INDEX

PART DESCRIPTION PAGE NO.

1
Part 1 - Notice Inviting Tender 002 - 007

2 Part 2a – Important Notice 008 - 012

3 013 - 017
Part 2b - Instructions to Contractor

018 - 052
4 Part 3 - General Conditions of Contract

5 Part 4a - Special Conditions of Contract 053 - 058

6 Part 4b - Additional Special Condition of Contract 059 - 063

7 Part 5 - Time Schedule

064 - 068
Resource Mobilisation Plan & Proposal Forms

8 Part 6a - Site Management

069 – 073
9 Part 6b - Client safety Standards
074 - 152

Part 7 - Bill of Quantities (BOQ) and Technical

10 153 - 491
Specifications and Tender drawings
 PART 1

NOTICE INVITING TENDER

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 PART 1

NOTICE INVITING TENDER

1. Sealed item rate tenders are invited by M/s Bayer Material Science Pvt Ltd., for
Equipment Erection & Fabrication & Erection of Piping works, associated with
PIC (Poly Isocynate) Unit at Ankleshwar, Gujarat, and will be received by
20/08/2009

2. Any tender received after the expiry of the time notified for receiving tenders will
not be considered.

3. The Contractor shall very carefully read the complete set of tender documents
basically containing “Form of Tender” the various “Terms and Conditions”,
drawings and copy of the “Schedule of Quantities”. The Contractors are required
to complete the “Form of Tender”, copies of the Schedule of Rates and sign all
the drawings. The duly completed and signed tender Documents is to be
enclosed in a sealed envelope on which shall be written prominently, the name of
the Project and the name of the Contractor and addressed to :

PRICED BID TECHNICAL BID

Mr Balaram Khot- Mr Kaushal Srivastava
Project Manager Project Manager
Bayer Material Science Pvt Ltd Aker Powergas Pvt Ltd
Building – C 195, 2nd Floor Powergas House
Thane - 400607 177, Vidya Nagari Marg, Mumbai 400098
Phone: 022-25311942 Phone: 022-66916054
Mobile:9870850866 Mobile : 9920298929

4. The Contractors are expected to price their tender so as to strictly confirm to the
various Terms and Conditions stipulated in the tender Document without making
any corrections, alterations, etc; of their own. If, however the Contractors wish to
specify their own Terms and Conditions, they may do so in a separate letter,
which shall be enclosed in a sealed envelope along with the tender.

5. The tender submitted on behalf of a firm shall be signed in ink by a person who
has the necessary authority on behalf of the firm to enter into the proposed
Contract, otherwise the tender is liable to be rejected. Each Page of the tender
document and each drawing accompanying is required to be signed by the
authorized person submitting the tender with the Company Seal in the token of
their having acquainted themselves with the General Conditions of Contract,
specifications, Instructions to Contractors as laid down. The form of tender is to
be filled in completely. Any tender with any of the documents not so signed will
be rejected.

6. The Contractor must quote the rates both in figures and words. All erasures and
alterations made while filling the tender must be attested by dated initials of the
Contractor. Over writing of figures is not permitted. Failure to comply with either
of these conditions will render the tender liable for rejection. No advice for any
change in rate or conditions received after the opening of the tender will be
entertained.

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7. Errors in rates quoted and amount quoted shall be dealt within the following
manner.

7a. In the event of a discrepancy between the rates quoted in words and the rates in
figures, the former shall be deemed to be correct.

7b. In the event of an error occurring in the amount column of the Schedule of
Quantities as a result of the wrong extension of the unit rate and the quantity, the
unit rate shall be regarded as firm and extension shall be amended on the basis
of the unit rates.

7c. All the errors in totaling in the amount column and in carrying forward the totals
shall be corrected.

8. The tender total shall be accordingly amended except that there shall be no
rectification of any errors, omissions or wrong estimate, in the prices inserted by
the Contractor in the Schedule of Quantities.

9. Where alternative items are given only the rates in figures and words are to be
entered and not the amounts thereof. A tender which does not show the rates in
figures and words for alternative items are liable to be rejected. The Owner
/Consultant reserves the right to take into account any of the alternative items
during the execution of the work, partly or fully as required.

10. The Contractors must obtain for themselves on their own responsibility and at
their own expense all the information which may be necessary, including risks,
contingencies and other circumstances to enable them in making a proper tender
and for entering into a contract, and must examine the drawings, specifications
and inspect the site of the work and acquaint themselves with all local conditions,
access to the work site, nature of the work and all the matters pertaining thereto
before submitting the tender. They can also get any clarifications required from
the Consultants, before tendering, by contacting them at their Office during
working hours.

No claim for extra payment on the pretext of not having full specifications, or not
understanding the drawings or misunderstanding any of the conditions of contract
and instructions to Contractors will be entertained.

11. The schedule of quantities are only probable quantities and are liable to
alterations by omission, deductions or additions to any extent. Payments will be
made on the actual quantities of work done at accepted unit rate. Each tender
should contain not only the rates but also the value of each items of work entered
in a separate column and all the items should be totaled in order to show the
aggregate value of the entire tender. Corrections, which are not attested, may
entail the rejection of the tender. Rates should be quoted both in figures and
words in the columns specified.

12. The rates quoted in the tender shall include cost of all materials, labour and all
charges for double scaffolding and meter rent charges, electric charges,
temporary plumbing, cost of cisterns, hire for any tools and plants, shed for
materials, marking out and clearing of site, watering, curing all cement work,
concrete as mentioned in the specifications, complete in all respects. The rates
quoted in the Tender shall be treated as rates for finally completing the item of
work.

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13. The rates quoted shall be deemed to be for the finished work to be measured at
site. Contractors must include in their rate transportation of materials to site,
sales tax, excise duty, Octroi and any other tax and duty or other levy levied by
the Central Government, or any State Government or Local Authorities, if
applicable. No claim in respect of any of the above levies will be entertained by
the Consultant.

Works Contract tax will be reimbursed to the Contractor only on production of

valid documentary evidences for having paid Works Contract Tax as per
prevailing rates applicable at Works Site.

The Rates quoted shall include all expenditure involved in providing contributions
towards provision for Provident Fund, Insurance coverage for all the works,
Labour cum third party risk also [i.e. Car Policy, Workmen’s Compensation Policy
and third party liability of maximum total Rs 30,00,000/- subject to individual limit
of Rs.2,00,000/- as indicated in the following pages of the tender document under
General Conditions of Contract. The cost of all the materials supplied by the
Owner shall also be included for the Insurance.

14. The calculations made by the Contractors should be based upon quantities of
several items of work which are furnished for the tender’s convenience in the bill
of quantities, but it must be clearly understood that the contract is a unit rate
contract and not a lump sum contract. The Owner do not in any way assure or
guarantee that the said probable quantities are correct or that the work would
correspond thereto. The items of work irrespective of the quantities which may
vary shall be carried out at the same accepted tender rates and no escalation in
the rates will be entertained whatsoever.

15. Within fifteen days of the receipt of the intimation from the owner/ Consultants of
the acceptance of the tender, the successful Contractor shall be bound to
implement the contract by signing the agreement in accordance with the draft
agreement and the schedule of conditions, along with other conditions that may
be mutually agreed to, subsequent to the receipt of the tender, but the written
acceptance by the Owner/Consultant of the tender will constitute a binding
whether such a formal contract is or is not subsequently entered into.

16. All compensations or other sums of money payable by the Contractor to the
Owner under the terms of this contract will be deducted from the bill amounts or
from the Retention Money, if the amount so permits and the contractor shall,
unless such retention money has become otherwise payable, within ten days
after such deductions, make good in cash the amount so deducted.

17. The Contractor shall carry out all the works strictly in accordance with the
drawing, details and instructions of the Consultant/Owner. If in the opinion of the
Consultant, changes have to be made in the design, and they desire the
Contractor to carry out the same, the Contractor shall be bound to comply. The
Consultant decisions in such cases shall be final. Compensation if payable for
this change will solely be at the discretion of the consultant.

18. The Contractor is bound to carry out any items of work necessary for the
completion of the job even though such items are not included in the schedule of
quantities and rates. Schedule of instructions in respect of such additional items
and their quantities will be issued in writing by the Consultant with the prior,
consent in writing of the Owner. The rate analysis shall be forwarded by
contractor in writing to consultant who will review and forward the same with
comments to the Owner.

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19. The Contractor shall not be entitled to any compensation for any loss suffered by
him on account of delays in commencing or executing the work whatever the
cause of delay may be, including delays arising out of modifications to the work
entrusted to him or in any sub contracts connected there with or delays in
awarding contracts for other trades of the Project or in commencement of
completion of such other works or in procuring Government controlled or other
building materials or for any other reason whatsoever and the Owner shall not be
liable for any claim in respect thereof. The Consultant does not accept liabilities
for any sum besides the tender amount, subject to such variations as are
provided for herein and as instructed by Consultant/Owner.

20. The successful Contractor must co-operate and co-ordinate the work with the
work of all the other Contractors appointed by the Owner, so that the work shall
proceed with the least possible delay and to the satisfaction acceptance of the
Consultant/Owner.

The Contractor’s co-ordination with other contractors appointed by the Owner is

essential to maintain smooth progress of work and any delays, which in the
opinion of the Owner/Consultant is due to non co-ordination and in efficient
management of the contractor, will not be entertained for any extension of time.

21. The Consultant/Owner will acknowledge the Tenders received.

22. The Price quoted, time required for the completion, and the standard of
workmanship and technical and financial capacities of the Contractors will be the
main criteria for considering the tenders.

23. The Owner do not bind themselves to accept the lowest or any tender and
reserve themselves that right to accept or reject any or all the Tenders, whether
in the whole or in part without assigning any reason for doing so.

24. Every Contractor shall furnish along with the Tender the latest Income Tax
Clearance Certificate without which this Tender is likely to be rejected.

25. NON TENDERED ITEMS

26. The rates furnished in the Schedule of Quantities will apply for the entire Project.
Any items of work which is not covered in the Schedule of Quantities which may
be required to be carried out on site shall be executed by the Contractor and
payment for such items of work shall be based on the rates that may be derived
from the rates quoted for similar comparable items of as finalized by Consultant.

27. And for such items which cannot be derived from the quoted rates the payment
shall be based on the actual cost of materials, labour, 3% towards tools and plant
plus 15% towards overheads and profit. The prevailing rate of Sales Tax on
Works Contract shall be paid extra over and above the rates arrived on the above
basis, if applicable. [Works Contract Tax shall be paid as per the provision made
in Clause No. 14].

28. GUARANTEE

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 The Contractor shall guarantee that the items supplies are in full accordance with
the requirements of enquiry specification any additions/revisions/deviations in the
same as agreed between Purchaser/Consultant/Contractor as per various
documents.

29. Programme for completion of work in the form of “M S PROJECT” should be

given by the Contractors within ten days of starting the work.

Time of completion and very good quality of all finished works should be treated
as “ESSENCE” of this Contract. The Contractor must conceive and adhere to
these requirements while quoting for this Tender.

30. This notice inviting Tenders will form part of the Tender document.

I / WE hereby declare that I / WE have read and understood the above instructions for
the guidance of the Contractors.

SIGNATURE OF THE CONTRACTOR

DATE :-

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 PART 2 A
IMPORTANT NOTICE

CONTRACTOR TO NOTE THE FOLLOWING

Page 1
 IMPORTANT NOTICE

CONTRACTOR TO NOTE THE FOLLOWING

Contractor to carefully read all points given below and consider the same when submitting the
offer. Stipulations in this part shall supersede other relevant clauses, if in contradiction.

LOCATION OF SITE :

The site for the M/s Bayer Material Science Pvt Ltd., for Equipment Erection & Fabrication &
Erection of Piping works hereinafter referred to as "Owner” is located at Ankleshwar, Gujarat

NATURE OF WORK :

Mechanical & Piping Works

DUE DATE OF OFFER :

20/08/2009

LAST DATE OF OFFER :

20/08/2009

EARNEST MONEY DEPOSIT :

No Earnest Money is required by Owner while submitting the Techno-commercial bids by

Contractor.

TIME SCHEDULE FOR THE JOB :

As per Part – 5 enclosed

WATER & POWER :

The owner shall provide construction power and water free of cost at one point and contractor
shall make all necessary arrangement for the proper distribution at locations needed.
Alternative- Contractor to quote power (by DG) and water for their construction
activities.

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VALIDITY PERIOD :

Tender will remain valid for a period of 60 days [ sixty days only] from the last date notified for
the receipt of the Tenders.

COMPRESSED AIR :

By Contractor if necessary

SECURITY DEPOSIT :

Contractor shall furnish within 10 days from date of issue of LOI, Security deposit
equal to 5% of the total estimated contract value in the form of Bank Guarantee.
Validity period of Bank Guarantee shall be initially up to the expiry of contract period.
Validity period shall be suitably extended if requested by Owner, so that the Bank
Guarantee shall always remain valid till issuance of completion certificate. No interest
shall be paid on security deposit amount. This security deposit, in the form of Bank
Guarantee, shall be in addition to Bank Guarantee bond for the retention initially valid
for the entire liquidity damages period and renewable suitably at a later date.

MATERIALS ISSUED BY OWNER

Free issue materials from Owner

RETENTION MONEY :

Refer to Terms of Payment

LIQUIDATED DAMAGES :

In case the Contractor fails to complete the work within the stipulated completion period as
mentioned in Special Conditions of Contract for reasons not attributable to the Owner, he
shall be required to pay to the Owner a sum equal to 1/2% of the total Contract value per
week or part thereof, beyond the scheduled completion period subject to a ceiling of 5% of
the total Contract value towards the liquidated damages. The Owner will have the right to
invoke the bank guarantee for security deposit towards the liquidated damages.

TERMS OF PAYMENT :

 Mobilisation Advance

The Contractor shall be paid 5%of the estimated Contract Value as interest free advance
against submission of Bank Guarantee of same amount.

The Contractor shall be paid 5%of the estimated Contract Value as interest free advance
against submission of Bank Guarantee of same amount after mobilisation at site.
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 Secured Advance for Construction Materials

Client will not pay secured advance..

Running Account Bills (R A Bills)

The Contractor shall submit one running account bill per month. Payments against running
bills shall be considered as Running Account Payment and shall be considered as an
Advance towards final settlement of accounts with the Contractor and not as payment
for the work completed and passed. The payment shall be made after deducting other
recoveries, taxes etc.

The bill shall be submitted once in a month and payment shall be made within Ten (10)
days from the date of certification after deduction of Retention money 5% and Mobilisation
advance 10%.

Retention Money / Performance Guarantee

Cash Retention of 5% of bill value shall be released to the Contractor after completion of
work along with final bill against performance guarantee of likewise amount valid till expiry
of defects liability period and shall be released on satisfactory completion of defects liability
period which shall be 12 months from the date of issue of virtual completion certificate.

 Final Bill

The final bill shall be submitted by Contractor within one month from the completion of
total work and handing over of the works. The final bill shall be accompanied by
supporting vouchers. No claims shall be entertained after receipt of final bill.

PAINTING :

The Contractor shall be responsible for all aspects of painting including surface
preparation by methods specified in the painting specification, procurement of paints
from approved paint manufacturers, application of paint including conducting all tests
during various stages of painting and guarantee of the work as per contract.

Contractor shall at his cost, deploy full time certified painting inspector at site to
monitor all aspects of painting work.

Contractor shall at his own cost, repair any defects noticed during the guarantee
period.

CALIBRATION OF TANKS :

Not Applicable

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PENALTY FOR DELAY :

In case contractor fails to complete the work within the stipulated completion period as
mentioned in Part 5 of Contract for reasons not attributable to the Owner, he shall be required
to pay to the Owner a sum equal to ½ % of the total contract value per week or part thereof
beyond the scheduled completion period, subject to a ceiling of 5% of the total contract value
towards the penalty. The Owner shall have the right to invoke the bank guarantee for security
deposit towards the penalty.

ARBITRATION :

All disputes or differences arising between the parties out of or relating to the construction,
meaning and operation or effect of this Contract or breach thereof or the rights and liabilities of
the parties hereunder shall unless settled amicably, be referred to arbitration in accordance
with the Arbitration Act, 1996 or any statutory modification or re-enactment thereof for the time
being in force. The venue of such arbitration shall be at Mumbai

Page 5
 PART 2B

INSTRUCTIONS TO CONTRACTOR

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 PART 2 b

INSTRUCTIONS TO CONTRACTOR

1.1 GENERAL

Instructions to Contractor, General Terms and Conditions of Contract Works

Involving Construction and Erection (GCC), Special Conditions of Contract
(S.C.C.), Technical Specifications, Drawings, Bill of Quantities, Addenda/
Corrigenda etc shall form part of the Tender and the Contract documents.
Contractor not complying with these instructions is liable to be rejected.

1.2 SITE VISITS

The intended Contractor is deemed to have visited the site of work at his own
cost, before submitting the Tender, in order to acquaint self with the general
terrain of site, subsoil conditions, access to site, working space within allotted
premises, and other conditions like availability and quality of water, labour,
construction materials and all matters needed for construction. Non familiarity
with the site conditions will not be considered as the basis for any claim for
additional compensation, extension of time for completion, any claim whatsoever
or for not carrying out the work in conformity with the drawings and
specifications.

1.3 ITEM RATE CONTRACT

The Tender is for an item rate Contract and not a lumpsum contract. The
payment shall be on item rate basis as per actual quantities of work jointly
approved and measured by Owner/Consultant.

1.4 DOCUMENT TO BE ENCLOSED WITH TENDER

1.4.1 The Contractor shall submit two sets of bill of quantities with rates duly
filled in and signed by the Contractor.

1.4.2 The Contractor shall also prepare two sets of all proposal forms duly
filled in and signed with all requisite details noted therein for labour
rates, schedule of material prices, list of equipment / machinery, site
organisation, power and water requirement deviations, list of non quoted
items, if any, etc.

1.5 TAXES AND DUTIES

1.5.1 Income - Tax

Income Tax at the prevailing rate, on gross amount billed, shall be

deducted from the Contractor's bills as per relevant provisions of the
Income Tax Act.

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 1.5.2 Excise Duty

Contractor shall be fully and exclusively liable for all the taxes present
and future such as works contract tax, octroi royalty and any other
statutory taxes, levies, cess etc. now in force and hereafter increased,
imposed or modified in respect of works and materials by central and
state government authorities. Works Contract Tax shall be reimbursed to
Contractor by the Owner at actual on submission of documentary
evidence.

1.6 DEFECTS LIABILITY PERIOD/MAINTENANCE PERIOD

The defect liability period shall be 12 months from the date of issue of completion
certificate by the Owner. In the event of more than one such certificate having
been issued by the Owner under the said clause, this defect liability
period/maintenance period will commence from the respective dates, so
certified.

All defective work shall be rectified by the Contractor at his own expense if
the necessity thereof shall in the opinion of the Consultant/Owner due to the
use of materials or workmanship not in accordance with Contract or due to
neglect or failure on the part of the Contractor.

1.7 RATES

Prices and rates quoted for all items shall be inclusive of all charges for supply of
materials(except free issue material mentioned elsewhere), transport, loading,
unloading, wastage, storing and preserving, fabrication, fixing, installation,
construction, erection, scaffolding, staging, working platforms, necessary use of
tools, tackles, plants and equipment, payment of works contract tax (reimbursed
by client at actual) royalty, octroi duties, testing, samples, any incidental
expenses etc. complete and also contractor's overheads and profits, and
everything necessary for due performance of work under this contract.

Contractor shall indicate the requirement of any special forms for concession in
Taxes/duties

No extra claims whatsoever shall be entertained on any account.

1.8 VALIDITY OF TENDER

The Tender shall be valid for 60 days from the due date of Submission.

1.9 VALIDITY OF RATES (CONTRACT PERIOD PLUS GRACE PERIOD

The rates shall remain valid and firm for the Contract period from the date of
issue of Letter of Intent. However, if the work is extended beyond contract
period because of reasons not attributable to the Owner, the Contractor shall be
suitably given the extension of time without any compensation for such
extension.

Rates will be valid 3 months after contract completion.

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1.10 EXTRA ITEMS

In order to facilitate the finalisation of the rate for items not covered in the Bill of
Quantities but which are similar in nature to the items already covered therein,
the rates for these items shall be arrived at by extending the rates for similar
items as applicable. In case it is not possible to derive rate of extra item as
mentioned earlier, Contractor shall submit detailed rate analysis based on norms
by CPWD for productivity and material consumption along with supporting
vouchers to substantiate the rate for approval to Owner. The contractor shall
consider 15% as overheads and profits over the cost of labour and materials
consumed, in the rate analysis.

1.11 INSURANCE

Without prejudice to the generally of clauses of the General Conditions of

Contract before commencement of the work at site, the Contractor shall take out
and deposit with the Consultant a ‘Contractor’s All Risk Insurance Policy’ in the
joint names of the Consultant and the Contractor for maximum Rs.30,00,000/-
subject to individual limit Rs 2,00,000/- as indicated I the following pages of the
tender document under General Conditions of Contract. The cost of all the
materials supplied by the Employer shall also be included for the Insurance.

Insurance policy as per tender will be obtained and submitted by

Contractor to Owner within 10 days.

Third party insurance shall be taken by contractor Rs. 5,00,000/- per incident
maximum 3 incidents i.e. 15,00,000/-.

1.11.1 Workmen's Compensation

Workmen's compensation in accordance with the statutory provisions

revised up to dates. Contractor shall provide for PF/ESI/BONUS
coverage for his employees and his sub-contractor's employees as per
the latest provisions of the act.

All statutory provisions like PF, Workmen compensation policy etc should
be complied & proofs submitted by Contractor to Owner within 7 days
from LOI

1.11.2 Personal Accident Policy

The Owner shall not be liable for or in respect or in consequence of any

accident or injury to any workman or other person in the employment of
Contractor or sub-contractor.

1.12 LOCAL LAWS AND REGULATIONS

It would be the full responsibility of the Contractor to abide by all local laws,
regulations etc.

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1.13 ARTICLES OF VALUE FOUND

All gold, silver and other minerals of any description and all precious stones,
coins, treasure relics, antiquities and other similar things which shall be found in
under or upon the site, shall be the property of the Owner, and the Contractor
shall duly preserve the same to the satisfaction of the Owner / Consultant and
shall from time to time deliver the same to such person or persons indicated by
the Owner.

1.14 GUARANTEE

In addition to the guarantee against defects, the Contractor shall arrange to

endorse the related manufacturer's guarantee, test certificate for bought out
items of his supply in the Owner's name at no extra cost.

1.15 QUOTE RATE ITEMS

Deleted

1.16 RIGHT TO ACCEPT OR REJECT TENDER

The Owner reserves the right to accept or reject any or every tender without
assigning any reasons whatsoever/or to negotiate with the Contractor(s) in the
manner the Owner considers suitable.

1.17 MOBILE PHONE

Cell phone numbers of all key personnel shall be furnished.

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 PART 3

GENERAL CONDITION OF CONTRACT

1
 PART 3

GENERAL CONDITIONS OF CONTRACT

(Referred to in Condition 1 of “Articles of Agreement”)

1.0 DEFINITIONS

1.1 The contract document shall consist of the various documents listed under
clause 2.0 here below.

1.2 The Owner, the Contractor and the consultant are those mentioned as such in
the Agreement and shall include their legal representatives, assigns or
successor. They are treated throughout the Contract Document as if each
were of the singular number and masculine gender.

1.3 The “Site” shall mean the site of the Contract Works including any building
and erections thereon and any other land allotted by the Owner / Consultant
for Contractor’s use.

1.4 The term “Sub-Contractor”, as employed herein, includes those having a

direct contract with the Contractor and it includes one who furnishes materials
worked to a special design according to the plans or specifications of the
Work but does not include one who merely furnishes materials, not so
worked. Any one doing work on a piece rate basis shall be deemed a Sub-
Contractor.

1.5 “Written Notice “ shall be deemed to have been duly served if delivered in
person to the individual or to a member of the firm or to an office of the
Corporation for whom it is intended, or if delivered at or sent by registered
mail to the last business address known to him who gives the notice.

1.6 The term “Work” of the Contractor or Sub-Contractor includes labour or

material or both.

1.7 “Clerk of Works” shall mean the person appointed by the Consultant to
inspect and certify measurement of the works at site and for supervising the
works on site.

1.8 All the time limits stated in the Contract Document are the essence of the
Contract.

1.9 The law of the place of work shall govern the construction under this contract.

1.10 The “Date of Virtual Completion" of the Work or specified portion of the Work
is the date when construction is sufficiently completed, in accordance with the
Contract Documents as modified by any change or variation order agreed to
by the parties, so that the Owner can take over such completed work and
occupy for the use it was intended as per certificate issued by consultant.

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2.0 CONTRACT DOCUMENT

2.1 The following documents shall constitute the Contract Document:

2.1.1 Articles of Agreement (executed by the Owner and the Contractor).

2.1.2 Notice inviting Tender.

2.1.3 Instructions to tenderrers and Special Conditions and Additional

Special Conditions of Contract.

2.1.4 Form of Tender (submitted by the Contractor)

2.1.5 General Conditions of Contract.

2.1.6 General Specifications.

2.1.7 Common Specifications.

2.1.8 Detailed item specifications.

2.1.9 Drawing submitted with the tender in terms of clause 3.0 of the Tender
Notice (Part 1) and subsequently revised / modified by consultant.

2.1.10 Contract Bills (including all modifications thereof incorporated before

execution of the agreement.

2.1.11 Letter (if any) accompanying the tender.

2.1.12 Correspondences (if any) between the parties hereto after submission
of the tender till completion of work and the Owner’s Letter of
Acceptance of the Tender.

2.1.13 Letter of Acceptance of the tender (or Work Order) issued to the
Contractor by the Owner.

2.1.14 Further drawings and / or instructions issued by the Consultant/

Owner from time to time relating to the Works.

2.1.15 Samples, Shop Drawings and Progress Charts referred to in Clause

12 and 13 herein below.

2.2 The Contract Document is complementary. What is called for in any one shall
be as binding as if called for by all.

2.3 The original Contract Document shall remain in the custody of the Owner so
as to be available at all reasonable times for the inspection of the consultant
or of the Contractor. Immediately after the execution of the Contract
Agreement, one copy of the Contract Document shall (without charge) be
supplied to the Contractor.

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 2.4 So soon as is possible after the execution of this Contract, two copies of the
Specifications, Drawings, Descriptive Schedules or other like documents
necessary for use in carrying out the Work shall (without charge) be supplied
to the Contractor. Provided that nothing contained in the said Specifications,
Descriptive schedules or other documents shall impose any obligation the
beyond those imposed by the Contract Document namely, the Contract
Drawing, the Contract Bills, the Articles or Agreement and this General
Conditions of Contract.

2.5 After the award of the Contract, the Contractor (without charge) shall be
supplied two copies of all such further drawings and details as may be
prepared by the Consultant / Owner from time to time as the Work proceeds
as are reasonably necessary either to explain or amplify the Contract
Drawings or to enable the Contractor to carry out and complete the work in
accordance with this General Conditions of Contract. Provided all such
drawings and details shall be a reasonable development of the work
described in the Contract Document.

2.6 The Contractor shall keep upon the Site one copy of the specifications,
Drawings, Descriptive Schedules or other like document referred to in
Clauses 2.4 and 2.5 above and written instructions referred to in clauses 8.0,
15.2 and 29.0 herein below so as to be available to the Consultant / Owner or
his representative / s at all reasonable times.

2.7 None of the documents herein before mentioned shall be used by the
Contractor for any purpose other than this Contract and neither the Owner /
Consultant shall divulge or use any of the prices in the Contract Bills except
for the purpose of this Contract.

2.8 Towards the issue of Final Certificate under clause 27.7 herein below, the
Contractor shall if so requested by the consultant forthwith return to the
Consultant all Drawings, Details, Specifications, Descriptive Schedules and
other documents of like nature which bears his name.

3.0 TYPE OF CONTRACT

The Contract shall be an item rate contract. The Contractor shall be paid for the
actual quantity of work done, as measured at site as per approved Contract Drawings
at the accepted contract rates as provided in the Contract Bills.

4.0 SCHEDULE OF QUANTITIES

4.1 The quantities given in the Schedule of Quantities are provisional and are
meant to indicate the intent of the work and to provide a uniform basis for
tendering. The consultant and / or the Owner, reserves the right to increase or
decrease any of the quantities or to totally omit any item of work and the
Contractor shall not claim any extra or damages on these grounds.

4.2 The quality and quantity of work included in the Contract Sum shall be
deemed to be that which is set out in the Contract Bills which bills, unless
otherwise expressly stated in respect of any specified item, shall be deemed
to have been prepared in accordance with the principles of the Standard
Method of Measurement of Building Works last before issued by the Indian
Standard Institution but save as aforesaid nothing contained in the Contract

4
 Bills shall override, modify or affect in that which is contained in any of the
clauses of this General Conditions of Contract.

4.3 Any error in description or in quantity or omission of items from the Contract
Bills shall not vitiate this Contract but shall be treated as a variation under
Clause 26.0 herein below.

5.0 CONTRACT DRAWINGS

5.1 In general, the Drawings shall indicate dimensions, positions and type of
construction, the specifications shall indicate the qualities and the methods
and the Bill of Quantities shall indicate the quantum and the rate for each item
of work. Any work indicated on the Drawings but not mentioned in the
Specification or vice- versa shall be furnished as though fully set forth in both.
Work not specifically detailed, called for, marked or specified shall be the
same as similar parts that are detailed, marked or specified.

5.2 The Contractor’s work shall not deviate from the Drawings and the
Specifications. The Consultants interpretation of these documents shall be
final and without appeal.

5.3 Errors or in consistencies discovered by the Contractor in the Drawings and

Specifications shall be promptly brought to the attention of the Consultant
through the clerk of works, for interpretation or correction. Local conditions,
which may affect the work, shall likewise be brought to the consultant’s
attention. If at any time, it is discovered that Work is being done which is not
in accordance with the Contract Drawings and Specifications, the Contractor
shall correct the work immediately. The contractor shall not carry on work
except with the knowledge of the clerk of works.

5.4 Figured dimensions on the Scale drawings and large size details shall take
precedence over small-scale drawings. Any work done before receipt of such
details, if not in accordance with the same, shall be removed and replaced or
adjusted by the Contractor at his own expense to the satisfaction of the
Consultant / Owner. This General Condition shall apply with equal force to all
the Work including Authorised extra works.

5.5 All drawings, Bill of Quantities and Specifications including copies thereof
furnished to the Contractor are the property of the Owner and Consultant.
They shall not be used on any other work and shall be returned to the
Consultant and Owner on request upon completion or termination of the
Contract.

6.0 CONTRACT SUM

The Contract Sum shall not be adjusted or altered in any way whatsoever otherwise
than in accordance with the express provisions of this General Conditions of Contract
and subject to Clause 5.2 above, any error (whether or arithmetic or otherwise) in the
computation of the Contract sum shall be deemed to have been accepted by the
parties hereto.

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7.0 SCOPE AND INTENT

7.1 Scope

The general character and the scope of the Work is illustrated and defined by
the signed drawings, the specifications and the Bill of Quantities hereto
annexed. If the Contractor shall find any discrepancy in or divergence
between the Contract Drawings, specifications and / or the Contract Bills, he
shall immediately give to the Consultant / Owner a written notice specifying
the discrepancy or divergence and the Owner / Consultant shall issue
instructions in regard thereto.

7.2 Extent

The Contractor shall carry out and complete the work in every respect in
accordance with the Contract and with the directions of and to the reasonable
satisfaction of the Consultant / Owner. The consultant may, in his absolute
discretion and from time to time issue further drawings, details and / or written
instructions, written directions and written explanations all of which are
collectively referred to as Consultants instructions. All such Drawings and
instructions shall be consistent with Contract Document, true developments
thereof and reasonably inferable therefrom.

7.3 Intent

This intention of the Document is to include all labour and materials,

equipment and transportation necessary for the proper execution of the Work.
Materials of work described in words, which so applied have a well-known
technical or trade meaning, shall be held to refer to such recognised
standard.

8.0 CONSULTANT’S INSTRUCTIONS

8.1 The Contractor shall forthwith comply with and duly execute any such works
comprised in such instructions issued to him by the consultant in regard to
any matter in respect of which the consultant is expressly empowered by
these conditions to issue instructions. Provided always that verbal
instructions, directions and explanations given to the Contractor (or his work
representative) by the Consultant shall if involving a variation be confirmed in
writing. If within seven days after receipt of a written notice from the
Consultant, requiring compliance with an instruction the Contractor does not
comply herewith, then the Owner may employ and pay other persons to
execute any work whatsoever which may be necessary to give effect to such
instructions and all cost incurred with such employment shall be recoverable
from the Contractor by the Owner as a debt or may be deducted by him from
any monies due or to become due to the Contractor under this Contract.

8.2 Upon receipt of what purpose to be instruction issued to him by the consultant
the Contractor may request the consultant to specify in writing the provision of
these conditions which empowers the issue of the said instruction. The
consultant shall forthwith comply with any such request and if the Contractor
shall thereafter comply with the said instruction, then the issue of the same
shall have been deemed for all purposes of this contract to have been

6
 empowered by the provision of these conditions specified by the consultant in
answer to the Contractor’s request.

8.3 All instructions issued by the consultant shall be in writing with copy to the
Owner. Any instruction issued orally shall be immediate effect, but shall be
confirmed in writing by the Contractor to the consultant within seven days and
if not dissented from in writing by the consultant to the Contractor within
seven days from receipt of the Contractor’s confirmation shall take effect as
from the expiration of the latter said seven days.

Provided always

8.3.1 That if the Consultant within seven days of giving such an oral
instruction shall himself confirm the same in writing, the Contractor
shall not be obliged to confirm as aforesaid and the said instruction
shall take effect as from the date of the consultant’s confirmation.

8.3.2 That if neither the Contractor nor the consultant shall confirm such an
oral instruction in the manner and the time aforesaid but the
Contractor shall nevertheless comply with the same, then the
Consultant may confirm the same in writing at any time prior to the
issue of the Final Certificate and the said instruction shall thereupon
be deemed to have taken effect on the date on which it was issued.

8.4 The Clerk of works shall maintain a register / memo book of all verbal
instructions and changes issued at site.

9.0 FACILITIES AND CO-OPERATION

9.1 In the case of works indicated on the Drawings but not included in the
contract the Contractor shall provide necessary facilities and co-operation for
any sub-contractor or supplier who may be approved by the Owner. The
Contractor shall do all cutting, filling or patching of his work that may be
required to make its several parts come together properly and fit it to receive
or be received by work of other contractors shown upon or reasonably implied
by the Drawings and Specifications for the completed structure and he shall
make good all such cutting, filling or patching after completion of works of
other contractors as the consultant may direct. Any cost caused by the
defectively or ill-timed work shall be borne by the partly responsible therefore.

9.2 The contractor shall not endanger any work by cutting, excavating or
otherwise altering the work and shall not cut or alter the work of any other
contractor save with the consent of the Owner / Consultant.

11.0 SITE VISIT

11.1 Before tendering, the Contractor shall have visited and examined the Site and
satisfied himself as the nature of existing roads or other means of
communication and the character of the soil and of the excavations, the
correct dimensions of the Work and the facilities for obtaining any special
articles called for in the Contract Document and shall have obtained generally
his own information on all matters affecting the commencement, continuation
and progress of the works. No extra charge made in consequence of any of
these points, or on the grounds of insufficient description, will be allowed.
Should the Contractor after visiting the Site, find discrepancies, omissions,

7
 ambiguities or conflicts in or among the Contract Document, or to be in doubt
as to their meaning, he shall bring the questions to the Owner / Consultant /
Owner attention, not later than seven days before the last date for submission
of tender and obtain all necessary clarifications thereto.

11.2 Possession

The Contractor shall be allowed admittance to the Site on the “Date of

Commencement “ stated in the Appendix hereto and he shall thereupon and
forthwith begin the Work and shall regularly proceed with and complete the
same on or before the “Date of Completion” stated in the Appendix hereto
subject nevertheless to the provision for extension of time hereinafter
contained.

11.3 Treasures

Any treasures, coins or objects of Antiquity which may be found at site shall
be handed over to the Owner immediately.

12.0 SAMPLES AND SHOP DRAWINGS

12.1 After the award of the Contract, the Contractor shall furnish to the Clerk of
Works for the approval of the Owner / Consultant with such promptness as to
cause no delay in his work or in that of any other Sub-Contractor, samples
and shop drawings required by the specifications or by the Owner /
Consultant. Samples shall be delivered free of cost.

12.2 The consultant shall check and approve such samples, with reasonable
promptness only for conformity with the design concept of the Works and for
compliance with the information in the Contract Documents. The work shall
be in accordance with the approved samples.

13.0 PROGRESS CHART

The Contractor shall prepare progress charts and submit the same for approval of
the consultant and for his record within ten days of the award of the Contract.

The charts shall indicate the “Accepted dates” of commencement and completion of
each of the items of the Work and shall be in a form approved by the Consultant.
The charts shall also indicate the scheduling of samples, shop drawings and the
approvals. The charts as approved by the consultant will form part of the Agreement.

8
14.0 ACCESS FOR OWNER / CONSULTANT TO THE WORKS

The Owner / Consultant and his representatives shall at all reasonable times have
access to the works and the workshops or other placed of the Contractor where work
is being prepared for the Contract and when work is to be so prepared in workshops
or other places of a Sub-Contractor (whether or not a nominated Sub-Contractor as
defined in clause 32 herein below), the Contractor shall have a term in the Sub-
Contract so as to secure a similar right of access to those workshops or placed for
the Owner / Consultant and his representatives and shall do all things reasonably
necessary to make right effective.

15.0 CONSULTANT’S STATUS AND DECISIONS

15.1 The consultant shall be the Owner’s representative during the construction
period. The consultant shall periodically visit the site to familiarise himself
generally with the progress and the quality of the work and to determine in
general if the work is proceeding in accordance with the contract document.
Consultant shall not be required to make exhaustive or continuous on site
inspection to check the quality or quantity or quantity of the work and he shall
not be responsible for the contractor’s failure to carry out the construction
work in accordance with the Contract Document. During such visits and on
the basis of this observations while at the site he shall keep the Owner
informed of the progress of the Work, shall endeavour to guard the Owner
against defects and deficiencies in the work of the contractor and he shall
condemn work which fails to conform to the Contract Document. He shall
have authority to act on behalf of the Owner only to the extent expressly
provided in the Contract Document or otherwise in writing which shall be
shown to the Contractor. He shall have authority to stop the work, whenever
such stoppage may be necessary in his reasonable opinion, to ensure the
proper execution of the Contract. The consultant shall be in the first instance
the interpreter of the conditions of this contract and the judge of its
performance. He shall side neither with the Owner nor with the Contractor
but shall use his powers under the Contract to enforce its faithful performance
by both. In case of the termination of the appointment of the consultant, the
Owner shall appoint a capable and reputable Consultant against whom the
Contractor shall make no reasonable objection and whose status under the
Contract shall be that of the former Consultant. Any dispute in connection
with such appointment shall be subject to Arbitration.

15.2 Decision

The consultant shall within a reasonable time make decisions on all claims of
the Owner or the Contractor and all other matters relating to the execution
and progress of the work or the interpretation of the Contract Document. The
consultant may in his absolute discretion and from time to time issue further
drawings, details and / or written instructions, written directions and written
explanations in regard to :

15.2.1 Variation or modifications of the design.

15.2.2 The quality or quantity of works or the additions or omissions or

substitution of any work.

9
 15.2.3 Any discrepancy in or divergence between the Drawings and / or
specifications.

15.2.4 The removal and / or re-examination of any works executed by the

Contractor.

15.2.5 The dismissal from the works of any persons employed thereon.

15.2.6 The opening up for inspection of any work covered up.

15.2.7 The amending and making good of any defects under Defects Liability
Period.

15.2.8 The removal from the Site of any materials brought thereon by the
Contractor and the substitution of any other material therefor.

15.2.9 Assignment and sub-letting.

15.2.10 Delay and extension time.

15.2.11 The postponement of any work to be executed under the provision

of this Contract.

15.3 Dismissal

The Contractor shall on the request of the Owner / Consultant immediately

dismiss from the Works any person employed thereof by Contractor who may
in the opinion of the Owner / Consultants be incompetent or misconducts
himself and such person shall not be again employed on the Work without the
permission of the Owner / Consultant.

16.0 CLERK OF WORKS

16.1 The contractor shall afford the Clerk of Works every facility and assistance for
inspecting the Works and materials and for checking and measuring time and
materials. Neither Clerk of Works nor any representative of the consultant
shall have power to set out works or to revoke, alter, enlarge or relax any
requirements of the Contract or to sanction any day work, additions,
alterations, deviations or omissions, or any extra work whatever except in so
far as such authority may be specifically conferred by a written order of the
Consultant / Owner.

16.2 The clerk of works or any representative of the consultant shall have power to
give notice to the contractor or to his representative of non approval of any
work or materials and such work shall be suspended or the use of such
materials shall be discontinued until the decision of the consultant is obtained.
The works will from time to time be examined by the consultant, the Clerk of
Works or the consultants representative but such examination shall not in any
way exonerate the contractor from the obligation to remedy any defects which
may be found to exist at any stage of the works or after the same is
completed. Subject to the limitations of this clause the contractor shall take
instructions only from the Consultant / Owner.

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17.0 CONTRACTOR’S FIELD ORGANISATION AND EQUIPMENT

17.1 Works Manager

The contractor shall constantly keep on his work during its progress one
qualified and competent Works Manager acceptable to the Owner /
Consultant (assisted by a team of Consultants, supervisors and Technicians)
who will be responsible for the carrying out of the Works to the true meaning
of Drawings, Specifications, Schedule of Quantities and Consultant
instructions and directions, to the satisfaction of the Owner / Consultant. Any
directions or instructions given to him ( or to his assistants) by the Owner /
Consultant shall be deemed to have been issued to the Contractor. Attention
of the Contractor is called to the importance of requesting instructions from
the Consultant before undertaking any work where consultant’s directions or
instructions are required. Any such work done in advance of such
instructions will be liable to be removed.

17.2 Equipment

The Contractor shall provide and install all necessary barricades, hoists,
ladders, stagings, scaffoldings, tools, tackles, plants, instruments, equipment
etc. and all transport for labour, materials and plant necessary for the proper
carrying on execution, completion and maintenance of the Work to the
satisfaction of the Consultant / Owner.

17.3 Security

The Contractor shall make his own security arrangements to guard the site
and works at all times, at his own expense. The security arrangements shall
be adequate to maintain strict control on the movement of material and
labour. The Contractor shall extend the security arrangements to guard the
materials stored and / or fixed on the premises by the Sub-Contractors.

17.4 Storage of Materials

The contractor shall provide, erect, maintain and removed after completion of
the works, proper temporary sheds for the storage and protection of the
materials etc. and also for the execution of work which may be prepared on
the site.

17.5 Sanitary Conveniences

The Contractor shall provide and erect all necessary temporary sanitary
convenience for the site staff and the workmen, maintain in a clean orderly
condition, clear away and deodorise the ground after removal at the site.

17.6 Scaffolding, Staging, Guard-rails, etc.

The Contractor shall provide all necessary temporary scaffoldings, staging,

platforms, guardrails, stairs etc. (with sufficiently strong and adequate
supports suitable for particular situations) which shall be required during
constructions. The temporary access to the various parts of the works shall
be rigid and strong enough to avoid any chance of mishaps. The
arrangement proposed shall be subject to the approval of the Owner /
Consultant.

11
 (Contractor shall use M.S. pipe / Acro material. Bamboos will not be
accepted as scaffolding material.)

18.0 TAXES

Unless otherwise specified under Clause 14 of Part -1 Notice of inviting tender the
Contractor shall include in his tender for all incidentals towards, Works Contract Tax
shall be (reimbursed at actual against documentary evidence) Octroi and similar
taxes, duties, levies etc. legally payable and it shall be assumed that his rates cover
for all taxes, duties and levies and no claim on this account will be entertained.

19.0 STATUTORY OBLIGATIONS, NOTICES, FEES AND CHARGES

19.1 The Contractor shall comply with and give all notices required by any
Government authority, and instrument, rule or order made under any Act of
Parliament or any regulation or bye-law of any local authority relating to the
work or with whose system the same is or will be connected. The Contractor,
before making any variation from the Contract Drawings or Contract Bills
necessitated by such compliance, shall give to the Owner / Consultant a
written notice specifying and giving reasons for such variations and the
Owner / Consultant may issue instructions in regard thereto. If, within 10
days of having given the said written notice, the Contractor does not receive
any instruction in regard to the matters therein specified, he shall proceed
with the work conforming to the act of Parliament, instrument, rule, order,
regulations or bye-law in question and any variation thereby necessitated
shall e deemed to be a variation required by the Owner / Consultant.

19.2 The contractor shall pay and indemnify the Owner against liability in respect
of any fees or charges (including any rates and taxes) legally demandable
under any Act of Parliament, instrument, rule or order or any regulation or
bye-law or any local authority in respect of the Work.

20.0 ROYALTIES AND PATENT RIGHTS

All royalties or other sums payable in respect of the supply and use in carrying out
the Work as desired by or referred to in the Contract Bills of any patented articles,
process or inventions shall be deemed to have been included in the Contract Sum
and the Contractor shall indemnify the Owner from and against all claims,
proceedings, damages, costs and expenses which may be brought or made against
the Owner or to which he may be put by reason of the Contractor infringing or being
held to have infringed any patent rights in relation to any such articles, processes
and inventions.

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21.0 ASSIGNMENT OR SUB-LETTING

The Contractor shall not without the written consent of the Owner assign this contract
and shall not without the written consent of the Owner / Consultant (which consent
shall not be unreasonably withheld to the prejudice of the Contractor) sub-let any
portion of the work.

22.0 SUB-CONTRACTOR

Before awarding any Sub-Contract, the Contractor shall notify the Owner /
Consultant in writing the names of the sub-contractors proposed for the principal
parts of the Work and for such other parts as the Consultant / Consultants may
direct and shall not employ any to whom the Owner / Consultant may have
reasonable objection. The Owner / Consultant, however, shall have power to obtain
estimate and select other agencies to carry out any of the work as described below :

22.1 All specialists, merchants, tradesmen and others executing any works or
supplying and fixing any goods, who may be nominated or selected by the
Owner / Consultant shall be deemed to be Sub-Contractors employed by the
Contractor and are to be referred as nominated Sub-contractors. No
nominated Sub-Contractor shall be employed on or in connection with the
work against whom the contractor shall make reasonable objection or (save
where the Owner / Consultant and Contractor shall otherwise agree) who will
not enter into a contract providing

22.1.1 That the nominated Sub-Contractor shall carry out and complete the
sub-contract works in every respect to the reasonable satisfaction of
the Contractor and of the Owner / Consultant and in conformity with all
the reasonable directions and requirements of the Contractor.

22.1.2 That the nominated Sub-Contractor shall observe, perform and

comply with all the provisions of this Contract on the part of the
Contractor to be observed performed and complied with (other than
clause 44 herein below) so far as they relate and apply to the sub-
contract works or to nay portion of the same.

22.1.3 That the nominated Sub-Contractor shall indemnify the Contractor

against the same liabilities in respect of the sub-contract work as
those for which the Contractor is liable to indemnify the Consultant
under this Contract.

22.1.4 That the nominated Sub-Contractor shall indemnify the Contractor

against claims in respect of any negligence, omission or default of
such sub-contractor, his servants or agents or any misuse by him or
them of any scaffolding or other plant and shall insure himself against
any such claims and produce the policy or policies and premium
receipts as and when required by the Contractor or consultants.

22.1.5 That payment in respect of any work, materials or good comprised in

the sub-contract shall be made within fourteen days after receipt by
the Contractor of the consultants certificate under clause 27 herein
below which states as due an amount calculated by including the total
value of such work, materials or goods and shall when due be subject

13
 to the retention by the Contractor of the sums mentioned in clause
22.1.7 herein below.

22.1.6 That the sub-contract work shall be completed within the period or
(where they are to be completed in sections) periods therein specified,
that the contractor shall not without the written consent of the Owner /
Consultant grant any extension of time for the completion of the sub-
contractor work or any section thereof and that the Contractor shall
inform the Owner / Consultant of any representation made by the
nominated Sub-Contractor as to the cause of any delay in the
progress of completion of the sub-contract work or of any section
thereof.

22.1.7 That the Consultant shall retain from the sum directed by the
consultant having been included in the calculation of the amount
stated as due in any certificate issued under Clause 27 herein below
in respect of the total value of work, materials or goods executed or
supplied by the nominated Sub-Contractor the percentage of such
value named in the Appendix hereto as “Retention Percentage” upto a
total amount not exceeding a sum which bears the same ratio to the
sub-contract price as the unreduced sum named in the Appendix
hereto as “Limit of Retention Fund” bears to the contract sum; and that
the Contractor’s interest in any sums so retained (by whomsoever
held) shall be fiduciary as trustee for the nominated Sub-Contractor
(but without obligation to invest); that the nominated Sub-Contractor’s
beneficial interest in such sums shall be subject only to the right of the
Contractor to have recourse thereto from time to time for payment of
any amount which he is entitled under the Sub-Contract to deduct
from any sum due or to become due to the nominated Sub-Contractor;
and that if and when such sums or any part thereof are released to the
nominated Sub-Contractor they shall be paid in full if paid within
fourteen days of the date fixed for their release in the Sub-Contract.

22.2 Before issuing any certificate, the consultant may request the Contractor to
furnish to him reasonable proof that all amounts included in the calculation of
the amount stated as due on previous certificates in respect of the total value
of work materials or goods executed or supplied by any nominated Sub-
Contractor have been duly discharged and if the contractor fails to comply
with request, the consultant shall issue a certificate to that effect and
thereupon the Owner may himself pay such amounts to any nominated Sub-
Contractor concerned and deduct the same from any sums due or to become
due to the Contractor.

22.3 Neither the existence nor the exercise of the foregoing powers nor anything
else contained in this General Conditions of Contract shall render the Owner
in any way liable to any nominated Sub-Contractor.

22.4 Where the Contractor in the ordinary course of his business directly carried
out works for which Prime Cost or Provisional sums are included in the
Contract Bills and the Owner / Consultant is prepared to receive tenders from
other Contractor for such items, then the contractor shall be permitted to
tender for the same or any of them out without prejudice to the Consultant’s
right to reject the lowest or any tender. If the Contractor’s tender is accepted
he shall not sublet the work without the consent in writing of the Owner /
Consultant.

14
 22.5 It shall be a condition of any tender accepted under Clause 22.4 above the
clause 26 herein below shall apply in respect of the item work included in the
tender as if for the reference therein to the Contract Drawings and the
Contract Bills there were references to the equivalent documents included in
or referred to in the Tender.

22.6 The Contractor shall allow for general attendance upon Sub-Contractors
including free use of plant, scaffolding etc. and is to allow them the use of
sanitary convenience, facilities for storing materials, other amenities and
affording them all reasonable facilities for carrying out their contracts.

23.0 PRIME COST

23.1 Such sums shall be understood to mean the net cost to be defrayed as Prime
Cost after deducting any trade or other discount and shall include sales tax
(where applicable) and other taxes, duties, levies and the cost of packing,
carriage and delivery. Provided that where in the opinion of the consultant
the Contractor has incurred expense for special packing, carriage and
delivery. Provided that where in the opinion of the consultant the Contractor
has incurred expense for special packing or special carriage such special
expense shall be allowed as part of the sums actually paid by the Contractor.

23.2 Such sums shall be expended in favour of such persons as the consultant
shall instruct and all specialists, merchants, tradesmen or others who are
nominated by the consultant to supply materials or goods are hereby declared
to be suppliers to the Contractor and are referred to in this General
Conditions of Contract as “Nominated Suppliers” provided that the consultant
shall not (save where the consultant and contractor shall otherwise agree)
nominate as a supplier a person who will not enter into a contract of sale
which provides (inter alia) :

23.2.1 That the materials or goods to be supplied shall be to the reasonable

satisfaction of the Owner / Consultant.

23.2.2 That the Nominated Supplier shall make good by replacement or

otherwise any defects in the materials or goods supplied with appear
within such period as is therein mentioned and shall not bear any
expenses reasonably incurred by the Contractor as a direct
consequence of such defects, provided that :

a) Where the materials or goods have been used or fixed such

defects are not such that examination by the Contractor ought to
have revealed them before using or fixing.

b) Such defects are due solely to defective workmanship or material

in the goods supplied and shall not have been caused by improper
storage by the Contractor or misuse or by any act or neglect of
either the Contractor, the Owner / Consultant by any person or
persons for whom they may be responsible.

24.0 ARTISTS AND TRADESMEN

The Contractor shall permit the execution of work not forming part of this Contract by
artists, tradesmen or others engaged by the Consultant. Every such person shall for

15
 the purposes of clause 41 herein below be deemed to be a person for whom the
Owner is responsible and not be a Sub-Contractor.

25.0 SEPARATE CONTRACTS

The Owner reserves the right to let other contractors in connection with his
work under similar general conditions. The Contractor shall afford other Contractors
reasonable opportunity for the introduction and storage of their materials and
execution of their work and shall properly connect and co-ordinate his work with
theirs. If any part of the Contractor’s or Sub-Contractor work depends for proper
execution or results upon the work of any other contractor or Sub-Contractor, the
Contractor shall inspect and promptly report to he Consultant any defects in such
work that render it unsuitable for such proper execution and results. Failure of the
Contractor to so inspect and report shall constitute an acceptance of the other
contractor’s works as fit and proper for the reception of his Work, except as to
defects which may develop in the other contractor’s or Sub-Contractor’s work after
the execution of his subsequent work the Contractor shall measure work already in
place and shall at once report to the Consultant / Owner and discrepancy between
the executed work and the Drawings.

26.0 VARIATIONS, PROVISIONAL AND PRIME COST SUMS

26.1 Where work cannot properly be measured and valued, the Contractor shall be
allowed day work rates on the prices prevailing when such work is carried out
(unless otherwise provided in the Contract Bills)

a) At the rates if any, inserted by the Contractor in the Contract Bills or

b) When no such rates have been inserted, at the rates prevailing in the
market for material and labour and at the control rates for the controlled
materials including in all cases the rate for delivery of the material at the
work.

Provided that in any case voucher specifying the time daily spent upon the
work (and if required by the Clerk of Works the workmen’s names) and the
materials employed shall be delivered for verification to the consultant or his
Authorised representative not later than the end of the week following that in
which the work has been executed.

26.2 Effect shall be given to the measurement and valuation of Variations in

Interim Certificates and by adjustment of the Contract sum; and effect shall be
given to the measurement and valuation of Work for which a provisional sum
is included in the Contract Bills under the said clause in Interim Certificate
and by adjustment of the Contract Sum in accordance with clause 27 herein
below.

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27.0 CERTIFICATES AND PAYMENT

27.1 At the “Period of Interim Certificate” named in the Appendix hereto, the
consultant shall issue a certificate stating the amount due to the Contractor
from the Owner and the Contractor be entitled to payment therefore within the
“Period of Honouring Certificates” named in the Appendix hereto. Interim
Certificates shall be made by the consultant not more than once a month
based on the “quantities” certified by the Clerk of Work against Running Bills
presented (in quadruplicate) by the Contractor.

27.2 The amount stated as due in an Interim Certificate shall, subject to any
agreement between the parties as to stage payments, be the total value of the
Work properly executed and of the materials and goods (for materials as per
clause 30 of Notice Inviting Tenders) delivered to or adjacent to the work for
use thereon upto and including a date not more than seven days before the
date of the said Certificate less any amount the Owner is bound to make
statutory deduction towards Income Tax (T.D.S) etc. less any amount which
shall be retained by the Owner (as provided in clause 27.3 herein below) and
less any instalments previously paid under these conditions, Provided that the
value of the unfixed materials and goods as agreed upon included in such
certificate shall only be upto (75%) seventy five percent of the value of the said
materials and goods as and from such time as they are reasonably, properly
and not prematurely brought to or placed adjacent to the Work and then only if
adequately protected against weather or other causalities.

27.3 The amounts retained by virtue of clause 27.2 above shall be subject to the
following rules :

27.3.1 The Owner’s interest in any amounts so retained shall be fiduciary as

trustee for the contractor (but without obligation to invest) and the
Contractor’s beneficial interest therein shall be subject only to the right
of the Consultant to have recourse thereto from time to time for
payment of any amount which he is entitled under the provisions of
this contract to deduct from any sum due or to become due to the
contractor.

27.3.2 On the issue of the Certificate of virtual completion, the consultant

shall issue an Interim Certificate for one moiety of the total amounts
then so retained and the contractor shall be entitled to payment of the
said moiety within the “Period of Honouring Certificate” named in the
Appendix hereto.

27.4 The measurement and valuation of the Work shall be completed within the
“Period of Final Measurement and Valuation” stated in the Appendix hereto
and the Contractor shall be supplied with a copy of the priced Bills of
Variation not later than the end of the said period and before the issue of the
Final Certificate under clause 27.7 herein below.

27.5 Either before or within a reasonable time after Virtual Completion of the work,
the Contractor shall send to the consultant all documents necessary for the
purposes of the computations required by these conditions including all
documents relating to the accounts of Nominated Sub-Contractors and
Nominated Suppliers.

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 27.6 So soon as is practicable but before the expiration of the “ Period for issue of
Final Certificate” stated in the Appendix hereto or from completion of making
good defects under Clause 38 herein below or from receipt by the consultants
of the documents referred to in Clause 27.5 above whichever is the latest, the
consultant shall issue the Final Certificate. The Final Certificate shall state

27.6.1 The sum of the amount paid to the Contractor under Interim Certificates and
the amount named in the said Appendix as limit of Retention Fund and

27.6.2 The Contract Sum adjusted as necessary in accordance with the terms of this
General Conditions of Contract and the difference (if any) between the two
sums shall be expressed in the said Certificate as a balance due to the
Contractor from the Owner or to the Owner from the Contractor as the case
may be and subject to any deductions Authorised by this General
Conditions of Contract, the said balance shall as from the fourteenth day
after the issue of the said certificate be a debt payable as the case may be by
the Owner to the Contractor or by the Contractor to the Owner.

27.7 Unless a written request to concur in the appointment of an Arbitrator shall

have been given under clause 51 herein below by either party before the
Final Certificate has been issued or by the Contractor within twenty eight days
after such issue, the said Certificate shall be conclusive evidence in any
proceedings arising out of this Contract (whether by Arbitration under clause
51 herein below or otherwise) that the works have been properly carried out
and completed in accordance with the terms of this contract and that any
necessary effect has been given to all the terms of this contract which require
an adjustment to be made to the contract sum, except and in so far as any
sum mentioned in the said certificate is erroneous by reason of :

27.7.1 Fraud dishonesty or fraudulent concealment relating to the Works, or

any part thereof, or to any matter dealt with in the said certificate, or

27.7.2 Any defect (including any omission) in the works, or any part thereof
which reasonable inspection or examination at any reasonable time
during the carrying out of the Works or before the issue of the said
Certificate would not have disclosed; or

27.7.3 Any accidental inclusion or exclusion of any work, materials, goods or

figure in any computation or any arithmetical error in any computation.

27.8 Save as aforesaid no certificate of the consultant shall of itself be conclusive

evidence that any works materials or goods to which it relates are in
accordance with this contract.

27.9 The Contractor, before settlement of payment against Final Bill, shall sign and
deliver to the Owner, either in the measurement books or otherwise, as may
be required a valid released and discharge from any and all claims and
demands whatsoever from the Owner for all matters arising out of this
contract, except in respect of Defects Liability under clause 38.

28.0 CLAIM FOR EXTRA

28.1 When any instruction or decision given at Site involves an extra or whereby
the contractor may plan to claim an extra, it shall be the responsibility of the
Contractor to inform the Owner / Consultant of the extra amount and get

18
 written authorisation from the Owner / Consultant before proceeding with the
work involved.

28.2 Any modification carried out for expediting or simplifying work at the request
of the Contractor his representatives shall not be taken as the basis for
claiming an extra. However, if such modification shall also involve an extra,
the rate for such modification shall be settled in advance and written
authorisation obtained by the Contractor from the Owner / Consultant before
proceeding with the work involved. If no such information is given by the
Contractor in writing to the Owner / Consultant, such modification shall not be
accepted as the basis for extra charge.

29.0 DEDUCTION FOR UNCORRECTED WORK

If the Consultant deems it inexpedient to correct work damaged or not done in

accordance with the Contract, an equitable deduction from the Contract sum as may
be decided by the Consultants shall be made therefor.

30.0 FLUCTUATIONS

The Contractor shall not claim any extra for fluctuation for price and the contract sum
shall not be subject to any rise or fall of prices, unless specifically provided
otherwise.

31.0 UNFIXED GOODS AND MATERIALS

Unfixed materials and goods intended for, delivered to and placed on or adjacent to
the work shall not be removed except for use upon the work unless the Consultant /
Owner has consented in writing to such removal which consent shall not be
unreasonably withheld. Where the value of any such materials or goods has in
accordance with clause 27.2 above been considered for payment of an advance to
the Contractor, such materials and goods shall become the property of the
Consultant, but subject to Clause 43.2 herein below, the Contractor shall remain
responsible for loss or damage to the same.

32.0 MATERIAL AND WORKMANSHIP

32.1 All materials and workmanship unless otherwise specified shall be as per the
relevant code of ISI specifications and other applicable codes and of
approved type and the Contractor shall immediately remove form the work
any material and / or workmanship which in the opinion of the Consultants are
defective or unsuitable and shall substitute proper materials and / or
workmanship at his own cost. The term approval used in connection with this
Contract shall mean the approval of the Owner / Consultants.

32.2 The Contractor, shall, if required, submit satisfactory evidence as to the kind
and quality of material.

32.3 Where special makes or brands are called for they are mentioned as
standard. Others of equal quality may be used provided approval is first
obtained in writing from the Owner / Consultants. Unless substitutions are
requested no deviation from the specification will be permitted. Failure to
propose the substitution of any article within thirty days after the award of the

19
 Contract will be deemed sufficient cause for denial of the request for
substitution.

32.4 The Contractor shall indicate and submit evidence in writing of those
materials or articles called for in the Specification that are not obtainable for
installation in the work within the time limits of the Contract. Failure to
indicate the above, within thirty days after the award of the Contract, will be
deemed sufficient cause for the denial of request for the extension of the
Contract time.

32.5 All materials shall be delivered so as to ensure speedy and uninterrupted

progress of the work. Such material shall be stored so as to cause no
obstruction and so as to prevent overloading of any portion of the structure
and the Contractor shall be entirely responsible for damage or loss by
weather or other causes.

32.6 Within thirty days after the award of the Contract the Contractor shall submit
for approval of the Owner / Consultants a complete list of all materials he and
his sub-contractors propose to use in the work of definite brand or make
which differ in any respect from those specified, also the particular brand of
any article where more than one is specified as a standard. He shall also list
item not specifically mentioned in the Specification but which are reasonably
inferred and necessary for the completion of the Work.

32.7 Inspection

32.7.1 All materials and workmanship shall be subject to inspection,

examination and test by the Owner / Consultants and or / any
inspecting Authority of the Owner at any and all times during and / or
after manufacture and / or construction. The Owner / Consultants and
/ or any Inspecting Authority of the Owner shall have the right to reject
defective material and workmanship or require its correction.
Rejected workmanship shall be satisfactorily replaced with proper
material without additional charge therefore and the Contractor shall
promptly segregate and remove the rejected material from the Works.
If the Contractor fails to proceed at once with the replacement of
rejected materials and / or the correction of the defective workmanship
and charge the cost thereof to the Contractor, or may terminate the
right of the Contractor to proceed further with the work.

32.7.2 The Contractor shall furnish promptly without additional charge all
reasonable facilities, labour and materials necessary for the safe and
convenient inspection and test that may be required by the Owner /
Consultants and / or the Inspecting Authority of the Owner. Stage-wise
review of progress/expediting at Vendor’s/Sub Vendor’s works shall
be carried out by Purchaser/Purchaser’s authorised representatives
during the period of manufacture of these equipment.

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33.0 DEFECTS

33.1 The contractor shall make good at his own cost and to the satisfaction of the
Consultants, all defects, shrinkages, settlements or other faults, arising in the
opinion of the Consultants from work or materials not being in accordance
with the Drawings or Specifications or Schedule of Quantities or the
Instructions of the Owner / Consultants, which may appear within “Defects
Liability Period” referred to in the Appendix hereto shall be specified and can
be amended and made good by the contractor at his own cost unless the
Owner shall decide that the amount to be paid for such amending and making
good and in case of default if the incidental thereto shall be made good and
borne by the Contractor and such damage, loss or expense shall be
recoverable from him by the Owner or may be deducted by the Owner upon
the Consultant’s certificate in writing from any amount due or may become
due to the and making good by the Contractor, deduct from any moneys due
to the Contractor a sum to be determined by the Consultants as equivalent to
the cost of amending such work and in the vent of the Retention Amount
being insufficient, the bank guarantee submitted in lieu of cash retention will
be encashed, if this amount is also insufficient, recover the balance from the
Contractor together with any expenses the Owner may have incurred in
connection therewith.

34.0 POSSESSION OF SITE, COMPLETION AND POSTPONEMENT

34.1 On the “Date of Commencement” stated in the Appendix here to possession

of the Site shall be given to the Contractor who shall thereupon begin the
works and regularly and diligently proceed with the same and who shall
complete the same on or before the “Date of Completion” stated in the
Appendix hereto subject nevertheless to the provisions for extension of time
contained in clause 25.0 herein below.

34.2 The Owner / Consultants may issue instructions in regard to the

postponement of any work to be executed under the provisions of this
Contract.

34.3 If at any time or times before Virtual Completion of the Work the Owner with
the consent of the Contractor shall take possession of any part or parts of the
same for his own use and / or for handing over to any other contractor agency
for carrying out, his work referred to in Clause 25.0 above, then not
withstanding anything expressed or implied elsewhere in the Contract.

34.3.1 Such part or parts shall not be deemed to be virtually complete.

34.3.2 Virtual Completion of such part or parts would occur on the completion
of the last element of work in such part or parts under this contract.

34.3.3 The Contractor shall no claim that such part or parts are complete and
request refund of payments in lieu thereof.

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35.0 EXTENSION

35.1 Upon it becoming reasonably apparent that the progress of the work is
delayed, the Contractor shall forthwith (within a maximum period of seven
days) give written notice of the cause of the delay to the Owner / Consultants
and if, in the opinion of the Consultants, the completion of the work is likely to
be or has been delayed beyond the “Date of Completion” stated in the
Appendix hereto or beyond any extended time previously fixed under this
clause.

35.1.1 By force majeure, or

35.1.2 By reason of any exceptionally inclement weather, or

35.1.3 By reason of loss or damage occasioned by any one or more of the

contingencies referred to in Clause 43.0 herein below, or

35.1.4 By reason of civil commotion, local combination of workmen strike or

lockout affecting any of the trades employed upon the works or any
of the traders engaged in the preparation, manufacture or
transportation or any of the goods or materials required for the work,
or

35.1.5 By reason of Consultants and / or the Owner’s instructions issued

under Clauses 25.0, 26.1 and / or 34.2 above or

35.1.6 By reason of the Contractor not having receiving in due time

necessary instructions, drawings, details or levels from the Owner /
Consultants for which he specifically applied in writing on a date
which having regard to the “Date of Completion” stated in the
Appendix hereto or to any extension of time then fixed under clause
35.1 herein was neither unreasonably distant from nor unreasonably
close to the date on which it was necessary for him to receive the
same, or

35.1.7 By delay on the part of Nominated Sub-Contractors or Nominated

suppliers which the Contractor has taken all practicable to avoid or
reduce, or

35.1.8 By delay on the part of artists, tradesmen or others engaged by the

Owner in executing work not forming part of this Contract, or

35.1.9 By reason of the opening up for inspection of any work covered up

or of the testing of any of the works, materials or goods in
accordance with Clause 32.7 above (including making good in
consequence of such opening up or testing) unless the inspection of
test showed that the work materials or goods were not in
accordance with this Contract, or

36.1.10 By reason of the Contractor’s inability for reason beyond his control
and which he could not reasonably have foreseen at the date of this
contract to secure such labour, goods or materials as are essential
to the proper carrying out of works , then the Architect shall so soon
as he is able to estimate the length of the delay beyond the date or
time aforesaid make in writing a fair and reasonable extension of

22
 time for completion of works, provided always that the contractor
shall use constantly his best endeavours to prevent delay and shall
do all that may reasonably be required to the satisfaction of the
Owner / Consultants to proceed with the work.

36.2 The Contractor will forfeit his claim for extension if he does not report the
cause of the delay in completion date within seven days of the date of
occurrence.

37.0 DAMAGES FOR NON-COMPLETION

If the Contractor fails to complete the work by the “Date of Completion” stated in the
Appendix hereto or within any extended time fixed under Clause 38.0 above and the
Owner certifies in writing that in his opinion the works ought to have been completed,
the Contractor shall pay or allow to the Owner a sum calculated at the rate stated in
the Appendix hereto as “Liquidated Damages” for the period during which the said
work shall so remain or have remained incomplete and the Owner may deduct such
damages from any monies otherwise payable to the Contractor under this contract.

38.0 VIRTUAL COMPLETION AND DEFECTS LIABILITY PERIOD

38.1 As soon as the works are virtually complete, the contractor shall inform the
fact to the Consultants / Owner and if in the opinion of the Consultants the
works are practically completed, he shall forthwith issue a certificate to that
effect and Virtual Completion of the Work shall be deemed for all the purpose
of this contract to have taken place on the day named in such certificate.

38.2 Any defects shrinkages or other faults which shall appear within the “Defects
Liability Period” stated in the Appendix hereto and which are due to materials
and workmanship not in accordance with this Contract shall be specified by
the Consultants in a “Schedule of Defects” which he shall deliver to the
Contractor not later than fourteen days after the expiration of the said
“Defects Liability Period” and within a reasonable time after receipt of such
“Schedule of Defects” the defects, shrinkages and other faults therein
specified shall be made good by the Contractor and (unless the Consultants
shall otherwise instruct in which case the Contract sum shall be adjusted
accordingly) entirely at his own cost.

38.3 Notwithstanding Clause 38.2 above, the Owner / Consultants may whenever
he considers it necessary so to do, issue instructions requiring any defects,
shrinkages or other fault which shall appear within the “Defects Liability
Period” named in the Appendix hereto and which is due to materials and
workmanship not in accordance with this Contract to made good and the
Contractor shall within a reasonable time (which shall be specified in such
instructions of the Owner / Consultants) after receipt of such instructions
comply with the same (and unless the Owner / Consultants shall otherwise
instruct in which case the Contract sum shall be adjusted accordingly)
entirely at his own cost. Provided that no such instruction shall be issued
after 14 days from the expiration of the said “Defects Liability Period”.

38.4 When in the opinion of the Consultants any defects, shrinkages or other faults
which he may have required to be made good under clauses 38.2 and 38.3
above shall have been made good he shall issue a certificate to that effect
and completion of making good such defects, shrinkages or other faults shall

23
 be deemed for all the purposes of this contract to have taken place on the
day named in such certificates.

38.5 In no case shall the contractor be required to make good at his own cost any
damage which took place before Virtual Completion of the works.

39.0 LOSS AND EXPENSE CAUSED BY DISTURBANCE OF REGULAR PROGRESS OF THE WORKS

39.1 If upon written application being made to him by the contractor the Owner /
Consultants is of the opinion that the contractors has been involved in direct
loss and / or expense for which he would not be reimbursed by a payment
made under any other provision in this contract by reason of the regular
progress of the works or of any part thereof having been materially affected
by.

39.1.1 The contractor not having receiving in due time necessary

instructions, drawings, details of levels from the Consultants for which
he specifically applied in writing on a date which having regard to the
“Date of Completion” stated in the Appendix hereto was neither
unreasonably distant from nor unreasonably close to the date on
which it was necessary for him to receive the same, or

39.1.2 The opening up for inspection of any work covered up or the testing of
any work material or goods in accordance with Clause 32.7 above
(including making good in consequence of such opening up or testing)
unless the inspection or test showed that the work materials or goods
were not in accordance with this contract, or

39.1.3 Any discrepancy or divergence between the contract drawings and / or

the contract bills, or

39.1.4 Delay on the part of the Artists, Tradesmen or others engaged by the
Consultant in executing work not forming part of this contract, or

39.1.5 Consultant’s instructions issued in regard to the postponement of any

work to be executed under the provisions of this contract and if the
written application is made within a reasonable time of it becoming
apparent that the progress of the work or of any part thereof has been
affected as aforesaid :

Then the Consultants shall ascertain the amount of such loss and / or
expense. Any amount from time to time so ascertained shall be
added to the amount which would otherwise be stated as due in such
certificate.

39.2 The provisions of Clause 39.1 above are without prejudice to any other rights
and remedies which the contractor may posses.

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40.0 PAYMENT WITHHELD

40.1 The Consultants may withhold or on account of a subsequently discovered

evidence nullify the whole or a part of any certificate to such extent as may be
necessary in his reasonable opinion to protect the Owner form loss on
account of :

40.1.1 Defective work not remedied.

40.1.2 Failure of the Contractor to make payments properly to sub-contractor or for

materials or labour.

40.1.3 A reasonable doubt that the contract can be completed for the balance then
unpaid.

40.1.4 Damage to another contractor or sub-contractor.

40.1.5 Claims filed on reasonable evidence indicating probable filing of claims.

40.2 When the above ground are removed payment shall be made for amounts
withheld because of them.

41.0 INJURY TO PERSONS AND PROPERTY OF CONSULTANT

41.1 The Contractor shall be liable for and shall indemnify the Owner against any
liability, loss, claim or proceedings whatsoever arising under any statute or at
common law in respect of personal injury to or the death of any person
whomsoever arising out of or in the course of or caused by the carrying out of
the works, unless due to any act or neglect of the Owner or of any person for
whom the Consultant is responsible.

41.2 The Contractor shall be liable for and shall indemnify the Owner against and
liability, loss, claim or proceedings in respect of any injury to or damage
whatsoever to any property real or personal in so far as such injury or
damage arises out of or in the course of or by reason of the carrying out of
the Works and provided always that the same is due to any negligence,
omission or default of the Contractor, his servants or agents of any Sub-
Contractor, his servant or agent.

42.0 INSURANCE AGAINST INJURY TO PERSONS AND PROPERTY

42.1 Without prejudice to his liability to indemnify the Owner under Clause 41.0
above, the Contractor shall take all the insurance (Car policy with third party
liability and Workmen’s Compensation Policy) at his cost in the joint names of
the Contractor and Owner and maintain and shall cause any sub-contractor to
maintain until Virtual Completion of the works.

42.1.1 Such insurances as are necessary to cover the liability of the

Contractor or as the case may be of such Sub- Contractor in respect
of personal injuries or deaths arising out of or in the course of or
caused by the carrying out of the work; and

42.1.2 Such insurances as may be specifically required by the Contract Bills

in respect of injury or damage to any property real or personal at site
arising out of or in the course of or by any negligence, omission or

25
 default of the Contractor, his servants or gents or, as the case be of
such Sub-Contractor, his servants or agents. The cost of all materials
supplied by the Owner shall be covered in the insurance policy.

42.2 The Contractor shall produce or cause any sub-contractor to produce for
inspection the relevant policy or policies of insurance together with the
receipts in respect of premiums paid under such policy or policies as and
when required so to do by the Owner / Consultant provided always that as
and when may be reasonably required by the Owner / Consultants the
production by either the Contractor or any Sub-contractor or a current
certificate of insurance from the company or firm which shall have issued the
policy or policies aforesaid shall be a good discharge of the Contractor’s
obligation to produce or to cause the production of the policy or policies and
the receipts in respect of premium paid.

42.3 Should the Contractor or any sub-contractor make default in insuring or in

continuing to insure as provided in Clauses 42.1 and 42.3 above or dose not
take the insurance policies, the Owner shall himself insure against any risk
with respect to which the default shall have occurred and may deduct a sum
equivalent to the amount paid in respect of the premium from any monies due
to or become due the Contractor.

43.0 INSURANCE OF THE WORKS AGAINST FIRE ETC.

43.1 The contractor at his cost shall in joint names of the Owner and Contractor
insure against loss or damage by fire, storm, telpest, lightning, flood,
earthquake, aircraft or anything dropped there form, aerial objects, riot and
civil commotion for the full value thereof all works executed and all unfixed
materials and goods intended for, delivered to and placed on or adjacent to
the work, including the cost of all materials supplied by the Owner for the
work which is in the custody of the Contractor, but excluding temporary
building plant, tools and equipment owned or hired by the Contractor or any
sub-contractor and shall keep such work materials and goods so insured
until virtual completion of the work. Such insurances shall be with insures
approved by the Owner / Consultants and the Contractor shall deposit with
the Owner / Consultants the policy or policies and the receipts in respect of
insuring or continuing to insure as aforesaid the Owner may himself insure
against nay risk with respect of which the default shall have occurred and
deduct a sum equivalent to the amount paid by him in respect of premium
from any monies due to or to become due to the contractor. Provided always
that if the contractor shall independently of his obligations under this contract
intern a policy of insurance which covers (inter alia) the said work, materials
and goods against the aforesaid contingencies to the full value thereof then
the maintenance by the Contractor of such policy shall if the Owner’s interest
is endorsed thereon, be a discharge of the Contractor’s obligation to insure in
the joint names of the Owner and the production by the Contractor as and
when may reasonably be required by the Owner / Consultants of a current
certificate of insurance from the Company or firm which shall have issued the
said policy shall be discharge of the Contractor’s obligation to deposit with the
Owner / Consultants a policy or policies and the receipts in respect of
premium paid.

43.2 Upon settlement of any claim by the insurance companies under the
insurance aforesaid, the contractor with due diligence shall restore work
damaged, replace or repair unfixed materials or goods which have been

26
 destroyed or injure, remove or dispose off any debris and proceed with
carrying out and completion of work. All monies received from such
insurance shall be paid to the contractor by instalments under certificates of
the Consultant issued at the “Period of Interim Certificates” named in
Appendix hereto. The Contractor shall not be entitled to payment in respect
of the restoration of work damaged, the replacement and repair of any unfixed
materials or goods and the removal and disposal of debris other than the
monies received under the said insurance.

44.0 DETERMINATION BY THE OWNER

44.1 Default

If the contractor shall make default in any one or more of the following
respects, that is to say :

44.1.1 If he without reasonable cause wholly suspends the carrying out of the
work before completion thereof, or

44.1.2 If he fails to proceed regularly and diligently with the works, or

44.1.3 If he refuses or persistently neglects to comply with a written notice

from the Owner / Consultants requiring him to remove defective work
or improper materials or goods and by such refusal or neglect the
work is materially affected, or

44.1.4 If he fails to comply with the provision of Clause 21.0 above, then the
Owner / Consultants may give him a notice by registered post or
recorded delivery specifying the default, if the Contractor either shall
continue such a default for fourteen days after receipt of such a notice
and shall at any time thereafter repeat such a default (whether
previously repeated or not), then the Consultant without prejudice to
any other rights or remedies may within ten days after such
continuance or repetition of notice by registered post or recorded
delivery forthwith determine the employment of the Contractor under
this contract, provided that such notice shall not be given
unreasonably or vexatiously.

44.2 Bankruptcy of Contractor

In the event of the Contractor becoming bankrupt or making a composition or

arrangement with his creditors or being a company having a winding up order
made or (except for purpose of reconstruction) a resolution for voluntary
winding up passed or a receiver or manager of his business or undertaking
duly appointed or possession taken by or on behalf of the holders of any
debentures secured by a floating charge, of any property comprised in or
subject to the floating charge, the employment of the Contractor under this
contract shall be forthwith automatically determined but the said employment
may be reinstated and continued if the Consultant and the Contractor, his
trustee in bankruptcy, liquidator, receiver or manager, as the case may be
shall so agree.

44.3 The Owner shall be entitled to determine the employment of the contractor
under this contract, if the contractor shall have offered or given or agreed to

27
 give to any person and gift or consideration of any kind as an inducement or
reward for doing or forbearing to do or for having done or forborne to do
any action in relation to the obtaining or execution of this contract with the
Owner, or, for showing or forbearing to show favour or disfavour
to any person relating to this contract or any other contract with the Owner,
or if the like acts shall have been done by any person employed by the
Contractor or acting on his behalf (whether with or without the knowledge of
the contractor), or if in relation to this contractor or any person employed by
him or acting on his behalf shall have committed any offence under the
prevention of corruption act, or shall have given any fee or reward the receipt
of which is an offence under the Local Government Act.

44.4 In the event of the employment of the contractor, being determined as

aforesaid and so long as it has not been reinstated and continued, the
following shall be the respective rights and duties of the Owner and
contractor.

44.4.1 The Owner may employ and pay other persons to carry out and
complete the works and he or they may enter upon the works and use
all temporary building plant, machinery, appliances, goods and
materials intended for delivered to and placed on or adjacent to the
works and may purchase all materials and goods necessary for the
carrying out and completion of the works.

44.4.2 The contractor shall if so required by the Owner or Consultants within

fourteen days of the date of determination assign to the Owner without
payment the benefit of any agreement for the supply of materials or
goods and / or for the execution of any works for the purposes of this
contract but on the terms that a supplier or sub-contractor shall be
entitled to make any reasonable objection to any further assignment
there of by the Owner. In any case the Owner may pay any supplier
of sub-contractor for any materials or goods delivered or works
executed for the purpose of the contract (whether before or after the
date of determination), in so far as the price thereof has not already
been paid by the Contractor. The Owner’s rights under this clause are
in addition to his rights to pay nominated sub-contractors as provided
in Clause 22.2 above and payments made under this clause may be
deducted from any sum due or to become due to the contractor.

44.4.3 The Contractor shall as and when required in writing by the Owner /
Consultants so to do (but not before) remove from the works any
temporary buildings, plant, tool equipments, goods and materials
belonging to or hired by him. If within a reasonable time after any
such requirements has been made the contractor has not complied
therewith, then the Owner may (but without being responsible for any
loss or damage) remove and sell any such property of the contractor,
holding the proceeds less all costs incurred to the credit of the
Contractor.

44.4.4 The Contractor shall allow or pay to the Owner in the manner
hereinafter appearing the amount of any direct loss and / or damage
caused to the Owner by the determination. Until after completion of
the works under clause 44.4.1 above, the Consultant shall not be
bound by any provisions of this contractor to make any further
payment to the contractor, but upon completion and the verification
within a reasonable time of the accounts therefore the Owner /

28
 Consultants shall certify the amount of any direct loss and / or damage
caused to the Owner by the determination and if such amounts when
added to the monies paid to the contractor before the date of
determination exceed the total amount which would have been
payable on due completion in accordance with this contract, the
difference shall be debt payable to the Consultant by the contractor
and if the said amount when added to the said monies be less than
the said total amount, the difference shall be a debt payable by the
Owner to the contractor.

45.0 DETERMINATION BY THE CONTRACTOR

45.1 Without prejudice to any other rights and remedies which the contractor may
possess, if :

45.1.1 The Owner does not pay to the Contractor the amount due on any
certificate within the “Period for Honouring Certificates” named in the
Appendix hereto and continues such default for seven days after
receipt by registered post or recorded delivery of a notice from the
contractor stating that notice of determination under this condition will
be served if payment is not made within seven days from receipt
thereof; or

45.1.2 The Owner interferes with or obstructs the issue of any certificate due
under this contract; or

45.1.3 The carrying out of the whole or substantially the whole of the
uncompleted works (other than the execution of work required under
clause above is suspended for a continuous period of the length by
reason of :

a) Force majeure, or

b) Loss or damage occasioned by any one or more of the

contingencies referred to in clause above; or

c) Civil commotion; or

d) Consultants instructions issued under this Contract and clause 8

above or

e) The Contractor not having received in due time necessary

instructions, drawings, details or levels from the consultant for
which he specifically applied in writing on a date which having
regard to the “Date of Completion” stated in the Appendix hereto
or to any extension of time then fixed under clause above was
neither unreasonably distant form nor unreasonably close to the
date on which it was necessary for him to receive the same, or

f) Delay on the part of Artists, Tradesmen or others engaged by the

Consultant in executing work not forming part of this Contract, or

g) The opening up for inspection of any work covered up or of the

testing of any of the work, materials or goods in accordance with

29
 clause above (including making good in consequence of such
opening up or testing.)

Then the Contractor may thereupon by notice by registered post or recorded

delivery to the Owner or Consultant forthwith determine the employment of
the contractor under this contract under this contract; provided that such
notice shall not be given unreasonably or vexatiously.

45.2 Upon determination, then without prejudice to the accrued rights or remedies
of either party or to any liability of the classes mentioned in clause above
which may accrue either before the Contractor or any Sub-Contractors shall
have removed his or their temporary buildings, plant, machinery, appliances,
goods or material or by reason of his or their so removing the same the
respective rights and liabilities of the Contractor and the Owner shall be as
follows that is to say :

45.2.1 The Contractor shall with all reasonable despatch and in such manner
and with such precautions as will prevent injury, death or damage of
the classes in respect for which before the date of determination he
was liable to indemnify the Owner under clause 41 above, remove
from site all his temporary buildings, plant, machinery, appliances,
goods and materials and shall give facilities for his Sub-Contractors to
do the same but subject always to the provisions of sub-paragraph ( c)
of Clause herein below.

45.2.2 After taking into account amounts previously paid under this Contract,
the Contractor shall be paid by the Owner :

a) The total value of the Works completed at the date of

determination.

b) The total value of work begun and executed but not completed at
the date of determination the value being ascertained mutually in
accordance with clause above.

c) The cost of materials or goods properly ordered for the Works for
which the contractor shall have paid or of which the Contractor is
legally bound to pay and on such payment by the Owner
materials or goods so paid for shall become the property of
the Consultant.

d) The reasonable cost of the removal under clause above.

e) Any direct loss and / or damage caused to the contractor by the

determination

Provided that in addition to all other remedies the Contractor upon such
determination may take possession which may have become the property of
the Owner under clause above until payment of all monies due to the
Contractor from the Owner.

46.0 CO-ORDINATION OF WORK

46.1 At the commencement of work, and from time to time, the Contractor shall
confer with the Sub-Contractors, persons engaged on separate contracts in

30
 connection with the work and with the consultant for the purpose of the co-
ordination and execution of the various phases of the work.

46.2 The Contractor shall ascertain the Sub-Contractors, persons engaged on

separate contracts in connection with the works, the extent of all chasing,
cuttings and forming of all openings, holes, grooves, etc. as may be required to
accommodate the various services, the routes of all services and the positions
of all floor outlets, traps, etc. in connection with the installation of plant and
services and arrange for the construction of work accordingly. The breaking
and cutting of completed work must be avoided.

47.0 LABOUR

The Contractor shall not employ child labour and female labour at site. No
labourer shall reside within the compound except Authorised guards.
All statutory clearances like labour licenses will be obtained by the contractor
within 7 days of LOI & submitted to Client

48.0 GUARANTEE

48.1 Besides guarantees required elsewhere, the Contractor shall guarantee the
work in general for one year as noted under clauses 33.0 and 38.0 above.

48.2 All required guarantees shall be submitted to the Consultant by the Contractor
when requesting certification of accounts for payment by the Consultant.

49.0 ANTIQUITIES

49.1 All fossils and other objects of interest or value which may be found on the site
or in excavating the same during the progress of the work shall become the
property of the Owner. The Contractor shall carefully take out and preserve all
such objects and shall immediately or as soon as conveniently may be after the
discovery of such articles deliver the same into the possession of the consultant
or of the clerk-of –works uncleaned and as excavated.

50.0 EXCEPTED MATTERS

The decision, opinion, direction, certificate (except for payment) with respect to all or
any of the matters under clauses 5.0 & 8.0, 17.0, 21.0, 22.0, 32.0, 35.1.1, 35.1.2,
35.1.4, 35.1.7, 35.1.8 and 44.0 hereof (which matters are herein referred to as the
Excepted Matters) shall be final and conclusive and binding on the parties hereto and
shall be without appeal. Any other decision, opinion, direction, certificate or valuation
of the Owner / Consultant or any refusal of the Consultant / Owner to give any of the
same shall be subject to any right of Arbitration and review in the same way in all
respects (including the provision as to opening the reference) as hereinafter
provided.

51.0 ARBITRATOR

51.1 All dispute and differences of any kind whatever arising out of or in connection
with the Contract or the carrying out of the works (whether during the progress

31
 of the works or after their completion and whether before or after the
determination, abandonment or breach of the Contract) shall be referred to and
settled by the Consultant who shall state his decision in writing. Such
decision may be in the form of a Final Certificate or otherwise. The decision of
the consultant with respect of any of the Excepted Matters (referred to under
clause hereinabove) shall be final and without appeal; but if either the
Consultant or the Contractor be dissatisfied with the decision of the Consultant
on any matter, question or dispute of any kind (except any of the Excepted
Matters) or as to the withholding by the Consultant of any certificate to which
the contractor may claim to be entitled then and in any such case either party
(the Owner) or the Contractor) may within 28 (twenty eight) days after receiving
notice of such decision give a written notice to the other party through the
consultant requiring that such matters in dispute be Arbitrated upon. Such
written notice shall specify the matters which are in dispute and such dispute or
difference of which such written notice has been given and no other shall be
and is hereby referred to the Arbitration and final decision of a single Arbitrator
being Fellow of the Indian Institute of Consultant / Owner to be agreed upon
and appointed by both the parties or in case of disagreement as to the
appointment of a single Arbitrator to the Arbitration of two Arbitrators both being
Fellows of the Indian Institute of Architects one to be appointed by each party,
which Arbitrators shall before taking upon themselves the burden of reference
appoint an Umpire.

51.2 The Arbitrator, the Arbitrators or the Umpire as the case may be shall have
power to open up review and revise any certificate, opinion, decision,
requisition or notice save in regard to the Excepted Matters (referred to in
clause 50 hereinabove) and to determine all matters in dispute which shall be
submitted to him or them and of which notice shall have been given as
aforesaid.

51.3 Upon every or any such reference the cost of and incidental to the reference
and award respectively shall be to the direction of the Arbitrator or Arbitrators or
the Umpire as the case may be who may determine the amount thereof or
direct the same to be taxed as between Attorneys and Client or as between
party and party and shall direct by whom and to whom and in what manner the
same shall be borne and paid. This submission shall be deemed to be a
submission to Arbitration within the meaning of the Arbitration Act 1996 or any
modification thereof for the time being in force. The Award of the Arbitrator or
Arbitrators or the Umpire as the case may be shall be final and
binding on the parties. Such reference except as to the withholding by the
consultant of any certificate under clause hereinabove to which the contractor
claims to be entitled shall not be opened or entered upon until after the
completion or alleged completion of the works or until after the practical
cessation of the works arising from any cause unless with the written consent of
the Owner and the Contractor. Provided always that the Owner shall not
withhold the payment of an Interim Certificate nor the Contractor except with
the consent in writing of the consultant in any way delay the carrying out of the
works by reason of any such matters, question or dispute being referred to
Arbitration but shall proceed with the work with all due diligence and shall until
the decision of the Arbitrator or Arbitrators or the Umpire as the case may be
given abide by the decision of the consultant and no Award of the Arbitration or
the Arbitrators or the Umpire as the case may be shall relieve the Contractor of
his obligations to adhere strictly to the Consultant / Owner’s instructions with
regard to the actual carrying out of the works. The Owner and the Contractor
hereby also agree that Arbitration under this clause shall be a condition
precedent to any right of action under the Contract.

32
52.0 PROTECTION AND CLEANING

52.1 The contractor shall protect and preserve the work from all damage or accident
providing any temporary cover or protection as required by the consultant. This
protection shall be provided for all property adjacent to the Site as well as on
the Site.

52.2 The Contractor shall properly clean the Work as it progresses and shall remove
all rubbish and debris from the site from time to time as is necessary and as
directed. On completion, the Contractor shall ensure that the premises and/or
Site are cleaned, surplus materials debris, sheds etc. removed, areas under
floors cleared of rubbish, gutters and drains cleared, doors and sashes eased,
locks and fastening oiled, keys clearly labelled and handed over to the Clerk-of-
Works so that the whole is left fit for immediate occupation or use and to the
satisfaction of the Owner / Consultant.

53.0 TOLERANCE

53.1 The Contractor shall exercise every care to ensure that all structural matters
are sufficiently plumb and true to dimensions called for on the Drawings to
receive prefabricated finishing elements such as doors, windows, cabinet work,
ceramic work, concrete, tiles etc. Any variations may require rectification in the
structural members or may involve remaking or replacing the finishing
elements, fabricated to fit into the openings or spaces, as called for on the
Drawings.

53.2 In case of separate contract, the contractor whose work does not conform to
dimensions called for, shall be liable for all the expenses which may have to be
incurred for rectification or replacement as may be required by the Architect for
the proper installation of the finishing elements. The consultants decision in this
respect shall be final and binding on the parties concerned.

33
 PART 4a

SPECIAL CONDITIONS OF CONTRACT (SCC)

1
 PART 4a

SPECIAL CONDITIONS OF CONTRACT (SCC)

These conditions shall be read in conjunction with relevant clauses of General

Conditions of Contract Works Involving General Construction and Erection
(GCC, hereinafter). In case of variance/discrepancies between SCC and
GCC, the conditions laid down in SCC shall take precedence. Further, in case of
variance/discrepancies between SCC and Contract documents, the latter shall
prevail.

4.1 VALIDITY OF RATES (VARIATION IN QUANTITIES)

The Contract rates shall remain valid and firm for variation to any extent in
individual quantities of items of work. However, variation will be allowed
if the final total Contract value varies by ± 25% with respect to total initial
LOI / Work order value. For variation beyond ± 25%, Contractor shall be
compensated for the difference over original contract value on
mutually settled terms in case contract value varies beyond ± 25 %.
While settling this claim, cost of extra items will not be considered.

4.2 COMMENCEMENT TIME

4.2.1 The Contractor shall be given possession of the site for work when
the Engineer notifies him that the Owner is ready to do so. Such
possession shall not be exclusive to the Contractor and the
Contractor shall in accordance with the requirement of the
Consultant/Owner afford all reasonable opportunities to any other
agencies employed by the Owner and their workmen for carrying our
their work and to the workmen of the Owner and of any other duly
constituted agencies who may be employed in the execution on or
near the site of any work not included in the Contract or of any
contract which the Owner may enter into in connection with or
ancillary to the works.

4.2.2 The Contractor shall commence the works on site within15 days on
receipt of Letter of Intent from the Owner and shall proceed with the
same with due expedition and without delay except as may be
expressly sanctioned or ordered by the Consultant/Owner or be
wholly beyond the Contractor's control. In case where the complete
site is not possible to be handed over to the Contractor, the
Consultant/Owner will ensure that enough portion of the area is
handed over for the Contractor to carry out the work as stipulated in
the agreed programme.

2
4.3 TIME SCHEDULE & TENTATIVE CONSTRUCTION PROGRAMME

The Contractor shall mobilise adequate number of tools & tackles and
machinery to complete the work as shown in construction programme. It will
be deemed that Contractor has allowed for mobilisation of this plant and
machinery including spares to replace in case of breakdown in his quoted
rates and any extra resource mobilisation required to achieve the
programme, quantity remaining same, will not be paid for.

The Contractor shall work on 2 shifts (Round the clock) if required to

complete the work as per construction programme and shall make
necessary lighting arrangements to facilitate working during night.
Contractor's quoted rates shall cover working on 2 shifts basis as
mentioned herein. No extra claim shall be entertained on this account.
Safety personnel to be available round the clock.

For time schedule and construction programme refer Part-5. These shall
be signed and submitted by the Contractor along with Tender, as an
acceptance of the same.

4.4 ALTERATIONS IN SPECIFICATIONS AND DESIGNS

4.4.1 During the execution of the work, the Consultant/Owner may desire
to make some alterations in specifications and design The
Contractor shall carry out such changes so ordered by the
Consultant/Owner in writing without any extra cost to the Owner.

No extra claims whatsoever shall be entertained on any

account.

4.4.2 The owner will inform to the Contractor, after Contractor starts site
mobilisation, the name and designation of the person who is
authorised to accept and approve alterations/ changes/ modifications
if they shall affect any of the Terms and Conditions including unit
item rates, completion period stipulated in the Contract, increase
in quantity of Contract works indicated in the Contract,
finalisation of rates of extra items and such other issues. The
Contractor shall implement any such change/alteration/modification
only after the Contractor has received approval in writing from
Owner's this authorised person.

4.5 COMPLETION

4.5.1 Virtual Completion Certificate

Consultant shall recommend to Owner to issue a Virtual Completion

Certificate to the Contractor after complying following:

a) Having obtained a written request from Contractor for issuing

Virtual Completion Certificate with an undertaking to finish
any outstanding work within next 1 month or lesser period.

b) Completed work have passed final tests as prescribed in the

contract, if any.

4.5.2 Completion Certificate

3
 Engineer shall recommend to Owner to furnish the Contractor with a
Completion Certificate of works after following conditions have been
complied with:

a) Having obtained a written request from Contractor for

issuing Completion Certificate after fulfilling his
obligations stated in (Sr.No.b to Sr.No.j) below.

b) Contractor has completed all the balance Contract Works in

all respects including rectification of any defects etc. within 1
month or less as stipulated by the Owner from the date
of issue of Virtual Completion Certificate.

c) All scaffolding, surplus material and rubbish/debris is cleared

from the site completely.

d) The executed Contract Works have been measured jointly by

the Consultant and Contractor assuming that these
measurements shall be binding and conclusive.

e) All the temporary works, labour and staff colony etc.

constructed by the Contractor are removed and the work
site cleaned to the satisfaction of Consultant/Owner.

f) Material reconciliation if any for materials issued by Owner

Ref. Cl.4.4) has been completed including return of surplus/
scrap material to the owner by the Contractor.

g) Preparation of as built sketches for areas where revisions

have been made have been completed by the Contractor.
The sketches shall be clear so as to enable the Engineer for
preparation of "As Built" drawings.

h) Entry passes of workmen/staff have been returned to the

Owner.

i) Accounts with other contractors have been settled by

the Contractor and Owner has been indemnified by the
Contractor against all claims for any cause whatsoever.

j) Performance Bank Guarantee for the defects liability period

has been submitted by the Contractor.

Defects liability period / maintenance period shall

commence from the date of issue of this certificate.

4.5.3 The Contractor shall, for a period of 12 months from the issuance of
the Completion Certificate, or in the event tests on performance are
delayed for reasons for which the Contractor is not responsible then
for 18 months from completion of supplies or 15 months from
completion of erection whichever is earlier, be responsible for any
defects that may develop in the work executed by him due to faulty
design/ material/ workmanship provided by him.

The contractor shall rectify such defects free of cost to the company
and to the satisfaction of the company. This warranty excludes fair
4
 wear and tear due to normal operation or defects arising out of mal-
operation. In case of default on the part of the contractor to promptly
rectify the defect, the company will be free to attend to these and
make them good and recover the expenses so incurred from any
amount due to the contractor or from any security deposit or other
deposit the contractor may have with the Owner.

4.5.4 Final Completion Certificate

The Final Completion Certificate shall be given by the Owner two

weeks after the expiry of the defect liability period/maintenance
period considering the following:

a) The Contract Works have been duly maintained by the

Contractor during monsoon or such period.

b) Any defects observed have been rectified to the

satisfaction of the Owner.

c) Obligations if any to be performed as per the contract.

Notwithstanding the issue of the Final Completion

Certificate, the Contractor and the Owner shall remain liable
for the fulfilment of any obligation incurred under provisions of
the Contract prior to the issue of the Final Completion
Certificate which remains unperformed at the time such
certificate is issued and the purpose of determining the nature
and extent of any such obligations, the Contract shall be
deemed to remain in force between the parties hereto.

4.6 SUBSTANDARD WORK

In case when quality of work/performance is not in accordance with

Contract and which Owner/Engineer, who deems it inexpedient to correct
and accepts it under special circumstances, Owner reserve the right to make
an equitable deduction from Contract price based on unit-item rates.

4.7 WORK DURING MONSOON

4.7.1 Contractor shall provide suitable covered shed to carryout Piping

fabrication work as per agreed schedule during monsoon at no
extra cost to Owner.

4.7.2 During monsoon and other periods, it shall be the responsibility of

the Contractor to keep the construction work free from water at his
own cost.

4.8 FORCE MAJEURE

5
The terms and conditions mutually agreed in respect of this Contract shall
be subject to "Force Majeure". Neither party shall be considered in default
in the performance of its obligations hereunder, if such performance is
prevented or delayed because of war, hostilities, revolution, civil
commotion, epidemic, accident, fire, wind, flood or because of any law and
order proclamation regulation, ordinance of any government or any
subdivision thereof or because of any act of GOD or any other cause
whether of a similar or dissimilar nature beyond the reasonable control of
the party affected. Exclusion from force majeure condition - labour strike of
Contractor's workers.

Should one or both the parties be prevented from fulfilling their obligations
by a state of force majeure continuously for a period of two months, the two
parties should consult with each other regarding the future implementation
of the Contract.

6
 PART – 4b

ADDITIONAL SPECIAL

CONDITIONS OF CONTRACT (SCC)

1
 PART 4 b

ADDITIONAL SPECIAL CONDITIONS OF CONTRACT

1. TEST FOR MATERIALS AND WORKMANSHIP

1.1. All materials and workmanship shall be subject to such tests as stipulated in the
Contract or as suggested by the Consultant/Owner’s representative. Contractor
shall on advise of Owner/Consultant conduct such tests, at his own expense and
establish quality strength and specifications of the material/workmanship.

2. UNCOVERING OF WORK

2.1. The Contractor shall uncover any part of the Works or make openings in or
through them as per the instructions of Consultant/Owner in case of doubt about
the quality of material or workmanship, and shall afterwards reinstate and make
them good. The Contractor shall bear all such expenses unless the need for this
was on account of owner’s default. In the later case, the owner shall bear the
expenses.

3. CONTRACTOR’S ARRANGEMENT FOR WORK

3.1. The Contractor shall arrange for fabrication, cutting, drilling, welding, assembling,
bolting, fitting, fixing, aligning etc; as required for the contract work of
construction, erection, testing or any other site work.

3.2. The Contractor shall supply/arrange all the materials necessary for carrying out
contract works, such a tools, tackles, equipment, plants, welding machines,
compressors, drilling machines, cranes, hoists, lifting tackles, ropes, pulleys,
packing shim hydraulic pumps, jacks, etc; and also other consumables such as
welding rods, brazing rods, fluxes, solders, gases, coal, fuel oils, kerosene,
cotton waste, etc; complete. All lifting tools, tackles must be in good
condition and identified by Sign & identification mark with rated test
certificates from competent Authorities.

3.3. The Contractor shall co-ordinate and arrange for the inspection/approval by
statuary authorities of the contract works carried out by him for the purpose of
compliance with the necessary regulations issued by the statutory authorities.

3.4. The Contractor shall arrange for protecting properly all site work carried out by
him from damage, pilferage and becoming dangerous to life and property.

3.5. The Contractor shall comply with all the work rules and safety regulations issued
by the owner and the statutory authorities, which may be necessary during
execution of the contract work.

3.6. All Plant, equipment and materials used by the contractor shall be safe and
comply with statuary regulations, work rules and safety rules and the contractor
shall be liable for any loss or damage arising from their use.

2
4. TRANSFER OF PROPERTY

4.1. The Contract works shall become the property of the owner before upon
acceptance of delivery. The contractor shall mark all such materials as the
property of the owner but it shall be at the contractor’s risk until delivered and
finally accepted by the owner on virtual completion of the work.

5. Wherever earthwork/excavation to be undertaken, original ground levels at 5M grid shall

be taken and jointly signed by the Contractor and representative of the Owner. The
payment on the item earthwork or filling will be worked out with reference to these
original levels.

5.1. The execution of the work shall be in strict adherence to the planned sequence
of work and time schedule or instructions issued by the representative of owner.

6. If for any reason, the progress of the Contract Works is slowed down due to Owner’s
exploit requirement, the contractor shall be entitled to proportionate extension of the
completion time.

7. ORDER BOOK

7.1. The Contractor shall maintain an Order Book at site of the work. Any special
orders and instructions to be issued to the contractor at site will be recorded in
this book which will be numbered and initialed by the representative of the owner.
The contractor will however sign all orders as a token of his having seen and
noted.

8. PAYMENT

8.1. All Payments shall be made in Indian Currency. The Contractor shall normally
be paid once in a month on its running bill or as per the stipulations of
agreement.

9. DELETED

10. LABOUR LAWS AND RULES

10.1. The Contractor shall maintain relevant records and fulfill all conditions and
requirements in accordance with

 The Payment of Wages Act

 Consultant’s Liability Act

 Workmen’s Compensation Act

 Contract Labour [Regulation and Abolition] Act 1970 and Central Rules,
1971.
3
  Apprentice Act, 1961.

 Any other Act or enactment relating thereto and rules framed thereunder from
time to time.

All statutory clearances like labour licenses will be obtained by contactor

within 7 days to Owner. Form V will be provided by Owner.

11. APPROVED BRAND NAMES

11.1. Wherever brand names/model number are specified in this contract, they shall be
followed strictly and a approved equivalent will be permitted only if the contractor
provide adequate proof to satisfy the Consultant/Owner that the particular item is
no longer manufactured by the said Company.

12. DISCREPANCIES AND ADJUSTMENT OF ERRORS

12.1. In case of discrepancy between Schedule of Quantities, the specifications and/or

the drawings the following order of preference shall hold good Consultant’s will
give instruction in writing.

 Description in Schedule of Quantities.

 Particular specification and special quantities if any.
 The drawings.
 General Specifications.

12.2. If there are any provisions varying or conflicting one another made in any
documents forming part of the Contract, the Owner/Consultant shall be the
deciding authority with regard to the intention of the document.

13. INCOME TAX DEDUCTION AT SOURCE

13.1. The Owner shall deduct T.D.S. as per provisions of Income Tax Act from the Bill
Amount of executed works. A Certificate of deduction will be issued to the
Contractor to the effect as per standard formats.

4
14. AS BUILT DRAWINGS

14.1. Two Copies of drawings released for “Issued for construction” shall be
given to Contractor. The Contractor shall put the AS BUILT mark ups in full
detail and submit the drawings to Owner / Consultant before handing over
the Work, failing which final Certificate shall not be issued by the
Consultant.

15. Items where Q.R. [Quote Rate] is mentioned are not envisaged at this stage. However,
the same will be executed if the need arises or those do become as substituted items
and it will be treated same as other items of the Contract.

16. FIRM PRICE

16.1. The Rates and Prices as per the Schedule of Quantities shall remain firm for the
entire period of completion plus a grace period of three months from date of
commencement.

16.2. However, for any extended period of contract due to reasons beyond the control
of the contractor, the contract price for the balance portion of the remaining
works shall be adjusted for increase or decrease in accordance with Standard
Escalation Clause which will be mutually agreed upon [Basic Indices prevailing
on the date of Letter of Intent].

17. Contractor to obey the Safety regulations as per Owner’s requirements.

18. Use of Rope for lifting purpose shall be strictly prohibited.

SIGNATURE OF THE CONTRACTOR

DATE :-

5
 PART-5

TIME SCHEDULE AND

RESOURCE MOBILISATION
 JOB NO:2090/1600 – BAYER - ANKLESHWAR
RESOURCE MOBILISATION
FOR
MECHANICAL/PIPING FABRICATION & ERECTION WORK

(A) MANPOWER Rev.01Dated.16/11/09

SR. DESCRIPTION NOS.
NO
1 Project Manager/Site Manager

2 Engineer

3 Safety Engineer

4 Planning Engineer

5 QA/QC Engineer

6 Supervisor

7 Foreman

8 Pipe Fitter

9 Pipe Welders

10 Structural Welders

12 Gas Cutter/Plasma Cutter

14 Grinder

15 Supporting Staff/Store Keeper

16 Helper

17 M W Fitters

18 Riggers

19 Draughtsman

20 Electrician

21 Scaffolders: - Manlift would be prefferred . Incase of

restriction of area where manlift cannot be used, than
scaffolders should be used.
(B) MACHINERY

SR.NO DESCRIPTION NOS.

1 Crane (Reqd. Capacity)

2 Derrick (Reqd. Capacity)

3 Truck/Trailor

4 Fork Lift/Hydra (5 Tons)

5 Welding Generator

6 TIG Welding Machine

7 Plasma Machine

8 Grinding Machine

9 Air Compressor

10 a) Water filling Pump with hoses & accessories etc.

b) Manual Test Pump with calibrated gauges, hoses &

accessories etc.

c) Hydraulic Test Pump (Motorised) with calibrated gauges,

hoses & accessories etc.

11 Drilling Machine

12 Hand Winch 5T

13 Chain Pulley Block (5/3/2 )

14 Gas Cutting Set

15 Welder Kits

16 Hand Tools & Accessories

17 Metallic Scaffolding & Landing Mats.

18 Slings, Wire Ropes & D Shackle

19 Electric Oven

20 Hydraulic Pipe Bending Machine

 21 D G Set

NOTE:
PLEASE NOTE THAT APART FROM THE ABOVE MANPOWER AND TOOLS &
TACKLES, ADDITIONAL MANPOWER , TOOLS & TACKLES AS AND WHEN
REQUIRED SHALL BE MOBILISED BY THE CONTRACTOR TO SUIT THE
CONSTRUCTION PROGRAMME.
 Mechanical and Piping Works Schedule
Project No: 2090 / 1600
Project Name: PIC Unit at Ankaleshwar
Customer: Bayer Material Science
Sl No Activity Description Start Date End Date Oct'09 Nov'09 Dec'09 Jan'10 Feb'10 Mar'10 Apr'10 May'10 Jun'10 Jul'10 Aug'10

Mobilization of Contractor with office

1 22-Oct-09 25-Nov-09
set-up
2 Piping Prefabrication 1-Dec-09 15-Mar-10

3 Piping Erection 21-Dec-09 10-Jun-10

4 Equipment Erection 1-Jan-09 10-May-10

5 Hydrotest 18-Mar-10 30-Jun-10

6 Insulation and Painting 8-Apr-10 21-Jul-10

 PART 6 a

SITE MANAGEMENT

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 PART 6a

SITE MANGEMENT

6.1 SITE PRELIMINARIES

The section shall be read in conjunction with General Terms and

Conditions of Contract Works Involving Construction and Erection
(GCC) as applicable. On commencement of the work apart from other
stipulations mentioned elsewhere in the Contract, the Contractor shall
undertake the following free of cost.

The Contractor shall accept the existing levels and dimensions of

ground, roads, ditches, culverts, nullahs, buildings, etc. jointly
recorded and agree in writing, as the same would be taken as the
basis for all subsequent measurements. The Contractor shall set out
the work properly in the field from base lines and datum levels. The
Contractor shall establish adequate number of bench marks at key
locations in such manner as the Consultant may determine. Whenever
required, Contractor shall also mark elevations and co-ordinates of
foundations, pedestals, walls, columns and at cross sections of roads
as required by the Consultant. All existing utilities such as water lines,
drains, transmission lines, etc which Contractor may encounter
during the operations shall be properly maintained and protected
by means of shoring, strutting, planking etc. from damage as directed
by the Consultant. Similarly, the Contractor shall take care to protect
Owner’s property during the construction. In case any property is
damaged, the same shall be made good by Contractor at his own
cost to the satisfaction of Owner and he shall face all
consequences arising therefrom (e.g. accidental death of his workman
after falling on underground live cable). The Contractor shall co-
operate fully in executing the work and work in harmony with other
agencies working simultaneously at site.

6.2 SITE ORGANISATION AND EQUIPMENT

Before the commencement of works, the Contractor shall

submit to the Consultant / Owner for his approval a complete site
organisation chart describing the activity of each individual and
also a complete list of equipment to be used by Contractor at site.
The Consultant reserves his right to ask the Contractor for augmenting
the personnel and equipment for proper and speedy Execution of
the works. The Contractor shall be particularly required to maintain
quality control, planning department and good industrial relations.

6.3 CO-ORDINATION PROCEDURE

6.3.1 The Contractor shall liaise closely with the Consultant, at

all times in day-to-day work. Contractor shall be responsible
for co-ordinating between the Consultant and the Owner’s
Site staff.

6.3.2 The Contractor shall programme, co-ordinate and phase all

works including delivery of Sub-Contractor's and Supplier’s
materials and execution of Sub-Contractor’s work in all
respects.
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 6.3.3 Contractor shall be responsible for working out quantities of
bulk materials such as pipes, pipe fitting, valves, structural
steel etc. as per drawings and documents submitted to
Contractor to ensure availability of material and manpower
as per planned schedule of work.

As soon as a drawing is released, Contractor shall submit

above to the Consultant, in the prescribed format.

6.3.4 All works which are carried out and which does not come
under the purview of the drawings, shall be supported by the
joint measurements and sketches, without which no bill shall
be entertained.

6.4 PROGRESS REPORTS

Within 7 days from the date of receipt of Letter of Intent the

Contractor shall submit to the Consultant a detailed programme of
work showing various activities in the form of bar-chart Contractor
will follow for the completion of work. He shall also submit minimum
resources such as manpower, equipment, machines and shuttering to
carryout the job as per schedule with a guarantee of reinforcement if
required to cater over lapses and re-adjustments in schedule. The
details shall be given in prescribed format. Contractor shall also
submit in quadruplicate the weekly progress reports (on every
Monday) outlining:-

a. Progress achieved during the previous week.

b. Programme for the following week covering status drawings,

material procurement, construction, fabrication and erection.

c. Manpower and supervisory personnel employed on the job.

d. Number and type of construction aids/tools/ tackles available

at site in working order

e. Shortfalls, if any, and reasons thereof.

f. Types and areas for which various permits are required.

6.5 SITE MEETINGS

During the course of the work, the Contractor shall hold

progress meetings on site at regular intervals as determined by the
Owner/Consultant for the purpose of co-ordinating the Contractor's
and Sub-Contractor's works and delivery of Sub-Contractor's
materials to ensure full compliance with the above. Minutes of
such site meetings will be recorded, copies will be distributed to all
persons concerned and full effect shall be given to all instructions
mentioned therein.

6.6 MEASUREMENTS

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 Mode of measurement shall be as per relevant provisions of
standard, spec & codes as applicable unless otherwise noted
specifically. The Contractor shall maintain up-to-date area/structure
wise record of measurements of all the works carried out by him,
jointly measured with the Consultant/Owner. No bill will be
entertained unless accompanied by measurement sheets and material
reconciliation statement duly signed by Consultant/Owner. Contractor
shall give due notice to the Consultant and Owner whenever any
works or materials are intended to be covered up in order that they
may be inspected or that correct measurements may be taken
before being so covered up. Owner/Consultant decision on mode of
measurement shall be final.

6.7 PRE-FINAL BILL

Contractor shall submit a pre-final bill minimum one month in advance

of final completion date, comprising of cumulative measurements
based on the drawings and as certified (along with the
reconciliation of material) upto the period. The final bill shall be
submitted by the Contractor within one month of pre-final bill (along
with material reconciliation).

6.8 NOTES AND OBSERVATIONS

During the entire construction period, the Contractor shall

maintain a duplicate book. Observations and remarks
pertaining to the construction will be entered into this book by the
Owner/Consultant. All notifications made directly by the
Owner/Consultant to the Contractor's address by means of registered
mail shall be deemed to be sufficient and legal.

6.9 RETURN OF SURPLUS

Not withstanding anything contained to the contrary anywhere

in this Contract, wherever any materials for the execution of the
Contract are procured with the assistance of the Owner either by
issue from Owner's stocks or purchase made under orders or
permits or licenses issued by the Owner, the Contractor shall use
the said materials economically and solely for the purpose of the
Contract and shall not dispose them off without the permission of
the Owner and shall return to the Owner all surplus or
unserviceable materials that may be left with the Contractor
after completion of the Contract or its termination for any
reasons whatsoever on being paid or credited such price as the
Owner shall determine having due regard to the initial cost and
present condition of the materials at the time of such return thereof.
The price to be allowed to the Contractor however, shall not
exceed the amount charged to him excluding the storage
charges, if any.

However, refer Clause No. 4.4 of SCC for materials supplied by

Company.

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 6.10 MATERIAL RECONCILIATION

It shall be Contractor's responsibility to prepare material

reconciliation statements for every two months and submit the
same alongwith R. A. Bills and final material reconciliation
statement alongwith final bill for any material that may be issued
by Owner as free issue or at issue rate.

6.11 DOCUMENTATION

6.11.1 Final Bill

At the end of the job, the Contractor shall submit three

copies of final certified quantities of each item of work
including any extra/additional items.

6.11.2 As built Sketches

At the end of the job, the Contractor shall submit three

copies of as built sketches for portion/areas not
constructed as per drawings but as per instruction of
Owner/Consultant for Mechanical/Piping works.

6.12 CLEANLINESS

The Contractor at all times shall keep the site reasonably free from all
rubbish, offensive and harmful matter. On completion of the works,
he shall remove all plant, tools, materials, sheds etc.

Apart from normal safety regulations as referred in General

Terms and Conditions for Contract Involving Construction and
Erection (GCC), it shall be clearly understood by the Contractor
that for the type of industrial structures covered by the Contract,
there are bound to be cut outs in floors for equipment, ducts, lifts,
pipes etc. Till the time they are erected in positions, the cut outs form
potential hazards and hence the same shall be properly barricaded at
no extra cost, as directed by the Consultant.

Storage areas for materials like, pipes, Pipe fittings & valves structural
steel etc. shall be as per the direction of the Consultant. The
Contractor shall be required to confine himself to these areas only for
good house keeping and for clear access.

6.13 SAFETY REGULATIONS

In respect of all labour, directly or indirectly employed for the

performance of the work by Contractor, the Contractor shall at his own
expenses arrange for all the safety provisions as per the safety
standards of clients (Owner) Part 6 b (Doc No: 1600/BS/01 Rev.01.
The Mines Act and such other Acts as applicable. The Contractor shall
also observe and abide by all Fire and Safety regulations of the land.

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PART 6 b

CLIENT SAFETY STANDARS

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Preface

On arrival at site the contractor’s Site Manager and the Safety Officer shall
draw out the Basic Safety Plan for the job to be carried out by them. This very
document shall be prepared in line with the regulations cited hereunder, the
prevailing site conditions, the local civic regulations and the HSE Manual of
Aker Powergas.

The attached document is prepared as a generalised document for all

discipline of works. Contractor shall strictly adhere to all the basic safety
regulations as mandatory requirements. All the necessary expenses towards
the compliance shall be catered for in their bid.
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CONTENTS

A Administrative Functions

1. Safety policy & Management Accountability

2. Safety Personnel & employee Responsibilities
3. Entry / exit to project premises.
4. Training Centre & Training Program
a. New Employee Orientation
b. Trade specific Trainings
c. Training to Employees
5. Personnel protective Equipment
6. Uniforms
7. Safety Notice Board / Sign Boards/Posters
8. Safety Meetings
9. First Aids Management
10. Site Space Management & Housekeeping
11. Safety Inspection & Audit System
12. Safety Reporting System
13. Job Safety Analysis / Risk Assessment
14. Work permit
15. Fire Protection
16. Emergency evacuation plan
17. Accident/ Incident Investigation
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B. Operational Functions

1. Open Flame & Hot Work

2. Hazard Warnings & Barricades
3. Confined Space Entry
4. Electrical Grounding ( Earthing)
5. Electrical Equipments & Tools
6. Power Tools
7. Hand Tools
8. Electrical Safety
9. Energy Isolation
10. Trenching & Excavation
11. Abrasive Blasting
12. Oxy Fuel Cutting/ Heating
13. Rigging Works
14. Material Handling Storage & Transportation
15. Concrete Work
16. Steel Erection & Dismantling
17. Ladders & Scaffolding
18. Floor Openings, Wall openings, Stairway
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1. Safety Policy

To execute projects by taking adequate safety measures, by providing safe working

conditions, by promoting safety awareness among workers. the Safety policy shall be
displayed at prominent places in English & local language understood by workers.

2. Management Responsibility & Employee Responsibilities:

Management will thrive to implement the safety policy effectively and give guidance by
reviewing safety reports.

The Director of all concerned companies associated with the project will review the
safety reports on monthly basis and take corrective action.

The Project Manager/ Project Co ordinator of all concerned companies associated

with the project will review the safety reports on weekly basis and take corrective
action.

The Site Manager/ In charge of all concerned companies associated with the project
will review the safety reports on daily basis and take corrective action. He will also
ensure reporting and proper documentation of all records. He will also be a member of
the Project Safety Committee.

Safety Compliance at site shall be considered as a line function for all the Site
Engineers of the companies associated with the project.

Safety Engineer shall continuously monitor the activities and functions at site. They
shall be considered as the guides for the HSE compliance. All the associated companies
must ensure that their work forces are guided by a qualified site safety engineer/officer
on a 1:100 basis. This means every 100 or less workmen shall be guided by at least
one Safety specialist. Reporting and documentation shall be exclusively the
responsibilities of Safety Head of the site organization of each company associated
with project.

3. Entry / Exit to project premises

Every employee of the contractor including there Managers and Engineers shall undergo
the mandatory 4 step process to obtain their entry badges from Safety Dept. of
corresponding companies and duly endorsed by BMS/APG.

Step 1 -

Undergo medical tests conducted by Medical Practitioner appointed by the respective

contractor and authorized by BMS/APG. The necessary fees for the medical practiotioner
shall be bourne by the contractor.
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Step – 2

 Medically cleared personnel in the capacity of Managers shall be assessed for

competency by APG/BMS. CV of such personnel shall be furnished even before
Medical Tests.
 Medically cleared personnel in the capacity of Engineers and Supervisors shall be
assessed for competency by APG. CV of such personnel shall be furnished even
before Medical Tests.
 All other persons who are medically cleared shall be assessed by the contractor’s site
in charge or engineers for the competency.

Step - 3

On satisfactory clearance all the persons in the capacity of Managers, Engineers,

Supervisors and staff category shall undergo a general Safety Induction / Orientation
Program conducted by BMS/APG Safety Officers. Persons at the workers level shall
undergo the orientation/induction program conducted by the safety head of the
concerned contractor/agency.
It is also mandatory that safety Officers of corresponding contractors shall maintain a
record of such orientation programs and a copy of all such records shall be furnished to
APG on daily basis.

Step – 4

After the Induction Training the workers and other personnel shall be provided with a
photo ID badge by the authority as stated above. The entry/exit of the employees and
workers shall be monitored in the following manner:

 The safety inspector will allow the personnel after checking the PPE and the ID
badges.

 The Safety officer at the safety office will maintain a master register of workers.

 The record of entry / exit of the personnel will be maintained by the timekeeper at
the entry gate.

4. Training Centre & Training Program

All the contractors with a peak labour strength of more than 50 (fifty) and a contract
duration more than 90 days shall install a training centre alongside their site office. Such
training rooms shall have a capacity of approximately sitting capacity of 50. The training
room shall be equipped with the followings

 A white board mounted on wall with white board markers

 All kind of PPEs one set each for demonstration
 A Television set with DVD player for viewing the demonstrative films
 Fascilities for provision of LCD projector as and when required
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 The room shall have proper ventilation facility with the provision for lights, fans,
drinking water etc.
 A mock up assembly for the scaffolding outside the room for demonstration
 Set of all blank protocols like work permit, method statements and JSA, Audit Forms
etc.

The training to be imparted shall be in the categories stated below

a) New Employee orientation

The new employee will be imparted induction training on the following topics on first
entry at site and for entry of visitors:

 Entry / exit system.

 Use of PPE
 Medical and first aid system.
 Emergency evacuation plan.
 Work permit system
 Basic rules of safety.
 House keeping.
 Use of fire extinguisher.
 Sign / traffic boards.

b) Trade specific Safety Training

The contractor shall organize periodic training programs for the different trade workers
like carpenters, Welders, Riggers, Drivers etc. Such programs shall be conducted in
consultation with the APG Safety Engineer. The project will have a target training hour of
one percent of the total exposure hour of the project. The contractor shall endeavor to
achieve the same for their respective exposure hour on quarterly basis.

c) Training to Employees (Periodic)

All the employees of all the companies shall have to be given refreshing training for HSE
compliance on a quarterly basis. This training shall mainly cover the following topics:

 HSE management system

 First Aid Policy
 Method Statements
 Job Safety Analysis
 HSE values and Just Rules Principle of APG
 Emergency preparedness and Emergency Evacuation
 PPE Management
 Hazard Observations Near Miss Analysis

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5. Personal Protective Equipments (PPE)

 The chart showing the information on trade-wise use of PPE as attached in this
document shall be displayed in the notice board for awareness and
implementation by all concerned.

 Basic PPEs like helmets, shoes, safety Harness, safety goggles, Fall Arrestors etc.
shall be provided according to their trade and nature of work.

 Workers shall be advised not to wear loose clothing.

 The personnel shall be advised to strictly adhere to the use of PPEs.

 Quality of all the PPE in use shall conform IS .

 Audit shall be carried out on weekly basis for the PPE inventories. The unusable
and rejected PPEs shall immediately be disposed from site and equivalent
quantity of the inventories shall be received in advance to avoid idling of the
labor.

 PPE inventory log will be auditable and hence need to be kept updated.

6. Uniforms and Dress Codes

 For the purpose of proper identification of workmen from different companies

associated in the project, uniforms/ coveralls of a particular color and design shall
be used by respective contractors.

 Fluorescent jackets can also be used for the purpose. Contractor must ensure
that all such dress accessories are properly maintained. Faded and torn dress
accessories shall be disposed on a periodic basis.

 All the loose dresses shall be avoided strictly in accordance with the safety
norms.

 Safety Helmets for the Safety Personnel shall be green and for the security
personnel shall be red. Rest of the workers shall wear helmets of yellow or blue
colour. White helmets shall be reserved for the Engineers, Staffs and visitors.
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7. Safety Notice Board, Sign Boards, Posters

All the contractors shall provide a notice board in their site offices to display

 HSE information on total man-hours worked

 Accidents occurred
 Training schedule
 Important telephone numbers
 Safety Awareness Program notices.
 Awards and achievement information

Safety posters & signboards shall be displayed at all the prime locations (approximately
one per 50 sqm area) as well as working areas. Such posters and signs shall cover the

 Awareness information.
 Caution notes,
 Danger notifications
 Motivation messages
 Award and appraisal information
 Tags and Marks for underground Services
 Safety Slogans etc.

8. Safety Meetings

Tool box talks

The safety officer will conduct daily counseling (tool box talk) to the supervisors /
subcontractors on their relevant subjects.

The supervisors / subcontractors will give toolbox talk to his group on safety on daily
basis at start of day’s work. The safety officer and safety inspector will attend one
group per day.

The weekly meeting:

The weekly meetings will be conducted on a mutually agreed pre decided day of the
week. This meeting will be attended by the Manager (Safety & Quality), Safety officer,
Project Manager, HSE supervisors.

The topics like previous week’s accidents / incident reports, unsafe working conditions,
suggestions etc. will be discussed in the meeting.

The minutes of the meeting containing reviews and suggestions given by the Director, if
any, will be recorded and the copies will be sent to all concerned.
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9. First Aid Management

All the contractors shall establish First Aid Booth (min 3.0 m x2.5m size) in their
respective office area. The first aid booth shall be attended by a qualified first Aider
during working hours. The booth shall be equipped with necessary equipment and
medicines. The minimum first aid equipments and medicines required to be maintained
are as under:

 Table & Chair for the First Aider

 Patient’s bed (180cm x75cm)
 A stretcher
 A sufficient number of eye wash bottle with suitable liquid clearly indicated by a
distinctive sign which shall be visible at all times
 Small sterilized dressing –24
 Medium sterilized dressing –12
 Large sterilize dressing –12
 Large sterilize burn dressing – 12
 Sterilized cotton wool –12
 Antiseptic solution
 Scissors –1

 Roll of adhesive plaster – 1 ( 6cm x 01 meter )

 Roll of adhesive plaster – 2 ( 2cm x 01 meter )
 Sterilized eye pad – 12 nos

 A bottle of analgesic tablet

 Safety pins – 3 packet
 One copy of first aid leaflet issued by the Directorate General
 Triangular bandages – 6 nos
 Two pair of suitable, sterilized latex hand gloves

The cases requiring further attention shall be transferred to nearest Hospital

An emergency vehicle shall be stationed at site for emergency transportation during

working hours.
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10. Site Space Management, Housekeeping & Sanitary

For the purpose of efficient utilization of available free space and also to maintain a
systematic housekeeping it is mandatory that all contractors shall indicate their space
requirement for the different logistical arrangements along with the utility needs like
power, water etc. A site layout plan for the temporary installations shall have to be
drawn out. This plan shall be approved by APG/BMS before actual installation. While
drawing out this facility plan the following norms must be taken care of.

 All the temporary structures shall be made of steel or masonry structure. No

wooden framing and asbestos sheets shall be allowed to be installed.
 The schematic drawing for the temporary bldgs .and structures shall be submitted
to APG for due approval before actual installation.
 All the temporary electrical installations shall be marked on the site facility plan
and the installations be certified by the certified electricians.
 Water supply locations shall be marked on the site facility plan.
 Waste disposal scheme shall clearly be written down and followed in strict
accordance.
 Waste Recycling program shall be drawn out and a log be maintained for the
same
 Environmental safety plan be displayed and program be drawn out
 Storage bins shall be marked with the traffic movement plan

Contractor shall also draw out a comprehensive house keeping program. This House
keeping program shall be monitored on daily basis. In the event the site is under the
control of multiple contractor, joint housekeeping program might have to be drawn out.
Contractor’s active participation and co operation in the program shall be a mandatory
requirement.

11. Safety Inspection & Audit System

Three tier audit system shall be enforced at site. Contractor shall comply all the rules &
regulation and participate in the audit program of the project. The audit procedures at
different tier are outlined below:

Tier 1

This level of audits is restricted to Risk Observation and Behavioral Observations on day
to day basis. Auditors could be any individual at any capacity irrespective of their status
and their organization. Even visitors will also be invited to make observations and
report in a prescribed form. All the observation reports shall be collected in a drop box
and the Safety Engineer from APG shall be co coordinating the corrective action plan on
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daily basis in consultation with the respective Safety Officers of the concerned
contractors.

Tier 2

This level of audits shall be carried out on weekly basis. Auditor shall be the Site safety
committee. Site Safety committee comprising with the Site in charges and safety heads
of all the companies. During weekly walk around before the weekly safety meeting the
unsafe work conditions, unsafe acts, housekeeping etc shall be taken in consideration.
A comprehensive report of Tier 1 Audits shall also be appraised by APG Safety Engineer.
The committee shall also draw out an action plan to be implemented during the
consecutive week.

Tier 3

This audit shall be conducted by the external party (APG HO / BMS) In this level all the
internal audit reports and the action taken status shall be reviewed. Exhaustive system
verification shall also be made. Besides the site rounds and the site observations shall
also be undertaken. The observations shall be done in line with the Safety Suveillance
plan for the project. The frequency of such audit shall preferably be once in a month.

12. Safety Reporting System

All the contractors shall furnish a daily Safety Report to APG. The report shall highlight
the followings

 Total Manpower for the day

 Number of exposure hours
 Number of people attended Medical Test
 Number of Workers attended the orientation/induction program
 Total Training hours which include orientation, tool box talks, trade oriented
trainings etc.
 Number of Risk observations
 Incidents/ Accidents
 Near Miss Incidents
 First Aid cases
 Number of work permit executed
 JSA Released

Contractor shall also compile all the above data on weekly basis and furnish to APG along
with the weekly progress report.

APG Safety Engineer shall all such weekly reports on a monthly basis for all the site
contractors and release the same as a Monthly Site Safety Report in the prescribed form
of Aker Solutions.
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13. Job Safety Analysis and Risk Assessment

For every new and major activities contractor shall prepare a Method Statement which
shall indicate the sequential steps for the job to be executed. The accessories and tools
& plants and other facility designs shall also be indicated. Such designs include formwork
designs, scaffolding designs, staging design, lifting tackle designs etc.

Based on the approved Method statement safety engineer shall identify the hazards
concerned and carry out a Job Safety Analysis. The precautionary measures are to be
indicated in JSA and the same shall form a part of the Work Permit.

Contractor shall strictly follow this procedure and all work sites are auditable on daily
basis for the purpose of JSA compliance.

14. Work Permit Systems

The work permit shall be obtained for the following activities:

The work permit shall be initiated by the concerned safety officer of the contractor and
shall have to be approved by APG Site Engineer & Safety Engineer. Apart from the
normal work permit is obtained special permits shall also be obtained for the following
activities

 Height work permit ( above 6 feet height).

 Excavation Work
 Hot work at site.

The work permit shall be approved by APG Safety Engineer.

On completion of the work or at the end of the day. The work permit shall be
surrendered to APG Safety Engineer. If the work needs to be continued on the next day
the permit shall be revalidated

15. Fire Protection System

Appropriate and adequate number of sand buckets and fire extinguishers will be
provided at location like DG set, welding / gas cutting areas, site office, electrical
installation where fire is anticipated.

Besides above the contractor shall strictly follow the Fire Safety Rules of the site.
Contractor shall also participate in the fire safety drills conducted perodically
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16. Emergency Evacuation plan

Contractor shall take a note of the Emergency evacuation plan. All the workers and
employees shall have proper orientation to respond to such emergency situation.
Emergency drills shall be conducted at regular intervals and contractor shall keep such
provision to cater for the time loss and the man-hour losses for the purpose.

CSA contractor being the first party to participate in the program, they shall keep
provision of certain common facilities like Assembly Point, provision of Siren/Hooter,
Facilitator for organizing motivation program, hazardous area identification etc.

17. Accident investigation

Near miss incidents and all reportable incidents/ accidents shall be investigated in line
with guidelines provided in HSE manual. Root Cause Analysis shall be carried out for
finding its cause and corrective / preventive actions
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1. Open Flame & Hot Works

This safety regulation will apply to any work wherein sufficient heat or sparks may be
generated to serve as a source of ignition in any work area.

 The person executing the work will sign the permit, thereby signifying that he
and his crew fully understand the conditions spelled out on the permit and will
honor those conditions.

 The form will be completed in duplicate. The hard copy is to be displayed at

the work site. The soft copy is to be retained in the project office or control
room of the area concerned until the work has been completed.

 On completion of the work, the bottom portion of the permit shall be

completed by the person executing the work and returned to the point of
issue.

 Contractors shall own, maintain, and operate their own oxygen and gas
detection devices. The approved-signature supervisor is the final authority
when conflicting test results are encountered.

 Contractor shall be responsible for testing and certifying in writing that no

flammable gas, oxygen deficiency or toxic materials are present in the
location.

 A fully charged fire extinguisher of a type and size designated as suitable

shall be provided where Hot Work is to be done.

 Gas-burning and welding torches and hose shall be removed from all vessels
or closed containers after termination of works.

 All openings from which releases occur shall be considered hazardous.

 When electric welding is to be performed, the ground connection shall be

attached to the work within the area covered by the permit, and the welding
machine shall be in the area. The ground and the stringer should be as close
together as possible and on the same equipment.

 Flammable gas and oxygen deficiency testing will only be undertaken using
an approved explosive meter or oxygen meter.
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2. Hazard Warnings and Barricades

Hazard warnings may come in several different forms, which include signs, tags,
permits, barricades, etc. The primary factor with any hazard warning is that all
contractors and their employees shall be educated as to the types of warnings and
their definition. The following section details suggested hazard warnings that should
be utilized.

COLOR DESCRIPTION
RED FIRE: Protectio n equipment and apparatus, including fire-
alarm boxes, fire-blankets boxes, fire extinguishers, fire
exit signs, fire hose locations, fire hydrants and fire pumps.
DANGER: Safety cans or other portable containers of
flammable liquids, lights at barricades and at temporary
obstructions, danger signs.
STOP: Emergency stop bars on hazardous machines,
stop buttons.
ORANGE DANGEROUS EQUIPMENT: Part of machines and
equipment that may cut, crush, shock or otherwise injure.
YELLOW CAUTION: Physical hazards such as stumbling, falling
tripping, striking against, and being caught in between.
GREEN SAFETY: First-aid equipment.
BLUE WARNING: Caution limited to warning against starting,
using or moving equipment under repair.
MAGENTA & YELLOW RADIATION: X-ray, alpha, beta, gamma, neutron, proton
radiation.
BLACK & WHITE BOUNDARIES: Traffic aisles, stairways (risers, direction
and border limit lines) and directional signs.

Barricading Hazardous Areas

Barricades are to prevent unauthorized personnel or equipment from entering an

area where a hazard may exist as a result of maintenance, construction, equipment
failure, weather or any other emergency condition.

Types of Barricades

 Permanent barricades usually consist of walls, dividers and fence

installations.
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 Temporary barricades usually consist of walls, dividers or fences erected to

serve as protection in connection with a hazardous job or project in progress,
but intended to be demolished at the completion of it.

 Portable barricades usually consist of horse barricades, rope barricades,

traffic cones and temporary fence installations.

Use of Barricades

 Barricades should be used to isolate those areas where a hazard exists to

control personnel or equipment travel. Examples of work that commonly
require barricading are:

 Open excavations, floor openings.

 Overhead work.
 Roadways made dangerous by weather, fire, or other unusual conditions.
 Roads under repair or with excavations that vehicles or personnel could
enter.
 Test areas.

Barricade Tape

Barricade tape or flagging shall be used to designate work areas that present a
particular hazard. The color of the tape/flagging or special markings shall indicate
the specific hazard. The project shall be evaluated periodically for proper sign
usage.

Yellow-Black

 Shall designate an area of "caution" (hot work overhead, excavation, etc.)

 Employees shall be allowed to move through an area marked with the caution
marking but only with the knowledge of why the area is marked and
precautions needed.

 Designed to alert employees to a hazard exposure.

Red

 Shall designate an area of "DANGER" (swing, radius, work overhead, high

noise, sandblasting, hydro-testing, etc.).

 Only authorized personnel shall enter a designated “DANGER" area. All

others shall go around. Any unauthorized crossing of a red barricade will
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result in disciplinary action.

 Denotes a high hazard or "DANGER" area.

Magenta-Yellow

 Shall designate a radiation area along with the required signals.

 Employees shall not be allowed to enter this special, controlled area unless
authorized by the radiographic personnel.

Word Markings

 Barricade tape/flagging with a wording label may be used, but the color code
should still apply.

Tags

Various tags/permits may be utilized during the course of a project to designate

hazards, status, condition of equipment, or some other condition which may present
a safety hazard. The tag information must include the name of the person-erecting
barricade, erected date and duration barricade will be up and hazard barricade is
identifying. Tags will be used as a temporary means of warning employees of an
existing hazard, such as defective tools, equipment, lock-out and tag, etc. They will
not be used in place of, or as a substitute for warning signs or labels. Specifications
for accident prevention tags are:

 Danger—White Tag—White letters on red oval with black square.

 Caution—Yellow Tag—Yellow letters on a black background.

 Instructional—White Tag—White letters on black background.

Electrical lockout

 Designates electrical equipment that has been taken out of service.

 Shall only be removed by the person who installed the tag.

Danger

 Designates a hazard (valve open, etc.)

 Shall only be removed by the employee who installed the tag.

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Defective equipment

 Designates unsafe material or equipment tools, scaffolds, ladders, etc.

 May be removed by the person repairing the defective tool or equipment.

Scaffold inspection

 Designates that a scaffold is completed for use.

 Alterations to scaffold after initial construction require the placement of a new

tag.

 Absence of the tag indicates that the scaffold should not be used.

 The tag may also be used to designate scaffold ownership in the event no
designated scaffold crew is used.

Removal

All hazard warnings, warning signals, signs, tags or barricades or barricade tapes,
shall be removed when the hazard no longer exists. Barricades shall not be used to
reserve or control an area or preventing other crafts from performing work. The
involved craft superintendents and the site HSE manager will resolve any barricade
conflicts or issues.

3. Confined Space Entry

Personnel are at times required to enter enclosed spaces, hereafter called vessels,
to clean, inspect, repair and perform other duties associated with the equipment of
the process of various testing activities. Enclosed spaces which are potentially
hazardous shall mandatorily be attended with following precautionary measures:

(1) Preparation of Vessel - The vessel should be thoroughly prepared prior to the
entry of personnel.

 Cleaning - According to the nature of the contents, the vessel should be

emptied and made clean and void of residue by hot or cold water flush, by
steaming, by chemical neutralization or by air purge with harmful vapors
vented safely to the outdoors where practicable.

 Ventilation - The vessel should be thoroughly ventilated preferably by

some positive method of mechanical exhaust to avoid recirculating
contaminated air. All ventilation or air moving equipment shall be
grounded to the vessel to avoid static sparks. After the vessel is cleaned
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and ventilated, the mechanical exhaust system should be kept operating.

Should decontamination involve flammable liquids, vapors, gases or
dusts, all sources of ignition shall be eliminated.

(2) Isolation - The vessel should be completely isolated from all other systems
and equipment. Positive and adequate measures must be taken to prevent
harmful material-solids, liquid or vapor from entering the vessel while workers
are inside. In all cases where lines have contained hazardous fluids or inert
gas, or where they contain fluids at high pressures or temperatures, the lines
should be physically disconnected and isolated by placing a blank in the lines
as close to the tank as practical.

Drains or overflow lines should be disconnected or blanked if they extend into

a sewer from which steam or fumes could be conducted back into the vessel
or if they connect to other equipment or extend to a remote location.

All lines to be disconnected or blanked or capped to prevent flow from

disconnected ends entering a vessel opening or draining on to assistants on
the outside. All blanks shall be sufficient thickness and tensile strength to
withstand maximum pressures that may be imposed and of material which will
withstand corrosion of chemicals to which they may be exposed.

(3) Lock Out - Motor control center disconnect switches supplying power to any
mechanical mixers, agitators, pumps and cover or door actuators should be
tagged and locked in the "OFF" position. It is not adequate to lock a local
push-button station as it still may be possible to energize the circuit. The man
in the vessel should keep the key, and he alone shall be authorized to unlock
the switch and remove the tag on completion of the job. Where more than
one man is exposed, each should place his own lock on the switch. In certain
cases, it may be advisable to have an electrician pull the line fuses in the
electrical circuit in addition to lock and tag requirements. See DP-802.7.10,
Energy Isolation Procedure (Lock, Tag, Try and Test).

(4) Testing Oxygen and Gas - Before entry is made into any vessel, a test for
oxygen and both flammable and toxic gases shall be made and a vessel
Entry Permit issued. The last substance contained in the vessel must be
considered for complete gas testing. Residue from the substance can leave
or generate toxic fumes that normal O2/combustible gas check will not detect.
Under no condition will entry be made until this procedure is carried out and
all potential gases and contaminants are checked for.

(5) Issuance of Entry Permits - The Entry Permit certifies and records approval
for vessel (enclosed or confined space) entry. It serves as a method of
formalizing agreed upon procedures and also as a checklist to ensure that all
existing hazards are considered, evaluated and correct protective measures
taken. No employee shall enter any vessel without reporting to and securing
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approval from the immediate supervisor and the HSE Coordinator. The
Supervisor shall discuss the project in detail with those entering the vessel.
He should review the hazards of the product or other materials to which they
may be exposed and document this training. The supervisors of all men
involved shall then review and complete the authorization form jointly. An
Entry Permit is not a work permit and is valid only for entry and inspection of a
vessel or confined space, etc. Should it be necessary to perform Hot Work
inside a vessel, both an entry and Hot Work Permit will be required prior to
commencing work. Appropriate supervisors must ascertain by personal
investigation immediately before vessel entry and before signing the
authorization that the entry and incidental work will be safe. To ensure
continuation of safe conditions if a break of appreciable duration occurs
during the job, the authorizing supervisors must reinvestigate the site before
the job can be allowed to resume. Commencement of a new shift will always
require reinvestigation and endorsement of a new authorization by new shift
supervision. No authorization shall be valid except for the job, location,
persons and time specified.

(6) Precautions - Hand tools shall be clean, in good condition and shall be
selected carefully according to the uses intended. Electrical tools and
equipment such as hand lamps and extension cords must be on a 12 volt
system or plugged into a working ELCB. In any Class I or Class II exposure
(in dangerous flammable dust concentration), use air-operated power tools.
Ladders used in tanks should be lashed at the top and, if possible, at the
bottom. Employees performing electrical welding in tanks shall be provided
with and required to use such personal protective equipment as may be
required. Welding and cutting torches must not be taken into the tank until
ready to be used and must be removed from the tank immediately after use.
Cylinders of oxygen or other gas shall never be taken into tanks, and they
should be turned off at the cylinder valve when not in use. Fire extinguisher
must be readily available.

Air power tools shall not be used in confined spaces if the air system is
backed with nitrogen or other inert gases.

(7) Signs - Signs posted near the vessel help keep unnecessary people away,
ensure that potentially harmful operations will not be started independently
nearby and help guide rescuers should to the scene if necessary.

(8) Barricades - Open pits and hazardous vessel operations require barricading
with substantial railing 42" high with toe boards or equivalent protection to
prevent kicking objects laying on the floor or ground into the pit. Rope with
streamers at the 42" level is recommended for closing aisles in adjacent
areas. Flashing lights on barricades are necessary when pits are open at
night or in dimly lighted areas inside.
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(9) Personal Protective Equipment - Proper protection may range from specially
designed, complete coverage suits for protection against highly toxic
chemicals harmful by absorption through contact with skin, chemical goggles,
hard hats, gloves and safety shoes normally worn to protect against routine
hazards. Employees should never unduly expose the skin when working in
vessels, and they should wear full coverage clothing at all times.

(10) Respirators - Certified breathing air for self-contained units shall be supplied if
the integrity of the atmosphere cannot be guaranteed and if there is any
possibility of air contamination of a harmful nature or of oxygen deficiency
while employees are within a tank. Canister type masks, which operate on
the principle of chemical absorption or mechanical filtration, may not afford
adequate protection and should not be used. For specifically recommended
protection from hazards of contaminating materials, refer to the HSE
Manager.

Respirators will be issued to individuals who are responsible for their safe and
sanitary keeping. Respirators shall be sanitized before they are reissued to
other individuals.

(11) Emergency and Rescue - Where potential exposure in the vessel is acute or
requires an employee to wear respiratory protection or where rescue may be
difficult, the employee must be provided with a body harness with a life line
attached. It is good practice to use a body harness for any vessel entry work.
Such safety harness and life line should be used when the shape, size and
location of the vessel space prohibits the safe emergency removal of workers
by standby personnel without requiring entry into the tank.

4. Electrical Safety

Electrical Rules

 Only authorized and qualified employees are permitted to start and operate
electrically driven equipment or energize and de-energize electrical circuits.
These employees must conform strictly to the rules covering such equipment.

 Electrical cords or cables furnishing power to portable electrical equipment

shall not contain splices or damaged insulation.

 Do not leave cords or cables in areas where they could be damaged or would
present tripping hazards. Examples: On stairways, truck aisles, doorways or
where heavy objects rest on or could fall on the cord.

 Do not allow cords or cables to lie in puddles of water.

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 Temporary portable wiring shall not be used to provide power to equipment

longer than three months during which time the affected electrical feed should
be scheduled for repair.

 All 220-volt and 440-volt portable electrical equipment shall be equipped with
an external, auxiliary ground cable that is independent of the ground in the
power cable. The auxiliary ground shall be equipped with a screw-type clamp
to ensure a positive ground. The auxiliary ground shall be attached to a
grounded source before the power cable is connected. The ground
connection must be connected to the metal frame or shell of the portable 220
or 440-volt equipment at a place where it is clearly visible.

 All electrically operated hand tools must be protected by an ELCB installed in

all and individual locations

 Each and every live or charged electrical equipments like DB, MCC etc shall
bear a tag of suitable nature.

 Cable routing for all underground cables irrespective of its nature ie;
permanent or temporary shall be marked with cable route tags. Besides the
underground cable routing drawing shall be drawn out and displayed in all the
offices, prime locations at site. Contractor shall make it compulsory that any
excavation permit shall contain an electrical clearance certificate also.

 Originator of excavation permit shall also ensure that area of excavation shall
have at-least a meter clearance on either side of the HT cable routed under
the ground .

 Contractor shall also follow all the protocols and comply all the check list
needs as pet the HSE Manual.

5. Electrical Grounding ( Earthing)

Electrical wiring, temporary or permanent that is used and is not protected by a

Ground Fault Circuit Interrupter (GFCI) between the panel box and any extension
cord or receptacle that any employee may plug into, the following program will be
followed without changes. The persons assigned to carry out this program shall be
the Site Safety Manager or a designated competent person.

 Before any electrical powered tool is used for the first time, it shall be checked
to see that the cord and plug are in good condition, that all three prongs are
intact (unless UL listed double insulated) and that there are no exposed wires
at plug or cord end.
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 Using proper test equipment (Ohmmeter, continuity tester, etc.), the inspector
shall make sure the case of the tool is in electrical contact with the ground
prong and that the other two prongs are not in electrical contact with any part
of the tool or case.
 The switch must work and shut off the motor when released.

 Each extension cord and drop light must be inspected before it is put into
service and during the regular monthly inspection thereafter.

 The inspector shall check male and female ends to make sure there is a tight
connection with no exposed wires. The inspector shall check to see that
there are no breaks in the insulation and that the ends are protected or that
they are of the "dead front" type.

 The inspector shall use a tester to make sure there is a good ground and that
the other wires are electrically continuous.

 All equipment grounding conductors shall be tested for continuity and shall be
electrically continuous.

 Each receptacle, attachment cap, and plug and receptacle of cord sets shall
be tested for correct attachment of the equipment grounding conductor. The
equipment grounding conductor shall be connected to its proper terminal.

 All required tests shall be performed as follows:

 Before the first use.

 Before equipment is returned to service following any repairs.

 Before equipment is used after any incident suspected to have caused

damage (e.g., when a cord set is run over).

 At periodic intervals.

 Tests shall be documented and visibly identified by means of color-coding.

 A visual inspection is required prior to the use of any electrical cord or tool by
the intended user

 Check male and female ends for secure connections and exposed wires.
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Welding Machines

Due to the hazard potential all users of portable welding machines must adhere to
the following rules and guidelines.

 Machine must be properly grounded to frame.

 An external ground wire must be used.

 The electrode holder must be in safe condition.

 Cables and connectors must be in safe condition.
 Connection posts must be tight and in good shape.

Use of Portable Electric Equipment

This applies to the use of cord- and plug-connected equipment, including flexible
cord sets (extension cords). The following is required:

1. Handling of portable electric equipment must be done in a manner that will

not cause damage to the equipment.

2. Visual inspection of portable electric equipment must be made, before use,

for external defects and for evidence of possible internal damage.

3. A flexible cord used with grounding type equipment must contain an

equipment-grounding conductor.

4. ELCB shall be used on all electrical equipment for outside work or in any
area that has potential for shock (e.g., a wet area).

6. Electrical Equipments

ELECTRICAL EQUIPMENT

General

Electricity as low as 110 Volts has been known to cause fatal injuries. If you would
see someone who appears to be getting shocked do not touch them. Turn off the
power at the power source or disconnect the cord if possible. Do not attempt to move
the victim or the electrical cord or tool with a piece of wood or broom handle, etc. as
wood can conduct electricity and you to may end up getting shocked. Electrical shock
can stop the heart and cause unstable heart rhythms. A physician must examine
anyone receiving a significant electrical shock. Notify the Aker Solutions HSE
department as appropriate and if qualified, provide first aid and or CPR once the
scene is safe to do so.
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Basic Protection

To prevent electrical shock:

 Never plug in a cord or tool with wet hands or feet or while standing in water.

 For work in wet or other conductive locations employees shall utilize a GFCI
(ground fault circuit interrupter) plugged in at the electrical source.

 Do not use defective equipment and never attempt repairs unless you are a
qualified technician.

 Be sure the cord or tool is properly grounded and has the current inspection
tape on it if an assured grounding program is in use.

 Never use an electric tool in the presence of flammable or combustible gases

unless it is specifically designed for such use and states so on the UL label.

 Store cords and tools properly out of the weather.

 Never use the cord of a tool for carrying or lowering - use a tag line.

 Do not use metal ladders or scaffolds in or around high voltage areas.

 Consider ALL exposed wires as "hot".

 Never work or operate equipment within ten feet of any outside power line.

 Treat all electrical tools with respect and use the proper personal protective
equipment for the situation.

Temporary Lighting

 Temporary lights shall be equipped with guards to prevent accidental contact

with the bulb.

 Working spaces, walkways and similar locations shall be kept clear of cords.

 Portable electric lighting used in moist or other hazardous locations (drums,

tanks, vessels, pipes, etc.) shall be operated at a maximum of 12 volts.
However, 120-volt lights may be used if protected by a Ground Fault Circuit
Interrupter (GFCI).

 Some Confined Space atmospheres may require the use of explosive proof
lighting systems.
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Cords and Portable Tools

 All extension cords, portable electric tools, and equipment shall be of three-
wire type unless they are UL approved double insulated tools. This UL
indication must be clearly marked on the tool.

 Portable tools will have any trigger lock devices removed.

 Flexible cords shall be used only in continuous lengths without splice unless
the insulation is equal to the cable being spliced and wire connections
soldered.

 Cables passing through work areas shall be protected or elevated a minimum

of 7 feet.

 Worn or frayed electric cables shall not be used.

 Extension cords shall not be fastened with staples, hung from nails, or
suspended by wire.

Disconnecting Means

 Disconnecting means shall be located or shielded so that employees will not

be injured and still be readily accessible.
 Boxes for disconnecting means shall be securely fastened to the surface
upon which they are mounted and fitted with covers.

 Boxes and disconnecting means installed in damp or wet locations shall be

waterproof and be GFCI protected.

ELECTRICAL TOOLS

General Precautions

 Ground Fault Interrupters must be used for all non-permanent / temporary

wiring cords and electrical tools.

 Do not use ungrounded electrical tools. Ground wires should be checked and
ground fault interrupters should be tested monthly.

 Do not use electrical power tools with frayed cords.

 Do not operate a machine you are not familiar with.

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 Examine extension cords carefully for worn insulation and exposed strands of
wire before using. Do not drag cords over sharp edges or run them across
aisles where they can be damaged or cause someone to trip. Never hang
extension cords across sharp objects.

 Extension cords should be elevated 7' above ground to avoid tripping hazards
and damage to the cord. Use non-conductive material to secure cords.
Never use nails, tie wire, or staples.

 Lock out and tag the power supply to machines while repairing or adjusting
them. A qualified electrician should make electrical repairs to equipment,
tools, cords, etc...

 Keep machine guards in position at all times.

 Do not wear loose or torn clothing, gloves, rings, neckties, wristwatches, etc.,
when working with electrical equipment.

 Ensure the electrical cords are clear of any moving parts.

 Unplug hand tools before changing parts or attempting to adjust them.

Never leave an electrical tool energized unattended, unplug it.

7. Power Tools

Pneumatic Tools

General

 When gas or diesel compressors furnish the air source, keep them outside or
vent them to the outside to prevent carbon monoxide poisoning.

 If you are using a permanent source of air, make sure it is not oxygen.
Oxygen mixed with the oil in your air hose and tool will cause an instant
explosion and fire.

 Air hoses and connections should be checked daily for defects.

 Air hoses should be protected from vehicle traffic, pedestrians and sharp
objects.
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 All connections must be pinned or chained to prevent whipping should

disconnection occur.

 Disconnect source and "bleed" hose before breaking connection on any air
tool. Never crimp hoses to stop air.

 Do not let your hoses create tripping hazards.

 Never point a pneumatic hammer at anyone. There is always the chance the
retainer might fail.

 The bit should be in contact with the work surface before pulling the trigger.

 Governors require strict maintenance to prevent dangerous over speeding of

grinders, drills, wrenches, etc.

 Always wear proper eye and hearing protection when using air tools. Double
hearing protection may be required.

 Air used for cleaning machines shall be regulated to 30 PSI or less.

 Air hoses and lines shall be depressurized before disconnect or disjointed,

unless the joint being separated has an automatic quick close disconnect
valve.

 Air hoses should have a minimum rated working pressure of 200 psi or 150
percent of the maximum pressure produced in the system, whichever is
higher.

 Air hoses should have an oil-resistant inner surface and an abrasion-resistant

exterior surface. When severe operating conditions make the possibility of
cutting or damaging the hose likely, the hose shall be of extra-ply armored or
other protective construction.

 Metatarsal guards must be worn for complete foot protection when using:

 Ground tampers that leave the ground such as "pogo sticks"

 Pavement breakers or jackhammers

 Extreme care shall be taken when working with compressed air. It should
never be blown against clothing or any part of the body.

 Storage and cleaning are very important with any tool. Keep tools clean and
stored properly where they belong.
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Pedestal, Bench, and Portable Grinders

General

The following precautions and guidelines are provided for the set up, use and storage
of abrasive equipment.

 Each employee is responsible for inspection of the grinder he is using.

 Wheel rating shall not exceed the maximum potential RPM of the grinder on
which it is mounted.

 No special adapters, arbors or other improvising is permitted. No more than

one wheel may be mounted between a single set of flanges.

 All abrasive wheels shall be mounted between flanges which are at least 1/3
the diameter of the wheel.

 On all portable tools, the control switch shall be instant-pressure controlled

without a locking pin. (Exception - grinder for wheels 2 inches or smaller may
have a positive on-off throttle.)

 Wheels should be stored in a dry place with constant temperature above

freezing and protected from physical damage that could cause cracking.

 Guards must be installed and maintained.

 The proper respiratory protection shall be used in the event dust hazards
exist.

 The proper eye/face and hand protection shall be used.

 Guards, work rests, eye shields and other permanent protection devices must
not be removed from any grinding or buffing wheels.

Pedestal and Bench Grinders

An appointed competent person shall perform the initial inspection and subsequent
maintenance of all grinders. Inspections will be made on an established schedule
and the Site Safety Manager shall maintain the records. The using craft shall be
responsible for installing all wheels and assuring that they are the properly
designated wheels for the speed of the grinder. When installing the wheels they shall
be responsible for maintaining the maximum distance between the work rest and the
wheel - 1/8" and tongue guard 1/4". Too much clearance may cause the job to jam
the wheel and break it.
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The following precautions and guidelines should be observed when operating

pedestal and bench grinders:

 Stand to one side out of line of wheel starting it up.

 The face of the wheel must be flat and free from grooves.

 Work should be fed slowly and gradually. Using too much pressure, or
striking wheel suddenly, may cause it to break.

 Do not set tool rest while machine is in motion.

 Use face of wheel only, unless it is designed for grinding on the side;
otherwise, side pressure may break the wheel. Whenever possible, use
entire face of wheel to avoid grooving.

 Never use a grinding wheel that is loose on the shaft or if its rate of speed is
not safe for the number of r.p.m. of the spindle.

 Stop wheel if it chatters or vibrates excessively. This may be a danger signal

that the wheel is not properly balanced or not attached securely to the
spindle.

 All wheels shall be tested for soundness by "ring" testing the wheel or by
testing machine use prior to issuance from the storeroom or tool crib.

 When grinding short pieces use locking pliers that grip firmly so the material
will not slip out and come in contact with the operator.

 Gloves may come in contact with the wheel and cause hands and fingers to
be pulled into the abrasive wheel causing severe injury, “locking pliers for
close work”.

 Always use face shield or goggles and mono goggles, even if grinder is
provided with protective glass shields.

 When dressing the wheel of pedestal or bench grinders, the following

precautions must be observed.

 Wear a face shield over your safety glasses for protection against heavy
particles.

 Use a dressing tool approved for the job. Never use a lathe-cutting tool.
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 Inspect star dressers for loose shaft and worn disks

 Round off the wheel edges with a hand stone before and after dressing to
prevent the edges from chipping.

 Use the work rest to support and guide the tool. Use a tool holder if one is
available.

 Apply moderate pressure slowly and evenly.

 Always apply diamond dressers at the center or slightly below the center,
never above.

Portable Grinders

 Grinders must be inspected prior to initial use and periodically thereafter (it is
mandatory that each grinder has a good speed tag or the speed is embossed
into the body of the grinder).

 Crafts using portable grinders will change wheels when necessary.

 Grinders shall not be operated at a speed exceeding its rated speed (rpm)
and shall not use abrasive wheels, stone, discs or brushes with rated speeds
(rpm) lower than that of the tool on which it is mounted. The wheel maximum
speed (rpm) is printed on the blotter, throw away adapter or the wheel itself.

 The using craft shall assure that grinders are inspected as required.

 The competent person shall maintain records of inspections as well as the

Site Safety Manager.

 All shirts must be tucked into trousers when using grinders. NO

EXCEPTIONS

 Safety guards of a proper type shall be provided and used on all portable
grinders except:

 Grinders for mounted wheels two (2) inches (50mm) or smaller in

diameter.
 Grinders for internal work where work offers protection to the operator.
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Wheel Handling and Storage

 Grinding wheels shall be protected from moisture and temperature extremes.

 Grinding wheels shall not be dropped or bumped.

 Grinding wheels shall be stored in their original shipping containers on

jobsites and in protective racks in shops.

 Installation of Abrasive Wheels, Discs and Brushes

 It is important that grinder operators be properly instructed in the mounting of

wheels on their tools. Operators shall be instructed to inspect wheel for
cracks or other marks which may indicate wheel damage.

 Defective wheels shall be tagged and marked "Danger - Defective Wheel - Do

Not Use" and returned to the Warehouse or Tool Crib.

 A wheel that is damaged by accidental handling shall be destroyed

immediately so that it will not be available for others to pick up and use at a
later time.

 Operators shall be instructed how to properly mount a wheel using the correct
driving and outer flanges, blotters and spaces if so required.

 Operator should not over tighten the spindle end nut that could cause wheel
failure.

Grinding Wheel Testing

Before starting a grinder, the operator shall make sure that no one is in the
unguarded plane of the wheel rotation. Upon mounting a new wheel, the tool shall
be run at operating speed with the safety guard in place for at least one minute
before applying the wheel to the work. No one shall stand in front of, or in line with
the wheel. Another method for testing new wheels calls for the operator to run the
tool up to speed in a protected enclosure such as a barrel for at least one minute.

Position of Operators - And Others

Operators and other personnel working around grinding, brushing or chipping

operations shall be made aware of the possible danger from:

 Flying sparks and grit that can cause foreign bodies in eyes of possible
clothing fire.

 The operator accidentally contacts the revolving wheel with part of his body or
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accidentally contacts another employee.

 The operator dropping the grinder causing the wheel to fall on a hard surface,
breaking the wheel and scattering projectiles all around with tremendous
force.

 The operator trying to work in tight quarters which can cause the grinder to
jam and possibly break the wheel - or jump out of his hands.

Operating Procedure - Portable Grinders

The following procedures should be followed when operating portable grinders.

 Start grinder up close to work - the work piece then becomes part of the
shield for the operator and others.

 Do not bounce or hit grinder wheel into the work surface - ease it in smoothly.

 Always grind with the grinding face of the wheel; do not grind on the side of
Type 1 (straight wheels).
 Do not try to dress a chipped stone or make repairs on portable grinders.

 If the tool motor begins to vibrate or starts up over speed shut it off
immediately.

 New employees should be instructed as to the best method to hold a grinder

for different types of work. Instruct the employee how to handle the grinder in
all work positions so that he/she will not be "manhandled" by the grinder.

Personal Protective Equipment for Portable Grinders

 It is mandatory that operators doing this work use Double-Eye Protection

(mono goggles and face shield), hearing protection and proper gloves.

 The operator should wear an approved dust mask when working in close
quarters or where ventilation is poor.

 Leather sleeves and aprons may be required in some operations where

sparks and/or broken wire brush projectiles are a problem.

 Sweatbands can be useful in preventing "dirty" perspiration dripping down

into the eyes.
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 Operator's clothing should include the following:

 Long sleeves with shirttails tucked into pants. Employees should wear
resistant clothing such as cotton for all outer garments. Never wear
Polyester or Nylon material near any heat source.

 Pants - cuffless and not tucked into boots.

 Shoes - safety toed shoes.

 Gloves - serviceable leather gloves.

8. Hand Tools

All supervisors will be responsible for ensuring that all employees follow these
procedures. The following give safety tips and recommendations for the safe use of
hand tools and power tools.

General Requirements

 Tools will be used only for the purpose for which they are designed.

 When tools are designed to accommodate guards, they will be equipped with
such guards when in use.

 All tools, regardless of ownership, will be of an approved type, maintained in first

class condition, and be subject to inspection at any time.

 Tools with sharp edges will be so stored and handled that they may not be
damaged or cause injury. They will not be carried in clothing pockets.

 Tools subject to impact, such as chisels, punches, drills, wedges, drift pins, and
hammers will be kept free from cracks and mushroom heads to eliminate the
possibility of flying spalls. They will be dressed, repaired, or replaced before use.

 Tools, except those normally carried on belts, which must be raised or lowered
from one elevation to another, will either be placed in an approved container or
firmly attached to hand lines.

 Tools will not be thrown from place to place or from person to person under any
circumstances.

 Tools will not be left lying around where they could cause tripping or stumbling.
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 Tools will never be placed unsecured on elevated places. When working on or

above open gratings or boards, care must be taken not to place tools on the
walkway, lest they be knocked off, causing injury to people below.

 Switches or valves on any type of power tools, especially air tools, will not be
wired or tied in the open position.

 Any tool which is damaged or defective will not be used. If a tool becomes
defective in any way, place an "Unsafe—Do Not Use" tag on it and return it to the
tool room. This includes wrenches with sprung or damaged jaws, and chisels,
drills, or punches with flared or damaged heads.

 Tools are not to be used beyond their capacity by either forcing them or using
"cheater" pipe (pipe used to extend the wrench handle for added leverage).

 When using tools, employees exposed to the hazard of falling, flying, abrasive,
and splashing objects, or exposed to harmful dusts, fumes, mists, vapors, or
gases will be provided with the particular personal protective equipment
necessary to protect them from the hazard.

 Only non-sparking tools will be used in locations where sources of ignition may
cause a fire or explosion.

Precautions

 Never remove or interfere with the operation of any tool guard or safety features.

 Always use the right tool for the right job.

 Keep tools clean, and check their condition before using. If heads of striking
tools become mushroomed or burred, have them dressed. If handles of tools are
splintered, broken or loose, have them repaired or replaced.

 Tools must be always returned to their proper storage place and not left where
they create a hazard.

 Carrying tools in pockets is dangerous, especially if tools are sharp or pointed.

Never climb ladders with tools in pockets.

 Do not use excessive pressure or force on any hand tool.

 Metal measuring tapes, tapes having metal strands woven into fabric, brass
bound rules, wire or metal bound hose or rope with wire core shall not be used
when working on or near energized electrical circuits or equipment.
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8. Tools should neither be dropped nor thrown from place to place nor from person
to person.

9. Tools that must be raised or lowered from one elevation to another shall be
placed in an approved tool bucket or firmly attached to hand-line.

10. Tethering of tools may be required when working above sensitive equipment.

Hand Tools

Screwdrivers

11. Never attempt to use a screwdriver as a pry tool, drift or chisel.

12. Use the right size and type screwdriver for the job.

13. Do not hold screwdriver work in palm of hand. The screwdriver may slip causing
injury.

14. Screwdrivers should be filed properly to prevent slipping.

Hammers

15. Hammers must have a clear path for back swing, and the target area must be
free from obstructions.

16. Hammers with "mushroomed" heads should never be used as they might glance
off the target, or the damaged head may splinter and send metal fragments flying.

Machetes

 New machetes should be blunted square one inch from the point. Two inches of
the blade next to the handle should also be blunted. Machetes may be
sharpened with a file by stroking toward the edge only when the file is fitted with a
handle.

 A machete should be carried in a sheath when not in use. It must not be

strapped or tied to the user's wrist.

 When using a machete, swing it down and away from the body. When two or
more people are working together, they should maintain a safe distance from one
another.
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Files

17. Do not use a file for a pry or hammer as it is brittle and breaks easily.

18. Files shall be fitted with wooden handles to protect workers from the pointed file
end.

Pry Bars

19. Be sure tip of bar is secure under load by first applying a slight pressure.

20. Check your own balance before exerting full force.

21. A cheater bar shall not be used on pry bars.

Wrenches

22. Wrenches should be pushed away from the body, if possible to reduce the
chance of the wrench slipping and striking the user in the face or body.

23. Adjustable (crescent) and combination wrenches should be snug on bolts and
nuts to avoid slipping.

24. Never use a wrench as a hammer or a hammer on a wrench that is not

designated to be used as such.

25. Never use a cheater bar on a wrench or "double wrench" a nut. Use a hammer
wrench or impact instead.

Chisels & Punches

26. Unsafe defects: Mushroomed heads, chipped points and over tempered surfaces.

27. Do not strike with hardened hammer or chip toward yourself or others.

28. Do not use without proper eye protection.

Drill Bits

29. Unsafe defects: Worn or battered heads, over tempered and dull cutting edges.

30. Do not use a drill bit to ream holes (get a larger bit). Use a reamer bit or a rat tail
file.

31. Do not change bits without unplugging cord.

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Knives

32. Unsafe defects: Dull or nicked edges or point, loose or broken handle.

33. Do not pull a knife towards body.

34. Use a knife with a locking blade.

Shovels, Pick Axes, and Axes

35. Unsafe defects: Rough, loose, cracked, or split handles; dull or nicked edges,
over-tempered surfaces.

36. Do not use as a wedge, pry bar or hammer.

37. Non conductive wood or fiberglass handles for shovels and pothole diggers
should be used to protect from electrical shock.

9. Electrical Isolation

This procedure will include all employees whose duties require them to service,
repair, adjust, lubricate or perform work on power driven equipment (i.e., anytime
accidental start-up would, or could, possibly endanger the employee).
Supervisory Responsibility

It shall be the responsibility of all supervisors of employees performing such

operations to:

 Instruct their employees as to the content of this procedure.

 New or transferred employees shall be instructed in the purpose and use of

this procedure.

 Continuously follow-up to assure compliance with this procedure. Ensure that

an adequate supply of locks, tags and multi-lock devices are available.

Scope

A. This Procedure is applicable to Aker Solutions.

B. This procedure defines the minimum requirements for safety Lock and Tag out
to assure the safety of personnel and of equipment when performing work on or
around equipment capable of having an energy source applied.
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Application

A. The requirements of this procedure apply to all situations where the unexpected
energization, start-up, or release of stored energy of the equipment/process
would be likely to endanger personnel or damage equipment.

B. This procedure acknowledges that there are conditions and standards, which
may be site-specific or particular to specific applications of work, which may
require consideration. Any safety lock & tag out procedure prepared for a site-
specific or task-specific condition shall conform to the minimum standards for
personnel or equipment protection as set forth within this procedure.

C. When and where work is being performed on an existing facility, the procedure
should be guided by the client’s active “in plant” procedure. However, the
procedure in use shall conform to the minimum safety standards for personnel
and equipment protection as set forth within this procedure.

Definitions

A. “Safety Tagout”- The placement of a tag accompanied by a lock as required on

the energy isolating device in accordance with an established procedure
indicating that the energy isolating device shall not be operated until removal of
the tag in accordance with an established procedure.

B. “Danger Tag”- A prominent warning device that is capable of being securely

attached and that, for the purpose of protecting personnel, forbids the operation
of an energy isolating device and identifies the authorized individual or authority
who has control of the clearance. A danger tag conforming to ANSI Z35.1,
Section 5.3.1 Class 1, is used for this purpose.

C. “Extension Control Tag”- A small RED TAG or label placed on remote operating
devices where applicable. It’s only function is to inform employee’s that the
equipment has been tagged out back at the source and to reference the
applicable safety tagout order number.

D. “Lockout Device”- A device that utilizes a lock and key to hold an energy isolating
device in the safe position for the purpose of protecting personnel and
equipment.

E. “Energy Source”- Any electrical, mechanical, hydraulic, pneumatic, chemical,

nuclear, thermal, or other energy source that could cause injury to personnel or
damage to equipment.

F. “ Energy Isolating Device”- a physical device that prevents the transmission or

release of energy, including, but not limited to, the following: a manually operated
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electrical circuit breaker; a disconnect switch; a manually operated switch; a slide

gate; slip blind; a line valve; blocks; and similar devices with a visible indication of
the position of the device. ( Push buttons, selector switches, and other
control/circuit type devices are not energy isolating devices.)

G. “Knowledgeable Individual”- One who knows the effect of operating the controls
or equipment.

H. “Authorized Individual”- A knowledgeable individual to whom the authority and

responsibility to perform a specific assignment has been given by the employer.

I. “Control Authority”- The authorized individual(s) responsible to administer the

safety tag out program.

J. “Affected Employee”- A person whose job includes activities such as erecting,

installing, constructing, repairing, adjusting, inspecting, testing, operating, or
maintaining the equipment/process.

K. “Safety Tagout Order”- A sequentially numbered form containing all the

necessary information to control, document, audit, and status the safety tagout
program at any time (Form FO1).

L. “Clearance”- The term used to identify acceptance of administrative control by an

authorized individual for an equipment/process which has been safety tagged to
allow performance of specific work tasks.

M. “Group Safety Tagout”- The term is used to identify the method by which safety
tagout is accomplished in a safe and effective manner so as to permit more than
one authorized individual, independent of others, to accept a clearance to allow
performance of specific work on an equipment/process under one safety tagout
order.

N. “Isolated”- Equipment/process is considered isolated when every energy source

has been blocked and/or vented by an energy isolating device to the extent
necessary for the work to be performed and such that the equipment cannot
change status and is administratively controlled.

O. “Verify”- The manipulation and placement of tags on energy isolating and other
devices are correct as called for by a tagout order, and as required for
personnel/equipment safety for specific work to be performed or instructions
followed. Ensuring that all physical blocks/grounds/metering have been
accomplished, in order to assure zero energy and zero mechanical state.

P. “Accept”- To take or assume the duties and responsibilities of administrative

control for an equipment/process by an authorized individual.
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Q. “Release”- To give up the duties and responsibilities of administrative control for

an equipment/process by an authorized individual.

R. “Restore”- A piece of equipment is considered to be restored when all safety tags

have been removed and all required energy sources have been established such
that the equipment can perform its intended function and all administrative
controls have been released.

S. Slash(/)- A slash (/) denotes ”and/or” and indicates that the two words or
expressions, such as tagout/lockout or equipment/process, are to be taken
together or individually.

T. “Shall”- The word “shall” denotes a mandatory requirement.

U. “Should”- The word “should” denotes an advisory recommendation.

General Procedure Rules

The safety tagout order is utilized to control, document, audit, and status the
safety tagout of equipment/processes. All information pertaining to safety
tagout necessary to satisfy these objectives shall be recorded on this form
including the means to accept and release administrative control for an
equipment/process. At a minimum, the three parts of the form shall include the
following information:

1. An index of all safety tagout orders.

2. An individual sequential order number.
3. The field site.
4. An accurate description of the equipment/process.
5. An accurate description of the work to be performed.
6. A complete listing of all energy isolating devices, sequential order of
manipulation, device position, and locks/tags shall be identified.
7. Any special instructions including the placement of protective grounds.
8. The signature, date, and time of the authorized individual (control authority)
reviewing and approving the safety tagout order.
9. The signature, date, and time of the authorized individual (control authority)
performing the safety tagout on the equipment/process.
10. The name and signature, date, and time of the authorized individual
accepting or releasing the equipment/process.
11. The signature, date, and time of the authorized individual (control authority)
ordering the equipment/process restored to service.
12. The signature, date, and time of the authorized individual removing the
tags/locks and restoring the equipment/process to service.
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When more than one authorized individual requests safety tagout on the same
equipment/process, a separate safety tagout order shall be prepared and
separate lock & tags shall be applied for each person except when “Group
Safety Tagout is Approved.

Group Safety Tagout is acceptable when the requirements to perform work by

more than one authorized individual on a given equipment/process can safely
and effectively be accomplished by a single safety tagout order. In this
instance the following actions shall be accomplished:

1. Control Authority shall Lock Out Specific Energy isolating devices, then
place his keys into a (Lock Box with a clear lid).
2. Each affected employee shall then place a lock on the box and keep their
key.
3. A list will be kept of each individual participating in “Group Lock Out”.
4. Restoration of equipment/process will be as outlined previously in this
procedure.

No affected employee shall perform any work on any equipment/process

under safety tagout except that such work is specifically covered by a safety
tagout clearance and as specifically directed by the authorized individual
identified on the safety tagout order.

The control authority and the Site HSE Manager shall conduct a monthly
review of the tagging system logbook. A more frequent review shall be
performed if deemed necessary. This review shall consist of:

1. Checking the active section of the logbook against the index to ensure
accountability of all active tagging orders.
2. A spot check of active tagging orders to verify compliance and trends of
noncompliance with the procedure.
3. A spot check of tags to ensure that the tags are still attached, that they
are on the correct equipment and that the equipment status is per the
tagging order.

Procedure Instructions

A. Prior to the beginning of any work, a survey shall be performed by an

authorized individual to identify any/all energy sources and related exposures
to determine if the need for safety tagging is required.

B. At any time that work progresses to the point where the potential exists for an
energy source to be applied to the work (such as with new construction or
modifications), the safety tagout program shall be initiated.
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C. To initiate a tagout on equipment/process, the authorized individual

responsible for the work shall prepare the appropriate order, identify the
equipment/process, detailing the work to be performed, and listing any special
instructions and/or considerations. The authorized individual shall also clearly
identify the order of each manipulation, the resultant position of each energy
isolating device, and the necessity for locks and /or grounds, which may be
required.

D. The control authority shall review the order to ensure that adequate safety is
being provided for all affected employees and/or equipment involved specific
to the work to be performed or the instructions to be followed and shall make
and discuss any corrections as shall be required with the authorized individual.
The control authority will approve the order and assign the sequential order
number.

E. The control authority shall arrange and be responsible for isolating the
equipment/process and placing the appropriate tags & locks on each energy
isolating device, and shall verify and assure the proper position of each energy
isolating device and that all tags/locks are placed at the correct points per the
order.

F. Upon notification that tagout is completed, the authorized individual

responsible for the work shall perform an inspection to verify that all energy
isolating devices are properly set and that all danger tags or caution tags are
correctly placed to meet safety requirements, also that any physical blocks and
protective grounds have been placed per the tagout order. Checking to ensure
that the equipment/process is in a zero energy state.

G. After ensuring that safety requirements are met, the authorized individual
responsible for the work shall then sign the safety tagout or caution order
accepting a clearance.

H. No person shall be given or accept clearance, or perform any work on

equipment or circuits requiring safety tagout in any other manner.

I. Any safety tagout order clearance issued to an authorized individual shall

remain in effect until it is properly released per this procedure. Danger tags
shall not be removed nor the equipment restored to service until the
equipment/process has been released by the authorized individual named on
the appropriate order.

J. Prior to releasing safety tagging, the authorized individual responsible for the
work shall inspect the work to assure all work is complete and all affected
individuals are clear.

K. The authorized individual shall notify the control authority that the work is
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complete and shall sign under “Release Authorization” on the appropriate

order.

L. Should any authorized individual accepting a clearance become unavailable

for any reasons prior to release of the clearance, that person’s supervisor and
the control authority shall have the responsibility for satisfying the
requirements of items J and K, and jointly ordering the equipment/process
restored to service.

M. The control authority will order the equipment/process restored only after the
completed work inspection and release authorization has been signed:

1. The control authority shall inspect the work and confirm the work is
complete before ordering the equipment restored.
2. The control authority shall indicate concurrence by signing the appropriate
order and ordering the equipment/process restored to service.
3. Restoring the equipment to service shall be the responsibility of the control
authority.

10. Trenching & Excavation

A trench is a narrow excavation having a depth greater than the width-generally with
a bottom width not greater than 15 feet. An excavation is any man-made cut, cavity,
trench or depression in the earth, formed by earth removal. This procedure will apply
to all personnel and subcontractors whose job function requires them to enter any
excavation.

Definitions

 Bell-bottom Pier - A type of shaft or footing excavation, the bottom of which is

made larger than the cross section above to form a bell shape.
 Benching (Benching System) - A method of protecting employees from cave-ins
by excavating the sides of an excavation to form one or a series of horizontal levels
or steps, usually with vertical or near-vertical surfaces between levels.
 Cave-in - The separation of a mass of soil or rock material from the side of an
excavation, or the loss of soil from under a trench shield or support system, and its
sudden movement into the excavation, either by falling or sliding, in sufficient
quantity so that it could entrap, bury, or otherwise injure and immobilize a person.
 Competent Person - One who is capable of identifying existing and predictable
hazards in the surroundings, or working conditions which are unsanitary,
hazardous, or dangerous to employees, and who has authorization to take prompt
corrective measures to eliminate them.
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 Cross Braces - The horizontal members of a shoring system installed

perpendicular to the sides of the excavation, the ends of which bear against either
uprights or walers.
 Excavation - Any man-made cut, cavity, trench, or depression in an earth surface,
formed by earth removal.
 Faces or Sides - The vertical or inclined earth surfaces formed as a result of
excavation work.
 Failure - The breakage, displacement, or permanent deformation of a structural
member or connection to reduce its structural integrity and its supportive
capabilities.
 Hazardous Atmosphere - An atmosphere which, by reason of being explosive,
flammable, poisonous, corrosive, oxidizing, irritating, oxygen deficient, toxic, or
otherwise harmful, may cause death, illness, or injury.
 Kickout - The accidental release or failure of a shore or cross brace.
 Protective System - A method of protecting employees from cave-ins, from
material that could fall or roll from an excavation face or into an excavation, or from
the collapse of adjacent structures. Protective systems include support systems,
sloping and benching systems, shield systems, and other systems that provide the
necessary protection.
 Ramp - An inclined walking or working surface that is used to gain access to one
point from another and is constructed from earth or from structural material such as
steel or wood.
 Sheeting - The members of a shoring system that retain the earth in position and,
in turn, are supported by other members of the shoring system.
 Shield (Shield System) - A structure that is able to withstand the forces imposed
on it by a cave-in and thereby protect employees within the structure. Shields can
be permanent structures or can be designed to be portable and moved along as
work progresses. Shields used in trenches are usually referred to as "trench boxes"
or "trench shields."
 Shoring (Shoring System) - A structure, such as a metal, hydraulic, mechanical, or
timber shoring system, that supports the sides of an excavation and which is
designed to prevent cave-ins.
 Sloping (Sloping System) - A method of protecting employees from cave-ins by
excavating to form sides of an excavation that are inclined away from the
excavation to prevent cave-ins. The angle of incline required to prevent a cave-in
varies with differences in such factors as the soil type, environmental conditions of
exposure, and application of surcharge loads.
 Stable Rock - Natural solid mineral material that can be excavated with vertical
sides and will remain intact while exposed. Unstable rock is considered to be stable
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when the rock material is secured against caving in or movement by rock bolts or
by another protective system that has been designed by a registered professional
engineer.
 Structural Ramp - A ramp built of steel or wood, which is usually used for vehicle
access. Ramps made of soil or rock is not considered structural ramps.
 Trench (Trench Excavation) - A narrow excavation (in relation to its length) made
below the surface of the ground. In general, the depth is greater than the width, but
the width of a trench (measured at the bottom) is not greater than 15 feet. If forms
or other structures are installed or constructed in an excavation so as to reduce the
dimension measured from the forms or structure to the side of the excavation to 15
feet or less (measured at the bottom of the excavation), the excavation is also
considered to be a trench.

General Requirements

 All employees shall be protected with personal protective equipment for the
protection of head, eyes, respiratory organs, hands, feet and other parts of the
body as required.

 All surface encumbrances that are located so as to be a hazard to employees

shall be removed or supported, as necessary, to protect workers.

 The location of utility installations that may be encountered during excavation

work will be determined prior to opening an excavation. When exact locations
cannot be established, proceed with caution using detection equipment or other
acceptable means to locate utility installations.

 A competent person will design structural stairs used solely by employees for
access and egress from excavations, while structural ramps for equipment will be
designed by a competent person qualified in structural design.

 A stairway or ladder for safe means of egress will be located in trench

excavations 4 feet or more in depth and at such locations which would require not
more than 25 feet of lateral travel for employees. Personnel shall not use
equipment ramps to access excavations.

 Employees exposed to vehicular traffic will be provided with and shall wear
reflective and/or highly visible warning vests. Traffic cones shall be utilized to
divert traffic a safe distance from the exposed employees.

 No person will be permitted to pass under loads handled by lifting or digging

equipment. No employee will stand near any vehicle being loaded or unloaded.
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 A warning system such as barricades, hand or mechanical signals or stop logs

will be used for the operators of mobile equipment when working adjacent to an
excavation where the operator does not have a clear direct view of the edge.

 Where oxygen deficiency (less the 19.5 percent oxygen) or a hazardous

atmosphere exists or could reasonably be expected to exist, the atmosphere in
excavations greater than 4 feet will be tested before employee entry.

 Employees will not work in excavations with accumulated water unless protected
against the water hazards. Protection could include special support or shield
systems to control cave-ins, water removal to control water level or the use of a
safety harness and line lifeline, depending on the circumstances involved.

 Support systems such as shoring, bracing or underpinning will be used to ensure

stability of adjacent structures for the protection of employees.

 A competent person will conduct daily inspections of excavations, the adjacent

area and protective systems for evidence of indications of possible cave-ins,
failure of protective systems, hazardous atmospheres or other hazardous
conditions. The inspection will be made prior to the start of work and as needed
throughout the shift as well as after every rainstorm, change in conditions or
hazard-increasing occurrence.

 Employees will be evacuated and removed from work areas when indications of
possible cave-in or other hazardous conditions are present or the competent
person finds evidence of a hazardous situation. Necessary precautions will be
taken to ensure employee safety before work is continued in the area.

 Walkways or bridges crossing over excavations used by employees will be

protected with complete guardrail system.

 Adequate barriers providing physical protection shall be provided at remotely

located excavations. Wells, pits, shafts, etc., will be barricaded or covered. Upon
completion of operations, temporary wells, pits, shafts, etc. will be back filled.

Soil Classification

 This procedure describes a method of classifying soil and rock deposits based on
site and environmental conditions and on the structure and composition of earth
deposits. Contained herein are definitions, set forth requirements, and acceptable
visual and manual tests for use in classifying soils.
 Classification of soil by a competent person is a prerequisite to determining and
designing protective systems needed for excavations.
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Inspections
 The individual designated as the Excavation Competent Person shall conduct
daily inspections of excavations, the adjacent areas, and protective systems for
evidence of possible cave-ins, indications of failure of protective systems,
hazardous atmospheres, or other hazardous conditions.

 The Competent Person prior to the start of “each shift” and as needed throughout
the shift to ensure a safe operation shall conduct an inspection of the excavation.
Inspections shall also be made after every rainstorm or other change or hazard-
increasing occurrence.

 Where the Competent Person finds evidence of a situation that could result in a
possible cave-in, failure of protective systems, hazardous atmospheres, or other
hazardous conditions, exposed employees shall be removed from the hazardous
area until the necessary precautions have been taken to ensure their safety.

 Workers shall be adequately instructed to immediately report any signs or

indications of weakness in shoring, sloping, or soil stability to responsible
superision.

11. Abrasive Blasting

The following guidelines shall be observed when operating abrasive blasting

equipment.

 Each site where abrasive blasting is performed shall have a written site-specific
respiratory protection program and each affected employee shall be enrolled.

 Where silica is used as an abrasive agent a Silica Medical Monitoring Program

shall be implemented and affected employees enrolled. Appropriate warning
signs shall be placed at designated locations. Appropriate atmospheric
monitoring of the area shall be employed to monitor silica levels. Engineering
controls shall be utilized where practical to contain and control silica dust.

 A Hot Work permit is required for any abrasive blasting operation where there are
or have been hydrocarbons or other flammables.

 Machines and hoses must be inspected frequently.

 There shall be no leaks all bronze hose couplings or nozzle holder.

 Nozzles must be externally attached to the hose by a fitting that will prevent
accidental disengagement.
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 The blast nozzle shall be equipped with an operating valve that must open
manually, this control will not be tied down to prevent automatic cut off.

 A support must be provided on which the nozzle may be mounted when it is not
in use.

 Blast hose shall be the static-dissipating type.

 Pressure blast vessels must be manufactured in accordance with the current

edition to the ASME Boiler and Pressure Vessel Code, Section VIII.

 Operators must be equipped with heavy canvas or leather gloves and aprons.
Safety shoes should also be worn.

 Eye, face and respiratory protection must be supplied to all personnel working in
the vicinity of abrasive blasting operations.

 Precaution must be taken to protect personnel in the blasting zone including the
blasting operator from excessive noise exposure by supplying earplugs or
earmuffs.

 A change shed or some facility should be available in a dust free area for blasters
to take breaks and eat lunch.

 As much of the blasting as possible should be done in a specified location. A

blasting zone (where dust is visible) should be established and marked off with
signs around the perimeter of the area such as:

CAUTION
ABRASIVE BLASTING AREA
EYE AND EAR PROTECTION AND RESPIRATORS
MUST BE WORN IN THIS AREA

 Another way to isolate the blasting is to do it on an "off shift" when few other
employees are working.

 Blasting should not be done when wind direction and velocity carry visible dust to
people unprotected by proper respirators.

 NIOSH/MESA approved disposable respirators should be worn by all persons in

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the blasting zone. (All persons within twenty feet of blasting nozzles, for more
than five minutes per hour, should wear an air-supplied hood.)

 No sandblasting shall be permitted in the immediate vicinity of operating, electric

motors or air intakes of operating, internal combustion engines. Such equipment
should be stopped and/or protected against sand particles in the atmosphere that
could contaminate the equipment or motors.

 Respirators must be cleaned and inspected regularly. Maintenance records must

be maintained.

 Hoods should be kept and hung in an upright position to prevent sand spilling
inside.

 If possible, air should be supplied from a separate compressor or fresh air blower
rather than from plant airlines.

 If plant air or an oil-lubricated compressor is used:

 A pressure reducing diaphragm or valve should be installed to reduce

pressure.
 An automatic control should be provided to either sound an alarm or shut
off the compressor in case of over heating.
 The air from the compressor must be frequently tested for carbon
monoxide.
 Verify that inert gas is not used as backup on plant air.

 Lines and fittings to supply breathable air should not be interchangeable to other
services.

 In case of hose failure, a safety device at the source of supply or branch line to
reduce the pressure must be present.

 Abrasive materials other than silica sand should be used when possible to limit
free silica generated by the operations. Black Beauty Abrasives may be used as
an alternate abrasive.

Respiratory Protection Guidelines

An employee performing sandblasting operations when must wear an approved

(MSHA/NIOSH) properly fitted airline respirator with a hood, apron, and dust collar:

 Working inside blast cleaning rooms.

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 Performing manual abrasive blasting operations in which the nozzle and the blast
are not physically separated from the operator in an exhaust ventilated enclosure.

 In addition to the hood, an employee performing sandblasting will also wear an

approved particulate-filter respirator when working in high dust concentrations.
This respirator provides the protection when sandblasting has ceased and the
hood has been removed.

 An approved particulate-filter respirator must be worn by all employees in the

abrasive blasting area. Short, intermittent, or occasional dust exposure such as
during cleanup, dumping of dust collectors, or unloading shipments of sand at the
receiving point require the use of a particulate-filter respirator.

 Compressed Air shall not be used for cleaning purposes unless pressure is
reduced to less than 30 PSI and effective chip guarding and PPE is utilized

 The blast cleaning nozzles will be equipped with an operating valve which must
be held open manually. A support will be provided on which the nozzle may be
mounted when it is not in use.

Equipment Condition/Inspection

General Requirements

Every component of the sandblasting setup must be checked out and its proper
operation/function assured before any attempt is made to put the unit into service.

 Hoses, valves, handles, and adjustment knobs must be in good condition. Hoses
with soft spots, broken couplings, and damaged outer casings are not to be used.

 Deadman lines and switches must be in good condition. Electric deadman lines
must not have cracked insulation or ban splices. Pneumatic deadman lines must
be crack free and must not have abraded outer casings.

 Deadman switches/valves must operate freely and without obstruction.

 Couplings that are missing parts or that are noticeably worn or deformed will be
removed from service.

 Deadman switches are never to be overridden. They are to be operating properly

at all times.

 Sandblast hoods and accessories must be complete and in proper operating

condition. This includes helmet, suspension, sock, cape, apron, and belt with
needle valve or vortex tube for conditioning and controlling air flow. The helmet
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must have a clear faceplate.

Hoses

Hoses are to be examined both visually and by feel; if a soft spot is found by
flattening the hose between the hand, the hose must be taken out of service.

 Bull hoses that develop blisters which can be seen when the hose is under
pressure will be taken out of service.

 Hose couplings that are noticeably worn or deformed must be removed and
discarded.

 Couplings that have wire holes worn through must be discarded.

 All screws must be installed on each coupling before the hose may be used.

Deadman Switches/Valves

Electric Deadman

 The deadman switch must be in proper working condition.

 No parts of the deadman will be missing and only approved manufacturer parts
will be used on the deadman.

 The cable from the switch to the junction box and from the junction box to the
battery must be undamaged and in good condition, and any splices will be made
by a qualified electrician. The splice insulation will be equal to or greater than the
original insulation.

 The on/off switch will never be blocked in the on position. The switch must be
manually held on by the sandblaster during blasting.

Pneumatic Deadman

 The deadman valves must be clean and free of any grit before being used.

 The duplex hose must be inspected before each use and be in good working
condition and must not have any cuts, abrasions, or cracks in the outer casing.

 Threaded fittings or couplings must be clean and free of damage.

 Warning: If the couplings that are being used on the sandpot are similar, they are
to be color coded to assure proper matching connection to prevent possible
reversing of air flow through the deadman valve.
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Operating / Set-up Procedure

 Position air compressor upwind of sandblasting area to prevent possible

contamination of air being taken into compressor.

 Sandblast machine is to be placed as close to the work as possible.

 Hoses are to be laid out, coupled together, and wired or otherwise secured to
prevent them from being twisted apart.

 Bull hose is to be coupled to both compressor and sandpot and wired to prevent
uncoupling.

 The bull hose is to be tied to the compressor and sandpot by means of a safety
strap, rope, or other suitable means.

 Sandblast hose is to be coupled to sandpot, and the couplings are to be wired

together.

 Electric deadman is to be plugged into terminal on junction box.

Pneumatic deadman lines are to be connected to the couplings at the pot.

Warning: It is possible to connect lines in reverse if couplings are similar. In this case
the hoses and respective couplings on sandpot must be color coded to prevent
mixup resulting in reverse flow and improper operation of deadman.

Attach deadman switch/valve to whip hose near nozzle. The switch/valve may be
wired to the coupling or taped to the hose.

The deadman lines are to be taped to the whip hose and sandblast hoses.
Close dump valve, choke valve, and inlet valve. Start air compressor.
Sandblaster puts on hood and takes control of sandblast hose. Connect lead wire to
compressor battery. Open inlet valve; once sandpot is pressured up, open choke
valve and signal sandblaster to begin.

Abrasive Blasting Materials

 It is preferred to use non-silica-based abrasive blasting materials. Where silica is

used as an abrasive agent a Silica Medical Surveillance Program shall be
implemented and affected employees enrolled and monitored. Appropriate
warning signs shall be placed at designated locations. Appropriate atmospheric
monitoring of the area shall be employed to monitor silica levels. Engineering
controls shall be utilized where practical to contain and control silica dust.
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12. Oxy Fuel Cutting

There are a number of hazards inherent in the use of an oxy-fuel cutting apparatus.
It is necessary that proper safety procedures be understood prior to the use of such
equipment. A thorough understanding of the following safety procedures will serve to
minimize the hazards involved.

Protective Apparel and Equipment

 The operator should be protected from sparks, flying slag and flame brilliance at
all times. Select goggles with tempered lenses shaded No. 5 or darker to protect
eyes from injury and to provide good visibility of the work.

 Protective gloves, sleeves, aprons, and shoes should be worn to protect skin and
clothing from sparks and molten slag. KEEP ALL CLOTHING AND
PROTECTIVE APPAREL ABSOLUTELY FREE OF OIL AND GREASE.

 Adjust clothing where necessary to keep out flying sparks and slag. Sparks may
lodge in rolled-up sleeves, in pockets of clothing or in cuffs of overalls or trousers.
Keep sleeves and collars buttoned when necessary. Low shoes with unprotected
tops are not suitable for work where there is possibility of sparks or slag getting
inside shoes.

 Hard hats will be worn to protect the head from sparks.

 The welding operation shall be shielded with a fire resistant screen to protect
those not directly involved in the operation from radiation injury to the skin or
eyes.

General Precautions for Welders/Cutters

 Inspect all tools and equipment prior to their use. Worn or damaged hoses,
welding leads and other equipment with defects affecting safe operation must be
repaired prior to use or discarded.

 Each area should have at least one 10 pound, all purpose, dry powder fire
extinguisher at the spot where welding or cutting is being performed.

 Do not weld, cut or grind drums, containers or hollow structures which have
contained toxic or flammable substances until they have been thoroughly cleaned
or purged and tested with a gas meter.
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 Do not stand in water when using an arc-welder. As necessary, stand on a dry

platform made of wood or some other non-conductive material.

 Do not dip electrode holders in water to cool them.

 Keep your body insulated from the work and the electrode holder during
welding operations.
 Do not weld in the rain.

 Wear proper clothing and the proper goggles or a welding hood with a filter lens
to protect against flash burn and flying objects.

 Always wear face shield with mono goggles when chipping or grinding.
 Welders helpers must wear safety glasses with side shields as a minimum
protection. Shaded glasses are preferred.
 Welders must wear safety glasses with side shields under welding hood.

 Obtain all necessary “Hot Work Permits” before beginning work.

 Contain all sparks during cutting / welding operations.

 When using fire blankets, procedures must be in place to avoid possible

contamination and reuse of the fire blanket.

 During gas welding or cutting:

 Keep wrenches used to open valves of gas cylinders in place.

 Close the valve of the gas cylinder and release all gas from the regulator
before removing the regulator.

 Keep all gas cylinders in their upright position and secured against falling
during use, transportation and storage. All cylinders (empty or full) must have
valve caps in place when not in use.
 Torches must be lit with a friction lighter or other approved device and not by
matches or from hot work.
 Do not remove cylinders by their valves or use them for any purpose for
which they were not designed.
 Both the oxygen and the acetylene or fuel gas lines must be equipped with
flashback arrestors.

Using Compressed Gas Cylinders

Safe procedures for the use of compressed gas cylinders include the following
guidelines and requirements.

 Use cylinders, particularly those containing liquefied gases and acetylene, in an

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upright position and secure them against accidentally being knocked over.

 Unless a recess in the head protects the cylinder valve, keep the metal cap in
place to protect the valve when the cylinder is not connected for use. A blow on
an unprotected valve might cause gas under high pressure to escape.

 Make sure the threads on a regulator or union corresponds to those on the

cylinder valve outlet. Do not force connections that do not fit.

 Open cylinder valves slowly. Cylinders not provided with a hand-wheel valve
should be opened with a spindle key or special wrench provided by the gas
supplier.

 Do not use a cylinder of compressed gas without a pressure-reducing regulator

attached to the cylinder valve, except where cylinders are attached to a manifold,
in which case the regulator will be attached to the manifold header.

 Before making connection to a cylinder valve outlet, "crack" the valve for an
instant to clear the opening of particles of dust or dirt. Always point the valve and
opening away from the body and not toward anyone else. Never crack a fuel gas
cylinder valve near other welding work or near sparks, open flames or other
possible sources of ignition.

 Use regulators and pressure gauges only with gases for which they are
designated and intended. Do not attempt to repair or alter cylinders, valves or
attachments. Only the manufacturer should do this work.

 Unless the cylinder valve has first been closed tightly, do not attempt to stop a
leak between the cylinder and the regulator by tightening the union nut.

 Fuel gas cylinders in which leaks occur should be taken out of use immediately
and handling as follows:

 Close the valve and take the cylinder outdoors well away from any source of
ignition. Properly tag the cylinder, and notify the supplier. A regulator
attached to the valve may be used temporarily to stop a leak through the
valve seat.

 If the leak occurs at a fuse plug or other safety device, take the cylinder
outdoors well away from any source of ignition, open the cylinder valve
slightly and permit the fuel gas to escape slowly. Tag the cylinder plainly.
Post warnings against approaching with lighted cigarettes or other sources of
ignition. A responsible person should stay in the area until the cylinder is
depressed to make sure that no fire occurs.
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 Promptly notify the supplier and follow his instructions for returning the
cylinder.

 Do not permit sparks, molten metal, electric currents, excessive heat or flames to
come in contact with the cylinder or attachments.

 Never use oil or grease as a lubricant on valves or attachments of oxygen

cylinders. Keep oxygen cylinders and fittings away from oil and grease, and do
not handle such cylinders or apparatus with oily hands, gloves or clothing.

 Never use oxygen as a substitute for compressed air in pneumatic tools, in oil
preheating burners, to start internal combustion engines or to dust clothing. Use
it only for the purpose for which it is intended.

 Never bring cylinders into tanks or unventilated rooms or other closed areas.

 Before a regulator is removed from a cylinder valve, close the cylinder valve and
release the gas from the regulator.

 Regulators or reducing valves must be used on both oxygen and fuel gas
cylinders to maintain a uniform gas supply to the torches at the correct pressure.
The oxygen regulator should be equipped with a safety relief valve, or be so
designated that, should the diaphragm rupture, broken parts will not fly. Workers
should stand to one side and away from regulator gauge faces when opening
cylinder valves.

 Only regulators listed by agencies such as Underwriters Laboratories, Inc., or a

Factory Mutual should be used on cylinders of compressed gas.

 The regulator is a delicate apparatus and should be handled carefully. It should

not be dropped or pounded on. Regulators should be repaired or tested only by
skilled workmen or sent to manufacturer for repairs.

 Leaky or "creeping" regulators are a source of danger and should be withdrawn

from service at once for repairs. If a regulator shows a continuous creep,
indicated on the low-pressure (delivery) gauge by a steady buildup of pressure
when the torch valves are closed, the cylinder valve should be closed and the
regulator removed for repairs.

 If the regulator pressure gauges have been strained so that the hands do not
register properly, the regulator must be replaced before it is used again.

 When regulators are connected but are not in use, the pressure-adjusting device
should be released. Cylinder valves should never be opened until the regulator is
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drained of gas and the pressure-adjusting device on the regulator is fully

released.

 The procedures should be followed in detail when regulators or reducing valves

are being attached to a gas cylinder.

 To blow out dust or dirt that otherwise might enter the regulator, "crack" the
discharge valve on the cylinder by opening it slightly for an instant and then
close it. On a fuel gas cylinder, first see that no open flame or other source of
ignition is near; otherwise, the gas may ignite at the valve.
 Connect the regulator to the outlet valve on the cylinder. Be sure that the
regulator inlet threads match the cylinder valve outlet threads. Never connect
an oxygen regulator to a cylinder containing fuel gas, or vice versa. Do not
force connections that do not fit easily. Be sure that the connections between
the regulators and cylinder valves are gas-tight.
 Release the pressure-adjusting screw on the regulator to its limit - turn it
counterclockwise until it is loose.
 Open the cylinder valve slightly to let the hand on the high pressure gauge
move up slowly. On an oxygen cylinder, gradually open the cylinder valve to
its full limit, but on an acetylene cylinder make no more than 1½ turns of the
valve spindle.
 Attach oxygen hose to outlet of oxygen regulator and to oxygen inlet valve on
torch. Attach acetylene hose to outlet of acetylene regulator and to acetylene
inlet on torch.
 Test oxygen connections for leaks. Be sure acetylene torch oxygen valve is
closed; then turn oxygen regulator pressure-adjusting screw clockwise to give
about normal working pressure. Using soapy water (nonfat soap) or
approved leak test solution, check connections for leaks. At the same time,
check regulator for creeping indicated by an increase in the reading on the
low-pressure (delivery) gauge. If the regulator creeps have it replaced or
repaired before it is used.
 Test acetylene connections for leaks. Be sure acetylene torch valve is closed
and proceed in manner similar for oxygen above - except that acetylene
regulator pressure-adjusting screw should be set to produce a pressure of
about 10 psi.
 If torch is to be used immediately, proceed as in the next paragraph. If not,
close cylinder valves, open torch valves to release pressure-adjusting screws
on regulators.
 To adjust pressures of oxygen and fuel gas prior to using torch, proceed as
follows. With all torch valves closed, slowly open oxygen cylinder valve, open
torch oxygen valve, turn in pressure-adjusting screw on oxygen regulator to
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desired pressure, then close torch oxygen valve. Open acetylene cylinder
valve (1½ times only), and with torch acetylene valve closed, turn in pressure-
adjusting screw on acetylene regulator to desired pressure.
 Purge each line individually. Open oxygen torch valve and release oxygen to
the atmosphere for a few seconds before closing the valve; then open
acetylene torch valve and release acetylene to the atmosphere for a few
seconds and close the valve.
 Open torch acetylene valve, light flame, and readjust regulator. Then close
torch acetylene valve. (Acetylene pressure should first be adjusted with torch
valve closed to prevent release of acetylene to the air.)
 Open torch valves and light torch according to procedure described in
instructions provided with the equipment.
Hose and Torches

Hose

The following guidelines and procedures shall be adhered to when using gas hoses.

 Examine hoses carefully at least daily for leaks, worn places and loose
connections.

 Leaks in the hose at the nipple connection should be repaired at once by cutting
off the hose a few inches from the end and remaking the connections. Leaks at
other locations should be repaired by cutting off the bad section and inserting a
hose coupling and a splice.

 Never repair a hose with tape. When hoses are taped together for convenience
and to prevent tangling, not more than four out of 12 inches shall be covered with
tape.

 Should a flashback occur and burn the hose, discard that length of hose.

 Use only hose and connections made especially for oxy-acetylene welding and
cutting.

 Do not use white lead, oil, grease or other pipe fitting compounds for making
joints.

 Blow out new hoses with oxygen before using. When acetylene hose have been
cleared by oxygen, blow through it from the mouth before attaching it to the
acetylene regulator.

Precaution: Do not blow out hose with acetylene.

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 Always protect hoses from damage or interference. Protect hoses from being
trampled on or run over. Avoid tangles and kinks, and place hoses so they will
not be tripped over. Connections might be pulled off or the cylinders and
equipment might be pulled over by a sudden strong tug on the hose. Do not
allow hoses to come in contact with oil or grease. These deteriorate the rubber
and constitute a hazard with oxygen. Protect hoses from flying sparks, hot slag
or other hot objects and open flames.

 All oxygen and gas hoses used together shall have flashback arrestors with built-
in check valves on both lines installed on the torch and regulator ends.

Torches

The following guidelines and procedures should be adhered to when utilizing cutting
torches.

 Only approved torches shall be used.

 Before changing torches, shut off the gas at the pressure-reducing regulators and
not by crimping the hose.

 To discontinue welding or cutting for a few minutes, closing only the torch valves
is permissible. If the welding or cutting is to be stopped for a longer period
(during lunch or overnight), proceed as follows:

 Close oxygen and acetylene cylinder valves.

 Open torch valves to relieve all gas pressure from hose and regulator.
 Close torch valves and release regulator pressure-adjusting screws.

 Do not use matches or cigarette lighters to light torches. Use a friction lighter,
stationary pilot flame or other suitable source of ignition. When lighting, point the
torch tip so no one will be burned when the gas ignites. Do not use butane
cigarette lighters they may be ignited by sparks or hot slag and shall not be
carried on Aker Solutions projects.

 Never put down a torch until the gases have been completed shut off. Do not
hang torches from a regulator or other equipment so that they come in contact
with the side of gas cylinders. If the flame has not been completely extinguished,
it may heat the cylinder or even burn a hole through it.

 When extinguishing the flame, close the acetylene and oxygen valves in the
order recommended by the torch manufacturer. However, if the oxygen valve is
closed first, the acetylene flame enlarges appreciably and could burn the welder.
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13. Rigging Works

General Precautions for Riggers

 Know the safe working capacity of all rigging and equipment. Do not exceed
this limit.

 Know the load weight; this includes the weight of the rigging. Avoid sudden
snatching, swinging or stopping of loads.

 Inspect all rigging before and during use and remove any defective equipment
from service.

 The most frequent killer in the rigging operations is electrocution caused by

contacting overhead power lines. Always maintain at least a 20-foot safe
working distance from any power line. There are specific procedures that
must be followed when operating within a booms length of a power line.

 Discontinue operations during thunderstorms or when winds exceed

manufacturers’ recommended safe working limits.

 Always keep the load line plumb to maintain a stable load. Cranes shall not
be side loaded except for freely suspended loads.
 When using slings:
- Never use kinked or otherwise damaged slings.
- Each sling should be marked with its rated capacity.
- Never sharply bend a sling as this will kink and permanently
weakening it.
- Whenever two or more rope eyes are placed over a hook, use a
shackle with the shackle pin resting on the load hook. This will
prevent the spread of the sling legs from opening the throat of the
hook.

 Loads must be kept under control at all times. Tag lines shall be used to
prevent spinning and guide the load.

 Loads must be safely landed and stable before unhooking. Chocks, blocks or
other means must be used to prevent movement of materials while hooking or
unhooking.

 NEVER pull slings out from under a load. Use cribbing to allow for safe
removal of slings. The sling may catch and suddenly fly free with extreme
force causing serious injury.
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 Do not give signals to the operator unless it is an emergency stop or you are
the designated signal person.

 Always use double slings when rigging loads like pipe, rebar or lumber over
12 feet long. Shackles are required when two or more slings are in the hook.

 Never ride the load or headache ball.

 Stay out from under suspended loads.

 Keep hands off suspended loads whenever possible.

Slings

The following practices will be observed whenever a sling is used:

 Slings that are damaged or defective will not be used.

 Slings will not be shortened with knots or bolts or other makeshift devices.

 Sling legs will not be kinked.

 Slings will not be loaded in excess of their rated capacities.

 Slings used in a basket hitch will have the loads balanced to prevent slippage.

 Slings will be securely attached to their loads.

 Slings will be padded or protected from the sharp edges of their loads.

 Suspended loads will be kept clear of all obstructions.

 All employees will be kept clear of loads about to be lifted and of suspended
loads.

 Hands or fingers will not be placed between the sling and its load while the
sling is being tightened around the load.

 Shock loading is prohibited.

 A sling will not be pulled from under a load when the load is resting on the
sling.

 Each day before being used, the sling and all fastenings and attachments will
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be inspected for damage or defects by competent persons designated by the

Rigging Superintendent. Additional inspections will be performed during the
use of the sling, where service conditions warrant. Damaged or defective
slings will be removed immediately from service.

14. Material Handling, Storage and Transportation

Manual Material Handling and Lifting

 Mechanical material handling equipment or aids should always be used when

possible to lessen the amount of manual lifting required for a job. The amount of
weight in a single lift should be limited to approximately 50 pounds when working
with sacked or bagged chemicals or materials.

 The following basic lifting practices should be used:

 Approach the load and size it up (weight, size and shape). Consider your
physical ability to handle the load and determine if the object can be lifted and
carried safely. Get help if it is too much for one person to handle alone.
 Place the feet close to the object to be lifted - 12" apart for good balance.
 Bend the knees to the degree that is comfortable and get a good handhold.
 Then, using both leg and back muscles, lift the load straight up - smoothly
and evenly.
 Pushing with your legs, keep load close to your body.
 Avoid awkward positions or twisting movements while lifting.
 Lift the object into carrying position, making no turning or twisting movements
until the lift is completed.
 Turn your body with changes in foot position after looking over your path of
travel making sure it is clear.
 Setting the load down is just as important as picking it up. Using your leg and
back muscles, comfortably lower load by bending your knees. When load is
securely positioned, release your grip.
 Avoid strain by storing heavy objects at least 12 inches above the floor if
possible.
 When lifting and carrying with another person - teamwork is important. The
load should be equally distributed. Movements must be coordinated so you
both start and finish the lift action at the same time and perform turning
movements together.
 When two persons carry a long object, it should be held at the same level by
both and on the same side of the body.
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 Detailed elements of safe lifting practices

 A person twisting as he/she lifts or sets down a load causes the most serious
back injuries. Twisting can be avoided when your feet are facing the loading
or unloading point.

 Stand as close as possible to the load with your feet about 12" apart - this
gives the most power from the legs.

 In order to get the weight of the load as close as possible to your body, turn
the object at a slant, with a corner in between the legs.

 Move one foot slightly behind the other to get even better balance as you lift
or set down a load.

 To improve your balance and keep your feet apart - lift with your arms placed
inside of your knees.

 For "heavy" loads (usually greater than 1/3 of your body weight), keep your
balance by starting to lift with your heels down flat on the ground.

 Grasping the Load: In order to securely hold the load when lifting, the following
technique should be used:

 Use the near hand (closest to the body) to grasp the bottom corner of the load
and support most of the load weight.
 Use the far hand to grasp the top far corner of the load. This hand keeps the
load pulled against the body.

 Keeping good balance: Keeping the burden of lifting on your legs - leg muscles
are stronger than back muscles.

 When lifting, keep your chin level and tucked in to force your back to
straighten. This maneuver will automatically help straighten the back.
 The legs, not the back, should do the work of lifting or setting down. The
back should be straight and the legs bent when starting to lift.
 Another hint on how to keep your back straight while carrying a heavy load -
pull in your stomach while walking.


Transporting

General Requirements

 All drivers must show proof of valid driver's license.

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 No employee will ride in the back or open bed of trucks. Generally, pickup or
dump trucks are designed for transporting material.

 Personal inspection of the loaded vehicle to determine the possibility of the load
rolling, shifting or tipping is required.

 Employees must be secured by seat belts with all parts of the body within the
confines of the truck. Vehicles regularly used to transport personnel must be
equipped with seats, seat belts and a safe means of mounting from bed.
Employees may mount or dismount vehicles only when vehicle is fully stopped.

 No power equipment (i.e., backhoes, cherry picker, etc.) will be ridden by

passengers unless provided with manufacturer designed and manufactured seats
or platforms.

 Personnel will vacate all vehicles being loaded or unloaded by a crane, backhoe,
power shovel, etc. The craft superintendent will make exceptions.

 All loads being transported must be boomed or secured to prevent rolling, sliding,
tipping, etc. All loads extending beyond the bed of the truck are to be flagged
with red materials. In addition, extended loads (side or back) must be identified
at night by means of a red lantern or red reflector lights.

 Softeners should be used between surfaces where steel rides on steel, such as
steel beams on steel bed of trailers.

 Only three people may ride in the cab of trucks and or pickups.

 Drivers are responsible for their vehicle and passengers. Drivers must be familiar
with and comply with state and project traffic regulations. Drivers shall not
operate the vehicle unless all safety regulations are complied with.

 When cranes travel with loads, it is important to:

 Inspect the route to ensure there are no overhead obstructions (i.e., power
lines, pipe racks, etc.).
 Ensure the load is securely tied to the rig to prevent swinging.
 Always know the weight of the load and the capacity of your rigging
hardware and crane.
 No employee is allowed to ride a suspended load and do not swing or
travel suspended loads over personnel.

 "Shock loading" is prohibited. Check the load balance while it is only a

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few inches off the ground.

 Stand clear of loads about to be lifted.

 Lower loads slowly and keep hands and feet clear.

 When unloading materials off trucks, remember to attach rigging first, then get
off of the truck before giving the go ahead signals.
 Report any defective rigging or equipment immediately and do not use it!

Storage

General Guidelines

 Maximum safe load limits in pounds per square feet must be posted in all storage
areas within buildings and structures except floor or slab.
 Aisle and passageways must be kept clear for free and safe movement of
material handling equipment and employees.
 Materials must not be placed within six feet of hoist way or floor openings nor
within 10 feet of exterior walls which do not extend above the top of the material
stored.
 Non-compatible materials must be separated in storage.
 Bagged materials must be stacked by stepping back the layers and cross laying
the bags at least ten bags high.
 Materials must not be stored on scaffolds or runways in excess of supplies
needed for immediate operations.
 Brick stacks must be a maximum of seven feet high. When loose brick stacks
reach a height of four feet, they will be tapered back two inches in every foot
above the four foot level.
 When masonry blocks are stacked higher than six feet, the stack shall be tapered
back one-half block per tier above the six foot level.
 Structural steel, poles, pipe and other cylindrical materials, unless racked, will be
stacked and blocked.
 Lumber piles must not exceed 20 feet in height or 16 feet when lumber is to be
handled manually.

Indoor Storage

 Exits must not be obstructed.

 A barrier having one hour fire resistant rating must separate non-combustible
material.
 Aisle space must be provided to accommodate the widest vehicle that may be
used inside the building for fire fighting purposes.
 The following clearances must be maintained:
 36 inches from sprinkler deflectors
 36 inches from fire door openings
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 24 inches around the path or travel of fire doors

15. Concrete Work

 All equipment and materials used in concrete construction and masonry work
shall meet the applicable requirements for design, construction, inspection,
testing, maintenance and operations.

 Stripped forms and shoring shall be removed and stockpiled promptly after
stripping in all areas in which persons are required to work or pass. Protruding
nails, wire, ties and other form accessories, not necessary to subsequent work,
shall be pulled, cut or other means taken to eliminate the hazard.

 Employees shall not be permitted to apply cement, sand and water mixture
through a pneumatic hose unless they are wearing protective head and face
equipment.

 Employees shall not be permitted to work above vertically protruding reinforcing

steel unless it has been protected to eliminate the hazard of impalement.

 Wire mesh rolls shall be secured at each end to prevent dangerous recoiling
action.

 Riding concrete buckets for any purpose is prohibited and vibrator crews shall be
kept out from under concrete buckets suspended from cranes or cableways.

 Employees (except those essential to the post-tensioning operations) must not be

permitted to be behind the jack during tensioning operations.

 Signs and barriers must be erected to limit employee access to the post-
tensioning area during tensioning operations.

 If a dump truck is used to make the pour, an inspection of the truck shall be made
prior to the pour for safety devices and any safety deficiencies.

 When discharging on a slope, the wheels of ready-mix trucks shall be blocked

and the brakes set to prevent movement.

 Handles of bull floats, used where they may contact energized electrical
conductors, shall be construed of non-conductive material or insulated with a
non-conductive sheath whose electrical and mechanical characteristics provide
the equivalent protection of a handle constructed of non-conductive material.
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 Powered and rotating type concrete troweling machines that are manually guided
shall be equipped with a control switch that will automatically shut off the power
whenever the operator removes his hands from the equipment handles (dead-
man switch).

16. Steel Erection & Dismantling work

Hoisting and Rigging

Cranes being used in steel erection activities shall be visually inspected prior to each shift by
a competent person; the inspection shall include observation for deficiencies during
operation. At a minimum this inspection shall include the following:

(A) All control mechanisms for maladjustment;

(B) Control and drive mechanism for excessive wear of components and contamination
by lubricants, water or other foreign matter;

(C) Safety devices, including but not limited to boom angle indicators, boom stops, boom
kick out devices, anti-two block devices, and load moment indicators where required;

(D) Air, hydraulic, and other pressurized lines for deterioration or leakage, particularly
those which flex in normal operation;

(E) Hooks and latches for deformation, chemical damage, cracks, or wear;

(F) Wire rope reeving for compliance with hoisting equipment manufacturer's
specifications;

(G) Electrical apparatus for malfunctioning, signs of excessive deterioration, dirt, or

moisture accumulation;

(H) Hydraulic system for proper fluid level;

(I) Tires for proper inflation and condition;

(J) Ground conditions around the hoisting equipment for proper support, including
ground settling under and around outriggers, ground water accumulation, or similar
conditions;

(K) The hoisting equipment for level position; and

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(L) The hoisting equipment for level position after each move and setup.

If any deficiency is identified, an immediate determination shall be made by the competent

person as to whether the deficiency constitutes a hazard.

If the deficiency is determined to constitute a hazard the hoisting equipment shall be

removed from service until the deficiency has been corrected.

Safety latches on hooks shall not be deactivated or made inoperable except:

1) When a qualified rigger has determined that the hoisting and placing of purlins and
single joists can be performed more safely by doing so; or

2) When equivalent protection is provided in a site-specific erection plan.

Working Under Loads

Routes for suspended loads shall be pre-planned to ensure that no employee is required to
work directly below a suspended load except for:

1) Employees engaged in the initial connection of the steel; or

2) Employees necessary for the hooking or unhooking of the load.

When working under suspended loads, the following criteria shall be met:

1) Materials being hoisted shall be rigged to prevent unintentional displacement;

2) Hooks with self-closing safety latches or their equivalent shall be used to prevent
components from slipping out of the hook; and

3) All loads shall be rigged by a qualified rigger

Structural Steel Assembly

Structural stability shall be maintained at all times during the erection process.

The following additional requirements shall apply for multi-story structures:

1) The permanent floors shall be installed as the erection of structural members

progresses, and there shall be not more than eight stories between the erection floor
and the upper-most permanent floor, except where the structural integrity is
maintained as a result of the design.
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2) At no time shall there be more than four floors or 48 feet whichever is less, of
unfinished bolting or welding above the foundation or uppermost permanently
secured floor except where the structural integrity is maintained as a result of the
design.

3) A fully planked or decked floor or nets shall be maintained within two stories or 30
feet whichever is less, directly under any erection work being performed.

17. Ladder & Scaffolding

 Purchase and use only approved construction grade ladders.

 Ladder rungs, cleats, and steps shall be parallel, level, and uniformly spaced
when the ladder is in position for use.

 Straight and extension ladders require non-skid feet.

 Portable ladders shall be placed on a substantial, level base and the area around
the top and bottom of the ladder shall be kept clear.

 The use of ladders with broken or missing rungs, broken or split side rails or other
faulty or defective construction is prohibited. Ladders with such defects will be
removed from service immediately.

 All ladders are to be inspected on a regular basis, inspection documentation will

be maintained and a copy submitted to the site safety office.

 Ladders shall not be loaded beyond the maximum intended load for which they
were built, nor beyond their manufacturer's rated capacity.

 Stair towers shall be used to provide access to elevated work platforms and
elevated work levels. Ladders shall be used to provide access only where stair
tower construction is physically prohibited. The Site HSE Manager shall review
this on a case by case basis a variance form must be completed and signed
before a ladder is used.

Straight Ladders

 Employees shall not work higher than the third rung from the top on straight or
extension ladders.

 Straight ladders shall not be used unless equipped with non-slip base.
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 All ladders greater than 12 feet shall be used in conjunction with retractable fall
protection or rope grab and vertical lifeline.

 Ladders shall be placed so the distance from the foot of the ladder to the base of
the wall or other support is one-fourth the working length of the ladder.

 Portable ladders shall be tied or otherwise secured to prevent their being

displaced.

 Ladders must be extended at least 36 inches (three rungs) above the landing
when used for access to elevated positions.

 Extension ladders shall not be separated and used.

 Extension ladders shall be used for a temporary task, any job that is repetitive or
requires access for an extended duration A stair tower must be constructed for
access.

Step Ladders

 Employees shall not use the top two steps of a stepladder nor work higher than
the third rung from the top.

 If an employee is working on a step ladder 10 feet or more above the floor, the
ladder shall be properly secured by tie off rope or held by at least one other
person at the ground level.

 Stepladders shall not be used as straight ladders.

 Stepladders shall be fully spread and locked open when the ladder is in use.

Job Made Ladders

Single and Double cleat ladders for use on the job shall be constructed as per the
approval of Engineer at site

Scaffolding

Guidelines for Scaffold Erection

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 A competent person (skill, experience and training) shall supervise the erection
process to assure the safe installation according to manufacturer's specifications
and regulatory requirements.

 Know the voltage of energized power lines, identify heat sources (steam pipes),
anticipate the presence of a hazardous atmosphere, etc. before erecting
scaffolds and keep a safe distance.

 Assure fall protection equipment is available prior to beginning erection and use
as appropriate.

 Have scaffolding material delivered as close to the erection site as possible to

minimize the need for manual handling. Arrange components in order of
erection.

 Assure material hoisting/rigging equipment is available to aid in lifting

components to erection point and, thus eliminate the need to climb with
components and reduce possibilities of sprains/strains, slips/falls.

 Examine all scaffold components prior to erection. Return (tag out of service, "Do
not use") and/or destroy defective components as appropriate.

 Restrict the intermixing of manufactured scaffolding components, unless the

components fit together properly without force and are so designed; the use of
dissimilar metals will not result in a reaction reducing strength; and design load
capacities are maintained.

 Lay full planking/platform units at all working, transition or rest levels. Spacing
between planks units should be no more than 1" wide with an absolute maximum
of 9-1/2". Generally, scaffold platforms and walkways should be at least 18"
wide. In most cases, the platform edge should not be more than 14" from the
structure. The platform unit should extend over the support not less than 6" and
maximum of 18". Use of cleats, hooks and other restraining devices are
recommended. When a platform unites is abutted together or overlapped to
make a long platform, each end should rest on a separate support or equivalent
support. Any overlaps should be at least 12".

Wood preservatives, fire retardant finishes and slip resistant finishes can be
applied to platform units, however no coating should obscure the top and bottom
of wooden surfaces, which would hinder inspection.

Guidelines for Scaffold Use

 Assure scaffolds and components are not loaded over their rated and maximum
intended capacities.
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 Prevent/restrict movement of scaffolds with employees on them.

 Maintain a safe distance from energized power lines.

 Prohibit work on scaffolds until removal of snow, ice or slippery material.

 Use tag lines when hoisting materials near scaffolds to prevent contact.

 Protect any suspension ropes from contact with heat producing sources (welding,
cutting, etc.), acids, corrosive substances etc.

 Prohibit scaffold use during storms and high winds.

 Remove debris and unnecessary materials from scaffold platforms.

 Prohibit use of ladders and other devices to increase working heights on

platforms.

Alteration & Dismantling

 Assure that scaffolds are altered, moved and dismantled under the oversight of a
competent person.

 Make alteration and dismantling planned activities and perform with the same
care as with erection.

 Tag any incomplete scaffold out of service and barricade to prevent accidental
use.

Requirements

 Scaffolds are to be erected, moved, altered and dismantled by competent and

experienced personnel or under the supervision of competent persons.

 On scaffolds of ten feet above the ground or floor, handrails, mid-rails and toe-
boards are to be installed and scaffolds completely decked.

 Guardrails shall be 2" x 4", or the equivalent, approximately 42 inches high

with a mid-rail.
 Supports shall be at intervals not to exceed eight feet.
 Toe-boards shall be minimum of four inches in height.
 All planking shall be Scaffold Grade or equivalent.

 If for some reasons a platform or scaffold cannot be equipped with standard

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handrails or completely decked, the scaffolding must be properly tagged as

incomplete.

 When scaffold heights exceed three times the smallest base dimension (or 26
feet), it must be secured to the building or structure at the second lift and every
other lift thereafter. Running scaffold is to be anchored every 30 feet horizontally
at the heights established in the preceding sentence. "Outriggers" or guidelines
may be used where it is impractical to secure scaffold to a building or structure.

 The footing or anchorage for scaffolds shall be sound, rigid and capable of
carrying four times the maximum intended load without settling or displacement.

 Unstable objects such as barrels, boxes, loose bricks, or concrete blocks will not
be used to support scaffolds. Mudsills 12" x 12" and base plates are
recommended.
 When using leveling jacks, 3/4 of its length must remain inside the scaffold leg.

 Scaffolds are to be capable of supporting at least four times the maximum

intended load.

 The poles, legs or uprights of scaffolds shall be plumb and securely and rigidly
braced to prevent swaying and displacement.

 Every person on a scaffold building crew shall be provided and use a safety
harness and lanyard during erection and dismantling operations.

 Do not stack brick, tile, block or similar material higher than 24" on the scaffold
deck.

 All scaffolds shall be provided with suitable safe access. Stair towers shall be
used to provide access to elevated work platforms and elevated work levels.
Ladders shall be used to provide access only where stair tower construction is
physically prohibited. Ladders shall rest on a suitable footing and stand level.
Ladders must extend 36" above the top rail or equivalent safe access shall be
provided.

 Manila ropes and No. 9 wire is not acceptable handrail material for scaffold or
elevated platforms.

 Scaffolds shall not be moved or dismantled without first removing all loose tools,
materials and equipment resting on the scaffold deck.

 All scaffolds shall rest on a suitable footing and shall stand level. Movable
scaffolds shall have the casters or wheels locked to prevent movement. Unstable
objects such as loose brick or concrete blocks shall not be used to support
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scaffolds or planks.

 Never work on a scaffold in high winds or storms.

 Do not climb bracing of scaffold.

 Scaffolds shall never be altered or moved while they are in use or occupied.

 Overhead protection shall be provided for men on a scaffold exposed to

overhead hazards. When practical, the area beneath shall be barricaded and
"Men Working Overhead" signs posted in all approach directions.

Inspection

 Before erecting and during dismantling, inspect all scaffold components. Those
found with defects must be discarded immediately.

 Handrails, mid-rails, cross bracing and steel tubing shall be inspected for nicks,
especially near center span, and indications where a welding arc has struck.

 Scaffold components shall be straight and free from bends, kinks, dents and
severe rusting.

 Scaffold frame weld zones shall be inspected for cracks and ends of tubing for
splitting or cracking.

 Manufactured decking shall be inspected for loose bolt or rivet connections and
bent, kinked, or dented frame. Plywood surface should be checked for softening
due to rot or wear, and peeling or laminated layers at edges. Safety planks
should be checked out for rot, cracks and other damage. Also, inspect the rod or
bolt and cleat.

 Each quick-connecting device, whether spring, threaded connection or toggle pin

arrangement, should be inspected to see that it operates properly.

 Casters, if used, should be inspected for smooth rolling surfaces, free turning,
free acting swivel and to be sure that the locking mechanism is in good working
order.

 Any scaffold over 25' high shall have the access ladder turned inside the framing,
and alternate sides of landing. (At no time will a person be required to climb the
outside of a scaffold over 25' high.)

 If welding is performed from a suspended platform, precautions must be taken to

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insulate any wire rope attachment points.

 Design drawings must be made prior to erection and kept on site for any scaffold
over 125' high. (A licensed professional engineer competent in this field must
make the design drawings.)

18. Floor Openings, Wall Openings & Stairways

This section outlines personnel protection of floor openings, wall openings and
stairways.

Floor Openings and Wall Openings

 Standard railings

 Top rail - 42 inches high

 Mid-rail - halfway between the top rail and floor
 Toe-board - 4 inches high and not more than 1/4 inch clearance from floor.

Minimum Requirements

 Wood railings - Post 2 x 4 inches, posts spaced a maximum of eight feet

 Pipe railings - Post and railings 1½" diameter, post spaced a maximum of eight
feet on center

 Structural steel - Post, railing, etc. 2" x 2" x 3/8" (or equivalent) or post spaced a
maximum of eight feet on center

 Toe-boards - 4" high with a maximum of 1/4" clearance above floor level

Standard Railings

Standard railings shall be installed in the following areas:

 Ladder way floor openings.

 Exposed skylight opening (except where cover is provided).

 Pits and trap door openings while cover is not in place.

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 Manhole floor openings when cover is not in place.

 Temporary floor openings.

 Wall openings (30" high and 18" wide) from which there is a drop of more than
four feet.

 Runways four feet or more above floor or ground level less than 18" wide, or
adjacent to dangerous equipment.

 Open sided floors and platforms ten feet or more over adjacent floor or ground
level shall be protected.

Stairways

A stairway will be provided at all points of access where the break in elevation is 19
inches or more and no ramp, runway, sloped embankment, ladder, or personnel hoist
is provided.

Temporary stairways will have landings that are 30 inches in the direction of travel
and 22 inches wide for every 12 feet or less of vertical rise.

 Standard handrail should be constructed similar to a standard railing. Attach to a

wall or partition with a 3" clearance. Handrails should be 30" to 34" high.

 Standard handrails shall be installed in the following location for stairways having
four or more risers:

 Stairways less than 44" wide one side enclosed need one handrail on open
side
 Stairways less than 44" wide open on both sides need stair railings on each
side
 Stairways more than 44" but less than 88" wide need one handrail on each
side
 Stairways 88" or more in width need one handrail on each side and one
handrail in the center

Floor Opening Covers

Must have a sign reading: "WARNING - TEMPORARY COVER - DO NOT REMOVE

UNLESS AUTHORIZED," or be otherwise identified on the surface of the cover.
Floor opening covers should be capable of supporting the maximum intended load.
Hole covering shall be a minimum of 3/4" plywood if one dimension is 18" or less;
otherwise 2" lumber is required. The covering shall be secure to prevent
displacement.
 Basic Safety Regulations
Document
Aker Powergas No

CLIENT: Bayer Material Science Pvt Ltd 1600/BSP/01

REV 0

Floor holes or penetrations shall be protected by a cover that leaves no openings

more than one inch wide. The cover shall be secure to prevent displacement and
shall be marked “Hole Cover” in bright or fluorescent paint.
All floor hole covers must be adequately secured to prevent them from being
accidentally moved, and they must extend adequately beyond the edges of the
opening. Nothing is to be stored or placed on any floor hole covers. Floor hole covers
are to be installed and removed only by approved employees.

Wall Opening Barriers

Wall opening barriers shall be provided for all wall openings in excess of 30" high and
18" wide from which there is a drop of more than four feet. Barriers shall be capable
of sustaining a 200-pound force.

Perimeter Barriers

 A standard guardrail system or the equivalent will guard all open sides on every
open-sided floor or platform 4 feet or more above the walking surface or ground
level.

 Ramps, runways, and other walkways will be guarded by a standard guardrail

system on all open sides 4 feet or more above the walking surface or ground
level. Whenever personnel perform work or tools, machine parts, and or materials
are to be used on runways, toeboards shall be installed.

 Regardless of height, open sided floors, platforms, ramps, runways, or other

walkways, above or adjacent to dangerous equipment, a standard guardrail
system or the equivalent will guard to protect any person from contacting or
falling into any dangerous equipment.

 Toe boards will be 4 inches vertical height from top edge to the level of the floor,
and must be installed not having more than 1/4 inch clearance above floor level.
Aker Powergas Pvt. Ltd.
PRICE BID
APPENDIX - I

(PRICE SCHEDULE FOR STATIC AND ROTARY EQUIPMENT ERECTION)

Rev. 01 Dated 16/11/2009

Rev.0 Job No :2090/1600Dtd:18/06/2009
SR. ITEM DESCRIPTION UNIT QTY UNIT RATE TOTAL AMOUNT
NO. Rs Rs

1.0 Static Equipment

A Transportation of static eqpt as per attached list from owner's storage points to work site including erectionon foundations or structural at all elevations., alignment,
grouting (Otrdinary grouting upto 6 M high and above 6m high shrink comp grouting to be used) including supply of grouting materials, packing plates, cleaning, draining
and installation of all mounting including as davit's and completing all work in all respects as per drawing , specifications and instruction of engineer in charge.if
Equipment has to be dismantled re-erected and handled during erection for obtaining final aligment, no extra payment will be made. Contractor to arrange all necessary
tools, tackles, manpower crane, and consumables required within quoted rates.

i] 0 to 2.0 Tons MT 40
ii] Above 2.0 to 10.0 Tons MT 60
iii) Above 10 to 25 Tons MT 600

B Fixing and erection of demisters, Process column internals like trays, MT 0.5
valves, etc

2.0 Rotary Equipment

Transportation of Rotary eqpt as per attached list from owner's storage points to work site assembly of parts/sub assemblies , placing the equipment on foundation or
Structural, levelling, aligning shrink comp grouting, including supply of grouting materials, packing plates, shims etc, carrying out trial run,start up runs, rectifying , defects
and completing the work in all respects as per drawings,specifications & instructions of engineer in charge. If equipment has to be dismantled, re-erected and handled
during erection for obtain final aligment, no extra payment will be made. Contractor to arrange all necessary tools, tackles, manpower, crane and consumables
required within quoted rates. Contractor is install mechanical seal assembly as per instruction of seal supplier representative.

i] 0 to 2.0 Tons MT 10
ii] Above 2.0 to 10.0 Tons MT 40
iii) Above 10.0 to 25.0 Tons MT QR

3.0 Erection & welding of Vessels Trim

1 of 4
SR. ITEM DESCRIPTION UNIT QTY UNIT RATE TOTAL AMOUNT
NO. Rs Rs
Carbon Steel Inch Dia 100
Stainless Steel Inch Dia 100

4.0 Hydrotesting of equipment

Hydrotesting of equipment provided all filling and testing,
eqpts and accessories , including dewatering
drying and boxing up of equipment M3 5

5.0 Unloading of the equipment , Pipes, Pipes Fittings, Valves, MT 600

special itmes, panels etc from truck/trailer stacking at
client's store and yard

2 of 4
 Labour

Aker Powergas Pvt. Ltd

MECHANICAL / PIPING ERECTION WORK

LABOUR HIRE CHARGES

NORMAL O.T SUNDAY/ HOLIDAY

SR. DESCRIPTION RATES RATES RATES
NO.
Per Day Per Hour Per Hour
1.0 LABOUR CHARGES
Labour charges with consumables,
hand tools, supervision, tools and
tackles for additional work if any
including pre-commissioning /trial
run activities

1 Foreman

2 Structural Welder

3 Pipe Welder - CS/SS

4 Gas Cutter/Tack Welder

5 Rigger

6 Pipe Fitter

7 Structural Fitter

8 Fitter

9 Mechanic

10 Electrician

11 Driller

12 Helper

13 Carpenter

14 Grinder

Page 3
 Labour

NORMAL O.T SUNDAY/ HOLIDAY

SR. DESCRIPTION RATES RATES RATES
NO.

2.0 MACHINERY

1 Mobile crane with operator 10T to 15T

capacity

2 Trailer (with driving unit) 10T

3 Welding Transformer

4 Welding Generator/ Rectifier

5 Welding Machine (diesel and

engine driven with C S electrode)

6 Drilling Machine

7 Grinding Machine with Grinding Wheel

NOTES

1. The above rates should be inclusive of all overheads.

2. Day rate means rate/day of normal eight hours work or prorata basis payment
for part work of normal day.

3. Overtime means work done beyond normal eight hours work and on declared
holidays.

Page 4
 PRICE BID

SUMMARY

PROJECT NO: 2090/1600 - Bayer Material Science

Rev. 01 Dated 16/11/2099

Rev.0 Dtd: 12/11/09

SR. ITEM DESCRIPTION AMOUNT
NO. (RS.)
A APPENDIX-I

1.0 Equipment Erection

Total of Appendix - I

B APPENDIX - II

1.0 Fabrication & erection of Pipes CS

2.0 Fabrication & erection of GI pipes

3.0 Fabrication & erection of SS pipes

4.0 Installation of valves & strainers

5.0 Installation of Inline mounting

6.0 Fabrication & erection of structural supports

i] Fabrication & erection (CS)/

ii] Fabrication & erection (SS)
iii] Supply of structural steel
iv] Clamps, nuts,U-Bolts

7.0 Fabrication & erection of tun dish

i] Carbon steel

8.0
A] Dismantling
B] Re-erection

9.0 Erection & welding of spring support/hangers

10.0 Supply of installation of wooden supports

11.0 Radiography

12.0 Expansion anchor fasteners

1 of 12
 SR. ITEM DESCRIPTION AMOUNT
NO. (RS.)

13.0 Flexible hoses/coupling

14.0 Cutting, bevelling & welding

15.0 Copper jumper

Total of Appendix II

C) APPENDIX - III
1.0
Insulation Supply & Application Work

Total of Appendix - III

D) APPENDIX - IV
1.0
Supply & Application of Painting Work

Total of Appendix IV
Total of Appendix I , II, III & IV

2 of 12
APPENDIX - II

(PRICE SCHEDULE FOR PIPING)

PROJECT NO: 2090/1600
Rev.0 Dated 11/06/09
Rev.01 Dated 11/11/09
SR. ITEM DESCRIPTION UNIT QTY UNIT RATES AMOUNT(RS)
NO.

B Fabrication & Erection of Pipelines

1.0 Transportation of CS pipes & fittings and other material from owner's storage point to work site/workshop including retransportation from workshop to work site, cutting, edge
preparation, cold bending (upto 40 NB), set on branches,threading including supply, application of teflon tapes, sealants as required, laying of pipelines above ground, on
overheads racks, at all elevations, trenches, connections to equipments, welding of pipelines of different pressure and temperature ratings, dye penetrant testing of all joints
including installation of pipe supports,hydrotest or pneumatic, testing, draining, drying of lines using compressed air, final box up and completing work in all respects as per
specifications, drawings & instructions of engineer in charge. Contractor shall arrange all necessary tools, tackles,machines consumables and metallic scoffolding required for
executing the job, arrangements to provide air compressor with all accessories for testing including supply of safety valves and manifolds , blowing, drying of pipelines. Fabrication
and installation of spool peices from plates/ pipes supplied as free issue by Client. Contractor shall test lines by water or air.

1.1 Carbon Steel Pipes of ASTM 106Gr B , IBR

15 MM NB 80 SCH M 6
25 MM NB 80 SCH M 876
50 MM NB 40 SCH M 444
80 MM NB 40 SCH M 288
100 MM NB 40 SCH M 90
150 MM NB 40 SCH M 6
200 MM NB 40 SCH M 126

1.2 CS Pipes of ASTM A53 Gr.B

25 MM NB 80 SCH M 6
 SR. ITEM DESCRIPTION UNIT QTY UNIT RATES AMOUNT(RS)
NO.
50 MM NB 40 SCH M 1758
80 MM NB 40 SCH M 378
100 MM NB 40 SCH M 474
150 MM NB 40 SCH M 1092
200 MM NB 40 SCH M 318
250 MM NB 40 SCH M 18
25 MM NB 80 SCH C S Pipes ASTM A 106Gr.B M 24

15mm Sch80 Pipe Smls . CS ASTM A106-B ASME B36.10M

1.3 M 6
25mm Sch80 Pipe Smls CS ASTM A106-B ASME B36.10M
M 1482

1.4 Copper Tubing of BS2871 PT.2 Gr. C106 for steam Tracing M 170
15 MM OD

2.0 Transportation of G I pipes & fittings and other material from owner's storage point to work site/workshop including retransportation from workshop to work site, cutting, edge
preparation, cold bending (upto 40 NB), set on branches,threading including supply, application of teflon tapes, sealants as required, laying of pipelines above ground, on
overheads racks, at all elevations, trenches, connections to equipments, welding of pipelines of different pressure and temperature ratings, dye penetrant testing of all joints
including installation of pipe supports,hydrotest or pneumatic, testing, draining, drying of lines using compressed air, final box up and completing work in all respects as per
specifications, drawings & instructions of engineer in charge. Contractor shall arrange all necessary tools, tackles,machines consumables and metallic scoffolding required for
executing the job, arrangements to provide air compressor with all accessories for testing including supply of safety valves and manifolds , blowing, drying of pipelines. Fabrication
and installation of spool peices from plates/ pipes supplied as free issue by Client. Contractor shall test lines by water or air.

2.1 Pipe Welded Threaded. ASME B1.20.1(NPT). CS ASTM A53-Type F. ASME B36.10M. Hot Dip Galvanised.

25 MM NB Sch 80 M 162
50 MM NB Sch 80 M 576
80 MM NB M 1
 SR. ITEM DESCRIPTION UNIT QTY UNIT RATES AMOUNT(RS)
NO.
2.2 Seal Welding both sides of socket fitted on the above Galvanised Pipes
25 MM NB Inch Dia 5
50 MM NB Inch Dia 5
80 MM NB Inch Dia 5

3.0 Transportation of SS pipes & fittings and other material from owner's storage point to work site/workshop including retransportation from workshop to work site, cutting, edge
preparation, cold bending (upto 40 NB), threading including supply, application of teflon tapes as required, laying of pipelines above ground, on overheads racks, at all
elevations, trenches, connections to equipments, welding of pipelines of different pressure and temperature ratings, dye penetrant testing of all joints including installation of pipe
supports, hydrotest pneumatic testing, draining, drying of lines using compressed air, final box up and completing work in all respects as per specifications, drawings and
instructions of engineer in charge. Contractor shall arrange all necessary tools, tackles and machines and mettalic scoffolding required for executing the job, arrangements to
provide air compressor with all accessories for testing, blowing, drying of pipelines. Fabricate and install spool pieces from plates/ pipes supplied as free issue by clients.
Contractor shall test line by water or air, water will not be provided by client.

3.1
Stainless Steel Pipes of ASTM A312 TP 304L Welded/ seamless
15 MM NB 40S M 18
20 MM NB 40S M 1
25 MM NB 40S M 1170
25 MM NB 10S M 720
50 MM NB 10S M 5280
80 MM NB 10S M 354
100 MM NB 10S M 1020
150 MM NB 10S M 180
250 MM NB 10S M 42

3.2 Stainless Steel Tubing of ASTM A269 TP316

12 MM OD 2.0 MM Thick M 12
 SR. ITEM DESCRIPTION UNIT QTY UNIT RATES AMOUNT(RS)
NO.

4.0 Installation of all types of valves viz. gate, globe, check, ball, diaphragm, needle, sampling valve, piston valves, Butterfly vales, etc. sight glass, steam trap, strainers, flame
arrestors, float valves, etc. including transportation from owner's storage point to work site/contractor's stores, retransportation from contractor stores to work site, bolting after
Installation of proper gaskets and completing the works in all respect as per drawings, specification and instructions of the engineer in charge. Contractor shall arrange all
necessary tools, tackles,machinesand consumables and metallic scoffolding required for executing the job.

4.1 Valves of all types steam trap, permanent Stainer, sight

glass, flame arrestors, float valve, expansion joints Bellow,
float valve, ball/plug , butterfly, CS/CI/SS/ etc., flanged ends
125/150/ 300# & 600# lbs rating.
15 MM NB No. 9
20 MM NB No. 2
25 MM NB No. 655
50 MM NB No. 385
80 MM NB No. 125
100 MM NB No. 43
150 MM NB No. 19
200 MM NB No. 8
250 MM NB No. 4

4.2
Valves of all types steam trap, permanent sight glass, flame
arrestors, expansion joints, float valve, ball/plug valve CS/SS
etc., flanged ends 125/150/300/600 # lbs rating IBR
15 MM NB No. 82
25 MM NB No. 141
40 MM NB No. 1
50 MM NB No. 25
 SR. ITEM DESCRIPTION UNIT QTY UNIT RATES AMOUNT(RS)
NO.
80 MM NB No. 10
100 MM NB No. 4
200 MM NB No. 1

4.3 Spectacle Blind inserted between flanges - 150#, 300#

25 MM NB No. 6

5.0 Installation of all types ofPressure Regulator Valves , safety valves, orifice plates & Reputre Disc etc. including transportation from Owner's storage point to work/contractor's
stores, retransportation from contractor stores to work site, bolting after fixing proper gaskets, removal for line testing/flushing and re-installed and completing the works in all
respect as per drawings, specification and instruction of the engineer in charge.Contractor shall arrange all necessary tools, tackles, machines, consumables and mettalic
scoffolding required for executing the job.

5.1 Pressure Regulators Valves

25 MM NB No. 2
50 MM NB No. 2
100 MM NB No. 1

5.2 Safety valves/Thermal safety Valve flanged ends screwed ends .

25 MM NB No. 20
50 MM NB No. 7
80 MM NB No. 4
100 MM NB No. 10
150 MM NB No. 1
200 MM NB No. 1

5.3 Orifice Plate/restriction orifice plate

 SR. ITEM DESCRIPTION UNIT QTY UNIT RATES AMOUNT(RS)
NO.

25 MM NB No. 7
50 MM NB No. 19
100 MM NB No. 2
200 MM NB No. 1

5.4 Rupture Disc

50 MM NB No. 12
80 MM NB No. 2
 SR. ITEM DESCRIPTION UNIT QTY UNIT RATES AMOUNT(RS)
NO.
6.0 Fabrication & Erection of Pipe Support Structures

Supply, Transportation to site, unloading at site, fabrication shop/contractor's stores, fabriation, pipe supports like shoes, triunion, pad plates, clamp, saddles pedestals, plate rings & angle around pipes, etc. of all
types including surface preparation & one coat of zinc phosphate primer & supply of consumables, labour, materials and supervision, etc. to complete the works in all respects as per drawing specs. of engineer in
charge including all the taxes and duties etc. Pipe supports having CS as well as SS portion shall be paid at corresponding rates applicable. Contractor shall arrange all necessary tools, tackles, machines
and consumables and mettalic scoffolding required the executing the job.

i] Fabrication & erection rate (CS) MT 34

ii] Fabrication & erection rate (SS) MT 0.07

iii] Supply rate of structural steel for CS MT 34

v] Supply fabrication & erection of U bolts, clamps etc.

Various Sizes MaterialsIS 1363 G I

8 No 1000

10 No 200

16 No 100

Various Sizes Material ASTM A320 Gr. B8M

8 No 600

10 No 400
16 No 100

7.0 Only Erection of Tun Dish (Funnel)

i] Drain Funnel C S 100 X 50 No 60

8.0 Dismantling & Re-erection of Piping Structural & Equipment

 SR. ITEM DESCRIPTION UNIT QTY UNIT RATES AMOUNT(RS)
NO.
Dismantling & re erection of piping, structural & euipment including
preparation of scaffolding, gas cutting, haksaw cutting & return of
dismantling materials in acceptable condition to owner storage and all
debris removed from site.

A] Dismantling Rate
Unit Rate for Piping C.S. Inch/M 10
Unit Rate for Equipment MT 0.1
Unit Rate for Structural Steel MT 0.05

B] Re-Erection Rate
Unit Rate for Piping C.S. Inch/M 10
Unit Rate for Equipment MT 0.1
Unit Rate for Structural Steel MT 0.05

9.0 Erection, Welding of Spring Supports & Hangers,etc. Kg 500

10.0 Supply, Fabrication, installation of Puff supports, clamps, lugs, screws etc. as per standards

Pipes Size
25 No. 10
50 No. 20
80 No. 10
100 No. 25
150 No. 10

11.0 Performance of Radiographic inspection on all type of piping including providing or hiring of all equipment and whatever else, even though not expressly mentioned but required to
perform the work as per specifications and instruction of engineer in charge. Repeat radiography due to defective films or on repaired joint due to contractors fault or for additional
radiography necessitated due to poor performance of contractor's, welders shall be done at contractor's cost. Radiographic film used shall be NDT 65 or equivalent. The contractor
shall provide radiography viewer with adjustable intensity of illumination with a pedal switch and adjustable slit opening within easy access of the clients/engineer. All joints
 SR. ITEM DESCRIPTION UNIT QTY UNIT RATES AMOUNT(RS)
NO.
50mm and below to be radiographed as double wall single image.

Radiograhpy Weld Joint Inch Dia 250

1 DP Test Per Inch 20

(For Extra Work)
If applicable in specially instructed by site-incharge

12.0 Providing & fixing rust proof expansion anchor fastners "Anchor" at all heights, as per manufacturer's spec. including nuts, washers, bolts scaffolding, drilling, with electric concrete
drill,etc. on concrete structures complete as specified & directed
a]
1/2" dia, 150mm long Nos. 5
b]
5/8" dia, 150mm long Nos. 5
c]
3/4" dia, 150mm long Nos. 5

13.0 Flexible Hose with hose coupling/Flanged ends

15 NB No. 2
20 NB No. 1
25 NB No. 72
50 NB No. 20
80 NB No. 13
100 NB No. 5

Hose Coupling Adaptor

25 NB No. 50

14.0 Cutting bevelling & welding both sides for modification work only.
CS pipes
Cutting Per inch dia 10
bevelling Per inch dia 10
 SR. ITEM DESCRIPTION UNIT QTY UNIT RATES AMOUNT(RS)
NO.
welding Per inch dia 10

SS pipes
Cutting Per inch dia 10
bevelling Per inch dia 10
welding Per inch dia 10

15.0 Supply, fabrication, installation of Copper Jumper 12 swg as per Aker Powergas std
15 to 40 No 15
50 to 100 No 15
125 to 200 No 15
250 to 300 No QR
Supply and application of Insulation work as per specification anf instruction of Site- in Charge
OPERATING TEMP.
EQPT. DIMENSIONS o INSULATION
SR. C

PVT. LTD.
AKER
EQPT.NO. QTY. DIA (O.D.) (mm) x EQPT. TYPE M.O.C REMARKS
NO. Unit Rates
TOTAL HEIGHT (mm) MAX. MIN. TYPE THK(mm) AREA (m 2) Amount
(Rs)

1 V100CA20RA110 1 2832 x 4416 BD / TD SS 150 60 ROCKWOOL 120 52

POWERGAS
2 V100CA20RA120 1 2832 x 4416 BD / TD SS 150 60 ROCKWOOL 120 52

3 V200CA20RA110 1 2832 x 4416 BD / TD SS 150 60 ROCKWOOL 120 52

4 V200CA20RA120 1 2832 x 4416 BD / TD SS 150 60 ROCKWOOL 120 52

4 E200ER20BA100 1 2224 x 3220 Hor. Vessel CS - - COLD 70 30

5 E100ER12BA100 1 2224 x 3220 Hor. Vessel CS - - HOT 25 29

CLIENT : BAYER MATERIAL SCIENCE

6 V100BE10BA100 1 2826 x 5424 Hor. Vessel SS 60 50 ROCKWOOL 80 61

7 V100BE10BA300 1 2826 x 5424 Hor. Vessel SS 80 60 HOT 25 59

8 V200DS30WA211 1 836 x 1700 BD / TD SS 120 56 POLYURETHANE 60 7

9 V200BE10BA300 1 2826 x 5424 Hor. Vessel SS 40 5 ROCKWOOL 80 61

10 V200DS30WA221 1 836 x 1700 BD / TD SS 120 56 POLYURETHANE 60 7

11 V200DS30BA223 1 219 x 703 BD / TD SS 40 - ROCKWOOL 80 1

12 V200DS30BA213 1 219 x 703 BD / TD SS 40 - ROCKWOOL 80 1

13 V200DS30BA123 1 219 x 703 BD / TD SS 40 - ROCKWOOL 80 1

14 V200DS30BA113 1 219 x 703 BD / TD SS 40 - ROCKWOOL 80 1

15 V100DS30BA200 1 219 x 703 BD / TD SS 40 - ROCKWOOL 80 1

16 V100DS30BA120 1 219 x 703 BD / TD SS 40 - ROCKWOOL 80 1

INSULATION SCHEDULE
17 V200DS30BA222 1 219 x 655 BD / TF SS 160 - ROCKWOOL 100 1

Equipment
18 V200DS30BA212 1 219 x 655 BD / TF SS 160 - ROCKWOOL 100 1

19 V200DS30BA122 1 219 x 655 BD / TF SS 160 - ROCKWOOL 100 1

20 V200DS30BA112 1 219 x 655 BD / TF SS 160 - ROCKWOOL 100 1

21 V200WS10BA100 1 1420 x 2024 BD / TD SS 140 - ROCKWOOL 110 13

22 V800TA10BA100 1 7012 x 6767 BF / TD SS 40 - HOT 60 233

23 V100DS30RA400 1 1220 x 1570 BD / TD SS 80 - ROCKWOOL 120 10

24 V100BE10RA400 1 1432 x 3046 BD / TD SS 100 - ROCKWOOL 120 20

G-VSL-002.020-F-00
Supply and application of Insulation work as per specification anf instruction of Site- in Charge
OPERATING TEMP.
EQPT. DIMENSIONS o INSULATION
SR. C

PVT.
AKER
EQPT.NO. QTY. DIA (O.D.) (mm) x EQPT. TYPE M.O.C REMARKS
NO. Unit Rates
TOTAL HEIGHT (mm) MAX. MIN. TYPE THK(mm) AREA (m 2) Amount
(Rs)

25 V300KF40RA110 1 2832 x 5166 BD / TD SS - - ROCKWOOL 120 59

26 V200CA20RA200 1 2832 x 5166 BD / TD SS - - ROCKWOOL 120 59

27 V100KF40RA120 1 2832 x 5166 BD / TD SS - - ROCKWOOL 120 59

28 V200KF40RA110 1 2832 x 5166 BD / TD SS - - ROCKWOOL 120 59

29 V100KF40RA110 1 2832 x 5166 BD / TD SS - - ROCKWOOL 120 59

30 V100CA20RA200 1 2832 x 5166 BD / TD SS - - ROCKWOOL 120 59

31 V200KF40RA120 1 2832 x 5166 BD / TD SS - - ROCKWOOL 120 59

SHEET NO :

SPECIFICATION NUMBER
INSULATION-X1
PIC-1600-REACTORS-
TOTAL INSULATION AREA m2 1161

NOTES :

1 OF
1) EQUIPMENT TYPE : TF - TOP FLAT TD - TOP DISH END TC - TOP CONICAL BF - BOTTOM FLAT BD - BOTTOM DISH END BC - BOTTOM CONICAL

2) AS PER FEL "INSULATION WORK GUIDELINE" DOCUMENT: A) INSULATED VERTICAL EQUIPMENTS WITH DIAMETER > DN 350 HAVE TO BE PROVIDED WITH SUPPORT RINGS FOR INSULATION.

1
SUPPORT RINGS ARE TO BE FABRICATED IN FORM OF A DOUBLE CLAMPING RING (AS PER DETAILS IN TABLE-6, PAGE 14/34 IN THE INSULATION WORK GUIDELINE DOCUMENT). THESE SUPPORT

RINGS ARE LOOSE NOT WELDED TO THE EQUIPMENT. THE SUPPORT RINGS REST ON SUPPORT LUGS WHICH ARE WELDED TO THE EQUIPMENT. THE SUPPORT LUGS WHICH ARE WELDED TO

EQUIPMENT WILL BE IN VESSEL VENDOR'S SCOPE. HOWEVER THE LOOSE SUPPORT RINGS ARE TO BE IN SCOPE OF THE INSULATION CONTRACTOR (AS PER CLAUSE 5.1( PAGE 12/34).

G-VSL-002.020-F-00
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA Doc No.:
PIC-1600-1000-X1 Under Rev 2
Plant: PIC (Poly Isocyanate Coatings)

BTS-ENG PP PSS PAGE NO. 1 of 9

EQUIPMENT LIST *
* BASED ON REVISED MDS AND P&ID UNDER REV 2

1 9-Jun-09 Design (PEM-S3 Status) ASV / 9 June 09 AMP / 9 June 09 KKS / 9 June 09
0 6-Mar-09 Design (PEM-S1 Status) ASV / 6 Mar 09 AMP / 6 Mar 09 KKS / 6 Mar 09

Rev Date Issued For Prepared by / Date Checked by / Date Approved by / Date

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com

PC1600010R0
1 of 8
 AKER POWERGAS PVT. LTD.
EQUIPMENT LIST
Client: Bayer Material Science Pvt. Ltd. Job No. : 2090/1600 BMS PIC Unit

Project : BMS PIC Unit Document No. PIC-1600-1000-X1 Under Rev 2

* BASED ON REVISED MDS AND P&ID UNDER
Note: REV 2
Operating Operating Allowable Allowable Shaft Rotary
process sub Working / Supporting diameter length volume surface flow rate Delivery weight weight with Material of PEM
item Equipment No. Equipment Name Technical Describtion PID No. pressure temperature pressure temperature Power speed RFQ No Vendor Rev Remarks
area process Standby Elevation mm mm m³ m² m³/h head m empty kg water kg Construction Priority
[barg] [°C] [barg] [°C] [kW] [1/min]
Movable waste water pump Diaphragm pump, compressed
A100 AA10 PA100 A100AA10PA100 W LE1336929-1 - - - - - 20 32.00 - - 3.600 30-40 6 120 304L - - 3 26 1
(Trolley Mounted) air drive
A300 AA30 BA100 A300AA30BA100 Offgas dip in tank vessel W LE1336975-1 109.400 800 2859 1.60 - - - 1775 3325 0.020 30-40 -1/6 250 304L - - 2 16 Triofab 1

A300 AA30 BA210 A300AA30BA210 Measuring pot vessel W LE1336975-1 100.450 219 422 0.02 - - - 70 85 0.005 30-40 -1/6 250 304L - - 3 15 1

A300 AA30 BA220 A300AA30BA220 Measuring pot vessel W LE1336975-1 100.450 219 422 0.02 - - - 70 85 0.005 30-40 -1/6 250 304L - - 3 15 1

A300 AA30 BA230 A300AA30BA230 Measuring pot vessel W LE1336975-1 100.450 219 422 0.02 - - - 70 85 0.005 30-40 -1/6 250 304L - - 3 15 1

A300 AA30 BA240 A300AA30BA240 Measuring pot vessel W LE1336975-1 100.450 219 422 0.02 - - - 70 85 0.005 30-40 -1/6 250 304L - - 3 15 1

A300 AA30 BA250 A300AA30BA250 Measuring pot vessel W LE1336975-1 100.450 219 422 0.02 - - - 70 85 0.005 30-40 -1/6 250 304L - - 3 15 1
Not to be
A300 AA30 BA300 A300AA30BA300 Waste Drum vessel NIL Deleted - 0.000 30-40 1
Procured
A300 AA30 BA400 A300AA30BA400 Offgas dip in tank vessel W LE1336976-1 109.400 800 2859 1.60 - - - 1775 3325 0.020 30-40 -1/6 250 304L - - 2 16 Triofab 1

A300 AA30 BA510 A300AA30BA510 Measuring pot vessel W LE1336976-1 100.450 219 422 0.02 - - - 70 85 0.005 30-40 -1/6 250 304L - - 3 15 1

A300 AA30 BA520 A300AA30BA520 Measuring pot vessel W LE1336976-1 100.450 219 422 0.02 - - - 70 85 0.005 30-40 -1/6 250 304L - - 3 15 1

A300 AA30 BA530 A300AA30BA530 Measuring pot vessel W LE1336976-1 100.450 219 422 0.02 - - - 70 85 0.005 30-40 -1/6 250 304L - - 3 15 1

A300 AA30 BA540 A300AA30BA540 Measuring pot vessel W LE1336976-1 100.450 219 422 0.02 - - - 70 85 0.005 30-40 -1/6 250 304L - - 3 15 1
Not to be
A300 AA30 BA600 A300AA30BA600 Waste Drum vessel W LE1336976-1 - 0.000 30-40 1
Procured
A300 AA30 BA700 A300AA30BA700 Blow down vessel vessel W LE1336973-2 101.050 1600 1500 3.55 - - - 2650 6500 0.000 30-40 - 0.3 / 3.5 250 CS - - 2 16 Triofab 2

A300 AA30 BA800 A300AA30BA800 Measuring pot vessel W LE1336991-1 100.450 219 422 0.02 - - - 70 85 0.000 30-40 -1/6 250 304L - - 3 15 1

A300 AA30 BA900 A300AA30BA900 Dip in vessel vessel W LE1336983-2 109.400 800 2859 1.60 - - - 1475 3025 0.010 30-40 -1/6 250 304L - - 2 16 Triofab 1

A300 AA30 FB110 A300AA30FB110 Active carbon filter barrel W LE1336983-2 108.800 - - 0.20 - 200.00 - - - 0.040 30 -1 / 2 80 304L - - 2 34 1

A300 AA30 FB120 A300AA30FB120 Active carbon filter barrel W LE1336983-2 108.800 - - 0.20 - 200.00 - - - 0.040 30 -1 / 2 80 304L - - 2 34 1

A300 AA30 FB130 A300AA30FB130 Active carbon filter barrel S LE1336983-2 108.800 - - 0.20 - 200.00 - - - 0.040 30 -1 / 2 80 304L - - 2 34 1

A300 AA30 FB140 A300AA30FB140 Active carbon filter barrel S LE1336983-2 108.800 - - 0.20 - 200.00 - - - 0.040 30 -1 / 2 80 304L - - 2 34 1

A300 AA30 FB150 A300AA30FB150 Cooling trap Basket filter W LE1336983-2 112.550 219 980 - - - - - - -0.060 30 -1 / 6 / 10 250 304L - - 3 33 1

A300 AA30 FB700 A300AA30FB700 Separator separator W LE1336973-2 100.450 219 980 - 0.20 100.00 - - - 0.000 30-40 Ambient 250 304L - - 3 33 1

A300 AA30 FB800 A300AA30FB800 Separator separator W LE1336991-1 108.800 219 980 - 0.50 100.00 - - - -0.06 40-60 -1 / 6 / 10 250 304L - - 3 33 1

A300 AA30 FF200 A300AA30FF200 Basket Filter Basket filter W LE1336976-1 108.800 219 980 - 0.20 10.00 - - - 0.010 30 -1 / 6 250 304L - - 3 33 1
Diaphragm pump, compressed
A300 AA30 PA210 A300AA30PA210 Diaphragm pump W LE1336976-1 109.100 - - - - 10 9.90 - - 0.712 30 6 120 304L - - 3 26 1
air drive
barrel pump (one pump can be
A300 AA30 PA100 A300AA30PA100 Mobile pump W LE1336975-1 108.800 - - 2.50 15.00 - - 1.430 30 6 120 304L - - 3 26 1
used for all positions) - -
barrel pump (one pump can be
A300 AA30 PA220 A300AA30PA220 Mobile pump NIL LE1336976-1 108.800 - - 2.50 15.00 - - 1.430 30 6 120 304L - - 3 26 1
used for all positions) - -
barrel pump (one pump can be
A300 AA30 PA900 A300AA30PA900 Mobile pump NIL LE1336983-2 108.800 - - 2.50 15.00 - - 1.430 30 6 120 304L - - 3 26 1
used for all positions) - -
A300 AA30 VA100 A300AA30VA100 Offgas blower Offgas blower W LE1336983-2 109.100 - - - - 400 - - - 0.190 30 Hold 250 304L / Al - - 2 37 1

A300 AA30 VA200 A300AA30VA200 Offgas blower Offgas blower W LE1336983-2 109.100 - - - - 400 - - - 0.200 30 Hold 250 304L / Al - - 2 37 1

E100 ER12 BA100 E100ER12BA100 Condensate vessel Vessel W LE1336994-0 109.400 2200 2100 10 - - - 4550 14950 0.000 100 -1/6 250 CS - - 2 16 Triofab 2
Centrifugal pump, magnetic
E100 ER12 PA100 E100ER12PA100 Condensate pump W LE1336994-0 100.450 - - 14.3+5.7 28.00 - - 3.240 100 16 250 CS - - 2 25 1
coupling - -
E100 ER12 WA100 E100ER12WA100 Condenser heat exchanger, tube bundle - Deleted - - - - - - - - - - - - - - - DELETED 1
- -
E100 ER22 PA100RES E100ER22PA100RES pump not available NIL Future - nil future 1

E100 ER22 WA100ERW E100ER22WA100ERW not available not available NIL Future - nil future 1

E200 ER20 BA100 E200ER20BA100 CW6 Water vessel Vessel W LE1336996-1 132.550 2200 2100 10 - - - 4850 15200 0.000 6-30 -1/6 250 CS - - 2 16 Triofab 2

E200 ER20 KU100 E200ER20KU100 Chiller Chiller W LE1336996-1 132.350 - - - - - - 1.100 6-14 - 1 / 16 250 CS / Copper - - 2 39 1
- -
E200 ER20 KU200 E200ER20KU200 Chiller Chiller W LE1336996-1 132.350 - - - - - - 1.100 6-14 - 1 / 16 250 CS / Copper - - 2 39 1
- -
E200 ER20 KU200 ERW E200ER20KU200 ERW Chiller Chiller NIL Future 131.450 nil future 1
Centrifugal pump, magnetic
E200 ER20 PA100 E200ER20PA100 CW6 Water pump W LE1336996-1 124.200 - - 69+14 36.00 - - 5.570 6 16 250 CS - - 2 25 1
coupling - -
Centrifugal pump, magnetic
E200 ER20 PA200 E200ER20PA200 CW6 Water pump W LE1336996-1 124.200 - - 69+14 36.00 - - 5.570 6 16 250 CS - - 2 25 1
coupling - -
E200 ER22 BA100 E200ER22BA100 CW40 Water vessel Vessel W LE1336995-1 132.550 2200 2100 10 - - - 4450 14800 0.000 40 -1/6 250 CS - - 2 16 Triofab 2

E200 ER22 BA200 E200ER22BA200 CW20 Water vessel Vessel W LE1336997-1 132.395 800 1200 0.63 - - - 950 1650 0.000 20-30 -1 / 6 250 CS - - 2 16 Triofab 2
Centrifugal pump, magnetic
E200 ER22 PA100 E200ER22PA100 CW40 Water pump W LE1336995-1 100.450 - - 86+17 37.00 - - 6.480 40 16 250 CS - - 2 25 1
coupling - -
Centrifugal pump, magnetic
E200 ER22 PA200 E200ER22PA200 CW20 Water pump W LE1336997-1 108.800 - - - - - - 4.300 30 -1 / 16 250 CS - - 2 25 1
coupling - -
E200 ER22 WA100 E200ER22WA100 CW40 Water cooler Air cooler with fan W LE1336995-1 132.100 - - 86.00 - - - 1.600 40-50 10 250 304L - - 3 13 1
- -
E200 ER22 WA200 E200ER22WA200 Plate Heat exchanger Plate Heat exchanger W LE1336997-1 109.100 - - - - - - - - 4.3 / 5.8 20-30 -1 / 21 225 304L - - 2 19 1

E300 ER30 BA100 E300ER30BA100 Plant water vessel vessel W LE1336993-1 117.340 1600 1700 4 - - - 2350 6700 0.000 30 -1 / 6 250 CS - - 2 16 Triofab 2

E300 ER30 BA200 E300ER30BA200 Expansion Vessel vessel - Deleted - - - - - - - - - - - - - - - - - DELETED 1

E300 ER30 PA100 E300ER30PA100 Plant water booster pump Centrifugal pump W LE1336993-1 116.900 - - 13 42.00 - - 5 30 -1 / 16 100 304L - - 2 32 1
- -
E300 ER32 BA100 E300ER32BA100 Potable water vessel vessel W LE1336989-1 132.550 2200 3200 10 - - - 4550 14500 0.000 30 -1 / 6 100 304L - - 2 16 Triofab 1

PC1600010R0 2 of 8
 Operating Operating Allowable Allowable Shaft Rotary
process sub Working / Supporting diameter length volume surface flow rate Delivery weight weight with Material of PEM
item Equipment No. Equipment Name Technical Describtion PID No. pressure temperature pressure temperature Power speed RFQ No Vendor Rev Remarks
area process Standby Elevation mm mm m³ m² m³/h head m empty kg water kg Construction Priority
[barg] [°C] [barg] [°C] [kW] [1/min]

E300 ER32 BA200 E300ER32BA200 Expansion Vessel vessel - Deleted - - - - - - - - - - - - - - - - - DELETED 1

E300 ER32 PA100 E300ER32PA100 Potable water booster pump Centrifugal pump W LE1336989-1 116.900 - - 13 28.00 - - 2.9 30 -1 / 16 100 304L - - 2 32 1
- -
V100 BE10 BA100 V100BE10BA100 TDI Buffer Vessel W LE1336940-1 101.085 2800 4000 25 - - - 11900 42000 0.005 40 -1 / 6 / 32 250 304L - - 2 16 Triofab 1

V100 BE10 BA200 V100BE10BA200 DEG Buffer Vessel W LE1336940-1 101.085 2800 4000 25 - - - 10200 40400 0.005 30 -1 / 6 250 304L - - 2 16 Triofab 1

V100 BE10 BA300 V100BE10BA300 TMP Buffer Vessel W LE1336941-1 101.085 2800 4000 25 - - - 11400 41450 0.005 30 -1 / 6 / 32 250 304L - - 2 16 Triofab 1

V100 BE10 FF400 V100BE10FF400 Polyole filter Basket filter W LE1336941-1 100.550 219 980 - 0.20 0.40 - - - 2.000 80 -1 / 6 250 304L - - 3 33 1
Centrifugal pump, magnetic
V100 BE10 PA100 V100BE10PA100 TDI Feed Pump W LE1336940-1 100.450 - - 12+3 33.00 - - 3.900 40 -1 / 16 250 316 - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V100 BE10 PA200 V100BE10PA200 DEG Feed Pump W LE1336940-1 100.450 - - 4.833+1.933 16.00 - - 1.740 30 -1 / 16 250 316 - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V100 BE10 PA300 V100BE10PA300 TMP Feed Pump W LE1336941-1 100.450 - - 7+2 15.00 - - 1.550 80 -1 / 16 250 316 - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V100 BE10 PA400 V100BE10PA400 Polyole Feed Pump W LE1336941-1 100.450 - - 0.33+3 38.00 - - 4.760 80 -1 / 16 250 316 - - 2 25 1
coupling - -
V100 BE10 PA500 V100BE10PA500 Offspec Product pump barrel pump W

V100 BE10 RA400 V100BE10RA400 Polyole mixing vessel agitator vessel W LE1336941-1 108.800 1400 2335 2.50 - - - 3500 7800 0.005 80 -1 / 6 / 32 250 304L - - 2 10 1
Agitator, blade typ, with
V100 BE10 RW400 V100BE10RW400 Agitator W LE1336941-1 108.800 350 - - - - - - - 0.005 80 -1 / 6 250 304L 1.1 390 3 10 1
mechanical seal
Package unit for mechanical
V100 BE10 XA300 V100BE10XA300 Buffer fluid system - Deleted - - - - - - - - - - - - - - - - - DELETED 1
seal
Package unit for mechanical
V100 BE10 XA400 V100BE10XA400 Buffer fluid system W LE1336941-1 108.800 - - - - - - - - - - - - - - - 3 10 1
seal
V100 CA20 BA110 V100CA20BA110 Expansion Vessel vessel W LE1336942-1 126.440 600 1365 0.44 - - - 590 1020 2.7 130 32 250 304L - - 3 15 1

V100 CA20 BA120 V100CA20BA120 Expansion Vessel vessel S LE1336943-1 126.440 600 1365 0.44 - - - 590 1020 2.7 130 32 250 304L - - 3 15 1

V100 CA20 FF110 V100CA20FF110 Fluid Filter Basket Filter W LE1336942-1 116.600 219 980 - 0.20 25.50 - - - 0.300 100 -1 / 6 250 304L - - 3 33 1

V100 CA20 FF120 V100CA20FF120 Fluid Filter Basket Filter S LE1336943-1 116.600 219 980 - 0.20 25.50 - - - 0.300 100 -1 / 6 250 304L - - 3 33 1

V100 CA20 FF210 V100CA20FF210 Fluid Filter Basket Filter W LE1336944-1 100.550 219 980 - 0.20 10.00 - - - 0.330 80 -1 / 6 250 304L - - 3 33 1

V100 CA20 FF220 V100CA20FF220 Fluid Filter Basket Filter W LE1336944-1 100.550 219 980 - 0.20 10.00 - - - 0.330 80 -1 / 6 250 304L - - 3 33 1
Centrifugal pump, magnetic
V100 CA20 PA110 V100CA20PA110 Water Pump W LE1336942-1 116.900 - - 74.00 36.00 - - 9.670 150 20 250 CS - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V100 CA20 PA120 V100CA20PA120 Water Pump S LE1336943-1 116.900 - - 74.00 36.00 - - 9.670 150 20 250 CS - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V100 CA20 PA210 V100CA20PA210 Feed Pump W LE1336944-1 100.450 - - 10 35.00 - - 4.300 80 -1 / 16 250 316 - - 2 25 1
coupling - -
V100 CA20 RA110 V100CA20RA110 Reactor agitator vessel W LE1336942-1 124.170 2800 2980 20.00 - - - 11600 38900 -1 / 3 150 -1 / 6 / 32 250 304L - - 2 12 1

V100 CA20 RA120 V100CA20RA120 Reactor agitator vessel S LE1336943-1 124.170 2800 2980 20.00 - - - 11600 38900 -1 / 3 150 -1 / 6 / 32 250 304L - - 2 12 1

V100 CA20 RA200 V100CA20RA200 Crude Vessel agitator vessel W LE1336944-1 108.800 2800 3730 25.00 - - - 16200 41200 0.005 80 -1 / 6 / 32 250 304L - - 2 10 1
Agitator, blade typ, with
V100 CA20 RW110 V100CA20RW110 Agitator W LE1336942-1 124.170 1800 - - - - - - - -1 / 3 150 -1 / 6 250 304L 15 54 3 12 1
mechanical seal
Agitator, blade typ, with
V100 CA20 RW120 V100CA20RW120 Agitator S LE1336943-1 124.170 1800 - - - - - - - -1 / 3 150 -1 / 6 250 304L 15 54 3 12 1
mechanical seal
Agitator, blade typ, with
V100 CA20 RW200 V100CA20RW200 Agitator W LE1336944-1 108.800 1800 - - - - - - - 0.005 80 -1 / 6 250 304L 17.5 54 3 10 1
mechanical seal
V100 CA20 WA111 V100CA20WA111 Plate Heat exchanger Plate heat exchanger W LE1336942-1 116.900 - - - 15.50 - - - - 2.7 / 6 165 -1 / 21 225 304L - - 2 19 1

V100 CA20 WA112 V100CA20WA112 Plate Heat exchanger Plate heat exchanger W LE1336942-1 116.900 - - - 15.50 - - - - 2.7 / 4.5 25 -1 / 21 225 304L - - 2 19 1

V100 CA20 WA121 V100CA20WA121 Plate Heat exchanger Plate heat exchanger S LE1336943-1 116.900 - - - 15.50 - - - - 2.7 / 6 165 -1 / 21 225 304L - - 2 19 1

V100 CA20 WA122 V100CA20WA122 Plate Heat exchanger Plate heat exchanger S LE1336943-1 116.900 - - - 15.50 - - - - 2.7 / 4.5 25 -1 / 21 225 304L - - 2 19 1
Package unit for mechanical
V100 CA20 XA110 V100CA20XA110 Buffer fluid system W LE1336942-1 124.170 - - - - - - - - - - - - - - - 3 12 1
seal
Package unit for mechanical
V100 CA20 XA120 V100CA20XA120 Buffer fluid system S LE1336943-1 124.170 - - - - - - - - - - - - - - - 3 12 1
seal
Package unit for mechanical
V100 CA20 XA200 V100CA20XA200 Buffer fluid system W LE1336944-1 108.800 - - - - - - - - - - - - - - - 3 10 1
seal
V100 DS30 BA120 V100DS30BA120 Distillate Measuring pot vessel S LE1336945-1 120.900 219 500 0.02 - - - 65 80 -1 40 -1 / 6 250 304L - - 3 15 1

V100 DS30 BA200 V100DS30BA200 Distillate Measuring pot vessel W LE1336946-1 120.900 219 500 0.02 - - - 65 80 -1 40 -1 / 6 250 304L - - 3 15 1

V100 DS30 FB110 V100DS30FB110 Cyclone Separator Vessel W LE1336945-1 127.175 1200 1385 2.50 2.43 - - 1235 3335 -1 197 -1 / 6 / 32 250 304L - - 2 17 1

V100 DS30 FF100 V100DS30FF100 TDI Distillate Filter Basket Filter W LE1336945-1 116.600 219 980 - 0.20 1.10 - - - 0.500 40 -1 / 6 250 304L - - 3 33 1

V100 DS30 FF200 V100DS30FF200 TDI Distillate Filter Basket Filter W LE1336946-1 116.600 219 980 - 0.20 1.10 - - - 0.500 40 -1 / 6 250 304L - - 3 33 1

V100 DS30 PA200 V100DS30PA200 Gear Pump External Gear pump W LE1336946-1 119.700 - - - - 1.20 - - - 0.56 140 -1 / 16 200 304L - - 2 30 1

V100 DS30 PA200ERW V100DS30PA200ERW Gear Pump External Gear pump NIL Future 119.700 nil future 1

V100 DS30 RA400 V100DS30RA400 Dilution Vessel agitator vessel W LE1336947-1 116.600 1200 950 1.30 - - - 2000 3500 0.005 80 -1 / 6 / 32 250 304L - - 2 10 1

V100 DS30 RA400ERW V100DS30RA400ERW Dilution Vessel agitator vessel NIL Future 116.600 nil future 1

V100 DS30 RW200 V100DS30RW200 wiper wiper for thin film evaporator W LE1336946-1 124.200 - 4627 - - - - - - -1 197 -1 / 6 250 304L 7.5 120 3 17 1
Agitator, blade typ, with
V100 DS30 RW400 V100DS30RW400 Agitator W LE1336947-1 116.600 350 - - - - - - - 0.005 80 -1 / 6 250 304L 1.10 310 3 10 1
mechanical seal
V100 DS30 WA110 V100DS30WA110 Main Condenser FFE Heat exchanger, U-Turn W LE1336945-1 130.350 500 3674 - 24 - - 1600 2700 -1 130 - 1 / 10 / 10 250 304L - - 2 18 1

V100 DS30 WA120 V100DS30WA120 Final Condenser FFE Heat exchanger, U-Turn W LE1336945-1 132.550 500 1548 - 6.50 - - 780 1100 -1 120 -1 / 6 / 10 250 304L - - 2 18 1

V100 DS30 WA210 V100DS30WA210 Main Condenser TFE Heat exchanger, U-Turn W LE1336946-1 126.625 500 4040 - 24 - - 2000 3000 -1 105 - 1 / 10 / 10 250 304L - - 2 18 1

V100 DS30 WA220 V100DS30WA220 Final Condenser TFE Heat exchanger, U-Turn W LE1336946-1 128.230 500 1548 - 6.50 - - 780 1100 -1 120 -1 / 6 / 10 250 304L - - 2 18 1

V100 DS30 WA400 V100DS30WA400 Final Condenser Heat Exchanger, U-Turn W LE1336947-1 121.225 500 1778 - 6.50 - - 1050 1500 0.005 150 -1 / 6 / 10 250 304L - - 2 18 1

V100 DS30 WA400ERW V100DS30WA400ERW Condenser Heat Exchanger, U-Turn NIL Future 117.000 nil future 1

V100 DS30 WV100 V100DS30WV100 Falling Film Evaporator Falling Film Evaporator W LE1336945-1 130.350 325 4883 NA 10.00 - - 935 1255 -1 197 -1 / 6 / 32 300 304L - - 2 17 1

V100 DS30 WV100ERW V100DS30WV100ERW Falling Film Evaporator Falling Film Evaporator NIL Future 130.350 nil future 1

PC1600010R0 3 of 8
 Operating Operating Allowable Allowable Shaft Rotary
process sub Working / Supporting diameter length volume surface flow rate Delivery weight weight with Material of PEM
item Equipment No. Equipment Name Technical Describtion PID No. pressure temperature pressure temperature Power speed RFQ No Vendor Rev Remarks
area process Standby Elevation mm mm m³ m² m³/h head m empty kg water kg Construction Priority
[barg] [°C] [barg] [°C] [kW] [1/min]

V100 DS30 WV200 V100DS30WV200 Thin Film Evaporator Thin Film Evaporator W LE1336946-1 124.170 600 3798 NA 6 - - - - -1 197 -1 / 6 / 32 300 304L - - 2 17 1

V100 DS30 WV200ERW V100DS30WV200ERW Thin Film Evaporator Thin Film Evaporator NIL Future 124.170 nil future 1
Package unit for mechanical
V100 DS30 XA200 V100DS30XA200 Buffer fluid system W LE1336946-1 124.200 - - - - - - - - - - - - - - - 3 17 1
seal
Package unit for mechanical
V100 DS30 XA400 V100DS30XA400 Buffer fluid system W LE1336947-1 116.600 - - - - - - - - - - - - - - - 3 10 1
seal
V100 KF40 FA110 V100KF40FA110 Final Product Filter Basket Filter W LE1336948-1 100.550 219 980 - 0.20 6.00 - - - 0.150 40 -1 / 6 250 304L - - 3 33 1

V100 KF40 FA120 V100KF40FA120 Final Product Filter Basket filter S LE1336949-1 100.550 219 980 - 0.20 6.00 - - - 0.15 40 -1 / 6 250 304L - - 3 33 1

V100 KF40 FF110 V100KF40FF110 Final Product Filter Basket filter W LE1336948-1 100.450 219 980 - 0.20 6.00 - - - 5 40 -1 / 10 250 304L - - 3 33 1

V100 KF40 FF120 V100KF40FF120 Cartridge Filter Cartridge filter W LE1336948-1 100.550 - - - - 6.00 - - - 4 40 -1 / 10 / 10 250 304L - - 2 34 1

V100 KF40 FF210 V100KF40FF210 Final Product Filter Basket filter S LE1336949-1 100.550 219 980 - 0.20 6.00 - - - 5 40 -1 / 10 250 304L - - 3 33 1

V100 KF40 FF220 V100KF40FF220 Cartridge Filter Cartridge filter S LE1336949-1 100.550 - - - - 6.00 - - - 4 40 -1 / 10 / 10 250 304L - - 2 34 1

V100 KF40 PA110 V100KF40PA110 Internal gear pump Internal gear pump W LE1336948-1 100.450 - - 6 - - - 4.734 40 -1 / 16 200 304L 2.40 440 2 31 1
- -
V100 KF40 PA120 V100KF40PA120 Internal gear pump Internal gear pump S LE1336949-1 100.450 - - 6 - - - 4.734 40 -1 / 16 200 304L 2.40 440 2 31 1
- -
V100 KF40 RA110 V100KF40RA110 Final Product Vessel agitator vessel W LE1336948-1 108.800 2800 3730 25.00 - - - 16200 41200 0.005 40-80 -1 / 6 / 32 250 304L - - 2 10 1

V100 KF40 RA120 V100KF40RA120 Final Product Vessel agitator vessel S LE1336949-1 108.800 2800 3730 25 - - - 16200 41200 0.005 40-80 -1 / 6 / 32 250 304L - - 2 10 1
Agitator, blade typ, with
V100 KF40 RW110 V100KF40RW110 Agitator W LE1336948-1 108.800 1800 - - - - - - - 0.005 40-80 -1 / 6 250 304L 17.5 54 3 10 1
mechanical seal
Agitator, blade typ, with
V100 KF40 RW120 V100KF40RW120 Agitator S LE1336949-1 108.800 1800 - - - - - - - 0.005 40-80 -1 / 6 250 304L 17.5 54 3 10 1
mechanical seal
Package unit for mechanical
V100 KF40 XA110 V100KF40XA110 Buffer fluid system W LE1336948-1 108.800 - - - - - - - - - - - - - - - 3 10 1
seal
Package unit for mechanical
V100 KF40 XA120 V100KF40XA120 Buffer fluid system S LE1336949-1 108.800 - - - - - - - - - - - - - - - 3 10 1
seal
V100 VA10 BA320 V100VA10BA320 Collector Vessel vessel W LE1336977-1 116.600 219 500 0.02 - - - 75 95 -1 40 -1/6 250 304L - - 3 15 1

V100 VA10 BA420 V100VA10BA420 Collector Vessel vessel W LE1336977-1 116.600 219 500 0.02 - - - 75 95 -1 40 -1/6 250 304L - - 3 15 1

V100 VA10 FB320 V100VA10FB320 Separator Cooling trap, heating jacket W LE1336977-1 124.200 219 980 - - - - - - -1 20 - 1 / 6 / 10 250 304L - - 3 28 / 29 1

V100 VA10 FB420 V100VA10FB420 Separator Cooling trap, heating jacket W LE1336977-1 124.200 219 980 - - - - - - -1 20 - 1 / 6 / 10 250 304L - - 3 28 / 29 1

V100 VA10 VA310 V100VA10VA310 Roots pump with Shaft seal Roots blower, heating jacket W LE1336977-1 124.500 - - - - 4000 - - - -1.013 40 2 200 CI - - 2 28 / 29 1

V100 VA10 VA320 V100VA10VA320 Roots pump with Shaft seal Roots blower, heating jacket W LE1336977-1 124.500 - - - - 1000 - - - -1.010 40 2 200 CI - - 2 28 / 29 1
Dry claw or screw vacuum
V100 VA10 VA330 V100VA10VA330 Rotary vane vacuum pump W LE1336977-1 116.900 - - - - 250 - - - 0.100 40 3 120 CI - - 2 28 / 29 1
pump, heating jacket
V100 VA10 VA410 V100VA10VA410 Roots pump with Shaft seal Roots blower, heating jacket W LE1336977-1 124.500 - - - - 4000 - - - -1.013 40 2 200 CI - - 2 28 / 29 1

V100 VA10 VA420 V100VA10VA420 Roots pump with Shaft seal Roots blower, heating jacket W LE1336977-1 124.500 - - - - 1000 - - - -1.010 40 2 200 CI - - 2 28 / 29 1
Dry claw or screw vacuum
V100 VA10 VA430 V100VA10VA430 Rotary vane vacuum pump W LE1336977-1 116.900 - - - - 250 - - - 0.100 40 3 120 CI - - 2 28 / 29 1
pump, heating jacket
V200 BE10 BA100 V200BE10BA100 De-water Buffer vessel W LE1336961-2 104.160 1400 1300 2.50 - - - 1600 4300 0.000 30 -1 / 6 250 304L - - 3 15 1

V200 BE10 BA300 V200BE10BA300 HDI Buffer Vessel W LE1336960-1 101.085 2800 4000 25.00 - - - 11700 41800 0.005 40 -1 / 6 / 32 250 304L - - 2 16 Triofab 1

V200 BE10 FA100 V200BE10FA100 De-water Filter Basket Filter NIL Deleted 100.550 219 980 - 0.20 0.11 - - - 0.100 30 -1 / 6 250 304L - - 3 33 1

V200 BE10 FA110 V200BE10FA110 Offgas filter Basket Filter W LE1336961-2 108.800 219 980 - 0.20 1.12 - - - 0.010 30 -1 / 6 250 304L - - 3 33 1

V200 BE10 FA200 V200BE10FA200 PVA Filter Basket Filter - Deleted - - - - - - - - - - - - - - - - - DELETED 1

V200 BE10 FA300 V200BE10FA300 HDI Filter Basket Filter W LE1336960-1 100.550 219 980 - 0.20 13.00 - - - -0.013 60 -1 / 16 250 304L - - 3 33 1
Diaphragm pump, compressed
V200 BE10 PA110 V200BE10PA110 De-water Supply pump W LE1336961-2 100.750 - - - - 1 9.90 - - 0.930 30 6 120 304L - - 3 26 1
air drive
V200 BE10 PA120 V200BE10PA120 De-Water Feed pump Piston - Diaphragm pump W LE1336961-2 100.450 - - - - 0.09 - - - 25.000 30 30 120 304L - - 3 27 1
Diaphragm pump, compressed
V200 BE10 PA210 V200BE10PA210 PVA supply pump W LE1336960-1 100.750 - - - - 1 10.00 - - 0.760 60 6 120 304L - - 3 26 1
air drive to be chanegd
Diaphragm pump, compressed
V200 BE10 PA220 V200BE10PA220 TEP feed pump W LE1336960-1 100.750 - - - - 1 10.00 - - 0.880 30 6 120 304L - - 3 26 1
air drive to be changed
Centrifugal pump, magnetic
V200 BE10 PA300 V200BE10PA300 HDI Feed Pump W LE1336960-1 100.450 - - 10+3 40.00 - - 3.820 60 -1 / 16 250 316 - - 2 25 1
coupling - -
V200 BE10 PA400 V200BE10PA400 Offspec Product pump barrel pump W

V200 BE10 TK100 V200BE10TK100 De-Water Chamber brick wall construction by Civil - Deleted - - - - - - - - - - - - - - - - - DELETED 1

V200 BE10 TK200 V200BE10TK200 PVA Heating Chamber PVA Heating Chamber W LE1336960-1 100.450 3.5x3.5x2.5 - - - - - - - - - 6 58 304L - - 3 36 1

V200 BE10 VE200 V200BE10VE200 Fan fan for PVA Chamber W LE1336960-1 100.450 - - - - - - - - - - - - 304L - - 2 36 1
Heat Exchanger (steam Coil)
V200 BE10 WA200 V200BE10WA200 Heat Exchanger (steam coil) W LE1336960-1 100.450 - - - - - - - - 6/ 165 -1 / 10.2 204 304L - - 2 36 1
for PVA Chamber
V200 CA20 BA110 V200CA20BA110 Expansion Vessel vessel W LE1336962-1 126.440 600 1365 0.44 - - - 590 1020 10 180 32 250 304L - - 3 15 1

V200 CA20 BA120 V200CA20BA120 Expansion Vessel vessel S LE1336963-1 126.440 600 1365 0.44 - - - 590 1020 10 180 32 250 304L - - 3 15 1

V200 CA20 FB100 V200CA20FB100 Separator separator W LE1336962-1 124.200 219 980 - 0.20 250.00 - - - -0.513 10 -1 / 6 / 16 250 304L - - 3 33 1

V200 CA20 FB110 V200CA20FB110 Offgas washer separator W LE1336962-1 126.415 - - - - - - - - 3 120 -1 / 6 / 16 250 304L - - 2 From China 1

V200 CA20 FB120 V200CA20FB120 Offgas washer separator S LE1336963-1 126.415 - - - - - - - - 3 120 -1 / 6 / 16 250 304L - - 2 From China 1

V200 CA20 FB200 V200CA20FB200 Separator separator W LE1336964-1 108.800 219 980 - 0.20 250.00 - - - -0.513 10 -1 / 6 / 10 250 304L - - 3 33 1

V200 CA20 FF110 V200CA20FF110 Fluid Filter Basket Filter W LE1336962-1 116.600 219 980 - 0.20 30.60 - - - 0.200 120 -1 / 6 / 10 250 304L - - 3 33 1

V200 CA20 FF120 V200CA20FF120 Fluid Filter Basket Filter S LE1336963-1 116.600 219 980 - 0.20 30.60 - - - 0.200 120 -1 / 6 250 304L - - 3 33 1

V200 CA20 FF210 V200CA20FF210 Fluid Filter Basket Filter W LE1336964-1 100.550 219 980 - 0.20 10.00 - - - -0.300 80 -1 / 6 250 304L - - 3 33 1

V200 CA20 FF220 V200CA20FF220 Fluid Filter Basket Filter W LE1336964-1 100.550 219 980 - 0.20 10.00 - - - -0.300 80 -1 / 6 250 304L - - 3 33 1
Centrifugal pump, magnetic
V200 CA20 PA110 V200CA20PA110 Water Pump W LE1336962-1 116.900 - - 74.00 37.00 - - 13.5 180 25 250 CS - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V200 CA20 PA120 V200CA20PA120 Water Pump S LE1336963-1 116.600 - - 74.00 37.00 - - 13.5 180 25 250 CS - - 2 25 1
coupling - -

PC1600010R0 4 of 8
 Operating Operating Allowable Allowable Shaft Rotary
process sub Working / Supporting diameter length volume surface flow rate Delivery weight weight with Material of PEM
item Equipment No. Equipment Name Technical Describtion PID No. pressure temperature pressure temperature Power speed RFQ No Vendor Rev Remarks
area process Standby Elevation mm mm m³ m² m³/h head m empty kg water kg Construction Priority
[barg] [°C] [barg] [°C] [kW] [1/min]
Centrifugal pump, magnetic
V200 CA20 PA210 V200CA20PA210 Feed Pump W LE1336964-1 116.900 - - 1.78+8.09 34.00 - - 3.080 80 -1 / 16 250 316 - - 2 25 1
coupling - -
V200 CA20 RA110 V200CA20RA110 Reactor agitator vessel W LE1336962-1 124.170 2800 2980 20.00 - - - 11600 38900 -1 / 3 150 -1 / 6 / 32 250 304L - - 2 12 1

V200 CA20 RA120 V200CA20RA120 Reactor agitator vessel S LE1336963-1 124.170 2800 2980 20.00 - - - 11600 38900 -1 / 3 150 -1 / 6 / 32 250 304L - - 2 12 1

V200 CA20 RA200 V200CA20RA200 Crude Vessel agitator vessel W LE1336964-1 108.800 2800 3730 25.00 - - - 16200 41200 -0.500 80-120 -1 / 6 / 32 250 304L - - 2 10 1
Agitator, blade typ, with
V200 CA20 RW110 V200CA20RW110 Agitator W LE1336962-1 124.170 1800 - - - - - - - -1 / 3 150 -1 / 6 250 304L 15 54 3 12 1
mechanical seal
Agitator, blade typ, with
V200 CA20 RW120 V200CA20RW120 Agitator S LE1336963-1 124.170 1800 - - - - - - - -1 / 3 150 -1 / 6 250 304L 15 54 3 12 1
mechanical seal
Agitator, blade typ, with
V200 CA20 RW200 V200CA20RW200 Agitator W LE1336964-1 108.800 1800 - - - - - - - -0.500 80-120 -1 / 6 250 304L 17.5 54 3 10 1
mechanical seal
V200 CA20 WA111 V200CA20WA111 Plate Heat exchanger Plate heat exchanger W LE1336962-1 116.900 - - - 15.50 - - - - 13.5 / 16 204 -1 / 21 225 304L - - 2 19 1

V200 CA20 WA112 V200CA20WA112 Plate Heat exchanger Plate heat exchanger W LE1336962-1 116.900 - - - 15.50 - - - - 13.5 / 5 56 -1 / 21 225 304L - - 2 19 1

V200 CA20 WA121 V200CA20WA121 Plate Heat exchanger Plate heat exchanger S LE1336963-1 116.900 - - - 15.50 - - - - 13.5 / 16 204 -1 / 21 225 304L - - 2 19 1

V200 CA20 WA122 V200CA20WA122 Plate Heat exchanger Plate heat exchanger S LE1336963-1 116.900 - - - 15.50 - - - - 13.5 / 5 56 -1 / 21 225 304L - - 2 19 1
Package unit for mechanical
V200 CA20 XA110 V200CA20XA110 Buffer fluid system W LE1336962-1 124.170 - - - - - - - - - - - - - - - 3 12 1
seal
Package unit for mechanical
V200 CA20 XA120 V200CA20XA120 Buffer fluid system S LE1336963-1 124.170 - - - - - - - - - - - - - - - 3 12 1
seal
Package unit for mechanical
V200 CA20 XA200 V200CA20XA200 Buffer fluid system W LE1336964-1 108.800 - - - - - - - - - - - - - - - 3 10 1
seal
V200 DS30 BA111 V200DS30BA111 Expansion Vessel vessel W LE1336965-1 126.440 600 1365 0.44 - - - 590 1020 16 200 32 250 304L - - 3 15 1

V200 DS30 BA112 V200DS30BA112 Level Pot vessel W LE1336965-1 119.800 219 524 0.02 - - - 135 150 -1 100-120 -1/6 250 304L - - 3 15 1

V200 DS30 BA113 V200DS30BA113 Distillate Measuring pot vessel W LE1336965-1 119.800 219 500 0.02 - - - 65 80 -1 65 -1 / 6 250 304L - - 3 15 1

V200 DS30 BA121 V200DS30BA121 Expansion Vessel vessel W LE1336966-1 126.440 600 1365 0.44 - - - 590 1020 16 200 32 250 304L - - 3 15 1

V200 DS30 BA122 V200DS30BA122 Level Pot vessel W LE1336966-1 119.800 219 524 0.02 - - - 135 150 -1 100-120 - 1 / 10 250 304L - - 3 15 1

V200 DS30 BA123 V200DS30BA123 Distillate Measuring pot vessel W LE1336966-1 119.800 219 500 0.02 - - - 65 80 -1 73 - 1 / 10 250 304L - - 3 15 1

V200 DS30 BA211 V200DS30BA211 Expansion Vessel vessel W LE1336967-1 126.440 600 1365 0.44 - - - 590 1020 16 200 32 250 304L - - 3 15 1

V200 DS30 BA212 V200DS30BA212 Level Pot vessel W LE1336967-1 119.800 219 524 0.02 - - - 135 150 -1 125 -1/6 250 304L - - 3 15 1

V200 DS30 BA213 V200DS30BA213 Distillate Measuring pot vessel W LE1336967-1 119.800 219 500 0.02 - - - 65 80 -1 58 -1 / 6 250 304L - - 3 15 1

V200 DS30 BA221 V200DS30BA221 Expansion Vessel vessel W LE1336968-1 126.440 600 1365 0.44 - - - 590 1020 16 200 32 250 304L - - 3 15 1

V200 DS30 BA222 V200DS30BA222 Level Pot vessel W LE1336968-1 119.800 219 524 0.02 - - - 135 150 -1 125 -1/6 250 304L - - 3 15 1

V200 DS30 BA223 V200DS30BA223 Distillate Measuring pot vessel W LE1336968-1 119.800 219 500 0.02 - - - 65 80 -1 56 -1 / 6 250 304L - - 3 15 1

V200 DS30 FA111 V200DS30FA111 Fluid Filter Basket Filter W LE1336965-1 116.600 219 980 - 0.20 10.00 - - - -0.500 100-120 -1 / 6 250 304L - - 3 33 1

V200 DS30 FA111ERW V200DS30FA111ERW Basket Filter Basket Filter NIL Future 116.600 - - - nil future 1

V200 DS30 FA121 V200DS30FA121 Fluid Filter Basket Filter W LE1336966-1 116.600 219 980 - 0.20 10.00 - - - -0.500 100-120 -1 / 6 250 304L - - 3 33 1

V200 DS30 FA121ERW V200DS30FA121ERW Basket Filter Basket Filter NIL Future 116.600 - - - nil future 1

V200 DS30 FA211 V200DS30FA211 Fluid Filter Basket Filter W LE1336967-1 116.600 219 980 - 0.20 10.00 - - - -0.670 125 -1 / 6 250 304L - - 3 33 1

V200 DS30 FA211ERW V200DS30FA211ERW Basket Filter Basket Filter NIL Future 116.600 - - - nil future 1

V200 DS30 FA221 V200DS30FA221 Fluid Filter Basket Filter W LE1336968-1 116.600 219 980 - 0.20 10.00 - - - -0.670 125 -1 / 6 250 304L - - 3 33 1

V200 DS30 FA221ERW V200DS30FA221ERW Basket Filter Basket Filter NIL Future 116.600 - - - nil future 1
Centrifugal pump, magnetic
V200 DS30 PA111 V200DS30PA111 Water Pump W LE1336965-1 116.900 - - 25.00 27.00 - - 18.5 200 25 250 CS - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V200 DS30 PA111ERW V200DS30PA111ERW WATER PUMP NIL Future 116.900 - - - - - - - - nil future 1
coupling
Centrifugal pump, magnetic
V200 DS30 PA112 V200DS30PA112 Feed Pump W LE1336965-1 116.900 - - 0.81+10 13.00 - - 0.860 120 - 1 / 16 250 316 - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V200 DS30 PA112ERW V200DS30PA112ERW FEED PUMP NIL Future 116.900 - - - - - - - - nil future 1
coupling
Centrifugal pump, magnetic
V200 DS30 PA121 V200DS30PA121 Water Pump W LE1336966-1 116.900 - - 25.00 27.00 - - 18.5 200 25 250 CS - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V200 DS30 PA121ERW V200DS30PA121ERW WATER PUMP NIL Future 116.900 - - - - - - - - nil future 1
coupling
Centrifugal pump, magnetic
V200 DS30 PA122 V200DS30PA122 Feed Pump W LE1336966-1 116.900 - - 0.69+10 9.00 - - 0.470 120 16 250 316 - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V200 DS30 PA122ERW V200DS30PA122ERW FEED PUMP NIL Future 116.900 - - - - - - - - nil future 1
coupling
Centrifugal pump, magnetic
V200 DS30 PA211 V200DS30PA211 Water Pump W LE1336967-1 116.900 - - 25.00 25.00 - - 18 200 25 250 CS - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V200 DS30 PA211ERW V200DS30PA211ERW WATER PUMP NIL Future 116.900 - - - - - - - - nil future 1
coupling
V200 DS30 PA212 V200DS30PA212 Internal gear pump Internal gear pump W LE1336967-1 116.900 - - 6 - - - 1 125 25 200 304L 1.53 488 2 31 1
- -
V200 DS30 PA212ERW V200DS30PA212ERW Internal gear pump Internal gear pump NIL Future 116.900 - - - nil future 1
Centrifugal pump, magnetic
V200 DS30 PA221 V200DS30PA221 Water Pump W LE1336968-1 116.900 - - 25.00 25.00 - - 18 200 25 250 CS - - 2 25 1
coupling - -
Centrifugal pump, magnetic
V200 DS30 PA221ERW V200DS30PA221ERW WATER PUMP NIL Future 116.900 - - - - - - - - nil future 1
coupling
V200 DS30 PA222 V200DS30PA222 Internal gear pump Internal gear pump W LE1336968-1 116.900 - - 6 - - - 1 125 -1 / 16 200 304L 1.53 488 2 31 1
- -
V200 DS30 PA222ERW V200DS30PA222ERW Internal gear pump Internal gear pump NIL Future 116.900 - - - nil future 1

V200 DS30 RW210 V200DS30RW210 wiper wiper for thin film evaporator W LE1336967-1 124.170 - 2570 - - - - - - -1 160 / 121 -1 / 6 250 316Ti 7 63 3 17 1

V200 DS30 RW220 V200DS30RW220 wiper wiper for thin film evaporator W LE1336968-1 124.170 - 2570 - - - - - - -1 160 / 121 -1 / 6 250 316Ti 7 63 3 17 1

V200 DS30 WA111 V200DS30WA111 Condenser Heat exchanger, U-Turn W LE1336965-1 127.200 500 3540 - 24 - - 1700 2500 -1 145 -1 / 6 / 10 250 304L - - 2 18 1

V200 DS30 WA111ERW V200DS30WA111ERW Condenser Heat exchanger, U-Turn NIL Future 127.200 nil future 1

V200 DS30 WA112 V200DS30WA112 Additional Condenser Heat exchanger, U-Turn W LE1336965-1 128.170 500 1548 - 6.50 - - 780 1100 -1 120 -1 / 6 / 10 250 304L - - 2 18 1

V200 DS30 WA112ERW V200DS30WA112ERW Additional Condenser Heat exchanger, U-Turn NIL Future 128.170 nil future 1

PC1600010R0 5 of 8
 Operating Operating Allowable Allowable Shaft Rotary
process sub Working / Supporting diameter length volume surface flow rate Delivery weight weight with Material of PEM
item Equipment No. Equipment Name Technical Describtion PID No. pressure temperature pressure temperature Power speed RFQ No Vendor Rev Remarks
area process Standby Elevation mm mm m³ m² m³/h head m empty kg water kg Construction Priority
[barg] [°C] [barg] [°C] [kW] [1/min]

V200 DS30 WA113 V200DS30WA113 Plate Heat exchanger Plate heat exchanger W LE1336965-1 116.900 - - - 5.70 - - - - 18.5 / 16 200 -1 / 21 225 304L - - 2 19 1

V200 DS30 WA113ERW V200DS30WA113ERW Plate heat exchanger Plate heat exchanger NIL Future 116.900 - - - - - - - - - - - - - - - nil future 1

V200 DS30 WA121 V200DS30WA121 Condenser Heat exchanger, U-Turn W LE1336966-1 127.200 500 3540 - 24 - - 1700 2500 -1 145 -1 / 6 / 10 250 304L - - 2 18 1

V200 DS30 WA121ERW V200DS30WA121ERW Condenser Heat exchanger, U-Turn NIL Future 127.200 nil future 1

V200 DS30 WA122 V200DS30WA122 Additional Condenser Heat exchanger, U-Turn W LE1336966-1 128.170 500 1548 - 6.50 - - 780 1100 -1 120 -1 / 6 / 10 250 304L - - 2 18 1

V200 DS30 WA122ERW V200DS30WA122ERW Additional Condenser Heat exchanger, U-Turn NIL Future 128.170 nil future 1

V200 DS30 WA123 V200DS30WA123 Plate Heat exchanger Plate heat exchanger W LE1336966-1 120.100 - - - 5.70 - - - - 18.5 / 16 200 -1 / 21 225 304L - - 2 19 1

V200 DS30 WA123ERW V200DS30WA123ERW Plate heat exchanger Plate heat exchanger NIL Future 120.100 - - - - - - - - - - - - - - - nil future 1

V200 DS30 WA211 V200DS30WA211 Additional Condenser Heat exchanger, U-Turn W LE1336967-1 124.170 800 1280 0.77 5.50 - - 1550 2300 -1 120 -1 / 6 / 10 200 304L - - 2 16 Triofab 1

V200 DS30 WA211ERW V200DS30WA211ERW CONDENSER Heat exchanger, U-Turn NIL Future 124.170 nil future 1

V200 DS30 WA212 V200DS30WA212 Plate Heat exchanger Plate heat exchanger W LE1336967-1 116.900 - - - 5.70 - - - - 18 / 16 200 -1 / 21 225 304L - - 2 19 1

V200 DS30 WA212ERW V200DS30WA212ERW Plate heat exchanger Plate heat exchanger NIL Future 116.900 - - - - - - - - - - - - - - - nil future 1

V200 DS30 WA221 V200DS30WA221 Additional Condenser Heat exchanger, U-Turn W LE1336968-1 124.170 800 1280 0.77 5.50 - - 1550 2300 -1 120 -1 / 6 / 10 200 304L - - 2 16 Triofab 1

V200 DS30 WA221ERW V200DS30WA221ERW CONDENSER Heat exchanger, U-Turn NIL Future 124.170 nil future 1

V200 DS30 WA222 V200DS30WA222 Plate Heat exchanger Plate heat exchanger W LE1336968-1 120.100 - - - 5.70 - - - - 18 / 16 200 -1 / 21 225 304L - - 2 19 1

V200 DS30 WA222ERW V200DS30WA222ERW Plate heat exchanger Plate heat exchanger NIL Future 120.100 - - - - - - - - - - - - - - - nil future 1

V200 DS30 WA223 V200DS30WA223 Plate Heat exchanger Plate heat exchanger W LE1336968-1 120.100 - - - 5.70 - - - - 1.35 / 4.5 120 -1 / 21 225 304L - - 2 19 1
Falling Film Evaporator with
V200 DS30 WV110 V200DS30WV110 Heat exchanger, tube bundle W LE1336965-1 124.170 500 / 1200 5893 - 21.60 - - 1820 4820 -1 60-237 -1 / 6 / 32 250 304L - - 2 17 1
Separator
V200 DS30 WV110ERW V200DS30WV110ERW FALLING FILM EVAPORATOR Heat exchanger, tube bundle NIL Future 124.170 nil future 1
Falling Film Evaporator with
V200 DS30 WV120 V200DS30WV120 Heat exchanger, tube bundle W LE1336966-1 124.170 500 / 1200 5893 - 21.60 - - 1820 4820 -1 174-176 -1 / 6 / 32 250 304L - - 2 17 1
Separator
V200 DS30 WV120ERW V200DS30WV120ERW FALLING FILM EVAPORATOR Heat exchanger, tube bundle NIL Future 124.170 nil future 1

V200 DS30 WV210 V200DS30WV210 Short Path Evaporator Short Path Evaporator W LE1336967-1 124.170 900 3995 - 6.50 - - - - -1 120-160 -1 / 6 / 10 / 32 250 316Ti - - 2 17 1

V200 DS30 WV210ERW V200DS30WV210ERW Short Path Evaporator Short Path Evaporator NIL Future 124.170 nil future 1

V200 DS30 WV220 V200DS30WV220 Short Path Evaporator Short Path Evaporator W LE1336968-1 124.170 900 3995 - 6.50 - - - - -1 120-160 -1 / 6 / 10 / 32 250 316Ti - - 2 17 1

V200 DS30 WV220ERW V200DS30WV220ERW Short Path Evaporator Short Path Evaporator NIL Future 124.170 nil future 1
Package unit for mechanical
V200 DS30 XA210 V200DS30XA210 Buffer fluid system W LE1336967-1 124.170 - - - - - - - - - - - - - - - 3 17 1
seal
Package unit for mechanical
V200 DS30 XA220 V200DS30XA220 Buffer fluid system W LE1336968-1 124.170 - - - - - - - - - - - - - - - 3 17 1
seal
V200 KF40 BA100 V200KF40BA100 Additive pot vessel W LE1336969-1 108.800 219 422 0.02 - - - 45 60 0 30 -1 / 6 250 304L - - 3 15 1

V200 KF40 BA200 V200KF40BA200 Additive pot vessel S LE1336970-1 108.800 219 422 0.02 - - - 45 60 0 30 -1 / 6 250 304L - - 3 15 1

V200 KF40 FA110 V200KF40FA110 Final Product Filter Basket Filter W LE1336969-1 100.550 219 980 - 0.20 6.00 - - - 0.150 40 -1 / 6 250 304L - - 3 33 1

V200 KF40 FA120 V200KF40FA120 Final Product Filter Basket Filter S LE1336970-1 100.550 219 980 - 0.20 6.00 - - - 0.150 40 -1 / 6 250 304L - - 3 33 1

V200 KF40 FF110 V200KF40FF110 Final Product Filter Basket filter W LE1336969-1 100.550 219 980 - 0.20 6.00 - - - 5 40 -1 / 10 / 10 250 304L - - 3 33 1

V200 KF40 FF120 V200KF40FF120 Cartridge Filter Cartridge filter W LE1336969-1 100.550 - - - - 6.00 - - - 4.5 40 -1 / 10 / 10 250 304L - - 2 34 1

V200 KF40 FF210 V200KF40FF210 Final Product Filter Basket filter S LE1336970-1 100.550 219 980 - 0.20 6.00 - - - 5 40 -1 / 10 / 10 250 304L - - 3 33 1

V200 KF40 FF220 V200KF40FF220 Cartridge Filter Cartridge filter S LE1336970-1 100.550 - - - - 6.00 - - - 4.5 40 -1 / 10 / 10 250 304L - - 2 34 1

V200 KF40 PA110 V200KF40PA110 Internal gear pump Internal gear pump W LE1336969-1 100.450 - - 6 - - - 5.090 40 -1 / 16 200 304L 2.29 369 2 31 1
- -
V200 KF40 PA120 V200KF40PA120 Internal gear pump Internal gear pump S LE1336970-1 100.450 - - 6 - - - 5.090 40 -1 / 16 200 304L 2.29 369 2 31 1
- -
V200 KF40 RA110 V200KF40RA110 Final Product Vessel agitator vessel W LE1336969-1 108.800 2800 3730 25 - - - 16200 41200 0.005 40 -1 / 6 / 32 250 304L - - 2 10 1

V200 KF40 RA120 V200KF40RA120 Final Product Vessel agitator vessel S LE1336970-1 108.800 2800 3730 25 - - - 16200 41200 0.005 40 -1 / 6 / 32 250 304L - - 2 10 1
Agitator, blade typ, with
V200 KF40 RW110 V200KF40RW110 Agitator W LE1336969-1 108.800 1800 - - - - - - - 0.005 40 -1 / 6 250 304L 17.5 54 3 10 1
mechanical seal
Agitator, blade typ, with
V200 KF40 RW120 V200KF40RW120 Agitator S LE1336970-1 108.800 1800 - - - - - - - 0.005 40 -1 / 6 250 304L 17.5 54 3 10 1
mechanical seal
Package unit for mechanical
V200 KF40 XA110 V200KF40XA110 Buffer fluid system W LE1336969-1 108.800 - - - - - - - - - - - - - - - 3 10 1
seal
Package unit for mechanical
V200 KF40 XA120 V200KF40XA120 Buffer fluid system S LE1336970-1 108.800 - - - - - - - - - - - - - - - 3 10 1
seal
V200 VA10 BA320 V200VA10BA320 Collector Vessel Collector Vessel W LE1336978-1 116.600 219 500 0.02 - - - 75 95 -1 40 -1/6 250 304L - - 3 15 1

V200 VA10 BA420 V200VA10BA420 Collector Vessel Collector Vessel W LE1336978-1 116.600 219 500 0.02 - - - 75 95 -1 40 -1/6 250 304L - - 3 15 1

V200 VA10 FB320 V200VA10FB320 Separator Cooling trap, heating jacket W LE1336978-1 124.200 219 980 - - - - - - -1 20 - 1 / 6 / 10 250 304L - - 3 28 / 29 1

V200 VA10 FB420 V200VA10FB420 Separator Cooling trap, heating jacket W LE1336978-1 124.200 219 980 - - - - - - -1 20 - 1 / 6 / 10 250 304L - - 3 28 / 29 1

V200 VA10 VA310 V200VA10VA310 Roots pump with Shaft seal Roots blower, heating jacket W LE1336978-1 124.500 - - - - 4000 - - - -1.013 40 2 200 CI - - 2 28 / 29 1

V200 VA10 VA320 V200VA10VA320 Roots pump with Shaft seal Roots blower, heating jacket W LE1336978-1 124.500 - - - - 1000 - - - -1.010 40 2 200 CI - - 2 28 / 29 1
Dry claw or screw vacuum
V200 VA10 VA330 V200VA10VA330 Rotary vane vacuum pump W LE1336978-1 116.900 - - - - 250 - - - 0.100 40 3 120 CI - - 2 28 / 29 1
pump, heating jacket
V200 VA10 VA410 V200VA10VA410 Roots pump with Shaft seal Roots blower, heating jacket W LE1336978-1 124.500 - - - - 4000 - - - -1.013 40 2 200 CI - - 2 28 / 29 1

V200 VA10 VA420 V200VA10VA420 Roots pump with Shaft seal Roots blower, heating jacket W LE1336978-1 124.500 - - - - 1000 - - - -1.010 40 2 200 CI - - 2 28 / 29 1
Dry claw or screw vacuum
V200 VA10 VA430 V200VA10VA430 Rotary vane vacuum pump W LE1336978-1 116.900 - - - - 250 - - - 0.100 40 3 120 CI - - 2 28 / 29 1
pump, heating jacket
V200 VA20 BA100 V200VA20BA100 Collector Vessel vessel W LE1336979-1 116.600 219 500 0.02 - - - 75 95 -0.500 40 -1/6 250 304L - - 3 15 1

V200 VA20 FB100 V200VA20FB100 Separator separator W LE1336979-1 119.320 219 980 - 0.20 250.00 - - - -0.500 40 -1/6/10 250 304L - - 3 28 / 29 1
Dry claw or screw vacuum
V200 VA20 VA100 V200VA20VA100 Rotary vane vacuum pump W LE1336979-1 116.900 - - - - 250 - - - 0.130 40 3 120 CI - - 2 28 / 29 1
pump, heating jacket

PC1600010R0 6 of 8
 Operating Operating Allowable Allowable Shaft Rotary
process sub Working / Supporting diameter length volume surface flow rate Delivery weight weight with Material of PEM
item Equipment No. Equipment Name Technical Describtion PID No. pressure temperature pressure temperature Power speed RFQ No Vendor Rev Remarks
area process Standby Elevation mm mm m³ m² m³/h head m empty kg water kg Construction Priority
[barg] [°C] [barg] [°C] [kW] [1/min]

V200 WS10 BA100 V200WS10BA100 Wash liquid buffer Vessel W LE1336974-1 108.800 1400 1300 2.50 - - - 2050 4750 3 120 -1 / 6 250 304L - - 3 15 1

V200 WS10 FA110 V200WS10FA110 Basket Filter Basket Filter W LE1336974-1 116.600 219 980 - 0.20 0.20 - - - 3.000 100 -1 / 6 / 10 250 304L - - 3 33 1

V200 WS10 FA120 V200WS10FA120 Basket Filter Basket filter W LE1336974-1 100.550 219 980 - 0.20 13.00 - - - 3.300 120 -1 / 6 250 304L - - 3 33 1
Column with packing, heating
V200 WS10 KF100 V200WS10KF100 Wash Column W LE1336974-1 116.600 - - - - - - - - 3 120-130 -1 / 16 / 10 250 304L - - 2 From China 1
coil
Centrifugal pump, magnetic
V200 WS10 PA100 V200WS10PA100 Supply Pump W LE1336974-1 100.450 - - 12.00 31.00 - - 6.6 120 -1 / 16 250 316 - - 2 25 1
coupling - -
V200 WS10 WA100 V200WS10WA100 Condenser Heat exchanger, U-Turn W LE1336974-1 120.370 500 4052 - 24.00 - - 1700 2600 3 130 -1 / 10 / 10 250 304L - - 2 18 1

V200 WS10 WA200 V200WS10WA200 HDI Preheater Heat exchanger, U-Turn W LE1336974-1 120.370 500 1772 - 6.50 - - 900 1350 5 60 -1 / 10 250 304L - - 2 18 1

V300 KF40 BA100 V300KF40BA100 Additive Pot vessel W LE1336971-1 108.800 219 422 0.02 - - - 45 60 0 30 -1 / 6 250 304L - - 3 15 1

V300 KF40 FA110 V300KF40FA110 Basket Filter Basket Filter W LE1336971-1 100.550 219 980 - 0.20 6.00 - - - 0.150 40 -1 / 6 250 304L - - 3 33 1

V300 KF40 FF110 V300KF40FF110 Basket Filter Basket filter W LE1336971-1 100.750 219 980 - 0.20 6.00 - - - 5 40 -1 / 10 / 10 250 304L - - 3 33 1

V300 KF40 FF120 V300KF40FF120 Cartridge Filter Cartridge filter W LE1336971-1 100.550 - - - - 6.00 - - - 4.5 40 -1 / 10 / 10 250 304L - - 2 34 1

V300 KF40 PA110 V300KF40PA110 Internal gear pump Internal gear pump W LE1336971-1 100.750 - - 6 - - - 5.030 40 -1 / 16 200 304L 2.29 369 2 31 1
- -
V300 KF40 RA110 V300KF40RA110 Final Product Buffer agitator vessel W LE1336971-1 108.800 2800 3730 25 - - - 16200 41200 0.005 40 -1 / 6 / 32 250 304L - - 2 10 1
Agitator, blade typ, with
V300 KF40 RW110 V300KF40RW110 Agitator W LE1336971-1 108.800 1800 - - - - - - - 0.005 40 -1 / 6 250 304L 17.5 54 3 10 1
mechanical seal
Package unit for mechanical
V300 KF40 XA110 V300KF40XA110 Buffer fluid system W LE1336971-1 108.800 - - - - - - - - - - - - - - - 3 10 1
seal
-0.02/
V800 TA10 BA100 V800TA10BA100 TDI Tank Tank W LE1336935-1 100.600 7000 5970 246.00 - - - 20700 266700 0.005 40 120 304L - - 2 14 1
+0.06
-0.02/
V800 TA10 BA110 V800TA10BA110 Breather Vessel vessel W LE1336935-1 107.830 400 1075 0.16 - - - 250 375 -0.0044/0.03 40 120 304L - - 3 15 1
+0.06
-0.02/
V800 TA10 BA210 V800TA10BA210 Breather Vessel vessel W LE1336935-1 107.780 400 1075 0.16 - - - 250 375 -0.0044/0.03 30 120 304L - - 3 15 1
+0.06
-0.02/
V800 TA10 BA200 V800TA10BA200 HDI Tank Tank W LE1336935-1 100.600 7000 5970 246.00 - - - 20700 266700 0.005 30 120 304L - - 2 14 1
+0.06
V800 TA10 FF100 V800TA10FF100 TDI Unloading filter Basket filter W LE1336931-1 103.000 219 980 - 0.50 10.00 - - - 2.200 30 -1 / 6 250 304L - - 3 33 1

V800 TA10 FF200 V800TA10FF200 HDI Unloading filter Basket filter W LE1336931-1 103.000 219 980 - 0.50 10.00 - - - 1.800 30 -1 / 6 250 304L - - 3 33 1
Diaphragm pump, compressed
V800 TA10 PA110 V800TA10PA110 TDI unloading pump W LE1336931-1 100.500 - - - - 10.00 15.00 - - 2.200 30 6 120 304L - - 3 26 1
air drive
Centrifugal pump, magnetic
V800 TA10 PA120 V800TA10PA120 TDI Supply Pump W LE1336935-1 100.000 - - 12+3 14.00 - - 3.120 40 -1/16 250 316 - - 2 25 1
coupling - -
Diaphragm pump, compressed
V800 TA10 PA210 V800TA10PA210 HDI unloading pump W LE1336931-1 100.500 - - - - 10.00 15.00 - - 1.840 30 6 120 304L - - 3 26 1
air drive
Centrifugal pump, magnetic
V800 TA10 PA220 V800TA10PA220 HDI Supply Pump W LE1336935-1 100.000 - - 12+3 41.00 - - 1.700 30 -1/16 250 316 - - 2 25 1
coupling - -
-0.02/
V800 TA20 BA100 V800TA20BA100 EA Tank Tank W LE1336936-1 100.600 5000 5970 124.00 - - - 13400 137400 0.005 30 120 304L - - 2 14 1
+0.06
-0.02/
V800 TA20 BA200 V800TA20BA200 MPA TANK Tank W LE1336937-1 100.600 3500 5970 61.00 - - - 8300 69300 0.005 30 120 304L - - 2 14 1
+0.06
-0.02/
V800 TA20 BA300 V800TA20BA300 BA Tank Tank W LE1336937-1 100.600 3500 5970 61.00 - - - 8300 69300 0.005 30 120 304L - - 2 14 1
+0.06
-0.02/
V800 TA20 BA400 V800TA20BA400 Xylol TANK Tank W LE1336938-1 100.600 3500 5970 61.00 - - - 8300 69300 0.005 30 120 304L - - 2 14 1
+0.06
-0.02/
V800 TA20 BA700 V800TA20BA700 Solvent Naphta TANK Tank W LE1336938-1 100.600 3500 5970 61.00 - - - 8300 69300 0.005 30 120 304L - - 2 14 1
+0.06
V800 TA20 FF100 V800TA20FF100 EA Unloading filter Basket filter W LE1336932-1 103.000 219 980 - 0.50 10.00 - - - 1.450 30 -1 / 6 250 304L - - 3 33 1

V800 TA20 FF200 V800TA20FF200 MPA Unloading filter Basket filter W LE1336932-1 103.000 219 980 - 0.50 10.00 - - - 1.540 30 -1 / 6 250 304L - - 3 33 1

V800 TA20 FF300 V800TA20FF300 BA Unloading filter Basket filter W LE1336933-0 103.000 219 980 - 0.50 10.00 - - - 1.510 30 -1 / 6 250 304L - - 3 33 1

V800 TA20 FF400 V800TA20FF400 Xylol Unloading filter Basket filter W LE1336933-0 103.000 219 980 - 0.50 10.00 - - - 1.480 30 -1 / 6 250 304L - - 3 33 1

V800 TA20 FF500 V800TA20FF500 DEG Unloading filter Basket filter W LE1336934-0 103.000 219 980 - 0.50 10.00 - - - 2.150 30 -1 / 6 250 304L - - 3 33 1

V800 TA20 FF600 V800TA20FF600 DesN 3300 Unloading filter Basket filter W LE1336934-0 103.000 219 980 - 0.50 10.00 - - - 6.100 40 -1 / 6 250 304L - - 3 33 1

V800 TA20 FF700 V800TA20FF700 Solvent Naptha Unloading filter Basket filter W LE1336933-0 103.000 219 980 - 0.50 10.00 - - - 1.430 30 -1 / 6 250 304L - - 3 33 1

V800 TA20 FF800 V800TA20FF800 TMP Unloading filter Basket filter W LE1336934-0 103.000 219 980 - 0.50 10.00 - - - 2.120 80 -1 / 6 250 304L - - 3 33 1
Diaphragm pump, compressed
V800 TA20 PA110 V800TA20PA110 EA unloading pump W LE1336932-1 100.500 - - - - 10 16.00 - - 1.450 30 6 120 304L - - 3 26 1
air drive
Centrifugal pump, magnetic
V800 TA20 PA120 V800TA20PA120 EA Supply Pump W LE1336936-1 100.300 - - 2.25+2 25.00 - - 2.600 30 -1/16 250 316 - - 2 25 1
coupling - -
Diaphragm pump, compressed
V800 TA20 PA210 V800TA20PA210 MPA unloading pump W LE1336932-1 100.500 - - - - 10 15.90 - - 1.540 30 6 120 304L - - 3 26 1
air drive
Centrifugal pump, magnetic
V800 TA20 PA220 V800TA20PA220 MPA Supply Pump W LE1336937-1 100.300 - - 2+2 12.00 - - 1.280 30 -1/16 250 316 - - 2 25 1
coupling - -
Diaphragm pump, compressed
V800 TA20 PA310 V800TA20PA310 BA Unloading pump W LE1336933-0 100.500 - - - - 10.00 17.00 - - 1.510 30 6 120 304L - - 3 26 1
air drive
Centrifugal pump, magnetic
V800 TA20 PA320 V800TA20PA320 BA Supply pump W LE1336937-1 100.300 - - 2+2 13.00 - - 1.260 30 -1/16 250 316 - - 2 25 1
coupling - -
Diaphragm pump, compressed
V800 TA20 PA410 V800TA20PA410 Xylol unloading pump W LE1336933-0 100.500 - - - - 10.00 17.00 - - 1.480 30 6 120 304L - - 3 26 1
air drive
Centrifugal pump, magnetic
V800 TA20 PA420 V800TA20PA420 Xylol Supply Pump W LE1336938-1 100.300 - - 2+2 13.00 - - 1.230 30 -1 / 16 250 316 - - 2 25 1
coupling - -
Diaphragm pump, compressed
V800 TA20 PA500 V800TA20PA500 DEG supply pump W LE1336934-0 100.300 - - - - 10.00 20.00 - - 2.150 30 6 120 304L - - 3 26 1
air drive
V800 TA20 PA600 V800TA20PA600 Internal gear pump Internal gear pump W LE1336934-0 100.300 - - 10.00 - - - 6.100 40 -1 / 16 200 304L 5.19 470 2 31 1
- -
Diaphragm pump, compressed
V800 TA20 PA710 V800TA20PA710 Solvent Naphta unloading pump W LE1336933-0 100.500 - - - - 10.00 16.10 - - 1.430 30 6 120 304L - - 3 26 1
air drive
Centrifugal pump, magnetic
V800 TA20 PA720 V800TA20PA720 Solvent Naphta Supply Pump W LE1336938-1 100.300 - - 2+2 13.00 - - 1.200 30 -1 / 16 250 316 - - 2 25 1
coupling - -
Diaphragm pump, compressed
V800 TA20 PA800 V800TA20PA800 TMP supply pump W LE1336934-0 100.300 - - - - 10.00 20.00 - - 2.120 80 6 120 304L - - 3 26 1
air drive
V900 UB50 FB100 V900UB50FB100 separator separator W LE1336972-1 100.450 - - - - - - 0 40 - 1 / 6 / 10 250 304L - - 3 33 1
219 980
V900 UB50 BA100 V900UB50BA100 Collector Vessel vessel W LE1336972-1 304L 2
roller conveyor, inside package
V900 UB50 HA100 V900UB50HA100 roller conveyor W LE1336972-1 100.450 - - - - - - - - - - - - - - - 2 38 1
drum filling
roller conveyor, inside package
V900 UB50 HA110 V900UB50HA110 roller conveyor W LE1336972-1 100.450 - - - - - - - - - - - - - - - 2 38 1
drum filling
roller conveyor, inside package
V900 UB50 HA120 V900UB50HA120 roller conveyor W LE1336972-1 100.450 - - - - - - - - - - - - - - - 2 38 1
drum filling

PC1600010R0 7 of 8
 Operating Operating Allowable Allowable Shaft Rotary
process sub Working / Supporting diameter length volume surface flow rate Delivery weight weight with Material of PEM
item Equipment No. Equipment Name Technical Describtion PID No. pressure temperature pressure temperature Power speed RFQ No Vendor Rev Remarks
area process Standby Elevation mm mm m³ m² m³/h head m empty kg water kg Construction Priority
[barg] [°C] [barg] [°C] [kW] [1/min]
roller conveyor, inside package
V900 UB50 HA200 V900UB50HA200 roller conveyor W LE1336972-1 100.450 - - - - - - - - - - - - - - - 2 38 1
drum filling
roller conveyor, inside package
V900 UB50 HA210 V900UB50HA210 roller conveyor W LE1336972-1 100.450 - - - - - - - - - - - - - - - 2 38 1
drum filling
roller conveyor, inside package
V900 UB50 HA220 V900UB50HA220 roller conveyor W LE1336972-1 100.450 - - - - - - - - - - - - - - - 2 38 1
drum filling
Drum Filling Device Package
V900 UB50 XA100 V900UB50XA100 Drum Filling Station W LE1336972-1 100.450 - - - - 6.00 - - - 1 40 - - 304L - - 2 38 1
unit
Drum Filling Device Package
V900 UB50 XA200 V900UB50XA200 Drum Filling Station W LE1336972-1 100.450 - - - - 6.00 - - - 1 40 - - 304L - - 2 38 1
unit
E600 ER61 ZZ001 E600ER61ZZ001 Air Handling Unit DX Type W NIL 124.200 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ002 E600ER61ZZ002 Air Handling Unit DX Type S NIL 124.200 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ003 E600ER61ZZ003 Condensing Unit condensing unit for AHU W NIL 124.200 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ004 E600ER61ZZ004 Condensing Unit condensing unit for AHU S NIL 124.200 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ005 E600ER61ZZ005 Chemical Filter unit Chemical Filter unit for AHU W NIL 124.200 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ006 E600ER61ZZ006 Blower for Chemical filter Blower for Chemical filter W NIL 124.200 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ007 E600ER61ZZ007 Blower for Chemical filter Blower for Chemical filter S NIL 124.200 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ008 E600ER61ZZ008 Forklift forklift W NIL 100.450 - - - - - - - - - - - - - - - 3 41 1

E600 ER61 ZZ009 E600ER61ZZ009 Forklift forklift W NIL 100.450 - - - - - - - - - - - - - - - 3 41 1

E600 ER61 ZZ010 E600ER61ZZ010 Cage Lift cage hoist W NIL 100.450 - - 2T - - - - - - - - - - - - 3 42 1
2 TR for conference room El
E600 ER61 ZZ011 E600ER61ZZ011 Split AC W NIL 120.400 - - - - - - - - - - - - - - - 3 40 1
+120m
2 TR for conference room El
E600 ER61 ZZ012 E600ER61ZZ012 Split AC W NIL 120.400 - - - - - - - - - - - - - - - 3 40 1
+120m
E600 ER61 ZZ013 E600ER61ZZ013 Split AC 1.5 TR for Plant Manager 1 W NIL 120.400 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ014 E600ER61ZZ014 Split AC 1.5 TR for Plant Manager 2 W NIL 120.400 - - - - - - - - - - - - - - - 3 40 1
1.5 TR for Additional room El +
E600 ER61 ZZ015 E600ER61ZZ015 Split AC W NIL 112.000 - - - - - - - - - - - - - - - 3 40 1
112m
1.5 TR for Plant Engineer El +
E600 ER61 ZZ016 E600ER61ZZ016 Split AC W NIL 112.000 - - - - - - - - - - - - - - - 3 40 1
112m
1.5 TR for PCT Engineer El +
E600 ER61 ZZ017 E600ER61ZZ017 Split AC W NIL 112.000 - - - - - - - - - - - - - - - 3 40 1
112m
Office (Filling Station) El
E600 ER61 ZZ018 E600ER61ZZ018 Split AC W NIL 100.450 - - - - - - - - - - - - - - - 3 40 1
+100.45
Exhaust Fans for IRR Battery
E600 ER61 ZZ019 E600ER61ZZ019 Exhaust Fans W NIL 104.000 - - - - - - - - - - - - - - - 3 40 1
room EL +104
Exhaust Fans for IRR Battery
E600 ER61 ZZ020 E600ER61ZZ020 Exhaust Fans S NIL 104.000 - - - - - - - - - - - - - - - 3 40 1
room EL +104
Exhaust Fans for Lavatory EL
E600 ER61 ZZ021 E600ER61ZZ021 Exhaust Fans W NIL 116.000 - - - - - - - - - - - - - - - 3 40 1
+116
E600 ER61 ZZ022 E600ER61ZZ022 Exhaust Fans for WC EL +116 Exhaust Fans W NIL 116.000 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ023 E600ER61ZZ023 Exhaust Fans for WC EL +116 Exhaust Fans W NIL 116.000 - - - - - - - - - - - - - - - 3 40 1
Exhaust Fans for Ladies Toilet EL
E600 ER61 ZZ024 E600ER61ZZ024 Exhaust Fans W NIL 112.000 - - - - - - - - - - - - - - - 3 40 1
+112
E600 ER61 ZZ025 E600ER61ZZ025 Exhaust Fans for WC EL +112 Exhaust Fans W NIL 112.000 - - - - - - - - - - - - - - - 3 40 1
Exhaust Fans for Gents Toilet EL
E600 ER61 ZZ026 E600ER61ZZ026 Exhaust Fans W NIL 112.000 - - - - - - - - - - - - - - - 3 40 1
+112
E600 ER61 ZZ027 E600ER61ZZ027 Exhaust Fans for WC EL +112 Exhaust Fans W NIL 112.000 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ028 E600ER61ZZ028 Exhaust Fans for WC EL +112 Exhaust Fans W NIL 112.000 - - - - - - - - - - - - - - - 3 40 1
Exhaust Fans for WC (Filling
E600 ER61 ZZ029 E600ER61ZZ029 Exhaust Fans W NIL 100.450 - - - - - - - - - - - - - - - 3 40 1
Station) EL +100.45
Exhaust Fans for WC (Filling
E600 ER61 ZZ030 E600ER61ZZ030 Exhaust Fans W NIL 100.450 - - - - - - - - - - - - - - - 3 40 1
Station) EL +100.45
Exhaust Fans for Battery Charger
E600 ER61 ZZ031 E600ER61ZZ031 Exhaust Fans W NIL 100.450 - - - - - - - - - - - - - - - 3 40 1
(Filling Stn) EL+100.45
Exhaust Fans for Battery Charger
E600 ER61 ZZ032 E600ER61ZZ032 Exhaust Fans S NIL 100.450 - - - - - - - - - - - - - - - 3 40 1
(Filling Stn) EL+100.45
Exhaust Fans for Trucker WC
E600 ER61 ZZ033 E600ER61ZZ033 Exhaust Fans W NIL 100.450 - - - - - - - - - - - - - - - 3 40 1
(Filling Station) EL +100.45
Exhaust Fans for Trucker WC
E600 ER61 ZZ034 E600ER61ZZ034 Exhaust Fans W NIL 100.450 - - - - - - - - - - - - - - - 3 40 1
(Filling Station) EL +100.45
E600 ER61 ZZ035 E600ER61ZZ035 Roof Extractor for Filling station Roof Extractor W NIL 107.250 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ036 E600ER61ZZ036 Roof Extractor for Filling station Roof Extractor W NIL 107.250 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ037 E600ER61ZZ037 Roof Extractor for Filling station Roof Extractor W NIL 107.250 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ038 E600ER61ZZ038 Roof Extractor for Filling station Roof Extractor W NIL 107.250 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ039 E600ER61ZZ039 Roof Extractor for Filling station Roof Extractor W NIL 107.250 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ040 E600ER61ZZ040 Roof Extractor for Filling station Roof Extractor W NIL 107.250 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ041 E600ER61ZZ041 Roof Extractor for Filling station Roof Extractor W NIL 107.250 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ042 E600ER61ZZ042 Roof Extractor for Filling station Roof Extractor W NIL 107.250 - - - - - - - - - - - - - - - 3 40 1

E600 ER61 ZZ043 E600ER61ZZ043 Manual pallet truck Manual pallet truck W NIL 100.450 - - - - - - - - - - - - - - - 3 41 1

PC1600010R0 8 of 8
 Summary of Insulation Work Job No:2090/1600

Sr. No. Description Amount (Rs)

A Equipment

1 Equipment Insulation

B Piping

1.0 Cold Insulation

2.0 Hot Insulation

3.0 Personal Protection

Total
Intermediate Cold Insulation MTO :Piping Appendix - III
Project No: 2090/1600 SCH OF RATES Rev .0 Dated
12/11/2009

Supply and application of insulation as per attached specification, drawings and instruction of site - in-charge. Contractor to include cost for valves boxes and flanges boxes and all inline fittings in equivalent length and quote No addtitional amount
for the same.will be paid later since the equivalent length converted is final considering all in line items

Pair of
Equivalent length
Pair of flanges Equivalent Total No. of
Pipe Equivalent of (manual
Equivalent length Equivalent flanges excluding length of TOTAL Insulation Area Total Area boxes for
Insula size Pipe size O.D. of Insu Pipe length of No. of No. of valve+control No. of Uint
No. of of reducer (OD of No. of No. of length of tee No. of excluding counter Pair of No. of EQUIVALEN based on Insu including (manual
tion (NPS (mm) pipe Thk Length elbow Manual Control valve+SM item) Flange- Rates Amount (Rs)
Reducer larger size Elbow Tee (2(D1+D2)*qty) Flanges counter flanges for flanges SM's T LENGTH OD in SQ. M. 20% extra valve+control
Spec in (NPS*25.4) (mm) mm mtr. (2*(1.5D)*q Valve Valve (1.5*qty) upto 12" box (Rs)
pipe*qty) (mtr) (mtr) flanges for valves/SM's (0.8*qty) (mtr) (Note-1) (SQ.M.) valve+SM
inch) ty) (mtr) & (2*qty) for above
valves/SM's (rounded-off (mtr) item)
12" (mtr)
value)

C 1/2 12.70 33.4 25 237.6 0.00 115 8.74 11 1.47 172 86 86 68.8 33 49.5 366.11 95.88 115.05 86 33
C 1 25.40 33.4 40 193.7 0.00 97 7.37 11 1.47 138 69 69 55.2 28 42 299.74 106.73 128.08 69 28
C 2 50.8 60.3 30 117.7 15 0.90 30 4.57 2 0.48 66 33 33 26.4 4 6 156.06 58.95 70.74 33 4
C 2 50.8 60.3 45 47.2 2 0.12 6 0.91 0.00 12 6 6 4.8 0 53.04 25.03 30.04 6 0
C 3 76.2 88.9 30 0.2 2 0.18 0.00 0.00 4 2 2 1.6 0 1.98 0.92 1.11 2 0
C 3 76.2 88.9 50 24 2 0.18 14 3.20 0.00 6 3 3 2.4 2 3 32.78 19.44 23.33 3 2
C 4 101.6 114.3 35 101.9 0.00 42 12.80 1 0.46 52 26 26 20.8 4 6 141.96 82.15 98.58 26 4
C 4 101.6 114.3 55 32.3 0.00 20 6.10 0.00 24 12 12 9.6 3 4.5 52.50 36.97 44.37 12 3
C 6 152.4 168.3 35 143.2 0.00 17 7.77 0.00 46 23 23 18.4 3 4.5 173.87 130.10 156.12 23 3
C 6 152.4 168.3 55 114.5 0.00 15 6.86 0.00 38 19 19 15.2 4 6 142.56 124.58 149.49 19 4
C 8 203.2 219.1 35 44.5 0.00 7 4.27 3 2.63 17 8.5 9 7.2 0 58.60 53.19 63.83 9 0
C 8 203.2 219.1 60 46.2 2 0.44 7 4.27 3 2.63 18 6 6 4.8 3 4.5 62.83 66.90 80.29 6 3
C 10 254 273.1 60 12.5 2 0.55 8 6.10 0.00 6 3 3 2.4 0 21.54 26.59 31.91 3 0

2 of 6
Intermediate Cold Insulation MTO :Piping Appendix - III
Project No: 2090/1600 SCH OF RATES Rev .0 Dated
12/11/2009

Supply and application of insulation as per attached specification, drawings and instruction of site - in-charge. Contractor to include cost for valves boxes and flanges boxes and all inline fittings in equivalent length and quote No addtitional amount
for the same.will be paid later since the equivalent length converted is final considering all in line items

Pair of
Equivalent length
Pair of flanges Equivalent Total No. of
Pipe Equivalent of (manual
Equivalent length Equivalent flanges excluding length of TOTAL Insulation Area Total Area boxes for
Insula size Pipe size O.D. of Insu Pipe length of No. of No. of valve+control No. of Uint
No. of of reducer (OD of No. of No. of length of tee No. of excluding counter Pair of No. of EQUIVALEN based on Insu including (manual
tion (NPS (mm) pipe Thk Length elbow Manual Control valve+SM item) Flange- Rates Amount (Rs)
Reducer larger size Elbow Tee (2(D1+D2)*qty) Flanges counter flanges for flanges SM's T LENGTH OD in SQ. M. 20% extra valve+control
Spec in (NPS*25.4) (mm) mm mtr. (2*(1.5D)*q Valve Valve (1.5*qty) upto 12" box (Rs)
pipe*qty) (mtr) (mtr) flanges for valves/SM's (0.8*qty) (mtr) (Note-1) (SQ.M.) valve+SM
inch) ty) (mtr) & (2*qty) for above
valves/SM's (rounded-off (mtr) item)
12" (mtr)
value)

NOTES :
1 "Insulation Area based on Insu OD in SQ. M.", indicates Total Sq.M. of insulation required for
particular insulation specification, Pipe diameter and Insulation thickness. (This area calculation
is only based on Pipe length including all inline components.) This is applicable only if insulation
material is bought as blankets. This is not required to be used, if preformed sections are used.
This can also be used to order cladding material around insulation.
2 All other requirement shall be as per Doc. No. PIC-1600-2801-C-000 Rev. 0 (stand. Spec. for Cold Insulation)

3 of 6
 Rev .0 Dated 12/11/2009
Intermediate Hot Insulation MTO : Piping Appendix - III
Project No: 2090/1600 SCH OF RATES
Supply and application of insulation as per attached specification, drawings and instruction of site - in-charge. Contractor to include cost for valves boxes and flanges boxes and all inline fittings in equivalent length and quote No addtitional
amount for the same.will be paid later since the equivalent length converted is final considering all in line items

Pair of
Equivalent length
Pair of flanges Total No. of
Equivalent of (manual TOTAL Insulation
Equivalent Equivalent flanges excluding Equivalent Total Area boxes for
Insulat Pipe size Pipe size O.D. of Insu Pipe length of No. of No. of valve+control EQUIVALE Area based on No. of
No. of No. of length of elbow No. of length of tee No. of excluding counter length of Pair No. of including (manual
ion (NPS in (mm) pipe Thk Length reducer (OD of Manual Control valve+SM item) NT Insu OD in Flange- Unit Rates Amount (Rs)
Reducer Elbow (2*(1.5D)*qty) Tee (2(D1+D2)*qty) Flanges counter flanges for of flanges SM's 20% extra valve+control
Spec INCH) (NPS*25.4) (mm) mm mtr. larger size Valve Valve (1.5*qty) upto 12" LENGTH SQ. M. (Note- box
(mtr) (mtr) flanges for valves/SM's (0.8*qty) (mtr) (SQ.M.) valve+SM
pipe*qty) (mtr) & (2*qty) for above (mtr) 1)
valves/SM's (rounded-off item)
12" (mtr)
value)

H 1/2 12.7 21.3 25 0 0.00 0.00 0.00 0 0 0 1 1.5 1.50 0.34 0.40 0 1
H 1/2 12.7 21.3 40 3.9 0.00 0.00 0.00 49 24.5 25 20 17 25.5 49.40 15.71 18.86 25 17
H 1 25.4 33.4 25 356.85 0.00 225 17.10 23 3.07 446 223 223 178.4 150 225 780.42 204.37 245.25 223 150
H 1 25.4 33.4 30 375.2 0.00 250 19.00 11 1.47 281 127.5 128 102.4 64 11 2 115.5 613.57 179.95 215.93 128 77
H 1 25.4 33.4 45 401.8 0.00 278 21.13 59 7.88 315 153.5 154 123.2 97 4 151.5 705.51 273.37 328.04 154 101
H 1 25.4 33.4 55 109.2 0.00 84 6.38 14 1.87 98 39 39 31.2 38 10 72 220.65 99.36 119.23 39 48
H 1.1/2 38.1 48.3 45 0 1 0.05 0.00 0.00 1 0.5 1 0.8 0 0.85 0.37 0.44 1 0
H 2 50.8 60.3 25 1656.1 19 1.15 721 109.88 80 19.30 1070 535 535 428 107 160.5 2374.87 822.52 987.02 535 107
H 2 50.8 60.3 35 421.2 4 0.24 220 33.53 18 4.34 264 93 93 74.4 30 30 9 103.5 637.21 260.71 312.85 93 69
H 2 50.8 60.3 50 177.6 7 0.42 74 11.28 5 1.21 107 42.5 43 34.4 11 16.5 241.41 121.51 145.81 43 11
H 2 50.8 60.3 60 0.00 0.00 0.00 0 0 28 42 42.00 23.78 28.53 28
H 2 50.8 60.3 65 37.6 0.00 25 3.81 4 0.96 35 7.5 8 6.4 10 15 63.77 38.11 45.73 8 10
H 3 76.2 88.9 25 191.7 31 2.76 125 28.58 5 1.78 162 55 55 44 26 39 307.81 134.25 161.10 55 26
H 3 76.2 88.9 35 208.1 7 0.62 86 19.66 20 7.11 136 47 47 37.6 17 4 31.5 304.59 151.98 182.37 47 21
H 3 76.2 88.9 50 143.5 1 0.09 94 21.49 5 1.78 61 16.5 17 13.6 11 3 21 201.46 119.49 143.39 17 14
H 3 76.2 88.9 70 56.2 0.00 9 2.06 2 0.71 16 4 4 3.2 1 3 6 68.17 49.00 58.80 4 4
H 4 101.6 114.6 25 34.5 0.00 28 8.53 0.00 36 14 14 11.2 4 6 60.23 31.13 37.36 14 4
H 4 101.6 114.6 35 58.2 7 0.80 46 14.02 6 2.75 89 32.5 33 26.4 8 4 18 120.17 69.66 83.59 33 12
H 4 101.6 114.6 55 76.9 6 0.69 49 14.94 11 5.04 51 16.5 17 13.6 7 2 13.5 124.67 87.92 105.50 17 9
H 4 101.6 114.6 75 43 0.00 7 2.13 3 1.38 13 0.5 1 0.8 2 4 9 56.31 46.78 56.14 1 6
H 6 152.4 168.3 25 0.4 0.00 2 0.91 0.00 1 0.5 1 0.8 0 2.11 1.45 1.74 1 0
H 6 152.4 168.3 80 0.6 0.00 0.00 0.00 0 0 0 0 0.60 0.62 0.74 0 0
H 8 203.2 219.1 60 21.5 0.00 4 2.44 0.00 6 3 3 2.4 0 26.34 28.04 33.65 3 0
H 8 203.2 219.1 80 91.2 0.00 17 10.36 4 3.51 10 4 4 3.2 1 1.5 109.77 130.67 156.80 4 1

Total

4 of 6
 Rev .0 Dated 12/11/2009
Intermediate Hot Insulation MTO : Piping Appendix - III
Project No: 2090/1600 SCH OF RATES
Supply and application of insulation as per attached specification, drawings and instruction of site - in-charge. Contractor to include cost for valves boxes and flanges boxes and all inline fittings in equivalent length and quote No addtitional
amount for the same.will be paid later since the equivalent length converted is final considering all in line items

Pair of
Equivalent length
Pair of flanges Total No. of
Equivalent of (manual TOTAL Insulation
Equivalent Equivalent flanges excluding Equivalent Total Area boxes for
Insulat Pipe size Pipe size O.D. of Insu Pipe length of No. of No. of valve+control EQUIVALE Area based on No. of
No. of No. of length of elbow No. of length of tee No. of excluding counter length of Pair No. of including (manual
ion (NPS in (mm) pipe Thk Length reducer (OD of Manual Control valve+SM item) NT Insu OD in Flange- Unit Rates Amount (Rs)
Reducer Elbow (2*(1.5D)*qty) Tee (2(D1+D2)*qty) Flanges counter flanges for of flanges SM's 20% extra valve+control
Spec INCH) (NPS*25.4) (mm) mm mtr. larger size Valve Valve (1.5*qty) upto 12" LENGTH SQ. M. (Note- box
(mtr) (mtr) flanges for valves/SM's (0.8*qty) (mtr) (SQ.M.) valve+SM
pipe*qty) (mtr) & (2*qty) for above (mtr) 1)
valves/SM's (rounded-off item)
12" (mtr)
value)

NOTES :
1 "Insulation Area based on Insu OD in SQ. M.", indicates Total Sq.M. of insulation required for
particular insulation specification, Pipe diameter and Insulation thickness. (This area calculation
is only based on Pipe length including all inline components.) This is applicable only if insulation
material is bought as blankets. This is not required to be used, if preformed sections are used.
This can also be used to order cladding material around insulation.
2 All other requirement shall be as per Doc. No. PIC-1600-2800-C-000 Rev. 0 (stand. Spec. for Hot Insulation)

5 of 6
Intermediate Personal Protection Insulation MTO : Piping Appendix - III
PROJECT NO: 2090/1600 SCH OF RATES
Supply and application of insulation as per attached specification, drawings and instruction of site - in-charge. Contractor to include cost for valves boxes and flanges boxes and all inline fittings in equivalent length and quote No addtitional amount
for the same.will be paid later since the equivalent length converted is final considering all in line items

Pair of flanges Equivalent length

Pair of Total No. of
Equivalent Equivalent excluding of (manual
O.D. Equivalent flanges Equivalent TOTAL Insulation Area Total Area boxes for
Insulat Pipe size Pipe size Insu Pipe length of length of counter No. of No. of valve+control No. of
of No. of No. of No. of length of tee No. of excluding length of Pair No. of EQUIVALEN based on Insu including (manual Unit
ion (NPS in (mm) Thk Length reducer (OD of elbow flanges for Manual Control valve+SM item) Flange- Amount (Rs)
pipe Reducer Elbow Tee (2(D1+D2)* Flanges counter of flanges SM's T LENGTH OD in SQ. M. 20% extra valve+control Rates
Spec mm) (NPS*25.4) mm mtr. larger size (2*(1.5D)*qty) valves/SM's Valve Valve (1.5*qty) upto 12" box
(mm) qty) (mtr) flanges for (0.8*qty) (mtr) (mtr) (Note-1) (SQ.M.) valve+SM
pipe*qty) (mtr) (mtr) (rounded-off & (2*qty) for above
valves/SM's item)
value) 12" (mtr)

P 1/2 12.7 21.3 25 0.00 0.00 1 0.09 2 1 1 0.8 0 0.89 0.20 0.24 1 0
P 1 25.4 33.4 25 68.4 0.00 43 3.27 3 0.40 26 13 13 10.4 2 3 85.47 22.38 26.86 13 2
P 1 25.4 33.4 40 1.6 0.00 4 0.30 2 0.27 3 1.5 2 1.6 2 3 6.77 2.41 2.89 2 2
P 2 50.8 60.3 25 384.6 2 0.12 136 20.73 0.00 38 19 19 15.2 1 1.5 422.15 146.21 175.45 19 1
P 2 50.8 60.3 30 2 1 0.06 6 0.91 0.00 7 3.5 4 3.2 0 6.17 2.33 2.80 4 0
P 2 50.8 60.3 45 14.5 2 0.12 18 2.74 0.00 16 8 8 6.4 1 1.5 25.26 11.92 14.31 8 1
P 3 76.2 88.9 25 1 0.09 0.00 0.00 1 0.5 1 0.8 0 0.89 0.39 0.47 1 0
P 4 101.6 114.6 25 33 3.78 0.00 0.00 0 0 0 0 3.78 1.95 2.35 0 0
P 4 101.6 114.6 35 4 0.00 6 1.83 0.00 12 6 6 4.8 0 10.63 6.16 7.39 6 0
P 4 101.6 114.6 50 3 0.00 6 1.83 0.00 10 5 5 4 2 3 11.83 7.97 9.56 5 2
P 6 152.4 168.3 25 28.8 0.00 8 3.66 8 5.39 24 12 12 9.6 0 47.44 32.52 39.02 12 0
P 8 203.2 219.1 25 4.4 0.00 2 1.22 0.00 3 1.5 2 1.6 1 1.5 8.72 7.37 8.84 2 1
P 10 254 273.1 25 1 0.27 0.00 0.00 0 0 0 0 0.27 0.28 0.33 0 0

Total

NOTES :
1 "Insulation Area based on Insu OD in SQ. M.", indicates Total Sq.M. of insulation required for
particular insulation specification, Pipe diameter and Insulation thickness. (This area calculation
is only based on Pipe length including all inline components.) This is applicable only if insulation
material is bought as blankets. This is not required to be used, if preformed sections are used.
This can also be used to order cladding material around insulation.
2 All other requirement shall be as per Doc. No. PIC-1600-2800-C-000 Rev. 0 (stand. Spec. for Hot Insulation)

6 of 6
 PROPOSED SITE ORGANISATION

NOTE:
The number of workmen/supervisor and tools, tackles and machinery shall be further augmented
as and when required to complete the work as per the agreed time schedule.

Signature of Contractor
 TOOLS, TACKLES & MACHINERY DEPLOYMENT AT SITE

NOTE:
The number of workmen/supervisor and tools, tackles and machinery shall be further
augmented as and when required to complete the work as per the agreed time
schedule.

Signature of Contractor
 EXCEPTION AND DEVIATION

(Deviations not listed in the format, will not be entertain even if elsewhere mention)

Tenderers may stipulate here, exception and deviations to the documents, if considered
unavoidable.

Sr. No. Sheet No of Tender doc. Clause No. Subject Deviation/Clarification

Signature of Contractor
 POWER, WATER AND SPACE FOR SITE OFFICE/STORES/YARD

Sr. No. Description Contractor to Indicate

1.0 Power in Peak in KVA

2.0 Water

3.0 Space for Site Office/Store/Fabrication Yard

Signature of Contractor
 PART - 7

BOQ & TECHNICAL SPECIFICATION

SR. SPEC. NO. DESCRIPTION
NO.
1.0 Appendix I,II, III & IV Sch of Rates (BOQ)/ Labour Hire Charges
2.0 Proposed Site Organisation/List of Tools
Exception & Deviation & water & Power &
Equipment List
3.0 Spec. No 1600-2002-c-X02 Pipe Specification Index No:1600-2002-C-X02
Rev.2 Rev.2
4.0 Technical Specification
1. STD-CONST-ISE-01 INSTALLATION OF STATIC EQUIPMENT
2. STD-CONST-VHE-02 INSTALLATION OF VESSEL/ HEAT EXCHANGERS
3. STD-CONST-IPB-03 INSTALLATION OF PUMP/ BLOWER
4. STD-CONST-ICT-04 INSTALLATION OF COMPRESSOR/ TURBINE
5. STD-CONST-WQT-05 WELDER QUALIFICATION
6. STD-CONSTNDT-06 NON-DESTRUCTIVE TESTING
7. STD-CONSTFECSP-07 FABRICATION & ERECTION OF CARBON STEEL
PIPING
8. STD-CONSTFESSP-08 FABRICATION & ERECTION OF STAINLESS STEEL
PIPING
9. STD-CONST-FEASP/29 FABRICATION & ERECTION OF G I PIPING
10. STD-CONST-FEPS-13 FABRICATION & ERECTION OF PIPE SUPPORTS
11. STD-CONST—14-HT HYDROTESTING OF PIPELINES
12. 2090-1600-2801-C-000 Rev.0 Cold Insulation of Piping, Vessels & equipment
13. 2090-1600-2800-C-000 Rev.0 Hot Insulation of Piping, Vessels & equipment
14. 2090-1600-2802-C-000 Rev.0 Steam Tracing of Piping, Vessels & equipment
15. BTS-SP-CIV-WERKNORM-2207 Corrosion Protection of Steel Structures
Rev.1
16. Corrosion Protection – CSA0056.doc Corrosion Protection of Civil, Structures,
Architectural, Process Equipment & Piping
17. Welder Chart 1
18. Copper Jumper
19. Drawings
Plot Plan
Equipment Layout
 PART 7
SCH OF RATES/LABOUR HIRE CHARGE/
PROPOSED SITE ORGANISATION/TOOLS &
TACKLES/WATER, POWER, PIPE SPEC. INDEX AND
TECHNICAL SPECFICATION
 Werknorm 2207
for India

PAGE 1 of 25
DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

Specification for Corrosion Protection of

steel structures
(Based on Werknorm 2207- corrosion protection by means of coatings)

1 Approved 07/01/09 DB MR VHP

0 Issued for approval 24/12/08 DB MR VHP

PREPARED CHECKED APPROVED
REV DESCRIPTION DATE BY BY BY CLIENT

_________________________________________________________________________________________________________________
BTS- INDIA , D .Baruah
 Werknorm 2207
for India

PAGE 2 of 25
DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

TABLE OF CONTENTS

1.0 INTRODUCTION ............................................................................................................. 3

2.0 SCOPE............................................................................................................................ 3
2.1 Definitions........................................................................................................................ 3

3.0 General Information .................................................................................................. 3

4.0 Coating systems ......................................................................................................... 6

5.0 Technical terms & requirements.............................................................................. 6

6.0 Quality control & documentation .............................................................................. 14

7.0 Special applications ................................................................................................. 17

8.0 Health Safety & Environment ................................................................................ 19

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BTS- INDIA , D .Baruah
 Werknorm 2207
for India

PAGE 3 of 25
DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

1.0 INTRODUCTION
This specification is intended to address the adequate corrosion protection requirements for
steel structures & equipments for all Projects for Bayer Material Science in India. This
specification shall also be used as a guideline for PEB vendors.

2.0 SCOPE
This specification covers the surface preparation, method of application and material to be
used for all coatings of equipment, steel structures and piping.

2.1 Definitions

OWNER Bayer Material Science

CONSULTANT BTS India

CONTRACTOR Discipline Contractor /PEB vendor who is selected by the

BMS/BTS.

Shall: Indicates a mandatory requirement.

Should: Indicates a strong recommendation to comply with the

requirements of this scope.

3.0 General Information:

3.1 General

All steel structures and all carbon or stainless steel objects shall be protected against corrosion
by coating. In this scope object means: pipes, pipe racks, valves, flanges, vessels, columns,
tanks, pumps…..,
Additionally the insulated stainless steel objects with an operating temperature which is critical
for stress cracking corrosion shall receive a corrosion protection coating. In this case
exceptional care shall be exercised in the execution of the work because of the very aggressive
nature of chlorides in the marine and chemical atmosphere together with a high humidity.

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BTS- INDIA , D .Baruah
 Werknorm 2207
for India

PAGE 4 of 25
DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

In all cases protective systems shall be applied strictly in accordance with the manufacturer’s
instructions.

Painting work can only be executed when:

- The ambient and the surface temperature is between + 8 °C and + 40 °C
- The relative humidity is below 85%
- The surface temperature is 3°C higher then the de w point

Before delivery to site all objects shall preferably have the surface preparation and their primer
coating applied in the workshop under conditioned environment. The areas for onsite welding
shall be left unpainted.
To guaranty the proper protection of the complete coating system these two steps are critical
and need close supervision.

It must always be ensured that open flange and valve faces, identification tags, moving parts or
internal areas are protected during preparation and coating work.

For the layer thickness, the so called 80/20 rule applies. On a number of measurements,
minimum 80% of the values shall be more than the specified layer thickness. The remaining
20% can be lower than the expected value, nevertheless not lower then 80% of this value.

3.2 Specifications and Standards

CONTRACTOR shall meet or exceed the requirements of the latest edition of the following codes,
regulations and standards, except as superseded herein. In cases where more than one code,
regulation or standard apply to the same condition, the most stringent shall be followed. In the
event of a conflict between this specification and other specifications or correspondence, the
OWNER shall be consulted and a ruling, in writing, shall be obtained before any work is started.

For design and installation of corrosion protection work, the details as described in the latest
version of this specification are always applicable, unless stipulated differently.

Planning of corrosion protection work must be based on this specification

If objects come onsite coated, the manufacturer shall have followed this specification.

The surface preparation of steel is based on:

- ISO 12 944, part 4
- ISO 8501
- ISO 8502
- ISO 8503
- ISO 8504
- SIS 05 5900
- IS 9954-1981

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BTS- INDIA , D .Baruah
 Werknorm 2207
for India

PAGE 5 of 25
DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

- IS 1477 (part I -2000)

The corrosion protection of steel by coating is based on:

- ISO 12944 - part 5

- IS 1477 (part II -2000)
- IS 14428-1997

3.3 Suggested color code list for Topcoat

This List is to clarify with the project and need’s approval by the Project Manager or Corrosion-
Protection-Supervisor of the project.

Fluids / other objects Basic Identification Color (RAL)

Water green (6018)
Fire fighting red (3000)
Air, O2 blue (5015)
Steam silver (9006)
Burnable gases yellow (1021) with red (3000) stripes
Non burnable gases yellow (1021) with black (9005) stripes
Acids yellow-orange (2003)
Caustic red-lilac (4001)
Oils, Fuels, Organic ochre-brown (8001)
Vacuum silver-grey (7001)
Tanks, Vessels gravel grey (7032)
Steel structures for buildings gravel grey (7032) or blue (5010)
Pipe bridges green (6021) or red (3002)

The color of the topcoat for the objects must be based on a project color-code list, for basic
identification. IS 2379:1990 may also be referred for color code for identification of pipe lines. It
is always advisable that top coat and intermediate coat should have different color so
that top coat could be well distinguished from the intermediate coat. In case of pipe
bridges, though green color is widely used in Bayer, red color may also be recommended for
main internal pipe bridges to differentiate it from the secondary pipe bridges.

The contractor can choose his paint supplier from the preferred supplier list (annexure-II). The
contractor has to inform the project manager or the corrosion protection supervisor, which
coating product from which supplier will be used.

Dry film thickness of each coating layer is given in this specification. The coating is to execute in
that way, the dry film thickness on the equipment surface is according to these specification.
Any deviation from the above defined standards has to be approved by the project manager or
the corrosion protection supervisor, responsible for the project.

_________________________________________________________________________________________________________________
BTS- INDIA , D .Baruah
 Werknorm 2207
for India

PAGE 6 of 25
DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

3.4 Deviations from the specification or standards, which are to be considered

A color list for the topcoat will be given by the project. This color list is only suggestions to the
project team. The final color code for top coating is to clarify with the corrosion protection
supervisor for this project.
If dry film thicknesses mentioned on the manufacturer’s data sheet are not compliant with the
ones mentioned in this specification, the Project Manager or the head of Technical Services
needs to be informed. He will make the final decision.
For using a coating system, a type of paint or a supplier, which is not mentioned in the preferred
supplier list (annexure: II), a written permission by the owner is necessary.

3.5 Criteria for the selection of the corrosion protection system

The corrosion protection system is to be selected primarily on the basis of technical operating
criteria. These requirements are:
- Object’s surface material
- Object’s operating temperature at the surface
- Object’s insulation type

4.0 Coating systems:

4.1 Coating systems

In accordance with this Specification, coating systems based on 1-component polyurethane

(MC-PUR) and 2-component polyurethane (2K-PUR) are to be used. The corresponding
coating systems are specified in Annexure I. Details of technical delivery conditions are
generally provided by BMS.
The technical supply systems are managed by Bayer Material Science in India and can be
ordered from the customer or the specialist department of BMS.
The coating system to be used in accordance with this Specification is to be specified by the
customer for each individual application.

Only approved products according to approved vendor products (annexure II ) are to be used.

5.0 Technical terms & requirements:

5.1 Objects

Objects are defined as:

Steel structures like pipes, pipe racks, valves and flanges, vessels, columns, heat
exchangers and tanks, pumps and the base plate.
Special applications include:

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BTS- INDIA , D .Baruah
 Werknorm 2207
for India

PAGE 7 of 25
DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

- Steel structures in high-salinity environments

- Steel structures in environments with highly abrasive conditions

This standard is not to be used for the corrosion protection of equipment surfaces in contact
with product.

5.2 Surface preparation

The surface preparation is the most critical and most important aspect in terms of the quality of
a corrosion protection system.
Surface preparation means: prepare the object’s surface in a way that a good adhesion of the
primer is possible. This means: remove oil and grease with the suitable detergent, remove salts,
dirt, dust and other contaminants by (high pressure) fresh water cleaning and give the surface
the required roughness.
Any contaminants that could have an adverse effect on the coating must be removed from the
surface to be coated.

Section 5.2.1 below lists general preparation measures for the surface to be coated, depending
on the substance to be removed. Details of measures are to be followed in accordance with IS
1477(part I)-2000. (Factory & onsite pretreatment)
Section 5.2.2 below lists different surface preparation standards and brief finishing description in
accordance with SIS 05 5900 & IS 9954-1981.

If it is anticipated that the surface will be in an environment with a high salinity then the
customer may agree a surface preparation for such environments in accordance with Section
7.1.1.
If not otherwise agreed, the pre-treatments given in Annexure I are to be carried out, depending
on the nature of the objects being coated.

5.2.1 Removal of coatings of the same or a different type and of contaminants

Table 1
Substances to Procedure Remarks
be removed
Grease and oil Cleaning with water Clean water with addition of cleaning agent. Pressure
(< 70MPa) may be applied. Finish by washing with clean
water
Steam jetting
Clean water. If a cleaning agent is added then finish by
washing with clean water

Cleaning with A large number of organic solvents are injurious to health. If

organic solvents rags are used for cleaning then these should be changed
regularly, otherwise oil and grease will not be removed, but
remain after evaporation of the solvent
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BTS- INDIA , D .Baruah
 Werknorm 2207
for India

PAGE 8 of 25
DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

Substances to Remarks
be removed Procedure

Water-soluble Cleaning with water Clean water1, pressure (< 70 MPa) may be applied
substances, e.g. Steam jetting Finish by washing with clean water
salts

Mill scale / scale Dry blasting Shot or grit as blasting agent. Residues in the form of dust
and loose deposits can be removed by blowing dry oil-free
compressed air over the surface or using a vacuum cleaner.

Rust Dry-blasting Shot or grit as blasting agent. Residues in the form of dust
and loose deposits can be removed by blowing dry oil-free
compressed air over the surface or using a vacuum cleaner.

Wet jetting Finish by washing with clean water

Cleaning with Machine brushing may be used for regions with loose rust,
power-driven tools grinding for rust that is not loose. Residues in the form of
dust and loose deposits are to be removed.
High-pressure water
jetting To remove loose rust. The roughness of the steel is not
influenced.
Coatings Blast-cleaning Shot or grit as blasting agent. Residues in the form of dust
and loose deposits can be removed by blowing dry oil-free
compressed air over the surface or using a vacuum cleaner.

Wet jetting Finish by cleaning with clean water

High-pressure water For removal of poorly adhering coatings. Ultra-high pressure

jetting water jetting (> 170 MPa) may be used for coatings that are
still adhering firmly.
Sweep blasting To roughen coatings or to remove the top layer

Spot blasting For local removal of coatings

Zinc corrosion Sweep blasting Sweep blasting of zinc may be carried out with aluminum
products oxide (corundum), silicates or olivine sand

Washing with An approx. 5 % ammonia solution, applied with a synthetic

ammonia-containing fleece with embedded abrasive, may be used for small
wetting agent areas with zinc corrosion products.

_________________________________________________________________________________________________________________
BTS- INDIA , D .Baruah
 Werknorm 2207
for India

PAGE 9 of 25
DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

N.B: Clean water: Normal drinking water with a conductivity range –- for example 600 -
700 µS/cm – may be sufficient to achieve a surface salt value of approx. 30 mg/ m².

Section 5.2.2 Surface standards

Table 2

Standard Method Description of finish

Blast Poorly adhering mill scale, rust and old paint and foreign matter
Sa 1
Cleaning are removed. Well adhered contaminants remain.
Blast Most of the mill scale rust and paint etc are removed and any
Sa 2
Cleaning remaining is very well adhered.
Mill scale, rust paint and foreign matter is removed completely.
Blast
Sa 2½ Any remaining traces are visible only as slight stains or
Cleaning
discoloration in the form of spots or stripes.
All mill scale, rust etc is removed and the surface has a uniform
Blast
Sa 3 white metal appearance with no shading, stripes, spots of
Cleaning
discoloration.
Hand or Poorly adhering rust, mill scale etc are removed, leaving surface
St 2
Powertool contamination that is well adhered.
Hand or As for St 2, but the surface now exhibits a metallic sheen arising
St 3
Powertool from the metal substrate.
Almost all mill scale, rust and other surface contamination is
F1 Flame removed leaving only a metallic shine but some discoloration
due to shading left by remaining contaminants.
All surface contamination including all mill scale rust, etc is
Acid
Be removed, leaving a uniformly grey clean surface. Paint etc must
Pickling
be removed prior to acid cleaning by some other means.

5.2.3 Mechanical cleaning (St ): Power tools and hand tools as per IS 9954-1981

As power tools, pneumatic or motor driven brushes and grinding wheels or various dust
removing machines can be used. For manual treatment, hand hammer, scraper, shovel, wire
brush and abrasive cloth (paper) can be used.
In any case, neither power tools nor manual means can deform or damage the object’s surface.

5.2.4 Blast cleaning (Sa) as per IS 9954-1981

A standard surface preparation grade of Sa 2½ must be attained with blast-cleaning.

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All blasting work should be executed in the prefabrication area of the equipment manufacture.
To prevent oxidation, the primer is to apply latest one hour after blasting.

For objects made of carbon steel, abrasive blasting is necessary. The blast cleaned area shall
leave surfaces with a dense, uniform, sharp angular anchor pattern.
After blasting, the degree of purity must be Sa 2½ and the profile roughness must be 30 to 50
µm

For objects, made of stainless steel or with a galvanized surface, light abrasive blasting (also
called sweep blasting) with a non metallic abrasive to an evenly roughened surface with a
dense profile is necessary. The aim of sweep blasting (mild surface blasting) is to increase the
roughness of the surface (e.g. to break up zinc bloom).
After blasting, the degree of purity must be comparable with Sa 2 ½ and the profile roughness
must be 30 to 50 µm.

Determination of the surface preparation grade after surface treatment is carried out using
photographs of comparative specimens as specified in ISO 8501-1.
If the specified preparation grade is not achieved then the blast cleaning must be repeated

Determination of roughness is to be carried out using the ISO roughness comparison method
(ISO 8503-1 and ISO 8503-2) using an ISO roughness specimen for comparison and a
magnifying glass with up to x7 magnification. If an angular abrasive agent (e.g. grit) is used then
the roughness must correspond to that in segment 2 to 3 (60-100 µm) of the comparative
specimen. If a rounded abrasive agent is used (e.g. shot) then the roughness must correspond
to that in segments 3 to 4 (70-100 µm).

If the required preparation grade (roughness as per ISO 8503-1 and ISO 8503-2; surface
appearance as per ISO 8501-1) is not reached then subsequent blast-cleaning is required with
altered parameters.

The method described under Section 5.2.1 for the removal of layers of the same or different
type is to be taken into consideration.

5.2.4.1 The following are of particular importance for residues after blast-cleaning:

Blasting debris is a waste and must be classified. The means of disposal is to be

specified according to the classification.

The party generating the waste is responsible for the correct disposal of the blasting
debris.

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5.2.5 High-pressure water jetting

With this method clean water under pressure is sprayed on to the surface to be prepared. The
pressure of the water will depend on the contaminants to be removed such as water-soluble
substances, loose rust and poorly-adhering coatings. If a cleaning agent is also used then the
surface must be washed with clean water afterwards.

One of the following methods is used:

- High-pressure water jets (70 MPa to 170 MPa)

- Ultra-high-pressure water jets (over 170 MPa)

5.3 Layers

Primer
The primer is the first layer of painting, applied on the prepared metal surface. Depending on
the coating system this layer contains an active rust preventive pigment (zinc powder or zinc
phosphate). This layer shall have a proper adhesion to the substrate.
Before applying primers, it is utmost necessary to demonstrate the surface preparation grade
achieved (purity grade, surface roughness) or to carry out a joint approval procedure with the
customer. The standard forms may be used for this purpose.

Care must be taken to ensure that the primer is applied shortly after surface preparation is
concluded to avoid the formation of rust films.

Where possible, the primer should be applied on the premises of the manufacturer during
fabrication (in-shop).

Primers of zinc dust or zinc phosphate may only be applied using a brush. Any deviations from
this require the approval of the customer.

The procedure described in Section 6.2 “Documentation ” is to be used to document the work

Intermediate

The intermediate is the second layer of paint; it’s applied on the primer. It shall have a proper
adhesion to the primer and serves for a further build up of the protection and sealing of the
object and primer against atmosphere attack. For a better visual inspection, this layer shall have
a color different as that of the primer. Any damage to the primer must be made good before
application of the intermediate coat.

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Top coat
The top coat is the colored third layer of paint; it’s applied on the intermediate layer and its main
function is to protect the system against UV radiation, dust and dirt.

5.4 Zinc rich

For zinc rich primers, the minimum zinc dust pigment content of the non-volatile portion of the
paint shall be 80 % by mass (m/m), both for organic and inorganic binders.

5.5 Dry film thickness

The dry film thickness is the thickness of a single layer or complete finished coating system after
24 hours drying time. This parameter is expressed in micrometer (µm). No single measured
value may lie below 80 % of the specified DFT. As a general rule, individual values must not be
more than 3x the specified DFT of the coating.

The overall thickness of the coating is given by summation of the thickness values for the
individual layers.

The film thickness values specified in this specification are minimum dry film thickness values. If
a film is too thick this may impact adversely on performance (for zinc rich primers). Zinc dust
primer coatings which are applied by brush in a single procedure must not exceed a maximum
DFT of 140 µm.

For corrosion protection systems, generally the manufacturer’s maximum dry film layer
thickness shall be regarded to avoid cracking or blistering.

If an individual film has a thickness value of less than 80 % of the specified DFT, then the
coating must be re-applied until the specified dry film thickness is attained.

If the thickness of an individual film is greater than 3x the specified DFT then the customer
reserves the right to reject the coating. This may then necessitate blast-cleaning of the surface
and re-application of the coating system.

If the visual appearance of the coating is unsatisfactory (e.g. it exhibits wrinkles or craters) or
the coating is inadequate (e.g. tears or bubbles) then the customer reserves the right to reject
the coating. This may also necessitate blast-cleaning of the surface and re-application of the
coating system.

The lifetime of any protective system is determined by the dry film thickness of the paint system
present on weld seams and sharp edges. Special attention should be given to sharp edges to
ensure that they are covered with an adequate coating thickness. Edge protection is to be
carried out in accordance with Annexure I to this standard. Any deviation from this is to be
agreed with the customer.
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5.6 Paint components

5.6.1 Binder
The binder is the non-volatile portion of the liquid portion of the paint. It binds the pigment
particles together and provides adhesion of the paint to the surface. The binder is responsible
for most of a coating’s physical and chemical properties, chemical and weather resistance,
adhesion properties and also influence the hardness and abrasion resistance. The binder
specified in this document refers to polyurethane binders only.

5.6.2 Solvent
Solvents are liquids to dissolve the binder and to adjust the viscosity of the paint. It also
influences the flow properties, drying speed, spraying or brushing characteristics and gloss.

5.6.3 Pigments
Pigments are responsible for a very specific characteristic of the paint. Therefore they can be
separated into: color pigments, extender pigment, anti-corrosive pigments, antifouling agents,

5.6.4 Adhesives
Adhesives are usually present in small quantities. They help to make homogeneous paints and
contribute to the ease in manufacture, improve stability, appearance, application and the quality
of resistance.

Seen the complexity of this matter, coatings from different manufactures or different
brands can not be mixed for use.

For the same reason as above it’s crucial to follow the manufacturer’s guidelines mentioned in
the data sheet. Most important to know are:

- Components’ mixing ratio

- Stirring methods
- Drying / Curing time
- Pot life
- Thinning recommendations
- Storage guideline (temperature, humidity,…)
- Transportation
- Shelf life

Bayer Material Science’s business units CAS (Coatings, Adhesives, and Specialties) and
PUR are manufacturing raw materials for these ingredients. It is preferred that as many of
those products are chosen in compliance with this specification.
In respect of Health and Environment it is utmost important that non- or low VOC (volatile
organic compounds) paints are used.
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5.7 Remediation of damage

Damage to the coatings during transport and/or assembly/installation must be remedied by

qualified contractors.

Two different scenarios are possible:

1. Damage to the top coat, possibly also the intermediate coat, but not extending down to the
steel;
Remedy: Immediate coating of the defective area with an appropriate coating compound
ensuring good integration into the system.

2. Damage of the entire system down to the steel;

Remedy: Removal of rust and loose contaminants (e.g. with a wire brush), application of primer
compound to points requiring it and then a 1x/2x application of the appropriate coating
compound with good integration into the system.

5.8 Storage of coating compounds

The coating compounds must be stored correctly – at the specified temperatures and for no
longer than specified by the manufacturer.
If coating compounds are used after their shelf life has elapsed then a declaration by the
manufacture that this is acceptable must be obtained.
Containers that have been opened may be sealed and subsequently used provided that this is
not expressly prohibited in the technical data sheet of the coating manufacturer. Containers that
have been opened must be labeled accordingly.

5.9 Storage of steel components on the construction site

Steel components that require a primer and which are stored on the construction site for longer
than 10 months must be given an intermediate coat in addition to the primer.

6.0 Quality control & documentation

6.1 Quality control

The quality of a coating applied is depending on at least three important factors. The first is the
specification that dictates which systems and products are to be used. The second is the
human factor or the application and execution in the workshop or onsite. The third important
point is proper inspection.
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Inspection is necessary to ensure that the intentions of the specification as well as its details are
carried out.

Good coating inspection means that every step in the application of a coating, from the surface
preparation to the final drying and curing, is monitored to ensure its conformity with
specifications.

The contractor for corrosion protection work shall establish a quality control system and submit
his proposal for approval to the Project Manger or the corrosion protection supervisor.

The quality parameters shall include but not be limited to:

Conditions:

- Ambient temperature
- Relative humidity
- General weather condition
- Dew point
- Surface temperature

Application:

- Substrate material
- Surface preparation
• Preparation method
• Abrasive material and degree of purity
• Profile roughness
• Anchor profile
• Chloride content (when applicable)

Coating:

- Application method
- Number of coats applied
- Conformity of the coating materials with this specification
- Adhesion between substrate and primer
- Adhesion between the layers
- Coating material list
- Dry film thickness test report
- Defect description and analysis

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A measurement of dry film thickness is to be carried out after application of a coating compound
once it has dried and are to be documented.

Measurements of the dry film thickness are to be carried out at uniform intervals (refer table 3)
for the steel structure concerned.

Table 3

Steel structure Measurement per Number of measurements

Support 1 10
Pipe bridges and 5m 20
pipelines
Vessels 5 m² 10
Other to be specified by customer to be specified by customer

Wrinkles, bubbles, runs or other film defects in any of the painting layers are not accepted.

To avoid detachment between the different painting layers, they shall be applied according to
the manufacturer’s recommendations within the suggested drying time.

For the purpose of control, sample panels of each type of corrosion protection system shall be
established on site. Also panels of proposed colors to be used in the work shall be established
on site.

6.2 Documentation

A coating report shall be established recording the following data for each piece of work.

The data given below shall be the minimum requirement:

- Description of the object

- Location of the object
- Date / Time of surface preparation and application of the layers
- Corrosion protection system
- Results of quality control required by 6.1
- Supplier of coating system
- Name and lot number of applied products

The corrosion protection work, done by the contractor is to check permanently by “Self-
inspection” of the contactors’ supervisor for corrosion protection work.

The contractor must have all the tools to ensure the correct supervision and control of all
parameters (Thermometer, hygrometer, layer thickness meter, WFT comb,…)
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In addition, the corrosion protection supervisor from customer side will execute quality checks
according to the Bayer standard checklist

In case, the quality does not comply with the requirements of this specification, the contractor
must repair or redo the work completely on his account.

7.0 Special applications

7.1 Corrosion protection of steel structures under special conditions

7.1.1 Steel structures in a high-salinity environment

To gain sufficient certainty about the presence of water-soluble substances during the planning
phase of a repair activity, it is necessary to carry out an adequate number of measurements at
exposed points. The number of measurements will depend on the size of the structure.
Measurement of salt concentration has to be carried out using the Bresle method (refer ISO
8502 part 6). A measurement over a total area of 100 m² should be adequate

Particularly at risk are steel structures that are close to storage facilities for substances that
have a potential electrolytic action such as salts and/or structures that have exhibited a
tendency to edge corrosion or gap corrosion after previous repair measures.

The measurement results obtained may depend on the proximity to the storage facility, the
exact point at which measurements are carried out on the structure and under certain
circumstances the time of the measurement. For example, a measurement carried out after a
rain shower may lead to different results from one carried out after a longer period (e.g. a
number of weeks) without rain. The quantity of water-soluble substances present before work
commences is not decisive – the important point is whether substances are present on the
surface or not. Note that water-soluble substances will always be present on the surface. If
necessary control measurements should be carried out on structures that are known to be
uncontaminated.
If the surface salt concentration is above 30 mg/m², then water-soluble substances must be
removed by steam-jetting before surface preparation work is commenced. The conductivity of
the water used should be as low as possible. Normal drinking water with a conductivity value in
the range 600 – 700 µS/cm may be sufficient to achieve a surface salt concentration of approx.
30 mg/m².

For quality assurance purposes approximately one measurement should be carried out for
every 50 m² after washing. The measurement points must be distributed over the entire height
of the structure. Tests should also be carried out at points that are difficult to reach by hand, but
which can be water-jetted (e.g. soffits in angular structures).
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Further control measures are necessary after subsequent dry-blasting since surfaces may
become coated with water-soluble substances from the air. Water-soluble substances may
therefore be found on a surface directly after blast-cleaning. As an alternative the surface may
be prepared by water-jetting at a very high pressure (2000 – 3000 bar). This has the advantage
that removing the old coating at the same time allows a visual control of the progress of the
washing procedure. A disadvantage may be a reduction in performance.

All coatings that are applied on site should be applied with as little time delay as possible.

For new plant all coatings should be applied at the premises of the manufacturer in the course
of production wherever possible. Testing is to be carried out as specified in section 6 above and
the results are to be documented.

The coating systems are specified in Annexure I to this document

7.1.2 Steel structures in highly-abrasive environments (as per IS 14428-1997)

To ensure that the greater corrosion protection requirements for structures in abrasive
environments are satisfied, a 4-layer corrosion protection system is to be adopted as given in
Annexure I.
Two component polyurethane system is the most practical and widely accepted system for this
type of structural painting. There are two general types of two component urethanes:

• Aliphatic
• Aromatic

The aliphatic type has excellent resistance to weathering and most commonly used where color
and gloss retention are important. The aromatic type polyurethanes are sometimes used as tank
linings. When properly formulated, applied and cured, two component polyurethane coatings
have outstanding hardness, abrasion resistance with chemical properties similar to epoxies.

In exceptional circumstances, removal of rust by hand or partial blast-cleaning are required to

be carried out for maintenance/repairing jobs , bearing in mind the requirements of Section 5.2
above. A substantial reduction in service life is to be expected. Therefore surface preparation
through manual rust removal or partial blast cleaning must be specifically agreed between the
customer and contractor.

For new plant all coatings should be applied at the premises of the manufacturer in the course
of production wherever possible. Testing is to be carried out as specified in Section 6 above and
the results are to be documented.

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8.0 Health, Safety and Environment (HSE)

8.1 The HSE hazards

Working with surface treatment and paints involves several hazards both for personnel involved
as well as for the environment. The most important ones are shown in the table below. The
hazards are grouped into safety (S), health (H) and environment (E) for the two activities
representing the major hazards within surface treatment: blast cleaning and paint application.

Source Blast cleaning Paint application

Dust H/E H
High pressure S
Noise H H
Solvents H/S/E
Paint (other chemicals H/E
than solvents)
Waste E E
Aerosols H

8.2 General checklist

To reduce the risk of having accidents and negative HSE impacts, the following general
checklist must be followed:

• Follow requirements from local / national authorities

• All personnel needs to be qualified and properly trained for the job
• Inspect areas where the work is going to take place and look for possible HSE traps
• Plan the work and coordinate with other nearby activities
• Place all products to be used, including thinners and hardeners in the mixing station and
keep them in the original closed cans
• The cans shall be provided with a label stating the brand, the name of the manufacturer,
the delivery date, the batch number, as well as the safety instructions.
• Collect all safety data sheet for the relevant products
• Know the hazard classification and health hazards involved as well as adequate
protective measures
• Read the label on the tin for HSE related information
• Check all equipment to be used, including safety protection equipment
• If required, close off areas to achieve necessary safety
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• Appropriate ventilation equipment must be installed

• Keep the products at a safe distance from open fire and/or other heat sources.
• Gas checks must be carried out before work commences in adjoining spaces.
• Use sufficient, approved personal protection during the work.
• Personal hygiene, particularly in connection with food and drink on the work place, is
important.
• Disposable overalls are recommended, particularly for use with epoxy paints.
• Respect waste handling.
• Painting in tanks or narrow spaces: Extra safety aids should be used. These include the
use of an assistant with a lifeline and intervals in the fresh air.
• At the end of the job, all equipment is cleaned at the mixing station.
• All waste is placed in a suitable container, which is emptied regularly.
• Remains of unused paint, thinner, etc. are returned to the paint store.
• The working area, facilities and different equipment, is to protect from color-splash and
drops.

-----------------

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Annexure I & II to DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

Annexure- I COATING SYSTEMS

Coating Type of Pretreatment & Primer Edge Designation Applicat- Intermediate & top Designa- Applicat- Max.
system part surface compound & protecti- of Coating ion coats , minimum DFT tion of ion Temp
No. preparation grade min. dry film on method Coating method ºC
(ISO 12944 -4 & IS thickness(DFT)
1477)

Steel parts, Rust removal to St 3 by Brush or Intermediate coat: See list of Brush or 160
1 equipment, hand or machine
2K-PUR, zinc 2K-PUR See list of
2K-PUR, DFT = 80 µm suppliers
phosphate, red zinc suppliers and spray spray
vessels, Partial sand-blasting to and current
pigmented, phosphate current technical
piping, fixing P Sa 2 ½ technical
DFT = 80 µm primer, delivery Top coat:
parts etc delivery
pigmented conditions 2K-PUR, DFT = 70 µm
conditions

Intermediate coat:
Steel parts, Blast cleaning to Sa 2 ½ Preferably MC-PUR See list of Brush or MC-PUR, containing micaceous See list of Brush or 120
2 equipment, (metallically pure, zinc dust or zinc dust
2K-PUR
suppliers and spray iron oxide, suppliers
zinc spray
vessels, cloudy) Min. roughness micaceous iron oxide, current technical DFT = 80 µm and current
phosphate
piping, fixing depth 40 to 50 µm DFT = 80 µm, delivery or technical
primer,
parts etc angular roughness pigmented, single conditions 2K-PUR, DFT = 80 µm delivery
pigmented
profile brush application conditions
Top coat: 2K-PUR, DFT=70 µm
Or
MC-PUR, DFT = 70 µm

Hot-dip Mild sweep blasting or Intermediate coat: See list of Brush or ≤120
3 galvanized steam jetting with No Primer required Not applicable Not suppliers
Not MC-PUR, containing micaceous spray
steel surfaces cleaning agent and applicable applicable iron oxide, DFT = 80 µm and current
of all types, all washing with clear technical
objects water, or washing with 5 Top coat: 2K-PUR, DFT=70 µm delivery
fabricated % ammonia solution, Or conditions
from then washing with clear MC-PUR, DFT = 70 µm
continuously water
galvanized
sheet

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Annexure I & II to DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

Coating Type of Pretreatment & Primer Edge Designation Applicat- Intermediate & top Designa- Applicat- Max.
system part surface compound & protecti- of Coating ion coats , minimum DFT tion of ion Temp
No. preparation grade min. dry film on method Coating method ºC
(ISO 12944 -4 & IS thickness(DFT)
1477)

Intermediate coat: See list of Brush or

Steel parts, Blast cleaning to Sa 2 ½ 2K-PUR, zinc 2K-PUR See list of Brush or 2K-PUR, DFT = 80 µm suppliers spray -20 to 160
equipment, (metallically pure, phosphate, red zinc suppliers and spray and current
4 vessels, cloudy) Min. roughness pigmented, phosphate current technical technical
delivery Top coat: delivery
piping, fixing depth 40 to 50 µm DFT = 80 µm primer,
conditions 2K-PUR, DFT = 70 µm conditions
parts etc angular roughness pigmented
profile

Heat-insulated Blast cleaning to Sa 2 ½ 2K-PUR, zinc Not See list of Brush or Intermediate coat: See list of Brush or -20 to 160
5 plant (metallically pure, phosphate, red applicable suppliers and spray 2K-PUR, DFT = 80 µm suppliers spray
components cloudy) Min. roughness pigmented, current technical and current
made of steel depth 40 to 50 µm DFT = 80 µm delivery technical
angular roughness conditions delivery
profile conditions
or
Rust removal by hand or
machine to St3

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Annexure I & II to DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

Coating Type of Pretreatment & Primer Edge Designation Applicat- Intermediate & top Designa- Applicat- Max.
system part surface compound & protecti- of Coating ion coats , minimum DFT tion of ion Temp
No. preparation grade min. dry film on method Coating method ºC
(ISO 12944 -4 & IS thickness(DFT)
1477)

2K-PUR Brush or 2x Intermediate coat:

Steel With salt load zinc See list of spray MC-PUR, containing micaceous See list of Brush or 120
structures in Blast-cleaning to Sa phosphate suppliers and iron oxide, DFT = 80 µm suppliers spray
6 high-salinity Salt concentration to be 2½ primer, current technical or and current
environments determined as per MC-PUR zinc dust or pigmented delivery 2K-PUR, DFT = 80 µm technical
Bresle method (ISO zinc dust micaceous conditions delivery
8502 part 6) water- iron oxide, red or Top coat: 2K-PUR, DFT=70 µm conditions
Steel soluble substances green pigmented, or
structures in removed by washing. DFT = 80 µm, MC-PUR, DFT = 70 µm
highly Process given in Section achieved through a
abrasive 7.1.1 to be carried out & single brush
environments then blast-cleaning to
Sa 2 ½ For rust removal by
hand
Rust removal by hand or
machine to St 3 with 2K-PUR, zinc
partial blast-cleaning if phosphate, red
necessary to P Sa 2 ½ pigmented, DFT = 80
µm, achieved through
Without salt load a single brush

Blast cleaning to Sa 2 ½
or
Rust removal by hand or
machine to St 3 with
partial blast-cleaning if
necessary to P Sa 2 ½

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Annexure I & II to DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

Annexure II: List of approved vendors and their products for Werknorm 2207(for india)

sl no. Company MC-PUR coatings 2K-PUR coatings

Layers Product name Layers Product name
Primer Primer Berger PU primer
Berger paints, Apeejay House, -----
1 Mumbai-400020 , Intermediate Intermediate Berger PU MIO
phone: 022-22821067/1116 1) Bergerthane 41 S/G
Urethane finish,
-----
2) Bergerthane finish
Top Top 3 ) Berger PU MIO

-----
Sika India Pvt. Ltd, Primer Primer Icosit primer PU
2 Commercial Complex II
620. Diamond Harbour Road. -----
Intermediate Intermediate Sikagard PU (UR)
Kolkata - 700034
Board - 033 -24472448 Top ----- Top Sikagard PU (UR)
Apcosil 605(alternate to
Asian paints, 6A, Primer MC PUR zinc dust) Primer Apcothane HB ZP
3 shantinager, santacruz east.
Intermediate ----- Intermediate Apcothane HB PU Finish
Mumbai- 55, Tel-02256958000
Top ----- Top Apcothane CF 678

3M India Limited.Concorde Block, UB City, Primer COPON polycote primer Primer -----
24, Vittal Mallya Road,
Bangalore 560 001, INDIA COPON polycote MIO
-----
Ph:91-80-22231414 Extn 738 Intermediate Intermediate
4
Direct - 91-80-66595738 1)COPON polycote MIO
Mobile:-09741399884 Top 2) COPON polycote Top
Fax No 91-80-22231450 -----
FINISH

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Annexure I & II to DOCUMENT NO.: BTS-SP-CIV-WERKNORM 2207 REV. NO. 1

Annexure II contd…

sl no. Company MC-PUR coatings 2K-PUR coatings

Layers Product name Layers Product name
Kansai Nerolac Paints Ltd Nerolac House
Ganpatrao Kadam Marg Primer Primer -----
Lower Parel, Mumbai 400 013 -----
5
Tel : 2493 4001/24992500 Intermediate Intermediate -----
Fax : 2491 9439
Amercoat 4124[I]
Top ----- Top

Epiplus 556
Primer ----- Primer (alternate to 2K- PUR primer)

1) Shalithane finish,
2) Shalithane PU finish
Intermediate Intermediate 3) Shalithane HS
-----
Shalimar Paints Limited, 4) Shalithane HB
5th Floor, 'C' Wing, Oberoi Garden Estate, 5) Epithane HB
6 Chandivili Farm Road, Chandivili,
Andheri (E), Mumbai - 400 072
Tel: 28574043 / 6147 1) Shalithane finish,
Top ----- Top 2) Shalithane PU finish
3) Shalithane HS
4) Shalithane HB
5) Epithane HB

BTS-INDIA, D Baruah
Project : 2090/1526 Paint Summary Date : 26.08.08
Rev 0 Document no : 946106-D840-X01

Intermediate Paint Summary - Bayer PIC Unit Ankleshwar

Appendix - IV - Sch of Rates
Project No 2090/1600
Rev.0 Dtd 12/11//09

Supply and Application of paints as per attached specification and as per instruction of Engineer in Charges

QTY OF
QTY OF
FITTINGS Unit Rates
Paintcode Size OD PIPE TOTAL QTY SURFACE AREA (m2) Amount (Rs)
[20% of (Rs)
(m)
pipe](m)

P4 100 114.60 111.9 22.4 134.3 48.3

P4 15 21.30 1.0 0.2 1.2 0.1

P4 150 168.30 679.4 135.9 815.3 430.8

P4 200 219.10 198.3 39.7 238.0 163.7

P4 250 273.10 6.0 1.2 7.2 6.2

P4 25 33.40 865.0 173.0 1038.0 108.9

P4 50 60.30 1893.6 378.7 2272.3 430.2

P4 80 88.90 139.4 27.9 167.3 46.7

Total 1234.9

Page 1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA Doc No.:
PIC-1600-2802-C-000 Rev. 0
Plant: PIC (Poly Isocyanate Coatings)

BTS-ENG PP PSS PAGE NO. 22 of 22

Annexure - 1
Steam Tracing Schedule

Sr. No. Line/Eqpt. to be Traced Steam supply Tracer No. No. of Tracers Condensate Return Grid ref./ Eqpt. Ref Remarks
Sub-header no. Sub header no.
2 LR125-80043-50-C4A04 LR107-22010-25-S2A02 LR014-22010-15-C4A04 1 (One) no. LR148-14010-25-S2A02 V100DS30FB110 P&ID NO. LE1336945-1.2
3 LR003-80043-80-C4A04 LR011-22010-25-S2A02 LR017-22010-15-C4A04 1 (One) no. LR552-14010-25-S2A02 V100DS30WV200 P&ID NO. LE1336946-1.2
4 LR001-80043-50-C4A04 LR011-22010-25-S2A02 LR018-22010-15-C4A04 1 (One) no. LR552-14010-25-S2A02 V100DS30WV200 P&ID NO. LE1336946-1.2
5 LR151-80043-50-C4A04 LR011-22010-25-S2A02 LR018-22010-15-C4A04 1 (One) no. LR552-14010-25-S2A02 V100DS30WV200 P&ID NO. LE1336946-1.2
6 V100DS30PA200 LR011-22010-25-S2A02 LR019-22010-15-S6X01 1 (One) no. LR552-14010-25-S2A02 V100DS30WV200 P&ID NO. LE1336946-1.2
7 V200CA20RA110 E100-ER10-LR202- LR028-22010-15-S6X01 1 (One) no. LR617-14010-25-S2A02 V200CA20RA110 P&ID NO. LE1336962-1.2
22010-25-S2A02
E100-ER10-LR202- LR029-22010-15-S6X01 1 (One) no. LR617-14010-25-S2A02 V200CA20RA110 P&ID NO. LE1336962-1.2
22010-25-S2A02
E100-ER10-LR202- LR030-22010-15-S6X01 1 (One) no. LR617-14010-25-S2A02 V200CA20RA110 P&ID NO. LE1336962-1.2
22010-25-S2A02
E100-ER10-LR202- LR031-22010-15-S6X01 1 (One) no. LR617-14010-25-S2A02 V200CA20RA110 P&ID NO. LE1336962-1.2
22010-25-S2A02
8 LR034-59001-100-S4A04 LR099-22010-25-S2A02 LR036-22010-15-S4A04 1 (One) no. LR617-14010-25-S2A02 V200CA20RA110 P&ID NO. LE1336962-1.2
9 V200CA20RA120 E100-ER10-LR204- LR032-22010-15-S6X01 1 (One) no. LR618-14010-25-S2A02 V200CA20RA120 P&ID NO. LE1336963-1.2
22010-25-S2A02
E100-ER10-LR204- LR033-22010-15-S6X01 1 (One) no. LR618-14010-25-S2A02 V200CA20RA120 P&ID NO. LE1336963-1.2
22010-25-S2A02
E100-ER10-LR204- LR034-22010-15-S6X01 1 (One) no. LR618-14010-25-S2A02 V200CA20RA120 P&ID NO. LE1336963-1.2
22010-25-S2A02
E100-ER10-LR204- LR035-22010-15-S6X01 1 (One) no. LR618-14010-25-S2A02 V200CA20RA120 P&ID NO. LE1336963-1.2
22010-25-S2A02
10 LR021-59001-100-S4A04 LR831-22010-25-S2A02 LR037-22010-15-S4A04 1 (One) no. LR618-14010-25-S2A02 V200CA20RA120 P&ID NO. LE1336963-1.2

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com

PC1600010R0
 OPERATING TEMP. oC INSULATION
EQPT. DIMENSIONS DIA

PVT. LTD.
AKER
SR. (mm)(O.D.) x TOTAL M.O.C. Unit Unit
EQPT.NO. QTY.
NO. LENGTH (mm) S.H. T.S. TYPE THK(mm) AREA (m2) Rates Rates Amount
(Rs) (Rs)
S.H. T.S. S.H. T.S. IN OUT IN OUT S.H. T.S. S.H. T.S. S.H. T.S. S.H. T.S. S.H+T.S.

POWERGAS
1 V200DS30WV220 1 1050 x 3730 - SS SS 200 199.1 - - R.W. R.W. 120 - 18 -

512 x 556 &

2 V200DS30WV120 1 516 x 2896 SS SS 185 / 185 178 / 129 174 / 126 176 / 128 R.W. R.W. 120 120 7 16
1212 x 2438
512 x 556 &
3 V200DS30WV110 1 516 x 2896 SS SS 200 195.4 60 237 R.W. R.W. 120 120 7 16
1212 x 2438

4 V100DS30WV100 1 341 x 4150 341 x 594 SS SS 204 204 60 197 R.W. R.W. 120 120 7 2

5 V200DS30WA210 1 1050 x 3730 - SS SS 200 199.1 - - R.W. R.W. 120 - 18 -

CLIENT : BAYER MATERIAL SCIENCE

6 V100DS30FB110 1 1220 x 2794 - SS - 164 164 - - R.W. - 120 - 11 -

7 V100DS30WV200 1 660 x 3796 - SS - 204 204 - - R.W. - 120 - 11 -

8 V100DS30WA400 1 524 x 1690 512 x 351 SS SS 88 60 6 14 P.U. P.U. 50 50 4 1

9 V100DS30WA220 1 524 x 1680 512 x 351 SS SS 120 58 6 14 P.U. P.U. 50 50 4 1

10 V100DS30WA210 1 632 x 3775 516 x 343 SS SS 105 52 20 30 R.W. R.W. 25 25 9 1

11 V100DS30WA120 1 524 x 1680 512 x 351 SS SS 120 70 6 14 P.U. P.U. 50 50 4 1

12 V100DS30WA110 1 816 x 3465 516 x 345 SS SS 130 54 20 30 R.W. R.W. 45 45 10 1

13 V200DS30WA122 1 520 x 1680 512 x 351 SS SS 120 / 120 101 / 60 6 14 P.U. P.U. 60 60 4 1

14 V200DS30WA121 1 524 x 3720 512 x 351 SS SS 145 / 145 73.3 / 60 20 30 R.W. R.W. 45 45 8 1

15 V200DS30WA111 1 524 x 3720 512 x 351 SS SS 145 53 / 63 20 30 R.W. R.W. 45 45 8 1

16 V200DS30WA112 1 520 x 1680 512 x 351 SS SS 120 / 120 100 / 70 6 14 P.U. P.U. 60 60 4 1

17 V200WS10WA200 1 512 x 1636 512 x 351 SS SS 165 165 60 127 R.W. R.W. 110 110 4 1

INSULATION SCHEDULE
( EVAPORATORS)
18 V200WS10WA100 1 520 x 3963 512 x 351 SS SS 130 60 20 30 R.W. R.W. 110 110 9 1

19 E100ER12WA100 1 375 x 987 375 x 697 CS CS 99.97 99.72 40 50 P.P - 25 - 2 -

20 V200CA20WA122 1 610 x 190 649 x 120 SS SS 56 50 40 48.03 P.P. P.P. 45 45 1 2

21 V200CA20WA112 1 610 x 190 649 x 120 SS SS 56 50 40 48.03 P.P. P.P. 45 45 1 2

22 E200ER22WA200 1 610 x 190 649 x 120 SS SS 30 20.46 6 14 COLD COLD 40 40 1 2

23 V100CA20WA122 1 610 x 190 649 x 120 SS SS 25 19 6 14 COLD COLD 40 40 1 2

24 V100CA20WA112 1 610 x 190 649 x 120 SS SS 25 19 6 14 COLD COLD 40 40 1 2

25 V200DS30WA212 1 356 x 144 378 x 70 SS SS 199 200 204 204 HOT HOT 80 80 1 1

26 V200DS30WA222 1 356 x 144 378 x 70 SS SS 199 200 204 204 HOT HOT 80 80 1 1

27 V200DS30WA113 1 356 x 294 378 x 70 SS SS 195.4 200 204 204 HOT HOT 80 80 1 1
G-VSL-002.021-F-00
 ATORS)
SCHEDULE
28 V200DS30WA123 1 356 x 294 378 x 70 SS SS 195.4 200 204 204 HOT HOT 80 80 1 1

29 V100CA20WA111 1 356 x 264 378 x 70 SS SS 124 130 165 165 HOT HOT 80 80 1 1

30 V100CA20WA121 1 356 x 264 378 x 70 SS SS 124 130 165 165 HOT HOT 80 80 1 1

31 V200CA20WA111 1 356 x 264 378 x 70 SS SS 170 180.09 204 204 HOT HOT 80 80 1 1

32 V200CA20WA121 1 356 x 264 378 x 70 SS SS 170 180.09 204 204 HOT HOT 80 80 1 1

33 V200DS30WA223 1 610 x 120 649 x 120 SS SS 40 50 97 80 P.P. P.P. 45 45 1 2

INSULATION-X1
PIC-1600-EVAPORATORS-

SPECIFICATION NUMBER
SHEET NO :
TOTAL INSULATION AREA m2 163 65

1
NOTES :

OF
1) S.H. INDICATES SHELL SIDE, T.S. INDICATES TUBE SIDE, R.W. INDICATES ROCKWOOL

2) AS PER FEL "INSULATION WORK GUIDELINE" DOCUMENT: A) INSULATED VERTICAL EQUIPMENTS WITH DIAMETER > DN 350 HAVE TO BE PROVIDED WITH SUPPORT RINGS FOR INSULATION.

1
SUPPORT RINGS ARE TO BE FABRICATED IN FORM OF A DOUBLE CLAMPING RING (AS PER DETAILS IN TABLE-6, PAGE 14/34 IN THE INSULATION WORK GUIDELINE DOCUMENT). THESE SUPPORT

RINGS ARE LOOSE NOT WELDED TO THE EQUIPMENT. THE SUPPORT RINGS REST ON SUPPORT LUGS WHICH ARE WELDED TO THE EQUIPMENT. THE SUPPORT LUGS WHICH ARE WELDED TO

EQUIPMENT WILL BE IN VESSEL VENDOR'S SCOPE. HOWEVER THE LOOSE SUPPORT RINGS ARE TO BE IN SCOPE OF THE INSULATION CONTRACTOR (AS PER CLAUSE 5.1( PAGE 12/34).

G-VSL-002.021-F-00
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2802-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 1 of 22

SPECIFICATION FOR STEAM TRACING FOR PIPING,

VESSELS AND EQUIPMENTS

0 30.10.09 Design (PEM Status – S3) PNK/30.10.09 IJM/30.10.09 RAM/30.10.09

Prepared by / Checked by / Approved by /
Rev. Date Issued For
Date Date Date
Aker Powergas Pvt. Ltd. © 2008 Aker Solutions
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2802-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 2 of 22

SPECIFICATION FOR STEAM TRACING FOR PIPING,

VESSELS AND EQUIPMENTS

Details of Revision
Rev. Date Details of Revision

0 30.10.09 Issued for Design (PEM Status – S3)

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2802-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 3 of 22

TABLE OF CONTENTS

1 GENERAL

2 SCOPE

3 DESIGN & INSTALLATION

4 TESTING

5 INSULATION

6 STEAM TRACING SCHEDULE

INSTALLATION SKETCHES
Sketch – 1 : Steam Supply Manifold for Reactor V200CA20RA110/RA120 Top Dish Tracing
Sketch – 2 : Manifold with Condensate Recovery for Reactor V200CA20RA110/RA120 Top
Dish Tracing
Sketch – 3 : Steam Supply Manifold for Steam Teaced Lines & Pump in P&ID LE1336946-1.2
Sketch – 4 : Manifold with Condensate Recovery for Steam Teaced Lines & Pump in P&ID
LE1336946-1.2
Sketch – 5 : Steam Supply Manifold for Steam Teaced Lines in P&ID LE1336945-1.2
Sketch – 6 : Manifold with Condensate Recovery for Steam Teaced Lines in P&ID
LE1336945-1.2
Sketch – 7 : Steam Supply Manifold for Steam Teaced Lines in P&ID LE1336962-
1.2/LE1336963-1.2
Sketch – 8 : Manifold with Condensate Recovery for Steam Teaced Lines in P&ID
LE1336962-1.2/LE1336963-1.2
Sketch – 9 : Steam Tracing For Reactor Top Dish
Sketch – 10 : Tracer Arrangement Details
Sketch – 11 : Position of Tracers along the pipes & Tracers arrangement around the valves,
flanges & fittings
Sketch – 12 : Accumulated Pipe Rise

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 4 of 22

1. GENERAL

The purpose of steam tracing is to keep the temperature high enough for free flow of fluid
and proper pumpability and to prevent the fluid passing through a process line from
freezing.

The pipe lines requiring steam tracing will be indicated on P& I Ds. The size and number of
tracers shall be based on this specification.

2. SCOPE

This specification outlines the requirements to be met in the design and installation of steam
tracers for piping and instrument. In case tracing is required for equipment, they shall be
reviewed separately on case to case basis.

2.1. Steam for tracing shall be as specified in the line list. The minimum steam pressure shall
be 1.5 kg/cm2 g. The minimum steam temperature shall be the saturation temp of the steam
at a given pressure.
2.2. In case of High temperature steam tracing requirements, the same shall be separately
looked at.

2.3. Sizes of sub-headers and manifolds shall not exceed 80 mm (3") nominal bore.

3. DESIGN & INSTALLATION

The lines and equipment to be traced shall be as given on P & I Diagram.

3.1. SOURCE OF STEAM SUPPLY

Steam supply for tracing can be obtained from the steam-main header/sub-header or
independent steam supply. In any case the source shall be such that tracers always get steam
even if other units are out of operation. As far as practicable, steam supply header shall be
laid such that lines requiring steam tracing are a minimum distance from the header.

3.2. MATERIAL

Material shall be as per piping material specification. The material shall be generally as
follows,

Steam Supply and Condensate return manifolds Carbon steel Pipes

Straight steam tracer For Carbon steel parent pipes Carbon Steel Pipes
For SS 304 parent Pipes
For SS 316 parent pipes
For SS 304L parent pipes SS 304 L Pipes
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 5 of 22

For SS 316L parent pipes SS 316 L Pipes

Spiral Steam Tracers For all parent materials SS 316 tubes

Wrap around valves and InstrumentsFor all parent materials SS 316 Tubes

3.3. SIZING

SR.
DESCRIPTION SIZE (mm) REMARKS
NO.
Steam Supply
1 80NB
Manifold
Condensate return
2 80NB
manifold
Parent Pipe No. of 15NB The size and number of
Size Tracers tracer shall be as per Line
List. In case the sizes are
3 No. of Steam tracers 100NB & Below 1 not mentioned there, the
150 to 400NB 2 following size and numbers
450NB & Above 3
may be used.
No. of tracers Sub Header size

1 15NB
Steam Sub header
2 20NB
size from header to
4 3 25NB
manifold (Based on
4–6 40NB
no. of 15NB tracers)
7 – 12 50NB
> 12 Calculate

No. of tracers Sub Header size

Condensate return
1-3 25NB
headers size (Based
5 4-6 40NB
on no. of 15NB
7 – 12 50NB
tracers)
> 12 Calculate

No. of tracers Lead Line Size

Steam Lead Line
size to tracers
6 1 15NB
(Based on no. of
2 20NB
15NB tracers)
3 25NB
Straight steam
7 15NB Pipe suitable to parent pipe
tracer

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 6 of 22

14mm SS 316 tube for all piping

systems

10mm OD SS 316 Tube for

This system shall be used
irregular shape components up to
8 Spiral Steam tracing only if specifically asked
80NB size
by client
14mm OD SS 316 Tube for
irregular components 100NB and
above
10mm OD SS 316 Tube for
irregular shape components up to
80NB size
Wrap around valves
9
and Instrument
14mm OD SS 316 Tube for
irregular components 100NB and
above
For Open system
Max. length = 38 m and vertical
Useful length of
rise 3 m Refer to 3.10 for further
10 tracers for steam
For Closed System details on vertical rise.
pressure 3.5 Bar G
Max. Length = 24 m and vertical
rise 3 m

3.4 The tracers shall be held in position by three turns of 16 SWG soft annealed galvanized
from iron spaced every one meter.
3.5 Each tracer line shall have its own steam supply valve and condensate trap.
3.6 Tracer line shall slope in the direction of condensate flow whenever possible. The tracer
line shall contain a horizontal expansion bend for each 15-m. of length.
3.7 For straight steam tracing, steam trap shall be installed every 30 m.
3.8 Tubing connectors shall be double Ferrule compression type.
3.9 Locate manifolds to minimize the length of the supply leads serviced by manifolds.
3.10Tracer pocket depth is the distance the tracer rises in the direction of flow from a low
point to high point. The total depth of pockets is the sum of all the pockets on the tracer
and must not exceed the given figure. The pocket should be considered from the point
where the tracer starts its run along the traced pipe upto the steam trap. Generally over
all vertical riser height = Delta P between inlet & trap discharge x 4420 mm.
3.11The tracers shall start at the highest point in a system in general. As far as possible
tracers shall be routed with a continuous slope towards trap.

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 7 of 22

3.12 Branch tracers to paired equipment and instruments to be provided with isolation valves
and each branch to have its own trap.

3.13Tracer shall not be provided with low point drains.

3.14The tracers shall be laid so as not to interfere with the normal working, operation and
maintenance of plant and machinery.

3.15Wherever the traced piping needs to be disconnected for frequent maintenance, flushing etc
break flanges shall be provided.

3.16The steam supply lead lines should be field routed together, as far as possible. In case of
several tracers routed together, the spacing between individual tracer may be reduced to allow
box type insulation. However the spacing will be adequate in all cases to permit good welding
and individual by U clamps, or other approved type of fastener.

3.17Expansion for steam tracing temperature upto 150o C the tracers shall be anchored at the
middle point of the tracer run. Ample free space shall be provided for the expansion of tracers
of the free ends.

3.18 STEAM TRAPS

3.18.1 Steam traps shall be provided on each tracer or each branch of a tracer that is split,
(i.e., a tracer on suction line of a parallel pump installation shall be separately
trapped at the end.)

3.18.2 Steam tracing traps need not be provided with by-pass except when specifically
asked. The same may be confirmed with process before undertaking design.

3.18.3 Steam tracing installation shall be installed so as to facilitate rapid and easy removal
and replacement of traps.

3.18.4 The trap discharge line shall have a block valve only if tied into a system into which
more than one trap discharge

3.18.5 For an open condensate system, locate traps so that condensate will drain from the
traps close to the ground to OWS or ditches to avoid hazard to personnel.

3.18.6 Thermostatic Bimetallic traps with in-built strainer size 15 NB shall be used.

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 8 of 22

3.19 ISOLATED STEAM SUPPLY AND CONDENSATE RETURN

In those cases where only single line is to be traced, the steam supply and condensate return
manifolds may be deleted. In such cases the steam sub-header will be same as steam supply
lead line and will supply the traced line in the usual manner. The condensate shall be
recovered or disposed off from the individual tracers after the run of tracers as the case may
be.

3.20 SUPPORTING OF STEAM TRACING SYSTEMS

All the components of steam tracing system shall be adequately supported. The supply lead
lines and condensate return lines should be routed together, as far as possible, with same
BOP, so that they can be supported from common structural steel. To avoid undue
deflection and vibration, the spacing of supports in horizontal or vertical runs should not
exceed 2 Meters. The small lines may be secured to structural members with U clamps.

4 TESTING

All tracers shall preferably be tested along with the steam piping to which they are
connected. In case where tracers are not tested with the feed steam piping, operate
hydrostatic test shall be performed with test pressure is assumed same for tracers falling
within/outside IBR scope.

5 INSULATION

5.1 Insulation thickness, material and methods of application shall be as specified in Insulation
Standards and Specifications. In addition the following points shall be noted.

5.2 Composite box type insulation may be provided on the steam supply lead lines, in case they
are routed together. Similarly this may be provided for the return lines to manifolds after
the run of tracers.

5.3 The insulation shall not be provided at free ends i.e. at locations where steam tracers start
the run along steam traced pipe and where steam tracers come apart from traced pipe for
being drained.
5.4 No insulation shall be provided after the flange of steam traps.

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 9 of 22

6 STEAM TRACING SCHEDULE

Refer Annexure – 1 for Steam Tracing Schedule.

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 10 of 22

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 11 of 22

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 12 of 22

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 13 of 22

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 14 of 22

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 15 of 22

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 16 of 22

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 17 of 22

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 18 of 22

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 19 of 22

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 20 of 22

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanat Coatings) PIC-1600-2802-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 21 of 22

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 1 of 14

SPECIFICATION FOR COLD INSULATION OF PIPING,

VESSELS AND EQUIPMENTS

0 3.06.09 Design PNK/3.06.09 SG/IJM/3.06.09 RAM/3.06.09

Prepared by / Checked by / Approved by /
Rev. Date Issued For
Date Date Date
Aker Powergas Pvt. Ltd. © 2008 Aker Solutions
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 2 of 14

SPECIFICATION FOR COLD INSULATION OF PIPING,

VESSELS AND EQUIPMENTS

Details of Revision
Rev. Date Details of Revision

0 3.06.09 Issued for Design

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 3 of 14

TABLE OF CONTENTS

1 SCOPE

2 GENERAL REQUIREMENTS

3 MATERIAL

4 GENERAL APPLICATION

5 SAFETY

6 GUARANTEE

7 ATTACHMENTS

ANNEXURE 1 – Insulation Thickness For Cold Insulation

ANNEXURE 2 – Cold Insulation Installation Details

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 4 of 14

1.0 SCOPE
This specification covers technical requirements and general application for self
extinguishing type insulation - Rigid polyurethane foam to piping, vessels, equipment, heat
exchangers, pump and instruments.

2.0 GENERAL REQUIREMENTS

2.1 Insulation shall be provided on all vessels, equipment, heat exchangers, piping and
instruments etc. containing fluids or vapour, for which it is necessary to :
- Maintain low temperature for process control
- Avoid surface condensation
2.2 All applications of insulation shall be made in accordance with this specification.
Contractor shall submit with his proposal, information on intended practices of
insulation application, which are not covered in this specification, for approval of the
Engineer-in-charge. This information shall include all the details and sketches
including those for the following :
- Removal insulation housings
- Flashing details
- Additional insulation supports
- Vessel head insulation supports
- Expansion joints
- Vessel insulation details
- Exchanger removal housing
- Machinery removable housing etc.
2.3 Protection of Materials During Storage
Insulation materials must be protected against any damage, from delivery to finish
cladding. Decking and covering with tarpaulins alone are not considered sufficient
protection from weather for any length of time and shall not be permitted. Insulation
material slabs and sections shall be stored on a flat surface in a horizontal position.
Insulation materials shall never be stacked directly on the ground. The contractor
shall provide covered storage for insulation materials as directed by the Engineer-in-
charge.
2.4 Protection of Partially Completed Jobs
All precautions shall be taken to ensure that each day’s work is vapour sealed and
cladded during erection and before being left over-night to prevent seepage of water
into the materials and getting trapped. The system shall be protected by tarpaulins,
water shed and other protective means.

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 5 of 14

2.5 Hydrostatic Test

Insulation shall be applied on vessels, heat exchangers, piping and other equipment
only after successful completing of hydrostatic test. In case insulation work starts
before completing of hydrostatic test, all welded and mechanical joints shall be left
exposed for testing and subsequently insulated after successful completing of the
hydrostatic test.
2.6 Co-ordination With Other Agencies
Contractor shall work in close co-ordination with the erection contractor. Wherever
temporary supports are provided the contractor shall remove these and provide the
necessary insulating wood blocks.
2.7 Extent of Insulation
2.7.1 Items Requiring Insulation
2.7.1.1 Items requiring insulation are specified in the piping line schedule and
equipment/ vessel/heat exchanger data sheets.
2.7.1.2 All attachments and projections such as vessel supports, structural steel
attached to vessel, piping hanger support, instrument lead lines, branch lines
like vents, drains and instrument connections connected directly to cold
insulated piping, vessels and equipment shall be cold insulated upto a
distance of 4 times the adjoining insulation thickness.
2.7.1.3 All flanged joints, manhole covers etc. shall be cold insulated with removable
box insulation.
2.7.2 Items Not Requiring Insulation
2.7.2.1 Bonnet of valves above the packing glands.
2.7.2.2 Nameplates, stampings and code inspection plates on vessels and equipment.

3 MATERIALS
3.1 General
All materials used for insulation, fixing, sealing and protection shall be new and shall
conform to the details given in Annexure – 1 and in clause 4.0. All insulating materials
whether dry or wet shall be non-corrosive to the surfaces insulated.
3.2 Basic Insulant
Insulation material for insulating piping, vessels and equipment in cold service shall be
Polyurethane Foam with following minimum properties :

1. The insulation material shall be rigid preformed cellular urethane foam of self
extinguishing type in accordance with ASTM C 591, Type II, Grade 2. The foam
shall be formulated in such a way that it shall be of a self extinguishing quality
which under no circumstances shall cause fire to spread. However due importance
should be given for selection of appropriate ancillaries like adhesive & vapor seal
which should also be fire resistive nature or at least at should not accelerate fire.
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 6 of 14

2. Composition
The insulation material shall be produced by reacting polyisocyanates with
polyhydroxy compounds and expanded with a fluorocarbon blowing agent. The
finished foam in the form of slabs or half sections shall be of uniform closed cell
structure, free from unreacted materials, shrinkage and distortion.
3. Density
The density of finished foam shall be within 36 ± 2 Kg/cum and shall be determined
in accordance with ASTM C-302.
4. Thermal Conductivity
Thermal conductivity of the polyurethane foam slabs and sections shall not exceed
0.019 k Cal/ hr.moC (0.16 BTU/ ft2 hroF/ in) at 10oC mean temperature after aging.
The thermal conductivity shall be tested by the method prescribed in ASTM C 335.
5. Closed Cell Content
The closed cell content shall be atleast 95% by volume.
6. Preinsulated Polyurethane Pipe Supports
At pipe support location select Polyurethane pipe support of appropriate density type
of pipe support as per pipe location minimum density >= 80 Kg / cu mtr.

3.3 Form of insulation shall be as follows :

Pipes upto 400 NB Preformed pipe sections

Pipes above 400 NB Preformed pipe sections/ Radial lags

Vessel Shells Radial lags

Vessel Heads Preformed sections or slabs contoured to the

profile of vessel heads.

Equipment Radial lags or slabs as applicable to form

contour of the surface to be insulated

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 7 of 14

3.4 Dimensions of preformed sections for piping insulation shall be defined by the outside
diameter and insulation thickness. Tolerances for preformed sections shall be as under :

Outside diameter - 0 %, + 5 %

Concentricity  3%OD

Bore + 2 mm
- 0 mm

Length, width and thickness  2 mm

of slabs

3.5 The material used shall not disintegrate, settle, change its form of composition, in a
detrimental way, at the service conditions.
3.6 The insulating material shall be chemically inert, moisture free, rat and vermin proof.
3.7 Preformed half sections and slabs shall be provided having their longitudinal and
circumferential faces flat and smooth so as to mate with the mating sections of the whole
face area. Ends of the preformed half sections shall be flat and perpendicular to the
centre line.
3.8 Ancilliary Materials

3.8.1 Wire-Netting, Lacing and Binding Wire / Bands

Insulation blocks to be secured with stainless steel wires/bands as specified below :

- For pipes with a diameter < DN 620, minimum 6 loops stainless-steel wire
(diameter ³ 0.5 mm) per meter, must be used.

- For pipes with a diameter > DN 620, minimum 4 loops stainless-steel bands (13.0
x 0.5 mm) per meter, must be used.
3.8.2 Adhesives
The adhesive to be used for bonding polyurethane sections shall be Foster Fire
Resistive Adhesive 81- 33. In case on non-availability of Foster’s adhesive,
equivalent adhesive can be used as an alternative.
3.8.3 Vapour Seal
The vapour seal for polyurethane insulation shall be Foster Fire Retardant Mastic
60- 30 or equal. In case of non-availability of Foster’s Mastic, Bitumen Emulsion
Mastic ‘Insulkote’, Grade T-12 or equivalent shall be used as an alternative.

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 8 of 14

3.8.4 Filler Material

Polyurethane foam dust mixed with specified adhesive shall be packed tightly so
as to fill all irregular voids and at contraction joints.

3.8.5 Joint Sealer

The joint sealer to be used for sealing polyurethane insulation joints and at flashing
of insulation shall be Foster Foam Seal Sealer 30 – 45.

3.8.6 Gloss Cloth

The glass cloth to be used for vapour barrier reinforcement, shall be open weave
10 mesh glass cloth having glass fibre thickness of 5 mils.

3.8.7 Weather Protective Jacketing

Al-Zn coated steel sheets shall be used for cladding of vapour barrier on the insulation.

Table 1 Minimum Sheet thickness and overlapping of cladding for equipment insulation jackets

Circumference of Min. sheet thickness Overlapping

Overlapping
the sheet jacket Longitudinal Seams Girth Seams

Upto 1200 mm 0.8 mm 50 mm 50 mm

Over 1200 mm 1.0 mm 50 mm 50 mm

Table 2 Minimum Sheet thickness and overlapping of claddig for pipes without heat extension
Circumference of Min. sheet thickness Overlapping
Overlapping
the sheet jacket Longitudinal Seams Girth Seams
Upto 400 mm 0.5 mm 30 mm Interlock ball swage
400 to 800 mm 0.6 mm 40 mm Interlock ball swage
800 to 1200 mm 0.6 mm 50 mm Interlock ball swage
Over 1200 mm 0.8 mm 50 mm Interlock ball swage

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 9 of 14

4 GENERAL APPLICATION
4.1. Workmanship
4.1.1. Insulation materials shall be warehoused on or near the jobsite and drawn from
the warehouse as required. Decking and tarpaulins are not considered adequate
protection.

4.1.2. Insulation materials shall be dry on installation and shall be kept free of water
And foreign matter before, during and after installation.

4.1.3. The Contractor shall submit a full set of drawings for Owner/Authorised
Representative approval along with an application specification covering all of
the details in the cryogenic system. This shall include, but not be limited to
expansion joints, vapour stops, secondary vapour barrier installation, pipe
supports, anchors fabricated covers and any other feature that due to
configuration is deemed non-standard.

4.1.4. The insulation shall be applied in accordance with BS5970 and good industrial
practice. When finished it shall have a neat and workmanlike appearance to the
satisfaction of the Owner/Authorised Representative.

4.1.5. The Contractor shall keep his working locations in a tidy condition and shall
remove all his waste and surplus material from the site at the end of work
completion or at any other time when, in the opinion of the Owner/Authorised
Representative said removal is necessary for a safety of personnel or any other
reason.

4.2. Surface Preparation

4.2.1. Prior to installation of insulation, all steel surfaces shall be dry, clean and free
from grease and dirt. Before installing insulation surfaces shall be fully painted,
in accordance with BTS-SP-CIV-WERKNORM 2207.

4.2.2. The applied Paint System must have an authorised acceptance certificate prior to
the application of any insulation.
4.3. Testing
4.3.1. Equipment which is to be hydrostatically pressure tested after installation shall
not be insulated until such tests have been successfully completed. Equipment
which has been successfully shop tested may be insulated prior to field test with
the permission of Owner/Authorised Representative, except for joints made in
the field.

4.3.2. If piping (welded or flanged) is insulated before field erection testing with the
permission of Owner/Authorised Representative, all untested joints must be left
temporarily uncovered until the test has been successfully carried out.

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 10 of 14

5 SAFETY
The insulation contractor shall provide adequate protective appliances like hand gloves, masks,
glasses etc. to the workmen carrying out the insulation work, to protect them from inhaling and
touching insulation dust and fibres
6 GUARANTEE
6.1 The insulation contractor shall submit along with the tender, authentic test certificates confirming
that the insulation materials offered conform to the requirements of this specifications and the
standards mentioned therein. Any deviations shall be clearly stated.
6.2 The insulation contractor shall guarantee the following :
6.2.1 The insulation and ancillary materials are new and unused and conform to the standards
mentioned in the specification.
6.2.2 The operating thermal conductivity shall be as specified.
6.2.3 The workmanship in execution of the insulation works shall be in accordance with sound
engineering practice.

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 11 of 14

ANNEXURE - 1

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 12 of 14

POLYURATHANE FOAM INSULATION THICKNESS TABLE FOR COLD INSULATION

COLD INSULATION
OPERATING TEMPERATURE
O
C 20 10 0 -10 -20 -30 -40 -50 -60 -70 -80 -90
SIZE INSULATION THICKNESS
in mm
21.3 25 35 45 55 65 70 80 90 95 105 110 120
26.7 25 40 50 60 70 75 85 95 100 110 120 125
33.4 25 40 50 65 75 80 90 100 110 115 125 135
42.2 25 40 55 65 75 85 95 105 115 125 135 140
48.3 30 45 55 70 80 90 100 110 120 130 140 145
60.3 30 45 60 75 85 95 105 115 125 135 145 155
73.0 30 50 65 75 90 100 110 120 130 140 150 165
88.9 30 50 65 80 95 105 115 125 140 150 160 170
114.3 35 55 70 85 100 110 125 135 145 160 170 185
141.3 35 55 75 90 105 115 130 140 155 170 180 195
168.3 35 55 75 90 110 120 135 150 160 175 190 200
219.1 35 60 80 95 115 130 145 160 175 185 200 215
273.1 40 60 85 100 120 135 150 165 180 195 210 230
323.9 40 65 85 105 125 140 155 170 185 200 215 235
355.6 40 65 85 105 125 140 155 170 190 205 220 240
406.4 40 65 90 105 125 145 165 180 195 210 225 245
457.2 40 65 90 110 130 150 165 185 200 215 230 250
508.0 40 70 90 110 130 150 165 185 200 220 235 255
558.8 40 70 90 115 135 155 170 190 205 220 235 255
609.6 40 70 90 115 135 155 170 190 205 225 250 260

0.0 40 70 90 115 140 170 185 215 230 260 285 305

NOTE: PIPE DIA "0" STANDS FOR DIA MORE THAN 610 AND FLAT SURFACE.

DESIGN CRITERIA

AMBIENT TEMP - 35O C

RELATIVE HUMIDITY - 85 %
SURFACE TEMPERATURE - 32.77778 0C
WIND VELOCITY - 0 m/s (Still Air)
EMISSIVITY - 0.30
- Thickness do not include finish thickness.
- Maximum single layer insulation thickness – 50 mm. Wherever thickness exceeds 50 mm two layers of
insulation shall be used for higher thickness several layers shall be used.

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 13 of 14

ANNEXURE – 2

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2801-C-000 REV 0

BTS-ENG PP PSS PAGE NO. 14 of 14

Table 1 : Cold insulation with one layer of insulation material

PC1600001R1
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural, Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc

Content:

1.0 Specification
1.1 General
1.2 Corrosion Protection Systems
1.3 Colors
1.4 Scope
1.5 Description of Systems
1.6 Quality Control
1.7 Documentation
2.0 Technical Standard

3.0 Supplier recommendations and information

Contact persons:

Hubert Pieper 18/F, Yunhai Mansion, No.1329, Huaihai Road, Shanghai 86-21-5465 2591-111 hubert.pieper.hp@bayer-ag.de
Name Address Tel/Fax No. E-mail

Document Revisions:
05
04
03
02 27.11.2002 Hubert Pieper Including supplier information Hubert Pieper
01 24.09.2002 Hubert Pieper Change acc. Piping group based on GB 2893/2001 Heinz Jung Hubert Pieper
00 06.08.2002 Wangxin Draft Wangxin Hubert Pieper
Rev. Date Prepared Description Checked Approved
D:\DATA\Package\Execution Specification\CSA9056-Corrosion Protection.doc

© Bayer Technology Service (Shanghai) 2003 Last printed 19.05.04 08:28

Page 1 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc
1.0 Specification
1 General
All carbon steel parts shall be protected against corrosion by coating. Additionally
the thermally insulated stainless steel parts shall receive a coating as corrosion
protection. Exceptional care shall be exercised in the execution of the work because
of the very aggressive nature of chlorides contained in the atmosphere. In all cases
protective systems shall be applied strictly in accordance with the manufacturers'
instructions.
It must always be ensured that flanges are protected during preparation and coating
work.
All inspection activities must be reported in a coating report. Especially the
measurements referring to actions regarding dew point have to be reported.

2 Corrosion protection systems

System 1: Hot-dip galvanizing
System 2: Hot-dip galvanizing and coating (DUPLEX)
System 3: Moisture-cure 2-component epoxy / 2-component polyurethane
coatings (MC 2K-EP/2K-PUR)
System 4: Moisture-cure 2-component polyurethane coatings (MC 2K-PUR) for
stainless steel
System 5: Coating for temperature over 120 °C for carbon steel
System 6: Coating for temperature over 120 °C for stainless steel

3 Colors
If paint systems are applied, the following colors shall be used according to the RAL
color schedule.
Intermediate coat: Matched to the color of the topcoat
Topcoat:
Fluid Basic identification Color ( RAL )
Water Green ( 6010 )
Firewater Flame Red (3000 )
Air, 0² Blue ( 5012 )
Steam Silver ( 9006 )
Gas, LPG Yellow ( 1004 )
Acids Yellow Orange ( 2000 )
Caustic Red Lilac ( 4001 )
Oils, Fuels Ocher Brown ( 8001 )
Acetylene Flame Red ( 3000 )
Vacuum Silver Gray ( 7001 )
Others Jet Black ( 9005 )
Tankage Vessels Gravel Gray ( 7032 )
Structural Steel Pale Green ( 6021 )

4 Scope - application of systems

4.1 Steel construction
System 3
Page 2 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc
4.2 Pipes and vessels, tanks etc. made of carbon steel, T ≤ 120 °C
(temperatures up to 120 °C).
System 3

4.3 Pipes and vessels, tanks etc. made of carbon steel, T > 120 °C
(temperatures over 120 °C).
System 5
4.4 Thermally insulated pipes and vessels, tanks etc. made of stainless steel, T < 120
°C (temperatures up to 120 °C).
System 4
4.5 Thermally insulated pipes and vessels, tanks etc. made of stainless steel, T > 120
°C (temperatures over 120 °C).
System 6

5 Description of systems
5.1 System 1: Hot-dip galvanizing
5.1.1 System application
Preparation of surface by pickling, degree of purity be, according to DIN EN ISO
12 944, part 4.
Impurities that cannot be removed by pickling - e.g. oil, grease residues, welding
particles etc. - shall be removed by other methods.
Thickness of galvanized coat shall be min. 100 µm, max. 300 µm.
5.1.2 Making good of defects
Preparation of surface for spots to be repaired shall be carried out by cleansing and
by removing rust by hand or by machine, degree of purity St 3, according to DIN EN
ISO 12 944, part 4.
Repair coat:
Moisture-cure polyurethane/zinc dust or zinc dust/miox (micaceous iron oxide)
combination according to Technical Standard TL No. 3, min. dry coating thickness
shall be 80 µm, or
2-component epoxy/zinc dust according to Technical Standard TL No. 3, min. dry
coating thickness shall be 80 µm.
Application by brushing.

5.2 System 2: Hot-dip galvanizing and coating (DUPLEX)

5.2.1 System application
This system is a combination of systems 1; 3 (repair coat) and 4 (moisture-cure 2-
component polyurethane coating)
Before application of polyurethane primer and topcoat the galvanized steel surface
shall be treated as follows:
- light blasting with corundum or glass shot

After pretreatment the primer shall be applied immediately to the dry and clean
surface.
The coating system consists of:
Primer:
Moisture-cure polyurethane/miox (micaceous iron oxide) according to Technical
Page 3 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc
Standard TL No.4, min. dry coating thickness shall be 80 µm, or
2-component polyurethane according to Technical Standard TL No. 3, min. dry
coating thickness shall be 80 µm.
Application by brushing, rolling or spraying.
Topcoat:
2-component polyurethane according to Technical Standard TL No. 4, min. dry
coating thickness shall be 60 µm.
Application by brushing, rolling or spraying.
Before delivery to site, all work pieces shall be supplied with their primer. Locations
for on-site welding shall be left unpainted.

5.2.2 Making good of defects

Preparation of surface for spots to be repaired shall be carried out by cleansing and
by removing rust by hand or by machine, degree of purity St 3, according to DIN EN
ISO 12 944, part 4.
Repair coat:
Moisture-cure polyurethane/zinc dust or zinc dust/miox (micaceous iron oxide)
combination according to Technical Standard TL No. 3, min. dry coating thickness
shall be 80 µm, or
2-component epoxy/zinc dust according to Technical Standard TL No. 3, min. dry
coating thickness shall be 80 µm
Application by brushing.
Application of primer and topcoat as described in 5.2.1.

5.3 System 3: Moisture-cure 2-component epoxy / 2-component polyurethane

coatings (MC 2K-PUR)
5.3.1 System application
Preparation of surface by blasting, degree of purity Sa 2 ½, according to DIN EN
ISO 12 944, part 4.
After rust removal the primer shall be applied immediately to avoid formation of any
further rust.
The coating material shall be applied to dry and clean surfaces only.
The coating system consists of:
Primer:
Moisture-cure polyurethane/zinc dust or zinc dust/miox (micaceous iron oxide)
combination according to Technical Standard TL No. 3, min. dry coating thickness
shall be 80 µm, or
2-component epoxy/zinc dust according to Technical Standard TL No. 3, min. dry
coating thickness shall be 80 µm
Application by brushing or spraying
Intermediate coat:
Moisture-cure polyurethane/miox (micaceous iron oxide) according to Technical
Standard TL No.3, min. dry coating thickness shall be 80 µm (not accepted on 2-
component epoxy primer), or
2-component polyurethane according to Technical Standard TL No. 3, min dry
coating thickness shall be 80 µm (also accepted on moisture-cure
polyurethane/zinc dust or zinc dust/miox primer)
Page 4 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc
Application by brushing, rolling or spraying.
Topcoat:
2-component polyurethane according to Technical Standard TL No. 3, min. dry
coating thickness shall be 60 µm.
Application by brushing, rolling or spraying.
Before delivery to site, all work pieces shall be supplied with their primer. Locations
for on-site welding shall be left unpainted.

5.3.2 Making good of defects

Preparation of surface for spots to be repaired shall be carried out by cleansing and
by removing rust by hand or by machine, degree of purity St 3, according to DIN EN
ISO 12 944, part 4.
Application of primer, intermediate and topcoat as described in 5.3.1.

5.4 System 4: Moisture-cure 2-component polyurethane coatings for stainless steel

5.4.1 System application
The surfaces to be protected shall be clear of slag residues, welding particles etc.
Before application of polyurethane primer and topcoat the galvanized
steel surface shall be treated as follows:
- light blasting with corundum or glass shot
After blasting:
Preparation of surface by washing with low-grade chloride water, max. chloride
concentration 6 PPM.
After pretreatment no primer shall be applied immediately to the dry and clean
surface.
The coating system consists of:
Primer:
Moisture-cure polyurethane/miox (micaceous iron oxide) according to Technical
Standard TL No.4, min. dry coating thickness shall be 80 µm, or
2-component polyurethane according to Technical Standard TL No. 3, min. dry
coating thickness shall be 80 µm
Application by brushing, rolling or spraying.
Topcoat:
2-component polyurethane according to Technical Standard TL No. 4, min. dry
coating thickness shall be 60 µm.
Application by brushing, rolling or spraying.
Before delivery to site, all work pieces shall be supplied with their primer. Locations
for on-site welding shall be left unpainted.
5.4.2 Making good of defects
Surface preparation of spots to be repaired by cleansing and roughening of the
adjoining coatings. Application of primer and topcoat as described for system
application in 5.4.1.

5.5 System 5: Coating for temperatures over 120 °C (up to 400 °C)
5.5.1 System application
Preparation of surface by blasting to remove rust, degree of purity Sa 2 ½,
according to DIN EN ISO 12 944, part 4.
Page 5 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc
After rust removal the primer shall be applied immediately to avoid the formation of
any further rust.
The coating materials shall be applied to dry and clean surfaces only.
The coating system consists of:
- Primer: ethyl silicate/zinc dust, dry coating thickness shall be 60-120 µm.
Application by brushing or spraying.
- Topcoat: ethyl silicate or silicone aluminum, min. coating thickness 40 µm.
Application by brushing, rolling or spraying.

Before delivery to site, all work pieces shall be supplied with their primer.
Locations for on-site welding shall be left unpainted.

5.5.2 Making good of defects

Preparation of surface for spots to be repaired shall be carried out by cleansing and
by removing rust by hand or by machine, degree of purity St 3, according to DIN EN
ISO 12 944, part 4.
Application of primer and finish coat as described in 5.5.1.

5.6 System 6 : Coating for temperatures over 120 °C (up to 500 °C) for stainless steel
5.6.1 System application
The surfaces to be protected shall be clear of slag residues, welding particles etc.
Preparation of surface by washing with low-grade chloride water, max. chloride
concentration 6 PPM.
After pretreatment the first topcoat shall be applied immediately to dry and clean
surface. The coating system consists of two coats of Baysilone according to
Technical Standard, TL No. 6, dry coating thickness shall be 30 - 50 µm each,
application by spraying..
5.6.2 Making good of defects
Surface preparation of spots to be repaired by cleansing and roughening of the
adjoining coatings. Application of finish coats as described for system application in
5.6.1.

6 Quality control
The contractor shall establish a quality control system and submit his proposal for
approval by Bayer.
The quality tests shall include but not be limited to:
- conformity of the coating materials with Technical Standard,
- degree of purity after rust removal, condition of surface before coating,
- number of coats applied,
- dry coating thickness,
- adhesion quality between layers and to base surface.
For the purpose of control, sample panels of each type of corrosion protection
system shall be established on site.
Panels of proposed colors to be used in the work shall be established on site.

7 Documentation

Page 6 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc
A document shall be established recording the following data for each piece of
work. The data given below shall be the minimum requirement:
- base surface material,
- type of preparation,
- corrosion protection system,
- date and weather conditions during application (incl. air temperature, air humidity,
surface temperature),
- results of quality control required by 1.6,
- supplier of coating system,
- name and lot number of applied products.

Page 7 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc
Technical Standards

Contents:

TL No. 3 Coatings based on polyurethane or epoxy for structures and

equipment made of carbon steel

TL No. 4 Coatings based on polyurethane for structures and equipment made of

stainless steel and hot-dip galvanized steel

TL No. 6 Coatings based on silicone (Baysilone) for equipment made of

stainless steel T > 120 °C

Page 8 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc

Technical Standard

TL No. 3 Coatings based on polyurethane for structures and equipment made of

carbon steel
Binders manufactured by Bayer AG are to be used.

3.1. Composition of materials as supplied

3.1.1 Materials for 1-component polyurethane/zinc dust or 1-component
polyurethane/zinc dust/miox primers

The composition of the 2-component EP (epoxy)/zinc dust primer is at the

discretion of the manufacturer and is not specified in detail.

Color : gray (perhaps pigmented)

Binder
Moisture-cure polyisocyanate, i.e. Desmodur E

Solvent
The composition is at the discretion of the manufacturer.

Thinner
PUR thinner
The composition is at the discretion of the manufacturer.

3.1.2 Materials for 1-component intermediate coats

Color : Matched to the topcoat but different from the primer

Binder
Moisture-cure polyisocyanate, i.e. Desmodur E

Solvent
The composition is at the discretion of the manufacturer.

Thinner
PUR thinner
The composition is at the discretion of the manufacturer.

3.1.3 Materials for 2-component polyurethane intermediate coats and topcoats

Color : As specified

Binder
Hydroxyl-bearing acrylic resin, i.e. Desmophen A

Page 9 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc

Hardener for 2-component polyurethane topcoats

Polyfunctional aliphatic isocyanate, i.e. Desmodur N

Mixing ratio mill base/hardener for 2-component polyurethane topcoats

As specified by the manufacturer.

Solvent
The composition is at the discretion of the manufacturer.

Thinner
PUR thinner
The composition is at the discretion of the manufacturer.

3.1.4 Pigments
If possible, pigments manufactured by Bayer AG are to be used.

Page 10 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc
TL No. 4 Coatings based on polyurethane for structures and equipment made of
stainless steel and galvanized steel
Binders manufactured by Bayer AG are to be used.

4.1. Composition of materials as supplied

Testing in accordance with relevant DIN standards or by generally accepted
methods.

4.1.1 Materials for 1-component polyurethane primers (no zinc dust)

Color : Matched to topcoat

Binder
Moisture-cure polyisocyanate, i.e. Desmodur E

Solvent

The composition is at the discretion of the manufacturer.

Thinner
PUR thinner
The composition is at the discretion of the manufacturer.

4.1.2 Materials for 2-component polyurethane primers and topcoats

Color : As specified

Binder
Hydroxyl-bearing acrylic resin, i.e. Desmophen A

Hardener
Polyfunctional aliphatic isocyanate, i.e. Desmodur N

Mixing ratio mill base/hardener

As specified by the manufacturer.

Solvent
The composition is at the discretion of the manufacturer.

Thinner
PUR thinner
The composition is at the discretion of the manufacturer.

4.1.3 Pigments
If possible, pigments manufactured by Bayer AG are to be used.

TL No. 6 Coatings based on silicone (Baysilone) for equipment made of stainless

steel T > 120 °

Page 11 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc

3. Supplier recommendations and information

System description:
System 3 System 4
for structures and equipment made of carbon steel for structures and equipment made of
stainless steel and hot-dip galvanized
steel
Supplier Primer Intermediate Top-coat Primer Top-coat

MC zinc- alternative MC Mio alternative 2 K-PUR MC-Mio alternative 2 K-PUR

dust 2K EP zinc- 2K PUR 2 K PUP
dust
Akzo Nobel Interthane Interzinc Interthane Interthane Interthane Interthane Interthane Interthane
International 611 52 566 870 990 566 870 990
Coatings

Hempel Hempel´s Hempadur Hempathane Hempel´s Hempel´s Hempathane Hempel´s Hempel´s

174 DE 17360 17570 5591 resp. 5591 resp. 17570 15552 5591
5521 5521

Sika Friazinc Friazinc R Icosit Not in supply Icosit Icosit Not in Icosit
PUR PUR 1 scope EG 5 BY PUR 1 supply EG 5 BY
scope

Sherwin Corothane/ Corothane/ Corothane/ Corothane/ Corothane/

Williams Galvapeac Mastic HS Mastic HS
Zinc Primer (1K system) (1K
system)
Eclatin Corozink- Eclon EP Coropur-FH Eclon Eclon Coropur-FH Eclon Eclon
FH 2K zinc dust Micaceous PUR-DS PUR-ACR Micaceous PUR-DS PUR-ACR
Zinc dust Primer ironoxid Monocolor 2 K Email ironoxid Monocolor 2 K Email
Primer
Jotun Barrier 77 Hardtop HB Hardtop HB Penguard Hard Top
Special HB
(Epoxy)

Page 12 of 13
Bayer Polymers (Shanghai) Co. Ltd.
Polycarbonate Project
Civil, Structural and Architectural, process equipment and piping
Execution Specification
revision proposal -Corrosion Protection CSA0056.doc

System No. 5 System TL No.6

for carbon steel temperature over 120° C for stainless steel with temperature
over 120° C
Primer Intermediate Top-coat Primer Intermediate Top-coat

ESI zinc-dust - ESI/Si-Al - - Baysilone

Fa. Akzo Interzinc 22 - Intertherm 50 - - Intertherm 50
Nobel
International
Coatings

Fa. Hempel Hempel´s - Hempel´s - - Hempel´s

Galvosil SI-Aluminum SI-Aluminum
15700 56910 56910

Fa. Sika Friazinc - Icosit - - nicht im

ZS Alutherm Liefer-
programm

Fa. Sherwin Zinc Clad II HS Heat Flex II 800 Heat Flex II 800
Williams

Fa. Eclatin Not in supply scope - Not in supply - - Corosilico

scope Aluminum

Fa. Jotun Resist 78 Silvalitt Silvalitt

Page 13 of 13
 Corrosion Protection System (Piping and Vessels)

Temperature Class

A B C D

T < 60o C T < 120o C T > 120o C T > -20o C

without insulation with hot insulation with hot insulation with cold insulation
and heat protection and heat protection

Carbon Steel (CS) CS-A CS-B CS-C CS-D

System 3 System 3 System 5 System 3

Primer Primer Primer Primer

Intermediate Coat Intermediate Coat
Top Coat

Stainless Steel (SS) SS-A SS-B SS-C SS-D

None System 6 System 6 System 4

Two Coats Two Coats Primer

Top Coat
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 1 of 55

SPECIFICATION FOR THERMAL INSULATION OF

PIPING, VESSELS AND EQUIPMENTS

0 3.06.09 Design PNK/3.06.09 SG/IJM/3.06.09 RAM/3.06.09

Prepared by / Checked by / Approved by /
Rev. Date Issued For
Date Date Date
Aker Powergas Pvt. Ltd. © 2008 Aker Solutions
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 2 of 55

SPECIFICATION FOR THERMAL INSULATION OF

PIPING, VESSELS AND EQUIPMENTS

Details of Revision
Rev. Date Details of Revision

0 3.06.09 Issued for Design

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 3 of 55

TABLE OF CONTENTS

1 GENERAL

2 DESIGN BASIS

3 MATERIAL

4 APPLICATION

5 INSUALTION FINISH

6 CONTRACTOR’S SCOPE OF WORK

7 CONTRACTOR’S OBLIGATION

8 INSPECTION

9 MEASUREMENTS

10 GUARANTEE

ANNEXURES

1. Project Specific Insulation Material & Thickness Chart

2. Hot Insulation Installation details

Aker Powergas Pvt. Ltd. © 2008 Aker Solutions

Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 4 of 56

1. GENERAL

1.1. This specification covers design, material specification, installation and inspection
requirements for above ground and below ground external hot insulation of piping,
vessels and equipment operating between ambient temperature and 1425o C for the
purpose of heat conservation, process stabilization, temperature maintenance,
personnel protection and fire protection. Wherever necessary this specification
indicates the basis for selecting type of insulation.

1.2. This specification is suitable for use in outdoor service with normal process plant
atmosphere. Alternative designs and materials shall not be used, unless approved in
writing by client.

1.3. This specification does not cover cold service insulation and dual temperature
services insulation.

1.4. This specification does not cover insulation for boiler or fired heaters and associated
air heaters, economizer, flue gas ducting and air ducting.

1.5. Piping, equipment, storage tanks and vessels requiring insulation are normally
specified on the following project documents.

1.5.1. Process and Instrument Diagrams (P&IDs) and Line Lists

1.5.2. Piping General Arrangement Drawings & Isometrics or 3D electronic model

1.5.3. Instrument Piping interface Details, Instrument Data Sheets

1.5.4. Vendor Drawings/ Engineering drawings/ Data sheets of vessels and

equipment.

1.5.5. Vendor General Arrangement Drawings for equipment within Package Plant

1.5.6. Steam tracing/manifolds/lead lines etc as specified in the Steam Tracing

Specification and drawings

1.5.7. Electrical tracing documents

2. DESIGN BASIS

2.1. GENERAL

2.1.1. In this Standard, Insulation for prevention of heat loss is designed to provide
economic thickness such that surface temperature on the cladding does not
exceed 55 o C.

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 5 of 56

2.1.2. Insulation comprises a layer of heat resisting fibre material enclosed within
protective metal sheeting, sealed against the ingress of moisture and designed
to allow differential expansion.

2.2. CRITERIA

2.2.1. Insulation Types

2.2.1.1. Heat Conservation Insulation (Code: H)

- The Primary consideration for using heat conservation

insulation shall be economics.
- Design of heat conservation insulation shall be based on local
average ambient climatic condition and project economics.
- Heat conservation insulation shall be used if normal operating
temperature exceeds 60 0 C, unless loss of heat is desirable.

2.2.1.2. Process Stability Insulation (Code: H)

- The primary consideration for using process stability

insulation shall be control of process temperatures, including
impact due to sudden changes in ambient conditions.
- Design of process stability insulation shall be based on
anticipated extremes in ambient conditions.

2.2.1.3. Personnel Protection Insulation (Code: P)

- The primary consideration for using personnel protection

insulation shall be to limit the temperature of exposed
surfaces.
- Design of personnel protection insulation shall be based on
summer dry bulb temperature and low wind velocity to reflect
a worst-case condition.

- Personnel protection insulation shall be used if normal

temperature of a surface exceeds 65 0 C. and if the surface is
in an area that are accessible to personnel. Accessible area
defined as an area in which personnel regularly perform duties
other than maintenance during plant shut down.
- Personnel protection shall be provided to 2.1m above grade of
platform and 900 mm horizontally from the periphery of
platform, walkways or ladders.
- Personnel protection shall be of insulation, shields, guards or
barriers

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 6 of 56

- If corrosion under the insulation is a concern, or if heat loss is

desirable, use of fabricated shields/ guards of wire netting in
lieu of insulation should be considered.

2.2.1.4. Insulation Types for Traced systems (Code: ST, E)

- The primary consideration for using tracing and associated

insulation shall be to control process temperatures.
- Design of insulation shall be based on the operating
temperature, the tracer temperature. The same insulation
thickness as that for heat conservation shall be used unless
design optimization dictates a different thickness.
- Over size insulation shall be considered to accommodate
tracers.
- Grooving of insulation to accommodate tracing will not be
allowed unless specified by client.

2.2.2. Internally refractory lined piping and equipment and any other items for
which heat loss is essential shall not be insulated.

2.2.3. Insulation is not desired for piping and equipment for which heat loss is
desired - excepting for personnel protection or to avoid thermal stress
problems.

2.2.4. Instruments and associated piping subject to operating flow and/ or

temperature condition prevailing in the connected piping or equipment shall
be insulated to the same requirements as that of piping or equipment.

2.2.5. Extent of Insulation

Refer to Table - 1 “Datasheet for extent of Insulation”

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 7 of 56

2.3. THICKNESS BASIS

The insulation thickness specified in this specification are base on the Indian
conditions. In case of different climatic and economic conditions, they need to be
reviewed. The basic criteria are highlighted below which are used to arrive at
thickness. Material properties used in thickness calculation are highlighted as part of
Insulation material specification.

Average Annual temperature: 35 0 C

Average Annual wind speed: still air

Personnel protection design wind speed still air

Personnel protection design summer dry bulb temperature:

Personnel protection maximum surface temperature: 55 0 C

Emittance of existing surface: 0.8

Emittance of Jacketing: 0.3 (Aluminium)

Design Factor for thermal conductivity: 1

Design factor for piping complexity: 1.2 simple

Refer to Annexure 1 for insulation thicknesses.

2.4. CODES AND STANDARDS

Refer to Insulation Material specification attached with this specification. All the
codes mentioned shall be the latest issues

3. MATERIALS
3.1. GENERAL
3.1.1. All material shall be of high quality and good appearance.
3.1.2. Insulation and accessory materials shall be formulated without Asbestos.
3.1.3. Materials shall be new and shall be used prior to expiration date. Sealants,
mastics and adhesives shall be supplied in factory sealed containers.
3.1.4. All material shall be qualified for use on austenitic stainless steel in
accordance with ASTM C 795. The material manufacturer shall furnish test
certificate.
3.1.5. Insulation material shall be low chloride content (Maximum limit 10mg/ kg.),
chemically inert, non – sulfurous, rot proof, vermin proof, impervious to hot

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 8 of 56

3.1.6. water and steam, non – injurious to health and non corrosive to steel and
Aluminum.
3.1.7. Insulation and jacketing material backed with paper or other flammable
material is not acceptable.
3.1.8. All mastics, cements, adhesives, caulks, labels, marking pens and tapes that
come in contact with stainless steel shall have a maximum leach able
chloride content of less than 50 ppm, when tested in accordance with ASTM
C 871
3.1.9. Use curved segments, beveled lags and V – grooved materials manufactured
to specific diameter that assure complete inside and outside diameter closure.
3.1.10. Special attention is required for fibrous material as its installed thickness
could be reduced due to compaction affecting performance.
3.1.11. The client shall have right to inspect any or all the tests conducted on
insulation material by manufacturer at his shop or any laboratory.

3.2. INSULATION MATERIAL

Insulation material shall be as per the Annexure 1 attached with this specification.

3.3. WEATHER PROTECTION JACKET

3.3.1. As insulation cladding material, Steel-sheets with aluminum-zinc coating is

to use, with an aluminum-zinc coating grade of AZ180, AZ185 or AZ200
and a coating weight of at least 180 g/m2. The composition of the aluminum-
zinc alloy is : Aluminum 55.0% +-2% and Zinc 43%+-2%. A portion silicone
of maximally 2% is acceptable.

3.3.2. The thickness of the sheets shall be as specified in Table - 2

3.4. ANCILLARY MATERIALS

3.4.1. Securement Bands/Wires

3.4.1.1 For Mineralwool Slabs on Equipment up to 3000 mm diameter,

Stainless-Steel-Bands with 19mm x 0.5mm are to used. Each layer of
mineralwool-slabs or blankets has to be fixed with 3 or more
Stainless-Steel-Bands per meter.
3.4.1.2 For Mineralwool Slabs on Equipment over 3000 mm diameter,
Stainless-Steel-Bands with 25mm x 0.5mm are to used. Each layer of
mineralwool-slabs or blankets has to be fixed with 3 or more
Stainless-Steel-Bands per meter.
3.4.1.3 There are always enough numbers of Stainless-Steel-Bands to
attached, so that no gaps remain in the Insulation. Also the
Slabs/Blankets for the Head-and Bottom of Equipment Insulation is
to be fixed with Stainless-Steel-Bands. To fixed Slabs/Blankets with
wire, is not acceptable.
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 9 of 56

3.4.2. Self-Tapping Screws:

3.4.2.1 Stainless-steel Self Tapping Screws (STS) with seal-washer are to be

used for fixing metal jacketing. Stainless-steel Hex flange self-
drilling screws with seal-washer are to be used for fixing metal
jacketing on supportring. Stainless steel bands are to be used for
fixing the metal jacketing of cold insulated pipes.

3.4.2.2 Layers of metal cladding are to interconnect with Stainless-steel Self

Tapping Screws (STS) with seal-washer. Cladding of hot-insulated
Equipment has to be interconnect with six (6) STS, 4.8 mmØ x 13mm
per meter. Cladding of hot-insulated pipes has to be interconnect with
six (6) STS, 4.2 mmØ x 13mm per meter. To fixed the Equipment
metal-cladding on the supportring, three (3) Hex flange self-drilling
screws, 5.5 mmØ x 16 mm with seal-washer per meter are to used.
The maximum horizontal distance between these screws is 400 mm.

3.4.3. Sealing Compound for Water Proofing

PE Joint Sealant Tape with self-adhesive and water absorption less than 0.002
g/m2 is to use.
The minimum thickness of the PE-tape must be 2.0 mm and the minimum
width must be 8.0 mm.

4.0 APPLICATION

4.1 GENERAL

4.1.1 The application methods, given in this Standard are general in nature. The contractor
is responsible for applying an insulating system that will give a satisfactory
operational performance and the requirements given herein shall be regarded as the
acceptable minimum. The contractor shall carry out the work in accordance with the
best practices of insulation application with the minimum of waste and the final job
shall have a neat efficient and workmanlike appearance.

4.1.2 All hydrostatic/ pneumatic tests on piping and equipment including steam-tracing
system shall be carried out before insulating material is applied. The insulation
contractor shall only insulate these sections of the plant that has been specifically
released for such work by the engineer-in-charge. If insulation must be installed
before pressure test, then all welds and flanged joints in the pipe shall be left
uncovered till successful completion of pressure test. Then insulation shall be
completed. Client prior to commencement of insulation shall approve this method of
testing.

4.1.3 Where insulation has been specified on piping or equipment flanges that are to be hot
bolted, the insulation shall not be installed until hot bolting has been accomplished
and the flange determined to be leak free.
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
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BTS-ENG PP PSS PAGE NO. 10 of 56

4.1.4 Unless otherwise specified, all insulation materials shall be installed in a single layer
when the total thickness does not exceed 75 mm.

4.1.5 When applying single layer insulation, other then hinged pipe covering, the
circumferential butt joints of each half section shall be staggered.

4.1.6 Thick nesses 90 mm and greater shall be applied in multi-layers with staggered
joints. Consideration shall be given to multi-layer insulation for operating
temperature over 316 0 C.

4.1.7 When applying double layer or multi-layer insulation, each succeeding layer shall be
staggered to the longitudinal and circumferential joint of the layer beneath. All joints
of all layers shall be staggered.

4.1.8 Each layer of double layer or multi-layer insulation shall be held in place separately.
4.1.9 All insulation shall be smooth and free from cracks, voids, gaps, and depression
greater than 3 mm. All cracks, voids, gaps and depressions greater than 3 mm shall
be refitted and not filled.

4.1.10 nsulation Contractor shall not carry out any welding or drilling on plant equipment
and piping. He shall however be responsible for carrying out a check and confirm
that all insulation supports as per drawings have been fabricated and installed.

4.1.11 nsulation shall be finished beveled and weather proofed at all terminal points where
it is required to remove bolts etc without damage to the insulation.

4.1.12 Equipment nameplates shall remain visible after beveling back the insulating
material and carefully sealing the exposed edges to prevent ingress of moisture have
applied insulation by silicon rubber compound.

4.1.13 All projections such as lifting lugs, turnings and stiffeners on piping and equipment
(i.e. vacuum rings) shall be insulated with the same thickness of insulation as
specified for the equipment item or pipeline.

4.1.14 Thermo well bosses, pressure tappings and weep hole nipples shall not be insulated
but left accessible. Flanges for hydrogen service shall never be insulated.

4.1.15 Wet or damaged insulation shall not be used under any circumstances.

Insulation material to be applied shall not be kept over bare ground to avoid water
absorption. Installed material awaiting its protective cover shall be adequately
protected from damage, rain and contamination and shall be covered with cladding
within minimum time.
Insulation materials shall be supplied completely dry suitably protected from
weather and stored in a dry warehouse.

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
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BTS-ENG PP PSS PAGE NO. 11 of 56

4.1.16 A minimum clearance of 25 mm between outside surface of any insulation finish and
adjacent equipment, pipe or structural members shall be maintained.

4.1.17 Insulation supports shall not project out of the insulation outer surface and shall be
given sufficient coverage of insulating material to avoid hot spots on the metallic
cover at support position

4.2 CORROSION PREVENTION

4.2.1 Carbon steel and low alloy piping and equipment with normal operating
temperatures of 200 o C and below shall be protected against corrosion by
painting as specified in the Standard Painting Specification. While for
equipment (Vessels, Exchangers, Tanks and Spheres) this coating shall be
provided by Painting Contractor. Note that the drying time for heat
resistance aluminum paint at ambient temperature is about 3-4 weeks. No
insulation shall be applied before paint is completely cured.
4.2.2 Insulation cement shall not be used on stainless steel piping or equipment.

4.2.3 All insulated austenitic stainless steel piping and equipment shall be
protected against chloride attack as follows:

- Wrap with 0.19mm thick aluminium foil before applying insulation up

to 450o C

4.3 APPLICATION ON PIPING

4.3.1 Horizontal Pipe

4.3.1.1 General

Insulation material shall be applied to fit snugly against the

contours and shaped only where necessary to achieve this
requirement. The insulation shall be carried out with the least
number of material pieces as possible and all unavoidable gaps,
cavities and voids suitably filled with compatible loose fill material.

4.3.1.2 Pipe Section/ Moulded Blocks/Segments

- End joints of adjacent blocks shall be staggered one half of the

length of the block.

- Included angle between segments shall not be less than 30 o for

both single and double layer insulation.

- Further minimum arc length of segments should meet the

following staggering requirements

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
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BTS-ENG PP PSS PAGE NO. 12 of 56

- When double layer is applied both longitudinal and

circumferential joints shall be staggered. There are between
the longitudinal seam lines of the inside and outside layers of
insulation shall have and angle over 15 o or the longitudinal
joints staggered at least by one layer thickness whichever is
more stringent.

- Circumferential seams of the inside and outside layers shall be

at least 100 mm apart.

4.3.1.3 Mattress (Fibrous Insulation Rock or Glass Wool)

Shall be applied over the surface with joints tightly butted and laced
together with binding wire.
Mineralwool shells must be applied and attached without any gaps.
They are to be fixed with stainless-steel wire or stainless-steel
bands.
- For pipes with a diameter < DN 620, minimum 6 loops stainless-
steel wire (diameter ³ 0.5 mm) per meter, must be used.
- For pipes with a diameter > DN 620, minimum 4 loops stainless-
steel bands (13.0 x 0.5 mm) per meter, must be used.

4.3.1.4 Insulation Securement

Each layer of insulation shall be secured firmly in place with at

least 3 loops of binding wire/band one loop to be placed not more
than 75 mm from each end and at least one loop to be equally
spaced between end loops for each section. Binding wire shall be
drawn about the insulation with ends tightly twisted together bent
under and pressed into the surface of insulation. Bands or wires in
no case are spaced more than 200 mm apart.

4.3.1.5 Framework for Supporting Cladding: Fibrous Insulation

This is not necessary for rigid materials. This is required mainly for
horizontal pipe runs provided with fibrous insulation in blanket
forms. Piping provided with fibrous resin bonded pipe sections
need not be provided with this framework.
Spacer rings shall be fabricated out of 40 x 4 MS flats. For
equipments with diameter smaller than 1000mm, spacer ring can be
made of 30 x 3 MS flats. The outside diameter of these rings shall
be equivalent to the outside diameter of the insulation. Spacer rings
shall be riveted to "Z" shaped slabs fabricated from the same sized
MS flats "Z" shaped lugs or ceramic studs shall be provided at

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Location: ANKLESHWAR, INDIA
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BTS-ENG PP PSS PAGE NO. 13 of 56

intervals of not more than 300 mm along the circumference of the

insulation subject to a minimum of 3 "Z" shaped lugs. Spacer rings
shall be provided at every approx. 900 mm. To minimise direct
heat conduction through the "Z" shaped lugs, a packing of 2 sheets
of 3 mm thick millboard shall be provided at the joints of the "Z"
shaped lugs and pipes. Joints between MS spacer ring and "Z"
shaped shall be rivetted by 5 dia MS rivets with 2 sheets of 3-mm
thick millboard interposed. Horizontal piping less than 1500 mm
below grade or 1500 mm above grade, where mechanical damage is
possible, shall be provided with support plates instead of spacer
rings.

4.3.2 Vertical Pipe

Insulation on vertical or near vertical piping (i.e. greater than 45 o angle from
horizontal) shall be supported by bolted on metal collars for pipe sizes above
200 mm and insulation thickness above 120 mm. Metal collars shall be of 6
thick MS or alloy steel bar (to suit piping material).

Outside diameter of collar shall be around 13 less than OD of insulation.

Where multi-layer insulation is used, support collar shall be extended to
provide for each layer.

Support positions shall be at no greater distance apart than 3.8 meter. They
shall be spaced so that the compressive strength of the insulation is not
exceeded as a minimum a support ring shall be installed the start of a vertical
rise. In addition also spacer rings may be required at every meter and before
and after elbow and valve.

4.3.3 Expansion Joints (both Vertical and Horizontal Piping)

Expansion joints for system using rigid insulation shall be provided at regular
intervals taking into account, as an example expansion joints may be required
as follows:

- Expansion of equipment and piping

- Expansion, contraction or shrinkage of insulating material

- The resilience of the insulation

- Method of supporting of the insulation; design details and sketches of

proposed joints shall be submitted to consultant for approval

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 14 of 56

Temp oC Spacing (M)

Upto 200 Not required

200 to 300 10
300 to 350 8
350 to 400 6
400 to 550 5

- Sheeting shall be provided with expansion facilities with an overlap of

at least 100 mm.

- Expansion joint shall be formed by a 25 mm space between the pipe

insulation sections and compressed mineral rock fibres shall fill the
space. Expansion joints in each layer shall be offset at least 150 mm
from each other in case of multi-layer insulation. Expansion joint for
first layer for vertical pipe shall preferably be just below insulation
support collars.

4.3.4 Elbows and Bends

Insulation material shall be mitred and shall be same as that of pipe.

Insulation securement bands/wires shall be same as that for equivalent dia
pipe. Each mitred section shall be secured with minimum 2 wires/bands.
For bends/elbows of nominal pipe size 5" and below due to lack of space for
all insulation materials, insulation shall be secured by spirally wound.
Insulation joints of block materials shall be suitably sealed with adhesive for
isocyanurate/cellular glass and by insulating cement for calcium silicate.
Fittings below 50 mm nominal dia if insulated with insulating cement build
up in 6 mm layers to the thickness of insulation of the adjacent piping. Each
layer of insulation cement shall be reinforced with 25 mm No. 20 SWG wire
mesh.

4.3.5 Tee

Preformed pipe sections or segments shall be carefully cut and shaped around
"Tee" junctions and the insulated material of the tangential pipe shall be
carefully and neatly cut to mate upto the material applied to the parent pipe
without the creation of voids or gaps at the junction. Insulation shall be
adequately secured by wire/band of same specification as that of same size
pipe.

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 15 of 56

4.3.6 Flanged Joints or Valves

Flanged joints or valves shall normally not be insulated. If to be insulated,

they shall be insulated with prefabricated removable aluminum enclosures,
lined with pipe sections/lags/slabs.

Welded valves, if insulated shall be insulated with oversized pipe sections or

lags cut and shaped to fit around the body of the valve. Insulated valves shall
be cut and shaped around the valve stem and kept clear of the stuffing box
gland.

4.3.7 Insulation Flashing

Insulation shall be stopped short of flanged joints and unions by a sufficient

distance to permit easy removal of the flange nuts and bolts or loosing of the
unions to take place without disturbance or damage to the insulating material.
At these positions the insulation shall be beveled and sealed with a metal
closure, which in turn shall be sealed with waterproof sealing material.
(Refer pg. 49 of 73)

4.3.8 Pipe Supports

Insulation at solid welded or clamped supports shall be cut and shaped to fit
around the support and banded securely to enable the insulation to be carried
with the pipe movement. When the pipe hangers pass through insulation on
piping outdoors, metal hoods packed with a waterproof sealing material shall
be furnished and installed. Upper bolts of the hanger clamps are not to be
covered with insulation. (Refer pg. 49 & 61 of 73)

4.3.9 Steam Trace Piping

Steam traced piping and fittings shall be installed with oversized sections to
allow accommodation of both parent pipe and tracer without damage or
deformation of the insulation. Traced instrument line and fittings shall be
totally enclosed by the insulation in a similar manner and the designed warm
air annulus maintained throughout the tracer pipe length. Insulation supports
for vertical pipe shall have suitable clearance for tracer pipe. Suitable putty
or cement shall be used to improve the contact between pipe and tracer
throughout length of tracers.
On traced pipes, tracing is to cover with one layer Aluminum-Foil, before
mineral wool shells are applied.

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 16 of 56

4.3.10 Electrical Traced Piping

Electrical traced piping shall be provided with the same size insulation as
could be provided if the piping were not electrically traced.

4.4 HORIZONTAL EQUIPMENT

4.4.1 Application :
Mineralwool slabs or blankets must be applied and attached without any
gaps. With multilayer execution, the seams must be staggered.
- For equipment with a diameter, smaller than 2 meters, blankets can be used.
- For equipment with a diameter, more largely than 2 meters, slabs must be
used.

4.4.1.1 Blanket shall be applied over the surface with joints tightly butted and
laced together with wire.

Other block insulation shall be applied with the longer dimension

parallel to the axis of the vessel or equipment. When blocks are
applied in multiple layer, all joints of successive layers shall be
parallel to the long axis shall be staggered and sealed with
insulating cement for calcium silicate or suitable adhesive for
others. In all cases the insulation is to fit the contour of the vessel or
equipment so that the use of leveling coat of insulating cement
should not be normally necessary to get an acceptable smooth
exterior.

In case mechanical damage is possible, rigid type of insulation shall

be supplied or alternative measures shall be proposed to the client
such as support plates.

4.4.1.2 Insulation Securement

- Each layer of insulation on shells of equipment shall be

secured by bands at every 300 mm centers and 50 mm from
the edge of each slab. Each band shall be machine stretched
and tensioned to remove slack only.

- Each layer of insulation on vessel heads shall be secured as

follows:

Band shall be in radial direction connecting the head central

floating ring and shell girth ring. The radial bands shall be
placed at not more than 150 mm centers for rigid and 300 mm
for fibrous insulation measured at the girth ring. These bands

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 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 17 of 56

shall be machine stretched and sealed. Outermost layer of

insulation shall also be supported by wire to the shell girth
ing. Insulation to heads shall be secured using wire and
floating rings or using wire mesh.

4.5 VERTICAL EQUIPMENT

4.5.1 Application

4.5.1.1 Surfaces to be insulated shall be supplied on support rings as

specified on the Vessel Standard

4.5.1.2 Application details on shell, top and bottom heads shall be similar to
that of horizontal equipment. Insulation shall be laid on insulation
support rings provided by the fabricator

4.5.2 Insulation Securement

4.5.2.1 Bottom and top head insulation shall be supported by wire drawn
through holes in the insulation supports provided by the vessel
fabricator.

4.5.2.2 Top head insulation shall be secured by floating ring/bands or wire

mesh provided by insulation fabricator similar to head of horizontal
vessel.

4.5.2.3 Shell insulation shall be supported by bands at every 300 mm on the

cylindrical portion and the bands shall be kept horizontal

4.5.2.4 Insulation securement for bottom head for vessel supported on legs
shall be wire/wiremesh secured to the welded on nuts provided by
the Vessel Manufacturer

4.5.2.5 For insulation on tank roofs, Insulator shall provide his proposal on
the method of protection for approval on areas where mechanical
damage may occur i.e. near the platform adequate support plates
shall be provided.

4.5.3 Expansion joints

Sufficient expansion points shall be provided as per the straight lengths

involved. The expansion joint shall be provided at the insulation support
rings. The details of the expansion joint proposed shall be got approved by
APG/ Client.

4.5.4 Flange, nozzle, channel cover, manway and handhole flanged cover

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 18 of 56

Insulation shall be stopped short of uninsulated flanges and nozzles etc. A

sufficient distance to permit withdrawal of bolts without damaging the
insulation is to be bolt length + 25 mm. Insulation shall be weather proofed
and sealed at these locations.

4.5.5 On Heat-traced equipment, the tracing is to cover with one layer 0.5mm
metal-sheets, before mineral wool blankets or slabs are applied. There is no
need for metal-sheet cover for equipment, which is traced with coil.
4.5.6 For equipment with thermal insulation, which needs a gas-vapor barrier,
mineralwool firmly glued on aluminum foil are to be used. Each seams of the
mineralwool is to be sealed by aluminum-tape.

4.6 IRREGULAR SURFACES SUCH AS PUMPS, COMPRESSORS, TURBINES ETC.

4.6.1 Application

4.6.1.1 Fibrous Material; Material Application & Insulation Securement

This shall be prefabricated removable aluminum cover lined with

mineral Rock/Glass wool pipe sections/legs/slabs/mattresses.

5. INSULATION FINISH

5.1 GENERAL

Protective coverings or finishes over the insulation are being provided for the
following reasons.

- Protection against Mechanical damage

- Protection against Chemical or atmospheric condition

- Good appearance

- Clean surface

- Retardation of flame from spreading

- Commonly aluminum or Aluminized steel, Galvanized sheets of suitable

thickness are used for this purpose. Refer to Aneexure

- To prevent ingress of water

- The shells of large and tall columns, vessels or tanks of 5 M diameter and
above shall be finished with corrugated sheet metal for better wind
resistance.

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 19 of 56

5.2 PIPING 1" AND LARGER

Insulation material shall be covered with aluminum zinc coated steel sheets.

Sheets shall be mounted with an overlap of at least 50 mm for both longitudinal and
circumferential seams such that no water can enter the insulation material.

Sheets shall be formed and edges furrowed. Longitudinal seams for horizontal lines
shall always be mounted in the area and longitudinal seams of adjacent sheets shall
be staggered.

For elbows, Flanges and Tees etc contractor shall cut furrow and form sections of
sheeting
Sheeting sections for bends, elbows, Tees and non-insulated protruding parts shall be
close fitted to prevent ingress of water.

If close fittings of sheeting around non-insulated protruding parts is not possible,

sheeting shall be provided with sealing plates. Sealing plates shall be cut to the
exact dimensions of the protruding part.

Seams where water can enter the insulation material (e.g. Tees, Sealing Plates etc.)
shall be sealed with sealing compound.

Pipe hangers shall be provided with rain caps

Ends of insulated parts such as flanges, flanged valves, instruments etc shall be
provided with end caps so as to allow for the withdrawal of bolts without disturbing
the insulation.

For non-insulated flanges, flanged valves and instruments, seams between caps, pipe
and sheeting shall be sealed with sealing compound.

Al-Zn coated steel sheeting shall be fastened with SS self-taping screws. Contractor
shall use at least six screws per meter for piping with a total insulated diameter
below 600 mm and at least ten screws per meter for piping the total insulated
diameter of 600 mm and more.

Sheeting segments for elbows and bends shall be fastened with two screws per
segment.

In addition to the two screws, segments shall also be attached to each other with four
screws equally spaced over the circumference of the sheeting.

Sealing plates and sheeting sections for Tees shall be fastened with minimum four
screws at maximum intervals of 100 mm.

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
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Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 20 of 56

Holes for self-tapping screws shall be drilled next to the longitudinal furrow.

Sheeting shall be provided with expansion facilities at the following locations :

1) Bends or elbows
2) Between hangers or supports in long straight lines
3) All locations where sheeting is fixed to a certain position (e.g. branch
connections)
Expansion seams shall be provided with an overlap of at least 100 mm, double
furrows and fastening with a stainless steel band between the furrows.

Holes in electrical traced piping for electrical cables shall be provided with rubber
sealing rings to prevent damage to the cable and to provide water tight sealing.

5.3 WEATHERPROOFING OF COLUMNS, VESSELS, HEAT EXCHANGERS,

REACTORS AND TANKS

Insulated surfaces shall be covered with Al-Zn coated steel sheets. Longitudinal
seams shall be staggered.

For heads and stiffeners, sheeting shall be cut in segments and formed to fit closely
to the head or stiffener.

To prevent ingress of water, sheeting shall be mounted with an overlap of 50-mm

minimum at all seams. Edges of all sheets shall be furrowed. To accommodate the
overlap of the adjacent top sheets for vertical furrow to each sheet shall be removed
over a length of 50 mm.

Sheeting shall be fastened with SS self-tapping screws at intervals of 100 mm.

When fastening the sheeting, contractor shall pay special attention to crossing of
longitudinal and circumferential seams.

Caps around reinforcing rings shall be used to compensate expansion of column,

vessel, reactor or tank.

If there is no reinforcing rings applied to the equipment, Contractor shall provide at

least one expansion seam per 10 metres from base. Expansion seams shall be
provided with two furrows and an overlap of at least 100 mm. Sheeting shall be
fastened with stainless steel band mounted next to the second furrow.

Openings in the sheets for protruding parts shall be provided for. For inspection
purpose, each opening shall be 100 mm larger than the protruding part. For
insulated protruding parts with an insulation thickness over 50 mm the diameter of
the opening shall be equal to the total insulated diameter of the protruding part.
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 21 of 56

For uninsulated protruding parts, opening shall be closed with sealing plates, which
fit close around the protruding part. Plates shall be mounted on top of the equipment
sheeting with an overlap of 50, and furrowed edges.

For insulated protruding parts such as nozzles, opening shall be closed by connecting
the sheeting of the insulated protruding part of the sheeting of the equipment with an
overlap of 50 mm.

All vertical seams between sheets all seams between sheeting on top of equipment,
seems between sealing plates and equipment sheeting, seams between nozzle and
equipment sheeting and seams between sheeting and end caps for flanges shall be
sealed with sealing compound to prevent ingress of water.
For horizontal equipment, longitudinal seams shall be located in the area shown in
figure A1. In those cases where this is not possible seams shall be sealed with
sealing compound.

Metal boxes from aluminized steel plate with Perspex glasses shall be inserted in the
openings provided for name plates, thermowells, sight glasses etc. Boxes shall be
screwed on top of the vessel sheeting with self-tapping screws and all seams shall be
sealed with sealing compound.

5.4 INSULATION CAPS FOR HEAD OF EQUIPMENT, MANHOLES, HAND

HOLES ETC

Heads of columns and vessels with a diameter upto 1000 heads of heat exchangers,
manholes, hand holes etc may be insulated with caps manufactured from Al-Zn
coated steel sheets. Seams shall have an overlap of 50 mm and shall be sealed with
sealing compound.

Caps shall be internally lined by mineral wool blankets. Blankets shall be cut to the
correct size and pressed against the wall of the cap with wire mesh facing the object
to be insulated. Blankets shall be fastened with clips. Riveted to the sheeting of the
cap. Total insulation thickness shall be equal to the insulation thickness specified for
the quipment.

To prevent mechanical damage due to frequent removal, caps for heat exchangers
shall be supplied with as steel reinforcing frame from angular steel reinforcing frame
from angular steel 25x 3 mm

Caps for heads and heat exchangers with a diameter upto 1000 mm shall be mounted
over the insulation of the equipment body and shall be attached to the body sheeting
by means of 20 mm wide flanged rim.

Caps for exchangers with a diameter over 1000 mm shall extent upto a distance "A"
of the connecting flange. The flange will be insulated as described for piping
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
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Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 22 of 56

flanges with the exception that enclosures for exchangers flanges shall be provided
with an angular steel reinforcing frame

Caps for manholes, hand holes etc shall be attached to the equipment sheeting by
means of a 20-mm wide flange rim forced to the open end of the cap.
Pipe-flanges and valves are to be covered with Insulation-Caps. The wire-mesh
mineralwool is to fixed on the inside of the caps, the wire-mesh must be shown to the
pipe/flange. If more then one layer of mineralwool necessary (thickness more than
120 mm), the other layers are to fixed on the flange/valve with hocks or stainless
steel bands.

Davit for manholes hall also be insulated by the removable cap.

Contractor shall use SS self-tapping screws to fabricate the caps and to mount caps
for manholes etc and caps for heads with diameter below 1000 mm on the equipment
sheeting. Screws shall be mounted at 100-mm intervals.

To attach the sheeting of caps for exchangers to the steel reinforcing frame
contractor shall use an aluminum rivets .

Holes for rivets shall have a maximum diameter of 4.1 mm.

Protruding parts in caps shall be insulated and jacketed.

6. CONTRACTOR’S SCOPE OF WORK

6.1 The scope of work of the Contractor shall include the supply and application of basic
insulation materials and all accessories as per Specifications.

6.2 Supply and application of insulation shall include all items such as but not limited to
all insulating materials, metallic sheet covering, wire netting, cement plaster, screws,
binding wires, scaffolding, aluminum foil for SS pipes, Al-Zn coated steel sheets for
heeting material, ribbon, spacer rings, stays, bands, studs, cleats, flat, support rings,
consumable etc as per the specification. No asbestos material should be used for
insulation purpose.

6.3 Supply and application for vapour barrier consisting of bituminous solution, glass
fibre material etc as per specification on Piping & Equipment, wherever shown as
insulated on the drawings, data sheets or any other documents forming part of this
specification.

6.4 Besides the labour and supervision required for insulation, Contractor shall be
responsible for providing :

- Equipment tools and tackles necessary to perform the work in a workmanlike

and efficient manner and to complete the work as per time schedule
PC1600001R1
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 23 of 56

- All scaffolding required for carrying out the work

- Supply of all materials and consumables required for performing the work

- Storage of insulation, consumables and all other equipment and materials

brought to the site.

- Provision of all safety gear and personal protection gear.

- Special protection required if any, for performing work during adverse

weather conditions as well as for avoiding deterioration / damage of the
insulated surface until ready for use, protection of surrounding equipment,
structures during the course of wash and any other precautions as may be
directed by the Engineer-in-charge.

- Cleaning up the working area regularly during the course of work for the
purpose of good housekeeping as well as cleaning up the site on completion of
work as directed by the Engineer-in-charge.

6.5 Bidders to note that the insulation on pipes/equipment located in open area shall be
provided with all necessary protection so that rainwater does not enter insulation
under any circumstances.

7 OBLIGATIONS OF THE CONTRACTOR

7.1 The Contractor shall work in accordance with this specification and the site rules and
regulations of the Owner.

7.2 Special treatment coatings etc shall be applied strictly in accordance with the procedure
lay down herein and with the manufacturer's instructions. Where the manufacturer's
instructions conflict with this specification, the former shall take precedence.

7.3 The Contractor shall remove all dirt from surfaces to be insulated and shall ensure that
all surfaces requiring insulation are clear and thoroughly dry before applying any
insulation.

7.4 The Contractor shall cover all opening in vessels, towers and any other equipment to
prevent the entry of insulating materials and shall daily remove from job site all cartons
wrappers and other debris.

7.5 Each day's application of insulation has to be weatherproofed overnight by either the
final protective cladding or some form of temporary weatherproof covering. For
“temporary insulation” flange and valves are to cover with Mineralwool, which is fixed
with wire. The mineralwool is to cover with plastic-foil. The plastic-foil is to fixed and
seal with tape. This plastic-cover must be closed as much as possible, that no rainwater
can touch the mineralwool. Contractor will not be allowed to use any water soaked

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 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 24 of 56

7.6 insulated material and if rain soaks any part of the installed insulated material. Then
those parts should be removed and reinsulated by fresh material.

7.7 Before starting the work, the Contractor and Engineer-in-charge shall agree to detailed
program of work. Before the application of insulation, the Contractor shall check with
Engineer-in-charge that the equipment or pipeline to be insulated is released for
insulation (i.e. all testing, picking, painting etc are complete). The Contractor shall not
start insulation job till he gets clearance from Engineer-in-charge in writing.

7.8 Code inspection plates or stampings, sight glasses, name plates and data plates on
equipment and piping shall be left exposed by the Contractor without insulation. The
opening left for these purposes shall be suitably sealed to prevent water entering into the
insulation.

7.9 Insulation of all flanges, valves etc where required shall be left off until authorization is
given by the Engineer-in-charge to carry out this work. In general this will be done after
lines or equipment joints have been proved tight by hydrostatic tests and/or have reached
operating conditions.

7.10 If additional supports such as supports on vertical piping welded studs on equipment,
floating rings around top of equipment to support the equipment head insulation etc
other than those shown in the drawings are found necessary the same shall be provided
by the Contractor without any extra cost to the Owner.

7.11 All the equipment, tools, tackles and scaffolding materials, consumables and all other
materials intended for use by the Contractor shall be of prime quality and offered for
inspection to the Engineer-in-charge before being put up to use. Such inspection shall
be carried out at site and only the approved items shall be employed for performing the
work.

7.12 The Contractor shall have to work in co-ordination with other contractor carrying out
works connected with other jobs without causing any interference to those works.
Under the above circumstances the Contractor will have to abide by the contract and will
have to abide by the instructions of the Engineer-in-charge, who will co-ordinate the
various activities. furrows

7.13 During the course of work as well as during an agreed period after completion of
work Contractor shall provide the requisite man materials, consumables and supervision
required for (a) the touch up repair of any insulation work already completed (either by
Contractor or otherwise) as may be requested by the Engineer-in-charge. All such work
shall also be performed in accordance with these specifications.

7.14 The Contractor shall guarantee that physical and chemical properties of the materials
used are equivalent to or better than that specified in the Technical Specifications of
work and shall furnish test certificates from an approved authority or an institution

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 25 of 56

mentioning all the properties and results of the test carried out for all insulating materials
supplied by them for the subject work.

7.15 The Contractor shall check and confirm that the thickness of insulation indicated is
suitable for the Design Basis covered in technical specification. If the insulation
thickness is not indicated in some cases, then it shall be furnished by the Contractor and
approved by Engineer in charge.

7.16 The Contractor shall abide by all safety norms applicable for PIC Project at Bayer
Material Science site at Ankleshwar, India.

8 INSPECTION

8.1 All materials supplied and used by the Contractor shall be the best to meet the
requirements of specification and shall be subject to inspection by the Owner / Engineer-
in-charge. Any material not meeting with the specified requirements shall be rejected
and such rejected material shall not be used and shall be replaced by the Contractor at
his own cost.

8.2 The installation workmanship shall also be subject to inspection by the Owner/Engineer-
in-charge at all times. Any work found to have been damaged or improperly installed
should be rectified or reinstalled to the satisfaction to the Owner at Contractor's
expenses.
8.3 Inspection and approval of materials and workmanship by the Owner / Engineer-in-
charge shall not relieve the insulation contractor or any of his responsibilities.

8.4 Prior to commencing insulation work on any particular section, the insulation contractor
should be satisfied that all insulation supports on Vessels, vertical pipelines and shoes on
horizontal pipelines have been correctly installed. Additionally all thermal tracing lines
are properly in place and all metal surfaces are clear and free of foreign or spattered
materials.

9 MEASUREMENTS

9.1 The Contractor in the presence of the Consultant and Owner shall take measurements.

9.2 The measurement for Hot Insulation/Steam Treated Line shall be as per IS 14164/1994.

Vendor to quote for cost of unit length of insulation for various pipe size and
insulation thickness combination for each type of insulation.

The purpose of quantification of fittings such as elbows, tees, reducers, flange and
valves etc in this Enquiry Spec is for bidder to device the equivalent length of
insulated pipes using the factor as per IS: 14164 for each inline piping component
and to arrive at final quantity & cost at the stage of enquiry. Since the cladding
thickness of valve is one size more than piping contractor may quote separately.
PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 26 of 56

10 GUARANTEE

The Contractor shall guarantee all insulation work carried out by him against defective
material and workmanship for a period of two years from the date of completion and
handing over and he shall repair or replace promptly without cost to the client any part or
parts of the insulation that fails within the said period.

The Contractor shall also conduct, within 3 months of commissioning of the plant or at a
time mutually agreed between the Contractor and the Purchaser/Owner, a performance test
by measuring the temperature as indicated in the insulation schedule and other parameters as
per Design Basis the temperature on the surface of the insulation does not exceed values
indicated in the Design Basis. Incase of defects, contractor shall rectify the defects at his
own cost.

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 27 of 56

TABLE - 1

DATA SHEET FOR EXTENT OF INSULATION

INSULATION REQUIREMENTS FOR PIPING & EQUIPMENT

INSULATION CODES: H - Heat Conservation

H - Process Stability
P - Personnel Protection
E - Electric Traced
S - Steam Traced

ITEMS H (1) P E, S
AMB - AMB -
649O C 649O C
Straight or bent pipe, socket weld, threaded
or butt weld pipe fittings (Elbows, Tees etc) YES YES YES
Socket weld, threaded or butt weld valves
Steam traps, related strainers, Pipe unions etc NO (4) NO (4) NO (2)
Flanged pipe fittings, flanged valves
(excluding relief and control valves) flange YES (5) NO (2, YES (5)
orifice sets, piping flanges connected to 5)
equipment nozzles and flanged special items
(i.e. strainers)
Primary piping for instrument connections,
sample piping, vent and drain piping NO NO YES
Expansion or rotation joints, slide valves etc NO (4) NO (4) YES (5)
Instruments and associated tube NO NO YES
Relief valves NO NO NO
Control valves NO (2, 5) NO (2, YES (5)
5)

PC1600001R1
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 28 of 56

Tee and inline strainers NO (2, 5) NO YES (5)

(2,5)
Vessels, shell and head surfaces YES (4) YES (4) YES
Vessel hand holes NO (2, 5) NO (2, N/A
5)
Vessel manways NO (2, 5) NO (2, N/A
5)
Vessel instrument trim NO NO YES
Shell and tube heat exchangers, excluding YES (5) YES N/A
flanged joints
Heat exchanger flanged joints NO (2, 5) NO (2, N/A
5)
Pump casings NO (2, 5) NO (2, YES (5)
5)
Steam turbines YES (3) (5) N/A
Compressors (5) NO (2) N/A
Blowers, fans (5) YES (4) N/A
Internally insulated items NO (4) NO (4) N/A
1 Economics of insulating these items will vary dependent on climate, fuel cost, labour and
material cost
2 Insulate or guard only where required for personnel protection
3 Insulation shall be furnished by the equipment supplier
4 Provide removable metal guards or suitable personnel barriers where required for personnel
protection
5 Removable/reusable covers should be considered

Personnel Protection (PP) shall be provided to 2.10 meters above grade or platforms and 0.900
meters horizontally from the periphery of platforms, walkways or ladders.

PC1600001R1
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 29 of 56

TABLE - 2
THICKNESS OF PLATE FOR WEATHER PROTECTION JACKET

a. Overlapping, minimum sheet thickness and sealing of insulation metal-cladding.

For AZ180, AZ185 or AZ200 as cladding:
Table 1.1 Minimum Sheet thickness and overlapping of cladding for equipment insulation jackets

Circumference of Min. sheet thickness Overlapping

Overlapping
the sheet jacket Longitudinal Seams Girth Seams
Upto 1200 mm 0.8 mm 50 mm 50 mm
Over 1200 mm 1.0 mm 50 mm 50 mm
Table 2.1.a Minimum Sheet thickness and overlapping of claddig for pipes with heat extension
Circumference of Min. sheet thickness Overlapping
Overlapping
the sheet jacket Longitudinal Seams Girth Seams
Upto 400 mm 0.5 mm 30 mm 50 mm
400 to 800 mm 0.6 mm 40 mm 50 mm
800 to 1200 mm 0.6 mm 50 mm 50 mm
Over 1200 mm 0.8 mm 50 mm 50 mm
Table 2.1.b Minimum Sheet thickness and overlapping of claddig for pipes without heat extension
Circumference of Min. sheet thickness Overlapping
Overlapping
the sheet jacket Longitudinal Seams Girth Seams

Upto 400 mm 0.5 mm 30 mm Interlock ball swage

400 to 800 mm 0.6 mm 40 mm Interlock ball swage
800 to 1200 mm 0.6 mm 50 mm Interlock ball swage
Over 1200 mm 0.8 mm 50 mm Interlock ball swage
Table 2.1.c Sheet thickness and overlapping for jackets of AZ-Steel sheet information for Valve,
Flange and Pump insulation boxes:
Boxes (see pictures) Min. sheet thickness Overlapping
Head and Botom of boxes for all diameter 1.0 mm 30 mm
Girth Cladding up to 1200 mm 0.6 mm 30 mm
Circumference
Girth Cladding over 1200 mm 0.8 mm 30 mm
circumference

PC1600001R1
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 30 of 56

ANNEXURE - 1

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 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 31 of 56

MINERAL WOOL

1. FIBEROUS MATERIAL – MINERAL WOOL (ROCK WOOL AND GLASS WOOL)

1.1. Mineral wool shall be a preformed insulation and shall be of long fibred rock or glass
material, processed from a molten state into fibrous form bonded, with a binder and suitable
for the intended operational temperature range from ambient to 650 oC. Slag wool is not
acceptable.

1.2. Unless otherwise specified it should conform to all the requirements of quality standards
listed below:
- Perforated Pipe Insulation: IS: 9842 Latest Issue/ ASTM C-547 / BS
3958 (Part 4)
- Metal mesh covered bonded IS: 8183/ BS:3958 Latest Issue for Piping
Mineral Fibre Blanket and and Equipment Faced on one side with 20
Blanket type Pipe Insulation mm galvanized No. 22 SWG wire mesh.
Stitched through with 22 SWG Galvanized
lacing wire: Mattress for lined covers Shall
be faced on one side with 20 mm galvanized
22 SWG wire mesh stitched through with
22 SWG Galvanized Lacing Wire.
- Mineral Fibre Block and Board IS: 8183 Latest Issue/ BS 3958 (Part-5)
Thermal Insulation
1.3 Insulation shall conform to following requirements and Test Certificates shall be issued as
per IS: 8183 / IS: 9842 (Latest Issue) for conformance to each of the following
requirements.
- Density : 140 to 150 kg/m3 (Density shall be within this range
and density test shall be as per IS: 5688/IS: 3144
(Latest Issue)
- Shot Content (IS: 3144) : Shot shall not be more than 5 mm in any dimensions;
shot content, when sieved shall not exceed the
following limits :
IS Sieve (IS: 460 Latest Shot Content, Percent
Issue) by Mass (Max)
500 Micron 5
250 Micron 15
- Moisture content and : Not more than 2%
Moisture Absorption
(IS:3144)
- Incombustibility : Incombustible; Loss in weight not more than 5%
(IS: 3144)

PC1600001R1
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 32 of 56

- Thermal Conductivity Mean Temperature o C Thermal / Conductivity

(IS: 3346) mW/cm o C
50 0.43
100 0.52
150 0.62
200 0.68
250 0.80
300 0.90

Mean Temperature = hot face temp + cold face temperature

2

- Sulphur content (IS: 3144) Not more than 0.6 percent

- Linear shrinkage (IS: 3144)
- Heat resistance (IS: 3144)
- Compressive strength (Average)
Minimum at 10% deformation
- Recovery after compression
- Alkalinity (IS: 8183 Appendix F,
IS: 9842 Appendix B)
- Chloride content (IS: 3144)
Not more than 2% when subjected to
soaking heart at the Stated maximum
temperature of use (650 o C) for 24 hrs
When heated to max. temperature (650o C),
sample shall maintain its general form and
shall not suffer visible deformation of the
fibrous structure
120 kg/m2
After compression to 75% of the original
thickness. Recovery shall not be less than
90% of the original thickness as per IS
8183 Appendix A and IS 9842 Appendix A
pH of the solution of the material shall be
between 7 and 10
Not to exceed 10 ppm

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 33 of 56

- Dimension Pipe Section :

Hollow cylinder, split lengthwise on one
or both sides of the cylindrical axis.
Thickness: 25, 40, 50, 60 an
75 mm
Tolerance in Length: + 3mm
Tolerance in Thickness: + 3mm
When installed on the pipe of the
specified size, sections shall fit snugly
and shall have tight longitudinal and
circumferential joint
Blanket :
Unless otherwise specifically required,
standard width shall be 600 to 1200 mm
and standard length 1500 to 2400 mm,
Thickness: 25, 30, 40, 50, 60 and 75 mm
Tolerance on thickness
Positive:3 mm
Negative:-3 mm
Block and Boards (IS:8183) :
Lengths:1000 to 1400 mm
Widths:500 to 1000 mm
Tolerance on width, length and thickness
Width and Length: + 3mm
Thickness: + 3mm

1.3. Insulation Thickness

Refer to Table – MW1 for Heat Conversation Insulation

Table – MW1 for Personal Protection Insulation

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 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 34 of 56

TABLE : MW 1

MINERAL WOOL INSULATION THICKNESS TABLE FOR HEAT CONSERVATION

HEAT CONSERVATION
OPERATING TEMPERATURE
O
C 100 150 200 250 300 350 400 450 500 550 600 650
SIZE INSULATION THICKNESS
in mm
21.3 25 30 40 50 65 80 95 110 130 150 175 205
26.7 25 30 40 55 70 85 100 120 140 160 185 215
33.4 25 30 45 55 70 85 105 125 145 170 195 225
42.2 25 30 45 60 75 90 110 130 150 175 205 240
48.3 25 30 45 60 75 95 115 135 155 185 215 250
60.3 25 35 50 65 80 100 120 140 165 195 225 265
73.0 25 35 50 65 85 105 125 145 175 205 235 275
88.9 25 35 50 70 90 110 130 155 180 215 250 290
114.3 25 35 55 75 95 115 135 165 195 230 265 305
141.3 25 40 55 75 95 120 145 175 205 240 280 320
168.3 25 40 60 80 100 125 150 180 215 250 290 335
219.1 25 40 60 80 105 130 160 195 230 265 305 350
273.1 25 40 60 85 110 140 170 205 240 280 325 370
323.9 25 40 65 90 115 145 175 210 250 290 335 385
355.6 25 40 65 90 115 145 180 215 250 295 340 390
406.4 25 45 65 90 120 150 185 220 260 305 350 405
457.2 25 45 70 95 120 155 185 225 265 310 360 415
508.0 25 45 70 95 125 155 190 230 270 315 365 425
558.8 25 45 70 95 125 160 195 230 275 320 375 430
609.6 25 45 70 95 125 160 195 235 280 325 380 440

0.0 25 45 75 105 145 185 235 295 360 435 525 630

NOTE: PIPE DIA "0" STANDS FOR DIA MORE THAN 610 AND FLAT SURFACE.

DESIGN CRITERIA

AMBIENT TEMP - 35O C

MAX HEAT LOSS - 85 KCAL/SQ M HR
SURFACE TEMPERATURE - 55 0C
WIND VELOCITY - 0 m/s (Still Air)
EMISSIVITY - 0.30
MATERIAL/DENSITY - LRB/120 KG/M3

PC1600001R1
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 35 of 56

TABLE : MW 2

MINERAL WOOL INSULATION THICKNESS TABLE FOR PERSONAL PROTECTION

PERSONNEL PROTECTION
OPERATING TEMPERATURE
O
C 100 150 200 250 300 350 400 450 500 550 600 650
SIZE INSULATION THICKNESS
in mm
21.3 25 25 35 45 60 75 90 105 125 150 175 205
26.7 25 25 35 50 60 75 95 115 135 160 185 215
33.4 25 25 40 50 65 80 100 120 140 165 195 225
42.2 25 30 40 55 70 85 105 125 150 175 205 240
48.3 25 30 40 55 75 90 110 130 155 185 215 250
60.3 25 30 45 60 75 95 115 140 165 195 225 265
73.0 25 30 45 65 80 100 120 145 175 205 235 275
88.9 25 30 50 65 85 105 130 155 180 215 250 290
114.3 25 35 50 70 90 115 135 165 195 230 265 305
141.3 25 35 55 75 95 120 145 175 205 240 280 320
168.3 25 35 55 75 100 125 150 180 215 250 290 335
219.1 25 40 60 80 105 130 160 195 230 265 305 350
273.1 25 40 60 85 110 140 170 205 240 280 325 370
323.9 25 40 65 90 115 145 175 210 250 290 335 385
355.6 25 40 65 90 115 145 180 215 250 295 340 390
406.4 25 45 65 90 120 150 185 220 260 305 350 405
457.2 25 45 70 95 120 155 185 225 265 310 360 415
508.0 25 45 70 95 125 155 190 230 270 315 365 425
558.8 25 45 70 95 125 160 195 230 275 320 375 430
609.6 25 45 70 95 125 160 195 235 280 325 380 440
0.0 25 45 70 95 125 165 205 255 315 385 460 555

NOTE: PIPE DIA "0" STANDS FOR DIA MORE THAN 610 AND FLAT SURFACE.

DESIGN CRITERIA
AMBIENT TEMP - 35O C
SURFACE TEMP - 550 C
WIND VELOCITY - 0 m/s (Still air)
EMISSIVITY - 0.30
MATERIAL DENSITY - LRB 120 Kg/M3

PC1600001R1
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 36 of 56

ANNEXURE - 2

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 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 37 of 56

Table 1 : Support lugs for supportings and position of spacerings for the insulation

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 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 38 of 56

Table 2 : Supporting of the equipment insulation

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 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 39 of 56

Table 3 : Spacerings of equipment insulation

For equipment insulation with 2 or more layers of mineral wool

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 40 of 56

Table 4 : Supporting on vertical vessels

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 41 of 56

Table 5 : Example for mineral wool slabs or blankets on equipment

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 42 of 56

Table 6 : Example for metal cladding on equipment

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
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Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 43 of 56

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Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 44 of 56

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Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 45 of 56

PC1600001R1
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 46 of 56

Table 8 : Examples of design for lateral nozzles

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 47 of 56

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 48 of 56

Table 9 : Examples of design for roof nozzles

PC1600001R1
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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 49 of 56

Table 10 : Examples for overlapping equipment name plates

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 50 of 56

Table 11: Insulation lengths for pipe branches and pipe nozzles

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Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 51 of 56

Table 12 : Reduced/Cut-out for horizontal pipe insulation

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Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 52 of 56

Table 13 : Reduced/Cut-out for vertical pipe insulation

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 53 of 56

Table 14 : Pipe insulation metal cladding, vertical flange area

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 54 of 56

Table 15 : Flange / valve insulation metal cladding, vertical area

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 55 of 56

Table 16 : Tank insulation, cone and flat roof

PC1600001R1
 Project No:
Client: BAYER MATERIAL SCIENCE 2090/1600:ANR-PIC
Location: ANKLESHWAR, INDIA
Doc No.:
Plant: PIC (Poly Isocyanate Coatings) PIC-1600-2800-C-000 Rev 0

BTS-ENG PP PSS PAGE NO. 56 of 56

Table 17 : Temporary insulation for flange and valves

PC1600001R1
 ANNEXURE B SHEET 7 OF 28

AKER POWERGAS PVTTD. WELDING PROCEDURE REPORT NO. DATE

MECHANICAL CONSTRUCTION DEPT. SPECIFICATION

SHEET 1 OF 3

PROJECT - CLIENT

JOB NO - LOCATION

WELDING PROCESS (ES) -

TYPE (S) -

SUPPORTING PQR NO (S) -

JOINTS (QW 402)

GROOVE DESIGN

(DETAILS AS PER ENCLOSED SKETCH)

BACKING YES _________________ NO _________________

BACKING MATERIAL (TYPE)

OTHERS

BASE METALS (QW 403)

P. NO. P. NO. _____________ TO P. NO. ____________

THICKNESS RANGE

PIPE DIA RANGE

OTHERS

FILLER METALS (QW 404)

ANALYSIS A. NO.

FILLER METAL F. NO.

SPEC. NO. (SFA)

AWS NO. (CLASS)

SIZE OF ELECTRODE

FILLER WIRE DIA

ELECTRODE / FILLER COMPOSITION

TYPE OF ELECTRODE FLUX

CONSUMABLE INSERT

DRYING OF ELECTRODE / FLUX

DRYING TEMPERATURE

DURATION

HOLDING TEMPERATURE

OTHERS

POSITION (QW 405)

POSITION OF FROOVE

WELDING PROGRESSION

OTHERS

PREHEAT (QW 406)

PREHEAT TEMPERATURE

INTERPASS TEMPERATURE

PREHEAT MAINTENANCE

OTHERS
CONTRACTOR ENGINEER APG ENGINEER CLIENT

Signature - Signature - Signature -

Name - Name - Name -

C03S004 R4
 SHEET 8 OF 28
ANNEXURE B

AKER POWERGAS PVT TD. WELDING PROCEDURE REPORT NO. DATE

MECHANICAL CONSTRUCTION DEPT. SPECIFICATION

SHEET 2 OF 3

PROJECT - CLIENT

JOB NO - LOCATION

POST WELD HEAT TREATMENT (QW 407)

TEMPERATURE

HEATING RATE

HOLDING TIME

COOLING RATE

OTHERS

GAS (QW 408)

SHIELDING GAS (ES)

GAS COMPOSITION

PURGING GAS

FLOW RATE

GAS BACKING

FLOW RATE

OTHERS

ELECTRICAL CHARACTERISTICS (QW 409)

CURRENT AC OR DC

POLARITY

AMPERAGE RANGE

VOLTAGE RANGE

OTHERS

TECHNIQUE (QW 410)

STRING OR WEAVE BEAD

ORIFICE OR CUP SIZE

INITIAL OR INTERPASS }

CLEANING METHOD }

METHOD OF BACK GAUGING

OSCILLATION

CONTACT TUBE TO WORK DISTANCE

SINGLE OR MULTIPLE PASS

SINGLE OR MULTIPLE ELECTODE

TRAVEL SPEED

OTHERS

CONTRACTOR ENGINEER APG ENGINEER CLIENT

Signature - Signature - Signature -

Name - Name - Name -

C03S004 R4
 ANNEXURE B
SHEET 9 OF 28

AKER POWERGAS PVTLTD. WELDING PROCEDURE REPORT NO. DATE

MECHANICAL CONSTRUCTION DEPT. SPECIFICATION

SHEET 3 OF 3

WPS REPORT NO.

DATED

GROOVE DESIGN DETAILS

DATED

CONTRACTOR ENGINEER APG ENGINEER CLIENT

Signature - Signature - Signature -

Name - Name - Name -

C03S004 R4
 ANNEXURE C

SHEET 10 OF 28

AKER POWERGAS PVT LTD. PROCEDURE REPORT NO. DATE

MECHANICAL CONSTRUCTION DEPT. QUALIFICATION RECORD

SHEET 1 OF 5

PROJECT - CLIENT

JOB NO - LOCATION

WELDING PROCESS (ES) -

TYPE (S) -

SUPPORTING PQR NO (S) -

JOINTS (QW 402)

GROOVE DESIGN

(DETAILS AS PER ENCLOSED SKETCH)

BACKING YES _________________ NO _________________

BACKING MATERIAL (TYPE)

OTHERS

BASE METALS (QW 403)

P. NO. P. NO. _____________ TO P. NO. ____________

THICKNESS RANGE

PIPE DIA RANGE

OTHERS

FILLER METALS (QW 404)

ANALYSIS A. NO.

FILLER METAL F. NO.

SPEC. NO. (SFA)

AWS NO. (CLASS)

SIZE OF ELECTRODE

FILLER WIRE DIA

ELECTRODE / FILLER COMPOSITION

TYPE OF ELECTRODE FLUX

CONSUMABLE INSERT

DRYING OF ELECTRODE / FLUX

DRYING TEMPERATURE

DURATION

HOLDING TEMPERATURE

OTHERS

POSITION (QW 405)

POSITION OF FROOVE

WELDING PROGRESSION

OTHERS

PREHEAT (QW 406)

PREHEAT TEMPERATURE

INTERPASS TEMPERATURE

PREHEAT MAINTENANCE

OTHERS
CONTRACTOR ENGINEER APG ENGINEER CLIENT

Signature - Signature - Signature -

Name - Name - Name -

C03S004 R4
 ANNEXURE C
SHEET 11 OF 28

AKER POWERGAS PVT LTD. PROCEDURE REPORT NO. DATE

MECHANICAL CONSTRUCTION DEPT. QUALIFICATION RECORD

SHEET 2 OF 5

PROJECT - CLIENT

JOB NO - LOCATION

POST WELD HEAT TREATMENT (QW 407)

TEMPERATURE

HEATING RATE

HOLDING TIME

COOLING RATE

OTHERS

GAS (QW 408)

SHIELDING GAS (ES)

GAS COMPOSITION

PURGING GAS

FLOW RATE

GAS BACKING

FLOW RATE

OTHERS

ELECTRICAL CHARACTERISTICS (QW 409)

CURRENT AC OR DC

POLARITY

AMPERAGE RANGE

VOLTAGE RANGE

OTHERS

TECHNIQUE (QW 410)

STRING OR WEAVE BEAD

ORIFICE OR CUP SIZE

INITIAL OR INTERPASS }

CLEANING METHOD }

METHOD OF BACK GAUGING

OSCILLATION

CONTACT TUBE TO WORK DISTANCE

SINGLE OR MULTIPLE PASS

SINGLE OR MULTIPLE ELECTODE

TRAVEL SPEED

OTHERS
CONTRACTOR ENGINEER AOG ENGINEER CLIENT
Signature - Signature - Signature -

Name - Name - Name -

C03S004 R4
 ANNEXURE C
SHEET 12 OF 28

AKER POWERGAS PVT LTD. PROCEDURE REPORT NO. DATE

MECHANICAL CONSTRUCTION DEPT. QUALIFICATION RECORD

SHEET 3 OF 5

WPS REPORT NO.

DATED

GROOVE DESIGN DETAILS

DATED

CONTRACTOR ENGINEER APG ENGINEER CLIENT

Signature - Signature - Signature -

Name - Name - Name -

C03S004 R4
 ANNEXURE C
SHEET 13 OF 28

AKER POWERGAS PVT LTD. PROCEDURE REPORT NO. DATE

MECHANICAL CONSTRUCTION DEPT. QUALIFICATION RECORD

SHEET 4 OF 5

WELDING PARAMETERS

SEQUENCE NO. OF PASSES ELECTRODE / ROD DIA AMP VOLTAGE TRAVEL SPEED

FILLER MM./ MIN.

TENSILE TEST (QW 150)

SPECIMEN NO. WIDTH THICKNESS AREA ULTIMATE ULTIMATE CHARACTER OF
TOTAL LOAD STRESS FAILURE AND
IN KGS KGS/MM2 LOCATION

GUIDED BEND TEST (QW 160)

TYPE AND FIGURE NO. RESULT

TOUGHNESS TEST (QW 180)

SPECIMEN NO. NOTCH NOTCH TYPE TEST IMPACT DROP WEIGHT

LOCATION TEMPERATURE VALUES BREAK NO BREAK

CONTRACTOR ENGINEER APG ENGINEER CLIENT

Signature - Signature - Signature -

Name - Name - Name -

C03S004 R4
 ANNEXURE C
SHEET 14 OF 28

AKER POWERGAS PVT LTD. PROCEDURE REPORT NO. DATE

MECHANICAL CONSTRUCTION DEPT. QUALIFICATION RECORD

SHEET 5 OF 5

FILLET WELD TEST (QW 180)

RESULT - SATISFACTORY YES OR NO

PENETRATION INTO PARENT METAL YES / NO

MACRO RESULT

OTHER TESTS

TYPE OF TEST

DEPOSIT ANALYSIS

OTHER

NAME OF WELDER

CLOCK NO.

STAMP NO.

TEST CONDUCTED BY

LABORATORY TEST NO. _____________ DATED ___________

WE CERTIFY THAT THE STATEMENTS IN THIS RECORD ARE CORRECT AND THAT THE TEST WELDS ARE PREPARED,

WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENT OF SECTION IX OF THE ASME CODE.

CONTRACTOR ENGINEER APG ENGINEER CLIENT

Signature - Signature - Signature -

Name - Name - Name -

C03S004 R4
Specification

Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 1 of 19

Project No. :209/1600

Document Title : Standard Specification For Installation Of Static Equipment

CONTENTS

1.0 GENERAL

1.1 Scope
1.2 Receipt and Storage
1.3 Relevant Standard
1.4 Specific Requirement
1.5 Manufacturer’s Installation Manual

2.0 INSTALLATION

2.1 General
2.2 Foundation
2.3 Packing Plates and Shims Plates
2.4 Grouting

3.0 MEASUREMENT

3.1 Basis of Measurement

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-ISE - 01 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 2 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

1.0 GENERAL

1.1 Scope

1.1.1 This standard specification covers receipt and storage, installation of Static
Equipment.

1.2 Receipt and Storage

1.2.1 Equipment shall be unloaded by contractor only on receiving written

instructions from the client or Consultant.

1.2.2 Equipment shall be unloaded by the contractor at stores / site as instructed by

client or consultant using proper tools and tackles including crane.

1.2.3 Contractor shall arrange to safely store the equipment until they are installed.

1.2.4 Contractor shall periodically, clean, lubricate equipment stored as instructed by

client or consultant.

1.2.5 Contractor shall arrange to protect all flanges, openings by covering them with
wooden blanks or polyethane covers as per instructions of client or consultant.

1.2.6 On receipt of material contractor shall unpack, examine verify all materials for
transit damage, shortage and then repack them until they are erected.

1.2.7 In case erection manual are provided then the instructions mentioned there in
shall be followed.

1.2.8 Security arrangements shall be provided by the contractor for materials issued to
the contractor. No separate payment shall be made by client on this account.

1.2.9 Static Equipment shall be properly tagged before storage.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 3 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

1.3 Relevant Standard

The following standard specification listed below are a supplement to this specification.

VHE-02 - Standard specification for Installation of

Vessels and Heat Exchangers

VF-17 - Standard specification for Vessel Filling

TI-19 - Standard specification for Installation of traps

1.4 Specific Requirement

In case where specific requirement are provided and there is a contradiction to this
specification, then specific requirement shall govern.

1.5 Manufacturer’s Installation Manual

The installation work shall be carried out in accordance with Manufacturer’s

Installation Manual, if the same is available.

2.0 INSTALLATION

2.1 General

2.1.1 Contractor shall visit the site at his expenses to gather any further information, if
so he desires.

2.1.2 Contractor shall within the quoted rate arrange to receive, unpack the equipment
and accessories examine, verify all materials for transit damage, shortage and
repack them until they are erected. Damage report shall be prepared and
forwarded to clients, consultant within three days of receipt of material to enable
raising insurance claim and transport it from the owners storage yard within the
plant to the erection site using trailer / truck/ crane. Unloading on or near
foundation shall be done free of cost.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 4 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

2.1.3 Contractor shall within quoted rate arrange to cover and safely store equipment
received until final acceptance by client or consultant.

2.1.4 Contractor shall within quoted rate clean, lubricate periodically equipment
received as per instruction of client or consultant.

2.1.5 Contractor shall within quoted rate cut, drill, tap, rivet, machine, base plate and
couplings assemble, fit, fix, weld, grind, polish, bolt, align equipment received
in parts on to the base frame or foundation including electric motor.

2.1.6 Contractor shall place, level, grout, bolt equipment on foundation or structure, as
the case may be ordinary or non shrink grout shall be used as specified. For
grouting equipments upto 6 m height ordinary grout shall be used. For grouting
equipment over 6 m height non shrink grout shall be used. The thickness of
grout shall be 50 mm. Contractor shall include cost of grouting upto 50 mm
thickness between top of concrete and base plate including pockets in the unit
rate quoted. Grouting shall mean filling of all pockets and underside of base
frame with grout. In case the thickness of grouting exceeds 50 mm contractor
shall measure, record and obtain client / consultant approval prior to grouting,
only the cost of grouting for every incremental increase of 5 mm beyond 50 mm
will be paid. If the thickness of grout is between 5 and 10 mm, 10 mm grout
thickness will be paid. The thickness of grout will be based on average reading.
Client / consultant interpretation of the reading will be final and binding on
contractor.

Wherever epoxy grout is specified then same shall be paid on unit rate
applicable. However in such a case contractor shall exclude from the unit rate to
be quoted for erection and alignment of equipment the cost for grouting using
ordinary grout or non shrink grout and state specifically that the unit rate quoted
excludes this cost, otherwise the cost of grouting using ordinary grout non
shrink indicated by him will be reduced from the cost of erection and alignment
of the equipment.

2.1.7 Contractor shall provide within quoted rates temporary supports, pipe
scaffolding, landing materials, staging inside or outside the equipment as
required during installation of the equipment.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 5 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

2.1.8 Contractor shall assemble, fix, level all internals of the equipment as indicated in
the specification / drawing.

2.1.9 Contractor shall within quoted rate make all necessary arrangements to provide
chutes, hopper, hose, temporary covers, pump and tools and tackles to enable
charging of catalyst, pall rings into the equipment.

2.1.10 Contractor shall within quoted rate drain, clean and box up equipment after
testing to the satisfaction of client / consultant.

2.1.11 Contractor shall fabricate and erect blinds for testing from free issue plates
supplied by client. No extra cost will be paid for fabricating and installing
these blinds.

2.1.12 Wherever required contractor shall install by bolting, welding, riveting,

drilling prefabricated piping, valves, in line items such as strainers, supports
which forms part of an equipment. Payment will be made considering weight
of items installed.

2.1.13 Contractor shall within quoted rates supply all materials and safety equipment
necessary to carry out the work including tools and tackles, equipments,
compressors, cranes of required capacity, hoist, lifting tackles, consumables
and required manpowers.

2.1.14 Contractor shall provide shims at his cost. Material of construction of shims
upto 1 mm thickness shall be stainless steel or brass. Shims above 1 mm
thickness shall made of carbon steel. Shims shall be provided by contractor
within quoted rates. Packing plates upto 50mm thickness at desired locations
shall be provided by the contractor within quoted rates for equipment erection.
Packing plates beyond 50 mm thickness shall be provided as free issue by
clients. The transportation from clients stores, gas cutting, grinding, welding,
return of balance material to stores shall be done by the contractor within the
quoted rate for erection of equipment.

2.1.15 Contractor shall dismantle all temporary supports, staging, scaffolding, after
erection.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 6 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

2.1.16 All debris, waste materials lying around the equipment after equipment
erection shall be removed by the contractor.

2.1.17 Adequate lighting around the work area shall be provided by the contractor.

2.1.18 Vessel lighting of 24 V hand lamp with proper protective enclosure shall be
provided by the contractor.

2.1.19 Contractor shall carry out tack or stitch welding of supports and brackets for
erection of equipment within quoted rates.

2.1.20 Contractor shall in the event of damage to equipment during unloading,

loading, shifting or erection carry out repair. Cost for such repair/ rectification
shall be borne by contractor.

2.1.21 Contractor shall return to client store all packing materials such as plastic
sheets, wooden planks, blinds received along with equipment, after
equipment is erected.

2.1.22 Contractor shall not undertake any extra work without written approval from
client / consultant. Contractor shall provide client / consultant with the
estimate for approval.

2.1.23 Contractor shall include cost of supply of all materials required for grouting.

2.1.24 Any access road / approach way for transportation of equipment for erection
including parking area for crane away from the main plant road shall be
prepared by contractor at his cost. Consultants decision on paving or
condition or access prepared shall be final contractor shall rectify it if so
desired by consultant without any financial implications.

2.1.25 Contractor shall check and accept all foundations.

2.1.26 Civil contractor shall mark reference elevation, centre line prior to
commencement of equipment erection and mechanical contractor shall check
and accept the foundations, before commencing erection.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 7 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

2.1.27 Contractor shall include and undertake chipping of foundation upto 30 mm

within the quoted rates.

2.1.28 Dismantling and re-erection along with necessary modifications of structural

members, gratings, piping, valves to facilitate erection of equipment shall be
carried out by the contractor within the quoted rates. Such work shall be
undertaken based on instructions from client or consultant. However during
the overall span of the contract if the total weight of structural/piping etc.
dismantled, modified or re-erected exceeds 2 MT then the quantum of work
exceeding beyond 2 MT shall be paid at the applicable unit rate.

2.1.29 Safety practice is of prime importance and contractor shall ensure all safety
rules and regulations are adopted during equipment erection. Client /
consultant will suspend / stop any unsafe practice when noticed and no
compensation will be paid for the stoppage.

2.1.30 Contractor shall ensure that Power Distribution Board installed is of good
quality and shall be approved by client / consultant Electrical Engineer.

2.1.31 Contractor shall deploy full time Safety Engineer during erection of
equipment.

2.1.32 Contractor shall maintained records of all reading checks conducted during
installation and obtain client / consultant approval.

2.1.33 Contractor shall co-ordinate with statutory bodies and obtain approval of the
installation. Any statutory fees payable on this account shall be reimbursed
against documentary evidence provided and approved by client.

2.1.34 Contractor shall furnish list of all tools and tackles which are to be deployed
indicating their capacity, make, year of manufacture for approval to client /
consultant.

2.1.35 Contractor shall conduct test and furnish certificates for all lifting equipments
being used. Contractor shall inform client/ consultant in writing when major
equipments like cranes, pulley block, hoists are being tested so that if need be
the same can be witnessed. Client/consultant shall approve the test laboratories
where items are sent for testing. Load testing of crane should be done at site
within quoted rates, if insisted by clients/ consultants.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 8 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

2.1.36 Contractor shall properly tag all tools and tackles measuring instruments and
provide client / consultant with testing calibration reports prior to using them
on the job.

2.1.37 Contractor shall provide clients / contractor with method study / procedure
write up prior to commencement of equipment erection work.

2.1.38 Any tools tackles, testing equipment not found satisfactory shall be rejected by
the client / consultant. Contractor shall arrange for immediate replacement.

2.1.39 Contractor shall arrange to insure all tools and tackles against fire, theft at his
own cost.

2.1.40 Contractor shall produce test certificate / batch certificates for all materials to
be used. In the absence of certificates clients / consultant can request the
contractor to retest the items. No compensation will be paid to the contractor
for this test.

2.1.41 Contractor shall furnish the list of manpower indicating the names of key
persons along with their experience.

2.1.42 Contractor shall post at site qualified and experienced persons to execute the
job.

2.1.43 Contractor shall interact with the consultant engineer for co-ordination work
with other agencies. Contractor shall co-operate and ensure that work of
other agencies is not generally interrupted. Prior planning shall be done in
such cases.

2.1.44 Contractor shall always interact with the client through the consultant only.

2.1.45 In case job requires supervision of manufacturer representative the same shall
be arranged by the client. Contractor shall extend all necessary co-operation
to the representative. However during the examination of work by the
representative if any rework is suggested then the same shall be done by
the contractor without any extra payment.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 9 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

2.1.46 Contractor shall submit Daily Report and Weekly Report in the format agreed
upon by the client / consultant. This report shall indicate list of manpower and
tools and tackles.

2.1.47 Contractor shall submit written method study plan when erecting any
equipment weighing more than 1.0 MT.

2.1.48 All erection work shall commence only after approval of erection plan.

2.1.49 Contractor shall furnish details of crane along with load chart and sketch of
scheme for approval.

2.1.50 In case the erection is being done using derrick then contractor shall furnish
design calculation for derrick and lifting arrangement for review to client /
consultant.

2.1.51 Fixing of dead man for erection using derrick will have to be done by
contractor within the quoted rate.

2.2 Foundation

2.2.1 Remove template from foundation.

2.2.2 Equipment may be erected on structural or concrete foundation.

2.2.3 Centre line shall be marked on foundation.

2.2.4 Elevation shall be marked on structural / foundation.

2.2.5 Foundation level shall be checked.

2.2.6 Centre to centre distances between bolt holes or anchor bolts shall be
checked. The following are the tolerances for the level and location of anchor
bolts.

Level :  3 mm
Location :  3 mm

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 10 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

2.2.7 Foundation surface shall be chipped to remove any unevenness and prepare it
for receipt of grout.

2.2.8 Foundation surface / foundation bolts shall be cleaned to remove oil grease or
rust using degreasing agent or rust remover.

2.2.9 Prior to erection of any equipment on structural member ensure that structural
is properly levelled and bolted.

2.2.10 Remove any projection of weld by grinding on surface of structural to make it

flush so that it does interfere with seating and alignment of equipment.

2.2.11 The pocket shall be cleaned and any debris lying shall be removed and the
pocket covered with gunny bag to prevent entry of any foreign matter.

2.3 Packing plates and shim plates

2.3.1 Packing plates shall unless otherwise specified be made of IS 2062 grade of
carbon steel. Shim plates shall be made of austentic stainless steel or brass.
Brass shims shall not be used for shimming equipments handling acid or
ammonia.

2.3.2 Packing plates shall confirm to the following dimensions.

Length - 20 to 30 mm longer than the width of base plate of the

equipment.

Width - The minimum width of liner shall be 50mm.

Thickness - The minimum thickness shall be 10 mm.

2.3.3 Packing plates shall be arranged to distribute the load uniformly on to the
foundation.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 11 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

2.3.4 Packing plates shall be placed on either side of the anchor bolts, leaving
enough place to pour grout into the anchor bolt sleeve.

2.3.5 In places where it is not feasible to place packing plates on either side of
anchor bolts, then the same can be placed in the centre distance between two
anchor bolts.

2.3.6 Where packing plates are used, the total number of packing plates per stack
shall not be more than five.

2.3.7 Shim plates used for final alignment shall not be more than 1 mm maximum.

2.3.8 After alignment is complete the stack or layer of packing plates shall be tacked
to one another. Electrode recommended for tack welding these plates is E
6013.

2.3.9 When using packing plates the maximum distance between each pack of layer
shall not be more than 600 mm.

2.3.10 Straight packing plates do not require machining when installing packing
plates ensure that all burrs and gas cut edges are ground smooth. If there are
any weld spatter or projection on the surfaces the same shall be ground
smooth. All edges shall be rounded off.

2.3.11 Alignment of equipment on structural should be done using shims.

2.3.12 For aligning heavy equipments wedge packing plates shall be used.

2.3.13 Wedge packing plates shall be machined on the sloping surface, other surfaces
need not be machined. However all edges shall be rounded off, if there are
any projection on the surface, the same shall be ground smooth.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 12 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

2.3.14 The dimensions of wedge packing plates should be as follows.

Length - 20 to 40 mm longer than the width of base plates of

equipment.

Width - The width shall be minimum 50 mm.

Thickness - The minimum thickness shall be 15 mm.

Slope of wedge - 1 in 30 to 1 in 40.

2.3.15 When installing wedge packing plate a minimum of 1/3rd the length of the liner shall project
outside as shown below to enable alignment.

2.3.16 Tack weld the wedge plates after alignment is completed.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 13 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

2.4 Grouting

2.4.1 Before grouting equipment spray the foundation with water for about 15
minutes.

2.4.2 The pocket shall be grouted first.

2.4.3 After pocket grouting the gap between foundation top and under side of base
frame shall be packed with grout material.

2.4.4 When pouring grout material vent tube shall be provided to allow air to escape
and prevent air pocket formation.

2.4.5 For grouting static equipments below 6 metres height ordinary cement shall be
used.

2.4.6 For grouting equipments over 6 metres in height non shrink grout shall be
used.

2.4.7 In case of skids where drain holes are not provided grouting mortar shall be
poured till the top of base frame to prevent rain water from accumulating
within the base frame.

2.4.8 Details of mortar pad to be provided is as shown below :

C930034 R4 CONT. STD-CONST-ISE - 01

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Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 14 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

A : Width of base + 0 through 15 mm

B : Width of straight liner + 50 through 70 mm

Length of straight liner + 50 through 70 mm

C : Width of straight liner + 100 through 140 mm

Length of straight liner + 100 through 140 mm

D : Minimum 30 mm

2.4.9 Grouting Table `A’ enclosed indicates the type of grout recommended for pad,
pockets and base frame.

Table `B’ enclosed indicates mixing ratio for ordinary cement grout.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 15 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

The following brand of ordinary cement is recommended.

Manufacturer Grade

1) Larsen & Toubro Ltd. 43/53

2) Gujarat Ambuja 43/53

The following brands of manufacturer non shrink cement is recommended.

Brand Name Manufacturer

1. Conbextra GP2 Fosroc

2. Shrinkcomp ACC
Manufacturer’s product literature is enclosed herewith for guidance only.
Contractor shall contact manufacturer for any further details required.

3.0 MEASUREMENT

3.1 Basis of Measurement is as follows :

3.1.1 Payment shall be made on unit rate basis.

3.1.2 The weight of equipment is as per attached equipment list.

3.1.3 The client deserves the right to add or delete any equipment without assigning
any reason whatsoever. The unit rate quoted by the contractor shall remain
firm.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 16 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

3.1.4 All equipments, trays etc. which are supplied loose or fitted in the equipment
shall be paid on tonnage basis.

3.1.5 The weight of equipment indicated in equipment list is for indicative. The
final weight for payment will be arrived at, from the weight shown in the
equipment list or from any one of the following documents.

1] Net weight indicated by manufacturer / supplier.

2] Net weight indicated in the packing list provided by the supplier.

3] Net weight indicated in the drawing.

3.1.6 Consultant / client decision on the weight to be billed will be final and binding
on the contractor.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 17 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

TABLE - A

GROUTING TABLE

Equipment Height FOR

Pad Pocket Base Frame

Static equipment such as Tank,
Tower, Heat Exchanger Upto 6 m height OCG OCG OCG

Over 6 m height NSG NSG NSG

In case manufacturer installation / manual or standard is provided then the same shall be followed.

KEY :

OCG - Ordinary Cement Grout with sand and gravel.

NSG - Non Shrink Grout (conbextra or shrinkcomp) as per enclosed specification.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 18 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

TABLE - B

MIXING RATIO FOR ORDINARY CEMENT GROUT

Location For Mixing Ratio % by weight of Curing

(in Weight) water Time
Cement Sand Gravel w.r.t. cement
Pad - 1 1 - < 30 7 days
or more
Pocket of upto 300 mm 1 2 -
Anchor deep pockets 40 - 50 7 days
or more
bolts Over 300 mm 1 2 3
deep pockets
Base Frame upto 100 mm 1 2 -
grout thickness 40 - 50 7 days
or more
Over 100 mm 1 2 3
grout thickness

C930034 R4 CONT. STD-CONST-ISE - 01

Specification
Document No. : STD-CONST-ISE-01 Rev. 2 Sheet : 19 of 19

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Static Equipment

Make of cement recommended - Larsen & Toubro, Gujarat Ambuja.

Grade of cement recommended - 43 or 53.

Grain size of sand recommended - 0.3 mm to 2.5 mm.

Gravel size recommended - 5 mm to 10 mm.

Water recommended Industrial or drinking, non saline.

C930034 R4 CONT. STD-CONST-ISE - 01

Specification

Document No. : STD-CONST-VHE-02 Rev. 2 Sheet : 1 of 5

Project No. :2090/1600

Document Title : Standard Specification For Installation Of Vessel/ Heat Exchanger

CONTENTS

1.0 GENERAL

1.1 Scope

1.2 Relevant Standard

1.3 Specific Requirements

2.0 INSTALLATION

2.1 General
2.2 Foundation Preparation
2.3 Packing Plate Setting
2.4 Placement of Equipment
2.5 Alignment
2.6 Grouting

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-VHE - 02 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-VHE-02 Rev. 2 Sheet : 2 of 5

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Vessel/ Heat Exchanger

1.0 GENERAL

1.1 Scope

1.1.1 This specification covers the general requirements for the installation and
inspection of vessels, heat exchangers which form a part of equipment to be
erected in a plant. However this specification does not include site fabricated
equipment such as tanks, silos, duct.

1.2 Relevant Standard

The specification is to be read in conjunction with the following specification.

ISE-01 - Standard specification for Installation of

Vessels and Heat Exchangers

VF-17 - Specification for Vessel Filling

TI-19 - Standard specification for Installation of

Trays

1.3 Specific Requirement

In case where specific requirements are provided and there is a contradiction to this
specification, then specific requirement shall govern.

2.0 INSTALLATION

2.1 General

The following points shall be taken care during installation.

C930034 R4 CONT. STD-CONST-VHE - 02

Specification
Document No. : STD-CONST-VHE-02 Rev. 2 Sheet : 3 of 5

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Vessel/ Heat Exchanger

2.1.1 Check orientation, elevation and co-ordinate when equipment is placed on

foundation before grouting.

2.1.2 During installation ensure that foundation, foundation bolts, threads on

foundation bolts, adjacent equipment, the equipment being erected itself or
structure and piping is not damaged.

2.1.3 Care should be taken to ensure that there is adequate clearance provided in
between the slotted holes and the foundation bolt to allow for expansion or
contraction which normally occur in heat exchanger.

2.1.4 Verify that the foundation bolt is so located that it will allow for free expansion /
contraction of the heat exchanger.

2.1.5 Incase of heat exchangers check and ensure that nut on foundation bolt is kept
about 1mm loose to allow expansion and sliding of support. To prevent the nut
on the foundation bolt from loosening a lock nut can be provided.

2.1.6 Unless specifically indicated in drawing no liner shall be provided between base
plate and sliding plate. Incase the contact surface is metal to metal, then the
surface shall be cleaned and a coating of grease or graphite as specified shall be
applied.

2.1.7 When grouting care should be taken to ensure that no material is trapped
between sliding plate and base frame.

2.1.8 After alignment the packing plate shall be tacked to the sliding plate. However
care should be taken to ensure that base plate and sliding plate are not
accidentally tacked.

2.1.9 Safety practices / regulations shall be followed as per safety manual or

instructions of clients / consultant.

C930034 R4 CONT. STD-CONST-VHE - 02

Specification
Document No. : STD-CONST-VHE-02 Rev. 2 Sheet : 4 of 5

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Vessel/ Heat Exchanger

2.2 Foundation Preparation

2.2.1 Clean the foundation surface and remove any oil and dirt present.

2.2.2 Clean the pockets of foundation bolts.

2.2.3 Check perpendicularity of foundation bolts.

2.2.4 Clean thread and ensure nuts movement in free.

2.3 Packing Plate Setting

2.3.1 Check and prepare the required numbers of packing plates.

2.3.2 Set packing plate on mortar padding.

2.3.3 Ensure that mixing and application of mortar pad is as per specification.

2.3.4 Check and confirm the elevation of the packing plate fixed in the mortar pad.

2.3.5 Check number and elevation of packing plates.

2.4. Placement of Equipment

2.4.1 Check orientation, elevation of equipment.

2.4.2 Ensure that during erection of equipment neither equipment, foundation or

adjacent equipment is damaged.

2.4.3 When erecting heat exchangers care should be taken to ensure that provision for
expansion and sliding is provided.

2.4.4 After alignment and grouting of equipment all internal trays like demister shall
be installed. All external fixtures like platform, ladders shall be also be erected.

2.4.5 Ensure crane / derrick used for erection is tested and certified.

C930034 R4 CONT. STD-CONST-VHE - 02

Specification
Document No. : STD-CONST-VHE-02 Rev. 2 Sheet : 5 of 5

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Vessel/ Heat Exchanger

2.5 Alignment

2.5.1 The tolerance permitted in alignment of equipment is as stated below, unless

otherwise stated in the drawing or supplier manual.

TOLERANCE TABLE

VERTICAL HORIZONTAL
ELEVATION  3.0 MM
LOCATION  3.0 MM
PERPENDICULARITY 1.0 mm/ 1000 mm Upto -
maximum of 19 mm
LEVEL - 1.0 mm/ 1000 mm Upto
maximum of 19 mm

Elevation reading shall be compared with the reference level or bench mark.

Location reading shall be measured with reference to centre line marking on the foundation.

2.6 Grouting

2.6.1 Grouting of equipment shall be done as specified in clause No.2.4 of

specification No. ISE-01.

2.6.2 During grouting ensure that all voids are filled.

2.6.3 Ensure grout is allowed to cure as per requirement.

2.6.4 Check grout after curing for any cracks, peeling or voids.

C930034 R4 CONT. STD-CONST-VHE - 02

Specification

Document No. : STD-CONST-VHE-02 Rev. 2 Sheet : 1 of 5

Project No. :2090/1600

Document Title : Standard Specification For Installation Of Vessel/ Heat Exchanger

CONTENTS

1.0 GENERAL

1.1 Scope

1.2 Relevant Standard

1.3 Specific Requirements

2.0 INSTALLATION

2.1 General
2.2 Foundation Preparation
2.3 Packing Plate Setting
2.4 Placement of Equipment
2.5 Alignment
2.6 Grouting

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-VHE - 02 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-VHE-02 Rev. 2 Sheet : 2 of 5

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Vessel/ Heat Exchanger

1.0 GENERAL

1.1 Scope

1.1.1 This specification covers the general requirements for the installation and
inspection of vessels, heat exchangers which form a part of equipment to be
erected in a plant. However this specification does not include site fabricated
equipment such as tanks, silos, duct.

1.2 Relevant Standard

The specification is to be read in conjunction with the following specification.

ISE-01 - Standard specification for Installation of

Vessels and Heat Exchangers

VF-17 - Specification for Vessel Filling

TI-19 - Standard specification for Installation of

Trays

1.3 Specific Requirement

In case where specific requirements are provided and there is a contradiction to this
specification, then specific requirement shall govern.

2.0 INSTALLATION

2.1 General

The following points shall be taken care during installation.

C930034 R4 CONT. STD-CONST-VHE - 02

Specification
Document No. : STD-CONST-VHE-02 Rev. 2 Sheet : 3 of 5

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Vessel/ Heat Exchanger

2.1.1 Check orientation, elevation and co-ordinate when equipment is placed on

foundation before grouting.

2.1.2 During installation ensure that foundation, foundation bolts, threads on

foundation bolts, adjacent equipment, the equipment being erected itself or
structure and piping is not damaged.

2.1.3 Care should be taken to ensure that there is adequate clearance provided in
between the slotted holes and the foundation bolt to allow for expansion or
contraction which normally occur in heat exchanger.

2.1.4 Verify that the foundation bolt is so located that it will allow for free expansion /
contraction of the heat exchanger.

2.1.5 Incase of heat exchangers check and ensure that nut on foundation bolt is kept
about 1mm loose to allow expansion and sliding of support. To prevent the nut
on the foundation bolt from loosening a lock nut can be provided.

2.1.6 Unless specifically indicated in drawing no liner shall be provided between base
plate and sliding plate. Incase the contact surface is metal to metal, then the
surface shall be cleaned and a coating of grease or graphite as specified shall be
applied.

2.1.7 When grouting care should be taken to ensure that no material is trapped
between sliding plate and base frame.

2.1.8 After alignment the packing plate shall be tacked to the sliding plate. However
care should be taken to ensure that base plate and sliding plate are not
accidentally tacked.

2.1.9 Safety practices / regulations shall be followed as per safety manual or

instructions of clients / consultant.

C930034 R4 CONT. STD-CONST-VHE - 02

Specification
Document No. : STD-CONST-VHE-02 Rev. 2 Sheet : 4 of 5

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Vessel/ Heat Exchanger

2.2 Foundation Preparation

2.2.1 Clean the foundation surface and remove any oil and dirt present.

2.2.2 Clean the pockets of foundation bolts.

2.2.3 Check perpendicularity of foundation bolts.

2.2.4 Clean thread and ensure nuts movement in free.

2.3 Packing Plate Setting

2.3.1 Check and prepare the required numbers of packing plates.

2.3.2 Set packing plate on mortar padding.

2.3.3 Ensure that mixing and application of mortar pad is as per specification.

2.3.4 Check and confirm the elevation of the packing plate fixed in the mortar pad.

2.3.5 Check number and elevation of packing plates.

2.4. Placement of Equipment

2.4.1 Check orientation, elevation of equipment.

2.4.2 Ensure that during erection of equipment neither equipment, foundation or

adjacent equipment is damaged.

2.4.3 When erecting heat exchangers care should be taken to ensure that provision for
expansion and sliding is provided.

2.4.4 After alignment and grouting of equipment all internal trays like demister shall
be installed. All external fixtures like platform, ladders shall be also be erected.

2.4.5 Ensure crane / derrick used for erection is tested and certified.

C930034 R4 CONT. STD-CONST-VHE - 02

Specification
Document No. : STD-CONST-VHE-02 Rev. 2 Sheet : 5 of 5

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Vessel/ Heat Exchanger

2.5 Alignment

2.5.1 The tolerance permitted in alignment of equipment is as stated below, unless

otherwise stated in the drawing or supplier manual.

TOLERANCE TABLE

VERTICAL HORIZONTAL
ELEVATION  3.0 MM
LOCATION  3.0 MM
PERPENDICULARITY 1.0 mm/ 1000 mm Upto -
maximum of 19 mm
LEVEL - 1.0 mm/ 1000 mm Upto
maximum of 19 mm

Elevation reading shall be compared with the reference level or bench mark.

Location reading shall be measured with reference to centre line marking on the foundation.

2.6 Grouting

2.6.1 Grouting of equipment shall be done as specified in clause No.2.4 of

specification No. ISE-01.

2.6.2 During grouting ensure that all voids are filled.

2.6.3 Ensure grout is allowed to cure as per requirement.

2.6.4 Check grout after curing for any cracks, peeling or voids.

C930034 R4 CONT. STD-CONST-VHE - 02

Specification

Document No. : STD-CONST-IPB-03 Rev. 2 Sheet : 1 of 5

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Pump Blower

CONTENTS

1.0 GENERAL

1.1 Scope

1.2 Receipt and Storage

1.3 Relevant Standard

1.4 Specific Requirement

1.5 Manufacturer’s Installation Manual

2.0 INSTALLATION

3.0 ALIGNMENT

4.0 TOLERANCES

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST- IPB - 03 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-IPB-03 Rev. 2 Sheet : 2 of 5

Project No. :

Document Title : Standard Specification For Installation Of Pump Blower

1.0 GENERAL

1.1 Scope

1.1.1 This specification covers the general requirement for installation of Pump and
Blower alongwith its accessories.

1.2 Receipt and Storage

1.2.1 Equipment shall be unloaded by contractor only on receiving written

instructions from the client or Consultant.

1.2.2 Equipment shall be unloaded by the contractor at stores / site as instructed by

client or consultant using proper tools and tackles including crane. Unloading of
equipment on or near foundation shall be done free of cost.

1.2.3 Contractor shall arrange to safely store the equipment until they are installed.

1.2.4 Contractor shall periodically, clean, lubricate equipment stored as instructed

by client or consultant.

1.2.5 Contractor shall arrange to protect all flanges, openings by covering them with
wooden blanks or polyethane covers as per instructions of client or consultant.

1.2.6 On receipt of material contractor shall unpack, examine verify all materials for
transit damage, shortage and then repack them until they are erected. Damage
report shall be prepared and forwarded to client, consultant within three days of
receipt of materials to enable raising of insurance claim.

1.2.7 In case erection manual are provided then the instructions mentioned there in
shall be followed.

1.2.8 Security arrangements shall be provided by the contractor for materials issued to
the contractor. No separate payment shall be made by client on this account.

1.2.9 Equipment shall be properly tagged before storage.

C930034 R4 CONT. STD-CONST-IPB - 03

Specification
Document No. : STD-CONST-IPB-03 Rev. 2 Sheet : 3 of 5

Project No. :

Document Title : Standard Specification For Installation Of Pump Blower

1.3 Relevant Standard

The following standard specification listed below are a supplement to this specification.

1.4 Specific Requirement

In case where specific requirement are provided and there is a contradiction to this
specification, then specific requirement shall govern.

1.5 Manufacturer’s Installation Manual

The installation work shall be carried out in accordance with Manufacturer’s

Installation Manual, if the same is available.

2.0 INSTALLATION

2.1 Check foundation level prior to installation of pump or blower.

2.2 Place pump alongwith base plate on the packing plate.

2.3 Fix anchor bolts.

2.4 Align pump base plate with reference to location.

2.5 Grout the anchor bolts upto the pocket height, mixing of grout shall be as recommended
by the manufacturer and as per clause 2.4 of spec. No.STD-CONST-ISE-01.

2.6 Now after grout is cured, do final alignment of base plate.

2.7 Grout should be non shrink grout of epoxy, if recommended. Ordinary cement grout is
not acceptable.

C930034 R4 CONT. STD-CONST-IPB - 03

Specification
Document No. : STD-CONST-IPB-03 Rev. 2 Sheet : 4 of 5

Project No. :

Document Title : Standard Specification For Installation Of Pump Blower

2.8 Now place the driver unit of the pump or blower.

2.9 Align the pump / blower with the driver unit within the axial and radial tolerances
specified and tighten the hold down bolts.

2.10 Do final grouting upto underside of base plate.

2.11 Allow grout to cure.

2.12 Now install the piping and check and correct the alignment readings if required.

2.13 Tighten all hold down bolts fully and ensure reading is within the tolerances specified.

2.14 To ensure that dial gauge does not indicate erroneous reading kindly fix the dial gauge
firmly.

2.15 The dial gauge holding arm should be as small as possible.

2.16 Tighten the assembly fully so that error are not reflected in the reading.

2.17 The measuring probe should be perpendicular to the surface where reading is being
taken so that error due to angular deviations of measuring probe are not obtained.

2.18 The coupling shall be installed after completion of alignment and verifying direction of
rotation of driver and also after completion of no load trials.

2.19 Install gland cooling piping assembly.

C930034 R4 CONT. STD-CONST-IPB - 03

Specification
Document No. : STD-CONST-IPB-03 Rev. 2 Sheet : 5 of 5

Project No. :

Document Title : Standard Specification For Installation Of Pump Blower

3.0 ALIGNMENT

3.1 Alignment is done using two dial gauges mounted on a bracket with their probes
perpendicular to one another.

3.2 One probe of the dial gauge is in contact with the face of the coupling and the other is in
contact with the circumference of the coupling as shown in sketch below :

4.0 TOLERANCES

4.1 The tolerances in alignment of the base frame is as follows.

Horizontal Vertical
Elevation  3.0
Location  3.0 -
Level 1.0 in 1000 -

4.2 The tolerances of deflection of shaft is as follows, unless otherwise specified.

Tolerance for parallel deflection of shaft is as follows :

Shaft Speed (rpm) Tolerance (mm)

Less than 1000 0.1
Between 1000 to 5000 0.05
Over 5000 0.03

4.3 Tolerance for angular deflection shall be 0.7 mm unless otherwise specified.

C930034 R4 CONT. STD-CONST-IPB - 03

Specification

Document No. : STD-CONST-ICT-04 Rev. 2 Sheet : 1 of 6

Project No. : 2090/1600

Document Title : Standard Specification For Installation Of Compressor / Turbine

CONTENTS

1.0 GENERAL

1.1 Scope

1.2 Receipt and Storage

1.3 Relevant Standard

1.4 Specific Requirement

1.5 Manufacturer’s Installation Manual

2.0 INSTALLATION

3.0 ALIGNMENT

4.0 TOLERANCES

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-ICT-04 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-ICT-04 Rev. 2 Sheet : 2 of 6

Project No. :

Document Title : Standard Specification For Installation Of Compressor / Turbine

1.0 GENERAL

1.1 Scope

1.1.1 This specification covers the general requirement for installation of Centrifugal
and reciprocating compressors, turbine and its accessories.

1.2 Receipt and Storage

1.2.1 Equipment shall be unloaded by contractor only on receiving written

instructions from the client or Consultant.

1.2.2 Equipment shall be unloaded by the contractor at stores / site as instructed by

client or consultant using proper tools and tackles including crane.

1.2.3 Contractor shall arrange to safely store the equipment until they are installed.

1.2.4 Contractor shall periodically, clean, lubricate equipment stored as instructed

by client or consultant.

1.2.5 Contractor shall arrange to protect all flanges, openings by covering them with
wooden blanks or polyethane covers as per instructions of client or consultant.

1.2.6 On receipt of material contractor shall unpack, examine verify all materials for
transit damage, shortage and then repack them until they are erected.

1.2.7 In case erection manual are provided then the instructions mentioned there in
shall be followed.

1.2.8 Security arrangements shall be provided by the contractor for materials issued to
the contractor. No separate payment shall be made by client on this account.

1.2.9 Static Equipment shall be properly tagged before storage.

C930034 R4 CONT. STD-CONST- ICT-04

Specification
Document No. : STD-CONST-ICT-04 Rev. 2 Sheet : 3 of 6

Project No. :

Document Title : Standard Specification For Installation Of Compressor / Turbine

1.3 Relevant Standard

The following standard specification listed below are a supplement to this specification.

1.4 Specific Requirement

In case where specific requirement are provided and there is a contradiction to this
specification, then specific requirement shall govern.

1.5 Manufacturer’s Installation Manual

The installation work shall be carried out in accordance with Manufacturer’s

Installation Manual, if the same is available.

2.0 INSTALLATION

2.1 Check foundation level prior to installation of compressor or turbine.

2.2 Install packing plates for Jacking after marking location of jack bolts.

2.3 Erect base plate on packing plates which are aligned.

2.4 Level and align base frame.

2.5 Fix anchor bolts and grout pockets.

2.6 Allow grouting to cure.

2.7 Erect compressor on base frame and locate.

2.8 Erect base frame of motor on packing plates and align.

C930034 R4 CONT. STD-CONST- ICT-04

Specification
Document No. : STD-CONST-ICT-04 Rev. 2 Sheet : 4 of 6

Project No. :

Document Title : Standard Specification For Installation Of Compressor / Turbine

2.9 Erect motor and align with shaft of compressor.

2.10 Grout both base frames.

2.11 Tighten all anchor bolts.

2.12 Complete final alignment of compressor and motor.

2.13 Connect piping.

2.14 Check alignment readings and correct it if required by modifying the piping so that
undue stress is not transferred to the equipment.

3.0 ALIGNMENT

3.1 Alignment is done using two dial gauge mounted on a bracket with their probes
perpendicular to one another.

3.2 One probe of the dial gauge is in contact with the face of the coupling and the other is in
contact with the circumference of the coupling as shown in sketch below :

C930034 R4 CONT. STD-CONST- ICT-04

Specification
Document No. : STD-CONST-ICT-04 Rev. 2 Sheet : 5 of 6

Project No. :

Document Title : Standard Specification For Installation Of Compressor / Turbine

3.3 Turn the shaft of the driven through 360 and check the deflection of the dial gauge.

3.4 Set both dial gauges to zero.

3.5 Then turn the shaft of the driven (compressor or turbine) and note the reading of both
the dial gauges at 90 intervals.

3.6 Turn the shaft of driver through 180 and then repeat the procedure indicated in 3.5.

3.7 Make necessary adjustment by shimming till the reading is within the tolerance
permitted.

4.0 TOLERANCES

4.1 The tolerance shall be as specified below, unless otherwise stated.

Compressor \ Steam Reciprocating

Turbine Compressor
Elevation 3 3
Location with respect to co-ordinates 3 3
Bearing Pedestal Levelness 0.05/1000 -
Cross Guide Levelness in Crankshaft Direction - 0.1/ 1000
Squareness to Cross guide to Crankshaft - 0.1/ 1000
Frame Levelness in Cross Guide Direction - 0.1/ 1000

C930034 R4 CONT. STD-CONST- ICT-04

Specification
Document No. : STD-CONST-ICT-04 Rev. 2 Sheet : 6 of 6

Project No. :

Document Title : Standard Specification For Installation Of Compressor / Turbine

4.2 The shaft alignment reading for parallel and face deflection shall be as stated below :

Compressor \ Steam Turbine Reciprocating Compressor

Axial Misalignment For speed upto  0.05
5000 rpm
5000 rpm and  0.03  0.1
above
Facial Misalignment -  0.07

Crankshaft web deflection `X’ pl. see enclosed sheet no 7  0.03

measured at 90 intervals of 7

Distance between the

Follow the coupling manufacturers drawing.
couplings

C930034 R4 CONT. STD-CONST- ICT-04

Specification
Document No. : STD-CONST-WQT-05
Rev. 2 Sheet : 1 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

CONTENTS

1.0 Scope

2.0 Relevant Standard

3.0 Test Preparation

4.0 Welder Test

5.0 Inspection

6.0 Test Positions and Qualification Thickness Range

7.0 Documentation

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-WQT-05 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-WQT-05 Rev. 2 Sheet : 2 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

1.0 Scope

This standard specification covers requirement for welder qualification test.

2.0 Relevant Standard

The latest edition of the following standards including all revisions and addendum shall be
applicable.

ASME Section V - Non Destructive Examination

ASME Section IX - Welding and Brazing Qualification

3.0 Test Preparation

Welders offering themselves for test shall have past experience executing similar
jobs.

Before conducting welder test, the contractor shall submit the following documents
with all particulars filled.

1) Application for qualification of welder. (refer Annexure A)

2) Welding Procedure Specification. (refer Annexure B)

3) Procedure Qualification Record/ except welding parameters filled in, this

shall be filled in when actual test is being conducted. (refer Annexure C)

3.3 For qualifying pipe welders, pipe test coupons are normally used, however plate test
coupons can also be used for qualifying pipe welders.

3.4 Edge preparation for pipe and plate for test specimen including dimensions of test
specimen shall be as shown in Annexure D.
3.5 The test coupon shall be prepared from the grade of material on which the welder is
to be qualified.

3.6 Test coupon material shall be provided by clients, however in case clients feel that
welders being tested are failing frequently then the test coupon can be issued on
chargeable basis at rates mutually agreed between contractor and client.

C930034 R4 CONT. STD-CONST-WQT - 05

Specification
Document No. : STD-CONST-WQT-05 Rev. 2 Sheet : 3 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

4.0 Welder Test

4.1 Procedure followed shall be as stated in welding procedure specification when

conducting the welder test.

4.2 When conducting welder test the parameters such as current and voltage shall be
recorded using tested and calibrated instruments.

4.3 Contractor shall produce for verification the relevant testing and calibration
certificates for all instruments used during welder test.

4.4 Welder shall be wear all personal protection gear prior to commencement of test.

4.5 Welder test will be conducted in presence of Consultant Engineer.

4.6 Proper record shall be maintained for the welder who has been qualified.

4.7 All qualified welder shall be issued identity card, specimen of this format is enclosed
herewith. (refer Annexure E)

5.0 Inspection

5.1 Visual examination of the weld shall be carried out after welding and the acceptance
criteria shall be as stated in Annexure F.

5.2 The specimen shall be sent to an approved laboratory for conducting the following
test.

a) Tensile Test
b) Guided Bend Test
c) Toughness Test

5.3 Radiographic examination of the test specimen shall be conducted in accordance

with article 2 of ASME section. V. This test and laboratory test shall be conducted
only if the specimen has been visually examined and approved.

5.4 Welder shall be qualified after interpreting the radiographic examination result with
QW 191 of ASME section IX.

5.5 Welder who has not been successful in qualifying can reappear only twice again for
test after undergoing adequate training.

C930034 R4 CONT. STD-CONST-WQT - 05

Specification
Document No. : STD-CONST-WQT-05 Rev. 2 Sheet : 4 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

5.6 Tack welders shall also have to undergo welder test based on the grade of material to
be tack welded.

5.7 Structural steel welders shall be qualified on the grade of materials they are to weld.
The welder shall be qualified on a test plate coupon so that one half weld seam shall
be done in 2G position and the other half on 3G position.

5.8 Structural steel welder shall be qualified based on Visual Inspection of the test
coupon.

6.0 Test Positions and Qualification Thickness Range

6.1 Annexure G indicates various test positions as per ASME section IX QW 461 for
pipe and plate.

6.2 Annexure H indicated the order for removal of test specimen for various tests.

6.3 Annexure I indicates the groove weld diameter limits.

6.4 Annexure J indicates pipe diameter and thickness range qualified for fillet weld.

6.5 Annexure K indicates details for fillet weld.

6.6 Annexure L indicates position and diameter limitations.

6.7 Annexure M indicates details of groove weld tension tests and transerve bend tests.

6.8 Annexure N indicates details of groove weld tension tests and longitudinal bend
tests.Annexure O indicates details on longitudinal bend test.

7.0 Documentation

7.1 Contractor shall comply four sets of the following documents and submit the same
to the Consultant Engineer.
a) Application for qualification of welder.
b) Welding Procedure Specification.
c) Procedure Qualification Record.
d) Welder Identification Card.
e) Test report received from laboratory for test specimen.
f) X – ray report for test specimen.

C930034 R4 CONT. STD-CONST-WQT - 05

Specification
Document No. : STD-CONST-WQT-05 Rev. 2 Sheet : 5 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

ANNEXURE A

APPLICATION FOR QUALIFICATION OF WELDER

Date

To From

The Site Manager The Site Incharge

Company _______________ Company_________

Location ________________ Location__________

Name of Welder _____________________________________________________

Present Address ______________________________________________________

______________________________________________________

Date of Birth ____________ Age ____________

RECENT
PHOTOGRAPH
Seal of Company Applying
Total years of experience ___________________________________________
Qualification already acquired ___________________________________________
Issued By ___________________________________________
Date of Issue ___________________________________________
Classification ___________________________________________
WPS No. Attached ___________________________________________

Date of Receipt ______________ Date of Test ___________

Contractor Contractor
Name Name
Sign Sign

C930034 R4 CONT. STD-CONST-WQT - 05

Specification
Document No. : STD-CONST-WQT-05 Rev. 2 Sheet : 6 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

ANNEXURE K

QW-451.3

FILLET WELD TESTS

Type of joints Thickness of Test Type and Number

Joints Coupons as, Welded in Range Qualified of Tests Required

[QW-462.4(a) or
QW-462.4 (d)] Marco

Fillet Per QW-462.4(a) All fillet sizes on all base 5

metal thicknesses and all
diameter

Fillet Per QW-462.4(d) 4

NOTES
(1) Production assembly mockups may be substituted in accordance with QW-181.1.1. When
production assembly mockups are used, range qualified shall be limited to the fillet sizes,
base metal thickness and configuration of the mockup.

QW-451.4

FILLET-WELDS QUALIFIED BY GROOVE-WELD TESTS

All groove tests
Thickness T of Test
Coupon (Plate or Pipe)
As Welded
All fillet sizes on all base Fillet welds are qualified
metal thicknesses and all when the groove weld is
diameters qualified in accordance
with either QW-451.1 or
QW-451.2 (see QW-202.2)
Range Qualified Type and Number
of Tests
Required

C930034 R4 CONT. STD-CONST-WQT - 05

Specification
Document No. : STD-CONST-WQT-05
Rev. 2 Sheet : 1 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

CONTENTS

1.0 Scope

2.0 Relevant Standard

3.0 Test Preparation

4.0 Welder Test

5.0 Inspection

6.0 Test Positions and Qualification Thickness Range

7.0 Documentation

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-WQT-05 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-WQT-05 Rev. 2 Sheet : 2 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

1.0 Scope

This standard specification covers requirement for welder qualification test.

2.0 Relevant Standard

The latest edition of the following standards including all revisions and addendum shall be
applicable.

ASME Section V - Non Destructive Examination

ASME Section IX - Welding and Brazing Qualification

3.0 Test Preparation

Welders offering themselves for test shall have past experience executing similar
jobs.

Before conducting welder test, the contractor shall submit the following documents
with all particulars filled.

1) Application for qualification of welder. (refer Annexure A)

2) Welding Procedure Specification. (refer Annexure B)

3) Procedure Qualification Record/ except welding parameters filled in, this

shall be filled in when actual test is being conducted. (refer Annexure C)

3.3 For qualifying pipe welders, pipe test coupons are normally used, however plate test
coupons can also be used for qualifying pipe welders.

3.4 Edge preparation for pipe and plate for test specimen including dimensions of test
specimen shall be as shown in Annexure D.
3.5 The test coupon shall be prepared from the grade of material on which the welder is
to be qualified.

3.6 Test coupon material shall be provided by clients, however in case clients feel that
welders being tested are failing frequently then the test coupon can be issued on
chargeable basis at rates mutually agreed between contractor and client.

C930034 R4 CONT. STD-CONST-WQT - 05

Specification
Document No. : STD-CONST-WQT-05 Rev. 2 Sheet : 3 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

4.0 Welder Test

4.1 Procedure followed shall be as stated in welding procedure specification when

conducting the welder test.

4.2 When conducting welder test the parameters such as current and voltage shall be
recorded using tested and calibrated instruments.

4.3 Contractor shall produce for verification the relevant testing and calibration
certificates for all instruments used during welder test.

4.4 Welder shall be wear all personal protection gear prior to commencement of test.

4.5 Welder test will be conducted in presence of Consultant Engineer.

4.6 Proper record shall be maintained for the welder who has been qualified.

4.7 All qualified welder shall be issued identity card, specimen of this format is enclosed
herewith. (refer Annexure E)

5.0 Inspection

5.1 Visual examination of the weld shall be carried out after welding and the acceptance
criteria shall be as stated in Annexure F.

5.2 The specimen shall be sent to an approved laboratory for conducting the following
test.

a) Tensile Test
b) Guided Bend Test
c) Toughness Test

5.3 Radiographic examination of the test specimen shall be conducted in accordance

with article 2 of ASME section. V. This test and laboratory test shall be conducted
only if the specimen has been visually examined and approved.

5.4 Welder shall be qualified after interpreting the radiographic examination result with
QW 191 of ASME section IX.

5.5 Welder who has not been successful in qualifying can reappear only twice again for
test after undergoing adequate training.

C930034 R4 CONT. STD-CONST-WQT - 05

Specification
Document No. : STD-CONST-WQT-05 Rev. 2 Sheet : 4 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

5.6 Tack welders shall also have to undergo welder test based on the grade of material to
be tack welded.

5.7 Structural steel welders shall be qualified on the grade of materials they are to weld.
The welder shall be qualified on a test plate coupon so that one half weld seam shall
be done in 2G position and the other half on 3G position.

5.8 Structural steel welder shall be qualified based on Visual Inspection of the test
coupon.

6.0 Test Positions and Qualification Thickness Range

6.1 Annexure G indicates various test positions as per ASME section IX QW 461 for
pipe and plate.

6.2 Annexure H indicated the order for removal of test specimen for various tests.

6.3 Annexure I indicates the groove weld diameter limits.

6.4 Annexure J indicates pipe diameter and thickness range qualified for fillet weld.

6.5 Annexure K indicates details for fillet weld.

6.6 Annexure L indicates position and diameter limitations.

6.7 Annexure M indicates details of groove weld tension tests and transerve bend tests.

6.8 Annexure N indicates details of groove weld tension tests and longitudinal bend
tests.Annexure O indicates details on longitudinal bend test.

7.0 Documentation

7.1 Contractor shall comply four sets of the following documents and submit the same
to the Consultant Engineer.
a) Application for qualification of welder.
b) Welding Procedure Specification.
c) Procedure Qualification Record.
d) Welder Identification Card.
e) Test report received from laboratory for test specimen.
f) X – ray report for test specimen.

C930034 R4 CONT. STD-CONST-WQT - 05

Specification
Document No. : STD-CONST-WQT-05 Rev. 2 Sheet : 5 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

ANNEXURE A

APPLICATION FOR QUALIFICATION OF WELDER

Date

To From

The Site Manager The Site Incharge

Company _______________ Company_________

Location ________________ Location__________

Name of Welder _____________________________________________________

Present Address ______________________________________________________

______________________________________________________

Date of Birth ____________ Age ____________

RECENT
PHOTOGRAPH
Seal of Company Applying
Total years of experience ___________________________________________
Qualification already acquired ___________________________________________
Issued By ___________________________________________
Date of Issue ___________________________________________
Classification ___________________________________________
WPS No. Attached ___________________________________________

Date of Receipt ______________ Date of Test ___________

Contractor Contractor
Name Name
Sign Sign

C930034 R4 CONT. STD-CONST-WQT - 05

Specification
Document No. : STD-CONST-WQT-05 Rev. 2 Sheet : 6 of 28

Project No. : 2090/1600

Document Title : Standard Specification For Welder Qualification Test

ANNEXURE K

QW-451.3

FILLET WELD TESTS

Type of joints Thickness of Test Type and Number

Joints Coupons as, Welded in Range Qualified of Tests Required

[QW-462.4(a) or
QW-462.4 (d)] Marco

Fillet Per QW-462.4(a) All fillet sizes on all base 5

metal thicknesses and all
diameter

Fillet Per QW-462.4(d) 4

NOTES
(1) Production assembly mockups may be substituted in accordance with QW-181.1.1. When
production assembly mockups are used, range qualified shall be limited to the fillet sizes,
base metal thickness and configuration of the mockup.

QW-451.4

FILLET-WELDS QUALIFIED BY GROOVE-WELD TESTS

All groove tests
Thickness T of Test
Coupon (Plate or Pipe)
As Welded
All fillet sizes on all base Fillet welds are qualified
metal thicknesses and all when the groove weld is
diameters qualified in accordance
with either QW-451.1 or
QW-451.2 (see QW-202.2)
Range Qualified Type and Number
of Tests
Required

C930034 R4 CONT. STD-CONST-WQT - 05

Specification
Document No. : STD-CONST-NDT-06
Rev. 2 Sheet : 1 of 6

Project No. : 2090/1600

Document Title : Standard Specification For Non Destruction Test

CONTENTS

1.0 Scope

2.0 Relevant Standard

3.0 Visual Examination

4.0 Liquid Penetrant Examination

5.0 Magnetic Particle Examination

6.0 Hardness Test Examination

7.0 Radiographic Examination

8.0 Hydrotest Examination

9.0 Pneumatic Test Examination

10.0 Documentation

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-NDT-06 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-NDT-06 Rev. 2 Sheet : 2 of 6

Project No. :

Document Title : Standard Specification For Non Destruction Test

1.0 Scope

This standard specification covers the requirement for non destructive testing of site fabricated
equipments and piping.

2.0 Relevant Standard

The latest edition of the following standards including all revisions and addendum shall be
applicable.

ASME Section V - Non Destructive Examination

ASME B 31.3 - Chemical Plant and Petroleum Refinery Piping

ANSI B 16.5 - Pipes flanges and flange fittings

ASME Section IX - Welding and Brazing Qualification

3.0 Visual Examination

3.1 Welds shall be usually examined and accepted based on parameter stated in Table 1.

4.0 Liquid Penetrant Examination

4.1 Liquid penetrant examination shall be carried out as specified in the piping specification
index/ drawing or as per instruction of the consultant engineer.

4.2 Contractor shall maintain record of all joints that have been liquid penetrant examined.

4.3 Liquid penetrant examination shall be carried out as per ASME Section V article 6.

C930034 R4 CONT. STD-CONST-NDT-06

Specification
Document No. : STD-CONST-NDT-06 Rev. 2 Sheet : 3 of 6

Project No. :

Document Title : Standard Specification For Non Destruction Test

5.0 Magnetic Particle Examination

5.1 Magnetic particle examination shall be carried out as specified in the piping
specification index or drawing or as per instruction of the consultant engineer.

5.2 Contractor shall maintain record of all joints that have been examined using magnetic
particle examination.

5.3 Magnetic particle examination shall be carried out as per ASME Section V article 7.

6.0 Hardness Test Examination

6.1 Hardness Test shall be carried out as specified in the piping specification index/
drawing or as per instruction of the consultant engineer.

6.2 Contractor shall maintain record of all joints that have been examined for hardness.

6.3 Hardness test shall be carried out by vickers hardness tester, brinell or poldy hardness
tester as approved by the consultant engineer.

7.0 Radiographic Examination

7.1 Procedure for radiographic examination to be adopted will have to be furnished by the
contractor to the consultant and approval obtained.

7.2 Contractor shall furnish the names and biodata of radiographic contractor the plan to
deploy and obtain the approval of the consultant. No agency or contractor shall be
deployed without the approval of consultant. Radiographer should have minimum level
II qualification.

7.3 The radiographic techniques and procedures adopted shall confirm to the requirements
mentioned in Article 2, as well as Article 22 (SE 94, SE 142) of ASME Section V.

C930034 R4 CONT. STD-CONST-NDT-06

Specification
Document No. : STD-CONST-NDT-06 Rev. 2 Sheet : 4 of 6

Project No. :

Document Title : Standard Specification For Non Destruction Test

7.4 The sensitivity of the radiograph obtained shall be equal to or better than the
requirements mentioned in table 262.2 and table 272 of ASME Section V for single and
double wall respectively.

7.5 The acceptable limits of defects and removal of defects shall be as per the relevant code
of fabrication.

7.6 Contractor shall carry out radiography, reradiography of welds that are repaired.

7.7 All statutory, safety requirements while handling X-ray or gamma ray source shall be
followed by the contractor.

7.8 Radiographic examination shall be carried out using X-ray, however gamma ray shall
be used with prior approval of consultant.

7.9 The percentage of radiography shall be as stated in the piping specification or drawing.

7.10 When radiographically examining dissimilar materials the percentage of radiographic

examination shall be the higher percentage of the two.

7.11 The contractor shall radiograph the joints selected by the consultant inspector.

7.12 After radiography the contractor shall furnish all the radiographs to the consultant
engineer after processing alongwith his observations.

7.13 All necessary documentation shall be prepared and maintained by the contractor and the
same will be forwarded to consultant for review and approval.

7.14 Contractor shall at his cost prepare and maintain pit for source, dark room with
necessary air conditioner, film viewer and other facilities to enable radiography work.

7.15 Contractor shall provide the consultant engineer with all necessary facilities to view and
interpret the radiographs.

C930034 R4 CONT. STD-CONST-NDT-06

Specification
Document No. : STD-CONST-NDT-06 Rev. 2 Sheet : 5 of 6

Project No. :

Document Title : Standard Specification For Non Destruction Test

7.16 For every weld performed by a welder, found unacceptable two additional checks
should be carried on joints welded by the same welder. The procedure of radiographing
two additional weld joints for every weld found unsatisfactory shall be continued till
two consecutive welds of satisfactory quality is found for every defective weld. No
joint shall be repaired more than twice. If repair persists than joint shall be cut and
rewelded.

7.17 Contractor shall arrange for prompt examination of welds so that the backlog of
radiography / repair is reduced.

7.18 Contractor shall at his expense rectify the defect weld and reoffer for radiography.
Additional radiographic testing will have to be undertaken by the contractor at his own
expense.

8.0 Hydrotest Examination

8.1 Lines to be hydrotested shall be as per piping specification / drawings.

8.2 Hydrotest pressure shall be as stated in line list or drawings.

8.3 Before conducting hydrotest contractor shall check and confirm that all lines are
installed as per P & I Diagram, this exercise shall be jointly done along with
Consultant Engineer.

8.4 Hydrotest examination shall be carried out as per Aker Solutions standard
specification No.STD-CONST-HT-14.

9.0 Pneumatic Test Examination

9.1 Lines to be pneumatically tested shall be as per piping specification/ drawings.

9.2 Pneumatic pressure shall be as stated in Line List or drawings.

C930034 R4 CONT. STD-CONST-NDT-06

Specification
Document No. : STD-CONST-NDT-06 Rev. 2 Sheet : 6 of 6

Project No. :

Document Title : Standard Specification For Non Destruction Test

9.3 Before conducting pneumatic test contractor shall check and confirm that all lines are
installed as per P & I Diagram, this exercise shall be jointly done along with Consultant
Engineer.

9.4 Pneumatic examination shall be carried out as per Aker Solutions standard specification
No.STD-CONST-PT-15.

10.0 Documentation

10.1 Contractor shall prepare and submit four sets of the following documents after
completion of the job.

a) Visual Examination Record

b) Liquid Penetrant Test Record
c) Magnetic particle Test Record
d) Hardness Test Record
e) Radiographic Test Record
f) Hydrotest Record
g) Pneumatic Test Record

C930034 R4 CONT. STD-CONST-NDT-06

Specification
Document No. : STD-CONST-FECSP-07
Rev. 2 Sheet : 1 of 33

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Carbon

Steel Piping

CONTENTS

1.0 Scope
2.0 Relevant Standard
3.0 Materials
4.0 IBR Piping
5.0 Electrodes and Filler Wire
6.0 Consumables
7.0 Tools and Tackles
8.0 Edge Preparation
9.0 Joints in Piping
10.0 Alignment and Spacing
11.0 Fabrication and Erection
12.0 Welding
13.0 Heat Treatment
14.0 Inspection
15.0 Measurement
16.0 Material Reconciliation
17.0 Documentation

2 Construction SS / June PKB / June ADM / June

1 Construction SS / July 2005 ADM / July PKD / July
0 Construction SS / May 1996 ADM / May PKD / May
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

C930034 R4 STD-CONST-FECSP-07 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-FECSP-07 Rev. 2 Sheet : 2 of 33

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

Client : BAYER MATERIAL SCIENCE - ANKLESHWAR

1.0 Scope

1.1 This specification covers site fabrication and erection of carbon steel piping.

1.2 This specification is not applicable for fabrication of alloy steel piping.

2.0 Relevant Standard

The latest edition of the following standards including all revisions and addendum shall
be applicable.

ASME 31.3 - Chemical plant and petroleum refinery piping

IBR - Indian Boiler Regulation

ASME Section } Specification for welding rods, electrode

II Part C } and filler metals.

ASTM Section IX - Welding and Brazing qualification

ASME Section V - Non Destructive Examination

C930034 R4 CONT. STD-CONST-FECSP-07

Specification
Document No. : STD-CONST-FECSP-07 Rev. 2 Sheet : 3 of 33

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

3.0 Materials

3.1 All free issue materials like pipes, flanges, fittings, valves, bolts and nuts,
gaskets, inline fittings, spring supports etc. shall be supplied.

3.2 Contractor shall arrange to receive and store materials in their stores till it is
erected.

3.3 Pipes, fittings, valves, flanges, gaskets, studs, in line fittings used in a particular
piping system shall be as specified in piping specification.

3.4 Contractor shall ensure that all materials received have been properly identified
by Aker Solutions colour code, punch mark or by engraving so that traceability
of material is ensured.

3.5 IBR materials shall be painted as per colour code and stored separately with
identification marks.

3.6 Valves, special in line fittings and other piping materials shall be properly
tagged.

3.7 Contractor shall visually inspect materials being collected and immediately bring
to the notice of the stores officer any discrepancy or short fall noticed. No claim
will be entertained once materials are issued.

3.8 All piping materials such as pipes valves, flanges, fittings in line fittings gaskets
etc. shall be drawn line wise against proper material issue ticket.

3.9 No bulk issue of material will be made.

3.10 Contractor shall collect all materials indented at one time and move it out of the
store.

3.11 Contractor shall make arrangements to deploy tractor, trailer, truck, wheel
barrow, hand cart, fork lift or hydra crane to shift material from clients stores to
their stores.

C930034 R4 CONT. STD-CONST-FECSP-07

Specification
Document No. : STD-CONST-FECSP-07 Rev. 2 Sheet : 4 of 33

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

3.12 Contractor shall construct at his cost covered stores for storage of materials
received from clients stores.

4.0 IBR Piping

4.1 Contractor shall be provided with all IBR drawings by clients/ consultant.

4.2 Contractor shall be responsible to obtain approval of the drawings. Consultant

shall assist contractor if required during the meeting with inspector to sort out
any technical points requiring clarification.

4.3 Contractor shall co-ordinate and arrange for the visit of the IBR inspector for
material identification and approval.. All material test certificates shall be
furnished by client, these shall be filed separately, to be available when IBR
inspector visits site for material identification.

4.4 Contractor shall ensure that all welders deployed on the job have necessary
IBR approval from the authorities.

4.5 Contractor shall include in his cost all expenses incurred to liaison with IBR
authorities like correspondence, phone calls, visits to IBR offices.

4.6 Client shall against documentary evidence reimburse the contractor statutory
fees paid to IBR authorities.

4.7 Contractor shall within quoted rate arrange for visit of IBR inspector during
various stages of execution of the job.

4.8 Contractor shall submit final drawings and documents to IBR inspector and
obtain approval of the installation.

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Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

4.9 Contractor shall maintain all documents such as Welding Procedure

Specification, Procedure Qualification Record, Daily Fit Up Report, Welding
Report, NDT Report, Line Check Report, Line Clearance Report & Hydrotest
Reports. Client / Consultant shall have access to review and comment on
these reports.

5.0 Electrodes and Filler Wire

5.1 Contractor shall arrange to supply electrodes and filler wire.

5.2 Contractor shall ensure only Aker Solutions approved brands of electrodes are
used.

5.3 Contractor shall produce batch test certificate for every batch electrodes and
filler wires.

5.4 Electrodes and filler wires shall be stores in a dry area. Manufacturers
recommendation shall be followed.

6.0 Consumables

6.1 Contractor shall arrange and supply and use consumables like Argon, oxygen,
D A Cylinder with safety guard and grinding wheels.

6.2 Contractor shall not use Liquidfied Petroleum Gas at site for gas cutting.

6.3 Contractor shall ensure that all regulators, hoses, cutting sets used are of
reputed brands and tested.

6.4 Purity of argon shall be 99.995% when used for shielding and purging.

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6.5 Initial purging shall be maintained for sufficiently long period to ensure that
pipeline is purged fully and all entrapped air is displaced, under no
circumstances should the purging be less than 15 minutes.

6.6 Flow rate of purging gas should be established during procedure qualification
record test.

6.7 Gas purging is not necessary for socket welded joints.

6.8 Soluble dams can be used after checking with client or consultant.

6.9 In places where water soluble dams are not used but removal dams are used,
contractor should number the dams used and the confirm that all dams are
removed after the welding operation.

7.0 Tools and tackles

7.1 Contractor shall at his expenses provide all necessary tools and tackles
required for the job. Contractor shall augment the resources, if required during
execution phase of the job, to maintain the completion schedule.

7.2 All tools and tackles shall be tested prior to use on the job.

7.3 All gauges shall be calibrated and test certificates made available for
verification.

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Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

8.0 Edge Preparation

8.1 The edge shall be prepared by gas cuttings, grinding or machining.

8.2 Edge preparation shall be done as shown in sheet 26.

8.3 Edges shall be cleaned to remove any dust, dirt or rust which may be present
prior to fit up.

9.0 Joints in Piping

9.1 Piping of sizes 1 1/2” and below may be socket welded or butt welded as
specified in piping specification.

9.2 Wherever screwed piping is involved the threads shall be as per specification.

9.3 Threads shall be cut by using die or machine, using coolant or lubricating oil.

9.4 Threads shall be made on pipes after bending operation is complete.

9.5 Before assembly all threaded joints shall be cleaned of dirt, oil or any foreign
matter.

9.6 Sealant shall be used on male threads and joint tightened sufficiently to make
the joint leak proof.

9.7 Flange face shall be true and perpendicular to the axis of the pipe.

9.8 Flange bolt holes shall straddle the normal centerline unless otherwise
specified.

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9.9 Where spectacle blind is to be installed, drilling and tapping for providing jack
screws on flange shall be completed within quoted rate for fabrication before
welding it to pipe.

9.10 Branch connection shall be provided as shown in branching details enclosed

with piping specification.

9.11 Reinforcement pads shall be provided as indicated in the drawings /

specifications.

9.12 Bending of pipe shall be as per ANSI 31.3. Cold bends with bend radius of 5
times the nominal diameter shall be used as stated in piping specification.

9.13 Bends shall have smooth surface, free of cracks, wrinkles bulges, flat spots.
D P test shall be carried out on outer side of bends to check for any crack
which may occur during bending.

9.14 Flattening of bends shall be measured as the difference between the

maximum and minimum diameters of any cross section. The difference shall
not exceed 8% to 3% of the nominal outside diameter for internal and external
pressures respectively.

9.15 Fabricated mitre bends shall be in accordance to piping specification. The

dimensions of fabricated mitre bend shall be as indicated in Table A. (refer
sheet 28)

9.16 Welding details for flanges shall be as shown on sheets 29 and 30.

9.17 Welding details for branch with and without reinforcement pads shall be as
shown on sheets 31 and 32.

9.18 Cutting details for site fabricated concentric reducers shall be as shown in
Table B on sheet 33.

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Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

10.0 Alignment and Spacing

10.1 Alignment and fit up of individual piping components is essential to obtain a

good joint therefore a lot of care must be taken during alignment.

10.2 Components to be aligned shall be spaced as per applicable code.

10.3 Wire spacers shall be used to obtain proper root gap, however after tack
welding these shall be removed.

10.4 Pipes having wall thickness above 6 mm. shall be secured in position using
pipe couplers or C clamps. Temporary cleats for alignment shall also be used,
however after alignment and tack welding these temporary cleats shall be
removed carefully, any surfaces dents of minor nature caused during removal of
cleats shall be repaired as per instruction of consultant.

10.5 All tack welders deployed shall be tested and qualified. All tack welds shall be
done with utmost care since this would form a part of final welding. Defective
tacks should be rectified prior to final welding.

10.6 Tacks shall be equally spaced. The minimum number of tacks for various sizes
of pipes shall be as follows :

Pipe Size No. of tacks

a) 3” diameter and below 2

b) Between 3 and 12” diameter 4

c) Above 12” diameter 6

10.7 Consultant shall check and approve alignment prior to welding.

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Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

11.0 Fabrication and Erection

11.1 Contractor shall fabricate and erect the piping in accordance with the latest
edition of code for petroleum refinery piping ANSI B 31.3 unless other specified.

11.2 Contractor shall be responsible for accuracy of fabrication. Contractor shall

review the drawing and in case any error or omission is identified the same
shall be brought to the notice of Consultant Engineer.

11.3 Contractor shall provide adequate number of field welds apart from those
shown on the drawing to take care of variations that normally occur at site due
to minor changes in location of equipments. At all field welds, so located
contractor shall leave an extra 100 mm over and above the dimensions shown
in the drawing, contractor may make necessary adjustments during erection by
cuttings the extra lengths provided at field welds to obtain the actual dimension
required based on site conditions.

11.4 Isometrics drawing shall indicate the field welds, however it is the responsibility
of the contractor to provide additional field welds, if required. No extra payment
will be made to the contractor for finish welding these additional welds.

11.5 Bevelling of ends shall be done manually or by machine. The bevelled ends
shall be clean smooth, free of slag and flame cut marks.

11.6 When tack welding, full penetration weld shall be used, this weld shall form a
part of the final weld.

11.7 All defective fit up weld or tack welds which are rejected by Piping Engineer or
Quality Control Engineer shall be redone at no extra cost.

11.8 All fit up cleats shall be removed and surface ground smooth after piping
fabrication and erection is completed.

11.9 Fit up can be done manually or using fixtures.

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Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

11.10 Welder qualification as per specification shall be carried out prior to

commencement of welding.

11.11 Only qualified tack welders or welders shall be allowed to work on the job.

11.12 Contractor shall maintain the following documents for all welders.

1] Welding Procedure Specification

2] Procedure Qualification Record
3] Welder Identification Card

11.13 Contractor shall prepare neat sketches with bill of quantities for line sizes 40 NB
and below, obtain approval of the Piping Engineer prior to commencement of
fabrication.

11.14 No piping isometric will be issued for rack lines, only piping layout will be
provided, contractor shall prepare working sketch.

11.15 Contractor shall deploy adequate number of draftsman at site for preparation of
sketches for piping and mark up of “As built drawings”.

11.16 All ends of prefabricated piping shall be properly blanked using wooden blanks
or polyethene sheets arranged by contractor at his cost. Contractor shall mark
line, numbers on all prefabricated spools with permanent marker or paint for
proper identification.

11.17 Contractor shall provide adequate number of tools, tackles and manpower to
execute the job within the schedule time.

11.18 Contractor shall at his cost provide erect and dismantle scaffolding along with
landing materials at desired locations during fabrication and erection of piping.

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Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

11.19 All scaffolding materials shall be metallic, wooden planks and bamboo
scaffolding will not be permitted.

11.20 Contractor shall ensure that all temporary scaffolding erected shall be
dismantled after work is completed.

11.21 Contractor shall carry out minor civil work such as making opening in brick
walls, concrete floors. After installation of piping contractor shall make good the
same. All civil work shall be done in co-ordination consultant Civil Engineer.

11.22 Contractor shall remove all waste materials, debris from the site. House
keeping shall be the responsibility of the contractor.

11.23 Contractor shall ensure all safety practice and procedure are adopted during
fabrication and erection.

11.24 Contractor shall fabricate, assemble couple, align pipelines, install pipe
supports, spring hangers all in line mounting as per drawing.

11.25 Contractor shall make set on branches, thread, screws, bolt, bevel fit and weld
pipes, flanges, fittings and other in line fittings.

11.26 Contractor shall wherever required cut floor gratings to introduce pipelines and
provide collars to gratings at no extra cost.

11.27 Contractor shall arrange to fabricate and erect pipe supports as shown in the
drawing.

11.28 Contractor shall furnish list of tools and tackles to be deployed on the job
indicating make, year of manufacture.

11.29 Contractor shall furnish list of manufacture to be deployed on the job.

11.30 Contractor shall furnish bio-data of key personnel to be deployed on the job.

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11.31 Contractor shall appoint full time Safety Engineer, Quality Control Engineer and
Planning Engineer on the job.

11.32 Contractor shall prepare and furnish daily reports for fit up, welding, NDT test,
manpower, tools and tackles as requested by client or consultant.

11.33 All documentation such as Daily Fit Up Report, Welding Report, History Sheet,
Line Clearance Report, Testing Report etc. shall be maintained by the
contractor. Client or consultant shall be free to inspect and record his
observation on these documents.

11.34 Contractor shall prepare and submit weekly plan based on availability of
drawings, front and materials.

11.35 Contractor shall inspect, test and calibrate all tools and tackles, necessary
instruments deployed and furnish testing and Calibration Reports for verification
to clients / consultants.

11.36 Contractor shall follow all procedures in execution as explained verbally or in

writing by client / consultant.

11.37 Contractor shall obtain prior approval from client / consultant for any extra work
or modification being undertaken. To enable client / consultant to approve the
same, contractor shall at his cost prepare and submit the cost of such extra
work for client / consultant to review and approve.

11.38 All temporary electrical installations being erected by the contractor shall be
approved by client/contractor and by Electrical Authorities.

11.39 Contractor shall post qualified and licensed electrician full time at site.

11.40 Contractor shall be equipped with first aid unit prior to commencement of work.

11.41 Contractor shall maintain at his disposal full time vehicle to transport his
workmen to a dispensary or hospital in case of any emergency.

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11.42 Contractor shall obtain labour license prior to commencement of job and
forward a copy to client / consultant.

11.43 Contractor shall insure all his workmen and furnish copy of insurance policy to
client / consultant.

11.44 Contractor shall be fully responsible for all statutory payments like Wages, PF,
ESIC, Bonus, Leave Wages, Gratuity etc. which are to be paid to workmen
employed by the contractor. No payment will be made by clients towards these
statutory payment.

11.45 Contractor shall furnish copies of PF statement, ESIC etc. to client for the
records every month.

11.46 Contractor shall at his cost insure all tools and tackles against theft and fire.

11.47 Contractor shall appoint full time security personnel for the office, stores,
fabrication yard and installation area.

11.48 Contractor shall provide labour colony transport and canteen facilities to the
staff and workmen.

11.49 All prefabricated piping shall be cleaned properly to remove any dirt or mud if
present before erection.

11.50 Contractor shall barricade and prevent entry of personnel during erection of
piping and during radiographic examination.

11.51 Contractor shall obtain and maintain all necessary permits during execution of
the job in a running plant.

11.52 Piping shall be erected as shown in drawing. Contractor shall not change the
route of piping without consent of the client / consultant. All such changes shall
be marked on the drawing and clients / consultant approval obtained.

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11.53 In case piping fouls with structure or equipment, then such discrepancy shall be
brought to the notice of the consultant and action to solve the problem shall be
taken as per instruction from the consultant.

11.54 Contractor shall maintain necessary slopes in pipeline as per drawing.

11.55 During fabrication and erection contractor shall include trimming, cutting and
grinding of fittings and pipes in his scope and execute such work within the
quoted rate.

11.56 Normally vents / drain may not be shown in the drawing. Contractor shall
provide these within the rate quoted for fabrication and installation of pipes at
locations as instructed by consultant. The specification of vents / drains shall
be as indicated in piping specification.

11.57 Valves shall be installed as shown in the drawing, in case the installation of
valve as shown is not feasible to then contractor shall consult the engineer and
follow his instructions.

11.58 Contractor shall ensure that globe valve, check valves and other unidirectional
valves are installed after confirming the marking of the direction of flow. In case
flow direction is not marked on the valve, then contractor shall install valve
based on instruction given by consultant engineer.

11.59 Contractor shall ensure that valves with pad locking are erected at proper
location as shown in the drawing.

11.60 All in line instruments such as restriction orifice, safety valves, control valves,
rotameter, venture meter, flow meter, strainers shall be installed by the
contractor.

11.61 Contractor shall handle all in line instruments with utmost care and take
necessary precaution to avoid any damage after installation.

11.62 Jacketed piping shall be preassembled to maximum extent in the shop.

Contractor shall erect jumpovers and nozzle on jacket pipe after erection of
pipeline based on ease of constructibility.

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11.63 Contractor shall exercise utmost care and ensure that core pipe is not damaged
during erection of jumpovers.

11.64 Contractor shall ensure that all piping are supported temporarily during erection
by contractor. All materials required for providing temporary supports shall be
provided by contractor at his cost.

11.65 Contractor shall fabricate and erect permanent supports at locations as shown
in the drawing.

11.66 Contractor shall use only approved brands of electrodes on the job.

1) Advani Oerlikon Ltd.

2) D & H Secheron
3) Esab India

11.67 Contractor shall furnish batch certificates for electrodes.

11.68 Contractor shall store electrodes in a dry area.

11.69 Contractor shall arrange to provide stationary and portable ovens as and when
required.

11.70 Contractor shall dismantle and reerect along with necessary modifications of
structural members, gratings, piping, valves to facilitate erection of piping, such
work shall be carried out by the contractor within the quoted rates. Such work
shall be undertaken based on instructions from clients or consultant. However
during the overall span of the contract if the total weight of structural / piping
etc. dismantled, modified or reerected exceeds 2 MT then the quantum of work
exceeding 2 MT shall be paid at the applicable unit rate.

11.71 Contractor shall at his cost provide fire extinguisher, sand buckets barricades,
fire water hoses if not provided by the clients.

11.72 All battery limit joints shall be executed by the contractor within the quoted
rates.

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11.73 Contractor shall be paid modification rates only if pipeline is prefabricated and
erected before issue of modification drawing.

11.74 All TIG welding shall be done with argon purging and shielding during fit up and
welding. The purity of argon shall be 99.995%.

12.0 Welding

12.1 Welding shall be carried out using one of the following methods.

- Shielded Metal Arc Welding Process - (SMAW)

- Gas Tungsten Arc Welding Process - (GTAW)

12.2 Contractor shall submit the welding procedure specification prior to

commencement of the job and obtain approval from client / consultant.

12.3 Contractor shall conduct procedure qualification record test and obtain approval
from client / consultant.

12.4 No welding shall commence till the process of welder qualification is complete.

12.5 Root Pass

12.5.1 Root pass shall be completed using filler wire or electrode as indicated
in welding procedure specification.

12.5.2 The recommended size of electrode is 2.5 mm diameter (12 SWG) for
root pass but under no circumstances shall 3.5 mm diameter (10 SWG)
electrode be used. If root run is being made by SMAW.

12.5.3 For pipes held in horizontal axis upward technique shall be used.

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12.5.4 During root pass it should be ascertained that full penetration with
complete fusion of root edges is achieved. The projection of weld
inside the pipe shall be as per applicable code.

12.5.5 Proper protection from rain shall be provided during welding in

monsoon.

12.5.6 Slag shall be removed by wire brushing, grinding or chipping after

completion of root run.

12.6 Filler Pass

12.6.1 Filler pass shall be completed using filler wire or electrode as specified
in the welding procedure specification.

12.6.2 During subsequent runs care should be taken to ensure that no weld
bead layers start from same point.

12.6.3 The joint surface shall be clean of weld spatter and free from notch.

12.6.4 Weld identification mark shall be clearly marked next to each joint.
Metal stamping shall not be used.

13.0 Heat Treatment

13.1 Preheating

13.1.1 Heat treatment of carbon steel is not generally required, unless

specifically stated in the drawing or applicable code.

13.1.2 Carbon steel material having carbon content 0.35% maximum and wall
thickness less than 19 mm do not require to be heat treated.

13.1.3 Carbon steel material having carbon content 0.35% maximum and wall
thickness 19 mm or above need to be stress relieved.

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13.1.4 Carbon steel material having carbon content above 0.35% max.
irrespective of wall thickness require to be heat treated.

13.1.5 No welding shall be carried out on a joint if the ambient temperature is

below 10C.

13.1.6 Preheating requirement shall be as per welding procedure

specification.

13.1.7 Preheating shall be performed using induction heating method, gas

burners or using oxygen acetylene mixture.

13.1.8 On each side of a joint being preheated a distance of atleast three

times the thickness of the pipe shall be heated but in no case shall this
distance be less than 50mm.

13.1.9 The preheating temperature shall be maintained over the entire

circumference of the joint during welding. Temperature chalks, crayons
or temperature indicating devices shall be used to monitor the
temperature of the joint.

13.2 Post Heating

13.2.1 Post weld heat treatment shall be as specified in the welding

specification chart. After the welding is completed and radiography
examination conducted then the weld joint and the adjacent portion of
the weld to a distance of 150 mm on both sides of the weld joint shall
be uniformly heated to 300C. The temperature shall be maintained for
two hours minimum and allowed to gradually cool to ambient
temperature.

The joint shall be wrapped in asbestos or mineral wool during heating

or cooling.

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13.2.2 Contractor shall submit procedure for post weld heat treatment for
approval of client / consultant prior to commencement of post weld heat
treatment.

13.2.3 Post weld heat treatment can be done by deploying a furnace or by

using electric resistance or induction heating equipment, based on
approval of the method by client / consultant.

13.2.4 During the heat treatment operation the portion outside the heat zone
shall also be wrapped with asbestos or insulation material so that there
is no sharp temperature differential between the joint being post weld
heat treated and the exposed portion of the pipeline. The temperature
of the exposed portion should not exceed 400C.

13.2.5 The temperature of the joint being post weld heat treated shall be
recorded by means of thermocouples.

13.2.6 Adequate number of thermocouples shall be provided. These shall be

attached to the pipe directly at equally spaced location along the
periphery of the pipe joint.

The minimum number of thermocouples to be provided per joint shall

be as stated below.

Joint Size No. of Thermocouples

Upto 6” 1
Upto 10” 2
For 12” and above 3

The number of thermocouples may be increased as per instruction of

client / consultant.

13.2.7 To record temperatures, automatic temperature recorders can also be

employed. Prior to commencement of recording the chart for each
recorder should be approved by the clients / consultant. Recorders
being used shall be calibrated and records maintained prior to use.

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13.2.8 After completion of post weld heat treatment the radiography of the
joint must be taken to check for defects if any that may have occurred
during Post Weld Treatment.

13.2.9 After completion of post weld heat treatment the hardness test shall be
conducted on the joint.

13.2.10 All records of post weld heat treatment such as temperature charts,
radiography, films, reports, hardness test records shall be submitted to
the client / consultant.

14.0 Inspection

14.1 During the various stages of fabrication of piping the inspector of client /
consultant shall have free access to the job site to review the quality.

14.2 All necessary co-operation and facilities to carry out inspection shall be
provided by contractor to client / consultant inspector.

14.3 Inspection shall be carried out in the shop or at site.

14.4 Contractor shall inform clients / Consultant two days in advance of

commencement of welder qualification test to enable them to witness.

14.5 Contractor shall discuss with client / consultant and prepare Inspection Test
Plan prior to commencement of work and obtain their approval.

14.6 Contractor shall conduct the following tests and maintain records approved by
client / consultant inspector.

a) Liquid Penetrant Test

b) Magnetic Particle Test
c) Radiographic Test
d) Preheat Records

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e) Post Weld Heat Treatment

f) Hardness Test Records.
g) Hydrotest Record.

15.0 Measurement

15.1 The payment for the job will be made of unit rate basis for the quantum of work
completed and measured.

15.2 Contractor shall prepare detailed measurement sheets for the work completed
as per schedule of rates and submit the same to the client / consultant for
approval.

15.3 Contractor shall submit measurement sheets and bills in floppies.

15.4 The quantities indicated in the schedule of rates are tentative. The final
payment will be made based on the accepted quantities measured in presence
of client / consultant.

15.5 The length of piping installed shall be measured along the centre lines
excluding valves, inline fittings such as strainers, flow meters and site fabricated
mitre reducer which are paid separately as per schedule of rates and terms of
payment.

15.6 Valves and inline fittings such as strainers, flow meters shall be counted and
paid as per schedule of rates based on size installed.

15.7 Site fabricated reducers and mitres shall be paid on unit rates as per schedule
of rates.

15.8 Site fabricated fittings which are fabricated but not erected will be paid as per
terms of payments.

15.9 No extra payment will be made for fabrication and erection of reinforcement
pads on nozzle branches.

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15.10 Fabrication and erection of galvanised iron piping will be made of metres
basis for the size installed. No separate payment will be made for threading
of piping and application of teflon tape or sealant.

15.11 In case where seal welding of galvanised piping is required unit rate as per
schedule of rate will be paid.

16.0 Material Reconciliation

16.1 Contractor shall be responsible for all materials issued to him by client /
consultant.

16.2 Contractor shall properly tag and store all material collected from client /
consultant.

16.3 Client / consultant shall have access to contractor store to verify and advise
about storage of material.

16.4 Contractor shall prepare and submit material reconciliation statement every two
months.

16.5 Contractor shall prepare and submit linewise material consumption report after
completion of job.

16.6 Contractor shall prepare and submit tagwise consumption statement.

16.7 Contractor shall return all excess material in his custody by properly cleaning
and tagging the parts.

16.8 All materials returned shall be accompanied with material return ticket. No
material will be accepted back in the absence of this document.

16.9 All straight pipe lines 1 M and above are returnable. Pipes shall be properly
colour coded tagged and returned to client / consultant stores.

C930034 R4 CONT. STD-CONST-FECSP-07

Specification
Document No. : STD-CONST-FECSP-07 Rev. 2 Sheet : 24 of 33

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

16.10 Total percentage of scrap permitted is 3% (Three) percent including

accountable and unaccountable scrap. Accountable scrap shall be less than
2% (Two) of the total quantity issued and these shall be established by
weighment in case of carbon steel pipes. In case of stainless steel, alloy steel
pipes the percentage of accountable scrap shall be established by
measurement of length. Invisible unaccountable scrap shall be 1% (One
percent).

16.11 Total percentage of scrap permitted is 4% (Four percent) including

accountable and unaccountable scrap for all plates and structurals materials
issued for fabricating and erecting pipe supports. The accountable scrap shall
not exceed 3% of total quantity fabricated. Invisible or unaccountable scrap
shall be 1% (One percent).

16.12 Cut pieces shall not be less than 1 M in length and shall be considered as
accountable steel and returned to client / consultant stores free of cost. Cut
pieces smaller than 1 M
in length for structural steel section and 0.1 sq. m or any dimension less than
0.2 sq. m for plates or chequered plates shall be considered as scrap. All
scrap materials shall be returned to clients / consultant stores. The off cut
structural in fraction between 1 M to 2 M length and plates between 0.1 sq.m
to 0.2 sq.m should not exceed 10% of useable steel returned by the
contractor. Client / consultant have the option not to accept such fractional
material being returned beyond permissible wastage and reject the same. In
case actual allowable consumption exceeds theoretical consumption plus
allowable wastage limits then recovery shall be made on excess consumption
at the rate of landed cost paid by client plus 50% (fifty) per MT.

16.13 Clients / Consultant is free to reject any material being returned if not found
satisfactory. The cost of these items will be recovered from the contractor at
the rate of landed cost plus 50%.

C930034 R4 CONT. STD-CONST-FECSP-07

Specification
Document No. : STD-CONST-FECSP-07 Rev. 2 Sheet : 25 of 33

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Carbon Steel Piping

17.0 Documentation

17.1 Contractor shall maintain and submit the following documents in four sets to
consultant after completion of the job.
a) Electrode Record
b) Welding Procedure Specification
c) Procedure Qualification Record
d) Linewise History Sheet
e) Liquid Penetrant Record
f) M P Test Record
g) Heat Treatment Record
h) Hardness Test Record
i) Radiography Record
j) Hydrotest/Pneumatic Record
k) As built drawing mark up
l) Material Reconciliation Record

C930034 R4 CONT. STD-CONST-FECSP-07

Specification
Document No. : STD-CONST-FESSP-08
Rev. 2 Sheet : 1 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless

Steel Piping

CONTENTS

1.0 Scope
2.0 Relevant Standard
3.0 Materials
4.0 Electrodes and Filler Wire
5.0 Consumables
6.0 Tools and Tackles
7.0 Edge Preparation
8.0 Joints in Piping
9.0 Alignment and Spacing
10.0 Fabrication and Erection
11.0 Welding
12.0 Inspection
13.0 Measurement
14.0 Material Reconciliation
15.0 Documentation

2 Construction SS / June PKB / June ADM / June

1 Construction SS / July 2005 ADM / July PKD / July
0 Construction SS / May 1996 ADM / May PKD / May
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-FESSP-08 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 2 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

1.0 Scope

1.1 This specification covers site fabrication and erection of stainless steel piping.

1.2 This specification is not applicable for fabrication of alloy steel piping.

2.0 Relevant Standard

The latest edition of the following standards including all revisions and addendum shall
be applicable.

ASME 31.3 - Chemical plant and petroleum refinery piping

ASME Section } Specification for welding rods, electrode

II Part C } and filler metals.

ASTM Section IX - Welding and Brazing qualification

ASME Section V - Non Destructive Testing

3.0 Materials

3.1 All free issue materials like pipes, flanges, fittings, valves, bolts and nuts,
gaskets, inline fittings, spring supports etc. shall be supplied.

3.2 Contractor shall arrange to receive and store materials in their stores till it is
erected.

C930034 R4 CONT. STD-CONST-FESSP-08

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Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 3 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

3.3 Pipes, fittings, valves, flanges, gaskets, studs, in line fittings used in a particular
piping system shall be as specified in piping specification.

3.4 Contractor shall ensure that all materials received have been properly identified
by Aker Solutions colour code, punch mark or by engraving so that traceability
of material is ensured.

3.5 Valves, special in line fittings and other piping materials shall be properly
tagged.

3.6 Contractor shall visually inspect materials being collected and immediately bring
to the notice of the stores officer any discrepancy or short fall noticed. No claim
will be entertained once materials are issued.

3.7 All piping materials such as pipes valves, flanges, fittings in line fittings gaskets
etc. shall be drawn line wise against proper material issue ticket.

3.8 No bulk issue of material will be made.

3.9 Contractor shall collect all materials indented at one time and move it out of the
store.

3.10 Contractor shall make arrangements to deploy tractor, trailer, truck, wheel
barrow, hand cart, fork lift or hydra crane to shift material from clients stores to
their stores.

3.11 Contractor shall construct at his cost covered stores for storage of materials
received from clients stores.

C930034 R4 CONT. STD-CONST-FESSP-08

Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 4 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

4.0 Electrodes and Filler Wire

4.1 Contractor shall arrange to supply electrodes and filler wire.

4.2 Contractor shall ensure only Aker Solutions approved brands of electrodes are
used.

4.3 Contractor shall produce batch test certificate for every batch electrodes and
filler wires.

4.4 Electrodes and filler wires shall be stores in a dry area. Manufacturers
recommendation shall be followed.

5.0 Consumables

5.1 Contractor shall arrange and supply and use consumables Argon, Oxygen, D A
Cylinder with valve safety guard & grinding wheels.

5.2 Contractor shall use Plasma cutter or hacksaw at site for cutting.

5.3 Contractor shall ensure that all regulators, hoses are used of reputed brands
and tested.
5.4 Purity of argon shall be 99.995% when used for shielding and purging.

5.5 Initial purging shall be maintained for sufficiently long period to ensure that
pipeline is purged fully and all entrapped air is displaced, under no
circumstances should the purging be less than 15 minutes.

5.6 Flow rate of purging gas should be established during Procedure Qualification
Record Test.

5.7 Gas purging is not necessary for socket welded joints.

C930034 R4 CONT. STD-CONST-FESSP-08

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Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 5 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

5.8 Soluble dams can be used after checking with client or consultant.

5.9 In places where water soluble dams are not used but removal dams are used,
contractor should number the dams used and the confirm that all dams are
removed after the welding operation.

5.10 When GTAW process alone or a combination of GTAW and SMAW processes
is recommended for production of a particular joints, the purging shall be
maintained during the root pass and for the first filling pass to minimise
oxidation on the inner side of the pipe, unless otherwise specified in welding
specification chart.

5.11 After initial purging, the flow of the backing gas should be reduced to a point
where only a slight positive pressure is prevailing. For systems which have
volume of about 1/2 cft a gas flow of about 6 CFH is adequate. Depending on
system volume higher flow rates may be required and needs to be established
during procedure qualification tests.

6.0 Tools and tackles

6.1 Contractor shall at his expenses provide all necessary tools and tackles
required for the job. Contractor shall augment the resources, if required during
execution phase of the job, to maintain the completion schedule.

6.2 All tools and tackles shall be tested prior to use on the job.

6.3 All gauges shall be calibrated and test certificates made available for
verification.

C930034 R4 CONT. STD-CONST-FESSP-08

Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 6 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

7.0 Edge Preparation

7.1 The edge shall be prepared by plasma cutting, grinding or machining.

7.2 Edge preparation shall be done as shown in sheet 23.

7.3 Edges shall be cleaned to remove any dust or dirt which may be present prior
to fit up.

8.0 Joints in Piping

8.1 Piping of sizes 1 1/2” and below may be socket welded or butt welded as
specified in piping specification.

8.2 Wherever screwed piping is involved the threads shall be as per specification.

8.3 Threads shall be cut by using die or machine, using coolant or lubricating oil.

8.4 Threads shall be made on pipes after bending operation is complete.

8.5 Before assembly all threaded joints shall be cleaned of dirt, oil or any foreign
matter.

8.6 Sealant shall be used on male threads and joint tightened sufficiently to make
the joint leak proof.

8.7 Flange face shall be true and perpendicular to the axis of the pipe.

8.8 Flange bolt holes shall straddle the principal centerline unless otherwise
specified.

C930034 R4 CONT. STD-CONST-FESSP-08

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Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 7 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

8.9 Where spectacle blind is to be installed, drilling and tapping for providing jack
screws on flange shall be completed within quoted rate for fabrication before
welding it to pipe.

8.10 Branch connection shall be provided as shown in branching details enclosed

with piping specification.

8.11 Reinforcement pads shall be provided as indicated in the drawings /

specifications.

8.12 Bending of pipe shall be as per ANSI B 31.3. Cold bends with bend radius of
5 times the nominal diameter shall be used as stated in piping specification.

8.13 Bends shall have smooth surface, free of cracks, wrinkles bulges, flat spots.
DP check shall be conducted on the outer side of bends to check for cracks.

8.14 Flattening of bends shall be measured as per latest edition off ANSI B 31.3.

8.15 Fabricated mitre bends shall be in accordance to piping specification. The

dimensions of fabricated mitre bend shall be as indicated in Table A. (refer
sheet 25)

8.16 Welding details for flanges shall be as shown on sheets 26 and 27.

8.17 Welding details for branch with and without reinforcement pads shall be as
shown on sheets 28 and 29.

8.18 Cutting details for site fabricated concentric reducers shall be as shown in
Table B on sheet 30.

C930034 R4 CONT. STD-CONST-FESSP-08

Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 8 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

9.0 Alignment and Spacing

9.1 Alignment and fit up of individual piping components is essential to obtain a

good joint therefore a lot of care must be taken during alignment.

9.2 Components to be aligned shall be spaced as per applicable code.

9.3 Wire spacers shall be used to obtain proper root gap, however after tack
welding these shall be removed.

9.4 Pipes having wall thickness above 6 mm. shall be secured in position using
pipe couplers or C clamps. Temporary cleats for alignment shall also be used,
however after alignment and tack welding these temporary cleats shall be
removed carefully, any surfaces dents of minor nature caused during removal of
cleats shall be repaired as per instruction of consultant.

9.5 All tack welders deployed shall be test and qualified. All tack welds shall be
done with utmost care since this would form a part of final welding. Defective
tacks should be rectified prior to final welding.

9.6 Tacks shall be equally spaced. The minimum number of tacks for various sizes
of pipes shall be as follows :

Pipe Size No. of tacks

a) 3” diameter and below 2

b) Between 3 and 12” diameter 4

c) Above 12” diameter 6

C930034 R4 CONT. STD-CONST-FESSP-08

Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 9 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

9.7 Consultant shall check and approve alignment prior to welding.

10.0 Fabrication and Erection

10.1 Contractor shall fabricate and erect the piping in accordance with the latest
edition of code for petroleum refinery piping ANSI B 31.3 unless other specified.

10.2 Contractor shall be responsible for accuracy of fabrication. Contractor shall

review the drawing and in case any error or omission is identified the same
shall be brought to the notice of Consultant Engineer.

10.3 Contractor shall provide adequate number of field welds apart from those
shown on the drawing to take care of variations that normally occur at site due
to minor changes in location of equipments. At all field welds, so located
contractor shall leave an extra 100 mm over and above the dimensions shown
in the drawing, contractor may make necessary adjustments during erection by
cuttings the extra lengths provided at field welds to obtain the actual dimension
required based on site conditions.

10.4 Isometrics drawing shall indicate the field welds, however it is the responsibility
of the contractor to provide additional field welds, if required. No extra payment
will be made to the contractor for finish welding these additional welds.

10.5 Bevelling of ends shall be done manually or by machine. The bevelled ends
shall be clean smooth, free of slag and flame cut marks.

10.6 When tack welding, full penetration weld shall be used, this weld shall form a
part of the final weld.

10.7 All defective fit up weld or tack welds which are rejected by Piping Engineer or
Quality Control Engineer shall be redone at no extra cost.

10.8 All fit up cleats shall be removed and surface ground smooth after piping
fabrication and erection is completed.

C930034 R4 CONT. STD-CONST-FESSP-08

Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 10 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

10.9 Fit up can be done manually or using fixtures.

10.10 Welder qualification as per specification shall be carried out prior to

commencement of welding.

10.11 Only qualified tack welders or welders shall be allowed to work on the job.

10.12 Contractor shall maintain the following documents for all welders.

1] Welding Procedure Specification

2] Procedure Qualification Record
3] Welder Identification Card

10.13 Contractor shall prepare neat sketches with bill of quantities for line sizes 40 NB
and below, obtain approval of the Piping Engineer prior to commencement of
fabrication.

10.14 No piping isometric will be issued for rack lines, only piping layout will be
provided, contractor shall prepare working sketch.

10.15 Contractor shall deploy adequate number of draftsman at site for preparation of
sketches for piping and mark up of “As built drawings”.

10.16 All ends of prefabricated piping shall be properly blanked using wooden blanks
or polyethene sheets arranged by contractor at his cost. Lines numbers shall
be marked using permanent marker or paint on all prefabricated spools/ lines.

10.17 Contractor shall provide adequate number of tools, tackles and manpower to
execute the job within the schedule time.

10.18 Contractor shall at his cost provide erect and dismantle scaffolding alongwith
landing materials at desired locations during fabrication and erection of piping.

C930034 R4 CONT. STD-CONST-FESSP-08

Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 11 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

10.19 All scaffolding materials shall be metallic, wooden planks and bamboo
scaffolding will not be permitted.

10.20 Contractor shall ensure that all temporary scaffolding erected shall be
dismantled after work is completed.

10.21 Contractor shall carry out minor civil work such as making opening in brick
walls, concrete floors. After installation of piping contractor shall make good the
same. All civil work shall be done in co-ordination consultant Civil Engineer.

10.22 Contractor shall remove all waste materials, debris from the site. House
keeping shall be the responsibility of the contractor.

10.23 Contractor shall ensure all safety practice and procedure are adopted during
fabrication and erection.

10.24 Contractor shall fabricate, assemble couple, align pipelines, install pipe
supports, spring hangers all in line mounting as per drawing.

10.25 Contractor shall make set on branches, thread, screws, bolt, bevel fit and weld
pipes, flanges, fittings and other in line fittings.

10.26 Contractor shall wherever required cut floor gratings to introduce pipelines and
provide collars to gratings at no extra cost.

10.27 Contractor shall arrange to fabricate and erect pipe supports as shown in the
drawing.

10.28 Contractor shall furnish list of tools and tackles to be deployed on the job
indicating make, year of manufacture.

C930034 R4 CONT. STD-CONST-FESSP-08

Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 12 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

10.29 Contractor shall furnish list of manufacture to be deployed on the job.

10.30 Contractor shall furnish bio-data of key personnel to be deployed on the job.

10.31 Contractor shall appoint full time Safety Engineer, Quality Control Engineer and
Planning Engineer on the job.

10.32 Contractor shall prepare and furnish daily reports for fit up, welding, NDT test,
manpower, tools and tackles as requested by client or consultant.

10.33 All documentation such as Daily Fit Up Report, Welding Report, History Sheet,
Line Clearance Report, Testing Report etc. shall be maintained by the
contractor. Client or consultant shall be free to inspect and record his
observation on these documents.

10.34 Contractor shall prepare and submit weekly plan based on availability of
drawings, front and materials.

10.35 Contractor shall inspect, test and calibrate all tools and tackles, necessary
instruments deployed and furnish testing and Calibration Reports for verification
to clients / consultants.

10.36 Contractor shall follow all procedures in execution as explained verbally or in

writing by client / consultant.

10.37 Contractor shall obtain prior approval from client / consultant for any extra work
or modification being undertaken. To enable client / consultant to approve the
same, contractor shall at his cost prepare and submit the cost of such extra
work for client / consultant to review and approve.

10.38 All temporary electrical installations being erected by the contractor shall be
approved by client/contractor and by Electrical Authorities.

10.39 Contractor shall post qualified and licensed electrician full time at site.

C930034 R4 CONT. STD-CONST-FESSP-08

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Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 13 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

10.40 Contractor shall be equipped with first aid unit prior to commencement of work.

10.41 Contractor shall maintain at his disposal full time vehicle to transport his
workmen to a dispensary or hospital in case of any emergency.

10.42 Contractor shall obtain labour license prior to commencement of job and
forward a copy to client / consultant.

10.43 Contractor shall insure all his workmen and furnish copy of insurance policy to
client / consultant.

10.44 Contractor shall be fully responsible for all statutory payments like Wages, PF,
ESIC, Bonus, Leave Wages, Gratuity etc. which are to be paid to workmen
employed by the contractor. No payment will be made by clients towards these
statutory payment.

10.45 Contractor shall furnish copies of PF statement, ESIC etc. to client for the
records every month.

10.46 Contractor shall at his cost insure all tools and tackles against theft and fire.

10.47 Contractor shall appoint full time security personnel for the office, stores,
fabrication yard and installation area.

10.48 Contractor shall provide labour colony transport and canteen facilities to the
staff and workmen.

10.49 All prefabricated piping shall be cleaned properly to remove any dirt or mud if
present before erection.

10.50 Contractor shall barricade and prevent entry of personnel during erection of
piping.

C930034 R4 CONT. STD-CONST-FESSP-08

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Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 14 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

10.51 Contractor shall obtain and maintain all necessary permits during execution of
the job in a running plant.

10.52 Piping shall be erected as shown in drawing. Contractor shall not change the
route of piping without consent of the client / consultant. All such changes shall
be marked on the drawing and clients / consultant approval obtained.

10.53 In case piping fouls with structure or equipment, then such discrepancy shall be
brought to the notice of the consultant and action to solve the problem shall be
taken as per instruction from the consultant.

10.54 Contractor shall maintain necessary slopes in pipeline as per drawing.

10.55 During fabrication and erection contractor shall include trimming, cutting and
grinding of fittings and pipes in his scope and execute such work within the
quoted rate.

10.56 Normally vents / drain may not be shown in the drawing. Contractor shall
provide these within the rate quoted for fabrication and installation of pipes at
locations as instructed by consultant. The specification of vents / drains shall
be as indicated in piping specification.

10.57 Valves shall be installed as shown in the drawing, in case the installation of
valve as shown is not feasible to then contractor shall consult the engineer and
follow his instructions.

10.58 Contractor shall ensure that globe valve, check valves and other unidirectional
valves are installed after confirming the marking of the direction of flow. In case
flow direction is not marked on the valve, then contractor shall install valve
based on instruction given by consultant engineer.

10.59 Contractor shall ensure that valves with pad locking are erected at proper
location as shown in the drawing.

C930034 R4 CONT. STD-CONST-FESSP-08

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Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 15 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

10.60 All in line instruments such as restriction orifice, safety valves, control valves,
rotameter, venture meter, flow meter, strainers shall be installed by the
contractor.

10.61 Contractor shall handle all in line instruments with utmost care and take
necessary precaution to avoid any damage after installation.

10.62 Jacketed piping shall be preassembled to maximum extent in the shop.

Contractor shall erect jumpovers and nozzle on jacket pipe after erection of
pipeline based on ease of constructibility.

10.63 Contractor shall exercise utmost care and ensure that core pipe is not damaged
during erection of jumpovers.

10.64 Contractor shall ensure that all piping are supported temporarily during erection
by contractor. All materials required for providing temporary supports shall be
provided by contractor at his cost.

10.65 Contractor shall fabricate and erect permanent supports at locations as shown
in the drawing.

10.66 Contractor shall use only approved brands of electrodes on the job.

1) Advani Oerlikon Ltd.

2) D & H Secheron
3) Esab India

10.67 Contractor shall furnish batch certificates for electrodes.

10.68 Contractor shall store electrodes in a dry area.

C930034 R4 CONT. STD-CONST-FESSP-08

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Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 16 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

10.69 Contractor shall arrange to provide stationary and portable ovens as and when
required.

10.70 Contractor shall dismantle and reerect alongwith necessary modifications of

structural members, gratings, piping, valves to facilitate erection of piping, such
work shall be carried out by the contractor within the quoted rates. Such work
shall be undertaken based on instructions from clients or consultant. However
during the overall span of the contract if the total weight of structural / piping
etc. dismantled, modified or reerected exceeds 2 MT then the quantum of work
exceeding 2 MT shall be paid at the applicable unit rate.

10.71 Contractor shall at his cost provide fire extinguisher, sand buckets barricades,
fire water hoses if not provided by the clients.

10.72 All battery limit joints shall be executed by the contractor within the quoted
rates.

10.73 Contractor shall be paid modification rates only if pipeline is prefabricated and
erected before issue of modification drawing.

10.74 All TIG welding shall be done with argon purging and shielding during fit up and
welding. The purity of argon shall be 99.995%.

11.0 Welding

11.1 Welding shall be carried out using one of the following methods.

- Shielded Metal Arc Welding Process - (SMAW)

- Gas Tungsten Arc Welding Process - (GTAW)

11.2 Contractor shall submit the welding procedure specification prior to

commencement of the job and obtain approval from client / consultant.

11.3 Contractor shall conduct procedure qualification record test and obtain approval
from client / consultant.

C930034 R4 CONT. STD-CONST-FESSP-08

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Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 17 of 30

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Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

11.4 No welding shall commence till the process of welder qualification is complete.

11.5 Grinding of austentic stainless steel pipes and fittings shall be carried out using
resin bonded alumina or silicon carbide grinding wheels. Rubber bonded
wheels or wheels containing sulphur shall not be used.

11.6 Stainless steel wire brush shall be used on stainless steel piping.

11.7 Stainless steel piping shall be fabricated in a separate area away from carbon
steel piping fabrication.

11.8 Separate set of tools shall be used for fabrication of stainless steel piping to
avoid contamination.

11.9 Root Pass

11.9.1 Root pass shall be completed using filler wire or electrode as indicated
in welding procedure specification.

11.9.2 The recommended size of electrode is 2.5 mm diameter (12 SWG) for
root pass but under no circumstances shall 3.5 mm diameter (10 SWG)
electrode be used, if root run is being made by SMAW.

11.9.3 For pipes held in horizontal axis upward technique shall be used.

11.9.4 During root pass it should be ascertained that full penetration with
complete fusion of root edges is achieved. The projection of weld
inside the pipe shall be as per applicable code.

11.9.5 Proper protection from rain shall be provided during welding in

monsoon.

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Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 18 of 30

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Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

11.9.6 Slag shall be removed by wire brushing, grinding or chipping after

completion of root run.

11.10 Filler Pass

11.10.1 Filler pass shall be completed using filler wire or electrode as

specified in the welding procedure specification.

11.10.2 During subsequent runs care should be taken to ensure that no weld
bead layers start from same point.

11.10.3 The joint surface shall be clean of weld spatter and free from notch.

11.10.4 Weld identification mark shall be clearly marked next to each joint.
Metal stamping shall not be used.

12.0 Inspection

12.1 During the various stages of fabrication of piping the inspector of client /
consultant shall have free access to the job site to review the quality.

12.2 All necessary co-operation and facilities to carry out inspection shall be
provided by contractor to client / consultant inspector.

12.3 Inspection shall be carried out in the shop or at site.

12.4 Contractor shall inform clients / Consultant two days in advance of

commencement of welder qualification test to enable them to witness.

12.5 Contractor shall discuss with client / consultant and prepare Inspection Test
Plan prior to commencement of work and obtain their approval.

C930034 R4 CONT. STD-CONST-FESSP-08

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Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 19 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

12.6 Contractor shall conduct the following tests and maintain records approved by
client / consultant inspector.

a) Liquid Penetrant Test

b) Radiographic Test

c) Hydrotest Record.

13.0 Measurement

13.1 The payment for the job will be made of unit rate basis for the quantum of work
completed and measured.

13.2 Contractor shall prepare detailed measurement sheets for the work completed
as per schedule of rates and submit the same to the client / consultant for
approval.

13.3 Contractor shall submit measurement sheets and bills in floppies.

13.4 The quantities indicated in the schedule of rates are tentative. The final
payment will be made based on the accepted quantities measured in presence
of client / consultant.

13.5 The length of piping installed shall be measured along the centre lines
excluding valves, inline fittings such as strainers, flow meters and site fabricated
mitre reducer which are paid separately as per schedule of rates and terms of
payment.

13.6 Valves and inline fittings such as strainers, flow meters shall be counted and
paid as per schedule of rates based on size installed.

C930034 R4 CONT. STD-CONST-FESSP-08

Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 20 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

13.7 Site fabricated reducers and mitres shall be paid on unit rates as per schedule
of rates.

13.8 Site fabricated fittings which are fabricated but not erected will be paid as per
terms of payments.

13.9 No extra payment will be made for fabrication and erection of reinforcement
pads on nozzle branches.

14.0 Material Reconciliation

14.1 Contractor shall be responsible for all materials issued to him by client /
consultant.

14.2 Contractor shall properly tag and store all material collected from client /
consultant.

14.3 Client / consultant shall have access to contractor store to verify and advise
about storage of material.

14.4 Contractor shall prepare and submit material reconciliation statement every two
months.

14.5 Contractor shall prepare and submit linewise material consumption report after
completion of job.

14.6 Contractor shall prepare and submit tagwise consumption statement.

14.7 Contractor shall return all excess material in his custody by properly cleaning
and tagging the parts.

14.8 All materials returned shall be accompanied with material return ticket. No
material will be accepted back in the absence of this document.

C930034 R4 CONT. STD-CONST-FESSP-08

Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 21 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

14.9 All straight pipe lines 1 M and above are returnable. Pipes shall be properly
colour coded tagged and returned to client / consultant stores.

14.10 Total percentage of scrap permitted is 3% (Three) percent including

accountable and unaccountable scrap. Accountable scrap shall be less than
2% (Two) of the total quantity issued and these shall be established by
weighment in case of carbon steel pipes. In case of stainless steel, alloy steel
pipes the percentage of accountable scrap shall be established by

measurement of length. Invisible unaccountable scrap shall be 1% (One

percent).

14.11 Total percentage of scrap permitted is 4% (Four percent) including

accountable and unaccountable scrap for all plates and structurals materials
issued for fabricating and erecting pipe supports. The accountable scrap shall
not exceed 3% of total quantity fabricated. Invisible or unaccountable scrap
shall be 1% (One percent).

14.12 Cut pieces shall not be less than 1 M in length and shall be considered as
accountable steel and returned to client / consultant stores free of cost. Cut
pieces smaller than 1 M in length for structural steel section and 0.1 sq. m or
any dimension less than 0.2 sq. m for plates or chequered plates shall be
considered as scrap. All scrap materials shall be returned to clients /
consultant stores. The off cut structural in fraction between 1 M to 2 M length
and plates between 0.1 sq.m to 0.2 sq.m should not exceed 10% of useable
steel returned by the contractor. Client / consultant have the option not to
accept such fractional material being returned beyond permissible wastage
and reject the same. In case actual allowable consumption exceeds
theoretical consumption plus allowable wastage limits then recovery shall be
made on excess consumption at the rate of landed cost paid by client plus
50% (fifty) per MT.

C930034 R4 CONT. STD-CONST-FESSP-08

Specification
Document No. : STD-CONST-FESSP-08 Rev. 2 Sheet : 22 of 30

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Stainless Steel Piping

14.13 Clients / Consultant is free to reject any material being returned if not found
satisfactory. The cost of these items will be recovered from the contractor at
the rate of landed cost plus 50%.

15.0 Documentation

15.1 Contractor shall maintain and submit the following documents in four sets to
consultant after completion of the job.

a) Electrode Record
b) Welding Procedure Specification
c) Procedure Qualification Record
d) Linewise History Sheet
e) Heat Treatment Record
f) Liquid Penetrant Record
g) Hardness Test Record
h) Radiography Record
i) Hydrotest/Pneumatic Record
j) As built drawing mark up
k) Material Reconciliation Record

C930034 R4 CONT. STD-CONST-FESSP-08

Specification

Document No. : STD-CONST-FEPS-13 Rev. 2 Sheet : 1 of 4

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Pipe

Support And Other Structural Supports

CONTENTS

1.0 Scope

2.0 Relevant Standard

3.0 Materials

4.0 Fabrication

5.0 Erection

6.0 Inspection

7.0 Measurement

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-FEPS-13 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-FEPS-13 Rev. 2 Sheet : 2 of 4

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Pipe Support And Other Structural
Supports

1.0 Scope

1.1 This specification covers the fabrication, erection and inspection requirement for site or
shop fabricated pipe supports.

2.0 Relevant Standard

The applicable standards shall be Aker Solutions standards alongwith pipe support register.

3.0 Materials

3.1 All materials supplied/used for fabrication and erection of pipe supports should be
accompanied by test certificate or shall be tested in approved test house in the absence
of test certificates.

3.2 Materials shall confirm to specification stated in drawing.

4.0 Fabrication

4.1 All supports shall be fabricated as per Aker Solutions standards or drawings.

4.2 Qualified welders shall be deployed on the job.

4.3 Holes shall be drilled on pipe support, gas cutting of holes is not permitted.

4.4 Only approved brands of electrodes shall be used.

4.5 For welding of stainless steel to carbon steel electrode suitable for dissimilar welding is
to be used.

C930034 R4 CONT. STD-CONST-FEPS-13

Specification
Document No. : STD-CONST-FEPS-13 Rev. 2 Sheet : 3 of 4

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Pipe Support And Other Structural
Supports

5.0 Erection

5.1 Pipe supports shall be installed at locations as indicated in pipe support layout drawings.

5.2 Welding of pipe supports if required is be done only by qualified welders.

5.3 Sliding supports erected should be examined to ensure that they are not tacked welded
to structure, since this would prevent sliding of the support during operation.

5.4 Permanent supports should be installed prior to hydrotest.

5.5 Adequate gap as specified shall be maintained between guide support and structure.

5.6 Prior to installation of pipe supports one coat of red oxide or specified primer paint shall
be applied on carbon steel pipe supports.

5.7 Tico pads shall be supplied and installed on supports fitted to high temperature
pipelines.

6.0 Inspection

6.1 Inspection shall be carried out during various stages of fabrication of pipe supports by
Consultant Inspection Engineer.

6.2 Consultant Inspection Engineer shall carry out welder qualification test prior to
commencement of job.

6.3 Visual examination of supports fabricated shall be done to check for defects such as
undercut, weld spatter or slag.

6.4 Dye penetrant test shall be done on welds as per instructions of Consultant Inspection
Engineer.

C930034 R4 CONT. STD-CONST-FEPS-13

Specification
Document No. : STD-CONST-FEPS-13 Rev. 2 Sheet : 4 of 4

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication And Erection Of Pipe Support And Other Structural
Supports

6.5 Dimensional check shall be conducted for about 5% of various types of support.
Rectification shall be carried out if possible on the pipe support to correct any
dimension discrepancy noticed. Rectification charges shall be borne by the agency
fabricating the support.

6.6 Any support not confirming to dimensions requirements shall be rejected and new
support shall be fabricated and installed free of cost.

6.7 Contractor shall use only approved brands of electrodes on the job.

- Advani Oerlikon Ltd.

- D & H Secheron
- Esab India

7.0 Measurement

7.1 Pipe supports are paid on weight basis, measured in the kilogram or MT.

7.2 Weight of pipe supports is to be calculated from fabrication drawing or standards by the
agency fabricating and erecting the pipe supports.

7.3 If support is fabricated using combination of carbon steel and stainless steel material
then payment will be made as per unit rates for the proportional quantity of carbon steel
or stainless steel used in fabrication and erection. Agency shall include in quoted rate
the cost of welding dissimilar materials.

7.4 Consultant Engineer shall certify the measurements.

7.5 Weight for pipe support shall include rate for supply of bolts, nuts and washers.

7.6 No separate payment shall be made for application of one coat red oxide primer on
carbon steel supports.

C930034 R4 CONT. STD-CONST-FEPS-13

Specification

Document No. : STD-CONST-HT-14 Rev. 2 Sheet : 1 of 6

Project No. : 2090/1600

Document Title : Standard Specification For Hydrotesting Of Pipelines

CONTENTS

1.0 Scope

2.0 Relevant Standard

3.0 General

4.0 Flushing

5.0 Hydrotest

6.0 Post Testing

7.0 Documentation

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONTS-HT-14 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-HT-14 Rev. 2 Sheet : 2 of 6

Project No. : 209/1600

Document Title : Standard Specification For Hydrotesting Of Pipelines

1.0 Scope

1.1 This specification covers hydro testing of site erected piping.

2.0 Relevant Standard

2.1 The latest edition of the following standards including all revisions and addendum shall
be applicable.

ASME 31.3 - Chemical plant and petroleum refinery piping

3.0 General

3.1 All piping to be tested shall be left unpainted till testing is complete.

3.2 Orifice plate shall be removed prior to hydrotesting.

3.3 All spring supports should be locked prior to hydrotest and unlocked during
commissioning after hydrotest.

3.4 Adequate number of calibrated pressure gauges shall be installed to monitor the
pressure.

3.5 Prior to testing ensure that adequate number of vents and drains are installed in the
pipeline.

3.6 Prior to testing ensure that all non destructive testing has been completed and cleared
and line is mechanically approved for hydro testing.

3.7 Ensure that all equipment nozzles are blinded.

C930034 R4 CONT. STD-CONTS-HT-14

Specification
Document No. : STD-CONST-HT-14 Rev. 2 Sheet : 3 of 6

Project No. : 209/1600

Document Title : Standard Specification For Hydrotesting Of Pipelines

3.8 Testing should not be conducted after sunset.

3.9 All lines shall be flushed prior to hydrotest.

3.10 Spools shall be fitted in place of control valves.

3.11 Water filling pump and test rig shall be tested prior to use.

3.12 All electrical appliances shall be earthed properly.

3.13 Ensure that pipeline to be tested is support properly.

3.14 Expansion joints shall be provided with temporary restrain if required for additional
load during testing or shall be isolated if possible during testing.

3.15 All weld joints to be cleaned with buffing or wire brush before water filling for hyrotest.

4.0 Flushing

4.1 Prior to hydro testing the erected pipeline shall be thoroughly flushed with water.

4.2 Water used for flushing and hydrotesting shall be demineralised water or industrial
grade water. Stainless steel piping shall not be tested with water containing chlorides
over 15 - 20 ppm.

4.3 Flushing shall be done using fire hydrant pressure or using pump of suitable pressure
and capacity.

4.4 During flushing the velocity of the water should be sufficient to clean the pipeline of
any foreign matters, flushing should be undertaken till the water being discharged is
clear. Period of flushing should in no case be less than 10 minutes.

4.5 During flushing and hydrotesting all in line instruments such as flow meter, inline,
strainers, control valve and instruments shall be removed.

C930034 R4 CONT. STD-CONTS-HT-14

Specification
Document No. : STD-CONST-HT-14 Rev. 2 Sheet : 4 of 6

Project No. : 209/1600

Document Title : Standard Specification For Hydrotesting Of Pipelines

4.6 During flushing and hydrotesting the following equipments shall be isolated.

a) Pumps, turbines or compressors.

b) Rupture discs, rotameter, flame arrestors, fitters, steam traps.

c) Safety Valves.

d) Instruments

4.7 Instrument take off piping upto first block valve shall be tested with piping or
equipment to which it is connected.

4.8 During flushing ensure that water flushed does not damage work of other agencies.

4.9 Contractor shall carry out all activities such as dropping of valves, removal of inline
instruments or any other component, installation of blinds, spool pieces, gaskets etc. as
per instruction of consultant/ client. Prior to flushing and shall reinstall these after
testing as per instruction of consultant / client.

5.0 Hydrotest

5.1 Water shall be used for hydrotest and shall be tested suitability, if required.

5.2 Lines comprising of similar test pressure shall be tested together by forming hydrotest
loops.

5.3 During water filling ensure that vent at the highest point is kept open to vent at the
highest point is kept open to vent air from pipeline.

5.4 Close vent after all air has been bled out.

5.5 Check and confirm that all drains are closed during water filling.

C930034 R4 CONT. STD-CONTS-HT-14

Specification
Document No. : STD-CONST-HT-14 Rev. 2 Sheet : 5 of 6

Project No. : 209/1600

Document Title : Standard Specification For Hydrotesting Of Pipelines

5.6 Pressure gauges used for observing test pressure shall be tested and calibrated and the
test pressure falls in the 40 - 80% of gauge scale reading.

5.7 All calibration certificates for pressure gauges shall be produced for examination by the
contractor, the consultant/client shall verify the same.

5.8 The hydrotest pressure shall be gradually increased in stages till the desired test
pressure is reached.

5.9 The test pressure is maintained for a minimum of 30 minutes and pipeline examined for
any leak or sweat through weld, flanged or threaded joint.

5.10 Contractor shall ensure that thickness of blinds are as per pressure rating

6.0 Post Test

6.1 After hydrotest drain the pipelines of all water.

6.2 All drains and vents shall be opened to ensure that lines are fully drained.

6.3 All blinds inserted during hydrotest shall be removed.

6.4 All vents/ drains shall be closed and plugged after draining is complete.

6.5 All instruments, control valves shall be fitted back.

6.6 All spool pieces shall be removed.

6.7 At location where temporary gaskets were installed for testing shall be fitted with
permanent gasket as per specification and boxed up.

6.8 All spring supports shall be unlocked by removing preset pins.

6.9 All wire meshes of strainers shall be reinstalled.

C930034 R4 CONT. STD-CONTS-HT-14

Specification
Document No. : STD-CONST-HT-14 Rev. 2 Sheet : 6 of 6

Project No. : 209/1600

Document Title : Standard Specification For Hydrotesting Of Pipelines

7.0 Documentation

7.1 The contractor shall prepare the following documents in four sets and forward same to
consultant / client in a dossier.

a) Line List forming the loop.

b) Linewise fit up report.
c) Linewise welding report.
d) Linewise X-ray report.
e) Linewise mechanical clearance report.
f) Linewise history sheet.
g) Isometric for the line indicating all joint numbers.
h) Hydrotest report for the loop.

C930034 R4 CONT. STD-CONTS-HT-14

Specification
Document No. : STD-CONST-VF-17
Rev. 2 Sheet : 1 of 5

Project No. :

Document Title : Standard Specification For Vessel Filling

CONTENTS

1.0 GENERAL

1.1 Scope
1.2 Receipt and Storage
1.3 Relevant Standard
1.4 Specific Requirement
1.5 Manufacturer’s Installation Manual

2.0 PREPARATION FOR FILLING

2.1 Scaffolding and Lifting Arrangements

2.2 Lighting and Earthing
2.3 Ventilation
2.4 Vessel Entry
2.5 Cleaning
2.6 Filling

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-VF-17 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-VF-17 Rev. 2 Sheet : 2 of 5

Project No. :

Document Title : Standard Specification For Vessel Filling

1.0 GENERAL

1.1 Scope

1.1.1 This specification covers the general requirement for Vessel Filling Work such
as Packing Filling, Catalyst Filling.

1.2 Receipt and Storage

1.2.1 Packing rings / catalyst shall be stored carefully.

1.2.2 Quantity of pall rings / catalyst received shall be weighed when received.

1.2.3 Catalyst shall stored in dry covered area.

1.2.4 After filling packing rings / catalyst returned shall be properly weighed.

1.3 Relevant Standard

The following standard specification listed below are a supplement to this specification.

STD-CONST-ISE-01 - Standard specification for Installation of Static Equipment

1.4 Specific Requirement

In case where specific requirement are provided and there is a contradiction to this
specification, then specific requirement shall govern.

1.5 Manufacturer’s Installation Manual

C930034 R4 CONT. STD-CONST-VF-17

Specification
Document No. : STD-CONST-VF-17 Rev. 2 Sheet : 3 of 5

Project No. :

Document Title : Standard Specification For Vessel Filling

The installation work shall be carried out in accordance with Manufacturer’s

Installation Manual, if the same is available.

2.0 PREPARATION FOR FILLING

2.1 Scaffolding and Lifting Arrangement

2.1.1 Proper steel scaffolding shall be installed inside and around the equipments.
When scaffolding is to be installed inside the equipment proper padding shall be
installed at the area where the scaffolding contacts the equipment so that there is
no damage to the surface of the equipment.

2.1.2 Lifting devices used to lift filling media shall be tested prior to use.

2.1.3 Area where filling media is being lifted shall be properly barricaded and sign
boards shall be displayed.

2.2 Lighting and Earthing

2.2.1 24 volt hand lamps shall be used for lighting inside vessel.

2.2.2 All electrically operated tools being used shall be proper earthed and earth
leakage breakers shall be fitted in the circuit.

2.2.3 Vessel shall be properly earthed.

2.3 Ventilation

2.3.1 Adequate provision to provide fresh air into the vessel shall be made.

2.3.2 Where possible exhaust fans shall also be fitted to displace air and ensure
circulation.

2.4 Vessel Entry

C930034 R4 CONT. STD-CONST-VF-17

Specification
Document No. : STD-CONST-VF-17 Rev. 2 Sheet : 4 of 5

Project No. :

Document Title : Standard Specification For Vessel Filling

2.4.1 Before entry of personnel into the vessel Safety Officer shall examine the vessel
and certify that it is safe for entry and that it is free from any dangerous fumes.

2.4.2 When personnel enter vessel for working, a person should stand by outside to
attend to any emergency.

2.5 Cleaning

2.5.1 Vessel should be cleaned of a foreign matter, dust prior to filling.

2.5.2 Internal parts / fittings should be cleaned and fitted.

2.6 Filling

2.6.1 Depending of the media to be filled the method of filling has to be adopted.

2.6.2 Pall rings shall be filled into the vessel using hopper and chute.

2.6.3 Ensure that packing rings do not fall freely from the chute for a distance of more
that 500 mm to avoid damage to packing rings.

2.6.4 Ensure that the packing rings are levelled after filling.

2.6.5 Packing rings shall not filled into the vessel without water filling, unless
specified otherwise.

2.6.6 The total quantity of packing rings to be filled shall be weighed and kept ready.

2.6.7 The quantity and height filled shall be recorded.

2.6.8 When loading catalyst the total quantity to be filled shall be weighed and kept
ready. Ensure proper type of catalyst is loaded in the right equipment.

2.6.9 Catalyst shall be kept in a dry area duly covered and away from rain and wind.

C930034 R4 CONT. STD-CONST-VF-17

Specification
Document No. : STD-CONST-VF-17 Rev. 2 Sheet : 5 of 5

Project No. :

Document Title : Standard Specification For Vessel Filling

2.6.10 Catalyst shall be loaded using hopper and chute.

2.6.11 Free fall height of catalyst shall be limited to 500 mm.

2.6.12 The following record shall be maintained.

Total quantity in Kgs of catalyst withdrawn from stores.

Quantity of catalyst loaded in Kgs.
Balance quantity of catalyst in Kgs returned back to stores.

2.6.13 After filling of catalyst ensure that the chute is removed and no section is left
behind accidentally.

2.6.14 After filling of catalyst level the top surface.

2.6.15 Box up manhole, ensure that gasket is properly fixed and all bolts are
tightened properly.

C930034 R4 CONT. STD-CONST-VF-17

Specification

Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 1 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

CONTENTS

1.0 Scope

2.0 Relevant Standard

3.0 Materials

4.0 Electrodes and Filler Wire

5.0 Consumables

6.0 Tools and Tackles

7.0 Joints in Piping

8.0 Fabrication and Erection

12.0 Welding

13.0 Inspection

14.0 Measurement

16.0 Material Reconciliation

17.0 Documentation

2 Construction SS / June 2008 PKB / June 2008 ADM / June 2008

1 Construction SS / July 2005 ADM / July 2005 PKD / July 2005
0 Construction SS / May 1996 ADM / May 1996 PKD / May 1996
Revision Issued for Prepared by/ Checked by/ Approved by/
Date Date Date
Project :

Client :

C930034 R4 STD-CONST-FEGASP-29 © 2008 Aker Solutions

Aker Powergas Pvt. Ltd.
Powergas House, P.O.Box 9789, 177, Vidyanagari Marg, Kalina, Mumbai 400 098
Tel +91 (022)6691 5901 Fax +91 (022)6691 5934 www.akersolutions.com
Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 2 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

1.0 Scope

1.1 This specification covers site fabrication and erection of galvanised steel piping.

2.0 Relevant Standard

The latest edition of the following standards including all revisions and addendum shall be
applicable.

ASME 31.3 - Chemical plant and petroleum refinery piping

ASME Section } Specification for welding rods, electrode

II Part C } and filler metals.

ASTM Section IX - Welding and Brazing qualification

3.0 Materials

3.1 All free issue materials like pipes, flanges, fittings, valves, bolts and nuts, gaskets,
inline fittings, spring supports etc. shall be supplied.

3.2 Contractor shall arrange to receive and store materials in their stores till it is erected.

3.3 Pipes, fittings, valves, flanges, gaskets, studs, in line fittings used in a particular piping
system shall be as specified in piping specification.

3.4 Contractor shall ensure that all materials received have been properly identified by Aker
Solutions colour code, punch mark or by engraving so that traceability of material is
ensured.

3.5 Valves, special in line fittings and other piping materials shall be properly tagged.

3.6 Contractor shall visually inspect materials being collected and immediately bring to the
notice of the stores officer any discrepancy or short fall noticed. No claim will be
entertained once materials are issued.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 3 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

3.7 All piping materials such as pipes valves, flanges, fittings in line fittings gaskets etc.
shall be drawn line wise against proper material issue ticket.

3.8 No bulk issue of material will be made.

3.9 Contractor shall collect all materials indented at one time and move it out of the store.

3.10 Contractor shall make arrangements to deploy tractor, trailer, truck, wheel barrow, hand
cart, fork lift or hydra crane to shift material from clients stores to their stores.

3.11 Contractor shall construct at his cost covered stores for storage of materials received
from clients stores.

4.0 Electrodes and Filler Wire

4.1 Contractor shall arrange to supply electrodes and filler wire.

4.2 Contractor shall ensure only Aker Solution approved brands of electrodes are used.

4.3 Contractor shall produce batch test certificate for every batch electrodes and filler wires.

4.4 Electrodes and filler wires shall be stores in a dry area. Manufacturers recommendation
shall be followed.

5.0 Consumables

5.1 Contractor shall arrange to supply and use consumables Argon, Oxygen, D A Cylinder
with valve safety guards & grinding wheels.

5.2 Contractor shall not use Liquidfied Petroleum Gas at site for gas cutting.

5.3 Contractor shall ensure that all regulators, hoses, cutting sets used are of reputed brands
and tested.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 4 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

6.0 Tools and tackles

6.1 Contractor shall at his expenses provide all necessary tools and tackles required for the
job. Contractor shall augment the resources, if required during execution phase of the
job, to maintain the completion schedule.

6.2 All tools and tackles shall be tested prior to use on the job.

6.3 All gauges shall be calibrated and test certificates made available for verification.

7.0 Joints in Piping

7.1 Wherever screwed piping is involved the threads shall be as per specification.

7.2 Threads shall be cut by using die or machine, using coolant or lubricating oil.

7.3 Threads shall be made on pipes after bending operation is complete.

7.4 Before assembly all threaded joints shall be cleaned of dirt, oil or any foreign matter.

7.5 Sealant shall be used on male threads and joint tightened sufficiently to make the joint
leak proof.

7.6 Flange face shall be true and perpendicular to the axis of the pipe.

7.7 Flange bolt holes shall straddle the normal centerline unless otherwise specified.

7.8 Branch connection shall be provided as shown in branching details enclosed with
piping specification.

7.9 Bending of pipe shall be as per ANSI 31.3. Cold bends with bend radius of 5 times
the nominal diameter shall be used as stated in piping specification.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 5 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

7.10 Bends shall have smooth surface, free of cracks, wrinkles bulges, flat spots. D P test
shall be carried out on outer side of bends to check for any crack which may occur
during bending.

7.11 Flattening of bends shall be measured as the difference between the maximum and
minimum diameters of any cross section. The difference shall not exceed 8% to 3%
of the nominal outside diameter for internal and external pressures respectively.

8.0 Fabrication and Erection

8.1 Contractor shall fabricate and erect the piping in accordance with the latest edition of
code for petroleum refinery piping ANSI B 31.3 unless other specified.

8.2 Contractor shall be responsible for accuracy of fabrication. Contractor shall review the
drawing and in case any error or omission is identified the same shall be brought to the
notice of Consultant Engineer.

8.3 Contractor shall provide adequate number of field welds apart from those shown on the
drawing to take care of variations that normally occur at site due to minor changes in
location of equipments. At all field welds, so located contractor shall leave an extra 100
mm over and above the dimensions shown in the drawing, contractor may make
necessary adjustments during erection by cuttings the extra lengths provided at field
welds to obtain the actual dimension required based on site conditions.

8.4 Isometrics drawing shall indicate the field welds, however it is the responsibility of the
contractor to provide additional field welds, if required. No extra payment will be made
to the contractor for additional srewed joints.

8.5 Welder qualification as per specification shall be carried out prior to commencement of
welding in case seal welding of fittings have to be done.

8.6 Only qualified tack welders or welders shall be allowed to work on the job.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 6 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

8.7 Contractor shall maintain the following documents for all welders.

1] Welding Procedure Specification

2] Procedure Qualification Record
3] Welder Identification Card

8.8 The welded joint shall be cleaned with wire brush and two coats of primer and
aluminium paint shall be applied.

8.9 Contractor shall prepare neat sketches with bill of quantities for line sizes 40 NB and
below, obtain approval of the Piping Engineer prior to commencement of fabrication.

8.10 No piping isometric will be issued for rack lines, only piping layout will be provided,
contractor shall prepare working sketch.

8.11 Contractor shall deploy adequate number of draftsman at site for preparation of sketches
for piping and mark up of “As built drawings”.

8.12 All ends of prefabricated piping shall be properly blanked using wooden blanks or
polyethene sheets arranged by contractor at his cost. Contractor shall mark line,
numbers on all prefabricated spools with permanent marker or paint for proper
identification.

8.13 Contractor shall provide adequate number of tools, tackles and manpower to execute the
job within the schedule time.

8.14 Contractor shall at his cost provide erect and dismantle scaffolding along with landing
materials at desired locations during fabrication and erection of piping.

8.15 All scaffolding materials shall be metallic, wooden planks and bamboo scaffolding will
not be permitted.

8.16 Contractor shall ensure that all temporary scaffolding erected shall be dismantled after
work is completed.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 7 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

8.17 Contractor shall carry out minor civil work such as making opening in brick walls,
concrete floors. After installation of piping contractor shall make good the same. All
civil work shall be done in co-ordination consultant Civil Engineer.

8.18 Contractor shall remove all waste materials, debris from the site. House keeping shall
be the responsibility of the contractor.

8.19 Contractor shall ensure all safety practice and procedure are adopted during fabrication
and erection.

8.20 Contractor shall fabricate, assemble couple, align pipelines, install pipe supports, spring
hangers all in line mounting as per drawing.

8.21 Contractor shall wherever required cut floor gratings to introduce pipelines and provide
collars to gratings at no extra cost.

8.22 Contractor shall arrange to fabricate and erect pipe supports as shown in the drawing.

8.23 Contractor shall furnish list of tools and tackles to be deployed on the job indicating
make, year of manufacture.

8.24 Contractor shall furnish list of manufacture to be deployed on the job.

8.25 Contractor shall furnish bio-data of key personnel to be deployed on the job.

8.26 Contractor shall appoint full time Safety Engineer, Quality Control Engineer and
Planning Engineer on the job.

8.27 Contractor shall prepare and furnish daily reports for fit up, welding, NDT test,
manpower, tools and tackles as requested by client or consultant.

8.28 Contractor shall prepare and submit weekly plan based on availability of drawings,
front and materials.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 8 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

8.29 Contractor shall inspect, test and calibrate all tools and tackles, necessary instruments
deployed and furnish testing and Calibration Reports for verification to clients /
consultants.

8.30 Contractor shall follow all procedures in execution as explained verbally or in writing
by client / consultant.

8.31 Contractor shall obtain prior approval from client / consultant for any extra work or
modification being undertaken. To enable client / consultant to approve the same,
contractor shall at his cost prepare and submit the cost of such extra work for client /
consultant to review and approve.

8.32 All temporary electrical installations being erected by the contractor shall be approved
by client/contractor and by Electrical Authorities.

8.33 Contractor shall post qualified and licensed electrician full time at site.

8.34 Contractor shall be equipped with first aid unit prior to commencement of work.

8.35 Contractor shall maintain at his disposal full time vehicle to transport his workmen to a
dispensary or hospital in case of any emergency.

8.36 Contractor shall obtain labour license prior to commencement of job and forward a
copy to client / consultant.

8.37 Contractor shall insure all his workmen and furnish copy of insurance policy to client /
consultant.

8.38 Contractor shall be fully responsible for all statutory payments like Wages, PF, ESIC,
Bonus, Leave Wages, Gratuity etc. which are to be paid to workmen employed by the
contractor. No payment will be made by clients towards these statutory payment.

8.39 Contractor shall furnish copies of PF statement, ESIC etc. to client for the records every
month.

8.40 Contractor shall at his cost insure all tools and tackles against theft and fire.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 9 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

8.41 Contractor shall appoint full time security personnel for the office, stores, fabrication
yard and installation area.

8.42 Contractor shall provide labour colony transport and canteen facilities to the staff and
workmen.

8.43 All prefabricated piping shall be cleaned properly to remove any dirt or mud if present
before erection.

8.44 Contractor shall barricade and prevent entry of personnel during erection of piping.

8.45 Contractor shall obtain and maintain all necessary permits during execution of the job
in a running plant.

8.46 Piping shall be erected as shown in drawing. Contractor shall not change the route of
piping without consent of the client / consultant. All such changes shall be marked on
the drawing and clients / consultant approval obtained.

8.47 In case piping fouls with structure or equipment, then such discrepancy shall be brought
to the notice of the consultant and action to solve the problem shall be taken as per
instruction from the consultant.

8.48 Contractor shall maintain necessary slopes in pipeline as per drawing.

8.49 During fabrication and erection contractor shall include trimming, cutting and grinding
of fittings and pipes in his scope and execute such work within the quoted rate.

8.50 Normally vents / drain may not be shown in the drawing. Contractor shall provide these
within the rate quoted for fabrication and installation of pipes at locations as instructed
by consultant. The specification of vents / drains shall be as indicated in piping
specification.

8.51 Valves shall be installed as shown in the drawing, in case the installation of valve as
shown is not feasible to then contractor shall consult the engineer and follow his
instructions.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 10 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

8.52 Contractor shall ensure that globe valve, check valves and other unidirectional valves
are installed after confirming the marking of the direction of flow. In case flow
direction is not marked on the valve, then contractor shall install valve based on
instruction given by consultant engineer.

8.53 Contractor shall ensure that valves with pad locking are erected at proper location as
shown in the drawing.

8.54 All in line instruments such as restriction orifice, safety valves, control valves,
rotameter, venture meter, flow meter, strainers shall be installed by the contractor.

8.55 Contractor shall handle all in line instruments with utmost care and take necessary
precaution to avoid any damage after installation.

8.56 Contractor shall ensure that all piping are supported temporarily during erection by
contractor. All materials required for providing temporary supports shall be provided
by contractor at his cost.

8.57 Contractor shall fabricate and erect permanent supports at locations as shown in the
drawing.

8.58 Contractor shall use only approved brands of electrodes on the job.

1) Advani Oerlikon Ltd.

2) D & H Secheron
3) Esab India

8.59 Contractor shall furnish batch certificates for electrodes.

8.60 Contractor shall store electrodes in a dry area.

8.61 Contractor shall arrange to provide stationary and portable ovens as and when required.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 11 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

8.62 Contractor shall dismantle and reerect alongwith necessary modifications of structural
members, gratings, piping, valves to facilitate erection of piping, such work shall be
carried out by the contractor within the quoted rates. Such work shall be undertaken
based on instructions from clients or consultant. However during the overall span of the
contract if the total weight of structural / piping etc. dismantled, modified or reerected
exceeds 2 MT then the quantum of work exceeding 2 MT shall be paid at the applicable
unit rate.

8.63 Contractor shall at his cost provide fire extinguisher, sand buckets barricades, fire water
hoses if not provided by the clients.

8.64 All battery limit joints shall be executed by the contractor within the quoted rates.

8.65 Contractor shall be paid modification rates only if pipeline is prefabricated and erected
before issue of modification drawing.

9.0 Welding

9.1 Welding shall be carried out using one of the following methods.

- Shielded Metal Arc Welding Process - (SMAW)

9.2 Contractor shall submit the welding procedure specification prior to commencement of
the job and obtain approval from client / consultant.

9.3 Contractor shall conduct procedure qualification record test and obtain approval from
client / consultant.

9.4 No welding shall commence till the process of welder qualification is complete.

9.5 Threaded joints are shown as welding after screwing, this will lead to damage of
galvanising inside and outside. Particularly loss of galvanising inside will be lead to
corrosion due to loss of galvanising.

9.6 Proper protection from rain shall be provided during welding in monsoon.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 12 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

9.7 Slag shall be removed by wire brushing, grinding or chipping after completion of weld.

9.8 The joint surface shall be cleaned of weld spatter and free from notch.

9.9 Weld identification mark shall be clearly marked next to each joint. Metal stamping
shall not be used.

10.0 Inspection

10.1 During the various stages of fabrication of piping the inspector of client / consultant
shall have free access to the job site to review the quality.

10.2 All necessary co-operation and facilities to carry out inspection shall be provided by
contractor to client / consultant inspector.

10.3 Inspection shall be carried out in the shop or at site.

10.4 Contractor shall inform clients / Consultant two days in advance of commencement of
welder qualification test to enable them to witness.

10.5 Contractor shall discuss with client / consultant and prepare Inspection Test Plan prior
to commencement of work and obtain their approval.

10.6 Contractor shall conduct the following tests and maintain records approved by client /
consultant inspector.

a) Pneumatic Test Records

b) Hydro Test Records

11.0 Measurement

11.1 The payment for the job will be made of unit rate basis for the quantum of work
completed and measured.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 13 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

11.2 Contractor shall prepare detailed measurement sheets for the work completed as per
schedule of rates and submit the same to the client / consultant for approval.

11.3 Contractor shall submit measurement sheets and bills in floppies.

11.4 The quantities indicated in the schedule of rates are tentative. The final payment will be
made based on the accepted quantities measured in presence of client / consultant.

11.5 The length of piping installed shall be measured along the centre lines excluding valves,
inline fittings such as strainers, flow meters and site fabricated mitre reducer which are
paid separately as per schedule of rates and terms of payment.

11.6 Valves and inline fittings such as strainers, flow meters shall be counted and paid as per
schedule of rates based on size installed.

11.7 Fabrication and erection of galvanised iron piping will be made of metres basis for the
size installed. No separate payment will be made for threading of piping and
application of teflon tape or sealant.

11.8 In case where seal welding of galvanised piping is required unit rate as per schedule
of rate will be paid.

12.0 Material Reconciliation

12.1 Contractor shall be responsible for all materials issued to him by client / consultant.

12.2 Contractor shall properly tag and store all material collected from client / consultant.

12.3 Client / consultant shall have access to contractor store to verify and advise about
storage of material.

12.4 Contractor shall prepare and submit material reconciliation statement every two months.

12.5 Contractor shall prepare and submit linewise material consumption report after
completion of job.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 14 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

12.6 Contractor shall prepare and submit tagwise consumption statement.

12.7 Contractor shall return all excess material in his custody by properly cleaning and
tagging the parts.

12.8 All materials returned shall be accompanied with material return ticket. No material
will be accepted back in the absence of this document.

12.9 All straight pipe lines 1 M and above are returnable. Pipes shall be properly colour
coded tagged and returned to client / consultant stores.

12.10 Total percentage of scrap permitted is 3% (Three) percent including accountable and
unaccountable scrap. Accountable scrap shall be less than 2% (Two) of the total
quantity issued and these shall be established by weighment in case of carbon steel
pipes. In case of stainless steel, alloy steel pipes the percentage of accountable scrap
shall be established by measurement of length. Invisible unaccountable scrap shall be
1% (One percent).

12.11 Total percentage of scrap permitted is 4% (Four percent) including accountable and
unaccountable scrap for all plates and structurals materials issued for fabricating and
erecting pipe supports. The accountable scrap shall not exceed 3% of total quantity
fabricated. Invisible or unaccountable scrap shall be 1% (One percent).

12.12 Cut pieces shall not be less than 1 M in length and shall be considered as accountable
steel and returned to client / consultant stores free of cost. Cut pieces smaller than 1 M
in length for structural steel section and 0.1 sq. m or any dimension less than 0.2 sq. m
for plates or chequered plates shall be considered as scrap. All scrap materials shall
be returned to clients / consultant stores. The off cut structural in fraction between 1
M to 2 M length and plates between 0.1 sq.m to 0.2 sq.m should not exceed 10% of
useable steel returned by the contractor. Client / consultant have the option not to
accept such fractional material being returned beyond permissible wastage and reject
the same. In case actual allowable consumption exceeds theoretical consumption
plus allowable wastage limits then recovery shall be made on excess consumption at
the rate of landed cost paid by client plus 50% (fifty) per MT.

C930034 R4 CONT. STD-CONST-FEGASP-29

Specification
Document No. : STD-CONST-FEGASP-29 Rev. 2 Sheet : 15 of 15

Project No. : 2090/1600

Document Title : Standard Specification For Fabrication & Erection Of Galvanised Steel Piping

12.13 Clients / Consultant is free to reject any material being returned if not found
satisfactory. The cost of these items will be recovered from the contractor at the rate
of landed cost plus 50%.

17.0 Documentation

17.1 Contractor shall maintain and submit the following documents in four sets to consultant
after completion of the job.

a) Electrode Record
b) Welding Procedure Specification
c) Procedure Qualification Record
d) Linewise History Sheet
e) Hydrotest/Pneumatic Record
f) As built drawing mark up
g) Material Reconciliation Record

C930034 R4 CONT. STD-CONST-FEGASP-29

 APG / CONST / WELD CHART REV 01

JUNE 2008

WELDING PROCEDURES FOR PIPES , PLATES , FITTINGS, FORGINGS

( FOR CONSTRUCTION ACTIVITIES )

BASE MAT BUTT JT LAP JT FILLET JT SOCKET PREHEAT DP TEST MP TEST RADIO- PWHT PURGING IMPACT BACKING CONSUM
JT GRAPHY TEST RING INSERT
IS 1239 R- SMAW R- SMAW SMAW SMAW NA AFTER IF IF NA NA IF IF IF
BS 3059 E - 6010 E - 6013 E - 6013 E - 6013 ROOT SPECIFIED SPECIFIED SPECIFIED SPECIFIED SPECIFIED
BS 806, F - SMAW F - SMAW PASS &
IS 226, E - 6013 E - 6013 B/CHIP
IS 3589
THK: 1.6
TO 19 mm

A 106 Gr B R- SMAW R- SMAW SMAW SMAW NA AFTER IF IF NA NA IF IF IF

A 515-60/70 E - 6010 E - 7018 E - 7018 E - 7018 ROOT SPECIFIED SPECIFIED SPECIFIED SPECIFIED SPECIFIED
A 516-60/70 F - SMAW F - SMAW PASS &
A 234-WPB E - 6013 E - 7018 B/CHIP
IS 2002
A 285
A 53 Gr B
API 5L Gr B
P NO: 1
THK : 1.6
TO 19 mm

A 312 TP 304 R - GTAW R - GTAW GTAW GTAW NA AFTER IF IF 99.5 % Ar IF IF IF

A 213 TP 304 ER - 308 ER - 308 ER - 308 ER - 308 ROOT SPECIFIED SPECIFIED NA ( FOR PIPES) SPECIFIED SPECIFIED SPECIFIED
A 182 TP 304 F - GTAW F - GTAW PASS
ER - 308 ER - 308

A 312 TP 304L R - GTAW R - GTAW GTAW GTAW NA AFTER IF IF 99.5 % Ar IF IF IF

A 213 TP 304L ER - 308L ER - 308L ER - 308L ER - 308L ROOT SPECIFIED SPECIFIED NA ( FOR PIPES) SPECIFIED SPECIFIED SPECIFIED
A 182 TP 304L F - GTAW F - GTAW PASS
ER - 308L ER - 308L

P No : 8
Thk upto
3 mm

SHT 1 OF 3
 APG / CONST / WELD CHART REV 01

JUNE 2008

BASE MAT BUTT JT LAP JT FILLET JT SOCKET PREHEAT DP TEST MP TEST RADIO- PWHT PURGING IMPACT BACKING CONSUM
JT GRAPHY TEST RING INSERT

A 312 TP 304 R - GTAW R - GTAW SMAW SMAW NA AFTER NA IF 99.5 % Ar IF IF IF

A 213 TP 304 ER - 308 ER - 308 E - 308 E - 308 ROOT SPECIFIED NA FOR ROOT SPECIFIED SPECIFIED SPECIFIED
A 182 TP 304 F - SMAW F - SMAW PASS & RUN AND
E - 308 E - 308 B/CHIP ONE
P No: 8 SUBSEQUENT
Thk > PASS
3 mm (FOR PIPES)

A 312 TP 316 R - GTAW R - GTAW GTAW GTAW NA AFTER NA IF 99.5 % Ar IF IF IF

A 213 TP 316 ER - 316 ER - 316 ER - 316 ER - 316 ROOT SPECIFIED NA ( FOR PIPES) SPECIFIED SPECIFIED SPECIFIED
A 182 TP 316 F - GTAW F - GTAW PASS &
ER - 316 ER - 316 B/CHIP
P No: 8
Thk UPTO
3 mm

A 312 TP 316 R - GTAW R - GTAW SMAW SMAW NA AFTER NA IF 99.5 % Ar IF IF IF

A 213 TP 316 ER - 316 ER - 316 E - 316 E - 316 ROOT SPECIFIED NA FOR ROOT SPECIFIED SPECIFIED SPECIFIED
A 182 TP 316 F - SMAW F - SMAW PASS & RUN AND
E - 316 E - 316 B/CHIP ONE

A 312 TP 316L R - GTAW R - GTAW SMAW SMAW NA AFTER NA IF 99.5 % Ar IF IF IF

A 213 TP 316L ER - 316L ER - 316L E - 316L E - 316L ROOT SPECIFIED NA FOR ROOT SPECIFIED SPECIFIED SPECIFIED
A 182 TP 316L F - SMAW F - SMAW PASS & RUN AND
E - 316L E - 316L B/CHIP ONE

P No: 8 SUBSEQUENT
Thk > PASS
3 mm (FOR PIPES)

A 333 Gr 6 R - GTAW R - GTAW SMAW SMAW NA AFTER IF IF NA 99.5 % Ar REQD IF IF

THK UPTO ER 70S-2 ER 70S-2 E 7018-1 E - 7018-1 ROOT PASS SPECIFIED SPECIFIED FOR ROOT SPECIFIED SPECIFIED
19 mm F - SMAW F - SMAW RUN AND
E - 7018 -1 E - 7018 -1 ONE

SHT 2 OF 3
 APG / CONST / WELD CHART REV 01

JUNE 2008

SUBSEQUENT
PASS
(FOR PIPES)

BASE MAT BUTT JT LAP JT FILLET JT SOCKET PREHEAT DP TEST MP TEST RADIO- PWHT PURGING IMPACT BACKING CONSUM
JT GRAPHY TEST RING INSERT

A 316 Ti R - GTAW R - GTAW GTAW GTAW NA AFTER NA IF NA 99.5 % Ar IF IF IF

P No: 8 ER 318 ER 318 ER 318 ER 318 ROOT PASS SPECIFIED ( FOR PIPES) SPECIFIED SPECIFIED SPECIFIED
THK UPTO F - GTAW F - GTAW
3 mm ER 318 ER 318

A 316 Ti R - GTAW R - GTAW SMAW SMAW NA AFTER NA IF NA 99.5 % Ar IF IF IF

P No: 8 ER 318 ER 318 E 318 E 318 ROOT PASS SPECIFIED FOR ROOT SPECIFIED SPECIFIED SPECIFIED
THK > F - SMAW F - SMAW & B / CHIP RUN AND
3 mm E- 318 E- 318 ONE
SUBSEQUENT
PASS
(FOR PIPES)

A 335 P11 ER 80S-B2-GTAW ER 80S-B2-GTAW ER 80S-B2-GTAW ER 80S-B2-GTAW NA AFTER IF 100% YES YES IF IF IF
P NO: 4 E 8018-B2-SMAW E 8018-B2-SMAW E 8018-B2-SMAW E 8018-B2-SMAW NA ROOT PASS SPECIFIED YES NA SPECIFIED SPECIFIED SPECIFIED
& FINAL PASS

A335 P22 ER 90S-B3-GTAW ER 90S-B3-GTAW ER 90S-B3-GTAW ER 90S-B3-GTAW NA AFTER IF 100% YES YES IF IF IF
P NO: 5A E 9018-B3 E 9018-B3 E 9018-B3 E 9018-B3 NA ROOT PASS SPECIFIED YES NA SPECIFIED SPECIFIED SPECIFIED
& FINAL PASS

NOTES : 1) FOR MATERIALS NOT LISTED IN THE ABOVE CHART, A SEPARATE SPECIFICATION SHALL BE ISSUED ALONGWITH THE TENDER
2) ONLY APPROVED MAKES OF WELDING CONSUMABLES SHALL BE USED.
3) APPROVED LIST OF WELDING CONSUMABLES SHALL BE ISSSUED ALONGWITH THE TENDER DOCUMENT.
4) ANY DEVIATION FROM THE ABOVE SHOULD BE BROUGHT TO THE NOTICE OF KVAERNER POWERGAS PRIOR TO PROCEEDING FURTHER

SMAW : Sheilded metal arc welding

GTAW : Gas Tungsten arc welding.

SHT 3 OF 3