tender. no. tata consulting engineers … no... · - design calculation for operating and...

TENDER. NO. TCE.6758A-B-300-002

TATA CONSULTING ENGINEERS LIMITED SECTION: Title

Master Index SHEET i OF i

ISSUE

R0

BHARAT PETROLEUM CORPORATION LIMITED

REQUEST FOR QUOTATION

NIT No. 6758A-TCE/BPCL-RFQ-002

RFQ NO: TCE.6758A-B-300-002

BUTANE PRE HEATER

Owner : BHARAT PETROLEUM CORPORATION LIMITED

Project : BLENDING UNIT

Location : URAN, MUMBAI (INDIA)

Job No. : TCE.6758A

TATA CONSULTING ENGINEERS LIMITED RAJ PLAZA, 2ND FLOOR, L.B.S. MARG, VIKHROLI (WEST)

MUMBAI – 400 083. INDIA. TEL 91-22-66472111 Fax 91-022-66472000

EMAIL: [email protected]

NIT NO. 6758A_TCE/BPCL_RFQ_002 of 118

mailto:[email protected]



Master Index SHEET i OF iii

ISSUE

R0

MASTER INDEX

TO

BIDDING DOCUMENT FOR BUTANE PRE HEATER

BHARAT PETROLEUM CORPORATION LIMITED, URAN, MUMBAI

(BIDDING DOCUMENT NO: TCE-6758A-B-300-002)




Master Index SHEET ii OF iii

ISSUE

R0

PART – I: GENERAL & COMMERCIAL

SL. NO.

SPECIFICATION NO. REV NO. DESCRIPTION NO. OF SHEETS

1. Acknowledgement & Intention To Bid (to be sent immediately after down loading of the tender)

2

2. TCE.6758A-B-300-002 R0 Instructions To Bidders 28

3. TCE.6758A-B-300-002 R0 Bidder‟s Qualification Criteria 1

4. TCE.6758A-B-300-002 R0 Concurrent Assignments and Experience list

2

5. TCE.6758A-B-300-002 R0 Deviation List 2

6. TCE.6758A-B-300-002 Integrity Pact 4

7. TCE.6758A-B-300-002 R0

ANNEXURE-I TO SPC Scope of Work

2

8. TCE.6758A-B-300-002 R0

ANNEXURE-II TO SPC Scope of Supply

3

9. TCE.6758A-B-300-002 R0 Quality Management System 6

10. TCE.6758A-B-300-002 R0 General Purchase Conditions 36

11. TCE.6758A-B-300-002 R0 Special Purchase Conditions 11

12. TCE.6758A-B-300-002 Approved Vendor List 8

13. TCE.6758A-B-300-002 R0 Commercial Questionnaire 10

14. TCE.M4-903 R5 Drawings, Engineering Documents and Instruction Manuals

6

15. TCE.M4-907 R7 Spares and Maintenance Tools and Tackles

2

16. TCE.M4-914 R7 Progress Schedule and Reports 3

17. TCE.6758A-954 R0 Schedule of Distribution of Drawings and Documents

2

18. TCE.6758A-B-300-002 R0 Performance Guarantee Parameters 3

19. TCE.6758A-B-300-002 R0 Schedule Of Price 5




Master Index SHEET iii OF iii

ISSUE

R0

PART II - TECHNICAL SL. NO. SPECIFICATION NO. REV NO. DESCRIPTION NO. OF

SHEETS

1. TCE.6758A-B-300-002 R0 Technical Specification - Process 17

2. TCE.6758A-300-SK-8602 R0 Schematic Diagram of Butane Pre Heater 1

3. TCE.6758A-B-300-002 R0 Data sheet for Butane Pre Heater 1

4.

TCE.M4-203-51 R4

Write-up on Induction motors for Hazardous area Data Sheet A1 Data Sheet A2 Data Sheet B Data Sheet C

7 5 3 2 1

5.

TCE.M4-203-71 P0

Variable Speed AC Drives Data Sheet A1 Data Sheet A2 Data Sheet A3

2 6 1

6. TCE.6758A-300-PP-1551 R0 Piping Material Specification 3

7. TCE.6758A-B-300-001 R0 Painting Specification 3

8. TCE.6758A-104-02 R0 Thermal Insulation for Cold Surfaces Insulation data sheet

7 2

9. TCE.6758A-134-01 R0 Welding Specification for Piping Systems 24

10. TCE.M4-405-01 R5 Supply and Fabrication of Structural Steel 12

11. TCE.M4-904 R9 Shop Inspection and Tests 7

12. TCE.6758A-SE-800 R0 Shop Inspection requirement for Air Cooled Heat Exchangers 9


SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION:

TCE.6758A-B-300-002 SHEET OF 4

ISSUE R0

PART II


TCE.6758A-300-B-002

TATA CONSULTING ENGINEERS LIMITED SECTION: WRITE UP

TECHNICAL SPECIFICATION SHEET 1 OF 17

Table of Contents

1. GENERAL INFORMATION…………………………………………………………….2

2. METEROLOGICAL DATA…................................................................................2

3. PROCESS DESCRIPTION…..............................................................................2

4. EQUIPMENT SPECIFICATIONS…...........................................................................................3

5. INSPECTION AND TESTING…..........................................................................3

6. GUARANTEE…...................................................................................................3

7. PERFORMANCE GURANTEE….........................................................................4

8. SCOPE OF SUPPLY…........................................................................................4

9. EXCLUSIONS FROM VENDOR’S SCOPE OF SUPPLY…................................8

10. INSTRUCTIONS TO BIDDER…..........................................................................8

11. APPROVED LIST OF VENDORS…....................................................................10


TCE.6758A-300-B-002



12. 1. GENERAL INFORMATION

12.1. Item No. : 10E005A & 10E005B

12.2. Project : Propane & Butane Blending

12.3. Customer : Bharat Petroleum Corp. Ltd.

12.4. Location : Uran, Maharashtra

12.5. Supplier : By vendor

12.6. Model No. : By vendor

12.7. Quotation No. & Date : By vendor

2. METEROLOGICAL DATA 2.1. Site Altitude : 7.5 m above Mean Sea Level

2.2. Seismic Zone Factor : ZONE IV

2.3. Seismic Coefficient : 0.05

2.4. Ambient Temperature : 10ºC (min), 40ºC (max)

2.5. Barometric Pressure : 1.02 kg/cm²a (min), 1.04kg/cm²a (max)

2.6. Design Wet Bulb Temperature: 29ºC

2.7. Relative Humidity : 60% (min). 95% (max)

2.8. Rainfall : 408 mm in 24 hours (Daily Maximum) Design Hourly Rainfall Avg. 2000 mm (3 months – mid June to mid Sept)

2.9. Wind : 50 m/s (Design Wind Load)

3. PROCESS DESCRIPTION Liquid Butane at (-) 4 degree C from Butane Storage Tank shall be pumped (using Butane Transfer Pump) through Butane Preheater (10E005A or B whichever is in operation) to heat Butane from (-) 4 deg C to a temperature of 15 deg C to be blended with propane and loaded into tanker. This preheater shall be located in open area. The Butane shall be heated using forced draft of air. Vendor shall provide required number of fans to blow air on the preheater side with VFD.


TCE.6758A-300-B-002



4. EQUIPMENT SPECIFICATIONS

Design Code – ASME Section VIII Div I, API-661, Latest Edition

Material of Construction:

Material Standard Specifications Tubes SA 213 TP 304 ASME By Vendor

Fins SB 209 ALLOY 1060 (Aluminum)

Dimension: By Vendor Fin Pitch: By Vendor Bond Type: Tension wound Wrapped L. Fin Frequency: By Vendor

Header SA 240, Type 304 ASME

Dimension: By Vendor Flange: 300 # RF Type: Plug Type Conn. Tube: Expanded & Seal welded Sht: SA 240 Gr. 304 Gasket: SS 304 spwd Corr. Allowance: 0 mm

Nozzle Pipes on tube side Headers

SA 312 Type 304 ASME Inlet Nozzle: By Vendor

Outlet Nozzle: By Vendor

Nozzle Flange on tube side SA 182 Type 304 ASME 300 # RF

Inlet line size: 200 mm (MOC – LT CS) Outlet line size: 200 mm (MOC – LT CS)

5. INSPECTION AND TESTING: 5.1. Vendor to submit Q.A. Plan for approval by TCE. All Inspection & Testing will

be carried out as per Approved QAP.

5.2. Material Test Certificates.

5.3. Following Tests shall be carried out at the works: - Checking of X-Ray report. - D.P. Test - Ultrasonic Test - Final Hydro test/ Pneumatic Test - Dimensional Checking

For detailed QAP refer to TCE.6758A-SE-800 R0

6. GUARANTEE: 6.1. Vendor shall guarantee the performance of Butane preheater against all defects

including Thermal Rating & Mechanical Design for a period of 12 months from the date of commissioning or 18 months from the date of supply whichever is earlier. Should any defect in design material, workmanship develop during the first year of operation, but not later than 18 months from the date of delivery, the supplier agrees to make all the necessary or desirable repairs or replacement of the defective equipments free of charge.


TCE.6758A-300-B-002



6.2. Vendor shall guarantee the performance of the Butane Preheater. - Thermal & Mechanical Design - Total Power Consumption in kWh: At Design Duty. - Equipment vibration level: As per clause No. 7.32 (Vibration Testing) of API 661

7. PERFORMANCE GUARANTEE 7.1. Performance test will be carried out at site. 7.2. Outlet temperature of Butane at the exit flange of Butane Pre-heater shall be

15 °C ± 2 °C at the design flow rate given in the data sheet. 7.3. Power Consumption.

8. SCOPE OF SUPPLY / WORK: Butane Pre-heater: 2 Nos. (1 working and 1 standby) as per attached datasheet.

The Vendor's scope of supply / work shall be, but not limited to, Thermal design, Complete mechanical & structural design, Detailed Engineering and preparation of fabrication drawings, Fabrication, Supply, Transportation. Supervision services for Erection, Pre-commissioning and Commissioning for Butane Air Preheater 10E005A & B with fans, and associated structures (bolted type) to site of M/s Bharat Petroleum Corporation Ltd. Uran.

8.1. DESIGN & ENGINEERING:

8.1.1. Thermal and Mechanical Design, design code calculations, structure design of Pre Heater and associated auxiliaries including detailed engineering.

8.1.2. Detail Engineering includes:

Preparation / completion of data sheets (with graphs & scale drawings wherever applicable) for:

- Pre Heater

- Fans

- Motors & VFD

- Vibration switches

- Temperature transmitter (with field indication) with RTD and Thermowell at inlet and outlet of Butane Pre-heater.

- Thermocouple to measure the skin temperature of fins, 2 no. of RTD with temperature transmitter per bundle along with integral display with mounting facility on fin.


TCE.6758A-300-B-002



- Structural design of columns, frames, operating and maintenance platforms

along with staircase (cage ladder is not acceptable).

8.1.3. Engineering Calculations

- Thermal Design

- ASME Code (Mechanical Design) Calculations

- Seismic Force & Wind Load Calculations

- Design calculations for structural including tube bundle frame

- Design calculation for operating and maintenance platform along with staircase (Cage ladder is not acceptable).

- Lifting and Tailing Lug Calculations

- Nozzle External Forces & Moment Analysis

- Belt Selection Calculation

8.1.4. Drawings:

8.1.4.1. Detailed fabrication drawings of bundle and frame including tube bundle drawing with material specifications stating all thickness, dimensions, component details, actual corrosion allowance available, amount of increased header thickness if used for nozzle reinforcement, all the main welds, nozzle locations and orientation, internals, accessories and tube to tube sheet joint details.

8.1.4.2. General arrangement of Air Fin Coolers shall indicate the major dimensions, maintenance, space required, weight of heaviest maintenance item to be lifted etc.

8.1.4.2. Structural drawings of columns, frames, operational and maintenance platforms along with staircase (cage ladder is not acceptable).

8.1.4.3. Foundation drawings and Foundation load data.

8.2. MATERIAL SUPPLY:

8.2.1. Tube bundles including tube bundle guards, nozzles, plenum chambers.

8.2.2. Headers


TCE.6758A-300-B-002



8.2.3. Fan Assembly along with Motors and it's mounting including the

interconnection like belt/couplings and control switches, vibration cut out switches. Variable Speed drives have been included in Vendor’s scope.

8.2.4. Complete supporting arrangement (bolted type) including supporting structure/column, operating and maintenance platforms along with staircase (Cage ladder is not acceptable), handrails and any other part not stated here but required for performing the intended service.

8.2.5. All foundations bolts, shims, embedded parts for all equipment.

8.2.6. All necessary blind flanges along with stud/bolt, nuts and gaskets, cl ips and spares.

8.2.7. Name plate and earthing connections.

8.2.8. Cleats for Fire proofing of all structural members as per OISD norms.

8.2.9. Vibrating switches for fan motors.

8.2.10. Thermocouple to measure the skin temperature of fins, 2 no. of RTD with temperature transmitter per bundle along with integral display with mounting facility on fin.

8.2.11. Temperature transmitter (with field indication) with RTD and Thermowell at inlet and outlet of Butane Pre-heater.

8.2.12. Interconnecting piping and isolation valves as per attached diagram TCE.6758A-300-SK-8602 and piping material specification.

8.2.13. Insulation of interconnecting piping as per attached diagram TCE.6758A-300-SK-8602 and insulation specification.

8.3. SITE ACTIVITIES:

8.3.1. Transportation of all Material

8.3.2. Supervision services during installation, Pre- commissioning and commissioning per diem basis.

8.3.3. Providing performance guarantee.

8.4 GENERAL:

8.4.1. For design of preheater, design minimum ambient temperature shall be 18 deg C at 60% RH. However the selected fans shall be suitable for maximum ambient temperature of 45 deg C.


TCE.6758A-300-B-002



8.4.2. Tube bundle assemblies including header boxes, tubes, plugs etc. shall be

designed, fabricated and tested in accordance with ASME section VIII, Division 1.

8.4.3. Butane pre-heater shall be suitable for mounting in open space.

8.4.4. Butane pre-heater shall have 20% extra surface area in-built.

8.4.5. Tube to tube sheet joint to be seal welded & expanded as per API 661 CL. 9.3

8.4.6. Vendor should calculate and consider maximum condensation load to over come pressure drop for estimating fan motor power required for maximum developed fan head and guarantee the same.

8.4.7. Supply of all mandatory spares, commissioning spares for preheater shall be as mentioned below; however mandatory spares, commissioning spares for motor, VFD shall be as mentioned in respective specifications.

Commissioning spares

- Nozzle gaskets: 100 %

- Plug gaskets- 1%

- Header Plugs: 2%

- 10% nuts & bolts for all equipments

Mandatory spares

- Nozzle gaskets: 200 %

- Plug gaskets- 20%

- Header Plugs: 20%

- Set of blades for one fan

- 1 No. belt

And special tools and tackles required for erection, site assembly and maintenance for the equipment.

8.4.8. Additional items (including mechanical, electrical and instrumentation and controls) not specified in this enquiry but recommended by Vendor for safe, reliable, smooth and efficient operation of the preheater.

8.4.9. Prime coating & finish paint, export packing, and rust prevention for long storage at site as per attached painting specification.


TCE.6758A-300-B-002



8.4.10. All documents / drawings as per the Vendor document requirements

attached.

8.4.11. Fans & motors are placed at top of the bundle to avoid fall of condensed water on motor. As air is becoming colder & denser, air flow is made from top to bottom i.e. counter current flow. Also bundles to be placed at height of 6 / 7 m to facilitate easy out go of cooled air and to minimize cold air recirculation.

9. Vendor to provide detailed operating manual mentioning procedure, instructions for the start & stop operation of preheater. Also manual shall contain how to break ice formation if any before/ after starting / shutting the unit daily.

9. EXCLUSIONS FROM VENDORS SCOPE OF SUPPLY:

9.1. Supply of all utilities.

9.2. Civil Works: Civil foundations based on Vendor inputs and design

9.3. Electrical: All cabling.

9.4. Operating personnel for start-up and commissioning.

9.5. Land for stores.

10. INSTRUCTION TO BIDDER:

10.1. The components procured by the Vendor shall generally be as per the sub-vendors mentioned in the attached vendor list. In case for any component sub-vendor is not specified in the list, Vendor shall obtain approval from owner / TCE prior to procurement.

10.2. Vendor’s quotation shall be in full confirmation with purchaser’s requirements.

Unless exception, deviations or alternative are clearly defined and listed by Vendors, the requirements and conditions of this specification shall be deemed accepted by Vendor

10.3. Vendor shall guarantee performance of the Pre Heater for the parameters as specified in technical specification. Vendor shall also guarantee the equipment against defective workmanship & material.

10.4. Variable Speed drives have been specified for preheater. For the air preheater, all the fans in the air bay shall have a variable speed drive system.

10.5. Induction motor shall be supplied as per specification.

10.6. Variable Speed drives have been included in Vendor’s scope (as per specifications

attached for VFD).


TCE.6758A-300-B-002



10.7. For maintenance of fan motors minimum head room of 2200 mm shall be kept.

Noise level is within 85 dBA at 1 m from equipment. Vendor shall provide proper safe guards for motors to avoid ingress of rainwater into the motor.

10.8. No. of fans per bay shall be 2.

10.9. Vendor to provide Vibration cut out switch for each fan drive.

10.10. Positioning of lifting lugs shall be such that horizontal balance of tube bundle is obtained.

10.11. Vendor to design & supply supporting structure & platforms for accessing Pre Heater. Platform shall be designed for load of 250 kg/m2.

10.12. Vendor to clearly give exact supporting details of preheater for structure. Pipe supports for inlet/outlet piping shall be as informed by TCE during detail engineering.

10.13. Fire proofing shall be provided for all structural members as per OISD requirements by purchaser, however vendor to provide necessary cleats for the same.

10.14. The allowable loads on Air Cooled Heat exchangers due to external piping shall minimum meet two (2) times the values stated in API 661 / ISO 13706.

10.15. One (1) 2” vent shall be provided at the highest point on the inlet header and one

(1) 2” drain at the lowest point in the outlet header of each Tube Bundle. These

Vents & Drains shall be provided with Blind Flange.

10.16. The size of Thermowell shall be 1½” flanged. Thermowell rating and MOC shall be

compatible to respective Pre Heater design.

10.17. Vendor to provide location & necessary mounting facility for thermocouple on fin surface to measure the skin temperature.

10.18. The area of plot for pre-heater shall be indicated by vendor considering optimum design parameters.


TCE.6758A-300-B-002



11. APPROVED LIST OF VENDORS - Mechanical Sr.No. Item Vendors

1 Seamless SS

Tubes

REMI (INDIA) SANDWIK INDIA JINDAL INDIA SAW PIPES HEAVY METAL SUMITOMO JAPAN NIPPOR B OEKI JAPAN RATNAMANI METALS & TUBES

2 Plates

ESSAR STEEL LTD. TISCO LTD JINDAL INDIA STEEL AUTHORITY OF INDIA LTD. THYSSEN GERMANY VDM KRUPP GERMANY

3 SS Pipes

SHRIRAM METAL METAL INDIA RATNAMANI METALS & TUBES LTD, MUMBAI RAJENDRA MECHANICAL INDUSTRIES LTD, MUMBAI REMI PROCESS PLANT & MACHINERY LTD.

4 Forged Flanges

AMFORGE INDUSTRIES, MUMBAI PIPEFIT ENGINEERS,VADODARA CHAUDHRY HAMMER WORKS LTD, GHAZIABAD SAWAN ENGINEERS, VADODARA PARMAR TECHNO FORGE, PUNE ECHJAY INDUSTRIES LTD PARAMOUNT FORGE, PANVEL

5 Gaskets

GOODRICH GASKET PVT LTD, MUMBAI IGP ENGINEERS LTD, CHENNAI JAY GAKSETS PVT LTD, VASAI(E) MADRAS INDUSTRIAL PRODUCTS,CHENNAI STARFLEX SEALING INDIA PVT LTD,MUMBAI


TCE.6758A-300-B-002



6 Plugs AEP LTD INDIA MULTI FASTERNERS INDIA HANDWIN INDIA

7 Vibration Switch FIRST INERTIA METRIX USA MURPHY UK

LIST OF MANUFACTURERS FOR ELECTRICAL ITEMS

SL. NO.

DESCRIPTION OF EQUIPMENT MANUFACTURER

1.0 VVVF Drives Siemens ABB Danfoss Allen Bradley (Rockwell Automation) Yaskawa Schneider Electric

2.0 Motors L.V.- (Hazardous Area) ABB Marathon Electric Motors (India) Ltd. (Formerly Alstom Ltd) Bharat Bijlee Ltd. Crompton Greaves Ltd. BHEL Kirloskar Ansaldo, Italy Siemens / Loher, Germany Cemp, Italy Mitsubishi, Japan Fuji, Japan

3.0 Switchgear/Switchboard L.V. Siemens Larsen & Toubro Schneider Electric ABB Danfoss

4.0 Panel (Enclosures) Siemens Larsen & Toubro Schneider Electric ABB Danfoss Rittal

5.0 9 Air circuit breakers L & T Siemens Schneider Electric (M&G)

6.0 MCCB’s L & T Siemens Schneider Electric (M&G)

7.0 0 Switch Disconnector Fuse Unit (SDF) And Switch Disconnector Isolator

Siemens Schneider Electric L&T


TCE.6758A-300-B-002



SL. NO.


8.0 0 Change-over switch Havells (euroload) C&S Areva GE Power Kraus & Naimer Siemens BCH L&T

9.0 1 MCB / RCCB / RCBO / MPCB / MCB Isolators

Siemens Schneider Electric Legrand Moeller ABB

10.0 31 LV capacitors (APP) Universal Cables

ABB Malde Epcos Aswani

11.0 LV Series Reactors For Capacitors Manohar Brothers WHEPL Epcos

12.0 2. LV Epoxy resin cast CTs / PTs Indcoil

Precise Silkaans ABB Pragati AE Huphen Crompton Greaves

13.0 Meters

13.1 1 Digital Meter – Ammeter & Voltmeter

Schneider Electric (Conzerv) AE Rishabh Schneider Electric (Power Measurement (ION) Circutor Siemens Massibus

13.2 Electromechanical – Ammeter & Voltmeter

Automatic Electric MECO IMP Rishabh

13.3 Load Manager / Multi Function Meter / kWh

Schneider Electric (Conzerv) Circutor Rishabh Schneider Electric (Power Measurement (ION) Alpha (ABB) Schlumberger SEMS (Secure)


TCE.6758A-300-B-002



SL. NO.


14.0 1 Contactors

14.1 AC Power Contactor (shall be heavyduty)

Siemens ABB L&T BCH Schneider Electric (Telemecanique)

14.2 DC Power Contactor BCH BHEL Siemens L&T Schneider Electric

14.3 1 Auxiliary contactors Siemens L & T Schneider Electric (Telemecanique)

15.0 1 Time switch GIC Theben Siemens Schneider Electric Legrand

16.0 15.

Timers GIC Theben BCH Siemens Electronic Automation Pvt Ltd. Minilec L&T Legrand Schneider Electric

17.0 Time Delay Relay Areva ABB Siemens BCH L&T Omron PLA

18.0 1 Overload relay

18.1 Electronic / Microprocessor based overload relay

Siemens ABB Schneider Electric

18.2 Bi-metal / Overload Relay Siemens Schneider Electric L&T

18.3 0 Thermister relay Alstom/ Minilec/ Insta controls

19.0 Pushbuttons Siemens Schneider Electric (Telemecanique) Teknic Controls L&T


TCE.6758A-300-B-002



SL. NO.


BCH Areva

20.0 8 Cables

20.1 8. LT Power Cables/ Earthing Cable Universal Cables Ltd.

NICCO KEC International Ltd Cable Corporation Of India Ltd Finolex INCAB Polycab LAPP

20.2 8. LT Control Cables LAPP

Polycab NICCO Universal Cables Ltd. KEC International Ltd Finolex INCAB KEI

20.3 7 HFFR wires (including panel wiring) Finolex Polycab LAPP RR Kabel

21.0 10 Alarm Annunciators (solid state type with LED illumination) / Facia Annunciator

Digicont Industrial Instruments & Controls Procon Inst. (P) Ltd MTL India Pvt. Ltd. Rochester Instruments System Ltd. IDECIZUMI Minilec IICP Proton Electronics Alstom Yashmun ICA Ronan (Waree)

22.0 Semiconductor Fuse Areva Siemens Ferraz Bussman GE

23.0 12 HRC fuse (Power & Control) L & T

Siemens GE Power Bussman Technoelectric

24.0 Hazardous Area Items Baliga Lighting Equipment Pvt. Ltd FCG Flameproof Control Gear Pvt. Ltd. R. Stahl


TCE.6758A-300-B-002



SL. NO.


Cooper - Crouse Hinds Sudhir Switchgear Pvt. Ltd. (For Junction Box)

25.0 10 Cable glands

25.1 Cable Glands (safe area - double seal cone grip type)

Comet Braco Baliga R. Stahl Crouse Hinds Siemens

25.2 Polyamide Cable Glands Lapp Hensel Gewiss

25.3 Cable Glands / Cable Plugs / Stoppers (Hazardous Area)

Same make as certification valid with corresponding hazardous area equipment. (Comet/ Baliga/ R. Stahl / FCG Flameproof Control Gear Pvt. Ltd. / Cooper - Crouse Hinds)

26.0 1 Cable lugs Dowells / Comet

27.0 Terminal Block / Connectors Wago / Connectwell / Pheonix / Elmex

28.0 Relays

28.1 Protective relays (Numerical Type) ABB Siemens GE Multilin SEL SEG Schneider Electric Areva

28.2 Protective relays (Electromechanical Type)

ABB Siemens GE Areva

28.3 2 Auxiliary Relay Areva ABB Siemens VA Tech L & T

28.4 Electronic circuit Relay OEN Omron Allen Bradley PLA

29.0 23 Control / selector switch Kraus n Naimer

Kaycee GE Power controls L&T Siemens Areva


TCE.6758A-300-B-002



SL. NO.


ABB Schneider Electric

30.0 5 Cable termination kits Raychem RPG 3M

31.0 2 Control transformer Indcoil Precise Silkaans NEC Gauss Electricals

32.0 35 Voltage / Power / Current / Frequency / Energy Transducer

ABB AEP Siemens Areva Schneider Electric (Conzerv) Rishabh Masibus

33.0 3 Encoders Hubner Honeywell Turck

34.0 3 Limit Switch BCH Honeywell Siemens Jay Balaji Wago

35.0 GI Conduit / Pipes AKG Zenith SAIL TATA Steel Jindal

36.0 Casing Capping Precision Circle ARK Mody

37.0 Single Phasing Preventer Siemens Minilec Alstom Schneider Electric L & T

38.0 Non-insulated Copper Earthing conductors

Gupta Industrial Corporation (Vasai, Mumbai) Bharat Wires & Ropes Diamond Cables

39.0 0 Indicating Lamps (Multi-chip LED) Binay Teknic Controls Vaishno Siemens L & T Schneider Electric BCH Areva

40.0 0 Decorative switches, sockets and M K Electric


TCE.6758A-300-B-002



SL. NO.


metal boxes (single plate arrangement)

Anchor Crabtree

41.0 Non metallic enclosures (including Industrial Receptacles & LPBS)

Rittal Hensel SCAME Menekkes Bals Siemens Schneider Electric BCH PCE Legrand Gewiss

42.0 FRP cable Trays Ercon Composites Kemrock Industries Indiana Sintex Sumip Composites

43.0 .0 Luminaire (including IP65 luminaires)

Philips Crompton Greaves Bajaj Wipro Lighting

44.0 Lamps Philips GE Osram Sylvania

45.0 Ballast Philips Crompton Greaves Bajaj ATCO

46.0 Choke (for VVVFD) Siemens ABB Danfoss Allen Bradley (Rockwell Automation) Yaskawa

47.0 Power Supply Unit Siemens MTL Aplab Pheonix Cosel


CONSULTING ENGINEERS LIMITEDMUMBAI


Plant Code UAN Page

ItemRev. R0

Doc. No.S.N. Rev. S.N. Rev. S.N. Rev.

1 22 332 23 * 34 Plug type3 24 * 354 m³ 25 * 36 *5 * 26 37 *6 Total

Extendm2 * 27 38

7 Bare Tube

m2 * 28 398 - 29 * 409 30 4110 31 4211 32 4312 4413 * 45 5414 * 46 5515 * 47 5616 m3/hr * 48 * 5717 Static

PressummWC

* 49 * 58 * deg C18 Mass

Vel. kg/h m2

50 * 5919 Altitude

above m 7.5

MSL51 * 60

20 °C 52 * 6121 °C 18 for thermal design 53 62636465666768697172 Kg/c

m2 g737475 Kg/c

m2 g76 kg/h77 kg/h78 kg/h79 kg/h80 kg/h81828384858687888990919293949596979899

100101102103104105106107108 MECH

ANICA109 Fan ,

Manuf. * Model 117 124

110 Fan RPM * 118 125

111Fan Dia.,mm

* 119 * 126

112 Pitch, mm MAP 120 127 Ratio

113 121

114 122 128

115 123 129 Yes

116

130

131

-

*

-VAPOUR/GAS

-

****

-

*

-

* *

*

------

-

Remarks : 1. DDE-Information will be provided by supplied during detailed engineering Cells with * shall be filled by Air Preheater Vendor

- -

No. / Bay *

*

Speed Reducer, Type

Driver RPM

**

*

587.72.331

0.09840.1779

--

*

Support (Structure)

*

Manuf//Model *

---

*

Motor Supply

Power consumpt on per fan

Driver, Type/ Manuf.

No.of Fan / Bay 2

*

0.0002

*

1484275.091 / *

0.5

-

Variable Speed Drive.

Open Close Lockup

---

--

Phase

*

°C

°C

Enclosure

Included in Vendor's scope

Flameproof

TUBE

-418.02

15

600.7

Gas

*

mmWC / mmWC*

*Al.(SB209Gr.1060)**

Yes / NoPlug Type

KJ/kg

144168-

SS 304 spwd0.0 mm

--

LIQUID

cPW/m-K

Kg/cm2 g°C

SHELL SIDE

-144168

SA182F304

Fin , TypeFin matlFin OD/Thick.No. of Fins / metreNo. / Bundle

Length mmTransverse Pitch

Tube Thickness

**300 # RF

Inlet Nozzle, No./Size

Fin Design Temp

OD / ID mm

Outlet Nozzle, No./SizeRating & Facing

Gasket Material

Surface PreparationCorrosion allowance

BaysBundle Frame

Deg

-

Stamp Yes IHeader Box Type

As per code25 kg/cm2 g

Outlet

Gas

- 45 / +55

kg/m3

*

°C -

No. / BayNo. of RowsArrangement

In Parallel / In SeriesIn Parallel / In Series

°C -

BPCL

Solidification point

Mass enthalpy

Area Ratio

No. of Bays

TypeSize of Unit

ASMEB16.5

TATA CONSULTING ENGINEERS LTD.

LPG Storage & Handling

10E005A / B

Arrangement Horizontal / Vertical2 (1W + 1S)

Tube Length TypeTUBE BUNDLE HEADER

Customer

SA240 ,SS304

Yes / NoAuto / Manual

SA213Gr. 304

Inlet

MaterialNo. of PassesSlopePlug Material

AIR AT 18 DEG C

Condensation enthalpy

Dynamic viscosityThermal conductivitySpecific heatDensityMolar weight

Condensation temperature

Design pressureTest pressure

AGMA Rating

Heat duty, Design Case(Overall) Heat transf. coeff., max/calc.

Effective mean temperature differenceNumber of passesHeat transfer coefficient, Finned Tube / Bare Tube

*Hub Matl.

KW/Driver

Volt

Fouling factor

*Fan Blade MOC

* / *

*

*

2

*

No. of Fans/Bay

No. of Blades

m/sKg/cm2

*

*

*

Pressure drop , admissible / calculatedVelocity (mean)

Cycle *

Fan Capacity M3/hr *

kg/kmolkg/m3

Kcal/kg °CKcal/hr.Kg °CcP°CKcal/kg

Kcal/m2.hr.°C

°CKcal/hrKcal/m².h.°C

-----

m2.hr.°C/Kcal

DATA SHEET FOR BUTANE AIR PREHEATER (Fin Tube Heat Exchanger)

Quantity (operating/stand-by)

Forced Draft

Flanges acc. to

PaintingWeight, delivery kg

Control Action on Air Failure - Fan Pitch Min. Max. Lockup Louvres :

Blade Angle, Deg. *

Developed Head mm WC

--

TUBE SIDEInlet Outlet

LiquidLiquid

Butane

OPERATING CONDITIONS PER UNIT

Weight, water filled kgWeight with process fluid kg

Inspection by TCE / BPCLAs per attached Spec.

18 for thermal designDesign Dry Bulb Temp.Design Ambient, Min.

Design code API661,ASME

*

Volume Flow/ Fan

Vibration Switches

Bundles

Seamless / Welded*

Louvres

Material

Mass flow, total

Mass flow, liquid,

Thermal conductivity

Normal Boiling Point (nbp)

Dynamic viscosity

DensitySpecific heat

Mass flow,( Water Vapour)

Operating Pressure

Mass flow, Air

Process fluid

Physical condition , in / out(S)oliClass of hazard : ZONE II, Gas Group : IIA, Temp Class T3pH-value

Allowable Pressure Min/Nor/Max.Design temperature

Allowable Temperature Min / Nor / Max.

**

-

-

*

*

**

Operating temperature

Mass flow, inerts

--

KJ/kg-°C 2.1990.10120.2137

*

*

Fan Head mmWCAs per code

*

-

-


TCE FORM NO. 329R5

SPEC.NO. TATA CONSULTING ENGINEERS LIMITED LIMITED SECTION: D TCE-M4-203-51

INDUCTION MOTORS FOR HAZARDOUS AREA (GENERAL PURPOSE)

SHEET OF 7 OF 4

1

ISSUE

R4

TITLE

1.0 SCOPE

1.1 This specification covers the design, material, construction features, manufacture, inspection and testing at the VENDOR’s/his SUB-VENDOR’s works, delivery to site and performance testing of three phase squirrel cage induction motors to be used in hazardous areas for general purposes.

1.2. Separate specification (TCE.M4-203-02) when enclosed covers the additional requirements, any or all of which shall be complied with as specified in Data Sheet - A1, A2.

2.0 CODES AND STANDARDS

2.1 The design, material, construction, manufacture, inspection, testing and performance of induction motors shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to the latest applicable standards. Nothing in this specification shall be construed to relieve the VENDOR of this responsibility.

2.2 Motors shall conform to the latest applicable standards specified in Data Sheet-A2. In case of conflict between the standards and this specification, this specification shall govern.

3.0 DRIVEN EQUIPMENT

3.1 When this specification forms part of the driven equipment specification, information not given in the Data Sheet-A will be governed by the driven equipment specification.

3.2 Motors shall be capable of satisfactory operation for the application and duty as specified in the Data Sheet-A1 and as required by the driven equipment.

4.0 PERFORMANCE AND CHARACTERISTICS

4.1 Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under either of the following supply conditions as specified in Data Sheet-A1.


TCE FORM NO. 329R5



SHEET OF 7 OF 4

2

ISSUE

R4

TITLE

Supply Condition I II

a) variation of supply voltage 6% 10% from rated voltage

b) Variation in supply frequency 3% 5% from rated frequency

c) Combined voltage and frequency 6% 10% variation 4.2 Motors shall be suitable for full voltage direct-on-line starting or star-

delta starting or any other method of starting as specified in the Data Sheet-A1.

4.3 Motors shall be capable of starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperatures, when the supply voltage is in the range of 85% of the rated motor voltage to maximum permissible voltage specified in Data Sheet-A1.

4.4 The locked rotor current of the motor shall not exceed 600% of full load current (subject to tolerance as per the applicable standard) unless otherwise specified.

4.5 Motors shall be designed to withstand 120% of rated speed for two minutes without any mechanical damage, in either direction of rotation.

4.6 The motor vibrations shall be within the limits specified in applicable standards unless otherwise specified for the driven equipment.

4.7 Except as mentioned herein, the guaranteed performances of the motor shall be met with tolerances specified in applicable standard.

5.0 INSULATION

5.1 Any joints in the motor insulation such as at coil connections or between slot and end winding sections, shall have strength equivalent to that of the slot sections of the coil.

5.2 The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate. The tropicalising treatment shall be as per the applicable standard.


TCE FORM NO. 329R5



SHEET OF 7 OF 4

3

ISSUE

R4

TITLE

6.0 TEMPERATURE RISE

6.1 The highest temperature attained under practical conditions of operations within the rating of the motor by any part or any surface shall not exceed the values given in Table below in IS:13346.

TABLE

Class Maximum Surface Temperature oC ------- ----------------------

T1 450 T2 300 T3 200 T4 135 T5 100 T6 85 These temperature rises are acceptable for an ambient temperature of

40 Deg. C. The temperature rises for other ambient conditions shall be as specified in Data Sheet-A1.

6.2 For motors specified for outdoor installation account shall be taken of heating due to direct exposure to solar radiation.

7.0 CONSTRUCTIONAL FEATURES

7.1 The following types of motors shall be used in hazardous area, depending upon the requirement given in data sheet A1 of this specification.

a) Flameproof construction type Ex `d’

b) Increased safety type Ex `e’

c) Non sparking fan Ex `n’

7.1.1 The constructional feature shall meet the requirements specified in respective IS & BS which are mentioned in Data Sheet A1 and A2 of this Section D of TCE-M4-203-51.

7.2 GENERAL FEATURES

7.2.1 The motor construction shall be suitable for easy disassembly and


TCE FORM NO. 329R5



SHEET OF 7 OF 4

4

ISSUE

R4

TITLE

reassembly. The enclosure shall be sturdy and shall permit easy removal of any part of the motor for inspection and repairs.

7.2.2 Motors weighing more than 25 kg. shall be provided with eyebolts, lugs or other means to facilitate safe lifting.

7.2.3 The motor bars shall not be insulated in the slot portion between the iron core laminations and the bars.

7.2.4 Except as noted, horizontal motors shall be foot mounted type and vertical motors shall be flange mounted type.

7.2.5 Unless otherwise approved, motors shall be designed to permit convenient access for drilling vertically through motor feet or mounting flange for installation of Purchaser’s dowel pins after motors are mounted with the driven equipment.

7.2.6 When the motor is supplied with driven equipment including a common base (bed place, channels etc.). The VENDOR shall ensure that such bed plate is adequately braced to keep vibrations and misalignment within satisfactory limits.

7.2.7 The motor name plate shall clearly indicate the type of enclosure, protection and gas group classification as per IS:13346

7.2.8 The test certificates shall be furnished from testing authorities like CMRS-Dhanbad, DGMS, DGFASLI-Mumbai or equivalent.

7.2.9 The motor shall be energy efficient if stated in Data Sheet A1.

8.0 BEARINGS

8.1 Greased ball bearings or greased roller bearings shall be of reputed make subject to the PURCHASER’s approval. The life expectancy of the bearing shall be stated.

8.2 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.

8.3 The bearings shall prevent dirt and water from getting into the motor. Bearing lubricant shall not find access to the motor windings.

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


TCE FORM NO. 329R5



SHEET OF 7 OF 4

5

ISSUE

R4

TITLE

8.5 If the bearings are oil lubricated, a drain plug shall be provided for draining residual oil and oil level sight guage shall be provided to show precise oil level required for stand-still and running conditions.

8.6 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.

8.7 When pressure oiling is required for horizontal motors, bearings shall be of sleeve type arranged for pressure oiling supplied from the lubrication system of the driven machine, with ring oiling for starting and emergency duty. The ring oiling system shall be adequate for at least 10 minutes, without the pressure oiling system in operation. Oil sight flow gauges shall be provided to indicate oil flow from each bearing.

8.8 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 minimise setting.

8.9 Sleeve bearing for use with motors having flexible couplings with limited end play, shall have adequate axial end play to permit assembly so as to prevent transmitting of thrust from driven equipment to motor bearings.

9.0 TERMINAL BOX

9.1 Terminal boxes shall be of same construction type as that of motor body construction designed for outdoor service, to eliminate entry of dust and water. Gaskets of neoprene or approved equivalent shall be provided at cover joints and between box and motor frame.

9.2 The terminal box shall be suitable for top and bottom entry of cables.

9.3 Unless otherwise approved, the terminal box shall be capable of being turned through 360 Deg. in steps of 90 Deg. in case of increased safety type Ex `e’ and non sparking fan type Ex `n’ motors.

9.4 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.


TCE FORM NO. 329R5



SHEET OF 7 OF 4

6

ISSUE

R4

TITLE

9.5 Suitable flame proof cable glands shall be supplied by the motor vendor to match Purchaser’s cables whenever specified in data sheet A1.

10.0 PAINT AND FINISH

10.1 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 primer and finished with two coats of gray enamel paint.

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

11.0 HEATING DURING IDLE PERIODS

11.1 For motors rated 30 kW & above rating, anticondensation heaters and separate auxiliary terminal box for heaters will be provided.

11.2 Whenever specified in Data Sheet A1 for motors rated below 30 kW, during idle periods, the stator winding will be connected to a 24 V single phase, 50 Hz, AC supply for heating and elimination of moisture. The supply will be connected between any two terminals for a delta connected motor and between one terminal and other for a star connected motor. The VENDOR shall clearly bring out in his offer if there is any objection to the above method of heating, stating reasons thereof.

12.0 ACCESSORIES

12.1 Two independent earthing points shall be provided on opposite sides of the motor, for bolted connection of the PURCHASER’s earthing conductors, as specified in the Data Sheet-A. These earthing points shall be in addition to earthing stud provided in the terminal box.

12.2 Except when otherwise specified, the motors shall be provided with a bare shaft extension having a key slot and a key at the driving end.

12.3 When the motor half coupling is supplied by the PURCHASER or driven equipment vendor, the motor vendor shall strictly adhere to the dimensional requirements and other instructions related to accessory.

13.0 TESTS

13.1 Motor shall be subjected to all the routine tests as per applicable standard in the presence of the PURCHASER’s representative. Copies


TCE FORM NO. 329R5



SHEET OF 7 OF 4

7

ISSUE

R4

TITLE

of test certificates of type and routine tests, as specified in the distribution schedule, shall be furnished for the PURCHASER’s approval.

13.2 All the meters, instruments, devices used for the testing purpose shall be properly calibrated by standard authorised agencies which shall be traceable to National standards. For each such instrument proper validity of calibration shall be documented by Vendor.


SPECIFICATION NO.

TATA CONSULTING ENGINEERS LIMITED SECTION D

DATA SHEET - A1 TCE-M4-203-51 INDUCTION MOTORS FOR HAZARDOUS AREA SHEET 1 OF 5

REV. NO. PPD. BY BY JOB NO. CLIENT: BHARAT PETROLEUM CORPORATION LIMITED

DATE CKD. BY BSY REV. BY DATE 13-04-2012 6758A PROJECT: BLENDING UNIT

PROJECT AT URAN LPG PLANT

TCE FORM 330 R3

ISS

UE

NO

.R4

1.0 APPLICATION: Butane Preheater Fan

2.0 NUMBER OF UNITS: As per respective package 3.0 TYPE OF MOTOR:

SQUIRREL CAGE

4.0 TYPE OF CONSTRUCTION: Flameproof type ex 'd'

5.0 SUPPLY SYSTEM FAULT LEVEL: 36MVA, 50kA 6.0 SUPPLY NEUTRAL : Effectively Earthed 6.1 COMPLIANCE WITH TCE-M2-203-

02 IS REQUIRED NO

6.2 IF YES ,WHICH CLAUSE Not applicable 7.0 RATED OUTPUT: (*)

8.0 RATED VOLTAGE 415 V 9.0 NUMBER OF PHASES &

FREQUENCY: 3 PHASE, 50 Hz

10.0 SUPPLY CONDITION (REF CL NO. 4.1 OF TCE.M4-203-51)

II

11.0 SYNCHRONOUS SPEED (*)

12.0 TYPE OF DUTY(IS 325 OR IS 12824)

(*) S1

13.0 DUTY DESIGNATION (IS 325 OR IS 12824)

(*)

14.0 CYCLIC DURATION FACTOR: Not applicable 15.0 CYCLES PER HOUR: (*) 16.0 MOMENT OF INERTIA: (*) kg-m2 17.0 METHOD OF STARTING: VVVFD (with bypass DOL) 18.0 STARTING TORQUE % Full load torque 19.0 PULL OUT TORQUE % Full load torque 20.0 CLASS OF INSULATION: F 21.0 REF AMBIENT TEMPERATURE 45 0C (Design Ambient

Temperature : 500C) 22.0 TEMPERATURE RISE BY

THEROMOMETER/WDG RES 75 0C (Corresponding to Class B

Insulation)


SPECIFICATION NO.






TCE FORM 330 R3

ISS

UE

NO

.R4

23.0 MAXIMUM SURFACE TEMPERATURE CLASSIFICATION (IS:8239):

T4

24.0 LOCATION: Outdoor A) HAZARDOUS AREA DIVISION

(IS5572 OR EQUIVALENT:) Zone2

B) GROUP CLASSIFACTION AS PER IS:2148 (FOR FLAME-PROOFENCLOSURES HAVING HAZARDOUS GAS)

IIA/IIB

C) WHETHER SUITABILITY FOR HAZARDOUS DUST REQUIRED:

No

IF YES, TYPE OF DUST : 25.0 ATMOSPHERE: Humid & Extremely corrosive (Coastal

salt laden). 26.0 TYPE OF COOLING (IS:6362) TEFC 27.0 DESIGNATION FOR DEGREE OF

PROTECTION (IS:4691): IP41/IP43/IP54/IP55

IP65

28.0 TERMINAL BOX A) LOCATION AS SEEN FROM NON- DRIVE END RIGHT/LEFT B) RATING SHORT TIME CURRENT: KA (RMS) DURATION:SECS. 0.21 DYNAMIC

KA (PEAK)

(*) 50 KA (RMS)

0.25 SECS 127.5 KA (PEAK)

29.0 EXTERNAL CABLE DETAILS A) TYPE B) NUMBER OF CORES

(#) 4 Core


SPECIFICATION NO.






TCE FORM 330 R3

ISS

UE

NO

.R4

C) SIZE: D) WHETHER FLAMEPROOF CABLE GLAND BY VENDOR

YES/ NO

Yes

30.0 EARTHING CONDUCTORS A) MATERIAL: B) SIZE:

AL, PVC insulated earthing cable As per motor rating (#)

31.0 SHAFT ORIENTATION: VERTICAL/HOLLOW VERTICAL (*)

32.0 MOUNTING SYMBOL (IS :2253 OR EQUIVALENT)

(*)

33.0 TYPE OF COUPLING DIRECT FLEXIBLE (*) 34.0 WHETHER HALF COUPLING

REQUIRED: YES/NO (*)

35.0 ROTATION AS SEEN FROM NON-DRIVEN END

CLOCKWISE/ANTICLOCKWISE (*)

36.0 TYPE OF BEARING DRIVE END/NON DRIVE END (*) 37.0 WHETHER BED PLATE

REQUIRED YES/NO (#)

38.0 WHETHER RAIL REQUIRED NO 39.0 COLOUR SHADES OF PLANT IF

SPECIAL Shade 632 as per IS 5

40.0 CTS FOR DIFFERENTIAL PROTECTION REQUIRED

NO

41.0 VIBRATION DETECTORS REQUIRED

NO

42.0 SPACE HEATERS FOR MOTORS REQUIRED

YES

43.0 WHETHER 24 V WINDING HEATING REQUIRED

NO


SPECIFICATION NO.






TCE FORM 330 R3

ISS

UE

NO

.R4

44.0 $ CT PARTICULARS A) 3 CTS, ONE IN THE NEUTRAL LEAD OF EACH PHASE B) RATIO C) CLASS P. S. D) KNEE POINT VOLTAGE E) MAX. R. C. T. SECONDARY WINDING, F) MAX. EXCITING CURRENT AT 1/2 KPV G) CLASS OF INSULATION

(KPV) OHMS

NOT APPLICABLE

NOTES: 1 Drawings should be submitted for review as follows: General Arrangement within 2 weeks after award of contract

2 Details marked thus (*) will be decided and intimated by the bidder based on driven equipment characteristics

3 Data marked thus (#) will be intimated to vendor after Placement of order. 4 Data marked thus (^) will be decided and intimated by the bidder.

5 VVVFD driven motors shall be inverter duty. These motors & VVVFD combinations should be certified as a combination for Zone-2, Gas group IIA/IIB, T4 application.

6 The bearings shall be sealed for life and having life of >20000hrs. The bearings shall have C3 clearance.

7 Motor terminal box shall be suitable for internal earthing using 4th core of the incoming power cable.

8 Motors shall have earthing terminals for internal as well as external earthing.

9 Cable shall be 4C, Al/Cu conductor, PVC insulated, Extruded FRLS PVC inner & outer sheathed, Armoured cable.

10 FRP Canopy shall be provided for all motors.

11 Starting current shall not exceed 7.2 times of Motor full load current (max.) (Inclusive

of IS/IEC tolerance).

12 The winding overhang shall be epoxy coated.


SPECIFICATION NO.






TCE FORM 330 R3

ISS

UE

NO

.R4

13 All constituent of the motor shall be suitable for highly corrosive, salt laden coastal

environment. Special focus shall be on windings, insulators, terminals, hardware

(including washers) and space heaters.

14 The paint shall be: One coat of inorganic zinc silicate primer with an average dry

film thickness (DFT) of 75 microns after initial surface preparation. One coat of

high build MIO epoxy with a minimum dry film thickness of 125 microns. One coat

of polyurethane finish with minimum dry film thickness of 40 microns.

15 Terminal box for space heater shall be independent of motor terminal box.

16 All items shall meet the requirements as specified in IS 5571 & 5572 alongwith

IS/IEC 60079.

17 In case aluminium housing is provided, it shall be of copper free aluminium.

18 IECEx alongwith ATEX certified items OR BIS licenced items conforming to IS/IEC

– 60079-1 are acceptable. The motors shall be PESO approved. All the hazardous

equipment shall be certified for use in Zone-2. Applicable statutory approval

certificates shall be submitted along with bid.

19 The VVVFD driven motors shall also be provided with temperature detector/PTC

Thermistors based protection to ensure that the surface temperature does not

exceed temperature class. The terminals, clearance and enclosure shall be

suitable for VVVFD application. Separate terminal box shall be provided for

thermistor termination.

20 The cable route length between VVVFD and motor shall be ~400m. Hence, the cable, filter/reactor/choke, terminal and other related components shall be suitably selected to avoid impact of dv/dt & df/dt and any resulting travelling wave.

21 Motor data-sheets shall be filled & submitted for each application/equipment.

22 The fan & cowl shall be of non-sparking, non-corrosive and anti-static material.


SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION D





TCE FORM 330 R3

ISS

UE

NO

. R

4

1. INDUCTION MOTORS – THREE PHASE

IS-325 BS-4999 IEC-60034

2. SPECIFICATION FOR THREE

PHASE INDUCTION MOTORS WITH TYPE OF PROTECTION ‘N’ (NON SPARKING FAN TYPE)

IS-9628

3. SPECIFICATION FOR

CONSTRUCTION & TESTING OF ELECTRICAL APPARATUS WITH TYPE OF PROTECTION ‘E’ (INCREASED SAFETY MOTORS)

IS/IEC 60079-7

4. FLAMEPROOF ENCLOSURES OF

ELECTRICAL APPARATUS IS/IEC 60079-1

5. MEASUREMENT AND

EVALUATION OF VIBRATION OF ROTATING ELECTRICAL MACHINES

IS-12075 BS-4999-142IEC-60034-9

7. DEGREE OF PROTECTION

PROVIDED BY ENCLOSURE FOR ROTATING ELECTRICAL MACHINERY

IS-4691 BS-4999-150 IEC-60034-5

8. CLASSIFICATION OF

HAZARDOUS AREAS FOR ELECTRICAL INSTALLATION

IS-5572 IEC-79

9. DESIGNATION FOR TYPES OF

CONSTRUCTION AND MOUNTING ARRANGEMENT OF ROTATING ELECTRICAL MACHINES

IS-2253 IEC-60034-7

10. ROTATING ELECTRICAL

MACHINES : TERMINAL MARKINGS AND DIRECTION OF ROTATION

IS/IEC 60034-8


http://www.standardsbis.in/Gemini/search/BasicSearch.action






TCE FORM 330 R3

ISS

UE

NO

. R

4

11. DESIGNATION OF METHODS OF COOLING FOR ROTATING ELECTRICAL MACHINES

IS-6362 BS-4999-106 IEC-60034-6

12. GUIDE FOR TESTING THREE

PHASE INDUCTION MOTORS IS-4029

13. DIMENSIONS OF SLIDE RAILS

FOR ELECTRIC MOTORS IS-2968

14. GENERAL REQUIREMENT FOR

ELECTRICAL APPARATUS FOR EXPLOSIVE GAS ATMOSPHERES

IS/IEC 60079-0

15. TYPE OF DUTY AND CLASSES

OF RATING ASSIGNED TO ROTATING ELECTRICAL MACHINES

IS-12824

16. INDUCTION MOTORS- ENERGY EFFICIENT, THREE PHASE, SQUIRREL CAGE- SPECIFICATION

IS-12615

17. ROTATING ELECTRICAL MACHINES

IS-4722

18. GUIDE FOR TESTING INSULATION RESISTANCE OF ROTATING MACHINES

IS-7816

19. GUIDE FOR SELECTION AND INSTALLATION OF ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS (OTHER THAN MINES)

IS-5571

20. GUIDANCE FOR THE DESIGN

AND PERFORMANCE OF A.C. MOTORS SPECIFICALLY DESIGNED FOR CONVERTER SUPPLY

IEC 60034-25

21.

PERMISSIBLE LIMITS OF NOISE LEVEL FOR ROTATING ELECTRICAL MACHINES

IS-12065

BSEN 60034-9

IEC 60034-9







TCE FORM 330 R3

ISS

UE

NO

. R

4

19. CAGE INDUCTION MOTORS WHEN FED FROM CONVERTERS – APPLICATION GUIDE

IEC-34-17

20.

ADJUSTABLE SPEED ELECTRICAL POWER DRIVE SYSTEM- EMC REQUIREMENTS AND SPECIFIC TEST METHODS.

BS-EN-61800

IEC-61800

21.

ELECTRICAL INSTALLATIONS DESIGN, SELECTION AND ERECTION

60079-14



DATA SHEET - B TCE-M4-203-51 INDUCTION MOTORS FOR HAZARDOUS

AREA SHEET 1 OF 2

ENQUIRY /SPECIFICATION NO.

SR.NO. ITEM BIDDER

NOTE TO BIDDER

1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE MARKED SIGNATURE

WITHIN ASTERISK(*) (DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS) OF BIDDER 2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL

BE ENCLOSED WITH EACH COPY OF THE BID. DATE

TCE FORM 294 R3

ISS

UE

NO

.R4

1.0 Application/Designation 2.0 Manufacturer 3.0 Type of construction 4.0 Applicable standards 5.0 Rated a) Output kW b) Speed RPM 6.1 Type of Duty (CI.10.2 of IS 325 OR

CL-9.3 OF IS 4722)

6.2 Duty Designation (CI.10.3 OF IS 325 OR CL-9.3 OF IS-4722)

7.0 Supply conditions a) 1) Rated voltage V 2) No. of phases 3) Frequency Hz b) Allowable Variations in 1) Voltage % 2) Frequency % 3) Combined % c) Permissible Unbalance in Supply

Voltage %

8.0 Current a) Full Load Amps b) Starting % FL c) Thermal Current Limit Itn d) Dynamic Current Limit Idyn 9.0 Full Load Efficiency % 10.0 Full Load Power Factor 11.0 Method of Starting 12.0 Torque a) Starting % Flt



DATA SHEET - B TCE-M4-203-51 INDUCTION MOTORS FOR HAZARDOUS

AREA SHEET 2 OF 2

ENQUIRY /SPECIFICATION NO.

SR.NO. ITEM BIDDER

NOTE TO BIDDER

1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE MARKED SIGNATURE

WITHIN ASTERISK(*) (DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS) OF BIDDER 2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL

BE ENCLOSED WITH EACH COPY OF THE BID. DATE

TCE FORM 294 R3

ISS

UE

NO

.R4

b) Maximum % Flt 13.0 Class of Insulation 14.0 a) Ref. Ambient temp. 0 C b) Temp. rise by res. Method 0 C 15.0 Type of Enclosure Ex'd'/Ex'e'/Ex'n' 16.0 Degree of Protection(IS 4691 or

equivalent)

17.0 Suitable for Outdoor Operation Yes/No 18.0 Normal winding connection Star/Delta 19.0 Type & No. of terminals brought out 20.0 Winding Suitable for 24V Winding

heating Yes/No

21.0 Shaft Orientation 22.0 Dimensional Dwg. Enclosed Yes/No 23.0 CMRS(Dhanbad) certification

Enclosed Yes/No

24.0 Temperature Class T1/T2/T3/T4/T5/T6 25.0 Time tE for Increased safety motors Secs 26.0 Suitability for hazardous dust Yes/No 27.0 Flameproof Cable gland provided ? Yes/No a) If Yes, suitable upto what size of

cable 3Cx mm2


TCE FORM NO. 329R5

SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: D TCE-M4-203-51


SHEET OF 1 OF 4

1

ISSUE

R4

TITLE

DATA SHEET - C

DATA TO BE FURNISHED BY THE VENDOR AFTER THE AWARD OF CONTRACT

1. Type and Frame Size :

2. Starting Time :

2.1 With 100% voltage at terminals



3. Safe stall time at 100% rated voltage and under hot condition.

4. Time tE for Increased Safety Motors.

5. Type and size of cable for which flameproof cable gland is provided in the terminal box:

6. Type of bearings and expected life.

7. Total weight of motor (kg)

8. Motor GD2 :

9. Motor outline dimension drawing (Number of copies as per distribution schedule)

10. Type and routine test certificates (Number of copies as per distribution schedule)

11. CMRS certification copy.

12. DRAWINGS

12.1 Vendor shall submit drawings within the time stipulated in Purchase Order for review by Engineer.

12.2 Vendor shall allow minimum 4 weeks for approval of drawings by Engineer while working out the manufacturing schedule.


SPECIFICATION NO. TCE.M4-203-71

TATA CONSULTING ENGINEERS LIMITED SECTION: D

DATA SHEET A1 - VARIABLE SPEED AC DRIVES (GENERAL REQUIREMENTS) SHEET 1 OF 2

SL. NO. ITEM UNIT

REV. NO. P0 JOB NO.

TCE.

6758A

CLIENT: BHARAT PETROLEUM CORPORATION LIMITED PPD. BY BY

CHD. BY BSY PROJECT: BLENDING UNIT PROJECT AT URAN LPG PLANT DATE 13-04-12

TCE FORM NO. 330 R2

GENERAL REQUIREMENT

1.0 Type of Drive Inverter (IGBT) controlled AC drives.

1.1 Application Butane Preheater Fan

1.2 Type of duty (cl. 3.4) Class II

1.3 Quadrants of operation I

2.0 Quantity As per respective package

3.0 Power supply 415 V, 3ph, N,50Hz

4.0 Variation voltage 415 V + 10%

5.0 Variation in Frequency 50 Hz + 5%

6.0 Combined voltage and frequency variation

10%

7.0 Environmental Conditions Coastal Mumbai

7.1 Location Indoor

a) Whether in air conditioned room No

b) If No:

7.2 Average ambient temperature 0 C 45

7.3 Design ambient temperature 0 C 50

7.4 Relative humidity % 85

7.5 Vibration As per IEC/EN 60068-2-6

8.0 Type of cooling for drive panel Natural air / Fan cooled

If water cooled, is DM water required Not Applicable

If yes, quantity of DM water ------ litres/minute

9.0 Cable

a) Size and type Later, Al conductor, PVC insulated, extruded FRLS PVC inner & outer sheath, armoured, 1100V grade

b) Entry Bottom

10.0 Dimensions Bidder to decide

11.0 Types of Protection

11.1 Instantaneous over current Yes

11.2 Motor overload protection Yes

11.3 Over voltage / under voltage Yes




DATA SHEET A1 - VARIABLE SPEED AC DRIVES (GENERAL REQUIREMENTS) SHEET 2 OF 2

SL. NO. ITEM UNIT

REV. NO. P0 JOB NO.

TCE.

6758A



TCE FORM NO. 330 R2

11.4 Momentary power loss Yes

11.5 Stall prevention Yes

11.6 Ground fault Yes

11.7 Inverter Overload Yes

11.8 Open Phase Yes

11.9 Fuse protection Yes

11.10 Fin Overheat Yes

12.0 Control characteristics for both AC/DC

a) Control Method IGBT with PWM technique

b) Freq. control range Bidder to decide and furnish

c) Accelerate/decelerate time Bidder to decide and furnish

13.0 Harmonics Limitations

a) Voltage Harmonics Load side and source side

It shall be as per IEEE- 519 guidelines and Bidder to indicate the figure of the drive offered (for PCC definition, harmonics on input side of drive shall be considered, even though PCC definition is normally not applied to standalone drive)

b) Current Harmonics on Source side

14.0 Controls on Drive Panel

a) Start / Stop YES ( However it shall have facility to block the start )

b) Speed Raiser / Lower YES ( However it shall have facility to block the same by software programming)

c) Auto / Manual Yes

d) Local / Remote Yes

e) DOL by-pass Yes (Coordinate with Fan motor manufacturer for suitability of the starting on DOL)

f) Emergency Stop Yes

g) Any other Stop from DCS, start Permissive.

Communication Protocol RS-485.

Feedback signals to DCS- Motor Running, stop, O\L Trip, other.




DATA SHEET A2 VARIABLE SPEED AC DRIVES

SHEET 1 OF 6

SL. NO. ITEM

REV. NO. P0 JOB NO.

TCE.

6758A



TCE FORM NO. 330 R2

INVERTER CONTROLLED AC DRIVES

1.0 a) Starting/rated torque Butane Preheater Fan Bidder to decide

b) Type of converters IGBT based PWM

c) Inverter capacity at specified pf Bidder to decide

d) Rated Current Bidder to decide

e) Load power factor 0.8

f) Max. continuous current Same as rated current

g) Rated voltage with number of phases

415V, 3 phase

h) Rated frequency 50Hz

i) Converter Bridge Full wave IGBT controlled (Bidder to take necessary measures to limit the harmonics as per IEEE 519 guidelines)

j) Single Quadrant/Two quadrant/ Four Quadrant

Single Quadrant

2.0 Control Characteristics

2.1 Speed Control

a) Rated speed 1500 rpm. Shall be adjustable from 50 to 100%

b) Speed ratio -

c) Constant torque/constant power Fan application

d) Speed accuracy +/-0.1%

e) Closed loop/open loop Closed loop (based on Butane temperature feedback)

f) If tachogenerator used (for

closed loop)

No

g) Accel./Deccel. Time Bidder to decide and furnish

h) Type of tacho-generator Not applicable

- If analogue, then reference signal mA/mV

j) Is remote operation required Yes

- If yes, is it through Stop from VVVFD panel. Start & Stop command from remote(LPBS near motor)





SHEET 2 OF 6

SL. NO. ITEM

REV. NO. P0 JOB NO.

TCE.

6758A



TCE FORM NO. 330 R2

k) Type of control

3.0 Braking Not Applicable

a) Type of braking

b) Braking Torque

4.0 Miscellaneous

Soft-start Yes

Flying restart Yes

Auto restart No

Kinetic Buffering Bidder to decide

5.0 Indication on Drive Panel (minimum)

a) Motor running Yes

b) Motor stopped / trip Yes

c) AC mains ‘ON’ Yes

d) System Ready to start Yes

e) VSD system fault Yes

6.0 Metering

Digital Display of the following Minimum parameters on the Drive Panels:-

a) Input AC Voltage Yes

b) Input AC Frequency Yes

c) Input AC Current Yes

d) Output Voltage Yes

e) Output Current VSD/Bypass Yes

f) Output Frequency Yes

g) Motor speed Yes

Necessary transducers shall be

Provided with 4-20mA output for

indicating motor speed & current

in DCS





SHEET 3 OF 6

SL. NO. ITEM

REV. NO. P0 JOB NO.

TCE.

6758A



TCE FORM NO. 330 R2

NOTES:

1. VVVFD panel will include protections for Butane Preheater Fan motor & VVVFD bypass DOL.

2. Panel shall have stop command provision.

3. The advanced control panel (withdrawable programming/monitoring unit) shall be provided. Also, the VVVFD shall be suitable for interface with automation system based on Modbus TCP/IP. Any related hardware & software to enable this shall be included.

4. VVVFD is located in safe area. VVVFD is being applied for control of hazardous area motors for Butane Preheater Fans. Accordingly, the VVVFD should have been type tested along with the motor being offered by the Butane Preheater Fan manufacturer. The VVVFD shall meet the requirements of IS 5571 for control of hazardous area equipment. VVVFD-Motor combination shall have PESO approval and CMRS/ATEX/IECEx certification. Also, type test certificates/heat run test shall be submitted with the offer.

5. All items shall meet the requirements as specified in IS 5571 & 5572 alongwith IS/IEC 60079.

6. IECEx alongwith ATEX certified items OR BIS licenced items conforming to IS/IEC – 60079-1 are acceptable for hazardous area. All the items used in hazardous area shall be PESO approved. All the hazardous equipment shall be certified for use in Zone-1.

7. The project site has salt laden corrosive coastal environment and very high level of humidity (located adjacent to a reservoir). Accordingly all the electronics and insulation and space heater shall be applied/selected.

8. Enclosure shall be of shade RAL 7035. Paint & hardware shall be suitable for coastal area.

9. Butane Preheater Fan are Inverter (VVVFD) driven. The motors offered should have been tested/certified for use with the selected VVVFD for Zone-2 application. Also, the motors shall be provided with thermistor based protection to ensure that the surface temperature is limited. The terminals, clearance and enclosure shall be suitable for VVVFD application.

10. Necessary interface modules/relays necessary to trip the motor based on Thermistor sensed overload shall be provided.

11. Filters/chokes as required to feed motor located at a distance of ~400m shall be provided.

12. All motor feeders shall be Type-II co-ordinated





SHEET 4 OF 6

SL. NO. ITEM

REV. NO. P0 JOB NO.

TCE.

6758A



TCE FORM NO. 330 R2

13. Essential & Recommended spares with quantity & their Unit Prices shall be furnished by

the bidder in their offer. 20% of the actual installed quantity of each type & rating of the following items:

A) Power Fuse (HRC) B) Control Fuse (HRC) C) Semiconductor Fuse D) Push Button unit E) Indicating lamps (each colour) F) Thermistor relay G) Door keys H) Control Terminal Blocks/connectors

14. Price quoted shall be inclusive of the Commissioning spares. 15. The panel shall be extensible on both sides. Cable entry shall be bottom.

16. The bus bars in all panels shall be Aluminium, 50kA for 1sec. Current density for

busbars shall be max. 0.8 A/mm². The main busbars (Horizontal as well as vertical) shall have uniform current ratings. Busbars shall be provided with colour coded heat shrunk PVC sleeves.

17. Cable supporting arrangement shall be provided in the Cable chamber/Cable alley.

18. Panel shall have Panel illumination lamp (CFL) and Space heater with adjustable thermostat, MCB.

19. Operating height shall be restricted between 250mm to 1800mm from finished floor level.

20. All indicating lamps shall be of multichip LED type.

21. All Multifunction meters shall be static type with modbus TCP-IP communication protocol to DCS. Ammeters & Voltmeters shall be Analogue type with selector switch.

22. All MCCBs/MPCBs shall be provided with extended rotary handle.

23. At least 20% spare terminals shall be provided in the terminal block. Each terminal shall be suitable for terminating min. 2x2.5sqmm wire.

24. Each Motor feeder shall have ON-OFF-Trip indication, overload reset button & Emergency STOP push button.





SHEET 5 OF 6

SL. NO. ITEM

REV. NO. P0 JOB NO.

TCE.

6758A



TCE FORM NO. 330 R2

25. One Marshalling Terminal Box (MTB) shall be provided in the panel. Number of contacts to be wired upto the MTB and terminal arrangement in MTB shall be as per control schematic diagram. Terminals in MTB shall be arranged in two groups labelled ‘A’ & ‘B’, physically separated from each other. Group ‘A’ shall comprise of terminals for all outgoing potential free contacts from board & Group ‘B’ shall comprise terminals for all incoming commands/interlocks from control room. Separate removal gland plate shall be provided for each MTB.

26. Control supply for Panel space heater, panel illumination lamp & socket shall be 230 V AC through control transformer.

27. Each compartment shall be provided with the door with suitable interlocks such that door cannot be opened unless MCCB is in off position. Also interlock defeat facility shall be provided.

28. Start of motor is envisaged only from Field. However, Motor Stop shall be possible from Field, MCC and DCS.

29. Local push button station shall have Start & Stop push button. Stop push button shall be mushroom head, Red colour, and stayput type.

30. Refer Approved Vendor List enclosed elsewhere in the tender for Make of components.

31. Panel wiring shall be done with HFFR wires of 1100V grade.

32. Phase reversal protection shall be provided.

33. All instrument transformer and control transformer shall be Cast resin type.

34. VVVFD shall be suitable to run motor at a speed low enough for the preheater to achieve performance with minimal energy consumption.

35. The panel shall be fan cooled with redundant fans. Alarm shall be generated in case of insufficient ventilation of the panel.

36. Ventilation shall be through louvers provided with dust pad/filter.

37. Runhour readings shall be generated for each fan.

38. All components shall be rated to take into consideration effects of harmonics being generated.

39. Following tests/checks shall be performed on Drive Panel: A) Drive System Efficiency (including all system constituents such as filters)

@100%, 75% and 50% inverter loading B) Measurement of THD(V & I) @100%, 75% and 50% inverter loading C) Measurement of acoustic noise @100%, 75% and 50% inverter loading D) Temperature Rise test





SHEET 6 OF 6

SL. NO. ITEM

REV. NO. P0 JOB NO.

TCE.

6758A



TCE FORM NO. 330 R2

E) Dimensional & Visual Checks F) Paint thickness G) IR measurement H) HV Test (min. 2.5kV for 1min.) I) Operational Checks





SHEET 1 OF 1

SL. NO. ITEM

REV. NO. P0 JOB NO.

TCE.

6758A



TCE FORM NO. 330 R2

NOTE : EQUIPMENT, ASSOCIATED ACCESSORIES, COMPONENTS/PARTS, RAW MATERIAL AND TESTS SHALL IN GENERAL CONFORM TO IS /IEC.

1. Specification for metal clad base materials for printed circuits for use in electronic and telecommunication Equipment

IS:5921

2. Specification of Transformers and Inductors (Power, Audio, Pulse and Switching) for Electronic Equipment

IS:6297

3. Safety code for Semiconductor rectifier equipment

6619

4. Specification for printed wiring Board IS:7405

5. Essential rating & characteristics Semiconductor devices

IS: 3700 IEC:146

6. Basic climate for mechanical durability tests for electronic components

IS:9000

7. Low-voltage switchgear & control gear – General Rules

IS:13947

8. Environmental requirements of semiconductor devices and integrated circuits

IS:6553

9. Ambient temp. of electronic Equipment IS:9676

10. Terminal for electronic equipment IS:4007

11. Busbars and Busbar connections IS:5082 BS:159

12. Code of practice for earthing IS:3043 BS:CP:1013

13. Current transformers IS:2705 BS:3938 IEC:185

14. Potential transformers IS:3156 BS:3941 IEC:185

15. Power transformers IS:2026 BS:171 IEC:75

16. Indicating meters IS:1248 BS:89 IEC:51

17. Semiconductor Converters IEC:146

18. Code of practice for electric wiring installation

IS:732

19. IEEE Recommended practice and requirements for harmonics control in power system.

IEEE-519

20. Adjustable speed electrical drive system IEC-61800


SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: Write-up

TCE.6758A-300-PP-1551 PIPING MATERIAL SPECIFICATION GRADE : BE57C SHEET : 1 OF 3

SERVICE :- PROPANE, BUTANE AND LPG

P-T

R

ATI

NG

TEMP. ºC -45 -29 CA (mm) :- 1.5

PR. kg/cm2 g 35.32 35.32 FLANGE FACING:- RF, 125 RA

NOM. PIPE SIZE NB 15 20 25 40 50 80 100 150 200 250 300 350

OUTSIDE DIA. mm 21.3 26.7 33.4 48.3 60.3 88.9 114.3 168.3 219.0 273.0 323.9 355.6

THICKNESS MM 3.73 3.91 4.55 5.08 3.91 5.49 6.02 7.11 6.35 6.35 6.35 7.92

NOM. PIPE SIZE NB 400

OUTSIDE DIA. mm 406.4

THICKNESS mm 7.92

LINE JOINT 40 NB & BELOW :- SW COUPLING

50 NB & ABOVE:- BUTT WELDED

ITEM

NOMINAL PIPE

SIZE RANGE NB

MATERIAL SPECIFICATION

DIMENSIONAL

STANDARD REMARKS

PIPES

15 – 40 ASTM A 333 GR. 6 ASME B-36.10 PE, SEAMLESS, SCH 80

50 – 150 ASTM A 333 GR. 6 ASME B-36.10 BE, SEAMLESS, SCH 40

200 – 400 ASTM A 333 GR. 6 ASME B-36.10 BE, SEAMLESS, SCH 20

NIPPLES 15 – 40 ASTM A 333 GR. 6 ASME B-36.10 PBE, SEAMLESS

BW

FI

TTIN

GS ELBOWS (90°/ 45°-

1.5D), CAPS, REDUCERS (ECC. / CONC.), TEES (EQUAL / RED.)

50 – 350 ASTM A 420 GR. WPL 6 ASME B-16.9 BW (THK. TO MATCH PIPE THK.)

SW

FI

TTIN

GS

ELBOWS (90°/ 45°), TEES (EQUAL / RED.), COUPLING (FULL / HALF/RED.)

15 – 40 ASTM A 350 GR LF2 CLASS 1

ASME B-16.11 SW

SWAGE (CONC. / ECC.) 15 – 80 ASTM A 350 GR LF2

CLASS 1 BS-3799 PBE (THK. TO MATCH PIPE THK.)

UNIONS 15 – 40 ASTM A 350 GR LF2 CLASS 1 BS-3799 SW

BRANCH CONNECTION 15 – 350 --- --- REFER BRANCH CONNECTION CHART

FLANGES

15 – 40 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 SW, 300, RF / 125 AARH

50 – 150 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 WN, 300, RF / 125 AARH, SCH 40

200 – 400 ASTM A 350 GR LF2 CLASS 1 ASMB B-16.5 WN, 300, RF / 125 AARH, SCH 20

BLIND FLANGES 15 – 400 ASTM A 350 GR LF2 CLASS 1 ASME B-16.5 300, RF / 125 AARH

STUD BOLTS 15 – 400 ASTM A 320 GR.L7 ASME B-18.2

REV. NO. R0 PPD. BY: SS JOB NO. CLIENT: BPCL, Uran ISSUE DATE 30-03-12 CHD. BY: KR TCE. PROJECT: PMC SERVICES FOR R0 REV. BY SS DATE: 30-03-12 6758A BLENDING UNIT AT URAN

TCE FORM NO. 087 R5 FILE NAME: 6758APP1551R0.DOC


SPECIFICATION NO. TATA CONSULTING ENGINEERS LIMITED SECTION: Write-up

TCE.6758A-300-PP-1551 PIPING MATERIAL SPECIFICATION GRADE : BE57C SHEET : 2 OF 3

ITEM NOMINAL PIPE SIZE RANGE

NB

MATERIAL SPECIFICATION

DIMENSIONAL STANDARD

REMARKS

HEAVY HEX. NUTS 15 – 400 ASTM A 194 GR. 4 ASME B 18.2

GASKETS 15 – 400 SP. WND SS304 + GRAFIL

ASME B 16.20 – ASME B 16.5 4.5MM THK, SPIRAL, 300

THREADED FITTINGS :- CAPS

15 – 40 ASTM A 333 GR. 6 ASME B-16.11 SCREWED

TYPE OF VALVE

SIZE RANGE MATERIAL PR.

RATING TYPE OF ENDS

SPECIFICATION OR

TAG NUMBER REMARKS

NB BODY TRIM ANSI

GLOBE VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B-16.11 G63 DMN. STD :- API-602

Note 1

GLOBE VALVE 50 – 250 ASTM A352 GR. LCB SS 304 300

FLGD, 300, B-16.5, RF /125

AARH T33 DMN. STD :- BS-1873

GLOBE VALVE 300 – 400 ASTM A352 GR. LCB SS 304 300

FLGD, 300, B-16.5, RF /125

AARH T33 DMN. STD :- B-16.34,

Note 2

CHECK VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B-16.11 C63 DMN. STD :- API-602

CHECK VALVE 50 – 400 ASTM A352 GR. LCB SS 304 300

FLGD, 300, B-16.5, RF /125

AARH C33 DMN. STD :- BS-1868

BALL VALVE 15 – 40 A350 GR

LF2 CLASS 1

SS 304 800 SW, 800, B 16.11 B33 DMN. STD :- ISO-

17292, Note 1

TYPE OF SPECIALITY

SIZE RANGE

NB

MATERIAL PR. RATING

ANSI

TYPE OF ENDS

SPECIFICATION OR

TAG NUMBER REMARKS

BODY TRIM & INT

STRAINER - 15 – 40 A350 GR

LF2 CLASS 1

INT: SS304 800 SW SP1–XXX Y-TYPE

STRAINER – 50 – 150 A 350 GR LCB INT: SS304 300 WN, RF SP2–XXX Y – TYPE

STRAINER – 200 – 400 A 350 GR LF2 CL 1 INT: SS304 300 WN, RF SP2–XXX Y – TYPE

NOTES:- 1. With 100 mm pipe piece on each side. 2. With Gear Operator 3.


TCE FORM NO. 087 R5 FILE NAME: 6165APP1551R0.DOC


SPEC. NO. TATA CONSULTING ENGINEERS LIMITED SECTION: Write-up

TCE.6758A-300-PP-1551 PIPING MATERIAL SPECIFICATION GRADE :

BE57C SHEET: 3 OF 3

BRANCH CONNECTION CHART

SIZE

BRANCH inch/mm

RUN 15 20 25 40 50 80 100 150 200 250 300 350 400

15 T

20 RT T

25 RT RT T

40 RT RT RT T

50 SL RT RT RT T

80 SL SL SL SL RT T

100 SL SL SL SL RT RT T

150 SL SL SL SL WL RT RT T

200 SL SL SL SL WL WL RT RT T

250 SL SL SL SL WL WL RT RT RT T

300 SL SL SL SL WL WL WL RT RT RT T

350 SL SL SL SL WL WL WL RT RT RT RT T

400 SL SL SL SL WL WL WL RT RT RT RT RT T

LEGEND : T - STRAIGHT TEE RT - REDUCING TEE C - HALF COUPLING TL -THREADOLET SL - SOCKOLET WL - WELDOLET P - PIPE TO PIPE N - NIPOLET

R - REINFORCED


FILE NAME: 6758APP1551R0.DOC TCE FORM NO. 088 R3


SPEC. NO. TATA CONSULTING ENGINEERS LIMITED

TCE.6758A-B-300-002

SECTION : D

PAINTING SPECIFICATION SHEET 1 OF 3

ISSUE R0

1.0 SCOPE

1.1 This specification establishes the minimum requirements for surface preparation, application and inspection of painting for carbon steel pipes, equipment and supports. Painting shall be applied for corrosion protection, service / temperature indication and warning for specific hazards.

1.2 Stainless steel surfaces, both insulated and non-insulated and galvanized steel items shall not be painted. Machined parts of operating equipment and gasket contact surfaces shall also not be painted.

1.3 The CONTRACTOR shall submit a detailed plan for surface preparation and painting for review in specific cases where painting shall be as per “Manufacturer’s Standard”.

2.0 CODES & STANDARDS

IS8629 : Code of practice for protection of iron and steel structures from atmospheric corrosion.

ISO 8501.1/1S: Preparation of steel substrates before application of paints and related products

SSPC : Steel Structure Painting Council – Surface preparation specification

3.0 SURFACE PREPARATION

3.1 Surface preparation of new steel surfaces includes removal of mill scale together with all rust and surface contaminants, such as grease, dirt and all pollutants.

3.2 All weld spatters, rough welds and sharp edges shall be removed or ground smooth prior to blast cleaning.

3.3 All insulated pipes - The surfaces shall be mechanically cleaned to St3 degree. Very thorough cleaning with wire brush shall be done

3.4 All structures

3.4.1 The surfaces shall be blast cleaned to SA 2½ - “Near white blast cleaning” as in ISO 8501.1/1S.

3.4.2 Blast cleaned surfaces shall provide good adhesion for the primers but shall not show excessive roughness. Anchor pattern shall be RZ: 40-70 for zinc silicate primer and RZ: 35-50 for all other primers.



TCE.6758A-B-300-002

SECTION : D


ISSUE R0

3.4.3 Blast cleaning shall not be executed when the surface temperature is less than 30C above dew point of surrounding air or the relative humidity is above 90%. Compressed air used for blast cleaning shall be free from water, oil or other contaminants.

3.5 Blast cleaning shall be executed using abrasives like steel / malleable iron shots, steel / crushed chilled iron grit or chopped steel wire.

4.0 PAINTING

4.1 All insulated pipes shall be applied with one coat of inert Pigment / Epoxy resin based aromatic / polyurethane as binder-Resin of 50 m DFT.

4.2 All structures shall be applied with primer coat of modified aluminium epoxy mastic of 100 m DFT / Intermediate coat of MIO/Epoxy resin of 75 m DFT followed by final two coats of inert Pigment / Epoxy resin based aliphatic / polyurethane as binder-Resin of 40 m DFT each.

4.3 Care shall be taken to ensure that the quality of prepared surface shall not deteriorate before application of paint.

4.4 Sufficient time, as recommended by the paint manufacturer shall be provided for curing of paint before application of next coat of paint. All painted surfaces shall be cured at ambient temperatures.

4.5 Primer, intermediate and finish coats shall be fully compatible and appropriate paint materials shall be obtained from the same paint manufacturer.

4.6 Any type of paint, crayon or tape shall not be used for colour coding of stainless steel surfaces. Solvents used for cleaning the stainless steel surfaces shall be free of chlorides.

4.7 Piping and equipment shall be painted as per colour code provided by the ENGINEER / OWNER.

4.8 In cases where shop coating has been damaged while handling, damaged and blistered coating shall be removed by blast cleaning wherever possible or by hand or power tool cleaning. Edges of breaks shall be feathered and specified number of primer and finish coats shall be applied.

5.0 INSPECTION AND TESTS

5.1 Visual examination of surface preparation shall be carried out in accordance with ISO 8501.1/1S. Profile checks for prepared surface shall be using “Profilometer” or comparator films.



TCE.6758A-B-300-002

SECTION : D


ISSUE R0

5.2 DFT check for intermediate and final coating layers shall be carried out and offered for ENGINEER / OWNER’s examination also. Acceptance criteria shall be as per SSPC-PA 2.

5.3 Painted portions shall be checked for porosity and adhesion visually. If the number of pores per square metre exceeds three, entire area shall be blast cleaned and painted again.


TCE.6758A-E-590-001

TATA CONSULTING ENGINEERS LIMITED SECTION: D SUBSECT D8

INSULATION SPECIFICATION FOR COLD INSULATION

SHEET 1 OF 7

ISSUE

R2

1.0 SCOPE

1.1 This specification covers the technical requirements and essential particulars for

the supply, application and finishing of the complete thermal insulation for cold

equipment, piping systems, air-conditioning ducts etc. for temperatures between

ambient and (-) 80oC and also for dual temperatures (both hot and cold) service

with hot temperature above ambient and up to 230oC. Unless specified otherwise

in section C and/or data sheet A, the scope of supply of the CONTRACTOR shall

include, but not be limited to, the following items :

(a) Insulation materials of all types as specified and required

(b) Insulation adhesives, vapour barriers and finishing materials of all types as

specified and required

(c) Auxiliary materials such as binding and lacing wires, wire netting, bands,

screws, pop rivets etc., as specified and required

(d) Angles, clamps, lugs etc. for supporting insulation

(f) Any other material as may be required for making the insulation complete

2.0 CODES AND STANDARDS

2.1 The supply and application of thermal insulation and finishing covered under this

specification shall comply with all currently applicable statutes, regulations and

safety codes in the locality where it is to be applied. The materials and application

shall also conform to the latest editions of the codes and standards listed. Nothing

in this specification shall be construed to relieve the CONTRACTOR of this

responsibility.

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

IS 737 Wrought Aluminium and Aluminium Alloy Sheet and Strip for

General Engineering Purposes

IS 3144 Mineral Wool Thermal Insulation Materials - Method of Test

IS 14164 Industrial Application and Finishing of Thermal Insulation

Materials at Temperatures above (-) 800C and up to (+) 750

0C

BS 5608 Preformed Rigid Polyurethane (PUR) and Polyisocyanurate

(PIR) Foams for Thermal Insulation of Pipework and Equipment

BS 5970 Thermal Insulation of Pipework and Equipment (in the

Temperature Range (-) 1000C to (+) 870

0C )

3.0 MATERIALS

3.1 GENERAL


TCE.6758A-E-590-001



SHEET 2 OF 7

ISSUE

R2

3.1.1 All materials shall be new and fresh, incombustible, fire retardant, rot-proof, non-

hygroscopic, vermin proof, fungus proof, non-injurious to health, chemically

inert, non-corrosive to steel and aluminium (even if soaked in water for extended

periods) and shall be guaranteed to withstand continuously and without

deterioration the minimum and maximum temperatures to which these shall be

subjected to under the specified applications.

3.1.2 The insulation materials and any component of the finished insulation job shall

not react chemically, singly or in combination, with water or moisture to form

substances that are more actively corrosive to applied surface than water or

moisture alone.

3.1.3 In order to protect the workers from the hazards of insulation materials, suitable

protective gadgets shall be provided. Required safety precautions shall be taken

during handling and application of insulation.

3.1.4 The insulation material shall be kept dry at all times during transport, storage and

installation. Decking and covering tarpaulins alone are not adequate for any

length of time and shall not be allowed except in extreme emergencies and only

for short period. Stacking of insulation materials directly on ground shall not be

done. No wet insulation shall be installed. If wet insulation is present, it shall be

removed and replaced with new dry insulation. The insulation may be protected

with plastic film but shall be vented to prevent sweating.

3.2 INSULATION MATERIALS

The insulation material shall be one or more of the following types as specified in

data sheet A.

SL.

NO.

INSULATION MATERIAL STANDARD DENSITY,

Kg/M3

TEMP. RANGE, 0C

MATERIAL

CODE

1. Rigid polyurethane / Polyisocyanurate foam BS 5608 32 (-)80 to 110 PUR/ PIR

3.3 INSULATION ADHESIVES

The insulation adhesive shall be one or more of the following types as specified

in data sheet A.

Material Description Material Code

3.3.1 Hot bitumen of grade 85/25 or 85/40 conforming to IS 702 shall

be uniformly applied at 1.5 Kg/M2 on the surface to be insulated.

A similar layer shall also be applied on the inside surface of the

insulation. This material shall not be used for stainless steel

surfaces.

BIT

3.3.2 MAS 83 with 0.5 mm wet film thickness shall be uniformly

applied at 0.5 lit/M2 by trowelling. MAS 83 shall not be used

with polystyrene as insulation material. MAS 83 can be used

MAS 83


TCE.6758A-E-590-001



SHEET 3 OF 7

ISSUE

R2


only between (-) 46 and (+) 149oC.

3.4 VAPOUR BARRIERS

The vapour barrier shall be one or more of the following types as specified in data

sheet A.


3.4.1 MAS 130 with 1.02 mm wet film thickness primer coat at 1.0

lit/M2 and 2.25 mm wet film thickness finish coat at 2.5 lit/M

2

shall be uniformly applied over the insulation by spatula or

trowelling. MAS 130 shall not be used with polystyrene as

insulation material. MAS 130 can be used only between (-) 40

and (+) 60oC.

MAS 130

3.5 FINISHING MATERIALS

The finishing material shall be one or more of the following types as specified in

data sheet A.


3.5.1 Aluminium sheet as per IS 737, designation 31000, condition

H3.

AL1

(a) Insulation outside diameter 150 to 450 mm - sheet

thickness 20 SWG

(b) Insulation outside diameter below 150 mm - sheet

thickness 22 SWG

(c) Equipment - sheet thickness 18 SWG

3.6 AUXILIARY MATERIALS

3.6.1 Binding and Lacing Wires

Binding and lacing wire shall be annealed GS 24 SWG.

3.6.2 Wire Netting

Wire netting shall be with GS 24 SWG wire and 20 mm hexagonal opening.

3.6.3 Bands

(a) For securing insulation material : 24 SWG GS, 20 mm wide

(b) For securing aluminium and GS : 24 SWG anodised


TCE.6758A-E-590-001



SHEET 4 OF 7

ISSUE

R2

sheets aluminium or

SS 304, 20 mm wide

3.6.4 Screws

Screws shall be of self-tapping type and shall be of aluminium or stainless steel

for aluminium sheets and GS for GS sheets.

3.6.5 Pop Rivets

Pop rivets shall be of aluminium or stainless steel for aluminium sheets and GS

for GS sheets.

4.0 APPLICATION

4.1 GENERAL

4.1.1 The application of insulation shall be made in a professional manner. The

insulation shall be applied to all surfaces when these are at ambient temperature.

Ample provision shall be made for the maximum possible thermal movement and

the insulation shall be applied in a manner which shall avoid breaking or

telescoping due to alternate periods of contraction and expansion. A single layer

of insulation shall not be more than 75 mm thick.

4.1.2 Insulation shall be applied after all leak tests on equipment and piping are over

and the section of the plant has been specifically released by the PURCHASER

for such work. If insulation has to be applied before the leak test, all welded and

flanged joints shall be left exposed and insulated after satisfactory completion of

the leak test.

4.1.3 All surfaces to be insulated shall be clean and dry before the insulation is applied.

The surfaces shall be cleaned of all foreign material such as scale, dirt, rust and

paint, by the use of steel wire brushes and steel scrapers, where necessary. Where

a surface is not free of paint the CONTRACTOR shall notify the PURCHASER

of the condition for remedial action. The insulation shall be applied after remedial

action, suggested by the PURCHASER, has been taken by the CONTRACTOR.

One coat of primer paint shall be applied and allowed to dry before application of

insulation.

4.1.4 After cleaning and application of one coat of primer paint on the surface to be

insulated, the insulation adhesive shall be applied for fluid operating temperatures

between 200C and (-) 20

0C. Insulation material of required thickness shall be

stuck to the surface with joints staggered. The adjoining sections shall be tightly

pressed together. All the joints shall be sealed with adhesive material. Voids, if

any, shall be packed with suitably cut pieces of insulation material. Vapour

barrier and insulation finish shall be applied as per paras 3.4 and 3.5 or 4.5

respectively.


TCE.6758A-E-590-001



SHEET 5 OF 7

ISSUE

R2

4.1.5 Where multilayer insulation is provided, insulation adhesive shall be used

between two layers, based on temperature criterion given in para 4.1.4.

4.1.6 If aluminium or GS sheet is specified as finishing material, all joints shall be

sealed with bitumastic paint and made effectively weather and water-proof. For

temperatures between (-) 40 and (+) 120oC, MAS 94 may also be used as sealant.

MAS 94 shall, however, not be used with polystyrene as insulation material. All

flat surfaces shall be adequately sloped to prevent pools of water collecting. The

sheet shall be protected internally with 2 coats of bitumastic paint.

4.1.7 All actions shall be taken to complete the application of finishing on exposed

surfaces covered with insulation before closing the day's work. If this is not

practicable, adequate precautions shall be taken to protect the insulation from

weather, for example by wrapping it with polythene sheet, roofing felt or other

approved material.

4.2 PIPES, PIPE FITTINGS, VALVES AND SPECIALITIES

4.2.1 All vertical pipes shall be provided with suitable insulation supports to prevent

the insulation from collapsing due to its own weight. Any welding required,

shall be carried out by the CONTRCATOR with the prior permission of the

PURCHASER and only under his direct supervision. Where welding is not

permitted, suitable clamped supports shall be used. The insulation shall be

applied starting from bottom up. Mattress type insulation materials shall be

clamped from top.

4.2.2 All pipe fittings, valves and specialities shall be covered with the same type and

thickness of insulation as specified for the adjoining pipe. On pipe fittings,

insulation outside diameter shall be same as the outside diameter of adjacent pipe

insulation. Unless specified otherwise in section C, valves and specialities of 100

mm NB and larger sizes shall be provided with removable box type insulation.

Box shall be fabricated from sheet material specified for adjoining pipes. Pipe

insulation on adjoining flanges shall be stopped at one bolt length plus 25 mm

before flange to permit removal of the bolts and nuts. The insulation shall be

applied after the finish has been applied over insulation on the adjacent piping.

Flanged joints shall also be insulated with removable type of boxes. Arrangement

shall be similar to that for valves.

4.2.3 The sheets shall be installed with the longitudinal lap joints at 450 below the

horizontal for horizontal pipes and the joints sealed with bitumastic paint.

4.2.4 On vertical pipes the sheets shall be applied working from bottom up. Each

section of sheets shall have a minimum overlap of 50 mm longitudinally and

circumferentially. Each circumferential joint shall be made weather-proof by

securing with a band of sheet material and sealing with bitumastic paint.

Longitudinal lap joints shall be fixed with screws or pop rivets at approximately

150 mm centres.


TCE.6758A-E-590-001



SHEET 6 OF 7

ISSUE

R2

4.2.5 Valves shall be insulated up to and including their bonnet flange.

4.3.1 Weather hoods shall be provided for insulated piping passing through roof and

external walls.

4.3.2 EQUIPMENT

4.3.3 Where the insulation material is in the mattress form, cleats in the form of wire

nails or nuts or angles and flats for supporting the insulation material, shall be

welded to the equipment by others. If wire nails are to be used as insulation

cleats, these shall be bent and secured with the metal fabric of the mattress, after

the insulation has been applied. Where insulation cleats are in the form of M6

and M10 nuts, the CONTRACTOR shall supply and install bolts of suitable

length for fixing the insulation. The insulation applied to equipment shall be

reinforced with wire netting. One course of wire netting shall be applied to the

surface of the equipment and each layer of insulation shall be backed up with

wire netting. All irregularities of the surface shall be filled and levelled over with

insulating cement. All mattress joints shall be butted tightly and the mattresses

shall be secured with 20 mm wide 24 SWG GS bands at 450 mm centres. After

banding, all mattress edges shall be laced tightly.

4.3.4 All equipment, unless specified otherwise, shall have a smooth aluminium or GS

sheet finish as specified in data sheet A, applied in a manner similar to that

specified for piping. For fixing of aluminium or GS sheets, wooden spacer rings

at 1000 mm centres shall be fixed to the equipment by the CONTRACTOR. All

vertical and horizontal sheets shall be overlapped a minimum of 75 mm. The

lapped joints of adjoining sections of sheets shall be secured with screws or pop

rivets. On all equipment above 2500 mm diameter and flat surfaces, the sheet

shall be further secured by circumferential bands at approximately 1000 mm

centres. Each sheet joint shall be sealed with bitumastic paint. The roof sections

shall overlap the side walls to prevent water seepage between insulation and the

equipment wall. Side wall sheets shall be securely banded at intersections of the

side wall and roof sections.

4.3.3 All equipment manholes, hatches, bolted or screwed cover plates, flanged ends

etc. shall have removable box type insulation, with same thickness of insulation

as for adjacent surfaces. Insulation adjoining such equipment openings shall be

tapered towards these openings to permit removal of bolts, screws, heads, covers

or plates with no damage to adjacent surface insulation or cover.

4.3.4 Nozzles and other connections on tanks and other equipment shall be insulated in

the same manner as the pipes.

4.3.5 Pump casing shall be completely insulated with removable type of boxes

fabricated from the specified sheet material. Proper care shall be taken to

maintain continuity of vapour barrier between static and removable portion of

insulation.


TCE.6758A-E-590-001



SHEET 7 OF 7

ISSUE

R2

4.3.6 Name plates on equipment shall not be insulated. Proper care shall be taken to

eliminate seepage of moisture from such un-insulated portions into the insulating

material.

4.4 CONTRACTION JOINTS IN INSULATION

Depending on the type of insulation material used and the operating temperature,

contraction joints shall be provided for equipment or pipes to prevent rupturing or

buckling when the cold surface contracts.

5.0 MEASUREMENT

5.1 Measurement of insulation over equipment and piping shall be as per IS 14164.

6.0 MISCELLANEOUS

Approval of the PURCHASER shall be obtained of samples of all materials and

necessary test certificates of approved national laboratories, before despatching

these to site. Insulation shall not be applied until specific release is given by the

PURCHASER.


TATA CONSULTING ENGINEERS LIMITED SECTION : D8

. DATA SHEET A

TCE.6758A-E-590-001

THERMAL INSULATION FOR COLD SURFACES SHEET : 1 OF 2

(CARBON STEEL EQUIPMENT & PIPING)

1. AMBIENT TEMPERATURE : 45 OC 13.

2. 14.

3. 15.

4. 16.

5. 17.

6. INSULATION MATERIALS 18.

6.1 EQUIPMENT: EP/PUR/PIR/PF/LRG/U150 19.

6.2 PIPING SYSTEMS : EP/PUR/PIR/PF/LRG/ 20.

PSG/U150 21.

6.3 AIR-CONDITIONING DUCT : EP/PUR/ 22.

PIR/PF/LRG/U150 23.

6.4 24.

6.5 25.

7. INSULATION ADHESIVES : BIT/CPRX/ 26.

MAS 83 27.

8. VAPOUR BARRIERS : VB1/ALF/MAS 130 28.

9. FINISHING MATERIALS 29.

9.1 EQUIPMENT : FC/AL1/GS1/MAS 134

9.2 PIPING SYSTEMS:FC/AL1/GS1/MAS 134 30. TEST CERTIFICATES FOR ALL

9.3 AIR-CONDITIONING DUCT : FC/AL1/ MATERIALS REQUIRED : YES/NO

GS1/MAS 134 31.

9.4 32.

9.5 33.

10. INSULATING CEMENT MATERIAL: 34.

SAME AS THE BASIC INSULATION 35.

MATERIAL 36.

11. 37.

12. 38.

NOTES

1.

REV. NO. PPD. BY : BSR JOB NO. CLIENT: BPCL, URAN

DATE CHD. BY : KR TCE. PROJECT: BLENDING PROJECT IN

URAN LPG BOTTLING PLANT REV. BY DATE : 30-03-12 6758A

GE

NE

RA

L

CO

MP

AN

ION

SP

EC

IFIC

AT

ION

S (

NO

TE

-1)

ISS

UE

NO

. R

4

MA

TE

RIA

LS

TE

ST

S A

ND

IN

SP

EC

TIO

N


TATA CONSULTING ENGINEERS LIMITED SECTION : D8

DATA SHEET A1

TCE.6758A-E-590-001

THERMAL INSULATION FOR COLD SURFACES SHEET : 2 OF 2

(CARBON STEEL EQUIPMENT & PIPING)

INSULATION THICKNESSES IN mm FOR INSULATION MATERIALS

PUR,PIR AND PF

OPERATING

TEMP. oC AMB.

TO 19 TO

9 TO -1 TO

-11 TO

-21 TO

-31 TO

-41 TO

-51 TO

-61 TO

-71 TO

PIPE SIZE

MmNB 20 10 0 -10 -20 -30 -40 -50 -60 -70 -80

15 20 20 30 40 40 50 65 75 75 100 125

20 20 20 30 40 40 65 65 75 75 100 125

25 20 20 30 40 50 65 75 75 100 100 125

40 20 30 40 50 65 75 75 75 100 100 125

50 20 30 40 50 65 75 75 75 100 125 150

65 30 30 40 65 65 75 75 100 100 125 150

80 30 30 40 65 65 75 75 100 100 125 150

100 30 40 40 65 75 75 100 100 125 125 150

125 40 40 40 65 75 75 100 125 125 150 175

150 40 40 65 65 75 100 100 125 125 150 175

200 AND ABOVE AND

FLAT SURFACES

40 50 75 100 125 150 150 150 175 200 225

NOTES

1. INSULATION THICKNESSES SPECIFIED DO NOT INCLUDE THICKNESS OF FINISHING

MATERIALS SUCH AS CEMENT SAND PLASTER, ALUMINIUM OR GS SHEET, BINDING AND

LACING WIRES, WIRE NETTING AND BANDS ETC.

2. FOR INSULATION THICKNESS FOR TAIL END AIR-CONDITIONING DUCT AND EVAPORATIVE

COOLING SYSTEM ETC. REFER SECTION C OF THE ENQUIRY DOCUMENT.

REV. NO. PPD. BY : BSR JOB NO. CLIENT: BPCL, URAN

DATE CHD. BY : KR TCE. PROJECT: BLENDING PROJECT IN

URAN LPG BOTTLING PLANT REV. BY DATE : 30-03-12 6758A

ISS

UE

NO

. R

4


SPEC. NO.

TATA CONSULTING ENGINEERS LIMITED SECTION: D TCE.6758A-B-300-001

WELDING SPECIFICATION FOR EQUIPMENT AND PIPING SYSTEM

SHEET OF 24 OF 4

1

ISSUE R0

TITLE

TCE FORM NO.329 R3 FILE NAME: 6165APP1568R0.DOC

1.0 SCOPE 1.1 This specification shall apply to site fabrication of all welded joints in

carbon steel, low alloy steel and stainless steel for LPG Marketing Terminal Project. Site fabrication also covers any fabrication in a shop set-up at site.

1.2 The welded joints include the following:

(a) All butt welding joints of the longitudinal and circumferential type for attachments in piping, castings and forgings of all components

(b) Socket welding and fillet joints

(c) All types of branch welds

(d) Any other joints not specifically covered above

1.3 For welding of materials not covered by this specification, reference shall

be made to specific project requirements covered in other section of enquiry specification.

2.0 CODES AND STANDARDS 2.1 The welding of all piping systems including equipment, welding

consumables, preheating, postweld heat treatment, other auxiliary functions and welding personnel shall comply with all currently applicable statutes, regulations and safety codes in the locality where the systems are to be installed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. Specifically, the latest editions of the codes and standards listed in following paragraphs shall apply :

(a) ASME B31.3 - Pressure Piping Code for Process Piping (b) Indian Boiler Regulations (IBR) (c) ASME Boiler and Pressure Vessel Code (BPV Code), Section II

Part C - Material Specifications for Welding Rods, Electrodes and Filler Materials

(d) ASME Boiler and Pressure Vessel Code (BPV Code), Section V -

Non-Destructive Examination (e) ASME Boiler and Pressure Vessel Code (BPV Code), Section IX -

Welding and Brazing Qualifications (f) Standards of the Pipe Fabrication Institute


SPEC. NO.



SHEET OF 24 OF 4

2

ISSUE R0

TITLE


(g) BS 2633-Specification for Class I Arc Welding of Ferritic Steel Pipe

work for Carrying Fluids (h) Any other codes and standards specified in Section C of enquiry

specification. 2.2 The codes and standards listed in para 2.1 form an integral part of this

specification. In the event of conflict between this specification and the codes and standards, the more stringent shall govern.

2.3 If no specific requirements are given in this specification, the requirements

of the applicable code shall govern. 3.0 WELDING PROCESSES 3.1 The following welding processes shall be used for shop-fabricated and

field- fabricated piping systems :

(a) Gas Tungsten Arc Welding (GTAW)

(b) Shielded Metal Arc Welding (SMAW) Welding by oxyacetylene process shall not be used. 3.2 GTAW process shall be used for the following :

(a) On butt welds in carbon steels, in sizes 40 mm and smaller in all passes for 300 class and higher systems (in case butt welds are required) and for steam tracers. Also refer Table 1.

(b) On butt welds in alloy steels for the root pass in all sizes (c) On butt welds in stainless steels for the root pass in all sizes 3.3 SMAW process shall be used for the following:

(a) On butt welds in carbon steel, in sizes 50 mm and larger, for the filler passes

(b) On butt welds in low alloy steel for the filler passes in all sizes (c) On butt welds in stainless steel for the filler passes in all sizes 3.4 For carbon steel piping, in sizes 40 mm and smaller, where butt welding is

required, the entire butt welding including root pass may be carried out by SMAW process in 150 class piping systems except for steam tracers.


SPEC. NO.



SHEET OF 24 OF 4

3

ISSUE R0

TITLE


3.5 For IBR systems, all processes used shall be as approved by the IBR inspector.

3.6 Other welding processes such as submerged arc welding are also

acceptable provided the process is properly qualified and approval obtained from the PURCHASER.

3.7 All butt welds shall be considered as full penetration welds. 3.8 Table 1 gives recommendations for welding procedures to be used for

carbon, low alloy and austenitic stainless steels. Welding from inside of the pipe after back gouging and chipping is not envisaged. However, if the CONTRACTOR proposes to use such a method, a detailed written procedure shall be submitted for the PURCHASER’s approval.

4.0 WELDING CONSUMABLES 4.1 The CONTRACTOR shall provide, at no additional cost, all the welding

consumables such as electrodes, filler wires, oxygen, acetylene, argon etc., in order to complete the welding in all respects. The consumables shall be from reputed and approved manufacturers. All the consumables shall be approved by the PURCHASER.

4.2 The electrodes and filler wires shall be of the class specified in the

welding electrode chart. 4.3 Electrode qualification test records shall be submitted for PURCHASER’s

approval. The CONTRACTOR shall also submit batch test certificates from the electrode manufacturer for physical and chemical tests.

4.4 Electrodes shall be in sealed containers and adequate care shall be taken

for storage, strictly in accordance with the manufacturer’s recommendations.

4.5 Electrodes, which have been removed from the original containers, shall

be kept in ovens as per the manufacturer’s recommendations and, once these are taken out, shall be consumed within the time limits stipulated by the manufacturer. Care shall be taken in handling the electrodes to prevent any damage to the flux covering. Portable ovens shall be used for carrying the electrodes from the main oven to the field.

4.6 The electrodes, filler wires and flux used shall be free from

contaminations such as rust, oil, grease and such foreign matter. 4.7 Low hydrogen electrodes shall be used for weld joints in carbon steel if

the wall thickness exceeds 19 mm, except that non-low hydrogen electrodes shall be permitted for the root pass.


SPEC. NO.



SHEET OF 24 OF 4

4

ISSUE R0

TITLE


4.8 E 6010 electrodes may be used for root pass of butt welds and for fillet

welds in carbon steel. 4.9 Refer Table 1 for welding specifications and electrodes. 5.0 WELDING QUALIFICATIONS 5.1 Qualification of the welding procedures to be used and the performance of

welders and welding operators shall conform to the requirements of the BPV Code, Section IX. For IBR systems, these shall also meet the requirements of IBR.

5.2 No production welds shall be undertaken until the qualification

requirements are completed to the satisfaction of the PURCHASER. 5.3 When impact testing is required by the code or by the specification, these

requirements shall be met in qualifying welding procedures. 5.4 The CONTRACTOR shall be responsible for qualifying any welding

procedure and welders intended to be used. The CONTRACTOR shall submit the Welding Procedure Specification (WPS) for acceptance by the PURCHASER. After approval by the PURCHASER, the procedure qualification test shall be carried out by the CONTRACTOR, at his own expense, duly witnessed by the PURCHASER. A complete set of test results shall be submitted to the PURCHASER for approval immediately after successful completion of procedure qualification test. All tests as required by the BPV code Section IX or IBR shall be carried out. The WPS shall require re-qualification if any of the essential variables or supplementary variables is altered.

5.5 Welders shall be qualified in accordance with BPV Code, Section IX or

IBR, as applicable. The qualification shall be carried out in the presence of the PURCHASER. Only those welders who are qualified and approved by the PURCHASER shall be used on the job. For IBR systems, approval of the local IBR inspector shall be obtained by the CONTRACTOR.

5.6 Welders shall always keep their identification cards with them and shall

produce them on demand. The CONTRACTOR shall issue the identity cards after the same are duly certified by the PURCHASER. Welder, who is not in possession of the identity card, shall not be allowed to work.

5.7 The CONTRACTOR shall use forms as per BPV code, section IX, form

QW-482, form QW-483 and form QW-484. Other forms are also acceptable subject to approval by the PURCHASER.


SPEC. NO.



SHEET OF 24 OF 4

5

ISSUE R0

TITLE


5.8 Unless agreed otherwise, the CONTRACTOR shall advise the PURCHASER, in writing, at least three (3) weeks before any welder is employed on the work, the names and qualifications of the proposed welders and welding supervisors. It shall be the CONTRACTOR’s responsibility to ensure that all welders employed by him or his SUB-CONTRACTORS, on any part of the CONTRACT either in the CONTRACTOR’s/his SUB-CONTRACTOR’s works or at site are fully qualified as required by the code. Each welder shall qualify for all types of welds, positions and materials or material combinations he may be called upon to weld.

5.9 Should the PURCHASER require to test or retest any welder, the

CONTRACTOR shall make available, at no extra cost to the PURCHASER, the men, equipment and materials for the tests. The cost of testing the welds shall be borne by the CONTRACTOR.

5.10 Welding supervisors shall have qualifications such as engineering degree

or engineering diploma in welding technology with adequate knowledge of non-destructive testing and a minimum of five (5) years of experience in supervising welding of pipe joints.

5.11 All welding, including the tacking up of all welds shall be carried out by

approved welders. Any weld made by other than an approved welder shall be cut out and re-welded.

5.12 For purposes of identification and to enable tracing full history of each

joint, each welder employed on the work shall be given a designation. The welder’s designation and the date on which the joint was made, shall be stamped on the relevant piping and marked on the relevant drawings also. Copies of the drawings so marked shall be furnished to the PURCHASER for record purposes. For austenitic stainless steels, welder’s designation shall be applied with water-proof paint that is not detrimental to the pipe. Alternatively, record charts may be used.

5.13 For each welder, a record card shall be maintained showing the

procedures for which he is qualified. These cards shall note the production welds, the date of the welding done, the type of defects produced and their frequency. The record shall be reviewed once in a week by the PURCHASER and those welders whose work required a disproportionate amount of repair shall be disqualified from welding. Requalification of welders disqualified more than three (3) times shall be entirely at the discretion of the PURCHASER.

6.0 PREPARATION FOR WELDING 6.1 Surfaces to be welded shall be smooth, uniform and free from fins, tears

and other defects, which would adversely affect the quality of the weld.


SPEC. NO.



SHEET OF 24 OF 4

6

ISSUE R0

TITLE


All welding faces and adjoining surfaces, for a distance of at least 150 mm from the edge of the welding groove or 12 mm from the toe of the fillet in the case of socket welded or fillet welded joints shall be thoroughly cleaned of rust, scale, paint, oil or grease, both inside and outside.

6.2 Joints for welding, whether socket welding or butt welding shall be as per

the project piping material specifications. 6.3 Butt joints shall be prepared as per ANSI B16.25 unless specified

otherwise. For piping under the purview of IBR, these shall be as per IBR. Any other end preparation which meets the WPS is acceptable.

6.4 Internal misalignment shall be reduced by trimming but such trimming

shall not reduce the finished wall thickness below the required minimum wall thickness. Root opening of the joint shall be within the tolerance limits of the WPS.

6.5 Fillet welds, socket welds and welded - on branch connections shall be as

per ASME B31.3 or in accordance with IBR for IBR systems. 6.6 Reinforcing pads and saddles shall have a good fit with the parts to which

they are attached. A vent hole shall be provided on the side of any pad or saddle to reveal leakage in the weld and to allow venting during welding and heat treatment. Pad or saddle shall be added after the branch weld has undergone examination and necessary repairs.

6.7 The ends shall be prepared by machining, grinding or flame cutting.

Where flame cutting is used, the effect on the mechanical and metallurgical properties of the base metal shall be taken into consideration. Flame cutting of alloy steel pipes is not allowed. However, flame cutting of carbon steel pipes is permitted. Wherever practicable, flame cutting shall be carried out by machine. Machine flame-cut edges shall be substantially as smooth and regular as those produced by edge planing and shall be cleaned free of slag. Manual flame cutting shall be permitted only where machine flame cutting is not practicable and with the approval of the PURCHASER, and such surfaces shall be ground or dressed to a smooth finish as required by the specification and to the satisfaction of the PURCHASER. Slag, scale or oxides shall be removed by grinding to bright metal at least two (2) mm beyond the burnt area.

6.8 Thermal cutting of carbon steel piping shall be performed under the same

conditions of preheating and postweld heat treatment as for the welding of each class of material. However, post-weld heat treatment is not required when :

(a) The heat affected zone produced by thermal cutting is removed by

mechanical means immediately after cutting. However, in any case,


SPEC. NO.



SHEET OF 24 OF 4

7

ISSUE R0

TITLE


all remaining slag, scale or oxides shall be removed by grinding to bright metal at least two (2) mm beyond the burnt area, or

(b) Thermal cutting is part of fabrication, manufacturing or erection

sequence leading to a weld end preparation where welding immediately follows.

6.9 On austenitic stainless steels, plasma cutting, machining or grinding

methods may be used for edge preparation. Cut surfaces shall be machined or ground smooth after plasma cutting.

6.10 Before fitting up the weld joint, the profile and dimensions of the weld end

preparation shall be checked by the PURCHASER. If the specified tolerances are exceeded, this shall be corrected (with prior approval) by grinding, machining or any other method acceptable to the PURCHASER.

6.11 Fit-ups shall be examined by the PURCHASER prior to welding the root

pass. 7.0 TECHNIQUE AND WORKMANSHIP 7.1 Components to be welded shall be aligned and spaced as per the

requirements of the code and WPS. Special care is required when GTAW process is employed.

7.2 Alignment and spacing shall be achieved using suitable wires to maintain

the gap. These shall be removed after tack welding. The ends to be welded shall be held using suitable clamps, yokes or other devices which will not damage the surfaces in any manner. It shall be ensured that welding operations do not result in distortions.

7.3 Tack welds at the root joint, for maintaining joint alignment, shall be made

only by qualified welders or welding operators and with filler metal equivalent to that used in the root pass. Tack welds shall be fused with the root pass weld, except that those which have cracked shall be removed. Peening is prohibited on the root and final passes of a weld. The required preheat shall be maintained prior to tack welding.

7.4 No welding shall be carried out if there is any impingement in the weld

area of rain, snow, excessive wind or if the weld area is wet. 7.5 Irrespective of the class of steel, root runs shall be made without

interruption other than for changing the electrodes or to allow the welder to reposition himself. Root runs made in the shop may afterwards be allowed to cool by taking suitable precautions to ensure slow cooling e.g. by wrapping in a dry asbestos blanket. Welds made at site shall not be


SPEC. NO.



SHEET OF 24 OF 4

8

ISSUE R0

TITLE


allowed to cool until the thickness of weld metal deposited exceeds one third of the final weld thickness or 10 mm, whichever is greater.

7.6 When welding alloy steels, it is strongly recommended that interruption of

welding be avoided. Where such interruption is unavoidable, either the pre-heat shall be maintained during the interruption or the joint shall be wrapped in dry asbestos blankets to ensure slow cooling. Before recommencing welding, preheat shall be applied again.

7.7 Welded-on bridge pieces and temporary attachments shall preferably be

avoided. Where approved by the PURCHASER, these may be used. Material of these shall be compatible with material with which they are temporarily welded. All such pieces shall be removed after welding of pipe joints and the weld area ground flush. These areas shall be subject to liquid penetrant or magnetic particle examination for high yield strength materials (YS > 3200 kg/cm2) or when the component thickness exceeds 20 mm or for P3 and P4 group materials. These pieces shall be welded by qualified welders and with electrodes compatible with the parent pipe material. The preheating requirements of pipe material shall be applied and maintained during the welding of attachments. These temporary attachments shall be removed by grinding, chipping, sawing or by arc or flame gouging. When arc or flame gouging is used, at least three (3) mm of metal shall be left around the pipe surface which shall be removed by grinding.

7.8 The arc shall be struck only on those parts of parent metal where weld

metal is to be deposited. When inadvertent arc-strikes are made on the base metal surfaces outside the joint groove, the arc-strikes shall be removed by grinding and shall be examined by liquid penetration or magnetic particle examination procedures.

7.9 Oxides shall not be permitted to form during welding or heat treatment or

both, on the internal surfaces of pipes which will not be subsequently cleaned. Inert gas purging is an acceptable method to prevent such oxidation. All joints in materials which contain more than 1¼% chromium shall be purged to assure that less than 1% of oxygen is present on the joint underside before initiation of the welding. The purging operation shall be maintained for a minimum of two (2) passes.

7.10 Argon gas used in GTAW process for shielding and purging shall be at

least 99.95% pure. Purging shall be carried out at a flow rate depending on diameter of pipe until at least five (5) times the volume between dams is displaced. In no case shall the initial purging period be less than 10 minutes. After initial purging, the flow of the backing gas shall be reduced to a point where only a slight positive pressure prevails. Any dams used in purging shall be fully identified and removed after welding and accounted


SPEC. NO.



SHEET OF 24 OF 4

9

ISSUE R0

TITLE


for in order to avoid leaving them in the system. The rate of flow for shielding purposes shall be established in the procedure qualification.

7.11 Thorough check shall be exercised to maintain the required inter-pass

temperature. 7.12 All equipment necessary to carry out the welding, for supporting of the

work, for preheating and post weld heating including thermal insulation for retaining the heat and for the protection of the welder shall be provided by the CONTRACTOR at no extra cost. All necessary precautions shall be taken during cutting and welding operations. It shall be ensured that proper ventilation is available in the welding area and adequate protective gear such as goggles, masks, gloves, protection for the ears and body are used at all times. For guidelines refer ANSI standard Z49.1, “Safety in Welding and Cutting”.

7.13 After deposition, each layer of weld metal shall be cleaned with a wire brush to remove all slag, scale and defects, to prepare for the proper deposition of the next layer. The material of wire brush shall be compatible with pipe material. Stainless steel materials shall be cleaned with grinding wheels or stainless steel brushes which have not been used on other materials. Either aluminium oxide or silicon carbide grinding wheels shall be used. Special care shall be taken to secure complete and thorough penetration of the fusion zone into the bottom of the weld. It is recommended that the root run be checked by liquid penetrant or magnetic particle procedures for critical process piping.

7.14 Upon completion of welding, the joints shall be wrapped in dry asbestos

blankets to ensure slow cooling, unless post-weld heat treatment is applied immediately.

7.15 No welding or welded parts shall be painted, plated, galvanised or heat

treated until inspected and approved by the PURCHASER. Welds shall be prepared and ground in such a way that the weld surfaces merge smoothly into the base metal surface.

7.16 Except where necessary to grind flush for non-destructive examination,

reinforcement for butt welds may be provided. The height of such reinforcement shall meet the requirements of the code. The reinforcement shall be crowned at the centre and tapered on each side of the joined members. The exposed surface of the weld shall be ground where required to present a workmanlike appearance and shall be free from depressions below the surface of the joined members. The exposed surface of the butt welds shall be free from undercuts greater than 0.5 mm in depth, overlaps or abrupt ridges or valleys and shall merge smoothly into the pipe surface at the weld toe. However, undercuts shall not encroach on the minimum section thickness.


SPEC. NO.



SHEET OF 24 OF 4

10

ISSUE R0

TITLE


7.17 Repair of weld metal defects shall meet the requirements of the code. 7.18 Any weld repair shall be subject to the approval of the PURCHASER. 7.19 In the event of several unsuccessful repair attempts or if the

PURCHASER feels that a satisfactory repair is not feasible, the joint shall be completely remade.

7.20 IDENTIFICATION OF WELDS Wherever code symbol stamps are required on carbon steel and ferritic

alloy steel piping they shall be applied directly to the pipe with low stress dotted design metal die stamps or to a small stainless steel plate especially provided for such marks. These plates shall be lightly tack welded to the pipe using electrodes, of diameter three (3) mm or less, of the type specified for the material. Before making the required tack weld, the pipe material in the immediate surrounding area shall be preheated, as required, by electric means or propane or natural gas burners. Cooling shall take place under asbestos insulation in a draft-free area. Stress relieving of these welds is not required. Steel stamping directly on the surface of alloy steel piping with other than low stress die stamps shall not be used.

7.21 SEAL WELDS 7.21.1 Seal welding shall be carried out by qualified welders and in accordance

with approved drawings. 7.21.2 Threaded joints that are to be seal welded shall be made without the use

of thread lubricating compound. Seal weld shall cover all exposed threads.

7.22 WELD ENCROACHMENT AND MINIMUM DISTANCE BETWEEN

WELDS 7.22.1 Welded joints, more specifically longitudinal welds, shall be placed not

closer than 50 mm to opening or branch welds, reinforcements, attachment devices or from supports, etc. In case of deviation, the PURCHASER may specify additional non-destructive examination.

7.22.2 The longitudinal welds of two adjacent pipes or components shall be

staggered by at least 30o. The minimum distance between welds shall be 50 mm or three (3) times the wall thickness, whichever is greater. Longitudinal welds shall not be situated at the bottom of the pipe. Intersection of welds shall be avoided as far as possible. If such welds are present, they shall be subject to suitable Non-Destructive Testing (NDT) at the discretion of the PURCHASER.


SPEC. NO.



SHEET OF 24 OF 4

11

ISSUE R0

TITLE


8.0 PREHEATING 8.1 Preheating prior to tack welding, welding and thermal cutting shall be used

as a means of crack prevention and improving weld reliability. The general requirements of post-weld heat treatment also apply to preheating.

8.2 Preheating shall be used as per the recommendations of ASME B31.3,

Table 330.1.1. For IBR systems, the requirements of IBR shall govern. Preheating of austenitic stainless steels is not required, except at low ambient temperatures, in which case a minimum preheat temperature of 10oC is recommended. Table 2 gives the requirements of preheating for commonly used materials.

8.3 The preheating zone shall extend 75 mm or a distance equal to four (4)

times the material thickness, whichever is greater, beyond the edge of the weld.

8.4 The preheat temperature shall be measured at least 75 mm away from

the weld preparation. 8.5 Where preheating is specified, welding shall continue without interruption.

In case interruption cannot be avoided, preheating shall be continued for at least thirty (30) minutes after interruption. Also refer para 8.9.

8.6 Oxy-acetylene preheating shall not be applied. 8.7 For preheating, fuel gas/air torches, burner systems (high velocity gas or

oil burners) or electrical heating may be used either locally or in a furnace. For preheating above 250oC, electric heating (resistance or inductive heating) is preferred.

8.8 Approved temperature - indicating crayons, thermocouples or digital

contact pyrometers shall be used to measure preheat and interpass temperatures. A calibration report of the pyrometers and thermocouples shall be available.

8.9 When the preheat temperature is 150oC or higher, the metal shall be

maintained at or above the preheat temperature until the weld is completed.

8.10 The welding of groove welds in low alloy steels of P-3 to P-5 groups with

wall thickness of 19 mm or greater may only be interrupted, provided at least 10 mm of weld metal is deposited, or 25% of the welding groove is filled, whichever is greater. If the welding is interrupted prior to the above, the weld area shall be adequately covered with insulating material to ensure slow cooling. After cooling and before welding is resumed, visual


SPEC. NO.



SHEET OF 24 OF 4

12

ISSUE R0

TITLE


examination of the weld shall be performed to assure that no cracks are formed. Required preheat shall be applied before welding is resumed.

9.0 POSTWELD HEAT TREATMENT Post-weld heat treatment shall meet the requirements of para 331 of

ASME B31.3. For IBR systems, post-weld heat treatment shall be as per IBR. Table 3 summarises the post-weld heat treatment requirements for commonly used materials.

9.1 GENERAL REQUIREMENTS 9.1.1 A complete automatic temperature recording shall be made of preheating

and stress relieving operations. Where propane gas burners or electrical resistance coils are employed, a complete temperature record of the preheating and stress relieving operation shall be made by means of a box type potentiometer. Other means of recording temperatures are permissible subject to the PURCHASER’S approval.

9.1.2 Stress relief may be local or full furnace. Local stress relief shall be

performed with electric induction or electric resistance coils. Suitable gas burning equipment using natural gas or propane may be employed.

9.1.3 At no time during a stress relieving/preheating cycle shall any water or liquid cooling medium be employed.

9.1.4 Where members being joined are unequal in thickness, the dimension of

the heavier section shall govern the selection of width of the heated band and the duration of the holding period.

9.1.5 For local stress relief, using electrical methods, a minimum of two (2)

thermocouples tack-welded to the surface and potentiometers shall be used on the pipe under at least four (4) layers of asbestos paper. The hot junctions of the thermocouples shall be located on either side of the joint at least 12 mm from the edge of the joint but no further away than 100 mm. When employing induction heating, at least six (6) turns of induction cable shall be used on each side of the weld. Induction coils shall be wrapped on top of the asbestos paper protecting the thermocouples with the first turn approximately 150 mm from the centre of the weld.

9.1.6 Local stress relief using gas torches or ring burners may be employed.

However, the procedure shall be limited to pipes below 100 mm NPS and shall be approved by the PURCHASER.

9.1.7 The stress relieving temperature shall be maintained for a period of time

proportioned on the basis of one (1) hour per 25 mm of wall thickness of the thickest section at the joint, but in no case less than one (1) hour.


SPEC. NO.



SHEET OF 24 OF 4

13

ISSUE R0

TITLE


9.1.8 For tubing joints and socket welded joints, pads, bosses, branch welds and couplings, one (1) thermocouple shall be positioned at a minimum distance of two (2) pipe wall thicknesses from the weld.

9.1.9 Piping on both sides of any joint shall be adequately supported throughout

the preheating, welding and stress relieving operations to prevent distortion. When a butt welded joint is to be post-weld heat treated and the piping is cold-sprung, the forces required to position the pipes shall be maintained by external means until the completion of the heat treatment procedure.

9.1.10 All heating and cooling must be performed in still air. 9.1.11 The governing thickness for the post-weld heat treatment shall be the

thicker of the two components joined by welding. For deviations from this requirement for branch welds, fillet welds etc., reference shall be made to the applicable paragraph of ASME B 31.3.

9.1.12 The CONTRACTOR shall submit a detailed written procedure for the post-

weld heat treatment for the approval of the PURCHASER. 9.2 CARBON STEEL 9.2.1 Welded joints in carbon steel piping systems shall be stress relieved,

upon completion of the welding operation, in accordance with Table 3. 9.2.2 When local stress relief is employed, the welded joint shall be heated to a

temperature of not less than 625°C the temperature level shall be maintained between 625°C and 675°C, one (1) hour per 25 mm of wall thickness but in no case less than one (1) hour. The weld area shall then be allowed to cool undisturbed in still air to a temperature not exceeding 315°C. All welded joints in pipe sizes 100 mm and larger, shall be heated by means of electric induction coils or resistance heating. Welded joints in pipes smaller than 100 mm shall be stress relieved by means of electrical resistance coils or suitable propane or natural gas torches only.

9.2.3 Heating and Cooling Carbon steels, after having reached their specific stress relief

temperatures, may be cooled in the furnace or under wraps, i.e., leaving the induction coils or resistance heaters and insulation in place. This means that, at the stress relief temperatures, the power to the furnace or heating coils may be shut off and cooling takes place in the furnace or with all insulation and coils remaining on the pipe. For furnace stress relief, the doors of the furnace may be opened after the power is shut off, at or below 315°C. Thermocouples controlling the temperatures shall remain during the cooling cycle so that excessive cooling, if it occurs, can


SPEC. NO.



SHEET OF 24 OF 4

14

ISSUE R0

TITLE


be observed and immediately corrected. The stress relieving coils and insulation shall only be removed after the piping has cooled to below 315°C or if stress relieved in a furnace the pipe may be removed from the furnace and permitted to cool in still air at a temperature not below 10°C.

9.3 ALLOY STEEL 9.3.1 All welds in alloy steel piping shall be stress relieved after the welding

operation in accordance with Table 3. Immediately after welding, the material shall be wrapped in asbestos and allowed to cool.

9.3.2 Local Stress Relief All welded joints in pipes 100 mm size and larger shall be locally stress

relieved by means of electric induction coils or resistance heating. Welded joints in smaller pipe sizes shall be stress relieved by means of electric resistance coils or suitable propane or natural gas torches only.

9.3.3 For full furnace stress relief of a welded assembly, the entire fabricated

section shall be heated uniformly to the temperature specified. The temperature shall be maintained for a period of time proportioned on the basis of one (1) hour per 25 mm of wall thickness of the piece having the greatest wall thickness in the furnace charge, but, in no case, less than one (1) hour.

9.4 AUSTENITIC STAINLESS STEEL Welded joints in austenitic stainless steel piping need not be stress

relieved after welding. 9.5 The rate of heating and cooling during stress relieving operations shall not

exceed 315°C per hour up to a thickness of 50 mm at the weld. 10.0 ELECTRODES 10.1 The specification and size of the electrodes, voltages and amperages,

thickness of beads and number of passes shall be as specified in the approved welding procedure or otherwise agreed in writing. Only basic coated electrodes shall be used, which will deposit weld metal having the same or higher physical properties and similar chemical composition to the members being joined. For each batch of approved brand, certificate showing compliance with the specification shall be submitted to the PURCHASER for review before being released for use. All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. All low hydrogen electrodes, after baking as per the manufacturer’s recommendations, shall be stored in ovens kept at 80 to 100°C before being used. Recommendations of the electrode


SPEC. NO.



SHEET OF 24 OF 4

15

ISSUE R0

TITLE


manufacturer shall be strictly followed. Until the electrodes are taken out for welding, they shall be stored in portable ovens. The electrodes shall not be exposed to open atmosphere.

10.2 For welding of all grades of steel and alloys by the GTAW process, a 2%

thoriated tungsten electrode conforming to SFA-5.12-86 EWTh-2 (AWS-A5.12-80, EWTh-2) classification shall be used.

10.3 All electrodes to be used on alloy and carbon steel shall conform to BPV

Code Section II Part C or any other equivalent code. 10.4 As welding electrodes deteriorate under adverse conditions of storage

leading to dampness in the electrode coating, they shall normally be stored in dehumidified air-conditioned rooms or in hot boxes or ovens in their original sealed containers whose temperatures shall be maintained within specified limits. The condition of electrodes shall be frequently inspected. Electrodes with damage to coating shall not be used. Electrodes shall remain identified until consumed. It is preferable to procure low hydrogen electrodes in hermetically sealed containers and preserve them without damage to the containers.

10.5 The type of electrodes used shall be only those recommended by the

manufacturer for the use in the position in which the welds are to be made. Electrodes which have the areas of flux covering broken away or damaged shall not be used.

10.6 Table 1 gives recommendations on electrodes to be used for carbon, low

alloy and austenitic stainless steels. 11.0 INSPECTION AND TESTING 11.1 The PURCHASER shall have free access to inspect welding or any other

related operations at any time and at any stage of fabrication. 11.2 The PURCHASER may require non-destructive testing of any weld for

reasons other than those given in the specification. The responsibility for the cost of such testing shall be mutually decided between the PURCHASER and the CONTRACTOR.

11.3 The CONTRACTOR shall inform the PURCHASER when the weld

preparation and setting up for welding of various members selected by the PURCHASER is in progress so that the PURCHASER can inspect the assembly before welding starts.

11.4 The responsibilities of the PURCHASER’s representative shall in no way

reduce the CONTRACTOR’s responsibilities to ensure that the work is carried out in accordance with the specification.


SPEC. NO.



SHEET OF 24 OF 4

16

ISSUE R0

TITLE


11.5 Any examination by non-destructive methods on low alloy steels shall be performed after post-weld heat treatment.

11.6 For a welded branch connection, the examination of and any necessary

repairs shall be completed before any reinforcing pad is added. 12.0 EXAMINATION OF WELDS 12.1 Examination refers to the quality control functions performed by the

CONTRACTOR during fabrication, erection and testing. 12.2 As a minimum, the following shall be examined by visual examination :

(a) Materials and components to ensure that these are as per the specification and are free from defects. If defects are noticed on “free-issue” items, these shall be brought to the notice of the PURCHASER without delay.

(b) Joint preparation and cleanliness (c) Preheating as applicable (d) Fit-up, joint clearance, and internal alignment prior to joining

(e) Variables specified by the welding procedure, including filler

material, position and electrode (f) Condition of the root pass after cleaning - external and where

accessible, internal (g) Slag removal and weld condition between passes (h) Appearance of the finished joint

12.3 Acceptance for the visual examination shall be as per ASME B 31.3 or IBR as applicable.

12.4 Other types of examination shall be as defined in Tables 4 and 5, unless

otherwise mentioned in section C of enquiry specification. For the purpose of examination, fluids are categorised, in accordance with ASME B 31.3, as Category D, Normal Service and Category M and supplemented by other requirements.

13.0 QUALIFICATION AND CERTIFICATION OF NON-DESTRUCTIVE

EXAMINATION PERSONNEL


SPEC. NO.



SHEET OF 24 OF 4

17

ISSUE R0

TITLE


13.1 The CONTRACTOR’s examining personnel shall have training and experience commensurate with the needs of the specified examinations. NDT supervisors/ examiners shall be qualified at level II or above.

13.2 The CONTRACTOR shall make available to the PURCHASER copies of

certificates of qualification of the examiners he proposes to use for the PURCHASER’s approval.

14.0 METHODS OF EXAMINATION The methods of examination used, radiographic (RT), liquid penetrant

(PT) or magnetic particle (MT), shall be in accordance BPV Code, Section V.

15.0 ACCEPTANCE STANDARDS 15.1 Levels of acceptance of defects in welds shall be in accordance with

ASME B 31.3. 15.2 For IBR piping, the levels of acceptable defects shall be as per IBR. 16.0 REPAIR WELDING 16.1 All defects in welds requiring repair shall be removed by flame or arc

gouging, grinding, chipping or machining. The major repairs may involve :

(a) Cutting through the weld (b) Cutting out a length of pipe containing the weld, or (c) Removing the weld metal down to the root depending upon the

magnitude of the defects.

16.2 After removing the defect, the welds shall be examined by the same non-destructive testing methods as specified for the original weld and the same acceptance criteria shall hold good.

16.3 All the repair welds shall be made using the same or other specified

welding procedures as those used in making the original welds including preheating and stress relieving if originally required.


SPEC. NO.



SHEET OF 24 OF 4

18

ISSUE R0

TITLE


TABLE 1

WELDING SPECIFICATION CHART

SL. NO.

BASE MATERIAL P. NO.

WELDING PROCESS FILLER MATERIAL GAS NOTES

ROOT FILLER ROOT FILLER PURGING

SHIELDING

1.0 CARBON STEELS

1.1

SIZES 40 mm AND/OR 3 mm THK

1 GTAW GTAW ER 70S2 OR

ER 70S3

ER 70S2 OR

ER 70S3

- - 1

1.2

SIZES 50 mm THK 19 mm

1 SMAW SMAW E 6010 E 6013 - -

1.3

SIZES 50 mm THK 19 mm

1 GTAW SMAW ER 70S2 OR

ER 70S3

ER 7018 OR

ER 7016

- - 2

2.0 LOW ALLOY STEELS

2.1

1¼% Cr ½% Mo

4 GTAW SMAW ER 80S B2

E8016/E 8018-B2

- -

2.2

2¼% Cr 1% Mo

5 GTAW SMAW ER90S B3

E9015/ E 9016/ E 9018-B3

ARGON ARGON 3 to 8

3.0 AUSTENITIC STAINLESS STEELS

3.1

TYPE 304 (304L)

8 GTAW GTAW for THK 4.5 mm

ER 308 (ER 308L)

ER 308 (ER 308L)

ARGON ARGON 3 to 8

SMAW for THK > 4.5mm

E 308 (E 308L)

3.2

TYPE 316 (316L)

8 GTAW GTAW for THK 4.5 mm

ER 316 (ER316L)

ER 316 (ER 316L)

ARGON ARGON 3 to 8


E 316 (E 316L)

3.3 TYPE 321 8 GTAW GTAW for

THK 4.5mm

ER 321/ ER 347

ER321/ ER 347

ARGON ARGON 3 to 8


E321/E347


SPEC. NO.



SHEET OF 24 OF 4

19

ISSUE R0

TITLE


TABLE 1 (CONTD.)

SL. NO.

BASE MATERIAL

P. NO.

WELDING PROCESS

FILLER MATERIAL GAS NOTES

ROOT FILLER ROOT FILLER PURGING SHIELDING 4.0 STAINLESS

STEEL TO CARBON STEEL

4.1 SS 304/321 8 to 1

GTAW/ SMAW

SMAW ER309

ER309

- -

4.2 SS 316 8 to 1

ER310Mo E310Mo - -

NOTES 1. For 300 and higher class systems. For 150 class systems, refer para 3.4. For

fillet welds SMAW process with E6013 can be used. 2. Low hydrogen electrodes shall also be used for critical systems such as

chlorine, hydrogen, caustic and similar toxic inflammable fluids and also whenever the wall thickness exceed 19 mm.

3. The argon shielding gas flow rate shall not be less than 0.34 m3/hr. 4. Nitrogen can be used as an alternative to argon for purging purpose only. 5. For fillet welds, electrode can be used instead of filler wire. 6. For GTAW process, electrode shall be 2% thoriated tungsten. 7. Initial purging prior to welding process shall be a minimum of five (5) times the

volume between dams or ten minutes minimum whichever is higher. When welding commences, the purge gas flow shall ensure that the gas pressure is only marginally higher than atmospheric pressure to ensure no roof concavity.

8. Back purging using argon/nitrogen shall be maintained for a minimum of two

passes. 9. Electrodes / filler wires manufactured by reputed firms duly approved by the

PURCHSER shall only be used. 10. Electrodes shall have at least the same or higher physical properties and

similar chemical composition to the members being joined. 11. Read the table in conjunction with para 3.0


SPEC. NO.



SHEET OF 24 OF 4

20

ISSUE R0

TITLE


TABLE - 2

PREHEAT REQUIREMENTS

SL. NO.

BASE MATERIAL P. NO. NOMINAL WALL

THICKNESS , mm

SPECIFIED MINIMUM TENSILE

STRENGTH, MPa

RECOMMENDED MINIMUM PREHEAT

TEMPERATURE, ° C

1. CARBON STEEL 1 25 490 10

2. LOW ALLOY STEEL - 1¼% Cr ½% Mo

4 ALL ALL 149

3. LOW ALLOY STEEL - 2¼%Cr 1% Mo

5 ALL ALL 177


SPEC. NO.



SHEET OF 24 OF 4

21

ISSUE R0

TITLE


TABLE 3

POSTWELD HEAT TREATMENT REQUIREMENTS

SL. NO

.

BASE MATERIAL P. NO.

NOMINAL WALL

THICKNESS,

mm

SPECIFIED MINIMUM TENSILE

STRENGTH, MPA

METAL TEMPERATURE

RANGE ° C

BRINELL

HARDNESS

MAX.

1. CARBON STEEL 1 19 ALL NONE -

2. CARBON STEEL 1 > 19 ALL 625-675 -

3. LOW ALLOY STEEL 1¼% Cr ½% Mo

4 13 490 NONE -


4 > 13 ALL 704 to 746 225


5 13 490 NONE -


5 > 13 ALL 704 to 760 241

7. AUSTENITIC STAINLESS STEELS

8, 9 ALL ALL NONE -

NOTES 1. In IBR systems, in carbon steels, postweld heat treatment is also required,

when the carbon percentage exceeds 0.25%, at the temperature range of 600 +/- 20°C.

2. All low alloy steel welds in IBR systems shall be postweld heat treated at the

temperature range of 620 to 660° C for 1 1/4% Cr 1/2% Mo steels and at a range of 660 to 750°C for 2 1/4% Cr 1% Mo steels.


SPEC. NO.



SHEET OF 24 OF 4

22

ISSUE R0

TITLE


TABLE 4 WELD EXAMINATION (OTHER THAN ‘IBR’)

SL. NO.

FLUID SERVICE CATEGORY AS PER

ASME B 31.3

TYPE OF EXAMINATION

EXTENT OF EXAMINATION

GIRTH BUTT WELD

SOCKET AND FILLET WELDS

BRANCH WELDS (FABRI-CATED)

FABRICATED MITRES /

REDUCERS

ATTACH MENT

WELDS

1.0 CATEGORY D VISUAL 100% 100% 100% 100% 100%

LT/MT - - 5% - -

RT (ABOVE GROUND)

10% - - 10% -

RT (UNDER GROUND)

100% - - - -

2.0 NORMAL VISUAL 100% 100% 100% 100% 100%

RT 10% - - 10% -

LT/MT - 10% 10% - 10%

3.1 CATEGORY M & PIPING GRADE – BE57C (Propane / Butane / LPG SERVICE)

VISUAL

RT

LT/MT

100%

100%

100% (FOR ROOT RUN)

100%

-

100%

100%

-

100%

100%

100%

100% (FOR ROOT RUN)

100%

-

100%

3.2 HIGH PRESSURE (ASME 600 CLASS AND HIGHER)

3.3 CRITICAL SERVICES SUCH AS CHLORINE, CAUSTIC, HYDROGEN AND OTHERS AS DEFINED IN SECTION-C

3.4 LOW TEMPERATURE [<(-)80°C]

3.5 SEVERELY CYCLIC AS PER ASME B 31.3

NOTES Fluid services are categorised as follows (as per ASME B 31.3) 1. Category D : Fluid is non-flammable, non-toxic, and not damaging to human

tissues, and design pressure is 1.035 M Pag(150 psig) and design temperature is 186°C and not below (-) 20°C.

2. Category Normal : Not Category D, not category M, not “high pressure” as per ASME B31.3 and not subject to severe cycling as defined in ASME B 31.3.


SPEC. NO.



SHEET OF 24 OF 4

23

ISSUE R0

TITLE


3. Category M : Toxic Services which can damage human tissue after a single exposure even if prompt remedial measures are taken.


SPEC. NO.



SHEET OF 24 OF 4

24

ISSUE R0

TITLE


TABLE 5

WELD EXAMINATION (IBR PIPING)

SL. NO.

ANSI PRESSURE CLASS

NOM PIPE SIZE, mm

TYPE OF EXAMINATION

EXTENT OF EXAMINATION

GIRTH BUTT WELD

SOCKET AND

FILLET WELDS

BRANCH WELDS

FABRICATED

ATTACHMENT WELDS

1. ALL ALL VISUAL 100% 100% 100% 100%

2. 150 AND 300

100 RT 10% - - -

50 to 80 RT 2% - 2% -

40 LT/MT - 2% - -

3. 600 AND HIGHER

50 RT 100% - - -

40 LT/MT NOTE 2

100% 100% 10%

NOTES

1. The extent of examination shown above is minimum and any additional requirement as required by ‘IBR’ shall also be considered.

2. For root runs of butt welds in sizes 50 mm (100%)


Spec No. TCE CONSULTING ENGINEERS LIMITED Section : D

TCE. M4-405-01 SUPPLY AND FABRICATION OF STRUCTURAL STEEL

Sh 1 of 1

REV.NO R1 R2 R3 ISSUE

INITIALS SIGN INITIALS SIGN INITIALS SIGN INITIALS SIGN

PPD.BY CKD.BY R5 APP.BY DATE

TCE FORM 329 R3

SUPPLY AND FABRICATION OF STRUCTURAL STEEL

FILE NAME : M4-405-01(R5).DOC




Sh 1 of 11

Issue No.R5

TCE FORM 329 R3

1.0 SCOPE 1.1 This specification covers the general requirements for supply where specified,

fabrication and delivery at site of structural steel. Section C covers the specific requirements for the project. The two parts are complementary and are to be read together for a correct interpretation of the provisions of this specification. Where requirements of the two parts conflict, those of Section C shall govern.

1.2 This specification also covers design of all connections and substituted members,

preparation of all shop fabrication drawings, inspection and shop painting of structures.

2.0. APPLICABLE CODES & SPECIFICATIONS The following specifications, standards and codes are made a part of this

specification. All standards, specifications and codes of practices referred to herein shall be the latest editions including all applicable official amendments and revisions.

In case of discrepancy between this specification and other documents referred to

herein, this specification shall govern. a) Materials i) IS : 808 Dimensions for Hot Rolled Steel sections ii) IS : 814 Covered Electrodes for Manual Metal Arc Welding

of Carbon and Carbon Manganese Steel iii) IS : 1161 Steel Tubes for structural purposes iv) IS : 1239 Mild steel tubes, tubulars and other Wrought steel

fittings Part 1 - Mild steel tubes Part 2 - Mild steel Tubulars and other wrought steel

pipe fittings v) IS : 1363 Hexagon Head Bolts,Screws and Nuts of product ( Parts 1 to 3) Grade C (Size range M5 to M64) vi) IS : 1367 Technical Supply Conditions for Threaded Fasteners (All Parts) vii) IS : 1852 Rolling and Cutting Tolerances for Hot Rolled Steel

Products viii) IS : 1977 Structural Steel (Ordinary Quality)




Sh 2 of 11

Issue No.R5

TCE FORM 329 R3

xi) IS : 2062 Steel for General Structural Purposes x) IS : 2074 Ready Mixed Paint, Air drying, Red Oxide Zinc

Chrome and Priming xi) IS : 3502 Steel Chequered Plate xii) IS : 3757 High Strength Structural Bolts • xiii) IS : 5369 General Requirements for Plain Washers and Lock

Washers xiv) IS : 5372 Taper Washers for Channels xv) : 5374 Taper Washer for I Beams xvi) IS : 6610 Heavy Washers for Steel Structures xvii) IS : 8500 Structural Steel-microalloyed (medium and high

strength qualities) b) Codes Of Practice i) IS : 800 Code of Practice for General Construction in Steel ii) IS : 801 Code of practice for use of Cold formed light gauge

steel structural members in general building construction iii) IS : 803 Code of practice for design, fabrication and erection of

vertical mild steel cylindrical welded storage tanks iv) IS : 806 Code of practice for use of steel tubes in general

building construction v) IS : 816 Code of Practice for use of Metal Arc Welding for

General construction in Mild Steel vi) IS : 822 Code of Procedure for Inspection of Welds vii) IS : 1182 Recommended Practice for Radiographic examination of

Fusion - Welded Butt Joints in Steel Plates viii) IS : 1200 Method of Measurement in Building Civil Engineering

Works ix) IS : 1477 Code of Practice for Painting of (Parts 1 & 2) Ferrous

Metals in Buildings




Sh 3 of 11

Issue No.R5

TCE FORM 329 R3

x) IS : 2595 Code of Practice for Radiographic Testing xi) IS : 3658 Code of Practice for Liquid Penetrant Flaw Detection xii) IS : 4000 High strength bolts in Steel Structures - Code of Practice xiii) IS : 5334 Code of Practice for Magnetic Particle Flaw Detection

of Welds xiv) IS : 7215 Tolerances for Fabrication of Steel Structures xv) IS : 9595 Recommendations for Metal Arc Welding of Carbon and

Carbon Manganese Steel 3.0 STEEL MATERIALS Steel materials shall comply with the specifications laid down under clause 2.0

and/or as called for on the design drawings. All materials used shall be new, unused and free from defects. Steel conforming to IS:1977 shall be used only for the following : Fe310-0(St 32-0) : for general purposes such as door/ window frames,

grills, steel gates, handrails, fence posts, tee bars and other non-structural use.

Fe410-0(St 42-0) : for structures not subjected to dynamic loading other

than wind loads such as: Platform roofs, foot over bridges, building, factory

sheds etc. Fe410-0(St 42-0) : grade steel shall not be used a) if welding is to be employed for fabrication. b) if site is in severe earthquake zone. c) if plastic theory of design is used. 4.0 USE OF STEEL SUPPLIED BY THE PURCHASER The VENDOR/CONTRACTOR shall use steel supplied by the PURCHASER

judiciously and to the best advantage so as to minimise splicing and wastage. All steel materials remaining after completion of the report, whether in the form of balance pieces or unutilised prime steel, shall be returned to the PURCHASER's stores by the VENDOR/CONTRACTOR at his own cost. An unaccountable




Sh 4 of 11

Issue No.R5

TCE FORM 329 R3

wastage upto a maximum of 1% of the fabricated steel will be allowed. This wastage does not include the balance cut lengths/pieces of steel returned to the PURCHASER.

5.0 DRAWINGS PREPARED BY THE OWNER 5.1 Design drawings will be furnished to the VENDOR/CONTRACTOR and all

drawings so furnished shall form a part of this specification. These design drawings prepared by the ENGINEER will show all the, levels,forces on members where shall necessary, size and orientation of each member, location/size of openings, to enable the VENDOR/CONTRACTOR to prepare drawings for fabrication and erection. It shall be clearly understood that these drawings are not intended to show connection details, thickness of members, cuts, notches, bends and such other details.

5.2 The ENGINEER reserves the right to make changes. Revisions to drawings, even

after release for preparation of shop drawings, are very likely to be made to reflect additional data/details received and updated requirements. Revisions to drawings and any new drawings made to include additional work by the VENDOR/CONTRACTOR shall be considered a part of this specification and contract. The PURCHASER shall not entertain IS any extra claims on this account.

5.3 Where the fabrication drawings are to be furnished by the ENGINEER, he will

issue to the VENDOR/CONTRACTOR the required copies of such drawings in the sequence required for the fabrication of the components in the order they will be required to be erected at site. Such drawings will be issued in such numbers as required for the VENDOR/CONTRACTOR to adhere to the project schedule.

5.4 Should the VENDOR/CONTRACTOR during the execution of his work, find

discrepancies in the information furnished by the ENGINEER, he shall refer such discrepancies to the ENGINEER before proceeding with such work.

6.0 DRAWINGS PREPARED BY THE VENDOR/CONTRACTOR 6.1 The VENDOR/CONTRACTOR shall prepare all fabrication and erection drawings

for the entire work. All the drawings for the entire work shall be prepared in metric units. The drawings shall preferably be of one standard size and the details shown there in shall be clear and legible.

6.2 The VENDOR/CONTRACTOR shall not commence detailing unless ENGINEER's

design drawings are officially released for preparation of shop drawings. The VENDOR/CONTRACTOR shall be responsible for the correctness of all fabrication drawings. Fabrication drawings shall be revised by the VENDOR/CONTRACTOR to reflect all revisions in design drawings as and when such revisions are made by the ENGINEER.

6.3 All fabrication drawings shall be submitted to the ENGINEER for approval.




Sh 5 of 11

Issue No.R5

TCE FORM 329 R3

6.4 No fabrication drawings will be accepted for ENGINEER's approval unless checked and approved by the VENDOR/CONTRACTOR's qualified structural engineer and accompanied by an erection plan showing the location of all pieces detailed. The VENDOR/CONTRACTOR shall ensure that connections are detailed to obtain ease in erection of structures and in making field connections.

6.5 Fabrication shall be started by the VENDOR/ CONTRACTOR only after

ENGINEER's approval of fabrication drawings. Approval by the ENGINEER of any of the drawings shall not relieve the VENDOR/CONTRACTOR from the responsibility for correctness of engineering & design of connections, workmanship, fit of parts, details, material, errors or omissions of any and all work shown thereon. The ENGINEER's approval shall constitute approval of the size of members, dimensions and general arrangement but shall not constitute approval of the connections between members and other details.

6.6 The drawings prepared by the VENDOR/CONTRACTOR and all subsequent

revisions etc. shall be at the cost of the VENDOR/CONTRACTOR for which no separate payment will be made.

7.0 FABRICATION 7.1 General All workmanship and finish shall be of the best quality and shall conform to the

best approved method of fabrication. All materials shall be finished straight and shall be machined/ground smooth true and square where so specified. All holes and edges shall be free of burrs. Shearing and chipping shall be neatly and accurately done and all portions of work exposed to view shall be neatly finished . Unless otherwise directed/ approved, reference may be made to relevant IS codes for providing standard fabrication tolerance. Material at the shops shall be kept clean and protected from weather.

7.2 Connections 7.2.1 Shop/field connections shall be as per approved fabrication drawings. 7.2.2 In case of bolted connections, taper washers or flat washers or spring washers

shall be used with bolts as necessary. In case of high strength friction grip bolts, hardened washers be used under the nuts or the bolt heads whichever are turned to tighten the bolts. The length of the bolt shall be such that atleast one thread of the bolt projects beyond the nut, except in case of high strength friction grip bolts where this projection shall be atleast three times the pitch of the thread.

7.2.3 In all cases where bearing is critical, the unthreaded portion of bolt shall bear on

the members assembled. A washer of adequate thickness may be provided to




Sh 6 of 11

Issue No.R5

TCE FORM 329 R3

exclude the threads from the bearing thickness, if a longer grip bolt has to be used for this purpose.

7.2.4 All connections and splices shall be designed for full strength of members or

loads indicated on ENGINEER's design drawings. Column splices shall be designed for the full tensile strength of the minimum cross section at the splice.

7.2.5 All bolts , nuts, washers, electrodes, screws etc. shall be supplied/brought to site

10% in excess of the requirement in each category and size. Rates shall cover the cost of this extra quantity.

7.2.6 All members likely to collect rain water shall have drain holes provided. 7.3 Straightening All materials, shall be straight and, if necessary, before being worked shall be

straightened and/or flattened by pressure and shall be free from twists. Heating or

forging shall not be resorted to without the prior approval of the ENGINEER in

writing. 7.4 Cutting, punching, drilling, welding and fabrication tolerances shall be generally

as per relevant IS codes. 7.5 Rolling And Forming Plates,channels, R.S.J. etc., for circular bins, bunkers, hoppers, gantry girders,

etc., shall be accurately laid off and rolled or formed to required profile/ shape as called for on the drawings. Adjacent sections shall be match-marked to facilitate accurate assembly, welding and erection in the field.

7.6 High Strength Friction Grip Bolting 7.6.1 Inspection after tightening of bolts shall be carried out as stipulated in the

appropriate standards depending upon the method of tightening and the type of bolt used.

7.7 Welding 7.7.1 Welding procedure shall be submitted to ENGINEER for approval. Welding shall

be entrusted to only qualified and experienced welders who shall be periodically tested and graded as per IS 817, IS:7310 (Part 1) and IS:7318 (Part 1).

7.7.2 While fabricating plated beams and built up members, all shop splices in each

component part shall be made before such component part is welded to other parts of the members. Wherever weld reinforcement interferes with proper fit-up




Sh 7 of 11

Issue No.R5

TCE FORM 329 R3

between components to be assembled for welding, these welds shall be ground flush prior to assembly.

7.7.3 Approval of the welding procedure by the ENGINEER shall not relieve the

CONTRACTOR of his responsibility for correct and sound welding without undue distortion in the finished structure.

7.7.4 No welding shall be done when the surface of the members is wet nor during

periods of high wind. 7.7.5 Each layer of a multiple layer weld except root and surfaces runs may be

moderately peened with light blows from a blunt tool. Care shall be exercised to prevent scaling or flaking of weld and base metal from overpeening.

7.7.6 No welding shall be done on base metal at a temperature below -5 Deg.C. Base

metal shall be preheated to the temperature as per relevant IS codes. 7.7.7 Electrodes other than low-hydrogen electrodes shall not be permitted for

thicknesses of 32 mm and above. 7.7.8 Inspection of Welds All welds shall be inspected for flaws by any of the methods described under

clause 8 "Inspection". The choice of the method adopted shall be determined by the PURCHASER/ENGINEER.

7.7.9 The correction of defective welds shall be carried out as directed by the

ENGINEER without damaging the parent metal. When a crack in the weld is removed, magnetic particle inspection or any other equally positive means as prescribed by the ENGINEER shall be used to ensure that the whole of the crack and material upto 25 mm beyond each end of the crack has been removed. Cost of all such tests and operations incidental to correction shall be to the VENDOR/CONTRACTOR's account.

7.8 Tolerances The dimensional and weight tolerances for rolled shapes shall be in accordance

with IS:1852 for indigenous steel and equivalent applicable codes for imported steel. The tolerances for fabrication of structural steel shall be as per IS:7215.

7.9 End Milling Where compression joints are specified to be designed for bearing, the bearing

surfaces shall be milled true and square to ensure proper bearing and alignment. 8.0 INSPECTION 8.1.1 The VENDOR/CONTRACTOR shall give due notice to the

PURCHASER/ENGINEER in advance of the works getting ready for inspection. All rejected material shall be promptly removed from the shop and replaced with




Sh 8 of 11

Issue No.R5

TCE FORM 329 R3

new material for the PURCHASER's/ENGINEER's approval/ inspection. The fact that certain material has been accepted at the VENDOR/CONTRACTOR's shop shall not invalidate final rejection at site by the PURCHASER/ENGINEER if it fails to conform to the requirements of these specifications, to be in proper condition or has fabrication inaccuracies which prevents proper assembly nor shall it invalidate any claim which the PURCHASER may make because of defective or unsatisfactory materials and/or workmanship.

8.1.2 No materials shall be painted or despatched to site without inspection and

approval by the PURCHASER/ ENGINEER unless such inspection is waived in writing by the ENGINEER.

8.1.3 The VENDOR/CONTRACTOR shall provide all the testing and inspection

services and facilities for shop work except where otherwise specified. 8.1.4 For fabrication work carried out in the field the same standard of supervision

and quality control shall be maintained as in shop fabricated work. Inspection and testing shall be conducted in a manner satisfactory to the ENGINEER.

8.2 Inspection and tests on structural steel members shall be as set forth below : 8.2.1 Material Testing If mill test reports are not available for any steel materials the same shall be got

tested by the VENDOR/CONTRACTOR to the ENGINEER's satisfaction to demonstrate conformity with the relevant specification.

8.3 Tests on Welds 8.3.1 Magnetic Particle Test Where welds are examined by magnetic particle testing, such testing shall be

carried out in accordance with relevant IS codes. If heat treatment is performed, the completed weld shall be examined after the heat treatment. All defects shall be repaired and retested. Magnetic particle tests shall be carried out using alternating current. Direct current may be used with the permission of the ENGINEER.

8.3.2 Liquid Penetrant Inspection In the case of welds examined by Liquid Penetrant Inspection, such tests shall

be carried out in accordance with relevant IS Code. All defects shown shall be repaired and rechecked.

8.3.3 Radiographic Inspection




Sh 9 of 11

Issue No.R5

TCE FORM 329 R3

All full strength butt welds shall be radiographed in accordance with the recommended practice for radiographic testing as per relevant IS code.

8.4 Dimensions, Workmanship & Cleanliness Members shall be inspected at all stages of fabrication and assembly to verify

that dimensions, tolerances, alignment, surface finish and painting are in accordance with the requirements shown in the VENDOR/CONTRACTOR's approved fabrication drawings and the ENGINEER's drawings.

8.5 Test Failure In the event of failure of any member to satisfy inspection or test requirement, the

CONTRACTOR shall notify the ENGINEER or his authorised representative. The VENDOR/CONTRACTOR must obtain permission from the ENGINEER before repair is undertaken. The quality control procedures to be followed to ensure satisfactory repair shall be subject to approval by the ENGINEER.

8.6 The ENGINEER has the right to specify additional testing as he deems

necessary, and the additional cost of such testing shall be borne by the PURCHASER, only in case of successful testing.

8.7 The VENDOR/CONTRACTOR shall maintain records of all inspection and testing

which shall be made available to the ENGINEER or his authorised representative.

9.0 SHOP MATCHING For structures like bunkers, tanks, etc. shop assembly is essential. For other

steel work, such as columns along with the tie beams/bracings may have to be shop assembled to ensure satisfactory fabrication, obtaining of adequate bearing areas etc. if so desired by the ENGINEER. All these shop assemblies shall be carriedout by VENDOR/CONTRACTOR at no extra cost to the PURCHASER.

10.0 DRILLING HOLES FOR OTHER WORKS As a part of this Contract, holes in members required for installing equipment or

steel furnished by other manufacturers or other contractors shall be drilled by the VENDOR/CONTRACTOR at no extra cost to the PURCHASER. The information for such extra holes will be supplied by the PURCHASER/ENGINEER.

11.0 MARKING OF MEMBERS 11.1 After checking and inspection, all members shall be marked for identification

during erection. This mark shall correspond to distinguishing marks on approved erection drawings and shall be legibly painted and stamped on it. The erection




Sh 10 of 11

Issue No.R5

TCE FORM 329 R3

mark shall be stamped with a metal dye with figures at least 20 mm high and to such optimum depth as to be clearly visible.

11.2 All erection marks shall be on the outer surface of all sections and near one

end, but clear of bolt holes. The marking shall be so stamped that they are easily discernible when sorting out members. The stamped marking shall be encircled boldly by a distinguishable paint to facilitate easy location.

11.3 Erection marks on like pieces shall be in identical locations. Members having

lengths of 7.0 m or more shall have the erection mark at both ends. 12.0 ERRORS Any error in shop fabrication which prevents proper assembling and fitting up of

parts in the field by moderate use of drift pins or moderate amount of reaming will be classified by the ENGINEER as defective workmanship. In case ENGINEER rejects such material or defective workmanship, the same shall be replaced by the materials and workmanship conforming to the ENGINEER's requirements by VENDOR/CONTRACTOR free of cost at site.

13.0 PAINTING 13.1 All fabricated steel material, except those galvanised shall receive protective

paint coating as specified in specification No. TCE.M4-405-04. 13.2 Galvanising of fabricated steel wherever specified, shall be as per TCE.M4-405-05

14.0 METHOD OF MEASUREMENT 14.1 For the purpose of payment, the weight of the actual completed structures shall

be calculated from the approved drawings for different items of work. The VENDOR/CONTRACTOR shall submit to the PURCHASER relevant material list containing weight of each item.

14.2 No allowances will be permitted for bolts, nuts, washers, studs, screws etc,

galvanizing, welding or for rolling margins. One tonne for the purpose of payment shall mean ONE METRIC TONNE i.e. 1000 Kg.

14.3 The weight of a member made out of standard rolled section such as beams,

channels, angles, etc. shall be based on the standard IS:808 without deductions for holes, notches, bevel cuts, etc. Where a component consists of a cut joist or channels, the full weight of the rolled section shall be considered only if more than half the depth of the original section is used. Otherwise, only half the section unit weight shall be considered for calculation of the weight of the components.




Sh 11 of 11

Issue No.R5

TCE FORM 329 R3

Deductions shall be made in the weight of gussets/plates for cuts and notches of 900 sq. cm. or larger.

14.4 For gussets/plates used in trusses, bracings, columns, beams, etc, the area

shall be that of the minimum circumscribing rectangle except as stated in 14.3 above.

14.5 The weight of any built-up members shall be based on the weight of each

component.


SPEC. NO. TCE.M4-904

TATA CONSULTING ENGINEERS LIMITED SECTION: E

SHOP INSPECTION AND TESTS SHEET 1 OF 7

ISSUE R9

TCE FORM NO. 329 R5 FILE NAME: M4904R9.DOC

1.0 SCOPE This specification covers the requirements for Shop Inspection and Tests to be

carried out by the PURCHASER/CONSULTANT/INSPECTION AGENCY. 2.0 GENERAL 2.1 The plant and equipment covered by the PURCHASE ORDER/CONTRACT

shall be subjected to inspection and testing. The VENDOR/CONTRACTOR shall provide all services to establish and maintain quality of workmanship in his works and that of his SUB-VENDOR’s/SUB-CONTRACTOR’s works to ensure the mechanical accuracy of components, compliance with approved drawings, identification and acceptability of all materials, parts and equipment.

2.2 For supply of systems, the VENDOR/CONTRACTOR shall, at the start of the

PURCHASE ORDER/CONTRACT, furnish a total list of items in his scope of work. This list, giving a brief description of the item, quantity, names of probable SUB-VENDORS/SUB-CONTRACTORS, and a blank column for agency for final approval of drawings and documents, shall be submitted for approval by PURCHASER/CONSULTANT. The blank column shall be filled by PURCHASER/CONSULTANT. The list shall be submitted within two weeks from the date of Letter of Intent.

2.3 For systems and major items such as pressure and load bearing items,

machineries etc., the VENDOR/CONTRACTOR shall furnish quality plan giving details of checks and tests to be conducted by them on material, process, sub-assembly and assembly. These shall include requirements as prescribed in the applicable specifications, codes and statutory requirements. The quality plan shall be reviewed by the PURCHASER/CONSULTANT and the stages to be witnessed and verified shall be indicated by the PURCHASER/CONSULTANT in the approved quality plan.

2.4 The VENDOR/CONTRACTOR shall give the PURCHASER/CONSULTANT

written notice of any material being ready for testing as per format enclosed. The clear notice period shall be seven (7) days for local inspection and fifteen (15) days for outstation inspection. Such tests shall be to the VENDOR’s/CONTRACTOR's account except for the expenses of the PURCHASER/CONSULTANT. The PURCHASER/CONSULTANT, unless the inspection of the tests is virtually waived, shall fix a date for inspection with the VENDOR/CONTRACTOR and attend such tests within fifteen (15) days of the date on which the equipment is notified as being ready for test and inspection failing which, the VENDOR/CONTRACTOR may proceed with the tests and shall forthwith forward to the PURCHASER/CONSULTANT duly certified copies of tests in triplicate. If the VENDOR/CONTRACTOR fails to offer the equipment for inspection as per the agreed date, he is liable to pay for the time and expenses for the infructuous visit of the PURCHASER/CONSULTANT.

2.5 In all cases where inspection and tests are required whether at the premises or

works of the VENDOR/CONTRACTOR or of any SUB-VENDOR/SUB-CONTRACTOR or at laboratory, the VENDOR/CONTRACTOR, except where otherwise specified, shall provide free of charge all facilities such as labour,





ISSUE R9


materials, electricity, fuel, water, stores, test bed, apparatus and instruments, laboratory tests etc. as may be required by the PURCHASER/CONSULTANT to carry out effectively such tests of the equipment in accordance with the PURCHASE ORDER/CONTRACT and shall give facilities to the PURCHASER/ CONSULTANT to accomplish testing.

2.6 The PURCHASER/CONSULTANT shall at all working hours have access to all

parts of the VENDOR’s/CONTRACTOR's and his SUB-VENDOR’s/SUB-CONTRACTOR's factory where the items of the plant are being prepared, for carrying out inspection activities as deemed necessary. A set of the relevant latest approved drawings with approval marking of the PURCHASER/ CONSULTANT and drawings for proprietary items shall be made available by the VENDOR/CONTRACTOR to the PURCHASER/CONSULTANT, for reference during inspection.

2.7 In the case of stage inspection hold points, the VENDOR/CONTRACTOR shall

proceed from one stage to another only after the component is inspected by the PURCHASER/CONSULTANT and written permission given to proceed further. The same procedure shall be adopted for any rectifications and repairs suggested by the PURCHASER/CONSULTANT.

2.8 The PURCHASER/CONSULTANT shall have the right to inspect any

machinery, material, structures, equipment or workmanship furnished or used by the VENDOR/CONTRACTOR and may reject any which is defective or unsuitable for the use and purpose intended, or which is not in accordance with the intent of the PURCHASE ORDER/CONTRACT. The VENDOR/ CONTRACTOR, upon demand by the PURCHASER/CONSULTANT, shall remedy or replace at the VENDOR’s/CONTRACTOR's expense such defective or unsuitable items of the plant, or the PURCHASER/CONSULTANT may, at the expense of the VENDOR/CONTRACTOR, remedy or replace such defective or unsuitable items of the Plant.

2.9 All principal mill test reports, the VENDOR/CONTRACTOR inspection and tests

reports, test certificates and test curves shall be supplied for all inspection and tests carried out including other records such as stress relieving charts, radiographic charts and other non-destructive testing records in accordance with the provisions of the PURCHASE ORDER/CONTRACT, duly certified by the main VENDOR/CONTRACTOR. The PURCHASER/CONSULTANT shall reserve the right to call for certificates of origin and test certificates for all raw material and equipment at any stage of manufacture.

2.10 The PURCHASER/CONSULTANT shall within fifteen (15) days from the date of

inspection as defined herein give notice in writing to the VENDOR/ CONTRACTOR of any non-conformance pertaining to all or any equipment and workmanship which in his opinion is not in accordance with the PURCHASE ORDER/CONTRACT. The VENDOR/CONTRACTOR shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the PURCHASER/CONSULTANT giving reasons therein that no modifications are necessary to comply with the PURCHASE ORDER/CONTRACT.





ISSUE R9


2.11 When the factory tests and documentation have been satisfactorily completed at the VENDOR’s/CONTRACTOR's or SUB-VENDOR's/CONTRACTOR's works, the PURCHASER/CONSULTANT shall issue acceptance note or shipping release note or a certificate to this effect within fifteen (15) days after completion, but if the tests are not witnessed by the PURCHASER/ CONSULTANT, the certificate or comments thereof shall be issued within fifteen (15) days of the receipt of the VENDOR’s/CONTRACTOR's test certificate by the PURCHASER/CONSULTANT. Failure of the PURCHASER/ CONSULTANT to take such an action shall not prevent the VENDOR/ CONTRACTOR from proceeding with the work. The completion of these tests or the issue of the certificates shall not bind the PURCHASER/ CONSULTANT to accept the equipment, should it, on further tests after erection, be found not to comply with the PURCHASE ORDER/CONTRACT.

2.12 None of the plant and the equipment to be furnished or used in connection with

the PURCHASE ORDER/CONTRACT shall be despatched until shop inspection, satisfactory to the PURCHASER/CONSULTANT has been made. However, such shop inspection and/or certification shall not relieve the VENDOR/CONTRACTOR of his responsibility for furnishing the plant and the equipment conforming to the requirements of the PURCHASE ORDER/ CONTRACT nor prejudice any claim, right or privilege which the PURCHASER/ CONSULTANT may have because of the use of defective or unsatisfactory items. Should the PURCHASER/CONSULTANT waive the right to inspect any item, such waiver shall not relieve the VENDOR/CONTRACTOR in any way from his obligation under the PURCHASE ORDER/CONTRACT. In the event of the PURCHASER’s/CONSULTANT's inspection revealing poor quality of goods, the PURCHASER/CONSULTANT shall be at liberty to specify additional inspection procedures, if required, to ascertain the VENDOR/CONTRACTOR's compliance with the equipment specifications.

3.0 SUB-ORDERS AND SUB-CONTRACTS 3.1 In order to facilitate the inspection of bought-out materials and plant, the

VENDOR/CONTRACTOR shall submit for approval, three (3) copies of all sub-orders and sub-contracts placed by him as soon as these are issued. Copies of any drawings referred to in the sub-order or sub-contracts shall also be submitted, unless agreed otherwise by the PURCHASER/CONSULTANT.

3.2 The sub-orders, sub-contracts and drawings referred to above shall include all

components which are subjected to electrical and mechanical pressure or stress when the plant is in operation, and also auxiliaries and spares which are to be directly despatched to site from the SUB-VENDOR’s/SUB-CONTRACTOR's works.

3.3 All sub-orders and sub-contracts of the main VENDOR/CONTRACTOR shall

clearly be marked with the main VENDOR’s/CONTRACTOR's name and the PURCHASER’s/CONSULTANT’s name and the PURCHASE ORDER/ CONTRACT reference. These shall include the following statement:

The plant or the equipment which is the subject of this PURCHASE ORDER/

CONTRACT shall comply in every respect with the requirements of the





ISSUE R9


PURCHASER’s/CONSULTANT's technical specifications and shall be subject to inspection and tests to the satisfaction of the PURCHASER/CONSULTANT.

3.4 For the purpose of this para, it is obligatory on the VENDOR/CONTRACTOR

that he advises his SUB-VENDOR/SUB-CONTRACTOR of the pertinent clauses in this specification when ordering bought-out plant, equipment or materials. In particular, the VENDOR/CONTRACTOR shall advise every SUB-VENDOR/SUB-CONTRACTOR that he is required to supply design calculations, drawings, inspection reports and test certificates strictly in accordance with this specification and technical information for inclusion in the Instruction Manual as specified in Section E of the Enquiry Document. The SUB-VENDORS/SUB-CONTRACTORS should also be reminded that they shall include with their offer all tools and appliances necessary for proper maintenance and all spare parts in accordance with Section E of the Enquiry Document. Itemised prices of the recommended spare parts shall be submitted together with the appropriate part numbers and drawings.

3.5 Sub-ordering and sub-contracting for major items such as pressure and load

bearing items, machinery etc. can be done only with the approval of the PURCHASER/CONSULTANT.

4.0 MATERIAL TESTS 4.1 In the event of the PURCHASER/CONSULTANT being supplied with the

certified particulars of tests which have been carried out for the VENDOR/ CONTRACTOR by the supplier of material, the PURCHASER/CONSULTANT may, at his own discretion, accept the same as proper evidence of compliance with the requirements of appropriate specifications for the materials.

4.2 The VENDOR/CONTRACTOR is to provide test pieces as required by the

PURCHASER/CONSULTANT to enable him to determine the quality of material supplied under the PURCHASE ORDER/CONTRACT. If any test piece fails to comply with the requirements, the PURCHASER/CONSULTANT may reject the entire lot of material represented by the test piece.

4.3 Critical materials used in manufacture of the equipment and construction of the

plant covered by the PURCHASE ORDER/CONTRACT may also be subjected to one or more of the Non-Destructive Tests (NDT) as called for in the enquiry document or as mutually agreed. Salvaging of material due to unacceptable defect is to be attempted by the VENDOR/CONTRACTOR only after getting specific concurrence from the PURCHASER/CONSULTANT and according to the approved procedures.

5.0 WELDING 5.1 All welding involved in construction and fabrication of the plant and items

covered under the PURCHASE ORDER/CONTRACT shall be carried out in accordance with specifications and applicable codes.

5.2 Welding procedures and welders' qualifications shall be approved by the

PURCHASER/CONSULTANT. Where applicable, welders shall be tested as





ISSUE R9


detailed in codes specified for pipe welding, vessel welding and structural welding and appropriate to the corresponding weld position using test pieces of appropriate parent metal to be used on the job. The PURCHASER/ CONSULTANT shall have the right to have any welder re-tested at any time during the PURCHASE ORDER/CONTRACT.

5.3 Recommendations of applicable codes shall be followed for non-destructive

tests, wherever applicable. 5.4 Copies of all welding procedures, procedure qualification records, welders'

performance qualification certificates, post-heating and stress relieving records, NDT records and other test results shall be made available upon request of the PURCHASER/CONSULTANT.

6.0 FABRICATION AND INSPECTION Fabrication and inspection procedures for vessels, heat exchangers, pipes,

tubes and valves etc. shall be in accordance with procurement specifications, quality plan, applicable codes or any other approved equal.

7.0 TESTS AT MANUFACTURER'S WORKS 7.1 GENERAL The tests at works shall include electrical, mechanical and hydraulic tests in

accordance with the appropriate clauses of Statutory Regulation, relevant codes and standards and approved drawings and specifications and in addition any test called for by the PURCHASER/CONSULTANT to ensure that the plant being supplied fulfils the requirements of the specifications. The VENDOR/ CONTRACTOR shall carry out all the shop tests and inspections specified under individual items of the equipment in Section-D of the enquiry document, in addition to those normally required as per codes and standards. For items not covered by any code or specifically mentioned in the specifications, the tests are to be agreed with by the PURCHASER/CONSULTANT. If considered necessary by the PURCHASER/CONSULTANT, multi-part assemblies shall be fully erected and tested in the works prior to packing and despatch to the site.

7.2 TEST CERTIFICATES Test certificates including test records, performance curves and balancing

certificates shall be supplied according to the Distribution Schedule. All the tests shall be carried out in accordance with the provisions of the PURCHASE ORDER/CONTRACT.

All test certificates must be endorsed with sufficient information to identify the

material or the equipment to which the certificates refer, and must carry at the top right hand corner the identification of the PURCHASER/CONSULTANT and the PURCHASE ORDER/CONTRACT.





ISSUE R9


7.3 CALIBRATION All instruments used for critical measurement such as pressure gauges for leak

tests, instruments for measuring performance parameters; instruments for precision dimension measurements shall have valid calibration certificates traceable to national standards. This means that the calibrating agency engaged by the VENDOR/CONTRACTOR shall use instruments which are in turn calibrated by Government approved agencies and such information shall be recorded in the calibration certificate issued by the calibrating agency by giving the certificate number, date and date of validity of the certificate given by the Government approved agency.

FORMAT FOR INSPECTION REQUEST FROM THE

VENDOR/CONTRACTOR To, TATA CONSULTING ENGINEERS LIMITED,

Attn: Mr/Ms

PROJECT MANAGER Dear Sir/Madam, Items detailed below are ready for inspection. Please arrange inspection and

confirm the date. 1. PURCHASER 2. PROJECT 3. PURCHASE ORDER/CONTRACT

REFERENCE NUMBER

4. CONSULTANT (TCE) REFERENCE

NUMBER

5. SUB-VENDOR/SUB-CONTRACTOR 6. SUB-VENDOR’s/SUB-CONTRACTOR’s

ADDRESS

7. PLACE OF INSPECTION AND ADDRESS 8. CONTACT PERSON, PHONE, FAX AND

E-MAIL ID

9. DESCRIPTION OF ITEM AND QUANTITY 10. NATURE OF INSPECTION REQUIRED





ISSUE R9


11. PROPOSED DATES 12. WEEKLY HOLIDAY We confirm that the items have been fully inspected and tested by us. All stages

of inspection as per approved quality plan have been carried out by us and all material test certificates, quality control records and test reports and valid calibration reports of measuring and testing instruments with traceability to national level are ready with us.

Thanking you and awaiting your confirmation, Yours faithfully, Note 1 Following clear notice periods (Date of Receipt at TCE to Date of

Inspection) are required: (a) Local Inspection - 7 days (b) Outstation Inspection - 15 days Note 2 Weekly Holidays for TCE - Saturday and Sunday cc: Purchaser cc: Sub-Vendor/Sub-Contractor


TATA Consulting Engineers Limited SECTION: D

SHOP INSPECTION REQUIREMENTS FOR AIR COOLED HEAT EXCHANGERS (TCE.6758A-SE-800) SHEET 1 OF 9

ISSUE R0

Scope of Inspection

Sr. No

Inspection Activity & Component Characteristics Quantum

of check Reference Document

Acceptance standard

Format of report Sub

VENDOR VENDOR Inspection Agency

1.0

Heat treatment, NDT and other procedures including tube expansion/ welding and mockup test and air / hydro test or both.

Documented Proceedures

100%

ASME Sec IIA / IIB, Sec VIII Div-I, Sec V/

Spec / Drawings

ASME Sec IIA/ IIB, Sec VIII

Div.1, Sec V / Spec /

Drawings

Document - W R

2.0 MATERIALS INSPECTION

2.1

MATERIALS AT MILLS Plates, Pipes, Tubes, Tube sheets, Forging, Fittings Fasteners etc. * (To be procured from reputed manufacturers under Third Party Inspection)

Chemical analysis, Mechanical properties, Additional Tensile on hub, Bend test, (Including impact test of plates / forging , Hardness check, Heat treatment if applicable) Non Destructive Test as applicable, Visual & dimensional inspection.

100%

ASME Sec II A / Spec / Drawings

,SA 388 ASME Sec VIII Div II.

ASME Sec II A / Spec/

Drawings / SA 388,

ASME Sec VIII Div II.

Mill Test Certificates W W / R * W / R*


TCE Consulting Engineers Limited SECTION: D


ISSUE R0

Scope of Inspection

Sr. No



Acceptance standard

Format of report

Sub VENDOR VENDOR Inspection

Agency

2.2 Aluminium fin material Chemical & size lot Spec /

Drawing Spec / Drawing Insp. Report W R

R

2.3

MATERIALS AFTER RECEIPT (for Pressure Parts) Plates ( Header Box / Tube Sheet), Pipes for nozzle, Forgings, Plugs, Tubes, Fittings, Fasteners, Gaskets etc.

Review of test certificates markings, Visual & dimensional inspection, Identification, Correlation & transfer of identity.

100% ASME Sec. II

A / PO / Drawing

ASME Sec. II A / PO / Drawing

Material Clearance

Record W W R

2.4

Non Pressure Parts (C Frames, tube spacers, plenum chambers, support structurals etc.)

Review of test Certificates 100%

ASME Sec II A / B Spec /

Drawings

ASME Sec II A / B Spec /

Drawings

Insp. Report W R R




ISSUE R0

Scope of Inspection

Sr. No



Acceptance standard



2.5 Motors, pulleys, belts, fans & vibration switches

Review of test Certificates 100% Spec /

Drawing Spec / Drawing Insp. Report W R R

Visual & Dimensional Inspection (pitch, height, length of unfined potion, straightness, etc

100% Drawing / SpecDrawing,

ASME Sec.VIII-1

Insp. Report W R R

3.0 Tube Fining

Pull out test Sample Spec Spec Test report W R R

4.0 WPS & PQR

4.1 PQR Welding parameters 100% ASME Sec IX / Spec.

ASME Sec IX / Spec. WPS / PQR - W R

4.2 WPQ Welding parameters 100% ASME Sec IX / Spec.

ASME Sec IX / Spec. WPQ - W R




ISSUE R0

Sr. No



Acceptance standard

Format of report

Scope of Inspection


Agency

4.3 Tube to Tube Sheet Welding

Chemical & mechanical properties

100% Spec / Drawing

Spec / Drawing - W W

4.4 Welding consumable

Chemical & mechanical properties

All batches

ASME Sec II C / Spec.

ASME Sec II C / Spec.

Batch test certificates - W R

5.0

INSPECTION DURING FABRICATION

Visual & Dimensional inspection, weld edge, Root gap. Offset, cleanliness etc

100% Drawing / ASME Sec.VIII-1

Drawing,/ ASME Sec.VIII-1

Insp. Check List - W R 5.1

Weld Edge preparation & set up of side plates including tube sheet & past partition plates MT / PT of weld

edges as applicable 100% Drawing / Spec

ASME Sec V / Spec Insp. Check List - W R

5.2

Intermediate Insp. of welds

Visual / interpass temp. / PT insp. after chipback

100% Drawing Drawing Insp. Check List - W R




ISSUE R0

Scope of Inspection

Sr. No



Acceptance standard



Visual inspection for reinforcement, Undercuts, surface defects etc.

100% Drawing, ASME Sec.VIII-1

Drawing, ASME Sec.VIII-1

Insp. Check List - W R

Nondestructive Test as applicable 100% ASME VIII-1

/ Spec ASME Sec V NDT Report - W R 5.3 Inspection of Completed welds

PWHT 100% ASME VIII-1 / Spec

Cust. Spec / Drawing HT Chart - W R

Hardness test

Each weld seam & as per spec / Drawing

Spec / Drawing

Cust. Spec/ Drawing Insp. Report - W W / R

Inspection of Completed welds (contd.) Production test

coupon Testing

As per Spec / Drawing

ASME Sec VIII-1

ASME Sec VIII-1 Insp. Report - W W / H

5.4

Structural ( Plenum chambers, support assly. etc.)

Dimensions, match marking and completeness of assembly

Drawing Drawing Cust. Spec / Drawing Insp. Report - W W / R

6.0 MACHINING / DRILLING




ISSUE R0

Scope of Inspection

Sr. No



Acceptance standard

Format of report


Agency

6.1 Tube Sheet

Hole dia, drift, surface finish, grove depth, ligament check and positional accuracy

100% Drawing, TEMA-R

Drawing, TEMA-R Insp. Report - W W

6.2 Plug sheet Threading, finish, ligament check and positional accuracy

100% Drawing, TEMA-R

Drawing, TEMA-R Insp. Report - W W

7.0 ASSEMBLY

7.1 Tube bundle -C Frame assly before tube insertion

Completeness of assembly Drawing Drawing STANDARD Insp. Report - W W

7.2 Final assembly after tubes insertion

Alignment, completeness of assembly

Drawing Drawing STANDARD Insp. Report - W W / R

7.3 Tube to Tube Sheet Expansion / Welding

% Thinning, Length of Expansion, finish & hardness / visual, distortion & DP of welds

Random Spec. Spec. Insp. Report - W W




ISSUE R0

Scope of Inspection

Sr. No



Acceptance standard

Format of report


Agency

8.0 FINAL INSPECTION

8.1 Visual and Dimensional Insp. of Tube Bundles

Dimensions, completeness of assembly

100% Drawing Drawing Insp. Report - W H

8.2 Air test of Tube to Tube Sheet joints leak Check 100% Drawing /

Spec Drawing / Spec Insp. Report - W R

8.3 Hydrostatic Test leak Check 100%

ASME Sec. VIII-1 / Spec / Drawing

Drawing / Spec Insp. Report - W R

8.4 Surface preparation / cleaning

Visual insp. for workmanship 100% Drawing /

Spec

ASME Sec. VIII-1 / Drawing / Spec

Insp. Report - W R

8.5

Pickling & Passivation/ Painting/ Hot Dip Galvanising ( Headers & Frames ) etc.

Visual insp. for workmanship 100% Drawing /

Spec Spec. Insp. Report - W R




ISSUE R0

Scope of Inspection

Sr. No



Acceptance standard



8.6 Final Stamping of equipment and marking etc

Verifying stamping details

Name plate & Rub off stamping

Drawing Drawing Name Plate/ Rub-off - W H

8.7 Drying of equipment Cleanliness Full Equipment

Drawing / Spec


8.8 Nitrogen Filling N2 pressure & non return valve

Full Equipment

Drawing / Spec


8.9 Trial run at shop (if required)

Dimensional accuracy, clearances etc

Structurals, plenum chamber along with fan and its mountings etc

Drawing / Spec

Drawing / Spec Insp. Report - W H




ISSUE R0

1.0 LEGEND H- Hold (Offer for Witness & obtain clearance) W-Witness R- Review PO- Purchase Order PR- Purchase Requisition

2.0 All the NDT / Leak testing / Heat treatment / Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used. In case of conflict between purchase specification, contract documents and Shop Inspection Requirements more stringent conditions shall be applicable. This document describes generally the requirements pertaining to all types of Air cooled Heat Exchangers. Requirements specific to the item are only applicable.

3.0 APPLICABLE CODES & SPECIFICATIONS 3.1 TEMA

3.2 Specification for Air Cooled Heat Exchangers

3.3 Other Standards / Specifications enclosed with MR / RFQ / Enquiry Specification / BID document

Scope of Inspection

Sr. No



Acceptance standard



9.0 DOCUMENTATION

Verification & Compilation of inspection & test records for submission to customer

100% Spec. (VDR) Spec. Q.C. Dossier - W H
