gujarat state electricity corporatiopn ltd office/ukai thermal power... · gujarat state...

EPC contract for disposing of fly ash and bottom ash for 200MW unit no. 3 & 4 and 210MW unit no. 5 from the

pumping station to the Dyke

GUJARAT STATE ELECTRICITY CORPORATIOPN LTD.

Engineering, procurement and construction (EPC) contract for disposing of fly ash and bottom ash for 200MW unit no. 3 &4 and 210MW unit no. 5 from the pumping station to the Dykes including Erection, Testing and Commissioning of pipes and Pumping Station with all Civil, Mechanical ,Electrical & instrumental Works with 1 year operation & maintenance for combine ash slurry pump house at Ukai TPS, Nr. Songadh, Dist. Tapi.

SECTION – IV

(SECTION-B)

Technical Specification

For Mechanical work



1.1 General

a. The scope of project Design, Manufacturing, Supply, Installation, Testing of New Proposed Bottom and Fly Ash Slurry disposal pumping station with all associated mechanical system at Ukai Thermal power plant.

b. Proposed pumping station having four set horizontal spilt case centrifugal (three

Working and one standby) of bottom and Fly ash disposal from power plant to ash dyke by laying of existing and new cast basalt pipe line.

c. The Contractor shall supply Mechanical Tools & Test Equipment Mandatory Spare Parts as per specified in Annexure M-1.

d. The contractor shall submit to the department such as QAP / data sheets / drawings / catalogues etc. and any other supporting documents (each 6 sets) of equipment / items of mechanical system before start of manufacturing and approval of Engineer-in-charge to be obtained. Before shipping of such items, the contractor shall obtain inspection release note / dispatch clearance from the Engineer-in-charge.

e. Where provisions of the pertinent codes and standards conflict with these Specifications, Drawings and Datasheets or with each other, comply with the more stringent provision.

f. Use the latest issue of Standards. Make available at least one copy of Standards for reference during construction.

g. Aforesaid project Unit we are proposed new Ash disposal project from Unit No 3, 4 and 5 herewith enclosed total detail project reports on Ash slurry disposal from plant Unit to Ash dyke.

h. Total Ash Slurry acquire in one of the rectangle type shape concrete structure

sump, its size 17.8 mtr Length,9 mtr Width and sump capacity of 400 M³.We are selecting maximum 2300m3/hr, medium 1400 m3/hr and Minimum 500m3/hr flow deliver Three set working and One Standby Ash slurry centrifugal pumps and install near to sump, Ash slurry flow controlled by fixing on suction side individual ash slurry 400 mm gate valve operate by the help of Pneumatic actuator and delivery side ash slurry 350 mm gate valve.

1. Scope of Work



Contractor will prior to inspect and execute existing individual 350 mm cast basalts delivery pipe of Ash Slurry Pump, can be reused, Refurnished as per site condition as well as Installed and laying at GSECL Ukai. Further, contractor will received balanced 350 mm Cast Basalts pipe isuued by main store GSECL, Ukai with his own transportation and forwarding charges. After remaining shortfall measured length of 350 mm Cast Basalts Delivery pipe can be procured by the contractor Prior to GSECL Approval.

New Combined ash slurry pumps sumps four set Pumps arrangement (As per shown in GA) with sump partition arrangement in equal margin and all partition controlled by the flow diversion by Plug valve system in sump. All suction side inlet of suction side pipe Air jet flushing and water jet flushing system arrangement propose in Project. Make up water arrangement planning for existing water source new pumps (one working and one stand by) and individual separate water pipe line lay from the Water pumps room to Combined Ash Slurry Pumps. Seal water pumps one working and one stand by system for all three Plus One Working Ash Slurry Pumps arrangement propose in project. Slurry pumps shaft connected with installed inline RPM reducing helical Gear Box, gear box ratio defined on the base of scoop controlled variable speed Fluid coupling system and minimum and Maximum flow requirements. major role of variable speed control by the Fluid coupling system as per required flow, variable speed fluid coupling providing steeples speed variation in a wide range when connected to fixed speed electric motor. The speed variation is obtained by varying the oil filling in coupling through a sliding scoop tube when in operation. Fluid coupling system advantages like no load starting of motor, controlled starting torque for machine acceleration, continuous declutching, steeples speed variation and synchronizing of motors in multi drive units, load limiting in a very wide range for safety of motors and machine. It offers flexibility in controls as it can respond to various electric (PLC), pneumatic or hydraulic signals and it is compatible with all types of controllers like pneumatic, hydraulic, electronic, electrical or manual. Beside it offers all the advantages of constant speed fluid coupling like load limiting, absorption of shock loads, torsional loads and vibrations, smooth acceleration etc. Its built-in safety arrangements make it fool-proof during operation. Coupling system consists of a fluid coupling housed in a self-supported stationary housing having a built-in oil Sump. Oil is continuously introduced in the working circuit of fluid coupling through an oil pump. The oil circulates through the working



circuit and finally passes to the secondary casing and is collected by a sliding scoop tube. The position of scoop tube governs the oil level in the working circuit, thus controlling the speed. The position of sliding scoop tube can be governed through suitable actuator and can also be operated manually. On the input and output ends, suitable flexible couplings are provided for the shafts connections. Labyrinth Seals provided on input and output shaft is an effective barrier and ensures no leakage from shaft ends. Operation of scoop controlled variable speed Fluid coupling system having sliding scoop tube governs the oil level in the working circuits depending on its (scoop tube) position between 0% to 100%. By varying the oil level in the working circuit the torque transmission capacity of the coupling varies, thus changing the slip of the coupling and provides steeples speed variation in a wide range. The heat generated in the coupling is picked up by the circulating oil which is cooled by oil cooler provided in the oil circuit. variable speed Fluid coupling system provides very useful steeples speed regulation in the range of 5:1 for centrifugal loads pumps, it is also very useful for continuous declutching of pump with motor running.

1.2 Codes & Standards

The machinery, equipment, component and material shall conform to the latest revision

of the following standards:

Sr.No. Code Description

01 IS -5 Colours for ready mixed paints and enamels.

02 IS -104 Ready mixed paint, brushing, zinc chrome, priming

03 IS -807 Code of practice for design, manufacture, erection and testing (structural portion) of cranes and hoists

04 IS -816 Code of practice for use of metal arc welding for general construction in mild steel

05 IS -900 Code of practice for installation and maintenance of induction motors.

06 IS – 1239 Mild steel tubes, tubular and other wrought steel fittings

07 IS – 1710 Vertical turbine pumps for clear, cold, freshwater.

08 IS – 2062 Steel for general structural purposes.




09 IS – 2629 Recommended practice for hot dip galvanizing on iron and steel

10 IS – 2633 Hot dip galvanizing

11 IS – 4691 Degree of protection provided by enclosures for rotating electrical machinery.

12 IS – 4137 Code of practice for heavy duty electric overhead travelling cranes including special service machines for use in steel work.

13 IS – 4722 Rotating electrical machines.

14 IS – 4889 Method of determination of efficiency of rotating Electrical machines.

15 IS – 12776 Galvanized strand for Earthling

16 IS – 13095 Wafer type butterfly valve size from 40 mm to 2000 mm

17 IS – 14846 Non-rising stem type sluice valve size from 50 mm to 1200 mm

18 IS -3589 Steel Pipes for Water and Sewage (168.3 to 2540 mm Outside Diameter-Specification

19 IS-4711 Methods for sampling of Steel Pipes, Tubes and Fittings

20 IS- 5312 Swing Check type reflux (non- return) valves for water work purposes-Specification Part-1

21 IS-14845 Resilient seated Cast Iron Air Relief Valves for water Works Purposes-Specification

22 IS -325 Three Phase Induction Motors Specification

23 IS-10981 Class of Acceptance Test for Centrifugal Mixed Flow And Axial Pumps - Class B

24 IS -1570(Part V)

Schedules for Wrought Steels - Part 5: Stainless And Heat-resisting Steels

25 IS -9866 Marking system for valves

26 IS- 638 Sheet Rubber Jointing and Rubber Insertion Jointing

27 IS-1363 (Part-1)

Hexagon Head Bolts, Screws and Nuts of Product Grade C - Part 1 : Hexagon Head Bolts (Size Range M 5 to M 64)

28 IS-1363 (Part 2)

Hexagon Head Bolts, Screws and Nuts of Product Grade C - Part 2 : Hexagon Head Screws (Size Range M 5 to M 64)

29 IS-1363( Part 3)

Hexagon Head Bolts, Screws and Nuts of Product Grade C - Part 3 : Hexagon Nuts (Size Range M5 to M64)

30 IS- 6603 Stainless Steel Bars and Flats

31 IS-3444 Corrosion Resistant High Alloy Steel And Nickel Base Castings for General Applications




32 IS -1367 Technical Supply Conditions for Threaded Steel Fasteners

33 IS-5620 Recommendations for Structural Design Criteria for Low Head Slide Gates

34 IS-4622 Recommendations for Structural Design of Fixed-Wheel Gates

35 IS-4029 Guide for Testing Three Phase Induction Motors

36 IS-807 Design, erection and testing (structural portion) of cranes and hoists - Code of practice

37 IS-3177 Code of Practice for Electric Overhead Travelling Cranes and Gantry Cranes other than Steel Work Cranes

38 IS-3938 Electric Wire Rope Hoists

39 IS-13834 Crane Classification

40 IS-2048 Parallel Keys and Keyways

41 IS-2291 Tangential keys and keyways

42 IS-2292 Taper Keys and Keyways

43 IS-2293 Gib-head Keys and Keyways

44 IS-2327 Straight sided splines for cylindrical shafts with internal cantering - Dimensions, tolerances and verification

45 IS-2610 Power transmission - Straight sided splines for machine tools - Dimensions

46 IS 10981 Test setup and test procedure & Details of instrumentation along with their least counts and calibration certificates

47 HI 20.3-2010

Hydraulic Institute Guideline for Rotodynamic (Centrifugal and Vertical) Pump Efficiency Prediction

48 IS-5749 Specification for Forged Ramshom hooks

49 HIS Hydraulic Institute Standards

50 API 594 Check Valves: Wafer, Wafer lugs and Double Flanged type

51 API 598 Valve Inspection and Testing



2.1 General

This specification covers design, manufacture, constructional features, erection, testing and commissioning of ash slurry pumps.

2.2 CODE STANDARDS The bidder s h a l l propose t he a p p l i c a b l e C o d e s and Standards or approval of GSECL, a p a r t from the requirements specified in General Technical Specification.

I IS 1520 Horizontal centrifugal pumps for clear,cold freshwater

II IS 5120 Technical requirements f o r roto-dynamic specialpurposepumps

III IS 5639 Pumps handling chemicals & corrosive liquids

IV IS 6536 Pumps for process water.

V IS 6536 Pumps for handling volatileliquids VI API 610 Centrifugal pumps for general refinery

Services StandardsofHydraulicInstituteofU.S.A.

2.3. TECHNICALREQUIREMENTS

Sr NO Description Ash Slurry Disposal Pumps & B.A. Slurry

Transportation pumps

1 Type Horizontal, single stage centrifugal type (all pumps shall be interchangeable

2 Duty Continuous

3 Fluid to be pumped

Highly abrasive slurry (slurryconcentration by pumped weight is specified in other relevantsections oftechnical specifications) Pumps shall be designedto handle maximum ash lump size expected at the at outlet of clinker grinder

4. Capacity and total dynamic head (Guaranteed)

As required and to be sized as per design guide lines contained in accompanying specification

2. ASH SLURRY HORIZONTAL CENTRIFUGAL PUMPS.



5. Suction Condition

Flooded suction (shall be designed to take two(2) Meter suction lift)

6 Pump speed (max.}

1000rpm 7 Type of coupling

between pump &motor

Variable speed Hydraulic Coupling with speed reduction by means of speed reduction gearbox. Speed varia tion+10% and-40%with respect t o rated design for First Stage.

8. Material of construction

Outer casing shall be of cast steel to ASTM-A216 or spheroid Graphite Ductile iron to

(I) Casing ASTMA-536,65-45-12 inner casing (Volute liners) shall be of chrome-nickel cast iron(Composition to Ni hard-IV)of 550BHN OR 24%chromium cast iron of 550 BHN

(ii) Impeller Chrome-nickel cast iron (composition to Ni-hard IV) Of 550 BHN OR 24%chromium cast iron o f 550BHN

(iii)Wear Plates/Liners

-do-

(iv) Shaft Carbon steel of AIS K1040/EM-8 Steel to IS:226 upto 20mm thickness and IS:2062 over 20mm thickness

(v) Base Plate Steel to IS-226 upto 20mm thickness and IS-2062 over 20mm thickness

9. Drive Motor

(ii) Speed Not greater than 1500 rpm

General

3.1.1 The, bottom ash slurry, transportation pumps (if applicable) and ash slurry disposal pumps shall essentially be horizontal and centrifugal type.

3.1.2 The equipment shall be capable of developing the required head at rated capacity for continuous operation.



3.1.3 All centrifugal pumps shall have a drooping characteristics curve, with the head continuously increasing with decreasing flow to maximum head at zero flow and the pumps shall preferably be non-overloading type beyond rated duty point.

3.1.4 The characteristics curves of each set of pumps shall match each other for equal load sharing in case of parallel operation and such pumps shall be identical and all parts shall be fully interchangeable.

3.1.5 Standard type pumps with a proven record of reliability shall only be provided.

3.2 Specific Design Requirements

3.2.2 - The rating of the ash slurry disposal pumps shall be based on the stipulations contained in Project Specifications.

3.2.3 To maintain the concentration limit and to run the ash slurry disposal pumps efficiently a provision shall be made for make-up water pipe connections complete with motor operated gate valves and manual gate valves as shown in the tender drawing.

3.2.4 Minimum 10% margin shall be considered for ash slurry pump sizing over the above the total slurry disposal head requirement comprising the straight pipe line frictional loss, bends loss the required static head. The above of the constant "C" in William-Hazen equation, shall be considered as 140 for calculating the system head.

3.2.5 The number of working streams shall be as per project specifications and the capacities of slurry pumps shall be selected accordingly.

3.2.6 The slurry pumps shall essentially slow rpm pumps. The rotational speed of the impeller at design point shall not exceed 1000 rpm.

3.2.7 The first stage of slurry disposal and transportation pumps shall be provided with variable speed hydraulic coupling of robust design to take care of the wear of pump (by increasing the speed) and for setting the optimum operating speed of the pumps based on actual site requirements after the system is installed. Minimum plus (+) 10% and minus (-) 40% speed variation with respect to speed at rated design point shall be provided. The slurry pump motor speed shall not exceed 1500 rpm.

3.2.8 To minimize the drive losses in the first stage slurry disposal pumps, a constant speed reduction gear box shall be provided. The gear boxes to be employed shall be suitable for heavy duty application and of such reputed make which have proven established record of trouble free service under heavy load transmission duties. 3.2.9 Continuous motor rating (name plate rating) at 50°C for ash slurry pumps shall have at least 20% margin above the maximum load demand of the driven equipment in the entire operating range at rated speed to take care of the system frequency variation and pump efficiency variation because of war and tear of impeller. The maximum load demand shall be calculated considering slurry density, efficiency of pump when handling slurry and the complete drive losses in the transmission (fluid coupling, gear box, belt drive etc.).



3.2.10 Pumps shall be single stage, end suction design provided with heavy duty impellers suitable for highly abrasive duty application.

3.2.11 All the wear parts of pumps, impellers and liners, etc. shall have a minimum guaranteed life of 8000 hours of operation.

3.2.12 Provision shall be made for adjustment to take up ear by axial movement of the shaft.

3.2.13 The seals shall be water flushed packed glands, fed from an external clean water supply source.

3.2.14 The impeller tip speed at the rated parameters shall not be more than 1676 meters/min. Bidders shall make selection of the pump size such as to limit the tip speeds to above specified.

3.2.15 Bidders shall furnish along with their bid complete technical data from pump supplier regarding head drop v/s mixture concentration and clearance diagram for impeller and casing and complete information as per data sheets.

3.2.16 The passages and clearances in pump components shall be properly designed, considering the size of ash and clinker to be handled.

3.2.17 The glands of the pumps should be suitably designed to prevent clogging of ash practices.

3.5 Construction Features

3.5.1 Casing

i) The casing shall be structurally sound to provide housing for the pump assembly and shall be designed hydraulically to minimise radial loads at part load operations.

ii) In case of ash slurry pumps, these shall be of either twin casing construction or single casing with metal lining construction or single volute casing construction. The pressure casing (or outer casing) shall be generally in accordance with the stipulation of API-610. The thickness of inner casing in case of single casing with metal lining pumps and the wear margin in case of single volute casing pumps shall not be less than 35 mm.

3.5.2 Impeller

i) The complete rotor assembly shall be structurally and dynamically balanced and designed with critical speed substantially above the operating speed.

ii) Impellers shall be made in one piece and securely fixed to the shaft. Means shall be provided to percent loosening during operation including rotation in reverse direction.

iii) Impeller fastening nuts (if provided) shall be of cap type and shall tighten in direction of normal rotation.



iv) For ash slurry pumps, the minimum impeller thickness shall not be less than 30 mm and shroud cover thickness shall no\ be less than35mm.

3.5.3 Impeller/Casing Wearing Rings (Where applicable)

Replaceable type wearing rings shall be provided at suitable locations for each pump. The rings shall be so fitted as to prevent turning while the pump is in operation.

3.5.4 Shaft

i) The shaft be finished to close tolerance at the impeller, coupling, pulley and bearing diameters. The impeller, pulley and shaft sleeves shall be firmly secured to the shaft by key and/or nuts.

Slurry pump impellers may be screwed on the shaft (threads to tighten during normal pump rotation).

ii) The shaft shall be adequately sized to withstand all stresses from rotor weight and hydraulic loads etc. and ground and polished to final dimensions.

iii) The design of the shaft shall also take into consideration the critical speed of the shaft which shall be at least 20 percent above the maximum operating speed or about 60 to 75 percent of the lowest operating speed.

3.5.5 Shaft Sleeve

Pumps shafts shall be protected by renewable type shaft sleeves which shall extend well beyond the pump glands. The sleeves shall be highly polished and shall. be securely fastened to the shaft to prevent any loosening.

3.5.6 Bearings

i) Heavy duty ball, roller (tapper roller wherever required) or sleeve bearings, adequately designed for the type of service specified and for long and trouble free operation, shall be furnished. Sleeve type bearing shall not be supplied for slurry handling liquids.

ii) The design of oil lubricated bearings shall be such that the bearing lubricating oil does not contaminate the liquid being pumped.

iii) Grease lubricated ball bearings are acceptable, if the pumps is specifically designed for grease lubrication and if shaft speed is less than the speed limit recommended by the bearing manufacturer and the fluid temperature does not exceed 65.5 deg. c (150 deg).

iv) Each bearing housing shall have drain plug.

3.5.7 Thrust Bearings



Adequately designed thrust bearings to absorb pump end thrust or other unbalanced forces, if any, shall be provided wherever required. Suitable arrangement for adjusting clearances shall be provided.

3.5.8 Stuffing Boxes & Sealing

i) Stuffing boxes of packed ring construction or of mechanical seal type as applicable shall be provided. Packed ring stuffing boxes shall be properly lubricated and sealed as per service requirement and manufacturer's standard.

If lantern rings are provided between the packages, these shall be complete. With inlet and outlet piping connections. Lantern rings shall be axially split type.

ii) For pumps handling clear cool water if external gland sealing is required it shall be done from the pump discharge or from any intermediate stage.

iii) For pumps handling sandy/muddy water or slurry, external clear water sealing shall be provided. The design should also provide for flushing of the clearance between pump rotation and stationary parts continuously by trickle clear water flow.

iv) The Bidder shall provide the necessary piping, valves, boosters, fittings, etc. for the gland sealing connection.

v) For mechanical seals, the mating surfaces shall be suitably hard faced to ensure long life.

3.5.9 Couplings

i) The pump & motor shaft shall be connected with a suitably designed flexible coupling of' approved design preferably with a spacer to facilitate dismantling of the pump without disturbing the motor. Necessary expanded metal coupling guards for the coupling shall also be furnished.

ii) Other arrangements for coupling the pump with prime mover may be employed only in case the same is categorically specified in the relevant "Specifications".

3.5.10 Base Plates

i) The base plates shall be of fabricated steel and of rigid construction properly ribbed as required. Drip lip with drain tap based on type of service specified shall be furnished.

ii) All directly coupled pump motor sets shall be supplied with common base plates.

iii) For pumps coupled with motor thru the variable speed drive transmission system, separate base plates for pumps and motors are acceptable.

iv) The common base plate together with all foundation bolts and nuts shall be supplied by the Contractor.



3.5.11 Connections/Nozzles

Cast iron flanges shall be flat faced. Flanges shall be full or spot faced on the back side also.

3.5.12 All accessories required for proper and safe operation of the complete pump motor set shall be furnished by Contractor.

3.5.13 Each pump shall be provided with drain, vent and a priming connection at suitable location, wherever applicable.

3.5.14 Pumps are required to operate for some period with discharge valve closed. The pumps shall be suitable for zero-flow operation for a reasonable period.

3.5.15 Accessories

The following accessories shall be supplied by Contractor for all pump motor sets:

i) Foundation bolts and nuts for pumps.

ii) Foundation bolts and nuts for motors.

iii) Foundation bolts and nuts for base plates.

iv) Foundation bolts and nuts for slide rails, if slide rails are provided.

v) Base plate for all pump

vi) Transmission guard for flexible coupling.

vii) Slide rails for motors if variable pitch, flexible coupling as applicable.

viii) Suitable connection for sealing/cooling/flushing water supply, if applicable.

ix) Lubrication fittings as necessary for proper and easy lubrication of the

equipment.

x) Drain and vent cocks as required.

xi) Priming funnel or overhead tank as required.

xii) Foundation bolts for hydraulic coupling.

xiii) Suitable adopter for pumps suction and discharge, if required.

xiv) Anchor Bolts, Sleeves, Inserts, Lifting Lugs, Eye Bolts etc.



The Bidder Shall supply all anchor bolts, foundation plates, sleeves nuts inserts etc. to be embedded in concrete for the equipment to be supplied. The length of foundation bolts shall be liberally sized to reach below the reinforcement level.

xv) Any other accessories mentioned elsewhere in this specification.

4.0.0 INSPECTION AND TESTING

The manufacturer shall conduct all the tests required to ensure that the equipment/system furnished shall conform to the requirements of this specification and in compliance with the requirement of applicable codes and standards. All materials used shall be of tested quality and test certificates shall be submitted to GSECL, Ukai. The particulars of the proposed tests shall be submitted to OWNER for approval before conducting the tests. MDI/DP tests on material ls shall be carried out.

4.1.0 Testing and Inspection at Manufacturer's Works

4.1.1 The manufacturer shall conduct all tests required to ensure that the equipment furnished shall conform to the requirements of this section and in compliance with requirements of the applicable.

The particulars of the proposed test and the procedures for the shall be submitted to the OWNER for approval before conducting the tests.

4.1.2 The OWNER's representatives shall be given full access to all tests. Prior to pump performance tests, the Manufacturer shall inform the OWNER allowing adequate time so that if the OWNER desire, his representatives can witness the test.

4.1.3 All materials and castings used for equipment shall be of tested quality.

The test certificates shall be made available to the OWNER

4.1.4 a) The pump casing shall be hydraulically tested at 300% at pump rated head or at 150% of shut-off-head, whichever is higher. The test pressure shall be maintained for at least half an hour.

b) For each ash slurry disposal pump the rated pressure corresponds to design pressure. Shut off head for each slurry pump shall be taken after adding the shut off head for all the pumps coming in a series. The testing for each pump shall be done corresponding to these pressures and as defined at (a) above.

4.1.5 The pump rotating parts shall be subjected to static and dynamic balancing tests.

Name Plate Eachpumpshallbeprovidedwithastainless-steelnameplateindicatingthefollowing details

a. Name of manufacturer

b. Pump make, model & Sr. no.



c. Manufacturer’s serial no.

d. T ype and duty

e. Ra ted capacity m3/hr

f. Rated head mwc

g. Speed (RPM)

h. Ope ra t i ng Range o f F low i n m3/hr

i. We igh t of pump

j. HP/KW rating

k. Rated Power in Kw, at 50 Hz.

l. Delivery Size in mm

m. Overall efficiency in %

n. Full Load Current in A



3.1 General

This specification covers the design, performance, manufacturing, construction features,

testing, delivery, installation and commissioning squirrel cage induction motor with to

drive pumps in Pumping station with all allied works, etc. complete.

3.2 Performance and Characteristics

a. Motors shall be suitable for satisfactory and efficient operation of pumps for application

and duty assigned. The rating of the motor shall be such that it should not get over

loaded when the pump would be delivering high discharge due to water level in the

sump at its highest level.

b. Motors shall be capable of satisfactory operation at full load at a supply voltage of 80%of

the rated voltage for 5 minutes, commencing from hot conditions.

c. Motors shall be capable of developing the rated full load torque even the supply voltage drops to 70% of the rated voltage. Such operation is envisaged for a period of one

second. The pull-out torque of the motor to meet this requirement shall be at least 205%

of full load torque.

d. The locked rotor current of the motors shall not exceed 550% of full load current

inclusive of 20% tolerance.

e. The motor vibration shall be within the limit specified in IS 4729 and IS 325 - 1978. The

permissible noise level shall not exceed the stipulations laid down in IEC 34-9. The motor

shall be designed to withstand 120% of rated speed for two minutes without any

mechanical damage.

f. Motors shall be capable of giving rated output without reduction in the expected life span

when operated continuously under following supply conditions.

Variation in supply voltage : ± 10%

Variation in supply frequency : ± 3%

Combined voltage and frequency variation : ±10%

g. The locked rotor withstand time under hot condition at 110% rated voltage shall be more

3. SQUIRREL CAGE INDUCTION MOTORS



than the starting time at 80% voltage by at least two seconds or 15% of the accelerating

time whichever is greater.

h. The motor shall be so designed that it shall have maximum efficiency on load varying

from 60% to 100% of full load. Dropping efficiencies from 100% full load to 60% of full

load will not be acceptable.

i. The rating of motor shall be 110% of the maximum power required by the pump over

the entire operating range from shut off to run out flow or 125% of power required at

duty point whichever is less. Motors shall be provided with eye bolts, lugs or other means

to facilitate safe lifting.

3.3 Insulation

a. Motors shall be given power house treatment. This comprises an additional treatment to

the winding over and above the normal specified

b. treatment. After the coils are placed in slots and all connections have been made, the

entire motor assembly shall be impregnated by completely submerging in suitable

insulating compound or varnish followed by proper baking. At least three such

submersions and baking shall be applied to the assembly, class of insulation ‘F’. Motor

winding shall be given a further treatment with epoxy paint to withstand atmospheric

conditions, polluted by hydrogen Sulphide.

c. Temperature rises shall not exceed the values for insulation equivalent to class B more

than 60°C to 75°C. These temperature rises are acceptable for an ambient temperature

of 50°C

d. The motor construction shall be suitable for easy disassembly and reassembly. The

enclosure shall be study and shall permit easy removal of any part of the motor for

inspection and repair.

e. The rotor bars shall not be insulated in the slot portion between the iron core lamination and the bars.

f. Motor shall be totally enclosed fan cooled type and the degree of protection shall be IP

55, and duty cycle S1 as per IS: 325: 1978, IS: 6362 & IS: 4691.

g. Motor shall be provided with thermister of positive temperature coefficient of P 130

grade and terminals shall be brought in separate box.



3.4 Constructional Features

a. The motor construction shall be suitable for easy disassembly and reassembly. The

enclosure shall be sturdy and shall permit easy removal of any part of the motor for

inspection and repair.

b. Motor shall be provided with eyebolts, lugs or other means to facilitate safe lifting.

c. The rotor bars shall not be insulated in the slot portion between the iron core laminations

for squirrel cage motors.

d. Vertical motor shall be flanged mounted type provided with thrust bearing.

3.5 Bearings

a. Motors shall have bearings of grease lubricated ball or roller type. Unless otherwise agreed the bearing shall be selected to give a minimum L-10 rating i.e. 40000 hours at

rated operating conditions.

b. Greased ball / roller / thrust bearings shall be of reputed make subject to the Owner’s approval. The life expectancy of the bearings shall be stated.

c. Bearings shall be adequate to absorb axial thrust in either direction produce by the motor

itself or due to shaft expansion. Motor bearings exposed to high temperature (i.e. motors

for hot oil pumps) shall have adequate provisions for cooling of bearings. Bearings shall

have steel / brass cages. Bearings with polyamide cages shall not be acceptable.

d. The bearings shall be so constructed that the loss of lubricating fluid is kept to a minimum and greasing shall be possible without any dismantling operation

e. The bearings shall prevent dirt and water from getting into the motor. Bearing lubricant

shall not find access to motor windings. Bearings shall be capable of grease injection

from outside without removal of covers. The bearing boxes shall be provided with

labyrinth seals, to prevent loss of grease or entry of dust or moisture. When grease

nipples are provided, these shall be associated, where necessary, with appropriately

located relief devices which ensure passage of grease through the bearings.

f. The bearings shall permit running of the motor in either direction of rotation.

g. If the bearings are oil lubricated, a drain plug shall be provided for draining residual oil



and oil level sight gauge shall be provided to show precise oil level required for stand-still

and running conditions.

h. Unless otherwise approved, bearing lubricating system shall be such that no external forced oil or water is necessary to maintain the required oil supply or keep bearing

temperature within design limits.

i. Lubricants shall be selected for prolonged storage and normal use of the motors in

tropical climate and shall contain corrosion and oxidation inhibitors. Grease shall have

suitable bleeding characteristics to minimize setting.

j. Safety measures for bearing temperature for tripping to be added. (High temperature).

3.6 Terminal Box

a. Terminal box shall be of weather proof construction designed for indoor service, to eliminate entry of dust and water, gaskets of approved make shall be provided at cover

joints and between box and motor frame.

b. Terminal box shall be suitable for single compression cable jointing kit. The terminal box

shall be suitable for top and bottom entry of cables.

c. Unless otherwise approved, the terminal box shall be capable of being turned through

360 degree in steps of 90 degree.

d. The terminals shall be of the stud type with necessary plain washers, spring washers and

check-nuts. They shall be substantially designed for the current carrying capacity and

shall ensure ample phase to phase and phase to ground clearances. Suitable cable

jointing kit shall be supplied by the motor vendor to match Owner’s cable.

3.7 Rotor

a. The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration level and a long service life to the bearings. The accepted values of peak to peak

vibration amplitudes for a motor at a rated voltage and speed on a machine surface bed

plate with the motor levelled and with a half key or coupling fitted shall not exceed those

given in IS 4729. The shaft ends shall be provided with a suitably threaded hole or holes

to facilitate the assembly or removal of couplings and bearing races.

b. Rotor shall have anticorrosive material for protection against environment.

3.8 Paint and Finish



a. Motor external parts shall be finished and painted to produce a neat and durable surface which would prevent rusting and corrosion. The equipment shall be thoroughly

degreased, all rust, sharp edges and scale removed and treated with one coat of zinc

epoxy primer and two coats of Epoxy paints.

b. The motor fan shall also be painted to withstand corrosion.

3.9 Anti-Condensation Heaters and Temperature Detectors

a. All motors shall be provided with 240-voltanti-condensation heaters, sized and located so as to prevent condensation of moisture during shut down period. The heater shall remain

"ON" when the motor is not in service, and shall not cause damage to the windings.

b. At least six resistance type temperature defectors for the stator winding each having D.C.

resistance of 100 at 0°C embedded in the stator winding at locations where highest

temperature may be expected and at bearings. The material of the RTD shall be

platinum.

c. The heater leads shall be brought out to a separate terminal box of the same

specification and grade of protection as the main power terminal box excepting that the

nickel plated brass glands provided shall be suitable for 2 core 4 Sq. mm aluminium

conductor, armoured cable.

d. A warning label with indelible red inscription shall be provided on the motor to indicate that isolation of the power line alone is not sufficient and that the heater supply should

also be isolated before carrying out any work on the motor. Motor supplied shall be

complete with all double compression cable glands, crimp type cable lugs.

e. Motor supplied shall be complete with all double compression cable glands, crimp type

cable lugs.

3.10 Noise Level

a. The permissible noise level shall not exceed the stipulations laid down in IEC 34-9.

3.11 Motor Vibration

a. Motor vibrations shall be within the limits of IS 4729 unless otherwise specified for the

driven equipment.

3.12 Name Plate

a. Each motor shall have a nameplate displaying all the particulars specified in relevant

standards. In addition, the nameplate shall indicate identification, number of bearings



used for motor and recommended lubricant indicating required quantity of lubricant and

interval at which the bearings are to be lubricated.

b. Nameplate shall be made of 2-mm thick stainless steel with the relevant details

embossed on it in English.

3.13 Routine Test a. Insulation resistance test b. High voltage test c. No load running of the motor and measurements of currents and voltages on all three

phases.

d. Locked rotor test at suitable voltage. e. Testing of accessories/auxiliaries for correct functioning. f. Vibration test.

g. Noise Level test. h. IP 55 test as per applicable standard.

Though the motors shall be accepted on the basis of the satisfactory results of the tests

at the works, it shall not absolve the vendor from liability regarding the proper

functioning of the motor coupled to the driven equipment at site.

3.14 Type Test

Measurement of stator resistance and rotor resistance of motor.

a. No load running of motor and reading of voltage, current, power and speed.

b. Open circuit voltage ration on motors. c. Reduced voltage running up test at no load to check the ability of motor to run up to full

d. Speed on no load in each direction of rotation with 1/√3 of the line voltage applied to the motor.

e. Locked rotor reading of voltage, current, power input and torque of motors. f. Full load reading of voltage, current, power input.

g. Temperature rise test. h. Momentary over load test

i. Insulation resistance test with before and after the high voltage test.

j. High voltage test

3.15 Accessories

a. Two independent earthing points shall be provided on opposite sides of the motor, for

bolted connection of the Owner’s earthing conductors. These earthing points shall be in

addition to earthing stud provided in the terminal box.



1.0 GENERAL

This specification covers design, Manufacture, Constructional features, erection, testing and commissioning of Gear Box.

GEARS: High quality alloy case hardening materials provide long life wear resistance and fatigue strength. Profile ground single helical gears and spiral bevel gears lapped in pairs ensure high standards of accuracy, surface finish and quiet running characteristics. Helical gears are fitted in parallel shaft units whilst units with shafts at right angles incorporate spiral bevel and helical gears.

2.0 CODES AND STANDARDS

The bidder shall propose the applicable Codes and Standards for approval of OWNER, apart from the requirements specified in General Technical Specification.

AGMA - American Gear Box Manufacturers Association

3.0 TECHNICAL REQUIREMENTS

3.1 Gear Box shall be provided as required as per the technical requirements mentioned in the table below and subsequent clauses. a Type : Totally enclosed and lubricated type

b Location In the drive arrangement of : Ash slurry disposal pumps

C Gear Types : Helical

d Material of Construction :To suit the rating of gear box.

3.2 Gear Boxes shall be used for speed reduction between motor drives and ash slurry disposal pumps

3.3 Gear boxes shall be totally enclosed and oil lubricated type. Positive lubrication shall be provided to all the bearings and to the working surface of the gear teeth.

3.4 BEARINGS: Roller bearings are used throughout. 3.5 GEAR CASES: Gear cases are of rigid cast iron construction with modern styling. MS Fabricated gear cases are available as optional. Inspection covers are provided for viewing gear contacts. Oil level dipsticks, ventilators and drain plugs are fitted. Cases are split in horizontal plain for horizontal gearboxes and in the vertical plain for vertical gearboxes. 3.6 Gear case Finish: Internal and external surfaces are painted with linear epoxy primer. External surfaces are finished with alkyd semi-gloss blue paint. These paints are resistant to dilute acids and alkalis, oils and solvents, sea water and temperatures up to 1400 C.

4. Gear Box for Ash Slurry Pumps



3.7 Lubrication :In horizontal units, lubrication in most instances is by transfer of oil by gears dipping in the sumps of gear unit bases. Where high pitch line speeds could cause churning of the lubricant, case baffles are fitted as indicated on rating tables. Forced lubrication is necessary where shown and complete systems can be supplied when required. In vertical units, lubrication in most instances is provided by a pump driven from the bottom of the high speed or second motion shaft. The low speed gears dip in the oil bath. In some cases, it is necessary to use a forced lubrication system with a separate oil tank. These are marked in the rating tables. All units are provided with combined dipsticks and ventilators and drain plugs. 3.8 COOLING: Depending on the application, standard gear units are cooled by: Normal heat dissipation by convection from external surfaces. 3.9 SHAFT MOUNTED UNITS: Shaft mounted units are of two designs, the first of which is mounted on the driven machine shaft extension and connected to the foundation by torque arm. Additionally, foot/ shaft design is available for mounting on a base plate with motor and coupling, the complete assembly being mounted on the driven machine shaft extension and connected to the foundation by a torque arm.

3.10 MOTORISED GEAR UNITS: Gear units of double and triple reduction types are available as standard assemblies with flanged motors directly mounted on gear case input shaft housing by adaptors. Motor and gear unit shafts are connected by flexible coupling. 3.11 HOLD BACKS: Hold backs can be fitted to all horizontal, two and three stage gear units, where required to operate in non-reversing drives. They are located on horizontal pinion shaft and have adequate capacities to deal with full rated torque. Lubrication is provided automatically from the oil in the gear unit. Changing the direction of locking rotation is a simple operation.

3.12 PRESERVATION/ PROTECTION: Premium helical gear units are dispatched without oil. Prior to dispatch they are test run with a rust preventative oil giving adequate protection to internal parts for a period of 6 months, covering normal transport and covered storage. 5. Mechanical Variable Speed Fluid Coupling.

Scope:



1.1 Design & Construction Features: a. The operating pressure of clarified water of fluid coupling cooler shall be 6.5 Kg/cm2(g). The oil cooler shall be tested to withstand min. 10 Kg/cm2(g) water pressure during inspection. b. Oil cooler shall be designed to withstand hydro test pressure of 1.5 times the working pressure of the liquid. c. Ultrasonic test for shaft shall be carried out as per ASTM 388 and the log report shall be submitted during final stage inspection. d. The Material test certificates/lab report/supplier’s TC for mechanical and chemical properties of raw materials like impeller, runner, back casing, scoop casing, shaft, oil cooler tubes, parts of oil pump, bearing, oil pump motor, scoop tube, HT bolts, fabrication box shall be submitted. e. The stage inspections which shall be carried out by the manufacturer shall include Balancing of impeller, runner, back casing as per ISO 1940 GR 6.3, DP test for shaft, runner, impeller etc for surface defect. The manufacturer shall submit the log report/inspection report for stage inspection tests during final stage inspection. f. The final stage inspection shall be witnessed by BHEL/customer/customer’s consultant at manufacturer’s factory. The witness shall include the check of overall dimensions, temperature rise, oil leak test, performance test (torque Vs Slip Regulation), Run test (free running for noise and vibration), Overspeed test for soundness, hydro test for the cooler. g. Pressure switches, pressure gauges, temperature switches and temperature switches shall be weather and dust proof as per IP65. Certificate for the same shall be submitted for review during inspection. h. The dial size of the pressure/temperature gauge shall be 150 mm with white background and black lettering. i. The model no. and maximum operating range of pressure/temperature gauges/switches shall be as per manufacturer’s standard. The over range protection for gauges/switch shall be 150% of the maximum design pressure. The maximum operating temperature shall be as per system requirement. j. Performance test certificates shall be submitted for oil circulating feed pump and the motor.



k. Painting shall be as per manufacturer standard, however the total DFT should not be less than 100DFT. l. Vibration level of fluid coupling shall be limited to as per the stipulations prescribed in relevant standards. m. Maximum noise level shall not exceed 85 dB (A) when measured at 1m away from noise emission source. 11.2 ACCESSORIES a. Each fluid coupling to include following minimum accessories as part of each fluid coupling. b. Companion couplings (gear box side and motor side) along with nuts & bolts and spacer plates (as applicable). c. During commissioning of fluid coupling, the oil present in fluid coupling shall be drained and fresh oil shall be filled in presence of BHEL. The supply of this first fill fresh oil shall be in the scope of bidder. d. HT bolts for fixing fluid coupling on base frames. e. All necessary instruments to ensure smooth and satisfactory operation of the fluid coupling and also for the safe and reliable operation of the equipment. f. Tool kit for operation and maintenance of the fluid coupling. g. Lubrication fittings as necessary for proper and easy lubrication of the equipment. h. Commissioning spares and all other accessories, which are not mentioned specifically but are essential for sound performance of the equipment. 11.3 INSPECTIONS & TESTING: a. Inspection and testing shall be carried out in presence of GSECL Ukai. The vendor shall furnish inspection & testing procedure & QAP for due approval from GSECL, Ukai is responsible for getting the Inspection & Test procedures and Quality Assurance Plans approved from the main Customer. b. Inspection & Test procedure, QAP will be furnished by vendor along with their offer. c. All Quality plans shall be submitted in soft copy (word file/excel file/ and pdf file) for GSECL/Customer/customer’s Consultant approval. As per the hold points mentioned



in QAP, Vendor shall submit the inspection calls by E-mail with clear notice of 10-15days followed by hard copy to be sent by courier so as to reach GSECL, Ukai desk within 3-4 days from the date of E- mailing of the document. d. GSECL, Ukai shall inform within 7-10 days of receipt of inspection call whether inspection shall be carried out or waived off. After completion of inspection the material will be treated as cleared for dispatch by GSECL /Customer/customer’s Consultant inspector, if inspection is OK as observed by Inspection Engineers. Vendor shall maintain strict quality norms and standards for Bought out/ self-manufactured items through its wide network of quality departments throughout the country who carryout stage and final inspection of the product as per quality standards agreed by engineering/quality specialists. Slurry pumps above 100 kW are also direct coupled to variable speed motors to fixed speed motors via variable speed hydraulic couplings or variable frequency controllers. These arrangements are used to compensate for wear and where flow conditions fluctuate and pump speed must be controlled either manually or automatically to make up for these changes and maintain steady flows. Technical requirement: The rotating components are supported in ball and roller bearings in a horizontally spilt oil tight stationary casing which also serves as an oil reservoir. An oil circulating pump, motor/gear driven from the input shaft provided. The robust casing, which is weatherproof and able to withstand extremes of temperature, enables the type fluid coupling to be used in open air installations. Movement of the external control varies the position of the scoop tube controlling the speed of the output shaft. Sr

No

Particulars Specification

1 Types of Fluid Coupling Scoop Controlled Fluid Coupling Motor input kw :180 KW Mechanical capacity :275 kw

2 Types of Cooling Water cooled

3 Type of actuation Electrical Operated Actuator responding to 4-20ma control signal & will provide scoop tube position output of 4-20ma.

4 Max.Starting Torque Can Be Set by Scoop Tube Position



5 Direction of Rotation Bi directional 6 specification of filling oil Servo System 46 of IOC or Equivalent 7 Electrical Panel PLC based control panel will be provided which

will enable start-up & operation of Fluid Coupling along with integration of operational parameters like temperature & pressure etc. for safety of Fluid Coupling.

8 Actuator with SMART & HART communicator.

Electrical type

9 Connecting coupling input & output side

Multi Disc Unit Type

10 Main Housing & Cover Fabricated Steel IS 2062 Gr A 11 Impeller, Runner, Back casing

& Scoop casing High Tensile Aluminum Alloy

12 Solid Input shaft High tensile Aluminum Alloy 13 Solid Output Shaft High tensile Aluminum Alloy 14 Bearings En 8 /IS 1875 CL-4 15 End Covers Anti-frictional bearings 16 Scoop Housing Cast Iron FG 200 IS 210



6.1 General

This specification covers the design, manufacturing, construction features, testing,

delivery, installation and commissioning vertical turbine mixed flow type, single stage

pumps with suction strainer, bell mouth, column assembly, discharge elbow, motor stool,

thrust bearing and all associated works.

6.2 Codes and Standards

The design, manufacturing, performance of vertical turbine pumps shall comply to all

currently applicable statutes, regulations and safety codes in the locality where the

equipment will be installed. The equipment shall conform to IS 10981 or its latest

version.

6.3 Design Features/Construction

a. The turbine pump shall be capable of developing the required total head at rated

capacity for continuous operation.

b. Pumps of a particular category shall be identical and shall be suitable for parallel

operation. Components of the identical pumps shall be interchangeable.

c. The head capacity curve shall be continuously rising towards shut-off shall be highest

at shut-off point.

d. The pump set shall be designed to operate up to a period of 5 minutes at shut off

head without causing damage to the part/s of the pump set.

e. The shutoff head shall not be less than 1.2 times the rated total head of the pump

set.

f. The impeller adjustment shall be such that the impellers run free in any installed

condition despite extension of line shaft (caused by hydraulic down thrust), the

weight of shafting and weight of impellers.

6. Clear Make Up Water Pumps (Vertical Turbine Pump)



g. The rating of the pump motor shall be larger of the following:

i. Maximum power input from zero discharge (shut off head) to zero head (full

discharge) or

ii. 115% of pump input at duty point.

h. The pump shall be designed to handle raw water having turbidity minimum up to

500 NTU.

i. The velocity of vibration shall be limited to 3.0 mm. / sec. at the thrust bearing. The

noise level shall be limited to 85 dB at a distance of 1.86 meters.

j. Pump shall work satisfactorily even when screen gets clogged up to 50%.

k. The bowl assembly shall consist of rotating impeller which is housed in stationery bowls having guide vanes. The bowl shall also include the housing of the bottom

pump shaft bearing.

l. The pump casing and impeller shall be with wearing ring.

m. The column assembly shall consist of the column pipe to convey the liquid handled

from bell mouth strainer, bowl assembly to shaft assemblies and shaft bearings,

discharge elbow.

n. The discharge shall be above finish floor level (FFL) of pump-house. If the Necessary

higher margin to be taken with respect to dam HFL (high flood level).

o. It shall be the responsibility of the contractor, to verify the submergence provided

with respect to Hydraulic Institute of Standards (HIS) or CPHEEO (Central Public

Health & Environmental Engineering Organisation) water supply manual.

p. The system resistance curves shall be developed for pumping station to check pump

performance for single pump operation and confirm that NPSH and submergence

requirements are satisfied at various water levels.

q. "Net Positive Suction Head (NPSH) required" shall be less than "NPSH available" during all operating conditions including run off condition by 1 m.



r. The pump shall also be designed to withstand the seismic loads.

6.4 Suction Strainer

a. Each pump shall be provided with suction strainer to prevent entry of floating

materials and debris which will damage the pump. The strainer shall be fabricated

from S.S. 304.It shall be designed in such way that, it will cause minimum choking or

clogging. The mesh selection shall be such that Pump shall work satisfactorily even

when screen gets clogged up to 50%.

6.5 Bowls a. The bowls shall be of 1.5 to 2% Ni, C.I. and free from blow holes and other

detrimental defects. The surface shall be smooth.

b. The bowls shall be equipped with replaceable wearing rings. Liquid passage shall be smooth finished and the bowl shall contain bushes to serve as bearings for the

impeller shaft.

c. The inside of pump casing shall be painted with anti-corrosive paint and the outside

shall be epoxy painted.

6.6 Impeller a. The impeller shall be of S.S. CF8M, mixed, enclosed type and shall be properly

balanced dynamically. The impeller shall be properly machined, with liquid passage

hand finished with seal rings on their hubs. They shall be adjustable vertically by

means of an adjusting nut in the head assembly.

b. Impeller shall be securely fastened to the impeller shaft with keys, taper bushings or lock-nuts.

c. To avoid internal resonance the number of vanes on diffuser shall not be equal to

or be a multiple or number of vanes on impeller.

6.7 Impeller Shaft

a. The impeller shall be mounted at the shaft sleeve located on the shaft. The impeller

shaft shall be made of stainless steel AISI-410 and having Brunel hardness number

not less than 230 BHN. It shall have a surface finish between 0.75 microns or less.

It shall be guided by bearings above and below each impeller. The butting faces of

the shaft shall be machined square to the axis and the shaft ends shall be

chamfered on the edges.

b. To protect the bearing of pump and motor, the shaft shall be limited with minimum



straightness within 0.125 mm (or less as required by manufacturer) for 3 mtr

length on dial indicator reading. However, If total design required.

6.8 Line Shaft

a. The size of the shaft shall be calculated on the basis of maximum combined shear

stress. This shall not exceed 30% of the elastic limit, in tension or 18% of the

ultimate tensile strength.

b. The design of the shaft shall also take into consideration the critical speed of the shaft which shall be at least 20 % lower or above the operating speed.

c. The shaft shall be furnished with interchangeable sections having a nominal length of

1.5 mtr. The maximum permissible error in the axial alignment of the thread axis

with the axis of the shaft shall be 0.05 mm in 150 mm.

d. Shaft shall be provided with shrunk or snug fitted shaft sleeves of compatible wear/corrosion resistant material precision ground and polished where pass through

bearing.

6.9 Line Shaft Coupling

Couplings shall be designed with a safety factor of 1.5 times the shaft factor and shall have threads to tighten during pump operation. The outside diameter of the couplings shall be concentric with the bore and with a small transverse hole in the middle.

6.10 Line shaft bearing

Bearings shall be of Thordon type which shall be integral with replaceable sleeves of metallic material with suitable securing arrangement in the bearing housing. Lubrication shall be by self-water.

6.11 Column Pipe

The standard lengths of column pipe shall be 1.5 Mtr. No part in the column pipe such as the flange outside diameter shall exceed the bowl outside diameter. The column pipe shall be welded flanged design.

The size of the column pipe shall be such that the friction loss will be limited to 0.5 M for every 10 M (length of column), when the pump-set is running at rated capacity.

6.12 Driver

Driver shall be coupled through flexible coupling to the head shaft.



6.13 Tests and Inspection

6.13.1 Pre-manufacturing inspection and documents

i. Pump manufacturer will submit i) Test setup and test procedure ii) Details of instrumentation along with their least counts and calibration certificates before commencing manufacturing/testing as per IS 10981.

j. Only after finalization/ acceptance/approval of test setup and test procedure the contractor will commence manufacturing/testing.

6.13.2 Hydraulic Test k. A standard hydrostatic test shall be conducted on all pump casings; discharge

elbow and bowl assemblies at 1.5 times the maximum discharge pressure of the pump-set or twice the shut-off head, whichever is higher.

l. The hydrostatic test on the casing shall be conducted for a minimum duration of 30 minutes.

6.13.3 Performance Test

Performance test at rated speed shall be conducted at manufacturer’s works in presence of Owner for each pump. No negative tolerance on bowl, capacity, head, & efficiency shall be permitted.

6.13.4 Standard Running test

m. Bowl assemblies shall be given running test over the full operating range, covering from free discharge with delivery valve fully open to the shut off head. The duration of tests shall be minimum one hour. A minimum of five readings shall be taken for plotting the performance curves in addition to duty point and shut off head.

n. The pump shall be tested for parallel operation at site.

o. Impeller shall be dynamically balanced at the operating speed.

p. Necessary test certificates of the above tests shall be furnished for the Owner’s approval.

q. Pump casing shall be offered for ultrasonic testing to detect casting defect.

6.14 Visual Inspection

Pumps shall be offered to the Owner for visual pumps inspection before dispatch. Pump components shall not be painted before inspection. After the inspection, test certificates shall be furnished.

6.15 Welding

All welding and related operation shall be done as per IS or equivalent code. Welders shall be qualified as per IS code. All welding procedures shall be submitted for Owner approval.



6.16 Drawings The following drawings shall be submitted by the Contractor. r. Preliminary outline dimensional drawings showing details of pump, motor, civil

foundation, clearances, minimum submergence, etc.

s. Performance curves for capacity V/s head, Efficiency, and KW & NPSHr requirement shall be furnished. The capacity range shall be zero flow to maximum flow.

t. Typical cross sectional drawing showing constructional details with the complete bill of material & relevant standards. Catalogues of all the components with part number shall be furnished.

6.17 Criteria for rejection

Even if guaranteed capacity V/s head, Efficiency, and KW (energy consumption) requirement are achieved prior to dispatch, the Owner reserve the right to reject the pump-set during the commissioning if the same performance parameters are not achieved.

6.18 Name Plate

Each pump shall be provided with a stainless-steel name plate of the manufacturer, indicating the following details.

u. Rated capacity in LPS / M³/HR v. Total head in Mtr. w. Speed in RPM. x. Test pressure y. Make & Model number z. Manufacturer’s special number aa. Weight of equipment

6.19 Technical Particulars of Vertical Turbine Pump

Sr. No

Description Particulars

1.0 Make/Application Contractor has to furnish

(As per approved vendor list)

1.1 Pump Type Vertical turbine

1.2 Number of pumps 1 Working + 1 Stand by

1.3 Number of normally working pumps(nos.)

01

1.4 Design capacity of each pump 325



Sr. No


(m3/hr.)

1.5 Minimum total head at design capacity(Mtr.)

26.0

1.6 Pump Efficiency 87% (Minimum)

1.7 Direction of rotation (viewed from top)

To be furnished by Contractor

1.8 Total duration of operation As per make up water Requirement

1.9 Speed(RPM) 1500 (Indicative), Contractor to specify

1.10 Submergence available (Mtr.) As per HIS or CPHEEO Manual

1.11 Location Indoor & Near to reservoir

2.0 Feature of Construction

2.1 Internal element Mixed flow impeller

2.2 Type of lubrication Self-water lubricated

2.3 Type of sealing Mechanical

2.4 Type of coupling Shaft Drive

2.5 Number of stage Single Stage

2.6 Column size To be furnished by Contractors

2.7 Discharge level with respect to floor Above floor

3.0 Liquid Data

3.1 Liquid handled Raw water

3.2 Temperature Ambient temp.

3.3 Turbidity Minimum turbidity: 500 NTU. However, the Contractor is advised to carry out physical and chemical analysis of Raw water, as for the most of the days, it is expected to pump flood water having high turbidity.

4.0 Material of Construction

4.1 Base plate M.S. IS 226

4.2 Discharge elbow M.S. IS 226

4.3 Column pipe ERW, M.S. minimum 14 mm. wall thickness with inside and outside epoxy painted, in, minimum 1.5 Mtr Sections.

4.4 Suction bell C.I. having 1.5 to 2.0% Nickle Cast Iron



Sr. No


I.S 210 GrFG260

4.5 Pump casing / Impeller bowl C.I. having 1.5 to 2.0% Nickle (M) with inside anti-corrosive coating

4.6 Impeller Stainless steel CF8M

4.7 Impeller Guide Piece Cast Steel

4.8 Line shaft with coupling Stainless Steel 410 (IS 1570 (part V) Gr. X12Cr12)

4.9 Impeller shaft Stainless Steel 410 (IS 1570 (part V) Gr. X12Cr12)

4.10 Head shaft Stainless Steel 410 (IS 1570 (part V) Gr. X12Cr12)

4.11 Shaft coupling Stainless steel 316

4.12 Line bearing Thrust type

4.13 Suction strainer Stainless Steel AISI – 304 (M)

4.14 Shaft sleeves S.S ASTMA 351 CF8M

4.15 Hardware in contact with water Hot dipped galvanized

4.16 Companion flanges M.S. as per IS 1538 table IV & VI, off centre drilling.

5.0 Accessories & Services required

5.1 Base plate YES

5.2 Foundation bolts YES

5.3 Suction strainer YES

5.4 Companion flanges YES

5.5 Spares parts recommended YES

5.6 Maintenance tools YES

5.7 Start-up / essential spares YES

5.8 Painting YES (Epoxy )

6.0 Testing

6.1 Hydrostatic test YES to be witnessed

6.2 Bowl Assembly YES to be witnessed

6.3 Pump casing Ultrasonic test not to be witnessed but certificate for testing during manufacturing to is to be produced.

6.4 Performance test YES to be witnessed



Sr. No


6.5 Standard running test YES to be witnessed

6.6 Static balancing test Required

6.7 Dynamic balancing test YES to be witnessed

6.8 Visual inspection check Required

6.9 Parallel Operation test at site Required

7.0 Prime mover

7.1 Motor for pumps with coupling Required

7.2 Specifications for the drivers Class “F” as per motor data sheet and suitable to operate on 415 V AC supply

7.3 Speed 1500 (Indicative), Contractor to specify

7.4 Minimum Efficiency @ Rated Speed

Duty point

• Full Load

• 0.75 Load

• 0.50 Load

94 % (minimum at full load without negative tolerance)

Contractor has to furnish



7.5 Power Factor

Duty point

a) Full Load

b) 0.75 Load

c) 0.50 Load

Minimum 0.78 Min. at full load & mini. 0.6 for part load (To be achieve 0.996 at full load & 0.9 at part load with the help of HV Capacitor bank across motor & APFC Panel)




7.6 Type of enclosure Contractor to specify

Note:

bb. Material certificates of components shall be furnished before inspection of components.

cc. Contractor to furnish GA drawing indicating overall dimensions, weight, and height details along with offer.

dd. The capacity range shall be zero flow to maximum flow. ee. Contractors shall submit performance test reports and, family curves (Head

(H)Vs. Discharge (Q), Efficiency Vs. Discharge, and Power (P) Vs. Discharge (Q) and Torque speed curve for similar model of pump.



ff. The difference of 50 BHN hardness shall be between casing ring and impeller ring.

gg. IftheguaranteedefficiencyofpumpquotedbytheContractorislessthanminimumspecifiedin the tender, then the offer of Contractor is liable to be rejected.

hh. Contractor shall furnish guaranteed technical particulars duly filled.



1.0 General: This specification covers design, manufactures, constructional features, erection, testing and commissioning of ash slurry sump 400 mm isolation plug valves, sump liners and agitating nozzles.

2. 0 CODES AND STANDARDS

The Bidder shall progress the applicable Codes and Standards for approval of NASL/OWMER, apart from the requirements specified in General Technical Specifications.

3.0 TECHNICAL REQUIREMENTS Sump isolation plug valves, sump liners, agitating nozzles shall be provided as required as per the technical requ1rements mentioned in the table below and subsequent clauses. I SUMP ISOLATION VALVE

A Type : Plug type, manually operated, suitable for outdoor, duty

B No. of slurry sump compartments : As per Project Specification Numbers

D Size of valves : 400 mm E Material : Corrosion and abrasion resistant construction materials to suit the service requirements II SUMP LINERS A Quantity :As per Project Specification B Thickness : Minimum 20 mm thick C Material of construction : Alloy Cast iron with Minimum

hardness of 350 III SUMP AGITATING NOZZLES

A Quantity : As per Project Specification B Material of construction : i) Body : MS/cast iron a. Anti-corrosion tool steel or stainless steel of hardness 500-550 BHN or Ceramic. 3.2 The bottom ash and fly ash slurries shall be led to a common distribution trough at the top of the slurry sumps which will have manually operated plug valves enabling the slurry to flow to the desired compartments {corresponding to the pump streams in operations). 3.3 It shall be possible to operate slurry sump isolation valves from top of sump level the valve shall be provided with gear operator if effort required to operate the valve exceeds 25 kgf.

7. Ash Slurry Isolation Plug valve/Pump/Trench Liners and

Agitating Nozzles



3.4 Material of construction for slurry isolation valves shall be corrosion and abrasion resistant and shall be of quality most suited to proposed application. Suitable measures to protect the bearings from ash ingress shall be provided. 3.5 Valves shall be suitable for outdoor duty. 3.6 All the slurry distributions troughs and sump compartments shall be provided with abrasion liners in the areas of slurry impingement A free board of min 100 mm shall be provided for the trench liners Detailed calculations in this regard shall be submitted for approval. Cast iron lining (IS: 210, FG 260) for the inner walls of the slurry trench shall be provided. The lining should be minimum 30 mm thick, on side walls and 35 mm thick at bottom. 3 7 To avoid the chocking of the sump and suction pipe of slurry pump stream, Bidder shall provide adequate number of high velocity water agitating nozzles in the slurry sumps to avoid setting of ash particles at the bottom of the sumps. 4.0 INSPECTION AND TESTING 4.1The manufacturer shall conduct all the tests required to ensure that the equipment/system furnished shall conform to the requirements of this specification and in compliance with the requirement of this standards. All materials used shall be of tested quality and test certificates shall be submitted to OWNER. The of the proposed tests shall be submitted to OWNER for approval before conducting the tests. MDI/DP tests on materials shall be carried out. 4.2 Plug valves, sump liners and nozzles shall be visually inspected and checked for dimensional accuracy at manufacture's works. 4.3 Any other test as per applicable codes or as per agreed QAP shall be carried out on plug valves liner and nozzles.



1.0 GENERAL

This section covers general requirement of design, manufacture, inspection and performance testing of miscellaneous horizontal centrifugal pumps handling cooling water at normal temperature and the associated equipment water seal application. The specific requirements are given at the technical data sheets enclosed at the end of this section.


The design, material, construction, manufacture, inspection and performance testing of horizontal pumps shall comply with all currently applicable statues, regulations and safety codes in the locality where the equipment is to be installed. Nothing in these specifications shall be construed to relieve the Contractor for meeting this responsibility. The equipment supplied shall comply with the latest applicable Indian Standards listed below. Other National Standards are acceptable provided they are established to be equal or superior to the Indian Standards mentioned herewith.

List of Applicable Standards: IS: 1520 Horizontal Centrifugal pumps for clear cold fresh water IS: 5120 Technical requirements of Roto-dynamic special purpose pumps BS: 599 Method of testing for pumps API: 610 Centrifugal pumps for general refinery service HIS: water Hydraulic Institute Standards, USA IS: 210Grey Iron Castings IS: 2062 Steel for general structural purposes ANSI 816.5 ASME Sec II Engineering Materials ISO: 8501Surface preparation In case of any contradiction between the aforesaid standards and the stipulations specified herewith (In the technical specifications), the stipulations of the technical specifications shall prevail.

3.0 DESIGN &PERFORMANCE REQUIREMENTS

3.1 The Equipment shall be capable of developing the required total head at rated flow under continuous operation. Also, the pumps shall be capable of being operated to

8. Water Seal and cooling Water Centrifugal Pumps



give satisfactory performance at any point on the H- Q characteristics curve o v e r the operating range of at least 50% to 120% of rated flow. The maximum e f f i c i e n c y of pump shall be within ±10% of the rated flow. 3.2 The pumps shall have a stable Head vs Flow characteristics, co n t i n uo u s l y rising towards t h e shut-off. and with a shut off head of at least115%ofthe rated head. 3.3 The pumps shall be designed for a water inlet temperature o f at least 45°C and it shall been sured that the pumps do not cavitate at this temperature. If a higher liquid temperature is indicated in the pump data sheets, then the same shall be considered for pump design. Further, a safety margin of at least 0.5M shall be provided between the NPSH required and NPSH available at run out condition. 3.4 The c r i t i c a l speed shall be well away f rom the operating speed and in no case less than 130% of the rated speed. 3.5 Pumps of a particular category shall be identical and shall be suitable for parallel operation w i t h equal load sharing. The Flow vs Head and Flow vs Power characteristics should match to ensure trouble free operation throughout the complete range. Components o f identical pumps shall be interchangeable. 3.6 Pump models with maximum size impeller shall not be offered. With the use of a higher size impeller in the offered pump, it should be possible to increase the pump head at rated flow by at least5%. 3.7 Pumps sha l l run smoothly without undue noise and vibration. Peak to peak vibration limits shall be restricted to the following values during

Speed Sleeve bearings Anti-friction bearings 1500rpm&below 75 microns 75 mi c rons 3000rpm 65 microns 50 microns Thenoiselevelatadistanceof1Mfromtheequipmentshallnotexceed85dBA. 3.8 Pumps shall be so designed that pump impellers and other components of the pumps are not damaged due to flow reversal. 3.9 The Contractor shall assume full responsibility in the operation of pump and motor as a unit. CONSTRUCTION REQUIREMENTS



4.1 Pump Casing Pump casing may be of axially or radially split type' construction. The casing shall be designed to withstand the shut-off pressure developed by the pump at the design temperature and maximum suction pressure. Pump casing shall be provided witha vent connection along with piping, fittings & valves unless pump is self-venting by the arrangement of nozzles. Casing drain, as required, shall be provided complete with drain valves, piping and plugs. It shall be provided with a connection for suction and discharge pr. gauge as standard feature. · 4.2 Impeller Impeller. shall be closed, semi-closed or open type as specified in the data sheets and designed in conformance with the quality of liquid to be handled. The impeller shall be secured to the shaft and shall be retained against circumferential movement by keying, pinning or lock rings. On pumps with overhung shaft, impellers shall be secured to the shaft by a locknut or cap sere':"', which tightens in the direction of normal rotation. 4.3 Impeller/Casing Wearing Rings Replaceable type wearing rings shall be provided at suitable locations of pumps. Suitable method of locking the wearing ring shall be used. Wearing rings shall be provided in pump casing and/or impeller as per manufacturer's standard practice. 4.4 Shaft The critical speed shall be well away from the operating speed and in no case less than 130% of the rated speed. The shaft shall be ground and polished to final dimensions and shall be adequately sized to withstand all stresses from rotor weight, hydraulic loads, vibration and torques coming in during operation. 4.5 Shaft Sleeves Renewable type fine finished shaft sleeves shall be provided at the stuffing boxes I mechanical seals. Length of the shaft sleeves must extend beyond the outer faces of gland packing or seal end plate so as to distinguish between the leakage between shaft and shaft !'\leave and that past the seals/gland Shaft sleeves shall be securely fastened to the shaft to prevent any leakage or loosening.



Shaft and shaft sleeve assembly should ensure concentric rotation. 4.6 Bearings Heavy-duty bearings, adequately designed for the type of service specified in the enclosed pump data sheet and for long, trouble free operation should be furnished. The bearings offered shall be capable of taking both the radial and axial thrust coming into play during operation. In case, sleeve bearings are offered additional thrust bearings shall be provided. Antifriction bearings of standard type, if provided, shall be selected for a continuous operation of at least 16,000 hours at maximum axial I radial loads and rated speed. Proper lubricating arrangement for the bearings shall be provided. The design shall be such that the bearing-lubricating element does not contaminate the liquid pumped. Where there is a possibilityof liquid entering the bearings suitable arrangement in the form of deflectors or any other suitable arrangement must be provided ahead of bearing assembly. Bearings shall be easily accessible without disturbing the pump assembly. A drain plug shall be provided at the bottom of each bearing housing. 4.7 Mechanical Seals The Pumps shall generally be employed with mechanical seals, which shall be so arranged that replacement of seat should be possible with minimum downtime. Unless otherwise recommended by the supplier, mechanical seals may be of single type with either sliding gasket or bellows between the axially moving face and shaft sleeves or any other suitable type. The sealing faces should be highly lapped surfaces of materials known for their tow frictional coefficient and resistance to corrosion against the liquid being pumped. The pump supplier shall co-ordinate with the seal maker in establishing the seal chamber circulation rate for maintaining a stable film at the seal face. The seal piping systemshall form on integral part of the pump assembly. For the seals under vacuum service, the seal design must ensure sealing against atmospheric pressure even when the pumps are not operating. Necessary provisionfor seal water supply along with complete piping fittings and valves as required shall form integral part of pump supply. 4.8 Stuffing Box Stuffing box, if provided, should permit replacement of packing without removing any part other than the gland. Asbestos shall not be used as a packing material. Stuffing Boxes of packed ring construction type shall be provided wherever specified.



Packed ring stuffing boxes shall be properly lubricated and sealed as per service requirements and manufacturer's standards. If external gland sealing is required, it shall be done from the pump discharge. The Bidder shall provide the necessary piping valves, fittings etc. for the gland sealing connection. 4.9 Pump & Motor Shaft Coupling The pump and motor shafts shall be connected with an adequately sized flexible coupling of proven design with a spacer to facilitate dismantling_ of the pump without disturbing the motor. Necessary coupling guards shall also be provided. 4.10 Base Plate A common base plate mounting both pump and the motor shall be provided. The base plate shall be of fabricated steel (minimum 6 mm thickness) and of rigid construction, suitably ribbed and reinforced. Base plate and pump supports shall be so constructed and the piping unit so mounted as to minimize misalignment caused by mechanical forces such as normal piping strain, internal differential thermal expansion and hydraulic piping thrust. Suitable drain troughs and drip lip shall be provided. 4.11 Material of Construction The material of construction of various components shall be as indicated in relevant equipment data sheets enclosed along with this specification. These are to be considered as minimum requirement and it is the responsibility of supplier to select and offer proper material of construction for the required service. 4.12 Assembly and Dismantling Assembly and dismantling of each pump with drive motor shall be possible without disturbing the grouted base plate or alignment. 4.13 Drive Motor Continuous Motor rating (at 50 deg.c ambient) shall be at least ten percent (10%) above the maximum load demand of the pump in theentire operating range including the run out condition to take care of the system frequency & voltage variation. Other design and construction features of the drive motor shall be as specified elsewhere, under Standard Electrical Specifications: 5.0 INSPECTION AND TESTING The manufacturer shall conduct all test required to ensure that the equipment furnished



shall conform to the requirements of this specification and in compliance with the requirement of applicable Codes and Standards. The particulars of the proposed tests shall be submitted to the Owner for approval before conducting the tests. The contractor shall note that on castings, no weld repair shall be allowed and components of the pumps shall not be painted before inspection. 5.1 Shop tests 5.1.1 Hydrostatic Test The pump casing shall be hydraulically tested for twice the pump rated pressure or 1.5 times the shut-off pressure, whichever is higher, after adding the maximum suction pressure specified in the relevant pump data sheet. The hydrostatic test on the casing shall be conducted for a minimum duration of 30 minutes and no leakage should be observed. 5.1.2 Mechanical Balancing All rotating components of the pumps shall be subjected to static and dynamic balancing at shop as per ISO 1940. The dynamic balancing shall be done at or near the operating speed and the contractor shall furnish its acceptance norms for OWNER approval, before conducting the test. 5.1.3 Non-destructive testing Non-destructive testing of the pump components shall be conducted in accordance with relevant standards. Prior to testing, the test procedure and repair procedure shall be submitted for OWNER approval. All components subjected to testing shall be identified and only those which are tested successfully shall be used for the manufacture of final product. All test results shall be submitted by the contractor for OWNER approval. DP tests shall be conducted on shaft and impeller. Further, UT shall be conducted on all bars with unmachined diameter 2': 50 mm. If required, the pump components shall be offer for visual inspection by OWNER, before assembly. 5.1.4 Performance Testing All pumps shall be performance tested at the Manufacturer's Works for the entire range covering from shut off to the maximum flow. The test shall be conducted to determine the following characteristics:



a) Flow vs Head (Q vs H) b) Flow vs Efficiency (Q vs N) c) Flow vs Pump input power (Q vs P) A minimum of seven readings, approximately equidistant, shall be taken for plotting the curves with one point at/near the design flow. Testing of pumps shall be in accordance with stipulations of Hydraulic Institute Standard or as per applicable equivalent codes/standard approved by OWNER. The test shall be conducted preferably with the tested job motor. Noise and vibration shall be measured during the performance testing, for reference purposes. The pumps showing any abnormal behavior during the performance testing or the pumps as required by OWNER, shall be stripped down for a thorough examination after the performance test. The performance test report shall be prepared by the contractor and submitted to OWNER for approval, before dispatch of the pumps. 5.2 Site Testing After installation, the pumps supplied shall be operated to prove satisfactory performance as individual equipment as well as a system. The noise and vibration level of the pumps shall be measured and it should be within the design values. For pumps operating in parallel, the load sharing should not vary by more than 5%. If performance at site is found to be unsatisfactory, then the Contractor shall rectify or replace the equipment. 5.3 Test Procedure /Instruments The test procedures to be followed and instruments to be used for testing shall be subject to the approval of OWNER. All instruments to be used for stage and performance testing shall be calibrated at reputed third party laboratories. The accuracy of instruments used for testing shall be as follows, unless otherwise agreed to: a) Pressure gauge ±0.5% b) Wattmeter ±0.5% c) Tachometer ± 1 rpm d) Vibration meter ±3% e) Sound level meter ±2dB



1.0GENERAL This specification covers design, manufacture, constructional features, erection, testing and commissioning of suction side 400 and delivery 350 mm Knife edge gate valves. 2.0 CODESANDSTANDARDS. The b i d d e r sh a l l propose th e appl i cab le C o d e s a n d Standa r ds for approval of OWNER, a p a r t from the requirements specified in General Technical Specification. 3.0 TECHNICALREQUIREMENTS 3.1Knife edge gate valves shall be provided as required as per the technical requirements mentioned in the table below and subsequent clauses. a) Type of Valves :Knife Edge Gate Valve b) Size of valves :Same as parent pipe size

c) Method of operation : Solenoid operated pneumatically actuated with provision of hand wheel for manual operation d) Material of Construction

i) Body Cast Iron FG-260 to IS:210 (min10mmthickness with alloy C.I/SS deflection Core(minimum400BHN Hardness) ii) GateStainlesssteelwithmin.400BHNHardnessonwear surface

iii) Stem Stainless steel(SS:316) iv) SleeveIYoke:Bronze v) Glandpacking:Tosuitservicerequirements. 3.2 Adequately,sized solenoidoperatedpneumatically actuatedknifeedgeGate valveshallbeprovidedattheoutletofJet pumps(incaseofJetpumpsystem)atthesuctionanddischargeofB.A slurrytransportationpumps(incase ofscrapperconveyorsystem)andat the suctionofslurrydisposalpumps. 3.3Valvesshallbeprovidedwith amechanicalindicatorandlimitswitchesto indicateopenorclosedpositionof thevalvelocallyandremotely 3.4 Valvesshallbeprovidedwithhandwheelformanualoperation. Valves shall be designed for tough, abrasive and corrosive services.

3.6 As the accumulation of solid material in seat could affect the tight closure of the

valve (which may lead to premature wear due to improper shut off or the gate remaining

partially in the flow path} seat purge connections and deflection cone/ wear liner to limit

such occurrences shall be provided.

9. Slurry Line Knife Edge Gate Valves



4.0 INSPECTION AND TESTING.

4.1The manufacturer shall conduct all the tests required to ensure that the

equipment/system furnished shall conform to the requirements of th1s specification and

in compliance with the requirement of applicable codes and standards. All materials used

shall be of tested quality and test certificates shall be submitted to OWNER. The

particulars of the proposed tests shall be submitted to OWNER for approval before

conducting the tests. MDIIDP tests on materials shall be carried out.

4.2 The valves shall be visually inspected and checked for dimensional accuracy at

Manufacturer's works.

4.3 All materials of valve components shall be e tested I inspected as per governing standard I code for its chemical and mechanical properties.

4.4 The valves shall be hydraulically tested at shop to following pressure:

a) Seat 1.5 times the normal operating pressure or shut off pressure whichever is higher.

b)Body2.0 times the normal operating pressure or 1.5 times the shut off pressure

whichever is higher.

4.5 All valves shall be subjected to cycle test for minimum 100 cycles for ON- OFF

operation before hydraulic test.

4.6 Any other test as per applicable codes I standards and as per agreed Q.P

Sr No

Particulars Specification

1 Size 400 mm Suction Side 350 mm Delivery side Uni directional Type, Rising Spindle, Wafer Type,

Knife Edge Gate Valve. Specialized Heavy Duty.

2 Quantity 4 Set 3 Body MOC ASTM A 216 GR. WCB (Cast Steel) 4 Sleeve Natural rubber 5 Gate MOC AISI SS 304 6 Yoke MS fabricated Yoke 7 Stem SS 304 8 Rating PN 10, 70 Deg. C 9 Wafer Semi lugged Flat face connection 10 Seat AISI 304 [Metal to Metal] 11 Gland Packing Graphited Asbestos Rope



12 End Connection Lugged, Wafer Type, Flangeless.

BSW Threaded Holes in Chest Area and

Through Holes in Two Lugs.

Suitable to Mount Between Class 150 Flanges

13 Drilling ANSI B 16.5, Class 150 14 Operation Pneumatic Cylinder Operated and

Hand wheel operated 15 Body Hydro test 8.0 Kg. /cm2 16 Seat test Max. Allowable Leakage of 2.25 LPMWhen

Tested with Water at 2.82 Kg/Cm2Applied in

The Normal Flow Direction.

17 Design & Testing Standard -

As Per MSS SP 81

Cylinder Detail 18 Make Provide by the Manufacture 19 Type Double acting 20 Cylinder Tube M.S. Material, Super Fine Grinding, Honningwith

Hard Chrome Plated 21 Piston Cast Iron 22 Top and Bottom Cap Cast Iron 23 Piston Seal Buna N (Nitrile Rubber) 24 Piston Rod Seat Buna N (Nitrile Rubber) 25 Piston Rod M.S./ EN 8 With Hard Chrome Plated 26 Air Connection ¼” (BSP) F 27 Air Pressure Required 5.0 Kg. /Cm2 28 Cylinder Suitable for 3.0 To 8.0 Kg. /Cm2 Solenoid detail

29 Type 5/2 Way 30 End Connection 1/4” (BSP) F 31 Media Air 32 Operating Pressure 2-10 BAR 32 Orifice 6 mm 33 Coil 24 Volt DC 34 Power Consumption Provide by Manufacture 35 Body Material Aluminum



10. Expansion Joints

1.0 GENERAL

This specification covers design, manufacture, constructional features, erection, testing

and commissioning of Expansion Joints in Ash slurry disposal pumping System.

Two set 263 mm size Expansion Joints Install at CWS pumping house for clear water

system and four set 356 mm size install at Ash slurry pumping station.




The Bidder shall propose the applicable Codes and Standards for approval of

OWNER, apart from the requirements specified in General Technical Specification.


3.1 Expansion joints shall be provided as required as per the technical

requirements mentioned in the table below and subsequent clauses.

a) Type : Metallic Bellows type with replaceable liner

b) Material of construction of component parts

i) Bellows : To suit the dutyconditions and meeting the requirements of EJMA

standard.

ii) Replaceable liner: Appropriate abrasion resistant material with a minimum

hardness of 300 BHN.

3.2 The thermal expansion, in various directions of the air heater, flues gas duct,

economizer, electrostatic precipitator ash collection chutes, and the max, Weight that can

be supported from each fly ash hopper shall be as per the project specifications.

3.3To the extent possible, the fly ash handling system loads shall be supported

from the respective collection chutes and other existing structure in the area.

3.4 Taking the above into consideration, theContractor shall assess the needfor providing

expansion joints in different legs of the fly ash handlingsystem and shall furnish the

details during the detailed engineering stage. The Contractor shall furnish to the

Engineer the complete pipe stress I flexibility analysis justifying their selection of number

and location of the expansion joints.

3.5 The expansion joints shall be designed for minimum cyclic life of 5000 cycles.

3.6 INSPECTION AND TESTING.

The manufacturer shall conduct all the tests required to ensurethatthe equipment/system

furnished shall conform to the requirements of this specification and in compliance with

the requirement of applicable codes and standards. All materials used shall be of tested

quality andtest certificates shall be submitted to OWNER. The particulars of the proposed

tests shall be submitted to NASLIOWNER for approval before conducting the tests.

MDI/DP tests on materials shall be carried out.



3.7 The expansion joint shall be visually inspected and checked for dimensional accuracy

at Manufacturer's works.

Required tests as per EJMA standard shall also be conducted at theManufacturer's works.



1.0 GENERAL

This specification covers design, manufacture, constructional features, erection, testing

and commissioning of water and air piping, fittings and accessories

2.0 CODES AND STANDARDS.

The bidder shall propose the applicable Codes and Standards for approval of apart from

the requirements specified in General TechnicalSpecification.

IS:1259 Mild steel tubes, tubularand otherwrought steel fittings.

(Part I & II)

IS:1367 Technical supply condition for threaded steelfastener introduction

and general information

IS:3589 Electrically welded steel pipes for water gas and sewage (200 to

2000 nominal dia)

IS:4736 Hot dip zinc coating on steel tubes

IS:6392 Steel pipe flanges

IS:1363 Black Hexagonal bolts, nuts and lock nuts

(Part I & II)

IS:1364 Precision and semi-precisionhexagonal screws, nuts and locks nuts

(dia 6 to 39 mm)

IS:2016 Plain washers

IS:2062 Structural steel fusion-welding quality

IS:2712 Compressor asbestos Fire Jointing Gaskets

IS:3138 Hexagonal bolts and nuts (M-42 to M-150)

IS:5822 Code of practice for laying steel pipes

IS: 9404 Colour code for identification of pipe lines used in thermal power

plants

BS:534 Black bolts, screws and nuts

BS:916 Black bolts, screws and nuts

BS:2633 Specification for Class-1 Arc welding of terrificsteel for pipework

carrying fluids

BS:4504 Flanges and bolting for pipes, valves andfittings metric series.

ANSI B.2.1 Dimensions of American Taper pipe threads

11WATER AND AIR PIPING, FITTINGS AND ACCESSORIES



ANSI B 16.5 Steel pipe flanges, flanges valves and fittings

ANSI B 16.9Factory made wrought steel butt welded fittings

ANSI B 16. 11Forged ·steel fittings (Socket-welding and threads)

ANSI B 16.21 Non-metallic gaskets for pipe flanges

ANSI B 16.25Butt welding Ends

ANSI B 16.28Steel short Radius fittings

ANSI B 31.1Power piping code

ANSI36.10 Welded and seamless wrought steel pipe

ANSI A-234 Carbon and Ferritic alloy steel fittings

ANSI A-53 Pipe, steel black and hot dipped, zinc coated, welded and seamless


3.1 Water and air piping, fittings and accessories shall be provided as required as per the

technical requirements mentioned below

3.1.1 WATER PIPES

a) Type of Pipes i)Upto & including 150 NB MS. ERW pipes to IS:1239 Heavy grade

ii)200 NB to 450 NB MS ERW pipes to IS:3589

OR

SAIL or equal make ERW commercial quality pipes

iii)500 NB and above Rolled and welded from MS plate to IS:226.

Dimensional tolerance as per IS:3589

b Pipe Sizes As required

c Thickness of Pipes a) Pipe specification as per IS:1239

Pipe thickness shall be of

Heavy grade.

b) Pipe spec. as perIS:3589 (ERW)

Min 6.35 mm thick for

200 NB to 400 NB size

c)Pipe spec. as per IS:3589 (ERW from IS:226

plates/spiral welded)

Min. 7.14 mm thick for

450 NB size. Min. 8 mm thick)

4.0 Type of Line joints a) 50 NB and below Socket welded to ANSI: B 16.11

b) 65 NB and above Butt welded to ANSI: B16.25



5.0 Quantity As required

6.0 Fittings (Bends) a) For sizes upto 65 NB 3D radius bends and material same as that of parent pipe

b) For sizes 80 NB to 300 NB

SR & LR elbow and

material same as that of parent pipe.

c) 350 NB & above Meter bends with Meter angle not exceeding 22.5 (Material shall be same as that of parent pipe and dimensional tolerance shall be as per BS:534

7.0 Flanges Sliponflatfacetypewithdrilledandpressurerating aspervalveandotherspecializes. Materialof constructionshallbeIS:226UPTO20MM

THICKNESSANDIS:2062forhigherthickness

8.0 Bolts AsperIS:1367CL.4.6ORASTM-A-307-Gr. B

9.0 Nuts AsperIS:1367Cl.4.0orASTMA-307Gr.B

10 Gaskets WireinsertedRedrubber. Thickness shallbe1.6mm forsizesuptoandincluding250NBand3.2mmfor II

AIRPIPES

highersizes

1.0 TypeofPipe a) ERWpipeasperIS:1239,heavygradewith

galvanisingasperIS:4736

b) Forcompressedairpipingforinstrumentand controlloops,bulkheadsthefollowingstandard shallbeadopted: i) Forsizes25NBand Seamless RedBrass

including 50NB ASTMB43Sch.40

ii) Forsizesbelow25 SeamlessCopperto NB ASTMB-75 2.0 Pipesizes Asrequired

3.0 Thicknessofpipes Pipethickness shallbeasheavygradeofIS:1239

4.0 TypeofLinejoints a) 65NBandBelow Screwed

b) 80NBandabove Sleevewelded. However, valveetc.shallbe screwedandwithflange 5.0 Quantity Asrequired



6.0 Fittings/(Elbows) AsperASTM-A-234Gr.WPB(GI)

7.0 Flanges Raised face type G.l screwed and pressure rating as per valve and other specialties., Material of construction shall be IS:226 upto 20mm thickness and18:2062 for higher thickness.

8.0 Bolts, nuts & Gaskets Same as for water pipes

In addition to the details specified above, the Bidder/Contractor shall comply with the

following requirements.

3.2 All required water and air transport pipework including all instrument impulse

piping and fitting from the tap off points upto and including root valves for

complete ash handling plant shall be furnished as specified.

3.3 All piping system shall be capable of withstanding the maximum pressure (pump

shut off) in the corresponding line at the relevant temperatures.

3.4 All piping system shall be properly designed to take care of water

hammer/pressure surges which may arise during operation of the system.

Bidder shall provide necessary protective arrangement for the safe guard of the

piping system under above mentioned conditions.

3.5 All piping shall be provided with vents at the highest points and drains at the lowest

points along with vent valves and drain cocks. Vents shall not be less than 15mm in

size. Drains shall not be less than 25 mm size.

3.6 At all intersection joints, it is Contractor's responsibility to design and provide

suitable reinforcements as per the applicable codes and standards.

3.7 Bends, loops, off sets, expansion or flexible joints shall be used as required in

order to prevent overstressing of the piping system due to thermal movements and

to provide adequate flexibility.

3.8 The design, supply and installation of all pipe supports and hangers including pipe

clamps, turn buckles, hanger rods, auxiliary steel etc. shall be furnished by the



Bidder along with the associated pipe work. The Bidder shall furnish all bolting

materials companion flanges, nuts gaskets etc. as required in the piping system and

at all terminal points.

3.9 All piping shall be routed to avoid interference with other pipes and their hangers

and supports, electrical cable trays, ventilation ducting structuralmembers,

equipment etc. Adequate clearance shall be ensured with respect to the above to

accommodate pipe movement.

3.10 The piping shall be arranged to provide clearance for the removal of equipment

requiring maintenance and for easy access to valves and other piping accessories

required for operational and maintenance.

3.11 Piping shall generally be routed above ground but where specifically

indicated/approved by the Engineer the pipes may be arranged in trenches or buried.

Bidder shall provide either coal tar and Bitumen tapes on conventional coat and wrap

system for corrosion protection of buried piping as per relevant codes and standards.

3.12 Overhead piping shall have a normal minimum vertical clearance of 2.3 meters

above walk ways and working areas and 6 meters above road ways unless otherwise

approved by the Engineer.

3.13 The following line velocities shall be considered for estimating the line sizes of

water pipes and Air pipes:

Service Pipe Size

Size below 50 mm

Velocity m/sec pipe size of 50 to 150 mm

Pipe Size of 200 mm and above

a water pump suction

0.6 - 0.9 1.2 -1.5 1.2 – 1.5

B Waterpump suction

0.9 -1.8 1.5 -2.4 1.8-2.8

C Compressed air below 2kg/cm2 (g)

15-20 15 -20 20-30

d Water pump discharge

20-30 20-25 25-35



Note

Pipe Size in (a) above shallbe at least one pipe size larger than the corresponding

pump discharge connection. (b) the proposed sizes of the water and air pipes shall

be submitted for Owners approval.

3.14 The pipe supports shall be spaced as follows:

NB 25 50 100 150 200 300 400 500

2.1 3.0 4.3 5.2 5.8 7.8 8.2 9.8

4.0 INSPECTION AND TESTING

4.1 All pipes and fittings shall be visually inspected and checked for

dimensionalaccuracies at manufacturer's works'. LPI & MPI test shall be carried out

as perStd. practice for weld.

4.2 Hydraulic test shall be carried out at manufacturer's works on pipes and fittings at

twice the normal operating pressure or 1.5 times the shut off pressure of pump

whichever is higher. The procedure and duration of test shall be as per applicable

standards.

After installation at site the pipes shall be hydraulically tested at twice the normal,

operating pressure or 1.5 times the design pressure of pump whichever is higher

12. Water and Airline Valves and Specialties

1.0 GENERAL

The Specification covers design, manufacture, construction features, erection, testing

and commissioning of water and Air line valve and specialties.

2.0 CODES AND STANDARDS.

The bidder shall propose the applicable Codes and Standards for approval of OWNER,

apart from the requirements specified in General Technical Specification.

IS:778 Gun Metal Gate, Globe and check valves for general purpose



IS:780Sluice valves for water works purpose 150 to 300 mm size

IS:1703Ball valves (Horizontal plunger type) including floats for water supply

IS:2685 Code of practice for selection, installation and maintenanceof sluice valves

IS:2906 Sluice valves for water works purposes (350 to 1200 mm size)

IS:5312Swing check type reflux (Non-return) valves

BS: 1868Specification for steel check valve (Flange & Butt welding ends).

BS:1873Steel globe and globe stop and check valves (flanged and butt

welding ends)

BS:5152 Specification for C.I. Globe, stop and check valves for generalpurpose.

BS:5353 Carbon and Alloy steel plug valve

BS:5153 C.I. check valves for general purpose.

BS:5154 Copper alloy globe I globe stop and check and gate valves for general

purpose.

BS:5158 C.I. and carbon steel plug valves for general purpose

ANSI B Steel pipe flanges, flanged valves and fittings

16.34 -

ANSI B Face to face and End to End dimensions of Ferrous valve

16.10

ANSI B Steel valves flanges and butt welding ends.

16.34

ANSI B-21 Dimensions of American tape pipe threads

API- 598 Valve inspection and test

API600 Steel gate valves

API- 602 Compact design carbon steel gate valves for refinery

3.1 Water and air line valves shall be provided as required as per the technical

requirements mentioned in the table below and subsequent clauses.

a Type of valves i) For isolation purpose A Gate/ plug/ Eccentric plug/Butterfly (double flanged or wafer type)

ii) For Regulation purpose

Globe/butterfly

(doublepurpose



flanged or wafer type)

iii) For non-return Check type

b Size of valves Same as parent pipe size

c Pressure class of To suit service conditions flow, valves temperature and shut off pressure

d Numbers required As per system needs

e Method of operation Manual I Solenoid operated and pneumatically actuated I motor operated as per system requirements.

f Fluid to be Handled Water and Air

g Material of construction

i) For sizes 50 mm and working pressure or shut off pressure (whichever is higher) is upto 15 kg/cm2

(g)/upto 10 kg/cm2 for plug valves

Body/Wedge/Disc: Gun Metal

ii) For sizes 50 mm and above working pressure or shut off pressure (whichever is higher) is upto 15 kg/cm2

(g)/upto 10 kg/cm2 for plug valves

i) Body/Wedge/Disc/Plug C I to IS :210 Gr FG 220

ii) Trim & stem: brass / Gun metal

h) for all sizes and working pressure or shut-off pressure

(which-ever is higher)

is above 15 kg/cm2 (g) (upto 10 kg/cm2

(g) for plug valves)

i) Body: Cast/Forged carbon steel

ii) Wedge/Disc/Plug: Cast carbon steel with 13% Cr.

iii) Trim and Stem: Stainless steel

Quantity As required

Fittings (Bends) i)For sizes upto 65 NB 3D radius bends and

Materials same as thatas parent pipe

ii)For sizes 80 NB to 300 NB

SR & LR elbow and

NBmaterial same as that

parent pipe



3.2 All valve shall be suitable for the service conditions i.e. Flow, temperature and

pressure under which they are required to operate and those performing similar

duties shall be interchangeable, with one another unless otherwise approved. All

valves and connections shall be suitably protected to prevent damage and entry of

dirt, till erected.

3.3 End to end dimensions shall be in accordance to ANSI 816.10 or as per codes to

which they conform.

3.4 All manually operated valves of all sizes 350 NB and above shall be provided with

gear operators of proven quality, reputed make and conforming to internationally

accepted standard.

3.5 All valves shall be fitted with open I close position indicators.

3.6 All valvesshall be provided with hand wheels; extension spindles and floor stands or

any other arrangement wherever required so that they can be operated manually

with ease by a single operator room the nearest operating floor wither at a lower or

higher elevation. Wherever necessary for safety purpose, locking devices shall be

furnished with valves.

3.7 All Gate and Globe valves shall be outside screw and yoke (OS & Y) type and

provided with back seat to permit repacking with valves in operation.

3.8 The actuator operated valves shall be designed on the basis of the following

prescriptions:

a) The internal parts shall be suitable to support the stresses caused by the actuator.

b) The valve actuator unit shall be suitably stiff so as to cause vibrations,misalignment

etc.

c) Valves shall be provided with hand operating gear, hand wheel and clutching and

declutching arrangement.

3.9 The size of all valves shall be the same as that of parent pipe

3.10 The endconnections, unlessotherwise requested, shall comply with

thefollowing:

Socket welding (SW) ANSI B 16.11

Butt welding (BW) ANSI B 16.25

Threaded (SC) ANSI B 2.1

Flanged (FL) ANSI B 16.5



3.11 Gate valves shall be used for isolation purposes, Globe valves shall be used for

regulation purpose, check valves shall be used for non-return service, and plug valves

shall be used for isolation purpose in those lines where quick opening and closing is

required in the system.

Double flanged or water type butterfly valves of low leakage rate conforming to AWWA-

C- 504 or BS:5155 can also be used for isolation, quick isolation and regulation purposes.

4.0 INSPECTION AND TESTING

4.1 The manufacturer shallconduct allthe 'tests required to ensure that the

equipment/system furnished shall conform to the requirements of this

specification and in compliance with the requirement of applicable codes and

standards. All materials used shall be of tested quality and test certificates shall be

submitted to OWNER. The Particulars of the proposed tests shall be submitted to

OWNER for approval before conducting the tests. MDI/DP tests on materials shall be

carried out.

4.2 All valves shall be visually inspected and checked for dimensional accuracies at

manufacturer's works.

4.3 All valves shall be tested hydraulically to minimum twice the normal operating

pressure or 1.5 times the design pressure whichever is higher (for body) and 1.0 times

(for seat and back seat) the shut-off pressure of pump. The procedure and duration of

tests shall be as per applicable standards.

4.4 Valve trim material shall be subjected to non-destructive test.

4.5 As Cast heat marks shall be provided on castings and must be correlated with test

certificates.

4.6 Air tests shall, also be conducted as per applicable codes to detect seat

leakages.



13 Air Compressor’s

1.0 GENERAL

This specification covers the design, manufacture, construction features, testing and

commissioning of Air compressor. Please also refer to the Standard Specifications of

individual equipment attached elsewhere.


The bidder shall propose the applicable Codes and Standards for approval of

OWNER in line with the following

BS 1571 Acceptance test for positive displacement compressors

(part 1&11)

IS 6206 Guide for selection, installation and maintenance of air

compressors



IS 5727 Glossary of termsrelating to compressors

ASME Power test code Displacement compressors, vacuum pump and blowers

IS 2825 Code for unfired pressure vessels

ASME sec VIII Div. 1 Code for unfired pressure vessels

IS 7936 Air receiver for compressed air installation


Air compressors shallbe provided as required as per the technical requirements

mentioned in the table below and subsequent clauses

3.1 Air compressors shall be provided as requiredas per the technical requirements

mentioned in the table below and subsequent clauses

a Location & type : Indoor, Reciprocating, balance opposite, non-

lubricated Type Compressor

b Number : As per Project Specification

c FAD of each set of working :At least 10% margin shall be provided on compressor

capacity over and above the maximum flow

requirement compressors at working pressure

d Duty : Continuous

3.2 Air Compressors shall be designed for continuous operation with high efficiency to

satisfy the system requirements.

3.3 The scope of supply shall include all the necessary compressed air plant complete

with compressor coolers, necessary isolating and non-return valves, standard inertia

flywheel, forced lubrication of rotating parts with gear pump fitted with a pressure

adjusting valve and oil filtering arrangement, suction air filter with silencer, pressure

relief valve, air driers, air receivers with the corresponding vent pipe work,

instruments which shall be ducted to a safe discharge outlet.

3.4 In order to have flexibility in operation the compressor discharge of all the units shall

be interconnected with suitable valve arrangement.



3.5 All air compressors and their drives provided under this contract shall be completely

interchangeable.

Horizontal water cooled after cooler of shell & tube type with air flow through tubes

and water in shell in counter current. The after cooler will be

complete with safety valve, inlet and outlet pulsation dampers, built in moisture

separator and auto drain cock.

3.6 Air drier

The compressed air must be oil free. Therefore, oil free compressed air system shall be

provided. Another essential requirement is for 'dryness' of the compressedair, and

toachieve it, biddersshall offer a compressed air system, which includes a air drier

system. This system should comprise of an after-cooling stage followed by a drying

process which may be of refrigerant oil absorption type. Fully automatic blower heat

reactivated type air dryer suitable to dry the required capacity of air at a working

pressure of 8 kg/cm2g and 40 deg C temperature maximum. To a dew point of- 40

deg C at atmospheric pressure with activated alumina as desiccant.

3.7 Air Receivers

3.7.1 Compressor shall be provided with an air receiver of ample size, so that delivered

air pressure is kept within ± 5% of rated pressure without excessive start/stop

operation in the working cycle.

3.7.2 Vertical air receiver suitable for a working pressure 8 kg/cm2 g withmaterial of

construction as per IS:2062 I IS-2002 and design code as per IS-2825 complete with

welded supporting stand, inspection window with opening cover, flanged in/out

connections, 1 No. pressure gauge, suitable safety valve, manual drain cock and

foundation bolts.

3.7.3 Air receivers shall be located convenient to compressor discharge.

3.8 Inspection and Testing

The bidder shall conduct all tests as per IS/international standards to ensure that the

equipment furnished shall conform to the requirement of this specification



14 BESALT LINED PIPE AND FITTINGS 1 GENERAL This specification covers design, manufacture, constructional features, erection, testing and commissioning of basalt lined pipes, fittings and accessories for ash slurry duty. It is not the intent to completely specify all the details of design, construction and installation herein. Nevertheless, the equipment, accessories and installation shall conform to a high standard of engineering, design and workmanship and capable of performing continuous operation without any accumulation of ash slurry in the pipes and its fittings 2 CODES AND STANDARDS The bidder shall propose the applicable Codes and Standards apart from the requirements specified in Technical Specification. The basalt liners shall be manufactured and tested as per DIN 52 108 I IS 1705 standard Standards of MS pipes I fittings in which basalt liners are to be fitted shall be as per following standards IS:1259 : Mild steel tubes, tubular and other wrought steel fittings (Part I & II) IS:1367 : Technical supply condition for threaded steel fastener introduction and general information IS:3589 : Electrically welded steel pipis for water gas and sewage (200 to 2000 nominal dia)



IS:4736 : Hot dip zinc coating on steel tubes IS:6392 : Steel pipe flanges IS:1363 (Part I & II) : Black Hexagonal bolts, nuts and lock nuts IS:1364 : Precision and semi-precision hexagonal screws, nuts and locks nuts (dia 6 to 39 mm) IS:2016 : Plain washers IS:2062 : Structural steel fusion-welding quality IS:2712 : Compressor asbestos Fire Jointing Gaskets IS:3138 : Hexagonal bolts and nuts (M-42 to M-150) IS:5822 : Code of practice for laying steel pipes IS: 9404 : Colour code for identification of pipe lines used in thermal power plants BS:534 : Black bolts, screws and nuts BS:916 : Black bolts, screws and nuts BS:2633 : Specification for Class-1 Arc welding of terrific steel for pipework carrying fluids BS:4504 : Flanges and bolting for pipes, valves and fittings metric series ANSI 8.2.1 : Dimensions of American Taper pipe threads ANSI B 16.5 : Steel pipe flanges, flanges valves and fittings NSI B 16.9 : Factory made wrought steel butt welded fittings ANSI 816.11 : Forged steel fittings (Socket-welding and threads) ANSI 8 16.21 : Non-metallic gaskets for pipe flanges ANSI B 16.25 : Butt welding Ends ANSI B 16.28 : Steel short Radius fittings ANSI B 31.1 : Power piping code ANS136.10 : Welded and seamless wrought steel pipe ANSI A-234 : Carbon and Ferritic alloy steel fittings ANSI A-53 : Pipe, steel black and hot dipped, zinc coated, welded and seamless

3 Technical Requirements

The basalt lined pipes are intended to carry ash slurry (both bottom ash and fly ash slurry) from ash slurry sump to ash dyke. Single sleeve/double sleeve coupling shall be provided at an interval of 18m- 20m and flange joints at bends/fittings/elbows laterals. The specification shall be as follows. 3.1Basalt liners for straight pipes and bends/laterals/fittings (As per standard) Thickness of basalt liner/bends. 20mm Tolerance on thickness ±2mm Hardness 8 mhos minimum Abrasion resistance 4-6 cm3/50cm2



Compressive strength 4500 kg/sq.cm Bending Strength 400 kg/sq.cm Abradibility max loss 5 cm2/50 cm2 Density 2.95 gm/cu.cm Water absorption Nil Apparent Porosity Nil Wear resistant max loss 11Omm3 Heat shock resistant min. 100°C Testing procedure DIN/IS 3.2 Couplings Sleeve coupling with minimum 9 mm thick sleeve Sleeve steel Flanges Steel Gasket rubber Nuts and bolts Hot dip galvanised as per IS 4759

3.3 Pipe specification for basalt lings shall be as follows:

Type of Pipes 200 NB to 500 NB MS ERW pipes to

IS:3589 Minimum 6 mm thick OR

SAIL or equal make ERW commercial quality pipes

Above 500 NB Rolled and welded from MS plate min 6mm thick to IS:2026. Dimensional tolerance as per IS:3589

Fittings

(Bends)

For sizes 80 NB to 300 NB

350 NB & above

30 radius bends

30 radius bends

Flanges, if applicable Slip on flat face type with drilled and pressure rating as per valve and other specialises. Material of construction shall be as IS:2026

Bolts As per IS:1367 CL. 4.6 OR ASTM-A-307-Gr. B

Nuts As per IS:1367 Cl. 4.0 or ASTM A-307 Gr. 8

Gaskets Wire inserted Red rubber. Thickness shall be 1.6 mm for sizes upto and including 250 NB and 3.2 mm for higher sizes



Bonding /Grouting cast basalt lining will be joined together by epoxy based resin with equivalent life.: sand grout will be fitted in the annular space cast basalt liner and pipe

3.4 In addition to the details specified above, the Bidder/Contractor shallcomply with the following requirements

3.4.1The ash slurry conveying piping shall be furnished complete with all steel supports, hangers, clamps, support inserts, nuts, bolts gaskets etc.

The bottom ash slurry transportation piping shall continue withoutbends, branches, or merging for a distance of at least six (6) metres from the Jet pump outlet and shall be basalt lined.

3.4.2 The diameter of bottom ash and fly slurry pipelines should be selected considering slurry velocity of minimum value of 1.41 M/Sec and maximum 2.8 M/ Sec in the pipe.

3.4.3 The routing of the ash conveying pipelines shall be as per site conditions. Detailed routing shall be decided during detailed engineering. The pipelines shall be provided with adequately sized drain connections with blind flanges as per final layout requirements.

The Bidder shall conduct line surge studies for the pipelines. Suitable arrangements as required to protect the system based on surge studies are included in Bidder's scope.

3.5 Fittings

3.5.1 All bottom ash Fly and slurry pipe fittings i.e. bends elbows, laterals, etc shall be basalt lined.

3.5.2 All the fittings, (bends, elbows/laterals etc) in the slurry pipe line shall be as per good engineering practice and of large radius of construction (Min 3 D)

3.6 Couplings

3.6.1 For ease of rotation and replacement of ash slurry conveying pipes and for maintenance purpose, sleeve type couplings shall be provided at regular intervals.

3.6.2 Straight length of pipes without any intermediate couplings shall not exceed 18m-20m. It shall be possible to replace or rotate (as applicable) any fitting and any particular spool or pipe during maintenance without unduly disturbing neighbouring healthy joints spools.

3.6.3 The couplings shall be capable of taking a minimum of 2° angular deflection. Sufficient gap between ends of pipes at couplings shall be provided to take care of expansion in piping.



3.4.4 The bidder shall furnish a time schedule in form of bar chart for the following -Completion of design and engineering. -Approval of design documents. -Procurement of raw materials & bought out equipment. -Manufacture. -Testing & Inspection schedule during manufacture -Final testing & inspection at works by Authorised agency -Painting, Packing and Despatch. -Receipt at Site. The above details shall be furnished in the form of a Bar. Chart along with the bid.

4. Specific Inspection and Testing Requirement as per DIN/IS standards

bidder shall guarantee life of basalt pipe/fittings.

Cast basalt fittings, liners shall be examined by NOT for detection of cracks and other defects. Acceptance criteria for defectsshall befinalised beforeaward of contract. Adequate care shall be taken bysupplier toensure thatlining does not get damagedduring transportation, loading, unloading. All damaged items shall be replaced by bidder free of cost.

Hydraulic test shall be carried out at manufacturer's work on pipes couplings and fittings attwice the normalpressure or1.5 times the shut off pressure which everand is higher. The procedure and duration of tests shall be as per applicable standards.



15 General

a. This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at the manufacturer’s works, delivery at

site, handling at site, erection, testing, commissioning, performance testing and

handing over of Double girder Electrically Operated Travelling Crane (Overhead).

15. 1 Codes and Standards

a. The design, materials, construction, manufacture, inspection, testing and

performance of the crane shall comply with all currently applicable statutes,

regulations and safety codes in the locality where the equipment is to be installed.

The equipment shall also conform to the latest applicable Indian or equivalent

standards. Other international standards are also acceptable, if these are established

to be equal or superior to the listed standards. Nothing in this specification shall be

construed to relieve the Contractor of his responsibility.

The following are some of the codes and standards relevant to this specification.

IS 807 Design, Manufacture, Erection and Testing (Structural Portion) of Cranes and Hoists

IS 3177 Electric Overhead Travelling Cranes and Gantry Cranes other than Steel Works Cranes.

IS 3938 Electric Wire Rope Hoists

IS 13834 Cranes – Classification.

15.1.1Construction Features

a. The crane shall be a complete unit with bridge girder, end carriages for long travel, travelling trolley for cross travel, rope drums, wire ropes, sheaves, drive units,

brakes, rails and fixtures, rail clamps, end stops, buffers, conductors, all electrical

etc. to make the equipment complete in all respects. All materials used shall be of

recent manufacture, free from defects, mill scales, laminations, pitting, flakes, rust

etc. All welds shall be free from defects like blow holes, lack of penetration, slag

intrusions etc. Impact factor for structural design shall be considered as per Table 1

of IS 3177.

15 Electrically Operated Travelling (E.O.T) Crane



15 .1 Bridge Girder

a. The crane bridge shall consist of double girder as specified. The bridge girder shall have enough strength to carry the rated load without causing undue stress or

deflection.

15. 2 End Carriages

a. End carriages connected with bridge girder at the two (2) ends shall be made from

structural steel.

b. End carriage design shall be such that it facilitates easy removal of the wheels for maintenance. Suitable jacking pads shall be provided for maintenance and easy

removal of crane wheels.

c. The wheels shall be double flanged for overhead crane. The wheels shall be

machined on their treads to match the runway rail section for overhead.

d. Wheel base and structural frame of the end carriages shall be designed and

connected with bridge girder in such a way that the crane remains square and

scenes is prevented. The ratio between wheel base and crane span shall be as

stipulated in IS 807.

15.3 Travelling Trolley

a. Trolley frames shall be fabricated from rolled structural steel sections.

b. For double girder crane, the trolley shall be provided with chequered plate platforms

with openings for ropes, sheaves etc. Hand railings shall be provided all around the

platform.

c. Suitable jacking pads shall be provided for maintenance and easy removal of wheels.

15.4 Operator’s Cabin

a. The operator’s cabin shall be open or closed type with ample space for mounting of

all control panels and adequate clearance for the safety of operator and maintenance

personnel. The main control panel and associated resistors may be located outside



the cabin on the trolley or bridge platform with adequate clearance for the safety of

operator and maintenance personnel.

b. The platform shall be of a non-slip surface and cabin size shall not be less than 2.5 M

x 1.85 M x 2.0 M clear heights.

c. The cabin shall be provided with a swing way operator’s seat and a protected ladder

to access the crane walkway. It shall be adequately illuminated. The cabin and its

access ladder shall be so arranged as to prevent personnel from making accidental

contact with runway conductors. A permanent frame indicating complete instructions

covering the crane operation, maintenance and lubrication shall be mounted in the

cabin for convenient reference. A non-oscillating ventilation fan of 240 V AC, single

phase and with suitable guard shall be provided in the cabin. The fan shall have 300

mm sweep and equipped with toggle switch and an independent regulator.

d. In addition to this an electrical horn shall be provided and mounted on under side of the cabin, operated by footswitches as and when required by the driver. Horn shall

be heavy duty howler to produce 95 dB at 3.5 M, double bell projector suitable for

240 V AC operations.

e. A 3 Kg CO2 type fire extinguisher conforming to IS 2878 shall be provided in the cabin. A sand bucket with sand shall also be provided in the cabin for minor fires.

15.5 Rope Drums

a. Rope drums shall be as per IS 3177. Rope drums shall be made of seamless pipe or

cast or welded to sustain concentrated loads resulting from rope pull. In case of

welded drum, same shall be stress relieved. Drums shall be machine grooved right

and left with grooves of a proper shape for the rope used. Grooving shall be of

proper length to handle entire rope required to make the specified lift plus the two

dead laps at each anchor point, without overlapping.

15.6 Wire Ropes

a. Wire ropes shall be extra flexible with well lubricated .Wire ropes shall be of Right

Hand Ordinary (RHO) lay construction. The rope shall be fastened to the drum with

an attachment having strength equal to that of the rope. The rope fastening at the

swinging end shall be aligned so as to prevent rope coming off its revving. Rope shall

be of sufficient length so that two (2) full laps shall remain on the drum at extreme



low position of the hook. Reverse bends or cross bends and bird caging shall be

avoided. The breaking loads for the hoist ropes shall not be less than the factor

specified in IS 3177. The load shall include rated load on hooks, weight of the

bottom block and the weight of rope.

15.7 Sheaves

a. Rope sheaves shall be rolled steel. Sheaves shall be as per IS 3177. Grooves shall

be machined to the proper shape for the rope used. These shall be equipped with

anti-friction bearings and shall be fully guarded to prevent the rope coming off.

Equalizing sheaves, if provided, shall also be as per IS 3177. Grooves shall be

machined to proper shape for the rope used

15.8 Gears

a. All gears shall be machine cut and profile ground. All gears shall be of cast or

wrought steel or forged from low or medium carbon alloy steel and suitably heat

treated. All gears and pinions shall be hardened and ground finished. Strength,

quality of steel, heat treatment, face, pitch of teeth and design shall conform to IS

4460. Gears and pinions shall be pressed on and keyed to shafts. All gears and

pinions shall be totally enclosed type up to last stage of reduction in all motions and

shall be carried in fabricated steel gear boxes which shall be dust proof and firmly

sealed to prevent oil leakages. Gear boxes shall have covers split horizontally and

arranged such that top half can be removed for inspection. The gear boxes shall be

fitted with bolted type machined inspection covers. Cast steel cartridge housings

shall be provided for carrying roller bearings. Dip sticks or indicator shall be provided

for indicating oil level. No overhanging gears shall be used. Drain plugs shall be

provided on all gear boxes. Lifting lugs shall be provided for handling purposes.

15.9 Bearings

a. Bearings may be ball, roller or removable bronze bushing type except that motor

bearings shall be of ball or roller type only. All anti-friction bearings shall be of

approved make, which are interchangeable with corresponding size bearings of other

make. Bearing housings shall be of split type or so designed to permit easy removal

of the shaft. The design shall be such that there is no ingress of dust and oil or

grease does not leak out. Drip pans shall be provided to accept accidental leakage

and drippings Bearings shall have minimum life expectancy of 40,000 working hours.



15.10 Shafts, Axles, Couplings, Keys and Splines

a. Shafts and axles shall be of forged steel and shall have ample strength, rigidity and

adequate bearing surface for intended duties. Shafts and axles shall be accurately

machined and properly supported. Shafts shall, as far as possible, be furnished

straight. If shouldered, these shall be provided with fillets of ample radius or shall be

tapered to avoid loss of strength and stress concentration. These shall be designed

considering allowances for keys and splines.

b. All couplings shall be of steel. Keys and keyways shall conform to IS 2048 / 2291 / 2292 / 2293 as applicable. Splines and serrations shall be of involutes or straight

sided form. Straight sided splines shall comply to IS 2327/ 2610 as applicable.

15.11 Brakes a. All brakes shall be of ‘fail-safe’ design and shall operate automatically in case of

power failure. Hoisting motion shall be provided with two brakes. Out of the two (2)

brakes, one shall be provided at the gear box input shaft and other on motor side.

For cross travel and long travel, brakes shall be provided on the high speed side of

the gear box. Hoisting brakes shall be designed to hold 1.5 times full load torque

while cross travel and long travel brakes shall be designed to hold 1.25 times full

load torque. Separate brakes shall be provided for creep motions. All brakes shall

have weather-proof enclosures. Coupling halves shall not be used as brake drums.

15.12 Lifting Hooks

a. The lifting hooks shall be plain shank type as per IS 5749. The hooks shall be solid,

forged, heat treated, of rugged construction and provided with a standard depress

type safety latch. Lifting hooks shall have swivels and operate on ball or roller thrust

bearings with hardened races. Lock to prevent hook from swiveling shall be provided.

15.13 Wheels and rails

a. Bridge and trolley track wheels shall be of forged or cast steel with cylindrical

straight tread The minimum hardness of the wheel rim shall be maintained between

300 and 350 BHN with minimum depth of 10 mm. Steel used for wheels shall not

contain more than 0.060 per cent of either sulphur or phosphorus. The wheels shall

be mounted in such a manner as to facilitate easy removal and placement.



b. The wheel diameter and rail sizes shall be suitably selected so as to meet the

requirements of wheel loading for the specified duty class of crane. The rail fasteners

shall be suitably machined to ensure full contact with the rail flanges. The bridge and

trolley track wheel bearings shall be anti-friction roller bearing and shall be carried on

specially designed bearing support blocks of ‘L’ type design (commonly known as ‘L’

type bearing housings).

c. Cross travel rails of required strength and rigidity along with rail clamps and other

accessories shall be provided.

d. In case of outdoor installation of overhead travelling crane, suitable rail clamps shall be provided for locking the crane on the runway when not in use or during storm

condition. The rail clamps shall be capable of preventing the movement of crane

under storm conditions.

15.14 Walkways and ladders

a. Access walkways of minimum 500 mm clear inside width with hand railings on both

sides of bridge girders for the full span length for inspection and maintenance of the

crane shall be provided. Walkways shall be of chequered plate or non-slip steel

surface of minimum 6 mm thick. Walkways shall be of rigid construction and

designed to sustain a distributed live load of not less than 3 KN/M2.

b. Walkway platform shall be complete with hand railings, posts and toe plate all

around. The hand railings shall consist of 32 mm NB pipe in two (2) tiers. Top pipe

shall be at about one (1) M and middle pipe shall be at about 450 mm height from

the walkway platform level. Posts shall be spaced at 1.5 M maximum centres. Toe

plate shall be 6 mm thick and shall project 100 mm above the walkway platform.

c. Ladder shall be provided to reach the walkway platform from the operating floor.

Ladder shall be at least 450 mm clear width with 20 mm diameter rungs spaced at

300 mm centres and shall be equipped with safety cages when the ladder is more

than three (3) M high.

d. One ladder for access from the crane girder walkway to long travel walkway on each side of crane span shall be provided, if long travel walkway is provided as per data

sheet.



e. For cabin operated cranes an access ladder shall be provided from the crane girder walkway to the operator’s cabin.

15.15 Buffers, Stops and Seeps

a. Spring or rubber buffers shall be provided on the trolley. Suitable end stops welded

to the bridge girder shall be provided to contact the buffers mounted on the trolley.

Spring or rubber buffers shall also be provided on the end carriages. Suitable end

stops welded to the long runway girder shall be provided to contact the buffers

mounted on the end carriages.

b. Bridge and trolley wheel stops shall be provided before the end stops. These shall match to wheel radius. Wheel stops to prevent rails from creeping and trolley from

running off the bridge shall be abutted against ends of rails. Wheel stops shall be

welded to the girder.

c. Sweeps shall be attached to the end carriages and to the trolley, to remove foreign material from the rails.

15.16 Guards

a. All exposed couplings, shafts, gear wheels, pinions, drives etc. shall be safely

encased and guarded.

b. The sheaves of hook blocks shall be guarded to prevent trapping of hand between a sheave and the in-running rope.

15.17 Lubrication

a. Centralized grease lubrication unit with hand operated grease pump shall be

provided for anti-friction bearings. One unit shall be provided on bridge platform for

line shaft anti-friction bearings and another unit shall be provided on trolley for top

sheave and drum anti-friction bearings.

b. All other anti-friction bearings shall be lubricated manually by hand operated grease pump through respective grease nipples. Accessibility shall be such that parts may be

safely lubricated from the walkways or ladders.

15.18 Nameplate



a. A name plate showing rated capacity and year of manufacture shall be placed on

either side of the girder in such a manner as to be legible from the ground or

operating floor. Manufacturer’s name, make, model number etc. may appear on the

name plate.

b. A steel box with hinged cover shall be provided. It shall be conveniently located and permanently secured in the operator’s cabin or fastened to the bridge girder side of

the walkway for storing of tools, oil can, grease and waste. It shall contain proper

tools necessary for minor repairs and maintenance work.

15.19 Electrical Equipment

a. All accessories and auxiliary electrical equipment including drive motors, electrically

operated brakes, controllers, resistors, conductors, protective devices, operating

devices, cables, conduits, etc. necessary for the safe and satisfactory operation and

maintenance of the crane shall be included in the Contractor’s scope of supply.

Electrical equipment shall be adequately rated to permit simultaneous operation of

any combination of motions of the crane for its duty service.

15.20 Motors

a. Drive motors shall be as per IS 325 and companion specifications indicated in data

sheet. Motors for long travel and cross travel, main and auxiliary hoist shall be totally

enclosed, slip ring type induction motors. Motors for creep speed operation of all

motions and thrust or brake may be squirrel cage type. Motors shall be suitable for

frequent reversal, braking and acceleration. Pull-out torque shall be 2.15 times the

rated torque.

b. In case motors with synchronous speed above 1000 rpm are selected, it shall be subject to Owner’s approval

15.21 Controls

a. All motors and control circuit components for the long and cross travel motions shall

be suitable for plugging control. Speed control of various motors shall be achieved by

adjusting the resistance in the rotor circuit of the drive motors. Resistors shall be

suitable for speed control duty cycle and inching operation. Relays and controllers

shall be suitable for start-stop operation of around 150 times per hour.



15.22 Controllers

a. Controller for crane motors shall comprise reversing type magnetic contactors.

b. Controllers shall have at least five (5) uniformly proportioned steps of control. Independent controllers shall be provided to control each crane motion. Also each

main and creep drive shall have independent controller.

c. Controller contact shall require current capacity for the duty cycle, type and number

of auxiliary contacts for required electrical interlocks.

15.23 Crane Control Equipment

a. All control equipment for the crane shall be housed in dust tight, sheet steel

cabinets. The control cabinets shall conform to the requirements of companion

specifications. Separate panels shall be provided for the following:

b. Main power panel comprising the following:

i. 415 V, 4 pole gang operated, manual air break isolating switch together with a set of three (3) suitably rated HRC fuses for the incoming power supply to the crane.

ii. Red and green indicating lamps with series resistors to indicate ‘ON’ and OFF’ conditions of the main power

iii. Suitably rated 415V / 110 V single phase transformer for the crane control supply.

iv. 110 V double pole, air break isolating switch across the secondary of the control transformer.

v. 415 V / 240 V single phase, lighting transformer to supply the crane lighting loads (g) 415 V double.

vi. 415 V double pole air break isolating switch together with suitably rated HRC fuses on the primary side of the lighting transformer.

vii. 415 V triple pole air break isolating switch, and a set of three suitable rated thermal overload relays for each motor serving as drive for all driven on the crane.

viii. Small wiring up to terminal blocks

c. 415 V triple pole main Contractor for controlling the incoming power supply, together

with ‘START’ and ‘STOP’ push buttons.

d. Compartmentalized panel(s) for housing the control gear comprising contactors,

timers, isolators switches, HRC fuses, Moulded case circuit breakers all brought up to



terminal blocks, etc. inside the panel and push buttons, indicating lamps, operating

handles, etc. brought out on the panel door. If necessary, separate compartments

may be provided for various crane motions.

e. The control panel shall essentially house the following:

b. A suitable sensing device for each drive motor for stopping the drive motor at zero speed during plugging

c. Two pole reversing contactors mechanically interlocked for each main as well as creep motion

f. Magnetic reversing type contact controllers as follows:

i. Two pole magnetic reversing contacts mechanically interlocked, accelerating contactors and suitable time relays for each controller.

ii. Three pole contactors required for control of the lowering motion of Hoisting

15.24 Protection a. Operation of the overload relays for any of the motors shall operate the main supply

contactor to cut off power supply to all the motors.

b. Under voltage interlock shall be provided to operate the main supply contactor and

open the main contactor contacts and its holding contact.

c. Start’ push button of the main supply shall be wired in series with the ‘Off’ position contacts of all the controllers, thus requiring that all controller circuits are in ‘Off’

position before the main supply contactor can be switched on.

15.25 Operating and indicating device a. In case the crane is cabin operated the following devices shall be provided:

iii. 415 V, triple pole air break isolating switch across the incoming power supply to the crane.

iv. ‘Start’ push button

v. ‘Stop’ push button

vi. ‘Horn’ foot switch for sounding warning horn.

vii. Red and Green indicating lamps with series resistors to indicate main supply contactor ‘ON’ and ‘OFF’ conditions.

viii. 240 V single phase, double pole miniature circuit breakers to control the main lighting circuit.

ix. 240 V single phase, single pole miniature circuit breakers to control each of the following circuits:

x. Cabin lighting circuit



xi. Flood lights

xii. Power receptacles for hand lamps, cabin fan

All control equipment mounted on the crane shall be furnished with uniform indelible name plate identifying various controls and indicating the direction wherever necessary.

15.26 Resistors a. Resistors shall be adequately protected to prevent contact with live parts.

b. Resistors shall be provided with terminal boards equipped with brass or copper

terminal studs.

c. Resistors shall be mounted in pressed sheet steel and plates with drip proof and

louvered side covered in separate units. All resistors shall be located on alongside

and adjacent to control cabinet with provision of at least 100 mm clear space at front

and rear of each panel.

d. Temperature of any exposed portion of the resistor enclosure shall not exceed 353º

K.

15.27 Limit Switches a. Automatic reset type of limit switches shall be provided to prevent over-travel for

each of the following motions:

i. For over-hoisting and over-lowering motions of the main hook.

ii. Long travel motion

iii. Cross travel motion

15.28 Conductors a. Crane shall be provided with three (3) phase power conductors and an earthing

conductor for the entire length of crane runway and trolley runway complete with

necessary power feed arrangement, insulators, brackets, mounting supports and

access platform.

b. Crane runway conductors carried on suitable insulators shall be rigidly fixed to the structural bracket pieces. All conductors are mounted in vertical formation. Insulators

shall be spaced not more than two (2) metres apart along each conductor. Design

shall be such that provision shall be made for future extension of conductors and

conductor joints are properly welded to ensure smooth surface to the conductors.

Conductors shall be provided with protective wire mesh guard over the entire length

to prevent injury to personnel and to guard against mechanical damage. Provision

shall be made to access the conductors for maintenance and replacement. A suitable

inspection cage shall be provided with access ladder for the collectors for



maintenance purposes. Flexible trailing cable arranged in festoon configuration with

festoon trolley on rollers, travel rail, supports etc.

c. Cross travel motion shall be achieved by flexible trailing cable arranged in festoon

configuration with festoon trolley on rollers, travel rail, supports etc. In case fixed

conductors are specified for cross travel option, all necessary feed boxes, insulators,

brackets and supports for mounting hall are furnished on top of bridge girder along

the cross-travel side. Conductor shall be provided with protective wire mesh guard

over the entire length to prevent injury to personnel and to guard against mechanical

damage.

15.29 Lighting and Miscellaneous Accessories

Cabin operated cranes shall be provided with following accessories in the cabin:

i. One (1) twin 40 W industrial type fluorescent fixture mounted in the cabin

ii. Two swivel type flood lights or light with deep bowl reflector for 400w mercury vapour lamp complete with ballast, mounted conveniently in the cabin and on the bridge girder so that the lamps can illuminate the load being lifted

iii. Three (3) 3 pin, 240 V 15 A single phase polarised interlocked industrial type power receptacles located one each in the cabin, control cabinet and middle of the bridge respectively.

15.30 Safety Switches a. Four (4) non-fusible air break isolating switches of adequate rating (not less than 15

amps) shall be fitted at the four corners of the crane so as to be accessible while

standing on the crane platform. These shall be wired up in series with the emergency

stop to open the main power contactors.

15.31 Cables and Conduits

a. All wiring shall be furnished and shall be installed in rigid galvanized steel conduit

with threaded type fittings, galvanized outlet and pull boxes. Pull boxes shall be

located at frequent intervals to allow cable or conductors to be pulled without

abrasion or injury. Conduits shall form a continuous system and shall be rigidly

supported and clamped within the structural of the crane. The entire conduit system

shall be installed so that any moisture is drained away from terminal boxes and

electrical devices. Power wiring and control wiring shall be kept in separate conduits.

Flexible conduits shall be used as required.

b. Wiring of all equipment and control devices located on the trolley bridge for the cabin

shall be completed in the shop and wires shall be terminated on terminal blocks

housed in a junction box.



c. Wiring adjacent to resistors and control panel wiring shall be of stranded 50 V grade,

flame, heat and moisture resistant with proper insulation for operation at elevated

temperatures.

d. Wires for motor primary and secondary circuits shall have adequate current carrying

capacities to carry maximum plugging control of the motors for the duty service of

the crane. Wires shall be properly connected to withstand vibrations. No splices shall

be made in any wiring on the panel or in conduit. All insulation and all clearances to

ground shall be designed so that the live parts will withstand a high potential test of

not less than 2500 V at 50 Hz for 60 seconds.

e. Conductors for main power circuits shall be selected taking into consideration

simultaneous operation of the main hoist and bridge motors.

15.32 Safety Earthing

a. Crane structures, motor frames and metal cases of all electrical equipment including

metal conduit and cable guards shall be effectively earthed.

b. All motors, brakes, limit switches, panels, drum, controllers, resistor unit sets, etc.

shall be provided with two studs for earthing.

c. A separate long travel conductor rail shall be fitted on the runway gantry girder in

the same plane as the three main power rails to serve as the earth bus. The earth

bus shall be solidly bonded to effective earthing stations at two independent points

by Owner.

d. An additional earth collector shall be provided to engage with the cross travel earthing rail located below all other rails.

e. All electrical equipment on the bridge and cabin shall be solidly bonded to the bridge

earth circuit. All electrical equipment in the trolley shall be solidly bonded to earthing

circuit tapped from the cross travel earth collector.

15.33 Control Schematic and Wiring Diagrams



a. One (1) set of as-built control connection diagrams shall be fitted inside the control

cabinet for ready reference for the operating staff.

15.34 Performance Guarantee

a. Performance parameters to be guaranteed by the Contractor and tolerances

permitted shall be as indicated specification. Crane or any portion thereof is liable for

rejection, if it fails to give any of the guaranteed performance parameters.

15.35 Additional technical requirement

15.35.1 General

a. The lift of the crane hook/hoist shall be such that the crane/hoist hook can reach the

bottom most floor of the building. The span of the crane and its hook approach shall

be suitable for maintenance of all heavy equipment within the building.

b. The lift of hoists shall be suitable to lift directly any equipment and move the same

over other equipment into the maintenance bay inside the building.

15.36 Manufacturing Tolerances

Sr. No Parameter Tolerance

1 Span over LT Wheels +6mm up to 40 metres

2 Wheel base: LT ±5 mm

3 Wheel base: C.T ±3 mm

4 Difference in diagonal: LT ±5 mm

5 CT ±3 mm

6 Long travel wheel alignment ±1 mm

7 Tilt of wheels or balancer axle + 1 mm/1000mm (Horizontal & Vertical)

8 Trolley wheel gauge +3mm up to 7500 mm span

+ 5mm above 7500 mm span

9 Trolley track gauge + 3mm up to 7500 mm span



Sr. No Parameter Tolerance

+ 5mm above 7500 mm span

10 Difference in height between trolley rails (H) in relation to the trolley track gauge (S) shall be within the following tolerances

Up to 2500 4

Above 2500 and up to 4500 6

Above 4500 10

11 Shift of the web plates of main & end girders from vertical over height ‘H’ measured near the mid span & close to the main diaphragm.

H/1500

12 Tolerances on camber +4

Up to 4 mm -0

Above 4 mm and up to 8 mm +5

-0

Above 8 mm and up to 16mm +6.3

-0

Above 16mm and up to 31.5mm + 8

- 0

Above 31.5 mm and up to 63 mm + 10

- 0

13 Over buffer length (over buffer dimension on two sides shall be same)

+ 5 mm

14 Height of centre of buffer (from top of track rail) + 5 mm

a. The Contractor shall ensure that minimum amount of assembly at site is necessary

for early commissioning of the crane after delivery. Site welding and riveting shall be

avoided as far as possible. The Contractor, before proceeding with design details

shall satisfy himself about the site conditions so as to avoid any difficulty in erection

arising out of design

b. The crane shall be completely assembled and tested in the Contractor’s works for full

load and 25 % overload on hoisting and cross traverse motion, in presence of

Owner’s representative in addition to other tests as specified in IS: 3177.



c. The following tests shall be carried out at manufacturer’s works during inspection.

The crane after erection shall be tested as follows:

i. Insulation tests and other tests mentioned in IS: 3177 shall be carried out.

ii. Deflection Test: The deflection test of the bridge girders shall be carried out as per IS: 3177 After the deflection test with safe working load, the crane shall be tested for deflection with 25% overload and there shall not be any permanent set after the removal of the load.

iii. Speed Tests

d. All motion of the crane shall be tested with rated load on all notches at the time of

commissioning of the crane at site and the speeds shall be attained within the

tolerance limit.

e. All motions of the crane shall be tested with 25% over load in which case the

specified speeds need not be attained but the crane shall show itself capable of

dealing with the overload without difficulty.

15.37 Brake Tests:

a. The hoist brakes shall be capable of braking the movement with rated as well as

overload. However, the braking path with rated load shall not exceed hoisting

speed.

b. The long travel and cross travel brakes shall be capable of arresting the motion

within a distance in meters equal to 10% of the speed in meters/min.

15.38 Technical Specification

15.38.1 General

a. All parts requiring replacement or inspection or lubrication shall be easily accessible

without the need for dismantling of other equipment or structures. All electrical

cables shall be so laid that they are not liable to be damaged and can be easily

inspected and maintained and when necessary any damaged cable can be accessed

and replaced individually.

b. No cast iron parts shall be used except for electrical equipment and no wood or other combustible material shall be used unless specifically mentioned otherwise.

c. For welded construction, such as that of bridge girders, end-carriages, rope drums,

gear-boxes etc. steel shall be as per IS: 2062 quality. For welding these member’s



low hydrogen electrodes be used.

d. All wheels, couplings, open gears etc. shall be provided with covers, opening on strong hinges. All heavy covers shall be provided with inspection windows.

e. Where down shop leads are located below runway rails, guards shall be provided on

the crane to prevent the hoist ropes from coming in contact with down shop leads.

For down shop leads, suitable guards of welded mesh type shall be provided

covering the bottom and side fitted to the girder keep of machine hall.

f. All bolts except those with nuts shall be provided with grip lock nuts or spring

washers.

g. The end-carriages shall be fitted with substantial safety stops to prevent the crane from falling more than 25 mm in the event of breakage of a track wheel. Bogie or

axle. These stops shall not interfere with the removal of wheels.

h. Power & control cables shall be clamped in groups separately. All trailing cables shall

be clamped with PVC or non-metallic clamps. Group dating factor shall be

appropriately taken according to the 'recommendations of the cable manufactures

based on the method of lying and number of cables being laid together.

i. Guards of approved design, which shall push forward off the-track, any object placed

across it, will be attached to each 'end of the end carriages.

j. Parts of steel frames carrying machinery shall be provided with doubling plates of

adequate thickness, riveted or welded and machined to true surface.

15.38.2 Structural Details

a. The crane bridges shall be of welded double web box construction and shall be

designed as per IS: 807- and/or AISE No.6. The materials of construction shall be

wieldable mild steel in compliance with the relevant standard. However, high

strength wieldable structural steel also may be used wherever required in compliance

with the relevant standards.

b. The crane bridge girders up to 12 m span shall be in one piece. The number of such



splices shall not exceed 2 up to 36m span. Beyond 36m span, the number of splices

may be 3. Splices shall be designed to resist all the forces and moments to which it is

subjected to, plus 50% thereof.

c. Splices shall be proportioned and arranged so that the gravity axis of the splice is in line with the gravity axis of the members joined so as to avoid eccentricity of the

loading.

d. Black bolts shall not be used in the main structure of the Crane.

e. Transverse fillet welding on load carrying members shall be avoided. All butt welds

on tensile zone shall be X-rayed.

f. Plates, bars, angles and where practicable other rolled sections used in the load

bearing members of structures shall not be less than 6 mm in thickness.

g. The end-carriages shall be of double web plate box construction and shall be connected to the girders by welding at shop or by large gusset plates and fitted bolts

to ensure maximum rigidity. Drop stops and jacking pads shall be built-in features of

the Crane. Full length chequered plate platforms shall be provided along both sides

of the Crane in order to ensure easy access to crane crab, long travel gears and

other parts. Safety railings shall be provided on crane bridges and crab frame. Access

to the Crane shall be via staircases only and not through ladders. Platforms to

facilitate inspection and dismantling of long travel wheels and main current collectors

shall be provided.

h. The crab frame shall be made of steel plates and rolled sections in welded

construction. Crab frame shall be fabricated in one piece if there are no transport

limitations. If the trolley is fabricated in more than one piece due to transport

limitation, the design of the splice shall be such that one unit of mechanism mounted

on one part of the trolley, does not come over the other part.

i. Foot walks shall be of sufficient width to give at least 500 mm clear passage at all

points except between railing and bridge girder where this clearance may be reduced

to not less than 440mm.

j. The Platforms along the bridge girders and over the crab shall allow convenient



access for replacement, inspection, lubrication etc. for different mechanical and

electrical components.

k. The minimum thickness of chequered plates shall be 6 mm for indoor crane

15.39 Technical Particulars for Electrically Operated Travelling (E.O.T)Crane

Sr. No.


1 Make To be furnished by Bidders (As per approved vendor list)

2 Location/Type To be furnished by Contractor (As per approved vendor list)Pump house Building/Overhead Double Girder E.O.T Crane

3 Crane Rail support R.C.C. brackets

4 Capacity(Ton)/Number Required 55(Minimum)/01

5 Location in Hazardous area No

6 Location Pump house building

7 Span(Mtr.) 11(Minimum)

8 Run way length (Mtr.) 65(Minimum)

9 Operating floor Pump house floor level

10 Test Load 125% of rated load of pumps, motor and accessories

11 Range of Lifting height(Mtr.) 8(Minimum)

12 Type of Hook Solid Forged Steel, IS:3815

13 Hook Approach(Mtr.) 0.5(Minimum)

14 Crane Classification IS 13837 M5-Mechanical

M7-Electrical

15 Hoist Drive Electric motor

16 Gearing Totally enclosed

17 Break Electrically released spring set or friction disc type

18 Drum Steel plates

19 Sheaves Rolled Steel

20 Bearing To be furnished by Contractors

21 Motor Variable speed motor.



Sr. No.


22 Creep speed control As per requirement

23 Long travel walkway required YES

24 Ladder Required for servicing

Crane & hoist

25 GA Drawing indicating overall dimensions weight, height and necessary details

To be furnished by contractors

a. ventilated by means of exhaust air fans/ roof exhausters and inlet louvers.

16 TESTING

16.1 Material Test

Materialto beusedforthevalvecomponentsshall be of tested quality. Chemical

analysisand mechanicaltestsonmaterialstobeusedshallbedoneasperrelevant standard.

16.2 Non-destructive Test

ValvebodyanddiscshallbesubjectedtoNon-DestructiveTesting(NDT).Components



subjected to NDT and shall be stamped for identification.

16.2 Hydrostatic Test

Eachvalvebodyshallbesubjectedtohydrostatictestasspecified.Forvalvessubjected to back

pressure condition, leakage test shall be carried out on both sides of the disc.

16.3 Performance Test

Eachvalvecompletewithoperatorshallbeshopoperatedatleastthree(3)timesfrom

fullyclosedtofullyopenconditionsandreverse,holdatintermediatepositionsunderno flow

condition, to prove the workability of the assembly.

16.3.1 Header loss certificate from NABL associated Labto the produced for verification.

16.4 TESTS ATSITE

Performanceof the valves shall be tested at site at actual working condition.

16.5 CLEANING

Priortofactoryinspection,allmanufacturingwastesuchasmetalchipsdebrisandall

otherforeign mattershallberemovedfrominteriorofvalve.Allmillscale,rust,oil,

grease,chalkandallotherdeleteriousmaterialshallberemovedfromtheinteriorand exterior

surfaces.

16.6 PAINTING

Valvesshallfirstbegiventwocoatsofzincbaseprimeraftercompletelycleaningthe

surfaceandthenitshallbecoatedwiththreecoatsofepoxypaint.Theresultingcoating shall be

uniformand smooth and shall adhere perfectly to the surface.



16.7 HANDWHEEL

Ahandwheelshallbeprovidedforemergencyoperation.Thehandwheeldriveshallbe

mechanicallyindependentofthemotordriveandanygearingshouldbesuchastopermit

emergency manual operation in a reasonable time.

16.8 TESTS AND INSPECTION

Valveshall be offered by vendor forvisualinspectionbeforeshipment. Valves shall be

tested asper the relevant standards. Thehydrostatic testing shall be witnessed by the

purchaser

16.9 Material of construction

Allsluice valves shall be ofbody Cast Steel, Spindle SS. Allvalvesshallbesuppliedwith

matchingcompanionflangeswithnecessarybolts,nuts and gaskets.

16.10 CAST STEEL SLUICE VALVES Endflanges shall be cast or forged integral with the body.

The bodytobonnetjointshallbeflanged,male&female,tongue&grooveorringjoint type. The

bonnet joint shall haveat least four through bolts.

16.11 Technical Particulars of Sluice Valve

Sr.

No.


1 Make Contractor has to furnish

(As per approved vendor list)

2 Type and Design Standard Non-rising sluice valve/IS 14845 (latest)

3a

(For pump house without valve key)

Size(mm)/ Qty (nos.)/Pressure rating(Kg/cm2)

DN 200 /10 /16



Sr. No.


3b

(For rising main’s below kinetic air valve and without valve key)

Size(mm)/ Qty (nos.)

DN 200 /180/10

3c

(For rising mains, scour valve with valve key)

Size(mm)/ Qty (nos.)/Pressure Rating(Kg/cm2)

DN 750/12/10

3d (For rising main-Suction Line

Size(mm)/ Qty (nos.)/Pressure Rating(Kg/cm2)

DN 1000/03/16

4 Pressure Rating (Kg/cm2) 16 (For Pump House) 10 (For Rising Mains)

5a (For Pump house)

Body

Ductile Iron

5b (For Rising Main)

Body

Cast Iron

6 Stem Stainless Steel

7 Operation Manually Operated

8 Application Raw Water

9a Hand Wheel

(For pump house without valve key)

Ductile Iron

9b Hand Wheel

(For rising main’s below kinetic air valve and without valve key)

Cast Iron

10 Total Weight (kg)of the complete assembly

As per Design Code

11 Over-all dimensions of the complete assembly – L X B X H (mm)

As per Design Code



17.1 General

a. All inspection and testing shall be carried out in accordance with the Specification and in absence of Specification relevant Indian Standard or internationally approved

equivalent standard code.

b. The Contractor shall carry out at the place of manufacture tests of the Plant

/Equipment at any part of the Works.

c. The Owner shall be entitled to attend the aforesaid inspection and/or tests by his

own duly authorized and designated representatives.

d. The Owner and his duly authorized representative shall have access to the manufacturer’s premises at all suitable times to inspect and examine the material

and workmanship of the mechanical and electrical plant and equipment during its

manufacture there. If part of the plant and equipment is being manufactured on

other premises, the Contractor shall obtain permission for the Owner or his duly

authorized representative, Testing (including testing for chemical analysis and

physical properties) shall be carried out by the Contractor.

e. The Contractor shall forward to the Owner 3 duly certified copies of the test certificates and characteristics performance curves for all equipment.

f. The test equipment, meters, instruments etc., used for testing shall be calibrated at

recognized test laboratories at regular intervals and valid certificates shall be made

available to the Owner representatives at the time of testing. The calibrating

instrument used as standards shall be traceable to National/International standards.

g. The following Testing shall be carried out for all the equipment as applicable

i. Visual Inspection.

ii. Material Certificates for all the specified material shall be furnished.

iii. Welding Qualifications

iv. Dimension Checking

v. Stage Inspections (in process inspection)

vi. Dynamic balancing for all rotating parts

vii. Hydrostatic / Leak testing for all pressure parts, Pneumatic Leak Test wherever applicable

17. Inspection and Testing at Manufacturer’s Premises



viii. Operation check

ix. Liquid penetrant tests or magnetic particle tests for all machined surfaces of pressure parts.

x. Ultrasonic test for forging materials viz.

xi. Radiographic testing for all butt welded parts, as per applicable codes.

xii. l) Hardness tests for all Hardened surfaces. h. The Contractor shall maintain proper identification of all materials used, along with

reports for all internal / stage inspection work carried out, based on the specific job

requirement and or based on the datasheets / drawings / specifications.

17.2 Induction Motor

17.2.1 Routine Tests

a. All routine tests shall be carried out as per the latest edition of IS 325.

17.2.2 Acceptance Tests

a. Full load test to determine efficiency, power factor and slip shall be conducted on all

the motors.

17.2.3 Type Tests

a. The following type tests shall be carried out on one motor of each rating

i. Temperature rise test

ii. Vibration measurement test

iii. MOMENTRY OVERLOAD TEST shall be conducted based on interpolation Method.

iv. Noise level test

v. Full load test to determine efficiency, power factor and slip

vi. Starting current and starting torque at reduced voltage

17.3 Valve

a. During testing there shall be no visible evidence of structural damage to any of the

valve component.

b. Motorized valves shall be tested with their actuators, with a differential head equivalent to their maximum working pressure, to prove that the actuators are

capable of opening and closing the valves under maximum unbalanced head

condition within the specified opening or closing period.



c. Sluice valves for isolation purpose shall be offered for open end test.

d. The following test shall be carried out for butterfly valves:

i. Seat leakage test at rated pressure.

ii. Body hydrostatic test at 1.5 times the rated pressure.

iii. Disc strength test at body test pressure.

iv. Valve operation.

v. 15 ° opening and closing test.

e. The following test shall be carried out for sluice valves:

i. Seat leakage test at rated pressure

ii. Hydrostatic test at 1.5 times the rated pressure

iii. Valve operation with and without actuator

f. The following test shall be carried out for Non-Return valves:

i. Seat leakage test at rated pressure

ii. Body hydrostatic test at 1.5 times rated pressure

iii. Operation

17.4 MS Pipe work (Pump house)

Testing of pipes and fitting shall be carried out in accordance with relevant Indian Standard. Pipes shall be hydrostatically tested as per as per specification available as per this tender document

17.5 E.O.T Crane

The cranes shall be completely assembled in the Contractor’s works and shall be subjected to the tests as specified in IS 807/IS 3177 or relevant internationally approved standard.



18. INSTALLATION, TESTING AND COMMISSIONING

18.1 Erection - General

a. The Contractor’s staff shall include adequate and competent erection engineers with proven, suitable, previous experience on similar contracts to supervise the erection o

the Works and sufficient skilled, semi-skilled and unskilled labor to ensure completion

of Works in time. The Contractor shall not remove any representative, erector or

skilled labor from the Site without prior approval of the Engineer’s Representative.

b. The Contractor shall ensure that no installation or erection work shall commence

until full and unconditionally approved working drawings, signed and stamped by the

Employer are available at Site.

c. The Contractor’s erection staff shall arrive on the Site on dates to be agreed by the

Engineer. Before they proceed to the Site, however, the Contractor shall first satisfy

himself, as necessary, that sufficient plant of his (or his sub-contractor’s) supply has

arrived on Site so that there will be no delay on this account.

d. One erection engineer who shall be required to be the Contractor’s representative shall be conversant with the erection and commissioning of the complete Works.

Should there be more than one erector, one shall be in charge and the Contractor

shall inform the Engineer’s Representative in writing which erector is designated as

his representative and is in charge. Erection engineer is to report to Project Manager.

e. The Contractor shall be responsible for setting up and erecting the plant to the line and levels of reference and of the positions, levels dimensions and alignment,

appliances and labor in connection therewith. The checking of setting out of any line

or level by the Engineer or Engineer’s Representative shall not in any way relieve

theContractor of his responsibility for the correctness thereof.

f. Erection of Plant shall be phased in such a manner so as not to obstruct the

workbeing done by other contractors or operating staff who may be present at the

time. Before commencing any erection work, the Contractor shall check the

dimension ofstructures where the various items of Plants are to be installed and shall

bring anydeviations from the required position, lines or dimensions to the notice of

theEngineer. Plant shall be erected in a neat and workmanlike manner on the

foundationsand at the locations shown on the approved drawings. Unless otherwise

directed by the Engineer, the Contractor shall adhere strictly to the aforesaid



approved drawings.If any damage is caused by the Contractor during the course of

erection to new orexisting Plant or buildings or any part thereof, the Contractor shall,

at no additionalcost to the Employer, make good, repair or replace the damage,

promptly andeffectively as directed by the Engineer and to the Engineer’s

satisfaction.

g. The Contractor shall align all equipment and holding down bolts and shall inform

theEmployer before proceeding with grouting-in the items concerned. The

Contractorshall ensure that all equipment is securely held and remains in correct

alignmentbefore, during and after grouting-in.

h. The approval by the Employer of the Contractor’s proposals for rigging and

hoistingany items of the Plant into final positions shall not relieve the Contractor from

hisresponsibility for damage to completed structures, parts or members thereof or

otherinstalled equipment. He shall at his own cost make good, repair or replace

anydamaged or injured items, whether structural, electrical, architectural, or of any

otherdescription, promptly and effectively to the satisfaction of the Employer.

i. No Plants or other loads shall be moved across the floors of structures without

firstcovering the floors with timber of sufficient size so that applied loads will

betransferred to floor beams and girders of steel or concrete. If it is required to

reducebending stresses and deflection, the beams and girders shall be provided

withtemporary supports.

j. During erection of the Plant the Engineer will inspect the installation from time

totime in the presence of the Contractor’s Site representative to establish

conformitywith the requirements of the Specification. Any deviations and deficiencies

found orevidence of unsatisfactory workmanship shall be corrected as instructed by

theEngineer.

18.1.1 Levelling and Grouting of Machinery

a. He shall undertake sufficiently in advance chipping of any unevenness of concrete onfoundations, anchor bolt pockets, cutouts etc., to achieve uniform level of

referencefor erection. All concrete surfaces receiving grout shall be hacked as

required toensure better bonding with grouting.

b. Contractor shall undertake the inspection of all components to be erected



sufficientlyin advance to check their soundness and conformity to drawings and the

inspectionrecords shall be signed by the Engineer as approval for undertaking the

installation ofthe components. Any damage, shortfalls etc. shall be made good to

the satisfaction ofthe Engineer.

c. All grout for equipment shall be carried out using non-shrinkable continuous

groutmaterials with suitable frame work of at least 12mm thickness. Surfaces to

receivethe grout shall be hacked and roughened and laitance shall be removed by

wirebrushing or blast of air. Concrete surface shall be blown off by compressed air

beforecommencing grouting. Grouting shall be done in one continuous operation

from oneside such that grout flows in a single wave until grout reaches all confined

spaces withno air pockets and air form all confined spaces is expelled. A hydro static

head of 150 mm shall be maintained during grouting operations. All grouting shall

be carried outin the presence of the Engineer’s Representative. All lines and levels

shall bechecked up after grout is set. Block outs shall be closed using cement

concrete of thesame grade as that of the parent structure.

18.2 Records, Procedures and Reports

a. The Contractor shall maintain records pertaining to the quality of installation/erectionwork and inspection, testing, compliance with all technical

requirements in respect ofall his works as described in the previous paragraphs. The

reporting formats shall bein the approved formats. The Contractor shall submit such

records to the Engineerafter the completion of any particular work before submitting

the bill ofsupply/progress of work. Such report shall comprise shop inspection

reports, shoptesting reports, material test reports, based on which dispatch

clearances are provided,all the quality control reports of welding, erection and

alignment records.

b. All the above mentioned records shall be submitted in the final form

dulycountersigned by the Engineer’s Representative attesting conformity to

specificationsand his approval of installation, and duly incorporating all the

additions, alternations,and information as required by the Engineer, on the basis of

preliminary reportsgiving the progress of the work. Such records notwithstanding,

any records submittedearlier with bill of supply/progress etc., shall be duly bound

and submitted to theEngineer in six copies by the Contractor on his notification of

the mechanical completion of erection.



18.3 General Preparations before Completion of the Plant

18.3.1 Necessary Documents

a. Technical Documents

i. Operation and Maintenance manual

ii. Design documents including the Contractor’s design data, drawings andSpecifications.

iii. Tools and test equipment list

iv. Spare parts list

v. Lubricant list

b. Procedures

i. Mechanical testing procedure

ii. Electrical testing procedure

iii. Instrumentation testing procedure

iv. Detailed Pre-commissioning and Commissioning procedure

v. Detailed Performance Test procedure

c. General and Coordination Documents.

i. Detailed organization charts for Pre-commissioning and Commissioning showinglines of authorities and responsibility, and functions of all key personnel.

ii. The job description of the members of the team.

iii. The scheduled dates of assignment of each member to Pre-commissioning and Commissioning Organization.

iv. A detailed schedule showing the time sequence which the Contractor anticipatesto follow for the various steps in Completion of Erection, Pre-commissioning andCommissioning of each unit and equipment.

v. The regulations for safety, hygiene and discipline.

vi. The practical organization of the relationship (meetings, reports, etc.) between theContractor and the Employer at the phases of Pre-commissioning andCommissioning.

vii. Emergency communication route.



18.4 Manpower

Required manpower shall be provided as agreed between the Contractor and

theEmployer in a Manpower Mobilization Plan which shall include the number

andqualifications of the operator and maintenance personnel to be furnished by

theEmployer for the Plant.

18.5 Completion of Erection

a. The completion of Plant under erection by the Contractor shall be deemed to occur,

ifall the units of the Plant are structurally and mechanically complete and will

includeamong other such responsibilities the following:

i. Plant in the Scope of the Contract has been erected, installed and grouted as perspecifications.

ii. Installation checks are completed and approved by the Engineer.

iii. The erected Plants are totally ready for commissioning checks.

b. At the stage of completion of erection, the Contractor shall ensure that all thephysical, aesthetic and workmanship aspects are totally complete and the Plant

is fitand sound to undergo tests on completion and subsequent pre-commissioning

checks.

c. Upon achieving the completion as described above, the Contractor shall notify theEngineer by a written notice intimating completion of erection and notify

theEngineer for inspection. The Engineer / Engineer’s Representative shall proceed

withthe inspection of such units within 14 days of such a notice.

d. The Engineer shall certify completion when there are no defaults in the Works.

e. The Engineer shall inform the Contractor list of deficiencies for

rectificationhereinafter referred as Punch list and the Contractor shall complete the

rectificationwork within a jointly agreed period before pre-commissioning activities

and obtainthe Engineer’s acceptance or approval of the same before proceeding

with the same.

f. The Engineer may inform the Contractor that the works are accepted with the

‘Punch’list (items which do not hamper operability, safety or maintainability) and



allow theContractors to proceed with the pre-commissioning checks when the

Contractorunder-takes to complete such outstanding works within an agreed time

during defectsliability period. Taking over shall be based on rectification of all

deficiencies asadvised by Punch lists.

g. The erection period indicated by the Contractor would be deemed to cover all theactivities up to Completion as stipulated in previous paragraphs, notice of

completionby the Contractor, inspection by the Engineer for Completion, and

Contractorrectification of all deficiencies as noticed by the deficiency/Punch list, and

acceptanceby the Engineer of such rectification’s, prior to Tests on Completion.

h. Minor defects, which in the opinion of Engineer which do not hamper operability andmaintainability will not be taken into account for deciding Mechanical

Completion.Such defects shall be rectified concurrent to commissioning checks

before Tests on Completion. However, the Engineer’s decision in this regard is final.

i. The commissioning period as notified by the Contractor shall be deemed to

occurbeyond the date of Completion and shall include all periods of pre-

commissioning,trials and Tests on completion.

j. It is in the Contractor’s interest to offer the section/units/systems, progressively

underidentified milestones within overall erection period, duly completed for

rectificationof any deficiencies pointed out by the Engineer and to achieve

MechanicalCompletion before undertaking the tests on Completion within the

specified erectionperiod. The Engineer also reserves the right to withhold the cost

as estimated to beequivalent to the rectification of deficiencies pointed out to the

Contractor until such atime such deficiencies are rectified to the satisfaction of the

Engineer.

18.6 Pre-commissioning

a. After the Completion of erection, Pre-commissioning activities listed below shall

becarried out to make the Plant ready for Commissioning. All instruments, materials

andprovisions necessary for conducting site tests shall be provided by the Contractor

athis own cost.

b. Upon completion of erection of each piece of equipment, facility or discrete part

ofthe plant, mechanical checks and tests shall be carried out according to



theContractor’s check list. The mechanical checks and tests shall be to establish that:

i. The Plant is erected in accordance with the Contractor’s construction drawings, pipework drawings, instrument diagrams, etc. issued for the Plant.

ii. The materials are installed and mechanically function in accordance with the Contract and

iii. Applicable codes as listed in the Contract are followed for Materials and Workmanship.

c. Items such as painting, thermal insulation and final clean-up which do not materiallyaffect the operation or safety of the Plant will be excluded. All these items

shall belisted and completed after Pre-commissioning or Commissioning at the

discretion ofthe Contractor, but before acceptance.

d. The Contractor shall prepare and maintain at Site test forms and records which shall

include:

i. Description of type of test or check,

ii. Date and times of test or check,

iii. Identification of equipment and facilities,

iv. Test pressure, test data and results, including remarks, if any,

v. Signature of the Contractor’s personnel attesting to data recorded, if any.Checks, tests and records thereof shall be carried out by the Contractors constructionforces.

e. Wherever the Employer’s witness or attesting of the check or test is required,

theEmployer’s personnel shall attend such check and test. For this purpose,

theContractor shall keep the Employer informed of a day-to-day test plan schedule.

Thetest plan schedule may be revised from time to time to reflect the actual progress

ofthe work and test.

f. Any items found incomplete or requiring repair or adjustment shall be marked as

suchon the test records and then reported by the Contractor to the Employer and

theContractor’s personnel in charge of the relevant construction area.

g. Checking procedures shall be repeated until all the items on the check list are cleared.

h. A complete set of test records shall be handed over to the Employer on completion.



i. The tests on the different Mechanical and Electrical equipment shall include but

notlimited to:

18.7 Pumps, Piping and Valves

a. Complete piping installation shall be subjected to hydrostatic test at a pressure of

1.5times the shut off pressure of pump or twice the working pressure of pump

whichever is higher to test the soundness of the joints. Provision of the necessary

pumps, gauges, blank flanges, tapings etc. for carrying out these tests shall be

included in the Contract.

b. Leakage tests shall be carried out on all erected pipe work, pumps and valves

immediately after erection and where possible before being built in.

c. Operating tests shall be conducted on valves.

d. The pump set shall be tested for performance. The vibration and noise levels shall

bechecked to be within the specified.

e. The pump shall be tested throughout the operating range with all working (excluding

stand-by) for all the pumps. No negative tolerance shall be permitted on any

parametersvisibly head, discharge and efficiency. All the pumps will be tested for

efficiency at dutypoint after installation.

18.8 Pump motors

a. Condition of winding insulation be tested and insulation values shall be restored

torequired level by suitable heating arrangements locally.

18.9 Cranes

a. The crane and lifting tackle shall be tested for the safe working load at

factory.TheContractor shall arrange the test load. Deflection and speed tests shall

also be conductedat site with load in presence of Engineer in- charge.



18.10 Instrumentation

a. The tests on the instrumentation equipment shall include but shall not be limitedto:

i. All cables shall be tested for polarity, continuity and insulation resistance. The commonmode D.C. voltage at each signal input terminal shall be measured and recorded.

ii. The pre-commissioning tests on the various main categories of plant shall be as listedbelow:

• The resistance of each electronic loop shall be measured

• Electronic equipment shall have been energized for at least 24 hours before

testing begins

• The zero setting of each display instrument including any local indicator on or

associatedwith a transmitter shall be checked

• The correct calibration of each items in each control or monitoring loop shall be

checkedby the introduction of appropriate signal at each source, at five cardinals

points of the rangefor increasing and decreasing signals

b. The following tests methods shall be used:

i. Pressure operated devices – dead weight testers or portable calibrators

ii. Level operated devices – actual level variation or simulation thereof. Instrument zeroreading shall be checked against a bench mark:

iii. For controlling devices the Contractor shall demonstrate the correct operation of the loopincluding the regulating devices. Each automatic controller shall be set to the appropriateestimated values of the terms. Which shall be optimized during the plant start-up. Eachcontrol valve shall be optimized during the plant start-up. Each control valve shall bechecked by operation of the manual control on the associated controller and the correctstroking verified. Valve petitioners, electronpeumatic converters and gauges shall bechecked during these tests.

iv. All systems shall be checked for “fail-safe” operation.

v. Initiating devices not covered by the foregoing e.g. plant stop/start controls shall bechecked in conjunction with the testing of the associated switchgear and machine.

c. The Contractor shall also demonstrate the data transfer as per data transfer

schedulebetween Pumping Stations.

18.11 Commissioning

a. After the completion of Precommissioning activities the final checks preparations



necessary for start-up of the plant shall be carried out. The Contractor shall submit

to theEmployer a written Notice of Mechanical Completion which shall include :

i. Identity of a part of the Plant considered mechanically complete,

ii. A copy of all relevant completed test reports,

iii. The date on which the completion of the tests was achieved.

iv. Check list, and

v. A request for issuance of a Mechanical Completion Certificate in respect of that part.

b. Within fourteen (14) days from the date of receipt of the Contractor’s written

Notice,the Employer shall :

i. In the case of acceptance, issue a Mechanical Completion Certificate.

ii. In the case of Objection, submit a rejection Statement setting forth remaining items tobe completed or defects or deficiencies to be corrected before Mechanical Completionstatus can be accepted. When the Employer rejects the Contractor’s Notice theContractor shall take any necessary action to complete or correct the items markedand give the Employer a second Notice of Mechanical Completion.

c. After the issuance by the Employer of a Mechanical Completion

Certificate,Commissioning activities listed below shall be carried out to enable

the start-up andoperation of the Plant. Procedures are described as below :

i. Commissioning Procedure shall be carried out in a methodical sequence as follows

a) Warming up,

b) Start-up,

c) Initial running,

d) Operability adjustment,

e) Stable operation

f) Final adjustment

ii. At all stages of commissioning sequence, the Plant shall be operated at optimum Plantconditions. To ensure this, the Contractor may make minor adjustment to theconditions indicated in the Operation and Maintenance Manual as necessary.

iii. The Contractor shall check the operating conditions of the Plant by constantlymonitoring operating data.



iv. The Contractor shall specify for each discrete part of the Plant the operational data tobe recorded and the manner in which the data is to be taken.

v. All the operating data shall be recorded by the Employer on the forms to be mutuallyagreed. A copy of the operating log and analytical data from initial operation throughto the completion of Performance Test shall be made available by the Employer to theContractor for evaluation.

Tender Bid Documents for EPC contract for combine ash slurry pump house at Ukai TPS, Nr. Songadh, Dist Tapi

Signature of Bidder Company’s Seal Date Place

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This specification covers the general requirements for Design, supply, fabrication, delivery at site laying, stacking at site, jointing, testing and commissioning of all welded M.S pipeline, appurtenances, specials etc. above/below ground, including Civil works required for the same.

19.1 Applicable codes (M.S. pipes)

The following standards and codes are made a part of the specification. All standards, tentative specifications, codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions.

In case of discrepancy between this specification and those referred to herein, this specification shall govern.

Sr.

No. Code Description

1. IS : 2062-2011 Hot Rolled Medium and High Tensile Structural Steel-Specification

2. IS : 814 Covered Electrodes for manual Metal Arc Welding of carbon and C-Mn steel.

3. BS EN 499 Welding Consumables. Covered Electrodes for Manual Metal Arc Welding of Non Alloy and Fine Grain Steel. Classification

4. AWS : A-5.1 Specification for Mild Steel Covered Arc Welding Electrodes.

5. IS : 3613 Acceptance Tests for Wire Flux combinations for Submerged – arc Welding.

6. AWS : A-5.17 Specification for Bare Mild Steel Electrodes and Fluxes for Submerged Arc Welding. IS : 1377 - Technical Supply Conditions for Threaded Fasteners

7. IS : 1367 Technical Supply Conditions for Threaded steel Fasteners (Parts 1 to 3).

8. IS : 2074 Ready Mixed Paint, Air drying, Red Oxide Zinc Chrome and Priming- specification

9. IS : 102 Ready Mixed Paint, Brushing, Red Lead, non-setting, Priming.

10. IS : 816 Code of practice for use of Metal Arc Welding for General Construction in mild steel.

11. IS : 4353 Submerged Arc Welding of Mild Steel & Low Alloy Steels – Recommendations.

19. Technical Specifications for MS Pipeline



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Sr.

No. Code Description

12. IS : 817 Code of practice for Training and Testing of Metal Arc Welders.

13. IS : 1182 Recommended practice for Radiographic examination of Fusion - Welded Butt Joints in steel plants

14. IS : 2595 Code of Practice for Radiographic Testing.

15. IS : 3658 Code of Practice for Liquid Penetrate Flaw Detection

16. IS : 5334 Code of practice for Magnetic Particle Flaw Detection of welds.

17. ASTM E 94 Guide for Radiographic Testing

18. ASTM E 709 Guide for Magnetic Particle Examination.

19. ASTM E 165 Test Method for Liquid Penetrate Examination.

20. IS : 3600 Methods of Testing Fusion Welded Joints and weld metal in steel (Parts 1 to 9)

21. IS : 4853 Recommended Practice for Radiographic Inspection of Fusion Welded Butt Joints in Steel Pipes.

22. IS : 3589 Seamless or Electrically welded steel pipes for Water Gas and Sewage (168.3 to 2540 Outside Diameter)

23. IS : 6631 Specification for Steel pipes for Hydraulic Purposes

24. IS : 7343 Code of practice for ultrasonic Testing of Ferrous Welded Pipes and Tubular Products

25. IS : 2598 Safety Code for Industrial Radiographic Practice

26. IS : 5822 Code of Practice for Laying of Electrically Welded steel pipes for water supply

27. IS : 1608 Metallic material-tensile testing at ambient temperature

28. IS : 9595 Metal Arc welding of Carbon and Carbon-Manganese Steels – Recommendations

29. IS : 2825 Code of unfired Pressure Vessels

30. IS : 5504 Specification for Spiral Welded pipes

31. IS: 10748 Hot-rolled Steel Strip for Welded Tubes and Pipes – Specification



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19.2 Manufacturing, Supplying, Delivery, Lowering, Laying, Jointing of MS Pipeline

19.2.1 Scope of Work

Design, Manufacture, supply and delivery of submerged Arc welded M.S Pipe having beveled ends from plate or coil conforming to IS-3589 and/or IS-5504 with its latest revision / amendment with inside 406 micron thick food grade epoxy coating and outside 3LPE coating conforming to DIN 30670 for the specified thickness & inner diameter of pipe at site with all type of specials, manholes, tees, bends & flanges, lowering, laying and jointing the pipes with welding in prepared trench with required excavation in all strata’s, necessary utility crossings, breaking the road surface/ canal / existing structures & reinstating the same, necessary traffic diversion work, 300 mm thick sand bedding, refilling around the MS pipeline shall be done as stated in clause no. 3.16 which do not damage the external 3LPE coating after completion of work, disposal of surplus excavated stuff, including providing & fixing pipe indicators at every 1 Km distance including hydro testing etc. complete with all taxes, insurance, freight charges, inspection charges, transportation, etc. complete including all labour, materials and ROU/ROW as per specification and to the satisfaction of Engineer-in-charge.

ROU/ROW: The bidder/ Contractor shall refer the Contract Conditions-Vol II, Clause No. 2.15

The contractor shall be responsible for the hydraulic and structural design of pipe for the required flow and head (including surge). However minimum pipe diameter and thickness shall be as specified in tender document.

Detail survey, Long section of pipe line, Hydraulic & structural design of pipe line shall get approved from Engineer In-charge by the contractor before commencing of the work.

After completion of laying, contractor shall provide L-section of the pipe line and shall give details of latitude and longitude of every air valve, butterfly valves, scour valve, change in direction, crossing, encasings etc.

Measurement for MS pipeline shall be made in meter of actual pipe laid in lines and levels required. Length shall be measured to the nearest 1cm.

19.2.2 Standards

Submerged Arc welded Hot finished mild steel Beveled pipes to be manufactured supplied and delivered under the scope of this contract shall be manufactured in accordance and conforming to IS-3589 and/or IS-5504. Pipes supplied shall be with



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inside 406 micron epoxy coating as per detailed technical specification and outside 3LPE coating as per DIN-30670,1991 or latest revision / amendments if any.

19.2.3 Marking

The methods of marking all the pipes to be delivered under scope of contract shall ensure that all the information will remain legible even after transportation storage in open space etc. In general the legible and marking upon the goods shall indicate the followings.

3. Manufacturer’s brand name and / or trade mark. 4. Purchaser’s mark as “GSECL” be stenciled 5. Diameter, Length and wall thickness. 6. Heat No., Pipe No., Pipe Designation 7. Date of manufacture 8. Any other important matter that the manufacturer deems fit to be inscribed. All the MS pipes of diameter up to 2540mm shall be provided with ISI certification mark on each pipe.

19.2.4 Packing and Handling

The materials shall always be packed separately dispatched from manufacturer’s works with adequate protective measures to prevent damages and deterioration while in transport or stored at any place. The pack shall always to be so neat and tidy that may withstand any robust and rough handling.

The supplier shall use proper handing instruments / equipments and shall follow to a suitable method of handing of pipes as may be approved by Engineer In-charge, while unloading and stacking materials in the stores.

19.2.5 Workmanship

All pipes with internal epoxy coating and external 3LPE coating shall be finished and shall conform to detail specifications & relevant IS codes.

19.2.6 Test Certificate

The contractor shall always provide manufacturer’s test certificate in accordance with every batch / lot of goods as manufactured and supplied.



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19.3 Materials

19.3.1 Steel Plates/H.R. coil

The steel plates for pipes, fittings, specials and stiffeners shall be of mild steel conforming to IS: 2062, Grade-E250 BR or H.R. coil conforming to IS: 10748 grade III.

19.3.2 Welding Consumable

Such as electrodes, filler rods and wires shall conform to IS: 814, IS: 3613, IS: 6419 and IS: 7280.

19.4 Manufacturing

The mild steel pipes shall be manufactured from H.R. coils conforming to IS-10748 Grade-III or mild steel plate confirming to IS 2062-2011. The pipes are to be fabricated as per terms and conditions as laid down in IS-3589 and/or IS-5504. The pipe shall be manufactured from Fe-410 grade steel.

The steel material viz. MS plate or coils having required thickness (with no negative tolerance) and minimum 1500 mm width with no negative tolerance in trimmed condition having length & width as shown in the schedules of material should have been manufactured and tested under ISI mark scheme or such license under other institution valid for the respective country conforming to IS specification No.IS-2062-2011 Grade-E250 BR for MS plates and IS 10748 Gr.-III for hot rolled steel coils.

The collection and testing of samples will be in accordance with the following Indian Standard and para testing of samples. Imported steel plates and coils shall not be allowed for manufacturing of pipeline.

Note:

• for MS Plate: IS 2062 is to be read as IS: 2062; Gr. E250 BR

• For H.R. Coil: IS 10748 is to be read as IS:10748 Gr. III

Sr.

No. I.S. No. Title

1 228 Method of chemical analysis of steel (Second revision)

2 1599:1985 Method for Bend test (Second revision)

3 1608:1995 Mechanical testing of metals- Tensile testing



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Sr.

No. I.S. No. Title

4. 3803:1984 Steel conversion of elongation value part-I Carbon and loow alloy Steel (Second revision)

5 8910:1978 General Technical delivery requirements for steel and steel product.

6 9595:1996 Metal arc welding of carbon and carbon manganese steels (First revision) – Recommendation

7 1730:1989 Dimension for steel plates, sheets, strips & flats for general engineering purposes (second revision)

8 1852:1985 Rolling & cutting tolerances for Hot re-rolled steel products. (Forth revision)

In addition to above wherever necessary and suggested by inspecting agency, API or other relevant standards will be used for testing and collecting of samples.

Unless otherwise specified, the MS plates supplied under this tender should conform to the applicable requirements of the current addition of the IS specifications No. IS: 2062-2011 Grade-E250 BR killed Quality or equivalent standard and or IS 10748, Gr. III for hot rolled steel coils for manufacturer of spirally welded pipes.

The permissible variations in dimensions & tolerances applicable in length and width of MS plates should be as per IS specification No 1852:1985 as applicable to rectangular, sheared cut MS plates but no negative tolerance in thickness will be acceptable.

The plates/ HR coil older than 6 months from the date of manufacturing shall not be allowed to manufacture pipes and these plates/ HR coil shall be free from any cracks, surface flaws, laminations, scares, pits, splits, harmful scratches and other defects.

The MS plates shall be capable of forming operations and should not un-duly loose the specified strength and property during various operations viz. drilling, threading, plugging welding etc. and process adopted for fabrications & erection of pipe line. Also the plates shall be resistant to cleavage, fractures & effect of ageing.

19.4.1 Technical Advice

The contractor shall be fully responsible for proper liaison with the department to evolve satisfactory welding procedure for fabrication & erection of pipe manufactured from the plates / coil supplied by them. The contractor on receipt of a request from the dept. shall without any cost to the dept. arrange to furnish manufacturer’s technical advice (with up to date instructions Booklet, technical literature etc. regarding any problem concerning fabrication in particular, suitability of welding,



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consumables weld grooves, design, heat treatment etc.) such advise shall be rendered till the expiry of contract.

19.4.2 Acceptance of Goods

At the time of delivery of materials, the manufacturer will have to provide test results in accordance with IS specification No. IS-2062-2011 or equivalent standard of the MS plates or IS 10748 for hot rolled steel coils supplied along with the challans. The material will not be accepted without test results of the manufacturer. If the test results of the respective lots will be found satisfactory with respect to relevant IS or equivalent standard specification and with no negative tolerance in thickness only then material will be accepted by the department otherwise rejected.

Thus in case of non-acceptance and return of materials by the department, the department will not be responsible for the cost of materials and it’s transportation or any other cost.

19.4.3 Inspection, Sampling & Testing

To have the quality assurance of the materials, the Engineer-in-charge may arrange inspection of his representative / consultant / third party inspection agency. The material unless inspected, passed and stamped for acceptance shall not be dispatched.

19.4.4 Testing of Samples

Three samples shall be drawn per heat or from a lot of 500MT of HR coils/MS plate whichever is less jointly as above by the Engineer-in-charge/ his representative and authorized representative of the Contractor. Each sample will be given identification No. and a slip indicating identification No., date of sampling and signature of above representatives should be kept with the samples.

Out of three samples drawn one sample will be sent for testing in accordance with relevant IS specifications by the Inspection team / third party agency to any one of the following laboratories as per testing requirement or any other laboratory as may be decided by the Engineer-in-charge.

9. Gujarat Engineering Research Institute (GERI) 10. State/ Central Govt. laboratory/ Government Engineering College. 11. State/Central Government/ BIS approved laboratory.

Out of remaining two samples, second sample will be kept by the department and third will be kept by the supplier as reference sample. The test result should be obtained within ten (10) days from the date of sampling positively without fail and



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furnish to the department duly countersigned by the authorized official of Inspection team / third party agency. The test result should indicate physical and chemical properties of the test samples in accordance with relevant IS specifications. The necessary Inspection & samples testing charges will also be borne by the Contractor. In addition to the above whenever necessary and suggested by Engineer-in-charge, API or other relevant standards will be used for testing and collection of samples. The M S plates supplied under this tender should confirm to applicable requirements of the current edition of IS specification No. IS:2062 Grade-E250 BR killed quality and IS10748 for hot rolled steel coils.

The Inspection/ Testing note regarding the testing of the plates/ HR coils shall have to be furnished with all relevant test certificates/ documents to the Engineer-in-charge and acceptance shall be given, if they are manufactured as per the standards.

19.4.5 Wall Thickness

The wall thickness of pipes shall be as per the design requirement or minimum mentioned in the tender. No negative tolerance will be allowed, only positive tolerance will be allowed.

19.4.6 Pipe Ends

The pipe shall have bevelled ends to an angle of 30°+5° measured from a line drawn perpendicular to the axis of the pipes. The root face shall be 1.6+0.8 mm. The root face of the bevel may be prepared by hand finishing if required.

19.4.7 Length of Pipes

The random length of pipes shall be 10 to 12 meter. In specific locations, smaller lengths can be accepted as per Engineer-in-charge.

19.4.8 Straightness of Pipes

Finished pipes shall not deviate from straightness by more than 0.2% of the total length checking for straightness shall be carried out using as taut string or wire from end to end along the side of the pipe to measure, the greatest deviation.

19.4.9 Testing of Pipes

The main tests among others to be conducted on each pipe shall be as per IS-3589 and/or IS-5504 with its latest version.



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19.4.10 Sampling of pipes

The sampling of pipes shall be as in IS:4711 with latest version/amendment or as directed by the Engineer-in- charge.

19.4.11 Condition of Supply

The pipes with inside epoxy coating & outside 3LPE coating shall be as per specifications.

19.4.12 Other Tolerances

As per IS-3589 and/or IS-5504 with latest version (Except for wall thickness). M.S. Pipes shall be welded either longitudinally or spirally.

Before fabrication of pipes and specials / fittings is commenced, the copies of the mill sheets and the manufacturer’s test certificates for plates and other materials required for fabrication shall be submitted by the Contractor to the Engineer In-charge for his approval.

When instructed by the Engineer In-charge, the Contractor shall supply free of charge to the Engineer-in-charge for testing suitable samples of the materials to be used / used in the Works.

19.4.13 Inspection

All materials will be subjected to inspection by the Engineer In-charge, his authorized representative. The inspection charges shall be borne by the Government / Department. However, in any case of re-inspection due to rejection / rework required of inspected goods or inspection could not be carried out due to non-readiness of material called for inspection etc., the additional charges for inspection will be borne by the contractor and are required to be paid directly to the inspection agency. All such incidents will be reported to the Engineer-in-charge in writing within a week.

The Contractor shall notify the Engineer In-charge, in advance of the production of materials and fabrication thereof, in order that the Employer may arrange for mill and shop inspection.

The Engineer In-charge may reject any or all materials or work that does not meet with any of the requirements of this specification. The Contractor shall rectify or replace such rejected material/performed work at his own cost, to the satisfaction of the Engineer In-charge.



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The Engineer In-charge shall have free access to those parts of all plants or any other premises and sites that are concerned with the furnishing of materials or the performance of work under this specification.

The Contractor shall furnish to the Employer's inspector reasonable facilities and space without charge for inspection, testing and obtaining of any information he desires in respect of the character of material used and the progress and manner of the work.

19.5 Fabrication of MS Pipe

19.5.1 General 12. The pipes shall be truly cylindrical, and straight in axis. The ends shall be

accurately cut and prepared for field welding. The external circumference of the pipe pieces, which are to be fixed adjacent to flange adapter with fixed outer diameter, shall not deviate from theoretical one by more than 1 mm. To obtain this accuracy the pipe shall be rolled several times, if necessary, as pipe pieces should be truly cylindrical. The external longitudinal welding of this pipe shall be ground smooth flush with surface to the satisfaction of the Engineer In-charge, for a length of 200 mm. No extra cost shall be charged by the Contractor for this grinding work.

13. Minor repair by welding or otherwise shall be permitted at the discretion of the

Engineer In-charge, but such repairs shall be done only after obtaining the previous permission of the Engineer. Any pipe or part thereof which develops injurious defects during shop welding or other operations shall be rejected.

19.5.2 Fabrication

Pipe shall be manufactured by continuous process, Spiral Submerged Arc Welding (SAW) facility with on line testing sequentially, dust free environment, X-ray, Ultrasonic testing, adequate Hydraulic testing, etc.

The contractor shall get the MS pipe fabrication at well established, proven, having adequate test facility, having pipe coating facility (inside-epoxy coating & outside – hot applied 3LPE coating), having valid factory license. The contractor shall propose such manufacturing unit/s for with credentials of manufacturing unit/s approval by the department prior to placement of order. The department shall not be responsible for non acceptance of MS pipes manufactured/ being manufactured in absence of such approval from the department of particular manufacturing unit/s.

In no case manufacturing/ fabrication of MS pipes shall be permitted at site.

This manufacturing unit/s should have the following minimum set-up viz.,

14. Continuous Plate bending machines for rolling.



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15. SAW (Submerged Arc Welding) machine & Automatic welding machines (suitable for circumferential as well as longitudinal welding)- suitable for 3000 mm Dia pipes.

16. Pipe coating facility (inside-epoxy coating & outside – hot applied 3LPE coating) set-up

17. Hydraulic Testing Machines 18. Travelling gantry or crane of suitable capacity 19. Mobile cranes of suitable capacity for loading/unloading of HR/Plates and Pipes. 20. Lathe for machining of the flanges rings, plates etc. 21. Equipment for abrasive/ shot blasting and applying paint by spray gun. 22. Equipment for cold forming of plates up to 25 mm thick to the required curvature 23. Pipe hydro-testing set-up 24. Testing equipment online and off line such as UT/ radiography/ DPT/ Chemical &

mechanical laboratory for DT & NDT etc. In addition to above, the details such as company profile, manufacturing experience, order in-hand, client list, quality certifications or other details pertaining to pipes fabrication information as asked by the department.

19.5.3 Cutting plates to size

The plates shall be indented in such length as to have minimum wastage and so as to make the pipe as far as possible with one longitudinal weld joints.

Before cutting, all the edges of the plates shall be cleaned by brushing/grinding on both the sides.

After the plates are cut, the edges shall be made smooth and even by polishing with an electrical or pneumatic grinder to remove all inequalities. Care shall be taken to see that the cut edges of the plate are perfectly straight. Jigs to be used for this purpose shall depend upon the types of cutting machine used. The plates cut to the required shape shall be checked for correctness before they are rolled into pipe drums. If any corrections are required, the Contractor shall do the same by re-cutting, if necessary. If any plate or flat is found to be warped, to have corrugations, the defects shall be removed by putting the plate or flat into a roller press, and no extra payment for this rectification work shall be made. The laminated or heavily corroded plate shall not be used in the manufacturing of the pipe.

19.5.4 Rolling of Plates

The plates cut to the exact size shall be put into a rolling machine to form a pipe of the required diameter. The Contractor shall adjust the rolling machine so as to give a uniform curvature to the pipe throughout its circumference. The curvature obtained shall be checked by the Contractor's foreman during the process of rolling and if



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proper curvature is not obtained at any place including the ends, the rolling operation shall be repeated at this stage or even after the longitudinal welding of the drum where directed. Heating of plates to obtain the desired curvature shall not be permitted.

19.5.5 Tacking the Drums

The rolled drums shall be kept on an assembly platform for tacking, care being taken to ensure that the tacked drums have their end faces at right angles to the axis of the pipe. While tacking the drum a gap of 2 mm to 4 mm shall be maintained where hand welding is permitted. However, where the welding is to be done on automatic welding machine, there is no need of maintaining such gap depending on the penetration through complete thickness of the welding required. To achieve this objective, clamp spiders, tightening rings and or any other approved gadgets shall be used. Each such drum, before being taken to the assembly platform, shall be numbered on the inside with oil paint, stating the plate thickness as well.

19.5.6 Assembly of Drums into Pipes

The tacked drums shall then be transported to an assembly platform where they shall be tack-welded together to form suitable pipe-lengths. Plate shall be bent in the maximum possible width to reduce the number of circumferential joints.

The longitudinal joints shall be staggered at 90 deg. The drums when tacked together shall have no circumferential gap when the welding is done on automatic welding machine. But when hand welding is adopted, a gap of 2mm to 4mm shall be maintained to obtain a good butt-welded joint.

The assembly shall be truly cylindrical and without any kinks. The faces shall be at right angles to the axis of the cylinder. A suitable arrangement for testing the correctness of the face shall be provided by the Contractor at the assembly platform.

Factory made spirally welded pipes are also permitted.

19.5.7 Welding

All components of a standard shell, either straight or bent etc. shall be welded, by use of automatic arc welding machine by Submerged Arc welding process with alternating current. Manual welding shall not be permitted except for sealing runs/ field weld joints and such other minor works at the discretion of the Engineer In-charge. The strength of the joint shall be at-least equal to that of the parent material.

The contractor shall use radiographic quality electrodes and to be carry-out the welding procedure specification (WPS) and Pre-qualification Requirement (PQR). For



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welding the contractor shall ensure use with standard current and arc voltage required for the machine. For this purpose, samples of welded joints shall be prepared and tested in the presence of the Engineer in-charge. The values once determined shall be maintained throughout the work and if any modifications are to be made, a written permission of the Engineer In-charge shall be obtained. In the case of thin sheets, electric arc welding may not give satisfactory results and gas welding shall be resorted to. Gas welding shall be subject to the same specifications and tests as those for electric welds. Welding should be carried out inside as well as outside. The contractor should engage all qualified welder for field welding at least having of 6G level qualification. The contractor should submit such qualified welders list prior taking up welding work.

All welding shall conform to the requirements of IS 4353 latest version

All longitudinal and circumferential joints shall be double welded butt joints. Field joints shall be from outside, with a sealing weld from inside. End preparation for such welding shall conform to IS:2825.

All circumferential welds involving plates of unequal thickness shall be so kept that the inside surfaces of plates match to provide stream lined joints without alteration in the internal diameter. As far as practicable, welding of dissimilar thickness of shells shall be carried out in the shops.

The welding shall be of the best workmanship free from flaws, burns, etc. and the Contractor shall provide for his own electrodes and equipments, ovens to keep the electrodes at the desired temperatures and dry. In order to maintain a good standard in welding, welders shall have to undergo for testing. Such testing’s shall be organized by the Contractor before they are entrusted with the job. Qualification standard for welding procedures, welders and welding operation shall conform to the requirements of IS:7307 and IS: 7310 (latest) and/or ASME section-IX (latest). Periodical tests as regards their efficiency shall also be taken at intervals of about 6 months and those found inefficient shall be removed from the job. Only those who pass the test shall be posted on the job. If an incompetent welder has already welded some pipes, all welding done by him previously shall be fully checked by X-ray in addition to the regular X-ray inspections. The defects if any shall be set right to the satisfaction of the Engineer In-charge. All such check tests and rectifications of defects shall be entirely at the cost of the Contractor. No pipes or steel sections shall be erected unless the work of the welder concerned has been proved to be satisfactory. Site welds shall be done by specially selected welders.

A record shall be maintained showing the names of welders and operators who have worked on each individual joint. Hand welding shall preferably be carried out by a pair of welders so that, by observing proper sequence, distortion can be avoided. A joint entrusted to a particular individual or a pair shall be as far as possible, completed



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by them in all respects, including sealing run. No helper or other unauthorized person shall be permitted to do any welding whatsoever. In case of infringement of above, the persons shall be punished as directed by the Engineer In-charge.

The welded joint after welding should not become brittle or sensitive to blows and there should be no loss of toughness due to welding or heat treatment. The material after welding and heat treatment is to be tougher than the base metal and is to retain its original ductility. No allowance will be made for thinning of weld and the weld should in no point be less than the nominal thickness of plate.

Upon receipt of the order and prior to the start of fabrication, the Contractor shall submit to the Engineer In-charge for his approval the “welding procedure'' he intends to use in the shop work. Similarly, prior to the start of the field welding, procedure for the field welding must be submitted to the Engineer In-charge for his approval. Manual welding shall be adopted only when machine welding is not possible.

19.5.8 Ultrasonic Test of Welded Joints

Minimum 15% of welded length in each pipe (well distributed along the pipe length) at random shall be subjected to ultrasonic test at factory. The acceptance / rejection criteria shall be as per API 5L (American Petroleum Institute). The ultrasonic test shall be conducted as per relevant ASME code. (American Society of Mechanical Engineering) The person who conducts the test shall have certificate as per ISNT or ASNT Level-2. (American Standards and Testing)

19.5.9 Radiographic test of welded Joints

In case of field joints, minimum 10 % of weld length of each joint at random shall be subjected to radiography test.

In case of failure of joints the contractor shall be required to carry out radiography of thrice the number of segments failing during the radiography test. Even after such radiography testing, if any one of the segment fails, the contractor shall be required to carry out radiography of full joint.

The weld ripples or weld surface irregularities, on both inside and outside shall be removed by any suitable mechanical process to a degree such that resulting radiographic contact due to any remaining irregularities cannot mark or be confused with that of objectionable defect. The radiograph shall be made in strict accordance with the latest requirements and as per the latest and most efficient technique either with X-ray or Gamma ray equipment.

The photographs are to be marked in such a way that the corresponding portion of the welded seam can be readily identified. All radiographs will be reviewed by the Engineer



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to identify the defect and determine those which must be removed. Defects that are not acceptable shall be removed by chipping, machining or flame gouging to sound metal and the resulting cavities shall be welded. After rectification, the joint is to be radiographed again to prove the quality of the repair. The radiographs will be judged as acceptable or unacceptable by the Engineer In-charge based on the latest standards prescribed by Indian Standard specification.

All X-ray shall be made with equipment and by personnel furnished by the Contractor. Films shall be developed within 24 hours of exposure and be readily accessible at all times for inspection by the Engineer In-charge. The Contractor shall provide for the use of the Engineer In-charge suitable X-ray viewing equipment. X-ray films shall be properly maintained by the Contractor and shall be handed over to the department on completion of the Contract. All films shall be identified by the no. and chart prepared indicating location of the joint each X-ray photo represents. In the event of additional radiographic inspections required of any work associated with the pipe erection, such inspection shall be performed by the Radiographer at the discretion of the Engineer In-charge.

19.5.9.1 Radiographic Inspection

25. General

The Engineer shall assure himself that the welding procedure employed in the construction of pipes has been qualified. The Contractor shall submit evidence to the Engineer In-charge that the requirements have been met. The Contractor shall certify that the welding of pipes has been done only by qualified welders and welding operators and the Engineer In-charge shall ensure himself that only qualified welders and welding operators have been used.

The Contractor shall make available to the Engineer In-charge a certified copy of the records of the qualification tests of each welder and welding operator. The Engineer In-charge shall have the right at any time to call for and witness tests of welding procedure or of the ability of any welder and welding operator.

26. Radiographic Inspection of Welded Joints

All welded joints are to be radio graphed and shall be examined in accordance with:

Code Description

IS : 2595-1978 Code of Practice for Radiographic Testing

IS : 4853-1982 Recommended Practice for Radiographic Inspection of Fusion Welded Butt joints in Steel Pipes.

IS :1182-1983 Recommended Practice for Radiographic Examination of Fusion



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Code Description

Welded Butt-Joints in steel plates.(second revision)

IS :2598-1966 Safety Code for Industrial Radiographic Practice.

The reinforcement on each side of all butt-welded joints shall not exceed 1.5 mm.

A complete set of radiographs and records as described in IS:2595 Clause 14, for each job shall be retained by the Contractor and kept on file for a period of at least five years.

Radiographers performing radiograph shall be qualified in accordance with SNT-TC-1A. Supplements and Appendices “Recommended Practice for Non-destructive Testing Personnel Qualification and Certification'' published by the American Society for Non-destructive testing as applicable for the technique and methods used.

Final acceptance of radiographs shall be based on the ability to see the prescribed penetrometer image and the specified hole.

Sections of welds that are shown by radiography to have any of the following types of imperfections shall be judged unacceptable and shall be repaired.

− any type of crack, or zone of incomplete fusion or penetration, − any elongated slag inclusion which has length greater than 6 mm, − any group of slag inclusion in line that have an aggregate length greater than

thickness in a length of 12 times thickness, except when the distance between the successive imperfections exceeds 6L where L is the length of the longest imperfection in the group

− Rounded indications in excess of that specified by the acceptance standards given earlier

19.5.10 Destructive Test

The destructive test of pipe joints on the field shall be carried out as per IS 3600. For every 2 km length of pipeline laid, one destructive test of field joint shall be carried out.

27. The welded joints shall be tested for Tensile test, Bend test & tree-panned plug

in accordance with procedure laid down in IS No. 3600 of 1966 and latest version of all part of the code "Code of procedure for testing of fusion welded joints and weld metals in steel".



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28. Test pieces shall be taken by the contractor from the welded joints at the position on fabricated pipes pointed out by the Engineer in-charge.

29. The sample so taken shall then be cut to the exact shape and dimensions and machined as described below and handed over to the Engineer-in-charge for testing.

19.5.11 Tolerance

The shell in the completed work shall be substantially round. The difference between maximum and minimum inside diameters at any cross section shall not exceed 1% of the nominal diameter of the cross section under consideration subject to a maximum of 10 mm.

Straight pipes shall have their faces perpendicular to the axis of the section with a maximum deviation of 2 mm on either side of the plane. Pipe ends shall be bevelled as per IS-3589 and/or IS-5504.

For the shell thickness, no negative tolerances are acceptable.

19.5.12 Shop Testing

After fabrication, but before application of protective coatings all pipes and specials shall be subjected to a shop hydraulic test. Standard lengths of pipes shall be directly subjected to test and non-standard pipe and elbows can be tested as standard pipe before being cut to size.

The Hydraulic test pressure for individual pipe in the factory shall be as per IS: 3589 (refer latest version).

Prior to testing, the pipe shall be inspected thoroughly and all the apparent defects in welding such as jumps, porosity etc. shall be repaired by gouge and re-welding.

The hydraulic test shall be carried out under cover at the fabrication shop, in the presence of and to the satisfaction of the Engineer In-charge or the inspection agency appointed by the Employer.

For indicating the pressure inside the pipe an accurate pressure gauge of approved make duly tested and calibrated for the accuracy of readings shall be mounted on one of the closures, which close the pipe ends.

The pressures shall be applied gradually by approved means and shall be maintained for at least 5 seconds or till the inspection of all welded joints is done during which time



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the pipe shall be hammered throughout its length with sharp blows, by means of a 1 Kg hand hammer.

The pipe shall withstand the test without showing any sign of weakness, leakage, oozing or sweating. If any leak or sweating is observed in the welded joints, the same shall be repaired by gouging and re-welding after dewatering the pipe. The repaired pipe shall be re-tested to conform to the specified pressure.

If any leak or sweating is observed in pipe shell the pipe under test shall be rejected temporarily. The Contractor shall stack such rejected pipes separately in his yard. The Engineer In-charge shall inspect the same and after taking cuts if necessary, shall determine the nature of repairs to be carried out thereon and shall then decide as to how and where they shall be used. No payment shall be made for handling or carrying out repairs, but, payment for the fabrication and hydraulic testing of the pipe shall be released only after acceptance of the pipe with necessary repairs and subsequent testing etc. are carried out by the Contractor to the satisfaction of the Engineer In-charge. The Engineer In-charge shall be supplied with two copies of the results of all the tests carried out.

19.5.13 Submission of Daily Progress Report

The Contractor shall submit to the Engineer In-charge a daily progress report in the Performa approved by the Engineer In-charge, wherein all the details of the work carried out in the factory shall be fully recorded. Similarly, works done in the various units in the factory shall be separately mentioned. The Contractor shall maintain a register of all the finished materials giving dates of carrying out important operations such as testing, transport, etc. The register shall be presented at least once a week to the Engineer In-charge who shall initial the entries after verification.

19.6 Transportation of Pipes, Specials, etc.

All pipes and specials fabricated in the factory and temporarily stacked in the Contractor's yard shall be transported to the site of laying after cleaning them internally etc. The loading in the factory shall be carried out by means of either a crane, gantry or shear legs, so as not to cause any damage to the finished material. Similarly, while unloading and stacking, great care shall be taken to ensure that the material (pipe & special) is not damaged or dented. The contrivances to be used for unloading will be different in different situations and in each case the one approved by the Engineer In-charge shall be adopted. The material stacked at site shall be jointly inspected by the Engineer In-charge and the Contractor and defect or damage noticed shall be repaired to the satisfaction of the Engineer In-charge before payment is admitted.



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Props of approved designs shall be fixed to the pipes during transit to avoid undue sagging and consequent distortion. After the pipes are carefully stacked, props may be removed and re-used for subsequent operations. The stacking ground, both in the Contractor's yard and at the site of laying shall be selected in such a way as not to get waterlogged during monsoon. If this cannot be done, the pipes shall be supported on sleepers to avoid contact with wet earth and subsequent rusting. In order to prevent sagging during transit, savings of steel plates can be utilized by cutting to the required length and tacking the same to the pipe ends, in place of props, if approved by the Engineer In-charge.

As explained in earlier paragraphs, materials such as pipes, tapers, etc. may be transported to the site of laying as soon as the material is finished in all respects with the permission of the Engineer In-charge to avoid congestion in the Contractor's yard. However, materials such as expansion joints, composite bends, ‘T' branches and other complicated materials shall be stacked in the Contractor's yard until they are required for laying in the field. In view of this, the work of fabrication of such materials shall be properly synchronized as far as possible with the laying operations.

Fabricated materials such as manhole covers, appurtenances, bolts, nuts, distance pipes, flanges, saddles, collars bypass arrangements etc. shall be transported to the site of laying from the fabrication shop according to the needs of the laying operations only. In regards access roads, the Contractor shall note that access road may lead up to some points on the alignment the Contractor shall have to make his own arrangement for connecting approaches to transport the pipes cross country to the actual site of laying at his own cost. Whatever may be the mode of transport he uses it shall be incumbent on the Contractor to carry and stack the pipes and specials along the alignment as close as possible to the site of laying.

19.7 Procedure for receiving Steel Pipes

19.7.1 General

To ensure that the work of erecting pipes is not held up at any stage and place, the Contractor shall maintain an adequate stock of standard specials, flange rings, plug plates, manhole covers, etc. and short length of smaller diameter pipelines, etc. at site in his field stores, in consultation with the Engineer. Wherever possible, the Contractor shall arrange one full month's requirement of pipes, specials, etc. stacked along the alignment.

19.7.2 Stacking of pipes, etc. and Inspection

The Contractor shall keep in each section a responsible representative to take delivery of the pipes, specials and appurtenances, etc. transported from the fabricating stockyard or received from any other work site to the site of laying and to stack along



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the route on timber skids. Padding shall be provided between coated pipes and timber skids to avoid damage to the coating. Suitable gaps in the pipes stacked shall be left at intervals to permit access from one side to the other. The pipes, specials, appurtenances so received on site shall be jointly inspected and defects recorded, if any, such as protrusions, grooves, dents, notches, damage to the internal coating etc. shall be pointed out immediately to the Engineer In-charge at the site and in the acknowledgement challans. Such defects shall be rectified or repaired to the satisfaction of the Engineer In-charge entirely at the Contractor's risk and cost.

19.7.3 Handling of Pipes, Specials, Appurtenances, etc.

It is essential to avoid damage to the pipes, fittings and specials, etc. or their coatings at all stages during handling. The pipes and specials shall be handled in such a manner as not to distort their circularity or cause any damage to their surface treatment. Pipes shall not be thrown down from the trucks nor shall they be dragged or rolled along hard surfaces. Slings of canvas or equally non-abrasive materials of suitable width of special attachment shaped to fit the pipe ends shall be used to lift and lower coated pipes to prevent damage to the coating.

Great care shall be taken in handling the pipe right from the first operation of manufacture until they are laid and jointed. The Contractor will provide temporary props in order to prevent any sagging of the pipes while they are stacked in their yard and while transporting to the site of delivery, i.e. laying. The props shall be retained until the pipes are laid. If at any time these props are found to be dislodged or disturbed, the Contractor shall immediately reinstate them in such a way that the true shape of the pipe shell or specials is maintained to the satisfaction of the Engineer In-charge. No defective or damaged pipe or special shall be allowed to be used in the work without rectification to the satisfaction of the Engineer In-charge. Any damage to the coating shall be repaired by the Contractor at his own cost to the satisfaction of the Engineer In-charge.

19.7.4 Dents

Whenever any dent, i.e. a significant alteration of the curvature of the pipe shell is noticed, the depth of the dent shall be measured between the lowest point of the dent and the pipe shell curvature line. All dents exceeding 2 percent of the outer diameter of the pipe shall be removed by cutting out a cylindrical portion of the pipe and replacing the same by an undamaged piece of the pipe. The Engineer In-charge may permit insert patching if the diameter of the patch is less than 25 percent of the nominal diameter of the pipe. Repairs by hammering with or without heating shall not be permitted. Any damage to the coating shall also be carefully examined and rectified.



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19.7.5 Marking

The component parts of the pipes shall be carefully marked for identification in the field. The marking shall be on the side, which will be the inside of the pipe after bending.

The marking operation shall be conducted with full size rulers and templates. Only blunt nose punches should be used.

The plates used for fabrication of pipes shall be laid out in such a way that when the shells are completed one set of original identification markings for the material will be plainly visible. In case these markings are unavoidably cut out, they shall be accurately transferred by the Contractor to a location where these markings will be visible on the completed work.

After hydraulic tests on the specials and other items, the number of the shell in the line as it will be erected and the direction of flow shall be stamped in a prominent manner on each piece.

A register shall be maintained in suitable proforma giving the following information for each shell tested:

i. Serial No. ii. Shell No. iii. Date of test iv. Thickness and specification of steel v. Weight of shell tested vi. Maximum test pressure vii. Details of test performance viii. Details of radiographic examination of welds ix. Name of Engineer's representative witnessing tests

A copy of these details shall be furnished to the owner at free of cost. No separate payment will be made for these markings and the rates for the items concerned shall be deemed to include the cost of such markings.

19.8 Specification for liquid epoxy coating systems for interior lining of steel water pipelines

Providing & applying internal coating to MS pipe with solvent free food grade epoxy having dry film thickness of 406 microns including scrapping the surface of the pipe.



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19.8.1 General

Buried steel pipeline shall be coated internally, with a single coat two part solvent free high build liquid epoxy lining as per AWWA C210-07 suitable for potable water application and shall be approved by NSF International Standard NSF/ANSI-61 2004 or by water regulations advisory scheme (WRAS), UK or Central food research Institute, Mysore as per standards BS 6920 UK. The Contractor shall perform all work in accordance with these specifications and the latest pipeline coating practices, and shall complete the work in all respects to the full satisfaction of the Owner / Owner’s Representative. The entire coating operation starting from cleaning and surface preparation till coating shall be performed under the supervision of skilled personnel who are well conversant with the work. Pipes which have been cleaned and primed, or cleaned, primed and coated, without having been inspected and approved shall be rejected.

This specification is not intended to be all inclusive and the use of guidelines set forth here does not relieve the Contractor of his responsibility for the quality and performance of the applied coating system, and to supply coating material capable of performing its intended service.

All steel special sections, connections fittings and field joints to be used for underground steel pipeline shall be internally coated with same liquid epoxy.

19.8.2 Reference Standards

The following standards (latest revision) referenced below are a part of this specification. In case of conflict between this specification and the referenced standards, this specification shall apply

x. ANSI/AWWA C210 - Standard for Liquid Epoxy Coating Systems for the Interior & Exterior of Steel Water Pipelines.

xi. NSF/ANSI 61 – Standard for Drinking Water System Components- Health Effects. xii. ANSI /ASTM D149 - Standard Test Method for Dielectric Breakdown Voltage and

Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies.

xiii. ANSI/ASTM D3359 - Standard Test Method for Measuring Adhesion by Tape Test. xiv. ANSI/ASTM D3363 - Standard Test Method for Film Hardness by Pencil Test. xv. ANSI/ASTM D4417 - Standard Test Method for Field Measurement of Surface

Profile of Blast Cleaned Steel. xvi. ANSI/ASTM D4541 - Standard Test Method for Pull-Off Strength of Coatings

Using Portable Adhesion Testers.



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xvii. ANSI/ASTM D2240 – Standard Test Method for Rubber Property – Durometer Hardness

xviii. ANSI/ASTM D5000 - Standard Test Method for Abrasion Resistance of Organic Coatings by the Taber Abraser

xix. SSPC-PA 2 - Measurement of Dry Paint Thickness with Magnetic Gauges xx. SSPC-SP l - Solvent Cleaning xxi. SSPC-SP 6/NACE No. 3 - Commercial Blast Cleaning

19.8.3 General

Protective lining shall consist of a coating system consisting of 100% solids epoxy comprising of resin & hardener mixed in a proportion as recommended by the manufacturer.

The mixed epoxy shall be applied to abrasive blasted steel surface in the coating plant using plural hot airless spray machine with extended boom to apply the lining to a smooth finish without any drip or sag. The epoxy shall also be capable of application by spray/brush at field joint locations and repair of damages to the spray/brush applied epoxy.

19.8.4 Internal Lining System

The internal epoxy lining shall consist of chemically cured resin (epoxy) & hardener (curing agent), mixed in the ratio as recommended by the manufacturer and applied to a dry film thickness (DFT) of minimum 406µ. Physical properties of the internal lining shall be as follows.

Table 19.1: Physical Property of Internal Lining

Property Requirement Test Method /

Reference

Long term contact with potable water

No effects for human consumption as certified by NSF International

NSF / ANSI -61

Thickness (applied min) 406µ SSPC-PA 2

Thickness deviation (min) - 0 / + 200µ SSPC-PA 2

Dielectric strength (min) 450 V/mil (15 V/µm) ASTM D149

Hardness Shore D 85 (min) ASTM D2240

Adhesion to Steel (min) 800 psi ASTM D4541

Tabor Abrasion 1560 cycles / mil ASTM D4060

Compressive strength 70 MPa ASTM C109



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19.8.5 Coating Application

19.8.5.1 General

All internal epoxy lining work for main pipeline shall be done in coating plant using two component airless plural spray machine. For internals of bends, short section of pipes, tees, fittings etc., internal epoxy will be manually spray applied either in the coating plant or in the field using suitable two component airless plural spray machine.

Internal field joint coating shall be spray/ brush applied. The internal epoxy lining shall be applied only on blasted steel surface.

19.8.5.2 Pipe preparation

Metal surface condition

Internal surface of the pipe shall be free from mud, mill scale, mill lacquer, wax, oil, grease, or any other foreign material. Before blast cleaning, surfaces shall be inspected and pre-cleaned according to SSPC-SP 1 to remove oil, grease, and loosely adhering deposits. Visible oil and grease spots shall be removed using a solvent. Only solvents that do not leave a residue shall be used. Preheating to remove oil, grease, and mill scale may be used provided that all pipe is preheated in a uniform manner to avoid distortion.

After drying and removing all loosely adhering foreign materials, the pipe surface shall be cleaned by blasting with grit or steel shots to achieve a surface preparation at least equal to SA 2.5 that specified in BS 7079/ISO 8501-1:2007. The blast anchor pattern or profile depth shall be 2 mils to 3 mils (50 µm to 75 µm) measured in accordance with ASTM D-4417 and/or ISO 8503-4.

For consistent surface finish, a stabilized working mix shall be maintained in abrasive recycling blasting machines by frequent small additions of new grit, shot infrequent large additions shall be avoided. The abrasive working mix, abrasive recycling blasting machines shall be maintained clean of contaminants by continuous effective operation of blasting machine scalping and air-wash separators.

The cleaned interior pipe surface shall be inspected for adequate surface preparation. Surface imperfections, such as slivers, scabs, burrs, weld spatter, and gouges, shall be removed by hand filing or grinding if necessary to prevent holidays.

Blast-cleaned pipe surfaces shall be protected from conditions of high humidity, rainfall, or surface moisture. No pipe shall be allowed to flash rust before coating. To ensure a dry pipe surface at the time of liquid epoxy application, the minimum steel substrate temperature shall be 10°C and at least 3°C above the dew point.



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19.8.5.3 Coating Application

� Main Pipe Line –

b. Application temperature

The temperature of the mixed coating material and of the pipe at the time of application shall be not lower than 10°C. Preheating of the coating material by using in line heaters to heat the coating material may be used to facilitate the application. Heating shall conform to the recommendations of the epoxy coating manufacturer.

c. Application of epoxy

The epoxy shall be applied directly to the abrasive roughened steel surface pipe using a hot plural component airless spray equipment, with all necessary ancillary equipment like spraying boom etc, in accordance with the epoxy coating manufacturer’s recommendations. Pipe will be rotated at a suitable speed and the boom of the spray machine carrying the spray gun will travel inside the pipe at a pre-determined speed to ensure that thickness of minimum 406 microns is achieved in one single spray application. Alternatively, fixed boom & spray machine with moving pipe with predetermined speed to achieve minimum thickness of 406 micron in a single spray is also accepted.

d. Curing

After application of epoxy, curing of the epoxy shall be natural air convection. Typical dry time of the epoxy at ambient temperature of 25-40°C shall be between one hour to three hours. Shore D hardness of the epoxy after 10 hours shall be > 65.

e. Internal coating cutback

Internal coating cutback on either side of the pipe shall be 75 mm +/- 25 mm.

19.8.6 Internal Coating of Field Joints

After the main pipes have been welded in the trench, internal epoxy coating shall be applied on the inside of the pipeline at the girth welds using brush/spray application. Internal epoxy for field joint coating shall be supplied by the same manufacturer and shall be NSF approved. The epoxy shall be supplied in small cans of appropriate size required per joint with applicator pad.

The internal surface of the field joint shall be inspected and weld spatter or slag shall be removed by grinding.



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The internal surface shall then be manually blasted to remove rust / contamination etc.

The resin & hardener will be mixed and the coating applied to a minimum thickness of 406µ. The internal field joint coating shall overlap the factory applied main line internal coating by 50mm on either side.

19.8.7 Material acceptance, inspection and testing

19.8.7.1 Material acceptance

Proposed internal epoxy lining materials shall be approved by the Owner / Owner’s representative. Test certificate from independent third party test laboratory shall be submitted conforming compliance to the physical properties as listed in Table 19.1 (Clause no 19.8.4) No deviation to the physical properties shall be acceptable.

When the material is supplied, acceptance of the material shall be based on submission of certificate of conformance of the internal epoxy to this specification along with manufacturing acceptance test certificates for various lots as per manufacturer’s quality assurance and quality control requirements.

19.8.7.2 Coating application inspection

The entire internal lining operation by the Contractor will be supervised by qualified experts from the manufacturer. The credentials of the manufacturer's expert shall be approved by the Owner / Owner’s representative. All coating work will be done in the presence of the Owner / Owner’s representative.

19.8.7.3 Thickness

Thickness of the coating system shall be checked in accordance with SSPC-PA 2. Thickness shall be in accordance with the values given in the Table 19.1 (Clause no 19.8.4). Out of 25 Nos. of pipes, one pipe shall be tested for the thickness at two selected places.

19.8.7.4 Holiday testing:

The completed pipe shall be subjected to holiday detection tests which shall be carried out to the satisfaction of the Engineer In-charge. The applied voltage shall be those appropriate to the coating under test as recommended by the coating material manufacturer.



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19.8.7.5 Pull Off Adhesion

The pull off adhesion of the internal epoxy lining to steel shall be checked in accordance with ASTM D-4541. The average value below the limits stated in the Table 19.1 shall constitute a failure of the system to meet the adhesion requirement. Out of 25 Nos. of pipes, one pipe shall be tested for the pull off adhesion test at two selected places.

19.8.7.6 Field procedures

At all times during construction of the pipeline, the Contractor shall use caution to prevent damage to the internal lining on the inside of the pipe. No metal tools or heavy objects shall be permitted to unnecessarily contact the finished coating. Workmen shall not be permitted to walk on the internal coating except when necessary. In these cases, they shall wear shoes with rubber or composition soles and heels or other suitable footwear that will not damage the coating. Any damage to the pipe or the protective coating from any cause during the installation of the pipeline shall be repaired.

19.8.7.7 Coating repair in field

All holidays visually or electrically discovered either at the coating plant or in the field shall be repaired by applying the same liquid epoxy coating using brush. The minimum over-lap at the damaged area shall be 100 mm all around. The repaired area shall be tested with a holiday detector as per specifications after the repair is completed. The thickness of the coating at the repair area shall be minimum 406µ.

19.8.8 Epoxy Coating for Internal Surface of Pipes and Specials

The epoxy coating shall be solvent-less, liquid epoxy coating of at least 406 microns thickness, for the interior surface of steel pipe lines & conforming to IS-3589 and/or IS-5504. Epoxy paint to be used for this work shall be suitable to local environmental conditions / ambient conditions.

19.8.8.1 General

All steel pipes and fittings outside the pumping station shall be internally lined with a spray applied solvent free epoxy approved for contact with potable water under the United Kingdom Water Regulations Advisory Scheme authorized for use under Regulation 31 (4)(a) of the water supply (Water Quality) Regulations 2000 for contact with potable water. The applicable specifications for the coating system shall be suitable to potable water at elevated ambient / air temperature tested as per BS – 6920. AWWA C210 is referred standard for coating application as per Sec. 4.4. Surface



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preparation application condition, post treatment of coated surface to be as per manufacturer’s specifications.

Paint – NSF standard 61 – NACE RP – 01 – 75. paint should be suitable for long time storing or potable water in the pipeline.

19.8.8.2 Materials & Workmanship

The coating system shall be factory lined and the lining shall be suitable for application in an environment with black bulb temperature up to 85ºC.

All steel pipes shall be lined at the factory. Pipes welded on site shall be lined on site to the same standards as for pipes.

Pipe ends – coating shall be held back in from the ends of pipe sections to be jointed by field welding.

Detailed proposals of the lining method, materials and apparatus to be used for both factory and site application shall be submitted to and approved by the Engineer In-charge before work starts. Storage and application shall be accordance with recommendations of the coating manufacturer, but as a minimum:

f. A visual examination of the surface to be coated shall be carried out and any slivers or similar deposits removed.

g. Prior to blasting all oil and grease shall be removed from the surface to be coated. h. Preparation of steel surfaces for both factory and site application shall be to a

minimum of SA 2.5 in accordance with BS 7079/ ISO 8501-1:2007 specifications /or as per client specifications and roughness should 50-75 micron.

i. The surface to be coated shall be dry, clean and free from foreign material and coating shall take place before any surface rusting and at least within 4 hours of blasting.

j. Surface preparation and coating shall not be carried out when the relative humidity exceeds 85% or when the surface to be coated is less than 3 deg C above the dew point.

k. The coating shall have a minimum mean dry film thickness of 406 microns. l. Coatings shall be used within the pot life specified by the manufacturer. m. The materials to be used for the work of each batch, test certificate shall be

reviewed. n. Paint shall be applied by brush / air-less or conventional spray method.

Pipe linings shall be inspected on site and damaged, defective or otherwise unsatisfactory linings may be condemned. All defective areas shall be made good to the satisfaction of the Engineer In-charge.



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19.8.9 Inspection and Testing:

It will be detailed in the contractor’s Quality Plan and will be undertaken as minimum to the following:

o. Visual Inspection of blasted profile on every pipe to be coated. p. Visual inspection of finished coating on every pipe. q. Measurement of coating thickness at four points on each pipe. r. The completed pipe shall be subjected to holiday detection tests which shall be

carried out to the satisfaction of the Engineer In-charge. The applied voltage shall be those appropriate to the coating under test as recommended by the coating material manufacturer.

s. The adhesion test as per clause no. 5.1.6 of AWWA-C-210.07 shall be carried out on one pipe per lot of every 10 pipes. Two parallel knife cuts about 100 mm long and 20 mm apart shall be made through the coating. If necessary, the test knife may be heated to make the cut. The painted surface between two cuts shall be lifted off the pipe with a stiff blade. If the paint film does not pill-off, more than the width of the cut, the bond shall be deemed to be satisfactory. If the width of the peel exceeds the width of the cut, two additional tests shall be made on the same pipe at two different locations. The painted surface shall be accepted if both the tests are satisfactory. If the results of either of the tests are un-satisfactory, the painting work of pipeline shall be rejected. Adhesion test shall be performed on 1 pipe out of 10 pipes. If the adhesion test fails for one pipe, then this test shall be performed on all the remaining 9 pipes of that particular lot.

t. Prior to acceptance and application of the material, the Epoxy coating material shall be submitted by the contractor & shall be tested in an independent third party / vendor’s test laboratory designated by the purchaser, in presence of client / consultant and the results shall be in accordance with the specified standards. The frequency of the test shall be minimum 1 sample in every 10000 litres or per batch of the coating material. Tests like: Specific Gravity, Hardness (shore – D), Adhesion to steel, Tabor abrasion, pull-off adhesion tests, will be carried out. Rejection: If the sample of coating material does not comply with the standard, the coating material represented by such a sample shall be rejected.

u. The pull-off adhesion of the internal epoxy lining to steel shall be checked in accordance with the ASTM D – 4541.

v. All holidays visually or electrically discovered either at the coating plant or in the field shall be repaired by applying the same liquid epoxy coating using the brush. The minimum over-lap at the damaged area shall be 100 mm all around. The repaired area shall be tested with a holiday detector as per specification after the repair is completed. The thickness of the coating at the repair area shall be minimum 406 micron.



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19.8.10 Preservation, Marking and Shipping Preservation

19.8.10.1 Preservation

The bare ends of each pipe shall be painted outside with a removable varnish as temporary corrosion protection during transportation.

Contractor to ensure proper protection at bevel ends of each pipe.

19.8.10.2 Marking

In addition to the marking required by API 5L, the specification MO1 “Steel Pipes for Mainlines and other applicable project specifications”, the Pipe Coating Contractor’s unique coating number shall be marked to the internal surface or the pipe with synthetic resin paint.

Further marking details like colour coding etc. shall be agreed upon with the Engineer In-charge. The marking shall have at least a distance of 150mm to the pipe end.

19.8.10.3 Shipping

Shipping and Loading preparation shall be in accordance with API Specification 5L or otherwise stated in the contract documents.

19.8.11 Documentation

19.8.11.1 Pre-Production Documentation

The Contractor shall submit the following documents to the Engineer In-charge for approval prior to commencing pipe coating work. Work shall not commence until these procedures have been reviewed and approved by the Engineer In-charge.

w. The manufacturer’s trade name and data sheets for all proposed coating materials. This includes cleaning and abrasive blasting consumables.

x. Procedure for identifying or maintaining the identification of each coated item. y. Handling procedure. z. Stacking procedure. aa. Materials control and traceability procedure for the batches of coating materials. bb. Materials control and traceability procedure (pipe and coating materials). cc. Procedure for steel surface preparation including materials, cleaning, inspection,

verification of cleanliness and surface profile. dd. Coating application procedures. ee. The results of the batch tests for batches to be used for pre-qualification tests.



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ff. Details of testing methods including instrument types and copies or current calibration certificates.

gg. Details of inspection methods for bare and coated pipe. hh. Full test results from the coating Procedure Qualification Test (PQT). ii. Repair procedure and results or tests on demonstration of repairs. jj. Project specific Quality Plan.

19.8.12 Production Records

A daily log containing the following data shall be maintained and be available for inspection by the Engineer In-charge during and/or after production. Data shall be recorded against the pipe unique identification number. kk. Bare pipe inspection data ll. Ambient temperature (every 4 hours) mm. Humidity (every 4 hours) n n . Coating progress (no. of items coated. Including item serial numbers) oo. Blast pipe surface amplitude pp. Tests for cleanliness of blast surface qq. Test for cleanliness or blast medium rr. Film thickness measurements ss. Average, maximum and minimum coating thickness during each shift tt. Details of any coating repairs uu. The unique identification number of all items that are stripped for recoating –

‘RP’ vv. Pipe coating test results

This log shall be available to the Engineer In-charge throughout all coating operations

19.8.13 Release Documentation

The Contractor shall submit to the Engineer In-charge the following documentation in hard copy and softcopy (format to be agreed upon with the Engineer In-charge) with each batch of pipes released:

ww. Mill certificates for line pipe xx. Unique pipe identification numbers yy. Unique coating identification number (if different) zz. Pipe length aaa. Length of the coated portion of each pipe and total coated lengths of all pipes. bbb. Reductions in length due to use in tests, damage or repairs, recorded against

pipe unique identification number ccc. Date of coating ddd. Batch numbers of coating materials used



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This shall be followed within two weeks by the following: eee. Manufacturer’s certificates for each batch of coating materials fff. Certification / calibration certificates for all testing and coating equipment ggg. Inspection and test records, results, and other documentation of all materials and

coating tests

All reports shall be signed by the Pipe Coating Contractor to signify compliance with the requirements of this specification.

The finished epoxy coating surface shall be able to deliver a guaranteed 'C' value of 145 for pipes. The arrangement for ‘C’ value testing is to be arranged by the contractor. On satisfactory completions of ‘C’ value testing, the amount retained for ‘C’ value testing will be released.

19.9 Outside 3LPE Coating

19.9.1 Scope

This Specification defines the minimum requirements for the application of three- layer polyethylene coating to the external surface of steel pipes.

For the factory applied coating the system shall comprise of a layer of fusion bonded epoxy (FBE), overlaid with adhesive with an outer layer for high density polyethylene (HDPE).

19.9.2 Codes and Standards

This latest edition of the following codes and standards shall establish the minimum standards for the work

Codes and Standards

Codes Standards

ANSI/AWWA C213 Standard for Fusion-bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines

ASTM D149 Standard test method for dielectric breakdown voltage and dielectric strength of solid electrical insulating materials at commercial power frequencies.

ASTM D257 Standard Test methods for dc resistance or conductance of insulating materials.

ASTM D570 Standard test method for water absorption of plastics

ASTM D638 Standard test method for tensile properties of plastics



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Codes Standards

ASTM D746 Standard test method for brittleness temperature of plastics and elastomers by impact.

ASTM D790 Standard test method for flexural properties of unreinforced and reinforced plastics and electrical insulating materials.

ASTM D1238 Standard test method for melt flow rates of thermoplastics by extrusion plastometer.

ASTM D1505 Standard test method for Density of plastics by the Density-Gradient Technique.

ASTM D1525 Standard test method for Vicat softening temperature of plastics.

ASTM D1531 Standard test methods for relatice permittivity (dielectric constant) and dissipation factor by fluid displacement procedures.

ASTM D1603 Standard test method for carbon black content in olefin in define plastics

ASTM D1928 Standard practice for preparation of compression- molded polyethylene test sheets and test specimens.

ASTM D2240 Standard test method for rubber property – durometer hardness.

ASTM D3417 Standard test method for enthalpies of fusion and crystallization of polymers by differential scanning calorimetry (dsc)

ASTM D4703 Standard test practice for compression Molding Thermoplastic Materials into Test Specimen, Plaques or Sheets.

ASTM F372 Standard test method for water vapour transmission rate of flexible barrier materials using an infrared detection technique

AWWA C 200-97 Steel water pipe line

ASTM G8 Standard test method for Cathodic Disbonding of pipeline Coatings.

CAN/CSA Z 245:1 Internal fusion bond epoxy coating / lining of steel pipes

DIN 30670 Polyethylene Coatings of Steel pipes and Fittings – Requirements and Testing.

DIN EN ISO 9001 2000 Quality management systems – Requirements



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Codes Standards

DIN EN ISO 8501-1 Preparation of steel substrates before application of paints and related products – Visual assessment of surface cleanliness – Part 1 : Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings.

DIN EN ISO 8502-2 Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 2 : Laboratory determination of chloride on cleaned surfaces.

DIN EN ISO 8502-3 Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 3 : Assessment of dust on steel surfaces prepared for painting (pressure-sensitive tape method)

DIN EN ISO 8502-4 Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 4 : Guidance on the estimation of the probability of condensation prior to paint application.

DIN EN ISO 8502-9 Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 9 : Field method for the conductometric determination of water-soluble salts.

DIN EN ISO 8503-1 Preparation of steel surfaces before application of paints and related products. Method for the grading of surface profile of abrasivety blast cleaned steel using a comparator (1995)

DIN EN ISO 8503-1 Preparation of steel substrates before application of paints and related products – Surface roughness characteristics of blast-cleaned steel substrates – Part 1: Specifications and definitions for ISO surface profile comparators for the assessment of abrasive blastcleaned surfaces.

DIN EN ISO 8503-2 Preparation of steel substrates before application of paints and related products – Surface roughness characteristics of blast-cleaned steel substrates – Part 2 : Method for the grading of surface profile of abrasive blast-cleaned steel – comparator procedure.



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Codes Standards

ISO 8502-5 Preparation of steel substrates before application of paints and related products – Tests for the assessment of surface cleanliness – Part 5 : Measurement of chloride on steel surfaces prepared for painting (ion detection tube method)

NACE RP0490 Holiday Detection of Fusion-Bonded Epoxy External

Pipeline Coatings of 250 to 760mm (10 to 30 mils)

NACE RP-01-75 Recommended practice : control of International corrosion in steel pipe line system.

SIS 05-5900 Preparation of steel substrates before application of paints and related products – visual assessment of surface cleanliness – PT 1: rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous.

19.9.3 General

19.9.3.1 Environmental Conditions

The environmental conditions operating conditions, product data, etc. under which the pipes shall operates and defined in Documents. Scope of Work, Project Design Data and Site Conditions and Specification for Pipeline construction.

19.9.3.2 Abbreviations

ANSI American National Standards Institute

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

DIN German Standards Institute

ISO International Organisation for Standardisation

NACE National Association of Corrosion Engineers



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NPS Nominal Pipe Size

MPI Magnetic Particle Inspection

UT Ultrasonic Testing

SIS Swiss standard

AWWA American Water Works Association

19.9.4 Handling of Coating Materials

19.9.4.1 General

Materials shall be handled and stored in accordance with the material manufacturer’s recommendations, which shall be available for review by the Engineer In-charge at the Contractor’s premises. Materials shall be stored in temperature controlled environment until required for use.

Coating materials shall be segregated by type and batch during storage and handling. Materials from damaged containers shall be rejected unless otherwise agreed with the Engineer In-charge.

As a minimum, all packages of the coating materials shall be marked with the following data:

hhh. Name of manufacturer iii. Complete material identification – trade name, chemical name and jjj. type of product details kkk. Batch number lll. Date of manufacture mmm. Place of manufacture nnn. Shelf life/expiry date (if appropriate) ooo. Health and safety, and environmental instructions ppp. Hazard Warnings qqq. Storage instructions rrr. Quantity sss. Manufacturing Standard



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Any material not labelled with the above information shall not be used.

19.9.4.2 Abrasive Grit

The abrasive shall be steel grit, also in combination with steel shot of the required grade to achieve the specified surface profile. The use of sand is not permitted.

Blasting abrasives shall be kept dry, clean and free from contamination. When recovered metallic grit systems are used, a stabilized working mix of blast cleaning material shall be established. This mix shall be maintained throughout the entire course of the production, by frequent small additions from fresh or cleaned stock at a rate sufficient to refurnish consumption. Blasting and other dust producing areas shall be kept separate from coating application areas. The surface cleaning shall be degree of cleanliness as per SA 2.5 & ISO 8502-3.

19.9.4.3 Fusion Bonded Epoxy (FBE) Powder

The FBE powder selected shall be suitable for use at the design temperatures in the proposed environment and be suitable for a three layer polyethylene coating system. The FBE shall be endorsed by the contractor of the adhesive and Polyethylene as being compatible with these products under the specified service conditions.

Each batch of FBE shall be accompanied by a certificate stating the following tests have been carried out on every batch and results are in accordance with the coating material manufacturer’s product specifications;

� Gel Time � Moisture content � Particle size distribution � Density � Infrared Scan � Thermal analysis

19.9.4.4 Adhesive

The adhesive selected shall be completely suitable for use at the design temperatures in the proposed environment and be suitable for a three layer polyethylene coating system.



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Each batch of adhesive shall be accompanied by a certificate stating the following tests have been carried out on every batch and results are in accordance with the coating material manufacturer’s product specifications:

� Adhesion � Density � Melt flow index

19.9.4.5 Polyethylene

The polyethylene selected shall be high density and shall be completely suitable for use at the design temperatures in the described environment. The polyethylene shall be suitable for a three-layer polyethylene can be stabilized against UV-rays by incorporation of minimum 2% well dispersed Carbon black of particle size 10-25 nm.

Each polyethylene batch shall be accompanied by a certificate stating the following tests (as per below table) have been carried out on every batch and results are in accordance with the coating material manufacturer’s product specification:

19.9.4.6 Properties of Epoxy Powder and Adhesive

i. The Contractor shall choose such a brand of epoxy powder and adhesive that will achieve the functional requirement and properties of coating system as specified in this specification. In addition, the coating material manufacturer shall also furnish Infra-red Scan for each batch of epoxy powder. The coating materials manufacturer shall issue test certificates as per EN 10204, 3.1 for each batch of materials supplied to the contractor and the same shall be submitted to the department for approval prior to their use. Epoxy powder properties shall be as per CSA Z245.20.98 (latest version). The colour of epoxy powder shall be either green or dark red or any other colour approved by the department except grey colour. Copolymer grafted adhesive shall have the following properties.

Sr.

No. Properties Unit Requirement Test Method

ttt. Melt Flow Rate (190°C/2.16 kg)

g/10 minutes

1.0 min ASTM D 1238

uuu. Vicat Softening Point °C 100 min ASTM D 1525



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Sr.

No. Properties Unit Requirement Test Method

vvv. Specific Gravity - 0.926 min ASTM D 792

ii. Properties of Polyethylene Compound

Sr. No.

Properties Unit Requirement Test Method

www. Tensile Strength @ + 25 °C N/mm2 17 min ASTM D638

xxx. Melt Flow Rate (190°C / 2.16 kg) g/10

minutes

0.25 ASTM D 1238 or DIN 53735

yyy. Specific Gravity + 25°C - 0.926 min. (MDPE)

0.941 min.(HDPE)

ASTM D 792

zzz. Hardness @ + 25°C Shore D 50 min. ASTM D 2240

aaaa. Water Absorptions, 24 hours @ + 25°C

% 0.05 max. ASTM D 570

bbbb. Volume Resistivity @ + 25 °C Ohm-cm 1015 min. ASTM D 257

cccc. Dielectric withstand, 1000 Volt/sec rise @ + 25°C

Volts/mm 30,000 min. ASTM D 149

dddd. Vicat Softening Point °C 110 min. ASTM D 1525

eeee. Elongation % 600 min. ASTM D 638

ffff. Oxidative Induction Time in Oxygen at 220°C, Aluminum pan, no screen

Minutes 10 min. ASTM D 3895

gggg. Environmental Stress Crack Resistance (ESCR) (for F50)

- Medium Density, Condition "C"

- High Density, Condition "B"

Hours

300

300

ASTM D 1693

hhhh. Carbon Black Content % 2 min. ASTM D 1603

iii. In addition to vendor’s certificate, the contractor shall draw samples from each batch of epoxy, adhesive and polyethylene in the presence of department’s representative and the test for the following properties at the coating yard at least one week prior to its use, to establish compliance with the Manufacturer’s test certificates.

iiii. Epoxy Powder: Gel Time, Cure Time, Moisture content, Thermal Characteristics (Tg1, Tg2, ∆H).

jjjj. Adhesive: Specific gravity, Melt Flow Rate, Vicat Softening Point. kkkk. Polyethylene: Melt Flow Rat, Specific Gravity, Vicat Softening Point,

Moisture content, Oxidative Induction Time.



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In Case of the failure of any of the above tests in a batch, that batch of material shall be tested for all other tests required as per this specification including the tests which failed. If all tests pass, the batch shall be accepted for coating. If any of the tests fail, entire batch of material shall be rejected and shall not be used for the coating.

iv. The Contractor shall ensure that all coating materials are properly stored in accordance with the Manufacturer’s recommendation at all times, to prevent damage and deterioration in quality prior to use.

v. Properties of coating System

Sr. No. Properties Unit Requirement Test Method

llll. Bond Strength (using Type 2 test assembly i.e. Dynamometer)

- @ 20+ /- 5°C

- @ 65 +/- 5°C

Kg/cm

15.0 min

5.0 min

DIN 30670

mmmm.Impact Strength (Mon. of 30 impacts on body along the length. No breakdown allowed when tested at 25 Kv)

Joules per mm of coating thickness

7 min DIN 30670

nnnn. Indentation Hardness

- @ 23 +/- 2°C

- @ 70 +/- 2°C

mm

0.2 max

0.3 max

DIN 30670

oooo. Elongation at Failure % 400 min DIN 30670

pppp. Coating Resistivity (*) Ohm-m2 108 min. DIN 30670

qqqq. Heat Ageing (*) - Melt Flow rate shall not deviate by more than 35% of original value

DIN 30670

rrrr. Light Ageing (*) - DIN 30670

ssss. Cathodic Dis-bondment

- @ + 65°C after 30 days

- @ + 65°C after 48 hrs

Min. radius of

Disbondment in mm

(**)

15 max

7 max

ASTM G42

tttt. Degree of Cure of Epoxy

- Percentage Cure, ∆H

- ∆Tg

%°C

95

+3/-2

CSA Z 245.20

– 98 (***)

(*) Test carried out in an independent laboratory of national / international

recognition of PE top coat is also acceptable.



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(**) Disbondment shall be equivalent circle radius of total unsealed area as per ASTM G

42.

(***) Temperature to which the test specimens are to be heated during cyclic heating

shall however be as per the recommendations of epoxy powder manufacturer.

19.9.5 Acceptance of Pipe Materials

19.9.5.1 Identification and Tracking

Upon receipt at the coating factory, the Contractor shall record the following pipe information:

The unique pipe identification number, measured length, and measured weight (both to be found stencilled in paint on one end or the pipe).

This data shall be used as a basis for monitoring pipe from the time of receipt until the delivery of coated pipe.

The Contractor shall identify (or maintain identification of) every coated item, by using a weatherproof mark on the inside of the pipe and on the outside of the coated item. The pipe identification shall be the unique pipe identification number (the number required by the applicable pipes specification). The contractor may use additional tracking numbers at his discretion but these shall relate simply to the unique pipe number in the QC documentation.

Pipe tracking shall be carried out in accordance with approved procedures.

19.9.5.2 Preliminary Inspection

The Contractor shall carry out visual inspection of all pipes.

The Contractor shall record all external damage on pipes against the unique item serial number. This damage shall be brought to the attention of the Engineer In-



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charge and the Pipe shall not be coated without prior release by Engineer In-charge.

Bevel protectors at each end of every pipe joint shall not be removed unless showing signs of damage or if removal is required to facilitate surface preparation, or they would be damaged by coating operations. If the protectors are removed the conditions of the bevel shall be recorded against the pipe serial number and any damage shall be brought to the attention of the Engineer In-charge.

19.9.5.3 Damage to Pipe and Pipe Ends and Repair

No repair work shall proceed until a written procedure has been prepared by the Pipe Coating Contractor and approved by the Engineer In-charge.

Minor damage to pipe and pipe ends/bevels, identified either at time of receipt or after abrasive blasting shall be repaired by grinding. The number of such damages shall be not more than 3 per pipe. Repair by grinding on the pipe or pipe ends/ bevels outside diameter shall not reduce the wall thickness to less than the minimum requirements of the line pipe specification, when measured using ultrasonic thickness measurement equipment.

All other damage to pipe ends/bevels shall be advised to the Engineer In-charge for review. Subject to Engineer’s approval, these defects may be repaired by removal of damaged pipe material and re-bevelling. No welding on the pipe surface shall be allowed.

Pipe identification numbers shall be preserved during repair. Any reduction in pipe lengths shall be recorded in the relevant forms and files.

19.9.6 Prior to Coating Application

19.9.6.1 Stages

The principle stages of pipe coating shall be as follows:

� Solvent cleaning followed by steam or hot bath cleaning (if required)



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� Abrasive blasting � Application of fusion bond epoxy (FBE) layer � Application of adhesive layer � Application of polyethylene layer

19.9.6.2 Cleaning Prior to Abrasive Blasting

All surface contaminants such as oil, grease, tar, salt, or other contaminants on the pipe shall be removed by solvent cleaning followed by steam or hot bath cleaning, in accordance with a procedure approved by the Engineer In-charge.

Following the steam or hot bath cleaning the pipe shall be tested for salt and chloride contamination in accordance with the requirements of DIN EN ISO:8502-2, DIN EN ISO: 8502-5, DIN EN ISO 8502-9.

The removal of hydrocarbon contamination shall be confirmed by a water spray test, where a fine spray is applied to the surface and uniform wetting confirms the removal. This check shall be performed before and after blasting, as a pre- qualification test and as a minimum, once per 100 items during production, or when necessary.

Items found to be contaminated shall be cleaned as above and re-blasted if testing after blasting establishes that salt, chloride or hydrocarbon contamination is still present. The remainder of the batch concerned shall all be checked individually.

All water used for rinsing or cleaning purposes shall be potable with less than 200 ppm total dissolved solids and 50 ppm chlorides.

19.9.6.3 Abrasive Blasting

Blasting and other dust producing areas shall be separate from coating application areas.

After cleaning and prior to abrasive blasting the pipe lengths shall be free from moisture, dust, grease and free from other foreign materials.



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Abrasive and dust, which entered the inside of the pipe during blasting operation, shall be removed by suitable means.

Weld joints, sharp-edge projections, weld spatter and slag etc. shall be dressed prior to blast cleaning.

Using dry blasting techniques only, the exterior surface of the pipe joints shall be abrasively cleaned to remove all mill scale, and other impurities from the surface.

No blast cleaning shall take place when the prevailing relative humidity is higher than 85 percent unless pipe is preheated to at least 3ºC above the dew point.

Twice per shift, samples of the abrasives mixture shall be removed from the hopper and checked for hydrocarbon contamination. The sample shall be placed in a beaker to which de-ionised water is added. The beaker shall then be sealed and shaken vigorously. Once the grit has settled the surface of the water shall be examined for signs of hydrocarbon contamination. If any signs are found all the abrasive in the hopper shall be rejected and not re-used.

Additionally, abrasive materials shall be checked at least once per shift to ensure that only uncontaminated angular grit with an acceptable size distribution is used. As a minimum the following shall be carried out.

� Correct abrasive size distribution shall be carried out by sieve analysis. � Placing a sample of abrasive on a clean, dry sheet of absorbent paper to determine

water contamination.

The surface of the pipes shall be blasted until a finish of Grade 2.5 to DIN EN ISO 8501-1 is attained. The surface profile shall be between 50 to 100 microns, measured in accordance with DIN EN ISO 8503-2. Profile measurements shall be made with a Keane Tator Profile Comparator, Testex Press –O-Film or other Engineer In-charge approved method suitable for the abrasive being used.



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Following abrasive blasting, the surface shall not be contaminated with dirt, dust, metal particles, hydrocarbons, water, chlorides, sulphates or any other foreign matter, which would be detrimental to the coating.

Prior to the coating application, the exterior surface shall be thoroughly inspected under adequate lighting. Any damage such as surface imperfections, slivers, scabs, burrs, gouges, or sharp edged defects, shall be repaired in accordance with this specification. Pipes that have damage repaired by grinding and have ground areas greater than 50 mm diameter shall be re-blasted to meet the requirements of the clauses above. After grinding or mechanical repairs the wall thickness shall be ultrasonically examined and compared with the minimum requirements of the applicable code / standard.

Any dust or loose residue that has accumulated during blasting and/ or grinding operations shall be removed by the use of clean compressed air or by vacuum extraction. Alternative methods for removing dust and lint shall require approval of the Engineer In-charge.

The elapsed time between the start of blasting and the heating of pipe shall be indicated in the application procedure submitted by the Contractor and shall be reflected on his plant scheme.

The total elapsed time between the start of blasting of any pipe and the heating of that pipe to the specified temperature shall not exceed the following time- humidity table:

PERCENT RELATIVE HUMIDITY ELAPSED TIME (HOURS)

85 0.5

80 1.0

70 2.0

60 2.0



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Any pipe surface not processed within the above time-humidity table shall be completely re-cleaned and re-blasted before coating.

The maximum time limit between blasting and coating for humidity below 60% shall be 4 hours.

19.9.7 Coating Application

19.9.7.1 General

The application of the coating shall be in accordance with the material manufacturer recommendations and the procedure outlined below.

The Contractor shall perform coating procedure qualification testing (PQT) prior to commencing production or on his own risk at the start of production in accordance with this specifications.

Prior to start-up of the coating process the powder application and recovery systems shall be thoroughly cleaned to remove any powder other than that is use, minimum once per day and the collected powder shall be disposed off.

19.9.7.2 FBE Layer

The FBE shall be applied to a minimum thickness of 200 microns.

The pipe shall be uniformly preheated in accordance with the FBE manufacturer’s instructions. This temperature shall have been confirmed during PQT. The surface temperature shall not exceed 260ºC in accordance with AWWA C213, section 4.4.3.1 Preheating”.

Pipe temperature shall be checked periodically using pyrometer. The pyrometer shall be checked for error not less than every four hours against a calibrated temperature measuring instrument.



P a g e 154 | 209

The coating shall be applied by electrostatic spray with the pipe at earth potential and the epoxy powder charged to high potential.

The use of reclaimed FBE powder is only permitted if the reclaimed powder is screened to remove foreign or deleterious material before being reintroduced into the powder application system.

The clean reclaimed powder upto a maximum of 20% shall be introduced back into the fresh virgin material by means of proport ional weight.

During application, the bevelled ends and pipe bore shall be protected against mechanical damage and from contamination with coating material.

19.9.7.3 Adhesive Layer

The adhesive shall be applied to a thickness of 200 microns.

The adhesive layer shall be applied before gel time of the FBE has expired. Application of the adhesive shall not be permitted after the FBE has fully cured. The Contractor shall establish to the satisfaction of the Engineer In-charge that the adhesive is applied within gel time window of the FBE and at the temperature recommended by the adhesive manufacturer. The Contractor shall state the proposed minimum and maximum time interval between FBE and adhesive applications at the proposed pre-heat temperature.

19.9.7.4 Polyethylene Layer/Cutback

The polyethylene layer shall be applied to a minimum thickness as per DIN 30670 over the pipe body and to a minimum of 90% body thickness over the production welds.

PIPE DN TOTAL THICKNESS OF POLYETHYLENE COATING

> DN 100 ≤ DN 250 2.7 mm

> DN 250 < DN 500 2.9 mm



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PIPE DN TOTAL THICKNESS OF POLYETHYLENE COATING

≥ DN 500 < DN 800 3.2 mm

≥ DN 800 3.7 mm

The thickness may be less than the minimum thickness locally as long as these local areas do not exceed 5cm2 per 1m length of pipe and the difference between the actual thickness and the minimum thickness is not greater than 10%.

Inspection of Thickness: Inspection of thickness shall be as per Annexure A (normative) of DIN 30670.

A polyethylene layer cutback of 150 mm (±20mm) shall be provided at pipe ends.

The polyethylene shall be applied over the adhesive within the time limits established during pre-production testing.

The coating shall be cooled to below 60°C before handling.

The ends of the coating shall be chamfered and bevelled to less than 30º.

Immediately after the coating is fully cured, pipe identification marks shall be re-applied to the coated pipe using a method approved by Engineer In-charge

19.9.8 Inspection, Testing and Certification

19.9.8.1 General

In order to demonstrate that the manufacturer’s proposed coating procedure is capable of meeting the specification, the Contractor shall undertake coating procedure qualification testing (PQT) prior to commencing production, or at his own risk at the start of production. The Contractor shall also be required to test the finished coating during production to demonstrate continued compliance with this specification. Details of all inspections and testing shall be fully documented in accordance with this section.

All states of the surface preparation, coating and testing shall be subject to 100% inspection by the Contractor. The Engineer In-charge shall be informed at least two weeks prior to the start of surface preparation to allow scheduling of inspection supervision work



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19.9.8.2 Coating Procedure Qualification Testing (PQT)

Prior to commencing or at the start of full production five pipe of each diameter coated with FBE only and five pipe of each diameter with the full coating system shall be selected for PQT. All coating shall be in accordance with the coating procedure specifications and shall be witnessed by the Engineer In-charge or its representative.

The produced pipes will not be released until the successful results of the PQT can be provided. In case of long-term tests the PQT report shall be updated once the results can be provided. Any failure in meeting the specified acceptance criteria for the PQT will result in rejection of the coated pipes. Engineer In-charge shall approve any remedial action, repairs or re-use.

The test methods for all tests required for PQT on the FBE and the complete coating system shall be performed in the same manner as the production tests described in this specification.

Pipes selected for PQT testing shall pass all the criteria containing in 19.9.8.3 before production commences.

Any change in the coating material or coating procedure shall require approval from Engineer In-charge.

If any of the tests fails to meet the minimum acceptance criteria defined in this specification, then the pre-qualification pipes shall be rejected. Further pipes may be prepared and coated using revised procedures and further tests performed. Once acceptable results are obtained and approved by Engineer In-charge, the Contractor’s quality plan and procedures shall be revised, and submitted to the Engineer In-charge for approval. All items coated using the rejected procedures shall be striped and recoated to the revised procedures.

19.9.8.3 PQT Inspection and Test Summary

Inspection and testing summary for procedure qualification test (PQT) for three layer



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coating system for each pipe diameter:

Property Acceptable Values Frequency of Tests

On Arrival

� Pipe Damage

Minor damage/grinding

<3 Per Pipe

Each Pipe

After Cleaning

Chloride

Oil

Salt

2 mg/cm2

No contamination

3 mg/cm2

Each Pipe

After Abrasive Blasting

� Cleanliness � Profile � Contamination

SA 2.5 acc to ISO 8501

50 – 100 um

No contamination

Each Pipe

Each Pipe

Each Pipe

� Visual Inspection � Holidays � Thickness � Adhesion

No surface defects

No holidays

Min/Max see clause 19.9.7.2

See clause 19.9.7.3

Each Pipe

Each Pipe

10 per pipe

2 per pipe

Holidays Visual Inspection

Coating

Bare steel at pipe ends

Production FBE PE cut backs

No surface defects

120+10/-0 mm width

10 to 40 mm width, Chamfered

150 ±20 mm bevel <30º

Each Pipe

Each Pipe

Each Pipe

Each Pipe

Adhesion

� Peel Test

> 100 N/cm at 20 °C +5°

> 50 N/cm at 50 °C +5°

2 per Pipe

2 per Pipe

Impact Resistance See Clause 19.9.8.4xxxx 1 per pipe

% Elongation at Failure See Clause 19.9.8.4zzzz 2 per pipe

Cathodic Disbondment See Clause 19.9.8.4bbbbb 2 per pipe

DIN 30670 See Clause 19.9.8.4aaaaa 1 per pipe

19.9.8.4 Production Testing

uuuu. Production testing shall be performed at the frequency shown below:



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Property Acceptable Values Frequency of Tests

On Arrival � Pipe Damage

Minor damage/grinding

<3 Per Pipe

Each Pipe

After Cleaning

Chloride

Oil

Salt

2 mg/cm2

No contamination

3 mg/cm2

Each Pipe

After Abrasive Blasting � Cleanliness � Profile � Contamination � Pipe Damage

ISO-SA

50 – 100 um

No contamination

See clause 19.9.5

Each Pipe 20

Each Pipe 20

FBE Layer � Visual Inspection � Holidays � Thickness � Adhesion

No surface defects

No holidays

Min/Max see clause 19.9.7.2

See clause 19.9.7.3

Each Pipe

Each Pipe

10 per pipe

2 per pipe

Holidays Visual Inspection

Coating

Bare steel at pipe ends

Production FBE PE cut backs

No surface defects

120+10/-0 mm width

10 to 40 mm width, Chamfered

150 ±20 mm bevel <30°

Each Pipe

Each Pipe

Each Pipe

Each Pipe

Adhesion � Peel Test

> 100 N/cm at 20° C +5°

1 Pipe per 25

2 per Pipe

Cathodic Disbondment at Room Temperature

See Clause 19.9.8.4bbbbb First pipe, last pipe and at intervals of every 500 pipes

The frequency of tests shown in the table above will be for normal production operations. This frequency of tests is subject to change at the discretion of the Engineer In-charge as a result of change of materials or consistent poor production performance.



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vvvv. Holiday Detection

� FBE Layer

The FBE coating shall be 100 % holiday tested with a pulse type DC holiday detector equipped with audible signaling device. The test shall be carried out in accordance with NACE RP0490 or equivalent.

� Final Coating

Each fully coated pipe shall be inspected for holidays over 100 percent of its coated surface using a high voltage DC detector.

The detector shall be a type, which maintains complete contact with the coating. It may be either constant or pulsed voltage type. If constant voltage type, holiday detection shall be carried out on a dry coating. The operating voltage between electrode and pipe shall be checked at least twice per working shift, and shall be maintained at 10 kilovolt/mm of coating thickness.

The Contractor shall demonstrate to the Engineer In-charge that the setting of the detector is satisfactory for detecting pinhole defects. This setting shall be checked once every two hours. The correct travel speed shall be determined by consistent detection of an artificial pinhole made in a good coating sample but shall not exceed 300 mm/s.

All holidays and other detects shall be marked for subsequent repair and re-testing. On retesting, no holidays shall be permitted in the final coating.

The number of holidays for each pipe length shall be recorded. Coated pipe having holidays in excess of 1 per 1 square meter shall be stripped and re-coated.

If there is an excess occurrence of holidays on successive pipes, the Contractor shall



P a g e 160 | 209

immediately stop the coating operation to determine the cause and remedy it.

wwww. Adhesion (Peel) Test

− FBE Layer:

With a sharp narrow bladed knife, two incisions (approximately 13 mm long) shall be made, in the form of an X. through to the metal substrate. At the intersection of the X. an attempt shall be made to force the lining from the steel substrate with the knife point. The point of the knife shall be inserted horizontally i,e., the flat of the blade under the lining at the point of intersection of the X such that the blade point is on the metal surface. Using a levering action, the flat point shall be forced away from the steel in an attempt to pry off the coating. Refusal of the lining to disbond from the substrate shall be recorded as a pass. A pass shall also be recorded where the lining fails cohesively. Partial or complete adhesive failure between the lining and the substrate shall be recorded as a failure. Disbondment at the point of the intersection is common due to the action of marking the 'X' cut. Therefore for 1 mm away from the tip of the intersection any disbandment shall be ignored.

− Final Coating:

The adhesion for the complete coating shall be determined in accordance with the requirements for bond strength in DIN 30670. The relevant test temperature and acceptance criteria for these tests shall be as detailed in procedure qualification and production testing of this specification. Automatic chart recording equipment shall be used and the average peeling force shall be recorded.

The failure mode shall be recorded. The failure should occur at the adhesive/polyethylene interface or adhesive/FBE interface or cohesively in the polyethylene layer. If failure should occur at the FBE/steel interface this will be considered a total failure of the system.

xxxx. Impact Test

A sample or coated pipe shall be impact tested in accordance with the procedures



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and acceptance criteria of DIN 30670.

yyyy. Resistance to Indentation Test (Indentation Hardness)

Once per shift (and when the FBE or polyethylene batch is changed), the indentation hardness of two coated samples shall be measured (at 20○C ± 5°C and 70ºC ± 2ºC) in accordance with DIN 30670.

Indentation depth shall not exceed 0.2mm at 20°C ± 5°C or 0.3mm at 70°C ± 2ºC.

zzzz. Percentage Elongation at Failure

This test shall be conducted in accordance with DIN 30670 on each of the full system pre-qualification pipes, but at least the coating of three pipes shall be tested for elongation at failure, from which five test pieces shall be taken. The percentage elongation at failure shall be at least 400% on each of the full system pre-qualification pipes, 2 samples per pipe to the requirements of DIN 30670.

aaaaa. Other DIN 30670 Tests

The Contractor shall demonstrate, for the same system to be applied for this order, attainment of DIN 30670 requirements for Coating Resistivity, to Thermal Ageing and Light Ageing as required by DIN 30670.

bbbbb. Cathodic Disbondment Test

Cathodic Disbondment testing shell be conducted:

as a pre-qualification test - 48 hours duration at 65 ± 2°C

as a pre-qualification test - 28 days duration at 23 ± 2°C



P a g e 162 | 209

as a production test - 48 hours duration, at the frequency of one test per 50D coated pipes at 65 ± 2°C

The test requirements shall be in accordance with ASTM G 8.

The final unsealed diameter (including the initial holiday diameter of 6.35 mm) shall not exceed 15 mm. This shall apply to both, the 28 day test at 23 ± 2°C and the 2 days test at 65 ± 2°C.

The Contractor may propose alternative cathodic disbondment test standards provided the essential requirements of this specification are retained. Any such alternatives shall be submitted to the Engineer In-charge for review and approval.

Every 24 hours the applied voltage and current flow shall be recorded. Any drift from the specified voltage setting shall be corrected.

ccccc. Destructive Tests

A sufficient length of production pipe shall be cold cut to provide the required number of samples for conducting the coating destructive tests listed in this specification.

Items that fail individual tests and that cannot be repaired in accordance with this specification shall be rejected. Subject to the approval of Engineer In-charge, the rejected coating shall be stripped and the joint shall be re-blasted and coated in the manner specified for new pipe in this specification.

Where a test relates to a quantity of coated items, e.g. 1 per 50 items or 1 per

100 items etc., the quantity or items represented by the item tested (e.g. 50 or

100) shall be considered to be a batch.



P a g e 163 | 209

If a test on an item in a batch fails then this item shall be rejected and two further items shall be randomly selected from the batch for repeat testing. If either of these tests fails then the whole batch shall be quarantined for review by Engineer In-charge. The cause of failure shall be established and reported to the Engineer In-charge and if deemed necessary by the Engineer the coating procedure shall be amended and re-qualified. The Engineer In-charge will decide whether the whole batch is rejected and sent for re-blasting and re-coating or whether acceptance may be on the basis of acceptable tests carried out on individual items.

ddddd. Coating Repairs

The Contractor shall submit detailed coating repair procedures for approval by Engineer in-charge. These shall include procedures for repair or 'pin-hole', 'small area' and 'large area' defects. The minimum and maximum areas for which each type of repair is applicable shall be stated taking into consideration the below mentioned requirements.

The maximum number of coating defects allowable, before a joint of pipe shall be classed as rejected and recoated, shall not exceed 1 per 1 square metre (exclusive of damage caused by testing).

� Repair areas of sizes < 5 mm2

Pinhole damage shall be repaired by cleaning with an emery cloth followed by application of a two (2) pack epoxy repay repair kit or an approved hot melt mastic smoothed flush with the polyethylene surface. If the mastic is used, it shall be spread with the aid of a hot air or a propane torch.

� Repair areas of sizes < 5 mm2 up to < 250 mm2

The area shall be swabbed with solvent and abraided with an emery cloth to ensure that the surrounding polyethylene is well bonded, the surface shall be roughened for a distance of at least 25mm beyond the damage area. An approved hot melt mastic shall be applied to the damage area and smoothed flush. The mastic and surrounding area shall be warmed with hot air or propane torch until the surrounding polyethylene has as slight sheen. An approved polyethylene patch material shall be applied overlapping the damage



P a g e 164 | 209

but not overlapping the pre-abraided areas. Torch heat and smoothing pressure shall be applied to fuse the patch and ensure that no blisters are formed.

� Repair areas of sizes 250 mm2 up to 625 mm2

Heat shrink-wrapping pipe sleeves shall be used for repair according to the following procedure:

Thoroughly clean the area to be coated.

Bevel the extremities of the mill-coating with a rasp.

Pre-heat the area to be coated to a temperature of approximately 70°C.

Install the sleeve over the area to be coated.

Warm the shrink sleeve to a temperature above 150°C with a propane torch or a warm-air ring.

� Repair areas of sizes exceeding 625 mm2

No single defect shall exceed an area or 625 mm2. Pipes with a coating defect exceeding 625 mm2 shall be cause for rejection and shall be subsequently rejections and recoated. All rejections shall be recorded.

Repairs shall provide a finished coating equal in effectiveness to that of the parent coating. The limit of the repair area shall be revised.

Each repaired area shall be holiday inspected as described in this specification.



P a g e 165 | 209

The Pipe Coating Contractor shall submit coating stripping procedure for pipes rejected for coating quality. The rejected coating may be stripped by heating in an oven. Under these circumstances, the temperature of the pipe joint shall not be allowed to rise above 400°C.

eeeee. Handling, Transport and Storage Rules

The contractor shall be responsible for any damage occurring to the pipes from

unloading to reloading on the relevant transportation means.

The contractor shall consequently:

− inspect the bare pipes upon delivery to check that they have suffered no previous damage,

− take all necessary precautionary measures to prevent any deterioration during the following operations: − handling, − transfer to storage yards. − storage, − loading of pipes for shipment.

All repairs and inspections shall be carried-out at the contractor's expense.

fffff. Handling

The pipes shall be handled without causing damage to the pipe bevels and coating.

Direct contact steel or hamp slings or with any material whose shape or nature may deteriorate the pipe coating shall be strictly prohibited. Polyamide slings or hooks



P a g e 166 | 209

fitted with thermoplastic protection may be used.

Use of electromagnetic device is recommended.

ggggg. Transfer to storage yard

During transport of pipes to the storage yard of the contractor, the latter shall take all their required measures to avoid pipe and coating damage.

hhhhh. Storage yard of the contractor

Stockpiling of coated pipes shall be made so as to avoid any deterioration of coating. Coated pipes, when non concrete weight coated, shall be protected against ultraviolet rays action in particular.

iiiii. Pipe loading for shipment

When loading the coated pipes for shipment, the contractor shall take all necessary measures to avoid the deterioration of pipes and coating during handling and transport.

jjjjj.Repair of Coating

The contractor shall submit to Department, its methods and materials proposed to be used for executing a coating repair and shall receive approval from the department prior to use. In open storage the repair materials must be able to withstand a temperature of at least (+) 80°C without impairing its serviceability and properties. The contractor shall furnish manufacturer's test certificates for the repair materials clearly establishing the compliance of the repair materials with the applicable coating requirements indicated in this specification.

All repair material will be of Class C.70 as specified in the relevant DIN Standard.

All pipe coating plan, shall have sound external with no holiday or porosity on 100%



P a g e 167 | 209

of the surface.

Defects, repairs and acceptability criteria shall be as follows:

− Pipes showing porosities or very small damage not picked up during holiday test and having a surface less than 0.5 cm2 or linear damage (cut) of less than 3 mm shall be repaired by stick using material of same quality.

− Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked up during holiday test, having a total reduced thickness on damaged portion not less than 2 mm and an area not exceeding 20cm2 shall be rebuild as per approved method and without exposing to bare metal.

− Defects of size exceeding the above and mentioned area of or holidays of width less than 300mm shall be repaired as per approved method by exposing the bare metal surface.

− Defect exceeding the above and in number not exceeding 2 per pipe and their length not exceeding 500 mm shall be repaired as per approved method.

− Pipes with bigger damage shall be stripped and recoated. − In case of coating defect close to coating cut back, the contractor shall remove

the coating throughout the entire circumference of the pipe down to the steel surface and increase the coating cut back length. Now, if the coating cut back exceeds by 30 mm than the specified cut back length, then the coating shall be repaired as per approved method thereby making up the coating cut back length as per specification.

In case the defect exceeds 70 mm from the original coating cut back length, the entire

coating shall be removed and the pipe shall be recycled through the entire coating

procedure.

Irrespective of type of repair, the maximum number of repair of coating shall be as

follows:

− Holiday repair of size ≤ 100cm2 attributable to process of coating application shall be maximum one number per pipe.

− In addition to the above, defects to be repaired as per approved method shall be maximum 2 (two) per pipe.



P a g e 168 | 209

Defects exceeding the above limits shall cause pipe coating rejection, stripping and

recoating. The above is exclusive of the repairs warranted due to testing as this

specification.

All repairs carried out to the coating for whatever reason shall be to the account to the

contractor.

Cosmetic damages occurring in the polyethylene layer only need not be repaired by

exposing up to steel surface, as deemed fit by the department. In any case the

contractor shall establish his material, methods and procedure of repair that result in

an acceptable quality of product by testing and shall receive approval from department

prior to use.

Testing of repairs shall be in the same form as testing coating. All repairs shall result in

a coating thickness no less than the parent coating thickness. the contractor shall test

repairs to coating as and when required as and when required by department.

Repair Material:

Heat Shrink Sleeves - HTPL-80, PERP 80 PERP FILLER, S 1239 Epoxy or Canusa GTS-80, CRP 80 Mastic Filler, S/E/liquid epoxy and then should be followed by or equivalent material to be qualified by the material manufacturer and approved by department.

� Any combination of epoxy, adhesive and polyethylene shall be tested and certified by an internationally recognized agency.

� In case the contractor proposed coating material other than above

mentioned combination of epoxy, adhesive and polyethylene, coating procedure and qualification need to be carried out by an internationally recognized agency by the coating material Manufacturer.

� All materials to be used shall be supplied in sealed, damage free containers and

shall be suitable marked with the following minimum information:



P a g e 169 | 209

kkkkk. Name of the Manufacturer lllll. Type of Materials mmmmm. Batch Number nnnnn. Place and Date of Manufacture ooooo. Shelf Life/Expiry Date (if Applicable) ppppp. Quantity

All materials noted to be without above identification shall be deemed suspect

and shall be rejected by the department. Such materials shall not be used for

coating and shall be removed from site and replaced by the contractor at his

expense.

LOFC: List of Operation of Fabrication and Control

Each LOFC must contain the following information as a minimum (all clearly marked and separated):

qqqqq. Company name and references relating to the order; rrrrr. All technical and other information required in order to define

the items covered. � The area of application will be limited to that item or those items considered

in fabrication and control as a natural unity. � Details of plants, layout, capacity, production rate, testing equipment,

yard facility. sssss. A numerical sequence of operations with description will be built-

up in a logical way of work progress. � The first operation will be the control over the incoming material(s) and

documents. � The last operation will be the control over the final documentation.

The following operations have to be included (not limited to):

� Procedure prior to the commencement of production shall be approved by the department

� Each step which call for own quality control (eventually QA); � Each applicable examination as part of this specification; � Document control-stamping and final documentation.

ttttt. Each operation will be followed by the applicable specification or procedure number (with the latest revision).

uuuuu. Columns to be provided for possible interventions of: � the manufacture's fabrication control;



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� the manufacturer's quality control (eventually QA); � inspection Agency; � and place of intervention if not by the manufacturer.

The interventions will be indicated per operations with H or w and/or R.

H = hold point - no further steps may be undertaken before the intervention of the

designated responsible takes place.

W = witness point - the designated responsible has to be notified of the operation in

advance, but production will continue whether the intervention took place or not.

R = point for which a control report or a recording has to be made.

The manufacturer will rill in his own H, W and R points. The inspection Agency will

do the same in its designated column, but this will not implicate a relaxation or

waiving of the requirements of the manufacturer's controls.

Each intervention has to be signed and dated by person acting as controller. Only the

original documents will be presented for this purpose.

vvvvv. One column to be provided for report or record number (point marked R) and one for the review or these documents by the Inspection Agency.

wwwww. Two extra columns may give reference to non-conformity report if any and to the resolution give to it.

Completion of the LOFC does not automatically rise to a release o the material or it

must be stipulated otherwise in the contract.



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The steps indicated in the LOFC must be executed following the sequence as

stipulated in LOFC.

19.10 Coating Of Field Joint, Special Sections & Connections Fittings Of Steel Pipelines For Water

19.10.1 Scope

� This specification establishes the minimum requirements of materials, equipment and installation of field joint anti-corrosion coating of buried onshore pipelines factory coated with three layer polyethylene coating, by heat shrink wraparound sleeves conforming to EN 12068- “Cathodic Protection – External Organic Coatings for the Corrosion Protection of Buried or Immersed Steel Pipelines used in Conjunction with Cathodic Protection – Tapes and Shrinkable Materials” and the requirements of this specification. Unless modified/replaced by this specification, all the requirements of EN 12068 shall remain fully applicable and complied with.

This specification shall be read in conjunction with the conditions of all specifications and documents included in the Contract.

19.10.2 Reference Documents

Reference has also been made to the latest edition (edition enforce at the time of issue of enquiry) of the following standards, codes and specifications:

xxxxx. ISO 8502-3 : Preparation of Steel Substrates before Application of Paints and Related Products – Part 3 – Assessment of Dust on Steel Surfaces Prepared for Painting (Pressure Sensitive Tape Method)

yyyyy. ISO 8503-1 : Part 1: Specification and definitions for ISO surface profile comparator for the assessment of abrasive blast cleaned surfaces.

zzzzz. ISO 8503-4 : Part 4: Methods for calibration of ISO surface profile comparator and for the determination of surface profile - Stylus instrument procedure.

aaaaaa. SIS 055900 : Pictorial Surface Preparation Standard for Painting Steel Surfaces.

bbbbbb. SSPC-SP1 : Steel Structure Painting Council.

In case of conflict between the requirements of this specification and that of above



P a g e 172 | 209

referred documents, the requirements of this specification shall govern.

The contractor shall be familiar with the requirements of these documents and shall make them readily available at the site to all personnel concerned with carrying out the works specified in this specification.

19.10.3 Materials and Equipment

19.10.3.1 Field Joint coating Material:

Field joint anti-corrosion coating material shall be heat shrinkable wraparound sleeve suitable for a maximum operating temperature of (+) 60°C (Tmax) and shall conform to designation EN 12068-C-HT-60UV. In addition, the field joint anti-corrosion coating shall comply the requirements specified in this specification.

cccccc. Heat shrinkable wraparound sleeves:

Heat shrinkable wraparound sleeve shall consist of radiation cross-linked, thermally stabilized, ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of high shear strength thermoplastic/co-polymer hot melt adhesive. The joint coating system shall consist of a solvent free epoxy primer applied to the pipe surface prior to sleeve application. The backing shall be provided with suitable means (thermo-chrome paint, dimple, or other means) to indicate the desired heat during shrinking in field is attained. The sleeve shall be supplied in pre-cut sizes to suit the pipe diameter and the requirements of overlap.

The total thickness of heat shrinkable wraparound sleeve in the “As Applied” condition shall be as follows:

Pipe Size (Specified Outside

Diameter) Thickness (mm)

On Pipe Body On Weld Bead

Average Min. (Min.)

<30” (762.0mm) 2.0 1.8 1.6

>32” (813.0mm) 3.0 2.7 2.5

The heat shrink wraparound sleeve shall have the required adhesive properties when applied on various commercial pipe-coating materials. The pre-heat and application temperatures required for the application of the shrink sleeve shall not cause loss of functional properties of the pipe coating.



P a g e 173 | 209

The Contractor shall propose the manufacturer's details, heat shrinkable sleeve details/ properties and the specific grade of field joint coating system meeting the requirements of this specification.

19.10.3.2 Functional Requirements of Field Joint Coating

− Properties of the PE backing shall be as follows:

Sr.

No. Properties Unit Requirement

a Tensile Strength @ +25 °C N/mm2 >12

b Ultimate Elongation @ +25 °C % >250

c Dielectric withstand with 1000

Volts/sec

KV >30

d Water absorption @ +25 °C For 24 hours % <0.05

e Volume Resistivity @ +25 °C Ohm-cm >1015

− Functional Properties of Joint Coating System (As supplied)

As applied field joint coating system shall comply the requirements of DIN EN 12068,

Table 1 & 2 corresponding to designation EN 12068 – C HT 60 UV, except as

modified below:

i. Cathodic Disbondment Resistance at Tmax i.e. 60°C shall be 20mm when tested as per Annexure K of EN 12068. Test shall be carried out at (+) 60°C.

ii. Peel Strength shall be as follows:

Peel Strength Unit Requirement for Mech.

Resistance Class-C (minimum)

To Pipe Surface @ 23ºC N/mm 3.5

@ Tmax N/mm 0.5

To Factory Coating

@ 23ºC N/mm 3.5

@ Tmax N/mm 0.5



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Contractor shall obtain prior approval from the department regarding the Manufacturer of the joint coating material and the specific grade of the joint coating system. Complete technical details along with test certificates complying with the requirements of clause 19.10.3.1 and 19.10.3.2 shall be submitted to Employer for this purpose. The Contractor shall furnish test certificates from an independent DIN recognized/approved laboratory for all the properties required for the specified EN designation of field joint coating and the requirements of this specification.

The material shall be tested at the manufacturers works before dispatch to the site in the presence of departmental representative.

19.10.3.3 Cut back

Cut back length of the pre-coated pipes shall be 150mm +20, - 0mm.

19.10.3.4 Field joint coating system

Field joint coating system shall be of suitable width considering an overlap to the factory

coated pipe coating by minimum 50 mm on each side 3 LPE coated pipes.

19.10.4 Application Procedure

19.10.4.1 General dddddd. The application procedure shall be in accordance with manufacturer’s

instructions and the minimum requirements specified below whichever are the most stringent and shall be demonstrated to and approved by the department. The contractor’s expert shall supervise the application and shall be available at site upon request during qualification of application procedure and during construction at Contractor’s cost.

eeeeee. Operators for coating application shall be given necessary instructions and training before start of work, by the Contractor. To verify and qualify the application procedures, all coating applied during the qualification test shall be removed for destructive testing as detailed subsequently in this specification. Contractor shall only utilize those operators who have been approved/ pre- qualified by the field joint coating manufacturer.

ffffff. Oil, grease and salt shall be removed from steel surface by wiping with rags soaked with suitable solvents such as naphtha or benzene. Kerosene shall not be used for this purpose. Solvent cleaning procedure according to SSPC-SP1 shall be followed.

gggggg. Each field joint shall be blast cleaned using a closed cycle blasting unit or open expandable blasting equipment. With the first equipment type, steel or chilled shot and iron grit shall be used and Garnet material with the second one (in case



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the authority having jurisdiction have no objection, the contractor may adopt sand blasting instead of garnet material). During blast cleaning the pipe surface temperature shall be simultaneously more than 5°C and more than 3°C above ambient Dew Point, while the ambient Relative Humidity shall not be greater than 85%. Prior to surface cleaning the surfaces shall be completely dry. The surface shall be cleaned to a grade Sa 2½ in accordance with Swedish Standard SIS-055900 with a roughness profile of 50-70 microns. Surface roughness profile shall be measured using an approved profile comparator in accordance with ISO 8503-1 and shall be calibrated prior to the start of the work in accordance with ISO 8503 or ISO 8503-4. The blast cleanliness shall be checked on every joint and the roughness profile shall be checked 1 every 10 joints.

Dust, grit or foreign matter shall be removed from the cleaned surface by an industrial vacuum cleaner. The dust contamination allowed shall be of a rating max 2 as per ISO 8502-3. The frequency of checking for dust contamination shall be 1 every 10 joints.

Blast cleaned field joint shall be coated with 2-4 hours according to the conditions

below:

� Relative Humidity (RH) >80% - 2 hours � Relative Humidity (RH) 70-80% - 3 hours � Relative Humidity (RH) <70% - 4 hours

Pipes delayed beyond this point or pipes showing any visible rust stain, shall be

blast cleaned again.

hhhhhh. The field joint surface shall be inspected immediately after blast cleaning and any feature of the steel surface such as weld spatter, scabs, laminations or other imperfections considered injurious to the coating integrity, made visible during blast cleaning, shall be reported to the Company Representative and on permission from Company Representative, such defects shall be removed by filling or grinding. Pipes affected in this manner shall be then re-blast cleaned if the defective area is larger than 50mm in diameter.

iiiiii. The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded portions of the coating shall be removed and then suitably trimmed. Portions where parent coating is removed shall be thoroughly cleaned as specified. The adjacent chamfered areas of the line pipe coating shall be cleaned and



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abraded, to expose a clean uniform fresh surface of uncontaminated factory applied coating.

jjjjjj. All steel joint surfaces shall be thoroughly examined before the application of the coating in order to ensure the surfaces are free of oil, grease, rust, mud, earth or any other foreign matter. All these substances shall be removed before coating, to the procedures herein described.

kkkkkk. Protection coating shall be applied on the joints immediately after the completion of cleaning operation.

19.10.4.2 Application Procedure for Heat Shrink Wraparound/Sleeves

In addition to the requirements stated above, following shall be complied with:

llllll. The wraparound sleeve shall be of a size such that a minimum overlap of 50mm is ensured (after shrinking) on both sides of the yard applied corrosion coating of pipes.

mmmmmm. In the cases where carrier pipe is installed by direct boring/jacking, the

overlap on the mill coating for the leading edges of the joints shall be minimum 200mm. When this extra overlap is achieved by providing an additional patch of heat shrink tape/ wraparound, it shall be applied in such a manner that the square edge of the patch on the joint coating is in the direction opposite to the direction of boring/ jacking.

nnnnnn. Before centering the wraparound sleeve, the bare steel surface shall be

preheated either with a torch moved back and forth over the surface or by induction heating. The minimum pre-heat temperature shall be as recommended by manufacturer and shall be checked by means of contact type temperature-recording thermometer (Digital Pyrometer with flat probe type contact). Temperature indicating crayons shall not be used. Pre-heat temperature shall be checked on every joint. Care shall be taken to ensure that the entire circumference of the pipe is heated evenly. Temperature measuring instruments shall be calibrated immediately before the start of the works and thereafter at intervals recommended by the manufacturer of the instrument.

oooooo. Upon pre-heating, the pipe surface shall be applied with two pack epoxy

primer of wet film thickness 200 microns or as per manufacturer’s recommendation whichever is higher, to cover the exposed bare metal of the welded field joint and 10mm min. onto the adjacent pipe coating if recommended by the manufacturer. The wet film thickness of the primer shall be checked on every joint with a wet film thickness gauge prior to installation of sleeve. Thickness gauge shall be calibrated once per shift.



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pppppp. Immediately after application of epoxy primer, the wraparound sleeve

shall be entirely wrapped around the pipe when the epoxy is still wet. Sleeve shall be positioned such that the closure patch is located to one side of the pipe in 10 or 2 O’clock position, with the edge of the undergoing layer facing upward and an overlap of min. 50mm. Gently heat by appropriate torch the backing and the adhesive of the closure and press it firmly into place.

qqqqqq. A heat shrinking procedure shall be applied to shrink the sleeve in

such a manner to start shrinkage of the sleeve beginning from the centre of the sleeve and heat circumferentially around the pipe. Continue heating from the centre towards one end of the sleeve until recovery is completed. In a similar manner, heat and shrink the remaining side. Shrinking has been completed when the adhesive begins to ooze at the sleeve edges all around the circumference.

The complete shrinking of the entire sleeves shall be obtained without undue heating of the existing pipe coating and providing due bonding between pipe, sleeve and pipe coating. The installed sleeve shall not be disturbed until the adhesive has solidified.

19.10.4.3 Joint Coating Application

Joint Coating Application shall be done under supervision of the contractor’s personnel during the field trial demonstration and testing work. Presence of manufacturer’s representative is a mandatory requirement and contractor shall be required to furnish specific commitment to this. Minimum 50 (fifty) field joint coating to be carried out under supervision of the joint coating supplier’s representative. Application procedure and environment protection methodology demonstrated at the time of field trial shall be strictly followed during the entire work.

19.10.5 Repairs

rrrrrr. If a field joint is detected to be unacceptable after testing as per relevant QA section of this specification the Contractor shall, at his own cost:

i. Determine the cause of the faulty results of the field coating. ii. Mobilise the expert of manufacturer, if required. iii.Test to the complete satisfaction of Company, already completed field coatings. iv. Stop the field coating works until remedial measures are taken against the

causes of such faults, to the entire satisfaction of the Company.



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ssssss. Contractor shall replace all joint coating found or expected to be unacceptable as per relevant section of this specification.

tttttt. Contractor shall, at his own cost, repair all areas where the coating has been removed for testing by the Company.

uuuuuu. After the coating work on welded joints and repairs to the coating have been completed the coating as a whole shall be tested with a spark-tester before lowering or jacking the pipeline.

vvvvvv. Employer shall be entitled to check the coating on buried pipelines or parts of pipelines with equipment such as the “Pearson Meter” and the resistance meter. If coating defects are established, the Contractor shall be responsible for excavation at such points, repairing the coating, spark testing and backfilling the excavations without extra charge.

19.10.6 Documentation

wwwwww. Prior to procurement of coating materials, Contractor shall furnish the following information for qualification of the Manufacturer and material.

i. Complete information as per clause 19.10.3.2 and DIN EN 12068 along with descriptive technical catalogues.

ii. Test certificates and results of previously conducted tests, for all properties listed in clause 19.10.3.2 of this specification.

iii. Reference list of previous supplies, in last 5 years, of the similar material indicating the project details such as diameter, quantity, operating temperature, year of supply, project name, contact person and feedback on performance.

Once the Employer’s approval has been given, any change in material or Manufacturer shall be notified to Employer, whose approval in writing of all changes shall be obtained before the materials are manufactured.

xxxxxx. Prior to shipment of materials from the Manufacturer’s Works, Contractor shall furnish the following documents:

i. Test certificates/results as per Manufacturer’s Quality Control Procedure for each batch of material.

ii. Specific application instructions with pictorial illustrations. iii. Specific storage and handling instructions.

yyyyyy. All documents shall be in English language only.



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19.11 Lowering, laying & jointing of pipe

19.11.1 General

The pipeline shall be buried with minimum cover of 1.2 m at top, however pipeline shall be laid as per detailed Engineering approved by Engineer In-charge. In case required cover is more than 1.20m, contractor has to laid the pipeline accordingly.

Erection of fabricated shells shall be carried out by the Contractor who shall equip himself, at his cost, with all necessary tools, machinery, labour etc. required for the purpose.

19.11.2 Welding

Except for routine welding of joints, no other work shall be done in the absence of Contractor's engineer, either during the daytime or at night.

Chipping shall not be kept in arrears for more than 15 joints.

Saddle pieces shall be fixed in position after checking bolts holes, by means of templates. These works shall be done together with the pipe laying work, if pipeline is to be laid above ground in unavoidable circumstances.

19.11.3 Temperature

The components of the pipeline such as base plates, top plates and pedestals have been so designed that the centres of the plates and pedestals shall coincide at the Mean Temperature (30º).

For this reason, all works such as fixing flanges, base plate etc. in true alignment, and in correct position and tack welding pipes shall be done at the mean temperature.

For ascertaining the temperature, the Contractor shall provide mercury cups and fix them to the pipe shell from outside and shall also provide thermometers of the required type and range. No extra payment shall be made for this.

19.11.4 Saddle Supports

Unless otherwise specified pipeline shall be underground. However at unavoidable reaches it shall be on R.C.C. saddles spaced as per design. The material and construction of R.C.C./Steel structures such as saddles, anchor blocks, crossings etc. associated with the work of pipe line shall conform with the relevant I.S. codes, good engineering practice and as directed by the Engineer In-charge. The pipes to be laid on saddle supports shall be erected at mean temperature. Saddle supports shall either



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be sliding type or fixed type. For both the types of supports a 10mm thick double plate shall be welded to the part circumference of the pipeline that will make contact with the saddle and another similar plate shall also be embedded in the concrete saddle with necessary arrangement to facilitate welding it to the double plate welded to the pipe, in case of fixed support. In case of sliding support, the pipe shall be allowed to slide freely over the plate embedded in the saddle. Alternatively to achieve fixity, the pipe shall be anchored by providing suitable anchor block. The rate for laying the pipe on saddle support shall include for laying, aligning, tack welding, provision of rigging screws with screw eyes etc., complete.

In addition to above, the pipe shall be held in position on saddles with two numbers 50mm x 8mm thick holding down traps fixed to the saddles with holding down bolts and nuts which shall be paid separately under relevant item of bill of quantities.

19.11.5 Erection of Pipes

The erection shall be true to position, lines and grade as shown in the drawings or as modified by the Engineer In-charge. The Contractor shall provide at his cost necessary saddles, pads, spider etc., all necessary instruments and other materials and labour required for proper erection of pipes in position and for the Engineer in checking the correctness of the erection.

Alignment of sections at edges to be butt welded shall be such that the maximum offset is not greater than the values given below:

Thickness ‘t’

(mm)

Offset in Longitudinal joints

(mm) Offset in Girth joints

(mm)

Up to 12 0.25 t 0.25 t

12 to 20 3 mm 0.25 t

20 to 40 3 mm 5 mm

40 to 50 3 mm 1/8 t

Over 50 Lesser of 0.0625 t or 10 mm Lesser of 0.125 t or 20 mm

The best of welders as selected from their work in the Contractor's workshop shall be selected for in-situ welding of the pipes . The relevant provision under welding such as qualification standard for welding procedures, tests on welder's work and removal of defects etc., shall also apply to in-situ welding.

19.11.6 General Sequence of Operations

Before commencing the work of pipe laying, the Contractor shall study the L-section of the pipeline for the section concerned. He shall also study the details of laying i.e.



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underground or aboveground. The underground pipeline shall be laid on sand cushioning/ bedding as shown on the drawing. The difference in depth due to uneven excavations shall be made up by sand cushioning.

Pipe laying shall generally start from the fixity points on either side, the expansion joints if required for pipeline aboveground being provided last. Fixing points are at all anchor blocks. Where such blocks are not required for long lengths, fixity shall be achieved by fixing the pipeline to the special type of R.C.C. or steel saddles as directed. The distance between successive fixity points shall not exceed 300 m.

Anchor blocks shall be constructed before commencing the pipe laying work in any section. The construction of the blocks shall be carried out in 3 stages: in the first stage the lower part up to 150 mm below the invert of the pipeline including concrete chairs to support it shall be constructed; in the second stage the pipeline on this part of the block shall be laid; and lastly, the remaining block around and over the pipeline shall be constructed. Necessary curing to concrete shall be carried out for 14 days or as instructed Engineer in charge.

The fixity saddles and ordinary saddles if the pipeline is aboveground shall be cast-at least 3 weeks before the pipeline is laid on them. After all saddles between successive fixity points have been cast, a line plan showing the actual position thereof shall be prepared, after taking levels and measuring distances. In case of any errors in casting the pedestals, corrections shall be applied. The pipe laying work shall then start from the fixity points and shall proceed towards the expansion joints. The method of jointing the pipes and erecting them on previously cast R.C.C. saddles shall be determined by the Contractor depending upon the type of plant equipment and personnel available with them.

The pipe stacking shall be assembled in position on the saddles either by the cranes, portable gantries, shear legs or any other equipment approved by the Engineer In-charge. Normally, not more than two pipes shall be aligned, tacked and kept in position on temporary supports. The Contractor shall not proceed with further work, until the circumferential joints of these pipes are fully welded. During assembly, the pipeline shall be supported on wooden sleepers and wedges, with the free end of the pipeline held in position by slings to avoid deflection due to temperature variations during the day. In general, the assembly of pipe stacking and one run of welding shall be done during the day time while full welding including the external gouging and sealing runs shall be done after 5 p.m. or so. The Contractor shall maintain the continuity of the work by adding two more pipes on the second day in a similar manner, after full welding of the previous joints is completed during the night. While this new work is being done, the Contractor shall proceed with the work of providing permanent supports for the pipeline assembled and welded previously.



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19.11.7 Fixing Expansion Joint

The work of laying pipeline in aboveground, laying starts from the fixity points and proceeds towards the expansion joints. It shall be continued until the gap between the pipe ends is less than the lengths of the expansion joint plus pipe strake length. At this stage, the exact gap between the pipe ends shall be measured at mean temperature of that locality. Let it be `X'. Similarly, the exact length of the pipe strake and the expansion joint bought at site shall be measured at the same temperature let these be `Y' and `Z' respectively. Normally, the length of the expansion joint (`Z') is standard. zzzzzz. Case when `Y' plus `Z' is more than `X' or equal to `X' (i.e. fixing of

expansion joint without strip)

At mean temperature the exact gap between pipes shall be measured. Free ends of pipes shall be brought in a correct line and level; lateral movement, if any, shall be corrected. Then the gap between the free ends shall be made equal to the exact length of the expansion joint by cutting one of the pipe ends. Choice of the end to be cut must be made from the point of view of bringing the expansion joint to a central position.

The expansion joints are normally supplied without packing. The normal length of the expansion joint shall be reduced by about 100 mm by cutting the inside locks and inserting the inner strake by means of turnbuckles. At mean temperature this expansion joint shall be inserted inside the gap (care being taken to keep the tapered portion on the down-stream side), and both ends shall be tack welded to the pipe ends, after pulling the expansion joint. (Tacks of these two joints shall be of longer length, approximately 100 mm long).

Welding of these two joints of the expansion joints shall be started only after it is ascertained by taking observations that the expansion joint is functioning properly. The procedure to be followed for taking observations is given in Clause bbbbbbb.

aaaaaaa. Case when `Y' plus `Z' is less than `X' (i.e. fixing of expansion joints with

strap)

The expansion joint shall be laid in locked position. Before laying the pipes adjacent to the expansion joint, the exact gap between the pipes shall be calculated by taking measurements of the first pipe (upstream of the expansion joint), and the second pipe (downstream of the expansion joint) at Mean Temperature.

If the gap is less than 100 mm, the second pipe shall be cut to make the desired gap of at least 100 mm. If the gap is more than 200 mm, suitable distance piece of



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not less than 700 mm shall be inserted after cutting necessary length of the first pipe.

The second pipe shall then be laid in position. Then a strap of length equal to three times the gap length shall be welded to the pipe, overlapping the second pipe by the gap length. The other end of the strip shall be kept free.

At mean temperature the other end of the strap shall be tacked to the first pipe, after checking of the line and level. Simultaneously, all the locks of the expansion joint shall be removed and chipped off properly.

Welding of the joints between the strap and the first pipe shall be started only after observations are over and it is ascertained that the expansion joint is functioning properly.

bbbbbbb. Observations

Before fixing the expansion joint, two mercury cups - one on the left and the other on the right side - shall be fixed on the pipe near the upstream side of the expansion joint.

Immediately after the expansion joint in case (a) above or the strap in case (b) above is tack welded, observations for total expansion or contraction shall be started and continued for 48 hours round the clock. Similarly, the central and end fixity pedestals shall be kept constantly under observation.

The expansion and contraction shall be measured by making a temporary marking on the inner strake (on the upstream side) and measuring the distance between this mark and the edge of the gland of the expansion joint.

The observations shall be recorded in the following proforma;

Reading

No.

Tim

e Pipe temp

on upstream

side

Pipe temp

on downstream

side

Atmospheric

temperature

Dist. between

edge of gland and marking

1 2 3 4 5 6



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19.12 Specials

19.12.1 General

Specials, such as tees, Y-pieces, bends (single or composite), tapers, etc. shall necessarily be in steel and shall be manufactured as per standards and tested and laid in the same manner as the pipes. Small branches, single piece bends, etc. may be fabricated at site, care being taken to ensure that the fabricated fittings have at least the same strength as the pipeline to which they are to be jointed.

19.12.2 Bends

ccccccc. Bends shall be fabricated taking into account the vertical and horizontal angles for each case.

ddddddd. The bends shall have welded joints and the upstream and downstream ends of each bend shall have a straight piece of variable lengths as required.

eeeeeee. Bends shall be designed with suitable deflection angle between segments. fffffff. When the point of intersection of a horizontal angle coincides with that of a

vertical angle, or when these points can be made to coincide, a single combined or compound bend shall be used, designed to accommodate both the angles. The combined bend should have a pipe angle equal to the developed angle, arrived at from appropriate formula.

ggggggg. All joints in bends shall be thermally stress relieved as specified. hhhhhhh. Details of thrust collars anchor bolts, holding down straps, saddle plates

should be furnished together with full specifications in Contractor's fabrication drawing.

19.12.3 Manholes

iiiiiii. Manholes of 600 mm dia shall be provided at locations generally 2.5 km apart, with additional manholes at both the sides of butterfly valves. Manholes in the pipeline shall be placed in suitable position in the top quadrant.

jjjjjjj. The Contractor shall fabricate different parts of manhole in conformity with relevant IS Specification, well established practices and as directed by the Engineer In-charge.

kkkkkkk. The manhole shall be provided with MS blank flange on top. The required MS nut, bolts & rubber packing shall be fixed of standard quality for fixing of flange.

19.12.4 Closing or Make up sections

Closing or make up sections shall be furnished at appropriate locations on the line to permit field adjustments in pipeline length to compensate for shrinkage in



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field welded joints, differences between actual and theoretical lengths and discrepancies in measurements.

19.12.5 Heads

Test heads may be ellipsoidal, standard dished as per ASME code or hemispherical heads. They shall be welded in the shop and removed after the test. Allowance should be made in the length of the pipe section receiving the test head for the welding and removal of the head and preparation of the plate edges for the final weld after testing.

The rate quoted for the hydraulic test shall be deemed to cover the cost of such installations.

19.12.6 Walkways, Stairs, Ladders, Hand Rails etc.

Walkways, stairs, rungs, ladders, hand rails, etc. shall be provided as shown in the drawings and/or as directed by the Engineer In-charge. They shall conform to well established design and construction for each accessory concerned.

19.12.7 Flanges

Flanges shall be provided at the end of pipes or special where, butterfly, air valve, scour valve, sluice valves, blank flanges, tapers, etc. have to be introduced. The flanges received from the manufacturers will have necessary boltholes drilled. The Contractor shall assemble the flanges in the exact position by marginal cutting, if necessary, so as to get the desired position of the valves, etc. either vertical or horizontal and shall then fully weld the flanges from both sides in such a way that no part of the welding protrudes beyond the face of the flanges. In case the welding protrudes beyond the flanges and if the Engineer orders that such protrusions shall be removed, the Contractor shall file or chip them off. If required and when ordered by the Engineer In-charge, the Contractor shall provide and weld gusset stiffeners, as directed on site. The drilling pattern shall be matching with the drilling pattern of flanges of valves.

19.12.8 Blank Flanges

Blank flanges shall be provided at all ends left unattended for the temporary closure of work and also for commissioning a section of the pipeline or for testing the pipeline laid. For temporary closures, non-pressure blank flanges consisting of mild steel plates, tack welded at the pipe ends may be used. For pipes subjected to pressures, the blank flanges or domes suitably designed as per Engineer's requirements shall be provided.



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19.12.9 Stiffener Rings

The Contractor shall provide stiffener rings wherever required by design. The Contractor shall weld the same to the pipes with one circumferential run on each side.

All fillet welds shall have a throat thickness of not less than 0.7 times the width of welding.

19.13 Field Hydraulic Test

The pressure test shall be conducted in dry weather to observe whether any leakage takes place or not. For field hydraulic test water will pass through entire pipe line with a working pressure of all working pumps (Six nos) for a period of seven days continuously after attaining the required pressure and water reaches at the outlet of transmission main. A leakage equivalent to 0.267 litre per mm of pipe dia. per kilometre of pipeline per day for testing at working pressure applied is permissible. Any leakage beyond that specified herein above shall be rectified to the satisfaction of the Engineer In-charge.

Water shall not spout, ooze or sweat either through joints-welded or bolted or the body of the pipe. If any leakage noticed shall be repaired by the Contractor, which shall include coating and repairing of the damaged portion. Repairs and replacements and further testing including the cost of the plates and other raw materials shall be carried out by the Contractor at his own cost. If any leakages are observed during the defects liability period due to defective workmanship or material supplied by the Contractor, he shall repair the same to the entire satisfaction of the Employer, at his own cost.

After completion of field hydraulic test as specified above and if no leakage is found in the entire pipeline / joints and all welded portion, then this may be considered as field hydraulic test.

19.14 Progress in laying

The contractor shall submit a detailed bar chart for manufacturing and laying of the pipeline. While preparing this bar chart, the contractor shall plan all activities such that the laying of pipes shall closely follow the manufacturing schedule and no pipes shall remain stacked in factory or at site for a period more than one month.

19.14.1 Lowering and Jointing

The pipe shall be lowered into the trenches by removing only one or two struts at a time. It shall be seen that no part of the shoring is disturbed or damaged and, if necessary, additional temporary struts may be fixed during the lowering operations. It shall also be necessary to see that the coating of pipe is not damaged in any way



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during the lowering and assembling. After the pipe is lowered into the trench, it shall be laid in correct line and level by using the leveling instruments, sight rails, theodolite, etc. Care shall be taken to see that the longitudinal joints of two consecutive pipes at each circumferential joints are staggered by 90°. While assembling the pipes, the ends shall have to be brought close enough to leave a uniform gap not exceeding 4mm. If necessary, a marginal cut may be taken to ensure a close fit of the pipe faces. For this purpose, only experienced cutters who can make uniform and straight cuts shall be permitted to cut the faces of the pipes. No extra payment shall be made for such marginal cutting. There shall be no lateral displacement between the pipe faces to be joined. If necessary, spiders from inside and tightening rings from outside shall be used to bring the two ends in perfect contact and alignment. It may also be necessary to use jacks for this purpose. In no case shall hammering or longitudinal slitting be permitted. When the pipe is properly assembled and checked for correct line and level, it shall be firmly supported on wooden beams and wedges and tack welded. Some portion of the trench may be refilled at this stage so as to prevent the pipeline from losing its alignment. The tack welded circumferential joints shall then be welded fully. Only experienced welders, who shall be tested from time to time shall be permitted to carry out the welding work.

On completion of the pipe jointing and external protection, the trench and the welding pits shall be cleaned. The welding pit shall be filled and compacted in 150mm layers with the bedding material.

Backfilling shall be carried out as detailed here under.

Providing Steel Props inside the Pipeline (Dia. 1200 mm and above).

It is necessary that the roundness of the pipes is maintained circular. To achieve the same, steel adjustable screw type props of screw or similar approved make consisting of minimum six (three on each side) legs shall be fixed inside the pipe. The deflection of the pipe should be limited to 1% of the average diameter. In no case shall the limit be exceeded, even under the full load, in case of pipes laid underground. The design and drawings of the props that the Contractor intends to use should be got approved by the Engineer In-charge before starting the work. While laying the pipes underground. In case the Engineer In-charge finds it necessary, they will have to be fixed in any position. The props should be kept in position at least for three days after the encasing of the pipe in that section is completed or till refilling is done to the full height of fill over the pipe in case the pipes are not encased. The props shall be removed only after obtaining permission from the Engineer In-charge. The height of earth fill over the pipe top shall normally be such as to avoid floatation under submerged conditions and to have a minimum earth cushion of about 1.20 metres over the pipe whichever is greater. It is also necessary that, in case of buried pipe, adequate side supports from the backfilled materials is developed to keep the diametrical deflection within the specified limits. Backfilling of the excavated



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trenches, particularly below the pipe and along the sides shall, therefore, have to be done with proper care and compaction as desired. No extra payment will be made for the above work.

19.14.1.1 Precautions against Floatation

When the pipeline laid underground or above ground in a long narrow cutting gets submerged in water collected in the trench of cutting it is subjected to an uplift pressure due to buoyancy and is likely to float if completely or partly empty. In the design of pipelines, provision is to be made to safeguard against floatation providing sufficient overburden or by providing sufficient dead weight by means of blocks, etc. Factor of safety for calculations for check against floating shall be taken as 1.2.

In the case of works extending over one or more monsoon seasons, however, special care and precautions are necessary during the progress of work on this account. The Contractor shall close down pipe laying operations well in time for the monsoon. The work of providing blocks, refilling the earth to the required level, compacting the same, etc. shall always be done as soon as the pipeline in the cutting has been laid.

The Contractor shall see that the water shall not be allowed to accumulate in open trenches. Where work is in an incomplete stage, precautionary work, such as blank-flanging in the open ends of the pipeline and filling the pipeline with water etc. shall be taken up as directed by the Engineer In-charge.

Such works shall be to the Contractor's account and no separate payment shall be made for the same. The Contractor's rate for pipe laying shall be deemed to include such precautionary measures against floatation.

Protection of the pipeline against floatation during the Contract Period shall be the responsibility of the Contractor. Should any section of the pipeline float due to his negligence, etc. the entire cost of laying it again to the correct line and level shall be to his account.

Electric and telephone line, gas line, cable and pole if required to be shifted, necessary charges for shifting to be paid to GEB/AEC/other department shall be paid by the contractor to the concern department.

L - section of route is tentative. Contractor has to prepare a fresh Longitudinal Section before starting the work, showing all service lines coming across or parallel.

Alignment of pipeline may require to be changed on same route due to any obstructs or service lines. No extra payment made to contractor.



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Manhole chamber and all other structure required to be constructed on road are to be designed for “AA” class loading and same shall be got approved from Engineer-in-charge.

All necessary actions required for diversion of the traffic on State high way, or any other routes are to arrange by the contractor at his own cost as per the requirement of the traffic rules and approval from concerned competent authority.

During the execution of work any damage occurred to the private / Govt. property is to be reimbursed by the contractor to the owner.

19.15 Additional requirement for pipe to be laid by pushing method

For insertion of casing pipe boring shall be carried out by auger type boring device with cutting head to drill a horizontal bore. The hole drilled shall be of suitable size to accommodate casing pipe. The casing pipe shall be inserted along with boring to keep the formation supported to prevent any settlement. The casing pipe shall be installed with even bearing throughout its length. The work will be done under the supervision of Engineer In-charge as per restrictions & precautions as may be stipulated by the Engineer In-charge.

The casing pipe will be minimum 1.2 m below the level & 0.9 m below the natural G.L. The length of casing pipe shall be up to the boundary of Road or as directed by Engineer-in-charge. Casing pipe shall be provided with minimum 50 mm dia GI pipe of 2 m height above G.L. with screen at top. Rates are inclusive of bottom & side rollers of suitable size to be provided inside casing pipe at 4 m interval to facilitate insertion of carrier pipe of required dia. The ends of casing pipe shall be suitable sealed.

The casing pipe is to be provided with epoxy treatment as below on outer face of the pipe before lowering. Zinc rich Epoxy Primer

Description Two pack zinc rich consisting of –

Base Fine Zinc Dust Ground in Epoxy Resin Solution, supplied in paste form

Catalyst Abduct type- the non volatile portion of the material (mixed) should consist of 92 % Zinc Dust & 8-10% Epoxy Resin & curing agent

Shade Grey Characteristics The paint shall provide a complete rust inhibitive barrier

coating of high mechanical & abrasion resistance. The film shall be compatible for fusion & spot weld.

Pot-life 4-6 hours



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Description Two pack zinc rich consisting of –

Mixing Ratio The proportion of mixing of base & hardener should be as specified by the Manufacturer by weight & volume. The mixed primer shall conform to the specifications detailed.

Viscosity of ready mixed paint

15-22 in Fort Cup No. 4 at 30ºC

Drying time i. Dust free – 10-15 minutes ii. Chamber curing – 24-28 hours

Thickness 4 mils

19.16 Back filling of trenches

On completion of the pipe laying operations in any section, for a length of about 100m and while further work is still in progress, refilling of trenches shall be started by the Contractor with a view of restricting the length of open trenches. Pipe laying shall closely follow the progress of Trench Excavation and the Contractor shall not permit unreasonably excessive lengths of trench excavation to remain open while awaiting testing of the pipeline. If the Engineer considers that the Contractor is not complying with any of the foregoing requirements, he may prohibit further trench excavation until he is satisfied with the progress of laying and testing of pipes and refilling of trenches. Backfilling shall be carried out from bottom of pipe to 30 cm. above top of pipe with useful excavated soil which do not damage the external 3LPE coating. In case of any damage to external coating (of pipe/joint/specials etc.), the damages shall be rectified by the contractor at no extra cost. In case of failure in attending satisfactory repairs, entire pipe/specials shall be replaced with new one at no extra cost. Only soft earth of good quality free from stones cinders, ashes, slag, refuse, rubbish, vegetable or organic material, lumpy or frozen materials, boulders, rocks or stone or other material which in opinion of Engineer in-charge is unsuitable or deleterious. Filling from bottom of pipe line upto centreline shall be done in layers not exceeding 225mm and compacted to 85 percent of the maximum dry density by hand compaction as per part VII of IS:2720. Filling from centre line of the pipe to a level 300mm above the top of pipe shall be done by hand or approved mechanical methods in layer of 225mm as per IS 3114. Care shall be taken during backfilling, not to injure or disturb the pipes, joints or coating. Filling shall be carried out simultaneously on both sides of the pipes so that unequal pressure does not occur. Walking or working on the completed pipeline unless the trench has been filled to height of at least 30 cm over the top of the pipe except as may be necessary for tamping etc., during backfilling work.

Soil of excavated stuff which is to be used for refilling / backfilling work shall be got tested for all chemical tests including SO3 % , sulphate as SO3 2:1 water soil extract as per I.S. 456:2000.



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No swelling soils shall be used for backfilling work. For the purpose of back filling requirements of I.S. 3114:1994 shall be satisfied.

As per approval by EIC suitable material in backfilling may be use in lieu of earth, sand, or rounded river-run gravel / crushed sand.

Alignment passing through cultivable land, top layer of back filling should be restored to original condition. Any change in above shall be approved by the engineer-in-charge. Engineer-in-charge may change the requirements of back filling, and method of back filling etc.

The trench shall be refilled so as to build up to the original ground level, keeping due allowance for subsequent settlement likely to take place. No extra payment will be made for material brought from outside. Backfill material shall be properly consolidated by watering and ramming, taking due care so that no damage is caused to the pipes.

To prevent buckling of pipe shell diameters 1200 mm and above, pipes shall be strutted from inside while the work of refilling is in progress, for which no separate payment shall be made.

Strutting shall be done by means of strong spiders having at least 6 arms which shall be sufficiently stiff to resist all deformation. Spiders shall be provided at a maximum interval of 4 m.

If suitable material sand for back filling is not available from excavated stuff, it shall be brought from borrow area for which no extra payment shall be made.

The Engineer shall, at all times, have powers to decide which portion of the excavated materials shall be for filling and in which portion of the site and in what manner it shall be so used.

If any material remains as surplus it shall be disposed off as directed by the Engineer In-charge, which includes loading, unloading, transporting and spreading as directed. Contractor has to make his own arrangement for disposal of surplus earth. Contractor has to identify and arrange for dumping zone to dispose of the excess excavated stuff. No extra payment for such arrangement shall be paid. If the Contractor fails to remove the earth from site within 7 days after the period specified in a written notice, the Engineer may arrange to carry out such work at the Contractor's risk and cost or may impose such fine for such omission as he may deem fit. Particular care shall be taken to keep the trench dry during the entire refilling operation.



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If suitable material / Sand for refilling is not available from excavation the Contractor shall bring selected material of approved quality as directed by the Engineer In-charge. No extra payment will be made for material brought from outside.

No mechanical plant other than approved compacting equipment shall run over or operate within the trench until backfilling has reached its final level or the approval of the Engineer In-charge has been obtained.

Subsidence in filling in: Should any subsidence take place either in the filling of the trenches or near about it up to completion of the Contract Works. The Contractor shall make good the same at his own cost or the Engineer may make good the same in any way and with any material that he may think proper, at the expense of the Contractor. The Engineer In-charge may also, if he anticipates occurrence of any subsidence, employ persons to give him timely notice of the necessity of making good the same, and the expenses on this account shall be charged to the Contractor.

19.17 Sand Bedding

The sand bedding of minimum 300 mm thickness & level shall be provided below pipe, prior to laying the pipe in trenches. It shall be compacted with a light hand rammer. Any reduction in thickness due to compaction shall be made up by adding sand during ramming.

Sand used for bedding below pipes shall be confirming to requirements of IS 383-1970 of grading zone – I & II combined. Gradation of sand used for pipeline bedding should be as below.

IS Designation Percentage passing

10 mm 100 %

4.75 mm 90 – 100 %

2.36 mm 60 – 100 %

1.18 mm 30 – 90 %

600 Micron 15 – 59%

300 Micron 5 – 30 %

150 Micron 0 – 10 % Limit Range for F.M. of Sand: 2.11 to 4

Sand shall not contain any harmful material such as pyrites, coal, lignite, mica, shale, or similar laminated material , clay, alkali, soft fragments sea shells and organic impurities. Deleterious material in sand shall satisfy requirements of I.S. 383-1970. Silt



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content shall not be more than 3%. Total deleterious finer than 75 micron shall not be more than 5 % (including silt content) for uncrushed natural sand.

If, sand is not available within 50 km lead, the contractor may use cone crusher at site to make sand from excavated rock. Sand grading for crushed sand shall confirm to relevant IS specification for sand.

Tests specified for determining silt in sand & organic impurities as described in IS: 383 shall apply. Sieved sand shall be stored on the works in such a manner as to prevent intrusion of any foreign matter, including coarser particles of sand or any clay or metal or chips. Tests as indicated above shall be performed if called for by the Engineer at the expense of the contractor.

During the work of providing sand bedding and laying the pipeline over it, loose material from the sides or edges of the trench shall be prevented from falling inside the trench, by providing shoring and taking other measures.

19.18 Distance indicators and Markings

The Contractor shall supply and fix indicators at all points of change of direction, at all valves and at every one kilometre intervals along the buried pipe line. Indicators shall consist of 10 cm x 10 cm pre-cast concrete posts 1.25 metre long, set 0.75 metre into the ground and painted white above ground level. The description shall be written in blue at one face of the pre-cast post.

In case of the pipeline laid above ground details such as chainage, Invert levels of pipe, appurtenance number, pedestal / saddle number, culvert number, anchor / thrust block number etc., shall be suitably marked either on the pipeline or the supporting structure etc., in distinct colour. The Contractor shall include the cost of this in his rates for the other items.

19.19 Temper Proof Air Valve with isolation Sluice Valve with M.S. Shaft minimum 5.0 m long

The C.I. temper proof valve shall be proposed at a distance not more than 200 to 250 m and / or near each peak point as per requirement and good engineer practice so as to allow easy escape and inlet of during filling and empting of pipeline. Detail specifications for material of this item are furnished in Mechanical specification. The item also includes the cost of MS pipe as a shaft for minimum 5 m. long. Steel pad of 750 mm x 750 mm x 12 mm thick, stiffener RCC encasing around MS pipe in M-20, including painting the MS pipe, pad, stiffener with 3 LPE coating or 1000 micron thick epoxy paint.

The CI temper air proof are to be erected as per drawing.



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This item includes

1. Designing and Constructing of Pedestal including excavation, concreting,

reinforcement, anchor strip/rod, etc. completed.

2. Procurement, Supply, Transportation, Lowering, Laying & Jointing MS

Casing Pipe lined with Cast basalt including hydraulic testing, trial run etc.

complete.

3. Procurement & Installation of Specials such as Bend, Tee, Reducer, Flange

Tail Piece, Saddle Piece etc. as per requirement.

4. Designing and Constructing of all crossing structure including all activity

etc. completed

5. Designing and Constructing of thrust block

6. Flow diversion arrangement

20.1 General Technical Specifications:

This items including all activity for pipe laying from pumping station to Dykes with multi discharge point in dykes in all manners.

20.2 Designing and Constructing of Pedestal

a) As per site situation & arability of space select the pedestal type

b) some types of pedestal are shown in Typical drawings.

c) This This item includes excavation, concreting, reinforcement, anchor strip/rod,

including all materials, labour, etc. complete.

20. Technical Specifications for MS Casing Pipe lined with Cast Basalt



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20.3 Procurement, Supply, Transportation, Lowering, Laying & Jointing MS Casing Pipe lined with Cast basalt including hydraulic testing, trial run etc. complete

This This item includes Procurement, Supply, Transportation, Lowering, Laying & Jointing MS Casing Pipe lined with Cast basalt including hydraulic testing, trial run etc. complete

All pipes shall be of tested quality as per IS-3589

a) The raw material shall also be of Tested quality.

b) These pipes shall be used for conveying Ash Slurry.

c) Ash Slurry disposal pipe shall be 350 NB cast basalt pipes. The casing MS ERW steel

pipe confirming to IS 3589, 6 .0 mm wall thickness. Cast Basalt lining thickness shall

be 20 mm. Cement Mortar between pipe and cast basalt pipe may be 8 -10 mm

thickness.

d) Fittings shall be 20 mm thick Cast basalt MS fittings (MS shell of min 6 mm thickness)

e) Cast Basalt:-

i) Hardness=8 mhos

ii) Bending Strength= Minimum 300 Kg/cm²

iii) Compressive strength : Minimum 4500 Kg/cm2

f) Type of Joints:-

i) Cast Basalt Fittings: Sleeve type coupling joint at an interval of approximately

40 meters in straight length.

ii) flanged joints at fittings, bends, Y – pieces etc.

iii) Flanged joints in pipe at every 6 mtrs.

h) Coupling should be provided at every 18m & remain joint are sleeve welded.



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i) for MS casing pipe detail item specification as above 3.0

20.3.1 Inspection & Testing: a) Cast Basalt liners shall be tested for Chemical & Mechanical properties.

b) Basalt liners shall be examined visually for detection of Cracks & defects.

c) Level difference between two cast basalt liners shall be minimum.

d) The Hydraulic pressure testing at shop for M S ERW pipe shall be as per IS: 3589

with no leakages.

e)These pipes will be inspected and tested as per IS-3589 by GSECL representatives at

manufacturer’s works.

20.3.2 Detail Specification of MS Casing Pipe lined with Cast Basalt pipe : 1 ITEM MS Casing Pipe lined with Cast Basalt pipe

2

CB ID

MS OD

356

426

3 CASING 6mm thick. M.S. Fabricated Pipe / Spiral Welded

Pipe confirming to IS-3589 Grade : Fe 410

4

CAST BASALT LINERS

Physical Properties



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Density

Hardness

Compressive Strength

Water Absorption

Bending Strength

Abrasion Resistance

Friction

2.8 - 3.1 gm/cc

8 on Moh’s Scale (Min.)

4500 Kg/cm2 (Min.)

0.5 % (Max.)

300 kg/cm2 (Min.)

0.7 mm Max. [As per IS1706]

Reduce Progressively as it acquires high polish.

1. Cast Basalt Permissible Tolerance

ID

Thickness

+/- 3 mm

+/- 1 mm

5 GROUT Mortar

6

END CONNECTIONS Flanged

ID

OD

PCD

NO. of Holes

Hole Dia

Flange Thk

429 mm

597 mm

540 mm

16 mm

28.6 mm

30 mm

7 FLANGE MATERIAL M.S. as per IS-2062 / equivalent

8 OUTSIDE PAINTING

Two coats of Red Oxide and Two coats of epoxy

based Anti-corrosive Paint

Shade: Smoke Grey



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9 Length of pipe Minimum 5m

20.4 Procurement & Installation of Specials such as Bend, Tee, Reducer, Flange Tail Piece, Saddle Piece etc. as per requirement

This items includes procurement & Installation of Specials such as Bend, Tee, Reducer, Flange Tail Piece, Saddle Piece etc. as per requirement.

i) Cast Basalt Fittings: Sleeve type coupling joint at an interval of approximately

40 meters in straight length.

ii) flanged joints at fittings, bends, Y – pieces etc.

iii) Flanged joints in pipe at every 6 mtrs.

iv)Coupling should be provided at every 18m & remain joint are sleeve welded.

v)for MS casing pipe detail item specification as above 3.0

vi)Fittings shall be 20 mm thick Cast basalt MS fittings (MS shell of min 6 mm

thickness)



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21.1 Pipe Pushing Method For Road

21.1.1 Scope

The scope of item includes following:

30. Preparing the required drawings & to get the permission / approval for lowering, laying & jointing pipeline below State Highway / National Highway / Major District Road under the supervision of the concerned authority & also obtaining completion certificate from the authority after completion of work. Department will sign the necessary papers related to the work as per requirement. All the statutory charges, other charges, expenditure, etc. for crossing are to be paid by the contractor. However, if the concerned department / authority insists to pay such statutory charges through owner, such charges will be paid by the owner & the such amount paid will be adjusted / recovered from the contractor in next bill.

31. Drilling horizontal bore & providing, fixing MS casing pipe with welding, etc.

complete. 32. Constructing temporary R.C.C. thrust block & base concrete as per requirement

for facility of pushing the pipeline and dismantling the same on completion of work.

33. Fixing of pipe.

34. Sealing the both ends of pipe with construction of brick work including C.C 1:3:6.

The contractor shall also refer the Clause no. 22 (Point no. 6) and Clause no. 80 of Volume-II in regards to the works of crossings (pipe pushing) and its structures.

21.1.2 General Technical Requirements

35. Casing pipe shall be of mild steel. These pipes shall be fabricated as per IS: 3589 and/or IS: 5504 from steel plates/HR coil conforming to IS: 2062. The casing pipe

21. Technical Specifications for Pipeline Crossings & Surge Control System



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shall be designed for MBG loading standard or any other current loading standard as defined in IRS Bridge Rules

36. The field welds (of casing pipe) shall be tested cent percent radio-graphically as per IS: 1182

37. The diameter of casing pipe & minimum thickness of the casing pipe to be provided shall be as per the approval from the concerned authority.

38. For insertion of a casing pipe, boring shall be carried out by auger type boring device with cutting head to drill a horizontal bore. The hole drilled shall be of suitable size to accommodate casing pipe. The casing pipe shall be inserted along with boring to keep the formation supported to prevent any settlement of the existing structure. The casing pipe will be installed with even bearing throughout its length. The work will be done under the supervision of the concerned authority under suitable speed restrictions & precautions as may be stipulated by the authority.

39. The casing pipe will be minimum 1.2 M below the formation level and 0.9 M below the natural ground level. The length of casing pipe shall be upto the end of SH/NH land boundary to accommodate future requirements. Casing pipe shall be provided with minimum 50 mm dia vent pipe MS or CI. Bottom and side rollers of suitable size are to be provided inside casing pipe at 4 M interval to facilitate insertion of carrier pipe of required diameter. The ends of casing pipe shall be suitably sealed.

40. Care shall be taken to isolate the pipeline crossing installation from aerial electrical wires & shall be suitably insulated from underground conduits carrying electrical wires.

41. The pipeline shall be tested for specified test pressure to check for leakage. 42. To protect casing pipes as well as carrier pipe against corrosion, following action

will be taken: a. Outer surface of casing pipe will be painted with a coat of zinc rich epoxy primer

of thickness 4 mils. b. Inside surface of casing pipe shall be painted with high build epoxy to RDSO

specification No. M&C C/PCN/111/88 to a dry film thickness of 250 micron. c. Suitably 3 roller supports at 4 M interval of steel pipe shall be welded spacers of

high density polyethylene or either similar material shall be installed in between the carrier & casing pipe to prevent carrier pipe forming metallic contact with casing pipe.

43. The alignment of the pipeline shall be so decided that it crosses the highway nearest to right angle.

44. These special conditions and the schedule of work shall govern the work to be executed under this contract in addition to and / or in part super session of the General Conditions of Contract & Standard Specifications.

In order to avoid interference to road traffic excavation on existing road intercepted on pipeline alignment, PIPE PUSHING technique is envisaged in preference to any other conventional methods for the laying of pipeline through such road particularly for State Highway / National Highway / Major District Road crossing intercepted.



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The MS pipe shall be as per detailed specifications given in this volume.

21.1.3 Scope also covers

45. Shifting of service lines and reinstating the same 46. Demolishing all types of R. C. C., masonry work 47. Pumping / Bailing out water etc. if required.

No extra payment shall be made for dewatering when any work is done below water level.

The rate quoted by the Contractor shall be deemed to include diversions, bunds, approach road to the site of work etc. and such other works, necessary for setting out and execution of works in different phases as ordered by the Engineer and / or his representative. No extra payment shall be made for such works or any other phase works carried out which are necessary for satisfactory execution of work.

Any timbering work required to be done for retaining earth during excavation of foundations will have to be arranged by the contractor which shall conform to the provision laid down in the relevant specifications & IS codes.

The working area may be water logged during monsoon or any untimely rains. Contractor should take the special note while preparing the program schedule for this work. Contractor should also specify the method which they propose to avoid water logging in the working area, however it may be clearly noted that bailing out / pumping out shall not be payable.

The rate is basis for specified length as per detail description in the item. However, during execution as per site condition, if the length of pushing is increased / decreased the excess or reduce payment will be adjusted according.

21.2 Pipeline markers

21.2.1 Intent

This specification covers the minimum requirements for supply, fabrication and erection of pipeline markers to be installed at various locations along the pipe route.

Following two (2) types of pipeline markers are proposed for the transmission mains. i. Pipeline Warning Signs ii. Kilometre Markers



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The pipeline markers shall be installed, as far as possible, at locations where no hindrance to the regular use of the land or to the traffic is caused.

21.2.2 Pipeline Warning Sign

Pipeline warning signs shall be generally installed at the following crossings: � Roads (excepting cart roads & kuchha roads) � Rivers � Nallahs

Pipeline warning sign will indicate existence of the buried pipeline at the crossing and display the name address of the client, name of the project and telephone number (for contact in case of emergency).

For the rest of the crossings as mentioned above, the warning signs shall be generally installed at a distance of 50 M on the upstream side only.

The warning sign shall be located 500 mm to the left of the pipe outside diameter, viewing in the direction of flow and shall face the item being crossed (i.e. road, river, rail track etc).

21.2.3 Kilometre Markers

Kilometre markers shall be installed along the pipe route at every one Kilometre interval. Markers will display the distance (in full kilometre) from the upstream pumping station (in case of rising mains) or upstream reservoir (in case of gravity mains) and name of the client. Kilometre markers shall be located 500 mm to the left of the pipe centreline viewing in the direction of flow.

21.2.4 Scheme of Painting

The underground steel structure except that embedded in concrete shall be painted with coal tar epoxy of minimum 300 micron DFT. For over ground steel structure, one coat of primer & two coats of colour paint shall be applied.

Colour scheme to be adopted for the markers shall be subject to Employer’s approval. Following colour scheme is proposed for reference:

Warning Sign

iii. (All letters shall be painted black except for the word “Warning” which shall be painted red. Background colour shall be yellow.

iv. (Post shall be painted with 250 mm wide alternate bands of black & white paint. v. All above ground steel structure shall be painted yellow.



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Kilometre

Markers

vi. All above points for warning sign shall be equally applicable for Kilometre markers also.

vii. Figures shall be stencilled on both sides of the post.

21.2.5 Language

Pipeline warning sign plates & kilometre markers shall be prepared in regional language in line with guideline for providing information as above & shall be approved by the client.

21.3 Thrust Block and Anchor Block

RCC thrust blocks of adequate size and shape in required grade shown in the drawing shall be provided on bend for anchorage as per design requirement to transmit the hydraulic thrust / force to the ground, spreading over a sufficient area, depending upon the type of soil met with.

Thrust blocks shall be provided for both horizontal and vertical bends wherever required in the pipeline to effectively transfer the hydrostatic thrust developed to the surrounding ground.

21.4 Encasing Pipeline

Encasing of pipeline with the reinforced concrete of desired grade as shown in the drawing shall be done as per design requirement wherever adequate cover on pipeline is not available as per site condition. Encasing of pipeline shall also be done for all the nallah crossing/River crossing/minor road crossings as per indicative drawing and to the design requirement and as directed by the Engineer In-charge.

21.5 Arrangement for Traffic During Construction

21.5.1 General

The Contractor shall at all times carry out work on the roads in a manner creating least interference to the flow of traffic while consistent with the satisfactory execution of the same. For all works involving improvements to the existing roads, the Contractor shall, in accordance with the directives of the Engineer in-charge, provide and maintain, during execution of the work, a passage for traffic either along a part of the existing carriageway under improvement, or along a temporary diversion



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constructed close to the road. The Contractor shall take prior approval of the Engineer in-charge regarding traffic arrangements during construction.

21.5.1.1 Passage of Traffic along a part of the Existing Carriageway under Improvement

For widening/strengthening existing carriageway where part width of the existing carriageway is proposed to be used for passage of traffic, treated shoulders shall be provided on the side on which work is not in progress. The treatment to the shoulder shall consists of providing at least 150 mm thick granular base course covered with bituminous surface dressing in a width of at least 1.5 m and the surface shall be maintained throughout the period during which traffic uses the same to the satisfaction of the Engineer In-charge. The continuous length in which such a work shall be carried out, would be limited normally to 500m at a place. However, where work is allowed by the Engineer in-charge in longer stretches passing places at least 20 m long with additional paved width of 2.5 m shall be provided at every 0.5 km interval.

After obtaining, permission of the Engineer In-charge, the treated shoulder shall be dismantled, the debris disposed off and the area cleared as per the direction of the Engineer In-charge.

21.5.1.2 Passage of Traffic along a Temporary Diversion

In stretches where it is not possible to pass the traffic on part width of the carriageway, a temporary diversion shall be constructed with 7 m carriageway and 2.5 m earthen shoulders on each side (total width of roadway 12 m) with the following provision for road crust in the 7 m width:

� 200 mm (compacted) granular sub base; � 225 mm (compacted) granular base course; and � Premix carpet with Seal Coat/Mix Seal Surfacing.

The alignment and longitudinal section of diversion including junctions and temporary cross drainage provision shall be as approved by the Engineer In-charge.

21.5.1.3 Traffic Safety and Control

The Contractor shall take all necessary measures for the safety of traffic during construction and provide, erect and maintain such barricades, including signs, markings, flags, lights and flagmen as may be required by the Engineer In-charge for the information and protection of traffic approaching or passing through the section of the highway under improvement. Before taking up any construction, an agreed phased programme for the diversion of traffic on the highway shall be drawn up in consultation with the Engineer in-charge.



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The barricades erected on either side of the carriageway/portion of the carriageway closed to traffic, shall be of strong design to resist violation, and painted with alternate black and white stripes. Red lanterns or warning lights of similar type shall be mounted on the barricades at night and kept lit throughout from sunset to sunrise.

At the points where traffic is to deviate from its normal path (whether on temporary diversion or part width of the carriage way) the channel for traffic shall be clearly marked with the aid of pavement markings, painted drums or a similar device as per the directions of the Engineer in-charge. At night, the passage shall be delineated with lanterns or other suitable light source.

One-way traffic operation shall be established whenever the traffic is to be passed over part of the carriageway inadequate for two-lane traffic. This shall be done with the help of temporary traffic signals or flagmen kept positioned on opposite sides during all hours. For regulation of traffic, the flagmen shall be equipped with red and green flags and lanterns/lights.

On both sides, suitable regulatory/warning signs as approved by the Engineer in-charge shall be installed for the guidance of road users. On each approach, at least two signs shall be put up, one close to the point where transition of carriageway begins and the other 120 m away. The signs shall be of approved design and of reflectory type, if so directed by the Engineer in-charge.

21.5.1.4 Maintenance of Diversions and Traffic Control Devices

Signs, lights, barriers and other traffic control devices, as well as the riding surface of diversions shall be maintained in a satisfactory condition till such time they are required as directed by Engineer in-charge. The temporary travelled way shall be kept free of dust by frequent applications of water, as directed by the Engineer in-charge.

21.6 Surge control system for pumping main

21.6.1 Accepted Control System

48. Following types of control systems are only accepted for control of water hammer pressures in the pumping mains. a) Zero Velocity Valves and b) Air Cushion Valves

49. The contractor has to submit the design of surge protection device and get approved by Engineer In-charge. Water hammer control devices shall be procured only after approval of the design as per design requirement.



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21.6.2 Water Hammer Control Devices

21.6.2.1 Specification for Zero Velocity Valve

Body: The Spring Loaded self-actuating Zero Velocity valve has an outer fabricated casing ('Main Body') in which a 'Central Rod' is held by struts. In order to create an annular flow the included angle of the cone at upstream of the disc should be 75-100° and the cone at downstream of the cone should be 20-35°. The barrel at inlet and outlet of the valve should suit the pipe diameter. The entry barrels should have minimum length of 900-1000 mm, while the exit barrel should be minimum 500-650 mm long for the ease of installation. The total length of the valve should not be less than 3800 mm.

The valve should be provided with 1 (One) No. of Manhole of internal dia 450 mm (min) on exit cone to facilitate attending the valve. A suitable cover shall be provided on manhole.

Two Bypass pipe with a Valve of 300 NB connecting upstream and downstream sides of valve should be provided. Minimum two plugs should be provided to mount Pressure gauges at the upstream and downstream of the valve.

Adequate transportation saddle should be provided on the valve as an integral part of the valve.

Internal: Closing Disc is mounted on 'Central Rod' cladded with Stainless Steel (SS as per AISI304) for the adequate length so that the disc moves on the cladded portion. Bush of the disc should be lined securely with Brass sleeve (minimum 3 mm thick) for smooth sliding of the disc.

Disc is held in closed position by a adequate number of 'Stainless Steel Springs' (SS as per AISI304). The anti-rotation guides should be provided on the edge of 'Central Disc' with minimum resistance to flow and minimum possibility to lock during sliding of the disc. The 'Anti Rotation Guide' should be claded with Stainless Steel Strip (SS as per AISI304) and 'Guide Fork' lined with brass liners. The valve should be provided with a 'Stationary Central Dome' to create an annular streamlined passage for smooth flow of water.

Painting: The Valve will be painted in Zinc Rich Epoxy Paint from outside and food grade epoxy from inside both in min two layers with total thickness of 406 microns.



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Material of construction of principal parts:

Sr No Items Material

A Entry Barrel Shell and Cone

MS IS:2062 -250 BR Fe. 410W A

B Exit Barrel Shell and Cone

C Lap Ring

D Guide Dome

E Central Shaft (S.S. 304 Lined)

F Spring SS 304

G Bypass Pipe Carbon Steel IS 1239 (part-I) /

ASTM 106 B

H Bush for Disc (With Brass inner

Bush) MS IS:2062 -250 BR Fe. 410W A I Bush for supporting ribs

J Hand Hole

Inspection and Testing:

The Zero Velocity Valves shall be subjected to Hydrostatic body test by applying the rated pressure for the hydrostatic test. Both the ends (upstream and downstream) of the valve shall be closed using the dish/dummy ends. In case of more than one valves of same size and pressure rating, the valves can be joined together from barrel (or bolted in case of flange ended valves). The Bypass pipe along with valve will be mounted the zero velocity valve. The bypass valve shall be kept in open condition during the testing. A pressure gauge shall be mounted on the Zero Velocity Valve to check the applied hydrostatic test pressure.

The ‘Test pressure’ specified shall be applied using the hand pump or motor pump for a duration of 15 (fifteen) Minutes. No water leakage is permissible through the main body of the zero velocity and bypass valve during the above period..

21.6.2.2 Specification for Air Cushion Valve

The valve consists of a 'Main Body' and 'Top Housing'. On the side of main body, two 'Air Inlet Valves' loaded with a light spring are fitted. The 'Inlet' is protected by a cover. The 'Top Housing' has an opening for air escape. A spring loaded 'Poppet' with a brass seat and Neoprene 'Sealing Ring' covers the top of the opening. The spring



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pressure on the valve is adjustable by a screw (S.S. as per AISI-304). The 'Housing' has a tapered outlet, the opening of which is adjustable by a tapered plug and Screw (S.S. as per AISI- 304). The outlet is protected by a cover. On its lower side a cage holding a ball float is fitted. 'Main Body', 'Top Flange', are fabricated from M.S. (as per I.S.2062/I.S.1239 Part I & II). The 'Top Housing' is made from high grade cast iron. Main body, float ball and air inlet flange are hydraulically pressure tested. Stems of valves are in stainless steel (as per AISI-304), and work in 'Brass Bushes'. Sealing rings are of good quality rubber and seats are of brass The Valve will be painted in Zinc Rich Epoxy Paint from outside and food grade epoxy from inside both in min two layers with total thickness of 406 microns.

All branched outlets including outlets for Air valves will be with compensation pads (Dia of Main / For branch Dia ratio greater than 3). Diameter of compensation pad will not be less than 1.75 times the O.D. of the branched outlet. Plate thickness for pads will be same that of the main.

For outlets with above ratio less than three, then the joints will be of plate reinforcement type.

All branched outlets including air valve, tees will be provided with one ½”BSP coupling duly plugged for measurement of pressure in due course. The closing plug will be in Stainless Steel (AISI 304 or equivalent) with Hex. Head and will be provided with copper washer for sealing.

All flanges will be drilled as per I.S. 1538. Thickness of all flanges will be as per I.S.

Thickness of pipes Strength of steel pipes is verified to check effect of positive and negative pressures during transients due to power failure and surge protection devices shall be provided to avoid any damage to the pipeline integrity, shape and structure.

21.6.3 Surge Control System - Requirements

50. The requirements given are tentative. The contractor must carry out the surge analysis based on the Longitudinal section, Pump and Motor characteristics of the selected pumps by the contractor.

51. During detailed engineering following information must be submitted based on

the Surge Control System’ selected by the contractor.

For design of surge control system following limits will be adhered to (The surge pressures will be estimated after all working pumps at designed discharge, trip simultaneously)



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a. Maximum upsurge anywhere in the system will not exceed 10.0 Kgf/cm2 or 1.2 times the Normal Working Pressure at manifold whichever is lower.

b. The lowest pressure (Minimum Down surge) anywhere in the system will not be lower than (-) 0.4 Kgf/cm2 (i.e @ 0.6 Kgf/cm2 above absolute zero) (Only 50% of the installed air valves can be assumed as operative for this condition.).

c. The contractor will submit Surge analysis without any control system to ascertain the requirement of surge control system and the results along with details will be submitted during detailed engineering in case of award of contract.