TENDER DOCUMENT
NIT No.: DLI/C&E/WI-665/284
FOR
Tender for ‘Design, Engineering, Supply , installation,
testing & commissioning of ‘DUST SUPPRESSION
PACKAGE AND ASSOCIATED WORKS’ for the
project of “Augmentation of Raw Material Handling
Receipt and Handling facilities with new OHP Part– B
(Package- 061) of Bhilai Steel Plant, (SAIL)”.
VOLUME – 4
General Technical Specification
of
Bhilai Steel Plant, SAIL
ENGINEERING PROJECTS (INDIA) LIMITED
(A GOVT. OF INDIA ENTERPRISE)
Core-3, Scope Complex, 7, Institutional Area,
Lodhi Road, New Delhi-110003
TEL NO: 011-24361666 FAX NO. 011- 24363426
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT
GENERAL SPECIFICATION
FOR
PREFFERED MAKES
(GS – 13)
MECON LIMITED
RANCHI – 834002
No. MEC/S/1901/11/38/0/00/00/F1889/R2
JULY, 2007
General Technical Specification
CONTENTS
SL.
NO.
01
PREAMBLE
02
FLUID SYSTEM
2
03
VENTILATION, AIR CONDITIONING AND AIR
9
DESCRIPTION
PAGE
NO.
1
POLLUTION CONTROL EQUIPMENT
04
HANDLING & HOISTING EQUIPMENT
11
05
REPAIR & MAINTENANCE FACILITIES
16
06
ELECTRICAL
17
07
INSTRUMENTATION
25
08
FIRE PROTECTION SYSTEM
30
09
BOF GCP EQUIPMENT
30
10
INFORMATION SYSTEM
32
11
FLUID SYSTEMS & PIPING ENGG
34
(LUBRICATION & HYDRAULICS)
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 1 of 1
GS-13
General Technical Specification
01.
PREAMBLE
This document “PREFERRED MAKES OF EQUIPMENT AND SUPPLIES” is a part of
the tender specification for various packages of BHILAI STEEL PLANT.
The makes of various equipment and supplies in respect of imported/indigenous
equipment/components/materials are listed out in this document. It is essential that the
equipment/component/materials to be supplied from imported/indigenous sources by the
Tenderer will be of any one of the makes listed against that particular equipment/
component/material in this documents..
In case the Tenderer/ Contractor intends to substitute any particular make of equipment /
components/ materials by a make other than that listed in this document, the Tenderer
shall clearly bring out the same in his tender along with justification and indicate the
alternative makes offered by him. It will be prerogative of the Purchaser to accept or
reject the alternative makes so offered.
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 1 of 37
GS-13
General Technical Specification
01
FLUID SYSTEM
01.01
Water Supply Facilities
Sl.
No.
Item Description
1
Horizontal
Centrifugal Pumps
:
Kirloskar Brothers, KSB, Beacon Weir, Khimline, Jyoti,
Sintech, Ghaziabad.
2
Vertical Turbine
Pumps
:
Kirloskar Brothers, Voltas, WPIL, Jyoti,
3
Vertical Wet Pit
Type Pumps
:
SU Motors, Kishore Pumps, Kirloskar Brothers, KSB.
4
Submersible Pumps
:
KSB, SU Motors, Kirloskar Brothers, Kishore Pumps,
Darling, Beacon Weir.
5
Slurry Pump
:
Akay, Sam Engg., MBE, KBL, KSB Pumps, WARMAN.
6
Dosing Pump
:
Shapo Tools, Asia LMI (Madras), Positive Metering Pumps,
Toshniwal, Milton Roy India.
7
Cooling Towers
:
PCTPL, Shri Ram Tower Tech, Gammon, Himgiri, Southern
Cooling Tower, BDT, GEA
8
Pressure Filters
:
Thermax, Ion-Exchange, Resin India, Driplex, Doshion, VA
Tech Wabag, UEM, Aquatech
9
Sluice Gates
:
Jash Engineering, IVPL
10
Travelling Water
Screen
:
Macmet, Triveni, Otokiln, Mecgale (Nagpur), General
Mechanical
11
Sludge Scrapper
:
Triveni, Neo – Parisrutan, Mata India, Geomiller
12
Fire Hydrants
:
New Age Industries, Steelage Industires, ASCO, Strumech,
Vijay Fire, Zenith
13
Basket Strainers
:
Filteration Engrs, J.N Marshall, Masturlal Fabrication , ARF
Engg, Purolator Filters, ABB, Filters Mfd India
14
Duplex Strainers
:
Filteration Engrs., Otokiln, Superflo
15
Rubber Dismantling
Joints
:
BDX, CORI Engineers, D.Wren,
16
Diesel Engine
17
Softening & DM
Plant
18
R O Plants
19
Effluent Treatment
Plant
:
20
Drinking water
Treatment Plant
:
UEM India, VA Tech, GEA Energy Systems, Driplex Water
Engg , Triveni,
21
Basalt Liners
:
DEMECH, Vidyut Green Bank, Enviro Abrasian, Garden
© 2007 MECON Limited
All rights reserved
Manufacturers
:
:
:
Cummins/Ashok Layland/Ruston
Doshi / Resin India / Thermax / Thermax Cullinyan / VA
Tech / Ion Exchange /Triveni / GEA Energy Systems/
Driplex Water Engg, Triveni,
UEM India, VA Tech, GEA Energy Systems, Ion Exchange,
Driplex Water Engg, Triveni,
UEM India, VA Tech, GEA Energy Systems, Triveni,
Preferred Makes
Page 2 of 37
GS-13
General Technical Specification
Sl.
No.
Item Description
22
Oil Skimmer
:
JVM Engg.
23
Plate Heat
Exchangers
:
Alfalaval, GEA Ecoflex, IDMC
24
Surge Tanks
:
Anup Engg., Zenith Erectors, Haldia., Perfect Engg., Sakthi
Hitech
25
C.I. Valves (gate,
globe, NRV)
:
Kirloskar Brothers, Steam & Mining, IVPL, AV Valves, Shiv
Durga, BDK, Fouress.
26
CS Valves (gate,
NRV)
:
Audco, Fouress, BHEL, Sakhi, KSB, Steam & Mining, BDK,
Kirloskar, Virgo
27
Plug Valves
:
Audco- L&T, Vass Ind., Xomox, Virgo, BDK, Steam &
Mining.
28
Ball Valves
:
Audco, KSB, AL Saunders, Xomox, Virgo, BDK, Virgo ,
29
GM Valves
:
Leader, Steam & Mining, NECO, Upadhyay Valves, Kalpana
Valves
30
Butterfly Valves
(Manually &
electrically
operated)
31
Diaphragm Valves
32
Float Valve
33
Control Valve
34
Solenoid Valve
35
Air Release Valve
36
Pressure Reducing
Valve
37
Strainer/Filter
38
Electric Actuators
39
Rotory Pneumatic
Actuators
40
Hoses
41
Pipes a) MS/GI
Manufacturers
Reach Ship Builders & Engg.
b) DI
:
:
:
:
:
:
:
:
:
:
:
:
:
L&T, Fouress, Kirloskar Brothers, IVPL, VIRGO, AL
Saunders, Steam & Mining, Keystone, BDK, XOMOX.
AL Saunders, Fluid System, BDK , Steam & Mining.
Leader, IVPL, IM Engineers, Steam & Mining.
BHEL, L&T, Fouress, IL, MIL Controls, NECO Scharbet,
Darling
Rotex, Sicmag, Scharder, NECO INDFOS, Eastern
Pneumatic, Bluestar, AVCON, ASCO, Mercury
Shiva Durga, IVPL, IM Engineers, Steam & Mining,
Schroder Duncum, Fluid Line Valves.
JNM, Fouress, Bestobell, IL, Mazda, Nirmal Ind., Forbes
Marshal
Otokiln, Superflo, Triveni Plenty, Filter Mfg. Ind., Purolator,
Filteration Engineers
Beacon Rotork, Auma, Marsh Engineers, Keystone,
Limitorque, Antrieb, IL, Palghat
AL Saunders, Xomox, EL-O-Matic, Virgo, L&T, Flocon,
Precision Processing Equipt. Co.
Aeroflox/Markwel/Senior Flexonics, Inalsa, Teksons
SAIL/TATA/Jindal/Zenith/Man/SAW/Surindra/Welspun/Prak
esh
Electro Steel Casting
42
RCC Pipes &
Fittings
:
SUR Industrial Pipes, Hind Ceramics, Indian Hume Pipes,
Daya Cuncrching.
43
HDPE Pipes &
:
EMCO, KWH Heliplastic Polyolefins, Oriplast
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 3 of 37
GS-13
General Technical Specification
Sl.
No.
01.02
Item Description
Manufacturers
Fittings
44
PVC Pipes &
Fittings
:
Oriplast, Finolex, Bharat Pipe & Fittings, Supreme
Industries.
45
SS Pipes / SS
Fittings
:
Heavy Metal Tubes, Nobel Tubes, Rajendra Mech. Ind.,
Vitrag, SAIL, Poonam Enterprises, N.L.Hazra, M.S.Fittings
46
Seamless, Stainless
Steel Pipes/Tubes
:
Choksy Tubes, MJ Patel, Nagardas Kanji, Poonam
Enterprises, Sandulk Asia, Noble Tubes, Allied Steel, SAIL,
Maharastra Seamless (P) Ltd,
47
Fittings for the
above Pipes/Tubes
:
EBY Ind., High-Tech, Hydro technic, Hydro-Air Engg.,
Project Toolings, Shivananda, M.J.Patel, Nobles Tubes,
Allied Steel, Poonam Enterprises, N.L.Hazra, M.S.Fittings
48
Wrapping & Coating
for pipes
:
Rustech Products, HOTACO, IWL, M P Tar Products
49
Chemical Dosing
System
Hindustan
Dorr
Oliver,
Chembonddrewtreat ltd., NALCO
Tellabs
Chemicals,
Valves For Fuel Gas, Steam, Nitrogen, LPG & Compressed Air Facilities
Item Description
Manufacturers
C.I. Valves for Fuel Gas &
Compressed Air (gate,
globe, NRV)
:
Kirloskar Brothers, GM Dalui, Steam &
Mining, H.Sarker, IVPL, AV Valves, Leader,
Associated tooling, BDK, Kalpana Valves
CS, FS, SS Valves for
Steam, Feed Water, &
LPG (Gate, Globe, NRV)
:
L&T (Audco Div), Fouress, BHEL, KSB, GM
Dalui, Leader, BDK, NECO, Associated
Tooling, Hawa Egr., Vass Ind, Advance
Valves, Kalpana Valves
CI, CS, SS & FS Plug
Valves
:
Vass Ind., Xomox, Virgo, BDK, Leader,
Steam and Mining, GM Dalui, H.Sarkar,
Audco
Ball Valves
:
Audco, Vass Ind, KSB, BDK, Microfinish,
Niton,AL Saunders, Xomox, Virgo, United
Engineers, Steam & Mining, Hi-Tech
B.Valves
GM Valves
:
Bombay Metals, GM Dalui, Leader, NECO,
Kalpana Valves
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 4 of 37
GS-13
General Technical Specification
02.03
Butterfly Valves
:
Audco, Fouress, Kirloskar Brothers, IVPL,
Inter Valve, Virgo, AL Saunders, Keystone,
BDK, Leader, AVC Engg., Crowley & Ray,
Xomox, Tyco, Hi-Tech.
Diaphragm Valves
:
AL Saunders, Fluid System, Leader, BDK,
Xomox, Steam & Mining
Pressure Control
Valve/Pressure Reducing
Valve
:
JNM, Fouress, Bestobell, IL, Mazda, Nirmal
Ind., Vanaz, Kosan Metal, Vass Ind., RK
Control, Fluid Line, Forbes Marshal, Leader.
Large Diameter Goggle
Valve
:
Audco, Fouress, Cimmco, L&T
Fabricated Gate Valves
:
Fouress, Cimmco,
Kalpana Valves
Safety Relief Valve
(Pressure relief Valves)
:
BHEL, Keystone, Bliss Anand, L&T (Audco
Div.), Sempell, Fainger, Leser Valves (P)
Ltd., IL, Anderson, Kosan.
BECO, Beekay, L&T,
Miscellaneous Gas Facility & Compressed Air Equipment
Item Description
Manufacturers
Oxygen Acetylene & LPG
Manifolds
:
Kamrup Industrial Gases, INOX, Titan
Engg., BOC, Ramba Hydrogen, Asiatic
Oxygen
SS Bellows Expansion
Joints
:
Flexican, Flexatherm, SURR Ind., Pressel
(Cuttack), BD Engr., Eludyne Engr., SPB,
SEPL, PEBI, Lonestar, GBM Mfg., TI
Flexible Tube.
Centrifugal Gas Booster
:
Andrew Yule, TLT, James Howden (U.K),
Donkin (U.K), Hibhen
Twin Lobe Type Booster
:
Skoda, CKD Kompressors, MD Pneumatics,
Demag Delavl, Bryan Donkin Sulzer, Oil &
Gas Plant Engg., (Tuthill), Kay International
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 5 of 37
GS-13
General Technical Specification
Gas/Air Compressors
:
Ingersoll Rand, Atlas Copco, KG Khosla,
Kirloskar Pneumatic, Chicago Pneumatic,
Mannesman Demag, Eliat, Cooper, Sulzor,
Corken (USA)
Hoses
:
Flexican, Gaytri Industrial Corpn., Inalsa,
Teksons, Sudeep Industries, Markwell
Valves for Oxygen Services:
Item Description
1.
Manufacturers
Non-Ferrous:
For Isolation
:
Bestobell (UK), ETH IRELAND (France),
RT Orseal (UK), Truflo (Belgium),
Worcestor Controls (UK),
Quick Sheet-off Valve
:
Bestobell (UK), ETH IRELAND (France),
RT Orseal (UK), Truflo (Belgium),
Worcestor Controls (UK), Moorco, SEBIM
:
SEVERN (UK), NELES SECK GLOKON
(UK), IL (Palghat)
Solenoid Valve
:
AVCON, SEITZ, ROTEX, ASCO
Safety Relief Valve (SRV)
:
KUNKLE (USA), KEYSTONE (USA),
BROADY (UK), MOORCO, SEBIM, IL
(Palghat)
Pressure Regulators (Self
regulating with pressure
gauge)for Oxygen
:
ESAB, BOC, Speciality Gases, Kamrup
Industrial Gases, Venaz Engineers, Nirmal
Ind.
Stainless Steel (SS)
:
Precision Engg., BDK, Niton, Akay, Leader,
Audco, Sakhi & Co., KSB
Pressure Control Valve (PCV) &
Flow Control Valve (FCV)
2.
(manual)
POWER & ENERGY
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 6 of 37
GS-13
General Technical Specification
Item Description
Manufacturers
Air Drying Uuit
:
Chemech, Cleanair, Delair, Indcon, Mellcon,
Mirch Mirex, Gasoenergy System Pune.
Condensate Pumps
:
KSB, BHEL, Kirloskar Brothers, Mather &
Platt, Khimline, Sigma
Ejector
:
BHEL, Weigand, Newfield, Mazda
Trap & Strainer for
Compressed Air & Steam
:
Uniklinger, ESCO, JNM, Dryton Greaves,
Forbes Marshall, Hawa Engrs., Mazda
Electrical
:
AUMA India, Beacon Rotork Controls,
Continental Profiles, Emtork Actuators,
Limitorque
Pneumatic
:
Marsh Engg., Keystone, IL, Massoneilan, ELO-MATIC, Virgo, AL Saunder, L&T, Flocan
:
BHPV, Kaveri, Texmaco, Thermax, Babcock
& Wicox, Parkair Engg., Rhine, Universal
Heat Exchanger, Godrej, L&T, GEI Godavari,
Patel Air Temp., Hindustan Radiaton
Control Valves
:
Blue Star, Fouress Engg., IL, JNM, Mazda,
Forbes Marshall
Pressure Vessel & Tanks
:
Beekay Engg., BHPV, ISGEC, Kaveri Engg.,
TSL, Lloyds Steel, Mukand, Parkair Engg.,
Grasim Industries, Anup Thermal System,
Texmaco, SV Tank, Grasim Industries,
Hyderfuel Industries.
Thermal Insulation
:
Hyderapad Industries, Lloyds Insulation,
Rockwool, Thermax Heat Tracers, U.P.
Twiga Fibreglass.
Suction Filters
:
FMI, KAAF, L&T, Flakt, Autokiln Filter, GEC
Alsthom, Filtration Engr., ARF Engg., ABB,
Dyna Filter, Purolator Filters, GM Dalui
Actuators
Heat Exchanger
(Shell & Tube Type)
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 7 of 37
GS-13
General Technical Specification
02.04
Pipes & Fittings
Facilities.
for Water Supply, Gas Facilities, Steam and Compressed Air
Item Description
Manufacturers
SW/SAW, ERW/EFW MS
Pipes
:
SAIL, BHEL, TISCO, Jindal, Ajanta, Zenith,
Saw Pipes, Welspun, Man Industries,
Surindra Engg., Maharastra Seamless,
Indian Seamless, BST, Advance Steel, Good
Luck, Indus Tubes, Mukat, Lloyds, Poonam
Enterprises, Soor Neogi Koumar.
SS Pipes / SS Fittings
:
Heavy Metal Tubes, Nobel Tubes, Rajendra
Mech. Ind., Sterling Supply Agency, Vitrag,
SAIL, Poonam Enterprises, N.L.Hazra,
M.S.Fittings
Seamless, Stainless Steel
Pipes/Tubes
:
Amardeep Steel, Choksy Tubes, MJ Patel,
Nagardas Kanji, Poonam Enterprises,
Sandulk Asia, MEC Tubes, Nagardas &
Kusai, Noble Tubes, Allied Steel, Kamlesh
Tube, Menilal & Bro, Uday Tubes, SAIL,
Maharastra Seamless (P) Ltd, Imperial
Steel, Soor Neogi Koumar.
Fittings for the above
Pipes/Tubes
:
EBY Ind., High-Tech, Hydro technic, HydroAir Engg., Project Toolings, Shivananda,
M.J.Patel, Nagardas & Kusai, MEC Tubes,
Nobles Tubes, Amardeep Steel, Allied Steel,
Kamlesh Tube, Menilal & Bros, Poonam
Enterprises, N.L.Hazra, M.S.Fittings
RCC Pipes & Fittings
:
SUR Industrial Pipes, Hind Ceramics, Indian
Hume Pipes, Daya Cuncrching.
HDPE Pipes & Fittings
:
EMCO, KWH Heliplastic Polyolefins, Oriplast
PVC Pipes & Fittings
:
Oriplast, Finolex, Bharat Pipe & Fittings,
Supreme Industries.
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 8 of 37
GS-13
General Technical Specification
03.
VENTILATION, AIR CONDITIONING & AIR POLLUTION CONTROL EQUIPMENT
Item Description
Manufacturers
Centrifugal fans for
Ventilation
:
C.Doctor, EFE, AEROVENT, Flow Link,
Andrew Yule, RIECO, ISEL, BATLIBOI,
Flaktwood,
REITZ,
ACCEL,
Dustven,
INDFAN,
Centrigugal fans for
Dedusting
:
BHEL, TLT, C.Doctor, Andrew Yule, RIECO,
Batliboi,
F.Harley,
Flaktwood,
REITZ,
DUSTVEN, ISEL, INDFAN
Tube axial fans / Propeller
Fans
:
C.Doctor, EFE, Flow Link, ALMONARD,
ACCEL, KHAITAN, AEROVENT, ISEL,
INDFAN
Panel filter for air
:
FMI, Clean Filter Industries, EFE, ACCEL,
FILTRONIC, FLOWLINK, CADILLAC, C.
DOCTOR
Air washer
:
C.Doctor, EFE, FLOW LINK, FHARLEY,
ALSTOM, Dustven, BATLIBOI, FMI
Man coolers
:
C.Doctor,
Ventura,
LM
KHAITAN,
ALMONARD,
FLOWLINK
Roof exhauster
:
C.Doctor, EFE, ACCEL, ALMONARD,
FLOWLINK, INDFAN, AEROVENT
Window air conditioners
:
Fedders Lloyd, VOLTAS, Blue Star, ARCTIC,
Carrier Aircon, LG, Samsung, HITACHI
Packaged air conditioners
:
VOLTAS, Blue Star, KIRLOSKAR, ACCEL,
BATLIBOI, EMERSON, FEDDERS LLOYDS,
ROOS TEMPKOOL, ROOTS COOLING
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 9 of 37
ENGINEERS,
DUSTVEN,
GS-13
General Technical Specification
Item Description
Manufacturers
Packaged chillers
:
VOLTAS, Blue Star, ALSTOM, Batliboi,
ACCEL, FEDDERS LLOYD, KIRLOSKAR,
PNEUMATIC
Air handling units
:
VOLTAS, BLUE STAR, ALSTOM, BATLIBOI,
PATELS AIR TEMP, ROOTS COOLING
Cooling towers
:
PAHARPUR, MIHIR, ADVANCE, GAMMON
INDIA, Southern Cooling Towers Ltd.,
SHRIRAM TOWER TECH.
Refrigerant compressors
:
VOLTAS, SHRIRAM, ACCEL, BLUE STAR, ,
Atlas Copco, Kirloskar, HITACHI
Cyclones
:
THERMAX, RIECO, ALSTOM, C.DOCTOR,
F.HARLEY, Dustven, EFE
Multicyclones
:
THERMAX,
ALSTOM,
C.
DOCTOR,
BATLIBOI, RIECO, F.HARLEY, EFE
:
THERMAX, ALSTOM, ANDREW YULE,
RIECO, C.DOCTOR. F.HARLEY, Dustven,
BATLIBOI, FMI
:
ALSTOM, RIECO, THERMAX, VAI, Dustven,
BATLIBOI
Wet scrubbers
:
ALSTOM, THERMAX, BATLIBOI, RIECO,
C.DOCTOR, F.HARLEY, EFE, SOIL &
ENVIRO SYSTEM
Venturi scrubbers
:
BATLIBOI, THERMAX, RIECO, ALSTOM,
Dustven
Electrostatic precipitators
:
ANDREW
YULE,
VOLTAS, ABB, VAI
Bag filters
3
(Cap – 10,000 m /h to
3
80, 000 m /h)
Bag filters
3
(Cap –Above 80,000 m /h)
Insulation
THERMAX,
TWIGA, LLOYDS, BAKELITE
MALANPUR ENTECH
BHEL,
HYLAM,
Valves for air conditioning
:
DANFOSS, HONEYWELL, BLUE STAR
Vibration isolators
:
DUNLOP, EMERALD
Centrifugal horizontal
pumps
:
KSB,
BEACON
KIRLOSKAR
Horizontal split casing
pumps
:
VOLTAS,
BEACON
KIRLOSKAR
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 10 of 37
WEIR,
WEIR,
VOLTAS,
KSB,
GS-13
General Technical Specification
04.
HANDLING & HOISTING EQUIPMENT & COMPONENTS
04.01
Equipment
Item Description
Manufacturers
EOT Crane
(Up to 10T capacity)
:
Armsel, Avon, FAFECO, Mukand,
Anupam, Shivpra, Tubrofurguson
EOT Crane
(Up to 50 T capacity)
:
HEC, Jessop, Mukand, Hyderabad Ind. Ltd.,
WMI, FAFECO, Unique, Anupam
EOT Crane
(Above 50 T capacity)
:
Jessops, HEC, Mukand, FAFECO, Unique,
WMI, .
Underslung Cranes (Upto
5t only)
Electric Hoists
:
Armsel, Brady & Morris, Shivpra
:
Armsel, Shivpra,WH Brady, Brady & Morris,
Grip Engrs., Hi-tech, Century Crane
Transfer Cars
:
HEC, L&T, Hyderabad Ind.,
Engrs, ELECON, TRF
Chain Pulley Blocks &
hand operated travelling
cranes.
Shunting Winch
:
Armsel, Century Cranes, Brady & Morris, Light
Lift Ind., Hi-tech, MR Engg. Lifting Equipment
:
Beekay, HEC, Armsel, Century Cranes, Nirmal
Equipments, Mining & MH Equipment, Cyclo
transmission
Jib Crane
:
Brady & Morris, Century Cranes, Hi-tech, Grip
Engrs., Elite, Light Lifting, Armsel
Crawler Mounted Mobile
Crane
Excavator/ Shovel
:
TIL, Hyderabad Industries, TATA-P&H
:
TIL, HEC, Hyderabad Industries, BEML
Elevator/Lift
:
OTIS, OMEGA, Kone, ECE
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 11 of 37
WMI,
Mukand, Eqipt
GS-13
General Technical Specification
04.02
Mechanical Components/ Equipment
Item Description
Manufacturers
Hooks
:
Herman Mohta, Free Trading Corporation,
Steel Forgings & Engg..
Flexible / Geared coupling
:
Hicliff, Concord, Wellman, GBM, Alliance, New
Allenbery Works,Elecon,
Wire rope
:
Bharat Wire Rope, Orion Ropes, Usha Martin
Bearings for Cranes
:
SKF, FAG
Bearings for other
equipment
:
SKF, FAG, Tata Timken, Asian Bearings,
NRB,MBM
Oil Seals
:
Vaco Oil Seals, Rubber Equipment & Engg.
Sealjet India (Pune), Sealpack, Champion
Seals
Lubrication Fittings
:
Lubcon, AFMC, Prakash, Lincoln
Lubricating Systems
:
AFMC, Prakash, Grindwell Norton, Lincoln
Helios
Gear box
:
New Allenburry, Greaves Cotton, ELECON,
Shanti Gears, Flender, AR Engg, Kirloskar,I.C.
Hydraulic Systems
:
Vickers Sperry, Yuken, Manesmann, Rexroth,
Hugglands Denison-Parker
Hydraulic Coupling
:
Fluidomat, Ghatge Patil, VOITH, Prembrill
Centrifugal blowers
Burners
:
:
Recuperators
:
REITZ, Flaht Wood, James Howden (UK)
Stein Heurtey, Techint, LOI, Weswan North
American, Ecllpse, Hotwork
Eastern
Equipment,
GEFFI
(Germany)
SAFMAT (France), North American Minnt. Co.
Thermal Transfer Corporation (USA)
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 12 of 37
GS-13
General Technical Specification
Item Description
Manufacturers
Hydraulic
Power/Cylinders
:
Rexroth, Vickers, Wipro,
Veljan, Yuken, Oscar.
High Pressure
Vane/Piston Pump
:
Vickers, Yuker, Rexroth, Hugglands, Denison
Crusher
:
Sayaji, HEC, McNally Bharat, TRF, ELECON
DCEM Brake
:
Track type Limit Switch
:
Electromag, BCH, Industries Syndicate, Storm
Kraft, Speed-O-Control
Electromag, BCH, Speed-O-Control, Jayshree,
EP&C, Bengal Technocrats
Thruster Brake
:
Electromag, BCH, Speed-o-Control, Elite
Belt changing Device
:
Nilos, Shawalmex
Conveyor Belting
:
Northland
Rubber
Vibrating Screen
:
IC, TRF, ELECON, McNally Bharat, L &T, HEC,
Orien, Electromag, Hydrabad Industries
Vibratory Feeder
:
Electromag, IC, TRF,
ELECON, McNally Bharat
Magnetic Separators
:
Electromag, WMI, Magnet Corporation, Electro
magnetic Ind., Ericz, Sartorius, Hans Bockels,
Krupp Forder, Technick ,L & T
Pneumatic Actuators
:
Prepec, Technomech, Nucon
OSCAR Equipt, Veljan Hydair.
Electro Mechanical
Actuators
:
PREPEC, Technomech, Pebco
© 2007 MECON Limited
All rights reserved
Rubber,
Preferred Makes
Page 13 of 37
Usha
Telehoist,
Phoenix-Yule,
Orien
Oriental
Engineers,
Industries,
GS-13
General Technical Specification
Item Description
Manufacturers
Rubber liner
:
TEGA, Kaveri
Polymer liner
:
TEGA, Kaveri
Polyethelene liner
:
Kaveri, Tega
Polyurethane liner
:
Kaveri, Tega
Cast Basalt liner
:
DECCAN, Enviro Abrasion
Belt Scraper/ Belt
Cleaner
:
Belt Switches
Bin Vibrator
:
:
Hosch Equipment, Vinar IDC, Kaveri Macmet,
Hindustan Udyog Ltd., Karam Chand Thapper,
Cobit Engg, Elecon, TRF,
Promac, BMH
Concare
Jayshree, PROTO CONTROL, EPC
Electromag, Electromagnetic Industries, IC
Samplers
:
Prisector (UK), Ramsay Engg (USA), Eastmn
Crusher, Advanced system sampling (P) Ltd.
Belt Vulcanisers
:
Shaw Almex, Nilos India, SV Dattar
Sector Gates, Diverter
Gates, Rack and Pinion
Gates etc.
:
Vinar,
IDC,
Macmet,
TRF,
Precision
Processing, Moktali, Holtzman, Mining &
Material, Chennai Radha,
Flexowel Conveyors
:
METSO, Flexowel
Drag Chain Conveyors
:
Moktali Engrs., TRF, Equipt Engrs, Redler
India, Enviro Abrasion, Karam Chand Thapar,
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 14 of 37
GS-13
General Technical Specification
Item Description
Manufacturers
Bucket Elevator
:
Moktali, Golden Electrical, Hindustan Udyog,
Vinar, Cobit, Shree Conveyor, IDC, Orien,
Macmet, Elecon, TRF
Belt Feeder
:
Reclaimer
:
Vinar, IDC, HEC, Orien, Macmet, Elecon, TRF,
Cobit
Metso, L&T, Elecon, TRF, HEC
Stacker
:
Metso, L&T, Elecon, TRF, HEC
Stacker – CumReclaimer
Wagon Tippler
:
Metso, L&T, Elecon, TRF, HEC
:
L&T, HEC, Elecon, TRF, Metso
Wagon Loader
:
L&T, HEC, Elecon, TRF, Metso
Belt Weigh Feeders &
Weigh Hopper
:
Kistler – Morse, Sartorius Mechatronics,
Transweigh, Avery, Jenson Nicholson
Belt Weigh Scale
:
Kistler-Morse, Transweigh, Avery, Sartorius
Mechatronics, Jenson Nicholson
Conveyor belt pulleys
:
Elecon, TRF, McNally Bharat, Macmet, HEC
Conveyor Idlers
:
Elecon, TRF, McNally Bharat, Kali, Hindustan
Udyog Ltd., Macmet
Pneumatic Handling
Equipment
:
TTG, Scorpio
Front – end – loader
:
TIL, Hyderabad Industries Ltd.,
Fork-lift-truck
:
Godrej, Voltas, TIL
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 15 of 37
GS-13
General Technical Specification
05.
REPAIR & MAINTENANCE FACILITIES
Item Description
Manufacturers
Centre Lathe
:
HMT, Mysore Kirloskar, HEC
Universal Milling m/c
:
HMT, BFW, Batliboi
Shaper
:
PAL, P&B, Loyal
Radial Drilling m/c
:
HMT, Batliboi, Kerry Jost, HEC
Horizontal Boring m/c
:
HMT, HEC, PAL
Submerged Arc Welding
Set
:
Advani, ESAB, ADOR, Mogora, COSMIC
Welding Rectifier
:
Advani, ESAB, ADOR, Mogora, COSMIC
Welding Transformer
:
Advani, ESAB, MEMCO
Universal Tool and Cutter
Grinding m/c
:
HMT, Praga, Batliboi
Hydraulic Press
:
BEMCO, P&B, Centerprise
Cast Iron Plate
:
Jash, Madras Gauge, P&B
Power Hacksaw
:
ITL, P&B, EIFCO
Column Drilling m/c
:
HMT, Thakoor, Kerry Jost, EIFCO, Batliboi
Bench Drilling m/c
:
Accuax, EIFCO, P&B, Thakoor
Double-ended Pedestal
Grinder
:
Grind Tools, GECO, AMC, P&B
Cylindrical Grinder
:
HMT, Mysore Kirloskar, ELP
Tools & Tackles
:
P&B, Mekaster, Centerprise, Ally
Measuring Tools and
Gauges
:
P&B, Bombay Tools
Garage Equipment
:
ELGI, USHA, WAP, P&B
Oiling & Greasing
:
ELGI, P&B
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 16 of 37
GS-13
General Technical Specification
06.
ELECTRICAL
The list of acceptable makes for various electrical and automation equipment is given below.
A ) POWER DISTRIBUTION EQUIPMENT
SL.
NO.
EQUIPMENT
PREFERRED MAKES
TRANSFORMERS
1.
a)
DISTRIBUTION
TRANSFORMER (OIL
TYPE) (11 or 6.6/0.433
KV)
ABB / AREVA / / CGL / BHEL / BHARAT BIJLEE / VOLT
AMP/ KIRLOSKAR /INTRA VIDYUT /
b)
DRY TYPE
TRANSFORMER
INTRA VIDYUT / VOLTAMP / KEC
2.
11kV / 6.6KV ISOLATOR
A BOND STRAND / S&S,MADRAS / HIVELM / SIEMENS /
DREISCHER-PANICKER.
3.
415V SWITCHBOARD
SIEMENS / L&T / GE POWER / SCHNEIDER
4.
LT BUSDUCT
STARDRIVE / C&S / PCE / ECC / BRIGHT ENGINEERS/
VIDHYUT CONTROL
5.
BATTERY
a)
NICKEL - CADMIUM
AMCO / HBL NIFE
b)
VALVE REGULATED
LEAD ACID
MAINTENANCE FREE
BATTERY (VRLA)
HBL NIFE / AMARARAJA / EXIDE
c)
BATTERY ( PLANTE)
HBL NIFE / AMARARAJA / EXIDE
6.
BATTERY CHARGER/
DCDB
CHHABI / HBL NIFE/ CALDYNE / AMARA RAJA /
KIRLOSKAR
7.
PROTECTIVE RELAYS
AREVA / ABB / SIEMENS/ER
8.
AUXILIARY RELAYS
ABB / ER / SIEMENS / AREVA
9.
HEAT
SRINKABLE
CABLE JOINTING KITS/
STRAIGHT
THROUGH
JOINTS (H.T)
RAYCHEM / DENSON / M-SEAL
10.
METER (ANALOGUE
TYPE)
IMP / AE / MECO / SECURE METERS / CONZERV / L&T /
RISHAV
11.
CURRENT
TRANSFORMERS
ABB / SILKANS / INSTRANS / PRAGATI / IMP/ AE /
KAPPA / PRAYOG / SIEMENS / L&T
12.
POTENTIAL
TRANSFORMER
ABB / BHEL / SILKANS / PRAGATI / IMP / KAPPA /
PRAYOG /SIEMENS / ABB / INDOCOIL / PRECISION
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 17 of 37
GS-13
General Technical Specification
SL.
NO.
EQUIPMENT
PREFERRED MAKES
13.
11KV/ 6.6KV CABLES
ASIAN CABLES (RPG) / CCI / UNIVERSAL / NICCO /
POLYCAB / HAVELLS
14.
DIGITAL TYPE
MULTIFUNCTION
METER
CONSERVE / L&T / SECURE / ER / RISHAV
B ) LT PANELS , DRIVES , AUTOMATION & CONTROL ACCESSORIES.
SL.NO.
1.
SUB GROUP
MAKES
MCC (NON DRAW
OUT)
POWER
DISTRIBUTION BOARD
(PDB)
CONTROL DESK
&POST
HINDUSTAN CONTROL / POWER & PROTECTION /
ECC / VENUS / BCH / HAVELLS / GEMCO
4.
LOCAL CONTROL
STATION (LCS)
HINDUSTAN CONTROL / POWER & PROTECTION /
ECC / VENUS / BCH / HAVELLS / GEMCO
5.
LIGHTING
DISTRIBUTION BOARD
MLDB, SLDB
HINDUSTAN CONTROL / POWER & PROTECTION /
ECC / VENUS / GEPC / BCH
6.
VVVF AC DRIVE
ABB / ROCKWELL AUTOMATION / SIEMENS / VACON /
SCHNEIDER / L&T
7.
SOFT STARTER
ROCKWELL AUTOMATION / ABB / SCHNEIDER /
SIEMENS
8.
PROGRAMMABLE
LOGIC CONTROLER
(PLC)
ABB ( 800 XA) / GE-FANUC ( PAC Rx7i) / ROCKWELL
AUTOMATION (CONTROLOGIX) / SIEMENS (S7
SERIES)
9.
UNINTERRUPTED
POWER SUPPLY
(UPS)
LT AC MOTOR
(SQ. CAGE)
TATA LIBERT (EMERSON) / GE / FUJI / DB
ELECTRONICS
ALSTOM / KEC / CGL / SIEMENS
12.
LT AC MOTORS
(CRANE DUTY)
HT AC MOTOR
13.
LT AC GEARED
KIRLOSKAR ELECTRIC / POWERBUILD / NEW ALLEN
2.
3.
10.
11.
© 2007 MECON Limited
All rights reserved
SCHNEIDER / L&T / SIEMENS / GEPOWER
HINDUSTAN CONTROL / VENUS / SIEMENS / ABB / L&T
/ GEPC / HAVELLS
ABB / BHARAT BIJLEE / CGL / KIRLOSKAR ELECTRIC
ALSTOM / SIEMENS
BHEL / ABB / CGL / SIEMENS / KIRLOSKAR ELECTRIC /
ALSTOM / WEG / GE
Preferred Makes
Page 18 of 37
GS-13
General Technical Specification
SL.NO.
14.
15.
16.
17.
18.
19.
20.
21.
22.
SUB GROUP
MAKES
MOTOR
BERRY / IEC / AUMA
FLAME PROOF LT
SQUIRREL CAGE AC
MOTOR
SLIPRING MOTOR
(OTHER THAN CRANE
DUTY)
LT AC VVVF MOTORS
FOR ROLLER TABLE
APPLICATION
STALL TORQUE
MOTOR
ACTUATOR
ALSTOM / BHARAT BIJLE / ABB / CGL
KIRLOSKAR ELECTRIC / SIEMENS
MOTOR PROTECTION
CIRCUIT BREAKER
(MPCB)
MOULDED CASE
CIRCUIT BREAKERS
(MCCB)
MINIATURE CIRCUIT
BREAKER (MCB)
CGL / ALSTOM / SIEMENS / KIRLOSKAR ELECT CO.
SIEMENS / ABB / KIRLOSKAR ELECT CO. / ALSTOM /
CGL
DEMAG
AUMA / ROTORK / LIMITORQUE
SCHNEIDER / ABB / L&T / GEPOWER / SIEMENS
SIEMENS / ABB / L&T / GEPOWER / SCHNEIDER
HAVELLS / MDS LEGRAND / SCHNEIDER / STANDARD
/ GEPOWER / HAGAR (L & T) / ABB / SIEMENS
EARTH LEAKAE
CIRCUIT
BREAKER.(ELCB)
HRC FUSES
HAVELLS / MDS LEGRAND / SCHNEIDER / STANDARD
/ GEPOWER / HAGAR (L & T) / ABB / SIEMENS
VACUUM
CONTACTOR (LT)
AC POWER
CONTACTORS
SIEMENS / L&T / ABB / SCHNIEDER
26.
CRANE DUTY POWER
CONTACTORS
ABB / SCHNEIDER / L&T / SIEMENS / GEPOWER
27.
THERMAL OVER LOAD
RELAY
ABB / C&S / BCH / L&T / SCHNEIDER/ GEPOWER /
SIEMENS
28.
ELECTRONIC
THERMAL OVERLOAD
RELAY
CONTROL SWITCHES
/
SELECTOR
SWITCHES
FANOX / SAMWHA / MOELLER / LG / SPECHER &
SCHUH
23.
24.
25.
29.
© 2007 MECON Limited
All rights reserved
L&T / SIEMENS / BUSMAN / GEPOWER / INDO-ASIAN
ABB / L&T / SCHNEIDER / SIEMENS / GE POWER /
BCH
ABB / ALSTOM / BCH / KAYCEE / GEPOWER / SIEMENS
Preferred Makes
Page 19 of 37
GS-13
General Technical Specification
SL.NO.
SUB GROUP
MAKES
30.
PUSH BUTTONS
BCH / L&T / SCHNEIDER / SIEMENS / GEPOWER
31.
TIMERS/TIME DELAY
RELAY
AUXILIARY RELAYS
ABB / BCH / L&T / GEPOWER / SIEMENS / EAPL
ABB / BCH / L&T / SCHNEIDER / GEPOWER / SIEMENS
33.
MASTER
CONTROLLER
EPCC (KAKKU) / SCHNIEDER / SIEMENS /
STROMKRAFT / TELEMECHANIQUE
34.
LIMIT SWITCHES
BCH / EPCC (KAKKU) / AG MECHANIC / ESSEN
GEPOWER / JAIBALAJI / SCHNEIDER / SIEMENS
35.
PULL CORD
SWITCHES
EPCC (KAKKU) / AG MECHANIC / TELEMECHANIQUE /
JAYSHREE ENTERPRISES / STROMKRAFT / PROTO
CONTROL
36.
BELT SWAY SWITCH
EPCC (KAKKU) / AG MECHANIC / TELEMECH /
JAYSHREE ENTERPRISES / STROMKRAFT /
PROTO CONTROL
37.
GRAVITY TYPE LIMIT
SWITCH
ROTARY LIMIT
SWITCH
EPCC (KAKKU) / STROMKRAFT / KAYCEE
EPCC (KAKKU) / AG MECHANIC ENTERPRISE /
SCHNEIDER / TELEMECH
39.
PROXIMITY &PHOTO
ELECTRIC SENSORS
ROCKWELL / SCHNIEDER / SIEMENS/ OMRON / SICK /
DELTA / LINE & LINDE / TELEMECHANIQUE
40.
PULSE ENCODER
HUBNER / HEIDENHEIN / ROCKWELL AUTOMATION
(ALLEN BRADLEY) / LEONARD BAUR GERMANY / SICK
(GERMANY)
41.
INDICATING LAMP
LED TYPE
SIEMENS / L&T / BINAY / ESSEN / BCH / VAISHNO
42.
HOOTER / BUZZER /
BELL / SIRENS
SOLID STATE
ANNUNCIATOR
EPCC (KAKKU) / KHERAJ
32.
38.
43.
ADVANI OERLIKON / AREVA / APLAB/ CONTROL &
DYNAMICS / DIGICON INSTRUMENTATION LTD. / L&T /
MINILEC
44.
TEMP. SCANNER
ADVANI OERLIKON / ECIL / INSTRUMENTATION LTD. /
MASIBUS / PYROTECH / SIEMENS
45.
LAMPS
BAJAJ / CROMPTON GREAVES / GE LIGHTING /
PHILIPS / OSRAM / SIGMA
46.
LIGHT FITTING
(FIXTURES)
BAJAJ / CROMPTON GREAVES / GE LIGHTING /
PHILIPS
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 20 of 37
GS-13
General Technical Specification
SL.NO.
SUB GROUP
MAKES
47.
COMPLETE WITH ALL
ACCESSORIES
EXCEPT LAMP.
LIGHTING WIRE (PVC)
48.
5A/15A PIANO SWITCH
ANCHOR / ELLORA / MDS LEGRAND / PRECISION /
HAVELLS
49.
50.
FLAME PROOF LIGHT
FITTING
EXHAUST FANS
GOVAN / BALIGA / FLEXPRO / SUDHIR / CEAG / FCG /
SIGMA
CGL / KHAITAN / BAJAJ
51.
CEILLING FANS
CGL / KHAITAN / HAVELS
52.
PERSONAL
COMPUTER
LAP TOP/ NOTEBOOK
HP / DELL. / LENOVO / IBM
53.
54.
CCI / DELTON / FINOLEX / NICCO / UNIVERSAL
IBM / HP / LENOVO / DELL
HRC FUSE
(SEMICONDUCTOR
PROTECTION)
ELECTRONIC
WEIGHING SYSTEM
ABB / SARTORIOUS / SANMAR / SCHENK /
TRANSWEIGH / KELK
56.
PVC POWER CABLES
(LT)
CCI / UNIVERSAL / NICCO / RPG CABLES (ASIAN) /
POLYCAB / FINOLEX / TORRENT / HAVELLS
57.
PVC CONTROL
CABLES
58.
HEAT RESISTANT
CABLES (EPR/CSP &
SR)
SCREENED CABLES &
SPECIAL CABLES
CCI / LAPP / NICCO / RPG CABLES (ASIAN) /
UNIVERSAL / POLY CAB / FINOLEX / TOSHNIWAL /
DELTON
CCI / LAPP / NICCO / RPG CABLES (ASIAN) /
UNIVERSAL / TOSHNIWAL / DELTON
55.
59.
60.
BUSMANN / JE MULLER / FERRAZ / GEPOWER /
SIEMENS
CCI / BELDEN / LAPP / FINOLEX / POLY CAB / NICCO /
TOSHNIWAL / DELTON
CABLE TERMINATION
KITS (XLPE)
TERMINAL
CONNECTOR
CONNECT WELL / ESSEN-DINKY / PHOENIX / WAGO /
LAPP
62.
TRAILING CABLES
LAPP / CCI / UNIVERSAL / ASIAN / NICCO
63.
WELDING SOCKET
BCH / SCHNIDER / BEST & CROMPTON / GEPOWER /
HAVELL / JAIBALAJI
64.
LIFTING MAGNETS
ELECTROMAG / EPCC (KAKKU) / STERLING
MAGNETICS / SUPERLIFT
65.
POWERPACK FOR
MAGNETS
ELECTROMAG / BCH / EPCC (KAKKU)
61.
© 2007 MECON Limited
All rights reserved
MSEAL, 3M / RAYCHEM
Preferred Makes
Page 21 of 37
GS-13
General Technical Specification
SL.NO.
SUB GROUP
MAKES
66.
RESISTORS (CRANE)
BCH / ELECTROMAG / AMP CONTROL / EPCC /
SIEMENS / RESITECH / NARKHEDGE
67.
LT CAPACITORS
GEPOWER / ABB / CGL / UNI STAR / BHEL
68.
CABLE REELING
DRUM
BENGAL TECHNOCRAT, / ELECTRO ZAVOD /
ELECTROMAG
69.
DC
ELECTROMAGNETIC
BRAKE
ELECTRO MAGNETIC
OVERLOAD RELAYS
BCH
71.
OIL DASH POT
OVERLOAD RELAYS
KILBURN ELECTRICALS LTD / ELECTROGEAR
72.
CONTROL
TRANSFORMERS
SIEMENS LTD. / INDCOIL MANUFACTURING CO. /
INTRAVIDYUT / AUTOMATIC ELECTRIC LTD. (AE) /
INDUSHREE / BHARTIA CUTLER-HAMMER LTD.
73.
CRANE CONTROL
PANELS
HINDUSTAN CONTROL / ECC / VENUS / MEDITRON /
EPCC
70.
BHARAT HEAVY ELECTRICALS LTD / BHARTIA
CUTLER-HAMMER LTD / KILBURN ELECTRICALS LTD.
C) FIRE DETECTION & ALARM. (F.D.A) SYSTEM
SL.NO
.
1.
2.
3.
4.
5.
6.
7.
DEVICES
MAKES
INTELLIGENT DETECTORS
( PHOTO ELECTRIC, HEAT, THERMAL)
UL /FM / APPROVED
INTELLIGENT FIRE ALARM CONTEROL
PANELS
UL /FM / APPROVED
ADDRESSABLE MANUAL CALL POINTS
INCLUDING HAND SETS .
UL /FM / APPROVED
MONITOR MODULES
UL /FM / APPROVED
FAULT ISOLATION MODULE
UL /FM / APPROVED
CONTROL MODULES
UL /FM / APPROVED
UV FLAME DETECTORS
UL /FM /APPROVED
© 2007 MECON Limited
All rights reserved
SIMPLEX / NOTIFIER / EDWARDS
-DO-DO-DO-DO-DOPATOL / DETRONICS / SPECTREX
Preferred Makes
Page 22 of 37
GS-13
General Technical Specification
8.
10.
BEAM DETECTORS
UL /FM / APPROVED
IR FLAME DETECTORS
SOLAR BLIND EMBER, FIRE
UL /FM / APPROVED
ANALOG LINEAR HEAT SENSING CABLE
11.
A) WITH METAL BRAID STEEL/BRONZE,
COPPER
B) WITH NYLON BRAID
UL /FM / APPROVED
DIGITAL LINEAR HEAT SENSING CABLE
KIDDE / L.G.M / PATOL
A) WITH NYLON BRAID
B) WITH METAL BRAID STEEL,
BRONZE, COPPER .
UL /FM / APPROVED
CONTROL UNIT FOR DIGITAL LHS
CABLE
UL /FM / APPROVED
VIDEO DISPLAY UNIT INCLUDING CPU,
PC, MONITOR, PRINTER ETC.
DELL / HP / HCL / WIPRO / IBM
COMPATIBLE.
9.
12
13
14
SIREN
CABLES
A: FOR DETECTOR CABLING
(I)
IMPORTED
(II)
KIDDE / L.G.M / PATOL.
BELDON / SOUTHWEST / ALPHA
INDIGENOUS
POWER CABLE
16
SIGNAL CABLE
17
M.S.CONDUIT AS PER IS-9537-PART-II1981
GI CONDUITS
ROAD CROSSING G.I PIPES
© 2007 MECON Limited
All rights reserved
ODTI / PATOL / DET-TRONIX /
SPECTREX
KHERAJ / BEMCO / TULU
15
18
19
EDWARDS / NOTIFIER / SIMPLEX
FINOLEX / DELTON / UNIVERSAL /
NICCO / POLYCAB / FORTGLOSTER
/ HAVELLS
FINOLEX / DELTON / UNIVERSAL /
NICCO / POLYCAB / FORTGLOSTER
/ HAVELLS
USHA BELTON / HCL / DELTON /
VINDHYA TELELINK
NICCO / BHARAT / ZENITH / BEC
/ CENTURY
BEC / NICCO / ZENITH
NICCO / TATA / JINDAL
Preferred Makes
Page 23 of 37
GS-13
General Technical Specification
1. ELECTRONICS CORPORATION
OF INDIA LTD,
2. TECHNICAL TRADE LINKS PVT.
LTD.
3. GUNNEBO INDIA LTD.,
4. MATHER & PLATT PUMPS (I) LTD.
5. M/S AGNICE FIRE PROTECTION
LIMITED.
20
F.D.A SYSTEM SUPPLIERS
6. M/S TECHNICO (INDIA) PVT.
LIMITED.
7. NOTIFIER.
8. SIEMENS.
9. TECHNO FIRE.
10. NEW FIRE.
11. TYCO FIRE & SECURITY.
21
ELECTRONIC PRIVATE AUTOMATIC
BRANCH TELEPHONE EXCHANGE
(EPABX) SUPPLIERS
1. M/S INDIAN TELEPHONE
INDUSTRIES LIMITED.
2. M/S AVAYA GLOBAL CONNECT
LIMITED.
3. M/S SIEMENS LIMITED.
4. M/S ALCATEL.
5. M/S B.P.L TELECOM PVT.
LIMITED.
6. M/S CROMPTION GREAVES
LIMITED.
7. ERICSSON.
1. M/S E.C.I.L.
2. M/S NELCO LIMITED.
22
C.C.T.V SYSTEM SUPPLIERS
3. M/S DATAMATICS INFORMATION
TECHNOLOGY LIMITED.
4. M/S PHILIPS/BOSCH
5. M/S PELCO
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 24 of 37
GS-13
General Technical Specification
23
LOUD SPEAKER TALK BACK(LSTB) /
LOUD SPEAKER
INTERCOMMUNICATION(LSIS)
SYSTEMS SUPPLIERS
1. M/S POWER SYSTEMS.
2. PHI-AUDIOCOM.
3.M/S MOTAWANE PRIVATE LIMITED
1. DELTON CABLES.
24
TELEPHONE CABLE SUPPLIERS
2. TELE-LINK NICCO.
3. FINOLEX.
25
26
07.
FIBRE OPTIC (F.O) CABLE.
MOLEX/LUCENT/AMPHINOL/BIRLA
ERRICSSON/OPTEL.
V.H.F SYSTEM
MOTORALA/ YEASU/SIMOCO/ADINO
INSTRUMENTATION
Sl.
No.
ITEM DESCRIPTION
PREFERRED MAKES
A.
Field Instruments:
1.
Pressure / Differential Pressure gauge
:
2.
Pressure
switches.
:
3.
Pressure / Differential Pressure
Transmitters
:
Emerson (Rosemount), Chemtrols (Fuji), Honeywell,
Yokogawa, Siemens , ABB
4.
Temperature gauges
:
WIKA, Manometer India, A.N. Instruments, General
instruments,
Waaree
instruments,
GE
gauges,
Walchandnagar, Precision Industries.
5.
Thermocouple & RTD / thermowell
:
General Instruments, Nagman Instruments, Toshniwal
/
© 2007 MECON Limited
All rights reserved
Differential
Pressure
WIKA, Manometer India, A.N. Instruments, Precision
Industries, General Instruments, Waaree instruments,
Forbes Marshall, Walchandnagar (Tiwac) , Hirlekar (DP
gauge)
Ifm. WIKA, Kasturba (Orion-Ashcroft),Switzer, Indfoss,
Vasutech,
Preferred Makes
Page 25 of 37
GS-13
General Technical Specification
Sl.
No.
ITEM DESCRIPTION
PREFERRED MAKES
Industries, Tempsens, Pyro-electric Instruments, Industrial
Instrumentation, Altop, Waree, Detriv.
6.
Temperature Switch
:
WIKA, Manometer India, A.N.Instruments,
Instruments, Indfoss, Switzer, Vasutech.
7.
Temperature transmitter
:
Emerson (Rosemount), Yokogawa, Honeywell, Siemens,
Fuji (Chemtrols,) , ABB
8.
Rotameters
:
Krohne-Marshall, Instrumentation engineers,
Eureka instruments. Chemtrols, Rota Instruments.
9.
Orifice Plate & flanges Assembly/
Venturi , Flow nozzle
:
Engineering Specialities, Micro-precision, Hydropneumatics, Chemtrols-Samil, Instrumentation ltd,
10.
DP type Flow / Level Transmitters
:
Emerson (Rosemount), Chemtrols (Fuji), Honeywell,
Yokogawa, Siemens , ABB
11.
Flow Switch
:
Ifm. , Krohne-Marshall, Switzer, Levcon, D.K. Instruments,
12.
Electromagnetic flow meter
:
Yokogawa, Emerson (Rosemount), Krohne-Marshall,
Endress & Hauser, ABB.
13.
Vortex Flow meter
:
Emerson(Rosemount), Krohne -Marshall, Yokogawa,
Vortex Instruments
14.
Mass (coriolis) flow meter
Emerson (Rosemount) , Yokogawa, Krohne –Marshall,
ABB, Endress & Hauser, Rockwin.
15.
Level gauge (magnetic & reflex type)
Chemtrol, Levcon Instruments, Pratolina Instruments,
Waaree Instruments, Forbes Marshall, Techtrol, Sigma,
Asian Industrial Valves & Instruments.
16.
Level Switch (Conductivity type)
:
Chemtrol (Vega), Endress & Hauser, Switzer Instruments,
SB Electro-mechanical, Techtrol, Nivo Controls, LevelTech
17.
Level Switch (Capacitance/RF type)
:
Chemtrol (Vega), Endress & Hauser, Switzer Instruments,
SB Electro-mechanical, Techtrol, Nivo Controls, LevelTech
18.
Level Switch (Tuning fork/ Rod type)
:
Chemtrol (Vega), Endress & Hauser, S.B. Electromechanical, ,Nivo Controls
19.
Level Switch (Float type)
:
Emerson,Trac, Chemtrols, Forbes Marshall, D K
Instruments, Levcon Instruments, Techtrol , V-Automat,
Warree
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 26 of 37
GS-13
General
Trac,
General Technical Specification
Sl.
No.
ITEM DESCRIPTION
PREFERRED MAKES
20.
Level Switch/ Transmitter (Displacer
type)
:
Emerson, Chemtrols (Eckard), Trac, D K Instruments,
Levcon Instruments,
21.
Level Switch/ Transmitter (Ultrasonic
type)
:
Chemtrol (Vega) , Endress & Hauser, Krohne Marshall,
Siemens (Miltronics) ,Toshbro controls (Enraf)
22.
Level Switch/ Transmitter (Radar type)
:
Chemtrol (Vega) , Emerson (Rosemount), , Endress &
Hauser ,Toshbro controls (Enraf), Krohne- Marshall
23.
Level Switch/ Transmitter (Nucleonic
type)
:
Concord International (Dr. Berthold), Emerson (Kay Ray),
ECIL.
24.
Level switch (Electro- mech type)
:
Nivo Controls,
mechanicals.
25.
Control valve
:
Fisher-Xomox ,Instrumentation Ltd, Dresser Industries
(Masoneilan) , Valtek, Samson Controls(Globe type),
Forbes Marshall ( Arca ), ABB, Fouress, Tyco valves
(Keystone- Butterfly), MIL Controls, Dembla
26.
Electrical Actuator
:
Auma, Limitorque, Marsh, Instrumentation Ltd
Endress
&
Hauser,
S.B.
Electro-
( Bernard), Rotork, Keystone.
27.
Pneumatic Actuator
:
Fisher-Xomox , Instrumentation Ltd., Dresser Industries
(Masoneilan), Valtek, Samson Controls, ABB, MIL
Controls, Forbes Marshall (Arca), Keystone, Virgo,
Habonim Vaas..
28.
Electro-hydraulic actuator
:
Reineke, Askania
29.
Self- regulating pressure control valve
:
Samson Controls, Nirmal Industries, Forbes Marshall,
Instrumentation Ltd.
30.
I/P converters
:
Shreyas-Barton, Fisher –Xomox, Forbes Marshall (Moore
products), Marsh-Bellofram, MIL controls, ABB, Watson –
Smith.
31.
Pneumatic Positioner,
:
Instrumentation Ltd., Fisher-Xomox , Dresser Industries
(Masoneilan), Samson Controls, Forbes Marshall ( Arca),
ABB, Fouress, MIL,
32.
Electro- pneumatic positioner
33.
Solenoid Valve
© 2007 MECON Limited
All rights reserved
Fisher-Xomox, ,Siemens, Dresser Industries (Masoneilan),
Samson Controls, Instrumentation Ltd., Forbes Marshall
(Arca), ABB, Fouress, MIL controls.
:
Burkert, Herion, Rotex, Schrader-Schovill, Jucomatic,
Avcon, .Asco
Preferred Makes
Page 27 of 37
GS-13
General Technical Specification
Sl.
No.
34.
B.
ITEM DESCRIPTION
Air filter regulator
PREFERRED MAKES
:
Shavo-Norgren,
Schovill.
Marsh-Bellofram,
Placka,
Schrader-
Control room Instrumentation
1.
Distributed Control System (DCS)
:
Yokogawa (CS 3000), Honeywell (Experion +C 300), ABB
(AC 800 XA), Emerson (Delta V), Siemens (PCS 7+
S7400H).
2.
Programmable Logic Controllers.
:
Refer Electrical list.
3.
Digital Indicator
:
Pyrotech Electronics, Lectrotek, Chino-Laxsons, Micro
systems, Master Electronics, Masibus Instruments,
Ranutrol, Honeywell.
4.
Bargraph Indicator
:
Chino-Laxsons , Masibus Instruments , Pyrotech
Electronics, Lectrotek, Teletherm. Ranutrol
5.
Recorders (Chart Less)
:
Eurotherm,
Yokogawa,
Siemens, ABB.
6.
Microprocessor based controller
:
Yokogawa, Siemens, Honeywell, Eurotherm, Fuji, ABB,
Forbes Marshall,Toshiba
7.
Digital scanners
:
Lectrotek, Micro systems, Master Electronics, MB controls,
Masibus Instruments, Procon.
8.
DC Power Supply Unit
:
Aplab, Elnova,Siemens, Phoenix, Schneider,
9.
IS Interface/Zenner Barrier
10.
Signal isolators
:
Pepperl & Fuchs, MTL, Stahl, Yokogawa, Forbes Marshall
(Protech), Chino-Laxsons, Phoenix
11.
Annunciation system
:
IIC, Procon, Micro Systems & Controls, Minilec,
Instrumentation Ltd, Lectrotek, Piri systems, Pyrotech
Electronics, MB controls & Systems Semuda.
12.
Instrument Panels/ Control Desk
:
Rittal, Pyrotech, Radha Krishna Controls, Instrumentation
Ltd.
13.
Instrumentation Cable
© 2007 MECON Limited
All rights reserved
Chino-laxsons,
Honeywell,
Pepperl & Fuchs, MTL, Stahl
Universal Cables, Delton, Thermopads, KEI industries,
Paramount Cables, Lapp cables, Cords cables, Uniflex
cables, Brooks Cables, Elkay Telelinks, Rajnigandha,
Special Cables, TCL Cables, Friends Cable, Daksha
Cable, Crystal Cables,
Udey Pyro-Cables, Elkay
Telelinks, Fort Gloster
Preferred Makes
Page 28 of 37
GS-13
General Technical Specification
Sl.
No.
ITEM DESCRIPTION
PREFERRED MAKES
14.
Thermocouple Compensating Cable
C.
Analytical / Special Instruments
1.
Gas analysis Instruments
2.
Gas Detectors
3.
Calorific Value (CV) analyzers
:
Reineke, Union. Yokogawa
4.
Moisture Analyzers (Nucleonic)
:
Concord International (Dr. Berthold), Emerson (Analytical)
5.
ORP/PH/ Conductivity meter /
Transmitter
:
Emerson (Analytical), Forbes Marshall (Polymetron),
Yokogawa, ABB, Ion Exchange, Honeywell.
6.
Moisture Sensor & Transmitter
:
Invensys (Foxboro), Bartec, GE-Panametrics
7.
Flame Detector
:
Honeywell, Durag Instruments
8.
Vibration sensors & monitors
:
Bentley Nevada, Schenck -Avery, Josts Engineering
(Bruel & Kjaer), SPM Instruments, , Mechanalysis India
(IRD).
9.
Positive Displacement meter
:
Toshbro controls.(Bopp & Reuther), Forbes Marshall (
Moorco products), Liquid Controls, Emerson.
10.
Annubar / Flow tube
:
Emerson, Switzer Instruments.
11.
Infrared radiation pyrometer
:
Land, Chino-Laxsons, Toshniwal (Raytek), Ircon, Nagman
(Wahl),
12.
Dip lance type Molten metal
temperature measurement system
T/C Tips
:
Ardee Enterprise ( Electronite) , Ferrotran
13.
Slag detection system
:
Elof Hanson (EMLI), Land.
© 2007 MECON Limited
All rights reserved
:
Toshniwal Cables, General Instruments, Paramount
Cables, Udey pyro-cables, Cords cables, Brooks, Daksha
Cables, Friends Cable.
:
ABB (H&B), MSA, Emerson, Siemens, Chemtrols
(Maihak), Forbes Marshall, Fuji, Beiler & lang (COMonitor), Honeywell, Yokogawa.
Beiler & lang (CO-Monitor), Dragger, Oldham, Industrial
Scientific Corporation, Detronics.
&
Preferred Makes
Page 29 of 37
GS-13
General Technical Specification
Sl.
No.
ITEM DESCRIPTION
14.
SPM analyser
15.
SOx- NOx analyser
08.
PREFERRED MAKES
Emerson, Yokogawa, Durag, ABB, Honeywell, Forbes
Marshall (Codel).
Forbes Marshall, Emerson, Yokogawa, ABB, Honeywell
FIRE PROTECTION SYSTEM
1.
Steel pipes
-
SAIL, ITC, JINDAL, Ajanta, Maharastra
Seamless, Prakash Tubes Gujarat Steel
tubes,
2.
Steel pipes fittings
-
Tube Bends, Jindal, Ajanta Shivananda,
EBY Industries.
3.
Spray nozzles/Projectors -
4.
Deluge valves
-
Mather & Platt, ACE turnkey, Vijay Fire
Protection System Ltd, HD Fire.
5.
Outside coating& Wrapping
for pipes
-
Llyods/STP
6.
Quartzoid bulb detector
-
H.D. Fire Protect Co., Mather &
Platt, Any other TAC approved
make
7.
Diesel Engine
:
Kirloskar-Cummins, CromptonGreaves, Ashok Leyland
8.
Fire extinguishers
:
New Fire, VIPL, Zenith, ASCO
Strumech
9.
Fixed fire protection system
-
New Age, Agnice, Vijay
Industries& Project , Lloyds
© 2007 MECON Limited
All rights reserved
Laxmi sprinklers, Reliable, Avon, Mather
and Platt, HD Fire.
Preferred Makes
Page 30 of 37
GS-13
General Technical Specification
10.
09.
Passive Fire protection
Insulation, Techno Fire Controls
New Fire Engineers
Llyod, 3M, Vijay System, Signum
BOF GCP EQUIPMENTS:Following equipment/supplies specific to BOF-Gas Cleaning Plant shall be
manufactured by any of the following vendors listed below:-
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 31 of 37
GS-13
General Technical Specification
SL.
NO.
EQUIPMENT
VENDOR/MANUFACTURER
1.
Hood, Stack and Lance
sealing device
ISGEC, ACC-BABCOCK (ABL), BHPVL, L & T
2.
Hood traverse carriage, Stack
inspection device, Hood
bottom closure device
L&T, WMI CRANES, JESSOP, MUKAND
3.
Pressure vessels
ISGEC, ABL, BHPVL, TSL, KAVERI ENGG.
- Expansion vessel, Mixing
drum, Make-up water tank,
Sample cooler, Blow-down
& drainage expansion tanks
and Emergency spray
vessel
4.
Additive feeding system
BEEKAY, SIMPLEX, MUKAND
5.
Gas holder
MICCO, SMS-DEMAG, CLAYTON – WALKER
6.
Fabricated gas ducts (Dia>
1200 mm), Trestles/Duct
Supports, Flare stack
structure Walkways/Accesses
BEEKAY, ROURKELA FABRICATION,
BHARAT WEST – FALIA, SUBURBAN ENGG.,
KM UDYOG, OTTO, APV
7.
Electrostatic precipitator (wet
type)
VOLTAS, OTTO, ORIENT, ANDREW YULE
8.
ID fan
NEU (France), JAMES HOWDEN (UK),
ROTHEMUHLE (Germany), DONKIN (UK),
FLAKTWOODS
9.
Centrifugal horizontal CW
pumps
INGERSOLL, SULZER
Fabricated equipments
NHEC, BHPVL, KCP, BINNY ENGG. WORKS,
ABL, ISGEC, OTTO
-
Stack
cover
plate,
Saturator, Hydraulic seal
Recycling
tank,
Convergent/Divergent
ducts,
Changeover
device, Hydraulic nonreturn valve, Condensate
seal pots, Sump cover
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 32 of 37
GS-13
General Technical Specification
-
For
any
other
equipment/supplies
which
are
not
covered
above,
the
make/manufacturer’s name shall be mutually agreed between Purchaser /Consultant
and the successful Tenderer.
10.
INFORMATION SYSTEM
Preferred Makes for Level-II automation
Server Computers
:
IBM/HP/SUN
Client Computers (PC)
:
IBM/Lenovo/HP-Compaq/DELL
Network Equipment
• Active components
• Passive components
:
:
CISCO
LUCENT/AMP
Application software including
Process control models
:
Technology Supplier
© 2007 MECON Limited
All rights reserved
Preferred Makes
Page 33 of 37
GS-13
General Technical Specification
11. FLUID
SYSTEMS & PIPING ENGG (LUBRICATION & HYDRAULICS)
PREFERRED MAKE OF ITEMS
SL.
NO.
ITEM
1
Piston / Vane Pumps &
Hydraulic Motors
2
Gear Pump
3
Screw Pump
4
5
6
7
Centrifugal Pump for
Descaling System
Piston Pump for Descaling
System
Centrifugal Pump (12 Bar &
below)
Submersible Type Sump
Pump
8
Grease Lubrication System
9
Oil Lubrication System
10
Air Oil System
11
Air Controls
12
Hydraulic Proportional Valve
13
14
15
16
16.3
Hydraulic System
Hydraulic Control Valve
Hydraulic Servo Valve
Manual Valves
Manual Gate / Globe Valves
with & without gear for High
Pressure application
Manual Gate / Globe Valves
with & without for Low
Pressure application (16 Bar
and Low)
Butterfly Valve
16.4
Ball Valve
16.5
Check Valve (Disc Type) –
16.1
16.2
© 2007 MECON Limited
All rights reserved
MAKE
Rexroth / Parker / Kawasaki /
Eaton
Del Pd Pumps (ROTODEL) /
Tushaco / Rexroth / Parker / Alfa
IMO / Allwiler / Nortek
AREA
Hydraulics
Hydraulics / Oil
Lubrication
Hydraulics / Oil
Lubrication
KSB / Halberg / Wier
Descaling
Uraca / Wepuko / Hauhinco
Descaling
KSB / Kirloskar / Voltas / Mather &
Platt / Beacon / Wier
Water
KSB / Flygt / Grundfos
Sump
Lincoln Helios / Bijur Delimon /
Nortek
Lincoln Helios / Shaan Lube
Rebs / Dropsa / Bijur Delimon /
Nortek
Rotex, / Schrader Duncan / Shavo
Norgren / Nucon / Ross / SMC /
Rexroth / Parker
Rexroth / Parker / Eaton / Yuken
(Japan)
Rexroth / Parker / Eaton / Yuken
Rexroth / Parker / Eaton / Yuken
Moog / Rexroth
KSB / BHEL / AUDCO / BDK
Grease
Oil Lubrication
Air-Oil Lubrication
Pneumatics
Hydraulics
Oil Lubrication /
Descaling
KSB / BHEL / VIRGO / AUDCO /
BDK / Fouress / Akay
AUDCO / VIRGO / BDK
AUDCO / FOURESS / BDK /
VIRGO /
AUDCO / BDK / FOURESS
Preferred Makes
Page 34 of 37
GS-13
General Technical Specification
SL.
NO.
16.6
16.7
16.8
17
ITEM
Low Pressure
Check Valve ( Spring
Loaded) – Low Pressure
Check Valve (Spring Loaded)
– High Pressure
Check Valve (Disc Type) –
High Pressure
Control Valve for oil
lubrication system
19
Spray Valve for Descaling
System
Air Release Valve
20
Air / Gas Safety Relief Valve
18
MAKE
AUDCO / BDK / FOURESS
AUDCO / BDK
AUDCO / BDK
Forbes Marshall / Samsung /
Fisher / RK Controls / Nirmal
Industrial Controls
Oil Lubrication
Hunt / Elwood
Descaling
Upadhyay / Steam & Mining / BDK
Moorco / L & T / Fainger /
Mankenberg
Water
L& T / Virgo / Rotex / AVCON
Oil Lubrication
Christie / Hydac / Parker / EPE
Hydraulics
Christie / Hydac / Parker / EPE
Hydraulics
WSR / BHPV / ISGEC
Descaling
Hydraulics
Hydraulics
25
26
Actuators for operating
Valves
Accumulator with safety shut
off block
Accumulator Charging Kit
Accumulator for Descaling
System
Pressure Filter
Return Filter
27
Basket Filter
28
Auto Back wash Filter
29
Basket Strainer for water
30
HP Compressor
Hydac / Pall / Internormen / Parker
Hydac / Pall / Internormen / Parker
Internormen / Hydac / Pall / Ball
Filters
Ball & Kirch, / Hydac / Fluid
engineering
Superflo / Hydac / EPE /
Internormen / Multitex
Ingersoll Rand / Aerotechnic Coltri
31
Heat Exchanger
Alfa Laval / Indswep / Tranter
32
Level Indicator Switch
Sigma / Levcon / Shridhan /
Magnetrol / Buhler / Tectral /
WEKA / Peneberthy / Kobold
33
Pressure Gauge &
Temperature Gauge
A.N. Instruments / H.Guru / Wika /
Forbes Marshal / Stauff / Hydac /
kobold
34
Pressure Switch
Rexroth / Switzer / Hydac / Parker /
Dadfoss (Indfoss) / Kobold
35
Differential Pressure
Fisher Rosemount / Forbes
21
22
23
24
© 2007 MECON Limited
All rights reserved
AREA
Preferred Makes
Page 35 of 37
Descaling
Oil Lubrication
Descaling / Water
Hydraulics / Oil
Lubrication
Descaling
Hydraulics / Oil
Lubrication
Hydraulics / Oil
Lubrication /
Descaling
Hydraulics / Oil
Lubrication /
Descaling / Utility
Services
Hydraulics / Oil
Lubrication /
Descaling
Descaling
GS-13
General Technical Specification
SL.
NO.
ITEM
Transmitter
36
Thermostat
37
Differential Pressure Gauge
cum Switch
38
Pressure Transmitter
39
Temperature Transmitter
39
Flow Switch
40
41
Flowmeter cum Totaliser
Pipes / Tubes
41.1
Carbon Steel Seamless Pipes
/ Tubes
41.2
Stainless Steel Seamless
Pipes / Tubes
41.3
Carbon Steel ERW - SAW
Pipes / Tubes
MAKE
Marshall
Hydraulics / Oil
Lubrication /
Descaling
Hydraulics / Oil
Switzer / Danfoss / Indfoss / Hydac Lubrication /
Descaling
Hydac / Forbes Marshall
Hydraulics
Hydac / Forbes Marshall / Kobold /
Johnson Control /
Switzer / Hydac / Stauff / Verma
Trafag / Johnson Control / Kobold
Forbes Marshall / Stauff / Kobold /
Rockwin / SMC / HYLOC / Flow
Mon
Rockwin / Forbes Marshall
Jindal / Ratnamani / Maharashtra
Seamless / MJ Patel / Indian
Seamless / Gandhi Special Tubes /
BHEL
Jindal / Choksi Tubes / Ratnamani /
MJ Patel
Maharashtra Seamless / MJ Patel /
Gandhi Special Tubes / SAIL /
Jindal Saw / Ratnamani / Surya
Roshni / MAN / Wellspun
Hyd-air / Hyloc Hydoitechnic / MS
Fittings / NL Hazra / Project Tooling
Systems / Tube Bend / Parker /
AVIT / Zest Technologies
42
Pipes / Tubes Fittings
43
Clamps (Polypropylene
Clamp, U-Bolts)
Project Tooling Systems / Stauff /
Hydair
44
Hose with end fittings
Hydrokrimp / Indo-industrial /
Hydrolines / Superseals / Parker
45
Flanges
Echjay / NL Hazra / MS Fittings
46
SAE Flange
AVIT / Parker / Hyloc / Stauff
47
Electrical Heater
Escorts / Alco / Helios
48
Air Breathers
Internormen / Parker / Hydac
49
Portable Filter Unit
Internormen / Hydac / Rexroth /
© 2007 MECON Limited
All rights reserved
AREA
Preferred Makes
Page 36 of 37
Oil Lubrication /
Descaling
Hydraulics / Oil
Lubrication /
Descaling
Hydraulics / Oil
Lubrication /
Descaling
Hydraulics / Oil
Lubrication /
Descaling
Hydraulics / Oil
Lubrication /
Descaling
Hydraulics / Oil
Lubrication /
Descaling
Hydraulics
Hydraulics / Oil
Lubrication
Hydraulics / Oil
Lubrication
Hydraulics
GS-13
General Technical Specification
SL.
NO.
ITEM
MAKE
Parker
PALL / Hydac / Internorman /
Parker
50
Contamination Analysis Kit
51
Centrifuge
Alfa Laval / Westfalia
52
Vacuum Dehydrator
Filtervac / Pall / Parker / Nortek
53
Electrostatic Liquid Cleaner
Mobile Motorised PumpMotor-Filter Unit for Oil Filling
Chain Pulley Blocks & Hand
Operating Traveling Cranes
KLEENTEK / Ferrocare
PALL / Hydac / Internorman /
Parker
56
Spray Nozzles
Lechler / Spraying system
57
58
Nitrogen Booster Station
Water in Oil detector
59
Lubricating oil
60
Hydraulic oil
61
Flushing Oil
62
Grease
63
Expansion Joint
Hydac / Parker
IMA / Parker / UCC
Indian oil / HP / BP / Castrol / Mobil
Exxon
Indian oil / HP / BP / Castrol /
Mobile Exxon
Indian oil / HP / BP / Castrol /
Mobile Exxon
Indian oil / HP / BP / Castrol /
Balmer Lourie
ESBI / STANFLEX / ELAFLEX
54
55
© 2007 MECON Limited
All rights reserved
Batliboi / Moris / WH Brady & Co.
Preferred Makes
Page 37 of 37
AREA
Hydraulics
Hydraulics / Oil
Lubrication
Hydraulics / Oil
Lubrication
Hydraulics
Hydraulics / Oil
Lubrication
Hydraulics / Oil
Lubrication
Descaling / Gear
boxes
Hydraulics
GS-13
General Technical Specification
02.
GASES AND LIQUID FUELS
02.01.
REGULATIONS
The entire interplant and in shop pipelines shall conform to the provisions of relevant
Indian statutory regulations, wherever applicable, such as :
-
Indian Safety Rules
-
Static & Mobile Pressure Vessels Rules
-
Indian Petroleum Regulations
-
Indian Explosives Manual
-
The Carbide of Calcium Rules
-
Indian Boiler Regulations
The Contractor shall have to obtain clearance/ approval of all the relevant drawings/
documents from such statutory bodies.
02.02.
PIPING LAYOUT
General
Routing and layout of piping system shall be as per good engineering practice. Following
factors shall be taken into consideration while designing piping system.
•
•
•
•
•
•
All functional requirements shall be fully satisfied.
Adequate clearance is provided for equipment and operating personnel.
Easy access for operation and maintenance of piping component.
Convenient supporting points for piping, equipment, valves, etc.
Adequate flexibility for thermal expansion / movements.
Aesthetics and neat appearance.
Pipe Laying for Fuel Gases, Industrial Gases, Liquid Fuels, Compressed Air and
Steam
01.
The gas pipes installed along building wall should not cross window and door
way.
02.
While laying high pressure gas pipes along the walls, the later should be fireproof. In doing so, the gas pipes should be laid along solid walls or above the
windows of upper floors of plant buildings.
03.
When gas pipes are installed along external walls of buildings below window
ways, installation of flange, thread joints and also installation of accessories is
not allowed.
04.
Gas pipe may be laid along with pipes of water, steam, air, etc. and also with
oxygen on a common support provided conditions stipulated under various
clauses are followed.
05.
The following conditions shall be observed when installing gas pipes with other
pipes :
© 2007 MECON Limited
All rights reserved
Gases & Liquid Fluids
Page 1 of 51
GS-02
General Technical Specification
a)
Additional pipes on existing gas pipes will be allowed to be laid only
with the permission of concerned plant personnel.
b)
In each case, the gas pipes and supporting structures shall be checked
with due consideration for additional loads and practical state of the
metal structure of gas pipes.
c)
When installing with pipes carrying corrosive fluids they shall be kept at
least 500 mm below or by the side of the gas pipe at a distance of
500mm.
If flange joints are provided on pipes carrying corrosive liquids, it is
necessary to mount protective baffle plate against falling of corrosive
liquids on gas pipes and their supports.
d)
The associated gas pipes at the places on gas pipes where valves and
other devices are mounted, should be kept at a minimum 800 mm
distance from the main pipe.
e)
Drainage of the associate pipes should be laid to one side at a distance
so that condensate does not fall on gas pipes/ its accessories,
supporting structures and their elements, etc.
06.
The branch line should generally be installed outside building along roof wall.
Branch line having diameter less than 500 mm may be laid inside shop building.
07.
Branch line from gas main entering into building through building wall should
pass through casings. Internal clearance between casing and pipe should be
suitably filled up, wherever required.
08.
Gas branch line from gas main passing through roof covering should have
circular opening. For this purpose, a circular opening should be made on roof
and a taper hood should be provided on the branch line above the roof for
protection from rain.
09.
Shop headers (except headers of By-product Plant) should be mounted at a
height having minimum ground clearance of 4500 mm, when laying them outside
the building wall.
10.
Layout of gas consuming units in various shops
possible to bring the gas pipes above ground.
11.
Gas pipes of coke oven, natural gas and also their mixtures with blast furnace
gas may be installed in channels and casings, in the region of gas supply to
furnace and other consuming units.
should be such that it is
The following conditions should be observed for this purpose :
a)
Clearance between wall and bottom should be at least 400 mm, and for gas
pipes of 200 mm and below clearances should not be less than the gas pipe
diameter.
b)
Installation of flanges, threaded joints and accessories (except accessories for
removal of condensate on a pipeline) is not allowed when it is laid in a channel.
The number of welds on such gas pipes should be restricted to a minimum.
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Gases & Liquid Fluids
Page 2 of 51
GS-02
General Technical Specification
c)
Installation of gas pipes with air pipes to gas consumer units is allowed to be laid
in channels.
d)
Channels with gas pipes should not cross other channels, In case, it is
unavoidable, air tight tie-plate should be made and gas pipe should be placed in
casing. Ends of casing should be taken out beyond the limit of tie-plate by 300
mm at both ends.
e)
Channels should have provisions for natural ventilation.
12.
Gas pipes in buildings should be located at places convenient for servicing,
inspection and repair. It is not allowed to lay gas pipes at places where there are
chances of damage due to shop transport.
13.
For gas lines installed in hot zone, it is recommended to provide protection
against overheating of gas pipes.
14.
It is allowed to fasten gas pipes to frames of furnaces, boilers and other units
provided these frames are checked for strength by calculations.
15.
Gas pipes are not allowed to pass through buildings producing or having
materials liable to explode or burn and building of power distributing devices and
substations and ventilation chambers and through buildings, in which gas pipe
may be damaged by intensive corrosion.
16.
Gas pipes should not cross ventilation doors, air exhauster, flue pipes and also
gas pipes should not be installed in insufficiently ventilated space and in
underground buildings.
17.
Installation of high pressure gas pipes below main working platforms of shops is
not permitted.
18.
Gas pipes along bridges should be made of seamless pipe and laid in the open
at a horizontal distance of one metre from ends of pavements for passing of
people and it should be within reach for servicing. Supporting elements of the
bridge should be accordingly checked for loads from gas pipes. Laying of gas
pipes in channels of bridges is not allowed. All welding joints of gas pipes in the
area of their attachment to bridge should be radiographed.
19.
Gas pipes passing through walls, ceilings, and other structures of buildings of
construction shall be encased in a steel pipe having inside dia at least 50 mm
more than that of the oxygen pipe. The Gas pipe shall have no joints in the
section at such crossings. The gap between the gas pipe and the outer pipe
shall be filled with non/inflammable material, but allowing vertical and horizontal
movement.
20.
The laying of moist fuel gas pipelines shall be as per IPPS: 1-06-014-95
21
Pressure pipe work for gases and liquid fuels generally shall be routed
overhead. All overhead interplant pipe work to be routed such that they will have
a minimum clearance of 6.0m between bottom of supporting structures / pipes
and road / railway track. The pipelines laid over hot tracks shall have a minimum
clearance of 10.0m. In case, protective shields are used in these places, this
clearance may be reduced to 6.0m. Buried pipes, wherever laid, shall be
provided with a minimum earth covering of 1200mm in areas subject to
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Gases & Liquid Fluids
Page 3 of 51
GS-02
General Technical Specification
temporary loads and minimum earth covering of 1000mm in areas not subject to
temporary loads, unless otherwise specified.
22.
For the pipelines laid on roof, the distance from the external edge of the pipe to
the roof shall be at least 0.5m.
23.
All shop headers, except for gravity fluids, shall be generally routed along
columns in multiple rows at a height 4 to 6m above floor level. The connections
to equipment shall be taken through suitable covered floor trenches for shops at
ground floor and for basements, for elevated operating floors, the equipment
pipe work connection may be taken below the floor level. All isolated single pipe
connections to equipment shall be buried in the flooring / equipment foundations.
Pipe work from basement and oil cellars to main equipment shall be routed in
pipe tunnels / trenches with adequate spacing for easy maintenance. All pipe
trenches shall be covered by chequered plate or by concrete slabs.
24.
The bleeder pipes for purging lines and other exhaust pipe work shall be routed
upward along columns / gable ends and / or walls to a minimum height of
4,000mm above the roof level / platforms.
25.
For the gas pipelines laid along the building walls, the clearance between the
gas pipelines and the wall shall be adopted so as to ensure the possibility for
maintenance of the gas pipelines. The gas pipelines laid on the walls must not
cross the window and door openings.
26.
Branch pipes from the headers to the building through walls and the roof shall be
encased.
27.
Gas pipelines shall be earthed. When laid under the high voltage lines, a
protective sheet guarding shall be provided above the gas pipelines. The
guarding shall be earthed. The earthing resistance must be not over 10 ohm.
28.
Platforms, access ladders, hand railing, etc. shall be provided for operation and
maintenance of valves, instruments and controls. Manholes and hatches shall be
provided for access inside the gas pipelines.
29.
At all the places of regular maintenance (gate valves, throttle valves, orifice
plates, hatches, manholes, bleeders, etc.) if located at a height of over 2.5m
from the maintenance level, provision shall be made for stationary platforms with
the railings and stairs / ladders.
30.
To ensure the condensate drainage, the gas pipelines shall be laid with a
gradient of about 0.005 towards the water drains.
Condensate drains shall be equipped with bleeders.
Necessary water pipe work for condensate seal pot shall be provided.
31.
Flash back arrestors shall be provided in each section of the pipe work for
acetylene and LP gas to prevent flame propagation or pressure surges. They
may be of hydraulic / cartridge type flash back arrestors or back pressure valves.
32.
All branch pipes from main header shall be connected through a hydraulic
arrestor.
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Gases & Liquid Fluids
Page 4 of 51
GS-02
General Technical Specification
33.
Shut-off globe valves shall be provided on both the inlet and outlet sides of the
arrestor and unions shall be provided for repair or replacement, if required.
34.
Oxygen pipelines may be laid on either side of the fuel gas line as per the
following norms.
Oxygen Pressure in
Kg/cm2
Diameter of Oxygen
pipe mm
Permissible gap in
mm
Upto 0.1
Upto DN 500
300
Upto 0.1
Above 500
600
0.1 to 16
Upto 500
800
16 to 35
Upto 200
800
Continuous installation is not allowed if the oxygen pressure is more than 16 Kg/cm2 and
diameter of pipe is more than 200mm and also if the oxygen pressure is more than 35
2
Kg/cm for any size.
Minimum clearances of overhead oxygen pipelines (surface to surface)
i)
ii)
iii)
iv)
Explosion Hazardous shops
Railway tracks
Railway bridge and platform
Roads
:
:
:
:
3 meters clearance
3 meters
3 meters
1.5
meters
upto
embankment
v)
High voltage Transmission lines
A. Parallel to pipelines
B. Crossing the pipelines upto 20kv
35 to 150kv 220kv
:
:
:
10 meters
3meters
4 meters
:
:
:
10 meters
0.5 meters
1.0 meters.
vi)
vii)
02.03.
To place of hot metal tapping and
Source of open fire
Insulated L.T cables
Bare conductor L.T
DESIGN PARAMETERS
Design pressure for various categories of piping shall be as follows :
Low Pressure Fuel gas piping
( Up to 1500 mm WC MOP)
: 1.25 Times Maximum Operating
Pressure
: But not less than 2000 mmWC
All other gas piping
: 1.25 Times Maximum Operating
Pressure
Steam piping
: 1.5 times Maximum Operating
Pressure.
Design temperature for all fluids shall be maximum working temperature of fluid. In case
of ambient temperature, design temperature may be taken as 60 deg C for piping
exposed to sun and 45 deg C for indoor piping.
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Gases & Liquid Fluids
Page 5 of 51
GS-02
General Technical Specification
Flow rate for design purpose shall be taken as peak flow rate for the respective section.
In case of branches to individual consumers, peak flow rate for the consumers shall be
considered. For common branches and main headers, peak flow rate based on
consumption pattern/ diversity factor may be used for pipe sizing.
Future augmentation of flow rate for common piping shall also be taken into
consideration for pipe sizing.
02.04.
SELECTION OF PIPE SIZE
•
Pipelines shall be sized by limiting the gas velocity in the pipeline as per Table
02-01.
Peak flow rate based on the distribution pattern shall be considered for sizing of
pipes.
Sizing shall be based on actual flow rate at worst combination of parameters i.e.
lowest pressure and highest temperature.
In case recommended velocity is dependant on diameter range, after initial
sizing, velocity should be re-checked and if required size should be recalculated.
Nearest higher standard pipe size shall be selected after calculation.
•
•
•
•
For critical applications, pipe sizes should be re-checked after pressure drop calculations
and availability of required pressure at consumer point. If required pipe size may be
increased to meet the pressure drop criteria.
TABLE 02-01
RECOMMENDED VELOCITIES IN CARBON STEEL PIPES
A:
Sl.
No
1
2
3
4
5
6
7
Low Pressure Fuel Gases
Nominal Pipe
Dia – (mm)
20 – 80
100 - 250
300 – 500
600 – 800
900 – 1200
1300 – 2000
> 2000
Gas Velocity, m/sec (maximum)
CO Gas,
Mixed BF &
BF & BOF Gas
Natural Gas Corex Gas
2
2
2
3-4
4–5
4 –5
5-6
6–7
5–7
6–7
7–8
7-8
8 - 10
9 – 12
8 – 11
11 - 18
13 – 20
12 – 19
20 - 25
23 - 28
21 - 27
Remarks
B : Medium Pressure & High Pressure Gases
Medium
Nitrogen, Argon,
Compressed Air,
Instrument Air
Oxygen
LPG
Acetylene
Liquid Fuels
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Pressure Range
2
(kgf/cm g)
Up to 6
6 - 16
16 - 40
Up to 16
16 - 40
Up to 3
Up to 1.2
All Pressures
Gas Velocity, m/sec
(maximum)
8 –10
12 – 16
Up to 20
12
8
8
8
1.5
Gases & Liquid Fluids
Page 6 of 51
Remarks
See Note 1
See Note 2
Up to DN 25
GS-02
General Technical Specification
C : FOR STEAM
Sl.
No
1
2
3
4
5
Fluid Condition
SATURATED AT SUBATMOSPHERIC
PRESSURE
SATURATED AT 1 TO 7
2
Kgf/cm (g)
SATURATED ABOVE 7
Kgf/cm2 (g)
SUPERHEATED UPTO 7
2
Kgf/cm (g)
SUPERHEATED ABOVE
2
7 TO 35 Kgf/cm (g)
Average Velocity, m/sec
DN 50 to
DN 200mm
Up to
DN 50mm DN 150mm and above
10 – 15
15 – 20
15 – 22
20 – 33
25 – 43
15 – 25
20 – 35
30 – 50
20 – 30
25 – 40
30 – 50
20 - 33
28 – 43
35 - 55
Remarks
Steam piping network comes under the purview of IBR and thickness calculation shall be
carried-out as per stipulations indicated in IBR and approval of CIB shall be obtained.
02.05.
EXPANSION AND FLEXIBILITY.
All Pipe work shall be designed to provide sufficient flexibility against thermal expansion
to prevent development of undesirable forces and moments at points of connection to
equipment, at anchorage or at guide points.
As far as possible, flexibility shall be provided by planning route with change of direction
or by the use of bends, loops or off-sets.
Whenever self-compensation can not be achieved by pipe routing, provision for thermal
expansion shall be made by providing expansion loops or expansion joints as per
following criteria:
•
U loops shall be provided for all low pressure fuel gas piping up to DN 300 size
and high pressure piping for all sizes.
•
For high pressure piping, where U-loop is not possible, bellow type expansion
joint shall be provided. Bellow type compensators shall also be provided in low
pressure gas lines.
While locating the expansion joints following guidelines should be followed:
•
Bellow compensators should be located preferably in the center of two fixed
points.
•
U-Compensators should be located in between two fixed points with variation in
pipe lengths in the ratio of 1:2 (max).
•
Gland Compensators should be
smooth functioning.
•
Bellow and gland compensators shall have flanged connection with pipes
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located near the fixed supports to facilitate
Gases & Liquid Fluids
Page 7 of 51
GS-02
General Technical Specification
U-loop Compensator
U-loops shall be provided in piping system using elbows/ bends as per piping material
specification.
U-loops shall be in horizontal plane and loops for many pipes running in parallel may be
provided at same location parallel to each other.
Loops shall be in the same plane as the pipe route. However, in some cases, where
there may be obstruction due to other parallel pipes, U-loop plane may be raised to clear
the pipes by providing bends.
Loops in vertical plane can be provided in exceptional cases if horizontal loop is not
possible due to layout considerations. Provision shall be made in piping for draining of
condensate, venting, etc.
Bellow Compensator
Bellow type expansion joints shall be made from SS sheet and can be single or multi
layer with number of convolutions.
Loads due to Compensators
Loads on anchor points due to bellow compensators shall be considered based on the
feed back from supplier / manufacturer.
02.06.
VALVES AND MEASURING DEVICES
Valves shall be provided on pipe work for isolation of pipe sections and equipment,
control of pressure, flow and level of fluids, venting, draining, pressure relief, etc. They
shall be suitable for the service conditions in all respects and located suitably
considering ease of operation and maintenance. Generally the following practice shall be
followed;
-
Stop valves :
On all pipelines both at the sources and consumers also in the branch pipes to
individual buildings and shops with a nominal diameter of 100 mm and above (if
required, for smaller diameter as well).
-
Isolating and by-pass valves for flow meters, filters, etc.
-
Check valve on all pipelines requiring unidirectional flow.
-
Quick action safety shut-off valve on fuel oil, gas/ air lines to furnaces and
heaters as well as before each consumer or group of consumers.
-
Pressure regulating valves with isolating, by-pass and relief valves for all
pressure reducing installations.
-
Manual drain valves at low points and manual vent valves at all high points of
pipe work.
-
Regulating valves with integral pressure gauge for all oxygen outlet points, fuel
gas outlet, etc.
-
All valves shall be provided with the operating handle/ lever/ wrench within easy
reach. Where necessary, operating platforms shall be provided. Valves located
in inaccessible locations such as basements, tunnels, etc. Shall have remote
actuation by means of electric motors, solenoids, etc.
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GS-02
General Technical Specification
02.07.
-
For fluid lines with working pressures over 16 atg, valves of diameter 300 mm
and above shall be provided with by-pass arrangement, unless otherwise
specified in technical specifications.
-
Shut-off valves of dia 500 mm and above as well as shut-off valves of all
diameter with remote or automatic control shall be provided with electric drives.
-
To facilitate operation of manually operated valves, adequate gearing and
handling arrangement shall be provided, wherever necessary
-
All gas branch pipes from the in shop collector to the consumers shall be
provided with bleed valve arrangement comprising two gate valves in succession
with a bleeder in between. After the second gate valve (upstream), a provision
shall be made for installation of a blank flange.
-
Shop pipe work for all production and ancillary units shall have metering of flow
and pressure at the battery limits.
-
Sectionalising of pipe work for fuel gases such as coke oven gas, blast furnace
gas, mixed gas and converter gas will be provided to facilitate maintenance
work. This may be achieved by water seals, goggle valves, spectacle blinds or
patented gas tight isolators.
CONDENSATE DISPOSAL
Fuel gases as well as other gasses contain moisture and other condensable impurities
which get separated during fluid transportation through piping system, effective
condensate removal system should be incorporated to prevent accumulation of
condensate in pipes which otherwise may cause obstruction to proper gas flow and
excess live load to the pipe/ structure.
All piping for gasses containing moisture etc. like BF / Coke oven / BOF gas, Mixed gas,
Compressed air, Steam & Natural gas are laid with gradient / slope. A slope of 5mm per
meter run shall be provided for the above pipelines. In case of space constraint to
accommodate slope, it may be reduced to 0.003 particularly for in shop piping. For
straight length of pipeline, low / high points should be located generally at a distance 100
meters. However, in no case it should exceed 300 meters.
Condensate drain points shall be provided at all low points. In case of low pressure gas
lines, automatic drainage system though seal pots shall be provided.
For compressed air lines and steam lines, automatic condensate / steam traps shall be
provided.
Condensate Drain Arrangement for Low Pressure Gases
i)
Drainage shall be provided at all the low points of gas pipes carrying moist
gases for condensate removal. Disposal of condensate shall be through seal
pots/ condensate drain installations.
ii)
Distance between any two drain points of a gas pipe within a radius of 100
meters from gas cleaning plant should not exceed 60 meters.
iii)
Drainage system for outdoor gas networks should be located in open air with
necessary accessibility for operation.
iv)
Pipes for condensate removal from inter shop gas pipes of blast furnace gas in a
radius of 400 m from gas cleaning plant should be at least 80 mm diameter. For
pipelines beyond 400 m and also for gas pipes for other moist gases, diameter
of condensate removal pipes should not be less than 50 mm.
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Gases & Liquid Fluids
Page 9 of 51
GS-02
General Technical Specification
v)
Separate seal pots shall be provided for different gasses.
vi)
Removal of condensate from branch line from inter shop gas pipe and inshop
gas pipe should be carried out in separate condensate seal pots.
vii)
Minimum height of the water seal in the condensate seal pot shall exceed the
maximum working pressure of gas by 500 mm, but this height in no case shall
be lower than 2000 mm.
If necessary, the height of water seal can be increased by adding more than one
seal pot in series. However, number of such seal pots shall not exceed three.
Further base plate of seal pot shall have minimum thickness of 16 mm.
While installing common seal pot for a number of gas pipe, height of water seal
should exceed by 500 mm the maximum working pressure in any of the
connected gas pipe.
viii)
Design of condensate seal pots should ensure protection against leakage of
harmful gases into building by providing vent of adequate height on the seal pot.
ix)
Condensate seal pot shall be provided with purging facilities.
x)
Installation of condensate seal pot for in shop gas network is allowed inside the
buildings.
Condensate Drain Arrangement for Medium pressure High pressures gas
02.08.
i)
Condensate disposal for gases having higher line pressure have to be done by
using adequate pressure seal pots.
ii)
In a high pressure seal pot the metallic float is utilized for disposal of condensate
and prevent leakage of gas from the pot.
iii)
The seal pot should be air tight and wall thickness should be decided on the line
test pressure.
iv)
Condensate coming out of seal pot should be discharged into phenolic sewerage
line or in a reservoir provided locally.
STEAM TRAPS / MOISTURE TRAPSAt low points in steam & compressed air pipeline steam traps / moisture traps with
strainer assembly will be provided to drain out the condensate. Selection of steam trap
shall be as per IPSS: 1-06-039 – 02. Installation of steam traps shall be as per IPSS: 106-037
02.09.
PURGING SYSTEM
System for feeding purge gas and venting of gas/ air from the piping system shall be
provided for all fuel gas piping.
Purging
i)
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Gas pipelines of blast furnace gas, coke oven gas, converter gas and mixed gas
shall be equipped with nitrogen or steam pipe connection with isolation valve.
The connection of nitrogen or steam pipeline to the gas pipeline shall be done by
means of flexible hose which shall be connected only during the period of
purging.
Gases & Liquid Fluids
Page 10 of 51
GS-02
General Technical Specification
02.10.
ii)
Location of purge gas inlet points and vents shall be such that entire section of
piping can be purged with minimum dead space. Purging points shall be
provided at low points.
iii)
Purging points shall not in any case be provided at bottom half of the gas mains.
iv)
Purge points for fuel gas pipes up to DN 950 mm shall be of minimum DN 25
mm same for pipes of DN 1000 mm & above shall be of minimum DN 50 mm.
BLEEDERS/ VENTS
Bleeders shall be provided on all the gas handling devices and pipelines for purging and
venting any section of the gas pipeline. The purging bleeders of pipelines carrying
different fluids, separated by gate valves, are not allowed to be combined into one
bleeders. The bleeders shall be taken above the gas pipeline or above roof of the
building by at least 4 m, but not lower than 12 m from the ground level. Bleeders on shop
roofs shall be located away from roof monitors.
i)
Bleeder/vents shall be provided for purging / venting any section of the pipeline.
Bleeders shall be located generally at all high points in the piping system.
Bleeder / vents shall also be provided at down stream / upstream of isolating
devices & U-seals.
ii)
All vents shall discharge at a safe height into atmosphere. The vents shall be
above the operating floor / platform for vent valve or roof of the building 4m, but
not lower than 8 meters from the ground level. In the presence of the aeration
monitors on the roof of the building, the vents shall be located so as to eliminate
the possibility of purged gas getting inside the premises.
iii)
On straight lengths bleeder/vent shall generally be provided at an interval of 100
meters.
iv)
All vents shall have T piece/cowl with bird screen preferably at the top. For
isolation of bleeder/vent pipe flanged gate valve of rising stem type shall be
provided. Sampling points (DN 25) below isolation valve with lubricated taper
plug valve shall be provided in the line to monitor gas samples at the time of
purging.
v)
Vent pipes of different gases shall not be connected through a common vent.
vi)
Recommended sizes of bleeder / vent pipes corresponding to gas pipe diameter
are indicated in Table – 02.02.
Table –02.02
RECOMMENDED SIZES OF BLEEDER / VENT PIPES
DN
(mm)
20
25
40
50
65
80
100
150
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Bleeder pipe dia. DN (mm)
Low Pressure Fuel gas
Natural gas/Corex Gas
20
20
20
50
20
50
20
50
20
50
20
50
25
Gases & Liquid Fluids
Page 11 of 51
GS-02
General Technical Specification
DN
(mm)
200
250
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1800
2000
2200
2400
2500
2800
3000
3200
3500
02.11.
Bleeder pipe dia. DN (mm)
Low Pressure Fuel gas
Natural gas/Corex Gas
50
25
50
25
50
25
80
50
80
50
80
50
100
80
100
80
100
80
150
100
150
100
150
100
150
150
150
150
200
150
200
200
250
250
250
250
250
250
300
300
-
VALVES AND ISOLATING DEVICES
Isolating devices shall be provided in piping system for isolation of pipe sections as well
as for isolation of all other mounted accessories for the purpose of operation and
maintenance. They shall be suitable for the service conditions in all respects and located
suitably considering ease of operation and maintenance.
Isolation valves shall be provided at the following locations:
•
•
•
•
•
On all pipe lines both at the source and at consumer ends
On all branch pipes to individual buildings and shops
On all bleeder / vent pipes, purge gas inlet points, drain points, sampling
connections, etc.
On all by-pass lines for large valve, regulators, filters, moisture traps etc.
Instrumentation tapping points.
Selection of Isolating devices:
The gas cut-off arrangement shall ensure the possibility of complete cut-off gas along
with fast and safe operation. Gate valves with rising stem shall be used normally for
isolation in piping system.
Pipe work for fuel gases such as Blast Furnace Gas, Coke Oven Gas, Converter Gas,
Mixed Gas with low operating pressure shall have some means of gas tight isolation of
sections of the pipe work to facilitate maintenance work. These may be water seals,
goggle valves, spectacle blinds, or gas tight isolators / slide plate valves, etc.
Necessary water pipe work shall be provided for water seal.
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Gases & Liquid Fluids
Page 12 of 51
GS-02
General Technical Specification
For sections where the gas tight isolating device can not be provided, provision to insert
blind flange at outlet of gate valve shall be made.
Sectionalizing / isolation for purging of fuel gas lines may be done with Spectacle blinds.
Gas tight butterfly valves may be used for isolation near consumption points requiring
frequent and quick operation. These can be valves with gas tight seating or eccentric
valves for gas tight isolation.
Emergency quick shut off valves shall also be double eccentric butterfly valves.
For fluid lines with working pressure over 16 kg/cm2 (g), valves of DN 300 and above
shall be provided with by-pass arrangement or depressurisation arrangement for pipe
sections.
Selection of Actuators for Isolating devices:
Manually operated shut-off gate valves of size DN 300 to DN 450 for low pressure lines
shall have gear drive. For high pressure lines, gear operator shall be provided as per
manufacturer’s recommendations for limiting the operating torque to acceptable limits.
Gate Valves of size DN 500 and above shall be provided with electric actuators. Electric
actuators for fuel gas lines shall be of flame proof design if located in gas zone/in shop.
In the interplant area these actuators need not be flame proof. Position and torque limit
switches shall be provided on actuators. Manual over ride shall also be available in
actuators.
Goggle valves shall have electrical actuators for disc/ plate movement and electro
hydraulic drive for flange separation. Manual arrangement for valve operation shall also
be provided with gear and chain operation from convenient location. The hydraulic power
pack for the valve shall include one motorized pump and one manual pump. Encased
design goggle valve with vent shall be used at locations closed to buildings.
Electrically operated gate valves for gas pipelines of smaller diameter are recommended
to be used only if they are incorporated in the automation scheme.
All valves located remotely, requiring frequent operation and / or with automatic control
shall be provided with electric drives, electro- pneumatic drive, solenoids etc.
Check valves shall be used in piping system where unidirectional flow is required. For
small size pipes below DN 50, lift check valves shall be used. For DN 50 and above,
swing check valves or dual plate check valve shall be used. Lift check valves shall be
used only in horizontal pipeline. It should not be used in vertical pipeline. For low
pressure gas lines dual plate check valve will be used.
The Pressure Regulating valve shall be of globe / needle type, with material
specifications, dimensional standards etc. as per the relevant Piping Material
Specification (PMS) for the service for which the valve is intended.
001
For Compressed Air
Pressure regulators of sizes up to DN 50 shall be complete with a prefilter having 40
micron porous bronze filtering element in shatterproof plastic or glass container,
pressure regulator and pressure relief arrangement to prevent overpressure at
downstream of the regulator.
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General Technical Specification
For higher sizes to meet larger flow rates, the pressure regulator shall be self actuating
type as per manufacturer’s standards, but capable of meeting the service conditions and
duty specified.
002
For Steam
For sizes up to DN 50, pressure reducing valves of single seated diaphragm type having
in-built strainer, with screwed ends up to DN 20 for PN 10 and below and flanged ends
for higher sizes and for higher PN. Body of main and pilot valves shall be of carbon steel
/ alloy steel castings / forging, diaphragms shall be of stainless steel, internal springs of
stainless steel and pressure adjustment springs of spring steel.
For higher sizes to meet larger flow rates, the pressure reducing valves shall be as per
manufactures standards, but capable of meeting the service conditions and duty
specified.
003
For Other Gases
For dry air, nitrogen and argon the pressure reducing valves shall be of stainless steel.
For oxygen service, the valve shall be of bronze construction and shall be degreased and
cleaned to meet the service requirements.
For acetylene and LP gas services, the pressure regulators shall have material for the
service.
Pressure regulators for large diameter gas lines shall comprise butterfly type valves
actuated by means of an oil hydraulic control system, which is actuated in turn by
changes in the preset downstream pressure through impulse pipe work.
Pressure Relief Valves
These shall be spring loaded type and shall automatically open when the pressure on
the pipelines, on which they are mounted, exceed preset values. The valves shall have
end connections and materials specified for throttling valves in relevant PMS.
Relief / Safety valves for steam service shall have IBR certification. Relief valves shall
have hand wheel / wrench for adjustment of preset value of relief pressure.
Pressure relief valves shall always be used on outlet lines from the pressure reducing
valves. Pressure relief valves shall be designed for full flow rate from pressure
regulators. Set pressure shall be 10 % higher than the maximum working pressure at
outlet of regulator.
Filters
Filters will be installed in piping system before the pressure regulators/ control valves
and at consumer points depending on nature of fluid and technological requirements. For
small size pipes below DN 50, Y-type strainers with sintered/ wire mesh cartridge may be
used. For higher sizes, straight line mounted filters with removable cartridge shall be
used.
Filter element can be of wire mesh, sintered material, woven fibers or other suitable type
as per process requirement. Filtration area shall be at least 500% of the inlet cross
section area.
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Gases & Liquid Fluids
Page 14 of 51
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General Technical Specification
Safety Shut-Off Valves
These shall shut-off in case the pressure on the upstream side of the valve becomes
less than preset values. The valves shall be of globe type for DN 50 and below and
butterfly type for sizes above DN 50; the material shall be suitable for service conditions.
The valves shall be actuated by electromagnetic or pneumatic device working in
conjunction with pressure switches located on the pipelines being safeguarded and shall
include all components required for its functioning.
Electrical continuity
Metallic electro static jumpers shall be provided at all locations on all flanged
connections, in case of flammable gases and oxygen. This is to prevent accumulation of
static electricity in pipe sections. Piping system shall be suitably earthed at a regular
length of pipeline.
Measuring and control devices
Instrumentation and control devices shall be provided for monitoring the fluid distribution
system, regulation of pressure and flow.
Flow measurement shall be provided at battery limit of all production and consuming
units, inlet/ outlet piping of storage installations, on surplus gas bleeder piping to flare
system etc. When orifice plates are used, proper care shall be taken in piping layout for
preventing accumulation of condensate by providing suitable slope or drain system.
Requirement of straight length upstream and downstream of flow sensors shall be
maintained as per instrumentation requirements. Normally the straight length
recommended is 10 times pipe dia before inlet and 5 times pipe dia after outlet of device.
Pressure measurement shall be provided at battery limits of production and consumer
units, at outlet of storage systems, inlet and outlet of pressure regulators/ controllers, etc.
Pressure and Flow Control valves shall be provided at gas mixing stations, main
pressure regulating stations, flare stack piping, inlet/ outlet piping of storage installations
(gas holders). For low pressure gas lines, butterfly type control valves shall be used. For
high pressure gases, globe valves may be used. Sizing of control valves shall be based
on flow rate and pressure parameters.
02.12.
HOSES & HOSE BOXES
General purpose oxygen and propane shall be provided with necessary isolating valves,
pressure control valves, Hoses & Hose boxes at each consumer points. Nipples along
with quick coupling hoses shall be provided for steam, compressed air and Nitrogen for
purging and other needs.
02.13.
SPECIAL CONSIDERATIONS FOR OXYGEN PIPING
Filters should be installed in the oxygen pipeline system at the following points:
a)
At the outlet of the oxygen plant.
b)
Upstream of components having soft seating in contact with the oxygen stream e.g.
pressure regulator and control valves.
Upstream of components that have moving parts in contract with the oxygen stream e.g.
flow measuring and limiting devices.
c)
Provision shall be made for safe and easy access for frequent cleaning and / or
replacement of the filter element. The larger capacity filters like (a) above should be
provided with differential pressure gauge for monitoring the condition and providing
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Page 15 of 51
GS-02
General Technical Specification
indication for cleaning / replacement of the filter element. The filter bodies shall
preferably be of copper alloy or stainless steel and filter element of copper alloy or glass
cloth suitably earthed to the filter body with copper wires.
Two (2) or more pressure relief valves should be provided downstream of each set of
pressure reducing valves. One or more main relief valve(s) should be capable of
discharging 100% of the full oxygen flow and limiting the pressure within the defined
limits. The secondary relief valve should be sized to discharge the nominal leakage from
the pressure reducing valves. The relief valves should be positioned as close as possible
to the pressure reducing valves. The vent lines from the relief valves should be
preferably of stainless steel or copper.
Consideration should be given for providing small size pressure equalisation bypass
isolation valves across large diameter isolation valves in large pipeline systems so as to
ensure safe pressurization of the downstream pipeline. The bypass pipe work and valve
should be of copper or copper alloy.
Fire break sections may be installed in the oxygen pipeline to limit the propagation of
combustion in a steel pipeline. Fire break sections may be introduced immediately
downstream of the main isolation and throttling valves where the velocities can be high.
The fire break section will be either a length of copper pipe having the same inside
diameter as the main pipe with flanges fitted at the two ends which is installed between
the steel pipes or a copper insert tube made from copper sheet / tube and inserted inside
the steel pipe downstream of the valves. The copper insert tube is generally used in
large diameter steel pipelines.
In steel pipelines, care should be taken to install isolation valves on straight sections of
the pipeline. Any pipeline component which is likely to cause a change in the flow
pattern, like reducer, bend, tee or “Y” connection, orifice plate etc., should be at a
distance of at least four diameters away from the valve.
For cleaning of the gaseous oxygen pipelines after erection, provision for “pigging” will
be provided for pipelines having diameters upto DN 200. However, if the pipeline is
pickled and phosphated as per approved procedure, pigging of pipelines is not essential.
The bends on these pipelines will have a radius of 5 DN. Extra care will be taken
regarding cleanliness of large dia. pipeline (DN 250 and above) during installation. The
bends for the larger dia. Pipes will have a radius of 3 DN.
Gaseous oxygen pipe work shall preferably have butt welded pipe joints. To reduce
safety hazards the number of components should be kept to a minimum compatible with
the system requirements. Flange joints shall be used only for connection of the pipe to
the system components on the pipe work. Threaded joints and couplings should be
sparingly used.
02.14.
DESIGN CONSIDERATIONS
Piping system shall be designed with high degree of reliability so that the systems
perform the duty of fluid handling without structural or functional failure under most
adverse condition of plant operation. All piping systems shall be designed with sufficient
corrosion and stress margins to ensure a life time without failure, not less than the life of
the plant. 7000 complete cycle of operation shall be considered for stress analysis
purpose. Piping system shall not impose reactions on equipment terminals exceeding
permissible limits even under adverse operating conditions. Personnel injury from
discharge of hot fluids from drains, steam traps, hot pipes or exposures to pipe vibrations
shall be guarded against.
Piping coming under the purview of Indian Boiler Regulations (IBR) shall be
designed in accordance with such regulations. The design criteria of piping coming
under the purview of IBR shall have to be approved by "Chief Inspector of Boilers"
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General Technical Specification
of the respective State prior to manufacture. All welding procedures, stress
relieving procedures, inspection / testing / certificates and all other records shall
have to be approved by Chief Inspector of Boilers in approved form.
Pipes having nominal bore less than 15 mm, shall not be used. Design pressure of
steam and all other service pipelines shall be considered as 1.2 times the
2
maximum expected pressure. However it shall not be less than 4.0 kg/cm gauge
2
for steam services and 3.5 kg/cm gauge for other services.
Design temperature for steam services shall be as pr IBR and for other pipelines
shall be 5 deg. above the maximum sustained service temperature expected.
All the piping coming under the purview of IBR, shall be designed with the
allowable design stresses as per IBR. For all other piping, the allowable design
stress shall not be more than that specified in ANSI B 31.1 or BS:806 latest
revision. Pipe thickness of all pipeline shall be taken as per the pipe thickness
schedules. The design and stress analysis shall take into account the effect of
internal/external pressures, thermal expansion, self weight of piping, support
reactions, shock due to relieving devices, surge and water hammer, earth quake
and wind effect, noise and vibrations, corrosion and erosion etc. and any other
effects dictated by recommended engineering practices.
Adequate flexibility shall be provided in the pipelines to keep stress and reactions
in the system arising due to thermal expansion or other effects within limits. Where
the piping terminates at an equipment or at the terminal point of a system, the
reactions and thermal movement imposed by piping on the equipment or the
system concerned shall be well within the limits specified.
The flexibility analysis of steam, condensate and hot service media pipelines shall
be furnished.
01. Pipes shall be sized for minimum pressure drops and considering the velocity limitation
for various types of fluids.
02. Adequate flexibility shall be provided in the pipelines to keep stresses and reactions in
the system arising due to thermal expansion or other effects within limits. Where the
piping terminates at an equipment or at the terminal point of a system, the reactions and
thermal movement imposed by piping on the equipment or the system concerned shall
be well within the limits specified.
03. If cold springing of pipeline is used, care shall be taken in determining the location and
amount of cold spring gap. Cold spring gap shall be located at points where the bending
and torsional moments are minimum. Use of cold spring gaps less than 10mm shall not
be acceptable and cold spring gaps above 100mm shall be avoided. All outdoor piping
0
exposed to sunlight carrying fluid at a temperature less than 80 C shall be designed
0
considering thermal expansion corresponding to 80 C and empty pipe as one of the
operating conditions although not necessarily the worst.
04. All piping shall have butt welded connections with minimum of flanged joints for
connection to vessels and equipment to facilitate erection and maintenance. All high
pressure steam valves and accessories shall have welded connections. Standard fittings
shall be used wherever practicable. Unless otherwise specified, for all welded lines with
0
pressure above 4 kg/cm2 g and / or temperature above 200 C, branch connections with
branch sizes upto 25% of welded mains shall be made with special forged steel welded
fittings.
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General Technical Specification
05. Bends for pipes for oxygen service shall have a radius of not less than three times the
nominal pipe dia unless otherwise specified.
06. In general pipes having size 50mm and above, shall be joined by butt welding and 40mm
& below by socket welding / screwed connection. Threaded joints shall have to be seal
welded except for galvanized pipes where teflon sealing tapes shall be used. For
galvanized pipeline, pipe joints which are to be made before galvanising shall be of
welding type. Those joints which are to be made after galvanising shall be either flanged
or screwed type. As far as practicable, whole fabricated piping assemblies shall be
galvanized at a time in order to minimize the number of joints to be made after
galvanising.
07. All pipelines shall be provided with drain connections, generally at the lowest point for
removing accumulated condensate or water and line draining. The drain piping shall
have drain pockets and isolation valves. Trap stations shall be provided where
necessary. Lines shall be given proper slope towards the drain points.
08 Piping coming under the purview of Indian Boiler Regulations (IBR) shall be designed in
accordance with such regulations. The design criteria of piping coming under the purview
of IBR shall have to be approved by "Chief Inspector of Boilers" of the respective State
prior to manufacture. All welding procedures, stress relieving procedures, inspection /
testing / certificates and all other records shall have to be approved by Chief Inspector of
Boilers in approved form.
09 Pipes having nominal bore less than 15 mm, shall not be used. Design pressure of steam
and all other service pipelines shall be considered as 1.2 times the maximum expected
pressure. However it shall not be less than 4.0 kg/cm2 gauge for steam services and 3.5
2
kg/cm gauge for other services. Design temperature for steam services shall be as pr
IBR and for other pipelines shall be 5 deg. above the maximum sustained service
temperature expected.
10 All the piping coming under the purview of IBR, shall be designed with the allowable
design stresses as per IBR. For all other piping, the allowable design stress shall not be
more than that specified in ANSI B 31.1 or BS:806 latest revision. Pipe thickness of all
pipeline shall be taken as per the pipe thickness schedules. The design and stress
analysis shall take into account the effect of internal/external pressures, thermal
expansion, self weight of piping, support reactions, shock due to relieving devices, surge
and water hammer, earth quake and wind effect, noise and vibrations, corrosion and
erosion etc. and any other effects dictated by recommended engineering practices.
11 Adequate flexibility shall be provided in the pipelines to keep stress and reactions in the
system arising due to thermal expansion or other effects within limits. Where the piping
terminates at an equipment or at the terminal point of a system, the reactions and
thermal movement imposed by piping on the equipment or the system concerned shall
be well within the limits specified.
12 The flexibility analysis of steam, condensate and hot service media pipelines shall be
furnished.
02.15
PIPE SUPPORTS, ANCHORS, RESTRAINTS
-
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In general pipe supports, restraints, braces or anchors shall be located at those
points in the building or outdoor where provision has been made for the loads
imposed. Loads at the supporting points or restraints shall be determined
sufficiently early and provisions shall be made in the building or outdoor structures
for pipe supports. The Tenderer shall locate, design, supply and erect all the
Gases & Liquid Fluids
Page 18 of 51
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General Technical Specification
supplementary steel structures to properly secure and support all pipe hangers,
supports, restraints, etc.
-
Provision shall be made for support of piping which may be disconnected during
maintenance work. All large pipes and all long pipes shall have at least two
supports each arranged in such a way that any length of piping or valve may be
removed without any additional supports being required.
-
Supports, guides and anchors shall be so designed that excessive heat is not
transmitted to the building steel. Supporting steel shall be of structural quality.
Perforated, strap, wire or chain shall not be used. Support components shall be
connected to support steel by welding, bolting or clamps. Bolt holes shall be drilled
and not gas cut. Structural steel work for supporting shall be designed on the basis
of a maximum design stress of 1265 kg/cm2. Pipe attachments coming in direct
0
contact with pipes having surface temperature above 400 C shall be made of alloy
steel. Use of insulating materials like asbestos between pipe clamp and pipe
surface to meet the above temperature limitation shall not be permitted. The
maximum spacing between two consecutive supports shall be not more than as
specified. Pipe hangers and supports shall be capable of supporting the pipelines
under all conditions of operation. They shall be capable of supporting the pipelines
under all conditions of operation. They shall allow expansion and contraction
without over stressing the piping system or overloading the terminal equipment due
to variation in supporting effort. Rigid supports or hangers shall be permitted only
for pipes with small movements. For hot lines, spring hangers shall be used. The
maximum permissible load variation on the terminals of sensitive equipment
between hot and cold conditions shall be limited to 6%. Variability in load between
hot and cold conditions expressed as a percentage of the design load shall be
taken as the criteria for spring selection for spring hangers. Variable spring hanger
shall be set at cold conditions so that they take design load under operating
condition after the designed thermal expansion has taken place.
Spring shall be encased in suitable cages and the hangers shall be provided with
spring locking arrangement, external load and movement indicator and turn buckles
for load adjustment. All the rigid hangers shall be provided with turn buckles for
vertical length adjustments. Hanger rods shall be subjected and designed for tensile
loads. At locations of high axial or lateral movement, suitable arrangement shall be
0
provided to permit the swing. The swing from vertical position shall be within 4 .
Double nuts and locknuts shall be used for hanger rods and bolts in all cases.
Hangers shall be designed so that they can not become disengaged by
movements of supported pipe.
-
The supporting structures at each support points shall be designed for the highest
of the following loads to take into account the extra load during hydraulic testing.
-
1.25 times the maximum load under operating condition
-
Weight of pipelines full of water (combined weight of pipe, insulation, valve
attachment etc. plus weight of water)
-
Weight of pipeline full of water as above plus any cold reaction as anticipated.
-
Where the piping system is subjected to shock loads such as thrust imposed by the
actuation of safety valves, hanger design shall include provision of shock absorbing
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General Technical Specification
devices of approved design. Vibration control devices shall be part of piping system
design.
Outdoor piping shall be designed with due consideration to expansion resulting from
exposure to sunlight and care shall be taken to prevent progressive movement of
long pipelines. Outdoor piping may be supported on shoes, saddles or steel
sections. Effect of support friction especially for large dia pipelines shall be
considered and friction forces minimized by suitable arrangement. Piping inside the
trenches shall be supported at intervals on steel sections and the arrangement shall
permit easy maintenance.
-
02.16
VALVES AND SPECIALTIES
-
All valves shall be of approved make and type. All valves shall be suitable for service
condition i.e. flow, pressure and temperature under which they are required to
operate. The valves for high and medium steam service shall have butt welded ends
unless otherwise approved and the internal dia shall be same as that of the pipes to
be joined.
-
All gate/ sluice, globe and needle valve shall be fitted with outside screwed spindles
and bolted type glands and covers. Spindle glands shall be of the bridge type
construction and screwed glands will not be accepted. All high pressure valves
having nominal dia more than 150mm, shall have integral steam bypasses concede
to the valve body by means of welded joints.
-
All gate/sluice, globe and needle valve shall be provided with hand wheel and
position indicator. The face of each hand wheel shall be clearly marked with words
“open” and “shut” with arrows to indicate the direction of rotation to which each
refers. Arrangement limiting the travel of any valve in the “open” or “shut” position
shall be provided exterior to the valve body. All globe valves shall be designed to
prevent erosion of valve seats when the valves are operated partially opened. Valves
which cannot be operated from the floor or walkways, shall be provided with suitable
extension rods and linkages to facilitate operation from the floor or walkways. Chain
operation will not be accepted for steam valves. Stems shall preferably be arranged
vertically with gland at the top. In no circumstances must the gland be at the bottom.
Valves shall not be installed in an inverted position. The design of valves shall be
such that it will permit packing of glands under pressure. Where required, valve
spindles shall be extended so that the hand wheel is at a height of about 1.0m above
the level of the floor or platform from where the valves are to be operated. Where
required, they shall be provided with head stocks and pedestals of rigid construction
and where gears or bevel wheels are used, these shall be of cast steel or suitable
grade cast iron with machine cut teeth.
-
Non return valves on all pumps discharges and steam line shall be of an approved
non slamming type. Draining arrangement shall be made on both sides of the
horizontal non-return valve where such a valve adjoins an isolating valve. Valve
bodies shall be provided with removable access cover to enable the internal parts to
be examined without removing the valves. Valves shall have a permanent “arrow”
inscription on its body to indicate direction of flow.
-
Gate sluice valves for low pressure service shall be outside screw rising spindle
type. For these valves wherever necessary, chain operator shall be provided to
operate the valve from the floor or walkways. Larger size gate valves for low
pressure applications shall be provided with bypass and draining arrangement and
valves with dia more than 350mm shall be provided with gear operator.
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General Technical Specification
02.17
-
Valves in corrosive service shall be diaphragm or rubber lined type. Diaphragm shall
be of reinforced rubber and rubber lining of body shall have minimum thickness of
3mm. Generally plug valves shall be used in compressed air line. Plug valves shall
be supplied with wrench operator. Valves shall be of taper plug type.
-
For motor operated valve, a 415V, 3 phase, 50Hz reversible speed motor shall be
furnished. Motor shall be capable of producing not less than 1.5 times the required
operator torque. Each operator shall be equipped with two adjustable limit and
torque switch for both open and closed position. The motor shall be of high torque
low starting current. Each operator shall be provided with auxiliary hand wheel for
manual operation. The hand wheel shall automatically disengage when the operator
is energized.
-
Manual operator shall be of worm and gear type, having permanently lubricated,
totally enclosed gearing with hand wheel diameter and gear ratio designed to meet
the required operating torque. The operator shall be designed to hold the disc in any
intermediate position between full opened & full closed without creeping and
fluttering. Adjustable stop shall be built into the operator to prevent over travel in
either direction. Operator shall be equipped with direct coupled position indicator and
suitable locking device.
-
Pressure reducing valves shall be perfectly stable, quiet and vibration less in
operation when reducing the pressure for any throughput up to maximum and shall
be suitable for continuous use at operating temperature. Valves shall be designed to
prevent erosion of the valve seats. Safety valves shall be direct spring loaded type
and shall have a tight, positive and precision closing. All the safety valves shall be
provided with manual lifting lever. Valves used for compressible fluids shall be of pop
type. Safety valve shall be so constructed and adjusted to permit the fluid to escape
without increasing the pressure beyond 10% above the set blow off pressure. Valve
shall reset at a pressure not less than 2.5% and more than 5% of the set pressure.
-
The seat and disc of safety valves shall be of suitable material to resist erosion. The
seat of valves shall be fastened to the body of valve in such away that there is no
possibility of seat lifting.
FABRICATION AND INSTALLATION OF PIPE WORK
-
Pipe joints shall be assembled with the inside of all pipes and fittings smooth, clean
and free from burrs, scale, welding slag, sand and dirt. The inside edges of pipe and
tubing shall be reamed after cutting to remove burrs. Screw threads shall conform to
ANSI B 2.1 for taper pipe threads. All the threaded joints shall be made up with a
lubricant or compound suitable for the service under which the piping is to be used.
-
Welded joints shall conform to “Code for pressure piping ANSI B31 1.0 (power
piping) or approved equivalent, except where the welding of such joints is covered by
other code requirements such as IBR, ASME pressure vessel and boiler code or
approved equivalent.
-
Branches shall, in general, be formed by welding standard fittings. Pipe bends and
tees shall be truly cylindrical and of uniform sections. Where permitted for certain
services, elbows or branch connections may be formed from steel pipe. Unless
otherwise agreed, slip-on welding flanges shall be used on pipe and for connection
to low pressure equipment. Weld neck flanges shall be used for butt welding fittings
as elbows, tees and reducers and for connection to high pressure equipment. Where
class 125 ANSI flanges are bolted to 150 ANSI steel fittings, the 1.5mm raised face
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General Technical Specification
on the steel flange shall be removed. When bolting such flanges, a full face gasket
shall be used. Equipment terminal flanges, if consist of a different standard, a
suitable companion flange shall have to be provided at the connecting points.
02.18
-
Flange drilling shall straddle the natural centre line of pipe. Faces of all flanges shall
0
be 90 to the longitudinal axis of the pipe to which they are attached. Slip-on flange
when used, shall be welded in accordance with ANSI B31.1 or any other equivalent
code. If distorted after welding, the flange shall be refaced. In all cases, flange faces,
must be free from particles of weld metal. The flange face and the pipe projecting
end shall then be machined to permit both pipe and flange to bear against.
-
All welding by the electric arc and gas welding process for pipe joints and fabrication
shall be done by qualified welders and done according to appropriate IBR, ANSI
code / regulations as applicable for welding, subject to accompanying code
regulations and standards for filler metal, pressure, temperature and fluid carried.
The ends of pipe and welding fittings shall be beveled according to the details shown
in ANSI B31.1 or equivalent. All welds shall be made in such a manner that complete
fusion and penetration are obtained without an excessive amount of filler metal
beyond the root area. The reinforcement shall be applied in such a manner that it will
have a smooth contour merging gradually with the surface of adjacent pipe and
welded fittings.
THERMAL INSULATION OF PIPELINES
Thermal Insulation
The tenderer shall furnish heat insulation for all necessary equipment and piping to
efficiently prevent abnormal heat loss from all exposed parts to limit surface temperature
within 60 deg.C. Resin bonded mineral wool/slag wool, fiber glass, asbestos ropes and
preformed pipe sections, mats/mattresses form of insulation conforming to
IS:8183/IS:9842/IS:7413 will be acceptable. However, the grades shall be selected
considering respective temperature. In case of using loose insulation, proper care shall
be taken at site to get recommended density. Packing density of the insulation wool shall
be 150 kg/m3.
Insulated surface of all equipment, piping, valves and fittings shall be covered with
aluminium sheet of 22 SWG (0.8 mm thick) held in place by self tapping screws of nickel
plated type. Apart from the screw, joints shall be further sealed with a suitable sealing
compound. All fastening materials such as clips, wires for field weld to the equipment,
galvanised wire mesh, metal corner bead shall be provided. Where valves, pipes fittings,
flanges, etc. occur, a clear space between end of covering and flange shall be left of
sufficient length, to permit withdrawal of flange bolts without interference. Ends of the
covering at those joints shall be leveled from the outside covering to the pipe and sealed.
Flanges, valves bonnet, end flanges and fittings shall be effectively insulated.
Valve & flange insulation covers shall be made in two halves so that these may be
removed/refitted readily without interfering with the adjacent covering.
Protrusions through the insulation which themselves do not require insulation
such as pipe clamps, supports, small piping, instrument take-offs, etc. shall be
covered to the same thickness as the adjacent insulation and be tightly sealed
except at hanger rods. Ample provision shall be made to prevent damage of
insulation due to thermal movement of the pipe or equipment. All the services to
be insulated shall be cleaned of all foreign materials such as scale, rust and paint
by use of steel wire brushes and steel scrapers. Anti corrosion painting (primer
coat) shall be applied on hot surfaces before application of insulation
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General Technical Specification
Thickness of Insulation
Table for Insulation thickness
Pipe size
Insulation thickness in mm for various temperature ranges
(outside dia)
1000C and
below
Between
101 and
0
200 C
Between
201 and
0
300 C
Between
301 and
0
400 C
Between
401 and
0
500 C
Above
5000C
Upto DN
50mm
25
50
50
75
100
100
DN 65 to DN
100mm
25
50
75
100
125
125
DN 125 &
DN 150mm
50
75
75
100
125
150
DN 200 mm
50
75
75
125
125
150
DN 250 mm
50
75
100
125
150
150
DN 300 mm
50
75
100
125
150
150
Pipe size
(outside dia)
Note:
The metallic jacket over the insulation shall be galvanized steel sheet conforming to IS:
277 with following thicknesses:
02.19
Pipe sizes up to 300 mm OD
Pipe sizes up to 300 mm OD
equipment, flanges, valves
:
0.63 mm
:
0.80 mm
LOAD CALCULATIONS AND FLEXIBILITY ANALYSIS
Load Calculations
Loads from the piping system are transferred to the pipe supports and connected
equipment. Depending on the direction of application, loads shall be calculated under
two major heads :
•
•
Vertical Loads
Horizontal Loads
Vertical load shall comprise of the following :
-
Platforms
Condensate collected in pipeline
Dust deposition on pipeline
Valves, compensators & fittings
Supports, ladders, etc.
2
-
Live load on platform shall be taken as 500 kg/m
-
Platform shall be provided at the following locations :
•
Location of valves
•
Location of compensators
© 2007 MECON Limited
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Gases & Liquid Fluids
Page 23 of 51
GS-02
General Technical Specification
•
Location of condensate drain installation
•
Water seals and tanks for water seals
•
Purging and vent connections
•
Manholes
•
Instruments
Following norms shall be followed for calculating the condensate load of gas mains:
Sl.
No.
Pipe Dia
(mm)
Height of filling of pipe
cross-section with
condensate (mm)
Filling in cross –
section (%)
1.
Upto 500
Full
100
2.
600 – 1400
500
88 – 35
3.
15oo and above
500 - 800
30 - 14
Condensate drain installation shall be located at approximately every 100 m length of the
pipeline.
Load due to dust deposition shall be as follows:
-
50 Kg per m2 area on pipelines at a distance within 100 m from blast furnaces.
-
25 Kg per sq metre area on pipelines at a distance between 100 to 500 from
blast furnaces.
Horizontal load along the axis of the pipeline shall comprise the following:
-
Load due to thermal expansion
-
Load due to internal gas pressure
-
Load due to friction (sliding of pipes on supports)
Horizontal load transverse to the axis of the pipelines shall comprise the following:
-
Load due to wind pressure
-
Load due to component of gas pressure at branch connections
-
Load due to component of force arising from thermal expansion or at change of
axis in plan.
For calculating load due to thermal expansion the co-efficient of linear expansion for mild
steel shall be taken as 0.012 mm/deg.c/ m.
Internal gas pressure for coke oven and blast furnace gas shall be taken as 2000
mmWC (g) (Test pressure for the gas pipeline).
Co-efficient of friction for steel to steel shall be taken as follows:
Sliding support : 0.30
Roller support
: 0.10
Ball support
: 0.10
IS:875 shall be applicable for calculating the wind load on the stockades.
IS:1873 shall be applicable for calculating seismic load.
© 2007 MECON Limited
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Gases & Liquid Fluids
Page 24 of 51
GS-02
General Technical Specification
-
The pipeline stockades shall be designed to take all vertical (dead) as well as
horizontal loads.
-
20% extra load (vertical and horizontal) shall be considered for the design of
structural and civil work to accommodate future pipeline on the stockades.
Horizontal loads due to thermal expansion, internal pressure and friction shall be
calculated by carrying out flexibility analysis on individual pipe. However, wherever
possible, standard software package like CEASER-II may be used for carrying out
flexibility analysis and calculations of loads transmitted to supports and nozzles of
equipment to which piping is connected.
02.20
LOCATION OF PIPE SUPPORTS
Supports for pipes shall be provided based on pipe layout. The unsupported span of
pipeline between two supports shall be calculated on the following basis;
I)
Maximum deflection in the span should not exceed 1/600 of length of the span.
II)
Maximum stress in pipe should not exceed the limit as per design codes.
III)
Maximum permissible spans are indicated below:
Maximum permissible spacing between pipe supports
Nominal Pipe size,
mm
Maximum span for
Liquid service, m
Maximum span for
other services, m
25
2.0
2.5
40
2.5
3.0
50
3.0
4.0
65
3.5
4.0
80
5.0
4.5
100
5.0
4.5
150
5.0
6.5
200
6.0
7.0
300
7.0
9.0
500
-
13.5
600
-
15
1000
-
18
1500 and above
-
24
In specific cases where span between two supports can not be provided as per the table,
alternative arrangement for intermediate support using bridge between trestles or guy
© 2007 MECON Limited
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Gases & Liquid Fluids
Page 25 of 51
GS-02
General Technical Specification
rope supports may be considered. In exceptional cases where distance exceeds the
limiting span, suitable stiffening of pipe section to prevent sagging may be considered.
At sliding supports pipe saddle shall be allowed to rest on bearing plate for free
movement. In case U-clamps are provided, clearance shall be maintained for pipe
movement by providing two nuts on opposite sides.
All intermediate supports shall be of sliding type. Anchor supports shall be located based
on piping configuration and layout to provide adequate flexibility.
Distance between two consecutive fixed supports in straight runs of pipe route should be
approx 70 m. However, in special cases it may go up-to 100 m (max.). In no case it
should exceed 100 m.
However, for steam pipeline it should be limited to 60 m. For pipe dia. above 100 mm
cold pull if any during erection may be given as per instructions of the respective
drawings.
To reduce friction force transmitted to supports, roller supports or anti friction pad
supports can also be used.
02.21
FLEXIBILITY ANALYSIS
Piping
arrangement shall provide for flexibility of lines to take care of the thermal
expansion, contraction and equipment settlement. Large reactions or moments at
equipment connections shall be avoided . Expansion computation shall be made on the
basis of a base temperature of 21.1deg C (70 deg F) and shall cover ( +ve, or –ve )
design temperature(s) as given.
i)
Flexibility analysis shall meet the requirement of Code ASME B-31.3 (Latest
Edition). Analysis shall consider stress intensification factors as per ASME
B31.3.
ii)
Lines which shall be subjected to steam out conditions, shall be designed and
analyzed at low –pressure steam design temperature of line whichever is more.
Lines having negative design temperature shall be analyzed for both conditions
separately.
iii)
Flexibility Analysis of lines shall be carried out using simplified methods or a
comprehensive computer program. Comprehensive computer analysis shall be
carried out for the piping for lines connected to equipment like vessels, pumps,
filters, furnace, compressors or other strain sensitive equipment. The result of
the analysis must satisfy the allowable loading on the nozzles of such
equipment.
iv)
Piping shall be adequately supported for the weight of piping, water, attached
unsupported components, wind, seismic, insulation and any other applicable
forces. Care should be taken that these supports are adequate to prevent
excessive stress, load or moments in either the piping or terminal nozzles of the
equipment to which it is connected. Adequacy of supporting of lines having
heavy valves shall be checked. The support shall be indicated in the piping
General Arrangement Drawings and Isometrics as applicable.
v)
Safety valve manifolds and downstream of control valves shall be adequately
supported to avoid vibrations.
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Gases & Liquid Fluids
Page 26 of 51
GS-02
General Technical Specification
vi)
The following factors shall be considered in the stress analysis
-
vii)
Friction for lines >= 8” NB ; @ steel to steel = 0.3: ( Sliding friction), @ steel
to Steel =0.1
(Rolling friction),
Corrosion Allowance.
Initial displacement of nozzles at design temperature(s).
Transverse deflections =25 mm( maximum)
Longitudinal expansion/contraction = 200 mm (maximum) Special care to be
taken to check for expansion loops and shoe support lengths shall be
finalized accordingly.
The following shall always be analyzed using comprehensive computer analysis:
a)
b)
c)
d)
e)
All lines 4” and above and Design Temp.> 300 deg. C.
All lines 8” and above and Design Temp. > 150 deg. C.
Al l lines 16” and above and Design Temp. > 80 deg. C.
All lines 6” and above and Design Temp. > deg. 65 C that are connected
to rotating Equipment, Air Coolers or any other sensitive equipment.
Any other system/line that stress engineer feels necessary for stress
check.
The report shall comprise of the following:
-
Basic input data and calculated conditions.
Layout isometric and supports configuration.
Load cases and calculated member stresses.
Forces, moments and displacements reports.
Spring hangers design parameters.
Allowable Stress Range.
Additional requirements ( reinforcement pad etc.)
WIND LOAD CALCULATION
Wind pressure shall be taken as per IS : 875. In cyclone prone areas maximum wind
pressure due to cyclonic wind pressure shall be taken.
In case of multiple pipes, for each tier of pipes, largest pipe may be considered for
calculating wind load.
02.22
PIPING MATERIAL SPECIFICATION
SCOPE
This PMS covers the various piping specification for process
Metallurgical plants and its related industrial Installation.
and utility piping in
REFERRED CODES & STANDARDS
All piping shall be designed in accordance with relevant latest codes and standards like
B 31.1, B 31.3 and different IPSS (Inter plant standard for steel industry)
Individual piping material specification has been designed to cover a set of services
operating within fixed pressure and temperature.
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Gases & Liquid Fluids
Page 27 of 51
GS-02
General Technical Specification
PIPES
Pipe dimension shall be in accordance with ANSI B36.10 : IS:1239, IS:3589 for carbon
steel pipe and to B36.10/B36.19 for stainless steel pipe.
Pipe made by acid Bessemer process shall not be acceptable. Pipes shall be made by
open hearth, electric furnace or basic oxygen process.
All pipe threads shall conform to ANSI B1.20.1 except where otherwise noted.
FLANGES
Flanges shall be in accordance with following codes except where otherwise noted.
DN 15 to DN 600 (150 # - 600#)
ANSI/ANSI B16.5 / IS : 6392
Above DN 600 API 605 / ANSI B16.47 / MSS-SP-44/IS:6392/DIN etc.
Flanges to MSS-SP-44 or any other std. like DIN, BS etc. may be specified to be made
with equipment or valve flanges with corresponding bolting.
Finish of steel flange faces shall conform to MSS-SP-6/ ASME B46.1/ASME B16.5. The
interpretation shall be as follows :
Serrated
:
250 – 500 Mu in AARH
Smooth (125 AARH)
:
125 – 250 Mu in AARH
For RTJ groves (32 AARH)
:
32 – 250 Mu in AARH
Bore of WN flanges shall match the ID of the attached pipe Bore of slip on flanges shall
suit the pipe OD and its thickness.
Dimensions of welded steel flanges for low pressure gas ( Pressure upto 1 kg/cm2) is
indicated in Table 06.01
FITTINGS
Forged steel socket welded and threaded fittings shall be in accordance with ANSI B
16.11 unless otherwise noted.
Butt welded fittings shall be in accordance with ANSI B16.9 unless otherwise noted.
Fabricated (site/factory) fittings shall conform to IPSS-06-020-95 unless otherwise
specified. Fittings thickness and tolerance shall match pipe thickness and tolerance.
Mitres and reducers fabricated from pipe may be used if specified in PMS. Same shall
conform to IPSS:1-06-020-95. In no case, thickness of mitres and material shall be
inferior to parent pipe.
GASKETS
Non metallic gasket shall conform to IS:2712.
Spiral wound gaskets (SPR, WND) shall conform to API 601/B16.20.
Ring type and spiral wound gasket shall be self aligning type.
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Page 28 of 51
GS-02
General Technical Specification
BOLTING
Dimensional std of Bolt/studs and nuts shall conform to B 18.2 / IS:1364-1992 unless
otherwise noted.
THREADS
Threads for threaded pipes, fitting, flanges and valves shall be in accordance with
B1.20.1 taper threads unless otherwise noted.
0
Upto 200 C threaded joints shall be made with 1” width PTEE joining tape.
0
Above 200 C threaded joints shall be seal welded with full strength fillet weld.
All threaded joints irrespective of pressure and temperature on lines carrying toxic fluid
shall be seal welded with a full strength fillet weld.
VALVES
Face to Face/End to End dimension of valves shall conform to B16.10 to the extent
covered. For valves not covered in B16.10. reference shall be made to BS2080 and / or
the manufacturer’s drawings.
Flange / weld ends of the valve shall be as per the corresponding Flange/Fitting ends of
the piping class, unless otherwise specified.
Pressure temperature rating for flanges and butt welding end valves shall be as per
ANSI B16.34 except for ball, plug & butterfly valves. For these valves refer TABLE FOR
PRESSURE TEMP. RATING FOR BALL, PLUG AND BUTTERFLY VALVES
Unless called-out specifically, valves shall be as per the following Standards.
Valve
Size DN mm
Rating
Des. Std.
Testing Std.
Gate
15 - 40
800/1500
API-602
API-598
Globe/Check
15 - 40
800/1500
BS – 5352
BS-6755 Pt-I
Gate
50 - 600
150/300/600
API-600
API-598
Gate
650 - 1050
150/300
BS-1414
BS-6755 Pt-I
Globe
50 – 200
150/300/600
BS-1873
BS-6755 Pt-I
Check
50 – 600
150/300/600
BS-1868
BS-6755 Pt-I
900/1500/2500#
B-16.34
API-598/
BS6755 Pt-I
Gate/Globe/Check
Ball
15 – 400
BS-5351
BS-6755
Plug
15 – 300
API-599
API-598 /BS5353
BS-6755
Butterfly
80 & above
-
API-609/
BS5155
AWWA C504
API-1898/
BS-6755 Pt-I
/AWWA
Diaphram
ALL
-
BS-5156
BS-6755 Pt-I
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Page 29 of 51
GS-02
General Technical Specification
If not covered above, the valve shall be as per B16.34 and relevant MSS SP Standard
DN 50mm and larger steel Gate, Globe & Check valves in Hydrocarbon and utility
service shall have bolted bonnets. Pressure seal bonnets or covers shall be used for
Class 900# and above to minimize bonnet leakage. However, valves with pressure seal
bonnet shall have wall thickness & seal stem diameter as per API600. Welded bonnets
or screwed & seal welded bonnets are acceptable for sizes lower than DN 50 for Class
900# & above.
PIPING MATERIAL SPECIFICATION
SERVICE :
BF Gas, CO Gas, BOF Gas, Corex gas & Mixed Gas
SERVICE CONDITIONS : Maximum Working Pressure 1500mmWC
Minimum Working Pressure 50 mmWC
o
Temp 60 C
Temp 5 oC
CORROSION ALLOWANCE : 2 m.m.
Item
Size Range
Description
ERW, PE; Sch Heavy
Dimension
Standard
IS : 1239 part-1
Material
Specification
IS:1239 - Black
Pipe
DN 15 to 40
DN 50 to 150
ERW, BE; Sch Heavy
IS : 1239 part-1
IS:1239 - Black
DN 200 to 350
ERW, BE; 6 mm Thk
IS : 3589
IS: 3589 Gr.330
DN 400 to 750
ERW/SWP,BE; 8 mm Thk
IS : 3589
IS: 3589 Gr.330
DN 800 to 3500
Fabricated – SWP, BE;
10mm Thk.
IS : 3589
IS : 2062, Gr.B
Plate shall have copper
content of 0.25 to 0.35 %
Fittings
Flanges
#150
Gaskets
DN 15 to 40
SW /Screwed Fittings
(Elbow R=1.5D)
IS : 1239 (P-2)
IS : 1239 (P-2)
Black
DN 50 to 150
BW (Elbow R=1.5D)
IS : 1239 (P-2)
IS : 1239 (P-2)
Black
DN 200 & above
IPSS-06-20
IS : 2062, Gr.B
Upto DN 150
Fabricated Miters bends &
fittings from pipe / plate
SORF; Serrated Finish
IS: 2062, Gr.B
DN 200 to 300
SORF; Serrated Finish
DN 400 & above
SORF; Serrated Finish
Upto DN 500
Gasket: Thk. 2 mm Ring
Type CAF
Asbestos rope graphite
impingnated. 8mm
IS : 6392
Table - 5
IPSS:1-06-20
Table 3
IPSS:1-06-20
Table 3
As per Flange
Above DN 500
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Gases & Liquid Fluids
Page 30 of 51
IS: 2062, Gr.B
IS: 2062, Gr.B
IS : 2712 Gr W/3
GS-02
General Technical Specification
Item
Size Range
Description
Valves
(Isolation)
DN 15 to 40
Gate valve; Screwed
DN 50 to 550
Gate valve; Flanged ;
Rising stem
Gate valve; Flanged; Rising
stem
IS : 14846
Check valve SW – Lift Type
#800
Check Valve Flanged swing
check valve/ dual plate
#150
BS 5352
DN 600 and
above
Non-return
DN 15 to 40
DN 50 and
above
Throttling
DN 15 to 40
DN 50 to 300
DN 350 & above
Sampling
DN 15 / DN 25
Bolting
All
Piping
Fabrication
Flanged Joints
Pipes Joints
Fabricated pipes
Globe valve SW / Screwed
; #800
Globe valve; Flanged ;
Serrated Finish; #150
Butterfly valve WAF Type;
#150
Screwed and lubricated,
Tapered Plug valve
Bolts
Nuts
Dimension
Standard
API 602
Material
Specification
Body ASTM
A105; Cr 13%
Trim
Body CI GR. FG
200; SS trim
Body IS-2062,
Gr. B, SS trim
Body A105, 13%
Cr Trim
CI IS–210 Gr. FG
200
BS 1868 / API
594
IS:5312 part-1
BS: 5153
BS 5352
BS 1873
BS 5155/ API 594
BS: 5158
Body A105, 13%
Cr Trim
Body CI, 13% Cr
Trim
Body CI; 13% Cr
Trim
Body & PLUG :
CI IS 210 FG 200
IS: 1364- 1992
IS: 1364- 1992
At valve/ equipment location and for sectionalising & Maintenance.
To be kept minimum
Butt Welded
Fillet welding using semi bandage on each segment.
Temp
Connections
DN 40 – Flanged set-on nozzle
Pressure
Tapping
DN 20 – SW Half Coupling Nipple Sch 80 with Gate valve to Spec.
Vents
On lines >= DN 50 ; MEC std.
Drains
On lines >= DN 80, MEC Std.
PIPING MATERIAL SPECIFICATION
SERVICE : LPG, Propane
SERVICE CONDITIONS : Maximum Operating Pressure 10 kgf /cm2
Minimum Operating Pressure Atm
Temp 60 oC
o
Temp 5 C
CORROSION ALLOWANCE : 1.5 mm.
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Gases & Liquid Fluids
Page 31 of 51
GS-02
General Technical Specification
Item
Pipe
Fittings
Size Range
DN 15 to 40
Seamless PE Sch. 80
Dimensional/
Design
Standard
B 36.10
DN 50 to 150
Seamless BE Sch.40
B36.10
DN 200 to 300
Seamless BE Sch.20
B36.10
DN 350
Seamless BE Sch.10
B36.10
DN 15 to 40
SW / Screwed Fittings
# 3000 (Elbow R=1.5D)
BW Fittings
#150
(Elbow R=1.5D)
Miter bends & fittings
fabricated from pipe
SW:RF : Serrated Finish;
#150
SORF : Serrated Finish;
#150
Gasket : Thk. 2.0 mm Ring
type CAF
Gate valve SW # 800
ANSI B 16.11
ASTM A106 GR.B,
Seamless
ASTM A106 GR.B,
Seamless
ASTM A106 GR.B,
Seamless
ASTM A 105
ANSI B16.9
ASTM A234 Gr WPB
IPSS-1-06-020
Same as parent pipe
B 16.5
ASTM A 105
B 16.5
ASTM A 105
B 16.21
IS : 2712 Gr W/3
API 602
Body A105 ; 13% CR
Trim
Body A216 Gr. WCB
13% Cr Trim
Body A105; 13% Cr
Trim
Body A216 Gr.WCB
13% Cr Trim
Body A105; 13% Cr
Trim
Body A216 Gr.WCB
13% Cr Trim
Body A216 Gr.WCB
13% Cr. Trim
DN 50 to 150
DN 200 & above
Flanges
DN 15 to 40
DN 50 & above
Gaskets
All sizes
Valves
DN 15 to 40
DN 50 to 600
DN 15 to 40
DN 50 to 200
DN 15 to 40
DN 50 to 600
DN 15 to 150
Description
Gate valve Flanged RF
Serrated Finish # 150
Globe valve, SW # 800
API 600
Globe valve : Flanged RF
Serrated # 150 finish
Check valve SW # 800 Lift
type
Check valve flanged RF
Serrated finish # 150
Ball valve flanged RF
Serrated finish #150
BS 1873
ANSI B 16.5 SRF
ANSI B 16.5 SRF
BS 1868
BS 5351
Material Carbon Steel
ASTM A106 GR.B,
Seamless
Bolting
All
Studs / Bolts
Nuts
B 18.2
B 18.2
ASTM A193 Gr B7
ASTM A194 Gr 2H
Miscellan
e-ous
DN 15 to 40
TRAP #150, THRMDNMC
MANF’ STD.
BODY A105, TRIM
13% CR , S: SS304
DN 15 to 40
PERM. STR, SW, Y Type
MANF’ STD.
BODY A105: INT.SS
304
DN 50 to 350
PERM. STR, BW, T Type
MANF’ STD.
BODY A234WPB :
INT SS 304
DN 400 to 600
PERM. STR, BW, T Type
MANF’ STD.
BODY A234WPBW:
INT SS 304
Above DN 600
TEMP. STR, FF, CONE
Type
MEC’ STD.
BODY A516GR. 70:
INT SS 304
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Page 32 of 51
GS-02
General Technical Specification
Item
Piping
Fabricatio
n
Size Range
Flanged Joints
Pipes
Joints
Pressure Tapping
Temp
Connections
Vents
Drains
Description
Dimensional/
Material Design
Carbon Steel
Standard
At valve/ equipment location and for sectionalizing & maintenance
To be kept minimum
DN 40 & below SW coupling
DN 50 & above Butt welded
DN 20 – SW half coupling Nipple Sch 80 with Gate valve to spec. Gate
DN 40 – Flanged set-on nozzle
On lines <= DN 40 ; MEC std.
On lines <= DN 40 ; MEC std.
PIPING MATERIAL SPECIFICATION
SERVICE : Fuel oil, LSHS
2
o
SERVICE CONDITIONS : Maximum working pressure 10 kg /cm (g) and temp 70 C
Minimum working pressure 1 kg /cm2 (g) and temp 5o C
CORROSION ALLOWANCE : 2 m.m.
Item
Size Range
Description
Pipe
DN 150 and
below
DN 200 to 450
ERW, Plain ends, Sch. –
Medium
ERW Pipe
DN 50 and below
Fabricated from pipes by
cold bending with radius 3
DN / 3000 lbs forged
carbon steel, SW
Seamless BW elbow Sch40
Mitred bends with radius
1.5 DN
3000 lbs, forged carbon
steel, SW
Seamless BW, carbon steel
Sch. – 40 / Fabricated
Pipe
Fittings
Bends
DN 65 to 200
Tees /
Reducers
DN 250 and
above
DN 50 and below
DN 65 and above
Screwed
fittings
Bolting
Gaskets
DN 50 and above
All sizes
All sizes
Flanges
All sizes
© 2007 MECON Limited
All rights reserved
Compressed asbestos, 1.5
mm thick
Plate flanges made from
Dimensional/
Design
Standard
IS:1239 (part1)
IS:1239 – Black
IS: 1978
API 5L Gr.B
IS: 1978
API 5L Gr.B
ANSI B16.11
ASTM A 105
ANSI B 16.9
From parent pipe
ASTM A-234 Gr.
WPB
From parent pipe
ANSI B16.11
ASTM A105
ANSI B16.11
ASTM A-234 Gr.
WPB
IS:1239 – Black
IS:1239 (part II)
IS:1367
IS:2712
IS:6392 (table 17)
Gases & Liquid Fluids
Page 33 of 51
Material Carbon Steel
IS:1367
IS:2712
Gr. 0/2
IS:2002 Gr. 2A
GS-02
General Technical Specification
Item
Valve
Isolation
Size Range
carbon steel plates with
bore to suit pipe OD
DN 50 and below
DN 65 and above
Throttling
DN 50 and below
DN 65 and above
Nonreturn
DN 50 and below
DN 65 and above
Filter
Hose
assembly
Description
DN 50 and below
DN 65 and above
Cast steel lubricated taper
plug valve, screwed similar
to AUDCO fig MW-32 / plug
valve
Cast steel lubricated taper
plug valve, screwed similar
to AUDCO flanged ends
Forged steel globe valve
with regular type discs, SS
rising spindle, Screwed
ends
Cast steel globe valve with
regulating type discs, SS
renewable seat rings,
outside screw with rising
stem, flanged / globe valve
Forged steel check valve,
body and cap material,
screwed ends / forged steel
check valve
Cast steel swing check
valve with renewable seat
rings, flanged generally,
flanged / cast steel check
valve.
Self cleaning filter operating
on the principle of edge
filtration
15 m long hose with swivel
SAE female coupling at
both ends and adaptor at
one end
Flanged ends
Dimensional/
Design
Standard
Material Carbon Steel
IS:10459
IS:10459
IS:23
IS:23
ASTM A105, ASTM
A182, Gr. F6
IS:10605
IS:10605
IS:10989
IS:10989
BS 5153
Body and cap: ASTM
A 105,
Trim material: ASTM
A 182, Gr. F6
IS:5312 (part1), BS
5153
IS: 635
IS: 635
IS: 635
IS: 635
PIPING MATERIAL SPECIFICATION
SERVICE : MEDIUM PRESSURE NITROGEN ,
ARGON, & COMPRESSED AIR
SERVICE CONDITIONS : Maximum Operating Pressure 10.5 kgf /cm2
Minimum Operating Pressure Atm
o
Temp 60 C
o
Temp 5 C
CORROSION ALLOWANCE : 1.5 m.m.
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Gases & Liquid Fluids
Page 34 of 51
GS-02
General Technical Specification
Item
Size Range
Description
Pipe
DN 15 to 40
Fittings
ERW, PE Sch. HEAVY
Dimensional/
Design
Standard
IS:1239 – part-1
IS:1239 BLACK
DN 50 to 150
ERW, BE Sch. HEAVY
IS:1239 – part-1
IS:1239 BLACK
DN 200 to 350
ERW, BE , THK 6.0mm
IS:3589
IS:3589 GR.330
DN 400 to 500
ERW, BE , THK 8.0mm
IS:3589
IS:3589 GR.330
DN 550 to 600
DN 650 &
above
ERW BE Thk. 10.0mm
ERW/ SAW, BE Thk.
10.0mm (min)
IS:3589
IS:3589
IS:3589 GR.330
IS:3589 GR.330
DN 15 to 40
SW / Screwed Fittings
# 3000 (Elbow R=1.5D)
BW Fittings #150
(Elbow R=1.5D))
Miter bends & fittings
fabricated from pipe
SW:RF : Serrated Finish
#150
SORF : Serrated Finish
#150
ANSI B 16.11
ASTM A 105
ANSI B16.9
ASTM A234 Gr WPB
IPSS-1-06-020
Same as parent pipe
B 16.5
ASTM A 105
IS:6392 Table-11
IS:2062 Grade B
B 16.21
IS : 2712 Gr W/3
API 602
Body ASTM A105 ;
13% CR Trim
Body ASTM A216
Gr. WCB 13% Cr
Trim
Body ASTM A105;
13% Cr Trim
Body A216 Gr.WCB
13% Cr Trim
Body ASTM A105;
13% Cr Trim
DN 50 to 150
DN 200 & above
Flanges
DN 15 to 40
DN 50 and
above
Material Carbon Steel
Gaskets
All sizes
Valves
DN 15 to 40
Gasket : Thk. 2.0 mm Ring
type CAF
Gate valve SW # 800
Isolation
DN 50 and
above
Gate valve Flanged RF
Serrated Finish # 150
API 600
DN 15 to 40
Globe valve, SW # 800
BS 5352
DN 50 and
above
DN 15 to 40
Globe valve : Flanged RF
Serrated # 150 finish
Check valve SW # 800 Lift
type
BS 1873
DN 50 and
above
Check valve flanged RF
Serrated finish # 150
BS 1868
Bolting
All
Studs / Bolts
Nuts
B 18.2
B 18.2
Miscellaneous
DN 15 to 40
TRAP #150, THRMDNMC
MANF’ STD.
BODY A105, TRIM
13% CR , S: SS304
DN 15 to 40
STRAINER, SW, Y Type
MANF’ STD.
DN 50 and
above
STRAINER, BW, T Type
MANF’ STD.
BODY ASTM A105 :
INT SS 304
BODY A234WPB :
INT SS 304
Flanged Joints
At valve/ equipment location and for sectionalizing & maintenance
To be kept minimum
Butt Welded
Throttling
Non-Return
Piping
Fabrication
Pipes
Joints
© 2007 MECON Limited
All rights reserved
BS 5352
Gases & Liquid Fluids
Page 35 of 51
Body ASTM A216
Gr.WCB 13% Cr
Trim
ASTM A307 Gr B
ASTM A563Gr B
GS-02
General Technical Specification
Item
Size Range
Pressure
Tapping
Description
Dimensional/
Material Design
Carbon Steel
Standard
DN 20 – SW half coupling Sch 80 Nipple with Gate valve to spec.
Temp
Connections
Vents
DN 40 – Flanged set-on nozzle
On lines <= DN 40 ; MEC std.
Drains
On lines <= DN 40 ; MEC std.
PIPING MATERIAL SPECIFICATION
SERVICE : HIGH PRESSURE NITROGEN , ARGON
SERVICE CONDITIONS : Maximum Operating Pressure 40 kgf /cm2
Minimum Operating Pressure 10.5 kgf /cm2
Temp 60 oC
o
Temp 5 C
CORROSION ALLOWANCE : 1.5 mm.
Item
Size Range
Description
Pipe
DN 15 to 40
Fittings
Seamless PE Sch. 80
Dimensional/
Design
Standard
B 36.10
ASTM A106 Gr.B
DN 50 to 150
Seamless BE Sch.40
B36.10
ASTM A106 Gr.B
DN 200 to 250
Seamless BE Sch.30
B36.10
ASTM A106 Gr.B
DN 300 to 350
Seamless BE Sch. Std.
B36.10
ASTM A106 Gr.B
DN 400 to 600
Seamless,
B36.10
ASTM A 106 Gr.B
DN 15 to 40
ANSI B 16.11
ASTM A 105
ANSI B16.9
ASTM A234 Gr WPB
ANSI B16.9
ASTM A234 Gr WPB
B 16.5
ASTM A 105
B 16.5
ASTM A 105
API 601
SS 304 SPR. WND +
CA FIL
Body A105 ; 13% CR
Trim
Body A216 Gr. WCB
13% Cr Trim
Body A105; 13% Cr
Trim
Gaskets
All sizes
SW Fittings
# 3000 (Elbow R = 1.5D)
BW Fittings, Seamless
(Elbow R = 1.5D)
BW Fittings, Seamless
(Elbow R = 1.5D)
SW:RF : Serrated Finish
#600
SW:RF : Serrated Finish
#600
SPIRAL; THK. 4.4 mm
Valves
DN 15 to 40
Gate valve SW # 800
API 602
Isolation
DN 50 to 600
API 600
Throttling
DN 15 to 40
Gate valve Flanged RF
Serrated Finish # 300
Globe valve, SW # 800
DN 50 to 350
DN 400 to 600
Flanges
DN 15 to 40
DN 50 and above
© 2007 MECON Limited
All rights reserved
BS 5352
Gases & Liquid Fluids
Page 36 of 51
Material Carbon Steel
GS-02
General Technical Specification
Item
Nonreturn
Size Range
Description
DN 50 to 200
Globe valve : Flanged RF
Body A216 Gr.WCB
Serrated # 300 finish
13% Cr Trim
Check valve SW # 800 lift
BS 5352
Body A105; 13% Cr
type
Trim
Check valve flanged RF
BS 1868
Body A216 Gr.WCB
Serrated finish # 300
13% Cr Trim
Studs /Bolts
B 18.2
ASTM A193 Gr B7
Nuts
B 18.2
ASTM A194 Gr 2H
At valve/ equipment location and for sectionalizing & maintenance
To be kept minimum
DN 40 & below SW coupling
DN 50 & above Butt welded
DN 20 – SW half coupling Nipple Sch 80 with Gate valve to spec.
DN 15 to 40
DN 50 to 600
Bolting
All
Piping
Fabricatio
n
Flanged Joints
Pipes
Joints
Pressure Tapping
Temp
Connections
Vents
Drains
Dimensional/
Design
Standard
BS 1873
Material Carbon Steel
DN 40 – Flanged set-on nozzle
On lines <= DN 40 ; MEC std.
On lines <= DN 40 ; MEC std.
PIPING MATERIAL SPECIFICATION
SERVICE :
INSTRUMENT AIR
SERVICE CONDITIONS : Maximum Operating Pressure Up to 10.55 kgf /cm2
RATING
o
Temp 65 C
:
# 150
Matching Companion Flanges of Valves & flow components as per corresponding
rating.
CORROSION ALLOWANCE : NIL
Item
Size Range
Description
Pipe
DN 15 to 40
ERW ; Screwed end
HEAVY
Fittings
DN 15 to 40
Flanges
DN 15 to 40
Screwed Fittings
# 3000
Screwed :RF : Serrated
Finish #150
Blind Flanged RF :
Serrated Finish #150
DN 15 to 40
DN 50 and above
Gaskets
All sizes
Valves
Isolation
DN 15 to 40
© 2007 MECON Limited
All rights reserved
Dimensional/
Design
Standard
IS:1239, Portal
Material Carbon Steel
IS:1239 (PART-I)
GALV.
ANSI B 16.11
ASTM A 105 (GALV.)
B 16.5
ASTM A 105 (GALV.)
API 590
ASTM A 105 (GALV.)
Flange ; FF Serrated Finish
#150
Gasket : Thk. 2.0 mm Ring
type
B 16.5
ASTM A 105 (GALV.)
B 16.21
IS : 2712 Gr W/3
Gate valve SCRF; # 800
API 602
Body ASTM A105 ;
13% CR Trim
Gases & Liquid Fluids
Page 37 of 51
GS-02
General Technical Specification
Item
Size Range
Description
Throttling
DN 15 to 40
Globe valve, SCRF; # 800
Nonreturn
Bolting
DN 15 to 40
Check valve SCRF; # 800
Lift type
M/C BOLT
B 18.2
Nuts
B 18.2
Piping
Fabricatio
n
All
Dimensional/
Design
Standard
BS 5352
BS 5352
Material Carbon Steel
Body ASTM A105;
13% Cr Trim
Body ASTM A105;
13% Cr Trim
ASTM A307 Gr B
(GALV)
ASTM A563 Gr B,
(GALV)
Flanged Joints
Pipes
Joints
Screwed Coupling
Temp. Conn.
Flanged Installation as MEC std.
Pressure Tapping
Vents
Drains
DN 20 – SW half coupling Nipple HEAVY with Gate valve to spec.
MEC std.
MEC std.
PIPING MATERIAL SPECIFICATION
SERVICE :
LOW PRESSURE STEAM, MEDIUM PRESSURE STEAM, CONDENSATE & BOILER
FEED WATER
SERVICE CONDITIONS : Maximum Operating Pressure 18 kgf /cm2
o
Temp 360 C
CORROSION ALLOWANCE : 1.5 m.m.
Item
Size Range
Description
Pipe
DN 15 To 500
Carbon steel seamless pipe
with bevel ends
Dimensional/
Design
Standard
ANSI B 36.10
Material Carbon Steel
ANSI B 16.11
ASTM A 105
ANSI B 16.9
ASTM A234 Gr. WPB,
Sch 40
ANSI B 16.11
ASTMA 105
ASTM 106 GR.B or
equivalent
Pipe
Fittings
Welded Fittings
Bends
Below DN 50
DN 50 to 500
Tees /
Reducers
Below DN 50
© 2007 MECON Limited
All rights reserved
Bends fabricated from
pipes by cold bending with
3D radius and socket
welded ends, 3000#
Forged carbon steel elbow,
3000# with socket welded
ends.
Bends fabricated from
pipes by cold/hot bending
with 3D radius, 3000#
Forged seamless carbon
steel LR elbow with butt
welded ends, 3000#
Forged carbon steel Tees /
Reducers with socket
welded ends
Gases & Liquid Fluids
Page 38 of 51
GS-02
General Technical Specification
Item
Size Range
Description
DN 50 to 500
Forged seamless carbon
steel Tees / Reducers with
butt welded ends
Bolts / studs / Nuts
Bolting
All sizes
Gaskets
All sizes
All sizes
Flanges
All sizes
Compressed Asbestos
Gaskets for condensate
and LP stream
Spiral wound SS304 with
CA filler for MP stream
SO/ WN / Blank flanges RF
125 AARH made from
carbon steel plates /
Forged carbon steel
flanges
Dimensional/
Design
Standard
ANSI B 16.9
IS 2712 Gr W/3,
1.5 mm thick
Material Carbon Steel
ASTM A234 Gr. WPB,
Sch 40
Bolts / Studs ASTM
A193 Gr B7. Nuts
ASTM A194 Gr. 2H
ANSI B 16.5
IS 2002 Gr. 2A
ANSI B 16.5
A105 / A 234 Gr.
WPB
API 602/BS 5352
Body / Bonnet to
ASTM A105, Stem /
trim SS to AISI 410
(13% Cr)
Body / Bonnet to
ASTM A216 Gr. WCB,
Stem / Trim SS to
AISI 410 (13% Cr)
Body / Bonnet to
ASTM A105, Stem /
trim SS to AISI 410
(13% Cr)
Body / Bonnet to
ASTM A216 Gr WCB,
Stem / Trim SS to
AISI 410 (13% Cr%)
Body / Disc / Cover to
ASTM A105, Internals
/ Trim SS to AISI 410
(13% Cr)
Body / Disc / Cover to
ASTM A216, Grade
WCB Internals / Trim
SS to AISI 410 (13%
Cr)
Valves
Isolation
Below DN50
DN50 and above
Throttling
Below DN50
DN50 and above
Non
return
Below DN50
DN50 and above
Strainer
Hose
assembly
© 2007 MECON Limited
All rights reserved
Forged carbon steel gate
valve, Class 800/900 with
rising stem and socket
welded ends.
Cast carbon steel gate
valve, Class 150/300 (for
MP steam) with rising stem
and BW/ Flanged ends
Forged carbon steel globe
valve class 800/900 with
rising stem and socket
welded ends
Cast carbon steel globe
valve class 150 / 300 (for
MP steam) with rising stem
and BW / Flanged ends
Forged carbon steel swing
check / piston lift valve
class 800/900 with socket
welded ends.
Cast carbon steel swing
check valve Class 150/300
(for MP steam) with rising
stem and BW / Flanged
ends
Strainer with cast steel
body and brass strainers of
16 G sheet with 1.25 mm
diameter perforation @ 20
per cm2 and SW / Flanged
ends.
Metallic hoses of 15 m
length complete with
screwed female swivel
couplings at both the ends
API 600
BS 5352
BS 1873/ API 600
BS 1868
BS 1868
Manufacturer’s
Standard
Manufacturer’s
Standard
Gases & Liquid Fluids
Page 39 of 51
GS-02
General Technical Specification
Item
Size Range
Description
Steam
trap
50 and below
Thermodynamic steam trap
with inbuilt strainer, Class
800/900 and SW ends
Dimensional/
Design
Standard
Manufacturer’s
Standard
Material Carbon Steel
Body / Cap / Plug
A743 Gr CA 40
Note:
1. Class 150 for condensate and LP steam
2. Class 300 for MP steam
3. For feed water, schedule / thickness of pipe fittings and class ratings are to be selected by the
tenderer based on pressure and temperature of feed water.
PIPING MATERIAL SPECIFICATION
SERVICE :
MEDIUM PRESSURE OXYGEN
SERVICE CONDITIONS : Maximum Operating Pressure 16 kgf /cm2
o
Temp 60 C
CORROSION ALLOWANCE : 2 m.m.
Cleaning, Pickling, Passivation & Degreasing As Per IGC / IPSS code
Item
Size Range
Description
Pipe
DN 6 to 10
Seamless Tube
DN 15 to 40
Seamless PE Sch. 80
B 36.10
DN 50 to 150
Seamless BE Sch.40
B36.10
ASTM A106 GR.B
DN 200 to 300
Seamless BE Sch.40
B36.10
ASTM A106 GR.B
DN 350 to 600
Seamless BE Sch.40
B36.10
ASTM A106 GR.B
DN 50 to 150
Copper Pipe
B36.10
Deoxidised non
Arsenic Copper
DN 200 to 600
Copper Pipe
B36.10
Deoxidised non
Arsenic Copper
DN 15 to 40
ANSI B 16.11
ASTM A 105
DN 50 and above
SW Fittings
# 3000
BW Fittings
ANSI B16.9
ASTM A234 Gr WPB
SW:RF : Serrated Finish
WNRF : Serrated Finish
PTFE LOX GRADE
B 16.5
B 16.5
B16.21
ASTM A 105
ASTM A 105
Gaskets
DN 15 to 40
DN 50 above
All sizes
Valves
DN 15 to 40
Ball valve class 800 for
isolation purpose Flanged
ends (class 300)
BS 5351
Body A182 GR. 304;
/BRONZE ;13% Cr
Trim / BRONZE
Fire
Breaker
Fittings
Flanges
© 2007 MECON Limited
All rights reserved
Dimensional/
Design
Standard
Gases & Liquid Fluids
Page 40 of 51
Material Carbon Steel
Deoxidized nonArsenic Copper or
Aluminum
Carbon Steel, ASTM
A106 GR.B
GS-02
General Technical Specification
Item
Size Range
Description
DN 50 and above
Ball valve class 300 for
isolation purpose Flanged
ends (class 300)
Globe valve class 800 for
throttling purpose, flange
end (class 300)
DN 15 to 40
DN 50 and above
Dimensional/
Design
Standard
API 600
BS 5352
Material Carbon Steel
Body A351 GR. CF8;
/BRONZE ;13% Cr
Trim / BRONZE
Body : Bronze
Trim: Bronze
Globe valve class 300 for
throttling purpose with
flange end
Check valve class 800 with
flanged end class 300
BS 1873
Body : Bronze
Trim: Bronze
BS 5352
DN 50 and above
Check valve class 300 with
flanged end
BS 1868
DN 15 & Above
Ball valve flanged RF
Serrated finish
BS 5351
Body A182 GR. 304;
/BRONZE ;13% Cr
Trim / BRONZE
Body A351 GR. CF8;
/BRONZE ;13% Cr
Trim / BRONZE
Body A351 GR.CF8 ;
A182 GR. 304
Trim;PTFE Seat
DN 15 to 40
PIPING MATERIAL SPECIFICATION
SERVICE :
HIGH PRESSURE OXYGEN
SERVICE CONDITIONS : Maximum Operating Pressure 40 kgf /cm2
Minimum Operating Pressure 16 kgf /cm2
RATING :
Temp 60 oC
o
Temp 5 C
# 300
Matching Companion Flanges of Valves & flow components as per
corresponding rating.
CORROSION ALLOWANCE : 2 m.m.
Cleaning, Pickling, Passivation & Degreasing As Per IGC / IPSS code
Item
Size Range
Description
Pipe
DN 6 to 10
Seamless tube
DN 15 to 40
Seamless PE Sch. 80
B 36.10
DN 50 to 150
Seamless BE Sch.40
B36.10
ASTM A106 GR.B
DN 200 to 250
Seamless BE Sch.40
B36.10
ASTM A106 GR.B
© 2007 MECON Limited
All rights reserved
Dimensional/
Design
Standard
Gases & Liquid Fluids
Page 41 of 51
Material Carbon Steel
Deoxidized nonArsenic copper or
Aluminum
Carbon Steel, ASTM
A106 GR.B
GS-02
General Technical Specification
Item
Fire
Breaker
Fittings
Size Range
Description
DN 300 to 600
Seamless BE Sch.40
Dimensional/
Design
Standard
B36.10
Material Carbon Steel
DN 50 to 150
Copper Pipe
B36.10
Deoxidised non
Arsenic Copper
DN 200 to 600
Copper Pipe
B36.10
Deoxidised non
Arsenic Copper
DN 15 to 40
SW Fittings
# 3000
ANSI B 16.11
ASTM A 105
ASTM A106 GR.B
DN 50 and above
BW Fittings
ANSI B16.9
ASTM A234 Gr WPB
Flanges
DN 15 to 40
SW:RF : Serrated Finish;
B 16.5
ASTM A 105
DN 50 and above
All sizes
WNRF : Serrated Finish
PTFE LOX GRADE
B 16.5
B16.21
ASTM A 105
Gaskets
Valves
DN 15 to 40
Ball valve class 800 for
isolation purpose flanged
ends (class 300)
Ball valve class 300 for
isolation purpose flanged
ends (class 300)
Globe valve class 800 for
throttling purpose, Flanged
ends (class 300)
Globe valve class 300 for
throttling purpose, Flanged
ends (class 300)
Check valve class 800, with
flanged ends (class 300)
BS 5351
Body A182 GR. 304;
/BRONZE ;13% Cr
Trim / BRONZE
Body A351 GR. CF8;
/BRONZE ; Trim:13%
Cr / BRONZE
Body: Bronze
Trim: Bronze
Check valve class 300 with
flanged ends
BS 1868
DN 50 and above
DN 15 to 40
DN 50 and above
DN 15 to 40
DN 50 and above
A)
API 600
BS 5352
BS 1873
Body: Bronze
Trim: Bronze
BS 5352
Body A182 GR. 304;
/BRONZE ;trim 13%
Cr / BRONZE
Body A351 GR. CF8;
/BRONZE ; Trim:13%
Cr / BRONZE
Erection of BF Gas, Cold Blast, Nitrogen, Instrument Air, Steam and LPG
Pipelines
01
General
02
Before erection, the equipment, valves and other fittings to be mounted on
pipelines/ equipment should be dismantled, (only if required), cleaned, oiled and
reassembled. Glands shall be packed with suitable materials as per approved
drawings.
-
All elements of the pipelines system shall be erected at site strictly as per the
drawings approved by the / Consultant.
-
Any modification to be carried out at site, shall have the prior approval of /
Consultant’s representatives.
-
While erecting, pipelines shall rest uniformly on each support. Yokes, if
provided, shall not allow lateral movement of pipes.
© 2007 MECON Limited
All rights reserved
Gases & Liquid Fluids
Page 42 of 51
GS-02
General Technical Specification
-
Matching faces of flanges shall be perpendicular to the axis of pipelines. Use of
gaskets of unusual thickness to fill gap between flanges shall not be allowed.
-
For horizontal pipes, the flanges shall be erected such that top two bolt holes are
displaced by half pitch from the vertical axis of the flange.
-
Flanges of adjoining pipes shall be located in staggered manner.
Flanged joints shall be laid as close to the support as possible.
-
Bends
for steam pipes shall have a radius of not less than
times the nominal pipe dia unless otherwise specified.
-
In general pipes are to be joined by butt welding. However, steam service
pipelines 40 mm & lower sizes shall be joined by socket welding.
-
For insulated pipe, steel protectors for the insulation shall be provided at
points where the pipe is supported on rollers, slides or other equipment where
contact with such members is required outside the insulation.
-
In case the location of spindle wheel of valves is not clearly shown in the
erection drawings, the same shall be located in a manner as to facilitate easy
operation from ground level of nearest operating platform.
-
For making pipe bends/ elbows at site using hot/ clod bending process, the
decrease in the pipe thickness shall not be more than 15% of the pipe thickness.
-
After erection of pipelines, the holes made in the walls shall be covered with
bricks & mortar. A gap of 10 to 20 mm shall be kept between wall and the pipe
for the movement due to thermal expansion. The gap shall be filled with felt/
asbestos.
-
Holes made in the roof shall be covered with removable CGI sheets.
-
The trenches for pipes shall be covered with removable chequered plate covers/
concrete slabs as per the drawings.
-
All pipeline branches not connected to equipment shall be closed using blank
flanges and gaskets.
03
Welding of pipelines
-
All pipelines shall be joined by welding. Flanged joints shall be used for
connecting the pipe with equipment, valve or fitting.
-
Electric arc welding shall be used for joining pipes, support, structures, etc.
-
All manufactured pipes shall be joined by butt welding. Large dia pipes,
fabricated from sheets, shall be joined by fillet welding using semi- bandages
attached to each section being joined.
-
Welding shall be done by qualified welders. Code of practice as per relevant
Indian Standards shall be followed for the welding procedure, use of electrodes,
etc.
-
Proper edge preparation and preheating of edges to be welded, whenever
required, shall be ensured before welding.
-
After every 50 butt welded joints of gas pipeline, one test sample shall be welded
by the same welder. Tensile teat and bend test shall be performed as per IS
:814 to check the strength of welding. Four test samples shall be made from the
test piece, two each for tensile and bend test.
© 2007 MECON Limited
All rights reserved
Gases & Liquid Fluids
Page 43 of 51
three
GS-02
General Technical Specification
-
Tensile strength shall not be less than 34 kg / mm2 and elongation less than 12
%.
-
Angle of bend at the appearance of first crack shall not be less than 70 deg.
-
Visual inspection shall be done for all welded joints to check for following
possible defects :
-
Surface cracks on weld metal or parent metal.
-
Fusion or cuts at the joining of weld metal and parent metal.
-
Sponginess or porosity on the surface of weld.
-
Non-uniform thickness or distortion in case of fillet welds.
-
Deviation in the pipe axes or dimension of the joint.
-
All defective spots found shall be chipped off and re-welded.
-
For high pressure pipes, radiographic examination of welds shall be carried out
as per IS : 2825.
04
Link lengths and tolerances
-
Straight sections of gas pipelines shall be manufactured as separate links and
joined at site by butt welding.
-
Link lengths for pipes shall be as follows :
i)
ii)
a)
Up to 13 m : for pipes with dia 1400 mm or less.
b)
Up to 26 m : for pipes above 1400 mm dia.
Following tolerances are allowed :
For length of links :
a)
+/- 3 mm for length up 1 m
b)
+/- 0.5 % for length more than 1 m, total deviation shall not exceed 10 mm for
every 10 m or part thereof .
Deviation in the pipe axis from the straight line :
Upto 0.12% of the link length but not more than 15mm for links with length more than 10
m. Deviation shall be checked by stretched cord.
iii)
For distance between the contacting surfaces from the geometrical axis for bends, tees,
crosses and other pipe fittings.
+/- 3 mm for distance upto 500 mm .
+/- 0.5% or 10 mm maximum for distance more than 1 m.
However, for BF gas and CO gas pipelines, the tolerance shall be limited to +/- 1.5 mm
only.
iv)
Deviation of pipe axes at the joining point from the diametral plane of pipes:
2 mm, irrespective of link length.
v)
For distance between two adjacent connections on a pipe :
+/- 2 mm for each length but not more than +/- 5 mm overall.
vi)
Distortion of the contacting surface of flange relative to the geometrical plane
perpendicular to the pipe axis :
0.004 times the outer diameter of the flange at the periphery.
© 2007 MECON Limited
All rights reserved
Gases & Liquid Fluids
Page 44 of 51
GS-02
General Technical Specification
vii)
Tolerance for clearance between flanges and flange rings :
Not more than 2 mm.
05
Erection of valves and fittings
-
Before erection, the valves, cocks and other fittings, to be mounted on pipelines,
shall be dismantled, cleaned, oiled and reassembled. Glands shall be packed
with suitable materials as per approved drawings.
-
All moving parts of the pipe fittings should move freely without jamming.
-
Valves shall be tested hydraulically for leakage by applying pressure on up
stream side with valve in closed position.
-
Bolts & nuts shall be cleaned and lightly oiled.
-
Proper grades of gaskets shall be used for erection as per approved drawings.
Testing of BF Gas, Cold Blast, Nitrogen, Instrument Air, Steam and LPG pipelines
-
Preliminary acceptance test for erected pipelines shall be carried out as follows :
a)
Checking of metal marked as per manufacturer’s certificate/ approved drawings.
b)
Checking of test result of mechanical tests for welding/ radiographic tests.
c)
Visual examination of welds.
d)
Dimensional checks as per the approved erection drawings.
e)
Checking of welded joints by chalk kerosene test.
-
In case defects are found by visual examination, these shall be rectified prior to
leakage test.
-
Checking of proper installation of supports, expansion joints, valves and fittings.
-
The pipeline shall be cleaned from inside, all debris removed and pipeline blown
with air to remove all dirt, rust particles, etc.
Strength and leakage test for BF gas, Cold Blast, Nitrogen, Instrument air, Steam and
LPG pipelines :
Test fluid for BF gas, Cold blast and LPG shall be air and for Nitrogen, Instrument air &
Steam service pipelines, test fluid shall be water.
All mounted equipment / instruments, control valves, etc. on pipelines shall be
temporarily replaced by spool pieces. End connection near equipment connection shall
be temporarily disconnected and blanked.
For BF gas, test pressure equivalent to 1.25 times the maximum operating pressure but
2
not less than
0.2 Kgf/cm (g) shall be applied using air as per the certified
drawings and instructions of OWNER/ MECON for ascertaining the strength.
For cold blast, compressed air, nitrogen & LPG test pressure shall be 1.25 times the
maximum working pressure.
For steam service pipelines test pressure shall be 1.5 times the maximum working
pressure.
a)
For BF gas, cold blast, compressed air, nitrogen & LPG pressure test shall be carried out
by maintaining the test pressure indicated above for a minimum period of 1/2 hour. For
steam pipes, the minimum duration shall also be 1/2 hour.
© 2007 MECON Limited
All rights reserved
Gases & Liquid Fluids
Page 45 of 51
GS-02
General Technical Specification
b)
c)
d)
During pneumatic test, pressure shall be gradually reduced to 1.1 times the operating
pressure to check the leakage by soap solution. Test duration shall be minimum 2 hours.
Soap solution shall be applied to the weld surfaces / flanges to check for any leakage.
Any defect found shall be rectified after releasing the test pressure and after rectification
of defects the test shall be repeated.
During pneumatic tests of all gas pipelines pressure and temperature readings shall be
taken at the beginning and end of the test. The percentage pressure drop (P) shall be
calculated as follows :
P = 100 (1 - P2 / P1 X T1/ T2)
Where P1 and P2 are absolute pressure in the pipe at the beginning and end of test and
T1 and T2 are absolute temperature at the beginning and end of the test.
e)
The maximum allowable pressure drop in all gas pipelines shall not exceed 1.0 % per
hour for outdoor pipelines during pneumatic test. For pipeline subjected to hydro test, no
leakage is permissible
1)
High pressure pipelines shall be tested as follows :
a)
Pipe sections shall be disconnected from the equipment using blank flanges.
b)
Vents shall be provided at high points for air release during pipe filling. The vents shall
be plugged with threaded nipples after the tests.
c)
Tests shall be carried out before painting of the pipelines and before application of
insulation.
d)
Pipe upto 300 mm diameter shall be tested hydraulically for strength by applying test
pressure equivalent to 1.25 times the operating pressure. Test pressure shall be
maintained for 30 minutes and then gradually reduced to the operating pressure. For
steam pipelines test pressure shall be 1.5 times the working pressure and duration 2 hrs.
e)
Leakage from welded joints shall be checked by tapping with light hammer. No sweating
should occur on the weld surface. Test shall be considered satisfactory if no visible
leakage is found and pressure in pipeline remains steady.
f)
In case hydraulic testing is not feasible, test shall be carried out by compressed air.
Leakage from joints shall be checked by soap solution.
g)
Test for tightness shall be carried out using compressed air at the operating pressure,
the test pressure shall be held for 12 hours. The percentage pressure drop calculated as
per formula given in para ( g ) of previous clause shall not exceed.
Commissioning of BF gas, Cold Blast, Nitrogen, Instrument Air, Steam and LPG
pipelines
Pipelines shall be commissioned only after successful completion of preliminary
acceptance test, strength tests and leakage tests.
All valves and regulating devices shall be checked for smooth & proper operation.
All safety relief valves shall be checked and set at required pressure setting.
All instruments, interlocks, etc., shall be checked.
Charging of BF Gas & LPG
Pipelines shall be commissioned only after successful completion of acceptance tests,
strength tests and leakage tests.
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Gases & Liquid Fluids
Page 46 of 51
GS-02
General Technical Specification
001
Before charging the pipelines with fuel gas, the entire air from
purged with nitrogen / Steam.
002
Before purging, all valves shall be set at required position, drain pots filled with water, all
hatches & manholes closed. All bleeders except the ones used for venting the purge
gas, shall be closed.
003
Discharge from the pipeline shall be through bleeder / vents only. The air / gas should
not be discharged into the shop / furnace.
004
Completion of purging shall be determined by taking samples from the bleeders. When
the oxygen content of two successive samples is less than 1%, the purging shall be
deemed to be completed.
005
After purging is complete, the gas shall be gradually charged into the pipelines. The
charging shall be done section wise gradually approaching the consumer end.
-
the
pipeline
shall
be
The gas shall be discharged through bleeders only. Exhaust gas from bleeders
can be set on fire.
Completion of filling shall be determined by taking samples from the bleeders. In
case oxygen content of two successive samples is less than 1 % the gas
blowing shall be deemed to be complete.
All activities of gas pipe purging and charging shall be co-ordinated in presence of
OWNER/ MECON, safety personnel, fire tenders, etc.
006
007
After charging the gas into the system, all isolating devices, instruments, controls, safety
devices, condensate seal pots, etc. shall be again checked for proper operation.
Charging of cold blast, nitrogen, Compressed Air
008
After pressure test, the nitrogen and instrument quality compressed air line / cold blast
line shall be purged with nitrogen and dry air respectively for removal of moisture, dirt ,
etc. from the piping system.
009
Nitrogen, Instrument quality compressed air, cold blast shall be subsequently charged in
the line by connecting with the existing network.
Charging of Steam.
B)
010
After pressure test steam pipeline shall be depressurised and drained of water fully
through drains/ by pass of steam traps. Subsequently, the pipeline shall be charged with
steam slowly by crack opening the steam supply valve keeping all drain points open.
011
When steam is observed from all drain points and consumer ends then steam valve at
the inlet to the system should be fully opened and all by pass valve on drains closed and
isolation valve on steam traps are kept open.
Oxygen pipelines
01
General
-
All work concerning oxygen pipeline system shall be done by persons of
contractor well conversant with the oxygen service and having proven ability in
the field.
-
All safety aspects with regards to selection of materials, erection procedure,
degreasing, testing and commissioning procedures, cleanliness, etc. shall be
kept in view by all personnel connected with the job.
-
Erection of pipes, fittings, instruments, etc. shall be done strictly as per the
approved drawings. Any change proposed to be done at site shall have the
approval of the Purchaser’s/ Consultant’s representatives.
© 2007 MECON Limited
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Gases & Liquid Fluids
Page 47 of 51
GS-02
General Technical Specification
02
003
Routing of oxygen pipes
-
Oxygen pipes can be laid along with other pipes on same stockades. Oxygen
pipeline shall have independent support from the same stockade.
-
Clear distance of 300 mm shall be kept between oxygen pipe and any other
pipe.
-
In-shop pipes can be laid along the wall and can be supported from building
structures, crane girders etc. by independent brackets, hangers, etc.
-
Pipelines laid in trenches shall be covered with sand/ earth.
-
Oxygen pipeline shall not be laid in tunnel/ basements. In case, it is necessary to
pass the pipeline through a tunnel, an encasing pipe shall be provided on
oxygen line extending 1.0 m on both the ends of the tunnel.
-
A clearance of 500 mm shall be kept between oxygen pipe and electrical cables
and in case of bare conductors, the clearance shall be 1000 mm.
-
Oxygen pipelines crossing the walls/ floors shall also have encasing pipe. The
gap between the pipe and casing shall be filled with non-inflammable material
allowing movement of the pipe.
-
Oxygen pipelines shall be effectively earthed, Jumpers of minimum 5
diameter shall be proved at all flanged joints.
Materials
-
004
mm
All materials supplied for erection shall have manufacturer’s test certificates
including materials test and hydraulic test reports.
Cleanliness
-
All steel pipes & fittings shall be pickled at the manufacture’s works or at site
prior to degreasing.
-
In case, pickling is done at manufacturer’s work, the ends of pipes shall be
sealed/ plugged, and then pipes packed and tagged ‘pickled for oxygen service’
before despatch.
-
Pickling shall be done using HCL of 20% concentration (w/ w). After pickling,
pipes shall be washed with water, neutralised with 0.25% NaOH solution and
again washed with water.
-
Before erection, the pipes & fittings shall be visually inspected for presence of
scales/ foreign matter like fillings, flux, corrosion products, dirt, wood and metal
chips, threading compounds, sealants, tar asphalt, moisture, paint, chalk, etc.
-
The pipe work shall be thoroughly cleaned to ensure removal of all foreign
matter.
-
Presence of grease or oil shall also be checked visually. Inside surface of pipes
shall be checked by passing clean white cotton piece.
Hands, clothes and aprons of the workers doing erection job shall be clean and free of oil
and grease.
005
Degreasing
-
Before erection, all pipelines, fittings, valves, gaskets, packing material,
instruments etc. shall be degreased using proper solvent like carbon
tetrachloride or trichloroethylene. For initial degreasing detergent made by
mixture of sodium hydroxide trisodium phosphate and calcium sodium silicate
can be used.
-
The quality of the solvent used for degreasing shall
application.
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Gases & Liquid Fluids
Page 48 of 51
be checked before its
GS-02
General Technical Specification
006
007
-
The parts to be degreased should be cleaned and dried by blowing air.
-
Outer surface of pipes is degreased by wiping with cloth dipped in solvent and
then dried till smell of solvent disappears.
-
For degreasing inner surface of pipes, pipe shall be plugged at one end, filled
with solvent and closed at the other end. Pipe shall be kept in horizontal position,
rotated about axis at least once in a minute. After continuing the process for
about 15 minutes, the solvent shall be drained and pipe blown with dry oil free
air or nitrogen for at least 5 minutes.
-
Drying after degreasing can also be done in open air for at least 24 hours.
-
Vapour degreasing method can also be applied for pipes.
-
For degreasing of valves, fittings and other components, the same shall be
dismantled and parts dipped in solvent for 5 to 10 minutes. After degreasing, the
parts shall be dried in open air till smell of solvent is eliminated.
-
Gaskets and packing material shall be degreased by dipping in solvent for 1.5 to
2 hours after which these shall be dried in open air for 24 hours.
-
Degreasing operation shall be done in open air.
-
The workers should use safety masks to prevent hazards due to inhaling of the
solvent vapours. Solvent contact with skin shall also be avoided.
-
Safety aspects regarding handling of solvents shall be kept in mind during
degreasing process.
Erection
-
Erection of oxygen pipelines shall be done as per approved drawings and
general guidelines for erection of pipelines.
-
Gas welding or electric arc welding shall be used for erection of pipelines.
Welding shall be done by qualified welders.
-
Qualifying tests for welding, welding procedures and quality control etc. shall be
generally as per IS: 2825, ‘ code of Practice for Unfired pressure Vessels’.
-
Radiographic examination of 100% welds for oxygen pipelines with working
2
pressure over 6 kgf/ cm (g) and OD above 76 mm shall carried out.
Interpretation of radiographs shall be done by a competent agency like Lloyds
Register of Shipping. Proper identification marking for welds and their
corresponding radiographs shall be carried out by the contractor.
-
For pipelines having working pressure below 6 kgf/ cm (g), 40% welds shall be
tested by radiography.
-
Cleanliness of personnel as well as tools and tackles shall be ensured.
2
Testing
-
All erected pipelines shall be tested for strength and leakage using dry and oil
free air or nitrogen.
-
Before testing, the pipeline shall be degreased by vapour degreasing method.
-
After degreasing, the pipelines shall be blown with dry and oil free nitrogen.
During blowing, velocity in the pipeline shall not be less than 20 m/ sec.
-
Blowing shall be done for a period of at least 1 hour to remove all particles of
dust, scale etc. from the system. Cleanliness shall be checked by holding a
piece of white paper at the air outlet.
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Gases & Liquid Fluids
Page 49 of 51
GS-02
General Technical Specification
-
After blowing, the line shall be pressurized up to 1.25 times the maximum
working pressure using air/ nitrogen. The test pressure shall be held for 30
minutes during which the joints shall be lightly tapped with a wooden hammer of
1.5 kg weight.
-
Pressure shall be gradually reduced to the operating pressure and all joints
checked by soap solution for leakage. If any leakage is detected, line shall be
depressurized and defect rectified.
-
Leakage test for the pipeline system shall be done at operating pressure for a
period of 24 hours. During this period, pressure and temperature readings shall
be taken at an interval of 1 hour. Duplicate gauge with least count of 0.1 kg/ cm2
for pressure and 0.5 deg. C for temperature shall be used.
-
The percentage pressure drop (P) shall be calculated as follows :
P = 100 (1 – P2/ P1= * T1/ T2 )
Where P1 and P2 are pressure in the pipe at the beginning and end of test and T1 and
T2 are absolute temperatures at the beginning and end of the tests.
008
009
-
Leakage of air / nitrogen determined by above formula shall not exceed 0.2%
per hour.
-
After satisfactory completion of leakage test, the pipeline shall be isolated and
2
kept under pressure of 1.0 kg/ cm till the line is commissioned.
Commissioning
-
Before charging the pipeline with oxygen, the line shall be blown with dry, oil free
air/ nitrogen at a velocity of minimum 20 m/ s for a period of at least 8 hours.
Cleanliness of outlet air shall be checked by holding a piece of white paper for 3
to 5 minute at air outlet. If dust particles are found on the paper, blowing shall be
continued till paper test shows negative results.
-
After completion of blowing, oxygen shall be introduced gradually increasing the
oxygen percentage in the pipe. The velocity of oxygen flow shall be limited to 10
m/ s till all air/ nitrogen is exhausted from the pipe.
-
Oxygen shall be vented through bleeders in open atmosphere at a safe place
away from open flames/ fire. Minimum height of bleeder outlet shall be 2.5 m
from ground/ platform level or shop roof.
-
After charging the line completely with oxygen, bleeder valves shall be closed
and line may be put into service.
Safety
-
Testing, cleaning and commissioning of oxygen pipelines shall be carried-out
only in the presence of and with the permission of senior engineers of the and
the Consultant.
-
The safety department of the shall be informed and their concurrence taken on
all matters related to cleaning, testing and commissioning of oxygen pipe lines.
-
All first aid and fire fighting facilities should be readily available.
-
During testing of pipelines by air, the area shall be cordoned off and clear
working placards shall be displayed.
-
All safety precautions shall be observed in storage and handling of solvents.
Passing and acceptance of pipelines
Prior to passing and acceptance of pipelines for operation they shall be inspected
with the view to check that all civil, structural, erection and special works are completed.
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Gases & Liquid Fluids
Page 50 of 51
GS-02
General Technical Specification
Before handing over the pipelines for operation, the Contractor shall provide the
following technical documents.
001
Certificates of inspection, degreasing and testing of fittings, pipe joints and parts.
002
Certificate on the inspection of internal cleanliness of pipes.
003
Certificates on pipe, flanges, plugs and welding material.
004
Copies of the welder`s certificates.
005
Results of mechanical testing of samples.
006
Certificate on testing of pipelines for strength and leaks.
007
Principal scheme of pipelines with indications of welded butts and labels.
© 2007 MECON Limited
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Gases & Liquid Fluids
Page 51 of 51
GS-02
General Technical Specification
01
G E N E R AL
01.01
This
specification covers the materials, tools, facilities and quality
requirement for surface preparation and painting of steel structures,
equipment, piping, ducts, chutes, wood work etc.
01.02
This is only a general guideline of the painting scheme to be followed by
the Tenderer. However, in case a specific painting procedure is stipulated
in any tendering specification, then this general guideline shall be
s u p e r c e d e d . A n y s p e c i a l c a s e w h i c h m a y a r i s e f r o m t im e t o t i m e s h a l l b e
dealt with individually on the merit of each case
01.03
The term “painting” referred herein covers rust preventive, fungus/insects
preventive and decorative coating along with surface protection of the
following area but not limited to the areas indicated below.
i)
ii)
iii)
iv)
v)
vi)
Structural steel works
Mechanical equipment
Electrical equipment
Instrumentation and control equipment.
Pipe work
O x yg e n p l a n t , e t c .
01.04
Surfaces made of asbestos, aluminum, brass, bronze, galvanized steel,
s t a i n l e s s s t e e l , c a s t i r o n a n d o t h e r c o r r o s i o n r e s i s t a n t a l l o ys a n d
r u b b e r / s yn t h e t i c p o l y m e r / f i b e r r e i n f o r c e m e n t p l a s t i c a n d b u r i e d p i p e w o r k
are not required to be painted unless specified except for aesthetic
purposes or for identification bands, wherever relevant.
01.05
T h e c o m p l e t e p a i n t s ys t e m f o r a n y i t e m i n c l u d e s t h e f o l l o w i n g b a s i c
activities:
i)
ii)
iii)
iv)
Proper surface preparation
Application of primer coats
Application of intermediate coats
Application of finished coats
All the above coats shall be of quality paint products and of approved
m ak e . T h e s c o p e o f w o r k s h a l l a l s o i n c l u d e s u p p l y o f a l l p a i n t m a t e r i a l s a s
per specification described herein.
01.06
I f t h e c o n t r a c t o r d e s i r e s t o a d o p t a l t e r n a t i v e p a i n t s ys t e m f o r a n y s p e c i f i c
i t e m f o r a n i m p r o v e m e n t o r e q u i v a l e n t t o t h e s ys t e m s p e c i f i e d h e r e - i n o r
as per recommendations of paint manufacturer, may do so subject to
purchaser’s approval in advance.
02
S U R F AC E
02.01
Surface preparation required for paint application, shall be such as to
clean the surface thoroughly of any material which will be conducive to
premature failure of the paint substrates.
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P R E P AR AT I O N
Painting
Page 1 of 19
GS-09
General Technical Specification
02.02
All surfaces shall be cleaned of loose substances, and foreign materials,
such as dirt, rust, scale, oil, grease, welding flux, etc. in order that the
prime coat is rigidly anchored to the virgin metal surface. The surface
preparation shall confirm to pictorial representation of surface quality
g r a d e o f S we d i s h S t a n d a r d s I n s t i t u t i o n
SIS – 055900 or equivalent
standards such as SSPC – VIS – 1.67 or DIN 55928(Part 4) or BS 4232 or
IS 1477 – 1971 (Part I)
02.03
The acceptable surface preparation quality / grade are described under
e a c h p a i n t s ys t e m . T h e p r o c e d u r e s i n c l u d e s o l v e n t c l e a n i n g , h a n d t o o l
cleaning, power tool cleaning, blast cleaning, wood surface cleaning,
f l a m e c l e a n i n g a n d p i c k l i n g . T h i s wi l l e n s u r e s u r f a c e q u a l i t y a s r e q u i r e d
by the specific primer paint. For ready reference surface preparation
quality grade to be adopted in respect of SIS 055900 and DIN 55928
(part-4) is given in Annexure-01.
02.03.01
Solvent Cleaning
T h e s u r f a c e s h a l l b e c l e a n e d b y w i p i n g , i m m e r s i o n , s p r a yi n g o r v a p o u r
c o n t a c t i n g o f a s u i t a b l e s o l v e n t o r wa s h i n g wi t h a n e m u l s i o n o r a l k a l i n e
solution to remove oil, grease, dirt, old paint, etc. Solvent cleaning shall
n o t r e m o v e r u s t , s c a l e s , m i l l s c a l e s o r we l d f l u x . T h e r e f o r e , b e f o r e
a p p l i c a t i o n o f p a i n t , s o l v e n t c l e a n i n g s h a l l b e f o l l o we d b y o t h e r c l e a n i n g
procedures as stated in subsequent clauses.
02.03.02
Hand Tool Cleaning
The surface shall be cleaned manually by vigorous wire brushing as per
g r a d e S t - 2 q u a l i t y o f S we d i s h S t a n d a r d I n s t i t u t i o n S I S 0 5 5 9 0 0 a n d D I N
555928. This method effectively removes loosely adherent materials, but
would not affect residues of rust or mill scales that are intact are firmly
a d h e r e n t . F i n a l l y t h e s u r f a c e i s t o b e c l e a n e d wi t h a v a c u u m c l e a n e r o r
with clean compressed air or with clean brush. After preparation the
surface shall have a faint metallic shine. The appearance
shall
correspond to the prints designated St – 2.
02.03.03
Power Tool Cleaning
The surface shall be cleaned by electric or pneumatic tools, such as
brushes, sanding machines, disc abrasive grinder, rotar y disc scaler etc.
t o S t – 3 q u a l i t y. T h e t o o l s s h a l l b e u s e d c a r e f u l l y t o p r e v e n t e x c e s s i v e
roughening of surface and formation of ridges and burrs. This method will
remove loosely adherent materials but would not affect residues of rust or
mill scales that are firmly adherent and intact.
02.03.04
Blast Cleaning
The surface shall be cleaned by impingement of abrasive materials, such
as graded sand at high velocity created by clean and dr y compressed air
blast as per the grade according to Swedish Standard Institution SIS
0 5 5 9 0 0 . T h i s m e t h o d wi l l r e m o v e l o o s e l y a d h e r e n t m a t e r i a l s a s w e l l a s
adherent scales and mill scales. Prior to application of blast, heavy
deposit of oil and grease are removed by solvent cleaning excessive
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Painting
Page 2 of 19
GS-09
General Technical Specification
surface scales are removed by hand tools or power tool cleaning. The
extent of removal of adherent scales is varied, depending on the
application and are defined by the surface quality grades Sa1, Sa2, Sa2.5
and Sa3 in the order of increasing cleanliness. The blast cleaning is not
recommended for sheet metal work.
02.03.05
Flame Cleaning
T h e s u r f a c e i s c l e a n e d b y r a p i d h e a t i n g b y m e a n s o f o x ya c e t yl e n e f l a m e
to loosen the adherent scales, followed immediately by wire brushing.
T h i s m e t h o d w i l l r e m o v e l o o s e l y a d h e r e n t m a t e r i a l s a s we l l a s m o s t o f t h e
a d h e r e n t s c a l e s a n d m i l l s c a l e s . I n o r d e r t o m i n i m i ze o r p r e v e n t d i s t o r t i o n
f l a m e c u t t i n g s h a l l n o t b e u s e d o n m em b e r s h a v i n g t h i c k n e s s o f 6 m m a n d
lower.
02.03.06
Pickling
In this method the surface is cleaned of mill scales, rust or rust scales by
c h e m i c a l r e a c t i o n o r e l e c t r o l ys i s o r b o t h .
03.
P AI N T AP P L I C AT I O N
03.01
Paints
03.01.01
Paint shall be applied in accordance with paint manufacturer’s
r e c o m m e n d a t i o n s . T h e wo r k s h a l l g e n e r a l l y f o l l o w I S 1 4 7 7 – 1 9 7 1 ( P a r t I I )
for jobs carried out in India and SSPC-PA-1 or DIN 55928 or equivalent
for jobs carried out outside India.
03.01.02
General compatibility between primer and finishing paints
established by the paint manufacturer supplying the paints.
03.01.03
In the event of conflict between this general procedure on painting and
the paint manufacturer’s specification, the same shall be immediately
brought to the notice of the Purchaser. Generally in cases of such
conflicts, manufacturer’s specifications/recommendations shall prevail.
03.01.04
B e f o r e b u yi n g t h e p a i n t i n b u l k , i t i s r e c o m m e n d e d t o o b t a i n s a m p l e o f
paint and establish “Control Area of Painting”. On Control Area, surface
preparation and painting shall be carried out.
03.01.05
If required, samples of paint shall be tested in laboratories to establish
quality of paint with respect to:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
03.01.06
shall
be
Viscosity
Adhesion/Bond of paint in steel surfaces
Adhesion/Simulated salt spray test.
C h e m i c a l a n a l ys i s ( p e r c e n t a g e o f s o l i d s b y w e i g h t )
Normal wear resistance as encountered during handling & erection.
Resistance against exposure to acid fumes, etc.
W h o l e q u a n t i t y o f p a i n t f o r a p a r t i c u l a r s ys t e m o f p a i n t s h a l l b e o b t a i n e d
f r om t h e s a m e m a n u f a c t u r e r .
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GS-09
General Technical Specification
03.01.07
The main Contractor shall be responsible for supply of paints and this
responsibility shall not be passed on to the sub-contractor.
03.01.08
The painting material as delivered to the Contractor, must be in the
manufacturer’s original container bearing thereon manufacturer’s name
b r a n d a n d d e s c r i p t i o n . P a i n t / P a i n t i n g m a t e r i a l i n c o n t a i n e r s wi t h o u t l a b e l s
or with illegible labels shall be rejected, removed from the area and shall
not be used.
03.01.09
T h i n n e r s wh e r e v e r u s e d s h a l l b e t h o s e r e c o m m e n d e d b y t h e p a i n t
manufacturers and shall be obtained in containers with manufacturer’s
name and brand name of thinner legibly printed, failing which the thinner
is liable to be rejected and shall not be used.
03.01.10
All paint containers shall be clearly labeled to show the paint
identification, date of manufacture, batch number, special instruction,
shelf life etc. The container shall be opened only at the time of use.
03.01.11
All paints shall be stored in accordance with the requirements of laid
down procedure by the paint manufacturer.
03.01.12
All ingredients in a paint container shall be thoroughly mixed to break-up
lumps and disperse pigments before use and during application to
maintain homogeneity.
The proposed make, quality and shade of the paint shall have the
approval of the client.
03.01.13
03.01.14
The colour code of the finishing paint to be followed shall be intimated to
the successful Tenderer after finalisaiton of order. The undercoat shall
have different tint to distinguish the same from the finishing coat.
03.01.15
The Contractor shall furnish paint manufacturer’s test report or technical
data sheet pertaining to the paint selected. The data sheet shall indicate
a m o n g o t h e r t h i n g s t h e r e l e v a n t s t a n d a r d s , i f a n y, c o m p o s i t i o n i n we i g h t
p e r c e n t o f p i g m e n t s , v e h i c l e s , a d d i t i v e s , d r y i n g t i m e , v i s c o s i t y, s p r e a d i n g
rate, flash point, method of application, quality of surface preparation
required, corrosion resistance properties and colour shades available.
03.01.16
For details of paint materials refer Annexure - 02
03.02
General
03.02.01
Each coat of paint shall be continuous, free of pores and of even film
t h i c k n e s s wi t h o u t t h i n s p o t s .
03.02.02
Each coat of paint shall be sufficiently dr y before application of next coat.
03.02.03
Paint shall be applied at manufacturer’s recommended rates. The number
of coats shall be such that the minimum dry film thickness specified is
a c h i e v e d . T h e d r y f i l m t h i c k n e s s o f p a i n t e d s u r f a c e s s h a l l b e c h e c k e d wi t h
ELCOMETER of measuring gauges to ensure application of specified DFT.
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Painting
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GS-09
General Technical Specification
03.02.04
Z i n c r i c h p r i m e r p a i n t s wh i c h h a v e b e e n e x p o s e d s e v e r a l m o n t h s b e f o r e
finishing coat is applied shall be washed down thoroughly to remove
soluble zinc salt deposits.
03.02.05
T h e m a c h i n e f i n i s h e d s u r f a c e s s h a l l b e c o a t e d w i t h wh i t e l e a d a n d t a l l o w
before shipment or before being put out into the open air.
03.02.06
Areas which become inaccessible after assemble shall be painted before
a s s e m b l y ( a f t e r o b t a i n i n g p a i n t i n g c l e a r a n c e f r om t h e i n s p e c t i n g a u t h o r i t y)
after requisite surface cleaning as specified.
03.02.07
P a i n t s h a l l n o t b e a p p l i e d wh e n t h e a m b i e n t t e m p e r a t u r e i s 5 d e g C a n d
below or 45 deg C and above. Also paint shall not be applied in rain,
wind, fog or at relative humidity of 80 % and above unless the
manufacturer’s recommendations permit. Applications of paint shall be
o n l y b e s p r a yi n g o r b r u s h i n g a s p e r I S 4 8 6 – 1 9 8 3 a n d I S 4 8 7 – 1 9 8 5 .
03.02.08
Primer paint shall be applied not later than 2 – 3 hours after preparation
of surface, unless specified otherwise.
03.02.09
Edges, corners, crevices, depressions, joints and welds shall receive
special attention to ensure that they receive painting coats of the required
thickness.
03.02.10
Surfaces which cannot be painted but require protection shall be given a
coat of rust inhibitive grease according to IS 958 – 1975 or solvent
deposited compound according to IS 1153 – 1975 or IS 1674 – 1960.
03.02.11
Surfaces in contact during shop assembly shall not be painted. Surfaces
which will be inaccessible after assembly shall receive minimum two coats
of specified primer.
03.02.12
Surfaces to be in contact with wood, brick or other masonr y shall be given
one shop-coat of the specified primer.
03.03
Site/Field Painting
03.03.01
W herever shop primer painting is scratched, abraded or damaged, the
surface shall be thoroughly cleaned using emery paper and power driven
w i r e b r u s h w h e r e v e r wa r r a n t e d , a n d t o u c h e d u p w i t h c o r r e s p o n d i n g
primer. Touching up paint shall be matched and blended to eliminate
conspicuous marks.
03.03.02
If more than 50% of the painted surface of an item requires repair, the
entire item shall be mechanically cleaned and new primer coats shall be
applied followed by intermediate and finishing coats as per painting
specification.
03.03.03
A l l f i e l d we l d e d a r e a s o n s h o p p a i n t e d i t e m s s h a l l b e m e c h a n i c a l l y
cleaned (including the weld area proper, adjacent areas contaminated by
w e l d s p a t t e r o r f u m e s a n d a r e a s wh e r e e x i s t i n g p r i m e r p a i n t i s b u r n t ) .
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Painting
Page 5 of 19
GS-09
General Technical Specification
S u b s e q u e n t l y, n e w p r i m e r a n d f i n i s h i n g c o a t s o f p a i n t s h a l l b e a p p l i e d a s
per painting specification.
03.03.04
T h e f i r s t c o a t o f f i n i s h p a i n t a t s i t e s h a l l b e a p p l i e d p r e f e r a b l e wi t h i n t h r e e
months of the shop paint.
03.04
Structural
03.04.01
All fabricated steel structure, fabricated steel pipes, etc. shall have a
m i n i m um o f t w o c o a t s o f p r i m e r p a i n t b e f o r e d i s p a t c h t o s i t e .
03.04.02
Parts of steel structures embedded in concrete shall be given a protective
coat of Portland cement slurry immediately after fabrication and after
s u r f a c e s o f t h i s p a r t i s t h o r o u g h l y c l e a n e d f r om g r e a s e , r u s t , m i l l s c a l e s ,
etc. No paint shall be applied on this part.
03.04.03
All structures shall receive appropriate number of primer and finishing
coats
in
order
to
achieve
overall
DFT
as
per
design
drawings/specification.
03.05
Hot Surfaces
03.05.01
Total DFT for heat resistant paints should not exceed 100 – 120 microns,
otherwise flaking occurs (as per paint manufacturer’s recommendations).
03.05.02
Heat resistant paints should be applied by brush.
03.05.03
Primer coat should not be applied on the surfaces having temperature
condition more that 120 deg C.
04
P AI N T I N G S C H E M E S
F o r a c o m p l e t e p a i n t i n g s c h e m e o f a n y i t e m b e i n g p r i n t e d , a l l t yp e s o f
p a i n t s a r e t o b e p r o c u r e d f r o m t h e s a m e m an u f a c t u r e r a s a p p r o v e d b y t h e
purchaser.
04.01
Legend
SP 2P1 1I1 2F1 DFT CRT-
Surface preparation quality as per SIS standard
T wo ( 2 ) c o a t s o f P r i m e r p a i n t t yp e P 1
O n e ( 1 ) c o a t s o f I n t e r m e d i a t e p a i n t t yp e I 1
T wo ( 2 ) c o a t s o f F i n i s h p a i n t t yp e F 1
Dry Film Thickness in microns developed
Clean and Retouch
T yp e o f p a i n t p r o d u c t s l i k e P 1 t o P 9 , I 1 t o I 4 a n d F 1 t o F 1 0 h a v e b e e n
specified under Annexure-02.
04.02
The painting scheme to be followed for various structure/equipment
exposed to different condition is briefly given in Annexure-03 for guidance
to the tenderer.
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Painting
Page 6 of 19
GS-09
General Technical Specification
04.03
The colour code for different applications are indicated in Annexure-04.
W herever colour codes are not specified, the same is to be mutually
agreed between the Purchaser and Contractor.
05.
G U AR AN T E E
05.01
T h e C o n t r a c t o r s h a l l g u a r a n t e e t h a t t h e p h ys i c a l a n d c h e m i c a l p r o p e r t i e s
of the paint materials conform with the specification of paint products.
05.02
The Contractor shall submit internal test reports from paint manufacturers
regarding
the
quality
of
paint
whenever
asked
by
the
Purchaser/Consultant.
05.03
Guarantee period shall commence from the date of completion of finishing
coat of paint. The guarantee period will be indicated depending on the
t yp e o f s u r f a c e p r e p a r a t i o n a n d s ys t e m o f p a i n t i n g . T o f u l f i l l t h i s
obligations the Contractor may obtain from the painting manufacturer,
guarantee for the performance of paint/painted surfaces.
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Painting
Page 7 of 19
GS-09
General Technical Specification
Annexure-01
Surface Preparation Grade
Sl.
No.
1
Surface Preparation
Blast cleaning to white metal
Removal of all visible rusts, mill-scales, paint and
foreign matters.
2
Sa 3
Sa 3
Sa 2.5
Sa 2.5
Sa 2
Sa 2
Sa 1
Sa 1
St 3
St 3
St 2
St 2
Blast cleaning to commercial quality:
At least 2/3 of any section of the surface area is free
from all rusts, mill-scales and visible residues.
4
DIN Std. Din
55928 (Part 4)
Blast cleaning to near white metal:
95% of any section of surface area is free from all
rusts, mill-scales and visible residues.
3
Swedish Std
SIS 055900
Brush-off blast cleaning:
Removal of all loose mill-scales, rust and foreign
matters etc.
5
Power tool cleaning:
Very thorough scrapping and wire brushing to
remove loose mill-scale, rust and foreign matters to
have pronounced metallic shine.
6
Hand tool cleaning:
Removal by hand brushing of loose mill-scale, loose
rust and foreign matters.
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Painting
Page 8 of 19
GS-09
General Technical Specification
Annexure - 02
P AI N T M AT E R I AL S
01.
P R I M E R P AI N T S ( P )
Primer paint products shall be applied only on dr y and clean surfaces.
01.01
P r i m e r P a i n t – P 1 ( P h e n o l i c – Al k y d B a s e d )
A s i n g l e p a c k a i r d r y i n g p h e n o l i c m o d i f i e d a l k yd c o m p o s i t i o n w i t h z i n c
phosphate as a primer paint conforming generally to IS : 2074.
Air drying time
01.02
-
About 60 minutes (touch dry)
-
Overnight (hard dry)
Dry film thickness (DFT)/Coat
-
40 microns (min)
Temperature resistance
-
Upto 100 C dry heat
Primer Paint – P2 (Chlororubber Based)
A single pack air
phosphate primer.
01.03
0
d r yi n g
high
build
chlorinated
rubber
based
Percent chlororubber
-
20 to 22 (% Chlorine above 65% in
chlororubber)
Air drying time
-
About 15 minutes (touch dry)
Overnight (hard dry)
DFT/ Coat
-
50 microns (min)
Temperature resistance
-
Up to 65 C dry heat
zinc
0
Primer Paint – P3 (PVC Copolymer Alkyd Based)
Polyvinyl chloride (PVC)
-
Alkyd zinc phosphate – redoxide
based primer
Ratio
:
PVC copolymer + alkyd resin (1:1)
Pigments
:
Zinc phosphate & Fillers
Air drying time
-
24 hours
DFT/Coat
-
80 microns
Temperature resistance
-
Upto 80 C dry heat
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Painting
Page 9 of 19
0
GS-09
General Technical Specification
01.04
Primer Paint – P4 (Epoxy Based)
A t w o p a c k a i r d r yi n g E p o x y p o l ya m i d e r e s i n b a s e d r e d o x i d e - z i n c
phosphate primer.
01.05
Epoxy content (% wt.)
-
15 to 18
Air drying time
-
About 30 minutes (touch dry)
overnight (hard dry)
DFT/Coat
-
30 microns (min)
Temperature resistance
-
Upto 120 C dry heat
0
Primer Paint – P5 (Epoxy Based)
A t w o p a c k a i r d r yi n g E p o x y p o l ya m i d e w i t h zi n c d u s t o f a t l e a s t 9 2 % z i n c
dust on the dr y film
01.06
Epoxy content (% wt.)
-
8 to 10
Air drying time
-
Less than 10 minutes (touch dry)
Less than 2 hours (hard dry)
DFT/Coat
-
40 microns (min)
Temperature resistance
-
Upto 300 C dry heat
0
Primer Paint – P6 (Poly – Vinyl Butyral Resin Based)
A t w o p a c k a i r d r yi n g p o l yv i n yl b u t yr a l r e s i n b a s e d w a s h p r i m e r w i t h r u s t
inhibitive pigments.
01.07
Air drying time
-
5 to 7 minutes (touch dry)
2 hours (hard dry)
DFT/Coat
-
8 microns
Temperature resistance
-
Upto 65 C dry heat
Application for
-
Galvanised iron, aluminium, light
alloys etc. on which the adhesion of
conventional paints are poor.
0
Primer Paint – P7 (Ethyl Zinc Silicate, EZS Based).
A t wo p a c k h e a v y d u t y z i n c d u s t r i c h s i l i c a t e p r i m e r wh i c h p r o t e c t s t h e
surface with just a single coat.
T ota l s o l i ds ( 3 wt)
De ns it y ( g / c c )
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-
84 +/- 2
3. 0 7 + /- 0. 0 5
Painting
Page 10 of 19
GS-09
General Technical Specification
A ir dr yi n g t im e
DF T / c o at
T em per at ur e r es is t a nc e
01 . 08
-
T o t op c o a t 16 ho ur s
60 m ic r o ns
Up to 45 0 d eg C dr y h e at
P ri m e r P a in t – P8 ( H i g h B u i ld Co al T a r Ep o x y)
A t wo p ac k c o l d c ur ed H. B. ep ox y c o a l tar c o at i ng – no pr im er is r e qu ir e d.
01 . 09
M ix i n g r a ti o
A ir dr yi n g t im e
-
DF T / C oa t
-
B as e : Ha r d e ner ( 4: 1b y v o l .)
48 ho ur s ( h ar d dr y)
F u l l c ur e 7 d a ys
10 0 m ic r o ns
W o o d V a rn i sh - P 9
T r eat e d o il bas e d pr im er p igm e nt ed wi th s u it ab l e p i gm ents :
02 .
A ir dr yi n g t im e
-
16 ho ur s f or a pp l ic at i o n of
to p c o at .
Co v er ag e
-
10 t o 1 4 s q . m /l it r e
INT E RM EDI AT E P AI N T S ( I)
T hes e p a in ts s ha l l be ap p l ie d o v er p r im er c o ats as an i n ter m ed i a te l a yer t o
pr o v i d e we a th er pr o of s ea l of pr im er c oa ts .
02 . 01
In t er m e d i at e P ain t - I I ( P h e n o l i c al k yd b a s e d )
A s i n g le p ac k hi g h b u il d p h en o l ic b as e d p a in t wit h m ic ac e o us i r on ox id e
( M 10) .
A ir Dr yi n g T im e
2 d a ys ( ha r d d r y)
DF T /C o at
T em per at ur e r es is t a nc e
Com pa t ib l e wi t h
02 . 02
-
4 to 6h o ur s ( to uc h dr y)
-
7 5 m ic r ons ( m in)
Up to 10 0 d eg C d r y h e at
P r im er P 1
-
In t er m e d i at e P ain t - I 2 ( Ch lo ro ru b b e r b a s ed )
A s i n gl e p ac k a ir dr yi n g h ig h b u i ld c h l or o b a s ed pa i nt wi th MIO .
A ir Dr yi n g T im e
DF T /C oa t
T em per at ur e r es is t a nc e
Com pa t ib l e wi t h
02 . 03
-
1 5 m i nu t es ( to uc h dr y)
24 ho ur s ( h ar d dr y)
70 m ic r o ns ( m i n )
U pt o 6 5 d eg C d r y h e at
P r im er P 2, P 3 & P 4
In t er m e d i at e P ain t - I 3 ( P V C – Al k yd B a se d )
P VC C op l o ym er
P igm e nts
DF T /C oa t
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-
Res i n 1 : 1
M ic ac e ous ir o n ox i d e ( MIO )
80 m ic r o ns ( m i n)
Painting
Page 11 of 19
GS-09
General Technical Specification
T em per at ur e r es is t a nc e
Com pa t ib l e wi t h
02 . 04
-
Up to 80 d e g C dr y h e a t
Pr im er P2 & P 3
In t er m e d i at e p ai n t - I 4
A t wo p ac k a ir dr yi n g h ig h b u il d e p ox y r es in bas e d p ai n t wi t h MI O .
A ir dr yi n g t im e
DF T / c o at
T em per at ur e r es is t a nc e
Com pa t ib l e wi t h
03.
-
6 to 8 ho ur s ( t o uc h d r y)
7 d a ys ( f u l l c ur e)
10 0 m ic r o ns
0
Up t o 1 80 C dr y h ea t
Pr im er P4 & P 5
F I N I S H P AI N T S ( F )
Finish paint costs shall be applied over primer coats and intermediate
coats after proper cleaning and touch up of primed surface.
03.01
Finish Paint – F1
A s i n g l e p a c k a i r d r y i n g h i g h g l o s s p h e n o l i c a l k yd m o d i f i e d s yn t h e t i c
enamel paint suitably pigmented.
03.02
Air drying time
-
3 to 4 hours (touch dry)
24 hours (hard dry)
DFT/Coat
-
25 microns (min)
Temperature resistance
-
Upto 100 C dry heat
Compatible with
-
Colour
-
Primer P1
Intermediate I1
Generally all shades
0
Finish Paint – F2
A s i n g l e p a c k a i r d r yi n g p o l yu r e t h a n e e n a m e l o f h i g h g l o s s a n d h a r d f i n i s h
suitably pigmented.
Air drying time
-
2 to 2 ½ hours (touch dry)
6 hours (hard dry)
DFT/Coat
-
30 microns (min)
Temperature resistance
-
Upto 100 C dry heat
Compatible with
-
Colour
-
Primer P1 & P8 and
Intermediate I1
Generally all shades
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Painting
Page 12 of 19
GS-09
General Technical Specification
03.03
Finish Paint – F3
A t w o p a c k a i r d r yi n g b i t u m i n o u s a l u m i n u m p a i n t .
03.04
Air drying time
-
1 to 2 hours (touch dry)
21 hours (hard dry)
DFT/Coat
-
25 microns (min)
Temperature resistance
-
Upto 100 C dry heat
Compatible with
-
Primer P1 and Intermediate I1
Colour
-
Bright metallic
0
Finish Paint – F4
A r e a d y m i x e d o i l - a l k yd b a s e d s yn t h e t i c e n a m e l p a i n t o f h i g h g l o s s a n d
hard wearing properties.
03.05
Air drying time
-
6 to 8 hours
Coverage
-
14 to 16 Sq. m /litre
Temperature resistance
-
Upto 60 C dry heat
Compatible with
-
P8
Colour
-
Generally all shades
0
Finish Paint – F5
A s i n g l e p a c k a i r d r yi n g p l a s t i c i z e d c h l o r o r u b b e r p a i n t s u i t a b l y p i g m e n t e d .
Air drying time
-
30 minutes (touch dry)
24 hours (hard dry)
DFT/Coat
-
35 microns (min)
Temperature resistance
-
Upto 65 C dry heat
Compatible with
-
Colour
-
Primer P2 & P3,
Intermediate I2 & I3
Nearly all shades except few.
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0
Painting
Page 13 of 19
GS-09
General Technical Specification
03.06
Finish Paint – F6
A P V C – C o p o l ym e r a l k yd b a s e d e n a m e l .
03.07
Density
-
1.17 + 0.05
Total solids (1 wt)
-
55 + 2
DFT/Coat
-
40 microns
Compatible with
-
P2 and P3
Finish Paint – F7
A t w o p a c k a i r d r yi n g e p o x y p o l ya m i d e e n a m e l s u i t a b l y p i g m e n t e d .
03.08
Air drying time
-
2 to 3 hours (touch dry)
7 days (full cure)
DFT/Coat
-
40 microns (min)
Temperature resistance
-
Up to 130 C dry heat
Compatible with
-
Primer P4 & P5,
Intermediate I4
Colour
-
Generally all shades.
0
Finish Paint – F8
A s i n g l e p a c k s yn t h e t i c r u b b e r b a s e d a l u m i n i u m p a i n t .
Air drying time
-
2 hours (touch dry)
24 hours (hard dry)
DFT/Coat
-
25 microns (min)
Temperature resistance
-
Upto 200 C dry heat
Compatible with
-
No Primer paint except primer P6 is
applicable in case of non-ferrous
substrate.
Colour
-
Smooth aluminium.
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0
Painting
Page 14 of 19
GS-09
General Technical Specification
Annexure - 03
PAINTING SCHEME
Sl.
No.
1.0
1.1
1.2
Painting Scheme
At Shop
At Site
Description
Steel Structures
0
(Temp. not exceeding 80 C)
Technological steel structures for plant and
equipment
Indoor
SP – Sa 2.5
2P1
CRT
2F1
130
Outdoor
SP – Sa 2.5
2P1
1I1
CRT
2F1
205
SP – St-2 and/
or St-3
2P1
CRT
Fabricated steel structures at site for rung
ladders, cat-ladders, gates, rolling shutters,
etc. (Springs/rubbing surfaces excluded)
- Indoor / Outdoor
1.3
SP – St-2 and/
or St-3
2P1
- Outdoor
SP- St2 and/
or St-3
2P1
1I1
130
CRT
2F1
130
CRT
2F1
205
Steel doors and windows
- Indoor / outdoor
Sl.
No.
2.0
2F1
Walkways, stairs, platforms etc. which are of
wearing surface
- Indoor
1.4
Total
DFT
(Refer
Note-1)
SP–St-2 and / or
St-3
2P1
1I1
2F2
Painting Scheme
At Shop
At Site
Description
MECHANICAL EQUIPMENT
2.1
Mechanical equipment
0
(Temp. not exceeding 80 C)
2.1.1
Static equipment like storage tanks, vessels,
bins, bunkers, heat exchangers, coolers,
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CRT
Painting
Page 15 of 19
215
Total
DFT
GS-09
General Technical Specification
Sl.
No.
Painting Scheme
At Shop
At Site
Description
cyclones, scrubbers, etc.
2.1.2
Sl.
No.
3.0
3.1
- Indoor
SP – Sa 2.5
2P2/2P3
CRT
2F5/2F6
170/240
- Outdoor
SP – Sa 2.5
2P2/2P3+1I2/1I3
CRT
2F5/2F6
240/320
- Indoor
SP – Sa 2.5
2P3/2P4
CRT
2F6/2F7
240/140
- Outdoor
SP-Sa 2.5
2P3 + 1I3/1I4
CRT
2F6/2F7
320/340
Rotary/moving equipment and machineries
like crushers, mills, vibratory screens, bin
activators,
blowers,
fan,
air/gas
compressors, pumps, gear boxes, machine
housings etc.
Painting Scheme
At Shop
At Site
Description
Pipe / Duct work
(Overground)
SP – St2 and
or St3
2P1
SP – St2 and /
or St3
2P1 + 1I1
- Outdoor
Insulated (hot)
- Indoor/Outdoor
SP- St2 and/
or St3
1P1
Sl.
No.
4.0
4.1
Total
DFT
Non – insulated
0
(temperature up to 80 C)
- Indoor
3.2
Total
DFT
Oxygen Plant
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2F1
CRT
130
2F1
205
Remove
paint and
insulate
Painting Scheme
At Shop
At Site
Description
Outdoor steel
structures
CRT
SP – St2 and /
or St3
Painting
Page 16 of 19
Total
DFT
CRT
GS-09
General Technical Specification
Sl.
No.
Description
4.2
Rotary equipment like air compressors
5.0
Others
5.1
Standard mobile equipment like chasis of
trucks, dumpers, crawler cranes bulldozers,
railway rakes, chasis of slag cars, ladle cars,
etc.
Laboratory equipment like ovens, screens,
magnetic stirrers, samplers, etc.
Steel structures partly immersed in water
5.2
5.3
Painting Scheme
At Shop
At Site
2P1 + 1I1
2F3
Sa 2.5
CRT
2P4
2F7
Total
DFT
205
140
As per manufacturer’s standards
Stove enamelling
CRT
SP – Sa 2.5
CRT
2P8
110
200
Notes: 1.
Painting scheme of all fabricated steel structures, fabricated pipe work, building
s t r u c t u r e , c o n v e yo r g a l l e r i e s , p i p e t r e s t l e s e t c . i s i n d i c a t e d i n t h e T e c h n i c a l
Specification of steel structures.
2.
Primer Paint
Primer coat shall be suitable for intended temperature applications as per
manufacturer’s recommendation. The primer selection shall be generally in line
with the specification laid down in Annexure-02.
3.
Finish Paint
I n c a s e o f A l u m i n i u m c l a d d i n g f i n a l p a i n t i n g wi l l n o t b e r e q u i r e d .
© 2007 MECON Limited
All rights reserved
Painting
Page 17 of 19
GS-09
General Technical Specification
ANNEXURE - 04
COLOUR CODE
The colour codes are mentioned for all the items including pipe work. Shades of finish coat of paint applied
over respective item indicated below are tentative and subject to alteration as per Purchaser’s request or due
to compatible paint system adopted. The service for which colour code/bands are not specified are to be
mutully agreed for by the Purchaser & the Contractor.
Sl.
No.
1.
2.
Items Painted
Structures
Building frames including bracings, side
girts, louvers etc.
Crane girders
Crane stops
Gutters
Fire escape platforms ladders, etc.
General hand railing, top runners
Rung ladders
All members blocking passages for
movement
Trestles, towers and pipe bridges
Conveyor gallery structures
Steel chimneys
Equipment and Machinery
General indoor equipment
General outdoor equipment
Crane bridges, trolleys, hooks etc. and
other mobile equipment
Furnaces
Tanks
Fire-fighting equipment
3.
Colour
Colour No. of
IS:5
Aircraft grey
693
Azure blue
Post office red
Black bituminous aluminium
Signal red
Lemon yellow
Lemon yellow
Lemon yellow
104
538
537
355
355
355
Dark admiralty grey
Aircraft grey
Aluminium
632
693
-
Light grey
Dark admiralty
Base : Lemon yellow
Stripes : Black (100 mm
wide)
Aluminium
Base : Same as for general
equipment
Strips : Same shade as for
piping around the tnk at half
the tank height
Signal red
631
632
355
537
Pipe work
Colours shall be as given below. The base colour shall be applied throughout entire length except
on surfaces of materials such as asbestos, aluminium, brass, bronze, galvanized steel, stainless
steel and other corrosion resistant alloys and rubber / synthetic polymers. In such cases
identification colour bands of at least 500mm width shall be provided near each branch, valve and at
distances not exceeding 10m either as local colour coatings or coloured adhesive type of suitable
material or label attached to the pipe work. Additional identification bands superimposed over the
base colour shall be provided near each branch, valve and at distance not exceeding 10m. The
bands shall be atleast 25mm wide except in care of double bands where the first band shall be about
100mm wide. Direction of flow shall be clearly marked on the pipelines at intervals not exceeding
10m and all branches and change of directions.
© 2007 MECON Limited
All rights reserved
Painting
Page 18 of 19
GS-09
General Technical Specification
Service
Sea or river water (untreated)
Cooling water
Boiler feed water
Condensate
Drinking water
Industrial water
Compressed air
Instrument air
Drainage
Fuel oil
Coke oven/BF gas/other fuel
gases
Argon
Acetylene
LP Gas (LPG)
Nitrogen
Oxygen
Non-acidic slurries
Fire-fighting system
Rain water down pipes
Duct work
Colour
Base – Sea green
Band - White
Base – Sea green
Band - White
Base – Sea green
Base – Sea green
Band – Light brown
Base – Sea green
First band - French blue
Second band – Signal red
Base – Sea green
Band – Light orange
Base – Sky blue
Base – Sky blue
Band – Light brown
Base – Black
Base – Light brown
Band – Signal red
Base – Canary yellow
Band – Signal red
Base – Canary yellow
Band – French blue
Base – Canary yellow
Band – Dark violet
Base – Canary yellow
First band – Signal read
Second band – Traffic
green
Base – Canary yellow
Band – Black
Base – Canary yellow
Band – White
Base – Sea green
Band – White
Base – Signal red
Base – Sea green
Band – Sky blue
Base – Aluminium
217
217
166
217
217
410
217
166
537
217
557
101
101
410
410
537
309
537
309
166
309
796
309
537
267
Colour No. of IS:5
309
309
217
537
217
101
-
Note : For these services, hazard marking as per fig. 4C of IS:2379 shall also be provided.
© 2007 MECON Limited
All rights reserved
Painting
Page 19 of 19
GS-09
FORM NO. 11.20 (DQM) F-09, REV-0
ORDER NO. & DATE
QUALITY ASSURANCE PLAN
FOR
SUB - CONTRACTOR
ORDER NO. & DATE
STRUCTURAL & MECHANICAL
EQUIPMENT
CONTRACTOR
QAP shall be submitted for each of the equipment separately w ith break
up of assembly / sub-assembly & part/component or for group of equipment having same specification.
2
Use numerical codes as indicated for extent of inspection & tests and
submission of test certificates & documents. Additional codes & description for extent of inspection & tests may be added as applicable for
the plant and equipment.
3
Separate identification number w ith quantity for equipment shall be
indicated w herever equipment having same specification belonging to
different facilities are grouped together.
4
Code
MFG
:
PACKAGE NAME
Code Description
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
13. Heat Treatment
14. Pressure Test
15. Leakage test
16. Balancing
17. Vibration Test
18. Amplitude test
ABBREVIATIONS USED :
:
Description
1. Visual(Welding etc.)
2. Dimensional
3. Fitment & Alignment
4. Physical Test(Sample)
5. Chemical Test (Sample)
6. Ultrasonic Test
7. Magnetic Particle Test(MPT)
8. Radiography test
9. Dye Penetration Test
10. Metallographic Exam.
11. Welder's Qualification &
Weld Procedure Test
12. Approval of Test and Repair
Procedure
Weight in tonnes (T) must be indicated under column 5 for each item.
Estimated w eights may be indicated w herever actual w eights are not
available.
CONTR
PACKAGE NO.
CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS :
INSTRUCTIONS FOR FILLING UP :
1
PROJECT
CONTRACTOR
MANUFACTURER
E Q U I P M E N T
Code
Sponge test
Dust/Water Ingress test
Friction Factor Test
Adhesion Test
Performance Test/
Characteristic curve
No. Load/Free Running Test
Load/Overload Test
Measurement of speeds
Accoustical test
Geometrical Accuracy
Repeatability and Positioning
Accuracy
Proving Test
Description
34. Internal Inspection report
by Contractor
35. Hardness test
36. Spark test for Lining
37. Calibration
38. Safety device test
39. Ease of Maintenance
40. Thickness measurement
of Zinc coating
31. Surface Preparation
32. Manufacturer's Test Certificates
for bought out items
33 IBR/Other statutory agencies'
compliance certificate
D E T A I L S
Description (w ith equipment
Identification
No.
heading,place of use and
No.
No / M
INSPECTION AND TESTS
Quantity
3
4
Manufacturer's
Expected Sche-
T
Name and Address
dule of Final
5
6
brief specification)
1
2
for MECON ( Stamp & Signature )
D1. Approved GA draw ings
D2. Information and other reference
drg / stamped drgs released
for manufacture
D3. Relevant catalogues
D4. Bill of Material/ item no./
identification.
D5 Matchmark details
D6 Line/Layout diagram
D7 Approved erection procedures
D8 Unpriced sub P.O.w ith
specification and amendments
if any
D9. Calibration Certificate of all
measuring instrument and
gauges.
D10. Ordering Specification
Raw Material and Inprocess
Sl.
DOCUMENTS :
Test Certificates &
stage Inspection
Final Inspection / Test by
Inspn
MFR
CONTR
MECON
MFR
CONTR
MECON
7
8
9
10
11
12
13
For CONTRACTOR / SUB - CONTRACTOR
(Stamp & Signature )
Acceptance Criteria
documents to be
Standards/IS/BS/
REMARKS/
submitted to MECON
ASME/Norms and
SAMPLING PLAN
Documents
14
15
( Q . A . P . NO. TO BE ALLOTTED BY MECON )
NO.
/
/
/
MSHEET : OF
16
REV.
FORM NO. 11.20 (DQM) F-09, REV-0
CONTINUATION SHEET
E Q U I P M E N T
D E T A I L S
INSPECTION AND TESTS
Raw Material and Inprocess
Sl.
Description (w ith equipment
Identification
Quantity
No.
heading,place of use and
No.
No / M
3
4
Manufacturer's
Expected Sche-
T
Name and Address
dule of Final
5
6
brief specification)
1
2
for MECON ( Stamp & Signature )
Test Certificates &
stage Inspection
Final Inspection / Test by
Inspn
MFR
CONTR
MECON
MFR
CONTR
MECON
7
8
9
10
11
12
13
For CONTRACTOR / SUB - CONTRACTOR
(Stamp & Signature )
Acceptance Criteria
documents to be
Standards/IS/BS/
REMARKS/
submitted to MECON
ASME/Norms and
SAMPLING PLAN
Documents
14
15
( Q . A . P . NO. TO BE ALLOTTED BY MECON )
NO.
/
/
/
MSHEET : OF
16
REV.
FORM NO. 11.20 (DQM) F-10, REV-0
QUALITY ASSURANCE PLAN
FOR
ELECTRICAL EQUIPMENT
CONTRACTOR
ORDER NO. & DATE
SUB - CONTRACTOR
PROJECT
PACKAGE NO.
PACKAGE NAME
ORDER NO. & DATE
CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS :
INSTRUCTIONS FOR FILLING UP :
1
QAP shall be submitted for each of the equipment separately w ith break
up of assembly / sub-assembly & part/component or for group of equipment having same specification.
2
Use numerical codes as indicated for extent of inspection & tests and
submission of test certificates & documents. Additional codes & description for extent of inspection & tests may be added as applicable for
the plant and equipment.
3
Separate identification number w ith quantity for equipment shall be
indicated w herever equipment having same specification belonging to
different facilities are grouped together.
4
Code
MFG
:
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
12. Routine test as per relevant
IS/other standard.
13. Type tests as per relevant IS/
other standard.
ABBREVIATIONS USED :
:
Code Description
1. Visual
2. Dimensional
3. Fitment & Alignment
4. Physical Test(Sample)
5. Chemical Test (Sample)
6. Ultrasonic Test
7. Magnetic Particle Test(MPT)
8. Radiography test
9. Dye Penetration Test
10. Measurement of IR Value :
a) Before HV Test
b) After HV Test
11. High voltage test/Dielectric
test.
Weight in tonnes (T) must be indicated under column 5 for each item.
Estimated w eights may be indicated w herever actual w eights are not
available.
CONTR
Description
CONTRACTOR
Code
Impalse Test.
Partial Discharge Test.
Heat run test/Temp. rise Test.
Enclosure protection Test.
Calibration.
Noise & Vibration.
Test Certificates for bought
out components.
Tank pressure Test.
Paint shade verification.
Short time rating.
Operation & functional
check.
Overspeed Test.
DOCUMENTS :
D1. Approved GA draw ings
D2. Approved single line /
schematic diagram.
D3. Catalogues / Approved data sheet
D4. Approved bill of materials.
D5. Unpriced P.O. copy.
D6. Calibration Certificate of all measuring
instrument and gauges
26. Flame proof Test
27. Clearance and creepage
distance.
28. Acceptance Tests
as per relevant IS
MANUFACTURER
E Q U I P M E N T
D E T A I L S
INSPECTION AND TESTS
Raw Material and Inprocess
Sl.
Description (w ith equipment
Identification
No.
heading,place of use and
No.
No / M
Quantity
3
4
Manufacturer's
Expected Sche-
T
Name and Address
dule of Final
5
6
brief specification)
1
Description
2
for MECON ( Stamp & Signature )
Test Certificates &
stage Inspection
Final Inspection / Test by
Inspn
MFR
CONTR
MECON
MFR
CONTR
MECON
7
8
9
10
11
12
13
For CONTRACTOR / SUB - CONTRACTOR
(Stamp & Signature )
Acceptance Criteria
documents to be
Standards/IS/BS/
REMARKS/
submitted to MECON
ASME/Norms and
SAMPLING PLAN
Documents
14
15
( Q . A . P . NO. TO BE ALLOTTED BY MECON )
NO.
/
/
/
ESHEET :
OF
16
REV.
FORM NO. 11.20 (DQM) F-10, REV-0
CONTINUATION SHEET
E Q U I P M E N T
D E T A I L S
INSPECTION AND TESTS
Raw Material and Inprocess
Sl.
Description (w ith equipment
Identification
Quantity
No.
heading,place of use and
No.
No / M
3
4
Manufacturer's
Expected Sche-
T
Name and Address
dule of Final
5
6
brief specification)
1
2
for MECON ( Stamp & Signature )
Test Certificates &
stage Inspection
Final Inspection / Test by
Inspn
MFR
CONTR
MECON
MFR
CONTR
MECON
7
8
9
10
11
12
13
For CONTRACTOR / SUB - CONTRACTOR
(Stamp & Signature )
Acceptance Criteria
documents to be
Standards/IS/BS/
REMARKS/
submitted to MECON
ASME/Norms and
SAMPLING PLAN
Documents
14
15
( Q . A . P . NO. TO BE ALLOTTED BY MECON )
NO.
/
/
/
ESHEET :
OF
16
REV.