht Fil - All rinhtc n?sprvArl
Page 839 of 851

7J
N .o.
DIMENSIONS (IN mm) - WELD NECK, RAISED FACE ORIFICE FLANGES
9 co
0 O O
CD 5.4 FLANGE NO. OF WEIGHT
74 A X 0 C Y f R G BOLT M h P1 t q U kg.
RATING NB
mm (") HOLES
300 25 (1) 33.5 54.0 124.0 88.9 38.1 82.6 17.5 50.8 1.6 4 6.4 102.2 12.7 9.5 21.8 19.1 82°30' 8
40 (1.5) 48.3 69.9 155.6 114.3 38.1 85.9 20.6 73.2 1.6 4 6.4 133.8 12.7 9.5 21.8 19.1 82°30' 12
- u
c 85.9 17.5 92.1 1.6 8 6.4 141.3 14.3 12.7 23.8 20.6 45° 15
50 (2) 60.5 84.1 165.1 127.0 38.1
CD
80 (3) 88.9 117.5 209.6 168.3 38.1 88.9 20.6 127.0 1.6 8 9.5 185.7 14.3 12.7 23.8 20.6 45° 22
Cl3fISSI32:1CI3SIA321
254.0 200.0 38.1 92.1 20.6 157.2 1.6 8 12.7 230.2 14.3 12.7 23.8 20.6 45° 31
C1311 SS131CI3SIA3H
100 (4) 114.3 146.1
150 (6) 168.4 206.4 317.5 269.9 38.1 100.1 22.4 215.9 1.6 12 12.7 293.7 14.3 12.7 23.8 20.6 60° 45
200 (8) 219.2 260.4 381.0 330.2 41.3 111.2 25.4 269.9 1.6 12 12.7 351.6 15.9 15.9 29.4 25.4 60° 70
lo 250 (10) 273.1 320.7 444.5 387.4 47.8 117.5 28.6 323.9 1.6 16 12.7 411.6 19.1 19.1 32.9 28.6 67°30' 100
o.
g.
1VNOI SN3INICI
300 (12) 323.9 374.7 520.7 450.9 50.8 130.2 31.8 381.0 1.6 16 12.7 482.2 22.2 22.2 38.5 33.3 67°30' 150
0 142.9 31.8 412.8 1.6 20 12.7 545.7 22.2 22.2 38.5 33.3 72° 193
350 (14) 355.6 425.5 584.2 514.4 54.0
G)
SONIV1JCINV3 01JI2J 0
a 400 (16) 406.4 482.6 647.7 571.5 57.2 146.1 35.1 469.9 1.6 20 12.7 603.6 25.4 25.4 44.1 38.1 72° 260
450 (18) 457.2 533.4 711.2 628.7 60.5 158.8 35.1 533.4 1.6 24 12.7 667.1 25.4 25.4 44.1 38.1 75° 340
0 5.
0 7J
O 0
D < 0
500 (20) 508.0 587.4 774.7 685.8 63.5 162.1 35.1 584.2 1.6 24 12.7 730.6 25.4 25.4 44.1 38.1 75° 413
3
2, 3
CD
CD (22) 558.8 641.4 838.2 743.0 66.7 165.1 41.3 641.4 1.6 24 12.7 783.4 31.8 31.8 54.8 47.6 75° 510
550
600 (24) 609.6 701.7 914.4 812.8 69.9 168.3 41.3 692.1 1.6 24 12.7 854.1 34.9 31.8 60.3 52.4 75° 618
-nab I. V00-ZS-L
•oN 012:IVCINVIS
0
z
.1-1alq uu11y 11344 0U

■
(ALL RATING AS PER ASME CLASS)
Page 840 of 851

CD Cc)
z
3
0 NO. OF
a 0
FLANGE WEIGHT
A X OK C Y f R G BOLT M h Pi t q U kg.
NB
RATING mm (") HOLES
600 25 (1) 33.5 54.0 124.0 88.9 38.1 82.6 17.5 50.8 1.6 4 6.4 102.2 12.7 9.5 21.8 19.1 82°30' 8
40 (1.5) 48.3 69.9 155.6 114.3 38.1 85.9 20.6 73.2 1.6 4 6.4 133.8 12.7 9.5 21.8 19.1 82 ° 30' 12
-13 50 (2) 60.5 84.1 165.1 127.0 38.1 85.9 17.5 92.1 1.6 8 6.4 141.3 14.3 12.7 23.8 20.6 45° 15
C
-2
o
co 1.6 8 9.5 185.7 14.3 12.7 23.8 20.6 45° 22
80 (3) 88.9 117.5 209.6 168.3 38.1 88.9 20.6 127.0
100 (4) 114.3 152.4 273.1 215.9 44.5 108.0 25.4 157.2 6.4 8 12.7 234.6 22.2 14.7 38.5 33.3 45° 44
C1311SS1 31G3SIAal
C1311SS132:1 COSIAal
150 (6) 168.4 222.3 355.6 292.1 54.0 123.8 28.6 215.9 6.4 12 12.7 311.5 25.4 21.1 44.1 38.1 60° 89
200 (8) 219.2 273.1 419.1 349.3 61.9 139.7 31.8 269.9 6.4 12 12.7 375.0 25.4 21.1 44.1 38.1 60° 130
250 (10) 273.1 342.9 508.0 431.8 69.9 158.8 35.1 323.9 6.4 16 12.7 463.9 25.4 21.1 44.1 38.1 67°30' 204
o- -o
s<
0.
a 300 (12) 323.9 400.1 558.9 489.0 73.0 161.9 35.1 381.0 6.4 20 12.7 514.7 25.4 21.1 44.1 38.1 72 ° 245
1VNO IS N3VVICI
350 (14) 355.6 431.8 603.3 527.1 76.2 171.5 38.1 412.8 6.4 20 12.7 559.2 25.4 21.1 44.1 38.1 72 ° 312
Cr co
co 400 (16) 406.4 495.3 685.8 603.3 82.6 184.2 41.2 469.9 6.4 20 12.7 636.2 28.6 21.1 49.6 42.9 72 ° 428
o.
S3ONVIJGNVS31V-Id 3 0Id12:1 0
450 (18) 457.2 546.1 743.0 654.1 88.9 190.5 44.5 533.4 6.4 20 12.7 693.3 28.6 21.1 49.6 42.9 72 ° 525
P'
D z 0 500 (20) 508.0 609.6 812.8 723.9 95.3 196.9 44.5 584.2 6.4 24 12.7 763.2 28.6 21.1 49.6 42.9 75 ° 650
3 < 0
CD 3
3 o 3.
D
550 (22) 558.8 666.8 870.0 777.9 101.6 203.2 47.6 641.4 6.4 24 12.7 820.3 28.6 21.1 49.6 42.9 75° 797
-11
600 (24) 609.6 717.6 939.8 838.2 108.0 209.6 50.8 692.1 6.4 24 12.7 890.2 28.6 21.1 49.6 42.9 75 ° 926
3.
ON C2:IVCINV1S
3. (ALL RATING AS PER ASME CLASS)
Page 841 of 851

O
0 O
FLANGE NO. OF WEIGHT
A X OK C Y f R G BOLT M h RI t q U kg.
NB
RATING mm (") HOLES
900 25 (1) 33.5 52.4 149.2 101.6 44.5 89.0 25.4 50.8 6.4 4 6.4 116.3 19.1 14.7 32.9 28.6 82°30' 12
40 (1.5) 48.3 69.9 177.8 124.0 44.5 95.3 28.6 73.2 6.4 4 6.4 144.9 19.1 14.7 32.9 28.6 82°30' 16
50 (2) 60.5 104.8 215.9 165.1 44.5 108.0 25.4 92.1 6.4 8 6.4 183.0 19.1 14.7 32.9 28.6 45 ° 29
0
80 (3) 88.9 127.0 241.3 190.5 44.5 108.0 25.4 127.0 6.4 8 9.5 208.4 19.2 17.9 32.9 28.6 45° 34
GTISSIal C13S1A32:1
C1311SSI3 2lCI3 SIA32:1
100 (4) 114.3 158.8 292.1 235.0 50.8 120.7 31.8 157.2 6.4 8 12.7 253.6 22.2 17.9 38.5 33.3 45° 57
150 (6) 168.4 235.0 381.0 317.5 61.9 146.1 31.8 215.9 6.4 12 12.7 336.9 25.4 24.2 44.1 38.1 60° 118
0
200 (8) 219.2 298.5 469.9 393.7 69.9 168.3 38.1 269.9 6.4 12 12.7 420.3 28.6 24.2 49.6 42.9 60° 190
CD
Cr "0 250 (10) 273.1 368.3 546.1 469.9 76.2 190.5 38.1 323.9 6.4 16 12.7 496.5 28.6 24.2 49.6 42.9 67°30' 277
•.<
a
1VNOISN31/1 10
300 (12) 323.9 419.1 609.6 533.4 85.7 206.4 38.1 381.0 6.4 20 12.7 560.0 28.6 24.2 49.6 42.9 72 ° 345
350 (14) 355.6 450.9 641.4 558.8 92.1 219.1 41.3 412.8 6.4 20 12.7 591.7 28.6 24.2 49.6 42.9 72° 441
m
.< 0 C)
S3ONVid CINV S 31` 1d 30 IAl2:10
400 (16) 406.4 508.0 704.9 616.0 95.3 222.3 44.5 469.9 6.4 20 12.7 655.2 28.6 24.2 49.6 42.9 72° 545
a 450 (18) 457.2 565.2 787.4 685.8 108.0 235.0 50.8 533.4 6.4 20 12.7 732.6 31.8 27.4 54.8 47.6 72 ° 761
N
0 -u
• 0
< 0
CD 3 500 (20) 508.0 622.3 857.3 749.3 114.3 254.0 54.0 584.2 6.4 20 12.7 802.5 31.8 27.4 54.8 47.6 75° 927
3
FIT - 1-
CD
600 (24) 609.6 749.3 1041.4 901.7 146.1 298.5 66.7 692.1 6.4 20 12.7 986.6 31.8 27.4 54.8 47.6 75° 1697
VI. Jo 01. 96ed
0a
nab 13,00-ZS-L
7" CA (ALL RATING AS PER ASME CLASS)

•IoN ClINCINVIS
tu • 0
w z
3 p)
2 C
Page 842 of 851

z DIMENSIONS (IN mm) - WELD NECK, RAISED FACE ORIFICE FLANGES
O
6
Y' FLANGE NO. OF WEIGHT
A X OK C Y f R G BOLT M h Pi t q U kg.
NB
RATING mm C) HOLES
1500 25 (1) 33.5 52.4 149.2 101.6 44.5 89.0 25.4 50.8 6.4 4 6.4 116.3 19.1 14.7 32.9 28.6 82°30' 12
40 (1.5) 48.3 69.9 177.8 124.0 44.5 95.3 28.6 73.2 6.4 4 6.4 144.9 19.1 14.7 32.9 28.6 82°30' 16
-o
a 50 (2) 60.5 104.8 215.9 165.1 44.5 108.0 25.4 92.1 6.4 8 6.4 183.0 19.1 14.7 32.9 28.6 45° 29
0
cn
co
80 (3) 88.9 133.4 266.7 203.2 54.0 123.8 31.8 127.0 6.4 8 9.5 228.2 22.2 17.9 38.5 33.3 45° 55
114.3 161.9 311.2 241.3 60.3 - 130.2 34.9 157.2 6.4 8 12.7 272.7 22.2 17.9 38.5 33.3 45° 82
13311SS I3 2:1C1 3SIA32:1

100 (4)
4311SSI321 CAS IAal

150 (6) 168.4 228.6 393.7 317.5 88.9 177.8 38.1 215.9 6.4 12 12.7 349.6 25.4 24.2 44.1 38.1 60° 184
200 (8) 219.2 292.1 482.6 393.7 98.4 219.1 44.5 269.9 6.4 12 12.7 433.0 28.6 24.2 49.6 42.9 60° 286 0
o -
0- -0CD 250 (10) 273.1 368.3 584.2 482.6 114.3 260.4 50.8 323.9 6.4 12 12.7 534.6 28.6 24.2 49.6 42.9 60° 498
0,
0.
a;
0.
288.9 54.0 381.0 6.4 16 12.7 623.5 28.6 24.2 49.6 42.9 67°30' 760
1VNOISN3INICI
300 (12) 323.9 450.9 673.1 571.5 130.2
C)
CD 350 (14) 355.6 495.3 749.3 635.0 139.7 304.8 60.3 412.8 6.4 16 12.7 694.5 31.8 27.4 54.8 47.6 67°30' 1053
CD
0
CD 0
CD
CL.
S3O NV1J GNVS31V-Id30IJ NO
400 (16) 406.4 552.5 825.5 704.9 152.4 317.5 66.7 469.9 6.4 16 12.7 765.2 34.9 27.4 60.3 52.4 67°30' 1406
450 (18) 457.2 596.9 914.4 774.7 168.3 333.4 73.0 533.4 6.4 16 12.7 854.1 34.9 27.4 60.3 52.4 67°30' 1836
0y
1)
< 00
3 500 (20) 508.0 641.4 984.3 831.9 184.2 362.0 79.4 584.2 6.4 16 12.7 923.9 34.9 27.4 60.3 52.4 67°30' 2324
3
g 3
T1 0 n)
co • 600 (24) 609.6 762.0 1168.4 990.6 209.6 412.8 92.1 692.1 6.4 16 12.7 1108.1 34.9 27.4 60.3 52.4 67°30' 3749
L t700-ZS-L
0.
CT
qI. JOJ96ed
7. (ALL RATING AS PER ASME CLASS)

.Aar
a
oN CIH NICINVIS
-
Page 843 of 851

0 el 1 771 ENGINEERS
$1g1Z11251eg INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 4
(NWT PROW 05130 IA Gov't of India Undertaking)
TOLERANCES ALLOWED ON FLANGES ACCORDING TO ASME B16.36 / B16.5
DIMENSIONS mm (Inches) TOLERANCES (Inches)
609.6 mm * 1.59 *
O ' 609.6 mm ± 3.18
NB < 450 + 3.18

(18) - 0
C
NB > 450 + 4.76
(18) - 0
5 609.6 mm ± 1.59 *
X
> 609.6 mm ± 3.18 *
<
_ 100 + 2.38
NB
(4) - 0.79
A
NB ....
< 150 + 3.96
(6) - 0.79
NB _
< 250 ± 1.59
(10)
Y
NB < 300 ± 3.18
(12)
K ± 1.59
DRILLING
CENTRES BETWEEN HOLES ± 0.79
FOR GV/GD < 6.35 mm ± 0.79

R
FOR GV/GD 3 6.35 mm ± 0.40
ECCENTRICITY BETWEEN K AND R DIAMETERS ± 0.79
ECCENTRICITY BETWEEN K AND D DIAMETERS ± 0.79
ECCENTRICITY BETWEEN R AND D DIAMETERS ± 0.79
150 ± 0.12 *
NB <
(6)
+ 0.12
200 8250
NB
(8 &10) - 0.25
+ 0.12
300 ,
D NB
(12) - 0.38
350 8100 + 0.12

NB
(14 816) - 0.50
450 + 0.12
NB
(18) - 0.76
* NOT COVERED BY ASME B16.5
WELD NECK RAISED FACE ORIFICE FLANGES

No. by by
Approved by
Format No R-00-0001-F4 RPV Corwrinht Fll - All rinhts nac.prvrgi
Page 844 of 851

Crt- , ENGINEERS
ligar fetOleg
ezREIREan3)
INDIA LIMITED
IA Govt. of India Undertaking)
DIMENSIONAL 7-52-0041 Rev. 4
DIMENSIONS AS SHOWN THREAD : ASME B 1.1

FORD" <1 - UNC - 2A
FORD" >1 1/8 - 8 UN - 2A
CONSTRUCTION FORGED, BAR STOCK
V (1.5 x THD. PITCH)
D mm (Inches) THREAD PITCH V 2V *

15.9 (5/8) 2.309 3.46 7
19.0 (3/4) 2.54 3.78 7.5
UNC
22.2 (7/8) 2.822 4.23 8.5
25.4 (1) 3.175 4.76 9.5
> 28.6 (1 1/8) 8 UN 3.175 4.76 9.5
APPROXIMATE VALUE OF THE TWO BEVELS

DIAMETER (NB,D) mm (INCHES) & LENGTH - (L) IN mm ( NOTE-1 )
RATING 300 600 900 1500

DIM. NB D L D L D L D L
25 (1) 15.9 (5/8) 127 15.9 (5/8) 127 22.2 (7/8) 152 22.2 (7/8) 152
40 (11/2) 19.0 (3/4) 133 19.0 (3/4) 133 25.4 (1) 159 25.4 (1) 159
50 (2) 15.9 (5/8) 127 15.9 (5/8) 127 22.2 (7/8) 152 22.2 (7/8) 152
80 (3) 19.0 (3/4) 133 19.0 (3/4) 133 22.2 (7/8) 152 28.6 (1 1/8) 184
100 (4) 19.0 (3/4) 133 22.2 (7/8) 152 28.6 (11/8) 178 31.7 (11/4) 203
150 (6) 19.0 (3/4) 133 25.4 (1) 178 28.6 (11/8) 203 34.9 (1 3/8) 266
200 (8) 22.2 (7/8) 146 28.6 (1 1/8) 203 34.9 (1 3/8) 229 41.3 (1 5/8) 298
250 (10) 25.4 (1) 165 31.7 (11/4) 222 34.9 (1 3/8) 241 47.6 (1 7/8) 343
300 (12) 28.6 (11/8) 178 31.7 (11/4) 229 34.9 (1 3/8) 260 50.8 (2) 381
350 (14) 28.6 (1 1/8) 191 34.9 (1 3/8) 248 38.1 (1 1/2) 282 57.1 (2 1/4) 418
400 (16) 31.7 (1 1/4) 203 38.1 (1 1/2) 266 41.3 (1 5/8) 295 63.5 (2 1/2) 456
450 (18) 31.7 (1 1/4) 209 41.3 (1 5/8) 286 47.6 (1 7/8) 333 69.8 (2 3/4) 503
500 (20) 31.7 (11/4) 216 41.3 (1 5/8) 298 50.8 (2) 355 76.2 (3) 548
600 (24) 38.1 (11/2) 241 47.6 (1 7/8) 337 63.5 (2 1/2) 445 88.9 (3 1/2) 623
TOLERANCES ON 'L'
L-LENGTH mm < 305 310 TO 455 > 455

-0 -0 -0
TOLERANCE mm
+ 1.6 + 3.2 + 6.4
STUD BOLT DETAILS FOR RAISED FACE FLANGES

NOTES :-
1. FOR BOLT DIAMETER 1" (25mm) & ABOVE IN EACH RATING, FOLLOWING SHALL BE CONSIDERED TO TAKE CARE OF BOLT TENSIONING.
(i) ONE EXTRA NUT SHALL BE CONSIDERED FOR EACH BOLT/STUD.
(ii) BOLT/STUD LENGTH SHALL BE INCREASED BY ONE DIAMETER.
4 28.03.17 REVISED & REISSUED Manoj/RS MN

3 30-05-11 REVISED & REISSUED Manoj RG RP/JMS
No. by by
Approved by
Format Nn R-(10-0001-F4 RAV Convrinht Fll - All rinhts rastarvad
Page 845 of 851

15itftel If= ENGINEERS
51gar 0151-eg INDIA LIMITED DIMENSIONAL 7-52-0041 Rev. 4
NIM FRZIN? CM.71;1.1) (A Govt of India Undertaking)
DIMENSIONS :ASME B 18.2.1 THREAD :ASME B 1.1

CONSTRUCTION FORGED, BAR STOCK FORD" <1 - UNC - 2A
TOLERANCES : ASME B 18.2.1 ASME B 1.1 FORD" > 1 1/8 - 8 UN - 2A
25 °
G mm
D mm (Inches) F H R
MAX. MIN. mm mm
9.5 (3/8) 14.3 20.2 19.0 6.4 0.8
11.1 (7/16) 15.9 22.5 21.0 7.5 0.8
12.7 (1/2) 19.1 26.9 25.3 8.3 0.8
15.9 (5/8) 23.8 33.7 31.6 10.7 1.6
19.1 (3/4) 28.6 40.4 37.9 12.7 1.6
22.2 (7/8) 33.3 47.1 44.2 15.1 1.6
25.4 (1) 38.1 53.9 50.6 16.7 2.4
28.6 (11/8) 42.9 60.6 56.9 19.1 2.4
31.8 (11/4) 47.6 67.4 63.2 21.4 2.4
38.1 (1 1/2) 57.2 80.8 75.8 25.4 2.4

DIAMETER (NB,D): mm (INCHES) AND LENGTH - (L) IN mm
RATING 300 600 900 1500

DIM. NB D L D L D L D L
25 (1) 9.5 (3/8) 75 9.5 (3/8) 75 15.9 (5/8) 90 15.9 (5/8) 90
40 (1 1/2) 9.5 (3/8) 75 9.5 (3/8) 75 15.9 (5/8) 90 15.9 (5/8) 90
50 (2) 11.1 (7/16) 85 11.1 (7/16) 85 15.9 (5/8) 100 15.9 (5/8) 100
80 (3) 11.1 (7/16) 85 11.1 (7/16) 85 15.9 (5/8) 100 19.1 (3/4) 115
100 (4) 11.1 (7/16) 85 19.1 (3/4) 100 19.1 (3/4) 110 19.1 (3/4) 120
150 (6) 11.1 (7/16) 90 22.2 (7/8) 115 22.2 (7/8) 130 22.2 (7/8) 160
200 (8) 12.7 (1/2) 100 22.2 (7/8) 130 25.4 (1) 140 25.4 (1) 170
250 (10) 15.9 (5/8) 110 22.2 (7/8) 135 25.4 (1) 145 25.4 (1) 190
300 (12) 19.1 (3/4) 115 22.2 (7/8) 140 25.4 (1) 155 25.4 (1) 215
350 (14) 19.1 (3/4) 120 22.2 (7/8) 140 25.4 (1) 165 28.6 (11/8) 235
400 (16) 22.2 (7/8) 130 25.4 (1) 155 25.4 (1) 170 31.8 (11/4) 255
450 (18) 22.2 (7/8) 130 25.4 (1) 160 28.6 (1 1/8) 200 31.8 (1 1/4) 275
500 (20) 22.2 (7/8) 140 25.4 (1) 165 28.6 (1 1/8) 205 31.8 (1 1/4) 295
550 (22) 28.6 (11/8) 155 25.4 (1) 180 - -
600 (24) 31.8 (11/4) 160 25.4 (1) 185 28.6 (11/8) 240 31.8 (11/4) 315
SEMI-FINISHED, SQUARE HEAD, FULL THREAD, JACK SCREW
4 28.03.17 REVISED & REISSUED 145 RN

3 30-05-11 REVISED & REISSUED Manoj RG P/JMS DM
No. by by
Approved by
Format No F1-00-11001-F4 Rev 0 Cnovrinht Fll - All rinhts reserved
Page 846 of 851

Page 847 of 851
Page 848 of 851
Page 849 of 851
Page 850 of 851
NOTES:-
1. ALL DIMENSIONS ARE IN MM AND LEVEL IN M UNLESS STATED OTHERWISE.
2. LOCATIONS WHERE THE ROAD TOP LEVEL AND GRADE LEVEL DIFFERENCE
IS MORE THAN 500mm, STEPS SHALL BE PROVIDED ON ROAD SIDE SLOPE,
FOR ACCESS TO THE HYDRANT.
CAP 3" FLANGE AS PER 3. IN CASE ROAD TOP LEVEL TO GRADE LEVEL DIFFERENCE IS LESS THAN
1000MM, PIPE LAYOUT SHALL BE FOLLOWED AS SHOWN.
ANSI 816.5 150 # RATING
S.O. FF (ASTM A-105) 4. WHERE ROAD TOP TO GRADE LEVEL DIFFERENCE IS MORE THAN 1000MM,
PIPE LAYOUT SHALL BE FOLLOWED AS SHOWN.
5. CLASS OF BRICK SHALL BE AS PER APPROVED PROJECT DESIGN BASIS.
6. SECTION A—A i.e. ONLINE HYDRANT SHALL BE PROVIDED ONLY IN CASE OF
HYDRANT VALVE UNAVOIDABLE SITUATIONS AS PER AREA DRAWING. 1600
(AS PER DATA SHEET)
ENDOR
4 4 04" POST (AS PER PMS)
CAP AND CHAIN URNISHED
[
4" FLANGE AS VENDOR
PER PMS CORROSSION PROTECTION FURNISHED
COATING (AS PER JOB SPEC [
04" ISOLATION VALVE
(AS PER VMS) 100 THICK M20 P.C.C. 1200x2000 MM
X
HYDRANT VALVE NEAT FINISH WITH SLOPE PLATFORM
ROAD BERM
(AS PER DATA SHEET) SECTION X-X CORROSSION PROTECTION CURB WALL
150 HIGH 1000 (ROAD BERM)
COATING (AS PER JOB SPEC
13THK PLASTER IN ROAD TOP LEVEL
VENDOR— 04" POST 1:3 CEM. MORTAR AS PER AREA DRG.
FURNISHED (AS PER PMS)
FIRE WATER HEADER SEE NOTE-4 —\
FIRE WATER HEADER OPTIONAL LOCATION
0 X
ON SLEEPERS OF HYDRANT
0
ROAD BERM WBM
600 1200x2000 MM LAYER
PLATFORM 104" BRANCH
PIPE
PCC M20 100 THK. BRICK WORK/STONE MASONARY
1:100 SLOPE F.G.L. 45*/90* ELBOW AS PER SITE IN CEM. MORTAR 1:4
F.G.L. 0 B.W./STONE MASONARY
0 ta_ to IN 1:6 CEM MORTAR DETAIL SIMILAR TO
0 SEC.—AA FOR
0 OPTIONAL LOCATION '
600 CLEAR (MIN.)
w
13 THK CEM MORTAR
1< 75
PLASTER ALL AROUND 04" BRANCH
SEE NOTE-3 I PIPE
1
PCC M20 75 THK
75
J.- A,
—7-- o'
z
NiNFIRE WATER HEADER FIRE WATER HEADER
U/G
U/G
SECTION-BB
SECTION-AA
SINGLE HEADED HYDRANT
HYDRANT ASSEMBLY POST L 1000 I 1000
CURB WALL 125 WIDE 2:

1000 A 150 HIGH
FIRE WATER TERMINAL
BRANCH E
tram
At A
1111116M.N11111 c.0
S E 4-1
S
DOUBLE HEADED Imuir
HYDRANT ASSEMBLY I 125 WIDE X 75 HIGH
CURB WALL
125 WIDEx75 HIGH
CURB WALL 5 THK 1:5:10 PCC
FIRE WATER HEADER
EA121 1_21±10.1
HYDRANT ON FIRE WATER TERMINAL BRANCH 1 100 THK PCC M20
(REPRESENTATION ON AREA DRG.) TYPICAL G.A. OF FIRE WATER HYDRANT ASSEMBLY
DETAIL-A I-I SECTION-EE
(REPRESENTATION ON AREA DRG.)
114 ,/ off
4 30.07.18 REVISED AND ISSUED AS STANDARD Anil GYAS R. SRIVASTAVA RK TRIEDI STANDARD No.
4cm el ENGINEERS 3 02.07.12 REVISED AND ISSUED AS STANDARD Anil RC RBB DM INSTALLATION DETAILS
OcgarfaWs esemie JLI +I)
INDIA LIMITED
Rev.
Date Purpose
Prepared Checked
by by
Stds. Committee
Convenor
Stds. Bureau
Chairman
OF FIRE WATER HYDRANT
7-65-0420 Rev.4
No. Page 1 of 1
Approved by
Format No. 8-00-0001-F5 Rev. 0 Copyright EL - All rights reservec
Page 851 of 851

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Dobhi-Durgapur-Haldia Pipeline Section alongwith spurlines under

Fire Protection and Fire AlarmSystem for DDPL (Part-C)

(DOBHI DURGAPUR HALDIA PIPELINE PROJECT) 1 B FCI SINDRI

6 D HFC DURGAPUR 24 6.626

DURGAPUR HALIDA SECTION

DOBHI DURGAPUR SECTION

DAMODAR BANK CANAL

RIGHT BANK CANAL

LEFT BANK CANAL

RIVER RAILWAY CH. 4.391

S.NO. LINE NAME CROSSING SIZE WT LENGTH CHAINAGE

1 MAINLINE JAMUNIYA RIVER 30 14.8 500 475.529 A JHARKHAND CP

PROJECT : DRAWING NO. REV.

SCOPE OF WORK & SUPPLY

FIRE PROTECTION SYSTEM

DOBHI- DURGAPUR PIPELINE SECTION

TENDER No. B035-001-81-41-FP-T-8106

PROJECT : DOBHI - DURGAPUR - HALDIA -

CONSULTANT : ENGINEERS INDIA LIMITED

JOB NO. : B035

A 24.09.18 ISSUED FOR TENDER AKS RS VG

1.0 SCOPE OF WORK

Detailed Work shall be carried out at following locations :

CONTRACTOR shall visit the site for familiarization of actual condition to

1.1 DETAILED SCOPE OF WORK

1.1.7 Design, Engineering, Supply, Erection, Fabrication, Testing and Commissioning

1.1.9 Supply and Installation of Restricted orifice plate Including manufacturing,

1.2 BASIS OF WORKS

a. Approved for construction' drawings, hook-ups and sketches issued by

b. Drawings, sketches and documents prepared by CONTRACTOR duly

c. EIL specifications/Documents as below:

v. Welding Specification Chart for Piping Classes

2.0 SCOPE OF SUPPLY

2.1 OWNER’S SCOPE OF SUPPLY

2.2 CONTRACTOR’S SCOPE OF SUPPLY

Procurement and supply of all materials (consumables / non-consumables) including

3.0 LIST OF ATTACHMENTS

Sl. Specification Rev. No. of

1 6-66-0004 Standard Specification for Portable Fire

4 6-44-0013 Standard specification for inspection, flushing

5 6-44-0016 Standard Specification for non- destructive

6 6-44-0051 6 10 Technical notes for pipes.

7 6-44-0052 7 12+8 Technical notes for valves.

8 6-44-0053 Technical notes for flanges, spectacle blinds

9 6-44-0054 Technical notes for but welded , socket

10 6-44-0056 4 5 Technical notes for gaskets.

11 6-44-0057 4 5 Technical notes for bolts and nuts.

12 6-44-0067 1 9 Technical notes for strainers.

13 6-65-0006 Standard specification for earthwork for

14 6-65-0030 Standard specification for fabrication and

18 6-66-0047 3 5 Standard specification for house cabinet

19 6-66-0074 3 9 Standard specification for fire hydrant system

20 6-68-0009 Standard specification - civil & structural

21 6-77-0001 4 40 Welding specification for fabrication of piping

22 6-77-0005 Welding specification charts for piping

23 6-78-0001 Specification for quality management system

24 6-78-0002 Specification for documentation requirement

25 6-78-0003 Specification for documentation requirement

Inspection and test plan ( ITP) for civil ,