Technical Specifications

PROJECT: RAIN WATER HARVESTING SYSTEM
ONGC TRIPURA POWER COMPANY LIMITED
TECHNICAL SPECIFICATION
(Annexure-4 to Installation Services Contract)
FOR
ERECTION & COMMISSIONING OF RAIN
WATER HARVESTING SYSTEM
AT
2 X 363.3 MW
GAS BASED COMBINED CYCLE POWER PLANT,
PALATANA, UDAIPUR, TRIPURA
(This document is meant for the exclusive purpose of bidding against this specification and shall not be
transferred, reproduced or otherwise used for purposes other than that for which it is specifically issued).
Technical Specification for Erection & Commissioning
Project:
726.6MW, COMBINED CYCLE POWER PROJECT

PALATANA, TRIPURA
Title:
TECHNICAL SPECIFICATION FOR ERECTION &

COMMISSIONING OF RAIN WATER HARVESTING /
DEEP TUBE WELL SYSTEM
Client:
ONGC TRIPURA POWER COMPANY LTD (OTPC)
REV
DOC NO
1 1 1 3 1 1 2 - M E - S P C - 7 0 0
NO OF SHEETS
(INCLUDING COVER SHEET)
R0
25.02.2014
REV
DATE
AS
INITIALS
PREPARED
A.CODE
AS
SIGN
- 0 0 4
INITIALS
RUV/DKS
SIGN
CHECKED
INITIALS
FOR APPROVAL
SIGN
DETAILS OF REVISION
PROJ. MANAGER
FICHTNER Consulting Engineers (India) Private Limited

CHENNAI BANGALORE
726.6 MW Combined Cycle

Power Project, Pallatana, Tripura
Tender Specification for Erection & Commissioning

of Rain Water & Deep Tube Well System
Index
SECTION NO.
DESCRIPTION
NO. OF
PAGES
COVER SHEET
CONTENT SHEET
VOLUME I
VOID
VOLUME II
TECHNICAL
GENERAL TECHNICAL SPECIFICATION
DETAILED TECHNICAL SPECIFICATION MECHANICAL
81
DETAILED TECHNICAL SPECIFICATION ELECTRICAL
26
TENDER DRAWINGS
25
VOID
QUALITY ASSURANCE PROGRAMME
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Index Sheets

Tender Specification for Erection &

Commissioning of Rain Water Harvesting /
Deep Tube Well System
VOLUME II
SECTION 1
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Section 1
General Technical Specification
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TABLE OF CONTENTS
1.0.0
INTENT OF SPECIFICATION ...................................................................................3
2.0.0
SCOPE OF WORK ....................................................................................................3
3.0.0
TERMINAL POINTS ..................................................................................................5
4.0.0
EXCLUSIONS FROM THE BIDDERS SCOPE OF WORK ......................................6
5.0.0
PROJECT INFORMATION ........................................................................................6
6.0.0
APPROVED SUB VENDORS/MAKES ......................................................................6
7.0.0
PAINTING AND CORROSION PROTECTION .........................................................6
8.0.0
QUALITY ASSURANCE, TESTING AND INSPECTION...........................................6
9.0.0
DOCUMENTATION ...................................................................................................6
ANNEX 1.1 PROJECT INFORMATION.....................................................................................9
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SECTION 1
1.0.0
INTENT OF SPECIFICATION
1.1.0
This specification includes but not limited to the Engineering, design, fabrication, construction,
erection, testing and commissioning at site for Piping Erection works and Erection of Pumps
for Rain Water harvesting/Deep Tube Well System as detailed in the scope of work.
1.2.0
Supplies and services shall be rendered in conformity with proven design principles, taking
into account the current technology. The requirements of the contract must be fulfilled in its
entirety. The supplies and services shall be rendered inclusive of all appliances and
interconnecting arrangements with other supplies, necessary for installation of all
accessories, needed for proper and reliable continuous operation and for satisfactory
maintenance and repair.
1.3.0
In so far as data on the execution of supplies and services as contained in drawings, but none
in specification and vice versa, such data shall be deemed to be contained in both.
Contradictions, if any, between drawings and specifications and within various sections of the
specification shall be brought to the attention of the Owner/Consultant by the Bidder and the
correct requirement shall be obtained.
1.4.0
It is mandatory for the bidders to furnish along with the bid the deviations if any, whether
major or minor in the Schedule of Deviations only. In the absence of the deviations listed in
the Schedule of Deviations, the offer shall be deemed to be in full conformity with the
specification not withstanding anything else stated elsewhere in the offer, data sheet, etc. The
hidden deviations or stated / implied deviations in the offer shall not be acceptable OR
binding on the Owner.
1.5.0
All materials supplied under this contract shall be new and unused.
1.6.0
The Bidder shall furnish along with the Bid the necessary information meeting the above
requirement.
2.0.0
SCOPE OF WORK
2.1.0
The scopes of work covered in this document include but not limited to the following.
2.1.1
Fabrication, construction, erection, testing and commissioning at site of complete piping

(including instrument tappings up to root valves & vent & drain connections), valves and
specialities, all field welding of pipes and fabrication of pipes, fittings & supports, heat
treatment, pre-qualification of welding procedures and welders (WPS, PQR), NDT
examinations as per ASME sec IX, flushing, Hydro testing, cleaning and flushing as per the
specification given hereinafter. The quantity of piping and equipment to be fabricated,
erected, installed and tested shall be as per the erection drawings.
2.1.2
Execution of field engineering, modification during execution, hydro testing etc. The Bidder
shall supply all required piping / supports etc on take back basis after dismantling the same.
2.1.3
Supply and application of coating and wrapping for all buried piping.
2.1.4
Supply and application of grouting material including non-shrinkable cement and erection of
grouting.
2.1.5
Supply and application painting for above ground piping (Except GI and SS pipes).
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2.1.6
Providing all labour, material, consumables and equipment as necessary for fabrication,
manufacture and testing at site as required.
2.1.7
Scope of work for erection of pumps is mentioned in Section-5 of Volume-1 of this

specification.
2.1.8
Erection of hoist on monorail shall be carried out by bidder. Monorail design and supply shall be
by Owner.
2.1.9
Erection & installation of cables, earthing, lighting, local control stations and accessories
required for the storm water pits and deep tube well package electrical system.
2.1.10 Erection & installation of Instruments and Junction box required for the storm water pits and
deep tube well package system.
2.2.0
Scope of supply
2.2.1
Piping supports for the above ground piping complete with all accessories.
2.2.2
Coating and wrapping material for the buried carbon steel piping.
2.2.3
Consumables and chemicals required for the piping fabrication, erection, cleaning and testing
works which includes electrodes, filler material, welding gases etc.
2.2.4
Supply of special tools, fixtures & test equipment required for the piping fabrication, erection,
cleaning and testing works.
2.2.5
Temporary piping material and supports for piping system cleaning and testing.
2.2.6
Paints for above ground piping.
2.2.7
Supply & erection of coarse screen for the sump pits
2.3.0
Scope of services
2.3.1
Receipt of material at site, site storage and handling, fabrication of piping, buried piping
works, complete erection of all piping and instruments, cleaning and painting, site supervision,
testing, calibration and commissioning, startup and run test, load test, hydro test, performance
and acceptance test.
The piping erection quantities involved are listed in Section-5 - price schedule of the
specification.
All valves and specialities as indicated in P&ID as within the piping contractors scope of
piping shall be erected by the contractor.
2.3.2
Following civil works are included in Bidders scope:

a)
b)
c)
d)
Excavation and backfilling for laying of pipes.

Laying of Hume pipes for pipes crossing roads.
Making good of the openings.
Making opening in the walls for routing of pipes
2.3.3
Obtaining necessary approvals from various agencies as applicable.
2.3.4
Providing all man power, material and complete erection equipment including hoists, tools
and tackles, consumable, welding electrodes, filler wires, oxygen, acetylene, sequence of
erection, calibration & measuring instruments etc. to enable execution of job including final
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testing, calibration and handing over in a planned manner and within the schedule of
stipulated time.
2.3.5
After completion of job arrange to clear the area of work of all loose materials, scraps, tools
equipment etc. Also update Owner's construction drawings to incorporate all the modifications
carried out and get same certified as 'as-built' drawings by the owners project manager.
2.3.6
Assisting the owner in successful commissioning of the system by providing skilled/unskilled

personnel, equipment & tools etc.
2.3.7
Any other activities found necessary for the successful completion of the job.
2.4.0
Drawings
2.4.1
Owner shall provide the following drawings & document

a.
b.
c.
d.
P&I drawings
Piping layout drawings
Standard piping support details
Equipment layout drawings
The list of drawings indicated above is furnished else where in this tender document. The
drawings will be made available to the contractor progressively after the award of contract.
2.4.2
Coordinating for approvals from the statutory authorities like Inspector of Explosives CCOE
(if required) and for calibration from Weights & Measures Department etc. & others for the
system under their purview. This includes getting approval of the welders from the above
authorities, arranging for the Inspector to visit site and obtain necessary approvals and
certificates for the erected pipe work etc.
2.4.3
Location, type and details of support for lines will be indicated in the Piping / G.A. drawing
support details wherever not shown in GA drawing, but required for the piping stability the
Contractor shall carry out supporting with the approval of Owners Project manager after
developing necessary support drawings.
2.4.4
All fabrication drawings for piping shall be developed by the Contractor and submit to the
Owners Project manager for approval.
2.4.5
Any alteration in pipe routing / supporting required to suit the site condition shall be done by
the bidder to the satisfaction of the Owners project manager at no extra cost.
2.5.0
Consumables
Supply of all consumables required for commissioning and performance test shall be included
in the scope and the same shall be supplied by the successful bidder at appropriate time.
3.0.0
TERMINAL POINTS
3.1.0
Mechanical
Terminal Point shall be as per the P&I Drawings & Piping Layouts.
3.2.0
Electrical
1.
Power supply of 415V / 230V, 3 PH, 50 HZ at all pump motor
2.
Power supply of 230VAC at all Field Instruments
3.
Digital/Signal cables for all the pumps on feedback at the plant DCS in Central control
Room
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4.

Cabling/Wiring for the level interlock at the storm water pump motors local control
stations
4.0.0
EXCLUSIONS FROM THE BIDDERS SCOPE OF WORK
4.1.0
Mechanical
4.2.0
5.0.0
The pipes, fittings, valves, pumps and specialties as specified. (The pipes, fittings, valves and
specialties, pumps and hoists are procured by Owner through a separate contract and the
procured material will be issued as Free Issue Material by Owner to the successful bidder.)
Civil
Pump foundations
Pipe support pedestals with embedded plates
Hume pipes for piping
PROJECT INFORMATION
Project Information is furnished in Annex 1.1 of this section of the specification.
6.0.0
APPROVED SUB VENDORS/MAKES
6.1.0
The makes of all material/equipment/ instruments under this specification shall be subject to
Owners approval in the event of order. Bidder shall furnish a list of makes/ sub-vendors/ subcontractors along with his bid. Owner reserves the right to accept/ reject any make or subvendor or add new makes/ sub-vendors for the project, after award of contract. Approval,
rejection or addition of makes shall not have any cost implication to the Owner after award of
contract.
7.0.0
PAINTING AND CORROSION PROTECTION
7.1.0
The painting specification for all the equipment shall be as specified in various sections of this
specification. The detailed painting specification and colour scheme shall be firmed up by the
Owner after award of contract. Necessary finish paints including touch-up paints, if not applied
at shop, should be supplied by the Bidder, in sealed containers for site application.
8.0.0
QUALITY ASSURANCE, TESTING AND INSPECTION

Quality assurance program for the project is furnished in Section - 6 of this specification
9.0.0
DOCUMENTATION
9.1.0
Drawings, data / documents to be submitted along with Bid.
9.1.1
Duly filled-in technical data, bill of material and prices as per specified schedules
9.1.2
Technical data sheets & manufacturers literature for supply items
9.1.3
Quality assurance documents for all supply items and erection of piping system
9.1.4
List of drawings / documents attached
9.1.5
List of tests the Bidder proposes to carry out in shop and at site after installation including those
pertaining to their sub-contractor.
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9.1.6
A bar chart indicating design engineering, installation, testing and commissioning activity /
duration of piping.
9.1.7
List of tools & tackles and accessories required for erection along with type & class of make.
9.1.8
Equipment list for Excavation & Bending to be mobilized at site by the Bidder.
9.1.9
List of sub-contractors / Sub vendors.
9.1.10 List of manpower to be deployed site

9.1.11 Deviation schedule
9.1.12 Concurrent commitments of the bidder
9.1.13 Details of similar works done in the past five years
9.1.14 Descriptive information of proposed welding procedures, including filler metal control procedure
9.1.15 Fabrication, erection and hydro test procedure including tentative schedule
9.1.16 List of codes & standards used in design of the pipe and accessories including issue date or
revision.
9.2.0
Drawings, data / documents to be furnished by the successful Bidder

The following drawings, data / documents shall be submitted for the approval / review of the
Owner / Consultant by the successful bidder.
Description
Category
9.2.1
Technical data sheet and GA drawings for supply items
9.2.2
Test procedures and details of test to be conducted.
9.2.3
Quality assurance document for all supply items
9.2.4
Quality assurance document for erection of piping and painting
9.2.5
Final welding procedure for piping
9.2.6
Test procedure and details of test to be conducted
9.2.7
Erection procedure for piping
9.2.8
Instruction manual for Operation & maintenance for supply items.
9.2.9
Bidders purchase order copy for all brought out items
A
I
I
9.2.10 Piping fabrication/spool piece details
9.2.11 Submission schedule from the date of LOI
9.2.12 Any other details if required.
9.2.13 Reports
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a) Type and Routine Test certificates material test certificates for major
components
b) Test reports for various bought out materials shall be furnished by the
successful Bidder
9.3.0
Erection Manuals
The erection manuals shall be submitted atleast three (3) months prior to the commencement
of erection activities of particular equipment / system. The erection manual should contain the
following as a minimum.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
Erection strategy
Sequence of erection
Erection instructions
Critical checks and permissible deviation / tolerances
List of tool, tackles etc.
Bills of Materials
Procedure for erection
Procedure for initial checking after erection
Procedure for testing and acceptance norms
Procedure / Check list for pre-commissioning activities
Procedure / Check list for commissioning of the system
Safety precautions to be followed in electrical supply distribution during erection
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ANNEX 1.1
PROJECT INFORMATION
1.0
Owner
ONGC - Tripura Power Company Ltd.
2.0
Project Title
726.6 MW Combined Cycle Power Project
3.0
Location
Palatana village, Near Udaipur town, Tripura, India
4.0
Power station site Elevation above

Mean Seal Level (MSL)
RL (+) 24.0 M
4.1
Latitude / Longitude
23 29 59.2 N and 91 26 13.7E
5.0
Nearest Railway station
Manughat (Assam)
6.0
Nearest Town
Udaipur (Tripura), India,
7.0
Nearest State Highway
Udaipur-Kakraban State Highway
8.0
Nearest Airport
Agartala
9.0
Nearest Sea Port
Nearest seaport in Indian territory is Kolkata.
10.0
Road Approach
Udaipur-Kakraban State Highway
11.00
Seismic data
(a)
(b)
Seismic intensity
Zone
:
:
As per IS-1893.
V
(c)
Importance factor
0.36
:
:
:
37.5 C and 6.7 C

0
30.5 C
0
20.5 C
40 C
12.0
(a)
(b)
(c)
(d)
Temperature
Maximum / Minimum temperature
Daily maximum mean temperature
Daily minimum mean temperature
Design temperature for elec
equipment/device/System
13.0
(a)
(b)
Relative Humidity
Maximum Relative Humidity
Minimum Relative Humidity
:
:
100%
40%
14.0
(a)
(b)
(c)
Rain fall
Max. recorded
Average Annual rain fall
Period of Monsoon (Avg) Showers
:
:
:
164.9 mm in 24 hrs
15.0
Wind data
Maximum wind speed
55 m/s
Climatic conditions
16.0
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726.6 MW Combined Cycle Power

Project, Pallatana, Tripura
Tender
Specification
for
Erection
&
SECTION 2.0
DETAILED TECHNICAL SPECIFICATION - MECHANICAL
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Section 2 Index sheet
Page : 1 of 2
Detailed Technical Specification - Mechanical

Tender
Specification
for
Erection
&
TABLE OF CONTENTS
SECTION 2.0
DETAILED TECHNICAL SPECIFICATION - MECHANICAL
SECTION
CONTENTS
SHEET NO
2.1
DETAILED TECHNICAL SPECIFICATION FOR

ERECTION OF PIPING
12
2.2
TECHNICAL SPECIFICATION - WELDING PROCEDURE
23
2.3
TECHNICAL SPECIFICATION - ERECTION OF

BURIED PIPING
2.4
TECHNICAL SPECIFICATION - HYDRO TEST PROCEDURE
2.5
TECHNICAL SPECIFICATION - PIPING FLUSHING AND

CLEANING PROCEDURE
2.6
TECHNICAL SPECIFICATION - PAINTING
16
2.7
TECHNICAL SPECIFICATION FOR ERECTION OF PUMPS
11
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Section 2 Index sheet
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Detailed Technical Specification - Mechanical

Tender
Specification
for
Erection
&
SECTION 2.1
TECHNICAL SPECIFICATION ERECTION OF PIPING
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Section 2.1
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Technical Specification Erection of Piping

Tender
Specification
for
Erection
&
TABLE OF CONTENTS
1.0.0
INTENT OF SPECIFICATION ............................................................................................ 3
2.0.0
CODES AND STANDARDS ............................................................................................... 3
3.0.0
SCOPE OF WORK ............................................................................................................. 3
4.0.0
EXCLUSIONS ..................................................................................................................... 4
5.0.0
LAYOUT, CUTTING AND FITTING UP .............................................................................. 5
6.0.0
ERECTION.......................................................................................................................... 8
7.0.0
BURIED PIPING ................................................................................................................. 8
8.0.0
INSTALLATION AND ASSEMBLY ..................................................................................... 9
9.0.0
ERECTION OF VALVES................................................................................................... 10
10.0.0 ERECTION OF SUPPORTS............................................................................................. 10

11.0.0 ERECTION OF INSTRUMENTS ...................................................................................... 11
12.0.0 LINE MOUNTED FILTERS, SIMPLEX / DUPLEX FILTERS, MIXERS & FLEXIBLE
HOSES.............................................................................................................................. 11
13.0.0 INSPECTION .................................................................................................................... 11
14.0.0 MATERIAL IDENTIFICATION .......................................................................................... 12
15.0.0 HYDROTEST .................................................................................................................... 12
16.0.0 INSTRUMENT CONNECTIONS ....................................................................................... 12
17.0.0 RECORDS ........................................................................................................................ 12
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Tender
Specification
for
Erection
&
SECTION 2.1
ERECTION OF PIPING
1.0.0
This specification covers the minimum requirements and guidelines to be adhered by the
bidder for Engineering, design, fabrication, construction, erection, testing and commissioning
of entire Piping System including supports and auxiliary structures, equipment, valves, pumps
and specialities (REJ etc.,).
2.0.0
CODES AND STANDARDS

The erection and testing of piping, valves and specialities shall comply with the requirements
of latest edition of ASME B31.1. The following standards shall be followed in particular.
3.0.0
ANSI B31.1
Power Piping
ANSI B 2.1
Pipe threads
ANSI B16.9
Wrought steel butt welding fittings.
ANSI B 16.20
Ring joint gaskets and grooves for steel pipe flanges
ANSI B 16.25
Butt welding ends
ASME BPVC Sec V
Nondestructive examination
ASME BPVC Sec IX
Welding and Brazing qualifications.
MSS-SP-55
Visual inspection & testing
MSS-SP-53
Magnetic particle testing
MSS-SP-54
Radiographic testing
SCOPE OF WORK
The scope of work shall be as per furnished in GTS - Section-1 CL.2.0.0 of this Specification
for the following piping systems.
Rain water harvesting system Scope shall be from Rain water harvesting pumps
discharge to Reservoir as per P&ID.
Deep tube well piping system Scope shall be from Deep tube well pumps discharge
to Reservoir as per P&ID.
Broad Guidelines for Erection and Installation of Low Pressure Piping
All fittings like T pieces, Elbows, weld neck flanges, reducers, etc., shall be suitably
matched with pipes for welding. The valves shall be checked, cleaned, or overhauled in
full or in part before erection, after chemical cleaning, and during commissioning.
Adjustments such as removal of ovailties in pipes shall be considered part of the work
and the Bidder is required to carry out such work, which shall include specified heat
treatment procedures, etc., wherever required.
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Tender
Specification
for
Erection
&
Certain adjustments in length may be necessary while erecting pipelines and the Bidder
shall remove the extra lengths / add extra lengths to suit the final layout after preparing
edges afresh and adopting specified heat treatment procedures.
All the valves, lighting equipment, actuators, power cylinders. etc., shall be serviced and
lubricated before erecting the same and also during precommissioning
Even after commissioning the equipment, if there are problems in the operation, these
shall be attended to by the Bidder.
Welding or jointing of extension spindle for valves to suit the site conditions and
operational facility shall be part of erection work.
All tubes and pipes shall be cleaned and blown with compressed air before erection.
Bigger size pipes shall be cleaned with flexible wire brush, wherever necessary.
Small bore piping have to be routed according to site conditions and hence shall be done
only in position. As such, layout of small bore piping shall be done in accordance with site
requirement. There is a possibility of slight change in routing the above pipelines even
after completion of erection. Work shall also include fabrication of small bends at site from
straight lengths to suit the site conditions.
No temporary supports shall be welded on the pressure parts. Welding of temporary

supports, cleats, etc., on the building columns shall also be avoided.
(a) All pipes shall be grouped wherever practicable and shall be routed to present a neat
appearance.
(b) The piping shall be arranged to provide clearance for the removal of equipment for
maintenance and for easy access to valves, instruments, and other piping
accessories required for operation and maintenance.
(c) Piping shall be generally routed above ground but, where specifically indicated /
approved, piping may be arranged in trenches or buried.
(d) Overhead piping shall generally have a minimum overhead clearance of 2.3 meters
above walkways and working areas and 8 metres above roadways.
(e) Drains shall be provided at all low points and vents at high points in accordance with
actual layout regardless of whether the same have been shown in the respective
drawings or not. The pipelines shall be sloped towards the drain points.
(f) For field run piping, the Bidder shall fabricate and erect all hangers and supports as
required with due regard to general arrangement and layout of other pipes, hangers,
cable trays, ducting, structural members etc.
4.0.0
All drips and drains for piping and equipment whether shown on the drawings or not shall
terminate on the ground floor at the station drain unless otherwise noted. Leading such
drains to the station drainage is also the responsibility of the Bidder.
EXCLUSIONS
1. All civil engineering works such as RCC foundation, buildings, roads etc.
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5.0.0
LAYOUT, CUTTING AND FITTING UP
5.1.0
Cutting and fitting-up
Tender
Specification
for
Erection
&
Pipes shall be cut to required length in accordance with piping layout drawings and /or
spool drawings.
Preparation of pipe ends shall preferably be done by any combination of turning and
grinding. When oxygen or arc cutting is resorted to then the cut shall be reasonably
smooth and true and all slag is cleaned from the flame cut surfaces.
Preparation of butt welding joints shall be as per ASME B 31.1/as per enclosed figure
elsewhere in this tender document, unless otherwise approved by the owners project
manager.
The ends of piping components to be joined shall be aligned as accurately as is

practicable within existing tolerance on diameters, wall thickness and out-of-roundness.
Internal radial misalignment exceeding 1.6 mm shall be taper trimmed as per enclosed
figure elsewhere in this tender document, after getting approval from owners project
manager.
5.2.0
5.3.0
Branch Connections
Openings for branch connections shall preferably be made by drilling. Oxygen or arc
cutting is acceptable only if the cut is reasonably smooth and true and all slag is cleaned
from the flame cut surfaces.
End preparation of branch and runner pipe shall be as per the relevant clause of
ASME B31.1. Edge Preparation details for branch connection joints shall be subjected to
approval of Consultant / Owner.
Minimum Distance between Longitudinal Welds

The distance between two longitudinal weld shall be staggered suitably.
5.4.0
Flanged Connections
Flange bolt holes shall straddle the established center-lines (horizontal or vertical) unless
otherwise shown.
5.5.0
Threaded Connections
Taper pipe threads shall be used in accordance with ANSI B.2.1 "Pipe Threads" for threaded
pipe joints.
5.6.0
Bending
Hot bending is not permitted except for non- pressure piping such as drain and vent lines.
Cold bending is only permitted and no hot bending is envisaged at site.
5.7.0
Mitre Bends
Mitre bends shall be fabricated in accordance with "Piping Standard Drawing" unless
otherwise specified in piping GA drawing. Single cut mitre are not allowed.
5.8.0
Threaded Joints
When threaded couplings or nipples are welded to the pipe spools, the thread must be
checked for fit and roundness after welding.
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5.9.0
Layout
For laying out headers, tees, laterals and other irregular details, templates shall be used
to ensure accurate cutting and proper fit-up.
All cutting shall follow the outline of the template.
Machine cut bevels to form the welding groove are preferred in carbon steel pipe.
However, smooth, clean, slag free, flame cut bevels using flame bevel cutting machines.
All buried piping shall be as per the specification given in Section 2.4.
5.10.0 Dimensional Tolerances

The dimension tolerances generally acceptable are as follows
a. Face to face/center to face
3 mm (max)
b. Lateral translation in any direction
1.5 mm (max)
c.
1.5 deg (max)
1 mm
Rotation
d. Out of alignment measured

across the diameter
e. Flattening measured as difference between maximum and minimum OD at any Cross

Section.
i.
ii.
For pipe with external

pressure
For pipe with internal
pressure
3% (max)
8% (max)
Bidder shall be responsible for working to the dimensions shown in the drawing. However,
there may be slight variations due to minor variation in the location of equipment, insert etc.
Field welds (F.W) to be provided to take care of these. An extra pipe length of 100 mm over
and above the dimension shown in the drawing may be left on one side of the pipe at each
end of field weld. During erection the pipe end with extra length of each field weld may be cut
to obtain proper dimension. The Bidder shall provide adequate number of field welds.
Wherever omissions / errors occur in drawings and bill of materials, it shall be the
responsibility of the Bidder to notify the Owner prior to fabrication and erection.
5.11.0 Pipe Joints
Pipe joints shall be generally welded or as indicated in piping drawings. In general, BW joints
shall be used for 65 NB and above and SW/Threaded/BW joints shall be used for sizes 50 NB
and below as specified in piping drawings. However, BW joints may be used after getting prior
approval from Owner/Consultant in place of SW/Threaded connections in long runs of piping.
This is applicable for non-galvanised piping and piping without lining. All welding shall be as
per the welding procedure specified.
Flanged joints shall be used at connections to vessels, equipment and where required for
ease of erection and maintenance as indicated in drawing.
5.12.0 Piping Alignment
The pipes to be jointed by welding shall be aligned correctly with the existing tolerances on
diameters, wall thickness and out of roundness. The same alignment shall be preserved
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during welding. For the internal misalignment due to difference in wall thickness of the mating
components exceeding 1.5 mm, the component with the higher wall thickness shall be
internally machined ground so that the adjoining surfaces are approximately flushed.
5.13.0 Cleaning of Piping
On completion of fabrication, all pipes and fittings shall be cleaned inside and outside by
suitable means (Mechanical tools, wire brush etc.) before erection to ensure that assembly is
free from all loose foreign material such as scale, sand, weld spatter particles, cutting chips
etc.
All field fabricated piping shall be cleaned at the conclusion of the fabrication. All burrs,
welding circles and weld spatter shall be removed by any suitable means (mechanical tools,
wire brush etc.)
Field fabricated piping shall be blown out with compressed air at the termination of cleaning
and capped.
5.14.0 Quality Control for Welding
5.14.1 Welding Machines
1. DC Machines only to be used.
Inspection and Maintenance of Welding Machines.
Welding machines shall be periodically inspected at least once a month for maintenance.
This inspection and maintenance shall be done mainly for quality control purpose and
shall be periodically recorded in a list showing the location and conditions of the welding
machines being used.
5.14.2 Installation
a) Location of welding machines and the switch boards to be connected with them shall be
decided in consultation with owners project manager to prevent them for disturbing other
work as well as to prevent overloading of the switchboards, cables and electrical power
sources. Proper earthing to be provided for welding machine.
b) Electric cables, switches and connections for welding machines shall be carefully
checked and repaired atleast once a month and before operating the welding machines.
c) Portable power cables used with welding machines shall be carefully examined and
repaired as necessary every day.
d) Proper earthing of the welding machines shall be ensured by the Bidder.
5.15.0 Welding
5.15.1 General
a) All welding and heat treatment shall be performed in accordance with the welding
requirements detailed in ASME B31.1.
b) No welding shall be done if there is impingement of any rain, or high winds on the weld
area except when suitable protection or shield against the rain or wind is provided.
c) Before welding, the ends shall be cleaned by wire brushing, filing or grinding. Each weldrun shall be cleaned of slag before the next run is deposited.
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d) Welding shall be done by certified welders only. Welding procedure and welder
qualification records shall be maintained for reference of Owner/Consultant at any time.
e) Welding at any joint shall be completed uninterrupted. If this cannot be followed for some
reason, the weld shall be completely removed and a new joint shall be made.
f)
Welding shall be done by manual shielded metal arc process and TIG welding as
applicable. Automatic or semi-automatic welding processes may be done only with the
specific approval of Owner/ Consultant.
5.15.2 Welding Procedure

For detailed welding procedure refer Section 2.2.
6.0.0
ERECTION
6.1.0
All piping shall be routed and located as shown in piping drawings keeping in view the piping
specifications. No deviations from the arrangement shown shall be permitted without the
approval of the owners project manager.
6.2.0
For erection of piping, use of davits, welding of temporary supports on adjacent equipment /
structure, use of existing foundation or steel structure shall be allowed only after approval of
owners project manager. In each case, maximum allowable load and erection procedure
shall be as directed by the owners project manager.
6.3.0
Location and design of pipe supports shown in support drawings should be strictly adhered to.
Pipe supports have been designed and located to effectively sustain the piping system for
weight and thermal offsets.
6.4.0
Erection and fabrication or supports i.e. restraints such as guides, stops and anchors must be
made in such a manner that they will not over stress a line while protecting a weaker or more
sensitive component e.g. turbine, pump compressor, vessel nozzles, etc.
6.5.0
Flanged connections at the pump, turbines, compressors and other equipment shall be made
in such a way as not to induce any stresses due to misalignment, excessive gap etc. The final
tightening shall be redone when the machines are aligned completely and specifically
authorised by the owners project manager. Pipes shall not be pulled and connected to
equipment as well as during welding. Temporary protective covers shall be provided at all
flanged connections of pumps, compressors, turbines and other similar equipment until the
piping is finally connected.
6.6.0
Slopes specified for various lines in the drawings shall be maintained by the Bidder. In case
the Bidder is unable to maintain the indicated slope he shall check the sagging of the pipe
with a precision spirit level and maintain a difference in levels higher than that. Vents and
drains are shown in the isometric of each line and these are intended for releasing the
trapped air during hydrostatic test and draining out the test fluid after testing. Valved vents
and drains are also shown wherever required. The Bidder shall provide vent and drain
connections even when these are not shown in the drawings and are found necessary by the
owners project manager. The details for the type of connections to be adopted shall be as
per enclosed drawings.
6.7.0
After the piping is erected in final position, it shall be cleaned, tested for tightness and kept
dry wherever instructed, as described in this specification.
7.0.0
BURIED PIPING
Buried piping shall be as per detailed procedure enclosed as Section .2.3 along with this
section.
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8.0.0
INSTALLATION AND ASSEMBLY
8.1.0
General
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a) Installation and assembly of fabricated spool and piping components shall be made so
that the completely installed piping system conforms to the requirements of relevant
drawings and specifications.
b) Care shall be taken to prevent damage to equipment nozzle caused by the weight and
moment of fabricated spools or piping components. Permanent or suitable temporary pipe
supports shall be installed prior to installation of such a piping.
8.2.0
Connection to Equipment Nozzles

a) Faces of flanges and the bolt holes shall accord reasonably to those of equipment nozzle
flanges.
b) Lines connected to rotating machinery shall be aligned so as to meet the following
requirements.
i)
Flange faces which connect piping to the primarily aligned machinery shall be strictly
parallel with the clearance between them equal to the thickness of the gasket so that
alignment of the machinery after tightening the flanges will be within the allowable
tolerances specified. No load shall be transferred to the connected equipment.
ii)
Off-center of bolt holes shall be minimised so that the bolt can pass smoothly through
the bolt holes.
The alignment of the piping shall be checked after completion of piping fabrication with
flanges disconnected and witnessed by the owners project manager.
8.3.0
Installation of Spools and Piping Components

a) Care shall be taken to protect/prevent tack welds at both weld ends from any damage
caused by weight and the moment of piping components.
b) For installation of angle, blow-down, check and needle valve, control valve and pressure
relief valve, the direction of those shall conform to the flow direction shown on piping
drawings.
c) Direction of the pressure balancing hole for gate valves, if drilled, shall conform to piping
drawings.
d) Care shall be taken that the faces of companion flanges for flanged cast iron components
shall be parallel with the required clearance for gasket thickness and that the flange bolts
shall not be off-centre.
8.4.0
Bolting Procedure
8.4.1
Anti galling compound shall be applied on all flanges bolts in order to prevent seizing.
8.4.2
All flanged joints shall be fitted so that the faces of the flange meet evenly with the gasket,
and then the bolts shall be tightened in a sequence to ensure uniform bolt stress.
8.4.3
In bolting flanged joints, the bolt shall be tightened in a proper manner to compress the gasket
to build up a compression suitable for the type of gasket used.
8.4.4
Steel-to-cast iron flange joints shall be assembled with care to prevent damage of the cast
iron flange.
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All bolts shall extend completely and uniformly through their nuts.
Bolt loads shall be in accordance with the manufacturer's recommendation.
8.5.0
Threaded Piping
8.5.1
Teflon seal tape/Araldite shall be used for all threaded piping. No lead based component shall
be used.
9.0.0
ERECTION OF VALVES
9.1.0
Erection and testing of the valves shall be in accordance with the applicable standards.
9.2.0
Valve spindle positions are shown in the arrangement drawings and the Bidder shall be
required to follow them. He shall, however, bring it to the notice of the owners project
manager in case he encounters some difficulty in installing them.
9.3.0
Where practicable and except when otherwise shown on the drawings, valve stems shall be
installed in a vertical direction and shall not be installed with stems below the horizontal.
9.4.0
For Safety valves, Pressure relief valves, Rupture discs and other safety devices against
excess pressure the directives of the Appendix II of the code ANSI B 31.1. "Non mandatory
rules for design and safety valve installations" shall apply.
9.5.0
All globe valves shall be installed with the pressure on the bottom of the disc.
9.6.0
Globe valve, check valve, control valves etc. shall be installed in the correct sequence and
direction as shown in P&I diagram and piping drawings.
10.0.0 ERECTION OF SUPPORTS

10.1.0 Welding
Pipe supports which are welded to the pressurised pipe directly shall be welded by qualified
pipe welders.
10.2.0 Fabrication
All supports shall be properly levelled and plumbed as per pipe support drawings. Shims and
wedges may be employed for levelling and alignment of the supports on the grade. Rigid
temporary wooden frames or other suitable devices may be used for supporting piping before
installation of pipe supports.
10.3.0 Supports Permitting Pipe Movement
Supports permitting pipe movement shall be assembled to allow the necessary movement of
pipes as caused by thermal expansion and contraction in accordance with the piping drawing
and stress analysis reports giving details of movements at individual support locations.
10.4.0 Bracing
10.4.1 The first nipple and valve of small connections including instrument connections to piping,
vessel or equipment shall be braced if required.
10.4.2 For 2" and smaller piping, additional pipe supports may be installed to improve the stability of
the piping after approval of the owners project manager.
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11.0.0 ERECTION OF INSTRUMENTS

11.1.0 All in-line instruments shall be installed only after final flushing of the line and when the line is
ready for commissioning.
11.2.0 The limits of piping Bidder are clearly shown in the drawings provided (such as upto first block
valve, nozzle and flange, taps etc.). In addition to this, he shall install all the in-line
instruments such as orifice flanges including orifice plates, with valves, venturi control valves,
flow integrators, positive displacement meters with strainers, pressure relief/safety valves,
rotameters, rupture/bursting discs etc.
11.3.0 For installation of all in-line instruments, reference may be made to relevant clause of the
chapter for pressure testing inspection procedures.
11.4.0 Care shall be exercised and adequate precautions to be taken to avoid damage to the
instruments while transportation, installation etc. protection cover shall be used at control
valves, flow meter etc. to avoid contamination with dust and foreign matter.
12.0.0 LINE MOUNTED FILTERS, SIMPLEX / DUPLEX FILTERS, MIXERS & FLEXIBLE HOSES
12.1.0 Installation of line mounted filters with by-pass arrangements, or any other arrangements, if
any, duplex filters, mixers, ejectors including installation of all types of supports will be done
by the Bidder as part of piping erection work.
12.2.0 Installation of temporary strainers as per requirements either during finishing or start-up, its
cleaning and up-keeping shall be part of the piping erection work and no separate payment
shall be made on this account.
12.4.0 Bolts, Nuts
12.4.1 During erection of the piping, the Bidder shall install proper number and size of bolts and nuts
as per drawings and specifications.
12.4.2 Grease and Graphite shall be supplied by the Bidder.
12.4.3 All bolts shall extend completely through their nuts. Only bolts of adequate length, required
die, specified material and machining quality shall be used. The number, material shall be
readable for all the same side. Hexagonal bolt heads shall be all at the same side with
horizontal flanges at the top. Threaded ends with machine bolts shall protrude adequately
through the nuts. Bolts/stud threads and compressed asbestos gaskets shall be treated with
graphite oil before assembly or as per the specification.
13.0.0 INSPECTION
13.1.0 General
13.1.1 Owner's/Consultant's inspector shall have free access to all places where the work is being
done or any other place concerned with the work.
13.1.2 Owner is entitled to send his own inspector or his representative to field where pre-fabrication
and erection of pipe lines are being done, with the following functions but not limited to:
i.
To check that the execution of welding and welding equipment used on the job are
suitable and conform to relevant standards.
ii.
To supervise welding procedure qualification.
iii. To supervise welder performance qualification.

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iv
To check whether welding is conforming to relevant specification and the procedure

followed and is in accordance with good pipeline construction practice.
v.
To check any other activity to ensure quality of work.
13.1.3 Bidder shall notify inspection dates sufficiently in advance with all facilities necessary for
carrying out his work at no extra cost to the Owner.
13.1.4 Approval from the Owner's inspector shall not relieve the Bidder partially or fully of his
responsibilities and guarantees under this Work order.
13.2.0 Details of inspection and defect acceptance norms its repair and removal shall be as per
Section - 2.2 of this tender document.
14.0.0 MATERIAL IDENTIFICATION
Specification of all materials shall be as per the relevant piping drawings and piping service
sections.
14.1.0 Material Check
a) All the materials before usage the materials shall be identified by means of stencil and/or
colour identification or other marking.
14.2.0 Thickness and Pressure Temperature Rating
a) Thickness and pressure temperature rating of piping components to be used shall be
checked by stencil or other marking and measurement referring to the material shown on
piping drawing and piping service classes.
b) Markings on pipe stencilled by manufacturer shall be left until final use of the pipe and be
transferred by painting on to the length to be cut off prior to cutting.
15.0.0 HYDROTEST
Hydrotest shall be as per Section 2.4 of this tender document.
16.0.0 INSTRUMENT CONNECTIONS
16.1.0 Stubs shall be provided for all pressure connections
17.0.0 RECORDS
Fabrication details and results of inspection of piping shall be recorded on the piping drawings
for records.
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SECTION 2.2
TECHNICAL SPECIFICATION WELDING PROCEDURE
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Technical Specification Welding Procedures

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TABLE OF COTNENTS
1.0.0
INTENT OF SPECIFICATION ............................................................................... 3
2.0.0
APPLICABLE CODES AND STANDARDS ........................................................... 3
3.0.0
BASE METAL......................................................................................................... 4
4.0.0
GENERAL STORAGE OF WELDING CONSUMABLES....................................... 4
5.0.0
EQUIPMENT AND ACCESSORIES ...................................................................... 4
6.0.0
WELDING PROCESS............................................................................................ 4
7.0.0
EDGE PREPARATION .......................................................................................... 5
8.0.0
ALIGNMENT & SPACING ..................................................................................... 5
9.0.0
WELDING TECHNIQUE ........................................................................................ 6
10.0.0
WELDING PROCEDURE QUALIFICATION ......................................................... 7
11.0.0
WELDERS QUALIFICATION................................................................................ 7
12.0.0
WELD HEAT TREATMENT PROCEDURES ........................................................ 8
13.0.0
INSPECTION AND TESTING ................................................................................ 9
14.0.0
SAFETY REQUIREMENTS ................................................................................. 13
ANNEX - A
FORMAT FOR WELDING PROCEDURE SPECIFICATIONS ............................ 15
ANNEX - B
FORMAT FOR PROCEDURE QUALIFICATION RECORD................................ 17
ANNEX - C
FORMAT FOR MANUFACTURERS RECORD OR WELDING OPERATOR

QUALIFICATION TESTS ..................................................................................... 19
ANNEX - D
FORMAT FOR STRESS RELIEF HEAT

TREATMENT PROCEDURE
SPECIFICATION.................................................................................................. 20
ANNEX - E
RADIOGRAPHIC TECHNIQUE LOG .................................................................. 21
ANNEX - F
WELDERS IDENTIFICATION CARD.................................................................. 22
ANNEX - G
LIST OF APPROVED ELECTRODE MANUFACTURER .................................... 23
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SECTION 2.2
TECHHNICAL SPECIFICATION WELDING PROCEDURE
1.0.0
This specification shall be followed for the fabrication of all types of welded joints of carbon
steel / mild steel piping system within the battery limits of the plant.
The welded pipe joints shall include the following:a. All pipe joints of the longitudinal and circumferential butt welded and socket welded types.
b. Attachments of forgings, flanges and other supports to pipes.
c.
Welded manifold headers and other sub-assemblies.
d. Welded branch connections with or without reinforcing pads.

e. Joints in welded / fabricated piping components.
f.
The attachments of smaller connections for vents, drain drips and other instrument
tappings.
Any approval granted by the Owners project manager or Owners inspector, shall not relieve
the Bidder of his responsibilities and guarantee.
2.0.0
APPLICABLE CODES AND STANDARDS

All welding works, equipments for welding heat treatment other auxiliary functions and the
welding personnel shall meet the requirements of the latest editions of the following
acceptable standards and procedures unless otherwise specified in the welding specification
chart. In case of conflicting requirements, the requirements mentioned in welding specification
chart/Technical notes shall be applicable.
Since this section covers welding procedure for low pressure piping all IBR related
procedure may be ignored.
ANSI B31.1
Power piping
ANSI B16.9
Wrought steel Butt Welding Fittings
IBR
Indian Boiler Regulations
In addition, the following codes and specifications referred in the relevant code of fabrication
shall be followed for the welding qualifications, consumable qualifications and non-destructive
test procedures.
ASME BPVC Sec.IX
Welding and Brazing Qualifications
ASME BPVC Sec.V
Non destructive examination
ASME Sec.II Part C
Material specifications; welding rods, electrodes and filler metals.
IS: 2825
Code for Unfired Pressure Vessels
MSS-SP-55
Visual inspection and testing
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3.0.0
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MSS-SP-53
Magnetic particle testing
MSS-SP-54
Radiographic testing
BASE METAL
Base metal shall be as detailed in Welding Specification chart.
4.0.0
GENERAL STORAGE OF WELDING CONSUMABLES

The welding electrodes and filler wires supplied shall confirm to the class specified in the
welding specification chart.
Electrode qualification test records have to be submitted in the enclosed format.
Batch test certificates has to be submitted from the electrode manufactures, giving details of
physical and chemical tests carried out has to be submitted by them.
All electrodes shall be purchased in sealed containers and stored properly to prevent
deterioration.
Welding rods shall be stored indoors free from moisture. The package of the welding rods
shall not be opened until immediately buffer use.
Drying of welding rods
Welding rods shall be baked in a heating cabinet in accordance with the manufacturers
recommendation. Welding rods not consumed in a day shall be baked by the same method
with only two rebakings permitted. Portable ovens shall be utilized to maintain a temperature
of 80C at actual site locations.
Handling of welding rods being used
During welding work welding rods shall not be laid down directly on the ground or any other
humid place to ensure that rods are not damaged by moisture.
5.0.0
EQUIPMENT AND ACCESSORIES
5.1.0
All the equipments for performing the heat treatment, including transformers, thermo-couples,
pyro-meters, automatic temperature recorders with suitable calibration certifications shall be
provided duly approved by Owners project manager
5.2.0
The make & type of radiographic equipments, radiographic films, and all the equipment /
materials required for carrying out the dye-penetrant/magnetic particle test shall be subjected
to approval of Owners project manager. All statutory regulations shall be adhered to
(including qualification of personnel) for radiographic equipment & personnel.
6.0.0
WELDING PROCESS
6.1.0
Welding of various materials under this specification shall be carried out at site using one or
more of the following processes with the approval of the Owners project manager.
-
6.2.0
Shielded Metal Arc Welding Process (SMAW)

Gas Tungsten Arc Welding Process (GTAW)
The welding processes to be employed are given in the Welding Specification Chart. Any
deviation desired shall be done through the consent of the Owners project manager.
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6.3.0
Automatic and semi-automatic welding processes shall be employed only with the approval of
the Owners project manager. The welding procedure adopted and consumables used shall
be specifically approved.
6.4.0
A combination of different welding processes could be employed for a particular joint only
after duly qualifying the welding procedure to be adopted and obtaining the approval of
Owners project manager.
7.0.0
EDGE PREPARATION
7.1.0
The edges to be welded shall be prepared to meet the joint design requirements by any of the
following methods recommended. Edge shall conform to B31.1
a)
Carbon Steel
Gas cutting, machining or grinding methods shall be used. After gas cutting, oxides
shall be removed by chipping or grinding.
b)
Low Alloy Steels (containing upto 2% Chromium): (Not applicable for low
pressure piping)
Gas cutting, machining or grinding, methods shall be used. After gas cutting,
machining or grinding shall be carried out on the cut surface.
c)
High alloy steels, cupro-nickel, nickel alloys, and aluminium alloys: (Not applicable
for low pressure piping)
Plasma cutting, machining or grinding methods shall be used. After plasma cutting,
cut surfaces shall be machined or ground smooth.
7.2.0
Cleaning
7.2.1
The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides,
sand, earth and other foreign matter. The ends shall be completely dry before the welding
commences.
7.2.2
On completion of each run, craters, welding irregularities, slag etc., shall be removed by
grinding and chiseling. Wire brushes used for cleaning stainless steel joints shall have
stainless steel wires and the grinding wheels used for grinding stainless steel shall be of a
suitable type. Suitable grinding wheels and wire brushes should be used for carbon steels
and stainless steels.
8.0.0
ALIGNMENT & SPACING
8.1.0
Components to be welded shall be aligned and spaced as per the requirements laid down in
applicable code. Special care must be taken to ensure proper fitting and alignment when the
welding is performed by GTAW process. Flame heating for adjustment and correction of ends
is not permitted unless specifically approved by the Owners project manager.
8.2.0
A wire spacer of suitable diameter may be used to maintain the weld root opening while
tacking, but it must be removed after tack welding and before laying the root bead.
8.3.0
For pipes of wall thickness 5 mm and above, the ends to be welded shall be secured in
position with the aid of couplers, yokes and `C clamps, to maintain perfect alignment. Yokes
shall be detached after the completion of weld, without causing any surface irregularity. Any
irregularity caused on the pipe surface must be suitably repaired to the satisfaction of the
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8.4.0
Tack welds, for maintaining the alignment, of pipe joints shall be made only by qualified
welders. Since the tack welds become part of the final weldment they shall be executed
carefully and shall be free from defects. Defective tack welds must be removed prior to the
actual welding of the joints.
8.5.0
Tacks should be equally spaced. Minimum number of tacks shall be

2 tacks - for 2 and smaller dia pipes
4 tacks - for 3 to 12 dia pipes
6 tacks - for 14 and larger dia pipes.
8.6.0
Owners project manager shall check and approve the fit-up and alignment of pipe joint prior
to the commencement of welding.
8.7.0
Dimensional tolerances generally acceptable are as follows.
8.7.1
Face to Face/Center to Face
3mm (Max)
8.7.2
Lateral translation in any

direction
1.5 mm (Max)
8.7.3
Rotation
1.5 deg Max
8.7.4
Out or alignment measured

across the diameter
1 mm
9.0.0
WELDING TECHNIQUE
9.1.0
Root Pass
a) Root pass shall be made with electrodes/filler wires recommended in the welding
specification chart. For fillet welding shall be done with consumables recommended for
filler passes. The preferable size of the electrodes is 2.5 mm diameter (12 SWG) but in
any case not greater than 3.25 mm (10 SWG).
b) Upward technique shall be adopted for welding pipe held fixed with its axis horizontal.
c) The root pass of butt joints should be executed so as to achieve full penetration with
complete fusion of the root edges. Weld projection inside the pipe shall not exceed 1.6
mm.
d) Any deviation desired from the recommended welding technique and electrodes indicated
in the welding specification chart should be adopted only after obtaining approval of the
e) Welding shall be uninterrupted.
f)
While the welding is in progress care should be taken to avoid any kind of movement of
the components, shocks, vibrations and stresses to prevent occurrence of weld cracks.
g) Penning shall not be used.

9.2.0
Joint completion
a) Joint shall be completed using the class of electrodes, recommended in the Welding
Specification Chart. Size of the electrode shall not exceed 4 mm in diameter for stainless
steels and alloy steels used for low temperature applications.
b) Two weld beads shall not be started at the same point in different layers.
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c) Butt joints shall be completed with a cover layer that would effect good fusion at the joint
edges and a gradual notch free surface.
d) Each weld joint should have a workman like finish.
e) Weld identification work shall be stamped clearly at each joint, just adjacent to the weld.
Metal stamping shall not be used as a standard. Suitable paint shall be used on thin wall
pipes for identification.
f)
No painting shall be done until the weld joint has been approved.
g) All welded joints are subjected to acceptance by Owners project manager.

9.3.0
Dissimilar Welds
Where welds are to be produced between carbon steels and alloy steels, preheat and
postweld Heat Treatment requirements shall be to those specified for corresponding alloy
steels and electrodes shall correspond to AWS E-7016 / 7018 type. For welds between two
dissimilar Cr-Mo low alloy steels, preheat and post weld heat treatment shall be those
specified for higher alloy steel and electrodes used shall correspond to those specified for
steel of lower alloy content. For carbon steel or alloy steel to stainless welds, use of
electrodes E-309/E-310/E NiCr Fe-2 shall be made. The welding procedure, electrodes/filler
wires to be used shall be approved by the Owners project manager.
Following shall be generally adopted to ensure proper welding:
i)
Relation of welding rods matches with parent material.
ii)
Preheating to the required value of the parent material before welding.
iii) Quality & brand of the welding rods approved by Owner.

iv) Overhead welding should be avoided to the extent possible.
10.0.0 WELDING PROCEDURE QUALIFICATION
Welding procedure qualification shall be carried out in accordance with the relevant
requirements of ASME Sec.IX latest edition or other applicable codes and the job
requirements. The welding procedure specifications in format as per enclosed Annex - A
should be submitted.
Owners inspector will review, check and approve the welding procedure submitted and shall
release the procedure for qualification tests. A complete set of test results in format as per
enclosed Annex - B shall be submitted to the Owners inspector for his approval immediately
after completing the procedure qualification test. Standard tests as specified in the code shall
be carried out in all cases. In addition to these tests, other tests like macro/micro examination,
hardness tests, dye penetrant examination, charpy V-notch and U-notch impact tests etc.
shall be carried out on specimens depending upon the type of base material, operating
conditions and requirements laid down in the detailed drawings and specifications.
11.0.0 WELDERS QUALIFICATION
11.1.0 Welders shall be qualified in accordance with the ASME Section - IX or other applicable
codes. The Owners inspector shall witness the test and certify the qualification of each
welder separately. Only those welders who have been approved by the Owners project
manager shall be employed for welding. The welder qualification test reports shall be
submitted in the format enclosed as Annex - C and obtain express approval before
commencement of the work.
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11.2.0 The welders shall always have in their possession the identification card as shown in
enclosed Annex - F and shall produce it on demand by the Owners project manager.
11.3.0 No welder shall be permitted to work without the possession of identity card duly certified by
the inspector.
11.4.0 If a welder is found to perform a type of welding or in a position for which he is not qualified,
he shall be debarred from doing any further work. All welds performed by an unqualified
welder shall be cut and redone by a qualified welder.
12.0.0 WELD HEAT TREATMENT PROCEDURES
12.1.0 Preheating
12.1.1 No welding shall be performed without preheating the joint to 10C (50F) when ambient
temperature is 10C and below.
12.1.2 Preheating requirements for the various materials shall be as per the welding specification
chart attached.
12.1.3 Preheating shall be performed using resistance or induction heating methods. Preheating by
gas burners, utilizing oxy-acetylene or oxy-propane gas mixtures, with neutral flame may also
be carried when permitted by the Owners project manager.
12.1.4 Preheating shall extend uniformly to atleast three times the thickness of the joint, but not less
than 50 mm, on both sides of the weld.
12.1.5 Preheating temperature shall be maintained over the whole length of the joint during welding.
Temperature indicating crayons or other temperature indicating devices shall be provided to
check the temperature.
12.2.0 Postweld Heat Treatment
12.2.1 Post weld Heat Treatment, wherever required for joints between pipes, pipes and fittings, pipe
body and supports shall be carried out as per the welding specification chart, applicable
codes standards and the instructions of the Owners project manager.
12.2.2 The details of the post weld Heat Treatment procedure (as per Annex - D attached), that is
proposed to adopt for each of the materials/assembly/part involved shall be submitted for the
approval of the Owners project manager well before carrying our actual heat treatment.
12.2.3 While carrying out local post weld Heat Treatment, technique of application of heat must
ensure uniform temperature attainment at all points of the portion being heat treated. Care
shall be taken to ensure that width of heated band over which specified post weld Heat
Treatment temperature attained complies with relevant applicable standards/codes.
12.2.4 Throughout the cycle of Heat Treatment, the portion outside the heated band shall be suitably
wrapped under insulation so as to avoid any harmful temperature gradient at the exposed
surface or pipe.
12.2.5 The temperature attained by the portion under heat treatment shall be recorded by means of
thermocouple pyrometers. Adequate number of thermocouples should be attached to the pipe
directly at equally spaced location along the periphery of the pipe joint. The minimum number
of thermocouples attached per joint shall be 1 upto 6 dia, 2 upto 10 dia and 3 for 12 dia and
above. However the Owners project manager can increase the required minimum number of
thermocouples to be attached if found necessary.
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12.2.6 Automatic temperature recorders which have been suitably calibrated should be employed.
The calibration chart of each recorder should be submitted to the Owners project manager
prior to starting the Heat Treatment operations and his approval should be obtained.
12.2.7 Immediately on completion of the Heat Treatment, the post weld Heat Treatment
Charts/records alongwith the hardness test results on the weld joints, wherever required as
per the welding specification chart, shall be submitted to Owners project manager for his
approval.
12.2.8 Each joint shall bear an identification number which shall be maintained in the piping sketch.
The joint identification number should appear on the corresponding post weld heat Treatment
Charts. The chart containing the identification numbers and piping sketch shall be submitted
to the Owners project manager in suitable folders.
13.0.0 INSPECTION AND TESTING
13.1.0 General
13.1.1 Owners/Consultants inspector shall have free access to all places where the work is being
done or any other place concerned with the work.
i.
To check that the execution of welding and welding equipment used on the job are
suitable and conform to relevant standards.
ii.
To supervise welding procedure qualification.
iii. To supervise welder performance qualification.

iv. To check whether welding is conforming to relevant specification and the procedure
followed is in accordance with good pipeline construction practice.
v.
To check any other activity to ensure quality of work.
13.1.2 Inspection dates shall be notified sufficiently in advance with all facilities necessary for
carrying out his work at no extra cost to the Owner.
13.1.3 Approval from the Owners inspector shall not relieve the Bidder partially or fully of his
responsibilities and guarantees under this work order.
13.2.0 Visual Inspection
13.2.1 Inspection of all welds shall be carried out as per ASME - B31.1. Finished welds shall be
visually inspected for parallel and axial misalignment of the work, cracks, incomplete
penetration, under cut on surface, weld reinforcement and lack of fusion, unrepaired burnthrough, dimensions, and other surface defects.
13.2.2 Inspection before welding
a) Dimension and orientation of spool assembly and installed spool and/or piping
components shall be checked with the piping drawings.
b) Width of root space, bevel angle and alignment of components shall also be checked on
each joint fitted up.
c) Surfaces to be welded shall be checked to assure that they are clean and free from
foreign material such as grease, oil, paint, scale, or others for a distance of at least
25 mm from the bevel ends.
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13.2.3 Inspection during Welding

Crack in tack welds, welding slag on inter passes, welding current conditions, and finish after
back chipping shall be checked.
13.2.4 Inspection of Welds
Bead appearance under cut, overlap, spatter, crater, reinforcement of weldment and size of
fillet weld shall be checked.
13.3.0 Radiography
1. Plate fabricated pipes & specials for Rain water shall have 10% radiography.
2. All alloy steel and SS welding shall have 100% Radiography.
3. All other IBR piping (steam) shall be tested as per regulation 360 of IBR or Table-A
whichever is higher (Not applicable for low pressure piping).
4. All fuel lines shall have minimum 50% radiography (Not applicable for low pressure
piping).
5. Gamma ray with Iridium-192 source is acceptable for carrying out radiography.
13.3.1 Radiographic Examination
Radiographic examination shall be performed in accordance with the following requirements.
13.3.2 Random Examination
a) Radiographic testing and acceptance shall be in accordance with MSS-SP-54.
b) Random radiographic examination shall be applied to the entire circumference of a
specified percentage of the girth butt welds as designated in Table A.
c) The welds to be examined shall be selected to ensure that the work product of each
individual welder is included.
d) The extent of radiographic examination shall be as per Table-A.
e) Conducting radiographic test outside the Owners premises should be performed only on
approval of Owners project manager.
13.3.3 Identification of Radiographs
Identification marks shall be marked on every radiograph and radiographs of repaired welds
shall be marked separately.
13.4.0 Liquid Penetrant or Magnetic Particle Examination
a) Socket welds in piping system shall be liquid penetrant or magnetic particle examined in
accordance with Table A.
b) All completed girth butt and socket welds of carbon steel to Austenitic steel shall be
subjected to 100% liquid penetrant examination.
c) Liquid penetrant or magnetic particle examination shall be performed in accordance with
section V ASME code.
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d) All fuel lines shall have for 100% LP/MP tested on welded joints (Not applicable for low
pressure piping).
TABLE - A
REQUIRED NONDESTRUCTIVE EXAMINATION OF WELDS
Material
A 106 Gr. A/B
P
NO.
Press. Temp.
Rating of
Piping (ANSI
B16.5)
Radiographic
Examination
for Girth Butt
Weld (*1,2)
(1)
Up to 900 #
1500# and
above
IS 1239
IS 3589
A312-TP316
(8)
Remarks
10 %
100%
Liquid
penetrant or
Magnetic
Particle Exam,
for Socket
Weld
10%
Up to 600#
Up to 600#
10%
10%
10%
10%
*4
*4
ALL
100%
*3, *4 LP/HP
piping
Note (*)
1) Examination shall be performed for complete circumference of weld.
2) For random examination, the percentage is defined as the ratio of selected welds, to the
produced welds by individual welder in a certain period.
3) Limitations on imperfections in welds shall conform to that of Random Radiography.
4) Refer clause 13.3.0, Point No.1.
TABLE B
PIPING WELDING DETAILS FOR ERECTION NON IBR (low pressure piping)
Sl.
No.
Specn.
A 312 TP
316
IS 3589 /
IS 1239 /
IS 2062
Material Combination
P.No. Gr. Specn.
No
8
1
P1
Any combination
P.No
8
P1
AWS Specification
Gr. Root
Further Run
No. Run
1
ER 316*
ER316* /
E316*
1
E6010* /
E 6013*
ER7016*/
E7018* /
E 6013*
Note : * For detailed welding specification chart refer Annexure H.

WPS shall be qualified (PQR) by the respective quality department of erection groups
(FQA) prior to welding.
13.5.0 Acceptance Standards
The following acceptance standards shall be used unless otherwise specified.
13.5.1 X-Ray Acceptance Standard
No cracks or lack of penetration are permitted.
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Elongated slag or tungsten inclusions with lengths greater than the following are not
permitted:
1/2 in. for T up to 3/4 in.
2/3 T for T from 3/4 in. to 2-1/4 in.
1-1/2 in. for T over 2-1/4 in. where
T is the thickness of the weld.
Groups of slag inclusions in line that have a aggregate length greater than T in length of 6T
are not permitted.
The through thickness of slag inclusions shall not exceed 1/4 of the thickness of the thinner
member being joined.
Porosity in excess of that specified in the following table shall not be permitted.
MAXIMUM PERMISSIBLE POROSITY IN
6 INCH LENGTH OF WELD
Weld Thickness
(inches)
Less than
1/8
1/8
1/4
1/2
3/4
1
2
3
4
Maximum Size
Pore
Total Permissible
Area
t/4
1/32
1/16
1/8
3/16
1/4
1/4
1/4
1/4
8(t/4)
0.088
0.030
0.060
0.090
0.120
0.240
0.360
0.480
13.5.2 Magnetic Particle and Liquid penetrant Acceptance standards

Linear MP and LP indications up to 1/2 T where T is the weld thickness or 1/4 inch in length,
whichever is smaller, and which are not visible cracks, are acceptable.
The cumulative length of linear magnetic particle or liquid penetrant indications shall not
exceed T in any 12T length of weld.
13.5.3 Ultrasonic Acceptance Standards
Indications are unacceptable if the amplitude exceeds the reference level established by the
basic calibration block for ultrasonic examination of welds as stipulated in ASME Boiler and
Pressure Vessel Code, section V, Article 5, and the lengths exceed the following:
1/2 in. for T up to 3/4 in.
2/3T for T from 3/4 in. to 2-1/4 in.
1-1/2 in. for T over 2-1/4 in. where
T is the thickness of weld.
Where indications are interpreted as cracks or lack of penetration, they are unacceptable
regardless of length.
13.5.4 Visual Acceptance Standards
The visual acceptance standards shall be as follows:
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Cracks-None
Linear Indications - None
Undercuts - (Including Burnback) - None for component thickness up to 1/8 in. include. 1/32 in
max. for component thickness over 1/8 in.
Porosity - None
Reinforcement - 1/16 in max. for component thickness up to 3/16 in include. 1/8 in max. for
component of 3/16 in. max. for component thickness over 1/2 in.
Appearance - Welds shall have a workmanship appearance with minimum variations in width
and size of weld, and absence of sharp notches at undercuts and surface ripples. Spatter
and projections from welding and any remaining tack welds shall be removed.
All arc strikes in the base metal are unacceptable. Any blending in the base metal shall not
exceed the undercut allowance.
13.6.0 Repair and removal of visual defects
13.6.1 Defects which are not within the acceptable limits shall be removed from the joint completely
by chipping or grinding.
13.6.2 When the whole joint is found unacceptable, the weld and the ends of the joints shall be
restored.
13.6.3 No repair shall be carried out without prior approval of the Owners project manager
13.6.4 Traces of jigs removed, undercutting, craters and beads shall be ground and weld metal
deposited.
13.6.5 Repairs of weld reinforcement and overlap shall be ground and weld metal deposited.
13.6.6 Repairs of weld reinforcement and overlap shall be ground smooth.
Spatter and slag shall be removed by a hammer or a brush. A crack found visually shall be
removed and examined by a magnetic particle or liquid penetrant test until assured no defect
remains.
14.0.0 SAFETY REQUIREMENTS
Utmost care shall be taken during welding and gas cutting process to avoid fire hazard.
Oxygen & Acetylene gas cylinders shall be stored and maintained properly including its
valves, regulators, etc.
Gas cutting torches shall be lighted by means of friction lighter and not with matches.
The welding sets shall be earthed properly and properly insulated cables shall be used for
welding purposes.
For carrying out welding work in plant area necessary work permit shall be obtained from the
Owners project manager and after ensuring from him that the environment is quite safe for
welding purpose the work shall be commenced.
The wearing of safety by the gas cutters, grinders and welders, such as hand gloves, safety
goggles, welding glass, helmet, etc. should be observed strictly.
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Overhead work
While carrying out the work in elevated positions, care should be taken to ensure that tools
and materials are not left in position from where they can fall on the persons below. No tools,
tackles and materials shall be dropped from any height which may endanger anybody.
While working on elevated position use of safety belt shall be ensured, which has to be
periodically checked for its suitability to provide safety.
Wherever necessary ladder and scaffolding shall be used to carry out work at elevated
positions.
Scaffolding and ladders should be maintained in good conditions.
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ANNEX - A : FORMAT FOR WELDING PROCEDURE SPECIFICATIONS
QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS)

(See QW-200.1, Section IX, ASME Boiler and pressure Vessel Code)
Company Name _________________________________________By: ____________________________________________________

Welding Procedure Specification No.______________________Date __________________Supporting PQR No (s)_________________
Revision No__________________________________________ Date____________________
Welding Process (es)____________________________________________Type(s)___________________________________________
(Automatic, Manual, Machine, or semi-Auto)
JOINTS (QW-402)
Details.
Joint Design ______________________________________________

Backing (Yes) ________________________(No) _________________
Backing material (Type) _____________________________________
(Refer to both backing and retainers.)
Metal
Nonfusing Metal
Nonmetallic
Other
Sketches, Production Drawings, Weld Symbols or Written Description

Should show the general arrangement or the parts to be welded. Where
applicable, the root spacing and the details of weld groove may be
specified
(At the option of the Mfgr., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedures, for multiple process procedures, etc.)
* Base Metals (QW-403)

P.No.
Group No.
to P.No.
OR
Specification type and grade
to Specification type and grade
OR
Chem. Analysis and Mech. Prop
to Chem. Anaysis and Mech. Prop.
Thickness Range:
Base Metal:
Groove
Pipe Dia. Range:
Groove
Other
Group No.
Fillet
Fillet
* FILLER METALS 9QW-404

Spec. No. (SFA)
AWS No. (Class)
F.No.
A.No
Size of Filler Metals
Weld Metal
Thickness Range :
Groove
Fillet
Electrode-Flux (class)
Flux Trade Name
Consumable Insert
Other
* Each base metal.filler metal combination should be recorded individually
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QW-482 (Back)
POSITIONS (QW-405)
Position (s) of Groove
Welding Progression: Up
Position (s) of Fillet
WPS No.
Rev.
POSTWELD HEAT TREATMENT (QW-407)
Temperature Range
Time Range
Down
GAS (QW-408)
PREHEAT (QW-406)
Preheat Temp. Min.
Interpass Temp. Max.
(Continuous or special heating where applicable should be recorded)
Percent Composition
Gas (es)
(Mixture)
Flow Rate
Shielding
Trailing
Backing
ELECTRICAL CHARACTERISTICS (QW-409)

Current AC or DC
Polarity
Amps (Range)
Volts (Range)
(Amps and volts range should be recorded for each electrode size,
position, and thickness, etc. This information may be listed in a
tabular form similar to that shown below.)
Tungsten Electrode Size and Type
(Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW
(Spray arc, short circuiting arc, etc.)
Electrode Wire feed speed range
TECHNIQUE (QW-410)
String or Weave Bead
Orifice or Gas Cup Size
Initial and Interpass Cleaning (Brushing, Grinding, etc.)
Method of Back Gouging
Oscillation
Contact Tube to Work Distance
Multiple or Single Pass (per side)
Multiple or Single Electrodes
Travel Speed (Range)
Peening
Other
Filler Metal
Weld
Layer (s)
Process
Class
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Current
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Polar
Amp.
Range
FICHTNER INDIA
Volt
Range
Travel
Speed
Range
Section 2.2
Other (e.g., Remarks,

Comments, Hot Wire Addition,
Technique, Torch angle, Etc.
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ANNEX - B : FORMAT FOR PROCEDURE QUALIFICATION RECORD

QA-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)
(See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code)
Record Actual Conditions used to Weld Test Coupon.
Company Name
Procedure Qualification Record No

WPS No.
Welding Process (es)
Types (Manual, Automatic, Semi-Auto)
Date
JOINTS (QW-402)
Groove Design of Test Coupon

(For combination qualifications, the deposited weld metal thickness shall be recorded for each filter metal or process used)
BASE METALS 9QW-403)
POSTWELD HEAT TREATMENT (QW-407)
Material Spec
Temperature
Type or Grade
Time
P.No
to P.No.
Other
Thickness of Test Coupon
Diameter of Test Coupon
Other
GAS (QW-408)
Percent Composition
Gas (es)
(Mixture)
Flow Rate
Sheilding
Trailing
FILLER METALS (QW-404)
Backing
SFA specification
AWS Classification
ELECTRICAL CHARACTERISTICS (QW-409)
Filler Metal F.No.
Current
Weld Metal Analysis A.No.
Polarity
Size of Filler Metal
Amps.
Volts
Other
Tungsten Electrode Size
Other
Weld Metal Thickness
POSITION (QW-405)
Position of Groove
Weld progresion (Uphill, Downhill)
other
PREHEAT (QW-406)
Preheat Temp
Interpass Temp
Other
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TECHNIQUE (QW-410)
Travel Speed
String or Weave Bead
Oscillation
Multipass or Single Pass (per side)
Single or Multiple Electrodes
Other
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QW-483 (Back)
Tensile Test (QW-150)
Specimen
No.
Width
Thickness
Ultimate
Total Load
Ib
Area
Ultimate
Unit Load
Psi
Type of
Failure &
Location
Guided-Band Tests (QW-160)

Type and Figure No.
Result
Toughness Tests (QW-170)
Specimen
No.
Notch
Location
Area
Test
Temp
Impact
Values
% Shear
Mils
Break
No Break
Fillet-Weld Test (QW-180)

Result _______ Satisfactory: Yes
Macro ---- Results
No
Penetration into Parent Metal : Yes
No
Other Tests
Type of Test
Deposit analysis
Other
...........................................................................................................................................................................................................................
Welder's Name
Clock No.
Stamp No.
Tests conducted by :
Laboratory Test No.
We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements
of Section IX of the ASME Code.
Manufacturer
Date
By
(Detail of record of tests are illustrative only and may be modified to confirm to the type and number of tests required by the Code.)
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ANNEX - C : FORMAT FOR MANUFACTURERS RECORD OR

WELDING OPERATOR QUALIFICATION TESTS
QW-484 SUGGESTED FORMAT FOR MANUFACTURER'S RECORD OR WELDER OR
WELDING OPERATOR QUALIFICATION TESTS (WPQ)
See QW-301, Section IX, ASME Boiler and Pressure Vessel Code
Welder's name
Clock number
Stamp no.
Welding process(es) used
Type
Identification of WPS followed by welder during welding of test coupon

Base material(s) welded
Thickness
Manual or Semiautomatic Variables for Each process (QW-350)
Actual Values
Range Qualified
Actual Values
Range Qualified
Backing (metal,weld metal, welded from both sides, flux, etc.) (QW-402)
ASME P.No.
to ASME P.no. (QW-403)
( ) Plate ( ) Pipe (enter diameter, if pipe)

Filler metal specification (SFA):
Classification (QW-404)
Filler metal F-no.

Consumable insert for GTAW or PAW
Weld deposit thickness for each welding process
Welding position (1G, %G, etc.) (QW-405)
progression (uphill/downhill)
Backing gas for GTAW, PAW, or GMAW; fuel gas for OFW (QW-408)
GMAW transfer mode (QW-409)
GTAW welding current type/polarity
Machine Welding Variables for the process Used (QW-360)
Direct/remote visual control
Automatic voltage control (GTAW)
Automatic joint tracking
Welding position (1G, 5G, etc.)
Consumable insert
Backing (metal, weld metal, welded from both sides, flux, etc)
Guided Bend Test Results
Guided Bend Test Type
( ) QW-462.2 (Side) Results
( ) QW-462.3 (a) (Trans. R&F) Type
( ) QW-462.3(b) (Long, R&F) Result
Radiographic test results (QW-304 and QW-305)

(For alternative qualification of groove welds by radiography)
Fillet Weld
Fracture test
Macro test fusion
Fillet leg size
Length and percent of defects
in.
in. X
in.
in. Concavity/convexity
Welding test conducted by

Mechanical tests conducted by
Laboratory test no.
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the requirements
of Section IX of the ASME Code.
Organization
Date
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Section 2.2
Page : 19 of 23

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ANNEX D : FORMAT FOR STRESS RELIEF HEAT

TREATMENT PROCEDURE SPECIFICATION.
STRESS RELIEF/HEAT TREATMENT PROCEDURE SPECIFICATION

Name of the project
_________________________
Name of the Heat Treater
Specification
Reference No.
_________
___________________ _________
1 General Details
Other Details
Name of the
Equipment :
_________ _________
Type of Heating :
Elec.Res:/ Induction
(Tick mark)
Name of the
Assembly/Part
_________ _________
Capacity (size)
_________ _________
Assembly/Part
Drawing No.
_________ _________
Maximum Temp.(C)
_________ _________
Material
_________ _________
Method of Temp.
Measurement
_________ _________
Thickness
_________ _________
Atmosphere Control
_________ _________
3 Heat Treatment Cycle Details

Charging Temp C
____________________________________________________________
Rate of heating C/Hr
____________________________________________________________
Soaking Temperature C ____________________________________________________________

Soaking time, Hrs
____________________________________________________________
Rate of Cooling /Hr
____________________________________________________________
Mode of Cooling
____________________________________________________________
4 Other details, if any
____________________________________________________________
____________________________________________________________
____________________________________________________________
5 Hardness test
______________________________C.S
A.S
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Section 2.2
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ANNEX E : RADIOGRAPHIC TECHNIQUE LOG
RADIOGRAPHIC TECHNIQUE LOG

1
Location
Date of Testing
Name of the Contractor and welder
Material : Carbon steel/Alloy Steel/Stainless

Steel
Diameter & Thickness
Type of Weld Joint
Radiation Source
Source strength
Screen
10
Screen thickness
11
Focus film distance
12
Limit of Film coverage
13
Film type and make
14
Exposure Time
15
Processing
16
Density
17
Sensitivity
18
Penetrameter thickness (Source

Side)
17
Penetrameter thickness
(Film slide)
18
Shim thickness
:
Signature of Contractor
with seal
Approval of Inspector
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ANNEX - F : WELDERS IDENTIFICATION CARD
WELDER'S IDENTIFICATION CARD

Photograph
1
Name
Identification
Date of Testing
Valid until
Process
Material
Thickness
Diameter
F.No.
10
Approval of welding
11
Position
Employee's Signature
with seal
Approved by :
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ANNEX - G: LIST OF APPROVED ELECTRODE MANUFACTURER
LIST OF APPROVED ELECTRODES AND MANUFACTURERS
Accepted manufacturers of 6010, 7018 and 6013 electrodes are given below:Root - run - Philips (ESAB) 31 CS E6010
7016 / 7018
- Supercito - Advani Oerlikon
- Philips 36 H - ESAB
- Supertherm - D & H
- Tenacito - Advani
- Ferro Weld 2 - ESAB
- Modi 7018 - MODI
6013
- Overcord S, Oerlikon
- Vordian
Esab/IOL
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SECTION 2.3
TECHNICAL SPECIFICATION ERECTION OF BURIED PIPING
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Vol 2 sec 2.3 DTS_E&C_Buried piping Rev.0.doc
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Section 2.3
Page : 1 of 9
Technical Specification Erection of Buried Piping

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TABLE OF CONTENTS
1.0.0
INTENT OF SPECIFICATION ............................................................................................. 3
2.0.0
CODES & STANDARDS..................................................................................................... 3
3.0.0
EXCAVATION FOR PIPE TRENCHES .............................................................................. 3
4.0.0
COATING AND WRAPPING OF PIPES ............................................................................. 4
5.0.0
LAYING OF UNDERGROUND PIPING .............................................................................. 7
6.0.0
DRAINING........................................................................................................................... 8
7.0.0
RECORDS .......................................................................................................................... 9
8.0.0
BACKFILLING ..................................................................................................................... 9
9.0.0
CLEAN UP OF SURROUNDINGS ..................................................................................... 9
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SECTION 2.3
ERECTION OF BURIED PIPING
1.0.0
bidder for the erection of complete underground piping of low pressure piping which includes
excavation, laying, backfilling and application of protective coating on external surface of
buried pipe.
2.0.0
CODES & STANDARDS

Piping design, reinforcement of branch
connection, materials, and fabrication
AWWA C200 and AWWA M11
Flanges: rating, facing, and drilling for 24 inches

(609 mm) and smaller
ANSI B16.5, Class 150 or AWWA C207

Class B, D, or E as indicated in the
specification
Flanges: rating, facing, and drilling for larger

than 24 inches (609 mm)
AWWA C207, Class B, D or E as

indicated in the specification
Pipe specification
Field applied external coatings for underground
piping
AWWA C200 / IS 3589 / IS 1239

AWWA C203 / IS 10221
Repair of damaged field applied coatings for

underground piping
AWWA C209, Section 3.4
Dimensional checks
AWWA C200, C208 and other applicable

AWWA standards
Steel structure painting council, (SP-I solvent

cleaning and SP-10 near white blast cleaning).
SPC-SPI & SP 10
Recommended Practice, High Voltage Electrical

Inspection of pipeline coating prior to
Installation.
NACE RP-02-74
3.0.0
EXCAVATION FOR PIPE TRENCHES
3.1.0
The trench shall be cut true to the line leveled with the help of sight rails provided at every
30 M, at change of direction, gradient and at any suitable distance as directed by the owners
project manager.
3.2.0
If the trench is excavated below the required level indicated in the drawing, the extra depth
shall be filled with concrete or approved equivalent material as directed by the owners project
manager at no extra cost to Owner.
3.3.0
The trench shall be excavated so as to provide an average cover of 1000 mm or equal to the
diameter of the largest pipe to be laid in the trench unless otherwise shown in drawings. The
minimum average cover will be reckoned from top of the pipe of the largest diameter to be
laid in the trench, to the finished grade. The width of the trench, shall be sufficient to give free
working space on each side of the pipe. The free working space shall conform to IS:783.
Generally it shall not be less than 150 mm on either side or 1/3 of dia of pipe whichever is
greater.
3.4.0
No excavated material shall be deposited within 1.5 meters from the excavated trench.
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3.5.0
In case of road cutting, all material ie. metal, bricks, etc. shall be taken out carefully and kept
separately for reuse and road work shall be redone upto the original level prior to cutting the
road with the excavated road materials after laying & testing of the pipeline within 10 days
from the date of starting the work at the cost of the Bidder. The Bidder shall provide suitable
signs and barricades to prevent accidents. He shall also provide reasonable by pass at his
own cost when a road is cut for laying pipeline. The dykes etc. affected due to laying of the
pipes, shall be redone conforming to the original specifications by the Bidder at his own cost.
3.6.0
During excavation if some obstacle is met with, same shall be reported to the owners project
manager and dealt with as instructed by him.
3.7.0
The Bidder shall dewater, shore or do whatever might be required to excavate the trench,
install the pipe in it and backfill the trench, in accordance with the specifications at no extra
cost to the Owner. Dewatering shall be done in advance of the laying of the pipe to allow
adequate inspection of padding of the bottom if required and dewatering shall be continued
throughout during laying of the pipe and backfilling of the trench.
3.8.0
In muddy/slushy ground, the bed shall be provided with a layer of a sand or lean concrete as
directed by the owners project manager.
3.9.0
The trench shall follow the gradient of pipeline as specified in the drawing. The Bidder shall
keep the trench in good condition, until the pipe is laid and tested. No extra claim shall be
entertained due to its caving or setting down either before or after the pipe is laid. All
materials to shore the trench in order to prevent caving are to be furnished and removed by
the Bidder at no extra cost to the Owner.
3.10.0 In case pipe is lowered in caved trench and back-filled before being inspected by the owners
project manager, the Bidder shall re-excavate the trench for inspection and backfill it at his
own cost.
4.0.0
COATING AND WRAPPING OF PIPES
4.1.0
General
4.1.1
The coating and wrapping of pipes shall be from a polymeric corrosion protective tape. It
incorporates a centre core of 20 microns HMHDPE film. On either side of this centre core is
polymeric mix, shall be manufactured with high softening point, penetration and high
resistance to ageing. The polymeric mix shall be on coal tar, rubber and other polymers. The
membrane shall be terminated on both exteriors by thermofusible HMHDPE film. All the 5
layers are calandered together to create 2 mm thick membrane. The sequence of coating and
wrapping of pipes shall consist of following operations.
i)
Surface Preparation
ii)
Application of First Layer of Pypkote Primer
iii) Application Layer of Pypkote Membrane, 2 mm thick

iv) Application of Second Layer of Primer
v) Application of Second Layer of Pypkote Membrane
vi) Tape Coating of Field Joints
4.1.2
All materials used shall conform to the quality and testing requirement ASTM standards and/or
as directed by owners project manager.
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Section 2.3
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Specification
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&
4.1.3
All appurtenances and equipment to be used for cleaning, priming, coating and wrapping and
testing shall be approved by the owners project manager.
4.2.0
Materials
Supply and providing Anti-corrosive coating and wrapping of two layers of 2 mm thick tape shall
have the following specification.
a. Wire Brush to be remove all foreign debris
3
b. Apply a coat of fibre, coal tar and solvent based primer of density 0.92 gms/cm and
viscosity of 1000-2000 cps. @ 150 gms/sqm (Pypkote primer).
c.
4.3.0
Tape should have a centre core of 20 microns HMHDPE film and 2 layers of polymeric
coal tar mix and terminated on either side by themrofusible HMHDPE film. Tape must be
wound spirally in 2 layer using thermofusion process. Each layer of tape consisting of the
above will be minimum of 2 mm thick. The first layer of 2 mm this tape must be
completely adhered to the first layer. Application should be with recommended over laps
and in accordance with manufacturer's specification.
Procedure for Coating and Wrapping

a) Surface Preparation
All oil and grease on the pipe metal surface shall be thoroughly removed by flushing with a
suitable solvent (such as xylene or 1,2,2 trichlorethane) and wiped with clean rags. The
solvent cleaning shall be as per SSPC-SP-1. The degreased pipe metal surface shall be
wire brushed / power brushed. Preferably priming shall be done within four hours of
completion of wire brushing.
After being cleaned the pipe shall be protected from and be maintained fee of oil, grease
and dirt that might fall on the pipe before it has received its final coat.
b) Application of First Layer of Pypkote Primer
Pypkote primer is to be applied on pipes immediately after cleaning. This to prevent any
further accumulation of rust on the pipe. Pypkote primer is a cold applied primer and is
applied by brush @ minimum 150 gms/sqm. After application, it is allowed to dry until the
surface becomes tacky. This primer is applied so as to produce effective bond between
metal and subsequent coating of pipe coating membrane.
After application the primer coat shall be uniform and free from floods, runs, sags, drips, or
bare spots. Any bare spots shall be recoated with an additional application of primer. All
runs, sags, or drips shall be removed by scraping and cleaning, and the cleaned area shall
be retouched or remedied by reblasting and repriming. Suitable measures shall be taken to
protect the wet primer from contact with rain, fog, mist, spray, dust or other foreign matter
until completely hardened and enamel applied.
The minimum and maximum drying times of the primer or the period of between application
of primer and application of Pypkote membrane shall be in accordance with instructions
issued by the manufacturer.
The cleaning and priming operation may be carried out in the Bidder's workshop or on site.
The entire pipe length shall be cleaned but the ends of the pipes shall be left without coating
and wrapping for a distance of 100 mm for joints, which shall be coated and wrapped
manually on site after laying, welding and testing the pipes.
c) Application Layer of Pypkote Membrane, 2mm Thick
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Section 2.3
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Specification
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&
After the surface is primed, Pypkote membrane is applied over the pipe in spiral fashion by
thermofusion process. A LPG torch or other heat source is applied onto the lower face of
the membrane till the polymeric mix attains a shiny appearance. The membrane is then
adhered to the primer coated surface. Overlaps are maintained as per specifications with a
minimum of 15 mm. The overlaps are doubly sealed by thermofusion on the exterior for
additional security.
d) Application of Second Layer of Primer
The second layer of Pypkote primer is applied over the first layer of Pypkote tape by
brushing or spraying @ minimum 150 gms/sqm. The primer is allowed to dry for 15 minutes
before commencement of application of second layer of Pypkote tape.
e) Application of Second Layer of Pypkote Membrane
Second layer of Pypkote membrane is wound over the wet second layer of primer. This is a
cold process, which does not involve thermofusing. Care is taken that the overlap of the
second layer does not coincide with the overlap of the first layer. Once again overlaps are
maintained at minimum 15 mm. However, overlaps are double sealed by thermofusion as
for the first layer.
f)
Tape Coating of Field Joints

Incase of site coated pipes the welded joints shall be coated. Primer shall be applied with
brushes after cleaning the pipe thoroughly.
The primer and tape coating materials shall be the same as used for yard coating the pipe.
The welded field joints shall be cleaned and dried in accordance with section-3. Primer shall
be applied on the clean joints in accordance with section. Primer shall be applied on
adjacent tape coating also. Over the primed surface tapes shall be applied in accordance
with sections c,d,e. Tapes shall overlap the coating on each side of the field joint to form a
continuous external coating free of defects. Overlaps on each side of the weld joints shall
be 50 mm.
No wrinkling in the wrapper shall be allowed. If coating and wrapping is found and
satisfactory to the Owners project manager the same area shall be recoated and wrapped
with above procedures.
4.4.0
Extent of Application
All buried piping of water and utility service shall be applied with above type of coating &
wrapping method.
Whenever buried pipe extents above the ground the coating of tape shall be applied as a
minimum length of 500 mm above ground level.
4.5.0
Inspection
4.5.1
General
Bidder shall test the coating and any repair subsequently made to it. The testing shall be
carried out prior to laying of pipes in the trench.
4.5.2
Holiday Detection
i)
All coated and wrapped pipes shall be subjected to a test with an electric holiday detector
as specified in AWWA-C-203-91.
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Section 2.3
Page : 6 of 9

ii)
Tender
Specification
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&
The holiday detector shall be supplied, correctly operated and always maintained in good
working condition along with adequate supply of spare parts. Any delay caused by the
incorrect functioning of the holiday detector will not be entertained.
iii) The operating voltage of the detector shall be determined by NACE RP-02-74.
iv) Any pipe having three (3) or more holidays shall be rejected. Similarly any pipe having any
one holiday bigger than 0.1 square metre shall be rejected. Any defective places shall be
plainly marked with chalk immediately after they are detected visually or by the holiday
detector.
v) For pipe with pre-fabricated tape, the test voltage which the pipe should pass with holiday
detector kit at voltage 15 kV for 4 mm thickness coating.
4.5.3
Measuring coating thickness

i)
All pipes shall be tested for thickness as per AWWA-C-203-91.
ii)
The thickness shall be measured by pushing the point of an approved pit depth gauge or
microtester through the coating and wrappers.
iii) The specified minimum thickness shall be present both at the pipe or any other point.
Testing and adhesion of the coating
i)
Atleast two tests a day shall be carried out on finished coating after 12 hours from
completion of coating. The test shall be carried out as per AWWA-C-203-91 Sec.7.8 / IS
10221 Section B-3.3.1 / 3.3.3 / 3.3.3.
ii)
The areas where the coating has been removed for testing by the inspector shall be
repaired by the BIDDER at his own expense.
5.0.0
LAYING OF UNDERGROUND PIPING
5.1.0
General
After prefabrication, coating and wrapping and trenching the Bidder shall lay the underground
piping in accordance with the following clauses and as per the approved piping arrangement
drawings. The Bidder shall be responsible for correct layout and gradient of the line. Errors, if
any, shall be rectified by the Bidder at his own cost.
5.2.0
Lowering & Laying

The pipes shall be lowered either by mechanical methods or by hand when the trench is
ready and bottom of the trench is graded as per required pipe laying conditions and
specifications.
5.2.1
By machine
The shop coated pipe, already transported to the pipe laying site/convenient length of pipe
assembly coated and wrapped near the trench after hydrostatic testing shall be placed on
clean square cut skids suitably spaced so as to keep the pipe away from touching the ground.
The pipe may be lowered down in the trench by the launcher cranes, with sufficient care to
protect the coating and wrapping of the pipeline. Bare cables, chains hooks etc. shall not be
permitted to come in contact with the coating.
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Section 2.3
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Specification
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&
At tie in welds and other places, the Bidder shall clean, prime, coat and wrap manually. Also
short sections of pipelines which are impracticable to shop treat may be hand treated but only
on the prior written approval of the Owners project manager.
5.2.2
By Hand
The pipe may be lowered with the help of tripods and chain pulleys blocks into the trench
immediately after the coating and wrapping. However if in the opinion of the Owners project
manager that the temperature condition do not allow direct lowering, then the pipe shall be set
down on clean square cut skids. The skids shall be so spaced as to keep the pipe away from
touching the ground.
5.3.0
Method & Time of lowering pipe
5.3.1
Under favorable temperature, conditions and using methods which will not damage coating
the pipe may be lowered into the trench.
5.2.2
Pipe previously set on skids, because of unfavorable temperature conditions shall be lowered
into the trench normally in the cool of the morning and only when the temperature of the pipe
is below the softening point of the coating materials.
5.3.3
All skid marks and other places of damages shall be thoroughly examined to ensure proper
patching where necessary, before the pipe is finally lowered into the trench.
5.4.0
Handling of Coated Pipes
5.4.1
Coated pipes shall not be placed in trench until cave in plugs, hard clods, stones, skids,
welding rods etc. have been removed there from. Where the trench has a hard or jagged
bottom sufficient fine dirt or sand shall be placed therein, before the pipe is lowered.
5.4.2
Coated pipe shall not be handled or moved by means of cable or chains or by prying with
skids or bars. It shall be tied and lowered by using lowering in belts of a standard width and
designs for the size of pipe being handled.
5.4.3
Coated pipe shall not be dragged along the ground or otherwise handled in a manner that will
be detrimental to the coating.
5.5.0
Lining up & Welding
5.5.1
The ends of the pipe line shall be kept securely closed to prevent entry of any foreign
material/ moisture after lowering into the trench.
5.5.2
Before making joints the pipe shall be carefully laid so as to be perfectly aligned in both plan
and profile and the end closures provided shall be removed.
5.5.3
Tie-in shall be made in the coolness of the morning or when the ambient temperature is not
exceeding 29C or softening temperature of the coating material whichever is less. All
beveling, aligning and welding shall be in accordance with the welding specifications.
5.5.4
Free access shall be provided for the welding of the circumferential joints by increasing the
width and depth of the trench at these points. There should be no obstruction to the welder
from any side so that a good welded joint is obtained.
6.0.0
DRAINING
6.1.0
All lines and equipment shall be completely drained after the hydrostatic test of a system has
been completed. High point vents shall be open to prevent excessive vacuum and permit
complete draining.
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Section 2.3
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Specification
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Erection
&
6.2.0
If it becomes necessary to leave a system filled with the testing medium from any abnormal
length of time, suitable arrangement such as venting shall be made to provide for possible
liquid expansion with change in ambient temperature.
7.0.0
RECORDS
7.1.0
Records in triplicate shall be made by the Bidder for each piping system as
follows:
7.1.1
In case of underground piping, layouts giving actual elevations of pipeline as laid.
7.1.2
Test certificates containing date of test, identification of the piping system, date of flushing &
approval by Owner's Inspector.
8.0.0
BACKFILLING
8.1.0
After testing and inspection of the pipeline to the entire satisfaction of the Owners project
manager, the trench shall be backfilled with the same material as the pipe bed above the top
of the pipe. No trench shall be backfilled without the approval of Owners project manager.
8.2.0
Backfilling with the excavated material shall be done in layers of 200 mm, well watered and
rammed to avoid any settling afterwards.
8.3.0
The Bidder shall place soil over the trench to such a height as to provide adequately for future
settlement of the trench backfill.
If due to exigencies of the work, some portion of the pipeline is backfilled without approval of
the Owners project manager, the Owners project manager shall have the right to order
uncovering of the pipe for examination and the cost of such uncovering shall be borne by the
Bidder.
8.4.0
The backfill material shall be free from stone pieces.
8.5.0
Surplus excavated soil or rubbish material shall be removed by the Bidder at his own cost to a
place designated by the Owners project manager.
8.6.0
When the trench has been dug through roads all backfill shall be thoroughly compacted. In
certain cases, special compaction methods may be required by the Owners project manager.
This shall be done by the Bidder at no extra cost to the Owner.
8.7.0
When the trench has been dug through unlined ditches the backfill shall be thoroughly
compacted in 150 mm layers for a distance of 1.50 m beyond the outside banks of the ditch
on either side. The banks of the ditch shall also be compacted in 150 mm layers at no extra
cost to the Owner.
8.8.0
After the roads have been already graded, if they are trenched or otherwise disturbed by the
Bidder during laying of the pipelines. The Bidder shall restore the road to its original level and
condition. In the event, the Bidder is required to place extra fill, gravel, or other special
material it shall be borne by him without any extra cost to the Owner.
9.0.0
CLEAN UP OF SURROUNDINGS
As soon as the backfill is completed, the Bidder shall immediately clean up the adjoining area
by removing all surplus and defective material and dispose of all refuse such as spurs, sheet
iron, broken skids etc. to the complete satisfaction of the owners project manager.
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Section 2.3
Page : 9 of 9

Tender
Specification
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Erection
&
SECTION 2.4
TECHNICAL SPECIFICATION HYDRO TEST PROCEUDRE
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Section 2.4
Page : 1 of 5
Technical Specification Hydro Test Procedure

Tender
Specification
for
Erection
&
TABLE OF CONTENTS
1.0.0
GENERAL .............................................................................................................................. 3
2.0.0
CODES AND STANDARDS................................................................................................... 3
3.0.0
LINE CHECKS BEFORE PRESSURE TEST ........................................................................ 3
4.0.0
TESTING................................................................................................................................ 4
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Section 2.4
Page : 2 of 5

Tender
Specification
for
Erection
&
SECTION 2.4
TECHNICAL SPECIFICATION HYDRO TEST PROCEUDRE
1.0.0
GENERAL
This specification covers the general requirements related to the Hydrotesting of low pressure
piping system.
2.0.0
CODES AND STANDARDS
2.1.0
The Hydrotest of piping, valves and specialties comply with the requirements of latest edition
the following standards.
2.1.1
ANSI B31.1
3.0.0
LINE CHECKS BEFORE PRESSURE TEST
3.1.0
General
Power piping
After completion of the fabrication and installation works and prior to pressure test, line
checks shall be carried out for all works to ensure that the works have been performed
properly and that the quality of work is adequate.
3.2.0
Check Points
This shall include the following confirmation of overall and individual workmanship, but not be
limited to these items :
a)
Lines and components

i)
Piping layout is in accordance with the applicable drawings including P&I

diagrams.
ii)
Size, dimension, rating and material specification are in accordance with the
applicable drawings.
iii)
Bend, tee, reducer and other fittings are in accordance with the applicable
drawings.
iv)
Drain, vent, thermal expansion, header and other components are in accordance
with applicable drawings.
v)
Valve, flange, blind, etc. are in accordance with applicable drawings and flange
connection is properly made with correct use of bolts and gaskets.
vi)
Orientation and direction of piping components are in compliance with piping

drawings.
vii)
Tightness and projection of flange bolts are adequate.
viii)
Thread connections are not damaged and free from weld spatter, slag etc.
ix)
All shipping and erection stoppers, welding jigs and temporary support
attachments are removed.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

FICHTNER INDIA
Section 2.4
Page : 3 of 5

b)
and
other
Tender
Specification
for
Erection
&
x)
Welding quality
specifications.
workmanship
complies
with
the
applicable
xi)
Applicable examination or inspection and the heat treatment (if applicable) has
been satisfactorily completed and accepted.
xii)
Piping (including all components and attachments) is sufficiently cleaned.
xiii)
Slope is maintained as indicated in relevant drawings.
Pipe Supports
i)
All pipe supports such as anchors, guided restraints, bands, hangers, etc. are to
permit free expansion and contraction of piping in the specified direction and are
assembled as indicated on support drawings.
ii)
Spring supports are to be properly set in cold position with setting pins.
iii)
Enough and adequate temporary supports are to be provided wherever

necessary to keep the piping stable.
iv)
Supports, guides and anchors for piping shall be fabricated and provided as
shown in the drawings. No anchors on piping shall be used except at locations
shown in the drawings. The pipe shall be secured firmly at anchor supports.
v)
Fabrication and erection of supporting elements and structural fixtures wherever

required and pointed out by the owners project manager, whether indicated in
drawing or not to prevent vibrations, excess sag etc. shall be carried out by the
Bidder.
vi)
Spring hangers shall be erected with springs locked in cold set position. The tie
rods shall be selected that the pipe center line with slope can be maintained in
cold position. The springs shall be released after hydrotesting and before passing
steam. When the hanger are released they shall be checked for cold set values
and if there is any disturbance, the series of hangers nearby shall be adjusted
using the turn buckle to activate the cold set load in all hangers.
4.0.0
TESTING
4.1.0
General
4.1.1
All pipes shall be tested for leakage to a hydrostatic test pressure of 1.5 times the design
pressure.
4.1.2
The testing shall be carried out in convenient sections as approved by Owners project
manager.
4.1.3
If some defect is noticed during the hydrostatic testing, the same shall be brought to the
notice of Owners project manager. Joints, if leaking shall be rectified as per welding
specifications and instructions of Owners project manager at no extra cost. If leakage is on
the threaded joints, necessary inert chemical bonding material shall be applied to arrest the
leak.
4.1.4
The Owners project manager shall be notified in advance by Bidder of all testing. The
hydrostatic testing / flushing of all piping shall be carried out by the Bidder at his own cost.
4.1.5
Bidder shall make his own arrangements for flushing at suitable points as per the instructions
of the Owners project manager. Any extra work / modification on this account shall be done
by the Bidder at his own cost.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

FICHTNER INDIA
Section 2.4
Page : 4 of 5

Tender
Specification
for
Erection
&
4.2.0
Test Medium
4.2.1
Soft water shall generally be used as the testing medium for the hydrostatic testing of piping
system.
4.2.2
In situation where water cannot be used air is used as a testing medium. Air testing shall be
carried as per ASME B31.1.
4.3.0
Cleaning
4.3.1
All systems shall be cleaned and flushed free of all dirt, debris and loose foreign material after
testing
4.3.2
Flushing and Pressure Test

a) The piping system shall be sufficiently flushed with the pressure test medium in the
presence of Owners project manager.
b) Care shall be taken during flushing that no foreign material can enter into equipment
which is connected to the test section.
c) After flushing and testing, water shall be drawn off by opening all drain valves and vents.
The piping system shall be dried internally to the satisfaction of the Owners project
manager.
4.4.0
Temporary Blinds
4.4.1
Open ends of piping systems such as at pumps or wherever equipment has been removed or
disconnected prior to hydrostatic testing or at termination point of piping branch connections
shall be blinded off by temporary blind flange made our of M.S. plate of suitable thickness.
4.5.0
Venting
4.5.1
All piping system and equipment shall be properly vented to remove air from the system
during filling.
4.6.0
Pressurizing
4.6.1
Pressure shall be applied by means of a suitable test pump which shall not be connected to
the system until it is ready to test. A pressure gauge shall be provided at the pump discharge
for guidance in bringing the system upto pressure. The pump shall be attended to constantly
during the test by authorized operator. The pump shall be disconnected immediately after the
test pressure is reached.
The test pressure is to be maintained for sufficient time to permit complete inspection of the
system under test. Test shall be considered complete only when approval is given by Owners
project manager.
4.7.0
Test Gauges
4.7.1
Bidders own gauge shall be installed as close as possible to the lowest point in the system
being tested. Calibration of test gauges shall be the responsibility of the Bidder.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

FICHTNER INDIA
Section 2.4
Page : 5 of 5

Tender
Specification
for
Erection
&
SECTION 2.5
TECHNICAL SPECIFICATION PIPING FLUSHING AND CLEANING PROCEDURE
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Vol 2 sec 2.5 DTS_E&C_Flushing Rev.0.doc
FICHTNER INDIA
Section 2.5
Page : 1 of 5
Technical Specification Piping Flushing &

Cleaning Procedure

Tender
Specification
for
Erection
&
TABLE OF CONTENTS
1.0.0
INTENT OF SPECIFICATIONS ............................................................................................. 3
2.0.0
CODES AND STANDARDS .................................................................................................. 3
3.0.0
INSPECTION ......................................................................................................................... 3
4.0.0
CLEANING METHODS.......................................................................................................... 3
5.0.0
FLUSHING ............................................................................................................................. 5
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FICHTNER INDIA
Section 2.5
Page : 2 of 5

Cleaning Procedure

Tender
Specification
for
Erection
&
SECTION 2.5
TECHNICAL SPECIFICATION PIPING FLUSHING AND CLEANING PROCEDURE
1.0.0
INTENT OF SPECIFICATIONS
This specification covers the general requirements for inspection, cleaning & flushing of
piping, valves and specialties for low pressure piping system.
2.0.0
CODES AND STANDARDS

The following codes and standards shall be followed for the work covered by this contract in
addition to the detailed specifications of the contract.
Swedish standard Institution - SIS-05 5900-1967 (Surface preparation standards for

painting steel surfaces).
Steel structures painting council, U.S.A. (Surface Preparation Specifications
(SSPC-SP).
British Standards Institution (Surface Finish of Blast cleaned steel for painting) BS-4232.
National Association of Corrosion Engineers, U.S.A. (NACE).
IS: 1477-1971 (Part - I) - code of practice for painting of Ferrous metals in buildings (Part
1, pre-treatment).
Various international standards equivalent to Swedish standard for surface preparation
are given in Table-1.
ASME B31.1 power piping
The Bidder shall arrange, at his own cost, to keep a set of latest edition of the above
standards and codes at site.
3.0.0
INSPECTION
During various stages and after completion of fabrication and erection, the piping system shall
be inspected by the Owners project manager to ensure that: Proper piping material has been used.
Piping has been erected as per drawings and instructions of Owners project manager.
All supports have been installed correctly.
Test preparations mentioned in this specification have been carried out.
4.0.0
CLEANING METHODS
4.1.0
General
The Piping components shall be mechanically and /or chemically cleaned during the following
stages of the Contract.
Cleaning in workshop
Cleaning before painting and/or corrosion protection (application of prime coat)
Cleaning before erection and after installation.
Cleaning of fabricated component items shall be carried out after fabrication and final heat
treatment or welding at manufacturer's works or at site, as appropriate.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

FICHTNER INDIA
Section 2.5
Page : 3 of 5

Cleaning Procedure

Tender
Specification
for
Erection
&
For cleaning in workshop and before painting mechanical cleaning as opposed to alternative
chemical cleaning is the preferred method for works cleaning except where this is precluded
by design or access considerations.
Machined surfaces shall be protected during the cleaning operations.
In the event of the surfaces not being cleaned to the owner's satisfaction, such parts of the
cleaning procedures or agreed alternatives as are deemed necessary to overcome the
deficiencies shall be carried out at the bidder sole expense.
For recleaning small areas, hand cleaning by wire brushing by puffing method may be
permitted. Wire brushes of austenitic steel bristles shall only be used.
Austenitic stainless steels, copper and aluminium alloys, cast iron, bimetallic and
metallic/plastic items, and components fabricated by spot welding or riveting shall not be
chemically cleaned. All weld areas shall be suitably stress relieved before chemical cleaning.
Any cleaning work on piping shall be commenced only when erection activities are completed
in all aspects and after the system tests have been completed and clearance for taking up
painting work is given by the owners project manager, who may, however, at his discretion
authorize in writing, the taking up of surface preparation or painting work in any specific
location, even prior to completion of system test.
All tools, brushes, rollers, spray guns, blast material, tarpaulin sheets for covering the
areas to be sandblasted ,hand power tools for cleaning and all equipment shall be
arranged by the Bidder at the site in sufficient quantity at his own cost.
4.2.0
Mechanical Cleaning
Mechanical cleaning shall preferably be carried out by abrasive blasting. The Owner is
prepared to consider alternative methods provided they achieve the necessary surface
condition.
4.3.0
Surface condition
The Metal surfaces shall be clean and free of mill scale, rust, dirt, grease and any other
deleterious matter.
Where metal surfaces are to be painted the surface profiles shall conform with the painting
specification requirements.
Where this does not apply surfaces shall have a surface texture not coarser than Grade 80
abrasive paper.
4.4.0
Abrasives
Abrasives containing silica, silicates or slag residues shall not be used for water/steam side
surfaces of plant except for cleaning sand castings, where hydro blasting with sand may be
used.
For austenitic materials only, abrasives containing 98% or more of aluminia, Al2 O3, shall be
used.
4.5.0
Removal of abrasive and debris

After cleaning, abrasive and debris shall be thoroughly removed from components.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

FICHTNER INDIA
Section 2.5
Page : 4 of 5

Cleaning Procedure

5.0.0
Tender
Specification
for
Erection
&
FLUSHING
Flushing of all lines shall be done before pressure testing.
Flushing shall be done by fresh potable water or dry compressed air, wherever water flushing
is not desirable, to clean the pipe of all dirt, debris or loose foreign material.
Required pressure for water flushing shall meet the fire hydrant pressure or utility water
pressure for air flushing the line / system will be pressurized by compressed air at the
required pressure which shall be 50 psi maximum. The pressure shall then be released by
quick opening of a valve, already in line or installed temporarily for this purpose. This
procedure shall be repeated as many times as required till inside of the pipe is fully cleaned.
In line instruments like control valves, orifice plates, rotometers, safety valves and other
instruments like thermo wells which may interfere with flushing instrument shall not be
included in flushing circuit.
From oil permanent strainers the screens / meshes shall be removed before flushing. Screen
/ meshes shall be reinstalled after flushing but before testing.
During flushing temporary strainers shall be retained. These shall be removed, cleaned and
reinstalled after flushing but before testing.
In case on equipment such as pumps forms part of a piping circuit during flushing, this shall
be done with the approval of Owners project manager. However equipments thus included in
the circuit, shall be completely drained and dried with compressed air, after flushing is
completed.
During flushing discharge of water / air shall be drained to the place directed by the Owners
project manager. If necessary, proper temporary drainage shall be provided by the bidder.
Care shall be taken during flushing so as not to damage / spoil work of other agencies.
Precautions shall also be taken to prevent entry of water / foreign matter into equipments,
electric motors, instruments electrical installations etc. in the vicinity of lines being flushed.
The bidder shall carry out all the activities required before, during and after the flushing
operation, arising because of flushing requirements, such as but not limited to the following:
Dropping of valves, specialities, distance pieces, inline instruments and any other piping part
before flushing. The flanges to be disengaged for this purpose shall be envisaged by the
bidder and approved by the Owners project manager. These flanges shall be provided with
temporary gaskets at the time of flushing.
After flushing is completed and approved the valve distance pieces, piping specialities etc.
shall be reinstalled by the bidder with permanent gaskets. However, flanges at equipment
nozzles and other places where isolation is required during testing only temporary gaskets
shall be provided.
Records in triplicate shall be prepared and submitted by the bidder for each piping system for
the flushing done in standard format. Bidder shall submit procedure for flushing and cleaning
in detail based on the above for owners project manager approval.
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FICHTNER INDIA
Section 2.5
Page : 5 of 5

Cleaning Procedure

Tender
Specification
for
Erection
&
SECTION 2.6
TECHNICAL SPECIFICATION PAINTING
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Vol 2 sec 2.6 DTS_E&C_Paint Rev.0.doc
0
FICHTNER INDIA
Section 2.6
Technical Specification Painting
Page : 1 of 16

Tender
Specification
for
Erection
&
TABLE OF CONTENTS
1.0.0
INTRODUCTION ..........................................................................3
2.0.0
CODES AND STANDARDS .........................................................3
3.0.0
GENERAL REQUIREMENTS ......................................................5
4.0.0
SURFACE PREPARATION..........................................................6
5.0.0
MECHANICAL CLEANING...........................................................7
6.0.0
ALTERNATIVE CHEMICAL CLEANING ......................................8
7.0.0
PROTECTION ..............................................................................8
8.0.0
WEATHER CONDITIONS............................................................8
9.0.0
STORAGE ....................................................................................9
10.0.0
PREPARATION OF COATING MATERIALS ...............................9
11.0.0
APPLICATION ..............................................................................9
12.0.0
DRY FILM THICKNESS (DFT).....................................................9
13.0.0
PROTECTIVE COATINGS AND PAINT SYSTEMS ....................9
14.0.0
COLOUR CODE FOR PIPING ...................................................10
15.0.0
IDENTIFICATION OF VESSELS, PIPING ETC. ........................10
16.0.0
INSPECTION AND TESTING ....................................................11
17.0.0
PRIMER APPLICATION .............................................................11
18.0.0
GUARANTEE .............................................................................11
19.0.0
GALVANIZING............................................................................12
20.0.0
SAFETY OF WORK ...................................................................13
ANNEX 2.6.1 COLOUR CODING FOR IDENTIFICATION OF PIPELINES ............14

ANNEX 2.6.2 PAINTING SYSTEM ..........................................................................15
ANNEX 2.6.3 SCHEDULE OF PRIMER & FINISH COATS.....................................16
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

0
FICHTNER INDIA
Section 2.6
Page : 2 of 16

Tender
Specification
for
Erection
&
SECTION 2.6
TECHNICAL SPECIFICATION - PAINTING
1.0.0
INTRODUCTION
This document provides the requirements for surface preparation and painting of piping
system and components
2.0.0
CODES AND STANDARDS

The following codes and standards shall be followed for the surface preparation, surface
protection and painting works.
IS: 5
: Colors for ready mixed paints and enamels.
IS: 101
: Methods of test for ready mixed paints and enamels.
IS: 104
: Ready mixed paint, brushing, Zinc Chrome, priming.
IS: 158
: Ready mixed paint, brushing, bituminous, black, lead free, acid,

alkali, water and heat resisting.
IS: 161
: Heat resistant paints
IS: 1303
: Glossary of terms relating to paints.
IS: 1477
: Code of practice for painting of ferrous metals in buildings

(Parts I & II).
IS: 2074
: Specifications for ready mixed paint, Air drying, red oxide zinc
chrome priming.
IS: 2338
: Code of practice for finishing of wood and wood based materials:

Parts 2 schedules.
IS: 2339
: Aluminium paint for general purposes, in dual container.
IS: 2395
: Code of practice for painting of concrete, masonry and plaster

surfaces: Part 2 schedules.
IS: 2524
: Code of practice for painting of non-ferrous metals in buildings

(Parts I & II).
IS: 2932
: Specification for enamel, synthetic, exterior (a) undercoating, (b)

Finishing
IS: 3140
: Code of practice for painting asbestos cement building products.
IS: 6158
: Recommended practice for design safeguarding

Embrittlement of hot dip Galvanized Iron & steel products.
IS: 6159
: Recommended practice for design & fabrication of Iron &steel

products prior to Galvanizing & metal spraying.
IS: 6278
: Code of practice for white washing and Color - Washing.
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0
FICHTNER INDIA
Section 2.6
against
Page : 3 of 16

Tender
Specification
for
Erection
&
IS: 10221
: Code of practice for coating & wrapping of underground mild steel

pipelines.
IS: 33
: Inorganic pigments and extenders for paints Methods of sampling

& test.
IS: 13183
: Aluminum paint, Heat resistant - specifications.
IS: 144
: Specification for ready mixed paint brushing, petrol resisting, Air

drying for Interior paints of tanks and containers, Red oxide.
IS: 9954
: Pictorial surface preparation standards for painting of steel

surfaces.
IS: 11883
: Specification for Ready Mixed Paint, Air Drying, Red Oxide Priming
for metals.
IS: 9404
: Color code for identification of pipelines used in the Thermal Power

Plants.
IS: 12744
: Specification for Ready Mixed Paint, Air Drying, Red Oxide-Zinc

Phosphate Priming.
BS: 2015
: Glossary of paint selected terms.
BS: 5252
: Final coat color.
BS: 5493
: Protective coating of iron & steel structures against corrosion.
BS: 7079A1/S1
: Specification for rust grades and preparation grades of uncoated

substrates after overall removal of previous coating.
BS: 7079A2
: Preparations grades of previously coated steel substrates.
BS: 7079GrC
: Surface roughness characteristics of blast cleaned steel substrates.
BS: 7079GrD
: Methods for surface preparation.
BS-4232
: Surface Finish of Blast cleaned steel for painting.
ASTM
: American Standard for Testing Material.
ASTM A 780
: Standard practice for repair of damaged galvanized coatings.
AWWA
: American Water Works Association.
ASA-A-13.1-1981
: Scheme for identification of piping system (American National

Standard Institution).
DIN
: Deutsehes Institute for Normung
S1S-055900-1967
: Surface preparation standards

(Swedish standard Institution)
SSPC-SP
: Preparation Specifications (Steel structures painting council,

U.S.A.).
for
painting
steel
surfaces.
National Association of Corrosion engineers, U.S.A. (NACE).

Doc. No. 1113112-ME-SPC-700-004, Rev. 0
0
FICHTNER INDIA
Section 2.6
Page : 4 of 16

Tender
Specification
for
Erection
&
Various international standards equivalent to Swedish standard for surface preparation are
given in Table-1.
Table-1 (Surface Preparation Standards)
Surface
preparation
method
Blasting acc.to
Sec. 8.item (a)
Blasting acc. to
Sec.8.item (b)
Blasting acc. to
Sec.8.item (c)
SIS 055900
DIN 55928,
Part 4
BS 4232
(only for
blasting)
First quality
SSPC-Vis
Sa 3
Sa 2
Sa 2
Second near
quality
Third quality
Hand/or
power
tool derusting acc
to Sec.8.item (g)
St 2
Hand tool Cleaning

SP 2
Acc.
to
Sec.8.items (e)
Flame
jet
cleaning
Pickling
St 3
F1
Be
Power tool
Cleaning SP 3
Flame cleaning
SP 4
Pickling
White metal SP 5
White SP 10
Commercial
SP 6
blast
The Bidder shall arrange, at his own cost, to keep a set of latest edition of the above
standards and codes at site.
3.0.0
GENERAL REQUIREMENTS
All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning and all
equipment, scaffolding materials, shot/sand blasting equipment & air compressors etc. shall
be arranged by the bidder at the site in sufficient quantity along with suitable paint thickness
measuring instruments such as Elko meters acceptable to the owners project manager (with
calibration facilities). Mechanical mixing shall be used for paint mixing operations in case of
two pack systems except that the owners project manager may allow the hand mixing of
small quantities at his discretion.
The paint manufacturer's instruction shall be followed as far as practicable at all times.
Particular attention shall be paid to the following:
a)
b)
c)
d)
e)
Proper storage to avoid exposure as well as extremes of temperature.

Surface preparation prior to painting.
Mixing and thinning.
Application of paints and the recommended limit on time intervals between coats.
Shelf life for storage.
Any painting work (including surface preparation) on piping or equipment shall be commenced
only after the system tests have been completed and clearance for taking up painting work is
given by the Owners project manager, who may, however, at his discretion authorize in
writing, the taking up of surface preparation or painting work in any specific location, even
prior to completion of system test.
In the event of the surfaces not being cleaned to the owner's satisfaction, such parts of the
cleaning procedures or agreed alternatives as are deemed necessary to overcome the
deficiencies shall be carried out at the Bidder's sole expense.
For reclining small areas, hand cleaning by wire brushing (with austenitic steel bristles) is
permitted.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0
0
FICHTNER INDIA
Section 2.6
Page : 5 of 16

Tender
Specification
for
Erection
&
Austenitic stainless steels, copper and aluminium alloys, cast iron, bimetallic and
metallic/plastic items, and components fabricated by spot welding or riveting shall not be
chemically cleaned.
All weld areas shall be suitably stress relieved before chemical cleaning.
4.0.0
SURFACE PREPARATION
In preparing any surface to be coated, all loose paint, dirt, grease, rust, scale, weld slag or
spatter or any other extraneous material shall be removed and defects repaired, so as to
obtain a clean, dry, even surface to receive the priming or finishing coat (s) as called for in the
painting schedules. Sharp edges shall be rounded, especially when tank linings have to be
applied. All machined surfaces, including flange faces, shall be suitably covered to prevent
damage during surface preparation. All surfaces shall be blast cleaned whenever possible.
Bare steel surfaces shall be prepared by one of the methods described below in order of
preference and in accordance with Swedish Standard SIS 05 59 00 or Steel Structures
Painting Council, SSPC, Vis , or DIN 55928, Section 4.
(a) White metal blast cleaning: Sa 3 or SSPC - SP 5
Sa 3 blast cleaning to bare metal. Mill scale rust and foreign matter must be removed
completely. Subsequently, the surface shall be cleaned with vacuum cleaner, clean dry
compressed air or a clean brush. It must then have a uniform metallic colour and
correspond in appearance to the prints designated Sa 3.
(b) Near white metal blast cleaning:
Sa 2 or SSPC - SP 10
Sa 2. very thorough blast cleaning. Mill scale, rust and foreign matter shall be removed
to the extent that the only traces remaining are slight imperfections in the form of spots or
strips. Subsequently, the surface shall be cleaned with a vacuum cleaner, clean dry
compressed air or a clean brush. It must then correspond in appearance to the prints
designated Sa 2.
Mechanical cleaning shall only be used when procedures (a) and (b) are not practicable.
c) Commercial Blast Cleaning: Sa 2 or SSPC - SP 6
Sa 2 Blast cleaning until atleast two-thirds of each element of surface area is free of all
visible residues. This method of Blasting shall be suitable for steel required to be painted
with conventional paints for exposure to mildly corrosive atmosphere for longer life of the
paint systems.
d) Near white metal blast cleaning:
P Sa 2
Very thorough blast cleaning. Very adhesive coatings remain. From all other surface mill
scale and rust are to be removed to such an extent that the only traces remaining are
slight imperfections in the form of spots or stripes. Further treatment refer to (b) above.
The adhesivity of residual coatings in the transition zone shall be tested even after the
application of the primer.
e) Very thorough mechanical scraping and wire brushing: St 3
St 3 very thorough scraping and wire-brushing - machine brushing - grinding - etc. shall be
preferred. Surface preparation as for St 2 but much more thoroughly. After the removal of
dust, the surface must have a pronounced metallic sheen and correspond to the prints
designated St. 3.
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FICHTNER INDIA
Section 2.6
Page : 6 of 16

f)
Tender
Specification
for
Erection
&
Acid Pickling
Prior to galvanizing the surface preparation shall be done by acid picking as per SSPCSP-08
g) Thorough scraping and wire brushing:
St 2
St 2 thorough scraping and wire-brushing - machine brushing - grinding - etc. The

treatment shall remove loose mill scale, rust and foreign matter. Subsequently, the
surface is cleaned with a vacuum cleaner, clean dry compressed air or a clean brush. It
shall then have a faint metallic sheen. The appearance must correspond to the prints
designated St 2.
Steel structures to be blast cleaned have to be free of pitting and other severely corroded
places in accordance with B.S. 4232 and SIS 055900.
The abrasives used for blast-cleaning shall be graded flint, grit, shot or silica sand and shall be
such that they will produce an average keying profile on the blast-cleaned surface of not more
than 40 microns. An air pressure of 7 bar (g) at the nozzle shall be used.
After blast-cleaning, all accumulated grit, sand, dust, etc., must be removed leaving the
surface clean, dry and free of mill scale, rust grease and other foreign matter.
In the event of rusting after completion of the surface preparation, the surface must be
cleaned again in the manner specified. Oil, grease, soil, cement, salts, acids or other corrosive
chemicals shall be cleaned from steel surfaces, by the use of solvents, emulsions or cleaning
compounds.
The final wiping shall be with clean solvent and clean rags or brushes. There shall be no
detrimental residue left on the surface. Primed areas, which suffer damage must be spot
blasted on site to a degree of cleanliness P Sa 2 before touching up.
Protective coating must be applied as quickly as possible after the completion of surface
preparation no matter what cleaning method has been used. No blast-cleaned surface shall
be allowed to remain uncoated overnight.
Steel work protected by shop primer after arrival on site must be cleaned of salt, sand, oil etc.
before the first coat of paint is applied on site. Shop primer damaged during transport must be
rectified by blast-cleaning and coating before application of the site coats.
Wood surfaces shall be sanded clean. All nail holes shall be puttied and sanded before
priming.
Concrete: If a protective coating is required, concrete shall be allowed to cure before painting.
5.0.0
MECHANICAL CLEANING
Mechanical cleaning shall be carried out by abrasive blasting or alternative methods to
Owner's approval, provided they achieve the necessary surface condition.
Surface condition:
The Metal surfaces shall be clean and free of mill scale, rust, dirt, grease and any other
deleterious matter.
Where metal surfaces are to be painted, the surface profiles shall conform to the painting
specification requirements.
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FICHTNER INDIA
Section 2.6
Page : 7 of 16

Tender
Specification
for
Erection
&
Where this does not apply surfaces shall have a surface texture not coarser than Grade 80
abrasive paper.
Abrasives:
Abrasives containing silica, silicates or slag residues shall not be used for water/steam side
surfaces of plant except for cleaning sand castings, where hydro blasting with sand may be
used.
For austenitic materials only, abrasives containing 98% or more of alumina, Al2 O3, shall be
used. After cleaning, abrasive and debris shall be thoroughly removed from components.
Removal of abrasive and debris:
Cleaning of fabricated items shall be carried out after fabrication and final heat treatment or
welding at manufacturer's works or at site, as appropriate.
For cleaning in workshop and before painting, mechanical cleaning as opposed to alternative
chemical cleaning is the preferred method for works cleaning except where this is precluded
by design or access considerations. Machined surfaces shall be protected during the cleaning
operations.
6.0.0
ALTERNATIVE CHEMICAL CLEANING

The procedure shall comprise of pre-treatment and acid treatment to achieve cleanliness
equivalent to that specified for mechanical cleaning to Owner's approval.
7.0.0
PROTECTION
As soon as all items have been cleaned and within four hours of the subsequent drying, they
shall be given suitable anti-corrosion protection.
All water, air and steam side surfaces shall be protected by the application of approved water
soluble corrosion inhibitors, or vapor phase inhibitors that shall be subsequently removed by
site water washing or steam blowing.
The rate of application of volatile corrosion inhibitors shall be at least 10 grams per square
meter or 35 grams per cubic meter, whichever is the greater, except for pipes up to 300 mm
diameter for which the minimum application rates shall be 5 grams per square meter.
Immediately after the protective treatment has been applied all vessels and pipes shall be
suitably sealed off by discs or caps or approved alternatives to prevent ingress from the
surrounds. Cylindrical plugs shall not be driven into the ends of pipes. These protective covers
shall not be removed until immediately before final connection is made to the associated
equipment.
8.0.0
WEATHER CONDITIONS
Painting shall be done only when the surface temperature is at least 3C above dew point to
ensure that condensation does not occur on the surface.
Reasonable protection against precipitation, corrosive fumes and vapors shall be exercised
for the painting of outdoor parts.
Precautions shall also be taken against solar radiation to ensure that the specified dry film
thickness of priming or finish coats is obtained.
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Any prime coat exposed to excess humidity, rain, dust etc., before drying, shall be permitted to
dry and the damaged area of primer shall be removed and the surface prepared and primed
again.
Sheltered or unventilated horizontal surfaces on which dew may collect, require more
protection, and to achieve this, an additional top coat of paint shall be applied.
9.0.0
STORAGE
All paints and painting material shall be stored only in rooms to Owners project manager's
approval. All necessary precautions shall be taken to prevent fire. The storage building shall
preferably be separated from adjacent buildings. A signboard bearing the words "PAINT
STORAGE - NO NAKED LIGHT - HIGHLY INFLAMMABLE - DANGER - NO SMOKING" shall
be clearly displayed outside. All paints shall be stored in the safest manner so that no
container rolls down and causes accidents. The shelf life of the paints shall be ensured so that
the paint materials are not in storage and use after the date of expiry.
10.0.0 PREPARATION OF COATING MATERIALS

All containers shall remain un-opened until required for use. Primers and paints, which have
livered, gelled or otherwise deteriorated shall not be used. The oldest primer or paint of each
kind shall be used first. All ingredients in any container shall be thoroughly mixed before use
and shall be agitated frequently during application to keep the primer in suspension. Primer or
paint mixed in the original container shall not be transferred until all settled pigment is
incorporated into the body of the liquid. Mixing in open containers shall be done in a well
ventilated area. Primer or paint shall be mixed in a manner ensuring the breakdown of all
lumps, complete dispersion of pigment and uniform composition. Two-component primers
shall be mixed in accordance with the manufacturer's instructions. Thinners shall not be
added to primers or paints unless necessary for proper application according to the
manufacturer's instructions. When use of thinners is permitted, it must be added to the primer
or paint during mixing.
11.0.0 APPLICATION
The supplier shall check all painting work to be carried out according to the specification of the
paint supplier further to all relevant prescriptions and regulations concerning the health and
safety of work. The paint supplier shall present a written specification including at least the
flash point of the paints, ventilation requirements, handling precautions such as inhalation, eye
and skin protection, and first aid procedure, storage requirements, spill or leak procedure, fire
precaution, waste disposal.
12.0.0 DRY FILM THICKNESS (DFT)
The paint coats shall be applied as a continuous film of uniform thickness and free of pores.
Overspray, skips, runs, sags and drips shall be avoided. The different coats shall not be of the
same colour. Each coat of paint shall be allowed to harden before the next is applied. For
epoxy paint, the hardening time normally is 12-14 hours. Supplier's recommendations
regarding hardening time of epoxy paints must be followed. Particular attention must be paid
to full film thickness at edges. The minimum total dry film thickness of the paint systems shall
be as recommended in Annex-2. The dft is given in microns (millionths of a metre).
13.0.0 PROTECTIVE COATINGS AND PAINT SYSTEMS
The type and number of protective coats for any item requiring painting shall generally be in
accordance in the attached tables "Paint Systems" (Annex-2).
All prime coatings shall be applied by brush or airless spray or a combination of these
methods, as approved by the coating manufacturer.
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Spray guns shall not be used outside in windy weather or near surfaces of a contrasting color
unless the latter is properly protected. All cold-spray painting shall be done using standard
equipment in accordance with accepted standards and methods.
Care shall be taken not to connect spraying devices for nitro and backelite paints
simultaneously to oil based paints. Paint applied to items that are not being painted shall be
removed at the supplier's expense, leaving the surface clean, unstained and undamaged.
Generally, all parts shall receive the specified prime coat (s) at the supplier's works to ensure
that no corrosion occurs during transport to the site and storage at the site. Parts which cannot
be damaged during transport shall receive the full number of coats.
14.0.0 COLOUR CODE FOR PIPING
a) The colour code scheme is intended for identification of the individual group of the pipeline.
The system of colour coding consists of a ground colour and colour bands superimposed
on it. The colour coding for the identification of pipelines shall comply with Annex 2.6.1
of this specification.
Ground Colour shall be applied throughout the entire length for uninsulated pipes. For
insulated pipes, on the metal cladding or on the pipes of material such as non-ferrous
metals, austenitic stainless steel etc., ground colour coating of minimum 2m length or of
adequate length not to be mistaken as colour band shall be applied at places requiring
colour bands. Colour band(s) shall be applied at the following location.
i.
At battery limit points
ii.
Intersection points & change of direction points in piping ways.
iii. Other points, such as midway of each piping way, near valves, junction joints of
service appliances, walls, on either side of pipe culverts.
iv. For long stretch/yard piping at 50 M interval.
v.
At start and terminating points.
b) Flow direction shall be indicated by an arrow in the location stated above and as directed
by Owners project manager. Colors of arrows shall be black or white and in contrast to
the color on which they are superimposed. The size of the arrows shall confirm to IS:2379.
Product names shall be marked at pump inlet, outlet and battery limit in a suitable size as
approved by Owners project manager. As a rule minimum width of color band shall
conform to 75 mm up to 300 NB and to 100 mm over 350 NB. Whenever it is required by
the Owners project manager to indicate that a pipeline carries a hazardous material, a
hazard marking of diagonal stripes of red and golden yellow as per IS:2379 shall be
painted on the ground color.
c) All uninsulated piping systems, hangers and supports shall have two coats of red oxide
Zinc Chromate primer (conforming to IS 2074) with minimum dry film thickness (DFT) of
25 microns per coat and two coats of finish paints using enamel paint to give a minimum
total DFT of 100 microns (after two coats of primer and two coats of finish paint). Shades
shall be as per IS 5 or as indicated by Owner /Owners project manager. Service of the
pipe/line designations shall be painted on all pipes at visible locations.
15.0.0 IDENTIFICATION OF VESSELS, PIPING ETC.
Equipment number shall be stenciled in black or white on each vessel, column, equipment
and machinery after painting.
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Line number in black or white shall be stenciled on all the pipelines of more than one location
as directed by Owners project manager, size of letters printed shall be 150 mm (high) for
column & vessels; 50 mm (high) for pump compressor and other machinery and shall be as
per IS:9404 for piping. The storage tanks shall be marked as detailed in the respective
drawing.
16.0.0 INSPECTION AND TESTING
a) All painting materials including primers and thinners brought to site for application shall be
procured directly from manufacturer as per specifications and shall be accompanied by
manufacturer's test certificates. Paint formulations without certificates are not acceptable.
Owners project manager at his discretion, may call for tests for paint formulations. Bidder
shall arrange to have such tests performed including batch wise test of wet paints for
physical & chemical analysis. All costs thereof shall be borne by the bidder. The paints
shall be tested as per IS: 101 / equivalent international standard and approved by the
Owner.
b) The painting work shall be subject to inspection by Owners project manager at all times.
In particular, following stage wise inspection shall be performed and bidder shall offer the
work for inspection and approval of every stage before proceeding with the next stage.
The record of inspection shall be maintained in the registers. Stages of inspection shall be
surface preparation, primer application and each coat of paint. In addition to above, record
shall include type of shop primer already applied on equipment e.g. red oxide zinc
chromate or zinc chromate or red lead primer etc.
c) Any defect noticed during the various stages of inspection shall be rectified by the bidder
to the entire satisfaction of Owners project manager before proceeding further.
Irrespective of the inspection, repair and approval at intermediate stages of work, bidder
shall be responsible for making good any defects found during final inspection/guarantee
period/defect liability period as defined in general condition of contract. Dry film thickness
(DFT) shall be checked and recorded after application of each coat and extra coat of paint
shall be applied to make-up the DFT specified without any extra coat to Owner.
17.0.0 PRIMER APPLICATION
a) After surface preparation, the primer shall be worked by brush application to cover the
crevices, corners, sharp edges etc. in the presence of inspector. The shades of
successive coats shall be slightly different in color in order to ensure application of
individual coats, the thickness of each coat and complete coverage shall be checked as
per specification approved by Owners project manager before application of successive
coats. The bidder shall provide standard thickness measurement instrument with
appropriate range(s) for measuring. Elko meter for measuring the Dry film thickness of
each coat, surface profile gauge for checking of surface profile in case of sand blasting.
Holiday detectors and pinhole detectors for checking the painted surface discontinuities
shall be provided by the bidder.
b) The bidder shall make arrangements for paint manufacturer to provide expert technical
service at site as and when required free of cost and without any obligation to the Owner,
as it would be in the interest of the manufacturer to ensure that both surface preparation
and application are carried out as per their recommendations. Final inspection shall
include measurement of paint dry film thickness, check of finish and workmanship. The
thickness shall be measured at as many points/locations as decided by the Owners
project manager and shall be within + 10% of the dry film thickness
18.0.0 GUARANTEE
The bidder shall guarantee that the chemical and physical properties of paint materials used
are in accordance with the specifications contained herein/to be provided during execution of
work. The bidder shall produce test reports from the manufacturer regarding the quality of the
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particular batch of paint supplied. The Owners project manager shall have the right to test wet
samples of paint at random for quality of the same. Batch test reports of the manufacturer's
for each batch of paints supplied shall be made available by the bidder.
19.0.0 GALVANIZING
a) Galvanizing works shall conform to IS.6158 performed by the hot dip process. It is
essential that details of steel members and assemblies, which are to be hot-dip
galvanized shall be designed in accordance with IS 6159. Vent-holes and drain-holes shall
be provided to avoid high internal pressures and air-locks during immersion, which may
cause explosions and to ensure that molten zinc is not retained in pockets during
withdrawal. Careful cleaning of welds is necessary before welded assemblies are dipped.
The welds and the surrounding metal shall be cleaned separately, preferably by blastcleaning, because the usual preliminary pickling cannot be relied on to remove the
welding slag.
b) All defects of the steel surface including cracks, surface laminations, laps and folds shall
be removed in accordance with relevant IS standards. All drilling, cutting, welding, forming
and final fabrication of unit members and assemblies shall be completed before the
structures are galvanized. The surface of the steelwork to be galvanized shall be free from
paint, oil, grease and similar contaminants. The weight of zinc coating per unit area shall
be noted in the manufacturing documents. Structural steel items shall be initially grit
blasted to BS:4232 second quality (Sa 2) or by pickling in a both and the minimum
average coating weight on steel sections 5 mm thick and over shall be 900 g/m.
c) On removal from the galvanizing bath, the resultant coating shall be smooth, continuous,
free from gross surface imperfections such as bare spots, lumps, blisters and inclusions
of flux, ash or dross. Galvanized contact surfaces to be joined by high-tensile friction-grip
bolts shall be roughened before assembly so that the required slip factor is achieved.
Care shall be taken to ensure that the roughening is confined to the area of the mating
faces.
d) Bolts, nuts and washers, including general grade high-tensile friction grip bolts shall be hot
dip galvanized and subsequently centrifuged. Nuts shall be tapped up to 0.4 mm oversize
after galvanizing and the threads oiled to permit the nuts to be finger-turned on the bolt for
the full depth of the nut. No lubricant, applied to the projecting threads of galvanized hightensile friction-grip bolt after the bolt has been inserted through the steelwork must be
allowed to come into contact with the mating faces of the steelwork. A local remelting of
the galvanized parts to achieve the nuts to be finger turned on the bolt shall be done as
per the relevant standards. Protected slings must be used for offloading and erection.
Galvanized work, which is to be stored at the works or on site shall be stacked so as to
provide adequate ventilation to all surfaces to avoid wet storage staining (white rust).
e) Small areas of the galvanized coating damaged in any way shall be restored in
accordance with relevant standards.
i)
Cleaning the area of any weld slag rust and other impurities and by thorough wire
brushing to give a metallic clean surface.
ii)
Application of suitable number of coats of zinc-rich paint containing more than 90%
w/w of zinc in dried film. The dry film thickness shall exceed at least 50% the
thickness of the desired galvanization. In case of application of a low melting point
zinc alloy repair rod, the rods shall be in accordance with IS:6158, the thickness of the
alloy shall be at least as of the desired galvanization.
iii) The restored area is not to exceed 1% of the galvanized surface.

iv) Surface restoration of parts in contact with drinking water is not allowed and the
quality of the galvanization shall be in accordance with relevant IS standards.
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v) After fixing, bolt heads, washers and nuts shall receive two coats of zinc-rich paint.
Connections between galvanized surfaces and copper, copper alloy or aluminum
surfaces shall be protected by suitable preferably hydrophone tape wrappings to the
Owner's approval.
20.0.0 SAFETY OF WORK
All precautions connected with this type of application of corrosion protection shall be in
accordance with relevant IS standards. Sprayed, unfused coating of metals and metallic
compounds applied by combustion gas flame, plasma arc, detonation and similar processes
and the preparation of components, spraying techniques, sealing, finishing and inspection
shall be according to relevant IS standards. The hot galvanized surface shall be cleaned
before the application of the coats to remove corrosion products, dirt, dust and grease. The
cleaning shall be achieved by brush off, washing with 1 to 1.5% ammonia water with up to
0.1% detergent added and followed by wet grinding using e.g. scotch britt to turn the foam to
grey color and steam blasting.
Protection of the blast cleaner operator's eyes and respiratory system shall be given prime
consideration in any open blast cleaning operation. Airfed helmets, respiratory filters, air
conditioned hoods etc. shall be provided in sufficient number to the blast cleaning operators to
avoid the harmful effect of blast cleaning abrasives. Also, an automatic shut-off device which
will shut-off the air supply to the blasting machine shall be installed which will prevent the
dangerous whipping of an operating blast hose if an operator becomes disabled.
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ANNEX 2.6.1
COLOUR CODING FOR IDENTIFICATION OF PIPELINES
Sl.No
1
Remarks
as per IS:5
a)
Untreated or raw /
Service
Sea green
217
White
b)
Treated/dematerialized
Sea green
217
Light orange
557
c)
Potable water
Sea green
217
French blue
166
d)
RO water
Sea green
217
Light orange
557
e)
Service & clarified water Sea green
217
French blue
166
White is not
included in
IS - 5-2007
Air system
a)
Instrument
Sky Blue
101
White
b)
Service water
Sky Blue
101
White
Effluent pipes
Black
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as per IS:5
Band Shade
Color
Color No.
Water system
Medium
Ground Shade
Color
Color No.
FICHTNER INDIA
Section 2.6
White not
included in
IS-5 - 2007
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&
ANNEX 2.6.2
PAINTING SYSTEM
SL.
NO
SURFACE/LOCATION
1 Steel pipes inside surface

such as cooling water lines
TEMP. c
SURFACE
PREPARATION
up to
60C
Sa 2
PAINT SYSTEM
APPLICATION
MICRONS
COAT NO. OF GENERIC
IN
ON
DFT
COATS
TYPE
SHOP SITE
Finish
4
F7
125
x
125
125
125
500
Total min.
dft
2 Water pipelines - outside
surface, indoor
up to
60C
Sa 3
Prime
Finish
P2
F3

0
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Section 2.6
50
50
30
30
30
190
Total min.
dft
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x
x

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ANNEX 2.6.3
SCHEDULE OF PRIMER & FINISH COATS
PRIMERS:
P-1
REDOXIDE ZINC CHROMATE PRIMER
P-2
HIGH BUILD CHLORINATED RUBBER ZINC PHOSPHATE PRIMER
P-3
HIGH BUILD ZINC PHOSPHATE PRIMER
P-4
ETCH PRIMER/WASH PRIMER
P-5
EPOXY ZINC CHROMATE PRIMER
P-6
EPOXY ZINC PHOSPHATE PRIMER
P-7
EPOXY HIGH BUILD MIO PAINT
P-8
EPOXY RED OXIDE ZINC PHOSPHATE PRIMER
P-9
EPOXY BASED TIE COAT
P-10
HIGH BUILD CHLORINATED RUBBER PAINT
P-11
EPOXY ZINC RICH PRIMER
P-12
DOUBLE BOILED LINESEED OIL
FINISH COATS
F-1
SYNTHETIC ENAMEL
F-2
ACRYLIC POLYURETHANE PAINT
F-3
CHLORINATED RUBBER PAINT
F-4
HIGH BUILD CHLORINATED RUBBER MIO PAINT
F-5
CHEMICAL RESISTANT PHENOLIC BASED ENAMEL
F-6
EPOXY HIGH BUILD COATING
F-7
HIGH BUILD COAL TAR EPOXY
F-8
SELF PRIMING EPOXY HIGH BUILD COATING
F-9
INORGANIC ZINC SILICATE COATING
F-10
HIGH BUILD BLACK
F-11
HEAT RESISTANT ALUMINIUM PAINT SUITABLE UPTO 250C
F-12
HEAT RESISTANT SILICONE PAINT SUITABLE UPTO 400C
F-13
SYNTHETIC RUBBER BASED ALUMINIUM PAINT SUITABLE UPTO 150C
F-14
EPOXY PAINTING
F-15
POWDER COATING
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SECTION 2.7
TECHNICAL SPECIFICATION FOR
ERECTION OF PUMPS
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Vol 2 sec 2.7 DTS_E&C_Pump Rev.0.doc
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Section 2.7
Page : 1 of 11
Technical Specification Erection of Pumps

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Specification
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Erection
&
TABLE OF CONTENTS
1.0.0
INTENT OF SPECIFICATION ..............................................................................3
2.0.0
SCOPE OF WORK ...............................................................................................3
3.0.0
DRAWINGS, SPECIFICATIONS & CODES.........................................................4
4.0.0
EXCLUSIONS.......................................................................................................4
5.0.0
PUMP TYPE, LOCATION AND SUPPLY .............................................................4
6.0.0
REMOVAL OF PACKING .....................................................................................5
7.0.0
PREPARATION FOR ERECTION........................................................................5
8.0.0
ERECTION ...........................................................................................................6
9.0.0
ALIGNMENT & TOLERANCES ............................................................................7
10.0.0
GROUTING ..........................................................................................................7
11.0.0
SUPERVISION DURING ERECTION ..................................................................8
12.0.0
FLUSHING & CLEANING .....................................................................................8
13.0.0
TESTING ..............................................................................................................9
14.0.0
PRE-COMMISSIONING TESTS & OTHER TESTS.............................................9
15.0.0
TEST RUNS .......................................................................................................10
16.0.0
FINAL INSPECTION AND STARTUP ................................................................10
17.0.0
LOADING THE UNIT & TRIAL RUN ..................................................................10
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SECTION - 2.7
TECHNICAL SPECIFICATION FOR
ERECTION OF PUMPS
1.0.0
1.1.0
Bidder for the erection of following pumps.
Pump service
1.
2.
3.
4.
5.
Capacity
Vertical turbine pumps for Storm water pit-1 ( 3 Nos.)

Vertical turbine pumps for Storm water pit-2 ( 2 Nos.)
Vertical turbine pumps for Storm water pit-3 ( 2 +1)
Vertical turbine pumps for Storm water pit-4 (1 No.)
Deep tube well pumps (6 Nos.)
:
:
:
:
900m3/hr
900m3/hr
900m3/hr & 400m3/h
270m3/hr
85m3/hr
1.2.0
The works shall be rendered in conformity with proven engineering construction principles,
taking into account the current technology. The requirements of the contract must be fulfilled
in its entirety.
1.3.0
In so far as data on the execution of works and services as contained in drawings, but none in
specification and vice versa, such data shall be deemed to be contained in both.
Contradictions between drawings and specifications if any shall be brought to the attention of
the Owner/Consultant by the Bidder and the correct requirement shall be obtained.
1.4.0
Omission of any specific reference to any method, parts, accessories required for proper and
efficient execution of the work shall not in any way relieve the bidder or from his
responsibilities from providing such facilities and performing the complete erection, testing and
commissioning at no extra cost to the Owner.
2.0.0
SCOPE OF WORK
The scope of work covered in this document includes but not limited to the following.
2.2.1
Identifying the pumps at Owners stores /yard.
2.2.2
Transportation of pumps from Owners stores/yard to erection site and vice versa.
2.2.3
Maintaining proper record of the materials/ pump received from stores and at various stages
of erection for ready reference.
2.2.4
Final adjustment of foundation levels by chipping and dressing, checking location, elevation
etc.
2.2.5
Assembling the parts or sub-assemblies at site prior to during/after erection.
2.2.6
Fabrication if any.
2.2.7
Minor drilling, machining welding & cutting wherever necessary.
2.2.8
Erection of pumps on prepared foundations.
2.2.9
Leveling & aligning.
2.2.10 Bolting, coupling, decoupling & erection of drive units.

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2.2.11 Grouting of anchor bolts and base plates with grouting material as per the pump
manufacturer's specification/Owners project manager.
2.2.12 Flushing, cleaning, draining & drying of pump.
2.2.13 Preparing the pump for trial run.
2.2.14 Final alignment after all piping connections.
2.2.15 Conducting pre-commissioning checks/tests to ensure correctness of erection and hook up
with other system.
2.2.16 Assisting the Owner for commissioning the plant.
2.2.17 Maintaining records of the readings & tests conducted.
2.2.18 Preparation of all pumps for startup.
2.2.19 Carrying-out all other necessary works and hand-over in fit condition for the startup of the
plant.
2.2.20 Watch & ward to ensure security and safety of materials under the Bidders custody.
3.0.0
DRAWINGS, SPECIFICATIONS & CODES
3.1.0
The following drawings will be furnished by the Owner which are to be followed for erection of
each pump.
i.
General arrangement drawings with outline dimensions including foundation details if

available.
ii. Manufacturer's manual/erection drawings.

iii. General arrangement/pump layout at various elevations & pump
power house & auxiliaries area.
layout
sections
of
iv. Manufacturers Standard erection procedure for pumps.

v. Manufacturers Standard testing procedure for the pumps.
vii. Chronology of handling.
Some/all of the above documents shall be furnished to the successful Bidder before starting
the work.
4.0.0
EXCLUSIONS
All civil engineering works such as RCC foundation, buildings, roads etc.
5.0.0
PUMP TYPE, LOCATION AND SUPPLY
5.1.0
Type of Pump
The types of miscellaneous pumps with motors covered in this specification include but not
limited to the following:
1. Rain water system
2. Deep tube well system

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Vertical turbine pump

-
Submersible type pump

Section 2.7
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5.2.0
Tender
Specification
for
Erection
&
Location of Pump
1. Vertical turbine pump
Storm water pit pump house
2. Submersible type pump
Deep tube well pump house
5.3.0
Pump Supply
5.3.1
Pumps
Pump shall be supplied for erection either in :
Completely assembled coupled to the drive and both mounted on top of a common base
frame
or
In three individual parts as pump assembly, motors and base frame or as pump assembly on
base plates, and motor separately.
6.0.0
REMOVAL OF PACKING
6.1.0
All packing cases and packages shall be opened in presence of the Engineer-in-charge or his
authorised representative. Timber packing case shall be carefully opened to avoid damage to
materials or timber.
6.2.0
Nails and packing strips should be pulled out with suitable appliances and kept separately in
container and not thrown away to random. All timber of packing cases shall have to be sorted
out and stored properly at a suitable place as directed by the Owners project manager. From
time to time packing materials, timber, nails and strips shall be delivered back to the Owners
project manager or otherwise disposed of as directed by the Owners project manager.
6.3.0
The timber reclaimed from the packing cases or any other materials shall not be used by the
Bidder for rendering facility in the erection work or any other job without prior permission of the
Owners project manager. All timber and packing materials shall remain the property of the
Owner.
6.4.0
Each material after stripping from boxes or received loose, shall be carefully inspected,
checked with shipping list and identified with erection drawing if necessary. Any short supply
and/or damaged part shall be reported forthwith to the Owner/Owners project manager in
writing. Once the materials are inspected, the same shall be preserved properly and
adequately protected from theft and deterioration or damage by rain, storm, dust and water,
tampering by casual visitors or workers. The Bidder shall prepare and maintain ledgers and
bid cards for all materials in his custody.
6.5.0
Carrying out all repairs to damages that might have suffered during transit and in subsequent
storage and modifications and rectification work are under the Bidder's scope.
7.0.0
PREPARATION FOR ERECTION
7.1.0
The Bidder shall be responsible for organizing the lifting of the pump in the proper sequence
so that orderly progress of the work is ensured and access routes for erecting the other pump
are kept open. Rigging procedures for all the major lifts (above 5 M.T) and at maximum crane
capacity shall be submitted by the Bidder for the approval of the Owners project manager.
However, approval to rigging procedure proposed by the Bidder shall not relieve the Bidder
from his responsibility.
7.2.0
Orientation of all foundations, elevations, length and disposition of anchor bolts and diameter
of holes in the supports saddles shall be checked by the Bidder well in advance. Minor
rectification including chipping of foundations shall be carried out by the Bidder after obtaining
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prior approval of the Owners project manager. The Bidder shall also be provided with the
necessary structural drawings and piping layouts etc., wherever required for reference.
8.0.0
ERECTION
8.1.0
General
8.1.1
Erection work shall be carried out in the manner and sequence as may be directed by
respective pump manufacturer's supervisory Engineers and the Owners project manager.
8.1.2
As erection proceeds each assembled part before being boxed up with a view to erecting it
finally, shall be inspected and approved by the concerned supervisor. Should any defect be
found out during such inspection, the Bidder shall make it good as per directives from Owners
project manager.
8.1.3
The pump shall be placed on respective foundation or support, leveled and aligned with
precision measuring instruments, checked for proper clearance between moving and
stationary parts wherever applicable and grouted on the foundation . Positions of ducts/piping
with respect to anchor points shall be checked for hot and cold clearances.
8.1.4
The installation of motors shall be carried out along with driven pump in accordance with
manufacturer's instructions and/or as directed by the Owners project manager.
8.1.5
Particular attention shall be given towards removal of buckles and other forms of distortion.
8.1.6
Holes in plate work to assist in erection should be avoided. Lugs required for erection shall be
removed and projections of weld shall be chipped and ground flush.
8.1.7
Misalignment in vertical joints shall not exceed 10% of plate thickness or 1.0 mm, whichever is
larger. Misalignment in horizontal joints shall not exceed 15% of upper plate thickness with a
maximum of 2 mm for plate thickness above 8 mm and a maximum of 1.0 for plate thickness
less than 8 mm. However the Owners project manager may insist for misalignment ranging
lesser than the above indicated value.
8.1.8
All pump shall be safeguarded from wind or other external causes by providing suitable steel
cables/ guys until completion of erection.
8.1.9
Welding sequence shall be adopted in such a way so as to minimise distortion due to weld
shrinkage and shall be got approved from the Owners project manager prior to
commencement of work.
8.1.10 Welding shall not be carried out on wet surfaces and shall be protected from high winds.
8.1.11 The erection of pumps shall be such that installation and operation instructions supplied by
manufacturers shall be adhered to before final grouting is taken in hand.
8.1.12 The Bidder shall provide all tools and gauges for erection and alignment. Special tools, if any,
received as part of machinery, will be used by the Bidder for erection, which shall be returned
to the Owner in good condition after use. The Bidder for the purpose of erection shall employ
at his own cost suitable lifting tackles, cranes and skilled men to the satisfaction of the
8.1.13 For all pumps, drilling of holes in the base plates for fixing motors, fixing of couplings on shafts
etc., and doweling including provision of dowel pins or similar arrangements for retaining the
alignment shall be carried out by the Bidder as part of erection work.
The Bidder may have to open some of the parts of the pump for cleaning and fitting it in its
original condition. No extra payment shall be made for such work.
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All parts of the pump shall thoroughly be cleaned with solvents to remove protective
compounds, if any, before assembly.
9.0.0
ALIGNMENT & TOLERANCES
9.1.0
The tolerances and alignment shall be maintained as per the manufacturer's specification. If
not specified, the Engineer-in-charge shall be discussed and finalized. The decision of
Engineer-in-charge is final.
In general following tolerances are valid unless otherwise specified by the manufacturer.
a. Radial alignment: Maximum 0.05 mm misalignment shaft (0.1 mm at travel)
b. Axial alignment: Maximum 0.05 mm at travel measured at coupling outer diameter
elevation.
Allowed tolerances for connecting piping 4" and above.
a. Vertical misalignment of bolt holes: 0.2 mm
b. Horizontal misalignment of bolt holes: 0.2 mm
c.
Torsion misalignment of bolt holes: 0.3 mm
d. Parallelism of flanges: 0.2 mm

e. Distance between flanges gasket thickness: 0.4 mm
9.2.0
For pumps, horizontal mis-alignment measures at the longitudinal and cross axis of the pump
shall not exceed 0.1 mm/M indicated at the shaft sprit level.
9.3.0
Final alignment, as specified by the manufacturers, shall be carried out after all piping
connections are made. Tolerance specified by the manufacturers shall be adhered to. To
ensure that no stresses are induced on the pumps by the piping, the Bidder shall again check
the alignment by disconnecting the piping or in the working condition or in both conditions.
Pipes shall never be pulled and connected to pump flanges. Final alignment should be shown
to the Owners project manager or his representative and his clearance should be taken.
9.4.0
Bidder to check direction of rotation of each machinery before trial run. Bidder to carry out
alignment by dial indicator and submit the readings in duplicate to the Owner.
10.0.0 GROUTING
10.1.0 Material
10.1.1 All the materials required for this item shall be conforming to the relevant Indian Standards
where applicable.
10.1.2 Under no condition shall heat cement be used for grouting.
10.1.3 Unless otherwise specified by manufacturer/in the drawing, the following grouting material
shall be used.
10.1.4 Non shrinking grout consisting of 1 part of O.P.cement + 1 part of clean dry well graded sand
+ 1 part of ferro grout or similar additives + minimum water to make mix placeable.
10.1.5 Ordinary grout consisting of 1 part of O.P. Cement + 2 part well graded sand / fine aggregate
+ minimum water to make mix placeable.
10.1.6 Notwithstanding 10.1.4 & 10.1.5 final decision on type of grouting for any pump shall be given
by Engineer-in-charge.
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10.1.7 The grouting material shall solidly fill the spaces to be grouted and permanently retain its
original volume so that the base plate will be held firmly in the set position. The amount of
water used in mixing shall be kept to a minimum such that the grout shall have a consistency
too stiff to flow.
10.2.0 Preparation of Surfaces for Grouting
The top of foundation shall be clean and free of all laitance, loose particles, oil or grease and
shall be wetted thoroughly leaving no puddles prior to grouting.
All trapped pockets shall be properly vented to allow full penetration of grout.
The grout shall cover all shims, which are to be retained.
10.3.0 Placement
10.3.1 All anchor bolt holes shall be completely filled with grout. The grout shall cover all shims,
which are to be retained. Shim plates shall not protrude out of the base plates or base rings or
foot flanges. Wedges and temporary packing shall be removed after pump/structures are
leveled.
10.3.2 The finished surface shall be floated smooth.
10.3.3 Care is to be taken during grouting so that the base plate level and alignment is not disturbed.
10.3.4 Over and above grouting clearance shown in foundation drawings, pockets made by base
frames for machinery, pump, steel structures etc., shall also be completely filled with grouting
as per directions of Owners project manager.
11.0.0 SUPERVISION DURING ERECTION
11.1.0 The Bidder shall be required to provide, at proper time, the necessary supervisory engineers,
supervisors and other supervisory personnel duly qualified and in sufficient number for
transportation, erection, pre-commissioning and post commissioning check up, start-up,
testing and trial operation of plants and pump.
11.2.0 The Bidder shall keep a competent representative who will be Resident Engineer and shall
remain as `Incharge' of Bidder's work-site and also remain answerable to the Owner/Owners
project manager for all activities of the Contractor at site. Before his placement at site, the
Contractor shall submit his bio-data to the Owner/Owners project manager for his approval.
11.3.0 The Resident Engineer shall supervise the work of all men of the Bidder working at site. He
shall work in complete harmony and co-operation with Owners project manager and
Manufacturer's Engineers working at site. All statutory rules and labor laws prevailing in the
area must be observed by the Bidder. All safety measures against occurrence of accidents
must be taken effectively. Resident Engineer shall not be withdrawn without written permission
of the Owner/Owners project manager. If any of the Bidder's personnel was found unsuitable
for the job, the Bidder shall remove him forthwith and a suitable replacement shall be posted
to site within a reasonable time. No compensation for withdrawal of unsuitable or unqualified
person(s) from site or for posting suitable person(s) to site at any stage of the project shall be
allowed by the Owner/Owners project manager.
11.4.0 External supervisory services (from the pump supplier) shall be provided for pumps.
12.0.0 FLUSHING & CLEANING
12.1.0 The Bidder shall observe strict cleanliness during execution of the work and shall be in
possession of vacuum cleaner for cleaning the internals of machinery under installation. They
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shall check that all the finished surfaces are greased and covered and all pipes and duct ends
are covered, with plastic or suitable type of cap during storage.
12.2.0 Before boxing up, the Bidder shall examine carefully to ensure that no foreign material, such
as welding rod ends, welding beads, metal chips, rope, working tools, etc., has been left inside
any pump.
12.3.0 Cleaning sequence and arrangement of temporary piping if any will be developed by the
Bidder and shall be executed by him to the satisfaction of the Engineer-in-charge.
12.4.0 In general all the pump shall be cleaned/flushed with either water/steam. If insisted by Owners
project manager chemical cleaning may be required and the same will be carried out by the
Bidder at no extra cost. The chemicals required for cleaning shall be provided by the Bidder at
no extra cost.
13.0.0 TESTING
13.1.0 Hydraulic Test
13.1.1 The pump erected shall be identified for the hydraulic test by the Owners project manager.
Hydraulic test shall be conducted as per the specification. If the hydro test procedure is not
specified for any particular pump, it will be carried out as per the instructions of Owners
project manager.
13.1.2 The test pump listed in the above specification, temporary piping shall be arranged by the
Bidder.
14.0.0 PRE-COMMISSIONING TESTS & OTHER TESTS
14.1.0 After completion of erection and/or installations and before start-up each plant and pump and
all its appurtenances shall be thoroughly cleaned and then, inspected in the presence of
Owners project manager for correctness, soundness and completeness of installation and
acceptability for start-up.
14.2.0 All works to be carried out by the Contractor shall be subject to inspection by third party
inspector, the Owners project manager as well as Boiler Inspectorate, and CEIG as
applicable. The work shall be carried out as per applicable specifications, codes of practice,
drawings and instructions of Owners project manager and Boiler Inspectorate and CEIG
where applicable. The Bidder shall provide necessary facilities, instruments, personnel etc.,
for carrying out the inspection as above and shall comply with the instructions given.
14.3.0 A check list in triplicate will be furnished for the approval of Owners project manager wherein
all items to be checked and necessary instructions will be listed. Inspection and checking shall
strictly follow this check list. On completion of the joint inspection and checking two (2) copies
of the check list will have to be handed over to the Owners project manager.
14.4.0 The check lists after checking will have to be jointly signed by the Bidders supervisor and the
Owners project manager to ensure that all inspection and checking have been properly
carried out. However, such endorsement shall not relieve the Bidder from the responsibility in
ensuring proper erection and cleaning.
14.5.0 During inspection all clearance, alignment and important measurements and adjustments as
may be directed shall be noted by the Bidder for future reference and guidance. Two (2)
copies of such notes shall be delivered to the Owners project manager.
14.6.0 All reports of radiographic examination in a format approved by the Owners project manager
shall be submitted to the Owners project manager for his approval and records
14.7.0 Any other pre-commissioning and field test not included in the above and which are specified
in the relevant standards, Electricity Rules, Code of Practice shall be carried out at no extra
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cost to Owners project manager. Also, if the Owners project manager wishes any particular
test is to be repeated or newly carried out, the same shall be done by the Bidder without any
extra cost.
15.0.0 TEST RUNS
15.1.0 Following the satisfactory completion of inspection, checking and cleaning of a unit, the plant
will be placed in test run. During this period, all adjustments and repairs as required shall be
made by the Bidder, the plant may be shut-down if necessary to carry out such adjustments
and repairs. On completion of satisfactory test run, the plant will be placed under trial
operation.
15.2.0 Prior to trial operation of any pump the following shall be checked:
a)
b)
c)
d)
e)
Proper installation of the drive and pump on the foundation.

Proper alignment of drive and the pump.
Proper connection of supports, hangers, piping, valves, instruments and other fittings.
Freeness of the rotors of drive and pump.
Healthiness of lube oil system, changing and filling as necessary.
All labours and operators for starting, trial operation, repairs and adjustments shall be
provided by the Contractor.
15.3.0 After no load test run of the motor each rotary pump shall be coupled and shall be subjected
to a test run. The duration of this test run shall be mutually agreed.
The objective of the test run shall be to ascertain that the following are within the permissible
limits and the operation is satisfactory.
a.
b.
c.
d.
e.
f.
g.
Vibration and noise level

Bearing vibration and temperature
Performance of the lube oil systems
Motor winding temperature
Performance of various control, interlocks and protective elements, wherever applicable
Performance of annunciation system and indication, wherever applicable.
Any other parameter considered necessary.
16.0.0 FINAL INSPECTION AND STARTUP

After completion of all tests as per specifications, the whole work will be subject to a final
inspection to ensure that job has been completed as per requirement. If any defect is noticed,
the bidder will be notified by the Owners project manager and he shall make good the defects
with utmost speed. If, however, the bidder fails to attend to these defects within a reasonable
time (time period shall be fixed by the Owners project manager) then Owners project
manager may have such defects rectified at Bidders, cost.
17.0.0 LOADING THE UNIT & TRIAL RUN
17.1.0 After the above pre-commissioning operations, the plant will be started up and loaded. During
this loading operations all the controls and protections shall be finally set.
17.2.0 The run will be for an uninterrupted minimum period of fifteen (15) days or agreed mutually
between Bidder and Owner at rated full load/part load as made available by the Owners
project manager. To demonstrate the following:a. The sustained capability of the plant.
b. The reliability of the plant and auxiliaries.
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The adequacy of the various auxiliaries, ancillaries and systems and instruments and
controls.
d. The capability of each pump of the plant to correctly perform the functions for which it was
specified.
e. The safety requirements.
This run shall be undertaken jointly with the Owner. A joint log would be maintained to record
various performance data, the malfunctions, output deficiency and short comings and would
be compiled and furnished at the end of the trial run .The malfunction, short comings and
deficiencies shall be rectified by the Bidder to the satisfaction of the Owners project manager
at no extra cost.
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VOLUME II
SECTION 3.0
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TABLE OF CONTENTS
CLAUSE NO.
DESCRIPTION
PAGE NO.
1.0.0 INTENT OF SPECIFICATION.................................................................................................3

2.0.0 CODES AND STANDARDS....................................................................................................3
3.0.0 GENERAL REQUIREMENTS .................................................................................................3
4.0.0 CABLING CONCEPTUAL DESIGN ........................................................................................6
5.0.0 INSTALLATION REQUIREMENT ...........................................................................................9
6.0.0 EARTHING INSTALLATION .................................................................................................20
7.0.0 PAINTING& GALVANISING .................................................................................................21
8.0.0 TESTING & COMMISSIONING ............................................................................................22
ANNEXUREA: BILL OF QUANTITTIES FOR CABLES ................................................................23
ANNEXUREB: ................................................................................................................................24
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SECTION 3
1.0.0
This section covers the requirements of Electrical installation.
2.0.0
CODES AND STANDARDS

Installation of cabling work shall comply with the latest edition of following Indian standards,
rules, regulations and acts..
IS: 1255
: Code of practice for installation and maintenance of power cables up to and

including 33 kV rating.
IS: 732
: Electrical wiring installation (system voltage not exceeding 650 V).
IS 10028 : Code of Practice for selection, Installation & maintenance of transformers.
IS 10118
: Code of practice for selection, installation & maintenance of Switchgear &
Control gear.
IS: 5216
: Guide for safety procedures and practices in electrical works.
IS 2551
: Danger notice plates
IS 8923
: Warning Symbol for dangerous voltages.
IS: 2062
: Structural steel (Standard Quality).
IS: 800
: Code of practice for use of structural steel.
IS: 816
: Code of practice for use of metal arc welding for general construction in mild
steel.
IS: 1363
: Hexagonal bolts, nuts and screws.
IS: IS72
: Electroplated coatings of cadmium on iron and steel.
IS: 2629
: Code of practice for hot dip galvanizing for iron and steel.
IS: 2633
: Method of testing uniformity of coating on zinc coated articles.
SP30
: National electric code.
Indian Electricity Act.
Indian Electricity Rules.
Fire insurance regulations.
Regulations laid down by the Chief Electrical Inspector of the State.
Regulations laid down by the Factory Inspector of the State.
3.0.0
GENERAL REQUIREMENTS
3.1.0
The Vendor shall make his own arrangement for moving/lifting all the equipment/items into the
respective buildings/erection sites. No part of the structure shall be utilized to lift or erect any
equipment without prior permission of the Purchaser.
3.2.0
Equipment/items shall be installed in a neat work manner so that it is leveled, plumbed, squared
and properly aligned and oriented. Tolerance shall be as established in manufacturer's drawings
or as stipulated by the Purchaser. No equipment shall be permanently bolted down to foundation
or structure until the alignment has been checked and found acceptable by the Purchaser.
3.3.0
Manufacturer's drawings, instructions and recommendations shall be correctly followed in
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handling, erecting, testing and commissioning of all items/equipment and care shall be
exercised in handling to avoid distortion to stationary structures, the marring to finish, or
damaging of delicate instruments or other electrical parts.
3.4.0
All care should be taken to avoid damage of galvanised/painted surfaces during installation. All
damaged surfaces of galvanised or ungalvanised faces of steel structures, conduits,
junction boxes, trays etc. shall be brushed up and shall be painted with red primer paint
followed by two coats of aluminium paint/enamel paint to the satisfaction of Purchaser.
3.5.0
The Vendor shall have a separate cleaning gang to clean all equipment under erection as well
as the work area of the project site at regular intervals to the satisfaction of the Purchaser. All
cable trenches/racks shall be thoroughly cleaned, before and after installation of cable. In case
the site cleaning is not to Purchaser's satisfaction, he will have the right to carry out the cleaning
operations and expenditure incurred by the Purchaser in this regard will be to the Vendor's
account.
3.6.0
The Vendor shall provide adequate and capable supervision for electrical installation work under
this contract. The staff provided shall be adequate to provide detailed supervision at each stage
of the work, in all areas so that any improvements modifications required to meet site
conditions/layouts is effected in time.
3.7.0
The Vendor shall be fully and finally responsible for proper erection, safe and satisfactory
operation of the equipment under his scope of work to the entire satisfaction of the Purchaser.
3.8.0
If in the opinion of the Vendor any work is insufficiently specified or require modification, the
Vendor shall refer the same in writing to the Purchaser and obtain instruction / approval before
proceeding with the work.
3.9.0
Equipment and material, which are wrongly installed, shall be removed and re-installed to
comply with the design requirement at the Vendors expense, to the satisfaction of the
Purchaser.
3.10.0 The installation shall be carried out in such a manner as to provide access to other equipment
installed. The Vendor shall restore floor / wall chipping, road cuttings & other such works done
including replacement of equipment.
3.11.0 The drawings and schedules will be issued to successful bidder to suit the actual requirement in
related systems. Additional drawings and schedules will also be furnished to Vendor if / when
necessary. Final drawings and schedules will be furnished to the Vendor from time to time as
detailed designs are developed.
3.12.0 The Vendor shall effectively protect his work, equipment and materials under his custody from
theft, damage or tampering. Finished work where required shall be suitably covered to keep it
clean and free from defacement or injury. Vendor shall be held responsible for any loss or
damage to equipment and material issued to him until the same is taken over by the Purchaser
according to contract.
3.13.0 All safety rules and codes as applicable to work shall be followed without exception. All safety
appliance and protective devices including belts, hand gloves, aprons, helmets, shields, goggles,
safety shoes etc. shall be provided by the Vendor for his personnel.
3.14.0 The Vendor shall provide guards and prominently display caution notices if access to any
equipment / area is considered unsafe and hazardous. The Vendor shall provide shock
treatment chart, danger notice boards and portable fire extinguisher in each switchgear room
and control room.
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3.15.0 The Vendor shall also be responsible for estimation of bill of quantities on the basis of the inputs
provided by Purchaser in the form of drawings etc., depending upon the scope. Any shortfall or
surplus in the estimated quantities shall be intimated to the Purchaser periodically during project
execution stages. Plan for reporting the estimated quantities shall be mutually agreed upon.
3.16.0 Cable installation shall be properly coordinated at site with other services and wherever
necessary suitable adjustment shall be made in the cable routings with a view to avoid
interference with any part of the building, structures, equipment, utilities and services Any such
adjustment shall be done with the approval of Purchaser.
3.17.0 All materials being supplied or consumed during erection by the Vendor in the process of
erection work shall be of the best quality and according to the relevant standards. All materials
shall be got inspected and approved by the Purchaser before the same is used for erection
same at any time during erection, testing and commissioning.
3.18.0 Motors for all mechanical equipment for the process like, pumps, fans etc. will be set in place by
other agencies. The Vendor shall make power, space heater and auxiliary cable connections to
the equipment and shall work in complete coordination with other Vendors and/or equipment
suppliers/ representatives in obtaining correct direction of rotation and the commissioning of the
equipment.
3.19.0 Any modification/rework required to be done on account of wrong practices (like connections
with wrong sequence at drive/equipment end) shall be at Vendor's cost.
3.20.0 Before energisation, physical inspection shall be carried out and all foreign bodies shall be
removed and loose connecting bolts etc. shall be tightened.
3.21.0 Erection Programme and Progress
The Vendor shall submit at such times and in such forms as may be requested by the
Purchaser, schedule showing the programme and the order in which the Vendor proposes to
carry out the work with dates and estimated time for various parts of the work.
Such schedules shall be approved by the Purchaser prior to starting the erection. The Vendor
shall adhere to this approved programme for all practical purposes. If for any reason the work is
held up, the Vendor shall bring it to the attention of the Purchaser in writing without any delay.
During the progress of work the Vendor shall submit monthly progress report.
If in the opinion of the Purchaser the progress of execution of work by the Vendor at any stage
needs expediting so as to ensure completion of work within stipulated time, the Purchaser shall
have the right to instruct the Vendor to increase Vendors man power in appropriate categories
and / or the working hours per day and / or erection tools and tackles and the Vendor shall
comply with such instruction forthwith.
3.22.0 Taking Delivery of Purchaser Supplied Items
The Vendor shall take delivery of materials from Purchaser store yard / shed. Materials delivered
shall be brought to the erection site, stored or erected as necessary. Indents for materials shall
be placed sufficiently in advance so as to enable the Purchaser to arrange for the delivery from
store in time. The Vendor shall submit a detailed account of materials issued to him after
completion of work.
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All packing cases and packages shall be opened in presence of Purchaser or his authorised
representatives.
All equipment, accessories and materials shall be carefully inspected and checked with packing
list and identified with the erection drawings. Any discrepancy shall be reported forthwith in
writing to the Purchaser and repair carried out as described herein before.
All parts shall be thoroughly cleaned, all rust removed and surface polished as required.
Cleaned and polished parts shall be coated with anti-corrosive paints where necessary and
stored with care, ready for erection.
4.0.0
CABLING CONCEPTUAL DESIGN
4.1.0
In the plant building, switchgear rooms, control rooms etc., power, control cables and
Instrumentation shall generally be laid on cable trays installed in concrete trenches, Over head
trays, cable vaults, cable shafts or along building / structures, buried under ground as shown in
the purchaser drawing, as the case may be. Short cable runs in auxiliary plant areas local to
equipment shall be laid in floor slits up to near the equipment. Refer ANNEXURE A for the
Cables BOM and the Cable list enclosed along with the tender for the cabling details.
4.2.0
Power & control cables installed along buildings, structures, ceilings, walls, etc., which are
required to be protected against mechanical damage, shall be taken in GI conduits.
4.3.0
GI Conduits shall also be used for flameproof installations, wherever required, with sealing at
both ends.
4.4.0
Entry of cables from trenches into buildings shall be by means of GI Pipes. Trenches / duct
banks/ embedded conduits shall enter buildings as per approved layout drawings. All such
entries shall be sealed against water ingress after completion of cable laying. The method of
sealing shall not be deleterious to the cables and shall be to the approval of Purchaser. During
cabling work, all such pits as are meant for cabling shall be kept in dry condition by use of
means such as portable sump pumps specially during rainy season. Suitable numbers of such
pumps shall be deployed to ensure no water collection/ retention in cable pits / indoor trenches
etc
4.5.0
Cables laid exposed in racks/trays and routed from trenches etc to individual drive / control
devices etc shall be taken in embedded/exposed/surface-grouted rigid GI conduits / rigid PVC
Conduits and / or flexible conduits as specified in the drawings, unless directly terminated to the
equipment in the panels located above trenches, tunnels or basement.
4.6.0
All cables routed along walls or in equipment rooms shall be protected by means of laying them
through G.I. pipes .
4.7.0
Where direct heat radiation from equipment/pipes exists, heat isolating barriers for cabling
system shall be adopted. System shall be to the approval of Purchaser.
4.8.0
If required, in exceptional cases, a few number of cables may be directly buried into the earth.
4.9.0
Wherever cables are to be laid below roads and railway tracks, the same shall be taken through
ducts buried at a suitable depth. Provisions of IS:1225 shall be followed for cables buried directly
in ground
4.10.0 At certain places where hazardous fumes/gases may cause fire to the cables, cable trenches
after installation of cables may be sand-filled.
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4.11.0 In corrosive atmosphere, PVC conduits shall be used for cables. Metallic pipes / conduits shall
not be used in corrosive areas
4.12.0 Single core cables, when pulled individually, shall be taken through PVC pipes only. No single
core cable shall pass through a GI conduit / pipe or duct singly except DC single core cables. AC
single core cables shall pass through GI conduit/ pipe in trefoil formation only, or through PVC
pipes
4.12.0 Cable routes shall be segregated unit wise, to the extent possible. Similarly, cables for the
standby drives shall preferably be taken through the alternative route. Separate routes shall also
be preferred for duplicate control supply cables, first and second channel protection cables, and
cables to common station service of two or more units.
4.13.0 Cables shall be avoided below oil pipes and in the vicinity of steam pipes.
4.14.0 Cable trays may be laid preferably in vertical formation in boiler, mill and ESP areas to avoid
accumulation of coal-dust / ash on cables and cable-trays.
4.15.0 Complete cable tray support structure after installation shall be inspected for straightness,
accuracy, use of proper sizes & compliance to drawings.
4.16.0 Complete cable tray & accessory installation work shall be inspected/tested for proper
alignment, levelling (by use of plumb lines), use of proper accessories, provision of proper
bending radius at bend for site fabricated accessories and high quality workmanship .
4.17.0 Cable trays shall be ladder type for power and electrical control cables, while perforated type
cable trays shall be used for instrumentation and control cables. However, in vertical cable tray
risers, all trays shall be ladder type.
4.18.0 Pre installation checks for cable tray installation shall be as under:
a) Availability of clear passage/ path for the cable tray network as per approved drawings.
b) Cold galvanisation / paint treatment for all damaged portions of galvanisation due to cutting /
repairs etc.
c) Correctness of installation of number and type of tray / tray accessories /support material
as per approved drawings.
d) Firmness/ tightness of all bolted joints
e) Alignment / inter tray separation as per approved layout drawings
f) Grounding connections for trays I cable boxes I marshaling boxes
4.19.0 Rollers shall be used at intervals of about 2.0 metres while pulling cables. Cable pulling without
rollers shall not be permitted.
4.20.0 Adequate length of cables shall be pulled inside the switchboards, control panels, terminal boxes
etc. so as to permit neat termination/ dressing of each core / conductor.
4.21.0 Screened control cables of small cross sectional area, shall be terminated by means of MaxiTermi termination system.
4.22.0 Individual cores of control cables shall have ferrules for identification. Ferrule numbers shall be
provided as per the control schemes and other related documents.
4.23.0 Termination and jointing of HT cables shall be done with approved type termination/ jointing kits
of proven design & type tested as per IS: 13573.
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4.24.0 Junction boxes may be used, wherever required, for jointing/ marshaling of control and
instrumentation cables.
4.25.0 All due care shall be taken during unreeling, laying and termination of cable to avoid damage
due to twists, kinks, sharp bends etc. Vendor shall adhere to the Field Quality Plan of the cable
supplier for carrying out the activities listed above in to..
4.26.0 Cable ends shall be kept sealed to prevent damage.
4.27.0 The Vendor shall remove the RCC/Steel trench covers before taking up the work and shall
replace all the trench covers after the erection work in the particular area is completed or when
further work is not likely to be taken up for some time.
4.28.0 In case the outer sheath of a cable is damaged during handling/installation, the Vendor shall
repair it at his own cost to the satisfaction of the Purchaser.
4.29.0 In case any part of cable, other than outer sheath, of a cable is damaged during
handling/installation, the same shall be replaced by a healthy cable at no extra cost to the
Purchaser, i.e. the Vendor shall not be paid for installation and removal of damaged cable.
4.30.0 Flexible conduits shall be used between fixed conduits and equipment terminal boxes, where
vibration is anticipated.
4.31.0 Junction boxes shall be installed so that they are level, plumb & properly aligned and present a
pleasing appearance. Boxes shall be adequately supported by means of proper supporting
arrangement to Purchasers approval. The Vendor shall perform all drilling, cutting, welding &
bolting required for attachment of supports.
4.32.0 Suitable earth risers, approved by Purchaser, shall be provided by Vendor after installation of
equipment, if the same have not been provided at the time of installation of earth grid.
4.33.0 Vendor shall have his own facility for bending, cutting, threading of various materials for cabling
& earthing system, at site.
4.34.0 All the damaged portions of areas of cabling and earthing system after installation shall be
touched up properly.
4.35.0 The erection work shall be carried out neatly and the areas of work shall be cleaned of all scrap
material, water etc. after completion of work in each area every day.
4.36.0 The Vendor shall seal off all the floor and wall openings after installation of conduits/pipes/trays
for cabling/earthing materials.
4.37.0 All welding work shall be carried out by electric arc welding method only with appropriate size of
welding electrodes to ensure sufficient welding strength.
4.38.0 Flexible conduits shall be used for the final connection between rigid conduits & motors, only for
vibrating equipment or equipment requiring regular removal.
4.39.0 Wherever it is possible for water or liquids to enter conduits, sloping of conduit runs and
drainage of liquids accumulated shall be ensured.
4.40.0 The entire metallic conduit system, whether embedded or exposed, shall be electrically
continuous and grounded, preferably with grounding bushings or grounding clamps.
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4.41.0 Conduits shall be so sized as to ensure that the conduit fill (i.e. ratio of area occupied by cable
conduit bore) does not exceed 40%.
4.42.0 Minimum bending radius for conduits shall be 10 times the external diameter of the conduit.
4.43.0 All conduits shall be permanently identified at each end with the conduit number assigned to it
as per the applicable drawings.
4.44.0 Pull boxes shall be installed between termination points wherever required to facilitate cable out
at a maximum interval of 30metres.
4.45.0 Conduits shall be firmly fastened within 900mm of each junction box, cabinet or fitting. Conduits
shall be supported at least every 2000mm.
5.0.0
INSTALLATION REQUIREMENT
5.1.0
Cable tray and Support System Installation (If required)
5.1.1
Cable trays shall be bolted to tray mounting supports with a minimum clearance of 300mm
between cable tray tiers / as shown in the drawings.
5.1.2
Cable trays shall be supported at an interval of 1500mm for all horizontal runs. For vertical cable
risers/shafts cables will be supported at every 1000 mm interval. Cable tray installation shall
generally be carried out as per typical drawings enclosed.
5.1.3
Support system shall be so designed that it is able to withstand weight of the cable trays,
Weight of the cables (75 Kg/metre run of each cable tray), Concentrated load of 75 Kg between
every support span without any permanent deflection. Factors of safety of atleast 1.5 shall be
considered.
5.1.4
Cable tray mounting structure shall be welded/bolted to the plate inserts or to steel structure
and the type of welding shall be of fillet type of at least 6mm size.
5.1.5
All cable way sections shall have identification, designations as per cable way layout drawings
and painted/stenciled at each end of cable way and where there is a branch connection to
another cable way. Minimum height of letter shall be not less than 60mm. For long lengths of
trays, the identification shall be painted at every 10 meter. Risers shall additionally be painted /
stenciled with identification numbers at every floor.
5.1.6
The Purchaser shall provide necessary embedded steel inserts in wall/floor/ceiling surfaces for
supporting cable trays. The cable racks shall be secured to the rack/tray supports by welding to
those inserts or other available building steel surfaces. In case of non-availability of embedded
steel
inserts in certain tray routes, the Vendor
shall have to secure the supports on
wall/floor/ceiling surfaces by providing suitable anchoring system/ steel inserts having adequate
load bearing capability.
5.1.7
In certain cases it may be necessary to site fabricate portions of trays, supports and other
non-standard bends where the normal prefabricated trays, supports and accessories may not
be suitable.
In such cases the Vendor shall fabricate at site suitable sections of trays,
supports and accessories to make the installation complete for the specific purpose after
obtaining Purchaser's prior approval, which shall be neat in appearance and shall match with
the prefabricated sections in the dimensions. They shall be applied with one coat of red lead
primer followed by two finishing coats of aluminium alloy paint.
5.1.8
Tray covers shall be provided for overhead cable trays on top most tier as per Purchasers
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drawings. The cable risers or vertical raceways shall also be covered by cable tray covers upto
1.5 metres from respective floor for mechanical protection. The sheet cover shall be of
removable type.
Atleast 250 mm spacing shall be maintained between top of the trays and beams/piping etc.
Solid covers shall be provided for outdoor trays, top tray of horizontal tray runs located under
grating floor or insulated piping, and for all trays routed in areas where oil might enter or
accumulate.
5.1.10 Wherever specified or directed by Purchaser, the Vendor shall install galvanized MS sheet
covers over cable trays. The width of the covers shall be same as that of cable trays. Bolting
shall be done to fasten covers to the cable trays, elbows, reducers, tees, crosses etc.
5.1.11 The Vendor shall install all angles, channels, beams, hangers, brackets, clamps etc. as may be
necessary to suit the actual site conditions to support the cable trays.
5.1.12 Straight pieces of standard MS angles/channels shall be used for fabrication of supports/racks.
All welded joints shall be smooth enough to provide a good appearance and shall not cause"
injury to working personnel.
5.2.0
Conduits/Pipes/Ducts Installation
5.2.1
Rigid steel conduits shall be used indoors in non-hazardous areas. PVC conduit shall be used
for duct banks and for some below grade concrete encased conduit. Liquid tight flexible metallic
conduit shall be used for connections to solenoid valves, limit switches; pressure switches etc.,
for connection to motors or other vibrating equipment and across areas where expansion or
movement of the conduit is required.
5.2.2
Exposed conduits shall be routed parallel or perpendicular to dominant surfaces with right angle
turns made of symmetrical conduit bends or fittings. Conduits shall be securely supported within
900 mm of connections to boxes and cabinet.
5.2.3
The Vendor shall be fully responsible for properly embedding conduit/pipe sleeves wherever
necessary for cabling work. All openings in the
floor/roof/wall/cable trenches made for
conduit installation shall be sealed and made water proof and fire proof by the Vendor. GI pull
wire of adequate size shall be laid in all conduits before installation. Metallic conduit runs at
termination shall have two lock nuts wherever required for junction boxes etc.
5.2.4
Conduit runs/sleeves shall be provided with PVC bushings having round edge at each end. All
conduits/pipes shall have their ends closed by caps until cables are pulled. After cables are
pulled, the ends of conduits/pipes shall be sealed with Glass wool/Cement Mortar/Putty to
prevent entrance of moisture and foreign material.
5.2.5
Embedded conduits shall have a minimum concrete cover of 50mm. Positioning and ensuring
proper alignment during concreting by other agencies shall be the responsibility of the
Vendor. All conduits to be embedded in concrete shall be inspected to ensure continuity and
accuracy of placement before concrete is poured. All embedded pipes/conduits, sleeves, long
radii bends etc. shall have at least 50mm long extension beyond the embedded part, for
extension of the same or for providing end plugs. If any embedded conduit is not required it
shall be plugged/sealed.
All accessories/fittings
required for making
the installation
complete, shall include tees, elbows, check nuts brass or galvanized steel end caps,
PVC/brass bell mouths for water proof sealing, pull boxes, saddles, spacers and required
steel supporting work.
5.2.6
Flexible conduit shall be terminated using suitable end coupler and check nut at both ends.
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5.2.7
All conduits installed outdoor shall be sloped towards pull boxes, hand holes/manholes for
drainage. Low points of conduits not terminating in pull boxes, hand holes/manholes shall be
provided with weep holes for drainage. Care shall be taken to see that no rough edge is left
around the weep holes. Where no provision for drainage can be made, both end of conduits
shall be sealed after cable is laid through. Minimum slopes of 1 in 400 shall be provided.
5.2.8
Exposed conduit shall be adequately supported by racks, clamps, straps or by other approved
means. Conduits supports shall be erected square and true to line and grade. For bending of
conduits, bending machine shall be arranged at site by the Vendor to facilitate cold bending.
The bends formed shall be smooth.
5.2.9
When two lengths of conduits are joined together through a coupling, running thread equal to
twice the length of coupling shall be provided on any one length to facilitate easy dismantling.
The Vendor shall have at site die for threading pipe or conduit. After threading of conduits anti
corrosive paint shall be provided.
5.2.10 For installation of cables in GI conduits, complete conducting system shall be installed first
without cables but having suitable pull wires laid in conduits.
5.2.11 For equipment and devices having GI conduit entry arrangement other than standard GI conduit
adopter, transition adopters shall be provided as required to enable the GI conduit to be properly
terminated, between conduit end and motor terminal block.
5.2.12 GI conduits shall run without moisture or water traps and shall be arranged to drain towards the
ends.
5.2.13 The entire GI conduit system shall be firmly fastened in position. All boxes and fittings shall
generally be secured independently from the GI pipes entering them.
5.2.14 Bends of GI pipes/conduits shall be made without causing damage to the pipes/ conduits.
5.2.15 Occupancy of conduits shall not be greater than 40%.
5.2.16 The adopter for coupling rigid GI pipe/ conduit and flexible conduit shall be of aluminium or
galvanized steel.
5.3.0
Transportation & storage of cable drums

Transportation and storage of cable drums shall generally conform to the requirements of IS:
1255. Transportation of cables from Purchaser's storage area to the work site shall be the
responsibility of Vendor. The cable drums shall be transported on wheels to the place of work.
Empty cable drums shall be the property of Purchaser.
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5.4.0
Cable Installation
5.4.1
Cable installation shall be carried out as per IS: 1255 and other applicable standards. Cable
drums shall be unloaded, handled and stored in an approved manner on hard and well drained
surface so that they may not sink. In no case shall the drum be stored flat i.e. with flange
horizontal. Rolling of drums shall be avoided as far as possible. For short distances, the drums
may be rolled provided they are rolled slowly and in proper direction as marked on the drum. In
absence of any indication, the drums may be rolled in the same direction as it was rolled during
taking up the cables. For unreeling the cable, the drum shall be mounted on suitable jacks or
on cable wheels and shall be rolled slowly so that cable comes out over the drum and not from
below. All possible care shall be taken during unreeling and laying to avoid damage due to
twist, kink or sharp bends. Cable ends shall be provided with sealed plastic caps to prevent
damage and ingress of moisture.
5.4.2
While laying cable, ground rollers shall be used at every 2 metre interval to avoid cable
touching ground. The cables shall be pushed over the rollers by a gang of people
positioned in between the rollers. Cables shall not be pulled from the end without having
intermediate pushing arrangements.
Pulling tension shall not exceed the values
recommended by cable manufacturer. Selection of cable drums for each run shall be so
planned so as to avoid using straight through joints. Cable splices will not be allowed except
where called for by the drawings or is unavoidable or permitted by the Purchaser. Care
should be taken while laying the cables so as to avoid damage to cables. In case any
particular cable is damaged, the same shall be repaired or changed to the satisfaction of
Purchaser without any extra cost.
5.4.3
Cables shall be laid on cable racks strictly in line with cable schedule furnished. In case of
any difficulties in following the cable schedule furnished, an alternate route shall be adopted
only after obtaining approval from Purchaser. Where specific cable layouts are not
shown on drawings, Vendor shall route these as directed by the Purchaser.
5.4.4
Power and control cables shall be laid on separate tiers. The laying of different voltage grade
cables shall be on different tiers according to the voltage grade of the cables. Generally H.T.
cables shall be laid on bottom most tier and cables of subsequent lower voltage grades on upper
tiers of trays. Separate cable trays shall be used for the following
HT Power Cables
LT Power Cables
Control Cables
Instrumentation/communication cables
Fire Survival cables
5.4.5
Single core cable in trefoil formation shall be laid with a spacing equal to the diameter of the
Trefoils and clamped at every two metre.
All multicore cables shall be laid in touching
formation. Power and control cables shall be securely fixed to trays /supports with selflocking type nylon cable strap with deinterlocking facility at every 5 meter interval for
horizontal run and cables laid in vertical run of trays shall be securely fixed to trays/supports
by galvanised steel clamps at every one metre interval. All power cables should be clamped
individually. In general power and control cables shall be laid in ladder type trays &
instrumentation cables shall be laid on perforated type trays.
5.4.6
Bending radii for cables shall be as per manufacturers recommendations.
5.4.7
Where cables cross roads/rail tracks, the cables shall be laid in hume pipes embedded in
ground with a minimum cover of 1 metre or with RCC covering for lower depth.
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5.4.8
In each cable run some extra length shall be kept at suitable point to enable one straight
through joints to be made, should the cable develop fault at a later stage. Control cable
termination inside equipment enclosure shall have sufficient lengths so that shifting of
termination in terminal blocks can be done without requiring any splicing.
5.4.9
Wherever cable pass through floor or through openings or other partitions, wall sleeves
with bushes having a smooth curved internal surface shall be supplied, installed and properly
sealed by the Vendor.
5.4.10 Wherever few cables are branching out from main trunk route perforated troughs of 50/75mm
width shall be used in place of cable tray/conduit for supporting these cables.
5.4.11 The erection work shall be carried out in a neat workman like manner. Vendor shall replace
RCC/Steel trench covers after the erection work in that particular area is completed or when
further work is not like to be taken up for some time.
5.4.12 For Directly Buried cables, construction of cable trench for cables shall include excavation,
preparation of sieved sand bedding, riddled soil cover, supply and installation of brick or
concrete protective covers, back filling and compacting, supply and installation of route
markers and joint markers. Before the cables are placed, the excavated portion shall be filled
with a layer of sand. This sand layer shall be leveled and the cables laid over it. The cables
shall then be covered with 150 mm sand on top of the largest diameter cable and sand shall be
lightly pressed. A protective covering with 70 mm thick bricks shall then be provided on top.
The remaining portion of the excavated trench shall then be back filled with soil, rammed and
leveled.
5.4.13 RCC cable route and RCC joint markers shall be provided wherever required. The voltage
grade of the higher voltage cables in route shall be engraved on the marker. Location of
underground cable joints shall be indicated with cable marker with an additional inscription
"Cable Joint'. The marker shall project 75mm above ground and shall be spaced at an interval
of 30 meters and at every change in direction. They shall be located on both sides of road
crossings and drain crossings. Top of cable marker/joint marker shall be sloped to avoid
accumulation of water/dust on marker.
5.4.14 Cable tags shall be provided on all cables at each end
(just
before
entering
the
equipment enclosure), on both sides of a wall or floor crossing, on each duct/conduit entry,
and at every 30 meters in cable tray/trench runs. Cable tags shall also be provided inside
the switchgear, motor control centers, control and relay panels etc. where a number of
cables enter together through a gland plate. Cable tag shall be of rectangular shape for
power cables and control cables. Cable tag shall be of 2mm thick aluminium with number
punched on it and securely attached to the cable by not less than two turns of 20 SWG GI wire
conforming to IS:280.
5.4.15 Proper slope shall be ensured in the cable trenches for draining of water. Cable entry to the
building from cable trench shall preferably be overhead (above plinth level) to avoid water entry
into the building. Depth of cable trenches shall be adequate to provide the required bending of
the largest sized cable at the terminating ends.
5.4.16 Where a cable route crosses a permanent road/railway line cables shall be drawn through hume
pipes or G.I. pipes. Pipes should be laid in a straight configuration. Filling criteria in any pipe
shall not be more than 40%.
5.4.17 Conduits shall be used for routing of cables (power / control) from cable trays to equipment/
junction boxes. Pipe sleeves shall be used for routing of cables between floors, road crossing,
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entry/exit from outside of building etc. All conduits/pipe shall have their ends closed by caps
till the cables are pulled. After the cables are pulled, the ends shall be sealed by suitable
sealing compound having fire withstand capability.
5.4.18 Each cable and cable tray shall be tagged with numbers. Cables and conduits shall be tagged at
their entrance, at every 30 m and exit from any equipment, junction box. The tags shall be of
aluminium or other approved means with the number punched on it and securely attached to
the cable. The location of cable joints, if any, shall be clearly indicated with cable marker with
an additional inscriptions "Cable-Joint" and "Cable Number".
5.4.19 The Vendor shall put ferrules on all control cable cores in all junction boxes and at all
terminations. The ferrules shall carry terminal numbers as per drawings. All ferrules shall be
coloured, plastic & interlocked type.
5.4.20 All cable entry points shall be properly sealed and
made vermin and dust proof. Unused
opening, if any, shall be effectively closed. Sealing work shall be carried out with approved fire
sealing compound.
5.4.21 Suitable extra length of cables shall be provided for all feeders for any future contingency.
Additional lengths shall be as under:
Power cables: one loop with permissible bending radius.

Control cables: 1 -1.5 metre
5.4.22 For vertical formations, the tray closest to the wall shall be considered as bottom most tray and
the other indicated in clause just above shall be followed. However where there is no clear
distinction of bottom/top trays, the order convenient for linking the horizontal and vertical
formations shall be followed.
5.5.0
Cable Terminations & Connections
5.5.1
The termination and connection of cables shall be done strictly in accordance with cable
termination kit manufacturer's instructions, drawings and/or as directed by Purchaser.
5.5.2
The equipment will be generally provided with undrilled gland plates for cables/conduit entry.
The Vendor shall be responsible for punching of gland plates, painting and touching up. Holes
shall not be made by gas cutting. The holes shall be true in shape. All cable entry points shall
be sealed and made vermin and dust proof. Unused openings shall be effectively sealed
by 2mm aluminium sheets.
5.5.3
Control cable cores entering control panel/switchgear/MCC/miscellaneous panels shall be

neatly bunched, clamped and tied with self-locking type nylon cable ties with de interlocking
facility to keep them in position.
5.5.4
The ferrules shall be indelible interlocking type and shall fit tightly on cores. Spare cores shall
be similarly ferruled with a suffix letter `S' along with cable numbers and coiled up after end
sealing.
5.5.5
All cable terminations shall be appropriately tightened to ensure secure and reliable
connections. Termination and connection shall be carried out in such a manner as to avoid strain
on the terminals. All cable entry points shall be properly sealed and made vermin and dust proof.
5.5.6
It is the responsibility of the Vendor to terminate the cables at motor terminals in correct
phase sequence to ensure the proper direction of rotation.
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If the cable end box or terminal enclosure provided on the equipment is found unsuitable and
requires major modification, the same shall be carried out by the Vendor at the discretion of
Purchaser.
5.5.7
Cables shall be installed without joints as far as practicable. Wherever a cable jointing operation
is necessary, the same shall be brought to the notice of the Purchaser before such jointing is
made. If however, jointing becomes necessary, it shall be made only by qualified cable jointer
and strictly in accordance with manufacturers recommendation.
5.5.8
Vendor shall carry out cable terminations at various electrical and electronic equipment
terminals.
5.5.9
When the equipment are provided with undrilled gland plates for cable/conduit entry into the
equipment, the Vendor shall perform all drilling & cutting on the gland plate and any minor
modification work required to complete the job at no extra cost to the Purchaser. The Vendor
shall prepare a drawing showing the holes for cable entry in the gland plate and take
Purchaser's approval before drilling holes. Gas cutting shall not be allowed.
5.5.10 Termination of cables shall be done as per termination drawings & interconnection diagrams
furnished to the Vendor. Looping of cores/ wires at terminals and, if required, between the
panels is to be done by the Vendor at no extra cost.
5.5.11 All cable entries in the equipment shall be sealed by cable glands.
5.5.12 Adequate length of cables shall be pulled inside the switchboards, control panels, terminal boxes
etc so as to permit neat termination of each core/conductor.
5.5.13 Power cable terminations shall be carried out in a manner such as to avoid strain on the
terminals by providing suitable clamps near the terminals.
5.5.14 Control cable cores entering switchboard or control panels shall be neatly bunched and strapped
with PVC perforated tapes/nylon ties and suitably supported to keep them in position at the
terminal block. All spare cores shall be connected to spare terminals wherever possible. If spare
terminals are not available, spare cores shall be neatly dressed and suitably taped at both ends.
5.5.15 Screened control cables of small cross sectional area, e.g. 0.5 sq mm, shall be terminated by
means of Maxi-termi termination system. Vendor shall ensure the availability of all tools, tackles
and accessories such as Maxi-termi guns, clips, wire etc. required for the termination of small
cross section screened control cables by this method. Compressed air supply for Maxi- termi
guns shall also be the responsibility of Vendor.
5.5.16 Individual cores of control cables shall have ferrules for identification. Ferrule numbers shall be
provided as per the control schemes and other related documents supplied by the Purchaser.
5.5.17 End sealing/termination of HT cables shall be done by means specified in the specification for
terminations. The system shall be suitable for types of cables specified and complete with stress
relief system.
5.5.18 Termination and jointing of aluminium / copper conductor power cables shall be done by means
of compression method using compression type aluminium / tinned copper lugs.
5.5.19 Copper conductor control cables shall be terminated directly into screwed type terminals
provided in the equipment. Wherever control cables are to be terminated by means of terminal
lugs, the same shall be of tinned copper compression type.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0


Electrical
Page : 15 of 26

Tender
Specification
for
Erection
&
5.5.20 Cable joint, not more than one in a circuit, shall normally be made at an intermediate point in the
straight run of the cable only when the length of the run is more than the standard drum length
supplied by the cable manufacturer. In such cases, when jointing is unavoidable, the same shall
be made by means of specified cable-jointing kit, subject to Purchaser's approval. Prior approval
of Purchaser shall be taken for deciding location of joint.
5.5.21 Junction boxes shall be used, wherever required, for jointing of control cables.
5.5.22 Termination and jointing shall generally conform to the requirements of IS: 1255 and shall strictly
conform to the recommendations of termination and jointing kit supplier.
5.6.0
Local Push Button Stations Installation

The control stations shall be either pedestal mounted or mounted on plant structures / wall near
each motor. The pedestal and frames / supports for mounting the control station shall be
supplied by the Vendor as per the instructions of the representative of Purchaser leveling
grouting and connecting up of the control stations including supply of the grouting bolts shall be
done by the Vendor. All the control stations shall be earthed.
5.7.0
Fire stop Installation
5.7.1
The Vendor shall take adequate care to ensure that cables are not damaged in any manner
during penetration system erection.
5.7.2
Wherever the floor / wall opening provided in the vicinity of penetration seals are larger of
smaller than that required for the cable fire penetrations, these openings size can be reduced or
increased in an approved manner by the Vendor using the same material as provided around
the opening and of the same thickness. Generally the wall in the power station comprises of
brickwork and the floors are made of RCC / steel work.
5.7.3
The work to be carried out under this specification shall be done under the supervision of
Purchasers representative.
5.7.4
Drawings for each penetration seal shall be prepared by the Vendor after verifying the actual
erection of cables at site and necessary approval shall be taken before proceeding with the
actual work. All work shall be carried out in accordance with the agreed quality plan and
approved drawings. The work shall be done to the satisfaction of the Purchaser and the
acceptance of the same shall be subject to site Purchaser approval.
5.7.5
The erection work shall be carried out in neat workmen like manner by skilled, experienced and
competent workmen.
5.7.6
Erection work at site shall be properly coordinated with other services. The work shall be carried
out under the supervision of Purchasers/Purchasers representative. The work shall be carried
out to the satisfaction of the Purchaser and acceptance of the work shall be subject to
Purchasers approval.
5.7.7
All materials being supplied or consumed during erection by the Vendor in the process of
erection work shall be of the best quality and according to the relevant standards. All materials
shall be inspected and approved by the Purchaser before the same is used for erection work.
Also regarding inspection of work, the Purchaser shall have the right to inspect at any stage
during erection, testing and commissioning.
5.7.8
The cutting and welding of building steel or fixing supports etc. shall be carried out by Vendor
after taking prior approval of Purchaser.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0


Electrical
Page : 16 of 26

5.7.9
Tender
Specification
for
Erection
&
Any work like chipping, breaking of existing structure like wall, floors, fabrications, any civil work
etc. shall be done after taking prior approval of the Purchaser.
5.7.10 After completion of the work, the Vendor shall remove all debris and take back all erection
implements, leftovers, surplus materials over and above the ordered quantity without any
financial implication to either party.
5.8.0
Civil works
All major civil works including equipment foundations, trenches will be carried out by other
Vendors on different scopes. However the following civil works, related to the electrical
installation work shall be done under the scope of this contract including supply of all necessary
materials. Scope of work shall also include all minor civil works such as the following:
a) Excavation, excavation as required for buried cable, (and also for ground connections, hume
pipe sleeves etc. where necessary) providing sand bedding, brick works, precast concrete
slabs, backfilling and compaction etc. including supply of necessary materials for such civil
works.
b) Providing necessary Cement-sand mortar on top of roof for fixing roof conductors of
lightning protection system, earthing conductors etc.
c) Civil works like drilling, chipping and punching holes and openings in concrete floors, slabs,
brick walls.
d) Providing concrete/brick work for reducing/covering floor/wall opening for cable route & fire
stop sealing system.
5.9.0
Illumination
a) The Bidder shall arrange necessary testing equipment such as test lamp, buzzer, 500 volt
meggar, earth resistance tester, lux-meter etc. as required.
b) Continuous rows of fluorescent tubes shall be mounted on a continuous M.S. angle for each
row of lights.
c) Bracket for fixture mounting shall be fabricated at site from conduits/angles/channels etc.
Necessary reducers to suit the fixtures shall be provided. The fixing shall be strong enough
to withstand vibration and high wind velocity. If a roof over platform is available, the fixture
can be pendant mounted.
d) Floodlights shall be mounted on steel frame. Fixing holes shall be provided with slot for
adjusting the mounting angle/ direction. Necessary spring washer shall be provided along
with the bolts.
e) Terminal connection to the floodlight shall be made through PVC coated flexible metallic
conduits.
f)
The fixtures after erection shall be marked up indelibly with corresponding circuit number for
easy identification of lamp circuit.
g) Erection of Street Lighting poles together with all its accessories including civil foundation
work, installing lighting fixture, wiring and cabling work are included within scope of Bidder.
h) Erection of Flood Lighting Towers including civil foundation work shall be done by Bidder
i)
Bidder shall also mount assembled fixtures, outdoor & lockable type isolating switch cubicle,
install necessary cabling and wiring and make connections.
j)
For indoor Lighting , following checks shall be carried out
Doc. No. 1113112-ME-SPC-700-004, Rev. 0


Electrical
Page : 17 of 26

Tender
Specification
for
Erection
&
Check dressing of cable.

Measurement of lux level at various places.
Check accessibility for replacement of lamps.
Checking for black spots or poor visibility near operating and indicating equipments.
Check for mechanical protection of cables.
Checking for adequacy of emergency DC light.
Checking for starting system of periphery lighting.
Check for auto switching of battery supply on failure of AC.
Checking of earthing of light panel, socket boards light fittings.
Checking of type of fittings wrt specification at various locations.
Check adequacy of support of fittings.
Check water tightness of outdoor located panels
k) For outdoor Lighting , following checks shall be carried out
Check lux level of general lighting.

Check for visibility of insulators, bushings and indicating instruments of transformers,
breaker and isolator cabinets etc. during night.
Check for adequacy of escape light during night after failure of general light.
Check for proper painting of lighting supporting structures.
Check for automatic switching of light
Check for earthing connections on light fittings and other control accessories.
Check for mechanical protection of cables.
IR measurement of lighting cables.
5.10.0 PDB/ACDB / DCDB / MLDB

Scope under equipment erection of items specified shall include:
IR test before and after HT test.

HV test by HV megger.
Checking for functions of components for each module.
Checking for interchangeability of similar components.
Checking of tightness of earth connection.
Testing and calibration of all indicating meters.
Check output of each feeder after energisation
5.11.0 AC Motors
Scope under equipment erection of items specified shall include:
IR test of stator and rotor windings.

Heating of both windings upto the permissible temp. limit from heating curve (only for HT
motors).
Ensure that checking / testing of associated switchboard, cables, relays / meter interlocking
as mentioned in relevant chapters are completed.
Check tightness of cable connection.
Winding resistance measurement of stator and rotor.
Checking continuity of winding.
Check tightness of earth connections.
Check space heaters and carryout heating of winding (if required).
Check direction of rotation in decoupled condition during kick start.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0


Electrical
Page : 18 of 26

Tender
Specification
for
Erection
&
Measure no load current for all phases.

Measurement of temperature of body during No-load and load conditions.
Check for tripping of motor from local / remote switches and from electrical
technological protection including differential protection.
Checking of vibration (if required)
Checking of noise level (if required).
During load running, measurement of stator and bearing temperatures (if applicable) for
every half an hour interval till saturation comes.
Checking tightness of foundation bolts.
Check operation of speed switch (if there).
Check continuity of temp. detectors.
Check alignment, paralleling of shafts, level of lubricating oil etc. as per manufacturers
manual.
Check contact of slip ring brush and measure brush pressure (150-200 gm/sq.cm).
For CACW drive check cooling water and system / piping, availability of pressure cleaning
and pressure testing of pipelines etc.
Check for polarization index of stator windings R10 / R1 by motorized megger. (The value
should not be less than 2.0). R60/R10 absorption co-efficient shall not be less than 1.5
Dielectric test (only for HT motors).
Measurement of open circuit rotor winding voltage for slip ring motor.
For actuator drives following shall be checked / tested.
o Visual and dimensional
o Hydraulic pressure for valves
o IR and operation of limit switches
o Winding resistance
5.12.0 Field Instruments installation

5.12.1 Calibration and installation of the following types of instruments and accessories as per
instrument hookup diagram & the P&ID. Refer the hook up drawing and the P&I D enclosed
along with the tender. The bidder shall have to submit and get approval from Engineer in charge
(site) for calibration and installation of the following instruments.
Electromagnetic flow meter
Ultrasonic level transmitter
Junction box
Level Interlocks for storm water pumps
5.12.2 The storm water pumps shall be started manually from the MCC and from Local push button
station (LPBS) located near the pump. The pumps shall also be started on storm water pit high
level interlock and shall be stopped on storm water pit low level interlock. High level and low
level interlocks shall be realized through wiring in the Junction box interconnecting the alarm
contacts of the level transmitter and the LPBS of the storm water pumps. And for this purpose, a
Junction box is proposed to be installed near each of the storm water pit.
5.12.3 Each pump is interlocked with the contact outputs of the respective/independent level
transmitter. Set points for the alarm contacts in the level transmitters are adjustable at site. In the
pit where three pumps are available, the high level settings shall be done such that the Pump
1 will start first on reaching the high level and then followed sequentially by other two pumps in
the pit. Similarly the low level settings shall be done such that the Pump 3 will stop first on
reaching low level and then followed sequentially by other two pumps in the pit.
5.12.4 Configuration of the Instruments including the set points for the level alarms in the ultrasonic
level transmitter shall be configured by the bidder at site as per the requirement. During
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Electrical
Page : 19 of 26

Tender
Specification
for
Erection
&
commissioning, if any requirement arises for the recalibration of the instruments, shall be done
on free of cost by the bidder.
5.12.5 The BOM of instruments and the Junction boxes is furnished in ANNEXURE-B. Refer Instrument
hook up diagram (Dwg No.: 40-1113112-I-103) for the installation details and all the required
mounting/fixtures accessories shall be as per the dwg nos. 10-1113112-M-002, 10-1113112-M003, 10-1113112-M-004 & 10-1113112-M-005 enclosed along with the tender. Refer CABLE
LIST (Doc No. 40-1113112-I-258) enclosed along with the tender for the cabling.
5.13.0 Installation Requirements
5.13.1 The installation details given here in the specification are the guide lines and the installation shall
be done as per the industrial standards. Owner / consultant reserve the right to approve the
suitable location of the field mounted junction boxes.
5.13.2 The actual location of the instruments shall be decided by the bidder depending on the site
conditions considering the layout and maintenance aspects.
5.13.3 The bidder shall get prior approval of the Owner / consultant before any installation work starts.
If any work is carried out by the bidder before prior approval from Owner / consultant and
modification is sought by Owner / consultant later, then the work will be redone by the bidder
without any cost / material implications to the Owner / consultant.
5.13.4 Supply of local supports / mounting bracket with necessary fixtures for all the equipment
supplied.
6.0.0
Earthing installation
6.1.0
Earthing installation shall be carried out as per IS 3043. Bare conductors to be installed below
grade spaced in a grid pattern. Each junction of the grid shall be bonded by an electric welding
process.
6.2.0
Electronic panels and equipment shall be grounded utilising an insulated copper ground wire
terminated at separate earth electrode.
6.3.0
All ground wires installed in conduit shall be insulated. Bare ground wires shall penetrate
concrete through a PVC sleeve.
6.4.0
Equipment shall be generally be furnished with two separate ground pads with tapped holes,
bolts, nuts and spring washers etc. Equipment ground connections, after being checked and
tested shall be coated with anti-corrosive paint.
6.5.0
Metallic frame of all electrical equipment shall be earthed by two separate and distinct
connections to earthing system, each of 100% capacity. Steel RCC columns, metallic stairs,
hand rails etc. of the building housing electrical equipment shall be connected to the nearby
earthing grid conductor by one earthing. Metallic sheaths, screens, and armour of all multi core
cables shall be earthed at both ends. Sheaths and armour of single core cables shall be earthed
at switchgear end only unless otherwise instructed by Purchaser. Every alternate post of the
metallic fence shall be connected to earthing grid by one GS flat and gates by flexible lead to
the earthed post. Railway tracks within the plant area shall be bonded across fish plates and
connected to earthing grid at several locations.
6.6.0
For prefabricated cable trays, a separate ground conductor shall run along the entire length of
cable tray and shall be suitably clamped on each cable
tray at periodic intervals. Each
continuous laid out lengths of cable tray shall be earthed at minimum two places by G.S.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0


Electrical
Page : 20 of 26

Tender
Specification
for
Erection
&
flats to Purchaser's earthing system, the distance between earthing points shall not exceed 30
metre. Wherever earth mat is not available Vendor shall do the necessary connections by
driving an earth electrode in the ground.
6.7.0
Connections between earth leads and equipment shall normally be of bolted type. Contact
surfaces shall be thoroughly cleaned before connections.
6.8.0
All ground conductor connections shall be made by electric arc welding and all equipment earth
connections shall be made by bolting with the earthing pads through flexible insulated cable
leads.
6.9.0
Resistance of the joint shall not be more than the resistance of the equivalent length of
conductor. For rust protection the welds should be treated with red lead compound and
afterwards thickly coated with bitumen compound.
6.10.0 Earthing conductors buried in ground shall be laid minimum 600 mm below grade level unless
otherwise indicated in the drawing. Earthing conductors crossings the road shall be installed at
1000 mm depth and where adequate earth coverage is not provided it shall be installed in hume
pipes. Earthing conductors embedded in the concrete floor of the building shall have
approximately 50mm concrete cover.
6.11.0 A minimum earth coverage of 300mm shall be provided between earth conductor and the
bottom of trench/foundation/underground pipes at crossings. Wherever earthing conductor
crosses on runs at less than 300mm distance along metallic structures such as gas, water,
steam pipe lines, steel reinforcement in concrete, it shall be bonded to the same.
6.12.0 Earthing conductors along their run on columns, walls, etc. shall be supported by suitable
welding/cleating at interval of 1000mm.
6.13.0 Earth pit shall be constructed as per Purchaser's drawing. Electrodes shall be embedded below
permanent moisture level. Minimum spacing between electrodes shall be 6000mm. Earth pits
shall be treated with salt and charcoal. Earthing conductor around the building shall be buried in
earth at a minimum distance of 1200mm from the outer boundary of the building.
6.14.0 On completion of installation, continuity of earth conductors and efficiency of all bonds and
joints shall be checked. Earth resistance at earth terminations shall be measured in presence of
Purchasers representatives. An equipment required for testing shall be furnished by Vendor.
6.15.0 Earthing of cabling system
7.0.0
Armour of the HT cables and LT single core cables shall be earthed only at one end of
cable.
Armour of other cables shall be earthed at both ends of cable.
Screen of HT power cables shall be earthed at one end only.
Screen of C&I screened control cables shall be earthed at one end.
Screen of electronic earthing system cables shall be earthed as per the requirements to be
furnished to the Vendor during contract stage.
PAINTING& GALVANISING
Painting shall be carried out by approved process. After preparation of the under surface the
equipment shall be painted with epoxy based paint. Oil resistant paint shall be applied as
required. The final thickness of paint film on steel shall not be less than 100 microns and shall
not be greater than 150 microns. Sufficient quantity of touch-up paint shall be furnished for
application at site. Final shade shall be 631 (light grey) of IS 5.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0


Electrical
Page : 21 of 26

Tender
Specification
for
Erection
&
The Vendor shall paint steel fabrications at site with two (2) coats of zinc chromate yellow primer
followed by two (2) final coats of epoxy anti corrosive paint. The prices for such painting shall be
included in the rates quoted for relevant items.
All damaged painted surfaces shall be cleaned and coated with two (2) coats zinc chromate
yellow paint followed by a finishing epoxy, anti-corrosive paint coat of approved colour. All
damaged galvanised surfaces shall be coated with cold galvanising paint. All equipment after
erection shall be touched-up where required with coats of finishing paint. All primer & paint
including touch-up paints shall be supplied by the Vendor.
Galvanising of steel components and accessories shall conform to IS:2629 & IS:2633.
Additionally galvanizing shall be uniform, clean, smooth, continuous and free from acid spots.
Should the galvanizing of the samples be found defective, the entire batch of steel shall have
to be regalvanised at Vendor's cost after pickling.
Wherever non-galvanised part are erected, they shall be brushed before giving one coat of
red lead primer, one coat of oil primer followed by two coats of aluminium alloy paint.
8.0.0
TESTING & COMMISSIONING
8.1.0
Field inspection shall be carried out as per approved Field Quality Plan.
8.2.0
On completion of erection work, the Vendor shall request the Purchaser for inspection & test.
The Purchaser shall arrange for joint inspection of the installation for completeness and
correctness of the work. Any defect pointed out during such inspection shall be promptly
rectified by the Vendor. The installation shall be then tested and commissioned in presence of
the representative of Purchaser and put on trial run for stipulated contract period.
8.3.0
The Vendor shall arrange for inspection of his installation work by Electrical Inspector and shall
obtain necessary approval certificate for his installation work. Any modification work required by
Electrical Inspector must be undertaken by the Vendor at his own cost. All rectification, repair or
adjustment work found necessary during inspection, testing, commissioning and trial run shall be
carried out by the Vendor without any extra cost.
8.4.0
Following successful inspection and testing, all the equipment shall be commissioned and put on
trial run in a manner mutually agreed upon based on the commissioning schedule of main plant.
The Vendor shall assist the Purchaser in commissioning and trial run with men and material as
required and / or as directed by the Purchaser .The Vendor shall carry out the
commissioning tests and checks after erection at site as per applicable standards and also as
recommended by the Manufacturers.
8.5.0
The following tests shall be specifically carried out for the complete Lighting & small power
installation.
Insulation resistance
Testing of earth continuity path
Polarity test of single phase switches
Resistance to earth test when the switch is ON and consuming device is in circuit, both
poles connected together.
Insulation resistance between poles with consuming devices removed and switches ON
Doc. No. 1113112-ME-SPC-700-004, Rev. 0


Electrical
Page : 22 of 26

Tender
Specification
for
Erection
&
ANNEXUREA: BILL OF QUANTITTIES FOR CABLES

I.
LOW VOLTAGE POWER CABLES

Quantity
in M
Sl.No.
Item Description
1.1kV earthed grade, multi stranded, compacted aluminium conductor, XLPE

insulated, PVC inner sheathed (extruded), armoured, overall FRLS PVC
sheathed (extruded) cables confirming to IS 7098, Part-I.
1.
3CX185 Sq.mm.
2300
2.
3CX120 Sq.mm.
1800
3.
3CX95 Sq.mm.
1000
4.
3CX50 Sq.mm.
4900
5.
2CX4 Sq.mm.
2700
II.
LOW VOLTAGE CONTROL CABLES

Quantity
in M
Sl.No.
Item Description
1.1kV earthed grade, multi stranded, compacted copper conductor, PVC

insulated, PVC inner sheathed (extruded), armoured, overall FRLS PVC
sheathed (extruded) cables confirming to IS 1554, Part-I.
1.
4CX2.5 Sq.mm
7750
2.
3CX1.5 Sq.mm
1000
III.
INSTRUMENTATION CABLES
Quantity
in M
Sl.No.
Item Description
1100 V Grade multiple pair, overall shielded, multi stranded copper

conductor, PVC insulated, PVC inner sheathed (extruded), overall FRLS
PVC sheathed (extruded) armored instrumentation cable
1.
2P x 0.5 Sq.mm
9000
Note : Quantities indicated are for bidding and evaluation purposes. Unit (per meter) adjustment prices
shall be provided for any increase /decrease in quantities during/subsequent to award of contract. Bidder
shall also furnish unit rate for cables one size higher and one size lower than what is indicated so that
the same can be used during engineering if required.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0


Electrical
Page : 23 of 26
726.6 MW Combined Cycle Power Project,

Pallatana, Tripura
Tender Specification for Erection & Commissioning of Rain water & Deep
Tube well System
ANNEXUREB:
I.BOQ FOR ELECTRO MAGNETIC FLOW METER
SL.
NO.
2
3
4
SERVICE
TAG NO.
FLUID/
STATE
DTWP-01 & DTWP-02 FLOW TO

RESERVOIR
WTR
00GUB05CF101
DTWP-03 FLOW TO
RESERVOIR
WTR
00GUB07CF101
DTWP-04 FLOW TO
RESERVOIR
00GUB13CF101
DTWP-05 & DTWP-06 FLOW TO

RESERVOIR
00GUB15CF101
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

OPERATING VALUE
DESIGN VALUE
PRES
(kg/cm2(g))
TEMP
(Deg C)
PRES
(kg/cm2(g))
TEMP
(Deg C)
1.5
31.00
2.5
50.00
RANGE
m3/Hr
0.00
NOM.PIPE
SIZE(NB)
MM
170.00
150
WTR
WTR
1.5
1.5
1.5
46.10
46.10
46.10
2.5
2.5
2.5
FICHTNER INDIA
50.00
50.00
50.00
Section 3
Electrical
0.00
0.00
0.00
PIPE
MATERIAL /
RATING
85.00
150
85.00
150
170.00
150
ACCESSORIES
To be
furnished
later
Matching
/Counter flanges
bolts and nuts
reqd for the
piping to be
provided
-do-
-do-
-do-
-do-
-do-
-do-
REMARKS
Page 24 of 26

Pallatana, Tripura
Tube well System
II. BOQ FOR LEVEL TRANSMITTER (ULTRASONIC)
SL.
NO.
TAG NO.
SERVICE
FLUID/
STATE
OPERATING VALUE
DESIGN VALUE
PRES
(kg/cm2(g))
TEMP
(Deg C)
PRES
(kg/cm2(g))
TEMP
(Deg C)
RANGE
PROCESS
CONNECTION
& RATING
ACCESSORIES
REMARKS
mm
00GUA10CL101
STORM PIT 1 LEVEL A
WTR
1.02
31.00
1.25
50.00
10000
100 NB, 150#,

SORF
100 NB FLANGE WITH

BOLTS & NUTS
00GUA10CL102
STORM PIT 1 LEVEL B
WTR
1.02
31.00
1.25
50.00
10000
100 NB, 150#,

SORF
100 NB FLANGE WITH

BOLTS & NUTS
00GUA10CL103
STORM PIT - 1 LEVEL C
WTR
1.02
31.00
1.25
50.00
10000
100 NB, 150#,

SORF
100 NB FLANGE WITH

BOLTS & NUTS
00GUA20CL101
STORM PIT 2 LEVEL A
WTR
1.02
31.00
1.25
50.00
10000
100 NB, 150#,

SORF
100 NB FLANGE WITH

BOLTS & NUTS
00GUA20CL102
STORM PIT 2 LEVEL B
WTR
1.02
31.00
1.25
50.00
10000
100 NB, 150#,

SORF
100 NB FLANGE WITH

BOLTS & NUTS
00GUA30CL101
STORM PIT 3 LEVEL A
WTR
1.02
31.00
1.25
50.00
10000
100 NB, 150#,

SORF
100 NB FLANGE WITH

BOLTS & NUTS
00GUA30CL102
STORM PIT 3 LEVEL B
WTR
1.02
31.00
1.25
50.00
10000
100 NB, 150#,

SORF
100 NB FLANGE WITH

BOLTS & NUTS
00GUA30CL103
STORM PIT - 3 LEVEL C
WTR
1.02
31.00
1.25
50.00
10000
100 NB, 150#,

SORF
100 NB FLANGE WITH

BOLTS & NUTS
00GUA40CL101
STORM PIT - 4 LEVEL A
WTR
1.02
31.00
1.25
50.00
10000
100 NB, 150#,

SORF
100 NB FLANGE WITH

BOLTS & NUTS
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

FICHTNER INDIA
Section 3
Electrical
Page 25 of 26

Pallatana, Tripura
Tube well System
III. BOQ FOR JUNCTION BOX

SL
no
Tag
Description
Location
Qty
JB01
24 Way Junction box
Near Storm water pit 1
JB02
24 Way Junction box
JB03
24 Way Junction box
JB04
12 Way Junction box
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

FICHTNER INDIA
Section 3
Electrical
Page 26 of 26

Tender
Specification
for
Erection
&
VOLUME II
SECTION - 4
LIST OF TENDER DRAWINGS
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Vol 2 sec 4 Dwg_E&C_Rev.0.doc
List of Tender Drawings
Page : 1 of 3

Tender
Specification
for
Erection
&
SECTION 4
LIST OF TENDER DRAWINGS
SL.
NO.
DRAWING NO.
TITLE
1.
PE-DG-319-100-M001
R9A
2.
00-1113112-M-001
R2
P&ID Rain water harvesting system and

Deep tube well piping system
3.
10-1113112-M-002
R1
General Arrangement & Layout for Storm

water pit -1
4.
10-1113112-M-003
R1

water pit -2
5.
10-1113112-M-004
R1

water pit -3
6.
10-1113112-M-005
R1

water pit -4
7.
20-1113112-M-010
R0
General Arrangement - Deep Tube Well

Pump House
8.
00-1113112-M-011
R0
Piping Layout for Tube Well-1,2 and Storm

Water Pit-1 to Raw Water Reservoir
9.
00-1113112-M-012
R0
Piping Layout for Tube Well-3 and Storm

10.
00-1113112-M-013
R0
Piping Layout for Tube Well-4 and Storm

11.
00-1113112-M-014
R0
Piping Layout for Tube Well-5,6 and Storm

12.
20-1113112-M-015
R0
Pipe Support Details - Tube Well-1,2 and

Storm Water Pit-1
13.
20-1113112-M-016
R0
Pipe Support Details - Tube Well-3 and

Storm Water Pit-4
14.
20-1113112-M-017
R0
Pipe Support Details - Tube Well-4 and

Storm Water Pit-2
15.
20-1113112-M-018
R0
Pipe Support Details - Tube Well-5,6 and

Storm Water Pit-3
16.
10-1113112-E-001
R0
Earthing layout for pump house
17.
10-1113112-E-002
R0
Lighting layout for pump house
18.
10-1113112-E-003
R0
Cable routing layout for Rain water

harvesting and Deep tube well motors
19.
10-1113112-E-004
R0
Lighting layout for Deep Tube wells
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Plot Plan
Page : 2 of 3

Tender
Specification
for
Erection
&
SL.
NO.
DRAWING NO.
TITLE
20.
10-1113112-E-005
R0
Earthing layout for Deep Tube wells
21.
40-1113112-I-103
R0
Instrument hook up diagram
22.
40-1113112-I-258
R0
Cable list
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Page : 3 of 3

Tender
Specification
for
Erection
&
VOLUME II
SECTION 6
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Vol 2 sec 6 QAP_E&C_Rev.0.doc
Quality Assurance Programme
Page : 1 of 11

Tender
Specification
for
Erection
&
SECTION 6
The Bidder shall adopt suitable quality assurance programme to ensure that the equipment and services
under the scope of contract whether manufactured or performed within the Bidders works or at his subsuppliers premises or at the employers site or at any other place of work are in accordance with the
specification. Such programme shall be outlined by the Bidder and shall be finally accepted by the
employer / authorized representative after discussion. The QA programme shall be generally in line with
ISO-9001.
GENERAL REQUIREMENT
All materials, components and equipments covered under this specification shall be procured,
manufactured, erected, commissioned, and tested at all stages, as per a comprehensive Quality
Assurance Programme. It is the contractors responsibility to draw up and implement such programme
duly approved by the Owner. The detailed Quality Plans for manufacturing (MQP) and field activities
(FQP) shall be drawn up by the Bidder and will be submitted to the Owner for approval in format no.
CQA/III Rev1 and CQA/IV Rev1 respectively. Bidder shall submit the schedule of submission of
MQPs, and FQPs along with the bid.
Manufacturing Quality Plan (MQP) will detail out for all the components and equipments, various
test/inspection, to be carried out as per the requirements of this specification and standard mentioned
therein and quality practices and procedures followed by Contractors/sub-contractors Quality Control
Organization, the relevant reference documents and standards, acceptance norms etc. during all
stages of manufacturing including raw material procurement, in-process manufacturing, assembly,
and final testing/performance testing.
Field Quality Plans (FQP) will detail out for all the equipments, the quality practices and procedures
etc. to be followed by the contractors site Quality Control Organization, during various stages of site
activities starting from receipt of materials/equipment at site.
The Bidder shall also furnish copies of the reference documents/plant standards/acceptance
norm/test and inspection procedures etc. as referred in Quality Plans along with Manufacturing and
Field Quality Plans. These Quality Plans will be subject to Owners approval without which
manufacturer and erector shall not proceed with the manufacturing and erection activities. These
approved documents shall form a part of the Contract. In these approved Manufacturing and Field
Quality Plans, Owner shall identify Customer Hold Points (H), e.g. test/checks which shall be carried
out in presence of the Owners representative or its nominated outside inspection agency and
beyond which the work will not proceed without consent of Owners representative or its nominated
outside inspection agency in writing. All deviations to this specification, approved quality plans and
applicable standards must be documented and referred to Owner along with technical justification for
approval and dispositioning.
The contractor shall submit to the Owner Field Welding Schedule (FWS) in format no. CQA/IX/R0 for
field welding activities. The field welding schedule shall be submitted to the Owner along with all
supporting documents like welding procedures, heat treatment procedure,
NDT procedures, etc. Bidder shall submit the schedule of submission of FWS along with the bid.
The contractor shall have suitable Field Quality Organization with adequate manpower at Owners
site, to implement the Field Quality Plans (FQP) and Field Quality Management System for site
activities .The contractor shall submit the details of the proposed FQA set up (organizational structure
and manpower) for Owners approval. The FQA set up shall be in place at least one month before the
start of site activities.
No material shall be dispatched from the manufacturers works before the same is accepted,
subsequent to pre-dispatch and final inspection including verification of records of all previous
Doc. No. 1113112-ME-SPC-700-004, Rev. 0
Page : 2 of 11

Tender
Specification
for
Erection
&
tests/inspection by Owners representative or their authorized outside inspection agency and

authorized for dispatch by issuance of Material Dispatch Clearance Certificate (MDCC).
All materials used for equipment manufacture including casting and forging etc. shall be of tested
quality as per relevant codes/standards. Details of results of the test conducted to determine the
mechanical properties, Chemical properties, details of Heat Treatment procedure recommended and
actually followed (H T Chart), results of NDT tests conducted shall be recorded on the test certificate.
All tests shall be carried out as per applicable material specification, code requirement and as
specified in this specification.
All welding and brazing shall be carried out as per procedure drawn and qualified in accordance with
requirement of ASME Section IX or any other equivalent International Standard acceptable to the
Owner. All welding and brazing procedures shall be submitted to the Owner or its authorized outside
inspection agency for approval prior to carrying out the welding/brazing.
All Welders, Brazers, and Welding Operators employed on any part of the contract either at the
Contractors/ sub- contractors works or at site or elsewhere shall be qualified as per ASME Section
IX or any other equivalent International Standards acceptable to the Owner. Welding Procedure
Qualification, Welders Qualification, Brazing Procedure Qualification and Brazers Qualification test
results shall be furnished to the Owner or its authorized outside inspection agency for approval.
However, where required by the Owner, tests shall be conducted in presence of Owners
representative or its authorized outside Inspection agency.
All statutory and safety requirements for the equipments/systems shall also be complied with.
Unless otherwise proven and specifically agreed with the Owner, Welding of dissimilar materials and
high alloy materials shall be carried out at shop only.
No welding shall be carried out on cast iron components for repair and up gradation of casting.
All the heat treatment results shall be recorded on time temperature Chart and verified with
recommended regimes.
All non-destructive examination shall be performed in accordance with written procedures as per
International Standards. The NDT operators shall be qualified as per American Society of NonDestructive Testing or any other International Standard acceptable to Owner. The result of NDT shall
be recorded in a report, which includes details of methods and equipment used, job identification no.
job detail, identification of personnel performing the test, result of evaluation and correlation of the test
report with the job
All bar stock/forging of diameter equal to or greater than 50 mm shall be ultrasonically tested. In
general all plates of thickness 40 mm and above used for non pressure application and plates of
thickness 25 mm and above used for pressure parts shall be ultrasonically tested unless otherwise
specified in respective specification.
The Bidder shall list out all major equipments/items/components to be manufactured in house as well
as to be procured from their suppliers and sub-suppliers. All suppliers and their sub-suppliers
proposed by the contractor for procurement of major equipments and components including casting,
forging, semi-finished and finished items /equipments etc. list of which shall be drawn up and
submitted by the Bidder along with the bid and shall be subject to Owners approval.
The Bidder shall submit their proposal for approval of suppliers and their sub-suppliers prior to
placement of orders including details of manufacturing facilities established at the respective works,
their Quality Management System followed, and experience list in manufacturing and supply of items
for which proposal has been submitted for approval along with their own technical evaluation of
proposed manufacturer.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Page : 3 of 11

Tender
Specification
for
Erection
&
The contractor shall have their own QA and Inspection organization for carrying out inspection at
manufacturers works and at site as per approved Quality Plan. In case , the contractor proposes to
engage third party Inspection Agency for carrying out inspection on his behalf, the same shall be
done only after obtaining due approval from the Owner/ Owner well in advance.
Owner reserves the right to carry out quality audit and quality surveillance of the system and
procedures of the contractor and their sub-contractors Quality Management and control activities. The
contractor shall provide all necessary assistance to enable the Owner carry out such audit and
surveillance.
The contractor shall carry out an inspection and testing of component and equipment during
manufacture at his work and at his sub-suppliers work and at site to ensure to ensure the compliance
with the drawing, quality, conformance to functional and performance requirements of the parts and
equipments.
Contractor shall carry out all tests/inspection required to establish that the items/equipments conform
to the requirements of the specification and relevant codes/standards specified in the specification , in
addition to carrying out tests as per the approved Quality Plans. Quality audit/ surveillance/approval of
the test results, inspection and acceptance of material will not, however, prejudice the right of the
Owner to reject the equipment if it does not comply with the Specification when erected or does not
give complete satisfaction in service and the above shall in no way limit the liabilities and
responsibilities of the Contractor in ensuring complete conformance of the materials/equipments
supplied to relevant specification, standard, data sheet, drawing etc.
For all spares and replacement items, the quality requirements as agreed for the supply of main
equipments shall be applicable.
Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the
approval of the Owner/ authorized Inspection Agency.
INSPECTION AND TESTING
The Bidder shall conduct all tests required to ensure that the equipment/components/parts being
manufactured shall conform to the requirements of the specification, applicable codes and standard,
manufacturers plant standard and approved General Arrangement Drawing and Data sheet.
The inspection and testing requirements of equipments mentioned in the specification may be
inadequate for the intended purpose, but the Bidder shall ensure proper inspection and testing of
equipment for its intended use.
The inspection and testing requirements of equipments, which are not specifically mentioned in the
specification shall also be inspected and tested as per applicable National or International standard.
The Owner Inspection Engineer or their nominated Inspection Agency shall be given full access to the
shop where the equipment is being manufactured or tested. The Owner shall be notified well in
advance to facilitate inspection of equipments at identified stage of inspection as per approved
Quality Plan (Inspection & Test Plan).
The particulars of the proposed Factory Acceptance tests and the test procedures shall be submitted
to the Owner for approval along with the Quality Plan prior to conducting the tests.
All materials, castings and forging shall be of tested quality and test certificates shall be made
available. If manufacturers test certificates are not available, Bidder shall arrange for testing of
materials as per applicable specification/ standard.
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Page : 4 of 11

Tender
Specification
for
Erection
&
In addition to the above, all major components shall be subjected to inspection of raw materials,
in- process inspection, final inspection, dimensional check, and NDT tests etc as per approved
Quality Plan (Inspection and Test Plan).
Reports of all shop tests shall be submitted to the Owner Inspection Engineer or their nominated
inspection agency prior to dispatch for review and approval.
Bidder shall not seek any deviation and ensure compliance to all inspection and testing requirements
mentioned in this section and the applicable section of the technical specification. If any test is not
expressly mentioned in the specification but subsequently considered necessary the same shall also
be carried out by the Bidder without any cost implication to Owner.
Piping and Fitting:All raw materials used shall have co-related mill test certificate meeting mandatory and
supplementary requirements of material specification.
All pipe lengths shall be subjected to 100% Ultrasonic examination or hydraulic tests and UT/RT on
longitudinal welds at the tube mill.
All mother pipes used for fittings shall be subjected to a hydraulic test or an Ultrasonic test at the tube
mill. Raw material of all forged fittings shall be ultrasonically tested. Forged fittings shall also be
ultrasonically tested.
Welded and cast fittings, if any, shall be subjected to suitable NDT as per application standards.
However, as a minimum 100% RT shall be carried out an all alloy steel fittings and on carbon steel
fittings for use above 71 bar design pressure.
The edge preparation for shop and site welds shall be checked by MT/PT However edge preparation
in stainless steel / alloy steel shall be subjected to a Dye Penetrant check.
Thickness for pipe bends shall be checked by ultrasonic or other acceptable methods on sample
basis for high pressure applications. Outer surface of bends shall be free from wrinkles and shall be
subjected to magnetic particle examination / PT.
WPS and Welders qualified as per ASME Sec IX shall be used for fabrication, if any.
Bidder shall established suitable facilities for storage, preservation, baking and holding of electrodes as
per electrodes manufacturers recommendations. All welders employed for welding work shall be
provided with suitable electrode holders with thermostat controlled heating arrangement so that temp of
electrodes can be maintained above ambient condition to avoid moisture pick up.
All electrodes and welding wires approved by Owner shall be used for fabrication.
Non- destructive examination of welds shall be carried out after post weld heat treatment, if any.
Non-destructive examination of welds shall be carried out in accordance with the relevant
design/manufacturing codes and statutory requirement, wherever applicable shall also be complied
with.
For all other pipes not covered above shall be subjected 100% MT/PT in case of under ground pipes
and 10% MT/PT in case of piping above the ground. Further, 10% of butt welds of all piping shall be
subjects to RT.
Hardness survey of welds shall be carried out on alloy steel/ stainless steel piping after PWHT. (100%
Hardness survey of welds on P92, P91, X20 & X22 material grade piping).
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Page : 5 of 11

Tender
Specification
for
Erection
&
For welds in P92, P91, X20 & X22 materials, only Induction type of hating shall be deployed for heat
treatment.
QA & I CO ORDINATION PROCEDURE
The QA & I co-ordination procedure shall include the following which will be discussed and finalized
with the successful bidder:
Procedure for approval of suppliers and sub-suppliers.

Procedure for approval of MQP, FQP and FWS
Procedure for inspection of equipment.
Procedure for issue of Material Dispatch Clearance Certificate (MDCC).
Procedure for dispositioning of Non-conformity/deviation.
Quality Audit
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Page : 6 of 11

Pallatana, Tripura
MANUFACTURING QUALITY PLAN
NAME & ADDRESS OF

MANUFACTURERS WORKS
Tel No:
Fax No:
E- Mail:
SL
NO
COMPONENT/
OPERATION
CHARACTERISTI
CS
MANUFACTURER/
SUBCONTRACTOR
MAIN
CONTRACTOR
Tender Specification for Erection & Commissioning of Rain Water

Harvesting / Deep Tube Well System
ITEM:
QP NO:
REV.NO.
DATE:
PAGE:. of.
SUB-SYSTEM:
CATEGORY
OF
CHECK
#
4
TYPE
OF
CHEC
K
PROJECT
:
PACKAGE
:
CONTRACT NO.:
MAIN-CONTRACTOR:
QUANTU
M OF
CHECK
M C
A
REFERENC
E
DOCUMENT
ACCEPTANC
E NORMS
FORMAT
OF
RECORD
INSPECTIO
N AGENCY
M C A
REMARKS
**10
11
D*
LEGEND:D* Records identified with tick () shall be essentially included by contractor in

quality documentation.
For Office Use

Reviewed by
Approved by
SIGN
SIGN
NAME
NAME
DESIGNATION
APPROVED BY
DESIGNATION
SEAL
SEAL
DATE
DATE
Category of Check:- CRITICAL, MAJOR and MINOR
** M: MANUFACTURER / SUB-CONTRACTOR,
A: ADANI or Their authorized representative.
C: MAIN CONTRACTOR,
Use the following term As appropriate in columns 10:

P:
PERFORM, V: VERIFICATION and H: CUSTOMER HOLD POINT to be

witnessed and work shall not proceeded till it is witnessed and cleared in writing.
Ref: Legend Appendix I
SIGNATURE:
NAME:
SEAL:
DATE:
SIGNATURE:
NAME:
SEAL:
DATE:
Format No: CQA/III/R1
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

FICHTNER INDIA
Section 6
Page 7 of 11

Tender
Specification
for
Erection
&
APPENDIX- I
LEGEND FOR MANUFACTURING QUALITY PLAN (QP)
(FORMAT NO. CAQ/III/R1)
Name and address of Manufacturers works: In the column of Name and address Manufacturers
works name and full address, Tel No. Fax No, Email shall be indicated in "QP".
Item: In the column of Item /Sub System:
a)
b)
Item: Full name of the item for which QP is being prepared should be indicated along
with the complete material, type, class, rating, range, size etc. or complete designation /
description of the item or as recommended in the product specification (attached sheet if
required).
Sub system: Full name of Sub-system to be given with details
Column 2: Component and Operation should be indicated in sufficient detail including exact
area and stage of processing, testing, delivery etc.
Column 3: Following Characteristics of Check should be indicated, as applicable:visual, dimensional, hydraulic, chemical, mechanical, performance, ultrasonic, magnetic
particle, dye penetrant, radiographic, polarization index, high voltage, insulation
resistance, etc.
Column 4: Check shall be classified as Critical, Major and Minor
Column 5:T ype of Check shall indicate nature of check i.e. visual, measurement,
verification, strength, chemical analysis, NDT etc.
Column 6: 100% Check or sample basis specifying percentage sample to be
checked. However the column "6" 'Quantum of Check' can be sub-divided into 2 or 3 columns
to facilitate clarity for a particular set of Contractor / Sub-Contractor / Manufacturer. The
quantum of Checks by manufacturer, Contractor and AG shall be clearly indicated.
Column 7: Plant standard, IS, DIN, BS, ASME, IEC or other national/international
standards, statutory codes, drawings etc. as per which checks/tests shall be carried out
shall be indicated.
Column 8: The acceptable norms as per Plant standard, design data,
national/international standard or other acceptance norms shall be indicated.
Column 9: Appropriate format/certificate on which test/inspection results recorded shall
be indicated.
Column 9 'D': Records shall be identified by AG with Tick () marks shall be essentially
included by Contractor in QA Documentation.
Column 10: Inspection Agency performing, reviewing or witnessing of tests/checks shall be
indicated. Sub column M C A stand for M: Manufacturer / Sub-contractor, C: Main
Contractor and A: AG respectively. Under these sub columns P, V and CHP shall be
indicated for Perform, Verification and Customer Hold Points respectively.
Column 11: Remarks: Any specific remark shall be written here.
(Attach additional sheets, if required.)
( Note: This format can be modified with the approval of Head, CQA&IG,
as per requirement).
CQA/III/R1
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Page : 8 of 11

Pallatana, Tripura
SUB-CONTRACTORS NAME AND ADDRESS:
Tel No :
Fax No:
E-mail :
ITEM:
SUB-SYSTEM:

FIELD QUALITY PLAN
QP NO:
REV.NO.
DATE:
PAGE.of
PROJECT
:
PACKAGE
:
CONTRACT NO.:
MAIN-CONTRACTOR:
SL
NO
ACTIVITY / OPERATION
CHARACTERISTICS
CLASS OF
CHECK #
TYPE OF
CHECK
QUANTUM
OF CHECK
REFERENC
E
DOCUMENT
ACCEPTAN
CE NORMS
FORMAT
OF
RECORD
9
REMARKS
D*
10
MANUFACTURE
R / SUBCONTRACTOR
MAIN
CONTRACT
OR
LEGEND :1. D* RECORDS, IDENTIFIED WITH TICK() SHALL ESSENTIALLY BE INCLUDED BY SUPPLIER IN QA
DOCUMENTATION
For Office use

Reviewed by
Appro
Sign:
ved by
Sign:
Sign:
Sign:
2. # CLASS OF CHECK: A, B & C
Name :
Name:
Name:
NOTE:- All classes of checks shall be H (Customer Hold Point) and work shall not proceeded till it is
witnessed and cleared in writing.
Name
:
Designation
Design
ation
Seal :
Seal :
Date :
Date :
Seal:
Date :
Seal:
Date :
ABBREVIATION to be used for format of record:SR=Site Register, TR=Test Report, TC=Manufacturers Test Certificate, LR=Lab Report, LB=Log Book.
Ref: Legend Appendix II
Format No CQA/IV/ R1
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

FICHTNER INDIA
Section 6
Page 9 of 11

Tender
Specification
for
Erection
&
APPENDIX II
LEGEND FOR FIELD QUALITY PLAN FQP
(FORMAT No. CQA/ IV/ R1)
Sub-Contractor name and address: Name and full address of Sub-Contractor shall be indicated in "
FQP"
a) Item: In the column of Item: Full name of the item for which FQP is being prepared should be
indicated along with the complete material, type, class, rating, range, size etc. or complete designation /
description of the item or as recommended in the product specification (attach sheet, if required).
b) Sub-system name of Sub-system with required details.
Column 2: ACTIVITY / OPEERATION: Name of components/ equipment / system and operations
like Site Receipts Inspection, Storage, Handling, Pre-Erection and Erection shall be indicated.
Column 3: Characteristics: Following characteristics of activity should be indicated, as applicable,
visual, dimensional, leveling, alignment, hydraulic, chemical, mechanical, performance, ultrasonic,
magnetic, particle, dye penetrant, radiographic, polarization index, high voltage, insulation resistance,
etc. along with the item on which the these are performed and Instruments used for checking shall be
indicated.
Column 4: Each Check shall be classified as A, B or C depending upon its criticality in over all
integrity of the equipment
Classification /
Categorization
Category A
Category B
Category C
Witnessing & Accepting

Authority
FQA Engineer (or Nominated FQA
Agency),
in
association
with
Engineer of Executing Department
(nominated by HOD at Site)
Engineer of Executing Department
(nominated by HOD at Site)
Contractors Field Quality Engineer
and
Engineer
of
Executing
Department (nominated by HOD at
Site)
Surveillance by AG
Head, FQA (Nominated FQA
Agency)
FQA Engineer (Nominated
FQA Agency)
Any other Engineer authorized
by Head of the Project / Station
(VP)
Column 5: Type of Check shall indicate nature of check i.e. visual, measurement, verification,
strength, chemical analysis, NDT etc.
Column 6: 100% Check or sample basis specifying percentage sample to be checked. In case check has
to be performed periodically frequency of testing to be indicated. However the column "6" 'Quantum
of Check' can be sub-divided into 2 or 3 columns to facilitate clarity for a particular set of
Contractor / Sub-Contractor /Manufacturer.
Column 7: Plant standard, IS, DIN, BS, ASME, IEC or other national/international standards, statutory
codes, drawings etc. as per which checks/tests shall be carried out and their acceptance norms shall be
indicated.
Column 8: Plant standard, design data, national/international standard or other acceptance norm
shall be indicated.
Column 9: Appropriate format/certificate on which test/inspection results recorded shall be indicated.
Column 9 'D': Records shall be identified by AG with Tick marks () shall be essentially included
by - Contractor in QA documentation.
Column 10: In Remark column any specific Remark shall be written here.
(Note : This format can be modified with the approval of Head, CQA&IG, as per requirement.)
CQA/IV/Ro1
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

Page : 10 of 11

Pallatana, Tripura

FIELD WELDING SCHEDULE

Description
of
Description of
Item/System/ Drawing No.
parts to be
Material
SL NO.
Sub& its Rev.
welded & their Specn
System/Weld
No.
size and ID No.
Joint
Location
Type of
weld
Joint
Welding
Process
Electrod
Min. Pre
e/filler
Post Weld Heat
WPS No. Heat
wire
Treatment
Temp
specn
Temp
10
11
Non- Destructive Test
Holdin Method Quant

g Time
um
12
13
14
Ref.
Doc
15
Remarks
Accep
tance
Norm
16
17
NOTE:-.
1) WPS means Welding Procedure Specification
2) Copies of WPS referred in column (9) along with supporting Procedure Qualification Records (PQR) should be annexed to the Field Signature.
welding schedule.
Name
Designation
Company Name
FORMAT NO. CQA/IX/ R 0
Doc. No. 1113112-ME-SPC-700-004, Rev. 0

FICHTNER INDIA
Section 6
Page 11 of 11

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PROJECT: RAIN WATER HARVESTING SYSTEM

ONGC TRIPURA POWER COMPANY LIMITED

726.6MW, COMBINED CYCLE POWER PROJECT

TECHNICAL SPECIFICATION FOR ERECTION &

ONGC TRIPURA POWER COMPANY LTD (OTPC)

(INCLUDING COVER SHEET)

FICHTNER Consulting Engineers (India) Private Limited

726.6 MW Combined Cycle

Tender Specification for Erection & Commissioning

GENERAL TECHNICAL SPECIFICATION

DETAILED TECHNICAL SPECIFICATION MECHANICAL

DETAILED TECHNICAL SPECIFICATION ELECTRICAL

QUALITY ASSURANCE PROGRAMME

Doc. No. 1113112-ME-SPC-700-004, Rev. 0

726.6 MW Combined Cycle

Tender Specification for Erection &

Doc. No. 1113112-ME-SPC-700-004, Rev. 0

726.6 MW Combined Cycle

Tender Specification for Erection &

INTENT OF SPECIFICATION ...................................................................................3

SCOPE OF WORK ....................................................................................................3

TERMINAL POINTS ..................................................................................................5

EXCLUSIONS FROM THE BIDDERS SCOPE OF WORK ......................................6

PROJECT INFORMATION ........................................................................................6

APPROVED SUB VENDORS/MAKES ......................................................................6

PAINTING AND CORROSION PROTECTION .........................................................6

QUALITY ASSURANCE, TESTING AND INSPECTION...........................................6

ANNEX 1.1 PROJECT INFORMATION.....................................................................................9

Doc. No. 1113112-ME-SPC-700-004, Rev. 0

726.6 MW Combined Cycle

Tender Specification for Erection &

Fabrication, construction, erection, testing and commissioning at site of complete piping

Doc. No. 1113112-ME-SPC-700-004, Rev. 0

726.6 MW Combined Cycle

Tender Specification for Erection &

Scope of work for erection of pumps is mentioned in Section-5 of Volume-1 of this

Paints for above ground piping.

Supply & erection of coarse screen for the sump pits

Following civil works are included in Bidders scope:

Excavation and backfilling for laying of pipes.

Obtaining necessary approvals from various agencies as applicable.

Doc. No. 1113112-ME-SPC-700-004, Rev. 0

726.6 MW Combined Cycle

Tender Specification for Erection &

Assisting the owner in successful commissioning of the system by providing skilled/unskilled

Owner shall provide the following drawings & document

Power supply of 415V / 230V, 3 PH, 50 HZ at all pump motor

Power supply of 230VAC at all Field Instruments

Doc. No. 1113112-ME-SPC-700-004, Rev. 0

726.6 MW Combined Cycle

Tender Specification for Erection &

EXCLUSIONS FROM THE BIDDERS SCOPE OF WORK

Pipe support pedestals with embedded plates

Hume pipes for piping

APPROVED SUB VENDORS/MAKES

PAINTING AND CORROSION PROTECTION

QUALITY ASSURANCE, TESTING AND INSPECTION

Drawings, data / documents to be submitted along with Bid.

Technical data sheets & manufacturers literature for supply items

List of drawings / documents attached

Doc. No. 1113112-ME-SPC-700-004, Rev. 0

726.6 MW Combined Cycle

Tender Specification for Erection &

List of sub-contractors / Sub vendors.