Project Management Consultancy (PMC) Services for Execution of

Rajasthan Refinery Project (RRP)

PR

(Document No : B224-111-CC-PR-6006-2025)

Page 1 of 674
 Click on the Document Title to go to that section of the document

Table of Contents
Document Number Rev. Document Title Page
Number
B224-111-CC-PR- A PR 5
6006-2025
B224-80-43-LL-6006- 0 PR LIST OF ATTACHMENTS 10
2520
B224-80-43-SP- 0 PR JOB SPECIFICATION 14
6006-2520
B224-80-43-SS- 0 PR SCOPE OF WORK AND SUPPY 20
6006-2520
B224-80-43-TR- 0 PR INSTRUCTIONS TO VENDOR 27
6006-2520
B224-111-80-43- 0 VDR FOR VDR COMPILATION 38
VDR-6006
B224-111-80-43-LL- 0 LIST OF ATTACHMENTS FOR COLUMN INTERNALS 43
6006
B224-111-80-43-SP- 0 JOB SPECIFICATION FOR COLUMN INTERNALS 45
6006
2025-I A Annexure-I 56
076405C-111-JSS- 0 Licensor Spec. 57
0400-0001
076405C-111-JSS- 0 Licensor Spec. 65
0400-0002
076405C-111-PDS- 2 COLUMN D/S-FREE NUMBER FORMAT 83
0500-2101
6-68-0001 5 Standard Specification Civil And Structural Works - General 106
Scope.
6-68-0002 5 Standard Specification Civil & Structural Works Materials. 110
6-68-0006 7 Standard Specification Civil & Structural Works Structural Steel 126
Works.
6-68-0008 7 Standard Specification Civil & Structural Works Miscellaneous 151
Steel Works
6-78-0001 2 Specification For Quality Management System Requirements 163
From Bidders
6-78-0003 2 Specification For Documentation Requirement From Suppliers 170
7-68-0507 8 Details Of Steel Ladder 181
7-68-0509 7 Steel ladder joint details 184
7-68-0512 6 Ladder support clips for hot vessels 188
7-68-0540 0 Platform Details for Horizontal Hot Vessels 190
7-68-0546 1 Details of brackets for circular platforms of hot vessels 196
7-68-0547 1 Platform support clips for hot vessels 201
7-68-0552 8 Circular platform for hot vessels 204
7-68-0553 8 Details of brackets of circular platforms for hot vessels 212
7-68-0557 6 Platform support clips for hot vessels 217
7-68-0697 4 Electroforged Grating Type-I & Type-Ii 220
B224 111 B ATTACHMENT TO VDR 228
ATTACHMENTS TO
VDR
B224- 109-86-41- 0 Revised Guidelines to Supplier for Movement of Critical ODC 230
SCT-0001
B224-000-79-41- 5 Specification for surface preparation & protective coating 233
PLS-01
B224-111-2-42-VDR- B VENDOR DATA REQUIREMENTS 280
0001
B224-111-81-41- B ANCHOR BOLT ASSEMBLY DET. FRACTIONATOR 111-C-2101 282
46901

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Table of Contents
Document Number Rev. Document Title Page
Number
B224-111-81-41-LL- A VENDOR LIST FOR STRL WORK FOR 111-C-2101 283
6006
B224-111-81-41- B SCHEDULE OF QUANTITIES FOR 111-C-2101 288
SOQ-6006
B224-111-81-41- B SCOPE OF WORKS FOR 111-C-2101 291
SOW-6006
B224-111-81-41- B VENDOR DATA REQUIREMENT 299
VDR-6006
B224-111-YT-SK-6 A MISCELLANEOUS SKETCHES 301
6-12-0001 6 General specification for pressure vessels. 302
6-12-0002 8 Supplementary specification for carbon steel vessels. 317
6-12-0003 5 Supplementary specification for low alloy steel vessels. 324
6-12-0007 5 Supplementary specification for clad vessels. 331
6-12-0011 8 Standard specification for boiler quality carbon steel plates. 341
6-12-0014 6 Standard specification for weldable structural quality steel plates 348
for tanks and vessels
6-12-0015 5 Standard specification for clad plates. 353
6-12-0017 5 Standard specification for 1% Cr- % Mo and 1 % Cr- % Mo steel 358
vessels
6-12-0018 4 Standard specification for 2.25 % Cr-1 % Mo steel plates 363
6-12-0020 8 Standard specification for stainless steel plates. 370
6-14-0009 5 Packing, marking & shipping specifications for tray and tower 375
internals.
6-79-0013 2 Material requirements for carbon steel components used in sour 381
service for petroleum refinery environments
6-81-0001 3 Standard specification for positive material identification (PMI) at 387
supplier's works
6-81-0011 4 ITP for pressure vessels / columns carbon steel. 395
6-81-0012 4 ITP for pressure vessels/ columns/ reactors low alloy steel 402
6-81-0013 4 ITP for SS clad pressure vessels/ columns/ reactors 410
6-82-0001 9 Standard Specification For Health, Safety & Environment (Hse) 418
Management At Construction Sites
6-82-0002 4 Standard specification for positive material identification (PMI) at 520
construction sites
6-14-0003 5 Installation procedure for trays and tower internals. 530
6-14-0007 4 Specification for fabrication of support ring & b/bar for trays & 546
tower internals.
6-14-0008 6 Standards specification for tray & tower Internals. 552
6-14-0015 4 Standard specification for trays and tower internals (un- 564
engineered).
6-14-0016 4 Specification for review of site installation of column internals 589
6-14-0018 2 Specification for preparation of TSR/BB/GA drawings of trays 605
6-81-0007 4 Itp For Bolting Material 619
6-81-0016 3 ITP for Tower Packagings 625
6-81-0017 3 ITP for un-engineered Trays & Tower Internals 630
7-14-0001 4 Construction tolerance for welded supports for tray/ tower internals 636
7-12-0018 6 Internal flanges. 637
7-12-0001 6 Vessel tolerances. 638
7-12-0004 7 Skirt base details. 640
7-12-0005 6 Skirt opening details. 641
7-12-0010 7 Manhole with davit. 643

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Table of Contents
Document Number Rev. Document Title Page
Number
7-12-0011 6 Ladder rungs for manhole/demister. 645
7-12-0013 7 Nozzle reinforcement and projection. 646
7-12-0015 6 Standard bolt hole orientation. 648
7-12-0016 6 Alloy liner details. 649
7-12-0022 6 Support ring sizes for packed tower's interns. 651
7-12-0023 7 Pipe davit. 652
7-12-0025 6 Fire proofing & insulation supports. 655
7-12-0026 6 Earthing lug. 657
7-12-0027 6 Name plate. 658
7-12-0028 6 Manufacturer name plate. 659
7-12-0029 6 Bracket for name plate. 660
7-12-0032 5 Supports for internal feed pipe. 661
7-12-0037 4 S.R. nozzle neck. 663
7-12-0038 1 Allowable nozzle loads 664
B224-111-80-43-DS- 0 111-C-2101 MAIN FRACTIONATOR 668
3001
B224-111-80-43-DS- 0 MECHANICAL DATASHEETS 669
3001A2
B224-111-80-43-DS- 0 MECHANICAL DATASHEETS 670
3001A3
B224-111-80-43-DS- 0 MECHANICAL DATASHEETS 671
3001A4
B224-111-80-43-DS- 0 MECHANICAL DATASHEETS 672
3001A5
B224-111-80-43-DS- 0 MECHANICAL DATASHEETS 673
3001A6
B224-111-80-43-DS- 0 MECHANICAL DATASHEETS 674
3001A7

Page 4 of 674
 PURCHASE REQUISITION (TOP SHEET)
This drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied,

ITEM DESCRIPTION: COLUMN/TOWER-CS/LAS+SS CLADDED.

GROUP ITEM CODE: 01BF DESTINATION: As per Commercial Documents
DELIVERY PERIOD: As per Commercial Documents

DOCUMENT NUMBER
( Always quote the Document Number given below as reference )

B224 111 CC PR 6006 / 2025 0 21/10/2020 80 43

JOB NO. UNIT/ MAIN DOC. SR. NO. REV. DATE DIVN. DEPT.
AREA COST CODE
exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1641-515 Rev.1 A4-210x297.

CENTRE ORIGINATOR

B010 BHEL-HEAVY PLATE & VESSELS PLANT

VENDOR CODE VENDOR NAME

( FOI Number: 2025 DATED 29/09/2020 )
NOTES :
1 This page is a record of all the Revisions of this Requisition.
2 The nature of the Revision is briefly stated in the "Details" column below, the
Requisition in its entirety shall be considered for contractual purposes.

REV. DATE BY CHK. APPD. DETAILS

0 21/10/2020 RKM PVSSN PVSSN ISSUED FOR PURCHASE
This is a system generated approved document and does not require signature.

Project: RAJASTHAN REFINERY PROJECT

ENGINEERS INDIA LIMITED
Client: HPCL RAJASTHAN REFINERY LIMITED
NEW DELHI
Sheet 1 of 5
File Name: D:\121\1212.pdf
Page 5 of 674
 List of Items Ordered
This drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied,

SR. NO. TAG NO./ DESCRIPTION QUANTITY

ITEM CODE/ [ ID. NO.]
01.00 Residual design & engineering, Hydraulic &
Mechanical Design of column internals,
procurement of all materials and bought
out components, fabrication including
assembly/ sub-assembly at shop, NDT, PWHT,
inspection,testing at Manufacturere's
works, Hydrotest of completed column,
surface preparation and application of
primer& finish painting, pickling &
passivation, cutting column into sections,
exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1641-515 Rev.1 A4-210x297.

packing, delivery of the following, supply

of all column internal,supply &
fabrication of platforms & other
structures (refer general notes 1 & 2),
transportation saddles, elevated unloading
saddle, supply of all mandatory spares &
documentation as per the enclosed EIL
standard specifications, instructions to
vendors, job specification, data sheets
etc. attached and codes and standards
referred to.
01.01 111-C-2101 MAIN FRACTIONATOR 1 Nos
02.00 Unloading & handling of column sections +
loose supplies at owner designated area/
fabrication yard, Site activities to be
carried as per job specification (document
no. B224-80-43-SP-6006), transportation of
internals from owner's store to work site,
unloading, storage & preservation at site
till installation, installation of
internals inside the column, leak testing
of internals (as applicable), inspection &
testing and completing the column in all
respects as per MR. All machinery, tools
and tackles, lifting equipments/ cranes,
pumps, etc. required for site assembly
(welding of Circ seam at site on ground)
and Local Hydrotest, Local PWHT and
strengthening/ compaction of ground on and
around owner designated area shall also be
in vendor's scope.
02.01 {02}111-C-2101 For Sr. No. 01.01 [111-C-2101] 1 Nos
03.00 Transportation of column sections,
internals and platforms & ladders (to be
supplied loose in packed condition) from
Vendors work/ shop to Site,
for the following as per the enclosed EIL
standard specifications, instructions to
bidders, job specification, data sheets
etc.
03.01 {03}111-C-2101 For Sr. No. 01.01 [111-C-2101] 1 Nos
05.00 Operation and Maintenance spares as
included in the Commercial part of the
Purchase Order.
Lot
07.00 Charges for Third Party Inspection
07.01 {07}111-C-2101 For Sr. No. 01.01 [111-C-2101] 1 Nos
09.00 Drawings and documents as per attached

Project: RAJASTHAN REFINERY PROJECT

REQUISITION NO. REV.
ENGINEERS INDIA LIMITED
Client: HPCL RAJASTHAN REFINERY LIMITED B224-111-CC-PR-6006 / 2025 0
NEW DELHI
Sheet 2 of 5
File Name: D:\121\1212.pdf
Page 6 of 674
 List of Items Ordered
This drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied,

SR. NO. TAG NO./ DESCRIPTION QUANTITY

ITEM CODE/ [ ID. NO.]
Vendor Data requirement for all supplies
and services covered above in Sr.Nos.1.00
to Sr.No.8.00
Lot
Unit rates for various items if any , shall be as included in the Commercial part
of the Purchase order.

Vendor to note that the numbers given in square '[]' and curly '{}' brackets are
not for their use and meant for store purpose only. Items shall be tagged as per
main equipment Tag No. only.
exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1641-515 Rev.1 A4-210x297.

Project: RAJASTHAN REFINERY PROJECT

REQUISITION NO. REV.
ENGINEERS INDIA LIMITED
Client: HPCL RAJASTHAN REFINERY LIMITED B224-111-CC-PR-6006 / 2025 0
NEW DELHI
Sheet 3 of 5
File Name: D:\121\1212.pdf
Page 7 of 674
 LIST OF ATTACHMENTS
This drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied,

REVISION
SL. REV. REV. REV. REV.
DOCUMENT TITLE DOCUMENT NO.
No.
DATE DATE DATE DATE
INSTRUCTIONS TO VENDORS
1 INSTRUCTIONS TO BIDDERS B224-80-43-TR-6006 A 0
23/08/2019 19/10/2020
SCOPE OF WORK
2 SCOPE OF WORK & SUPPLY B224-80-43-SS-6006 A 0
23/08/2019 19/10/2020
JOB SPECIFICATION
exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1641-515 Rev.1 A4-210x297.

3 JOB SPEC. FOR SITE ASSEMBLY OF B224-80-43-SP-6006 A 0

MAIN FRACTIONATOR 23/08/2019 19/10/2020
4 JOB SPECIFICATION FOR SURFACE B224-000-79-41- 5
PREPARATION AND PROTECTIVE PLS-01 10/05/2019
COATING
LIST
5 LIST OF APPLICABLE B224-80-43-LL-6006 A 0
SPECIFICATIONS AND STANDARDS 23/08/2019 19/10/2020
VENDOR DATA REQUIREMENTS
6 VENDOR DATA REQUIREMENTS B224-111-80-43- A 0
VDR-6006 23/08/2019 19/10/2020
DATASHEET
7 MECHANICAL DATASHEET FOR MAIN B224-111-80-43-DS- A 0
FRACTIONATOR (111-C-2101) 3001 23/08/2019 19/10/2020
PROCESS
8 PROCESS DATASHEET FOR MAIN 076405C001-111- 0 2
FRACTIONATOR (111-C-2101) PDS-0500-2101 12/08/2019
STRUCTURAL
9 SCHEDULE OF QUANTITIES FOR B224-111-81-41- A B
0
LADDER & PLATFORM OF COLUMN SOQ-6006 11/06/2019
10 STRUCTURAL SCOPE OF WORKS FOR B224-111-81-41- A 0
B
LADDER & PLATFORM OF COLUMN SOW-6006 11/06/2019
11 VENDOR DATA REQUIREMENT OF B224-111-81-41- A 0
B
STRUCTURAL ITEMS VDR-6006 11/06/2019
12 VENDOR LIST FOR STRUCTURAL B224-111-81-41-LL- A 0
ITEMS 6006 11/06/2019
13 ANCHOR BOLT ASSEMBLY DETAIL B224-111-81-41- A 0
B
FOR MAIN FRACTIONATOR (111-C- 46901 22/08/2019
2101)
MISCELLANEOUS DOCUMENTS
14 GUIDELINES TO SUPPLIER FOR B224-109-86-41- 1
MOVEMENT OF CRITICAL ODC SCT-0001 18/08/2019
HMTD
15 VDR FOR COLUMN INTERNALS B224-111-2-42-VDR- A 0
B
0001 27/06/2019
16 ATTACHMENT TO VDR ATTACHMENT TO VDR -

17 JOB SPECIFICATION FOR GRID B224-111-80-43-SP- A 0

PACKING & ASSOCIATED INTERNALS 6006 23/08/2019 19/10/2020
18 LIST OF ATTACHMENT FOR COLUMN B224-111-80-43-LL- A 0
INTERNALS 6006 23/08/2019 19/10/2020

In case of any subsequent revision of MR or PR, only revised sheets of the

attachments listed above shall be issued alongwith the revision.

GENERAL NOTES:
Project: RAJASTHAN REFINERY PROJECT
REQUISITION NO. REV.
ENGINEERS INDIA LIMITED
Client: HPCL RAJASTHAN REFINERY LIMITED B224-111-CC-PR-6006 / 2025 0
NEW DELHI
Sheet 4 of 5
File Name: D:\121\1212.pdf
Page 8 of 674
 LIST OF ATTACHMENTS
This drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied,

REVISION
SL. REV. REV. REV. REV.
DOCUMENT TITLE DOCUMENT NO.
No.
DATE DATE DATE DATE

1. BIDDER TO INCLUDE COST OF SUPPLY AND FABRICATION OF ALL PLATFORMS INCLUDING

BRACKETS, SAFETY CHAINS, LADDERS, CAGE LADDERS, HOT DIPPED ELECTRO FORGED GALVANIZED
GRATING, HAND RAILING, PACKING PLATES AND OTHER STRUCTURAL WORKS RELATED TO PLATFORM
FOR ITEMS MENTIONED IN S.NO. 01.01 OF PR.

2. FOR SCOPE AND SCHEDULE OF QUANTITIES RELATED TO PLATFORM AND ITS COMPONENTS REFER
STRUCTURAL DOCUMENT (DOCUMENT NO. B224-111-81-41-SOQ-6006 & B224-111-81-41-SOW-6006).
exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1641-515 Rev.1 A4-210x297.

FOR LIST OF APPLICABLE ENGINEERING STANDARDS AND STANDARD SPECIFICATIONS FOR

STRUCTURAL WORK ALSO REFER B224-111-81-41-SOW-6006.

3. M/S TECHNIPFMC IS THE PROCESS LICENSOR FOR PFCCU UNIT. LICENSOR WILL REVIEW THE
FABRICATION DRAWINGS OF COLUMN AND ANY COMMENTS OR REQUIREMENTS STIPULATED BY
LICENSOR DURING THE DOCUMENT REVIEW SHALL BE BINDING ON THE VENDOR WITHOUT ANY EXTRA
COST AND DELIVERY IMPLICATIONS.

Project: RAJASTHAN REFINERY PROJECT

REQUISITION NO. REV.
ENGINEERS INDIA LIMITED
Client: HPCL RAJASTHAN REFINERY LIMITED B224-111-CC-PR-6006 / 2025 0
NEW DELHI
Sheet 5 of 5
File Name: D:\121\1212.pdf
Page 9 of 674
 LIST OF APPLICABLE DOCUMENT No.
SPECIFICATIONS & B224-80-43-LL-6006-2025
STANDARDS Rev. 0
Page 1 of 4

LIST OF APPLICABLE
SPECIFICATIONS & STANDARDS

0 19.10.2020 ISSUED FOR PURCHASE RKM PVSSN PVSSN

A 23.08.2019 ISSUED FOR BIDS AJ/ NNM RKM KJH

Rev. Prepared Checked
Date Purpose Approved by
No by by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 10 of 674
 LIST OF APPLICABLE DOCUMENT No.
SPECIFICATIONS & B224-80-43-LL-6006-2025
STANDARDS Rev. 0
Page 2 of 4

LIST OF APPLICABLE SPECIFICATIONS

[X] indicates applicability

Title Doc No. Shts. Rev

[X] General specification for pressure 6-12-0001 15 6
Vessels
[X] Supplementary specification for carbon 6-12-0002 7 8
steel vessels
[X] Supplementary specification for low 6-12-0003 7 5
alloy steel vessels
[] Supplementary specification for 6-12-0006 7 6
austenitic stainless steel vessels
[X] Supplementary specification for 6-12-0007 10 5
stainless steel clad vessels
[] Supplementary specification for 6-12-0008 7 5
3½ % Ni steel pressure vessels
[X] Standard specification for boiler quality 6-12-0011 7 8
carbon steel plates
[X] Standard specification for weldable 6-12-0014 5 6
structural quality steel plates for
storage tanks and vessels
[X] Standard specification for clad plates 6-12-0015 5 5
[] Standard specification for 6-12-0016 6 4
3½%Ni steel plates for pressure
vessels
[X] Standard specification for 1%Cr-½%Mo 6-12-0017 5 5
& 1½%Cr-½%Mo steel plates
[X] Standard specification for 2.25-Cr-1 6-12-0018 7 4
Mo steel plates
[X] Standard specification for stainless 6-12-0020 5 8
steel plates
[X] Material requirements for carbon steel 6-79-0013 6 2
components used in sour service in
petroleum refinery environments
[X] Packing, marking & shipping 6-14-0009 6 4
specification for trays and tower
internals
[] Standard specification for mechanical 6-26-0001 11 4
agitators
[ ] Standard specification for erection of 6-76-0001 22 4
equipment and machinery
[X] Specification for quality management 6-78-0001 7 1
system requirements from bidders
[X] Specification for documentation 6-78-0003 8+1 1
requirements from suppliers
[X] Standard Specification for Positive 6-81-0001 8 3
Material Identification (PMI) at Vendor’s
works

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 11 of 674
 LIST OF APPLICABLE DOCUMENT No.
SPECIFICATIONS & B224-80-43-LL-6006-2025
STANDARDS Rev. 0
Page 3 of 4

Title Doc No. Shts. Rev

[X] Inspection & Test Plan for Pressure 6-81-0011 7 3
Vessels/Columns CS
[X] Inspection & Test Plan for Pressure 6-81-0012 8 3
Vessels/Columns/Reactors LAS
[X] Inspection & Test Plan for SS Clad 6-81-0013 7 3
Pressure Vessels/Columns/Reactors
[] Inspection & test plan for wire mesh 6-81-0060 5 3
demisters
[X] Standard Specification For Health, 6-82-0001 102 8
Safety & Environment (HSE)
Management At Construction Sites
[X] Standard specification for positive 6-82-0002 9+1 4
material identification (PMI) at
construction sites
[X] Job Specification for Surface B224-000-79-41-PLS-01 47 5
Preparation & Protective Coating

LIST OF APPLICABLE STANDARDS

[X] indicates applicability
Title Doc No. Shts. Rev

[X] Vessel tolerances 7-12-0001 2 6

[] Support for horizontal vessel 7-12-0002 1 6
[] Wooden pillows for saddle support 7-12-0003 1 6
[X] Skirt base details 7-12-0004 1 7
[X] Skirt opening details 7-12-0005 2 6
[] Angle leg support 7-12-0006 2 6
[] Pipe leg support 7-12-0007 1 6
[] Bracket support for vertical vessel 7-12-0008 1 6
[] Manhole with hinged cover 7-12-0009 2 7
[X] Manhole with davit 7-12-0010 2 7
[X] Ladder rungs for manhole/ demister 7-12-0011 1 6
[] Retaining plate 7-12-0012 1 6
[X] Nozzle reinforcement and projection 7-12-0013 1 6
[] Pad nozzles for vessels 7-12-0014 1 6
[X] Standard bolt hole orientation 7-12-0015 1 6
[X] Alloy liner details 7-12-0016 2 6
[ ] Sight glasses for pressure vessels 7-12-0017 2 6
[ ] Internal flanges 7-12-0018 1 6
[] Vortex breakers 7-12-0019 1 6
[] Inlet deflector baffle 7-12-0020 1 6

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 12 of 674
 LIST OF APPLICABLE DOCUMENT No.
SPECIFICATIONS & B224-80-43-LL-6006-2025
STANDARDS Rev. 0
Page 4 of 4

Title Doc No. Shts. Rev

[ ] Support ring and bolting bar 7-12-0021 1 6

[X] Support ring sizes for packed towers 7-12-0022 1 6
internals
[X] Pipe davit 7-12-0023 3 7
[] Lifting lug top head type 7-12-0024 1 8
[X] Fire proofing and insulation supports 7-12-0025 2 6
[X] Earthing lug 7-12-0026 1 6
[X] Name plate 7-12-0027 1 6
[X] Manufacturer name plate 7-12-0028 1 6
[X] Bracket for name plate 7-12-0029 1 6
[] Name plate for small equipment 7-12-0030 1 5
[ ] Details of forged nozzles 7-12-0031 1 5
[X] Supports for internal feed pipe 7-12-0032 2 5
[] Hot insulation supports for horizontal 7-12-0033 1 5
vessel
[] Pipe davit support detail for cold 7-12-0034 1 5
insulated vessels
[] Typical details of wire mesh demister 7-12-0036 4 4
and its supports
[X] SR nozzle neck 7-12-0037 1 4
[ ] Piping Loads / Allowable nozzle loads 7-12-0038 4 1

LIST OF APPLICABLE LICENSOR SPECIFICATIONS

[X] indicates applicability

Title Doc No. Shts. Rev

[X] Project specification for Design of 076405C-111-JSS-0400-0001 8 0
pressure Vessels
[X] Project specification for carbon and 076405C-111-JSS-0400-0002 18 0
Alloy steel Pressure vessels for
PFCCU

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 13 of 674
 DOCUMENT No.
JOB SPEC. FOR SITE
ASSEMBLY OF MAIN B224-80-43-SP-6006-2025
FRACTIONATOR, M/s HRRL Rev 0
Page 1 of 6

JOB SPECIFICATION
FOR SITE ASSEMBLY OF MAIN
FRACTIONATOR COLUMN,
PFCC UNIT
OF
M/s HRRL

0 19.10.20 ISSUED FOR PURCHASE RKM PVSSN PVSSN

B 09.10.19 REVISED & REISSUED FOR BIDS AJ NNM KJH
A 23.08.19 ISSUED FOR BIDS AJ/NNM RKM KJH
Rev. Prepared Checked Approved
Date Purpose
No by by by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 14 of 674
 DOCUMENT No.
JOB SPEC. FOR SITE
ASSEMBLY OF MAIN B224-80-43-SP-6006-2025
FRACTIONATOR, M/s HRRL Rev 0
Page 2 of 6

1.0 GENERAL

This specification covers broad scope of work for assembly of Main Fractionator
Column (111-C-2101) of PFCC Unit of Rajasthan Refinery Project of M/s HRRL,
Barmer, Rajasthan, India. Vendor to also refer other specifications attached with the
requisition for complete scope of work and supply.

2.0 ASSEMBLY AND TRANSPORT PHILOSOPHY

a) Vendor to note that Main Fractionator Column (111-C-2101) shall be

transported to site in two sections i.e. one no. of site circumferential seam.
Vendor to strictly adhere to the number of site joints.

b) Vendor to note that any deviation against the number of sections shall make
the offer liable to rejection is not acceptable.

c) Assembly of main equipment shall be performed by Vendor themselves and shall

not be sub-contracted.

d) EIL/HRRL will allocate 25 m X 75 m area to the Vendor for site assembly

work of Column in green belt area & same is marked in Annexure-1 of this
spec.

e) Transportation of column sections from vendor shop to owner designated area

/fabrication yard, unloading the same on elevated saddles (by Vendor) at owner
designated area /fabrication yard is to be carried out by Vendor.

f) Vendor shall provide elevated unloading saddles to carry out all site assembly
work. These unloading saddles shall be different than transportation saddle.
Elevated unloading saddles shall not be taken back by Vendor. Vendor to quote
accordingly.

g) Crane (if required) for handling of column sections during assembly (performing
welding of C-seam) of column shall be in Vendor’s scope.

h) Route survey & selecting a suitable route and obtaining all necessary approval /
permission from statutory authorities concerned shall be in Vendor’s scope.
Tentative location of site joint is marked in MDS. However section length shall be
selected by Vendor based on his route survey report with prior intimation to M/s
EIL.

3.0 SITE SCOPE OF WORK AND SUPPLY

a) Vendor shall first fabricate, PWHT and carry out the Hydrotesting of entire
column in single piece at shop. Before transporting, the column shall be cut in
two sections (initially the whole column shall be fabricated at shop considering
some extra length to account for cutting in sections & re-welding at site).
Fabricator shall trial assemble the column sections after cutting the column into
sections at shop, match mark, provide alignment/ fitment cleats, spiders at open
end sections to maintain circularity, etc., before dispatch of column sections.

b) Assembly of column sections shall be carried out at owner designated area/

fabrication yard in all respects including alignment, fit-up, welding, all NDT,

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ASSEMBLY OF MAIN B224-80-43-SP-6006-2025
FRACTIONATOR, M/s HRRL Rev 0
Page 3 of 6

radiography/UT, local PWHT & local box hydro test of Column Section-1 &
Column Section-2 (tentative location of site joint is marked in MDS) in horizontal
condition on ground. Arrangement of manpower, machinery, Cranes, tools &
tackles including welding rectifies, consumables etc. is included in Vendor’s
scope. Vendor to quote accordingly.
Final location of site joint shall be finalized by Vendor in such a manner so that no
fouling with internal/ external attachment will happen. In addition to this the
location of site joint as well as lifting trunion/ tailing lug as suggested by Column
vendor shall be shared with EPC contractor who is responsible for erection of
complete column in single piece. Any modification proposed by EPC Contractor
as per their rigging analysis shall be incorporated by column vendor without any
time & price implication.

c) Installation of all internals at site in in-situ vertical condition is in scope of

Vendor.

d) Arrangement of man power, machinery, tools & tackles including welding

rectifies, consumables etc. required for installation of column internals is included
in vendor’s scope. Vendor to quote accordingly.

e) Strengthening/ compaction of ground (for assembly of sections etc) at owner

designated area /fabrication yard shall be carried out by Vendor and the same
shall be included in quoted price.

f) Vendor to note that round the clock permission will be made available. Execution
inside the refinery will be under permit system. All safety measures at site are in
Vendor’s scope.

g) Primer, intermediate & Finish paint as per painting specification shall be

applied by column fabricator after hydro test in horizontal position for the
site weld joint.

h) Pickling and passivation as per applicable specification shall be done by column

fabricator for the site weld joint.

i) MP/DP test of the cut edges of the column sections shall be carried out at site.
Fabricator to ensure cutting margins to achieve the final height of the completed
column.

j) Scaffolding/ platforms up to complete column height inside & outside (as

required) to carry out Installation of Internals, painting & assembly of
column sections, is in the scope of Column vendor.

k) Erection of pipe davit structure is in scope of Others.

3.1 Care shall be taken to remove temporary supports / spiders from column during
transportation of columns section.

3.2 While transportation and handling, column sections shall be supported properly with
adequate supports of proper design so that no damage occurs to any component.
Suitable steel saddles shall be designed and fabricated by Vendor for transportation.
These transportation saddles shall be taken back by the Vendor after unloading of
column sections on elevated saddles (supplied by Vendor).

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Page 4 of 6

3.3 Adequate handling equipment & lifting equipment of required capacities for handling
& assembly of column section and for installation of internals at site is in Vendor’s
scope.

3.4 All above works and any additional activities/ works required to be carried out
for completion of job shall be carried out by Vendor with single point
responsibility.

4.0 Compaction / strengthening, if required, at any location for storage, assembly etc.
shall be in Vendor's scope.

5.0 Fabricator to provide all suitable arrangement required for completion of site activity
i.e. circumferential seams, NDT, PWHT (if applicable), Local hydrotest, surface
preparation, application of primer/paint, pickling & passivation etc.

6.0 While making assembled sections, adequate care shall be taken by Vendor while
providing proper stiffener at open ends as well as in between the section so that no
buckling takes place. Fabricator shall erect stationary shed for all site activities. In
addition a temporary movable shed shall also be provided by fabricator to ensure
protection from wind and rain for all site activities like welding, stress relieving (if
required) etc. In addition, fabricator shall provide proper storage for all critical
equipments, machinery, tools & tackles, consumables etc.

7.0 Space for dark room for development and review of radiographs and heat treatment
facility shall be provided. Dark room facility will be approved by EIL/HRRL. Proper
storage arrangement for radiography films shall be provided.

8.0 Based on the schedule and quantum of site activities, fabricator shall provide all
resources such as welders, fitters, markers, supervisors, QA/QC personnel, NDT
personnel, NDT equipments, welding materials, temporary circumferential stiffeners,
saddles of adequate strength, tools & tackles, baking ovens/portable ovens for
electrodes, saw machines etc. required for carrying out in-situ (vertical position)
/horizontal circ welds, NDT, PWHT (if applicable) etc. All welding shall be carried out
by qualified welders with approved procedures. NDT personnel shall be qualified to
ASNT level-II. Qualified welding inspectors from approved body shall be employed.

9.0 Vendor shall keep the column/ column sections well ventilated and well illuminated
during all activities inside the column. For this purpose suitable exhaust, air purge
equipments and low voltage/ 12 V with step-down transformer connection shall be
provided.

10.0 It is vendor’s responsibility to remove all debris and clean the fabrication yard/owner
designated area once all activities are completed to the satisfaction of Engineer-in-
charge (EIC).

11.0 Document for complete sequence of assembly & layout including procedure for
installation & inspection of TSR/BB shall be submitted for review / approval of
inspection agency.

12.0 Records of ovality at the start of set up / after welding / after overlay to be maintained
for verification by inspection agency. All cones shall be checked for concentricity
before & after welding.

13.0 Lifting trunions and tailing lugs shall be provided on each of column section/sections.
Design of trunion and tailing lug along with stiffeners are in Vendor’s scope.

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14.0 Hydro-test water shall be discharged suitably as per instructions of EIC. Necessary
arrangement for the same shall also be arranged by Equipment fabricator.

15.0 Pumps for hydrostatic test shall be of adequate capacity so that filling and
pressurizing is possible. While draining water, adequate care shall be taken to avoid
any damage to the equipment. This shall be done as per instructions of the Engineer-
in-Charge.

16.0 All safety requirements of the plant as dictated by EIL/HRRL shall be adhered to by
Vendor. All necessary safety equipments required shall be arranged by Vendor.
Vendor shall provide dedicated safety engineer throughout the contract period. The
following health/safety / Environment points shall be taken care of by Vendor.

a) Helmets, fall arrestors, safety belts, goggles etc. for personnel safety of
people working on ground and at elevations.
b) Proper illumination and ventilation in and around the work area.
c) Welding fumes to be vented out and exhausted suitably.
d) Waste water after pickling & passivation and draining after testing shall be
disposed suitably.
e) Safety/work permits to be obtained, as and when required

17.0 For carrying out site welding/ NDT/ hydrotest/ installation of internals etc proper steel
tubular scaffolding/ temporary platforms, temporary ladders of good design shall be
provided by Vendor inside and outside of the columns. After completion of all
activities, all materials used for testing/ NDT etc shall be removed and all area shall
be cleared as per the instructions of the Engineer-in-Charge. Bamboo scaffoldings
and wooden platforms are not permitted.

Bamboo scaffolding may be used during Pickling & Passivation of site joint.

18.0 Supporting of scaffoldings/temporary platforms inside the clad column by welding the
same to the clad surface is not permitted. Vendor shall provide suitable non-welded
isolators for installation of the same.

19.0 Proper tools / tackles / cranes / measuring instruments duly calibrated shall be made
available at site for supervision / inspection.

20.0 Care shall be taken for protection of clad portion during handling of sections.

21.0 For site installation checking and review of internals refer doc. no. 6-14-0016
attached elsewhere in bid package.

22.0 After hydrotest, drying of the columns shall be carried out by blowing hot/ dry air.

23.0 Inside of columns (clad portions) shall be suitably protected from oxidation during
heat treatment (Normalising / PWHT).

24.0 SCOPE OF SUPPLY FOR POWER AND WATER

a. Construction Power: As per commercial Document attached with RFQ Doc..
b. Construction Water/Hydrotest Water: As per commercial Document attached with
RFQ Doc..

25.0 DOCUMENTS/ INFORMATION REQUIRED WITH OFFER

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a. Vendor shall submit complete procedure and schedule for all site activities
indicating all machinery requirements, resources in the offer.
b. Vendor to provide Suggestive Nozzle orientation for Main Fractionator Column
(111-C-2101) duly vetted by internal supplier of Main Fractionator column
internals along with BID.
c. Documents as mentioned in clause 2.1 of Document No. B224-111-80-43-SP-
6006 attached with MR.
d. Vendor shall submit list of Manhole for which increase in diameter is required for
removal of internals in line with job specification of internals.

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SCOPE OF SUPPLY B224-80-43-SS-6006-2025
Rev. 0
Page 1 of 7

SCOPE OF SUPPLY

0 19.10.20 ISSUED FOR PURCHASE RKM PVSSN PVSSN

A 23.08.19 ISSUED FOR BIDS AJ/NNM RKM KJH

Rev. Prepared Checked Approved
Date Purpose
No by by by

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SCOPE OF SUPPLY

[X] Indicates applicability

The following materials will be supplied by

1. Owner

1.1 Boiler quality/low-alloy/stainless/clad steel plate conforming to specification

NIL for

[] Shell

[] Dished head/intermediate head/cone

[] Sump and sump head

[] Skirt

[] Manhole neck, nozzle neck 300 NB and above in carbon steel and 125 NB and
above in stainless steel

[] Renforcement pad

[] Wrapper plate

[] Plate type flange

[] Internal piping

[] Tray support ring/bolting bar/seal pan welded to the vessel

[] Pad for external attachment (directly welded to shell)

[] Insulation support

[] Lifting lugs

[] Baffle

[] Demister support

1.2 [] Forged flange/matching blind flange

[] Pipe for nozzle neck

[] Pipe fitting

[] Gasket

1.3 [X] Foundation/anchor bolts

[] Platform and ladder

[X] Permanent instruments

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[] Demister with grid &bolting

[X] Fire proofing and insulation

[] Pump assembly with bolting

[] Agitator assembly with bolting

[] Tray/down comer/seal pan/chimney tray not welded to the vessel

[] Brick lining

[X] Refractory lining in Feed nozzles (1 A/B) of Main Fractionator (111-C-2101)

[] Spray nozzle/ Distributor Nozzles

[] Tower packing & associated internals including distributor, feed pipes, support
grid / plates, retaining grid / bed limiters

[] Light and sight glass assembly

[X] Thermowells

[] Feed device for feed nozzles

[X] Hard stand near foundation for erection

[X] Erection of Pipe davit structure

2. VENDOR

2.1 Boiler quality carbon/low alloy/stainless/Clad/monel steel plate conforming to

specification
SA-516 Gr.60 (NACE+HIC), SA-516 Gr.70, SA-387 Gr.11 Cl.2, (SA-387 Gr.22 Cl.2
(Impact tested) +SA-240 Gr. 304L CLAD), (SA-387 Gr.11 Cl.2 (Impact tested) +SA-240
Gr. 304L CLAD), SA-240 Gr. 304L, SA-240 Gr. 304H & SA-240 Gr. 316L as indicated in
Mechanical Datasheet for

[X] Shell

[X] Dished head/intermediate head/cone /Toricone.

[] Sump and sump head

[X] Skirt/ anchor chair assembly

[X] Manhole neck, nozzle neck 300 NB and above in carbon steel and 125 NB and
above in stainless steel & 200 NB and above in clad steel.

[X] Renforcement pad/ Insert Plate

[] Wrapper plate

[ ] Plate type flange.

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[X] Internal distributor supports

[X] Tray Support Ring/ Chimney tray support/ Packing support ring/Support Angles/
Inlet Weir/Bolting Bar/Seal Pan/ Tray Downcomer welded to the equipment.

[X] Tray/down comer/seal pan/chimney trays, Quench tray & associated internals as
required etc.

[X] Tower packing & associated internals including distributor, feed pipes, support
grid/ plates, retaining grid/ bed limiters and all internals as required.

[X] Pad for external attachments

[X] Fire proofing and insulation supports

[] Saddle support/bracket/leg support

[X] Lifting trunion/ Lugs / Tailing lug on column

[X] Internal baffles, vortex breaker, ladder rungs, coke trap

[] Demister support ring and beam

[X] Structural & Piping Clips

[X] Vacuum stiffening rings

[X] All welded internal support as required

[X] Anchor for refractory lining for feed nozzles (nozzle 1A & 1B).

[ ] Vapor Horn attached to Feed Nozzles

2.2 Structural steel section and plate conforming to IS: 226/IS: 2062 Gr.E250 Quality BR/ SA
53/ SA-283 Gr.C for

[] Shell

[] Skirt (Partly) /anchor chair assembly/base plate/saddle and bracket support

[] Internals

[] Insulation support/fire proofing support on skirt (IS-2062 portion)

[] Flat cover
[] Manway flange/cover

[X] Transportation & Elevated unloading saddle

[X] Tailing lug and Stiffening Block/Beam in skirt portion

[X] Structural and Piping Clips (Top CS portion of column)

[ ] Section for stiffeners

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[ ] Leg supports and base plate

[X] Structural support cleat for pipe davit

[X] Structural sections for platform, ladders, hand railing, Safety Chain, Grating etc
as defined in bid document.

2.3 [X] Forged flanges/ matching blind flange wherever shown

[X] Studs/bolts and nuts for manway/handholes/internal ANSI SORF flanges

/nozzles with blind flange/ companion flange/ shell flange, including jack bolts for
manways and shell flanges

[X] Gasket for manway/ internal flange/ companion flange/ shell flange/ nozzles
shown with blind flanges

[X] Welding consumables and gases

[ ] Demisters with grid and bolting

[] Wire Mesh

[] Agitator assembly with bolting

[] Pump assembly with bolting

[X] Seamless nozzle necks 250 NB & below in Carbon Steel, 100NB& below in
Stainless Steel & 150 NB & below for weld overlayed nozzle

[X] Internal piping, coupling and pipe fitting wherever indicated in datasheet or as
Designed/proposed by internal supplier

[X] Spray nozzle, if required/ proposed by internal supplier

[X] Internal packing as per recommendation of internal supplier

[X] Design (both hydraulic & mechanical) as required for Tower internals, supply &
installation of all column internals at site is in scope of the Vendor. For other
requirements related to tower internals refer job specification (doc. no. B224-111-
80-43-SP-6006-2025) attached elsewhere in PR.

[X] Davit/hinge assembly for manway / Shell Flange

[X] Pipe davit assembly for equipment

[X] Items covered in applicable EIL standards

[X] All other metallic and non-metallic parts, consumables and gases not covered
under 1 and 2 but required to complete fabricated equipments including
inspection, testing and supply of equipments as per this requisition

[X] LWN Nozzles

[X] Design & supply of Nozzle Flanges for nozzle mark “1A”, “1B” & “2”.

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[X] Design & supply of Companion flange for O.H. Vapor nozzles (nozzle mark “2”).

[X] Spool piece, gasket, bolting, Temporary Dished End, Weld Edge Preparation
etc. for nozzle mark “2” as per Mechanical datasheet.

[X] Design and supply of tailing lug, lifting Lug/ trunion for column sections as well as
complete column. Also any bracing arrangement required to reinforce base block
shall also be designed &supplied by Vendor.

[X] Supply of self reinforced nozzles

[X] All scaffolding /temporary assembly platforms required for Assembly of column
sections, painting & installation of internals

[X] Site welding of C-seam, local PWHT and local box type Hydro-testing of the
same is in scope of Vendor (refer doc. no. B224-80-43-SP-6006 in this regard
attached elsewhere in bid document).

[X] All machinery/tools & tackles/ lifting equipment/ labors required for loading/
unloading, assembly, heat treatment & testing of column at site in horizontal
condition and for installation of column internals in as erected (vertical) condition.

[X] Template for foundation.

[X] Treatment facilities/ Chemicals required for treating the water to meet the
specification requirements for hydrotest water.

[X] Compaction/ strengthening of fabrication yard/ owner designated area,

road/temporary approaches etc. on and around fabrication yard/ owner
designated area.

[] Supply of all material for non-shrink grouting.

[X] Pump and other equipment required for hydrotesting.

[X] Design and supply of all temporary circumferential stiffeners.

[X] Structural frame work for monorail/ pipe davit mounting for Main fractionator
Column.

[X] Supply & application of all primer & finish paint as per painting specification
attached with PR.

[X] Supply of all materials, fabrication of all equipment platforms, ladders,

cage ladders, hand railing, hot dip electroforged galvanized grating and
other structural works as per schedule of quantities (Document No. B224-
111-81-41-SOQ-6006) attached with PR & Scope of Work Document No.
B224-111-81-41-SOW-6006. Transportation &Loading/Unloading of loose
supplied platforms, ladders, cage ladders, hand railing, hot dip
electroforged galvanized grating and other structural works at site is in the
scope of Vendor.

[X] Supply of Anchor Bolts as per sketch attached with PR.

[X] Rain shield of 75 mm width X 6 mm thickness below 50 mm from head & skirt joint

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2.4 Spares Parts for Column & Column Internals:

[X] Spares –10% of fasteners (min 2 nos. in each size) and two sets of gaskets for
each nozzle shown with blind/companion flange, Internal Plate Flanges etc.
(Joint having spacer-blind shall be provided with 4 sets of gaskets as spare)

[] Spares (for demister) - 10% (min. 4 nos.of each size/type) extra fasteners (bolts,
nuts, clamps, spacers etc.) as required for holding the demister.

[X] For Spares requirements of Trays & Tower Internals refer document no. B224-
111-80-43-SP-6006-2025 attached elsewhere in PR document.

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 DOCUMENT No.
INSTRUCTIONS TO VENDOR B224-80-43-TR-6006-2025
Rev. 0
Page 1 of 11

INSTRUCTIONS TO VENDOR

0 19.10.20 ISSUED FOR PURCHASE RKM PVSSN PVSSN

B 20.09.19 REVISED & REISSUED FOR BIDS AJ/NNM RKM KJH

A 23.08.19 ISSUED FOR BIDS AJ/NNM RKM KJH

Rev. Prepared Checked Approved
Date Purpose
No by by by

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INSTRUCTIONS TO VENDOR

(A) Bidding Instructions (Category-II PR)

1. This bid is intended for “ZERO DEVIATION BIDDING”. Vendor after studying the
contents of this requisition may decide to obtain clarifications before submitting the
offer. Vendor to attend Pre-Bid meetings and obtain all clarifications required. All the
Vendor queries shall be discussed & reverted in pre-bid meeting only.

2. Any ambiguity shall be discussed at the pre-bid stage only and once having done so,
the offer shall be in strict compliance to the requirements as specified in RFQ.

3. Vendor to note that bid evaluation may be carried out without any post-bid
correspondence. In view of the same Vendor in his own interest is advised not to
submit any deviation/clarification.

4. If the bid does not include complete scope in compliance with the requirement, the
offer shall be liable for rejection.

5. Record notes of Pre-bid meeting/reply to pre-bid queries shall be considered as part

of RFQ.

6. Vendor to furnish duly signed and stamped letter as per Annexure-1 for “Format of
Letter of Waiver”.

7. Vendor shall submit documents along with bid as per clause no 25.0 of document no
B224-80-43-SP-6006, and as per cl. no. 2.1 of doc. no. B224-111-80-43-SP-6006 &
VDR doc. no. B224-111-2-42-VDR-0001 attached with PR.

(B) It is understood that

1. The quoted price includes for the “HOLDS” details of which are indicated on the
Engineering Drawing/ existing drawings.

2. The weights indicated on Engineering Drawings/ existing drawings do not form the
basis for offer, since these are approximations only.

3. Spares included in cl. 2.4 of doc. B224-80-43-SS-6006-2025 & Cl. No. 3.0 of Doc. No.
B224-111-80-43-SP-6006-2025 have been included in the base price.

4. Fabricator to note that quoted price shall include the following weight for external
piping and structural cleats. Any decrease/ increase in weights shall be recovered/
paid as per Unit Rates of Addition and Deletion. Refer Commercial Document
attached with RFQ Document for details.

IS 2062 Gr. E250

Item no SA 516 Gr.60 SA387 Gr.22 Cl.2 SA387 Gr.11 Cl.2
Quality BR
111-C-
3000 KG 3000 KG 2000 KG 3000 KG
2101

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5. Fabricator to note that quoted price shall include following weights for Pipe Davit
Structure. Any decrease/ increase in weights shall be recovered/ paid as per Unit
Rates of Addition and Deletion. Refer Commercial Document attached with RFQ
Document for details.

ITEM NO. SA 516 GR-60 IS 2062 Gr.E250 Quality BR

111-C-2101 200 KG 2500 KG

6. Vendor to note that quoted price shall include the weights of Structural platforms,
ladders, grating, hand rail etc. as per doc. no. B224-111-81-41-SOQ-6006 and B224-
111-81-41-SOW-6006 attached elsewhere in bid package.

7. The quoted price shall include stiffeners; insert plates, basering/top ring of adequate
thickness required as per requirement of design calculation for lifting and tailing
forces. No price implication shall be paid on this account.

(C) Transportation of equipment shall be governed by commercial conditions. However

the following shall be strictly complied with:

1. Equipment shall be transported in two pieces. Transportation, unloading & handling of

all equipment section + loose supplies from Vendor’s workshop to owner designated
area/ fabrication yard is in Vendor’s scope.

2. It is the sole responsibility of Vendor to adhere to the rules of all statutory authorities
enforced from time to time in the transportation sector during movement at their risk &
cost.

3. Vendor shall carry out route survey on his own and shall finalize transportation
philosophy/ scheme and section length accordingly.

4. Vendor to also refer doc. no. B224-109-86-41-SCT-0001 in this regard attached with
PR.

Technical Instructions

1. The shape of dished end/ toricone, profile of conical reducer, knuckle radius, cone angle
and overall height shall be as per engineering drawing. Minimum thickness of shell, cone
and dished end shall be achieved taking into account thinning and scaling etc.
All cones shall be checked for concentricity before & after welding.

2. Dished ends and hot formed pressure parts shall have 10% or 2mm (whichever is
higher) allowance for scaling and thinning, in order to achieve minimum thickness
specified on the drawing.

3. a. Wherever hot forming and subsequent heat treatment is involved, adopted

procedure shall not impair the mechanical properties of the material beyond the
limits specified in respective material specification.

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b. For low temperature equipment and hot formed parts, number of production
coupons and the tests thereon shall be as per requisition.

4. Post weld heat treatment and all non destructive testing like radiography, ultrasonic
testing, magnetic particle/dye penetrant examinationetc. shall be conducted as per
requisition.

5. Workmanship and materials, in Vendor's scope of supply, shall be guaranteed.

6. Pickling and passivation of internal/external surfaces of stainless steel/ monel clad and
internal / external surface of SS / Monel internals shall be carried out as per ASTM A-
380.

7. For IBR vessels complete design of equipment as per IBR, approval of drawings,
documents, stagewise inspection and final certification of the equipment by Inspectorate
of Boilers shall be included in Vendor’s scope.

8. For items which are to approved by PESO,Nagpur ,approval of drawings, documents,

stagewise inspection and final certification of the equipment by PESOshall be included in
Vendors scope and getting approval from PESO shall be sole responsibility of Vendor.

9. The main equipment shall not be subcontracted, however the bought out items/
components can be sub-ordered or sub-contracted to EIL approved vendors/sub-
contractors only.

10. Fabricator to supply template for checking the orientation of anchor bolts on foundation
and to ensure matching of base plate that is drilled in advance. The schedule of supply
of template at site shall be 12-16 weeks from LOI.

11. Gaskets used for hydrotesting of equipment shall be of the same specification as service
gaskets and the fabricator shall supply new gaskets for manholes and nozzles with blind
/companion flanges apart from spares. Gaskets used for hydrotest shall not be used for
actual hook up.

Torispherical / 2:1 Ellipsoidal dished ends shall be designed and supplied to nozzle
connections provided with spool piece as per MDS for the purpose of hydrotest. After
hydrotesting, the dished ends shall be cut and removed and weld edges of spool piece
for Nozzle mark “2” i.e. O.H. Vapor” shall be prepared & supplied as per MDS.

12. Fabricator shall exercise utmost care during loading/unloading of equipment segments
so that no damage to any part of the equipment occurs. Suitable type and nos. of
supports shall be provided for supporting the equipment.

13. Fabricator shall also design and provide suitable stiffening arrangement viz. spider beam
etc. at the base anchor chair location & column sections so that deformation/buckling of
base and bottom zone of shells does not occur at the time of lifting while the column/
column sections are being erected.

14. Fabricator shall design and provide lifting trunions & tailing lugs for handling of column
sections and erection of complete Equipment as a whole. Tailing lugs, when provided
shall be designed to limit the skirt Base block stresses to 0.9 Fy any case. An impact
factor of 2.0 shall be considered for design of lifting trunion & tailing lug. Necessary

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stiffening inside Base block shall be provided to ensure the same. For additional design
requirements refer drawing/ PR. Lifting trunion/ tailing lug shall be located such that
there shall be no fouling of lifting wire sling with external attachments during erection.
Top trunion/ lug and bottom most tailing lug shall be designed by Vendor for erection of
complete Equipment. Lifting lug/ trunion shall be located at 90° to the tailing lug location.
Details mentioned in MDS are minimum to be followed by Vendor.

15. Erection weight given in equipment data sheet is approximate. Vendor shall
calculate the actual equipment weight and furnish calculation. Erection weight
furnished in vendor drawing shall be based on fabricator’s calculation.
Calculation of Centre of Gravity (C.G.) of the equipment shall also be done by
vendor and marked on the equipment & in the fabrication GA drawing.

16. Column fabricator has to supply & install all column internals (Such as Chimney
Trays, Quench tray, Distributors, Support grids, Support Beams, Bed limited/Hold
Down plate, packing etc.) Bolted or welded to equipment. Vendor shall design
(both hydraulic & mechanical) Internal of column as required. For further details of
regarding column internals refer document no B224-111-80-43-SP-6006-2025
attached elsewhere in PR.

17. Unless otherwise specified in MDS, for stainless steel internals min thk shall be
6mm. for SS internal distributors\ internal pipes, min thk shall be 6 mm for size
upto 200 NB and 10 mm for size 250 NB and above. Minimum element thk &
support thk for SS distributors/ internal pipes shall be 10 mm and for CS
distributors\ internal pipes shall be 6 mm+2*Corrosion allowance.

18. Vendor shall design & supply Nozzle flanges for nozzles 1A, 1B and Nozzle flange
with companion flange for nozzles 2 of Main Fractionator column. Below
mentioned are the preliminary nozzle loads to be considered while designing
these flanges. Detail of these flanges as shown in MDS is the minimum to be
followed. If required by analysis higher thickness of flanges shall be provided
without time and price implication.
UNIT T UNIT T-m
NOZZLE MARK AND LOAD CASE
FX FY FZ MX MY MZ
DESIGN 4 -23 6 -46 37 200
OPERATING + WIND X 11 -23 6 -51 7 187
OPERATING + WIND X -5 -20 5 -42 59 178
OPERATING + WIND X 4 -21 11 -44 60 176
Nozzle 1A
OPERATING + WIND X 9 -22 3 -45 -4 183
ONLY SEIS 1 ± 17 5 5 17 54 21
ONLY SEIS 2 ± 7 9 3 17 25 58
ONLY SEIS 3 ± 15 6 9 15 63 22
DESIGN 4 -23 -6 46 -37 200
OPERATING + WIND X 11 -23 -6 51 -7 187
OPERATING + WIND X -5 -20 -5 42 -59 178
Nozzle 1B OPERATING + WIND X 4 -20 -2 38 -8 171
OPERATING + WIND X 9 -22 -8 51 -23 185
ONLY SEIS 1 ± 17 5 4 17 55 18
ONLY SEIS 2 ± 7 9 3 15 24 48

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ONLY SEIS 3 ± 13 6 8 13 53 18
1. Global direction +X towards South, +Z towards west, +Y Vertical Up
Direction.
2. Loads are in Global Directions.
Notes for 3. Loads are at Nozzle-Shell Intersections
above 4. Loads marked as SEIS are for only Seismic Loading, Exclude any other
mentioned Loading.
Loads: 5. SEIS 1 for X governing, 2 for Y & 3 for Z.
Nozzle 2 DESIGN 33 35 33 120 190 110
Notes for
above
mentioned
Loads: Refer Load Directions as mentioned in Doc. No. 7-12-0038 attached with PR.

Actual Piping loads shall be intimated to Vendor in due course of time± & the flange
design shall be checked/verified based on the same. Necessary up-gradation shall be
carried out, if required.

19. Number of temporary attachments/cleats, lifting lug/trunion used for site assembly
should be kept minimum. Temporary attachments/ cleats shall be removed by fabricator
after complete execution of work leaving 12mm from the shell & grinding of all cut edge
burrs.

20. All vertical equipments supported on Skirt, Pipe Leg or Angle Leg shall be provided with
fire proofing (50 mm thickness). For skirt supported equipments, 50 mm thick fire
proofing shall be provided both inside and outside surface of skirt. Fire proofing shall be
performed by others, Vendor to provide fire proofing nuts accordingly.

21. Unless otherwise specified, all Internals shall be removable through Manway.
Suitable nos. of Internal ANSI SORF Flanges (to be decided by Vendor) shall be
provided on Distributors, Feed pipe etc such that the same is removable through
nearest Manway. Necessary Manway check from removability point of view shall
be carried out by Vendor. If there is any requirement of increase in manhole no./
diameter, the same shall be highlighted and also submitted along with the offer.

22. Unless otherwise specified, all distributors shall be provided with minimum one vent &
drain hole suitably.

23. Vendor should provide match marking/proper identification for the entire Ladder
and platform materials supplied loose with the equipments. Platforms materials
for each elevation shall be packed in individual Boxes for supply to site. For
tentative quantity & Scope of work/Supply of Structure parts (Ladder & Platforms)
refer Document no B224-111-81-41-SOQ-6006 & B224-111-81-41-SOW-6006
attached with PR.

24. For marine transportation, the following shall be taken care / provided by vendor:

After completion of all testing and inspection, the inside of complete equipment shall be
thoroughly drained and dried out. Equipment shall be completely dried by passing hot air
for sufficient time until no further increase in relative humidity of outgoing air is observed.
After drying, the equipment shall be purged and filled with dry N2 at 0.25 kg/cm 2. The

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equipment shall be provided with pressure gauge to monitor N2 pressure and ½” non-
return valve. For column / vessel sections to be transported via sea routes, temporary
adequate closure (design & arrangement by vendor) shall be provided at open end
(which shall be cut & removed at site before assembly) so that dry N 2 at 0.25 kg/cm2
pressure is maintained inside. All threaded holes other than tell tale holes for testing
shall be suitably protected with steel bar plugs. All nozzles not provided with blind flange
shall be provided with steel covers, temporary gaskets and bolts. All external surfaces
shall be properly protected / covered against sea environments.

25. Vendor shall design & provide the followings:

- Transportation saddles for all sections
- Elevated saddles for carrying out site assembly work of column sections
Vendor can take back the transportation saddles after unloading & has to leave elevated
saddles for client. Vendor to quote accordingly.

General Instructions

6. All materials including those used for internals shall be procured with stage-wise
inspection. Stagewise and final inspection of equipments and its components shall be
carried out as follows:

(i) Stagewise & final inspection of the equipment at vendor shop and/or fabrication
yard including inspection of all components and internals shall be carried out by
Third Party Inspection Agency (TPIA). Charges for TPIA shall be included in quoted
prices. Additionally, if felt necessary,EIL inspection is envisaged over and above
TPI at critical stages and final inspection to maintain overall quality of the work
being carried out. Cost of EIL inspection is not to be included in quoted price.

(ii) For acceptable third party inspection agencies (TPIA), refer commercial documents.

7. Raw material procurement may proceed prior to approval of vendor drawings on the
basis of Purchase Requisition. However for plates& nozzles where there is no Hold in
size, thickness, etc, material procurement shall be initiated by successful vendor based
on PR drawings immediately after placement of order.

8. Shell rolling/ welding and dished - head fabrication shall commence without awaiting
fabrication drawing approval. Inspection shall be carried out in accordance with
Purchase Requisition documents till approved fabrication drawings are available.

9. Material for shell, dished ends and skirt shall be considered as major raw material
wherever identification of major raw material is one of the payment milestones.

10. Purchase requisition shall be issued within two weeks of Fax of intent (FOI). Following
details / drawings shall be furnished to the Vendor as per mutually agreed time frame
during kick-off meeting.

a. Nozzle Sizes / Elevations and Nozzle Orientation

b. Piping Cleat
c. Structural Cleat & ladder/Platform drawing for each column.
d. Pipe Davit Structure Cleat Detail welded with equipment.

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11. Minimum course width shall be 1 metre. Maximum no. of longitudinal seams shall be as
follows:
( a) vessels upto 2 metre diameter : 1 seam
( b) vessels from 2 metre upto 4 metre dia. : 2 seam
( c) vessels from 4 metre upto 6 metre dia. : 3 seam
( d) vessels from 6 metre upto 8 metre dia. : 4 seam
( e) vessels from 8 metre upto 12 metre dia. : 5 seam
In any case, distance between two longitudinal seams shall not be less than 3 meter.

12. If any discrepancy is found during design and fabrication stages, the fabricator shall
inform EIL immediately and shall obtain necessary clarification/approval before
proceeding with that portion of the job any further.
EIL's review of fabricator's drawings and documents must not be considered as a check
and shall not relieve the fabricator of his responsibilities to supply equipment as per
requisition. Fabricator shall remain responsible for conflicts between his
drawings/documents and EIL drawings/documents.

13. English language and metric units shall be used in all documents. Drawings shall be
prepared in prescribed sizes as standardized by bureau of Indian standards (BIS) and
shall be preferably in the sizes such as 210 x 297, 297 x 420, 420 x 597, 597 x 841, 841
x 1189 mm.

14. All fabricator's drawings submitted to EIL shall be based on purchase requisition and
shall bear reference number and revision of the corresponding EIL drawings. In addition,
it shall indicate item number, client's name, project name, fabricator's name, purchase
order number, purchase requisition number, drawing number, revision number etc. all in
the lower right hand corner. All revisions shall be clearly marked by encircling with
revision marks.

15. Submission of required drawings/documents shall be the responsibility of fabricator. In

the event of fabricator's failure to meet this requirement, the supply of equipment shall
be considered as incomplete.

16. Vendor shall submit a list of those drawings, which are to be submitted for review
to EIL along with the submission dates for each drawing within 15 days of
placement of FOI. Vendor shall strictly adhere to this drawing submission
schedule. Updated vendor drawing / document submission schedule shall be
forwarded along with each submission. This shall be submitted in soft copy also.

17. All drawings shall be thoroughly checked and duly signed by fabricator. Unchecked
drawings and drawings without revisions clearly marked shall be returned without review.
Successive review of the same fabricator's drawing shall apply only to EIL's latest data
sheet/comments on the previous revision. Drawings and documents returned to
fabricator for revision shall be resubmitted preferably within ten days of receipt.

18. Dimensions of all flanges shall be as per ANSI B16.5 for nozzle sizes 24"NB and below
and as per ANSI B16.47 Series B for sizes greater than 24"NB unless otherwise stated.

19. Fabrication drawings shall be submitted in following stages:

Stage-I
- General arrangement drawing indicating design data, fabricated equipment's
weight, general notes, nozzle schedule, detail of shell, heads, skirt/supporting

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arrangement, main weld seams, nozzle orientation plan, cutting layout (in case of
free issue material) etc.

- Detail of all nozzles, manholes, accessories etc.

- Bill of material for each item showing part size, quantity, material specification,
scope of supply and weight etc.
Stage-II

- Detail of tray and associated internals, packing etc.

- Detail of internal attachments such as tray support ring / bolting bar, support beam,
inlet weir and bolting bar, support for packed beds, distributor, spray header,
chimney trays etc.

- Detail of internal distributor, demister support and packing support, etc.

- Detail of external clips for ladder, platform, pipe support, insulation, fire proofing,
pipe davit, lifting trunion, tailing lugs, lifting lugs etc.

- Shell development drawing incorporating all attachments and weld seams,

highlighting all the fouling along with suggestions for resolution.

- Bill of material for each item showing part size, quantity, material specification,
scope of supply and weight etc.

- In case of owner's free issue plate material, fabricator shall submit plate cutting
diagram for EIL's approval.

20. After receipt of order, fabricator shall submit to EIL, the planning of fabrication which
shall indicate the details and scheduled date of:

- Sub orders.

- Purchase of materials such as plates, pipes, forged flanges, bolting, gaskets, etc.

- Start of fabrication of dished ends and shell, welding of shell and heads.

- Welding of nozzles and external attachments such as cleats etc.

- Phased program of assembly of equipment, testing and dispatch to site.

This planning shall be established to extend from purchasing of equipment components

to the end of fabrication and delivery of equipment.

21. All drawings shall be drawn in AUTOCAD R-14 or above. No hand drawn drawings shall
be accepted. All residual calculations shall be computerized.

22. Documents and letters shall be furnished in electronic format. The software used shall
be as follows.

a) MS OFFICE 2000 or above

b) ADOBE ACROBAT 5.0 & ABOVE

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23. In case of owner's free issue plate material, fabricator shall tabulate each plate detail as
per following table:

Plate No./ Material Size of Plate Equipment Ref. Dwg. Part

Plate mark Specification Thk x Width x Length Number No. number and
(mm) x (M) x (M) qty.

Size of Plate Heat/ Plate Weight Used plate Burnout

Thk x Width x Length sample (Kgs.) weight (Kgs.) losses
(mm) x (M) x (M) number (Kgs.)

Returnable offcut Returnable offcut Non returnable scrap Remarks

size with sketch weight (Kgs.) weight (Kgs.)

Fabricator shall be allowed 2% burnout losses against the material consumed in case of
pressure vessels and 1% in case of storage tanks and spheres unless otherwise specified. In
general purchase conditions.all offcuts of width 800mm and perimeter 2400mm in carbon
steel materials and 150mm width and perimeter 1500mm in stainless steel materials shall be
returned to owner, unless otherwise specified. Returnable offcuts shall have original plate
markings transferred and duly stamped by inspector. All other non returnable scrap shall be
sold by fabricator on the basis of owner's instructions and approval.

24. Words “fabricator”, “vendor”, “contractor” appearing anywhere in the PR/Specifications/

Standards etc. shall be read as “Vendor”.

25. Vendor to note that interference of nozzles with circumferential seams is not acceptable.
Vendor to take suitable care to avoid fouling of external/internal attachments with shell
seams. Vendor to submit shell development for information.

26. Vendor shall note that the vendor drawing for the following standard components (as
applicable) shall not be reviewed by EIL. It shall be solely vendor's responsibility to
ensure the correctness of these drawings as per EIL Standards and Drawings. If any
discrepancy/ mistake are found at a later date the vendor shall rectify the same at his
time and cost.

- Manhole davit/ hinge arrangement & Ladder rungs

- Pipe Davit
- EIL Name plate, Manufacturer's Nameplate, Nameplate bracket
- Skirt (Pipe) opening details, Access Opening Details, Skirt vent.
- Lifting lugs (Standard Type)
- Fireproofing and Insulation Support
- Earthing lug
- Pipe support cleats and ladder and platform cleats (Fouling of external support
cleats (if any), shall be highlighted to EIL along with shell development drawing
and suggestion for resolution)

However all these above listed drawing shall be submitted in a separate drawing for
information to EIL ensuring adherence to all the respective EIL Standards and Drawings.
Clarifications (if any) shall be obtained by Vendor from EIL before fabrication.

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27. Standard Inspection and test plans are attached with requisition for guidance. Vendor
shall submit inspection test plans for the approval of visiting inspection engineer.
Inspection shall take care of all the requirements of specifications. Inspection engineer
has the authority to modify the plan depending on the criticality of the item.

28. Submission of drawings/documents shall be as per doc. no. B224-111-80-43-VDR-

6006, B224-111-81-41-VDR-6006 & B224-111-2-42-VDR-0001 attached with PR.

29. In the event of conflict, most stringent requirement in following order of

precedence shall govern:

a) EIL Mechanical Data Sheet

b) Licensor PDS
c) Licensor Specifications
d) EIL specifications and standards
e) Codes

However in event of conflict it shall be the duty of the Vendor to bring it to EIL’s
attention for resolution and resolve it before proceeding with the manufacture.
EIL’s comments shall be final and binding on vendor without any cost and
delivery implications.

30. Cl. No. 3.10 of M/s EIL Spec. shall be read as following:
“ Following additional tests shall be applicable”.

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 VENDOR DATA REQUIREMENTS Document No.
B224-111-80-43-VDR-6006
FOR Rev. 0
MAIN FRACTIONATOR + COLUMN
INTERNALS Page 1 of 5

VENDOR DATA REQUIREMENTS

FOR
MAIN FRACTIONATOR + COLUMN INTERNALS

0 19-OCT-2020 Issued for Purchase RKM PVSSN PVSSN

A 23-AUG-2019 ISSUED FOR BIDS NNM RKM KJH
Rev. Date Purpose Prepared by Checked by Approved by
No.

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 VENDOR DATA REQUIREMENTS Document No.
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FOR Rev. 0
MAIN FRACTIONATOR + COLUMN
INTERNALS Page 2 of 5

VENDOR DATA REQUIREMENTS

The following drawings/documents marked " " shall be furnished by the bidder.

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. GENERAL ARRANGEMENT DRAWING
INDICATING DESIGN DATA FABRICATED
EQUIPMENT WEIGHT, GENERAL NOTES, 3 - 5 WEEKS AFTER
NOZZLE SCHEDULE, DETAIL OF SHELL, THE RECEIPT OF
HEADS, SUPPORTING ARRANGEMENT, FOI.
MAIN WELD SEAMS, NOZZLE ORIENTATION
PLAN.
2. DETAIL OF NOZZLES, MANHOLES, 3 - 5 WEEKS AFTER
THE RECEIPT OF
ACCESSORIES ETC FOI.
3. DETAIL OF INTERNALS SUCH AS TRAY 8 - 10 WEEKS AFTER
SUPPORT RING, SUPPORT RING FOR BED THE RECEIPT OF
ETC. FOI.

4. DETAIL OF INTERNAL DISTRIBUTOR,

8 - 10 WEEKS AFTER
REDISTRIBUTORS, PACKING BED THE RECEIPT OF
SUPPORT , SUPPROTING BEAMS, CLEATS FOI.
ETC..
5. DETAIL OF EXTERNAL CLIPS FOR LADDER,
10 - 12 WEEKS
PLATFORM, PIPE SUPPORTS, INSULATION AFTER THE RECEIPT
CLEATS, FIRE PROOFING CLEATS, PIPE OF FOI.
DAVIT ETC.
6. CALCULATION & DETAIL FOR LIFTING LUG / 3 - 5 WEEKS AFTER
THE RECEIPT OF
TRUNION AND TAILING LUG ETC. FOI.
7. SHELL DEVELOPMENT DRAWINGS 3 - 5 WEEKS AFTER
INCORPORATING ALL ATTACHMENTS AND THE RECEIPT OF
WELD SEAMS FOI.

8. BILL OF MATERIAL FOR EACH ITEM

SHOWING PART SIZE, WITH EACH DWG.
QUANTITY,MATERIAL SPECIFICATION,
SCOPE OF SUPPLY AND WEIGHT ETC.
9. DETAILS OF ANCHOR BOLTS AND 3 - 5 WEEKS AFTER
THE RECEIPT OF
TEMPLATE FOR FOUNDATION FOI.
10. MATERIAL TEST CERTIFICATES @ ONE WEEK AFTER
FINAL INSPECTION
11. WELDING PROCEDURES AND 5 - 8 WEEKS AFTER
THE RECEIPT OF
QUALIFICATION TEST REPORTS @ FOI.
12. DESTRUCTIVE AND NON-DESTRUCTIVE 5 - 8 WEEKS AFTER
THE RECEIPT OF
TEST REPORTS @ FOI.
13. RADIOGRAPHIC EXAMINATION REPORTS VENDOR TO STORE
WITH FILMS @ THESEFOR 5 YEARS

14. HEAT TREATMENT PROCEDURE AND TIME ONE WEEK AFTER

TEMPERATURE CHARTS @ FINAL INSPECTION

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 VENDOR DATA REQUIREMENTS Document No.
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FOR Rev. 0
MAIN FRACTIONATOR + COLUMN
INTERNALS Page 3 of 5

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
15. CODE CERTIFICATES (INCLUDING
INSPECTION CERTIFICATE, HYDROSTATIC ONE WEEK AFTER
TEST CERTIFICATE, LOCAL CODE FINAL INSPECTION
REQUIREMENTS, NAME PLATE ETC.) @
16. FABRICATION ASSEMBLY DETAILS @ 10-12 WEEKS AFTER
RECEIPT OF FOI
17. HYDROTEST PROCEDURE 10-12 WEEKS AFTER
RECEIPT OF FOI
18. ERECTION DRAWINGS (INCLUDING 10-12 WEEKS AFTER
WEIGHTS, CENTRE OF GRAVITY AND RECEIPT OF FOI
SLINGING FACILITIES ETC.)
19. CERTIFIED 'AS BUILT' DRAWINGS
TWO WEEKS AFTER
INCORPORATING ACTUAL DIMENSIONS DESPATCH OF
AND MATERIAL USED, DULY CERTIFIED BY EQPT.
THE INSPECTOR @
20. DATA FOLDER AS PER SPECIFICATION @ TWO WEEKS AFTER
DESPATCH OF
EQPT.
21. INSPECTION AND TESTING PLAN @ ONE WEEK AFTER
FINAL INSPECTION
22. PACKING AND FORWARDING ONE WEEK AFTER
INSTRUCTIONS @ FINAL INSPECTION

23. Transportation Scheme 10-12 WEEKS AFTER

RECEIPT OF FOI
24. List of Mandatory spares
25. Design Calculation & Detail of Nozzle Flanges 8 - 10 WEEKS AFTER
for Nozzle mark 1A, 1B & 2 and Companion THE RECEIPT OF
Flange for Nozzle mark 2. FOI.

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. Technical Information for Tower Packing
(Annexure-I of Job Specification)
2. Filled in Datasheet Annexure II of 6-14-
0015
3. Hydraulic Design Calculations/ Computer
Outputs (Structured/Grid Packing)
4. Itemized Price List for two years operation &
Maintenance Spares.
5. Mechanical design calculations
6. Support Rings, Support Cleats and Bolting Bar
Drawings for packed beds, Trays etc
7. General Arrangement Drawings & Details
Fabrication Drawings for Support grids, Hold
down grid, Distributors, Redistributors, internal
supports etc.
8. Bill of Material
9. Material Test Certificates @
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FOR Rev. 0
MAIN FRACTIONATOR + COLUMN
INTERNALS Page 4 of 5

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
10. Inspection Records / Data (including WPS/
PQR) @
11. Site Installation Procedure/Check Lists
12. List of Spares
13. Assembly Schedule @
14. Vendor Drawing Index and Submission
Schedule
15. Site Installation Reporting Formats (attached
with 6-14-0016) duly filled and signed

Notes :
1. "TICK" denotes applicability.
2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
3. All post order documents shall be submitted / approved through EIL eDMS portal.
4. Final documentation shall be submitted in hard copy (Six prints) and soft ( two CDs/DVDs ) in addition to
submission through EIL eDMS.
5. Refer - 6-78-0001: Specification for quality management system from Bidders.
6. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.
7. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall
be submitted in exceptional circumstances or as indicated in the MR/Tender.
8. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /
contractor / supplier during finalization of Document Control Index (DCI).
9. "@" indicates submission of documents to Inspection Agency.
10. Bill of Material shall form part of the respective drawing.
11. ALL THE DATA FOLDERS SHALL BE MARKED ON BOTH FRONT AND SPINE WITH THE FOLLOWING
DATA:
- PROJECT TITLE / PURCHASE ORDER NO.
- EQUIPMENT / MATERIAL DESCRIPTION.
- TAG NUMBER(S) IF APPLICABLE
- DATA BOOK TITLE
12. SOFT COPIES OF VENDOR DOCUMENTS SHALL BE SUBMITTED (IN AUTOCAD AS WELL AS PDF
FORMAT) ON C.D (4 NOS. CD SHALL BE SUBMITTED)
13. For all Equipment, Contractor Quality Assurance Plan, Weld procedures, Inspection Records/Data and
Material Test Certificates shall be reviewed by Authorized Inspector.
14. Each Vendor data item must be identified with Purchase Order Number and Equipment tag Number located
on the cover sheet of the first page of the said item and in case of Engineering Drawing on each and every
drawing.
15. SUCCESSFUL BIDDER TO SUBMIT DCI(DOCUMENT CONTROL INDEX) AND ALL THE VENDOR DATA
THROUGH VENDOR PORTAL(HTTP://EDOCX.EIL.CO.IN/VPORTAL) ONLY. THE DETAIL GUIDELINES FOR
UPLOADING THE DOCUMENT ON VENDOR PORTAL ARE AVAILABLE ON THE SITE ITSELF.

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 VENDOR DATA REQUIREMENTS Document No.
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FOR Rev. 0
MAIN FRACTIONATOR + COLUMN
INTERNALS Page 5 of 5

SUCCESSFUL BIDDER TO SUBMIT ALL THE DOCUMENT AS SCHEDULED DOCUMENT ONLY.

16. All fabrication drawings submitted by vendor to EIL shall be retained for information only. Submission of
documents to EIL for information shall not be a HOLD point for fabrication. Vendor can proceed with fabrication
based on requirements of requisition. Any clarification required from EIL shall be obtained prior to proceeding
with fabrication of the equipment. However, it is EIL prerogative to review fabrication drawings at its discretion
and EIL comments in line with requirements of requisition shall be incorporated by vendor without any cost and
delivery implications.
17. For vendor data requirements regarding Column Platforms, ladders and others structural parts refer Doc.
No B224-111-81-41-VDR-6006 attached elsewhere with PR.
18. For vendor data requirements regarding Hydraulics design of column Internals refer Doc. No B224-111-2-
42-VDR-0001 attached elsewhere with PR.

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 DOCUMENT No.
LIST OF ATTACHMENTS B224-111-80-43-LL-6006-0
Page 1 of 2

LIST OF ATTACHMENTS

PROJECT : RAJASTHAN REFINERY PROJECT

OWNER : HRRL, BARMER, INDIA

CONSULTANT : ENGINEERS INDIA LTD.

JOB NO. : B224

B 19.10.20 ISSUED FOR PURCHASE

RKM PVSSN PVSSN
A 23.08.19 ISSUED WITH MR NNM RKM KJH
Rev. Prepared Checked Approved
Date Purpose
No by by by

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 DOCUMENT No.
LIST OF ATTACHMENTS B224-111-80-43-LL-6006-0
Page 2 of 2

S.NO. DESCRIPTION DOCUMENT NO. Rev

1.0 Job Specification
Job Specification for Structured Packing &
1 Associated Internals for main Fractionator B224-111-80-43-SP-6006-2520 0
Column
2 Instruction to Bidders B224-111-80-43-TR-6006 A
3 Technical Questionnaire B224-111-80-43-TQS-6006 A
4 Vendor Data Requirements B224-111-80-43-VDR-6006 0
2.0 Standard Specification
Installation procedure for trays and tower 6-14-0003
1 5
internals

Specification for fabrication of bolting bar &

2 6-14-0007 4
support ring for trays & tower internals

Standard specifications for trays and tower 6-14-0008

3 6
internals

Packing, marking & shipping specifications 6-14-0009

4 4
for trays and tower internals

Standard specification for trays and tower

5 6-14-0015 3
internals

Standard specification for review of site

6 6-14-0016 4
installation of column internals
Specification for preparation of
7 6-14-0018 2
TSR/BB/GA drawings of trays
3.0 Standards
1 Internal Flanges 7-12-0018 6
Construction tolerance for welded supports
2 7-14-0001 4
for tray / tower internals
4.0 Standard Inspection Test Plan
Positive Material Identification at supplier
1 6-81-0001 3
work
2 Inspection & test plan for bolting material 6-81-0007 4
3 ITP for Tray & Tower Packaging 6-81-0016 2
ITP for un-engineered tray &
4 6-81-0017 2
tower internals
5.0 Specification
Specification for Quality Management
1 6-78-0001 1
System requirement from Bidder
2 Specification for Documentation
6-78-0003 1
Requirements from Suppliers
Standard specification for health, safety and
3 environment (HSE) management at 6-82-0001 7
construction sites

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 JOB SPEC. FOR STRUCTURED/ DOCUMENT No.
GRID PACKING & ASSOCIATED B224-111-80-43-SP-6006-0
INTERNALS FOR MAIN
FRACTIONATOR COLUMN Page 1 of 11

JOB SPECIFICATION
FOR
STRUCTURED/GRID PACKING
&
ASSOCIATED INTERNALS
FOR
MAIN FRACTIONATOR COLUMN

PROJECT : RAJASTHAN REFINERY PROJECT

OWNER : HRRL, BARMER, INDIA

CONSULTANT : ENGINEERS INDIA LTD.

JOB NO. : B224

0 19.10.20 Issued for Purchase

RKM PVSSN PVSSN
A 23.08.19 ISSUED WITH PR NNM RKM KJH
Rev. Prepared Checked Approved
Date Purpose
No by by by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 45 of 674
 JOB SPEC. FOR STRUCTURED/ DOCUMENT No.
GRID PACKING & ASSOCIATED
INTERNALS FOR MAIN B224-111-80-43-SP-6006-0
FRACTIONATOR COLUMN Page 2 of 11

1.0 INTENT

This Specification define the additional requirements for Design (Hydraulic &
Mechanical), Engineering, Material Procurement including bought-out components,
Fabrication, Assembly at shop, Inspection/Testing, Packing, Supply and Site Installation
of the following:

i) Structured/ Grid Packings (Bed #1 to #8) & Associated Internals

ii) Liquid Distributor / Redistributor required as per licensor PDS (Attached with PR).
iii) Tower Internals including Chimney Trays (CT #1 to #3), Lattice Girders/Major
Beams etc.

For Material of construction for Top, Middle & Bottom section Column internals
refer to column PDS attached with PR.

Fabrication, supply and installation shall include all the components such as chimney
trays, structured / Grid packings, lattice girders, major beams, support grids, retaining
grids, liquid distributors/redistributors, feed pipes, etc. collectively called as Tower
Internals. These tower internals are required for Main Fractionator Column (Item No.
111-C-2101) for PFCCU Unit of Rajasthan Refinery Project for M/s HRRL- Barmer, India.

2.0 GUIDELINES FOR SUBMITTING OFFERS

2.1 Following documents duly filled-in/replied shall be furnished with offer:

2.1.1 Computer outputs/hydraulic calculations for all loading conditions including turn-up/turn-
down for each Packed Bed.

2.1.2 Filled-in Hydraulic Data Sheets for Packings, with complete data as per Annexure II of
Specification No. 6-14-0015.

2.1.3 “Technical Information for Tower Packings” duly filled-in, signed & stamped for each bed
separately as per Annexure-I to this specification.

2.1.4 Document No. B224-111-80-43-TQS-6006 i.e. “Technical Questionnaire” sheet duly

filled-in, signed & stamped. (Ensure that all queries are properly answered without any
ambiguity).

2.1.5 Vendor to ensure Format of letter of waiver attached with Instructions to Vendors (Doc.
No. B224-111-80-43-TR-6006) has been filled-in, signed, stamped and submitted on
Letterhead.

2.1.6 Ensure that all applicable documents as listed in Document No. B224-111-80-43-VDR-
6006 i.e. “Vendor Data Requirement” have been submitted with offer.

2.1.7 Schematic details of all Feed Pipes. Vendor shall confirm that all components in their
scope of supply are accessible through the Manhole ID’s as indicated in the enclosed
Mechanical Data Sheet No. B224-111-80-43-DS-3001.

2.2 While quoting following shall be ensured/noted.

2.2.1 Vendors, after studying the contents of this specification and attachments to requisition,
may decide to obtain clarifications before making their offer. Any ambiguity shall be
discussed and concluded at the pre bid stage only and once having done so, the offer
shall be in strict compliance to the requirements and technical specifications of this
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FRACTIONATOR COLUMN Page 3 of 11

package i.e. various technical specifications/drawings/documents as referred to in this

specification and other attachments of requisition.

Any deviation to this and referred specifications should have prior approval of Owner /
EIL. All such deviations shall be raised at pre bidding stage (i.e. before submission of
bid). Clarifications/ deviations listed in the bid documents shall not be considered during
offer evaluation.

2.2.2 Any missing document shall be obtained prior to submitting offer.

2.2.3 Proprietary Structured / Grid Packing & Associated Tower Internals shall be procured
from any of the approved vendors only as per list included in this specification.

2.2.4 Any clarification (if required by vendor), shall be obtained prior to submitting offer. Do not
seek any clarification in offer.

2.2.5 Offer may be rejected, if not in line with above guidelines.

2.2.6 The technical evaluation of offers for the internals of Main Fractionator column shall be
carried out by EIL & recommendation shall be furnished to vendor. However, vendor
shall submit the selection of final Chimney tray / internal supplier to EIL / Owner for
information, prior to placement of order.

2.2.7 The technical evaluation of offers shall be based on the “Hydraulic Calculations/
computer outputs”, “Technical Information (Annexure-I) of this requisition”, replies to
“Technical Questionnaire”, “letter of waiver” & other documents as per “Vendor Data
Requirement”.

2.2.8 The “Nozzle Orientation Drawing” shall be given to Successful Vendor at Post Order
Stage, same nozzle orientation drawing is required to be followed during designing of
internals. Vendor to provide Suggestive Nozzle orientation for Main Fractionator
Column (111-C-2101) duly vetted by internal supplier of Main Fractionator Column
internals along with BID.

2.2.9 Vendor shall review the elevations of the Process Nozzles as specified in the
Mechanical Data Sheets and shall give their concurrence along with offer. Vendor
shall also review the elevations of the nozzles shown on HOLD (if any) as specified
in the Mechanical Data Sheets of Main Fractionator Column and shall give the
concurrence / revised elevation for the same.

2.2.10 Indian arms of Foreign Vendor’s shall obtain written consent for executing this job
(for bidding in this PR) on behalf of their foreign counterparts. Same shall be
submitted along with offer. In absence of this consent their offer shall be liable for
rejection.

3.0 SPARES
Following Spares shall be supplied:
3.1 Mandatory Spares shall be supplied as per clause 4.4.1 of Specification No. 6-14-0015.

3.2 Erection & Commissioning Spares:

i) Erection & Commissioning spares shall be supplied as per clause 4.4.2 of
Specification No. 6-14-0015.

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FRACTIONATOR COLUMN Page 4 of 11

ii) In addition to above following Plates shall also be supplies as erection &
commissioning spares. These plates may be used for minor modification work, if
required at site.
Item Size MOC Qty. Remark
Plate 2 m x 1 m x 3 mm thk SA240 TP304H 01 No.
Plate 2 m x 1 m x 3 mm thk SA240 TP304L 01 No. For Main
Plate 2 m x 1 m x 3 mm thk SA240 TP316L 01 No. Fractionator
Plate 2 m x 1 m x 6 mm thk SA240 TP304H 01 No. Column
Plate 2 m x 1 m x 6 mm thk SA240 TP304L 01 No.
Plate 2 m x 1 m x 6 mm thk SA240 TP316L 01 No.

3.3 The price of Mandatory and Erection & Commissioning spares have been included in
base price.

3.4 Unused Erection & Commissioning Spares after completion of the Site work shall be
handed over to the Owner.

3.5 Two Year Operational Spares: Vendor shall submit itemized price list of Recommended
Spares, over and above Mandatory Spares, for two years of satisfactory operation &
maintenance. If desired by the owner, order shall be placed for these spares separately.

3.6 SPECIAL TOOLS & TACKLES

Supply of Special Tools and Tackles (if required) for Erection / Operation / Maintenance
of Packings and Associated Internal components.

4.0 SCOPE OF WORK/SUPPLY

4.1 Main Fractionator Column (111-C-2101)

4.1.1 STRUCTURED/GRID PACKINGS & ASSOCIATED INTERNALS

Bed Nos. #1 to #8 shall be provided with Structured Packings/Grid (As mentioned in

PDS) & Associated Internals such as Support Grid, Retaining/Locating Grid, Liquid
Distributors including Feed Pipes etc. Vendor’s scope of work/supply for these beds
include Hydraulic & Mechanical Design, Detail Engineering, Fabrication,
Inspection/Testing, Supply in duly packed condition and Site Installation of Structured
Packings/Grid, Chimney trays and Associated Internals as per Process Data sheet/
Mechanical datasheet of column enclosed with this requisition.

4.1.2 All supporting/fixing arrangement (i.e. Support Rings etc.) required to be welded to
column for the fitment of Internals shall be designed by internal supplier & detail
Drawings (Issued for Construction) for the same shall be furnished to column vendor.
These shall be Procured, Fabricated, Supply & Installed by column vendor.

5.0 ADDITIONAL TECHNICAL REQUIREMENTS

All Chimney Trays, Structured/Grid Packings and Associated Internals covered under
this requisition shall be Designed, Fabricated and Supplied in accordance with EIL
Specification No. 6-14-0015. In addition to various requirements indicated in the
requisition & its attachments, following shall also be applicable and mandatory. No
deviation to these requirements shall be entertained at any time during the project
execution.

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FRACTIONATOR COLUMN Page 5 of 11

5.1 DESIGN REQUIREMENTS

In addition to the design requirements given in EIL Specification No. 6-14-0015, following
shall also be applicable:

(a) GRID

Support Grid of Bed No # 1 shall be designed for design loading of 1000 kg/m².
Moreover, Grid shall be securely bolted/clamped with supporting Girders/Beams
and Support Rings.

(b) SUPPORT GRID

The height of Support Grid for all the beds shall be restricted to 75mm above the
support ring.

(c) RETAINING GRID/LOCATING GRID

Retaining Grid/Locating Grid may be used on the top of the structured packings to
support the distributor above and to avoid movement of packed bed. Retaining grid
shall be designed so as to take care of dead weight of distributors and liquid hold
up equivalent to distributor riser height.

5.2 All lattice girders and loose major beam boltings shall be provided with lock nuts.

5.3 All SS pipes shall be with minimum Sch. 40S thickness. All CS pipes shall be minimum
12 mm thick.

5.4 All vendor’s Proprietary Liquid distributors/redistributors shall be performance tested as

per EIL Spec. 6-14-0015 with water at vendor’s shop only and test results shall be
furnished to EIL. No Deviation on this shall be acceptable.

5.5 All Proprietary Liquid distributor/redistributor shall be leak tested at Site, with all orifices
temporarily plugged. It shall be ensured that leakage is uniform and not from few
concentrated places/corners. All plugs shall be removed after leak testing is over.
Leakage rate shall not exceed 0.5 percent of design liquid flow rate unless otherwise
specified.

5.6 Vendor to note that all internals shall be designed to pass through the clear manhole ID’s
as indicated in Mechanical Data Sheets No. B224-111-80-43-DS-3001. In case any of
the Feed Pipe/Distributor/Redistributor is not accessible through indicated
manhole ID’s, vendor to specify the minimum size of manholes required for
installation of Feed Pipe/Distributor/Redistributor inside the column.

5.7 Vendor to note that Pipe davit Capacity for this column is 1000 kg (max). Vendor to
ensure that erection weight of all the components including Feed Pipe Headers etc. is
less than 750 kg. If required, additional number of break-off flanges in the pipe headers
shall be provided to ensure this.

5.8 Vendor shall review the elevations of the process nozzles as specified in the Mechanical
Data Sheet No. B224-111-80-43-DS-3001 and shall give their concurrence along with
offer. Maximum diagonal dimension of the components shall be restricted to Vessel
manhole ID – 12mm clearance. Alternately elevation as required for Process Nozzles
and Manholes shall be furnished along with offer, which are under HOLD as per MDS.
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FRACTIONATOR COLUMN Page 6 of 11

5.9 Proprietary Structured / Grid Packing & Associated Tower Internals shall be procured
from approved vendors only as per list given in Clause 12.0 only.

5.10 For gasketed construction, all clamps & boltings shall be provided with gasket washer
along with metallic washer. Size of gasket washer shall be same as of metallic washer
except hole diameter, which shall be 9.0 mm for gasket washer instead of 11.0 mm for
metallic washer.

5.11 Following changes to various Documents shall be as follows:

Document No. 6-81-0017:

i) S. No. 3.5 Refer Inspection of completed welds – “100% DP Tests of all welds
shall be replaced with “100% DP test shall be carried out for all
welds of load bearing members only. However, random 10% DP
test shall be carried out on other column internals”.

ii) S. No. 4.2 PMI is not applicable.

5.12 In the event of conflict among the various documents attached with the Requisition,
following order of precedence shall apply. However, as a general rule, more stringent
requirement shall govern:

 This specification and other job specifications.

 Statutory Requirements.
 Datasheets
 Standard specifications, standards, ITPs etc.
 Codes and Standards.

However, all such conflicts shall be referred to Owner / EIL for clarification and the
decision of Owner / EIL shall be final and binding on the vendor without any cost and
delivery implications.

6.0 SPECIFIC INSTRUCTIONS FOR VENDOR DRAWING PREPARATION/REVIEW

6.1 Vendor to note that all vendor drawings/documents submission shall be strictly as per
EIL Specification No. B224-111-80-43-VDR-6006 attached with the requisition.

6.2 All drawings / documents for Structured Packing & Associated Internals submitted to
Client / EIL shall be reviewed & signed by vendor.

6.3 Vendor to follow EIL Specification No. 6-14-0018 for Guidelines for preparation of
TSR/BB/GAD’s.

6.4 Vendor to note that General Arrangement Drawings submitted by them shall contain
adequate information for evaluation of the performance, to enable independent
inspection & installation at site.

Vendor to note that vendor’s offer in the absence of compliance to this requirement is
liable for “Technical Rejection”.

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6.5 The drawings for the Gravity Type Distributors shall include the information on No. of
holes, Hole diameter and tolerance on hole diameter, liquid head on the distributors along
with corresponding flow rates at turn-up and turn-down conditions. Similar data for
Parting box (if used) shall also be furnished.

6.6 Preparation & Submission of Document Control Index (DCI):

a). Vendor shall prepare Document Control Index (list of drawings / documents, which
are to be submitted to EIL along with the submission dates for each drawing) within 07
days of placement of FOI. Vendor shall strictly adhere to this drawing submission
schedule. Successful Vendor shall submit DCI and all the vendor data through vendor
portal (http://edocx.eil.co.in/vportal) only. The detail guidelines for uploading the
documents on vendor portal are available on the site itself.

b). Vendor to note that unscheduled documents (documents which are not listed in DCI)
shall not be accepted by EIL. All vendor drawings/documents shall be submitted as
scheduled document only.

All subsequent submissions of drawings / documents must contain Compliance

Statement with respect to incorporation of each EIL comment. All subsequent
submissions without revisions clearly marked & compliance statement shall not be
entertained by EIL. Any delay because of this shall be to vendor’s account.

6.7 All GAD's shall be submitted in a single lot. Vendor to ensure that the item numbers used
for different items in the same column shall be unique.

6.8 GAD's shall be prepared on standard drawing sheets with scale chosen such that all
dimensions and details are legible. All drawings shall contain title block with minimum
essential information such as Vendor’s name, Client’s name, Consultant’s name, Project,
Equipment No., Drawing No. and Drawing description. For trays GAD’s ‘A1' size is
preferred.

6.9 Following drawings/documents in the given sequence shall be submitted for review/
information as per VDR:

AA) First lot

i) Hydraulic Design Calculations / Data Sheets

ii) Relative nozzle orientation drawing

BB) Second lot

i) Mechanical design calculations

iii) TSR/Bolting Bar Drawings

CC) Third lot (After Hydraulic Design is reviewed at least in Code-2 by EIL)

i) General Arrangement Drawing along with Bill of Material

ii) Feed Arrangement drawings

Vendor to note that drawings proposed to be submitted in third lot shall not be reviewed
until all the Hydraulic Calculations/Data Sheets are approved. Any delay because of this
shall be to vendor’s account.

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FRACTIONATOR COLUMN Page 8 of 11

6.10 Vendor to note that fabrication of structured packings/grid, support/retaining grids,

distributor along with associated internals shall start only after the review of General
Arrangement drawings of the same by EIL.

6.11 Vendor to note that Licensor M/s TechnipFMC will review Hydraulic Calculation &
Design & Fabrication documents of column internals. Licensor comments (if any)
at any stage shall be complied by internal supplier without any time and price
implication.

7.0 GUARANTEE

7.1 Vendor shall fully guarantee the Structured Packings/Grid, Chimney Trays and
Associated Internals and Supporting Lattice Girders/Major Beams for Main Fractionator
Column for:

(a) Material.
(b) Fabrication, workmanship and strength.
(c) Performance of packed beds with regard to proper operation at desired flow
rate/ranges for its
i) Capacity
ii) Pressure drop (across the column).
iii) No. of theoretical stages, HETP, Heat Transfer duty, Entrainment

In case of mal-performance, vendor shall depute their or their collaborator experts to

study and diagnose the problem, suggest suitable corrective measures and implement
the same to achieve the desired performance without any cost/additional expenses to the
client.

8.0 MATERIAL

All materials shall conform to those specified on the Data Sheet. All the materials unless
specified otherwise in the requisition for the fabrication & supply including sheets/plates,
bolting etc. shall be in vendor’s scope of supply. No substitution of material will be
permitted without prior approval from EIL. In case of substitution of material, vendor shall
clearly indicate the reason for requiring such change and giving chemical & physical
properties for the alternate material with their complete standard specification number.

All the material used for fabrication & supply of “Structured/Grid Packing & Associated
Internals” shall be new & of first quality and shall be duly supported with material test
certificate from the mills.

9.0 INSTALLATION AT SITE

Following is a broad list of activities to be carried out by vendor at site. Any other work
not specifically listed but required for completion of job shall also be in vendor's scope.

9.1 Installation of Chimney trays, Tower Internals and associated components in Main
Fractionator Column as per as per Installation Procedure 6-14-0003 and strictly as per
General Arrangement Drawings under surveillance and stage-wise inspection of
Engineer-in-Charge. All requirements of the drawings shall be complied with in totality.

9.2 Installation of structured/Grid packing and associated internals inside the columns.

9.3 Installation of Grid inside the column.

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9.4 Carrying out minor adjustments, modifications, seal welding of seal plates etc. wherever
necessary during Installation.

9.5 Carrying out seal welding of chimney trays inside the Main Fractionator Column.

9.6 Carrying out welding of lattice girders inside the Column.

9.7 Carrying out various leak tests as per requirements of drawings/specifications. These
shall be witnessed by Engineer-in-Charge.

9.8 Checking of installed trays and filling of "Installation Reporting Formats" and getting
these counter checked by Engineer-in-Charge as per "Standard specification for review
of site installation of column internals (6-14-0016)". These shall be submitted to
Engineer-in-Charge.

9.9 Providing following infrastructural facilities and all necessary help/manpower to Engineer-
in-Charge and/or specialist during checking/review of tray installations.

i) Exhaust fan at the column to free it of welding gases, fumes etc. before entry of EIL-
personnel into the column.
ii) Proper lighting arrangement (24V) inside the column.
iii) Rope ladder inside the column in case trays are not easily approachable from
column manhole.
iv) Access platforms and caged ladder on the column, wherever permanent platforms
are not available.
v) Suitable scaffolding and other inspection aids required inside or outside the column.
vi) Water manometer for levelness checking.
vii) Hose pipe connection etc. for supply of water and teflon tape for sealing threaded
joints.

9.10 Attending to Punch List points and carrying out necessary rectifications/ modifications.

9.11 After completion of Installation, internals/packed beds shall be offered to EIL/ Owner for
box up clearance. Vendor/Contractor work shall be deemed complete only after
necessary clearance of Engineer-in-Charge.
9.12 General Notes

i) All consumables like electrodes etc. shall be in the scope of vendor. All welding
shall be done by qualified welders only. The electrodes/filler material to be used
shall be compatible with the metallurgy of component and shall be used only after
prior approval of Engineer-in-Charge.

ii) A proposed Welding Procedure Specification (WPS) for any welding to be done at
site shall be submitted to EIL/Owner's Inspector for his approval. On approval, a
Procedure Qualification Test (PQT) shall be conducted which shall be witnessed
by owner's inspector. On acceptance of all tests as per ASME Section IX, a final
WPS along with Procedure Qualification Record (PQR) shall be submitted. Site
welding shall start only after approval of final WPS/PQR and qualification of
welders as ASME Section IX. EIL/Owner's Inspector may accept previously
qualified WPS/PQR at his sole discretion.
9.13 Safety, Health & Environment

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The Vendor shall install an exhaust fan for exhaling welding/ cutting fumes etc. and to
maintain adequate oxygen level, before any work is started inside confined spaces (i.e.
columns). Adequate ventilation shall be maintained at all times. Gas/LPG cylinders shall
not be taken inside confined space. When a worker/supervisor enters a confined space,
it shall be mandatory to have a second man as standby. Safety belts shall be worn while
entering columns, if there is a danger of falling. All ladders/stair cases shall be in place
before any item is offered to owner's inspectors. Rope ladders/scaffolding shall be
provided inside the column in case trays are not easily approachable from column
manhole. Low voltage (24V) lamps equipped with guards shall be used to prevent
accidental contact with bulb. All electrical connections shall be through ELCB's and
proper earthing shall be ensured. Acids and other materials used for pickling shall be
disposed off to a designated place as directed by owner/EIL. All statutory Regulations
and owner's safety, health and environment requirements shall be complied with.
Inspection aids for carrying out the inspection of internals shall also be provided.

10.0 INSPECTION/TESTING
10.1 All the items covered in this specification i.e. Structured Packings, Grid, Valve trays,
Chimney trays, Vapor Horn and Associated Internals including Demisters, Spray
Nozzles, Distributors etc. shall be subjected to stage wise and final inspection by
EIL/Owner representative. All necessary facilities shall be extended to the inspection
agency.
10.2 Inspection of Structured/Grid Packings, Chimney trays and Associated Internals shall be
carried out as per EIL Specifications No. 6-14-0015, 6-81-0016 & 6-81-0017.
10.3 Trial assembly of grid/ packing for one such layer of each bed shall be carried out at
shop floor in a manner comparable with actual installation. Trial assembly shall be
witnessed by EIL/ Owner representative.

11.0 PACKING & FORWARDING

11.1 Following change regarding Packing, Marking & Shipping Specification for Trays / Tower
Internals (Specification 6-14-0009) is made.

S. No. 2.5:- Shall be read as “Trays & Tower Internals shall be wrapped in polythene
and supplied in wooden cases for damage free transportation” instead of
Trays shall be packed in polythene lined wooden cases.
11.2 All components shall be marked with proper Item Nos. to facilitate identification at site
and same shall be as per vendor’s duly approved General Arrangement Drawings.
It will be, however, vendor’s responsibility to ensure that the packing of Trays / Tower
Internals & Associated Internals are adequate for the mode of transportation actually to
be adopted.
11.3 Vendor shall recommend guidelines for safe storage of equipment / items at site for the
period of 6 months or till completion of job as per execution plan, whichever is later.
Equipment / items shall normally be stored at site in the original boxes as supplied by the
vendor, under covered hard stand.
12.0 LIST OF APPROVED VENDORS
Note: Vendor may procure material from any of the below listed vendors. However
workload, stability and solvency need to be verified by the vendor before placement of
order.

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 JOB SPEC. FOR STRUCTURED/ DOCUMENT No.
GRID PACKING & ASSOCIATED
INTERNALS FOR MAIN B224-111-80-43-SP-6006-0
FRACTIONATOR COLUMN Page 11 of 11

STRUCTURED/GRID PACKING & ASSOCIATED INTERNALS

S. No. Vendor Remark
i) M/s Koch-Glitsch LP -
ii) M/s Sulzer Chemtech -
ANNEXURE-I

TECHNICAL INFORMATION FOR TOWER PACKINGS REQUIRED WITH OFFER

BED DESCRIPTION
Packing type
Packing size/number
Thickness of packing
Minimum Bed height required
Bed height offered to meet guarantee
REQUIRED FOR ALL DESIGN CASES
Top of Bed Minimum Normal Maximum
% MOC / FLOOD
∆P mm H2O/m of packed height
Bottom of Bed
% MOC / FLOOD
∆P mm H2O/m of packed height
Complete Bed (*)
∆P in bed mm H2O

HETP - Allowed, mm

HETP - Calculated, mm
Physical Data
1) Material of Construction
2) Surface Area M2/M3
3) Void Fraction (percent)
4) Corrugation Angle
5) Crimp Height (mm)
6) Crimp Side/Base (mm)
7) Element (Layer) ht.

This sheet is to be submitted separately for all the beds.

(*) For heat transfer beds, heat transfer data shall be furnished.

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 55 of 674
 ANNEXURE-1

FRAC
25

PFCCU
75
Page 56 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0001 0 1/8

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

PROJECT SPECIFICATION FOR

DESIGN OF PRESSURE VESSELS

Information contained in this document is the work product of one or more legal entities of the TechnipFMC Process Technology
business unit and embodies confidential and proprietary information of the applicable entity and/or its client. Use of this information
is restricted in accordance with conditions specified by the contract. TechnipFMC Process Technology and its affiliates disclaim any
and all liabilities for any changes or modifications to this document which are made by any person other than the entity that issued
the document under the applicable client contract.
THIS DOCUMENT IS UNCONTROLLED WHEN REPRODUCED

Digitally signed by: Dylan Sutton Matthew Manning

Bryan Hart
Date: 2019.07.25 08:52:58 - 2019.07.24 22:13:47
-06'00' 2019.07.25 09:56:53 -06'00'
06'00'

0 25JUL2019 ISSUED FOR BEDP D.SUTTON M.MANNING B.HART

WRITTEN BY CHECKED BY APPROVED BY
REV. DATE STATUS
(name & sign) (name & sign) (name & sign)

DOCUMENT REVISIONS

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 57 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0001 0 2/8

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

TABLE OF CONTENTS

1.0 GENERAL.................................................................................................................................. 3
1.1 SCOPE ...................................................................................................................................... 3
2.0 DESIGN ..................................................................................................................................... 3
2.1 DESIGN CONDITIONS AND STRESSES .................................................................................. 3
2.2 DESIGN PRESSURE AND TEMPERATURE ............................................................................. 4
2.3 DEAD LOADS ............................................................................................................................ 5
2.4 DYNAMIC LOADS...................................................................................................................... 5
2.5 CORROSION PROTECTION ..................................................................................................... 5
2.6 SHELLS AND HEADS ................................................................................................................ 5
2.7 SUPPORTS ............................................................................................................................... 5
2.8 FLANGES AND GASKETS ........................................................................................................ 6
2.9 CONNECTIONS ......................................................................................................................... 6
2.10 MANHOLES ............................................................................................................................... 6
2.11 INTERNALS ............................................................................................................................... 6
2.12 REINFORCEMENTS .................................................................................................................. 6
3.0 MATERIALS .............................................................................................................................. 7
3.1 GENERAL .................................................................................................................................. 7
3.2 BOLTS AND GASKETS ............................................................................................................. 7
4.0 INSPECTION AND TESTING .................................................................................................... 7
4.1 INSPECTION ............................................................................................................................. 7
4.2 TESTING.................................................................................................................................... 8

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 58 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0001 0 3/8

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

1.0 GENERAL
1.1 SCOPE
1.1.1 This specification covers the requirements for the design, materials, fabrication, inspection, and testing
of fusion welded pressure vessels of solid steel or steel material when protected with alloy linings or
claddings or refractory lining.
1.1.2 Pressure vessels shall be designed, fabricated, inspected, and tested in accordance with the
requirements of this specification and ASME Section VIII, Division 1 and the appropriate sections of
the ASME Boiler and Pressure Vessel Code i.e. Section II, V and IX.
1.1.3 The local statutory regulations for health, safety and environmental requirements shall apply.
1.1.4 Unless otherwise noted in the requisition requirements, the metric system of units, shall be used on
all drawings and documents to be submitted. When the metric system of units is required, pipe, fitting,
and flange sizes shall be expressed in inches.
1.1.5 The latest issue of codes and standards specified herein shall be as follows:
a) ASME Boiler and Pressure Vessel Code
b) AISC Steel Construction Manual
c) ASME B1.20.1, B16.20, B16.47, and B16.5

2.0 DESIGN
2.1 DESIGN CONDITIONS AND STRESSES
2.1.1 Vessels and their supports shall be designed to withstand the results of the following combinations of
loads and forces within the limits of stress specified herein. Wind and earthquake shall be considered
not to occur simultaneously.
a) Erection: erection dead load combined with wind or earthquake load. The wind loads shall be
per the Indian Standard (IS) 875 Part 3 (Detailed Engineering Contractor (DEC) to confirm).
The seismic loads shall be determined by the DEC from the site specific seismic spectra.
b) Operation: operating dead load, design pressure, maximum operating contents load,
equipment and external attachment operating loads, and any other operating effects such as
unbalanced pressure, thermal, etc., combined with or without wind or earthquake load.
c) Test: test dead load, test pressure, test contents load, and equipment and external attachment
test loads combined with 1/3 of the design wind pressure.
d) Short time: Operating dead load, the effects of any short time overload or upset conditions that
might reasonably be expected to occur and be subject to immediate remedial correction or
properly conducted startup or shutdown operations which may result in increased temperature,
pressure, weight, differential temperature, etc. No more than one short time form of overload
condition shall be considered at one time and wind or earthquake load shall not be combined
with short time loads.
e) Empty equipment: the operating dead load less the fluid weight combined with wind or
earthquake load.

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 59 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0001 0 4/8

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

2.1.2 The basic allowable stresses for pressure parts shall be the values specified in the applicable code.
2.1.3 The basic allowable stresses for non-pressure parts, except as listed below, shall be 33 1/3 percent
of the ultimate tensile strength, 66 2/3 percent of the yield strength, or that producing a creep rate of
1 percent in 10,000 hours, whichever is lower.
a) Welds attaching non-pressure parts to the pressure shell and supports for large internals shall
be designed to the allowable stresses of the pressure parts.
b) Anchor bolting shall be designed to the allowable tension and shear stresses (without further
increase) specified in the AISC Steel Construction Manual.
c) Carbon steel anchor bolting shall be designed to an allowable stress of 20,000 psi based on
the root area of the thread.
2.1.4 The calculated stresses for the design conditions shall be held within the following limits:
a) Erection: based on the uncorroded thickness at ambient temperature using the basic allowable
stress.
b) Operation: based on the corroded thickness at the design metal temperature using the basic
allowable stress.
c) Test: based on the uncorroded thickness at the temperature during testing using the stress of
the applicable code for pressure parts increased as permitted by the code up to 90 percent of
the minimum specified yield stress and the basic allowable stresses increased by 33 1/3
percent for non-pressure parts.
d) Short time: based on the corroded thickness at the metal temperature during the condition
using the basic allowable stress increased by 33 1/3 percent for pressure parts (provided that
any increased pressure effects are maintained within the applicable code limits) and the basic
allowable stresses increased by 33 1/3 percent for non-pressure parts.
e) Empty: based on the corroded thickness at ambient temperature using the maximum allowable
stress increased by 20 percent.
f) All design conditions: the maximum allowable longitudinal compressive stress for cylindrical
shells, including pressure parts and support skirts, shall be determined in accordance with
Paragraph UG-23b of Sec. VIII, Div. 1 of the ASME Code. The maximum allowable longitudinal
compressive stress for conical sections shall also be determined by this method using the cone
meridian radius as the equivalent cylinder diameter.
2.1.5 The cladding thickness of clad plate shall be considered as corrosion allowance only and shall not be
included in the total plate thickness as permitted by the applicable code.
2.1.6 Vessel design shall consider effects on the shell of internal attachments and external loads on nozzles,
using applicable methods outlined in the Welding Research Council Bulletin (WRC) No. 537, or other
applicable methods.
2.2 DESIGN PRESSURE AND TEMPERATURE
2.2.1 The Operating and Design Pressures and Temperatures shall be as specified on Vessel drawings or
data sheets.

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 60 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0001 0 5/8

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

2.2.2 The Design Temperature for vessels having internal refractory lining shall be based on calculated skin
temperatures and code considerations.
2.3 DEAD LOADS
2.3.1 Erection dead load of the vessel shall be the weight of the fabricated vessel (steel) without; refractory,
internal or external cyclones, internal distributors, internal riser, or any other internals or external
attachments.
2.3.2 Empty dead load shall be the erection weight plus refractory (or insulation), internals, and external
attachments.
2.3.3 Operating dead load shall be the empty weight plus fluid (catalyst) weight during normal operation.
2.3.4 Test dead load or maximum load on foundation shall be the empty dead load without refractory and
full of water.
2.4 DYNAMIC LOADS
2.4.1 Vessels shall be designed for wind & seismic loads in accordance with the requirements specified in
the requisition documents.
2.4.2 The site location is Pachpadra, Barmer, Rajasthan. The DEC shall determine the wind & seismic
requirements and incorporate in the specification.
2.5 CORROSION PROTECTION
2.5.1 The corrosion protection required for each vessel shall be as indicated on the vessel drawings or data
sheets.
2.5.2 When non-pressure parts exposed to the vessel fluids are welded to pressure parts and are not of
corrosion resistant materials, a corrosion allowance equal to the specified vessel corrosion allowance
shall be added to all exposed surfaces and their welds. When non-pressure parts are removable, a
corrosion allowance equal to one-half of the specified vessel corrosion allowance shall be added to
all exposed surfaces.
2.6 SHELLS AND HEADS
2.6.1 The minimum corroded shell and head thickness for all vessels shall be 3/16 inch (5 mm).
2.6.2 Semi-ellipsoidal heads with a 2:1 ratio of major-to-minor axis, hemispherical heads or toriconical heads
shall be used for all top and bottom heads.
2.6.3 A toriconical transition section shall be used when a cone to shell transition serves as a support point
for the vessel.
2.6.4 External stiffening rings are not permitted on refractory lined vessels.
2.7 SUPPORTS
2.7.1 Vertical vessels shall be supported on skirts, or lugs. When a vessel is supported on a skirt attached
to the underside of the head, the centerline of the skirt and the centerline of the shell plate (after
deducting corrosion allowance) shall be approximately coincident.
2.7.2 All skirts shall have vent holes to remove trapped gases and at least one access opening (two for
diameters over 8 feet (2440mm)) unless access is possible from below the vessel. Access openings

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 61 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0001 0 6/8

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

shall be at least 12 inches by 18 inches (305 mm x 457 mm) for vessels with diameters under 3 feet
(915 mm); and 16 inches (406 mm) [18 inches (457 mm) when practicable] for vessels with diameters
3 feet (915 mm) and over.
2.8 FLANGES AND GASKETS
2.8.1 Flanges for non-pressure connections shall be of the flat faced type and may be of light plate
construction. Slip-on flanges are not permitted for vessels in FCC/DCC units.
2.8.2 Facings for other than proprietary flanges shall be raised face for ASME ratings of 900 pounds and
under and ring joint for ASME ratings of 1,500 pounds and over except that in steam service raised
face flanges shall be used for all ASME ratings.
2.8.3 Flange facings and gaskets for piping and instrument connections shall be 125- 250 AARH.
2.8.4 Gaskets shall conform to the requirements of ASME B16.20. Octagonal type gaskets shall be used
with ring joint flanges.
2.9 CONNECTIONS
2.9.1 Internal non-pressure connections may be threaded or socket welded 3,000 pound half couplings for
size 2 inches NPS and less and may be flanged or butt welded for sizes over 2 inches NPS. Socket
welded connections for internal piping in reactor and regenerator are preferred. Flanged connection
at the internal of a nozzle in lined or clad vessels or vessel sections may be made by extending the
corrosion resistant sleeve liner and flanging the liner.
2.9.2 Flanged connections shall not be located inside the skirt of skirt supported vessels.
2.9.3 All threaded connections shall conform to ASME B1.20.1.
2.9.4 All connections shall be as listed on Vessel drawings or data sheets.
2.10 MANHOLES
2.10.1 Handling facilities, i.e. davit, shall be provided for blind flanges and covers weighing over 75 pounds
(35 kg).
2.10.2 Hand grips/ rungs shall be furnished inside for vessels, except for refractory lined vessels and for
manholes located in vertical planes.
2.10.3 At least one large diameter manhole shall be provided on reactors and regenerators for cyclone and
internals replacement purposes. This large manhole shall be in addition to access manhole. The final
location of manholes shall be decided by DEC based on constructability studies.
2.11 INTERNALS
2.11.1 Internal pressure piping shall be as required by the service.
2.11.2 Internal non-pressure piping shall be as shown on Vessel drawings.
2.12 REINFORCEMENTS
2.12.1 Integrally reinforced connections, i.e. insert plate type, shall be provided where very high thermal and
mechanical loads are encountered. Typical (but not limited to) connections for FCC, DCC, and RFCC
units are:
a) Regenerated catalyst outlet(s) on regenerator

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 62 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0001 0 7/8

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

b) Spent catalyst outlet on stripper and inlet on regenerator

c) Riser attachment at stripper bottom
d) External riser connection to reactor
e) Cyclone outlets on reactor and regenerator
f) Overhead vapor line outlet on reactor
g) Flue gas outlet on regenerator.
h) Large diameter man ways
i) Plug valve connections
2.12.2 The shell and head thickness may be increased sufficiently to eliminate insert plates for economical
(or ease of fabrication) reasons.

3.0 MATERIALS
3.1 GENERAL
3.1.1 Materials shall be as indicated on the Vessel drawings or data sheets.
3.2 BOLTS AND GASKETS
3.2.1 Bolt and gasket materials for pipe and instrument connections shall be in accordance with the vessel
drawings.
3.2.2 Gaskets for raised face flanges shall be spiral-wound metal flat ring gaskets with non-metallic filler
and a solid steel ring type centering device. The filler material shall be non-asbestos.
3.2.3 Gaskets for ring joint flanges shall be of the octagonal type conforming to the requirements of ASME
B16.20. Gasket materials shall generally be as follows for the indicated flange, flange lining, or flange
cladding material.
a) Carbon and C - 1/2Mo steels: low carbon iron or low carbon steel with a maximum Brinell
hardness of 120.
b) 1/2 to 10 percent Cr-Mo and 11 to 13 percent Cr steels: 5Cr-1/2Mo steel with a maximum
Brinell hardness of 130.
c) AISI type 304, 321, and 347 steels: AISI type 304 steel with a maximum Brinell hardness of
160.
d) AISI type 316 steels: AISI type 316 steel with a maximum Brinell hardness of 160.
3.2.4 Gasket material for internal non-pressure connections shall be as specified for the service.

4.0 INSPECTION AND TESTING

4.1 INSPECTION
4.1.1 Vessels constructed of the following materials shall be subjected to a 100 percent radiographic
examination:

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 63 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0001 0 8/8

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

a) Carbon steel with a specified minimum tensile strength greater than 70,000 psi (4922 Kg/cm^2)
when the wall thickness is over 3/4 inch (19 mm).
b) All Cr-Mo steels when the nominal Cr content is over 1/2 percent.
c) Austenitic steels when the thickness is over 3/4 inch (19 mm).
d) Austenitic steels of any thickness when the design metal temperature is over 750°F (399°C).
4.1.2 Weld surfaces of ferritic materials shall be examined by either the magnetic particle or liquid penetrant
method, and those of austenitic materials shall be examined by the liquid penetrant method, in
accordance with the following:
a) When the vessel wall thickness is greater than 2 inches (50 mm), the examination shall be
performed after any required post weld heat treatment and hydrostatic testing.
b) Carbon steels and ferritic alloy steels with a maximum nominal chromium content of 1/2
percent: Nozzle welds when the vessel is required by the applicable code to be 100 percent
radiographed; and nozzle and attachment welds when the vessel is required to be 100 percent
radiographed and post weld heat treated.
c) Ferritic alloy steels with a maximum nominal chromium content over 1/2 percent: nozzle and
attachment welds.
d) Austenitic steels with a design metal temperature of 750°F (399°C) or less and a thickness of
3/4 inch (19 mm) or less: nozzle welds when the vessel is required by the applicable code to
be 100 percent radiographed.
e) Austenitic steels with a design metal temperature of 750°F (399°C), or with a lower design
metal temperature and a thickness over 3/4 inch (19 mm): longitudinal, girth, nozzle, and
attachment welds.
f) Nozzle welds include the welds between the nozzle and the vessel under the reinforcing pad,
the vessel and the reinforcing pad, and the nozzle and the reinforcing pad. Welds that will be
under the reinforcing pad shall be examined before the pad is attached. This is an exception
to Paragraph 4.1.2a.
g) Attachment welds include structural support clips and skirt attachment welds.
h) The butt welds between insert plates, i.e., integral reinforcements and shell and head shall be
100% radiographed.
4.1.3 Welds attaching welding pins or studs shall be tested by tapping with a light hammer.
4.2 TESTING
4.2.1 When practicable, all pressure vessels shall be subjected to a hydrostatic test. When a field fabricated
pressure vessel is to be pneumatically tested, the vessel seams shall be subjected to a 100 percent
radiographic examination and all nozzle and attachment welds except welds attaching welding pins or
studs shall be subjected to either a magnetic particle or liquid penetrant examination on all exposed
surfaces before the pneumatic test is performed.
4.2.2 Hydrostatic testing shall be performed before application of any internal refractory lining.

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 64 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 1/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

PROJECT SPECIFICATION FOR

CARBON AND ALLOY STEEL PRESSURE VESSELS
FOR PFCCU

Information contained in this document is the work product of one or more legal entities of the TechnipFMC Process Technology
business unit and embodies confidential and proprietary information of the applicable entity and/or its client. Use of this
information is restricted in accordance with conditions specified by the contract. TechnipFMC Process Technology and its
affiliates disclaim any and all liabilities for any changes or modifications to this document which are made by any person other
than the entity that issued the document under the applicable client contract.
THIS DOCUMENT IS UNCONTROLLED WHEN REPRODUCED

Matthew Manning
Digitally signed by: Dylan Sutton 2019.07.24 22: Bryan Hart
Date: 2019.07.25 08:59:03 - 14:10 -06'00' 2019.07.25 09:59:17 -06'00'
06'00'

0 25JUL2019 ISSUED FOR BEDP D.SUTTON M.MANNING B.HART

WRITTEN BY CHECKED BY APPROVED BY
REV. DATE STATUS
(name & sign) (name & sign) (name & sign)
DOCUMENT REVISIONS

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 65 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 2/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

TABLE OF CONTENTS

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

1.1 SCOPE....................................................................................................................................... 3
1.2 REFERENCED CODES AND STANDARDS .............................................................................. 3
1.3 BIDS ........................................................................................................................................... 3
1.4 DRAWINGS AND CALCULATIONS ........................................................................................... 3
1.5 RECORDS ................................................................................................................................. 5
2.0 DESIGN ..................................................................................................................................... 6
2.1 SHELLS AND HEADS ................................................................................................................ 6
2.2 REINFORCEMENT OF OPENINGS ........................................................................................... 6
2.3 MANHOLES, HANDHOLES, AND INSPECTION OPENINGS.................................................... 7
2.4 CORROSION PROTECTION AND WELD OVERLAYS ............................................................. 8
2.5 INTERNALS ............................................................................................................................... 8
3.0 MATERIALS .............................................................................................................................. 9
3.1 GENERAL .................................................................................................................................. 9
3.2 GASKETS .................................................................................................................................. 9
4.0 FABRICATION........................................................................................................................... 9
4.1 TYPE AND FINISH OF JOINTS ................................................................................................. 9
4.2 PREPARATION FOR WELDING .............................................................................................. 10
4.3 WELDING ................................................................................................................................ 10
4.4 POST WELD HEAT TREATMENT ........................................................................................... 10
4.5 TOLERANCES ......................................................................................................................... 12
4.6 PAINTING ................................................................................................................................ 12
5.0 TESTS, INSPECTION, AND REPAIRS .................................................................................... 13
5.1 TESTS...................................................................................................................................... 13
5.2 INSPECTION ........................................................................................................................... 13
5.3 REPAIRS ................................................................................................................................. 16
6.0 LOW TEMPERATURE VESSELS............................................................................................ 16
6.1 GENERAL ................................................................................................................................ 16
6.2 MATERIALS AND FABRICATION ............................................................................................ 16
7.0 NAMEPLATES, MARKING AND SHIPPING ........................................................................... 16
7.1 NAMEPLATES ......................................................................................................................... 16
7.2 MARKING ................................................................................................................................ 17
7.3 SHIPPING ................................................................................................................................ 17

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 66 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 3/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

1.0 GENERAL
1.1 SCOPE
1.1.1 This specification covers the requirements for the design, materials, fabrication, inspection, and
testing for purchasing fusion welded pressure vessels constructed of solid steel or steel materials
when protected with alloy linings or claddings. Requirements of this specification are minimum for
FCCU items. Requirements of 076405C-111-JSS-0400-0001 “Project Specification for Design of
Pressure Vessels” shall also be applied. In case of conflict, the more stringent requirement shall
apply.
1.1.2 The metric system of units shall be used for all drawings and documents to be submitted when
specified per the requisition documents, except that pipe fitting and flange sizes shall be
expressed in inches.
1.2 REFERENCED CODES AND STANDARDS
1.2.1 The issue of codes and standards specified herein shall be the latest edition:
a) ASME Boiler and Pressure Vessel Code, ASME Section VIII, Div.1
b) AISC Specification for the Design, Fabrication and Erection of Structural Steel for
Buildings.
c) Additionally, the Detail Engineering Contractor (DEC) shall determine and specify local
code requirements.
d) Alternately, the DEC may use their pressure vessel purchasing specification in lieu of this
specification. This specification contains the minimum requirements.
1.3 BIDS
1.3.1 The Supplier shall give full information on the fabrication, inspection and testing of attached type
alloy linings proposed for vessel pressure parts.
1.3.2 Proposals shall include the cost of all required inspection. Equipment conforming to the ASME
Code shall be inspected by a National Board commissioned inspector. National Board numbers
shall be assigned by the Supplier and stamped on the equipment conforming to Section VIII. All
vessels designed and fabricated in accordance with the ASME Code shall be stamped.
1.3.3 The Supplier, as a fabricator, shall be responsible for the procurement of all code inspections and
shall also determine and comply with the requirements of city, state, county, national, etc., codes,
ordinances, or mandatory rules which apply where the vessel is to be installed.
1.4 DRAWINGS AND CALCULATIONS
1.4.1 The Purchaser will furnish the Supplier with the drawings, engineering data, dimensions,
materials, and any construction details required for the mechanical design. All materials shown
on the drawings and reference data shall be furnished by the Supplier.
a) In the event that the Supplier be required to furnish a pressure vessel containing internal
features of the Supplier's proprietary design, such features may be withheld from the
approval process. Nevertheless, all design features of the pressure envelope shall be

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 67 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 4/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

submitted to the Purchaser for approval in such a way as to document compliance with
applicable codes and specified design conditions.
b) For field erected vessels, Supplier's drawings shall show the method and sequence of
field assembly.
1.4.2 In addition to the information requested to be furnished by the Supplier, the Supplier shall furnish
the number of copies in the form specified on the schedule of required Supplier data of the
following drawings, data, and reports. Drawings shall show, as a minimum, the following
information:
a) Reference to applicable codes, specifications and drawings and National Board Number
if registered.
b) Operating and design pressures.
c) Operating and design temperatures.
d) Materials of construction, thickness and corrosion allowance(s).
e) Specific indication of non-destructive examinations required by applicable codes and
specifications.
f) Complete details and dimensions of the vessel, of its supports and of external and internal
attachments supplied by Vessel Supplier.
g) Definition of all welded joints
h) Weld seam locations
i) Weld joint efficiencies and stress reduction factors used in the vessel design.
j) Weld procedure number
k) For flanges 24 inches nominal diameter and smaller, Supplier's drawings shall show their
size, rating, bore and finish of flange face. For flanges larger than 24 inches, Supplier's
drawings shall list manufacturer, part no., catalog no., bore, and finish of flange face, bolt
circle diameter and number and size of bolts.
l) Location and facsimile (or photo or copy) of the actual nameplate to be attached to the
vessel.
m) Final Code hydrostatic test pressure and the altitude of the pressure vessel during the
hydrostatic test.
n) All Suppliers’ drawings sent to Purchaser for review shall be completely checked and
signed. Purchaser reserves the right to back charge the Supplier for time spent correcting
excessive errors and/or for non-compliance with the specification(s) and of vessel
drawing(s).
o) Supplier shall assume full responsibility for accuracy of all his drawings. Review of
Supplier's drawing by Purchaser shall constitute a general review only and in no way
relieves the vessel Supplier of his responsibilities.

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 68 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 5/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

p) Supplier's drawings shall use the same identification numbers and letters used on vessel
drawing(s) to designate vessel chambers, trays, nozzles, etc. Owner's equipment
identification number and service shall be noted on all vessel drawing title blocks.
q) Additional requirements pertinent to drawings in the technical requisition documents shall
be noted and followed by vessel Supplier.
1.4.3 Computer based calculations shall show all input, results and intermediate calculations, equations
and formulas.
1.4.4 All Supplier drawings shall indicate: requisition number, purchase order number and equipment
tag number.
1.5 RECORDS
1.5.1 The records listed below shall be available for examination by the Purchaser or his representative
at the time of inspection:
a) Mill test reports for primary pressure parts shall state the specification to which the material
complies; the heat, lot, or melt number; the heat treatment (if any) given to the material;
and the results of chemical analysis and mechanical tests. Certificates are acceptable for
heat treatment information missing on mill test reports.
b) Certificates for pressure and non-pressure part materials obtained from stock, except as
required by Paragraph 1.5.1a, for which mill test reports are not available.
c) Certificates for bolting material.
d) No records are required unless specified by code or the material standard for pipe fittings
and flanges made in accordance with an acceptable standard, provided they are marked
in accordance with Paragraph PG-11.1 of Section 1 or Paragraph UG-11a of Section VIII,
Division 1 of the ASME Code, nor are they required for pipe marked in accordance with
the ASME material standard. Certificates are required when the markings are removed
during fabrication operations.
e) Welding procedure specifications and the results of welding procedure and operator
qualification tests, which have been reviewed by the Purchaser.
f) Radiographic film for required radiographic tests and certificates for the results of any
required magnetic particle, liquid penetrant or other method of examination.
g) Charts or other records of required hydrostatic, pneumatic, and other tests.
h) Pyrometer charts or other detailed records of heat treatment (post weld, normalizing,
heating for forming, etc.).
i) Hardness test results (when applicable).

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 69 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 6/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

2.0 DESIGN
2.1 SHELLS AND HEADS
2.1.1 When clad plate or weld overlay type lining is specified, the cladding or weld overlay thickness
shall be considered as corrosion allowance only and shall not be included in stress calculations
unless otherwise noted on the vessel data sheets or drawings.
2.1.2 All vessel seams shall be located to clear important internals and in horizontal vessels to clear
saddle supports.
2.1.3 Longitudinal seams in cylindrical and conical shells and all seams in spherical shells and in built-
up heads shall be located to clear openings and their reinforcement.
2.1.4 Circumferential seams in cylindrical and conical shells shall clear openings when practicable.
When openings must occur in these seams, and reinforcing pads are required, the seam weld
shall be ground flush and 100% radiographically examined before the pad is attached. The butted
shell plate alignment shall be sufficiently accurate to permit proper fit-up of the reinforcing pad
with the shell.
2.1.5 Attachments shall be located to clear seams by at least one plate thickness. If this is not
practicable, the vessel seam weld shall be ground flush and examined, if required, before the
attachment is welded into place.
2.2 REINFORCEMENT OF OPENINGS
2.2.1 Nozzle reinforcement shall be designed for the maximum allowable working pressure (MAWP)
for which the vessel can be rated. The MAWP shall be determined by calculation; it shall not be
assumed to be the vessel's design pressure. Nozzle reinforcement shall not limit the vessel's
MAWP. For refractory lined vessels, including the Reactor, Regenerator, and Flue Gas Orifice
Chamber, the MAWP shall be assumed to be the design pressure. No MAWP calculations are
required for these items.
2.2.2 The reinforcement of openings in the shell and heads (including the reinforcement for piping loads
that are specified) shall be designed in accordance with the applicable code for the pressure and
temperature stamped on the vessel, the specified vessel test pressure and test temperature. Each
reinforcing pad or segment thereof shall be provided with one ¼ inch (6.4 mm) diameter NPT
threaded telltale hole at the lowest point and the hole packed with grease prior to shipment.
2.2.3 For vertical vessels having a ratio of height (length between tangents) to inside diameter (smallest
diameter when vessels have more than one diameter) greater than 12, the reinforcement of
openings in shell courses shall be calculated using the nominal thickness of the shell course under
consideration minus the corrosion allowance instead of the thickness required by Paragraphs UG-
37(b) and (c) of Section VIII, Division 1 of the ASME Code.
2.2.4 Integrally reinforced connections, i.e., insert plate type shall be provided where very high thermal
and mechanical loads are encountered. The typical connections this applies to includes, but is
not limited to, the following:
a) Regenerated catalyst outlets on Regenerator
b) Spent catalyst outlet on stripper and inlet on Regenerator

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 70 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 7/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

c) Main Riser attachment at Stripper bottom

d) External riser attachment to Reactor
e) Flue gas outlets on Regenerator
f) Reactor overhead vapor line outlets
g) Large diameter manholes
2.2.5 The head and shell thickness may be increased sufficiently to eliminate the need for insert plates
for economy and/or ease of fabrication purposes.
2.3 MANHOLES, HANDHOLES, AND INSPECTION OPENINGS
2.3.1 All pipe, manhole and handhole nozzles in vessels equipped with close fitting internal parts (trays,
baffles, etc.) that may obstruct the entrance into the vessel or the assembly of such parts, shall
not project more than ½ inch (13 mm) beyond the inside surface of the vessel. Projection of all
other nozzles or similar parts into the inside of the vessel shall be ½ inch (13 mm), maximum at
short side, and may be governed by the function of the vessel. Unless otherwise noted, all drains,
vents and safety relief valves shall be flush with inside of vessel.
2.3.2 The inside diameter of manholes shall be at least the nominal diameter minus 1" (25.4 mm).
2.3.3 Except for refractory lined vessels, any access opening in the pressure envelope for
entrance/egress (manhole) whose axis is horizontal, or nearly so, shall be furnished with a hand
grip (grab rung) inside the vessel above the manhole. Ladder rungs shall be provided below
manholes to permit access to a location that provides firm footing.
2.3.4 Handholes and inspection openings may be larger than the specified size, but they shall not be
smaller than the following:
a) For 1 through 3 inch opening sizes, inclusive, the opening dimension shall be greater than
or equal to the inside diameter of the corresponding size of double extra strong pipe.
b) For 4 through 12 inch opening sizes, the opening dimension shall be greater than or equal
to the inside diameter of the corresponding size of schedule 160 pipe.
c) For opening sizes larger than 12 inch, the opening dimension shall be greater than or
equal to the nominal diameter minus one inch.
2.3.5 Unless otherwise specified on the drawings, flanges for all external nozzles 24 inches nominal
size and smaller shall be in accordance with ASME B16.5 for the rating and type of facing
specified. For sizes over 24 inches, the dimensions shall be in accordance with ASME B16.47,
Series B. For sizes over 60 inches, the dimensions shall be Taylor Forge “Industry Standard”
Class 175.
2.3.6 Raised and flat face pressure flanges shall be furnished with either a stock, smooth, spiral
serrated, or concentric serrated gasket surface finish. Internal non-pressure flanges shall be
machined to give a flat surface. The face finishing of the flanges shall be as indicated on the
drawings.
2.3.7 Slip-on flanges shall not be used above 850°F (454°C) design temperature. Slip-on flanges shall
be welded to nozzles by a full thickness fillet weld at the flange face and a fillet weld at the back

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 71 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 8/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

of the flange. Slip-on flanges may be used only on 150 and 300 pound classes. For FCC & DCC
units, slip-on flanges shall not be used.
2.3.8 Flange bolt holes shall straddle the vertical or north-south horizontal centerlines, unless otherwise
noted.
2.3.9 All threaded connections shall conform to ASME B1.20.1.
2.4 CORROSION PROTECTION AND WELD OVERLAYS
2.4.1 All surfaces of pressure parts in the following vessels or vessel sections shall be protected as
indicated.
a) Unlined surfaces shall be fabricated of the material specified for the vessel or vessel
section. Minimum thickness shall have the calculated required thickness plus the specified
corrosion allowance; or they shall be fabricated of a corrosion resistant material specified
by the Purchaser.
b) Lined surfaces shall be fabricated of or protected by the alloy lining material specified for
the vessel or vessel section.
2.4.2 When non-pressure parts exposed to the vessel fluids are welded to pressure parts and are not
of corrosion resistant materials, a corrosion allowance equal to the specified vessel corrosion
allowance shall be used with all exposed surfaces and their welds. When non-pressure parts are
removable, a corrosion allowance equal to one-half of the specified vessel corrosion allowance
shall be used with all exposed surfaces.
2.4.3 The minimum corroded thickness of attachments fabricated from noncorrosion resistant materials
and of all fillet welds (as measured through the throat) shall be 1/8 inch (3.2 mm).
2.4.4 Weld overlays shall consist of at least two layers so that the top layer for the first 1/16" will have
the desired alloy composition. The first or bottom layer may be made with electrodes of higher
alloy content to compensate for dilution effects. The finished surface shall be examined by the
liquid penetrant method of examination.
2.5 INTERNALS
2.5.1 Removable internal parts shall be sized to be removed through the nearest or specified manhole
or opening. Parts shall be as large as practical for clearance. When internals are obviously not
capable of being removed through a manhole (i.e. NPS 24 internal piping in a vessel with NPS
24 manhole), they shall have a corrosion allowance added to each surface.
2.5.2 Internal non-pressure carbon and low alloy (6% Cr maximum) steel pipe and fittings removable
through the vessel manhole shall have wall thickness or ratings equal to or greater than the
following:
a) For pipe size NPS 12 and/or smaller the wall thickness shall be equal to or greater than
the wall thickness of standard wall pipe.
b) Pipe NPS 14 and/or larger the wall thickness shall be equal to or greater than ¼ inch.
2.5.3 Internal non-pressure medium-alloy and high-alloy (8% Cr and greater) steel pipe and fittings shall
have wall thickness or ratings equal to or greater than the following:

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 72 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 9/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

a) For pipe size NPS 6 and/or smaller the wall thickness shall be equal to or greater than the
wall thickness of Schedule 40S pipe.
b) For pipe size NPS 8 and/or larger the wall thickness shall be equal to or greater than the
wall thickness of Schedule 10S pipe.
2.5.4 Internal non-pressure piping for Reactor and Regenerator shall be stainless steel type 304H. The
pipe schedule shall be as shown on vessel drawings.
2.5.5 The vessel Supplier shall furnish all welded-in tray support clips and rings and shall install baffles,
distributors, etc., in the Supplier's shop. Details for attaching tray support rings, and support clips
shall be in accordance with the tray support drawings and specifications listed on the purchase
order.

3.0 MATERIALS
3.1 GENERAL
3.1.1 Permanent backing rings or strips shall not be used. Temporary backing rings may be used
provided the backing material is of a composition similar to the base metal or weld metal and that
the material is removed upon completion of welding.
3.1.2 The heat treatment required for clad plate conforming to ASTM A263, A264, and/or A265 shall be
done at the mill.
3.1.3 Explosion clad plate not conforming to ASTM A263 or A264 shall be stress relieved in accordance
with the times and temperatures required by the applicable code and Paragraph 4.4.1 before
commencing fabrication operations. Cold flattening shall be performed before stress relieving
when required.
3.1.4 Welding materials used for welding the base metal of clad or lined plate shall conform to the
mechanical and chemical requirements of the base material.
3.2 GASKETS
3.2.1 All gaskets furnished shall be new and shall be installed before the vessel is shipped. Gaskets
used for shop test purposes shall be replaced with new materials prior to shipment.
3.2.2 Except for ring joint gaskets, one spare gasket shall be furnished for each flanged connection
provided with a closure and for all internal flanged joints.

4.0 FABRICATION
4.1 TYPE AND FINISH OF JOINTS
4.1.1 Pressure part seams (including nozzle and manhole attachment welds) shall be full penetration,
double welded butt joints except nozzles and manhole attachments 3/8 inch (9.5 mm) thick or
less may be single welded without backing strips or rings.
4.1.2 Joints in alloy steels shall be made without the use of permanent backing strips or rings.
Temporary strips and rings may be used if they are removed after the weld is completed and the
joint is examined visually for contour and undercutting, and examined by magnetic particle or

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 73 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 10/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

liquid penetrant for cracks. Such examination shall be performed after any post weld heat
treatment.
4.2 PREPARATION FOR WELDING
4.2.1 Plate edges shall be beveled by any method that will produce a reasonably smooth surface
suitable for welding. If flame cutting is used to prepare alloy clad plate edges, any flame gouged
areas at the junction of the base metal and the alloy shall be repaired by stripping back the alloy
cladding from the gouged area and building up the base metal, first with base metal weld deposits
and then the clad surface with alloy metal weld deposits.
4.2.2 Weld metal shall not be used to build up the edges of plates that are too short or that contain
large cavities unless the deficiency or cavity is small enough [(equal to or less than 1/2 inch (12.7
mm)] to be bridged by welding without adding cold metal, and the weld meets the applicable
requirements of the ASME Code. Supplier is to receive prior approval of Purchaser before repair.
4.2.3 The maximum allowable gap between nozzle and manhole reinforcing pads and the curvature of
the vessel shall be 1/8 inch (3.2 mm).
4.2.4 The Supplier shall bevel the ends of nozzles to be welded by others. The bevel profiles shall be
in accordance with ASME B16.25 for the size, schedule, and type specified on the drawings or
vessel specification sheets.
4.3 WELDING
4.3.1 Welding procedures for ferritic alloys shall be qualified at the same post weld heat treatment
temperature ranges and holding times as will be used for production welds.
4.3.2 Temporary attachment welds on pressure shells shall be removed. The surface under such welds
and under backing rings which have been removed shall be properly conditioned to eliminate
surface stress risers. Such surfaces shall be examined by either the magnetic particle or liquid
penetrant method.
4.3.3 Arc strikes on the pressure shell shall be avoided. When they occur, the surface shall be properly
conditioned to eliminate surface stress risers and shall be examined by either the magnetic
particle or liquid penetrant method of examination.
4.3.4 Gas used both as a primary shield and as a backup stream in gas arc welding processes shall be
argon or helium or a combination of both.
4.3.5 All weld procedures including non-pressure welds shall be identified by number and shall be
referenced as weld details on fabrication drawings.
4.3.6 The profile of the fillet weld attaching the non-pressure, load bearing part to the vessel shall meet
the requirements of AWS D.1.1.
4.4 POST WELD HEAT TREATMENT
4.4.1 When post weld heat treatment is required, vessels shall be post weld heat treated in accordance
with the applicable code and the following additional requirements:
a) Post weld heat treatment for welds between dissimilar metals shall conform to the
requirements of the material having the more stringent requirements and shall be verified
by the procedure qualification tests.

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 74 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 11/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

b) Local post weld heat treatment may be performed only with the prior written approval of
the Purchaser.
c) The maximum stress relief or post weld heat treatment temperature shall not exceed the
maximum temperature listed in the applicable code, the tempering temperature at which
mill test report test pieces were tempered (if tempering was performed) or the following
whichever is lower for the listed material:
1) Carbon, C-1/2 percent Mo and Mn-Mo steels: 1275°F (690°C)
2) 1/2 percent Cr-Mo steels: 1275°F (690°C); except that for design metal temperatures
of 900°F (482°C) and over, the post weld heat treatment temperature shall be in the
range of 1250°F (676°C) to 1325°F (718°C) and shall be held for a period of 4 hours
minimum.
3) 3/4 to 9 percent Cr-Mo steels: 1375°F (746°C).
4) 2-1/4 to 9 percent Ni steels: 1125°F (607°C).
4.4.2 Plates, seamless heads, parts of built-up heads and similar pressure containing parts subject to
cold or hot bending or forming or to forging shall be heat treated as follows: Cold bending or
forming for ferritic materials is defined as occurring when the temperature is below the maximum
temperature permitted by Paragraphs 4.4.1c and for austenitic materials when the temperature is
1100°F (593°C) or less. Hot bending or forming for ferritic materials is defined as occurring when
the temperature is above 1600°F (871°C) and for austenitic materials when the temperature is
above 1100°F (593°C). Bending and forming shall not be performed on ferritic materials at
temperatures between the highest permitted cold temperature and 1600°F (871°C).
a) Cold bending: no heat treatment required for components of Carbon, C-1/2Mo, 1/2 to 9
percent Cr-Mo steels, and AISI Type 304, 304L, 316, 316L, 321, and 347 materials.
Components of impact tested Carbon and 2 to 6 percent Ni steels shall be stress relieved
after bending in accordance with the post weld heat treatment requirements of Paragraph
4.4.1 when cold bending causes strains in the outer fibers greater than 5 percent.
b) Cold forming: no heat treatment required for components of AISI Type 304, 304L, 316,
316L, 321, and 347 materials. Components of Carbon, C-1/2Mo, 2 to 6 percent Ni and 1/2
to 9 percent Cr-Mo steel shall be stress relieved in accordance with the post weld heat
treatment requirements of Paragraph 4.4.1 only when the cold formed parts have a ratio
of thickness to local radius greater than 5 percent.
c) Hot bending or forming: no heat treatment required for components of Carbon and C-
1/2Mo. Components of impact tested carbon steel shall be normalized, of 1/2 to 9 percent
Cr-Mo steels shall be normalized and tempered in accordance with their mill test report
heat treatment requirements, of 2 to 6 percent Ni steels shall be normalized and tempered,
and of AISI Type 304, 304L, 316, 316L, 321, and 347 materials shall be solution annealed.
d) Forging: components of carbon steel shall be normalized only when heat treated above
1800°F (982°C). Impact tested carbon steel and C-1/2 Mo steels shall be normalized, 1/2
to 9 percent Cr-Mo and 2 to 6 percent Ni steels shall be normalized and tempered in
accordance with their mill test report heat treatment requirements, and AISI Type 304,
304L, 316, 316L, 321, and 347 materials shall be solution annealed.

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 75 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 12/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

4.4.3 Welds made by the electroslag or single pass electrogas processes when approved in
components that are ¾ inch (19 mm) or greater in thickness shall be normalized.
4.4.4 Solution annealing of AISI Type 304, 304L, 316, 316L, 321, and 347 materials shall be performed
at soaking temperatures of 1900°F (1037°C) to 2000°F (1093°C) for 1 hour per inch (25.4 mm) of
thickness or ½ hour, whichever is longer. The components shall be cooled by means of a water
quench or airblast at a rate of approximately 400°F (204°C) per minute in the entire component.
Materials shall be certified regarding their mechanical properties.
4.4.5 Normalizing shall be performed at the following soaking temperatures. The holding time shall be
½ hour per inch (25.4 mm) of thickness or ½ hour, whichever is longer, and the parts cooled in
still air.
a) Carbon, C-1/2Mo, and ½ to 9 percent Cr-Mo steels: 1650°F (899°C) to 1750°F (954°C)
b) 2 to 6 percent Ni steels: 1500°F (815°C) to 1550°F (843°C)
4.4.6 Tempering shall be performed at the following soaking temperatures. The holding time shall be 1
hour per inch of thickness or 1 hour, whichever is longer. After completing the holding time at the
soaking temperature, the time required to cool the components to 800°F (426°C) shall be at least
one hour.
a) 1/2 to 9 percent Cr-Mo steels: 1300°F (704°C) to 1400°F (760°C)
b) 2 to 6 percent Ni steels: 1100°F (593°C) to 1200°F (649°C)
4.4.7 When post weld heat treatment is required on P1 materials 1-1/2 inches (38.7 mm) and over in
thickness, and P3 materials 1 inch (25.4 mm) and over in thickness, no welding shall be done on
pressure parts after the post weld heat treatment is performed without prior approval by
Purchaser.
4.5 TOLERANCES
4.5.1 Tolerances shall conform to the requirements of the applicable code, the engineering standard
listed in the List of Applicable Specifications and Standards, data sheets and drawings.
4.5.2 The tolerances on the thickness specified for the alloy cladding on integrally clad plate shall be
as follows:
a) Specified nominal thickness: minus 1/64 inch (0.396 mm); plus 1/16 inch (1.6 mm)
b) Specified minimum thickness: minus 0 inch; plus 1/16 inch (1.6 mm)
4.6 PAINTING
4.6.1 Vessels shall be shop painted in accordance with the drawings or standard listed in the List of
Applicable Specifications and Standards.
4.6.2 Machined surfaces shall not be painted.
4.6.3 Weld bevels made by the Supplier on carbon and ferritic alloy steel parts that are to be welded
by others shall be coated on the inside and outside for a distance of 3 inches (75 mm) from the
end of the part with Deoxaluminite weld-through primer. Other coatings may be used subject to
the prior approval by the Purchaser.

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© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 76 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 13/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

4.6.4 When austenitic steels are to be marked with fabrication or shipping information, the marking shall
be done with water-insoluble ink that contains no metallic pigments and no sulfur and halogens.
Acceptable ink markers are: “Uni Paint” marker from Eberhard Faber Inc., and “Action Marker Jr.
No. 44” from Mark-Tex Corp. Other inks may be used subject to the prior approval of the
Purchaser.
4.6.5 Austenitic alloy steel material parts with design metal temperatures above 750°F (399°C), except
as required by Paragraphs 4.6.1 and 4.6.4, shall be kept free of paint and low melting point
materials to avoid the possibility of corrosion at operating temperatures. All traces of paint
accidentally spattered on such materials parts shall be removed.

5.0 TESTS, INSPECTION, AND REPAIRS

5.1 TESTS
5.1.1 Only potable water shall be used for washing or hydrostatically testing vessels or vessel parts
containing or fabricated from chromium-nickel stainless steel materials. Maximum chloride
content shall be 50 ppm.
5.1.2 Each reinforcing pad or part of a pad and similar attachments shall be tested at a pressure of 15
psig (1.1 kg/cm2) by compressed air and soap suds and all welds inside and outside of the vessel
and on the reinforcing pad or part of the pad inspected during the test. Test holes in pads shall
be left open.
5.1.3 Service gaskets for ring type joint and service bolting of materials other than austenitic steel to be
furnished with the vessel may be used for shop tests. Any materials damaged during the tests
and all types of service gaskets used in the tests shall be replaced by the Supplier with new
material. Austenitic service bolts shall not be used during the shop tests.
5.2 INSPECTION
5.2.1 An inspection shall be made of all jacketed vessels prior to attachment of the jacket. The vessel
shell shall be hydrostatically tested at this time.
5.2.2 Welds made on or in any part, regardless of material or thickness, that are subjected to working
by any means including spinning, pressing, and rolling shall be given a complete radiographic
examination and either a magnetic particle or liquid penetrant examination after completion of the
working and before further fabrication is performed when the ratio of thickness to local radius of
the worked part is greater than 5 percent.
5.2.3 Welds made by the electroslag process shall be subjected to an ultrasonic examination, after heat
treatment is completed, in accordance with the requirements of Paragraph PW-52 of Section I or
of Appendix 12 of Section VIII, Division 1 of the ASME Code.
5.2.4 Weld surfaces of ferritic materials shall be examined by either the magnetic particle or liquid
penetrant method. Austenitic materials shall be examined by the liquid penetrant method.
Examinations shall be in accordance with Table 1 using the procedures of ASME Section V,
Articles 6 and 7, respectively. The examination shall be performed after any required post weld
heat treatment and hydrostatic testing except as specified by Paragraph 5.2.4e for welds under
reinforcing pads.

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 77 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 14/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

a) Carbon steels and ferritic alloy steels with a maximum nominal chromium content of ½
percent: nozzle welds when the vessel is required by the applicable code to be 100 percent
radiographed; and nozzle and attachment welds when the vessel is required by the
applicable code to be 100 percent radiographed and post weld heat treated.
b) Ferritic alloy steels with a maximum nominal chromium content over 1/2 percent: nozzle
and attachment welds.
c) Austenitic steels with a design metal temperature of 750°F (399°C) or less and a thickness
of 3/4 inch (19 mm) or less: nozzle welds when the vessel is required by the applicable
code to be 100 percent radiographed.
d) Austenitic steels with a design metal temperature over 750°F (399°C) or with a lower
design metal temperature and a thickness over 3/4 inch (19 mm): longitudinal, girth, nozzle
and attachment welds.
e) Nozzle welds include the welds between the nozzle and the vessel under the reinforcing
pad, the vessel and the reinforcing pad, and the nozzle and the reinforcing pad. Welds
that will be under the reinforcing pad shall be examined before the pad is attached.
f) Attachment welds include structural support, tray support and skirt attachment welds.
g) The butt welds between insert plates, i.e. integral reinforcements, and shell and head shall
be 100% radiographed.

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 78 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 15/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

Table 1 - EXAMINATION OF WELD SURFACES

LONGITUDINAL NOZZLE WELDS ATTACHMENTS

AND GIRTH WELDS
CONDITION OF VESSEL (Note 1)
WELDS
(Note 2)

MATERIAL RADIOGRAPHED

Ferritic steels with Not post weld heat Not 100% No No No

a maximum of treated
1/2% (nominal)
chromium
100% No Yes No

Post weld heat treated Not 100% No No No

100% No Yes Yes

Ferritic steels with over ½% (nominal) 100% or less No Yes Yes

chromium
Austenitic steels with a design metal Not 100% No No No
temperature of 750F (399C) or less and a
thickness of ¾" or less
100% No Yes No

Austenitic steels with a design metal 100% or less Yes Yes Yes
temperature above 750F (399C) or a
thickness over 3/4 in.

NOTES:
1. Nozzle welds include the welds between the nozzle and the reinforcing pad, vessel and
the reinforcing pad, and the nozzle and vessel under the reinforcing pad. Welds under the
reinforcing pad shall be examined before the pad is attached.
2. Attachment welds include structural support, tray support, and skirt attachment welds.

5.2.5 Welds attaching welding pins or studs shall be tested by tapping the pin or stud with a light
hammer.
5.2.6 In addition to ASME Code requirements, the image quality indicator and radiographic examination
shall be in accordance with ASTM E142 except that the penetrameter design shall conform to the
ASME Code. Radiographic film shall be of the fine grain type possessing high contrast and
definition, ASTM E94, Types I and II and shall be used with lead screens only. Film densities for
radiographs made shall be in accordance with the requirements of Article 2 of Section V of ASME
Code.
5.2.7 When liquid penetrant examination is required, it shall be performed on all accessible weld
surfaces. Any surface irregularities which interfere with the examination shall be removed by
grinding, machining, or wash blending with a tungsten inert gas (TIG) torch. When the surface is
of austenitic alloy steel, the liquid penetrant material shall be tested for freedom from sulfur and

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 79 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 16/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

chloride or, after completion of testing, the surface shall be cleaned with “Alconox” (manufactured
by Alconox Incorporated, www.alconox.com). Other cleaners may be used subject to the prior
approval of the Purchaser.
5.3 REPAIRS
5.3.1 Welds with the defective areas removed shall be rewelded using qualified welding procedures
and the repaired welds shall be re-post weld heat treated, if originally required, and reexamined
by the original method for freedom from defects. If correction involves serious alterations, the
approval of the Purchaser shall be obtained before proceeding with such corrections.

6.0 LOW TEMPERATURE VESSELS

6.1 GENERAL
6.1.1 The requirements of paragraphs 6.2.1 through 6.2.4 shall be followed for vessels having design
metal temperatures below -20°F (-29°C). The requirements are in addition to the requirements of
the ASME Code and Sections 1 through 5 of this specification.
6.2 MATERIALS AND FABRICATION
6.2.1 The weld metal used in welding any part to a pressure part shall be the same as that used to weld
pressure parts.
6.2.2 Welding studs shall be of Supplier's standard materials.
6.2.3 The welding done on pressure and non-pressure parts, except welding studs, shall be performed
with the make and brand of electrode (and the flux if an automatic submerged arc welding process
is to be used) which had been used in the qualification of the welding procedure.
6.2.4 When post weld heat treatment is required by the applicable code or specification, no welding
shall be done on pressure parts after such heat treatment.

7.0 NAMEPLATES, MARKING AND SHIPPING

7.1 NAMEPLATES
7.1.1 All vessels shall be furnished with a stainless steel nameplate. Required markings shall not be
stamped directly on the vessel. Nameplates shall be installed on the manufacturer's standard
nameplate holder of sufficient length to project at least 1 inch beyond the vessel insulation. The
following information shall be included on vessel nameplate: vessel item/tag number, Purchaser's
purchase order number, pressure-temperature design condition(s), maximum allowable working
pressure and all other information required by the Code.
a) Low stress stamps only shall be used for steel stamping vessels with minimum operating
temperatures below 60°F (15°C).
b) The nameplate or stamping on vertical vessels shall be located on the shell above the
lowest manhole, and on horizontal vessels shall be located in the center of a head or
above a manhole in a head.

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 80 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 17/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

7.2 MARKING
7.2.1 Vessels that have been post weld heat treated, shall have the following notation painted on the
vessel prior to shipment:
"NO WELDING PERMITTED ON THIS VESSEL"
The letters shall be approximately 3 inches high painted with a contrasting color.
a) On vertical vessels, this sign shall be located on two opposite sides near the bottom
tangent line and repeated at approximately each 20 feet of height, but rotated 90 degrees.
b) On horizontal vessels, the sign shall be located on both sides near the horizontal
centerline.
7.2.2 The North and East orientations shall be center-punched on the outside of each vertical vessel
approximately 6 inches above the bottom tangent line and 6 inches below the top tangent line.
The punch marks shall be circled with white paint.
7.2.3 Center of gravity for shipment shall be paint marked on the two opposite sides of vessels.
7.3 SHIPPING
7.3.1 Internals, clips, lugs, or other attachments which are removable or are to be assembled by others
shall be marked with piece numbers for identification in assembly and match-marked if required.
All such components are to be properly crated, marked and shipped with the vessel. Spare
gaskets shall be tagged with the equipment item number, boxed and shipped with the vessel.
They shall be clearly tagged as spares.
7.3.2 Vessels shall be shipped as required by the drawings. When clearances for shipment require
alteration or elimination of vessel nozzles, clips, lugs, or similar attachments, the Supplier shall
submit to the Purchaser the shipment loading diagrams that show the attachments which required
reorientation or removal. No changes shall be made until written approval has been obtained from
the Purchaser.
a) The inside and outside of vessels ready for shipment shall be cleaned of rust, loose scale,
grease, spatter, etc.
b) Internal and exposed machined surfaces shall be coated with an easily removable
protective coating equal to Rust-Ban 385. Other coatings may be used subject to the prior
approval of the Purchaser.
c) If internal parts or components require temporary supports to prevent damage during
shipment, those supports shall be furnished by the Supplier and shall be painted yellow.
d) All weld bevels shall be closed with metal or plastic caps to prevent damage and entrance
of foreign materials.
e) All socket-weld ends and plain ends shall be closed with metal or plastic protectors that fit
either inside or outside to prevent damage and entrance of foreign materials.
7.3.3 All telltale holes in pads, etc. shall be packed with grease prior to shipment. In the event of alloy
material, the grease shall be low-lead and suitable to prevent contamination of material.

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 81 of 674
 Doc. No. Rev. Page

076405C-111-JSS-0400-0002 0 18/18

Client HPCL Rajasthan Refinery Limited (HRRL)

Project Rajasthan Refinery Project
Site Pachpadra, Barmer, Rajasthan
Unit Petrochemical FCC Unit (PFCCU) Block

7.3.4 For vessels where ocean shipment is not required, all flanged connections not supplied with a
permanent blind flange shall be blanked with bolted wood covers or waterproof plastic covers no
smaller than the flange OD. Beveled ends of nozzles for field welding shall be protected by metal
covers.
7.3.5 The Supplier shall provide any special protection or packaging, and details of any storage, shelf
life, or maintenance instructions which are not within the scope of the purchase order but which
pertain to the manufacturer's guarantee or are otherwise necessary for protection of the vessel.

Confidential–Do Not Disclose Without Written Authorization Technip Stone & Webster Process Technology, Inc.
© Copyright TechnipFMC All Rights Reserved TBPE Firm Reg. No. F-14791

Page 82 of 674
 Doc. No.: 076405C001-111-PDS-0500-2101
Client No.:
Item No.: 111-C-2101
Page Cover

PROCESS PLANT EQUIPMENT CALCULATION

ITEM NO.: 111-C-2101

SERVICE: MAIN FRACTIONATOR

DOC. NO.: 076405C001-111-PDS-0500-2101

CLIENT: HPCL RAJASTHAN REFINERY LTD. (HRRL)

PROJECT: RAJASTHAN REFINERY PROJECT

SITE: PACHPADRA, BARMER, RAJASTHAN

JOB NO.: 076405C001

UNIT: PETROCHEMICAL FLUID CATALYTIC CRACKING UNIT (PFCCU)

AREA: MAIN FRACTIONATOR AND UNSATURATED GAS PLANT

COMMENTS:

Information contained in this document is the work product of one or more legal entities of the TechnipFMC Process Technology business unit and embodies
confidential and proprietary information of the applicable entity and/or its client. Use of this information is restricted in accordance with conditions specified by the
contract. TechnipFMC Process Technology and its affiliates disclaim any and all liabilities for any changes or modifications to this document which are made by any
person other than the entity that issued the document under the applicable client contract.

THIS DOCUMENT IS UNCONTROLLED WHEN REPRODUCED

REVISION LOG
REV ISSUE REASON DATE BY CHECKED APPROVED
B CLIENT COMMENTS INCORPORATED 6-Jun-19 G.Lawson L.Bayac P. Marchant
C CLIENT COMMENTS INCORPORATED 22-Jul-19 G.Lawson L.Bayac P. Marchant
0 ISSUED FOR BEDP 21-Aug-19 G.Lawson L.Bayac P. Marchant
1 REISSUED FOR BEDP 11-Oct-19 G.Lawson L.Bayac P. Marchant
2 REISSUED FOR BEDP 12-Dec-19 G.Lawson L.Bayac
ludovic.
bayac@technipfmc.
P. Marchant
Nicola Salazar
2019.12.12 15:
Digitally signed com
Confidential-Do Not Disclose Without Written Authorization Technip Stone & Webster Process
by: Glenn
Technology, Inc. TBPE
2019.12.12 15:50: Firm Reg. No. F-14791
59:45 -06'00'

13 -06'00'
© Copyright TechnipFMC All Rights Reserved Lawson
Date: 2019.12.12
15:48:01 -06'00'

Page 83 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO. ITEM NO.
DATA SHEET HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE NO. REQUIRED
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT LOCATION PAGE REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 1 OF 22
ITEM/SECTION BOTTOM MIDDLE TOP
2:1 ELLIPTICAL HEAD 2 9 TRAY NO. BEDS 1-2 BEDS 3-5 BEDS 6-8
OPERATING NORMAL 0.79 0.78 0.72
PRESSURE(kg/cm²(g)) MAX 1.083 1.065 1.009
OPERATING NORMAL 349 271 172
TEMPERATURE (°C) MAX 355 277 178
NOTE 4 TYPE OF TRAY PACKING PACKING PACKING
25A 3 NO OF PASSES --- --- ---
3450

SP. GRAVITY IN BOTTOM SECT. @ 340 °C 0.91

BED 8
FULL VACUUM DESIGN YES @ 200°C
NOTE 13 EMERG VAC. DESIGN kg/cm²(a) @ °C NO
30A PROCESS REQ'D INSULATION: HC- SEE SKETCH
NOZZLE MARK NO. SIZE IN. QTY. REMARKS
25B 35
FEED 1 72 2 NOTE 7
NOTE 4
11 O.H.VAPOR 2 96 1
4170

31A REFLUX IN 3 8 1 NOTE 4

BED 7

TOP SECTION
BOTTOMS 4 30 1
STEAM OUT 8 3 1
NOTE 13 VENT 9 2 1
30B 32I RICH OIL RETURN 11 14 1
25C
LEAN OIL DRAW 12 8 2
31B
12B 32J LCO STRIPPER VP. RET. 13 6 1
12A
LCO PA RETURN 14 16 1 NOTE 4
5500

NOTE 4 LCO DRAW 15 18 2

25K
HCO PA RETURN 16 14 1 NOTE 4
BED 6 HCO DRAW 17 18 2
HCO WASH 18 10 1
NOTE 13 SLURRY PA RET. 19 20 1 NOTE 4
54540

13 QUENCH RETURN 20 6 1
30C SPARGE STEAM 21 6 1
8000 ID FRESH FEED 22 8 1 START-UP
25D UTILITY 24 3 1
4510

NOTE 4 MANHOLES 25 24 13
14
31C PRESSURE BALANCE 26 3 1 FROM 111-V-2601
BED 5 PRESSURE BALANCE 27 10 1 FROM 111-V-1104
PRESSURE BALANCE 28 3 1 FROM 111-V-2602
NOTE 13 THERMOWELLS 30 NOTE 14 13 LIQ.SHIELD EXCEPT 30M
30D 32K PRESS. CONN 31 NOTE 15 8
25E LEVEL XMTR 32 NOTE 15 18 2
25L
15A LEVEL GAUGE 34 3 4
6160

26 15B 32L LO STRIPPER VAP.RET. 35 12 1

NOTE 4 LOCATE THERMOWELLS IN:
VAPOR SPACE BELOW PACKING: NOZZLES 30A-F; BOTTOMS LIQ: NOZZLE 30M
MIDDLE SECTION

31D
FEED ZONE/SLURRY BED TOP AT 120° SPACING: NOZZLES 30G, 30H, 30I &
BED 4
30J, 30K, 30L
NOTE 13 PRESSURE INSTRUMENT IN VAPOR PHASE

27 30E NOTES:
1) ALL DIMENSIONS IN mm.
4030

31E
2) EXCEPT WHERE NOTED, ALL NOZZLES RATINGS ARE PER DESIGN
NOTE 4 16
25F CONDITION REQUIREMENTS.
3) FOR THERMOWELL LIQUID SHIELD DETAIL SEE PAGE 22.
BED 3
32A 34A 4) PACKING VENDOR TO DESIGN THE COLLECTOR TRAYS, PACKED BED
34B 32B
DISTRIBUTOR, AND THE INTERNAL PIPE DISTRIBUTORS FOR THE
NOTE 13
PUMPAROUND RETURNS AND REFLUX.
25G 32M/ 30F 5) TECHNIPFMC TO REVIEW FINAL DESIGN OF INTERNALS.
O/Q 32N/ 6) FINAL SWAGE DIMENSION AND DIMENSION FROM SWAGE TO QUENCH NOZZLE
17A P/R
NOTE 12 TO BE SPECIFIED BY ENGINEERING CONTRACTOR.
28 17B
7340

7) REFRACTORY LINED AND ORIENTED 180° APART. ACTUAL PROCESS ID IS 63".

31F NOTE 4 25M
8) VESSEL SUBJECT TO STEAM OUT AT 0.5 kg/cm²(g) AND 150°C.
18
9) VAPOR FEED TEMPERATURE: 570°C; BOTTOM BOOT TEMPERATURE: APPROX. 350°C
BED 2 10) DESIGN PRESSURE = 3.5 kg/cm²(g) AT TOP OF TOWER; 4.1 kg/cm2(g) AT BOTTOM.
DESIGN TEMP.:TOP SECTION=200°C; MIDDLE SECTION=295°C; BOTTOM SECTION=475°C;
NOTE 13 BOTTOM SECTION FROM TOP OF BED 1 TO BOTTOM OF CONE SECTION DESIGNED
30G
FOR INTERMITTENT/EXCURSION OF 570°C FOR < 100 HOURS/YEAR FOR 30 YEARS.
31G 30I MINIMUM DESIGN METAL TEMPERATURE = 3.4 °C
30H
5900

19 11) MATERIALS OF CONSTRUCTION:

25H
BOTTOM SECTION

NOTE 4
TOP SECTION (SHELL HEAD AND NOZZLES): SA516 GR 70N (HIC RESISTANT)
30J BED 1 NACE MR0103 HARDNESS < 200 BHN, CA = 3 MM, PWHT - YES.
30K
TOP SECTION INTERNALS INCLUDING THE PACKING AND CHIMNEY TRAYS:
NOTE 13 316L SS (CA=0) EXCEPT INTERNAL PIPE DISTRIBUTION
25I
1B FOR NOZZLES: SA106-B; NACE MR0103.
3000 6780

MIDDLE SECTION:(SHELL, NOZZLES): 1 1/4 CR-1/2MO WITH 304L SS CLAD

30L 31H (3 MM MIN); AND/OR 304L SS WELD OVERLAY 5 MM MINIMUM (3 MM UNDILUTED)
1A NOTE 6 MID SECTION: INTERNALS INCLUDING PACKING AND CHIMNEY TRAYS:
304L SS OR DUAL CERTIFIED 304/304L SS (CA=0) EXCEPT SUPPORT 304H SS (CA=0)
1900 APPROX.

20 25J 4950 ID BOTTOM SECTION (SHELL, HEAD, NOZZLES): 1 1/4CR-1/2MO WITH 304L SS CLAD
(3 MM MIN) AND/OR 304L SS WELD OVERLAY 5 MM MINIMUM (3 MM UNDILUTED)
3700

32C/E/G
24 HOL 34C BOTTOM SECTION INTERNALS INCLUDING PACKING AND CHIMNEY TRAYS:
22 1500 304L SS OR DUAL CERTIFIED 304/304L SS (CA=0) EXCEPT SUPPORT 304H SS (CA=0)
LOL 30M
21 THE MATERIAL FOR THE PACKING BED SUPPORT AND HOLD DOWN IS TO BE
32D/F 304H (CA=0) STAINLESS STEEL
/H 34D
Below are applicable for the bottom section only:
10500 mm NOTE 18

8 2 1/4CR-1MO COULD BE SUBSTITUTED FOR 1 1/4CR-1/2MO

4 2 1/4CR-1MO IS REQUIRED WHEN THICKNESS IS EQUAL TO OR GREATER THAN 75 MM
2:1 ELLIPTICAL HEAD COKE TRAP 2 1/4CR-1MO SHALL COMPLY WITH REQUIREMENTS FOR STEP COOLING, J FACTOR
LESS THAN OR EQUAL TO 100 AND X FACTOR LESS THAN OR EQUAL TO 15
2 1/4CR-1MO AND 1 1/4CR-1/2MO SHALL BE NORMALIZED AND TEMPERED.
NORMALIZED WITH ACCELERATED COOLING AND TEMPERED IS ACCEPTABLE.
12) PROVIDE DOWN PIPE TO SUPPLY WASH OIL TO BED-2 IN CASE OF 111-P-2102A/B
FAILURE. DOWN PIPE TO BE SIZED TO COMPLY WITH NOTE 6 ON SHT 21.
INSULATION: BOTTOM SECTION- 90 mm ROCK WOOL 13) FOUR SKIN THERMOCOUPLES REQUIRED ON VESSEL AT MID POINT OF EACH
MIDDLE SECTION- 65 mm CELLULAR GLASS
TOP SECTION- 40 mm CELLULARY GLASS BED 90° APART.
14) ALL THERMOWELL NOZZLES ARE 300#; 2" THERMOWELL NOZZLES: 30A/B/C
3" THERMOWELL NOZZLES: 30D, 30E, 30F, 30G, 30H, 30I, 30J, 30K, 30L, 30M
REVISION C 0 1 2 15) ALL PRESS.INST.NOZZLES ARE 300#; 2" NOZZLE: 31A/B/C; 3" NOZZLE: 31D/E/F/G/H
2
DATE 7/22/19 8/19/19 10/11/19 12/12/19 LEVEL INSTR.NOZZLES 32I,32J ARE 2"; 32A/B/C/D/E/F/G/H/K/L/M/N/O/P/Q/R ARE 3".
BY/REVIEW/QC GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM 16) TOP AND BOTTOM HEAD ARE 2:1 ELLIPTICAL.
FLUID SYSTEMS 17) ALL INTERNALS SHALL HAVE ANSI RF FLANGE CONNECTIONS AND BE SIZED
MATERIALS TO PASS THROUGH THE NEAREST MANHOLE.
18) HEIGHT OF BTM TL TO BE FINALIZED IN DETAIL ENGINEERING BASED ON
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION 111-P-2101A/B/C HYDRAULICS. REQUIRED COLUMN CHANGE BY COL VENDOR

Page 84 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 2 OF 22
01
02
03 LEAN OIL DRAW
04
05
06
NUMBER OF CHIMNEYS
07 AND CHIMNEY DESIGN BY
08 VENDOR
09
10
11
12 12A 12B
13
14
15
16 VORTEX BREAKER
(BY PACKING VENDOR) OR
17 PER PAGE 22
18
19
20
21 TOP VIEW
22
23
24
25
26
27
BED 7
28
29
30
31 (3)
32
33 150 MIN HOL 2430
34
875
35 LLL
36 150
37
12A 350
38
12B
39
350
40 (1) 1470
41
NOZZLE TO BE
42
FLUSH WITH
43 BOTTOM OF
44 SUMP
45 BED 6
46
47
48
49 NOTES: SIDE VIEW
50 1. REFER TO NOTE 4 ON PAGE 1.
51 2. ALL DIMENSIONS IN mm.
3. COLLECTOR TRAY DESIGN BY PACKING VENDOR SHALL HAVE AN HOL-LLL THAT
52 CORRESPONDS TO A MINIMUM 9 MINUTES HOLDUP FOR RATES DEFINED ON PAGE
53 21. ALL OTHER DIMENSIONS SHALL BE MAINTAINED
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 85 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 3 OF 22
01
02
03 LCO DRAW
04
05
06
07 NUMBER OF CHIMNEYS
08 AND CHIMNEY DESIGN BY
VENDOR
09
10
11
12
15A 15B
13
14
15
16
VORTEX BREAKER
17 (BY PACKING VENDOR)
18 OR PER PAGE 22.
19
20
21 TOP VIEW
22
23
24
25
26
27 BED 5
28
29
30 (3)
31
32 150 MIN 2380
HOL
33 825
34 LLL
35 150
36 750
15A
37 15B
38
39 750 (1) 1870
40
NOZZLE TO BE
41 FLUSH WITH
42 BOTTOM OF
43 SUMP
44 BED 4
45
46
47
48 NOTES: SIDE VIEW
49
1. REFER TO NOTE 4 ON PAGE 1.
50 2. ALL DIMENSIONS IN mm.
51 3. COLLECTOR TRAY DESIGN BY PACKING VENDOR SHALL HAVE AN HOL-LLL THAT
CORRESPONDS TO A MINIMUM 1.35 MIN. HOLDUP FOR RATES DEFINED ON PAGE 21. ALL
52 OTHER DIMENSIONS SHALL BE MAINTAINED
53
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 86 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 4 OF 22
01
02
03 HCO DRAW
04
05
06 NUMBER OF CHIMNEYS AND
07 CHIMNEY DESIGN BY VENDOR
08
09
10
11
12
17A 17B
13
14
15
16 VORTEX BREAKER
17 (BY PACKING VENDOR) OR
18 PER PAGE 22
19
20
21 TOP VIEW
22
23
24
25
26
BOTTOM OF BED 3
27
28
29
30
31 NOZZLE TO BE
32 FLUSH WITH 150 MIN 3730
33 BOTTOM OF HLL
34 SUMP 2175
LLL
35 (1) 150
36
37 17A 700
38
17B
700 150
39
18 2070
40
41 (1)
42 1118
43
44
BED 2
45
46
47
48 NOTES: SIDE VIEW
49
1. REFER TO NOTE 4 ON PAGE 1.
50 2. ALL DIMENSIONS IN mm.
3. COLLECTOR TRAY DESIGN BY PACKING VENDOR SHALL
51 HAVE AN HLL-LLL THAT CORRESPONDS TO A MINIMUM 5 MIN.
52 HOLDUP FOR RATES DEFINED ON PAGE 21. ALL OTHER
DIMENSIONS SHALL BE MAINTAINED
53
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 87 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 5 OF 22
01
02 INTERNAL FLANGE
03
QUENCH TRAYS
04 SHORT RADIUS ELBOW
05
06 20
07
08 200 300
600
09 B2
10 1260
480 1260
11
SLOPE 20/100
12
13 1580 B1
14 1685
15 3700
16 4950 ID
17
18
19
20 HOL
21
22 1500
23 LOL
24 350
25
26
27
28 COKE TRAP
29
30 4
31
32
33
34 250
35 15mm DRAIN HOLES
36 OPEN AREA
37
38
39
6" NPS
40
41
42
2480

43
20
44
45
46
47
48
49
50 6" OPEN TEE
TRAY B-2 (BOTH ENDS
51 OPEN) TRAY B-1
52 NOTES:
1. ALL DIMENSIONS IN mm.
53
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 88 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 6 OF 22
01
02
03 COKE TRAP
04
05
06
07
08
09 2 D + 150 mm
10
11 15 DEG
12
13
2D/3 2D
14 LOL OPEN TOP
15
16
17
18
19
20
21
SLOTS 5/8" X D/2
22 VOID AREA 400% OF
23 OUTLET NOZZLE (MIN)
24
25
26
27
28
29
30
31
32
33
34 D
35
36
37
38 4 DRAIN HOLES 5/8" ID
39
VORTEX BREAKER
40
41 D: NOMINAL DIAMETER OF OUTLET PIPE
D
42 2 D: NOMINAL DIAMETER OF COKE TRAP
43
44
4
45
46
47
48
49
50
51 NOTES:
52 1. ALL DIMENSIONS IN mm.
53
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 89 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 7 OF 22
01
02
03 SPARGER STEAM
04
05
06
07
08
09
10
11
12
13
14 4950 ID
15
16
17
18
19
20
21
22 45° ELBOWS 21
23
24 T/L MIN.
25 150 MIN TOS

26
27
28
29 4
30
31
32
33
34
35
36
37 A' A'
38 D 21
39
40 45º
41
42 A' - A'
43
44
45 PROVIDE 46 EVENLY SPACED 13 mm
46 STEAM RING ID HOLES FACING DOWNWARD AND
47 OUTWARD AT A 45 DEGREE ANGLE
D = 1/3 HEAD DIAMETER
48 AT ELEVATION
49
50
51
NOTES:
52 1. ALL DIMENSIONS IN mm.
53
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 90 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE:
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 8 OF 22
01 PACKING SECTION REFLUX BED (BED 8)
02 TYPE OF PACKING STRUCTURED
03 BED HEIGHT mm (4)
04 BED DIAMETER mm 8000
05 BED VOLUME m³ BY VENDOR (4)
06 HEIGHT OF PACKING mm 1350 (5)
07 HEIGHT OF GRID OR MESH mm
08 LOADS ARE NORMAL
09 BASED ON CASE 1
10
11
12 VAPOR FROM TOP OF BED TO BOTTOM OF BED
13 FLOW RATE kg/hr 623876 618702
14 DENSITY kg/m³ 2.25 2.19
15 VOLUMETRIC FLOW m³/s 76.91 78.44
16
17 TEMPERATURE °C 127 147
18 PRESSURE kg/cm²(g) 0.65 0.67
19 MOLECULAR WEIGHT 44.86 45.36
20 VISCOSITY cP 0.012 0.012
21
22
23 LIQUID TO TOP OF BED (4) FROM BOTTOM OF BED (4)
24 FLOW RATE kg/hr 155061 149887
25 DENSITY kg/m³ 827.79 821.58
26 VOLUMETRIC FLOW m³/hr 187 182
27
28 TEMPERATURE °C 70.0 141
29 VISCOSITY cP 0.424 0.354
30 SURFACE TENSION dyne/cm 24.81 21.68
31 MOLECULAR WEIGHT # 122.63 150.43
32 FOAMING TENDENCY 1.00 1.00
33
34 HEAT TRANSFER
35 HEAT REMOVED MMkcal/hr
36 HEAT TRANSFER COEFFICIENT kcal/hr-m²-°C
37
38 TYPE & MATERIAL
39 PACKING STRUCTURED (8), PAGE 1- NOTE 11
40 GRID OR MESH
41 INTERNALS (4), PAGE 1- NOTE 11
42 SPRAY HEADERS / NOZZLES (4), PAGE 1- NOTE 11
43
44 REMARKS:
45 1) MINIMUM FLOW IS 50% OF NORMAL RATE SHOWN ABOVE.
46 2) MAXIMUM FLOW IS 116% OF NORMAL RATE SHOWN ABOVE.
47 3) MAXIMUM ALLOWABLE PRESSURE DROP THROUGH TOWER 0.140 kg/cm² AT MAXIMUM DESIGN RATE.
48 4) LIQUID/VAPOR DISTRIBUTORS/BED SUPPORT AND HOLD DOWN PLATES BY VENDOR. HEIGHT FOR
49 THEM HAS BEEN PROVIDED IN THIS BED'S SECTION HEIGHT. SEE SECTION HEIGHTS ON PAGE 1.
50 5) BASED ON 2 THEORETICAL STAGES; PACKING VENDOR TO CONFIRM HEIGHT.
51 6) DESIGN FOR 80% JET FLOOD AT MAX DESIGN RATES.
52 7) SIMULATION FILE HRRLGP102.PRZ
53 8) KOCH-GLITSCH TYPE 250YHC OR SULZER TYPE M350.Y
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 91 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 9 OF 22
01 PACKING SECTION RICH OIL & LEAN OIL (BED 7)
02 TYPE OF PACKING STRUCTURED
03 BED HEIGHT mm (4)
04 BED DIAMETER mm 8000
05 BED VOLUME m³ BY VENDOR (4)
06 HEIGHT OF PACKING mm 1620 (5)
07 HEIGHT OF GRID OR MESH mm
08 LOADS ARE NORMAL
09 BASED ON CASE 1
10
11
12 VAPOR FROM TOP OF BED TO BOTTOM OF BED
13 FLOW RATE kg/hr 615104 653450
14 DENSITY kg/m³ 2.19 2.25
15 VOLUMETRIC FLOW m³/s 77.89 80.83
16
17 TEMPERATURE °C 147 167
18 PRESSURE kg/cm²(g) 0.67 0.70
19 MOLECULAR WEIGHT 45.46 47.93
20 VISCOSITY cP 0.012 0.013
21
22
23 LIQUID TO TOP OF BED (4) FROM BOTTOM OF BED (4)
24 FLOW RATE kg/hr 292097 330442
25 DENSITY kg/m³ 853.11 822.93
26 VOLUMETRIC FLOW m³/hr 342.39 401.55
27
28 TEMPERATURE °C 98 162
29 VISCOSITY cP 0.49 0.35
30 SURFACE TENSION dyne/cm 25.44 20.97
31 MOLECULAR WEIGHT # 150.92 160.25
32 FOAMING TENDENCY 1.00 1.00
33
34 HEAT TRANSFER
35 HEAT REMOVED MMkcal/hr
36 HEAT TRANSFER COEFFICIENT kcal/hr-m²-°C
37
38 TYPE & MATERIAL
39 PACKING STRUCTURED (8), PAGE 1- NOTE 11
40 GRID OR MESH
41 INTERNALS (4), PAGE 1- NOTE 11
42 SPRAY HEADERS / NOZZLES (4), PAGE 1- NOTE 11
43
44 REMARKS:
45 1) MINIMUM FLOW IS 50% OF NORMAL RATE SHOWN ABOVE.
46 2) MAXIMUM FLOW IS 116% OF NORMAL RATE SHOWN ABOVE.
47 3) MAXIMUM ALLOWABLE PRESSURE DROP THROUGH TOWER 0.140 kg/cm² AT MAXIMUM DESIGN RATE.
48 4) LIQUID/VAPOR DISTRIBUTORS/BED SUPPORT AND HOLD DOWN PLATES BY VENDOR. HEIGHT FOR
49 THEM HAS BEEN PROVIDED IN THIS BED'S SECTION HEIGHT. SEE SECTION HEIGHTS ON PAGE 1.
50 5) BASED ON 3 THEORETICAL STAGES; PACKING VENDOR TO CONFIRM HEIGHT.
51 6) DESIGN FOR 80% JET FLOOD AT MAX DESIGN RATES.
52 7) SIMULATION FILE HRRLGP102.PRZ
53 8) KOCH-GLITSCH TYPE 250YHC OR SULZER TYPE M352.Y
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 92 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 10 OF 22
01
02 SKETCH NO. 1
03 HCD/RICH OIL AND RICH OIL/LEAN
04 OIL FRACTIONATION SECTION
05
06
07
08
09
10 623876 KG/HR
REFLUX
11
155061 KG/HR
12
13
14
15
16 BED 8
17
18 (1) HCD/RICH OIL
FRACTIONATION
19
20
21
22 149887 KG/HR
23
24 3598 KG/HR
25 RICH OIL RETURN (3)
26 145807 KG/HR
27 142210 KG/HR 615104 KG/HR
28
29
30
31 BED 7
32
(2) RICH OIL - LEAN OIL
33
34
35
36 LO STRIPPER VAPOR
37
330442 KG/HR 5342 KG/HR
38
39
TO LO STRIPPER 648108 KG/HR
40
41 147600 KG/HR
42
43
LEAN OIL CHIMNEY
44
45
182842 KG/HR
46
47
48
49 BED 6
NOTES: LEAN OIL - LCO
50 1. REFER TO NOTE 5 ON PAGE 8.
51 2. REFER TO NOTE 5 ON PAGE 9.
52 3. VENDOR TO ENSURE DISTRIBUTOR IS AQEQUATE FOR TWO PHASE STREAM. RICH OIL PROPERIES:
VAPOR DENSITY = 3.936 KG/M³ , VISCOSITY = 0.011 cP, LIQUID DENSITY = 879.8 KG/M³, VISCOSITY = 0.73 cP,
53 SURFACE TENSION = 29.64 DYNE/CM
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 93 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 11 OF 22
01 PACKING SECTION LEAN OIL / LCO (BED 6)
02 TYPE OF PACKING STRUCTURED
03 BED HEIGHT mm (4)
04 BED DIAMETER mm 8000
05 BED VOLUME m³ BY VENDOR (4)
06 HEIGHT OF PACKING mm 1600 (5)
07 HEIGHT OF GRID OR MESH mm
08 LOADS ARE NORMAL
09 BASED ON CASE 1
10
11
12 VAPOR FROM TOP OF BED TO BOTTOM OF BED
13 FLOW RATE kg/hr 648108 607485
14 DENSITY kg/m³ 2.25 2.11
15 VOLUMETRIC FLOW m³/s 80.17 80.01
16
17 TEMPERATURE °C 167 181
18 PRESSURE kg/cm²(g) 0.70 0.72
19 MOLECULAR WEIGHT 47.93 45.99
20 VISCOSITY cP 0.013 0.013
21
22
23 LIQUID TO TOP OF BED (4) FROM BOTTOM OF BED (4)
24 FLOW RATE kg/hr 182842 142219
25 DENSITY kg/m³ 822.93 838.61
26 VOLUMETRIC FLOW m³/hr 222.2 169.6
27
28 TEMPERATURE °C 162 172
29 VISCOSITY cP 0.35 0.44
30 SURFACE TENSION dyne/cm 20.97 21.46
31 MOLECULAR WEIGHT # 160.25 171.62
32 FOAMING TENDENCY 1.00 1.00
33
34 HEAT TRANSFER
35 HEAT REMOVED MMkcal/hr
36 HEAT TRANSFER COEFFICIENT kcal/hr-m²-°C
37
38 TYPE & MATERIAL
39 PACKING STRUCTURED (8), PAGE 1- NOTE 11
40 GRID OR MESH
41 INTERNALS (4), PAGE 1- NOTE 11
42 SPRAY HEADERS / NOZZLES (4), PAGE 1- NOTE 11
43
44 REMARKS:
45 1) MINIMUM FLOW IS 50% OF NORMAL RATE SHOWN ABOVE.
46 2) MAXIMUM FLOW IS 116% OF NORMAL RATE SHOWN ABOVE.
47 3) MAXIMUM ALLOWABLE PRESSURE DROP THROUGH TOWER 0.140 kg/cm² AT MAXIMUM DESIGN RATE.
48 4) LIQUID/VAPOR DISTRIBUTORS/BED SUPPORT AND HOLD DOWN PLATES BY VENDOR. HEIGHT FOR
49 THEM HAS BEEN PROVIDED IN THIS BED'S SECTION HEIGHT. SEE SECTION HEIGHTS ON PAGE 1.
50 5) BASED ON 2 THEORETICAL STAGES; PACKING VENDOR TO CONFIRM HEIGHT.
51 6) DESIGN FOR 80% JET FLOOD AT MAX DESIGN RATES.
52 7) SIMULATION FILE HRRLGP102.PRZ
53 8) KOCH-GLITSCH TYPE 250YHC OR SULZER TYPE M170.X
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 94 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 12 OF 22
01 PACKING SECTION LCO PA (BED 5)
02 TYPE OF PACKING STRUCTURED
03 BED HEIGHT mm (4)
04 BED DIAMETER mm 8000
05 BED VOLUME m³ BY VENDOR (4, 5)
06 HEIGHT OF PACKING mm 1560 (5)
07 HEIGHT OF GRID OR MESH mm
08 LOADS ARE NORMAL
09 BASED ON CASE 1
10
11
12 VAPOR FROM TOP OF BED TO BOTTOM OF BED
13 FLOW RATE kg/hr 606071 779415
14 DENSITY kg/m³ 2.11 2.30
15 VOLUMETRIC FLOW m³/s 79.79 94.04
16
17 TEMPERATURE °C 181 235
18 PRESSURE kg/cm²(g) 0.72 0.74
19 MOLECULAR WEIGHT 46.00 55.65
20 VISCOSITY cP 0.013 0.014
21
22
23 LIQUID TO TOP OF BED (4) FROM BOTTOM OF BED (4)
24 FLOW RATE kg/hr 1016720 1190065
25 DENSITY kg/m³ 890.59 846.98
26 VOLUMETRIC FLOW m³/hr 1141.6 1405.1
27
28 TEMPERATURE °C 141 205
29 VISCOSITY cP 0.71 0.41
30 SURFACE TENSION dyne/cm 25.94 20.63
31 MOLECULAR WEIGHT # 187.28 190.10
32 FOAMING TENDENCY 1.00 1.00
33
34 HEAT TRANSFER
35 HEAT REMOVED MMkcal/hr 29.10
36 HEAT TRANSFER COEFFICIENT kcal/hr-m²-°C BY VENDOR
37
38 TYPE & MATERIAL
39 PACKING STRUCTURED (7), PAGE 1- NOTE 11
40 GRID OR MESH
41 INTERNALS (4), PAGE 1- NOTE 11
42 SPRAY HEADERS / NOZZLES (4), PAGE 1- NOTE 11
43
44 REMARKS:
45 1) MINIMUM FLOW IS 50% OF NORMAL RATE SHOWN ABOVE.
46 2) MAXIMUM FLOW IS 116% OF NORMAL RATE SHOWN ABOVE.
47 3) MAXIMUM ALLOWABLE PRESSURE DROP THROUGH TOWER 0.140 kg/cm² AT MAXIMUM DESIGN RATE.
48 4) LIQUID/VAPOR DISTRIBUTORS/BED SUPPORT AND HOLD DOWN PLATES BY VENDOR. HEIGHT FOR
49 THEM HAS BEEN PROVIDED IN THIS BED'S SECTION HEIGHT. SEE SECTION HEIGHTS ON PAGE 1.
50 5) MAXIMUM HEAT REMOVAL IS 116% OF DESIGN GIVEN ABOVE. VENDOR TO ENSURE THE VOLUME OF
51 PROVIDED PACKING IS SUFFICIENT TO REMOVE THIS DUTY. SEE SKETCH NO. 2 ON PAGE 13.
52 6) SIMULATION FILE HRRLGP102.PRZ
53 7) KOCH-GLITSCH TYPE 3X OR SULZER TYPE M2X
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 95 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 13 OF 22
01
02 SKETCH NO. 2
03 LCO PUMPAROUND SECTION
04
05
06
648108 KG/HR
07
08 182842 KG/HR
09
10
11 BED 6
12
13 (2) LEAN OIL/LCO PA
14
15
16
17
18 142219 KG/HR
607485 KG/HR
19
LCO STRIPPER VAPOR
20 LCO PA FLOW
1414 KG/HR
21 874502 KG/HR @
22 1016720 KG/HR 606071 KG/HR
135°c
23
24
25 BED 5
26 29.1 MKCAL/HR
LCO PUMPAROUND
27 (3)
SECTION
28 (1)
29
30
31 1190065 KG/HR
32
33
33285 KG/HR
34
35 LCO PUMPAROUND
LCO STRIPPER CHIMNEY TRAY
36 FEED
37 282278 KG/HR
38
779415 KG/HR
39
40
41
42 LCO - HCO
BED 4
43
44
45
46
47
48
NOTES:
49 1. PUMPAROUND ZONE TO BE DESIGNED FOR 116% OF FLOWS AND DUTY SHOWN ABOVE.
50 2. REFER TO NOTE 5 ON PAGE 11.
51 3. REFER TO NOTE 5 ON PAGE 12.
52
53
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 96 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 14 OF 22
01 PACKING SECTION LCO / HCO (BED 4)
02 TYPE OF PACKING STRUCTURED
03 BED HEIGHT mm (4)
04 BED DIAMETER mm 8000
05 BED VOLUME m³ BY VENDOR (4)
06 HEIGHT OF PACKING mm 1910 (5)
07 HEIGHT OF GRID OR MESH mm
08 LOADS ARE NORMAL
09 BASED ON CASE 1
10
11
12 VAPOR FROM TOP OF BED TO BOTTOM OF BED
13 FLOW RATE kg/hr 779415 698762
14 DENSITY kg/m³ 2.30 2.05
15 VOLUMETRIC FLOW m³/s 94.04 94.81
16
17 TEMPERATURE °C 235 271
18 PRESSURE kg/cm²(g) 0.74 0.77
19 MOLECULAR WEIGHT 55.65 52.26
20 VISCOSITY cP 0.014 0.015
21
22
23 LIQUID TO TOP OF BED (4) FROM BOTTOM OF BED (4)
24 FLOW RATE kg/hr 282278 201625
25 DENSITY kg/m³ 846.98 884.72
26 VOLUMETRIC FLOW m³/hr 333.28 227.90
27
28 TEMPERATURE °C 205 265
29 VISCOSITY cP 0.41 0.42
30 SURFACE TENSION dyne/cm 20.63 20.43
31 MOLECULAR WEIGHT # 190.10 237.37
32 FOAMING TENDENCY 1.00 1.00
33
34 HEAT TRANSFER
35 HEAT REMOVED MMkcal/hr
36 HEAT TRANSFER COEFFICIENT kcal/hr-m²-°C
37
38 TYPE & MATERIAL
39 PACKING STRUCTURED (8), PAGE 1- NOTE 11
40 GRID OR MESH
41 INTERNALS (4), PAGE 1- NOTE 11
42 SPRAY HEADERS / NOZZLES (4), PAGE 1- NOTE 11
43
44 REMARKS:
45 1) MINIMUM FLOW IS 50% OF NORMAL RATE SHOWN ABOVE.
46 2) MAXIMUM FLOW IS 116% OF NORMAL RATE SHOWN ABOVE.
47 3) MAXIMUM ALLOWABLE PRESSURE DROP THROUGH TOWER 0.140 kg/cm² AT MAXIMUM DESIGN RATE.
48 4) LIQUID/VAPOR DISTRIBUTORS/BED SUPPORT AND HOLD DOWN PLATES BY VENDOR. HEIGHT FOR
49 THEM HAS BEEN PROVIDED IN THIS BED'S SECTION HEIGHT. SEE SECTION HEIGHTS ON PAGE 1.
50 5) BASED ON 3 THEORETICAL STAGES; PACKING VENDOR TO CONFIRM HEIGHT.
51 6) DESIGN FOR 80% JET FLOOD AT MAX DESIGN RATES.
52 7) SIMULATION FILE HRRLGP102.PRZ
53 8) KOCH-GLITSCH TYPE 2YHC OR SULZER TYPE M252.Y
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 97 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 15 OF 22
01 PACKING SECTION HCO PA (BED 3)
02 TYPE OF PACKING STRUCTURED
03 BED HEIGHT mm (4)
04 BED DIAMETER mm 8000
05 BED VOLUME m³ BY VENDOR (4, 5)
06 HEIGHT OF PACKING mm 1430 (5)
07 HEIGHT OF GRID OR MESH mm
08 LOADS ARE NORMAL
09 BASED ON CASE 1
10
11
12 VAPOR FROM TOP OF BED TO BOTTOM OF BED
13 FLOW RATE kg/hr 698762 853496
14 DENSITY kg/m³ 2.05 2.29
15 VOLUMETRIC FLOW m³/s 94.81 103.65
16
17 TEMPERATURE °C 271 299
18 PRESSURE kg/cm²(g) 0.77 0.78
19 MOLECULAR WEIGHT 52.26 61.03
20 VISCOSITY cP 0.015 0.016
21
22
23 LIQUID TO TOP OF BED (4) FROM BOTTOM OF BED (4)
24 FLOW RATE kg/hr 836886 991621
25 DENSITY kg/m³ 930.34 893.27
26 VOLUMETRIC FLOW m³/hr 899.6 1110.1
27
28 TEMPERATURE °C 216 271
29 VISCOSITY cP 0.67 0.43
30 SURFACE TENSION dyne/cm 24.81 20.60
31 MOLECULAR WEIGHT # 242.08 243.62
32 FOAMING TENDENCY 1.00 1.00
33
34 HEAT TRANSFER
35 HEAT REMOVED MMkcal/hr 22.50
36 HEAT TRANSFER COEFFICIENT kcal/hr-m²-°C BY VENDOR
37
38 TYPE & MATERIAL
39 PACKING STRUCTURED (7), PAGE 1- NOTE 11
40 GRID OR MESH
41 INTERNALS (4), PAGE 1- NOTE 11
42 SPRAY HEADERS / NOZZLES (4), PAGE 1- NOTE 11
43
44 REMARKS:
45 1) MINIMUM FLOW IS 50% OF NORMAL RATE SHOWN ABOVE.
46 2) MAXIMUM FLOW IS 116% OF NORMAL RATE SHOWN ABOVE.
47 3) MAXIMUM ALLOWABLE PRESSURE DROP THROUGH TOWER 0.140 kg/cm² AT MAXIMUM DESIGN RATE.
48 4) LIQUID/VAPOR DISTRIBUTORS/BED SUPPORT AND HOLD DOWN PLATES BY VENDOR. HEIGHT FOR
49 THEM HAS BEEN PROVIDED IN THIS BED'S SECTION HEIGHT. SEE SECTION HEIGHTS ON PAGE 1.
50 5) MAXIMUM HEAT REMOVAL IS 116% OF DESIGN GIVEN ABOVE. VENDOR TO INSURE THE VOLUME OF
51 PROVIDED PACKING IS SUFFICIENT TO REMOVE THIS DUTY. SEE SKETCH NO. 3 ON PAGE 16.
52 6) SIMULATION FILE HRRLGP102.PRZ
53 7) KOCH-GLITSCH TYPE 3X OR SULZER TYPE M125.X
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 98 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 16 OF 22
01
02
SKETCH NO. 3
03
HCO PUMPAROUND SECTION
04
05 779415 KG/HR
06
07 282278 KG/HR
08
09
BED 4
10
11 LCO/HCO
(2)
12
13
14
15
16
17 201625 KG/HR
18 HCO PA FLOW
19 635261 KG/HR @ 200°C 698762 KG/HR
20 836886 KG/HR
21
22
23
BED 3
24
25 HCO PUMPAROUND
(3)
26 22.5 MKCAL/HR
27 (1)
28
29
30 HCO FLUSH RECYCLE 991621 KG/HR
31 4115 KG/HR @ 220°C
32 (4)
33
HCO PUMPAROUND
34 CHIMNEY TRAY
35 4115 KG/HR @ 220°C
853496 KG/HR
36
37 352244 KG/HR
38 (REFER TO NOTE 13 ON
SHT 1)
39
0.11 MKCAL/HR
40
41
BED 2 HCO WASH
42
43
44
45
46 TO TOP BED 1
47
48 NOTES:
49 1. PUMPAROUND ZONE TO BE DESIGNED FOR 116% OF FLOWS AND DUTY SHOWN ABOVE.
50 2. REFER TO NOTE 5 ON PAGE 14.
3. REFER TO NOTE 5 ON PAGE 15.
51
4. HCO RETURN IS CONTINUOUS TO THE COLUMN FROM THE INSTRUMENTS BEING FLUSHED
52
53
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 99 of 674
 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 17 OF 22
01 PACKING SECTION HCO WASH (BED 2)
02 TYPE OF PACKING GRID
03 BED HEIGHT mm (4)
04 BED DIAMETER mm 8000
05 BED VOLUME m³ BY VENDOR (4)
06 HEIGHT OF PACKING mm
07 HEIGHT OF GRID OR MESH mm 1540 (5)
08 LOADS ARE NORMAL
09 BASED ON CASE 1
10
11
12 VAPOR FROM TOP OF BED TO BOTTOM OF BED
13 FLOW RATE kg/hr 853496 835420
14 DENSITY kg/m³ 2.29 2.21
15 VOLUMETRIC FLOW m³/s 103.65 104.80
16
17 TEMPERATURE °C 299 313
18 PRESSURE kg/cm²(g) 0.78 0.78
19 MOLECULAR WEIGHT 61.03 60.27
20 VISCOSITY cP 0.016 0.016
21
22
23 LIQUID TO TOP OF BED (4) FROM BOTTOM OF BED (4)
24 FLOW RATE kg/hr 352244 334168
25 DENSITY kg/m³ 893.27 889.05
26 VOLUMETRIC FLOW m³/hr 394.33 375.87
27
28 TEMPERATURE °C 271.1 299
29 VISCOSITY cP 0.43 0.39
30 SURFACE TENSION dyne/cm 20.60 19.30
31 MOLECULAR WEIGHT # 243.62 252.69
32 FOAMING TENDENCY 1.00 1.00
33
34 HEAT TRANSFER
35 HEAT REMOVED MMkcal/hr
36 HEAT TRANSFER COEFFICIENT kcal/hr-m²-°C
37
38 TYPE & MATERIAL
39 PACKING
40 GRID OR MESH GRID (8), PAGE 1- NOTE 11
41 INTERNALS (4), PAGE 1- NOTE 11
42 SPRAY HEADERS / NOZZLES (4), PAGE 1- NOTE 11
43
44 REMARKS:
45 1) MINIMUM FLOW IS 50% OF NORMAL RATE SHOWN ABOVE.
46 2) MAXIMUM FLOW IS 116% OF NORMAL RATE SHOWN ABOVE.
47 3) MAXIMUM ALLOWABLE PRESSURE DROP THROUGH TOWER 0.140 kg/cm² AT MAXIMUM DESIGN RATE.
48 4) LIQUID/VAPOR DISTRIBUTORS/BED SUPPORT AND HOLD DOWN PLATES BY VENDOR. HEIGHT FOR
49 THEM HAS BEEN PROVIDED IN THIS BED'S SECTION HEIGHT. SEE SECTION HEIGHTS ON PAGE 1.
50 5) BASED ON 1 THEORETICAL STAGE; PACKING VENDOR TO CONFIRM HEIGHT.
51 6) DESIGN FOR 80% JET FLOOD AT MAX DESIGN RATES.
52 7) SIMULATION FILE HRRLGP102.PRZ
53 8) KOCH-GLITSCH TYPE PROFLUX64 OR SULZER TYPE M2X
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 100 of 674

 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 18 OF 22
01 PACKING SECTION SLURRY PA (BED 1)
02 TYPE OF PACKING GRID
03 BED HEIGHT mm (4)
04 BED DIAMETER mm 8000
05 BED VOLUME m³ BY VENDOR (4, 5)
06 HEIGHT OF PACKING mm
07 HEIGHT OF GRID OR MESH mm 3150 (5)
08 LOADS ARE NORMAL
09 BASED ON CASE 1
10
11
12 VAPOR FROM TOP OF BED TO MIDDLE OF BED
13 FLOW RATE kg/hr 835420 1199246
14 DENSITY kg/m³ 2.21 2.75
15 VOLUMETRIC FLOW m³/s 104.80 121.30
16
17 TEMPERATURE °C 313 349
18 PRESSURE kg/cm²(g) 0.78 0.79
19 MOLECULAR WEIGHT 60.27 78.66
20 VISCOSITY cP 0.016 0.016
21
22
23 LIQUID TO TOP OF BED (4) FROM BOTTOM OF BED (4)
24 FLOW RATE kg/hr 1510308 1874134
25 DENSITY kg/m³ 959.48 911.87
26 VOLUMETRIC FLOW m³/hr 1574.1 2055.3
27
28 TEMPERATURE °C 253.8 313
29 VISCOSITY cP 0.70 0.42
30 SURFACE TENSION dyne/cm 24.58 19.82
31 MOLECULAR WEIGHT # 276.49 273.73
32 FOAMING TENDENCY 1.00 1.00
33
34 HEAT TRANSFER
35 HEAT REMOVED MMkcal/hr 66.29
36 HEAT TRANSFER COEFFICIENT kcal/hr-m²-°C BY VENDOR
37
38 TYPE & MATERIAL
39 PACKING
40 GRID OR MESH GRID (7), PAGE 1- NOTE 11
41 INTERNALS (4), PAGE 1- NOTE 11
42 SPRAY HEADERS / NOZZLES (4), PAGE 1- NOTE 11
43
44 REMARKS:
45 1) MINIMUM FLOW IS 50% OF NORMAL RATE SHOWN ABOVE.
46 2) MAXIMUM FLOW IS 116% OF NORMAL RATE SHOWN ABOVE.
47 3) MAXIMUM ALLOWABLE PRESSURE DROP THROUGH TOWER 0.140 kg/cm² AT MAXIMUM DESIGN RATE.
48 4) LIQUID/VAPOR DISTRIBUTORS/BED SUPPORT AND HOLD DOWN PLATES BY VENDOR. HEIGHT FOR
49 THEM HAS BEEN PROVIDED IN THIS BED'S SECTION HEIGHT. SEE SECTION HEIGHTS ON PAGE 1.
50 5) MAXIMUM HEAT REMOVAL IS 116% OF DESIGN. VENDOR TO INSURE THE VOLUME OF PROVIDED PACKING
51 IS SUFFICIENT TO REMOVE THIS DUTY. SEE SKETCH NO. 4 ON PAGE 20.
52 6) SIMULATION FILE HRRLGP102.PRZ
53 7) KOCH-GLITSCH TYPE FLEXIGRID 2-45 OR SULZER TYPE MG64.X
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 101 of 674

 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 19 OF 22
01 PACKING SECTION SLURRY PA (BED 1)
02 TYPE OF PACKING GRID
03 BED HEIGHT mm (4)
04 BED DIAMETER mm 8000
05 BED VOLUME m³ BY VENDOR (4, 5)
06 HEIGHT OF PACKING mm
07 HEIGHT OF GRID OR MESH mm 3150 (5)
08 LOADS ARE NORMAL
09 BASED ON CASE 1
10
11
12 VAPOR TO BOTTOM OF BED
13 FLOW RATE kg/hr 538086
14 DENSITY kg/m³ 1.09
15 VOLUMETRIC FLOW m³/s 137.47
16
17 TEMPERATURE °C 570
18 PRESSURE kg/cm²(g) 0.79
19 MOLECULAR WEIGHT 42.51
20 VISCOSITY cP 0.024
21
22
23 LIQUID TO TOP OF BED (4)
24 FLOW RATE kg/hr 1212974
25 DENSITY kg/m³ 899.23
26 VOLUMETRIC FLOW m³/hr 1348.9
27
28 TEMPERATURE °C 349
29 VISCOSITY cP 0.37
30 SURFACE TENSION dyne/cm 17.96
31 MOLECULAR WEIGHT # 284.78
32 FOAMING TENDENCY 1.00
33
34 HEAT TRANSFER
35 HEAT REMOVED MMkcal/hr SEE PAGE 18 OF 21
36 HEAT TRANSFER COEFFICIENT kcal/hr-m²-°C BY VENDOR
37
38 TYPE & MATERIAL
39 PACKING
40 GRID OR MESH GRID (7), PAGE 1- NOTE 11
41 INTERNALS (4), PAGE 1- NOTE 11
42 SPRAY HEADERS / NOZZLES (4), PAGE 1- NOTE 11
43
44 REMARKS:
45 1) MINIMUM FLOW IS 50% OF NORMAL RATE SHOWN ABOVE.
46 2) MAXIMUM FLOW IS 116% OF NORMAL RATE SHOWN ABOVE.
47 3) MAXIMUM ALLOWABLE PRESSURE DROP THROUGH TOWER 0.140 kg/cm² AT MAXIMUM DESIGN RATE.
48 4) LIQUID/VAPOR DISTRIBUTORS/BED SUPPORT AND HOLD DOWN PLATES BY VENDOR. HEIGHT FOR
49 THEM HAS BEEN PROVIDED IN THIS BED'S SECTION HEIGHT. SEE SECTION HEIGHTS ON PAGE 1.
50 5) MAXIMUM HEAT REMOVAL IS 116% OF DESIGN. VENDOR TO INSURE THE VOLUME OF PROVIDED PACKING
51 IS SUFFICIENT TO REMOVE THIS DUTY. SEE SKETCH NO. 4 ON PAGE 20.
52 6) SIMULATION FILE HRRLGP102.PRZ
53 7) KOCH-GLITSCH TYPE FLEXIGRID 2-45 OR SULZER TYPE MG64.X
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 102 of 674

 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 20 OF 22
01
02
03 SKETCH NO. 4
04
SLURRY PUMPAROUND SECTION
05
06
07
08 853496 KG/HR
09 352244 KG/HR
10
11
BED 2
12
13 (2) HCO WASH
14
15
16 HCO FLUSH RETURN 4115
17 KG/HR (4)
18
LCO FLUSH RETURN
19 4437 KG/HR (5)
20 334168 KG/HR
835420 KG/HR
21
22
23 1510308 KG/HR
24
25
26 SLURRY PA FLOW
27 1167589 KG/HR @ 240 ºC
28
29 SLURRY
66.2 MKCAL/HR PUMPAROUND
30 (3)
(1) SECTION
31
32
33
34 BED 1
35
36
37 1212974 KG/HR
38
39
40
41 538086 KG/HR
42
43
44
45
46 NOTES:
47 1. PUMPAROUND ZONE TO BE DESIGNED FOR 116% OF FLOWS AND DUTY SHOWN ABOVE.
48 2. REFER TO NOTE 5 ON PAGE 17.
3. REFER TO NOTE 5 ON PAGE 18 AND 19.
49
4. HCO RETURN IS CONTINUOUS TO THE COLUMN FROM THE INSTRUMENTS BEING FLUSHED.
50 5. LCO RETURN IS NOT CONTINUOUS BUT RETURNS TO THE COLUMN VIA LCO PA PIPING.
51
52
53
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 103 of 674

 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 21 OF 22
01 TRAY LOCATION LEAN OIL DRAW LCO PA DRAW HCO PA DRAW
02 TRAY NUMBERS
03 TRAY TYPE CHIMNEY CHIMNEY CHIMNEY
04 TRAY SPACING mm
05 TOWER INSIDE DIAMETER mm 8000 8000 8000
06 NO. OF PASSES
07 LOADS ARE NORMAL NORMAL NORMAL
08 BASED ON CASE 1 CASE 1 CASE 1
09
10 VAPOR TO TRAY
11 FLOW RATE kg/hr 648108 779415 853496
12 DENSITY kg/m³ 2.25 2.30 2.29
13 VOLUMETRIC FLOW m³/s 80.16 94.05 103.67
14
15 TEMPERATURE °C 167 235 299
16 PRESSURE kg/cm²(g) 0.70 0.74 0.78
17 MOLECULAR WEIGHT 47.93 55.65 61.03
18 VISCOSITY cP 0.013 0.014 0.016
19
20
21 LIQUID FROM TRAY
22 FLOW RATE kg/hr 330442 ( 4 ) 1190065 (5) 991621 (6)
23 DENSITY kg/m³ 822.93 846.98 893.27
24 VOLUMETRIC FLOW m³/hr 282.68 1557.6 1342.5
25
26 TEMPERATURE °C 162 205 271
27 VISCOSITY cP 0.35 0.41 0.43
28 SURFACE TENSION dyne/cm 21.00 20.60 20.60
29 MOLECULAR WEIGHT 160.25 190.10 243.62
30 FOAMING TENDENCY
31
32
33
34
35 REMARKS:
36 1) MINIMUM FLOW IS 50% OF DESIGN RATE SHOWN ABOVE.
37 2) MAXIMUM FLOW IS 116% OF DESIGN RATE SHOWN ABOVE.
38 3) ALLOWABLE PRESSURE DROP 0.007 KG/CM² PER TRAY (AVERAGE) AT MAXIMUM DESIGN RATE.
39 4) 147,600 KG/HR FLOW IS DRAWN FROM THIS TRAY. THE REMAINING 182,842 KG/HR FLOW IS INTERNAL
40 REFLUX TO THE FRACTIONATION SECTION BELOW. SEE SKETCH NO. 1 OF PAGE 10.
41 REQUIRED LIQUID HOLDUP IS 9 MINUTES OF THE DRAW RATE OF 147,600 KG/HR.
42 5) 907,787 KG/HR FLOW IS DRAWN FROM THIS TRAY. THIS CONSISTS OF PRODUCT DRAW AND PUMPAROUND. THE
43 REMAINING 282,278 KG/HR FLOW IS INTERNAL REFLUX TO THE FRACTIONATION SECTION BELOW. SEE SKETCH NO. 2
44 OF PAGE 13. REQUIRED LIQUID HOLDUP IS 1.35 MINUTES OF THE CIRCULATING REFLUX (PA) RATE OF 874,502 KG/HR.
45 6) THIS IS A TOTAL DRAW TRAY. THE TOTAL 991,621 KG/HR IS DRAWN FROM THIS TRAY, OF WHICH
46 352,244 KG/HR FLOW IS PUMPED AS INTERNAL REFLUX TO BED 2 BELOW. A DOWNPIPE TO OVERFLOW
47 THIS AMOUNT TO BED 2 WHEN P-2102A/B FAILS IS TO BE PROVIDED. SEE SKETCH NO. 3 OF PAGE 16. REQUIRED LIQUID
48 HOLDUP IS 5 MINUTES OF CIRCULATING REFLUX (PA) RATE OF 635,261 KG/H.
49 7) SIMULATION FILE HRRLGP102.PRZ
50
51
52
53
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 104 of 674

 DOCUMENT NUMBER: 076405C001-111-PDS-0500-2101
PROCESS LOCATION: J.O. NO.: ITEM NO.:
DATA SHEETS HOUSTON, TX, USA 076405C001 111-C-2101
SERVICE: NO. REQUIRED:
(METRIC UNITS) MAIN FRACTIONATOR ONE
CLIENT: LOCATION: PAGE: REV
HPCL RAJASTHAN REFINERY LTD. (HRRL) PACHPADRA, BARMER, RAJASTHAN 22 OF 22
01 THERMOWELL DETAIL
02
03
VAPOR THERMOWELL - SIDE VIEW
04
05
75 MIN.

06 450 50
07
08 C
L
09 50 x 50 ANGLE IRON
10
11 SUPPORT STRAP FOR LIQUID
SHIELD OVER VAPOR THERMOWELL
12
13
VAPOR THERMOWELL - END VIEW
14
15 50
16
17
18
19 SUPPORT STRAP IS SUPPORT STRAP IS
20 CONNECTED TO EDGE CONNECTED TO EDGE
OF ANGLE IRON COVER OF ANGLE IRON COVER
21 25 MM TW MAX.
22 (NOTE 2)

23 NOTES:
1) DIMENSIONS IN mm EXCEPT WHERE NOTED.
24 2) THERMOWELL TO BE TAPERED.
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
REVISION A B C 0 1 2
DATE 4/17/19 6/6/19 7/22/19 8/19/19 10/11/19 12/12/19
BY/REVIEWED/QC GML/NMD/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM GML/LB/PM
BOX HAS BEEN CHECKED TO DENOTE NO CHANGES TO THIS SHEET THIS REVISION (x)

Page 105 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
4oi
`ifaeit4ift, ENGINEERS CIVIL & STRUCTURAL WORKS -
fge_liefordgw INDIA LIMITED 6-68-0001 Rev.5
evaznIaciaJooM In Govt of India Undendond) GENERAL SCOPE Page 1 of 4

1-11114) 111 kill

"fttqF **1011-110-14) 4)14

STANDARD SPECIFICATION
CIVIL AND STRUCTURAL WORKS

tiffq
GENERAL SCOPE

If
REAFFIRMED AND REISSUED AS
5 04 07 2019 AVM AJS RS RKT
SPECIFICATION
4 REAFFIRMED AND REISSUED AS
28 03 2013 AJS RS PKM DM
SPECIFICATION
REAFFIRMED AND REISSUED AS
3 26 02 2008 PKB PKM VK VC
SPECIFICATION
REAFFIRMED AND REISSUED AS
2 08 06 2001 DPN RPM SCJ MI
SPECIFICATION
1 02 03 1994 ISSUED AS STD SPECIFICATION HM GPL AS
Standards Standards
Rev. Prepared Checked Committee Bureau
Date Purpose Convenor Chairman
No by by
Approved by

Format No 8-00-0001-F1 Rev 0 Copyright EIL - All rights reserved

Page 106 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
M ENGINEERS
LIMITED CIVIL & STRUCTURAL WORKS —
51geff
1.11E,
1 RJR 4513a31ii)
INDIA 6-68-0001 Rev.5
IA Govt of India Undenaiond)
GENERAL SCOPE Page 2 of 4

Abbreviations:

IS : Indian Standards

Structural Standards Committee:

Convenor: Mr. Rajanji Srivastava

Members: Mr. Anurag Sinha

Mr. VK Panwar
Mr. Samir Das
Mr. Amitabh Kishore
Mr. Gyasuddin
Mr. Charanjeet Singh (Projects)
Mr. Ravindra Kumar (Construction)

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Page 107 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
401 el ENGINEERS
$fieff 2151-eg INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0001 Rev.5
I NPR. eit,151110151.3P4f A)
Govt of Inds Undertaking)
GENERAL SCOPE Page 3 of 4

1. These specifications establish and define the material and constructional requirements for
CIVIL and STRUCTURAL WORKS.

2. Methods of measurements are indicated in these specifications; where not so specified, latest
revision of IS: 1200 shall be applicable.

3. Providing and operating all necessary measuring and testing devices/ equipments including all
materials and consumables are included in the scope of work. No separate measurement or
payment for testing the quality of work and materials shall be made; rates quoted for various
items shall be deemed to include the cost of such tests which are required to ensure
achievement of specified quality.

4. All materials shall be of standard quality, manufactured by renowned concerns conforming to

Indian Standards or equivalent, and shall have IS mark as far as possible unless otherwise
approved by the Engineer-in-Charge. Vendor List attached in the Tender document shall be
followed. The Contractor shall get all materials approved by the Engineer-in-Charge prior to
procurement and use. The Contractor shall furnish manufacturer's certificates for the
materials supplied by him when asked for. Further to that he shall get the materials tested
from an approved test house if asked for by the Engineer-in- Charge. The cost for all the tests
and test certificates for the material procured by the Contractor shall be borne by the
Contractor. No separate payment shall be made for the testing. The Engineer-in-Charge shall
have the right to determine whether all or any of the materials are suitable. Any materials
procured or brought to site and not conforming to specifications and satisfaction of the
Engineer-in-Charge shall be rejected and the Contractor shall have to remove the same
immediately from site at his own expense and without any claim for compensation due to such
rejection.

5. Wherever referred to in the tender document, only the latest revision of Specifications, Codes
of Practice and other publications of Bureau of Indian Standards shall be applicable.

6. Wherever the Contractor executes civil and structural works involving buildings, equipment
foundations, supporting structures, pipe racks, etc., the following works are deemed to have
been included in the quoted rates for various works.

- Marking of centre lines of foundations etc.

- Establishing layout and levels of foundations and superstructure etc., including

establishment of reference lines, bench marks on various floors, platforms etc.

General upkeep of the plant site.

Preparation of Fabrication drawings and getting approval from Engineer-in-Charge after

incorporating all the comments.

Preparation of "As-Built" scheme of structural drawings indicating constructed details

including levels, centre lines, layouts, member sizes etc. complete.

7. The provisions of Schedule of Rates, specifications and drawings shall be read in conjunction
with each other and in case of conflict amongst them, clarification shall be obtained from the
Engineer-in-Charge whose decision shall be final and binding. However, the following
procedure may generally be followed:

Description of items in schedule of rates shall be followed when provisions therein are
different from those in specifications.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
dara.it4 = ENGINEERS
es felf5teg INDIA LIMITED CIVIL & STRUCTURAL WORKS —
CORM 212ZINE,2151.3.41.0
6-68-0001 Rev.5
IA Govt of Ind., Undertaking)
GENERAL SCOPE Page 4 of 4

Where the description of item does not call for some specific requirement but the
same is given in specifications, the specifications shall be followed in addition to the
requirement given in description of item.

Where drawings call for requirements different from or additional to those given in
item description and specifications, the decision of the Engineer-in-Charge shall be
obtained as to what shall be followed.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
k3n
- ENGINEERS CIVIL & STRUCTURAL WORKS
Ifgar f6ifteu INDIA LIMITED 6-68-0002 Rev.5
411V,1 twaAV sPIJ.V.31 A Govt Inn o Urdettalung) MATERIALS Page 1 of 16

1-11vich q 11 kill
"tr-4-ff "R-4 4)14

STANDARD SPECIFICATION
CIVIL & STRUCTURAL WORKS

MATERIALS

5 16.05.16 UPDATED & REISSUED MK AJS RS R.NANDA

4 21.08.14 UPDATED & REISSUED ASR AS PKM S.CHANDA

VINAY
3 19.06.09 REAFFIRMED & REISSUED AS SCH N. DUARI
KUMAR

2 18.02.00 UPDATED & REISSUED DPN SKP SC JAIN A. SONI

1 JUNE'94 ISSUED AS STANDARD SPECIFICATION SKP GPL A. SONI

Standards Standards
Rev. Committee Bureau
Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
Ogar Elfa
(WrI ereinV crIJW.1)
INDIA LIMITED
f n Govt of India Undeltakng)
CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
MATERIALS Page 2 of 16

Abbreviations:

API American Petroleum Institute

ASTM American Society for Testing & Materials
BIS Bureau of Indian Standards
BS British Standard
C&D Waste Construction and Demolition Waste
DIN Deutsches Institut' filr Normung
IS Indian Standards
PCC Plain Cement Concrete
PVC Poly Vinyl Chloride
RA Recycled Aggregates
RCA Recycled Concrete Aggregates
RCC Reinforced Cement Concrete

Structural Standards Committee

Convenor: Mr. Rajanji Srivastava

Members : Mr. Anurag Sinha

Mr. J K Bhagchandani
Mr. S K Naskar
Mr. V K Panwar
Mr. Charanjit Singh (Projects)
Mr. Ravindra Kumar (Construction)

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 er-
STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
ftr faffleg
E4VVNE,1)1,A41.11
INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
IA GOY* Of InCIO UMIeltaking)
MATERIALS Page 3 of 16

CONTENTS

1.0 SCOPE 4

2.0 REFERENCES 5

3.0 WATER 5

4.0 AGGREGATE 5

5.0 SAND 7

6.0 CEMENT 8

7.0 STEEL 9

8.0 BRICK 11

9.0 STONE 13

10.0 ADMIXTURES 13

11.0 WATER BARS (WATER STOPS) 15

12.0 BITUMEN/BITUMINOUS MATERIALS 15

13.0 PVC PIPES 15

14.0 WOOD/TIMBER 16

15.0 EPDXY COMPOUNDS 16

16.0 PAINT 16

17.0 ANTITERMITE COMPOUNDS 16

18.0 POLYSULPHIDE SEALANTS 16

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
lf..aA ENGINEERS
51ga EiflegWr INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
urveitakngi
A Govt of InOw
MATERIALS Page 4 of 16

1.0 SCOPE

1.1 This specification establishes and defines the requirements of various materials to be used in
Civil and Structural works.

1.2 Whenever any reference to BIS Codes is made, the same shall be taken as the latest revision
(with all amendments issued thereto) as on the date of submission of the bid.

1.3 Apart from the BIS Codes mentioned in particular in the various clauses of this specification,
all other relevant codes related to specific job under consideration regarding quality, tests,
testing and/ or inspection procedures shall be applicable. Reference to some of the Codes in
the various clauses of this specification does not limit or restrict the scope of applicability of
, other referred or relevant codes.

1.4 In case of any variation/contradiction between the provision of BIS Codes and this
specification, the provision given in this specification shall be followed.

1.5 All materials shall be of standard quality and shall be procured from renowned sources/
manufacturers approved by the Engineer-in-Charge. It shall be the responsibility of the
Contractor, to get all materials/ manufacturers approved by the Engineer-in-Charge prior to
procurement and placement of order.

1.6 Whenever called for by the Engineer-in-Charge all tests of the materials as specified by the
relevant BIS Codes shall be carried out by the Contractor in an approved laboratory and test
reports duly authenticated by the laboratory, shall be submitted to the Engineer-in-Charge for
his approval. If so desired by the Engineer-in-Charge, tests shall be conducted in the presence
of the Engineer-in-Charge or his authorized nominee.

1.7 Quality and acceptability of materials not covered under this specification shall be governed
by the relevant BIS Codes. In case BIS code is not available for the particular material, other
codes e.g. BS or DIN or API/ ASTM shall be considered. The decision of Engineer-in-Charge,
in this regard, shall be final and binding on the Contractor.

1.8 Whenever asked for, the Contractor shall submit representative samples of materials to the
Engineer-in-Charge for his inspection and approval. Approval of any sample does not
necessarily exempt the Contractor from submitting necessary test reports for the approved
material, as per the specification/relevant BIS Codes.

1.9 The Contractor shall submit manufacturer's test reports on quality and suitability of any
material procured from them and their recommendation on storage, application, workmanship
etc. for the intended use. Submission of manufacturer's test reports does not restrict the
Engineer-in-Charge from asking fresh test results from an approved laboratory of the actual
material supplied from an approved manufacturer/ source at any stage of execution of work.

1.10 All costs relating to or arising out of carrying out the tests and submission of test reports and
or samples to the Engineer-in-Charge for his approval during the entire tenure of the work
shall be borne by the contractor and included in the quoted rates.

1.11 Materials for approval shall be separately stored and marked, as directed by the Engineer-in-
Charge and shall not be used in the works till these are approved.

1.12 All rejected materials shall be immediately removed from the site by the Contractor at his own
cost.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
Zgar fal5leg INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
eVIZTP MI, I Gout of Infla Undettaking)
MATERIALS Page 5 of 16

2.0 REFERENCES
As mentioned in the respective clauses.

3.0 WATER
3.1 Water used in construction for all civil & structural works shall be clean and free from
injurious amount of oil, acids, alkalies, organic matters or other harmful substances which
may be deleterious to concrete, masonry or steel. The pH value of water sample shall be not
less than 6. Potable water shall be considered satisfactory. Underground water can also be
used with the prior approval of Engineer-in-Charge, if it meets all the requirements of IS:456.

3.2 Tests on water samples shall be carried out in accordance with IS:3025 and they shall fulfill
all the guidelines and requirements given in IS:456.
3.3 The Engineer-in-Charge may require the Contractor to prove, that the concrete prepared with
water, proposed to be used, shall have average 28 days compressive strength not lower than
90% of the strength of concrete prepared with distilled water.
3.4 The Engineer-in-Charge may require the Contractor to get the water tested from an approved
laboratory before starting the construction work and in case the water contains any oil/ organic
matter or an excess of acid, alkalies or any injurious amount of salts etc., beyond the
permissible maximum limits given in IS:456, the Engineer-in-Charge may refuse to permit its
use. In case the water is supplied by the owner, contractor shall get himself satisfied regarding
its quality before using the same in his works at his own expense. In case there is any change
in source of water, water samples shall be tested again to meet the specified requirements.
3.5 Water shall be stored in tin barrels, steel tanks or water-tight reservoirs made with bricks /
stone or reinforced concrete. Brick/ stone masonry reservoirs shall have RCC base slab and
shall be plastered inside, with 1 part of cement and 4 parts of sand and finished with neat
cement punning. These reservoirs shall be of sufficient capacity to meet the water
requirement, at any stage of construction.

3.6 Water for curing shall be of the same quality as used for concreting and masonry works. Sea
water shall not be used for preparation of cement mortar, concrete as well as for curing of
plain/reinforced concrete and masonry works. Sea water shall not be used for hydrotesting and
checking the leakage of liquid retaining structures also.

4.0 AGGREGATE
4.1 General
4.1.1 Coarse and fine aggregates for Civil and Structural Works shall conform in all respects to
IS:383 (Specification for coarse and fine aggregates for concrete). Aggregates shall consist of
naturally occurring (crushed or uncrushed) stones, gravel and sand or a combination thereof or
manufactured aggregates produced from other than natural sources. These shall be chemically
inert, hard, strong, dense durable, clear and free from veins, adherent coatings, injurious
amount of disintegrated pieces, alkalies, free lime, vegetable matter and other deleterious
substances such as iron pyrites, coal, lignite, mica, shale, sea shells etc. Naturally occurring
aggregates shall be obtained from an approved source known to produce the same
satisfactorily.

Manufactured aggregates shall consists of Iron and Steel slag aggregates, Copper slag
aggregates or aggregates made from Construction & Demolition (C&D) waste such as
Recycled Aggregates (RA) and Recycled Concrete Aggregates (RCA). RA shall comprise of
waste from concrete, brick, tiles, stone, etc. and RCA shall be derived from concrete after
requisite processing. Extent of utilization of manufactured aggregates in RCC and PCC works
shall be as per Table-1 of IS:383.

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 STANDARD SPECIFICATION No.
ENGINEERS STANDARD SPECIFICATION
III EifAtg
(awn emart12 %Durum)
INDIA LIMITED
(A Gov* of :nda Undertaking)
CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
MATERIALS Page 6 of 16

4.1.2 Source and type of aggregates shall be got approved by the Engineer-in-Charge prior to
procurement. Change in source and type of aggregates, at later stage, shall not be generally
permitted; but under specific circumstances, Engineer-in-Charge can allow a change in source
and type of aggregate. Contractor shall produce necessary test certificates from approved
laboratories regarding the quality and suitability of the proposed aggregates and submit fresh
mix design for approval of the Engineer-in-Charge. Any such change, if permitted by the
Engineer-in-Charge, shall be without any time and cost implication to the owner.

4.1.3 Aggregates which may chemically react with alkalies of cement or might cause corrosion of
the reinforcement, shall not be used. If so desired by the Engineer-in-Charge, the Contractor
shall carry out alkali reactivity tests and submit the results to him for approval.

4.1.4 The maximum quantities of deleterious materials in the aggregates as determined in

accordance with IS:2386 - Part II (Methods of Test for aggregates for concrete), shall not
exceed the limits defined in IS: 383. No special test is required to prove the absence of such
deleterious matters if the aggregates are from a known source with satisfactory prior data on
the properties of concrete made with them. In case of newly developed quarry sites, the
contractor shall submit necessary test results as per IS:383 and IS:2386 to the Engineer-in-
Charge prior to his acceptance and approval. The method of Sampling shall be in accordance
with the requirements given in IS:2430.

4.1.5 Coarse and fine aggregates shall be batched separately. All-in-aggregate shall be used only
where specifically permitted by the Engineer-in-Charge.

Separate sieve analysis and grading curves shall be prepared by the Contractor for any/ all
batches of coarse and fine aggregates, and submitted to the Engineer-in- Charge, whenever
asked for, to ensure conformity with those submitted along with the mix design.

4.1.6 Whenever required by Engineer-in-Charge, the aggregates (coarse/ fine) shall be washed and/
or sieved by the contractor before use in the works to obtain clean and graded aggregate at no
extra cost to the owner.

4.1.7 Aggregates not in conformity with the specifications shall be rejected and the Contractor shall
immediately remove them from the site of work.

4.2 Coarse Aggregates

4.2.1 Coarse aggregates are the aggregates, which are retained on 4.75 mm BIS Sieve. It shall have
a specific gravity not less than 2.6 (saturated surface dry basis).

4.2.2 These may be obtained from crushed or uncrushed gravel or stone or may be manufactured
from other than natural sources like RCA or RA from C&D waste and may be supplied as
single sized or graded. The grading of the aggregates shall be as per IS:383 or as required by
the mix design, to obtain densest possible concrete. For this purpose, the contractor shall
submit to the Engineer-in-Charge at least three sets of mix design and test results, each with
different gradings of coarse aggregates, proposed to be used. The Engineer-in-Charge may
allow "All-in-aggregates" to be used provided they satisfy the requirements of IS:383.

4.3 Fine Aggregates

4.3.1 Fine aggregates are the aggregates which pass through 4.75 mm BIS sieve but not more than
ten percent (10%) pass through 150 micron BIS sieve. These shall comply with the
requirements of grading zones I, II and III of IS:383. Fine aggregates conforming to grade
zone IV shall not be used for reinforced concrete works.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
tsar faffleg W INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
MA., er-Zar7asisAromi, (A Gort of India Undertaking(
MATERIALS Page 7 of 16

4.3.2 Fine aggregates shall consist of material resulting from natural disintegration of rock and
which has been deposited by streams or glacial agencies, or crushed stone sand or gravel sand
or manufactured from other than natural sources like RCA from C&D waste. Sand from sea
shores, creeks or river banks affected by tides, shall not be used for filling or concrete works.

4.4 Sampling and Testing

The Contractor shall carry out all tests including mix designs of concrete, at his own expense,
at the start of work as well as during any stage of construction as required by the
Engineer-in-Charge. Test shall be carried out in accordance with IS:516 - Methods of test for
strength of concrete and IS:2386 - Methods of test for aggregates for concrete. Testing shall be
carried out from laboratories approved by the Engineer- in-Charge. The method of sampling
shall be in accordance with the requirements given in IS: 2430.

4.5 Storage of Aggregates

4.5.1 Storage of all types of aggregates at site of work shall be at contractor's expense and risk and
shall be stored as specified in IS:4082. Aggregates shall in no case be stored near to the
excavated earth or directly over ground surface.

4.5.2 The Contractor shall maintain sufficient quantities of aggregates, near to the place of work,
required for the continuity of the work. Each type and grade of aggregate shall be stored
separately on hard, firm surface having adequate slope for drainage of water.

4.5.3 Aggregates delivered at site in wet condition or becoming wet due to rain or any other means,
shall not be used for atleast 24 hours. The Contractor shall obtain prior approval of the
Engineer-in-charge for the use of such aggregates and shall adjust the water content in
accordance with IS:2386 to achieve the desired mix. In the absence of test results, and to allow
variation in mass of aggregates and water content on account of moisture content, the
Contractor can make suitable adjustment in the masses as per IS:456, for preparation of
nominal mix concrete only.

5.0 SAND

5.1 Sand for Masonry Mortars

5.1.1 The sand shall consist of natural sand, crushed stone sand or crushed gravel sand or a
combination of any of these. The sand shall be hard, durable, clean and free from adherent
coatings and organic matter and shall not contain the amount of clay, silt and fine dust more
than specified in IS:2116.

5.1.2 The sand shall not contain any harmful impurities such as iron pyrites, alkalis, salts, coal or
other organic impurities, mica, shale or similar laminated materials, soft fragments, sea shells
in such form or in such quantities as to affect adversely the hardening, strength or durability of
the mortar.

5.1.3 Unless found satisfactory as a result of further tests as may be specified by the Engineer-in-
Charge, or unless evidence of such performance is offered which is satisfactory to him, the
maximum quantities of clay, fine silt, fine dust and organic impurities in the sand, when tested
in accordance with IS:2386, shall not be more than 5% by mass in natural sand, or crushed
gravel sand or crushed stone sand. For organic impurities, when determined in accordance
with IS:2386, colour of the liquid shall be lighter than that indicated by the standard solution
specified in IS:2386.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
101 eJ ENGINEERS
0g-en51e-g
eurark .voral
INDIA LIMITED
IA Govt of inota undettaking)
CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
MATERIALS Page 8 of 16

5.1.4 Grading of Sand

The particle size grading of sand for use in mortars shall be within the limits as specified
below:

GRADING OF SAND FOR USE IN MASONRY MORTARS

IS SIEVE DESIGNATION PERCENTAGE REF. TO

IS: 460 (PART I) PASSING BY MASS METHOD OF

4.75 mm 100 IS:2386 (Part I)

2.36 mm 90 to 100
1.18 mm 70 to 100
600 micron 40 to 100
300 micron 5 to 70
150 micron 0 to 15

In case of a sand whose grading falls outside the specified limits due to excess or deficiency of
coarse or fine particles, this shall be processed to comply with the standard by screening
through a suitably sized sieve and/or blending with required quantities of suitable sizes of
natural sand particles or crushed stone screenings which are by themselves unsuitable. Based
on test results and in the light of practical experience with the use of local materials, deviation
in grading of sand may be considered by the Engineer-in-Charge. The various sizes of
particles of which the sand is composed shall be uniformly distributed throughout the mass.

5.1.5 Sampling and Testing

The method of sampling shall be in accordance with IS:2430. The amount of material required
for each test shall be as specified in relevant parts of IS:2386. Any test which the engineer-in-
charge may require in connection with this, shall be carried out in accordance with the
relevant parts of IS:2386.

If further confirmation as to the satisfactory nature of the material is required, compressive test
on cement mortar cubes (1:6) may be made in accordance with IS:2250 using the supplied
material in place of standard sand and the strength value so obtained shall be compared with
that of another mortar made with a sand of acceptable and comparable quality.

5.2 Sand for Filling

Sand for filling shall meet the requirements of IS:383 and shall be natural sand, hard, strong,
free from any organic and deleterious materials. Any sand proposed for filling, shall be used
only after it is approved by the Engineer-in-Charge. Sand obtained from sea shores, creeks or
river banks affected by tides, shall not be used for filling. Fine aggregates suitable for
concreting works shall be suitable for filling also. No sand below grading zone-III as per
IS:383 shall be allowed for filling.

6.0 CEMENT

Cement to be used for civil and structural works shall be one of the following. Specific
requirement for the type of cement to be used shall be as shown in the drawings or as specified
in the contract or as directed by the Engineer-in-Charge.

• Specification for 33 grade ordinary portland cement IS:269

• Specification for 43 grade ordinary portland cement IS:8112
• Specification for 53 grade ordinary portland cement IS:12269

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
t5-1i ENGINEERS
IfgZITH5leg INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
mien eireZne IA Govt of Mao undertaiongl
MATERIALS Page 9 of 16

• Specification for portland slag cement IS :455

• Specification for Portland pozzolana cement (fly ash based) IS:1489 Pt.l
• Specification for Portland pozzolana cement (calcined clay based) IS:1489 Pt.2
• Specification for Masonry Cement IS:3466
• Specification for high alumina cement for structural use IS:6452
• Specification for rapid hardening portland cement IS:8041
• Specification for 43 grade ordinary portland cement IS:8112
• Specification for 53 grade ordinary portland cement IS:12269
• Specification for Sulphate Resisting Portland cement IS:12330

6.1 Storage at Site

6.1.1 The storage of cement (lifted from the Owner's godown or procured by the Contractor
himself) at the site of work shall be at contractor's expense and risk and shall meet the
requirements of IS:4082. The cement shall be stored above ground in a suitable weather tight
building or godown and in such a manner as to permit easy access for proper inspection and
also to prevent deterioration due to moisture. In the event of any damage occurring to the
quality of cement due to faulty storage or on account of negligence on the part of the
contractor, such damages shall be borne by the contractor himself.

6.1.2 All approved cement shall be arranged in batches with type, brand and date of receipt flagged
on them. A maximum of eight bags shall be stacked one over the other. Cement bags shall be
used in the same order as received from the manufacturer/ owner. The contractor shall
maintain a register, on day to day basis, giving the details of the receipt/ consumption, source
of supply and type of cement etc. The register shall always be accessible to the
Engineer-in-Charge for verification.

6.2 Tests after Delivery

Each consignment of cement supplied by Owner or contractor, shall, after delivery at site and
at the discretion of the Engineer-in-Charge, be subjected to any or all of the tests and analyses,
required by the relevant Indian Standard Codes. In case the cement is supplied by the owner,
the contractor shall get himself satisfied regarding its quality before using the same in his
works at his own expense. The contractor shall carry out and bear the cost of all tests and
analyses required to ensure quality of cement before using in actual works, irrespective of the
fact whether the cement is supplied by the Owner or procured by him.

6.3 Rejection

The Engineer-in-Charge may reject at his discretion any cement, notwithstanding the
manufacturer's certificate or failing to meet the requirements of relevant BIS Codes for testing
of cement. He may similarly reject any cement which has deteriorated owing to inadequate
protection from moisture or due to intrusion of foreign matter or any other cause. Any cement
which is considered defective, shall not be used and shall be promptly removed from the site
by the contractor.

7.0 STEEL

7.1 General

All steel bars, sections, plates, and other miscellaneous steel materials, etc shall be free from
loose mill scales, rust as well as oil, mud, paint or other coatings. The materials, construction
specifications such as dimensions, shape, weight, tolerances, testing etc, for all materials
covered under this section, shall conform to respective BIS Codes. Steel sections shall be
conforming to IS:808 or IS:12778.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
11 056
Zig.ZWel INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
eIRIAV..porsil (A G04 Of India Und.da.91
MATERIALS Page 10 of 16

7.2 Reinforcement Bars

Reinforcement bars, to be used for civil and structural works shall be one of the following or
in combination thereof.

• Mild Steel and Medium Tensile Steel Bars and Hard-Drawn

Steel Wire for Concrete Reinforcement IS: 432
• Specification for hard drawn steel wire fabric for concrete reinforcement IS:1566
• Specification for plain hard-drawn steel wire for prestressed concrete. IS:1785
• Specification for High strength deformed steel bars and wires for
concrete reinforcement. IS:1786
• Specification for indented wire for prestressed concrete. IS:6003
• Specification for fusion bonded epoxy coated reinforcing bars IS:13620

7.3 Structural Steel

Structural steel to be used for general structural purposes shall be one of the following or in
combination thereof.

Structural steel sections shall conform to following BIS Codes:

• Steel tubes for structural purposes. IS:1161

• Mild Steel Tubes, tubulars and other wrought steel fittings. IS:1239
• Steel for general structural purposes (Grade A/BR/BO). IS:2062
• Hollow steel sections for structural use. IS:4923

7.4 Miscellaneous Steel Materials

Miscellaneous steel materials shall be conforming to the following BIS Codes.

• Expanded Metal Steel Sheets for General purposes. IS:412

• Mild steel bars of anchor bolts, rungs, metal inserts, grating etc.) IS:2062
• Hexagonal headbolts, screws & nuts of product grade C. IS:1363
• Cold formed light gauge structural steel sections. IS:811
• Technical supply conditions for threaded steel fasteners. IS:1367
• Plain washers IS:2016
• Steel wire ropes for general engineering purposes IS:2266
• Thimbles for wire ropes. IS:2315
• Bulldog grips. IS:2361
• Mild Steel Tubes, tubulars and other wrought steel fillings.
(For Hand rail tubular sections). IS:1239
• Drop forged sockets for wire ropes for general engineering purposes. IS:2485
• Steel chequered plates. IS:3502
• Hexagonal bolts and nuts (M42 to M150). IS:3138
• High Strength Structural Bolts IS:3757
• High Strength Bolts IS:4000

7.4.1 Anchor Bolts

Material for Anchor Bolts such as MS bars, washers, nuts, pipe sleeves and plates etc. shall be
as per relevant BIS Codes mentioned above.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
4t31 e1 ENGINEERS
fEt5teg
I W FreTrAP eTJ.1 VA,
INDIA LIMITED
(A Govt of I mho Unoertalomgi
CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
MATERIALS Page 11 of 16

7.5 Storage

The storage of all materials at site of work shall be at the contractor's expense and risk and
shall be done as per the requirements given in IS:4082. The contractor shall maintain the
proper records of receipt/consumption. The records shall always be accessible to the
Engineer-in-Charge for verification.

The reinforcement bars, structural steel sections and other miscellaneous steel materials etc,
shall be stored in such a way as to avoid and prevent deterioration, corrosion, bending,
twisting and wrapping. In case of any damage occurring to the material on account of faulty
storage or negligence by the contractor, same shall be borne by the contractor himself.

7.6 Tests after Delivery

Materials supplied by the Owner or Contractor, shall, after delivery at site and at the discretion
of Engineer-in-Charge, be subjected to any or all of the tests, required by the relevant BIS
Codes. The Contractor shall carry out and bear the cost of such tests irrespective of the fact
whether the material is procured by the Owner or the contractor. In case steel is supplied by
the Owner, the Contractor shall get himself satisfied regarding its quality before using the
same in his works at his own expense.

7.7 Rejection

The Engineer-in-charge may reject at his discretion any material, not withstanding the
manufacturer's certificate or failing to meet the requirements of relevant BIS Codes for testing
of materials. He may similarly reject any material, which has deteriorated or corroded etc., due
to improper storage, handling or transport. Defective materials shall not be used and removed
from the site by the contractor at his own expense.

8.0 BRICK

8.1 General

All Bricks used for masonry works shall conform to the requirements of following BIS Codes:

• Common Burnt Clay Bricks- Specifications IS:1077

• Pulverized Fuel Lime Ash Bricks- Specifications IS:12894
• Burnt Clay Fly Ash Bricks- Specifications IS:13757

8.1.1 Common Burnt Clay Bricks

Bricks for masonry works shall conform to IS:1077 - Specification for common burnt clay
building bricks and shall be of class 5.0 (with minimum compressive strength of 5.0 N/mm 2 ).
Specific requirement for any other class of bricks shall be as shown in drawings or as
described in the contract for a particular site or type of work. Physical requirements, quality,
dimensions, tolerances etc. of common burnt clay building bricks shall conform to the
requirements of IS:1077.

Bricks shall be hand - moulded or machine moulded and shall be made from suitable soils.
The bricks shall have smooth rectangular faces with sharp corners and shall be well burnt,
sound, hard, tough and uniform in colour. These shall be free from cracks, chips, flaws, stone
or humps of any kind.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ziel. ENGINEERS
lisal iegleg
I iiTeff efeaR2.477.-.1)
INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
CA Govt of Incla UndertakIng)
MATERIALS Page 12 of 16

8.1.2 Fly Ash Lime Bricks (FALG Bricks)

The Fly Ash Lime Bricks (FALG Bricks) shall conform to IS 12894. Visually the bricks shall
be sound, compact and uniform in shape free from visible cracks, warpage, flaws and organic
matter. Fly ash shall conform to IS 3812.

8.1.3 Burnt Clay Fly Ash Bricks

The burnt clay fly ash bricks shall conform to IS 13757. The bricks shall be sound, compact
and uniform in shape and colour. Bricks shall have smooth rectangular faces with sharp and
square corners. The bricks shall be free from visible cracks, flaws, warpage, nodules of free
lime and organic matter, the bricks shall be hand or machine moulded. The bricks shall have
frog of 100 mm in length 40 mm width and 10 to 20 mm deep on one of its flat sides. If made
by extrusion process may not be provided with frogs. Fly Ash shall conform to grade I or
grade II of IS 3812.

8.1.4 Mechanized Autoclave Fly Ash Lime Brick

These bricks shall be machine moulded and prepared in plant by appropriate proportion of fly
ash and lime. The autoclave fly ash bricks shall conform to IS 12894. Visually, the bricks
shall be sound, compact and uniform shape, free from visible cracks, warpage and organic
matters. The brick shall be solid with or without frog, and of 100/80 mm in length, 40 mm
width and 10 to 20 mm deep one of its flat side as per IS 12894. The brick shall have smooth
rectangular faces with sharp corners and shall be uniform in shape and colour. Fly ash shall
conform to IS 3812 and lime shall conform to class 'C' hydrated lime of IS 712.

8.2 Tests after Delivery

The Contractor shall take samples of each type of brick as directed by the Engineer-in-Charge
as per the requirements of IS:5454 and tests shall be carried out as per IS:3495. The cost for
carrying out any or all the tests, shall be borne by the Contractor. The bricks, when tested, as
per IS:3495 shall have a minimum average compressive strength, as given in the Code, for a
particular class of brick. Water absorption shall not be more than 20% by its dry weight, when
soaked in cold water for 24 hours.

Brick samples so approved, shall be deposited with the Engineer-in-Charge. All subsequent
deliveries shall be upto the standards of the approved samples.

8.3 Stacking of Bricks

Bricks shall be stored at site as per the requirements given in IS:4082 and shall not be dumped
at site. They shall be unloaded from trucks to a place on a levelled surface near to the work
site. They shall be stacked in regular tiers even as they are unloaded, to minimise breakages
and defacement of bricks. The supply of bricks shall be so arranged that as far as possible, at
least two days' requirements of bricks are available at site at any time. Bricks, of different
class & types, shall be stacked separately.

8.4 Local Bricks/ Class 3.5 Bricks.

Where shown on drawings, locally available bricks of non modular size (230 mm x 110 mm x
70 mm) in place of bricks of modular size (190 mm x 90 mm x 90 mm) can be used in case
the bricks satisfy the other requirements of respective BIS codes. Minimum compressive
strength of these bricks shall not be less than 3.5 N/mm 2 .

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
Ogzil faajeg INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
werr eiNfAVCRIJ4214i) (A Govt of 1ncla Undettakng)
MATERIALS Page 13 of 16

8.5 Concrete Block Masonry

Concrete Block Masonry shall be as per EIL Specification No. 6-68-0016.

9.0 STONE

9.1 General

All Stones used for masonry works shall conform to the requirements of following BIS Codes.

• Method of identification of natural building stones. IS:1123

• Recommendations for dimensions and workmanship of natural
building stones for masonry work. IS:1127
• Recommendations for dressing of natural building stones. IS:1129

9.2 Quality of Stones

Stones shall be of approved quality, hard, dense, strong, sound, durable, clean and uniform in
colour. They shall also be free from veins, adherent coatings, injurious amount of alkalies,
vegetable matters and other deleterious substances such as iron pyrites, coal, lignite, mica, sea
shells etc. Unless otherwise approved, stones from one single quarry shall be used for any one
work. The strength of stones should be adequate to carry the imposed load and shall meet all
the requirements of IS:1905, taking into account the appropriate crushing strength of stone and
type of the mortar used. The percentage of water absorption, when tested in accordance with
IS:1124, shall not exceed 5 percent.

Stones normally used, shall be small enough to be lifted and placed by hand. The length of the
stone shall not exceed 3 times the height. Width of stone on base shall not be less than 150
mm and in no case exceed 3/4th thickness of the wall. Height of the stone shall not be more
than 300 mm.

9.3 Unloading/Stacking

The stones shall be unloaded from the trucks to a site near to the place of work as defined in
IS:4082 and shall be stacked on a firm ground having adequate stope for drainage. The supply
of stones shall be so arranged that as far as possible, at least two days' requirements of stone
are available at site at any time.

10.0 ADMIXTURES

10.1 General Requirements for Admixtures

10.1.1 All concrete admixtures shall in general comply with the following BIS Codes unless
otherwise stipulated in this specification.

• Specification for integral cement water proofing compounds. IS:2645

• Specification for other admixtures for concrete. IS:9103

10.1.2 Generally, admixtures shall have ISI certification marks. However, even in case of BIS
certified admixtures, Engineer-in-Charge may require the Contractor to carry out and submit
any or all the tests (as specified in relevant BIS Codes), from BIS approved laboratories, over
and above the manufacturer's test certificate, before giving his final approval.
In case, admixtures certified by BIS are not available, the contractor shall submit to the
Engineer-in-Charge the type and/or proprietary brand of the admixture from only reputed
manufacturers along with necessary test certificates from BIS recognized/ BIS approved
laboratories or any other document directed by Engineer-in-Charge for the latter's final

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
@s.,1 ENGINEERS
Ifgar Etatg INDIA LIMITED
(.01212Z731E'CD14.2re,
CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
IA Govt 01 .ncha Urulettaking)
MATERIALS Page 14 of 16

approval. In such cases, names of at least two manufacturers shall be submitted to the
Engineer-in-Charge for his selection. In case, both the names are rejected, the contractor shall
submit a fresh list of two manufacturers for approval by the Engineer-in-Charge.

The Engineer-in-Charge may direct the contractor to submit test results as required by IS:2645
or IS:9103 for any admixture proposed to be used in the concrete in any approved laboratory
at his discretion at any stage of the work. The cost of any/all tests required to satisfy
compliance with this specification shall be borne by the Contractor.

In case of non-availability of any BIS code for testing and acceptability criteria, relevant
American, British or German Code shall be applicable.

10.1.3 Prior approval of the Engineer-in-Charge shall be obtained while using water reducing
admixtures in the concrete (PCC/ RCC) or mortar. Other type of admixtures such as
accelerating admixtures, retarding admixtures or air entraining admixtures, shall not be used
unless specified on the design drawings or prior approval taken from the design approving
authority. Once approved, utmost care shall be exercised at site by the Contractor to maintain
the consistency in the quality of admixture and the concrete/ mortar so produced.

10.1.4 The suitability and effectiveness of any admixture shall be verified by trial with the designed
concrete mixes using cement, aggregates together with any other materials to be actually used
in the works as per the direction of Engineer-in-Charge. If two or more admixtures are to be
used simultaneously in the same concrete mix, the Contractor must submit necessary test
results from an approved laboratory to show their interaction and compatibility. Any/all tests
specified in BIS Codes shall be carried out only with the type of material and mix design, to
be actually used in the work site.

10.1.5 No admixture shall impair the durability of the concrete nor combine with the ingredients to
form harmful compounds nor increase the risk of corrosion of reinforcement. Use of
admixtures shall not reduce the dry density of concrete. Once the proportion of admixture has
been established, strict check shall be maintained not to alter the proportions of ingredients
and water-cement ratio of the Design Mix during execution.

10.1.6 The chloride contents in admixtures shall not exceed 2% by mass of the admixture or 0.03%
by mass of the cement.

10.1.7 Admixtures which do not meet the requirements stipulated in this specification shall be
rejected and shall not be used.

10.2 Water Proofing Compounds

10.2.1 Water proofing compounds shall be mixed with cement only.

10.2.2 The permeability of the specimen with the admixture shall be less than half of the
permeability with similar specimen without the use of these compounds. These compounds
shall be used in such proportion as recommended by manufacturer but in no case it shall
exceed 3% by weight of cement.

10.2.3 The initial setting time of the cement with the use of these compounds shall not be less than 30
minutes and final setting time shall not be more than 10 hours. Test shall be carried out in
accordance with IS:4031.

10.2.4 Compressive strength of specimen at 3 days shall not be less than 160 kg/sq.cm nor 80% of
the 3 days compressive strength of mortar cubes prepared with same cement and sand only,
whichever is higher. Similarly compressive strength at 7 days shall not be less than 220
kg/sq.cm nor less than 80% of the 7 days compressive strength prepared with the same cement
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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
/a12-ZreT ENGINEERS
It sleg INDIA LIMITED CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
MX,/ F97,,IP M.1413.11 Uridertaknq)
IA Govl of Inoe
MATERIALS Page 15 of 16

and sand only, whichever is higher. The test to determine the compressive strength shall
conform to IS:4031.

10.3 Concrete Penetrating Corrosion Inhibiting Admixture shall be as per EIL Specification No. 6-
68-0017.

11.0 WATER BARS (WATER STOPS)

PVC water bars shall be used in reinforced concrete construction of liquid retaining structures
or any other structure to safeguard them from hydrostatic pressure and water leakage and any
relative movement between two parts of the structure due to thermal loading shrinkage or
differential movement of foundations. Wherever desired or shown in the drawings, they shall
be used at expansion/contraction/construction joints. These shall be pre-formed and shall
provide a permanent water tight seal along the entire joint in the poured concrete structures.
These shall also be flexible enough to withstand deflection/displacements at joints arising due
to variation of temperatures or settlement of foundations. The minimum thickness of water bar
shall be as shown on drawings or described in the schedule of rates and unless otherwise
mentioned, these shall be able to withstand a water head of at least 12 meters.

11.2 Performance requirements of PVC water bars shall meet the requirements of IS:12200. These
shall be of approved make and of ribbed/ serrated/ plane type with a bulb at the centre. The
thickness and width of water bars shall be as per schedule of rates/ drawings but in no case the
thickness shall be less than 5 mm and width less than 150 mm. The joining of the water bars
shall be carried out by vulcanising strictly as per the manufacturer's specifications. Lapped
joints shall not be allowed under any circumstances.

12.0 BITUMEN/BITUMINOUS MATERIALS

Bitumen to be used for various types of work shall meet all the requirements of relevant BIS
Codes as given below:

• Specification of Paving Bitumen IS:73

• Specification for bitumen mastic for flooring IS:1195
• Specification for Bitumen felts for water proofing and damp proofing IS:1322
• Specification for Bituminous compounds for water proofing
and caulking purposes IS:1834
• Specification for preformed fillers for expansion joint in concrete
pavements and structures IS:1838
• Specification for bitumen mastic for use in water proofing of roofs IS:3037
• Specification for bitumen primer for use in water proofing & damp proofing IS:3384
• Specification for Bitumen Mastic for Tanking and Damp proofing IS:5871
• Specification for Glass fibre base coal tar pitch & bitumen felts IS:7193
• Code of practise for damp proofing using bitumen mastic IS:7198
• Specification for bitumen Mastic, Anti Static and electrically
conducting grade IS:8374

The type and grade shall be as shown on the drawings or as indicated in schedule of quantities
or as directed by Engineer-in-Charge. Tests and acceptable criteria shall be as per relevant BIS
Codes.

13.0 PVC PIPES

PVC Pipes shall conform to the requirements of IS:4985.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
Igar laffleg
(711Pef ■91.PRIRIP
INDIA LIMITED
:A Govt of mold Undettaltlom
CIVIL & STRUCTURAL WORKS 6-68-0002 Rev.5
• MATERIALS Page 16 of 16

14.0 WOOD/ TIMBER

14.1 Wood recommended for platforms of cold vessels or below cold vessels/ exchangers shall be
hard and shall be of group A, grade I, and shall have safe permissible stress of 7 N/mm 2 in
compression, perpendicular to grains on outside location as per IS:883. General characteristics
like durability, treatability etc. shall conform to IS:883 and IS:3629.

14.2 Timber required to be used for formwork shall be fairly dry before use. It should maintain its
shape during the use and even when it comes into contact with moisture from the concrete.
Storage of Wood/Timber shall be as per the requirements of IS:4082.

For proper identification and selection of suitable timber for formwork, following codes shall
be referred.

• Classification of commercial timbers and their zonal distribution IS:399

• Specification for ballies for general purposes IS:3337
• Specification for Ply wood for concrete shuttering work IS:4990

15.0 EPDXY COMPOUNDS

Refer EIL Specification No. 6-68-0056.

16.0 PAINT

16.1 Refer EIL Specification No. 6-79-0020 or the job specification whichever applicable.

17.0 ANTITERMITE COMPOUNDS

17.1 Chloropyrifos emulsifiable concentrates (1%) conforming to IS:8944 shall be used for
treatment of soil for protection of buildings against attack by subterranean termites.

18.0 POLYSULPHLDE SEALANTS

Polysulphide Sealants shall conform to IS:12118 and be of approved make. Test conditions
and requirements shall be as given in the above referred BIS code.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
lai;Wei aft
: ENGINEERS CIVIL & STRUCTURAL WORKS
6-68-0006 Rev.7
Igar faReswiINDIA LIMITED STRUCTURAL STEEL WORKS
1.41a97 mow et atom IA Govt al We Untlertakm9)
Page 1 of 25

*Mu
Thr4K vrzi

STANDARD SPECIFICATION
CIVIL & STRUCTURAL WORKS

tuc111Clict) t.‘111 if

STRUCTURAL STEEL WORKS

7 13.01 20 UPDATED & REISSUED

6 26.08.14 UPDATED & REISSUED SP AS PKM S CHANDA

5 18.06 09 PKM VINAY

REAFFIRMED & REISSUED AS N DUARI
KUMAR
4 18 04.00 UPDATED & REISSUED DPN RS SCJ MI

3 MAY'94 UPDATED & REISSUED DPN RS GPL A SONI

Standards Standards
Rev. Prepared Committee Bureau
Checked
Date Purpose Convenor Chairman
No by by
Approved by

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
eielaft ENGINEERS CIVIL & STRUCTURAL WORKS
lafgegW INDIA LIMITED 6-68-0006 Rev.7
MOT MARV 4013013.0 IA Govt of Aldo Undertaking) STRUCTURAL STEEL WORKS
Page 2 of 25

Abbreviations:

AFC Approved For Construction

AWS American Welding Society

BIS Bureau of Indian Standards

IS Indian Standards

Structural Standards Committee

Convenor: Mr. Rajanji Srivastava

Members: Mr. Anurag Sinha

Mr. VK Panwar
Mr. Samir Das
Mr. Amitabh Kishore
Mr. Gyasuddin
Mr. Charanjit Singh (Proj.)
Mr. Ravindra Kumar (Constn)

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
.31faeleieft
, ENGINEERS CIVIL & STRUCTURAL WORKS
sigez Et151egviV INDIA LIMITED 6-68-0006 Rev.7
1“Perf elitiRealJa9.1) IA GM of India unaertakni) STRUCTURAL STEEL WORKS
Page 3 of 25

CONTENTS

1.0 SCOPE 4

2.0 REFERENCE 4

3.0 MATERIALS 4

4.0 FABRICATION DRAWINGS 5

5.0 FABRICATION 7

6.0 MARKING FOR IDENTIFICATION 16

7.0 SHOP ERECTION 16

8.0 INSPECTION & TESTING OF STRUCTURES 16

9.0 SHOP PAINTING 16

10.0 PACKING 17

11.0 TRANSPORTATION 17

12.0 SITE (FIELD) ERECTION 17

13.0 SAFETY & SECURITY DURING ERECTION 18

14.0 FIELD CONNECTIONS 18

15.0 GROUTING 18

16.0 SCHEME AND SEQUENCE OF ERECTION 19

17.0 PAYMENT 19

18.0 PAINTING AFTER ERECTION 20

ANNEXURE-'A' 23

ANNEXURE-'W 25

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
laiReitaiaft
' ENGINEERS CIVIL & STRUCTURAL WORKS
S~LII fifiilegMe
: INDIA LIMITED 6-68-0006 Rev.7
1
.I eR.V. Jq0.11 IA Govt o India Undertaking) STRUCTURAL STEEL WORKS
Page 4 of 25

1.0 SCOPE

This specification describes the information to be included in a Project Specification and

also covers the requirements for material, storage, preparation of fabrication drawings,
fabrication, assembly, tests/examinations, transportation, erection and painting of all types
of bolted and/or welded structural steel works for general construction work. Fabrication of
structures shall also include fabricating:

(a) Built up sections/plate girders made out of rolled section and/or plates.

(b) Compound sections made out of rolled sections.

2.0 REFERENCES

2.1.1 BIS Codes

IS: 800, 808, 816, 819, 822, 919, 1024, 1261, 1323, 1477, 1852, 2074, 7205, 7215, 7307,
7310, 7318, 9595, 12778 and other relevant BIS Codes.

SP: 6(1)

2.1.2 International Standard

AWS D1.1

2.2 EIL Specifications

6-68-0002- Materials
6-79-0020 (or relevant Job Specification) — Surface preparation & protective coating
(New construction)

2.3 In case of conflict between the clauses mentioned in this specification and those in the
Indian Standards, this specification shall govern. Any special provision as shown or noted
on the design drawings or any project specific specification specified elsewhere shall govern
over the provisions of this specification.

3.0 MATERIALS

3.1 General

All materials shall conform to their respective specifications given in EIL Specification no.
6-68-0002. The use of equivalent or alternative materials shall be permitted only in very
special cases and for all such cases prior written approval of the Engineer-in-Charge shall be
obtained.

3.2 Receipt & Storing of Materials

3.2.1 Each section shall be marked for identification and each lot shall be accompanied by
manufacturer's quality certificate, chemical analysis and mechanical characteristics.

3.2.2 All sections shall be checked, sorted out and arranged by grade and quality in the store. Any
instruction given by the Engineer-in-Charge in this respect shall be strictly followed.

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 4=
7/ ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
CIVIL & STRUCTURAL WORKS
INDIA LIMITED 6-68-0006 Rev.7
1.17, ?wow +=Jot./ (A Govt of India Undeftakong) STRUCTURAL STEEL WORKS
Page 5 of 25

3.2.3 All material shall be free from surface defects such as pitting, cracks, laminations, twists etc.
Defective material shall not be used and all such rejected material shall be immediately
removed from the store/site. The decision of the Engineer-in- Charge in this regard shall be
final and binding.

3.2.4 Welding wires and electrodes (packed in their original cartons) shall be stored separately by
quality and lots inside a dry and enclosed room in compliance with IS:9595 and as per the
instructions given by the Engineer-in-Charge. Electrodes shall be kept perfectly dry to
ensure satisfactory operation and weld metal soundness.

3.2.5 Each lot of electrodes, bolts, nuts etc. shall be accompanied by manufacturer's quality/test
certificates.

3.2.6 All bolts (including nuts & washers) shall be checked, sorted out and arranged
diameter-wise by grade and quality in the store.

3.3 Material Tests

3.3.1 The Contractor shall submit manufacturers' quality certificates for all the materials supplied
by him. In case, quality certificates are not available or are incomplete or when material
quality differs from standard specifications, such materials shall not be used in the
construction. However, the Contractor shall get all appropriate tests conducted in approved
test houses for such materials as directed by the Engineer-in-Charge, at no extra cost, and
submit the same to Engineer-in-Charge for his approval. The Engineer-in-Charge may
approve the use of such materials entirely at his discretion.

3.3.2 The Contractor shall ensure that all materials brought to site are duly approved by the
Engineer-in-Charge. Rejected materials shall not be used and shall be removed from site
forthwith. Any material of doubtful quality for which specific tests are to be carried out as
per the instruction of the Engineer-in-Charge shall be separately stacked and properly
identified and shall not be used. These shall be removed from site forthwith.

4.0 FABRICATION DRAWINGS

4.1 Fabrication and erection drawings shall be prepared by the Contractor on the basis of
"Approved for Construction" (AFC) design drawings, EIL Standards issued to the
Contractor. These drawings shall be prepared by Contractor or by an agency engaged by the
contractor using TEKLA or AUTODESK Advance Steel or equivalent 3D Modeling
software and approved by the Engineer-in-Charge.

4.2 Fabrication and erection drawings shall be thoroughly checked, stamped "Approved for
Construction" and signed by the Contractor's own responsible Engineer irrespective of the
fact that such drawings are prepared by the Contractor or his approved agency, to ensure
accuracy and correctness of the drawings. Unchecked and unsigned drawings shall not be
used for the purpose of proceeding with the work. The Contractor shall proceed with the
fabrication and erection work only after thoroughly satisfying himself in this regard.

4.3 All fabrication and erection drawings shall be issued for construction by the Contractor
directly to his work- site. Six copies of such drawings shall simultaneously be submitted to
the Engineer-in-Charge who may check/ review some or all such drawings at his sole
discretion and offer his comments for incorporation in these drawings by the Contractor.

However, the Contractor shall not proceed with the fabrication of such structures whose
fabrication drawings are required to be reviewed before taking up the fabrication work as
noted on "Approved for Construction (AFC)" design drawings issued to the Contractor or as

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
k3lfa eft
- ENGINEERS CIVIL & STRUCTURAL WORKS
OgezWeed!, INDIA LIMITED 6-68-0006 Rev.7
eAgtere ac3Aerft) (A Govtof Inds lindArbA.A0 STRUCTURAL STEEL WORKS
Page 6 of 25

conveyed by the Engineer-in-Charge. The fabrication of such structures shall be done only
as per the reviewed fabrication drawings.

The review of such drawings by ElL shall be restricted to the checking of the following
only:

i) Structural layout, orientation and elevation of structures/members.

ii) Sizes of members.

iii) Critical joint details.

4.4 Fabrication drawings shall be drawn to scale and shall convey the information clearly and
adequately. Following information shall be furnished on such drawings:

i) Reference to design drawing number (along with revision number) based on which
fabrication drawing has been prepared.

ii) Structural layout, elevations & sections (with distinct erection marking of all
members).

iii) Framing plans, member sizes, orientation and elevations.

iv) Layout and detailing of rain water pipes and gutters showing all necessary levels,
connections and provisions wherever required.

v) Detailing of shop/field joints, connections, splices, for required strength and

erection.

vi) Location, type, size and dimensions of welds and bolts.

vii) Shapes and sizes of edge preparation for welding.

viii) Details of shop and field joints/welds.

ix) Bill of materials/D.O.D. Lists.

x) Quality of structural steel, plates etc., welding electrodes, bolts, nuts and washers to be
used.

xi) Erection assemblies identifying all transportable parts and sub-assemblies with
special erection instructions, if required.

xii) Method of erection and special precautions to be taken during erection as required.

xiii) Details of holes and fittings in components necessary for safe lifting and erection
purpose.

4.5 The Contractor shall additionally ensure accuracy of the following and shall be solely
responsible for the same:

i) Provision for erection and erection clearances.

ii) Marking of members

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS CIVIL & STRUCTURAL WORKS
gejlieggi-egW" INDIA LIMITED 6-68-0006 Rev.7
1.110, rweem ea mom IA Govt a1 India Undert.k.9) STRUCTURAL STEEL WORKS
Page 7 of 25

iii) Cut length of members

iv) Matching of joints and holes.

v) Provision kept in the members for other interconnected members.

vi) Bill of materials/D.O.D. Lists.

4.6 Connections, splices and other details where not shown on the design drawings shall be
suitably designed and shown on the fabrication drawings based on good engineering
practice developing full member strength. Design calculations for such connections/
splices shall be submitted to the Engineer-in-Charge alongwith the fabrication
drawings.

4.7 Any substitution or change in section shall be allowed only when prior written approval of
the Engineer-in-Charge has been obtained. Fabrication drawings shall be updated
incorporating all such substitutions/changes by the Contractor at no extra cost to the Owner.

4.8 In case during execution of the work, the Engineer-in-Charge on review of drawings
considers any modifications/ substitutions necessary to meet the design parameters/ good
engineering practice, these shall be brought to the notice of the Contractor who shall
incorporate the same in the drawings and works without any extra cost to the owner. The
Contactor will be totally responsible for the correctness of the detailed fabrication drawings
and execution of the work.

4.9 Contractor shall incorporate all the revisions made in the design drawings during the course
of execution of work in his fabrication drawings, and resubmit the drawings at no extra cost
to the Owner. All fabrication shall be carried out only as per the latest AFC design drawings
and corresponding fabrication drawings.

4.10 The Contractor shall supply two prints each of the final/as built drawings alongwith their
native soft file to Engineer-in-Charge for reference and record. The rates quoted shall
include for the same.

5.0 FABRICATION

5.1 General

5.1.1 Fabrication of structures shall be done strictly as per "Approved for Construction"
fabrication drawings (prepared by the Contractor based on the latest design drawings) and in
accordance with IS:800, 9595 & other relevant BIS Codes and BIS Hand Book SP:6(1).

5.1.2 Prior to commencement of structural fabrication, undulations in the fabrication yard, if any,
shall be removed and area levelled and paved by the Contractor.

5.1.3 Any defective material used in the work shall be replaced by the Contractor at his own
expense. Necessary care and precautions shall be taken so as not to cause any damage to the
structure during any such removal and replacement.

5.1.4 Any faulty fabrication pointed out at any stage of work by the Engineer-in- Charge, shall be
made good or replaced by the Contractor at his own cost.

5.1.5 Tolerances for fabrication of steel structures shall be as per IS:7215.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
4oi ENGINEERS CIVIL & STRUCTURAL WORKS
51ge..11 laites NW INDIA LIMITED 6-68-0006 Rev.7
197351711:9J,
10.11 IA Govt o Inca Undertakm) STRUCTURAL STEEL WORKS
Page 8 of 25

5.2 Fabrication Procedure

5.2.1 Straightening & Bending

5.2.1.1 All materials shall be straight and, if necessary, before being worked shall be straightened
and/or flattened (unless required to be of curvilinear form) and shall be free from twists.

5.2.1.2 Bending of rolled sections and plates shall be done by cold process to shape/s as shown on
drawings.

5.2.1.3 After completion of bending or straightening, welds within the area of bending or
straightening shall be thoroughly visually inspected. Nondestructive tests required to be
carried out for such locations shall be done only after straightening or bending activity.

5.2.2 Clearances

The erection clearance for cleated ends of members shall be not greater than 2mm at each
end. The erection clearance at ends of beams without web cleats and end plates shall be not
more than 3mm at each end but where for practical reasons, greater clearance is necessary,
suitably designed seatings approved by the Engineer-in-Charge shall be provided.

5.2.3 Cutting

5.2.3.1 Prior to cutting, all members shall be properly marked showing the requisite cut
length/width, connection provisions e.g. location and dimensions of holes, welds, cleats etc.
Marking for cutting shall be done judiciously so as to avoid wastages or unnecessary joints
as far as practicable. Marking shall be done by placing the members on horizontal
supports/pads in order to ensure accuracy. Marking accuracy shall be limited to + 1 mm.

5.2.3.2 Cutting may be affected by shearing, cropping or sawing. Gas cutting by mechanically
controlled torch shall be permitted for mild steel. Hand flame cutting may be permitted
subject to the approval of the Engineer-in-Charge.

5.2.3.3 Except where the material is subsequently joined by welding, no loads shall be transmitted
into metal through a gas cut surface.

5.2.3.4 Shearing, cropping and gas cutting shall be clean, square, free from any distortion & burrs,
and should the Engineer-in-Charge find it necessary, the edges shall be ground afterwards,
to make the same straight and uniform at no extra cost to the Owner.

5.2.4 Holing

5.2.4.1 Holes for bolts shall not be formed by gas cutting process.

5.2.4.2 Holes through more than one thickness of material of members such as compound
stanchions and girder flanges shall, where possible, be drilled after the members are
assembled and tightly clamped/bolted together. Punching may be permitted before
assembly, provided the thickness of metal is less than 16mm and the holes are punched
3mm less in diameter than the required size and reamed, after assembly, to the full diameter.
Punching shall not be adopted for dynamically loaded structures.

5.2.4.3 Holes may be drilled in one operation through two or more separable parts and burrs
removed from each part after drilling.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
daP1S ENGINEERS CIVIL & STRUCTURAL WORKS
WegW INDIA
"e"002,70..7.0.0
LIMITED
IA Govt of Me Undertaking) STRUCTURAL STEEL WORKS
6-68-0006 Rev.7
Page 9 of 25

5.2.4.4 Holes in connecting angles and plates, other than splices, also in roof members and light
framing, may be punched full size through material not over 12mm thick, except where
required for close tolerance bolts or barrel bolts.

5.2.4.5 All matching holes for black bolts shall register with each other so that a gauge of 2mm less
in diameter than the diameter of hole shall pass freely through the assembled members in the
direction at right angle to such members. Finished holes shall be not more than 2mm in
diameter larger than the diameter of the black bolt passing through them, unless otherwise
specified by the Engineer- in-Charge.

5.2.4.6 Holes for turned and fitted bolts shall be drilled to a diameter equal to the nominal diameter
of the shank or barrel subject to H8 tolerance specified in IS:919. Parts to be connected with
close tolerance or barrel bolts shall be firmly held together by tacking bolts or clamps and
the holes drilled through all the thicknesses in one operation and subsequently reamed to
size. Holes not drilled through all the thicknesses in one operation shall be drilled to a
smaller size and reamed out after assembly. Where this is not possible, the parts shall be
drilled and reamed separately.

5.2.4.7 To facilitate grouting, holes shall be provided in column bases or seating plates exceeding
300mm in width for the escape of air.

5.2.4.8 To avoid accumulation of water in gussetted column bases of laced, battened or box type
stanchions, suitable reverse U-type holes shall be provided at the junction of base plate and
column section in the vertical gussets for draining out of any water.

5.2.4.9 Slotted holes shall be punched or formed by drilling two holes and completed by cutting.

5.2.5 Assembly

The component parts shall be assembled and aligned in such a manner that they are neither
twisted nor otherwise damaged, and shall be so prepared that the required camber, if any, is
provided. Proper clamps, clips, jigs and other fasteners (bolts and welds) shall be placed in a
balanced pattern to avoid any distortion in the members and to ensure their correct
positioning (i.e. angles, axes, nodes etc.). Any force fitting, pulling/stretching of members to
join them shall be avoided. Proper care shall be taken for welding shrinkage & distortion so
as to attain the finished dimensions of the structure shown on the drawings.

5.2.6 Welding

5.2.6.1 General

a) All joints shall be welded unless noted otherwise on the design drawings.

b) Welding shall be in accordance with IS:816, IS:819, IS:1024, IS:1261, IS:1323 and
IS:9595 as appropriate.

c) The Contractor shall make necessary arrangement for providing sufficient number of
welding sets of the required capacity, all consumables, cutting and grinding equipment
with requisite accessories/ auxiliaries, equipment & materials required for carrying out
various tests such as dye penetration, magnetic particle, ultrasonic etc.

d) Adequate protection against rain, dust, snow & strong winds shall be provided to the
welding personnel and the structural members during welding operation. In the absence
of such a protection no welding shall be carried out.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
CIVIL & STRUCTURAL WORKS
6-68-0006 Rev.7
IA Gort of Aldo UnderPlong) STRUCTURAL STEEL WORKS
Page 10 of 25

e) It shall be the responsibility of the Contractor to ensure that all welding is carried out in
accordance with the terms of this specification and relevant BIS codes. The Contractor
shall provide all the supervision to fulfil this requirement.

5.2.6.2 Preparation of Member for Welding

a) Edge Preparation
Edge preparation/bevelling of fusion faces for welding shall be done strictly as per the
dimensions shown in the drawings. In case, the same are not indicated, edges shall be
prepared (depending on the type of weld indicated in the drawing) as per the details
given in IS:9595. Bevelling of fusion faces shall be got checked and approved by the
Engineer- in-Charge. The tolerances on limits of gap, root face & included angle shall
be as stipulated in IS:9595.

b) Cleaning

Welding edges and the adjacent areas of the members (extending upto 20mm) shall be
thoroughly cleaned of all oil, grease, scale and rust and made completely dry. Gaps
between the members to be welded shall be kept free from all foreign matter.

c) Preheating

Preheating of members, shall be carried out as per IS:9595 when the base metal
temperature is below the requisite temperature for the welding process being used.
Preheating shall be done in such a manner that the parts, on which the weld metal is
being deposited, are above the specified minimum temperature for a distance of not less
than 75mm on each side of the weld line. The temperature shall be measured on the face
opposite to that being heated. However, when there is access to only one face, the heat
source shall be removed to allow for temperature equalization (1 minute for each 25mm
of plate thickness) before measuring the temperature.

d) Grinding

i) Column splices & butt joints of struts and compression members (depending on
contact for load transmission) shall be accurately ground and close-butted over
the whole section with a tolerance not exceeding 0.2mm locally at any place. In
column caps & bases, the ends of shafts together with the attached gussets,
angles, channels etc., shall be accurately ground so that the parts connected butt
over minimum 90% surface of contact. In case of connecting angles or channels,
care shall be taken so that these are fixed with such accuracy that they are not
reduced in thickness by grinding by more than 2mm.

ii) Ends of all bearing stiffeners shall be ground to fit tightly at both top and bottom.
Similarly bottom of the knife edge supports along with the top surface of column
brackets shall be accurately ground to provide effective bearing with a tolerance
not exceeding 0.2mm locally at any place.

iii) Slab bases and caps shall be accurately ground over the bearing surfaces and shall
have effective contact with the ends of stanchions. Bearing faces which are to be
grouted direct to foundations need not be ground if such faces are true & parallel
to the upper faces.

iv) Tack welding shall be thoroughly removed by grinding or gouging such that
subsequent welding shall be done properly.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
lara.Jeift ENGINEERS CIVIL & STRUCTURAL WORKS
Igen Etteg W INDIA LIMITED 6-68-0006 Rev.7
1.IETT 212i52,6,3917.1) IA Govt of Inds Undertaking) STRUCTURAL STEEL WORKS
Page 11 of 25

5.2.6.3 Welding Processes

Welding of various materials under this specification shall be carried out using one or more
of the following processes.

- Manual Metal Arc Welding Process (MMAW)

- Submerge Arc Welding Process (SAW)

- Gas Metal Arc Welding Process (GMAW)

- Flux Cored Arc Welding Process (FCAW)

The welding procedure adopted and consumables used shall be specifically approved by the
Engineer-in-Charge. A combination of different welding processes or a combination of
electrodes of different classes/makes may be employed for a particular joint only after
qualifying the welding procedures to be adopted and obtaining the written approval of the
Engineer-in-Charge.

5.2.6.4 Approval & Testing of Welders

The Contractor shall satisfy the Engineer-in-Charge that the welders are suitable for the
work upon which they will be employed. For this purpose the welders shall have satisfied
the relevant requirements of IS:7318 or AWS D1.1. If the welders will be working to
approved welding procedures, they shall have satisfied the relevant requirements of IS:7310
or AWS D1.1.

Adequate means of identification shall be provided to enable each weld to be traced to the
welder by whom it was made. The Contractor shall intimate the Engineer-in-Charge
sufficiently in advance, the commencement of tests, to enable him to be present to witness
the same.

5.2.6.5 Approval & Testing of Welding Procedures

The Contractor shall carry out procedure tests in accordance with IS:7307 or AWS D1.1 to
demonstrate by means of a specimen weld of adequate length on steel representative of that
to be used, that he can make welds with the welding procedure to be used for the work to the
complete satisfaction of the Engineer- in-Charge. The test weld shall include weld details
from the actual construction and it shall be welded in a manner simulating the most
unfavourable instances of fit-up, electrode condition etc., which are anticipated to occur on
the particular fabrication. Where material analysis is available, the welding procedure shall
be carried out on material with the highest carbon equivalent value.

After welding, but before the relevant tests given in IS:7307 or AWS D1.1 are carried out,
the test weld shall be held as long as possible at room temperature, but in any case not less
than 72 hours, and shall then be examined for cracking. The examination procedure shall be
sufficiently rigorous to be capable of revealing significant defects in both parent metal and
weld metal.

After establishing the welding method, the Contractor shall finally submit to the
Engineer-in-Charge for his approval the welding procedure specification in standard format
given in IS:9595 before starting the fabrication.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS CIVIL & STRUCTURAL WORKS
2154-egNiV INDIA LIMITED 6-68-0006 Rev.7
men nemeamaticavi) IA Govt of lode Undedalongl STRUCTURAL STEEL WORKS
Page 12 of 25

5.2.6.6 Sequence of Welding

a) As far as practicable, all welds shall be made in a sequence that will balance the applied
heat of welding while the welding progresses.

b) The direction of the general progression in welding on a member shall be from points
where the parts are relatively fixed in position with respect to each other towards points
where they have a greater relative freedom of movement.

c) All splices in each component part of a cover-plated beam or built up member shall be
made before the component part is welded to other component parts of the member.

d) Joints expected to have significant shrinkage shall be welded before joints expected to
have lesser shrinkage.

e) Welding shall be carried continuously to completion with correct number of runs.

f) The Contractor shall choose the welding sequence after carefully studying each case
such as to minimize distortion and shrinkage & submit the same to the
Engineer-in-Charge for comments and approval.

5.2.6.7 Welding Technique

a) After the fusion faces are carefully aligned and set with proper gaps, the root pass of
butt joints shall be executed properly so as to achieve full penetration with complete
fusion of the root edges.

b) On completion of each run, all slag and spatters shall be removed and the weld and the
adjacent base metal shall be cleaned by wire brushing and light chipping. Visible defects
such are cracks, cavities and other deposition faults, if any, shall be removed to sound
metal before depositing subsequent run of weld.

c) All full penetration butt welds shall be completed by chipping/gouging to sound metal
and then depositing a sealing run of weld metal on the back of the joints. Where butt
welding is practicable from one side only, suitable backing steel strip shall be used and
joint shall be arranged in such a way as to ensure that complete fusion of all the parts is
readily obtained.

d) While welding is in progress care shall be taken to avoid any kind of movement of the
components, shocks, vibrations to prevent occurrences of weld cracks.

e) Any deviation desired from the recommended welding technique and electrodes shall be
adopted only after obtaining written approval of the Engineer-in-Charge.

5.2.6.8 Inspection & Testing of Welds

The method of inspection shall be according to IS:822 and extent of inspection and testing
shall be in accordance with the relevant applicable standard or, in the absence of such a
standard, as specified by the Engineer-in-Charge. Welds shall not be painted or otherwise
obscured until they have been inspected, approved and accepted.

The Engineer-in-Charge or his representative shall have access to the Contractor's work at
all reasonable times and the Contractor shall provide him with all facilities necessary for
inspection during all stages of fabrication and erection with, but not limited to, the following
objectives.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
laraeleift, ENGINEERS CIVIL & STRUCTURAL WORKS
Itgar tiPtsw INDIA LIMITED
29K012,1XJR1.11 IA Govt of India undataking) STRUCTURAL STEEL WORKS
6-68-0006 Rev.7
Page 13 of 25

i) To check the conformity with the relevant standards and suitability of various welding
equipments and their performance.

ii) To witness/approve the welding procedure qualification.

iii) To witness/approve the welders performance qualification.

iv) To check whether shop/field welding being executed is in conformity with the relevant
specifications and codes of practice.

Inspection and testing of all fabricated structures shall be carried out by the Contractor
by any, or, a combination of all the following methods as directed by the
Engineer-in-Charge and no separate payment shall be made, unless otherwise
mentioned, for inspection and testing of welds/fabricated structures:

A. Visual Inspection

All finished welds (i.e. 100 percent) shall be visually inspected for identification of the
following types of weld defects & faults.

a) Weld defects occurring at the surface such as blow holes, exposed porosity,
unfused welds etc.

b) Surface cracks in the weld metal or in the parent metal adjacent to it.

c) Damages to the parent metal such as undercuts, burning, overheating etc.

d) Profile defects such as excessive convexity or concavity, overlapping, unequal

leg lengths, excessive reinforcement, incompletely filled grooves, excessive
penetration beads, root grooves etc.

e) Distortion due to welding i.e., local shrinkage, camber, bowing, twisting, rotation,
wariness etc.

f) Linear eccentric, angular and rotational misalignment of parts.

g) Dimensional errors.

B. Mechanical Tests

The mechanical testing (such as tensile load tests, bend tests, impact tests etc.) shall be
done in accordance with the relevant standards and as per the instructions of the
Engineer-in-Charge.

C. Magnetic Particle/Dye Penetration/Ultrasonic Examination

The examination shall be done at random as directed by the Engineer-in-Charge.

Whenever such tests are directed, the tests shall be carried out on joints chosen by him.
The tests shall be carried out by employing approved testing procedure in accordance
with IS:822.

D. Radiographic Examination

Radiographic examination shall be carried out only in special cases for random joints as

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
MT, ENGINEERS CIVIL & STRUCTURAL WORKS
learIMItn
EVIegW INDIA LIMITED 6-68-0006 Rev.7
M.IRE'193.10.1)
IA Govt 01 UndellaitilV) STRUCTURAL STEEL WORKS
Page 14 of 25

directed by the Engineer-in-Charge. The Contractor shall be paid extra for such
examination except for penalty radiographic tests for which the cost shall be borne by
him. The Contractor shall make necessary arrangement at his own expense for providing
the radiographic equipment, films and all other necessary materials required for carrying
out the examination. The tests shall be carried in the presence of the Engineer-in-Charge
by employing approved testing procedure in accordance with IS:822. The Contractor
shall fulfill all the statutory safety requirements while handling X-ray and Gamma-ray
equipment and provide the Engineer- in-Charge all the necessary facilities at site such as
dark room, film viewer etc., to enable him to examine the radiographs.

5.2.6.9 Repair of Faulty Welds

No repair of defective welds shall be carried out without proper permission of the
Engineer-in-Charge and his approval for the corrective procedure.

Welds not complying with the acceptance requirements (as specified by BIS Codes & the
Engineer-in-Charge), as revealed during inspection & testing of welds or erection or in-situ
condition, shall be corrected either by removing & replacing or as follows:

a) Excessive convexity - Reduced to size by removal of excess weld metal.

b) Shrinkage cracks, cracks in - Defective portions removed down to sound metal

in parent plates and craters and re-welded.

c) Under cutting. - Additional weld metal deposited.

d) Improperly fitted/ - Welding cut & edges suitably prepared and parts.
misaligned parts.

e) Members distorted - Member straightened by mechanical means or

by the heat of welding careful application of limited amount of heat,
temperature of such area not to exceed 650 degree
Centigrade (dull red heat).

In removing defective parts of a weld, gouging, chipping, oxygen cutting or grinding shall
not extend into the parent metal to any substantial amount beyond the depth of weld
penetration, unless cracks or other defects exist in the parent metal. The weld or parent
metal shall not be undercut in chipping, grinding, gouging or oxygen cutting.

Any fabricated structure or its component which, in the opinion of Engineer- in-Charge, is
defective and/or beyond any corrective action shall be removed forthwith from the site as
instructed by the Engineer-in-Charge without any extra claim. The owner reserves the right
to recover any compensation due to any loss arising out of such rejections.

5.2.7 Bolting

5.2.7.1 All bolts shall be provided such that no part of the threaded portion of the bolts is within the
thickness of the parts bolted together. Washers of suitable thickness shall be used under the
nuts to avoid any threaded portion of the bolt being within the thickness of parts bolted
together.

5.2.7.2 The threaded portion of each bolt shall project through the nut at least one thread.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS CIVIL & STRUCTURAL WORKS
fill5leg INDIA LIMITED 6-68-0006 Rev.7
1.401 Ma"? ,P1390.1) IA Gad of India Um:*Oolong) STRUCTURAL STEEL WORKS
Page 15 of 25

5.2.7.3 Flat washers shall be circular and of suitable thickness. However, where bolt heads/nuts bear
upon the bevelled surfaces, they shall be provided with square tapered washers of suitable
thickness to afford a seating square with the axis of the bolt.

5.2.7.4 Different bolt grades of the same diameter shall not be used in the same structure, except if
agreed otherwise by the Engineer-in-Charge.

5.2.7.5 Bearing type bolts shall be used (unless noted otherwise) and tightened firmly by available
means.

5.2.8 Splicing

5.2.8.1 Splicing of built up/compound/latticed sections shall be done in such a fashion that each
component of the section is joined in a staggered manner.

5.2.8.2 Where no butt weld is used for splicing, the meeting ends of two pieces of
joist/channel/built up section shall be ground flush for bearing on each other and suitable
flange and web splice plates shall be designed and provided for the full strength of the
flange/ web of the section and welds designed accordingly.

5.2.8.3 Where full strength butt weld is used for splicing (after proper edge preparation of the web
and flange plates) of members fabricated out of joist/ channel/ angles/ built up section,
additional flange and web plates shall be provided, over and above the full strength butt
welds, to have 40% strength of the flange and web.

5.2.8.4 Where a cover plate is used over a joist/channel section the splicing of the cover plate and
channel/joist sections shall be staggered by minimum 500mm. Extra splice plate shall be
used for the cover plate and joist/channel section as per clause 5.2.8.2 or 5.2.8.3.

5.2.8.5 Prior approval shall be obtained by the Contractor for locations of splices where not shown
on design drawings. For members upto a length of 7m, generally no splice shall be allowed
but in exceptional cases one splice shall be allowed at approved location. Maximum two
numbers of splices shall be allowed for members exceeding this length.

5.2.9 Machining & Grinding

5.2.9.1 All slab bases and slab caps shall be accurately machined over the bearing surfaces and shall
be in effective contact with the ends of column sections (shafts).

5.2.9.2 For slab bases and slab caps, ends of column shafts shall be accurately machined. However,
for gussetted bases and caps, the column shafts shall be ground flush for effective contact
with parts connected together.

5.2.9.3 Gussetted bases and caps shall be ground flush for effective contact with ends of column
sections.

5.2.9.4 End of all bearing stiffeners shall be machined or ground to fit tightly at top and bottom
without any air gap.

5.2.9.5 While machining or grinding care shall be taken so that the length or thickness of any part
does not get reduced by more than 2.0mm.

5.2.9.6 For all machining or grinding works for gassetted base and cap plates, the clearance between
the parts joined shall not exceed 0.2mm at any location.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
loiReiei (ft ENGINEERS CIVIL & STRUCTURAL WORKS
*laza faiitegvow INDIA LIMITED STRUCTURAL STEEL WORKS
6-68-0006 Rev.7
1.1W1 elerfee.aq054, ) (A Gail of WM Undertakm)
Page 16 of 25

6.0 MARKING FOR IDENTIFICATION

6.1 Each component shall be distinctly marked (with paint) before delivery in accordance with
the marking diagrams and shall bear such other marks as will facilitate erection.
Components which are identical in all respects may have the same erection mark.

6.2 For small members which are delivered in bundles or crates, the required marking shall be
done on small metal tags securely tied to the bundle.

7.0 SHOP ERECTION

The steel work shall be temporarily shop erected complete or as directed by the
Engineer-in-Charge, so that the accuracy of fit may be checked before despatch.

8.0 INSPECTION & TESTING OF STRUCTURES

8.1 The Engineer-in-Charge (or his authorised representative) shall have free access at all times
to those parts of the Contractor's works which are concerned with the fabrication of the steel
work and shall be provided with all reasonable facilities for satisfying himself that the
fabrication is being undertaken in accordance with the provisions of these specifications &
other relevant BIS Codes.

8.2 Should any structure or part of a structure be found not to comply with any of the provisions
of this specification (or relevant BIS Codes as referred to), it shall be liable to rejection. No
structure or part of the structure, once rejected shall be resubmitted for inspection, exception
cases where the Engineer-in-Charge or his authorised representative considers the defect as
rectifiable.

8.3 Defects which may appear during/after fabrication/ erection shall be made good only with
the consent of the Engineer-in-Charge and procedure laid down by him.

8.4 All necessary gauges and templates shall be supplied free to the Engineer-in-Charge by the
Contractor whenever asked for during inspection. The Engineer-in- Charge, may at his
discretion, check the test results obtained at the Contractor's works by independent tests at a
test house, and the cost of such tests shall be borne by the Contractor.

9.0 SHOP PAINTING

9.1 All components and members of steel work shall be given one shop coat of primer, as
specified in the tender, immediately after the surfaces have been properly prepared (i.e.
degreased, derusted, descaled & cleaned) in accordance with the job specification or
6-79-0020, as applicable.

The primer coat shall be applied over completely dry surfaces (using brushes of good
quality) in a manner so as to ensure a continuous and uniform film without "holidaying".
Special care shall be taken to cover all the crevices, corners, edges etc. However, in areas
which are difficult to reach by brushing, daubers/mops shall be used by dipping the same in
paint and then pulling/ pushing them through the narrow spaces. The primer coat shall be air
dried and shall have the thickness as per EIL Specification no. 6-79-0020 or the relevant job
specification.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
aft ENGINEERS CIVIL & STRUCTURAL WORKS
Ogea Rated"INDIA LIMITED 6-68-0006 Rev.7
IA Govt of Inds Unclertakeng) STRUCTURAL STEEL WORKS
Page 17 of 25

9.2 Surfaces which are inaccessible after shop assembly, shall receive the full specified
protective treatment before assembly (this shall not apply to the interior of sealed hollow
sections).

9.3 Steel surfaces shall not be painted within a suitable distance of any edges to be welded if the
paint specified would be harmful to welders or impair the quality of the welds.

9.4 Welds and adjacent parent metal shall not be painted prior to deslagging, inspection and
approval by the Engineer-in-Charge.

9.5 Parts to be encased in concrete shall have only one coat of primer and shall not be painted
after erection.

10.0 PACKING

10.1 All items shall be suitably packed in case these are to be despatched from the fabrication
shop to the actual site of erection so as to protect them from any damage/distortion or falling
during transit. Where necessary, slender projecting parts shall be temporarily braced to
avoid warping during transportation.

10.2 Small parts such as gussets, cleats etc., shall be securely wired on to their respective main
members.

10.3 Bolts, nuts washers etc. shall be packed in crates.

11.0 TRANSPORTATION

Loading and transportation shall be done in compliance with transportation rules. In case,
certain parts can not be transported in the lengths stipulated on the drawings, the position
details of such additional splice joints shall be gpt approved by the Engineer-in- Charge.

12.0 SITE (FIELD) ERECTION

12.1 Plant & Equipment

The suitability and capacity of all plant and equipment used shall be to the complete
satisfaction of the Engineer-in-Charge.

12.2 Storing & Handling

All steel work shall be so stored and handled at site so that the members are not subjected to
surface abrasion, excessive stresses and any damage.

12.3 Setting Out

Prior to setting out of the steel work, the Contractor shall get himself satisfied about the
correctness of levels, alignment, location of existing concrete pedestals/columns/brackets
and holding down bolts/pockets provided therein. Any minor modification in the same
including chipping, cutting and making good, adjusting the anchor bolts etc., if necessary,
shall be carried out by the Contractor at his own expense. The positioning and levelling of
all steel work including plumbing of columns and placing of every part of the structure with

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
.31Reit4ift, ENGINEERS CIVIL & STRUCTURAL WORKS
ElPesw INDIA LIMITED
1>Rn?RmRm J913.1/IA Gout of Me Undertaking) STRUCTURAL STEEL WORKS
6-68-0006 Rev.7
Page 18 of 25

accuracy shall be in accordance with the drawings and to the complete satisfaction of the
Engineer-in-Charge.

12.4 Tolerances

Tolerances for erection of steel structures shall be as per Annexure 'A'

13.0 SAFETY & SECURITY DURING ERECTION

13.1 The contractor shall comply with IS:7205 for necessary safety and adhere to safe erection
practices and guard against hazardous as well as unsafe working conditions during all stages
of erection.

13.2 During erection, the steel work shall be securely bolted or otherwise fastened and when
necessary, temporarily braced/guyed to provide for all loads to be carried by the structure
during erection till the completion, including those due to the wind, erection equipment &
its operation etc. at no extra cost to the owner. For the purpose of guying, the Contractor
shall not use other structure in the vicinity without prior written permission of the
Engineer-in-Charge.

13.3 No permanent bolting or welding shall be done until proper alignment has been achieved.

13.4 Proper access, platform and safety arrangement shall be provided for working and
inspection, (at no extra cost to the owner) whenever required.

14.0 FIELD CONNECTIONS

14.1 Field Bolting

Field bolting shall be carried out with the same care as required for shop bolting.

14.2 Field Welding

All field assembly and welding shall be executed in accordance with the requirements for
shop assembly and welding. Holes for all erection bolts - where removed after final erection
shall be plugged by welding. Alternatively erection bolts may be left and secured.

15.0 GROUTING

15.1 Prior to positioning of structural columns/girders/ trusses over the concrete

pedestals/columns/brackets, all laitance & loose material shall be removed by wire brushing
& chipping. The bearing concrete surfaces shall be sufficiently levelled, hacked with flat
chisels to make them rough, cleaned (using compressed air) and made thoroughly wet. All
pockets for anchor bolts shall also be similarly cleaned and any excess water removed.
Thereafter, the structural member shall be erected, aligned & plumbed maintaining the base
plates/shoe plates at the levels shown in the drawings, with necessary shims/pack
plates/wedges.

15.2 After final alignment and plumbing of the structure, the forms shall be constructed allround
and joints made tight to prevent leakage. Grouting (under the base plates/shoe plates
including grouting of sleeves & pockets) shall be done with non-shrink grout having
compressive strength (28 days) not less than 40N/sq.mm Non shrink grout shall be of free

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS CIVIL & STRUCTURAL WORKS
Oge.11€15reg INDIA LIMITED 6-68-0006 Rev.7
Inert elatelFenandian
IA Govt d India Undertaking) STRUCTURAL STEEL WORKS
Page 19 of 25

flow premix type and of approved quality and make. It shall be mixed with water in
proportion as specified by the manufacturer. Ordinary 1:2 cement/sand mortar grout shall be
used only for small, isolated structures e.g. operating platforms not supporting any
equipment, pipe supports, crossovers, stairs & ladders. The thickness of grout shall be as
shown on the drawings but not less than 25 mm nor more than 40mm in any case.

15.3 The grout mixture shall be poured continuously (without any interruption till completion) by
grouting pumps from one side of the base plate and spread uniformly with flexible steel
strips and rammed with rods, till the space is filled solidly and the grout mixture carried to
the other side of the base plate.

15.4 The grout mixture shall be allowed to harden for a period as decided by the
Engineer-in-Charge. At the end of this period, the shims/wedges/pack plates may be
removed and anchor bolts tightened uniformly. The alignment of the structure shall now be
rechecked and if found correct, the voids left by the removal of shims/wedges/pack plates (if
removed) must be filled up with a similar mixture of grout. In case after checking, serious
misalignment is indicated, the grout shall be removed completely and fresh grouting done
after making appropriate correction of alignment.

16.0 SCHEME AND SEQUENCE OF ERECTION

The Contractor shall furnish the detailed scheme and sequence of erection to match with the
project schedule and get the same approved by the Engineer-in- Charge. All necessary
co-ordination and synchronization shall be done with the Civil contractor where Civil works
are not included in the scope of structural contractor at no extra cost so as to match with the
project schedule.

17.0 PAYMENT

This clause shall apply to Item Rate tender only.

17.1 Payment for structural steel works shall be made on the basis of admissible weight in metric
tons (determined as described in clause 17.2 and 17.3) of the structure accepted by the
Engineer-in-Charge. The rate shall include supplying (as per supply conditions given in the
Tender) fabricating, erecting in position (at all levels & locations), testing/examining
(excluding radiography only) of bolted and/or welded structural steel works of all types
(including all built up/compound sections made out of rolled sections and/or plates)
including all handling, transporting, storing, straightening if required, cutting, edge
preparation, preheating, bolting and welding of joints (including sealing the joints of box
sections with continuous welding), finishing edges by grinding/machining as shown, fixing
in line & level with temporary staging & bracing and removal of the same after erection,
grouting with non-shrink/ordinary grout as specified, preparation of fabrication & erection
drawings, & erection schedule and getting them reviewed, preparation and submission of as
built drawings, preparing the surfaces for painting, and applying the primer as specified after
fabrication, return of surplus materials to owner's stores and material reconciliation in the
case of materials supplied by the owner as per relevant contract conditions etc. all complete
for all the operations mentioned in the foregoing clauses.

17.2 The weight for payment shall be determined from the fabrication drawings and respective
bill of materials prepared by the Contractor. The bill of materials shall be checked and
approved by the Engineer-in-Charge before making the payment. The Contractor shall
prepare full scale template in order to supplement/verify the actual cutting dimensions
where so directed by the Engineer-in-Charge. The weight shall be calculated on the basis of

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS CIVIL & STRUCTURAL WORKS
51gex EtRes INDiA LIMITED 6-68-0006 Rev.7
1.1Z,€92W1e OX.7111.1)
IA Gori of moo Undertakolg) STRUCTURAL STEEL WORKS
Page 20 of 25

BIS Hand Book wherever applicable. In case sections used are different from BIS sections,
then Manufacturers' Hand Book shall be adopted. No allowance in weight shall be made for
rolling tolerances.

17.3 Welds, bolts, nuts, washers, shims, pack plates, wedges, grout and shop painting shall not be
separately measured. The quoted rate shall be deemed to include the same.

17.4 The rate shall include all expenses related to safety & security arrangements during erection
and all plants & tools required for fabrication, transportation & erection.

18.0 PAINTING AFTER ERECTION

18.1 General

18.1.1 The scope of painting after erection shall be at the sole discretion of the Engineer-in-Charge
and the Contractor shall obtain written instruction in this regard sufficiently prior to taking
up any procurement of paint and execution of painting work after erection of steel
structures.

18.1.2 The Contractor shall carry out the painting work in all respects with the best quality of
approved materials (conforming to relevant EIL Specification no. 6-79-0020 or the job
specification, as applicable) and workmanship in accordance with the best engineering
practice. The Contractor shall furnish characteristics of paints (to be used) indicating the
suitability for the required service conditions. The paint manufacturer's instructions
supplemented by Engineer-in-Charge's direction, if any, shall be followed at all times.
Particular attention shall be paid to the following:

- Proper storage to avoid exposure & extremes of temperature.

- surface preparation prior to painting.
- Mixing & thinning.
- Application of paint and the recommended limit on time intervals between consecutive
coats.
18.1.3 Painting shall not be done in frost or foggy weather, or when humidity is such as to cause
condensation on the surfaces to be painted.

18.1.4 Surface which shall be inaccessible after site assembly shall receive the full specified
protective treatment before assembly.

18.1.5 Primers & finish coat paints shall be from the same manufacturer in order to ensure
compatibility. Painting colour code shall be as per Annexure-'B' or the job specification.

18.2 Rub Down & Primer Application

The shop coated surfaces shall be rubbed down thoroughly with emery/abrasive paper to
remove dust, rust, other foreign matters and degreased, if required, in accordance with ELL
specification no. 6-79-0020 or the job specification, as applicable, cleaned with warm fresh
water and air dried. The portions, from where the shop coat has peeled off, shall be touched
up and allowed to dry.

Primer coat as per EIL specification no. 6-79-0029 or the job specification, as applicable,
shall be applied by brushing/ spraying over the shop coat in a manner so as to ensure a
continuous and uniform film throughout. Special care shall be taken to cover all the
crevices, corners, edges etc. The final primer coat shall be air dried and shall have a

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS CIVIL & STRUCTURAL WORKS
Ogeji Weglii, INDIA LIMITED 6-68-0006 Rev.7
(aRri PROW =MOM) (A Govt of InClu Undertaking) STRUCTURAL STEEL WORKS
Page 21 of 25

minimum film thickness as per E1L Specification no. 6-79-0029 or job specification after
drying, as applicable.

In case a different cleaning procedure & primer specifications are specified in the
drawing/Tender, the same shall be adopted.

18.3 Final Paint Application

After the primer is hard dry, the surfaces shall be dusted off and the paint as per EEL
specification no. 6-79-0029 or the job specification, as specified, shall be applied by
brushing/spraying so that a film free from "holidaying" is obtained. The colour & shade of
first coat of paint shall be slightly lighter than the second coat in order to identify the
application of each coat. The second coat of paint shall be applied after the first coat is hard
dry. The minimum thickness of each film shall be 20 microns (± 10% tolerance) after
drying.

In case a different type of paint & painting procedure are specified in the drawing/tender,
the same shall be adopted.

18.4 Inspection & Testing of Painting Works

18.4.1 All painting materials including primers & thinners brought to site by the Contractor for
application shall be procured directly from reputed and approved manufacturers and shall be
accompanied by manufacturer's test certificates. Paint formulations without certificates shall
not be accepted.

18.4.2 The Engineer-in-Charge at his discretion may call for additional tests for paint formulations.
The Contractor shall arrange to have such tests performance including batch wise test of wet
paints for physical & chemical analysis. All costs shall be borne by the Contractor.
18.4.3 The painting work shall be subject to inspection by the Engineer-in-Charge at all times. In
particular, the stage inspection will be performed and Contractor shall offer the work for
inspection and approval at every stage before proceeding with the next stage. The record of
inspection shall be maintained. Stages of inspection are as follows:

(a) Surface preparation

(b) Primer application
(c) Each coat of paint

18.4.4 Any defect noticed during the various stages of inspection shall be rectified by the
Contractor to the entire satisfaction of the Engineer-in-Charge before proceeding further.
Irrespective of the inspection, repair and approval at intermediate stages of work the
Contractor shall be responsible for making good any defects found during final
inspection/guarantee period/defect liability period, as defined in General Conditions of
Contract. Dry film thickness (DFT) shall be checked and recorded after application of each
coat. The thickness shall be measured at as many locations as decided by the
Engineer-in-Charge. The Contractor shall provide standard thickness measuring instrument
such as elkometer (with appropriate range for measuring dry film thickness of each coat)
free of cost to the Engineer-in-Charge whenever asked for.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
a IR eft
- ENGINEERS CIVIL & STRUCTURAL WORKS
ligart9151egWiT INDIA LIMITED 6-68-0006 Rev.7
WWI EAMICARJAINA) (A Govt of India Undertaking) STRUCTURAL STEEL WORKS
Page 22 of 25

18.5 Payment

Payment for painting of structural steel works shall be made on the basis of admissible
weight in metric tons of the painted structures accepted by the Engineer-in-Charge.

The rate shall include supplying & applying the paint, specified in the tender, of approved
quality and shade over the primer, specified in the tender, over the shop primer already
applied to structural steel works of all types/shapes at all levels, locations & positions
including storage, surface preparation, degreasing, cleaning, drying, touching up of shop
primer coat, providing temporary staging, testing etc. all complete to the entire satisfaction
of the Engineer-in-Charge.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
lalaeieiaft
- ' ENGINEERS CIVIL & STRUCTURAL WORKS
51g en E1151-
euW INDIA LIMITED 6-68-0006 Rev.7
(A Gent al Me Undertakm STRUCTURAL STEEL WORKS
Page 23 of 25

ANNEXURE-'A'
(Clause 12.4)

Maximum Permissible Erection Tolerances

A. Columns

1. Deviation of column axes at foundation top level with

respect to true axes.

i) In longitudinal direction ± 5 mm

ii) In lateral direction ± 5 mm

2. Deviation in the level of bearing surface of columns at

foundation top with respect to true level ± 5 mm

3. Out of plumb (Verticality) of column axis from true vertical

axis, as measured at top:

i) Upto and including 30m height ± H/1000 or ± 25 mm

whichever is less.

ii) Over 30m height f H/1200 or ± 35 mm

whichever is less.

4. Deviation in straightness in longitudinal & transverse planes

of column at any point along the height. ± H/1000 or ± 10 mm
whichever is less.
5. Difference in the erected positions of adjacent pairs of columns
along length or across width of building prior to connecting
trusses/beams with respect to true distance. ± 5 mm

6. Deviation in any bearing or seating level with respect to true ± 5 mm

level.

7. Deviation in difference in bearing levels of a member on

adjacent pair of columns both across & along the building. ± 5 mm

Note: 1. Tolerance specified under 3 should be read in conjunction with 4 & 5.

Note: 2. 'II' is the column height in mm.

B. Trusses

1. Shift at the centre of span of top chord member ± 1/250 of height of

with respect to the vertical plane passing through truss in mm at centre
the centre of bottom chord. of span or ± 15mm
whichever is less.

2. Lateral shift of top chord of truss at the centre of span ± 1/1500 of span of
from the vertical plane passing through the centre of truss in mm or ± 10mm
supports of the truss. Whichever is less.

3. Lateral shift in location of truss from its true position. • 10mm

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
eiel. ENGINEERS CIVIL & STRUCTURAL WORKS
51gen k'italeg
101,271Q920174,13,10.1)
INDIA LIMITED
(A Govt of In Undonelong) STRUCTURAL STEEL WORKS
6-68-0006 Rev.7
Page 24 of 25

4. Lateral shift in location of purlin from true position. ± 5mm

5. Deviation in difference of bearing levels of truss from ± 1/1200 of span of

the true level. truss in mm or 20mm
whichever is less.

C. Gantry Girders & Rails

1. Shift in the centre line of crane rail with respect ± [(web thickness (mm)}+2 mm]
to centre line of web of gantry girder. 2

2. Shift of alignment of crane rail (in plan) with respect

to true axis of crane rail at any point. ± 5 mm

3. Deviation in crane track gauge with respect to true

gauge.

i) For track gauge upto and including 15 m. ± 5 mm.

ii) For track gauge more than 15m. ± [ 5 + 0.25 (S-15)]

Subject to maximum + 10mm, where S in metres is true gauge.

4. Deviation in the crane rail level at any point from

true level. ± 10 mm.

5. Difference in level between crane track rails

(across the bay) at

i) Supports of gantry girders 15 mm.

ii) Mid span of gantry girders 20 mm.

6. Relative shift of crane rail surfaces (at a joining) in

plan and elevation. 2 mm.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
lara ENGINEERS CIVIL & STRUCTURAL WORKS
Oge..11 fafaez Tow INDIA LIMITED 6-68-0006 Rev.7
1.1117f maw .3,13,11P.1) Govt Of IWO undertaking) STRUCTURAL STEEL WORKS
Page 25 of 25

ANNEXURE-'B'
(Clause 18.1)

PAINTING COLOUR CODE FOR STRUCTURAL STEEL

1. GANTRY GIRDER & MONORAIL DARK GREEN

2. GANTRY GIRDER & MONORAIL STOPPER SIGNAL RED

3. BUILDING STRUCTURAL STEEL COLUMNS, DARK ADMIRALITY

BRACKETS, BEAMS, BRACINGS, ROOF TRUSS, GREY
PURLINS, SIDEGIRTS, LOUVERS, STRINGERS

4. PIPE RACK STRUCTURE & TRESTLE DARK ADMIRALITY

GREY

5. CHEQUERED PLATE (BOTH FACES) BLACK

6. GRATING BLACK

7. LADDER RUNGS BLACK

VERTICALS & CAGE RED
8. HAND RAILING

HANDRAIL, MIDDLE SIGNAL RED

RAIL, TOE PLATE

VERTICAL POST BLACK

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS CIVIL AND STRUCTURAL WORKS
$fig-ar iaWs
efenfe .3,40.1)
INDIA LIMITED
IA Govt 011ndA Unclettaking) MISCELLANEOUS STEEL WORKS
6-68-0008 Rev.7
Page 1 of 12

11147
1 cl 11 k I vl
ilzirqF •k11-11clict) mid

STANDARD SPECIFICATION
CIVIL & STRUCTURAL WORKS

Faiti-T7 wrrd. cbiti

MISCELLANEOUS STEEL WORKS

7 27.08.18 REVISED & REISSUED

6 24.01.14 REVISED & REISSUED AJS RS PKM SC

5 10.06.08 REVISED & REISSUED PKB PKM VK VC

4 18.04.00 UPDATED & REISSUED DPN RS SCJ MI

3 MAY'94 UPDATED & REISSUED DPN RS GPL AS

Standards Standards
Rev. Prepared Checked Committee Bureau
Date Purpose Convenor Chairman
No by by
Approved by

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
tIci ei M-ENGINEERS
ligeg fafategMV INDIA LIMITED CIVIL AND STRUCTURAL WORKS 6-68-0008 Rev.7
GoA of Intim Und.taung) MISCELLANEOUS STEEL WORKS
Page 2 of 12

Abbreviations:

AFC Approved for Construction

BIS Bureau of Indian Standards
IS Indian Standard
M.S. Mild Steel
PCC Plain Cement Concrete
RCC Reinforced Cement Concrete

Structural Standards Committee

Convenor: Mr. Rajanji Srivastava

Members: Mr. Anurag Sinha

Mr. VK Panwar
Mr. Samir Das
Mr. Amitabh Kishore
Mr. Gyasuddin
Mr. Charanjeet Singh (Projects)
Mr. Ravindra Kumar (Construction)

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
INDIA LIMITED CIVIL AND STRUCTURAL WORKS 648-0008 Rev.7
IA Govt of India Unclertalung) MISCELLANEOUS STEEL WORKS
Page 3 of 12

CONTENTS

1.0 GENERAL 4

2.0 REFERENCES 4

3.0 MATERIAL 4

4.0 ANCHOR BOLTS 4

5.0 METAL INSERTS 5

6.0 CHEQUERED PLATES 5

7.0 GRATINGS 6

8.0 TUBULAR HAND RAILING 7

9.0 MILD STEEL RUNGS 8

10.0 LIGHT GAUGE STEEL STRUCTURAL SECTIONS 9

11.0 EXPANSION FASTENERS 10

12.0 CHEMICAL ANCHORS AND DOWELS 11

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
*igen LAGS INDIA LIMITED CIVIL AND STRUCTURAL WORKS 6-68-0008 Rev.7
• (A Govt of India UnOettakIng) MISCELLANEOUS STEEL WORKS
Page 4 of 12

1.0 GENERAL

1.1 All materials supplied by the Contractor shall conform to specifications given in EIL
Standard Specification No. 6-68-0002.

1.2 The Contractor shall furnish test certificates for all materials prior to their use in the works.
Structural steel materials not supported by mill test certificates may be used after confirming
their quality by carrying out appropriate tests in accordance with the method specified in
IS:1608.

1.3 Other requirements not covered under this specification shall be in accordance with EIL
Standard Specification No. 6-68-0006.

2.0 REFERENCES
As mentioned in the respective clauses.

3.0 MATERIAL
As mentioned in the respective clauses.

4.0 ANCHOR BOLTS

4.1 Material

Materials for anchor bolts, nuts, locknuts, washers, pipe sleeves and anchor plates shall
conform to their respective clauses given in EIL Standard Specification No. 6-68-0002.

4.2 Fabrication

Fabrication of anchor bolts and their complete assemblies shall be strictly in compliance
with the specifications and drawings/standards.

4.3 Placement

Anchor bolt assemblies shall be placed in position strictly as per drawings and securely held
during pouring and vibrating of concrete with necessary templates and other dummy
structures to prevent their dislocation.

4.4 Tolerances

Tolerances allowed for anchor bolts positioning shall be as below:

a) For sleeved bolts, one tenth of the bolt nominal diameter.
b) For bolts without sleeves, one twentieth of the bolt nominal diameter.

4.5 Protection

The exposed surfaces of bolts shall be properly covered (after greasing of bolts and packing
of sleeves) with jute cloth so as to protect them from damage till final erection of structure/
equipment is over.

4.6 Payment
4.6.1 Payment shall be made on the basis of actual weight in metric tons of the anchor bolt/anchor
bolt assembly. The rate shall include supply (as per scope of supply conditions given in the

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
tif5teg INDIA LIMITED CIVIL AND STRUCTURAL WORKS 6-68-0008 Rev.7
ONTirl eletORMIJATil, (A Govt ol India Undertaking) MISCELLANEOUS STEEL WORKS
Page 5 of 12

tender) of all materials, handling, transporting, fabrication, turning from available size to
required diameter, threading, welding, fixing in position at all levels and locations,
providing necessary templates, greasing, packing of sleeves, covering with jute cloth and
other protective measures etc. all complete.
4.6.2 The rate shall cover bolt of any diameter and nomenclature.

4.6.3 Payment for fixing anchor bolt assembly (already fabricated and supplied by the Owner as
free issue) in position shall be made on the basis of actual weight of anchor bolts/bolt
assemblies in metric tons. The rate shall include handling, transporting, fixing in position at
all levels and locations, welding if required, providing necessary templates, greasing,
packing of sleeves, covering with jute cloth and other protective measures etc. all complete.
4.6.4 No separate payment shall be made for templates, dummy structures, supports etc. and the
rate quoted shall be inclusive of all cost related to such provision required for correct and
accurate installation of anchor bolts/anchor bolt assembly.

5.0 METAL INSERTS

5.1 Material

Materials required for fabricating metal inserts shall conform to their respective
specification given in EIL Standard Specification No. 6-68-0002.

5.2 Fabrication
Fabrication of inserts shall be done strictly as per drawings/standards and in compliance
with the requirements given in EIL Standard Specification No. 6-68-0006.

53 Placement
Metal inserts shall be correctly embedded (in plain concrete/ reinforced concrete) as per
their location shown on the drawings. Care shall be taken that these are securely held in
position and do not get disturbed during concreting. Where necessary, these may be welded
to the reinforcement bars. Suitable templates, spacers, dummy structures and temporary
staging shall be provided. Necessary cutting in the formwork and adjustment of
reinforcement bars shall be done for the placement of metal inserts where required.

5.4 Painting
The exposed surfaces of metal inserts shall be cleaned and given one coat of primer as per
EIL Standard Specification No. 6-79-0020 or job specification (wherever applicable), as
specified, after fabrication.

5.5 Payment
Payment shall be made on the basis of actual weight in metric tons of the metal inserts. The
rate shall include supply (as per supply conditions given in the tender) of all materials,
handling, transporting, fabrication, welding, fixing in position at all levels and locations,
providing necessary templates, spacers, dummy structures, adjusting the formwork and
reinforcement, staging, preparation of surface for painting, applying one coat of primer as
per EIL Standard Specification No. 6-79-0020 or job specification (wherever applicable), as
specified, etc. all complete.

6.0 CHEQUERED PLATES

6.1 Material

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ENGINEERS
51gex Was v INDIA LIMITED CIVIL AND STRUCTURAL WORKS 6-68-0008 Rev.7
lariern eizaaa a9Jc101711 (A Goat al India Undertaking) MISCELLANEOUS STEEL WORKS
Page 6 of 12

Material required for chequered plates shall conform to the specifications given in EIL
Standard Specification No. 6-68-0002. Chequering shall be closed or open-ended or of any
other pattern as shown on drawings.
6.2 Fabrication Drawings
As per the requirements given in EIL Standard Specification No. 6-68-0006.
63 Fabrication
Chequered plates shall be fabricated as per the "Approved for Construction" fabrication
drawings (prepared by the Contractor based on design drawings). These shall be perfectly
flat and without any dents/deformations and shall be cut to the required size and shape.
Holes/ notches/ openings of the required size, if any, shown on drawings shall be made.
Nosing for staircase treads shall be made by cold bending of chequered plates. All edges
shall be made smooth and even. All chequered plate units shall be given distinct erection
marks in accordance with the marking drawings. Stiffeners of any description shall be
welded with the chequered plates where shown on drawings.

6.4 Erection/Fixing
Chequered plates shall be fixed to the bearing members by welding/ bolting/ screwing as
shown on drawings. All bolts/ screws shall be of counter-sunk type so that the heads remain
flush with the top of plate. Where welding is used for fixing, stitch welds of minimum
50mm length with a pitch of 150 mm shall be used. Continuous sealing run of weld shall be
provided along the junction of two consecutive chequered plates parallel to the span. For
removeable flooring, details as shown on drawings shall be followed.

6.5 Painting
Chequered plates shall be cleaned (both the surfaces) and given one coat of primer/
galvanization as per EIL Standard Specification No. 6-79-0020 or job specification, as
specified, on both surfaces.

6.6 Payment
6.6.1 Payment shall be made on the basis of actual weight in metric tons of the chequered plate. If
any stiffening sections are provided below the chequered plates for strengthening, the same
shall be separately measured & paid under Structural Steel item (Refer EIL Standard
Specification No. 6-68-0006).

6.6.2 The rate shall include supplying (as per supply conditions given in the tender), fabricating,
erecting M.S. chequered plates including transporting, handling, straightening if required,
cutting to required size and shape, making holes/ notches/ opening of required size and
nosing, smoothening the edges, fixing by welding/bolting/screwing, at all levels and
locations, preparing detailed fabrication drawings, surface cleaning, removal of rust, scale,
grease and applying one coat of primer/ galvanization as per EIL Standard Specification No.
6-79-0020 or job specification (wherever applicable), as specified, etc. all complete.
6.6.3 Welds, bolts, nuts, screws, washers, clips shall not be measured. The quoted rate shall be
deemed to include the same.

7.0 GRATINGS
7.1 Categories
The electroforged galvanized gratings shall be either Type-I or Type-II as per EIL Standard
No. 7-68-0697 and shall be procured from approved manufacturers as per Vendor List.
7.2 Material

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
4ge-Jr faaj
eg
taken a:ROW ON.3r10.1)
INDIA LIMITED
(A Govt. At India Undertaking)
CIVIL AND STRUCTURAL WORKS
MISCELLANEOUS STEEL WORKS
6-68-0008 Rev.7
Page 7 of 12

Materials for fabrication and fixing of Gratings shall conform to specifications given in EIL
Standard Specification No. 6-68-0002.

7.3 Fabrication Drawings

As per the requirements given in EIL Standard Specification No. 6-68-0006.

7.4 Fabrication

The gratings shall be manufactured by electroforging process strictly as per the "Approved
for Construction" fabrication drawings prepared by the Contractor based on EIL standard.
All units shall be given distinct erection marks in accordance with the marking drawing. The
Contractor shall submit sample gratings for inspection and approval by the
Engineer-in-Charge whenever asked for.

7.5 Erection/Fixing

Gratings shall be fixed to the bearing members by welding/ clamping and bolting as
indicated in the Standard.

7.6 Galvanisation

Gratings and the fixing clamps, bolts, nuts shall be cleaned as per EIL Standard
Specification No 6-79-0020 or job specification (wherever applicable), as specified and
galvanisation shall be done as specified in accordance with IS 2629 and tested as per IS
2633 & IS 6745.

7.7 Payment

7.7.1 Payment shall be made on the basis of actual weight in metric tons of the gratings
manufactured in accordance with EIL Standard and accepted by the Engineer-in-Charge.

The weight for payment shall also include the weight of galvanization and welding.

7.7.2 The rate shall include supplying, fabricating, erecting electroforged galvanized gratings (of
the specified category) including transporting, handling, cutting to required size and shape,
making holes/ notches/ openings, smoothening the edges, fabricating clamps, fixing by
welding/ clamping/ bolting, at all levels and locations, preparing detailed fabrication
drawings, surface cleaning, removal of rust, scale, grease and carrying out galvanization, all
complete.

7.7.3 Bolts, clamps, nuts and washers shall not be measured. The quoted rate shall be deemed to
include the same.

8.0 TUBULAR HAND RAILING

8.1 Material

Materials for fabrication and fixing of Tubular Hand Railing shall confirm to specification
given in EIL Standard Specification No. 6-68-0002.

8.2 Fabrication Drawings

As per the requirements given in EIL Standard Specification No. 6-68-0006.

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 STANDARD SPECIFICATION No.
aft
,( ENGINEERS STANDARD SPECIFICATION
CIVIL AND STRUCTURAL WORKS
*11ge.a lakr/e.,5 W INDIA LIMITED 6-68-0008 Rev.7
wren egeorre nearelnir (A Gout o India Undertaking) MISCELLANEOUS STEEL WORKS
Page 8 of 12

8.3 Fabrication

8.3.1 Hand railing shall be fabricated strictly as per the "Approved for Construction" fabrication
drawings prepared by the Contractor based on design drawings and standards. All tubes
shall be straight and without any dents/ deformations. Tubes shall be cut and ends shall be
prepared to a neat and workman-like finish. All elements shall be directly welded. All
welded joints shall be cleaned and filed or ground smooth, if required, to have a smooth
surface and aesthetically pleasant appearance. Splicing of top rail shall not be allowed.
Tubes shall be cold bent to shape and curvature in case of discontinuous ends of handrails.
Ripples, kinks and/ or dents at bends shall not be accepted.
8.3.2 Lower ends of vertical posts shall be cut and splayed (for grouting in pockets in the concrete
members). For removable type of hand railing, suitable base plates (with provision for
bolting) shall be welded to the lower end of vertical posts. All units shall be given distinct
erection marks in accordance with the marking drawing.
8.4 Erection/ Fixing

Hand railing, shall be fixed to the bearing members by welding/ bolting/ grouting as
indicated on the drawings. Local notching shall be made in the floor plate/ grating to
accommodate vertical posts/ their base plates which shall always be welded to the main
supporting member. When the posts are to be fixed in concrete members, suitable pockets
shall be made in concrete for grouting as shown on drawings/standards.
8.5 Painting

All hand railing components shall be cleaned and given one coat of primer/ galvanization as
per EIL Standard Specification No. 6-79-0020 or job specification (wherever applicable), as
specified, after fabrication.

8.6 Payment

8.6.1 Payment shall be made on the basis of measured length in meters (m) of top rail only
(Horizontal and/or inclined lengths). The rate shall include preparation of fabrication
drawings, supply of all materials, handling, transporting, straightening if required, cutting to
required size, bending, welding, bolting, fixing in position at all levels and locations,
grouting with 1:2 (cement:sand) mortar, surface cleaning, removal of rust, scale, grease and
applying one coat of primer/ galvanization as per EIL Standard Specification no. 6-79-0020
or job specification (wherever applicable), as specified, after fabrication etc. all complete.
8.6.2 The rate shall include making suitable notches in floor plates/ gratings and pockets in
concrete structures for fixing the vertical posts.
9.0 MILD STEEL RUNGS
9.1 Material

All materials shall conform to specifications given in EIL Standard Specification No.
6-68-0002.
9.2 Fabrication

Rungs shall be fabricated as per EIL standards/ drawings. Mild steel bars shall be
straightened if required, cut, bent to shape and given one coat of primer and two coat of
finish paints per EIL Standard Specification No. 6-79-0020 or job specification (wherever
applicable) as specified, on exposed portions after fabrication.
9.3 Fixing

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
$.© ENGINEERS
*igen felfReg iwr INDIA LIMITED CIVIL AND STRUCTURAL WORKS 6-68-0008 Rev.7
Govt of inOia Undertalong) MISCELLANEOUS STEEL WORKS
Page 9 of 12

Rungs shall be fixed in position as per detailed drawing and firmly tied/welded with
reinforcement to prevent their displacement during vibration of concrete.
9.4 Payment

Payment shall be made on the basis of actual weight in kilogram (Kg) of the M.S. rungs.
The rate shall include supply of all materials, handling, transporting, straightening if
required, cutting to required size, bending to shape, tying/welding with reinforcement bars,
fixing at all levels and locations, adjustment of formwork, applying one coat of primer and
two coats of finish paint as per EIL Standard Specification No. 6-79-0020 or job
specification (wherever applicable), as specified, on the exposed portion of rungs etc. all
complete.

10.0 LIGHT GAUGE STEEL STRUCTURAL SECTIONS

10.1 Material

All materials required for fabrication and fixing in position of Light Gauge Steel Structural
Sections shall conform to EIL Standard Specification No. 6-68-0002.

10.2 Fabrication Drawings

As per the requirements given in EIL Standard Specification No. 6-68-0006.

10.3 Fabrication

10.3.1 Fabrication of members shall be done strictly as per the "Approved for Construction"
fabrication drawings prepared by the Contractor based on the latest design drawings and in
accordance with IS 800, IS 801 and other relevant BIS Codes.

10.3.2 All members shall be straight and free from any dents/deformations/ twists. Members shall
be cut to the required sizes and ends prepared to a neat and workman like finish. Holes (for
sag rods and cleat bolts) of appropriate size shall be drilled and all members/ components
shall be given distinct erection marks in accordance with the marking drawings. Holes shall
not be formed by gas cutting probess.

10.4 Erection

Structural members shall be erected in proper sequence and aligned properly without
causing any twist. Permanent bolting/ welding shall be done only after proper alignment has
been achieved. Proper access, working platforms and safety arrangements shall be provided
by the Contractor for working and inspection.
10.5 Painting

All structural components shall be cleaned and given one coat of primer as per EIL Standard
Specification No. 6-79-0020 or job specification (wherever applicable), as specified, after
fabrication.

10.6 Payment

10.6.1 Payment shall be made on the basis of admissible weight in metric tons of the structure
accepted by the Engineer-in-Charge. The weight for payment shall include all structural
members, cleats, splices, gussets and sag rods and shall be determined from the fabrication
drawings along with respective bill of materials prepared by the Contractor. The bill of
materials shall be checked and approved by the Engineer-in-Charge before making the
payment. The weight shall be calculated as per IS 808/ IS 1161. BIS Handbook/

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
09fae_i^ENGINEERS
$11gez itiPtegir INDIA LIMITED CIVIL AND STRUCTURAL WORKS 6-68-0008 Rev.7
(A God of India Undertaking) MISCELLANEOUS STEEL WORKS
Page 10 of 12

Manufacturer's catalogues/ charts shall be adopted in case relevant weights of sections used
are not covered in IS 808/ IS 1161. No allowance in weight shall be made for rolling
tolerances. In case of any doubt, actual weight of the section shall be measured at site.

The rate shall include supplying, fabricating, erecting, at all levels and locations, testing of
bolted and/ or welded Light Gauge structural steel works including cleats, crook bolts,
splices/ sleeves, all other fixtures and accessories, straightening if required, cutting, edge
preparation, welding and bolting of joints, fixing in line and level with temporary staging
and removal of the same after final alignment, handling, transporting, storage, preparation of
detailed fabrication drawings and getting them reviewed by the Engineer-in-Charge, surface
cleaning, removal of scale, rust, oil or grease and applying one coat of primer as per EIL
Standard Specification No. 6-79-0020 or job specification (wherever applicable), etc., all
complete.

10.6.2 All welds, bolts, nuts, washers, fixtures and accessories shall not be measured. The quoted
rate shall be deemed to include the same.

11.0 EXPANSION FASTENERS

11.1 Material

Expansion fasteners (medium and heavy duty) shall be of mild steel/ high tensile steel with
rust proof coating.

11.2 Classification

The expansion fasteners shall be designated as medium and heavy duty depending on their
usage. The broad classification is given below for general guidance.

11.2.1 Medium Duty (Mild steel/ High tensile steel) for:

a) Ladders and stairs supports.

b) Cables and cable trays supports.

c) Electrical panels and fixtures.

d) Hangers for pipes and cable trays.

e) Pipe supports.

11.2.2 Heavy Duty (Mild steel/ High tensile steel) for:

a) Platform supports (beam and columns)

b) Knee brackets for pipes/ multi tiers cable trays/ walkways etc.

Note:- Expansion fasteners shall not be used for:

1. Members supporting equipment and pipes subjected to vibrations.

2. Cantilever connections designed to cater for effective cantilever spans greater than
1,000 mm and 1,000 Kg of concentrated load at the free end.

11.3 Selection

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
5.2.41taws NI, - INDIA LIMITED CIVIL AND STRUCTURAL WORKS 6-68-0008 Rev.7
— Mmrr mt t I A G" d AAA 0.1"0.9) MISCELLANEOUS STEEL WORKS
Page 11 of 12

The Contractor shall procure the expansion fasteners from the approved manufacturers as
per Vendor List.

11.4 Testing

If so desired by the Engineer-in-Charge, the Contractor shall carry out all the requisite tests
(pullout test, torque test etc.) of specimen expansion fasteners (representative of those to be
used) from approved laboratory/ test house and submit the report to him for approval. The
decision of the Engineer-in-Charge regarding the adequacy of strength and load carrying
capacity of the expansion fastener shall be fmal and binding to all. The cost of all such tests
shall be borne by the Contractor.

11.5 Installation

The Contractor shall install the expansion fasteners at their correct location (to suit the
requirement of fixtures as shown in drawings) as per the procedure laid down by the
manufacturer. Location of all holes shall be pre-marked on the concrete surfaces and then
holes drilled carefully with an electric drill to the correct recommended size and depth.
Holes shall be exactly round and true perpendicular to the concrete surface. Edge distance
and pitch of fasteners shall be as recommended by the manufacturer. The contractor shall
suitably shift the hole with the approval of the Engineer-in-Charge in case any
reinforcement bar is met with while drilling the hole in RCC structure. Necessary staging
shall be provided for working and the Contractor shall take requisite safety precautions so as
not to cause any damage to the existing structure/ equipment. Any damage done while
executing the job shall be made good by the Contractor at his cost.

11.6 Protection
The exposed surfaces of expansion fasteners shall be properly greased & covered with jute
cloth so as to protect them from damage.

11.7 Payment
Payment for installing rust proof expansion fasteners shall be made on number basis (each).
The rate shall include supply of complete assembly, handling, transporting, providing
necessary temporary staging, installing (as per manufacturer's specifications) in PCC/ RCC
structures, at all levels and locations, testing, drilling, cleaning, covering with jute cloth,
relocating and re-drilling in case of any obstruction, making good any damage done to the
structure, grouting the abandoned holes and any gap left between the contact surfaces of
PCC/ RCC and fixtures to be added, etc. all complete.

12.0 CHEMICAL ANCHORS AND DOWELS

12.1 Material
Chemical Anchors shall be of high tensile steel rods of minimum grade 5.8 galvanised to at
least 5 microns.

Grade of Rebars for chemical anchoring shall be as per the General Notes of the project.

12.2 Selection

The Contractor shall select the chemical anchors based on the parameters such as Loads and
rebars for dowels as specified in the AFC drawings/ documents. The chemical anchors shall
be procured from the approved manufacturers as per Vendor List.

12.3 Testing

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
(--"" ENGINEERS
sl eit aiiteg
1041V1 mew 0,1390.9)
INDIA LIMITED CIVIL AND STRUCTURAL WORKS 6-68-0008 Rev.7
Govt of India Undertaking) MISCELLANEOUS STEEL WORKS
Page 12 of 12

The Contractor shall carry out, at the work place, the requisite tests like pull out test, shear
test, etc. for chemical anchors and pull out test for dowels. The chemical anchors shall
withstand the load specified in the drawing/ documents and the Dowels shall be tested for
full tensile capacity of the rebars. The decision of the Engineer-in-Charge regarding the
adequacy of strength and load carrying capacity of the anchors/ dowels shall be final and
binding to all. The cost of all such tests shall be borne by the Contractor.
12.4 Installation

The Contractor shall install the chemical anchors/ dowels at their correct location (to suit the
requirement of fixtures as shown in drawings) as per the procedure laid down by the
manufacturer. Location of all holes shall be pre-marked on the concrete surfaces and then
holes drilled carefully with an electric drill to the correct recommended size and depth.
Holes shall be exactly round and true perpendicular to the concrete surface. Edge distance
and pitch of fasteners shall be as recommended by the manufacturer. The contractor shall
suitably shift the hole with the approval of the Engineer-in-Charge in case any
reinforcement bar is met with while drilling the hole in RCC structure. Necessary staging
shall be provided for working and the Contractor shall take requisite safety precautions so as
not to cause any damage to the existing structure/ equipment. Any damage done while
executing the job shall be made good by the Contractor at his cost.

12.5 Payment

Payment for installing chemical anchors shall be made on number basis (each). The rate
shall include supply of complete assembly i.e. chemical anchors along with chemical foils as
per manufacturer specifications.

Payment for installing chemical dowels shall be made on number basis (each). The rate shall
include fixing of dowels by drilling/ cleaning hole and injecting odourless chemical as per
manufacturer specifications. Rebars used as dowels shall be paid separately under relevant
SOR item.

For chemical anchors/ dowels, the rate shall be inclusive of handling, transporting,
providing necessary temporary staging, installing (as per manufacturer's specifications) in
PCC/ RCC structures to a required depth with a specified hole diameter, at all levels and
locations, testing, drilling holes, cleaning, covering with jute cloth, relocating and re-drilling
in case of any obstruction, making good any damage done to the structure, grouting the
abandoned holes and any gap left between the contact surfaces of PCC/ RCC and fixtures to
be added, etc. all complete.

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 SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
MANAGEMENT SYSTEM 6-78-0001 Rev. 2
REQUIREMENTS FROM BIDDERS Page 2 of 7

Abbreviations:

ISO - International Organization for Standardization

MR - Material Requisition
PO - Purchase Order
PR - Purchase Requisition
QMS - Quality Management System

QMS Standards Committee

Convener: Mr. S.K. Badlani

Members: Mr. Sanjay Mazumdar (Engg.)

Mr. R.K. Singh (SCM)
Mr. B. Biswas (SCM)
Mr. Ravindra Kumar (Const.)
Mr. Vinod Kumar (CQA)
Mr. Swapnil Vaishnav (Projects)

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 SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
MANAGEMENT SYSTEM 6-78-0001 Rev. 2
REQUIREMENTS FROM BIDDERS Page 3 of 7

CONTENTS

Clause Title Page

No.
1.0 SCOPE ........................................................................................................................................ 4
2.0 DEFINITIONS ............................................................................................................................ 4
3.0 REFERENCE DOCUMENTS .................................................................................................... 4
4.0 QUALITY MANAGEMENT SYSTEM – GENERAL .............................................................. 4
5.0 QUALITY SYSTEM REQUIREMENTS ................................................................................... 4
6.0 AUDITS ...................................................................................................................................... 7
7.0 DOCUMENTATION REQUIREMENTS .................................................................................. 7

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 SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
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REQUIREMENTS FROM BIDDERS Page 4 of 7

1.0 SCOPE

This specification establishes the Quality Management System requirements to be met by

BIDDER for following purpose:

 QMS requirements to be met by suppliers / contractors after award of work / during

contract execution.

2.0 DEFINITIONS

2.1 Bidder

For the purpose of this specification, the word “BIDDER” means the person(s), firm,
company or organization who is under the process of being contracted by EIL / Owner for
delivery of some products (including service). The word is considered synonymous to
supplier, contractor or vendor.

2.2 Project Quality Plan

Document tailored from Standard Quality Management System Manual of BIDDER,

specifying how the quality requirements of the project will be met.

2.3 Owner

Owner means the owner of the project for which services / products are being purchased and
includes their representatives, successors and assignees.

3.0 REFERENCE DOCUMENTS

6-78-0002 Specification for Documentation Requirements from Contractors

6-78-0003 Specification for Documentation Requirements from Suppliers

4.0 QUALITY MANAGEMENT SYSTEM – GENERAL

Unless otherwise agreed with EIL / Owner, the BIDDER proposed quality system shall fully
satisfy all relevant requirements of ISO 9001 “Quality Management Systems –
Requirements.” Evidence of compliance shall be current certificate of quality system
registration to ISO 9001 or a recent compliance audit recommending registration from a
certification agency. The quality system shall provide the planned and systematic control of
all quality related activities for execution of contract. Implementation of the system shall be
in accordance with BIDDER’S Quality Manual and PROJECT specific Quality Plan.

5.0 QUALITY SYSTEM REQUIREMENTS

5.1 BIDDER shall prepare and submit for review / record, Project Quality Plan / Quality
Assurance Plan for contracted scope / job. The BIDDER’S Quality Plan shall address all of
the applicable elements of ISO 9001, identify responsible parties within BIDDER’S
organization, for the implementation / control of each area, reference the applicable
procedures used to control / assure each area, and verify the documents produced for each
area. The Project Quality Plan shall necessarily define control or make reference to the
relevant procedures, for design and engineering, purchase, documentation, record control,
bid evaluation, inspection, production / manufacturing, preservation, packaging and storage,
quality control at construction site, pre-commissioning, commissioning and handing over (as
applicable) in line with contract requirement and scope of work.

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REQUIREMENTS FROM BIDDERS Page 5 of 7

5.2 BIDDER shall identify all specified or implied statutory and regulatory requirements and
communicate the same to all concerned in his organization and his sub contractor’s
organization for compliance.

5.3 BIDDER shall deploy competent and trained personnel for various activities for fulfillment
of PO / contract. BIDDER shall arrange adequate infrastructure and work environment to
ensure that the specification and quality of the deliverable are maintained.

5.4 BIDDER shall do the quality planning for all activities involved in delivery of order. The
quality planning shall cover as minimum the following:

 Resources
 Product / deliverable characteristics to be controlled.
 Process characteristics to ensure the identified product characteristics are realized
 Identification of any measurement requirements, acceptance criteria
 Records to be generated
 Need for any documented procedure

The quality planning shall result into the quality assurance plan, inspection and test plans
(ITPs) and job procedures for the project activities in the scope of bidder. These documents
shall be submitted to EIL / Owner for review / approval, before commencement of work.

5.5 Requirements for sub-ordering of outsourced items / sub-contracting / purchasing of services

specified in MR / contract / tender shall be adhered to. In general all outsourced items will be
from approved vendors of EIL. Wherever requirements are not specified, or approved sub
vendors do not exist, the sub-contractor shall establish and maintain a system for purchasing
/ sub-contracting to ensure that purchased product / service conforms to specified
requirements in concurrence with EIL / Owner. Criteria for selection of sub-contractor,
evaluation, re-evaluation, maintenance of purchasing data and verification of purchased
product (sub-contractor services), constitute important components of this requirement.

5.6 BIDDER shall plan and carry production and service provision under controlled conditions.
Controlled conditions shall include, as applicable

a) the availability of information that describes the characteristics of the product

b) the availability of work instructions
c) the use of suitable equipment
d) the availability and use of monitoring and measuring devices
e) the implementation of monitoring and measurement
f) the implementation of release, delivery and post-delivery activities

5.7 BIDDER shall validate any processes for production and service provision where resulting
output cannot be verified by subsequent monitoring and measurement. This includes any
process where deficiencies become apparent only after the product is in use or service has
been delivered.

5.8 BIDDER shall establish a system for identification and traceability of product / deliverable
throughout product realization. Product status with respect to inspection and testing
requirements shall be identified.

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5.9 BIDDER shall identify, verify, protect and safeguard EIL / Owner property (material /
document) provided for use or incorporation into the product. If any Owner / EIL property is
lost, damaged or otherwise found to be unsuitable for use, this shall be reported to the EIL /
Owner.

5.10 BIDDER shall ensure the conformity of product / deliverable during internal processing and
delivery to the intended destination. Requirements mentioned in the MR/ tender shall be
adhered to.

5.11 BIDDER shall establish system to ensure that inspection and testing activities are carried out
in line with requirements. Where necessary, measuring equipment shall be calibrated at
specified frequency, against national or international measurement standards; where no such
standard exists, the basis used for calibration shall be recorded. The measuring equipment
shall be protected from damage during handling, maintenance and storage.

5.12 BIDDER shall ensure effective monitoring, using suitable methods, of the processes
involved in production and other related processes for delivery of the scope of contract.

5.13 BIDDER shall monitor and measure the characteristics of the product / deliverable to verify
that product requirement has been met. The inspection (stage as well as final) by BIDDER
and EIL / Owner personnel shall be carried out strictly as per the approved ITPs or ITPs
forming part of the contract. Product release or service delivery shall not proceed until the
planned arrangements have been satisfactorily completed, unless otherwise approved by
relevant authority and where applicable by Owner / EIL.

5.14 BIDDER shall establish and maintain a documented procedure to ensure that the product
which does not conform to requirements is identified and controlled to prevent its unintended
use or delivery

5.15 All non-conformities (NCs) / deficiencies found by the BIDDER’S inspection / surveillance
staff shall be duly recorded, including their disposal action shall be recorded and resolved
suitably. Effective corrective actions shall be implemented by the BIDDER so that similar
NCs including deficiencies do not recur. The BIDDER shall take appropriate actions to
address the Risks and Opportunities in the project.

5.16 All deficiencies noticed and reported by EIL / Owner shall be analyzed by the BIDDER and
appropriate corrective actions shall be implemented. BIDDER shall intimate EIL / Owner of
all such corrective action implemented by him.

5.17 BIDDER should follow the standards, specifications and approved drawings. Concessions /
Deviations shall be allowed only in case of unavoidable circumstances. In such situations
Concession / deviation request must be made by the BIDDER through online system of EIL
eDMS. URL of EIL eDMS is http://edocx.eil.co.in/vportal.

5.18 BIDDER shall have documented procedure for control of documents.

5.19 All project records shall be carefully kept, maintained and protected for any damage or loss
until the project completion, then handed over to EIL / Owner as per contract requirement
(Refer Specification Nos. 6-78-0002 - Specification for Documentation Requirements from
Contractors and 6-78-0003 - Specification for Documentation Requirements from Suppliers),
or disposed as per relevant project procedure.

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 SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.
MANAGEMENT SYSTEM 6-78-0001 Rev. 2
REQUIREMENTS FROM BIDDERS Page 7 of 7

6.0 AUDITS

BIDDER shall plan and carry out the QMS audit for the job. Quality audit programme shall
cover design, procurement, construction management and commissioning as applicable
including activities carried out by sub-vendors and sub-contractors. This shall be additional
to the certification body surveillance audits carried out under BIDDER’S own ISO 9001
certification scheme.

The audit programmes and audit reports shall be available with bidder for scrutiny by EIL /
Owner. EIL or Owner’s representative reserves the right to attend, as a witness, any audit
conducted during the execution of the WORKS.

In addition to above, EIL, Owner and third party appointed by EIL / Owner may also
perform Quality and Technical compliance audits. BIDDER shall provide assistance and
access to their systems and sub-contractor / vendor systems as required for this purpose.
Any deficiencies noted shall be immediately rectified by BIDDER.

7.0 DOCUMENTATION REQUIREMENTS

BIDDER shall submit following QMS documents immediately after award of work (Within
one week) for record / review by EIL / Owner/ TPIA, as applicable.

 Organization chart (for complete organization structure and for the project)
 Project Quality Plan / Quality Assurance Plan
 Job specific Inspection Test Plans, if not attached with PR
 Job Procedures
 Inspection / Test Formats

In addition to above QMS documents, following documentation shall be maintained by the

BIDDER for submission to EIL / Owner on demand at any point of time during execution of
the project.

 Quality Manual
 Certificate of approval for compliance to ISO: 9001 standard
 Procedure for Control of Non-conforming Product
 Procedure for Control of Documents
 Sample audit report of the QMS internal and external audits conducted during last one
year
 Customer satisfaction reports from at least 2 customers,
 Project QMS audit report
 Technical audit reports for the project
 Corrective action report on the audits

Documents as specified above are minimum requirements. BIDDER shall submit any other
document / data required for completion of the job as per EIL / Owner instructions.

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Page 170 of 674
 SPECIFICATION FOR STANDARD SPECIFICATION No.
DOCUMENTATION
6-78-0003 Rev. 2
REQUIREMENTS FROM
SUPPLIERS Page 2 of 9

Abbreviations:

DCI - Document Control Index

eDMS - Electronic Document Management System
FOA - Fax of Acceptance
IC - Inspection Certificate
IRN - Inspection Release Note
ITP - Inspection and Test Plan
LOA - Letter of Acceptance
MR - Material Requisition
PO - Purchase Order
PR - Purchase Requisition
PVC - Polyvinyl Chloride
QAP - Quality Assurance Plan
QMS - Quality Management System
RPO - Regional Procurement Office
TPIA - Third Party Inspection Agency
URL - Universal Resource Locator
V-Portal- Vendor Portal

QMS Standards Committee

Convener: Mr. S.K. Badlani

Members: Mr. Sanjay Mazumdar (Engg.)

Mr. R.K. Singh (SCM)
Mr. B. Biswas (SCM)
Mr. Ravindra Kumar (Const.)
Mr. Vinod Kumar (CQA)
Mr. Swapnil Vaishnav (Projects)

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 SPECIFICATION FOR STANDARD SPECIFICATION No.
DOCUMENTATION
6-78-0003 Rev. 2
REQUIREMENTS FROM
SUPPLIERS Page 3 of 9

CONTENTS

Clause Title Page No.

1.0 SCOPE ........................................................................................................................................ 4
2.0 DEFINITIONS ............................................................................................................................ 4
3.0 REFERENCE DOCUMENTS .................................................................................................... 4
4.0 DOCUMENTATION REQUIREMENTS .................................................................................. 4

Attachments

Format for completeness of Final Documentation : Format No. 3-78-0004

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 SPECIFICATION FOR STANDARD SPECIFICATION No.
DOCUMENTATION
6-78-0003 Rev. 2
REQUIREMENTS FROM
SUPPLIERS Page 4 of 9

1.0 SCOPE
This specification establishes the Documentation Requirements from Suppliers.
All documents / data against the PO / PR / MR shall be developed and submitted to EIL /
Owner by the suppliers for review / records, in line with this specification.

2.0 DEFINITIONS

2.1 Supplier

For the purpose of this specification, the word “SUPPLIER” means the person(s), firm,
company or organization who has entered into a contract with EIL / Owner for delivery of
some products (including service). The word is considered synonymous to bidder, contractor
or vendor.

2.2 Owner

Owner means the owner of the project for which services / products are being purchased and
includes their representatives, successors and assignees.

3.0 REFERENCE DOCUMENTS

6-78-0001 Specification for Quality Management System Requirements from

Bidders

4.0 DOCUMENTATION REQUIREMENTS

4.1 Order Acknowledgement and Assigning Project Manager

After placement of order, Supplier shall acknowledge order through V-Portal within 7 days
of receipt of FOA / PO. Supplier shall assign a Project Manager for that order though online
portal and provide requisite details. Project Manager details shall include e-mail address,
mailing address, mobile/telephone nos., fax nos. and name of Project Manager. All the
system generated emails pertaining to that order shall be sent to the assigned Project
Manager.

4.2 Documents / Data to be submitted by the Supplier

4.2.1 The Supplier shall submit the documents and data against the PO / PR / MR as per the list
given in respective PO / PR / MR.

4.2.2 Review of the supplier drawings / documents by EIL would be only to review the
compatibility with basic designs and concepts and in no way absolve the supplier of his
responsibility / contractual obligation to comply with PR requirements, applicable codes,
specifications and statutory rules / regulations. Any error / deficiency noticed during any
stage of manufacturing / execution / inspection/ installation shall be promptly corrected by
the supplier without any time and cost implications, irrespective of comments on the same
were received from EIL during the drawing review stage or not.

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 SPECIFICATION FOR STANDARD SPECIFICATION No.
DOCUMENTATION
6-78-0003 Rev. 2
REQUIREMENTS FROM
SUPPLIERS Page 5 of 9

4.2.3 Unless otherwise specified, submission of documents for Review / Records shall commence
as follows from the date of Fax of Intent / Letter of Intent / Fax of Acceptance (FOA) / Letter
of Acceptance (LOA):
QMS - 1 week
Document Control Index - 2 weeks
Other Documents / Drawings - As per approved Document Control Index

4.2.4 Documents as specified in PO / PR / MR are minimum requirements. Supplier shall submit

any other document / data required for completion of the job as per EIL / Owner instructions.

4.3 Style and Formatting

4.3.1 All Documents shall be in ENGLISH language and in M.K.S System of units.

4.3.2 Before forwarding the drawings and documents, contractor shall ensure that the following
information are properly mentioned in each drawing:
Purchase Requisition Number
Name of Equipment / Package
Equipment / Package Tag No.
Name of Project
Client
Drawing / Document Title
Drawing / Document No.
Drawing / Document Revision No. and Date

4.4 Review and Approval of Documents by Supplier

4.4.1 The Drawing / Documents shall be reviewed, checked, approved and duly signed / stamped by
supplier before submission. Revision number shall be changed during submission of the
revised supplier documents and all revisions shall be highlighted by clouds. Whenever the
supplier require any sub-supplier drawings to be reviewed by EIL, the same shall be submitted
by the supplier duly reviewed, approved and stamped by the supplier. Direct submission of
sub-supplier’s drawings without contractor’s / suppliers’ approval shall not be entertained.
4.5 Document Category

4.5.1 Review Category

Following review codes shall be used for review of supplier Drawings / Documents:

Review Code 1 - No comments. Proceed with Manufacture /

Fabrication as per the document.
Review Code 2 - Proceed with Manufacture / Fabrication as per
commented document. Revised document
required.
Review Code 3 - Document does not conform to basic requirements as
marked. Resubmit for review.

R - Document is retained for Records. Proceed with

Manufacturing / Fabrication as per PR / Tender
requirements.
V - Void

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 SPECIFICATION FOR STANDARD SPECIFICATION No.
DOCUMENTATION
6-78-0003 Rev. 2
REQUIREMENTS FROM
SUPPLIERS Page 6 of 9

4.6 Methodology for Submission of Documents to EIL/Owner

4.6.1 Document Control Index (DCI)

Supplier shall create and submit Document Control Index (DCI) for review based on PO / PR
/ MR along with schedule date of submission of each drawing / document on EIL Vendor
Portal. The DCI shall be specific with regard to drawing / document no. and the exact title.
Proper sequencing of the drawings / documents should be ensured in schedule date of
submission.

4.6.2 Submission of Drawings / Documents / Data

Drawings / documents, data and DCI shall be uploaded on the EIL Vendor Portal as per
approved DCI. The detailed guidelines for uploading documents on EIL Vendor Portal are
available on following URL
http://edocx.eil.co.in/vportal

4.6.3 Statutory Approvals

Wherever approval by any statutory body is required to be taken by Supplier, the Supplier shall
submit copy of approval by the authority to EIL.

4.6.4 Manufacturing Schedule

Supplier shall prepare manufacturing schedule for the order, with key milestone activities (such
as document submission, sub ordering, manufacturing, Inspection, dispatches, etc) to meet
delivery as per FOA / PO terms. Supplier shall submit manufacturing schedule to concerned
Regional Procurement Office (RPO) of EIL / Owner for review within 2 weeks from date of
FOA / PO.

4.6.5 Schedule and Progress Reporting

Supplier shall submit monthly progress (MPR) report and updated procurement, engineering,
manufacturing status, Inspection and dispatch status (schedule vs. actual) and highlight
constraints, if any, along with action plan for mitigation, to the concerned Regional
Procurement Office (RPO) of EIL / Owner by 1st week of every month., First MPR shall be
submitted within 2 weeks from FOA / LOA. In case of exigencies, EIL / Owner can ask for
report submission as required on weekly / fortnightly / adhoc basis depending upon supply
status and supplier shall furnish such reports promptly without any price implication. Format
for progress report shall be submitted by the Supplier during kick off meeting or within 2 weeks
of receiving FOA / LOA, whichever is earlier.

4.7 Inspection and Testing

4.7.1 Quality Assurance Plan / Inspection and Test Plan

If Inspection and test plans (ITP) are attached with MR / PR same shall be followed along with
additional tests requirement (if any) mentioned in MR/ PR. However for cases wherein EIL
Standard ITPs not available / have not been attached with MR / PR, Supplier shall submit
within one week of receiving FOA / LOA, the Quality Assurance Plan for inspection & testing
at various stages of production, quality control records for critical bought out items / materials
and site assembly & testing as may be applicable to the specific order and obtain approval from
concerned Regional procurement Office of EIL / third party inspection agency, as applicable.

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 SPECIFICATION FOR STANDARD SPECIFICATION No.
DOCUMENTATION
6-78-0003 Rev. 2
REQUIREMENTS FROM
SUPPLIERS Page 7 of 9

For Package equipment contracts, the supplier shall prepare a list of items / equipment and
their inspection categorization plan for all items included in the scope of supply immediately
after receipt of order and obtains approval for the same from EIL. The items shall be
categorized into different categories depending upon their criticality for the scope of inspection
of TPIA and / or EIL.

4.7.2 Inspection Requisition:

Supplier shall perform internal inspection as per ITP/ approved QAP at their works based on
approved documents / drawings. Upon satisfactory internal inspection, supplier shall raise
inspection call to concerned Regional Procurement Office (RPO) of EIL / TPIA / Owner with
advance notice as per contract along with Internal test reports.

All changes w.r.t. PR shall be recorded through agreed variations or Concessions & Deviations.
Conflict, if any, between PR / Job specifications and approved drawings, shall be brought to
the notice of EIL / owner by the supplier / contractor. Decision of EIL / owner will be binding
on the supplier and to be complied without time and cost implications.

Identified bought out items/ raw material shall be procured under TPIA as per ITP.

4.7.3 Inspection Release Note (IRN)/ Inspection Certificate (IC)

IRN / IC shall be issued by EIL Inspector / third party inspection agency on successful
inspection, review of test reports / certificates as per specifications & ITP / agreed quality plan
(as applicable) and only after all the drawings / documents as per DCI are submitted and are
accepted under review code-1 or code R. Supplier shall ensure that necessary documents /
manufacturing and test certificates are made available to EIL / TPIA as and when desired.

Note 1: Non fulfilling above requirement shall result into appropriate penalty or with- holding
of payment as per conditions of PO / PR / MR.

Note 2: For items where IRN/IC is issued by TPIA, supplier to ensure that following as a
minimum must be mentioned by TPIA in IRN / IC

a) PR document number
b) List of drawings / documents with EIL approval code
c) Tests witnessed, documents reviewed
d) Compliance statement by TPIA that product meets the requirement as specified in
EIL PR, standard specifications, Inspection Test Plan / QAP and approved
documents.

4.8 Transportation Plan

Transportation Plan for Over Dimensional Consignments (ODC), if any, shall be submitted
within 2 weeks of receiving FOA / LOA, for approval. Consignment with parameters greater
than following shall be considered as over dimensional.

Dimensions: 4 meters width x 4 meters height x 20 meters length

Weight : 32 MT

Dimensions and weight provided above are inclusive of all nozzles, attachments, transportation
saddles etc.

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 SPECIFICATION FOR STANDARD SPECIFICATION No.
DOCUMENTATION
6-78-0003 Rev. 2
REQUIREMENTS FROM
SUPPLIERS Page 8 of 9

Physical Rout survey for ODC movement shall be submitted to EIL within 8 weeks of
receiving FOA / LOA.

4.9 Dispatch Details

Upon receipt of IRN / IC from EIL inspector / TPIA, supplier shall dispatch items within 2
days. Supplier shall submit dispatch details to concerned RPO of EIL / Owner within a day of
dispatch. Dispatch details shall include Lorry Receipt (LR) number / Dispatch Number,
Transporter Name, Date of dispatch, Packing list, Invoice copy etc.
4.10 Final Documentation
4.10.1 Supplier shall prepare final documents in line with VDR (Vendor Document Requirements)
attached with PR/Tender. A copy of final document along with filled in Format for
Completeness of Final Documentation (Format No. 3-78-0004) to be submitted to EIL
Inspector / TPIA for review & approval within 2 weeks from dispatch. Upon receipt of
EIL/TPIA endorsement on Completeness of Final Documents, supplier shall submit soft / hard
copies of Final documents to EIL / Owner in requisite quantity as per PO / PR details, along
with covering letter. A copy of covering letter to be submitted to the concerned Regional
Procurement Office (RPO) of EIL/Owner.
4.10.2 As Built Drawings
Minor Shop changes made by Supplier after approval of drawings under ‘Code 1’ by EIL and
deviations granted through online system ,if any, shall be marked in hard copies of drawings
which shall then be stamped ‘As-built’ by the supplier. These ‘As-built’ drawings shall be
reviewed and stamped by EIL Inspector / TPIA. Supplier shall prepare scanned images files
of all marked – up ‘As – built’ drawings. Simultaneously Supplier shall incorporate the shop
changes in the native soft files of the drawings also.
4.10.3 Packing / Presentation of Final Documents
Final Documents shall be legible photocopies in A4, A3 size only. Drawings will be inserted
in plastic pockets (both sides transparent, sheet thickness minimum 0.1 mm) with an extra strip
of 12 mm wide for punching so that drawings are well placed.
Final Documentation shall be bound in Hard board Plastic folder(s) of size 265 mm x 315 mm
(101/2 inch x 121/2 inch) and shall not be more that 75 mm thick. It may be of several volumes
and each volume shall have a volume number, index of volumes and index of contents of that
particular volume. Where number of volumes are more, 90mm thickness can be used. Each
volume shall have top PVC sheet of minimum 0.15 mm thick duly fixed and pressed on folder
cover and will have 2 lever clip. In case of imported items documents, 4 lever clip shall also
be accepted. All four corners of folders shall be properly metal clamped. Indexing of contents
with page numbering must be incorporated by supplier. Spiral/Spico bound documents shall
not be acceptable. As mentioned above, books should be in hard board plastic folders with
sheets punched and having 2/4 lever clips arrangement.
Each volume shall contain on cover a Title Block indicating package Equipment Tag No. &
Name, PO / Purchase Requisition No., Name of Project and Name of Customer. Each volume
will have hard front cover and a reinforced spine to fit thickness of book. These spines will
also have the title printed on them. Title shall include also volume number (say 11 of 15) etc.
4.10.4 Submission of Soft Copies
Supplier shall submit to EIL, the scanned images files as well as the native files of drawings /
documents, along with proper index.
In addition to hard copies, Supplier shall submit soft copies of all the final drawings and
documents in pen drive or any other specified medium with proper identification tag, all text
documents prepared on computer, scanned images of all important documents (not available
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 SPECIFICATION FOR STANDARD SPECIFICATION No.
DOCUMENTATION
6-78-0003 Rev. 2
REQUIREMENTS FROM
SUPPLIERS Page 9 of 9

as soft files), all relevant catalogues, manuals available as soft files (editable copies of
drawings/text documents, while for catalogues / manuals / proprietary information and data,
PDF files can be furnished).
All the above documents shall also be uploaded on the EIL Vendor Portal and if applicable on
Client Server also.
4.10.5 Completeness of Final Documentation
Supplier shall get the completeness of final documentation verified by EIL / TPIA, as
applicable, and attach the Format for Completeness of Final Documentation (Format No. 3-78-
0004) duly signed by EIL Inspector or TPIA as applicable to the final document folder.

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 COMPLETENESS OF FINAL
DOCUMENTATION
Page 1 of 2

COMPLETENESS OF FINAL DOCUMENTATION

Name of Supplier/Contractor :
Customer :
Project :
EIL’s Job No. :
Purchase Order No./ :
Contract No.

Purchase Requisition No./ :

Tender No. Rev. No. :

Name of the Work/ Equipment :

Tag. No. :
Supplier’s / Contractor’s Works :
Order No.

Certified that the Engineering Documents / Manufacturing & Test Certificates submitted by the
supplier (as per Index sheet mentioned in Annexure-1) are complete in accordance with the Vendor
Data Requirements of Purchase Requisition / Tender.

Signature : ………………………………. Signature : ……………………………….

Date : ………………………………. Date : ……………………………….
Name : …………………………….. Name : ……………………………..
Designation : ……………………………… Designation : ………………………………
Department : ……………………………… Department : ………………………………

Supplier / Contractor EIL / TPIA

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 COMPLETENESS OF FINAL
DOCUMENTATION
Page 2 of 2

Annexure-1

Final Documentation Index Sheet

PR/PO/Tender Rev. No.
No.

Serial No. Document Title Page/ No. of Pages

Folder No.

Signature : ………………………………. Signature : ……………………………….

Date : ………………………………. Date : ……………………………….
Name : …………………………….. Name : ……………………………..
Designation : ……………………………… Designation : ………………………………
Department : ……………………………… Department : ………………………………

Supplier / Contractor EIL / TPIA

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Page 180 of 674

 STANDARD No.

#50adErsIGINEERS DETAILS OF STEEL LADDER 7.68-0507 Rev. 8

Ogar emeg
N972RmRY13aRiD
INDIA UNITED
(A Govt of Indio Undertaking)
Page 1 of 3

0 `e' INSULATION THICKNESS (50 mm UNLESS NOTED OTHERWISE)

TOP
RUNG D REFER SEC. 11-11 OF 7-68-0509 (SHT. 1 OF 3)

O
10 O
L•r) In
EL. — TOP
SUPPORT RUNG
X1
O
Oz
BETWEE N SUPPORTS

(NL
O
O
O
7
0

O
0
O
C) 0 O
w N O
0
EL 0
SUPPORT L-
0
X2 X

vi

O
O
1.0
N
EL.
SUPPORT O
SAFETY CAGE O
X1
LADDER HEAD
AT SIDE
EL.
SUPPORT O
X2 O
O
BOTTOM
t RUNG
(REFER SHT. 3 OF 3)
O
O LOWER OR
INTERNED
HOOPS

LADDER FOR SIDE ENTRY LADDER FOR SIDE ENTRY

DISTANCE `D' (mm) * MC100 SHALL BE ADOPED FOR DISTANCE

VESSEL DIA (mm)
MORE THAN 1350 UPTO 2000
UPTO 800 200 + e
> 800 < 3200 260 + e
> 3200 < 8000 275 + e

*11(4,1 it144
8 01 08 19 REAFFIRMED AND ISSUED AS STANDARD JG AVM RAJANJI SRIVASTAVA TRIdit)
VEDI

7 28 11 13 REVISED AND ISSUED AS STANDARD vPs AJS P K MITTAL S.CHANDA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copyright EIL - All nghts reserved

Page 181 of 674

 STANDARD No.
DETAILS OF STEEL LADDER
4 MOINEwek LIMITED
lig7 (A Govt of India Undertaking)
7-68-0507 Rev. 8
Page 2 of 3

800 800
O
_
z 400 400 0 FLAT 0
75x10 0
a
O TOP OF
GRATING/
CHEQ. PL. CONTINUOUS
TOE PLATES
EL. ON
SUPPORT
SECTION

LADDER POST._

M AX. HEIGHTWITHOUTSAFETYCAGE =4500

0 1/1
0 z z
0
rn
0
O 0 0

0 CA
0 °
Z 0 2
EL. ON X II x II
SUPPORT
SECTION
Z z zz

400 0
0 TOE ANGLE/EDGE OF
PLATFORM MEMBER

0
x

0 LADDER FOR FRONT ENTRY

0
WI 0
0
u)
N
o 1A1re)
0 REF. EL. H REF. EL.
Ln
TOP OF PEDESTAL/
CHEQ. PL. /GRATING
N
larlo0K)
—\
+ C
BOTTOM
L RUNG
—I. 'L-

TYPE OF ATTACHMENT DEPENDING

ON FLOORING TYPE. LADDER FOR FRONT ENTRY
(REF. SHT. 3 OF 3)
LADDER FOR SIDE ENTRY
NOTES :-
1. LADDER POSTS SHALL BE OF FLAT (75x10) UPTO 3.60m (MAX.) BETWEEN SUPPORTS AND ISMC 100 UPTO
7.0m (MAX.) BETWEEN SUPPORTS.
2. RUNGS SHALL BE 20 0.
3. SUPPORT TYPE `X1' CORRESPONDS TO FIXED SUPPORT AND 'X2' CORRESPONDS TO SLIDING SUPPORT.
4. SUPPORT ELEVATION X1, X2 CORRESPOND TO OF BOLT HOLES.
5. SUPPORTS `X1' IS CAPABLE TO SUSTAIN A LOAD FOR 9000 mm LONG LADDER ONLY.
6. LADDER SHALL BE GIVEN A SUITABLE SLOPE (MAX.6*),IF NECESSARY, TO AVIOD FOULING WITH AN OR CHAIRS.

8 01 08 19 REAFFIRMED AND ISSUED AS STANDARD

P.4,114,
JG
ck:
.1\o
AVM
A1 /4 1--
RAJANJI SRIVASTAVA
4.0du
R IVEDI

7 28 11 13 REVISED AND ISSUED AS STANDARD VPS MS P K.MITTAL S CHANDA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copyright EIL - All nghts reserved

Page 182 of 674

 STANDARD No.
#6dRad ENGINEERS DETAILS OF STEEL LADDER
$11gar laReg INDIA LIMITED 7-68-0507 Rev. 8
VIRIWN13001S0 (A Govt of India Undertaking)
Page 3 of 3

TYPE OF ATTACHMENT NATURE OF SUPPORT SECTION REMARKS

Al , A2 SITE WITHOUT PAVING
B1, 82 CONCRETE FLOOR Al, B1, Cl, D1 : FIXED TYPE
C1, C2, D1, D2 CHEQUERED PLATE / GRATING FLOORING A2, 132, C2, D2 : SLIDING TYPE

BOTTOM BOTTOM
BT REFERENCE
ELEVATION
(TYP)
M.S. GRATING
ATEIL
A
II
PLATE (1 20x1 20x6)

TYPE - Al TYPE - B1 TYPE - Cl

WITHOUT
NUT
L.100x100x8
(TYP)
BOTTOM
BT BOTTOM
BT REFERENCE
ELEVATION
WITHOUT (TYP)
/NUT 8 WITHOUT
M.S. GRATING

PLATE (120x120x6)

TYPE - A2 TYPE - B2 TYPE - C2

WITHOUT
TOP NUT

CHEQ. EL. X1
PLATE OR X2
CHEQ.
PLATE

PLATE (1 20x1 20x6)

TYPE - D1 TYPE - D2

0
I _
O
O TYPE - E
NOTE :- (FREE)
1,100 IN CASE OF TOWERS BOTTOM RUNG SHALL
280 280 BE 300 mm FROM FGL /HPP.
560 24 0 HOLES FOR
M20 BOLTS
TYPE OF ATTACHMENT AT BASE
LADDER BOTTOM DETAILS
AttZr
.tr/
8 01 08 19 REAFFIRMED AND ISSUED AS STANDARD JG AVIA RAJANJI SRIVASTAVA

7 28 11 13 REVISED AND ISSUED AS STANDARD VPS AJS P K.MITTAL S CHANDA

Rev Prepared Checked Stds Committee Stds. Bureau

Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copyright EIL - All nghts reserved

Page 183 of 674

 REFERENCE ELEVATION

EL.`X1' WELDED

18 0 HOLES FOR
M16 BOLTS

EL.`X2'
GUIDE 12x12x50 200(M N )
WELDED
550(MAX.)

LADDER ATTACHMENT SECTION 12-12 SECTION 13-13

TO VESSELS
75 13
e = INSULATION THICKNESS BIM L-75x75x6
CUT BACK
470
1mm CLEARANC 4
GUIDE 12x12x50 1 mm CLEARANCE
WELDED
REFER
A %//////%%//%/ EL. X2
-4t
N .2 ME
N

I—I MC 100 12 6 6
18 0 HOLES STRUCTURE
38 5 43.5 FOR M16 BOLTS SUPPLY

325(MIN.)
DETAIL 'X2'
WWI CIVIL WORK SUPPLY

675(MAX )
DETAIL e X2' LADDER ATTACHMENT TO
SECTION 11-11 (FOR LADDER POST FLAT 75x10)
CONCRETE
420 1
,
TOE PLATE

LADDER HEAD
AT FRONT
LADDER HEAD AT
SIDE PL. 50x6 AH4
SAFETY

rat CLOSURE

O 0
N
. . • •.
SAFETY CHAIN

O
SAFETY CAGE HOOP DETAILS
LOCATION OF RUNG FOR LADDER
FLAT 50x6
20 0 BAR WELDED

1St

0
FLAT 35x6 ON

101e, }6
(FOR FLAT 75x10r (FOR MC100)

LOWER AND INTERMEDIATE CAGE ATTACHMENT OF BAR

Pe.c441,4- JO* L
7 01 08 19 REAFFIRMED AND ISSUED AS STANDARD JG AVM RAJANJI SRIVASTAVA O
R Kt"tb>)
TRIVEDI

6 28 11 13 REVISED AND ISSUED AS STANDARD VPS AJS P K MITTAL S CHANDA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copyright EIL - All nghts reserved

Page 184 of 674

 STANDARD No.
OR:adENGNEERS STEEL LADDER JOINT DETAILS
4igof Wen INDIA LIMITED
I.O217 IFIRINEM3,111.0 (A Goof of India Undertaking)
7-68-0509 Rev. 7

Page 2 of 4

5 30 740 30
/
16 0 32 0 (NB) MEDIUM DUTY
/ TUBULAR HANDRAIL
12 0
4/ a 8
0 v

I
I
I
_L
T
0 160
0 120 II
0

/9

14 0 HOLES FOR
M12 BOLTS SECTION 5-5
800
2(

111111111111111111 90' 111111111111111111

SECTION 6-6 11111111111111111 111111111111111111
.24
AUTOMATIC BARRIER
30 5

A)
CV

STOPPER
L-75x50x6
CUT FROM 90' o
co
L-75x75x6

SECTION 8-8

SECTION 1 0-1 0

14 0 HOLES FOR
M12 BOLTS

v II
Av . IN111110
SECTION 9-9
10 al
,i, 30 1,
NEOPRENE OR 6
I—I
SIMILAR PAD MC 100 50 50

iliM 1mm CLEARANCE

IIMINIMMI
102

SECTION 7-7
DETAIL `X2'
(FOR LADDER POST MC 100)

if
7 01 08 19 REAFFIRMED AND ISSUED AS STANDARD .. A\A RAJANJI SRIVASTAVA R K TRIVEDI

6 28 11 13 REVISED AND ISSUED AS STANDARD VPS AJS P K MITTAL S CHANDA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
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Page 185 of 674

 STANDARD No.
#51tilad ENGINEERS STEEL LADDER JOINT DETAILS 7-68-0509 Rev. 7
leaf fl'11151eg INDIA LIMITED
1.11211 rkeleUe013141/RD (A Govt of India Undertaking)
Page 3 of 4

LADDER POST
STOPPER PL. 85* OPENING
WELDED
35x16x5 THK.

\ Lr)

C:f Ns
M
,Oc, \
0
1.0 \
77
1 1
\ \

415 TUBE DIA 33 7mm THICKNESS 3.25

SAFETY BAR INSTALLATION ON LADDER POSTS

POSTS PLATE 75x10

POST MC 100

\ \

%'..". TUBE SQUARE CROSS SECTION

Ill 45x45x5 il
420 LADDER g

16 0 HOLES FOR M14 BOLTS

735
1 / /

30 95
SECTION 5-5
0

800 M14 BOLT 1mm CLEARANCE

SECTION 1 -1
SECTION 4-4
85*

PLATING OUTSIDE 755 HANDRAIL

LIMITS 120 POST RING
V
213 /17 0
0
I

6 THK PLATE
HANDRAIL POST BUTT WELD
SAFETY CAGE HOOP
ATTACHMENT TO
16 0 HOLES FOR M14 BOLTS
HANDRAIL POST
SAFETY CAGE HOOP
SECTION 3-3
SECTION 2-2
A
7 01 08 19 REAFFIRMED AND ISSUED AS STANDARD JG AVM RAJANJI SRIVASTAVA R TRIVEDI

6 28.11 13 REVISED AND ISSUED AS STANDARD VPS AJS P K MITTAL S CHANDA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copyright EIL - All nghts reserved

Page 186 of 674

 STANDARD No.
#30taelENIGNEERS STEEL LADDER JOINT DETAILS 7-68-0509 Rev. 7
dIgaiIgleg INDIA LIMITED
(A Govt of Indio Undertaking)
1.1161Eli6ieeN3116.0
Page 4 of 4

REF EL. (T 0 S)
(SLIDING SUPPORT S2 )

OF 18 0 HOLE IN LADDER POST &

SLOTTED HOLE IN 10 THK. FLAT SEE DETAIL

Cl OR Al (LADDER ATTACHMENT) AS PER

EIL STD 7-68-0507 SHT 3 OF 3

REF. EL (T.O.S)

SLIDING CONN. DET. OF LADDER

(WITH TOE ANGLE OF PLATFORM ON THE
HEAD OF VESSEL) OFtLADDER POST
R=9
35

OF M16 BOLT

10 THK FLAT

DETAIL OF SLOTTED HOLE

(FOR SLIDING SUPPORT S2)

Nr REF EL
EL. (LADDER EXPN JOINT)
X1 c9
ADDITIONAL

EL.
X2
VESSEL

DET. OF LADDER EXPANSION JOINT

(WHEN DISTANCE BETWEEN TOP AND BOT.
MOST SUPPORT > 9000)

7 01 08 19 REAFFIRMED AND ISSUED AS STANDARD JG AVM RAJANJI SRIVASTAVA

0"11/
R K TRIVEDI

6 28 11 13 REVISED AND ISSUED AS STANDARD VPS AJS P K MITTAL S.CHANDA

Rev. Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copyright EIL - All nghts reserved

Page 187 of 674

 STANDARD No.
LADDER SUPPORT CLIPS
FOR 7-68-0512 Rev. 6
daWege UMMED
WWI mormaimpo (A Govt. of Indio Und•rtaking) HOT VESSELS Page 1 of 2

TO CYLINDRICAL PART TO CONICAL PART

190

-cr REFERENCE REFERENCE

EL EL.

50 1
/

90 70
- 30

TYPE-1 TYPE-2

of
o.o.
.6550-
REFERENCE
AXIS

90

190

PLAN
(CLIP TYPE 1 & 2)

6 17.06.19 REVISED AND ISSUED AS STANDARD GULSHAN RAJANJI SRIVASTAVA R.K. NEDI

5 28.11.13 REVISED AND ISSUED AS STANDARD VPS AJS P.K.MITTAL S.CHANDA

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by

Format No. 8-00-0001-F4 Rev.O Copyright Ell. - All rights reserved

Page 188 of 674

 STANDARD No.
LADDER SUPPORT CLIPS
FOR 7484512 Rev. 6
NUIR MONIMI (A Govt of Indio Undirtaking) HOT VESSELS Page 2 of 2

TO CYLINDRICAL PART TO CONICAL PART

2-200 HOLES 2-200 HOLES

8 THK. STIFFENER
(TYP)

REFERENCE REFERENCE
EL. EL.
0

TYPE-3 TYPE-4

X
8 THK. STIFFENER
PLATE (TYP)
30
VESSEL 0 c< X (mm)

400 54'-8' 53

450 48' —16' 60

500 43'-43' 65

550 40' —5' 69

REFERENCE
AXIS 600 37' —3' 72

650 34*-30' 74

700 3T —17' 76

750 30'-22' 78

800 28*-40' 79

PLAN
(CLIP TYPE 3 & 4)

NOTES:-
1. FOR LADDER DETAILS REFER STD. NO. 7-68-0507 AND 7-68-0509
2. ALL CLIPS SHALL BE USED FOR LADDER SUPPORTS 'Xl & 'X2' UNLESS SPECIFIED OTHERWISE.
3. ALL STRUCTURAL CONNECTION BOLTS SHALL BE GALVANIZED AND 8.8 GRADE
4. MATERIAL FOR CLIPS SHALL BE AS PER MECH. DATA SHEET OF THE VESSEL.

A14).
6 17.06.19 REVISED AND ISSUED AS STANDARD GULSHAN APIA RAJANJI RIVASTAVA R.K.MEDI

5 28.11.13 REVISED AND ISSUED AS STANDARD VPS AJS P.K.MrTTAL S.CHANDA

Prepared Checked Stds. Committee Stds. Bureau

Rev.
Date Purpose Convenor Chairman
No. by by

Frvmat Nn R-nn_nnni -F4 RPV n rnnvrinht Fll - All rinhtc rpcprvpr

Page 189 of 674
 STANDARD No.
Ofaeiel ENGINEERS PLATFORM DETAILS FOR
faf5leg
riramed513,gr(R)
INDIA LIMITED
(A Goy( of India Undertaking)
HORIZONTAL HOT VESSELS 7-68-0540 Rev.O
SHT. 1 of 6

1(pING SUPPORT (S.S.) OF WITH

G TYPE BOLTS, REF. EXT. A (SH. 4 OF 6)

L 100x100x8
ALROUND

200
Fk SLUING-SIF_PORT _QF _YESsFI f TYP
O.D. OF! V

ELECTROFORGED GRATING _t_QE 141111FR

TYPE-I (TYP)
LADDER AS EIL STD.

HANDRAIL
(REF. EIL STD. 7-68-0552, SH. 8 OF 8)

■n
°

EDIEDSUPPQRI_CIF_YESSEL_

FIXED SUPPORT (F.S.) OF

PLTF. WITH 180 HOLES FOR M16
BOLTS (IN TOE ANGLE)

G. A. OF PLATFORM

HANDRAIL POST
TYP

I 5° 15 011
i

6 50-50
6 50-50
1-100X100X8

*SECTION 1 1
- VIEW 2-2

*WHEREVER HANDRAIL ON ANGLE 'A' IS DISCONTINUED FOR ENTRY TO THE PLATFORM

FROM LADDER/STAIR/ADJACENT PLATFORM THE UPSTAND LEG OF ANGLE 'A' SHALL BE CUT
AND L100X1 00X8 WELDED AS PER SEC. 1-1 FOR THE LENGTH HANDRAIL IS DISCONTINUED.

NOTES:-
1. FOR LOCATION & EXTENT OF BRACKETS REFER GENERAL ARRANGEMENT DRAWING.
2. SPLICING OF TOE ANGLE SHALL BE DONE ONLY IF IT IS ESSENTIAL.

3. ELECTROFORGED GRATING TYPE-I SHALL BE AS PER EIL STD. NO. 7-68-0697.

4. FOR FURTHER DETAILS REFER GENERAL ARRANGEMENT DRAWINGS.
3. IN CASE OF DIFFERENCE BETWEEN THIS STD. & GENERAL ARRGT. DRG.,
THE LATER SHALL GOVERN.
6. FOR OTHER NOTES REFER SHT. 2 OF 6.

0 25.07.16 ISSUED AS STANDARD NKK

4 1
R.SRIVASTAVA R.NANDA

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
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Page 190 of 674

 STANDARD No.
Lit? ENGINEERS PLATFORM DETAILS FOR
ui EVeg INDIA LIMITED HORIZONTAL HOT VESSELS 7-68-0540 Rev.0
(4Iren ew e aucgmi) (A Govt of India Undertaking)
SHT. 2 of 6

W=1000 (MAX.)

10
EL.(T.O.G.) (MAX.)

1 6TH. STIFF. PL TYP

MC150
'N s\
CUP-CL1
/t OF CUP
EL C.L OF VESSEL 250 I y
(MIN.)

OF VESSEL
VESSEL ( e)

BRACKET BKT.1
(DIMENSIONS X, Y & W SHALL BE AS PER G.A. DRAWING)

W=1400 (MAX.) XI

EL. (T.O.G.) 1 (MIN)

STIFF. PL TYP

MC150

CUP-CL2
/ OF CUP
EL (C.L OF VESSEL 250 ; Y SEA
(MIN.)

(e)
t OF VESSEL

BRACKET BKT.2
(DIMENSIONS X, Y & W SHALL BE AS PER G.A. DRAWING)

NOTES:-
CONTD. FROM SHT. 1 of 6
7. ALL CLIPS ARE IN THE SCOPE OF VESSEL FABRICATOR.

8. ALL BOLTS CONFORMING TO ASTM A193 Gr.B7 AND NUTS CONFORMING TO

ASTM A194 Gr. 2H SHALL BE USED FOR CONNECTIONS TO THE VESSEL.
9. THESE PLATFORMS ARE DESIGNED FOR AN IMPOSED LOAD OF 3.0KN/SO.M
AND THE BRACKETS FOR THE SPECIFIC CONDITION INDICATED. NO PIPE
SHALL BE ANCHORED OR GUIDED ON THE PLATFORM.
10. MATERIAL FOR CLIPS SHALL BE AS PER VESSEL DRAWING.

t-ts&
0 25.07.16 ISSUED AS STANDARD NKK ' 2P1
31A R.SRIVASTAVA R.NANDA

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reservec

Page 191 of 674

 Q
r3 1 ENGINEERS
PLATFORM DETAILS FOR STANDARD No.
r WegilliWr INDIA LIMITED
Reen eliasren5f3g0570 (A Govt of India Undertaking) HORIZONTAL HOT VESSELS 7-68-0540 Rev.0
SHT. 3 of 6

W=2800 (MAX.)
800 200
(MIN.) 10
EL. (TOG) 1° (MAX.)

CUP-CUS

6TH. STIFF. PL TYP MC150

CUP-CL1
1 N. MC125 SHALL BE PROVIDED
\ WHEN 'W' > 1400
//
t OF CUP t OF CUP

1 , Y1
f
Y
I
f
EL C.L OF VESSEL
1 ESSEX.
I

I
i
/1
REFERENCE EL 'X'
X
1 —1
1 /// 2-140 MC125
4

\\„‘, FOR M12 BOLTS.

IN PLATES (TYP)
8 TH. PLATE
-.__ .......-- 2-SLOTTED HOLES
-- 1 --- *.(6.\ INSULATION FOR M12 BOLTS.
t OF VESSEL (6) IN MC125 (TYP)
SECTION 3-3
BRACKET BKT.3
(DIMENSIONS X, Y, Y1 & W SHALL BE AS PER G.A. DRAWING)

BRACKET

W=2800 (MAX.)

MC125 SHALL BE PROVIDED

800 WHEN > 1400 200
10
(MAX) (MIN)
SECTION 4-4
6TH. STIFF. PL TYP

CUP-CL1

Y1
CUP CUP
EL (C.L OF VESSEL1

INSULATION
t OF VESSEL (8)

BRACKET BKT.4
(DIMENSIONS X, Y, Y1 & W SHALL BE AS PER G.A. DRAWING)

FOR NOTES REFER SH. 1 OF 6 & SH. 2 OF 6

25.07.16
&L 11)*
0 ISSUED AS STANDARD NKK 1S1)-{A IA R.SRIVASTAVA R.NANDA

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Format Nn 8-00-0001-F4 RAN/ 0 Convnaht Fll - All nnhts rasarver

Page 192 of 674

 STANDARD No.
ei ENGINEERS PLATFORM DETAILS FOR
Otar Mirdg
aliVr elecrne aqi7S9)
INDIA LIMITED
Govt of India undertaking)
HORIZONTAL HOT VESSELS 7-68-0540 Rev.0
SHT. 4 of 6

10 W=2800 (MAX.)
800 (MAX) 10
MC125 SHALL BE PROVIDED
WHEN W > 1400 200 (MIN) zEL. (TOG)
16TH. STIFF. PL (TYP)
MC150
3
-----
CUP-CL1S
10TH. PL

10TH. PL.
MC125 FOR LENGTH <2000
MC150 FOR 2000< LENGTH <3500 TYP

EL.
111;i OF VESSEL)

W.P.

2-220 HOLES FOR M20 BOLTS 250 1, oo

(TYP) M IN.)
\( if SPLICE DETAIL OF TOE ANGLE

10 THK. PL
(AT TOP OF CUPS)
,•/

INSULATION
t OF VESSEL
(4)
I
BRACKET BKT.5
(DIMENSIONS X, Y & W SHALL BE AS PER G.A. DRAWING)

SECTION 5-5 BOLT TYPE 'G'

W=2800 (MAX.)

10
10!

6TH. STIFF. PL (TYP)

CUP-CL1S MC150

10TH. PL
MC125 SHALL4 PROVIDED
WHEN W ,.•> 1400
60
CI 10_7_0 i

1
SLOTTED HOLE 24x44 LG.
Y Y1 250(MIN.) IN TOE ANGLE & 20 0
EL (C.L OF VESSEL
HOLE IN BKT. FOR 18/ 'G
TYPE BOLT (REF. DET.)

7 TYPE BOLT

BKT. MC150 200

\s, TOE ANGLE

100x100x8 TYP
10

'G' TYPE BOLT

r . "(s. INSULATION
OF VESSEL (0)

BRACKET BKT.6 DETAIL—'A'

(DIMENSIONS X, Y, Y1 & W SHALL BE AS PER G.A. DRAWING)

0 25.97.16 ISSUED AS STANDARD

14‘k
NKK 19401A
AL
W.7.
21V STAVA
-
„)‘/
R.NANDA

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Format No a-n0-0001-F4 RFIV Convrinht Fll - All rinhts rAnArvpil

Page 193 of 674

 STANDARD No.
0 ENGINEERS
el PLATFORM DETAILS FOR
Itar 201-eg INDIA LIMITED
1717e71 rtecnie 0513,70570 IA Govt. of India Undertaking)
HORIZONTAL HOT VESSELS 7-68-0540 Rev.0
SHT. 5 of 6

10 W=4200 (MAX.) 10
MC125 SHALL BE PROVIDED WHEN 1000 (MAX.)
EL. TOG
GRATING SPAN > 1400
1' 200 (MIN.)
3
ii
6TH. STIFF. PL (TYP)
MC200

CI IP-C1.2 CLIE=CL25

EL C.1. Cf

4t\INSULATION
t OF VESSEL (a)

BRACKET BKT.7
(DIMENSIONS Y, Y1 & W SHALL BE AS PER G.A. DRAWING)

O
rs-
FOR 1420 LONG BOLTS
W=1000 (MAX.) X El. cLaF
0
EL.(T.O.G.) I 6TH. STIFF. P TYP) 0

8TH. PL
MC150

EL C.L OF
Op _I DETAIL—B

4-220 HOLES
OR M20 BOLTS

INSULATION
t OF VESSEL (a)

BRACKET BKT.8
(DIMENSIONS X, Z & W SHALL BE AS PER G.A. DRAWING) VIEW 6 6-

0 25.07.16 ISSUED AS STANDARD NKK R.S VASTAVA R.NANDA

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Format Nn £1-00-0001-F4 Rev 0 Convrinht FII - All rinhts reserver

Page 194 of 674

 STANDARD No.
ENGINEERS PLATFORM DETAILS FOR
INDIA LIMITED HORIZONTAL HOT VESSELS 7-68-0540 Rev.0
$ifta "5441
INTeR elecore m1 3UOM) (A Govt of India Undertaking)
SHT. 6 of 6

If OF CUP OF CUP
80 80 7 90 90

X MEMBER

MCI 50 MC150
2-22 0 HOLES 2-22 0 HOLES
FOR 1120 BOLTS FOR 1120 BOLTS 10 THK. PL
(SLOTTED HOLES IN MC)
(REFER DET. 51)

80 90

CLIP TYPE-CL1 CLIP TYPE-CL1 S VIEW 7-7

OF CUP
80

QE MEMBER

4-22 0 HOLES 4-22 0 HOLES

FOR 1120 BOLTS FOR 1120 BOLTS 10 THK. PL.
(SLOTTED HOLES IN MC)
(REFER DET. S2)

80

CLIP TYPE-CL2 CLIP TYPE-CL2S VIEW 8-8

OF CUP OF 1170 901 TS OF M70 ROWS

I I

PAD PL AS SED
TYP
SLOTTED HOLE
REFER DETAIL

DETAIL 'S1' DETAIL 'S2'

4-220 HOLES
FOR 14200 BOLT

CLIP TYPE-CL3 VIEW 9-9 SLOTTED HOLE

(FOR DET. S1 / S2)

0 25.07.16 ISSUED AS STANDARD

-t*NKK
4kt-
R.SRIVASTAVA 4 R.NANDA

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Fnrrnat No R-00-0001-F4 RAN/ ennvrinht FII - All rinhts rtAscirverr

Page 195 of 674

 DETAILS OF BRACKETS (ROLLED SECTIONS) STANDARD No
ea-Vele-1 -,== ENGINEERS
ligen fai5e5 W INDIA LIMITED FOR CIRCULAR PLATFORMS 7-68-0546 Rev 1
(iIRK MDT Mr3M1.1) (A Govt of Inds Undsnalungl
OF HOT VESSELS SHT 1 of 5

0 /— CLEARANCE MIN. 35

SHELL
4-220 HOLES 10
OUTSIDE DIA.
20 FOR M20 BOLTS
LB 1 GRATING LA

•cjir REFERENCE EL. 'X'

Ampi.-311 •
(T.0.5)
0 I I 4F TOP OF BRACKET
1± — 8 TH. STIFF. PL.
Csl
BRACKET CLIP BRACKET
TYPE-1 ISMC200
40 150
— 200x 150x8TH WASHER PL.
e e
'J
BRACKETS LB1 AND RB1
(FOR PLTF. 900 < L 1400 & e 100)

"—CLEARANCE MIN. 35
L/2
SHELL
OUTSIDE DIA. 6-220 HOLES sl 10
2
FOR M20 BOLT
LB 3 GRATING LA
REFERENCE EL. 'X'
(T.0 S.)
8 t r b 2 (TYP) 4F TOP OF BRACKET
1+- — 8 TH. STIFF. PL
0

— 8 TH PL. BRACKET
250x150x8 TH.
ISMC200
WASHER PL.
3j
BRACKET CLIP
TYPE-2

BRACKETS LB2 AND RB2

(FOR PLTF. 1400 <L 61800 & e

NOTES:
1. THESE DETAILS ARE VALID FOR PLATFORMS 5. NO PIPE SHALL BE SUPPORTED ON BRACKETS/PLATFORMS.
TO HOT VESSELS FOR e 300mm 6. ALL STRUCTURAL CONNECTION BOLTS SHALL BE GALVANIZED AND
(e = INSULATION THICKNESS)
8.8 GRADE.
2. FOR DETAILS OF CUPS REFER STANDARD NO.
7. STRUCTURAL STEEL GRADE SHALL BE E250.
7-68-0547.
8. FOR DETAIL OF PLATFORMS REFER EIL STD. NO. 7-68-0552.
3. REFER G.A. DRG. OF PLATFORMS FOR BRACKET
TYPES AND VALUE OF 'R', 'L', 'X', 0:1 AND 112.
4. ORIENTATION OF BRACKETS IS GIVEN ACCORDING
TO ARROW' F' (REFER SHEET-5)

LB = LEFT BRACKET (FLANGE ON LEFT)

RB = RIGHT BRACKET (FLANGE ON RIGHT)

1 28 06 19 REVISED AND ISSUED AS STANDARD GOLSHAN KUL/PIL." RAJANJI SRIVASTAVA WEN

0 26 06 13 ISSUED AS STANDARD GR/RT PAPIA/RS P.K.MITTAL D.MALMOTRA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Format No 8-00-0001-F4 Rev 0 Copyright EIL - All rights reserved

Page 196 of 674

 DETAILS OF BRACKETS (ROLLED SECTIONS) STANDARD No
101 ENGINEERS
Ogeir fal;i4s INDIA LIMITED FOR CIRCULAR PLATFORMS 7-68-0546 Rev 1
(alw ietorear,avowl) (A Govt of India unoonsionoi
OF HOT VESSELS SHT 2 of 5

TOE ANGLE AND

BKT. CONNECTED TOE ANGLE
WITH 'G' TYPE BOLT
SEE 7-68-0552 INSIDE STRINGER
SHT. 8 OF 8)

8 TH. WASHER PL

BRACKET CUP AS PER.

STD. NO. 7-68-0547
BRACKET
12 ,4

SECTION 1 -1 SECTION 2 -2

20
50 75, i50

I! I REFERENCE EL 'X'

4 ZIFF
4.11
7/1
MC125
2-140 HOLES
FOR M12 BOLTS. 8 TFI. PLATE
IN PLATES (TYP)

2—SLOTTED HOLES
FOR M12 BOLTS.
IN MC125 (TYP)
SECTION 4-4
SECTION 3-3

34

R=7

OF 1112 BOLTS

DETAIL OF SLOTTED HOLE

SECTION 5 -5

t-Y• i24N
1 28 06 19 REVISED AND ISSUED AS STANDARD GULN KMT./S1--". RAJANJI SRIVASTAVA R.K. EDI

0 26 06 13 ISSUED AS STANDARD OR/RT PAPIA/RS DJAALNOTRA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Format No 8-00-0001-F4 Rev 0 Copyright EIL - All rights reserved

Page 197 of 674

 DETAILS OF BRACKETS (ROLLED SECTIONS) STANDARD No
laia..Aft ENGINEERS
Igar 25teg NW INDIA LIMITED FOR CIRCULAR PLATFORMS 7-68-0546 Rev 1
21MIE easiaA> IA Govt of Incite UndertokIng)
OF HOT VESSELS SHT 3 of 5

• 35(MIN)
/
SHELL
4-270 HOLES 10
OUTSIDE DIA. FOR M24 BOLTS
LB LA
GRATING
-sp. REFERENCE EL 'X'
(T.O.S.)

ost
O I F
— 8 TH. STIFF. PL
TOP OF BRACKET

0
BRACKET CLIP BRACKET
TYPE-3 10 TH. FACE PLATE ISMC200
7/

BRACKETS LB3 AND RB3

(FOR PLTF. 900 < L -.51400
. & 100 < e 300)

e t 35(MIN)
L/2
SHELL
4-300 HOLES 10
OUTSIDE DIA. FOR M27 BOLTS
LB 31 LA
GRATING
•cv REFERENCE EL. 'X'
(T.O.S.)

1F
— 8 TH. STIFF. PL.
TOP OF BRACKET

— 8 TH. PL
BRACKET CLIP BRACKET
TYPE-4 10 TH. FACE PLATE ISMC200

2 3j

BRACKETS LB4 AND RB4

(FOR PLTF. 1400 <L :51800 & 100< 300)

28 06 19 REVISED AND ISSUED AS STANDARD LSHAN KIIL/P RAJANJI SRIVASTAVA NEDI

0 26 06 13 ISSUED AS STANDARD OR/RT PAPIA/RS P.K.MITTAL D.MALHOTRA

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 DETAILS OF BRACKETS (ROLLED SECTIONS) STANDARD No
61
12.1ek ENGINEERS
*Igen felPeg INDIA LIMITED FOR CIRCULAR PLATFORMS 7-68-0546 Rev. 1
(A Govl of India undertaking)
OF HOT VESSELS SHT 4 of 5

R
* 45
0
10
/ / /

L/2

SHELL
6-300 HOLES
OUTSIDE DIA.
FOR M27 BOLTS
LB 3 GRATING LA
0 •sy• REFERENCE EL. 'X'
(T.0 S.)
ig MC125
TOP OF BRACKET
0 — 8 TH. STIFF. PL.

— 8 TH. PL.
BRACKET CUP BRACKET
TYPE-7 ISMC250
3J

5j
i /
BRACKETS LB7 AND RB7
(FOR PLTF. 1800 < L ..-.2400 & e <300)

* — FOR TYPE-7 'e' SHALL NOT BE CONSIDERED LESS THAN 100mm

- A,L kkm)
1 28 06 19 REVISED AND ISSUED AS STANDARD ok KI/L/PAQ"-- RAJANJI SRIVASTAVA R.

0 26 06 13 ISSUED AS STANDARD OR/RT PAPIA/RS P.K.MITTAL D.MALHOTRA

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 DETAILS OF BRACKETS (ROLLED SECTIONS) STANDARD No
ENGINEERS
faiegliiiv INDIA LIMITED FOR CIRCULAR PLATFORMS 7-68-0546 Rev 1
04,WMPrewavt100 (A GoA of India Undertaking(
OF HOT VESSELS SHT 5 of 5

KNEE BRACE W.P.

X3

INSULATION e
THK.
SHELL
OUTSIDE DIA.

SUPPLIED & INSTALLED BY

EQUIPMENT VENDOR
WP

X2
4,

BRACKET CONNECTION WITH KNEE BRACING

(SPECIAL CASE)
(FOR CLIP DETAIL, DIMENSION X2 & MEMBER SIZE X3 REFER PLTF. GA DRAWING)

( B ) DETAIL

'G' TYPE BOLT

REFERENCE
AXIS

N
F
DETAIL
9I
(
BRACKETS ORIENTATION
(F—INDICATES VIEW FROM OUTSIDE TOWARDS CENTRE OF VESSEL FOR BRACKET ORIENTATION)
(RB—FLANGE ON RIGHT HAND SIDE)
(LB—FLANGE ON LEFT HAND SIDE)

1 28 06 19 REVISED AND ISSUED AS STANDARD 01./1 RAJANJI SRIVASTAVA N.II. IVEDI

0 26 06 13 ISSUED AS STANDARD OR/117 PAPIA/RS P.K.MITTAL D.MALHO7RA

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 STANDARD No.
PLATFORM SUPPORT CLIPS
VL...''•..J, ENGINEERS
INDIA LIMITED FOR 7-68-0547 Rev. 1
Itta taordg) IA Goat of India Undertaking)
HOT VESSELS
SHT. 1 of 3

TO CYLINDRICAL PART TO CONICAL PART

4-220 HOLES 4-220 HOLES
0
.4- M REFERENCE EL 'X'
REFERENCE EL 'X'

BRACKET CUP BRACKET CLIP

12 THK 12 THK

TYPE-1 TYPE-1A
(FOR BRACKETS LB1 AND RB1) (FOR BRACKETS LB1 AND RB1)

e) REFERENCE EL 'X' ,,, REFERENCE EL 'X'

BRACKET CLIP BRACKET CUP

12 THK 12 THK

TYPE-2 TYPE-2A
(FOR BRACKETS LB2 AND RB2) (FOR BRACKETS LB2 AND RB2)

FOR RIGHT
BRACKET 'RB'
CLEAT PLAN
(FOR TYPE 1.1A. 2 AND 2A)

NOTES:-
1. DETAILS ARE VALID FOR e < 100 (e=INSULATION THICKNESS)
2. DIMENSION X1 SHALL BE e+35 BUT NOT LESS THAN 85.
3. FOR BRACKET DETAILS REFER STANDARD NO. 7-68-0546.
4. ALL STRUCTURAL CONNECTION BOLTS SHALL BE GALVANIZED AND 8.8 GRADE.
5. MATERIAL FOR CUPS SHALL BE AS PER VESSEL DRAWING.
6. SUPPORT CUP FOR EACH BRACKET SHALL BE SUPPUED AND INSTALLED BY EQUIPMENT VENDOR.

JAL
1 28.06.19 REVISED AND ISSUED AS STANDARD PAPIA RAJANJI SRIVASTAVA
0 26.06.13 ISSUED AS STANDARD OR/RT PAPIA/RS P.KJAITTAL D.MALHOTRA

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Page 201 of 674
 STANDARD No.
,J1faelerf- 1"-- ENGINEERS PLATFORM SUPPORT CLIPS
Ig-ar Ot5ieg (7 _) INDIA LIMITED
,,,,7If?.....7d513,1P.1) IA Gout of Incha Undeftaong)
FOR 7-68-0547 Rev. 1
HOT VESSELS
SHT. 2 of 3

TO CYLINDRICAL PART TO CONICAL PART

L',3
I§_ 8 THK. PLATES 8 THK. PLATES

F. 4-270 HOLES 4-270 HOLES

c, ° N REFERENCE EL 'X' ° REFERENCE EL 'X'

0 0

TYPE-3 TYPE-3A
BRACKETS
BRACKETS LB3 AND RB3) (FOR BRACKETS LB3 AND RB3)
t2
8 THK. PLATES 'c_ 8 THK. PLATES
N
4-300 HOLES 2
I-
4-300 HOLES
2 0, REFERENCE EL 'X' 0 .2 EN REFERENCE EL 'X'
c=k ,_ *Nor 4-

rD\ o II E\
2 01-- - -
"8
0

0" ;\
'I\ 4 \
O 0
A

TYPE-4 TYPE-4A
(FOR BRACKETS LB4 AND RB4) (FOR BRACKETS LB4 AND RB4)
FOR LB/RB

CLEAT PLAN
(FOR TYPE 3. 3A 4 AND 4A)

NOTES:-
1. DETAILS ARE VAUD FOR e > 100, A=e+10
2. ALSO REFER NOTES 3 TO 6 OF SHEET 1 OF 3 OF THIS STD.

k\ L
1 28.06.19 REVISED AND ISSUED AS STANDARD
,1.- OW))
oPss.ua-
PAPIA RAJANJI SRP/ASTAVA R.100,11 .------
0 26.06.13 ISSUED AS STANDARD GRAT PAPIA/RS P.K.INTTAL DAIALISOTRA

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Page 202 of 674
 STANDARD No.
ENGINEERS PLATFORM SUPPORT CLIPS
Ogeff faReg INDIA LIMITED FOR 7-68-0547 Rev. 1
evawasuRisAl IA Gov! of India Undertaking)
HOT VESSELS SHT. sal 3

TO CYLINDRICAL PART TO CONICAL PART

V)
Ld 1.4.J
8 TH. PLATES 8 TH. PLATES

6-300 HOLES 6-300 HOLES

o N REFERENCE EL 'X' 0 N REFERENCE EL 'X'
u.)\, \ o\ Lnks-
O
O O
o
Ir\ O
0
N
N N O

tr‘ 12)4,
A O A 0

TYPE —7 TYPE —7A

(FOR BRACKETS LB7 AND RB7) (FOR BRACKETS LB7 AND RB7)
V) V)

8 TH. PLATES 8 TH. PLATES

6-300 HOLES 6-300 HOLES

0 o F-) N REFERENCE EL 'X' 0 0 ° N REFERENCE EL 'X'
0
0

N
rn 0
N
CO
N)

TYPE —8 TYPE —8A

(FOR BRACKETS LB8 AND RB8) (FOR BRACKETS LB8 AND RB8)

NOTES:-
1. DETAILS ARE VALID FOR ALL THICKNESSES OF INSULATION. A=e+10
HOWEVER 'A' SHALL NOT BE LESS THAN 110.
CLEAT PLAN
2. ALSO REFER NOTES 3 TO 6 OF SHEET 1 OF 3 OF THIS STD.
(FOR TYPE 7, 7A, 8 AND 8A)

114
1 28.06.19 REVISED AND ISSUED AS STANDARD Oucsww PAPA RAJAM.II SRNASTAVA R.. TRIVEDI
0 26.06.13 ISSUED AS STANDARD ORM PAPIA/RS P.K.IRTTAL DAM/10M

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Page 203 of 674
 CIRCULAR PLATFORM STANDARD No
t_11 ENGINEERS
Ifgar faRes INDIA LIMITED
(A Govt a India Under* mg)
FOR
HOT VESSELS
7-68-0552 Rev 8
SHT 1 of 8

FOR R+L FOR R+L= 4.0M. FOR R+L= 8 OM.

LESS THAN 4.00M. TO LESS THAN 8.00M. TO 10.00M

A L looxiooxa Li00X100X8 L 1 oox 100X8

/ L 75X75X8 L 9OX9OX5 L 1 ooxiooxa

INSULATION THICKNESS '6' D

STD. 7-68-0507 SHT 1 OF 3
400

6`. (REFER SHT. 6 OF 8)

SEE DETAILV SEE DETAIL 'A' FOR NOTCH IN GRATING

HANDRAIL IN SHT. 8 OF 8 IN SHT 8 OF 8
(REF SHT. 8 OF 8)

INTERMEDIATE PLATFORMS
(FOR e-4100mm)

ALL CONNECTIONS ARE BOLTED AS SHOWN

NOTES:-
1. FOR 0C1 AND o<2REFER GENERAL ARRANGEMENT DRAWING
2. DIMENSION X1 SHALL BE e+35 BUT NOT LESS THAN 85 IN THE PLATFORM WHERE BRACKET
TYPE— LB7/RB7 OR LB8/RB8 ARE NOT USED
3. DIMENSION X1 SHALL BE e+45 BUT NOT LESS THAN 145 IN THE PLATFORM WHERE
BRACKET TYPE—LB7/RB7 OR LB8/RB8 ARE USED.
4. FOR FURTHER DETAILS REFER GENERAL ARRANGEMENT DRAWINGS.
5. FOR BRACKET DETAILS REFER STD.NO. 7-68-0553/0546 AND FOR CLIP DETAILS REFER
STD. NO. 7-68-0557/0547
6. SPLICING OF TOE ANGLE SHALL BE DONE ONLY IF IT IS ESSENTIAL.
7. ELECTROFORGED GRATING TYPE—I SHALL BE AS PER EIL STD. NO. 7-68-0697.
8. FOR OTHER NOTES REFER SHT. 2 OF 8.

8 27 06 19 REVISED AND ISSUED AS STANDARD

11-
GULSHAN OPAPIA RAJANJI SRIVASTAVA R. . TRIVEDI

7 21 01 14 REVISED AND ISSUED AS STANDARD VPS AJS P.K.NITTAL S.CHANDA

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 CIRCULAR PLATFORM STANDARD No
lf=t ENGINEERS FOR
IgartIVIN7 INDIA IJMETED 7-68-0552 Rev 8
lartart mew cindetnan IA Gent of India Undertaking) HOT VESSELS
SHT 2 of 8

INSULATION THICKNESS FOR R+L— FOR R+L... 4.0M. FOR R+L— 8 OM

D LESS THAN 4.00M. TO LESS THAN BOOM. TO 10 00M.
STD. 7-68-0507 SHT.1 OF 3
400 L Li 00X100X8 L100X100X8 Lioox100X8

LADDER fr L 75X75X8 L 90X90X8 Liooxioox8

(REFER SHT. 6 OF 8)

SEE DETAILV SEE DETAIL 'A' (FOR NOTCH IN GRATING

HANDRAIL IN SW. 8 OF 8 IN SHEET 8 OF 8)
(REF. SHEET 8 OF 8)

INTERMEDIATE PLATFORMS
(FOR e >100mm)

ALL CONNECTIONS ARE BOLTED AS SHOWN

NOTES:—
CONTD. FROM SHT. 1 of 8
9. IN CASE OF DIFFERENCE BETWEEN THIS STD. & GENERAL ARRGT. DRG.,
THE LATER SHALL GOVERN.
10. FOR SECTIONS 1-1 TO 5-5 REFER SHT. 4 of 8 TO SHT. 7 of 8.
11. LB INDICATES LEFT BRACKET, RB INDICATES RIGHT BRACKET, LB OR RB TO SUIT
THE LOCAL CONDITIONS & TO AVOID INTERFERENCE WITH OTHER FIXTURES.
12. ALL CLIPS ARE IN THE SCOPE OF VESSEL FABRICATOR.
13. STRUCTURAL STEEL GRADE SHALL BE E250. ALL STRUCTURAL CONNECTION BOLTS
SHALL BE GALVANIZED AND 8.8 GRADE.
14. NO PIPE SHALL BE SUPPORTED ON BRACKETS/PLATFORMS.

A.,t_ AyJ
REVISED AND ISSUED AS STANDARD
0,
8 27 06 19 GULSNAN IA RAJANJI SRIVASTAVA R. . IVEDI

7 21 01 14 REVISED AND ISSUED AS STANDARD vps MS P.K.MITTAL S.CHANDA

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 STANDARD No
n elENGINEERS
loi Iff= CIRCULAR PLATFORM FOR
...MUM) INDIA
Ifgar iiilffies LIMITED 7-68-0552 Rev 8
(A Govt of India Undertaking) HOT VESSELS
SHT 3 of 8

FOR X FOR X= 2.0M. FOR Xt.. 5 OM.

LESS THAN 2.00M. TO LESS THAN 5.00M. TO 7.00M

A Liooxiooxa Liooxiooxa Liooxiooxa

L L 75X75X8 L 90X90X8 Liooxiooxa

INSULATION THICKNESS

HEAD PLATFORMS

FOR NOTES REFER SHT 1 OF 8 AND 2 OF 8

8 27 06 19 REVISED AND ISSUED AS STANDARD .....V

OULSHAN YAPU1 RAJANJI SRIVASTAVA R.K. fRNEDI
7 21 01 14 REVISED AND ISSUED AS STANDARD VPS AJS P.K.MITTAL S.CHANDA

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 STANDARD No
ENGINEERS CIRCULAR PLATFORM FOR
ligar offildg
etal.P .3,117M)
INDIA LIMITED
(A Govt of India Undertaking) HOT VESSELS
7-68-0552 Rev 8
SHT 4 of 8

SEE DETAIL® WITH 'C'

SEE DETAIL® WITH TYPE BOLT
TYPE BOLT

2-220 HOLES
FOR M20 BOLTS
INSULATION
(e)
6 THK. STIFF. PL (TYP)

MC150

OF VESSEL

SECTION 1 -1 RBI (Lai I OPP. HAND)

DIMENSIONS )(NA L SHALL BE AS PER SECTION 6-6
GEN. ARRANGEMENT DRAWING

L=1400(MAX.)

10 Y 200 800(MAX.) 0
(MIN.) SEE DETAIL @ WITH 'C'

0 0 31
:
SEE DETAIL ® WITH 'C' TYPE BOLT
TYPE BOLT 4-200 HOLES
FOR M18 BOLTS

II J REF. EL
INSULATION Ns, NW
A li
(T.O.S.)

(e)
CAPP-
MC150 6 THK. STIFF. PL (TYP)

75

10 THK PL(TYP)

"sir EL. T.T.L.

OF VESSEL
150

SECTION 2-2 RB12 (LB12 OPP. HAND)

SECTION 7-7
DIMENSIONS X,YAL SHALL BE AS PER
GEN. ARRANGEMENT DRAWING

NOTE:-
FOR DETAIL , & BOLT TYPE 'G' REF. SHT. 8 OF 8 AND
FOR OTHER NOTES REFER SHT. 1 OF 8 & 2 OF 8

8 27 06 19 REVISED AND ISSUED AS STANDARD GUN aA"-- RAJANJI SRIVASTAVA R.K. IVEDI
7 21 01 14 REVISED AND ISSUED AS STANDARD vPs AJS P.K.MITTAL S.CHANDA

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 STANDARD No
ENGINEERS CIRCULAR PLATFORM FOR
INDIA LIMITED 7-68-0552 Rev 8
(41174 ele1117C111.7RWA) (A Gavt al Inds Undertalong) HOT VESSELS
SHT 5 of 8

L=2800(MAX.
EQ EQ
180 HOLES FOR M16 BOLTS
IN CUP AND SLOTTED HOLES 10 2 10
IN MC150 SEE DET. 'S1' (MIN.) / SEE DETAIL WITH 'G'
M s 125 SHALL BE PROVIDED TYPE BOLT IN SHT 8 OF 8
/90790/ -t3 EN > 1400
SEE DETAIL® WITH 'G'
TYPE BOLT IN SHT.8 OF 8
1.7
-.K. REF. EL
(T.O.S.)
INSULATION
(e)
6 THK. STIFF. PL (TYP)
00

10 THK PL(TYP) 125 /90 8 THK. PL (TYP)

MC125 FOR LENGTH 42000

MC150 FOR 2000< LENGTH 43500

180 HOLES FOR M16 BOLTS

EL. T.T.L. 0
(TYP)

„„
OF M16 BOLTS
W.P.

300(M IN ) 20

SLOTTED HOLE O.R

REFER DETAIL
OF VESSEL SLOTTED HOLE
DETAIL 'Si' (FOR DET 'S1')

SECTION 3-3 R1313 (LB13 OPP. HAND)

DIMENSIONS X.Y.& L SHALL BE AS PER
GEN. ARRANGEMENT DRAWING

REFERENCE EL 'X'

miftaine-
75 10 THK. PL
(AT TOP OF CUP) 2-140 HOLES
Apr MC125

FOR M12 BOLT5. 8 TH. PLATE

IN PLATES (lIP)

2—SLOTTED HOLES
FOR M12 BOLTS.
IN MC125 (TYP)

SECTION 17-17
10 THK. PL

150 BRACKET

SECTION 8-8 SECTION 9-9 /2 CA

FOR NOTES REFER SHT. 1 OF 8 & 2 OF 8 SECTION 18-18

8 27 06 19 REVISED AND ISSUED AS STANDARD GULSHAN QIA

--....---- RAJANJI SRNASTAVA R.K. TRIVEllr'
7 21 01 14 REVISED AND ISSUED AS STANDARD VP3 AJS P.K.MIRAL S.CHANDA

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Page 208 of 674

 STANDARD No
ENGINEERS CIRCULAR PLATFORM FOR
IgaiEP& INDIA LIMITED 7-68-0552 Rev. 8
Ulrtii ~or MAWR) (A Govt of India Undertaking) HOT VESSELS
SFIT 6 of 8

L-1400(MAX

10

SEE DETAIL® WITH 'C'

TYPE BOLT IN SHT.8 OF 8

v REF. EL
(T.O.S.)

6 THK. STIFF PL (TYP)

v EL. T.T.L.
cv
cv

18 0 HOLES FOR
M16 BOLTS
6 THK. STIFF PL (TYP)
Z=0 R.+e+100
PEI
1111

pm!
!
OF VESSEL

SECTION 4-4 RBA 4 (LB14 OPP. HAND)

DIMENSIONS L.X AND Z SHALL BE AS PER 10 THK. PL
GEN. ARRANGEMENT DRAWING

SECTION 10-10

10

*SECTION 15-15 VIEW 16-16

FOR NOTES REFER SHT 1 OF 8 & 2 OF 8

*WHEREVER HANDRAIL ON ANGLE'A' IS DISCONTINUED FOR ENTRY TO THE PLATFORM

FROM LADDER/STAIR/ADJACENT PLATFORM THE UPSTAND LEG OF ANGLE 'A' SHALL BE CUT AND
1 0 0 X 1 0 0 X8 WELDED AS PER SEC 15-15 FOR THE LENGTH HANDRAIL IS DISCONTINUED

8 27 06 19 REVISED AND ISSUED AS STANDARD OULSKAN IA RAJANJI SRIVASTAVA R.K. TRI .1

7 21 01 14 REVISED AND ISSUED AS STANDARD VPS MS P.K.MITTAL S.CHANDA

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Page 209 of 674

 STANDARD No
ENGINEERS CIRCULAR PLATFORM FOR
ligar VVeg INDIA LIMITED
lailiVV 210151V 17713017,A) (A Govt of India Undertaking) HOT VESSELS
7-68-0552 Rev 8
SI iT 7 of 8

L. 2800(MAX.

180 HOLES FOR M16 BOL

10
IN CUP AND SLOTTED HOLES
IN MC150 SEE DET. 'Si' SEE DETAIL 'Q' WITH 'C'
(SHT 5 OF 8) TYPE BOLT IN SHT 8 OF 8

SEE DETAIL @ WITH '0'

TYPE BOLT IN SHT. 8 OF 8 A
vir REF. EL
(T.O.S.)
INSULATION
(0)
6 THK. STIFF. PL (TYP)

10 THK. PL (TYP)

MC125 TO BE PROVIDED (AS SHOWN)

c, WHEN 'P' IS MORE THAN 800
P
1
•cip. EL. T.T.L.

1 :4cl
OF VESSEL

10 THK. PL

ZO.R.+6+120
SECTION 11-11
SECTION 5-5 R1315 (LB15 OPP. HAND)
DIMENSIONS X.Y.Z & L SHALL BE AS PER
GEN. ARRANGEMENT DRAWING

c_ 200 HOLE
FOR M18 BOLTS SECTION: 12-12

SECTION 13-13 SECTION 14-14 VIEW-F

(BASE PLATE) (CLIP)

FOR NOTES REFER SHT. 1 OF 8 AND 2 OF 8

FOR SECTION 17-17 REFER SHT. 5 OF 8

8 27 06 19 REVISED AND ISSUED AS STANDARD

/
OULSHAN
Ig -----
RAJANJI SRIVASTAVA R.KlrRIVEDI

7 21 01 14 REVISED AND ISSUED AS STANDARD VPS AJS P.K.MDTAL S.CHANDA

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Page 210 of 674

 STANDARD No
do! a
ENGINEERS CIRCULAR PLATFORM FOR
Igar 251e,s INDIA LIMITED 7-68-0552 Rev 8
WWI 2ANoir imadarg) (A Govt Of India Undertakalg) HOT VESSELS
SHT 8 of 8

10 TIT PL 10 TI-p. PL
32 NB(M) PIPE OR L 100X100XB
N
N
-. 91\
nn \
4
to t- g\
r) \ . r,
-,
150
FOR L 90X90X8

II

Mi
r Al

50X6 FLAT
M12 BOLTS M12 BOLTS

FOR ANGLE SIZES 90X90X8/ FOR ANGLE SIZE

100X100X8 75X75X8
DETAIL-'L'
(SPLICE)

R=12

0,
50X6 FLAT

DETAIL OF SLOTTED BOLT TYPE 'G'

(REFER DET. P & Q)
HOLE IN TOE ANGLE
Nair REF. E
(TOG ) (REFER DET. P &

HANDRAIL HALF HANDRAIL

BOLT TYPE-.G.

mi =i Iza mil ra BRACKET OUTER TOE

INNER TOE
al =mum= ANGLE LA
ANGLE LB
7i NEM M M
-----
MN MOM MEM MO II
MI MEIN =I Ell )
IM MEE MN
JIM —
- =IN MEM ME 10
MIME 2
mI
"No ow.11111 1.11 42 10
/ //

OF 020 HOLE ON BKT AND

OF SLOTTED HOLE ON TOE ANGLE
(SEE DETAIL)
fE OF 020 HOLE ON BKT
DETAIL-'A' WITH TYPE BOLT

DETAIL-'P' DETAIL-'Q'
(THE BOLT SHALL BE HAND TIGHTENED )

FOR NOTES REFER SHT 1 OF B AND 2 OF 8

NOTCH IN GRATING

8 27 06 19 REVISED AND ISSUED AS STANDARD GULSHAN RAJANJI SRIVASTAVA

RAM913
R.K.
7 21 01 14 REVISED AND ISSUED AS STANDARD VPS AJS P.K.NTITAL S.CHANDA

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Page 211 of 674

 DETAILS OF BRACKETS FOR STANDARD No.
dt'ilifjP_JelatkENIGNEERs
Oa( 05iteg w INDIA LIMITED CIRCULAR PLATFORMS 7-68-0553 Rev. 8
WWI MINE 4,, 3,T16,0 EA Govt. of Ind Undertaking)
OF HOT VESSELS SHT 1 of 5

INSULATION s "55,(MIN.) 1 10

SHELL „////
OUTSIDE DIA. /
j/ / ELEVATION 'X'

6 THK. BENT UP STEEL PLATE

10 THK.

35
lAj
BRACKETS LB1 & RB1 (900 < L4 1400)
R
INSULATION
1
, r2.
L/2 L/2 10

SHELL (///,
(/ LB GRATING
OUTSIDE DIA. /
81_ z
74 —7/ 1
t 8-200 HOLES FO
in M18 BOLTS
cr, 140 HOLES
• /- FOR M12 BOLTS 6
MC125
an • / 8 THK. BENT UP STEEL PLATE
U)
CJ

8 THK. BENT UP STEEL PLATE

of e /

SUPPORT CUP
Z 10 THK.
)1/48

35/ ,40 BRACKETS LB2 & RB2 (1aim< isoo)

4.35

TYPE LB & RB1 TYPE LB2 & RB2

NOTES:
1. THESE DETAILS ARE VALID FOR PLATFORMS
LENGTH (mm) WEIGHT(kg) LENGTH(mm) WEIGHT(kg) TO HOT VESSELS HAVING INSULATION THICKNESS
100 mm
985 16.00 1485 37.42
2. FOR DETAILS OF CUPS REFER STANDARD NO.
1085 17.60 1585 39.72
7-68-0557 SHT. 1 OF 3
1185 19.12 1685 42.06
3. REFER G.A. DRG. OF PLATFORMS FOR BRACKET
1285 20.62 1785 44.38
TYPES AND DIMENSIONS R, L, X, oCi & 0C2
1385 22.14 1885 46.72
4. ORIENTATION OF BRACKETS IS GIVEN ACCORDING
1485 23.65
TO ARROW 'F'
LB = LEFT BRACKET (FLANGE ON LEFT)
RB = RIGHT BRACKET (FLANGE ON RIGHT)
- LENGTH = L + 75+10 (FOR 35 CLEARANCE BETWEEN
INSULATION & INNER TOE ANGLE OF PLATFORM) 5. STRUCTURAL STEEL GRADE SHALL BE E250. ALL
- ABOVE WEIGHTS INCLUDE WEIGHT OF STIFFENERS STRUCTURAL CONNECTION BOLTS SHALL BE GALVANIZED AND 8.8 GRADE.
6. NO PIPE SHALL BE SUPPORTED ON BRACKETS/PLATFORMS.

8 27 06 19 REVISED AND ISSUED AS STANDARD p

asw , RAJAIUI SRNASTAVA LK.

7 21 01 14 REVISED AND ISSUED AS STANDARD VPS AJS P.K.MITTAL S.CHANDA

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Page 212 of 674

 DETAILS OF BRACKETS FOR STANDARD No.

4651ege INDIA WI I E6
WRffeliMITMMWM (A GovL of Inds Undeolaking)
CIRCULAR PLATFORMS 7-68-0553 Rev. 8
OF HOT VESSELS SHT 2 of 5

'F'- INDICATES VIEWING FROM OUTSIDE TOWARDS THE CENTRE OF VESSEL FOR BRACKET ORIENTATION

OF M12 BOLTS
35
GRATING

3 C1
2
TOE ANGLE AND
BKT. CONNECTED SLOTTED HOLE IN
WITH 'G' TYPE BOLT
SEE 7-68-0552 SHT. CUP B THK. PLATE WEB OF MC125
8 OF 8 SEE 7-68-0557
SHT. 1 OF 3 B THK. PLATE

SECTION 2-2

SECTION 1 -1
SIMILAR SEC. 1A-1A EXCEPT BOLTS /

SECTION 3-3

'G' TYPE BOLT REF. SHT.

EFERENCE 8 OF 8 STD. 7-68-0552
AXIS

BRACKETS ORIENTATION DETAIL 'A' DETAIL 'B'

KAL449V
8 27 06 19 REVISED AND ISSUED AS STANDARD GNSIMN RAJANJI SRWASTAVA
7 21 01 14 REVISED AND ISSUED AS STANDARD VPS AJS PJCJITTAL SJNANDA

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Page 213 of 674

 DETAILS OF BRACKETS FOR STANDARD No
ofaexiimENGNEERs
1ga 015ftw INDA LIMITED,
POUT AMR MR3.10.1) (A Govt of Indio UnOeitaking)
CIRCULAR PLATFORMS 7-68-0553 Rev. 8
OF HOT VESSELS SHT 3 of 5

R
INSULATIONr5 MIN.)
4Z1 L 10

SHELL LB
OUTSIDE DIA. ' GRATING

ELEVATION 'X'
O\-- // F (T.O.S.)
—Of
♦ / / /
o3 • // • 6-200 HOLES FOR

• /•••
0 1418 BOLTS
N
co 5•/ / / 0 THK. FACE PLA

„ 6 THK. BENT UP STEEL PLATE

• • /
0 / /-- 4AJ

SUPPORT CUP

BRACKETS LB3 & R63 (900 < 1.4,c 1400)

41
INSULATION MIN.) 10
L/2
1°35
SHELL
OUTSIDE DIA. v/%/
LB GRATING
o /
T.O.S.
8-200 HOLES FOR F
M18 BOLTS
MC12

8 THK. BENT UP STEEL PLATE

THK. FACE PLATE

6 THK. PLATE

4j

SUPPORT CUP BRACKETS L84 & RB4 0400<L4 'Boo

NOTES:
TYPE LB3 & RB3 TYPE LB4 & RB4
1. THESE DETAILS ARE VALID FOR PLATFORMS
LENGTH (mm) WEIGHT( kg) LENGTH(mm) WEIGHT( kg) TO HOT VESSELS HAVING INSULATION THICKNESS
100 mm BUT NOT MORE THAN 300 mm
935 18.40 1435 40.60
2. FOR DETAILS OF CLIPS REFER STANDARD NO.
1035 19.90 1535 42.60
7-68-0557 SHT. 2 OF 3
1135 21.40 1635 45.00
1235 22.90 1735 47.30
FOR NOTES 3 TO 6 REFER SHEET 1 OF 3.
1335 24.50 1835 49.60
1435 25.90

LENGTH = L+10+25 (FOR 35 CLEARANCE BETWEEN

INSULATION & INNER TOE ANGLE OF PLATFORM)
ABOVE WEIGHTS INCLUDE WEIGHT OF STIFFENERS
AND WEIGHT OF FACE PLATE.

REVISED AND ISSUED AS STANDARD

PI4 a
8 27.06 19 WUHAN KIL/PQ." RALUIJI SRNASTAVA K. 7RI~D1
7 21 01 14 REVISED AND ISSUED AS STANDARD VPS AJS PJLIIITTAL S.CHANDA

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Page 214 of 674

 DETAILS OF BRACKETS FOR STANDARD No.
la A
,S, ENGINEERS
ligar lell5ftW IN DIA LIMITED CIRCULAR PLATFORMS 7-68-0553 Rev. 8
(A Govt of Indio UndoUking)
OF HOT VESSELS SHT 4 of 5

R
INSULATION 10

SHELL
OUTS DE DIA.
0 ELEVATION 'X'
T.O.S
F
140 HOLES FOR
VA 5A M12 BOLTS
8 (TYP)
8-300 HOLES FOR
M27 BOLTS
12 THK.
8 THK. BENT UP STEEL PLATE

4B
SUPPORT CUP

BRACKETS LB7 & RB7 (1800 < L 2400)

INSULATION L
f45 L/3 L/3 L/3

SHELL / / LB GRATING
OUTSIDE DIA. / / j
o / EMS EL y
e /
(T.O.S)

F
1 40 HOLES FOR
17-5-A II 5A M12 BOLTS
8-330 HOLES MC125 (TYP)
FOR IA30 BOLTS
16 THK.
FACE It
— 8 THK. BENT UP STEEL PLATE

SUPPORT CUP

BRACKETS LB8 & RB8 (2400 < L.< 3000)

NOTES:
TYPE LB7 & RB7 TYPE LB8 & RB8
1. THESE DEAILS ARE VALID FOR PLATFORMS TO HOT
LENGTH (mm) WEIGHT(kg) LENGTH(mm) WEIGHT(kg) VESSELS HAVING INSULATION THICKNESS UP TO 300mm.
1845 60.40 2545 83.80 HOWEVER 'e' SHALL NOT BE CONSIDERED LESS THAN 100mm.
1945 63.10 2645 86.50 2. FOR DETAILS OF CUPS REFER STANDARD NO.
2045 65.80 2745 89.20 7-68-0557 SHT. 3 OF 3
2145 68.50 2845 91.90
2245 71.20 2945 94.60
2345 73.90 3045 97.30
2445 76.60 FOR NOTES 3 TO 6 REFER SHEET 1 OF 3.
LENGTH = L + 0 + 35
ABOVE WEIGHTS INCLUDE WEIGHT OF STIFFENERS
AND WEIGHT OF FACE PLATE

8 27 06 19 REVISED AND ISSUED AS STANDARD CULSHAII

9.4 KIAL/PQ." RAJANJI SRIVASTAVA R.K.

7 21 01 14 REVISED AND ISSUED AS STANDARD VPS AJS P.LIATTAL S.CHANDA

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Page 215 of 674

 DETAILS OF BRACKETS FOR STANDARD No.
do ErsoNEERs
Igar tiffiegy. INDIA IJMITED CIRCULAR PLATFORMS 7-68-0553 Rev. 8
wen emcee, ) (A Gort el India Undenseng)
OF HOT VESSELS SHT 5 of 5

BENT UP STEEL PLATE

BRACKET

SECTION 5-5
SEC. 5A-5A, SIMILAR EXCEPT AS NOTED

REF. DETAIL 'A'

SHOWN IN SHT. 2 OF

/45/ GRATING

200 HOLES FOR

TOE ANGLE AND M18 BOLTS FOR
SEC. 4-4, 4A-4A S0
BKT. CONNECTED
WITH 'G' TYPE BOLT MAX.
SEE STD. 7-68-0552 300 HOLES FOR
SHT. 8 OF 8 505 50 M27 BOLTS FOR
SEC.4B-4B

er- 330 HOLES FOR

M3O BOLTS FOR
SEC.4C-4C
EFERENCE
AXIS

SSEL O.D.

10 80 90 ASEC.4-4, 4A-4A)
24 80 100 (SEC.4B-4B, 4C-4C)
9
SECTION 4-4
SIMILAR SEC. 4A-4A, 4B-4B & 4C-4C BRACKETS ORIENTATION
EXCEPT BOLTS

'F'— INDICATES VIEWING FROM OUTSIDE TOWARDS THE CENTRE OF VESSEL FOR BRACKET ORIENTATION

8 27 06 19 REVISED AND ISSUED AS STANDARD RAJANJI SIWASTAVA

7 21 01 14 REVISED AND ISSUED AS STANDARD VPS AJs P.KANYTAL LCHANDA

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Page 216 of 674

 STANDARD No.
ENGINEERS PLATFORM SUPPORT CLIPS
e kii5ieU
5 lf INDIA LIMITED FOR 7-68-0557 Rev.6
10/11,7T ?IiIVIVCE,13.1CIFA) IA Govt of Ind,a Unctertakangt
HOT VESSELS SHT 1 of 3

TO CYLINDRICAL PART TO CONICAL PART

- 10 THK PL
0 THK PL

F 00
REFERENCE
EL 'X'
REFERENCE
EL 'X'

+ + ----%
85
++— 85
,c,1

++ ,, _
TYPE -1 TYPE -3
(FOR BRACKETS LB1 & RB1)
(FOR BRACKETS LB1 & RB1)
10 THK PL
co
REFERENCE
EL 'X'
/1

+ + Rs
Lo
cs

—I— +
345

u-)
cn

+ +
0 co
0,
REFERENCE
EL 'X'
+ +

n^ +
Lr)
CT,

TYPE -2 +
(FOR BRACKETS LB2 & RB2)

FOR LEFT-
BRACKET 'LB'
A 88 35
L=A+123

TYPE-4
(FOR BRACKETS LB2 & RB2)

FOR RIGHT
BRACKET 'RB'

(CLIPS -TYPE 1,2,3 &4)

NOTES:-
1. DETAILS ON PAGE 1 ARE VALID, FOR e< 100(e=INSULATION THICKNESS)
2. A=45 FOR 0 < e< 50 AND A= e-5 FOR 50 < e < 100.
3. FOR e> 100, REFER DETAILS ON SHEET 2 OF 3
4. FOR BRACKET DETAILS REFER STANDARD NO 7-68-0553.
5. ALL STRUCTURAL CONNECTION BOLTS SHALL BE GALVANIZED AND 8.8 GRADE
6. MATERIAL FOR CLIPS SHALL BE AS PER VESSEL DRAWING.

6 11 07 19 REVISED AND ISSUED AS STANDARD KAUTUK KML/P A RAJANJI RIVASTAVA RKT

5 17 09 13 REVISED AND ISSUED AS STANDARD VPS AJS P K MITTAL S.CHANDA

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Page 217 of 674

 STANDARD No.
ENGINEERS PLATFORM SUPPORT CLIPS
INDIA LIMITED FOR 7-68-0557 Rev. 6
IA Govt of India UrK*oolong)
HOT VESSELS SHT 2 of 3

TO CYLINDRICAL PART TO CONICAL PART

—6 THK. PLATE 6 THK. PLATE
o " O (NI
REFERENCE REFERENCE
EL X' EL. 'X'

U)
aD CD
10 THK. PLATE 200 HOLES (TYP)
0 oo 0 10 THK. PLATE
01 aD
N rn
200 HOLES (TYP) N

TYPE-5 TYPE-7
(FOR BRACKETS LB3 & RB3 ) (FOR BRACKETS LB3 & RB3)

ir)
O
N
10 THK PLATE
U)
0)
0 200 HOLES (TYP) 6 THK PLATE
0 )r) 0 N
O rn REFERENCE
N
EL 'X'
o

A 10 THK. PLATE
U)
0

TYPE-6 200 HOLES (TYP)

(FOR BRACKETS LB4 & RB4)

042 TYPE-8
10 TI-IK PLATE (TYP)
0 (FOR BRACKETS LB4 & RB4 )
00- °'

THK. PLATE (TYP)

PLAN NOTES:-
(CLIPS TYPE 5, 6, 7 & 8) 1. THIS DETAIL IS VALID FOR e .100, BUT NOT MORE THAN 300MM A=e+1 0
2. FOR BRACKET DETAILS, REFER STD. NO. 7-68-0553
3. ALSO REFER NOTES 4,5, & 6 (SHT. 1 OF 3) OF THIS STD

6 11 07 19 REVISED AND ISSUED AS STANDARD

oak
KAUTUK KUL/PA RAJANJI SRIVASTAVA TR111‹..-

5 17 09 13 REVISED AND ISSUED AS STANDARD VPS AJS P K MITTAL S CHANDA

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Page 218 of 674

 STANDARD No.
ti = ENGERS
IN PLATFORM SUPPORT CLIPS
Ifgel fengje
05T
g INDIA
(WTI FIRISIE'
LIMITED
3W1) (A Govt of Indta Undertalonw
FOR 7-68-0557 Rev. 6
HOT VESSELS SHT 3 of 3

TO CYLINDRICAL PART TO CONICAL PART

SHELL - 8 THK. PLATE 8 THK. PLATE
OUTSIDE DIA. o " 0 (NJ
REFERENCE REFERENCE
o EL 'X' o EL 'X'
in Lo
--0--`, --1,-

II II)
cI4,"1 CV

I N. 10 THK PLATE
\ 10 THK. PLATE
in
cs, to V)
0) C•1
300 HOLES (TYP) '4'
300 HOLES (TYP)
N
II 12 THK. PLATE
12 THK PLATE
_.__ --s,,-
0
til
\
A

TYPE-13 TYPE-15
(FOR BRACKETS LB7 & RB7)
(FOR BRACKETS LB7 & RB7)

SHELL -8 THK. PLATE

8 THK. PLATE
OUTSIDE DIA. o CV 0 CV
REFERENCE REFERENCE
0 EL. 'X' EL. `X'
N

II
et......‹f
CV

I \ 10 THK. PLATE
10 THK. PLATE

o)
330 HOLES (TYP) -4
330 HOLES (TYP)
In
II 16 THK PLATE
_.— ____,,.. 16 THK. PLATE
0
to

,i,
Os'
0
A
A

TYPE-14 TYPE-16
(FOR BRACKETS LB8 & RB8)
(FOR BRACKETS LB8 & RB8)

NOTE:
1. THESE DETAILS ARE VALID FOR ALL THICKNESSES OF
INSULATIONS A=e+10 HOWEVER A SHALL NOT BE LESS
THAN 110
2. ALSO REFER NOTES 4,5 & 6 (SHEET. 1 OF 3) OF THIS STD.

6 11 07.19
(CLIPS TYPE 13, 14, 15 & 16)

REVISED AND ISSUED AS STANDARD (.7

KAUTUK KML/PA9
4
RAJANJI SRIVASTAVA R K TRIVEDI
5 17 09 13 REVISED AND ISSUED AS STANDARD VPS AJS P K MITTAL S.CHANDA

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Page 219 of 674

 STANDARD No.
Peiel• ENONEERS ELECTROFORGED GRATING

St-a r Rift
,..enel2zinrzOT3air.i)
INDIA LIMITED
IA Govt of India Unftertaungf
TYPE-I & TYRE-II 7-68-0697 Rev 4

SHT 1 of 8

NOTES :-

1. ALL DIMENSIONS ARE IN mm.

2. THE TYPE OF GRATING TO BE USED SHALL BE CALLED OUT ON THE DESIGN DRAWING.
3. MATERIAL FOR THE GRATING (TWISTED BARS/M.S. FLATS) SHALL BE OF GRADE E250 SUB QUALITY-A/BR/BO
CONFORMING TO IS:2062. BEARING FLATS AND END FLAT SHALL BE AS PER IS:1730. FLAT FOR CLAMPS
SHALL BE AS PER IS:513.
4. ALL GRATINGS SHALL BE MADE BY ELECTROFORGING PROCESS.
5. GRATINGS SHALL BE HOT DIP GALVANISED IN ACCORDANCE WITH IS:2629 AND TESTED AS PER
IS:2633 AND IS:6745. QUANTITY OF ZINC COATING SHALL BE MINIMUM 900 gm/m2 OF SURFACE
AREA (0.12mm UNIFORM THICKNESS)
6. THE PANEL WIDTH SHOWN ON THE SUBSEQUENT SHEETS IS INDICATIVE. IT MAY BE INCREASED OR
DECREASED AS REQUIRED TO SUIT THE GEOMETRY OF THE PLATFORM & CONVENIENCE OF HANDLING.

7. GRATINGS SHALL NOT BE USED FOR SUPPORTING THE PIPES DIRECTLY. ADDITIONAL MEMBERS
(MINIMUM MC125) SHALL BE PROVIDED UNDER THE GRATING FOR SUPPORTING THE PIPE HAVING
A MAXIMUM LOAD OF 500 Kg. THIS MEMBER SHALL SPAN IN SAME DIRECTION AS GRATING.
8. GALVANISED GRATING PANEL SHALL BE ALIGNED AND TACK WELDED TO THE SUPPORTING MEMBERS.
THEREAFTER FIXING OF GRATING PANEL WITH SUPPORTING MEMBERS SHALL BE DONE BY CLAMPS
(WITHOUT REMOVING TACK WELD) OR ALTERNATIVELY BY WELDING.

REMOVABLE GALVANISED GRATING PANEL AS SHOWN IN DWGS SHALL BE FIXED BY CLAMPS ONLY.

9. FOR GRATING PANELS WITH CUTOUTS / OPENINGS; STRENGTHENING SHALL BE CARRIED OUT
AS PER THE DETAILS GIVEN ON SHEET 6. ADDITIONAL MEMBERS WHEREVER SHOWN SHALL BE PROVIDED
IN THE STRUCTURE.
10. THE FABRICATED GRATING SHALL FULFILL THE FOLLOWING MINIMUM REQUIREMENTS:
(a) THE UNFUSED JOINTS ARE NOT IN EXCESS OF 5% OF THE TOTAL JOINTS AND ARE WELDED
BY SMAW/GMAW PROCESS
(b) THE JOINTS ARE ABLE TO SUSTAIN A MINIMUM PULL OUT LOAD OF 1.2 TIMES THE ALLOWABLE
SHEAR CAPACITY OF THE CROSS MEMBER.

11. EVERY FIFTH MAIN MEMBER SHALL NECESSARILY BE WELDED TO THE END FLAT FROM (ONE SIDE)
HOWEVER, THE END MAIN MEMBER SHALL ALWAYS BE WELDED TO THE END FLATS.

12. OPENINGS UP TO 200mm DIA ARE NOT SHOWN ON THE DRAWING THE SAME SHALL BE MADE AT SITE
DURING ERECTION OF PIPING.

13. REPAIR TO THE DAMAGED AREA OF GALVANIZED COATING DUE TO WELDING AFTER ERECTION SHALL BE
CARRIED OUT AS PER RECOMMENDED PRACTICE OF IS:11759 USING COLD GALVANIZING SPRAY PROCESS.
ORGANIC PAINT SYSTEM IS NOT ACCEPTABLE.

14. MAXIMUM LENGTH OF SINGLE CONTINUOUSLY SUPPORTED GRATING SHALL BE FIXED ON THE BASIS OF
HANDLING. HOWEVER PREFERABLY LENGTH OF GRATING SHALL BE RESTRICTED TO 4.2M.

4 02 01 19 REVISED & ISSUED AS STANDARD ARUN AL

Ant,
AMARJEET
II
MAN SRIVASTAVA 'R.K TRIVEDI

3 04 11 15 REVISED & ISSUED AS STANDARD JRENDER GUPTA AMARJEET RAJA?. SRIVASTAVA S. CHANDA

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Page 220 of 674
 STANDARD No
at
ENGINEERS ELECTROFORGED GRATING
5fgar tMegd INDIA LIMITED TYPE-I & TYPE-II 7-68-0697 Rev 4
Govt 01 India UndenAingl
SHT 2 of 8

TABLE-1

USE OF GRATING TYPE AT VARIOUS LOCATIONS &

NET SAFE WORKING LOADS FOR GRATING TYPE-I & II

/ 500 TO 800 900 1000 1100 1250 1400

TYPE APPLICATION

EITHER OF w(UDL IN KN/m2 ) OR P(LINEAR LOAD IN KN/M)

1. EQUIPMENT PLATFORM W
2. WALKWAY FOR CABLE 19.60 14.80 10.80 8.10 5.30 3.40
TRAY IN PIPE RACK
3. OPERATING PLATFORM FROM -
GRADE/SUPER STRUCTURE 9.00
4. APPROACHES P 8.00 6.60 5.40 4.00 2.70

1. STAIRS
2. FLOOR GRATING FOR w 19.60 17.60 13.20 8.70 5.50
a) COMPRESSOR HOUSE
II b) TECHNOLOGICAL STRUCTURE
e) PIPE RACK WITH
VALVE / PIPE SUPPORTS P 14.60 13.00 10.70 8.80 6.30 4.40
d) MAINTENANCE PLATFORM

NOTE:— THE NET SAFE WORKING LOADS GIVEN ON TABLE-1 ARE BASED ON LIMITING VERTICAL
DEFLECTION OF SPAN/200 OR 6mm, WHICHEVER IS LESS.

SYMBOLS :-

= EFFECTIVE SPAN IN mm
b = BEARING WIDTH IN mm

= UDL IN KN/m2
p = LINEAR LOAD IN KN/m AT MID SPAN ALONG PANEL WIDTH.

= GRATING SPAN DIRECTION

4 02 01 19 REVISED & ISSUED AS STANDARD d at

ARUN LAL AMARJEET RAJAN SRIVASTAVA R.K.TRIVEPr
3 04 11 15 REVISED & ISSUED AS STANDARD JITENDER GUPTA AMARJEET RAJAN SRIVASTAVA S. CHANDA
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Page 221 of 674
 STANDARD No
ot(el ENGINEERS ELECTROFORGED GRATING
tlf ___U INDIA LIMITED TYPE-I & TYPE-II 7-68-0697 Rev 4
(A Govt 01 India Undertaking)

SHT 3 of 8

'A' 36 NOS. FLAT 25x3

r
_ (MAIN MEMBER)

-ilk-L- -I-
1053 OVERALLWIDTH

100 100 100 4,

LL
I

MAIN
g II I EMB El

i I H
-
HT—IIi-i--I

I
1 I U I

.60
Zr z
C , II
I
(REFER NOTE-11)
II.
CROSS
1/CLAIDCD
CING0030 c/c

Z
0 DI
DETAIL - 'A'
0
I
—-

I
35 SPACING

O
Zr
CD
35

0 __FAc
100 100 100
E x z
1 I 'B' rI
i 1
I 1
-- -
— I---I

I. Li FLAT 25x3
-

SECTION 1 -1
n i

si
-
b1-1

CROSS MEMBER
/

MAIN MEMBER

CLEAR SPAN = 1—b

ff

ti
E

PLAN DETAIL - 'B'

* (REFER VIEW 4-4 IN SHEET 5 OF 8)

TABLE-2

WT. OF GRATING IN kg/m 2 PROPERTIES REMARKS

(INDICATIVE ONLY, NOT FOR AYMENT) WIDTH = 1053mm
6mm SQUARE" lxx Zxx MR
25x6 25x3 TWISTED TOTAL
BAR cm4 cm3 kg m

2.36 20.13 2.54 25.03 14.84 11.87 195.94

GRATING TYPE - I

ANT
4 02 01 19 REVISED & ISSUED AS STANDARD ARV N LAL AMAR JE RAJAH SRIVASTAVA
3 04 11 15 REVISED & ISSUED AS STANDARD -MENDER GUPTA AMARJEET RAJAH SRIVASTAVA S. NANDA

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 STANDARD No.
A31 ENGINEERS ELECTROFORGED GRATING
$1g-a tapreg
Idled eiezreanotoug
INDIA LIMITED TYPE-I & TYPE-II 7-68-0697 Rev. 4
IA Govt 01 India Undettakpng)

SHT 4 of 8

•
E 31 NOS. FLAT 25x6
E e/ C
r L _ (MAIN MEMBER)
e-k—1 1 -
1 I a 75 75 1
, 75 1'
i I
i—
[ _ __ _ _ _ _ ji3j MAIN
EL I 11)
ific
En
mo
1Hi

/ I oi 1
gi MEMBEI

ls
on
PI
111 I 1 N HI
1 a

C
in
lo
I I NI
1 z

I 0 C (REFER NOTE-11)
Il
Il
CROSS
LICLADPD

0
-.... ''''...
0 0 u
to
to I
DETAIL - 'C'
g
i
i
30 SPACING 0

../ ....--

814
D
BAR
----•

I
75 75 75
X Xt X X
II
1
D' I
1
I
ROSS MEI
WARETWI'

4
-1-7-

Ili i1
Li FLAT 25x6
;-
// "" SECTION 2-2
III . I I tO
I
E
E I CROSS MEMBER
Il
t3,
I I MAIN MEMBER

CLEAR SPAN = /-b ir

/
T1 .11

PLAN
DETAIL - 'D'
* (REFER VIEW 4-4 IN SHEET 5 OF 8)

TABLE-3
WT. OF GRATING IN kg/m2 PROPERTIES
REMARKS
(INDICATIV ONLY, NOT FOR PAYMENT) WIDTH = 1056mm

8mm SQUARE lxx Zxx MR

25x6 TOTAL
TWISTED BAR cm4 cm3 kgm

36.92 6.14 43.06 24.2 19.4 319.69

GRATING TYPE - II

4 02 01.19 REVISED & ISSUED AS STANDARD ARM AMARJEET RAJAN SRIVASTAVA R.K.TRNEDI
3 04 11 15 REVISED & ISSUED AS STANDARD JITENDER GUPTA AMARJEET RAJAN SRIVASTAVA S. GMANDA

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Page 223 of 674
 STANDARD No
aaa-ei ENGINEERS ELECTROFORGED GRATING
Ogen fePleg
own pve/Hemacpp)
INDIA LIMITED
IA Goo of ocba Una/riming)
TYPE-I & TYPE-II 7-68-0697 Rev 4
SHT 5 of 8

CLAMP 25x3 THK. M.S. FLAT,

WITH 8 0 HOLES (AS/IS:513) CLAMP TWISTED BAR
ncup
5mm7 8mm/6mm

IMMEI
. um' J.

GRATING
25x6 THK. M.S.
FIAT WITH 8 0
HOLES, TACK
WELDED TO STRL.
MEMBER
VIEW 3-3 VIEW 4-4
GRATING FIXED WITH CLAMP GRATING FIXED WITH CLAMP
(REFER NOTE-8&13) (REFER NOTE-8&13)

25 min. FULL FLANGE WIDTH

FOR ONE SIDE SUPPORT
TWISTED BAR

GRATING
(min.)

VIEW 4-4
GRATING FIXED WITH WELDING
(REFER NOTE-13)

3 7
WELD/CLAMP (TYP) a E a
K4 -44
MIDDLE FLAT/

4-

E El 3

L (SPAN)
I

FIXING DETAIL FOR GALVANISED GRATING PANELS

4 02 01 19 REVISED & ISSUED AS STANDARD 444

ARUN LAI
A-A.L
MAAR/EFT RAJAH SRIVASTAVA R.K.TRIVEDI

3 04 11 15 REVISED & ISSUED AS STANDARD JITENDER GUPTA Al/ARJECT RAJAH SRIVASTAVA S CHANDA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copynght EIL - All nghts reserved
Page 224 of 674
 STANDARD No.
ELECTROFORGED GRATING
ENGINEERS
51gzirftWeg
own
INDIA LIMITED
;IC,21517//110:1M1,0 (A Govt of Inde Unoenaking)
TYPE-I & TYPE-II 7-68-0697 Rev 4

SHT 6 of 8

GALVANISED
FLAT 25x6 ALROUND GALVANISED
& WELDED TO MIMI=11111,
FLAT 25x6
GRATING FLAT RR
IMM ;
BENT TO SHAPE
111111111M1111 • & WELDED TO
GRATING FLAT
3
3r WELDING SHALL BE
DONE ON ALL THE
3V WELDING SHALL BE
FLATS AND BARS
DONE ON ALL THE
FLATS AND BARS

RECTANGULAR CIRCULAR

(SIZE OF OPENING >200 & UP TO 400 mm)

(FOR OPENING UP TO 200 MM REFER NOTE-12)

r GALVANISED GALVANISED
/ FLAT 25x6 ALROUND FLAT 25x6 BENT TO SHAPE
/ 8c WELDED TO GRATING FLAT & WELDED TO GRATING FLAT

SIMISPIPIRENRM
M NRRRR~r
MINN Mr
MONSEN'
NM I RI
=MIN
SUPPORTING MEMBER AS NI SUPPORTING MEMBER AS
AS PER DESIGN DWG OR RR~I•I • AS PER DESIGN DWG OR
RR~Ir I.c.
L-75x75x6 MINIMUM L-75x75x 6 MINIMUM
BELOW GRATING SINIEL BELOW GRATING
alRINEL:
RR~InRR
aGiGaGiGiGiGIMMMTHISIMM
3 3 WELDING SHALL BE
W WELDING SHALL BE
DONE ON ALL THE DONE ON ALL THE
FLATS AND BARS
FLATS AND BARS
RECTANGULAR CIRCULAR

SIZE OF OPENING GREATER THAN 400 mm

TYPICAL DETAIL OF GRATING STRENGTHENING AT OPENINGS
(REFER NOTE-9)

4 02 01 19 REVISED & ISSUED AS STANDARD A.1.9 AMARJEET RAJAH SRIVASTAVA

m
R.K.1RY
j4)"

3 04 11 15 REVISED & ISSUED AS STANDARD JITENDER GUPTA AMARIEET RAJAH SRIVASTAVA S. CHANDA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Approved by
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Page 225 of 674
 STANDARD No
oira_i ENGINEERS
INDIA LIMITED
ELECTROFORGED GRATING
ligeittaileg TYPE-I & TYPE-II
7-68-0697 Rev 4
Govr of India Unded*Ing}
SHT 7 of 8

DET. OF 25 THK. GRATING STAIRCASE

TREAD FOR 750 & 1000 WIDE STAIR

E
STRINGER E
co
8mm SQ. TWISTED CROSS BAR ❑

25x6 THK. FLATS MAIN BAR)

CROSS MEMBER
LEADING EDGE OF TREAD MAIN MEMBER
THK. PLATE

14 0 HOLE
40x14 FOR M12 BOLTS
SLOTTED HOLE
FOR M12 BOLTS
(AS/IS:1367) DETAIL- ' E'

VIEW 6-6

GALVANISED
END PL. 65x6

SECTION 5-5
*ALL THE FLATS TO BE WELDED TO THE END FLATS

_ CHEQUERED PL. (AS/IS:3502)

NOSING 5mm THK.
FULL WELDING AT
ALL FOUR CORNERS
OMNWhOUMMUMSOMPW:OWS
r.7 3
o

\ FULL WELDING TO BE DONE

f f I i AT EVERY BEARING
GALVANIZED 65X6 THK.

6 MEMBER FROM ONE SIDE

8mm SQ. TWISTED
CROSS BAR
3
6-NOS. 25X6 THK. FLAT
ENDPL. (TYP)

MAIN MEMBER
70 8 SPACINGS 0 75 c/c = 600 70 FOR 750 WIDE STAIRS
/
45 12 SPACINGS 0 75 c/c = 900 45 FOR 1000 WIDE STAIRS

746 FOR 750 WIDE STAIRS

996 FOR 1000 WIDE STAIRS

PLAN
TYP. DETAIL OF GRATING TO BE USED AS TREAD FOR 750/1000 WIDE STAIRS

Ans.:
4 02 01.19 REVISED & ISSUED AS STANDARD 'Oa
ARUN LAL AMARJEET RAJAH SRIVASTAVA

3 04 11 15 REVISED & ISSUED AS STANDARD JITENDER GUPTA AMARJEET RAJAH SRIVASTAVA S. CHANDA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copynght EIL - All nghts reserved
Page 226 of 674
 STANDARD No
ELECTROFORGED GRATING
O
riaeJ ENGINEERS
taMeg INDIA LIMITED TYPE-I & TYPE-II
7-68-0697 Rev. 4
INW eVeNtrilil."12571) (A Goof of India Uncleffak'o91
SHT 8 of 8

10
r trs

I I
I I
9 94
k 4
••••-- -,--c°.

OR OR

SECTION 9-9 SECTION 1 0-1 0

(TB=TRANSVERSE BOW) (LB=LONGITUDINAL BOW)

TABLE-4 (PERMISSIBLE AND MANUFACTURER TOLERANCES)

PERMISSIBLE TOLERANCES
LOCATION TOLERANCE ( M M)

LENGTH OF GRATING PANEL OR INDIVIDUAL BEARING BAR +0 / —5

WIDTH OF GRATING +0 / —5

DEPTH OF BEARING BAR:

FOR 25MM +1 / —0.5

THICKNESS OF BEARING BAR: ±0.4

BINDING:
TOP OF BINDING BAR ABOVE BEARING BAR +0.5 / —0.5

MANUFACTURING TOLERANCES

LOCATION TOLERANCE (MM)

DIFFERENCE BETWEEN THE LENGTH OF DIAGONALS ±5 (OUT OF SQUARENESS OF

GRATING PANEL)

TRANSVERSE BARS IN EITHER DIRECTION FROM 1:100

PERPENDICULAR ALIGNMENT WITH BEARING BARS

TRANSVERSE BAR SPACING ±5 PER 1500 LENGTH OF

BEARING BARS

BEARING BAR LEAN 1:10

TRANSVERSE BOW OF PANEL BEFORE FASTENING TO SUPPORTS 1:100

LONGITUDINAL BOW OF PANEL BEFORE FASTENING TO SUPPORTS 1:200

4 02 01 19 REVISED & ISSUED AS STANDARD 44.-k

ARUN LAL
fiely,
AMARJEET WAN SRIVASTAVA kLM
.K.TRIVE 0 )1

3 04 11 15 REVISED & ISSUED AS STANDARD JITENDER GUPTA AMARJEET WAN SRIVASTAVA S. CHANDA

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
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Page 227 of 674
 DOCUMENT NO.
ATTACHMENT-1 XXXX-XXX-XX-XX-XXXX Rev. 0
Page XX of XX

TECHNICAL INFORMATION FOR STRUCTURED TOWER PACKINGS REQUIRED WITH OFFER

BED DESCRIPTION

Packing Type
Packing size/ number
Thickness of Packing
Minimum Bed height required
Bed height offered to meet guarantee
REQUIRED FOR ALL DESIGN CASES
MINIMUM NORMAL MAXIMUM
Top of Bed
% MOC/ FLOOD
Δ P mm H2O/ m of packed height

Bottom of Bed
% MOC/ FLOOD
Δ P mm H2O/ m of packed height

Complete Bed (*)

Δ P in bed mm H2O
HETP - Allowed, mm
HETP - Calculated, mm

Physical Data
1) Material of Construction
2) Surface Area M2/M3
3) Void Fraction (percent)
4) Corrugation Angle
5) Element (Layer) ht.

This sheet is to be submitted separately for all beds.

(*) For heat transfer beds, heat transfer data shall be furnished.

Format No. 3-05-45-3001 Rev. 0 Copyrights EIL – All rights reserved

Page 228 of 674

 DOCUMENT NO.
ATTACHMENT-2 xxxx-xx-xx-xx-xxxx Rev. yy
PACKED COLUMN DATASHEET Page 1 of 1

EIL ENQ. NO./ JOB NO.:- COLUMN NO. :-

PROJECT :- SERVICE OF UNIT :-
CUSTOMER :- TOTAL NO. OF PACKED SECTIONS :-
CUSTOMER REF. NO./ PROCESS DATA SHEET NO. TOTAL HEIGHT OF PACKED SECTIONS (MM):-
TYPE OF PACKING :-

INPUT DATA
LOADING AT
BOTTOM / TOP OF PACKING TOP BOTTOM
RATE, Kg/hr
DENSITY, kg/m3
VAPOUR
VISCOSITY, cP
MOLECULAR WEIGHT
RATE, Kg/hr
DENSITY, kg/m3
LIQUID
VISCOSITY, cP
SURFACE TENSION, Dynes/cm
PRESSURE, mm Hg A/ Kg/cm2(g)
OPERATING CONDITION
TEMPERATURE, oC V/L
SYSTEM FACTOR
HEIGHT OF PACKED SECTION, mm
HEAT DUTY ACROSS SECTION, K Cal/hr x 106
ALL. MAX. PRESSURE DROP ACROSS BED, mmHg/ Kg/cm2
INTERNALS
MATERIAL OF CONSTRUCTION
PACKING
TOTAL CORROSION ALLOWANCE ON INTERNALS
MIN./MAX. %OF DESIGN LOADS

OUTPUT DATA HYDRAULIC PERFORMANCE AT DESIGN/MAX. LOADS

COLUMN INSIDE DIAMETER, mm
TYPE AND SIZE OF PACKING
MOC PERCENT
PRESSURE PER METER OF PACKING mm Hg/m
DROP TOTAL ACROSS BED Kg/cm2
TURNDOWN % OF DESIGN LOADS
HETP, METER/FEET / NO. OF THEORETICAL STAGES
LMTD, oC
VOL.HEAT TRANSFER COEFF. K Cal/hr m 3 oC
SUPPORT PLATE
LIQUID DISTRIBUTOR
HOLD DOWN PLATE / BED LIMITER
LIQUID REDISTRIBUTOR
NOTES:

REV. DATE PURPOSE DESIGN CHECKED APPROVED

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Page 230 of 674
Page 231 of 674
Page 232 of 674
 SPECIFICATION Specification No.
FOR SURFACE PREPARATION B224-000-79-41-PLS-01
AND PROTECTIVE COATING Rev. 5
PAGE 1 OF 47
HRRL

JOB SPECIFICATION
FOR
SURFACE PREPARATION
AND PROTECTIVE COATING

5 10-05-2019 ISSUED AS A JOB SPECIFICATION SM SS SG

4 09-05-2019 ISSUED AS A JOB SPECIFICATION SM SS SG

3 19-02-2019 ISSUED AS A JOB SPECIFICATION SM SS SG

2 07-02-2019 ISSUED AS A JOB SPECIFICATION SM SS SG

1 11-01-2019 ISSUED AS A JOB SPECIFICATION SM SS SG

0 29-10-2018 ISSUED AS A JOB SPECIFICATION SM SS SG

Rev.
Date Purpose Prepared by Checked by Approved by
No

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 SPECIFICATION
Specification No.
FOR SURFACE PREPARATION B224-000-79-41-PLS-01
AND PROTECTIVE COATING Rev. 5
HRRL PAGE 2 OF 47

Abbreviations:

AS : Alloy Steel
ASTM : American Society for Testing and Materials
AWWA : American Water Works Association
CS : Carbon Steel
DFT : Dry Film Thickness
GI : Galvanized Iron
ID : Internal Diameter
ISO : International Organization for Standardization
LTCS : Low temperature Carbon Steel
MS : Mild Steel
MR : material requisition
NB : Nominal Bore
NA : Not applicable
OD : Outside Diameter
OSHA : Occupational Safety and Health Act
RCC : Reinforced Cement Concrete
RH : Relative humidity
SS : Stainless Steel
SOR : Schedule of Rate
SSPC : Steel Structure Painting Council
WFT : Wet Film Thickness

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 SPECIFICATION
Specification No.
FOR SURFACE PREPARATION B224-000-79-41-PLS-01
AND PROTECTIVE COATING Rev. 5
HRRL PAGE 3 OF 47

Sl. PAGE
CONTENT
No. NO.
1.0 General 4
2.0 Scope 4
3.0 Reference codes & standards 5
4.0 Equipment 6
5.0 Surface preparation, shop primer, coating application, repair 7
and documentation
6.0 Paint materials 15
7.0 Coating systems 22
8.0 Storage 36
9.0 Colour code 36
10.0 Identification of vessels, piping 42
11.0 Painting for civil defense requirements 42
12.0 Quality control, inspection and testing 43
13.0 Guarantee 45
14.0 Qualification criteria of painting CONTRACTOR/sub 45
CONTRACTOR
15.0 Qualification/acceptance criteria of paint coating system 45
16.0 Method of sampling & dispatch for laboratory testing 48

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 SPECIFICATION
Specification No.
FOR SURFACE PREPARATION B224-000-79-41-PLS-01
AND PROTECTIVE COATING Rev. 5
HRRL PAGE 4 OF 47

1.0 GENERAL

1.1 This technical specification shall be applicable for the work covered by the contract
and without prejudice to the provisions of various international codes of practice,
standard specifications etc. It is understood that the CONTRACTOR shall carry out
the work in all respects with the best quality of materials and workmanship and in
accordance with the best engineering practice and instructions of Engineer-In-
Charge.

1.2 Wherever it is stated in the specification that a specific material is to be supplied or

a specific work is to be done, it shall be deemed that the same shall be supplied or
carried out by the CONTRACTOR.

Any deviation from this standard without written deviation permit from appropriate
authority will result in rejection of the job.

1.3 This specification covers the requirement for protective coating for new
construction.

2.0 SCOPE

2.1 Scope of work covered in the specification shall include, without being limited to,
the following:

This specification defines the requirements for surface preparation, selection and
application of primers and paints on external surfaces of equipment, vessels,
machinery, piping, ducts, steel structures, external & internal protection of storage
tanks for all services and chimneys, if any. The items listed in the heading of tables
of paint systems are indicative only. However, the CONTRACTOR is fully
responsible for carrying out all the necessary painting, coating and lining job on
external and internal surfaces as per the tender requirement.

2.2 Extent of work

2.2.1 The following surfaces and materials shall require shop, pre-erection and field
painting:

- All un-insulated carbon steel & alloy steel equipment like vessels, columns,
storage tanks, exchangers, parts of boilers etc.

- All un-insulated carbon steel and low alloy plant and related piping, fittings and
valves (including painting of identification marks), furnace ducts and stacks.

- All insulated parts of vessels, boilers, chimneys, stacks, piping and steam piping
and other insulated items present, if any.

- All items contained in a package unit.

- All structural steel work, pipes, structural steel supports, walkways, handrails,
ladders, platforms etc.

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 SPECIFICATION
Specification No.
FOR SURFACE PREPARATION B224-000-79-41-PLS-01
AND PROTECTIVE COATING Rev. 5
HRRL PAGE 5 OF 47

- Flare lines, external surfaces of MS chimney with or without refractory lining and
internal surfaces of MS chimney without refractory lining.

- Identification of colour bands on all piping, as required, including insulated

aluminium clad, galvanized, SS and nonferrous piping.

- Identification lettering/ numbering on all painted surfaces of equipment/piping

insulated aluminium clad, galvanized, SS and non-ferrous piping.

- Marking / identification signs on painted surfaces of equipment and piping

including hazardous service.

- Supply of all primers, paints and all other materials required for painting (other
than OWNER supplied materials)

- Application of pre-erection/fabrication and shop primer.

- Repair work of damaged pre-erection/ fabrication and shop primer and weld
joints in the field/site before and after erection.

- All CS piping, equipment, storage tanks and internal surfaces of RCC tanks in
ETP plant.

- Quality control, testing and inspection during all stages of work (surface
preparation, application of coating and testing of furnished coating).

2.2.2 The following surfaces and materials shall not require painting in general. However,
if there is any specific requirement by the OWNER, the same shall be painted as
per the relevant specifications:

a. Un-insulated austenitic stainless steel.

b. Plastic and/or plastic coated materials.
c. Non-ferrous materials like aluminum, Cu-Ni alloys, galvanized steel.

In general Galvanized steel doesn’t require painting. However if painting is required

due to OWNERs instructions, contractual or for colour coding requirement then
coating system in Table 4.0 shall be followed.

2.3 Unless otherwise instructed, final paint coating (i.e. application of field primer,
intermediate and top coats) on pre-erection/ shop primed equipment shall be applied
at site, only after all welding, testing on systems are completed as well as after
completion of steam purging.

3.0 REFERENCE CODES & STANDARDS

3.1 Without prejudice to the provision of clause 1.1 above and the detailed
specifications of the contract, latest editions of the following codes and standards
are applicable for the work covered by this contract:

ISO-12944 : Corrosion protection of steel structures by protective

paint system.

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 SPECIFICATION
Specification No.
FOR SURFACE PREPARATION B224-000-79-41-PLS-01
AND PROTECTIVE COATING Rev. 5
HRRL PAGE 6 OF 47

ASTM-Vol. 6.01&6.03 : American standard test methods for paints and

coatings.
IS-101 : Methods of sampling and test for paints, varnishes and
related products.
IS-5 : Colours for ready mixed paints and enamels.
RAL DUTCH : International standard for colour shade (Dutch standard).
IS-2379 : Indian standard for pipe line identification-colour code

3.2 Surface preparation standards

The latest editions of any of the following standards shall be followed for surface
preparation:

3.2.1 ISO 8501-1 / SIS-05 59 00: ISO standard for preparation of steel substrates before
application of paints and related products. This standard contains photographs of
the various standards on four different degrees of rusted steel and as such is
preferable for inspection purpose by the Engineer-In-Charge.

3.2.2 Steel Structures Painting Council, U.S.A. (surface preparation specifications

SSPC-SP).

3.2.3 National Association of Corrosion Engineers (NACE), U.S.A.

3.2.4 Various international standards equivalent to Swedish standard for surface

preparations are given in Table-1.

3.3 The CONTRACTOR shall arrange, at his own cost, to keep a set of latest edition of
above mentioned standards and codes at site.

3.4 The paint manufacturers’ instructions shall be followed as far as practicable at all
times for the best results. Particular attention shall be paid to the following:

a. Instructions for storage to avoid exposure as well as extremes of temperature.

b. Surface preparation prior to painting shall be followed as per Table-4 to 13 of
this standard.
c. Mixing and thinning.
d. Application, recommended limit on time intervals in between coats & DFT.

4.0 EQUIPMENT

4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning,
all equipment, scaffolding materials, shot & grit blasting equipment , air
compressors etc. required shall be suitable for the work and shall be arranged by
the CONTRACTOR in sufficient quantity at the site. The manufacturers test
certificates / data sheets for all the above mentioned items shall be reviewed by
Engineer-In-Charge at site before start of the work.

4.2 Mechanical mixer shall be used for paint mixing operations in case of two pack
systems except in case of specific requirement; the Engineer-In-Charge may allow
the hand mixing of small quantities at his discretion for touch up work only.

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 SPECIFICATION
Specification No.
FOR SURFACE PREPARATION B224-000-79-41-PLS-01
AND PROTECTIVE COATING Rev. 5
HRRL PAGE 7 OF 47

5.0 SURFACE PREPARATION, SHOP PRIMER / COATING APPLICATION,

REPAIR AND DOCUMENTATION

5.1 General

5.1.1 Adhesion of the paint film to the surface depends largely on the degree of
cleanliness of the metal surface. Proper surface preparation contributes more to
the success of the paint protective system. In order to achieve the maximum
durability, one or more of the following methods of surface preparation shall be
followed, depending on condition of surface to be painted and as instructed by the
Engineer-In-Charge.

a. Abrasive blast cleaning

b. Mechanical or power tool cleaning

5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a
clean and dry surface is obtained. Unless otherwise specified, surface preparation
shall be done as per provisions of relevant tables given elsewhere in this
specification. The minimum acceptable standard, in case of thermally sprayed
metal coatings, in case of mechanical or power tool cleaning shall be St. 3 or
equivalent. In case of blast cleaning, it shall be Sa 2-1/2 as per Swedish standard
SIS-055900 (latest edition) or SSPC-SP or ISO 8501-01.Blast cleaning shall be Sa
3 as per Swedish standard in case of thermally sprayed metal coatings.

Before surface preparation by blast cleaning, the surface shall be degreased by

aromatic solvent to remove all grease, oil etc as per SSPC-SP-1.

5.1.3 Irrespective of whether external or internal surface to be coated, blast cleaning

shall not be performed where dust can contaminate surfaces undergoing such
cleaning or during humid weather conditions having humidity >85%. In case of
internal coating of storage tanks, dehumidifier shall be used to control humidity
level below 60%. Dehumidifier should depress the dew point of air in the enclosed
space, sufficient enough so as to maintain it 3⁰C below the metal substrate
temperature during entire period of blasting and coating application. During the
interval time between application of primer coat and subsequent intermediate and
top coats or between blast cleaning completion and start of application of primer
coat, dehumidifier unit should be in continuous operation to ensure that no
condensation occurs on the substrate.

Dehumidifier should be able to maintain grain drop (moisture removal) at the rate of
25 grains per pound of air per hour. Dehumidifier should have capacity of at least 2
air changes per hour of the enclosed space. All necessary psychometric data
should be collected by the CONTRACTOR for the given site conditions, before
starting operation of dehumidifier, to ensure that desired values of dew point and
moisture content in enclosed space is achieved.

Dehumidification to be maintained round the clock for surface preparation and

painting till the total coating application is over.

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 SPECIFICATION
Specification No.
FOR SURFACE PREPARATION B224-000-79-41-PLS-01
AND PROTECTIVE COATING Rev. 5
HRRL PAGE 8 OF 47

Dehumidifier shall not be stopped under any condition till the entire blasted surface
is primed to the satisfaction of the technical representative of the paint
manufacturer. In case the dehumidifier breaks down in middle of the job, the same
shall be replaced at the risk and cost of the CONTRACTOR.

5.1.4 The Engineer in-Charge shall have the right to disallow usage of dehumidifier if the
performance is not meeting the specified requirements. Under such circumstances,
the CONTRACTOR shall remove the equipment and replace the same with
another equipment to provide satisfactory results without any additional cost to the
OWNER.

5.1.5 Irrespective of the method of surface preparation, the first coat of primer must be
applied by airless spray/ air assisted conventional spray, if recommended by the
paint manufacturer, on dry surface. This should be done immediately and in any
case within 4 hours of cleaning of the surface. However, at times of unfavorable
weather conditions, the Engineer-In-Charge shall have the liberty to control the
time period, at his sole discretion and/or to insist on re-cleaning before primer
application is taken up. In general, during unfavorable weather conditions, blasting
and painting shall be avoided as far as practicable.

5.1.6 The external surface of R.C.C. chimney to be painted shall be dry and clean. Any
loose particle of sand, cement, aggregate etc. shall be removed by scrubbing with
soft wire brush. Acid etching with 10-15% HCl solution for about 15 minutes shall
be carried out. The surface must be thoroughly washed with water to remove acid
and loose particles and then dried completely before application of paint.

5.2 Procedure for surface preparation

5.2.1 Air blast cleaning with abrasives

The surfaces shall be blast cleaned using one of the abrasives such as Al2O3
particles, chilled cast iron or steel grit, copper slag or nickel slag at a pressure of
7.0 kg/cm2 and at an appropriate distance & angle depending on nozzle size
maintaining constant velocity and pressure. Chilled cast iron or steel shall be in the
form of shot or grit of size in the range of G16 – G42 conforming to SSPC AB1 and
S250 grade size of steel shots (maximum) to obtain a desired surface profile of
35-50 microns trough to peak. For all other abrasives, size shall be in the range of
G16 – G24. The combination of steel grits and shots shall be normally in the ratio
of 3:1. The quality of abrasives shall be free from contaminants and impurities and
shall meet the requirements of SSPC AB1. The compressed air shall be free from
moisture and oil. The blasting nozzles should be venturi style with tungsten
carbide or boron carbide as the material for liners. Nozzle orifice may vary from
3/16” to 3/4”. On completion of blasting operation, the blasted surface shall be
clean and free from any scale or rust and must show a grey-white metallic luster.
Primer or first coat of paint shall be applied within 4 hours of surface preparation.
Blast cleaning shall not be done outdoors in bad weather without adequate
protection. If there is dew on the metal surface, it shall be cleaned. The surface
profile shall be uniform to provide good adhesion (i.e. 35 to 50 microns) to the
paint. If possible, a vacuum collector shall be installed to collect and recycle the
abrasives.

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 SPECIFICATION
Specification No.
FOR SURFACE PREPARATION B224-000-79-41-PLS-01
AND PROTECTIVE COATING Rev. 5
HRRL PAGE 9 OF 47

5.2.2 Mechanical or power tool cleaning

Power tool cleaning shall be done by mechanical striking tools, chipping hammers,
grinding wheels or rotating steel wire- brushes. Excessive burnish of the surface
shall be avoided as it can reduce paint adhesion. On completion of cleaning, the
detached rust, mill scale etc. shall be removed by clean rags and /or washed by
water/steam and thoroughly dried with compressed air jet before application of
paint.

5.3 Non-compatible shop coat primer

For equipment on which application of total protective coating (primer +

intermediate + top coat) is carried out at shop, compatibility of finish coat with
primer should be checked with the paint manufacturer. If the shop coat is in
satisfactory condition showing no major defect upon arrival at site, the shop coat
shall not be removed.

5.4 Shop coated equipment (coated with primer & finishing coat) should not be
repainted unless paint is damaged. Repair shall be carried out as per Table-3 of
paint systems depending upon the compatibility of paint.

5.5 Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas
by means of power tool brush cleaning or hand tool cleaning and then spot primed
before applying one coat of field primer, unless otherwise specified. If shop primer
is not compatible with field primer, then shop coated primer should be completely
removed before application of selected paint system for a particular environment.

5.6 For package units/equipment, shop primer should be as per the paint system given
in this specification. However, manufacturers’ standard can be followed after
review.

5.7 Coating procedure and application

All coatings shall be applied by airless spray except for the following special cases,
where application can be carried out by brush subject to suitability of the
application of the paint product by brush.

- Spot repair
- Stripe coating on edges
- Small bore parts not suitable for spray application

Irregular surfaces such as sharp edges, welds, small brackets, and interstices may
stripe coated to ensure specified DFT is achieved. Paint manufacturer
recommendation should be followed before deciding for brush application.

5.7.1 Surface shall not be coated in rain, wind or in an environment where injurious
airborne elements exist, when the steel surface temperature is less than 5 0F
above dew point, when the relative humidity is greater than 85%, when the
temperature is below 40oF and when the ambient/substrate temperature is below
the paint manufacturers recommended temperature of application and curing. De-

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humidifier equipment shall be used to control RH and Dew point. The paint
application shall not be done when the wind speed exceeds 20 km per hour.

5.7.2 Blast cleaned surface shall be coated with complete application of primer as soon
as practicable but in no case later than 4 hours the same day.

5.7.3 To the maximum extent practicable, each coat of paint shall be applied as a
continuous film with uniform thickness and free of probes. Any spots or areas
missed in application shall be re-coated and permitted to dry before the next coat is
applied. Applied paint should have the desired wet film thickness.

5.7.4 Each coat shall be in proper state of cure or dryness before the application of
succeeding coat. Material shall be considered dry for re-coating when an additional
coat can be applied without the development of any detrimental film irregularities
such as lifting or loss of adhesion of the under coat. Manufacturer’s instructions
shall be followed for inter coat interval.

5.7.5 When the successive coat of the same colour have been specified, alternate coat
shall be tinted, when practical, sufficiently to produce enough contrast to indicate
the complete coverage of the surface. The tinting material shall be compatible with
the material underneath and shall not be detrimental to its service life and shall be
recommended by the original paint manufacturer.

5.7.6 Airless spray application shall be in accordance with the following procedure:
As per steel structure paint manual Vol.1 & Vol.2 by SSPC, USA. Airless spray
relies on hydraulic pressure rather than air atomization to produce the desired
spray. An air compressor or electric motor, issued to operate a pump to produce
pressures of 1000 to 6000 psi paint, is delivered to the spray gun at this pressure
through a single hose within the gun. A single paint stream is divided into separate
streams, which are forced through a small orifice resulting in atomization of paint
without the use of air. This results in more rapid coverage with less over spray.
Airless spray usually is faster, cleaner, more economical and easier to use than
conventional air spray.

Airless spray equipment is mounted on wheels, and paint is aspirated in a hose

that sucks paint from any container, including drums. The unit shall have in-built
agitator that keeps the paint uniformly mixed during the spraying. The unit shall
consist of in-built strainer. Usually, a very small quantity of thinning is required
before spray. In case of high build epoxy coating (two packs), 45:1 pump ratio and
0.020-0.023” tip size will provide a good spray pattern. Ideally, fluid hoses should
not have ID less than 3/8” and not longer than 50 ft. to obtain optimum results.

In case of gun choking, de-choking steps shall be followed immediately.

5.7.7 Brush application of paint shall be in accordance with the following:

a. Brushes shall be of a style and quality that will enable proper application of
paint.

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b. Round or oval brushes are most suitable for rivets, bolts, irregular surfaces,
and rough/ pitted steel. Wide flat brushes are suitable for large flat areas but
they shall not have width over 5 inches.

c. Paint shall be applied into all corners.

d. Any runs or sags shall be brushed out.

e. There shall be a minimum of brush marks left in the applied paint.

f. Surfaces not accessible to brushes shall be painted by spray, daubers, or

sheepskin.

5.7.8 For each coat, the painter should know the WFT corresponding to the specified
DFT and standardize the paint application technique to achieve the desired WFT.
This has to be ensured in the qualification trial.

5.8 Drying of coated surfaces

5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be
considered dry for re-coating when another coat can be applied without the
development of any film irregularities such as lifting or loss of adhesion of
undercoats. Drying time of the applied coat should not exceed maximum specified
for it as a first coat. If this exceeds, the paint material has possibly deteriorated or
mixing is faulty.
5.8.2 No paint shall be force dried under conditions which will cause chalking, wrinkling,
blistering formation of pores, or detrimentally affect the conditions of the paint.
5.8.3 No drier shall be added to paint on the job unless specifically called for in the
manufacturers’ specification for the paint.

5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing
until dried to the fullest extent practicable.

5.9 Spot repair of damaged primer

5.9.1 Where pre-erection/shop primer has been damaged at isolated localized spots
during handling and transportation or after erection / welding, its repair shall be
done as given below and as per the Table-3 of this specification.

5.9.2 Surface preparation: Quickly remove the primer from damaged area by mechanical
scraping and emery paper conforming to SSPC-SP-3 to expose the white metal.
Blast clean the surface, if possible. Feather the primed surface, over the intact
adjacent surface surrounding the damaged area, by emery paper.

Primer coating: One coat of F-9 shall be applied wherever damage was observed
on pre-erection / pre fabrication or shop primer of inorganic zinc silicate coating (F-
9). Similarly one coat of F-12 shall be applied wherever damage observed on pre-
erection / pre-fabrication/shop primer of silicone aluminium (F-12).

5.9.3 If damaged areas are found to be extensive and spread over large areas, then
entire pre-erection/pre-fabrication/shop primer shall be removed by blasting to

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achieve SSPC-SP-10 and entire blasted surface shall be primed again with F-9 or
F-12, as applicable, for the intended design temperature. (See note of Table-3).

5.10 Assessment of painting requirement

The paint system to be applied for a specific job shall be arrived at sequentially as
given below:

- Identify the environment from area classification details and choose the
appropriate table.
- Identify the design temperature from the technical documents.
- Identify the specific field paint system and surface preparation requirement from
the above identified table and temperature range.
- Identify the shop priming requirement from based on compatibility of the above
paint system.
- Identify the need of repair of shop primer and execute as per Table-3.

5.11 Documentation / records

5.11.1 A written quality plan with procedure for qualification trials and for the actual work
including test and inspection plan & procedure for approval before start of work.

5.11.2 Daily progress report with details of weather conditions, particular of applications,
no. of coats and type of materials applied, anomalies, progress of work versus
program.

5.11.3 Results of measurement of temperatures, relative humidity, surface profile, film

thickness, holiday detection, adhesion tests with signature of appropriate authority.

5.11.4 Particulars of surface preparation and paint application during trials and during the
work.

5.11.5 Details of non-compliance, rejects and repairs.

5.11.6 Type of testing equipment and calibration.

5.11.7 Code and batch numbers of paint materials used.

The coating applicator must maintain a job record consisting of all the information
as per 5.11.2 -5.11.7 above as well as the approved procedure of work (5.11.1
above). The job record consisting of information in accordance to 5.11.2 – 5.11.7
shall be entered on daily basis and should be daily signed by Engineer-in-charge.

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TABLE-1: SURFACE PREPARATION STANDARDS

VARIOUS INTERNATIONAL
Sl. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
Manual or hand tool
cleaning

Removal of loose rust, St 2 SSPC-SP-2 -

loose mill scale and
1
loose paint, chipping, This method is
scrapping, standing and applied when the
wire brushing. Surface surface is
should have a faint exposed to
metallic sheen. normal
Mechanical or power atmospheric
tool cleaning conditions when
other methods
Removal of loose rust St 3 SSPC-SP-3 - cannot be
loose mill scale and adopted and also
loose paint to degree for spot cleaning
specified by power tool during
2
chipping, de-scaling, maintenance
sanding, wire brushing painting.
and grinding, after
removal of dust,
surface should have a
pronounced metallic
sheen.
Dry abrasive Blast cleaning
3
There are four common grades of blast cleaning:
White metal

Blast cleaning to white Extremely clean

metal cleanliness. surface can be
NACE
3.1 Removal of all visible Sa 3 SSPC-SP-5 expected to have
No.1
rust. Mill scale, paint & prolonged life of
foreign matter 100% paint system.
cleanliness with desired
surface profile.
Near white metal The minimum
requirement for
Blast cleaning to near chemically
white metal cleanliness, resistant paint
SSPC-SP- NACE
3.2 until at least 95% of Sa 2½ systems such as
10 No.2
each element of epoxy, vinyl,
surface area is free of polyurethane
all visible residues with based and
desired surface profile. inorganic zinc

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VARIOUS INTERNATIONAL
Sl. STANDARDS (EQUIVALENT)
DESCRIPTION REMARKS
No. ISO 8501-1/ SSPC-SP, NACE,
SIS-05 59 00 USA USA
silicate paints.
Also for
conventional paint
systems used
under fairly
corrosive
conditions to
obtain desired life
of paint system.
Commercial Blast For steel required
to be painted with
Blast cleaning until at conventional
least two-third of each paints, for
NACE
3.3 element of surface area Sa 2 SSPC-SP-6 exposure to mildly
No.3
is free of all visible corrosive
residues with desired atmosphere and
surface profile. for longer life of
the paint systems.
Brush-off Blast

Blast cleaning to white

metal cleanliness,
NACE
3.4 removal of all visible Sa 1 SSPC-SP-7 -
No.4
rust, mill scale, paint &
foreign matter. Surface
profile is not so
important.

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6.0 PAINT MATERIALS

Typical characteristics and codes of various paint materials used in this specification
are as follows.

TABLE-2: PAINT MATERIALS

(Refer to general notes at the end of this table)

DESCRIPTION P-6 P-7 P-4

Epoxy Zinc Cold Galvanizing Etch Primer/Wash
Phosphate Primer product Primer
Technical name

Two component One pack synthetic Two pack polyvinyl

polyamine cured resin based zinc butyral resin medium
epoxy resin medium, galvanizing containing cured with phosphoric
pigmented with zinc min 92% of electrolytic acid solution pigmented
phosphate. zinc dust of 99.95% with zinc tetroxy
Type and purity. chromate.
composition

Volume solids % 49 37 9
Minimum
DFT per coat,
40-50 40-50 8-10
μ
Theoretical
covering capacity 8-10 4m²/kg 8-10
in m2/coat/ litre
Weight per litre in
1.4±0.05 2.67 kg at 15oC 1.2±0.05
Kg/litre
Touch dry at
10 min. 2 hrs.
30oC (max.) 30 min.

Hard dry at
30oC (max.), 8 24 24
hrs
Over-coating
interval, hrs Min. 8 Min. 4 Min. 4-6

Pot life at
30⁰C for two 6-8 NA NA
component
paints, hrs
Adhesion
(ASTM D 4541) >7 NA NA

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Temperature
resistance (min)
⁰C 80 50
NA
(ASTM D 2485) (Method A) (Method A)
*Note 8

TABLE- 2: PAINT MATERIALS (Contd.)

DESCRIPTION F-2 F-3 F-6A/B F-6C

Acrylic Chlorinated Epoxy-High Solvent less epoxy
Polyurethane rubber based Build coating coating
Technical name
finish paint finish paint

Type and Two-pack Single pack F-6A Two- Two pack,

composition aliphatic plasticized Pack Aromatic cured with Amine
isocynate chlorinated polyamine Adduct; catalyzed
cured acrylic rubber based cured epoxy epoxy resin
finish paint medium with resin medium suitably
(free of chemical and suitably pigmented
alkyd/polyeste weather pigmented.
r resins). resistant F-6B:
pigments. polyamide
cured epoxy
resin medium
suitably
pigmented with
MIO.
Volume Solids % 40 36 57 98
Minimum.
DFT per coat, μ
30-40 30-40 100-125 250-500
Theoretical
covering
capacity in 10-15 11-15 5-6 2-3
m2/coat/litre
Weight per liter in
1.15±0.03 1.15±0.03 1.42±0.03 1.40±0.03
Kg/litre
Touch dry at
30 min. 30 min. 3 hrs 3 hrs
30⁰C (max)

Hard dry at 30⁰C 8 8 16 16

(max.), hrs

Full cure at 30⁰C

NA NA 5 days 5 days
(for immersion/ high
temperature service)

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Over-coating
Min. Overnight
Interval, hrs Min.12. Min. Overnight Min. 8.
Max. 5 days
Max. 48

Pot life (approx.) at

30⁰C for two 5-8
NA 3-6 0.5
component paints,
hrs
Adhesion
(ASTM D 4541) >5 >4 >7 >8

<300 mg /1000
Abrasion Resistance cycles/CS17
(ASTM D4060) or NA NA NA
For 1000 g load <100 mg /1000
cycles/CS10

Temperature
resistance (min.) 80 60 80 120
⁰C (Method A) (Method A) (Method A) (Method A)
(ASTM D 2485)
*Note 8

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TABLE- 2: PAINT MATERIALS (Contd.)

DESCRIPTION F-7 F-8 F-9 (primer) F-11 F-12

Technical name High build coal Self priming Inorganic zinc Heat Heat
tar epoxy type surface silicate resistant resistant
coating. tolerant high Coating synthetic silicone
build epoxy medium Aluminium
coating based two Paint suitable
(complete rust pack up to 540°C
control Aluminium dry temp.
Coating) Paint suitable
up to 250°C
dry temp.

Type & Two pack Two pack A two pack air Heat Single pack
composition polyamide cured epoxy resin drying self resistant silicone resin
epoxy resin based suitable curing solvent synthetic based
blended with pigmented and based medium medium with
coal tar medium, capable of inorganic zinc based two Aluminium
suitably adhering to silicate pack flakes.
pigmented manually coating with Aluminium
prepared minimum 80% paint suitable
surface and old zinc content up to 250°C.
coating. on dry film.
The final cure
of the dry film
shall pass the
MEK rub test
as per ASTM
D4752.
Volume Solids % 62 75 57 35 18
Minimum.
DFT per coat in
100-125 100-125 65-75 15-20 15-20
μ
Theoretical
covering capacity 5.2-6.5 6.0-7.2 8-9 10-12 8-10
in M2/coat/ litre
Weight per liter in
1.40±0.03 1.41±0.03 2.3±0.03 0.95±0.03 1.00±0.03
Kg/litre
Touch dry at 30oC
(maximum), hrs 4 3 0.5 3 0.5
Hard dry at 30oC
(maximum), hrs 48 24 12 12 24

Full cure 30oC (for

immersion /high
5 days 5 days NA NA NA
temperature
service)

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Min. 24 hrs Min. 12 hrs

Over-coating interval,
max.5days Min. 10 at 20oC Min. 24 Min. 24
hrs
& 50% RH
Pot life at 30oC for
two component 4-6 1.5 4-6 NA NA
Paints, hrs
Adhesion MPa
(ASTM D 4541) >5 >5 >5 NA NA

Temperature
80 80 400 250 540
resistance⁰ C (min)
Dry service Dry service Dry service Dry service Dry service
(ASTM D 2485
method B)

Temperature
resistance (min.) 80 80 400 250 540
⁰C (Method A) (Method A) (Method B) (Method A) (Method B)
(ASTM D 2485)
*Note 8

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TABLE- 2: PAINT MATERIALS (Contd.)

DESCRIPTION F-14 F-15 F-16 F-17 F-20

Technical name Polyamine Two- Inert polymeric Novolac epoxy Glass flake
cured coal tar component matrix phenolic coating reinforced vinyl
epoxy Epoxy coating suitable cured with ester coating.
phenolic for under Polyamine
coating cured insulation for CS adduct hardener
with and SS.
Polyamine
adduct
hardener

Type & Specially Two pack Suitable for high Novolac Two
composition formulated ambient temperature epoxy phenolic component
polyamine temperature service and coating cured glass flake
cured coal tar curing epoxy under insulation with Polyamine filled vinyl ester
epoxy phenolic coating for CS, adduct hardener lining for under
suitable for coating alloy steel and immersion
application system SS services up to
under suitable for 90 deg. C.
insulation application
under
insulation
Volume Solids % oCS/SS
Minimum. 67 piping67 50 98 98
DFT per coat
100-125 75-100 100-125 300-450 500-600
in microns
Theoretical
covering
1.6 minimum
capacity in 5-8 4-5 3 minimum 6.5 – 8
M2/coat/ litre
Weight per liter
in Kg/litre 1.45±0.03 1.65±0.03 >1.3 1.7 >1.2
(mix paint)
Touch dry at
4 3 1 2
30oC (max) , 2
hrs
Hard dry at
24 24 16 24
30oC (max), hrs 4

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Full cure
30oC (for 168 hrs 168 hrs 168 hrs
NA 96 hrs
immersion (7 days) (7 days) (7 days)
/ high temp (4 days )
service)
Over-coating Min. 6 hrs Min. 36 hrs Min.6 hrs Min. 16 hrs Min. 4 hrs
interval Max.5 days Max.21 days Max. Not Max.21 days Max.3 days
applicable

Pot life at 30⁰C,

hrs 4 4-6 1 1
(for two 50 min-1 hr
component
paints)

>7,
Adhesion, MPa Tensile
(ASTM D 4541) >6 >7 NA >8 strength
>20N/mm2
(ASTM D 638)

Temperature
resistance (min.)
125 150 650 150 90
⁰C
(Method A) (Method A) (Method B) (Method A) (Method A)
(ASTM D 2485)
*Note 8 & 9

General notes for TABLE-2:

1. Covering capacity and DFT achieved per coat depends on method of application. Covering
capacity specified above is theoretical. For estimation of actual quantity of paints required,
include the losses during application. Minimum specified DFT should be maintained in any case.
2. All primers and finish coats should be ambient temperature curing and air drying unless
otherwise specified.
3. All paints shall be applied in accordance with manufacturer's instructions for surface preparation,
intervals, curing and application. The surface preparation, quality and workmanship should be
ensured. Wherever a deviation is noticed from the specification in manufacturer data sheet,
more stringent one between the data sheet and the specification shall prevail e.g. if this
specification recommends Sa 2 ½ and the manufacturer data sheet requires Sa3, the surface
preparation shall be done as per Sa 3. However in another case if this specification requires
the surface preparation of Sa 2 ½ and the manufacturer data sheet recommends only Sa 2 as
minimum, the surface preparation shall be done as per Sa 2 ½.
4. Technical data sheets for all paints shall be supplied at the time of submission of quotations.
5. Higher specific gravity of F-9 is also acceptable.
6. Internationally recognized & acceptable testing method shall be used for lab testing wherever
testing standards are not mentioned.
7. Touch dry, hard dry, pot life, full cure period, & over coating interval shall be as per
manufacturer’s data sheets and no testing is required. Slight variation in the values of these
parameters along with weight per liter may be permissible with the discretion of engineer-in-
charge only.

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8. Temperature resistance tests (ASTM D2485) shall be carried out for minimum required
temperature resistance indicated.
9. Wherever ASTM D 2485 method B is applicable, test results of the panels subjected to salt
spray (ASTM B 117) after muffle furnace exposure shall be submitted for pre-qualification
purpose.
10. F-6A shall be suitable for immersion services in line with recommendations in tables-7 to 9.
11. F-6C shall be suitable for immersion services of hydrocarbons and DM water ( in line with
recommendations in table-9)
12. F-7 shall be suitable for immersion service of hydrocarbons & underground service up to 80 Deg
C minimum.
13. F-14 shall be suitable for under insulation service up to 125 deg C.
14. F-15 shall be suitable for high temperature immersion & under insulation services in line with
recommendations from table-8 to 13.
15. F-17 shall be suitable for high temperature immersion service and underground services as
recommended in table-9 to 10.

7.0 COATING SYSTEMS

The coating system should be selected based on the plant location as given below:

Classification based on plant location:

a) Plant located in inland area (more than 50 km from coast).

Environment classification – Industrial

- For offsite areas: Table-5 to be followed.

- For all process unit areas including DM, CPP and Cooling tower: Table-6
to be followed.

b) Plant located on sea coast or within 50 km from sea coast.

Environment classification- Industrial marine

- For offsite areas, process unit areas including DM, CPP, Cooling tower etc.:
Table-6 to be followed.

c) For external surface of above ground tanks, Table-8 to be followed for all
locations (inland or coastal)

General notes for clause 7.0:

1. Coating systems (primers, finish paints etc.) based on area

classification/environments/applications are tabulated in Table-4 to Table-13

2. Repair of pre-erection/pre-fabrication & shop priming after erection/ welding

shall be done as per Table-3.

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TABLE-3: REPAIR OF PRE-ERECTION/PRE-FABRICATION OR SHOP PRIMER AFTER

ERECTION/WELDING
(For all un-insulated CS, LTCS & low allow steel items in all environments)

Total DFT
Sl. Design Temp. in Surface Coating
o in Microns Remarks
No. C Preparation System
(min.)
See Note-1
3.1 -45 to 400 SSPC-SP-3 1 coat of F-9 65-75
below and
clause
3.2 401 to 550 SSPC-SP-3 1 coat of F-12 20 5.9.3

Notes for Table-3:

Note-1: The application and repair of pre-erection/pre-fabrication or shop primer given in

above tables shall be done for all the items to be painted. In case the damages of
primer are severe and spread over large area, entire primer shall be removed by
blasting to achieve SSPC-SP-10 and surfaces to be primed again with F-9 or F-12
as applicable.

TABLE-4: COATING SYSTEM FOR GI HAND RAILS & GI ITEMS

(Refer clause 2.2.2)

Design
Sl. Total DFT
Temp. Coating System Remarks
No. in Microns (min.)
in oC
Hot Dip Galvanizing to 80-85
microns (600-610 gm/m2)as per
80 of finish coat
Up to IS 4759, 2629, 4736, 2633 +
4.1 (excluding the thickness -
60 1 coat of P-6 @ 40µ DFT/coat + 1
of galvanizing )
coat of F-2 @ 40 microns
DFT/coat

General notes for Table-4:

1. No galvanized specimen shall have thickness less than 80 microns.

2. Repair of the damaged areas of galvanized coatings due to welding during erection
shall be carried out as per recommended practice IS: 11759, using cold galvanizing
spray process. Organic paint systems are not acceptable for the repair.
3. After repair of damaged galvanized coating by cold galvanization (P-7), the repaired
area shall be top coated with paint system as given in table-4 above (i.e. 1 coat of P-6
@ 40µ DFT/coat + 1 coat of F-2 @ 40µ DFT/coat).
4. Suggested cold galvanizing manufacturers are ZINGA, LOCTITE or Z.R.C.
5. Galvanized gratings don’t require painting in general until otherwise specified
elsewhere or as per the requirement of the OWNER. Ladders, stairways & hand rails
require painting to meet the colour coding requirement of the OWNER. Contractor has
to ensure the applicable colour coding prior to application of coating as per this clause.

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TABLE-5: COATING SYSTEM FOR NORMAL CORROSIVE AREAS (OFFSITES)

(For all un-insulated above ground CS, LTCS & low allow steel piping, equipment,
structures, valves, vessels & columns etc.)

Surface Coating System Total

Sl. Design Preparation & Final DFT
No Temp. in Pre- in Remarks
. o
C erection/Shop Primer Finish Coat Microns
Primer (min.)
SSPC-SP-10;
1coat of F-9 @
5.1 -45 to -15 - None 65-75 No over-
65-75µ
coating
DFT/coat
shall be
1coat of F-6B
SSPC-SP-10; done on
1 coat of @ 100 µ
1coat of F-9 @ F-9
5.2 -16 to 80 P-6 @ 40 DFT/coat+ 1 245-255
65-75µ
µ DFT/coat coat of F-2 @
DFT/coat
40µ DFT/coat
SSPC-SP-10; 2 coats of F-
1coat of F-9 @ 11 @ 20µ
5.3 81 to 250 - 105-115 F-12 shall
65-75µ DFT/coat
be ambient
DFT/coat (2x20=40)
temperature
SSPC-SP-10; 2 coats of F-
curing type
1coat of F-9 @ 12 @ 20µ
5.4 251 to 400 - 105-115
65-75µ DFT/coat
DFT/coat (2x20=40)
2 coats of F-
SSPC-SP-10; This system
12 @20µ
5.5 >400 1coat of F-12 @ - 60 is suitable
DFT/coat
20µ DFT/coat up to
(2x20=40)
5400 C

General notes for Table-5:

1. The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The CONTRACTOR is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated through his scope of work as per tender document.
2. Flare line within unit or offsite areas shall be coated as per clause 6.3 of Table-6.
3. If the application of pre-erection/pre-fabrication/shop primer has already been completed, the
same shall not be repeated in the field. In case the damages to the primer coat are severe and
are spread over large areas, the Engineer-In-Charge may decide & advise re-blasting and re-
application of the primer coat. Repair of pre-fabrication/pre-erection primer, if required, shall be
done as per Table-3.
4. In case of paint systems as per sl. nos. 5.4 and 5.5, the colour bands shall be applied over the
aluminum paint as per the colour coding requirement for specific service of the piping.
5. All coating system including surface preparation, primer, intermediate and finish coat for piping
is recommended to be done at field only until otherwise specified.
6. For equipment, vessels, columns & valves etc scope of surface preparation, application of
primers to finish coat including repair shall be as per applicable contractual documents like
SOR, MR and PR etc.

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TABLE-6: COATING SYSTEM FOR CORROSIVE AREAS (PROCESS UNITS, COOLING

TOWER, DM AND CPP)
(For all un-insulated above ground CS, LTCS & low allow steel piping, equipment,
structures, valves, vessels & columns etc.)

Surface Coating System

Total
Preparation
Design DFT
& Pre-
Sl. Temp. oC in Remarks
erection/Sho
No. Primer Finish Coat Microns
p Primer
(min.)

SSPC-SP-10;
-45 to -15 1coat of F-9
6.1 - - 65-75
@ 65-75µ
DFT/
coat

2 coats of F- a) No over
6B @ 100 µ coating on F-
DFT/coat + 9 is allowed
SSPC-SP-10; 1 coat of 1 coat of F-2
-16 to 80 1coat of F-9 P-6 @ @ 40µ b) F-12 shall
6.2 345-355
@ 65-75µ 40 DFT/coat be ambient
DFT/ µ DFT/ (2x100 + temperature
coat coat 40= 240) curing type

2 coats of F-
SSPC-SP-10;
12 @ 20µ
81 to 400 1coat of F-9
6.3 - DFT/coat 105-115
@ 65-75µ
2x20=40
DFT/
coat
2 coats of F-
SSPC-SP-10; 12 @ 20-
>400 1coat of F-12 This system
6.4 - 25µ 60
@ 20-25µ DFT/coat is suitable up to
DFT/coat (2x20=40) 540O C

Coating system for furnace stacks

SSPC-SP-10
3 coats of
6.5 Up to 200 1coat of F-9 185-195
--- Silicone acrylic
@ 65-75µ
DFT/ coat (black) @40 µ
DFT/coat

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General notes for TABLE-6:

1. The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The CONTRACTOR is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated as per tender document and scope of work.
2. If the application of pre-erection/pre-fabrication/shop primer has already been completed, the
same shall not be repeated in the field. In case the damages to the primer coat are severe and
spread over large areas, the Engineer-In-Charge may decide & advise re-blasting and re-
application of the primer coat. Repair of pre-fabrication/pre-erection primer, if required, shall be
done as per Table-3.
3. For external surface of RCC Chimney, 2 coats of F-6 B@ 100µ DFT/coat to obtain a total DFT
of 200 µ shall be applied after proper surface preparation as per guidelines in 5.1.6.
4. In case of paint systems as per sl. Nos. 6.3 and 6.4, the colour bands shall be applied over the
aluminum paint as per the colour coding requirement for specific service of piping given in
clause 9.0.
5. For piping, equipment, vessels, columns & valves etc, scope of surface preparation,
application of primers to finish coat including repair shall be as per applicable contractual
documents like SOR, MR, and PR etc.

TABLE-7: COATING SYSTEMS FOR EFFLUENT TREATMENT PLANT (ETP)

Coating system Total

Sl. Design DFT in
Surface Preparation Finish Remarks
No. Temp. in oC Primer Microns
Coat (min.)
For external surfaces of C.S./M.S. items: screens, walk way bridges, baffles, dual
7.1 media filters, vertical pumps, piping in treated effluent sump, bio sludge pump, screw
pump and pump house, CS tanks, sumps and vessels.
2 coats of
F-6A
@100µ
1 coat of
DFT/coat +
F-9 @ 65-
-14 to 80 SSPS-SP-10 1 coat of 305-315 -
75µ
F-2 @ 40µ
DFT/coat
DFT/coat
(2x100+40
=240)
For internal surfaces of CS/MS Items: bio-sludge sump, filter feed sump, process
7.2 sump, sanitary sump, transfer sump, sludge, slop oil tank, scrapping mechanism in
clarifier.
2 coats of
1 coat of F-6A
F-6A @ 65- @100µ
-14 to 80 SSPS-SP-10 300 Note-1
100µ DFT/coat
DFT/coat. (2x100=30
0)
All R.C.C./concrete surfaces exposed to effluent water / liquid such as tanks,
7.3 structures, drains etc. in process sump, TPI separator (process and oil), aeration tank
and transfer sump etc.

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Epoxy
screed
Blast cleaning to lining shall
SSPC-SP guide lines be applied
and acid etching with as per
-14 to 80 Epoxy screed lining 3000
10-15% HCl acid manufactur
followed by thorough er and
water washing. Engineer-
In-Charge
instructions
7.4 CS dual media filters, chemical dosing tanks – internal surface
1 coat of clear two
component solvent free
vinyl ester primer @
Up to 60 SSPC-SP-10 1100 -
100µ DFT/ Coat + 2
coats of F-20 @ 500µ
DFT/ Coat

TABLE-8: EXTERNAL COATING SYSTEMS FOR CARBON STEEL AND LOW

ALLOY STEEL STORAGE TANKS

Coating system Total

Design Surface DFT
Sl. (Note-1)
Temp. in Preparation in Remarks
No. o
C Microns
Primer Finish Coat
(min.)
All external surfaces of shell, wind girders, appurtenances, roof tops of all above ground
8.1 tank including top side of external and internal floating roof and associated external
structural works.
F-6 should
1coat of F-9 @ 2 coats of F-6B @
be suitable
65-75µ DFT/coat 100µ DFT /coat +
SSPC-SP- for
8.1.1 -14 to 80 + 1coat of P-6 @ 1 coat of F-2 @ 345-355
10 occasional
40µ DFT/ coat 40µ DFT/ coat
water
immersion
1 coat of F-15
1 coat of F-15
primer @ 80µ
finish coat @80µ
SSPC-SP- DFT/ coat + 1
8.1.2 81 to 150 DFT/ coat + 1coat 280 -
10 coat of F-15
of F-2 @ 40µ
intermediate coat
DFT/ coat
@ 80µ DFT/coat

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For higher
design
2 coats of F-12 105-115 temperatur
@20 µ DFT/ coat es, system
SSPC-SP- 1coat of F-9 @
8.1.3 151 to 400 or or as per
10 65-75µ DFT/coat
1 coat of F-16 @ 8.2.3 of
125 µ DFT / coat 190-200 this table
is
applicable
8.2 External surfaces of bottom plate (in contact with soil) for all storage tanks.

F-7 should
3 coats of F-7@
SSPC-SP- 1 coat of F-9 @ be suitable
8.2.1 -14 to 80 100µ DFT/coat 365-375
10 65-75µ DFT/ coat for
(3x100=300)
immersion
service
1 coat of F-17 1 coat of F-17
SSPC-SP-
8.2.2 81 to 150 primer @ 400µ finish coat @ 800-825 -
10
DFT/ coat 400µ DFT/ coat
For underside of the bottom plate (not in contact with soil )
8.3
(in case tank is not lifted during PWHT) (Note- 2)

1 coat of inert 1 coat of inert

-29 to 400 SSPC SP-
8.3.1 polymeric matrix polymeric matrix 250-300 -
(CS) 10
coating @ 125 µ coating @ 125 µ

Notes for TABLE-8:

1. All paint coating application including primer for tanks shall be carried out at field after erection
and completion of entire welding.
2. For underside of bottom plate :
a) Painting shall be carried out before laying the bottom plate for tanks with non-Post Weld
Heat Treatment (PWHT).
b) For tanks with PWHT, painting shall be carried out after PWHT.
c) In case tank is not lifted during PWHT then painting shall be applied before laying the
bottom plate, clause no.8.3.1 shall be followed.

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TABLE-9: INTERNAL COATING SYSTEMS FOR CARBON STEEL AND LOW ALLOY
STORAGE TANKS

Coating system Total

Design Surface DFT
Sl.
Temp. in Preparation in Remarks
No. o
C Primer Finish Coat Microns
(min.)
Crude oil, ATF, turpentine oil, lubricating oil:

Underside of floating roofs, internal surface of cone roof, inside of bottom plate,
9.1
internal surfaces of bare shell for full height, underside of floating roof, oil side
surfaces of deck plates, oil side surfaces of pontoons, support structures and ladders
etc.
1 coat of F-15
intermediate coat
1 coat of F-15
@ 80µ DFT/coat
9.1.1 -14 to 90 SSPC-SP-10 primer @ 80µ 240 -
+ 1 coat of F-15
DFT/ coat
finish coat @ 80µ
DFT/ coat
Petroleum products & intermediates like LDO, HSD, gas oil, feeds of FCC-PC, FCC-
LCO, VGO-HDT, ISOM, DHDT, reformate, DCU, NHT & gasoline, naphtha, isomerate
and kerosene:
9.2 Underside of floating roofs, internal surface of cone roof, inside of bottom plate,
internal surfaces of bare shell for full height, underside of floating roof, oil side
surfaces of deck plates, oil side surfaces of pontoons, support structures and ladders
etc.
1 coat of F-9
@
9.2.1 -14 to 45 SSPC-SP-10 - 65-75 -
65-75 µ
DFT/coat
1 coat of F-15
intermediate coat
1 coat of F-15
@ 80µ DFT/coat
9.2.2 46 to 90 SSPC-SP-10 primer @ 80µ 240 -
+ 1 coat of F-15
DFT/ coat
finish coat @ 80µ
DFT/ coat
Potable, Raw & Fire water
9.3
All internal surfaces, accessories and roof structures of cone and dome roof tanks
2 Coats of F-6A
1 Coat of F-6A
@ 100µ DFT/
9.3.1 -14 to 60 SSPC-SP-10 @ 300 Note-1
Coat
100 µ DFT/coat
(2x100=200)
De-mineralized (DM) water & Condensates etc.:
9.4
All internal surfaces, accessories and roof structures of cone and dome roof tanks.
Single coat
1 Coat of F-6A 2 coats of F-6C @ of F-6C @
9.4.1 -14 to 60 SSPC-SP-10 @ 200µ DFT/ coat 500 400 µ is
100µ DFT/coat (2x200=400) also
acceptable

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1 coat of F-15
intermediate coat
1 coat of F-15 @ 80µ DFT/coat
9.4.2 61 to150 SSPC-SP-10 primer @ 80µ + 1 coat of F-15 240 -
DFT/ coat finish coat @ 80µ
DFT/ coat
(80+80=160)
Hydrochloric acid (HCl) 10 %:
9.5
All internal surfaces, accessories and roof structures of cone and dome roof tanks
1 Coat of clear
two component
solvent free 2 Coats of F-20 @
9.5.1 -14 to 60 SSPC-SP-10 1100 -
vinyl ester 500µ DFT/ Coat
primer @ 100µ
DFT/ Coat
Aggressive solvents like hexane, exane, benzene, xylene and toluene:
9.6
All internal surfaces, accessories and roof structures of cone and dome roof tanks

1 coat of F-9
9.6.1 -14 to 65 SSPC-SP-10 @ 65-75µ DFT/ - 65-75 -
coat

Ethylene glycol tanks:

9.7
Internal shell-full height, bottom plate, underside of roof and all accessories
3 coats of vinyl
chloride co-
9.7.1 All SSPC-SP-10 - polymer @ 225 -
75µ /Coat;
(3x75=225)
9.8 Inside pontoon and inside of double deck of all floating roofs
1 coat of F-8 @ 1 coat of F-8 @
9.8.1 -14 to 80 SSPC-SP-3 200 -
100µ DFT/coat 100µ DFT/coat
1 coat of F-15
intermediate coat
1 coat of F-15 @ 80µ DFT/coat
9.8.2 81 to150 SSPC-SP-10 primer @ 80µ + 1 coat of F-15 240 -
DFT/ coat finish coat @ 80µ
DFT/ coat
(80+80=160)
Wet slops, amine solutions, sour water , water draw off:
9.9
All internal surfaces, accessories and roof structures of cone and dome roof tanks
1 coat of F-15
intermediate coat
1 coat of F-15 @ 80µ DFT/coat
9.9.1 -14 to 90 SSPC-SP-10 primer @ 80µ + 1 coat of F-15 240 -
DFT/ coat finish coat @ 80µ
DFT/ coat
(80+80=160)

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Vacuum residue, fuel oil , dry slop, bitumen and other high temperature hydrocarbon
liquids:
9.10 Underside of floating roof, internal surface of cone roof, bottom plate, inside of bare
shell- including wetted and non wetted surfaces, oil side surfaces of deck plates,
oil side surfaces of pontoons, roof structures, structural steel and ladders
1 coat of F-17 @
Up to
9.10.1 SSPC-SP-10 375µ DFT/coat 375-425 -
150oC
Alkalis up to 50 % concentration:
9.11
All internal surfaces, accessories and roof structures of cone and dome roof tanks
1 coat of F-15 2 Coats of F-6 A
Up to
9.11.1 o SSPC-SP-10 primer @ 80µ @ 100µ DFT/coat 280 -
60 C
DFT/ coat (2x100=200)

Notes for TABLE-9:

1. F-6 A shall be suitable for drinking water service and should have competent
authority certification.

TABLE-10: COATING SYSTEMS FOR EXTERNAL SIDE OF UNDERGROUND CARBON

STEEL PLANT PIPING AND VESSELS

Surface Coating system Total

Preparation
Design DFT
Sl. & Surface
Temp. in in Remarks
No. o Shop Preparation & Finish Coat
C Microns
Primer Primer (min.)
10.1 Underground carbon steel plant piping
3layer
As per polyethylene
document (3LPE) coating as 3.5mm
10.1.1 25 to 80 - --
B224-000-79- per document Min.
41-PLS-04 B224-000-79-41-
PLS-04

SSPC-SP-10;
1 coat of F-17 @ 800
10.1.2 81 to 150 -1 coat of F-17 Note-2
400 DFT/coat Min.
primer @400 µ
DFT/ coat
10.2 External side of underground storage vessels
SSPC-SP
-10;
1 coat of 3 coats of F-7 @
10.2.1 -45 to 80 - 365-375 -
F-9 @ 100µ DFT/coat
65-75µ DFT/
coat

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1 coat of F-17
SSPC-SP 1 coat of F-17 800
10.2.2 81 to 150 primer @400 µ Note-2
-10 @400µ DFT/ coat Min.
DFT/ coat

Notes for TABLE-10:

1 For underground vessels, scope of surface preparation, application of primers to finish coat
including repair shall be as per applicable contractual documents like SOR, MR, PR etc.
2 This coating system can be used for the lines/equipment/vessels which have operating
temperature between ambient and 150 oC (normal operating temperature) with occasional
rise in the temperature up to 200 oC (design temperature).

TABLE-11: COATING SYSTEMS FOR UNDER INSULATION (ALL UNIT AREAS &
OFFSITES)
(For insulated piping, equipment, storage vessels, tanks, columns etc. of CS, LTCS, Low
alloy steel & stainless steels in all environments.)

Surface Coating system Total DFT

Sl. Design Preparation & Remarks
Microns
No. Temp. o C Pre-erection/Shop Primer Finish paint
(min.)
Primer
Carbon steel, LTCS and Low alloy steel Piping, Storage tanks, Vessels,
11.1
Equipments etc

2 coats of
SSPC-SP-10;
F-15 @75µ
11.1.1 -45 to 125 1coat of F-15 @ None 225
DFT/coat
75µ DFT/coat

SSPC-SP-10; 1 coat F-16 @

126 to 450
11.1.2 1 coat of F-16 @ None 125µ DFT/coat 250
(CS) 125µ DFT/coat

11.2 Stainless Steel, Alloy Steel, Alloy-20 Piping, Tanks, Vessels & Equipments
SSPC-SP-7;
(15-25µ surface 2 coats of
11.2.1 -45 to 125 profile) None F-15 @75µ 225
1 coat of F-15 @75 DFT/coat
µ DFT/coat
SSPC-SP-7;
(15-25µ surface
1 coat of
profile)
11.2.2 126 to 550 None F-16 @125μ 250
1 coat of
DFT/coat
F-16 @125μ
DFT/coat

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11.3 Cyclic service of CS, LTCS, SS, & Alloy Steels (Note-1)
SSPC-SP-10 For
CS, LTCS & low
Alloy steel. 2 coats of
-45 to 150 SSPC-SP-7 for SS; F-15 @75µ Note-2
11.3.1 None 225
(Note-1) (15-25µ surface DFT/coat
profile)
1 coat of F-15 @75
µ DFT/coat
-29 to 400 SSPC-SP-10 for
(CS) CS, LTCS & Alloy
steel.
1 coat of F-16
-180 to 400 SSPC-SP-7 for SS
@ 125µ
11.3.2 (SS) (15-25µ surface None 250 Note-3
DFT/coat
profile)
-29 to 650 1 coat of F-16 @
(LAS) 125µ DFT/coat

Notes

1. In case of overlapping of cyclic temperature ranges as mentioned in 11.3.1 and 11.3.2 then
clause 11.3.1 shall be followed.
2. Alternatively, for this temperature range, 1 coat of F-17 @ 400 μ is also acceptable.
3. The coating system applicable for any other temperature range shall be reviewed if it is
encountered.
General notes for TABLE-11:
1. “Cyclic Service” is characterized by rapid or periodical temperature fluctuation or temperature
cycles.
2. The blasting abrasives for SS and alloy steels shall be aluminum oxide or garnet only.
3. For insulated vessels & equipment scope of surface preparation, application of primers to finish
coat including repair shall be as per applicable contractual documents like SOR , MR, PR etc.

TABLE-12: COATING SYSTEMS (INTERNAL PROTECTION) FOR CARBON STEEL

COMPONENTS OF COOLERS/CONDENSERS WITH FRESH COOLING
WATER SERVICE
Coating System Total
Surface Final
Design
Sl. Preparation & DFT Rema-
Temp. in
No. o Pre-erection/Shop Primer Finish paint in rks
C
Primer Microns
(min.)
1 coat of F- 2 coats of F-15
12.1 Up to 80 SSPC-SP-10 15 @ 80 µ @ 80 80 µ 240 -
DFT/coat DFT/coat
2 coats of F-
12.2 81 to 150 SSPC-SP-10 --- 1000 -
17@ 500μ/coat

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TABLE-13: COATING SYSTEM (INTERNAL PROTECTION) FOR GALVANIZED OR NON

FERROUS OR STAINLESS STEEL/ DUPLEX STAINLESS STEEL
COMPONENTS OF COOLERS/ CONDENSERS WITH FRESH COOLING
WATER SERVICE

Coating System Total

Surface
Final
Design Preparation &
Sl. DFT Rema-
Temp. in Pre-
No. o Primer Finish paint in rks
C erection/Shop
Microns
Primer
(min.)
1 coat of F-15 2 coats of F-15
13.1 Up to 80 Sweep Blasting @ 80µ @ 80µ 240 -
DFT/coat; DFT/coat;

2 coat of F-17@
13.2 81 to 150 Sweep Blasting - 1000 -
500μ/coat

Note:
Coating systems in Table – 12 & 13 are applicable only as per the requirement specified in
the data sheets of the respective exchangers/equipment.

8.0 STORAGE
8.1 All paints and painting materials shall be stored in rooms only which are to be
arranged by CONTRACTOR and approved by Engineer-In-Charge for the purpose.
All necessary precautions shall be taken to prevent fire. The storage building shall
preferably be separate from adjacent building. A signboard bearing the word
“PAINT STORAGE- NO NAKED LIGHT-HIGHLY INFLAMMABLE” shall be clearly
displayed outside. Manufacturers’ recommendation shall be followed for storage of
paint materials.

9.0 COLOUR CODE

The colour coding system as per Table-14 shall be followed.

TABLE-14: COLOUR CODING

SR. SERVICE RECOMMENDED COLOUR RAL COLOUR CODE

No. FOR PAINT SYSTEM BASE BAND
COLOUR COLOUR

HYDROCARBON LINES (UNINSULATED)

‘
1 CRUDE SOUR Dark Admiralty grey with 1 7012 2011
orange band
2 CRUDE SWEET Dark Admiralty grey with 1 red 7012 3001

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band
3 LUBE OILS Dark Admiralty grey with 1 green 7012 6010
band
4 FLARE LINES Heat Resistant Aluminium 9006
5 LPG Orange with 1 oxide red band 2011 3009
6 PROPYLENE Orange with 2 blue bands 2011 5013
7 NAPTHA Orange with 1 green band 2011 6010
8 M.S. Orange with 1 dark admiralty 2011 7012
grey band
9 AV.GASOLINE (96 Orange with 1 band each of 2011 6010 9010 3001
RON) green, white and red bands
10 GASOLINE (regular, Orange with 1 black band 2011 9005
leaded)
11 GASOLINE (premium, Orange with 1 blue band 2011 5013
leaded)
12 GASOLINE (white) Orange with 1 white band 2011 9010
13 GASOLINE (Aviation Orange with 1 red band 2011 3001
100/130)
14 GASOLINE (Aviation Orange with 1 purple band 2011 4006
115/145)
15 N-PENTANE Orange with 2 blue bands 2011 5013
16 DIESEL OIL (White) Oxide red with 1 white band 3009 9010
17 DIESEL OIL (Black) Oxide red with 1 yellow band 3009 1023
18 KEROSENE Oxide red with 1 green band 3009 6010
19 HY.KEROSENE Oxide red with 2 green bands 3009 6010
20 DISUFIDE OIL (EX- Oxide red with 1 black band 3009 9005
MEROX)
21 M.T.O Oxide red with 3 green bands 3009 6010
22 DHPPA Oxide red with 2 white bands 3009 9010
23 FLUSHING OIL Oxide red with 2 black bands 3009 9005
24 LAB FS Oxide red with 2 dark admiralty 3009 7012
grey bands
25 LAB RS Oxide red with 3 dark admiralty 3009 7012
grey bands
26 LAB (Off. Spec) Oxide red with 1 light grey band 3009 7035
27 N-PARAFFIN Oxide red with 1-blue band 3009 5013
28 HEAVY ALKYLATE Oxide red with red band 3009 3001
29 BLOW DOWN, VAPOR Off white / Aluminum with 1- 9006 8004
LINE Brown band
30 BLOWDOWN Off white / Aluminum with 2 9006 8004
brown bands
31 A.T.F. Leaf brown with 1 white band 8003 9010
32 TOULENE Leaf brown with 1 yellow band 8003 1023
33 BENZENE Leaf brown with 1 green band 8003 6010
34 LAB PRODUCT Leaf brown with 1 blue band 8003 5013
35 FUEL OIL Black with 1 yellow band 9005 1023
36 FULE OIL (Aromatic Black with 2 yellow bands 9005 1023
rich)
37 ASPHALT Black with 1 white band 9005 9010
38 SLOP AND WASTE Black with 1 orange band 9005 2011

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OILS
39 SLOP AROMATICS Black with 2 orange bands 9005 2011

CHEMICAL LINES

40 TRI-SODIUM Canary yellow with 1 violet band 1012 5000

PHOSPHATE
41 CAUSTIC SODA Canary yellow with 1 black band 1012 9005
42 SODIUM CHLORIDE Canary yellow with 1 white band 1012 9010
43 AMMONIA Canary yellow with 1 blue band 1012 5013
44 CORROSION Canary yellow with 1 Aluminum 1012 9006
INHIBITOR band
45 HEXAMETA Canary yellow with 2 black 1012 9005
PHOSPHATE bands
46 ACID LINES Golden Yellow with 1 red band 1004 3001
47 RICH AMINE Canary yellow with 2 blue bands 1012 5013
48 LEAN AMINE Canary yellow with 3 blue bands 1012 5013
49 SOLVENT Canary yellow with 1 green band 1012 6010
50 LCS Canary yellow with 1 smoke grey 1012 7031

WATER LINES

51 RAW WATER Sky blue with 1 black band 5015 9005

52 INDUSTRIAL WATER Sky blue with 2 signal red band 5015 3001
53 TREATED WATER Sky blue with 1 oxide red band 5015 3009
54 DRINKING WATER Sky blue with 1 green band 5015 6010
55 COOLING WATER Sky blue with 1 light brown band 5015 1011
56 SERVICE WATER Sky blue with 1 signal red brown 5015 3001
57 TEMPERED WATER Sky blue with 2 green bands 5015 6010

58 DM WATER Sky blue with 1 aluminum band 5015 9006

59 DM WATER ABOVE Sky blue with 2 black bands 5015 9005
150F
60 SOUR WATER Sky blue with 2 yellow bands 5015 1013
61 STRIPPED WATER Sky blue with 2 blue bands 5015 5013
62 ETP TREATED WATER Sky blue with 2 oxide red bands 5015 3009

FIRE PROTECTION SYSTEM (ABOVE GROUND)

63 FIRE WATER FOAM & Post office red 3002

EXTINGUISHERS

AIR & OTHER GAS LINES (UNINSULATED)

64 SERVICE AIR Yellow green with 1 signal red 6018 3001

band
65 INSTRUMENT AIR Yellow green with 1 black band 6018 9005
66 NITROGEN Yellow green with 1 orange band 6018 2011
67 FREON Yellow green with 1 yellow band 6018 1023

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68 CHLORINE Canary yellow with 1 oxide band 1012 3009

69 SO2 Canary yellow with 2 white 1012 9010
bands
70 H2S Orange with 2 red oxide bands 2011 3009
71 GAS (Fuel) Orange with 1 aluminum band 2011 9006
72 GAS (Sour) Orange with 2 aluminum bands 2011 9006
73 GAS (Sweet) Orange with 2 signal red band 2011 3001
74 HYDROGEN Orange with 1 light green band 2011 6021

STEAM AND CONDENSATE LINES (UNINSULATED)

75 HP STEAM Off white / Aluminum with 1 9006 1023

yellow band
76 MP STEAM Off white / Aluminum with 1 red 9006 3001
band
77 MLP STEAM Off white / Aluminum with 1 9006 2011
orange band
78 LP STEAM Off white / Aluminum with 1 light 9006 6021
green band
79 CONDENSATE Sky blue with 1 white band 5015 9010
80 CONDENSATE ABOVE Sky blue with 3 oxide red band 5015 3009
150F
81 BFW Sky blue with 2 red bands 5015 3001
Note: For all insulated steam lines, the colour coding shall be followed as given for un-insulated
lines with the specified length of colour bands.

INSULATED HYDROCARBON PIPING

82 IFO SUPPLY 1Black ground colour with 1

9005 1023
yellow band in centre
83 IFO RETURN Black ground colour with 1 green 9005 6010
band in centre
84 HPS Black ground colour with 1 red 9005 3001
band in centre
85 BITUMEN Black ground colour with 2 red 9005 3001
bands in centre
86 CLO Black ground colour with 1 9005 8004
brown band in centre
87 VB TAR Black ground colour with 2 9005 8004
brown bands in centre
88 VR AM (BITUMEN / 1 Black ground colour with 1 9005 5013
VBU FEED) blue band in centre
89 VR BH 1 Black ground colour with 2 9005 5013
blue bands in centre
90 VAC. SLOP 1 Black ground colour with 1 9005 9010
white band in centre
91 SLOP 1 Black ground colour with 1 9005 2011
orange band in centre
92 CRUDE SWEET 1 Dark admiralty grey ground 7012 3001
colour with 1 red band in centre

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93 CRUDE OUR 1 Dark admiralty grey ground 7012 2011

colour with 1 orange band in
centre
94 VGO / HCU 1 Oxide red ground colour with 2 3009 7011
steel grey bands in centre
95 OHCU BOTOM / FCCU 1 Oxide red ground colour with 2 3009 7011
FEED steel grey bands in centre

UNINSULATED EQUIPMENT, TANKS AND STRUCTURES

96 HEATER STRUCTURE Steel grey 7011

97 HEATER CASING Heat resistant aluminium 9006
98 VESSELS & COLUMNS Aluminium 9006
99 HYDROGEN BULLETS Pink 3014
100 LPG VESSELS Oxide red 3009
101 SO2 VESSEL Canary yellow 1012
102 HEAT EXCHANGER Heat resistant aluminium 9006
103 FO TANK AND HOT Black 9005
TANKS
104 ALL OTHER TANKS Aluminum / Off white 9006
105 CAUSTIC / AMINE / Golden yellow 1004
ACID TANKS
106 SOUR WATER Sky Blue 5015
107 OUTER SURFACE IN Heat resistant aluminum 9006
BOILER HOUSE
108 COMPRESSORS AND Dark admiralty grey 7012
BLOWERS
109 PUMPS Navy blue 5014
110 MOTORS & SWITCH Bluish green 5024
GEAR
111 HAND RAILING Signal red 3001
112 STAIRCASE, LADDER Black 9005
AND WALKWAYS
113 LOAD LIFTING Leaf brown 8003
EQUIPMENT AND
MONORAILS ETC
114 GENERAL Black 9005
STRUCTURE
115 FLUE GAS STACK Black 9005

PIPES AND FITTINGS OF ALLOY STEEL AND SS MATERIAL IN STORE

115 IBR Signal red 3001

116 9Cr-1Mo Verdigris green 6021
117 5Cr-0.5Mo Satin blue 5012
118 21/4Cr-1 Mo Aircraft yellow 1026
119 11/4Cr- ½ Mo Traffic Yellow 1023
120 SS-304 Dark blue grey 5008
121 SS-316 Dark violet 4005
122 SS-321 Navy blue 5014

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SAFETY COLOUR SCHEMES

123 DANGEROUS Black and alert orange band 9005 2008

OBSTRUCTION
124 DANGEROUS OR Alert orange 2008
EXPOSED PARTS OF
MACHINERY

General notes for table-14:

1. All LPG service PSVs shall be painted deep blue.
2. All drains & vents shall be painted in main line colour.
3. The colour code scheme is for identification of piping service group. It consists of a
ground colour and 1 / 2 colour bands.
.
9.1 Identification
The system of colour coding consists of a ground colour and secondary colour
bands superimposed over the ground colour. The ground colour identifies the basic
nature of the service and secondary colour band over the ground colour
distinguishes the particular service. The ground colour shall be applied over the
entire length of the un-insulated pipes. For insulated lines, ground colour shall be
provided as per specified length and interval to identify the basic nature of service
and secondary colour bands to be painted on these specified length to identify the
particular service. Above colour code is applicable for both unit and offsite pipelines.

9.2 Ground colour

On un-insulated pipes, the entire pipe has to be painted in ground colour. On metal
cladded insulated lines, minimum 2 m long portion should be painted.

9.3 Colour bands

9.3.1 Location of colour bands:

a. At battery limits.
b. Intersection points & change of direction points in piping.
c. Midway of piping section, near valves, across culverts.
d. At 50 m interval on long stretch pipes.
e. At starting and termination points.

9.3.2 Minimum width:

NB Width
3” and below 75 mm
Above 3” to 6” NB X 25 mm
Above 6” to 12” NB X 18 mm
Above 12” NB X 15 mm

For insulated pipes, NB indicates OD of the insulation.

Sequence: Colour bands shall be arranged in sequence as shown above and
the sequence follows the direction of flow. The width of the 1st Band to 2nd band
is 4:1.

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Wherever deemed required by process department or safety, pipes handling

hazardous substances will be given hazard marking of 30 mm wide diagonal
stripes of black and golden yellow as per IS : 2379.

9.4 Special camouflage painting for un-insulated crude and product storage tanks
Coating system shall be as per this standard.
Camouflage painting scheme for defense requirement in irregular patches will be
applied with 3 colours.

Dark green : Light green : Medium brown

5 : 3 : 2

a. The patches shall be irregular and asymmetrical and inclined at 30 to 60

degrees.
b. Patches should be continuous at surface meeting lines / points.
c. Slits / holes shall be painted in dark green shade.
d. Width of patches shall be 1 to 2 m.

9.5 Identification markings on equipment/piping

Equipment tag numbers shall be stenciled/neatly painted using normal ‘Arial’
lettering style on all equipment and piping (both insulated & un-insulated) after
completion of all paint works. Lettering colour shall be either black or white,
depending upon the background, so as to obtain good contrast.

Operations group shall specify the location of the marking.

Size of the making shall be as follows:
Columns, vessels, heaters : 150 mm
Pumps and other M/c machinery : 50 mm
Piping : OD / 2 with maximum 100 mm
Storage tanks : (as per drawings)

9.6 Colour coding for control valve

a) Carbon steel body : Light grey
Alloy steel body : Canary yellow
Stainless steel body : Natural

b) The actuator of the control valve shall be painted as:

Direct action (open on air failure) valves : Green
Reverse acting (close on air failure) valves : Red

The painting status shall be comprehensively updated every 6 months for

compliance.

10.0 IDENTIFICATION OF VESSELS, PIPING ETC.

10.1 Equipment number shall be stenciled in black or white on each vessel, column,
equipment & machinery (insulated or un-insulated) after painting. Line number in
black or white shall be stenciled on all the piping of more than one location as
directed by Engineer-In-Charge. Size of letter printed shall be as below:

Column & vessels : 150 mm (high)

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Pump, compressor & other machinery : 50 mm (high)

Piping : 40-150 mm

10.2 Identification of storage tanks

The storage tanks shall be marked as detailed in the drawing.

11.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS

11.1 The following items shall be painted for camouflaging, if required by the client:
a. All columns
b. All tanks in offsite
c. Large vessels
d. Spheres

11.2 Two coats of selected finishing paint as per defence requirement shall be applied in
a particular pattern as per clause 11.3 and as per the instructions of Engineer-In-
Charge.

11.3 Method of camouflaging

11.3.1 Disruptive painting for camouflaging shall be done in three colours in the ratio of
5:3:2 (all matte finish).

Dark Green Light Green Dark Medium Brown

5 : 3 : 2

11.3.2 The patches should be asymmetrical and irregular.

11.3.3 The patches should be inclined at 30º to 60º to the horizontal.
11.3.4 The patches should be continuous where two surfaces meet at an angle.
11.3.5 The patches should not coincide with the corners.
11.3.6 Slits and holes shall be painted in dark shades.
11.3.7 Width of patches should be 1 to 2 m.

12.0 QUALITY CONTROL, INSPECTION AND TESTING

12.1 All painting materials including primers and thinners brought to site by CONTRACTOR
for application shall be procured directly from manufactures as per specifications and
shall be accompanied by manufacturers’ test certificates. Paint formulations without
certificates are not acceptable (see section 14.0 & 15.0).

12.2 The CONTRACTOR must produce test certificate from pre qualified paint
manufacturer for various tests as detailed out in section 15.0 of this document. The
Engineer-In-Charge shall have the right to test wet samples of paint at random for
verifying quality of paint supplied. CONTRACTOR shall arrange to have such tests,
when required by Engineer-in-Charge, performed at his cost at any one of the NABL
accredited laboratories.

Samples for the test will be drawn at random in presence Engineer-In-Charge or his
representations. Following tests to be carried out if called for by Engineer-in-Charge:

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- Specific Gravity
- % solids by weight (% zinc content in case of inorganic or organic zinc primer)
- Drying time (touch dry & full curing)
- Adhesion
- Storage stability (pot life)

Test methods for above tests shall be as per relevant ASTM or ISO Standard.

12.3 The painting work shall be subject to inspection by Engineer-In-Charge at all times. In
particular, following stage-wise inspection will be performed and CONTRACTOR shall
offer the work for inspection and approval of every stage before proceeding with the
next stage. The record of inspection shall be maintained in the registers. Stages of
inspection are as follows:

a) Surface preparation
b) Primer application
c) Each coat of paint

Following tests are to be carried out during surface preparation:

- Test for presence of oil/grease and contamination

The steel substrate after degreasing as per SSPC-SP-1 shall be tested as per
following procedure to validate absence of oil and grease contamination:

a) Visual inspection - continue degreasing until all visible signs of contamination are
removed.
b) Conduct a solvent evaporation test by applying several drops or a small splash of
residue-free tri-chloromethane on the suspect area especially pitting, crevice
corrosion areas or depressed areas. An evaporation ring formation is indicative of
oil and grease contamination. Continue degreasing and inspection till test is
passed.
- Tests for surface finish of blasted surface shall be done by visual inspection
using SSPC-VIS1. Clear cellophane tape test as per ISO 8502-3 shall be used
to confirm absence of dust on blasted surface. Checks shall be done on each
component at least once per 200 m2 of blasted surface and a minimum of 3
checks per shift.
- Test for presence of soluble salt as per method ISO 8502-9. Maximum allowable
salt content shall be considered 20 mg/m2.Checks shall be done on each
component at least once per 200 m2 of blasted surface and minimum of 3
checks per shift. In case salt exceeds specified limit, the contaminated surface
shall be cleaned by method as per Annexure-C of IS 12944-4 (water cleaning).
After cleaning, surface shall be retested for salt after drying.
Blast Profile Measurement: (In-Process testing during actual production before
application coating)

The angular profile depth measurement shall be done by profile tape as per method
NACE Standard RP 0287 or ASTM D 4417 method B (Profile depth gauge
micrometer). Spot measurement shall be carried out every 15m2 of blasted surface.

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At each spot three measurements shall be taken over an area of 10 cm 2 and

average of measurements to be recorded and reported.
If profile is <65 microns blasting shall continue till grater than 65 microns depth
profile is achieved.
-
Tests for blasting media, blasting air

Blasting Media (For every fresh batch of media and one random test during
blasting)

Blasting Media shall be visually inspected for absence of contamination and debris
using 10 X magnification.

a) Inspection for the absence of oil contamination shall be conducted using

following procedure :
- Fill a small clean 200 ml bottle half full of abrasive.
- Fill the bottle with potable water, cap and shake the bottle.
- Inspect water for oil film/slick. If present, the blasting media is not to be
used.

b) Soluble salt contamination if suspected shall be verified by method ASTM D

4940. If present, media to be replaced.

c) Clean blasting equipment, especially pot and hoses, and then replace
blasting media and retest.

Test for Blasting Air (Once Daily before start of blasting and once at random during
blasting)

The air for blasting shall be free from moisture and oil. The compressor air shall be
checked for oil and water contamination per ASTM D 4285.

In addition to above, record should include type of shop primer already applied on
equipment e.g. zinc silicate or zinc rich epoxy or zinc phosphate. Any defect noticed
during the various stages of inspection shall be rectified by the CONTRACTOR to the
entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, CONTRACTOR shall
be responsible for rectifying any defects found during final inspection/guarantee
period/defect liability period as defined in general conditions of the contract. Dry film
thickness (DFT) shall be checked and recorded after application of each coat and
extra coat of paint should be applied to make-up the DFT specified without any extra
cost to OWNER, the extra coat should have prior approval of Engineer-in-charge.

12.4 Final inspection of finished coating shall consist of the following:

1) Coating dry film thickness check: DFT measurement shall be as per ISO 2808.
Type II electromagnetic gauges should be used for ferrous substrates. DFT gauge
calibration, number of measurement shall be as per SSPC-DA-2. Measured DFT
shall be within + 10% of the dry film thickness, specified in the specifications.

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2) Adhesion testing: Adhesion of the primer to the steel substrate and inter-coat
adhesion of the subsequent coat(s) after curing for at least a week after application
of the topcoat shall be examined by a knife test in accordance with ASTM D6677.
For the knife test, if the rating is better than 8, the adhesion is considered
acceptable. The adhesion is destructive and tested areas shall be repaired
afterward using the spot repair procedure. Alternatively, the applicator may perform
the adhesion test on a steel panel coated using the same surface preparation and
coating application procedure as the work piece. Adhesion testing shall be carried
out for each component at least once per 200 m2 of coated surface.

3) Holiday detection check: Holiday testing shall be conducted in accordance with

NACE SP0188. For immersion services, 100% of coated area shall be inspected
for holidays. For atmospheric exposure, 10% of coated area which must include
weld seams, corners and edges to be holiday tested. Voltage at which test is to be
carried out will depend upon DFT of coating being tested and shall be as per NACE
SP0188. Any holiday is unacceptable and should be marked and repaired
immediately.

The CONTRACTOR shall arrange for spot checking of paint materials for specific
gravity, glow time (ford cup) and spreading rate.

13.0 GUARANTEE
The CONTRACTOR shall guarantee that the chemical and physical properties of
paint materials used are in accordance with the specifications contained herein/to be
provided during execution of work.

14.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR/SUB-CONTRACTOR

Painting CONTRACTOR who is awarded any job for EIL, Projects under this
standard must have necessary equipment, machinery, tools and tackles for surface
preparation, paint application and inspection. The CONTRACTOR must have
qualified, trained and experienced surface preparator, paint applicator, inspector and
supervisors. The CONTRACTOR supervisor, inspector, surface preparator and paint
applicator must be conversant with the standards referred in this specification.

15.0 QUALIFICATION/ACCEPTANCE CRITERIA FOR PAINT COATING SYSTEM

15.1 Pre-qualification of paint coating manufacturer and his products

Paint manufacturer meeting the following requirements shall be considered by the
CONTRACTOR for supply of the paint products.

- Manufacturer should have been in continuous business of paint coating formulation

and manufacturer for at least past 5 years.
- Manufacturer should posses past experience of supplying his products to
hydrocarbon, petrochemical, fertilizer. Chemical processing industry or offshore
platforms in the past 5 years.
- Coating manufacturer should have supplied at least 10000 litre of an individual
product to hydrocarbon, petrochemical, fertilizer. Chemical processing industry or
offshore platforms.
- The manufacturer’s manufacturing procedure & QA/QC system shall meet ISO
9001 requirements and preferably should posses ISO 14000 certificate.

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- The Quality control set up should be manned by qualified paint technologists

whose bio data should be sent along with quality control organization chart.

CONTRACTOR shall procure the paint materials from the qualified manufacturer
meeting above requirements and after obtaining prequalification testing approval as
per requirements mentioned in clause 15.2 below.

15.2 Pre-Qualification Testing procedure:

The paint manufacturer engaged by the mechanical contractor shall carry out the
tests in NABL accredited government laboratories like national test house (NTH), as
a part of qualification. Paint manufacturer shall provide the paint samples to
laboratory for testing of the parameters mentioned in Table-2 (typical characteristics)
and Table-15 (tests on coating systems) of this specification. The testing laboratory
will confirm the compliance of the paint material with respect to the acceptance
criteria mentioned in the respective tables. Contractor shall furnish these test
certificates along with all necessary supporting documents/information to EIL site for
approval/ acceptance. The paint manufacturer will be qualified and approved by EIL
site for supply of paints after review/assessment of the submissions made by the
contractor. Test certificates which are more than 3 years old will not be considered.
Paint manufacturers are advised to carryout pre-qualification testing accordingly for
paints supply to EIL projects.

TABLE-15: PRE-QUALIFICATION TESTING

SYSTEM REFERENCE CLAUSE TOTAL DFT μ

COATING SYSTEM
No. (from table-3 to 12) (min)
1. F-9+P6+F6B+F2 6.2 345
2. F12+F12+F12 6.4 60
3. F15+F15+F15 9.1.1 240
4. F16+F16 8.3.1 250
5. F17 9.10.1 375
6. F8+F8 9.8.1 200
7. F20+F20 9.5.1 1100
8. F6A+F6C+F6C 9.4.1 500
9. F6A+F6A+F6A 9.3.1 300

FOR
ACCEPTANCE
S. No. TEST SYSTEM DURATION
CRITERIA
NUMBER
Cyclic Test Shall pass.
Salt Spray : 72 hrs. No chalking,
Drying in air: 16 hrs. cracking,
1. UV-A340 nm weather meter: 80 hrs. 1 4200 hrs flaking,
One cycle: 168 hrs. blistering or
(25 cycles at 168 hrs. each cycle) peeling shall be
(ASTM D5894) observed.

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2. Chemical Resistance Test (ASTM D543)

2a. 10% & 40% NaOH 1000 hrs

2b. 5% H2SO4 168 hrs

Shall pass.
3,5,7 & 9*
4 weeks No cracking,
2c. Xylene
discoloration,
2d. *H2SO4 4 weeks
Acetone blistering,
solution pH
peeling or
= 5.0 to 4 weeks
2e. Ethanol 5.5 for softening of film
system 10 4 weeks shall be
2f. Kerosene observed.

2g. Sea water 2000 hrs

Immersion in DM/DI water @900 3,5 & 7 30 days No softening,

3.
(ASTM C868) blistering or film
damage.
Shall pass.
No chalking,
Resistance to DM water using water cracking,
4. 8 2000 hrs
immersion. (ASTM D870) flaking,
blistering or
peeling.

1 to 9
100% Humidity Test
5. (except 1440 hrs Shall pass
(ASTM D2247)
system-2 )

2,3 & 4

(For
Thermal Shock Resistance Test;
system-2,
5 cycles @ 30 minutes in furnace at
testing to Shall pass
6. 120 ⁰ C and 15 minutes in water after -
be done
quenching in water for each cycle.
after
(ASTM D2485 method A)
heating the
panels at
175°C for
2 hrs.)
Cathodic Disbondment Test
7. 3&5 - Shall pass
(ASTM G8 @60°C)

Each coating product to be qualified shall be identified by the following:

1) Specific gravity of Base and curing agent (Ref. ISO 2811)

2) Ash content (ASTM D1650), volatile and non-volatile matters (ISO 3251) of each
component
The identification shall be carried out on the batch, which is used for the Pre-
qualification testing.

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15.3 Information to be furnished during delivery of paint materials:

CONTRACTOR along with delivery of paint material has to furnish following

information from paint manufacturer to EIL for acceptance/approval of products:

a) Batch test certificates:

Along with paint products delivery to site from the pre-qualified coating
manufacturer, CONTRACTOR has to produce test certificate (from paint
manufacturer) for each category of product for the following test items. All test
results must mention clearly the batch no. and category of product tested. Tests
to be conducted for following properties:

- Specific Gravity
- % solids by weight (% zinc content in case of inorganic or organic zinc primer)

b) Product information sheet/ technical data sheet for each category of product.

The contractor shall be fully responsible for the quality of the paints products as
per prequalification testing. After the paint materials are supplied to site, the
supplier shall organize random sampling and testing in a NABL laboratory as
per discretion of the Engineer-in-charge. Failing to meet the specified quality
requirements may cause rejection of the paint products.

16.0 METHOD OF SAMPLING & DISPATCH FOR LABORATORY TESTING

(Pre-Qualification tests (sec. 15.2), Batch testing (sec. 15.3) and Inspection testing
(sec. 12.0))
16.1 Samples of coating materials should be submitted to the laboratory in sealed
containers with batch no. and test certificate on regular format of manufacturer’s
testing laboratory.
16.2 All test panels should be prepared by testing laboratory. Surface preparation for a
system shall be done in accordance with this specification. For individual products
testing, minimum shall be Sa 2.5. Colour photographs of test panels should be
taken before and after the test and should be enclosed along with test report.
Sample batch no. and manufacturer’s test certificate should be enclosed along with
the report. Test report must contain details of observation and rusting if any, as per
the testing code.
16.3 Manufacturers should intimate EIL, details of sample submitted for testing, name of
testing agency, date, and contact personnel of the testing agency.

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 Document No.
VENDOR DATA REQUIREMENTS B224-111-2-42-VDR-0001
FOR Rev. B
COLUMN INTERNALS Page 1 of 2

VENDOR DATA REQUIREMENTS

FOR
COLUMN INTERNALS

B 21-OCT-2020 ISSUED WITH PR HD RS RS

A 27-JUN-2019 ISSUED WITH MR HD RS SKS
Rev. Date Purpose Prepared by Checked by Approved by
No.

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 Document No.
VENDOR DATA REQUIREMENTS B224-111-2-42-VDR-0001
FOR Rev. B
COLUMN INTERNALS Page 2 of 2

VENDOR DATA REQUIREMENTS

The following drawings/documents marked " " shall be furnished by the bidder.

POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. TECHNICAL INFORMATION FOR TOWER
PACKING (ATTACHMENT- 1)
2. FILLED IN DATASHEET (ATTACHMENT-2)
3. HYDRAULIC DESIGN CALCULATIONS /
COMPUTER OUTPUTS
4. HYDRAULIC DESIGN CALCULATIONS FOR
OTHER COLUMN INTERNALS SUCH AS
CHIMNEY TRAY, LIQUID DISTRIBUTOR
GIVING DETAILS OF NO. OF HOLES, HOLE
DIA, LIQUID HEADS, FLOW VARIATION,
ETC.

Notes :
1. "TICK" denotes applicability.
2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
3. All post order documents shall be submitted / approved through EIL eDMS portal.

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

Page 281 of 674

 RAJATHAN REFINERY PROJECTREV.
A
DATE
22.08.2019
REVISION
ISSUED FOR MR
BY
SAGAR
CHECKED
RMD
APPD.
SP
APPD.

HRRL B 21.10.2020 ISSUED FOR PR SAGAR RMD SP

THREAD
LENGTH
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they

LOCK NUT
NUT
will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

WASHER
T

ANCHOR CHAIR
P=900

10

(T.O.C) GROUT
~

~
K
CONCRETE THICKNESS

PIPE SLEEVE
**INDICATED DIMENSION ONLY & FINAL VALUE
ANCHOR BOLT SHALL BE PROVIDED DURING DETAIL ENGINEERING,
Ø
H

BEFORE MANUFACTURING OF BOLTS PACKAGE

CONTRACTOR NEED TO GET THIS DRAWING
APPROVED BY CLIENT/ PMC/ DE CONTRACTOR.
CIRCULAR BEARING
PLATE
~

~
T
t

NUT
10

LOCK NUT
THREAD
LENGTH

Db
(DIAMETER)

ELEVATION

NOTES:-
1. ANCHOR BOLT ROD MATERIAL SHALL CONFORM TO ASTM SA193 GR. B7.
2. THREADS SHALL CONF0RM TO ASME B1.1 8-UN SERIES HAVING CLASS 2A TOLERANCE FOR BOLT.
3. NUTS AND WASHERS SHALL CONFORM TO ASTM SA 194 GR. 2H AND ASTM F436 RESPECTIVELY.
4. PIPE SLEEVE SHALL BE OF SCHEDULE XS CONFORMING TO ASTM SA 106 GR. B.
5. BEARING PLATE & SUPPORT PLATE SHALL CONFORM TO ASTM SA 516 GR. 70.
6. CONCRETE GRADE SHALL BE M35.
7. MINIMUM EDGE DISTANCE OF ANCHOR BOLT FROM R.C.C. PEDESTAL FACE SHALL BE 6 X DIA OF BOLT.
8. MINIMUM BOLT TO BOLT SPACING SHALL BE 4 X DIA OF BOLT & MAXIMUM BOLT TO DOWEL BAR DISTANCE
SHALL NOT EXCEED L/3.

TABLE 1:-
BOLT DIA. H** T DET. OF BEARING PLATE K
Ø (mm) (mm) (mm) Db (mm) t 1 (mm) (mm)
M72 2000 - 2500 240 385 85 150

FCC DRAWING NO. REV.

ENGINEERS INDIA LIMITED ANCHOR BOLT ASSEMBLY DETAIL B224-111-81-41-46901 B
NEW DELHI FOR MAIN FRACTIONATOR
111-C-2101
1-1641-0504 REV.0 A4-210x297

Page 282 of 674

 VENDOR LIST STRUCTURAL WORKS DOCUMENT No.
LADDERS & PLATFORMS FOR B224-111-81-41-LL-6006
COLUMNS OF PFCC UNIT, Rev. A
RAJASTHAN REFINERY PROJECT
Page 1 of 5
(HRRL)

VENDOR LIST
FOR
STRUCTURAL WORKS

PROJECT : RAJASTHAN REFINERY PROJECT

UNIT : 111

OWNER : HPCL Rajasthan Refinery Ltd. (HRRL)

PMC : EIL

JOB NO. : B224

A 11.06.2019 ISSUED FOR MR VV RMD BNM

Rev. Prepared Checked Approved
Date Purpose
No. by by by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 283 of 674

 Date :29/05/2019 11:53:55
Potential Suppliers List
Page 1 of 4

Sr No Supplier Name City Phone E-Mail Remarks

Department : STRCTL
Area of Experience: Other
Item : A. INTEGRAL WATER-PROOFING COMPOUNDS FOR CONCRETE (AS PER IS:2645)
1 KRYTON BUILDMAT CO PVT LTD DELHI ,, BRAND NAME-KIM
(CRYSTALLINE TYPE)
2 XYPEX CHEMICAL CORP. (THROUGH NOIDA ,, BRAND NAME-XYPEX ADMIX
M/S APAAR INFRA PVT LTD) C-2000 (CRYSTALLINE TYPE)
3 ZZ-Refer Remarks (ZZ inserted to India ,, NA All other Integral Waterproofing
maintain the alphabetic chronology) Compounds for Concrete which
carry "ISI" certification mark of BIS
along with standard number "IS
2645" and the license number
"CM/L**....*)" and listed at BIS
website "http://www.bis.org.in".
Item : B. CONCRETE ADMIXTURES -(AS PER IS:9103
1 Refer Remark India ,, All Accelerating, Retarding,
Water-reducing, Air-entraining &
Super-plastizing Admixtures for
067054055055 Concrete which carry "ISI"
certification mark of BIS along with
standard number "IS 9103" and the
license number "CM/L**....*)" and
listed at BIS website
"http://www.bis.org.in".
Item : C. BI-POLAR CONCRETE PENETRATING CORROSION INHIBITING ADMIXTURE (AS PER EIL STD SPEC NO 6-68-0017)
1 BASF INDIA LTD DELHI ,, PRODUCT NAME- MASTERLIFE
CI 220 (DOSAGE 1% W/W OF
CEMENT)
2 CLEAN COATS PVT LTD THANE ,, PRODUCT NAME-CONPROOF IA
(DOSAGE 1% W/W OF CEMENT)
3 KRISHNA CONCHEM PRODUCTS PVT NAVI MUMBAI ,, PRODUCT NAME-EPCO KP-200
LTD (DOSAGE 1% W/W OF CEMENT)
4 STP LTD. DELHI ,, PRODUCT NAME-SHALIPLAST
MCI (DOSAGE 1% W/W OF
CEMENT)
5 SUNANDA SPECIALITY COATING MUMBAI ,, PRODUCT NAME-POLYALK CP
PVT LTD 293 (DOSAGE 1% W/W OF
CEMENT)
Item : D. POLYSULPHIDE SEALANTS (TWO PART, AS PER IS:12118)

067054055055
Copyrights EIL - All rights reserved

Page 284 of 674

 Date :29/05/2019 11:53:55
Potential Suppliers List
Page 2 of 4

Sr No Supplier Name City Phone E-Mail Remarks

1 CHOWKSEY CHEMICALS PVT LTD MUMBAI ,, PRODUCT NAME-TECHSEAL
940/941
2 CICO TECHNOLOGIES LIMITED DELHI ,, PRODUCT NAME-CICO SEAL T680
3 DON CONSTRUCTION CHEMICALS CHENNAI ,, BRAND NAME- 1. FLEXSEAL
INDIA LTD PS660 (GUN GRADE) 2. FLEXSEAL
PS660 (POUR GRADE)
4 DURA BUILD CARE PVT LTD DELHI ,, PRODUCT NAME- DURASIL PPS
(POURING GRADE)
5 FOSROC CHEMICAL (I) PVT LTD DELHI ,, PRODUCT NAME-THIOFLEX 600
6 PERMA CONSTRUCTION AIDS PVT MUMBAI ,, PRODUCT NAME- 1. PERMA
LTD POLYSEAL (GUN GRADE) 2.
PERMA POLYSEAL (POUR
GRADE)
7 PIDILITE INDUSTRIES LTD (DR. FIXIT) MUMBAI ,, PRODUCT NAME-1. PIDISEAL
PS41G, 2. PIDISEAL PS42P
8 SIKA INDIA PVT LTD KOLKATA ,, BRAND NAME- 1. SIKA
POLYSULPHIDE (SIKALASTIC) 2.
SIKAFLEX CONSTRUCTION 3.
IGAS Ih
067054055055
9 STP LIMITED NEW DELHI ,, PRODUCT NAME- SHALISEAL PS
10 ZZ-Refer Remarks (ZZ inserted to India ,, NA All other Polysulphide Sealants
maintain the alphabetic chronology) (Two Parts) which carry "ISI"
certification mark of BIS along with
standard number "IS 12118" and the
license number "CM/L**....*)" and
listed at BIS website
"http://www.bis.org.in".
Item : E. ANCHOR FASTENERS - CHEMICAL TYPE (EOTA / DIBt/ FM/ ICBO-ES APPROVED)
1 FISCHER FIXING SYSTEMS(MICO) BENGALURU ,, BRAND NAME-FISCHER
LTD ANCHORS
2 HILTI INDIA PVT LTD DELHI ,, BRAND NAME-HILTI ANCHORS
3 MARION WUERTH INDIA PVT LTD DELHI ,, BRAND NAME-WUERTH
ANCHORS
4 POWERS FASTENERS(THROUGH M/S PUNE ,, NA BRAND NAME-POWERS
KRAFT SALES & SERVICES (I) LTD.) FASTENERS
5 UIP SYSTEMS (INDIA) PVT LTD Mumbai ,, UIP FASTENERS
Item : F. ANCHOR FASTENERS - MECHANICAL TYPE (EOTA / DIBT/ FM/ ICBO-ES APPROVED)
1 FISCHER FIXING SYSTEMS(MICO) BENGALURU ,, BRAND NAME-FISCHER
LTD ANCHORS
2 HILTI INDIA PVT LTD DELHI ,, BRAND NAME-HILTI ANCHORS

067054055055
Copyrights EIL - All rights reserved

Page 285 of 674

 Date :29/05/2019 11:53:55
Potential Suppliers List
Page 3 of 4

Sr No Supplier Name City Phone E-Mail Remarks

3 MARION WUERTH INDIA PVT LTD DELHI ,, PRODUCT NAME- WUERTH
ANCHORS
4 POWERS FASTENERS(THROUGH M/S PUNE ,, NA BRAND NAME-POWERS
KRAFT SALES & SERVICES (I) LTD.) FASTENERS
5 UIP SYSTEMS (INDIA) PVT LTD Mumbai ,, UIP FASTENERS
Item : G. ELECTRO-FORGED GALVANISED GRATINGS (AS PER EIL STD 7-68-0697, BS:4592)
1 BHOLA RAM STEEL PVT LTD PATNA ,, BRAND NAME-BHOLARAM
GRATINGS
2 CELLCOM TELESERVICES PVT LTD SIKANDRABAD ,, BRAND NAME-CELLCOM
GRATINGS
3 GREATWELD STEEL GRATINGS PUNE ,, BRAND NAME-GREATWELD
PVT.LTD GRATINGS
4 INDIANA GRATING PVT.LTD MUMBAI ,, BRAND NAME-INDIANA
GRATINGS
5 JACINTH ENGINEERING PVT LTD MUMBAI ,, BRAND NAME-JACINTH
GRATINGS
6 KANADE ANAND UDYOG PVT LTD MUMBAI ,, BRAND NAME-KANADE
GRATINGS
7 OMKAR GRATINGS PVT LTD MUMBAI ,,
067054055055 BRAND NAME-OMKAR
GRATINGS (FOR EIL TYPE-II
GRATING ONLY)
8 PINAX STEEL INDUSTRIES PVT LTD KOLKATA ,, BRAND NAME-PINAX GRATINGS
9 PREMIER POWER PRODUCTS PVT KOLKATA ,, BRAND NAME-PREMIER
LTD GRATINGS
10 RATAN PROJECTS & ENGINEERING KOLKATTA ,, BRAND NAME- RATAN
CO.PVT LTD. GRATINGS
11 SUTTATTI ENTERPRISES LTD PUNE ,, BRAND NAME-SUTTATTI
GRATINGS
12 VINFAB GRATINGS MUMBAI ,, BRAND NAME-VINFAB
GRATINGS
13 WHEELS INDIA LTD CHENNAI ,, PRODUCT NAME-WHEELS
GRATINGS
Item : H. IN HOUSE CIVIL & CIVIL RELATED JOBS
1 ACE India 9810482871, , [email protected]
2 ARSH CONSTRUCTIONS 9810732288, , [email protected],
[email protected]
3 AVM Constructions , , 9873625131 [email protected]
4 DKD PROJECTS PVT LTD 9810877557, , 9811735667 [email protected]

067054055055
Copyrights EIL - All rights reserved

Page 286 of 674

 Date :29/05/2019 11:53:55
Potential Suppliers List
Page 4 of 4

Sr No Supplier Name City Phone E-Mail Remarks

5 DYNAMIC ENGINEERS NEW DELHI 011-24675421, 9810041071, [email protected]
,
6 ESS DEE Industries , , 9810111055 [email protected]
7 M/s Harish Kumar 9810785777, , [email protected]
8 MSR ASSOCIATES NEW DELHI 9810265737, 9810265831, , [email protected]
9 SSA Techno Construction Pvt Ltd , , 9871855887 [email protected]

067054055055

067054055055
Copyrights EIL - All rights reserved

Page 287 of 674

 SCHEDULE OF QUANTITIES Document No.
LADDERS & PLATFORMS FOR COLUMNS B224-111-81-41-SOQ-6006
OF PFCC UNIT Rev No B
(STRUCTURAL) Page 1 of 3

SCHEDULE OF QUANTITIES

LADDERS & PLATFORMS FOR COLUMNS

(111-C-2101) PFCC UNIT

(MR NO.: B224-111-CC-MR-6006)

(STRUCTURAL)

PROJECT : RAJASTHAN REFINERY PROJECT (RRP)

OWNER : HPCL Rajasthan Refinery Ltd. (HRRL)

B 21.10.2020 ISSUED WITH PR VV RMD/RK VKG

A 11.06.2019 ISSUED WITH MR VV RMD BNM

Rev No Date Purpose Prepared by Reviewed by Approved by

Template No 5-0000-0001-T3 Rev 1 Copyrights EIL – All rights reserved

Page 288 of 674

 SCHEDULE OF QUANTITIES Document No.
LADDERS & PLATFORMS FOR COLUMNS B224-111-81-41-SOQ-6006
OF PFCC UNIT Rev No B
(STRUCTURAL) Page 2 of 3

SL.NO. DESCRIPTION OF ITEMS UNIT B224-111

111-C-2101

STRUCTURAL MAIN FRACTIONATOR

Refer Item Description at S. No. 1

1. Below MT 25 - - -

Refer Item Description at S. No. 2

2. Below MT 8 - - -

Refer Item Description at S. No. 3

3. Below M 300 - - -

ITEM DESCRIPTION:-
S. No. Item Description

Supplying & fabricating bolted and/ or welded structural steel works of Grade E250 A/B0/BR (conforming to IS:2062) comprising of rolled/ built-up sections made of joists, channels, angles, flats rounds, plates cut and/ or bent to any shape and size, in beams, girders,
1. trusses columns, brackets, bracings, ladders (with or without cage), safety chain brackets, staircases and platforms of any shape and size (excluding chequered plates/ gratings), on vertical and/ or horizontal equipments, in miscellaneous valve operating platforms,
pipe supports etc., including preparation and submission of all fabrication drawings, straightening, cutting and/ or bending the steel to required size/ shape, edge preparation, preheating, bolting, welding of joints (including sealing of joints of box sections with
continuous welding wherever shown), grinding the prepared edges/ surfaces to a smooth finish, preparation of surfaces and applying shop primer as per Job Specification No. B224-000-79-41-PLS-01 after fabrication, Including touching up of shop primer coat as per
SI.No. 3.1 of Table 3.0 of Job specification B224-000-79-41-PLS-01 for steel structures (excluding ladders, spiral stairways & handrails) at all location & levels etc., Supplying and applying final coating system of approved quality and shade as per SI. No.6.2 of Table
6.0 of Job Specification B224-000-79-41-PLS-01 over the coat of shop primer already applied, including storage, surface preparation , degreasing, cleaning, drying, providing necessary arrangement for access, testing etc. all complete as specified, for unit (inland)
areas considering environment classification as industrial supply of all material in contractors’ s scope etc., all complete as shown, specified and directed. SUPPLY OF ALL MATERIAL IN PACKAGE VENDOR'S SCOPE.

Supplying & fabricating ELECTROFORGED GALVANISED GRATING (purchased from approved manufacturer by the PACKAGE VENDOR) conforming to EIL Standard No. 7-68-0697 (in walkways, platforms, stair treads etc.) including cutting to required size,
2. shape, making holes, notches, openings of required size, nosing, straightening if required, making the edges smooth, removing the burrs, providing manufacturer's supplied galvanized clamps, preparation and submission of fabrication drawings, all complete as
specified and directed.(SUPPLY OF ALL MATERIALS IN PACKAGE VENDOR'S SCOPE).

Supplying & fabricating ONLY TOP RAIL 32mm nominal diameter medium grade M.S. Tubes conforming to IS:1239 including straightening if required, cutting, welding, bending, surface preparation and coating system (including galvanisation , primer & final coat) as
3. per Table No:4 of Job specification No. B224-000-79-41-PLS-01, including storage, surface preparation, degreasing, cleaning, drying, providing necessary arrangement for access, testing etc. Including touching up of shop primer coat, for ladders, spiral stairways &
handrails at all location & levels, all complete as specified. Supply of all material in contractor’s scope. Preparation and submission of fabrication drawings etc. all complete as specified, shown and directed. (SUPPLY OF ALL MATERIALS IN PACKAGE VENDOR'S
SCOPE). (Complete handrail work shall be measured as length of top rail only and not length of each element fixed).

SPECIFIC INSTRUCTIONS:-
1) Bidder to ensure that all connections made for structural steel members are bolted connections and no field welds shall be envisaged.

2) Bidder to ensure that proper traceability is maintained right from preparation of drawing to identification of supplied parts at site. All fabrication drawings must contain the proper part number of the finished member being supplied loose and proper stencilling or punching is
carried out in the finished member at fabrication shop. The packing list must clearly specify these identification numbers along with the referred drawing so that after receipt of material at site, no problem is encountered at site.

3) During fabrication, bidder to ensure that the platform is pre-assembled at shop. Prior to detaching and packing, all parts are properly match marked so that no mismatch or missing members are encountered during erection at site.

4) In case the vendor’s stay at site for supervision erection gets extended due to such mismatches or missing members at site, the supervision charges shall not be considered tenable.

5) Refer Annexure-I of this document for considering rates for addition and deletion of any structure.

Template No 5-0000-0001-T3 Rev 1 Copyrights EIL – All rights reserved

Page 289 of 674

 SCHEDULE OF QUANTITIES Document No.
LADDERS & PLATFORMS FOR COLUMNS B224-111-81-41-SOQ-6006
OF PFCC UNIT Rev No B
(STRUCTURAL) Page 3 of 3

LIST OF APPLICABLE JOB STANDARDS/JOB SPECIFICATIONS (STRUCTURAL)

(For Structural steel works in platforms under scope of this MR)

S. No. STD. NO. DESCRIPTION OF STANDARD

1. 1 7-68-0507 Details of Steel Ladder
2. 2 7-68-0509 Steel ladder joint details.
3. 3 7-68-0512 Ladder support clips for hot vessels.
4. 4 7-68-0540 Platform details for horizontal hot vessels
5. 5 7-68-0546 Details of brackets for circular platforms of hot vessels
6. 6 7-68-0547 Platform support clips for hot vessels
7. 7 7-68-0552 Circular Platforms
8. 8 7-68-0553 Details of Brackets of Circular Platform
9. 9 7-68-0557 Platform support clips for hot vessels.
10. 10 7-68-0697 Electro forged Grating Type I or Type II
11. 11 6-68-0001 General Scope
12. 12 6-68-0002 Materials
13. 13 6-68-0006 Standard Specification for Structural Steel Works.
14. 14 6-68-0008 Miscellaneous steel works
15. 15 6-78-0001 Specification for quality management system from Bidders
16. 16 6-78-0003 Specification for documentation requirement from suppliers
17. 17 B224-000-79-41-PLS-01 Specification for surface preparation & protective coating

(SIGNATURE OF THE BIDDER)

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Page 290 of 674

 SCOPE OF WORK (STRUCTURAL) DOCUMENT No.
FOR LADDERS AND PLATFORMS FOR B224-111-81-41-SOW-6006
COLUMNS OF PFCC UNIT Rev. B
RAJASTHAN REFINERY PROJECT,
Page 1 of 8
HRRL

SCOPE OF WORK (STRUCTURAL)

FOR

LADDERS AND PLATFORMS FOR COLUMNS

(111-C-2101) PFCC UNIT
RAJASTHAN REFINERY PROJECT, HRRL

PROJECT : RAJASTHAN REFINERY PROJECT

UNIT : 111

OWNER : HPCL Rajasthan Refinery Ltd. (HRRL)

PMC : EIL

JOB NO. : B224

B 21.10.2020 ISSUED FOR PR VV RMD/RK VKG

A 11.06.2019 ISSUED FOR MR VV RMD BNM

Rev. Prepared Checked Approved
Date Purpose
No. by by by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 291 of 674

 SCOPE OF WORK (STRUCTURAL) DOCUMENT No.
FOR LADDERS AND PLATFORMS FOR B224-111-81-41-SOW-6006
COLUMNS OF PFCC UNIT Rev. B
RAJASTHAN REFINERY PROJECT,
Page 2 of 8
HRRL

TABLE OF CONTENTS

SL TITLE PAGE

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

2. SCOPE OF SUPPLY ................................................................................................................. 3

3. SPECIFIC REQUIREMENTS ................................................................................................. 3

4. LIST OF SPECIFICATIONS, STANDARDS & OTHER DOCUMENTS .......................... 4

5. PREAMBLE TO SCHEDULE OF QUANTITIES/ RATES ................................................. 5

6. ADDENDUM TO SPECIFICATIONS/ STANDARDS ......................................................... 5

7. SCHEDULE OF QUANTITIES/ RATES ............................................................................... 8

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 292 of 674

 SCOPE OF WORK (STRUCTURAL) DOCUMENT No.
FOR LADDERS AND PLATFORMS FOR B224-111-81-41-SOW-6006
COLUMNS OF PFCC UNIT Rev. B
RAJASTHAN REFINERY PROJECT,
Page 3 of 8
HRRL

1. SCOPE OF WORK

The scope of work under this contract shall include in general, but not limited to supply,
fabrication, transportation etc. for all relevant structural works (excluding erection at site)
for Ladders and platforms (circular or any shape) on Column 111-C-2101 in PFCC unit for
HRRL, Rajasthan including supply of all materials (as defined in scope of supply), tools &
tackles, labour, etc., as per the detailed scope of work, scope of material supply, schedule
of quantities, specifications, standards, drawings included in this Document (including
addendums/ amendments) and the directions of Engineer-in-charge and as per approved
for construction (AFC) drawings (including subsequent revisions) made available to the
successful bidder.

Major structural activities involved shall include but not be limited to the following:

1.1 Structural steel works with rolled steel or tubular/ hollow sections or builtup section,
including supply, transportation, fabrication and preparation of detailed fabrication
drawings, for platform and ladder for equipment No. 111-C-2101.
1.2 Protective Coating/ Painting of Structural steel & handrail as per Job Specification No.
B224-000-79-41-PLS-01.

Any other structural work, not specifically mentioned herein, but required for the
satisfactory and successful completion of the project as per directions of the
Engineer-in-Charge shall also be in the scope of the contractor.

2. SCOPE OF SUPPLY

2.1 Owner’s scope:

NIL.

2.2 Contractor’s scope:

2.2.1 All items consumables/ non consumables required to complete the job as per
Specifications, standards, drawings & instructions of Engineer-in-Charge.

2.2.2 All labor, tools tackles, plant machinery etc. to complete the job.

2.2.3 Nuts, bolts and washer for all field connection shall be supplied by Contractor.

2.3 For all bolted connections EIL Standard with addendum shall be followed.

3. SPECIFIC REQUIREMENTS

Note: In case of any contradiction between these Specific Requirements and

Requirements/ Specification specified elsewhere in the tender document, the
Specific Requirements given below shall have precedence.

3.1 All works shall be done to the entire satisfaction of the Engineer-in-Charge/ TPI. Any
work not carried out in accordance with the instructions shall be dismantled and made
good without any extra cost and time implication to the owner.

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 293 of 674

 SCOPE OF WORK (STRUCTURAL) DOCUMENT No.
FOR LADDERS AND PLATFORMS FOR B224-111-81-41-SOW-6006
COLUMNS OF PFCC UNIT Rev. B
RAJASTHAN REFINERY PROJECT,
Page 4 of 8
HRRL

3.2 Assembly & Shop erection of platforms as per specification shall be ensured before
supplying to site.

3.3 The contractor shall ensure proper co-ordination / co-operation with other agencies,
while working in the unit area, without affecting others work front areas.

4. LIST OF SPECIFICATIONS, STANDARDS & OTHER DOCUMENTS

4.1 ENGINEERING STANDARDS:

S. No. of
Standard No. Title Rev No.
No. Sheets

1 7-68-0507 Details of Steel Ladder 7 3

2 7-68-0509 Steel ladder joint details. 6 4

Ladder support clips for hot
3 7-68-0512 5 2
vessels
Platform details for horizontal
4 7-68-0540 0 6
hot vessels
Details of brackets for circular
5 7-68-0546 0 5
platforms of hot vessels
Platform support clips for hot
6 7-68-0547 0 3
vessels
Circular platform for hot
7 7-68-0552 7 8
vessels.
Details of brackets of circular
8 7-68-0553 7 5
platforms for hot vessels.
Platform support clips for hot
9 7-68-0557 5 3
vessels.
Electro forged Grating Type I &
10 7-68-0697 3 8
Type II

4.2 STANDARD SPECIFICATIONS:

S. Specification No. of
Title Rev No.
No. No. Sheets

1 6-68-0001 General Scope 4 4

2 6-68-0002 Materials 5 16

3 6-68-0006 Structural Steel works 6 24

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 294 of 674

 SCOPE OF WORK (STRUCTURAL) DOCUMENT No.
FOR LADDERS AND PLATFORMS FOR B224-111-81-41-SOW-6006
COLUMNS OF PFCC UNIT Rev. B
RAJASTHAN REFINERY PROJECT,
Page 5 of 8
HRRL

4 6-68-0008 Miscellaneous steel works 6 12

Specification for quality

5 6-78-0001 management system from 1 7
Bidders.
Specification for documentation
6 6-78-0003 1 8
requirement from Suppliers

4.3 JOB SPECIFICATIONS:

S. Specification No. of
Title Rev No.
No. No. Sheets

B224-000-79-41- Surface preparation and

1 5 47
PLS-01 protective coating

4.4 VENDOR LIST:

S. Specification No. of
Title Rev No.
No. No. Sheets

B224-111-81-41-
1 Vendor list – Structural A 5
LL-6006

5. PREAMBLE TO SCHEDULE OF QUANTITIES/ RATES

5.1. Prices for quantities of items mentioned in SOQ (Doc. No. B224-111-81-41-SOQ-6006)
shall be included in the quoted prices. Unit rate quoted against each SOR item (as per
Doc. No. B224-111-81-41-SOR-6006) shall be applicable for any addition and deletion
during execution of the project.

6. ADDENDUM TO SPECIFICATIONS/ STANDARDS

6.1 Mode of Measurement for item for STRUCTURAL STEEL WORKS

6.1.1. The payment terms/ mode of measurement shall be read in conjunction with the
Specification No. 6-68-0006.

6.1.2. Mode of measurement for structural steel works shall be made on the basis of
admissible weight in metric tons (determined as described in Clause 6.1.3 and
6.1.4) of the structure accepted by the Engineer-in-Charge. The rate shall
include supplying (as per supply conditions given in the Tender) fabricating,
testing/examining (excluding radiography only) of bolted and/or welded

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 295 of 674

 SCOPE OF WORK (STRUCTURAL) DOCUMENT No.
FOR LADDERS AND PLATFORMS FOR B224-111-81-41-SOW-6006
COLUMNS OF PFCC UNIT Rev. B
RAJASTHAN REFINERY PROJECT,
Page 6 of 8
HRRL

structural steel works of all types (including all built up/compound sections made
out of rolled sections and/or plates) including all handling, transporting,
straightening if required, cutting, edge preparation, preheating, bolting and
welding of joints (including sealing the joints of box sections with continuous
welding), finishing edges by grinding/machining as shown, preparation of
fabrication drawings, preparation and submission of as-built drawings, preparing
the surfaces for painting, and applying the primer as specified after fabrication,
etc. all complete for all the operations mentioned in the foregoing clauses.

6.1.3. The weight for payment shall be determined from the fabrication drawings and
respective bill of materials prepared by the Contractor. The bill of materials shall
be checked and approved by the Engineer-in-Charge before making the
payment. The Contractor shall prepare full scale template in order to
supplement/verify the actual cutting dimensions where so directed by the
Engineer-in-Charge. The weight shall be calculated on the basis of BIS Hand
Book wherever applicable. In case sections used are different from BIS
sections, then Manufacturers' Hand Book shall be adopted. No allowance in
weight shall be made for rolling tolerances.

6.1.4. Welds, bolts, nuts, washers, shims, pack plates, wedges, shop painting shall
not be separately measured. The quoted rate shall be deemed to include the
same.

6.1.5. The rate shall include all expenses related to safety & security arrangements
and all plants & tools required for fabrication & transportation.

6.1.6. The rate shall include supplying & applying the paint, specified in the tender, of
approved quality and shade over the primer, specified in the tender, over the
shop primer already applied to structural steel works of all types/shapes at all
levels, locations & positions including storage, surface preparation ,
degreasing, cleaning, drying, touching up of shop primer coat, providing
temporary staging, testing etc. all complete to the entire satisfaction of the
Engineer –in-charge.

6.2 Mode of Measurement for item for GRATINGS

6.2.1 The payment terms/ mode of measurements shall be read in conjunction with
the Specification No. 6-68-0008.

6.2.2 Mode of measurement shall be made on the basis of admissible weight in

metric tons (determined as described in clause 6.2.4) of the gratings accepted
by the Engineer- incharge.

6.2.3 The rate shall include supplying & fabricating M.S. gratings (purchased from
approved manufacturer) including transporting, handling, cutting to required
size and shape, making holes/notches/openings, smoothening the edges,
fabricating clamps, preparing detailed fabrication drawings, surface cleaning,
removal of rust, scale, grease and galvanising as required, all complete.

6.2.4 The weight for payment shall be determined from the fabrication drawings and
respective bill of materials prepared by the Contractor. The bill of materials
shall be checked and approved by the Engineer-incharge before making the

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 296 of 674

 SCOPE OF WORK (STRUCTURAL) DOCUMENT No.
FOR LADDERS AND PLATFORMS FOR B224-111-81-41-SOW-6006
COLUMNS OF PFCC UNIT Rev. B
RAJASTHAN REFINERY PROJECT,
Page 7 of 8
HRRL

payment. The weight shall be calculated on the basis of BIS Handbook as

mentioned above. No allowance in weight shall be made for rolling tolerances.

6.2.5 Welds, bolts, clamps, nuts and washers shall not be measured. The quoted
rate shall be deemed to include the same.

6.3 Mode of Measurements for item for HAND RAILINGS

6.3.1 The payment terms/ mode of measurement shall be read in conjunction with
the Specification No. 6-68-0008.

6.3.2 Payment shall be made on the basis of measured length in meters (m) of top
rail only (Horizontal and/or inclined lengths). The rate shall include preparation
of fabrication drawings, supply of all materials, handling, transporting,
straightening if required, cutting to required size, bending, welding, bolting,
surface cleaning, removal of rust, scale, grease and applying one coat of
primer as per Job Specification no.B224-000-79-41-PLS-01 , after fabrication
etc. all complete.

6.3.3 The rate shall include making suitable notches in floor plates/gratings for fixing
the vertical posts.

6.3.4 The rate shall include supplying & applying the paint, specified in the tender, of
approved quality and shade over the primer, specified in the tender, over the
shop primer already applied to structural steel works of all types/shapes at all
levels, locations & positions including storage, surface preparation ,
degreasing, cleaning, drying, touching up of shop primer coat, providing
temporary staging, testing etc. all complete to the entire satisfaction of the
Engineer –in-charge.

DOCUMENT CLAUSE
S. NO. MODIFICATIONS
NUMBER NO.

Clauses 12, 13, 15, 16, 17 & 18 not

1 6-68-0006 -
applicable for this MR.
Clauses 7.5, 7.7, 8.4 & 8.6 not applicable
2 6-68-0008 -
for this MR.

6.4 Addendum to Standard for structural connection

DOCUMENT CLAUSE
S. NO. TITLE OF DOCUMENT
NUMBER NO.
“Mild Steel bolts” shall be replaced with
“Galvanized high strength bolts of
Notes: property class of 8.8 (min.) grade as per
1 7-68-0547
S.No.-5 IS 3757 & IS 4000 shall be used. Nuts
and washer shall confirm to IS 6623 &
IS6649 respectively.”

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 297 of 674

 SCOPE OF WORK (STRUCTURAL) DOCUMENT No.
FOR LADDERS AND PLATFORMS FOR B224-111-81-41-SOW-6006
COLUMNS OF PFCC UNIT Rev. B
RAJASTHAN REFINERY PROJECT,
Page 8 of 8
HRRL

“Carbon Steel bolts” shall be replaced

with “Galvanized high strength bolts of
Notes: property class of 8.8 (min.) grade as per
2 7-68-0557
S.No.-5 IS 3757 & IS 4000 shall be used. Nuts
and washer shall confirm to IS 6623 &
IS6649 respectively.”

7. SCHEDULE OF QUANTITIES/ RATES

For schedule of quantities, refer Document No. B224-111-81-41-SOQ-6006.

For schedule of rates for Addition and deletion, refer Document No. B224-111-81-41-
SOR-6006.

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 298 of 674

 DOCUMENT No.
VENDOR DATA REQUIREMENTS
FOR B224-111-81-41-VDR-6006
MR NO. B224-111-CC-MR-6006 Rev. B
Page 1 of 2

VENDOR DATA REQUIREMENTS

FOR

MR NO. B224-111-CC-MR-6006

B 21.10.2020 ISSUED FOR PR VV RMD/RK VKG

A 11.06.2019 ISSUED FOR MR VV RMD BNM

Rev. Prepared Checked Approved
Date Purpose
No. by by by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 299 of 674

 DOCUMENT No.
VENDOR DATA REQUIREMENTS
FOR B224-111-81-41-VDR-6006
MR NO. B224-111-CC-MR-6006 Rev. A
Page 2 of 2

VENDOR DATA REQUIREMENTS

The following drawings/ documents marked “√” shall be furnished by Bidder.

POST ORDER
WITH WITH DATA
S. No. Description REMARKS
BID REVIEW RECORD BOOK
(FINAL)
Fabrication & Erection (*) Remaining
drawings of any one platforms drawings
intermediate platform and (fabrication &
1. √ (*) (*) √
top platform with complete erection) shall be for
connection details for all Information only.
Structural Steel members.
Monthly updated status of
√ √
2. BOQs of major items
(Structural Steel).
Miscellaneous document
3. √ √
other than above.

Notes:

1. "√" denotes applicability.

2. Post order, drawing / document review shall commence only after approval of Document
Control Index (DCI).
3. All post order documents shall be submitted / approved through EIL eDMS portal.
4. Refer - 6-78-0001: Specification for quality management system from Bidders.
5. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.
6. Final documentation shall be submitted in hard copy (Six prints) and soft (two CDs/DVDs)
in addition to submission through EIL eDMS.
7. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in
higher paper size shall be submitted in exceptional circumstances or as indicated in the
MR/Tender.
8. Post order- The schedule of drawing / data submission shall be mutually agreed between
EIL & the bidder/ contractor / supplier during finalization of Document Control Index (DCI).
9. Bill of Material shall form part of the respective drawing.

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Page 300 of 674

 PFCCU 08.10.20
1 10.09.19 ISSUED WITH PR RK SB SB

OTHERS

VESSEL VENDOR)

VESSEL VENDOR)

CONNECTION ON VESSEL

111 01

Page 301 of 674

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ui palmoads as!miatpo ssalun dogs p pang aq Hugs swatudInba jo •ola Joloalloo lapno
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.10 1(q 13011sImInJ
sp-wap alp imm aotrep000r ui JoIropqrj lassan Xq !wpm puu pagddns aq Hugs lassan alp of
papiam spoddns umaq `sirtualut IIu puu &mg BugIoq Jatuoaumop `s2up poddns tied was/Swi S.5.17
-amid wag pairopgrj aq Imo 2u!d!d awssaid-uou
Joj tetualu! JanamoH -sa5treg pa Joj aq Hugs 2u!dird amssaid Joj saugg lutuang 17. S't
add papiam JO ssapiteas Jaw aq Imo Ouult4 awssaid-uou !minim! JanamoH .2tud!d
paloatwoo tetualxa ago su uoprog!oads aures jo puu ssapuras aq Hugs Swd!d anissaid mutant' £.S.17
-Hags Lassan alp par
Ind atp uaamiaq uo!suedxa tetwatp lugualajm mop suratu wpm pap!Aold aq Hugs lassan
alp jo Jalaturm JO pogo u Suwurds sirtualu! Jatpo JO sureaq poddns /can `sauseg Z.S.17
-alogurtu atp g2nomp ssud Hugs sirtualu! amenowai Hy 1.5.17
stuuialxa puu slut:Liam
H Puu OZ'9Ig MAISV 01 ULLIOJUO0 Hugs slalsro
-aaej apes Rogipua pins atp 4u 2upputu
Joloo lounsm Xq pagguap! aq °sir Hugs gnu 2g grog iginuelatu SS/J(01Iu Itu J°J 1041111.1
'gajC 1.1920S 4aNsg2 atp 2wcptusgi wowtm Nog alp "eau pmpetu Round aq Huts azts alp
Nog paddw jo asuotq -sans' aw jo auo uo pa3prui Round azIs ow a/mg Hugs sinu aw XpErs
•priis ago Jo spua ago jo aut uo p331.MUI Bound Xprap aq hugs az!s tuoprog!oads irpnew
MAISV ui pag!oads su !Naas mannorwu-etu 2g suogrog!oads aw jo Otudwels w uon!ppe uI 17'17'17
-anneJadutal Jag2!g Joj apuldinsm tunuapq/clow !ppm pur 3000Z (On
an-uwadulal 5uppom J0J OSEOB a4igdeJ2 gpm palropqn! aq Hugs 2uplog irwapca uo spraigi £ .17.17
-mu aignop tp!m pap!noid aq Hugs sqoq irtuaw! Hy Z.17.17
•siolundas plop
2g loll pm S1013.0311 ICEH-ODA/SGHCILLCIIICl/J331orioawicll Joj /quo algrogddv
(ft) sioirJudasisiolorai jo saugg aizzou gouanb puu lapno law'
300LE anocir annwadwai tiO!saci mm 8E oi tutu sz
(ft) sioluirdas/siopeat jo saugg aizzou gouanb par ppm 'mu'
DopLE anoge annwadwai a!saci
(2 worBN L < ua5oipXH JO aitISSOld
z mind) amnias ua&)JpX}i
°Amp puu 009 ssup tutu pc 04 puu unu 8E
snip!. °&.1u1J III' JOAOpue unu pc
suoprogloads loacomposuami ssaoold /Cq pag!oads uagm S3Z!S Ily
suompuoa az!s moll ieu!tuusi
:uows!nbaN alp w pag!oads as!mlawo ssawn Jopuan /cc! pagddns
aq Hugs pure suon!puo° puu saz!s nog 5wmollo3 Joj pasn aq Hugs Jaumsual mog ogruripicH
9 1. Jo L °Bed 16.... Pun .P.1P No9 P OnCIPED2E12.11:21.0.2.1
S13SS3A 31:111SS32Id
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Page 308 of 674
 p9A18S9J sp.& IIV — 113 I46pAdoo 0 '^9:1 Id-1.000-00-8 'oN leunod
pud Owo.kgwal tplm saizzoN (q
•swpgr anuottoo tpoows tp!m papptaid aq hogs ppm ppg pssan aizzoN
•saizzou Jo uopupulsw Jauu apis qoua uo aizzou Jo .131.3mulp ammo Jo satup g•
.a.i aizzou Jo ialaurem aplswo Jo smug £ of pub° g ual u pawurexa ututpuad
aicp puu pagdeBo!pw Xpnj aq pugs Ouluado aizzou quiet Ougnoj areas piano Cud 0!
•a0pa aizzou (3.4 lwod Isamu
wag painsuatu apis qoua uo tutu 001 04 pub° tp2uai a tu paupuuxa lueuauad
aicp puu paqdw2o!pw Xpnj aq pegs (=as plane gum Ougnoj 1ou lnq) uluu
pc unplm saizzou 04 (a0pa ppm 04 °Op ppm) aotruls!p Oupveq mum ppm Cud 0
pud Owatojwannotwm saizzoN
:Xidde hugs swatuaqnbat Owmopoj ammo/ mu su atuus
atp ageo ul .(a0pa ppm of a0pa ppm) tuntwunn !nut pc Xq sOup Otquagps puu swap `soup
poddns Amu; 'wapiti! 'sped watuaawjwat taizzou Jo nap aq pugs suruas ppm wew IIV g. t
•tpp!m sl! ao!Au aq weal lu pugs 4110!aq 54t pug ssatop!tp upis
alp 04 priba aq pugs pua upts w ppm alp Jo tpp!m walls wup Ownau!Oua alp ui pawo!pu!
as!miatpo ssalun ppm paaej lul3 tpoows u tptm aputu aq putts puag pssan puu upis Imampq
suopoauuoD •spiam uing uopanauad pnj gum °pew aq pugs ppis 21quoddns to sums
•spiam uopanauad
pnj quiet pssan of pagoeue aq putts spud luatuaatojwat .qatp puu siCumuulAI pug saizzoN
•pasn aq lot pugs
sd!us Ouppeq tammadwal onz-qns 4od tuog funaidde 'oud Otqutelqo pug /quo pasn
aq two dims Ouplogg •uopeuauad pnJ amsua ou pasn aq uuo (pa) ssaoald sup uatg ualsOuni
uru low glum sw!of unq pappm al2ws `Xl!pq!ssaoovu! 01 anp alq!ssod lot! s! 2u!ppm Opts
puooas uaqm •sw!or pappm amnop `uogulauad IIn3 aq pugs sppm unq 2upgaq amssatd
4
•sa0pa Jo Xiputopun uou pug uopEmoioosq)
tuwauquap `Outs anotual of paqnba! su 4o4uouquj atp Aq punatO aq pegs sa0pa inn attre14
u!PlaA1 L't
•sp.mpuuls
II3 tad su algid alum lampujnuutu puu amid auruu -pa quiet pagcldns aq pugs pssan pug
aigia atugm 917
.awes
lioddns of paq 4sAieleo moiaq pap/wig aq iieqs aup lioddns !IN 'as!Nuatuo pagpads ssaiun 6*S*47
•aioquutu lsanau tiSnaup ssud maw aq pptoqs puu
as!mialpo pag!oads ssalun adX4 aiqunoutat aq pugs pssan atp ap!su! mid paiwojiad teu.tang 8- g.t.
—pa cq paqs!tunj
spupp atp quiet aourp000u u! Anuouquj pssan pappm puu pagddns aq pegs sretnauca IIV Ct
-uopupwsui puu uopuogilwap! ppg pangl aq molls
small magi lassan tplm tiowds!p loj pawn puu panowal !pm 'pug aq pegs swatudwba
Jo •op 104001loo pun° `sacl!d lowq!usIp `sicuu Oupowilowq!usm ioddns 'swans
qsaw `spIsuq [umlau! atp `uop!sInbal .tad su asooi pagcldns aq ou alE spluanq alp asuotg
51 jo 8 abed
S13SS3A 321f1SS32Id
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Page 309 of 674
 pemasai sp46P Ily -113 I460d00 .Aa:1 ld-1.000-00-9 'ON leuucu
•alquogonid
Janatagm Iloddnsitspis 2tutpuput 4iun ataldwoo u sg patnan wag ppm 4sod aq Hugs slassaA Z.8.17
•apoo age ui pagtoads imp untp ssal aq patulopad tuauggan wag plane 4sod aquings asgo
ou ut •s2tumnip 2wJaaut2ua aqt uo pagtoads uaqm pateau Iraq ppm 4sod aq gals slassaA 1'8'17
junumail, wall PPM 4sod 817
LIMOS f : Jatattrew allow 9 coldn OJTOULI b 1.110.1J slassan )
LIMOS Z : Jatatuntp allow t cudn allow z wog slassan (q )
areas i Jatatuum anatu z ouln slassan )
:smogoj
su aq !tugs swum reutpnu2uoi jo •ou wnwpcm •anatu i aq !lugs gyp& °smut° gags tuntwum L. t
•paptAaul aq !lugs
Jnowoo annottoo snonua2 pun wows punat2 aq Hugs pats /Coign moi Joj Jaq2u4 pun 30S 1,
pun pats uogino Joj Jatt2p4 pun 300LE augnJadtuat uStsap gum slassan `Jamo! pun 3o6Z(-)
angendwat u2Isap qpM SI3SS3A pun ao!Ans ogoico 'ao!Alas ua2cupiCH jo OSUO stuauodwoo
amssaid pssan alp sppm tau gum (•ota swap `saizzou) stuatugonun inwapcannuJaw!
.2tuppm Joj paXoldwa aq !lugs ampaoald paulaoon atg u! paggurtb ain oqm sJappm /quo 6' L'17
•panauldn are sampaomd patuaotwo atg ssalun aouatutuoo tou gulls 2wpiam 8' L' t
•atumnip uognopqnj ut pateo!pu! aq !Tugs pun
3 Ind IF 03S apop lassaA amssaJd pun Jallog Hylsy Jad se aq Hugs saignuunsuoo 2utplam L. L't
•algutdaoon aq osin ins snuJaA riming pun Aar ANQ `spicoli
`Tap Japun (116d) piooax uognoggen6 ampaoald 2wpiam paggunb XIsnotnaJd
0 'XI u°933S 0p03 •
slassaA amssaid pun JagoEl giAlsy .tad sr In/mid& Joj angutuasaulat pastiotpue JO Joloadsu!
magegoind !wow uutwogifunb pun uognolpoads ampaoaul 2utplam utuqns Hugs JopuaA 9•L•t7
luautgonun pus
Aun Jo 2tuppm a.iojaq pauguexa tungauad aXp pun pa id-m.2011)-w Xlinj `gsng punat2 aq !lugs
opts gaga uo t2ua! um ON snid twtugarge atg Japun 2u!tuoo uoipod tunas ppm mg 'tunas
ppm gum 2ugnoj s! -op strap `s2up poddns knit trutuatut wig stuatugonun Jaw asno tti
•aps gaga uo
tutu 00I + ped tuautaatojwat mopq tunas ppm jo uotpod of puha tp2ual JO opts
Ilona uo aizzou Jo Jatatuntp ap!swo jo smut g• i •a•t aizzou jo Jatatuntp ap!suto
jo south £3o Jaq2N innba tplual n paulaunxa tunuauad aXp pun pagdat2o!put
Xlinj `gsng punadi aq gulls 21quado aizzou gum 2ugnoj tunas ppm Amy,
'31)1s
Lima uo tutu NI pnd 11101I100.10jU!al Mopq tunas ppm jo uogiod fertba tp2ual
n paunuexa tungauad acp pun pagdwilatput Xgrg `tisng punadi aq gulls pnd
tuatuaaugutai Japun 2u!woo tug 2uwado aizzou gum 2tulnoj tou tunas ppm Cud 0!
.a2pa pnd 5utaugwal w!od 1.SajBOU
Wag pamsnaw opts Ilona uo tutu 00! tenba t2ual n pawutexa tungauad acp
pun pagdeBotpui Xlinj aq gags (tunas ppm qum 2ugnoj tou tnq) tutu oc tugum
pnd 2watojutat (a2pa ppm ot a2pa ppm) aountstp 2wAng tunas ppm Cud
91. 0 6 a6ed
Sl3SS3A 31311SS32ld
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Page 310 of 674
 pemesai sp.& IIV — 113 iy6pAdo3 0 'Ae?:J ld-1,000-00-8 'ON lewioj
- slassan Joj watuannbal umw!ww s! ialdw2o!pw
Jods JanamoH •apoo pagpads ssai aq uoguinutexa o!gdw2olveJ
Hugs asuo ou •aulAnwp Otniaaw2ua uo pagpads aq Hugs icgduBo!pw jo luaixa I .17.
Xgdy.Mnpra t'S
.5untnud puu Jaw!Jd 'uoguJudaJd aoujins (o
- ow ssaupieg 'uo!solloo Joj gons wal wpads Jamo (u
•Osal onumnaudiogulsoipicH)Jsai amssald (w
- swawn.nsu! Owinsuatu jo sploom uonulggeD (I
.2u!Aagai ssans (31
- uogutnutuxa apg.red ogamiumuoguuntrexa Juanauad aicu
•uoguunuexa onideJ,Sollaux
'310340 1[6010!SUOWM (q
- 51nuas aizzoN (5
.2wpiam aiojaq 2u!Jeap ssud wow
suogoas jo Juatually
suogoas funp!Agmn uo 30uuniol. 2uHioN (P
•sureas tewptupuoi jo Juatually (3
4 4
*StIORCITIIEI Joj rag° juns!A ti!pniou! '21npiam Joj uogundaid a2pa (a
uoguogguap! wpm!!! Anux
:ft!molloj atp panuall Jug '21npnpu!
uogeopqvj Jo saSuls w Jampujnuum am icq patnelqo aq Hugs witaiddu uan9An silopadsui
`Joloadsui icq uonuogglao puu uogoadsw pug uoggwv tri •icuu j! `sw!Jawm paJapJo-qns
Joj osiu pug /Ciampi) apjaq pue uoguo!Jquj 2tninp moq papuuo aq Hugs uonoadsui i'S
•siopu.nuoo-qns SiOpeil.u00 Jo sdogs llom ol ssaoau aag °Aug Hugs siopadsui VS
•Jopadsu! paspotpnv Jasugoind uogoadsu! Joj pang° aq Hugs siassan VS
OISILLS31 moupaastsa ws
- aolpuid 5utJaauigua
poo2 lad su suo!suaunp wennutu Hugs Jowo!iguj `saouuJaiw gpm pappkold Jou suo!suawm Jod Z.6.17
•apoo/parepums/Bwmwp Jaci su aq Hugs saouwapi 1'6'17
saaumoiol, 617
luaunuan wag ppm wod 2wInp uogup!xo lanau papamid Xiqunns aq Hugs saouj aSuug Hy E-817
Sl Jo 01. e6ed (6.1e4aPun .1.110
SlaSS3A 3211199321d y) aught`uaAsuaidakei
9 *A821 1000-Z1.-9 NOA VIGNI 1121V
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Page 311 of 674
 pe/U9S8.1 SILI6P Hy — 113 ill6pAd00 0 'Ao2:1 IA-1000-00-8 'ON leueod
•I c ma wud apop lad su aq pugs upaluo aouuldaooy (A
Ln uuojiod paicoidap aq pugs suoslad Dam paggunO (J:
•uan!2 aq pugs walsics Inv .natp
puu sawed ag43o iunaiddu ago go!qm uo pasug •anpu4uasaida4 jo TISIA alts aw 2uunp
uaalos aims alp u! uopuniuna goajap ago puu aupputu Inv jo killutuduo aw. Agrussaoons
aimusuowap pugs 404ddng agZ •MO!Aal -Ha Joj asn o4 .toad plooai rug alp tp!m
2uoru pappuqns aq pugs Xqdw2o!pw jo nag ut paicoidap aq o4 pasodaid s! Imp tualsics agZ (a
•iquo aoupns auo wag 244utruos
apqm ap!sul su gam su ap!sino uo sloajap 2upoalap jo alguduo aq wogs drips •aoupns
ap!sut pug ap!sino UO S)IOEI3 0SJ3ASUEll. SE gam su Tutun42uoi aluintws satplou aigmws
anug pugs Noolq uourIggeD -pasn aq pugs ssauloppituummu .4upuus jo Nooiq uopulgllup (I)
jo nag u! panp!suoo 0g icutu UO3.10S apws r uo Xisnoauminuus susai wog Owicuids!p pue
papadsut aq o4 snip!' alp 2uoiu sasianup Xpuoputuolnu 4144 s!ssugo atuus alp uo palunoui
/Cully pasugd puu ado' sagoid oqoa asind puu ado' 2upwothoout in mummy (a
.(apoD icg paugap su nnofjo kw2aw3) •w!o[pua
pagsm tuopagds!waqw gags ldaoxa ni!of g iGio2a4u3 to d kw2a103 40q4a Si nip!. ata (q
•unu EI uutp JairaiS st piam jo ssau)Ioup ata (g
:244mopo3 loalqns sigualutu lams Xopy puu lams uog.tuD Ioj aiguldaoou st awes
alp '( 7) (u) 1g mn used apop uo pasug pj jo nag 4.4 uuopad wum iallddns asuo uI 8.17'S
•sluoulaw-tbal apop ago 5upaaw
samnn aiguidaom aonpaid Xill!qudeo mopu0A maid 01 Id iapun Ono pal.uuo aq pings
map ualp 'anburtioal Agdeao!pull pawdwoD Aq Agd1u2o!pui ono £UEO 04 spuawt lopuan jI
woo alp jo walualwbal ago laaw pugs pananiougmenb ppm alp pug paXoLdwa anburgoal 041
..L1-1Md pauuopad aq Hugs uopuu!tuuxa
owosuppi 'iganputualte JO XtiduBo!pui puop!ppe uu allmd °RIJN pauuopad 3I •(.mmd)
luauguau wag piamisod .Toga .to awjag pauuopad aq /tutu spiam jo Xgdw2o!pai palpoods aqi
•icur
jt luauguan wag pug 2u!uuoj law pagdw2o!pw %00I aq pugs spua patwoj jo suruas piam
•2144g o4 aduI puu ad!d
ad!d Vau aizzou o4 02trug aizzou 2u!pniout spiam ung Iiu jo Ono pal.uuo aq jugs Xgdw2o!pul
%00I Itiatualwbal ao!mas o4 anp pag!oads s! AtideBo!pw iind uaqm •pagduhlo!pw
%00I aq pugs 'aluid jo ssauppp Jo an!padsau! 'aiuid wag paluouguj saizzou
•paqdw2o!pw
aq o4 SEOJE ago 2upputu ut paqnsuoo aq pugs via •poup.trexa aq pugs Iomado 2u!piamipapiam
`ampaoald 4.41:40m goua wag sppm •paloaias aq osiu pugs mum ruguanjtunago gm°
ut mu+1auo lsual 4u Apuuop!ppy limas imnpnOuoi 2g lugualajuma4o qua 14 paloalas aq
Hugs pods auo lununt4w puu 4124.40! u! (ww05 1) sagow 20s jo umuqww u aq Hugs gdw2o!pw
wds pug quatuaunbal wnw!unu u su ZS-ma gdw2uxed IIIA-u9P3S MISV
tp!m aouup.woou ut paqdw2o!pw pods aq pugs ppm 244u!u4uoo amssaid g JO V ic10201E0 gong
I aotstnIu IIIA uo PaS MANY ut pag!oads sluatuagnbal
age wawaiddns pugs swawaigibal 2wmopoj 044 'pag!oads s! Xgdw2o!pul wds uagm Z.17.
9 40 l l abed (NPRIPPurl opus P 1.09 y) (1.1213Elaa.mak21,21.1
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Page 312 of 674
 pamesai sly6P — 113 Iti6pAdo0 0 •nad L3 - 6000-00-8 'ON leuno
1114m
midwoo aq ow Hugs sluawannbal 2wmoHo3 agl `suog!puon asugnind iwauaD of uon!ppu uI
2uppelk V9
.2ugu!ud rung puu uogoaia °Agog a2mols
pue 1!suan 2winp 32.m-up JO uoiso.uoo luanaid of palmed aq Hugs spoddns iw2alu!
puu sp«is 2u!pnioui suumioo puu siassan Jo saoujms io!Japca Iiu `saoupns pauniouvu J03 ldaoxg 17'1'9
- 2unuon anguanad
Isni glom paloalaid JO pasuai2 aq Hugs saoupns pawqouw Jaw puv saouj pa2uug Hy £'r'9
- num u2!alo3 pue .[alum
`puus 1.qp 'alum aA01110.1 of Alluwaixa puu All-maw! pauuaio aq Hugs luawd!nba palaidwoo Hy Z'1'9
.2u!muip 2upaaw2ua uo pag!oads sluauwannua
atp iad su papaias aq Hugs lualsXs lured -alquo!iddu su uogeolyoads gof 'ad su JO (170001717-9)
2uguled Nag pure dogs ioj uoguog!oads piupums iad sv aq Hugs 2uguired puu 2uweap aoujins 1.1.9
3upiqud pug 2tquirao aaqins 1'9
ArlddflS 0'9
•1000-18-9 lad su luawd!nba jo goludsm wojaq Jaziquuu u palsal loop icuvug puu
pagguap! Xpadoid aiv lupalutu pals ssannuls puu pals 'cop He Imp mato 111E14S Jopu3A 8'S
- spagsulup
ui as!mialgo pagIoads ssalun smog st act Hugs aura 2wpioll -sloaqsnup u! as!miaglo
pagloads ssalun (-tqw) .ig/Do00t xi Hugs 2ull000 jo alvg lunoidde Joj 1coua2v uogoadsui
of pau!wqns aq Hugs ampaoald alp pug suoggwon u2!sap fume atp jo anguluasaidal
aq Hugs uoippuoo Isal auZ ino ppm aq Hugs 'sal. 2u!puogsm ua2o1p/CH 'DoggE
uutn annwadwal u2!sap tp!m ao!nias szll JO ua2oip1cq ui pasn siCupano ppm iiu JOA
•spoddns ampus Amodwal agl lu repalutu °quo w2uans pia!X 0114
30 % 06 2wpaaoxa wog Hags sassags [coo' p!onu of ualul aq Hugs AM Isalovicq 2u!ina V9* C
- pasn aq Tau Hugs 'alum vas isawipicti Joj pasn aq Hugs Jalum alqulod Imo E.9.c
%nu Lip 2wmoiq Xq papp 1(10110.1°w.
aq Hugs iassan '2ugsal ogulsolpicq logy luauguau luaq ppm Tsod !we uogeo!iquj aialdwoo
nue s2u!mwp 2upaaw2ua ui pauoguatu samssaid lu papnpuo0 aq Hugs 4504 ogulsoipicll Z.9'S
*I3SS3A wag
panowai aq Hugs -op pip `aluos twus ppm `Jaguds pram He ogulsoipeCti 01 io!id -apop
lad su aq Hugs wwpaw 2ugsal jo angwadwal aqZ -ails IE puu dogs alp u! Isal ogelsoipXq
2winp anuoug aplpq jo lswau p.run2 of umful aq Hugs suognunaid klussanau Hy '9.
pal 39e)soapiCH 9'S
•uoguwurexa luugauad
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56;o Zl a6ed
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Page 313 of 674
 pamasai sly6P Ily - 113 41460:100 0 •na1:1 1A-1.000-00-9 "ON ieW.10j
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Page 316 of 674
 SUPPLEMENTARY STANDARD SPECIFICATION No.
ENGINEERS
ei SPECIFICATION FOR
sigem faReg INDIA LIMITED 6-12-0002 Rev. 8
t41,215 Venn ...3-Rassil IA Govt of India Undertaking) CARBON STEEL VESSELS Page 1 of 7

(-dlo th7R4
Tff fq-1--#7-r

SUPPLEMENTARY SPECIFICATION
FOR
CARBON STEEL VESSELS

+.0t- •
REAFFIRMED AND REISSUED AS STD.
8 26.06.2018 SK KJH f RKT
SPEC.
7 30.06.2010 REVISED AND REISSUED AS STD. SPEC. KA RKT AKM/DM N.DUARI

6 25.09.09 REVISED AND REISSUED AS STD. SPEC. VB RKG AKM N.DUARI

5 12.04.04 REVISED AND REISSUED AS STD. SPEC. DNN AKM SSA SKG

4 18.09.00 REVISED AND REISSUED AS STD. SPEC. RKT AKM CRMN MI

Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 317 of 674

 150-4:le? ENGINEERS SUPPLEMENTARY STANDARD SPECIFICATION No.
ititeg INDIA LIMITED SPECIFICATION FOR 6-12-0002 Rev. 8
(WM melee arratakrart (A Govt o India Undertaking)
CARBON STEEL VESSELS Page 2 of 7

Abbreviations:

ASME American Society of Mechanical Engineers

BHN Brinell Hardness Number

HAZ Heat Affected Zone

LWN Long Weld Neck

NB Nominal Bore

PWHT Post Weld Heat Treatment

UTS Ultimate Tensile Strength

Static Equipment Standards Committee

Convenor: Mr. K.J Hari Narayanan

Members: Mr.Sanjay Mazumdar
Mr.K.Anjaneyulu
Mr. Arun Kumar
Mr. hider Kumar
Mr. Tarun Kumar
Mr. Srikanth Karanam
Mr. M.Azim (Projects)
Mr. S. Ghosal (Process)
Mr. T.Kamalakannan (Inspection)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 318 of 674

 n t
Og acs
da e N
ENGIEERS
INDIA LIMITED
SUPPLEMENTARY
SPECIFICATION FOR
STANDARD SPECIFICATION No.

6-12-0002 Rev. 8
I 411E7T 212,58 4AJR1.1) to Govt of India Undertaking)
CARBON STEEL VESSELS Page 3 of 7

CONTENTS

1.0 SCOPE 4

2.0 DESIGN 4

3.0 ELECTRODES 4

4.0 FABRICATION 5

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 319 of 674

 1 ENGINEERS SUPPLEMENTARY STANDARD SPECIFICATION No.
Ogen laffleg INDIA LIMITED SPECIFICATION FOR 6-12-0002 Rev. 8
1.11171 eIRIAE MAMA) (A Goo. of India Undertaking)
CARBON STEEL VESSELS Page 4 of 7

1.0 SCOPE

This supplementary specification indicating additional requirements for fusion welded

carbon steel vessels shall form addenda to General Specification for Pressure Vessels
(6-12-0001) in its latest revision.

2.0 DESIGN

Reinforcement for nozzle openings of size 80 NB (3") and above shall be self
reinforced forged nozzle for equipments where nominal thickness of shell/head
exceeds 50 mm.

For nozzles of size up to 50 NB LWN can be used in place of self reinforced nozzles.

3.0 ELECTRODES

3.1 Electrodes conforming to following specification shall be used. In case of any

deviation, prior approval from EIL shall be obtained.

S.No. Material to be welded Electrode Specification

1. General Structure Welding ASME IIC SFA 5.1 E-6013

2. Pressure Parts

a. Steels with UTS ASME IIC SFA 5.1 E7016/

upto 70,000 psi E7018

b. Steels with UTS ASME IIC SFA 5.5 E8016-X/

upto 80,000 psi E8018-XX depending upon the alloy
element.

c. Low temperature service

Below 0°C and upto ASME IIC SFA 5.1 E 7016-1/

(-) 46°C Steels to E7018-1
SA-516 / 516M, SA-537 / 537M,
SA-333 / 333M Gr. 6 and
SA-350 / 350M LF2

3.2 All electrodes and fluxes shall be properly baked/dried as per manufacturer's
recommendation before use.

3.2.1 All bare electrodes and fluxes shall be selected as per ASME IIC weld metal shall
have equal or better mechanical properties than the parent metal.

3.2.2 Only dry flux shall be used.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL—All rights reserved

Page 320 of 674

 SUPPLEMENTARY STANDARD SPECIFICATION No.
INIRae? ENGINEERS
tiikegw INDIA LIMITED SPECIFICATION FOR 6-12-0002 Rev. 8
Imferf 2.kmareosi3,10%1) (A Govt of India Unde!taking)
CARBON STEEL VESSELS Page 5 of 7

4.0 FABRICATION

4.1 Plate Forming

4.1.1 Forming of shell plates and heads shall be carried out by machine, either hot or cold,
in such a way so as to preserve the specified material properties and to produce a
regular finish.

4.1.2 Magnetic particle/Dye penetrant examination shall be carried out on the outside and
inside surfaces including edges of torispherical or elliptical heads in knuckle zone,
after forming, for detection of cracks.

4.2 Edge Preparation

4.2.1 The preparation of edges to be welded shall be done by machining, chipping,

grinding, cold shearing, Oxy- acetylene flame cutting or a combination of these.

4.2.2 Chipping shall be followed by grinding to a smooth and regular finish.

4.2.3 Oxy-acetylene flame cutting done in any circumstances, shall be followed by

machining or grinding to eliminate any discolouration of material affected.

4.2.4 All welding edges shall be checked by Magnetic particle/Dye penetrant examination
for detection of cracks, laminations or segregations.

4.2.5 No welding shall be carried out when ambient temperature is less than 10° Celsius
unless preheating is carried out.

43 Heat Treatment

4.3.1 Heat treatment of formed parts shall be carried out as per following:

a. Cold formed dished ends or knuckles shall be stress relieved, unless otherwise
specified in requisition.

b. Hot formed dished ends or similar parts, which have not been uniformly
heated in the normalising range in the final stages of manufacture shall be
normalised.

c. When the completed vessel involves post weld heat treatment, heat treatment
recommended in (a) above shall not be applicable.

4.3.2 Vessels in Hydrogen/Amine/ Sour (H2 S)/Cyclic service shall be PWHT.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 321 of 674

 SUPPLEMENTARY STANDARD SPECIFICATION No.
‘s-dt-aeirei. ENGINEERS
Ogeji leltifeg INDIA LIMITED SPECIFICATION FOR 6-12-0002 Rev. 8
(A Gout. of India Undertaiong)
CARBON STEEL VESSELS Page 6 of 7

4.4 Production Weld Tests

Production Weld Tests shall be applicable for vessels over 50 mm nominal thickness.
The following requirements shall apply:

a. Two production test plate coupons representative of one longitudinal and

another circumferential seam shall be provided for each procedure, position
and thickness in each vessel shell.

b. One production test plate representative of the weld seams shall be provided
for each procedure, position and thickness for welded dished ends/cones.

c. The production test plate shall be from material of the same heat and
thickness as of shell/head. During and after welding, the test plates shall be
subjected to same heat treatment as and together with the course they
represent. Extra coupons shall be preserved to take care of eventuality of
retests.

d. The tests mentioned below shall be carried out as per methods of testing in
governing codes:

i. One transverse tension test

ii. Two side bend tests with weld located in the centre of bend.

iii. Hardness test on production test coupon weld & HAZ (The hardness
value shall not exceed 200 BHN)

iv. Micro & macro examination of welds

v. Charpy V notch tests on weld and HAZ.

a. For low temperature service (0°C & colder) impact test

temperature shall be lowest of minimum ambient
temperature, design temperature and minimum design metal
temperature.

b. For vessel over 50 mm nominal thickness used for warmer

service, the test temperature shall be lower of 0°C or lowest
ambient temperature of the site.

c. The acceptance criteria for energy absorption shall be as per

Table A 2.15 of SA-20 / 20M. Incase the acceptance criteria
is not available in SA-20, then applicable design code shall be
referred unless otherwise specified in requisition.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 322 of 674

 SUPPLEMENTARY STANDARD SPECIFICATION No.
(31
-1fRe_iel ENGINEERS
*Igen feffiteg INDIA LIMITED SPECIFICATION FOR 6-12-0002 Rev. 8
IA 6004 of India Undenalong)
CARBON STEEL VESSELS Page 7 of 7

4.5 Hardness Survey

For vessels required to meet stress corrosive conditions (such as Hydrogen/Caustic/

Sour (H2S)/Amine), one Brinell hardness reading shall be taken on the inside of each
shell section, head, longitudinal weld, circumferential weld and nozzle longitudinal
weld after final post weld heat treatment. The value shall be limited to the specified
value as per requisition.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 323 of 674

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- paJou2! aq Hugs puaq jo alum ail (Sot / SO I t) laaos
ssaltauls oguiaj Jo asgo uI - pauuojlad aq Hugs uoggoggunb ampaowd plane pep jo Ism puag 8'S
luamaJalbal ssaupseq sag laaul of ktessaoau su luaungaa Teal plan lsod JO / pug wag
lsod luotpal tpm paggunb /*pips aq Hugs ampaoaal 2u!plam ag,I, -all 88 jo ssaupigq -xulu
anug hugs SOLIOZ paloajje wag pug spiam pup (got / SOIt) Iaals ssapauls ouplaj jo ssauptuff L'S
- 2u!muip 2upaat42ua
ago uo 214ppulo Joj pag!oads /Cogu are4sIsal uo!solloo agl Joj alquogcldu spaumanbai
kasauaqo ato 04 twojuoo ins ssattrup Xupano paqs!ug all jo dol wag ssourap 2u!ppup
aql Jo pluz Jo voclap u lu s!s/Cpuy paidures aq osp Hugs 'salmi; pug saizzou uo asoto su
goes quiJam) plane [mum gong -s!s/Cpue popuatio pa4nbal uuguoo of pgaq gaga pug uogoas
gags pupano 40E0 tuog uaNui aq Hugs /Cupano piaul plan atop saidures om4 jo tuntup!ul 9'S
- 2u!pup2 Xq pa/km= aq Hugs kupaAo atop 2u!puoq
twit aJapani! ppom Tell ppm mug all jo aoujins ago uo smell -slag!sualui ssaas su lou
pinom )ego sinampun pug satiolou ou Ipm wows Xiang-glair aq Hugs Kellam) paw plan ata S'S
- JapunaJaq 9- g asngp lad sg aq Hugs paulaanbai sIs/Cpue po!tuatio
ato `JOAOMOH XI U0900S °pop amy lad su paggunb aq gulls ampaooid /Cullom) plane ata t'S
- 2ugsal armaauad a/Cp %00I /Cq paradsu! aq Hugs °owns pandaid acg '2u!plam
uoggJoisal pup alojaq Tsui- -Trio papluo s! 2uIplam opts pep alojaq `S#AUIRSNOUJO Jo uogoapp
Joj pails Ewa -22ug 044 ui pag!oads su patidui2o!pul aq gulls algid mug alp ui alp!' plan aqi C'S
- 9- c 28 L• i•S ui uaA!2 patual!nbai alp ipm pals!suoo
Inq `ssai Si lanatio!qm aoujins pup anoqu tutuE JO ssatopap RI! ao!ml uggl JalgaJ2 ou Inq 2upg
all se pap su isuar Ig aq Hugs Kellam) ppm plan 041 -kupano ppm plain alquollddu ago
tpm pa l0A00 Xonj puu uouuJolsoi pup 04 Joud °owns ppalutu 2uppuq all Minn qsng punal2
aq Hugs plata ppm Imam asgq atop 2u!plam maidtuoo laluad of sago!' puatugatis of aizzou
all puu sums ato Iig Ig rug Imo aq gels 2upg alp `pose Si mid pup papuoq Xoufilaiu! uatim Z'S
- alquldaoau
aq hugs spawagnbai ato 2ugaaul 2g sargaX c uugl Japio iou `sampaoaKI pamuddu
paggunb Xisno!nald -aoujins kuiJam) patispg all jo dot wag ssaurap 214ppep 0144 jo piEiz
jo todap e lu uou!sodwoo ppm ppm papppun s4quixa Jell 4!sodap ppm g pia!X of Joioadsut
paspotprtu jo aouasaal ur Xplundas pagifunb aq Hugs ampaoald 2u!ppgio uou!soclap plats LT 5
- asn aJojaq Joloadsut paspotone jo Tulsa)) uallum mug Hugs pug spmudde amplbaJ all 1pm
Iaauoujnuutu oiquumsuoo papdal wag pamooal aq Hugs Joluouquj icq paraps salqutunsuo3 9'1'5
- ppolutu aseq ago 2uuplutu aiquainsuoo 214plam u Xq uato puu ppalutu Jagg 2u!plam (uoli
coa-Ny->uoDonly) uoli sand jo Jake' ampatalopt g icq pamogoj punetu pup all &Jammu
alqutunsuoo 214plam -e 44m auop aq gulp `alcussaoog lou Si aps pup wag qouoJddu aJaqm
aps aptas wag 214144 acialiod!d 04 ad!d se lops samodwoo 2u!d!d pup Jo 2u!plam and
01. 40 9 °Bed (64.1el.P.11.1.1 P,00 V) (.121zr Bsati w.211e1
Sl3SS3A avio
9 *A821 L000-Z1-9 4allA111 VICINI 2afg 'rPOP
tIOJ
•coN NOLLVOI3133dS aavaNvis NOLLVOld133dS A2IVIN3111131ddf1S
9133N191\13 Pr?JEP
Page 336 of 674
 paivasai sill6P 11V - 113 4116pAcloo 0 . Aa:1 13-1-000-00-9 'ON leituo
aq Hugs ANT Tamil wag ppm isod aq ot. am 91E ss puu tOE SS -0-a apui5 uogiuo
mot trutp Imp° lams ssatututs otituaisnu paztllquisun lutm pup stassan pals uogiuo uagm Z'L
- wags mup 5utiaaut&ta angoadsat ati ut pauopuatu
jo sinawagnbai aip lad su mean-watt ppm 4sod aq Hugs slassan jo spud JO stassan pappuo I'L
ixamuvalu, lVaH O'L
- 2unsal suodnoo
uononpakI 2utsn Act luatuluan. wag puu uotTuogHunb ampaowd 2utuuoj (q
.0uHsal uonuoullenb ampaoald 2utplam puu 2unsal uopeoullunb ammunsuoo 2utplam
:sasgo 5utmotto3 atp loj aiquotiddu
aq Hugs isal stgi Tuncyddu Joj Anoadsui pazpolpny pannugns aq Hugs anuomusoiotw
agi .2utddaip utuiii JO Wen Aug JO 034 aq Hugs uaugoads luaq 3111 *X002 Jo uolITuogIuBum
iapun paloadsut aq Hugs uaugoads pug retialum sapas NE Hu Joj g-aogould 79Z V IALLSY
Jad sw ino 1)3!ilU° 3C1 Hugs ODD uotsolloo .reinueBialui pagtoads astmlatpo ssaiun
'59I
g lAnsy ut pagposap spoglaw gifts aouupl000u ut aq Hugs uoguututexa ltruiouod a Cp puibri t'9
.uoneutwuxaluumuad pulbti
%00I papacqns act Hugs min panedax .pagudal puu panotual Atalaldwoo act Hugs kupano
itsodap ppm ut Jalaulutp (ulw9.1) clout 91/I uutp Jalea.12 majap Juinago puu samsstg `slouiD £'9
.2unsal. oHeisolpiCit dogs puu luataigan
wag pug Jaw (joamp UOROUJJ JO laaj annbs Hi gaga ut looj alunbs i uutp ssal ou t.ttpniout
`aoujins Jo %HI jo turuntutui u) pautwuxa luenauad pp-thil cods aq Hugs /cup/to ilsodap
ppm luawluan Tuag futig rage paupuuxa lue.uauad ptnbll %00I act Hulls saaujJns patugouw
uo Aupano Ilsodap ppm %lake' Tuutj qsodap jo niCut gaga .tags paututuxa Tumuauad
Mb!! %00I aq Hugs tan-ippon' ogutuoine JO tumuli' Act ampagm 'sic-upon° ltsodap ppm IIV Z*9
•Ls luawa.gnbal kruluatuatddns acp. 2ugaam puu lanai pnpuels aoueldaoau
8LSd a1AISY 111Im aouupi000-u ut aq Hugs uonuuttauxa otuoszun -paututexa Tuumuad
ptnbq %00I aq Hugs sumas ppm le Aepano Ttsodap ppm puu SE3JU pagedax -pauturexa
Affuotuosumnluaolad 001 aq Hugs lassan `pagnbai are "BM pauturexa rem amp Tuaolad E
JO SSOOX3 ut SITC10.1 uagm -uonuogtoads sup. jo z. i .s cptm 30treploom cg *40/10 ltsodap ppm
Act paguclai aq Hugs apt° Jalaututp gout i u Cq passudwooua aq locum° imp goose papuoqun S' I '9
luaunto-une jo saps
Tog uo SUM luaourpu jo glptm unuos apnput Hugs SEare anoqg aq i •Outppup alp Apoagp
pappm aq ot. atu stuatugounu aiagm SUOJE JO lno patmeo aq Hugs uoguututexa otuosanin %NI v1.9
.motag s.1-9 Jad se aq Hugs ampaowd itudai puu uotloadsuupuoct jo Joj luatinean
Tuag Twig rays paututuxa Alluotuosenin aq Hugs mid pup wag ap-um auoopol spua pagsta E'I'9
•Suutuoj rage puoq jo rui Joj pauturexa aq Hugs joaiatp LIOROUJJ JO Tooj °nubs
0I re° U! looj °nubs auo uutp ssai lou `aoujIns Put° JO %0I JO umw!u!tu u '1.1.9 Imp J31110 Z. I .9
.sauoopol puu spua pagstp jo lgat-u.ns pug ware appnum Jo aouj.ms jo %00 I 1.1.9
:molaq palluiap su puoq jo lout
loj paunuuxa Alluotuosznin aq Hugs ateld pup u cum pawn' sauoopol puu pua pagstp `Hags 1'9
NOI.13acISNI 0'9
01. Jo L abed Si3SS3A avio 16uMeimPun .out to 1..9 vl atatteao.o.a uzike)
9 'AOm L000-Z1.-9 HOd CHIM111 VIGNI Saf1B IngS
'torsi NOII.V313133dS aavaNvis NOILVOld103dS AtIVIN31A131ddfIS S2133NON3 Pr?MeP
Page 337 of 674
 peA.19Sal SIllop IN- 113 iii6pAdoo 0 .A8):11•J-1•000-00-8 'ON iewnd
.2unreap glop kip io lsnp mus tp!At 2untualp 0
•asup Jaium log Xci pamoHoj uollrgos gsu upos voz- 2uNguAts Xszi uogesgagnaN (0
'33s ow!I
Ou3Iclum) 00 I-OL
fa I :OH ZI7) PIog
la : JOT%
tHIAA uourgos tHIAA gums puooas (p
08I) JaTem log tHIAA Xipatuadat map (o
.00s ouu
la 0u3Nwg) ooi-oL :*chu3.1,
.4cH : TIES UOUIL1103
ia :(3EI oa Z17) p!ou
la : JOWM
jo apuut uourgos tp!m. gums (q
-2u!ppep jauow atp jo saoujins
tallow! atp 2uweap Joj pit:lope aq Amu ampaowd 2uIpp!d 2ulmolloj alp `paogou
s! aoupns atp uo dn Io!cl uol! puu 2u!ppAt anp uouumo aoujms asuo (E
:sAtolloj s! (Lzi gs) pup puow jo 2uweap aoujins Joj ampaoald 17'8
.08 E-y lAnsy tH!At aottupwoou u!
iXxonad Xq paratp aq Hugs sna -dn r!d uol! jo aau aq Hugs saoujins pals ssaltqws agi £'8
•Ana!Aal Joj pamwqns aq Hugs
ampaoatd uogen!ssud puu 2uHr!d .08E-y TALLsy 'rpm aouupwoou u! palun!ssud puu
pappd aq Hugs saoujins peio pals ssamws '2uRsal pue uogeopguj jo uoualdwoo atp Jauy Z*8
luaatatap alqwws
tHIAt puu JalunA uRap Jog 2u!sn p0A0W0.1 aq Hugs asuaJ2 puu po .(sapponu wpm°
wag aau) wamos atqwws 2u!sn Xq panowat aq Hugs gulud •sagstug agAt pats ssaitquis
2u!sn -op xnu 2Inpiam `areos `sappto jo patreap aq Jsmu saaujins pep pals ssamws 1'8
ommvala O*8
.2uHrag aJojaq
ams pep aw wou Xplaidwoo panowat aq wogs Ho an!loatoid puu lu!ud 2uppulAI (A!
-0/0 g•H paaoxa Jou pinogs tag u! wawoo mgdins tunw!xuw 0!!
.2uguag 2winp angdsoww 2u!s!p!xo Jo teunau agnbal siassan pup pals ssaitnws
lark; su pasn s! Ho JO sa j! atuuu Joagp pasodxa aq Jou molls te!Jalutu pep agi
:siassan pup jo TuatuTuag wag 2ulunp paiunsgo aq pinogs suoHneoald 21qmolloj agi ttL,
•anoqu ammo In pauljap su Hum aiquAkoHu spaaoxa ssaupmq jo asuo
papsuo aq Hugs auoz paloaire Juag puu spiam pals ssaiweis opylaj jo Juaunuag tuaH C'L
•Jauoi s!
Janago!qm smog HI Jo ssattrlw got!! lad smog HI jo po!Jad Joj 300z OIS paluall-Iml
0 1. 10 8 96ed (6.,feu.oun .0.1P IA00 VI Malt:fug 1221.1
Sl3SS3A avio
9 •AGN L000-Z1.-9 210d C131RAIll VICINI
.0N NOLLVOIAI33dS auvaNvis
RIANON3
NOLLV31A103dS ANVIN31A131dalS
Page 338 of 674
 pamasal sil161.1 11V — 113 11469Ado0 0 .AGIJ LA- L000-00-8 'ON lewiod
•(panajard s! kulds razguoTe) qums u ro 'spud pals JO U0.1! OU
Ou!Aug razituoTe raqqnr `ssul2 '3gs-cid 'iumulwnte uu rprim uognios Xiddy
•sur5 % TriO!am E ainuicoruai wrnssmod
'LIMO oz % Nopm c NOL-09) ploy 3!IIIN
.1110.113 0001 % V•1210M 176 raTem paugsm
•suogiodord 2mmolloj
'ap!uXopraj uunssmod 2mppu puu MUM paligsm opnu Omppe
Tsrg Xq pamdard s! uognios Tsal "op ap!xo uon ro uor! pappaqura 'swim
u! snsodap uon 'Tsnp uon `suognios 511113130 wag squs Iran turip!sar
looi-uon 211qmpu! 'uogemureluoo uon paw pals ssaimms uo aq Imo
Tsal •aiquuogoarqo aq Tri5nu appco uor! uor! aag jo saouri. uana uaqm
/quo pasn aq moils puu Tsai. amnsuas Xitpq s! uon aag roj Tsai. !Xxonad
ampaoord Tsai !Xxagad
•saoujrns
°as ol Tinomp JO alq!ssaoaeu! auntruxa Xpadord ol krussaoau sg gnu raw ro
Taunt' `adoosoroq Xq pawatuaiddns (satpueoloo OCZ) XI 069Z JO sl3AaI
awnbape rapun uogemiumuoo ssaa raw pue sdurep puu salogrud amsErqu
pug !maw Vag. 'pm 'alum 2intruoj wag pue Ouguag Teal 'gels `xng 2mplam
asuar0 'llo 'Tura! wag wopaag ssassu papnpuoo aq 11-eqs uogoadsm lurts!A
2uureap rage uogoadsui (c
- smog tz loj paw-1z' jo
angeradrual suoguinano Toil 2u!Xrp pug 2u!sup raTem ING puooas
/cog pamolioj sammtu 1-g roj ja08-0L jo amTeradrual %i7 -0mAIN
pire maorad Trit!am Xq %0 I 'HON 2unnemoo uognios ogsneo gip& paqqems
aq Hugs aogjms `&1!sull raTem pue 2um-eap Nog rage Xiampaturui (z
c•L - c•9 jo a2trer am in pallanuoo Hd raTem asup alp tipm asup
ram& pvci -e pamolloj aq Hugs spu uoweoggenb ampaoord 2u!pplA
Xq pappap aq Hugs poluad aum tenpu `10A0k1.011 •sammur 09-fiE 10J
pas c-Iz Nopm %9-z Jo (suo!Tein2ar reTuauruannua tr!!!-eikarcl pm
aouupr000e Xpadord jo pasodsm pug papailoo aq moils •surerp mu!
opzii LozipzEN
— 2inurenroo Tuangja am jo aaruipsflp immappou pIoAu uaIgT
aq Hugs areo) cozH Lozr3z-em 2mtnewoo amnion Al ageTuaorad 'Eomi
qnm paqqems aq 11-egs Tuaruplam puu maul matud arp. jo saoujrns aqua aru (I
ampaoord uogun!ssudAmpp!d (ci
•pasn aq truo (!sd 000'01) udw oL ogIn samssard
ralum TuaRrapp 2inurmuoo ugi.a[ MUM arrissard XiaTeuraTiv (z
• u!treaio uo9nios Tuaralap Xq pamolloj `sumaiagad
ogeridgu su !ions guamos ouram palumuremooun X14 2upleap wasps (I
•saounsqns Xsuar2/Xllo !prim palumiumuoo aoujins amp aumualo-ard
:smolloj su aq Hugs 3o-urns SOItSS JO ainPaoard uogumsseemplom S'8
lassan alp uo pacoldwa 2maq arojaq paggenbard aq Hurls ampa3ord atT1
01. Jo 6 afied (6..Nel.Pun .1.1 1,00 btA213Cloalsia?1:2 Lea.,
Sl3SS3A avio
g •AON L000-Z1.-9 1:10A tr?ElP
-oN NOI1V31d103dS aavaNvis NOI1VOIA133dS ANV.I.N31A131ddrIS 91ANIDN] Pr?ME9P
Page 339 of 674
 pamasai st46u IIV 113 1146pAdoo 0 . A0 :1 I.d- L000-00-8 'oN leutioj
•sapponu puu sappopp
Jo uoganuaouoo puu uoguioduna jo ki!!!q!ssod luanaid of '2u!u!-eip Xiampaunu!
`.nu log 2u!sn Xppnairoto pup aq Hugs pssaA •tudd sz uutp ssal aq ins mem In
luawoo °ppm° tiassan pm!l pals ssalums o9!ualsne jo aseo ui ..lasuqamd a p Xq pa/void&
si mum= Tuanipp u jo asn ssalun pasn aq Hugs aralum qsaij !map oguisamXt! Joj
9NIISal-01141mi ()III
"SlUpOjeill IONS SSOIUMS SOUS 00E IOJ
2u!plam keliano pup teu!2!Jo Joj pagpads su aims ato aq Hugs 2u9sal Doi Ku upanio aouu
-pziaoou aqj •uo!padsui Iig jo uo!s!madns alp lapun 2u9sai. Doi tinm paimunb Xquogpads
aq wags ampaoald .nudai aqi •omi paaoxa lou molls gods awes ato snuda.! jo Jaquinu
age `aperup!oituun 3I -paponx aq pinoqs pals ssalums pup jo .nudat ato `apzilssodluapca oi
Invaall arlHAA 0'6
•Xluo uognios patudaid Xiqsao asn skumly
Xluo spuuq pa/top to!im palpueq aq pinoqs uognps -smog paluguaouoo
qnm puluoo u! 2upq wan wag ualui aq molls °IUD Janamoq
`sap!uXo aiduns age 3JU su uostod snoia5uep st apnao!naj tun!ssuTod : aioN
'PPE
OR0OU JO au atun jo asn Jaw sauna tennas mum wa tp!m aorpns qsuij
•qstuq Jaqg u topn 2inqqmos puu pion o!pov % lipam oz s Jo uo9nlos
u JO .re2au!A anqm kressaoau j! `JO INEM ING 2u!sn 2u9sal Jaw apzilssod
se Aplomb se ao-ej.ms am wag panowal aq pings uo9nlos ato (pals ap!xo
jo uogoapp aroj pannbai aq Xuuz salnunu feJanas) uoguunueinoo uan aoujins
Jo aouap!na si (uopuollcide jo -oas si uumm) u!Els aniq u jo aouneadde aqi
01. lo 01. abed Si3SS3A avio v, (1.123C.D210221:21d21.1
9 'AOd L000-Z1.-9 210d anitAin VIGNI 22
,414 "21P
NOLI.V31d103dS aavaNvis NOLLVOIJI93dS ANVIN31A131ddrIS SNAN ION3 Pr?eiSiP
Page 340 of 674
 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
‘31 el ENGINEERS BOILER QUALITY CARBON
$tazir 251e-6 INDIA LIMITED 6-12-0011 Rev. 8
AMIAPOP3,19.1 , IA Govt of locha Undsrtal.og)
STEEL PLATES Page 1 of 7

GIN(YR craiiciz1 74e1

I vi fq-W

STANDARD SPECIFICATION FOR

BOILER QUALITY CARBON
STEEL PLATES

7
19.01.2017

30.06.2010
REVISED & REISSUED AS STD. SPEC.

REVISED & REISSUED AS STD. SPEC.

RK

KA
SK/KJH

RKT
1W1A,
AKM/DM
RN

N.DUARI

6 10.09.09 REVISED & REISSUED AS STD. SPEC. VB RKG AKM N.DUARI

5 16.04.04 REVISED & REISSUED AS STD. SPEC. DNN AKM SSA SKG

4 26.11.99 REVISED & REISSUED AS STD. SPEC. RKT AKM CRMN A SONI
Standards Standards
Rev. Committee Bureau
Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

Format No. 8 00 0001 F1 Rev. 0

- - - Copyright Ell — All rights reserved

Page 341 of 674

 STANDARD SPECIFICATION No.
711 elei
- ENGINEERS STANDARD SPECIFICATION FOR
51g- 1 faf5leu INDIA LIMITED BOILER QUALITY CARBON 6-12-0011 Rev. 8
I wen cArame an X21(.4) (A Govt of India Undertaking) STEEL PLATES
Page 2 of 7

Abbreviations:

ASME American Society of Mechanical Engineers

EN European Norm
HIC Hydrogen Induced Cracking
IBR Indian Boiler Regulations
SSC Sulphide Stress Cracking

Static Equipment Standards Committee

Convenor: Mr. K.J. Hari Narayanan

Members: Mr. P.Bhattacharjee
Mr. Sanjay Mazumdar
Mr. PP.Pandey
Mr. Nalin Kumar
Mr. K. Anjaneyulu
Mr. Arun Kumar
Mr. Inder Kumar
Mr. Tarun Kumar
Mr. Anish Trehan
Mr. M.Azim (Projects)
Mr. S. Ghosal (Process)
Mr. T. Kamalakannan (Inspection)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 342 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS
511gar m Eiardu INDIA LIMITED BOILER QUALITY CARBON 6-12-0011 Rev. 8
Mln ciltaxed31J031.1/ G01.4 01 India Uncle'taking)
STEEL PLATES
Page 3 of 7

CONTENTS

1.0 SCOPE 4
2.0 GENERAL 4
3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS 4
4.0 CERTIFIED DOCUMENTS 6
5.0 PAINTING AND COATING 7
6.0 INSPECTION AUTHORITY 7

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 343 of 674

 STANDARD SPECIFICATION No.
ENGINEERS STANDARD SPECIFICATION FOR
51gzir agjeg INDIA LIMITED BOILER QUALITY CARBON 6-12-0011 Rev. 8
10117710,0me 0113900:0 (A Goof. 01 India UndeItaking)
STEEL PLATES
Page 4 of 7

1.0 SCOPE

1.1 This specification covers requirements for carbon steel plates intended primarily for pressure
vessels/heat exchangers. The steel plates shall meet the requirements of ASME Boiler and
Pressure Vessel Code Section II (latest). This is intended to supplement the minimum
applicable requirements of the material specification indicated in the material requisition.

1.2 Following codes, standards etc shall be followed in their latest edition and addenda, errata,
amendments unless specified otherwise:

1.2.1 ASME Sec VIII Div 1

1.2.2 ASME Sec II part A

1.2.3 EN 10163: Delivery Requirements for Surface Conditions.

1.2.4 EN 10204: metallic products — Types of Inspection Documents.

2.0 GENERAL

2.1 Plates supplied to this specification shall conform to specification SA-20 of ASME sec II part
A with additional requirements mentioned herein.

2.2 The tolerance on thickness of steel plates shall be positive only.

2.3 Final Rolling shall be lengthwise.

2.4 The plates shall be free from injurious defects and shall have workmanlike finish.
Reconditioning/repair of plates by welding shall not be permitted. Surface conditions shall
meet requirements of EN 10163 Class A Subclass 3.

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS

3.1 All plates shall be supplied in normalised condition except when the applicable material
specifications require supply of plates in quenched and tempered condition.

3.2 a. One product analysis of each heat shall be carried out and reported. Chemical
analysis shall be as per applicable specification.

b. The carbon content for plates shall not exceed 0.23%.

Additionally, one of the following requirements for carbon equivalent based on heat
analysis, shall be also satisfied:

Ceq = C + Mn < 0.42 (Eqn. - 1)

6

Ceq = C + Mn + Cr+Mo+V + Cu+Ni < 0.43 (Eqn. - 2)

6 5 15

Equation-1 shall be used when applicable material specification specifies C and Mn

only.

Equation-2 shall be used when applicable material specifies the above elements or
restricted chemical requirements are specified or supplementary requirements S 19 and
S21 of SA-20 are specified in material requisition.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 344 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
k31 ENGINEERS
Igar Elf5ieg INDIA LIMITED BOILER QUALITY CARBON 6-12-0011 Rev. 8
lairen rIrAme an JqiNA) (A Govt al India Undeltaking)
STEEL PLATES
Page 5 of 7

For HIC services, these requirements shall be as listed separately.

3.3 Ultrasonic Examination of Plates

a. Plates having thickness 16 mm to 50 mm (both inclusive) shall be examined

ultrasonically as per SA-435.
b. For thicknesses above 50mm ultrasonic examination shall be carried out as per SA-
578 and shall have acceptance standard of level-B.
c. For quenched and tempered steel plates, ultrasonic examination shall be done after the
heat treatment of plates.

3.4 Simulated Heat Treatment of Test Coupons

The following heat treatment shall be conducted on the test coupons representative of heat
treated plates before the specified mechanical testing like tensile, bend, impact tests, etc. to
meet minimum ASME Sec. II Part - A requirements and these details shall also be recorded on
the test certificates.

a. All plates supplied in Normalised condition and intended for hot rolling / hot
forming:

Heat Treatment Cycle

One normalising* + One stress relieving as per UCS-56 of ASME Sec. VIII Div.1
complying with UCS-85 of ASME Section VIII Div. 1.

Note: Any other special requirement shall be specified in MR.

b. All plates supplied in Quenched & Tempered condition and intended for hot rolling/
hot forming:

Heat Treatment Cycle

One normalising* + quenched & tempering + One stress relieving as per UCS-56
ASME Section VIII Div.1 complying with UCS-85 of ASME Section VIII Div.1 .

Note : Tempering temperature shall be at least 20° C above highest stress relieving
temperature.

* Recommended normalising cycle :

i) Soaking temperature: 900°C to 1000°C
ii) Holding time one hour per 25 mm thickness but not less than half an hour
iii) Cooling in still air

c. All plates supplied in Quenched & Tempered condition and intended for cold
forming:

Heat Treatment Cycle

One stress relieving as per UCS-56 ASME Section VIII Div.1 complying with UCS-
85 of ASME Section VIII Div.1 .

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Page 345 of 674

 STANDARD SPECIFICATION No.
tri-draelei ENGINEERS STANDARD SPECIFICATION FOR
$fgar faoleg INDIA LIMITED BOILER QUALITY CARBON 6-12-0011 Rev. 8
laarn riecnir ansgar,a) (A Govt Ind.. Undertaking)
STEEL PLATES
Page 6 of 7

3.5 Impact test requirements shall be ascertained as per ASME Sec VIII Div.1 or Div.2 as
applicable. When required, Impact testing shall be performed as per supplementary
requirement of S5 of specification SA-20 and acceptance criteria for energy absorption shall
be as per table A2.15 of SA-20.

3.6 If specified in the material requisition, plates shall meet the requirements of Indian Boiler
Regulations (IBR).

3.7 Additional Requirements for High Thickness Plates

Plates above 50mm thickness shall meet following additional requirements:

a. Vacuum Degassing treatment as per the supplementary requirement Si of

specification SA-20. If vacuum degassing is not reported in the test certificates, then
through thickness tests as per SA 770 shall be conducted and minimum reduction in
area of 35% shall be ensured.

b. Charpy V-notch impact test as per the supplementary requirement S5 of specification

SA-20.

Material meant to be used for design temperature warmer than 0°C, impact test shall
be carried out at 0°C or MDMT whichever is lower and acceptance criteria for energy
absorption shall be as per Table A2.15 of SA-20. Incase the acceptance criteria is not
available in SA-20, then applicable design code shall be referred unless otherwise
specified in material requisition.

c) Simulated heat treatment of test coupons for all plates as per Clause 3.4 mentioned
above.

4.0 CERTIFIED DOCUMENTS

The supplier shall furnish certificates/documents (number of copies as specified in requisition)

inclusive of all the following tests required as per specification duly certified by the Inspecting
Authority before shipment of plates. The actual values obtained shall be recorded in the test
certificates/documents. Material certificates shall conform to EN 10204 Type 3.1/3.2 as
required.
a. Chemical Analysis

b. Mechanical Tests

c. Data of heat treatment i.e. initial temperature, heating rate, soaking temperature,
cooling rate, etc.

d. Simulated Heat Treatment of Mechanical Test coupons (S3 of SA-20) at indicated

Heat Treatment Cycle (if specified in the requisition or whenever applicable)

e. Ultrasonic Examination (S8 or S12 of SA-20)

f. Charpy V-notch impact tests (S5 of SA-20 if specified in the requisition or whenever
applicable)

g. Certification as per IBR (if specified in the requisition)

h. SSC and/or HIC tests (if specified in material requisition)

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Page 346 of 674

 •
STANDARD SPECIFICATION No.
ENGINEERS STANDARD SPECIFICATION FOR
5fgar &Reg INDIA LIMITED BOILER QUALITY CARBON 6-12-0011 Rev. 8
NEW efeont onoTiM A Govt of India Uncle, talong) STEEL PLATES Page 7 of 7

Additional tests (if specified in requisition).

5.0 PAINTING AND COATING

No painting/coating of any kind is permitted on the steel plates, except stencil marking.
However steel plates shall be carefully protected and packed against any damage during transit
and shall be of sea worthy condition.

6.0 INSPECTION AUTHORITY

Material test certificates, duly certified by Mill's Quality Assurance Department are acceptable
i.e. 3.1 certification as per EN 10204. However, if third party inspection is required
specifically for plates in material requisition, all test certificates and documents shall be duly
certified by the third party. i.e. 3.2 certification as per EN 10204.

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Page 347 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
t31 ei (ft ENGINEERS WELDABLE STRL. QUALITY STEEL
ogej, EII51-es.W INDIA LIMITED PLATES FOR STORAGE TANKS 6-12-0014 Rev. 6
1 V.A.7A(AA) (A Govt of India Undeftak.9)
AND VESSELS Page 1 of 5

1:MR UI Ch *(:1 4R-Ytrr

4 '&(%1 Ct CI I Fri a ci -61.
4-1 lot) f-4-9fti

STANDARD SPECIFICATION FOR

WELDABLE STRUCTURAL QUALITY
STEEL PLATES FOR STORAGE
TANKS AND VESSELS

6 22.09.2017 REVISED AND REISSUED AS STD. SPEC. SK KJH RKT RN

5 30.06.2010 REVISED AND REISSUED AS STD. SPEC. KA RKT AKM/DM N.DUARI

4 15.09.09 REVISED & REISSUED AS STD. SPEC. VB RKG AKM, N.DUARI

3 08.04.04 REVISED & REISSUED AS STD. SPEC. DNN AKM SSA SKG

2 19.09.00 REVISED & REISSUED AS STD. SPEC. KPS AKM CRMN MI

Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

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Page 348 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS WELDABLE STRL. QUALITY STEEL
Offleg
lawn riemll M13.70.0
INDIA LIMITED
(A Govt of India UndertakIng)
PLATES FOR STORAGE TANKS AND 6-12-0014 Rev. 6
VESSELS Page 2 of 5

Abbreviations:

EN European Norm

IS Indian Standard

Static Equipment Standards Committee

Convenor: Mr. R.K. Trivedi

Members: Mr. K.J Hari Narayanan

Mr. P. Bhattacharjee
Mr. Sanjay Mazumdar
Mr. P.P. Pandey
Mr. Nalin Kumar
Mr. K. Anjaneyulu
Mr. Arun Kumar
Mr. Inder Kumar
Mr. Tarun Kumar
Mr. Anish Trehan
Mr. Srikanth Karanam
Mr. M. Azim (Projects)
Mr. S. Ghosal (Process)
Mr. T. Kamalakannan (Inspection)

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Page 349 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
alReA ft, ENGINEERS: - WELDABLE STRL. QUALITY STEEL
o1 at ofwegv_v INDIA LIMITED
aaJoirtal) (A Govt of India Undertaking)
PLATES FOR STORAGE TANKS AND 6-12-0014 Rev. 6
VESSELS Page 3 of 5

CONTENTS

1.0 SCOPE 4

2.0 GENERAL 4

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS 4

4.0 CERTIFIED DOCUMENTS 4

5.0 PAINTING AND COATING 5

6.0 INSPECTION AUTHORITY 5

Copyright EIL — All rights reserved

Format No. 8-00-0001-F1 Rev. 0

Page 350 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
45-tifR_Ie-i ft ENGINEERS WELDABLE STRL. QUALITY STEEL
Ogell lEffiregW INDIA LIMITED PLATES FOR STORAGE TANKS AND 6-12-0014 Rev. 6
(A Govt of moo uneertakm91
VESSELS Page 4 of 5

1.0 SCOPE

1.1 This specification covers additional and supplementary requirements for weldable structural
quality Steel Plates to IS: 2062 (latest), intended primarily for storage tanks and vessels.

1.2 Following Codes, standards etc. shall be followed in their latest edition and addenda, errata,
amendments unless specified otherwise:

1.3 IS:2062, IS:1852, IS:10842

1.4 EN 10163: Delivery for Surface Condition.

1.5 EN 10204: Metallic products — Types of Inspection Documents.

2.0 GENERAL

2.1 The maximum under tolerance permissible on the thickness of plate shall be 0.25 mm.
Tolerances on other dimensions of plates shall be as per IS: 1852.

2.2 Direction of final rolling shall be lengthwise.

2.3 Reconditioning/Repair of plates by welding shall not be permitted. Surface finish shall be
ground/flush smooth and shall be free from any surface imperfection.

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS

3.1 Heat analysis and product analysis shall be carried out for each heat and chemical composition
shall meet the limits as specified in IS: 2062.

3.2 Y-groove weld crackability test as per IS: 10842 shall be carried out for plates conforming to
Gr. E250 C having thickness 12mm and above.

3.3 Charpy impact test shall be carried out on the plates having thickness greater than 12 mm
conforming to Grade E250 BR, E250 BO & E250 C. Test temperature and acceptance criteria
for energy absorption shall be as mentioned in Table-2 of the specification IS: 2062.

4.0 CERTIFIED DOCUMENTS

The supplier shall furnish certificates/documents (number of copies as specified in requisition)

inclusive of all the following tests required as per specification, duly certified by the
Inspecting Authority before shipment of plates. The actual values obtained during tests shall
be recorded in the test certificates/documents. Material certificates shall conform to EN 10204
Type 3.1/3.2 as required.

a. Chemical Analysis
b. Mechanical Tests
c. Data of heat treatment
d. Charpy V-notch impact tests
e. Y- groove crackability test

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Page 351 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
4arael ENGINEERS WELDABLE STRL. QUALITY STEEL
51gem faitegW INDIA LIMITED PLATES FOR STORAGE TANKS AND 6-12-0014 Rev. 6
21EvoR tolJoilta) (A Govt of Inds Undeftakmg)
VESSELS Page 5 of 5

5.0 PAINTING AND COATING

No painting/coating of any kind is permitted on the steel plates except stencil marking.
However steel plates shall be carefully protected and packed against any damage during transit
and shall be of sea worthy conditions.

6.0 INSPECTION AUTHORITY

Material test certificates, duly certified by Mill's Quality Assurance Department are acceptable
i.e. 3.1 certification as per EN 10204. However, if third party inspection is required specially
for plates in material requisition, all test certificates and documents shall be duly certified by
the third party. i.e. 3.2 certification as per EN 10204.

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Page 352 of 674

 STANDARD SPECIFICATION No.
ENGINEERS STANDARD SPECIFICATION
EllWeg INDIA LIMITED FOR CLAD PLATES 6-12-0015 Rev. 5
.,e:,,w4513P0.1) (A Govt of India Undertaking)
Page 1 of 5

Tft. -0e1
1-414RT

STANDARD SPECIFICATION

FOR CLAD PLATES

5 26.06.18 REVISED AND REISSUED AS STD. SPEC.

4 30.07.10 REVISED AND REISSUED AS STD. SPEC. KA RKT AKM/DM N.DUARI

3 30.09.09 REVISED AND ISSUED AS STD. SPEC. KA RKG AKM N. DUARI

2. 29.03.04 REAFFIRMED & REISSUED AS STD. SPEC. DNN AKM SSA SKG

1 16.12.98 REVISED AND REISSUED AS STD. SPEC. USG AKM CRMN A SONI
Standards Standards
Rev. Prepared Committee Bureau
Checked
Date Purpose Convenor Chairman
No by by
Approved by

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Page 353 of 674

 STANDARD SPECIFICATION No.
ENGINEERS STANDARD SPECIFICATION
fell5leg
INIETr eiRMEMIJR:Ifil)
INDIA LIMITED FOR CLAD PLATES 6-12-0015 Rev. 5
(A Govt of India Undertaking)
Page 2 of 5

Abbreviations:

ASME American Society of Mechanical Engineers

ASTM American Society For Testing & Materials

BHN Brinell Hardness Number

EN European Standards

IBR Indian Boiler Regulations

IGC Inter Granular Corrosion

Static Equipment Standards Committee

Convenor: Mr. K.J Hari Narayanan

Members: Mr. Sanjay Mazumdar
Mr.K.Anjaneyulu
Mr. Arun Kumar
Mr. Inder Kumar
Mr. Tarun Kumar
Mr. Srikanth Karanam
Mr. M.Azim (Projects)
Mr. S. Ghosal (Process)
Mr. T.Kamalakannan (Inspection)

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Page 354 of 674

 STANDARD SPECIFICATION No.
09 ENGINEERS STANDARD SPECIFICATION
-
"V' eu
Itgar NR- aR3,10.0
INDIA LIMITED
(A Govt lotto Undertaking)
FOR CLAD PLATES 6-12-0015 Rev. 5
Page 3 of 5

CONTENTS

1.0 SCOPE 4

2.0 GENERAL 4

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS 4

4.0 CERTIFIED DOCUMENTS 5

5.0 PAINTING AND COATING 5

6.0 INSPECTION AUTHORITY 5

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Page 355 of 674

 STANDARD SPECIFICATION No.
ENGINEERS STANDARD SPECIFICATION
eg laPift INDIA LIMITED FOR CLAD PLATES 6-12-0015 Rev. 5
14aerr eiernie+01.3.Rmi) (A Govt India Undertaking)
Page 4 of 5

1.0 SCOPE

This specification covers clad plates of a carbon steel or low alloy steel base integrally and
continuously bonded on one side with a layer of chromium steel , chromium nickel steel and
Monel. The base as well as the alloy cladding metal shall meet the requirements of ASME
Boiler and Pressure Vessel Code Section II and ELL specifications 6-12-0011, 6-12-0017 and
6-12-0018. This is intended to supplement the minimum applicable requirements of material
specification indicated in the material requisition.

2.0 GENERAL

2.1 Plates supplied to this specification shall conform to the latest issue of applicable
specification SA-263, SA-264, SA-265, SA-20 and SA-578 with additional requirements
mentioned herein.

2.2 The tolerance on thickness of base metal as well as cladding metal shall be positive only.

2.3 Final rolling shall be lengthwise.

2.4 Outside surface of base metal shall meet requirements of EN 10163 class- A sub clause 3.

2.5 Unless otherwise specified in the requisition the surface of alloy cladding shall have No.1
finish for hot rolled and 2B finish for cold rolled.

2.6 Acid pickling shall be done for chromium nickel stainless steel cladding as per ASTM A-380.
Manufacturer's standard practice for pickling shall be followed for chromium steel cladding.

2.7 Repair of cladding surface by welding shall not exceed 3% of surface area of individual plate.

2.8 The integral & continuous cladding shall be produced by roll bonding or explosion bonding
process with bond integrity Class 1.

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS

3.1 Chemical composition of the clad metal shall meet the requirement of the applicable material
specification. But in case of straight chrome (13% Cr) cladding material, carbon content shall
be less than 0.06%.

3.2 Unless otherwise specified in the requisition, heat treatment of the clad steel plate shall be as
per the applicable clad plate material specification. All stabilized grades of austenitic
Stainless Steel (SS 321, SS 347etc.) clad plate shall be in stabilization heat treated condition
in addition to solution annealing.

3.3 Alloy cladding representative of each heat shall be subjected to inter-granular corrosion test
as per ASTM A-262, Practice E for all 300 series material. IGC test shall be carried out after
cladding process.

3.4 During the mill tension test of all clad steel plates, the cladding shall be removed and the
tensile properties shall meet the requirements of the base material. Test specimen shall be
taken transverse to rolling direction.

3.5 For all clad steel plates, shear test shall be conducted. Strength of bond shall be at least
20,000 psi in shear.

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Page 356 of 674

 STANDARD SPECIFICATION No.
OWE? ENGINEERS STANDARD SPECIFICATION
*gem EffReg INDIA LIMITED FOR CLAD PLATES 6-12-0015 Rev. 5
(A Govt Undertaking(
Page 5 of 5

3.6 All clad steel plates shall be ultrasonically examined in accordance with SA-578 with
acceptance standard level-C and shall meet the supplementary requirements S 1. Integrity of
clad plate shall be ensured Quality level: class-1 as per SA 263 or SA 264 or SA 265.

3.7 The ultrasonic examination shall be conducted after the specified final heat treatment of the
clad steel plates.

4.0 CERTIFIED DOCUMENTS

The supplier shall furnish 6 copies of the following certificates/documents inclusive of all
tests required as per specification, duly certified by the Inspecting Authority before shipment
of plates. The actual values obtained shall be recorded in the test certificates/documents.
Purchaser's technical requirements shall be clearly shown in the test certificates. Material
certificate shall conform to EN 10204 Type3.2

4.1 Chemical Analysis for both cladding metal and base metal.

4.2 Mechanical test for base metal and shear strength for clad plate.

4.3 Data of heat treatment of clad plate i.e. initial temperature, heating rate, soaking
temperature/time, cooling rate etc. For simulation heat treatment of base plate test coupon,
chart of heat treatment is to be attached to Mill's Certificate.

4.4 Ultrasonic examination.

4.5 Inter-granular corrosion test.

4.6 Finish for a cladding & base metal.

4.7 Method of cladding.

4.8 Certification as per IBR (if specified in material requisition)

4.9 Date of manufacture.

4.10 Pickling procedure.

5.0 PAINTING AND COATING

Plates are not to be painted/coated but shall be covered with plastic foils or paper or by other
means for careful protection and shall be packed against any damage during transit and sea
weather conditions.

6.0 INSPECTION AUTHORITY

ELL/Lloyds Register of Shipping/Third party approved by Eli as indicated in the requisition.

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Page 357 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS 1% Cr-1/2% Mo AND 11/4% Cr-1/2 % Mo
INDIA LIMITED 6-12-0017 Rev. 5
14 Govt M Ind. Undertaking) STEEL PLATES
Page 1 of 5

1% 9111 FW-11-1-1/2% 1-11c1r1011-1 alT

11A% WIRRTIT-1/2% 1-1 101 co 111

(-ao *fa Hilcb fq-w-Tr

STANDARD SPECIFICATION
FOR
1% Cr-1/2%Mo AND 11/4% Cr-1/2 `)/0Mo
STEEL PLATES

5 28.08.2018 REVISED AND REISSUED AS STD. SPEC SK KJH • - RKT

4 30.06.2010 REVISED AND REISSUED AS STD. SPEC. KA RKT AKM/DM N.DUARI

3 15.09.09 REVISED & REISSUED AS STD. SPEC. VB RKG AKM N.DUARI

2 15.04.04 REVISED AND REISSUED AS STD. SPEC. DNN AKM SSA SKG

1 15.05.00 REVISED AND REISSUED AS STD. SPEC. DNN AKM CRMN MI

Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

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Page 358 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS
cigar Wes INDIA LIMITED 1% Cr Y2% Mo AND 11/4% Cr-%% Mo 6-12-0017 Rev. 5
lawn e9eturea613,41.1/ IA Govt ot India Umbertakulgt STEEL PLATES
Page 2 of 5

Abbreviations:

ACC Accelerated Cooling Cycle

ASME American Society of Mechanical Engineers

BUN Brinell Hardness Number

EN European Norms

IBR Indian Boiler Regulations

N Normalised

T Tempered

Static Equipment Standards Committee

Convenor : Mr. K.J Hari Narayanan

Members : Mr.Sanjay Mazumdar
Mr.K.Anjaneyulu
Mr. Arun Kumar
Mr. Inder Kumar
Mr. Tarun Kumar
Mr. Srikanth Karanam
Mr. M.Azim (Projects)
Mr. S. Ghosal (Process)
Mr. T.Kamalakannan (Inspection)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 359 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS
lit ElPieg INDIA LIMITED 1% Cr-1/2% Mo AND 11/4% Cr-1/2% Mo 6-12-0017 Rev. 5
1924,12 4,139CRA) (A Govtd •. Undertaloogl STEEL PLATES
Page 3 of 5

CONTENTS

1.0 SCOPE 4

2.0 GENERAL 4

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS 4

4.0 CERTIFIED DOCUMENTS 5

5.0 PAINTING AND COATING 6

6.0 INSPECTION AUTHORITY 6

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 360 of 674

 STANDARD SPECIFICATION No.
09-aelei ENGINEERS STANDARD SPECIFICATION FOR
sigen 251-e390.g1)
_-„21VIMIZOST. INDIA LIMITED 1% Cr-1/2% Mo AND 11/4% Cr-1/2% Mo 6-12-0017 Rev. 5
IA Govt of India Undettaklog) STEEL PLATES
Page 4 of 5

1.0 SCOPE

1.1 This specification covers 1% Cr-V2%Mo and 11/4% Cr-Y2%Mo steel plates intended primarily
for Pressure Vessels/heat exchangers. The steel plates shall meet the requirements of ASME
Boiler and Pressure Vessels Code Section II. This specification is intended to supplement the
minimum applicable requirements of the material specification.

1.2 Following codes, standards etc. shall be followed in their latest edition and addenda, errata,
amendments unless specified otherwise:

1.2.1 ASME Sec II part A

1.2.2 EN 10163 : Delivery Requirements for Surface Conditions.

1.2.3 EN 10204 : Metallic products — Types of Inspection Documents

2.0 GENERAL

2.1 Plates supplied to this specification shall conform to specification SA-20 with additional
requirements mentioned herein.

2.2 The tolerance on thickness of steel plates shall be positive only.

2.3 Final Rolling shall be lengthwise.

2.4 The plates shall be free from injurious defects and shall have workmanlike finish.
Reconditioning/repair of plates by welding shall not be permitted. Surface conditions shall
meet requirements of EN 10163 Class A sub Class-3.

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS

3.1 Plates shall be supplied in Normalized and Tempered condition unless otherwise specified.
Alternatively accelerated, cooling from an austenitizing temperature by liquid quenching
followed by tempering is also acceptable ( N + ACC. + T)

3.2 One product analysis for each plate shall be carried out. Chemical composition shall be as per
applicable material specification with additional requirement of phosphorus equal to 0.01%
maximum and phosphorus plus tin equal to 0.016% maximum.

3.3 Ultrasonic Examination of Plates

Plates shall be ultrasonically examined after specified heat treatment as per following:

a. Plates having thickness 16 mm to 50 mm (both inclusive) shall be examined ultrasonically

as per SA-435.

b. For thicknesses above 50mm ultrasonic examination shall be carried out as per SA-578
and shall have acceptance standard of level-B.

3.4 Charpy V-notch impact test shall be carried out for each plate at minus 18°C with average
value of three specimens as 33 joules with minimum value of each specimen as 22 joules.

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Page 361 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS
~ r es INDIA LIMITED 1% Cr-1/2% Mo AND 11/4% Cr-1/2% Mo 6-12-0017 Rev. 5
M 2.2¢1517 051,10.1) (A Govt of lode Undertaking) STEEL PLATES
Page 5 of 5

3.5 Simulated Heat Treatment on Test Coupons

All test specimens representative of heat treated plates shall be subjected to simulated heat
treatments before the specified mechanical tests like tensile, impact etc. and these details shall
be recorded on the test certificates. Simulated heat treatments shall include all heat treatments
involved during fabrication of the equipment (including intermediate stress-relief etc.) and
final PWHT plus two additional PWHT cycles (One for repair at shop and another for future).
Impact tests and hardness tests shall be carried out in both minimum and maximum heat
treatment condition while other mechanical tests (tensile etc.) shall be conducted at maximum
heat treatment condition.

Note : Tempering temperature shall be minimum 20°C higher than the final PWHT
temperature.

3.6 Additional Requirements for High Thickness Plates

Plates of thickness 50mm and above shall meet the following additional requirements:

a) Vacuum treatment as per supplementary requirement S1 of specification SA-20.

b) Through thickness tensile test shall be carried out as per specification SA-770 for each
plate and reduction of area shall be determined as per SA-370. Minimum reduction in area
shall not be less than 35%.

3.7 If specified in the Material Requisition, each plate shall meet the requirements of Indian
Boiler Regulation (IBR).

3.8 The hardness of each plate shall be limited to such an extent that the final hardness in base
metal, HAZ and welds of the vessel shall not exceed 225 BUN.

4.0 CERTIFIED DOCUMENTS

The supplier shall furnish 6 copies of the following certificates/documents inclusive of all
tests required as per specification duly certified by the Inspecting Authority before shipment
of plates. The actual values obtained shall be recorded in the test certificates/documents.
Material certificates shall conform to EN 10204 Type 3.1/3.2 as required.

- Chemical Analysis

- Mechanical Tests

Data of heat treatment i.e. initial temperature, heating rate, soaking temperature and
cooling rate etc.

Simulated Heat Treatment of Mechanical Test Coupons (S3 of SA-20) at indicated Heat
Treatment cycle only.

Ultrasonic Examination (S8 or S12 of SA-20/ SA-20M)

Charpy V-notch impact test (S5 of SA 20/ SA-20M)

Through thickness tensile test as per SA-770

Certification as per IBR (If specified in the requisition)

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Page 362 of 674

 STANDARD SPECIFICATION No.
ENGINEERS STANDARD SPECIFICATION FOR
INDIA LIMITED 2.25% Cr - 1% Mo STEEL PLATES 6-12-0018 Rev. 4
0151eg
1.11VR MI J,/{1,34 (A Goat of India Undertaking) Page 1 of 7

2.25 %*ffgrzigi- 1% 11101Q1 4i *iazi ore

-N-r9ft

STANDARD SPECIFICATION FOR

2.25% Cr —1% Mo STEEL PLATES

4 22.12.15 REVISED AND REISSUED AS STD SPEC. TK KJH RKT

3 15.09.09 REVISED AND REISSUED AS STD.SPEC. VB RKG AKM N.DUARI

2 12.04.04 REVISED AND REISSUED AS STD. SPEC. DNN AKM SSA SKG

1 05.01.01 REVISED AND REISSUED AS STD. SPEC. DNN AKM CRMN MI

0 01.03.96 ISSUED AS STANDARD SPECIFICATION DNN CRMN VC AS

Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 363 of 674

 STANDARD SPECIFICATION No.
k.71 el ENGINEERS STANDARD SPECIFICATION FOR
$‘gar 015reg INDIA LIMITED 2.25% Cr - 1% Mo STEEL PLATES 6-12-0018 Rev. 4
(Wen eleAACtInJW1,11, (A Govt of India Undertaking)
Page 2 of 7

Abbreviations:

ASME : American Society of Mechanical Engineers

ASTM : American Society for Testing and Materials
ACC : Accelerated Cooling Cycle
BHN : Brinell Hardness Number
EN : European Standard
IBR : Indian Boiler Regulations
ISR : Intermediate Stress Relieving
N : Normalised
PWHT : Post Weld Heat Treatment
T• Tempered

Static Equipment Standards Committee

Convenor : Mr. R. K. Trivedi

Members : Mr. K. J. Hari Narayanan

Mr. K. Anjaneyulu
Mr. Arun Kumar
Mr. Tarun Kumar
Mr. Anish Trehan
Mr. Deepak Gupta (Projects)
Mr. S. Ghosal (Process)
Mr. D. Jana (Construction)
Mr. T. Kamalakannan (Inspection)

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Page 364 of 674

 STANDARD SPECIFICATION No.
ei ENGINEERS STANDARD SPECIFICATION FOR
sigu Eif5ieu
MET, eteave JrIPM)
INDIA LIMITED
(A Govt of India Undertaking)
2.25% Cr - 1% Mo STEEL PLATES 6-12-0018 Rev. 4
Page 3 of 7

CONTENTS

1.0 SCOPE 4

2.0 GENERAL 4

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS 4

4.0 CERTIFIED DOCUMENTS 6

5.0 PAINTING 6

6.0 INSPECTION AUTHORITY 7

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Page 365 of 674

 STANDARD SPECIFICATION No.
ENGINEERS STANDARD SPECIFICATION FOR
$1g-ar INDIA LIMITED 2.25% Cr - 1% Mo STEEL PLATES 6-12-0018 Rev. 4
(OWN cwaNe .3,70,71) (A Govt of India Undeffalfing)
Page 4 of 7

1.0 SCOPE

1.1 This specification covers additional and supplementary requirements of SA-387 / SA-387M
Gr.22 CI.2 (ASME Sec. II Part A) plates intended primarily for pressure vessels/heat
exchangers with design temperature exceeding 375 °C in hydrogen service.

1.2 Following codes, standards etc. shall be followed in their latest edition and addenda, errata,
amendments unless specified otherwise:

1.2.1 ASME Sec II part A

1.2.2 EN 10163 : Delivery Requirements for Surface Conditions.

1.2.3 EN 10204 : Metallic products — Types of Inspection Documents

2.0 GENERAL

2.1 Plates supplied to this specification shall conform to specification SA-20 with additional
requirements mentioned herein.

2.3 The tolerance on thickness of steel plates shall be positive only.

2.4 Final rolling shall be lengthwise.

2.5 The plates shall be free from injurious defects and shall have workmanlike finish
Reconditioning, repair of plates by welding shall not be permitted. Surface conditions shall
meet requirements of EN 10163 (Part: 2) Class A Subclass 3.

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS

3.1 The steel shall be made by electric furnace or basic oxygen process and shall be vacuum
degassed.

3.2 Plates shall be supplied in Normalised and Tempered condition (N+T). Alternatively
accelerated cooling from an austenitizing temperature by liquid quenching followed by
tempering is also acceptable ( N + ACC. + T).

3.3 The tensile strength at room temperature shall not exceed 690 N/mm 2 and the yield strength
should not exceed 620 N/mm 2

3.4 Certified chemical analysis shall be carried out on heat as well as on product. In addition to
chemical analysis required by applicable material specification, analysis of Ni, Cu, As, Sn,
and Sb shall be reported. However, Copper and Nickel content shall be limited to 0.20%
(max.) and 0.30% (max.) respectively. Material shall have a T factor, as defined as (Si + Mn)
x (P + Sn ) x 104 less than or equal to 100, where the concentration of elements are in percent.

3.5 The material shall have an austenitic grain size 5 (Five) or finer as determined by the method
of ASTM E 112.

3.6 Ultrasonic Examination of Plates

Plates shall be ultrasonically examined after specified heat treatment as per following:

a. Plates having thickness 16 mm to 50 mm (both inclusive) shall be examined ultrasonically

as per SA-435.

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Page 366 of 674

 STANDARD SPECIFICATION No.
Ills el l ENGINEERS STANDARD SPECIFICATION FOR
$igar faatcg
(airerr rironfe ar1,3rgre)
INDIA LIMITED
(A Gov! of India Undertakong)
2.25% Cr - 1% Mo STEEL PLATES 6-12-0018 Rev. 4
Page 5 of 7

b. For thicknesses above 50mm ultrasonic examination shall be carried out as per SA-578
and shall have acceptance standard of level-B.

3.7 Simulated Heat Treatment on Test Coupons

All test specimens representative of heat treated (N+T) / (N+ACC+T) plates shall be subjected
to simulated heat treatments. Simulated heat treatments shall include all heat treatments
involved during fabrication of the equipment. This shall include PWHT of the equipment plus
two additional PWHT cycle (one for shop repair and one for future) including all intermediate
heat treatments (ISR). Simulated heat treatment shall be conducted on the test coupons before
the specified mechanical tests like tensile, bend, impact tests etc. All tests shall be carried out
with minimum PWHT condition and maximum PWHT condition including all ISR. These
details shall be recorded on test certificates clearly indicating all heat cycle conditions.
Simulated heat treatments shall be decided by fabricator based on fabrication technique
employed.

3.7.1 Impact tests (Charpy V-Notch) shall be carried out at minus 29 °C with 55J average value for
three specimens and with no single specimen below 48J. The orientation of test specimen
shall be transverse to the direction of final rolling.

3.8 a) Impact energy versus temperature (transition) curves shall be developed for each heat of
plate.
i) A minimum of eight sets of three impact tests of completely heat treated material with
minimum PWHT condition and maximum PWHT condition including all ISR shall be
performed for each curve. Sample location shall be as specified in ASME code.

ii) The eight sets of impact test shall be performed at different temperature but shall
include minus 29 °C. The generated transition curve shall clearly define the transition
zone and the upper shelf. The maximum test temperature shall correspond to the upper
shelf energy level.
b) Step cool tests shall be performed on completely heat treated material with minimum
PWHT condition and maximum PWHT condition including all ISR from each heat of
plate.

i) Samples shall be heated from 316°C to 593°C with maximum rate of 56°C.

ii) Step cooling shall be in accordance with the following temperatures, holding times
and cooling rates to the next lower temperature:

Temperature Holding time Cooling rate to the next temperature

°C Hrs. °C/hr

593 1 5.6
538 15 5.6
524 24 5.6
496 60 2.8
468 100 27.8
315 - air cooling

iii) Impact test of each step cooled sample shall be performed and transition curve shall
be developed following the procedure outlined in clause 3.8(a) above.

c) Acceptance criteria for materials shall be in accordance with the following:

vTr 55 + 3.0 xA vTr < 10 °C

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Page 367 of 674

 STANDARD SPECIFICATION No.
ENGINEERS STANDARD SPECIFICATION FOR
0151tg INDIA LIMITED 2.25% Cr 1% Mo STEEL PLATES
—
6-12-0018 Rev. 4
(Wert elecole JOirw0 (A Govt Of India Undedalong)
Page 6 of 7

Where vTr 55 Charpy V-notch 55J impact energy transition temperature of

completely heat treated specimens before step cooling.

AvTr 555c The shift in Charpy V-notch 55J impact energy transition
temperature after step cooling tests.

3.9 Hardness of plates shall not exceed 225

3.10 Additional Tests

Following additional tests shall be applicable, if specified in Purchase/tender documents:

a. High temperature tension test for each heat as per S7 of SA-20 / SA- 20M at temperature
specified in Material Requisition with maximum PWHT condition including all ISR. Test
results shall also be furnished in the test certificates. The acceptance criteria shall be 90 %
of the value specified in AME Sec II Part D Table U for the test temperature.

b. Through-thickness tension test for plates 25 mm and above in thickness shall be

conducted with frequency and test procedure as per SA-770 / SA-770M with maximum
PWHT condition including all ISR and determination of reduction of area as per SA-370.
Minimum reduction area shall not be less than 35%. Test results shall also be furnished in
the test certificates.

4.0 CERTIFIED DOCUMENTS

The supplier shall furnish certificates/documents (number of copies as specified in the

requisition) inclusive of all the following tests required as per specification, duly certified by
the Inspecting Authority before shipment of plates. The actual values obtained shall be
recorded in the test certificates/documents. Material certificates shall conform to EN 10204
Type 3.1/3.2 as required.

a. Chemical Analysis

b. Mechanical Tests

c. Additional Tests (if specified in the requisition)

d. Data of heat treatment i.e. initial temperature including heat rate soaking temperature
soaking time /cooling rate, etc.

e. Simulated Heat Treatment of Mechanical Test Coupons (S3 of SA-20 / SA-20M)

f. Ultrasonic Examination (S 12 of SA-20 / SA-20M)

g. Certification as per IBR (if specified in the requisition).

h. Charpy V-notch impact tests (S5 of SA-20 / SA-20M)

i. Impact - temperature transition curves and acceptance criteria.

5.0 PAINTING

No painting of any kind is permitted on the steel plates except stencil marking. However,
steel plates shall be carefully protected and packed against any damage during transit and shall
be of sea-worthy condition.

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Page 368 of 674

 STANDARD SPECIFICATION No.
k31 ENGINEERS STANDARD SPECIFICATION FOR
fgzir iameg
mrtR eleaxt mUram ,
INDIA LIMITED
(A Govt of India UncleftalON)
2.25% Cr 1% Mo STEEL PLATES
—
6-12-0018 Rev. 4
Page 7 of 7

6.0 INSPECTION AUTHORITY

Material test certificates, duly certified by Mill's Quality Assurance Department are acceptable
i.e. 3.1 certification as per EN 10204. However, if third party inspection is specified in
material requisition, all test certificates and documents shall be duly certified by the third
party i.e. 3.2 certifications as per EN 10204.

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Page 369 of 674

 STANDARD SPECIFICATION No.
/t3I ENGINEERS STANDARD SPECIFICATION FOR
INDIA LIMITED STAINLESS STEEL PLATES 6-12-0020 Rev. 8
*Igen 'Meg
meet, eventra ort•avkrna) (A Govt a India Undertaking) Page 1 of 5

-47-14U tera
I 1-1 feffbi

STANDARD SPECIFICATION
FOR
STAINLESS STEEL PLATES

s&k
8 22.09.2017 REVISED AND REISSUED AS STD. SPEC. RNK SK/KJH RKT r RN

7 30.06.2010 REVISED AND REISSUED AS STD. SPEC. KA RKT AKM/DM N.DUARI

6 25.09.09 REVISED AND REISSED AS STD. SPEC VB RKG AKM N.DUARI

5 16.04.04 REVISED AND REISSED AS STD. SPEC DNN AKM SSA SKG

4 26.11.99 REVISED AND REISSED AS STD. SPEC RKT AKM CRMN A. SONI
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

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Page 370 of 674

 STANDARD SPECIFICATION No.
ENGINEERS STANDARD SPECIFICATION FOR
$1g-ar Rift
(.7A rircAte om.3,70(.3)
INDIA LIMITED
(A Govt Of Incto UndettakIng)
STAINLESS STEEL PLATES 6-12-0020 Rev. 8
Page 2 of 5

Abbreviations:

ASME American Society of Mechanical Engineers

ASTM American Society for Testing & Materials

EN European Standard

RB Rockwell Hardness Scale B

SS Stainless Steel

Static Equipment Standards Committee

Convenor: Mr. R.K. Trivedi

Members: Mr. K.J Hari Narayanan

Mr. P. Bhattacharjee
Mr. Sanjay Mazumdar
Mr. P.P. Pandey
Mr. Nalin Kumar
Mr. K. Anjaneyulu
Mr. Arun Kumar
Mr. Inder Kumar
Mr. Tarun Kumar
Mr. Anish Trehan
Mr. Srikanth Karanam
Mr. M. Azim (Projects)
Mr. S. Ghosal (Process)
Mr. T. Kamalakannan (Inspection)

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Page 371 of 674

 STANDARD SPECIFICATION No.
18diazie aft ENGINEERS STANDARD SPECIFICATION FOR
slgeir fairegW INDIA LIMITED STAINLESS STEEL PLATES 6-12-0020 Rev. 8
own eRtnre MIJ.91.1) (A Govt 04 inch Undeltak ,n9)
Page 3 of 5

CONTENTS

1.0 SCOPE 4

2.0 GENERAL 4

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS 4

4.0 CERTIFIED DOCUMENTS 5

5.0 PAINTING AND COATING 5

6.0 INSPECTION AUTHORITY 5

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Page 372 of 674

 STANDARD SPECIFICATION No.
t.191aeitlift ENGINEERS STANDARD SPECIFICATION FOR
Oaez lell5ftW INDIA LIMITED STAINLESS STEEL PLATES 6-12-0020 Rev. 8
1.1R,f 2,244'
i W3.2.1) to °m<. of India UncIntalong)
Page 4 of 5

1.0 SCOPE

1.1 This specification covers requirements for chromium, chromium-nickel and chromium-
manganese-nickel stainless and heat resisting steel plates intended primarily for pressure
vessels/heat exchangers. The steel plates shall meet the requirements of ASME Boiler and
Pressure Vessel Code Section II (latest). This is intended to supplement the minimum
applicable requirements of the material specification indicated in the material requisition.

1.2 Following codes, standards etc shall be followed in their latest edition and addenda, errata,
amendments unless specified otherwise:

1.2.1 ASME Sec II Part A.

1.2.2 EN10163: Delivery Requirements for Surface Conditions.

1.2.3 EN 10204: Metallic products- Types of Inspection Documents.

2.0 GENERAL

2.1 Plates supplied to this specification shall conform to specification SA-480 with additional
requirements mentioned herein.

2.2 Plate length and width provide tolerance for shear and plasma cutting only. The tolerance on
thickness of plates shall be positive only.

2.3 Final Rolling shall be lengthwise.

2.4 Plates shall have no. 1 finish on both sides with reference to SA-480.

3.0 SUPPLEMENTARY TECHNICAL REQUIREMENTS

3.1 All plates shall be supplied in hot-rolled, fully annealed and pickled condition. All stabilized
grades of Stainless Steel (SS 321, SS 347etc.) shall be given stabilization heat treatment in
addition to solution annealing. The soaking temperatures for stabilization heat treatment shall
be 915°C ± 10° C and soaking period shall be minimum of 4 hours (2 hours for thickness <
3.5mm).

3.2 Unless specified otherwise in material requisition, plate representative of each heat shall be
subjected to intergranular corrosion tests as per ASTM A-262 Practice E for all the 300 series
materials. The bend test specimen shall be examined at a magnification of 200 x; and bent
specimen shall be free of any cracks or grain dropping.

3.3 For straight chrome (13% Cr) material, maximum carbon content shall not exceed 0.06%.
Hardness of UNS No. S41000, S41008 and S40500 shall not exceed 88 RB.

3.4 a. Plate having thickness 16 mm to 50 mm (both inclusive) shall be examined ultrasonically

as per SA-435.

b. For thickness above 50mm ultrasonic examination shall be carried out as per SA-578 and
shall have acceptance standard of level-B.

3.5 All mandatory tests as per material specification shall be carried out. However tension test
specimen shall be from finished material and shall be selected in transverse direction.

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Page 373 of 674

 STANDARD SPECIFICATION No.
‘39f-Qt4ift,
- ENGINEERS STANDARD SPECIFICATION FOR
OfftliPT
: INDIA S TA INLESS STEEL PLATES 6-12-0020 Rev. 8
Page 5 of 5

4.0 CERTIFIED DOCUMENTS

The supplier shall furnish certificates/documents (number of copies as specified in requisition)
inclusive of all the following tests required as per specification duly certified by the Inspecting
Authority before shipment of plates. The actual values obtained shall be recorded in the test
certificates/documents. Material certificates shall conform to EN 10204 Type3.1/3.2 as
required.

a. Chemical Analysis

b. Mechanical Tests

c. Data of heat treatment i.e. initial temperature, heating rate, soaking temperature, cooling
rate, etc.

d. Ultrasonic Examination

e. Intergranular corrosion test for 300 series

f. Intergranular corrosion test for series other than 300 (whenever specified in the
requisition)

g. Type of finish for plate surfaces

5.0 PAINTING AND COATING

Plates are not to be painted/coated but shall be covered with plastic foils or paper or by other
means for careful protection and shall be packed against any damage during transit and sea-
weather conditions.

6.0 INSPECTION AUTHORITY

Material test certificates, duly certified by Mill's Quality Assurance Department are acceptable
i.e. 3.1 certification as per EN 10204. However, if third party inspection is required
specifically for plates in material requisition, all test certificates and documents shall be duly
certified by the third party. i.e. 3.2 certification as per EN 10204.

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Page 374 of 674

 PACKING, MARKING AND STANDARD SPECIFICATION No.
711104 ENGINEERS SHIPPING SPECIFICATIONS
111 acs INDIA LIMITED
6-14-0009 Rev. 5
efinntAnn.AdunI IA God of India UndertakIng)
FOR TRAYS AND TOWER
INTERNALS Page 1 of 6

t diat aiwa.

*Tut fe4:47
PACKING, MARKING
AND
SHIPPING SPECIFICATIONS .

FOR
TRAYS AND TOWER INTERNALS

REVISED AND REISSUED AS STANDARD

5 10.07.20
SPECIFICATION
REVISED AND REISSUED AS STANDARD
4 12.09.14 DSG IK/ SKM AP SC
SPECIFICATION
REAFFIRMED AND REISSUED AS
3 16.11.09 PG SKM/HCN AKG ND
STANDARD SPECIFICATION
REAFFIRMED AND REISSUED AS
2 21.07.04 PB SKM/HCN RKA SKG
STANDARD SPECIFICATION
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

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Page 375 of 674

 PACKING, MARKING AND STANDARD SPECIFICATION No.
ENGINEERS
INDIA IJMITED SHIPPING SPECIFICATIONS FOR 6-14-0009 Rev. 5
Unde"") TRAYS AND TOWER INTERNALS Page 2 of 6

Abbreviations:

SME Static & Machinery Equipment

SCM Supply Chain Management

SME Standards Committee

Convenor: Mr. K Anjaneyulu

Members: Mr. Sanjay Mazumdar

Mr. Arun Kumar
Mr. Inder Kumar
Mr. Tarun Kumar
Mr. Anish Trehan
Mr. Srikanth Karanam
Mr. Neeraj Agarwal (Projects)
Mr. S Ghosal (Process)
Mr. T Kamalakannan (SCM)

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Page 376 of 674

 PACKING, MARKING AND STANDARD SPECIFICATION No.
ENGIN/EELS
zgar ivegwNDIA UNITED SHIPPING SPECIFICATIONS FOR 6-14-0009 Rev. 5
(A G'tM Unde""%) TRAYS AND TOWER INTERNALS Page 3 of 6

CONTENTS

1.0 INTENT 4

2.0 PACKING 4

3.0 MARKING 5

4.0 SHIPMENT 5

SKETCHES 6

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Page 377 of 674

 PACKING, MARKING AND STANDARD SPECIFICATION No.
zi ENGINEERS
faigleg ©INDIA LIMITED SHIPPING SPECIFICATIONS FOR 6-14-0009 Rev. 5
Of Wt JW.1,
IA Govt of India Undertaking)
TRAYS AND TOWER INTERNALS Page 4 of 6

1.0 INTENT

This specification defines the minimum requirements for packing, marking and shipping of
Trays, Tower Internals, Tower Packing and other associated components so as to ensure the
damage free transportation. This specification shall not be construed as final and shall not
relieve the vendor of their responsibility of adequate packing of the same for damage free
transportation depending upon the mode of transportation to be adopted finally.

2.0 PACKING

2.1 Trays, Tower Internals and Tower Packing for different columns shall not be mixed in one
box and shall be packed (item wise) separately for each column.

2.2 Unless otherwise in the Engineering drawings, the internals and its associated components
shall not be painted.

2.3 All carbon steel components are to be protected against rusting with two coats of rust
preventive coating such as Castrol Rustilo DWX 32 and all the stainless steel components are
to be cleaned free from foreign materials and shall be supplied duly pickled and passivated.

2.4 All components shall be provided with match and identification marks and also bear the
column number. All identical components shall have the same markings which shall strictly
correspond with numbers given on fabrication drawings. Markings shall be done with
indelible paint or ink which does not contain any metallic pigments.

2.5 All Internal components shall be properly packed, crated and boxed in a manner such as to
protect all parts from damage or loss during transit. It will be Internals Supplier's
responsibility to pack and ensure damage free transit for the mode of transportation finally
adopted and adequate for storage at site for a minimum period of 6 months. Trays & Tower
Internals shall be wrapped in polythene and supplied in wooden cases, as per either EIL
Standard specification or Vendor's proven Standard (In case, Installation of internals is in
Vendor's Scope otherwise follow EIL standard specification). Vendor may use Euro Bags or
equivalent for Random Packings (if installation by same agency otherwise follow EIL
standard specification). Maximum weight of each case shall preferably be limited to 250 kgs.

2.6 Nuts, Bolts, Studs, Clips, Washers, Clamps, Gaskets, Pipes etc.

All supplementary materials like nuts, bolts, clips, washers, clamps, gaskets, pipes and other
components required for internals assembly shall be placed in separate boxes item wise. Nuts,
bolts, clamps, washers etc. for individual item shall be packed in separate containers and due
care shall be taken to ensure that different types as well as sizes of bolting, clamps etc. are not
allowed to get intermixed. Separate packages for different types of bolts, nuts, clamps,
washers etc. for identical components for each column should be made out and then encased
in a bigger container which shall be properly marked with the description of materials packed
and the column number etc. as directed in 3.1 below. The quantity and description of materials
packed shall also be displayed on the smaller packages enclosed in these boxes. All
Constructional Spares shall be packed in separate containers. The packing for individual
components would be done in the same manner as required for supplementary materials and
the box shall be marked with "MANDATORY SPARES"/"OPERATIONAL SPARES" in
addition to other particulars as per 3.1 below. All Mandatory Spares shall be packed separately
and shall not be mixed with Constructional Spares.

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Page 378 of 674

 PACKING, MARKING AND STANDARD SPECIFICATION No.
eie-1 ENGINEERS
Ogem tE101-eu INDIA LIMITED SHIPPING SPECIFICATIONS FOR 6-14-0009 Rev. 5
'A "4 of I'
d'Unde"*";) TRAYS AND TOWER INTERNALS Page 5 of 6

2.7 Packing Cases

Packing Cases can be constructed as per following general guidelines and drawing attached
with this specification. However, vendor may adopt his own practices if same is equivalent or
better, to ensure damage free transportation.

(a) Crates and boxes over 500 mm long shall be reinforced with a minimum of two steel
straps or hoop spaced in 500 mm centers maximum. When the container weight
exceeds 250 kg, skids shall be bolted to the container frame.

(b) Sheathed crates and boxes containing a net weight over 200 kg and all open sided
crates shall have diagonal bracing in all faces.

(c) Flat boxes (containers with two dimension that are four times the third) shall have
diagonal bracing on the two large faces and shall have the four steel straps secured
with nails or screws when the contained weight is over 200 kg.

2.8 Extra precaution shall be taken while packing the Trays, Packings and internals for overseas
jobs. Seaworthy packing must be ensured for overseas jobs to further reinforce and withstand
the harsh conditions of maritime transport and extreme stresses.

3.0 MARKING

3.1 Cases and crates containing tray materials shall be marked at least on 3 sides; for the project,
consignees, consignors, Job No., Order No., Gross & Net Weights, dimensions, description
and quantity of materials etc. Column No. must appear on all the packing cases/boxes in bold
letters.

3.2 Additional markings such as "handle with care", "this side up" etc to be indicated by arrow.
"Fragile" or any other additional indications for protection and safe handling shall be added in
accordance with the type of materials.

3.3 For bulk uniform materials, when packed in several cases, progressive serial numbers shall be
indicated on each cases.

3.4 A packing list shall accompany the material and shall be enclosed in a waterproof envelope /
plastic lamination fastened to the package to enable verification on arrival of the consignment
or when taking up of the delivery. It is necessary that additional copy of packing list with one
copy of drawings along with one copy of installation instructions enclosed in a waterproof
envelope / plastic lamination is also to be placed under the upper lid in each package.

4.0 SHIPMENT

All dispatches of material shall be done in accordance with the relevant terms of the purchase
order. Any other means of transport shall be resorted to only after prior approval in writing.

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Page 379 of 674

 PACKING, MARKING AND STANDARD SPECIFICATION No.
01-4-it4^ENGINEERS
WY INDIA LIMITED SHIPPING SPECIFICATIONS FOR 6-14-0009 Rev. 5
, Ac.......-t"'"`"g) TRAYS AND TOWER INTERNALS Page 6 of 6

W
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Page 380 of 674

 MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
araeleIft-ENGINEERS CARBON STEEL COMPONENTS 6-79-0013 Rev. 2
Ogegfaileg rtir INDIA LIMITED USED IN SOUR SERVICE IN
OW. ew.z.. rm., ( A Govt Undettakm9)
PETROLEUM Page 1 of 6
REFINERY ENVIRONMENT

truziri ancitui
.44;rre tr4 chick tati 3T-47-41.
.41 aTife.

MATERIAL REQUIREMENTS FOR

CARBON STEEL COMPONENTS USED
IN SOUR SERVICE IN
PETROLEUM REFINERY
ENVIRONMENTS

coif?

2 05 07.19 REAFFIRMED AND RE-ISSUED

SM DD SG RKT
REVISED & ISSUED AS STANDARD
1 07 10.11 AR SG PPL DM
SPECIFICATION
REVISED & ISSUED AS STANDARD
0 07 10 04 GM VRK KKM SKG
SPECIFICATION
Standards Standards
Rev. Committee Bureau
Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

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Page 381 of 674

 MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
CARBON STEEL COMPONENTS 6-79-0013 Rev. 2
USED IN SOUR SERVICE IN
PETROLEUM Page 2 of 6
REFINERY ENVIRONMENT

Abbreviations:

ANSI American National Standards Institute

API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
ISO International Organization for Standardization
NACE National Association of Corrosion Engineers

Materials & Coating Standards Committee:

Convener : Mr. S.Ghosal

Members : Mr. Deepak Gupta (Projects)

Mr. M. Ismaeel (Piping)
Mr. K.J Harinarayan (SME)
Mr. D.C.Brahma (Structure)
Mr. R. Muthu Ramalingam (SCM)
Mr. Divyajyot Singh (Construction)
Mr. Naveen Parashar (Projects)
Mr. Satya Sridhar (Process-2)

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Page 382 of 674

 MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
5-mae,t4
t. ENGINEERS CARBON STEEL COMPONENTS
6-79-0013 Rev. 2
4geir OtYlez
1.11Pfl ?IMP MOW.°
INDIA LIMITED
0 Govt of !mks Undertalang)
USED IN SOUR SERVICE IN
PETROLEUM Page 3 of 6
REFINERY ENVIRONMENT

CONTENTS

1.0 SCOPE 4
2.0 REFERENCED CODES/STANDARDS 4
3.0 GENERAL REQUIREMENTS 4
4.0 MATERIAL SPECIFICATION 5
5.0 PRODUCT SPECIFIC REQUIREMNTS 5
6.0 POST WELD HEAT TREATMENT (PWHT) AND HARDNESS REQUIREMENT 6

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Page 383 of 674

 MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
d01 ethENGINEERS CARBON STEEL COMPONENTS 6-79-0013 Rev. 2
$1.42.1i faRegillir INDIA LIMITED USED IN SOUR SERVICE IN
M".".'M. Gort ol trwde Undertaking)
IA PETROLEUM Page 4 of 6
REFINERY ENVIRONMENT

1.0 SCOPE

1.1 In general, for refinery services, NACE International Standard MR0103 shall be applicable.
For refinery services where Hydrogen Induced Cracking (HIC) resistant carbon steel is
specifically mentioned in the process documents, this specification shall be followed.

1.2 This specification lays down the requirements related to the chemical composition,
manufacture, fabrication and testing requirements for carbon steel components intended to be
used in sour service in petroleum refinery environments. These requirements are specified in
order to make the carbon steel component resistant to the various forms of material damage in
a sour environment, such as Sulfide Stress Cracking (SSC), Hydrogen Induced Cracking
(HIC), Stress Oriented Hydrogen Induced Cracking (SOHIC), Blistering etc. These
requirements can be used for resisting Alkaline Stress Corrosion Cracking (ASCC) also. This
specification is applicable for corrosive petroleum refining facilities.

1.3 The service medium is defined as "Sour" when the service environment conforms to one of
the following conditions, as defined in NACE International Standard MR0103:

Service environments containing free water (in liquid phase) and

(a) >50 ppmw dissolved H2S in the free water,

(b) Free water pH < 4 and some dissolved H2S present,

(c) Free water pH >7.6 and 20 ppmw dissolved hydrogen cyanide (HCN) in the water and
some dissolved H2S present,

(d) >0.003 MPa absolute (0.05psia) partial pressure H2S in the gas in processes with a gas
phase.

2.0 REFERENCED CODES/STANDARDS

NACE MR 0103 ASTM A 694 ASTM A 770

NACE RP 0472 ' ASTM A 216 ASTM A 370
NACE Publication 8X194 & 8X294 ASTM A 106 ASTM A 578
NACE TM 0284 API 5 L ASME SEC II PART C
ASTM A 20 API 6 A ASME SEC VIII-DIVA
ASTM A 516 ASTM E 18 ASME SEC IX
ASTM A 105 ASTM E 45 ANSI B 16.34
ASTM A 234 ASTM E 92 ANSI B 31.3

All ASTM Standard designations shall be applicable for corresponding ASME designations
which would be read as ASME SA XXX instead of ASTM A XXX.

3.0 GENERAL REQUIREMENTS

3.1 The steel for sour service shall be manufactured by either basic oxygen or electric arc furnace
route and shall be fully killed and fine grained.

3.2 Carbon steel shall not contain intentional additions of elements such as lead, selenium or
sulphur to improve machinability.

3.3 Carbon steel shall be used in one of the following heat treatment conditions.

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 MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
,31 ENGINEERS CARBON STEEL COMPONENTS
6-79-0013 Rev. 2
51gexidtReg
.11fAIPAAAM.51 ARM
WA LIMITED USED IN SOUR SERVICE IN
IA Gout of inde U.dertalung)
PETROLEUM Page 5 of 6
REFINERY ENVIRONMENT

(i) Hot-rolled
(ii) Annealed
(iii) Normalised
(iv) Normalised and tempered
(v) Normalised, austenitised, quenched and tempered
(vi) Austenitised, quenched and tempered.

3.4 All material after cold forming shall be thermally stress relieved to meet a hardness
requirement of 200 BHN maximum.

3.5 All products shall be free of low temperature transformation microstructures such as bainite
bands or islets of martensite.

4.0 MATERIAL SPECIFICATION

All items are required to conform to the chemical composition of the respective specification
as listed below.

Plate: ASME SA516 Gr.60

Pipe: ASME SA106 Gr. B or SA333 Gr.1 or 6

Forgings: ASME SA105 or SA350 Gr.LF1 or LF2 or SA266 Class 1

Fittings: ASME SA234 Gr. WCB or SA420 Gr.WPL6

Castings: ASME SA216 Gr. WCA, WCB or WCC or SA352 Gr. LCA, LCB or LCC

Tubing: ASME SA179 or SA214

5.0 PRODUCT SPECIFIC REQUIREMNTS

5.1 Plates and Rolled Products

All rolled products such as plates and sheets and fittings / pipes made of rolled products shall
meet the following specific requirements.

5.1.1 The steel shall be made through a clean steel making route and shall have minimum of
inclusions.

5.1.2 The sulphur level shall be restricted to 0.003 wt%.

5.1.3 The steel shall be calcium treated for inclusion morphology control and the Ca/S ratio shall
be in the range of 2 to 3. When sulphur content is less than 0.0015%, then Ca/S ratio is not
applicable and calcium can be present up to 50 ppm.

5.1.4 For plates including and above 25 mm thick, through-thickness tensile testing shall be carried
out in accordance with ASTM A770, with minimum reduction in area being 35% as
determined in accordance with ASTM A370, on one plate per heat.

5.1.5 No repair welding shall be permitted on plated.

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Page 385 of 674

 MATERIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
ENONEERS CARBON STEEL COMPONENTS 6-79-0013 Rev. 2
51geg 119Wg mir INDIA LIMITED USED IN SOUR SERVICE IN
MAIAVAA'AIVAI IA Govt a inda Undeflaktngi
PETROLEUM Page 6 of 6
REFINERY ENVIRONMENT

5.1.6 When the fabrication of the components from the previously HIC tested plates involves no
heavy wall thickness reduction or material flow, such as bending, spinning or welding, no
fresh HIC test would be required on the final product. However, for fabrication of products
where heavy reduction of thickness and heavy flow of material is encountered while forming
such as like forging, extrusion or drawing, metallographic examination of the final product
shall be required to be carried out to ensure absence of elongated inclusions.

5.1.7 The plates shall be procured only from pre-qualified manufacturers.

5.2 Pre-qualification criteria for manufacturers/suppliers with prior experience track record

The manufacturers/suppliers who have proven track record of supplying materials for sour
service applications in petroleum refineries to any of the process licensors such as
UOP/IFP/EXXON/BP/CHEVRON or any of the reputed operating companies/consultants like
ONGC/IOCL/HPCL/BPCL/EIL will be considered as 'pre-qualified manufacturers", on
production of the relevant purchase orders and test certificates, certified by a witnessing third
party inspection agency such as DNV/LLOYDS/BV/ABSTECH/TUV/SGS/CEIL for the
conformance of the materials to the respective materials specification of the mentioned
operators/engineering consultants. For pre-qualified vendors, Clause No. 5.4 is not applicable.

5.3 Pre-qualification criteria for new manufacturers/suppliers without track record

The manufacturers/suppliers who have no track record of supplying sour service materials to
any of the process licensors or the reputed operating companies/consultants as mentioned in
Clause No. 5.2 above, shall be considered as new manufacturers and shall be subjected to the
elaborate pre-qualification by any one of the reputed third party inspection agencies like
DNV/LLOYDS/BV/ABSTECH/TUV/SGS/CEIL as per the requirements.

5.4 Hydrogen Induced Cracking (HIC) Test

The requirements for HIC test shall be as follows.

(i) This test is required for manufacturers pre-qualification only.

(ii) This test shall be performed on a set of three specimens representing each production
batch/heat of rolled products in accordance with NACE TM0284 with the following
acceptance criteria:

(a) Crack Length Ratio (CLR) 10.0%

(b) Crack Sensitivity Ratio (CSR) 1%

(iii) In case of failure of any one of the specimens, three (3) more specimens from the same
product shall be retested and all the specimens shall meet the acceptance criteria. In case
of failure of any retest sample, the material shall be rejected.

6.0 POST WELD HEAT TREATMENT (PWHT) AND HARDNESS REQUIREMENT

All the weld joints, irrespective of thickness, shall be given a post weld heat treatment. The
temperature range for PWHT is 595-650°C with a close control. Other aspects such as rate of
heating, holding time etc. for PWHT shall be as per ASME Sec.VIII, Div.I /ANSI B31.3
requirements. The hardness of the weldment after PWHT shall be 200 BHN maximum.

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Page 386 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
■311 ENGINEERS FOR POSITIVE MATERIAL
Ogeg fai5ieg LJMITED 6-81-0001 Rev. 3
I MKT, Mn1512 011 A Govt of Indict Undertaking) IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS Page 1 of 8

fir ~i~fYnc~i
110111010 111+1 4 11 116t111 .

fe4hr

STANDARD SPECIFICATION
FOR
POSITIVE MATERIAL
IDENTIFICATION
(PMI)
AT SUPPLIER'S WORKS

3 19.09.16. REVISED AND RE-ISSUED TKK RKS RN

2 20.10.11 REVISED AND RE-ISSUED RKS SCG AKC DM

1 15.07.08 REVISED AND RE-ISSUED

NKR SSL SKP VC
0 07.12.00 ISSUED AS STANDARD SPECIFICATION AKC AKB AKB MI
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 387 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
401 ei ENGINEERS FOR POSITIVE MATERIAL
sigez INDIA LIMITED 6-81-0001 Rev. 3
INFer eRmiletel39RIMI (A Govt d tie Undertaking) IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS Page 2 of 8

Abbreviations:

API American Petroleum Institute

AS Alloy Steel
HIC Hydrogen Induced Cracking
LSTK Lump Sum Turn Key
NACE National Association of Corrosion Engineers
PMI Positive Material Identification
RTJ Ring Type Joint
Sch Schedule
SS Stainless Steel
TPI or TPIA Third Party Inspection Agency

Inspection Standards Committee

Convenor: Mr.R K Singh

Members: Mr. Rajeev Kumar

Mr. Himangshu Pal
Mr. Neeraj Mathur
Mr. T Kamalakannan
Mr. Mahendra Mittal
Mr. Deepak Gupta (Project)

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Page 388 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
,311ae, ENGINEERS FOR POSITIVE MATERIAL
O1 ii id1151-eg INDIA LIMITED 6-81-0001 Rev. 3
(KU( t.larolZeimanO.1) (A Govt of Info Undertaking) IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS Page 3 of 8

CONTENTS

1.0 SCOPE 4
2.0 REFERENCE DOCUMENTS 4
3.0 DEFINITIONS 4
4.0 PMI EXAMINATION 5
5.0 ACCEPTABLE METHODS FOR PMI 5
6.0 EXTENT OF PMI EXAMINATION 6
7.0 ACCEPTANCE CRITERIA .6
8.0 REJECTION CRITERIA ... ...... .... ..... ............ ...... ... ...... ............... ..... . ......... ..8
9.0 RECORDING AND DOCUMENTATION 7
10.0 MARKING 7

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Page 389 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
15inazieT ENGINEERS FOR POSITIVE MATERIAL
O1 ii INDIA LIMITED 6-81-0001 Rev. 3
MKT, oxemeenoqwwo IA Govt A Inds Undertaking) IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS Page 4 of 8

1.0 SCOPE

1.1 This specification applies to the requirements for Positive Material Identification (PMI) to be
performed at the Supplier's works on Metallic Materials procured either directly by the
Owner/EIL/ LSTK contractor or indirectly through the sub-Suppliers.

1.2 This specification covers the procedures and methodology to be adopted to assure that the
chemical composition of the material is consistent with the material specifications as specified
in purchase documents using 'Alloy Analyzer' at the time of fmal inspection before dispatch.

13 The scope of this specification shall include but shall not be limited to Positive Material
Identification (PMI) to be performed on Materials listed below:

1.3.1 For alloy Steel materials as below:

Alloy Steel Pipes including Clad Pipes
- Alloy Steel Flanges & Forgings
- Alloy Steel Fittings including Clad Fittings
Alloy Steel Fasteners
- Alloy Cast & Forged steel valves
Alloy Steel Instrumentation Items (Control Valves, Safety Valves etc.)
- Longitudinal Pipe & Fittings Welds.
- Gaskets (for Ring Type Joints)

1.3.2 For Carbon Steel materials as below:

- All Carbon Steel Piping items under NACE or MC or 112 or Wet Hydrogen Sulfide
(1-12S), Hydrofluoric acid (HF), Sulfuric acid (H2 SO4) services etc.
- Carbon Steel flanges and valves (Rating 900# and above)

Following items shall be excluded from scope of PMI examination.

Gaskets other than for Ring Type Joints

- Internal Components of Valves

1.4 All grades of material supplies including Stainless Steels shall be liable for PMI test at site. In
case of any defective materials being found at site, the Supplier shall be responsible to effect
replacement of such defective materials at project site without any delays to the satisfaction of
E1L site RCM (Resident Construction Manager).

2.0 REFERENCE DOCUMENTS

2.1 API Recommended Practice 578 (First Edition, May 1999) - Material Verification Program for
New and Existing Alloy Piping Systems.

3.0 DEFINITIONS

3.1 Supplier: Any Supplier or Manufacturer on whom an order is placed for the supply of referred
items. This definition shall also include any sub-Supplier or manufacturer on whom a sub-order
is placed by the Supplier.

3.2 Inspection Lot: A group of items offered for inspection covered under same size, Heat and
Heat treatment lot.

33 Alloy Material: Any metallic material (including welding filler materials) that contains
alloying elements such as Chromium, Nickel, Molybdenum or Vanadium, which are
intentionally added to enhance mechanical or physical properties and/or corrosion resistance.

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Page 390 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
lagtael ENGINEERS FOR POSITIVE MATERIAL
*Igelf ti5teg
1.12n 2 IETIWQRJ■10.11
INDIA LIMITED
(A Govt Of India undenaong) IDENTIFICATION (PMI) AT
6-81-0001 Rev. 3
SUPPLIER'S WORKS Page 5 of 8

4.0 PMI EXAMINATION

4.1 The Supplier shall submit a procedure of PMI to comply with the requirements of this
Specification. Approval of PMI Procedure shall be obtained from Owner / EIL / TPIA prior to
commencing manufacture / inspection of product.

4.2 PMI examination of materials is independent of any certification, markings or colour coding
that may exist and is aimed at verifying that the alloy used are as per specified grades.

4.3 The Supplier shall identify all incoming alloy materials and maintain full traceability of all alloy
materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to
cutting to ensure maintenance of identification on off-cuts.

4.4 The Supplier shall ensure that all alloy materials are segregated and stored in separately
identified locations to prevent the mix up of materials of different alloy specifications or alloy
material with carbon steel. Non ferro-magnetic materials shall be segregated at all times from
ferro-magnetic materials.

4.5 PMI examination is subject to surveillance inspection by Owner / EIL / TPIA.

5.0 ACCEPTABLE METHODS FOR PMI

5.1 The method used for PMI examination shall provide a quantitative determination of the alloying
elements like Chromium, Nickel, Molybdenum or Vanadium in Alloy Steel items.

5.2 Instruments or methods used for PMI examination shall be able to provide quantitative,
recordable, elemental composition results for positive identification of alloying elements
present.

5.3 The acceptable instruments for alloy analyzer shall be either "Portable X-Ray fluorescence" or
"Optical Emission" type each capable of verifying the percentage of alloy elements within
specified range.

5.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current or
triboelectric testing methods are not acceptable for PMI examination.

5.5 The PMI instrument used shall have the sensitivity to detect the alloying elements in the
specified range.

5.6 All PMI instruments shall have been serviced within a 6 month period of the time of use to
verify the suitability of batteries, sources etc., and the data of the last service shall be stated on
the PMI Report Form (Sample enclosed).

5.7 Each analyzer must be calibrated according to the manufacturer's specification at the beginning
and end of each shift. Instrument must be checked against known standard for each alloy type
to be inspected during the shift.

5.8 Certified samples, with full traceability, of a known alloy materials shall be available for use as
a random spot check on the instrument calibration.

5.9 The surfaces to be examined shall be prepared by light grinding or abrasive paper and solvent
cleaner. Evidence of Arc burn resulting from examination shall be removed by light grinding or
abrasive paper. No permanent marks, which are injurious to the usage of product in service, are
acceptable.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
t11 ENGINEERSt—
ft-
FOR POSITIVE MATERIAL
**gel' fililegW INDIA LIMITED 6-81-0001 Rev. 3
IvilVA PROW =Jowl/ (A Govt d b16H Undertakmg) IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS Page 6 of 8

5.10 Alloy Steel ring type joint Gaskets shall be inspected by using portable X-Ray fluorescence
instrument.

5.11 Testing shall be done as per the procedures outlined by the manufactures of alloy analyzer
being used. Modification of these procedures if any must be approved by Owner/EIL.

5.12 The persons performing PMI shall demonstrate their capabilities to the satisfaction of
Owner/EIL/TPIA visiting engineer. If the Supplier has qualified operator on their rolls, he may
perform the examination. Otherwise PMI examination shall be sub-contracted to an independent
testing agency approved by EIL.

5.13 Whenever material is identified as not meeting requirements by the visiting engineer a rejection
note shall be issued.

6.0 EXTENT OF PMI EXAMINATION

Following sampling plans shall be applicable for PMI examination of various items.

A. Flanges, Fittings 100%

Valves, RTJ Gaskets

B. Pipes 100% (for pipes procured from traders).

2 random samples drawn from each

Size/Heat/Lot (for pipes procured directly from mills)
C. Fasteners

Lot Size Sample Size

Upto 100 2% (Min 2)

101 to 500 1% (Min 3)
501 and above 0.5% (Min 5)
Note:

a. For Welded Pipes and Fittings, PMI shall be performed on Base Metal as well as
weldments.

7.0 ACCEPTANCE CRITERIA

7.1 Base Metal

PMI test results showing presence of characteristic elements upto 10% less than the minimum
specified value in the material specification and upto 10% more than the maximum specified
value in the material specification shall be acceptable.

7.2 Deposited Weld Metal

For deposited weld metal using welding consumables matching with base metals, the recorded
presence of characteristic elements upto 12.5% less than the minimum specified value in the
welding consumable specification and upto 12.5% more than the maximum specified value in
the welding consumable specification shall be acceptable.

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Page 392 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
7-77 ENGINEERS FOR POSITIVE MATERIAL
5.1geal laZg
(wed ereenZeld3O0en)
INDIA LIMITED
In Govt or India UndertakIng) IDENTIFICATION (PMI) AT
6-81-0001 Rev. 3
SUPPLIER'S WORKS Page 7 of 8

8.0 REJECTION CRITERIA

8.1 If PMI test results fall outside the acceptable range as specified in 7.0 above, the supplier shall
obtain a quantitative check analysis performed by a laboratory acceptable to Owner / EIL /
TPIA for a complete chemical analysis. Alternatively, the item can be tested with a spark
analyser for verification. Results of this analysis shall be submitted to Owner / EIL / TPIA for
final decision.

Decision of Owner / EIL / TPIA shall be final in this regard.

8.2 If any sample drawn to PMI test on the basis of percentage selection as per 6.0 above, fails to
meet specification requirements, 100% of items of lot shall be tested for PMI by supplier. Any
failure thereafter during sample check shall mean rejection of whole lot.

9.0 RECORDING AND DOCUMENTATION

The results of PMI examination shall be recorded in a Report Format as enclosed with this
specification.

10.0 MARKING

10.1 All alloy materials tested by PMI shall be identified using either of the following methods by
indicating "PMI OK"

a) Bar Code/Hologram Sticker

b) A low stress stamp marking

Copyright EIL — All rights reserved

Format No. 8-00-0001-F1 Rev. 0

Page 393 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
lafitzAr tft ENGINEERS FOR POSITIVE MATERIAL
ogeil■ ElfiThegW7 INDIA LIMITED 6-81-0001 Rev. 3
1.1 2i1 MOW 4,13,R1.0 (A Govt d India Undertaking) IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS Page 8 of 8

POSITIVE MATERIAL IDENTIFICATION REPORT Page of

BULK MATERIALS

Project: Client Job No.

PMI Report No. Supplier/Sub-Supplier

Purchase Order No. Testing Agency

Purchase PMI Location

Requisition No:

Bulk Item Type (as per Requisition)

Material Specification/Grade

Number of items in Lot

Requisition Item No./ Description Major content, Weight Percent Remarks

Accept/Reject
Element Cb
/
Cr Ni Mo V Ti*
Nb
**

Specified Range

Actual observations
1.

2.

3.

4.

5.

6.

7.

8.

Instrument Type / ID

Last Service Date

Inspection Agency Witnessed By
To be reported in case of SS321 Material
** To be reported in case of SS347 Material

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Page 394 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
ENGINEERS FOR 6-81-0011 Rev. 4
ligar faleg
litreT MrIlmi.rva%NI
INDIA LIMITED
INDIA
IA Govt of India Undertaking) PRESSURE VESSELS/ COLUMNS CARBON STEEL Page 1 of 7

taei thri- *FR- cpieldi ar4e-

fAttaTur a trttalur 44101(di

INSPECTION AND TEST PLAN

FOR
PRESSURE VESSELS/ COLUMNS CARBON STEEL
LoC
4 14.05.2020 REVISED AND RE-ISSUED RKS SKS

3 09.09.2013 REVISED AND RE-ISSUED TKK RKS SCG DM

2 15.07.2011 REVISED AND RE-ISSUED HP SCG AKC DM

28.09.2007 REVISED AND RE-ISSUED PD RB MVKK VC

0 10.12.2002 ISSUED FOR IMLEMENTATION NKN SPS AKB GRR

Convenor Chairman
Rev. Prepared Checked Standards Committee Standards Bureau
Date Purpose
No. by by
Approved by

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 395 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0011 Rev. 4
PRESSURE VESSELS/ COLUMNS CARBON STEEL Page 2 of 7

Abbreviations:

AS / CS / SS Alloy Steel / Carbon Steel / Stainless Steel MRT : Mechanical Run Test
CEIL : Certification Engineers International Limited NDT : Non Destructive Testing
CIMFR : Central Institute of Mining & Fuel Research NPSH : Net Positive Suction Head
CE : Carbon Equivalent PO : Purchase Order
DFT : Dry Film Thickness PESO : Petroleum Explosive Safety Organization
DPT : Dye Penetrant Testing PQR : Procedure Qualification Record
DHT : De-hydrogen Heat Treatment PR : Purchase Requisition
ERTL : Electronics Regional Test Laboratory PMI : Positive Material Identification
FCRI : Fluid Control Research Institute PWHT : Post Weld Heat Treatment
HT : Heat Treatment RT : Radiography Testing
HIC : Hydrogen Induced Cracking SSCC : Sulphide Stress Corrosion Cracking
ITP : Inspection and Test Plan TC : Test Certificate
IP : Ingress Protection TPI or TPIA : Third Party Inspection Agency
IHT : Intermediate Heat Treatment UT : Ultrasonic Testing
IC : Inspection Certificate VDR : Vendor Data Requirement
IGC : Inter Granular Corrosion WPS : Welding Procedure Specification
MPT/MT : Magnetic Particle Testing WPQ : Welders Performance Qualification
MTC : Material Test Certificate
:

Inspection Standards Committee

Convenor : Mr. R K Singh

Members:
Mr. Rajesh Sinha Mr. Himangshu Pal Mr. R. Muthuramalingam (RPO Representative)
Mr. Chandrashekhar Mr. Avdhesh Agrawal Mr. P V Satyanarayana (Engg. Representative)
Mr. Mahendra Mittal

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Page 396 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0011 Rev. 4
PRESSURE VESSELS/ COLUMNS CARBON STEEL Page 3 of 7

1.0 SCOPE

This Inspection and test plan covers the minimum testing requirements of Pressure vessels/ Columns carbon steel

2.0 REFERENCE DOCUMENTS

PO/PR/ Standards referred there in/ Job specifications /approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER

1.0 Procedures

Hydro test, heat treatment,

Procedure
1.1 NDT, hot forming and other Documented procedures. 100% - H R
documents
Procedures
As per PR/ Purchase Procedure
1.2 Weld Plan & NDT Plan 100% - H R
Specification/ Applicable codes documents

Procedure R-Existing
1.3 WPS/ PQR /WPQ Documented procedures. 100% - H
documents W-New

2.0 Materials Procurement

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Page 397 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0011 Rev. 4
PRESSURE VESSELS/ COLUMNS CARBON STEEL Page 4 of 7

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Plates, pipes, Forgings,
Expansion Bellows, Fittings,
As per PR/Purchase
2.1 Fasteners, Gaskets, etc 100% Mill TC H H R
Specification
(As applicable)
(Note-3)
Internals like Demister,
As per PR/Purchase
2.2 Johnson screen, support grid 100% Mill TC H H R
Specification
etc (As applicable) (Note-4)
3.0 In process inspection
Review of test certificates,
markings Material
Materials identification for
3.1 visual & dimensional inspection, 100% clearance - H H
plates, pipes (pressure parts)
identity correlation & transfer of record
identity
Material identification for Review of test certificates, Material
3.2 forgings, fittings, fasteners, markings 100% clearance - H R
gaskets (pressure parts) Identity correlation. record
Non pressure parts (including Material test
3.3 Review of test certificates 100% W R R
internals, supports etc.) certificate
NDT Reports /
NDT of weld seam as applicable 100% H H R
Inspection of formed Films
3.4 components (cold or hot NDT (dished ends and tori-cone)
formed) 100% Inspection
on inside & outside surfaces in H H R
report
knuckle zone and edges.

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Page 398 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0011 Rev. 4
PRESSURE VESSELS/ COLUMNS CARBON STEEL Page 5 of 7

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER

HT chart review as applicable 100% HT Chart W W R

Inspection
Test coupon as applicable 100% H H W
report
Visual & dimensional (min.
100% Inspection
thickness, profile, ovality etc ) H H H
report
inspection
100% Batch test
3.5 Welding consumable Chemical & mechanical properties W R R
certificates
Visual & dimensional inspection,
Inspection
weld edge, root gap, offset, 100% - W -
Weld edge preparation & set check list
3.6 alignment, cleanliness etc
up of pressure parts

NDT of weld edges, as applicable 100% NDT Reports - W R

Intermediate inspection of Inspection

3.7 Visual, Welding Parameters, NDT 100% - W -
welds report
4.0 Final inspection
Visual and dimensional Visual, dimensions, completeness
inspection (internals & of assembly and weld visual for Inspection
4.1 100% - H H
externals) including welds reinforcement, undercuts, Surface report
(before PWHT as applicable) defects, etc.

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 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0011 Rev. 4
PRESSURE VESSELS/ COLUMNS CARBON STEEL Page 6 of 7

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Each Inspection
4.2 PMI (AS/SS components) Chemical check W RW
component report

4.3 Pneumatic test of RF pads Leak check 100% Test report - W R

Trial assembly of internals and

Dimensions, completeness of Inspection
4.4 column/vessel sections as 100% - H W
assembly and alignment report
applicable

PWHT as applicable 100% HT chart W R

4.5
Inspection of completed welds
NDT Reports /
NDT as applicable 100% - W R
RT Films
Hardness check on all welds, 100% Inspection
4.6 Hardness - W RW
HAZ as applicable report
Production test coupon as As per Inspection
4.7 Production test coupon testing - H H
applicable spec/drg. report

4.8 Hydrostatic test Leak check 100% Test report - H H

5.0 Template Inspection

Foundation Template & Visual & Dimensions, Orientation Inspection
5.1 100% - H H
Gauge plate inspection markings report
6.0 Painting

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Page 400 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0011 Rev. 4
PRESSURE VESSELS/ COLUMNS CARBON STEEL Page 7 of 7

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Visual inspection (after surface
preparation and final painting for Inspection
6.1 Final painting 100% - H -
workmanship, uniformity) DFT report
check
7.0 Documentation and IC

Final stamping, review of IC /

Verifying stamping details and
7.1 inspection documents and 100% Inspection - H H
review of inspection documents
issue of IC reports
Verification & compilation of
Final
7.2 Final documents as per PR inspection & test records for 100% - H H
dossier
submission to customer

Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk item)),
R-Review, W-Witness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable):

1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be
applicable. (Unless otherwise agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.
3. Third Party Certifications shall be as per EN 10204 Type 3.2 for CS Plates (NACE/H2/HIC), Forgings, Fittings and Expansion Bellows and TPIA
shall be arranged by supplier. Certifications shall be as per EN 10204 Type 3.1 for Pipes, CS Plates (non-NACE/H2/HIC), Gaskets and Fasteners.
4. Inspection of Internals shall be as per EIL Std ITP no. 6-81-0060.
5. For EPC jobs, all inspection shall be carried out by TPIA, unless notified otherwise.

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Page 401 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
sii-aeJel• ENGINEERS FOR 6-81-0012 Rev. 4
5g-ar 2154-e-g INDIA LIMITED
ewa.W mIj4aI1, IA Goa of India Undertaking, LOW ALLOY STEEL PRESSURE VESSELS/ COLUMNS/REACTORS Page 1 of 8

ter •taei thr-{ ticra- chieldi ilvctici eravE

Walur a rittaiuT glom!
INSPECTION AND TEST PLAN
FOR
LOW ALLOY STEEL
PRESSURE VESSELS / COLUMNS/REACTORS
(.9
4 14.05.2020 REVISED AND RE-ISSUED SK CS RKS SKS

3 09.09.2013 REVISED AND RE-ISSUED TKK RKS SCG DM

2 15.07.2011 Revised and Re-Issued HP SCG AKC DM

1 28.09.2007 Revised and Re-Issued PD RB MVK VC

0 19.07.2002 Issued For Implementation NKN SPS AKB SB

Convenor Chairman
Rev. Prepared Checked Standards Committee Standards Bureau
Date Purpose
No. by by
Approved by

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 402 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0012 Rev. 4
LOW ALLOY STEEL PRESSURE VESSELS/ COLUMNS/REACTORS Page 2 of 8

Abbreviations:

AS/CS/SS : Alloy Steel/Carbon Steel/Stainless Steel MRT : Mechanical Run Test

CEIL : Certification Engineers International Limited NDT : Non Destructive Testing
CIMFR : Central Institute of Mining & Fuel Research NPSH : Net Positive Suction Head
CE : Carbon Equivalent PO : Purchase Order
DFT : Dry Film Thickness PESO : Petroleum Explosive Safety Organization
DPT : Dye Penetrant Testing PQR : Procedure Qualification Record
DHT : De-hydrogen Heat Treatment PR : Purchase Requisition
ERTL : Electronics Regional Test Laboratory PMI : Positive Material Identification
FCRI : Fluid Control Research Institute PWHT : Post Weld Heat Treatment
HT : Heat Treatment RT : Radiography Testing
HIC : Hydrogen Induced Cracking SSCC : Sulphide Stress Corrosion Cracking
ITP : Inspection and Test Plan TC : Test Certificate
IP : Ingress Protection TPI or TPIA : Third Party Inspection Agency
IHT : Intermediate Heat Treatment UT : Ultrasonic Testing
IC : Inspection Certificate VDR : Vendor Data Requirement
IGC : Inter Granular Corrosion WPS : Welding Procedure Specification
MPT/MT : Magnetic Particle Testing WPQ : Welders Performance Qualification
MTC : Material Test Certificate

Inspection Standards Committee

Convenor : Mr. R.K. Singh

Members:
Mr. Rajesh Sinha Mr. Himangshu Pal Mr. R. Muthuramalingam (RPO-Representative)
Mr. Chandrashekhar Mr. Avdhesh Agrawal Mr. P V Satyanarayana (Engg. Representative)
Mr. Mahendra Mittal

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 403 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0012 Rev. 4
LOW ALLOY STEEL PRESSURE VESSELS/ COLUMNS/REACTORS Page 3 of 8

1.0 SCOPE

This Inspection and Test Plan covers the minimum testing requirements of Pressure vessels/ Columns/Reactors low alloy steel

2.0 REFERENCE DOCUMENTS

PO/PR/ Standards referred there in/ Job specifications /approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS:

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
1.0 Procedures

Hydro test, heat treatment, NDT, Procedure

1.1 Documented procedures. 100% - H R
hot forming, and other Procedures Documents

As per PR/ Purchase Specification/ Procedure

1.2 Weld Plan & NDT Plan 100% - H A
Applicable codes documents

Procedure R-Existing
1.3 WPS/ PQR /WPQ Documented procedures. 100% - H
documents W-New

2.0 Materials Procurement

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 404 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0012 Rev. 4
LOW ALLOY STEEL PRESSURE VESSELS/ COLUMNS/REACTORS Page 4 of 8

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Plates, pipes, forging, fittings,
Mill Test
2.1 Expansion Bellows, Fasteners, 100%
As per PR / Purchase Specification Certificates and H H R
Gaskets etc (as applicable)
TPI reports
(NOTE – 3)
Internals like Demisters, Johnson
screens, support grids, Diffusers As per PR/Purchase Mill TC and
2.2 100% H H R
etc. (as applicable) Specification TPI reports
(NOTE – 4)
3.0 In process inspection
Review of test certificates, markings
Material
Materials identification for plates, visual & dimensional inspection,
3.1 100% clearance - H H
pipes (pressure parts) identity, correlation & transfer of
record
identity
Material identification for Material
Review of test certificates, markings
3.2 forgings, fittings, fasteners, 100% clearance - H R
Identity correlation.
gaskets (pressure parts) record

Non pressure parts (including Material test

3.3 Review of test certificates 100% W R R
internals, supports etc.) certificate

NDT report/
3.4 Inspection of formed components NDT of weld seam as applicable 100% RT Films H H R

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Page 405 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0012 Rev. 4
LOW ALLOY STEEL PRESSURE VESSELS/ COLUMNS/REACTORS Page 5 of 8

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
NDT ( dished ends and tori-cone) on
100%
inside & outside surfaces in knuckle NDT report H H R
zone and edges.
HT chart review as applicable 100% HT Chart W W R
Inspection
Test coupon as applicable 100% H H W
report
Visual & dimensional (min.
100% Inspection
thickness, profile, ovality etc ) H H H
report
inspection
Batch test
3.5 Welding consumable Chemical & mechanical properties 100% W R R
certificates
Visual & dimensional inspection,
Inspection
weld edge, root gap, offset, 100% - W R
3.6 Weld edge preparation & set up of check list
alignment, cleanliness etc
pressure parts
NDT of weld edges as applicable for
100% NDT report - W R
cracks, laminations or segregations

Visual, Welding parameters, NDT (as Inspection

100% - W R
Intermediate inspection applicable) report
3.7
of welds
Heat treatment
100% HT chart - H R
as applicable during welding
Intermediate Stress Relieving /
3.8 Heat treatment cycle 100% HT Chart - H R
De-Hydrogen Treatment

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Page 406 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0012 Rev. 4
LOW ALLOY STEEL PRESSURE VESSELS/ COLUMNS/REACTORS Page 6 of 8

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
4.0 Final Inspection
Visual and dimensional inspection Visual, dimensions, completeness of
(internals & externals) including assembly and weld visual for Inspection
4.1 100% - H H
welds (before PWHT as reinforcement, undercuts, surface report
applicable) defects, etc.
All
Inspection
4.2 PMI Chemical check components - W RW
report
and weld

4.3 Pneumatic test of RF pads Leak check 100% Test report - W R

Trial assembly of internals and

Dimensions, completeness of Inspection
4.4 column/vessel sections as 100% - H H
assembly and alignment report
applicable

PWHT as applicable 100% HT chart W R

NDT Reports /
4.5 Inspection of completed welds NDT, as applicable /100% - W R
Films

Production test coupon Testing as As per Inspection

- H H
applicable spec/drg. report

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Page 407 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0012 Rev. 4
LOW ALLOY STEEL PRESSURE VESSELS/ COLUMNS/REACTORS Page 7 of 8

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER

Hardness Checking of welds after 100% Inspection

4.6 Hardness - W RW
PWHT report

100% Hydro test H H

4.7 Hydrostatic test Leak check -
report

NDT of all weld surfaces

100%
4.8 (external and internal) after hydro Check for cracks NDT Reports - W R
test as applicable

Drying and Nitrogen Purging Inspection

4.9 Visual, Gas Pressure 100% - W -
(as applicable) report

5.0 Template Inspection

Foundation Template and Gauge Visual & Dimensions, Orientation Inspection
5.1 100% - H H
plate markings report
6.0 Painting
Visual inspection (after surface
preparation and final painting for Inspection
6.1 Final painting (As applicable) 100% - H -
workmanship, uniformity) , DFT report
check
7.0 Documentation and IC
Final stamping , review of IC /
Verifying stamping details and review
7.1 inspection documents and issue of 100% Inspection - H H
of inspection documents
IC reports

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Page 408 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0012 Rev. 4
LOW ALLOY STEEL PRESSURE VESSELS/ COLUMNS/REACTORS Page 8 of 8

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Verification & compilation of
Final
7.2 Final documents as per PR inspection & test records for 100% - H H
dossier
submission to customer

Legend: A-Approval, H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk
item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable):

1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable.
(Unless otherwise agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.
3. Third Party Certifications shall be as per EN 10204 Type 3.2 for Plates, Pipes, Forgings, Fittings, Fasteners and Expansion Bellows; and TPIA shall be
arranged by supplier. Certifications shall be as per EN 10204 Type 3.1 for Gaskets.
4. Inspection of Internals shall be as per relevant EIL Std ITP’s attached with PR; if not attached with PR, separate ITP’s shall be submitted for EIL
approval.
5. For EPC jobs, all inspection shall be carried out by TPIA, unless notified otherwise.

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 409 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
ENGINEERS 6-81-0013 Rev. 4
Ogar iaal
egw INDIA LIMITED
ORR e-lea,?,
FOR
SS CLAD PRESSURE VESSELS/ COLUMNS/ REACTORS
.1,111.11 (A Goof of India Undertalongi
Page 1 of 8

ter ter cr4s tfrg chimai /

iWthliuT a trtraiuT 441.71•11

INSPECTION AND TEST PLAN

FOR
SS CLAD PRESSURE VESSELS/ COLUMNS/ REACTORS
oc
4 14.05.2020 REVISED AND RE-ISSUED SK CS RKS SKS

3 09.09.2013 REVISED AND RE-ISSUED TKK RKS SCG DM

2 15.07.2011 REVISED AND RE-ISSUED HP SCG AKC DM

1 15.07.08 REVISED AND RE-ISSUED

NKR SSL SKP VC

0 19.07.02 ISSUED FOR IMPLEMENTATION NKN SPS AKB GRR

Convenor Chairman
Rev. Prepared Checked Standards Committee Standards Bureau
Date Purpose
No. by by

Approved by

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 410 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0013 Rev. 4
SS CLAD PRESSURE VESSELS/ COLUMNS/ REACTORS Page 2 of 8

Abbreviations:

AS/CS/SS : Alloy Steel/Carbon Steel/Stainless Steel MRT : Mechanical Run Test

CEIL : Certification Engineers International Limited NDT : Non Destructive Testing
CIMFR : Central Institute of Mining & Fuel Research NPSH : Net Positive Suction Head
CE : Carbon Equivalent PO : Purchase Order
DFT : Dry Film Thickness PESO : Petroleum Explosive Safety Organization
DPT : Dye Penetrant Testing PQR : Procedure Qualification Record
DHT : De-hydrogen Heat Treatment PR : Purchase Requisition
ERTL : Electronics Regional Test Laboratory PMI : Positive Material Identification
FCRI : Fluid Control Research Institute PWHT : Post Weld Heat Treatment
HT : Heat Treatment RT : Radiography Testing
HIC : Hydrogen Induced Cracking SSCC : Sulphide Stress Corrosion Cracking
ITP : Inspection and Test Plan TC : Test Certificate
IP : Ingress Protection TPI or TPIA : Third Party Inspection Agency
IHT : Intermediate Heat Treatment UT : Ultrasonic Testing
IC : Inspection Certificate VDR : Vendor Data Requirement
IGC : Inter Granular Corrosion WPS : Welding Procedure Specification
MPT/MT : Magnetic Particle Testing WPQ : Welders Performance Qualification
MTC : Material Test Certificate

Inspection Standards Committee

Convenor : Mr. R.K. Singh

Members:
Mr. Rajesh Sinha Mr. Himangshu Pal Mr. R. Muthuramalingam (RPO Representative)
Mr. Chandrashekhar Mr. Avdhesh Agrawal Mr. P V Satyanarayana (Engg. Representative)
Mr. Mahendra Mittal

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 411 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0013 Rev. 4
SS CLAD PRESSURE VESSELS/ COLUMNS/ REACTORS Page 3 of 8

1.0 SCOPE

This Inspection and Test Plan covers the minimum testing requirements of SS clad pressure vessels/ columns/ reactors

2.0 REFERENCE DOCUMENTS

PO/PR/ Standards referred there in/ Job specifications /approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
1.0 Procedure

Hydro test, heat treatment, NDT, Procedure

1.1 Documented procedures 100% - H R
hot forming, and other Procedures Documents

As per PR/ Purchase Procedure

1.2 Weld Plan & NDT Plan 100% - H A
Specification/ Applicable codes documents

Procedure R-Existing
1.3 WPS/ PQR /WPQ Documented procedures 100% - H
documents W-New

2.0 Material Procurement

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 412 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0013 Rev. 4
SS CLAD PRESSURE VESSELS/ COLUMNS/ REACTORS Page 4 of 8

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Plates, Clad plates, pipes,
forging, fittings, Expansion Mill test
As per PR / Purchase
2.1 Bellows, Fasteners, Gaskets etc. 100% certificates and H H R
specification
(as applicable) TPI reports
(Note-3)

Internals like Demisters, Johnson

screens, support grids, Diffusers As per PR/Purchase Mill TC and TPI
2.2 100% H H R
etc. (as applicable) Specification reports
(Note-4)
3.0 In process inspection
Review of test certificates,
Materials identification for markings, visual & dimensional Material
3.1 100% - H H
plates, pipes (pressure parts) inspection, identity, correlation & clearance record
transfer of identity
Material identification for Review of test certificates,
Material
3.2 forgings, fittings, fasteners, markings 100% - H R
clearance record
gaskets (pressure parts) identification, correlation .
Non pressure parts (including Material test
3.3 Review of test certificates 100% W R R
internals, supports etc.) certificate
NDT Report/
Inspection of formed components NDT of Weld Seam, as applicable 100% W W R
Films
3.4 rolled shell belts (cold or hot
formed) NDT on knuckle & straight face
100% DPT report W W R
and weld deposit overlays

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 413 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0013 Rev. 4
SS CLAD PRESSURE VESSELS/ COLUMNS/ REACTORS Page 5 of 8

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
UT for lack of bond (after final
heat treatment if any) and area As per Purchase UT
W W RW
where attachments to be welded specification report
on clad surfaces
HT chart review (as applicable) 100% HT Chart W W R
Inspection
Test Coupon (as applicable) 100% W W W
report
Visual & dimensional (min.
Inspection
thickness, profile, roundness, 100% H H H
report
ovality etc ) inspection
Chemical & mechanical Batch test
3.5 Welding consumable 100% W R R
properties including IGC certificates
Visual & dimensional inspection,
Weld edge preparation & Set up Inspection
weld edge, root gap, offset, 100% - W -
3.6 of pressure Parts check list
alignment, cleanliness etc.
DPT of weld edges 100% DPT Report - W R
Inspection
Visual, Welding parameters 100% - W -
Intermediate Inspection of Base report
3.7 NDT (as applicable) 100% NDT Report - W R
Metal Welding
Heat treatment as applicable 100% HT chart W R
Visual inspection for
Inspection
Intermediate Inspection of weld reinforcement, undercuts, Surface 100% - W -
3.8 report
overlay defects, etc.
DPT after each layer 100% DPT report - W R

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Page 414 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0013 Rev. 4
SS CLAD PRESSURE VESSELS/ COLUMNS/ REACTORS Page 6 of 8

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
4.0 Final Inspection
Visual and dimensional inspection Visual, dimensions, completeness
(internals & externals) including of assembly and weld visual for Inspection
4.1 100% - H H
welds (before PWHT as reinforcement, undercuts, Surface report
applicable) defects, etc.
All component Inspection
4.2 PMI Chemical check - W RW
and weld report

4.3 Pneumatic test of RF pads Leak check 100% Test report - W R

Trial assembly of internals and

Dimensions, completeness of Inspection
4.4 column/vessel sections as 100% - H H
assembly and alignment report
applicable
PWHT as applicable 100% HT chart W R
NDT report/
NDT as applicable 100% - W R
Films
Production test coupon testing as Inspection
100% - H H
applicable report
4.5 Inspection of completed welds
as per
Sample selection for weld overlay Inspection
specification / - H W
chemistry, as applicable report
drawing
As per
Weld chemical results for Inspection check
specification/ - W R
undiluted chemistry list
drawing

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 415 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0013 Rev. 4
SS CLAD PRESSURE VESSELS/ COLUMNS/ REACTORS Page 7 of 8

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Hardness check of welds after 100% Inspection
4.6 Hardness as applicable - W RW
PWHT (As applicable) report
Inspection
Leak check 100% - H H
report
4.7 Hydrostatic test
One sample per Laboratory Test
Water Quality check - H R
equipment Report
Inspection
4.8 NDT after hydro test as applicable NDT of welds as applicable 100% - W R
report
Pickling/ passivation, drying of Inspection
4.9 Visual inspection for cleanliness 100% - W R
equipment as applicable report
Ferroxyl test/ Copper Sulphate Inspection
4.10 Fe pick up check 100% - W RW
Test, as applicable report
Drying and Nitrogen Purging (as Inspection
4.11 Visual, Gas Pressure 100% - W -
applicable) report
5.0 Template Inspection
Foundation Template and Visual & Dimensions, Orientation Inspection
5.1 100% - H H
Gauge plate, as applicable markings report
6.0 Painting
Visual inspection (after surface
preparation and final painting for Inspection
6.1 Final painting (As applicable) 100% - H -
workmanship, uniformity) DFT report
check
7.0 Documentation and IC
Final stamping, review of IC /
Verifying stamping details and
7.1 inspection documents and issue 100% Inspection - H H
review of inspection documents
of IC reports

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 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0013 Rev. 4
SS CLAD PRESSURE VESSELS/ COLUMNS/ REACTORS Page 8 of 8

SCOPE OF INSPECTION
SL QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
NO. OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Verification & compilation of
Final
7.2 Final documents as per PR inspection & test records for 100% - H H
dossier
submission to customer

Legend: A-Approval, H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% (min.1 no. of each size and type of Bulk
item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable):

1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable.
(Unless otherwise agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.
3. Third Party Certifications shall be as per EN 10204 Type 3.2 for Clad Plates, Forgings, Fittings and Expansion Bellows; and TPIA shall be arranged by supplier.
Certifications shall be as per EN 10204 Type 3.1 for Pipes, CS Plates, Gaskets and Fasteners.
4. Inspection of Internals shall be as per relevant EIL Std ITP’s attached with PR; if not attached with PR, separate ITP’s shall be submitted for EIL approval.
5. For EPC jobs, all inspection shall be carried out by TPIA, unless notified otherwise.

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
'Pr') ENGINEERS HEALTH, SAFETY & 6-82-0001 Rev.9
INDIA LIMITED ENVIRONMENTAL MANAGEMENT
I iiRTf FRO512 E1513CIPAR) (A Govt of India Undettolongt
AT CONSTRUCTION SITES Page 1 of 102

WiCri TQM- IT{ 4-014-2,-4, Taff lTd

cr4Ew cHicrich idrdt*U

STANDARD SPECIFICATION FOR

HEALTH, SAFE TY&ENVIRONMENTAL
(HSE) MANAGEMENT AT
CONSTRUCTION SITES

9 24/01/2020
REVISED & UPDATED
691fr
BT
60
AKK
AKK
,1r,di*
RKT

8 25/10/2018 BT AP AKK RKT

REVISED & UPDATED
7 31/01/2017 REVISED & UPDATED AS AP AKK RN

6 26/02/2014
REVISED & UPDATED SM DJ RKD SC

5 19/12/2012 REVISED & UPDATED SM SM RKD DM

4 13/02/2008 REVISED & UPDATED AS RK SCB VC

3 17/07/2007 REVISED & UPDATED AS MPJ VNP VC

2 11/08/2005 REVISED & UPDATED MPJ MPJ VNP VJN

Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No. by by
Approved by

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY &
6-82-0001Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 2 of 102

Abbreviations:

AERB : Atomic Energy Regulatory Board

ANSI : American National Standards Institute
BARC : Bhabha Atomic Research Centre
BS : British Standard
EIL : Engineers India Limited
ELCB : Earth Leakage Circuit Breaker
EPC : Engineering, Procurement and Construction
EPCC : Engineering, Procurement, Construction and Commissioning
ESI : Employee State Insurance
GCC : General Conditions of Contract
GM : General Manager
GTAW : Gas Tungsten Arc Welding
HOD : Head of Department
HSE : Health, Safety & Environment
OH&S : Occupational Health and Safety
LTI : Lost Time Injuries
HIRAC : Hazard, Identification Risk Assessment & Control
OISD : Oil Industry Safety Directorate
HV : High Voltage
IS : Indian Standard
ISO : International Organization for Standardization
IE : Indian Electricity
LOTO : Lock Out & Tag Out
LPG : Liquefied Petroleum Gas
LSTK : Lump Sum Turn Key
MV : Medium Voltage
PPE : Personal Protective Equipment
RCCB : Residual Current Circuit Breaker
RCM : Resident Construction Manager or Site-in-Charge, as applicable
SCC : Special Conditions of Contract
SLI : Safe Load Indicator
SWL : Safe Working Load
TPI : Third Party Inspection
TBT : Tool Box Talks

Construction Standards Committee

Convenor:   Sh.AK Kundu, ED-I/C (Construction)

Members:  Sh. Janak Kishore, GGM (Projects)

    Sh. Rajeev Jain, GM (Projects)
    Sh. Udayan Chakravarty, GM (Piping)
    Sh. Ravindra Kumar, GM (Construction)
Sh. S K Goel, AGM (Construction)
Sh. Pankaj Kumar Rai, AGM (Construction)

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY &
6-82-0001Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 3 of 102

CONTENTS
CLAUSE TITLE PAGE NO.
1.0 SCOPE ………………………………………………………………………... 5
2.0 REFERENCES ………………………………………………………………... 5
3.0 REQUIREMENT OF HEALTH, SAFETY AND ENVIRONMENTAL
(HSE) MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS ........ 5
3.1 Management Responsibility ………………………………………... 5
3.1.1 HSE Policy & Objective ……………………………… 5
3.1.2 Management System ………………………………….. 5
3.1.3 Indemnification ……………………………………….. 5
3.1.4 Deployment &Qualification of Safety Personnel ……. 6
3.1.5 Implementation, Inspection& Monitoring …………… 8
3.1.6 Behavior Based Safety ……………………………….. 8
3.1.7 Awareness …………………………………………….. 9
3.1.8 Fire Prevention &First-Aid …………………………... 9
3.1.9 Documentation ………………………………………... 10
3.1.10 Audit ………………………………………………….. 10
3.1.11 Meetings ………………………………………………. 11
3.1.12 Intoxicating Drinks & Drugs and Smoking …………... 11
3.1.13 Penalty ………………………………………………… 11
3.1.14 Accident/Incident Investigation ……………………… 14
3.2 House Keeping ……………………………………………………… 14
3.3 HSE Measures ……………………………………………………… 15
3.3.1 Construction Hazards …………………………………. 15
3.3.2 Accessibility …………………………………………... 16
3.3.3 Personal Protective Equipments (PPEs) ……………… 16
3.3.4 Working at Height ……………………………………. 17
3.3.5 Scaffoldings …………………………………………... 19
3.3.6 Electrical Installations ………………………………… 20
3.3.7 Welding/Gas Cutting …………………………………. 22
3.3.8 Ergonomics and Tools &Tackles …………………….. 23
3.3.9 Occupational Health …………………………………... 24
3.3.10 Hazardous Substances ………………………………… 25
3.3.11 Slips, Trips & Falls …………………………………… 25
3.3.12 Radiation Exposure …………………………………… 25
3.3.13 Explosives/Blasting Operations ……………………… 26
3.3.14 Demolition/Dismantling ……………………………… 26
3.3.15 Road Safety …………………………………………… 26
3.3.16 Welfare Measures …………………………………….. 27
3.3.17 Environment Protection ………………………………. 27
3.3.18 Rules & Regulations ………………………………….. 28
3.3.19 Weather Protection ……………………………………. 28
3.3.20 Communication ……………………………………….. 28
3.3.21 Confined Space Entry ………………………………… 29
3.3.22 Heavy Lifts ………………………………………….… 29
3.3.23 Key Performance Indicators ………………………….. 29
3.3.24 Unsuitable Land Conditions ………………………….. 30
3.3.25 Under Water Inspection ………………………………. 30
3.3.26 Excavation …………………………………………….. 30

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AT CONSTRUCTION SITES Page 4 of 102

3.4 Tool Box Talks ……………………………………………………... 31

3.5 Training & Induction Programme ………………………………….. 32
3.6 Additional Safety Requirements for Working Inside a Running
Plant ………………………………………………………………… 33
3.7 Self-Assessment and Enhancement ………………………………… 34
3.8 HSE Promotion ……………………………………………………... 34
3.9 LOTO for Isolation of Energy Source ……………………………… 34
4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR ……... 35
4.1 On Award of Contract ……………………………………………… 35
4.2 During Job Execution ………………………………………………. 35
4.3 During Short Listing of the Sub-Contractors ………………………. 36
5.0 RECORDS ……………………………………………………………………. 36
Appendices
1. Standards/Codes on HSE ………………………………. Appendix-A
2. Details of First AID Box ……………………………….. Appendix-B
3. Types of Fire Extinguishers & their Application ………. Appendix-C
4. Indicative List of statutory Acts & Rules ………………. Appendix-D
5. Construction Hazards and their Mitigation …………….. Appendix-E
6. Training Subjects / Topics ……………………………… Appendix-F
7. Construction Power Board (typ.) ……………………..... Appendix-G
8. List of HSE Procedures ………………………………… Appendix-H
Attachments (Reporting Formats)
I Safety Walk through Report …………………………… HSE-1 Rev.0
II Accident/Incident Report ………………………………. HSE-2 Rev.1
III Suppl. Accident/Incident Investigation Report …………. HSE-3 Rev.1
IV Near Miss Incident Report/Dangerous Occurrence …….. HSE-4 Rev.1
V Monthly HSE Report …………………………………… HSE-5 Rev.2
VI Permit for Working at Height …………………………... HSE-6 Rev.0
VII Permit for Working in Confined Space ………………… HSE-7 Rev.0
VIII Permit for Radiation work ……………………………… HSE-8 Rev.0
IX. Permit for Demolishing/ Dismantling ………………….. HSE-9 Rev.0
X Daily Safety Checklist ………………………………….. HSE-10 Rev.0
XI Housekeeping Assessment & Compliance ……………... HSE-11 Rev.0
XII Inspection of Temporary Electrical Booth/ Installation ... HSE-12 Rev.0
XIII Inspection for Scaffolding ……………………………… HSE-13 Rev.0
XIV Permit for Erection / Modification & Dismantling of
Scaffolding ……………………………………………… HSE-14 Rev.0
XV Permit for Heavy Lift/Critical Erection ………………... HSE-15 Rev.0
XVI Permit Energy Isolation & De-Isolation ………………... HSE-16 Rev 0
XVII Permit for Excavation …………………………………... HSE-17 Rev 0
XVIII Environmental Aspect Impact Register ………………… HSE-18 Rev 0
XIX HIRAC Register ………………………………………… HSE-19 Rev 0
XX Checklist for Tower Crane ……………………………... HSE-20 Rev 0
XXI Crane Inspection Checklist ……………………………... HSE-21 Rev 0
XXII Hydra Inspection Checklist …………………………….. HSE-22 Rev 0
XXIII Hydraulic Rig Inspection Checklist ……………….. HSE-23 Rev 0
XXIV Boom Lift Inspection Checklist …………………… HSE-24 Rev 0

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1.0 SCOPE

This specification establishes the Health, Safety and Environment (HSE) management
requirement to be complied by Contractors/Vendors including their sub-contractors/sub vendors
during construction.

This specification is not intended to replace the necessary professional judgment needed to
design & implement an effective HSE system for construction activities and the contractor is
expected to fulfill HSE requirements in this specification as a minimum. It is expected that
contractor shall implement best HSE practices beyond whatever are mentioned in this
specification.

Requirements stipulated in this specification shall supplement the requirements of HSE

Management given in relevant Act(s)/ Legislations, General Conditions of Contract (GCC),
Special Conditions of Contract (SCC) and Job (Technical) Specifications. Where different
documents stipulate different requirements, the most stringent shall apply.

2.0 REFERENCES

The document should be read in conjunction with following:

- General Conditions of Contract (GCC)

- Special Conditions of Contract (SCC)
- Building and other construction workers Act,
- Indian Factories Act
- Job (Technical) specifications
- Relevant International/ National Codes (refer Appendix-A for standards/codes on HSE)
- Relevant State & National Statutory requirements.
- Operating Manuals Recommendation of Manufacturer of various construction Machineries
- Occupation Health and Safety Management System (OHSAS 18001:2007/ISO 45001) and
Environmental Management System (ISO 14001:2015)
3.0 REQUIREMENTS OF HEALTH, SAFETY & ENVIRONMENTAL (HSE)
MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS

3.1 Management Responsibility

3.1.1 HSE Policy & Objectives

The Contractor should have a documented and duly approved HSE policy &objectives to
demonstrate commitment of their organization to ensure health, safety and environmental
aspects in their line of operations.
3.1.2 Management System

The HSE management system of the Contractor shall cover the HSE requirements &
commitments to fulfill them, including but not limited to what have been specified under
clauses 1.0 and 2.0 above. The Contractor shall obtain the approval of its site specific HSE Plan
from EIL/ Owner prior to commencement of any site works. Corporate as well as Site
management of the Contractor shall ensure compliance of their HSE Plan at work sites in its
entirety in true spirit.

3.1.3 Indemnification

Contractor shall indemnify & hold harmless, Owner/EIL & their representatives, free from any
and all liabilities arising out of non-fulfillment of HSE requirements or its consequences.

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3.1.4 Deployment &Qualifications of Safety Personnel

The Contractor shall designate/deploy various categories of HSE personnel at site as indicated
below in sufficient number. In no case, deployment of safety Supervisor / Safety Steward shall
substitute deployment of Safety Officer / Safety Engineer what is indicated in relevant statute of
BOCW Act i.e. deployment of safety officer/Safety Engineer is compulsory at project site.The
Safety supervisors, Safety stewards/Observer etc. would facilitate the HSE tasks at grass root
level for construction sites and shall assist Safety Officer /Engineers.

Contractor shall appoint safety personnel as given below for every work shift (As per table
below):

(i) Safety Observer/Steward: Contractor shall depute one Safety Observer/Steward for
every 100 workers and additionally thereon.
(ii) Safety Supervisor: In addition to above (i), contractor shall depute one Safety
Supervisor for every 250 workers and additionally thereon.
(iii) Safety Engineer: In addition to above (i &ii), one safety engineer/ officer for every
1000 workers and additionally thereon.

Requirement of Safety Personnel for every shift

No. of Workers
deployed Safety Safety Engineer/
Safety Supervisor
Observer/Steward Officer
One
1-100 One (1-250)

101-200 Two

201-300 Three
One
Two (250-500)
301-400 Four

401-500 Five

Up to 1000 Ten Four

Up to 2000 Twenty Eight Two

In case any of the safety personnel leave the contractor the same shall be intimated to the
owner/ Consultant/ EIL. The contractor shall recruit new personnel and fill up the vacancy.
a) Safety Steward/Observer
As a minimum, he shall possess class XII pass certificate and trained in fire-fighting as
well as in safety/occupational health related subjects, with minimum two year of practical
experience in construction work environment and should have adequate knowledge of the
local language spoken by majority of the workers at the construction site.

b) Safety Supervisor
As a minimum, he shall possess a recognized graduation Degree in Science (with Physics
& Chemistry) or a Diploma in Engg. Or Tech. with minimum Two years of practical
experience in construction work environment and should possess requisite skills to deal
with construction safety & fire related day-to-day issues.

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c) Safety Officer / Safety Engineer

Safety Officer/Engineer should possess following qualification & experience:

(i) Recognized degree in any branch of Engg. or Tech. or Architecture with practical
experience of working in a building or other construction work in supervisory
capacity for a period of not less than two years, or possessing recognized diploma in
any branch of Engg. or Tech with practical experience of working in a building or
other construction work in supervisory capacity for a period of not less than five
years.
(ii) Recognized degree or one year diploma in Industrial safety(from any Indian
Institutes recognized by AICTE or State Council of Tech. Education of any Indian
State/Union territory) with at least one paper in construction safety (as an elective
subject).
(iii) Preferably have adequate knowledge of the language spoken by majority of the
workers at the construction site.

Alternately
(i) Person possessing Graduation Degree in Science with Physics & Chemistry and
degree or one year diploma in Industrial Safety (from any Indian institutes
recognized by AICTE or State Council of Tech. Education of any Indian State/
Union Territory) with practical experience of working in a building, plant or other
construction works (as Safety Officer, in line with Indian Factories Act, 1948) for a
period of not less than five years, may be considered as Safety Officer.

d) HSE In-Charge

In case there is more than one Safety Officer at any project construction site, one of them,
who is senior most by experience (in HSE discipline), may be designated as HSE In-
Charge. Duties & responsibilities of such person shall be commensurate with that of
relevant statute and primarily to coordinate with top management of EIL/Client and
contractors.
In case the statutory requirements i.e. State or Central Acts and / or Rules as applicable like
the Building and Other Construction Workers’ Regulation of Employment and Conditions
of Service- Act,1996 or State Rules (wherever notified), the Factories Act, 1948 or Rules
(wherever notified), etc. are more stringent than above clarifications, the same shall be
followed.
Contractors shall ensure physical availability of safety personnel at the place of specific
work location, where Hot Work Permit is required/granted. No work shall be started at any
of the project sites until above safety personnel & concerned Site Engineer of Contractor
are physically deployed at site. The Contractor shall submit a HSE Organogram clearly
indicating the lines of responsibility and reporting system and elaborate the responsibilities
of safety personnel in their HSE Plan.
The Contractor shall verify & authenticate credentials of such safety personnel and furnish
Bio-Data/Resume/Curriculum Vitae of the safety personnel as above for EIL/Owner’s
approval, at least 1 month before the mobilization. The Contractor, whenever required,
shall arrange submission of original testimonials/certificates of their Safety personnel, to
EIL/Owner (for verification/scrutiny, etc.)
Imposition/ Realization of penalty shall not absolve the Contractor from his/her
responsibility of deploying competent safety officer at site.
Adequate planning and deployment of safety personnel shall be ensured by the Contractor
so that field activities do not get affected because of non-deployment of competent &
qualified safety personnel in appropriate numbers.

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3.1.5 Implementation, Inspection/Monitoring

a) The Contractor shall be fully responsible for planning, reporting, implementing and
monitoring all HSE requirements and compliance of all laws & statutory requirements.
b) The Contractor shall also ensure that the HSE requirements are clearly understood &
implemented conscientiously by their site personnel at all levels at site.
c) The Contractor shall ensure physical presence of their field engineers / supervisors, during
the continuation of their contract works / site activities including all material transportation
activities. Physical absence of experienced field engineers / supervisors of Contractor at
critical work spot during the course of work may invite halting / stoppage of work.
d) The Contractor shall regularly review inspection report internally and implement all
practical steps / actions for improving the status continuously.
e) Contractor skilled workmen like riggers, scaffold erectors, welders, crane operators etc.
should have sufficient past experience and skill on the relevant job.
f) The Contractor shall ensure important safety checks right from beginning of works at every
work site locations and to this effect format No. HSE-10 “Daily Safety Check List” shall be
prepared by field engineer & duly checked by safety personnel for conformance.
g) The Contractor shall carry out inspection to identify various unsafe conditions of work
sites/machinery/equipment’s as well as unsafe acts on the part of
workmen/supervisor/engineer while carrying out different project related works.
h) Adequate records for all inspections shall be maintained by the Contractor and the same
shall be furnished to EIL/Owner, whenever sought.
i) To demonstrate involvement/commitment of site management of Contractor, at least one
Safety Walk through in a month shall be carried out by Contractor’s head of site (along
with his area manager/field engineers) and a report shall be furnished to EIL/Owner as per
format No: HSE-1” Safety walk through report” followed by compliance for unsatisfactory
remarks.
j) As a general practice lifting tools/tackles, machinery, accessories etc. shall be inspected,
tested and examined by competent person(approved by concerned State authorities) before
being used at site and also at periodical interval (e.g. during replacement, extension,
modification, elongation/reduction of machine/parts, etc.) as per relevant statutes. Hydra,
cranes, lifting machinery, mobile equipment’s/ machinery/ vehicles, etc. shall be inspected
regularly by only competent / experienced personnel at site and requisite records for such
inspections shall be maintained by contractor. Contractor shall also maintain records of
maintenance of all other site machinery (e.g. generators, rectifiers, compressors, cutters,
etc.) &portable tools/equipment’s being used at project related works (e.g. drills, abrasive
wheels, punches, chisels, spanners, etc.).The Contractor shall not make use of arbitrarily
fabricated ‘derricks’ at project site for lifting/ lowering of construction materials.
k) Site facilities /temporary. installations, e.g. batching plant, cement godown, DG-room,
temporary electrical panels/distribution boards, shot-blasting booth, fabrication yards, etc.
and site welfare facilities, like labour colonies, canteen/pantry, rest-shelters, motor
cycle/bicycle-shed, First-aid centers, urinals/toilets, etc. should be periodically inspected by
Contractor (preferably utilizing HR/Admin. personnel to inspect site welfare facilities) and
records to be maintained.

3.1.6 Behaviour Based Safety

a) The contractor shall develop a system to implement Behavior-Based Safety (BBS) through
which work groups can identify, measure and change the behaviors of employees and
workers towards construction safety aspects.
b) The BBS process shall include the following:
- Identify the behaviors critical to achieve required safety performance.
- Communicate the behaviors and how they are performed correctly by all

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- Observe the work force and record safe/at risk behaviors. Intervene with workers to
give positive reinforcement when unsafe behaviors are observed. Provide
coaching/correction when at risk behaviors are observed
- Collect and record observation data
- Summarize and analyze observation data
- Communicate observation data and analysis results to all employees
- Provide recognition or celebrate when safe behaviour improvements occur
- Change behaviours to be observed or change activators or change consequences as
appropriate.
- Communicate any changes to workforce
c) Contractor through its own HSE committee shall implement the above process.
d) The necessary procedures and Monthly reporting formats shall be developed by the
contractor for approval by EIL/Owner.
e) The HSE committee of contractor shall observe individual’s behavior for safe practices
adapted for utilization/execution of work for followings a minimum:-
- PPE
- Tools & equipment’s
- Hazard Identification & control
- House keeping
- Confined space entry
- Hot works
- Excavation
- Loading & unloading
- Work at height
- Stacking & storage
- Ergonomics

3.1.7 Awareness and Motivation

a) The Contractor shall promote and develop awareness on Health, Safety and Environmental
protection among all personnel working for the Contractor.
b) The contractor shall display safety statistics board at all prominent location .Also shall
provide dedicated notice board for displaying of safety alerts or any other safety related
notices for awareness site workforces.
c) Regular awareness programs and fabrication shop/work site meetings at least on monthly
basis shall be arranged on HSE activities to cover hazards/risks involved in various
operations during construction.
d) Contractor’s workmen & supervisory staff shall participate in common Tool Box
Meeting as & when organized/required at site to avoid any incident/accident or
occupational disease arising out of multidisciplinary jobs/activities being performed
by various contracting agencies in the same location at different elevation.
e) Contractor to motivate & encourage the workmen & supervisory staff by issuing/ awarding
them with tokens/ gifts/ mementos/ monetary incentives/ certificates etc. The motivational
program shall be organized on regular basis.
f) Contractor shall assess & recognize the behavioral change of its site engineers / supervisors
periodically and constantly motivate / encourage them to implement HSE practices at
project works

3.1.8 Fire Prevention & First-Aid

The Contractor shall arrange suitable First-aid measures such as First Aid Box (Refer
Appendix-B for details), stand-by Emergency Vehicle .Additionally separate ambulance with
trained personnel/male or female nurse to administer First Aid shall be provided by the
Contractor beyond deployment of 500 workmen during day/night working hours.

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a) The Contractor shall arrange installation of fire protection measures such as adequate
number of steel buckets with sand & water and adequate number of appropriate portable
fire extinguishers (Refer Appendix-C for details) to the satisfaction of EIL/Owner.
b) The Contractor shall arrange EMERGENCY MOCK DRILL like fire, bomb threat, gas
leakage, earth quake, etc. at each site at least once in three months, involving site workmen
and site supervisory personnel & engineers. The Contractor shall maintain record of such
mock drills at project site.
c) The contractor shall require to tie-up with the hospitals located in the neighborhood for
attending medical emergency.

3.1.9 Documentation

The Contractor shall evolve a comprehensive, planned and documented system covering the
following as a minimum for implementation and monitoring of the HSE requirements and the
same shall be submitted for approval by owner/EIL.
- HSE Organogram
- Site specific HSE Plan
- Safety Procedures, forms and Checklist. Indicative list of HSE procedures is attached as
Appendix :H
- Inspections and Test Plan
- Risk Assessment &HIRAC for critical works.
- HIRAC Register as per Format no: HSE-19 to identify, assess, analyze & mitigate the
construction hazards& incorporate relevant control measures before actually executing site
works.
- Environmental Aspect Impact Register as per Format no: HSE-18 (identify, assess, analyze
& mitigate the environmental impact & incorporate relevant control measures).
- Legal Register to identify and comply to all applicable HSE related legal requirements.
The monitoring for implementation shall be done by regular inspections and compliance of the
observations thereof. The Contractor shall get similar HSE requirements implemented at his
sub-contractor(s) work site/office, if applicable. However, compliance of HSE requirements
shall be the responsibility of the Contractor. Any review/approval by EIL/Owner shall not
absolve contractor of his responsibility/liability in relation to fulfilling all HSE requirements.

3.1.10 Audit

The Contractor shall submit an Audit Plan to EIL/Owner indicating the type of audits covering
following as minimum:
a) Internal HSE audits regularly on six monthly basis by engaging internal qualified auditors
(viz safety officers/Construction personnel having 5years experience in construction safety
and Lead Auditor Course: OHSAS 18001/ISO 45001 certification).However, minimum
two internal HSE audit will have to be conducted irrespective of time period of the
contract.
b) External HSE audits regularly on yearly basis by engaging authorized auditing agencies
(viz. National Safety Council etc.)or qualified external auditors (viz safety
officers/Construction personnel having 10years experience in construction safety and Lead
Auditor Course: OHSAS 18001/ISO 45001certification). However, minimum one external
HSE audit will have to be conducted irrespective of time period of the contract.

All HSE shortfalls/ non-conformances on HSE matters brought out during review/audit, shall be
resolved forthwith(generally within a week) by Contractor& compliance report shall be
submitted to EIL/Owner.
In addition to above audits by contractor, the contractor’s work shall be subjected to HSE audit
by EIL/Owner at any point of time during the pendency of contract. The Contractor shall take
all actions required to comply with the findings of the Audit Report and issue regular

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Compliance Reports for the same to OWNER/ EIL till all the findings of the Audit Report are
fully complied.
Failure to carry-out HSE Audits& its compliance (internal & external) by Contractor, shall
invite penalization.

3.1.11 Meetings
i. The Contractor shall ensure participation of his top most executive at site (viz. Resident
Construction Manager / Resident Engineer/ Project Manager / Site-in-Charge) in Safety
Committee/HSE Committee meetings arranged by EIL/Owner usually on monthly basis or
as and when called for. In case Contractor’s top most executive at site is not in a position
to attend such meeting, he shall inform EIL/Owner in writing before the commencement of
such meeting indicating reasons of his absence and nominate his representative – failure to
do so may invite very stringent penalization against the specific Contractor, as deemed fit
as per Contract. The obligation of compliance of any observations during the meeting shall
be always time bound. The Contractor shall always assist EIL/Owner to achieve the targets
set by them on HSE management during the project implementation.
ii. In addition, the Contractor shall also arrange internal HSE meetings chaired by his top most
executive at site on fortnightly basis and maintain records. Such internal HSE meetings
shall essentially be attended by field engineers / supervisors including safety personnel of
the Contractor and its associates. Records of such internal HSE meetings shall be
maintained by the Contractor for review by EIL/Owner or for any HSE Audits.

iii. Agenda of internal HSE meeting should broadly cover: -

a) Confirmation of record notes /minutes of previous meeting
b) Discussion on outstanding subjects of previous points / subjects, if any
c) Incidents / Accidents (of all types) at project site, if any
d) Current topics related to site activities / subjects of discussion
e) House keeping
f) Behavioral Safety
g) Information / views / deliberations of members / sitesub-contractors
h) Report from Owner / Client
i) Status of Safety awareness, Induction programs & Training programs

The time frame for such HSE meeting shall be religiously maintained by one and all.

3.1.12 Intoxicating drinks & drugs and smoking

a) The Contractor shall ensure that his staff members & workers (permanent as well casual)
shall not be in a state of intoxication during working hours and shall abide by any law
relating to consumption & possession of intoxicating drinks or drugs in force.
b) The Contractor shall not allow any workman to commence any work at any locations of
project activity who is/are influenced / effected with the intake of alcohol, drugs or any
other intoxicating items being consumed prior to start of work or working day.
c) Awareness about local laws on this issue shall form part of the Induction Training and
compulsory work-site discipline.
d) The Contractor shall ensure that all personnel working for him comply with “No-Smoking”
requirements of the Owner as notified from time to time. Cigarettes, lighters, auto ignition
tools or appliances as well as intoxicating drugs, dry tobacco powder, etc. shall not be
allowed inside the project / plant complex.
e) Smoking shall be permitted only inside smoking booths, if any, exclusively designated &
authorized by the Owner/EIL.
3.1.13 Penalty
The Contractor shall adhere consistently to all provisions of HSE requirements. In case of non-
compliances and also for repeated failure in implementation of any of the HSE provisions,

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EIL/Owner may impose stoppage of work without any cost & time implication to the Owner
and/or impose a suitable penalty.
The amount of penalty to be levied against defaulted Contractor shall be up to a cumulative
limit of
2.0% (Two percent) of the contract value for Item Rate or Composite contracts with an overall
ceiling of 1,00,00,000(Rupees One Crore).
0.5% (Zero decimal five percent) of the contract value for LSTK, OBE, EPC, EPCC or Package
contracts with an overall ceiling of 10,00,00,000(Rupees Ten Crores)

This penalty shall be in addition to all other penalties specified elsewhere in the contract. The
decision of imposing stop-work-instruction and imposition of penalty shall rest with
EIL/Owner. The same shall be binding on the Contractor. Imposition of penalty does not make
the Contractor eligible to continue the work in unsafe manner.
The amount of penalty applicable for the Contractor on different types of HSE violations is
specified below:

Sl.
Violation of HSE Norms Penalty Amount
No.
1. For not using personal protective equipment like Rs.500/- per day/Item / Person
Helmet, Safety Shoes, and other safety gadgets as
applicable as per nature of work.
2. Working without Work Permit/Clearance Rs.20,000/- per occasion
3 Execution of work without deployment of requisite Rs.5,000/- per violation per day
field engineer / supervisor at work spot
4. Unsafe electrical practices (not installing ELCB, Rs.10,000/- per item per day
using poor joints of cables, using naked wire without
top plug into socket, laying wire/cables on the roads,
electrical jobs by incompetent person, etc.)
5. Working at height without full body harness, using Rs.10,000/- per case per day
non-standard/ rejected scaffolding and not arranging
fall protection arrangement as required, like hand-
rails, life-lines, Safety Nets etc.
6. Unsafe handling of compressed gas cylinders (No Rs.1,000/- per item per day
trolley, jubilee clips double gauge regulator, and not
keeping cylinders vertical during storage/handling,
not using safety cap of cylinder).
7. Use of domestic LPG for cutting purpose / not using Rs.5,000/-per occasion
flash back arresters on both the hoses/tubes on both
ends.
8. No fencing/barricading of excavated areas / Rs.5,000/- per occasion
trenches.
9. Not providing shoring/strutting/proper slope and not Rs.5,000/-per occasion
keeping the excavated earth at least 1.5M away from
excavated area.
10. Non display of scaffold tags, caution boards on Rs.1,000/- per occasion per day
erected scaffolds.
11. Traffic rules violations like over speeding of Rs.3,000/-per occasion per day
vehicles, rash driving, talking on mobile phones
during vehicle driving, wrong parking, not using seat
belts, vehicles not fitted with reverse horn / warning
alarms / flicker lamps during foggy weather.
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Sl.
Violation of HSE Norms Penalty Amount
No.
12. Absence of Contractor’s RCM/SIC or his nominated Rs.10,000/- per meeting
representative (prior approval must be taken for each
meeting for nomination) from site HSE meetings
whenever called by EIL/Owner& failure to nominate
his immediate deputy for such HSE meetings.
13. Failure to maintain HSE records by Contractor Rs.10,000/- per month
Safety personnel, in line with approved HSE
Plan/Procedures/Contract specifications.
14. Failure to conduct daily site safety inspection (by Rs.10,000/- per occasion
Contractor’s Site Engineer &safety officer), internal
HSE meeting, internal HSE Awareness/Motivation
Program and Site HSE Training at predefined
frequencies (as approved in HSE Plan).
15. Failure to fill online/submit the monthly HSE report
Rs10,000/-per occasion and
by 5th of subsequent month to Engineer-in-Charge/ Rs.1,000/-per day of further
Owner delay
16. Poor House Keeping Rs.5,000 /- per occasion per
subject
17. Failure to report &follow-up accident (including Rs.20,000/- per occasion
Near Miss) reporting system within specific time-
frame.
18. Degradation of environment (not confining toxic Rs.10,000/- per occasion
spills, spilling oil/lubricants onto ground)
19. Not medically examining the workers before Rs.5,000/- per occasion per
allowing them to work at height / to work in worker
confined space / to work in shot-blasting / to work
for painting / to work in bitumen or asphalt works,
not providing ear muffs while allowing them to work
in noise polluted areas, made them to work in air
polluted areas without respiratory protective devices,
etc.
20. Violation of any other safety condition as per job Rs.5,000/- per occasion
HSE plan / work permit and HSE conditions of
contract (e.g. using crowbar on cable trenches,
improper welding booth, not keeping fire
extinguisher ready at hot work site, unsafe rigging
practices, non-availability of First-Aid box at site,
not providing dead man handle switch for blasting,
whiplash arrestor for the compressor line, not using
hood with respiratory devices by blaster for
shot//grit blasting, etc.)
21. Penalty for non-deployment of ambulance in case of Rs.3,000 per day
man-power more than 500 or not providing
dedicated emergency vehicle in case of man-power
less than 500.

22. Failure to carry-out Safety audit in time (internal & Rs.20,000/- per occasion (for
external),close-out of identified shortfalls of internal audit &OSA).
Observations of Safety Aspects(OSA),etc. Rs.30,000/-per occasion for
external audit
23. Carrying out sand blasting instead of grit/shot Rs.50,000/- per day
blasting

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Sl.
Violation of HSE Norms Penalty Amount
No.
24. Failure to deploy adequately qualified and Rs.10,000/- per day per Officer
competent Safety Officer

25. Utilization of hydra/back-hoe loader for material Rs.25,000/- per occasion

shifting or any other unauthorized /unsafe lifting
works
26. Any Fatal Accident Rs.10,00,000/-per fatality
27. Any violation not covered above To be decided by EIL/Owner.
Note: Penalty amount deducted from the contractor shall be utilized by owner/EIC for the
promotion of the safety during the currency of the project.

The Contractor shall make his field engineers/supervisors fully aware of the fact that they keep
track with the site workmen for their behavior and compliance of various HSE requirements.
Safety lapses / defects of project construction site shall be attributable to the concerned job
supervisor / engineer of the Contractor, (who remains directly responsible for safely executing
field works). For repeated HSE violations, concerned job supervisor / engineer shall be
reprimanded or appropriate action, as deemed fit, shall be initiated (with information to EIL &
Owner) by the concerned Contractor.

Contractor shall initiate verbal warning shall be given to the worker/employee during his first
HSE violation. A written warning shall be issued on second violation and specific training shall
be arranged / provided by the Contractor to enhance HSE awareness/skill including feedback on
the mistakes/ flaws. Any further violation of HSE stipulations by the erring individuals shall call
for his forthright debar from the specific construction site. A record of warnings for each
worker/employee shall be maintained by the Contractor, like by punching their cards / Gate
passes or by displaying their names at the Project entry gate. Warnings, penalizations,
appreciations etc. shall be discussed in HSE Committee meetings by site Head of the
Contractor.

3.1.14 Accident/ Incident investigation

All accidents/incidents shall be informed to EIL/Owner at least telephonically by Contractor

immediately and in writing within 24 hours on Format No. HSE-2 as applicable, by Contractor.
Thereafter, a Supplementary Accident/Incident investigation Report on Format No. HSE-3 shall
be submitted to EIL/Owner within 72 hours. Near Miss incident(s), Dangerous
accidents/incident shall also be reported on Format No. HSE-4 within 24 hours. The accident/
incident shall be investigated by a team of Contractor’s senior Site personnel (involving Site-in-
Charge or at least by his deputy) for establishing root-cause and recommending corrective &
preventive actions. Findings shall be documented and suitable actions taken to avoid
recurrences shall be communicated to EIL/Owner. Owner/EIL shall have the liberty to
independently investigate such occurrences and the Contractor shall extend all necessary help
and cooperation in this regard. EIL/Owner shall have the right to share the content of this report
with the outside world.

3.2 House Keeping

The Contractor shall ensure that a high degree of housekeeping is maintained and shall ensure
inter-alia; the followings:
a) All surplus earth and debris are removed/disposed-off from the working areas to designated
location(s).
b) Unused/surplus cables, steel items and steel scrap lying scattered at different places within
the working areas are removed to identify location(s).
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c) All wooden scrap, empty wooden cable drums and other combustible packing materials,
shall be removed from work place to identified location(s).
d) Roads shall be kept clear and materials like pipes, steel, sand, boulders, concrete, chips and
bricks etc. shall not be allowed on the roads to obstruct free movement of men &
machineries.
e) Fabricated steel structural, pipes & piping materials shall be stacked properly.
f) Water logging on roads shall not be allowed.
g) No parking of trucks/trolleys, cranes and trailers etc. shall be allowed on roads, which may
obstruct the traffic movement.
h) Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the working
areas.
i) Protective measures to be ensured with projected rebar by suitable means.
j) Trucks carrying sand, earth and pulverized materials etc. shall be covered while moving
within the plant area/ or these materials shall be transported with top surface wet.
k) The contractor shall ensure that the atmosphere in plant area and on roads is free from
particulate matter like dust, sand, etc. by keeping the top surface wet for ease in breathing.
l) At least two exits for any unit area shall be assured at all times – same arrangement is
preferable for digging pits/ trench excavation/ elevated work platforms/ confined spaces
etc.
m) Welding cables and the power cable must be segregated and properly stored and used.The
same shall be laid away from the area of movement and shall be free from obstruction.
n) Schedule for upkeep/cleaning of site to be firmed up and implemented on regular basis.

The Contractor shall carry-out regular checks (minimum one per fortnight) as per format No.
HSE-11 for maintaining high standard of housekeeping and maintain records for the same.The
Contractor shall provide supervisor for housekeeping exclusively for management of day-to-day
housekeeping activities.

3.3 HSE Measures

3.3.1 Construction Hazards

The Contractor shall ensure identification of all Occupational Health, Safety & Environmental
hazards in the type of work he is going to undertake and enlist mitigation measures. Contractor
shall carry out HIRAC specifically for high risk jobs/critical jobs like

a) Working at height (+2.0 Mts height) for cold (incl. colour washing, painting, insulation
etc.) & hot works.
b) Work in confined space,
c) Deep excavations &trench cutting (depth > 2.0 mts.)
d) Operation & Maintenance of Batching Plant.
e) Shuttering / concreting (in single or multiple pour) for columns, parapets & roofs.
f) Erection & maintenance of Tower Crane.
g) Erection of structural steel members / roof-trusses / pipes at height more than 2.0 Mts. with
or without crane.
h) Erection of pipes (full length or fabricated) at height more than 2.0 Mts. height with Crane
of 100T capacity.
i) All lifts using 100T Crane plus mechanical pulling.
j) All lifts using two cranes in unison (Tandem Lifting).
k) Any lift exceeding 80% capacity of the lifting equipments (hydra, crane etc.).
l) Laying of pipes (isolated or fabricated) in deep narrow trenches – manually or
mechanically.
m) Maintenance of crane / extension or reduction of crane-boom on roads or in yards.

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n) Erection of any item at >2.0 Mts. height using 100T crane or of higher capacity
o) Hydrostatic test of pipes, vessels & columns and water-flushing.
p) Radiography jobs (in-plant & open field)
q) Work in Live Electrical installations / circuits
r) Handling of explosives &Blasting operations
s) Demolishing/ dismantling activities
t) Welding/ gas cutting jobs at height (+2.0 Mts.)
u) Lifting/placing roof-girders at height(+2.0 Mts.)
v) Lifting & laying of metallic / non-metallic sheet over roof/structures.
w) Lifting of pipes, gratings, equipment’s/vessels at heights (+2.0 Mts.) with & without using
cranes
x) Calibration of equipment, instruments and functional tests at yards / work-sites.
y) Operability test of Pump, Motors (after coupling) & Compressors.
z) Cold or Hot works inside Confined Space.
aa) Transportation & shifting of ODC consignments into project areas.
bb) Working in “Charged/Live” elect. Panels
cc) Stress Relieving works (Electrically or by Gas-burners).
dd) Pneumatic Tests
ee) Card board blasting
ff) Grit Blasting activity
gg) Catalyst loading/unloading
hh) Erection/dismantling of scaffolding
ii) Chemical cleaning

The necessary HSE measures devised shall be put in place, prior to start of an activity &also
shall be maintained during the course of works, by the Contractor. Copies of such HIRAC shall
be kept available at work sites by the Contractor to enable all concerned carrying out checks /
verification.
A list of typical construction hazards along with their effects & preventive measures is given in
Appendix-E.

3.3.2 Accessibility

g) The Contractor shall provide safe means of access(in sufficient numbers)& efficient exit to
any working place including provisions of suitable and sufficient scaffolding at various
stages during all operations of the work for the safety of his workmen and EIL/Owner.
h) The Contractor shall implement use of all measures including use of “life line”, “fall-
arresters”, “retractable fall arresters”, “safety nets” etc. during the course of using all safe
accesses& exits, so that in no case any individual remains at risk of slip & fall during their
travel.
i) A ladder or step- ladder must have a level and firm footing, in case of use of fixed ladders,
sufficient foot hold and hand hold to be provided.
j) The access to operating plant / project complex shall be strictly regulated. Any person or
vehicle entering such complex shall undergo identification check, as per the procedures in
force / requirement of EIL/Owner.
k) Accessibility to ‘confined space’ shall be governed by specific system / regulation, as
established at project site.

3.3.3 Personal Protective Equipment (PPEs)

a) The Contractor workmen shall be permitted entry inside the project premises only with
proper PPEs.
b) The Contractor shall ensure that all their staff, workers and visitors including their sub-
contractor(s) have been issued (records to be kept) & wear appropriate PPEs like nape strap
type safety helmets preferably with head &sweat band with ¾” cotton chin strap (made of

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industrial HDPE), High ankle safety shoes with steel toe cap and antiskid sole, Coverall,
full body harness (CЄ marked and conforming to EN361), protective goggles, gloves, ear
muffs, respiratory protective devices, etc. All these gadgets shall conform to applicable IS
Specifications/CE or other applicable international standards. The Contractor shall
implement a regular regime of inspecting physical conditions of the PPEs being issued /
used by the workmen of their own & also its sub-agencies and the damaged / unserviceable
PPEs shall be replaced forthwith.
c) Owner/EIL may issue a comprehensive color scheme for helmets to be used by various
agencies. The Contractor shall follow the scheme issued by the owner/EIL and shall choose
colour other than white (for Owner) or blue (for EIL). All HSE personnel shall preferably
wear dark green band on their helmet or green color safety helmet so that workmen can
approach them for guidance during emergencies. HSE personnel shall preferably wear such
dresses with fluorescent stripes, which are noticeable during night, when light falls on
them.
d) Florescent jackets with respective company logo to be worn by the contractor workmen
with different color coding for categories like supervisor and workmen.
e) Workers required using or handling alkalies, acid or other similar corrosive substance at
site shall be provided with appropriate protective equipment, in accordance with MSDS.
f) For shot blasting, the usage of protective face shield and helmets, gauntlet and protective
clothing is mandatory. Such protective clothing should conform relevant IS Specification.
g) For off-shore jobs/contracts, contractor shall provide PPEs (new) of all types to EIL &
Owner's personnel, at his (contractor's) cost. All personnel shall wear life jacket at all time.
h) An indicative list of HSE standards/codes is given under Appendix-A.
i) Contractor shall ensure procurement & usage of following safety equipment’s/ accessories
(conforming to applicable IS mark / CE standard) by their staff, workmen & visitors
including their subcontractors all through the span of project construction / pre-
commissioning/ Commissioning:-‘

i. PPEs (Helmet with company name/logo, Safety Goggles, Coverall, Ear-muff, Face
Shield, Hand Gloves, High Ankle Safety Shoes, Gum Boot etc.)
ii. Barricading tape / warning signs
iii. Rechargeable Safety torch (flame-proof)
iv. Safety nets (with tie-chords)
v. Fall arresters
vi. Portable ladders (varying lengths)
vii. Life-lines (steel wire-rope, dia. not less than 8.0 mm)
viii. Full body double lanyard Safety harness with Rebar/ladder hook or scaffolding hook.
ix. Lanyard
x. Karabiner
xi. Retractable fall arresters (various length)
xii. Portable fire extinguishers (DCP type) – 5 kg&10 kg capacity
xiii. Portable Multi Gas detector
xiv. Sound level meter
xv. Digital lux meter
xvi. Fire hoses & flow nozzles
xvii. Fire blankets/ Fire retardant cloth (with eyelets)

3.3.4 Working at height

a) The Contractor shall issue permit for working (PFW) at height after verifying and
certifying the checkpoints as specified in the attached permit (Format No. HSE-6). He
shall also undertake to ensure compliance to the conditions of the permit during the
currency of the permit including adherence of personal protective equipment’s.
Contractor’s Safety Officer shall verify compliance status of the items of permit document
after implementation of action is completed by Contractor’s execution / field engineers at

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work site. HIRAC for specific works at height duly commented by EIL/Owner, shall be
kept attached with particular Permit for Work (PFW) at site for ready reference & follow-
up.

b) Such PFW shall be initially issued for one single shift or expected duration of normal work
and extended further for balance duration, if required. EIL/Owner can devise block-permit
system at any specific area, in consultation with project specific HSE Committee to specify
the time-period of validity of such PFW or its renewal. This permit shall be applicable in
areas where specific clearance from Owner’s operation Deptt./Safety Deptt. is not required.
EIL / Owner’s field Engineers/Safety Officers/Area Coordinators may verify and counter
sign this permit (as an evidence of verification) during the execution of the job.

c) All personnel shall be medically examined & certified by registered doctor, confirming
their ‘medical fitness(Vertigo or epilepsy must be covered under test report)for working at
height. The fitness examination shall be done once in six months.
d) In case work is undertaken without taking sufficient precautions as given in the permit,
EIL/Owner Engineers may exercise their authority to cancel such permit and stop the work
till satisfactory compliance/rectification is arranged made. Contractors are expected to
maintain a register for issuance of permit and extensions thereof including preserving the
used permits for verification during audits etc.
e) The Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems by his
workers. Fall arresters are to be used while climbing/descending tall structures or vessels /
columns etc. These arresters should lock automatically against the anchorage line,
restricting free fall of the user. The device is to be provided with a double security opening
system to ensure safe attachment or release of the user at any point of rope. In order to
avoid shock, the system should be capable of keeping the person in vertical position in case
of a fall. All the fall arrest systems should be cleaned after use and stored in a clean & dry
area .Defective Safety Harness, lanyards & life line must be discarded from workplace and
record to be maintained.
f) The Contractor shall ensure that Full body harnesses with double lanyards conforming
EN361 and having authorized CЄ marking is used by all personnel while working at
height. The lanyards and life lines should have enough tensile strength to take the load of
the worker in case of a fall. One end of the lanyard shall be firmly tied with the harnesses
and the other end with life line. The harness should be capable of keeping the workman
vertical in case of a fall, enabling him to rescue himself.

g) The Contractor shall provide Roof Top Walk Ladders for carrying out activities on sloping
roofs in order to reduce the chances of slippages and falls.
h) The Contractor shall ensure that a proper Safety Net System is used wherever the hazard of
fall from height is present. The safety net, preferably a knotted one with mesh ropes
conforming to IS 5175/ ISO 1140 shall have a border rope & tie cord of minimum 12mm
dia. The Safety Net shall be located not more than 6.0 meters below the working surface
extending on either side upto sufficient margin to arrest fall of persons working at different
heights.
i) In case of accidental fall of person on such Safety Net, the bottom most portion of Safety
Net should not touch any structure, object or ground.
j) Grade separators shall be provided in Pipe-rack/Tech-structures to arrest falling objects like
welding spatters, welding rods, nuts, bolts, tools etc. and to facilitate U/G and A/G works
simultaneously.
k) Beam Clamps may be used for construction of localized temporary working platforms
sheds for welding booths etc. at height in all types of steel structure due to faster
installation and requirement of less scaffolding materials.
l) Hanging Platform, manufactured by Standard HSE equipment vendors must be
encouraged for painting of Buildings etc.

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m) All the tools used at height (like spanner, screw driver etc.) shall be provided with securing
arrangement like back-pack/waist pouch to prevent accidental slippage from worker hand.
n) The Contractor shall install temporary lightening arrester in tall structures during
construction to save human life and to avoid damage to equipment’s& machineries. During
the possibility of a thunderstorm, all the work at height where a person can be exposed to
lightning shall be stopped.
o) To the extent possible use Roller arrangement to shift overhead pipes from one end to other
in Pipe Racks Area.
p) Providing of steel scaffold stair tower system with landings at regular intervals as and when
required for height work.
q) The Contractor shall ensure positive isolation while working at different levels like in the
pipe rack areas. The working platforms with toe boards & hand rails shall be sufficiently
strong & shall have sufficient space to hold the workmen and tools & tackles including the
equipment’s required for executing the job. Such working platforms shall have mid-rails, to
enable people work safely in sitting posture.

3.3.5 Scaffoldings& Barricading

a) Suitable steel scaffoldings only shall be provided to workmen for all works that cannot be
safely done from the ground or from solid construction except such short period work that
can be safely done using ladders or certified (by 3rd party competent person) man-basket.
When a ladder is used, an extra workman shall always be engaged for holding the ladder.
The ladder shall be inspected before use for cracked or split stiles, missing, broken, loose
or damaged rungs & splinters. The ladder shall be of adequate length to enable it to extend
to at least 1.0m above the landing place or working point. Metallic ladders shall be only
used as access.
.
b) The Contractor shall ensure that the scaffolds used during construction activities shall be
strong enough to take the designed load. Main Contractor shall always furnish duly
approved construction-design details of scaffold &SWL (from competent designers) free of
charge, before they are being installed/ constructed at site. Owner/EIL reserves the right to
ask the Contractor to submit certification and or design calculations from his Head Office/
Design/Engineering expert regarding load carrying capacity of the scaffoldings. All steel
tubing, couplers and fittings used for scaffolding shall conform to IS 3696 or an acceptable
equivalent. Only metallic scaffold boards shall be allowed to use. Steel tubes shall be free
from cracks, splits. Surface flaws & other defects. All couplers & fittings shall be properly
oiled and maintained. Nuts shall have a free running fit on their bolts. Bolts with worn or
damaged thread shall be replaced.

c) All scaffolds shall be inspected by a competent Scaffolding Inspector (person with

scaffolding related experience in construction field and having a training of scaffolding
supervisor from a institute/agency like National Safety Council etc.). He shall paste a
GREEN tag (duly signed by competent Scaffolding Inspector) on each scaffold found safe
and a RED tag (duly signed by competent Scaffolding Inspector) on each scaffold found
unsafe. Scaffolds with GREEN tag only shall be permitted to be used and Scaffolds with
RED ones shall immediately be made inaccessible. Work being found continuing on
scaffolds with RED tag shall be considered unauthorized work by Contractor and may
invite penalization from EIL/Owner. For every 120-125 m2 /m3 area / volume or its parts
thereof minimum one TAG shall be provided.
d) The Contractor shall ensure positive barricading (indicative as well as protective) of the
excavated, radiography, heavy lift, high pressure hydrostatic & pneumatic testing and other
such areas. Sufficient warning signs shall be displayed along the barricading areas.
e) Scaffolding shall be constructed using foot seals or base plates only. Base plates shall be
used below each standard on surface .Sole plate of timber shall be used beneath the base
plate to achieve greater load distribution.

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3.3.6 Electrical installations

a) All electrical installations/ connections shall be carried out as per the provisions of latest
revision of following codes/standards, in addition to the requirements of Statutory
Authorities and IE/applicable international rules& regulations:

- OISD STD 173 : Fire prevention & protection system for electrical installations
- SP 30 (BIS) : National Electric Code

b) All electrical installations shall be approved by the concerned statutory authorities.

c) All temporary electrical installations / facilities shall be regularly checked by the

licensed/competent electricians of the Contractor and appropriate records shall be
maintained in format no: HSE-12” Inspection of temporary electrical booth/installation at
project construction site”. Such inspection records are to be made available to EIL/Owner,
whenever asked for.

3.3.6.1 The Contractor shall meet the following requirements:

a. Shall make Single Line Diagram (SLD) for providing connection to each equipments&
machinery and the same (duly approved by EIL/Owner) shall be pasted on the front face of
DBs (distribution boards) or JBs (Junction boxes) at every site.(A typical Switch Board
Sketch is attached as Appendix -G)

b. Ensure that electrical systems and equipment including tools & tackles used during
construction phase are properly selected, installed, used and maintained as per provisions
of the latest revision of the Indian Electrical/ applicable international regulations.

c. Shall deploy qualified & licensed electricians for proper & safe installation and for regular
inspection of construction power distribution system/points including their earthing. A
copy of the license shall be submitted to EIL / Owner for records. Availability of at least
one competent (ITI qualified) / licensed electrician (by State Elec. authorities) shall be
ensured at site round the clock to attend to the normal/emergency jobs.

d. All switchboards / welding machines shall be kept in well-ventilated & covered shed/ with
rain shed protection. The shed shall be elevated from the existing ground level to avoid
water logging inside the shed. Installation of electrical switch board must be done taking
care of the prevention of shock and safety of machine.

e. No flammable materials shall be used for constructing the shed. Also flammable materials
shall not be stored in and around electrical equipment / switchboard. Adequate clearances
and operational space shall be provided around the equipment.

f. Fire extinguishers and insulating mats shall be provided in all power distribution centers.

g. Temporary electrical equipment shall not be employed in hazardous area without obtaining
safety permit.

h. Proper housekeeping shall be done around the electrical installations.

i. All temporary installations shall be tested before energizing, to ensure proper earthing,
bonding, suitability of protection system, adequacy of feeders/cables etc.

j. All welders shall use hand gloves irrespective of holder voltage.

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k. Multilingual (Hindi, English and local language) caution boards, shock treatment charts and
instruction plate containing location of isolation point for incoming supply, name &
telephone No. of contact person in emergency shall be provided in substations and near all
distribution boards / local panels.

l. ELCB tester /test meter shall be used for testing the ELCBs operation. ELCBs testing shall
be carried out by using ELCB tester on monthly basis but in specific cases like heavy rain
as decided by owner/EIC. Record of the testing shall be maintained.

m. Regular inspection of all installations at least once in a month. (Ref. Format HSE-12).

3.3.6.2 The following features shall also be ensured for all electrical installations during construction
phase by the contractor:

a. Each installation shall have a main switch with a protective device, installed in an
enclosure adjacent to the metering point. The operating height of the main switch shall not
exceed 1.5 M. The main switch shall be connected to the point of supply by means of
armoured cable.

b. The outgoing feeders shall be double or triple pole switches with fuses / MCBs. Loads in a
three phase circuit shall be balanced as far as possible and load on neutral should not
exceed 20% of load in the phase.

c. The installation shall be adequately protected against overload, short circuit and earth
leakage by the use of suitable protective devices. Fuses wherever used shall be HRC type.
Use of rewirable fuses shall be strictly prohibited. ELCB/RCCB (Residual Current Circuit
Breaker) must be fitted with all Electrical installation. The earth leakage devices shall
have an operating current not exceeding 30 mA.

d. All connections to the hand tools / welding receptacles shall be taken through proper
switches, sockets and plugs.

e. All single phase sockets shall be minimum 3 pin type only. All unused sockets shall be
provided with socket caps.

f. Only 3 core (P+N+E) overall sheathed flexible cables with minimum conductor size of 1.5
mm2 copper shall be used for all single phase hand tools.

g. Only metallic distribution boxes with double earthing shall be used at site. No wooden
boxes shall be used.

h. All power cables shall be terminated with compression type cable glands. Tinned copper
lugs shall be used for multi-strand wires / cables.

i. Cables shall be free from any insulation damage.

j. Minimum depth of cable trench shall be 750 mm for MV & control cables and 900 mm for
HV cables. These cables shall be laid over a sand layer and covered with sand, brick & soil
for ensuring mechanical protection. Cables shall not be laid in waterlogged area as far as
practicable. Cable route markers shall be provided at every 25 M of buried trench route.

When laid above ground, cables shall be properly cleated or supported on rigid poles of
atleast 2.1 M high. Minimum head clearance of 6 meters shall be provided at road
crossings.

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k. Underground road crossings for cables shall be avoided to the extent feasible. In any case
no underground power cable shall be allowed to cross the roads without pipe sleeve.

l. All cable joints shall be done with proper jointing kit. No taped/temporary joints shall be
used.
m. An independent earthing facility should preferably be established within the temporary
installation premises. All appliances and equipment shall be adequately earthed. In case of
armored cables, the armour shall be bonded to the earthing system.IS: 3043 Code for
earthing practices shall be followed at project site.

n. All cables(green colour) and wire rope used for earth connections shall be terminated
through tinned copper lugs.

o. In case of local earthing, earth electrodes shall be buried near the supply point and earth
continuity wire shall be connected to local earth plate for further distribution to various
appliances. All insulated wires for earth connection shall have insulation of green colour.

p. Separate core shall be provided for neutral. Earth / Structures shall not be used as a neutral
in any case.

q. ON/OFF position of all switches shall be clearly designated / painted for easy isolation in
emergency.

3.3.7 Welding/ Grinding/Gas cutting

a) Contractor shall ensure that flash back arrestors conforming to BS:6158 or equivalent are
installed on all gas cylinders as well as at the torch end of the gas hose, while in use.
b) All cylinders shall be mounted on trolleys and provided with a closing key. Empty &
filled-up gas cylinders shall be stored separately with TAG, protecting them from direct
sun or rain. Minimum 2 nos. of Portable DCP type fire extinguishers (10 kg) shall be
maintained at the gas cylinder stores. Stacking & storing of compressed gas cylinders shall
be arranged away from DG set, hot works, Elect. Panels / Elec. boards, etc.
c) The burner and the hose placed downstream of pressure reducer shall be equipped with
Flash Back Arrester/Non Return Valve device.
d) The hoses for acetylene and oxygen cylinders must be of different colours. Their
connections to cylinders and burners shall be made with a safety collar.
e) At end of work, the cylinders in use shall be closed and hoses depressurized.
f) Cutting of metals using gases, other than oxygen &acetylene, shall require written
concurrence from Owner.
g) Grinding activity shall not be carried out in confined spaces without a valid work permit.
h) All grinding/cutting machines shall be guarded and fitted with Dead-Man switch and this
shall not be bypassed any time.
i) All welding/grinding machines shall have effective earthing at least at distinctly isolated
two points.
j) In order to help maintain good housekeeping, and to reduce fire hazard, live electrode bits
shall be contained safely and shall not be thrown directly on the ground.
k) The hoses of Acetylene and Oxygen shall be kept free from entanglement & away from
common pathways / walkways and preferably be hanged overhead in such a manner which
can avoid contact with cranes, hydra or other mobile construction machinery.
l) Hot spatters shall be contained / restricted appropriately (by making use of effective fire-
retardant cloth/fabric) and their flying-off as well as chance of contact with near-by

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flammable materials shall be stopped. The Fire retardant blanket shall be woven from
ceramic yarn with eyelets.
m) The Contractor shall arrange adequate systems & practices for accumulation / collection of
metal & other scraps and remnant electrodes and their safe disposal at regular interval so as
to maintain the fabrication and other areas satisfactorily clean & tidy.
n) All gas cylinders must have a cylinder cap on at all times when not in use.

3.3.8 Ergonomics and tools & tackles

a) The Contractor shall assign to his workmen, tasks commensurate with their qualification,
experience and state of health. Competency of the crane operator to be thoroughly checked
prior to engaging in crane operation.
b) All lifting tools, tackles, equipment, trailers, trucks/dumpers, accessories including cranes
shall be tested periodically by statutory/competent authority for their condition and load
carrying capacity. Valid test & fitness certificates from the applicable authority shall be
submitted to Owner/EIL for their review/acceptance before the lifting tools, tackles,
equipment, trailers, trucks/dumpers, accessories and cranes are used. Third party inspection
certificate is mandatory for all lifting tools & tackles before put into use.
c) Load testing of Cranes by competent person must be made mandatory after each
modification/alteration of crane configuration/change in boom length. All heavy
equipment’s including cranes must be maintained in good condition & record of such
maintenance shall be maintained. Routine preventive maintenance of the crane to be carried
out & record to be maintained for such preventive maintenance. Healthiness of the crane to
be checked by Crane Expert on regular basis as per manufacturer guidelines.
d) HIRAC/JSA for assembly/dismantling activity of the crane to be submitted for approval of
EIC.
e) No one should stand/work below the mast & boom of the crane. Mast of the crane should
not be used for unintended lifts.
f) Mast of the crane to be kept in right position during dismantling activity of the crane.
g) Log book of all crane to be maintained.
h) Only authorized person shall be allowed to give signal to the operator.
i) Lifting/Loading/Unloading activities shall be carried out by the trained riggers under
supervision of rigging Foreman.
j) Prior to marching/movement of the crane, obstructions free access/route to be ensured.
k) Manufacturer’s instructions to be followed without any deviation.
l) The contractor shall not be allowed to use defective equipment or tools not adhering to
safety norms.
m) Adequate capacity of Chain pulley blocks with valid TPI certificate to be used for
lifting/lowering/dragging/erection of piping material .
n) Colour coding system for lifting tools & tackles shall be followed on quarterly basis for a
particular colour as mentioned below:
Period Colour Code
January, February, March Blue
April, May, June Yellow
July, August, September Green
October, November, December Orange
For Quarantine (Unsafe Tools & Tackles) Red

Contractor shall arrange non-sparking tools for project construction works in operating plant
areas / hydrocarbon prone areas.
i. Wherever required the Contractor shall make use of Elevated Work Platforms (EWP) or
Aerial Work Platforms (mobile or stationary) to avoid ergonomical risks and workmen
shall be debarred to board such elevated platform during the course of their shifting /
transportation.

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ii. Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes (while in
use) to minimize overloading risk. SLI shall have capability to continuously monitor
and display the load on the hook, and automatically compare it with the rated crane
capacity at the operating condition of the crane. The system shall also provide visual
and audible warnings at set capacity levels to alert the operator in case of violations.
iii. The contractor shall be responsible for safe operations of different equipments
mobilized and used by him at the workplace like transport vehicles, Tower Crane,
engines, cranes, mobile ladders, scaffoldings, work tools, etc. Strictly avoid standing
close to Hydra/vehicles tyres during operation.
iv. In general Man basket shall not be lifted by Hydra. Generally Crane shall be used for
lifting the man basket.
v. Tower Crane, Crane, Hydra mobile Crane (F-15 or equivalent), Hydraulic Rig & Boom
Lift shall be inspected on fortnightly basis as per Format No. HSE-20, HSE-21, HSE-
22, HSE-23 & HSE-24.
vi. The Contractor shall arrange periodical training for the operators of hydra mobile crane,
crane, excavator, mobile machinery, Tower Crane, etc. at site by utilizing services from
renowned manufacturers.
vii. Hydra mobile crane (F-15 or equivalent) having steering control mechanism shall be
permitted at construction site only for the purpose of loading/unloading. However,
continuous rigger availability during marching of hydraulic crane at site shall be
ensured by contractor.

3.3.9 Occupational Health

a) The contractor shall identify all operations that can adversely affect the health of its
workers and issue & implement mitigation measures.
b) For surface cleaning operations, sand blasting shall not be permitted even if not explicitly
stated elsewhere in the contract.
c) To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc Welding
shall not contain Thorium.
d) Appropriate respiratory protective devices(hood with respiratory devices) shall be used to
protect workmen from inhalation of air borne contaminants like silica, asbestos, gases,
fumes, etc.
e) Workmen shall be made aware of correct methods for lifting, carrying, pushing & pulling
of heavy loads. Wherever possible, manual handling shall be replaced by mechanical lifting
equipments.
f) In view of the congested working environment and associated hazards, deployment of
manpower/machineries shall be in staggered manner keeping adequate safe distance
between two adjacent work spot.
g) For jobs like drilling/demolishing/dismantling where noise pollution exceeds the specified
limit of 85decibels, ear muffs shall be provided to the workers.
h) To avoid work related upper limb disorders (WRULD) and backaches, Display Screen
Equipments' workplace stations shall be carefully designed & used with proper sitting
postures. Power driven hand-held tools shall be maintained in good working condition to
minimize their vibrating effects and personnel using these tools shall be taught how to
operate them safely & how to maintain good blood circulation in hands.
i) The Contractor shall arrange health check-up(by registered medical practitioner) for all the
workers at the time of induction. Health check may have to be repeated if the nature of duty
assigned to him is changed necessitating health check or doubt arises about his wellness.
EIL/Owner reserves the right to ask the contractor to submit medical test reports. Regular
health check-ups are mandatory for the workers assigned with Welding, Radiography,

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Blasting, Painting, Heavy Lift and Height (>2m) jobs. All the health check-ups shall be
conducted by registered Medical practitioner and records are to be maintained by the
Contractor.
j) The Contractor shall arrange Medical Camps at regular intervals at work sites and labor
colonies to assess health condition of workers.
k) The Contractor shall ensure vaccination of all the workers including their families, during
the course of entire project span.

3.3.10 Hazardous substances

a) Hazardous, inflammable and/or toxic materials such as solvent coating, thinners, anti-
termite solutions, water proofing materials shall be stored in appropriate containers
preferably with lids having spillage catchment trays and shall be stored in a good ventilated
area. These containers shall be labeled with the name of the materials highlighting the
hazards associated with its use and necessary precautions to be taken. Respective MSDS
(Material Safety Data Sheet) shall be made available at site &may be referred whenever
problem arises.
b) Where contact or exposure of hazardous materials are likely to exceed the specified limit or
otherwise have harmful effects, appropriate personal protective Equipments such as gloves,
goggles/face-shields, aprons, chemical resistant clothing, respirator, etc. shall be used.
c) The work place shall be checked prior to start of activities to identify the location, type and
condition of any asbestos materials which could be disturbed during the work. In case
asbestos material is detected, usage of appropriate PPEs by all personnel shall be ensured
and the matter shall be reported immediately to EIL/ Owner.

3.3.11 Slips, trips & falls

a) The contractor shall establish a regular cleaning and basic housekeeping programme that
covers all aspects of the workplace to help minimize the risk of slips, trips & falls. The
contractor shall take positive measures like keeping the work area tidy, storing waste in
suitable containers & harmful items separately, keeping passages, stairways, entrances &
exits especially emergency ones clear, cleaning up spillages immediately and replacing
damaged carpet/ floor tiles, mats & rugs at once to avoid slips, trips & falls.

b) Grating removal permit system should be implemented during construction phase. So that
after permanent gratings are installed on platforms and tech structure floors; removal of
any gratings for whatever purpose (including for lifting piping material etc.) is required to
be sanctioned by signed permit by HSE officers of both contractor and Engineer-in-charge.
The spot where gratings are removed shall be hard-barricaded during course of work. The
removed gratings shall be re-installed immediately after completion of work or at the time
of cessation of work every day whichever is earlier and the permit shall be closed on daily
basis. A register shall be maintained for recording all the grating removal permits and their
closure shall be monitored on daily basis.
3.3.12 Radiation exposure
a) All personnel exposed to physical agents such as ionizing &non-ionizing radiation,
including ultraviolet rays or similar other physical agents shall be provided with adequate
shielding or protection commensurate with the type of exposure involved.
b) For Open Field Radiography works, requirements of Bhabha Atomic Research Centre
(BARC)/ Atomic Energy Regulatory Board (AERB) shall be followed.
c) The Contractor shall implement an effective system of control (as described in the AERB
regulations) at site for handling radiography-sources & for avoiding its misuse & theft.
d) The contractor shall generate the Format No: HSE-8 “Permit for radiation work” before
start of work.

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e) In case the radiography work has to be carried out at day time, suitable methodology to be
used so that other works, people are not affected.
3.3.13 Explosives/Blasting operations

a) Blasting operations shall be carried out as per latest Explosive Rules (Indian/ International)
with prior permission. The Contractor shall obtain license from Chief Controller of
Explosives (CCoE) for collection, transportation, storage of explosives as well as for
carrying out blasting operations.
b) The Contractor shall prepare exclusive method statement (in cognizance with statutory
requirements)for rock blasting works &diffusing unfired explosives, if any, at project site
before carrying out actual task. Nowhere blasting shall be carried out by the Contractor or
its agency without the involvement of competent supervisor and licensed blaster.

3.3.14 Demolition/ Dismantling

a) The contractor shall adhere to safe demolishing/ dismantling practices at all stages of work
to guard against unsafe working practices.
b) The contractor shall disconnect service lines (power, gas supply, water, etc.)/ make
alternate arrangements prior to start of work and restore them, ifrequired as directed by
EIL/ Owner at no extra cost.
c) Before carrying out any demolition/dismantling work, the contractor shall take prior
approval of EIL/Owner and generate the Format No.HSE-9. For revamp jobs in operating
plants where location of underground utilities is not known with certainty, the contractor
shall depute an experienced engineer for supervision and shall make adequate arrangements
for Fire-fighting& First-Aid during the execution of these activities.
d) The Contractor shall arrange approved HIRAC/ Method Statement for the specific
demolition / dismantling task and corresponding action plan commensurate with hazards /
risks associated therein. In no case any activity related to demolition / dismantling shall be
carried out by the Contractor without engaging own supervision / field engineer.

3.3.15 Road Safety

a) The Contractor shall ensure adequately planned road transport safety management system.
b) The vehicles shall be fitted with reverse warning alarms & flashing lights / fog-lights and
usage of seat belts shall be ensured.
c) The Contractor shall also ensure a separate pedestrian route for safety of the workers and
comply with all traffic rules & regulations, including maintaining speed limit of 20 KMPH
or indicated by owner for all types of vehicles / mobile machinery. The maximum
allowable speed shall be adhered to.
d) In case of an alert or emergency, the Contractor must arrange clearance of all the routes,
roads, access. The Contractor shall deploy sufficient number of traffic controllers at project
site routes / roads/ accesses, to alert reversing movement of vehicles & machinery as well
as pedestrians. Experienced drivers/operators with valid driving license (LMV/HMV)shall
be allowed to drive/operate the vehicles/equipments.
e) Dumpers, Tippers, etc. shall not be allowed to carry workers within the plant area and also
to & from the labour colony to & from project sites.
f) Hydra mobile crane (F-15 or equivalent) shall only be allowed for
handling(loading/unloading) the materials at fabrication/ storage yards and in no case shall
be allowed to transport the materials over project / plant roads.
g) The Contractor shall not deploy any such mobile machinery / Equipments, which do not
have competent operator and / or experienced banks-man/signal-man. Such
machinery/equipments shall have effective limit-switches, reverse-alarm, front& rear-end
lights etc. and shall be maintained in good working order.

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h) The Contractor shall not carry-out maintenance of vehicles / mobile machinery occupying
space on project / plant roads and shall always arrange close supervision for such works.
i) For pipeline jobs, the contractor shall submit a comprehensive plan covering transportation,
loading / unloading of pipes, movement of side booms, movement of vehicles on the ROW,
etc.
j) Contractor’s shall arrange /install visible road signs, diversion boards, caution boards, etc.
on project roads for safe movement of men and machinery.

3.3.16 Welfare measures

Contractor shall, at the minimum, ensure the following facilities at work sites:
a) A crèche at site where 10 or more female workers are having children below the age of 6
years.
b) Adequately ventilated / illuminated rooms at labour camps & its hygienic up-keeping.
c) Reasonable canteen facilities at site and in labour camps at appropriate location depending
upon site conditions. Contractor shall make use of “industrial” variety of LPG cylinder &
satisfactory illumination at the canteens. Necessary arrangement for efficient disposal of
wastes from canteens & urinals /toilets shall also be made and regular review shall be made
to maintain the ambience satisfactorily hygienic &shall also comply with all applicable
statutory requirements.
d) Adequately lighted & ventilated Rest rooms at site (separate for male workers and female
workers).
e) Provision for suitable mobile toilets to be made available by Contractor for remote/scattered
job locations.
f) Urinals, Toilets, drinking water, washing facilities, adequate lighting at site and labour
camps, commensurate with applicable Laws/ Legislation.
g) The contractor at periodic interval shall arrange to prevent mosquito breeding by
fumigation/spraying of insecticides at workplace/fabrication yard.

3.3.17 Environment Protection

Contractor shall ensure proper storage and utilization methodology of materials that are
detrimental to the environment. Where required, Contractor shall ensure that only the
environment friendly materials are selected and emphasize on recycling of waste materials, such
as metals, plastics, glass, paper, oil & solvents. The waste that cannot be minimized, reused or
recovered shall be stored and disposed of safely. In no way, toxic spills shall be allowed to
percolate into the ground. The contractor shall not use the empty areas for dumping the wastes.

Contractor to submit Environmental Aspect Impact Register detailing the list of activities in his
scope, the respective environmental impact and the actions taken to minimize the impact.
Environmental Aspect Impact Register to be prepared as per Format HSE-18 and to be updated
and maintained till job completion.
The contractor shall strive to conserve energy and water wherever feasible.
The contractor shall ensure dust free environment at workplace by sprinkling water on the
ground at frequent intervals. The air quality parameters for dust, poisonous gases, toxic releases,
harmful radiations, etc. shall be checked by the contractor on daily basis and whenever need
arises.
The contractor shall not be allowed to discharge chemicals, oil, silt, sewage, sullage and other
waste materials directly into the controlled waters like surface drains, streams, rivers, ponds. A
discharge plan suggesting the methods of treating the waste before discharging shall be
submitted to EIL/Owner for approval.

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For pipeline jobs, top soil shall be stacked separately while making ROW through fields. This
fertile soil shall be placed back on top after backfilling.

For offshore construction barges, arrangements shall be made for safe disposal of human, food
& other wastes and applicable laws in this regard shall be followed.

3.3.18 Rules & Regulations

All persons deployed at site shall be knowledgeable of and comply with the environmental laws,
rules & regulations relating to the hazardous materials, substances and wastes. Contractor shall
not dump, release or otherwise discharge or disposes off any such materials without the express
authorization of EIL/Owner. An indicative list of Statutory Acts & Rules relating to HSE is
given under Appendix-D.

3.3.19 Weather Protection

Contractor shall take appropriate measures to protect workers from severe storms, rain, solar
radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses, Sun
screen lotions, respirators, dust masks, etc. and rearranging/ planning he construction activities
to suit the weather conditions. Effective arrangement (without creating inconvenience to project
facilities & permanent installations) for protecting workmen from hailstorm, drizzle in the form
of temporary shelter shall be made at site.

3.3.20 Communication

All persons deployed at the work site shall have access to effective means of communication so
that any untoward incident can be reported immediately and assistance sought by them.

All health & safety information shall be communicated in a simple & clear language easily
understood by the local workforce.

For information to all, typical subjects that should be communicated are: -

Inside the company (Top to down)

a. Quality Policy
b. HSE Policy contents
c. Environment Policy
d. HSE Objectives
e. Safety Cardinal Rules
f. HSE Target – reached or missed
g. Praises & Warnings to personnel for HSE Management
h. Safety Walk Through Reports and safety defects / shortfalls (by management)
i. HSE Audit results
j. Revised Statutory Health & Safety provisions, if any
k. H & S publicity
l. Suggestions

Inside the Company (Bottom to up)

a. Complaints
b. Compliances on safety defects / shortfalls
c. Suggestions
d. Proposals for changes & improvements
e. HSE Reports (including near-miss reports)

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3.3.21 Confined Space Entry

The contractor shall generate a work permit (Format No. HSE -7) before entering a confined
space. People, who are permitted to enter into confined space, must be medically examined &
certified by registered doctor, confirming their ‘medical fitness for working in confined space’.
All necessary precautions mentioned therein shall be adhered to. An attendant shall be
positioned outside a confined space for extending help during an emergency. Effective
communication shall be maintained between personnel in confined space and outside by
combination of visual/voice or portable radio. Compressed gas cylinders shall not be taken into
confine space. Entry Register for confined space to be maintained with the name and time of
entry/exit.All appropriate PPEs and air quality parameters shall be checked before entering a
confined space. It shall be ensured that the piping of the equipment which has to be opened is
pressure- free by checking that blinds are in place, vents are open and volume is drained. Inside
confined space works, only electrical facilities / installations of 24V shall be permitted.
Contactor shall ensure usage of safe & suitable arrangement of oxygen supply for individual
workmen (during the course of work in confined space), if oxygen concentration is found to be
less than 19.5% (v/v) there. All persons must be made aware of the risk associated with
Nitrogen &all precautionary measures shall be taken when vessel/sphere/pipelines etc. are being
purged with nitrogen.
Rescue arrangement must be readily available at workplace to fulfill requirement of the
emergency situation.

3.3.22 Heavy Lifts

a) The contractor shall submit detailed rigging study/ plan for EIL/ Owner approval prior to
lifting equipment requiring a crane of approx. 100 MT capacity or more due to constraints
of its dimensions, location of foundation height, approach & weight.
b) Contractor shall generate the format no. HSE-15 “Permit for heavy lift/critical erection”
c) The Safe Working Load (SWL) and manufacturer’s serial numbers shall be clearly marked
on the slings and the lifting gears, either by tagging, stamping, engraving or embossing.
d) Prior to actual lifting activities, contractor shall check the validity of the crane inspection
certificate issued by statutory/ competent authority. This requirement shall also apply to all
rigging equipments utilized for the job.
e) The contractor shall, at all times, be responsible for all rigging activities.
f) The Contractor shall ensure medical fitness of all workmen who are engaged / involved in
erection of equipments, vessels etc. and such fitness checks shall be carried-out every six
months interval with the help of a registered medical practitioner & record shall be
maintained
g) Adequate safety measures such as positive barricading, usage of appropriate PPEs, permit
to work, etc. shall be taken during all heavy or critical lifts.
h) Ground condition should be suitable tosustain the Ground Bearing Load of the Crane with
full load condition.
i) For lifting any material (irrespective of shape, size or volume), at any height, it is always
advisable to prepare a Plan of Erection (PoE) taking into consideration hazards & risks
associated therein – this can enable people to put their own experiences of various natures
& side-by-side establish a practical method for risk-free erection / lifts.The contractor shall
prepare PoE& shall document the same, when risks are identified as “medium” or “high”
and the same shall be approved by its competent / qualified engineer.

3.3.23 Key Performance Indicators

The contractor shall measure an activity in both leading & trailing indicators for statistical and
performance measurement. The activities pertaining to key performance indicators are covered

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in Monthly HSE Report (Format No. HSE-5). The contractor shall try to achieve a statistically
fair record and strive for its continual improvement.

Leading Indicators viz:-:

- Number of Safety Inductions carried-out at site (for workmen & staff members)
- Number of HSE inspections carried out
- Number of “Safety Walk Through” carried-out by site-head.
- Number of HSE shortfalls / lapses identified per contractor& closed-out in time.
- Number of Safety Meetings conducted (in-house / with contractors)
- Number of HSE Audits made (internal & external) vis-à-vis non conformances raised
- Number of HSE Awareness / Motivational program conducted by contractors
- Number of HSE Trainings conducted at site for supervisors & workmen
- Study of Near miss case reported
- Encouragements / Awards / Recognitions to workmen, job supervisors & field engineers.
- Suggestions for improvement

Trailing Indicators viz:-:

- Calculation of HSE statistics viz frequency rate, severity rate, LTA free manhoursetc.
- Analysis of incidents / accidents (nature, severity, types etc.)
- Study of Incident / Accident with respect to :-

 Variety
 Period of the year / project span
 Timings of the incident / accident
 Age profile of victims
 Body parts involved
 Penalty levied for causing incident / accident

3.3.24 Unsuitable Land Conditions

Contractor shall take appropriate measures and necessary work permits/clearances if work is to
be done in or around marshy areas, river crossings, mountains, monuments, etc. The Contractor
shall make right assessment and take all necessary action for developing work areas to make
them safe & suitable for crane operations or other vehicular movement before carrying out any
project related activity / operation. Contractor shall take all necessary actions to make the
surroundings of its site establishments (site office, stores, lay-down area etc.) work-worthy
safe and secure.

3.3.25 Under Water Inspection

Contractor shall ensure that boats and other means used for transportation, surveying &
investigation works shall be certified seaworthy by a recognized classification society. It shall
be equipped with all life saving devices like life jackets, adequate fire protection
arrangementsand shall possess communication facilities like cellular phones, wireless, walkie-
talkie. All divers used for seabed surveys, underwater inspections shall have required
authorized license, suitable life-saving kit. Number of hours of work by divers shall be limited
as per regulations. EIL/ Owner shall have the right to inspect the boat and scrutinize documents
in this regard.

3.3.26 Excavation

The Contractor shall obtain permission from competent authorities prior to excavation wherever
required.

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The Contractor shall locate the position of buried utilities (water line, cable route, etc.) by
referring to project / plant drawing / in consultation with EIL/Owner. The Contractor shall start
digging manually to locate the exact position of buried utilities & thereafter use mechanical
means.
In case of non-availability of sufficient data/drawings, underground services i.e. underground
cable/ pipe shall be checked by cable detector/pipe locator by the contractor.
The Contractor shall keep soil heaps at least 1.5 M away from edge or a distance equal to depth
of pit (whichever is more)
All excavated pits greater than 10 Sq.M plan area and depth more than 1.5M shall have at least
two access routes for ingress and egress. Also, additional access routes shall be provided such
that distance between any two access routes shall not be more than 20M.
The Contractor shall maintain sufficient “angle of repose” during excavation – shall also
provide slope or suitable bench as decided by EIL / Owner.
The Contractor shall arrange “battering” or “benching” wherever required for preventing
collapse of edge of excavations.
Avoid vertical wall of less than 2mtrs between two adjacent deep excavated pit/area. Further
deep excavation should not be kept open for a longer duration.
The Contractor shall identify & arrange de-watering pump or well-point system to prevent earth
collapse due to heavy rain / influx of underground water.
The Contractor shall arrange protective fencing/hard barricading with warning signal around
excavated pits, trenches, etc. along with minimum 2 (two) entries, exits / escape ladders.
The Contractor must avoid “underpinning” / under-cutting to prevent collapse of chunk of earth
during excavation.
The Contractor shall use “stoppers” to prevent over-run of vehicle wheels at the edge of
excavated pits / trenches. Vehicles movement should be restricted to minimum three meters
away from the excavated pit.

The Contractor shall arrange strengthening of “shoring” & “strutting” proactively to avoid
collapse of earth / edges due to vehicular movement in close proximity of excavated areas / pits/
trenches, etc.

3.4 Tool Box Talks (TBT)

Contractor shall conduct daily TBT with workers prior to start of work and shall maintain
proper record of the meeting. A suggested format is given below. The Job specific TBT is to be
conducted by the immediate supervisor of the workers.

The Contractor shall conduct TBT before start of every morning or evening shift or night shift
activities, for alerting the workers on specific hazards and their appropriate dos & don’ts. The
Contractor shall provide sufficient rests to the site workmen and their foremen to avert fatigue
& thereby endangering their lives during the course of site works.

TOOLBOX TALK RECORDING SHEET

Date & Time
Work Location
Subject (Nature of work)
Presenter
Hazards involved
Precautions to be taken
Worker's Name Signature Section

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Remarks, in any

The topics during TBT shall include

- Hazards related to work assigned on that day and precautions to be taken.

- Any forthcoming HSE hazards/events/instruction/orders, etc.

The above record can be kept in local language, which workers can read. These records shall be
made available to EIL/ Owner whenever demanded.

3.5 Training & Induction Programme

a) Initial induction of workers into Construction oriented activities and appraising them about
the methodology of works and how to carry-out safely and the same should not be inter
mixed with Tool Box Talks or HSE Training. In this regard careful action should be made
& maintained for imparting HSE induction to every individual, irrespective of his
task/designation/level of employment, whereas, HSE Training should be imparted to
specific person/group of people who are to carry-out that specific task more than once – for
example, Riggers must be trained for working at heights, welders must be trained for work
in confined space, fitters/carpenters, mesons must be trained for work at heights, etc.

b) Contractor shall conduct Safety induction programme on HSE for all his workers and
maintain records. The Gate Pass shall be issued only to those workers who successfully
qualify the Safety induction programme.

c) The Contractor shall brief the visitors about the HSE precautions which are required to be
taken before their proceeding to site and make necessary arrangements to issue appropriate
PPEs like Aprons, hard hats, ear-plugs, goggles & safety shoes etc., to his visitors. The
Contractor shall always maintain relevant acknowledgement from visitor on providing him
brief information on HSE actions.

d) Contractor shall ensure that all his personnel possess appropriate training to carry out the
assigned job safely. The training should be imparted in a language understood by them and
should specifically be trained about

- Potential hazards to which they may be exposed at their workplace

- Measures available for prevention and elimination of these hazards
The topics during training shall cover, at the minimum: -
- Why safety should be considered during work - explanation
- Education about hazards and precautions required
- Employees’ duties & responsibilities
- Emergency and evacuation plan
- HSE requirements during project activities
- Fire fighting and First-Aid
- Use of PPEs
- Occupational health issues – dos & don’ts
- Local laws on intoxicating drinks, drugs, smoking in force
- Common environmental subjects – lighting, ventilation, vibration, smoke/fumes etc.
e) Records of the training shall be kept and submitted to EIL/ Owner.

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f) The Contractor shall make regular program for conducting Safety Training on various
topics related to various activities & their safe-guarding utilizing experienced persons /
outside agency / faculty. A program for Safety Training (indicative list as per Appendix –F)
shall be furnished by the Contractor in its HSE Plan.

g) For offshore and jetty jobs, contractor shall ensure that all personnel deployed have
undergone a structured sea survival training including use of lifeboats, basket landing, use
of radio communication etc. from an agency acceptable to Owner/EIL.

3.6 ADDITIONAL SAFETY REQUIREMENTS FOR WORKING INSIDE A RUNNING

PLANT

As a minimum, the contractor shall ensure adherence to following safety requirements while
working in or in the close vicinity of an operating plant:

a) Contractor shall obtain permits for Hot work, Cold work, Excavation and Confined Space
from Owner in the prescribed format.

b) The contractor shall monitor record and compile list of his workers entering the operational
plant/unit each day and ensure & record their return after completing the job.

c) Contractor’s workers and staff members shall use designated entrances and proceed by
designated routes to work areas only assigned to them. The workers shall not be allowed to
enter units' area, tanks area, pump rooms, etc. without work authorization permit.

d) Work activities shall be planned in such a way so as to minimize the disruption of other
activities being carried out in an operational plant/unit and activities of other contractors.

e) The contractor shall submit a list of all chemicals/toxic substances that are intended to be
used at site and shall take prior approval of the Owner.

f) Specific training on working in a hydrocarbon plant shall be imparted to the work force and
mock drills shall be carried out for Rescue operations/First-Aid measures.

g) Proper barricading/cordoning of the operational units/plants shall be done before starting

the construction activities. No unauthorized person shall be allowed to trespass. The height
and overall design of the barricading structure shall be finalized in consultation with the
Owner and shall be got approved from the Owner.
h) Care shall be taken to prevent hitting underground facilities such as electrical cables,
hydrocarbon piping during execution of work.

i) Barricading with water curtain shall be arranged in specific/critical areas where

hydrocarbon vapors are likely to be present such as near horton spheres or tanks.
Positioning of fire tenders (from owner) shall also be ensured during execution of critical
activities.

j) Emergency evacuation plan shall be worked out and all workmen shall be apprised about
evacuation routes. Mock drill operations may also be conducted.
k) Flammable gas test shall be conducted prior to any hot work using appropriate measuring
instruments. Sewers, drains, vents or any other gas escaping points shall be covered with
flame retardant tarpaulin.

l) Respiratory devices shall be kept handy while working in confined zones where there is a
danger of inhalation of poisonous gases. Constant monitoring of presence of
Gas/Hydrocarbon shall be done.

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m) Clearance shall be obtained from all parties before starting hot tapping, patchwork on live
lines and work on corroded tank roof.
n) Positive isolation of line/equipment by blinding for welding/cutting/grinding shall be done.
Closing of valve will not be considered sufficient for isolation.

o) Welding spatters shall be contained properlyby using fire retardant blanket and in no case
shall be allowed to fall on the ground containing oil. Similar care shall be taken during
cutting operations.
p) The vehicles, cranes, engines, etc. shall be fitted withspark arresters on the exhaust pipe
and got it approved from Safety Department of the Owner.
q) Plant air should not be used to clean any part of the body or clothing or use to blow off dirt
on the floor.
r) Gas detectors should be installed in gas leakage prone areas as per requirement of Owner's
plant operation personnel.
s) Flame proof electrical distribution board, plug and socket shall be used for electrical
appliances.
t) Experienced full time safety personnel shall be exclusively deployed to monitor safety
aspects in running plants.

3.7 Self-Assessment and Enhancement

The contractor shall develop a method of check & balance through self-assessment&
enhancement techniques and shall explore the opportunities for continual improvement in the
HSE system.

3.8 HSE Promotion

The contractor shall encourage his workforce to promote HSE efforts at workplace by way of
organizing workshops/seminars/training programs, celebrating HSE awareness weeks
&National Safety Day, conducting quizzes & essay competitions, distributing pamphlets,
posters & material on HSE, providing incentives for maintaining good HSE practices and
granting incentives/ bonus for completing the job without any lost time accident.

3.9 Lock Out and Tag Out(LOTO) for Isolation of Energy Source
a) Contractor shall follow the LOTO/Isolation procedure of owner for all energy source
isolations installed/under purview by /of owner i.e. “Brown field”
b) For all the other energy source (not under purview of client/owner)i.e. “Green field”
Contractor shall develop a system to ensure the isolation of equipments, pipelines, Vessel,
electrical panels from the energy source covering following as minimum:-
- Identification of all energy source viz electrical, mechanical, hydraulic, pneumatic,
chemical, thermal, gravitational, radiation and other forms of stored or kinetic
energy.
- Establishing the energy isolation devices viz manually operated electrical circuit
breakers, disconnection switches, blind flanges, etc.
- Installation of Lock Out devices for preventing the inadvertent release of stored
energy and Tag Out devices (“Danger”, “Do Not operate” or Do not Remove” tags)
to indicate that testing, maintenance or servicing is underway and the device cannot
be operated until the tag out device is removed.
- Lock Out and Tag out log book
- Permit for isolation and de-isolation of energy source as per format No.: HSE-16
- Availability of competent persons like experienced operators at substations, pump
house, units etc., supervisors etc.

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c) Contractor shall ensure that all the sources are locked out and tagged properly before giving
clearance to start the job.
d) After the completion of job, contractor shall ensure all tools and tackles are removed and
nobody is present in the working area and signing on LOTO log book.
e) Only on confirmation of above the contractor will remove their lock and tag from the
isolation points and give instructions for energizing the same. Only the person carrying out
the task shall himself carry the key for the lock in /Lock out.
4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR
4.1 On Award of Contract
The Contractor shall submit a comprehensive Health, Safety and Environmental Plan or
programme for approval by EIL/Owner prior to start of work. The Contractor shall participate in
the pre-start meeting with EIL/Owner to finalize HSE Plans which shall including the
following:
- HSE policy & Objectives
- Job procedure to be followed by the Contractor for construction activities including
handling of equipment’s, scaffolding, electric installations, etc. describing the risks
involved, actions to be taken and methodology for monitoring each activity. Indicative list
of procedures is enclosed as Annexure-H
- EIL/Owner review/audit requirement.
- Organization structure along with responsibility and authority, on HSE activities.
- Administrative & disciplinary steps involving implementation of HSE requirements
- Emergency evacuation plan/ procedures for site and labour camps
- Procedures for reporting & investigation of accidents and near misses.
- HSE Inspection
- HSE Training programme at project site
- HSE Awareness programme at project site
- Reference to Rules, Regulations and statutory requirements.
- HIRAC
- Environment Aspect Impact Register
- Legal Register
- HSE documentation viz reporting, analysis & record keeping.
4.2 During Job Execution

Contractor shall implement approved Health, Safety and Environment management plan or
programme including but not limited to as brought out under para 3.0. Contractor shall also
ensure:
a) to arrange workmen compensation insurance, registration under ESI Act, third party
liability insurance, registration under BOCW Act etc., as applicable.
b) to arrange all HSE permits before start of activities (as applicable), like permits for hot
work, working at heights (Refer Format No. HSE-6), confined space (Refer Format No.
HSE-7), Radiation Work Permit (Refer Format No. HSE-8), Demolishing/ Dismantling
Work Permit (Refer Format No. HSE-9),Permit for erection/modification & dismantling of
scaffolding(Refer Format No:HSE-14),Permit for heavy lift/critical erection (Refer Format
No:HSE-15) ,Permit for energy Isolation & De-isolation” (HSE-16) ,storage of
chemical/explosive materials & its use and implement all precautions mentioned therein.
In this regard, requirements of Oil industry Safety Directorate StandardNo. Std -105 "Work
Permit Systems” shall be complied with while working in existing Oil or Gas processing
plants. List of the persons involved shall be maintained as annexure to the work permit
issued for a particular activity.
c) to submit, timely, the completed checklist on HSE activities in Format No.HSE-1, Monthly
HSE report in Format No.HSE-5 (use of web based package (www.eil.co.in/conthse) is
compulsory wherever the facility is available else a hard copy is to be submitted), accident/

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incident reports, investigation reports etc. as per EIL/Owner requirements. Compliance of

instructions on HSE shall be done by Contractor and informed urgently to EIL/Owner.
d) that his top most executive at site attends all the Safety Committee/HSE meetings arranged
by EIL/Owner and carries out safety walk regularly. Only in case of his absence from site
that a second senior most person shall be nominated by him, in advance, and
communicated to EIL/Owner for performing the above tasks.
e) display at site office and at prominent locations HSE Policy, caution boards, list of
hospitals, emergency services available, safety signs like Men at work, Speed Limits,
Hazardous Area, various do’s & don’ts, etc.
f) provide posters, banners for safe working to promote safety consciousness.
g) identify, assess, analyze & mitigate the construction hazards& incorporate relevant control
measures before actually executing site works. (HIRAC = Hazard Identification, Risk
Analysis and Control).
h) identify, assess, analyze & mitigate the environmental impact & incorporate relevant
control measures through Environmental Aspect Impact Register
i) Identify and comply to all applicable HSE related legal requirements by preparing and
maintaining a Legal register
j) arrange testing, examination, inspection of own as well as borrowed construction
equipment’s/ machinery (stationary &mobile) before being used at site and also at
periodical interval, through own resources and also by 3rd party competent agencies (as
deemed fit in statutes). Records of such test, examination etc. shall be maintained & shall
be submitted to EIL/Owner as & when asked for.
k) carryout audits/inspection (internal & external) at his works as well as sub-contractor
works as per approved HSE plan/procedure/programme& submit the compliance reports of
identified shortfalls for EIL/Owner review.
l) Arranging HSE training for site workmen (of his own &subcontractors) through internal or
external faculty at periodical intervals.
m) Assistance& cooperate during HSE audits by EIL/Owner or any other 3rd party and submit
compliance report.
n) Generate& submit of HSE records/report as per this specification.
o) Contractor shall arrange minimum 100 lux illumination level at construction site for night
works& record shall be maintained.
p) The contractor shall assign responsible person as in charge for night works and it shall be
informed to owner/EIL.
q) Appraise EIL/Owner on HSE activities at site regularly.
r) Carry-out all dismantling activities safely, with prior approval of EIL/Owner
representative.
s) The Contractor shall ensure that “Hot works” and painting works do not continue at the
same place/ location at project site for which chance or probability of “fire” incident exists.

4.3 During Short Listing of the Sub-Contractors

The contractor shall review the HSE management system of the sub-contractors in line with the
requirements given in this specification. The contractor shall be held responsible for the
shortcomings observed in the HSE management system of the sub-contractor(s) during
execution of the job.

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5.0 RECORDS
At the minimum, the contractor shall maintain/ submit HSE records in the following reporting
formats:
Safety Walk Through Report HSE-1
Accident/ Incident Report HSE-2
Supplementary Accident/ Incident Investigation report HSE-3
Near Miss Incident Report HSE-4
Monthly HSE Report HSE-5
Permit for working at height HSE-5
Permit for working in confined space HSE-7
Permit for radiation work HSE-8
Permit for demolishing/ dismantling HSE-9
Daily Safety checklist HSE-10
Housekeeping Assessment & compliance HSE-11
Inspection of temporary electrical booth/installation HSE-12
Inspection for scaffolding HSE-13
Permit for erection/modification &dismantling of scaffolding HSE-14
Permit for heavy lift/critical erection. HSE-15
Permit for Energy isolation and de-isolation. HSE-16
Permit for Excavation HSE-17
Environmental Aspect Impact Register HSE-18
HIRAC Register HSE-19
Checklist for Tower Crane HSE-20
Crane Inspection Checklist HSE-21
Hydra Crane Inspection Checklist HSE-22
Hydraulic Rig Inspection Checklist HSE-23
Boom Lift Inspection Checklist HSE-24
Inspection reports of Equipment/tools/tackles *
Report of Toolbox Talks As indicated in
specification
PPE issue report/register *
Site inspection reports *
Training records *

(*) The formats shall be developed in consultation with EIL/Owner.

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APPENDIX-A
(Sheet 1 of 2)
A. IS CODES ON HSE

SP: 53 Safety code for the use, Care and protection of hand operated tools.
IS: 838 Code of practice for safety & health requirements in electric and gas welding
and cutting operations
IS: 1179 Eye & Face precautions during welding, equipment etc.
IS: 1860 Safety requirements for use, care and protection of abrasive grinding wheels.
IS: 1989 (Pt -II) Leather safety boots and shoes
IS: 2925 Industrial Safety Helmets
IS: 3016 Code of practice for fire safety precautions in welding & cutting operation.
IS: 3043 Code of practice for earthing
IS: 3764 Code of safety for excavation work
IS: 3786 Methods for computation of frequency and severity rates for industrial injuries
and classification of industrial accidents
IS: 3696 Safety Code of scaffolds and ladders
IS: 4083 Recommendations on stacking and storage of construction materials and
components at site
IS: 4770 Rubber gloves for electrical purposes
IS: 5121 Safety code for piling and other deep foundations
IS: 5216 (Pt-I) Recommendations on Safety procedures and practices in electrical works
IS: 5557 Industrial and Safety rubber lined boots
IS: 5983 Eye protectors
IS: 6519 Selection, care and repair of Safety footwear
IS: 6994 (Pt-I) Industrial Safety Gloves (Leather & Cotton Gloves)
IS: 7293 Safety Code for working with construction Machinery
IS: 8519 Guide for selection of industrial safety equipment for body protection
IS: 9167 Ear protectors
IS: 11006 Flash back arrestor (Flame arrestor)
IS: 11016 General and safety requirements for machine tools and their operation
IS: 11057 Specification for Industrial safety nets
IS: 11226 Leather safety footwear having direct moulded rubber sole
IS: 11972 Code of practice for safety precaution to be taken when entering a sewerage
system
IS: 13367 Code of practice-safe use of cranes
IS: 13416 Recommendations for preventive measures against hazards at working place

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APPENDIX-A
(Sheet 2 of 2)

B. INTERNATIONAL STANDARDS ON HSE

Safety Glasses : ANSI Z 87.1, ANSI ZZ 87.1, AS 1337, BS 2092,

BS 1542, BS 679, DIN 4646/ 58311

Safety Shoes : ANSI Z 41.1, AS 2210, EN 345

Hand Gloves : BS 1651

Ear Muffs : BS 6344, ANSI S 31.9

Hard Hat : ANSI Z 89.1/89.2, AS 1808, BS 5240, DIN 4840

Goggles : ANSI Z 87.1

Face Shield : ANSI Z 89.1

Breathing Apparatus : BS 4667, NIOSH

Welding & Cutting : ANSI Z49.1

Safe handling of compressed:P-1 (Compressed Gas Association Gases in cylinders 1235

Jefferson Davis Highway,
Arlington VA 22202 - USA)

Full body harness : EN-361

Lanyard : EN-354

Karabiner : EN-362 and EN-12275

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APPENDIX-B
DETAILS OF FIRST AID BOX
------------------------------------------------------------------------------------------------------------------------
SL. DESCRIPTION QUANTITY
NO.
------------------------------------------------------------------------------------------------------------------------

1. Small size Roller Bandages, 1 Inch Wide (Finger Dressing small) 6 Pcs.
2. Medium size Roller Bandages, 2 Inches Wide (Hand & Foot Dressing) 6 Pcs.
3. Large size Roller Bandages, 4 Inches Wide (Body Dressing Large) 6 Pcs.
4. Large size Burn Dressing (Burn Dressing Large) 4 Pkts.
5. Cotton Wool (20 gms packing) 4 Pkts.
6. Antiseptic Solution Dettol (100 ml.) or Savlon 1 Bottle
7. Mercurochrome Solution (100 ml.) 2% in water 1 Bottle
8. Ammonia Solution (20 ml.) 1 Bottle
9. A Pair of Scissors 1 Piece
10. Adhesive Plaster (1.25 cm X 5 m) 1 Spool
11. Eye pads in Separate Sealed Pkt. 4 pcs.
12. Tourniqut 1 No.
13. Safety Pins 1 Dozen
14. Tinc. Iodine/ Betadine (100 ml.) 1 Bottle
15. Polythene Wash cup for washing eyes 1 No.
16. Potassium Permanganate (20 gms.) 1 Pkt.
17. Tinc. Benzoine (100 ml.) 1 Bottle
18. Triangular Bandages 2 Nos.
19. Band Aid Dressing 5 Pcs.
20. Iodex/Moov(25 gms.) 1 Bottle
21. Tongue Depressor 1 No.
22. Boric Acid Powder (20 gms.) 2 Pkt.
23. Sodium Bicarbonate (20 gms.) 1 Pkt.
24. Dressing Powder (Nebasulf) (10 gms.) 1 Bottle
25. Medicinal Glass 1 No.
26. Duster 1 No.
27. Booklet (English& Local Language) 1 No. each
28. Soap 1 No.
29. Toothache Solution 1 No.
30. Vicks (22 gms.) 1 Bottle
31. Forceps 1 No.
32. Snake –Bite Lancet 1No.
33. Note Book 1 No.
34. Splints 4 Nos.
35. Lock 1 Piece
36. Life Saving/Emergency/Over-the counter Drugs As decided at site

-----------------------------------------------------------------------------------------------------------------
Box size:Suitable size first aid box to be used for first aid items
-----------------------------------------------------------------------------------------------------------------

Note : The medicines prescribed above are only indicative. Equivalent medicines can also be used.
A prescription, in this regard, shall be required from a qualified Physician.

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APPENDIX-C

TYPE OF FIRES VIS-À-VIS FIRE EXTINGUISHERS

Fire
Extinguisher
Multi
Fire Water Foam CO2 Dry Powder purpose
(ABC)

Originated from can control can control

  minor 
paper, clothes, wood minor
surface fires surface fires

Inflammable liquids
like alcohol, diesel,     
petrol, edible oils,
bitumen
Originated from
gases like LPG,     
CNG, H2

Electrical fires     

LEGEND :  : CAN BE USED

 : NOT TO BE USED

Note: Fire extinguishing equipment must be checked atleast once a year and after every use by an
authorized person. The equipment must have an inspection label on which the next inspection
date is given. Type of extinguisher shall clearly be marked on it.

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APPENDIX-D

List of Statutory Acts & Rules Relating to HSE

- The Indian Explosives Act and Rules

- The Motor Vehicle Act and Central Motor Vehicle Rules
- The Factories Act and concerned Factory Rules
- The Petroleum Act and Petroleum Rules
- The Workmen Compensation Act
- The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules
- The Indian Electricity Act and Rules
- The Indian Boiler Act and Regulations
- The Water (Prevention & Control & Pollution) Act
- The Water (Prevention & Control of Pollution) Cess Act
- The Mines & Minerals (Regulation & Development) Act
- The Air (Prevention & Control of Pollution) Act
- The Atomic Energy Act
- The Radiation Protection Rules
- The Indian Fisheries Act
- The Indian Forest Act
- The Wild Life (Protection) Act
- The Environment (Protection) Act and Rules
- The Hazardous Wastes (Management & Handling) Rules
- The Manufacturing, Storage & import of Hazardous Chemicals Rules
- The Public Liability Act
- The Building and Other Construction Workers (Regulation of Employment and Condition of
Service) Act
- Other statutory acts Like EPF, ESIS, Minimum Wages Act.

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APPENDIX-E(Sheet 1 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
(A) Falling into pit Personal injury Provide guard rails/ barricade with warning
EXCAVATION signal
Provide at least two entries/ exits.
Pit Excavation Provide escape ladders.
upto 3.0m Earth Collapse Suffocation/ Provide suitable size of shoring and strutting,
Breathlessness if required.
Buried Keep soil heaps away from the edge
equivalent to 1.5m or depth of pit whichever
is more.
Don't allow vehicles to operate too close to
excavated areas. Maintain at least 2m
distance from edge of cut.
Maintain sufficient angle of repose. Provide
slope not less than 1:1 and suitable bench of
0.5m width at every 1.5m depth of excavation
in all soils except hard rock.
Battering/benching the sides.
Contact with Electrocution Obtain permission from competent
buried electric Explosion authorities, prior to excavation, if required.
cables Locate the position of buried utilities by
Gas/ Oil referring to plant drawings.
Pipelines Start digging manually to locate the exact
position of buried utilities and thereafter use
mechanical means.
Pit Excavation Same as above Can cause Prevent ingress of water
beyond 3.0m plus drowning situation Provide ring buoys
Flooding due to Identify and provide suitable size dewatering
excessive rain/ pump or well point system
underground
water
Digging in the Building/Structure Obtain prior approval of excavation method
vicinity of may collapse from local authorities.
existing Loss of health & Use under-pining method
Building/ wealth Construct retaining wall side byside.
Structure
Movement of May cause cave-in Barricade the excavated area with proper
vehicles/ or slides. lighting arrangements
Equipments Persons may get Maintain at least 2m distance from edge of
close to the buried. cut and use stop blocks to prevent over-run
edge of cut. Strengthen shoring and strutting

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APPENDIX-E: (Sheet 2 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
Narrow deep Same as above plus May cause Battering/benching of sides
excavations for Frequent cave-in or severe injuries or Provide escape ladders
pipelines, etc. slides prove fatal
Flooding due to May arise Same as above plus
Hydro- static drowning Bail out accumulated water
testing situation Maintain adequate ventilation.
Rock by Improper handling May prove fatal Ensure proper storage, handling & carrying
excavation of explosives of explosives by trained personnel.
blasting Comply with the applicable explosive acts &
rules.
Uncontrolled May cause Allow only authorized persons to perform
explosion severe injuries or blasting operations.
prove fatal Smoking and open flames are to be strictly
prohibited
Scattering of stone Can hurt people Use PPE like goggles, face mask, helmets
pieces in etc.
atmosphere
Rock Entrapping of May cause Barricade the area with red flags and blow
excavation by persons/ animals. severe injuries or siren before blasting.
blasting (Contd) prove fatal
Misfire May explode Do not return to site for atleast 20 minutes or
suddenly unless announced safe by designated person.
Piling Work Failure of pile- Can hurt people Inspect Piling rigs and pulley blocks before
driving equipment the beginning of each shift.
Noise pollution Can cause Use personal protective equipment’s like ear
deafness and plugs, muffs, etc.
psychological
imbalance.
Extruding Can hurt people Barricade the area and install sign boards
rods/casing Provide first-aid
Working in the Can cause Keep sufficient distance from Live-
vicinity of 'Live- electrocution/ Electricity as per IS code.
Electricity' Asphyxiation Shut off the supply, if possible
Provide artificial/rescue breathing to the
injured
(B) Air pollution by May affect Wear respirators or cover mouth and nose
CONCRETING cement Respiratory with wet cloth.
System
Handling of Hands may get Use gloves & other PPE.
ingredients injured
Protruding Feet may get Provide platform above reinforcement for
reinforcement rods. injured movement of workers or provide end caps
for protection on reinforcement bars.

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APPENDIX-E :(Sheet 3 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
Earthing of Can cause Ensure earthing of equipments and proper
electrical electrocution/ functioning of electrical circuit before
mixers, asphyxiation commencement of work.
vibrators, etc.
not done.
Falling of Persons may get Use hard hats
materials from injured Remove surplus material immediately from
height work place.
Ensure lighting arrangements during night
hours
Continuous Cause tiredness of Insist on shift pattern
pouring by workers and may Provide adequate rest to workers between
same gang lead to accident. subsequent pours.
Revolving of Parts of body or Allow only mixers with hopper
concrete mixer/ clothes may get Provide safety cages around moving motors
vibrators entrapped. Ensure proper mechanical locking of
vibrator.
Super-structure Same as above Shuttering/props Avoid excessive stacking on shuttering
plus may collapse and material
Deflection in prove fatal Check the design and strength of shuttering
props or material before commencement of work
shuttering Rectify immediately the deflection noted
material during concreting.
Passage to Improperly tied Ensure the stability and strength of passage
work place and designed before commencement of work.
props/planks may Do not overload and stand under the
collapse passage.
(C) REINFOR- Curtailment Persons may get Use PPE like gloves, shoes, helmets, etc.
CEMENT and binding of injured Avoid usage of shift tools
rods
Carrying of Workers may get Provide suitable pads on shoulders and use
rods for short injured their hands safety gloves.
distances/at and shoulders. Tie up rods in easily liftable bundles
heights Ensure proper staging.
Checking of Rods may cut or Use measuring devices like tape, measuring
clear distance/ injure the fingers rods, etc.
cover with
hands
Hitting Persons may get Use safety shoes and avoid standing
projected rods injured and fell unnecessarily on cantilever rods
and standing on down Avoid wearing of loose clothes
cantilever rods.

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APPENDIX-E:(Sheet 4 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
Falling of material May prove fatal Use helmets
from height Provide safety nets

Transportation of Protruded rods Use red flags/lights at the ends

rods by trucks/ may hit the Do not protrude the rods in front of or by
trailers persons the side of driver's cabin.
Do not extend the rods 1/3rd of deck length
or 1.5m whichever is less
(D)WELDING Welding radiates Radiation can Use specified shielding devices and other
AND GAS invisible damage eyes and PPE of correct specifications.
CUTTING ultraviolet and skin. Avoid thoriated tungsten electrodes for
infra-red rays GTAW
Improper Explosion may Move out any leaking cylinder
placement of occur Keep cylinders in vertical position
oxygen and Use trolley for transportation of cylinders
acetylene cylinders and chain them
Use flashback arrestors
Leakage/ cuts in May cause fire Purge regulators immediately and then turn
hoses off
Never use grease or oil on oxygen line
connections and copper fittings on
acetylene lines
Inspect regularly gas carrying hoses
Always use red hose for acetylene & other
fuel gases and black for oxygen
Opening-up of Cylinder may Always stand back from the regulator while
cylinder burst opening the cylinder
Turn valve slowly to avoid bursting
Cover the lug terminals to prevent short
circuiting
Welding of tanks, Explosion may Empty & purge them before welding
container or pipes occur Never attach the ground cable to tanks,
storing flammable container or pipe storing flammable liquids
liquids Never use LPG for gas cutting

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APPENDIX-E:(Sheet 5 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES …(Contd.)

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
(E) Ionizing Radiations may Ensure Safety regulations as per
RADIOGRAPHY radiation react with the skin BARC/AERB before commencement of job.
and can cause Cordon off the area and install Radiation
cancer, skin warning symbols
irritation, Restrict the entry of unauthorized persons
dermatitis, etc. Wear appropriate PPE and film badges issued
by BARC/AERB
Transportation Same as above Never touch or handle radiography source
and Storage of with hands
Radiography Store radiography source inside a pit in an
source exclusive isolated storage room with lock and
key arrangement. The pit should be approved
by BARC/AERB.
Radiography source should never be carried
either in passenger bus or in a passenger
compartment of trains.
BARC/AERB has to be informed before
source movement.
Permission from Director General of Civil
Aviation is required for booking radio
isotopes with airlines.
Loss of Radio Same as above Try to locate with the help of Survey Meter.
isotope Inform BARC/AERB (*)
(F) Short circuiting Can cause Use rubberized hand gloves and other PPE
ELECTRICAL Electrocution or Don't lay wires under carpets, mats or door
INSTALLATION Fire ways.
ANDUSAGE Allow only licensed electricians to perform
on electrical facilities
Use one socket for one appliance
Ensure usage of only fully insulated wires or
cables
Don't place bare wire ends in a socket
Ensure earthing of machineries and
equipments
Do not use damaged cords and avoid
temporary connections
Use spark-proof/flame proof type field
distribution boxes.

(*) Atomic Energy Regulatory Board (AERB),

Bhabha Atomic Research Centre (BARC)
Anushakti Nagar, Mumbai – 400 094

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APPENDIX-E:(Sheet 6 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)

TYPE OF EFFECT OF
ACTIVITY
HAZARD HAZARD
PREVENTIVE MEASURES
Do not allow open/bare connections
Provide all connections through 30mAELCB
Protect electrical cables/equipments from
water and naked flames
Check all connections before energizing
Overloading of Bursting of system Display voltage and current ratings
Electrical can occur which prominently with 'Danger' signs.
System leads to fire Ensure approved cable size, voltage grade and
type
Switch off the electrical utilities when not in
use
Do not allow unauthorized connections.
Ensure proper grid wise distribution ofPower
Improper laying Can cause Do not lay unarmoured cable directly on
of overhead and electrocution and ground, wall, roof of trees
underground prove fatal Maintain atleast 3m distance from HT cables
transmission All temporary cables should be laid atleast 750
lines/cables mm below ground on 100 mm fine sand
overlying by brick soling
Provide proper sleeves at crossings/ inter-
sections
Provide cable route markers indicating the
type and depth of cables at intervals not
exceeding 30m and at the
diversions/termination
(G) FIRE Small fires can Cause burn injuries In case a fire breaks out, press fire alarm
PREVENTION become big and may prove fatal system and shout "Fire, Fire".
AND ones and may Keep buckets full of sand & water/ fire
PROTECTION spread to the extinguishing equipment near hazardous
surrounding locations.
areas Confine smoking to 'Smoking Zones' only.
Train people for using specific type of fire
fighting equipments under different classes of
fire.
Keep fire doors/shutters, passages and exit
doors unobstructed.
Maintain good housekeeping and first-aid
boxes (for details refer Appendix-B).
Don't obstruct assess to Fire extinguishers.
Do not use elevators for evacuation during
fire.
Maintain lightening arrestors for elevated
structures.
Stop all electrical motors with internal
combustion.

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APPENDIX-E :(Sheet 7 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
Move the vehicles from dangerous locations.
Remove the load hanging from the crane
booms
Remain out of the danger areas.
Improper It may not Ensure usage of correct fire extinguisher
selection of Fire extinguish the fire meant for the specified fire (for details refer
extinguisher Appendix-C).
Do not attempt to extinguish Oil and electric
fires with water. Use foam
cylinders/CO2/sand or earth.
Improper Same as above Maintain safe distance of flammable
storage of substances from source of ignition.
highly Restrict the distribution of flammable
inflammable materials to only min. necessary amount.
substances Construct specifically designed fuel storage
facilities.
Keep chemicals in cool and dry place away
from heat. Ensure adequate ventilation.
Before welding operation, remove or shield
the flammable material properly.
Store flammable materials in stable racks,
correctly labeled preferably with catchment
trays.
Wipe off the spills immediately
Short circuiting Same as above Don't lay wires under carpets, mats or door
of electrical Can cause ways
system Electrocution Use one socket for one appliance.
Use only fully insulated wires or cables.
Do not allow open/bare connections.
Provide all connections through
30mAELCB.
Ensure earthing of machineries and
equipments.
(H) Crossing the Personal injury Obey speed limits and traffic rules strictly.
VEHICULAR Speed Limits Always expect the unexpected and be a
MOVEMENT (Rash driving) defensive driver.
Use seat belts/helmets.
Blow horn at intersections and during
overtaking operations.
Maintain the vehicle in good condition.
Do not overtake on curves, bridges and
slopes.
Adverse Same asAbove Read the road ahead and ride to the left.
weather Keep the wind screen and lights clean.
condition Do not turn at speed.
Recognize the hazard, understand the
defense and act correctly in time.

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APPENDIX-E :(Sheet 8 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
Consuming Same as above Alcohol and driving do not mix well. Either
alcohol before choose alcohol or driving.
and during the If you have a choice between hitting a fixed
driving object or an on-coming vehicle, hit the fixed
operation object
Quit the steering at once and become a
passenger. Otherwise take sufficient rest
and then drive.
Do not force the driver to drive fast and
round the clock.
Do not day dream while driving
Falling objects/ May prove fatal Ensure effective braking system, adequate
Mechanical visibility for the drives, reverse warning
failure alarm.
Proper maintenance of the vehicle as per
manufacturer instructions
(I) PROOF Bursting of May cause injury Prepare test procedure & obtain EIL/owner's
TESTING piping and prove fatal approval.
(HYDROSTATIC/ Collapse of Provide separate gauge for pressurizing
PNEUMATIC tanks pump and piping/equipment.
TESTING) Tanks flying Check the calibration status of all pressure
off gauges, dead weight testers and temperature
recorders.
Take dial readings at suitable defined
intervals and ensure most of them fall
between 40-60% of the gauge scale range.
Provide safety relief valve (set at pressure
slightly higher than test pressure) while
testing with air/ nitrogen.
Ensure necessary precautions, stepwise
increase in pressure, tightening of
bolts/nuts, grouting, etc. before and during
testing.
Keep the vents open before opening any
valve while draining out of water used for
hydro-testing of tanks.
Pneumatic testing involves the hazard of
released energy stored in compressed gas.
Specific care must therefore be taken to
minimize the chance of brittle failure during
a pneumatic leak test. Test temperature is
important in this regard and must be
considered when the designer chooses the
material of construction.

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APPENDIX-E :(Sheet 9 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
A pressure relief device shall be provided,
having a set pressure not higher than the test
pressure plus the lesser of 345 KPa (50 psi) or
10% of the test pressure.
The gas used as test fluid, if not air, shall be
nonflammable and nontoxic.
(J) Person can fall May sustain severe Provide guard rails/barricade at the work
WORKING AT down injuries or prove place
HEIGHTS fatal Use PPE like full body harness, life line,
helmets, safety shoes, etc.
Obtain a permit before starting the work at
height above 2 meters
Fall arrest and safety nets, etc. must be
installed
Provide adequate working space(min. 0.6 m)
Tie/weld working platform with fixed support
Use roof top walk ladder while working on a
slopping roofs
Avoid movement on beams
May hit the Keep the work place neat and clean
scrap/material Remove the scrap immediately
stacked at the
ground or in
between
Material can May hit the Same as above plus
fall down workers working at Do not throw or drop materials or equipment
lower levels and from height. i.e. do not bomb materials
prove fatal All tools to be carried in a tool-kit
Bag or on working uniform
Remove scrap from the planks
Ensure wearing of helmet by the workers
working at lower levels
(K) Suffocation/ Unconsciousness, Use respiratory devices, if reqd.
CONFINED drowning death Avoid overcrowding inside aconfined space
SPACES Provide Exhaust fans for ventilation
Do not wear loose clothes, neck ties, etc.
Fulfill conditions of the permit

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APPENDIX-E:(Sheet 10 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
Check for presence of hydrocarbons, O2 level
Obtain work permit before entering a confined
space
Ensure that the connected piping of the
equipment which is to be opened is pressure
free, fluid has been drained, vents are open and
piping is positively isolated by a blind flange
Presence of Inhalation can pose Same as above plus
foul smell and threat to life Check for hydrocarbon and Aromatic
toxic compounds before entering a confined space
substances Depute one person outside the confined space
for continuous monitoring and for extending
help in case of an emergency
Ignition/ Person may sustain Keep fire extinguishers at a hand distance
flame can burn injuries or Remove surplus material and scrap
cause fire explosion may immediately
occur Do not smoke inside a confined space
Do not allow gas cylinders inside a confined
space
Use low voltage (24V) lamps for lighting
Use tools with air motors or electric tools with
max. voltage of 24V
Remove all equipment’s at the end of the day
(L) Failure of load Can cause accident Avoid standing under the lifted load and within
HANDLING lifting and and prove fatal the operating radius of cranes.
AND moving Check periodically oil, brakes, gears, horns and
LIFTING equipments tyre pressure of all moving machinery.
EQUIPMENTS Check quality, size and condition of all chain
pulley blocks, slings, U-clamps, D-shackles,
wire ropes, etc.
Allow crane to move only on hard, firm and
leveled ground.
Allow lifting slings as short as possible and
check gunny packings at the friction points.
Do not allow crane to tilt its boom while
moving
Install Safe Load Indicator.
Ensure certification by applicable authority.

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6-82-0001Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 53 of 102

APPENDIX-E :(Sheet 11 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES (…Contd.)

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
Overloading Same as above Safe lifting capacity of derricks and winches
of lifting written on them shall be got verified
equipments The max. safe working load shall be marked on
all lifting equipments
Check the weight of columns and other heavy
items painted on them and accordingly decide
about the crane capacity, boom and angle of
erection
Allow only trained operators and riggers during
crane operation.
Overhead Can cause Do not allow boom or other parts of crane to
electrical electrocution and come within 3m reach of overhead HT cables
wires fire Hook and load being lifted shall preferably
remain in full visibility of crane operators.
(M) Person can Person May sustain Provide guard rails for working at height.
SCAFFOLDING, fall down severe injuries and Face ladder while climbing and use both hands.
FORMWORK prove fatal Ladders shall extend about 1m above landing for
AND LADDERS easy access and tying up purpose.
Do not place ladders against movable objects
and maintain base at 1/4 unit of the working
length of the ladder.
Suspended scaffolds shall not be less than 500
mm wide and tied properly with ropes.
No loose planks shall be allowed.
Use PPE, like helmets, safety shoes etc.
Failure of Same as above Inspect visually all scaffolding materials for
scaffolding stability and anchoring with permanent
material structures.
Design scaffolding for max. load carrying
capacity.
Scaffolding planks shall not be less than 50X250
mm full thickness lumber or equivalent. These
shall be cleated or secured and must extend over
the end supports by at least 150mm and not
more than 300mm.
Don't overload the scaffolds.
Do not splice short ladders to make a longer
one. Vertical ladders shall not exceed 6m.
Material can Persons working at Remove excess material and scrap immediately.
fall down lower level gets Carry the tools in a tool-kit bag only.
injured Provide safety nets.

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HEALTH, SAFETY &
6-82-0001Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 54 of 102

APPENDIX-E:(Sheet 12 of 12)

CONSTRUCTION HAZARDS, THEIR EFFECTS &PREVENTIVE MEASURES (…Contd.)

TYPE OF EFFECT OF
ACTIVITY PREVENTIVE MEASURES
HAZARD HAZARD
(N) Personal Can cause injury or Do not take rest inside rooms built for welding
STRUC- negligence and casualty machines or electrical distribution system.
TURAL danger of fall Avoid walking on beams at height.
WORKS Wear helmet with chin strap and full body
harness while working at height.
Use hand gloves and goggles during grinding
operations.
Cover or mark the sharp and projected edges.
Do not stand within the operating radius of
cranes.

Lifting/ slipping Same as above Do not stand under the lifted load.
of material Stack properly all the materials. Avoid slippage
during handling.
Control longer pieces lifted up by cranes from
both ends.
Remove loose materials from height.
Ensure tightening of all nuts & bolts.

(O)PIPELIN Erection/ Can cause injury Do not stand under the lifted load.
E WORKS lowering failure Do not allow any person to come within the
radii of the side boom handling pipes.
Check the load carrying capacity of the lifting
tools & tackles.
Use safe Load Indicators (SLI).
Use appropriate PPEs.

Other Same as above Wear gum boots in marshy areas.

Allow only one person to perform signaling
operations while lowering of pipes.
Wedges to be provided below the pipe to
prevent spool/pipe roll out.
Provide night caps on pipes.
Provide end covers on pipes for stoppage of
pigs while testing/ cleaning operations.

(P) Pollution in Can cause personal Ensure the blasting is done in enclosed shed.
GRIT neighboring injury Keep safe distance while blasting operations.
BLASTING area, hit by grits Wear positive pressure blast hood or helmet
and high with view-window, ear-muff/plug, gloves,
pressure air overall or leather coat /apron, rubber shoes.

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6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 55 of 102

APPENDIX-F

TRAINING SUBJECTS / TOPICS

(For contractors’ personnel)

1. The Law & Safety – Statutory Requirement / Applicable statutes / Duties of employer /
employee.
2. Policy & Administration – Why HSE? / Duties & Responsibilities of Safety Personnel at
project site / Effect of incentive on accident prevention.
3. HSE & Supervision – Duties of Supervisor / HSE integrated supervision / Who should be held
responsible for site accidents?
4. Safety Budget / Cost of Accidents – Direct costs / Indirect costs.
5. Hazard Identification / Type of hazards / HIRAC.
6. Behavioral Safety & Motivation.
7. Housekeeping – Storage / Stacking / Handling of materials / Hydra handling.
8. Occupational Health in Construction sector.
9. Personal Protective Equipments – Respiratory & Non- respiratory.
10. Electricity & Safety – ELCB / Fuse / Powered tools / Project illumination.
11. Handling of Compressed Gas – Transportation / Storage / FBAs / Fire prevention.
12. Machine Safety – Machine guarding / Maintenance.
13. Transportation – Hazards & risks in transp. of materials / ODC consignments.
14. Cranes & Other Lifting machinery – Legal requirements vis-à-vis essential safetyrequirements.
15. Communication – HSE Induction / TBTs / Safety Committee / Safety meeting / Safety
propaganda / Publicity.
16. Excavation – Risks & Dangers / Safety measures.
17. Working at Heights – Use of ladder / Work on roofs / Scaffolds / Double harness lanyards /
Life-line / Fall arrester / Safety Nets / Floor openings.
18. Hazards in Welding & important safety precautions.
19. Gas Cutting – Hazards & safety measures.
20. Fire prevention & fire protection.

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ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 56 of 102

APPENDIX - G
CONSTRUCTION POWER BOARD(typ)

DRAFT

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ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 57 of 102

APPENDIX-H

LIST OF PROCEDURES (MINIMUM) TO BE FORMING PART OF HSE PLAN:-

A. HSE Management Procedures:

 HSE Risk Management (including HIRA)

 HSE Legal Compliance and Other Requirements
 HSE Objectives & Performance
 HSE Training and Competence (including Induction)
 HSE Motivation &Award Scheme
 HSE Audits
 HSE Sub Contractor Management
 HSE Emergency Management
 HSE Incidents Reporting and Management
 HSE procedure for Behaviour based Safety
 First Aid & Management
 Roles, Responsibility, accountabilities and Authorities

B. Job procedures/Safe Operating procedures

 Setting Up Site &Signages

 Working at Height
 Confined Space Entry
 Permit to Work (including hot works)
 Housekeeping
 Transportation of materials including Manual Handling
DRAFT

 Earthmoving Operations & excavation

 Scaffolding
 Fire Prevention/Protection
 Hazardous Substance handling & Storage
 Personal Protective Equipment

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ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 58 of 102

FORMAT NO. : HSE-1 REV 0

(Sheet 1 of 6)
SAFETY WALK-THROUGH REPORT
(Name & signature of walk through performer to be inserted at the bottom of each page)

Project : _____________ Report no. : ___________

Date : _____________ Ccontractor : ___________

Inspection by :_____________ Owner : ___________

Frequency : Monthly Job no. : ___________

Note : Write ‘NA’ wherever the item is not applicable

Non
SL. Satisfactory/
ITEM satisfactory/ Remarks Action
NO. Yes
No
1. HOUSEKEEPING
a) Waste containers provided and used
b) Sanitary facilities adequate and Clean

c) Passageways and Walkways Clear

d) General neatness of working areas

e) Other
2. PERSONNEL PROTECTIVE EQUIPMENT
DRAFT

a) Goggles; Shields
b) Face protection

c) Hearing protection

d) Foot protection
e) Hand protection

f) Respiratory Masks etc.

g) Full body harness conforming to CЄ, EN 361

h) Hard hat (HDPE)

i) Other

3. EXCAVATIONS/OPENINGS

a) Openings properly covered or barricaded

b) Excavations shored

c) Excavations barricaded

d) Overnight lighting provided

e) Other

Safety walk-through performer (Name& Signature)……………………………………….

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ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 59 of 102

FORMAT NO. : HSE-1 REV 0

(Sheet 2 of 6)

Non
SL. Satisfactory/
ITEM satisfactory/ Remarks Action
NO. Yes
No
4. WELDING & GAS CUTTING

a) Gas cylinders chained upright

b) Cables and hoses not obstructing

c) Screens or shields used

d) Flammable materials protected

e) Live electrode bits contained properly

f) Fire extinguisher (s) accessible

g) Other

5. SCAFFOLDING & BARRICADING

a) Fully decked platforms

b) Guard and intermediate rails in place

c) Toe boards in place

d) Adequate shoring DRAFT

e) Adequate access

f) Positive barricading for critical activities

g) Installation of warning signs

h) Other

6. LADDERS

a) Extension side rails 1 m above

b) Top of landing

c) Properly secured

d) Angle + 700 from horizontal

e) Other

Safety walk-through performer (Name & Signature)…………………………………………..

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ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 60 of 102

FORMAT NO. : HSE-1 REV 0

(Sheet 3 of 6)

Non
SL. Satisfactory/
ITEM satisfactory/ Remarks Action
NO. Yes
No
7. HOISTS, CRANES AND DERRICKS

a) Condition of cables and sheaves OK

b) Condition of slings, chains, hooks and eyes

O.K.
c) Inspection and maintenance log-books
maintained
d) Outriggers used

e) Reverse horn installed / active / coupled with

gear
f) Signs/barricades provided

g) Signals observed and understood

h) Qualified operators

i) Other

8. MACHINERY, TOOLS AND EQUIPMENT

a) Proper instruction

b) Safety devices

c) Proper cords

d) Inspection and maintenance

e) Other

9. VEHICLE AND TRAFFIC

a) Rules and regulations observed

b) Inspection and maintenance

c) Licensed drivers

d) Other

Safety walk-through performer (Name& Signature)………………………………

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ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 61 of 102

FORMAT NO. : HSE-1 REV 0

(Sheet 4 of 6)

Non
SL. Satisfactory/
ITEM satisfactory/ Remarks Action
NO. Yes
No
10. TEMPORARY FACILITIES

a) Emergency instructions posted

b) Fire extinguishers provided

c) Fire-aid equipment available

d) Secured against storm damage

e) General neatness

f) In accordance with electrical requirements

g) Other

11. FIRE PREVENTION

a) Personnel trained & instructed to make use

of facility
b) Fire extinguishers checked periodically &
record maintained
c) No smoking in Prohibited areas.
d) Fire Hydrants not obstructed

e) Regular fire drill conducted

12. ELECTRICAL

a) Use of 3-core armored cables everywhere

b) Usage of 'All insulated' or 'double-insulated'

electrical tools
c) All electrical connection are routed through
ELCB
d) Natural Earthing at the source of power
(Main DB)
e) Continuity and tightness of earth conductor

f) Effective covering of junction boxes, panels

and other energized wiring places
g) Ground fault circuit interrupters provided

h) Prevention of tripping hazards maintained

f) DCP extinguishers arranged & licensed

electrician engaged at site

Safety walk-through performer (Name& Signature)…………………………………………

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ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 62 of 102

FORMAT NO. : HSE-1 REV 0

(Sheet 5 of 6)

Non
SL. Satisfactory/
ITEM satisfactory/ Remarks Action
NO. Yes
No
13. HANDLING AND STORAGE OF
MATERIALS
a) Safely stored or stacked
b) Passageways clear / free from obstructions
c) Fire fighting facility in place
14. FLAMMABLE GASES AND LIQUIDS
a) Containers clearly identified / protected from
fire
b) Safe storage & transportation arrangement
made
c) Fire extinguishers positioned nearby
d) Facilities kept away from electric spark, hot
spatters & ignition source.
15. WORKING AT HEIGHT
a) Approved Erection plan and work permit in
place
b) Safe access, Safe work platform & Safety nets
provided
c) Life lines, Fall arrester, Full body harness
with double lanyards used;
d) Health Check record available for workers
going up?
e) Protective handrails arranged around floor
openings
16. CONFINED SPACE
a) Work Permit obtained from requisite authority
b) Test for toxic gas and sufficient availability of
oxygen conducted & status
c) Supervisor present at site & at least one
person outside the confined space for
monitoring deputed
d) Availability of safe means of entry, exit and
ventilation (register for entry & exit
maintained)
e) Fire extinguisher and first-aid facility ensured
f) Lighting provision made by using 24V Lamp
g) Proper usage of PPEs ensured
17. RADIOGRAPHY
a) Proper storage and handling of source as per
BARC/ AERB guidelines (authorized
radiographer available)
b) Work permit obtained

Safety walk-throughperformer (Name& Signature)…………………………………………

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AT CONSTRUCTION SITE Page 63 of 102

FORMAT NO. : HSE-1 REV 0

(Sheet 6 of 6)

Non
SL. Satisfactory/
ITEM satisfactory/ Remarks Action
NO. Yes
No
c) Cordoning of the area done
d) Use of appropriate PPE's ensured
e) HSE training to workers/supervisors imparted
during the fortnight (indicate topic)
f) Minimum occupancy of workplace ensured

18. HEALTH CHECKS

a) All Workers medically examined and found

be fit for working at heights (slinging, rigging,
painting etc.)
in confined space
in excavation / trenching
in shot blasting
b) Availability of First Aid box with contents
c) Proper sanitation at site, office and labour
camps
d) Arrangement of medical facilities.

e) Measures for dealing with illness at site

&labour camps.
f) Availability of Potable drinking water for
workmen & staff.
g) Provision of crèches for children.

h) Stand by vehicle / ambulance available for

evacuation of injured
19. ENVIRONMENT
a) Chemical and Other Effluents properly
disposed
b) Cleaning liquid of pipes disposed off properly

c) Seawater used for hydro-testing disposed off

as per agreed procedure
d) Lubricant Waste/Engine oils properly
disposed
e) Waste from Canteen, offices, sanitation etc.
disposed properly
f) Disposal of surplus earth, stripping materials,
Oily rags and combustible materials done
properly
g) Green belt protection

Safety walk-through performer (Name& Signature)…………………………………………

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ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 64 of 102

FORMAT NO. : HSE-2 REV 1

(Sheet 1 of 3)

ACCIDENT REPORT

(To be submitted by Contractor after everyAccident within 24 hours to EIL/ Owner)

Report No.: ____________________________ Date: ______________________

Project site: ____________________________ Name of work: _______________________
Contractor’s name: ________________ Contractor’s Job Engineer (name) ________

Non-disabling injury (Non- LTI) Hospitalized but resumed duty before end of 48 hrs of
accident
Disabling injury (other LTI) Hospitalized & failed to resume duty within next 48 hrs
Fatal (LTI ): Death / Expiry
First Aid case Resume duty after first aid

Name of the injured:_______________________ Father's name of victim: _________________

Sub Contractor’s Name: ……………………………………………………………………………….
Gate Pass No.:………..Age: _____Yrs. Victim’s medical fitness exam. (Pre-empl.) date: - ______

Date & time of Accident / Incident: _______________________________________________

Names of Witnesses: (1________________ (2)___________________ (3) ________________
Profession of victim:
Bar bender Carpenter Meson
Fitter Helper Gas cutter
Grinder Welder Electrician
Driver Rigger M/c.operator
Engineer Manager Other/specify

Qualification
No formal education Non-Matriculate Matriculate
Graduate Post- grad Other/specify

Job Experience
NIL Less than 2 yrs 2-5 yrs
5-10 yrs 11-15 yrs 15 years and above

Location where the incident happened: ___________________________________________

______________________________________________________________________________

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FORMAT NO. : HSE-2 REV 1

(Sheet 2 of 3)

Activity / Works that were continuing during incident / accident: -

Excavation Demolition Concrete carrying
Concrete pouring Transportation of materials Transportation of
(manually) materials (mechanically)
Work on or adjacent to water Work at height (+2.0 mts) Scaffold preparation
Scaffold dismantling Piling works Welding
Grinding Gas-cutting Pipe fit-ups & fabrication
Structural fabrications Machine works Hydro-testing works
Electrical works Erection activities Other/specify

What exactly the victim was doing just before the incident / accident? ..........................................
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
Nature of injury:
Bruise or Contusion Abrasion (superficial wound) Sprains or strains
Cut or Laceration Puncture or Open wound Burn
Inhalation of toxic or Absorption Amputation
Poisonous fumes or gases
Fracture Other/specify

Parts of body involved in incident / accident

Head Face Eyes
Throat Arm (above wrist) Hand (including wrist)
Fingers Truck (Abdomen / Back / Throat
Chest / Shoulder)
Leg (above ankle) Foot (incl. ankle) Toes
Multiple Other/specify

Accident type:
Struck against Struck by Fall from Elevation
Fall on same level caught in caught under
caught in between Rubbed or abraded Contact with (Electricity)

Contact with (Temp./ Contact with chemicals Vehicle accident

extremes) oroils
Other/specify

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AT CONSTRUCTION SITE Page 66 of 102

FORMAT NO. : HSE-2 REV 1

(Sheet 3 of 3)

Medical Aid provided:-(indicate specific aids / treatment etc.)-

………………………………………………………………………………………………………….
…………………………………………………………………………………………………………..
-------------------------------------------------------------------------------------------------------------------------
Actions taken to prevent recurrence of similar incident / accident:………………………………
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
…………………………………………………………………………………………………………….
.………………………………………………………………………………………………………...

_____________________________________________________________________________

Intimation to local authorities (Dist. Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ………………………………………………………………………………………..

Safety Officer Site Head / Resident Construction Manager

(Signature and Name) (Signature and Name)
Stamp of Contractor

To : Owner
: RCM/Site-in-charge EIL (3 copies)
Nodal Officer HO through RCM (In case of major accident)
Divisional Head (Constn) through RCM
Project Manager, EIL, through RCM

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AT CONSTRUCTION SITE Page 67 of 102

FORMAT NO. : HSE-3 REV 1

(Sheet 1 of 5)

SUPPLEMENTARY ACCIDENT INVESTIGATION REPORT

TICK THE APPROPRIATE ONEAS APPLICABLE (furnish within 72 hours)
Supplementary to Incident / Accident Report No: ______ (Copy enclosed)
Report No.: ____________________________ Date: ______________________
Project site: ____________________________ Name of work: _______________________
Contractor’s name: ________________ Contractor’s Job Engineer (name) ________

Non-disabling injury (Non-LTI ) Hospitalized but resumed duty before end of 48 hrs of
accident.
Disabling injury (other LTI ) Hospitalized & failed to resume duty within next 48 hrs.
Fatal (LTI) Death / Expiry
First Aid case Resume duty after first aid

Name of the injured: _______________________ Father's name of victim: _________________

Sub Contractor’s Name: ……………………………………………………………………………….
Gate Pass No.:……….. Age: _____Yrs. Victim’s medical fitness exam. (Pre-empl.) date: - ______

Date & time of Accident / Incident: _______________________________________________

Names of Witnesses: (1________________ (2)___________________ (3) ________________
Profession of victim:
Bar bender Carpenter Meson
Fitter Helper Gas cutter
Grinder Welder Electrician
Driver Rigger M/c.operator
Engineer Manager Other/specify

Qualification
No formal education Non-Matriculate Matriculate
Graduate Post- grad Other/specify

Job Experience
NIL Less than 2 yrs. 2-5 yrs.
5-10 yrs. 11-15 yrs. 15 years and above

Location where the incident happened: ___________________________________________

______________________________________________________________________________

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AT CONSTRUCTION SITE Page 68 of 102

FORMAT NO. : HSE-3 REV 1

(Sheet 2 of 5)
Activity / Works that were continuing during incident / accident: -
Excavation Demolition Concrete carrying
Concrete pouring Transportation of materials Transportation of
(manually) materials (mechanically)
Work on or adjacent to water Work at height (+2.0 mts) Scaffold preparation
Scaffold dismantling Piling works Welding
Grinding Gas-cutting Pipe fit-ups & fabrication
Structural fabrications Machine works Hydro-testing works
Electrical works Erection activities Other/specify

What exactly the victim was doing just before the incident / accident? ....................................
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….

Particular of tools & tackles being used and condition of the same after incident/accident:
…………………………………………………………………………….........................................
………………………………………………………………………………………………………
Description of Incident/Accident (How the incident was caused) : …………………………………...
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
……………………………………………………………………………………………………………
Nature of injury:
Bruise or Contusion Abrasion (superficial wound) Sprains or strains
Cut or Laceration Puncture or Open wound Burn
Inhalation of toxic or Absorption Amputation
Poisonous fumes or gases
Fracture Other/specify

Parts of body involved in incident / accident

Head Face Eyes
Throat Arm (above wrist) Hand (including wrist)
Fingers Truck (Abdomen / Back / Throat
Chest / Shoulder)
Leg (above ankle) Foot (incl. ankle) Toes
Multiple Other/specify

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AT CONSTRUCTION SITE Page 69 of 102

FORMAT NO. : HSE-3 REV 1

(Sheet 3 of 5)
Accident type:
Struck against Struck by Fall from Elevation
Fall on same level caught in caught under
caught in between Rubbed or abraded Contact with (Electricity)

Contact with (Temp./ Contact with chemicals or Vehicle accident

extremes) oils
Other/specify

Name & Designation of person who provided First-Aid to the victim: ___________________________

Name & Telephone number of Hospital where the victim was treated ___________________________

Mode of transport used for transporting victim – Ambulance / Private car / Tempo / Truck / Others

How much time taken to shift the injured person to Hospital________________________________

In case of FATAL incident, indicate clearly the BOCW Registration No. of the
victim/Company…………………………………………………………………………………………
…

Comments of Medical Practitioner, who treated / attended the victim/injured (attached / described
here)_____________________________________________________________________

What actions are taken for investigation of the incident, please indicate clearly – (Video film /
Photography / Measurements taken etc. ……………………………………………………………..)

Immediate cause (Please tick the right applicable) –

Hazardous methods or Poor housekeeping Inadequate or improper
procedures inadequately PPE
guarded
Environmental hazards improper Working on dangerous
(excess noise/ space illumination/Moving on oval equipment
constraint/ inadequate surface
ventilation

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FORMAT NO. : HSE-3 REV 1

(Sheet 4 of 5)

Failure to secure Horse-play Failure to use PPE

Inattention to surroundings Improper use of hands & By-passing safety devices

body-parts
Unsafe mixing or placement Bypassing standard Failure in communication
of tools & tackles procedures
Operating without authority Improper use of equipment drug or alcoholic
or tools & tackles influence
excessive haste Others(specify)

Basic cause

Over confidence Impulsiveness over-exertion

Faulty judgement or poor Failing to keep attention Nervousness & Fear
understanding constantly
Fatigue Defective vision Ill health or sickness

Slow reaction Others(specify)

Root cause

Inadequate Engg Improper Design Inadequate Planning &

organization
Inadequate knowledge Inadequate skill Inadequate training
Inadequate supervision Improper work procedure Inadequate compliance
with standard
Substandard performance Inadequate maintenance Improper inspection

Others(specify)

Loss of man days and impact on site works, (if any) –

Remarks from Contractor’s Safety Officer/ Engineer –

Was the victim performing relevant tasks for which he was engaged /employed? Yes / No
Was the Supervisor present on work-site during the incident? Yes / No
Have the causes of incident rightly identified? Yes / No
Cause of Accident was_________________________________________________________

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 71 of 102

FORMAT NO. : HSE-3 REV 1

(Sheet 5 of 5)

Remedial measures recommended by Safety Officer of Contractor for avoiding similar incident in
future
: ………………………………
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
………………………………………………………………………………………………………….
……………………………………………………………………………………………………………
………………………………………………………………………………………………………...

Intimation to local authorities (Dist. Collector / Local Police Station / ESI authority): Yes / No / NA.
If yes, to whom ………………………………………………………………………………………..
_____________________________________________________________________________

Safety Officer Site Head / Resident Construction Manager

(Signature and Name) (Signature and Name)
Stamp of Contractor

To : Owner
: RCM/ Site-in-charge of EIL (3 copies)
Nodal Officer HO through RCM (In case of major accident)
Divisional Head (Constn) through RCM
    Project Manager EIL, through RCM 

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 72 of 102

FORMAT NO. : HSE-4 REV 2

NEAR MISS INCIDENT/ DANGEROUS OCCURRENCE REPORT PROFORMA

(to be submitted within 24 hours)
Report No.: _________________

Name of Site: _________________________ Date: ______________________

Name of work: __________________________ Contractor: __________________

__________________________________________________________________________________
Incident reported by :

Date & Time of Incident :

Location :
_________________________________________________________________________________

Brief description of incident

__________________________________________________________________________________
Probable cause of incident
__________________________________________________________________________________
Suggested corrective action
__________________________________________________________________________________

Steps taken to avoid recurrence Yes No

Safety Officer Site Head / Resident Construction Manager

(Signature and Name) (Signature and Name)
Stamp of Contractor

Note:
 Near Miss: Human injury escaped & no damage to property, equipment or
interruption to work.
 Dangerous Occurrence: Occurrences as mentioned below shall be considered as “Dangerous
occurrences”
a. collapse or failure of lifting appliances or hoist or conveyors or other similar equipment for handling
building or construction material or breakage or failure of rope, chain or loose gears; overturning of
cranes used in building or other construction work; falling of objects from height;
b. collapse or subsidence of soil, any wall, floor, gallery, roof or any other part of any structure, platform,
staging, scaffolding or any means of access including formwork;
c. collapse of transmission tower;
d. fire and explosion causing damage to property at Construction site.
e. spillage or leakage of hazardous substances and damage to their container;
f. Collapse, capsizing, toppling or collision of transport equipment;
g. Leakage or release of harmful toxic gases at the construction site.

To : Owner
: RCM/Site-in-charge EIL (3 copies)

Divisional Head (Const) through RCM

Project Manager EIL, through RCM (Applicable for Dangerous Occurrence only)

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 73 of 102

FORMAT NO. : HSE-5 REV 2

MONTHLY HEALTH, SAFETY &ENVIRONMENTAL (HSE) REPORT
(To be submitted by each Contractor)
Actual work start Date: _______________ For the Month of: __________________
Project: ____________________________ Report No: ________________________
Name of the Contractor: ______________ Status as on: ______________________
Name of Work: _____________________ Job No : __________________________
(Contractor in consultation with EIL shall generate the reports through web based package
(www3.eil.co.in/eilhse)only.
UPTO PREVIOUS
ITEM THIS MONTH CUMULATIVE
MONTH
1) Average number of Staff & Workmen
(average daily headcount, not man days)
2)Total Man-hours worked
3) Number of Induction programmes conducted
4) Number of HSE meetings organized at site
5) Number of HSE awareness programmes conducted at site
6) Number of Tool Box Talks conducted
7) Number of Loss Time Injuries (LTI) Fatalities
Other LTI
8) Number of Non disabling injury (Non-LTI)
9) Number of First Aid Cases
10) Number of Near Miss Incidents
11) Number of Dangerous Occurrences
12) No. of unsafe acts/ practices detected
13) No. of disciplinary actions taken against staff/ workmen
14) Man-days lost due to injury
15) LTI Free man-hours i.e. LTI free man-hours counted from the Last LTI
(enter date: ……….)
16) Frequency Rate (No. of reportable LTI per 10 lacs man-hours worked)
17) Severity Rate (No. of man days lost due to LTI per 10 lacs man-hours
worked)
18) No. of activities for which HIRA Completed
19) No. of incentives/ awards given
20) No. of occasions on which penalty imposed by EIL/ Owner
21) No. of Audits conducted
22) No. of pending NCs in above Audits
23) Compensation cases raised with Insurance
24) Compensation cases resolved and paid to workmen
25) No of Vehicular Accident cases
26) No of fire/Explosion cases
27) Whether workmen compensation policy taken Yes No
28) Whether workmen compensation policy is valid Yes No
29) Whether workmen registered under ESI Act, as applicable Yes No
30) Whether HIRAC Register prepared and updated Yes No
31)Whether Environment Aspect Impact Register prepared and updated Yes No
32) Whether Legal Register prepared and updated Yes No
Remarks, if any
Date:
Prepared by Safety Officer Approved by Site Head / Resident Construction Manager
(Signature and Name) (Signature and Name)

To: -
- RCM EIL

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 74 of 102

FORMAT NO. : HSE-6 REV 0

PERMIT FOR WORKING AT HEIGHTS (ABOVE 2.0 METER)

(In duplicate to be issued daily for site and for office)

Permit No…………….. Name of Main Contractor……………………

Name of work executing agency / sub agency / vendor:…………………………………………………...
Date……………… Exact Location of work……………………………………
Nature of work ……………………………………..Duration of work (from) ………… (to) ……….......
Number of workers covered within this permit……………………………………………………………
(List enclosed with name & gate pass numbers.)

Sl. Status of compliance

Items / Subjects
No. (Yes / No)
1 Work areas / Equipments inspected
2 Work area cordoned off
3 Adequate lighting is provided
4 Precautions against public traffic taken
5 Concerned persons in & around have been alerted & cautioned
Hazards / risks involved in routine / non-routine task assessed and control
6
measures have been implemented at specific task
7 ELCB provided for electrical connection & found working
8 Ladder safely attached / fixed
9 Scaffoldings are checked and TAGs are found used correctly
10 Working platforms are provided and are found sound /safe for use
Safe access & egress arrangements (e.g. ladders, fall arresters, life-lines etc.)
11
are satisfactorily incorporated
a. Openings on platform / floors are effectively cordoned / covered
12
b. Safety Nets are provided wherever required
Use of following safety gadgets by people working at area under this permit, is
checked and found satisfactory -
Safety helmet
13 Safety harness (full body) with double lanyard
Safety Shoes
Safety gloves
Safety goggles
14 Housekeeping of work area found satisfactorily tidy / clean & clear
Adequate measures have been taken for works being continued at the ground
15
level, when simultaneous works are permitted overhead at that very location.
16 Materials are not thrown from heights on to ground
17 Medical examination of workers are made & found satisfactory
Responsible job engineer / supervisor found physically present at work spot for
18
overall administration of work as well as safety of people.

Above items have been checked & compliance has been found in place. Hence work is permitted to
start / continue at the above-mentioned location. Work shall not start till identified lapses are rectified.

Additional Precautions, if any …………………………………………………………….

……………………………………………………………………………………………..

Work Permit issued by Verification By

Contractor Engineer/RCM Contractor Safety Officer

AT THE END OF THE DAY/WORK:

All works at height are completed & workmen have returned safely from work location at
(time)………….. (date)……………

(Sig. Contractor Engineer)

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 75 of 102

FORMAT NO. : HSE-7 REV 0

CONFINED SPACE ENTRY PERMIT

Project site ___________________________ Sr.No. _________________________
Name of the work ______________________ Date ___________________________
Name of Contractor ____________________ Nature of work ___________________
Exact location of work _____________

Safety Requirements POSITIVE ISOLATION OF THE VESSEL IS MANDATORY

(A) Has the equipment been ?
Y NR Y NR Y NR
 Isolated from  water flushed &/or  radiation sources
power/steam/air steamed removed
 isolated from liquid or  Man ways open &  proper lighting
gases ventilated provided
 depressurized &/or  cont. inert gas flow 
drained arranged
 blanked/ blinded/  adequately cooled 
disconnected
(B) Expected Residual Hazards
 lack of O2  combustible gas/ liquid  H2S / toxic gases
 corrosive chemicals  pyrophoric iron / scales  electricity / static
 heat/ steam / frost  high humidity  ionizing radiation
  
(C) Protection Measures
 gloves  ear plug / muff  goggles / face shield
 protective clothing  dust / gas / air line mask  personal gas alarm
 grounded air duct/blower  attendant with SCBA/air  rescue
/AC mask equipment/team
 Fire fighting arrangements  safety harness & lifeline  communication
equipment
  
Authorization / Renewal (It is safe to enter the confined space)
Signature Time Signature
No. of
Name of persons
persons Contractor's Contractor's
allowed From To Workman
allowed Supervisor Safety Officer

Permit Closure :

(A) Entry  was closed  stopped  will continue on ...

(B) Site left in a safe condition  Housekeeping done

(C)Multilock removed  key transferred

 Ensured all men have come out  Man-ways barricaded

Remarks, if any:

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 76 of 102

FORMAT NO. : HSE-8 REV 1

RADIATION WORK PERMIT

Project : Sr.No. :
Name of the work : Date :
Name of site contractor : Job No. :

Location of work :

Source strength :

Cordoned distance (m) :

Name of Radiography agency : Approved by Owner/EIL

No. of workers engaged :

(List enclosed with name & gate pass numbers.)

The following items have been checked &compliance shall be ensured during currency of the
permit:

S.
Item description Done
No.
Safety regulations as per BARC/AERB ensured while source in use/in transit & during storage
Area cordoned off / safe working platform provided
Lighting arrangements for working during nights ensured
Warning signs/ flash lights installed
Cold work permit taken (if applicable)
PPEs like film badges, dosimeters used

Additional precautions, if any ______________________________________________________

(Radiography Agency’s BARC/AERB authorized Supervisor)

Permission is granted.

Permit is valid from ___________ AM/PM ____________ Date to ___________ AM/PM _________
Date

(Signature of permit issuing authority-RCM of contractor)

Name : Designation: Date:

Permit renewal:
Sign of issuing
Additional precautions
Permit extended up to authority with date (of
required, if any
site contractor)
Date Time

Work completed/ stopped/ area cleared at ________ Hrs of Date ______________

(Sign. of permit issuing authority)
Name& Signature of site contractor:

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY & 6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITE Page 77 of 102

FORMAT NO. : HSE-9 REV 1

DEMOLISHING/DISMANTLING WORK PERMIT
Project : Sr.No. :
Name of the work : Date :
Name of contractor : Job No. :

Name of sub-contractor : No. of workers to be engaged:

(List enclosed with name & gate pass numbers.)

Line No./ Equipment No./ Structure to be dismantled :

Location details of dismantling/ demolition with sketch : (clearly indicate the area)

The following items have been checked &compliance shall be ensured during currency of the
permit:

S. Not
Item description Done
No. Applicable
Services like power, gas supply, water, etc. disconnected

Dismantling/ Demolishing method reviewed & approved

Usage of appropriate PPEs ensured

Precautions taken for neighboring structures

First-Aid arrangements made

Fire fighting arrangements ensured

Precautions taken for blasting

(Contractor’s Supervisor) (Contractor’s Safety Officer)

Permission is granted.

(Permit issuing authority-Client)

Name :
Date :

Completion report:

Dismantling/ Demolishing is completed on _____________ Date at ____________ Hrs.

Materials/ debris transported to identified location Tagging completed (as applicable)

Services like power, gas supply, water, etc. restored

(Permit issuing authority-Client)

CONTRACTOR’s NAME

Format No. 8-00-0001-F7 Rev. 0

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 78 of 102

FORMAT NO. : HSE-10 REV 1

DAILY SAFETY CHECKLIST

(To make use of before start of day’s work)

Project : Sr.No. :
Name of the work : Date :
Name of contractor : Job No. :
Description of Job decided to perform : -

 Use of PPE / Safety Gadgets

Sl. Compliance Sl. Compliance

PPEs PPEs
No (Yes / No) No (Yes / No)
1 Safety Helmets 6 Face Shield
2 Safety Shoes 7 Full body harness
3 Hand Gloves 8 Fall Arrest System
4 Dust Musk 9 Safety net
Horizontal life-line made of
5 Safety Goggles 10 steel wire, (dia not less than
8.0 mm.)
(Serial No. 1 & 2 are compulsory for everyone. Specify & ensure use of other safety gadgets as required for the job)

 Identify following important unsafe conditions: -

Sl. No Conditions Yes / No

1 Access to work site / emergency escape clear
2 Soil / Loose earth kept away from excavated pit / slope / ladder provided
Electrical wire / welding lead lying entangled on ground / welding m/c. booth
3
accessible
4 Elevated work platform / open ends are protected
Ground area cordoned off before lifting works or erection at height / ground
5
area checked & cordoned-off before start of height works
Structural members / erected pipes / wooden boards/pieces etc. are safely
6 anchored at heights and are not likely to fall down on people when working
beneath
Ladders tied-up on tall steel structures, long before are removed to get rid of
7
their use
8 Any Other

 Indicate actions taken, if status of any of the above items is found “No”
……………………………………………………………………………………………………………
…………………………………………………………………………………………………………….

 Specific Safety guidelines / precautions, if any (communicated thro’ TBT)

……………………………………………………………………………………………………………..
….………………………………………………………………………………………………………….

 Above conditions and PPE compliances are checked by undersigned and correct status are indicated after
verification

Prepared by Verification By
Contractor Site Engineer Contractor Safety Officer

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 79 of 102

FORMAT NO. : HSE-11 REV 0

(Sheet 1 of 2)
HOUSEKEEPING ASSESSMENT& COMPLIANCE
Project : Sr.No. :
Name of the work : Date :
Name of contractor : Job No. :
Name of contractor : Fortnightly

Sl. Satisfactory/ Non

Subjects of Review Remarks Action
No. Yes satisfactory/No
1. Cleanliness at the Main entry / access of site
2. Ground condition / floor areas free from water-
logging / oil spillage
3. Ground & elevated floors free from rubbish /
wastes / accumulated debris / scraps.
4. Manholes / openings are covered / fenced
5. Trenches are barricaded / walkways are in
place
6. Drains are cleaned / not choked / not occupied
by dumped materials
7. Sufficient CAUTION boards / instructions
displayed
8. Construction machinery are maintained &
parked in orderly manner.
9. Movement of site people are not obstructed
because of dumping / storing of construction
materials
10. Access / egress to Electrical Distribution
Boards / Panels clear from wires / cables /
earth-strips etc.
11. Electrical panel rooms / sheds / MCC / Control
rooms / Substations etc. are clean & tidy and
not used for storing dress / clothes, tiffin-box
or bicycles.
12. Passage behind Elec. panels are free for access
13. Fire extinguishers / fire-buckets are accessible
without any difficulty.
14. Stair-steps, platforms & landings are clear &
tidy
15. Sheds / rooms & work areas have got sufficient
illumination as well as ventilation
16. Cables / Wires / welding leads are routed /
hanged appropriately & are not creating unsafe
condition.
17. Stacking / storing of insulation materials or
their packing.
18. Removal or cleanliness of left-over sand,
concrete, brick-bats, insulation-materials,
excess earth, wastes etc.
19. Storing / stacking of sand, metal chips, re-
bars, steel pipes, valves, fittings etc.
20. One escape route at ground & minimum two
escape routes at elevation available,

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HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 80 of 102

FORMAT NO. : HSE-11 REV 0

(Sheet 2 of 2)

Sl. Satisfactory/ Non

Subjects of Review Remarks Action
No. Yes satisfactory/No
21. Captions / Posters / Slogans on various safety
instructions are displayed legibly in local
language
22. Cable trenches are water-free or regular
arrangement for taking out accumulated water
exists.
23. Windows of rooms / offices are regularly
cleaned
24. Facilities for cycle sheds, drinking water,
washing, rest-rooms etc. are maintained in tidy
manner.
25. Toilet, Urinals, Canteen / kitchen / pantry etc.
are maintained & free from obnoxious smell.
26. Construction tools / tackles are stored
systematically - the items are tagged / tested /
certified by competent third party.
27. Sufficient numbers of Dust-bins / Waste-bins
found at site and are regularly emptied.

Additional remarks, if any -

………………………………………………………………………………………………………………
………………………………………………………………………………………………………………
……………………………………

Inspected by Verification By
Contractor Engineer Contractor Safety Officer

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HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 81 of 102

FORMAT NO. : HSE-12 REV 0

INSPECTION OF TEMPORARY ELECTRICAL BOOTH / INSTALLATION

Project : Sr.No. :
Name of the work : Date :
Name of contractor : Job No. :
Sub Station No:/Booth No Location:

SL
SUBJECTS OBSERVATION (YES /NO) ACTION TAKEN
NO
Switchboards installed properly are in order and
1
protected from rain & water-logging.
Adequate illumination provided for switchboard
2 operation during night hours & the lamps are protected
from direct human contact.
Voltage ratings, DANGER signs, Shock-Treatment-
3
Chart displayed in the installation / booth
Fire extinguisher (DCP or CO2) & Sand Bucket kept in
4
close vicinity of Switchboards
Valid License & Competent Electrician / Wireman
5 available & name/ license no. displayed at booth /
installation.
General housekeeping in & around booth / installation
6
found in order.
7 Cable-route-markers for U/G cables provided.
Monthly inspection report of Electrical hand tools
8
available in booth / installation.
9 Insulated Mat provided in front of Elec. Panels.
10 Rubber hand gloves available/ used by Electricians
Availability of CAUTION boards for shutdown & / or
11
repairing works.
All incoming & outgoing feeders have proper MCCB /
12
HRC fuses / Switches.
Switchboards “earthed” at two distinctly isolated
13
locations.
Switchboards have adequate operating space at the front
14
face & at the rear face too.
15 All connections provided through 30mA ELCB.
16 Testing records of all ELCBs available at site
17 Only industrial type plugs & sockets are used.
Temporary connections are 3-core double insulated &
18 free from cuts & joints and 3rd core is earthed at both
ends
Socket boards are properly mounted on stand &
19
protected from water ingress.
Electrical equipments operating above 250V have two
20
earthing / double earthing.
All incoming / outgoing cables are properly glanded&
21
terminated with “lugs”.
22 Switch-boards are of industrial variety / type.
Sketch for installation / connection (SLD) made &
23
pasted& other safety labels/display boards
24 Labeling of incoming / outgoing feeders made.
25 All hand lamps are protected from direct contact.
26 All electrical cable / joints are in safe condition

Inspected by Verification By
Contractor Engineer Contractor Safety Officer

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HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 82 of 102

FORMAT NO. : HSE-13 REV 0

(Sheet 1 of 2)
INSPECTION FOR SCAFFOLDING
Project : Sr.No. :
Name of the work : Date :
Name of contractor : Job No. :
Sl. Actions
Description Yes No N.A.
No taken
1 Whether work permit is obtained to take up work at height above 1.5 Mts?
Whether atmospheric condition is “stormy” or “raining” and works at
2
heights have been permitted?
3 Whether steel pipes scaffoldings are used for units /off-site areas?
Whether scaffolding has been erected on rigid/firm/leveled surfaces /
4 ground? Whether “foot-seals” or “base-plates” are used beneath the up-
rights (vertical steel pipes)
Whether scaffold construction is as per IS specification with toe-board and
5
hand-rails (top-rail as well as mid-rail)?
Whether distance between two successive up-rights are less than 2.5 Mts
6 (height of scaffold & load carrying capacity governs the distance between
two uprights)
Whether all uprights are extended at least 900 mm above the top most
7
working platform (to enable fitting of handrails)?
Whether vertical distance of two successive ledgers is satisfactory?
8
(varying between 1.3 Mts. To 2.1 Mts)
Whether the peripheral areas of working at height are cordoned-off? (for
9
avoiding accident to people arising out of dropped / deflected materials)
10 Whether platform is provided? Is it safely approachable?
Whether end of scaffold platform / board are extended beyond transoms?
11
(125mm to 150 mm)
Whether CE / IS approved quality and worthy conditioned full-body safety
12 harness (with double lanyard & karabiners) are used while working at
heights?
Whether life-line of safety harness is anchored to an independent secured
13
support capable of withstanding load of a falling person?
Whether the area around the scaffold is cordoned off to prohibit the entry of
14
unauthorized person / vehicle?
Whether clamps used are of good condition, of adequate strength and free
15
from defects?
16 Whether ladder is placed at secured and leveled surface?
17 Whether water-pass and oil-spills are avoided around the scaffold structure?
18 Whether ladder is extended 1.5mts. above the landing point at height?
19 Whether more than one access/egress provided to the scaffold?
Whether ladder used are of adequate length and overlapping of short
20
ladders avoided?
Whether metallic ladders are placed much away from near-by electrical
21
transmission line?
22 Whether rungs of ladder are inspected and found in good order?
23 Whether fall-arresters provided on both the access/egress routes?
Whether diagonal (cross) bracings are provided at regular interval on the
24
scaffold?
Whether working platform on the scaffold has been made free from “jolt”
25
or “gap”?
Whether tools or materials are removed after completion of the day’s job at
26
heights?
Whether a valid Permit for Work (PFW) is obtained before taking up work
27
over asbestos or fragile roof?
28 Whether sufficient precaution is taken while working on fragile roof?

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HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 83 of 102

FORMAT NO. : HSE-13 REV 0

(Sheet 2 of 2)

Sl. Actions
Description Yes No N. A
No taken
Whether provision is made to arrange duck ladder, crawling board for
29
working on fragile roof?
Whether scaffold has been inspected by qualified civil engineers prior to
30
their use?
Whether the scaffolding has been designed for the load to be borne by the
31
same?
Whether the erection and dismantling of the scaffolding is being done by
32
trained persons and under adequate supervision?
Whether safety net with proper working arrangement and life-line has
33
been provided?
Whether TAGS (Green for acceptable and Red for incomplete/unsafe
34
scaffolds) are used on scaffolds?
Whether sufficient illumination is provided in and around the scaffold
35
and access?
Whether emergency rescue / response arrangements are made in place
36

Inspected by Verification By
Contractor Engineer Contractor Safety Officer

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HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 84 of 102

FORMAT NO. : HSE-14 REV 0

(sheet 1 of 2)
PERMIT FOR ERECTION / MODIFICATION & DISMANTLING OFSCAFFOLDING
Project : Sr.No. :
Name of the work : Date :
Name of contractor : Job No. :
Nature of activities : Duration: From………To…………

SL. NOT
SUBJECTS / ITEMS DONE REMARKS
No. DONE
Specific task of Erection / Modification / Dismantling of scaffolds,
1 identified & TAGGED accordingly (before as well as after carrying-out
jobs).
People engaged in doing the job are identified & are certified by Job Names to be
2
Engineer of Main Contractor as experienced / trained. noted
Concerned persons are alerted by the Job Engineer of Main Contractor in
3 connection with possible hazards & what the workmen MUST do /
MUST not do.
Verification by Job Engineer of Main Contractor made for confirming
that all persons permitted to carry-out the jobs are making use of Helmet,
4
Safety Shoes, Goggles, Gloves & Double lanyard safety harness and
other relevant PPEs.
5 Area of work is effectively cordoned-off / barricaded / illuminated.
For taking-up / lowering down Scaffolding members / clamps / couplings
etc. appropriate ropes / pulleys/ chains etc. have been arranged for use
6
(not to throw any item) & the same have been verified as “fit for
purpose”.
Items / members of scaffold, being lowered are removed from the area &
7
stacked correctly.
Ropes, chains, pulley blocks etc. being used for lifting or lowering
scaffold items, are inspected by the Job Engineer & their certifications as
8
well as physical conditions have been found O.K, before signing this
PERMIT.
Safety Net / Life-line / Fall Arresters etc. are arranged in position and Job
9
Engineer has found working conditions favorable for activities to start.
Scaffold erection or dismantling tasks are being supervised by
10
Experienced Engineer / Competent person.
Only competent & experienced people have been selected / engaged in
11
Scaffolding erection, modification or dismantling tasks.
Adequate & effective actions for traffic and movement of people around
12
the cordoned-off area taken to avoid inadvertent incident
13 Working platforms are protected with handrails & toe-boards.
14 Access & Exit (for reach & escape) are safe for use by people.
Tools, tackles to be used for above jobs are verified by job Engineers of
15 Main contractor as genuinely good and tied-up at height (to prevent their
fall).
16 Site important Telephone Nos. are made known to everyone
SOP (Safe Operating Procedure) for the specific task is made & followed
17
too.
18 Emergency vehicle has been arranged at work locations.

 This permit for work shall be available at specific work location all the time.
 After completion of work, permit shall be returned to safety cell of main contractor, without fail.
 This Permit shall be issued maximum upto (Monday to Sunday).
 Additional Precautions, if any
…………………………………………………………………………………………………………………
 ACCORD OF PERMISSION (to be ticked) - YES ( ) / NO ( )

Inspected by Verification By
Contractor Engineer Contractor Safety Officer]

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HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 85 of 102

FORMAT NO. : HSE-14 REV 0

(sheet 2of 2)

Everyday Site working conditions & performance of workmen shall be assessed / checked by Contractor
Site Engr. and Safety Officer shall verify the same.

Name / Sign. MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY

Site
Engr.
Safety
Off.

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6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 86 of 102

FORMAT NO. : HSE-15 REV 0

PERMIT FOR HEAVY LIFT/CRITICAL ERECTION

Project : Sr.No. :
Name of the work : Date :
Name of contractor : Job No. :
Nature of activities : Duration: From………To…………
Location of work : Name /Type of crane :
Equipment/Structure to be erected: Wt. of equipment/ structure to be erected

SL. COMPLIANCE STATUS

Description of Item
NO. Remarks
Yes No Not applicable
1) Is the crane type suitable for lift or as per erection
procedure?
2) Is the crane have the correct number of counterweights
fitted?
3) Availability of Load Certification of crane from
authorized agency.
4) Is the load chart of crane available in carne cabin/or with
Crane operator?
5) Is the device to check the Wind speed in crane is working?
Is the safety features in crane are working?
6) Availability of Load certification of slings and other
accessories from authorized agency
7) Availability of Licensee/certificate for crane operator from
authorized agency.
8) Availability of approved HIRAC for the subject activities.
9) Availability of approved erection/rigging procedures.
10) Availability of temporary gratings/ platforms for critical
lifting(as applicable)
11) Tool Box conducted before erection?
12) Has the area been cordoned off?
13) Are the authorized persons during erection are identified?
14) Does each person identified for erection understand their
roles and responsibilities?
15) Is the ground on which crane will rest or outrigger support
are correct?
16) Is hard stand requirement (if any) complied?
17) Is the communication system (viz walkie- talkies, etc. are
working properly?
18) If more than one crane is lifting the load, is an
Intermediate rigger will supervise the lift?
19) If there is other obstruction within the operating radius of
the crane, have correct precautions been taken to prevent
collision?
20)
All the persons are wearing the requisite PPE?

Inspected & Issued by Verification By

Contractor Engineer/RCM Contractor Safety Officer

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6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 87 of 102

FORMAT NO. : HSE-16 REV 0

PERMIT FOR ENERGY ISOLATION & DE-ISOLATION

Project : Sr.No. :
Name of the work : Date :
Name of contractor : Job No. :
ENERGY ISOLATION PERMIT
 Clearance required from:…..Hrs ………Date To ……..Hrs ….Date
 Name of equipment/ energy sourceetc. ………………………………………………………………….
 Nature of job to be done: ……………………………………………………………………………….
 Area………………………….Location:…………………………………………………………………..

PERMIT VALIDATION PERFORMING AUTHORITY

I hereby authorize the …………..personnel(performer) The work and precautions will be carried out under my
to isolate the above equipment/energy source from all overall responsibility.(Testing/execution engineer)
sources of power and handover the equipment/energy
source for maintenance/repair.
Signature: Date:
Issuing authority Name:
Area –Incharge/RCM
Signature: Date:
Name:

SAFETY PRECAUTIONS FOR CLEARANCE NORMALISING AFTER CLEARANCE

1. Notify workers of intent to de- energize 1. Notify workers of intent to re- energize
2. Obtain lock,tag or locking/tagging devices 2. Conduct visual inspection to confirm that the
3. Shut down,de energize,dissipate any danger zone is clear of workers
residual energies. 3. Conduct visual inspection to confirm that tools
4. Apply lock ,tag and locking and/or tagging ,equipments danger zone is clear of workers
devices 4. Reposition the safety devices(interlocks,
5. *Any other job specific precautions valves, guards, covers ,sensors, as applicable,
6. Verify effectiveness of lockout by etc)
attempting to restart. 5. *Any other job specific normalizing details
7. Proper PPE is ensured 6. Removelock,tag and locking and/or tagging
devices.
I certify that the energy source mentioned above is 7. Re-energize.
isolated from all sources and is safe to start the work. 8. Confirm system is operating properly& safely
I certify that the energy source mentioned above is
Tag No:…… Lock No:…………. isolated from all sources and is safe to start the work.

Issuing authority Tag No:…… Lock No:………….

Area –Incharge/RCM Issuing authority
Signature: Date: Area –Incharge/RCM
Name: Signature: Date:
(*to be included by contractor in consultation with Name:
EIL/owner) (*to be included by contractor in consultation with
EIL/owner)
ENERGY DE-ISOLATION PERMIT
PERMIT VALIDATION PERFORMING AUTHORITY
I hereby authorize the …………..personnel(performer) I hereby certify that the equipment/energy source
to de- isolate the above equipment/energy source from mentioned above has been de-isolated and is ready for
all sources of power and handover the equipment/energy normal operation.(Testing/execution engineer)
source for normal operation..

Issuing authority Signature: Date:

Area –Incharge/RCM Name:
Signature: Date:
Name: Countersigned by Issuing authority

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6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 88 of 102

FORMAT NO. : HSE-17 REV 1

PERMIT FOR EXCAVATION (depth 2m and above)

(Sheet 1of 2)
Project : Sr.No. :
Name of the work : Date :
Name of contractor : Job No. :
Job Description : Location:
Size of excavation :

COMPLIANCE STATUS
SL.
Description of Item Not Remarks
NO. Yes No
applicable
1) Suitable and sufficient risk assessments and method
statements has been carried to ensure that the work shall be
undertaken in accordance with specification and standard.
2) Are plans/details of underground services available and the
same has been reviewed?
3) Has survey done to locate the services/obstacles etc.
4) Has the live services (electrical, water line, air line,
telephone line, etc)has been disabled for carrying out the
job.
5) Is adequate barriers/fences to protect the excavation are in
place?
6) Is Adequate warning signs are in place?
7) Is Assessment of ground conditions done and remedial
action(if any) taken?
8) Safe access / egress (e.g. ramp / steps / ladders etc.)
provided for site workmen & supervisors.
9) Is the excavation work being undertaken in proximity of
structure, etc. ?If Yes, it’s effect is considered?
10) Availability of competent person for supervising the
excavation work?
11) Adequate safe arrangement to prevent collapse of edges
(e.g. shoring / strutting / benching / sloping etc.) made at
site.
12) Hard barricades (at least 1.0M away from edge & for
excavation near site access roads) with warning
signs/caution boards are provided
13) Accumulation / passage-ways of water at periphery of
excavation / trench stopped/ restricted.
14) Is the equipment being used for excavation has been
checked for adequacy and is in good working condition
having all the safety features?
15) Age & fitness of workmen ensured by medical test before
engagement in job ?
16) Arrangement of Monitoring of possible oxygen deficiency
or obnoxious gases done & action taken?

PERMIT GRANTED - Yes / No

(List enclosed with name & gate pass numbers.)

Name & Signature of Site Engr. Name & Signature of Area – In charge/RCM of

Contractor (Initiator) Contractor (Issuing authority)

Verification by Contractor Safety Officer

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HEALTH, SAFETY &
6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
AT CONSTRUCTION SITES Page 89 of 102

FORMAT NO. : HSE-17 REV 1

PERMIT FOR EXCAVATION

(Sheet 2of 2)

NOTES: -

1. Slopes or benches for excavation beyond 2.0M depth shall be designed & approved by Contractor’s site head.
2. Excavated earth to be kept at least 1.5M away from edges
3. Safety helmets, Safety shoes or gum-boots, gloves, goggles, Face shield, Safety Harness shall be essential
PPEs.
4. Permit shall be made in duplicate and original shall be available at site of work.
5. Permit shall be issued for maximum one week only (Monday to Sunday)
6. After completion of works, permit shall be closed & preserved for record purpose

GRANT OF PERMIT AND EXTENSIONS

Issuing
authority
Validity period Initiator (site Review by EIL /
Sl. Working Time (Area In
From ____To Engr. of Main Owner (Remarks
No. From _____To _____ charge/RCM of
____ Contractor) with date
Main
Contractor)

1.

2.

3.

4.

5.

6.

7.

Additional safety instructions if any: -

1.
2.
3.

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ENVIRONMENTAL MANAGEMENT 6-82-0001 Rev. 9
AT CONSTRUCTION SITES Page 90 of 102

FORMAT NO. : HSE-18 REV 0 (Sheet 1of 2)

IDENTIFICATION OF ENVIRONMENTAL ASPECTS, IMPACT ASSESSMENT AND CONTROL MEASURES

Risk
Environmental Environment Consequences Significant Gaps/
S.No Activity N/A/E Control Measures Level
Aspect Impact Recommendations
A B C D E F G Yes/No

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ENVIRONMENTAL MANAGEMENT 6-82-0001 Rev. 9
AT CONSTRUCTION SITES Page 91 of 102

(Sheet 2 of 2)

INITIAL ENVIRONMENT REVIEW TECHNIQUE

WP = DNR = Depletion of
Environmental Impacts AP = Air Pollution LC = Land Contamination NP = Noise Pollution
Water Pollution Natural Resources

Legal and other

Scale Quantity (A) Occurrence (B) Severity of Impact (C) Detection (D) Control (E)
requirements (F)
In compliance or not
1 Negligible Very Rare Negligible visual impact Immediately Available & effective at place
applicable
Has in-built Secondary
2 Low Once a month or less Causes Discomfort or Nuisance Within 1 hour
control

3 Moderate Once a day Resource Depletion Within 8 hours Needs human Intervention

Affects Aquatic Life, flora, Mechanism in place but not

4 High Several times a Day Within 24 hours
fauna or global issue reliable

5 Excessive Continuous Human health effect More than 24 hours Absent or no effective control Not in compliance

Risk Level - G : A x B x C x D x Ex F

Aspects with score of 100 and above are considered as significant.

Also, Irrespective of the score, all legal noncompliance’s to be considered as significant

Condition
N NORMAL
A ABNORMAL
E EMERGENCY

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ENVIRONMENTAL MANAGEMENT 6-82-0001 Rev. 9
AT CONSTRUCTION SITES Page 92 of 102

FORMAT NO. : HSE-19 REV 0 HIRAC

Recommended
Desired Controls & Existing Control Actions Action
Risk Identification Risk Assessment Remarks
Gaps, If Any To Reduce The By
Risk Level
SN Activity Activity Hazards Condition( Associat Desired Control Gaps If Probabi Impact Risk Risk
Type N/An/E) ed Risk Measures Any lity(P) (I) R= Classific
(R/Nr) P*I ation

Likelihood – Possibility of occurrence of risks based on present gaps (technological / operational / competence / measurement and monitoring);

UL: Unlikely, L: Likely, VL: Very Likely, FR: Frequent, C: Continuous

Impact –

SI: Slight Injury, MI: Minor Injury, MJ: Major Injury, SF: Single Fatality, MF: Multiple Fatalities

Level of consequence – Refer Guidance criteria for this i.e. possible degree of damage;

Condition- N: Normal, AN: Abnormal, E-Emergency

Activity Type: R- Routine, NR- Non Routine

RISK –

L: Low Risk, M: Moderate Risk, H: High Risk

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ENVIRONMENTAL MANAGEMENT
Page 93 of 102
AT CONSTRUCTION SITES

FORMAT NO.: HSE-20 REV 0

Inspection of Tower Crane

Name of Contractor: Project:

Name of Work: Job No:
Vehicle Identification/Registration No: Date:

Sr. Remarks &

Description Observation
No. Suggestions
1 Serial number plate &SWL marking
2 Valid TPI Certificate
3 Valid Insurance
4 Safe access and egress are provided to the crane operator.
5 Front glass of Operator cabin
6 Operator crane cabin is provided with a locking mechanism so as to
prevent unauthorised entry.
7 A safety bar is fitted across the operator’s cabin window where there is
likelihood of the operator falling through it.
8 Manufacturer Operating Manual and Maintenance Manual are made
available.
9 An updated Operation and Maintenance log book is available in the
operator cabin.
10 All mounting bolts are in good condition.
11 Load chart provided
12 SLI available
13 Crane hooks have got smooth surface and no dent

14 Hook-latch / Dog-clamp in hook is effective

15 Over hoist limit switch
16 Double body earthing of Tower Crane
17 Jib angle indicator is provided (For Luffing Jib Tower Crane).
18 Emergency stop button, which will terminate the operation of the crane
engine, is installed in the operator cabin and correctly identified.
19 Effective braking mechanisms for Hoisting, Derricking, Slewing,
Trolley Travelling maintained:
20 Trolley Travelling limiter to prevent over-travelling of trolley is
functional.
21 Limit switches to prevent over-derricking and over-lowering of jib (For
Luffing Jib Tower Crane) is functional.
22 Slewing limiter to restrict slewing of crane is functional.
23 Over load Limiter to prevent overloading of crane is functional.
24 Load Moment Limiter to prevent over-turning moment is functional.
25 Anti-collision devices are tested to stop the tower crane’s operation
such that the crane-to-crane interference must be maintained at not less
than 3 m.
26 Condition of boom
27 Counter weight placement and pins
28 Winches, pulleys and wire ropes are in good working condition.
29 Colour coding
30 Leakage in hydraulic cylinder
31 Fire Extinguisher

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HEALTH, SAFETY & 6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
Page 94 of 102
AT CONSTRUCTION SITES

32 Tower crane is adequately grounded or protected against lightning.

33 Wind anemometer is installed and is in good working condition.
34 Aviation lamp is functional (Reqd. for 30mt and above)
35 Pre Medical Check-up& Periodic Medical check-up (every 6 months)
including vision test for Operator
36 Safety Induction for Operator
37 Others

Signature & Name of Signature and name of Job

Operator: Engineer

Signature & Name of Contractor's Safety Officer

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HEALTH, SAFETY & 6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
Page 95 of 102
AT CONSTRUCTION SITES

FORMAT NO. : HSE-21 REV 0

Crane Inspection Checklist

Name of Contractor: Project:

Name of
Work: Job No:
Vehicle Identification/Registration No: Date:

Remarks &
Sr. No. Description Observation
Suggestions
1 Crane hooks have got smooth surface and no dent

2 Hook-latch / Dog-clamp in hook is effective

3 Over hoist limit switch
4 Over Load Indicator
5 Over Boom limit switch
6 Boom angle indicator
7 Colour coding
8 Condition of boom
9 Condition of wire rope
10 Rope drum / sheaves are in good working condition
11 Swing break & lock
12 Swing Alarm
13 Over hoist break & lock
14 Boom break & lock (For Telescopic Boom)
15 Leakage in hydraulic cylinder
16 Condition of Outrigger (For Tyre Mounted Crane)
17 Outrigger fully extended Marking (For Tyre Mounted
Crane)
18 Condition of Tyre (For Tyre Mounted Crane)
19 Wheel chokes are present and are used whenever
required (For Tyre mounted)
20 Battery & lamps
21 Moving & rotating parts guarded
22 Load chart provided
23 Reverse horn (For Tyre Mounted Crane)
24 Body Condition of crane
25 Front glass of Operator cabin
26 Both side Mirror
27 Number Plate (For Tyre Mounted Crane)
28 Fire Extinguisher
29 Horn
30 Windshield and wipers
31 Working of light & Indicator
32 SLI
33 Spark Arrestor( For Running Refinery/
Petrochemical/Chemical Plant)

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34 Foot-steps and hand-holds are in good working

condition for exit /enter in to cabin
35 TPI Certificate
36 RC Document (For Tyre Mounted Crane)
37 Fitness Certificate of Vehicle by authority
38 Insurance
39 PUC
40 HMV License for Operator
41 Pre Medical Check-up& Periodic Medical check-up
(every 6 months) including vision test for Operator
42 Safety Induction for Operator
43 Others

Signature & Name of Signature & Name of Contractor's

Operator: Concern Engineer

Signature & Name of Contractor's Safety

Officer

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ENVIRONMENTAL MANAGEMENT
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AT CONSTRUCTION SITES

FORMAT NO. : HSE-22 REV 0

Hydra Crane Inspection Checklist

Name of Contractor: Project:

Name of Work: Job No:
Vehicle Identification/Registration No: Date:

Remarks &
Sr. No. Description Observation
Suggestions

1 Identification number of Hydra crane boldly scribed in

front and rear end of machine
2 Hydra Operator has got adequate document in support of
his competency (i.e. HMV driving license, knowledge &
training)
3 Marking of SWL on hook position is clearly visible

4 Test & examination of Hydra crane by statutory /

competent authority is carried out & document is valid
5 Colour Coding

6 RC Document

7 Fitness Certificate of Vehicle by authority

8 Valid Insurance

9 Valid PUC

10 Pre Medical Check-up& Periodic Medical check-up

(every 6 months) including vision test for Operator
11 Safety Induction for Operator

12 Crane hooks have got smooth surface and no dent

13 Hook-latch / Dog-clamp in hook is effective

14 Over hoist limit switch

15 Over Load Indicator

16 SLI

17 Condition of boom

18 Condition of wire rope

19 Rope drum / sheaves are in good working condition

20 Leakage in hydraulic cylinder

21 Tyre condition

22 Battery

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ENVIRONMENTAL MANAGEMENT
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AT CONSTRUCTION SITES

23 Moving & rotating parts guarded

24 Break

25 Parking Break

26 Front horn

27 Reverse horn

28 Hydra cabin body and frame of machine is in good order

29 Both side Mirror

30 Fire Extinguisher

31 Front glass pane of the Hydra operator’s cabin is clean &

clear (i.e. not cracked / damaged / broken)
32 Windshield and wipers condition

33 Working of front & back lights, turn Indicators, parking

lights & fog lamps
34 Spark Arrestor( For Running Refinery/
Petrochemical/Chemical Plant)
35 Wheel chokes are present and are used whenever required

36 Foot-steps and hand-holds are in good working condition

for exit /enter in to cabin
37 Others

Signature & Name of Operator Signature & Name of

Contractor's Concern
Engineer

Signature & Name of Contractor's Safety Officer

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ENVIRONMENTAL MANAGEMENT
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AT CONSTRUCTION SITES

FORMAT NO. : HSE-23 REV 0

Hydraulic Rig Inspection Checklist

Name of Contractor: Project:

Name of Work: Job No:

Vehicle Identification/Registration No: Date:

Remarks &
Sr. No. Description Observation
Suggestions

Control panel is clean & all buttons/switches are clearly

1
visible (no paint over spray, etc.)
All switch & mechanical guards are in good condition and
2
properly installed

3 All Safety Indicator lights work

Drive controls function properly & accurately labelled (up,

4
down, right, left, forward, back)

5 Motion alarms are functional

6 Safety decals are in place and readable

Any defects such as cracked welds, fuel leaks, hydraulic

7
leaks, damaged control cables or wire harness, etc.

8 Braking devices are operating properly

Winches, pulleys and wire ropes are in good working

9
condition.

10 Function of interlocks and limit switch

The manufacturer’s operations manual (in all languages of the

11
operators)

12 Oil level, Hydraulic Oil Level, Fuel Level, Coolant Level

13 Battery Charge

14 Outriggers in place or functioning. Associated alarms working

15 Moving & rotating parts guarded

16 Load chart provided

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17 Fire Extinguisher

Spark Arrestor, if operated by using fuel( For Running

18
Refinery/ Petrochemical/Chemical Plant)

19 Serial number plate

20 SLI

21 TPI Certificate

22 Colour Coding

23 Insurance

Pre Medical Check-up& Periodic Medical check-up (every 6

24
months) including vision test for Operator

25 Safety Induction for Operator

26 Others

Signature & Name Signature & Name of Contractor's Concern

of Operator: Engineer

Signature & Name of Contractor's Safety Officer

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ENVIRONMENTAL MANAGEMENT
Page 101 of 102
AT CONSTRUCTION SITES

FORMAT NO. : HSE-24 REV 0

Boom Lift Inspection Checklist

Name of Contractor: Project:

Name of Work: Job No:

Vehicle Identification/Registration No: Date:

Remarks &
Sr. No. Description Observation
Suggestions

1 Operating and emergency controls are in proper working

condition, EMO button or Emergency Stop Device

2 Functional upper drive control interlock (i.e. foot pedal,

spring lock, or two hand controls)
3 Emergency Lowering function operates properly

4 Lower operating controls successfully override the upper

controls
5 Both upper and lower controls are adequately protected
from inadvertent operation.
6 Control panel is clean & all buttons/switches are clearly
visible (no paint over spray, etc.)
7 All switch & mechanical guards are in good condition and
properly installed
8 All Safety Indicator lights work

9 Drive controls function properly & accurately labelled

(up, down, right, left, forward, back)
10 Motion alarms are functional

11 Safety decals are in place and readable

12 Guardrails and anchor points are in place, and in good

condition
13 Work platform & extension slides are clean, dry, & clear
of debris
14 Work platform extension slides in and out freely with
safety locking pins in place to lock setting on models with
extension platforms.
15 Any defects such as cracked welds, fuel leaks, hydraulic
leaks, damaged control cables or wire harness, etc.
16 Braking devices are operating properly

17 The manufacturer’s operations manual is stored on AWP

(in all languages of the operators)
18 Oil level, Hydraulic Oil Level, Fuel Level, Coolant Level

19 Battery Charge

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 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
HEALTH, SAFETY & 6-82-0001 Rev. 9
ENVIRONMENTAL MANAGEMENT
Page 102 of 102
AT CONSTRUCTION SITES

20 Outriggers in place or functioning. Associated alarms

working
21 Tyres and wheels are in good condition, with adequate air
pressure if pneumatic
22 Wheel chokes are present and are used whenever required

23 Moving & rotating parts guarded

24 Load chart provided

25 Fire Extinguisher

26 Spark Arrestor, if operated by using fuel( For Running

Refinery/ Petrochemical/Chemical Plant)
27 Serial number plate with Load capacity

28 TPI Certificate

29 Colour Coding

30 Insurance

31 Pre Medical Check-up& Periodic Medical check-up

(every 6 months) including vision test for Operator
32 Safety Induction for Operator

33 Others

Signature & Name of Signature & Name of

Operator: Contractor's Concern
Engineer

Signature & Name of Contractor's Safety

Officer

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

Page 519 of 674

Page 520 of 674

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 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENGINEERS FOR TRAYS AND TOWER
INDIA LIMITED 6-14-0003 Rev. 5
INA?f toron ) IA GoN of InOla uneertaiong) INTERNALS Page 1 of 16

(r4. C.1 cl *C<G1 ei

. 1;frfif-2TTI:RT
cr) I

INSTALLATION PROCEDURE FOR

TRAYS AND TOWER INTERNALS

f
REVISED AND RE-ISSUED AS STANDARD
5 29.10.2014 VDY IK/ SKM
SPECIFICATION
REVISED AND RE-ISSUED AS STANDARD
4 11.03.2010 AK SKM/HCN AKG ND
SPECIFICATION
REAFFIRMED AND RE-ISSUED AS
3 22.07.2004 AK KKG RKA SKG
STANDARD SPECIFICATION
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 530 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENGINEERS
22-dg
14.11771 c./~ M1 vcmi
INDIA LIMITED
in Govt of InOta Undertakingt
FOR TRAYS AND TOWER
INTERNALS
6-14-0003 Rev. 5
Page 2 of 16

Abbreviations:
BB Bolting Bar
D/C Downcomer
M/W Manway
TSR Tray Support Ring

SOME IMPORTANT GUIDELINES

SLOTS Slots are provided for adjustments of the tray segments. Vessels are made
to manufacturing tolerances which are fully accounted for in Distillation
Tray design.

CLEARANCES Clearances between Deck Beams/Downcomers from Support Rings are

provided to ensure that the trays fit the vessels without modification to
parts. POSITION tray deck beams and downcomers with equal clearances
at each end.

SPACINGS Spacings of loose beams or deck plates shown on drawings are TYPICAL
for perfectly round and sized vessels. The vessels may not be perfect, so
spacings will need to be ADJUSTED.

INSTALLATION INSTRUCTIONS ON THE FOLLOWING PAGES SHOULD BE READ

CAREFULLY.

Heat and Mass Transfer Standards Committee

Convenor: Sh. Amit Prakash

Members: Sh. Mandip Kapoor

Sh. Inder Kumar
Sh. Ratan Lal (Projects)
Sh. G. K. Iyer (Const.)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 531 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENGINEERS
INDIA L1MITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
IA Govt ol India UndertakIngt
INTERNALS Page 3 of 16

CONTENTS

1.0 INTRODUCTION 4

2.0 ORDER OF INSTALLATION 4

3.0 FITTING MAJOR BEAMS 6

4.0 FITTING DOWNCOMERS & EXIT WEIRS 7

5.0 FITTING DECK PLATES: INTEGRAL BEAM DESIGN 9

6.0 SUPPORT PLATES 11

7.0 BED LIMITERS 12

8.0 DISTRIBUTORS/REDISTRIBUTORS 12

9.0 FLASHING FEED GALLERY 14

10.0 LIQUID COLLECTOR/CHIMNEY/ACCUMULATOR TRAY 15

11.0 LATTICE GIRDERS 15

12.0 TIGHTENING OF BOLTS AND CLAMPS 15

13 .0 LEAK TESTING 16

14.0 REMOVAL OF LINSEED OIL COATING FROM CARBON STEEL TRAYS AND
INTERNALS 16

15.0 INSTALLATION CHECKLIST & REPORTING FORMATS 16

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 532 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
■
31 ENGINEERS
Og.,102e- g INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
nreasaTassr) IA Govf Of Ind. Undertakog) INTERNALS Page 4 of 16

1.0 INTRODUCTION

The purpose of this specification is to help in effecting satisfactory installation of EIL-

designed trays and tower internals in the minimum time.

Whether installation involves a small number of trays, tower internals or is a large complex
involving thousands of components, it is vital that care is taken to ensure efficient handling
and assembly of tray components.

This specification should be used only as a "General Guide". The work in each tower and for
each tray/tower internal should be carried out in accordance with General Arrangement
Drawings prepared for specific tray/tower internal.

An adequate number of components with installation spares, where applicable, are supplied
for every assembly. Significant time and Cost can be saved by efficient storage and usage of
such components.

2.0 ORDER OF INSTALLATION

These instructions are based upon the following order of installation:

2.1 Review the drawings provided for respective tray/tower internals. It is an important aid for
installation. The drawings show the relative position of each component and corresponding
item number. After all trays/tower internals are uncrated, identify each piece of the tray/tower
internal with the item number w.r.t. its location on the General Arrangement Drawing.

2.2 Ensure that protective oil coating is removed from carbon steel tray/tower internal parts prior
to initiating installation of trays and tower internals in the tower. (For suggested procedure
for removal of linseed oil coating, refer clause 14.0 of this specification).

2.3 Check levelness of tray support rings & various dimensions of bolting bar welded to the
tower to ensure that these are as per relevant drawings and within specified tolerances. In
case of any deviation observed, refer this to EIL-HMTD. Levelness of support ring and other
dimensions of bolting bar shall be recorded in Format attached in EIL Specification No. 6-
14-0016.

2.4 Trays

2.4.1 Work upwards from lowest tray in tower.

2.4.2 Fit/complete installation (including welding) of lattice girder, if any.

2.4.3 Fit and leak test seal pan below bottom tray, if provided.

2.4.4 Fit major beam, if any.

2.4.5. Fit downcomer for bottom tray.

2.4.6 Fit support beam (if any) for bottom tray.

2.4.7 Fit deck plates for bottom tray except man way deck plate. (However proper fitment of man
way decks plate shall be ensured).

2.4.8 Leak test recessed seal pans, wherever provided.

2.4.9 Fit/install lattice girder/major beam, if required, for tray above bottom tray.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 533 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENGINEERS
$1
1g-
ar IMeg INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
1.11771 excm, .3721,
71, IA Govt of Inda Undertaking)
INTERNALS Page 5 of 16

2.4.10 Fit downcomers for tray above bottom tray.

2.4.11 Fit beams and decks for tray above bottom tray except man way deck plate. (However proper
fitment of man way decks plate shall be ensured).

2.4.12 Fit each successive tray as above.

2.4.13 Remove all the foreign material and ensure that trays are clean and unobstructed for proper
performance.

2.5 Tower Internals

2.5.1 Work upward from bottom most bed in the tower.

2.5.2 Fit/install lattice girder/major beam, if any.

2.5.3 Install (including welding and leak testing) vapour distributor/chimney tray/accumulator tray,
if any.

2.5.4 Install support plate/support grid.

2.5.5 Pack the tower with random packings in accordance with EIL spec. 6-14-0011 titled
"Specification for Packing the Tower".

In case bed is provided with proprietary packings/grid/structured packings, follow the

instructions provided by the supplier. Successive layers of grid/structured packings may
require to be rotated by specific angle as mentioned in supplier's drawings/procedure for
installation.

2.5.6 Install the bed limiter/hold down grid wherever specified in drawings, in case of random
packings

Install bed retainer/distributor support grid, in case of structured packings.

2.5.7 Install distributor/redistributor, Leak test pan/trough type distributor/redistributor and hydro
test spray header, if specified, on the drawings.

2.5.8 Fit the pre-distributor/feed pipe.

2.5.9 Repeat from paragraph 2.5.2 to 2.5.8 above, for the next bed.

2.5.10 Remove all the foreign material from respective tower internal. Ensure that the same are
clean and un-obstructed for proper performance.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 534 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
■
31 ENGINEERS
INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
mlaRr.1) IA Govt of Incla Undertakog) INTERNALS Page 6 of 16

3.0 FITTING MAJOR BEAMS

3.1 Carefully place shims, as necessary, under major beams to bring top of beam exactly in level
with tray support ring (Refer sketch 3.1.1). Tack weld/bolt shims in position.

NOTE: Depth of stool is always designed to allow for minimum shim thickness of 3 mm
(although this may be taken up in vessel or tray manufacturing tolerances).

TOP OF SUPPORT RING &

THICKNESS TRAY DECK
PLATE MAJOR BEAM SHALL BE
IN SAME LEVEL

THICKNESS
et... OF CLAMP

BEAM
THICKNESS

y s
PROVIDE SHIMS
AS NECESSARY

SKETCH No. 3.1.1

(C BEAM SHOWN, MAJOR BEAM MAY BE OF OTHER SHAPES ALSO)

3.2 Line-up down comer bolting bars, if fitted, on beam with downcomer bolting bars attached to
vessel wall. See sketch No. 3.2.1.

UNE—UP BOLTING VESSEL WALL

BAR THIS SIDE BOLTING BAR
VESSEL WALL
BOLTING BAR

MAJOR BEAM

MAJOR BEAM UNE—UP BOLTING

MAJOR BEAM
BOLTING BAR BAR THIS SIDE
BOLTING BAR

SKETCH No. 3.2.1

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 535 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
■31 ENGINEERS
INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
A GoN of InON Undeftaking)
INTERNALS Page 7 of 16

4.0 FITTING DOWNCOMERS & EXIT WEIRS

4.1 Where no down comer support stools are provided

(a) Top section of downcomers for one tray fitted by:

i) Level exit weir base (top) with top of support ring and/or support beam top
surface.

ii) Bolting securely in position.

(b) Fit bottom downcomer sliding plate into position, position bottom of plate in
downcomer support bracket while fitting on tray below. Check clearance under
downcomer bottom edge. See Sketch No. 4.1.1.

HORIZONTAL SLOTS
IN BOLTING BAR D/C THICKNESS
EQUAL TO BEAM
TRAY DECK
END CLEARNCE TO BE IN
THICKNESS
SAME LEVEL
EXIT WEIR

25 x 11 VERTICAL EXIT WEIR

SLOT IN D/COMER I

TOP D/C SECTION

— —F

25x11 HORZ. SLOT BOTTOM D/C

IN TOP D C APRON SECTION
25x11VE . SLOT IN D/C RETAINING
BOTTOM D/C APRON
BRACKET

TRAY DECK
FIT STANDARD TRAY
THICKNESS
EDGE CLAMP WHEN UNDER D/C CLEARANCE
BOLTING IS OMITTED
IN BOTTOM PIECE OF TOLERANCE ± 3
DOWNCOMER.

SKETCH No. 4.1.1

4.2 Where downcomer support stool is provided

(a) Place shims, as necessary, under top downcomer section to bring exit weir base (top)
exactly in level with support ring and/or lattice girder/major beam (if provided) and
then bolt downcomer sections including exit weir securely. Tack weld/bolt shims in
position.

(b) Fit bottom-sliding plate of downcomer in position in downcomer support bracket, set
clearance under downcomer plate within plus or minus 1/8" (3mm). The clearance
obtained should be maintained as near constant across the width as possible (See
Sketch No. 4.2.1).

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 536 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENGINEERS
$'gLIE IC1Ws INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
IA Govt ol Incha Undertak■ng) INTERNALS Page 8 of 16

HORIZONTAL SLOTS
IN BOLTING BAR D/C THICKNESS
EQUAL TO BEAM
TRAY DECK
END CLEARNCE TO BE IN
THICKNESS
SAME LEVEL
EXIT WEIR

25 x 11 VERTICAL EXIT WEIR

SLOT IN D/COMER I HEIGHT
TOP D/C SECTION I
BEAM END L
CLEARANCE j_

25x11 HORZ. SLOT PLACE SHIMS BOTTOM D/C

IN TOP D/C APRON AS REQUIRED
SECTION
25x11VERT. SLOT IN D/C RETAINING
BOTTOM D/C APRON
BRACKET

TRAY DECK
Fff STANDARD TRAY
THICKNESS
EDGE CLAMP WHEN UNDER D/C CLEARANCE
BOLTING IS OMI1TED
IN BOTTOM PIECE OF TOLERANCE ± 3
DOWNCOMER.

SKETCH No. 4.2.1

4.3 Use of Washer & Location of Nut

Unless otherwise specified on drawing, two washers (one on bolt head side & one on nut
side) shall be used for every bolt. The nut shall be provided towards the side accessible from
Tray man way. Lock nuts shall not be provided on clamp/bolting for Man way deck plate.

Nuts for supporting pipes (i.e. U clamps) shall be kept loose so as to have free
movement/expansion of the pipe.

4.4 Downcomer Vent Tubes

Vent Tubes are standard feature in Three (3) / Four (4) pass trays.

(a) Fit one top section of center/off-center downcomer as in paragraph 4.1/4.2 and then
position tube as shown in Sketch 4.4.1.

(b) Fit top section of opposite downcomer.

(c) Place shims, as necessary, between vent tube flanges and tighten the bolts.

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Page 537 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
01nz ENGINEERS
INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
v.1 20. lA Govt o11n0ia Undertakogt
INTERNALS Page 9 of 16

D/C BOLTING BAR

ON VESSEL WALL

TOP D/C

VENT TUBE

SHIMS AS
NECESSARY

SKETCH No. 4.4.1

4.5 Downcomer Bracer Panels

After downcomer sections have been fitted, position bracer panels and bolt securely.

4.6 Adjustable Exit Weirs

Bolt loosely into position after down comer has been leveled and tightly secure. Weir top
edge then to be leveled upto desired height and bolts tightened securely. Unless otherwise
specified on the drawings, adjustable weirs to be set at mid point.

5.0 FITTING DECK PLATES: INTEGRAL BEAM DESIGN

5.1 Measure distance across area of deck to be installed at 90° to run of minor beams. See Sketch
No. 5.1.1

SKETCH No. 5.1.1

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Page 538 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENGINEERS
$.
1g faWg INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
171QT r1rane d513:12ffil) I A Govt of Incha Undertaking)
INTERNALS Page 10 of 16

5.2 Compare measurement taken in paragraph 5.1 with dimensions stated on tray General
Arrangement Drawings.

5.3 If comparison shows measured distance GREATER than shown on drawings, INCREASE 25
mm typical spacing difference - see Sketch No. 5.3.1.

25 mm NOMINAL GAP
TO BE OPENED OR CLOSED
(MAX 27mm, MIN 23mm)

20/23/25mm NOMINAL OVERLAP

INTEGRAL BEAM

SKETCH No. 53.1

5.4 If distance measured is SMALLER than shown on drawings, DECREASE 25mm typical
spacing between the deck plates to absorb the difference - EXCEPT at each side of man way
section, which must remain at 25 mm to allow man way clamps to operate properly. See
Sketch No. 5.3.1.

5.5 Position deck plates as required from paragraph 5.3 to 5.4 on support ring and/or down comer
top flange.

5.6 Position deck plates centrally along their length i.e. leave EQUAL clearance at each end.

NOTE: Edge clamps must be orientated correctly (see Sketch No. 5.6.1). Stud/pin of all tray
edge clamps are provided with screwdriver slot and center punch mark as aid in
installation and fitting of edge clamps properly. Slot shall be in radial direction,
while punch mark be towards center of the tower.

II II
II I
I

II II

CLAMPS STUDS TO BE PUSHED

CLAMP ORIENTED 90*
AGAINST SUPPORT RING
TO VESSEL WALL

SKETCH No. 5.6.1

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Page 539 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENQNEERS
gigz-Jr0fmg INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
1.177, ,fe,cnf, C51~) IA Govt of Inda Undertalongt
INTERNALS Page 11 of 16

5.7 Position man way plate in place to check that this can be put in position from top as well as
bottom of tray without fouling or interfering with man way beam clamp or adj acent tray deck
plate.

5.8 Remove man way plate and keep it on the tray or in downcomer area so that tray man ways
are accessible for inspection of trays.

5.9 Bubble cap trays, seal pans, draw off etc. shall be leak tested to ensure that drop in water
level does not exceed the specified limit mentioned in the drawing. In case the leakage
exceeds the allowable limit, consult EIL-HMTD.

5.10 Proceed with installation of next tray.

5.11 Tray man way plate shall be clamped in position only after all the trays installed in the tower
have been inspected, tested and approved by competent authority.

6.0 SUPPORT PLATES

6.1 Gas Distribution Support Plate

6.1.1 Start installation with the short piece of decicing and work across the tower. When gasketing
is specified, place the gasket on the support ring. If a mid span is required, place gasket on
the mid span also. Install the support ring clamps in the deck sections; leave the clamps loose.
Place the deck section on the support ring. Place the minor beam against the edge of the deck.
Minor beams are not always required (see drawing). Install the adjacent deck section. Install
the bolting through the deck section and through the minor beams when provided. When
gasketing is required between the deck sections, the bolts should also go through the gasket.
Tighten the bolting. Continue this procedure until all deck sections are installed.

For some applications, liquid downcomer tubes are provided which hang below the deck
sections. The downcomer tubes may or may not be removable (check drawing provided).

6.1.2 When the tubes are removable they should be installed before the deck sections are installed
on the support ring.

6.1.3 For various applications, riser tubes with covers are provided (which may or may not be
removable). When the tubes or covers are removable, install the tubes with the gaskets and
bolting provided as the deck sections are being installed. When the gas riser tube covers are
removable, ensure that they are fastened firmly in place.

6.1.4 After all deck plates are installed; rotate clamps under support ring and tighten clamps.
Ensure that all gasketing is in proper position.

6.1.5 Remove all foreign material so that the support plate is clean and unobstructed for proper
performance.

6.2 Gas Injection Support Plate

6.2.1 Place the sections in position on top of the support ring starting with the shorter sections at
one side of the tower. Proceed across the tower. Make sure all sections are making proper
contact with the support ring. The sections shall be equally spaced so that the gap between
sections is uniform.

Ensure that at any location on the support plate, gap is not large enough for the random
packings to pass through.

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Page 540 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
+31 ENGINEERS
OgZIT 02-dg ' INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
I.27f twzn, erfi Jcrasaal I A Go. of Inoia Undertaking)
INTERNALS Page 12 of 16

6.2.2 When clamps are required, the clamps are to be assembled in position as the sections are set
in place. Tighten clamps after sections are properly positioned.

6.2.3 Remove all foreign material so that the support plate is clean and unobstructed for proper
performance.

7.0 BED LIMITERS

7.1 After the Bed Limiter is uncrated, identify each section of the Bed Limiter with the tag
number. The tag numbers locate the relative position of the sections.

7.2 Install the packing in the tower upto the depth of the minor beams from the support ring, as
shown on the drawing provided.

7.3 Install the minor beams to the support ring as shown on the drawing in their correct
positions. Finish installing the tower packing such that packings level is same as the top of
the minor beams and support ring/support cleats.

7.4 Install the screened Bed Limiters sections. Some of the sections may require tray clamps (see
drawings). If tray clamps are required, install them in the sections before installing the
sections on the support ring/support cleats.

7.5 Bolt all the sections with the hardware provided, as shown on the drawings.

7.6 Ensure removal of all foreign materials so that the bed Limiter is clean and unobstructed for
proper performance.

7.7 Ensure that the packings do not fly from the gaps. If so, adjust/reduce the gap.

8.0 DISTRIBUTOR/REDISTRIBUTOR

8.1 Orifice/Deek Type

8.1.1 Start installation with the short piece of deck and working across the tower. Place the gasket
on the support ring. Install the support ring clamps in the deck sections; leave the clamps
loose. Place the deck sections on the support ring. Place the minor beam, if provided, against
the edge of the deck. Gasketing is to be installed on both sides of the minor beam. Install the
bolting through the deck sections, gasketing and minor beams. Tighten the bolting. Continue
this procedure until all deck sections are installed.

8.1.2 Some applications require covers or hats over the gas riser area. Install the same.

8.1.3 When specified, the distributor shall be leak tested after installation.

8.1.4 Ensure that all foreign materials are removed so that the distributor/redistributor is clean and
unobstructed for proper performance

8.2 Trough Type Liquid Distributor/Redistributor

8.2.1 Review the drawing provided with the distributor/redistributor plate.

8.2.2 Install the tray clamps (wherever provided) loosely in the deck sections and the end closing
plates. If the plate is equipped with a center sump (see drawing), install the center sump first.

8.2.3 For some low-flow applications, gasketing is provided with the plate. If gasketing is required
(see drawing), place the gasket along with the support ring and sump top edges.

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 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENQNEERS
02-dg
' ) INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
17.M7T 0traol0n. (A Govt of ioo.a Undertalongt
INTERNALS Page 13 of 16

8.2.4 To install the main deck of the distributor/redistributor, begin by placing the short deck
section in its proper position on the support ring. Using the tag numbers as a guide, place the
adjacent deck section on the support ring. Bolt the deck sections together with the proper end
closing plates. If gasketing is provided with the plate, ensure providing gaskets in the joints
between the deck sections and the end closing plates. Tighten the bolting at these joints to
minimize leakage.

Some applications require covers or hats over the gas riser area. If covers are required, install
the same. Continue this, until the entire distributor/redistributor is installed.

8.2.5 After the plate is assembled on the support ring, rotate the tray clamps under the support ring
and tighten the clamps. Ensure gasketing (if required) is in proper position.

8.2.6 If parting box(es) are provided with the distributor, install the parting box brackets to the
parting box(es), then bolt this assembly in proper position on the distributor/redistributor.

8.2.7 Remove all foreign materials so that distributor/redistributor is clean and unobstructed to
ensure proper performance.

8.2.8 For some applications, distributors are provided with leveling screws. Level the troughs
wherever leveling screws are provided to bring within level as specified in the respective
drawings.

8.2.9 Leak test the distributor, wherever specified on the drawing.

8.3 Lateral Type Dishibutor/Redishibutors

8.3.1 If mounting clips have not been previously welded to the tower wall this is to be done before
installing distributor. The drawing provided for the job will show the proper position of the
mounting clips. Layout and weld the clips in position.

8.3.2 Place the laterals in position resting on top of the bed limiter.

8.3.3 If the tower is larger than 1250 mm I D , support members are provided. When support
members are provided, they are to be installed next. Loosely bolt the support members to the
mounting clips. Lift laterals and loosely bolt laterals to support members.

8.3.4 Place the gasketing provided on top of the lateral flanges in the proper position.

8.3.5 Place header in position and loosely bolt header to clips. Then assemble bolting through
header, gasket and lateral flange. Be sure to keep gasket in proper position. Tighten lateral
flange bolting. Leave other bolting loose.

8.3.6 Install connecting pipe and flange gaskets to header and inlet nozzle. Tighten pipe flange
bolting.

8.3.7 Tighten all bolting on support members.

8.3.8 Ensure to remove all foreign materials so that the distributor is clean and unobstructed for
proper performance.

8.4 Spray Nozzle Distributor

8.4.1 Review the drawing provided with the distributor.

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Page 542 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENGINEERS
02-'eg INDIA LIMITED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
•>■wn ,wowerA,rom) IA Govt of India Unclertak.g) INTERNALS Page 14 of 16

8.4.2 If mounting clips have not been previously welded to the tower wall, this is to be done before
installing the distributor. The drawing provided for the job will show the proper position of
the mounting clips layout. Weld the clips in position.

8.4.3 Check to see that all the piping is clean and unobstructed inside.

8.4.4 Place the laterals in position resting on top of the bed limiter.

8.4.5 Place header in position and loosely bolt to wall clip. Assemble the bolting and gasket at the
inlet flange. Tighten inlet flange bolting.

8.4.6 Place the lateral pipes in position and loosely bolts to wall clips. Assemble the bolting and
gasket at the flange end. Tighten the flange bolting.

8.4.7 Secure the wall clip bolting as shown on the drawing provided.

8.4.8 Hydro tests the spray header, without spray nozzles, if specified on the drawings.

8.4.9 Assemble the spray nozzles to the header and lateral assembly as shown on the drawing
provided.

If the spray nozzles are threaded, it is recommended that an anti seize pipe thread compound
be used for installation.

If the spray nozzles are flanges, use gaskets and tighten the bolting securely.

8.4.10 The bolting provided at end of pipe (i.e. for U clamps) shall be kept loose so as to have free
movement/expansion of the pipe.

8.4.11 Check the spray pattern visually by running the pump with water. If spray pattern is
defective, replace the spray nozzle with spare spray nozzles supplied.

9.0 FLASH1NG FEED GALLERY

9.1 Review the drawing provided with the Flashing Feed Gallery plate.

9.2 Install the tray clamps loosely in the sections that go on the support ring.

9.3 For most applications, gasketing is required and is provided with the plate. When gasketing is
required, place the gasket along with the support ring.

9.4 Place the first section on the support ring and snug up the tray clamps enough to hold it in
place. Place the adjacent section on the support ring with a gasket between the two sections.
Bolt the two sections together. Install all the sections on the support ring in a similar manner.
Tighten the tray clamps and the bolting to ensure leak free operation.

In some instances, where a high gallery wall is required, more sections are provided which
need to be bolted on top of the first row of sections. If angle braces are provided, they are to
be bolted to the first row of sections. It is advisable to bolt them in place before the upper
sections are installed.

After all the sections are bolted tightly together and all the joints are gasketed, install all
bracing when required, as shown on the drawing provided. Attach wall clips as shown on the
drawing, when required.

Remove all foreign materials so that the Flashing Feed Gallery is clean and unobstructed to
ensure proper performance.
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Page 543 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
31 ENQNEERS
FOR TRAYS AND TOWER
Iu faWg
lafWf rarcnIcf tuf.34m-41)
INDIA LIMITED
(A Govt of Incha Undertakog)
INTERNALS
6-14-0003 Rev. 5
Page 15 of 16

10.0 LIQUID COLLECTOR/CHIMNEY/ACCUMULATOR TRAYS

10.1 Review the drawing provided with the collector plate.

10.2 Start installation with the short piece of decking and work across the tower.

10.3 Collector/Chimney/Accumulator trays may be provided with gaskets or may be of seal welded
construction to achieve leak tight joints.

10.4 In case trays are provided with gaskets, place the gasketing on the support Ring. Install the
support ring clamps in the deck sections and end closing plates. Leave the clamps loose.
Attach the proper end closing plate with gasket to each end of the deck sections by bolting
through the deck section, gaskets and end closing plate. Tighten the bolting. Continue this
procedure until all sections are installed.

10.5 After deck plates are installed, rotate clamps under support ring and tighten clamps. Ensure all
gasketing, when required, is in proper position.

10.6 In case of seal welding, welding to be completed after assembly of deck plates and before
building the riser height. After completion of floor level assembly and seal welding, leak test
the tray to locate deficiency of seal welding and ensure leak tightness.

Install next level of risers to build-up riser height, seal weld and leak test. Continue till tray
assembly, seal welding and leak testing is complete.

10.7 Place gas riser covers in position and bolt covers to gas riser using the bolting provided.
Tighten the bolts.

10.8 Install a vortex breaker in the draw off nozzle, if required.

10.9 Remove all foreign materials so that collector is clean and unobstructed to ensure proper
performance.

11.0 LATTICE GIRDERS

Lattice girders, where utilized, will be of a special design to suit the job. Lattice girders are
normally provided to support Two trays/internale (i.e. top lip/flange of each primary member
supporting one tray/internal). Lattice girders are supplied in segments so as to enable
individual segment pass through the tower manhole, for final installation and welding inside
the tower.

It is to be ensured that out of levelness of primary members is within 2 mm and is in level

with respective support rings.

Do not install tray, unless installation (including welding) of Lattice Girder is complete.

12.0 TIGHTENING OF BOLTS & CLAMPS

While tightening bolts & clamps, care should be exercised to apply proper force to avoid
deformation in clamps. A spanner with a lever arm of 200 mm (8 inch) maximum should be
employed so as to apply a torque of approximately 15 ft. Lbs. for tightening of bolts, studs &
clamps of M10 size; torque of 18-22 ft. Lbs. for tightening of bolting/clamps of M12 size and
torque of 24-36 ft. Lbs. for tightening of bolting/clamps of M16 size.

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Page 544 of 674

 INSTALLATION PROCEDURE STANDARD SPECIFICATION No.
ENGINEEFZS
$1g-ar OfMg INDIA LIM1TED FOR TRAYS AND TOWER 6-14-0003 Rev. 5
1«1771 kwo,41ovaotr.0 IA Govt of Inda Undertak.g) INTERNALS Page 16 of 16

13.0 LEAK TESTING

(a) Preferred Method

Bubble caps, Collector/Accumulator trays, Distributors/Redistributors and other liquid

holding portion of other trays such as seal pans, draw off pans, recessed seal pans etc.
shall be leak tested with water. Drain holes/orifices shall be temporarily plugged
during testing. These holes are to be kept open during operation (unless otherwise
stated on the drawing). Leakage rate (i.e. fall in liquid level) shall not be more than the
value specified on the drawing. If leakage rate is excessive or a small area has a leak
rate which is appreciable, deck section shall be loosened and gasketing to be
repositioned to stop leakage.

(b) Alternate Method

If filling the plate with water is not practical, spot leak testing should be done. Using a
small stream of water from a hose, pour water on the joints and see if leakage occurs.
The main joints to check are the joints at support ring. A small liquid pool will occur.
If leakage occurs loosen the bolting and reposition the gasketing to stop the leakage.

If leak testing cannot be done, all gaskets should be closely inspected to assure proper
gasket sealing. This can be done with a small diameter wire by probing the joint or by
light testing the joint. If holes/gaps are found, loosen joints and reposition gasket to
obtain proper sealing.

14.0 REMOVAL OF LINSEED OIL COATING FROM CARBON STEEL TRAYS AND
TOWER INTERNALS

14.1 Prepare 10% caustic soda solution at about 80°C in a trough.

14.2 Immerse Tray or Tower Internal component coated with linseed oil for about 10 minutes.

14.3 Remove the component, scrub with wire brush using sand followed with rinse in clean
potable water for 15 minutes.

14.4 Repeat rinse in potable water two more times.

15.0 INSTALLATION CHECK LIST & REPORT1NG

After completion of Installation of each tray/tower internal, review the installation and report
the same in accordance with EIL specification for Review of Site Installation of Tower
internale (Specification No. 6-14-001 6).

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Page 545 of 674

 SPECIFICATION FOR SPECIFICATION No.
ei ENGINEERS FABRICATION OF SUPPORT
*grif acs INDIA UMITED 6-14-0007 Rev. 4
(A Govt o India Undertaking)
RINGS AND B/BARS FOR
TRAYS/TOWER INTERNALS Page 1 of 6

t, "T4 dIcR
*V-IV Thi qir— Tr W-{
-ftrffkr

SPECIFICATION
FOR
FABRICATION OF

SUPPORT RINGS AND BOLTING BARS

FOR

TRAYS AND TOWER INTERNALS

b,1••■/‘
,(
}

REAFFIRMED & REISSUED AS STANDARD

4 25-09-17 SK/ IK KJ 1A- RKT
SPECIFICATION
3 16-11-10 REVISED AND REISSUED IK KKG AKG ND

2 18-01-06 REVISED AND REISSUED SKM HCN AKM VJN

REVISED AND ISSUED AS STANDARD
1 24-08-99 PG YVR/HCN RKA AS
SPECIFICATION
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 546 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
LSPeltLi ENGINEERS FABRICATION OF SUPPORT
Ifgar INDIA LIMITED 6-14-0007 Rev. 4
rvrame ostaair.) (A Govt of India Undeitaking) RINGS AND B/BARS FOR
TRAYS/TOWER INTERNALS Page 2 of 6

Abbreviations:

B/Bars - Bolting Bars

CA - Corrosion Allowance
TSR - Tray Support Ring

Static Equipment Standards Committee

Convenor: Mr. R.K. Trivedi

Members: Mr. K.J Hari Narayanan

Mr. P. Bhattacharjee
Mr. Sanjay Mazumdar
Mr. P.P. Pandey
Mr. Nalin Kumar
Mr. K. Anjaneyulu
Mr. Arun Kumar
Mr. Inder Kumar
Mr. Tarun Kumar
Mr. Anish Trehan
Mr. Srikanth Karanam
Mr. M. Azim (Projects)
Mr. S. Ghosal (Process)
Mr. T. Kamalakannan (Inspection)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 547 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS FABRICATION OF SUPPORT
Ogeil Eiwg INDIA LIMITED 6-14-0007 Rev. 4
(Own RIERVIV 4510 (A Gout Of India undertaking)
RINGS AND B/BARS FOR
TRAYS/TOWER INTERNALS Page 3 of 6

CONTENTS

1.0 SCOPE 4

2.0 REFERENCES 4

3.0 MATERIALS 4

4.0 DIMENSIONS 4

5.0 GENERAL CONSTRUCTION FEATURES 4

6.0 INSPECTION AND ACCEPTANCE 6

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 548 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
!it ENGINEERS FABRICATION OF SUPPORT
Ogeli 20leg INDIA LIMITED 6-14-0007 Rev. 4
IMIETTeRlAteeCTIMI9) IA Govt of Wide Undertaking) RINGS AND B/BARS FOR
TRAYS/TOWER INTERNALS Page 4 of 6

1.0 SCOPE

This specification covers the fabrication and inspection requirements emphasizing the
important parameters, which shall be taken into consideration while welding tray supports and
bolting bars to the column. The requirements as specified in tray support drawings take
precedence over those specified in this specification.

2.0 REFERENCES

Following shall form the reference documents for carrying out the work:

i) Tray Support Ring (TSR) and Bolting Bar (B/Bar) drawings.

ii) Construction Tolerances for Welded Standard No. 7-14-0001

Supports for Trays/Tower Internals

3.0 MATERIALS

Unless otherwise specified the materials of TSR and B/Bars, Support Cleats etc. shall be same
as that of the column shell (cladding if any). All the materials shall be new, of first quality and
of the type & grade as specified on the column drawing and shall meet all the requirements
such as NACE, HIC etc. if specified on the column drawings.

4.0 DIMENSIONS

The dimensions as shown on the engineering drawings are final and shall be maintained (in as
welded condition) within the tolerances furnished either on the TSR & B/Bar drawings itself
or as covered in this specification and General Construction Tolerances Standard No. 7-14-
0001. For any deviation, written acceptance shall be obtained from EIL.

5.0 GENERAL CONSTRUCTION FEATURES

5.1 All support rings, bolting bars, beam support brackets and other components which are welded
to the column shell inside, will be supplied and installed by column fabricator in accordance
with details supplied by EIL.

In case of revamp jobs, the supply and installation shall be as covered in the relevant Project
Specification.

5.2 All parts shall be fabricated smooth, true, clean & free from burrs, creases and dents.

53 Welding shall be done by qualified and approved welders using suitable fillers and fluxes.

5.4 Welding of Support Ring

5.4.1 Carbon Steel Material

Support Rings shall be continuously welded with column shell on top as well as bottom side
or as specified in Job Specifications.

5.4.2 Other Nobler Material

In case of SS columns or in case of shell cladding with nobler metallurgy with no CA on

column internals (i.e. Incoloy, Monel etc.) support rings shall be provided with continuous
welding on top side and stitch weld (25mm @50mm pitch) or continuous welded on bottom
side.
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Page 549 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
/SafTid ENGINEERS FABRICATION OF SUPPORT
ell Meg
1.27, evenrz M13,10.1)
S INDIA LIMITED
(A Gout of India Undertaking)
RINGS AND B/BARS FOR
6-14-0007 Rev. 4
TRAYS/TOWER INTERNALS Page 5 of 6

5.4.3 No gap shall be left at the joint of bolting bar and the support ring. Refer Figure 5.4.3.1 and
Figure 5.4.3.2 below:

t_

FIGURE 5.4.3.1

NO GAP HERE

PROVIDED HERE

FIGURE 5.4.3.2

5.4.4 No welding to be done at the top and edge of support ring at support ring and bolting bar joint.
Refer Figure 5.4.4.1 and Figure 5.4.4.2 below:

FIGURE 5.4.4.1 FIGURE 5.4.4.2

5.4.5 Provide seal run weld on top and bottom of support ring at locations wherever support ring is
crossing longitudinal weld on the vessel. No gaps shall be allowed between vessel wall and
support ring.

5.4.6 In case the support ring is fabricated out of various pieces, butt weld provided on support ring
shall be ground flushed on top and bottom faces of the ring.

5.4.7 Support Ring Width (W) and minimum Thicknesses (T) shall be as per respective TSR &
B/Bar Drawings furnished by EIL or the Tray Vendors duly approved by EIL.

5.5 Welding of Bolting Bar

5.5.1 Size of the B/Bars shall be as specified in the drawings. These can, however, be
varied/adjusted to achieve the dimensions of various parts within the tolerances as specified in
the drawings.
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Page 550 of 674

 451P-ae?
2151-eu
=o) INDIA
( ENGINEERS
LIMITED
SPECIFICATION FOR
FABRICATION OF SUPPORT
RINGS AND B/BARS FOR
STANDARD SPECIFICATION No.

6-14-0007 Rev. 4
1.0, 212,1,970,3,111.1) (A Govt of India Undertaking)

TRAYS/TOWER INTERNALS Page 6 of 6

5.5.2 B/Bars wherever crossing circumferential seam of the vessel, shall be provided with seal run
weld. No gap is permitted between vessel wall and bolting bar edge.

5.5.3 The weld joint between straight and sloping downcomer shall be ground flushed. Alternately,
bolting bar may be bent by making a groove on one side and tack welding on the groove
thereafter. Refer Figure 5.5.3.1 below:

TACK WELD

BEND BB AFTER
MAKING GROOVE

FIGURE 5.5.3.1

5.5.4 Bolting Bar Width (W) and Thicknesses (T) shall be as per respective TSR & B/Bar Drawings
furnished by EIL or the Tray Vendors duly approved by EIL.

6.0 INSPECTION AND ACCEPTANCE

6.1 Correct location and fixing of tray support rings/bolting bars and the support cleats are
extremely important for smooth installation of the trays and internals at the site. It is
absolutely necessary that careful inspection of the supports welded to the shell is done in the
shop floor in order to avoid unnecessary delays and inconvenience during the installation of
trays and internals inside the column at site.

It is the responsibility of the vessel fabricator to ensure that all the supports are welded as per
drawing/standards/specification and 100 percent checked by the fabricator's inspection
department before offering the same for inspection by Owner's representative/nominated
inspection authority. Records of fabrication and quality check shall be maintained by the
vessel fabricator duly counter checked by Owner's representative/authorized inspection
authority.

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Page 551 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
tkl ENGINEERS
fr-s8) INDIA FOR
*Igen fEttaift LJMTED 6-14-0008 Rev. 6
(A Govt 01 India undertakm
TRAYS AND TOWER
INTERNALS Page 1 of 12

t, 74 dm *1-dlicril
q i1ckiwi

STANDARD SPECIFICATION
FOR
TRAYS AND TOWER INTERNALS

6 25.09.17 REAFFIRMED & REISSUED AS STD. SPEC.

SK/I WSJ RKT ' SRN
5 05.12.11 REVISED AND REISSUED AS STD. SPEC.
DSG IK / KKG AKG DM
4 12.07.06 REVISED AND REISSUED AS STD. SPEC.
RSR HCN AKM VJN
3 25.05.00 REVISED AND REISSUED AS STD. SPEC.
SKM HCN RKA MI
2 06.03.00 REVISED AND REISSUED AS STD. SPEC.
SKM HCN RKA AS
Standards Standards
Rev. Committee Bureau
Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

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Page 552 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
k`511Welt'?("ENGINEERS
Ogen Ofzie-G- W INDIA LIMITED FOR 6-14-0008 Rev. 6
ew.,,45,3`WO (A Govt. ol India Undertaking)
TRAYS AND TOWER INTERNALS Page 2 of 12

Abbreviations:

AIA Authorized Inspection Agency

ASME : American Society of Mechanical Engineers
ASTM : American Society for Testing and Materials
AWS : American Welding Society
CAD : Cost Analysis Datasheet
CD Compact Disc
ELCB : Earth Leakage Circuit Breakers
GAD : General Arrangement Drawing
LPG Liquefied Petroleum Gas
PQR • Procedure Qualification Record
PQT • Procedure Qualification Test
TIG : Tungsten Inert Gas
TSRBB: Tray Support Ring & Bolting Bar
WPS : Welding Procedure Specification

Static Equipment Standards Committee

Convenor: Mr. R.K. Trivedi

Members: Mr. K.J Hari Narayanan

Mr. P. Bhattacharjee
Mr. Sanjay Mazumdar
Mr. P.P. Pandey
Mr. Nalin Kumar
Mr. K. Anjaneyulu
Mr. Arun Kumar
Mr. Inder Kumar
Mr. Tarun Kumar
Mr. Anish Trehan
Mr. Srikanth Karanam
Mr. M. Azim (Projects)
Mr. S. Ghosal (Process)
Mr. T. Kamalakannan (Inspection)

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Page 553 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
Wei& ENGINEERS
5ifgar fairdg INDIA LIMITED FOR 6-14-0008 Rev. 6
Govt of India Undertaking) TRAYS AND TOWER INTERNALS Page 3 of 12

CONTENTS

1.0 INTENT 4

2.0 DEFINITION 4

3.0 SCOPE OF WORK & SUPPLY 4

4.0 INSTRUCTIONS FOR PREPARATION OF DRAWINGS 5

5.0 MATERIALS 5

6.0 FABRICATION 7

7.0 SPARES 8

8.0 INSPECTION AND TESTING 9

9.0 PACKING, MARKING AND SHIPPING 11

10.0 SITE INSTALLATION AND SUPERVISION 11

11.0 GUARANTEES 11

12.0 VENDOR DATA REQUIREMENT 11

13.0 AS BUILT DOCUMENTATION 12

14.0 DATA FOLDER 12

15.0 REFERENCES 12

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Page 554 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
o9faei MENGINEERS
LII MVP' INDIA LIMITED FOR 6-14-0008 Rev. 6
1.17,, 212=2 msi3rm..0 (A Govt of India Undenak.g)
TRAYS AND TOWER INTERNALS Page 4 of 12

1.0 INTENT

This specification covers the general requirements for residual engineering, material
procurement, fabrication, inspection/testing, packing, supply (including spares) and
installation (inside the columns at site, if specified in requisition) of Trays and Packed Column
Internals separately and collectively known as "Internals". The requirements laid down in this
specification are minimum requirements.

Supplementary specifications indicating specific or special requirements, wherever applicable,

shall form addenda to this specification and shall govern whenever in conflict with the
provisions contained herein. Addenda, when made part of this specification, shall be
referenced in the Material Requisition and/or Purchase Order.

2.0 DEFINITION

2.1 Assembly or assemblies shall be interpreted to include all the component parts of internals
such as tray decks, weirs, downcomers, seal pans, draw-offs, baffles, risers, caps, minor/major
beams, trusses, downcomer bolting bars for trusses, clamp assembly, bolts, studs, nuts,
washers, gaskets, valves etc.. Pressure equalising pipes (vent tubes) across downcomers are
standard feature of three/four pass trays.

2.2 The materials required for fabrication and supply of Support Rings and Bolting Bars welded to
the vessels are not included in scope of work/supply of internals vendor for new vessels and
shall be supplied as welded with the columns by column fabricators. For revamp jobs, support
rings, bolting bars required for modifications shall be included in internals vendor scope of
work/supply, unless specified otherwise. In addition to this, for all revamp jobs, all
material/facilities required for Hydrogen Diffusion Treatment (if specified in the requisition)
shall be in vendor's scope of supply. However, any material required for
modification/replacement of existing nozzles on the columns shall be excluded from vendor's
scope of work/supply.

3.0 SCOPE OF WORK & SUPPLY

3.1 EIL shall furnish Tray Supporting Ring & Bolting Bar Drawings (TSRBB drawing) and
Layout Sketches, if specified in Material Requisition / Purchase Requisition.

3.2 The illustrative scope of work and major responsibilities are as mentioned below.

(In case tray installation is not included in vendor's scope of work, relevant clauses shall be
read and deemed rectified accordingly.)

3.2.1 Based on drawings or data furnished by EIL, vendor shall prepare TSRBB drawings, General
Arrangement Drawings (GADs) and Bill of Material for all the Internals as per instructions
given in Clause 4.0.

3.2.2 Drawings shall be submitted to EIL/Owner for review prior to start of the fabrication as per
Vendor Data Requirements given in the requisition. Bill of Materials shall be submitted to
EIL/Owner for information/records only. In case of licensed units, drawings shall also be
reviewed by Process Licensor. Licensor's comments, if any, shall be taken care by vendor
without any cost impact.

3.2.3 Drawing Index (for all internals of all columns included in Purchase Requisition) shall be
submitted within 2 weeks of order and updated index (indicating status of other column
internal drawings) along with each submission.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS
51gel faiteg INDIA UMTED FOR 6-14-0008 Rev. 6
■
IN 271 411.3.10.1) AGaR
TRAYS AND TOWER INTERNALS
Unde"'"))
Page 5 of 12

3.2.4 All drawings for a particular column shall be submitted in a single lot. Spares shall be
included in the part of supply.

3.2.5 Proceed with ordering of materials / bought-outs and fabrication after receipt of approval.

3.2.6 Arrange for stage-wise inspection of Internals. EIL would normally be the inspection agency
for all Indian supplies, unless otherwise specified in the requisition.

3.2.7 Packing, despatch, transportation, insurance etc.

(Caution: Internals shall not be despatched unless all the approvals are received.)

3.2.8 Safe storage during installation of Internals including leak testing wherever required in the
columns. This shall be done by an agency well versed in the installation of Internals and who
have carried out such activities in the past. Reference list of such an agency shall be
furnished.

3.2.9 "Supervision during Installation" of Internals and certify the column as good for boxing-up
and operation.

3.2.10 Submit bound sets of all data/drawings (As built) along with specifications, material test
reports for all components, tolerance standards, installation instructions, inspection
procedures, reports of leak testing at site etc., for each column as per Vendor Data
Requirements for records and future reference. The documentation may be so compiled in
different volumes to facilitate their submission at various phases of the project.

4.0 INSTRUCTIONS FOR PREPARATION OF DRAWINGS

Refer Specification N. 6-14-0018, for guidelines for preparation of Drawings. In case TSRBB
drawings and Layout drawings / sketches are furnished by EIL, relevant clauses shall be read
and deemed rectified accordingly.

5.0 MATERIALS

5.1 All materials unless specified otherwise in requisition shall be part of vendor's scope and shall
conform to those specified in the respective drawings or Cost Analysis Data Sheets (CADS)/
Mechanical Detail Sheets furnished along with the requisition.

No substitution of material will be permitted without the written consent of EIL/ Owner in
required formats as per procedure. In case substitution of material is proposed, vendor shall
clearly indicate the reasons for requiring such change and give chemical and physical
properties of the proposed alternate material with their standard specification number.

All materials supplied by vendor shall be new and of first quality supported with mill test
certificates. The inspector shall check material test certificates and identify the material used
for internals. In case test certificates are not available, check test shall be carried out.

All bolting shall be minimum M10 size for internals and minimum M16 for lattice girders.
All bolting shall have threads on full length of bolt, unless otherwise indicated in standards /
drawings. In addition to stamping, the specification and manufacturer's symbols as specified
in ASME Material specifications, on one of the ends, the size the studs shall be clearly punch
marked. Similarly the nuts shall have the size punch marked on one of the face. In case of
tapped hole, the size shall be punch marked near the hole without disturbing the gasket sealing
area.

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 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
el ENGINEERS
Oge..11 idt5teg INDIA LIMITED FOR 6-14-0008 Rev. 6
INIFTF 2120,17¢“J.R1.1)
Unde"") TRAYS AND TOWER INTERNALS Page 6 of 12

Unless specified in data sheets, material shall be as per clause from 5.2 to 5.8.

5.2 12 Cr Stainless Internals

All sheet and plate material shall be in accordance with SA 240 Type 410/ 410S or 405 having
No.1 finish. For thickness upto 4.0 mm, no. 2B/2D finish is also acceptable.

All bolting material shall be 12 Cr - SA 193 Gr B6X or B6 for bolts and SA 194 Grade 6 for
nuts and lock-nuts.

5.3 16 Cr - 12 Ni Stainless Internals

All sheet and plate material shall be in accordance with SA 240 Type 316/ 316L having No.1
finish. For thickness upto 4.0 mm, no. 2B/2D finish is also acceptable.

For sheet material SA 240 Type 316/ 316L, all bolting material shall be SA 193 B8M for bolts
and SA 194 Gr.8M for nuts and lock nuts. For sheet material SA 240 Type 316L, Carbon
content shall be <= 0.03% for bolting material.

5.4 18 Cr - 8 Ni Stainless Internals

All sheet and plate material shall be in accordance with SA 240 Type 304/ 304L having No.1
finish. For thickness upto 4.0 mm, no. 2B/2D finish is also acceptable.

For sheet material SA 240 Type 304/ 304L, all bolting material shall be SA 193 B8 for bolts
and SA 194 Gr.8 for nuts and lock nuts. For sheet material SA 240 Type 304L, Carbon
content shall be <= 0.03% for bolting material.

5.5 Monel Internals

All sheet and plate material shall be in accordance with SB 127 in hot rolled, annealed and
pickled condition.

All bolting material shall be Monel, made from rod or bar stock SB164.

5.6 Carbon Steel Internals

Unless otherwise specified, sheets and plates shall be procured in hot rolled conditions and
shall be free of mill scale. Material shall be suitable for bending. The bend test specimens
shall stand being bent cold through 180 degree without cracking on outside of the bent
portion, to an inside diameter equal to or less than twice the thickness of the specimen or as
per relevant material specification, whichever is severe. All sheet, plate material shall
conform to SA283, SA285 or better unless specified otherwise on the Drawings/Cost Analysis
Datasheets.

All fasteners including clamps, material shall be as per clause 5.2 above, unless specified
otherwise.

5.7 Gaskets

Gasketing material shall be fabricated from Asbestos Free Material such as Woven Fiber-
glass Tape (Amatex-G36-P752 or equal), Woven Teflon Tape, Woven Expanded Flexible
Graphite Tape, Soft Graphite or Ceramic Fiber Tape etc. and shall be suitable for process fluid
and column design temperature, unless specified otherwise in the Data Sheets/ Purchase
Specifications. The thickness of the woven tape shall be 1.5mm minimum.

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 elei E ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.

Ogeir Riitez
(werr maw
INDIA LIMITED FOR 6-14-0008 Rev. 6
4313W.1) Govt of India Undedal..9)
TRAYS AND TOWER INTERNALS Page 7 of 12

5.8 Support rings, downcomer or upcomer bars and other parts welded to vessel for revamp jobs
shall be of same metallurgy as that of vessel.

For cladded vessels, the material of support rings, downcomer or upcomer bars and other parts
welded to vessel directly shall be of same metallurgy as that of the cladding.

6.0 FABRICATION

6.1 Dimensions

The dimensions shown on the drawings are final and shall be maintained within the tolerances
furnished either on drawing itself or in the standards/specifications referred on the drawings.
In case of conflict between dimensions given on drawings and standards/specifications,
dimensions given on drawings are to be considered final.

6.2 Tolerances

All sections shall be truly flat within 2 mm and shall be free from burrs & weld spatters.

Tolerances wherever unspecified to be taken as ±1 mm & not to be accumulative, except on

thickness and assembly diameter. Tolerance on thickness shall be as per applicable
specification and tolerance on assembly diameter shall be as below:

Cartridge Trays D

Other Assemblies D 1500, DiT

1500 < D 4500, D_To
D > 4500,D:10

63 Welding

6.3.1 All welding shall be done by metal arc welding. For welding on thinner gauge sheets TIG
welding is preferred.

6.3.2 Gas or Carbon arc welding shall not be used.

6.3.3 Welding electrodes of composition similar to Internals material shall be used except austenitic
electrodes of higher chromium & nickel content such as AWS A5.4, ASME SFA 5.4 class
E309 & E310 may be used for 12 Cr stainless steel. For dissimilar material welding, electrode
composition shall be similar to nobler material being welded. Following electrodes shall be
used unless specified otherwise in the drawings.

E 7018 for all CS material

E308 for all SS 304 to SS 304
E 308L for all SS 304L to SS 304L
E-309 MoL for SS 4105 to SS 410S *, SS to CS and SS 410S to SS 304, 304L, 316, 316L
E-316 for SS 316
E-316L for SS 316L
E Ni Cu7 for Monel to Monel and Monel to CS/SS **

* For chloride service, for welding of SS410S to SS410S, 1' run shall be of E309MoL and
subsequent layers with E 410 / ER 410 to meet the service conditions.

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Page 558 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
elei ENGINEERS
Ig-41 Rift INDIA LIMITED FOR 6-14-0008 Rev. 6
I MEW 212O8 .2 4,13.1i7.1) (A GoN of India Undertak.91
TRAYS AND TOWER INTERNALS Page 8 of 12

** For Monel to CS/SS welding, 1St run shall be of ENi (Pure nickel) and subsequent layers
with ENiCu7 to avoid cracking problems.

6.3.4 Welding wherever specified, shall be done by qualified and approved welders using the
suitable fillers and fluxes recommended for the materials. For welding the stud on tray decks
or support beams, use of stud welding gun with suitable flux is acceptable. In manually
welding the studs, care should be taken to minimise the weld spatter and the outside diameter
of the weld so that it should not foul with tray deck or washer. For stud welding, proper
welding procedure shall be established. Torque required for welding failure shall be higher
than the torque required for failure of the stud.

6.3.5 A proposed Welding Procedure Specification (WPS) shall be submitted to Authorized

Inspection Agency (AIA) for approval. On approval, a Procedure Qualification Test (PQT)
shall be conducted which shall be witnessed by AIA. On acceptance of all tests as per ASME
Section IX, a final WPS along with Procedure Qualification Record (PQR) shall be submitted.
Production welding shall start only after approval of final WPS/PQR and qualification of
welders as per ASME Section IX. AIA may accept previously qualified WPS/PQR at his sole
discretion.

6.4 General Construction

6.4.1 All parts fabricated shall be smooth, true, clean, free from burrs, grease and dents. Openings
for passage of workman must have exposed edges rounded.

6.4.2 All parts shall be fabricated in accordance with good shop practice and in uniformity so that
all corresponding parts will be inter-changeable.

6.4.3 Construction of trays and tower internals shall be strictly as per approved drawings. If any
mismatch is found on dimensions, fabrication work shall be taken-up only after getting
clarification.

6.4.4 Perforation in sieve trays must not come over support beam flanges.

6.4.5 All punching shall be done from top side of plate, unless specified otherwise in the drawing.

6.4.6 All stainless tray assemblies/internals and their component shall be pickled and passivated as
per ASTM A-380.

6.4.7 Bubble Caps may be heat treated during various stages of fabrication for case of forming. On
completion of forming, bubble caps shall be annealed and pickled (stainless steel caps only).

6.4.8 Single bolt beam end connections shall not be permitted.

6.4.9 Trays / Internals are/shall be configured in such a way that no joint is provided in tray decks in
active area. However, Loose beams, Downcomers, Seal pans, Recessed seal pans etc. in
thickness 3 mm & higher with length more than 3000 mm are permitted with welded joint
with backing plate. Butt joint shall preferably be at 45° angle.

7.0 SPARES

For packings, bulk volume indicated includes margins. In addition, following constructional
and operation spares shall be included in supply

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Page 559 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
eitz? rro
j ENGINEERS
**gem INDIA LIMITED FOR 6-14-0008 Rev. 6
,01,277 idkiteg
2178,12 EISIJWICH) IA Gout UndertakIng)
TRAYS AND TOWER INTERNALS Page 9 of 12

a) Constructional Spares

Bolts/Nuts 10% of total for each size (minimum 10 nos. of each

size).
Clamp assemblies 10% of total for each type and size (minimum 10 nos.
of each size).
Valves for trays 5% of each type
Bubble caps 5% of each type and size
Gasketing or tapes 100% of each type and size
Sealing foils for cartridge trays 200% of each size
U-clamps 10% of each type and size or 1 no. whichever is more.
Tower Packings (Random) 10% for Metallic and Plastic Packings
15% for Carbon and Ceramic Packings
Spray Nozzles (for each type)
Upto 25 Nos. 100%
25 - 100 Nos. 25 Nos.
Above 100Nos. 25%

b) Operational Spares

Valves for trays 10% of each type

Bolts/Nuts 10% of total of each type and size (minimum 10 nos. of
each size)
Clamp Assemblies 10% of total of each type and size (minimum 10 Nos.
of each size)
Gaskets or Tapes 100% of each type and size
Seal Foils for Cartridge Trays 200% of each size
Spray Nozzles 25% (subject to 5 nos. of each type)

8.0 INSPECTION AND TESTING

8.1 General

8.1.1 The materials, fabrication, testing and trial assemblies are subject to inspection by EIL/Owner
and/or their designated representative at shop floor before shipment.

8.1.2 Any rejection made by Inspector shall be final. Approval/Inspection by ELL/Owner and/or
their designated representative shall in no way relieve the vendor of his responsibility to meet
all the requirements of the Purchase Order.

8.1.3 EIL/Owner's inspectors shall have free entry to the vendor's shop at all times where and while
the work is being performed. The vendor shall offer the inspectors all reasonable facilities to
satisfy them that the materials are being furnished in accordance with the specifications.

8.1.4 EIL/Owner's Inspectors will cooperate with the vendor in so far as is possible to minimise any
interferences with the operation of the vendor's shop.

8.1.5 The vendor shall notify EIL/Owner sufficiently in advance of any fabricating operations to
permit the inspector to arrive at the vendor's shop.

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Page 560 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
Ofgra-e7 11—r& ENGINEERS ,
FOR
Oge.JI INDIA LIMITED
1.2Pr 1205,7 dAJ4001)
TRAYS AND TOWER INTERNALS
6-14-0008 Rev. 6
Ind* U'den"9)
Page 10 of 12

8.2 Stage Inspection during Fabrication

8.2.1 Dimensions

The inspector will check that the thickness and the dimensions of all parts for the Decks,
Weirs, Seal and Draw off pans, Downcomers, Draw-off pipes, Supports, Beams, Valves,
Bubble caps, Clamps, Studs, Bolts, Nuts, Risers, Washers and Gaskets etc. are as per the
approved drawings.

8.2.2 Fabrication

The inspector shall check each individual part of the equipment fabricated as per approved
drawings and specifications. For instance, for the Bubble cap dimensions, height, width and
number of slots, heights, Outside Diameter and Inside Diameter for riser and cap, shroud ring
height, exit and inlet weirs height etc. shall be measured. The inspector will check that all
identical parts shall be interchangeable.

Inspector shall check that the sharp edges on the Internal components, manway covers, weirs,
downcomers etc. are properly removed. Also that all burrs from punched holes and loose
weld slag and materials are removed from all components. Stage-wise inspection during
fabrication will be thoroughly carried out. Before starting welding, welders' qualification test
will be carried out, if required, as per ASME Sec. IX. Where number of similar items are to
be manufactured, inspector shall give the clearance for the fabrication of the lot only after
checking and approving the first sample piece.

83 Trial Assembly

One tray of each size, type and variety with its accessories shall be assembled on a test fixture
resembling the tower, inside the fabricators' shop. The components for such an assembly will
be taken at random from each lot of identical items. The assembled tray shall be carefully
checked for its dimensions, tolerances, number and arrangement of perforation, the working of
the valves in case of valve trays, V-notch or Blocked Weir, adjustability of weir, vent tube
details, downcomer clearance, weir heights, downcomer length and width, number of clamps,
gaps and potential leakage points etc.

The assembly shall also be checked for each type of packed tower internals.

Inspector will also check the flatness and deflection of the trays, internals, beams, tray edges
and beam ends clearance.

8.4 Leak Testing

Gasketted Bubble Cap Trays, Collector trays, Liquid holding portion of other tray components
such as Seal pans, Recessed seal pans, Draw-off pans, Distributors and Redistributors shall be
subjected to leakage test at shop floor as well as in the field by filling water upto weir level or
upto normal liquid level as the case may be. Seal pans & recessed seal pans need not be leak
tested at shop floor if fabricated in single piece and installation is also included in tray
vendor's scope.

Appropriate ring fixture or a portion of column shell with supports for seal pan/recessed seal
pans/draw off box etc. shall be made by Vendor to facilitate leak testing in the shop.

Leak testing shall be carried out with service gaskets and drain holes temporarily plugged.
Leakage rate permitted shall be as specified on the respective drawings of the internals.

For welded internals, the leak testing shall be done at site only, after welding of internals.

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 uo ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.

4igea Eil aleg

(WM 212011E• =JOUR.
INDIA LIMITED
Govt al incha unded*.9)
FOR
TRAYS AND TOWER INTERNALS
6 14 0008 Rev. 6
- -

Page 11 of 12

9.0 PACKING, MARKING AND SHIPPING

All trays and tower internals shall be packed and supplied as per EIL Spec.No.6-14-0009.
Packing shall be suitable for a minimum period of 6 months at site on covered hardstand in
original cases.

10.0 SITE INSTALLATION AND SUPERVISION

10.1 Installation of trays, tower internals, tower packings and associated components shall be as per
Specification No. 6-14-0003 and the General Arrangement Drawings for each column duly
approved by EIL/Owner. All requirements of the drawing shall be complied in totality.

10.2 Safety, Health and Environment

Vendor shall arrange for installation of an exhaust fan for exhaling welding/ cutting fumes etc.
and to maintain adequate oxygen level, before any work is started inside confined spaces (i.e.
columns). Adequate ventilation shall be maintained at all times. Gas/LPG cylinders shall not
be taken inside confined space. When a worker/supervisor enters a confined space, it shall be
mandatory to have a second man as stand by. Safety belts shall be worn while entering
columns, if there is a danger of falling. All ladders/stair cases shall be in place before any
item is offered to EIL/Owner's Inspectors. Rope ladders/scaffolding shall be provided inside
the column in case trays are not easily approachable from column manhole. Low voltage
(24V) lamps equipped with guards shall be used to prevent accidental contact with bulb. All
electrical connections shall be through Earth Leakage Circuit Breakers (ELCB) and proper
earthing shall be ensured. Acids and other materials used for pickling shall be disposed off to
a designated place as directed by EIL/Owner. All statutory regulations and owner's safety,
health and environment requirements shall be complied with. Inspection aids for carrying out
the inspection of internals shall also be provided.

10.3 It shall be the responsibility of the vendor to provide trained engineers to supervise the
erection of trays, packings and internals to ensure that these are assembled properly and meet
the expected leakage rates and tolerances. The Vendor's engineer shall satisfy himself before
offering to EIL/Owner specialist for review that the column is having all Internals duly and
correctly fitted, clean and without leakage (as required per drawings) and bolts are tight with
lock-nuts (wherever specified). The leakage test data, levelness of each tray and other
dimensions as per specification no. 6-14-0016 shall be recorded.

10.4 The Internals shall be reviewed by EIL/Owner specialists as per EIL Specification No.6-14-
0016, after vendor has satisfied himself with the quality of installation. In case of Licensed
units, internals shall also be reviewed by Process Licensor's representative before boxing-up
of manways / manholes.

11.0 GUARANTEES

Vendor shall guarantee all items supplied by him against defective material, poor
workmanship and improper failure from normal usage for a period as specified in Commercial
Terms and Conditions.

12.0 VENDOR DATA REQUIREMENT

Vendor shall furnish drawings as per Vendor Data Requirements given in the requisition.

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 . ti

STANDARD SPECIFICATION STANDARD SPECIFICATION No.

ENGINEERS
**gem felfitez INDIA LIMITED FOR 6-14-0008 Rev. 6
GO' t Unde"'rg) TRAYS AND TOWER INTERNALS Page 12 of 12

13.0 AS BUILT DOCUMENTATION

Shop changes made by Vendor after approval of drawings under Code-1 by EIL and
deviations granted in deviation permits, if any, shall be marked in hard copy of drawings
which shall then be stamped 'As-built' by the vendor. These 'As-built' drawings shall be
reviewed and stamped by Authorised Inspector also. Vendor shall prepare scanned image files
of all marked-up 'As-built' drawings. Vendor shall also incorporate the above changes in the
native soft files of the drawings.

Authorised Inspector shall ensure/certify completeness of Vendor's Final/As-built documents

before equipment dispatch.

In addition, vendor shall also incorporate site changes, if any, based on mismatch observed at
site and resubmit the 'As-built' documents.

14.0 DATA FOLDER

Vendor shall complete requisite copies of data folders for each column along with one set of
reproducible and electronic floppy/CD for drawings prepared on AUTOCAD 14 or later.
These folders shall contain the following documents.

a. Support Rings, Support Cleats and Bolting Bar drawings, if supplied

b. As built General Arrangement Drawings with Bill of Material for Trays and Tower
Internals.

c. Material Certificates

d. Inspection reports and leak test records.

e. Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR).

f. Site Installation Records.

Without receipt of data folders, supply shall be considered incomplete.

15.0 REFERENCES

6-14-0003 Installation Procedure for Trays and Tower Internals.

6-14-0009 Packing, Marking and Shipping Specifications for Trays and Tower Internals.

6-14-0016 Standard Specification for Review of Site Installation of Column Internals.

6-14-0018 Specification for preparation of TSRBB / GA Drawing.

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Page 563 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
101 ENGINEERS FOR TRAYS AND TOWER
0151eg INDIA LIMITED 6-14-0015 Rev. 4
.271 04,114, INTERNALS (UN-ENGINEERED) Page 1 of 25

t7-4 dIcK 6\4i '( 61 )

Hfrich

STANDARD SPECIFICATION FOR

TRAYS AND TOWER INTERNALS
(UN-ENGINEERED)

REVISED AND RE-ISSUED AS STANDARD

4 29.07.20
SPECIFICATION
REVISED AND RE-ISSUED AS STANDARD
3 12.03.14 UT AK/SKM AP SC
SPECIFICATION
REVISED AND RE-ISSUED AS STANDARD
2 09.03.09 IK SKM/HCN AKG ND
SPECIFICATION
REVISED AND RE-ISSUED AS STANDARD
1 16-12-03 SKM HCN/SKK RKA SKG
SPECIFICATION
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

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Page 564 of 674

 18itf5ta€4 ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
faP12...q ILIA UMITED
1 NWT everfwmaknali Gan a Inda unoonarong)
FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 2 of 25

Abbreviations:
AIA Authorized Inspection Agency
ASME American Society of Mechanical Engineers
AWS American Welding Society
CD Compact Disk
CS Carbon Steel
CV Coefficient of Variation
ERW Electric Resistant Welding
ELCB Earth Leakage Circuit Breaker
GAD General Arrangement Drawings
GTAW Gas Tungsten Arc Welding
HDS Hydraulic Data Sheet
HETP Height Equivalent to Theoretical Plate
HVGO Heavy Vacuum Gas Oil
ID Internal Diameter
LPG Liquefied Petroleum Gas
LSTK Lumpsum Turnkey
MOC Material of Construction
MR Material Requisition
OD Outside Diameter
PDS Process Data Sheet
PL Process Licensor
PMC Project Management Consultant (This shall be EIL unless specified
otherwise).
SS Stainless Steel
TIG Tungsten Inert Gas

Static Equipment Standards Committee

Convenor: Mr. K.Anjaneyulu

Members: Mr. Sanjay Mazumdar

Mr. Arun Kumar
Mr. Inder Kumar
Mr. Tarun Kumar
Mr. Anish Trehan
Mr. Srikanth Karanam
Mr. Neeraj Agarwal (Projects)
Mr. S. Ghosal (Process)
Mr. T.Kamalakannan (Inspection)

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 `i1k ut at ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
Ogrj
WW1
f evaore 41.
INDIA LIM1 1 ED
Govt Uroeftakinql
FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 3 of 25

CONTENTS

1.0 INTENT 4

2.0 SCOPE OF WORK 4

3.0 DESIGN 6

4.0 FABRICATION AND SUPPLY 14

5.0 INSPECTION AND TESTING 17

6.0 SITE INSTALLATION AND SUPERVISION 19

7.0 VENDOR DATA REQUIREMENTS 20

8.0 SHIPPING 22

9.0 EVALUATION OF BIDS 23

10.0 GUARANTEE REQUIREMENT 23

11.0 PATENT INFRINGEMENT 23

12.0 LIST OF ATTACHMENTS 23

ANNEXURE - I TRAY DATA SHEET 24

ANNEXURE - II PACKED COLUMN DATA SHEET 25

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Page 566 of 674

 ,_19ta4t1- ftENGINE.ERS
;--- STANDARD SPECIFICATION STANDARD SPECIFICATION No.
Lll &Reg W INDIA LIMITED FOR TRAYS AND TOWER
Go., w intia 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 4 of 25

1.0 INTENT

This specification covers the general requirements for hydraulic and mechanical design,
engineering, procurement of material, fabrication, inspection/testing, packing, supply and
installation (in the columns at site) of Trays, Packed Column Internals and Tower
Packings separately and collectively known as "Internals". The requirements laid down in
this specification are the minimum requirements. Supplementary specifications indicating
special or specific requirements, wherever applicable, shall form addenda to this
specification and shall govern whenever in conflict with the provisions contained herein.
Addenda, when made part of this specification, shall be referenced in the Material
Requisition and/or the Purchase Order.

2.0 SCOPE OF WORK

2.1 All relevant data required for hydraulic design of Internals shall be furnished to vendor.
This data may include fluids handled, operating pressures, pressure drops, temperatures,
flow rates, fluid properties including foaming characteristics, number of theoretical
stages required above and below the feed/number of actual trays to be used, type/height
of packings, type of Internals to be used, column diameter, tray spacing, detail's of
demister, mist eliminator, spray nozzles, baffles, vortex breakers etc. Over design and
turndown requirements shall also be furnished.

2.2 The illustrative scope of work and major responsibilities of Internals vendor are given in
clauses 2.2.1 to 2.2.13. All other activities required to ensure the proper design and
operation of the Internals over the entire range of loadings, whether explicitly stated or
not, are implied.

2.2.1 Carry out the hydraulic design of trays, associated Internals like collector trays, internal
piping, feed arrangement, demisters, de-entrainment baffles etc. In case of packed beds,
the design shall include packings selection, HETP calculations, pressure drop
calculations, capacity check, heat transfer adequacy check and design of associated
support plates, bed limiters, liquid distributors, pipe headers, vapour distributors,
collector trays etc.

2.2.2 Review of Elevations & Orientations of Process Nozzles and Manholes, Process fluid
feed/withdrawal arrangements etc.

2.2.3 Summarize the hydraulic design in the form of the data sheets attached as per Annexure-I
and II for trays and packed columns respectively. Alternatively, vendor may use their
own formats for hydraulic design, ensuring all the details as required in EIL formats are
available in Vendor's format. These data sheets along with back-up
calculations/computer outputs and vendor's catalogues shall be submitted for review prior
to proceeding for mechanical design of Internals.

2.2.4 Carry out the mechanical design of Internals etc. for the type and quantum of design
loadings covered elsewhere in this specification.

2.2.5 Prepare the support rings/support cleats and bolting bars drawings for fabrication. Co-
ordinate with pressure vessel vendor for nozzles elevations & orientations and welding of
the support rings/support cleats and bolting bars etc. The set of drawings for support
rings/support cleats shall include the following as a minimum:

• Column sketch indicating location of Tray support ring.

• Support Ring plan with location of bolting bars, slot centers and applicable tolerances.

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 4°I ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
eir telffteg
1.11P71 PRP,41)
CIA LIMITED
A Gore oe inwa Veeele.*$rege
FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 5 of 25

• Sectional details with applicable tolerances.

• Material of construction. (MOC of welded attachment shall be compatible with MOC
of Shell).
• Extent and details of welding requirement for support rings/bolting bars/support cleats.
• Feed pipe arrangement details with Nozzle orientation.

2.2.6 Prepare the detailed General Arrangement Drawings (GAD's) of all the Internals along
with part detail/fabrication drawings and Bill of Material. These drawings shall be
submitted for review/information prior to start of the fabrication, as per Vendor Data
Requirements. The GAD's for Internals shall include the following as a minimum:

• Column sketch indicating Tray/tower internal elevation.

• Tray related information like Exit Weir Height, UDF Clearance, Inlet Weir Height,
total weight of trays/internals and weight of heaviest component etc. on first sheet of
GAD.
• Fully dimensioned PLAN view clearly showing the layout of valves/bubble
caps/orifices/risers or as the case may be. (Part Plan are NOT ACCEPTABLE)
• Sectional views illustrating the installation of internals.
• Mechanical design parameters such as beam depths, thickness etc.
• Material of construction.
• Item numbers of individual segments that should also tally with the bill of material
prepared by the vendor and shall be marked on plan and sectional views.
• Bill of material indicating item number, number of various components, thickness,
weight of heaviest components and total weight.

2.2.7 Proceed with fabrication/ordering and supply of Internals after receipt of approval.

2.2.8 Arrange for inspection of Internals as per approved ITP.

2.2.9 Arrange for packing, dispatch, transportation, insurance etc. and receipt of all internals at
site.

2.2.10 Arrange for storage at site during installation to avoid any deterioration. The mode to be
adopted for storage of Internals at site shall be suitable for a minimum period of 6
months. These shall be stored on covered hard stand in original boxes.

2.2. 1 1 Arrange for installation of Internals in the columns, in case specified in the requisition.
This shall preferably be done by the vendor himself In case, vendor decides to get the
installation work done by some agency other than the vendor himself, the agency
selected by the vendor shall be well versed in the installation of Internals and who have
carried out such activities in the past. Reference list of such an agency shall be furnished
for approval. In such a case, installation shall be carried out under vendor's supervision.

2.2. 1 2 Arrange for installation supervision of Internals by experts in mass transfer along with
leak testing wherever required and certify the column as good for boxing and operation.
Certification for box-up of column shall be provided by tray designer. All installed
internals shall also be finally checked and cleared for box-up by Process Licensor (In
case of licensed units) and Owner's representative.

2.2. 1 3 Submit final data folder (As Built Documents) as per contract document and reports of
leak testing at site, for each column along with one set of electronic files (pdf etc.) in Pen
Drive / CD of all documents for records and future reference. The documentation may be
so complied in different volumes to facilitate their submission at various phases of the
project.

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 laPilett4 ft ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ziffaiteZNI,INDIA LIMITED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
• Go,• of India UmbertoOongi
INTERNALS (UN-ENGINEERED) Page 6 of 25

2.2.14 Vendor to Submit / Upload all documents through V-Portal only.

Notes:

(1) In case hydraulic design is not included in vendor's scope of work as per requisition,
relevant clauses shall be read and deemed rectified accordingly.

(2) If vendor desires to sub-order hydraulic and/or mechanical design, it shall be done
only by reputed regular designers of Internals. Reference list of sub-vendor shall be
furnished for Owner/PMC approval.

3.0 DESIGN

3.1 Materials

3.1.1 All materials shall conform to those specified in the respective process drawings or data
sheets.

No substitution of material will be permitted without the written consent of Owner/PMC

in required formats as per procedure. In case substitution of material is proposed, vendor
shall clearly indicate the reasons for requiring such change and give chemical and
physical properties of the proposed alternate material with their standard specification
number.

All the material supplied by vendor shall be new and of first quality supported with mill
test certificates.

The inspector shall check material test certificates used for internals. In case test
certificates are not available, check test shall be carried out.

All bolting shall be minimum M10 size for internals and minimum MI6 for lattice girders.
All bolting shall have threads on full length of bolt, unless otherwise indicated in
standards /drawings. In addition to stamping, the specification and manufacturer's
symbols as specified in ASME Material specifications, on one of the ends, the size the
studs shall be clearly punch marked. Similarly the nuts shall have the size punch marked
on one of the face. In case of tapped hole, the size shall be punch marked near the hole
without disturbing the gasket sealing area.

Unless specified in data sheets, Material shall be as per clause from 3.1.2 to 3.1.7.

3.1.2 11-13 Cr Stainless Internals

All sheet and plate material shall be in accordance with SA 240 Gr 410/ 410S or 405
having No.1 finish. For thickness upto 4.0 mm, No. 2B/2D finish is also acceptable.

All bolting material shall be 12 Cr - SA 193 Gr B6X or B6 for bolts and SA 194 Gr 6 for
nuts and lock-nuts.

3.1.3 16 Cr - 12 Ni Stainless Internals

All sheet and plate material shall be in accordance with SA 240 Gr 316/ 316L having
No.1 finish. For thickness upto 4.0 mm, No. 2B/2D finish is also acceptable.

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 311aelt4 ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
faffiftwINDIA LIMITED
e.Ave IA Go, of India Unde/Ulong)
FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 7 of 25

For sheet material SA 240 Gr 316/ 3I6L, all bolting material shall be SA 193 B8M for
bolts and SA 194 Gr.8M for nuts and lock nuts. For sheet material SA 240 Gr 316L,
Carbon content shall be < 0.03% for bolting material.

3.1.4 18 Cr - 8 Ni Stainless Internals

All sheet and plate material shall be in accordance with SA 240 Gr 304/ 304L having
No.1 finish. For thickness upto 4.0 mm, No. 2B/2D finish is also acceptable.

For sheet material SA 240 Gr 304/ 304L, all bolting material shall be SA 193 B8 for bolts
and SA 194 Gr.8 for nuts and lock nuts. For sheet material SA 240 Gr 304L, Carbon
content shall be < 0.03% for bolting material.

3.1.5 Monel Internals

All sheet and plate material shall be in accordance with SB127 in hot rolled, annealed and
pickled condition. For sheet / plate thickness upto 4.0 mm, cold rolled annealed and
pickled plates are also acceptable.

All bolting material shall be Monel, made from rod or bar stock SB 164.

3.1.6 Carbon Steel Internals

Unless otherwise specified, sheets and plates shall be procured in hot rolled conditions
and shall be free of mill scale. Material shall be suitable for bending. The bend test
specimens shall stand being bent cold through 180 degree without cracking on outside of
the bent portion, to an inside diameter equal to or less than twice the thickness of the
specimen or as per relevant material specification, whichever is severe. All sheet, plate
material shall conform to IS2062 Gr E250 B, SA285, SA283 or better unless specified
otherwise on the data sheets/drawings.

All Valves, fasteners including clamps, material shall be as per clause 3.1.2 above, unless
specified otherwise.

3.1.7 Gaskets

Trays gasketing material shall be woven tape, fabricated from Asbestos Free Material
such as Woven Fiber-glass Tape (Amatex-G36-P752 or equal), Woven Teflon Tape,
Woven Expanded flexible graphite tape, soft graphite or Ceramic Fiber Tape etc. and
shall be suitable for process fluid and column design temperature, unless specified
otherwise in the Data Sheets/Purchase Specifications. The thickness of the woven tape
shall be 1.5 mm minimum.

3.1.8 Support Rings/Bolting Bars/Support Cleats

Support rings, downcomer or up comer bars and other parts welded to vessel shall be of
same metallurgy as of vessel. Minimum thickness excluding corrosion allowance of
welded parts shall be 6 mm for Vessel ID up to 3000 mm, 10 mm for ID 3000-12000 mm
and 12mm for ID>12000mm. Corrosion allowance as specified in vessel data sheets shall
be added on both sides of Support Ring, Bolting Bar and other welded parts.

3.2 Thickness of Internals

3.2.1 Corrosion Allowance

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Page 570 of 674

 Ofz&rei ft ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
5 dl Ofgtegw.;WA LIMITED FOR TRAYS AND TOWER
1.4g71 2.10.1., a Ina. undroaaaa
10 1441.41 A &ni 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 8 of 25

The following corrosion allowance shall be added to calculate thickness of Internals

unless otherwise specified on data sheets or bid specification.

i) No corrosion allowance is required for Monel or Stainless steel alloy assemblies.

ii) The corrosion allowance for all surfaces of floor of carbon steel assembly shall be
higher of 1.5 mm (total) or one quarter of Vessel corrosion allowance on each surface.

3.2.2 Minimum Thickness of Internals:

Corrosion allowance, wherever specified in the data sheets for Internals in excess of
corrosion allowance as indicated in clause 3.2.1 shall be added to the minimum thickness
specified below:
Alloy CS

i) Deck plates, seal pans, draw-off 2.0 3.5*

Pans, weirs/seal plates, Struts, other
Removable Components

ii) Welded deck plates, welded downcomer 3.0 3.5*

aprons and other welded components

iii) Down comer/Down comer pipes 2.0 3.5*

iv) Bubble Caps 1.5 2.0

Risers (fixed) 2.0 3.5*
Risers (removable) 1.5 2.0
v) Valves 1.5 (will not be used)

vi) Structured Packings 0.15 (will not be used)

vii) Support Grid for Structured Packings 5.0 8.0

viii) Support Plate for Random Packings 2.0 5.0

ix) Locating Grid/Retaining 5.0 8.0

Grid/Bed Limiter

x) Grid Packings 1.0 (As per vendor's standard)

xi) Feed Pipes (Seam Less/ ERW) Sch 40S /10thk Sch 80 /12thk

xii) Random Packings (As per vendor's standard, **)

xiii) Loose Beams To suit load To suit load

xiv) Lattice Girders

(a) Primary Members 5.0 8.0
(b) Secondary Members 3.0 6.0
(c) Gusset Plates 10.0 10.0
(d) Downcomer bolting bars 6.0 10.0

Minimum thickness specified above for CS internals, is inclusive of 1.5 mm

Corrosion Allowance.

10 USSG is also acceptable in lieu of 3.5 mm.

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 Of Pei& ftENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ogeit Ofiltgw:INDIA LIMI I ED
Mr. eVt1.21191 PILMIS G. ug India uclettano
FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 9 of 25

**
Random packing thickness shall be suitable for test load comprising of dead weight
of the packed bed + liquid load (10% for metallic & 15% for Ceramic). Maximum
compression shall be limited to 5% of the bed height without damaging the bottom
packing. Crushing Test shall be carried out to establish selected thickness if
required by Client/EIL post order.

All bolting shall be minimum M10 for Internals and M16 for Lattice Girders. All nuts
shall be hexagonal.

Minimum corroded thickness of the internals for the loading condition as per Clause 3.3.3.
(i) and (ii) below, shall be 3.0 mm.

3.3 Design Loadings

3.3.1 Design loads for tray decks shall be based on a liquid height of 50 mm liquid above weirs
plus self weight of deck plates and beams or live load of 150 kg/m2 whichever is higher.
In case liquid density is less than water, 1000 kg/m3 shall be considered for purpose of
calculating liquid load.

3.3.2 Under-down-flow plates and seal pans shall be designed to withstand self weight &
weight of liquid equal to half the normal tray spacing or 300 kg/m2, whichever is higher.
In case liquid density is less than water, 1000 kg/m3 shall be considered for purpose of
calculating liquid load.

3.3.3 Five trays above and below 2-phase feed inlets and five trays in bottom zone of column
wherever process steam / vapour feed or two-phase feed is admitted, shall be provided
with lock nuts. Trays shall be capable of sustaining a net thrust of

i) 1464 kg/m2 and shall be provided with shear clips at Beam Ends for Vacuum
Column (Stripping + Wash + HVGO Sections)
ii) 1000 kg/m2 and shall be provided with shear clips at Beam Ends for Crude Column
/ Main Fractionator Column.
iii) 450 kg/m2 for all other services.

3.3.4 One tray above and below the intermediate vapour/liquid feeds shall be provided with
lock nuts. Additionally, all lattice girders and major beam boltings shall be provided with
lock nuts.

3.3.5 Chimney / Collector Trays shall be designed to withstand a load of self weight & lower
of liquid weight of (Riser height+50mm) or (Weir height+50mm) OR 300 kg/m2
whichever is higher.

3.3.6 The packing support plate shall be designed to support the maximum expected load of
tower packings, liquid hold-up (min 10 percent for metallic & 15% for ceramic). In case
of liquid density is less than water, 1000 kg/m3 shall be considered for purpose of
calculating load due to liquid hold-up.

3.3.7 Bed limiters frame shall be strong enough to take care of surges/uniformly distributed
load of 100 kg/m2 and 135 Kg concentrated load at any point.

3.3.8 Hold down plate shall exert sufficient static load on the bed to restrict movement of the
packing. The hold down plate shall be designed for exerting a load of 100 kg/m2
minimum on the packed bed.

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Page 572 of 674

 ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
tet Oleg
.414,1 eVATA,711,14,44
INDIA LIMITED
Govl of Inds Ondertilong)
FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 10 of 25

3.3.9 Liquid distributors/Redistributor shall be designed for self weight plus maximum
expected liquid load.

3.3.10 All Internals assemblies except cartridge tray assemblies, shall be able to withstand the
self weight plus the following number of 135 Kg concentrated loads (maintenance loads)
at ambient temperature.

Vessel Diameter Number of 135 kg loads

Up to 1200 mm 1 (at center of diameter)
1201 to 3600 mm 2 (at center and 1/4 point of diameter)
Over 3600 mm 3 (at center and 1/4 points of diameter)

3.3.11 Deck plates for extra stiffened loading (as per clause 3.3.3) to be checked for skin
stresses. Same can be carried out assuming deck plates to be of rectangular shape with
uniform loading.

3.4 Allowable Stress and Deflection

3.4.1 Unless specified otherwise by licensor, allowable stresses for all Internals shall be as per
ASME Sec. II. Part D, latest edition for all design loadings as per Clause 3.3.

3.4.2 The maximum deflection of tray/tower internal assembly shall not exceed 1 mm per
meter of column diameter or 7.5 mm, whichever is lower for the design loadings given in
clause 3.3.1 and 3.3.2 above. Deflection for distributor assembly shall be limited so that
overall liquid maldistribution does not exceed the limit as per clause 3.5.18(v).
Deflection for support plate and seal pans shall be limited to L/400, where L is the length
of individual component.

3.4.3 Deflection as per clause 3.4.2 may be ignored for trays designed based on design
loadings as per clause 3.3.3 and 3.3.9.

3.4.4 For large diameter vessels (More than 6000mm), initial camber (6mm Max.) may be
made in the principal support members of the assemblies so as to limit the deflection as
specified in clause 3.4.2 above.

3.5 Arrangement/Details of Internals

3.5.1 All assemblies except one piece cartridge type trays for column ID < 750mm shall be of
removable type unless otherwise indicated. The general design, number, type and spacing
shall be established on the individual vessel drawing/data sheets. Cartridge type trays
shall be designed to rest on four support cleats. Rope Type of arrangement shall be
provided for sealing unless otherwise specified.

3.5.2 Each removable section shall be so dimensioned / sized to permit passage through vessel
manhole and shall be suitable for assembly/ dismantling from upper side in so far as
structural contingencies permit. Maximum diagonal dimension of the components shall
be restricted to vessel manhole ID - 12mm clearance.

3.5.3 Internals support trusses supporting more than one Internal, as are commonly used in
large diameter columns and which can not be installed through manholes, shall be split
into sections for access through manhole and minimising welding work inside the
column.

3.5.4 Internals decks shall have a maximum length of 4000 mm. To achieve this, maximum
distance between main support beams or girders shall be limited to 4000 mm. However,

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 Plelei ; ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
sige.iffetigreg W INDIA LIMI ED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
evra., 9.4. GoA IrOa Undeftnixincp
INTERNALS (UN-ENGINEERED) Page 11 of 25

the main support beams or girders having length more than 4000 mm shall be provided
with butt joint with splice plates of the same thickness on both sides. The butt joint shall
be off-centre from beam centre and numbers of butt joints shall be as minimum as
possible.

3.5.5 Manways

i) One(1) manway in single cross flow decks, two(2) manway in double flow decks and so
on shall be provided. These manway shall be freely removable from top and bottom.
Manway shall be in the same vertical line for a set of trays. These shall be at such a
location and of a shape and size to permit easy access to every area of the tray. Manway
of different set of trays (about 20 trays) shall be staggered to each other. Minimum clear
opening on tray shall be 380mmx450mm.

ii) Where manway cannot be provided, decks shall be split (turn-up - turndown) to provide
suitable access for Inspection and assembly from top as well as bottom.

3.5.6 Unless specified otherwise, support rings, bolting bars, support bracket/cleats when
required shall be designed for welding to the vessel. All other parts shall be designed for
bolting or clamping in place. Clamping shall be used on Tray floor and all downcomer/
upcomer shall be through bolted. Spacing of bolting or clamping shall be close enough to
ensure optimum liquid tight construction but shall not exceed 120 mm on deck portion in
downcomer area/liquid holding area/downcomer apron bolting etc. For active area,
bolting/clamp spacing shall be limited to maximum 120 mm in general. However, in case
some fouling occurs with valves or other components, maximum 140 mm spacing may
be adopted. All joints and seams of trays specified to be liquid tight without gasketted
joints shall be seal welded at site except for manways which shall be gasketed. Maximum
spacing for clamps/bolting for gasketted & Stiffened Internals and Manways shall be
restricted to 80-110 mm.

3.5.7 Drawings and instructions for installation and fabrication of support ring, bolting bar and
support bracket/cleats welded to vessel shall be furnished by Internals supplier. They
shall show clearly the type, size and extent of welding. All support rings and bolting bars
shall be welded as per EIL Standard Specification No. 6-14-0007 unless specified
otherwise by licensor. All support brackets shall be welded all around.

Support stool shall be provided for downcomer (first piece) or loose beams in excess of
1500 mm length.

3.5.8 When locations of bed support, retainer and distributor are not indicated on data sheets,
Tower Internal/Packing supplier shall determine and indicate dimensional requirement.

3.5.9 Unless otherwise specified, gasket need not be used in the design or installation of
Internals except for all liquid holding portions (e.g. seal pans, recess seal pans, draw-
offs), collector trays, distributors and redistributors. Fabrication shall provide tight metal
to metal joints. Metal seal plates shall be used to close construction joints where
necessary. For gasketed construction, all clamps and bolting shall be provided with
gasket washer along with metallic washer.

3.5.10 All stiffeners and support members shall be located on the underside of the tray floor
with the exception of open type trusses supporting two trays. Stiffeners and support
members in bubbling areas shall not exceed 75 mm in width and shall be designed so as
not to impede or channel the liquid flow on the tray. Depth of stiffeners and support
members transverse and parallel to the liquid flow shall not exceed 20 and 30 percent
respectively of tray spacing.

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tafileg NDIA LIMITED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 12 of 25

3.5.11 A minimum of 20 mm overlap shall be provided between tray floor section and support
members.

3.5.12 Trays and seal pans not specified to be liquid tight, and of a design which would not
easily drain shall be provided with one or more 11 mm diameter/square drain holes/slots
located in the outlet weir directly above the tray flow. Size and number of drain hole/slot
may be reduced depending upon liquid rate. Draw off sumps shall be located flush with
the invert inside of draw off nozzles to allow complete draining of sumps.

3.5.13 All the three (3) and four (4) pass trays shall have pressure equalising pipes (vent tubes)
across the downcomers. For Two (2) Pass Trays where central downcomer length is more
than 3000 mm, Downcomer spacers shall be provided at the spacing of 1500 mm.

3.5.14 Lip slot construction is also acceptable provided it is as strong as bolted construction.

3.5.15 Bubble Cap Trays

Unless specified otherwise, Bubble Cap Trays shall be seal welded at site except manway
decks which shall be of gasketed construction. Suitable drain hole shall be provided in
the outlet weir.

Risers

Fixed Risers

Fixed risers shall be used unless otherwise specified in the data sheets. For deck plates
less than 3 mm in thickness, riser shall be expanded into upward flanged opening in the
deck plates and then stitch welded to upturned edges of the opening.

For deck plate 3 mm thickness and more, the riser shall be continuously welded to the
deck plates with the holes in the deck plate being plane, not upturned. Caps shall be
attached to the attachments welded to the top of risers.

Removable Risers

Removable risers shall be used only where specified on the drawings. These shall be
flanged at the bottom to fit over upturned flanged/venturi openings in the deck plates.
Each cap and riser shall be held rigidly in place by a special snap-on bar to which is
welded either a bolt or a bar with a wedge. Caps, risers and snap-on bars shall be
removable from top.

Bubble Cap

Bubble caps are to be furnished in Full Annealed and scale free bright condition.

3.5.16 Valve Trays

Valve assemblies of proprietary trays shall be provided with following features.

i) A means of preventing the orifice covers from adhering to tray floor.

ii) A means of preventing the orifice covers with integral guide legs and lift stops
from popping out of place during operation.

Anti jump baffle whenever provided shall be designed with a removable section to
facilitate access across the tray.

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 ENONEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
INDIA LIMITED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
Gori M Intka undernionq,
INTERNALS (UN-ENGINEERED) Page 13 of 25

3.5.17 Sieve Trays

All perforations shall be punched and made from top side and burr side on tray decks
must be downwards when installed, unless specified otherwise. In case of liquid-liquid
extractor column trays, punching direction shall depend on the direction of liquid flow of
continuous phase.

3.5.18 All noticeable burrs shall be removed from all perforated areas and edge of Internal
sections.

3.5.19 Distributors/Redistributors

Distributors of liquid feed to packed beds, unless otherwise specified in data sheets, shall
be gravity flow type (e.g. orifice drip trays, tubed drip trays, trough type, orifice header
laterals) in accordance with following requirements:

i) Distributors shall preferably be provided with side elevated orifices. For such
elevated orifices, anti fouling covers are not required.

ii) In case deck type distributors are provided/specified, orifices shall preferably be
minimum 6.0 mm diameter and shall be arranged on an approximate equal spacing
throughout the distributor. Distributor supports shall be designed and arranged so
as not to interfere with flow from orifices.

In case orifice diameter calculated is less than 6.0 mm, then antifouling covers
shall be provided on each orifice if required as per datasheet.

iii) Vapour risers shall have a total cross sectional area as per Vendor's design but not
less than 15 percent of vessel cross sectional area. Number, size and arrangement
of vapour risers shall be such so as not to affect the orifice spacing and liquid
distribution to the packings.

iv) Distributor joints shall be gasketted to be liquid tight. Gasket material used shall be
suitable for service and soft enough for leak tight joint.

v) Distributor shall be capable of performing satisfactorily for the range of loadings

specified to cover entire range of plant operation.

vi) Flow variation from orifice to orifice shall not be more than 10 percent at turndown
condition.

vii) Feed pipe shall form part of Distributor supply. All internal flanges shall be as per
EIL Standard and shall have gasketed connection unless specified otherwise.

3.5.20 Packing Support Plate / Support Grid

Packed bed support plate shall be vapour-injection type, providing separate passage for
liquid and vapour flow. The support plate shall have at least 90 percent free area based on
cross sectional area of vessel. Slot size shall be so selected to avoid any sneak through of
packings from slots.

For liquid liquid extraction column, vendor shall design suitable disperser plate.

Support Grid Height for Structured Packings shall be limited to 75 mm above Support
Ring.

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 ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
INDIA LIMITED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
In6a Undeflacn9
INTERNALS (UN-ENGINEERED) Page 14 of 25

3.5.21 Bed Limiters/Bed Retainers

Bed Limiters/Bed Retainers shall be located just above top of packings to avoid
fluidising of bed and shall be fixed in position so as not to be moved by the packings and
shall be designed so as not to affect distribution from the liquid distributor to the
packings. Bed Limiters/Bed Retainers for use with spray nozzle distributor shall be
designed with major structural support on the underside of the retainer so as not to affect
the spray distribution on the packings. Expanded metal of 2 mm thickness and equivalent
open area is also acceptable in place of wire mesh. The Bed limiter shall have at least
70% open area with respect to cross sectional area of vessel.

3.5.22 Hold Down Plates

Hold down plates shall be provided on the top of ceramic or carbon tower packings. The
hold-down plate shall directly rest on the bed without any support cleats. Hold-down
plate shall exert sufficient static pressure on the bed to restrict movement of the bed. Care
shall be taken not to use hold-down grid with metallic or plastic tower packings.
Expanded metal of 2 mm thickness and equivalent open area is also acceptable in place
of wire mesh.

3.5.23 Flash Feed Distributor

Flash feed distributor for flashing or mixed phase, vapour and liquid feeds to packed bed
shall be designed to separate the two phases and distribute the liquid phase on
distributor/redistributor. If flashing feed gallery is used, riser area shall be 50% of vessel
cross sectional area.

3.5.24 Tower Packing

If type of packings is not specified in the process data sheets, following shall be taken as
guidelines:

i) For wash zone of vacuum column, Grid Packings shall be used.

ii) For all other applications preferably Pall Rings shall be used. If pall rings are not
expected to perform to desired performance, proprietary random packings may be
used. Alternatively, Vendor may also adopt/recommend use of Structured Packings.

The maximum allowable pressure drop for a packed bed shall include packed bed
support, bed limiter and distributor.

The volume of random packing supplied shall include at least 5 % over the calculated
bed volume apart from spares.

4.0 FABRICATION AND SUPPLY

4.1 Tolerances

All sections shall be truly flat within 2 mm and shall be free from noticeable burrs and
welds spatters.

Tolerances wherever unspecified shall be taken as ±1 mm and not to be accumulative,

except on thickness and assembly diameter. Tolerances on thickness shall be as per
applicable specification and tolerances on assembly diameter shall be as below:

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 lot _It.qftENGINfERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
kii5jeg wINDIA
.fg .—ltettRert4144.4 LIMITED
of Inda Underta.n91
CAA
FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 15 of 25

Cartridge Trays D-3

Other Assemblies D 1500, D

1500 < D 4500, f) i°0
D > 4500, DF2°0

Tolerance on individual layer of Structured Packing shall be ±2 mm.

4.2 Welding

4.2.1 All welding shall be done by TIG/GTAW Process only. However for Site welding where
TIG welding cannot be done due to access/Practical Constraints, Metal Arc welding may
be carried out after taking approval from Engineer-In-Charge. Resistance welding is
permitted for minor details where weld is a non strength weld. Gas or Carbon arc
welding shall not be used.

4.2.2 Welding electrodes of composition similar to Internals material shall be used except
austenitic electrodes of higher chromium and nickel content such as AWS A5.4, ASME
SFA 5.4 class E309 and E310 may be used for 12 Cr stainless steel. For dissimilar
material welding, electrode composition shall be similar to nobler material being welded.
Following electrodes shall be used unless specified otherwise:

E 7018 for all CS materials

E 308 for all SS 304 to SS 304
E 308L for all SS 304L to SS 304L
E 309MoL for SS 410S to SS 410S, SS to CS,
SS 410S to SS 304, 304L, 316, 316L
E 316 for all SS 316
E 316L for all SS 316L
E Ni Cu7 for Monel to Monel.
Pure Nickel for Monel to CS/SS.

4.2.3 Welding wherever specified, is to be done by qualified and approved welders using the
suitable fillers and fluxes recommended for the materials in the fabrication drawings. For
welding the stud on tray decks and support beams, use of stud welding gun with suitable
flux is acceptable. In manually welding the studs, care should be taken to minimise the
weld spatter and the outside diameter of the weld so that it should not foul with tray deck
or washer. For stud welding, proper welding procedure shall be established. Torque
required for welding failure shall be higher than the torque required for failure of the
stud.

4.2.4 A proposed Welding Procedure Specification (WPS) shall be submitted to AIA for his
approval. On approval, a Procedure Qualification Test (PQT) shall be conducted which
shall be witnessed by AIA. On acceptance of all tests as per ASME Section a, a final
WPS along with Procedure Qualification Record (PQR) shall be submitted. Production
welding shall start only after approval of final WPS/PQR and qualification of welders as
per ASME Section IX. AIA may accept previously qualified WPS/PQR at his sole
discretion.

4.3 Miscellaneous

4.3.1 All parts fabricated shall be smooth, true, clean and free from noticeable burrs, grease
and dents. Openings for passage of workman must have exposed edges rounded.

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 zlt4 tepENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
$1g 00:leg MAW INDIA LIMITED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 16 of 25

4.3.2 All support rings, bolting bars, beams support brackets and other components which are
integral and therefore welded to the column shell inside, shall be supplied and installed
by column fabricator.

4.3.3 Total draw-off trays shall be designed for zero leakage construction and may be seal
welded (if required) at site to attain zero leakage.

4.3.4 Seal welds shall have a throat thickness at least equal to the minimum thickness being
welded together.

4.3.5 All stainless steel tray assemblies/internals and their components (e.g. Bubble caps,
valves etc.) shall be pickled and passivated. However, for SS400 series material, Pickling
and Passivation of only weld affected zone is also permitted by Pickling paste method.
Pickling and Passivation shall be as per ASTM A380. However, vendor shall prepare
procedure for Pickling and Passivation and obtain approval from Owner/PMC.

4.3.6 All parts shall be fabricated in accordance with good shop practice and in uniformity so
that all corresponding parts will be inter-changeable.

4.4 Spares

Following minimum spares shall be included as part of the supply:

4.4.1 Mandatory Spares: Following operational spares as a minimum shall be supplied as

Mandatory Spares:

i) Valves for Trays 10% of each type

ii) Bolts/Nuts 10% of total for each type/size (minimum

10 nos. of each size)
iii) Clamp Assemblies - do -

iv) Gaskets or Tapes 100% of each type and size

v) Sealing Ropes / Sealing - 200% of each size

Foils for Cartridge Trays
vi) Spray Nozzles 25% subject to minimum 5 Nos. of each
type and size.
vii) Random Packings 5% of each type and size.

4.4.2 Erection & Commissioning Spares:

The supply shall include the following as constructional spares:

i) Bolts/Nuts 10% of total for each size

(minimum 10 nos. of each size).
ii) Clamp assemblies 10% of total for each type and size
(minimum 10 nos. of each size).
iii) Valves for trays 5% of each type

iv) Bubble caps 5% of each type and size

v) Gasketing or tapes 100% of each type and size

vi) Sealing Ropes / Sealing 200% of each size

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 15110-aei ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
eir 0151eg W INDIA LIMITED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
gran rya.,am NON, A Go.< ot inch UndetatImp
INTERNALS (UN-ENGINEERED) Page 17 of 25

Foils for Cartridge trays

vii) U-clamps 10% of each type and size or 10 nos.

whichever is minimum.
viii) Tower Packings 10% for Metallic and Plastic Packings
15% for Carbon and Ceramic Packings
ix) Spray Nozzles Up to 25 Nos. (of each type) - 100%
More than 25 (of each type) - 25%
(subject to minimum of 25 Nos.)

Unused spares shall be handed over to Client.

4.4.3 Vendor shall submit itemized price list of spares recommended for two years of
satisfactory operation, over and above mandatory spares. If desired by Owner, order shall
be placed for these spares.

5.0 INSPECTION AND TESTING

5.1 General

5.1.1 The materials, fabrication, testing and trial assemblies are subject to inspection by AIA,
nominated by Owner/PMC, at shop floor before shipment and during installation.

5.1.2 Any rejection made by Inspector shall be final. Approval/Inspection by EIL/Owner

and/or their designated representative shall in no way relieve the Vendor of his
responsibility to meet all the requirements of the Purchase Order.

5.1.3 AIA/PMC/Owner shall have free entry to the Vendor's shop at all times where and while
the work is being performed. The Vendor shall offer the inspectors all reasonable
facilities to satisfy them that the materials are being furnished in accordance in
accordance with the specifications.

5.1.4 AIA will cooperate with the Vendor in so far as is possible to minimise any interferences
with the operation of the Vendor's shop.

5.1.5 Vendor shall prepare a detailed ITP based on EIL-ITPs for Shop / Site activities and
obtain EIL / TPIA / Owner approval.

5.1.6 Vendor shall notify the AIA/Owner sufficiently in advance of any fabricating operations
to permit the AIA to arrive at the Vendor's shop.

5.2 Stage Inspection during Fabrication

5.2.1 Dimensions

The inspector will check that the thickness and the dimensions of all parts for the Decks,
Weirs, Seal and Draw off pans, Downcomers, Draw off pipes, Supports, Beams, Valves,
Bubble caps, Clamps, Studs, Bolts, Nuts, Risers, Washers and Gaskets etc. are as per the
approved drawings.

5.2.2 Fabrication

The inspector shall check each individual part of the equipment fabricated as per
approved drawings and specifications. For instance, for the Bubble cap dimensions,
height, width and number of slots, heights, O.D. and I.D. or riser and cap, shroud ring

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 Ofte/IFIA ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.

NW, erotra,
W WA LIMITED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
!A Go of InCaa LAXIBilylvng,
INTERNALS (UN-ENGINEERED) Page 18 of 25

height, exit and inlet weirs height etc. shall be measured. The inspector will check that all
identical parts shall be interchangeable.

Inspector shall check that the sharp edges on the internal components, manway covers,
weirs, downcomers etc. are properly removed. Also that all burrs from punched holes and
loose weld slags and materials are removed from all components. Stage-wise inspection
during fabrication will be thoroughly carried out. Before starting welding, welders'
qualification test will be carried out, if required, as per ASME Sec. IX. Where number of
similar items are to be made, inspector shall give the clearance for the fabrication of the
lot only after checking and approving the first sample piece.

5.3 Trial Assembly

One tray/one layer of structured packing of each type and size with its accessories shall
be assembled as floor mock-up, inside the fabricators' shop. The components for such an
assembly will be taken at random from each lot of identical items.

The assembled tray will be carefully checked for its dimensions, tolerances, number and
arrangement of perforation, the working of the valves in case of valve trays, V-notch or
Blocked Weir, adjustability of weir, vent tube details, downcomer clearance, weir
heights, downcomer length and width, number of clamps, gaps and potential leakage
points etc.

The assembly shall also be checked for each type and size of packed tower internals.

Inspector will also check the flatness and deflection of the trays, internals, beams, tray
edges and beam ends clearance.

5.4 Leak Testing

Bubble cap, Collector trays, Liquid holding portion of other trays such as Seal pans,
Recessed seal pans, Draw off pans shall be subjected to leakage test at the field by filling
water up to weir level or up to normal liquid level as the case may be.

Leak testing shall be carried out with service gaskets and drain holes temporarily
plugged. Leakage rate shall not exceed 0.5 percent of design liquid flow rate unless
otherwise specified.

5.5 Distributor Testing

All Liquid distributors/redistributors shall be water tested in the vendor's shop by the
following procedure at 50%, 100% and 110% of the design liquid volumetric flow rate.
The vendor shall certify to the purchaser at the time of bidding that they believe their
equipment can meet the testing requirements listed below:

(i) If the distributor contains a predistributor, it shall be tested first to ensure that it has
a CV of 5 or less at the design flow rate. Each orifice in the predistributor shall be
tested. The CV is defined as the ratio of the standard deviation to the sample mean,
expressed as a percent.

(ii) The distributor/redistributor itself shall be tested and the CV determined. To

determine the CV, at least 30 pour points or at least 10% of the pour points
(whichever is higher) shall be randomly selected and tested. If the CV specified
below cannot be met, the vendor will correct the problem at its expense.

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 k3
-iIiaeit4 ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ogeiT la5reg W INDIA LIMITED
A Govt M Imo
FOR TRAYS AND TOWER 6-14-0015 Rev. 4
U.1.1.14,,n91
INTERNALS (UN-ENGINEERED) Page 19 of 25

(a) For orifice pans, tubed drip pans and other similar devices, a CV of 10 or less
must be achieved at the design liquid volumetric flow rate.

(b) Four orifice parts, tubed drip pans or trough distributors that employ a
modular (sectional) design, (wherein many pieces are geometrically identical)
all pieces of the same geometry shall be treated as one group or strata. One
piece from each strata shall then be tested by the procedure outlined above.

(c) The average flow rate per pour point for any grouping of 10 of the tested pour
points from a single area should differ by no more than 5% from the average
for the group or strata being tested.

(d) Spray nozzle distributors shall not be tested in the vendor's shop but must be
tested in the tower prior to start-up to ensure that all nozzles are operable and
develop the desired spray pattern. This test shall be carried out as close to
design rates as possible.

(e) The test results shall be furnished to PMC/Owner in a written report. This
report shall also contain a drawing of the distributor in plan view. This
drawing shall be broken down into 3 radial zones of equal area and the
location of pour points sampled in each zone.

All distributors/redistributors shall be leak tested at shop floor as well as at site. For
distributors/redistributors, if performance testing is carried out at shop floor, leak testing
at shop floor is not required.

Whenever performance testing of distributor is to be carried out at shop, its detailed

procedure needs to be submitted to PMC/Owner for review. After approval of test
procedure, testing shall be carried out as per approved test procedure.

SPRAY NOZZLES

Apart from the usual material quality tests (chemical analysis and mechanical properties)
and manufacturing quality control tests, vendor shall include for & carry out the testing
of the spray nozzles with respect to the flow rates for specific AP, spray angle, spray
coverage and distribution for the tip distance given in the data sheet. The testing medium
shall be water. These results shall be submitted to Owner/EIL for review. Tests and
acceptance criteria is as below:

Flow rates ±10 % for specific AP

Spray angle f50

Flow variation As per vendor's Standard.

(Data to be reported for Information)

No. of nozzle to be tested - 10% of each size and type. (Min. 2 nos. of each
type & size)

6.0 SITE INSTALLATION AND SUPERVISION

6.1 Installation of trays, tower internals, tower packings and associated components shall be
as per the Vendor's Installation Procedure and the approved General Arrangement

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 INIPael ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
IMIReg WA LIMITED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
A GOA a UndertI.V
INTERNALS (UN-ENGINEERED) Page 20 of 25

Drawings for each column. All requirements of the drawing shall be complied in totality.
Installation records in vendor's installation formats giving following parameters
(Dimension as per drawing v/s actual readings) of trays and internals shall be furnished:

• Distance between tray support rings (Tray Spacing).

• Location of downcomer bolting bars
• Tray support ring levelness (Minimum 4 diametrically opposite locations).
• Height of Exit Weir (From top of tray deck)
• Under Down Flow Clearance (At tray and seal pan locations).
• Horizontal clearance between downcomer apron and seal/recessed seal pan.
• Drop in water level during leak testing of seal pans, recessed seal pans, chimney
trays, liquid distributors/redistributors and other liquid holding portions.

Vendor shall also furnish a certificate stating that all installed trays and internals have
been inspected and the column is good for boxing up the manways. The above mentioned
installation records and the certificate shall be furnished by vendor prior to offering the
trays and internals for Owner/PL inspection.

6.2 Health, Safety and Environment

Vendor shall arrange for installation of an exhaust fan for exhaling welding/ cutting
fumes etc. and to maintain adequate oxygen level, before any work is started inside
confined spaces (i.e. columns). Adequate ventilation shall be maintained at all times.
Gas/LPG cylinders shall not be taken inside confined space. When a worker/supervisor
enters a confined space, it shall be mandatory to have a second man as stand by. Safety
belts shall be worn while entering columns, if there is a danger of falling. All
ladders/stair cases shall be in place before any item is offered for inspection. Rope
ladders/scaffolding shall be provided inside the column in case trays are not easily
approachable from column manhole. Low voltage (24V) lamps equipped with guards
shall be used to prevent accidental contact with bulb. All electrical connections shall be
through ELCB's and proper earthing shall be ensured. Acids and other materials used for
pickling shall be disposed off to a designated place. All statutory Regulations and
owner's safety, health and environment requirements shall be complied with. Inspection
aids for carrying out the inspection of internals shall also be provided.

6.3 It shall be the responsibility of vendor to provide trained engineers to supervise the
erection of trays, packings and internals to ensure that these are assembled properly and
meet the expected leakage rates and tolerances. Final clearance shall be obtained from
designer of Internals. Vendor's engineer shall satisfy himself that the column before it is
boxed-up, is having all Internals duly and correctly fitted, clean and without leakage (as
required per drawings) and bolts are tight with lock-nuts (wherever specified). A
certificate shall be issued by the vendor that the column is good for boxing up the
manways. The leakage test data and levelness of each tray shall be recorded and
submitted in data folders. Vendor's offer shall include for this service and charges
indicated separately.

6.4 The Internals shall be offered by vendor for final clearance by Process Licensor (if
applicable) and Owner after vendor has satisfied themselves with the quality of
installation.

7.0 VENDOR DATA REQUIREMENTS

7.1.1 Vendor shall furnish design, drawings and documents as per Vendor Data Requirements,
indicated in the Purchase Order/Contract Documents.

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 kit l ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
$vigz.il fafftegyeili INDIA LIM I ED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
1.4.4, A Ci..1 ol UnCkqUianqi
INTERNALS (UN-ENGINEERED) Page 21 of 25

7. 1 .2 It is emphasized that review of documents shall be done for each column only after
receipt of complete information such as vendor's designs/specifications, column
fabrication drawings including feed arrangement GAD's etc. Part submission of data
shall not be entertained and PMC/Owner shall not be held responsible for holding the
work or schedule slippages.

7.2 SUBMISSION OF BIDS

Vendor shall submit the bids containing following information unless otherwise specified
in Job specification:

a) Column sketch showing all Internals and nozzles.

b) Completed data sheet (as per Annexure I) for trays with computer outputs for
maximum, normal and minimum cases.
c) Completed data sheet (as per Annexure II) for each different packed bed.
d) Data for spray nozzles, if used.
e) Data on distributors - type and salient features.
f) Details of other Internals.
g) List of Deviations from this specification and/or MR requirements.
h) Reference list for the type of Internals offered in this enquiry supplied earlier for
similar service. This shall cover at least client's name, type of Internal, plant,
service, column diameter and year of commissioning.
i) Quality plan
j) Vendor's catalogues

Bidder's offer shall be liable to rejection in absence of data as requested vide (a) to (j)
above.

7.3 AS BUILT DOCUMENTATION

Shop changes made by Vendor after approval of drawings under Code-1 by EIL and
deviations granted in deviation permits, if any, shall be marked in hard copy of drawings
which shall then be stamped 'As-built' by the vendor. These 'As-built' drawings shall be
reviewed and stamped by Authorized Inspector also. Vendor shall prepare scanned image
files of all marked-up 'As-built' drawings. Vendor shall also incorporate the above
changes in the native soft files of the drawings.

Authorized Inspector shall ensure/certify completeness of Vendor's Final/As-built

documents before equipment dispatch.

In addition, vendor shall also incorporate site changes, if any, based on mismatch
observed at site and resubmit the 'As-built' documents.

7.4 DATA FOLDER

Vendor shall complete requisite copies of data folders along with one set of electronic
copies (PDF / native files), of the drawings in CD / Pen drive. These folders shall contain
the following documents.

(a) Hydraulic and mechanical design calculations along with computer print out.
(b) Final hydraulic data sheets for trays and tower internals as per Annexure-I and II
respectively / Vendor format.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 584 of 674

 Ifitaztegeft ,,: ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
lafAeglreiii/INDIA LIMITED FOR TRAYS AND TOWER
MILT etta0.,. G.t., Ymtha Undert0
0,91 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 22 of 25

(c) Support Rings, Support Cleats and Bolting Bar drawings.

(d) As built General Arrangement drawings with Bill of Material for Internals.
(e) Part detail drawings.
(f) Material Certificates
(g) Shop testing procedure and installation procedure.
(h) Inspection reports and leak test records.
(i) Vendor's certificate stating that Internals have been designed, fabricated, supplied
and installed as per Vendor practices so as to meet design conditions.
(j) Welding Procedure Specifications (WPS) and Procedure Qualification Records
(PQR).
(k) Site Installation Procedures/Instructions and Records.

8.0 SHIPPING

8.1 Preparation

8.1.1 All metal parts shall be free of all foreign matter, except that any oil coating inherent
with the manufacturing process need not be removed.

8.1.2 All Carbon Steel Internals shall be given two coats of rust preventive coating preferably
which can be easily removed by moist cotton (such as Castrol Rustilo DWX32, Rust
Guard P224 etc). All stainless steel internals shall be supplied duly pickled and
passivated as per Clause 4.3.5. Internals supplier shall also indicate procedure for
removal of rust preventive coating (if applied) in the instructions for Installation of
Internals.

8.2 Packing

8.2.1 All Internal components shall be properly packed, crated and boxed in a manner such as
to protect all parts from damage or loss during transit. It will be Internals Supplier's
responsibility to pack to ensure damage free transit for the mode of transportation finally
adopted and adequate for storage at site for a minimum period of 6 months. All trays and
tower internals shall be wrapped in polythene and supplied in wooden cases for damage
free transportation as per either EIL Standard specification or Vendor's proven Standard
(In case, Installation of internals is not in Vendor's Scope, follow EIL Standard
Specification). Vendor may use Euro Bags or equivalent for Random Packings (if
installation by same agency otherwise follow EIL Standard Specification). Maximum
weight of each case shall preferably be limited to 250 kgs.

8.2.2 All Internal components are to be provided with match and identification marks and shall
also bear the column number. All identical elements shall have the same markings.
Markings shall be done with indelible paint or ink which contains non-metallic pigments.

8.2.3 Materials for different columns shall not be intermixed.

8.2.4 Material test certificates, test reports, Inspector's approval certificates, release notes etc.
and two sets of assembly and fabrication drawings are to be enclosed along with
shipment of Internals.

8.2.5 All support rings, bolting bars and other attachments of the vessel, if made by Internals
supplier shall be shipped directly to vessel fabricator unless otherwise designated. This
shipment shall include two sets of drawing and instructions for Installation, Welding etc.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 585 of 674

 tlf~it " ENGINEERS
eft STANDARD SPECIFICATION STANDARD SPECIFICATION No.
s1 rfafgrezw INDIA LIMITED
ORM 14..1 i • GoN d OW. Uncle02.,N1
FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 23 of 25

8.2.6 Packaging of Spares

8.2.6.1 All shipments of spares shall include fasteners, gaskets and valves/bubble caps, packings
etc. to cover loss, waste and shrinkage as specified in clause 4.4 in a separate container.

8.2.6.2 All spares shall be packaged and supplied separately so as to preserve them in new
condition, tagged properly so as to identify them as and when needed and shall be clearly
marked "Spares".

9.0 EVALUATION OF BIDS

The information provided in the bids shall be reviewed for information and not for
correctness of the design or its approval. PMC/Owner shall not be held liable to price
increase/delays in case changes are necessitated on detailed scrutiny of documents
submitted as per Clause 7.0 after the placement of order.

10.0 GUARANTEE REQUIREMENT

10.1 Hydraulic Performance Guarantee

Vendor shall guarantee hydraulic performance as specified in specifications sheets

(PDS/HDS) for all the Internals for which Vendor is required to carry out functional
process design also.

10.2 Mechanical Guarantee/Warranty

Vendor shall guarantee all items supplied by him against defective material; poor
workmanship, improper design and failure from normal usage for a period as per Client's
commercial terms and conditions.

In case of maloperation or failure of the trays and internals, vendor shall be responsible
to carry out re-engineering and modify/replace the hardware without any cost to the
Client and without delay. In case modifications are required due to inadequate
performance, the guarantee period shall be extended for 12 months from the date the
column is put back into operation.

11.0 PATENT INFRINGEMENT

Vendor shall defend any and all infringement suits in which the Owner, PMC and/or EIL
is made a defendant, alleging patent infringement. Vendor shall pay all costs and
expenses incident to any such litigation. It being further agreed and understood, however,
that Owner, PMC and/or EIL shall have the right to be represented therein by counsel, of
their own selection and paid by them. Vendor shall pay all damages, profits and/or cost
which may be awarded by the plaintiff in any such litigation; and, in general, shall defend
Owner, PMC and/or EIL against all claim or demand of every kind to which they may be
subjected under the patent laws, in connections with equipment purchased under this
specification.

12.0 LIST OF ATTACHMENTS

ANNEXURE

I. Tray Data Sheet

II. Packed Column Data Sheet

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 586 of 674

 atkieit4 ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
latiteg INDIA LIMITED FOR TRAYS AND TOWER
.14,1 orrtnivm GO., t.doLok,), 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 24 of 25

ANNEXURE - I
DOCUMENT NO.
fidrarleyek
,B\ci\EERs
Itar faRegWNDIA MED TRAY DATA SHEET moc-xx-xx-xx-xm Rev. y
KlrtMKWAV. Page 1 of 1

JOB NO. COLUMN NO. REV.

PROJECT CUSTOMER
SERVICE OF UNIT TOTAL TRAYS
PR DM NO. DESIGN FOR TRAYS

PROCESS DATA MECHANICAL DATA

TYPE OF TRAY COLUMN I D.,M M NO OF PASSES

LOADING AT TRAY TRAY SPACING, MM
VAPOUR FLOW, KG/HR OFF CENTRE
VAPOR DENSITY, KG/M3 SIDE CENTRE INSIDE OUTSIDE
LIQUID FLOW, KG/HR D/C CHORD HT.,MM
LIQUID DENSITY, KG/M3 EXIT WEIR LEN., MM
LIQUID ST, DN/CM E.W.BLOCKING %
LIQUID VISC. ,CP DOVVNCOM ER AR .,M 2
OPER. PRESS ,KG/CM 2A EXIT WEIR HT. MM
OPER.TEMP. DEG .0 (V/L) EWEIR ADJUSTABILITY, MM
SYSTEM FACTOR UDF CLEARANCE, MM
ALL. RR.DROPITRAY, KG/CM2 TYPE OF DOWVCOMER
MATL. OF TRAY RECESSED IN SEAL PAN
MATL OF VALVE/CAP TYPE /SIZE OF VALVES/CAPS/HOLES
CORR AL/DECK THK.,MM NO. OF VALVES/CAPS/HOLES
MIN./MAX % OF NORMAL LOADS APPROX. PITCH, MM

HYDRAULIC PERFORMANCE

LOA DING OFF CENTRE

JET FLOOD % SIDE CENTRE INSIDE OUTSIDE

D/C BACKUP FLOOD % EW. LOAD, M3/MHR
TRAY PRIDRY MM L10. D/C LOAD, M3IM2HR
DROP MET KG/CM2 LID. HT. OVER WEIR,MM
UDF LID VEL M/HR TOTAL LID. HT. ON TRAY
UDF DELP MM LIQ TURN % OF DES LOADS
D/C LJQIMM CLEAR OPERATING RANGE! VAP
BACKUP IM M FOAM %OF DESIGN LOADILJQ

NOTES

REV. DATE PURPOSE DESIGN ;NECKED APPROVED

Format No. 3-05-45-3001 Rev 0 Copyrights EIL — All rights reserved

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 587 of 674

 f
;-t
:
- ; ENGINEERS STANDARD SPECIFICATION STANDARD SPECIFICATION No.
lawgw,INDIA LIMITED FOR TRAYS AND TOWER 6-14-0015 Rev. 4
INTERNALS (UN-ENGINEERED) Page 25 of 25

ANNEXURE-II

DOCUMENT NO_
latlitaek ENGINEERS
ItfaVieg W WA LIMITED
IA Go.. Al Mk. tIrd.,,A..4,
PACKED COLUMN DATASHEET XXXX-XX-XX-XX-XXXX
Pegs 1 of 1

EIL ENO. NO./ JOB NO. COLUMN NO.

PROJECT SERVICE OF UNIT
CUSTOMER TOTAL NO. OF PACKED SECTIONS
CUSTOMER REF. NO./ PROCESS DATA SHEET NO. TOTAL HEIGHT OF PACKED SECTIONS
TYPE OF PACKING

INPUT DATA
LOADING AT TOP BOTTOM
BOTTOM / TOP OF PACKING
RATE, Kg/hr
DENSITY. Kg/m3
VAPOUR
VISCOSITY, Cp/Cst
MOLECULAR WEIGHT
RATE, Kg/hr
DENSITY. Kg/m3
UQUID
VISCOSITY, Cp/Cst
SURFACE TENSION. Dines/cm
OPERATING PRESSURE. Kg/cm2 abs.
CONDITION TEMPERATURE, 'C
SYSTEM FACTOR
HEIGHT OF PACKED SECTION. mm
HEAT DUTY ACROSS SECTION. K Cal/hr X 106
ALL MAX. PRESSURE DROP ACROSS BED
MATERIAL OF INTERNALS
CONSTRUCTION PACKING
TOTAL CORROSION ALLOWANCE ON INTERNALS
MIN./MAX. X OF DESIGN LOADS

OUTPUT DATA HYDRAULIC PERFORMANCE AT DESIGN/MAX. LOADS

COLUMN INSIDE DIM& ILK. mm
TYPE AND SIZE OF PACKING
MOC PERCENT
PRESSURE PER METER OF PACKING mm Hg/
DROP TOTAL ACROSS BED Kg/amt
TURNDOWN X OF DESIGN LOADS
HEW. Mt. ILK/FEET
LMTD. 'C/T
VOL HEAT TRANSFER COEFF. K Col/hr m3 *C
SUPPORT PLATE
UQUID DISTRIBUTOR
HOLD DOWN PLATE / BED UMITER
UQUID REDISTRIBUTOR

NOTES:

REV. NO. DATE PURPOSE BY CHECKED APPROVED

- - - •0. 3-05453002.F4 RBVJ

Copyright E_ - All rights reserved

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 588 of 674

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
el ENGINEERS FOR REVIEW OF SITE
Sts' eir 22eg
wren eledeetraJ01700
INDIA LIMITED
IA GOvt 01 India Undertaking)
INSTALLATION OF COLUMN
6-14-0016 Rev. 4
INTERNALS Page 1 of 15

comdi

ga-M-49-0-r Dq itr4gT

SPECIFICATION
FOR
REVIEW OF SITE INSTALLATION
OF
COLUMN INTERNALS

REVISED AND REISSUED AS

4 13.03.15 Ot41.
P1t1 P SC
STANDARD SPECIFICATION
REAFFIRMED AND REISSUED AS
3 30.03.10 JA SKM/DK AKG ND
STANDARD SPECIFICATION
REVISED AND REISSUED AS
2 27.08.04 RSR HCN RKA SKG
STANDARD SPECIFICATION
REVISED AND REISSUED AS
1 17.07.02 SK YVR/HCN RKA GRR
STANDARD SPECIFICATION
0 16.12.96 ISSUED AS STANDARD SPECIFICATION HCN SKK RKA AS
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 589 of 674

 ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
$fgar kiWeg- INDIA LIMITED REVIEW OF SITE INSTALLATION 6-14-0016 Rev. 4
eiterle (A GOA (71 WOO Undertak.ng)
OF COLUMN INTERNALS Page 2 of 15

Abbreviations:

HMTD Heat & Mass Transfer Division

Heat and Mass Transfer Standards Committee

Convenor : Sh. Amit Prakash

Members : Sh.Mandip Kapoor

Sh. Inder Kumar
Sh. Ratan Lal (Projects)
Sh. G K Iyer (Const)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 590 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
faeJtqra I ENGINEERS
oge.11 tagtegw)INDIA LIMITED REVIEW OF SITE INSTALLATION 6-14-0016 Rev. 4
■
adVrr eled,rearrOdin-
A, (A Govt of India Undertaking)
OF COLUMN INTERNALS Page 3 of 15

CONTENTS

1.0 PURPOSE .4

2.0 REFERENCES 4

3.0 DEFINITIONS 4

4.0 SCOPE .5, 6

5.0 ANNEXURES 7-15

LIST OF ANNEXURES:

Site Installation Reporting Format for Column Internals & Structured Packing 3-0542-4001

Site Installation Review Check List 3-0542-4002

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved

Page 591 of 674

 ENGINEERS STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.

5'fgar taiZs
411, T7127, MT
INDIA LIMITED REVIEW OF SITE INSTALLATION 6-14-0016 Rev. 4
Genet 01 Tna. UndnnanTng OF COLUMN INTERNALS Page 4 of 15

1.0 PURPOSE

This document outlines the requirements of site installation checking and review of
installed trays and tower internals. This is necessary so as to ensure that the
requirements as per approved drawings are met and equipment performs according to
the design specification.

It is the responsibility of Installation Contractor to ensure that all components are

fitted as per drawing/standards/specifications and 100 percent checked by Installation
Contractor's Supervisor and Engineer-in-Charge. Records of installation and quality
checks shall be maintained by Installation Contractor duly counter checked/signed by
Engineer-in-Charge as per Format 3-0542-4001 attached.

Review by specialist shall be subsequently carried out.

2.0 REFERENCES

Following shall form the reference documents for carrying out the work:

i) General Arrangement drawings of Trays and Tower Internals.

ii) Tray Support Ring and Bolting Bar drawings of Column fabricator.

iii) Vessel Design Data.

iv) Nozzle Orientation Drawing.

v) Installation Procedure for Trays & Tower Internals No. 6-14-0003

vi) Standard Specification for packing the column - No.6-14-0011

vii) Construction Tolerance for Welded Supports for

Trays/Tower Internals - No.7-14-0001

viii) Typical detail of Trays - No.7-14-0202

3.0 DEFINITIONS

Column Internals
These are mechanical devices used inside the column or other process equipment to
carry out desired process function and shall include trays, tower internals, tower
packings, demisters, spray nozzles etc.

Revamp
The word is used for modifications being done to any process equipment or scheme so
as to achieve higher throughput or better product quality or both.

Engineer-in-Charge
Authorised engineer either from client/or EIL site, responsible to interact with
Installation Contractor & getting the jobs done under his surveillance & inspection.

Specialist
The nominated personnel of HMTD, assigned to perform the review of the
tray/internal installations after these are cleared by Engineer-in-Charge.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 592 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
,51
! ENGINEERS
Oem Wes INDIA LIMITED REVIEW OF SITE INSTALLATION 6-14-0016 Rev. 4
etrave
WWI 951,3W7 IA Govt ot Indo Undertaking)
OF COLUMN INTERNALS Page 5 of 15

Set of Trays
Identical trays in a continuous bank having same chord heights, number and type of
valves, exit weir heights, under down flow clearances, tray spacing etc.

Installation Contractor
Agency who has been assigned the job for carrying out the Installation of Column
Internals.

Punch List
List of comments given by specialist at site which needs to be attended for necessary
rectification by the Installation Contractor under direction of Engineer-in-Charge.

4.0 SCOPE

The scope of activities and responsibilities of Installation Contractor, Engineer-in-

Charge and Specialist shall be as per para 4.1, 4.2 and 4.3 hereafter. These shall be
carried out for all trays/tower internals in each column.

4.1 Installation Contractor

i) Before Installation of Trays and Tower Internals, checking the levelness of

support rings and location of bolting bars.
ii) Recording the final levelness/dimensions measured in Format 3-0542-
4001(sht.1 & 2) and getting these counter checked by Engineer-in-Charge.
iii) After installation of trays under vendor supervision and stage-wise inspection
of Engineer-in-Charge, recording important tray dimensions for all trays as
per Format 3-0542-4001 (sht.3 & 4) and getting these counter checked by
Engineer-in-Charge.
iv) Carrying out various checks /leak testing on fitted trays as per Format 3-0542-
4001 (sht.5) and recording the compliance duly counter checked by Engineer-
in-Charge.
v) In case of packed beds, after installation of various internals carrying out
various checks/leak testing as per Format 3-0542-4001 (sht.6 & 7) and
recording the compliance duly counter checked by Engineer-in-Charge.

4.2 Engineer-in-Charge

i) Stage-wise and final inspection of installation of Trays and Tower Internals

done by the Installation Contractor.
ii) Counter checking the various dimensions/levelness/checks as recorded by
Installation Contractor as per para 4.1. These records shall be maintained at
site and shown to specialist for his review.
iii) In case dimensions/levelness/location of support rings and bolting bars is not
as per column drawings and within tolerances as per EIL Std. 7-14-0001,
directions shall be provided to Installation Contractor/Column Fabricator for
necessary rectification/modification.
iv) Submit filled & signed format 3-0542-4001 to HMTD-HO for each column
before calling for checking/review by specialist.
v) EIL-Site to ensure that Tray/Tower Internals Supplier's representative should
be present at site during HMTD-Specialist visit at site.
vi) Attending to Punch List provided by specialist at the end of his review and
ensuring that these are carried out by Installation Contractor. Rectifications
required as per Punch List shall be finally cleared by Engineer-in-Charge and
no further review by specialist shall be required. Columns shall be cleared for
boxing-up subsequently.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 593 of 674

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
7111~ ENGINEERS
T fZ5 INDIA LIMITED REVIEW OF SITE INSTALLATION 6-14-0016 Rev. 4
Go, of IndLa Undeld.ncp
OF COLUMN INTERNALS Page 6 of 15

4.3 Specialist

i) Review of readings/observations on site installation and leak testing recorded

in format 3-0542-4001 before carrying out his own random checking.
ii) Carry out random check on installed trays. Number of trays selected for this
shall depend upon the quality of work. However, as a minimum, 25 percent
of trays (minimum 2 nos. per set) shall be checked. Trays so selected shall be
true representative of the total tray bank. Record the findings in the form of
punch list and handover to Engineer-in-charge for rectification/compliance.
iii) Review of Installed Column Internals to the extent access is available. Record
the findings in the form of punch list and handover to Engineer-in-charge for
rectification/compliance.
iv) List out the discrepancies observed. If specialist finds it necessary to discuss
with head office, it shall be referred to HO for decision. Jobs which need
rectification shall be reported to Engineer-in-Charge through a Punch List.
These shall be attended to by Engineer-in-Charge and no further review by
specialist would be required.
v) Submit filled format 3-0542-4001, 3-0542-4002 and copy of Punch List to
Head Office along with tour report.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 594 of 674

 SITE INSTALLATION REPORTING DOCUMENT No.
ENGINEERS FORMAT FOR COLUMN
INDIA LIMITED
(A Govt of India Undertaking) INTERNALS
(BEFORE INSTALLATION) Page of

COLUMN NO.: EILNENDOR'S DRG. NO.:

SERVICE: JOB NO.:
PLANT: CLIENT:

1. DISTANCE BETWEEN TRAY SUPPORT RING (BETWEEN CONSECUTIVE TRAYS

TRAY NO.
DRG. DIMENSION
A
B
C
D
AS BUILT
DIMENSION AT E
POINT F

DIMENSION TO BE TAKEN FROM TOP TO TOP OF TSR WITH PO NTS MARKED ON THE SAME
ORIENTATION FOR ALL TRAYS MINIMUM AT FOUR POINTS UPTO 20000 & MINIMUM SIX POINTS
ABOVE 20000
2. LOCATION OF BOLTING BAR
TRAY NO.
DRG.DIMENSION
G1
ACTUAL
DRG.DIMENSION
G2
ACTUAL
DRG.DIMENSION
G3
ACTUAL
DRG.DIMENSION
G4
ACTUAL
DRG. DIMENSION
G5
ACTUAL
DRG.DIMENSION
G6
ACTUAL
DRG.DIMENSION
G7
ACTUAL
DRG.DIMENSION
G8
ACTUAL

INSTALLATION CONTRACTOR: ENGINEER-IN-CHARGE:

(SIGNATURE) (SIGNATURE)

NAME: NAME:
DATE: DATE:

Notes:
(1) This format shall be filled for all Trays by Installation Contractor and counter checked by Engineer-
in-Charge.
(2) Tolerance on various drawing dimensions shall be as per applicable drawing/standard.
(3) Refer Standard 7-14-0202 for abbreviations & typical detail of trays.

Format No. 3-0542-4001, Rev. 1, Sheet 1 of 7 Copyright EIL — All rights reserved

Page 595 of 674

 SITE INSTALLATION REPORTING DOCUMENT No.
In~l ENGINEERS FORMAT FOR COLUMN
id0=1"e-s- INDIA LIMITED
INTERNALS
(BEFORE INSTALLATION) Page of

COLUMN NO.: EILNENDOR'S DRG. NO.:

SERVICE: JOB NO.:
PLANT: CLIENT:

3. LEVEL READING

LEVEL AT TSR REF.

11 (TRAY/INTERNAL)
REF. POINT

A
B
C

LEVEL AT A, B, C, D ....... TAKEN WITH WATER TUBE WITH "A" AS REFERENCE POINT MINIMUM AT
FOUR POINTS UPTO 20000 & MINIMUM SIX POINTS ABOVE 20000. MINIMUM 3 POINTS PER TSR
SEGMENTS SHALL BE SELECTED.

INSTALLATION CONTRACTOR: ENGINEER-IN-CHARGE:

(SIGNATURE) (SIGNATURE)

NAME: NAME:
DATE: DATE:

Notes:
(1) This format shall be filled for all Trays/Internals by Installation Contractor and counter checked by
Engineer-in-Charge.
(2) Tolerance on various drawing dimensions shall be as per applicable drawing/standard.
(3) Refer Standard 7-14-0202 for abbreviations & typical detail of trays.

Format No. 3-0542-4001, Rev.1, Sheet 2 of 7 Copyright EIL — All rights reserved

Page 596 of 674

 SITE INSTALLATION REPORTING DOCUMENT No.
fa..0 ENGINEERS FORMAT FOR COLUMN
*Igeji Ia5leg INDIA LIMITED
N12,kworkt ...Aim, (A GOV! of India Undertaking) INTERNALS
(AFTER INSTALLATION) Page of

COLUMN NO.: EILNENDOR'S DRG. NO.:

SERVICE: JOB NO.:
PLANT: CLIENT:

TRAY NO.
Al, A3, A4, A5, A7, A8
A DRG. DIMENSION
A2, A6

Al

A2

A3

HEIGHT OF EXIT WEIR A4

(FROM TOP OF TRAY DECK TO TOP OF
AS
WEIR) (mm)
A6

A7

A8

Bl, B3, B4, B5, B7, B8

B DRG. DIMENSION
B2, B6

B1

B2

B3
UNDER DOWNFLOW CLEARANCE, B4
(DISTANCE BETWEEN DOWNCOMER
BOTTOM & TRAY DECK/RECESSED SEAL B5
PAN PLATE) (mm)
B6

B7

B8

Cl, C3, C4, C5, C7, C8

C DRG. DIMENSION
C2, C6
Cl

C2

C3

HORIZONTAL DISTANCE BETWEEN C4

DOWNCOMER PLATE & RECESSED SEAL
C5
PAN (mm)
C6

C7

C8

INSTALLATION CONTRACTOR: ENGINEER-IN-CHARGE:

(SIGNATURE) (SIGNATURE)
NAME: NAME:
DATE: DATE:
Notes:
(I) This format shall be filled for all Trays by Installation Contractor and counter checked by Engineer-in-Charge.
(2) Tolerance on various drawing dimensions shall be as per applicable drawing/standard.
(3) Refer Standard 7-14-0202 for abbreviations & typical detail of trays.

Format No. 3-0542-4001, Rev. 1, Sheet 3 of 7 Copyright EIL — All rights reserved

Page 597 of 674

 SITE INSTALLATION REPORTING DOCUMENT No.
k51-1 ENGINEERS FORMAT FOR COLUMN
ligariaw8 INDIA LIMITED
IA Go, of Inc Unclertalong, INTERNALS
(AFTER INSTALLATION) Page of

COLUMN NO.: EIL/VENDOR'S DRG. NO.:

SERVICE: JOB NO.:
PLANT: CLIENT:

TRAY NO.

DI, D3, D4, D5, D7, D8

D DRG. DIMENSION
D2, D6

DI

D2

D3

UNDER DOWNFLOW CLEARANCE D4

(DISTANCE BETWEEN DOWNCOMER
D5
PLATE & SEAL PAN (mm))
D6

D7

D8
E1, E3, E4, E5, E7, E8
E DRG. DIMENSION
E2, E6

El

E2

E3

CLEAR DISTANCE BETWEEN E4

DOWNCOMER PLATE & SEAL PAN
E5
(mm)
E6

E7

E8

INSTALLATION CONTRACTOR: ENGINEER-IN-CHARGE:

(SIGNATURE) (SIGNATURE)

NAME: NAME:
DATE: DATE:

Notes:
(1) This format shall be filled for all Trays by Installation Contractor and counter checked by Engineer-in-Charge.
(2) Tolerance on various drawing dimensions shall be as per applicable drawing/standard.
(3) Refer Standard 7-14-0202 for abbreviations & typical detail of trays.

Format No. 3-0542-4001, Rev. 1, Sheet 4 of 7 Copyright EIL — All rights reserved

Page 598 of 674

 SITE INSTALLATION REPORTING DOCUMENT No.
ei ENGINEERS FORMAT FOR COLUMN
taPieg INDIA LIMITED
I aiTeat ereowe =Jetta, (A Govt of India Undertaking) INTERNALS
(AFTER INSTALLATION) Page of

COLUMN NO.: EILNENDOR'S DRG. NO.:

SERVICE: JOB NO.:
PLANT: CLIENT:

TRAY NO
CHECK THE FOLLOWING :

CHECK EACH BOLT FOR TIGHTNESS

CHECK ORIENTATION, PROPER MARK (TYPE) AND
TIGHTNESS OF EACH CLAMP
CHECK PROVISION OF LOCK NUTS AND SEAL
PLATES WHEREVER SPECIFIED
CHECK EACH TOP DOWNCOMER PIECE FOR
CORRECT INSTALLATION OF SHIMMING
INCLUDING TACK WELDING/BOLTING
CHECK SEAL WELDING/GASKETING WHEREVER
APPLICABLE
CHECK LEAK TESTING OF SEAL PANS, RECESSED
SEAL PAN, CHIMNEY TRAYS, DISTRIBUTOR, DRAW-
OFF BOXES ETC. AS PER DRAWING
CHECK OVERLAPPING OF DECKS
CHECK FOR DAMAGED, MISSING VALVES AND
VALVE MOVEMENT FOR ALL VALVES FOR VALVE
TRAYS
CHECK FOR FITTING OF PROPER VALVE
COMBINATION (MR2, MR6 ETC.)
CHECK FOR NOTICEABLE DAMAGE TO DECK
COMPONENTS
CHECK LEVELNESS AND ALIGNMENT OF INLET
WEIR AND EXIT WEIR AND ADJUST IF NECESSARY
CHECK BEAM & CLIPS ARE PROPERLY FITTED
CHECK THAT TRAY MANWAY CAN BE OPENED
FROM TOP AS WELL AS FROM BOTTOM
CHECK THAT ALL SLOTS ON TRAY COMPONENTS
ARE FULLY COVERED
CHECK THAT GAPS AT DOWNCOMER ENDS AND
OTHER PLACES ARE WITHIN SPECIFIED LIMITS
CHECK ORIENTATION IN CASE OF RIPPLE TRAYS
FOR LATTICE GIRDERS, CHECK THE LEVELNESS
OF PRIMARY MEMBERS AND COMPLETENESS OF
WELDING OF ALL THE BRACINGS AND
SECONDARY MEMBERS
CHECK TEMPORARY PLUGS WHEREVER
PROVIDED FOR TESTING HAVE BEEN REMOVED
CHECK THAT TRAYS HAVE BEEN CLEARED OFF
ALL FOREIGN MATERIALS

INSTALLATION CONTRACTOR: ENGINEER-IN-CHARGE:

(SIGNATURE) (SIGNATURE)
NAME: NAME:
DATE: DATE:

Notes:
(1) This format shall be filled for all Trays by Installation Contractor and counter checked by Engineer-in-Charge.
(2) Tolerance on various drawing dimensions shall be as per applicable drawing/standard.
(3) Refer Standard 7-14-0202 for abbreviations & typical detail of trays.

Format No. 3-0542-4001, Rev. 1, Sheet 5 of 7 Copyright EIL — All rights reserved

Page 599 of 674

 SITE INSTALLATION REPORTING DOCUMENT No.
ENGINEERS FORMAT FOR COLUMN
Ig•7161W5 INDIA LIMITED
INTERNALS
(AFTER INSTALLATION) Page of

COLUMN NO.: EILNENDOR'S DRG. NO.:

SERVICE: JOB NO.:
PLANT: CLIENT:

BED NO.
CHECK THE FOLLOWING :

CHECK THAT MULTIBEAM SUPPORT PLATE SITS PROPERLY ON

THE TSR WITH NO UNDESIRED GAPS. ALL SPACINGS AND GAPS
ARE EVENLY DISTRIBUTED ACROSS THE VESSEL DIAMETER.
CHECK FOR PROPER LEVELLING OF TOP OF BED AND GAP
BETWEEN TOP OF BED AND BED LIMITER (NO GAPS PREFERRED,
MAXIMUM GAP AT FEW LOCATIONS NOT TO EXCEED ONE
PACKING SIZE).
CHECK THAT BED LIMITER IS PROPERLY BOLTED AND THE GAP
ON THE PERIPHERY IS UNIFORM AND NOT MORE THAN THAT
SPECIFIED IN THE DRAWING. ALSO CHECK THAT PACKING IS
NOT FREE TO COME OUT FROM ANY OPENING. ALSO CHECK
THAT BED LIMITER MESH IS INTACT.
CHECK LEVELNESS FOR DISTRIBUTOR/REDISTRIBUTORS/FLASH
GALLERIES/SPRAY HEADER. SAME TO BE WITHIN TOLERANCE
SPECIFIED IN THE DRAWINGS/STANDARDS AND TO BE
RECORDED IN SHT.1.
CHECK THAT THE DISTRIBUTOR/REDISTRIBUTORS/FLASH
GALLERIES/SPRAY HEADERS ARE PROPERLY CLAMPED/BOLTED.
CHECK THAT THE DISTRIBUTOR/REDISTRIBUTORS/FLASH
GALLERIES (IF REQUIRED) ARE PROPERLY GASKETTED AS
SPECIFIED IN THE DRAWING.
CHECK LEAK TIGHTNESS OF THE DISTRIBUTOR/REDISTRIBUTOR/
FLASH GALLERY (IF REQUIRED), TO BE ENSURED BY FILLING
WATER AND CHECKING LEAKAGES FROM GASKETTED JOINTS.
FOR CHIMNEY/COLLECTOR TRAY, DRAW-OFF BOXES,
WHEREVER APPLICABLE, CHECK COMPLETENESS OF SEAL
WELDING, GASKETTING, PROPER FITMENT OF VAPOUR RISER
COVERS AND REVIEW RECORD FOR LEAK TESTING.
FOR SPRAY NOZZLE DISTRIBUTOR, CHECK FOR
i) HYDROTEST FOR SPRAY HEADER
ii) CLOGGING OF SPRAY NOZZLES, BY RUNNING PUMP, IF
FEASIBLE
iii) CHECK TIP DISTANCE FROM TOP OF THE BED (TOLERANCE
TO BE WITHIN 25 mm)
iv) CHECK GASKET AT FLANGE JOINT, THREAD SEALANT AT
THREADED JOINTS
v) ANY OBSTRUCTION IN THE UNIFORM SPRAY PATTERN
REVIEW OF PROPER ORIENTATION OF VARIOUS TOWER
INTERNALS LIKE BED LIMITER, FEED PIPE W.R.T. DISTRIBUTOR/
REDISTRIBUTORS, AS PER DETAIL SHOWN IN RESPECTIVE
DRAWINGS.
CHECK TEMPORARY PLUGS WHEREVER PROVIDED HAVE BEEN
REMOVED AFTER TESTING

INSTALLATION CONTRACTOR: ENGINEER-IN-CHARGE:

(SIGNATURE) (SIGNATURE)
NAME: NAME:
DATE: DATE:

Notes:
(1) This format shall be filled for all Tower Internals by Contractor and counter checked by Engineer-in-Charge.

Format No. 3-0542-4001, Rev. 1, Sheet 6 of 7 Copyright EIL — All rights reserved

Page 600 of 674

 SITE INSTALLATION REPORTING DOCUMENT No.
ENGINEERS FORMAT FOR COLUMN
~Qllffaigeg
".","
INDIA LIMITED
IA Govt cot incto Undenaking) INTERNALS
(DURING INSTALLATION) Page of

COLUMN NO.: EILNENDOR'S DRG. NO.:

SERVICE: JOB NO.:
PLANT: CLIENT:

BED NO.
CHECK THE FOLLOWING : (FOR STRUCTURED PACKING)

FOR LATTICE GIRDERS (IF ANY), CHECK THE LEVELNESS OF

PRIMARY MEMBERS AND COMPLETENESS OF WELDING OF ALL
THE BRACINGS AND SECONDARY MEMBERS
CHECK THAT SUPPORT GRID SITS PROPERLY ON THE TSR WITH
NO UNDESIRED GAPS. ALL SPACINGS AND GAPS ARE EVENLY
DISTRIBUTED ACROSS THE VESSEL DIAMETER.
CHECK PROPER BOLTING OF SUPPORT GRID SEGMENTS.
ORIENTATION OF STRUCTURED PACKING SEGMENTS LAYERS
SHOULD BE AS PER DRAWING.
CHECK THAT GAP BETWEEN EACH MODULE OF STRUCTURED
PACKING IS WITHIN TOLERANCE LIMIT.
CHECK THAT GAP BETWEEN STRUCTURED PACKING AND
COLUMN WALL IS MINIMIZED AND COLLARS ARE FITTED
PROPERLY.
CHECK FOR PROPER LEVELLING OF TOP OF STRUCTURED
PACKING AND GAP BETWEEN TOP OF STRUCTURED PACKING
AND RETAINING GRID.
CHECK THAT RETAINING GRID IS PROPERLY BOLTED AS PER
DRAWING.
FOR DISTRIBUTOR / REDISTRIBUTOR / FLASH GALLERY (REFER
SHEET 6 OF 7)

INSTALLATION CONTRACTOR: ENGINEER-IN-CHARGE:

(SIGNATURE) (SIGNATURE)
NAME: NAME:
DATE: DATE:

Notes:
(1) This format shall be filled for all Tower Internals by Contractor and counter checked by Engineer-in-Charge.

Format No. 3-0542-4001, Rev. 1, Sheet 7 of 7 Copyright EIL — All rights reserved

Page 601 of 674

 DOCUMENT No.
,?-1 ENGINEERS SITE INSTALLATION
0`-ar Wag
(441,12=r2zAr2
INDIA LIMITED
(A Govt of India Unde(taklAg)
REVIEW CHECK LIST
Page of

TRAY INSTALLATION REVIEW CHECK LIST

(To be filled by Specialist)

(I) Review of filled formats for Tray levelness and other tray installation data
Formats (3-0543-4001sht.1 to 6 of 6) to be completed by Contractor and duly certified
for 100% checking by EIL site.
If any dimension is out of permissible tolerances as per 7-14-0001. Specialist to
review and suggest remedial action, in consultation with HO (if required).

(2) Provide clarification to site on any matter w.r.t. Installation of trays and tower
internals.

(3) Random check minimum 25 % of trays (subject to minimum two trays per set)
(Trays selected shall be true representative).

- EWH & Adjustability (permissible deviation +/- 1 mm)

- UDFC (permissible deviation +/- 3, D/C bottom piece to rest on D/C bracket.
- Gap at deck joints (max. gap - 3 mm at deck joint, 5 mm at EW location).
- Overlapping of tray decks (no overlapping allowed)
- Valve movement, missing & damaged valves (check approx 5% of valves)
- For bubble cap trays, check skirt height & locknuts on caps
(check approx 5% caps)
- Check plugging of holes in case of sieve trays
- Noticeable damage in Internal components, wooden hammers to be used in case
flattening is required.
- Chord heights (acceptable limit V (Col. ID/200 + 4))
- Check inlet weir/inlet weir seal plate at respective location
- Check for proper fitting of gaskets for gasketed deck components.
- Also check whether same has been leak tested or not. Also check that drain
holes are open unless specified otherwise in the drawings.
- Light & heavy valve combination adopted at right place
- Check provision of lock-nuts wherever specified
- For Ripple trays, check relative orientation of trays
- For Catridge trays, check the top tray of each bundle orientation and removal
of lifting box.
- Check the provision of antijump baffle wherever specified
- Check for seal plates on recessed seal pans
- Check temporary plugs wherever provided has been removed after testing

(4) For Chimney/Collector Tray, Draw-off boxes, wherever applicable, check

completeness of seal welding, gasketting, proper fitment of vapour riser covers and
review record for leak testing.

(5) Check arrangement for proper feeding & liquid withdrawal

- Reflux at top tray

- Transition arrangement from one tray to other
- Intermediate feed including direction/angle of vapour & liquid slots
- Feed from bottom most seal pan to partitioned column bottom
- Vapour/reboiler return, if flush, should be parallel to down comer of bottom
most tray.
- Location/Orientation of withdrawal nozzle. Also check provision of vortex
breaker
- Drain & vent holes wherever provided in the feed system shall be clear & open

(6) List out all discrepancies in a punch list for individual column

Signature

Date Name

Format No. 3-0542-4002, Rev. 1, Sheet 1 of 2 Copyright EIL-All rights reserved

Page 602 of 674

 DOCUMENT No.
ENGINEERS SITE INSTALLATION
215:1--eg
>AVM ,r-rasre
JAI:IFA,
INDIA LIMITED
Govt et 1,10. Unoertaiting)
REVIEW CHECK LIST
(A
Page of

TOWER INTERNALS INSTALLATION REVIEW CHECK LIST

(To be filled by Specialist)

1 Review site record for levelness for distributor/redistributors/flash galleries/spray

header. Same to be within tolerance specified in the drawing/standards.

2. Check that the distributor/redistributors/flash galleries/spray headers are

properly clamped/bolted.

3. Check that the distributor/redistributors/flash galleries (if required) are properly

gasketed as specified in the drawing.

4. Review site record of leak tightness of the distributor/redistributors/flash gallery (if

required), to be ensured by filling water and checking leakages from gasketed joints.

5. For Chimney/Collector Tray, wherever applicable, check, if possible, completeness

of seal welding, gasketting, proper fitment of vapour riser covers and review record
for leak testing.

6. For spray nozzle distributor, check for

i) Hydrotest record for spray header

ii) Clogging of spray nozzles, by running pump, if feasible

iii) Sample check tip distance from top of the bed (to be within +25 mm)

iv) Check proper gasket fitment at flange joint, thread sealant at threaded joints.

v) Any obstruction in uniform spray pattern

7. Review of proper orientation of various tower internals like bed limiter w.r.t.
Distributor/redistributors, as per detail shown in respective drawings is mandatory.

Signature

Date Name

Format No. 3-0542-4002, Rev. 1, Sheet 2 of 2 Copyright EIL — All rights reserved

Page 603 of 674

Page 604 of 674
 SPECIFICATION FOR STANDARD SPECIFICATION No.
15d5i-zreq 1=1, ENGINEERS PREPARATION OF TSR/BB/GA 6-14-0018 Rev. 2
iet5teg,
1.11F71
INDIA UMITED
manianA ,.WIS DRAWINGS OF TRAYS
(A Govt 1,4 India Undettaiongi
Page 1 of 11

tr. ter. 3TR./t. tult. r.

SPECIFICATION FOR PREPARATION

OF
TSR/BB/GA DRAWINGS
OF
TRAYS

2 25-09-17
REAFFIRMED & REISSUED AS
STANDARD SPECIFICATION
REVISED & REISSUED AS
<11rIK
S1
96.41 KJHN RKT RN

1 04-01-11
STANDARD SPECIFICATION AK SKM AKG ND

0 17-09-05 ISSUED AS STANDARD SPECIFICATION SKM HCN AKM VJN

Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 605 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
10tll ei ENGINEERS
51gar tif5leg INDIA LIMITED PREPARATION OF TSR/BB/GA 6-14-0018 Rev. 2
1.4lio/rieforeffAJO2F.0 ind. undertak.ng )
fA Govl of DRAWINGS OF TRAYS Page 2 of 11

Abbreviations:

D/C Down Corner

EWH : Exit Weir Height
GAD : General Arrangement Drawing
IWH Inlet Weir Height
MR Material Requisition
OD Outer Diameter
PR Purchase Requisition
TS Tray Spacing
TSRBB: Tray Support Rings & Bolting Bars
UDFC : Under Down Flow Clearance

Static Equipment Standards Committee

Convenor: Mr. R.K. Trivedi

Members: Mr. K.J Hari Narayanan

Mr. P. Bhattacharjee
Mr. Sanjay Mazumdar
Mr. P.P. Pandey
Mr. Nalin Kumar
Mr. K. Anjaneyulu
Mr. Arun Kumar
Mr. Inder Kumar
Mr. Tarun Kumar
Mr. Anish Trehan
Mr. Srikanth Karanam
Mr. M. Azim (Projects)
Mr. S. Ghosal (Process)
Mr. T. Kamalakannan (Inspection)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 606 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
15i1WeY ENGINEERS
PREPARATION OF TSR/BB/GA
Ogeir16115i-eu INDIA UMITED 6-14-0018 Rev. 2
Govt India Unentaking)
DRAWINGS OF TRAYS Page 3 of 11

CONTENTS

1.0 PURPOSE 4

2.0 SCOPE 4

3.0 DRAWING PREPARATION 4

4.0 DESIGN/CONSTRUCTIONAL FEATURES 5

ANNEXURE - I GUIDELINES FOR PREPARATION OF TSRBB DRAWINGS

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 607 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
laRTRY ENGINEERS
Ogeir Of5i-eg INDIA LIMITED PREPARATION OF TSR/BB/GA 6-14-0018 Rev. 2
(WM eli•EM dA310.i) Govt of India Undertalongl
DRAWINGS OF TRAYS Page 4 of 11

1.0 PURPOSE

This specification outlines the minimum requirements of preparation of Tray Support

Rings/Bolting Bars (TSRBB) and General Arrangement Drawings (GADs) for trays. Various
constructional features, standard design dimensions and guidelines for preparation of TSRBB
and GADs of trays have been outlined here. It shall be vendors' responsibility to ensure
completeness and correctness of TSRBB and GAD so as not to have any modifications to the
columns or trays during any stage of execution and have uniform approach while carrying out
design and engineering.

2.0 SCOPE

These guidelines will apply for all the tray design & engineering jobs handled by EIL for EIL
designed trays. For licensed units, these guidelines shall be reviewed by vendor with respect to
any contradictions and discrepancies to the Process Licensor's Specifications and shall be
brought into notice of EIL for resolution. As a rule, the guidelines given by Process Licensor
shall supersede the requirements given in this specification.

3.0 DRAWING PREPARATION

For each column, vendor shall prepare two sets of drawings as below:

3.1 Tower Attachment Drawings

Vendor shall prepare the support rings/support cleats and bolting bars drawings for fabrication.
This set of drawings for support rings/support cleats shall include the following as a minimum:

i) Column sketch indicating location of Tray support rings.

ii) Support Ring plan with location of bolting bars, slot centers and applicable tolerances for
all trays.
iii) Sectional details with applicable tolerances.
iv) Material of construction.
v) Extent and details of welding requirement for support rings/bolting bars/support cleats.
vi) Location/Orientation of Process Nozzles i.e. Feed and Withdrawal Nozzles w.r.t.
Downcomer B/Bar and Draw-off box.

3.2 Tray Layout Drawings

Vendor shall prepare the detailed Trays Layout Drawings of all the trays along with Bill of
Material. The layout drawings for trays shall include the following as a minimum:

i) Column sketch indicating Elevation of Trays, Manholes, Feed Nozzles & Draw-off Box.
ii) Summary of table indicating EWH, EWH adjustability, IWH, UDFC, Leak Testing
requirements etc.
iii) Fully dimensioned PLAN view clearly showing the layout of valves/bubble
caps/orifices/risers or as the case may be for each set of Trays. (Part Plan view are NOT
ACCEPTABLE).
iv) Vent tube details for 3/4 Pass Trays (wherever required).
v) Anti Jump baffle details (wherever required).
vi) Swept back weir details (wherever required).
vii) Sectional views illustrating the installation of internals.
viii) Mechanical design parameters such as beam depths, thickness etc.
ix) Complete detail of beam welding joint (if any).
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 608 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
OPT1E'T ENGINEERS
5ge_JI Mieg INDIA LIMITED PREPARATION OF TSR/BB/GA 6-14-0018 Rev. 2
e.R,VE =MUM) undertakm)
(A Govt of India
DRAWINGS OF TRAYS Page 5 of 11

x) Material of construction.
xi) Item numbers of individual segments that should also tally with the bill of material
prepared by the vendor and shall be marked on plan and sectional views.
xii) Bill of material indicating item number, number of various components, thickness, weight
of individual components, fasteners, spares and total weight.

4.0 DESIGN/CONSTRUCTIONAL FEATURES

4.1 TSR & Bolting Bar

For details of TSR, Bolting Bars, Support Cleats etc., Refer ANNEXURE — I.

4.2 Trays

The General Tray Information for the trays shall be as below:

i) TRAY REFERENCE RADIUS (TRR) = Column I/Radius — W— b

Fillet Weld Size of Tray Support Ring.

Radial Beam End Clearance

ii) CLAMP REFERENCE RADIUS (CRR) = Column I/Radius — TSR Width — S.

Edge Clamp Clearance

iii) BEAM END CLEARANCES

Radial Refer Table — 1.0 below for dimension 'b'.

Exit Weir Side 1 step lower than the radial beam end clearance.
M/W Section Beams Min. beam end clearance (12 or 15 as applicable).

iv) SLOT SIZE

Radial Refer Table — 1.0 below for dimension 'L'.

Adjustable weir (Total adjustability + 11) x 11
Other 25 x 11

v) EDGE CLAMP CLEARANCE

Radial Refer Table — 1.0 below for dimension 'S'.

(Minimum 15 mm for manway edge clamps).

Exit Weir Side 13 mm for Tray Edge Clamps.

(15 mm for Manway Edge Clamps)

TABLE 1.0

COLUMN ID "b" "L" "S" REMARKS

Up to 1200 mm 12(*) 25 13 For 13 mm joggling, adopt
1201 to 2000 mm 15 25 18 next Beam End Clearance.
2001 to 3000 mm 20 35 18
3001 to 4500 mm 25 50 22
4501 to 6000 mm 30 50 25
6001 to 7500 mm 35 50 25
7501 to 9000 mm 35 50 25
9001 to 14000 mm 50 50 25
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 609 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
/5iffaZI€1? ENGINEERS
eir 1854-e g INDIA LIMITED PREPARATION OF TSRIBB/GA 6-14-0018 Rev. 2
I allErrr JiDIA/ (A Govt of India Un0eflak ■ o9)
DRAWINGS OF TRAYS Page 6 of 11

vi) HOLE TOLERANCE

Valve holes ± 0.2

Sieve tray hole ± D/100 (Maximum off 0.1 mm)
No. of holes ± 2 percent

vii) HOLE DISTANCE

(a) Valve Trays

From plate edge 29 + overlap

or 52 mm minimum for MR7 and Two stage valves.

From beam offset - 48 mm (Preferred)

36 mm minimum for MR2/MR4/ MR6 valves (beam
clamps to clear valve locations) with 8mm offset.
(40 mm with 13 mm offset)

From Exit Weir 122 mm (Preferred)

90 mm minimum for MR2/MR4/ MR6 valves
(Clamps to clear fouling with valve locations)
112 mm minimum for MR7 and two stage valves
(Clamps to clear fouling with valve locations)

From TSR/Central Major Beam Edge

Minimum 29 + beam end clearance (Preferred).

(Clamps to clear valve locations).

Maximum 54 + Edge Clamp clearance + (Slot length-11)/2.

(b) Sieve Trays

From plate edge Overlap + hole dia (Preferred)

or Overlap+3 mm + hole dia/2 (min.)

From Offset Offset + hole dia (Preferred)

(Joggling) Offset + hole dia/2 (min.)

From exit weir end- 50+3 * Exit Weir Thk + Hole dia
(63 minimum)

From TSR/Major - Hole dia/2 + Beam End Clearance

Beam Edge

(c) Bubble Cap Trays

D

From plate edge - Cap 9— + 25 (Preferred)

2
riser OD
or + 30 + deck thk. for Skirt ht D 15
2

From beam offset - Offset + riser OD/2 + 5 + deck thk (min)

Riser OD/2 + deck thk + 30 (Preferred)

From EW edge 65 + 25 + Cap OD/2 (Preferred)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 610 of 674

 - -

SPECIFICATION FOR STANDARD SPECIFICATION No.

1511WE'T ftENGINIEFRS
c
Ogeji 051-egWINDIA LIMITED PREPARATION OF TSR/BB/GA 6-14-0018 Rev. 2
(men mew Govt In Undertaiong)
dA3,117.i) (A
DRAWINGS OF TRAYS Page 7 of 11

56 + D/C thk x 3 + Cap OD/2 (Minimum & clamp

fouling to be checked)

From TSR edge Beam end clearance + riser OD/2 + 5 + deck thk.
(Minimum & clamps to clear fouling, distance
between clamp & cap centres to be 27 + cap OD/2)

viii) STANDARD PITCHES

Valve Trays

Standard Triangular Pitches

(Normally used with MR2/MR4/MR6 valve)

Height 61, 65, 75, 90, 108

Base Minimum ht/ 0.866

(Rounded off to integer and 70 mm for Ht. = 61& 65)
Maximum 150

NOTE:

If the number of valves can not be accommodated with the Minimum pitch of 70
mm X 61 mm, as a special case, pitch can be reduced to Either 69 mm X 61 mm
OR 70 mm X 59 mm.

Rectangular Pitches
(Normally used with MR7/Two Stage Valve)

Height 70, 75, 80, 85, 90

Base Minimum = Height

Maximum = 150

Equilateral Triangular Pitches

Pitch 70, 80, 90, 108

Sieve Trays

Sieve trays are normally provided with Equilateral triangular pitches as below:

Minimum pitch 2 x Orifice diameter

Maximum pitch 3 x Orifice diameter

For Extractor Trays, Orifice Pitch shall be kept maximum possible (Ignore pitch given
above) so as to accommodate given number of orifices uniformly and utilizing
maximum active area.

Bubble Cap Trays

These are normally used with Equilateral triangular pitches

Minimum pitch Cap OD + 25

Maximum pitch Nominal Cap size x 1.5

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 611 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
k3ifaeJei#A ENGINEERS
*Igeji 215teg W INDIA LIMITED PREPARATION OF TSR/BB/GA 6-14-0018 Rev. 2
(MEW 2:107RE 4513,10.0 IA Govt of India Undertaking)
DRAWINGS OF TRAYS Page 8 of 11

ix) INTEGRAL BEAM SIZE

Sizes of the trays integral beams shall be as given in Cost Analysis Data Sheets OR
Mechanical Details Sheets given alongwith MR/PR. However, following guidelines
shall be followed, if no details are available:

Beam Depth = 65 mm minimum

TS/5 preferred
TS/4 maximum

Lip = 25 mm for t = 2
35 mm for t = 3
40 mm for t = 4
50 mm (for t > 4 and beam with stiffeners welded inside).
60 mm (Minimum) for Positively Fastened Integral Beams.

Overlap = 20 mm for t < 3 0 mm and column dia < 3000

23 mm for t > 3.0 and column dia < 3000
25 for t > 3 mm and column dia >3 000

Offset = 8 mm for t < 3.0 mm.

(Joggling) = 13 mm for t > 3.0 mm.

Where "t" = Tray Deck Thickness

INTEGRAL BEAM DETAIL

x) UDF PLATES

Sizes of the UDF Plates integral beams shall be as given in Cost Analysis Data Sheets
OR Mechanical Details Sheets given alongwith MR/PR. UDF Plates shall be
positively fastened with the support cleats welded with the columns shell, in case
beam length exceeds 1500 mm.

Positively Fastened Side UDF Plates with Integral Beams

Side UDF Plates with Integral beams, whenever beam length exceeds 1500 mm, shall
be positively fastened with the support cleats welded with the column shell. For such
cases, the lip of the integral beam shall be increased suitably. For details, refer
Annexure-I, Detail-1.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 612 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
lalfRZJET ENGINEERS
ifs' ~n agteg INDIA LIMITED PREPARATION OF TSR/BB/GA 6-14-0018 Rev. 2
Cm MAINZ trAac(*(A( (A Govt In&A I.MArtalon9) DRAWINGS OF TRAYS Page 9 of 11

Positively Fastened Side UDF Plate with loose beam

Loose Beams (C-Section) shall be provided at Side UDF Plate, if length of Side UDF
Plate (for all thickness) exceeds 3000 mm. For details, refer Annexure-I, Detail-2.

Centre/Off-Centre UDF Plates with Integral Beam

Positively Fastened Integral Beams shall be provided at Centre/Off-Centre UDF

Plates, if length of central/off-centre UDF Plate lies between 1500 mm 3000 mm (for
all thickness). The vertical portion of the support cleat shall be flush with the edge of
the Tray Support Ring. Integral Beam of the UDF Plate shall be bolted with Support
Cleat through 5 mm Thick Splice Plate/Shear Clip. For typical details, refer
Annexure-I, Details-3.

Centre/ Off-Centre UDF Plate with Loose Beam

Loose Beams shall be provided at Centre/Off-centre UDF Plates, if length of UDF

Plate (for all thickness) exceeds 3000 mm. For typical details for central/off-centre
UDF plate with loose beams, refer Annexure-I, Detail-4.

xi) MAJOR BEAM/LATTICE GIRDERS ACROSS COLUMN

Major Beams (T Section OR 'C' Section) and Lattice Girders shall be used for
column diameters >3000 mm. When major beams/lattice girders are used, these shall
be oriented along the liquid flow from UDF Plates to Downcomers. For such
configurations of the Valve Trays, the tray decks shall be oriented such that all
integral beams shall be perpendicular to the liquid flow. The pitch of the valves shall
also be rotated (Tray deck layout and valve pitch shall be on the pattern similar to
Sieve Trays and Bubble Cap Trays).

xii) OTHER FEATURES

a) For valve trays, in case no major beam or lattice girder is provided, beams of
the tray decks shall be oriented along the liquid flow (i.e. Beams shall run from
UDF Plates to Downcomers). However, in case a major beam/lattice girder is
provided along the direction of liquid flow, beams for tray decks shall be
provided perpendicular to the direction of liquid flow. For Sieve trays and
Bubble cap trays, beams for tray decks shall always be provided perpendicular
to the direction of liquid flow.

b) The base of the Valve Pitch (i.e. Dimension of triangle of the pitch parallel to
beam) shall be decided in such a way that first row of valves is located

preferably at 122 mm from the Exit Weir. This shall never exceed 130 mm
except for the case when the base of the Valve Pitch exceeds 150 mm. In order
to achieve this, if required, the base of the valve pitch can also be used other
than multiple of 5 (i.e. 71, 72, 73, OR 92, 93, 94, 95 etc. and
so on).

c) For valve trays Interrupter Bar/ Interrupter Angle shall be provided on all trays
except where inlet weir is provided as per Cost Analysis Data Sheets OR
Mechanical Details Sheets.

Interrupter Bar/Interrupter Angle may be omitted for Sieve/Bubble Cap Trays

and Valve Trays with Recessed Seal Pans.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 613 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
18d1WA ENGINEERS
El5feu INDIA LIMITED PREPARATION OF TSR/BB/GA 6-14-0018 Rev. 2
Rom evow oo.Atoo) (A Govt of India Unclertalang)
DRAWINGS OF TRAYS Page 10 of 11

d) Three Pass and Four Pass trays shall normally be provided with Vapour
Equaliser Tubes as per applicable standard in Downcomers at approximately
150 mm below tray level.

e) For recessed seal pans and sloping downcomers, spacer at approx 1200 mm
spacing shall be provided between recessed seal pan & sloping downcomer to
maintain appropriate clearances.

f) Removable inlet weirs are preferred. Welded inlet weir angle/strip may be used
only if removable weir is not feasible due to valve fouling etc.

Inlet Weir strip shall be used only for t > 3 mm. Else use welded angles.

Inlet Weir Seal Plates shall always be located towards UDF plate.

g) Drain hole size, unless specified otherwise shall be 11 mm diameter.

h) Wherever Inlet weir is provided, interference/fouling with valve/sieve holes to

be checked for all cases.

i) In case, radial valve distance with vessel wall exceeds 150 mm, baffles of size
150 x 100 shall be provided to prevent channeling of liquid along with vessel
wall.

j) Maximum Deck plate width shall be 450 mm unless specified in Cost Analysis
data sheet.

k) Valves Allocation

Wherever, combinations of MR2/MR6 (OR Light and Heavy) valves are

indicated in Datasheets, MR2/MR6 (Light/Heavy) valves to be provided in
alternative 2 rows. First 2 rows from UDF Plate side to be provided with
MR2/Light valves and next 2 rows to be provided with MR6/Heavy valves &
so on.

1) Welding

i) Weld joint in the tray deck is not acceptable.

ii) Loose beams, seal pans, recessed seal pans in thk. 3 mm & higher
with length more than 3000 mm are permitted with welded joint with
backing plate (weld joint shall be kept away from centre line).

iii) For Inlet weir, interrupter angle welding, stitch welding can be
substituted by resistance spot welding at a spacing of 40 mm with
strength of each spot 25 kg.

iv) Fillet Weld Size of the tray components, wherever welding is

required, shall be equal to the minimum plate thickness of the two
plates being welded together.

m) All Radial Tray Edge clamps for radial slot sizes more than 35 X 11 mm shall
be provided with rectangular washers.

n) All Tray Edge clamps shall be indicated with marks.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 614 of 674

 SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS
*1ge..n 215teg INDIA LIMITED PREPARATION OF TSR/BB/GA 6-14-0018 Rev. 2
miaow°
(airTer ?Woe? IA Govt of India Undertaking)
DRAWINGS OF TRAYS Page 11 of 11

o) For Draw-off Boxes and Chimney Trays, where all metal to metal joints are to
be seal welded, the clamps shall be provided at a pitch of 250 mm to 400 mm
for initial positioning of the tray decks/components inside the column. After
all seal welding is completed, all clamps shall be removed and the hole/slots
shall be covered with the blind washers of the same size as that of the clamps,
and these blind washers shall also be seal welded with the tray decks. Blind
washers required for this purpose shall also be included in the scope of
supply.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 615 of 674

 IR-CHOC(OS) 0
I/DIA.RANGE
TOLERANCE
(NOTE-1)
SIDE CEN/OFFCEN
B/BAR SIZE 8/BAR SIZE S/RING SIZE 'C' 'b' r . E. sLoir) SIZE
(
UP TO 1200 ±12 85 X 6 - 40 X 6 • 62 12 50 25 25 X 11
' 1201 TO 2000 150 X 6 50 X 6 91 15 76 38 35 X 11
■
NO WELD ±20 110 X 6
OFF-CENTRE I S R-CHOC 5 ::
HERE 2001 TO 3000 ±30 125 X 6 150 X 6 65 X 6 96 20 76 38 45 X 11
(3/ I 3001 TO 4500 ± 35 150 X 10 175 X 10 75 X 10 115 25 90 45 55 X 11
Dirat tr"63
4501 TO 6000 ±40 175 X 10 200 X 10 90 X 10 120 30 90 45 55 X 11
6001 TO 7500 ±45 200 X 10 225 X 10 90 X 10 ** 135 35 100 50 65 X 11
OFF-CENTRE 0 S TRAY ELEVATION
I rzzzz, 7501 TO 9000 ±50 200 X 10 235 X 10 100 X 10 135 35 100 50 65 X 11
AtratiEBBOLThgraB8R
li 9001 TO 12000 ±60 225 X 10 280 X 10 110 X 10 170 50 120 60 75 X 11

LT
1

il
ISI7E AS PER TAR F.)
12001 TO 14000 ±70 225 X 10 305 X 10 125 X 1 180 50 130 65 75 X 11
i NOTES;
II _a I NO WELD 0 1 TOLERANCE ON INSIDE DIAMETER OF VESSEL(TOTAL OUT OF ROUNDNESS). THE VALUES
,D M • •
G HERE GIVEN ARE PERMISSIBLE TOLERANCES TO SUIT TRAY DESIGN. DIMENSIONS AND TOLERANCES
a
43 <49
I COVERED UNDER THIS STANDARD ARE NOT FOR CARTRIDGE TYPE TRAYS.

8
2 VESSEL CL TO REF. DOWNCOMER FACE ON BOLTING BAR : ±1
+
3 VESSEL CL TO REF. DOWNCOMER FACE ON BOLTING BAR : (SIDE AND OFF-CENTER
I 75 DOWNCOMERS)
0 UP TO 1200 1201 TO 2000 2001 TO 3000 3001 TO 4500 4501 TO 6000 6001 TO 7500
±2 ±2 ±4 ±4 ±6 ±6

cwi
O 7501 TO 14000
±6
I- TRAY ELEVATION 4. SLOT CTRS IN CENTRE/OFF-CENTRE DOWNCOMER BOLTING BAR :
to
UP TO 1200 1201 TO 2000 2001 TO 3000 3001 TO 4500 4501 TO 6000 6001 TO 7500
±12 ±20 ±27 ±35 ±40 ±45
L
7501 TO 9000 9001 TO 12000 12001 TO 14000
±50 ±60 ±70
a la ■ 09
5 SLOT CTRS IN SIDE DOWNCOMER BOLTING BAR :
: . UP TO 1200 1201 TO 2000 2001 TO 3000 3001 TO 4500 4501 TO 6000 6001 TO 7500
O :::
II

II ±4 ±6 ±13 ± 21 ±27 ± 35
7501 TO 9000 9001 TO 12000 12001 TO 14000
WI ll - . ±40 ± 45 ± 50
0 11." 6 BACK MARK FROM EDGE OF BOLTING BAR TO SLOT CTRS ; ±1
.
7 SUPPORT RING CUT-BACK FROM EDGE OF BOLTING BAR : ±i
: ±F,
+ nO
0 1., 8 SUPPORT RING NOTCH WIDTH FROM FACE OF BOLTING BAR 58
CTR D COMER
illil 9 DOWNCOMER STOOL FACE FROM EDGE OF BOLTING BAR : ±g
BOLTING BAR
I 0 10 BETWEEN CONSECUTIVE TRAY SUPPORT RINGS : ±3 NON-ACCUMULATIVE.
N
.o 11 SUPPORT RING ELEVATION TO DOWNCOMER STOOL : ±S
+ 12 SUPPORT RING TO TOP OF WEIR BOLTING BAR : ±1
In
0
to SIDE 0 COMER
BOLTING BAR
a
:LJ I:e
/
13 CLEARANCE BETWEEN SUPPORT RING & BOTTOM OF DOWNCOMER BAR : ±3
14 SUPPORT RING OUT OF LEVEL: (MEASURED FROM HIGHTEST TO LOWEST POINT)
13..50 mm FOR VESSEL DIA UP
U15
P 0TIOT0153
0 0 00mm
m.
w
0 ._. 1 _..
it)
V1
-. 4.5 mm FOR VESSEL DIA. 3001 TO 4500 mm.
mm.

6.0 mm FOR VESSEL DIA. GREATER THAN 4500 mm.

_
15 LEG LENGTH FOR FILLET WELD (W) SHALL BE, 6mm FOR TSR PLT. THICKNESS (T)
UPTO 12mm, 10mm FOR 12mm<T&16mm & 0.7 ' Tmm FOR T>16mm.
16 THICKNESS OF SUPPORT RINGS/BOLTING BARS AS INDICATED ABOVE IS MINIMUM
EXCLUDING VESSEL CORROSION ALLOWANCE. DOUBLE THE VESSEL CORROSION ALLOWANCE
SHALL BE ADDED TO THE ABOVE THICKNESS.
17 WHEREVER VESSEL CORROSION ALLOWANCE (6mm) IS ENCOUNTERED
LEGEND:— OL = TRAY OVERLAP • - 50mm SUPPORT RING WIDTH SHALL BE ADOPTED.
N = NO. OF SLOTS
IR = INSIDE RADIUS OF COLUMN BD = BEAM DEPTH ** - FOR DESIGN LOADING IN EXCESS OF 1500 Kg/m2 PROVIDE 100 mm DEEP
L = LENGTH OF SLOTS GUSSET AT A SUITABLE SPACING AS REQUIRED.
CHS = CHORD HEIGHT - SIDE
b •• BEAM END CLEARENCE 88 THK. = BOLTING BAR THICKNESS
CHC =CHORD HEIGHT - CENTER
EWH = EXIT WEIR HEIGHT
CHOC-(0S) = CHORD HEIGHT - OFF CENTER(OUTSIDE)
CHOC-(IS) = CHORD HEIGHT - OFF CENTER (INSIDE) UDFC = UNDER DOWN FLOW CLEARENCE
& g? j
2 25-09-17 REAFFIRMED AND REISSUED AS STD. SPEC. SK / IK `----- KJFM RKT /
SPECIFICATION No
OM. OSpEERS v 04-01-11 REISSUED AS STANDARD SPECIFICATION AK SKM AKG ND SPECIFICATION FOR PREPARATION
eldit.CerMen Stds. Bureau
6-14-0018 ANNEXURE - I, Rev 2
Rev Prepd Checked OF TSR/BB/GA DRAWING OF TRAYS
111111111111•111Olanfal (A Govt. of India Undertaking) Date Purpose Convenor Chairman
No by by Page 1 of 3
Approved by
Format No. 8-00-0001-F5 Rev. 0 Copyright EIL - All rights reserver
Page 616 of 674
 ■

52 4+ t
3 CHC-D/C THK.-25
1 25 1 cm_ 5 STHR SHEAR CUP

-r-
-..--
— M:II
'".• BEAM END
+3 I 1 ,..... CLEARANCE CHC - D/CTHK- 50 + (TOP UP OF BEAM)
43 2
C4 ."*. i Mir SEAL PLATE
X in i
*2
1..... -1 4I -I-11
ii A

- '
BEAM END CLEARANCE
-k ,-

1
-

111I
11 5 1,, I
200 HOLE IN SUPPORT 1
35 ..- 1
, 1 1
CLEAT 25X11 VERT
a

-
01 20 SLOT IN SHEAR CUP
1'.. I ...,
/
I / 4 A
UP OF INT GRAL BEAM (UDF) ../ E
IIT g
25 40 T Pr ..45+T+t (ROUNDED OFF TO NEXT 5) w (;)
0
'
I
(...
.
1
?5
u) to
z •
.SECII0=6.9 ILIDY=2S SECTION—AA m s
I —
VIEW—X
U)

CENTRE/OFF—CENTRE UDF PLATE WITH POSITIVE FASTENED INTEGRAL BEAM (DETAIL —3 CENTRE/ OFT CENTRE UDF WITH LOOSE BEAM
IDETAIL-4

t-
CHS+0/C THK + 50 - (TOP
25 OL UP OF LOOSE BEAM)
......... -...-- CHS+D/C THK.+22 3 2.
aaaaaarm SLOTS IN
BOLTING BAR \
I I _— 04 ■r — 1-1
I I
BEAM END 1
X.._ I III
I I ItiI/ CLEARANCE —I— 11
I 1 11
71 ihl
, V111-,-, 11 x ,,c):2 T?".03,:
/ 1 11 00+ ' I1
1. (III II
p
+ 20 -. -

IL_
I / L -II, _I 5
I

_
1 1 11
II A
MB

25 25+
8 IIPP
• A I.

35
.
I
u)
[A :,i ,
LL_

II
_ 41

1 A1

(MIN.) 25 0
cn b JIL,.,...„..„
0 11.'
UP OF INTEGRAL BEAM (UDF) z
SECTION-AA ∎45+T+t (ROUNDED OFF TO NEXT 5) S ECTION—AA to u" VIEW—X

SIDE UDF PLATE WITH POSITIVE FASTENED INTEGRAL BEAM ......4, it."-:.„- SIDE UDF PLATE WITH LOOSE BEAM
IDETAI IDETAIL-2
2 25-09-17 REAFFIRMED AND REISSUED AS STD. SPEC. s I JHN RKT RN SPECIFICATION No.
ygme RiSparED v 04-01-11 REISSUED AS STANDARD SPECIFICATION AK SKM AKG ND SPECIFICATION FOR PREPARATION
6-14-0018 ANNEXURE - I. Rev. 2
Rev Prepd Checked SW Carman Stds. Bureau
1811111.11111111111•111.11110 (A Gov! of Inds Undortaldrig) Date Purpose Convenor Chairman OF TSR/BB/GA DRAWING OF TRAYS
No by by Approved by Page 2 of 3
Format No 8-00-0001-F5 Rev. 0 Copyright EIL - All rights reserver
Page 617 of 674
 N—LX 11 HORZ. SLOTS
IN EACH BOLTING BAR
NO WELD HERE
NOTES : —
. ''' 71, r..7

EWHi l
*1 1. DOWNCOMER STOOL IS NOT REDO FOR DOWNCOMER LENGTH <1500 mm.
N—Lx18 HORZL SLOTS --• A
ii 0 i 2. FOR EWH <40mm, FIRST SLDT (ABOVE SUPPORT RING) SHALL NOT BE
QIx,.Ts.:M=IiVulael T.T: 5 I-- OF S
N PROVIDED. FIRST D/COMER APRON SHALL BE REDUCED TO 290 mm

OH-WM%
INSTEAD OF 325 mm.
/ 0' .4 I
r• n M 3. IN CASE, D/COMER FIRST PIECE IS INCREASED BEYOND 325 mm DUE TO

f
STRENGTH REQUIREMENTS, D/COMER STOOL LOCATION SHALL BE CHANGED

325+t+ 31
I ACCORDINGLY.

TRAYSPACING
1

ir —

1
4. FOR EXIT WEIR WITH ADJUSTABLE EWH OR WITH BLOCKING DIMENSION SHALL
I

3dan-HM3+ONI3WISAV&
0tt
BE KEPT CORROSPONDING TO MINIMUM am.

(c+t+on)
I

Irks
5. DIMENSIONS MARKED (•) SHALL BE TO SUIT THE BOLTING BAR HEIGHT
g SHALL BE MAINTAINED AS 100, 90, 80 OR 70 mm.

out
PS 11 6. DIMENSION MARKED (44) SHALL BE 25 mm TO 50 mm.

91.
z
CS M
.<
VS Li. i0 . an

I(*
1
T/47i -Er
Ir

)
I, i-...',. 4dt/-

MEE
15
.;
I li
willki l'....
-CIE*
' II
/ ■ i NIMION99 IM
- 7--
..,
41+
Tir 0
L.,...
0
VIFV/ FROM—Y
(DOWNCOMER STOOL)
n M. (NOTE-1)
*1
TO
O SUIT
l ■
DETAIL OF BOLTING BAR FOR STRAIGHT DOWNCOMER
25 FLANGE+10)
I DETAIL-7
NO WELD
.1kLE6C111101.11NraWB
NO WELD JIIACILIKILIIII11265
DETAIL OF BOLTING BAR FOR LATTICE GIRDERS HERE

EWH+2t+75
2

i (ot -t-3z +m3 ),

L +4Z-1
IDETAIL-5 00
+I

325+t+ 38

'
o
N—Lx18 HORZL SLOT il —
IN EACH B/BAR BEAM THK 2
T 2

AYlLL
2 m
cti
...
— .,--

I
1- + (1)
0 II
Etil ...

. . • ■ •

(ou,s+ L),
,...Or .T i .,.. 1113
TO SUIT
FLANGE+10 RECESS SEAL PAN
RECESS SEAL PAN
VIEW-Z I
DETAIL OF SUPPORT CLEAT FOR "I" TYPE MAJOR BEAM VIM -Z
DETAIL OF BOLTING BAR FOR SLOPING DOWNCOMER DETAIL OF BOLTING BAR FOR SLOPING DOWNCOMER
um (CENTRE1
DETAIL-6 An _ ilk. ETAIL-8 ft?,--- DETAIL-9
OM. MIMS
2
v
Rev
25-09-17
04 01 11
- -
REAFFIRMED AND REISSUED AS STD. SPEC.
REISSUED AS STANDARD SPECIFICATION
K / IK
AK
Prepd
KJ
SKM
Checked
AKG
RKT

MIL Commilis Stds. Bureau

RN
ND SPECIFICATION FOR PREPARATION
SPECIFICATION No.

6 - 14 - 0018 ANNEXURE- I, Rev. 2

mrlemiratamo (A Cost of India Undartaldng) Date Purpose Convenor Chairman OF TSR/BB/GA DRAWING OF TRAYS
No by by Approved by Page 3 of 3

Format No. 8-00-0001-F5 Rev. 0 Copyright EIL All rights reserve(

Page 618 of 674

 ex ..
?
INSPECTION AND TEST PLAN STANDARD SPECIFICATION No.
ENGINEERS
INDIA LIMITED FOR 6-81-0007 Rev. 4
wen rircntero, IA Govt of India Undertaking)
BOLTING MATERIAL Page 1 of 6

tr"e4r AaRqm
fkftut a trftur
INSPECTION AND TEST PLAN
FOR
BOLTING MATERIAL

4 19.09.2016 REVISED AND RE-ISSUED TKK HP teRN

3 17.06.2013 REVISED AND RE-ISSUED TKK RKS SCG DM

2 15.07.2011 REVISED AND RE-ISSUED TKK SCG AKC DM

1 28.09.2007 REVISED AND RE-ISSUED PD RB MVKK VC

0 23.04.02 ISSUED FOR IMPLEMENTATION NKN SPS AKB SB

Convenor Chairman
Rev. Prepared Checked
Date Purpose Standards Committee Standards Bureau
No. by by
Approved by

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 619 of 674

 INSPECTION AND TEST PLAN STANDARD SPECIFICATION No.
■31 el ENGINEERS
Ifgzrr Elf51eg INDIA LIMITED FOR 6-81-0007 Rev.4
ING71 mtm atiOrAt IA Govt. of Indio Undettaking)
BOLTING MATERIAL Page 2 of 6

Abbreviations:

CELL Certification Engineers International Limited MRT Mechanical Run Test

CIMFR Central Institute of Mining & Fuel Research NDT Non Destructive Testing
CE Carbon Equivalent NPSH Net Positive Suction Head
DFT Dry Film Thickness PO Purchase Order
DPT Dye Penetrant Testing PESO Petroleum Explosive Safety Organization
DHT De-hydrogen Heat Treatment PQR Procedure Qualification Record
ERTL Electronics Regional Test Laboratory PR Purchase Requisition
FCRI Fluid Control Research Institute PMI Positive Material Identification
HT Heat Treatment RT Radiography Testing
HIC Hydrogen Induced Cracking SSCC Sulphide Stress Corrosion Cracking
ITP Inspection and Test Plan TC Test Certificate
IP Ingress Protection TPI or TPIA Third Party Inspection Agency
IHT Intermediate Heat Treatment UT Ultrasonic Testing
IC Inspection Certificate VDR Vendor Data Requirement
IGC Inter Granular Corrosion WPS Welding Procedure Specification
MPT/MT Magnetic Particle Testing WPQ Welders Performance Qualification
MTC Material Test Certificate

Inspection Standards Committee

Convenor : Mr. R.K. Singh

Members:
Mr. Rajeev Kumar Mr. Himangshu Pal Mr. Neeraj Mathur
Mr. T Kamalakannan Mr. Mahendra Mittal Mr. Deepak Gupta (Project)

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 620 of 674

 INSPECTION AND TEST PLAN STANDARD SPECIFICATION No.
1,531ReJe1 eh ENGINEERS
ftitMes NW INDIA LIMITED
1.11771 ereCIRE
FOR 6-81-0007 Rev.4
BOLTING MATERIAL Page 3 of 6

1.0 SCOPE:

This Inspection and Test Plan covers the minimum testing requirements of Bolting Material.

2.0 REFERENCE DOCUMENTS:

PO/PR/ Standards referred there in/ Job specifications /Approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS:

SCOPE OF INSPECTION
SL NO. QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
1.0 Procedure

Heat Treatment & NDT Procedure

1.1 Documented Procedures 100% - H R
Procedures Documents
2.0 Material Inspection

2.1 Chemical, Steel making Test

Raw Material Inspection 100% H H R
process, Macro Etch , etc. Certificates
3.0 In Process Inspection
Thread Rolling,
3.1 Hot forging of Nuts/Bolt Inspection
Process Parameters 100% - H -
Heads, Machining Report

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 621 of 674

 INSPECTION AND TEST PLAN STANDARD SPECIFICATION No.
eJel. ENGINEERS
I.tryn rirowe
INDIA LIMITED FOR 6 81 0007 Rev.4
- -
(A Govt of India Undertalongj
BOLTING MATERIAL Page 4 of 6

SCOPE OF INSPECTION
SL NO. QUANTUM
STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Normalising & Tempering,
Quenching & Tempering
Solution Annealing,
Heat Treatment Inspection
3.2 Stabilization Heat 100% - H R
Report
Treatment, Strain
Hardening, Nitriding etc.
as applicable
3.3 NDT (as applicable) Defects detection 100% Test Reports - H R
Product Chemical, Proof
Load Test, Stress Rupture,
Identification of Test Lot as per
3.4 Tensile, Hardness, Impact, Test Reports - H W
Samples specification.
and Other test as
applicable
Product Chemical, Proof
Destructive Testing Load Test , Stress Rupture, Lot as per
3.5 Test Reports - H W
Mechanical, Impact and specification.
Other test as applicable
.
Galvanizing Inspection
3.6 Integrity Of Galvanised
(If Applicable) 100% Report - H R
Coating

4.0 Final Inspection

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 622 of 674

 INSPECTION AND TEST PLAN STANDARD SPECIFICATION No.
ENGINEERS
aem laaj eg INDIA LIMITED FOR 6-81-0007 Rev.4
WWI m.o,fecolawanil IA Govt. of Indio Undefteking)
BOLTING MATERIAL Page 5 of 6

SCOPE OF INSPECTION
QUANTUM
SL NO. STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
100% by
Visual Marking & supplier & Inspection RW
4.1 Visual & Dimension -
Dimensions Random by EIL Report (Note-3)
/ TPIA
Stamping of
bolting material
which are
Stamping of Accepted witnessed by Inspection _
4.2 Final Stamping H W
Bolting Material EIL/TPIA. Report
Others to have
suppliers
identification.
As Per ElL
PMI Check Inspection _
4.3 Chemical Check Spec. - H W
report
repo
6-81-0001

5.0 Painting

Rust Preventive & Color Visual & Color Coding as Inspection

5.1 100% - H -
Coding (as applicable) applicable Report

6.0 Documentation & IC

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL —All rights reserved

Page 623 of 674

 INSPECTION AND TEST PLAN STANDARD SPECIFICATION No.
401 ei
ENGINEERS
1g-a faiteg INDIA LIMITED
(.112Fr frelAVIRMINA) (A Gout at India Undedaking)
FOR 6-81-0007 Rev.4
BOLTING MATERIAL Page 6 of 6

SCOPE OF INSPECTION
QUANTUM
SL NO. STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB
OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Review of Stage
Documentation & Supplier TC
6.1 Inspection Reports / Test 100% - H H
Inspection Certificate(IC) & IC
Reports & Issue of IC

Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness {As specified or 10% Max. ( min.1 no. of each size and type of Bulk
item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).
Notes (as applicable):
1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be
applicable.( unless otherwise agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.

3. Final visual and dimension shall be checked as per below sampling plan:

Lot Size (Nos.) Sample Size (Minimum)

Upto 100 2% (Min. 2 Nos.)

101 to 500 1% (Min. 3 Nos.)

501 and above 0.5% (Min.5Nos.)

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 624 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
ENGINEERS
5Qzlf 16151-
ag INDIA LIMITED FOR 6-81-0016 Rev. 3
eirRIA2 C151.FRFA A Govt of Indo Undertaking)
TOWER PACKINGS
Page 1 of 5

rra-{ 4RI• d FAT-

WA-TuT a tittaiuT
INSPECTION AND TEST PLAN
FOR
TOWER PACKINGS

_1112.}<1.
3 14.05.2020 REVISED AND RE-ISSUED K CS RKS SKS

2 18.06.13 REVISED AND RE-ISSUED TKK RKS SCG DM

1 15.07.08 REVISED AND RE-ISSUED

NKR SSL SKP VC

0 19.07.02 ISSUED FOR IMPLEMEMTATION NKN SPS AKB GRR

Convenor Chairman
Rev. Prepared Checked Standards Committee Standards Bureau
Date Purpose
No. by by

Approved by

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 625 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0016 Rev. 3
TOWER PACKINGS
Page 2 of 5

Abbreviations:

AS/CS/SS : Alloy Steel / Carbon Steel / Stainless Steel MRT : Mechanical Run Test
CEIL : Certification Engineers International Limited NDT : Non Destructive Testing
CIMFR : Central Institute of Mining & Fuel Research NPSH : Net Positive Suction Head
CE : Carbon Equivalent PO : Purchase Order
DFT : Dry Film Thickness PESO : Petroleum Explosive Safety Organization
DPT : Dye Penetrant Testing PQR : Procedure Qualification Record
DHT : De-hydrogen Heat Treatment PR : Purchase Requisition
ERTL : Electronics Regional Test Laboratory PMI : Positive Material Identification
FCRI : Fluid Control Research Institute PWHT : Post Weld Heat Treatment
HT : Heat Treatment RT : Radiography Testing
HIC : Hydrogen Induced Cracking SSCC : Sulphide Stress Corrosion Cracking
ITP : Inspection and Test Plan TC : Test Certificate
IP : Ingress Protection TPI or TPIA : Third Party Inspection Agency
IHT : Intermediate Heat Treatment UT : Ultrasonic Testing
IC : Inspection Certificate VDR : Vendor Data Requirement
IGC : Inter Granular Corrosion WPS : Welding Procedure Specification
MPT/MT : Magnetic Particle Testing WPQ : Welders Performance Qualification
MTC : Material Test Certificate

Inspection Standards Committee

Convenor : Mr. R.K. Singh

Members:
Mr. Rajesh Sinha Mr. Himangshu Pal Mr. R. Muthuramalingam (RPO Representative)
Mr. Chandrashekhar Mr. Avdhesh Agrawal Mr. P V Satyanarayana (Engg. Representative)
Mr. Mahendra Mittal

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 626 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0016 Rev. 3
TOWER PACKINGS
Page 3 of 5

1.0 SCOPE

This Inspection and Test Plan covers the minimum testing requirements of Tower Packings

2.0 REFERENCE DOCUMENTS

PO/PR/ Standards referred there in/ Job specifications /Approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS

SCOPE OF INSPECTION
S. QUANTUM
STAGE/ACTIVITY CHARACTERISTICS RECORD SUB
NO OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
1.0 Procedures

NDT and other Procedures Inspection

1.1 Documented Procedures 100% - H R
(as applicable) Report

2.0 Materials Procurement

Chemical Analysis
Mechanical Properties,
Condition, Finish, Bend Mill Test
2.1 Sheets/Coils/ Strips 100% W W R
Test, Hardness Check, Certificates
HT, IGC test, Visual &
Dimensional Inspection

3.0 In Process

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Page 627 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0016 Rev. 3
TOWER PACKINGS
Page 4 of 5

SCOPE OF INSPECTION
S. QUANTUM
STAGE/ACTIVITY CHARACTERISTICS RECORD SUB
NO OF CHECK SUPPLIER EIL/TPIA
SUPPLIER
Visual (Finish - Smooth,
Clean, Free from Burs,
3.1 Slitting, Shearing, Punching, Bending 100% Inspection Report - W -
Tears, Cracks) &
Dimensional Accuracy

4.0 Final Inspection

Pall Ring, Hypak Ring, Nutter Rings Dimensional Accuracy and 100%
4.1 Inspection Report - W R
and other types of packing Visual Inspection for (Sample Pieces)
Workmanship and Free of
Burs

Nesting Check for Intalox Metal No Ring to enter another at

4.2 Random Inspection Report - H R
Tower Packing (IMTP) any orientation

Density (No of Pieces in a

4.3 Piece Density Lot Inspection Report - H R
given volume)

PMI As per EIL

4.4 Chemical Check Inspection Report - W R
(AS / SS Components) Specifications

4.5 Packing Visual Inspection 100% Inspection Report - W R

5.0 Documentation & IC

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Page 628 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0016 Rev. 3
TOWER PACKINGS
Page 5 of 5

SCOPE OF INSPECTION
S. QUANTUM
STAGE/ACTIVITY CHARACTERISTICS RECORD SUB
NO OF CHECK SUPPLIER EIL/TPIA
SUPPLIER

Documentation Review & Review of Stage

Manufacturer
5.1 Issuance of Inspection Inspection Reports / Test 100% - H H
TC & IC
Certificate(IC) Reports

Final data
Compilation of Inspection
Final Document submission folder
5.2 reports, drawings etc as 100% - H H
(If applicable) /Completeness
per VDR / PR
certificate

Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% (min.1 no. of each size and type of Bulk item)),
R-Review, W-Witness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable):

1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable.
(Unless otherwise agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.
3. For EPC jobs, all inspection shall be carried out by TPIA, unless notified otherwise.

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 629 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
ENGINEERS
Ifgar taW5 w INDIA LIMITED FOR 6 -81 -0017 Rev. 3
Goo of India Undettaking) UN-ENGINEERED TRAY AND TOWER INTERNALS
Page 1 of 6

*011PtiRdi ,t v-4 zrd-{

t FAT.
gNiuT a riNitIT ei1‘71

INSPECTION AND TEST PLAN

FOR
UN-ENGINEERED TRAYS AND TOWER INTERNALS

3 14.05.2020 REVISED AND RE-ISSUED RKS SKS

2 18.06.13 REVISED AND RE-ISSUED TKK RKS SCG DM

1 02.01.08 REVISED AND RE-ISSUED AM RB MVKK VC

0 10.12.02 ISSUED FOR IMPLEMENTATION NKN SPS AKB GRR

Standards Committee Standards Bureau

Rev. Prepared Checked Convenor Chairman
Date Purpose
No. by by
Approved by

Copyright EIL — All rights reserved

Format No. 8-00-0001-F7 Rev. 0

Page 630 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0017 Rev. 3
UN-ENGINEERED TRAY AND TOWER INTERNALS Page 2 of 6

Abbreviations:

AS/CS/SS : Alloy Steel / Carbon Steel / Stainless Steel MRT : Mechanical Run Test
CEIL : Certification Engineers International Limited NDT : Non Destructive Testing
CIMFR : Central Institute of Mining & Fuel Research NPSH : Net Positive Suction Head
CE : Carbon Equivalent PO : Purchase Order
DFT : Dry Film Thickness PESO : Petroleum Explosive Safety Organization
DPT : Dye Penetrant Testing PQR : Procedure Qualification Record
DHT : De-hydrogen Heat Treatment PR : Purchase Requisition
ERTL : Electronics Regional Test Laboratory PMI : Positive Material Identification
FCRI : Fluid Control Research Institute PWHT : Post Weld Heat Treatment
HT : Heat Treatment RT : Radiography Testing
HIC : Hydrogen Induced Cracking SSCC : Sulphide Stress Corrosion Cracking
ITP : Inspection and Test Plan TC : Test Certificate
IP : Ingress Protection TPI or TPIA : Third Party Inspection Agency
IHT : Intermediate Heat Treatment UT : Ultrasonic Testing
IC : Inspection Certificate VDR : Vendor Data Requirement
IGC : Inter Granular Corrosion WPS : Welding Procedure Specification
MPT/MT : Magnetic Particle Testing WPQ : Welders Performance Qualification
MTC : Material Test Certificate

Inspection Standards Committee

Convenor : Mr. R.K. Singh

Members:
Mr. Rajesh Sinha Mr. Himangshu Pal Mr. R. Muthuramalingam (RPO Representative)
Mr. Chandrasekhar Mr. Avdhesh Agrawal Mr. P V Satyanarayana (Engg. Representative)
Mr. Mahendra Mittal
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 631 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0017 Rev. 3
UN-ENGINEERED TRAY AND TOWER INTERNALS Page 3 of 6

1.0 SCOPE:

This Inspection and Test Plan covers the minimum testing requirements of Un-Engineered Trays and Tower Internals.

2.0 REFERENCE DOCUMENTS:

PO/PR/ Standards referred there in/ Job specifications /Approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS:

SCOPE OF INSPECTION
S. QUANTUM
STAGE/ACTIVITY CHARACTERISTICS RECORD SUB
NO OF CHECK SUPPLIER EIL/TPIA
SUPPLIER

1.0 Procedures
R (existing)
Leak Test, NDT, WPS/ PQR and Inspection
1.1 Documented Procedures 100% - H W (for new
other Procedures(as applicable) Report
WPS/PQR)

2.0 Materials Procurement

Chemical Analysis
Mechanical Properties,
Plates/Sheets/Coils, Pipes, Fittings
Condition, Finish, Bend
Fasteners With Lock Nuts, Gaskets, Mill Test
2.1 Test, Hardness Check, 100% W H R
Welding Consumable etc. Certificates
Heat Treatment, IGC
Visual & Dimensional
Inspection

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 632 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0017 Rev. 3
UN-ENGINEERED TRAY AND TOWER INTERNALS Page 4 of 6

SCOPE OF INSPECTION
S. QUANTUM
STAGE/ACTIVITY CHARACTERISTICS RECORD SUB
NO OF CHECK SUPPLIER EIL/TPIA
SUPPLIER

3.0 IN PROCESS

Visual (Finish -Smooth,

Slitting, Shearing Punching, Bending
True, Clean, Free From Inspection
3.1 (Deck Plates, Down Comers, Weir 100% - H -
Burs) & Dimensional Report
Plates etc.)
Accuracy
Visual (Finish-Smooth,
True, Clean, Free From Inspection
3.2 Bubble Caps, Valves, ‘U’ Clamps 100% - H -
Burs) & Dimensional Report
Accuracy

Heat Treatment of Bubble Caps

3.3 100% HT Chart - W R
(As applicable) As per specification

Dimensions, Completeness
Inspection of one type of Inspection
3.4 of Assembly. 100% - H RW
Component of each type Report
Visual Inspection of Welds

Visual Inspection For

Inspection
Reinforcement, Undercuts, 100% - W RW
Check List
Surface Defects Etc.
3.5 Inspection of Completed Welds

Inspection
DPT Of Welds 100% - W R
Check List

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 633 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0017 Rev. 3
UN-ENGINEERED TRAY AND TOWER INTERNALS Page 5 of 6

SCOPE OF INSPECTION
S. QUANTUM
STAGE/ACTIVITY CHARACTERISTICS RECORD SUB
NO OF CHECK SUPPLIER EIL/TPIA
SUPPLIER

4.0 Final Inspection

Mock Assembly of Each Type of Dimensions, Completeness

One
Trays, Down Comers, Chimney Trays, of Assembly. Inspection
4.1 Assembly/Each - H H
Seal Pans, Trial Assembly of Support Visual Inspection of Welds Report
Type of Tray
Beams etc. etc.

As Per EIL Inspection

4.2 PMI (as applicable) Chemical Check - W RW
Spec. Report

Leak Test for Seal Pan, Chimney And

Check for Leakage rate Inspection
4.3 Bubble Cap Trays, Distributors, etc. 100% - H H
Report

Visual Inspection & Inspection

4.4 Pickling & Passivation (as applicable) 100% - W R
Surface Finish. Report

Marking / Etching on Each

4.5 Final Marking Individual 100% Report - W R
Tray/Component

Inspection
4.6 Packing Visual Inspection 100% - W -
Report

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 634 of 674

 STANDARD SPECIFICATION No.
INSPECTION AND TEST PLAN
FOR 6-81-0017 Rev. 3
UN-ENGINEERED TRAY AND TOWER INTERNALS Page 6 of 6

SCOPE OF INSPECTION
S. QUANTUM
STAGE/ACTIVITY CHARACTERISTICS RECORD SUB
NO OF CHECK SUPPLIER EIL/TPIA
SUPPLIER

5.0 Documentation & IC

Documentation Review & Issuance of Review of Stage Inspection Manufacturer

5.1 100% - H H
Inspection Certificate (IC) Reports / Test Reports TC & IC
Compilation of Inspection Final data folder
5.2 Final Document submission reports, drawings, etc as 100% /Completeness - H H
per VDR / PR certificate

Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% (min.1 no. of each size and type of Bulk item)), R-Review,
W-Witness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable):

1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable.
(unless otherwise agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.
3. For EPC jobs, all inspection shall be carried out by TPIA, unless notified otherwise.

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL – All rights reserved

Page 635 of 674

 WELDED INTERNALS SHALL BE FABRICATED WITHIN THE FOLLOWING
TOLERANCES AND ALL PARTS SHALL BE INTERCHANGEABLE
E E
SYMBOL DESCRIPTION

EXIT WEIR HEIGHT SHALL BE IN LEVEL WITHIN ±1 mm RELATIVE TO THE SPECIFIED

A
DATUM SURFACE AND TO EACH OTHER.

E iE B
CLEARANCE BETWEEN BOTTOM EDGE OF DOWNCOMER BOLTING BAR AND TOP OF
SUPPORT RING SHALL BE WITH IN ±3 mm OF SPECIFIED DIMENSION.

M DISTANCE BETWEEN RELATED TRAY SUPPORT RING SHALL BE WITHIN ±3 mm OF

C
SPECIFIED DIMENSION.
THE DEPTH OF SEAL PAN AND DRAW—OFF PAN SHALL BE WITHIN ±1 mm OF
D
THE SPECIFIED DIMENSIONS.
DIMENSIONS IN THE HORIZONTAL DIRECTION OF VERTICAL DOWNCOMER BOLTING BAR,
E
SUPPORT BRACKET OR CUPS SHALL BE WITHIN TOLERANCES AS PER DRAWINGS.
BOLTING BARS WELDED ON OPPOSITE FACES OF COLUMN SHOULD UE EXACTLY ON
F
ONE LINE.
TRAY SUPPORT RING AND BOLTING BAR SHALL NOT HAVE WAVINESS EXCEEDING
G
1.5mm FOR ANY 500mm OF CIRCUMFERENTIAL LENGTH.
LEVEL DIFFERENCE OF A TRAY SUPPORT RING OVER ITS WIDTH SHOULD NOT EXCEED
H
0.75mm.
ORIENTATION OF DOWNCOMER REFERENCE UNE SHALL BE WITHIN ±3 mm OF ITS
J
NOMINAL DISTANCE FROM THE VESSEL REFERENCE CENTER UNE.
INCLINATION OF SUPPORT RING TO HORIZONTAL PLANE TO BE WITHIN TOLERANCES
GIVEN BELOW:
1.5mm FOR COLUMN I/D <= 1500mm.
K 3.0mm FOR 1500mm < COLUMN I/D <= 3000mm.
4.5mm FOR 3000mm < COLUMN I/D <= 4500mm.
6.0mm FOR COLUMN I/D > 4500mm.

HORIZONTAL SLOTS ON BOLTING BARS SHALL BE FABRICATED WITHIN FOLLOWING

jI TOLERANCES:
z L
+2.0mm
LENGTH—O.Omm WIDTH ±0.25mm, MAX. INCLINATION WITH HORIZONTAL ±1.0mm.

M THE VERTICALITY OF BOLTING BAR SHOULD BE WITHIN ±1 mm.

B
THE ELEVATION OF DOWNCOMER AND MAJOR BEAM STOOL WITH RESPECT TO
N —0 mm
REFERENCE TRAY SUPPORT RING SHOULD BE WITHIN + 6 mm
SLOT CENTERS FOR DOWNCOMERS (AS SHOWN) SHALL BE WITHIN TOLERANCES
P
AS SPECIFIED ON DRAWINGS.

NOTES:-
1. TOLERANCES SHOWN IN THE FABRICATION DRAWINGS TAKE PRECEDENCE OVER THOSE
SHOWN HERE IN.
2. IN CASE OF THESE TOLERANCES CLASHING WITH THAT OF VESSEL, THE DIMENSIONS ARE
WIDTH/2
TO BE MAINTAINED SO THAT IT SATISFIES BOTH TOLERENCES.
3. TOLERANCES ON CONSECUTIVE DIMENSIONS ARE NON—CUMULATIVE.
WORKING ELEVATION OF SUPPORT RING .1ACLINATION BETWEEN
CENTER LINE 4. FOR DETAILS SUCH AS WIDTH, THICKNESS OF BOLTING BARS, WELDING REQUIREMENTS,
TOLERANCES NOT COVERED IN THIS STANDARD, REFER TSR/BB DRAWINGS.
500

NNNNNNNNNNNNNNNNNNN,,,,,,;::."
SUPPORT RING
REFER 'L' BELOW
SP

21.03.2018 RE—AFFIRMED & REISSUED AS STANDARD STANDARD NO.

CONSTRUCTIONAL TOLERANCES
3 17-08-10 RE—AFFIRMED & ISSUED AS STANDARD SKJ/VDY KKG AKG ND
FOR WELDED SUPPORTS 7 -14 - 0001 Rev. 4
MIA LIMITED Rev Prepd Checked Stds. Committee Stds. Bureau
Convenor Chairman FOR TRAYS/TOWER INTERNALS
mew eneweememe (A Govt. of India Undertaking) Date Purpose
No by by Approved by
Page 1 of 1

Format No. 8-00-0001-F5 Rev. 0 Copyright EIL - All rights reserved

Page 636 of 674
 STANDARD No.
ENIGN335 INTERNAL FLANGES 7-12-0018 Rev. 6
INDIA LAVED
(A Govt. of Inds, Undertoldns)
Page 1 of 1

O.D.

B.C.D.

I.D. REFER NOTE-4

4.*

18 DIA. HOLES /
FOR M16 BOLTS

THICKNESS OF
NOMINAL FLANGE t
NUMBER
PIPE SIZE I.D. B.C.D. O.D.
OF BOLTS CARBON S. STEEL
(mm)
STEEL OR MONEL

40 51 110 160 4 16 10

50 63 120 170 4 16 10

80 92 150 200 4 16 10

100 117 180 230 4 16 10

150 171 240 290 4 16 10

200 222 290 340 8 20 12

250 276 350 400 8 20 12

300 327 400 450 8 20 12

350 358 430 480 12 24 16

400 409 480 530 12 24 16

450 460 530 580 12 24 16

500 511 580 630 12 24 16

600 612 680 730 12 24 16

NOTES
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.
• 3. FILLET SIZE IN BRACKET ARE FOR STAINLESS STEEL / MONEL.
4. FULL FACED GASKETS SHALL BE USED.
5. DIMENSIONS EXCEPT THICKNESS FOR INTERNAL FLANGES OF SIZE 25NB OR LESS SHALL BE AS PER
ASME B16.5 CLASS 150. FLANGE THICKNESS AND FACING SHALL BE .EQUIVALENT TO 40NB FLANGE
COVERED IN THIS STANDARD.
6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH SK/KJH taVAti 04—
RN
5 30.07.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 637 of 674
 STANDARD No.

diar 134GIsEERS
eb-NNA LIMITED
... (A Govt of Indk, U.d.riakin9)
VESSEL TOLERANCES 7-12-0001 Rev. 6
Page 1 of 2

®
4- I-- 11----1-

L ,_ so
so
r II-
-

&
— – – -L =-)) REF. PLANE

1— — --

-c)

1
(§, 1
6 It
wv.l
j% 11"ij
6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH .,/ SK/KJH RKT RN
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 638 of 674
 STANDARD No.
ENG/NEF36 VESSEL TOLERANCES 7-12-0001 Rev. 6
OkilirbeNDIA Utv'dTEll (A Govt. of India Undertaking)
Page 2 of 2

NOTES
1. REFERENCE LINES SHALL BE LIGHTLY PUNCH—MARKED INSIDE AND OUTSIDE AROUND THE CIRCUMFERENCE OF
THE SHELL PLATE ON THE TANGENT LINES OF THE VESSEL
2. a) OUT OF ROUNDNESS (OVAUTY) SHALL BE AS PER APPLICABLE CODE.
b) OUTSIDE CIRCUMFERENCE OF SHELL SHALL BE WITHIN THE FOLLOWING LIMITS.
± 10 mm FOR NOMINAL DIAMETER 1200 mm AND UNDER.
± 12 mm FOR NOMINAL DIAMETER 1201 mm THROUGH 2400 mm.
± 20 mm FOR NOMINAL DIAMETER ABOVE 2400 mm.
c) FOLLOWING TOLERANCES ON DIAMETER SHALL APPLY THROUGHOUT ITS LENGTH FOR VESSELS WITH TRAYS
AND / OR PACKING. (FOR CARTRIDGE TYPE TRAY REFER SPECIAL NOTE—E).
VESSEL NOM. DIA. TOLERANCE ON NOM. DIA.
2000 mm AND UNDER ± 0.5%
2001 mm TO 4000 mm GREATER OF ± 10 mm OR ± 0.35%
4001 mm TO 8000 mm GREATER OF ± 14 mm OR ± 0.25%
ABOVE 8000 mm TO BE SPECIFIED ON VESSEL DRAWING.
3. TOLERANCE FOR LENGTH ± 5 mm PER 3000 mm, MAXIMUM 15 mm.
4. OUTSIDE SURFACE OF CYLINDER MAY BE OUT OF ALIGNMENT / STRAIGHTNESS NOT MORE THAN 6 mm PER 6000 mm
STRAIGHT LENGHT, BUT NOT MORE THAN 20 mm FOR ANY LENGTH.
5. TOLERANCE FOR CENTRE TO CENTRE DISTANCE BETWEEN ANY PAIR OF INSTRUMENT CONNECTIONS TO BE AS FOLLOWS:—
DISTANCE BETWEEN NOZZLES : * 1 mm
ORIENTATION : f 1 mm
NOZZLE FACE INCLINATION : * 1/4 °
6. ELEVATIONS FROM REFERENCE PLANE MAY VARY AS FOLLOWS:—
MANHOLE: ± 12 mm, NOZZLE ± 6 mm, INTERNAL SUPPORTS: ± 3 mm, EXCEPT THAT LOCATIONS OF MANHOLES
AND NOZZLES NEAR THE TRAY SHALL NOT VARY MORE THAN ± 3 mm FROM THE TRAY.
7. PROJECTION OF FLANGE FACE FROM SHELL CENTRAL LINE / TANGENT UNE MAY VARY ± 5 mm FOR NOZZLES
AND ± 12 mm FOR MANHOLES.
8. CIRCUMFERENTIAL AND RADIAL DEVIATION OF NOZZLES, MANHOLES AND SUPPORTS FROM THE TRUE POSITION SHALL
NOT VARY MORE THAN I 3 mm.
9. BOLT HOLE ORIENTATION OF NOZZLES MAY VARY ± 2 mm AT BOLT CIRCLE.
10. VERTICAL AND HORIZONTAL DEFLECTION OF NOZZLE FLANGE FACES FROM PLANES NORMAL TO NOZZLE CENTRE LINES
OR PARALLEL TO VESSEL CENTRE UNE SHALL NOT BE MORE THAN ± 1/2?
11. ALL TOLERANCES OF TRAY SUPPORTS TO BE AS PER TRAY SPECIFICATIONS / DRAWING.
12. THE BASE RING BOLT CIRCLE DIAMETER MAY VARY ± 5 mm. FOR ANY DIAMETER MEASURED AT POINTS 90* APART,
DISTANCE BETWEEN TWO CONSECUTIVE HOLES MAY VARY BY ± 5 mm.
13. a) DEVIATION OF SUPPORT BASE FROM HORIZONTAL MAY BE AS FOLLOWS:—
FOR VESSEL DIA. 1500 mm AND UNDER 3 mm
FOR VESSEL DIA. OVER 1500 mm TO 2000 mm 5 mm
FOR VESSEL DIA. OVER 2000 mm TO 4000 mm 6 mm
FOR VESSEL DIA. OVER 4000 mm TO 5000 mm 8 mm
FOR VESSEL DIA. OVER 5000 mm 10 mm
b) DEVIATION OF SUPPORT BASE FOR BRACKET TYPE SUPPORT / SADDLE SUPPORT FROM HORIZONTAL MAY BE ±
14. DISTANCE BETWEEN CL TO CL OF SUPPORTS AND BOLT HOLES IN SUPPORTS FOR HORIZONTAL VESSELS MAY VARY ± 3 mm.
15. DISTANCE BETWEEN CENTRE UNE OF HORIZONTAL VESSEL AND BOTTOM OF SUPPORT MAY VARY ± 3 mm.
16. a) TOLERANCE FOR CENTRE TO CENTRE DISTANCE BETWEEN ANY PART OF EXTERNAL STRUCTURAL
ATTACHMENT SHALL NOT VARY MORE THAN ± 3 mm.
b) TOLERANCE FOR DISTANCE FROM REFERENCE PLANE TO BASE OF VERTICAL SUPPORTS AND CENTRE UNE OF
SADDLE SUPPORT MAY VARY ± 6 mm.

SPECIAL NOTES
A. CUMULATIVE TOLERANCES ON CONSECUTIVE DIMENSIONS SHALL BE LIMITED BY OVERALL DIMENSIONAL TOLERANCES.
ALL TOLERANCES ARE FROM REFERENCE PLANE UNLESS OTHERWISE INDICATED.
B. INTERFERENCE BETWEEN INTERNAL AND EXTERNAL PARTS OR ANY RESTRICTION TO THE INTENDED FUNCTION OF ANY
PART SHALL BE KEPT IN VIEW WHERE TOLERANCES ARE CUMULATIVE.
C. SPECIFIC TOLERANCES FOR ANY PART SHOWN ON EIL DRAWING SHALL BE GIVEN PREFERENCE TO THOSE GIVEN
IN THIS STANDARD.
D. UNUSUALLY LARGE OR COMPLEX VESSELS MAY BE EXECUTED AS PER FABRICATOR'S STANDARD WHEN THE TOLERANCES
AS SHOWN ARE UNREASONABLE. IN SUCH INSTANCES FABRICATOR'S TOLERANCES & LIMITS MUST BE SUBMITTED
FOR APPROVAL.
E. VESSEL UPTO AND INCLUDING 750 mm NOMINAL DIAMETER SHALL HAVE CARTRIDGE TYPE TRAY. FOLLOWING
TOLERANCES ON DIAMETER SHALL APPLY THROUGHOUT ITS LENGTH.
VESSEL NOMINAL DIAMETER TOLERANCE
500 mm AND UNDER VESSEL I.D. *- oI own
m1"
501 mm TO 750 mm VESSEL I.DY1 + 3 run
AvA
i/
\
6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH SK/J 01 RN
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00 - 0001 - F4 Rev.0 Copyright EIL - All rights reserved
Page 639 of 674
 STANDARD No.

SKIRT BASE DETAILS 7-12-0004 Rev. 7

POIMPINIMIDNIPO (A Govt. of Indio Undortoking)
Page 1 of 1

CHAIR CAP
NOTCH GUSSET TO WASHER WELD AT SITE
CLEAR WELD
CONTINUOUS RING
NOTCH GUSSET TO
CLEAR WELD
EARTHING LUG ,m
,.
BOLT 0
+ 3mm
mIlm
■ Il ■

■i
BOLT 0
+ 12mm
(ALL DIMENSIONS
DIMENSIONS AND DETAILS ARE
BCD SAME AS SHOWN FOR TYPE-2
EXCEPT CONTINUOUS RING)
[BOLT 0 + 12mm
WIDE SLOT

TYPE-1 TYPE-2 SLOT DETAIL TYPE-3

(SEE NOTE-6) (FOR CONTINUOUS RING ONLY)

BOLT0 t1 * t2 * t3 * A v B C E F H K L* W TYPE REMARKS

24 20 — 10 60 — — — — 250 75 165 10
1
27 20 — 10 60 — — — — 250 80 170 10
30 25 25 12 55 60 150 12 60 300 80 180 10
33 25 25 12 58 65 150 12 70 300 80 185 10
36 25 25 12 66 70 150 12 80 300 90 200 10
39 32 25 12 70 70 160 14 80 300 95 215 12
42 32 25 12 72 70 160 14 90 300 100 230 12
45 32 25 12 80 75 160 14 90 300 105 245 12 2
48 32 30 14 83 75 180 16 100 380 110 260 14 AND
52 38 30 14 87 80 180 16 110 380 110 275 14 3
56 38 30 16 91 85 180 18 120 380 115 280 14
60 38 35 18 95 85 200 20 120 430 125 285 14
64 38 35 18 104 90 200 25 130 430 135 300 16
68 42 40 20 108 90 220 25 140 450 145 320 16
72 42 40 20 112 95 220 25 150 450 150 340 16

NOTES
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2. BOLT CIRCLE DIAMETER ( BCD ), NUMBER AND SIZE OF THE BOLTS SHALL BE AS PER ENGINEERING DRAWING.
* 3. DIMENSIONS t1, t2, t3 AND 'L' ARE TO BE CHECKED IN EVERY CASE.
4. IN CASE OF ANY CONFUCT THE ENGINEERING DRAWING SHALL GOVERN.
5. NUMBER OF BOLTS USED IS TO BE A MULTIPLE OF 4 AND BOLTS SHALL STRADDLE VESSEL NORTH—SOUTH
CENTRE LINE IN PLAN.
6. USE CONTINUOUS RING ( CHAIR CAP ) IF DISTANCE BETWEEN CONSECUTIVE BOLTS IS LESS THAN 400 mm.
7. CIRCULAR WASHER SHALL BE SHIPPED LOOSE AND WELDED AT SITE AFTER ANCHOR BOLTS ARE IN POSITION.
• 8. PREFERRED DIMENSION 'A'
9. EARTHING LUG SHALL BE LOCATED BETWEEN THE ANCHOR BOLTS AND SHALL BE AS PER STANDARD 7-12-0026.
10. WHEN THE ANCHOR CHAIR CAP IS NOT CONTINUOUS, THE BASE PLATE SHALL BE SUITABLY STIFFENED USING
REMOVABLE STRUCTURAL SECTIONS (BEAM/SPIDER) AT SITE DURING ERECTI7.

7 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGHA 11.#;-

1411iN
'
6 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM

Rev. Prepared Checked Stds. Committee Stds. Bureau

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Page 640 of 674
 STANDARD No.

SKIRT OPENING DETAILS 7-12-0005 Rev. 6

11111111.101111•11.11111111 (A Cwt. of India Undertaking)
Page 1 of 2

PAD ALL AROUND

SEE NOTE-7

REF. SHT. 2 FOR

COVER PLT. DETAIL

100N8 SCH. 40
40 PIPE VENT
EQUISPACED INSIDE

ACCESS OPENING PLAN VENT

(SEE NOTE-5)

ACCESS OPENING/PIPE OPENING/

VENT OPENING (TYPICAL)

SKIRT
80x6THK. PLATE
INSIDE
2mm(TENTATNE)
CHECK FOR PIPE
THERMAL EXPANSION.

OR INSULATED PIPE+10
S MALLER OF ts+2
OR 14mm (FOR PIPE
SEE NOTE-6)
SEE NOTE-10

PIPE OPENING VIEW A VIEW A FLARED SKIRT

(HOT TYPE VESSEL) (COLD TYPE VESSEL)

6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH SK/KJH RN

5 23.05.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT

Rev. Prepared Checked Stds. Committee Stds. Bureau

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Page 641 of 674
 STANDARD No.
IENGNEERS SKIRT OPENING DETAILS 7-12-0005 Rev. 6
ISIBMO NDIA LIMITED (A Govt. of Indio Untiurto!Ong)
Page 2 of 2

25
6 WIDE SLOT FOR
5 N
125 125

DETAIL — A
3-50 PINS-15 LG
EQUISPACED

VIEW—P
NOTES (HOT TYPE VESSEL) (COLD TYPE VESSEL)
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2. ACCESS OPENING SHALL BE LOCATED BETWEEN ANCHOR BOLTS WHEREVER POSSIBLE.
3. ACCESS OPENING IS NOT TO BE BLOCKED BY BOTTOM HEAD.
4. SKIRT DIAMETER ACCESS OPENING DIA.(D) NO. OF ACCESS OPENING
UP TO 1000 400 1
OVER 1000 UPTO 1500 450 1
OVER 1500 UPTO 3000 500 1
OVER 3000 500 2
5. SKIRT DIAMETER NO. OF VENT HOLES
UP TO 1000 2
OVER 1000 UPTO 2000 3
OVER 2000 4
6. MINIMUM SIZE OF PIPE SLEEVE IS 150NB SCH 40. USE SCH 40 UPTO 25ONB PIPE SLEEVE. FOR 300NB AND
ABOVE, PIPE SLEEVE SHALL BE FABRICATED FROM PLATE.
7. ALL OPENINGS 300 DIA. AND ABOVE SHALL BE PROVIDE WITH REINFORCEMENT PADS ON INNER SURFACE OF SKIRT.
8. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.
9. IN FLARED SKIRT, OPENING DETAIL IS SAME AS THAT FOR CYLINDRICAL SKIRT.
10. WOODEN BLOCK SHALL BE FIXED TO SLEEVE WITH TWO NO. OF WOOD SCREWS.
11. ACCESS OPENING/PIPE OPENING/VENT SHALL BE OF SAME MATERIAL AS THAT OF SKIRT.
12. ALL FILLET WELDS SHALL BE 6 mm MINIMUM.
* 13. PROJECTION OF SLEEVE/NECK SHALL BE GREATEST OF (30+INSULATION THK.), (30+ FIRE PROOFING) & 50mm.
14. CENTER LINE OF ACCESS OPENING SHALL BE 850 MM (MINIMUM) ABOVE BOTTOM BASE RING FOR ANCHOR
BOLTS OF SIZE M45 & BELOW AND 1100 MM (MINIMUM) FOR ANCHOR BOLTS OF SIZE ABOVE M45. IF ANCHOR
CHAIR HEIGHT IS MORE THAN THAT OF GIVEN IN STANDARD. LOCATION OF ACCESS OPENING SHALL BE ESTABLISHED
SUITABLY.

6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH SK/KJ

W-A. ? RN

5 23.05.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT

Rev. Prepared Checked Stds. Committee Stds. Bureau

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Page 642 of 674
 STANDARD No.

ORMOENGNEERS
A INDIA LIMITED
( Govt. of Indio Undertaking)
MANHOLE WITH DAVIT 7-12-0010 Rev. 7
Page 1 of 2

20 0 x 25 LG. SNAP
HEAD RIVET

240 ROD
B(C0)+70 1.5 THK. S.S. WASHER
PIPE 'B' SCH. 80
30 VENT
10 THK. RIB

10

6R 15

PIPE 'A' 1NO. 60

DRAIN HOLE

1NO. 3mm NPT DETAIL 'X'

TELL TALE HOLE

3N0.—M16 SS JACK SCREWS

ON BOLT CIRCLE DIAMETER
( SEE NOTE-3 )

DETAIL OF EYE BOLT

M16

07;4 [..:110
BOND
FLANGE 20 0

I M16

TYP. DETAIL FOR SR MANHOLE DETAIL OF JACK SCREW

7 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH _ 4s1Z)1-

KJH
fr.j7--
RN
6 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM

Rev. Prepared Checked Stds. Committee Stds. Bureau

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Page 643 of 674
 STANDARD No.
INGNEIRS MANHOLE WITH DAVIT 7-12-0010 Rev. 7
41i1MO INDIA UWE"
to Govt. of Indko UndortokIng)
Page 2 of 2

160 ROD FOR S.S. VESSEL

B(00)+20 / 200 ROD FOR C.S. AND
PIPE '8' SCH. 80 LOW ALLOY STEEL VESSEL
1.5 THK. VESSEL INSIDE
S.S. WASHER IMO 0
BSI 10 THK. RIB 20R 0

II
g
260 350
(32 0)
4OR
WI7—\
DETAIL OF HAND GRIP
■ ••
HAND GRIP

—F-
20 0 x 25 LG. SNAP
250
// PIPE 'A'
//
//
//

30 VENT

I/ o
//
//
//
//
././
Y 41

3N0.-M16 SS JACK SCREWS

ON BOLT CIRCLE DIAMETER
(SEE NOTE-3)
INO. 6 0
DRAIN HOLE
/11 I15
DETAIL 'Y'
INO.-3mm NPT
TELL TALE HOLE

mak CLASS
SIZE
( NB) A (NB) B (NB)

.111 1°V.:111 _-.....0111111/11111 400 50 NB SCH. 80 40

1 200 200
20 0 ROD HANDLE
150
450
500
50 NB SCH. 80
65 NB SCH. 40
40
50
600 65 NB SCH. 40 50
400 65 NB SCH. 40 50
450 65 NB SCH. 40 50
300
500 65 NB SCH. 40 50
NOTES
600 90 NB SCH. 40 80
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2. DIMENSIONS IN BRACKETS ARE FOR CLASS 900. 400 80 NB SCH. 40 65
3. B.C.D. OF JACK SCREWS IS TO BE SUITABLY CHANGED IF MANHOLE
450 90 NB SCH. 40 80
STUDS INTERFERE WITH JACK SCREWS. 600
4. THE SLEEVE PIPE 'A' SHOULD BE IN TRUE VERTICAL POSITION WITHIN 500 125 NB SCH. 80 100
A TOLERANCE OF 2 1/2 DEGREE, AFTER WELDING TO THE FLANGE.
600 125 NB SCH. 80 100
5. EDGES SHALL BE ROUNDED OFF IF SQUARE ROD IS USED
FOR HANDGRIP. 400 125 NB SCH. 80 100
6. MATERIAL OF DAVIT COMPONENTS SHALL BE C.S. UNLESS OTHERWISE
SPECIFIED IN ENGINEERING DRAWING. 450 125 NB SCH. 80 100
900
7. ALL FILLET WELDS SHALL BE 6mm MINIMUM. 500 150 NB SCH. 80 125
8. THIS STANDARD IS NOT APPLICABLE FOR LOW TEMPERATURE SERVICES.
600 150 NB SCH. 80 125
9. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.

7 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT livdrotr

6 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM

Rev. Prepared Checked Stds. Committee Stds. Bureau

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Page 644 of 674
 STANDARD No.
LADDER RUNGS FOR
ENGINEERS 7-12-0011 Rev. 6
ORM.) (A Govt. of India Undertaking)
INDIA LIMITED MANHOLE / DEMISTER
Page 1 of 1

TOP OF DEMISTER

.!.!..t.!-:•!•,..:•!•!•!•!•:•:•!•!•!>!•!•!•!•:•!•!•!•!•:-!•!•!•:•'."_?..

HORIZONTAL VESSEL

TOP LADDER RUNGS EQUISPACED AT BOTH LEVELS

2—NOS. FOR DIA. < 1000.
4—NOS. FOR 1000 < DIA. < 2000
6—NOS. FOR 2000 < DIA. 3000
8—NOS. FOR DIA. > 3000

175 175

MANHOLE Q

ti
200
DETAIL—X
DETAIL—X

175 175

20(16)RODFI
VERTICAL VESSEL C.S. AND LOW ALLOY
STEEL (NOTE-7)
20R

HANDGRIP

NOTES
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
• 2. VARIATION IN SPACING BETWEEN LADDER RUNGS IS PERMITTED
IN CASE OF INTERFERENCE WITH SOME NOZZLE OR INTERNALS.
HOWEVER THE SPACING OF RUNGS SHALL BE EQUAL.
3. SQUARE RODS MAY BE USED FOR HANDGRIP / LADDER RUNGS.
IF FABRICATED FROM PLATE THE EDGES ARE TO BE ROUNDED OFF.
4. MATERIAL SHALL BE AS PER ENGINEERING DRAWING.
5. ALL FILLET WELDS SHALL BE 6 mm MINIMUM.
6. ORIENTATION OF LADDER RUNGS SHALL BE SAME AS OF MANHOLE.
7. DIMENSIONS SHOWN IN BRACKETS ARE FOR STAINLESS STEEL MATERIAL.

gi-
6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SING SK/KJH Rif RN
5 30.06.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM

Rev. Prepared Checked Stds. Committee Stds. Bureau

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Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 645 of 674
 STANDARD No.
41d ENGINEERS NOZZLE REINFORCEMENT
Ogee felffleg INDIA LIMITED
INEW E9E401170X391111.1) (A Govt of India Undertalong)
7-12-0013 Rev 7
AND PROJECTION
PROJECTIO N Page 1 of 2

1-30 NPT TELLTALE HOLE

L (WIDTH OF PAD) ® PROJECTION 'A' SEE NOTE-4,5,9&10

NOMINAL OUTSIDE
PIPE SIZE DIAMETER SHELL WELD SHELL WELD CLASS 150 CLASS 300 CLASS 600 CLASS 900
EFF.=0.85 EFF. =1.0
BELOW 3" STANDARD - - 150 150 150 150
3" 88.9 40 45 200 200 200 200
4" 114.3 50 60 200 200 200 200
6" 168.3 70 85 200 200 200 250
8" 219.0 95 110 200 200 250 250
10" 273.0 115 135 200 200 250 300
12" 323.8 135 160 200 200 250 300
14" 355.6 150 175 250 250 250 300
16" 406.4 170 200 250 250 250 300
18" 457.2 195 225 250 300 300 350
20" 508.0 215 250 250 300 300 350
24" 609.6 255 300 250 300 300 400
26" 660.4 285 330 250 300 350 450
28" 711.2 305 355 250 300 350 450
30" 762 325 380 250 300 400 450
32" 812.8 350 405 300 350 400 500
34" 863.6 370 430 300 350 400 500
36" 914.4 390 455 300 350 - -
38" 965.2 410 480 300 350 - -
40" 1016 435 505 300 350 - -
42" 1066.8 455 530 300 400 - -
44" 1 1 1 7.6 475 555 300 400 - -
46" 1168.4 500 585 300 400 - -
48" 1219.2 520 610 300 400 - -

tot/.
74(
7 23 01 2020 REAFFIRMED AND REISSUED AS STANDARD DP -- KJH RKT

6 07 06 2013 REVISED AND REISSUED AS STANDARD NIKHIL KA RKT/SC DM

5 23 05 2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose by by
Convenor Chairman
No Approved by
Format No 8-00-0001-F4 Rev 0 Copynght EIL - All nghts reserved

Page 646 of 674

 STANDARD No
$1k NOZZLE REINFORCEMENT
ENGINEERS
Oge.ii faffleg INDIA LIMITED
(A Govt of India Undertatong)
7-12-0013 Rev. 7
OVER E9E41,
1¢0,
13.111CH)
AND PROJECTION
Page 2 of 2

NOTES
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.
® 3. WIDTH IS MINIMUM AND SHALL BE CHECKED AGAINST CODE REQUIREMENT. CHECK REINFORCEMENT REQUIREMENT FOR
ALL EXTERNAL PIPING LOADING ALSO.
4. NOZZLE PROJECTIONS ARE BASED ON INSULATION THICKNESS EQUAL TO 75mm. FOR INSULATION THICKNESS
GREATER THAN 75mm, THE NOZZLE PROJECTION IS 'A' + [INSULATION THICKNESS(mm)-75].
5. PROJECTION 'A' FOR SELF—REINFORCED NOZZLE SHALL BE BASED ON DESIGN OF REINFORCEMENT SUBJECT TO
MINIMUM REQUIREMENTS AS PER THIS STD
6. EXTEND PAD LOCALLY FOR MANHOLE DAVIT SUPPORT, IF REQUIRED
7 EXTERNAL REINFORCING PADS SHALL HAVE A MINIMUM OF 1 NO. TELL—TALE HOLE EXCEPT THAT PADS FOR
NOZZLES GREATER THAN 10"NB(250NB) SHALL HAVE MINIMUM TWO NOS. TELL—TALE HOLES AND NOZZLES IN
EXCESS OF 36"NB (9 OONB) SHALL HAVE 4 NOS. TELL—TALE HOLES. PAD INSTALLED IN SECTIONS SHALL HAVE
ATLEAST ONE TELL—TALE HOLE PER SECTION TELL—TALE HOLES ON REINFORCEMENT PADS SHALL BE
EQUALLY SPACED IN CIRCUMFERENTIAL DIRECTION OF PAD.
8. TELL—TALE HOLE SHALL NOT BE PLUGGED AND SHALL BE FILLED WITH HARD GREASE ONLY, AFTER
HYDROTEST/PNEUMATIC TEST OF EQUIPMENT
9. a) FOR COLUMNS & VERTICAL VESSELS, PROJECTION OF NOZZLE ON TOP HEAD SHALL BE 400mm MINIMUM FROM
OUTSIDE.
b) FOR HORIZONTAL VESSELS, PROJECTION OF NOZZLES ON TOP SIDE OF SHELL SHALL BE 300mm MINIMUM FROM
OUTSIDE.
10. PROJECTIONS ARE BASED ON ASME B16.5 FLANGES FOR UPTO AND INCLUDING 24"NB NOZZLES AND ASME B16.47
SERIES 'B' FLANGES FOR NOZZLE SIZES ABOVE 24"NB.

7 23 01 2020 REAFFIRMED AND REISSUED AS STANDARD DIDCZ4S„... / K KJH RKT

6 07 06 2013 REVISED AND REISSUED AS STANDARD NIKHIL KA RKT/SC DM
5 23 05 2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT
Rev Prepared Checked Stds Committee Stds Bureau
Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copyright EIL - All rights reserved

Page 647 of 674

 STANDARD No.
STANDARD BOLT HOLE
ENGINEERS 0 MIA WITH) 7-12-0015 Rev. 6
41114= (A Govt. of WIG Undortoldng) ORIENTATION
Page 1 of 1

HORIZONTAL VESSEL
(ELEVATION)
et_

VERTICAL VESSEL
(PLAN)

6
5
31.10.2016

23.05.2011
REAFFIRMED AND REISSUED AS STANDARD JIT SINGH ,..••••• SK/KJH h:T) RN
REAFFIRMED AND REISSUED AS STANDARD POREL RKT

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
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Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 648 of 674
 STANDARD No.
ENGINEERS ALLOY LINER DETAILS 7-12-0016 Rev. 6
dear
IM lownewirunsum
OINDIA LYME.
(A Govt. of Indio Undertaking)
Page 1 of 2

SS/ALLOY WELD SS/ALLOY WELD SS ALLOY WELD

METAL DEPOSIT METAL DEPOSIT
CS/LOW ALLOY CS/LOW CS/LOW ALLOY
FLANGE ALLOY FLANGE FLANGE

' 3mm NPT

TELL—TALE HOLE
(TYP.)
CS LOW ALLOY PIPE
CS LOW ALLOY
CS LOW ALLOY PIPE FORGING
3mm NPT
TELL—TALE HOLE
(TYP.)

** **

NOZZLE WELDING DETAIL WELDING DETAIL FOR

FOR SIZE UPTO 150NB SR NOZZLES

SS/ALLOY SS/ALLOY
WELD METAL CS/LOW ALLOY WELD METAL
CS/LOW ALLOY DEPOSIT FLANGE DEPOSIT
FLANGE
**

CORNER ROUNDED
TO 3mm RADIUS

THICKNESS OF WELD
METAL DEPOSIT NOT LESS
THAN CLADDING IN VESSEL CLAD
PLATE
PLATE
DETAIL-Y
(TYPICAL)

** CHIPBACK CLADDING
A \ \ ■ f)
(0
,.:&
.7..6
BEFORE WELD METAL DEPOSIT
MkIP• Y
** **
SS ALLOY SS ALLOY
WELD METAL WELD METAL
DEPOSIT DEPOSIT
NOZZLE WELDING DETAIL
FOR SIZE ABOVE 150NB.

**
WELD METAL DEPOSIT

30- 6 6 30
WELD METAL DEPOSIT
WELDING DETAIL FOR CIRCUMFERENTIAL
WELD DEPOSIT DETAIL
AND LONGITUDINAL JOINTS
FOR BLIND FLIANGES
6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH ,„../* WKJHATA/v ■ P./f RN
5 20.11.2009 REVISED AND REISSUED AS STANDARD POREL RKG AKM ND
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
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Page 649 of 674
 STANDARD No.

afr 134G1t•EERS
ebAbINDIA
wourommo
LIMITED
(A Govt. of Mao Undortokbvg)
ALLOY LINER DETAILS 7-12-0016 Rev. 6
Page 2 of 2

NOTES
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.

2. WELD DEPOSIT SHALL BE OF MINIMUM TWO LAYER CONSTRUCTION WITH TOP 2mm OF FINISHED
WELD THICKNESS HAVING THE SAME CHEMISTRY AS THAT OF ALLOY SPECIFIED FOR CLADDING
/ LINING (NOTE-7). CHECK OF FERRITE CONTENT AND ITS ACCEPTANCE CRITERIA SHALL BE
AS PER MATERIAL REQUISITION.

* 3. FINISHED RAISED FACE AS WELL AS GROOVE DIMENSIONS OF RTJ AND T&G SHALL BE AS PER
APPLICABLE STANDARD.

4. CS/LOW ALLOY WELDMENT OF S.O. FLANGE AND OF RF PAD SHALL BE PNEUMATICALLY

CHECKED AT 1.8 kg/cm 2 (g) FOR LEAK—TIGHTNESS BEFORE DEPOSITING SS/ALLOY
WELD METAL

5. THE TELL—TALE HOLE SHALL NOT BE PLUGGED AND SHALL BE FILLED WITH GREASE.

6. CORNER RADIUS OF WELD METAL DEPOSITS SHALL BEAR SMOOTH FINISH.

7. WELDING IN CONJUNCTION WITH ALLOY LINING SHALL BE DONE WITH COVERED

ELECTRODES OR FILLER WIRE MADE IN ACCORDANCE WITH SPECIFICATION LISTED BELOW:—

CLADDING APPLIED UNING BARRIER/FIRST LAYER TOP LAYER

A 263 A 240 TYPE 405,410S (2) (8)
A 264 A 240 TYPE 304 (1) (3)
A 264 A 240 TYPE 304L (8) (4)
A 264 A 240 TYPE 316 (2) (5)
A 264 A 240 TYPE 316L (8) (6)
A 264 A 240 TYPE 321 OR 347 (a) (7)
A 265 B-127 (10) (9)

SPECIFICATION ELECTRODE CLASSIFICATION

(1) AWS A 5.4, ASME SFA 5.4 E 309L
(2) AWS A 5.4, ASME SFA 5.4 E 309MoL
(3) AWS A 5.4, ASME SFA 5.4 E 308
(4) AWS A 5.4, ASME SFA 5.4 E 308L
(5) AWS A 5.4, ASME SFA 5.4 E 316
(6) AWS A 5.4, ASME SFA 5.4 E 316L
(7) AVIS A 5.4, ASME SFA 5.4 E 347
(8) AWS A 5.4, ASME SFA 5.4 E 410S/E430
(9) AWS A 5.11, ASME SFA 5.11 ENi Cu7
(10) AWS A 5.11, ASME SFA 5.11 ENi1

FILLER WIRE FOR GTAW, GMAW, SAW PROCESS SHALL BE AS FOLLOWS:—

A) FOR STAINLESS STEEL SPECIFICATION AS PER AWS A 5.9, ASME SFA 5.9
WITH COMPOSITION AS LISTED ABOVE FROM (1) TO (8).

B) FOR MONEL (NICKEL COPPER ALLOY) SPECIFICATION AS PER AWS A 5.14,

ASME SFA 5.14 WITH COMPOSITIONS AS LISTED ABOVE AT (9) & (10).

(ii). WHEREVER SPECIFIED ENiCr Fe3 (INCONEL) WELDING SHALL BE DONE DUE TO
SERVICE REQUIREMENTS.

(iii). FOR JOINTS BETWEEN PIPE TO PIPE/PIPE—FITTING IN ALLOY/SS LINED CONSTRUCTION

IF OTHER SIDE OF JOINT IS NOT ACCESSIBLE, SHALL BE DONE WITH WELDING
CONSUMABLE MATCHING THE CLAD MATERIAL FOLLOWED BY A BARRIER LAYER OF
PURE IRON (ARMO/KATDO IRON) AND THEN BY WELDING CONSUMABLE MATCHING
THE BASE MATERIAL.

8. IN CASE OF MONEL CLAD CONSTRUCTION, FREE IRON CONTENT IN THE WELD OVERLAY
SHALL NOT EXCEED 2.5% AT A DEPTH OF 2mm FROM FINISHED OVERLAY THICKNESS.

6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH"9 K KJH

5 20.11.2009 REVISED AND REISSUED AS STANDARD POREL RKG AKM ND

Rev. Prepared Checked Stds. Committee Stds. Bureau

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Page 650 of 674
 STANDARD No.
SUPPORT RING SIZES FOR
B4GINE136 7-12-0022 Rev. 6
WSW'S&114a1, LIM ITE. PACKED TOWER'S INTERNALS
Page 1 of 1

SUPPORT RING

SECTION AA

INSIDE DIAMETER OF TOWER

TOWER INTERNAL DETAILS
250 TO 5001501 TO 9001901 TO 160011601 TO 300013001 TO 450014501 TO 750017501 TO 900019001 TO 12000112001 TO 14002
MATER
TYPE OF INTERNALS coNsTRu SIZE OF SUPPORT RING ( W X T ) **
CONSTRUCTION
PACKING SUPPORT METAL *25X4 *35X6 50 X 6 65 X 6 75 X 10 90 X 10 100 X 10 110 X 10 125 X 10
PLATE CERAMIC 30 X 4 50 X 6 65 X 6 — — — — — —
METAL *25X4*35X6 50X6 65X6 75X10 90X10 100X10 110X10 125X10
UQUID DISTRIBUTOR
CERAMIC 30 X 4 50 X 6 65 X 6 — — — — — —
REDISTRIBUTOR METAL *25X4*35X6 50X6 65X6 75X10 90X10 100X10 110X10 125X10
BED UMITER METAL * 45 X 4 *45 X 6 50 X 6 65 X 6 75 X 10 90 X 10 100 X 10 110 X 10 125 X 10

WORKING ELEVATION OF
SUPPORT RING

500rirn

SUPPORT RING

— i SEE NOTE-6

SUPPORT RING

NOTES
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2. INDICATED THICKNESS OF SUPPORT RING IS MINIMUM TO WHICH TWICE THE
CORROSION ALLOWANCE IS TO BE ADDED.
3. THIS STANDARD IS FOR PURPOSE OF QUATATION & INFORMATION ONLY. SIZE AND THICKNESS SHALL
BE CHECKED FOR THE LOAD APPLIED (SUPPORTED INTERNALS + DIFFERENTIAL PRESSURE).
** 4. FINAL SIZE OF THE RING SHALL BE AS SPECIFIED ON ENGINEERING DRAWING FOR INTERNALS.
5. SUPPORT RING SHALL NOT HAVE WAVINESS EXCEEDING 1.5 mm FOR ANY 500 mm
OF CIRCUMFERENTIAL LENGTH.
6. INCLINATION OF SUPPORT RING OVER ITS WIDTH SHALL NOT EXCEED 0.75 mm.
* 7. SUPPORT RING WIDTH SHALL BE MIN. 50MM WHEREVER VESSEL CORROSION ALLOWANCE
IS 6.0MM OR MORE.
8. MATERIAL OF CONSTRUCTION SHALL BE AS PER ENGG. DRAWING.

6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JITSINGH SIQKJH RRT ORN

5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
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Page 651 of 674
 STANDARD No.
INGNEERS PIPE DAVIT 7-12-0023 Rev. 7
OitgrgeNDIA LIMITED (A Go& of Mcb UndorWedng)
Page 1 of 3

DETAIL-Z LOCKING PIN

DETAIL-X
A (NOTE-3) POSITIONING PLATE
LOCKING PLATE
NAME PLATE 60* 10 THK. (DETAIL= K')
DETAIL-Y
--, .
H CM
o 'mimmotonii..
\......"
Id -4111116%•
....... 7v

ANGLE SIZE
TAPPED HOLE
ce
U

4
WITH TM 1 6 BOLT

cr
a
DETAIL IN TOP BRACKET
SHT. 2
DETAIL IN
SHT. 2
TOP OF PLATFORM I

40R
60

200
z
TAPPED HOLE x
8VIM6BOLT
I 0
4
0 HO
PIPE
SIZE 'IV I AIL-10
Cu
U
I U
TOP OF
DETAIL
'PLATFORM
D AVIT SUPPORT

(TYPE-1) (TYPE-2) • 1
DEVIT FOR TOP DEVIT FOR SIDE 6l 4 1- I TO )UIT
lu";
MOUNTED PLATFORM MOUNTED PLATFORM PIPE O/D.

8-180 HOLES
A (MAX) B CAPACITY PIPE SIZE ANGLE SIZE
121 R2 r t
(mm) (rim) (kgs.) D S
500 100NBxSCH.160 75x75x6 75 60 10 20
1000 1000 150NBxSCH.80 100x100x8 110 60 12 25 160 LOCKING
PIN
,<40 00 (NO TE-13)

500 150NBxSCH.80 100x100x8 110 60 10 20

2000 1000 200NBxSCH.80 150x150x10 140 60 12 25

500 200NBxSCH.B0 150x150x10 140 60 10 20

3000 1000 200NBxSCH.160 150x150x12 140 60 12 25 DETAIL—X DETAIL—Y

RI
3 THK. DEFLECTOR CONE

D (NB)
0
100 120
150 175
16 DI 200 225
_ 0 I HI

DETAIL—K DETAIL—Z (DAVIT EYE)

DETAIL—P

7 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SK/ K ft RN

6 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 652 of 674
 STANDARD No.

leziMON)v■ uvam (A Govt. of bleb Uodertoldng)

PIPE DAVIT 7-12-0023 Rev. 7
Page 2 of 3

LOCKING PLATE LOCKING PIN LOCKING PIN

LOCKING PLATE

TOP OF PLATFORM TOP OF PLATFORM

EXTENSION ANGLE
---

LOCKING ARRANGEMENT OF DAVIT PIPE LOCKING ARRANGEMENT OF DAVIT PIPE

PASSING THROUGH PLATFORM PASSING THROUGH SIDE OF PLATFORM

REF. LEVEL

018 HOLE RADIUS TO SUIT GUSSET FOR BOTTOM

PIPE O.D. SUPPORT ONLY

ELEVATION
PLATFORM
v

EXTENSION ANGLE REF. AXIS

BY MECH. CONTRACTOR

DETAIL — Q co

25NB SCH.80
PIPE SLEEVE
030x10 THK.
PLAN (TOP BRACKET)
020 TURNING
12 THK.

REF. AXIS

PLAN (BOTTOM BRACKET)

TURNING HANDLE DETAIL DAVIT SUPPORTS

7 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT &-KJH frISRN

6 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 653 of 674
 STANDARD No.

ferIM INGIsEERSONDIAMIRED
ONIPVIIIIIIIR1101111111 (A Govt. of Indio Undertaking)
PIPE DAVIT 7-12-0023 Rev. 7
Page 3 of 3

170

17 60 15 25 10 20 17

\\\\\\\
0

CAPACITY KGS
N
R

NAME PLATE

NOTES
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2. NAME PLATE
a) MATERIAL STAINLESS STEEL 2mm THICK.
b) NAME PLATE IS TO BE TACK WELDED TO THE DAVIT PIPE.
c) THE LETTERS AND NUMBERS SHALL HAVE RAISED POLISHED FACE.
d) BACKGROUND SHALL BE BLACK.
3. DIMENSION 'A' SHALL BE SUCH THAT THE DAVIT EYE EXTENDS PREFERABLY BY 900 mm OUTSIDE PLATFORM.
4. REFER ENGINEERING DRAWING FOR DIMENSIONS A, B, C, E, CAPACITY OF DAVIT AND INSULATION THICKNESS.
5. THE DAVIT USED SHALL CLEAR HANDRAIL OF THE EQUIPMENT.
6. MATERIAL OF PIPE SHALL BE A-53 / IS:1978 OR EQUIVALENT AND STRUCTURAL PARTS SHALL BE IS:2062 GR.B
OR EQUIVALENT.
7. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.
8. FOR THIN WALLED EQUIPMENT, DESIGNER SHALL ANALYSE THE STIFFNESS OF SHELL AT THE BRACKET LOCATIONS.
9. DETAIL DIMENSIONS AND NOTES IN ENGINEERING DRAWING TAKE PRECEDENCE OVER THOSE SHOWN HERE.
10. LOCKING PLATE (DETAIL —Y), LOCKING PIN (DETAIL —X) WITH CHAIN, POSITIONING PLATE (DETAIL —K), DEFLECTOR
CONE (DETAIL—P) AND LOCKING SUPPORT CHANNEL (DETAIL —Q) SHALL BE SUPPLIED LOOSE BY FABRICATOR AND
WELDED AT SITE BY MECHANICAL CONTRACTOR.
11. ALL FILLET WELDS SHALL BE 6 mm MINIMUM.
12. FOR LOW TEMPERATURE SERVICE, BRACKET DETAILS SHALL BE AS PER EIL STD. 7-12-0034
13. IN CASE DIMENSIONS 'B' IS BEYOND THIS STANDARD, IT IS RECOMMENDED TO INSTALL PIPE DAVIT
ON STRUCTURAL PLATFORM.

7 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SK/KJH RKT RN

6 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 654 of 674
 FIRE PROOFING STANDARD No.
BsIGINEERS
ORMONDIA UMRED
MIN11111011 Medi (A GovL of bxIct Undertaking)
AND 7-12-0025 Rev. 6
INSULATION SUPPORTS . Page 1 of 2

M6 x 4OLG. G.I. BOLTS 2–M6 BOLTS

6 DIA. HOLE FOR VESSEL DIAMETER ABOVE 600, x25LG. G.I.
TACK WELDED AT 600 PITCH
(TYP•) PROVIDE 30X6 THK. FLATS WITH BOLTS AND
60 HOLE AT NUTS (TYP.)
10 HEIGHT EQUAL TO INSULATION
600 PITCH
THK. AT 600 CIRCULAR PITCH
100 MIN. (1YP.) NOTE-7)
CORRUGATED
/SHEET
10 DA. LOOSE
3 THK. X 00.D
RING (TYP.)
100 MIN. NEOPRENE WASHER
THK. UMINIUM
WASHER
T.L
IV (NJ (NJ IV r•-■
WL1
-41— 'A'

3 THK.
ASBESTOS SHEET
6 THK. ANGLE RINGS
VIEW —
(WELD ENDS)
8 THK. T–CLEATS AT
1000 PITCH(MINIMUM 8
3 CLEATS PER RING)

010 HOLE ON
DETAIL—X ANGLE LEG
(FOR HOT INSULATED VESSELS)
(WHERE S –> 40) VIEW — 'B'
INSULATION
THICKNESS (5)
0

to

W.L 0
9
T.L 2

600 MIN. FOR VESSELS

INSULATED FOR TEMP.
ABOVE 400*C.

5 X COLD INSULATION
THICKNESS ( MIN 600MM)

C
an
M12 SQUARE NUTS TACK WELD t•I
ON INSIDE AND OUTSIDE OF PIP
SUPPORT
SKIRT ON 450 TRIANGULAR PITCH
FOR FIRE PROOFING (SEE DETAIL–Y) ANGLE LEG
(REFER NOTE-8) SUPPORT

M12 SQUARE NUTS TACK

WELDED AS SHOWN IN
SEC.D–D FOR FIRE PROOFING
(REFER NOTE-8)

DETAIL—Y

SECTION 'C—C'

6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH/ RN

5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 655 of 674
 FIRE PROOFING STANDARD No.

arr ENCMERS
egeNDIA LIMITED
INSPIUMI•11111841•0 (A Goa. of We Undertaking)
AND
INSULATION SUPPORTS
7-12-0025 Rev. 6
Page 2 of 2

2 NOS. 100 HOLES IN

PROVIDE ONE HEAT BREAK T—CLEAT / RING FOR
BETWEEN TWO CLEATS (TYP) M6 X 25 LG G.I. BOLTS w
w0
AND NUTS. Z
AIR POCKET
0 6 THK. FLAT (FOR VESSEL TEMP. ce
ABOVE 400*C)

1111 'p'
MOM 111111111•1111111111
1111
III
3 THK.
ASBESTOS SHEET

8 THK. T—CLEATS AT 40X6 THK. FLAT

1000 PITCH(MINIMUM
3 CLEATS PER RING) WITH 60HOLES
500 PITCH
10 TYP.
6 THK.
SUPPORT RING
WITH 6 DIA.
HOLE AT 600
* =
= (COLD INSULATION — 50 MM) PITCH
50 MM
VIEW — 'P'
DETAIL — 'Z'
DETAIL—X
(FOR COLD INSULATED VESSELS)

M6 x 4OLG. G.I. BOLTS

CORRUGATED TACK WELDED AT 600 PITCH
SHEET 60 HOLE AT
3 THK. X 20 0.D 600 PITCH
NEOPRENE WASHER
1(
II 2 THK. ALUMINIUM
1S1 0 _I c_ WASHER
,==.,E=
..iiii
S l '

6 THK. ANGLETSRINT`
GA
IN SEGMENTS
T THK. T—CLEA A
10•1000 PITCH (MINIMUM
2 CLEATS PER SEGMENT)
(TYP) VIEW — 'Al
DETAIL—X lomm GAP
(FOR HOT INSULATED VESSELS) (rYP)
(WHERE S < 40)

NOTES VIEW —
1. ALL DIMENSIONS ARE IN mm.
2. FOR MATERIAL SPECIFICATION REFER ENGINEERING DRAWING.
3. '12 . SHALL BE EQUAL TO 175mm FOR VESSELS UPTO 3000mm DIAMETER AND 300mm FOR VESSELS ABOVE 3000mm
DIAMETER.
4. DETAILS, DIMENSIONS AND NOTES ON ENGINEERING DRAWING SHALL TAKE PRECEDENCE OVER THOSE SHOWN HEREIN.
5. CLIPS SHALL CLEAR WELD SEAMS AND INSULATION RINGS SHALL BE SUITABLY NOTCHED INCASE OF INTERFERENCE
WITH NOZZLES/ATTACHMENTS.
6. ONLY T—CLEATS WITH ASBESTOS SHEET AND G.I. BOLTINGS, ANGLE RING ALONG WITH TACK WELDED BOLTS, INSULATION
SUPPORT CLEATS WELDED TO EQUIPMENT, LOOSE RINGS & M12 NUTS SHALL BE SUPPLIED BY EQUIPMENT FABRICATOR.
7. a) FOR COLD INSULATED VESSELS CLEATS ON DISHED ENDS ARE NOT REQUIRED.
b) FOR COLD INSULATED VESSELS CLEATS ON SHELL ARE TO BE PROVIDED IF COLD INSULATION THICKNESS IS MORE
THAN 60mm.
8. FOR UNINSULATED VESSELS SQUARE NUTS SHALL BE PROVIDED FOR ENTIRE HEIGHT OF SUPPORT (SKIRT, PIPE/ANGLE LEG).

41^^ Atti
ver...
6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SING4 SK/KJH RN
5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM

Rev. Prepared Checked Stds. Committee Stds. Bureau

Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
Page 656 of 674
 STANDARD No.

ORMO ENGINEERS NDIALIMITED

porrinnormsero (A G.A. of Ind. U.O.A.PAA9)
EARTHING LUG 7-12-0026 Rev. 6
Page 1 of 1

10 THK. PLATE
VESSEL PART

re)

to
N
to

\ 14 DIA. HOLE
(FOR M12 BOLT)
75 25

NOTES
1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2. ALL EQUIPMENTS SHALL BE PROVIDED WITH TWO(2) EARTHING
LUGS, UNLESS OTHERWISE STATED.
340 EARTHING LUGS SHALL BE LOCATED DIAMETRICALLY OPPOSITE ON
NORTH—SOUTH CENTER LINE ON SKIRT SUPPORTED EQUIPMENTS,
ON ANY TWO(2) LEGS OF THREE(3) LEG SUPPORTED VERTICAL VESSEL,
ON DIAMETRICALLY OPPOSITE LEGS OF FOUR(4) LEG SUPPORTED
VERTICAL VESSEL AND ON EACH SADDLE OF HORIZOTAL VESSEL.
(b) TWO(2) EATHING LUGS ARE TO BE LOCATED ON EACH SADDLE OF
HORIZONTAL VESSEL OF LENGTH GREATER THAN 20 METERS.
(c) FOR SPHERE, TOTAL 4—NOS. OF EARTHING LUGS SHALL BE PROVIDED
PREFERABLY ON DIAMETRICALLY OPPOSITE AND EQUALLY SPACED LEGS.
(SPHERES ARE USUALLY PROVIDED WITH LEGS IN NUMBERS WHICH ARE
MULTIPLE OF 4 FOR THE SYMMETRY)
4. DO NOT WELD EARTHING LUG ON PRESSURE PART.
5. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.
6. MATERIAL OF CONSTRUCTION SHALL BE CARBON STEEL.

6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH SK/KJH 114- RN

5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
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Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 657 of 674
 O
z
P

0
6
8

1:1
C

REAFFIRMED AN D REI SS UED AS STANDARD

REAFF IRME D AN DREISS UED AS STANDARD

- 13 L_
17
0)
0)

m O
6)
3lVld 31AWN

C)
cr o

a
NOTES

1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.

C) 2. ALL LETTERS, BLOCKS AND BORDER SHALL BE OF RAISED POLISHED FACE.

3. BACK GROUND SHALL BE BLACK.
4. NAME PLATE SHALL BE TACK—WELDED TO THE BRACKET. WHERE NOT POSSIBLE IT MAY BE RIVETTED.
NC12:1VONVIS

5. REFER STANDARD 7-12-029 FOR BRACKET DETAIL OF NAME PLATE.

'0

9.nati LZO0-Z1-1.

0
6. NAME PLATE SHALL BE OF STAINLESS STEEL OF 2mm THICK.

Page 658 of 674

 ii
0

0
fD

000-00-9"oN
0

DESIGNED BY
MANUFACTURED FOR
ITEM NUMBER
MANUFACTURER SERIAL NO.
YEAR OF FABRICATION
CODES

DESIGN PRESSURE TEST PRESSURE

ONVCINVIS SY 03119S 131:1CINV 0 3140:1 1ddVal

REAFF IRMED AND REISS UED AS STANDARD
DESIGN TEMPERATURE DATE OF TEST
CAPACITY CORROSION ALLOW.
OPERATING FLUID RADIOGRAPHY
-0 TOTAL WEIGHT EMPTY HEAT TREATMENT
s<

cn
311/ldMANN21 3211110VAIINVIN

0.
0
0 NOTES
3 U)
C)
9 3. 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2. ALL LETTERS, BLOCKS AND BORDER SHALL BE OF RAISED POLISHED FACE.
3. BACK GROUND SHALL BE BLACK.
4. NAME PLATE SHALL BE TACK—WELDED TO THE BRACKET. WHERE NOT POSSIBLE IT MAY BE RIVETTED.
oN C1 1:1VCI NVIS
.

9'net! 8200- Z1.-L

5. REFER STANDARD 7-12-029 FOR BRACKET DETAIL OF NAME PLATE.

c3
z 6. NAME PLATE SHALL BE OF STAINLESS STEEL OF 2mm THICK.

Page 659 of 674

 STANDARD No.
ENG11•1336 BRACKET FOR NAME PLATE 7-12-0029 Rev. 6
(AINDIAof LIMITED
Co. Indio Undartak110
Page 1 of 1

0 O
O
tn
La

10 R

BRACKET

O
N NAME PLATE

4-
EIL NAME PLATE

4-
E
O
M

MANUFACTURER NAME PLATE

0

<TYP.
2V

—L_

200

230

NOTES

1. ALL DIMENSIONS ARE IN run UNLESS OTHERWISE STATED.

2. BRACKET MATERIAL SHALL BE SAME AS SHELL MATERIAL.

6 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH ,„..•-•" SK/KJH RN

5 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 660 of 674
 SUPPORTS STANDARD No.

diarftraC
EN MED FOR 7-12-0032 Rev. 5
WIII1111•10 (A Gs& of WI. UndArtal*Ig)
INTERNAL FEED PIPE Page 1 of 2

SEE
VESSEL DRG. 0
0

TYPE—IA

100
VENT HOLE
SEEVESS EL D RG.

50 TO 75
AS PER
PIPE SIZE
it

TYPE—I

INTERNAL FEED PIPE FOR HORIZONTAL VESSEL

SPARGER/FEED PIPE SUPPORT
NOTE TYPE—IA IS APPLICABLE FOR LARGE THERMAL EXPANSION (AIR / GAS SERVICE)

(6+2xC.A.)
THK. MIN. FLAT

TYPE-2
INTERNAL SPLASH FEED PIPE FOR HORIZONTAL VESSEL

65
15 0 HOLE IN PIPE CLEAT (6+2xC.A.)
& 30 LONGx15 WIDE SLOTTED THK. MIN. FLAT
HOLE IN SHELL CLEAT

SUPPORT CLEAT
FOR VERTICAL VESSEL
TYPICAL DETAIL OF BOLTING CLEATS

5 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGH

/164
SK/KJH
°; 14.T
q/t
tt":"41N RN
4 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
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Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 661 of 674
 SUPPORTS STANDARD No.
ENGIM336 FOR 7-12-0032 Rev. 5
Ofiar gOINDIALIMTED
(A cwt. of Indio Undotioking)
INTERNAL FEED PIPE Page 2 of 2

TS

20 MIN. D NB

SHELL

REINFORCEMENT PAD
(NOTE-6)

TYPE-A
(FOR PIPES UPTO 250NB)

TS
20 MIN.

TI
SHELL
II
REINFORCEMENT PAD
(NOTE-6)
10
C.5
ul

0.5G
0

TYPE-B
(FOR PIPES ABOVE 250NB)

INTERNAL FEED PIPE FOR VERTICAL VESSEL/COLUMN

T
PIPE N.B.
BOLT SIZE E F G
D CA=O CA=1.5 CA=3 CA=5 CA=7

50 — 80 M 12 6 10 12 16 20 60 40 60

100 — 200 M 16 10 14 16 20 25 100 50 100

250 ,..- OVER M 16 14 18 20 25 28 150 100 150

NOTES
1 ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2. IN CASE OF CONFLICT VESSEL ENGG. DRAWING SHALL GOVERN.
3. MATERIAL OF CLEATS SHALL BE AS PER VESSEL ENGG. DRAWING.
4. ALL FILLET WELDS TO BE ALL AROUND & SIZE OF WELDS ARE (6+1xC.A.) MINIMUM UNLESS OTHERWISE STATED.
5. ALL INTERNAL BOLTS SHALL BE MIN. M 12 SIZE AND OF STAINLESS STEEL WITH DOUBLE NUTS.
6. REINFORCING PAD SHALL BE LARGER BY 50mm ALL AROUND THAN BRACKET CLEATS. NO PAD IS REQUIRED FOR
VESSELS WITH WALL THICKNESS GREATER THAN 25mm.

12
j eh K1611
5 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SK/
4 31.08.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT AKM/SC DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
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Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
Page 662 of 674
 STANDARD No.

S. R. NOZZLE NECK 7-12-0037 Rev. 4

1611111.11111•1111111.1PNI (A Get. of Indio Undortoklog)
Page 1 of 1

SELF REINFORCED NOZZLE

NOTES :— SELF REINFORCED WELD ENDS

1. DESIGN CALCULATION FOR ALL THE DIMENSIONS OF S.R. NOZZLES / WELD
ENDS SHALL BE APPROVED BY EIL
2. ANY DEVIATION IN THE OVERALL PROJECTION FROM THE SPECIFIED DESIGN
DATA SHALL BE MADE ONLY AFTER OBTAINING PRIOR APPROVAL FROM EIL.
3. FLANGES MAY BE FORGED INTEGRALLY WITH S.R. NOZZLE NECK.
4. I.D. OF FORGING SHALL BE AS SPECIFIED ON ENGG. DATA SHEET.
* 5. APPLICABLE FOR ASME SEC. VIII DIV.1 EQUIPMENT ONLY.
6. ALL SHARP CORNERS SHALL BE ROUNDED—OFF SMOOTH.

4 31.10.2016 REAFFIRMED AND REISSUED AS STANDARD JIT SINGHlk' SK/KJH R it2 RN

3 23.05.2011 REAFFIRMED AND REISSUED AS STANDARD POREL RKT
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved
Page 663 of 674
 STANDARD No.
kliRe_Jelta ENGINEERS ALLOWABLE NOZZLE LOADS
4gestMegiiiir INDIA LIMITED
NWT MOW =JAM)
7-12-0038 Rev. 1
(A Go& of India UndeAtekno
Page 1 of 4

MC

y FL

NOTES: -
1. THIS STANDARD COVERS ALLOWABLE NOZZLE LOADS FOR PRESSURE VESSELS & COLUMNS ONLY.
2. EACH PROCESS NOZZLE OF VESSELS SHALL BE ANALYZED FOR THE LOADS PROVIDED IN THIS
STANDARD.
3. THESE LOADS SHALL BE CONSIDERED TO BE ACTING SIMULTANEOUSLY WITH INTERNAL/EXTERNAL
DESIGN PRESSURE. ALLOWABLE STRESS SHALL BE AS PER APPLICABLE DESIGN CODE.
4. STRESS CALCULATIONS SHALL BE CARRIED OUT AS PER WRC BULLETIN NO. 107/297. WRC 107
SHALL BE USED FOR NOZZLES ON DISHED ENDS AND WRC 297 SHALL BE USED FOR NOZZLES
ON CYLINDRICAL SHELL.
5. IN CASE OF FAILURE DUE TO WRC, FEM ANALYSIS / PD 5500 ANALYSIS CAN BE CARRIED
OUT TO ESTABLISH THE ADEQUACY OF PROVIDED CONFIGURATION.

QAVO
I
1 20 06 2019 REAFFIRMED AND REISSUED AS STANDARD DP SK KJH 7 1/

0 31 07 14 ISSUED AS STANDARD GCP KA RKT SC

Prepared Checked Stds Committee Stds Bureau
Rev
Date Purpose Convenor Chairman
No by by
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Format No 8-00-0001-F4 Rev 0 Copynght EIL - All nghts reserved

Page 664 of 674

 STANDARD No.
4a1ReitLithENGINEERS ALLOWABLE NOZZLE LOADS
L11 WesWINDIA LIMITED 7-12-0038 Rev. 1
Olen OMR MAWR) (A Govt of (Adis Unarming)

Page 2 of 4

CARBON STEEL AND LOW ALLOY STEEL EQUIPMENTS

(CLASS 150 AND CLASS 300)

NOZZLE
FA FL FC MT ML MC
SIZES
(Kgf) (Kgf) (Kgf) (Kgf-m) (Kgf-m) (Kgf-m)
(DN)
50 135 200 200 50 40 30
80 202 300 300 112 90 67
100 270 400 400 200 160 120
150 405 600 600 450 360 270
200 540 800 800 800 640 480
250 675 1000 1000 1250 1000 750
300 810 1200 1200 1800 1440 1080
350 945 1400 1400 2450 1960 1470
400 1080 1600 1600 3200 2560 1920
450 1215 1800 1800 4050 3240 2430
500 1350 2000 2000 5000 4000 3000
600 1620 2400 2400 7200 5760 4320
650 1755 2600 2600 8450 6760 5070
700 1890 2800 2800 9800 7840 5880
750 2025 3000 3000 11250 9000 6750
800 2160 3200 3200 12800 10240 7680
850 2295 3400 3400 14450 11560 8670
900 2430 3600 3600 16200 12960 9720
950 2565 3800 3800 18050 14440 10830
1000 2700 4000 4000 20000 16000 12000
1050 2835 4200 4200 22050 17640 13230
1100 2970 4400 4400 24200 19360 14520
1150 3105 4600 4600 26450 21160 15870
1200 3240 4800 4800 28800 23040 17280
1250 3375 5000 5000 31250 25000 18750
1300 3510 5200 5200 33800 27040 20280
1350 3645 5400 5400 36450 29160 21870
1400 3780 5600 5600 39200 31360 23520
1450 3915 5800 5800 42050 33640 25230
1500 4050 6000 6000 45000 36000 27000

1 20 06 2019 REAFFIRMED AND REISSUED AS STANDARD DPW- Kriff KJH .c;k11 RKT
C
0 31 07 2014 ISSUED AS STANDARD GCP KA RKT SC

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copynght EIL - All nghts reserved

Page 665 of 674

 STANDARD No
ENGINERS
ligar0154-eg INDIA UNIFIED ALLOWABLE NOZZLE LOADS 7-12-0038 Rev 1
1102“ MOW .3411.4) (A Govt of Ind& UndestiVono
Page 3 of 4

CARBON STEEL AND LOW ALLOY STEEL EQUIPMENTS

(CLASS 600 AND ABOVE)

NOZZLE
FA FL FC MT ML MC
SIZES
(Kgf) (Kgf) (Kgf) (Kgf—m) (Kgf—m) (Kgf—m)
(DN)
50 168 250 250 62 50 37
80 253 375 375 140 112 84
100 337 500 500 250 200 150
150 506 750 750 562 450 337
200 675 1000 1000 1000 800 600
250 843 1250 1250 1562 1250 937
300 1012 1500 1500 2250 1800 1350
350 1181 1750 1750 3062 2450 1837
400 1350 2000 2000 4000 3200 2400
450 1518 2250 2250 5062 4050 3037
500 1687 2500 2500 6250 5000 3750
600 2025 3000 3000 9000 7200 5400
650 2193 3250 3250 10562 8450 6337
700 2362 3500 3500 12250 9800 7350
750 2531 3750 3750 14062 11250 8437
800 2700 4000 4000 16000 12800 9600
850 2868 4250 4250 18062 14450 10837
900 3037 4500 4500 20250 16200 12150
950 3206 4750 4750 22562 18050 13537
1000 3375 5000 5000 25000 20000 15000
1050 3543 5250 5250 27562 22050 16537
1100 3712 5500 5500 30250 24200 18150
1150 3881 5750 5750 33062 26450 19837
1200 4050 6000 6000 36000 28800 21600
1250 4218 6250 6250 39062 31250 23437
1300 4387 6500 6500 42250 33800 25350
1350 4556 6750 6750 45562 36450 27337
1400 4725 7000 7000 49000 39200 29400
1450 4893 7250 7250 52562 42050 31537
1500 5062 7500 7500 56250 45000 33750

1 20 06 2019 REAFFIRMED AND REISSUED AS STANDARD DP "A KJH ti 404--

0 31 07 14 ISSUED AS STANDARD GCP KA RKT SC
Rev Prepared Checked Stds Committee Stds Bureau
Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copynght EIL - All nghts reserved

Page 666 of 674

 STANDARD No
4o11 fill4 ENGINEERS ALLOWABLE NOZZLE LOADS
ige.,fl Was VW INDIA LIMTED 7-12-0038 Rev. 1
OWN gimme =mow) (A Govt d kMia Undettaking)
Page 4 of 4

STAINLESS STEEL EQUIPMENTS

(ALL CLASSES)

NOZZLE FA FL FC MT ML MC
SIZES
(Kgf) (Kgf) (Kgf) (Kgf-m) (Kgf-m) (Kgf-m)
(DN)
50 135 200 200 50 40 20
80 202 300 300 112 90 45
100 270 400 400 200 160 80

150 405 600 600 450 360 180

200 540 800 800 800 640 320

250 675 1000 1000 1250 1000 500

300 810 1200 1200 1800 1440 720

350 945 1400 1400 2450 1960 980
400 1080 1600 1600 3200 2560 1280

450 1215 1800 1800 4050 3240 1620

500 1350 2000 2000 5000 4000 2000

600 1620 2400 2400 7200 . 5760 2880

650 1755 2600 2600 8450 6760 3380

700 1890 2800 2800 9800 7840 3920

750 2025 3000 3000 11250 9000 4500

800 2160 3200 3200 12800 10240 5120

850 2295 3400 3400 14450 11560 5780

900 2430 3600 3600 16200 12960 6480
950 2565 3800 3800 18050 14440 7220

1000 2700 4000 4000 20000 16000 8000

1050 2835 4200 4200 22050 17640 8820

1100 2970 4400 4400 24200 19360 9680

1150 3105 4600 4600 26450 21160 10580

1200 3240 4800 4800 28800 23040 11520

1250 3375 5000 5000 31250 25000 12500

1300 3510 5200 5200 33800 27040 13520

1350 3645 5400 5400 36450 29160 14580

1400 3780 5600 5600 39200 31360 15680

1450 3915 5800 5800 42050 33640 16820

1500 4050 6000 6000 45000 36000 18000

1 20 06 2019 REAFFIRMED AND REISSUED AS STANDARD DP KJH RKT

0 31 07 2014 ISSUED AS STANDARD GCP KA RKT SC

Rev Prepared Checked Stds Committee Stds Bureau

Date Purpose Convenor Chairman
No by by
Approved by
Format No 8-00-0001-F4 Rev 0 Copyright EIL - All rights reserved

Page 667 of 674

 The drawing, design and details given below on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited, or used, except in the limited way permitted by written consent given by the lender to

NOZZLES AND CONNECTIONS ¼uksty o duSD'ku½ (CS+HIC & NACE ZONE) GENERAL NOTES (tujy uksV~l½ SPECIFICATIONS ¼LisflfQds'kUl½ DESIGN DATA ¼fMtkbu MkVk½
MARK QTY
NOM. DIA
SCH./THK.
FLANGES PROJECTION
PAD WxT SERVICE
UNLESS STATED OTHER WISE X DENOTES APPLICABLITY CODE ASME SEC.VIII DIV.-1 2017
(INCH) CLASS TYPE FACING NOTE-4
1 ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE STATED. X GENERAL SPEC. FOR PRESSURE VESSELS 6-12-0001 WORKING PRESSURE (kg/cm2g) SEE TABLE-1

ekdZ DokfUVVh
ukfeuy 'kMwy o
Dykl VkbZi Qsflx izksts'ku iSaM lfoZl 2 ALL ANCHOR BOLT HOLES TO STRADDLE N/S CENTRE LINE. X SUPP. SPEC. FOR CS VESSELS 6-12-0002 DESIGN PRESSURE
2
(kg/cm g) INT. 3.5 AT TOP EXT. F.V. @ 200° C
Mka;k bap fFkduSl 3 NORTH DIRECTION WHEREVER SHOWN IS WITH RESPECT TO PLAN VIEW. X SUPP. SPEC. FOR LOW ALLOY STEEL VESSELS 6-12-0003 WORKING TEMPERATURE
0
( C) SEE TABLE-1

2 1 96 48 THK. - WN RF
REF
## O.H. VAPOR+COMP. FLG.
4 (A) FOR NOZZLES ON SHELL PROJECTIONS ARE REFERRED FROM VESSEL CENTER LINE X SUPP. SPEC. FOR CLAD VESSELS 6-12-0007 DESIGN TEMPERATURE 0
( C) **
SHT.-5 TO FLANGE CONTACT FACE.
X STD. SPEC. FOR BQCS PLATE 6-12-0011 MDMT (0C) 3.4

3 1 8 80 150 WN RF 4230 110xT REFLUX IN (NOTE-38)

4 (B) FOR NOZZLES ON HEAD PROJECTIONS ARE REFERRED FROM HEAD T.L TO FLANGE X STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 CORROSION ALLLOWANCE (MM) 3.0 (FOR CS PORTION ONLY)
CONTACT FACE.
X STD. SPEC. FOR CLAD PLATES 6-12-0015 TYPE OF HEAD 2:1 ELLIPSOIDAL

9 1 2 160 150 WN RF
REF.
- VENT
5 THE INDICATED THICKNESS IS THE MINIMUM ACCEPTABLE AFTER CONSTRUCTION. X STD. SPEC. FOR 1.25% Cr-1/2% Mo STEEL PLATES 6-12-0017 JOINT EFFICIENCY SHELL SEE DRG. HEAD/TORICONE 1
SHT.-5 6 FLANGE GASKET FACE SHALL HAVE 125 AARH FINISH. X STD. SPEC. FOR 2.25% Cr-1 MO STEEL PLATES 6-12-0018 RADIOGRAPHY (NOTE-19) SHELL SEE DRG. HEAD/TORICONE FULL

11 1 14
24
150 WN RF 4250 175xT RICH OIL RETURN
7 DIMENSIONS OF FLANGES FOR NOZZLES UPTO 600NB SHALL BE AS PER ASME B16.5 X STD. SPEC. FOR SS PLATES 6-12-0020 POST WELD HEAT TREATMENT (NOTE-22) SEE DRG.
THK. AND FOR NOZZLE ABOVE 600NB SHALL BE AS PER ASME B16.47 SERIES-B UNLESS SPEC. FOR SURFACE PREPARATION & PROTECTIVE HEAT TREATMENT HEAD/TORICONE-AS PER SPEC.
12 LEAN OIL DRAW+VORTEX
SPECIFIED OTHERWISE. X COATING B224-000-79-41-PLS-01
OPERATING MEDIUM -
2 8 80 150 WN RF 4230 110xT
A-B BREAKER 8 ID OF WELD NECK FLANGES SHALL MATCH WITH CORRESPONDING ID OF NOZZLE X STD. SPEC. FOR CS COMPONENT IN SOUR SERVICE 6-79-0013 SP. GRAVITY 0.91 @340 C
0

PIPE. WIND SPECIFICATION IS:875

13 1 6 80 150 WN RF 4230 85xT LCO STRIPPER VP. RET.
9 ALL REMOVABLE INTERNALS (EXCEPT COKE TRAP) SHALL BE SIZED SO AS TO PASS THROUGH
STANDARDS ¼LVS.MMZl½ EARTH QUAKE SPECIFICATION IS: 1893 & SITE SPECTRA
MANHOLE. SUITABLE MANWAY CHECK SHALL BE CARRIED OUT BY VENDOR. NUMBER OF
14 1 16 24 THK. 150 WN RF 4280 200xT LCO PA RERURN (NOTE-38) INTERNAL FLANGES FOR DISTRIBUTORS SHALL DECIDED BY VENDOR ACCORDINGLY. X VESSEL TOLERANCES 7-12-0001 CAPACITY (M3) 2640
10 PAINTING: SURFACE PREPARATION, PRIMER (PRE-ERECTION) & FINAL PAINT (PRE- SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 PAINTING/CLEANING AS PER SPEC. (NOTE-10)
25 24 ERECTION/FIELD) AS PER B224-000-79-41-PLS-01. TABLE 11.1.2 FOR TOP/MIDDLE 7-12-0003 INSULATION THICKNESS (mm) (IH) (BY OTHERS) (NOTE-25, 37a) X HOT COLD
WOODEN PILLOWS FOR SADDLE SUPPORT
5 24 150 WN RF 4280 300xT MANHOLE + B.F. + DAVIT SECTION & TABLE 11.3.2 FOR BOTTOM SECTION SHALL BE FOLLOWED.
A-D, K THK. X SKIRT BASE DETAILS 7-12-0004 FIRE PROOFING (BY OTHERS) 50 mm YES NO
30
3 2 I/D - 300 LWN RF 4180 -
THERMOWELLS + 11 LIFTING TRUNION, TAILING LUGS INCLUDING BRACING ARRANGEMENT FOR SKIRT SHALL BE
DESIGNED BY VENDOR. (CONSIDERING AN IMPACT FACTOR OF 2). CALCULATION TO BE
X SKIRT OPENING DETAILS 7-12-0005 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL VERTICAL (AT TOP)
A-C (LIQUID SHIELD) SUBMITTED FOR REVIEW. VENDOR TO PROVIDE INSERT PLATE OF 2 x SHELL THK. WHEREVER ANGLE LEG SUPPORT 7-12-0006 PRESSURE (NEW & COLD) 4.732
31 PRESSURE CONNECTION TAILING LUGS & LIFTING TRUNIONS ARE WELDED TO SHELL. VENDOR TO DESIGN TRUNION & PIPE LEG SUPPORT 7-12-0007 INSPECTION BY EIL CIB X TPIA
3 2 160 300 WN RF 4180 - TAILING LUGS FOR HANDLING COLUMN SECTIONS AT SITE. TOPMOST TRUNION & BOTTOM MOST
A-C (NOTE-42) TAILING LUG SHALL BE ADEQUATE ENOUGH TO WITHSTAND TOTAL ERECTION WT. OF COMPLETE
BRACKET SUPPORT FOR VERTICAL VESSEL
COLUMN. MANHOLE WITH HINGED COVER 7-12-0009
32 I-J 2 3 160 150 WN RF 4230 45xT DP TYPE LEVEL TRANSMITTER 0
12 NOZZLE 50NB & BELOW SHALL BE STIFFENED WITH 2 NOS. 40x6 THK. FLATS 900 X MANHOLE WITH DAVIT 7-12-0010 ** TOP SECTION=200°C, MIDDLE SECTION=295°C, BOTTOM SECTION=475°C; BOTTOM SECTION FROM TOP OF BED1 TO

35 1 12 24 THK. 150 WN RF 4230 160xT LO STRIPPER VAP. RET.

APART. X LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 BOTTOM OF CONE SECTION DESIGNED FOR INTERMITTENT/EXCURSION OF 570 ºC FOR ≤ 100 HOURS/YEAR FOR 30 YEARS.
13 ALL FABRICATED NOZZLES SHALL BE FULLY RADIOGRAPHED. RETAINING PLATE 7-12-0012
MATERIAL OF CONSTRUCTION ¼eSfVfj;y vk¡Q dUlVªD'ku)
14 TOLERANCE ON COLUMN DIAMETER UPTO & ABOVE 8000mm SHALL BE GREATER OF X NOZZLE REINFORCEMENT AND PROJECTION 7-12-0013
± 20mm OR ±0.2% OF DIAMETER. HOWEVER IF STRINGER TOLERANCE ARE
PAD NOZZLES FOR VESSELS 7-12-0014 (AS PER ASME / IS OR EQUIVALENT) (CS ZONE)
RECOMMENDED BY INTERNALS SUPPLIER, THE SAME SHALL BE COMPLIED WITH.
X STANDARD BOLT HOLE ORIENTATION 7-12-0015 SHELL/INSERT PLATE SA 516 GR.60 *

15 COLUMN SHALL BE SUBJECTED TO STEAM OUT CONDITIONS OF 0.5 Kg/cm g 2

X ALLOY LINER DETAILS 7-12-0016 REINFORCEMENT PAD SA 516 GR.60
@1500C. SIGHT GLASSES FOR PRESSURE VESSELS 7-12-0017 HEADS SA 516 GR.60 *
## INSERT PLATE OF 4800 Ø X 48 THK. SHELL FLANGES -
16 NOZZLE SCHEDULES INDICATED FOR WELD OVERLAY NOZZLES ARE MINIMUM INTERNAL FLANGES 7-12-0018
REQUIRED. IT SHALL BE FABRICATORS RESPONSIBILITY TO SELECT NOZZLE VORTEX BREAKERS 7-12-0019 NOZZLE FLANGES/LWN NOZZLES SA 105 *
SCHEDULES SO THAT NO SHRINKAGE OR WRAPPING OCCURS DURING WELD INLET DEFLECTOR BAFFLE 7-12-0020 NOZZLE NECK UPTO 250 NB SA 106 GR. B *
OVERLAY. 7-12-0021 NOZZLE NECK ABOVE 250 NB SA 516 GR.60 *
SUPPORT RING AND BOLTING BAR
`T' DENOTES CORRESPONDING NOMINAL THICKNESS OF SHELL/DISH END.
17 ALL SS SURFACES SHALL BE PICKLED AND PASSIVATED AS PER ASTM A380. X SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 PIPE FITTINGS (SEAMLESS) SA 234 GR.WPB *

18 A) ALL C & L SEAMS INCLUDING C-SEAM, NOZZLE NECK TO FLANGE, PIPE TO PIPE X PIPE DAVIT (FOR GUIDANCE) 7-12-0023 GASKET EXTERNAL SPIRAL WOUND WITH SS 316L METAL WINDING & GRAFOIL FILLER WITH SS
INNER & CS OUTER RING AS PER ASME B16.20
FITTING & PIPE TO PIPE SHALL BE FULLY RADIOGRAPHED. LIFTING LUG TOP HEAD TYPE 7-12-0024
B) ALL C & L SEAMS OF SKIRT SHALL BE FULLY RADIOGRAPHED. X FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 GASKET INTERNAL CNAF (SEE NOTE-26)

19 LlCENSOR SHALL REVIEW FINAL DESIGN OF INTERNALS. ANY COMMENTS X EARTHING LUG 7-12-0026 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B7M / SA 194 GR.2HM

TABLE-1
OF LICENSOR AT ANY STAGE SHALL BE ABSORBED BY FABRICATOR
WITHOUT ANY TIME & PRICE IMPLICATION.
X NAME PLATE 7-12-0027 INTERNAL STUDS/BOLTS/NUTS SS 316L

X MANUFACTURER NAME PLATE 7-12-0028 SKIRT/ SUPPORT -

BEDS
BOTTOM MIDDLE TOP 20 CS SHELL SECTION & TOP DISHED END INCLUDING NOZZLE SHALL MEET NACE+HIC X BRACKET FOR NAME PLATE 7-12-0029 SKIRT/ SUPPORT BASE -
1-2 3-5 6-8 REQUIREMENTS AS PER NACE MR 0103 & EIL SPEC. 6-79-0013. HARDNESS OF BASE NAME PLATE FOR SMALL EQUIPMENT INTERNAL PARTS (BOLTED) SS 316L
7-12-0030
METAL, WELD & HAZ AFTER PWHT SHALL BE 200 BHN MAXIMUM.
OPERATING PRESSURE NORMAL 0.79 0.78 0.72 DETAILS OF FORGED NOZZLES 7-12-0031 INTERNAL SUPPORTS (WELDED) SA 516 Gr.60*
(Kg/cm2g) MAXIMUM 1.083 1.065 1.009 21 INTERNAL DETAILS SHOWN IN MDS ARE MINIMUM REQUIRED TO BE FOLLOWED. X SUPPORTS FOR INTERNAL FEED PIPE 7-12-0032 INTERNAL PIPE DISTRIBUTOR SA 106 GR. B * / SA 516 GR.60 *
NORMAL 349 271 172 HOWEVER, FABRICATOR TO REFER PDS FOR FINALIZING DETAIL ON INTERNALS HOT INSULATION SUPPORT FOR HORIZONTAL VESSEL 7-12-0033 CLIPS & ATTACHMENTS (EXTERNAL) SA 516 GR.60
O
OPERATING TEMP. ( C) WHILE OBTAINING FEEDBACK OF THEIR APPOINTED INTERNAL SUPPLIER.
MAXIMUM 355 277 178 PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034 INTERNALS PARTS (WELDED) SA 516 GR.60 *

22 WELDED QUENCH THICKNESS GIVEN IS TENTATIVE AND MINIMUM. VENDOR SHALL TYP. DETAILS OF WIRE MESH DEMISTER SUPPORTS 7-12-0036 DEMISTER/GRID -
DESIGN THE QUENCH TRAYS & SUPPORTING ARRANGEMENT CONSIDERING
2
X S.R NOZZLE NECK 7-12-0037 PAD FOR EXTERNAL ATTACHMENT SA 516 GR.60
LOAD=1000 Kg/m AND PROVIDE HIGHER THICKNESS, IF REQUIRED. FINAL SWAGE 7-12-0038 PIPE DAVIT SA 106 GR.B / SA 53
ALLOWABLE NOZZLE LOADS
DIMENSION AND DIMENSION FROM SWAGE TO QUENCH NOZZLES TO BE FINALIZED
LIFTING TRUNION SA 516 GR.60
BY FABRICATOR IN CONSULTATION WITH THEIR APPOINTED INTERNAL SUPPLIER.
TAILING LUG SA 516 GR.70
23 ALL 80 NB NOZZLES COMING IN CLAD PORTION SHALL BE LWN TYPE AND WELD VACUUM STIFFENER SA 516 GR.60
OVERLAYED. CHIMNEY TRAYS SS 316L
24 INLET LINE TO COLUMN IS REFRACTORY LINED. ACTUAL PROCESS I/D IS 63". PACKED BED SUPPORT & HOLD DOWN SS 316L
(REFRACTORY ON NOZZLE ASSEMBLY BY OTHERS) (DETAIL AS PER SHT.6 OF 7) REFERENCE DRAWINGS¼jsQjsUl MkbZx½ PACKING & ASSOCIATE ATTACHMENTS SS 316L
(REFRACTORY ANCHORS BY VENDOR). NOZZLES ARE 180° APART.
NOZZLE ORIENTATIONS DAVIT STRUCTURE IS 2062 E250 QUALITY BR

25 HOT INSULATION : LADDERS/PLATFORM CLEATS

TOP SECTION = 40 mm.
PIPE SUPPORT CLEATS
MIDDLE SECTION = 65mm
TRAY SUPPORT AND BOLTING BARS N.A. * (REFER NOTE-20 & 33)
BOTTOM SECTION = 90 mm.
DEMISTER DATA SHEET N.A.

26 ALL INTERNAL GASKETS SHALL BE SUITABLE FOR THE DESIGN TEMPERATURE. X PROCESS DATA SHEETS 076405C001-111-PDS-0500-2101 $ EXCLUDING WEIGHT OF BOLTED INTERNALS & CHIMNEY TRAYS/SUPPORTS
27 PROCUREMENT & SUPPLY OF ANCHOR BOLTS/NUTS (BY COLUMN FABRICATOR)- SA X SKIN THERMOCOUPLE MOUNTING DRG. B224-111-YT-SK-6003
0
193 GR.B7/SA 194 GR.2H. FOR DETAIL REFER SKETCH ATTACHED WITH MR.
28 COLUMN SHALL BE TRANSPORTED TO THE SITE IN TWO PIECES & SITE ASSEMBLED
AS PER JOB SPEC. NO. B224-80-43-SP-6006 ATTACHED ELSEWHERE IN MR.
FILE NAME: B224-111-80-43-DS-3001-0-1

29 LOCAL HYDROTEST, 100% RADIOGRAPHY & LOCAL PWHT SHALL BE CARRIED OUT STATUTORY REGULATIONS ¼LVSpqvjh jsxqys'kUl½
LICENSOR'S SPECIFICATION FOUNDATION LOADING DATA (OPERATING CONDITION) FOR SITE JOINT. INDIAN BOILER REGULATIONS (IBR)
ykbZlsUlj LisflfQds'lUl QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku) 30 FOUR SKIN THERMOCOUPLES (BY OTHERS) REQUIRED ON COLUMN AT MID POINT
HOLD UPS ¼gksYM vIl½ 0 DEPARTMENT OF EXPLOSIVES, NAGPUR (CCOE)
OF EACH BED 90º APART (FOR DETAIL OF SKIN THERMOCOUPLE INSTALLATION.
X NOZZLE ORIENTATIONS SIZE OF NOZZLES (AS MARKED)
the borrower for the intended use.

MAX. SHEAR FORCE AT BASE (H)

TYPE MAX MOMENT AT BASE (M) (kgm) 0 REFER DRAWING NO. B224-111-YT-SK-6003, ATTACHED WITH PR). $ APPROXIMATE WEIGHT (kgs) (PER ITEM) ¼,ijkSfDlesaV otu½
(kg) NOZZLE ELEVATIONS - AS
X MARKED X PIPE SUPPORT CLEATS
SEISMIC
9953000 261000
31 MOC FOR NOZZLE NECK / FLANGE / GASKET / NUTS / BOLTS SHALL BE COMPATIBLE X LADDER/PLATFORM CLEATS
ERECTION $ 664000 OPERATING 1146300
LICENSOR'S STANDARD (DBE) WITH CORRESPONDING SHELL MOC.
X SUPPORT HEIGHT TRAY SUPPORT/BOLTING BARS
ykbZlsUlj LVS.MlZ SEISMIC X DETAILS OF INTERNALS X PIPE DAVIT
(MCE) 12740000 342000 HYDROTEST(SHOP) $ 3304000 HYDROTEST ( FIELD ) 3426000
DETAILS OF SKIN THERMOCOUPLES
INSTALLATION ON SHELL
WIND 7896000 227000 NUMBER OF ITEMS : ONE

JOB NO: UNIT NO: DESIGN DATA fMtkbu MkVk DRAWING NUMBER
ENGINEERS INDIA LIMITED dk;Z l[;k B224
;÷fuV l[;k 111
MkbZx uEcj REV
NEW DELHI CLIENT :
DykbZV M/S HRRL, RAJASTHAN
0 21.10.2020 ISSUED FOR PR AKP RKM PVSSN MAIN FRACTIONATOR esu QjSD'usVj B224-111-80-43-DS-3001 0
B 20.09.2019 REVISED & REISSUED FOR ENGG/BIDS AKP NNM/RKM KJH
bathfu;lZ bafM;k fyfeVsM PLANT : A 23.08.2019 ISSUED FOR ENGG/BIDS AKP NNM/RKM KJH
RAJASTHAN REFINERY PROJECT ITEM NO. : 111-C-2101 vkbVe uEcj % 111&lh&2101 SHEET 1 OF 7
¼Hkkjr ljdkj dk midze½ IykaV REV DATE REVISION BY CHECKED APPROVED
FORMAT NO.3-1646-0113 REV.2 (20.09.2011) A3-420 X 297

Page 668 of 674

 NOZZLES AND CONNECTIONS ¼uksty o duSD'ku½ (1.25 Cr+0.5 MO+CLAD ZONE) GENERAL NOTES (tujy uksV~l½ SPECIFICATIONS ¼LisflfQds'kUl½ DESIGN DATA ¼fMtkbu MkVk½
The drawing, design and details given below on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited, or used, except in the limited way permitted by written consent given by the

0
MARK QTY
NOM. DIA
SCH./THK.
FLANGES PROJECTION
PAD WxT SERVICE
UNLESS STATED OTHER WISE X DENOTES APPLICABLITY CODE ASME SEC.VIII DIV.-1 (LATEST)
(INCH) CLASS TYPE FACING NOTE-4
6-12-0001 WORKING PRESSURE (kg/cm2g) INT. TOP - BOT. -
GENERAL SPEC. FOR PRESSURE VESSELS
ukfeuy Mka;k 'kMwy o 32 ALL SELF REINFORCED INTEGRALLY FORGED NOZZLES SHALL HAVE LIP SUPP. SPEC. FOR CS VESSELS 6-12-0002 DESIGN PRESSURE (kg/cm2g) INT. TOP - BOT. -
ekdZ DokfUVVh
¼bap½
Dykl VkbZi Qsflx izksts'ku iSaM lfoZl CONFIGURATION (100% RADIOGRAPHABLE) WITH SMOOTH RADIUS AT 0
fFkduSl STD. SPEC. FOR BQCS PLATE 6-12-0011 WORKING TEMPERATURE ( C) TOP - BOT. -
CORNERS AS SHOWN IN SKETCH.
24+3 REF. STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 DESIGN TEMPERATURE (0C) -
4 1 30 300 WN RF 380xT BOTTOMS
CLAD SHT.-5 33 CS/LAS PLATES SHALL BE IMPACT TESTED AS PER CODE/SPEC. STD. SPEC. FOR SHOP & FIELD PAINTING 6-44-0004 MDMT ( 0C) 15
34 ALL CLAD PLATES SHALL CONFIRM TO SA263. CORROSION ALLLOWANCE (MM) -
8 1 3 I/D @ 300 LWN RF 2720 45xT STEAM OUT 35 ONLY ISR IS ACCEPTABLE. DHT IN PLACE OF ISR IS NOT PERMITTED. TYPE OF HEAD -
15 20+3 36 FULL RADIOGRAPHY WHEREVER SPECIFIED SHALL IMPLY 100% JOINT EFFICIENCY SHELL - HEAD/TORICONE -
2 18 150 WN RF 4280 225xT LCO DRAW+VORTEX BREAKER RADIOGRAPHY OF ALL BUTT WELDS.
A-B CLAD RADIOGRAPHY SHELL - HEAD/TORICONE -
20+3 37 a) NO INSULATION SHALL BE PROVIDED FOR NOZZLE-1. POST WELD HEAT TREATMENT AS PER CODE
16 1 14 150 WN RF 4280 175xT HCO PA RETURN (NOTE-38) STANDARDS ¼LVS.MMZl½
CLAD 37 b) PROVIDE RETAINING PLATE FOR REINFORCING REFRACTORY (DETAILS AS HEAT TREATMENT HEAD/TORICONE-
17 20+3 SHOWN ON SHEET 6 OF 7). VESSEL TOLERANCES 7-12-0001 OPERATING MEDIUM -
2 18 300 WN RF 4360 225xT HCO DRAW+VORTEX BREAKER
A-B CLAD 38 PACKING VENDOR TO DESIGN THE COLLECTOR TRAYS, PACKED BED, SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 SP. GRAVITY -
20+3 DISTRIBUTORS & INTERNAL PIPE DISTRIBUTOR. WOODEN PILLOWS FOR SADDLE SUPPORT 7-12-0003 WIND SPECIFICATION IS:875
18 1 10 300 WN RF 4260 135xT HCO WASH
CLAD 39 PACKING VENDOR TO CONFIRM PACKED BED HEIGHT. SKIRT BASE DETAILS 7-12-0004 EARTH QUAKE SPECIFICATION IS: 1893 + SITE SPECTRA
24+3 40 LOCATE THERMOWELLS IN: VAPOR SPACE BELOW PACKING: NOZZLES 30A-F; SKIRT OPENING DETAILS 7-12-0005 CAPACITY (M3) -
19 1 20 300 WN RF 4370 250xT SLURRY PA RET. (NOTE-38) BOTTOMS LIQ: NOZZLE 30M
CLAD ANGLE LEG SUPPORT 7-12-0006 PAINTING/CLEANING AS PER SPEC.
41 FEED ZONE/SLURRY BED TOP AT 120° SPACING: NOZZLES 30G, 30H, 30I & PIPE LEG SUPPORT 7-12-0007 INSULATION THICKNESS (mm) - X HOT COLD
21 1 6 80+@ 300 WN RF 2720 85xT SPARGE STEAM 30J, 30K, 30L. FIRE PROOFING YES
BRACKET SUPPORT FOR VERTICAL VESSEL 7-12-0008 NO
14+3 42 LOCATE ALL PRESSURE INSTRUMENTS IN VAPOR PHASE. MANHOLE WITH HINGED COVER 7-12-0009 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL VERTICAL (AT TOP)
22 1 8 300 WN RF 2720 110xT FRESH FEED (START UP)
CLAD 43 SPARES SHALL BE SUPPLIED BY FABRICATOR AR PER MR SCOPE OF MANHOLE WITH DAVIT 7-12-0010 PRESSURE (NEW & COLD) -
WORK/SUPPLY DOC. LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 INSPECTION BY EIL CIB LLOYDS
24 1 3 I/D @ 300 LWN RF 2720 45xT UTILITY 44 ALL REQUIREMENTS MENTIONED IN COLUMN PROCESS DATA SHEET RETAINING PLATE 7-12-0012
25E,F, 24+3 ATTACHED WITH MR SHALL BE COMPILED BY VENDOR. NOZZLE REINFORCEMENT AND PROJECTION 7-12-0013
3 24 150 WN RF 4280 300xT MANHOLE + B.F. + DAVIT
L CLAD 45 DESIGN (BOTH HYDRAULIC & MECHANICAL) PROCUREMENT, FABRICATION, PAD NOZZLES FOR VESSELS 7-12-0014
25G,H, 24+3 SUPPLY & INSTALLATION OF COLUMN INTERNALS (BOTH WELDED AND STANDARD BOLT HOLE ORIENTATION 7-12-0015
3 24 300 WN RF 4350 300xT MANHOLE + B.F. + DAVIT BOLTED) ARE IN SCOPE OF COLUMN FABRICATOR. REFER JOB
M CLAD ALLOY LINER DETAILS 7-12-0016
24+3
SPECIFICATION & OTHER DOCUMENTS RELATED TO SAME IN BID DOCUMENT.
7-12-0017
MATERIAL OF CONSTRUCTION ¼eSfVfj;y vk¡Q dUlVªD'ku)
SIGHT GLASSES FOR PRESSURE VESSELS
25J 1 24 300 WN RF 2820 300xT MANHOLE + B.F. + DAVIT (CLAD ZONE) (NOTE-33 & 34)
CLAD 46 SUPPLY OF LADDER & PLATFORMS IS IN SCOPE OF VENDOR. COLUMN INTERNAL FLANGES 7-12-0018 (AS PER ASME / IS OR EQUIVALENT)

20+3 PRESSURE BALANCE (FROM VENDOR SHALL PROVIDE MATCH MARKED STRUCTURAL MEMBERS FOR VORTEX BREAKERS 7-12-0019 SHELL/INSERT PLATE SA 387 GR.11 CL.2 + SS 304L CLAD
27 1 10 150 WN RF 4230 135xT PLATFORMS & LADDER SUPPORTED ON COLUMN.
CLAD 111-V-1104) INLET DEFLECTOR BAFFLE 7-12-0020 REINFORCEMENT PAD SA 387 GR.11 CL.2

PRESSURE BALANCE (FROM 47 TENTATIVE LOCATION OF SITE JOINT IS MARKED ON SHT.4 OF 7. HOWEVER SUPPORT RING AND BOLTING BAR 7-12-0021 HEADS SA 387 GR.11 CL.2 + SS 304L CLAD
26 1 3 I/D @ 150 LWN RF 4230 45xT ACTUAL LOCATION SHALL BE FINALIZED BY COLUMN VENDOR. VENDOR
111-V-2601) SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 SHELL FLANGES -
SHALL CONSIDER EXTRA LENGTH SUITABLY TO ACCOUNT FOR CUTTING
PRESSURE BALANCE (FROM PIPE DAVIT 7-12-0023 NOZZLE FLANGES/LWN $$
28 1 3 I/D @ 300 LWN RF 4230 45xT SECTION, EDGE PREPARATION FOR REWELDING AT SITE BEFORE
111-V-2602) TRANSPORTATION FROM SHOP TO SITE. LIFTING LUG TOP HEAD TYPE 7-12-0024 SELF REINFORCED NOZZLES+NECK EXTENSION -

THERMOWELLS FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 NOZZLE NECK ABOVE 80 NB UPTO 150 NB SA 335 P11+SS304L WELD OVERLAY
30D-I 6 3 I/D @ 300 LWN RF 4260 45xT
(LIQUID SHIELD) 48 FOR DETAIL OF SHEILD FOR LIQUID THERMOWELL (EXCEPT NOZZLE 30M) & EARTHING LUG 7-12-0026 NOZZLE NECK ABOVE 150 NB SA 387 Gr.11 CL.2+SS304L CLAD
DETAIL OF VORTEX BREAKER REFER SHT. 22 OF PDS. NAME PLATE 7-12-0027 PIPE FITTINGS (SEAMLESS) SA 234 WP 11+SS304L WELD OVERLAY
30 M 1 3 I/D @ 300 LWN RF 2720 45xT THERMOWELL 49 ALL INTERNALS SHALL HAVE ANSI RF FLANGE CONNECTIONS & BE SIZED TO GASKET EXTERNAL SPIRAL WOUND WITH SS 321H METAL WINDING & GRAFOIL FILLER WITH CS
MANUFACTURER NAME PLATE 7-12-0028
PASS THROUGH THE NEAREST MANHOLE. OUTER & SS INNER RING AS PER ASME B16.20
31 PRESSURE CONNECTION BRACKET FOR NAME PLATE 7-12-0029
4 3 I/D @ 300 LWN RF 4260 45xT
D-G (NOTE-42) 50 LAS MOC OF MIDDLE & BOTTOM SECTION AS DEFINED IN SHT.4 . NAME PLATE FOR SMALL EQUIPMENT 7-12-0030 GASKET INTERNAL
32
MATERIAL SUPPLY CONDITION AS DEFINED IN PDS. DETAILS OF FORGED NOZZLES 7-12-0031 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B16 / SA 194 GR.4
A-B, M-R 8 3 I/D @ 300 LWN RF 4260 45xT DP TYPE LEVEL TRANSMITTER 0
INTERNAL STUDS/BOLTS/NUTS SS 304L
SUPPORTS FOR INTERNAL FEED PIPE 7-12-0032
32 HOT INSULATION SUPPORT FOR HORIZONTAL VESSEL 7-12-0033 SKIRT/ SUPPORT -
6 3 I/D @ 300 LWN RF 2720 45xT DP TYPE LEVEL TRANSMITTER
C-H 51 COLUMN VENDOR SHALL USE CROWN AND PETAL CONSTRUCTION FOR DISH PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034 SKIRT/ SUPPORT BASE -

32 ENDS. WHENEVER A NOZZLE IS POSITIONED AT THE CENTRE OF THE DISHED TYP. DETAILS OF WIRE MESH DEMISTER SUPPORTS 7-12-0036 INTERNAL PARTS (WELDED/BOLTED) SS 304L
2 3 I/D @ 300 LWN RF 4260 45xT DP TYPE LEVEL TRANSMITTER END, CROWN DIAMETER SHOULD BE LARGER THAN NOZZLE/ RF PAD
K-L DIAMETER.
S.R NOZZLE NECK 7-12-0037 SKIRT VENT SA 335 GR.P11

34
2 3 I/D @ 300 LWN RF 4260 45xT MAGNETIC TYPE LEVEL GAUGE
A-B VACUUM STIFFENER SA 387 GR.11 CL.2

34 PAD FOR EXTERNAL ATTACHMENTS SA 387 GR.11 CL.2

2 3 I/D @ 300 LWN RF 2720 45xT LEVEL GAUGE MAGNETIC TYPE
C-D CLIPS & ATTACHMENTS (EXTERNAL) SA 387 GR.11 CL.2

SKV LIFTING TRUNION/TAILING LUG SA 387 GR.11 CL.2

8 4 40 AS PER EIL STD. - SKIRT VENT
1-8 ANCHOR BOLTS/NUTS/WASHER SA 193 GR.B7 / SA 194 GR.2H / ASTM F436

AO BED SUPPORT & HOLD DOWN SS 304H

2 20 30 THK. AS PER EIL STD. 250x60 ACCESS OPENING
1-2 PACKING + CHIMNEY TRAY & ASSOCIATE ATTACHMENT SS304L

REFERENCE DRAWINGS¼jsQjsUl MkbZx½

NOZZLE ORIENTATIONS $$ SA 182 GR.F11 CL.2 + SS 304L WELD OVERLAY/ SA 336 GR.F11 CL.2 + SS 304L WELD OVERLAY.
LADDERS/PLATFORM CLEATS
PIPE SUPPORT CLEATS
TRAY SUPPORT AND BOLTING BARS
DEMISTER DATA SHEET
FILE NAME : B224-111-80-43-DS-3001-0-2

STATUTORY REGULATIONS ¼LVSpqvjh jsxqys'kUl½

@ 5 mm MINIMUM SS 304L WELD OVERLAY
lender to the borrower for the intended use.

LICENSOR'S SPECIFICATION FOUNDATION LOADING DATA (OPERATING CONDITION) INDIAN BOILER REGULATIONS (IBR)
ykbZlsUlj LisflfQds'lUl QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku) (FOR MIN. 3 mm UNDILUTED SS304L HOLD UPS ¼gksYM vIl½ DEPARTMENT OF EXPLOSIVES, NAGPUR (CCOE)
CHEMISTRY) NOZZLE ORIENTATIONS
MAX. SHEAR FORCE AT BASE (H)
TYPE MAX MOMENT AT BASE (M) (kgm)
(kg) NOZZLE ELEVATIONS
SIZE OF NOZZLES APPROXIMATE WEIGHT (kgs) (PER ITEM) ¼,ijkSfDlesaV otu½
SEISMIC SUPPORT HEIGHT PIPE SUPPORT CLEATS
LICENSOR'S STANDARD (DB) - - DETAILS OF INTERNALS LADDER/PLATFORM CLEATS
ERECTION - OPERATING -
ykbZlsUlj LVS.MlZ SEISMIC TRAY SUPPORT/BOLTING BARS
(MC) - - PIPE DAVIT
HYDROTEST(SHOP) - HYDROTEST ( FIELD ) -

WIND - - NUMBER OF ITEMS : -

JOB NO: UNIT NO: DESIGN DATA fMtkbu MkVk DRAWING NUMBER
ENGINEERS INDIA LIMITED dk;Z l[;k B224
;÷fuV l[;k 111
MkbZx uEcj REV
NEW DELHI CLIENT :
DykbZV M/S HRRL, RAJASTHAN
0 21.10.2020 ISSUED FOR PR AKP RKM PVSSN MAIN FRACTIONATOR esu QjSD'usVj B224-111-80-43-DS-3001 0
B 20.09.2019 REVISED & REISSUED FOR ENGG/BIDS AKP NNM/RKM KJH
bathfu;lZ bafM;k fyfeVsM PLANT : A 23.08.2019 ISSUED FOR ENGG/BIDS AKP NNM/RKM KJH SHEET 2 OF 7
¼Hkkjr ljdkj dk midze½ IykaV RAJASTHAN REFINERY PROJECT
REVISION APPROVED
ITEM NO. 111-C-2101 vkbVe uEcj % 111&lh&2101
REV DATE BY CHECKED
FORMAT NO.3-1646-0113 REV.2 (20.09.2011) A3-420 X 297

Page 669 of 674

 NOZZLES AND CONNECTIONS ¼uksty o duSD'ku½ (2.25 Cr.+1 MO+CLAD ZONE) GENERAL NOTES (tujy uksV~l½ SPECIFICATIONS ¼LisflfQds'kUl½ DESIGN DATA ¼fMtkbu MkVk½
The drawing, design and details given below on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited, or used, except in the limited way permitted by written consent given by the

MARK QTY
NOM. DIA
SCH./THK.
FLANGES PROJECTION
PAD WxT SERVICE
UNLESS STATED OTHER WISE X DENOTES APPLICABLITY CODE ASME SEC.VIII DIV.-1 (LATEST)
(INCH) CLASS TYPE FACING NOTE-4
6-12-0001 WORKING PRESSURE (kg/cm2g) INT. TOP - BOT. -
GENERAL SPEC. FOR PRESSURE VESSELS
ukfeuy Mka;k 'kMwy o SUPP. SPEC. FOR CS VESSELS 6-12-0002 DESIGN PRESSURE (kg/cm2g) INT. TOP - BOT. -
ekdZ DokfUVVh
¼bap½
Dykl VkbZi Qsflx izksts'ku iSaM lfoZl 0
fFkduSl STD. SPEC. FOR BQCS PLATE 6-12-0011 WORKING TEMPERATURE ( C) TOP - BOT. -
STD. SPEC. FOR STRUCTRAL QUALITY PLATES 6-12-0014 DESIGN TEMPERATURE (0C) -
1 A-B 2 72 REFER SHT.-7 FEED (NOTE-24 & 37) 0
STD. SPEC. FOR SHOP & FIELD PAINTING 6-44-0004 MDMT ( 0C) 15
REF. REF. CORROSION ALLLOWANCE (MM) -
20 1 6 300 SRWN RF - QUENCH RETURN
SHT.-7 SHT.-7 TYPE OF HEAD -
REF. REF. JOINT EFFICIENCY SHELL - HEAD/TORICONE -
25I 1 24 300 SRWN RF - MANHOLE + B.F. + DAVIT
SHT.-7 SHT.-7 RADIOGRAPHY SHELL - HEAD/TORICONE -
REF THERMOWELLS POST WELD HEAT TREATMENT AS PER CODE
30J-L 3 3 I/D @ 300 SRLWN RF - STANDARDS ¼LVS.MMZl½
SHT.7 (LIQUID SHIELD) HEAT TREATMENT HEAD/TORICONE-
REF PRESSURE CONNECTION VESSEL TOLERANCES 7-12-0001 OPERATING MEDIUM -
31H 1 3 I/D @ 300 SRLWN RF -
SHT.7 (NOTE-42) SUPPORT FOR HORIZONTAL VESSEL 7-12-0002 SP. GRAVITY -
WOODEN PILLOWS FOR SADDLE SUPPORT 7-12-0003 WIND SPECIFICATION IS:875
SKIRT BASE DETAILS 7-12-0004 EARTH QUAKE SPECIFICATION IS: 1893 + SITE SPECTRA
SKIRT OPENING DETAILS 7-12-0005 CAPACITY (M3) -
ANGLE LEG SUPPORT 7-12-0006 PAINTING/CLEANING AS PER SPEC.
PIPE LEG SUPPORT 7-12-0007 INSULATION THICKNESS (mm) - X HOT COLD
BRACKET SUPPORT FOR VERTICAL VESSEL 7-12-0008 FIRE PROOFING YES NO
MANHOLE WITH HINGED COVER 7-12-0009 HYDROSTATIC TEST (kg/cm2g) HORIZONTAL VERTICAL (AT TOP)
MANHOLE WITH DAVIT 7-12-0010 PRESSURE (NEW & COLD) -
LADDER RUNGS FOR MANHOLE/DEMISTER 7-12-0011 INSPECTION BY EIL CIB LLOYDS
RETAINING PLATE 7-12-0012
NOZZLE REINFORCEMENT AND PROJECTION 7-12-0013
PAD NOZZLES FOR VESSELS 7-12-0014
STANDARD BOLT HOLE ORIENTATION 7-12-0015
ALLOY LINER DETAILS 7-12-0016
7-12-0017
MATERIAL OF CONSTRUCTION ¼eSfVfj;y vk¡Q dUlVªD'ku)
SIGHT GLASSES FOR PRESSURE VESSELS
INTERNAL FLANGES 7-12-0018 (AS PER ASME / IS OR EQUIVALENT) (CLAD ZONE) (NOTE-33 & 34, #*)
VORTEX BREAKERS 7-12-0019 SHELL/INSERT PLATE SA 387 GR.22 CL.2 + SS 304L CLAD

INLET DEFLECTOR BAFFLE 7-12-0020 REINFORCEMENT PAD -

SUPPORT RING AND BOLTING BAR 7-12-0021 TORICONE SA 387 Gr. 22 CL.2+SS 304L CLAD

SUPPORT RING SIZES FOR PACKED TOWERS 7-12-0022 SHELL FLANGES -

PIPE DAVIT 7-12-0023 NOZZLE FLANGES/LWN $$

LIFTING LUG TOP HEAD TYPE 7-12-0024 SELF REINFORCED NOZZLES+NECK EXTENSION $$

FIRE PROOFING AND INSULATION SUPPORTS 7-12-0025 NOZZLE NECK ABOVE 80 NB UPTO 150 NB -

EARTHING LUG 7-12-0026 NOZZLE NECK ABOVE 150 NB SA 387 Gr.22 CL.2+SS304L CLAD

NAME PLATE 7-12-0027 PIPE FITTINGS (SEAMLESS) SA 234 WP 22+SS304L WELD OVERLAY

MANUFACTURER NAME PLATE 7-12-0028 GASKET EXTERNAL SPIRAL WOUND WITH SS 321H METAL WINDING & GRAFOIL FILLER WITH CS
OUTER & SS INNER RING AS PER ASME B16.20
BRACKET FOR NAME PLATE 7-12-0029
NAME PLATE FOR SMALL EQUIPMENT 7-12-0030 GASKET INTERNAL
DETAILS OF FORGED NOZZLES 7-12-0031 EXTERNAL STUDS/BOLTS/NUTS SA 193 GR.B5 / SA 194 GR.3

SUPPORTS FOR INTERNAL FEED PIPE 7-12-0032 INTERNAL STUDS/BOLTS/NUTS SS 304L

HOT INSULATION SUPPORT FOR HORIZONTAL VESSEL 7-12-0033 SKIRT/ SUPPORT SA 387 Gr. 11 CL.2

PIPE DAVIT SUPPORT FOR COLD INS. VESSELS 7-12-0034 SKIRT/ SUPPORT BASE SA 516 Gr.70

TYP. DETAILS OF WIRE MESH DEMISTER SUPPORTS 7-12-0036 INTERNAL PARTS (WELDED/BOLTED) SS 304L

S.R NOZZLE NECK 7-12-0037 SKIRT VENT SA 335 GR.P11 CL.1

SPOOL PIECE FOR NOZZLE 1 & 2 SA 336 GR.11 CL.2 + SS 304L WELD OVERLAY
VACUUM STIFFENER SA 387 GR.22 CL.2
PAD FOR EXTERNAL ATTACHMENTS SA 387 GR.22 CL.2
CLIPS & ATTACHMENTS (EXTERNAL) SA 387 GR.22 CL.2
LIFTING TRUNION/TAILING LUG SA 387 GR.22 CL.2/SA 516 Gr.70 (FOR TAILING LUG ON SKIRT ONLY)
ANCHOR BOLTS/NUTS/WASHER SA 193 GR.B7 / SA 194 GR.2H / ASTM F436
BED SUPPORT & HOLD DOWN SS 304H
PACKING+CHIMNEY TRAYS SS 304L

REFERENCE DRAWINGS¼jsQjsUl MkbZx½

NOZZLE ORIENTATIONS $$ SA 182 GR.F22 CL.3 + SS 304L WELD OVERLAY/ SA 336 GR.F22 CL.3 + SS 304L WELD OVERLAY.
LADDERS/PLATFORM CLEATS
PIPE SUPPORT CLEATS #* 2.25 Cr.+1 MO SHALL COMPLY WITH REQUIREMENT FOR STEP COOLING, J FACTOR LESS THAN OR EQUAL TO 100 & X
TRAY SUPPORT AND BOLTING BARS FACTOR LESS THAN OR EQUAL TO 15.
DEMISTER DATA SHEET
FILE NAME : B224-111-80-43-DS-3001-0-3

STATUTORY REGULATIONS ¼LVSpqvjh jsxqys'kUl½

@ 5-6 mm SS 304L WELD OVERLAY (FOR MIN.
lender to the borrower for the intended use.

LICENSOR'S SPECIFICATION FOUNDATION LOADING DATA (OPERATING CONDITION) INDIAN BOILER REGULATIONS (IBR)
ykbZlsUlj LisflfQds'lUl QkaÅMs'ku yksfMxa MkVk ¼vksijsfVax dufM'ku) 3 mm UNDILUTED SS304L CHEMISTRY) HOLD UPS ¼gksYM vIl½ DEPARTMENT OF EXPLOSIVES, NAGPUR (CCOE)

MAX. SHEAR FORCE AT BASE (H) NOZZLE ORIENTATIONS

TYPE MAX MOMENT AT BASE (M) (kgm)
(kg) NOZZLE ELEVATIONS
SIZE OF NOZZLES APPROXIMATE WEIGHT (kgs) (PER ITEM) ¼,ijkSfDlesaV otu½
SEISMIC SUPPORT HEIGHT PIPE SUPPORT CLEATS
LICENSOR'S STANDARD (DB) - - DETAILS OF INTERNALS LADDER/PLATFORM CLEATS
ERECTION - OPERATING -
ykbZlsUlj LVS.MlZ SEISMIC TRAY SUPPORT/BOLTING BARS
(MC) - - PIPE DAVIT
HYDROTEST(SHOP) - HYDROTEST ( FIELD ) -

WIND - - NUMBER OF ITEMS : -

JOB NO: UNIT NO: DESIGN DATA fMtkbu MkVk DRAWING NUMBER
ENGINEERS INDIA LIMITED dk;Z l[;k B224
;÷fuV l[;k 111
MkbZx uEcj REV
NEW DELHI CLIENT :
DykbZV M/S HRRL, RAJASTHAN
0 21.10.2020 ISSUED FOR PR AKP RKM PVSSN MAIN FRACTIONATOR esu QjSD'usVj B224-111-80-43-DS-3001 0
B 20.09.2019 REVISED & REISSUED FOR ENGG/BIDS AKP NNM/RKM KJH
bathfu;lZ bafM;k fyfeVsM PLANT : A 23.08.2019 ISSUED FOR ENGG/BIDS AKP NNM/RKM KJH SHEET 3 OF 7
¼Hkkjr ljdkj dk midze½ IykaV RAJASTHAN REFINERY PROJECT
REVISION APPROVED
ITEM NO. 111-C-2101 vkbVe uEcj % 111&lh&2101
REV DATE BY CHECKED
FORMAT NO.3-1646-0113 REV.2 (20.09.2011) A3-420 X 297

Page 670 of 674

 A
NOTE:-

DETAIL - A

esu QjSD'usVj
vkbVe uEcj % 111&lh&2101

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Page 672 of 674
DETAIL-1

# INVERT INSIDE OF WITHDRAWAL NOZZLE

TO BE FLUSH WITH TOP OF DRAW-OFF
PAN SUPPORT RING.

LOCATE THERMOWELLS IN
- VAPOUR SPACE BELOW PACKING : NOZZLES 30A-F
- BOTTOM LIQUID : NOZZLE 30M
- FEED ZONE/SLURRY BED TOP AT 120° SPACING : NOZZLES
30G, 30H, 30I,
30J, 30K, 30L
- FOR INSTALLATION/LOCATION DETAIL OF THERMOWELL REFER PDS.

LOCATE PRESSURE INSTRUMENT IN VAPOUR SPACE

esu QjSD'usVj
vkbVe uEcj % 111&lh&2101

LIQUID LEVEL
DETAILS
 esu QjSD'usVj
vkbVe uEcj % 111&lh&2101

Page 673 of 674

 esu QjSD'usVj
vkbVe uEcj % 111&lh&2101

Page 674 of 674