TABLE OF CONTENT -...

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STANDARD SPECIFICATION FOR

INSPECTION, FLUSHING

AND TESTING OF PIPING SYSTEMS SHEET 8 of 8

Pressure shall be applied by means of a suitable test pump or other pressure source which shall be isolated from the system as soon as test pressure is reached and stabilized in the system. A pressure gauge shall be provided at the pump discharge for guidance in bringing the system to the required pressure. The pump shall be attended constantly during the test by an authorized person. The pump shall be isolated from the system whenever the pump is to be left unattended. Test pressure shall be maintained for a sufficient length of time to permit thorough inspection of all joints for leakage or signs of failure. Any joint found leaking during a pressure test shall be retested to the specified pressure after repair. Test period shall be maintained for a minimum of three hours. The pump and the piping system to be tested are to be provided with separate pressure indicating test gauges. These gauges are to be checked by the standard test gauge before each pressure test.

Care shall be taken to avoid increase in the pressure due to temperature variation during the test.

5.4.2 Air Test

When testing with air, pressure shall be supplied by means of a compressor. The compressor shall be portable type with a receiver, after cooler and oil separator.

Piping to be tested by air shall have joints covered with a soap and water solution so that the joints can be examined for leaks.

All other details shall be same as per hydro testing procedure (specified above) 5.5 Completion of Testing

After the hydrostatic test has been completed, pressure shall be released in a manner and at a rate so as not to endanger personnel or damage equipments.

All vents and drains shall be opened before the system is to be drained and shall remain open till all draining is complete, so as to prevent formation of vacuum in the system. After draining, lines / systems shall be dried by air.

After testing is completed the test blinds shall be removed and equipment/ piping isolated during testing shall be connected using the specified gaskets, bolts and nuts. These connections shall be checked for tightness in subsequent pneumatic tests to be carried out by the contractor for complete loop / circuit including equipments (except rotary equipments).

Pressure test shall be considered complete only after approved by the Engineer-in-Charge. Defects, if any, noticed during testing shall be rectified immediately and retesting of the system / line shall be done by the contractor at his cost.

5.6 Test Records

Records in triplicate shall be prepared and submitted by the contractor for each piping system, for the pressure test done in the Performa provided/approved by the Engineer-in-Charge. Records shall also be submitted for the PMI.

GAIL GAS LIMITED

CITY GAS DISTRIBUTION PROJECT

CLIENT JOB NO. STANDARD SPECIFICATION FOR FABRICATIOIN AND

ERECTION OF PIPING

TOTAL SHEETS 13

DOCUMENT NO 11 0290 02 08 02 012

0 16/10/09 ISSUED FOR TENDER GV DDS PKS

B 26/08/08 ISSUED FOR CLIENT’S COMMENTS GV DDS PKS

A 25/08/08 ISSUED FOR IDC GV DDS PKS

REV DATE DESCRIPTION PREP CHK APPR

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FABRICATION AND ERECTION OF

PIPING

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ABBREVIATIONS: PMI - Positive Material Identification NDT - Non Destructive Testing P&ID - Process and Instrumentation Diagram A.S. - Alloy Steel C.S. - Carbon Steel C.I. - Cast Iron S.S. - Stainless Steel LTCS - Low Temperature Carbon Steel NACE - National Association of Corrosion Engineers

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TABLE OF CONTENT

1.0 SCOPE...................................................................................................................................... 4

2.0 SCOPE OF WORK OF CONTRACTOR................................................................................... 4

3.0 BASIS OF WORK..................................................................................................................... 5

4.0 FABRICATION.......................................................................................................................... 7

5.0 ERECTION.............................................................................................................................. 10

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1.0 SCOPE

This specification covers general requirements of fabrication and erection of above ground and trench piping systems at site. The specification covers the scope of work of contractor, basis of work to be carried out by contractor and standards, specifications and normal practice to be followed during fabrication and erection by the contractor.

2.0 SCOPE OF WORK OF CONTRACTOR Generally the scope of work of contractor shall include the following:

2.1 Transportation of required piping materials (as described in Cl.2.1.1), pipe support (material as described in Cl. 2.3) and all other necessary piping materials from Owner’s storage point or contractor’s storage point (in case of contractor’s scope of supply) to work site/shop including raising store requisitions for issue of materials in the prescribed format & maintaining an account of the materials received from Owner’s stores.

2.1.1 Piping materials include the following but not limited to the same. a. Pipes (All sizes and schedule) b. Flanges (All sizes, types & Pressure ratings). c. Fittings (All sizes, types and schedule) d. Valves (All sizes, types and Ratings) e. Gaskets (All sizes, types & Ratings) f. Bolts, Nuts or M/C Bolts (All types) g. Expansion Joint/Bellows (All types) h. Specialty items like online filters, ejectors, sample coolers, steam traps, strainers, air traps etc. i. Online instruments like control valve, orifice flange, rotameter, safety valves etc.

2.2 Shop & field fabrication and erection of piping in accordance with documents listed under ‘BASIS OF WORK’ including erection of all piping materials enumerated above.

2.3 Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors, clips, cradles, hangers, turn buckles, supporting fixtures, bracket cantilevers, struts, teeposts including erection of spring supports and sway braces.

2.4

2.4.1 Fabrication of piping specials like special radius bends, reducers, miters etc.

2.4.2 Fabrication of plain and threaded nipples from pipes as required during erection.

2.4.3 Fabrication of swage nipples as and when required.

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2.4.4 Fabrication of odd angle elbow like 60º, 30° or any other angle from 90/45° elbows as and when required.

2.4.5 Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when required.

2.4.6 Fabrication of stub-in connection with or without reinforcement.

2.4.7 Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven/different thickness wherever required.

2.5 Modifications like providing additional cleats, extension of stem of valve, locking arrangement of valves etc. as and when required.

2.6 Preparation of Isometrics, bill of materials, supporting details of all NON-IBR lines up to 2- 1/2 within the unit battery limit and get subsequent approval from Engineer-in-Charge as and when called for.

2.7 Obtaining approval for drawings prepared by contractor from statutory authority, if required.

2.8 Spun concrete lining of the inside of pipes 3” NB & above including fittings and flanges as required in accordance with specification.

2.9 Rubber lining inside pipes, fittings, flanges as and when required, in accordance with specification.

2.10 Radiography, stress relieving, dye penetration, magnetic particle test etc. as required in specification.

2.11 Performing PMI using alloy analyzers as per Standard Specification at Construction Sites.

2.12 Casting of concrete pedestals and fabrication & erection of small structures for pipe supports including supply of necessary materials.

2.13 Providing insert plates from concrete structures and repair of platform gratings around pipe openings.

2.14 Making material reconciliation statement and return of Owner’s supply left over materials to Owner’s storage.

2.15 Flushing and testing of all piping systems as per standard specification for inspection, flushing and testing of piping systems.

2.16 Pickling (as and when applicable) as per standard specification for chemical cleaning of C.S. suction piping of compressors.

2.17 Submission of job execution procedure for review and approval of Engineer-in-charge covering all above activities.

3.0 BASIS FOR WORK

3.1 The complete piping work shall be carried out in accordance with the following

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3.1.1 “Approved for Construction” drawings and sketches issued by J P KENNY to the Contractor - Plans and/or Isometrics.

3.1.2 “Approved for Construction” drawings and sketches issued by Turn-key bidders to the Contractor - Plans and/or Isometrics.

3.1.3 Approved Process licensor’s standards and specifications.

3.1.4 Drawings, sketches and documents prepared by contractor duly approved by Engineer-in- Charge (such as isometrics of small bore piping and offsite piping etc.)

3.1.5 Approved construction job procedures prepared by Contractor as stipulated in 2.16.

3.1.6 J P KENNY specifications/documents as below: a. Process and Instrument Diagram. b. Piping Materials Specification. c. Piping support standards. d. Line list e. Piping support indices (only in offsite), if supports are not shown in plan. f. Standard specification of Non-destructive Requirement of Piping. g. Welding specification charts for piping classes . h. Standard specification for Pressure Testing of Erected Piping System. i. Welding specification for fabrication of piping. j. Any other J P KENNY or OTHER specifications attached with Piping Material Specification or special condition of contract (such as standard for cement lining of pipe, standard of jacketed piping, standard for steam tracing, Dimensional Tolerances etc.) k. Procedure for storage, preservation and positive identification of materials at Contractors works/ stores.

3.1.7 Following codes, standards and regulations a. ASME B 31.3 : Process Piping b. ASME B 31.4 : Pipeline Transportation System for Liquid Hydrocarbons and Other.

c. ASME B 31.8 : Gas Transmission and Distribution Piping Systems

d. ASME Sec. VIII : Code for unfired pressure vessel. e. IBR Regulations

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f. IS: 823 : Code for procedure for Manual Metal Arc Welding of Mild Steel (for structural steel).

g. NACE Std. : Code for Sour Services material requirements MR-0 1-75

h. PNGRB NOTIFICATION: Technical Standards and specifications including safety standards for Dated: 27/08/08 city or local natural gas distribution network. Schedule-1

Note: All codes referred shall be latest edition, at the time of award of contract. 3.2 Deviations Where a deviation from the “Basis of Work and approved job procedure described above is required or where the basis of work does not cover a particular situation, the matter shall be brought to the notice of Engineer - in - Charge and the work carried out only after obtaining written approval from him in each case.

4.0 FABRICATION

4.1 Piping Material

Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system shall be strictly as per the “Piping Material Specification” for the “Pipe Class” specified for that system. To ensure the above requirement, all piping material supplied by the Owner/Contractor shall have proper identification marks as per relevant standards/specifications/Licensors specification. Contractor shall provide identification marks on left over pipe lengths wherever marked up pipe lengths have been fabricated/ erected. Material traceability is to be maintained for A.S., S.S., NACE, LTCS, material for Hydrogen service and other exotic materials by way of transferring heat number, etc. (hard punching) as per approved procedure. This shall be in addition to color coding for all piping materials to avoid mix-up. For the purpose of common understanding the construction job procedure, to be submitted by the contractor, shall include proposal for - Maximizing prefabrication, inspection and testing at fabrication shop with minimum field joints. - Positive material identification, handling, storage & preservation. 4.2 Dimensional Tolerances Contractor shall be responsible for working to the dimensions shown on the drawings. However, the Contractor shall bear in mind that there may be variations between the dimensions shown in the drawing and those actually existing at site due to minor variations in the location of equipments, inserts, structures etc. To take care of these variations “Field Welds” shall be provided during piping fabrication. An extra pipe length of 100 mm over and above the dimensions indicated in the drawing may be left on one side of the pipe at each of the field welds. During erection, the pipe end with extra length at each field weld shall be cut to obtain the actual dimension occurring at site. Isometrics, if supplied may have the field welds marked on them. However, it is the responsibility of the Contractor to provide adequate number of field welds. In any case no extra claims will be entertained from the Contractor on this account. Wherever errors I omissions occur in drawings and Bills of Materials it shall be the Contractor’s responsibility to notify the Engineer-in-Charge prior to fabrication or erection. 4.3 IBR Piping 4.3.1 Contractor shall be supplied generally with all drawings for steam piping falling under the purview of Indian Boiler Regulations duly approved by Boiler Inspectorate. The Contractor shall carry out the fabrications, erection and testing of this piping as per requirements of Indian Boiler Regulations and to the entire satisfaction of the local Boiler Inspector. The Contractor shall also get the approval of IBR

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inspector for all fabrication and testing done by him at his own cost. All certificates of approval shall be in proper IBR forms. 4.3.2 Approval of boiler inspector on the drawings prepared by the contractor shall be obtained by the contractor at his own cost. 4.4 Pipe Joints The piping class of each line specifies the type of pipe joints to be adopted. In general, joining of lines 2” and above in process and utility piping shall be accomplished by butt welds. Joining of lines 1-1/2” and below shall be by socket welding/butt welding/threaded joints as specified in “Piping Material Specifications”. However, in piping 1-1/2” and below where socket welding/threaded joints are specified butt - welds may be used with the approval of Engineer-in-Charge for pipe to pipe joining in long runs of piping. This is only applicable for non galvanized piping without lining. Flange joints shall be used at connections to Vessels, Equipment’s, Valves and where required for ease of erection and maintenance as indicated in drawings. 4.5 Butt Welded and Socket Welded Piping End preparation, alignment and fit-up of pipe pieces to be welded, welding, pre-heating, post-heating and heat treatment shall be as described in the welding specification and NDT specification. 4.6 Screwed Piping

In general, Galvanized piping shall have threads as per IS: 554 or ANSI B2.l NPT as required to match threads on fittings, valves etc. All other piping shall have threads as per ANSI B2.l, tapered unless specified otherwise.

Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed. Threading of pipes shall be done preferably after bending, forging or heat treating operations. If this is not possible, threads shall be gauge checked and chased after welding heat treatment etc. During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly cleaned of cuttings, dirt, oil or any other foreign matter. The male threads shall be coated with thread sealant and the joint tightened sufficiently for the threads to seize and give a leak proof joint. Threaded joints to be seal-welded shall be cleaned of all foreign matter, including sealant and made up to full thread engagement before seal welding.

4.7 Flange Connections All flange facings shall be true and perpendicular to the axis of pipe to which they are attached. Flanged bolt holes shall straddle the normal centerlines unless different orientation is shown in the drawing.

Wherever a spectacle blind is to be provided, drilling and tapping for the jack screws in the flange, shall be done before welding it to the pipe.

4.8 Branch Connections Branch connections shall be as indicated in the piping material specifications. For end preparation, alignment, spacing, fit-up and welding of branch connections refer welding specifications. Templates shall be used wherever required to ensure accurate cutting and proper fit-up. For all branch connections accomplished either by pipe to pipe connections or by using forged tees the rates quoted for piping shall be inclusive of this work. Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc.

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4.9 Bending

Bending shall be as per ASME B3 1.3 except that corrugated or creased bends shall not be used. Cold bends for lines 1-1/2” and below, with a bend radius of 5 times the nominal diameter shall be used as required in place of elbows wherever allowed by piping specifications. Bending of pipes 2” and above may be required in some cases like that for headers around heaters, reactors etc. The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles, bulges, flat spots and other serious defects. They shall be true to dimensions. The flattening of a bend, as measured by the difference between the maximum and minimum diameters at any cross-section, shall not exceed 8% and 3% of the nominal outside diameter, for internal and external pressure respectively.

4.10 Forging and forming Forging and forming of small bore fittings, like reducing nipples for piping 1-1/2” and below, shall be as per ASME B 31.3.

4.11 Miter Bends and Fabricated Reducers The specific application of welded miter bends and fabricated reducers shall be governed by the Piping Material Specifications. Generally all 90 deg. miters shall be 4-piece 3-weld type and 45 deg. miters shall be 3-piece 2-weld type unless otherwise specified. Reducers shall be fabricated as per directions of Engineer-in-Charge. The radiographic requirements shall be as per Material Specifications for process and utility systems and NDT Specification for steam piping under IBR, radiographic requirements of IBR shall be complied with.

4.12 Cutting and Trimming of Standard Fittings & Pipes

Components like pipes, elbows, couplings, half-couplings etc. shall be cut/trimmed/edge prepared wherever required to meet fabrication and erection requirements, as per drawings and instructions of Engineer-in-Charge. Nipples as required shall be prepared from straight length piping.

4.13 Galvanized Piping Galvanized carbon steel piping shall be completely cold worked, so as not to damage galvanized surfaces. This piping involves only threaded joints and additional external threading on pipes may be required to be done as per requirement.

4.14 Jacketed Piping The Jacketing shall be done in accordance with J P KENNY Specification or Licensors specification as suggested in material specification or special condition of contract. Pre-assembly of jacketed elements to the maximum extent possible shall be accomplished at shop by Contractor. Position of jumpover and nozzles on the jacket pipes, fittings etc. shall be marked according to pipe disposition and those shall be prefabricated to avoid damaging of inner pipe and obstruction of jacket space. However, valves, flow glasses, in line instruments or even fittings shall be supplied as jacketed.

4.15 Shop Fabrication / Prefabrication The purpose of shop fabrication or pre-fabrication is to minimize work during erection to the extent possible. Piping spool, after fabrication, shall be stacked with proper identification marks, so as facilitate their withdrawal at any time during erection. During this period all flange (gasket contact faces) and

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threads shall be adequately protected by coating with removable rust preventive. Care shall also be taken to avoid any physical damage to flange faces and threads.

4.16 Miscellaneous

4.16.1 Contractor shall fabricate miscellaneous elements like flash pot, seal pot, sample cooler, supporting elements like turn buckle’s, extension of spindles and interlocking arrangement of valves, operating platforms as required by Engineer-in-Charge.

4.16.2 Spun Concrete lining The work of inside spun concrete lining of pipes and specials of diameter 3 and above shall be done as per material specifications and special conditions of contract.

4.16.3 Fabrication of pipes from plate Pipes shall be fabricated at site as and when required as per the specifications and the actual Piping Material Specification.

5.0 ERECTION

5.1 Cleaning of Piping before Erection Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and outside by suitable means. The cleaning process shall include removal of all foreign matter such as scale, sand, weld spatter chips etc. by wire brushes, cleaning tools etc. and blowing with compressed air/or flushing out with water. Special cleaning requirements for some services, if any shall be as specified in the piping material specification or isometric or line list. S.S jacketed piping requiring pickling shall be pickled to remove oxidation and discoloring due to welding.

5.2 Piping Routing No deviations from the piping route indicated in drawings shall be permitted without the consent of Engineer-in-Charge.

Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the drawings shall be strictly followed as these clearances may be required for the free expansion of piping / equipment. No deviations from these clearances shall be permissible without the approval of Engineer-in-Charge.

In case of fouling of a line with other piping, structure, equipment etc. the matter shall be brought to the notice of Engineer-in-Charge and corrective action shall be taken as per his instructions.

5.3 Cold Pull Wherever cold pull is specified, the Contractor shall maintain the necessary gap, as indicated in the drawing. Confirmation in writing shall be obtained by the Contractor from the Engineer-in-Charge, certifying that the gap between the pipes is as indicated in the drawing, before drawing the cold pull. Stress relieving shall be performed before removing the gadgets for cold pulling.

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5.4 Slopes Slopes specified for various lines in the drawings / P&ID shall be maintained by the Contractor. Corrective action shall be taken by the Contractor in consultation with Engineer- in-Charge wherever the Contractor is not able to maintain the specified slope.

5.5 Expansion Joints / Bellows Installation of Expansion Joints/Bellows shall be as follows:

5.5.1 All Expansion joints / Bellows shall be installed in accordance with the specification and installation drawings, supplied to the Contractor.

5.5.2

a. Upon receipt, the Contractor shall remove the Expansion Joints/ Bellows from the case(s) and check for any damage occurred during transit.

b. The Contractor shall bring to the notice of the Engineer-in- Charge any damage done to the bellows / corrugations, hinges, tie-rods, flanges / weld ends etc.

c. Each Expansion Joint / Bellow shall be blown free of dust and foreign matter with compressed air or cleaned with a piece of cloth.

5.5.3

a. For handling and installation of Expansion Joints, great care shall be taken while aligning. An Expansion Joint shall never be slinged from bellows corrugations / external shrouds, tie / rods, angles.

b. An Expansion Joint / Bellow shall preferably be slinged from the end pipes / flanges or on the middle pipe.

5.5.4

a. All Expansion Joints shall be delivered to the Contractor at “Installation length”, maintained by means of shipping rods, angles welded to the flanges or weld ends or by wooden or metallic stops.

b. Expansion Joints stop blocks shall be carefully removed after hydrostatic testing. Angles welded to the flanges or weld ends shall be trimmed by saw as per manufacturer’s instructions and the flanges or weld ends shall be ground smooth.

5.5.5

a. The pipe ends in which the Expansion Joint is to be installed shall be perfectly aligned or shall have specified lateral deflection as noted on the relevant drawings.

b. The pipe ends / flanges shall be spaced at a distance specified in the drawings.

5.5.6 The Expansion Joint shall be placed between the mating pipe ends/flanges and shall be tack welded/ bolted. The mating pipes shall again be checked for correct alignment.

5.5.7 Butt-welding shall be carried out at each end of the expansion joint. For flanged Expansion Joint, the mating flanges shall be bolted.

5.5.8 After the Expansion Joint is installed the Contractor shall ensure that the mating pipes and Expansion Joints are in correct alignment and that the pipes are well supported and guided.

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5.5.9 The Expansion Joint shall not have any lateral deflection. The Contractor shall maintain parallelism of restraining rings or bellows convolutions.

5.5.10 Precautions

a. For carrying out welding, earthing lead shall not be attached with the Expansion Joint.

b. The Expansion bellow shall be protected from arc weld spot and welding spatter.

c. Hydrostatic Testing of the system having Expansion Joint shall be performed with shipping lugs in position. These lugs shall be removed after testing and certification is over.

5.6 Flange Connections While fitting up mating flanges, care shall be exercised to properly align the pipes and to check the flanges for trueness, so that faces of the flanges can be pulled together, without inducing any stresses in

the pipes and the equipment nozzles. Extra care shall be taken for flange connections to pumps, turbines, compressors, cold boxes, air coolers etc. The flange connections to these equipments shall be checked for misalignment, excessive gap etc. after the final alignment of the equipment is over. The joint shall be made up after obtaining approval of Engineer-in-Charge. Temporary protective covers shall be retained on all flange connections of pumps, turbines, compressors and other similar equipments, until the piping is finally connected, so as to avoid any foreign material from entering these equipments. The assembly of a flange joint shall be done in such a way that the gasket between these flange faces is uniformly compressed. To achieve this, the bolts shall be tightened in a proper sequence. All bolts shall extend completely through their nuts but not more than 1/4”. Steel to C.I. flange joints shall be made up with extreme care, tightening the bolts uniformly after bringing flange flush with gaskets with accurate pattern and lateral alignment.

5.7 Vents and Drains High point vents and low point drains shall be provided as per the instructions of Engineer- in-Charge, even if these are not shown in the drawings. The details of vents and drains shall be as per piping material specifications / job standards.

5.8 Valves Valves shall be installed with spindle / actuator orientation / position as shown in the layout drawings. In case of any difficulty in doing this or if the spindle orientation / position is not shown in the drawings, the Engineer-in-Charge shall be consulted and work done as per his instructions. Care shall be exercised to ensure that globe valves, check valves, and other uni-directional valves are installed with the “Flow direction arrow “on the valve body pointing in the correct direction. If the direction of the arrow is not marked on such valves, this shall be done in the presence of Engineer-in-Charge before installation. Fabrication of stem extensions, locking arrangements and interlocking arrangements of valves (if called for), shall be carried out as per drawings/ instructions of Engineer-in- Charge.

5.9 Instruments

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Installation of in-line instruments such as restriction orifices, control valves, safety valves, relief valves, rotameters, orifice flange assembly, venturimeters, flow meters etc. shall form a part of piping erection work. Fabrication and erection of piping upto first block valve / nozzle I flange for installation of offline Instruments for measurement of level, pressure, temperature, flow etc. shall also form part of piping construction work. The limits of piping and instrumentation work will be shown in drawings / standards specifications. Orientations / locations of take-offs for temperature, pressure, flow, level connections etc. shown in drawings shall be maintained. Flushing and testing of piping systems which include instruments mentioned above and the precautions to be taken are covered in flushing, testing and inspection of piping. Care shall be exercised and adequate precautions taken to avoid damage and entry of foreign matter into instruments during transportation, installation, testing etc.

5.10 Line Mounted Equipments/ Items Installation of line mounted items like filters, strainers, steam traps, air traps, desuperheaters, ejectors, samples coolers, mixers, flame arrestors, sight glasses etc. including their supporting arrangements shall form part of piping erection work.

5.11 Bolts and Nuts The Contractor shall apply molycoat grease mixed with graphite powder (unless otherwise specified in piping classes) all bolts and nuts during storage, after erection and wherever flange connections are broken and made-up for any purpose whatsoever. The grease and graphite powder shall be supplied by the Contractor within the rates for piping work.

5.12 Pipe Supports Pipe supports are designed for and located to effectively sustain the weight and thermal effects of the piping system and to prevent its vibrations. Location and design of pipe supports will be shown in drawings for lines 3” NB & above line below 3” NB Contractor shall locate and design pipe supports in line with J P Kenny Standards and obtain approval of Engineer - in - Charge on drawings prepared by Contractor, before erection. However, any extra supports desired by Engineer-in-Charge shall also be installed.

No pipe shoe/cradle shall be offset unless specifically shown in the drawings. Hanger rods shall be installed inclined in a direction opposite to the direction in which the pipe moves during expansion. Preset pins of all spring supports shall be removed only after hydrostatic testing and insulation is over. Springs shall be checked for the range of movement and adjusted if necessary to obtain the correct positioning in cold condition. These shall be subsequently adjusted to hot setting in operating condition. The following points shall be checked after installation, with the Engineer-in-Charge and necessary confirmation in writing obtained certifying that: - All restraints have been installed correctly. - Clearances have been maintained as per support drawings. - Insulation does not restrict thermal expansion. - All temporary tack welds provided during erection have been fully removed.

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- All welded supports have been fully welded.

GAIL GAS LIMITED CITY GAS DISTRIBUTION PROJECT

CLIENT JOB NO. ---- TECHNICAL SPECIFICATION

FOR WELDING OF STATION PIPING TOTAL SHEETS 21

DOCUMENT NO 11 0290 02 08 02 011

0 16/10/09 ISSUED FOR TNDER GV DDS PKS

B 25/08/09 ISSUED FOR CLIENT’S COMMENTS AS DDS PKS

A 24/08/09 ISSUED FOR IDC AS DDS PKS


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TECHNICAL SPECIFICATION

FOR WELDING OF STATION PIPING

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TABLE OF CONTENTS

1.0 GENERAL..................................................................................................................3

2.0 WELDING PROCEDURES........................................................................................4

2.1 CONSUMABLES...........................................................................................4

2.2 WELDING PROCESS....................................................................................5

2.3 Joint Preparation .............................................................................................7

2.4 Preheating .......................................................................................................8

2.5 welding details……………………………………………… ………. 8

2.6 Welding Techniques……………………………………………………….10

2.7 Defects And Repairs .....................................................................................10

2.8 Post Weld Heat Treatment (PWHT).............................................................10

2.9 WELDING PROCEDURE QUALIFICATION...........................................12

2.10 Welder’s Qualification..................................................................................12

2.11 Destructive Testing .......................................................................................12

3.0 NON DESTRUCTIVE EXAMINATION.....................................................................13

3.1 GENERAL....................................................................................................13

3.2 CODES AND STANDARDS.......................................................................13

3.3 ABBREVIATIONS ......................................................................................13

3.4 NDE COMPANY CERTIFICATION ..........................................................14

3.5 VISUAL INSPECTION................................................................................14

3.6 NON-DESTRUCTIVE TESTING................................................................16

3.7 MAGNETIC PARTICLE INSPECTION.....................................................16

3.8 DYE PENETRATION..................................................................................16

3.9 ULTRASONIC EXAMINATION ………………………………………...17

3.10 EXTENT OF INSPECTION AND TESTING……………………………..18

4.0 REPAIRS OF WELDS .............................................................................................19

5.0 INSPECTION ...........................................................................................................20

6.0 DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR...............................21

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1.0 GENERAL 1.1 Scope This specification shall be followed for the fabrication of all types to welding joints of

piping system within the battery limits of all pressure piping of station. This specification shall apply to all suppliers, vendors, manufacturers, and fabricators

of welded pipes. The CONTRACTOR is responsible for all and shall ensure that all components to be incorporated into the work meeting this specification.

No supplier, vendor, manufacturer or fabricator shall subcontract the welding

fabrication of any item without written approval from the OWNER and the OWNER will not issue such an approval unless the proposed welding fabricator has received prior OWNER approval for the type of welding to be carried out.

The welded pipe joints shall include the following and shall not relieve the contractor of

his responsibilities and guarantee. a) All pipe joints, longitudinal butt welds, circumferential butt welds and socket welds.

b) Attachments of forging, 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 connection for vents drain drips and other instrument

tapings. 1.2 Codes, Standards and Regulations All welding performed under this Specification shall meet or exceed the requirements

specified by the latest revisions of the following applicable Codes and Regulations a) Indian Provincial regulations governing the welding of piping systems, argumented

with the following: 1. AWS (American Welding Society).

a. A2.4 (Symbols for Welding and Non destructive Testing).

b. A3.0 (Standard Welding Terms and their Definitions).

c. A5.1 (Specification for Mild Steel Covered Arc Welding Electrodes).

d. A 5.17(Specification for Bare Carbon Steel Covered Electrodes).

e. A 5.18 (Specification for Carbon Steel Filler Metals for Gas Shielded Arc Welding).

f. A 5.20 (Specification for Mild Steel Electrodes for Flux Cored Arc Welding Electrodes). 2. Applicable Local Boilers and Pressure Vessels Act and Regulations. 3. ASME B 31.3 Chemical Plant and Petroleum Refinery and Process Piping. 4. ASME Sec. VIII Div. 1 - Pressure Vessels.

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5. ASME Sec. IX - Welding. 6. ASME/ANSI B31.8 - Gas Transmission and Distribution Systems. 7. ASME Sec V - Non-destructive examination. 8. API Std 1104 – Standard for Welding Pipelines and Related Facilities. 9. AWS D 1.1 10. PNGRB NOTIFICATION: Technical Standards and specifications including Dated: 27/08/08 safety standards for city or local natural gas distribution Schedule-1 network All welding procedures used by fabricators and CONTRACTORS shall have been

established and qualified in accordance with the appropriate sections of one or more of the codes and standards listed above, and approved by the OWNER.

Where a conflict occurs between these specifications and / or any of the above codes

or standards the more stringent shall apply.

2.0 WELDING PROCEDURES 2.1 CONSUMABLES The CONTRACTOR shall provide at his own expenses, all the welding consumables

necessary for the execution of the job such as electrodes, filler wires, argon etc, and these should bear the approval of the OWNER.

The welding electrodes and filler wires supplied by the contractor shall confirm to this

specification and standard codes and shall be of the make approved by the OWNER and shall submit all test certificates to the Engineer in Charge for review and approval.

The contractor shall submit batch test certificates from the electrodes manufacturers,

giving details of physical and chemical tests carried out by them, for each batch of the electrodes to be used.

Electrode qualification test records for each batch shall be carried by contractor and

test records submitted, for obtaining the approval of the ENGINEER INCHARGE. The electrodes, filler wires and flux used shall be free from rust, oil, grease, earth and

other foreign matter, which affect the quality of the welding. All coated metal arc-welding electrodes shall comply with AWS specification A 5.5.

A5.1type unless approved otherwise by the OWNER. All welding consumables. including fluxes shall be supplied in sealed containers and

stored in a dry location at a minimum temperature of 68°F/20˚C. and a maximum relative humidity of 60%. Low-hydrogen electrodes, after removal from factory seal containers, shall be stored at a minimum temperature of 150°F/66˚C and suitably dried prior to use.

The welding filler metals shall have a chemical composition as near as possible to the

parent metals to be welded. The finished weld as deposited, or after post weld heat treatment (PWHT) when required, shall be at least equal to the parent metal as to unit strength, ductile, and other physical properties and in resistance to corrosion, hydrogen attack, or other operating environment factors as required. Permission to change filler metals to those other than the ones qualified in accordance with this specification must be obtained in writing, from the OWNER.

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Electrode and rod diameters shall conform to the parameters of the weld procedure. The CONTRACTOR shall provide adequate drying ovens and take proper precautions

in the storage and handling of low-hydrogen electrodes. Electrodes and filler rods shall be protected from mechanical damage or deterioration.

All unidentified damaged or deteriorated electrodes or filler wires shall be removed from the working area and rejected. Any low hydrogen type SMAW electrodes not contained in heated quivers shall be removed from the site. Electrodes shall not be exposed to wet or high humid conditions.

Care of welding consumables is the responsibility of the CONTRACTOR however, the

following are minimum requirements: Low-hydrogen SMAW electrodes shall be kept in commercial electrode ovens after the

factory container has been opened. The electrode holding oven temperature shall be maintained between 175°F (79°C) and 250°F (121°C). Any low-hydrogen SMAW electrodes that have been exposed for more than 4 hours prior to restocking into the holding oven or any SMAW low-hydrogen electrodes that have become wet or have damaged coatings shall not be used rejected and removed from site.

Other (non-low-hydrogen) SMAW electrodes shall be kept in a dry and dust-free

enclosure after opening of the factory container. These non-low-hydrogen electrodes shall be held at a temperature below 150°F (66°C).

Bare wire and bare filler rod (GTAW) shall be stored in a dry and free from dust,

grease etc. 2.2 WELDING PROCESS Welding of various materials under this specification shall be carried out using one or

more welding process as given below with the approval of the ENGINEER IN CHARGE.

- Shielded Metal Arc Welding Process (SMAW)

- Gas Tungsten Arc welding process (GTAW) The CONTRACTOR shall have a separate welding procedure for each method of

welding be intends to employ. Automatic and semiautomatic welding processes shall be employed only with the

express approval of the ENGINEER IN CHARGE. The welding procedure shall be adopted and consumables used shall be specifically approved.

A procedure qualification record (PQR) shall be included for each WPS. The PQT

shall be witnessed by the OWNER/ OWNER’s Representative or shall be supported with the lab report from the testing laboratory, if so previously agreed to by the OWNER.

A combination of different welding process could be employed for a particular joint

only after duly qualifying the welding procedure to be adopted and obtaining the approval of ENGINEER IN CHARGE.

All testing shall be performed and certified by OWNER approved testing laboratory,

agency or equivalent. The minimum acceptable written procedure shall detail information on the following parameters.

1. The scope of work performed under the procedures.

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2. The base metals and applicable specifications. 3. The welding process.

4. Type, size, classification and composition of filler metals. (The specific brand name(s)

of the flux-wire shall become an essential variable of the procedure qualification)

5. Type of current and voltage range As per range

6. Width of electrode weave or oscillation

7. Joint preparation and cleaning procedures.

8. Tack welding procedures. Method of marking the location of tack welds to facilitate post weld inspection shall also be included

9. Electrode polarity. 10. Applicable welding positions. 11. Preheat and inter pass temperatures. (Control method) 12. Welding travel speed. 13. Root preparation prior to welding from second side, (where applicable). 14. Removal methods for weld defects and stray arc strikes. 15. Inter pass-cleaning method. 16. Repair welding. 17. Post welding heat treatments (if required). 18. Shielding gas, and flow rates 19. Type of (GTAW) electrode, size and tip angle. 20. Welders qualified and deployed in production welds shall always bear an identity card

in the manner so approved by OWNER/OWNER’s representative. The CONTRACTOR shall only employ welders who have a valid welding certificate for

the procedures being used.

The CONTRACTOR shall have all welders tested in accordance with the applicable

code or standard. Testing shall be at the Contractor's expense including test pieces. Irrespective of pre qualification all welders proposed to be deployed in the work shall be tested and qualified a fresh.

No welder shall be allowed to make any weld for which he is not qualified. Welding with larger-size electrodes for specific applications may be allowed only if

each welder qualifies with the largest-size electrode to be used in production. This option is strictly at the OWNER discretion. OWNER shall specify the details of the welder qualification tests.

For carbon steel, filler wire combinations shall be chosen such that the deposited

hardness of the cap pass shall not exceed 240 BHN. For low-temperature materials and other materials heat input shall be minimized and comply with the WIPS

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parameters. The CONTRACTOR may propose alternate process in addition to those listed. Any

proposed process shall require written OWNER approval and qualification prior to implement CONTRACTOR and OWNER shall agree on tests, results, and other criteria before OWNER approval is granted.

All butt welds in pipe smaller than 60.3 mm O/D ("NPS 2" inch) Schedule 40 shall be

made by GTAW or shielded metal arc process, Root pass by gas metal arc is acceptable for pipe larger than 60.3 mm O/D (NP (2'') inch).

All welds in pressure equipment must be qualified for Charpy V impact testing at (-)

20°C when the code requirements indicate that the parent material requires impact testing.

When impact tests are required, tests shall be taken from the weld metal, fusion line,

2mm from fusion line, and 5mm from fusion line. Permanently installed backing rings shall not be used, All butt welds in pressure equipment shall have the same chemical and mechanical

properties as the parent metal. All welding procedures must be qualified for Charpy V impact testing when the Code

requirements indicate that the parent material requires impact testing. Extreme care shall be taken to ensure that electrode separation by classification is

maintained in the CONTRACTOR's inventory. All storage bins and ovens for welding consumables shall be clearly labeled. In addition, all GTAW bare rod filler metals shall be tagged with the AWS designation of the filler metal. Any welding consumables not readily identifiable shall not be used.

All pressure containing welds shall be of a minimum of two passes with overlap of

starts and stops. This shall include socket welds and seal welds of threaded connections.

Weld stops and starts shall he staggered so that adjacent weld passes do not contain

stops/starts within 25mm (1 "inch) of each other. The electrodes shall be purchased from the list of approved manufacturer's and the

same shall be supplied with proper certificates and batch certificates. The width of weave during production welding shall be within the acceptable limit of

the OWNER approved and qualified welding procedure, qualification certificates, and production welding operating sheets. As a norm this will be limited to a maximum of 3 times the core diameter of SMAW electrodes, whichever is the lesser.

Each weld pass layer shall be completed in one full cycle/ circumference before

proceeding with the next. Blocking out or segmental welding is not permitted. All tools and equipment used in the welding operations shall be in first class operating

condition and shall be of sufficient capacity to ensure welds of the specified quality are achieved throughout the work. It shall be the right of the OWNER to request at any times the re-calibration of gauges and meters. etc. to ensure compliance with welding procedure-operating sheets/ WPS.

2.3 Joint Preparation The surface of the pipe at the weld area shall be free from dust, grease, scale, paint,

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grit or any other foreign material, which may adversely affect the final weld quality. Bevels shall be 37½° and all field cuts shall be normal to the axis, of the pipe, Miter

welds are prohibited. All pipes shall be beveled for welding with an approved mechanical beveling machine. Damage to bevels, which could possibly affect the quality of the weld, shall be

remedied prior to welding. If beyond repair the pipe shall be cut and the pipe end re beveled. Lamination check by UT method shall be done prior to welding of gas cutting end pipe.

Where welding pipe both to a flange or another pipe or component, there must be a

band of at least 25M mm (1" inch) wide around the internal / external joint weld preparation that is ground to bright metal, and is free of all foreign matter,

To assure proper spacing and alignment in accordance with the applicable Code, an

approved lineup clamp shall be used. All Weldments shall conform to the straightness and alignment specified herein.

Correction of improperly fitted parts shall be accomplished by disassembly and refitting. Reworking by hammering or flame straightening shall not be permitted.

The ends of piping components to be joined shall be aligned as accurately as is

practicable within existing commercial tolerance on diameters, wall thickness, and out of roundness. Maximum bore mismatch shall not exceed 1/16” inch (1.6 mm), Alignment shall be preserved during welding.

When joints of unequal thickness are joined, the internal offset shall not exceed 1.6

mm (1/16"). If this value is exceeded, the excess thickness of the heavier end shall be machined or ground back from the bevel on a one-to-four (1:4) taper.

Maximum bore mismatch shall not exceed 0.8mm (1/32 inch), Where ends are to be

Joined and the internal misalignment due to difference in wall thickness, etc. exceeds 1.6 min (1/16 inch), the wall extending internally shall be internally trimmed, Internal machining shall be performed so that the inside diameters of the components coincide.

When cutting pipe to length, it should be cut by mechanical means. if practical. Ends

that are to have flanges attached either in the shop or field must be cut true and square.

2.4 Preheating Preheat for pressure piping and furnace tubs shall be in accordance with ASME B31.3

and B31.8. All pipe joints having a wall thickness greater than 9.5 mm (0.375") shall he preheated

to 100°C prior to welding when the ambient temperature is less than 10°C (500 F).

Preheating shall he carried out with an approved torch system or with electrical

induction coils which will provide uniform heating. The preheating area shall be at least 200 mm (8") wide centered about the weld and

shall extend around the entire circumference of the pipe. Preheat temperatures shall be checked with temperature sensitive crayons or by other

approved methods. If a joint requires preheating, the same temperature requirements shall be maintained

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for each succeeding pass, 2.5 WELDING DETAILS 2.5.1 All pressure welding shall be performed in accordance with approved and qualified

welding procedures as required per code. 2.5.2 Each weld shall be uniform in width and size throughout its full length. 2.5.3 Each layer or welding shall be smooth and free of slag cracks, pinholes, undercuts

(Internal and external), porosity and excessive bead shall be completely fused to the adjacent weld beads and base metal.

2.5.4 The cover pass shall be free of coarse ripples, irregular surface, non-uniform pattern,

high crown, deep ridges or valleys undercut, arc strikes, porosity, undercut, slag, or shatter.

2.5.5 Butt welds shall be slightly convex, of uniform height, and have full penetration, unless

otherwise approved. 2.5.6 For piping, limitations on weld reinforcement shall apply to the internal surfaces as

well as to' the external.

2.5.7 Fillet welds shall be of a specified size with full throat and the legs of uniform length. 2.5.8 Arcs shall only be struck in the weld groove. A controlled arc must be maintained while

welding. Should an arc strike occur, it shall be removed by grinding and the area shall be etched (10% Nital) to confirm heat affected area removal, and MT examined to ensure absence of any surface cracking.

2.5.9 After each pass the layer of weld metal must be cleaned to remove all slag, scale dirt

etc. wire brushes, grinder, or chipping hammer shall be used as needed to prepare proper surface for each succeeding weld pass.

2.5.10 Repair, chipping or grinding of welds shall be done in such a manner as not to gouge,

groove or reduce the base metal thickness. 2.5.11 No welding shall be done if the temperature of the base metal is below 50°F. Nor shall

there be any wedding done if there is moisture, grease, or any foreign material on the joint to be welded.

2.5.12 A qualified welder shall make tack welds. Cracked lack welds shall be completely

ground out and NDE by MT/PT prior to re-weld. 2.5.13 The CONTRACTORS shall make no substitution of materials or modifications to

details without the prior written approval of the OWNER. 2.5.14 Welders and welding operators shall not be qualified on production welds. 2.5.15 The CONTRACTOR shall ensure that welders and welding operators are only

employed on those parts of the work for which they are qualified. 2.5.16 Each welder and welding operator shall possess an appropriate temperature-

measuring device. All supervisors shall possess a copy of the approved welding procedures.

2.5.17 Alternatively, welding procedures may he clearly display at each welding location.

Welders shall be familiar with the requirements of the appropriate approved welding procedures. Any welder found not complying with the approved welding procedures during production welding shall be removed from the work and the non-conforming

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weld(s) may be completely rejected, at the discretion of' the OWNER. 2.5.18 No welding should be undertaken without approved WPS. 2.5.19 The OWNER will not provide any WPS for the CONTRACTOR. 2.6 Welding Techniques 2.6.1 General a) All welding shall be performed in accordance with an approved and qualified welding

procedure. 2.6.2 Cleaning a) All weld impurities shall be removed between passes. Cleaning may be done with

either hand or power tools. b) All rough irregularities in the cover pass and weld spatter shall be removed. 2.6.8 Weld Identification Each finished weld shall be clearly marked to identify the portion made by each welder.

2.7 Defects and Repairs Welds containing defects not exceeding an aggregate of five (5) percent of the length

of the root bead may be removed by grinding, chipping or arc gouging and re-welded in accordance with an approved procedure. Welds containing defects exceeding that amount shall be cut out and replaced.

When defects are ground out the entire weld shall be preheated to a temperature of

150 °C (300 °F) prior to welding. All repaired welds shall be radio graphed or by the same method of original defect

detention. 2.8 Post Weld Heat Treatment (PWHT) 2.8.1 CONTRACTOR is responsible for all PWHT requirements. Which shall be performed

as specified by the OWNER and in accordance with ANSI/ASME B31.3. 2.8.2 PWHT of pressure piping and furnace tubes shall be in accordance with ASME B31.3,

B31.8 and the specification for Post Weld - Heat Treating.

2.8.3 Controlled atmosphere furnaces are preferred for heat treatment. Procedures using

electric resistance, induction, or flame burner rings are acceptable for shop or field heat treatment. OWNER prior to heat treatment must approve these procedures.

2.8.4 CONTRACTOR must notify the OWNER prior to starting PWHT operations. 2.8.5 CONTRACTOR shall furnish a PWHT record chart. The chart must be dated,

numbered and labeled with job identification. CONTRACTOR name, and person Responsible for the PWHT. Heat-treated lane, welds and spool numbers shall be identified on the chart.

2.8.6 The completed PM/HT record chart shall be submitted for OWNER approval following

completion of heat treatment. 2.8.7 Stress relieving of piping shall be performed as per ASME B31.3 ASME B31.8. as

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applicable. 2.8.8 Stress relieving may he performed by electrical induction or by electric resistance

heating devices, or by furnace that has a large enough capacity to accommodate the entire piece being heat-treated.

2.8.9 The stress relieving temperature to be attained shall be 1100°F/593˚C minimum.

1150°F/621˚C maximum. The soak period of this temperature shall be one hour per 25.0 mm (1 inch) of pipe wall thickness and in no case shall the soak period be less than one hour.

2.8.10 Rate of heating and cooling shall be in accordance with the requirements for thermal

stress relief presented in Section VIII of the ASME Boiler and Pressure Vessel Code. In any event, the rate of heating above 600°F/315˚C may not be more than 400°F/205˚C per hour, nor the rate of cooling more than 500°F/260˚C per hour when above 600°F/315˚C.

2.8.11 For field stress relieving, a continuous temperature record Log shall be furnished of

the program from heating, soaking and cooling to 600°F. A minimum of two thermocouples shall be installed at each weld so that continuous readings can be assured in the event of thermocouple failure.

2.8.12 Local heat treatment of welds shall consist of heating ID pipe length completely

around the circumference of the pipe welds or pipes as required to eliminate thermally induced stresses. A continuous record of time and temperature shall be maintained for at least two points on each weld during the course of heat treatment with methods other than exothermic kits.

2.8.13 During heat treatment, the ends of the pipe shall be temporarily plugged to minimize

air-cooling. Sufficient insulation shall be applied to maintain the required heat treatment temperature. The full thickness of 75mm (3"-inch) insulation shall be continued for a minimum distance of 610 mm (2 feet) on each side of the heating elements, and shall be in place until the weld has cooled to below 100°F/37˚C.

2.8.14 When local heat treatment is used, care shall be exercised with restrained piping so

that no upsetting will be caused by thermal expansion. 2.8.15 A minimum 10% of all locally (field) heat-treated welds shall require Brinell hardness

testing. 2.8.16 Unless otherwise indicated by OWNER, Brinell hardness limits apply to welds after

PWHT. The hardness of the weld shall be determined by the average value of three tests (of 3 indentations) taken per 120 degrees quadrant around the weld.

2.8.17 The test areas of the weld shall be ground or filled to provide a suitable surface for

testing. If a Tele brineller is used to measure the hardness the bar shall be as close as practical to the anticipated weld hardness. If a poor indention is obtained on an individual test, a retest shall be made on an adjacent area.

2.8.18 Hardness tests other than Brinell may be used if the values obtained can be equated

to the Brinell hardness numbers, and the proposed equipment and procedures have received prior OWNER approval.

2.8.19 Flange facing and threaded connections must be adequately protected against

oxidation during stress relieving and must be cleaned and freed of defects after stress relieving.

2.8.20 No heating or welding may be applied to any piping or weld joint after stress relieving

is complete. 2.8.21 All stress relieving equipment and execution shall be supplied at Contractor’s

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expense. 2.9 WELDING PROCEDURE QUALIFICATION Welding procedure qualification shall be in accordance with the relevant requirement

of ASME Sec. IX latest edition or other applicable codes and the job requirements. The Contractor shall submit the welding procedure specification in format as per PQR. Format immediately after the receipt of the order. Owner’s representative will review, check and approve the welding procedure submitted and shall release the procedure for qualification test. The complete set of test result as per ASME sec. IX shall be submitted to the OWNER/ OWNER’s representative for approval immediately after completing the procedure qualification test and at least 2 weeks before the commencement of actual work. Standard test specified in the code shall be carried out in all cases. In addition to these test the following test shall be carried out.

1) Macro/ Micro Examination.

2) Hardness test. 3) Dye Penetrate examination. 4) Charpy V-notch Impact test at Weld and HAZ at 0 °C These tests shall be carried out on specimens depending upon the type of base

material, operating conditions and requirements laid down in the detailed drawing and specification. It shall be the responsibility of the Contractor to carry out all the tests required to the satisfaction of the OWNER/ OWNER’s representative.

2.10 Welder’s Qualification Welders shall be qualified in accordance with the ASME sec. IX or other applicable

codes. It shall be the responsibility of the Contractor to carry out qualification tests of welders.

No welder shall be permitted to work without the possession of identity card. If a welder is found to perform a type of welding or in a position for which he is not

qualified, he shall be debarred from doing any further work. All welds performed by an unqualified welder shall be cut and redone by a qualified welder at the expenses of the contractor.

2.11 Destructive Testing OWNER has the authority to order the cutting of up to 0.1% of the total numbers of

welds completed for subjecting to destructive test at no extra cost to OWNER. The destructive testing of joints shall be as per ASME- Sec IX welding procedure qualification.

In addition, welds already cut out for defects for any reason may also be subjected to

destructive testing. The sampling and the re-execution of welds shall be carried out by the contractor at his own expenses. If the results are unsatisfactory, welding operations shall be suspended and may not be restarted until the causes have been identified and the contractors have adopted measures which guarantee acceptable results.

If it is necessary in OWNER opinion the procedure shall be re-qualified. The weld joint

represented by unsatisfactory welds shall stand rejected unless investigation proves otherwise.

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3.0 NON DESTRUCTIVE EXAMINATION 3.1 GENERAL a) This specification shall govern the basic requirements for Non Destructive

Examination (NDE) as it applies to the fabrication, testing and inspection of all Pressure Piping, and Transmission Piping.

b) No supplier, vendor, manufacturer or fabricator shall subcontract the non destructive

examination of any such equipment without written approval from the OWNER, and the OWNER will not issue such an approval unless the proposed NDE SUB-CONTRACTOR has received prior OWNER approval for the type of NDE work proposed.

3.2 CODES AND STANDARDS a) Work performed under this section shall confirm to the latest edition of following codes

and standards: i) ASME B31.3 Process Piping.

ii) ASME. Section V - Non destructive Examination.

iii) ANSI/ASIA. B31.8 Gas Transmission and Distribution System.

iv) ASNT/PCN/CGSB Standards for certification of Non Destructive testing Personnel. b) Work shall also be carried out in compliance with all general specification dealing with

welding and fabrication of various equipment. 3.2.1 CONFLICT Where a conflict occurs between this Specification and any of the above Codes or

Standards the more stringent shall apply. The contractor shall inform the OWNER in writing and receive written certification form the OWNER. The contractor shall have readily available for use at the request of the OWNER latest editions of all codes, specification and standards necessary for execution of the work at work site.

3.3 ABBREVIATIONS

ASME American Society of Mechanical Engineers ANST American Society for Non-Destructive Testing ASTM American Society for Testing and Materials AWS American Welding Society DPI Dye Penetrant Inspection HS&E Health Safety and Environment MPI Magnetic Particle Inspection NDT Non-Destructive Testing PCN Personnel Certification in Non-Destructive Testing

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PWHT Post Weld Heat Treatment UT Ultrasonic Testing

3.4 NDE COMPANY CERTIFICATION All Non Destructive Examination (NDE) CONTRACTORs contracted by the OWNER

or working for fabricators or CONTRACTORs carrying out work on the OWNER behalf shall have in place an up-to-date Quality Control Manual and Code of Practice which shall cover the following:

i) All aspects of NDE of which the CONTRACTOR SUB-CONTRACTOR is qualified.

ii) Current resumes of all presently employed personnel including their certifications

(PCN, ASNT, CGSB or equivalent). iii) All proposed specific NDE procedure, A registered copy of QC manual shall be made available to OWNER and shall be

reviewed and approved by the OWNER quality assurance personnel prior to services being used. Updates to the Manual shall be forwarded to the registered holder as they become available.

The OWNER will review and approve element's i), ii) & iii) above: prior to start on any

said company work. Any approval given by the OWNER does not relieve the CONTRACTOR of his obligations under governing, codes, rules and specifications.

All equipment shall be certified and current, to recognized calibration standard and in

first class working condition. Full compliance with all governmental and local regulatory requirements of HS&E,

which shall be fully complied with. 3.5 VISUAL INSPECTION a) Visual examination shall be carried out before, during and after fabrication in

accordance with ASME Sec. V article 9 and ASME B31.3.

b) Cracks, (regardless of size and location) and under cutting or any evidence of poor workmanship, materials, etc., if not repairable shall be cause for rejection.

c) Welds shall be visually inspected wherever accessible in accordance with the following requirements:

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1. Internal misalignment 1.5 MM or Less

2. Cracks or lack of fusion None permitted.

3. Incomplete penetration (for other than 100% Radiography butt-weld)

Depth shall not exceed the lesser of 0.8 MM or 0.2 times thickness of thinner component joined by butt-weld. The total length of such imperfections shall not exceed 38 MM in any 150 MM of weld length.

4. Surface porosity and exposed slag inclusions (4.7mm.Nom Wall thickness and less)

Not permitted

5. Concave root surface (SLICK UP)

For single sided welded joints concavity of the root surface shall not reduce the total thickness of joint including reinforcement to less than the thickness of the thinner of the components being joined.

6. Weld ripples irregularities 2.5 MM or Less

7. Lack of uniformity in bead width

2.5 MM or Less

8. Lack of uniformity of leg length

2.5 MM or Less

9. Unevenness of bead 2.0 MM or Less

10. Weld undercutting 0.8 MM or 'A thickness of thinner components joined by butt weld, whichever is less. (shall be smooth finished)

11. Overlap 1.5 MM or Less

12. Bead deflection 2.5 MM or Less

13. External weld reinforcement and internal weld protrusion (when backing rings are not used) shall be fused with and shall merge smoothly into the component surfaces. The height of the lesser projection of external weld reinforcement or internal weld protrusion from the adjacent base material surface shall not exceed the following limits

Wall thickness of thinner component joined by butt weld (MM)

Weld reinforcement or internal weld protrusion (MM) Max

6.4 and under 1.6

Over 6.4 – 12.7 3.2

Over 12.7 – 25.4 4.0

Over 25.4 4.8

14. Throat thickness of fillet welds: Nominal thickness of the thinner component x 0.7 or more.

15. FLATTENING Flattening of a bend, as measured by difference between the nominal outside diameter and minimum or maximum diameter at any cross section shall not exceed 5% of the nominal outside diameter of pipe.

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16. REDUCTION OF WALL THICKNESS Reduction of wall thickness of a bend, as measured by difference between the nominal thickness and minimum thickness shall not exceed 10% of the nominal wall thickness of pipe. Welds having any imperfections which exceed the limitations specified in various clauses shall be repaired by welding, grinding or overlaying etc.

However number of times of repair welding for the same weld shall be as follows:

MATERIAL NO. OF TIMES OF REPAIR WELDING

1.0 CS UPTO 300# 3 OR LESS

2.0 CS ABOVE 300# 2 OR LESS

3.6 NON-DESTRUCTIVE TESTING 3.6.1 GENERAL a) All NDT shall be performed in accordance with ASME B31.3 /ASME 8.31.8/ ASME

code Section V except as modified by this specification. b) Category of piping are defined by categories I, II, III as shown in Table 1. The minimum requirement for extent of NDT inspection shall be as stated in Table 2.

c) The CONTRACTOR shall prepare NDT procedure covering all aspects of the

work. The NDT procedure shall be submitted to OWNER for review and approval. Approval of the NDT procedure shall be required before any NDT can be performed.

d) The CONTRACTOR shall prepare and maintain documentation to track percentage of welds tested and the weld repair rate. The proposed documentation shall be made available for review and approval.

e) Unless otherwise specified, 10% of welds in each pipe class rating shall be inspected

by NDT. Welds selected for examination shall include, as a minimum, 10% of each welder, welding operator and welding procedure such that welding quality can be established.

f) All non-pressure tie-in welds and all field welds, regardless of pipe class shall be

examined by 100% visual, radiography and MPI, DPI. g) CONTRACTOR shall not deviate from any requirement of this specification

without written approval to do so from OWNER.

h) No exemption permitted in regards to full HS&E compliance. 3.6.2 RADIOGRAPHIC EXAMINATION 3.6.2.1 General a) The quality of radiographs shall meet or exceed all requirements of the appropriate b) International standards and applicable general specifications.

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c) X - Ray is the preferred radiographic method. Use of Gamma ray for examination is not permitted. d) Particular attention shall be paid to using radiographic ultra fine grain film suitable for

the application, maintaining correct radiographic geometry during exposure, obtaining correct density also required by the appropriate standard and the correct placement and exposure of image quality indicators (IQI's or penetrameters).

e) ASTM wire type IQI's are preferred. The OWNER may permit the use of ASTM hole

type IQI's on a pre-approved basis, provided the NDT CONTRACTOR can demonstrate satisfactory results.

f) Radiographic technique shall produce maximum contrast and good definition of IQI wires and shall obtain minimum radiographic density of 10 in the weld image. Fluorescent intensifying screens shall not be used.

f) Max radiographic density shall be 4.0 in all areas of the weld and parent metal. g) The inability to view the appropriate wire or hole on any radiograph shall be cause for

automatic rejection of that radiograph which shall be re-radiographed at no expense to the OWNER.

3.6.2.2 Operator Certification a) Radiographers supplied by the CONTRACTOR shall be certified to ASNT Level II,

AWS QC] and as per AWS B1.10 (guide for non-destructive inspection of welds).

b) An operator qualified to ASNT Level I may assist the Level II operator but all film and sentencing interpretation shall be carried out by a Level ll or higher operator who shall sign off all report sheets.

c) Visual welding inspection shall be conducted only by a qualified welding inspector, who shall have a minimum AWS (QC. I) CWI or CSWIP 3.1 certification.

d) The OWNER shall review and approve all QA/QC personnel prior to deployment on the project.

3.7 MAGNETIC PARTICLE INSPECTION (WPI) a) MPT shall be carried out in accordance with the requirements of ASME. Section V.

Article 7, & Section VIII DIV 1, Appendix 6. and as modified by this specification.

b) AC electromagnetic yokes shall be used. A background of white contrast paint shall be used in conjunction with a black magnetic ink (wet particle). The technique shall be carried out in the continuous mode and two examinations shall be carried out at right angles to cover for both transverse and longitudinal defects. There shall be sufficient overlap to allow 100% coverage.

c) All unacceptable or spurious indications found by this method shall be investigated and removed by grinding followed by thickness check.

3.8 DYE PENETRATE INSPECTION (DPI)

a) DPI shall be carried out accordance with the requirements of ASME BPV, Section V, Article 6, & ASME Section VIII DIV 1, Appendix 8, and as modified by this specification.

b) Unless requested otherwise, DPI shall be carried out using the solvent removable method.

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c) If necessary welds may be lightly dressed to facilitate DPI testing or to assist in the

interpretation of any indications.

d) All unacceptable or spurious indications found by this method shall be investigated and removed by grinding followed by thickness check.

3.9 ULTRASONIC WELD EXAMINATION (UT) 3.9.1 Ultrasonic Operators a) Ultrasonic operators supplied by the NDE CONTRACTOR shall be certified to a

General Standards Board (ASNT/PCN) approved by the OWNER. 3.10 EXTENT OF INSPECTION AND TES'T'ING 3.10.1 a) Piping systems which are designed and constructed in accordance with ASME

Standard B3 I.3, Chemical Plant and Petroleum Refinery Piping, shall be radiographed as per Table II.

b) Piping systems which are designed and constructed in accordance with ASME B31.8

standard for gas pipeline systems shall have all welds radiographically inspected for 100%,

3.10.2 Hardness testing shall be carried out of welds on vessels and piping in sour or

corrosive service and 10% of local PWHT weld as per ASTM Specification E 10, ANSI 1331.3.

3.10.3 Ultrasonic Testing a) UT testing shall be carried out as per ASME B31.3 and ASME Sec. V article 5. b) All category 'D' welds which are not being radio graphed and all other welds

configuration, which does not permit to be radio graphed, shall be ultrasonic tested. c) All tie-in welds where pressure testing are not possible.

TABLE-I

EXAMINATION CATEGORIES

CATEGORY I HIGHER DUTY PIPING

• Severe cyclic conditions as indicated in the respective isometric drawings, all service.

• Carbon Steel material, ASME rating 600# all services

• All ASME classes for lethal substances.(Category `M' fluid service)

CATEGORY II NORMAL FLUID SERVICE ASME rating 150 & 300# not covered by Categories I & III

CATEGORY III CATEGORY 1) FLUID SERVICE

ASME rating 150 for all systems in Category `1' Fluid services such as:

• Service air

• Instrument air

• Open Drains

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TABLE – II

EXTENT OF TESTING AND INSPECTION

METHOD EXAMINATION CATEGORY I

EXAMINATION CATEGORY II

EXAMINATION CATEGORY III

Visual 100% 100% 100% MPI (or DPI for non-ferromagnetic materials) (Note 2)

100% examination of all branch and attachment welds

100% examination of 1 in 10 branch and attachment welds

100% examination of 1 in 10 branch and attachment welds

RT (butt weld) (Note 1)

100% examination of all welds

100% examination of 1 in 10 welds (Nose 5)

100% examination of I in 10 welds

UT (Branch weld)

(Note 5)

100% examination of all welds

0 0

Hydro test (or pneumatic test)

Yes Yes (Note 3)

Service Test

Minimum Duration

1 hour 1 hour 1 hour

Records Yes Yes Yes Notes: I) Ultrasonic testing, in lieu of radiography, is acceptable only where radiography is not

practicable e.g. branch connections. 2) UPI or DPI of branch welds to be performed prior to and lifter attachment of

compensating plate if applicable. 3) Open drains vents or other open ended line shall be leak tested only. 4) For piping within skid packages, the CONTRACTOR shall use this table as a guide

only and prepared NDE plan for review and approval by OWNER as required in the respective package specification.

5) Vat required where wall thickness of scanning surfaces are less than 10mm and where branch size is less than NPS 4". Non-ferrite materials shall not be examined with UT methods.

6) RT shall be 20% of welds for all class 300# series.

4.0 REPAIRS OF WELDS 4.1 With the prior permission of ENGINEER IN CHARGE welds that do not comply with

the standards of acceptability shall be repaired or the joint cut out and re-welded. A separate welding procedure specification sheet shall be formulated and qualified by

CONTRACTOR for repair welds simulating the proposed repair to be carried out. Separate procedures are required to be qualified for (a) through thickness repair (b) external repair and (c) internal repair. Welders shall be qualified in advance for repairs. The root pass, for repairs opening the root, shall be replaced by the vertical uphill technique. The procedure shall be proven by satisfactory procedure tests to API 1104 including the special requirements of the specification, and shall also be

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subjected to metallographic examination, hardness surveys and Charpy test to determine the effects of repair welding on the associated structure.

Root sealing or single pass repair deposit shall not be allowed. Internal root defects

shall be ground thoroughly and welded with a minimum of two passes. However, while grinding for repairs, care shall be taken to ensure that no grinding marks are made on the pipe surface anywhere.

The repair shall be subjected, as a minimum requirement, to the same testing and

inspection requirements as the original weld. Re-radiography of the repaired area shall be carried out. In addition, a minimum of 6” weld length on the either side of the repaired area, shall be re-radiographed. A 100% ultrasonic test shall be done at the repaired area externally. Any repaired area that is wide, irregular or rough shall be rejected and a full cut out shall be done.

Repairs are limited to a maximum of 30% of the weld length. Welds containing cracks

shall be cut out and rebeveled to make a joint. COMPANY shall authorize all repairs. 4.2 Weld Rejected by Accumulation of Defects Where a weld is rejected by accumulation of defect clause, as defined by API 1104

and this specification, repairs within these limitations are permitted. Defects in the filling and capping passes shall be repaired preferentially.

5.0 INSPECTION 5.1 The CONTRACTOR shall extend all facilities, assistance and co-operate fully with the

OWNER in all aspects of inspection and NDE and shall give adequate notice of any required fabrication inspection stages, together with sufficient time for thorough inspection by the OWNER. OWNER shall have the right to establish hold points at any point in the fabrication sequence.

5.2 Although is the Contractor’s primary responsibility to perform weld examination,

OWNER shall have the right to observe the examination of all welds by nondestructive means. The inspection may be at any time before, during and after fabrication. The CONTRACTOR shall conduct daily NDE percentage of welds to assess weld quality. Up-to-date examinations are required to identify and prevent the reoccurrence of weld defects on subsequent welds. Records and evidence of all weld examinations shall be available at all times for OWNER to review and approve.

5.3 OWNER may use any method of inspection necessary to establish quality control and

ensure adherence to welding procedures. OWNER shall have the right to accept or reject any weld not meeting the requirements of this specification.

5.4 OWNER reserves the right to perform inspection at shop / field where fabrication and

erection of piping is in progress for (but not limited) for the following objective: a) To check conformance to relevant stands and suitability of various welding

equipments and welding performance. b) To witness the welding procedure qualification. c) To witness the welder performance qualification. d) To witness the Electrode qualification Test. 5.5 Contractor shall intimate sufficiently in advance the commencement of qualification

test, welding works and acceptance tests to enable the owner/ owner’s representative to be present to supervise them.

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5.5 Any discrepancies between the approved WPS and the production welds noted by OWNER, any or all of the work made under these conditions is subject to rejection.

6.0 DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR a) Electrode and welding consumables qualification records for the welding consumables

tested and approved for the work. b) Batch test certificate, for the electrodes used, obtained from the Electrode

Manufacturers. c) Proposed heat treatment chart procedure. d) Heat treatment chart. e) Weld joint tensile, hardness test, Impact test result. f) Welding procedure specification immediately after receipt of order. g) Welding procedure qualification records. h) Welder performance qualification records immediately after conducting welder

qualification tests. i) Radiography procedure and the NDT procedure.


CLIENT JOB NO. - TECHNICAL NOTES FOR BUTT WELDED,

SOCKET WELDED AND SCREWED FITTINGS TOTAL SHEETS 5

DOCUMENT NO 11 0290 02 08 02 008

0 16/10/09 ISUUED FOR TENDER GV DDS PKS




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TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS 1.0 GENERAL 1.1 Chemical composition, physical properties, tests, dimensions and tolerances, heat treatment and marking

shall conform to the applicable latest codes/standards/specifications as specified in the material requisition (MR). Any deviation shall be highlighted on a separate sheet by the vendor in the quotation itself.

1.2 Test reports shall be supplied for all mandatory tests as per the material specifications Test reports shall

also be furnished for any supplementary tests as specified in the MR, Clauses 1.7.8, 1.9, 1.10 & 1.11. Material test certificates (physical properties, chemical composition & heat treatment report) shall also be furnished for fittings supplied.

1.3 All fittings shall be seamless in construction unless otherwise specified. If fittings are specified as welded,

the same shall conform to Clause 1.7. Seamless fittings can be supplied in place of welded fitting but with maximum negative tolerance of 0.3mm (max.) on wall thickness. Welded fittings shall not be acceptable in place of seamless fittings.

1.4 Outside diameters and wall thickness (unless otherwise mentioned) of butt welded fittings shall be in

accordance with ASME B36.10 and ASME B36.19 as applicable. 1.5 For reducing butt weld fittings having different wall thicknesses at each end, the greater wall thickness of

the fitting shall be employed and inside bore at each end shall be matched with the specified inside diameter.

1.6 Bevelled ends for all fittings shall conform to ASME B16.25. Contour of bevel shall be as follows:

Material Wall Thickness Weld Contour

Upto 22 mm Figure 2 Type A Carbon Steel (Except Low Temp. Carbon Steel)

> 22 mm Figure 3 Type A

Upto 10 mm Figure 4

> 10 mm & Upto 25 mm

Figure 5 Type A Alloy Steel, Stainless Steel & Low Temp. Carbon Steel

> 25 mm Figure 6 Type A

1.7 Welded Fittings: 1.7.1 All welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm. Welds shall be

ground smooth at least 25 mm from the ends. 1.7.2 For fittings made out of welded pipe, the welded pipe shall be double welded type & shall be manufactured

with the addition of filler metal. 1.7.3 Welded tees shall not be of fabricated (stub-in) type. 1.7.4 All welded fittings shall be normalised & 100% radiographed by X-ray on all welds made by fitting

manufacturers & also on the parent materials. 1.7.5 Welded pipes employed for manufacture of fittings shall be made by automatic welding only. 1.7.6 All welded carbon steel, alloy steel & stainless steel fittings shall have maximum negative tolerance of 0.3

mm. 1.7.7 Specified heat treatment for carbon steel & alloy steel fittings shall be carried out again after weld repairs.

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1.7.8 Irrespective of the material code requirement, all welded fittings indicated in the MR as “Cryo”& “LT” shall meet impact test requirements of ASME B31 .3. The impact test temperature shall be -196°C & -45°C for stainless steel & carbon steel respectively unless specifically mentioned otherwise in the MR.

1.8 Stainless Steel Fittings: 1.8.1 All stainless steel fittings shall be supplied in solution heat treated condition. 1.8.2 Solution annealing for stainless steel fittings shall be carried out again after weld repairs. 1.8.3 For all stainless steel fittings Inter Granular Corrosion (IGC) test shall have to be conducted as per the

following: - ASTM A 262 Practice “B” with acceptance criteria of “60 mils/year (max.)”.

Or - ASTM A 262 Practice “E” with acceptance criteria of “no cracks as observed from 20X magnification” & “microscopic structure to be observed from 250X magnification

1.8.4 When specifically asked for in MR for high temperature application of some grades of austenitic stainless steel (eg. SS309, 310,316,316H etc.) ASTM A 262 Practice “C” with acceptance criteria of “15 mils/year” shall have to be conducted.

1.8.5 For the IGC test as described in Clauses 1.8.3 & 1.8.4, two sets of samples shall be drawn from each

solution treatment lot, one set corresponding to the highest carbon content and other set to the highest fitting thickness. When testing is conducted as per ASTM A 262 Practice “E”, photograph of microscopic structure shall he submitted for record.

1.9 Fittings under “NACE” category shall meet the requirements of MR-01-75. 1.10 Thickness/schedule lower or higher than specified shall not be accepted. 1.11 The gasket contact surfaces of stub ends shall be flat with face finish as specified below:

• Serrated Finish Serrations with 250 to 500µ in AARH

• Smooth Finish: Serrations with 125 to 250 µ in AARH 1.12 Seamless stub ends shall not have any welds on the body. 1.13 Galvanised fittings shall be coated with zinc by hot dip process conforming to IS 4736/ ASTM A 153. 1.14 Threaded ends shall have NPT taper threads in accordance with ASME/ANSI B 1.20.1 upto 1.5” NB & IS

554 from 2” to 6” NB. 1.15 Unless and otherwise specified in the MR, all socket welded and screwed fittings shall be in accordance

with ASME B16. 11 to the extent covered in the specification except for unions which shall be in accordance with MSS-SP-83.

1.16 Special fittings like weld-o-let, sock-o-let, sweep-o-let etc. which are not covered in ASME, MSS-SP & J P

Kenny Standards shall be as per manufacturer’s std. Contours of these fittings shall meet the requirements of ASME B3 1.3. Manufacturer shall submit drawings / catalogues of these items along with the offer.

1.17 Length of all long half couplings shall be 100 mm unless otherwise specified. 1.18 All seamless pipes employed for manufacturing of fittings shall be required to have undergone hydrotest to

ASTM A 530. Welded pipes employed for manufacture of fittings shall be tested as given below:

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Welded Pipe Employed For Manufacture Of Welded Fittings. Test Criteria

ASTM A671 Gr. C65,70 (Cl.32) ASTM A672 Gr. C60,65,70 (C1.12, 22) ASTM A671 Gr. CF60,65,70,66 (CL32) ASTM A691 Gr. 1/2Cr, 1Cr, l¼ Cr, 2¼ Cr, 5Cr, 9Cr (Cl.42)

P = 2ST/D S = 90% of SMYS. T = Nom. Wall Thickness D = O.D. of Pipe.

API5L ASTM A358 TP 304, 304L, 304H,318, 318L, 318H,321,347 (Cl.1, 3, 4)

P = 2ST/D S = 85% of SMYS. T = Nom. Wall Thickness D = O.D. of Pipe.

ASTM B725 ASTM B725

ASTM B517 ASTM B517

ASTM B514 ASTM B514

1.19 The bevel ends of all butt weld fittings shall undergo 100% MP/DP test. 1.20 Swage nipples (concentric/eccentric) if specified as pipe materials are acceptable in forging materials

(upto 1½”) and wrought fitting materials (above 11/2”) also in the corresponding material grades. 1.21 Abbreviations for ends of swages and nipples shall be as follows:

PBE : Plain Both Ends TBE : Threaded Both Ends

2.0 IBR REQUIREMENTS 2.1 IBR Documentation Required: 2.1.1 Fittings under the purview of “IBR” (Indian Boiler Regulations) shall be accompanied with original IBR

certificate in Form Ill-C duly approved and countersigned by IBR authority / local authority empowered by Central Boiler Board of India. Photocopy of the original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance.

2.1.2 For materials 1¼Cr - ½Mo (ASTM A 234Gr.WP11 & ASTM A234 Gr.WP11W) & 2¼Cr - 1Mo (ASTM A

234 Gr.WP22 & ASTM A234 Gr. WP22W),where fittings are manufactured from pipe, Form Ill-C approved by IBR shall include the tabulation of Et, Sc, & Sr values for the entire temperature range given below. Et, Sc, & Sr values shall be such that throughout the temperature range

Et /1.5 ≥ SA Sr /1.5 ≥ SA Sc ≥ SA SA : Allowable stress at the working metal temperature.

Et : Yield point (0.2% proof stress at the working metal temperature) Sc : The average stress to produce elongation of 1 % (creep) in 100000 hrs at the working metal temperature. Sr : The average stress to produce rupture in 100000 hrs at the working metal temperature and in no case more than 1.33 times the lowest stress to produce rupture at this temperture.

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SA (psi)

Temp(°F) Material

500 600 650 700 750 800 850 900 950 1000 1050 1100

A 234 Gr.WP11 / A234 Gr.WPI1W

21700 20900 20500 20100 19700 19200 18700 13700 9300 6300 4200 2800

A 234 Gr.WP22 / A234 Gr.WP22W

17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200

Note : SA values given above are from ASME B31.3-1996. Values shall be as per the latest edition prevailing. 2.2 For carbon steel fittings described “IBR” chemical composition shall conform to the following:

Carbon (max) : 0.25% Others (S, P, Mn) : As prescribed in IBR regulations

The above composition is not valid for non-IBR fittings.

3.0 MARKING AND DISPATCH 3.1 Each fitting shall be legibly and conspicuously stamped in accordance with the requirements of

applicable standards along with special condition like “IBR”, “Cryo”, “NACE” etc. 3.2 Steel die marking with round bottom punch may be permitted on body of butt weld CS & lower alloy steel

fittings, but for SS & higher alloy steel fittings, the same should be marked by electro-etching only. 3.3 Paint or ink for marking shall not contain any harmful metals or metal salts such as Zinc, Lead or Copper

which causes corrosive attack on heating. 3.4 Fittings shall be dry, clean and free of moisture, dirt and loose foreign materials of any kind. 3.5 Fittings shall be protected from rust, corrosion and mechanical damage during transportation, shipment

and storage. 3.6 Rust preventive used on machined surfaces to be welded shall be easily removable with a petroleum

solvent and the same shall not be harmful to welding. 3.7 Fittings under “IBR”, “Cryo”, “NACE” shall be painted in red, light purple and canary yellow stripes

respectively for easy identification. Width of the stripe shall be 25 mm. 3.8 Each end of fitting shall be protected with a wood, metal or plastic cover. 3.9 Each size of fitting shall be supplied in separate packaging marked with the purchase order number, item

code number, material specification, size and schedule I thickness / rating.

PIPING STANDARD DRAWINGS

SPECIFICATIONS

MECHANICAL

GAIL GAS LIMITED


CLIENT JOB NO. -

MECHANICAL DESIGN BASIS TOTAL SHEETS 13

DOCUMENT NO 11 0290 02 09 04 001

0 06/10/09 ISSUED FOR ENGINEERING RM DDS PKS

A 10/07/09 ISSUED FOR APPROVAL RM DDS PKS


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TABLE OF CONTENT 1.0 PROJECT DESCRIPTION……………………………..................................................3 2.0 DEFINITIONS............................................................................................................. 4 3.0 WORK TENDERED....................................................................................................4 4.0 SCOPE OF WORK………………………………………………………………………….4 5.0 DESIGN CODES, STANDARDS AND SPECIFICATIONS …………………………... 5 6.0 BASIC DESIGN ……………………………………………………………………………..6 7.0 PRESSURE VESSEL…………………….....................................................................7 8.0 FILTER/COALESCER………………………………………………………………………9 9. 0 MECHANICAL DESIGN CRITERIA……………………………………………………….9 10.0 MATERIAL HANDLING FACILITIES……………………………………………………..10 11.0 INSPECTION, TESTING ANDCERTIFICATES……….…………………………………11 12.0 MATERIAL AND WELDING INSPECTION………………………………………………11 13.0 SPARE PARTS AND TOOLS……………………………………………………………...11 14.0 SPECIAL TOOLS……………………………………………………………………………12 15.0 BATTERY LIMITS………………………………………………………………………….. 12 16.0 COLOUR CODING…………………………………………………………………………. 12 17.0 RESPONSIBILITIES OF THE CONTRACTOR………………………………............... 12 18.0 GUARANTEE TEST…………………………………………………………………………..14

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1.0 PROJECT DESCRIPTION

a) DEWAS CITY GAS DISTRIBUTION

M/s Gail Gas Ltd intend to lay 8”/6”/4” City Gas Distribution spurline (from Sanwer to Dewas) from Jagoti Pithampur Pipeline network of Gail (India) Ltd to supply the Natural Gas for Dewas City Gas Project. A 12” dia Spurline connects Dewas from Tap Off at Sanwer from Jagoti Pithampur

Pipeline. The Proposed pipeline as envisaged is of ~ 31.1 km length.

City Gate Station and Steel Grid Pipe Line

The City Gate Station has been proposed in Industrial Area No.3. Natural Gas from the CGS is fed into single pipeline supplying gas to the city network. The pressure at the downstream of CGS shall be 19 bar. A Primary network of steel pipeline shall connect the various CNG stations and District Regulating Stations (DRS) for further gas supply distribution to automotive and and PNG consumers. SV Stations are installed at approx every 2.5 km distance. As far as possible, SV Stations are planned to be installed near CNG stations for prompt maintenance response.

b) MEERUT CITY GAS DISTRIBUTION M/s Gail Gas Ltd intend to lay Steel Grid Pipeline by taking Tap-off from GAIL’s proposed Dadri-Nangal-Bhatinda Pipeline at Baghpat Road intersection which is considered as the source of gas supply for Meerut City Gas Distribution Project, is approximately 23.8 kms from the proposed City

Gate Station. The Proposed pipeline as envisaged is of ~45.1 km length.

City Gate Station and Steel Grid Pipe Line The City Gate Station has been proposed to be located at crossing of Baghpat road and by-pass road in Meerut. Natural Gas from the CGS is fed into single pipeline supplying gas to the city network. The pressure at the downstream of CGS shall be 19 bar. A Primary network of steel pipeline shall connect the various CNG stations and District Regulating Stations (DRS) for further gas supply distribution to automotive and and PNG consumers. SV Stations are installed at approx every 2.5 km distance. As far as possible, SV Stations are planned to be installed near CNG stations for prompt maintenance response.

c) SONIPAT CITY GAS DISTRIBUTION M/s Gail Gas Ltd intends to lay Steel Grid Pipeline by taking Tap-off from GAIL’s proposed Dadri-Nangal-Bhatinda Pipeline at Bawana which is considered as the source of gas supply for Sonipat

City Gas Distribution Project. The Proposed pipeline as envisaged is of ~41 km length.

City Gate Station and Steel Grid Pipe Line The City Gate Station has been proposed to be located near Rai enroute the Bawana spur Pipeline. Natural Gas from the CGS is fed into single pipeline supplying gas to the city network. The pressure at the downstream of CGS shall be 19 bar. A Primary network of steel pipeline shall connect the various CNG stations and District Regulating Stations (DRS) for further gas supply distribution to automotive and and PNG consumers. SV Stations are installed at approx every 2.5 km distance. As far as possible, SV Stations are planned to be installed near CNG stations for prompt maintenance response.

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d) KOTA CITY GAS DISTRIBUTION

M/s Gail Gas Ltd intends to lay 10”/8”/4” City Gas Distribution spurline (from Naya Nohra to Kota)by taking Tap-off at Naya Nohra, from 16” Gadepan-Naya Nohra Pipeline network of Gail (India) Ltd to supply the Natural Gas for Kota City Gas Project. The Proposed pipeline as

envisaged is of ~41 km length.

City Gate Station and Steel Grid Pipe Line

The City Gate Station has been proposed near Samcor Glass Factory. Natural Gas from the CGS is fed into single pipeline supplying gas to the city network. The pressure at the downstream of CGS shall be 19 bar. A Primary network of steel pipeline shall connect the various CNG stations and District Regulating Stations (DRS) for further gas supply distribution to automotive and and PNG consumers. SV Stations are installed at approx every 2.5 km distance. As far as possible, SV Stations are planned to be installed near CNG stations for prompt maintenance response.

2.0 DEFINITIONS CLIENT / OWNER : GAIL Gas Ltd CONSULTANT : Wood Group Engineering India Pvt. Ltd. CONTRACTOR : The person, firm or company on the Purchase

Order and to whom the Purchase Order is addressed.

VENDOR : “Vendor” means the person(s), firm, company,

organization from whom contractor procures products/services.

3.0 WORK TENDERED 3.1 The work tendered in this bid package consists of fabrication, installation, testing and

commissioning of the City Gas Distribution Spurline inclusive of City Gate Station, Online/Mother Station, Daughter Booster Station, Steel Grid Pipe lines, CP works, SV station, District Regulating Stations & above ground piping including all associated mechanical, civil, structural, Telecommunication works.

3.2 Contractor will organize equipment and manpower accordingly to meet this requirement as per

instruction of Engineer-in-charge.

4.0 SCOPE OF WORK 4.1 The scope of work shall generally be, but not limited to the following:-

“The Contractor’s scope of work shall consist of preliminary activities like check survey, supply as required, fabrication, installation, hook-up, testing and pre-commissioning of steel pipeline and assistance during commissioning along with all associated mechanical, civil, structural, HDPE conduit laying works and installation of OFC cable works. All such works, which are not indicated here below but are otherwise required to complete the work in all respects shall form part of

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Contractor’s scope of work. Further, the scope indicated below shall be read in conjunction with the schedule of rates, drawings, standards, specifications, and other requirements forming part of the contract document.”

5.0 DESIGN CODES, STANDARDS & SPECIFICATION

Design, engineering, fabrication, testing etc. shall be as per the list of codes and standards. ASME Section - II, Div-1: Boilers and Pressure Vessel Code- Materials

ASME V : Boiler and Pressure Vessel Code - Non Destructive

Testing.

ASME VIII : Boiler and Pressure Vessel Code - Div 1- Pressure

Vessels.

ASME IX : Boiler and Pressure Vessel Code - Welding & Brazing

qualifications

ASME B 31.1 : Power Piping.

ASME B 31.3 : Process Piping.

ASME B 31.8 : Gas Transmission and Distribution Pipeline System.

ASME B 16.5 : Steel Pipe Flanges and Flanged Fittings.

ASME B 16.9 : Factory-made Wrought Steel Butt Welding Fittings.

ASME B 16.11 : Forges Steel Fittings, Socket Welding and Threaded.

ASME B 16.25 : Butt Welded Ends.

ASME B 16.47 : Large Diameter Steel Flanges: NPS 26 through NPS 60.

ASTM A 105 : Forging, Carbon Steel for Piping Components.

ASTM A 181 : Forging, Carbon Steel for General-Purpose Piping.

ASTM A 234 : Piping Fitting of Wrought Carbon Steel and Alloy Steel

for moderated and Elevated Temperatures.

ASTM A 370 : Mechanical Testing of Steel products .

ASTM A 216 : Carbon Steel Castings suitable for Fusion Welding for

High temperature Service.

ASTM A 20 : General requirements for steel plate for pressure

vessels.

ASTM A 516 : Carbon steel pressure vessel plates for moderate and

low temperature service.

ASTM A 106 : Carbon steel seamless pipe for high temperature

service.

ASTM A 193 : Alloy steel and stainless steel bolting materials for high

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temperature.

ASTM A 194 : Carbon and alloy steel nuts for bolts for high pressure or

temperature.

MSS-SP-6 : Standard Finishes for Contact Faces of Pipe Flanges

and Connecting – End Flanges of Valves and Fittings.

MSS-SP-44 : Steel pipeline flanges.

MSS-SP-75 : High test wrought butt-welded fittings.

ISO 9712 : Non-destructive testing qualification and certification of

personnel.

ISO 10474 : Steel and Steel Structures Inspection documents.

ISO 9000 : Quality Management and Quality Assurance Standards.

ISO 9001 : Quality Systems – Model for quality assurance in design,

development, production, installation and servicing.

OISD – 179 : Safety Requirements on Compression, Storage, Handling

& Refueling of Natural Gas for use in Automotive Sector

P & N G R B : Petroleum & Natural Gas Regulatory Board

6.0 BASIC DESIGN

6.1 General Considerations

Various equipments, their capacity and quantity envisaged in the project are indicated in the

Scope of work (Basic Bid work). To minimize the interface responsibility, wherever practical,

Mechanical equipment shall be grouped together and specified in packages. Packages may be

procured in complete from a single point Contractor who would have sole responsibility for the

package performance. All packaged equipment shall be supplied as skid mounted, fully

assembled, piped, wired and tested as per specifications. Structural steel base frame of skid shall

be designed for single lift operation. Equipment shall be designed and selected for continuous

duty, unless specified otherwise.

Filled in Data-Sheets as stated in specifications for each item along with the drawings and

documents asked for in the specifications will be furnished for review and approval of the Owner.

During detailed engineering, the successful bidder shall furnish all the design details, calculations,

and drawings for approval by the Owner.

The equipment prone to leakage/spillage/moisture condensation shall be provided with drip pans

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so as to avoid spillage of any liquid on the ground. Ease of accessibility to drain points and piping

connections shall be specified on all equipment that has an oil lubrication or heat transfer system.

In addition, following general considerations have to be kept in view for all Items while formulating

their specifications & also downstream procurement engineering activities.

6.1.1 Safety to personnel and equipment during both operation and maintenance

6.1.2 Reliability of service

6.1.3 Minimal fire risk

6.1.4 Ease of maintenance and convenience of operation

6.1.5 Design for location in outdoor area

6.1.6 Packaged unit shall be furnished as skid mounted fully assembled equipment

6.1.7 Adequate provision for future extension and modification

6.1.8 Fail-safe feature

6.1.9 Suitability for applicable environment factors

6.1.10 Optimized spares inventory

The equipment in general, shall conform to requirements of data sheets, Functional specification

and the latest revision of relevant codes & Standards and shall be suitable for installation and

satisfactory operation in the applicable service conditions. Pressure piping within package shall

be designed and fabricated to ASME B 31.3.

Vendor shall be responsible for thermal and mechanical design and for Obtaining ASME code

stamping. Latest computer programs will be used.

7.0 PRESSURE VESSELS:

7.1 All vessels & columns shall be designed in accordance with equipment Specifications.

7.2 Calculations used to establish & check mechanical design of vessels shall be as per codes,

standards & code practices.

7.3 It shall be ensured that the equipment is free from overstressing for any loading within specified

maximum loading class.

7.4 Thinning allowance for dished ends should be 2 mm for cold pressing / 4 mm for hot pressing or

10% of nominal thickness whichever is lower.

7.5 The vessels sizing shall be on outside diameter for CS Alloy steel / SS and inside diameter for

clad steel vessels.

7.6 For cladded vessel, cladding thickness shall be minimum 3 mm

7.7 The preferred head cover shall be deep tori-spherical for medium pressure, hemispherical for high

pressure. Flanged covers shall be provided for vessels up to 800 mm diameter. For other vessels

with Demisters, demisters shall be removable from bottom / manhole.

7.8 All vertical vessels are to be designed considering liquid hold up in addition to the design

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pressure.

7.9 Minimum plate thickness for vessels shall be minimum 6 mm.

7.10 Skirt mounted vertical vessels & columns will include full diameter skirt.

7.11 Horizontal vessels shall include standard saddles.

7.12 All vessels shall be radio graphed as per code. However heads shall either be single piece

construction or shall be fully radio graphed.

7.13 All nozzles shall be welded and flanged.

7.14 Minimum manholes size shall be DN 500 unless restricted by vessel Diameter. Covers shall be

equipped with swinging type davits. Davit Shall be provided for all pressure vessel man ways.

7.15 Vessel shall have 750 MM wide platform at all manholes and at any other identified maintenance

Location.

7.16 To ensure proper fit, level indication and instrumentation directly attached to the vessel shall be

included in the scope of vessel vendor.

7.17 Piping within equipment package should be as per given relevant specs.

7.18 All columns and vessels shall be fabricated at shop and shall be transported in single piece to

site.

7.19 For shop fabricated items, hydro-testing shall be carried out at shop also.

Scope in respect of PRESSURE VESSELS, includes but not limited to the following:

7.20 Design and detailed engineering of all pressure vessels based on data sheets provided as per

“ASME code section VIII, Division – I, Pressure Vessels” ( latest edition ), submission of design

calculations and detailed drawings including foundation drawings for approval by Owner, if any.

7.21 Fabrication of vessels at shop / site including all materials supply as per fabrication drawing duly

approved by Owner / consultant, if any.

7.22 NDT inspection by third party as per relevant standards mentioned in detailed scope

7.23 Transportation of vessels to site if fabricated at shop.

7.24 Construction of civil foundation as per approved drawings with all Materials supplied at site.

7.25 Erection of vessels in respective foundation and hydro-testing at the rated pressure as per

recommendation of relevant code and approved test procedure by owner.

7.26 Hooking-up of vessel to integrate with installation as per P&ID and Approved drawings.

7.27 Trial run and pre-commissioning test with water/ fluid.

7.28 Final commissioning of the system.

7.29 Insulation / Painting of Pressure Vessels

a) Cleaning and insulation / painting as per the requirement as per detail specification for insulation

/ painting.

b) Any other work which may necessary to complete the pressure vessels with respect to integrate

with the Gas GGS in all respects.

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8.0 FILTER/COALESCER

Filters / Coalescer shall be complete and operable units comprising of supports, nozzles, flanged

inlet/outlet connections, drain connection, flange cover with pipe davit, filter element, relief valve,

differential pressure indicator and other accessories as required. The filter shall remove solid

particles / moisture content that may be present in the diesel system. Refer process design

criteria and P & ID for capacity and instrumentation requirements. The vessel shall be designed,

fabricated and tested in accordance with ASME Section VIII Div-1. As a minimum requirement,

the vessel shall be designed for spot radiography. Dish ends to shell circumferential joints shall,

as a minimum requirement, be fully radio graphed.

Filter shall be provided with Quick opening end end closure with davit assembly for easy removal

/ Replacement of filter element. Filter shall be cartridge type. The selection criteria along with the

specifications and other details for the filter elements shall be fully described in the Tender.

9.0 MECHANICAL DESIGN CRITERIA

9.1 The design criteria give the minimum requirements for mechanical design to be carried out. This

shall be read in conjunction with the specifications attached elsewhere in the bid.

9.2 The equipment proposed to meet the specification shall be designed and manufactured to

achieve the highest possible reliability for design life of 40 years.

9.3.1 All design calculations for pressure requirements, vibrations, considering seismic factors etc.

shall be made in accordance with code requirements and submitted to the OWNER for Approval.

9.4 In the event of conflict, the following order of priority shall govern:

9.4.1 Mechanical Design Basis

9.4.2 P&ID’s

9.4.3 Data Sheet

9.4.4 Drawings

9.4.5 Specifications

9.4.6 Codes and Standards

9.5 LAUNCHERS / RECEIVERS AND HINGED CLOSURE

9.5.1 The Launcher / Receivers shall be supplied along with hinged closure, pig detector and

accessories like trolley, jib crane and other pig handling devices. Launcher / Receiver shall be by

directional type.

9.5.2 The material specification shall be governed by the design conditions of

pressure, temperature, corrosion allowance and compatibility with contained media.

9.5.3 Contractor to calculate thickness / schedule against each size of piping class. Pipe internal

diameter from launcher / receivers shall be critically checked for the safe passage of pig. There

should not be any negative tolerance in internal diameter of Launcher/Receiver barrel.

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9.5.4 Pig launchers and pig receivers are important for any pigging systems to ensure safe and efficient

working and handling of pigs. Both Launchers and receivers are required with suitable bandlock

type hinged closure and shall be provided for easy and safe access during pig loading and

unloading. Such closure shall be as per data sheets. Barrel shall be designed to suit the

intelligent pigging. The barrel and hinged closure shall be designed as per latest edition of ASME

Sec VIII Div 1. Launcher / Receiver dimensions shall be suitable for intelligent pigging.

9.5.5 The design pressure and temperature for launching / receivers and hinged closure is 49 barg for

and 0 to 60 deg. C respectively.

9.5.6 Pipes, fittings, flanges of size 3/8”, 1 ¼”, 2 ½”, 3 ½”, 4 ½”, 5”, 7” and 9” shall not be used.

However, where equipment is regular supplied by the manufacturer with piping connections of the

above odd sizes, connection shall be made to approve nominal sizes using reducers.

9.5.6 Spectacle blind at the flanged end of Launcher / Receiver to be provided with other spectacle on

kicker line and by-pass line.

9.5.8 The venting arrangement in station should have ball and globe valve combination.

9.6 SCRAPPER TEES / BAR TEES

9.6.1 Scrapper tee is basically used for preventing the pig from entering into the branch line.

9.6.2 The design code followed shall be ASME B31.8 and ASME B16.9.

9.6.3 The design pressure and temperature for the scrapper tees shall be 49 barg and 0 to 60 deg. C.

10. 0 MATERIAL HANDLING FACILITIES

Material handling facilities study shall be carried out by contractor during

Detailed engineering stage based on the equipment sizes and weight. Actual requirement shall

be established based on this study and the facilities shall be provided accordingly. Necessary

hooks/Beam clamps shall be provided in the process areas and above all such maintenance

prone equipment where material Handling facilities are not permanently located or crane access

is not Available. All equipment supplied for mechanical handling including lifting points

And beams shall be identified with its applicable safe working load and shall be certified for that.

Material handling facilities to be provided in hazardous area shall be suitable for operation in

hazardous area application / requirements. Adequate facilities shall be provided on the site for the

following :

i) Handling and transfer of equipment assemblies / subassemblies during routine maintenance.

ii) Handling and transfer of materials, consumables from storage to respective consumption areas,

with most convenient manner requiring minimum time.

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11.0 INSPECTION, TESTING AND CERTIFICATIONS

11.1 General

The responsibility for inspection and testing rests with the Contractor. The owner reserves the

right to witness any manufacturing operation, assembly or testing of the Equipment / Packages

within the Contractor’s or Manufacturer’s plant and review any audits and reports for the subject

works.

11.2 Inspection and Testing

All the systems/ equipment required to meet the design conditions as stated shall be

Performance and Function tested preferably at the manufacturer’s works in accordance with

respective codes and functional specifications.The Contractor shall submit for review and

approval by the Company a comprehensive Inspection and Test Plan (ITP) covering all relevant

components, completed equipment and systems. No work by the Contractor or its subcontractors

may commence without prior approval by the owner/consultant of the ITP’s. A detailed test

procedure of shop tests shall be submitted at least two (2) months in advance of any testing and

shall be approved by the Company. A dimensional check of the Package assembly and

components shall be performed for compliance with approved drawings. String tests and site

performance test shall also be carried out as per the requirement.

12.0 MATERIAL AND WELDING INSPECTION

Non-destructive material tests and pressure testing shall be in accordance with the ASME section

V and other Functional specifications enclosed in the bid. All non-destructive testing shall be

performed by an approved third party and accredited Non-Destructive Testing (NDT) inspection

organization.Full traceability of all material components (to material certificates) is require

13.0 SPARE PARTS & TOOLS

In view of above, the complete maintenance and spare parts requirements for the Equipment/

Package shall be furnished with the Tender. This shall include spares for start-up, commissioning

and one year’s operations.

Contractor shall supply spares for commissioning and start up. All spare parts furnished by the

Contractor shall be wrapped and packaged to preserve the parts as in original condition. The

same parts shall be appropriately tagged using stainless steel tags and coded so that later

identification as to their intended equipment usage will be facilitated. All items supplied shall be

packaged separately and clearly marked as “Spare Parts” and shipped with the equipment in

accordance with the instruction from the Company. Packing lists shall be furnished complete in

detail so that parts can be handled without uncrating,

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14.0 SPECIAL TOOLS

With its Tender the Contractor shall provide a list of relevant special tools required for the

erection, maintenance for the all equipment. Included in the list of special tools shall be tools

required for access & removal operations such as mechanical handling and lifting aids, slings,

spreader bars, etc. Prior to shipment each special tool shall be packed in rugged tool box, tagged

with stainless steel tag detailing its description and where it is to be used.

15. 0 BATTERY LIMITS

15.1 Battery limits for station shall be as per the drawings attached in the bid.

16.0 COLOUR CODING

16.1 Ball Valve (Above Ground) : Off White-- RAL 9010

16.2 Globe Valve (Above Ground) : Oxford Blue –RAL 5005,IS- 519941005

16.3 Check Valve (Above Ground) : Oxford Blue –RAL 5005,IS-519941005

16.4 ALL UNDER GROUND VALVES : Grey Epoxy

16.5 Pipelines (Above Ground) : Yellow Golden

16.6 Launcher/Receiver : Yellow Golden

16.7 Jib Crane/Trolley : Red & White Straps

16.8 All under ground valves shall have epoxy base coating after surface finish Of SA2.5

16.9 Valves and above ground pipes need to be properly blasted to achieve

surface Finish of SA 2:5 before the application of paints

17.0 RESPONSIBILITIES OF THE CONTRACTOR

17.1 All surveys such as pre-engineering, pre-construction, post construction etc shall be carried out as

required.

17.2.1 Design and detail engineering of all facilities in accordance with design parameters and

International codes and standards, but incorporating changes / revisions which are not

adequately covered and reflected, considering that the bid documents is solely based on

functional specifications.

17.2.2 Prepare all fabrication drawings, purchase specification for all equipment and specialty items,

specifications and procedure for fabrication, installation, coating of all items, painting, hook-up,

testing, pre-commissioning and commissioning and start-up as recommended for the items

supplied by him as per the specification attached in the bid.

17.3 Procurement including expediting and inspection of all materials and equipment for construction

and incorporation in the facilities. In addition to OWNER or OWNER appointed inspection agency,

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the contractor has to carry out the inspection of material / equipment through third party

inspection agency duly approved by the OWNER.

17.4 Fabrication and assembly of all facilities included installation of equipment into the facilities in

accordance with the approved drawings and specifications.

17.5 Installation of all facilities, hook-up, testing and pre-commissioning all Such activities shall be

witnessed by the OWNER.

17.6 Any other works specified elsewhere in the bid document.

17.7 Contractor shall furnish all the information as sought by the OWNER in Formats for its data

storage and retrieval system at no cost to the OWNER.

17.8 Procurement of all items shall be done from vendor list approved by OWNER. Necessary

documents such as purchase specifications, test certificates shall be furnished for review /

approval.

17.9 Contractor to plan and carry out suitable isolation, de-pressurization, purging, cleaning, Hydro

testing, Flushing, drying, painting and removal of temporary supports, scaffolding etc. Contractor

to execute the job safely without any operational hazard.

17.10 Any other work not specifically mentioned above but required for completeness of the work as per

specifications / drawings / codes and standards and instructions of engineer- in – charge at site.

17.11 It is the responsibility of the contractor to ascertain space and exact routing for meeting the

requirements of finally approved P&ID’s and design criteria.

17.12 The contractor shall conduct necessary site surveys, prepare additional drawings / data required

which are not parts of the enclosed bid package to ensure proper completion of work. The

contractor shall gather all information from existing facilities in case as-built drawings are not

available.

17.13 Contractor’s scope of work shall include modification / integration as per approved P&ID and other

requirements listed elsewhere in the bid package. For carrying out his scope of work, contractor

may be required to open / dismantle / realign / modify any facilities or instrument or piping or

equipment of the existing facilities and the cost of the same shall be included in the lump sum

price. IT will be contractor’s responsibility to make good, test and pre-commission all such facility

during and after completion of work with minimum period of shutdown. Details of total shutdown if

required for each modification / integration shall be indicated in the bid against each activity.

17.14 Contractor shall perform the necessary modification / integration work on the basis of actual

physical conditions / data / parameters foundduring the site survey during pre-engineering stage.

Contractor shall not be entitle to any cost and time compensation on this account.

17.15 Contractor shall ensure, before submission of his bid, that the space allocated for the various

facilities for the modification is adequate and satisfactory. In case any additional space / facility

such as provision of any walkway / operating platform for maintenance and operation of

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equipment is required, the contractor shall indicated the same in his bid and the cost shall be

included in the lump sum price.

17.16 If the bid document / P&ID’s specifically required any existing facility to be altered or reused, the

same shall be done by the contractor after verifying / checking the condition of existing facility. IF

whole or any part of it is found to be defective, contractor, without any extra cost, shall replace the

same.

17.17 In accomplishing the above task the contractor shall take the total responsibility of executing the

project in accordance with this bid document including the supply of all materials and

consumables, construction equipment, labour etc. and will adhere to bid document instructions

and requirements in respect of all matter relating to the project.

18.0 GUARANTEE TEST

In addition to the routine tests and guarantees by the manufacturers for the items being procured

and installed, the EPC contractor to demonstrate, as called for by the OWNER / OWNER’s

representative, by carrying out additional tests viz Hydro testing, NDT etc. at pressure and

temperatures as specified by the OWNER in order to ensure that the entire system is safe and

meeting the parameters specified in the bid documents.

GAIL GAS Limited CITY GAS DISTRIBUTION PROJECT

DEWAS

CLIENT JOB NO. TECHNICAL SPECIFICATION FOR

MONOLITHIC INSULATING JOINTS TOTAL SHEETS 9

DOCUMENT NO 11 0290 02 09 02 002





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FOR MONOLITHIC INSULATING JOINTS SHEET 2 of 9

TABLE OF CONTENTS

Sl.No. DESCRIPTION PAGE NO. 1.0 SCOPE 3 2.0 REFERENCE DOCUMENTS 4

3.0 MATERIALS 5 4.0 DESIGN & CONSTRUCTION REQUIREMENTS 5 5.0 INSPECTION & TESTING 6 6.0 TEST CERTIFICATES 7 7.0 PAINTING, MARKING & SHIPMENT 8 8.0 SPARES AND ACCESSORIES 8 9.0 DOCUMENTATION 8

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1.0 SCOPE This specification covers the basic requirements for design manufacture, testing and supply of

carbon steel insulating joints to be installed in onshore cross country pipeline systems used for transporting non-sour hydrocarbon gases including LPG.

This specification does not cover the Insulating joints for sour hydrocarbons (liquid/gas) service as defined in NACE standard MR-01-75.

1.1 Abbreviations

The following definitions shall apply:

• ASME : American Society of Mechanical Engineers.

• ASNT : American Society for Non-destructive Testing.

• ASTM : American Society for Testing and Materials.

• ISO : International Standards Organization.

• NDE : Non-destructive Examination.

• MSS : Manufacturers Standardization Society.

• NPS : Nominal Pipe Size.

• UNS : Unified Numbering System.

1.2 Definitions

Purchaser : The Company which makes purchase order.

Manufacturer : Manufacturer who receives the purchase order.

Shall : This verbal form indicates requirements strictly to be followed in order to confirm to the standards and form in which no deviation is permitted.

Should : This verbal form indicates that among several possibilities one is particularly suitable without mentioning or excluding others or that a certain course of action is preferred but not necessarily required.

May : This verbal form indicates a course of action permissible within the limits of this standard.

Can : This verbal form used for statements of possibility & capability , whether material, physical or casual. 1.3 Compliance

Compliance by the MANUFACTURER with this specification shall not relieve him of his responsibilities to supply Monolithic insulating joints suited to meet the specified requirements and/or local codes governing health and safety.

The MANUFACTURER shall notify the CONSULTANT in writing, of any proposed deviation from this Specification. The Consultant’s decision in respect of concession requests will be final. The CONTRATOR shall continually verify the quality and fitness for purpose of the Monolithic insulating joint, and shall propose appropriate actions/measures if any aspects of manufacture are found to be unsatisfactory.

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1.4 Quality Conformance

The MANUFACTURER shall demonstrate to the satisfaction of the OWNER / CONSULTANT that his activities within the scope of this document are in accordance with the relevant section of BS EN ISO 9001. The MANUFACTURER shall submit to the CONSULTANT for review and approval, a Quality Plan and procedural specifications prior to commencement of work. The Quality Plan shall define all sub manufacturers’ involvement in the work. The review in this Specification shall only indicate a general requirement and shall not relieve the MANUFACTURER of his obligations to comply with the requirements of the Contract.

1.5 Safety

Safety is paramount. All work shall be performed in accordance with the safety requirements listed in the contract documentation.

2.0 REFERENCE DOCUMENTS 2.1 Reference has been made in this specification to the latest edition of, the following Codes,

Standards and Specifications.

API 1104 : Specification for welding pipelines and related facilities.

ASME B 31.3 : Process piping.

ASME B 31.4 : Liquid transportation systems for hydrocarbons, LPG, Anhydrous Ammonia and Alcohols

ASME B 31.8 : Gas Transmission and Distribution piping systems.

ASME Section VIII : Boiler & pressure Vessel Code. ASME Section IX ASTM A 370 : Standard Test Methods and Definitions for Mechanical Testing

of steel Products. ASTM B 733 : Auto catalytic Nickel Phosphorous coating on metals.

ANSI B 16.25 : Butt Welding Ends

EN 1024 : Metallic Materials-Types of inspection documents.

MSS-SP-25 : Standard marking systems for valves, Fittings, Flanges and union.

MSS-SP-53 : Quality standard for steel casting and forging for valves,

flanges, fittings and other piping components –Magnetic particle Examination method.

MSS-SP-75 : Specification for High Test Wrought welding fittings. NACE RP 286 : The electrical isolation of catholically protected pipelines. ISO 13623 : Petroleum & Natural Gas industry –Pipeline transportation

system.

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ISO 14313 : Petroleum & Natural Gas Industry, Pipeline transportation

system –pipeline valves. SSPC-VIS-I : Steel structures painting council-Visual standard

2.2 In case of conflict between the requirements of this specification and any code, Standard or Specification referred to in this Specification, the requirements of this specification shall govern.

3.0 MATERIALS 3.1 Material for the pressure containing parts of the insulating joints shall be as indicated in the

Monolithic insulating joint data sheets. Material for pups shall be equivalent or superior to the material of connecting pipeline, which is indicated in the data sheets. Pup piece material shall be such as to limit the thickness of pup piece to be welded with pipeline. Other part shall be as per Manufacturer's standard suitable for the service condition indicated in Insulating Joint Data Sheets and shall be subject to approval by purchaser / Purchaser’s representative.

All process wetted parts, metallic and non-metallic shall be suitable for the commissioning fluids and service specified by the company. Manufacturer shall confirm that all wetted parts are suitable for treated water/sea water environment, which may be used during field testing.

3.2 Insulating joints which are subjected to field welding by purchaser shall have carbon equivalent (CE)

not exceeding 0.43 based on check analysis for each heat of steel calculated according to the following formula:

CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni +Cu)/15 3.3 Charpy V-notch test shall be conducted on each heat of base material, weld metal and heat affected

zone of all pressure containing parts such as body, welding ends in accordance with the impact test provisions of ASTM A 370 at a temperature of 0 °C. The charpy impact test specimens shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of the plate of forging. Average impact energy value of three full sized specimens shall be 35 joules. Minimum impact energy value of individual specimen shall be 27 joules. No specimen shall exhibit less than 80% shear area.

When Low Temperature carbon steel (LTCS) materials are specified in data sheet or offered by manufacturer, the charpy V-notch test requirements of applicable material standard shall be complied with.

3.4 Carbon steel used for the manufacture shall be fully killed. 3.5 Hardness test shall be carried out as per ASTM A370 for each heat of steel used. The maximum

hardness of base metal, weld metal and heat affected zone of all pressure parts shall be 248 HV10, unless specified otherwise.

3.6 Insulation material shall be minimum 20 mm thick and shall comply section 5, NACE RP 0286. 4.0 DESIGN & CONSTRUCTION REQUIREMENTS 4.1 Mechanical 4.1.1 Insulating joints shall be of integral type fabricated by welding and with suitable pups on either side.

A corrosion allowance as indicated in data sheet shall be considered in design. Bolted and threaded joints are not acceptable.

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4.1.2 All materials used for the manufacture of the insulating joint shall be in accordance with clause 4.0 of

this Specification. 41.3 Insulating joints shall be designed using the design principles of ASME Section-VIII Div. 1. 4.1.4 Insulating joint design and materials shall be capable of being vacuum tested to 1 millibar. 4.1.5 The joint between pipe pup pieces and main forging shall be full penetration butt weld type. Weld

design shall be such as resulting in a weld joint factor of 1.0. 4.1.6 Butt weld ends shall have ends as per ASME B16.25. However, end preparation for butt welding

ends having unequal thickness with respect to connecting pipe, shall be as per ASME B31.4/ B31.8 as applicable.

4.1.7 The reinforcement of inside weld seam, in case pups fabricated from LSAW pipes, shall be removed

for a distance of at least 50mm from each end to facilitate welding. 4.1.8 Insulating joints shall allow free passage of scraper/ instrumented pigs. The internal bore shall be

same as that of connecting pipe including its tolerances.

4.1.9 The insulating joint shall be formed by sandwiching and locking in positions the insulating material in a bell and spigot type of joint. The joint shall be assembled in such a way that its various components are firmly locked in position and the completed joint is capable of withstanding stresses due to designed operating conditions and field hydrostatic testing.

4.1.10 Insulating joints shall be suitable for aboveground installations as indicated in the data sheets. 4.1.11 All welds shall be made by welders and welding procedures qualified in accordance with the

provisions ASME section IX. The procedure qualification shall include impact test and hardness test and shall meet the requirements of clause 3.3 & 3.5 of this specification.

4.1.12 Repair welding on parent metal is not allowed. Purchaser’s representative for each repair shall carry

out repair of welds only after specific approval. Welders shall carry out the repair welding and welding procedures duly qualified as per ASME section IX and records for each repair shall be maintained.

4.1.13 Internal diameter at the welding end shall not vary more than + 1, -3 mm from the nominal internal

diameter. 4.1.14 Out of roundness measured at the root face of the welding ends shall not be more than 0.5% of the

specified inside diameter. 4.2 Electrical 4.2.1 The average dielectric strength of the insulating joint shall be minimum 15 kilo Volts. 4.2.2 Two cleats as shown in data sheet shall be provided on the pups on either side of the insulating joint

for connecting 10 mm2 and 50 mm2 cables for measurement/ shorting purposes. Cleats shall be attached to the insulating joint by welding.

5.0 INESPECTION & TESTING 5.1 The manufacture shall perform all inspection and tests as per the requirements of this specification

and the relevant codes, prior to shipment at his works. Inspection & tests shall be performed to ascertain the requirements of this specification & not limited to the following:

5.1.1 All insulating joints shall be visually inspected.

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5.1.2 Dimensional checks shall be carried out as per the purchaser approved drawings. 5.1.3 Chemical composition and mechanical properties including hardness shall be checked as per

relevant material standards and this specification, for each heat of steel used. 5.1.4 Non-destructive inspection of insulating joints shall be carried out as given below:

a) 100% radiography shall be carried out on all butt & repair welds of pressure containing parts. Acceptance limits shall be as per API 1104.

Welds, which in purchaser's Representative opinion cannot be inspected by radiographic

methods, shall be checked by ultrasonic or magnetic particle methods. Acceptance criteria shall be as per ASME Section VIII Appendix-12 and Appendix-6 respectively.

b) All finished weld ends shall be 100% ultrasonically tested for lamination type defects for a

distance of 50mm from the ends. Any lamination larger than 6.35 mm shall not be acceptable. c) All forgings shall be wet magnetic particle inspected on 100% of forged surfaces. Method and

acceptance shall comply MSS-SP-53.

d) All fillet weld of thickness < 6mm shall be examined 100% by magnetic particle inspection and ≥ 6mm shall be examined 100% by UT. Acceptance criteria for MPI & UT shall be as per ASME Sec.VIII Appendix-6 & Appendix-12 respectively.

5.1.5 Insulating joint shall be hydrostatically tested to a pressure as indicated in data sheet. The test

duration shall be of 15 minutes. 5.1.6 After the hydrostatic test insulating joints shall be tested with air at 5 kg/cm2 for 10 minutes. The tightness shall be checked by immersion or with a frothing agent. No leakage shall be acceptable. 5.1.7 Dielectric Test a) Insulation resistance of each insulating joint shall be at least 50 mega-ohms when checked

with1000 V DC. b) Insulating joint before and after the hydrostatic test, shall be tested for dielectric integrity for

one minute at 5000 V A.C., 50 cycles and the leakage current before and after hydrostatic test shall be equal. Testing time voltage and leakage shall be recorded and certified. No repair shall be permitted to the insulating joints failed in the above mentioned tests.

5.2 Purchaser reserves the right to perform stage wise inspection and witness test as indicated in Para

5.1 at Manufacturer's works prior to shipment. Manufacturer shall give reasonable notice of time and shall provide without charge reasonable access and facilities required for inspection to the purchaser's Representative. Owner’s approved Third Party Inspection Agency (TPIA) shall be deputed by the MANUFACTURER for inspection at manufacturer premises to witness / review material Tests certification as per EN-10204 type 3.2C certification at manufacturer’s cost.

Inspection and tests performed/witnessed by the Purchaser's Representative shall in no way relieve

the Manufacturer's obligation to perform the required inspection and test. 6.0 TEST CERTIFICATES 6.1 Manufacturer shall submit following certificates to Purchaser's Representative.

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a) Test certificates relevant to the chemical analysis and mechanical properties including hardness of the materials used for construction of insulating joint as per this specification and relevant standards.

b) Test reports on non-destructive testing. c) Test certificates for hydrostatic and air tests. d) Test certificate for electrical resistance test.

e) Test report for dielectric strength test. 7.0 PAINTING, MARKING AND SHIPMENT 7.1 Insulating joint surface shall be thoroughly cleaned, freed from rust and grease and applied with

sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with "steel structures painting council - Visual standard SSPC-VIS-l.". External surfaces of buried insulating joints shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry film thickness of 300 microns.

Manufacturer shall indicate the type of corrosion resistant paint used, in the drawings submitted for

approval. 7.2 Insulating joints shall be marked with indelible paint with the following data:- a. Manufacturer's name b. Suitable for- inch nominal diameter pipeline c. End thickness in mm d. Material

e. Design Pressure/ Hydrostatic Test Pressure f. ANSI Class Rating

g. Tag No.

h. Year of Manufacture

i. PO No.

7.3 Insulating joints shall be suitably protected to avoid any damage during transit. Metallic bevel

protectors shall be provided to weld ends. 7.4 Only those insulating joints, which have been inspected and certified by Purchaser, shall be shipped. 8.0 SPARES AND ACCESSORIES Not Applicable 9.0 DOCUMENTATION 9.1 All documents shall be in English Language.

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9.2 At the time of bidding, Bidder shall submit the following documents:- a) General arrangement drawing along with cross sectional view, overall dimensions and

details of insulating materials recommended. b) Reference lists of previous supplies of insulating joint of similar specification. c) Clause wise list of deviation from this specification, if any.

9.3 Within two weeks of placement of order, the Manufacturer shall submit four copies of but not limited

to the following drawings, documents and specifications for approval. a) Fabrication drawings and relevant calculations for pressure containing parts. b) Welding procedure and method of manufacture for all phases of manufacture. c) Quality Assurance Plan (QAP) Once the approval has been given by purchaser any changes in design, material and method of

manufacture shall be notified to the Purchaser whose approval in writing of all changes shall be obtained before the insulating joint are manufactured.

9.4 Within four weeks from the approval date Manufacturer shall submit one reproducible and six copies

of the approved drawings, documents and specifications as listed in 9.3 of this specification. 9.5 Prior to shipment, the manufacturer shall submit one reproducible and six copies of the test

certificates as listed in Clause 6.0 of this specification.


CLIENT JOB NO. - DATA SHEET FOR MONOLITHIC INSULATING JOINT TOTAL SHEETS 02

DOCUMENT NO 11 0290 02 09 03 002

0 16/10/09 ISSUED FOR TENDER AS DDS PKS

B 26/08/09 ISSUED FOR APPROVAL AS DDS PKS

A 25/08/09 ISSUED FOR IDC AS DDS PKS


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DATA SHEET

FOR MONOLITHIC INSULATING JOINT SHEET 2 of 2

PROCESS DATA: PIPE CLASS 3A1 RATING: 300 # FLUID R.L. NATURAL GAS FLUID SYMBOL RLNG DESIGN CONDITIONS: PRESSURE 49 Barg TEMPERATURE 0 to 60 C OPERATING CONDITIONS: PRESSURE Barg TEMPERATURE C CORROSION ALLOWANCE: 0.5 MM CONSTRUCTION DATA:

DESIGN AND CONSTRUCTION CODE : ASME VIII, DIV. 1 APP.2, ASME IX AND ANSI B31.8

ALLOWABLE STRESS VALUE : 50 % SMYS (Design factor : 0.4) CONSTRUCTION MATERIAL BODY

:

MSS SP-75, WPHY Gr. 52/ ASTM A 694 Gr. F 52.

PIPE PUPS : AS PER PIPE MATERIAL SPECIFICATION

INSULATION : AS PER MANUFACTURER’S STANDARD INSULATING JOINTS : Carbon steel, fully killed, fine grain (*) SEALING GASKETS : (*) SPACING RING : (*) FILLING MATERIAL : (*) EXTERNAL COATING Epoxy Resin (*) INTERNAL LINING Epoxy Resin (*)

TESTING INSPECTION AND CERTIFICATES: HYDROTEST : 1.5 X Design pressure

ELECTRICAL TEST : 5 000 VAC, 50 Hz Holding time at least one minute > 50M ohm (1000VDC)

DIMENSIONAL STANDARD ANSI B 16.5 END CONNECTION : BUTT WELDED ENDS AS PER ANSI B 16.25 Machined True round MARKING : Manufacture name : Note: (*) To be selected by Vendor in his bid and submitted for approval. 1. For the welding end, the out of roundness shall be 5 mm and tolerance on internal diameter at pipe ends shall be Same as diameter tolerance for the pipe ends indicated in API 5L Table 8

CLIENT: GAIL GAS LIMITED REV NO: 0CONSULTANT: WGIVENDOR: JOB NO.: 110290

PAGE NO: 1 of 2

PROJECT: CITY GAS DISTRIBUTION PROJECT

QUALITY ASSURANCE PLAN

4 - Outside Laboratory

P - Performing TestR - Review of Test ReportW - Witnessing Report

1 - Client/Third Party2 - Vendor3 - Sub Vendor

Physical & Electrical Properties

Test certificate 2 1,2

Test certificate 3

1 sample per lot ASTM D 709 Company Standard

NDT

Final Weld (W 3)1,2 1,2M.P.I 100%

ASME Sec VASME Sec VIII

Div.01

100%API1104 API 1104

NOTE: 1. Qualified welders & procedure will be used as per ASME Sec. IX for all welds. 2. In case Mill certificates are not available test certificates from approved laboratory shall be furnished. 3.TPI to issue 3.2 certificate as per EN1 10204 format.

Dye Penetration Test &

Radiography Test100% API1104 API 1104 Test certificate 2,3 1,2

1,2

Test certificate 3 1,2

1 RAW MATERIAL

Test certificate

Test certificate

4 1,2

4

ASTM A 370 ASTM A 370

P W R

Dye Penetration Test

ASTM A 694 F52

Physical & chemical properties

Physical & chemical properties

1 sample per lot

1 sample per lot ASTM A 370

QAP NO: 11-0290-02-09-10-002

Epoxy Laminated Glass Fabric Base1.3

2

Forged Rings1.2

SR.

NO.

COMPONENTS &

OPERATIONS

TYPE OF

CHECK

QUANTAM OF

CHECK

ITEM DESCRIPTION/ QUANTITY: MIJ

2.2

Forged Ring welded with pipe(w1 & w2)2.1

Pipe1.1

REFERENCE

DOCUMENT

ACCEPTANCE

NORMS

FORMAT OF

RECORD

INSPECTION

CLIENT: GAIL GAS LIMITED REV NO: 0CONSULTANT: WGIVENDOR: JOB NO.: 110290

PAGE NO: 2 of 2

100% No breakdown

1,2Inner & Outer Testing Report 3 1,2

Test Certificate

Random

4 - Outside Laboratory

R - Review of Test ReportW - Witnessing Report

1 - Client/Third Party2 - Vendor3 - Sub Vendor

P - Performing Test

1

QAP NO: 11-0290-02-08-10-002

ITEM DESCRIPTION/ QUANTITY: MIJ

2 1

INSPECTION

1 1,2

1,2

R

Hydro Test

3

3.2

FINAL INESPECTION

QUANTAM OF

CHECK

Dimensional Report

PROJECT: CITY GAS DISTRIBUTION PROJECT

QUALITY ASSURANCE PLAN

3.3

3.4

3.5

COATING Inespection3.6

5000V AC for 1 min. Testing

Pneumatic Test

Di-Electric Strength

5 Bar for 10 min Testing

1000 V DC for 1 min Testing

1,2Normal Measurement 100% Appd.Drg. Report3.1

FORMAT OF

RECORD

CONDITION

W

ACCEPTANCE

NORMS

Testing

1,2

Appd.Drg. 1,2

Test Certificate 1

Test Certificate 1100%

Appd.Drg.

2

Test Certificate

100% Min. 25 MΩ

2

SR.

NO.

COMPONENTS &

OPERATIONS

TYPE/METHOD

OF CHECK

Insulation Electrical Resistance

100%

P

74 Bar for 15 Min.

2

2

GAIL GAS LIMITED


CLIENT JOB NO. TECHNICAL SPECIFICATION FOR PAINTING

TOTAL SHEETS 27

DOCUMENT NO 11 0290 02 09 02 005





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TABLE OF CONTENT 1.0 GENERAL................................................................................................................................. 3 2.0 CODES & STANDARDS .......................................................................................................... 3 3.0 CONDITIONS OF DELIVERY................................................................................................... 4 4.0 COMPOSITION OF THE PAINT PRODUCTS USED .............................................................. 4 5.0 IDENTIFICATION...................................................................................................................... 5 6.0 SURFACE PREPARATION STANDARDS.............................................................................. 6 7.0 PREPARATION OF THE SURFACES..................................................................................... 6 8.0 METALLISATION ................................................................................................................... 10 9.0 CARRYING OUT THE PAINTWORK ..................................................................................... 10

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1.0 GENERAL 1.1 These technical specifications shall be applicable for the work covered by the contract, and without

prejudice to the provisions of various codes of practice, standard specifications etc. It is understood that contractor shall carry out the work in all respects with the best quality of materials and workmanship and in accordance with the best engineering practice and instructions of Engineer-In-Charge.

Wherever it is stated in the specification that a specific material is to be supplied or a specific work is to

be done, it shall be deemed that the same shall be supplied or carried out by the contractor. Any deviation from this standard without written deviation permit from appropriate authority will result in rejection of job.

1.2 SCOPE 1.2.1 Scope of work covered in the specification shall include, without being limited to the following. 1.2.2 This specification defines the requirements for surface preparation, selection and application of primers

and paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures, external & internal protection of storage tanks for all services, MS Chimney without Refractory lining and Flare lines etc. The items listed in the heading of tables of paint systems is indicative only, however, the contractor is fully responsible for carrying out all the necessary painting, coating and lining on external and internal surfaces as per the tender requirement.

1.2.3 Extent of Work 1.2.3.1 The following surfaces and materials shall require shop, pre-erection and field painting:

a. All uninsulated C.S. & A.S. equipment like columns, vessels, drums, storage tanks(both external & internal surfaces), heat exchangers, pumps, compressors, electrical panels and motors etc.

b. All uninsulated carbon and low alloy piping, fittings and valves (including painting of identification

marks), furnace ducts and stacks. c. All items contained in a package unit as necessary. d. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders, platforms etc. e. Flare lines, external surfaces of MS chimney with or without refractory lining and internal surfaces of

MS chimney without refractory lining. f. Identification colour bands on all piping as required including insulated aluminium clad, galvanised,

SS and nonferrous piping. g. Identification lettering/numbering on all painted surfaces of equipment/piping insulated aluminium

clad, galvanized, SS and non-ferrous piping. h. Marking / identification signs on painted surfaces of equipment/piping including hazardous service. i. Supply of all primers, paints and all other materials required for painting (other than Owner supplied

materials) j. Over insulation surface of equipments and pipes wherever required. k. Painting under insulation for carbon steel, alloy steel and stainless steel as specified. l. Painting of pre-erection/fabrication and Shop primer. m. Repair work of damaged pre-erection/fabrication and shop primer and weld joints in the field/site

before and after erection as required.

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n. All CS Piping, equipments, storage tanks and internal surfaces of RCC tanks in ETP plant.

1.2.3.2 The following surfaces and materials shall not require painting in general. However, if there is any specific requirement by the owner, the same shall be painted as per the relevant specifications:

a. Uninsulated austenitic stainless steel. b. Plastic and/or plastic coated materials c. Non-ferrous materials like aluminum.

1.2.4 Documents 1.2.4.1 The contractor shall perform the work in accordance with the following documents issued to him for

execution of work.

a. Bill of quantities for piping, equipment, machinery and structures etc. b. Piping Line List. e. Painting specifications including special civil defence requirements.

1.2.5 Unless otherwise instructed, final painting on pre-erection/ shop primed pipes and equipments shall be

painted in the field, only after the mechanical completion, testing on systems are completed as well as after completion of steam purging wherever required.

1.2.6 Changes and deviations required for any specific job due to clients requirement or otherwise shall be

referred to J P Kenny for deviation permit. 2.0 CODES & STANDARDS Without prejudice to the specifications of the contract, the following codes and standards shall be

followed for the work covered by this contract.

IS: 5 Colors for ready mixed paints and enamels. IS: 101 Methods of test for ready mixed paints and enamels, IS: 161 Heat resistant paints. IS: 2074 Specifications for ready mixed paint, red oxide zinc chrome priming. IS: 2339 Aluminum paint for general purposes in dual container. IS: 2379 Color code for identification of pipelines. IS: 2932 Specification for enamel, synthetic, exterior (a) undercoating. (b) Finishing.

3.0 CONDITIONS OF DELIVERY Packaging Every recipient will be fitted with a hermetically-sealed lid with an opening that is sufficiently large to allow the contents to be stirred: the outside and inside are protected against oxidation, and, the lid, are marked with a strip of color identical to the contents. 4.0 COMPOSITION OF THE PAINT PRODUCTS USED

a) Quality The composition and quality of the products may not differ from batch to batch. A batch is all of

the products of a specified manufacture. If the analyses of products bring to light that the

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composition does not conform to the specifications of the paint manufacturer, the OWNER may refuse to use this batch of products. The paint products must comply with the following conditions

• They must have the viscosity necessary for the described use and the established

condition: use of the brush - paint roller (spray gun only for special cases and in the workshop)

b) Quality control - Sampling

While the works are in progress on the construction site, the OWNER may carry out sampling on

the paint being used for the purpose of checking conformity. The paint products must be made available free of charge to the laboratory or the approved supervisory body in sufficient quantities so that all the tests can be carried out on the same batch.

If analyses reveal a non-conformity in the composition of the products used (tolerance of + 3 %

of the dosage of every component), the OWNER may refuse application of the product under consideration, halt the work and have the nonconforming product already applied removed.

Before proceeding the work, a product that does conform will be required. The only Purpose of

the analysis is to reveal any nonconformity of the composition of the products. Their purpose is therefore not to assess the quality of the different components. The analyses concerned are not acceptance tests of the products supplied and in no way affect the obligations of the contractor specified in the contract towards the OWNER.

5.0 IDENTIFICATION Every recipient will bear the following information:

• Name of the manufacturer • Date and number of manufacture

• Name of the product type

• Batch no

• Net weight of the produced or the contents of the recipient

• Date of the expiry.

At the time of delivery, this packaging must bear labels in conformity with the legal stipulations in force. Leaving the site after work After completion of a job a general clean-up shall be carried out by the Contractor to remove all debris,

materials or irregularities that his work has brought to the site so that it is left tidy: The restoration work includes among other things:

• the removal of abrasives. • the removal of the different protective coverings. • the Contractor will make the required repairs to any damage after refitting the supports.

• the removal of paint and cleaning of the stains on the floor.

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6.0 SURFACE PREPARATION STANDARDS Following standards shall be followed for surface preparations: 1 Swedish Standard Institution- SIS-05 5900-1967 2 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP) 3 British Standards Institution (Surface Finish of Blast-cleaned for Painting) BS-4232. 4 National Association of Corrosion Engineers. U.S.A. (NACE). 5. IS-1477-1971 (Part-1) - Code of Practice for Painting of Ferrous metals in Buildings. (Part 1,

Pre-treatment) a) The contractor shall arrange, at his own cost to keep a set of latest edition of above

standards and codes at site. b). The paint manufacturer's instruction shall be followed as far as practicable at all times.

Particular attention shall be paid to the following:

• 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.

c) 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 OWNER, 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.

7.0 PREPARATION OF THE SURFACES 7.1 General Specifications The cases that occur in practice on building sites, with regard to painted surfaces, can be broken down

as follows:

• Material of which the oxide content disappears by natural oxidation.

• Material that has already been covered with a layer of paint in the workshop.

• Material that is covered with old paint layers that show different degrees of weathering.

Good preparation oldie surface is the best guarantee for good anti-corrosion protection. Paintwork may never begin until the surface to be treated is dry and is independent of the base coat and

cleared of dirt, dust, rust, scale, grease, salt attack, cement powder, cement mud-scale, sand, oil, etc.

Based on the environmental conditions of coastal and saline nature, the Painting specification for station pipes defines the complete requirements like:

• Surface preparation standards like NACE etc. • Sand blasting process

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• Color Codes for piping • Paint materials types and their DFT measurement. • Selection and application of paints on external surfaces.

The pipeline passes through the coastal and marine environment, the Table-4 of this specification to be followed for the painting works.

The method of preparation of the surface will be implemented in accordance with the preparation methods described below:

• Cleaning (bright blast-cleaning);

• Mechanical cleaning;

• Manual derusting.

The Contractor should have the required material at his disposal to clean the surfaces to be coated

thoroughly in accordance with the preparation methods regardless of the form or the condition of such surfaces. The cleaning devices that might be damaged during the surface preparation shall be screened off by the Contractor.

7.2 Sandblasting Before beginning cleaning by blasting, the person carrying out the work will take the following measures:

• Clear the steel surface of oil and/or grease;

• Ensure that each flange collar (section where the sealing is applied) is properly screened off

against the blasting and the subsequent works;

• Check that no blasting grains can act into the pipes during this process. Any openings not

sealed off must be screened off;

• Where there are valves, regulators and other devices, the manufacturer's identification plate will

be dismantled so that all surfaces can be treated. The plate will then be put back again.

• Screen off all non-metal structures such as rubber where there is a filter;

• With valves, operators and other devices, care should be taken to ensure that no metal filings or

paint get into the apparatus:

• The OWNER reserves the right to carry out part or all of these works himself.

To prevent rust forming quickly as the result of humidity on the blasted surface, cleaning by blasting may

only be carried out when the temperature of the steel surface is at least 3°C higher than the dew-point of the ambient air.

Blasting may not be carried out if the relative degree of humidity exceeds 80%. The choice of the type of

blasting medium used depends on local circumstances such as the possible presence of gas and the material to be blasted.

The abrasive to be used must conform to the local low i.e. it may contain no carbon and less than 1%

free silicon dioxide. The Sa 3 will always be requested and must at least reach Sa 2½ during the initial stage of the paintwork. For blasting followed by metallisation, the surface preparation degree to be achieved is always Sa 3. The degree of cleanliness to be obtained will be inspected in accordance with the Swedish standard SVENSK STANDARD ISO 8501-1-1988 SS 05.5900.

• Sa 3: surface blasted down to the bare metal; when the surface is inspected with a magnifying

glass, scale, rust and foreign bodies must be completely removed and it should be possible to raise a metallic -shine on the treated surface.

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• Sa 2 1/2: blasted very carefully. Scale, rust and foreign bodies must be removed in such a way

that anything left behind will only be visible as nuances (shading) or strips. The blast-cleaning will be carried out by means of compressed air free of water and oil. After the blasting and before painting, the surface should be completely cleaned of blasting material and

so forth with a soft brush, a dry cloth or dry compressed air. 7.3 Mechanical cleaning If sandblasting is not permitted or if the metal structures are not easily accessible for blasting or blasting

for one reason or another is technically unfeasible, mechanical derusting can be used instead. With mechanical cleaning by means of chipping, rotating steel brushes and sanding discs, a degree of cleanliness St. 3 should be reached.

St 3 : removal of the old paint layers of which the adhesion leaves something to be desired and/or of

which the paint layer no longer fulfils the requirements. If parts are present that are so corroded that St 3 is difficult to achieve, this should be notified to the

OWNER representative prior to the start of the works. N.B: St. 3 : means removal of every old paint layer. Retouching means local polishing with St. 3 or Sa 3

followed by application of the desired painting system. After mechanical cleaning, the surface should be made dust-flee with a cloth or a so brush, washed with

an organic solvent and thoroughly dried off with a dry cloth (e.g. with 1.1.1. Trichoroethane such as Solvethane, Chloroethene).

7.4 Manual Derusting Manual derusting with the aid of scrapers. steel brushes, sandpaper etc. shall only be permitted in

exceptional cases for local repairs. Any deviation there from must be requested from the OWNER/ OWNER 's Representative.

With manual derusting, a surface preparation degree St 3 must be obtained. The length of the handles

of the equipment used may not exceed 50 cm. 7.5 Preparation of a surface covered with a layer of paint in the workshop. This layer is in general applied by the manufacturer, for example, on valves, regulators etc. Layers of

this kind will be checked for their proper adhesion in accordance with ASTM D 3359, method A (Standard Test Method for measuring adhesion by tape test). The adhesion should be at least .

If the paint layer shows less adhesion or is incompatible with the rest of the system it should be

completely removed. If the paint layer is not removed, the Contractor accepts it in the state in which the coating is found and the guarantee remains in force. The adhesion does not have to be examined if system 63 has already been applied in the workshop on behalf of the OWNER.

The Contractor, who must provide for the protection on the construction site, must therefore obtain the

information regarding the treatment of the surface and the quality of the paint that was used and must, moreover, examine the adhesion of the layer on the construction site, the percentage of damage and weathering as well as the value of the preparation of the surface in the workshop together with the thickness thereof that must be supplemented if necessary.

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a) Galvanized surface Galvanized surfaces, both old and new will be carefully roughened up. Every foreign body

(concrete splatters, chalk marks, grease and oil stains, etc.) will be removed. Thereafter, rub the surfaces with abundant water and, if necessary, with cleaning products.

To this end, nylon brushes will be used for every kind of dirt as well as for removing zinc salt

residue. Thereafter, the surfaces will be treated in accordance with system 21. Where the zinc layer is lacking, it will be derusted manually to a degree of cleanliness St 3, after which a primer coat will be applied in accordance with system 22.

b) Metallised surfaces treated with an impregnation layer

• degrease with the desired degreasing product:

• clean under high pressure or with a product prescribed by the paint supplier.

If the paint layer adheres well and is applied on a clean base, the painting system described may be continued. If the percentage of damage and weathering does not exceed 5 % m. retouching may be considered. These partial repairs will be carried out.

If on the other hand, the percentage of damage does exceed 5 %/m or if the layer applied in the

workshop comes loose the Contractor must draw the attention of the OWNER to this and carry out the complete application system.

7.6 Preparation of surfaces covered with earlier paint layers that show different degrees of weathering. If the surfaces do not show deep weathering limited to the spread of rust by small pitted areas or non-

penetrative rust in spots, it will very often be sufficient to clean the surfaces with abrasives or with an abrasive disc, then to rub them down with steel wool, remove the dust and wash off. If thick rust appears, in spots, scale rust and active rust canker, this should be removed with needle hammers or stripped away directly by blasting, removing the dust and washing oft.

7.7 Preparation of concrete or cement plaster surfaces Remove unsound paint layers and loose components with scrapers, blades or rotating steel brushes.

Thoroughly clean the entire surface with water containing ammonia. Thoroughly remove moss, algae and fungal growths. Where these growths have been removed, treat the area with a fungicide in accordance with the instructions for use.

Once the entire area is completely dry, brush off the dead residue of moss, algae and fungus with a hard

brush. In the case of reinforcement steel that has been laid bare, remove as rust, dust and grease as possible and treat with a printer coat. When painting concrete surfaces, they must first be checked for cracks. Cracks larger than 0.3 mm must be repaired with an appropriate system in accordance with the type and extent of the repairs (e.g. injection with epoxy mortar). Repair damage such as cracks and bursts to concrete parts with a two-component mortar or preferably with micro-mortars. Finally check the alkalinity of the surface with the aid of litmus paper and neutralize it if necessary.

7.8 Use of solvents It is sometimes necessary to use solvents when the surfaces to be painted are streaked with grease or

oil. In this case a suitable organic solvent should be applied. The operation should be carried out with the aid of clean brushes or rags and clean solvent.

All the legal specifications in connection with solvents etc. must be adhered to. The OWNER/OWNER's

Representative will be informed in advance of any toxicity or flammability. All measures must be taken to prevent any risk of fire and to nick out any possibility of poisoning (ventilation). The Contractor will provide drip collectors to keep the environment free of pollution.

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7.9 Condition of the metal after stripping The Contractor must call in a representative of the OWNER/OWNER's representative or of the Approved

supervisory Body responsible for checking the condition of the metal during stripping and informing the OWNER/OWNER's representative immediately of any damage that he might have noticed.

• Deep corrosion of the plates - rivets - bolts • Faulty welding • Fittings that appear to be dangerous because of their age.

7.10 Removing coating from surface pipelines The Contractor must have the equipment necessary for the removal of asphalt from the pipe without

damaging the latter (scratching, impact, etc,). The Contractor undertakes to carry out the work in accordance with an approved procedure.

8.0 METALLISATION 8.1 Applying the metallisation Metallisation must be carried out in accordance with ISO 2063, Metallisation is carried out as rapidly as possible after blasting in order to limit corrosion of the pipes

(max. 3 hours later). With metallisation, a surface preparation degree Sa 3 is compulsory. The roughness of the blasted surfaces should be from 25 to 50µ R Max.

• The metallising is always carried out on dry parts in good weather conditions (maximum relative

humidity 80 %); • For metallisation, a wire composed of 85 % zinc and 15 % aluminum with a minimum

guaranteed degree of purity of 99.5 % is used (subject to other specifications). The application thereof is always carried out in accordance with the conditions of the manufacturer and may at all times be submitted to the OWNER’s representative.

• The sealant should be applied maximum 3 hours alter metallisation. • The sealant must be thinned and applied as per the present specifications. A visual inspection

whereby the sealant completely covers the metallisation will suffice here. • When evaluating the metallisation, a negative deviation from the minimum coating thickness, to

80 µ for 20% of the measurements will be permitted. 9.0 CARRYING OUT THE PAINTWORK 9.1 Conditions for carrying out paintwork Painting may not be carried out in unsuitable conditions. All preparatory work and painting may only he carried out in dry weather and at a minimum temperature

of 10 C, except for special eases requested by the OWNER's Representative. Unless otherwise stipulated in the specifications of the paint supplier, application of the paint is forbidden

if it is forecast that the temperature will fall to below 0 C before the paint is dry. The temperature of-the surface to be painted must be at least 3°C higher than the dew point of the ambient air. Application of the paint is also not permitted if there is a danger that the coat of paint will not be dry before dew or condensation sets in.

The work must be stopped:

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• If the temperature of the surface to be painted is higher than that described by the supplier. • In rain, snow, mist or fog or when the relative humidity is higher than 80 %.

Coats that have not yet dried and have been exposed to frost, mist, snow or rain and might thereby be

damaged must be removed after drying and the surfaces must be repainted at the expense of the Contractor.

Working in direct sunlight or in hot weather must be avoided, The first coat of paint must be applied maximum 3 hours after the preparation of the surface of the

relative humidity of the air is between 50% and 80%. This time span may be increased to 6 hours if the relative humidity is less than 50%. In all cases, the preparation of the surface must exhibit degree Sa 3 and at the very least the appearance of degree Sa 2 ½ at the time of painting.

The coats of paint may only be applied on carefully cleaned surfaces that must be dry and free of grease

and dust. 9.2 Special conditions Painting may be carried out when the Contractor can be sure that the instructions of the paint supplier

have been scrupulously followed with regard to the parameters in the following (non-exhaustive) list:

• Ambient temperature. • Surface temperature. • Relative humidity. • Dew point. • Drying times.

The Contractor must in this respect be able to produce the instructions for the paint on the site. The

OWNER/CONSULTANT will guarantee 100% supervision in this regard during the execution of the work.

In addition, the paintwork may only be carried out to a minimum ambient temperature of 5°C and/or to a

maximum relative degree of humidity of 85 %. Application of the paint is also not permitted if there is a danger that the coat of paint will not be dry before dew or condensation sets in.

9.3 Paint Materials Manufacturers shall furnish the characteristics of all paints indicating the suitability for the required

service conditions. Primer and finish coats shall be of class-I quality and shall conform to the following:

a) Primer (P-1)

Red oxide Zinc Chromate Primer Type and Composition Single pack, Modified phenolic alkyd medium pigmented with

red oxide and zinc chromate. Volume solids 30 - 35% DFT 25 microns/coat (min) Covering capacity 12-13 M²/Lit/coat

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b) Primer (P-2) High build chlorinated rubber zinc phosphate primer

Type and Composition Single pack, Chlorinated rubber medium Plasticised with

unsaponifiable plasticiser pigmented with zinc phosphate Volume solids 35- 40% DFT 50 MICRONS/COAT (MIT) Covering capacity 7-8 M²/Lit/Coat

c) Primer (P-3) High build zinc phosphate primer

Type and Composition Single Pack, Synthetic medium, pigmented with zinc

phosphate. Volume solids 40-45% DFT 35-50 microns/coat Covering capacity 10-12 M²/Lit/coat Heat resistance Upto 100º C (dry)

d) Primer (P-4)

Etch Primer / Wash Primer Type and Composition Two pack Poly vinyl butyral resin medium cured with

phosphoric acid solution pigmented with zinc tetroxy chromate.

Volume solids 7-8% DFT 8-10 microns/coat Covering capacity 7-8 M²/lit/coat

e) Primer (P-5)

Epoxy Zinc Chromate Primer Type and Composition Two pack, Polyamide cured epoxy resin medium pigmented

with zinc chromate. Volume solids 40%(min) DFT 35 microns/coat (min) Covering capacity 11-12 M2/lit/Coat

f) Primer (P-6) Epoxy Zinc Phosphate Primer

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Type and Composition Two pack, Polyamide cured Epoxy resin medium pigmented

with zinc phosphate. Volume solids 40% 35 microns / coat (min) Covering capacity 11-12 M²/lit/coat

g) Primer (P-7) Epoxy high build M10 Paint (Intermediate Coat) Type and composition Two pack Poly Polyamide cured epoxy resin medium

pigmented with micaceous iron oxide. Volume solids 7- 8% Volume Solids 50% DFT 100 microns/coat (min) Covering capacity 5.0 M²/lit/coat

h) Primer (P-8) Epoxy Red Oxide zinc phosphate primer Type and Composition Two pack. Polyamine cured epoxy resin pigmented with Red

oxide and Zinc phosphate. Volume solids 42% DFT 30 microns/coat (min) Covering capacity 13-14 M/lit/coat i) Primer (P-9) Epoxy based tie coat (suitable for conventional alkyd based coating prior to application of acrylic

polyurethane epoxy finishing coat) Type and Composition Two pack, Polyamide cured epoxy resin medium

suitably pigmented. Volume solids 50-60% DFT 50 microns/coat (min) Covering capacity 10-12 M²/Lit/Coat

j) Finish Coats (F-1)

Synthetic Enamel Type and Composition Single pack, Alkyd medium pigmented with superior

quality water and weather resistant pigments Volume solids 30-40% DFT 20-25 microns/coat

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Covering capacity 16-18 M/²lit/Coat k) Finish coat (F-2) Acrylic Polyurethane paint Type and Composition Two pack, Acrylic resin and iso-cyanate hardener

suitably pigmented. Volume Solids 40% (min) DFT 30-40 microns / coat Covering Capacity 10-12 M²/lit/ coat

l) Finish Coat (F-3)

Chlorinated Rubber Paint Type and Composition Single pack, Plasticised chlorinated rubber medium with

chemical & weather resistant pigments. Volume solids 30% DFT 30 microns/coat (min) Covering capacity 1 0.0 M² / lit /coat

m) Finish Coat (F-4)

High build chlorinated rubber M10 paint.

Type and Composition Single pack Chlorinated rubber based high build pigmented with micaceous iron oxide.

Volume solids 40-50%

DFT 65-75 microns/coat

Covering capacity 6.0-7.0 M² / lit / coat

n) Finish coat (F-5)

Chemical Resistant Phenolic based Enamel

Type and Composition Single pack phenolic medium suitably pigmented.


DFT 25 microns/ coat

Covering capacity 15.0 M² /lit/ coat

o) Finish Coat (F-6)

Epoxy High Building Coating

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Type and Composition Two pack. Polyamide cured epoxy resin medium suitably pigmented.


DFT 100 microns/coat (min)


p) Finish Coat (F-7)

High build Coal Tar Epoxy Type and Composition Two pack, Polyamine cured epoxy resin blended with Coal Tar.

Volume solids 65% (min)



q) Finish Coat (F-8)

Self-priming epoxy high build coating (complete rust control coating)

Type and Composition Two packs. Polyamide-amine cured epoxy resin suitably pigmented. Capable of adhering to manually prepared surface and old coatings.



Covering capacity 4-5 M² / lit / coat

r) Finish Coat (F-9)

Inorganic Zinc Silicate coating

Type and Composition Two pack , Self cured Ethyl silicate solvent based Inorganic Zinc

coating.

Volume solids 60% (min)


Covering capacity 8-9 M² / lit / coat

s) Finish coat (F-10)

High build Black

Type and Composition Single pack. Reinforced bituminous composition phenol based

resin.


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Covering capacity 5.50-6.0 M ²/ lit / coat

t) Finish Coat (F-11)

Heat Resistant Aluminium Paint Suitable up to 250°C.

Type and Composition Duel container (paste & medium). Heat resistant spec varnish medium combined with aluminium flakes.



Covering capacity 10-12 M² / lit/ coat

u) Finish Coat (F-12)

Heat Resistant Silicon Paint suitable up to 400º C.

Type and Composition Single pack Silicone resin based with aluminium flakes.



Covering capacity 10-12 M²/lit/coat

v) Finish Coat (F-13)

Synthetic Rubber Based Aluminium Paint Suitable up to 150 C.

Type and Composition Single Pack, Synthetic medium rubber medium combined with

leafing Aluminium,

DFT 25 microns/coat

Covering capacity 9.5 M² /lit/ coat

Notes 1 Covering capacity and DFT depends on method of application Covering capacity specified above

is theoretical. Allowing the losses during application, min specified DFT should be maintained. 2. All paints shall be applied in accordance with manufacturer's instructions for surface preparation,

intervals, curing and application. The surface preparation quality and workmanship should be ensured.

3. Selected chlorinated rubber paint should have resistance to corrosive atmosphere and suitable

for marine environment, 4 All primers and finish coats should be cold cured and air-drying unless otherwise specified. 5. Technical data sheets for all paints shall be supplied at the time of submission of quotations. 6. In case of use of epoxy tie coat, manufacturer should demonstrate satisfactory test for inter coat

adhesion. In case of limited availability of epoxy tie coat (P-9) alternate system may be used taking into the service requirement of the system.

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7. In case of F-6, F-9, F-1 1 & F-1 2 Finish Coats, No Primer are required.

MANUFACTURERS The paints shall conform to the specifications given above and Class-I quality in their products range of

any of the-following manufacturers:

i) Asian Paints (India) Ltd, ii) Bombay Paints iii) Berger Paints India ltd. iv) Gaodlass Nerolac Paints Ltd. v) Jenson & Nicholson vi) Shalimar Paints

STORAGE All paints and painting material shall be stored only in rooms to be provided by contractor and approved

by OWNER/ OWNER 's Representative for the purpose. AlI necessary precautions shall be taken to prevent fire. The storage building shall preferably be separate from adjacent, building.

A signboard bearing the words given below shall be clearly displayed outside: PAINT STORAGE No NAKED LIGHT highly -inflammable COLOR CODE FOR PIPING:

i) For identification of pipelines, the color code as per Table -1 shall be used. ii) The color code scheme is intended for identification of the individual group of the pipeline. The

system of color coding consists of a ground color and color bands superimposed on it. iii) Colors (Ground) as given in Table-2 shall be applied throughout the entire length of uninsulated

pipes, on the metal cladding & on surfaces. Ground color coating of minimum 2m length or of adequate length not to he mistaken as color band shall be applied at places requiring color bands. Color bands shall be applied as per approved procedure.

V) Line coating shall meet DIN 30670 standard for external coating and API 5L RP – 2 for internal coating.

VI) The thickness for the epoxy should be 180 microns, adhesive 200 microns and balance should be PE

VII) The minimum coating thickness on weld seam shall be 3.2 mm and minimum coating thickness on body should be 3.2.

VIII) Minimum thickness for liquid epoxy for internal coating should be 100 ± 20 microns. Max design temperature for coating should be considered +80 ºC

COLOR CODE:

A) Ball Valve (Above Ground) : Off White B) Globe Valve (Above Ground) : Oxford Blue-RAL 5005, IS-519941005 C) Check Valve(Above Ground) : Oxford Blue-RAL 5005, IS-519941005 D) Launcher / Receiver : Yellow Golden E) Jib Crane / Trolley : Yellow Golden F) All underground valves shall have epoxy base coating after surface finish of SA 2:5 G) Valves and above ground pipes need to be properly blasted to achieve surface finish of Sa 2:5 before

the application of paints. IDENTIFICATION SIGN

i) Colors of arrows shall be black or white and in contrast to the color on which they are superimposed.

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ii) Product names shall be marked at pump inlet, outlet and battery limit in a suitable size as

approved by OWNER. iii) Size of arrow shall be either of the following:

a) Color Bands

Minimum width of color band shall be as per approved procedure.

b) Whenever it is required by the OWNER to indicate that a pipeline carries a hazardous material,

a hazard marking of diagonal stripes of black and golden, yellow as per IS:2379 shall be painted on the ground color.

IDENTIFICATION OF EQUIPMENT All equipment shall be stenciled in black or white on each vessels, column, equipment, painting as per

approved procedure. INSPECTION AND TESTING

1. All painting materials including primers and thinners brought to site by contractor for application shall be procured directly from manufactures as per

specifications and shall be accompanied by manufacturer's test certificates Paint formulations without certificates are not acceptable.

2. The painting work shall be subject to inspection by OWNER/ OWNER's Representative at all

times. In particular, following stage wise inspection will be performed and contractor shall offer the work for inspection and approval at every stage before proceeding with the next stage.

In addition to above. record should include type of shop primer already applied on equipment e.g. Red

oxide zinc chromate or zinc chromate or Red lead primer etc. Any defect noticed during the various stages of inspection shall be rectified by the contractor to the

entire satisfaction of OWNER/ OWNER's Representative before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work. Contractor shall be responsible for making good any defects found during final inspection/guarantee period/defect liability period as defined in general condition of contract. Dry film thickness (DFT) shall be checked and recorded after application of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra cost to OWNER.

PRIMER APPLICATION i. The contractor shall provide standard thickness measurement instrument with appropriate

range(s) for measuring. Dry film thickness of each coat, surface profile gauge for checking of surface profile in case of

sand blasting. Holiday detectors and pinhole detector and protector whenever required for checking in case of immerse conditions.

ii. At the discretion of OWNER/ OWNER's Representative, contractor has to provide the paint

manufacturers expert technical service at site as and when required. For this service, there should not be any extra cost to the OWNER.

iii. Final Inspection shall include measurement of paint dry film thickness, check of finish and

workmanship. The thickness should be measured at as many points/ locations as decided by OWNER/ OWNER's Representative and shall be within +10% of the dry film thickness.

iv. The contractor shall produce test reports from manufacturer regarding the quality of the

particular batch of paint supplied. The OWNER shall have the right to test wet samples of paint

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at random for quality of same. Batch test reports of the manufacturer's for each batch of paints supplied shall be made available by the contractor.

PAINT SYSTEMS The paint system should vary, with type of environment envisaged in and around the plants. The types

of environment as given below are considered for selection of paint system. The paint system is also given for specific requirements.

a) Normal Industrial Environment, Table 2. b) Corrosive industrial Environment, Table3 c) Coastal & Marine Environment, Table 4

Notes 1. Primers and finish coats for any particular paint systems shall be from same

manufacturer in order to ensure compatibility.

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Table – 1

Colour Coding Scheme for Pipes and Equipment

SI. No. Content Ground Color First Color

Band Second Color

Band 1 COMPRESSED AIR

a) Plant Air Sky Blue Silver Grey - b) Instrument Air Sky Blue French Blue -

2 GASES

a) Charge Gas Canary Yellow Signal Red Smoke Grey b) Regeneration Gas Canary Yellow White Dark Violet c) Residue Gas Canary Yellow White French Blue d) LPG Canary Yellow Brilliant Green White e) Acetylene Canary Yellow Dark violet -

3 ALL EQUIPMENT

a) Such as vessels. columns, exchangers, etc. containing non- hazardous fluids.

Light Grey

b) All equipment containing hazardous fluids

Canary Yellow

c) Pipe carrying hazardous fluids Bar is to be replaced by Hazardous Marking as per IS: 2379 Clause 7.1C

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Table 2

Normal Industrial Environment (Above Ground)

Sl. No.

Description Temp. Range

Surface Preparation

Primer Finish Coat Total DFT

Remarks

1.0 External surface of equipment's and piping.

1.1 -Do- -10 to 20 SSPC-SP-3 One coat P-2 50 microns / coat (min)

One coat F-4 65 microns/ coat (min) Two coats F-3, 30 Microns/coat (min)

175 Primer and Finish coat can be applied at ambient temp.

1.2 -Do- 21 to 60 SSPC-SP-6 Two coats P-1, 25 microns/ coat (min.)

Two coats of F-1, 20 microns/coat (min)

90 -

1.3 -Do- 61 to 80 SSPC-SP-6 Two coats P-3, 50 microns/ coat (min)

Two coats of F-13, 25 microns/coat (min)

150 -

1.4 -Do- 81 to 250 SSPC-SP-6 Covered in Finish coat

Three coats of F-11, 20 microns/ coat (min)

60 Paint application at ambient temp. curing at elevated temp. during start-up.

1.5 -Do- 251 to 400 SSPC-SP-10 Covered in Finish coat.

Three coats of F-12, 20 microns/ coat (min)

60 -do-

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Table- 3

Corrosive Industrial Environment (Above Ground)

SI. No.


Surface preparation


Remarks

1.0 External surface of un-insulated and other equipment

I.1 - do - -10 to 20

SSPC-SP-3 Two coat P-2, 50 microns) coat (min.)

Two coat F-3, 30 microns / coat (min.)

160 Primer and paint application at ambient temp.

1.2 - do - 21 to 80

SSPC-SP-10

Two coats P-5, 35 microns / coat (min.)

Two coats F- 6, 100 microns coat (min.)

270 Paint application at ambient temp.

I.3 - do - 81 to 400

SSPC-SP-3 Covered in finish coat

Three coats F- 12, 20 Microns / coat (min.)

60 Paint application. at ambient temp, and curing at 250'C for 4 hours,

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Table – 4

Coastal and Marine Environment (Above Ground)

SI. No.


Surface Preparation


Remarks

1.0 External surface of equipment’s and piping.

1.1 -do- -10 to 60

SSPC-SP-3 Two coats P-2, 50 micron/ coat (min)

Two coats F- 3, 30 Microns/coat (min.)

160 Primer and Finish coat application at Ambient temp.

1.2 do - 61 to 80

SSPC-SP-10

Two coats P-5. 35 Microns. coat (Min.)

Two coats of F-6, 100 Microns/Coat (min.)

270 -do-

1.3 - do - 81 to 400

SSPC-SP-I0 One coat F-9, 83 Microns/ Coat(Min.)

- 85 Paint application at Ambient temp. Primer is acting as primer cum finish coat.

1.4 - do - i) Upto 80

SSPC-SP- 10

One coat F-9, 6.5 microns / coat (Min)

One coat of F-2. 30 Microns/coat (min.)

95 Paint application at ambient temp.

ii) 8l to 400

SSPC-SP- 10

-do- -do- 85 Paint application at ambient temp. Primer is acting as primer cum finish coat.

1.9.4 Precautions to be taken Neither the environment of the site nor the marking labels of devices may be covered with paint and they

must be kept free of paint splashes. To this end, it is advisable to use removable masking tape. Paint splashes, leaks, etc. on any adjacent installations such as measuring apparatus, valves, pipes.

sources of light, insulation, heat insulators, walls, concrete, etc, must immediately be wiped up and the damage repaired before the paint is dry.

Otherwise, the OWNER will be obliged to have the cleaning carried out at the expense of the Contractor.

The paint recipient will only be opened at the time of use (unless otherwise specified by the manufacturer).

The product will be mixed in the recipient with the aid of suitable tools and thus homogenized.

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1.9.5 Method of application Normally, three methods of application will be used on the construction site for the paint products. i.e.

with a brush, with a roller or with a spray gun. • The brush method makes it possible to obtain good penetration of the paint over irregularities in the

metal. • Only this method will be used for application of the base coats, for retouching and for protrusions,

welded areas, riveted joints or bolted joints: • The roller method may be used on large flat surfaces for the intermediate and topcoats. • The spray gun method must be used in accordance with the instructions of the manufacturer and carried

out by qualified personnel. The Contractor must guarantee that all safety measures have been taken for such work. The spray gun

method may only he used on site for places that arc difficult to reach with the brush. In this case, a request must be made to the OWNER/ OWNER's Representative for a deviation.

All paintwork will be carried out with good brushes or rollers that are suitable for the type of paint being

used and for the form of the material to be painted and fitted with short handles. The maximum length of the brush and roller handles will be 50 cm; longer handles may only be used for places that are absolutely inaccessible. The maximum width of a brush will be 13 cm.

1.9.6 Application of the coating Application of the paint will be carried out in accordance with best practice in order to obtain a

homogeneous and continuous layer. The OWNER or the Approved Supervisory body demands that painting of a layer will only be started after acceptance by them of the surface preparation or of the previous layer of paint.

The layers of paint must have a uniform thickness. They must he spread in such a way that all concave

parts are dried out and that the surface is completely covered and has a glossy appearance without leaving brush marks and without exhibiting bubbles, foam, wrinkles, drips, craters, skins or gums that arise from weathered paint,

Each layer must have the color stipulated in the tables of the present specifications, which clearly differs

from the previous layer, taking account of the Color of the top layer, all of which for the purpose of being able to identify the number of coats and their order of sequence. If the color of the coats is not mentioned in the tables the color difference in consecutive coats must, if possible, he at least 100 RAL. The color of the top layer is given in the table.

The coating power should be such that the underlying layer is not visible. Only 1 layer per day may be

applied, unless otherwise specified by the OWNER or the Approved Supervisory Body. The drying times prescribed by the paint manufacturer must be strictly observed in relation to the

environmental conditions before proceeding with the application of the next layer. The dry coating thickness indicated in the description of the paint systems are minimum thickness. In

this connection, the Contractor is obliged to contact the paint manufacturer and conform to his guidelines. The Contractor must respect the thickness specified by the supplier.

1.9.7 Transporting treated items In the case of works being carried out in a workshop, the metal structures will be surrounded by

ventilated contraction film that prevents damage during transportation. This film may only be applied after complete polymerization of the paint.

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1.10 GROUND-LEVEL TRANSITION POINT 1.11 Polyester protection system The Contractor will provide system 02 over the entire length of the pipes above ground and below

ground and up to a height of 20 cm and a depth of 40 cm. perpendicular to the ground level mark. In each case, he must ensure that the jointing below the asphalt is in good condition and assures' faultless adhesion. He will apply the following products over the entire surface area, prepared in accordance with is Sa 3:

1) The primer of system 01.

2) Reinforced polyester ± 20 cm above the ground level marker and ± 5 cm on the asphalt cleaned

beforehand (application of reinforced polyester is carried out in accordance with the work method prescribed by the manufacturer). Moreover, in the case of PE, in contrast to asphalt, he will apply a polygon primer to PE immediately before applying the reinforced polyester.

3) He will then apply the other coats of system 01a to the surface section and thus cover the

reinforced polyester with about 5 cm. 4) For new constructions, the polygon primer will be applied to PE and then subsequently

processed as described under point 2. 1.11.1 USE OF SCAFFOLDING Mounting, maintenance and dismantling of scaffolding for carrying out adaptation and/or paintwork to

surface gas pipes or gas transport installations in use;

• The Contractor will specify the cost of scaffolding in the price list.

• The supplementary rental price for delays attributable to the Contractor will be charged to him:

• In his price quotation the Contractor should present the OWNER with diagrams of the scaffolding that he intends to install for carrying out the works of the OWNER.

1.12 QUALITY CONTROLS AND GUARANTEE 1.12.1 The Contractor is responsible for checking the weather conditions to ascertain whether the paintwork

can be carried out within the technical specifications. The Contractor should have the required calibrated monitoring apparatus for this purpose on site (with

calibration certificates). The personnel who will have to use this apparatus should have the training for this purpose.

The OWNER or his representative and possibly the approved supervisory body indicated by the

OWNER will maintain supervision during the works and inspect the works with random checks. A daily report will be drawn up in relation to the department that maintains supervision of these works.

The supplementary inspection and the supervision by the OWNER or the approved supervisory body do

not diminish in any way the liability of the Contractor. The proper execution of the work and the materials used may be checked at any time.

1.12.2 Reference Surfaces At the start of the works. the OWNER or the approved supervisory body will indicate a few surfaces that

the Contractor will prepare and cover in accordance with the recognized method of operation under the inspection and to the satisfaction of all parties ; the OWNER or his representative, the approved supervisory body. the contractor and possibly the paint manufacturer. These reference surfaces will serve as a point of comparison for the good adhesion of the paint on the installations as a whole. The

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parties will together work out a system for the identification of these surfaces in order to be able to monitor the conditions of the coatings over time. If the paintwork on a section of the installations is in a worse condition than the reference surfaces, the Contractor may be obliged to treat these parts again.

1.12.3 Measures to be taken in the event of a dispute If on delivery of the works no agreement can be reached between the Contractor and the OWNER

regarding the conformity of the works to the requirements of these specifications, an Approved Supervisory Body will he Called in. The Approved Supervisory Body will then carry out inspections' on site whereby the following assessment criteria wilt be used:

• The Swedish standards ISO 8501-1 1988 SS 05.5900 concerning the degree of cleanliness of

the areas derusted by blasting, by machine or by hand. • The wet film thickness of the paint will be measured in accordance with ISO 2808 or ASTM DI

212; • The dry layer thickness of the film will be measured electronically, will complete statistical

information. in accordance will, ISO 2808 or ASTM D 1186. • The thickness of each layer will he measured in accordance with ISO 2808. ASTM 4138 or DIN

50986. • Adhesion tests will be carried out in accordance with ISO 2409. ASTM 3359 or DIN 53151. • Traction tests will he carried out in conformity with ISO 4624 or ASTM D 4541. • The rugosity will be measured electronically in accordance with DIN 4768; • The non-porosity will be measured with a test tension depending on the type of coating, the

layer thickness and after consultation with the Paint manufacturer. • Any defects in the paint film may be inspected visually by means of a magnifying glass or

microscope. If necessary a photographic report may be drawn up in accordance with ASTM Standard D 4121-82,

The final judgement of the Approved Supervisory Body is irrevocable and binding for the Contractor and

the OWNER. In the event of non-conformity of the works with the criteria of these specifications, all costs arising from the inspection by the Approved Supervisory Body shall be borne by the Contractor.

1.12.4 Guarantee a) General Principles The Contractor declares that he is aware of:

The maximum operating temperature of the surfaces to be covered. • The maximum permitted degree of humidity of the bearing surface. • The properties of the environment to which the surfaces to be covered are: subject.

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b) Summary of the Guarantee. The contractor fully guarantees the following without reservation:

• The observance of all stipulations of the specifications for paintwork regarding, among other things:

o The preparation of the surfaces. o The thickness of each layer. o The total thickness of the covering.

• The uniformity of the materials used. • The repair of all defects before delivery of the works.

The Contractor will carry out the requested repair work as promptly as possible.


DEWAS

CLIENT JOB NO CATHODIC PROTECTION DESIGN BASIS

TOTAL SHEETS 11

DOCUMENT NO 11 0290A 02 10 04 002

1 06/10/09 ISSUED FOR TENDER SB SB PKS

0 10/07/09 ISSUED FOR APPROVAL SB SB PKS

A 07/07/09 ISSUED FOR IDC SB SB PKS


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DESIGN BASIS CATHODIC PROTECTION

Page 2 of 11

TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 SCOPE OF WORK

3.0 MATERIAL & EQUIPMENTS

4.0 PRECEDENCE OF DOCUMENTS

5.0 CODES AND STANDARDS

6.0 AREA CLASSIFICATION AND EQUIPMENT SELECTION

7.0 OPERATING REQUIREMENTS

8.0 CATHODIC PROTECTION ACCEPTANCE CRITERIA

9.0 CATHODIC PROTECTION DESIGN

10.0 CASING PIPE PROTECTION

11.0 INSULATION MONO-BLOCKS

12.0 SOLID STATE POLARIZATION CELLS

13.0 ER PROBES & CORROSION COUPONS

14.0 CTSU WITH READER

15.0 ANODEBED PLOT AND CABLE ROUTE ACQUISITION ON BEHALF OF

GAIL GAS LIMITED

16.0 [PSP] CONVERTER AND REFERENCE ELECTRODE

17.0 DOCUMENTATION

18.0 MONITORING

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1.0 INTRODUCTION

This Document is to establish minimum criteria & requirements for Cathodic Protection

system of City Gas Distribution Project(DEWAS) of GAIL GAS LIMITED.

1.1 The proposed pipeline details are :

1) Dia of Pipe - 8”, 6” & 4”

2) Thickness of pipe - 6.4 mm

3) Pipe Grade - API 5L X-42

4) Coating –

External coating - 3LPE

5) Girth Weld Coating - Heat Shrink Sleeve HTLP 50 or Equivalent

Stress Class C

The proposed cathodic protection system for 8”, 6” & 4” Dia GAIL GAS LIMITED City Gas

Distribution Project will form a composite cathodic protection system.

It is envisaged to provide :

1. Temporary Cathodic Protection [TCP] for a period of one (1) year or till commissioning of

Permanent Cathodic Protection [PCP] system.

2. Permanent Cathodic Protection [PCP] system for a design life of 40 years.

The sequence of doing work to be [TCP] as pipe is laid in ditch, followed by [PCP].However,

[TCP] to be dis-connected only after [PCP] is commissioned.

2.0 SCOPE OF WORK

The Proposed new pipeline system of section along with associated facilities would be designed

for a life of [1+40] years and would be protected by sacrificial anodes for temporary cathodic

protection, till PCP commissioning. CP stations shall be utilized for protection of the new pipe

line. The power input could be UPS Power.

3.0 MATERIAL & EQUIPMENTS :

All Material and Equipment to be used for this project to conform to following site conditions :

3.1 Site Conditions The equipment will be designed for the following site conditions:

Min/Max. Temperature 00 C to 600 C

Design Temperature 600 C

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Relative Humidity 90%

Height above MSL < 1,000 M

Atmospheric Pollution To withstand the site conditions, dust, vapour

Hazardous area classification for plant Zone 2,Gas Group IIA,IIB Temp. Class T3

Control Room/Electrical Room/

D.G.Room/Guard Room/Battery Room Safe Area

3.2 All material required and to be used for this project, except only Zn & Mg Anodes [required

exclusively for [TCP],to conform in totality to [PCP] requirements.

The following Electrical equipments are envisaged for GAIL GAS LIMITED City Gas

Distribution Project:

3.2.1 Power Source UPS System as a power source along with TRU [Transformer Rectifier Unit]/CPPSM for cathodic protection] at each Locations. The Power source to be SCADA compatible with potential free contacts for Auto Monitoring from central console to be located in DB room and to have IP55 enclosure.

3.2.2 Anodes

For [TCP] depending on Soil Resistivity variation along pipeline ROW

From soil resistivity 1 to 1,000 Ω Cms. Zn anode at 2M from pipe

From soil resistivity 1,001 to 5,000 Ω Cms. Mg anode at 5M from pipe

Mg Ribbon anodes to be used from 5,001 to 10,000 Ω Cms.

Both to be buried in appropriate back-fill.

However, Only one type [Zn or Mg] anode to be used, for the entire pipeline, to avoid inter

anode current.

• For [PCP] MMO Anodes (in carbonaceous backfill) to be placed in most suitable configuration such as shallow, deep or semi-deep anodebed with appropriate justification.

3.2.3 Cables

Single Core multi-strand copper conductor PE PVC cable are to be used for this project

3.2.4 Reference Electrodes

Reference Electrodes to be used for this project are as follows : In Soil Copper Copper Sulphate [CSE] Permanent type to be buried along

the pipe In Water Standard Calomel [SCE] or Silver Silver chloride [SSC] to be used when monitoring

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3.2.5 Junction Boxes

All junction boxes such as Anode Junction Box [AJB], Cathode Junction Box [CJB] and

Test Stations [TLP] to be IP 55 enclosure duly certified by Approved agency only.

3.2.6 Cable to Pipe connection

All cable to pipe connection only by Pin Brazing, and all pin brazed cable to pipe connections to

be epoxy encapsulated and checked by holiday detector to avoid any necking possibility.

3.2.7 Solid State Polarization Cells

At all locations of un-acceptable AC Interference, as detected by AC Interference surveys, on

underground pipeline, solid state Polarization cell to be provided and earthed through a

sacrificial anode sized appropriately.

3.2.8 Insulation Mono-blocks to be used for Isolation purposes.

3.2.9 Surge divertors to be installed across each Insulation Mono-block.

3.2.10 Computerized Test Station Units [CTSU] to be installed alongwith readers.

3.2.11 ER probes and Coupons to be installed for internal and external corrosion monitoring.

3.2.12 Miscellaneous such as Markers, Cable Glands, Tags, Ferrules, Shunts & Resistors etc.


In case of any contradiction/conflict between the tender specification and drawings, the precedence of documents in the tender shall be as follows:-

Design basis. Technical Specification. Relevant codes and standards Drawings.


The Cathodic Protection System design, performance and materials to be supplied shall unless otherwise specified, conform to the requirements of latest relevant applicable standards:

BIS Standards

BS Standards and codes of practice

ANSI Standards

NFPA Standards

NACE Standards and Recommended practices

IEC Standards

DNV Standards

IEEE Standards

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DIN Standards

ASTM Standards

OISD Standards & CCE Norms & PNGRB Norms & Guidelines

API Model code of safe practices

GAIL GAS Safety Standards

All statutory, state, local requirements and norms

[All latest available editions only.]

However, In case of conflicting requirements amongst any of the above standards, the publication having most stringent requirement shall be governing. However, the priority in such instance shall be as follows:

Statutory Regulations and norms

This Specification

Codes & Standards


Classification of hazardous area will be in accordance with API 500 , IS:5572 & OISD:149.

Following factors will be considered for proper selection of electrical equipment for use in hazardous areas:

Area Classification - Zone-2 Gas Group - IIA and IIB Temperature Classification - T3

All electrical equipment installed in hazardous area will be selected as per IS:5571.

All electrical equipment for hazardous area will be certified by CMRI or equivalent independent testing agency.


Power supply

Voltage - 230V AC ± 1%

Frequency - 50 Hz ± 5% Phase & Wire - 1P, N & 2W Fault level - 10KA for 1 sec Neutral Earthing - Solidly earthed

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8.0 CATHODIC PROTECTION ACCEPTANCE CRITERIA :

Cathodic protection system shall be designed to meet the following criteria.

Temporary Cathodic Protection [TCP]

8.1 The pipe to soil potential measurements shall be between –0.95V (“On”) and –1.5V (“On”) both “On” Potentials w.r.t. Cu-CuSO4 reference electrode. In case sulphate reducing bacteria [SRB] are present in soil the minimum protective potential shall be (-) 0.95V (“On”), the maximum remaining the same (-) 1.5V (“On”) w.r.t. Cu-CuSO4 reference electrode. At the location of Polarization coupons, the coupon to soil potential measurement shall be between (-) 0.95V (“Off”) minimum and (-) 1.18 V(“Off) maximum w.r.t. CuCuSO4 reference electrodes, both being “Off” potential.

8.2 In rare circumstances a minimum polarisation shift of (-) 100 millivolts w.r.t. Cu-CuSO4 reference electrode shall indicate adequate levels of cathodic protection for the pipeline.

Discretion to use any of the criteria, listed above, shall solely rest with the Owner/ Owner’s representative.

8.3 A positive potential swing of ›20 mV [P-S-P] shall be considered as the criteria for presence of an interaction situation requiring investigation and incorporation of suitable mitigation measures by the C P Contractor.

PERMANENT CATHODIC PROTECTION [ P C P ]

8.4 The pipe to soil potential measurements [PSP] shall be between (–) 0.95V (“Off”) minimum and (–)1.18V (“Off”) maximum [both “Off” Potentials] w.r.t. Cu-CuSO4 reference electrode, the maximum remaining the same (-) 1.5V (“On”) w.r.t. Cu-CuSO4 reference electrode.At the location of Polarization coupons, the coupon to soil potential measurement shall be between (-) 0.95 (“Off”) minimum and (-) 1.18 V (”Off”) maximum w.r.t. CuCuSO4 reference electrodes [both being “Off” potential].




9.0 CATHODIC PROTECTION DESIGN :

Cathodic Protection Design to be based on site data to be generated by CP contractor prior to [TCP] and [PCP] Design. The available site data is annexed but it’s veracity is to be verified by CP contractor before CP Design.

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9.1 Data to be generated from site :

a) Soil resistivity upto appropriate depth [1,3,5,10,15,20,25,30,35,40,45,50...] from ROW and Proposed Anode bed locations[at Grid intersections]-more than one plot at each location.

b) Soil analysis for Microbial and chemical loading of soil samples collected from pipeline ROW every 5Km and proposed anodebed locations,from at least two depths at each location [1M and 3M] after drying,coning and quartering of soil samples,an aqueous extract to be analysed for Sulphate Reducing bacteria [SRB],Cations [Ca,Mg,Na.K] and Anions [Cl,SO4,CO3,HCO3,S,NO2,NO3,PO4,] besides Total dissolved solids [TDS],pH,Redox potential,Moisture (%) etc.

c) Details of Crossings along pipeline ROW viz: Rail, Road, River, Canal, Pipeline, H.T. Lines with distance from pipe etc.

d) Details of CP system on parallel pipelines ROW or crossing it

e) Details of any switching yards &/or welding stations etc.

f) Topographic details along ROW

g) Likelihood of Telluric currents

9.2 Design Parameters :

i. Pipelines having polyethylene coating on external surface Protection Current Density :

Pipeline surrounding Protection Current density *

Temporary CP (µA/m2) Permanent CP (µ A/m2)

Normal soil 30 25

Marshy area/ buried in sea water

40 35

High resistivity area (more than 100 Ώm)

25 20

However, the Protective Current Density to be chosen at site as per Environmental conditions obtained as per Detailed Chemical & Microbial Analysis and presence or absence of interfering elements in close vicinity of pipeline ROW.

Pipe to soil [P-S-P] potential shall not be more negative than (-) 1.5V (“ON”) or (-)1.18V (“Off”) w.r.t. Cu-CuSO4 Reference electrode.

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*Actual current density to be adopted shall be decided based upon soil/water corrossivity and other environmental conditions, proximity of foreign pipelines and structures resulting in interference. Where considered necessary for satisfactory protection of pipeline the current density shall be suitably increased by contractor with appropriate justifications Approved by Owner.

9.3 other parameters for design Other parameters to be considered for [TCP] and [PCP] design:

Safety factor Sf for current density : 1.3

Anode utilization factor Uf : 0.85 for centre connected Anode

: 0.5 for Ribbon Anode

Pipeline natural potential (-) 0.45V [as measured from existing /upcoming structure in the same soil matrix].If pipeline potential is (+) then Mg ribbon anodes should be first laid to bring it to (-) before doing Cathodic Protection.

Unless otherwise specified in project specification the design life of [TCP] temporary CP shall be min. 1 year and that of [PCP] permanent CP shall be 40 years.

Along the ROW where soil resistivity is higher than 100 Ώ m temporary CP for the pipeline may not be necessary, if agreed by Owner or unless otherwise specified in project documents.

Steel Resistivity : 2.2 X 10-7Ω M

Maximum Loop Resistance : 1 Ω

9.4 Design Report : On completion of all field work a composite report incorporating all the results generated from site surveys for data generation and details of additional data collected as well as collated shall be furnished to owner for Approval. The report shall also contain detailed interpretation of survey results and resistivity, chemical & microbial analysis data enclosed, probable interference prone areas etc. to form design basis for the scheme of cathodic protection [TCP] & [PCP] system. This report shall also include various drawings prepared in connection with the above work. The soil resistivity values shall be plotted on semi-log graph sheets and in Histograms. Log mean resistivity values to be calculated and used for the Design of CP system.

The Cathodic Protection Design calculations & formulae for [TCP] and [PCP] systems should form part of this composite Report. The Bill Of Materials [B.O.M.], Technical Specifications, Vendor list, QA/QC, Inspection formats, Post commissioning survey methodology and System adequacy Monitoring Formats and Schedule of work etc. will be included in this Report for Approval of Owner. The Construction Drawings for Owners Approval shall be part of this composite Cathodic Protection Design report.

After Commissioning of [PCP], after an interval of one month, following post commissioning surveys shall be carried out as per procedure Approved by the Owner, on all existing and 10” /12” Dia and 8” / 10” Dia pipeline. However, Post commissioning surveys should be carried out on AC DC Interference free pipeline. Prior to starting of Post commissioning surveys Interference must be totally detected and mitigated.

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Following surveys shall be carried out :

1. Coating Conductance surveys.

2. Pearson surveys followed by DCVG surveys at Holidays detected by Pearson detection.

3. Close Interval Potential [On & Off ] Logging/surveys.

4. I/J and Casing Carrier short surveys

10.0 CASING PIPE PROTECTION :

Railway crossings and some other crossings such as NHW, River will be cased and will, therefore, require (casing) protection for [40+1] years using sacrificial anode cathodic protection. Anodes shall be installed at both the ends of the casing.

Further, carrier pipe inside casing for railway crossing shall be additionally protected using ribbon anodes for carrier pipe bottom protection. The Anode cable inside the casing pipe on carrier pipe bottom shall be terminated outside the casing in TLP on both sides.

The Annulus between casing & carrier pipe except for railway crossing, for all casing larger than 20M shall be filled with Bentonite to control moisture ingress in the annulus and additional carrier pipe protection with sacrificial anodes for carrier pipe bottom protection shall be provided.The annulus between casing and carrier pipe for casings less than 20M shall be filled with Bentonite but no additional cathodic protection for carrier pipe bottom shall be provided.

11.0 INSULATION MONO-BLOCKS :

All insulation Mono-Blocks shall be provided a Surge Divertor / or grounding cell if Approved by Owner, to provide a path for surge grounding. The surge divertor shall be installed in an appropriate box. Also TLP shall be provided for short monitoring periodically.

12.0 SOLID STATE POLARIZATION CELLS :

Solid state Polarization device shall be installed in a safe enclosure, as per overseas expert agency recommendations, at locations on pipe showing un-acceptable levels of AC induction levels.

13.0 ER PROBES & CORROSION COUPONS :

ER Probes to be installed for internal corrosion monitoring as per the design calculation for the whole system.

14.0 CTSU WITH READER :

Computerized Test Station Unit [CTSU] shall be installed & supplied with Reader.

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15.0 ANODEBED PLOT AND CABLE ROUTE ACQUISITION ON BEHALF OF GAIL (INDIA) :

All Anodebed plots and anode tail cable route shall be acquired by the CP contractor in the name of GAIL GAS LIMITED and handed over to GAIL GAS LIMITED at the time of system handover to GAIL.


[PSP] converter and Reference electrode shall be provided at all RTU and SCADA interface locations. Besides other such as CP Stations,[Halfway] In between CP Stations,Corrosion Monitoring Coupons etc.

17.0 DOCUMENTATION :

As-Built Documentation including Drawings and O&M Manual to be prepared and handed over to GAIL at the time of System handover.

18.0 MONITORING :

Installed system to be monitored by the CP contractor for one year from the date of commissioning and any repairs/refurbishment to be carried out at contractors cost to achieve protective system adequacy.

* * * * *


MEERUT


TOTAL SHEETS 11

DOCUMENT NO 11 0290B 02 10 04 002





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TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 SCOPE OF WORK














GAIL GAS LIMITED


17.0 DOCUMENTATION

18.0 MONITORING

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1.0 INTRODUCTION


system of City Gas Distribution Project (MEERUT) of GAIL GAS LIMITED.


1) Dia of Pipe - 10”, 8”, 6” & 4”



4) Coating –



Stress Class C

The proposed cathodic protection system for 10”, 8”, 6” & 4” Dia GAIL GAS LIMITED City

Gas Distribution Project will form a composite cathodic protection system.







2.0 SCOPE OF WORK










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3.2.2 Anodes







anode current.


3.2.3 Cables





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BIS Standards


ANSI Standards

NFPA Standards


IEC Standards

DNV Standards

IEEE Standards

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DIN Standards

ASTM Standards








This Specification

Codes & Standards








Power supply



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Normal soil 30 25


40 35


25 20



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18.0 MONITORING :


* * * * *


SONIPAT


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DOCUMENT NO 11 0290C 02 10 04 002





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TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 SCOPE OF WORK














GAIL GAS LIMITED


17.0 DOCUMENTATION

18.0 MONITORING

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1.0 INTRODUCTION


system of City Gas Distribution Project (SONIPAT) of GAIL GAS LIMITED.


1) Dia of Pipe - 10”, 8”, 6” & 4”



4) Coating –



Stress Class C









2.0 SCOPE OF WORK










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3.2.2 Anodes







anode current.


3.2.3 Cables





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BIS Standards


ANSI Standards

NFPA Standards


IEC Standards

DNV Standards

IEEE Standards

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DIN Standards

ASTM Standards








This Specification

Codes & Standards








Power supply



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Normal soil 30 25


40 35


25 20



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18.0 MONITORING :


* * * * *


KOTA


TOTAL SHEETS 11

DOCUMENT NO 11 0290D 02 10 04 002





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TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 SCOPE OF WORK














GAIL GAS LIMITED


17.0 DOCUMENTATION

18.0 MONITORING

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1.0 INTRODUCTION


system of City Gas Distribution Project (KOTA) of GAIL GAS LIMITED.


1) Dia of Pipe - 10”, 8”, 6” & 4”



4) Coating –



Stress Class C









2.0 SCOPE OF WORK










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3.2.2 Anodes







anode current.


3.2.3 Cables





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BIS Standards


ANSI Standards

NFPA Standards


IEC Standards

DNV Standards

IEEE Standards

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DIN Standards

ASTM Standards








This Specification

Codes & Standards








Power supply



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Normal soil 30 25


40 35


25 20



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18.0 MONITORING :


* * * * *


CLIENT JOB NO TECHNICAL SPECIFICATION OF CATHODIC PROTECTION (TCP/PCP)

TOTAL SHEETS 43

DOCUMENT NO 11 0290 02 10 02 010

0 15/10/09 ISSUED FOR TENDER VSR SB PKS

B 31/08/09 ISSUED FOR APPROVAL VSR SB HM

A 27/08/09 ISSUED FOR IDC VSR SB HM


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TECHNICAL SPECIFICATION OF CATHODIC PROTECTION (TCP/PCP)

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1.0 GENERAL

GAIL Gas Limited; a wholly owned subsidiary of GAIL proposes to install refuelling outlets

in Dewas, Meerut, Sonipat & Kota Cities. GGL is inviting tenders on Competitive Bidding basis

for laying of steel pipeline network at Dewas, Meerut, Sonipat & Kota cities.

The scope of work for this tender covers Cathodic Protection (TCP/PCP) of steel pipeline for

various destinations of Dewas, Meerut, Sonipat & Kota cities. The total pipeline network of

Dewas, Meerut, Sonipat & Kota cities consists of 10”, 8”, 6” & 4” size of approximately 31.097

Kms., 45.10 Kms., 40.89 Kms. & 40.90 Kms. respectively.

2.0 Gas Network Architecture:

In order to supply gas to various consumers, metered and filtered gas taken from CGS shall be

fed to the main steel network ring laid strategically in the entire city.

3.0. Pipeline Details :

3.1 The proposed pipeline details for Dewas are :

1) Dia of Pipe - 8” - 10178 meter

6” - 10680 meter

4” - 10239 meter


3) Pipe Grade - API 5L X 52

4) Coating –



Stress Class C

3.2 The proposed pipeline details for Meerut are :

1) Dia of Pipe - 10” – 3500 meter

8” - 14400 meter

6” - 21100 meter

4” - 6100 meter


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4) Coating –



Stress Class C

3.3 The proposed pipeline details for Sonipat are :


8” - 12700 meter

6” - 6500 meter

4” - 3000 meter



4) Coating –



Stress Class C

3.4 The proposed pipeline details for Kota are :


8” - 12400 meter

6” - 2000 meter

4” - 3000 meter



4) Coating –



Stress Class C

4.0. Cathodic Protection :

To prevent soil-side corrosion the underground pipeline will be provided Cathodic Protection as

follows :

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1. Temporary Cathodic Protection [TCP],for the construction period of minimum one (1) year,

using sacrificial anodes in suitable back-fill

2. Permanent Cathodic Protection [PCP] using single phase 230V AC Input and DC Output

50V 50A Transformer Rectifier Unit [TRU] as Power source and Mixed Metal Oxide

[MMO] Linear Dimensionally Stable Tubular Anode LIDA® for a design life of forty (40)

years.

TRU to be installed only at locations where dedicated A C feeder is available.

The Cathodic Protection System both [TCP] as well as [PCP] to be designed based on site data

such as soil resistivity along pipeline ROW [Right Of Way] and at proposed anode-bed

locations, including soil characteristics such as Ionic & Microbial loading and other existing as

well as upcoming Interfering elements such as existing underground pipelines, tanks, metal

structures such as Electric Transmission Power Transformer and Tower earthing, etc. Also, other

existing pipeline CP system in close vicinity and DC rail traction, switching yard etc.

The CP contractor to arrange site data generation and collation prior to design of the CP system.

All site data generation to be as per GGL/WGI Approved methodology.

4.1. SCOPE OF WORK :

This specification defines the requirements of site surveys for design data generation from pipeline ROW, CP design, detailed engineering, supply of materials, quality assurance (QA) and quality control (QC), installation, testing and pre-commissioning, Commissioning, Testing of temporary cathodic protection system [TCP] and permanent cathodic protection system [PCP]for protecting throughout the design life [1+40 years] the external surface of 3LPE coated underground [CGDP] GGL pipeline including detection of A.C & D.C. interference / interaction with neighbouring structures/utilities all along the pipeline ROW, as well as Installation of requisite Mitigative measures for the [A.C/D.C.] interaction / Interference mitigation. Also included in the scope of work are post-commissioning surveys, to be conducted one month after the Commissioning of [ICCP] system, such as Computerized Potential Logging [CPL] and Coating conductance measurements along the pipeline ROW, followed by Pearson, DCVG [for defect classification] at defect locations indicated by CPL & Pearson surveys and Casing Carrier pipe short.

This specification defines the basic guidelines to develop a suitable temporary cathodic protection [TCP]

system followed by permanent cathodic protection [PCP] system for the underground [CGDP] GGL mild steel [API 5LX 52] pipeline [external surface coated with 3LPE] required to be protected from ravages of soil side corrosion. All data required in this regard including site surveys to verify, prior to CP design, the data annexed shall be taken into consideration by the CP contractor to develop an acceptable state of the art [TCP],[PCP] design and for appropriate engineering of the [TCP],[PCP] systems for GAIL Gas City Gas Distribution Project,GGL [CGDP].

4.2. Compliance with these specifications and/or approval of any of the contractor’s documents shall in no

case relieve the contractor of his contractual obligations of providing adequate cathodic protection [TCP], [PCP] system suitable for desired number of service [1+40] years free of interference.

4.3. Activities of [ICCP] permanent cathodic protection [PCP] system which are common to temporary [TCP]

system shall be completed as part of temporary [TCP] system. The facilities installed for [TCP], if useful & required in [PCP] system (such as TLP, Reference electrodes, Corrosion coupons, Pin Brazing etc.) shall be utilized for [PCP] also & hence are to be designed as per [PCP] requirements.

4.4. All works to be performed and supplies to be effected as part of this contract shall require specific

approval of owner or his authorised representative. Major activities requiring Owner’s approval shall include, but not be limited to, the following:

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a) Methodology of Corrosion survey for site data generation, verification and interpretation

report and design basis for [TCP],[PCP] system. b) CP System design package including formulae used for calculations, design calculations, BOQ,

Technical Specifications and Post Commissioning Monitoring Methodology, Data Recording Formats, Frequency.

c) Quality Assurance/Control [QA/QC] methodology.

d) Methodology for Erection, Field testing and commissioning.

e) Methodology for A.C and D.C. interference testing, detection and mitigation.

f) Procedure for Post Commissioning surveys.

g) As-Built Documentation.

h) O&M Manual and Monitoring Methodology, Frequency and Formats.

4.5. The Intending Bidder shall be deemed to have visited the Site [CGDP] GGL pipeline ROW and Familiarized with site conditions before Submitting the tender. Non familiarity with site conditions will not be accepted as a reason subsequently either for extra claims or for not carrying out the work in total conformity with these tender specifications.

4.6. The main pipeline laying contract may be divided into more than one spreads. The CP contractor will

have to accordingly mobilize simultaneously at all spreads concurrently, deploy adequate Manpower, Tools & Tackles, Construction & Testing Equipments requisite for smooth work progress so that CP work could also be completed within Schedule specified for the project. The CP contractor shall work in close coordination with the main pipeline contractor.

4.7. The installed [TCP] system to be monitored once a month and Monitoring Report submitted to Owner for Review and Approval.After installation & commissioning of [PCP] system the installed [ICCP] system to be Monitored by CP contractor,once a month,for a period of one (1) year from date of [PCP] commissioning and Monitoring Report to be submitted to Owner for Review and Approval every month.Any deficiency observed in the installed system during this period shall be made good by CP contractor without any extra cost to owners during this one year monitoring period.

5.0.CODES AND STANDARDS

The system design, performance and materials to be supplied shall unless otherwise specified, conform to the requirements of latest relevant applicable standards:

• BIS Standards

• BS Standards and codes of practice

• ANSI Standards

• NFPA Standards

• NACE Standards and Recommended practices

• IEC Standards

• DNV Standards

• IEEE Standards

• DIN Standards

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• ASTM Standards

• OISD Standards, CCE Norms & PNGRB Recommendations

• API Model code of safe practices

• GGL City Gas company Safety Standards

• All statutory, state, local requirements and norms

All latest available editions only.

In case of conflicting requirements amongst any of the above standards, the publication having most stringent requirement shall be governing. However, the priority in such instance shall be as follows: Statutory Regulations and norms

This Specification

Codes & Standards

6.0. CORROSION SURVEY DATA

Corrosion Survey Data collected already from site [pipeline ROW] viz: Soil Resistivity, Soil Chemical analysis for chemical and microbial loading is enclosed: i Soil Resistivity along pipeline ROW - As per Annexure. However, verification of its veracity and Adequacy, prior to CP Design, shall be the entire responsibility of the CP contractor. In addition the CP contractor shall have to generate/collect additional Data from site such as:

6.1. The CP contractor shall carry out a site survey along GGL pipeline ROW and at proposed Anode bed locations, in order to verify as well as generate requisite design data, prior to the final design of the [TCP], [PCP] system. The site survey shall generally include the following:

General information [Topographic] of terrain along which the pipeline is to be routed.

6.1.1. Anode bed locations proposed: Measurement of soil resistivity [ρ] along GGL pipeline ROW and at Anode bed locations/plots. Each

selected Anode bed plot shall be sub-divided into sub-plots. Size of the sub-plots shall depend upon investigation of soil resistivity up to requisite depth. Each of these sub-plots shall be investigated individually. Sufficient observations at each of these plots shall be recorded as recommended by the Owner’s representative. This to obtain sufficient information about sub-soil stratification and water table depth wherever possible. The number of sub-plots shall be decided at site by Owner’s representative.Number, location, demarcation and size of sub-plots shall be individually decided for each ground bed plot location. One or more plots may be selected and surveyed at each CP station to finalize suitable ground bed location. For shallow Anode beds Soil Resistivity to be measured at depths 1,3,5,7 M and upto/beyond proposed Anode bed length. But at deep well Anode bed locations Soil Resistivity to be measured at 1,3,5,7,10,15,20,25,30,35,40,45,50……M depths depending on depth of deep well anode bed proposed.

Soil / water analysis for Chemical & Microbial loading from Anode bed plots from requisite depths such

as 1,3,5,7 M for shallow Anode beds and further at 15,20,25,30,35,40,45,50…M Depths for deep well Anode beds.

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S.No. Sample from Location Kms.

0

0 5 5

1 Depth in M 1 3 1 3

2 pH

3 RedoxPotential V

4 Total Dissolved Solids ppm

5 Chloride ppm

6 Sulphate ppm

7 Sulphide ppm

8 Carbonate ppm

9 Bi-Carbonate ppm

10 Nitrate ppm

11 Nitrite ppm

12 Phosphate ppm

13 Sodium ppm

14 Potassium ppm

15 Calcium ppm

16 Magnesium ppm

17 Sulphate Reducing Bacteria [SRB] Counts

Survey for investigating possible sources of stray currents DC and AC Interference so that requisite mitigative measures are included in the CP design. At the time of handing over the installed [ICCP] system to GGL the pipeline need to be free of interference.

ADDITIONAL SITE DATA TO BE COLLECTED

In addition contractor shall have to collect/ generate additional Data as required for completeness of the job as follows:

The following data shall be collected to generate design data for evaluation of interaction/ interference possibilities due to presence of other services in ROW/ in close vicinity:

i. Route, type, material of construction of foreign service/pipeline utilities in and around or crossing the

right of way (including those existing and those which are likely to come up during this contract execution or any abandoned underground pipelines/utilities).

ii. Grade, Diameter, wall thickness, pressure, pipeline coating against corrosion, soil cover used in

case of pipelines and methods of jointing [weld, flanged etc.].

iii. Details of the existing pipeline cathodic protection systems protecting the services i.e. location, rating, type of protection, anode beds, test station locations and their connection schemes.

iv. Graphical representation of existing structure/pipe-to-soil potential [P-S-P] records, T/R unit current/

voltage input/output ratings, present current/Potential Input/Output Data etc for the existing pipelines.

v. Remedial measures existing on foreign pipeline/ services to prevent interaction.

vi. Possibility of integration/ isolation of existing CP systems, which may involve negotiations with owners of other existing pipeline services.

vii. Crossing and parallel running of electrified and non-electrified traction (along with information

regarding operating voltage, type AC/DC etc.) as well as abandoned tracks near ROW having electrical continuity with the tracks in use.

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viii. Crossing or parallel running of any HT AC/DC overhead line (existing/proposed) along with details of distance from pipeline, voltage, type AC/DC, distance from pipeline of earthing of towers etc.

ix. Voltage rating, number of cores and sheathing details of underground power cables, along ROW or

in its vicinity.

x. Information on existing and proposed DC/AC power sources and system having earth as return path, in the vicinity of the entire pipeline route such as HV DC sub stations, fabrication yards with electric welding etc.

xi. Any other relevant information that may be needed in designing and implementing proper protection

scheme for the proposed GGL pipeline.

Unless otherwise mentioned, CP contractor shall conduct necessary potential gradient survey for any existing anode ground bed that may interfere with the CP system of the pipeline covered under this GGL project.

CP contractor,for the purpose of Resistance Bonding, will have to get necessary permissions from other underground utilities such as underground pipelines of ONGC, IOCL, HPCL, GAIL, City Gas, and other utility owners etc., aboveground water pipeline running parallel on concrete pedestal, and DC rail traction etc. so that composite studies for interference detection are done and recommended mitigative measures are installed.Mitigative measures may also include relocation of existing H.T.Tower earthing etc. At the time of handing over the interference free system to owners GGL, the contractor will hand over these permissions of other utility owners, for further needful by GGL.

At the time of handing over the installed [ICCP] system to GGL the pipeline need to be free of interference.

Post Commissioning of [ICCP] Interference detection and mitigation will be requisite and only after achieving full interference mitigation the post commissioning surveys shall be carried out.

REPORT

On completion of all field work a composite CP design report incorporating all the results generated from site surveys for data generation and details of additional data collected as above shall be furnished to owner for Approval. The report shall also contain detailed interpretation of survey results and resistivity data,ionic & Microbial loading enclosed, probable interference prone areas etc. to form design basis for the scheme of cathodic protection [TCP] & [PCP] system. This report shall also include various drawings prepared in connection with the above work. The soil resistivity values shall be plotted on semi-log graph sheets and in Histograms. Log mean resistivity values to be calculated and used for the Design of CP system. The Cathodic Protection Design of [TCP] and [PCP] systems should be part of this composite Report. The Bill of Materials [B.O.M.], Technical Specifications, Vendor list QA/QC methodology, Erection methodology, Work schedule etc. will be included in this Report for Approval of Owner. All The Construction Drawings for Owners Approval shall be part of this composite report. COMPLIANCE The CP Design Report to include an explicit statement for Total Compliance with Technical Specifications for this Project and Deviation, if any, is brought out clearly giving justification/reasons for the deviation sought. This (deviation) needs owner Approval.

7.0 CATHODIC PROTECTION DESIGN PARAMETERS

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Unless expressly varied and otherwise specified in the project specifications, following parameters shall be used for design of temporary cathodic protection [TCP] system and permanent [ICCP] cathodic protection [PCP] system. Those parts of sacrificial anode cathodic protection [TCP] system which will be integrated with permanent CP system [PCP] such as Reference Cu-CuSO4 electrodes, Test Lead Points, Junction Boxes, Pin Brazing connections, Epoxy encapsulation, Markers, Polarization coupons etc. shall be designed based on permanent CP parameters.

PROTECTION CURRENT DENSITY

Pipelines having polyethylene coating.


Temporary CP (µA/m2) Permanent CP (µ A/m

2)

Normal soil 25 25


35 35


20 20

However, the Protective Current Density to be chosen at site as per Environmental conditions obtained as per Detailed Chemical & Microbial Analysis and presence or absence of interfering elements in close vicinity of GGL pipeline ROW.

Pipe to soil potential shall not be more negative than (-) 1.5V (“ON”) or (-) 1.18V (“Off”) w.r.t. Cu-CuSO4 Reference electrode.

*Actual current density to be adopted shall be decided based upon soil/water corrossivity and other environmental conditions, proximity of foreign pipelines/Interfering elements and structures resulting in interference. Where considered necessary for satisfactory protection of pipeline the current density shall be suitably increased or decreased by contractor with appropriate justifications subject to GGL/WGI Approval.

8.0 Other parameters for design Other parameters to be considered for [TCP] and [PCP] design:

Safety factor for current density : 1.3

Anode utilization factor : 0.85 for centre connected Anode : 0.5 for Ribbon Anode

Pipeline natural potential (-) 0.45V [as measured from existing /upcoming structure in the same soil matrix].

Unless otherwise specified in project specification the design life of [TCP] temporary CP shall be One (1)

year and that of [PCP] permanent CP shall be (40) years.

Along the ROW where soil resistivity is higher than 100 Ώ m temporary CP for the pipeline may not be necessary unless otherwise specified in project documents and Approved by Owner.

Steel Resistivity 2.2 X 10-7Ω M

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Maximum Loop Resistance 1 Ω [More than 1 may be permitted in exceptional circumstances]

9.0 CATHODIC PROTECTION DESIGN CRITERIA



The pipe to soil potential [PSP] measurements shall be between –0.95V (“On”) and –1.5V (“On”) both “On” Potentials w.r.t. Cu-CuSO4 reference electrode. At the location of Polarization coupons, the coupon to soil potential measurement shall be between (-) 0.95 (“Off”) minimum and (-) 1.18 V(“Off) maximum w.r.t. CuCuSO4 reference electrodes, both being “Off” potential.Using Reed Switch the “Off” potentials can be recorded for [TCP].

In rare circumstances a minimum polarisation shift of (-) 100 millivolts w.r.t. Cu-CuSO4 reference electrode shall indicate adequate levels of cathodic protection for the pipeline subject to Owner’s Approval.

Discretion to use any of the criteria, listed above, shall solely rest with the GGL/WGI.

A positive potential swing of ›20 mV [P-S-P] shall be considered as the criteria for presence of an interaction situation requiring investigation and incorporation of suitable mitigation measures by the C P Contractor.

PERMANENT CATHODIC PROTECTION [P C P]

The pipe to soil potential measurements [PSP] shall be between (–) 0.95V (“Off”) minimum and (–) 1.18V

(“Off”) maximum [both “Off” Potentials] w.r.t. Cu-CuSO4 reference electrode, the maximum remaining the same (-) 1.5V (“On”) w.r.t. Cu-CuSO4 reference electrode. At the location of Polarization coupons, the coupon to soil potential measurement shall be between (-) 0.95 (“Off”) minimum and (-) 1.18 V (”Off”) maximum w.r.t. CuCuSO4 reference electrodes [both being “Off” potential].

In rare circumstances a minimum polarisation shift of (-) 100 millivolts w.r.t. Cu-CuSO4 reference electrode

shall indicate adequate levels of cathodic protection for the pipeline.

Discretion to use any of the criteria, listed above, shall solely rest with GGL/WGI.

A positive potential swing of ›20 mV [P-S-P] shall be considered as the criteria for presence of an interaction situation requiring investigation and incorporation of suitable mitigation measures by the C P Contractor.

10.0 SYSTEM DETAILS


The [TCP] system unless specified otherwise, may include the following major equipment/ sub-systems.

Sacrificial anodes [Zn or Mg] ground beds in carbonaceous back-fill

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Test stations [Type A,B,C,D,E or a combination of these] Junction Boxes with shunts and resistors Permanent Reference Cu-CuSO4 Electrodes Pin Brazing Cable to Pipe connection, epoxy encapsulated Surge diverter/ Grounding cell at Insulation Mono - blocks Polarization cells at A.C. Interference locations Earthing of Motor Operated Valve and other Electrical equipments without disturbing CP

System, using sacrificial anodes Polarization Coupons Interconnecting cables Markers CP System at Cased Crossings


The [PCP] system may include the following major equipment/ sub-systems unless otherwise specified.

Digital Power Source AC Input DC Output TRU with built-in Current interrupter and GPS based timer.

Distribution Board MMO anodes and anode ground beds in carbonaceous back-fill Test stations [TLP] Computerized Test Stations [CTSU] with readers Junction Boxes with shunts and resistors Permanent Reference Cu-CuSO4 Electrodes Pin Brazing for pipe to cable connection [ epoxy encapsulated ] Surge diverter/ Grounding cell across Insulation Mono - blocks Solid State Polarization cells at A.C. Interference locations Polarization Coupons Interconnecting cables Markers [for cable route, Anode bed etc.] Insulating fittings

Sacrificial Anodes for Earthing

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Non Toxic Rodent Resistant Tape for C P Marking

Site Conditions

The equipment will be designed for the following site conditions:

Min/Max. Temperature 00 C to 55

0 C

Design Temperature 50

0 C

Relative Humidity 90% Height above MSL < 1,000 M Atmospheric Pollution To withstand the site conditions, dust, vapour Hazardous area classification for plant Zone 2,Gas Group IIA,IIB Temp. Class T3 Control Room/Electrical Room/ D.G.Room/Guard Room/Battery Room Safe Area

11.0 EQUIPMENTS

All equipment shall be new and supplied by CP contractor sourcing only from approved manufacturers of repute with proven track record and approved by GGL/WGI for the supply for this project. Equipment offered shall be field proven. Equipment requiring specialised maintenance or operation shall not be acceptable hence should be avoided, as far as possible, and prototype equipment shall not be accepted. Make and construction of all materials shall be subject to GGL/WGI approval. The detailed specification of each system and equipment shall be furnished by the contractor. However, certain minimum requirements for the major equipment are highlighted in this document.

12.0 Equipment Location In Hazardous / Non Hazardous Area

As far as possible equipment including Power source, test stations, anodes, junction boxes, etc. shall be located in safe area. However, all equipment located in hazardous areas shall be flame proof type as per BIS: 2148, IEC 79 for gas groups IIA & IIB and temp. Class T3 (200

0 C).All equipment to be

located in Hazardous area should conform to and comply with BIS 2148 and IEC 79 (or equivalent) code requirements. All indigenous flame proof equipment should be certified by CMRS. All flame proof equipment of indigenous origin should also be BIS marked.

13.0 ANODE GROUND BEDS


Zinc (Zn) anodes, in suitable back-fill, shall be provided Along ROW where soil resistivity predominantly remains low and ranges from 0-10 Ώ m

Magnesium (Mg) anodes shall be provided Along ROW where soil resistivity is predominantly higher than 10 Ώ m.

Magnesium (Mg) ribbon anodes shall be provided At high resistivity area where resistivity is of the order of 50 Ώ m and above.

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Anodes shall be installed along the pipeline at suitable intervals as per pipeline protection voltage attenuation calculations and ground bed resistance/current output of anode installations.

Each electrically continuous section of pipeline shall preferably be protected totally by one type (material) of anodes [either Zn or Mg] to avoid inter-anode [Zn ↔ Mg] circulation currents. Grounding cell should also conform to this specific requirement.

The anodes shall be installed at sufficient depth to reach perennially moist soil [ascertained by ground water table data] but minimum 2M depth from grade level and shall be separated linearly from the pipe line by at least 5m and 2m for Magnesium (Mg) and Zinc (Zn) anodes respectively. The ribbon anodes should be laid at least 0.5 M away from pipe. The anode connections to pipe line shall be routed through test stations. However, environment suitability [such as excessive carbonate, bi-carbonates, sulphates, chlorides, nitrates etc. which could result in anode passivation] should be checked prior to lowering of sacrificial anodes suitability in the Anode beds. At the temporary [TCP] anode ground bed, the leads of all the anodes shall be connected individually through Shunt and Resistor [for controlling each anode output individually] in a junction box. For sacrificial anode ground beds which shall be integrated with permanent CP system the leads of all the anodes shall be brought up to the test station and shall be terminated individually with shunts inserted in between so that individual anode current output can be regulated & measured as required. For Sacrificial anode CP system the Anodes shall be supplied with Tail cable [6 mm2 PE PVC copper conductor single core multistrand cable] of sufficient length so as to reach Junction box, for termination, without difficulty. No joints are permissible on the cable run from anode tail to junction box. The tail cable connection with the Iron Insert of Cable should be tightly done followed by Epoxy encapsulation so as to ensure that no Necking takes place [which could result in snapping of cable connection due to spark]. Anode cap of heat shrinkable PE material should be able to ensure this. The casing pipe shall be coated with 2 pack epoxy, 750 microns thick as approved by owner on both sides (internal and external sides of the casing pipe).

14.0 PERMANENT CATHODIC PROTECTION [P C P] Anode beds To be installed at every CP Station and located at least 100 M away from pipeline ROW to ensure adequate remoteness which should also be calculated. All [MMO] Anodes to be placed in Petroleum coke breeze, in appropriate [shallow –horizontal or vertical, or deep well configuration as per design to achieve requisite circuit resistance and protective Current output throughout the [40 years] service life. In view of land constraint in city area it is preferable to use Deep Well Anodebed requiring smaller plot [8 x 5M] for locating anodebed. The MMO anode should be supplied with sufficient length of 10 mm2 XLPE PVC cable so as to run upto junction box for termination in the junction box without in between joints. No joints are permitted in cable run from Anode tail to junction box. This cable size is minimum only and wherever necessary for appropriate safe operation of the CP system higher sized cables should be provided. Appropriate tamping of carbonaceous backfill [petroleum coke breeze] should be done so as to ensure appropriate compaction around [MMO] anode. Anode bed Plot: CP contractor shall make available [On Ownership basis to (GGL) a plot of land measuring 8 M X 5 M at least 100 M away from pipeline ROW for locating Anode bed, at each Anode bed location along the pipeline ROW and cable laying route upto Anode Junction box and TRU for 40 years service life. CP Contractor to indicate the location of Anode beds along pipeline ROW and handover the requisite ownership documents to (GGL) at the time of Handing over of the system.

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15.0 ANODES

SACRIFICIAL ANODES

MAGNESIUM ANODE

The Magnesium [Mg] alloy anode shall be of low voltage (-) 1.5 V type packed in special back fill and suitable for use with three layer extruded polyethylene coating. The anode to conform to ASTM B 843 specifications such as the metallurgical composition, potential and consumption rate of anode shall be as below: i Composition:

Element Weight

Manganese 0.15 – 0.7% Copper 0.02% max. Silicon 0.10% max. Zinc 2.5 – 3.5%% max. Aluminium 5.3 – 6.7% max Iron 0.003% max Nickel 0.002% max Other metallic elements - Each 0.05% max. - Total 0.3% max. Magnesium (Mg) Balance

ii Anode open circuit potential (-)1.5 volts. W.r.t. CSE iii Anode consumption rate 7.9 kg / (A Yr) Max.

ZINC [Zn] ANODE

The Zinc [Zn] alloy anode shall conform to ASTM B 418 standard. The anode (other than ribbon anode) shall be packaged with special back fill. The metallurgical composition of anode, potential and consumption rate shall be as below:

i.Composition: Element Weight Aluminium 0.3 – 0.5% max. Cadmium 0.075-0.1% max. Copper 0.005% max. Iron 0.002% max. Silicon 0.005% max. Lead 0.005% max.

Zinc Remainder

ii. Anode open circuit potential (-) 1.1 volts w.r.t. CSE iii. Anode consumption rate 11.24 kg / (A yr) Max.

Contractor shall furnish spectrographic analysis from each heat both for Zinc (Zn) and Magnesium (Mg)

anodes along with electrochemical test results .CP Contractor shall mention specifically the method of Spectrography (Atomic Absorption/Emission Spectrometry/Photometrics) for GGL/WGI Approval.

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SPECIAL BACKFILL FOR SACRIFICIAL ANODES

The composition of special backfill for sacrificial anodes shall be as below:

Gypsum 75% Bentonite 20%

Sodium sulphate 5%

Some Specific Requirements for sacrificial anodes are as follows:

The anodes shall be provided with cable tail of sufficient length to reach junction box/test station [TLP] as applicable in single run without tension and without in between joints.

TOLERANCE IN FABRICATION OF SACRIFICIAL ANODES

Visual Inspection shall be carried out on all the Anodes regarding surface finish, excessive shrinkage, cracks, cable joint to anode core etc.

The anode surface shall be free from cracks (which may reduce the performance of the anode.). Any cracks which follow the longitudinal direction of elongated anodes shall not be acceptable. Small cracks in the transverse direction of elongated anodes and in anodes of other shapes may be

accepted provided the cracks would not cause any mechanical failure during service of the anode considering that the combination of cracks and lack of bond to the anode core is detrimental.

For transverse cracks the acceptable limits shall be furnished by the bidders along with the offer. The anode shall be free from excessive shrinkages. The following limits shall be used.

• Maximum 10% of the depth of anode or 50% of the depth of the anode core whichever is less. The depression may be measured from the edges of one side.

The surface of the anodes shall be free from coatings and slag/ dross, inclusions etc. The maximum deviation from straightness shall not exceed 2%. The weight tolerance on individual anodes may be taken as ± 5%. The total weight of the anodes shall

not have negative tolerance. Recommended dimensional tolerance shall be as follows:

Length ± 2.5% Width/ thickness ± 5%

One Anode per heat shall be radiographed to evaluate slags, voids, inclusion etc. At least 10% number of Anodes from each heat to be checked for conformity to Dimensions & Weight. One Anode, at least shall be Tested Destructively to check bond between Anode material and steel

insert, slag, inclusion etc. Failure of one anode during the test shall make the entire anode lot liable for rejection.

16.0 FOR PERMANENT CATHODIC PROTECTION [P C P]

Mixed Metal Oxide [MMO] Anodes: LIDA SINGLE

The Permanent Cathodic Protection [PCP] system will have Mixed Metal Oxide [MMO] Strip Anodes also known as LIDA [Linear Distributed] Anodes and LIDA single. The [MMO] LIDA single anodes shall be

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centre connected sealed tubular type. These Anodes shall be of Noble metals [group VIII] Mixed Metal Oxide coated Titanium [having Ti substrate composition conforming to ASTM B 338 Grade I and/or Grade II]. The LIDA [MMO] anodes shall be dimensionally stable. The characteristics of the [MMO] LIDA single Tubular anodes are as follows:

• Shape and Dimension 1,000 mm ± 5 mm long 25 mm ± 0.2 mm wide

3 mm ± 0.1 mm thick

• Weight 0.27 Kgs ± 0.020 Kgs. Recommended Maximum

OPERATING CURRENT DENSITY

• With Carbonaceous Backfill 75 Amp / M2

• Current Output with Carbonaceous Backfill 3 Amp /M

2

• Electrical Resistivity 6 x 10-5 Ω cms.

• Type of Joint Epoxy Splicing

• Contact Resistance of Anode to Cable joint 9 x 10-5 Ω maximum

• MMO Coating thickness ≥ 6 gms/M2

• Anode Consumption Rate 1 mg/Amp. Yr.

• Type of Cable XLPE PVC 10 mm2

• Length of Cable As Required so as to reach JB

• Design Life 40 Years

• The Anodes shall be provided with sheet steel canisters and petroleum coke breeze

• The Anodes to be Installed at a distance of 5m (Minimum) apart and shall be electrically remote to the pipeline [to be ascertained by calculations]. Normally the nearest part of anode for shallow horizontal/vertical type of Anode beds shall not be less than 100M from the pipeline. However, the actual distance will be as per site conditions. For Deep well Anode bed the first anode should be at least more than 15 M deep [as per NACE RP 0572 Standard] and the actual depth shall be as per Approved Design. However, for Deep well Anode bed instead of LIDA Single [MMO] anodes LIDA String Anodes shall be used.

• Anode LIDA [MMO] Single to cable [XLPE PVC 10 mm2] jointing and insulation shall be done by

anode manufacturer at his shop.

• Dimension & weight of all anodes to be checked & recorded. Negative tolerance will not be acceptable.

• Routine & type test certificates of cable manufacturer to be furnished for anode lead cable as per IEC 502 – 1983 or relevant BIS code. Length and identification tag to be verified by measurement.

• Each anode to cable joint shall be tested for its electrical contact resistance & its value in Ω shall be recorded.

• First anode to cable joint shall be subjected to accelerated ageing test & destructive test to determine pullout strength of cable to anode joint as well as effectiveness of the joint insulation.

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• Manufacturer shall furnish detailed dimensioned fabrication drawing of anodes as well as details of cable connection& its insulation sealing to owner for approval. Manufacturer of anode will commence only after this Approval from owner.

• Vendor shall furnish for Owner’s Approval the following information type & make of Heat Shrink cap & it’s properties procedure for making the joint procedure for accelerated ageing test Vendor shall submit all test reports for Owners review.

Petroleum Coke Breeze

Lubricated calcined petroleum coke breeze backfill material for use with LIDA Single [MMO] Anodes in [PCP] system shall have a carbon content of 91.77% minimum and a bulk density of 74 pounds per cubic ft. Zero percent shall be retained by a screen size of 16 mesh. The coke breeze shall have low resistance carbon lubricant added for lowering the combined resistance while developing the pumping qualities. Earth contact resistance shall be 0.1 Ω cm at 150 PSI.

BACKFILL DATA SHEET Carbon 91.770% Volatiles 00.700% Ash 02.230% Sulphur 05.850% Silicon 00.060% Iron 00.020% Moisture 00.000% TYPICAL PARTICLE ANALYSIS Screen Size % Retained % Retained (Cumulative) 16 Mesh 00.000 000.00 28 Mesh 02.100 002.10 48 Mesh 21.100 023.20 100 Mesh 60.300 083.50 200 Mesh 15.000 099.50 200+Mesh 01.500 100.00 TYPICAL PHYSICAL ANALYSIS Bulk Density 54 lb/cu ft. Real Density 02 gm/ml Porosity 40.8%

The Petroleum Coke Breeze Material shall be tested for chemical composition, bulk

density, real density, particle size and resistivity, sieve analysis.

17.0 AC INPUT DC OUTPUT Auto/Manual Transformer Rectifier Unit [TRU] 50V 50A

The TRU shall be supplied in accordance with the following specifications and Data sheets:

[ICCP] system to be powered by an AC Input DC Output transformer rectifier unit [TRU].

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Transformer to be double wound,air cooled type with electrostatic shield between the

windings.Transformer Insulation to be F class.[TRU] to be floor mounted & suitable for indoor use and to

be dust and vermin proof IP55 enclosure.

Inbuilt 100% spare capacity for current demand,from each [TRU], to be a special feature of all [TRU] to

be installed for this project.

The C P Transformer Rectifier [TR] Unit’s scheme for protection, monitoring, control, metering and

indication shall be designed to meet requirements of this specification. The control shall be achieved

using thyristors and fully solid state logic only. The various features of the unit will be as per the details

provided in the data sheet in this specification.

Transformer shall be of double wound, air cooled type with an electrostatic shield between the windings.

The transformer insulation shall be Class F. The winding size shall be based on maximum current density

of 1.6 Amps/sq. mm of copper conductor.

Rectifier shall be silicon type of approved make with adequate cooling arrangement and with moisture

and humidity resistant finish. It shall be mounted on spindles or other suitable supports. It shall have

configuration suitable for full wave rectification. Adequate filtering in the form of L-C filtering circuit shall

be provided on output side to smoothen out the D.C. output to limit ripple content to less than 5% at rated

output.

The input and output of rectifier shall be protected by fast acting fuses of suitable ratings. Lightning

Arrestors/Surge Suppressors shall also be provided across D.C. output terminals and A.C. input

terminals to protect the rectifier against surges. Each diode and SCR shall be provided with suitable

surge suppressors.

The T/R unit shall be provided with two modes of working as under. A mode selector switch shall be

provided to select the desired mode of operation. Both the modes shall be independent of each other and

failure of the unit in one mode shall not affect working of the unit in other mode. A brief description of

these modes is given below.

A) Auto Ref. Mode

The unit will be generally working in this mode. The operation of the unit in this mode shall be controlled by a reference signal. The output D.C. voltage of the unit in this mode shall vary right from 0V to rated voltage and form 0A to rated current to maintain the reference signal within ± 20 mV of the set value under all operating conditions.

The response of the unit shall be instantaneous to suppress extremely fast acting external stray currents if present. The typical reference regulation in this mode shall be within ± 20 mV under all conditions.Fully solid state Automatic Reference Selector logic shall be provided to select the lowest of the Three Reference Inputs automatically. Facility shall also be provided for Manual selection of any one out of the three reference inputs for control. Suitable metering arrangement shall also be provided to monitor all the three external reference signals as well as the internal reference signals independently.

In the event of failure of all the reference signals, the unit will provide alarm - " All Reference Fail" and the output of the unit shall get adjusted to a preset value, which will be operator adjustable from 0 V to rated voltage.

Independent ultra fast acting electronic current limit circuit shall be provided to limit the output current of the unit in Auto mode to any value from 0 A to rated value as desired by the operator. The current limit circuit will be capable of protecting the unit even under dead short circuit across output. The unit will be

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capable of sustaining dead short circuit across output indefinitely without degrading or damaging any internal components in this mode.

B) Automatic Voltage-Current Control mode (AVCC mode)

This will be the second mode of operation. The working of this mode shall be totally independent of the Auto mode and failure of the unit in Auto mode shall not affect operation in this mode.

The output voltage of the unit shall be adjustable to any value from 0 V to rated voltage by means of a stepless voltage setter. The set voltage shall be maintained within ±0.25V of the set value for change in DC input voltage within specified limits and change in load from 0 A to full load.

The output current of the unit shall also be adjustable to any value from 0 A to rated current by means of a stepless current setter. The current shall be regulated within ± 0.5A of the set value for change in DC input voltage within specified limits and change in load from zero to the rated value. The response of both current controller and voltage controller shall be ultra fast, instantaneous type. The current limit circuit will be capable of protecting the unit even under dead short circuit across output. The unit will be capable of sustaining dead short circuit across output indefinitely without degrading or damaging any internal components in this mode.

LOCAL & REMOTE MONITORING & CONTROL

The unit will be capable of working in Local Mode of control as well as Remote mode of control. For this purpose a mode selector switch will be provided on the unit. With this switch in ‘Local Mode’ it will be possible to control the various parameters of the unit by means of local controls located in the unit. With this switch in ‘Remote Mode’ it will be possible to control the various parameters of the unit remotely thru the RTU/SCADA system.

Local Monitoring & Local Control

Facility will be provided for monitoring and control of various parameters by means of controls provided

on the front panel of the unit.

The details of the parameters to be monitored and controlled locally are as under:

A) Metering on Panel

1. AC Input Voltage - Digital Voltmeter

2. AC Input Current - Digital Ammeter

3. DC Output Voltage - Digital Voltmeter

4. DC Output current - Digital Ammeter

5. PSP (Set & Actual) - Digital Voltmeter with 10 Meg Impedance

B) LED Indications on Panel

6. AC Supply ON - LED indication

7. Pipeline Underprotection - LED indication

8. Pipeline Overprotection - LED indication

9. Reference 1 Lowest - LED indication



12. Reference 1 Fail - LED indication

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15. All Reference Fail - LED indication

16. Overcurrent (Current Limit) - LED indication

17. Unit Working in Auto Mode - LED indication

18. Unit Working in AVCC Mode - LED indication

19. Unit Working in Local Mode - LED indication

20. Unit Working in Remote Mode - LED indication

SPECIAL REQUIREMENTS

Built-in Microprocessor Based Programmable & Synchronisable Current Interrupter Current interruption facility will be provided by means of a built-in contactor & microprocessor based synchronisable digital timer with real time clock & ON/OFF time display. The timer will have facility for adjusting the ON time & OFF time from 0 to 999 sec. by means of digital setting facility. Timer will have START, STOP facility thru local keypad or thru remote potential free contacts. The timer will have facility for Synchronisation to Master Timer or similar Timer in another unit.

Built-in 4-20mA Converters & Potential Free contact for SCADA Monitoring

Facility for SCADA Monitoring will be provided as under :

A) 4-20mA Isolated Converter Modules for Monitoring of the following Parameters

i) P.S.P.

ii) DC Output Voltage

iii) DC output Current

B) Potential Free Digital contacts for Monitoring of the following Alarms

i) Pipeline Underprotected

ii) Pipeline overprotected

iii) Reference fail

iv) Unit working in AUTO REF Mode

v) Unit working in AVCC Mode

vi) AC supply Fail

OPTIMUM RATED CAPACITY

Maximum DC Voltage Output to be 50 V and DC Current Output to be 50 Amps.

INSPECTION All TRU to be Inspected as per C P Contractor submitted and WP/HPCL Approved methodology and CP Contractor to make available all testing facilities or agree to samples being sent for testing by E-I-C to a suitable laboratory.This cost of Testing to be borne by C P Contractor as part of this bid.

DATA SHEET FOR AC/DC OPERATED AUTOMATIC CP RECTIFIER UNIT

A) Input Voltage : 180V to 270V, 1Ph., A.C. OR 44V to 64V DC - For 48V DC operation 22V to 32V DC - For 24V DC operation

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B) Input Current : AC Operation:

Less than 20A at 230V Input & 50V, 50A output Less than 6A at 230V Input & 25V, 25A output

C) DC Output Voltage : AC Operation : 0 to 50V or 25V

D) DC Output Current : 0 to 50A

E) DC Power Output :

KVA rating of Transformer : 5.0 KVA Derating factor for diodes / SCRs /Transistors

: Voltage - At least 300% factor of Safety PIV - 1200V Minimum Current - 300% factor of safety

Full load efficiency of Complete Unit : Better than 75% in AC as well as

DC operation Full Load Power Factor : Not less than 0.8 lagging Insulation Level : 2 KV for 1 minute Peak Inverse Voltage Diode SCR Transistor

: 1200 V (Min) 1200V (Min) 500V (Min)

Cable entry : A.C. input, DC output and

Reference Cell. Through bottom plate of the unit through suitable cable glands.

Filtering circuit : L.C. Filter Ripple & Hum at rated output : Less than 5% RMS Surge Diverters for diodes /SCRs/Transistors

: Metal oxide varistors/capacitors/R-C Networks.

Lightning Arrestor : At Input & output side of the T/R

unit RMS voltage rating : 500V Impulses discharge current : 5.0 KA. LAMCO make LT 0.5 or Eqv.

Protection/Isolation : 2 pole MCB in AC Input for

overload protection & isolation.

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2 pole MCB in DC Input for overload protection & isolation. 2 pole MCB in DC Output. HRC fuses in input & output. - Glass cartridge fuses in the live line of all lamps, auxiliary power lines to control circuit and AC voltmeter.

Battery Deep discharge protection. In the event of battery voltage falling below the minimum recommended level, the unit will automatically shutdown and provide battery low indication.

- Ref. Fail indication and automatic setting of DC voltage to the preset value In case of failure of the selected Ref. Electrode.

Built in overcurrent & short ckt. protection feature. Current limit adjustable from 0 to rated value.

Reference Input : 3 Nos. Cu/CuSO4 Automatic Reference Selector

Logic shall be provided to automatically select the lowest (least protected) reference signal out of three reference signals fed to the unit simultaneously.

Facility shall also be provided to select one out of three ref. Electrodes by means of a Manually operated Reference Selector switch.

In case of failure of all the Ref. Electrodes, the DC output voltage will automatically get adjusted to a programmable preset value.

Control element : The DC output will be controlled

using latest solid state thyristors (SCRs) & Transistors. These SCRs & Transistors will be controlled by the commands from the electronic circuits. All the electronic circuits will be assembled on plug-in type, glass epoxy control cards.

Modes of operation : Following modes of control shall

be provided. a) Auto Ref. Mode: Fully automatic operation with

reference electrode feedback. The output voltage and current of the unit will vary over the entire range to maintain the pipe soil potential constant at the set value.

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b) AVCC Mode: This will be the second mode of

operation. In this mode the unit can be operated in either constant voltage mode or constant current mode.

The DC voltage will be adjustable from 0 to rated value by means of a stepless voltage setter potentiometer.

The DC current will be adjustable from 0 to rated value by means of a stepless current setter potentiometer.

c) Manual Mode : This will be the third mode of

operation. The control of DC output in this mode shall be without any electronic component. In AC mode of operation a separate Autotransformer with 24-step controller will be provided to control the DC output voltage from 0 to rated voltage in 24 symmetrical steps.

In DC mode of operation, a separate variable power resistor shall be provided for current control in this mode. The output current shall be adjustable from 10% to rated current.

Ref Fail Safe Feature : Will be provided.

In the event of failure of selected Ref Electrode, the DC output voltage of the T/R Unit will automatically get adjusted to a operator set preset voltage.

Ref. (P.S.P.) Voltage setting in Auto ref. Mode

: -0.80V to -2.5V

Ref. (P.S.P.) Voltage Regulation in Auto Ref. Mode

: Batter than ± 15mV

DC Voltage Setting Range in AVCC Mode : 0 to 50V/40V - For 48V System

0 to 25V/20V - For 24V System DC Voltage Regulation in AVCC Mode : ± 0.25V DC Current Setting Range in Auto Mode & AVCC Mode

: 0 to 50A

DC Current Regulation in Auto Mode : ± 1.0A - For 50A Unit

Indications/Annunciations : AC Supply ON

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a) b) c) d) e) f)

DC supply ON Operation on AC Supply Unit in Auto Ref. Mode Unit in AVCC Mode Underprotection

h) i) j) k) l) m) n) o) p) q)

Overprotection Reference 1 Lowest Reference 2 Lowest Reference 3 Lowest Reference 1 Fail Reference 2 Fail Reference 3 Fail All Reference Fail Unit in current limit Battery Voltage Low

Meters/instruments : 48 X 96mm Digital meters for the

following: AC Voltage : 0 to 300V AC AC Current : 0 to 50A AC with C. T. DC O/P Voltage : 0 to 50V DC DC O/P Current : 0 to 50A DC with shunt P.S.P. : 0 to ± 19.99V DC Time Totaliser in AC Input Supply

Current Interruption Facility (Optional Feature)

: Current interruption facility will be provided by means of a built-in contactor & microprocessor based synchronisable digital timer with real time clock & ON/OFF time display. The timer will have facility for adjusting the ON time & OFF time from 0 to 999 sec. by means of digital setting facility. Timer will have START, STOP facility thru local keypad or thru remote potential free contacts. The timer will have facility for Synchronisation to Master Timer or similar Timer in another unit. If required the Interrupter Timer will be provided with GPS Sync Facility.

Facility for interconnection of an external timer shall also be provided. A removable bypass link will be provided for bypassing the interrupter contactor contacts.

SCADA Monitoring Facility (Optional)

: Following signals/contacts shall be provided a) Isolated 4-20mA Analog signal for

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the following: AE) SCADA Monitoring Facility

(Optional) : Following signals/contacts shall be

provided a) Isolated 4-20mA Analog signal for the following:

i) P.S.P. ii) DC O/P Voltage iii) DC O/P Current

b) Potential free digital contacts for the

following C.P. faults: i) Pipeline Underprotected

ii) Pipeline overprotected iii) All ref fail iv) Unit working in AUTO REF Mode v) Unit working in AVCC Mode vi) AC supply Fail

AF) Auto Switching facility : Automatic switching logic to select AC

input from Mains or DC input from batteries shall be provided. The unit will work on AC supply priority and switch over to DC supply only in the event of failure of AC supply.

AG) Enclosure/Construction : Floor mounted indoor type. Confirming to IP55 class. To be fabricated

from 3.0 mm sheet steel. Lockable doors shall be provided in the front and back.

AH) Cooling : Natural air cooled AI) Painting : Baked epoxy paint/powder coating of

shade RAL7032 Siemens Grey with proper pre-treatment as per standard industrial practice.

AJ) Earthing : 2 Nos. suitably sized earthing bolts and 1

No. nickel plated copper earthing bus bar shall be provided.

AK) Environments : Max Ambient Temp

Relative Humidity 50 °C

Upto 99%

MANUFACTURER'S TECHNICAL EXPERTISE & EXPERIENCE IN THE FIELD OF CATHODIC PROTECTION RECTIFIERS The manufacturer should be a reputed and established manufacturer of CP Rectifier Units and should have experience in manufacturing of C.P. rectifiers of similar specifications. The manufacturer should have Experienced Design Engineers with thorough knowledge of CP Technology with field & design experience in the CP Rectifier design.

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TESTING AND INSPECTION The manufacturer shall provide all the necessary facilities to carry out full performance test on the C.P. rectifiers in his premises at his expense.

GUARANTEE

The manufacturer will have to guarantee the successful working of the units for a period of 12 months from date of installation & commissioning of the unit at user premises.

PACKAGING The unit to be packed in all weather proof packaging for transporting to site by the manufacturer before despatch.

GUARANTEE

The

manufacturer/Contractor

will have to guarantee

the successful working

of the units for a period

of 12 months from date

of Installation &

commissioning.

- All reference fail indication

and automatic Setting of DC O/P

voltage to preset value.

18.0 REFERENCE ELECTRODE [CuCuSO4] PERMANENT TYPE

Permanent Copper Copper sulphate reference electrodes three (3) numbers at each CP Station and one at middle of two consecutive CP Stations are to be installed for [P-S-P] Monitoring.

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19.0 TEST STATIONS [TLP]

Test stations [TLP] shall be provided along the pipeline ROW for monitoring the performance of the cathodic protection system at intervals not exceeding 1,000 meters unless otherwise specified. In addition to above, test stations of requisite type [A,B,C,D,E or Combination of any two of these Viz: DE] shall be provided at the following locations:

a) At both sides of major road crossings b) At all insulating joints c) At vulnerable locations with drastic changes in soil resistivity.

d) At connections of surge diverters, grounding cells and polarisation cells. e) At HT AC/DC overhead line crossings and selected locations where HT overhead line is in the close vicinity of the pipeline.

f) At railway line crossings and running parallel to the pipeline.

g) At both sides of major river crossings. h) At high voltage cable crossings or along routes where HV cables are running in parallel. i) In the vicinity of DC net works or grounding system where interference problems are

suspected.

j) At crossings/parallel running of other pipelines/ structures.

k) At both sides of cased crossings.

l) At any other locations considered vulnerable/locations where interference is expected.

m) At any other locations considered necessary by owner/ owner’s representative.

Between the pipeline and foreign pipelines or structures that may exist in common ROW. Test stations

for bonding shall be provided with shunt and resistor as a means to monitor and control current to ensure zero net flow of Current from one to the other.

Test stations used for sacrificial anodes shall have shunt for measurement of individual anode current,

and provision of resistance to limit & control the anode current output. Test station with current measuring facility shall be provided at each intermediate CP station drainage

point ( to measure pipeline current on any one or both side of the pipeline from drainage point), at interference prone areas, on both sides of major river crossings and at least at two additional locations along the pipeline ROW between two CP stations.

All test stations shall have weather proof enclosure, having degree of protection IP55 with hinged lockable shutter. Enclosure shall be made of sheet steel of at least 3 mm thickness and shall be suitable for M.S. post mounting. The test stations shall be designed with terminals required for both temporary [TCP] and permanent CP system [PCP] and shall be suitable for total life of permanent CP system.

The test stations shall be installed with the front of the test station facing the pipeline. The name plate of

test stations shall in minimum carry following information.

• Test station number

• Chainage in km

• Test station connection scheme type

• Distance from pipeline in meters

• Direction of product flow

Terminal blocks and different scheme of wiring as required shall be provided in the test station as per the test station connection scheme sketch.

The location of all the test stations shall be marked with their connection schemes and other relevant

information on alignment sheets. A detailed test station schedule shall be prepared.

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20.0 SURGE DIVERTER, GROUNDING CELL AND SOLID STATE POLARISATION

CELL

At the crossing or parallel run of pipeline and overhead HT line of 11 KV and above, the pipeline shall be

grounded through solid state polarisation cell/device. Alternatively, grounding could also be done with galvanic anodes [grounding cells] at the discretion of GGL/WGI. The grounding shall be done at regular intervals where transmission line run parallel within 25 m of the pipeline, to ground any surges in the pipeline potential that may appear in case of faults [phase to phase or phase to ground] in overhead transmission line.

Locations along pipeline where continuous induced over-voltage due to HT line etc. is expected &/or

observed during commissioning, the pipeline shall be earthed through solid state polarisation cell/device to the HT tower earth system causing the voltage induction to ground or through a separate earthing system. Alternatively the pipeline shall be grounded with galvanic anodes [Grounding cells] at the discretion of the GGL/WGI.

The solid state polarisation cell/device shall be installed in a vandal proof steel housing by the CP

contractor. Spark gap surge diverter shall be connected across each insulating joint to protect it from high voltage

surges.

Alternatively, Zinc or Magnesium grounding cell may be provided across insulating joints along ROW where the pipelines on both sides of the insulating joint are cathodically protected and difference of protection voltage is not more than 0.4 volts.

Surge diverter shall be provided for the protection of insulating joints located at the ends of the pipe line/at terminals & in between. Alternatively GGL/WGI on own discretion may permit use of Magnesium (Mg)/Zinc (Zn) galvanic anodes [grounding cells] appropriately sized for protection of insulating joints. Choice between Zn & Mg anodes will depend up on the potential values on either side of the insulating joint locations. These anodes shall be sized for the specified design life of permanent cathodic protection system [PCP].

The total system including cable, cable termination, anodes/surge diverters shall be suitable for the anticipated fault current magnitude at the location of its installation.

Unless otherwise specified the minimum rating of grounding cell, polarization cell and surge diverter shall

be as below:

i. Grounding Cell - Type : 2 or 4 plate type - Current rating : Suitable to pass more than 10 kA surge ii. Solid State Polarisation Cell - Type : Solid state device

- Current rating : The rating shall be based on actual fault current expected at site.

iii. Surge Diverter - Type : Spark gap - Current 8/20 µs) : 100 kA - Spark over AC voltage : - 50 Hz : 1 KV - Impulse (1.2/50 µs) : 2.2 KV

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The grounding cell, surge diverter and the solid state polarisation cell/device system shall be sized for the design life of permanent CP system. The Zinc (Zn) or Magnesium (Mg) anodes meant for pipeline grounding shall also be sized for the life of the permanent CP system and the surge magnitude taking into account the current discharge from the anodes. The grounding system shall have minimum resistance to earth to restrict the pipeline voltage [PSP] as per NACE protection criteria.

21.0 CP AT CASED CROSSING

At all cased crossings the casing shall be coated using 2 pack epoxy, 750 micros thick, both on internal and external surface of the casing. The casing shall be protected additionally by independent [from carrier pipe protection system] sacrificial anode installations for design life [1+40] years. The sacrificial anode installations shall be provided at both ends of casing. The anode installation shall be sized based on the permanent CP design parameters specified for the main pipeline. The carrier pipe inside casing shall be protected by Zn or Mg ribbon anodes well connected to the outer surface of bottom of carrier pipe extending between hour hand positions of 4 and 8 o’ clock. The anodes shall be placed at close intervals as per design calculations and sized based on the permanent CP design parameters. Casings upto 20 mts in length may not be provided additional cathodic protection to carrier pipe bottom inside casing. More than 20 mts length casing additional cathodic protection to carrier pipe bottom shall be provided. The annulus between the casing and the carrier pipe shall be filled with graded sand + bentonite. The HDD contractor will arrange an agency to check the coating condition of the casing pipe post erection of HDD so that requisite repairs(if required) are done to the damaged coat.

22.0 POLARIZATION ER PROBES/COUPONS

Polarization ER probes/coupons to be installed by CP contractor at pre-identified two (2) locations, along ROW. The ER probes should have access for internal Corrosion monitoring while system is under full operating pressure.The tools are to be designed for exposure, insertion, retrieval and replace under pressure through [preferably] a 2” access fitting body and should incorporate such features to ensure that the equipment may be used safely, swiftly, and without difficulty by operating personnel that are versed in it’s simple principle of operation [Electrical Resistance Technique]. The Material of the ER Probe shall be pipeline alloy. The ER probes are to be integrated with corrosion monitoring system so that these can be readily retrieved for resistance measurement. Portable ER probe resistance measuring instruments shall be supplied with the system. The reading instrument to be re-chargeable-battery operated and capable of directly reading ER probe resistance. For External Corrosion monitoring Polarization Coupons to be placed at every CP Station and midway between two CP Stations,and other vulnerable locations alongwith a permanent reference Copper Copper Sulphate electrode placed very close to the coupon [made of pipe alloy] so that iR drop free potential could be monitored. The Coupons shall be integral part of the installed CP System.

23.0 PAINTING:

The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surfaces shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under surfaces shall be free from all imperfections before undertaking the finished coat. After preparation of the under surface, spray painting with two coats of final paint shall be done. The finished panel shall be dried in oven in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off paint etc. All unpainted steel parts shall be cadmium plated to prevent rust formation.

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24.0 CABLES

Cables shall be annealed high conductivity, tinned, stranded copper conductor, PE insulated 650V grade, and PVC sheathed FRLS. The size of the copper conductor shall be 6 sq mm for anode cable from anode to junction box, 10 mm2 from junction box to test station, 10 mm2 from test station to pipeline. The size of the conductor shall be 4 mm2 for potential measurement and 25 mm2 for bonding, polarisation cell / grounding cell and surge diverter connection purpose. The anode cable from anode to junction box shall be enamoured. The length of anode tail cable shall be sufficient enough to reach junction box (buried) in case of temporary CP anode and up to test station in case of permanent CP anodes.

25.0 INSTALLATION

CABLE LAYING

Cables shall be laid in accordance with approved layout drawings to be prepared by the contractor. No straight through joint shall be permitted in a single run of cable. Cable route shall be carefully measured and cables cut to required length.

All cables inside station/plant area shall be laid at a depth of 0.75 M. Cables outside station/plant area shall be laid at a depth of 1.5 m. Cables shall be laid in sand under brick cover back filled with normal soil. Out side the station/ plant area the routes shall be marked with polyethylene cable warning mats placed at a depth of 0.9 m from the finished grade.

All underground unarmoured cables forming part of permanent CP system shall run through PE sleeves. Cables along the pipeline shall be carried along the top of the pipe by securely strapping it with adhesive tape or equivalent as required.

RCC or GI pipes of proper size shall be provided for all underground cables for road crossings.

Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and final take off to equipment is facilitated.

Cable root markers shall be installed aboveground at suitable intervals.

In no case cables shall pass from below underground pipeline. All cables shall be placed above underground pipeline and tightened with tape.

CABLE TO PIPE CONNECTIONS

All cable connections to the pipeline including charged foreign pipeline shall be made using an (owner) approved exothermic process e.g.: Pin Brazing & in exceptional cases with prior approval of owner Cadwelding. The Pin Brazing to have

• Extremely low Contact Resistance ≤ 0.1 Ω.

• Low transition resistance 7.5 to 14 µΩ per brazed joint

• High mechanical strength Binding strength 490 N/mm2

Shear Strength 245 N/mm

2

• Brazing Temperature 6500 C

• Time per Braze 2 Seconds

• Weather Effect Suitable for all weather operation

• Life 35 Years

• Field Test Cable Connection through Pin Brazing to be field tested for contact resistance & Temperature etc.

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26.0 CIVIL WORKS

All civil works associated with the complete cathodic protection work shall be included in the scope of CP contractor. This shall include providing cable trenches, foundation for equipment and all test stations etc.

27.0 ANTI RODENT PVC WARNING TAPE

To prevent third party damage,the most prevalent cause of damage to existing pipeline it is envisaged to install a Anti Rodent PVC Tape as warning mat for any agency carrying out future excavations,to avoid damage to GGL pipeline.Tape to be made of Virgin quality PVC with Anti Rodent properties and the supplies to conform to an Approved quality [ having PVC Density 1.45 – 1.5 gm/cc,Tensile strength 180 Kg./cm

2,Elongation at break 165% minimum].Laying as per GGL/WGI Approved laying Methodology.

28.0 TESTING AND INSPECTION AT WORKS

GGL/WGI shall visit the works during manufacture of various equipment [Anodes, Cables, Junction Boxes, Test Lead Points etc.] to assess the progress of work as well as to ascertain that only quality raw material and fabrication technology is used for the same. All necessary assistance during such inspections shall be provided by the contractor/fabricator to GGL/WGI.

The minimum testing, inspection requirements for all components/ equipment shall conform to the requirements as defined in the relevant codes and standards. Detailed inspection and testing procedures along with the acceptance criteria, including various stages where hold points, review etc shall be for GGL/WGI inspection, shall be prepared by CP contractor for GGL/WGI approval.

Test certificates including test records, performance curves etc. shall be furnished. All test certificates shall be endorsed with sufficient information to identify equipment to which the certificate refers to and must carry project title, owner’s name and purchase order details etc.

GGL/WGI reserves the right to ask for inspection of all or any item under the contract and witness all tests and carry out inspection or authorise his representative to witness test and carry out inspection. CP contractor shall notify the GGL/WGI at least 20 days in advance giving exact details of tests, dates and addresses of locations where the tests would be carried out.

29.0 PACKING AND TRANSPORT

All equipment/ material shall be protected for inland/ marine transport, carriage at site and outdoor storage during transit and at site. All packages shall be clearly, legibly and durably marked with uniform block letters giving the relevant equipment/ material details. Each package shall contain a packing list in a water proof envelope. Copies of the packing list, in triplicate, shall be forwarded to owner prior to despatch. All items of material shall be clearly marked for easy identification against the packing list.

30.0 SYSTEM TESTING, COMMISSIONING AND INTERFERENCE MITIGATION

SYSTEM TESTING AT SITE

Contractor shall furnish the detailed field testing and commissioning procedure for approval. Field tests as per the approved procedures shall be carried out on the equipment/ systems before being put into service. The acceptance of the complete installation shall be contingent upon inspection and field test results being satisfactory.

Before the CP facilities are placed in operation all necessary tests shall be carried out to establish that all equipment, devices, wiring and connection, etc. have been correctly installed, connected and are in good working condition as required for intended operation.

GGL/WGI may witness all the tests. At least one week’s notice shall be given before commencing the tests.

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All tools, equipment and instruments required for testing shall be provided by C P Contractor.

Generally following tests shall be carried out and recorded in proforma given in subsequent clauses.

Checking : Visual inspection, comparison with drawings and specifications. Inspection : Detailed physical inspection & Dimensions measurement Testing : Simulation tests of equipment to determine its operational fitness. Cables

• Cable no.

• Voltage grade

• Conductor cross section

• Continuity check

• Voltage test

• Insulation resistance values between core and earth.

• All cables shall be tested by 500 V megger.

Insulating Joints

Checking of insulating joint for leakage, before and after energisation of C.P.by means of insulating joint tester. Structure-to-electrolyte potential of both protected and non-protected sides of insulating joint shall be checked before and after energisation of CP system. Grounding cell/Surge divertor shall be connected thereafter.

Polarisation cell

• Location/ identification number

• Rating

• Check for continuity

• Check for wiring

• Check for standby current drain with CP energisation (current drain with respect to voltage across the device/cell shall be recorded).

Grounding Cell

• Location

• Type (no. of anodes)

• Ratings

Surge diverter

• Location/ identification number

• Ratings

• Check for healthiness

Anode ground beds

• Location/ test station number

• Current Output of each Anode

• Current output of the ground bed

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31.0 COMMISSIONING

Natural pipe to soil potential [P-S-P] shall be measured at each test station [TLP] location prior to connecting anodes to pipeline. The pipe to soil potential observation shall be repeated after connecting the anodes and allowing sufficient time for polarization. The current output of the anode installation shall also be measured to ensure that it does not exceed the output current capacity of the anodes. In case the anode output current exceeds the rated capacity it shall be controlled by insertion of resistance element in the anode circuit inside test station and the pipe to soil potential shall be rechecked for adequacy of protection. Additional anodes shall be provided where required to achieve desired level of protection [PSP].

Each anode installation shall become individually operational as above. After connecting all the anode ground beds to pipe line, measurement of pipe to soil potentials shall be taken at each test station [TLP] to ensure adequate conformity to protection criteria.

In case of insufficient protection as per the NACE CP design criteria on any portion of the pipe line, Contractor shall carry out necessary additions/ modifications to the provided protection in consultation with the ENGINEER so that NACE criteria is met.

32.0 INTERFERENCE MITIGATION

Investigation shall be made by an expert agency with prior experience [such as Penspen U.K., PLE GmbH, Van De Velde etc.] for stray current electrolysis of the pipeline. Interference due to high voltage DC lines, electric traction & installed CP System of existing underground utilities (such as underground pipelines of ONGC,GAIL,IOCL H.P.C.L.,City Gas etc.), and make suitable Recommendations so that recommended D.C. Interference mitigative measures could be installed. The C.P. Contractor to carry out Interference due to overhead AC lines and install suitable mitigative measures for AC Interference. Measurements including pipe to soil potential [PSP] and pipe line current etc. on the pipeline/ structure being CP protected shall be made to investigate the current discharge [into surrounding soil electrolyte] and collection/pick-up locations. In case of fluctuating stray currents investigation shall be made continuously over a period of time 24 – 72 Hrs. using computerized data logger and if required simultaneously at different locations to find out the stray current source. For long line measurements, recorders data loggers (computerized) shall preferably be used. Where foreign pipeline (unprotected or protected by independent CP system) runs in parallel to the pipeline in same trench or very near to the pipeline, and is not bonded to the pipeline then investigation shall be made for current pickup & discharge points on both the pipelines. Mitigation measures shall be provided depending on type of interference. These shall include installation of bond with variable resistor and diodes, installation of galvanic anodes for auxiliary drainage of current, adjustment/ relocation (if possible) of offending interference source, provision of electrical shield etc. depending on the type of interference.

Between an existing pipeline & upcoming pipeline a concrete raft [size to be approved by GGL/WGI as per OISD] is to be provided as a barrier. The new pipeline will pass below the existing U/G Pipeline. Bonding with foreign pipeline/ structure as a mitigation measure shall be provided where the utility owner of the pipeline/ structure has no objection, otherwise alternative mitigation measure shall be provided. Wherever bonding is provided for mitigation the bonding resistor shall be adjusted for optimum value for minimum / no interference so that no net current flows from one to the other pipeline. Galvanic anodes installed as a mitigation measure shall be sized for the life specified for permanent CP.

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33.0 SYSTEM MONITORING

The temporary CP system provided shall be monitored at all test stations once in a month for healthiness/ adequacy of protection till commissioning of permanent CP or for design life of temporary CP specified, whichever is more. During this period if any deficiency/ interference in protection system is noticed the same shall be rectified / augmented by additional anodes etc. as required. The monitoring report shall be submitted regularly to GGL/WGI for review / information / Approval.

34.0 DRAWINGS AND DOCUMENTS

GENERAL

Within three weeks from the date of issue of PURCHASER ORDER, CONTRACTOR shall submit four copies of the list of all drawings/ data manuals/procedures for approval, identifying each by a number and descriptive title and giving the schedule date. This list shall be revised and extended, as necessary, during the progress of work.

All drawings and documents shall be in English and shall follow metric system. Number of copies of each submission shall be as follows unless otherwise specified.

Submission No. of copies a. For review / approval 4 copies b. Final/ As built drawings execution/ construction 6 copies + 2 set of [CD] c. Drawings issued for execution/ construction 4 copies + [CD] d. Operation/ Maintenance manual, vendor data 6 copies + [CD] e. Original permissions for Interference detection and Mitigation from other utility owners. f. The Original deed for Anode Bed Plot shall be handed over to GAIL.

35.0 CONTRACT DRAWINGS AND DOCUMENTS

As a part of the contract, drawings and documents shall be furnished which shall include but not be limited to the following:

a. Report on corrosion survey b. Basis of system design and design calculations, equipment selection criteria and sizing calculations. c. Bill of material, material requisitions, purchase requisitions. d. Quality assurance / Quality control procedures

Detailed construction drawings (including as built status)

a. Sacrificial anode fabrication drawings b. Typical layout drawing for anode ground bed installation and connection. c. Equipment layout, cable layout and schedules. d. TLP & Junction Box Erection / Installation Details Drawing e. Permanent Cu-CuSO4 reference electrode installation Drawing f. Fabrication, installation details of surge diverter, grounding cell and polarisation cell with its enclosure

and housing. g. Cable- to-pipe joint details for charged and non charged pipelines. h. Incorporation of anode beds, polarisation cell, surge diverters, test stations, etc. and other relevant

features of CP system-design in Pipeline alignment sheet and other related drawings. i. Identification of section of pipeline affected by interference, source of interference and details of

interference mitigation arrangements provided. Various measurement data at all relevant test stations with and without mitigation measures provided.

j. Detailed commissioning report including various measurement data at all test stations etc. k. Vendor drawings and catalogues, test certificates. l. Operation and maintenance manual. m. Miscellaneous

• Equipment inspection and testing procedure

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• Construction, installation procedures

• Field testing and commissioning procedures

• Procedure for monitoring of cathodic protection after commissioning

• Quality control procedures.

• Post Commissioning Testing/Monitoring Periodicity and Methodology

36.0 INSTRUMENTS, TOOLS AND SPARES

CONTRACTOR shall include a List of all instruments, tools and tackles necessary for proper operation

and maintenance [O&M], Monitoring of complete cathodic protection [TCP] [PCP] systems and associated equipment that are to be deployed at site, such as Corrosion Voltmeter, Multi-combination Meter, CPL Survey Data Logger, DCVG Meter, Holiday Detector, Pipe Locator, Elcometer for Coating thickness measurement, CAT survey, Soil resistivity meter etc.

CONTRACTOR shall provide number of spares and consumables being provided for proper operation and maintenance of part of cathodic protection [TCP] system to be integrated with permanent CP system [PCP] designed on the basis of permanent CP design parameters and associated equipment, for two (2) years un-interrupted operation of the system.

37.0 INFORMATION REQUIRED WITH THE BID

Bidders are advised in their own interest to provide the following information along with the bid without which the bids are liable for summary rejection. A. Work Experience, in detail, Project wise, giving Job content, Year, Status for client etc. B. List of Equipments, Tools, Tackles, etc. likely to be deployed at site

1. Basis and calculations for preliminary system design for cathodic protection system [TCP] and [PCP] Viz: Surface Area, Protective Current Required, Anode Weight and size required/provisioned, Anode bed type, Coke Breeze/Backfill required/provisioned, Anode bed Loop Resistance, Remoteness adequacy, Surge Redressal calculated/provisioned, etc.

2. List of formulae with legends to be used for detailed system design calculations. 3. Basis of system design, design calculations, equipment selection criteria, sizing calculations

along with characteristic curves for various equipment. 4. Preliminary bill of material [B O M] for major equipment for [TCP] and [PCP]. 5. Details of the equipment/ material offered along with technical leaflets / related literatures/

catalogues, make, rating, type test certificates. 6. Dimension, weight and general arrangement drawings for each offered equipment. 7. List of instruments, tools and tackles offered for maintenance and operation. 8. List of recommended maintenance / operation spares. 9. Clause-wise deviations, if any, to the specifications along with justifications. 10. List & Credentials of Crew to be deployed at site and contractors home office.

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38.0 APPROVED MAKE OF EQUIPMENT / COMPONENTS FOR C.P. SYSTEM

38.1 Transformer Rectifier Unit [TRU] AC Input DC Output, & CPPSM

M/s Kristrons System Mumbai M/s Canara Electric Controls Mumbai M/s CIMCON Software Services Inc.,Ahmedabad

38.2 MMO Anodes

M/s Titanor Components,Goa M/s Eltech, Netherlands M/s Oranzio De Nora,USA M/s Corpro Technologies, Singapore

38.3 SACRIFICIAL ANODES

M/s METAL FOUNDERS MUMBAI M/S SHAKTI ENTERPRISES AHMEDABAD M/s PROTECH ALLOY ANODES KARAIKUDI M/s SCIENTIFIC METAL ENGINEERS KARAIKUDI M/s CORPEN ANODES M/s ELECTRO-PROTECTION SERVICES

38.4 REFERENCE COPPER COPPER SULPHATE ELECTRODES

M/s Harco USA

M/s MC Miller USA M/s BORIN USA M/s Electrochemical Devices USA M/s Caltech Engineering Mumbai M/s CorrTech International Ahmedabad

38.5 JUNCTION BOXES [AJB,CJB,TLP]

M/s EX PROTECTA, MUMBAI M/s FCG LIMITED, MUMBAI M/s FLEXPRO, NAVSARI M/s BALIGA LIGHTING EQUIPMENTS, CHENNAI M/s UNDERGROUND PIPELINE & NDT SERVICES, NOIDA M/s CORROSION CONTROL SERVICES, MUMBAI M/S CORR-TECH INTERNATIONAL, AHMEDABAD

38.6 CABLES

M/s NETCO CABLES M/s FORT GLOSTER CABLES M/s CABLE CORPORATION OF INDIA LTD.

38.7 PIN BRAZING

M/s SAFETRACK

38.8 THERMITWELD

M/s ERICO EUROPA

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38.9 SURGE DIVERTORS

M/s DEHN GmbH M/s CITEL M/s MC MILLER M/s CONTROL TECHNOLOGY M/s DAIRYLAND ELECTRICAL INDUSTRIES M/s INTERNATIONAL CORROSION CONTROL Inc. M/s RAYCHEM

38.10 POLARIZATION CELLS / A C DECOUPLING DEVICE

M/s KIRK ENGINEERING M/s INTERNATIONAL CORROSION CONTROL Inc. M/s ELK ENGINEERING ASSOCIATES Inc, M/s Dairy Land Electricals

38.11 INSULATION MONO BLOCKS

M/s BASCO M/s ALFA M/s R M A M/s NUOVAGIUNGAS M/s ZUNT M/s PHOCENNE M/s PIPELINE ENGINEERING & SUPPLY CO. M/s TUBE TURN TECHNOLOGIES M/s KEROTEST MFG. M/s INTERNATIONAL CORROSION CONTROL Inc. M/s PIPELINE SEAL & INSULATORS Inc.,

38.12 E R PROBES

M/s ROHRBACK COSACO SYSTEMS,INC. M/s METAL SAMPLES M/s CORRTEST

38.13 WARNING MAT

M/s SPARCO AHMEDABAD

38.14 EXECUTING AGENCY

M/s CORRTECH INTERNATIONAL PVT LTD., AHMEDABAD M/s CCS, MUMBAI M/s RAYCHEM RPG, MUMBAI M/s SSS ELECTRICALS, MUMBAI M/s CONSULTECH, BARODA M/s UNDERGROUND PIPELINE NDTS SERVICES PVT. LTD., NOIDA M/s CCC, BANGALORE

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APPENDIX – A

POST C.P. COMMISSIONING SURVEYS

1. Coating Conductance Surveys For evaluation of the electrical strength of the coating, post commissioning of the C.P. System, after one (1) Month, Coating Conductance surveys to be conducted, to serve as Reference for future comparison. Although same coating specifications are used throughout the length of the pipeline, effective electrical strength thereby it’s ability to resist flow of current would reasonably vary on account of terrain, construction defects, soil resistivity along the Pipeline length.

For conducting coating conductance surveys, Potential (∆V)& (∆I) Current are to be measured at two consecutive “B” type Test Lead Points [TLP],w.r.t remote earth using CuCuSO4 reference electrode, alternatively with current interrupter “On” & “Off” at each measurement point.

The difference of the two ∆∆∆∆I will be the C.P. Current being collected by this section of the

pipeline.

The difference of the two ∆∆∆∆V will be the average change in pipeline potential within the test

section owing the current received from C.P. System.

The above procedure to be repeated for all “B” type TLP for evaluating coating conductance value for different sections along the pipeline. All the Data obtained is to be handed over to the owner & will form part of final Technical Documentation. Before commencement of site surveys the survey procedure shall be got duly approved from the Owner.

2. Pearson & DCVG Survey Post commissioning of the C.P. System, after 30 days of Line polarization, CPL Survey will be conducted for evaluation of coating condition to serve as future Benchmark for comparative evaluation. Any finding of coating defect in particular, where coating defects and holidays are high, have to be further established through a separate Pearson cum DCVG survey for the defective stretch delineated as above from CPL survey findings. Prior to commencement of Pearson cum DCVG survey, the survey procedure to be got approved from the Owner. Only Good & Proven survey equipment and trained, experienced manpower to be used. Defects identified by Pearson to be further Surveyed using DCVG technique for defect classification. All survey Data to be submitted to Owner as part of Technical Documentation.

3. Computerized Potential Logging [CPL] survey

Post commissioning of the C.P. System, after 30 days of Line polarization, a Computerized Potential Logging [CPL] survey will be conducted, as per procedure, already got approved by the Owner. The “On”/”Off” Potential survey. For the survey, Data Logger of repute & Current interrupter [if not available in the TRU] will be used by experienced and trained manpower. All the survey data and findings of under-protected, over-protected zones, short etc. shall be handed over to the owner as part of final technical Documentation. Suitable remediation measures to be recommended for achieving adequacy of protection throughout the pipeline length. This CPL survey Data will serve as base Data for future comparative evaluations of the Protective system adequacy.

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4. A.C. /D.C. Interference Detection & Mitigation

Post commissioning of the C.P. System, after 30 days of Line polarization, an AC / DC Interference survey to detect presence (or absence) of induced AC Voltages [which in certain circumstances may be fatal] on the underground pipeline that run parallel to AC transmission systems [having voltages greater than or equal to ≥11KV] shall be carried out. Measurement of P-S-P shall be taken at every TLP of the pipeline that run parallel to overhead AC transmission lines and are within 20 M of transmission line alignment. On detection of AC induced Hazardous voltages suitable Mitigative measures such as grounding of the pipeline with Zn / Mg Grounding cell, installation of Polarization cell etc. shall be resorted to dissipate Ac induced hazardous voltages to ground in controlled manner. Type “A” TLP shall be provided at these locations having AC induced Hazardous voltages on the pipeline. DC Interference Detection from existing CP system in close vicinity of [CJ] ROW and any other DC source such as electric traction, switching yard, welding shop etc. Appropriate measures for mitigation to be recommended for installation by CP contractor. Prior to site survey commencement, the Approval for survey procedure, from the Owner, shall be taken.

Σ Σ Σ

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APPENDIX-B

INTERFACING WITH SCADA

Cathodic Protection (CP) panel shall be properly interfaced with RTU through RS 485 serial link for various signals like pipeline under protection, pipeline overprotection, all reference fail, unit working in auto mode, unit working in AVCC mode, unit working in local / remote mode, setting of DC O/P voltage, setting of DC output current, setting of Pipe soil potential (PSP), setting of auto / AVCC mode. CONTRACTOR to note that SCADA vendor shall provide RS 485 serial link at the RTUs for interfacing with CP system. Hence, CONTRACTOR shall also provide RS 485 serial link (Modbus ASCII & Modbus RTU protocol which shall be user selectable). The digital and analog data shall be made available to RTU (SCADA) and it shall be mapped in the contiguous registers so that data can be fetched / written in minimum transactions. CONTRACTOR shall furnish all details like pin configuration and signal wise MODBUS address mapping list etc. for smooth interfacing of this communication link with RTU (SCADA). CONTRACTOR shall also furnish the details of implemented MODBUS protocol like function codes for read and write, CRC implementation, BCC implementation, register addressing methods / mapping etc. during detail engineering for serial interfaces with RTU (SCADA). The following hardwired signals shall be taken from CP system to SCADA system (however hardwired cables shall be routed through PLC cabinet):

PSP Value Impressed Voltage Impressed Current Start / Stop of Current Interrupter

Σ Σ Σ

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COMPLIANCE CERTIFICATE

CP Contractor to submit the following Compliance certificate in case of compliance and attach

Deviation if any duly Approved by The Owner

a. TABLE OF COMPLIANCE : to be filled by C P Contractor

S.No. Specification

Clause Reference

Compliance

Yes/No

Deviation

Justification Remarks

This being a no deviation bid,any deviation sought without appropriate justification

is liable to be not accepted & rejection of Bid.

Additional sheets,if required,may be attached duly signed by CP contractor with seal.

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ANNEXURE –I

SOIL RESISTIVITY DATA

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ANNEXURE –II

LSIT OF THIRD PARTY INSPECTION AGENCIES

SPECIFICATIONS INSTRUMENTATION & CONTROL

GAIL GAS LIMITED


CLIENT JOB NO. - TECHNICAL SPECIFICATION FOR PRESSURE GAUGES

TOTAL SHEETS 04

DOCUMENT NO 11 0290 02 11 02 003

0 16.10.09 ISSUED FOR TENDER GV AP SB

B 25.08.09 ISSUED FOR CLIENT’S COMMENTS BG AP SB

A 24.08.09 ISSUED FOR IDC BG AP SB


1

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TECHNICAL SPECIFICATION FOR PRESSURE GAUGES

SHEET 2 OF 4

CONTENTS

1.0 GENERAL................................................................................................................................................3

2.0 INSTRUMENTS/ACCESSORIES ............................................................................................................3

3.0 TAG PLATE .............................................................................................................................................3

4.0 SHIPPING PROTECTION........................................................................................................................3

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1.-1 GENERAL

1.1 SCOPE

This specification covers the Purchaser's requirements for the design, materials, tag plate marking, testing and shipping of pressure gauges.

1.2 LIST OF APLICABLE CODES/ STANDARDS

Vendor shall also comply with the applicable requirements of the latest editions of the following standards. ANSI B1.20.1 Pipe threads.

IS: 3624 Specifications for pressure and vacuum gauges

API RP 551 Process measurement instrumentation

Prior to shipment, Manufacturer shall submit following: a) Test / calibration / inspection certificate for all items. b) Manual for installation, erection instructions, maintenance and Operation instructions.

2.-1 INSTRUMENTS/ACCESSORIES

2.1 Pressure Gauges

i) The pressure element shall be bourdon type. ii) Bourdon elements shall be directly connected to the socket without any capillary in between. iii) Pressure gauges shall have over-range protection and be capable of withstanding the full

static design pressure of the system without loss of calibration. Admissible over pressure for bourdon tube: +30% up to 100 bar +15% over 100 bar. When its not possible, gauge protection devices may be used.

iv) The gauge movement shall be adjustable for the purpose of calibration. The use of S link for

calibration of span is not permitted. v) Dial marking and dial colour shall be as per IS 3624. vi) Pressure gauge shall be provided with a device such as a disc inert or blow out back,

designed to relieve excess case pressure.

3.-1 TAG PLATE

Each instrument shall have a SS tag plate attached firmly to it at a visible place and bearing the tag number as per Purchaser's data sheets and other relevant details of the instrument.

4.-1 SHIPPING PROTECTION

i) All openings shall be suitably protected and all machined surfaces suitably covered to prevent entry of foreign material and avoid any damage during shipment.

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ii) Proper care shall be taken in shipping gauges with diaphragm seals to ensure safety of the diaphragm. Seals, extensions and capillaries where specified shall also be suitably protected.

iii) All items shall be adequately packed to withstand shipping conditions without damage.

GAIL GAS LIMITED


CLIENT JOB NO. - SPECIFICATION FOR OPTICAL FIBRE CABLE AND HDPE DUCT

TOTAL SHEETS 24

DOCUMENT NO 11 0290 02 11 02 008





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SPECIFICATION FOR OPTICAL FIBRE

CABLE AND HDPE DUCT

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CONTENTS

1.0 INTRODUCTION......................................................................................................................................4

2.0 QUALITY REQUIREMENTS....................................................................................................................4

3.0 CABLE MARKING...................................................................................................................................4

4.0 RAW MATERIAL .....................................................................................................................................4

5.0 DOCUMENTATION .................................................................................................................................5

6.0 SAFETY REQUIREMENT........................................................................................................................5

7.0 OPERATING REQUIREMENT ................................................................................................................5

8.0 CABLE ENDS ..........................................................................................................................................5

9.0 THE NOMINAL DRUM LENGTH.............................................................................................................5

10.0 COLOUR CODING IN OFC CABLES .....................................................................................................6

11.0 SPECIFICATION OF OPTICAL FIBRES ................................................................................................6

12.0 OFC PIT ...................................................................................................................................................7

13.0 OPTICAL FIBRE CABLE CONSTRUCTION SPECIFICATIONS...........................................................8

14.0 MECHANICAL CHARACTERISTICS, AND TESTS ON OPTICAL FIBRE CABLES............................9

15.0 CHECK OF THE QUALITY OF THE LOOSE TUBE (CONTAINING OPTICAL FIBRE) METHOD:....13

16.0 DRAINAGE TEST FOR LOOSE TUBE.................................................................................................14

17.0 OPTICAL FIBRE CABLE LAYING........................................................................................................15

18.0 THE SCOPE OF WORK FOR LAYING.................................................................................................16

19.0 CABLE PROTECTION DURING INSTALLATION................................................................................16

20.0 CABLE LAYING PROCEDURE ............................................................................................................16

21.0 LUBRICATION.......................................................................................................................................18

22.0 JOINTING / INSTALLATION AT PULL BOXES...................................................................................18

23.0 CROSSING ............................................................................................................................................18

24.0 BACKFILLING & TESTING...................................................................................................................19

25.0 HDPE CONDUIT ....................................................................................................................................19

26.0 STANDARDS APPLICABLE.................................................................................................................19

27.0 APPROVAL OF DOCUMENTS .............................................................................................................20

28.0 GENERAL GUIDELINES.......................................................................................................................20

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29.0 SOLID PERMANENTLY LUBRICATED PIPE CONDUIT.....................................................................20

30.0 PACKING...............................................................................................................................................21

31.0 QUALITY ASSURANCE PROGRAMME & TESTING ..........................................................................22

32.0 SUMMARY OF REQUIREMENT ...........................................................................................................22

33.0 LIST OF ABBREVIATIONS...............................................................................................................22

34.0 LIST OF DOCUMENTS REFERED .......................................................................................................23

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1.0 INTRODUCTION This document describes the specification of metal free Optical Fibre Cable for GAIL (GAS) Pipeline.

The optical fibre cable shall have low weight. Small volume and high flexibility. The optical fibre cable shall be suitably protected for the ingress of moisture by flooding belly and by water swellable tape. The raw material used in the cable shall meet the requirements of the specs for the raw materials.

2.0 QUALITY REQUIREMENTS

The cable shall be manufactured in accordance with the international quality standards, ISO 9000 series of standards for which the manufacturer should be duly accredited.

3.0 CABLE MARKING

3.1 A suitable marking, which can last long, shall be applied in order to identify this cable from other cables. The cable marking shall be imprinted' indented. The marking on the cable shall be indelible of durable quality and at regular intervals of one meter length. Alternatively, permanent printing with the laser (the impression shall not exceed the depth of 0.15 mm) shall also be acceptable.

3.2 The markings must clearly contrast with the surface. The colours used must withstand the

environmental influences experienced in the field. 3.3 The marking shall be in black colour over the orange colour nylon jacket and shall be done by hot oil

indentation method. 3.4 The accuracy of the sequential marking must be within -0.25% to +0.5% of the actual measured length.

The sequential length markings must not rub off during normal installation. The total length of the cable supplied shall not be in negative tolerance.

3.5 The type of legend marking on OFC cable shall be as follows: Name of manufacturer. Part number. "OPTICAL FIBRE CABLE". Type of Fibre. Number of Fibres. Year of manufacture. Sequential length marking. Drum number 4.0 RAW MATERIAL

4.1 The cable shall use the raw materials approved. 4.2 The materials used other than the above materials shall be clearly indicated by the manufacturer. The

Manufacturer shall furnish detailed technical specifications of such raw materials used. 4.3 The source / sources of raw materials from where these have been procured shall be submitted by the

manufacturer. 4.4 The change of raw materials from one approved source to other approved source shall be allowed,

provided there is no change in the design of the cable. However change in design or construction of the metal free optical fibre cable requires approval from owner/consultant.

4.5 The HDPE Red/Black in colour used for sheath shall be UV stabilized. A test certificate from a

recognized laboratory or institute may be acceptable for the UV stability of the HDPE sheath material. 4.6 The material used in optical fibre cable must not evolve hydrogen that will effect the fibre loss.

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5.0 DOCUMENTATION

Complete technical literature in English with detailed cable construction diagram of various sub-components with dimensions & test data and other details of the cable shall be provided. All aspects of installation, operation, and maintenance shall also be covered in the handbook.

6.0 SAFETY REQUIREMENT

The material used in the manufacturing of the metal free optical fibre cables shall be non-toxic and dermatologically safe in its lifetime.

7.0 OPERATING REQUIREMENT

7.1 The design and construction of metal free optical cable shall be inherently robust and rigid under all conditions of operations, adjustment, replacement, storage and transport.

7.2 The optical fibre cable shall be able to work in a saline atmosphere in coastal areas and should be

protected against corrosion. 7.3. Life of cable shall be better than 40 years. The bidder shall submit necessary statistical calculations. 7.4 It shall be possible to operate and handle the metal free optical fibre cable with tools. In case any

Special tool requirement for operating and handling the optical fibre cable. The same shall be provided along with the cable.

8.0 CABLE ENDS

8.1 Both ends of the cable shall be kept inside the drums and shall be located so as to be easily accessible for the test. The drum should be marked to identify the direction of rotation of the drum. Both ends of cable shall be provided with cable pulling (grip) stocking and the anti twist device (free head hook)

8.2 An anti twist device (Free head hook) shall be provided attached to the front end of the cable pulling

arrangement. The arrangement of the pulling eye and its coupling system along with the anti twist system shall withstand the prescribed tensile load applicable to the cable.

9.0 THE NOMINAL DRUM LENGTH

9.1 To supply OFC cable in 4 km drum with no negative tolerance on length for one cable drum. Shorter length (not less than 1KM) may be accepted to arrive at the total quantity to be supplied. There shall be no tolerance on the total cable quantity to be supplied. Measurement for the purpose of payment shall be physical length of the cable.

9.2 The fibre in cable length shall not have any joint. 9.3 The drum shall be marked with arrows to indicate the direction of rotation. 9.4 Packing list supplied with each drum shall have at least the following information: Drum No. Type of cables Physical cable length No. Of fibres

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10.0 COLOUR CODING IN OFC CABLES

The colorant applied to individual fibres, fibre units and hinders shall be readily identifiable throughout the lifetime of the cable and shall match and confirm to the MUNSELL COLOUR STANDARDS (FOR EIA STANDARD EIA-359M and IEC Publications 304 (4)).

11.0 SPECIFICATION OF OPTICAL FIBRES

Single Mode Optical Fibre used in manufacturing optical fibre cables shall be as per ITU - T (earlier CCITT) Recommendation G-652. The specification of optical fibres is as below:

11.1 Type of Fibre Single mode 11.2 Number of fibres Twenty Four 11.3 Wavelength and band optimized 1300 nm & 1550 nm (2nd

window) GEOMETRICAL CHARACTERISTIC 11.4 Nominal MFD

For depressed Clad For Matched Clad Tolerance

9 um 10 um +/- 10% of the nominal

value 11.5 Nominal Cladding Diameter 125 um +/- 0.7um 11.6 Cladding Non-Circularity </=0.7% 11.7 Mode field concentricity error </=0.5um 11.8 Protective materials/coatings

(The coating should provide maximum resistance to micro bending and abrasion and ensure mechanical and optical strength. The coating shall be easily striped with mechanical tools)

Optical fibres shall be primary coated with UV cured Acrylate Resin. It should not have any reaction with cladding or core material.

11.9 Fibre identification: - The coatings shall be in various colours in order to facilitate fibre identification. The colours shall correspond reasonably with standard colours, shall readily be identifiable, and shall be durable. The colours should have good colour (fast properties) also in the presence of other materials during the lifetime of cable. Unit identification shall be done by individual colour of the fibres and by Marker and Tracer method.

11.10 The coating and the colour shall not react with surrounding jelly.

11.11 Diameter over primary coated with double UV cured acrylate (shall be measured on uncoloured fibre)

245 um +/- 5 um

11.12 Overall diameter Bidder to specify 11.13 Attenuation coefficient of the cabled fibre

At 1300nm wavelength region At 1550 nm Sudden irregularity in attenuation shall be less than 0.1 dB. The spectral attenuation shall be measured on uncabled fibre.

In bare fibre </=0.33-0.35Db/Km </=0.19-o.20Db/Km

11.14 A) Total Dispersion In 1285 – 1330 nm band

< 3.5 ps/nm. Km

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In 1270 - 1340 nm band At 1550 nm B) Polarization mode dispersion at 1300 & 1550 nm Fibre Cabled Fibre Note: measurement on uncabled fibre may be used to generate cabled fibre statistics and correlation is established C) Zero Dispersion Slope D) Zero Dispersion wave length range

< 6.0 ps/nm. Km < 18.0 ps/nm. Km < 0.2 ps/√Km < 0.3 ps/√Km < 0.092 ps/(nm2.Km) 1300 – 1342 nm

11.15 Cut off wavelength of optical fibres For Coated Fibre (For 2 m samples length of fibre) For Cabled Fibre (For 22 m sample length of cable)

1320 nm maximum 1270 nm maximum

MECHANICAL CHARACTERISTICS 11.16 Proof test for minimum strain level

Strippability force to remove primary Note: The force required to remove 30 +/- 3 mm of

the fibre coating shall not exceed 8.9 N and shall not be less than 1.3 N

Dynamic Tensile Strength Unaged Aged Dynamic Fatigue Static Fatigue

1% 1.3 </= F </= 8.9 N >550 KPSI (3.80 Gpa) >440 KPSI (3.00 Gpa) >/=20 >/=20

11.17 Change in attenuation measured at 1550 nm when fibre is coiled with 100 turns on 30+1.0 mm radius mandrel.

< 0.10 dB

11.18 Fibre Curl >4 Meter radius of curvature

11.19 Fibre micro bend (1 around 32+0.5 diameter mandrel)

<0.5 dB at 1550 nm

MATERIAL PROPERTIES 11.20 Fibre Materials

The substances of which the fibres are made. Protective materials requirement The physical and chemical properties of the material used for the fibre primary coating and for single jacket fibre. The best way of removing protective coating material. Refractive index of Fibre

It shall meet the requirement of Fibre coating stripping force.

12.0 OFC PIT

The pit for jointing / inspection testing of OFC shall be of RC. Water Retaining, structure of minimum size 1.5mx 1.5m in Plan. Depth of the pit shall be as required to carryout jointing inspection & testing of OFC.

Blowing and inspection of pit at every 2 Km. Joining pit at every 4 Km.

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The pit shall be provided with a concrete cover slab with a man-hole. The top of this slab shall be minimum 300mm above the finished ground level or depth of water logging during monsoon whichever is higher.

A cat ladder shall be provided if depth of pit is more than 1 m. 13.0 OPTICAL FIBRE CABLE CONSTRUCTION SPECIFICATIONS

13.1 SECONDARY PROTECTION The primary coated fibres may be protected by loose packaging within a tube, which shall be filled with

thixotropic jelly. Number of fibres: 24 Number of loose tubes: 4 Number of fibres per loose tube: 6 (Six) Material for loose tube: PBT (Polybutylene terephthalate) Outer diameter of loose tube: 2.5 mm nominal 13.2 STRENGTH MEMBER Solid FRP non-metallic strength member with a minimum diameter of 2.5 mm nominal in the cable core

shall be provided. The strength member(s) in the cable shall be for strength and flexibility of the cable and shall have anti buckling properties. These shall also keep the fibre strain within permissible values

To achieve the required tensile strength of the optical fibre cables, the manufacturer may use Aramid

Yarn along with solid Rigid FRP Rod. The use of solid rigid FRP Rod(s) is mandatory in Optical Fibre Cable design. The Aramid yarn shall be equally distributed over the periphery of the cable core. The quantity of the Aramid yarn per km length of the cable along with its dimensions shall be indicated by the manufacturer.

13.3 Cable Core Assembly: Primary coated fibres in loose tubes stranded together around Central strength

member using helical or reverse lay techniques shall form the cable core. 13.4 Core Wrapping: The main cable core containing fibres shall be wrapped by layer/layers of Polyester

wrapping tape. Minimum thickness of Polyester wrapping tape shall be 250 um. The nylon/ polyester binder thread shall be used to hold the tape.

13.5 Moisture barrier (protection): The main cable core (containing fibres core wrapping) shall be protected

by flooding compound (Jelly) having properties of non-hygroscopic dielectric material and by water swellable tape. The core wrapping shall not adhere to the secondary fibre coating.

13.6 Filling compound: The filling compound used in the loose tube and to the cable core shall be compatible

to fibre, secondary protection of fibres core wrapping etc. The drip point shall not be lower than 71 degree C. The fibre movement shall not be constrained by stickiness & shall be removable easily for splicing. Reference material test method to measures drop point shall be as per ASTM D 556.

13.7 Sheath: A non-metallic moisture barrier sheath may be applied over and above the cable cores. The

core shall be covered with tough weather resistant High Density. Polyethylene (HDPE) sheath red black in colour with minimum outer diameter of 1.5mm (UV stabilized) and Colour shall conform to Munsell Colour Standards. Thickness of the sheath shall be uniform & shall not be less than 1.5 mm including the. Strength members it used in the sheath. The sheath shall be circular, smooth, and free from pinholes, joints. Mended pieces and other defects. Reference test method to measures thickness shall be as per IEC 189 para 2.2.1 and para 2.2.2.

Overall cable diameter shall not exceed 16mm

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Note: in case HDPE: material black in colour is used; the material from finished product shall be subjected to following tests (on sample basis)

1) Density 2) Melt Flow Index 3) Carbon Black Content Carbon Black Dispersion 4) ESCR 5) Moisture Content 6) Tensile Strength and Elongation at break

13.8 Outer Jacket: A circular Sheath I Jacket of not less than 0.65 mm thick of polamide-12/ nylon - 12

material (orange colour), free from pin holes, scratches and other defects etc. shall be provided over and above the HDPE sheath, The nylon Jacket shall have smooth finish and hydrocarbon resistant.

13.9 Cable diameter: The manufacturer shall specify the over-all cable diameter. (shall not exceed 16mm) 13.10 RIP Cord: Suitable rip cord(s) shall be provided which shall be used to open the HDPE sheath of the

cable. The ripcords shall be properly waxed to avoid wicking action. 14.0 MECHANICAL CHARACTERISTICS, AND TESTS ON OPTICAL FIBRE CABLES

14.1 TENSILE STRENGTH TEST Objective: This measuring method applies to optical fibre cables, which are tested at a particular

tensile strength in order to examine the behaviour of the attenuation as a function of the load on a cable, which may occur during installation.

Method: IEC 794 - l - E l Test Specs: The cable shall have sufficient strength to withstand a load of value T (N) = 9.81 x 2.5 W

Newtons or 2670 N which ever is higher. (Where W=mass of 1 km of cable in Kg) The load shall be sustained for two minutes and the strain of the fibre monitored.

Requirement: The load shall not produce a strain exceeding 0.25% in the fibre and shall not cause any

permanent physical and optical damage to any component of the cable. The attenuation shall be noted before strain and after the release of strain. The change in attenuation of each fibre after the Test shall be < 0.05 dB both for 1300 nm and 1550 nm wavelength.

14.2 ABRASION TEST Objective: To test the abrasion resistance of the sheath and the marking printed on the surface of the

cable. Method: IEC - 794-1-E2 or by any other international test method. Requirement: There shall be no perforation & loss of legibility of the marking on the sheath 14.3 CRUSH TEST (COMPRESSIVE TEST) Objective: The purpose of this test is to determine the ability of an optical fibre cable to withstand

crushing Method: IEC 794-1-E3.

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Test Spec.: The fibres and component parts of the cable shall not suffer permanent damage when subjected to a compressive load of 2000 Newtons applied between the plates of dimension 100 x l00mm. The load shall be applied for 60 secs. The attenuation shall be noted before and after the completion of the test.

Requirement: The change in attenuation of the fibre after the test shall be < 0.05 dB/Km both for 1300

nm and 1550 nm wavelength. 14.4 IMPACT TEST Object: The purpose of this test is to determine the ability of an optical fibre cable to withstand impact Method: IEC 794-1-E4 Test Spec.: The cable shall have. Sufficient strength to withstand art impact caused) by a mass weight

of 50 Newtons, when falls freely from a height of 0.5 meters. The radius R of the surface causing impact shall be 300 mm. ten such impacts shall be applied at the same place with a gap between one impact to another of approximately at 60 seconds.. The attenuation shall be noted before and after the completion of the test.

Requirement: The. Change in attenuation of the fibre after the test shall be < 0.05 dB/Km both for 1300

nm and 1550 nm wavelength. 14.5 REPEATED BENDING Objective: The purpose of this test is to determine the ability of an optical fibre cable to withstand

repeated bending Method: EIA-455-104 Test Specs. The cable sample shall be of sufficient length (5 m minimum) to permit radium power

measurements as required by this test. Longer lengths may be used if required.

Parameters 5 Kg Minimum distance from Pulley center to holding

device 216 mm

Minimum device from Wt. To Pulley center 457 mm Pulley Diameter (U-cable diameter) 20 D Angle of Turning 90° No. of cycles 30 Time requirement for 30 cycles 2 minutes.

Requirement: During this test, no fibre shall break and the attenuation shall be noted before and after

the completion of the test. The change in attenuation of the fibre after the test shall Be < 0.05 dB both for 1300 nm and 1550 nm wavelength.

14.6 TORSION TEST Object: The purpose of this test is to determine the ability of an optical fibre cable to withstand torsion. Method:IEC 794- l -E7 Test Spec.: The length of the specimen under test shall be 2 meters and the load shall be 100 N. The

sample shall be mounted in the test apparatus with cable clamped in the fixed clamp sufficiently tight to prevent the movement of cable sheath during the test. One end of the cable shall be fixed to the rotating clamp, which shall be rotated in a clockwise direction for one turn. The sample shall then be returned to

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the starting position and then rotated in an anti-clock wise direction for one turn and returned to the starting position. This complete movement constitutes one cycle, the cable shall withstand ten such complete cycles. The attenuation shall be noted before and after the. Completion of the test.

Requirement: The cable shall be examined physically for any cracks. Tearing on the outer sheath and

for the damage to other component parts of the cable, The twist mark shall not be taken as damage. The change in attenuation of the fibre after the test shall be < 0.05 dB/Km. both for 1300 nm and 1 550 nm wavelength.

14.7 KINK TEST Object: The purpose of this test is to verify whether kinking of an optical fibre cable results in breakage

of any fibre, when a loop is formed of dimension small enough to induce a kink on the sheath. Method:IEC 794-1-E10. Test Spec.:The sample length shall be 10 times the minimum bending radius of the cable. The sample

is held in both hands. a loop is made of a bigger diameter and by stretching both the ends of the table in opposite direction. the loop is made to the minimum bend radius, and no kink shall form, the cable is then normalized and attenuation reading is taken.

Requirement: The kink should disappear after normalizing the cable. The change in attenuation of the

fibre after test shall be < 0.05 dB both for 1300 nm 1550 nm wavelength. 14.8 CABLE BEND TEST Objective: The purpose of this test is to determine the ability of an optical fibre cable to withstand

repeated flexing. The procedure is designed to measure optical transmittance changes and requires an assessment of any damage occurring to other cable components.

Method: IEC 794-1-E 11 (Procedure-1) Test Spec.:The fibre and the component parts of the cable shall not suffer permanent damage when the

cable is repeatedly wrapped and unwrapped 4 complete turns of 10 complete cycles around a mandrel of 20 D, where D is the diameter of the cable. The attenuation shall be noted before and alter the completion of the test.

Requirement: The change is attenuation of the fibre after the test shall be < 0.05 dB both for 1300 nm

and 1550 nm wavelength. Sheath shall not show any cracks visible to the naked eye when examined whilst still wrapped to the mandrel.

14.9 TEMPERATURE CYCLING Objective: To deter-mine the stability behaviour of the attenuation of a cable subjected to temperature

changes, which may occur during storage, transportation and usage. Method:IEC 794-1-F1 (To be tested on cable length of 200 m). Test Specs.: The permissible temperature range for storage and operation will be from -200C to +700C.

The rate of change of temperature during the test shall be 10 per minute approx. The cable shall be subjected to temperature cycling for 12 Hrs. at each temperature as given below:

i) at room temperature : 1 hr. ii) at zero degrees : 12 hrs. iii) at 65 degrees : 12 hrs. iv) from 65 degrees to room temperature : 1 hr. The test shall be conducted for 2 cycles at the above temperatures.

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Requirement: The change in attenuation of the fibre under test shall be < 0.05 dB/Km for 1300 nm and 1550 nm wavelengths for the entire range of temperature.

14.10 WATER PENETRATION TEST Objective: The aim of this test is to ensure that installed jelly filled Metal free Optical fibre cable will not

allow water passage along its length. Method: IEC 794-1-F5 (Fig. B) 1992. Test Specs.: A circumferential portion of the cable end (with HDPE sheath after removing the nylon

jacket) shall face the water head. The watertight sleeve shall be applied over the cable. The cable shall be supported horizontally and two meter head of water. Containing a sufficient quantity of water soluble fluorescent dye for the detection of seepage; shall be applied on the HDPE sheath for a period of 7 days at ambient temperature.

Requirement: No dye shall be detected when the end of the 3 m length is examined with ultraviolet light

detector. The cable sample under test shall be ripped open after the test and it shall be examined for seepage of water into the cable and the distance to be noted.

14.11 FLEXURAL RIGIDITY TEST ON THE OPTICAL FIBRE CABLE Objective: To check the Flexural Rigidity of the metal free optical fibre cable. Method: To be tested as per ASTM D-790 Test Specs.: The fibre and the component parts of the cable shall not suffer permanent damage in the

cable subjected to Flexural Rigidity Test as per the above method. The attenuation shall be noted alter and before the completion of the test.

Requirement: The change in attenuation of the fibre after the test shall be < 0.05 dB both for 1300 nm

and 1550 nm wavelength. The sheath shall not show any cracks visible to the naked eye. 14.12 TEST OF FIGURE OF 8 (FIGURE ON THE CABLE) Objective: Check of easiness in formation of figure of 8 of the cable during installation in the field. Test method: 1000 meter of the cable shall be uncoiled from the cable reel and shall be arranged in

figure of 8(eight) shape. The dimensions of each loop of the figure of 8 shall be maximum 2 meters. Requirement: It shall be possible to make figure of 8 of minimum 1000 meters of the cable uncoiled

from the cable reel without any difficulty. No visible damage shall occur. 14.13 CABLE AGING TEST Objective: To check the cable material change dimensionally as the cable ages. Method: At the completion of temperature cycle test. The test cable shall be exposed to 85+2 degree C

for 168 hours. The attenuation measurement at 1300 & 1550 nm wavelength to be made after stabilization of the test cable at ambient temperature for 24 hours.

Requirement: The increase in attenuation allowed:< 0.05 dB at 1300 & 1550 nm. Method: The attenuation changes are to be calculated with respect to the base line attenuation values

measured at room temperature before temperature cycling. 14.14 STATIC BEND TEST Objective: To check the cable under Static bend

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Method: As per clause no. 13.8 of the GR. alternatively as per ASTM D790 Test Specs.: The cable shall be subjected to static bend test. The optical fibre cable shall be bent on a

mandrel having a radius of 10 D (D- is diameter of the cable). Requirement: The change is attenuation of the fibre after the test shall be < 0.05 dB both for 1300 nm

and 1550 nm not wavelength. Sheath shall not show any cracks visible with the naked eye when examined whilst wrapped on the mandrel.

14.15 JOINTING CLOSURES Jointing closures shall be suitable for the cables, jointing closures shall be dust tight (No dust ungrss)

and protected against –immersion in water (Suitable for continuous immersion in saline water 0 and should be complete with all accessories including splice cassettes,splice protection and all accessories for electrical continuity of metallic layer of optical fibre cable. The jointing enclosures shall be provide with suitable jointing pit support hardware to secure the jointing closures to a 1200 mm dia circular jointing pit.

14.16 JOINTING CLOSURE TESTS The following shall be conducted as a minimum :

a) Water ingress test The cable jointing box shall be assembled along with a continuous piece of cable passing through. The jointing box shall then be secured at the bottom of a immersion tank containing water upto a height of 2.0m at normal room temp. for a period of 24 hrs. The joint box will then be opened as per the specified procedure and visually examined for any ingress of water. It shall be declared to have passed the test in case there is no water present inside the box. b) Impact test The cable joint box shall be kept on a metal platform. A weight of 5 kgs spherical type having radius of R 50 mm at striking end will be made to stike the box at the middle after having been released from a height of 500mm for 10 times.The joint box will be declared to have passed the test in case there are no cracks or fracture inside or outside of the box. c) Drop and topple test A drop test platform consisting of a steel plate not less than 6.5 mm thick is to be used. The steel plate is bolted to a fully set concrete block at least 460mm thick. The joint box shall then be allowed to topple and fall freely from a height of 200mm. The joint box will be declared to have passed the test in case there is no visible damage to the enclosure. d) Pulling test The joint box should be assembled with a long length of cable so that it can be pulled to the required tension of 100 KGS to check the strength of fixing arrangement inside the joint box. d) Static load test The assembled cable joint closure shall be kept on a platform with dimension more than that of cable joint closure. A curved hollow profiled mandrel shall be used for applicaton of load and the mandrel shall be at the middle straight part of the joint closure. Weights shall be gradually placed on the mandrel till the weight becomes 250 kgs. The joint box shall be kept under the weight for a period of 24 hrs. The joint closure shall be declared to have passed the test in case there is no visible damage.

15.0 CHECK OF THE QUALITY OF THE LOOSE TUBE (CONTAINING OPTICAL FIBRE) METHOD:

a) Embitterment Test of Loose Tube

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The test method is based on bending by compression and reflects embitterment much better than the

other used tensile test. The test is independent of wall thickness of the loose tube. Sample: The minimum length of the test sample depend on the outside diameter of the loose tube and

should be 85 mm for tubes upto 2.5 mm outside dirt. The length of the bigger tubes should be, calculated by using the following* equation:

L0 > 100 x √ ( D2 + d2 ) / 4 Where Lo = Length of tube under test D = Outside dia of loose tube d = Inside dia of loose tube Procedure: Both the ends of a butler tube test sample may be mounted in a tool which is clamped in

taws of a tensile machine which exert a constant rate of movement The movable jaw may move at a rate of 50 mm per minute toward the fixed jaw. Under load the tube will be bent, so that the tube is subjected to tensile and compressive stresses. The fixture for holding the tube should be designed in a manner that the tube might bend in all directions without further loading.

Requirement: The tube should not get embitter. No kink should appear off the tube upto the sale bend

dia of tube (20 D) where D is the outside diameter of the loose tube. There should not be any physical damage or mark on the tube surface.

(b) Kink Resistance Test-on the loose tube To safeguard the delicate optical fibres, the quality of the loose tube material should be such that no

kink or damage to the tube occurs while it is being handled during installation and in splicing operations. To check the kink resistance of the loose tube. A longer length of the loose tube is taken (with fibre and

gel). A loop is made and loop is reduced to the minimum bend radius of loose tube i.e. 20 D. (where D is the outside dia of the loose tube). This test is to be repeated 4 times on the same sample length of the loose tube.

Requirement: No damage or kink should appear on the surface of the tube. 16.0 DRAINAGE TEST FOR LOOSE TUBE

Sample Size: 30 cm tube length. Test Procedure: 1. Cut the tube length to 40 cm 2. Fill the tube with the tube filling gel ensuring there are no air hubbies and the tube is completely full. 3. Place the filled tube in a horizontal position on a clean worktop and cut 5 cm from each end so that

the finished length of the sample is 30 cm. 4 . Leave the filled tube in a horizontal position at an ambient temperature for 24 hrs. (This is necessary

because the gel has been sheared and the viscosity has been reduced during the filling process).

5 The sample tube is then suspended vertically in an environment heat oven, over a weighted beaker. It is left in the oven at a temperature of 700C for a period of 24 Hrs.

6 At the end of the 24 Hrs period the beaker is checked and weighted to see if there is any gel in the Beaker Requirement:

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1 If there is no gel or oil in the beaker the tube has PASSED the drainage test. 2 If there is gel or oil in the beaker the tube has FAILED the drainage test. CHECK OF EASY REMOVAL OF SHEATH: Check of the easy removal of sheath of the optical fibre cable by using normal sheath removal tool. To check easy removal: The sheath shall be cut in circular way and about 300 mm lengths of the sheath

should be removed in one operation. It should be observed during sheath removal process that no undue extra force is applied and no component part of the cable is damaged. One should be able to remove the sheath easily.

Note:- Easy removal of both the outer jacket and the inner sheath shall be checked separately. EFFECT OF AGGRESSIVE MEDIA ON THE CABLE SURFACE (ACIDIC AND ALKALINE

BEHAVIOR): To check the effect of the aggressive media. Solution of PH4 and PH10 shall be made. The two test

samples of the finished cable each of 600 mm in length are taken and die ends of the Samples are sealed. These test samples are put in the PH4 and PH10 solutions separately. After 30 days these samples are taken out from the solutions and examined for any corrosion etc. on the sheath and other markings of the cables. (Test method No. ISO 175).

Requirement: The sample should not show any effect of these solutions on the sheath and other

marking of the cable. 17.0 OPTICAL FIBRE CABLE LAYING

17.1 The Contractor shall determine a suitable cable installation method to ensure that all cable installation requirements shall be met in all conduit sections. All work shall be carried out in accordance and consistent with the highest standards of quality and craftsmanship in the communication industry with regard to the electrical and mechanical integrity of the connections, the finished appearance of the installation as well as the accuracy and completeness of the documentation.

17.2 The scope of installation of OFC shall include all that is necessary to lay the optical Fibre cable in the

same trench as the pipeline and it shall be generally as described below:- Route survey to collect cable routing information such as crossing of railways, roads, nala, rivers etc,

and requirements of any local detours etc., and also to determine the exact length of cable required. Vendor shall obtain the cable as per the requirement (based on survey conducted by the vendor).

i) Laying of optical fibre cable along the pipeline in the same trench as that of the pipeline including

crossing of railways, roads. Nala, rivers etc and splicing jointing, earthing (as required) along with all associated cabling work. The cable laying shall be by Compressed air blowing method. Necessary tools and tackles for cable laying shall be arranged by the Contractor

The cable shall be laid at level approx. depth of 1.6m from ground level. ii) Laying of optical fibre cable within the terminals/Repeater station areas where telecom cable leaves the

pipeline trench and is required to be laid in a separate trench up to the control building cabinets (Telecom room).

Sealing of the cable ends as required to prevent moisture ingress. iii) Warranty & guarantee for performance of the laid cable. iv) Transit & storage insurance of all materials (cable & accessories) till the System is fully handed over v) Provision of necessary power supply at site for the splicing etc.

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18.0 THE SCOPE OF WORK FOR LAYING

The cable in the same trench as the pipeline shall be as follows:- Trench excavation in pipeline trench, as needed. Laying bed preparation. Laying the HDPE pipe. Installation of cable in 50mm outer dia mm, HDPE pipe. The HDPE pipes shall be suitable to withstand

a load of 10 kg/cm. All HDPE duct couplers shall be of Fusion type only. Procurement and supply of any other materials required for laying jointing & end sealing of cable

including jointing-pit. splice-closures. cable-markers, sand, bricks, HDPE pipe etc. SUPPLY OF CABLE ROUTE SHEET The Contractor shall survey the cable route and prepare cable route sheers on the basis of the pipeline

route sheets. For the sections where the cable route may leave the pipeline route, the contractor shall make a proper

topographic survey to define the route and to determine what could interfere with the installation. The contractor shall thereafter prepare a cable route sheet with proper scale showing all the crossings and topographic details as needed to define the route and its characteristics.

Where service crossing exists, in addition to the general guidelines stated in this specification, the

Contractor shall follow all the particular requirements of the purchaser. 19.0 CABLE PROTECTION DURING INSTALLATION

19.1 The Contractor shall comply with the cable manufacturer's recommended installation procedures at all times.

19.2 To reduce the possibility of damage to the outer jacket of the fiber optic cable protective measures shall

be used when the cable is installed. The requirements herein shall be renewed, but does not limit the installation to only those identified. The purpose of the installation specifications is to ensure protection of the fibre optic cable when it is installed. Other protective measures not specified herein may be taken during installation if it will ensure protection of the cable.

19.3 A cable feeder guide shall be used between the cable reel and the face of the duct and conduit to

protect the cable and guide it of the reel and into the duct. 19.4 Precautions shall be taken during installation to prevent the cable from being kinked, crushed or twisted.

A pulling eye shall be attached to the cable end and be used to pull the cable through the duct and conduit system. As the cable is pulled off the reel and into the cable feeder guide, it shall be lubricated with a lubricant that shall be of the water based type and approved by the cable manufacturer.

19.5 Crushed or kinked cable shall be replaced with new cable. 19.6 Dynamometers or breakaway pulling swings shall be used to ensure the pulling line tension does not

exceed the installation tension values specified by the cable manufacturer. The mechanical stress placed upon the cable during installation shall not be such that the cable is twisted and stretched. Maximum allowable cable strain during: installation shall be less than 0.75%.

20.0 CABLE LAYING PROCEDURE

20.1 TRENCH EXCAVATION The trench shall be enlarged at the splicing points as needed to carry out the splicing works. The

enlargement shall be carried out on the same side of the cable for the entire route.

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20.2 LAYING BED PREPARATION (IN CASE OF SEPARATE TRENCH AT TERMINALS AND

REPEATERS) All works concerning the preparation of the laying bed shall be carried out by the contractor. The laying bed of 10cm depth shall be made of sand or riddled earth obtained by passing through a

sieve having meshes not exceeding 15 mm2, or of a natural soft around not requiring riddling. 20.3 CABLE LAYING All works concerning the cable laying shall be earned out by the Contractor. Vendor shall plan the cable-laying operation such that the complete drum-length of cable can be laid

without cutting in-between. The cable can be laid using a mobile reel system or a fixed reel system in relation to the characteristics

of each section (excavation partially open, crossings, etc.) The cable shall be carefully inspected for jacket defects as it is removed from the reel. If defects are

noticed, the pulling operation shall be terminated immediately and the CONSTRUCTION MANAGER (SITE-INCHARGE) notified.

The contractor shall establish section by section the ways and means for the cable laying taking into

account the characteristics of the layout. Extra cable at jointing locations & termination points. In all jointing locations. Including the normal joint at the end of the drum length and also at points of

cable-cuts due to laying necessities, at least one of cable From each end of the cables at the joint location shall be left in a coiled form in the pit to allow for splicing and jointing of the cable.

At all telecom building locations (including terminals and intermediate stations) an extra length of about

20meter of each cable shall be kept in a coiled form. Vendor shall provide the necessary cable leading pipes for cable(s) entry inside the telecom room. All

these leading-in-pipes shall be properly scaled to prevent entry of rodents, snakes, insects and foreign materials. At locations where the telecom room shall not be available. the extra length of the cable shall be kept buried in ground near the proposed telecom room location.

If the splicing or termination operation does not follow immediately after the cable laying, all cable ends

must be sealed carefully with heat-shrinkable end-caps. To accommodate long continuous installation lengths, bi-directional "center pull" techniques for pulling

of the fiber optic cable is acceptable and shall be implemented as follows: From the midpoint pull the fibre optic cable into the conduit from the shipping reel in accordance with

the manufacturer's specifications. When this portion of the pull is complete. the remainder of the cable must be removed from the reel to

make the inside end available for pulling in the opposite direction. This is accomplished by hand pulling the cable from the reel and laying into large "figure eight”. Loops

on the grouted. The purpose of the figure eight pattern is to avoid cable tangling and kinking. This loops shall be laid carefully one upon the saber (to prevent subsequent tangling) and shall be in a

protected area. The inside reel end of the cable is then available for installation.

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In some cases, it may be necessary to set up a winch at an intermediate cable vault. The required length of cable shall be pulled to that point, and brought out of the cable vault and coifed

into a figure eight. The figure eight is then turned over to gain access to the tree cable end. This can then be reinserted

into the duct system for installation into the next section. When power equipment is used to install libel optic cables, the pulling speed shall not exceed 30 meters

per minute. The pulling tension, bending radius and twist limitation for fiber optic cable shall not be exceeded under any circumstances.

Large diameter wheels, pulling sheaves. and cable guides shall be used to maintain the appropriate

bending radius. Tension monitoring shall be accomplished using commercial dynamometers or load-cell instruments.

The pulling eye/sheath termination hardware on the fiber optic cables shall not be pulled over any

sheave blocks Under no condition shall FOC be left exposed or unattended. Repairs: Repair of cable jacket shall not be permitted. Jacket damage shall require removal and re-

installation of a new cable run at the Contractor's expense. 21.0 LUBRICATION

As the cable is pulled into the conduit system, it shall be sufficiently lubricated with a lubricant that shall be the water-based type and approved by the cable manufacturer, Lubricant shall be applied at a rate to provide a continuous 10-mil coating, as recommended by the manufacturer.

22.0 JOINTING / INSTALLATION AT PULL BOXES

The pulling of the cable shall be hand assisted at each handhole or pullbox. The cable shall not be crushed, kinked or forced around a sharp corner. Sufficient slack shall be left at each end of the cable to allow proper cable termination.

The extra length of fiber optic cable shall be coiled and secured with cable tics in the pullbox. The

Contractor shall ensure that the minimum heading radius of the fibre optic cable is not compromised when preparing this stored cable slack.

Imprinted plastic coated cloth identification f warding tags shall be securely attached to the cables in at

least two locations in each handhole. When all cables at each pullbox are securely racked, unused conduits and void area around conduit

containing cables shall be sealed. The joint enclosure shall support an optical fibre organizer and allow sealing-off the outer sheaths of the

cable. Vendor shall provide detailed procedure for jointing of the cable along with the details of the jointing pits

to be used for housing the joint enclosure and the excess cable after jointing. Splicing loss shall not be more than 0.7db/Splice. 23.0 CROSSING

23.1 Cable laying for rail, road. Canal & river crossings shall be through a min. 50 mm outer with HDPE pipe, provided as part of the pipeline laying. An additional pulling rope shall be kept inside to meet future requirements.

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After installation the casing pipe shall be cleaned inside of any kind of dirt. stones, etc. Bituminised jute

shall be used to close the ends of the conduit to prevent any dirt deposit. Similarly, Bituminised jute shall be used to close the conduits ends after introduction of the cable.

23.2 CROSSING OF UNDERGROUND SERVICES Where crossing of existing underground pipelines and cables, pipes on sleepers, etc. occur, the same

requirements for normal laying shall apply, the cable maintaining the normal position with respect to the pipeline.

24.0 BACKFILLING & TESTING

24.1 BACKFILLING PROCEDURE Above the laid cable, a cover of 75 mm minimum depth of sand or riddled earth or of natural earth not

requiring riddling (as stated elsewhere) shall be provided. Such an operation shall be under the responsibility of the contractor.

Above this cover a single layer of second-class brick shall be laid in a transverse manner over the cable

laid in the trench. The bricks shall be fully soaked in water before being laid in the trench. There shall be minimum seven bricks per meter laid with uniform spacing over the length of the laid

cable. A warning mat made of PVC sheet of red colour and 150 mm, 0.1 mm size shall be laid over the cable. Thereafter the trench shall be backfilled with the excavated earth. Normally, no mechanical protection shall be provided on the cable except at spiking points and rocky

areas and as stated in particular cases. The joints, relevant cable rings and other underground constructions shall be protected by bricks or

concrete slabs to be supplied by the vendor. At the splicing points, the contractor shall also take care to backfill the trench and to restore the relevant

area and to repair any damaged works. 25.0 HDPE CONDUIT

25.1 Design, Engineering, Manufacture, Testing and supply of solid lubricated HDPE conduit, HDPE conduit couplers. End plugs, cable staling plugs and end caps for sealing conduits.

25.2 Furnish complete technical literature and documentation. 25.3 Quality Assurance and Testing as described at Clause 30.0, to the complete satisfaction of the

Owner/Owner's representatives &/or third appointed agency. 26.0 STANDARDS APPLICABLE

The materials provided shall conform to the latest editions of standards like IS, TEC etc: In case of any conflict between the above standards and the specifications, the matter shall be referred

to Owner/Owner's representatives. Vendor shall proceed with design of the HDPE conduit only after obtaining clarifications from

Owner/Owner's representative in all such cases.

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27.0 APPROVAL OF DOCUMENTS

The Vendor / Contractor shall be completely responsible for the successful completion of the job. However, to ensure good quality of workmanship. As also of the uttered system, vendor shall prepare and submit the documents to be approved by the Owner/Owner's representatives. Vendor shall proceed with the manufacture / procurement / installation of the respective materials and/or equipment only after obtaining the necessary approval from the Owner/Owner's representatives.

28.0 GENERAL GUIDELINES

Vendor shall be a regular manufacturer of the type of solid lubricated HDPE conduit offered for this project & the type of solid lubricated HDPE conduit construction offered shall be field proven. Owner/Owner's representatives reserves the right to verify the field proven-ness of the offered type of solid lubricated HDPE conduit at any time during the execution of the project.

Vendor shall be totally responsible for the offered solid lubricated HDPE conduit. In the event any

modifications in the specifications included in the Bid document are warranted. He shall clearly spell out all such requirements at the time of submission of his offer. It shall be expressly understood that the specifications provided herein are given as presently envisaged to meet the design objectives, In case of construction changes in addition to the listing and providing justification to the same in the deviation form, bidder to provide successful field proven-ness certificate (for more than 6 months, before hid due date) from end user for the same.

Owner/Owner's representatives reserve the right to modify/revise/alter the specifications provided

herein prior to acceptance of any offer. During the course of execution of the work any discrepancy or inconsistency. Error or omission in any of

the provisions of the contract is discovered; the same shall be referred to die Owner's representatives who shall give his decision in the matter and issue instruction directing the manner in which the work is to be carried out. The decision of the Owner/Owner’s representatives shall be final and conclusive and the contractor shall Carry out the work in accordance therewith.

29.0 SOLID PERMANENTLY LUBRICATED PIPE CONDUIT

The bidder shall be totally responsible for the desired performance of the offered solid lubricated HDPE conduit including design, engineering, manufacture, testing and supply.

The intent of the following specifications is to establish the minimum requirements and guidelines for the

solid lubricated HDPE conduit and associated items offered for this project. 29.1 TECHNICAL SPECIFICATIONS OF SOLID LUBRICATED HDPE CONDUIT Solid lubricated HDPE conduit shall be of l km drum length (nominal). The HDPE conduit shall be

permanently Iubricated with an inner layer of solid permanent lubricant continuous throughout its length co-extruded during the manufacturing process to minimize internal co-efficient of friction.

The HDPE conduit shall have smooth surfaces and shall be free from defects. Break, Shrink holes,

flaking, and chips. Scratches, Roughness &. Blisters HDPE conduit shall be supplied in orange colour and one colour shall be maintained throughout its

drum length. HDPE conduit shall follow the following specifications as a minimum: Outer diameter. 50mm Pressure rating 6 kg/cm2 Melt flow index 0.2 to 1.1 gms. Per 10 min. At 190"

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(As per IS: 2530-1963) under 5 kg load Density 940 to 958 kg/m3 at 27° C (As per IS: 7328:1992) Tensile strength & elongation20 N/mm2 (min) 350% (min.) [As per 14151 (part-l )] Impact strength There should be no crack or split [As per IS: 12235 (Part-9) – 1986 & C/CDS-08/01)] HDPE conduit shall also conform to the following specifications: IS: 7328. IS: 4984 ASTM:D-1963 HDPE Conduit Identification The outer surface of the conduit shall be permanently & legibly marked with colour in contrast to the

outer sheath of the cable at regular intervals not exceeding one meter with name of client name of manufacturer part number.

29.2 HDPE conduit couplers, end plugs. Cable sealing plugs, end caps for scaling conduits shall be suitable

for 50 mm OD HDPE conduit. Joint of HDPE conduit shall be by fusion type HDPE duct coupler. 29.3 SOLID LUBRICATED HDPE CONDUIT TESTS Following sample tests shall be conducted on three randomly selected solid lubricated HDPE conduits

drums. These shall be tested as per the latest edition of TEC standard for Permanently lubricated HDPE ducts for use as underground optical fiber cable conduits.

Visual Inspection Impact strength Crush resistance Quality test Coil test Hydraulic characteristics Internal co-efficient of friction In case solid lubricated HDPE conduit. Tested and inspected in accordance with this specification. Fail

to pass the test or comply with the specification requirement, the tests shall he repeated on a further representative sea of conduit pieces. And if it again fails, the whole lot shall be rejected subject to the discretion of the Owner/Owner's representatives.

Bidder shall provide detailed test procedures for each of the above mentioned tests after award of contract for approval and the tests shall be conducted as per approved procedures.

30.0 PACKING

All drums shall be individually packed to avoid damage during transit and storage in accordance with best commercial practice and with the requirements of applicable. Specifications. The materials used for packing, wrapping, sealing etc. shall be of recognized brands and shall conform to best standards in the areas in which the articles are packaged. This packing shall protect the HDPE conduit from impact. Vibration, rough handling, rodents, etc.

The minimum-bending diameter of the coiled duct shall be 25 times the outer diameter of the duct. Each drum shall have a copy of factory acceptance test report enclosed in it.

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31.0 QUALITY ASSURANCE PROGRAMME & TESTING

QUALITY ASSURANCE PROGRAMME The bidder shall submit QA/QC procedures and inspection plan for Owner/Owner's representative

review and approval before manufacturing the solid lubricated HDPE conduit. Manufacturing by the vendor and inspection by owner/owner's representative shall be in accordance with the approved QA/QC procedures and inspection test plan.

32.0 SUMMARY OF REQUIREMENT

SL.No. ITEM DESCRIPTION QUANTITY (Kms) LOCATION 1. 2. 3. 4.

24 Fibres Single Mode Optical Fibre Cables

24 Fibres Single Mode Optical Fibre

Cable. 24 Fibres joint enclosure/joint kit or

Pullboxes. HDPE conduit for Above optical fibre

cable.

(Note-1) Main pipeline (Note-1) Spurlines (Note-2) -Main pipeline -Spurline.

Note : 1) Length indicated above is the approx. length of the pipeline, Bidder has to estimate actual requirement of the cable. & HDPE conduit based on routine and other requirements. Note: 2) Quantity to be decided by Contractor during detail engineering based on drum length, actual cable length, no. of crossings etc. Vendor to furnish brochures, catalogue / technical literature, track record & drawings for all items supplied under this package.

33.0 LIST OF ABBREVIATIONS

ASTM - American Society for Testing and Materials FRP - Fibre Reinforced Plastic HDPE - High Density Polyethylene IEC - International Electra -Technical Commission ISO - International Standard Organizations ITU-T - International Telecommunication Union- Transmission KV - Kilo Volt MFD - Mode Field Diameter OF - Optical Fibre OTDR - Optical Time Domain Reflectometer QA - Quality Assurance QM - Quality Manual RMS - Route Mean Square UV - Ultra Violet KM - Kilometer dB - decibel Ps/nm - pica second/nanometer nm - nanometer um - micrometer Gpa - Gega Pascal

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SMOF - Single Mode Optical Fibre Ps - Pico second °C - Degree Celsius N - Newton EIA - Electronic Industry Association KPSI - Kilogram per sq. inch F - Force TEC - Telecommunication Engineering Centre

34.0 LIST OF DOCUMENTS REFERED

Specification for environmental Testing Specification for Optical Joint Closure Specification Protection Sleeve Raw Material Colour Standards ITU-T Recommendation Generic requirement for optical Fibre cable(Bell core) Test Method: EEC 811-5-I 11~C 794-1-El MC 794-1.-E2 IEC 794-1-E3 EEC 794-i-E4 IEC 794-1-E7 IEC 794-1-MP IBC 794-1-El I EEC 794-1-Fl IEC 794-1-F3:: IEC 794-l-F5 TEC 455-104 EIS. / TIA - 455-181 Instructions To Bidder’s: - (1) The Bidder Shall Submit Clause Wise Compliance To The Tender Specifications Including Clauses

Pertaining To Inspection, Sampling. Rejection. Factory Acceptance Testing And Purchaser's Note. (2) The Bidder Shall Submit A Copy Of All -Tie Specifications Sheets Duly Signed And Stamped On

Each Page By Authorized Signatory (3) The Bidder Shall Submit The List Of The Customers Where The Bidder Has Already Supplied Tile

Optical Fibre Cable Along With The Performance Report From The End User's. The Bidder Shall Also Furnish The Record Specifying The Quantity Of The 'Cable Supplied Along With The Date Of Supply.

(4) The Bidder Shall. Submit Approval Certificate From Telecommunication Engineering Centre (Tec)

For Manufacturing Of Optical Fibre Cables. (5) The Bidder Shall Also Submit The Proof Of The Manufacturing Capacity Of The Optical Fibre

Cable. This Shall Be Supported By The Certificate From The Tec. The Bidder Shall Specify The Time Within Which The Cable Shall Be Supplied

(6) The Bidder Shall Furnish The Cross Sectional Drawing Of The Offered Optical Fibre Cable. (7) The Cable Should Undergo All The Acceptance. Routine & Optional Tests As Marked Above To

Meet The Purchaser's Specific Requirement. (8) All The Details Of Manufacturing 1 Test Equipment' Available Alongwtth Their Make / Type Eke

Should Be Furnished Alongwith The Bid. Also The Current Order Booking/ Loading Should Be Furnished By The Vendor.

(9) The Cable Shall Be Packed And Supplied Stationwise In (As Per The Summary Of Requirement)

Drums According To Standard Practice To Avoid Any Damage During Transit And Handling At Site. (10) Vendor Shall Supply 6 Sets Of Test Certificates Before Despatch Of Ti Ie Material.

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(11) The Cables Are Subjected To Purchaser's Inspection At Vendors Works Prior To Despatch. (12 )Before Final. Inspection By Owner/Owner's Representative, The Bidder Shall Carry Out The In-

House Inspection On The Finished Cables And Submit The Results For Owner's Review. The Tests During The In-House Inspection And The Final Inspection Shall Be As Per The Codes And Procedures Defined In The Specifications. The Sample Size For Such Inspection Shall Be Minimum 10 % Of The Ordered Quantity, Also, During Inspection All The Tests Shall Be Carried Out On The Same Sample. The Owner May Also Carry Out The Optical Tests During Final Inspection. The Bidder Shall Be Equipped With The Equipment / Machinery To Conduct Such Tests.

(13) The Bidder Shall Submit Qa/Qc Procedures And Inspection Plan' For Owner's Review And

Approval. Before Manufacturing The Cables. Manufacturing By The Vendor And Inspection By Owner's Representative Shall Be Carried Out Tn Accordance With The Approved Qa/Qc Procedures And Inspection Plan.

(14) The Bidder Shall Also Submit The Test Results Of The Optical Tests To Be Conducted On Tile

Fibres Of The Cable The Same Shall Be Submitted For Owner's Review Before Carrying Out The Final Inspection.

(15) The Bidder Shall Take The Otdr Traces For Each Fibre And Every Cable And Submit The Same

For Owner's Record Before Final Inspection. (16) Cable Drum Should Be Marked Properly. (17) In Case, No Deviation/Exceptions To This Specifications Are Mentioned, It Shall Be Taken As

Granted That Vendor Agrees To The Customer's Specification Requirements. (18) Vendor Shall Offer Optical Fibre Cable In Line With The Specific Requirements Given Above.

HEALTH, SAFETY & ENVIRONMENT

GAIL GAS LIMITED


CLIENT JOB NO. - STANDARD SPECIFICATION FOR HEALTH, SAFETY AND ENVIRONMENT (HSE) MANAGEMENT AT CONSTRUCTION

SITES TOTAL SHEETS 37

DOCUMENT NO 11 0290 02 18 02 001





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1.0 SCOPE

This specification establishes the health, Safety and environment (HSE) management requirement to be complied by Contractors during construction.

Requirements stipulated in this specification shall supplement the requirements of HSE management given in relevant Act (s)/legislations, General Conditions of Contract (GCC), Special Conditions of Contract (SCC) and Job (Technical) Specifications. Where different documents stipulate different requirements, the most stringent shall apply.

2.0 REFERENCES The document should be read in conjunction with following: - General Conditions of Contract (GCC)

Special Conditions of Contract (SCC) Building and other construction workers (regulation of employment and condition of service) Act,1996 Job (Technical) specifications Relevant IS Codes refer Annexure-I) Statutory requirements

3.0 REQUIREMENTS OF HEALTH, SAFETY & ENVIRONMENT (HSE) MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS

3.1 MANAGEMENT RESPONSIBILITY

3.1.1 HSE Policy & Objectives

The Contractor should have a documented HSE policy & objectives to demonstrate commitment of their organization to ensure health, safety and environment aspects in their line of operations.

3.1.2 Management System

The HSE management system of the Contractor shall cover the HSE requirements including but not limited to what is specified under para 1.0 and para 2.0 above.

3.1.3 Indemnification

Contractor shall indemnify & hold harmless Owner/Consultant & their representatives free from any and all liabilities arising out of non-fulfillment of HSE requirements.

3.1.4 Personnel deployment

Contractor as a minimum requirement shall designate/deploy the following persons at site: a) Up to 250 persons - Designate one safety supervisor deployed by him at site b) For 251 to 500 persons - Deploy one qualified & \Experienced safety Engineer/Office in addition to Deployed by him at site the Safety Supervisor as described in (a) above. c) For more than 500 persons - Deploy an additional Safety

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Engineer/ Officer for every 500 Persons or part deployed by him at site thereof, in addition to (b) above. No work will be started at site until above safety personnel are mobilized at site. The contractor shall submit a safety organogram clearly indicating the lines of responsibility, reporting system and furnish Bio-Data/Resume/Curriculum Vitae with contact details of the safety personnel he intends to mobilize, at least 1 moth before the intended mobilization.

3.1.5 Implementation & Monitoring

Contactor shall be fully responsible for planning, implementing and monitoring all HSE requirements and compliance of all laws & statutory requirements. The Contractor shall also ensure that the HSE requirements are clearly understood & faithfully implemented at all levels at site.

3.1.6 Awareness

The Contractor shall promote and develop consciousness about Health, Safety and Environment among all personnel working for the Contractor. Regular awareness programs and fabrication shop/work site meetings shall be arranged on HSE activities to cover hazards involved in various operations during construction.

3.1.7 Fire prevention & First-aid

The contractor shall arrange suitable first aid measures such as First Aid Box (Refer Annexure-II for details), trained personnel to administer First Aid, stand-by ambulance or vehicle and install fire protection measures such as: adequate number of steel buckets with sand & water and adequate number of appropriate fire extinguishers (Refer Annexure-III for details) to the satisfaction of OWNER/CONSULTANT.

3.1.8 Documentation

The contractor shall evolve a comprehensive, planned and documented system for implementation and monitoring of the HSE requirements. This shall be submitted to OWNER/CONSULTANT for approval. The monitoring for implementation shall be done by regular inspections and compliance to the observations thereof. The Contractor shall get similar HSE requirements implemented at his sub-contractor(s) work site/office. However, compliance of HSE requirements shall be the responsibility of the Contractor. Any review/approval by OWNER/CONSULTANT shall not absolve contractor of his responsibility/liability in relation to all HSE requirements.

3.1.9 Audit

Non-Conformances on HSE by Contractor (including his sub-contractors) as brought out during review/audit by his internal audit team as well as OWNER/Consultant’s representative shall be resolved forthwith by Contractor. Compliance report shall be submitted to OWNER/CONSULTANT.

3.1.10 Meetings

The Contractor shall ensure participation of his top most executive at site (viz. Resident Engineer/Site-in-Charge) in Safety committee/HSE Committee meetings arranged by OWNER/CONSULTANT. The compliance of any observations during the meeting shall be arranged urgently. He shall assist OWNER/CONSULTANT to achieve the targets set by them on HSE during the project implementation.

3.1.11 The Contractor shall adhere consistently to all provisions of HSE requirements. In case of non-

compliance or repeated failure in implementation of any of the HSE provisions;

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OWNER/CONSULTANT may impose stoppage of work without any cost & time implication to the Owner and/or impose a suitable penalty, up to a cumulative limit of 1.0% (one percent) of the contract value with a ceiling of Rs.10 lacs (Rupees Ten Lacs only). This penalty shall be in addition to all other penalties specified elsewhere in the contract. The decision of imposing stoppage work, its extent and penalty shall rest with OWNER/CONSULTANT. The same shall be binding on the Contractor. The penalty does not make the contractor eligible to continue the work in unsafe manner.

3.2 HOUSE KEEPING

3.2.1 Contractor shall ensure that a high degree of house keeping is maintained and shall ensure interalia;

the following:

All surplus earth and debris are removed/disposed off from the working areas to identified location(s). Unused/surplus cables, steel items and steel scrap lying scattered at different places within the working areas are removed to identified location(s). All wooden scrap, empty wooden cable drums and other combustible packing materials, shall be removed from work place to identified location(s). Roads shall be kept clear and materials like pipes, steel, sand, boulders, concrete, chips and bricks etc. shall not be allowed on the roads to obstruct free movement of men & machines. Fabricated steel structural, pipes & piping materials shall be stacked properly for erection.Water logging on roads shall not be allowed. No parking of trucks/trolleys, cranes and trailors etc. shall be allowed on roads, which may obstruct the traffic movement. Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the working areas. Trucks carrying sand, earth and pulverized materials etc. shall be covered while moving within the plant area/or these materials shall be transported with top surface wet. The contractor shall ensure that the atmosphere in plant area and on roads is free from particulate matter like dust, sand, etc. by keeping the top surface wet for ease in breathing. At least two exits for any unit area shall be assured at all times.

3.3 HSE MEASURES

3.3.1 Construction Hazards

Contractor shall ensure that during the performance of the work, all hazards have been identified, assessed and eliminated. A list of construction hazards along with their effects & preventive measures is given in the Annexure-V.

3.3.2 Accessibility

The Contractor shall provide safe means of access to any working place including provisions of suitable and sufficient scaffolding at various stages during all operations of the work for the safety of his workmen and OWNER/CONSULTANT.

3.3.3 Personal Protective Equipments (PPEs)

The contractor shall ensure that all their staff and workers including their sub-contractor(s)’s have been issued & wear appropriate PPEs like safety helmets, safety shoes, safety belt, full body harness, protective goggles, gloves etc. All these gadgets shall conform to applicable IS Specifications/CE or other applicable international standards. For shot blasting, the usage of protective helmets (approved by the competent authority), gauntlet and protective clothing is mandatory. For offshore contracts, contractor shall provide PPEs (new) to CONSULTANT & Owner’s personnel at his (contractor’s) cost. All personnel shall wear life jacket at all time.

3.3.4 Working at height

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The contractor shall issue height permit for working above 3 meters height after verifying and certifying the checkpoints as specified in the attached permit. He shall also undertake to ensure compliance to the conditions of the permit during the currency of the permit including adherence to personal protective equipments. The permit shall be issued initially for one week or expected duration of an activity and extended further for the balance duration. This permit shall be applicable in areas where specific clearance from Owner’s operation Department/Safety Department is not applicable. CONSULTANT field Engineers/Safety Officers/Area Coordinators may verify and sign this permit during the execution of the job. In case work is undertaken without taking sufficient precautions as given in the permit, CONSULTANT Engineers may cancel the permit and strop the work till satisfactory compliance is arranged. Contractors are expected to maintain a register for issuance of permit and extensions thereof including preserving the used permits for verification during audits etc. Contractor shall arrange (at his cost) and ensure sue of Fall Arrester Systems by his workers. Fall arresters are to be used while climbing tall structures. These arresters should lock automatically against the anchorage line, restricting free fall of the user. The device is to be provided with a double security opening system to ensure safe attachment or release of the user at any point of rope. In order to avoid shock, the system should be capable of keeping the person in vertical position in case of a fall. Contractor shall ensure that Life Lines are used by all personnel while working at height. One end of the life line shall be firmly tied with the worker and the other end with a fixed and rigid structure. The life line should be strong enough to take the load of the worker in case of a fall. Contractor shall provide Roof Top Walk ladders for carrying out activities on sloping roofs in order to reduce the changes of slippages. Contractor shall ensure that a proper Safety Net System is used wherever the hazard of fall from height is present. The safety net shall be located not more than 9.0 meters below the working surface extending on either side up to sufficient margin to arrest or to reduce the consequences of a possible fall of persons working at different heights.

3.3.5 Electrical installations

The contractor shall ensure that electrical systems and equipment including tools and tackles are properly selected, installed, used and maintained. The contractor shall deploy qualified and licensed electricians for proper and safe installation and for regular inspection of construction power distribution lines/points including their earthing. A copy of the license shall be submitted to CONSULTANT for records.

3.3.6 Welding/Gas cutting

Contractor shall ensure that flash back arresters conforming to BS: 6158 or equivalent are installed on all gas cylinders while in use. All cylinders shall be mounted on trolleys. All welding machines shall have effective earthing. To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc Welding shall not contain Thorium.

3.3.7 Ergonomics and tools & tackles

The Contractor shall assign to his workmen, tasks commensurate with their qualification, experience and state of health. All lifting tools, tackles, equipment, accessories including cranes shall be tested periodically by statutory/competent authority for their condition and load carrying capacity. Valid test and fitness certificates from the authority shall be submitted to Owner/CONSULTANT for their review/acceptance before the lifting tools, tackles, equipment, accessories and cranes are used.

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Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes (while in use) to minimize overload risk. SLI shall have capability to continuously monitor and display the load on the hook, and automatically compare it with the rated crane capacity at the operating condition of the crane. The system shall also provide visual and audible warnings at set capacity levels to alert the operator in case of violations.

3.3.8 Occupational Health

The contractor shall identify all operations that can adversely affect the health of its workers and issue and implement mitigation measures. For surface cleaning operations, sand blasting shall not be permitted even if not explicitly stated elsewhere in the contract.

3.3.9 Hazardous substances

Hazardous and/or toxic materials such as solvent coating or thinners shall be stored in appropriate containers, which shall be labeled with the name of the materials, the hazards associated with its use and necessary precautions to be taken. Where contact or exposure of hazardous materials/Noise pollution exceeds the specified limit or otherwise have harmful affects, appropriate personal protective equipments such as gloves, earmuffs, goggles, aprons, chemical resistant clothing, respirator, etc. shall be used.

3.3.10 Spills

Chemical and other spills shall be contained and cleaned up immediately to prevent further contamination.

3.3.11 Radiation exposure

a) All personnel exposed to physical agents such as non-ionizing radiation, ultraviolet rays

or similar other physical agents shall be provided with adequate shielding or protection commensurate with the type of exposure involved.

b) For ionizing radiation, requirements of Bhabha Atomic Research Centre (BARC) shall be followed.

3.3.12 Road Safety

The contractor shall ensure adequately planned road transport safety management system. The vehicles shall be fitted with reverse warning alarms. The contractor shall also ensure a separate pedestrian route for safety of the workers and comply with all traffic rules and regulations. For pipeline jobs, the contractor shall submit a comprehensive plan covering transportation of pipes, movement of side booms, movement of vehicles on the ROW, etc.

3.3.13 Welfare measures

Contractor shall at the minimum, ensure the following facilities at work sites :

A crèche where 10 or more female workers are having children below the age of 6 years.

Reasonable canteen facilities at appropriate location depending upon site conditions.

Rest rooms (separate for male workers and female workers) Toilets, drinking water, adequate lighting at site and labour camps, commensurate with applicable

Laws/Legislation.

3.3.14 Environment Protection

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Contractor shall ensure proper storage and utilization methodology of materials that are detrimental to the environment. Where required, contractor shall ensure that only the environment friendly materials are selected and emphasize on recycling of waste materials such as metals, plastics, glass, paper, oil and solvents. For pipeline jobs, top soil shall be stacked separately while making ROW through fields. This fertile soil shall be placed back on top after backfilling.

3.3.15 Rules & Regulations

All persons deployed at site shall be knowledgeable of and comply with the environmental laws, rules and regulations relating to the hazardous materials, substances and wastes. Contractor shall not dump, release or otherwise discharge or dispose off any such materials without the express authorization of OWNER/CONSULTANT.

3.4 TOOL BOX MEETING (TBM)

Contractor shall conduct daily TBM with workers prior to start of work and shall maintain proper record of the meeting. A suggested format is given below. The TBM is to be conducted by the immediate supervisor of the workers.

TOOL BOX MEETING RECORDING SHEET

Date & Time Subject Presenter Hazards Involved Precautions to be taken Worker’s Name Signature Section Remarks, if any

The topics during TBM shall include:

Hazards related to work assigned on that day and precautions to be taken. Any forthcoming HSE hazards/events/instruction/orders, etc.

The above record can be kept in local language, which workers can read. These records shall be made available to OWNER/CONSULTANT whenever demanded.

3.5 TRAINING

Contractor shall ensure that all his personnel possess appropriate training to carryout the assigned job safely. The training should be imparted in a language understood by them and should specifically be trained about.

Potential hazards to which hey may be exposed at their workplace Measures available for prevention, recurrence and elimination of these hazards

The topics during training shall cover, at the minimum:

Education about hazardous jobs and precautions required Emergency and evacuation plan HSE requirements Fire fighting and First-Aid

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Use of PPEs Records of the training shall be kept and submitted to OWNER/CONSULTANT whenever demanded. For off-shore and jetty jobs, contractor shall ensure that all personnel deployed have undergone structured training on swimming, use of lifeboats, basket landing, etc.

3.6 INSPECTION/AUDIT

The contractor shall carry out daily HSE inspection and record observations at a central location. These inspection records shall be freely accessible to Owner/CONSULTANT representatives. He shall also carry out internal HSE audits as well as cooperate during HSE audits by Owner/CONSULTANT, which will be at least two times during the project execution period.

4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR

4.1 ON AWARD OF CONTRACT

The Contractor shall submit a comprehensive Health, Safety and Environment manual or procedure and HSE Plans for approval by OWNER/CONSULTANT prior to start of work. The Contractor shall participate n the pre-start meeting with OWNER/CONSULTANT to finalize HSE Plans including the following:

Job procedure to be followed by Contractor for activities covering handling of equipments,scaffolding, electric installations, etc. describing the risks involved, actions to be taken and methodology for monitoring each activity. OWNER/CONSULTANT review/audit requirement. Organization structure along with responsibility and authority, records/reports etc. on HSE activities. Procedures for reporting and investigation of accidents and near misses HSE Training programmes. Reference to Rules, Regulations and Statutory requirements. HSE reports.

4.2 DURING JOB EXECUTION

4.2.1 Contractor shall implement approved Health, Safety and Environment management procedure/plan/manual including but not limited to as brought out under para 3.0. Contractor shall also ensure :

to arrange workmen compensation insurance, registration under ESI Act, third party liability insurance etc., as applicable to arrange all HSE permits before start of activities (as applicable), like permits for hot work, confined space, working at heights, storage of chemical/explosive materials and its use and implement all precautions mentioned therein. In this regard, requirements of Oil industry Safety Directorate Standard No. Std-105 “Work Permit Systems” shall be complied with while working in existing plants.

to submit, timely, the completed checklist on HSE activities Monthly HSE report, accident reports, investigation reports etc. as per OWNER/CONSULTANT requirements. Compliance of instructions on HSE shall be done by Contractor and informed urgently to OWNER/CONSULTANT.

That his top most executive at site attends all the Safety Committee/HSE meetings arranged by OWNER/CONSULTANT. Only in case of his absence from site that a second senior most person shall be nominated by him, in advance, and communicated to OWNER/CONSULTANT.

Display at site office and work locations caution boards, list of hospitals, emergency services available, etc.

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SHEET 9 OF 37

Provide posters, banners for safe working to promote safety consciousness.

Assess, analyze and mitigate the construction hazards. Carryout audits/inspection at his works as well as sub contractor works as per approved HSE document and submit the reports for OWNER/CONSULTANT review. Assistance and cooperation during HSE audits by OWNER/CONSULTANT, and submit compliance report. Generation and submission of HSE records/report as per HSE Plan. And this specification. Apprise OWNER/CONSULTANT on HSE activities at site. Carryout all dismantling activities safely, with prior approval of OWNER/CONSULTANT representative.

1.0 RECORDS

The contractor shall maintain/submit HSE records in the following reporting formats: 1. Monthly HSE checklist cum compliance report Accident/Fire report Supplementary Accident & Investigation report 2. Monthly HSE report 3. Permit for working above 3 mete height 4. HSE Plan

IS – CODES FOR HSE

SP:53 Safety code for the use, Care and protection of hand operated tools. IS: 816 Code of practice for safety and health requirements in electric and gas

welding and cutting operations IS: 1179 Eye and Face precautions during welding, equipment etc. IS: 1860 Safety requirements for use, care and protection of abrasive grinding

wheels. IS: 1989(Part–I & II) Leather safety boots and shoes IS: 2925 Industrial Safety Helmets IS: 3016 Code of practice for fire safety precautions in welding and cutting

operations. IS: 3043 Code of practice for earthing. IS: 3521 Industrial Safety belts and harness. IS: 3738 Rubber boots. IS: 3996 Safety Code of scaffolds and ladders. IS: 4770 Rubber gloves for electrical purposes IS: 5216 (Part-I Recommendations on Safety procedures and practices in electrical works IS: 5557 Industrial and Safety rubber lined boots. IS: 5983 Eye protectors IS:6519 Selection, care and repair of Safety footwear IS: 6994 (Part-I) Industrial Safety Gloves (Leather & Cotton Gloves) IS: 7293 Safety Code for working with construction Machinery IS: 9167 Ear protectors IS: 11006 Flash back arrestor (Flame arrestor) IS:11016 General and safety requirements for machine tools and their operation IS: 11226 Leather safety footwear having direct moulded rubber sole IS: 11972 Code of practice for safety precaution to be taken when entering a

sewerage system IS: 13367 Code of practice-safe use of cranes IS: 13416 Recommendations for preventive measures against hazards at working

place

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SHEET 10 OF 37

ANNEXURE - II

DETAILS OF FIRST AID BOX SL.NO.

DESCRIPTION QUANTITY

1. Small size Roller Bandages, 1 inch wide (Finger Dressing small)

6 Pcs.

2. Medium size Roller Bandages, 2 inch wide (Hand and Foot Dressing)

6 Pcs.

3. Large size Roller Bandages, 4 inch wide (Body Dressing Large)

6 Pcs.

4. Large size Burn Dressing (Bun Dressing Large) 4 Pkts. 5. Cotton wool (20 gms packing) 4 Pkts. 6. Antiseptic Solution Dettol (100 ml.) or Savalon 1 Bottle 7. Mercurochrome Solution (100 ml.) 2% in water 1 Bottle 8. Sal-volatile (20 ml. Ammonia) 1 Bottle 9. A Pair of Scrissors 1 Piece 10. Adhesive Plaster (1.25 cm x 5 m) 1Spool 11. Eye pads in Separate Sealed Packet 4 Pcs. 12. Tourniqut 1 No. 13. Safety Pins 1 Dozen 14. Tine IODINE (100 ml.) 1 Bottles 15. Ointment for burns (Burnol 20 gms.) 1 Bottole 16. Polythene Wash cup for washing eyes 1 No. 17. Potassium Permanganate (20 gms.) 1 Pkt. 18. Tinc. Benzoine (100 ml.) 1 Bottole 19. Triangular Bandages 2 Nos. 20. Band Aid Dressing 5 Pcs. 21. Iodex (25 gms.) 1 Bottole 22. Tongue Depressor 1 No. 23. Boric Acid Powder (20 gms.) 2 Pkt. 24. Sodium Bicarbonate (20 gms.) 1 Pkt. 25. Dressing Powder (Nebasulf) (10 gms.) 1 Bottole 26. Medicinal Glass 1 No. 27. Duster 1 No. 28. Booklet (English & Local Language) 1 No. each 29. Soap 1 No. 30. Toothache Solution 1 No. 31. Eye Ointment 1 Bottle 32. Vicks (22 gms.) 1 Bottle 33. Forceps 1 No. 34. Cottom Buds (5 nos.) 1 Pkt. 35. Note Book 1 No. 36. Splints 4 Nos. 37. Lock 1 Piece 38. Life Saving/Emergency/Over-the Counter Drugs As decided at site NOTE : Type of Box

Size Aluminum 14” x 12” x 4”

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SHEET 11 OF 37

Annexure-III TYPES OF FIRE EXTINGUISHERS AND THEIR APPLICATION

CARBON

DIOXIDE

DRY CHEMICAL WATER TYPE FOAM

SODIUM POTASSIUM MULTI PURPOSE

BICARBONATE A B C

CO2 CARTRIDGE OPERATED

STORED PRESUR

E

STORED PRESSUR

E

CARTRIDGE

OPERATED

STORED PRESSU

RE

CARTRIDGE

OPERATED

WATER PUMP TANK

SODA

ACID

FOAM

CLASS A FIRES x x x _/ _/ _/ _/ _/ _/ _/ WOOD PAPER TRASH HAVING GLOWING EMBERS

(BUT CAN CONTROL MINOR

SURFACE FIRES) CLASS B FIRES _/ _/ _/ _/ _/ X X X X _/ FLAMMABLE

LIQUIDS GASOLINE OIL PAIN GRASE ETC. CLASS C FIRES _/ _/ _/ _/ _/ X X X X X ELECTRICAL EQUIPMENT

LEGEND : _/ : CAN BE USED

X : NOT TO BE USED

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SHEET 12 OF 37

ANNEXURE-IV

INDICATIVE LIST OF STATUTORY ACTS & RULES

Indian Explosives Act, 1984 The Motor Vehicles Act, 1988 The Factories Act, 1949 The Petroleum Act, 2002 Workmen Compensation ‘act Static/Mobile Pressure Vessel Act Indian Electricity Act Indian Boiler Act, 1923 Water (Prevention & Control Pollution) Act, 1974 Water (Prevention & Control of Pollution) Cess Act-1977 The Mines & Minerals (Regulation & Development) Act-1947 The Air (Prevention & control of Pollution) Act-1981 The Atomic Energy Act-1962 The Radiation Protection Rules-1971 The Indian Fisheries Act-1954 The Indian Forest Act-1927 The Wild Life (Protection) Act-1972 The Environment (Protection) Act-1986 The Environment (Protection) Rules-1986 The Hazardous Wastes (Management & Handling) Rules-1989 The Manufacture, Storage & Import of Hazardous Chemicals Rules-1989 The Central Motor Vehicles Rules-1989 The Building and Other Construction Workers (Regulation of Employment and Condition of Service) Act, 1996

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SHEET 13 OF 37

ANNEXURE-V

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES

ACTIVITY TYPE OF

HAZARD EFFECT OF

HAZARD PREENTIVE MEASURES

(A) EXCAVATION •

it Excavation up to 3.0m

Falling into pit

Personal injury

Provide guard rails/barricade with warning signal.

Provide at least two entries/exits.

Provide escape ladders. Earth

Collapse Suffocatio

n/ Breathlessness

Buried

Provide suitable size of shoring and strutting, if required.

Keep soil heaps away from the edge equivalent to 1.5m or depth of pit whichever is more.

Don’t allow vehicles to operate too close to excavated areas. Maintain at least 2m distance from edge of cut.

Maintain sufficient angle of repose. Provide slope not less than 1:1 and suitable bench of 0.5m width at every 1.5m depth of excavation in all soils except hard rock.

Battering/benching the sides.

Contact with buried electric cables

Gas/Oil Pipelines

Electrocution

Explosion

Obtain permission from competent authorities, prior to excavation, if required.

Locate the position of buried utilities by referring to plant drawings.

Start digging manually to locate the exact position of buried utilities and thereafter use mechanical means.

• it Excavation beyond 3.0m

Same as above plus

Flooding due to excessive rain/ underground water

Can cause drowning situation

Prevent ingress of water Provide ring buoys Identify and provide

suitable size dewatering pump or well point system

Digging in the vicinity of existing Building/Structure

Building/Structure may collapse

Loss of health & wealth

Obtain prior approval of excavation method from local authorities

Use under-piping method Construct retaining wall

side by side Movem May Barricade the excavated

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SHEET 14 OF 37

ACTIVITY TYPE OF HAZARD

EFFECT OF HAZARD

PREENTIVE MEASURES

ent of vehicles/ equipments close to the edge of cut.

cause cave-in or slides

Persons may get buried

area with proper lighting arrangements

Maintain at least 2m distance from edge of cut

Strengthen shoring and strutting

• arrow deep excavations for pipelines, etc.

Same as above plus

Frequent cave-in or slides

May cause severe injuries or prove fatal

Battering/benching of sides Provide escape ladders

Flooding due to Hydro testing

May arise drowning situation

Same as above plus Bail out accumulated water Maintain adequate

ventilation •

ock excavation by blasting

Improper handling of explosives

May prove fatal

Ensure proper storage, handling & carrying of explosives by trained personnel.

Comply with the applicable explosive acts & rules.

Uncontrolled explosion


Allow only authorized persons to perform blasting operations.

Smoking and open flames are to be strictly prohibited.

Scattering of stone pieces in atmosphere

Can hurt people

Use PPE like goggles, face mask, helmets etc.

• ock excavating by blasting (Contd)

Entrapping of persons/animals.


Barricade the area with red flags and blow siren before blasting.

Misfire May explode suddenly

Do not return to site for at least 20 minutes or unless announced safe by designated person.

• iling Work

Failure of pile-driving equipment

Can hurt people

Inspect Piling rigs and pulley blocks before the beginning of each shift.

Noise pollution

Can cause deafness and psychological imbalance.

Use personal protective equipments like ear plugs, muffs, etc.

Extruding rods/casing

Can hurt people

Barricade the area an install sign boards

Provide first-aid Workin

g in the Can

cause Keep sufficient distance

from Live-Electricity as per IS

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SHEET 15 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

vicinity of ‘Live-Electricity’

electrocution/ asphyxiation

code. Shut off the supply, if

possible Provide artificial/rescue

breathing to he injured. (B) CONCRETING

Air pollution by cement

May affect Respiratory System

Wear respirators or cover mouth and nose with wet cloth.

Handling of ingredients

Hands may get injured

Use gloves and other PPE.

Protruding reinforcement rods.

Feet may get injured

Use Safety shoes. Provide platform above

reinforcement for movement of workers.

Earthing of electrical mixers, vibrators, etc. not done

Can cause electrocution/ asphyxiation

Ensure earthing of equipments and proper functioning of electrical circuit before commencement of work.

Falling of materials from height

Persons may get injured

Use hard hats Remove surplus material

immediately from work place Ensure lighting

arrangements during night hours.

Continuous pouring by same gang

Cause tiredness of workers and may lead to accident.

Insist on shift pattern Provide adequate rest to

workers between subsequent pours.

Revolving or concrete mixer/ vibrators

Parts of body or clothes may get entrapped.

Allow only mixers with hopper

Provide safety cages around moving motors

Ensure proper mechanical locking of vibrator

• uper-structure

Same as above plus

Deflection in props or shuttering material

Shuttering/props ma collapse and prove fatal

Avoid excessive stacking on shuttering material

Check the design and strength of shuttering material before commencement of work

Rectify immediately the deflection noted during concreting

Passage to work place

Improperly tied and designed props/planks may collapse

Ensure the stability and strength of passage before commencement of work

Do not overload and stand under the passage

(C) REINFORCEMENT

Curtailment and binding of

Persons may get injured

Use PPE like gloves, shoes, helmets, etc.

Avoid usage of shift tools

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SHEET 16 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

rods Carryin

g of rods for short distance/at heights

Workers may get injured their hands and shoulders.

Provide suitable pads on shoulders and use safety gloves

Tie up rods in easily liftable bundles

Ensure proper staging. Checki

ng of clear distance/cover with hands

Rods may cut or injure the finger

Use measuring devices like tape, measuring rods, etc.

Hitting projected rods and standing on cantilever rods

Persons may get injured and fell down

Use safety shoes and avoid standing unnecessarily on cantilever rods

Avoid wearing of loose clothes

Falling of material from height

May prove fatal

Use helmets Provide safety nets

Transportation of rods by trucks

Protruded rods may hit the persons

Use red flags/lights at the ends

Do not protrude the rods in front of or by the side of driver’s cabin.

Do not extend the rods 1/rd of deck length or 1.5 m which is less

(D) WELDING AND GAS CUTTING

Welding radiates invisible ultraviolet and infrared rays

Radiation can damage eyes and skin.

Use specified shielding devices and other PPE of correct specifications

Avoid throated tungsten electrodes for GTAW

Improper placement of oxygen and acetylene cylinders

Explosion may occur

Move out any leaking cylinder

Keep cylinder in vertical position

Use trolley for transportation of cylinders and chain them

Use flash back arrestors Leakag

e/cuts in hoses

May cause fire

Purge regulators immediately and then turn off

Never use grease or oil on oxygen line connections and copper fittings on acetylene lines

Inspect regularly gas carrying hoses

Use the current for which

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SHEET 17 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

the cable is designed Always use red hose for

acetylene and other fuel gases and black for oxygen

Opening-up of cylinder

Cylinder may burst

Always stand back from the regulator while opening the cylinder

Turn valve slowly to avoid bursting

Cover the lug terminals to prevent short circuiting.

Welding of tanks, container or pipes storing flammable liquids

Explosion may occur

Empty them before welding Never attach the ground

cable to tanks, container or pipe storing flammable liquids

Never use LPG for gas cutting

(E) RADIOGRAPHY

Ionizing radiation

Radiations may react with the skin and can cause cancer, skin irritation, dermatitis, etc.

Ensure safety regulations as per BARC before commencement of job.

Cordon off the area and install Radiation warning symbols

Restrict the entry of unauthorized persons

Wear appropriate PPE and film bagdges issued by BARC

Transportation and Storage of Radiography source

Same as above

Never touch or handle radiography source with hands

Store radiography source inside a pit in an exclusive isolated storage room with lock and key arrangement. The pit should be approved by BARC

Radiography source should never be carried either in passenger bus or in a passenger compartment of trains.

BARC have to be informed before source movement.

Permission from Director General of Civil Aviation is required for booking radio isotopes with airlines.

Loss of Radio isotope

Same as above

Try to locate with the help of Survey Meter

Inform BARC(*) (F) ELECTRICAL INSTALLATION AND USAGE

Short circuiting

Can Cause Electrocution or Fire

Use rubberized hand gloves and other PPE

Don’t lay wires under carpets, mats or door ways.

Allow only licensed electricians to perform on

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SHEET 18 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

electrical facilities Use one socket for one

appliance Ensure usage of only fully

insulated wires or cables Don’t place bare wire ends

in a socket Ensure earthing of

machineries and equipments Do not use damaged cords

and avoid temporary connections

Use spark-proof/flame proof type field distribution boxes.

Do not allow open/bare connections

Provide all connections through ELCB

Protect electrical cables/equipment’s from water and naked flames

Check all connections before energizing

Overloading of Electrical System

Bursting of system can occur which leads to fire

Display voltage and current ratings prominently with ‘Danger’ sings.

Ensure approved cable size, voltage grade and type

Switch off the electrical utilities when not in use

Do not allow an authorized connections

Ensure proper grid wise distribution of Power.

Improper laying of overhead and underground transmission lines/cables

Can cause electrocution and prove fatal

Do not lay unarmored cable directly on ground, wall, roof of trees

Maintain at least 3m distance from HT cables

All temporary cables should be laid at least 750 mm below ground on 100 mm fine sand overlying by brick soling

Provide proper sleeves at crossings/intersections

Provide cable route markers indicating the type and depth of cables at intervals not exceeding 30m and at the diversions/termination.

(G) FIRE PREVENTION AND

Small fires can become

Cause burn injuries and may

In case a fire breaks out, press fire alarm system and shout “Fire, Fire”

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SHEET 19 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

PROTECTION big ones and may spread to the surrounding areas

prove fatal Keep buckets full of sand & water/fire extinguishing equipment near hazardous locations

Confine smoking to ‘Smoking Zones’ only

Train people for using specific type of fire equipments under different classes of fire

Keep fire doors/ shutters, passages and exit doors unobstructed

Maintain good house keeping and first-aid boxes (for detail refer Annex-2)

Don’t obstruct assess to f Fire extinguishers Do not use elevators for

evacuation during fire Maintain lightening

arrestors for elevated structures

Improper selection of Fire extinguishers

It may not extinguish the fire

Ensure usage of correct fire extinguisher meant for the specified fire (for details refer Annexure-III)

Do not attempt to extinguish Oil and electric fires with water. Use foam cylinders/CO2/sand or earth.

Improper storage of highly inflammable substances

Same as above

Maintain safe distance of flammable substances from source of ignition

Restrict the distribution of flammable materials to only min. necessary amount

Construct specifically designed fuel storage facilities

Keep chemicals in cool and dry place away from hat. Ensure adequate ventilation

Before welding operation, remove or shield the flammable material properly

Store flammable materials in stable racks, correctly labeled

Wipe off the spills immediately

Short circuiting of electrical system

Same as above

Can cause Electrocution

Don’t lay wires under carpets, mats or door ways

Use one socket for one appliance

Use only fully insulated wires or cables

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SHEET 20 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

Do not allow open/bare connections

Provide all connections through ELCB

Ensure earthing of machineries and equipments

(H) VEHICULAR MOVEMENT

Crossing the Speed Limits (Rash driving)

Personal injury

Obey speed limits and traffic rules strictly

Always expect the unexpected and be a defensive drive

Use sat belts/helmets Blow horn at intersections

and during overtaking operations.

Maintain the vehicle in good condition

Do not overtake on curves, bridges and slopes

Adverse weather condition

Same as above

Read the road ahead and ride to the left

Keep the wind screen and lights clean

Do not turn at speed Recognize the hazard,

understand the defense and act correctly in time.

Consuming alcohol before and during the driving operation

Same as above

Alcohol and driving do not mix well. Either choose alcohol or driving.

If you have a choice between hitting a fixed object or an on-coming vehicle, hit the fixed object

Quit the steering at once and become a passenger. Otherwise take sufficient rest and then drive.

Do not force the driver to drive fast and round the clock

Do not day dram while driving

Falling objects/ Mechanical failure

May prove fatal

Ensure effective braking system, adequate visibility for the drives, reverse warning alarm

Proper maintenance of the vehicle as per manufacturer instructions

(I) PROOF TESTING (HYDROSTATIC/ PNEUMATIC TESTING

Bursting of piping

Collapse of tanks

Tanks flying off

May cause injury and prove fatal

Prepare test procedure & obtain CONSULTANT/ Owner’s approval

Provide separate gauge for pressurizing pump and piping/equipment

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SHEET 21 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

Check the calibration status of all pressure gauges, dead weight testers and temperature recorders

Take dial readings at suitable defined intervals and ensure most of them fall between 40-60% of the gauge scale range

Provide safety relief valve (set at pressure slightly higher than test pressure) while testing with air/nitrogen

Ensure necessary precautions, stepwise increase in pressure, tightening of bolts/ nuts, grouting, etc. before and during testing

Keep the vents open before opening any valve while draining out of water used for hydro testing of tanks

Pneumatic testing involves the hazard of released energy shored in compressed gas. Specific care must therefore be taken to minimize the chance of brittle failure during a pneumatic leak test. Test temperature is important in this regard and must be considered when the designer chooses the material of construction

A pressure relief device shall be provided, having a set pressure not higher than the test pressure plus the lesser of 345 KPa (50 psi) or 10% of he test pressure.

(J) WORKING AT HEIGHTS

Person can fall down

May sustain severe injuries or prove fatal

Provide guard rails/barricade at the work place

Use PPE like safety belts, full body harness, life line, helmets, safety shoes, etc.

Obtain a permit before starting the work at height above 3 meters

Fall arrest systems like safety nets, etc. must be installed

Provide adequate working space (min. 0.6 m)

Tie/weld working platform

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SHEET 22 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

with fixed support Use roof top walk ladder

while working on a slopping roofs

Avoid movement on beams May hit

the scrap/ material stacked at the ground or in between

Keep the work place neat and clean

Remove the scrap immediately

Material can fall down

May hit the workers working at lower levels and provide fatal

Same as above plus Do not throw or drop

material or equipment from height

All tools to be carried in a tool-kit bags or on working uniform

Remove scrap from the planks

Ensure wearing of helmet by the workers at low level

(K) CONFINED SPACES

Suffocation/ drowning

Unconsciousness, death

Use respiratory devices, if required

Avoid over crowding inside a confined space

Provide Exhaust Fans for ventilation

Do not weal loose clothes, neck ties, etc.

Check for presence of hydrocarbons, O2 level

Obtain work permit before entering a confined space

Ensure that the connected piping of the equipment which is to be opened is pressure free, fluid has been drained, vents are open and piping is positively isolated by a blind flange

Presence of foul smell and toxic substances

Inhalation can pose threat to life

Same as above plus Check for hydrocarbon and

Aromatic compounds before entering a confined space

Depute one person outside the confined space for continuous monitoring and for extending help in case of an emergency

Ignition/flame can cause fire

Person may sustain burn injuries or explosion may occur

Keep fire extinguishers at a hand distance

Remove surplus material and scrap immediately

Do not smoke inside a

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SHEET 23 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

confined space Do not allow gas cylinders

inside a confined space Use low voltage (24V)

lamps for lighting Use tools with air motors or

electric tools with max. voltage of 24V

Remove all equipments at the end of the day

(L) HANDLING AND LIFTING EQUPMENTS

Failure of load lifting and moving equipments

Can cause accident and prove fatal

Avoid standing under the lifted load and within the operating radius of cranes

Check periodically oil, brakes, gears, horns and tyre pressure of all moving machinery

Check quality, size and condition of all chain pulley blocks, slings, U-clamps, D-shackles, wire ropes, etc.

Allow crane to move only on hard, firm and leveled ground

Allow lifting slings as short as possible and check gunny packings at the friction points

Do not allow crane to tilt its boom while moving

Install Safe Load Indicator Overloa

ding of lifting equipments

Same as above

Safe lifting capacity of derricks and winches written on them shall be got verified.

The max safe working load shall be marked on all lifting equipments

Check the weight of columns and other heavy items painted on them and accordingly decide about eh crane capacity, boom and angle of erection

Allow only trained operators and riggers during crane operation

Overhead electrical wires

Can cause electrocution and fire

Do not allow boom or other parts of crane to come within 3 m reach of overhead HT cables

Hook and load being lifted shall preferably remain in full visibility of crane operator.

(M) SCAFFOLDING, FORMWORK

Person can fall down

Person may sustain severe

Provide guard rails for working at height

Face ladder while climbing

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SHEET 24 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

AND LADDERS injuries and prove fatal

and use both hands Ladders shall extend about

1m above landing for easy access and tying up purpose

Do not place ladders against movable objects and maintain base at ¼ unit of the working length of the ladder

Suspended scaffolds shall not be less than 500 mm wide and tied properly with ropes

No loose planks shall be allowed

Use PPE, like helmets, safety shoes, etc.

Failure of scaffolding material

Same as above

Inspect visually all scaffolding materials for stability and anchoring with permanent structures.

Design scaffolding for max. load carrying capacity

Scaffolding planks shall not be less than 50x250 mm full thickness lumber or equivalent. These shall be cleared or secured and must extend over the end supports by at least 150mm and not more that 300 mm

Don’t overload the scaffolds

Do not splice short ladders to make a longer one. Vertical ladders shall not exceed 6m.

Material can fall down

Persons working at lower level gets injured

Remove excess material and scrap immediately

Carry the tools in a tool-kit bag only

Provide safety nets (N) STRUCTURAL WORKS

Personal negligence and danger of fall

Can cause injury or casualty

Do not take rest inside rooms built for welding machines or electrical distribution system

Avoid walking on beams at height

Wear helmet with chin strap and safety belts when working at height

Use hand gloves and goggles during grinding operations

Cover or mark the sharp and projected edges

Do not stand within the operating radius of cranes

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SHEET 25 OF 37


EFFECT OF HAZARD

PREENTIVE MEASURES

Lifting/slipping of material

Same as above

Do not stand under the lifted load

Stack properly all the materials. Avoid slippage during handling

Control longer pieces lifted up by cranes from both ends

Remove loose materials from height

Ensure tightening of all nuts and bolts

(O) PIPELINE WORKS

Erection/lowering failure

Can cause injury

Do not stand under the lifted load

Do not allow any person to come within the radii of the side boom handling pipes

Check the load carrying capacity of the lifting tools and tackles

Use safe Load Indicators Use appropriate PPEs

Other Same as above

Wear gum boots in marshy areas

Allow only one person to perform signaling operations while lowering of pipes

Provide night caps on pipes

Provide end covers on pipes for stoppage of pigs while testing/cleaning operations

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SHEET 26 OF 37

MONTHLY HSE CHECKLIST CUM COMPLIANCE REPORT

PROJECT : ………………………. CONTRCTOR: …………..…………………….

DATE : ………………………. OWNER : ………………………………...

INSPECTED BY: ……………………….

Note: Write ‘NA’ wherever the item is not applicable.


SL. NO.

ITEM

YES

NO

REMARKS

ACTION

1 HOUSEKEEPING a) Waste containers provided and used b) Sanitary facilities adequate and clean c) Passageways and Walkways clear d) General neatness of working areas e) Others 2 PERSONNEL PROTECTIVE EQUIPMENT a) Goggles; Shields b) Face protection c) Hearing protection d) Safety shoes e) Hand protection f) Respiratory Masks etc. g) Safety Belts h) Safety Helmet/Hard Hat I) Others 3 EXCAVATIONS/OPENINGS

a0 Openings properly covered or barricaded b) Excavations shored c) Excavations barricaded d) Overnight lighting provided e) Others 4 WELDING & GAS CUTTING a) Gas cylinders chained upright b) Cables and hoses not obstructing c) Screens or shields used

DOCUMENT NO. REV

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SHEET 27 OF 37


SL. NO.

ITEM

YES

NO

REMARKS

ACTION

d) Flammable materials protected e) Fire extinguisher(s) accessible f) Others 5 SCAFFOLDING a) Fully decked platforms b) Guard and intermediate rails in place c) Toe boards in place d) Adequate shoring e) Adequate access f) Others 6 LADDERS a) Extension side rails 1m above b) Top of landing c) Properly secured d) Angle + 70 from horizontal e) Others 7 HOISTS, CRANES AND DERRICKS a) Condition of cables and sheaves OK b) Condition of slings, chains, hooks and eyes OK c) Inspection and maintenance logs maintained d) Outriggers used e) Signs/barricades provided f) Signals observed and understood g) Qualified operators h) Others 8 MACHINERY, TOOLS AND EQUIPMENT a) Proper instruction b) Safety devices c) Proper cords d) Inspection and maintenance e) Others 9 VEHICLE AND TRAFFIC a) Rules and regulations observed b) Inspection and maintenance c) Licensed drivers d) Others 10 TEMPORARY FACILITIES a) Emergency instructions posted b) Fire extinguishers provided c) Fire-aid equipment available d) Secured against storm damage e) General neatness f) In accordance with electrical requirements g) Others 11 FIRE PREVENTION

DOCUMENT NO. REV

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SHEET 28 OF 37


SL. NO.

ITEM

YES

NO

REMARKS

ACTION

a) Personnel instructed b) Fire extinguishers checked c) No smoking in Prohibited Areas d) Hydrants Clear e) Others 12 ELECTRICAL a) Use of 3-core armoured cables

b) Usage of 'All insulated' or 'double insulated' electrical tools

c) All electrical connection are routed through ELCB d) Natural Earthing at the source of power (main DB) e) Continuity and tightness of earth conductor

f) Covering of junction boxes, panels and other energized wiring places

g) Ground fault circuit interrupters provided h) Prevention of tripping hazards I) Others 13 HANDLING AND STORAGE OF MATERIALS a) Properly stored or stacked b) Passageways clear c) Others 14 FLAMMABLE GASES AND LIQUIDS a) Containers clearly identified b) Proper storage c) Fire extinguishers nearby d) Others 15 WORKING AT HEIGHT a) Erection plan and work permit obtained b) Safety nets c) Safety belts, full body harness and lanyards; chute lines d) Others 16 CONFINED SPACE a) Work permit obtained

b) Test for toxic gas and sufficient availability of oxygen conducted

c) At least one person outside the confined space for monitoring deputed

d) Availability of sufficient means of entry, exit and ventilation

e) Fire extinguishers and first-aid facility ensured f) Lighting provision made by using 24V lamps g) Proper usage of PPEs ensured 17 RADIOGRAPHY

a) Proper storage and handling of source as per BARC guidelines

b) Working permit obtained c) Cordoning of the area done

DOCUMENT NO. REV

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SHEET 29 OF 37


SL. NO.

ITEM

YES

NO

REMARKS

ACTION

d) Use of appropriate PPE's ensured e) Proper training to workers/supervisors imparted f) Minimum occupancy of workplace ensured 18 HEALTH CHECKS a) Hygienic conditions at labour camps OK? b) Availability of First-aid facilities c) Proper sanitation at site, office and labour camps d) Arrangement of medical facilities e) Measures for dealing with illness f) Availability of Portable drinking water for workmen & staff g) Provision of crèches for children 19 ENVIRONMENT a) Chemical and other effluents properly disposed b) Cleaning liquid of pipes disposed off properly

c) Seawater used for hydro-testing disposed off as per agreed procedure

d) Lubricant Waste/Engine oils properly disposed

e) Waste from Canteen, offices, sanitation etc. disposed properly

f) Disposal of surplus earth, stripping materials, oily rags and combustible materials done properly

g) Green belt protection

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SHEET 30 OF 37

ACCIDENT / FIRE REPORT

(To be submitted by Contractor after every accident within 24 hours of accident)

Report: ………………………….

Name of Site Date: ……………………………. ----------------------------------------------------------------------------------------------------------------- NAME OF THE INJURED FATHER’S NAME SUB-CONTRACTOR M/S. DATE & TIME OF ACCIDENT LOCATION ----------------------------------------------------------------------------------------------------------------- BRIEF DESCRIPTION OF ACCIDENT

----------------------------------------------------------------------------------------------------------------- CAUSE OF ACCIDENT

----------------------------------------------------------------------------------------------------------------- NATURE OF INJURY/DAMAGER

----------------------------------------------------------------------------------------------------------------- MEDICAL AID PROVIDED/ACTIONS TAKEN

----------------------------------------------------------------------------------------------------------------- INTIMATION TO LOCAL AUTHORITIES

----------------------------------------------------------------------------------------------------------------- DATE: SIGNATURE OF CONTRACTOR

WITH SEAL

TO : OWNER 1 COPY

RCM/SITE-IN-CHARGE CONSULTANT 1 COPY CONSULTANT HO Constn. Through RCM 3 COIES Proj.Mgr. CONSULTANT, Through RCM 1 COPY

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SHEET 31 OF 37

SUPPLEMENTARY ACIDENT & INVESTIGATION REPORT

Project: ……………………………

Supplementary to Report No. : ………………………………. (Copy enclosed)

Site: ………………………………………………………………. Date:

Contractor: ………………………………………………………………………………………… ----------------------------------------------------------------------------------------------------------------- NAME OF INJURED FATHER’S NAME SUB-CONTRACTOR M/S. DATE & TIME OF ACCIDENT LOCATION ----------------------------------------------------------------------------------------------------------------- BRIEF DESCRIPTION & CAUSE OF ACCIDENT

----------------------------------------------------------------------------------------------------------------- NATURE OF INJURY/DAMAGE

----------------------------------------------------------------------------------------------------------------- COMMENTS FROM MEDICAL PRACTITIONER, WHO ATTENDED THE VICTIM/INJURED

----------------------------------------------------------------------------------------------------------------- SUGGESTED IMPROVEMENT IN THE WORKING CONDITION, IF ANY

----------------------------------------------------------------------------------------------------------------- LOSS OF MAN HOURS AND IMPACT ON SITE WORKS

----------------------------------------------------------------------------------------------------------------- ANY OTHER COMMENT BY SAFETY OFFICER

----------------------------------------------------------------------------------------------------------------- DATE :

SIGNATURE OF CONTRACTOR WITH SEAL

TO : OWNER 1 COPY

RCM/SITE-IN-CHARGE CONSULTANT 1 COPY CONSULTANT HO Constn. Through RCM 3 COIES Proj.Mgr. CONSULTANT, Through RCM 1 COPY

DOCUMENT NO. REV

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SHEET 32 OF 37

MONTHLY Health, Safety & Environment (HSE) REPORT

(To be submitted by each Contractor)

Actual work start Date: ……………………………… For the month of : ……………

Project : ………………………………………………. Report No. : …………………

Name of the Contractor : …………………………….. Status as on : …………………

Name of work : ………………………………………. Name of Safety Officer : ………

ITEM THIS MONTH CUMULTIVE

Total strength (Staff + Workmen) Number of HSE meetings organized at site Number of HSE awareness programmes conducted at site

Whether workmen compensation policy taken Y/N -- Whether workmen compensation policy is valid Y/N -- Whether workmen registered under ESI Act Y/N -- Number of Fatal Accidents Number of Loss Time Accidents (Other than Fatal) Other accidents (Non Loss Time) Total number of accidents Total man-hours worked Man-hour loss due to fire and accidents Compensation cases raised with Insurance Compensation cases resolved and paid to workmen Remarks, if any :

DATE : SIGNATURE OF CONTRACTOR WITH SEAL

TO : OWNER 1 COPY

RCM/SITE-IN-CHARGE CONSULTANT 1 COPY

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SHEET 33 OF 37

PERMIT FOR WORKING ABOVE 3 METER HIGHT (Strike out whichever is not applicable)

Project Site : ……………………………………… Sr. No.: ……………………… Name of the work: ………………………………. Date: ………………………… Name of Contractor : …………………………….. Nature of Work : …………… Total No.of Workers: …………………………….. Exact location of work : ……

Duration of work: from ..…… to The following items have been checked and compliance shall be ensured during the currency of the permit: ------------------------------------------------------------------------------------------------------- Sl. ITEM DONE NOT REQD.

------------------------------------------------------------------------------------------------------- 1. Equipment/Work Area inspected 2. Considered hazard from other routine/non-routine operations and concerned person alerted 3. ELCB provided 4. Proper lighting provided 5. Area cordoned off. 6. Precautions against public traffic taken 7. Sound Scaffolding provided 8. Adequate protected Platform provided 9. Acces and Exit to the area

(Ladder properly fixed) 10. Floor Openings covered 11. Safety Net provided ------------------------------------------------------------------------------------------------------- A. Following personal protective equipment are provided (√ mark) and used as relevant Safety

helmet/Gloves/Goggles/Shoes/Face Shield/Life Line/Safety Belt/Safety Harness. B. This permit shall be available at the work site at all times. C. Permit shall be issued for maximum one week only (Monday to Sunday). D. This permit shall be applicable in non-operational areas. E. After completion of the work, used permits shall be preserved for record purposes. F. Additional precautions, if any …………………………………………………………. Permission is granted to work (See overleaf) = Yes/No. Name of Contractor’s Supervisor Name of Contractor’s Safety Officer (Initiator) (Issuing Authority)

DOCUMENT NO. REV

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SHEET 34 OF 37

GRANT OF PERMIT AND EXTENSIONS

Sl. No.

Validity Period From ……… To ………

Work time From …..Hrs. To ……….Hrs.

Initiator (Supervisor of

Contractor)

Issuing Authority

(Safety Officer) of Contractor

Verification by CONSULTANT

with date

Additional safety instructions, if any.

DOCUMENT NO. REV

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SHEET 35 OF 37

HEALTH, SAFETY & ENVIRONMENT (HSE) PLAN

Division/Department : Project

Name :

Activity/Process Procedure Code of Performer Checker Approver Sampling Plan Owner's/ PMC's Audit

Description Number Conformance Reviewer Reviewer Approver Requirements

DOCUMENT NO. REV

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SHEET 36 OF 37

ELECTRICAL Electrical power is the mainstay of any construction activity, at the same time it requires utmost care in it’s utilization to avoid accidents due to electrical shock, fire incidents or electric short circuits. Exposure of electrical installation to adverse environmental conditions increase the risk of such accidents. Hence it is necessary to take extra precautions for such installations to ensure safety of personnel and equipment. This standard addresses the safety measures required to be adopted for the electrical installations by all contractors during construction phase.

All electrical connections/work for electrical installations shall be carried out as per provisions of the latest revision of the following codes and standards in addition to the requirements of statutory authorities and ie rules : Oisd-std-173 : fire prevention and protection system for electrical installations. Sp-30 (bis) : national electric code. The installation shall have approval from concerned statutory authorities.

1. All electrical connections shall be done by an electrician with valid licence and to the satisfaction of engineer-in-charge.

2. One competent licenced electrician shall be made available by contractor at site round the clock to attend to the normal/emergency jobs.

3. All switch boards/welding machines shall be kept in well ventilated and covered shed. The shed shall be elevated to avoid water logging. No flammable materials shall be used for constructing the shed. Also flammable materials shall not be stored in and around electrical equipment/switchboard. Adequate clearances and operational space shall be provided around the equipment.

4. Fire extinguishers and insulting mats shall be provided in all power distribution centres. 5. Temporary electrical equipment shall not be employed in hazardous areas without obtaining safety

permit. 6. Proper housekeeping shall be done around the electrical installations. 7. All temporary installations shall be tested before engineering, to ensure proper earthing, bonding,

suitability of protection system, adequacy of feeders/cables etc. 8. All welders shall use hand gloves irrespective or holder voltage. 9. Multilingual (english, hindi and local language) caution boards, shock treatment charts and instruction

plate containing location of isolation point for incoming supply, name and telephone number(s) of contact person in emergency shall be provided in substations and near all distribution boards/local panels.

10. Operation of earth leakage device shall be checked regularly by temporarily connecting series test lamp (2 bulbs of equal rating connected in series) between phase and earth.

11. The following design features shall be ensured for all electrical installations during construction phase. 12.1 Each installation shall have a main switch with a protective device, installed in an enclosure adjacent to

the metering point. The operating height of the main switch shall not exceed 1.5 m. The main switch shall be connected to the point of supply by means of armoured cable.

12.2 The outgoing feeders shall be double or triple pole switches with fuses/mcbs. Loads in a three phase circuit shall be balanced as far as possible and load on neutral should not exceed 20% of load in the phase.

12.3 The installation shall be adequately protected against overload, short circuit and earth leakage by the use of suitable protective devices. Fuses wherever used shall be hrc type. Use of rewirable fuses shall be strictly prohibited. The earth leakage device shall have an operating current not exceeding 30 ma.

12.4 All connections to the handtools/welding receptacles shall be taken through proper switches, sockets and plugs.

12.5 All single phase sockets shall be 3 pin type only. All unused sockets shall be provided with socket caps. 12.6 Only 3 core (p+n+e) overall sheathed flexible cables with minimum conductor size of 1.5 mm2 copper

shall be used for all hand tools. 12.7 Only metallic distribution boxes with double earthing shall be used at site. No wooden boxes shall be

used. 12.8 All power cables shall be terminated with compression type cable glands. Tinned copper lugs shall be

used for multistrand wires/cables. 12.9 Cables shall be free from any insulation damage. 12.10 Cables shall be laid underground at a minimum depth of 900 mm, covered with sand, brick and soil for

ensuring mechanical protection. Cables shall not be laid in water logged area as far as practicable. Cable route markers shall be provided at every 25 m of buried trench route. When laid above ground,

DOCUMENT NO. REV

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SHEET 37 OF 37

cables shall be properly cleated or supported on rigid poles of atleast 2 m high. Minimum head clearance of 6 meters shall be provided at road crossings.

12.11 Under ground road crossings for cables shall be avoided to the extent feasible. In any case no under ground power cable shall be allowed to cross the roads without pipe sleeve.

12.12 All cable joints shall be done with proper jointing kit. No taped/temporary joints shll be used. 12.13 An independent earthing facility should preferably be established within the temporary installation

premises. All appliances and equipment shall be adequately earthed. In case armoured cables are used, the armour shall be bonded to the earthing system.

12.14 All cables and wire rope used for earth connections shall be terminated through tinned copper lugs. 12.15 In case of local earthing, earth electrodes shall be buried near the supply point and earth continuity wire

shall be connected to local earth plate for further distribution to various appliances. All insulated wires for earth connection shall have insulation of green colour.

12.16 Separate core shall be provided for neutral earth/structures shall not be used as a neutral in any case. 12.17 On/off position of all switches shall be clearly designated/ painted for easy isolation in emergency. 12.18 All insulations shall be inspected by engineer-in-charge atleast once in a month.

VENDOR LIST

VENDOR LIST

S. No. Vendor Name Address Remarks

1L&T Limited

(Audco India Ltd.)

32, Shivaji Marg

New Delhi – 110 015

2 HawaValves (I) Pvt. Ltd.R - 16 TTC INDUSTRIAL AREA , RABALE ,

NAVI MUMBAI , MAHARASHTRA - 400701

3 Micro Finsh Valves LtdSF 015-017 3RD FLOOR, K - 89, FORTUNE

ARCADE, SECTOR-18, NOIDA - 201301

4 Virgo Enginners7 / 39, 2ND FLOOR, VIKRAM VIHAR, LAJPAT

NAGAR, PHASE - IV, NEW DELHI - 110024

5 OSWAL INDUSTRIES LTD.

BLOCK NO - 258, VILLAGE - OLA,

AHMEDABAD, MEHSANA EXP HIGHWAY

GUJRAT, PIN - 382729

6 Flow Chem Industries10, Navdurga Indl. Estate Opp. Forge Blower,

Naroda Road Ahmedabad – 25

7 BDK Engineering

SF(015-017),3RD Floor,K-89,

Ansal Fortune Arcade,

Sector-18,Noida-201301

8 GURU Valves

GURU HOUSE , W - 101 (D), TIC,MIDC,

KHAIRANE VILLAGE , NAVI MUMBAI,THANE,

MAHARASHTRA - 400710

9 SHAYBURG VALVES PRIVATE LTD.PLOT NO A/4,MIDC ROAD 1, WAGLE

INDUSTRIAL ESTATE, THANE, MUMBAI

1 JINDAL PIPES LTD.PLOT NO. 30, INSTITUTIONAL SECTOR -44,

GURGAON, HARYANA, INDIA

2 MAHARASHTRA SEAMLESS LTD. PLOT NO. 30, INSTITUTIONAL SECTOR -44,

GURGAON, HARYANA, INDIA

3 SURYA ROSHNI LTD.PRAKASH NAGAR, BAHADURGARH,

HARYANA, INDIA

4WELSPUN GUJRAT STAHL ROHREN

LTD.

T-11, 3RD FLOOR, VASANT SQUARE MALL,

SECTOR - B, POCKET - 5, VASANT KUNJ,

NEW DELHI - 110070

5 PSL LTDPSL HOUSE, B-96,GREATER KAILASH - I,

NEW DELHI - 110048 (INDIA)

Only HSAW pipe 16" and above +

Coating plant

6THE INDIAN SEAMLESS METAL TUBE

LIMITED

LUNKAD TOWERS, VIMAN NAGAR,

PUNE – NAGAR ROAD, PUNE – 411 014

7 JINDAL-SAW LIMITED JINDAL CENTRE, 12 BHIKAJI CAMA PLACE,

NEW DELHI – 110 066

1 Corrtech International Pvt. Ltd22,Dhara Centre, Vijay CharRasta, Navrangpura,

Ahmedabad.Gujarat 380009

2 Raychem RPG Limited510,511 Ansal Bhawan, Kasturba Gandhi Marg,

New Delhi 110001

3Corrosion Control Services (Bombay) Pvt.

Ltd.

405, Arun Chambers, Tardeo Road, Mumbai

400034

4 Central Electronics Limited 4,Industrial Area, Sahibabad (U.P.) 201010

5 AFCON

AFCON HOUSE

16 SHAAH INDL EST, VEERA DESAI ROAD

ANDHERI (W), MUMBAI – 400053

6CONSULTECH CATHODIC PROTECTION

ENGINEERS

878/1,G.I.D.C ESTATE, MAKARPURA

BARODA - 390 010, GUJRAT

7MITCORR CATHODICPROTECTION

PVT.LTD.,

No.18,19,20 Pratibha Complex, First Floor,

Arunachal Samata Road,

Subhanpura, Vadodara – 390023

1 Invensys India Pvt.Ltd.

975, AGGRAWAL MILLENNIUM

TOWERS II, E-4, NETAJI

SUBHASH PLACE, PITAMPURA

NEW DELHI – 110034

2 M.B. CONTROL & SYSYTEMS PVT.LTD

L-2/114, NEAR MAHAVIR NAGAR

2ND FLOOR, TILAK NAGAR


3 SIMENS LTD. 4-A, RING ROAD, I.P. ESTATE


Main Line Valves

Vendor List

Line Pipe

Cathodic Protection

RTU & SCADA

2.0 Vendor List - GGL.xls1/3


Vendor List

4 ABB Limited

PLOT NO 5&6, 2ND PHASE

PEENYA INDUSTRIAL AREA

BANGALORE - 560058

5 TOTAL AUTOMATION SOLUTIONS K 601 MEGACENTER

MAGRAPATH HADAPSAR, PUNE – 411028

1 SWAYIN & ASSOCIATESD/96, SUBHRAM BUILDING, FLAT NO.15, 2ND

FLOOR, MUNIRKA, NEW DELHI - 110067,

INDIA

2 CENGRS GEOTECHNICA PVT.LTDA-100, SECTOR-63, NOIDA - 201309 (UP),

NOIDA, INDIA

3DBM GEOTECHNICS AND

CONSTRUCTION PVT.LTD,

301, Centaur House, Shanti Nagar Ind. Estate,

Near Grand Hyatt Hote, Vakola, Santacruz

(East), Mumbai - 400055, India

4 Furgo Geonics (India) Ltd.Plot No.51, Sector-6

Sanpada, Navi Mumbai-400 705

Maharashtra, India.

5 Rai Coastal Surveys Consultancy

Services (P) Ltd.

6 Secon Survey New delhi

7 Elcome Surveys

8 National Institute of Ocean Technology

9 RITES Gurgaon

10 Theo Tech Engineers.

1 Aksh Optifibre Ltd.

1/1, B-1 Extension, Mohan Co-operative

Industrial Estate,

Mathura Road, New Delhi -110 044,E53

2Vindhya Telelink Ltd / Birla Ericsson

Optical Limited

4th Floor, UCO Bank Building

Parliament Street, New Delhi - 110 001

3 Finolex Cables Ltd26-27, Mumbai - Pune Road,

Pimpri,Pune 411 018

4 RPG Cables Ltd.Zensar Business Center,Pratap Buliding N-83,1st

Floor,Cannaught Place

New Delhi - 100 001

5 UM Cables Limited

168, C.S.T. Road, Agarwal Industrial Estate,

Kalina, Santacruz East Mumbai - 400 098

Maharashtra, India

6Himanchal Futuristic Communication

Ltd

8, Commercial Complex, Masjid Moth, Greater

Kailash-II, New Delhi-110001

7 ARM Ltd. Cable Division 605,Tolstoy House, Tolstoy Marg,

New Dlehi-110001

8 Uniflex Cable Ltd.

12 & 13, Jyoti Wire House,

1st floor, 23 A Shah Industrial Estate

Off Veera Desai Road, Andheri (W)

Mumbai - 400 053

9 Sterlite Optical Technologies Ltd604, Tolstoy House, Tolstoy Marg, New Delhi-

110001

10 Tamilnadu Telecommunication Ltd.E-18 B-24, CMDA Industrial Complex,

Maraimalai Nagar 603209

1 Essar Construction (India) Ltd. A-5, Sector - 3, Noida - 201301 (U.P)

2 Corrtech International Pvt.Ltd.

1ST FLOOR, 51, MAHAGUJARAT INDUSTRIAL

ESTATE, OPP. NOVA PETRO CHEMICALS

CHANGODHAR, AHMEDABAD - 382 213

3Kazstroy Services Infrastructure India

pvt.Ltd.

"A" WING, 1ST FLOOR,

VATIKA TOWER,SECTOR - 54,

GURGAON - 122001

4 GAMMON INDIA LTD.

GAMMON HOUSE, V.S MARG

PRABHADEVI, MUMBAI - 400 025

MAHARASHTRA

5 MAYTAS INFRA LTD.

#6-3-1186/5/A, III FLOOR

AMOGH PLAZA,BEGUMPET, HYDRABAD -

400099, ANDHRA PRADESH

6 PUNJ LLOYD LTD.

CORPORATE OFFICE

78, INSTITUTIONAL AREA, SECTOR - 32

GURGAON - 122 001

GEO-TOPO

OFC

Line Pipe Laying



Vendor List

7 JAIHIND

5TH FLOOR SHANTI ARCADE,132FT. RING

ROAD, NEAR SAPTAK PARTY PLOT

NARANPURA, AHMEDABAD - 380 063

8 Kalpataru Power Transmission Ltd.81, Kalpataru Synergy, Opp. Grand Hyatt,

Santa Cruz (E), Mumbai - 400 055, India

9 ACE PIPELINE CONTRACTS PVT.LTD4, STANBURG ESTATE, GROUND FLOOR,

JUHU KOLIWADASANTA CRUZ (W), MUMBAI

10 JSIW Infracture Pvt.Ltd.JSIW House, B/s. Khoraj Fly Over, S.G. Road,

Dist - Ghandhi Nagar, - 382421, Gujrat

11L&T Limited (Hydrocarbon Construction and

Pipelines)

Mount Poonamallee Road, Manapakkam, P.B.

No - 979, Chennai - 600 089

12 ARIO BROTHERS

288-289, Ichhapor,GIDC Opposite ITI

Post Office - Bhatpur, Surat - 394510

Gujrat, India

13 ANERI CONSTRUCTIONS 1ST FLOOR, Anjali Chamberts, RC Datt Road,

Baroda - 390007, Gujrat

1 IGP Engineers Pvt. Ltd.PB. No. 8674, 79 Valmiki Strret, Thiruvanmiyur,

Chennai -600041Only IJ

2 ADVANCE Electronics System878/1, GIDC Estate, Makarpura

Baroda - 390 010, Gujrat , IndiaOnly IJ

3MULTITEX FILTRATION ENGINEERS

LTD.

MULTITEX FILTRATION LTD

217, HANS BHAWAN, BAHADUR SHAH ZAFAR

MARG, NEDELHI - 110002

Only Flow Tee

4 Pipe Fit Engineers496/1, G.I.D.C MAKARPURA,

VADODARA - 390010, GUJARAT, INDIAOnly Flow Tee

1 ECHJAY Forgings Ltd.Kanjur Village Road , Kunjan Marg east

MUMBAI - 400 042

2 Choudhary Hammer WorksPO Box 20, Near Hapur Road Opp.

Power House, GHAZIABAD

3 Metal Forgings (P) Ltd.B-1, Mayapuri Indl. Area PH-I

NEW DELHI - 110 064

4 Punjab Steel Works38B, Mayapuri, Indl.Area Phase-I

NEW DELHI - 110 064

5 Amforge Industries16/A, Modi Compond, Ist Ghorupdeo, Cross

Road, Reay Road, Mumbai- 400 010

6 C D Engineering Co.C-199, Bulandshahar Road Industrial

Area , GHAZIABAD

7 Aditya Forging Ltd.496/1, GIDC, Makarpura

BARODA - 390 004

8 J K ForgingsB-83, Mayapuri Industrial Area, Phase-1,

New Delhi-64

9 Golden Iron and Steel Co7/19, Industrial Area Kirti Nagar,

New Delhi-110015

10 Sawan Engineers

213, Alakhnanda complex,

Opp. Bharat Petrol pump,Akota – Munjmuda

Road,Vadodara – 390003, Gujarat (India).

11 Tube Products

TUBE PRODUCTS INCORPORATE

748/7, GIDC ESTATE, MAKARPURA,

VADODARA, GUJRAT - 390010

12 GUJARAT INFRAPIPES Pvt. Ltd.89-GIDC Industrial Estate.,

POR - 391 243,DIST. - Vadodara

State - Gujarat, India.

13 Pipe Fit Engineers496/1, G.I.D.C MAKARPURA,

VADODARA - 390010, GUJARAT, INDIA

1 Sparco Multiplast Pvt Ltd.

2Jain Irrigation Pvt.Ltd.

WARNING MAT

Insulating Joints & Flow Tee

Flanges & Fittings


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