Jacobs Spec For Heat Exchangers PDF

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Table of Contents
Document Number Rev. Document Title Page
Number
A133-086-EE-MR- 0 ENQUIRY DOCUMENT 3
6142-52-RFQ
A133-086-EE-MR- A S&T EXCHANGERS-CS&SDSS 73
6142
44NC-4600-0000- 1 General Specification for Painting 80
V.02-0111-A4
44NC-4600-0000- 0 LICENSOR STANDARD 125
V.02-0104-A4
44NC-4600-0000- 0 GENERAL NOTES SS CLAD EXCHANGERS 133
V.02-0167-A3 Sht.- 2
of 2_
44NC-4600-0000- 1 LICENSOR SPECIFICATION 134
V.02-0001-A4
44NC-4600-0000- 0 General Spec for hardness requirements 183
V.02-0113-A4
44NC-4600-C.02- D LICENSOR SPECIFICATION 186
0001-A4
44NC-4600-0000- 1 General Spec for Pressure vessels 231
V.02-0101-A4
44NC-4600-0000- 0 GENERAL NOTES KCS EXCHANGERS 272
V.02-0166-A3_
6-79-0016 1 Specification for welding of duplex stainless steel and super 273
duplex stainless steel
7-15-0007 rev3.pdf 3 Stds 284
44NC-4600- A Quality management system 285
000/N.02/0040/A4
44NC-4600- A Quality management system 292
000/N.02/0040/A4
Annesure 1 to V
A133-00-000--ITP- A INSPECTION AND TEST PLAN (JOB SPECIFIC) 298
09A
44NC-4600-0000- 0 Supp spec for CS vessels 302
V.02-0120-A4
A133-086-16-46- A VDR FOR VDR COMPILATION 307
VDR-6142
INDVSD101-3 0 Standard 310
INDVSD110-2 0 Welded tube to tubesheet joint 311
INDVSD108-1 0 LICENSOR SPECIFICATION 312
44NC-4600-0000- 0 Standard Specification for BQ plates 314
V.02-0117-A4
INDVSD117 0 Licensor Standard 319
A133-000-16-46-SK- 0 JOB SKETCHES 320
12
INDVSD114 Model 0 Licensor Standard 322
(1)
INDVSD102 0 LICENSOR SPECIFICATION 323
A133-16-46-SP-6142 A MR JOB SPECIFICATION 324
44NC-4600-0000- 0 Scope of work for Fab equipment 331
V.02-0172
INDVSD110-1 0 Welded tube to tubesheet joint 340
INDVSD101-2 0 LICENSOR STANDARD 341
6-79-0015 1 Specification for duplex stainless steel and super duplex stainless 342
steel
A133-000-16-46-SK- 0 JOB SKETCHES 355
14
Page 1 of 441
Table of Contents
Document Number Rev. Document Title Page
Number
A133-086-16-46-DS- A MECHANICAL DATASHEETS 356
4024
A133-086-16-46-DS- A ENGINEERING DRAWINGS/SETTING PLAN 357
4024A2
44NC 4600 0 COMPLIANCE STATEMENT 358
(Compliance
Statement)
A133-086-05-45- 0 TUBE LAYOUT 359
4026
A133-16-46-TL-6142 A GUIDELINES TO VENDOR FOR TUBE LAYOUT 361
44NC-4600-0000- 0 General Spec for Materials 365
V.02-0114
6-15-0021 4 Standard specification for vendor-designed shell and tube heat 386
exchangers.
A133-000-16-46-SK- 0 JOB SKETCHES 400
13
INDVSD111 o Licensor Standard 401
44NC-4600-0000- 0 LICENSOR SPECIFICATION 402
V.02-0102-A4
A133-16-46-TR-6142 A INSTRUCTIONS TO VENDOR/ TECHNICAL REQUIREMENTS 423
INDVSD112 0 LICENSOR SPECIFICATION 427
A133-000-16-46-SK- 0 JOB SKETCHES 429
011
A133-16-46-SS-6142 A SCOPE OF WORK AND SUPPLY 431
INDVSD080 0 Earthing lug 435
44NC-4600-0000- 0 GENERAL NOTES SS CLAD EXCHANGERS 437
V.02-0167-A3 Sht.- 1
of 2_
A133-086-16-46-DS- B ENGINEERING DRAWINGS/SETTING PLAN 438
4023
A133-086-16-46-DS- B ENGINEERING DRAWINGS/SETTING PLAN 439
4023S2
44NC 4600 (Drawing 0 DRAWING TITLE SAMPLE 440
Title Sample)
A133-086-05-45-25 1 TUBE LAYOUT 441
Page 2 of 441
Regd. Office: Engineers India Bhawan, 1-Bhikaiji Cama Place, New Delhi-110066, India
Phone No. : 00 91 11 26762121 ; Fax No. : 00 91 11 26191714, 26167664
REQUEST FOR QUOTATION (RFQ)-(INDIGENOUS / FOREIGN / GLOBAL)
(e-Tendering)
Date: 03-April-2014
M/s Client Chennai Petrochemical Corporation Limited

For Limited Bidders Only: Project Coker Block of Resid Upgradation Project at Manali
The Suppliers to whom this RFQ is Refinery, Chennai
issued are only required to quote. RFQ No. RC/A133-086-EE-MR-6142/0052
Item Heat Exchanger Ss-Duplex, Heat Exchanger Carbon
Steel
Category II
Due Date 24-April-2014 [Up to 1200 Hrs. (IST)]
UNPRICED BID OPENING: At 1400 Hrs.(IST) on final bid due date
(In case the bid due date happens to fall on Holiday, the next working day
shall be deemed to be due date)
PRE-BID MEETING At 1000 HRS. (IST) on 14-April-2014(at Business Centre, Engineers India
Limited, 1-Bhikaiji Cama Place, New Delhi-110066).
PRICED BID OPENING : DATE & TIME SHALL BE INTIMATED LATER

REVERSE AUCTION IF CONDUCTED, DATE & TIME SHALL BE INTIMATED LATER
Gentlemen,
1. Chennai Petroleum Corporation Limited (CPCL), a subsidiary of Indian Oil Corporation Limited has
existing Refinery Facilities at Manali, Chennai, Tamil Nadu (India). The present capacity of CPCL at
Manali Refinery is 9.5 MMTPA. CPCL is currently implementing a Revamp of existing units to increase the
crude processing capacity by 1 MMTPA to take the overall complex capacity to 10.5 MMTPA unit.
Chennai Petroleum Corporation Limited (CPCL) has awarded the work of Resid Upgradation Project-
Coker Block to Engineers India Limited (EIL) and EIL is the CONTRACTOR for this Project.
2. Bids are requested for the captioned item in complete accordance with enquiry documents and its
attachments.
3. The complete RFQ can be downloaded from the EIL website (http://tenders.eil.co.in or from CPP Portal
(URL: http://eprocure.gov.in)
4. Bidders are requested to submit e-bids electronically on the CPP Portal (URL: http://eprocure.gov.in) only
in accordance with the instructions and terms & conditions enclosed with this RFQ Covering letter.
Bids should be submitted separately in two parts as follows:
Part-I : The techno-commercial Part consisting of following:
i) Offer Covering letter (in bidder’s letter head)
ii) Techno-commercial compliance to the RFQ terms & Conditions.
1_RFQ_A133_6142_0052 Page 1 of 4
Page 3 of 441
iii) Duly filled-in, signed & stamped Annexure I to Prefilled ATC giving basic details on
transportation charges, taxes/ duties etc.
iv) Bank Certified Mandate Form as per Annexure-II to Prefilled ATC, duly signed and
stamped with the Banker’s certification alongwith cancelled cheque.
v) Unpriced copy of Price Schedule (Excel file) (available in the RAR format which is
uploaded on EIL website (http://tenders.eil.co.in or CPP Portal (URL:
http://eprocure.gov.in) (Indicating ‘Q’ in place of price and ‘NQ’ for not quoted).
vi) Unpriced copy of 2 years recommended spares for Operation & Maintenance of
equipment in the format enclosed with RFQ
vii) Unpriced copy of Supervision Charges quoted in the “Terms & Conditions for Supervision
of Erection, Testing & Commissioning” indicating “Q” in place of Prices.
viii) Unpriced copy of unit rates required as per Sr. No 06.00 of MR.
ix) Latest Complete Audited Balance Sheet.
x) Fresh Bank Solvency Certificate, date of issue of this certificate should not be earlier
than 1 year from the date of Opening of Techno-commercial part.
xi) Integrity Pact (Clause # 22 of Special Commercial Notes to RFQ).
xii) Concurrent Commitment, in the format enclosed with RFQ
xiii) Technical Compliance/ datasheets/ documents, required as per Material Requisition.
Part-II : PRICED BID
Containing only prices filled in the prescribed price schedule excel format and other formats provided in
the RFQ Document, consisting of the following priced documents:
i) Prices in Price Schedule Format (only as per Excel file available in the RAR format
which is uploaded on EIL website (http://tenders.eil.co.in or CPP Portal (URL:
http://eprocure.gov.in).
ii) Prices for 2 years recommended spares for Operation & Maintenance of equipment, in
the format enclosed in the RFQ.
iii) Per-diem charges for Supervision of Erection, Testing, Pre-commissioning and
Commissioning.
iv) Prices for unit rates required as per Sr. No 06.00 of MR.
Note:
a) Deviations to terms and conditions, presumptions etc shall not be stipulated in Price part of bid
and price bids shall not contain any stapled slips. In case of any conditions stipulated in price bids
or the price bid containing any stapled slips, the bids of such bidders shall be summarily rejected
and shall not be considered for further evaluation. Evaluation shall be carried out excluding such
bidder(s.)
5. Offers received through Fax / Telex / Telegraphic / E-Mail / hard form (other than the documents
specifically required in hard form) shall not be considered.
1_RFQ_A133_6142_0052 Page 2 of 4
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6. EIL will open the bids received online at their office, at the specified date and time given in the RFQ or
extended date, if any.
The bidders who have submitted their bid will be able to view online the name & status of all the bidders at
their respective windows, after unpriced bid opening by EIL.
Similarly, all technically and commercially acceptable bidders will be advised of date and time of online
priced bid opening. Aforesaid Bidders, will be able to view online the price sheets of other techno-
commercially acceptable bidders at their respective windows, after priced bid opening by EIL.
7. Please furnish your response to our RFQ either through EIL’s website http://tenders.eil.co.in or by
sending email/fax to EIL as per Proforma of Reply/ Acknowledgement Letter enclosed, by the pre-bid
meeting.
If not bidding, please return enquiry documents along with regret letter within the due date with reason(s)
of not participating in the RFQ.
The bidders should respond to this enquiry either by submitting their bids or by explaining the reason for
non-submission of the offer. In case there is no response either way continuously, the bidder shall
be liable for suitable action including review of their enlistment with EIL for that particular item.
8. Offer Validity: Offer shall be valid for 03 Months from the final / extended bid due date.
9. PAYMENT TERMS
For Supply (excluding Mandatory Spares): As per clause No. 1.1.1 (vi) of Instruction to Bidders.
For supply of Mandatory Spares: As per clause No. 1.1.2 of Instruction to Bidders.
For other scope: As per Instruction to Bidders
10. Delivery/Completion Period :
Supply :
Indigenous Supplier:
Within 8 (Nine) Months on FOT Site basis from date of Fax of Acceptance / Purchase Order. The date
of receipt of material at site shall be considered as the date of delivery.
11. Price Reduction Schedule: As per clause No. 12.1 & 12.4 of Instruction to Bidders.
12. Repeat Order is not applicable for this RFQ.
13. Contact Persons for this RFQ are:
Ms. Rekha Choudhary–AGM (C&P) ; Phone:011-26762071 ; E-mail: r.choudhary@eil.co.in

Mr. Uttam Kumar-Sr. Engineer (C&P): Phone: 011-26763033; E-mail: uttam.kumar@eil.co.in
* Please specify Ref. No. (i.e. RFQ No.) in all correspondence
THIS IS NOT AN ORDER Very truly yours,
( REKHA CHOUDHARY )
Asst. General Manager (C&P)
Enclosures :
 Techno-Commercial Compliance To Bid Requirement
 Price Schedule (for Indian Bidders / Foreign Bidders, as applicable) – uploaded on EIL
website (http://tenders.eil.co.in or CPP Portal (URL: http://eprocure.gov.in) as RAR file.
1_RFQ_A133_6142_0052 Page 3 of 4
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Standard Commercial Documents Containing:
 Forms & Formats

 Reply/ Acknowledgement letter
 Proforma of Letter of Authority Rev.0
 Format for Bidders’ Pre-bid Queries
 Exceptions and Deviations (Commercial)
 Format for Present/ Concurrent Commitments
 Annexure – A : Particulars required for Tax Residency Certificate (TRC) & Form 10F
 Format For 2 Years Spares of normal operation & maintenance
 Special Instructions To Bidders
 Special Commercial Notes to RFQ
 Instructions to Bidders
 Methodology and terms & conditions for Reverse Auction
 Instructions to Bidders for e-Tendering
 Terms & Conditions For Supervision Of Erection, Testing & Commissioning
 Terms & Condition for Annual Maintenance Contract (AMC)
 Terms & Condition for Site Work
 General Purchase Conditions (Respectively for Indian and Foreign Bidder)
 Integrity Pact
 Agreed Terms & Conditions (Respectively for Indian and Foreign Bidder)
 Material Requisition
MR No. A133-086-EE-MR-6142 Rev. A
1_RFQ_A133_6142_0052 Page 4 of 4
Page 6 of 441
DO NOT OPEN - THIS IS A QUOTATION
Client : Chennai Petrochemical Corporation Limited

Project : Coker Block of Resid Upgradation Project at Manali Refinery, Chennai
RFQ No. : RC/A133-086-EE-MR-6142/0052
Item : Heat Exchanger Ss-Duplex, Heat Exchanger Carbon Steel
Bid Due Date : 24-April-2014 [Up to 1200 Hrs. (IST)]
From : To :
Ms. R. Choudhary
The Asst. Gen. Manager(C&P)
Engineers India Limited
EI Annexe, 2nd Floor,
Bhikaji Cama Place,
New Delhi – 110066
(To be pasted on the envelope containing Integrity Pact)
Page 1 of 1
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REPLY/ACKNOWLEDGEMENT LETTER
FAX Nos. : 00-91-11-26191714, 26167664

SELF ADDRESSED FAX
(PLEASE REFAX TO EIL WITHIN TEN DAYS OF RECEIPT OF RFQ)

Engineers India Bhawan,
nd
EI Annexe, 2 Floor,
1-Bhikaiji Cama Place,
New Delhi – 110066
Attn. : Ms. Rekha Choudhary – Asst. General Manager (C&P)

RFQ No. : RC/A133-086-EE-MR-6142/0052
Bid Due Date : 24-April-2014 [Up to 1200 Hrs. (IST)]
Project : Coker Block of Resid Upgradation Project at Manali Refinery of M/s CPCL, Chennai
Dear Sirs,
We acknowledge with thanks receipt of your above cited RFQ along with enclosures. We undertake that the
contents of the above RFQ shall be kept confidential including all the drawings, specifications and documents
and the said documents shall be used only for the purpose, for which they are intended.
Further, our response is as under:- (Bidders to put a tick , as applicable).
1. We will submit the bid within due date.
2. We regret to submit our offer/quote because of the following reasons:
a. _____________________________________________________
b. _____________________________________________________
Thanking you,
Very truly yours,
Name of Bidder :
Bidder’s Address :
Contact Person :
Bidder’s Phone No. :
Bidder’s Fax No. :
Bidder’s E-mail No. :
Bidder’s Ref. No. & Date :
Page 1 of 1
Page 8 of 441
PROFORMA OF LETTER OF AUTHORITY FOR ATTENDING PRE-BID CONFERENCE
No. Date:
To,
Engineers India Bhawan, EIA-2
1, Bhikaiji Cama Place
New Delhi – 110 066
(India)
Attn . : Ms. Rekha Choudhary, Asst. General Manager (C&P)
Dear Sirs,
We……………………………………..hereby authorise following representatives (s) to attend the Pre-Bid

Meeting against your RFQ No.: ……………………………………. for Item ……………………….……………
1. Name & Designation ………………………………Signature …………………………..
2. Name & Designation ……………………………… Signature …………………………
We confirm that we shall be bound by all and whatsoever our representative (s) shall commit.
Yours faithfully,
Signature ……………………………
Name & Designation ……………….
For & on behalf of ………………….
Note :
This Letter of Authority should be on the letter head of the bidder and should be signed by a person
competent and having the power of attorney to bind the bidder.
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TECHNO-COMMERCIAL COMPLIANCE TO BID REQUIREMENT
RFQ No. : RC/A133-086-EE-MR-6142/0052

We hereby agree to fully comply with, abide by and accept without variation, deviation or reservation
to all technical, commercial and other conditions whatsoever of the RFQ documents and Amendment/
Addendum to the RFQ Documents, if any, for subject RFQ.
SIGNATURE OF BIDDER : _______________________
NAME OF BIDDER : _______________________
COMPANY SEAL : _______________________
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FOR BIDDERS’ QUERIES
RFQ No. : RC/A133-086-EE-MR-6142/0052

SL. REFERENCE OF RFQ DOCUMENT BIDDER'S QUERY EIL'S REPLY

NO.
PART/ Page Clause Subject
VOL. No. No.
NOTE: The Pre-Bid Queries may be sent on fax numbers 0091-11-26187664 and also by e-mail to concern person of EIL.
SIGNATURE OF BIDDER : ___________________________
NAME OF BIDDER : ___________________________
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EXCEPTIONS AND DEVIATIONS
RFQ No. : RC/A133-086-EE-MR-6142/0052

SL.NO REF. OF RFQ DOCUMENT SUBJECT DEVIATIONS

DOCUMENT
PAGE NO. CLAUSE NO.
NOTE: This shall be submitted separately for Commercial & Technical Sections.

NAME OF BIDDER : _______________________
COMPANY SEAL : _______________________
Page 1 of 1
Page 12 of 441
PRESENT COMMITMENTS (CONCURRENT COMMITMENT) AS ON …………………………………..
(Due Date for submission of Bid)
RFQ No. : RC/A133-086-EE-MR-6142/0052

FULL POSTAL DATE OF

SCHEDULE %AGE EXPECTED
ADDRESS OF COMMEN-
SR. DESCRIPTION VALUE OF DELIVERY/ COMP. DATE OF
CLIENT & NAME OF CEMENT OF REMARKS
NO. OF THE ITEM ORDERS COMPLETION AS ON SUPPLY
OFFICER-IN- SUPPLY/
PERIOD DATE /COMPLETION
CHARGE WORK
NAME OF BIDDER : _______________________
COMPANY SEAL : _______________________
Page 1 of 1
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Special Commercial Notes to RFQ
1. Bids complete in all respects should be successfully Submitted online on or before the bid due date
and time specified above.
2. Technical specifications should be strictly as per the material requisition attached.
3. As Purchaser intends to contract directly with suppliers of the goods for which bids are invited, the
bids should be prepared by the suppliers and submitted directly. Purchaser reserves the right to
reject offers made by intermediaries.
4. The bidder shall bear all costs associated with the preparation and submission of its bid, and the
Purchaser shall in no case be responsible or liable for these costs regardless of the conduct or
outcome of the bidding process.
5. Bidders who are enlisted with EIL are required to quote as per their capabilities registered with EIL.
6. EIL reserves the right to use in-house information for assessment of bidder’s capability for
consideration of bid.
7. EIL reserve the right to make any changes in the terms and conditions of purchase and to reject
any or all the bids.
8. The order, if placed will be issued by EIL.
9. Net Worth of the Bidder shall be positive as per the immediate preceding year’s Audited financial
results. Bidder is therefore requested to furnish the latest Audited Financial Statement including
Profit & Loss Account.
In case, the bidder’s Net Worth is negative, their bid shall not be evaluated further. However
this criteria will not be applicable for Indian Central Public Sector Undertaking/Enterprises.
10. Purchaser reserves the right to allow purchase preference to Central Public Sector
Undertakings/enterprises, as admissible under prevailing policy of Government of India.
11. Preference to MSEs
11.1 In case the bidder is a Micro or Small Enterprise under the Micro, Small & Medium Enterprises
Development Act, 2006, the bidder shall submit the following:
a) Documentary evidence that the bidder is a Micro or Small Enterprises.
b) If the MSEs is owned by SC/ST Entrepreneurs, the bidder shall furnish appropriate
documentary evidence in this regard.
The above documents submitted by the bidder shall be duly certified by the statutory Auditor of the
bidder or a practicing Chartered Accountant (not being an employee or a Director or not having any
interest in the bidder’s company/ firm) where audited accounts are not mandatory as per law.
If the bidder does not provide the above confirmation or appropriate document or any evidence,
then it will be presumed that they do not qualify for any preference admissible in the Public
Procurement Policy (PPP), 2012.
Owner reserves the right to allow Micro & Small Enterprises as well as MSEs owned by SC/ST
Entrepreneurs, Price preference as admissible under the prevailing Procurement policy for MSEs.
11.2 In case of MSEs quote against the RFQ, the quantities against the items will be split to enable the
splitting of item in terms of 20% and 80% between the MSEs and non-MSEs respectively. In that
case, the quoted prices against various items shall remain valid in case of splitting of quantities of
the items as above.
12. In case any bidder is found to be involved in cartel formation, his bid will not be considered for
evaluation / placement of order. Such bidder will also be debarred from bidding in future.
13. In case a supplier seeks any suo-moto price increase subsequent to the bid due date and which is
not as a result of any change in scope of supply or terms and conditions, the bid of such a supplier
shall be rejected for the items in which such suo-moto increase is sought.
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14. FRAUDULENT PRACTICES
The Owner requires that Bidders/ Vendors/ Contractors observe the highest standard of ethics
during the award/ execution of Contract. "Fraudulent Practice" means a misrepresentation of facts
in order to influence the award of a Contract to the detriment of the Owner, and includes collusive
practice among bidders (prior to or after bid submission) designed to establish bid prices at artificial
non-competitive levels and to deprive the owner of the benefits of free and open competition.
a) The owner will reject a proposal for award if it determines that the bidder recommended for
award has engaged in fraudulent practices in competing for the Contract in question.
Bidder is required to furnish the complete and correct information/ documents required for
evaluation of their bids. If the information/ documents forming basis of evaluation is found to
be false/ forged, the same shall be considered adequate ground for rejection of bids and
forfeiture of Earnest Money Deposit.
b) In case, the information/ document furnished by the Bidder/ Vendor/ Contractor forming basis
of evaluation of his bid is found to be false/ forged after the award of the contract, Owner shall
have full right to terminate the contract and get the remaining job executed at the risk & cost of
such Bidder/ Vendor/ Contractor without any prejudice to other rights available to Owner under
the contract such as forfeiture of CPBG/ Security Deposit, withholding of payment etc.
c) Incase, this issue of submission of false documents comes to the notice after execution of
work, Owner shall have full right to forfeit any amount due to the Bidder/ Vendor/ Contractor
along with forfeiture of CPBG/ Security Deposit furnished by the bidder/vendor/ contractor.
d) Further, such bidder/ vendor/ contractor shall be put on Blacklist/ Holiday/ Negative List of
owner debarring them from future business with Owner for a time period, as per the prevailing
policy in EIL.
15. Submission of authentic documents is the prime responsibility of the bidder. Wherever EIL has
concern or apprehension regarding the authenticity/correctness of any document, EIL reserves a
right of getting the document cross verified from the document issuing authority.
16. SPECIAL INSTRUCTIONS TO FOREIGN BIDDERS
a) The bidder must ascertain and confirm along with supporting documents in the bid, if any
Customs Duty exemption / waiver is applicable to the products being supplied by him under
any multi-lateral / bi-lateral trade agreement between India and bidder's country.
b) The bidder shall be liable to provide all documentation to ensure availment of the exemption /
waiver. In case' the bidder defaults on this due to any reason, whatsoever, he shall be liable to
bear the incremental Customs Duty applicable, if any.
c) Any Customs Duty applicability on account of any change in the bi-lateral / multi-lateral
agreement shall be to bidder's account.
d) Documentation to be furnished for availing the exemption / waiver of Customs Duty shall be
specifically listed in the Letter of Credit also as the pre-requisite for release of payment against
shipping documents and this documentation shall necessarily form a part of shipping
documents
e) COMPLIANCE TO REQUIREMENT OF PAN NO. , TAX RESIDENCY CERTIFICATE AND
FORM NO.10F
It is mandatory for the foreign supplier/contractor/consultant to furnish the following information
in case his receipts are subject to tax deduction at source in India:
i) PAN No.
As per the Indian Income Tax requirements failing which the
Supplier/Contractor/Consultant shall be responsible for any additional tax deduction at
source as per the provisions of the Indian Income Tax Act/Rules and the same shall be
deducted from the payment made to supplier/contractor/consultant.
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ii) Tax Residency Certificate (TRC)
TRC containing prescribed particulars as per the enclosed Annexure-A from the
Government of foreign country in order to claim the benefits of DTAA as per the Indian
Income Tax requirements failing which the relief under DTAA will not be available and
consequently the higher rate of withholding tax @25% will be applicable and deducted
from the payment made to supplier/contractor/consultant (i.e., non-resident taxpayer).
The TRC shall be duly verified by the Government of the country of which the assessee
claims to be a resident for the purposes of tax.
iii) Form 10F
In additional to TRC, bidder in order to claim the benefits of DTAA shall also submit
additional information in form no. 10F (enclosed as Annexure-A). Form 10F has to be
signed & verified by the assessee himself.
If some information is already contained in TRC, the bidder shall not be required to
provide that information in Form no. 10F but even then Form no. 10F is required to be
provided by the bidder.
However, the bidder may write Not Applicable in the relevant column in case that
information is already contained in TRC.
The above shall be furnished before release of any payment or within one month of the
release of Order, whichever is earlier.
Failing submission of the above information, any additional tax liability on purchaser, will be
deducted from the payment due to the supplier.
17. SHIFTING OF ORDER
Based on the lowest evaluated item wise prices out of the techno-commercial acceptable bidders,
the shifting of order shall be carried out provided the following conditions are met:
a) Shifting shall be done only if shifting cost of each order is up to Rs.1, 00,000/-.
b) Shifting shall not be resorted to if the value is more than 25% of the total order value of the
recommendation (i.e. total order valued for MR/RFQ). However, this ceiling will not be
applicable where total order value of recommendation is up to Rs. 4, 00,000/-.
c) In case the order value on L1 bidder is more than Rs. 2, 00,000/- then shifting shall not be
resorted.
With above shifting the selected bidder for award will be deemed to be L1 bidder
18. CLARIFICATION REQUESTS FROM BIDDERS
A bidder may seek clarification regarding the bidding document provisions, bidding process and / or
rejection of his bid. EIL shall respond to such requests with in a reasonable time.
19. SETTLEMENT OF DISPUTE BETWEEN GOVT. DEPT./ PUBLIC SECTOR UNDERTAKING
In the event of any dispute or difference relating to the interpretation and application of the
provisions of the contracts, such dispute or difference shall be referred by either party for
Arbitration to the sole Arbitrator in the Department of Public Enterprises to be nominated by the
Secretary to the Government of India in-charge of the Department of Public Enterprises. The
Arbitration and Conciliation Act, 1996 shall not be applicable to arbitration under this clause. The
award of the Arbitrator shall be binding upon the parties to the dispute, provided, however, any
party aggrieved by such award may make a further reference for setting aside or revision of the
award to the Law Secretary, Department of Legal Affairs, Ministry of Law & Justice, Government of
India. Upon such reference the dispute shall be decided by the Law Secretary or the Special
Secretary/Additional Secretary, when so authorized by the Law Secretary, whose decision shall
bind the Parties finally and conclusively. The Parties to the dispute will share equally the cost of
arbitration as intimated by the Arbitrator.
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20. PRE BID MEETING
Bidder’s authorized representative(s) shall attend the pre bid meeting on the prescribed day at the
given venue. During the pre bid meeting, all the technical and commercial issues shall be discussed
and concluded to ensure that the bid received subsequent to pre bid meeting shall be without any
deviations to terms and conditions. Hence, bidders shall treat the pre bid meeting as utmost
important and depute competent & senior person capable of taking on the spot decision to sort out
all the technical and commercial issues.
However, in case any bidder does not attend the pre bid meeting, it shall be understood that the
bidder has a clear understanding of the scope & terms & conditions of the bidding document and
does not have any comments/ deviations to the requirements of the bidding document.
In order to ensure fruitful discussions during pre bid meeting, the bidder is requested to submit any
queries/clarification/information pertaining to Bidding document in writing delivered by hand or by
fax/ e-mail as per format enclosed in the Bidding Document so as to reach two days prior to Pre-bid
meeting. These queries shall be replied during pre-bid meeting. The editable soft copies of the
queries shall also be e-mailed to enable EIL to prepare replies to the queries against each query in
the same format expeditiously.
The bidders are required to participate in the pre-bid meeting with the following essential
documents, so that the same can reviewed & discussed during the meeting to avoid any techno-
commercial clarifications/ discussions post bid:
a) Latest annual report including Profit & loss account
b) Solvency certificate from bank
c) Concurrent Commitments
d) Details of work experience meeting the Bidders Qualification Criteria(BQC) (if applicable)
e) Technical details, documents, design, filled datasheets as per MR
f) Any other relevant document/ details
Record notes of meeting, including the questions raised and the responses given will be furnished
as expeditiously as possible to all the bidders and shall also be uploaded on the website. After pre-
bid meeting, no further queries will be entertained from the bidders.
Any modification of the Bidding Document, which may become necessary as a result of the pre-bid
discussion, shall be intimated to all bidders through the issue of an Addendum/Amendment.
Based on the pre-bid discussions, no-deviation form/techno-commercial compliance shall be signed
and submitted by the bidders as part of their offer. After pre-bid meeting, no deviation shall be
accepted and if any deviation is found in the bid of such bidder, their offer shall be liable to be
rejected without raising any technical/ commercial queries.
Technical/ Commercial queries shall not be issued once the bid have been opened. However,
wherever CQ/ TQ are unavoidable, the same shall be raised only once and the cut-off date given
for CQ/ TQ replies shall be adhered to. Offers shall be evaluated based on the information available
upto cut-off date for CQ/ TQ replies.
Extension in bid due date shall not generally be granted.
21. REVERSE AUCTION
EIL reserves the right to go in for reverse auction among the technically and commercially
acceptable bidders. The decision to conduct reverse auction or not, will be conveyed to short listed
bidders prior to opening of price bid. In view of this, the bidders must quote most competitive prices
in the first instance itself.
The methodology and terms & conditions applicable for reverse auctioning is enclosed with this
RFQ.
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However please note that in case of Reverse Auction, Rebate offered on Total Evaluated Price of
item/Group shall be prorated for all quoted prices of particular Items / Groups, which were
considered for evaluation and accordingly ordering shall be carried out.
22. INTEGRITY PACT
The attached copy of the Integrity Pact shall be included in the Bid submitted by the bidder (to be
executed by the bidder for all RFQ of value Rs. 5 (Five) crore and above). In case a bidder does not
sign the Integrity Pact, his bid shall be liable for rejection.
INDEPENDENT EXTRNAL MONITORS (IEMS)
The following two Independent External Monitors (IEMs) have been appointed by EIL, in terms of
Integrity Pact (IP) which forms part of EIL Tenders / Contracts.
i) Dr. U. K. Sen
C-162, Belvedere Park,
DLF Phase 3, Gurgoan-122002
(email : uksen@hotmail.com)
ii) Shri P. R. Balasubramanian
th st
229, 9 A Main, 1 Block,
HRBR Layout, Kalyan Nagar,
Bangalore-560043
(email : prbalasubramanian@gmail.com)
23. INSTRUCTION FOR ENROLMENT OF BIDDER TO CPP PORTAL:

a. NIC Portal mandates that the bidders are to be registered on the portal before any enquiry can
be issued to them. In order to expedite issue of enquiries, the enquiry is being issued through
EIL Tender Portal and also being published on Central Public Procurement Portal. The enquiry
shall be issued to the bidders on the NIC e-Procurement Portal as soon as their registration is
completed in the NIC Portal (https://eprocure.gov.in/eprocure/app ).
b. All those vendors who have still not registered on the NIC Portal are required to register on the
same (immediately after issue of enquiry on EIL portal but not later than ten days before the bid
due date) for facilitating issue of enquiry to them on the NIC Portal failing which it will not be
possible for them to upload their bids. Pursuant to registration, the vendors are also required to
login in EIL tender portal and update NIC’s registration details and inform the undersigned
regarding the same for the subject enquiry.
In any case, the enquiry shall be issued on NIC portal to NIC registered vendors about one
week before the bid due date. Therefore, all those bidders who have not complied with the
above registration requirements will not be issued this enquiry on NIC portal and will not be
eligible to bid. Request for extension in due date of submission of bids due to non registration or
delayed registration in NIC portal shall not be entertained.
c. The bid has to be necessarily submitted on the NIC Portal and only those bidders who are
issued the enquiry through NIC Portal will be eligible to submit their bids. In case a bidder does
not register on the NIC Portal and as a consequence, cannot be issued the enquiry through NIC
Portal, it shall be deemed that he is not interested in bidding against this enquiry and no further
correspondence will be entertained.
d. In future, EIL shall be issuing all enquiries through NIC Portal alone and bidders who do not
register with NIC Portal may not be able to submit their bids. Therefore, it is in the interest of
the bidders that they register on the NIC Portal at the earliest.
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Document No.
INSTRUCTION TO BIDDERS (ITB) A133-01- ITB Rev. 0
CPCL – LSTK Page 1
1 PAYMENT TERMS
1.1 FOR INDIGENOUS BIDDERS:

1.1.1 Supply:
(i) Where the MR is for supply of materials and there is no Vendor Data requirement (VDR)
specified in the MR:
- 90% against despatch documents directly to EIL on pro-rata basis together with full taxes, duties
and transportation charges and on submission of Performance Bank Guarantee valid for the 3
(Three) Months beyond guarantee period.
- 10% on receipt and acceptance of last consignment of materials at site and on submission of
E1/E2 Form (wherever applicable).
(ii) Where the MR is for supply of materials and calls for Vendor Data requirement: (Without
site work):
- 5% against approval of drawings, wherever required (identified in Purchase Requisition) at least
in Code-2 and manufacturing Schedule.
- 80% (85% in cases where drawing approval is not required) against despatch documents
directly to EIL on prorate basis together with full taxes, duties and transportation charges and on
submission of Performance Bank Guarantee valid for the 3 (Three) Months beyond guarantee
period.
- 5% on receipt of Final/As built Drawings/Documents/Data/Manual in requisite number of
copies/sets/CDs as per VDR specified in Purchase Requisition.
- 10% on receipt and acceptance of goods/ materials at Site and on submission of E1/E2 Form
(wherever applicable).
(iii) Where the MR is for supply of materials and calls for Vendor Data requirement: (With site
work)
- 5% against approval of drawings, wherever required (identified in Purchase Requisition) at least
in Code-2 and manufacturing Schedule.
- 80% against dispatch documents directly to EIL on prorate basis together with full taxes, duties
- 10%. on successful completion of Site Work and on submission of E1/E2 Form (wherever
applicable).
Note: In case site is not available upto 6 (Six) months after receipt of all supplies at site, the last
10% payment shall be released against submission of additional Bank Guarantee of equivalent
amount valid for 1 (One) year or such extended period as may required.
(iv) Where the MR is for Packages (with significant Bought out item) and calls for Vendor Data
requirement: (Without site work)
- 5% on approval of drawings, wherever required (identified in Purchase Requisition), in at least
Code-2 and manufacturing schedule.
- 10% against placement of sub-order for specified major raw material (to be identified by PEM
and PM before issue of enquiry) against submission of equivalent Bank Guarantee.
T&C FOR ED COMMITTEE APPL- LSTK-A133
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL- All rights reserved
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Document No.
- 10% on receipt and acceptance of goods/ materials at Site and on submission of E1/E2 Form
(v) Where the MR is for Packages (with significant Bought out item) and calls for Vendor
Data requirement: (With site work)
5% on approval of drawings, wherever required (identified in Purchase Requisition), in at least
- 10% against placement of sub-order for specified major raw material (to be identified by PEM
and PM before issue of enquiry) against submission of equivalent Bank Guarantee.
(Three) Months beyond guarantee period and on submission of Performance Bank Guarantee
valid for the 3 (Three) Months beyond guarantee period.
- 10% on successful completion of Site Work and on submission of E1/E2 Form (wherever
applicable).
Note: In case site is not available up to 6 (Six) months after receipt of all supplies at site, the last
(vi) For Pumps, Compressors, Heat Exchangers, Columns and Vessels: (Without site work)
- 15% against receipt and identification of specified major raw materials and against submission of
equivalent BG.
and transportation charges and on submission of Performance Bank Guarantee valid for 3
months beyond guarantee period
- 10% on receipt and acceptance of goods/ materials at Site on submission of E1/E2 Form
Major Raw Material for payment against receipt & identification of raw materials:
Columns and Vessels : Plates and Forgings
Heat Exchangers : Plates, Forgings and Tubes
Pumps : Castings
Compressors : Castings / Forgings
(vii) For Pumps, Compressors, Heat Exchangers, Columns and Vessels: (With site work)
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Document No.
- 15% against receipt and identification of specified major raw materials and against submission of
equivalent BG..
and transportation charges and on submission of Performance Bank Guarantee valid for 3
months beyond guarantee period
- 10% on successful completion of Site Work on submission of E1/E2 Form (wherever applicable).
Pumps : Castings
(viii) For all Site Fabricated Columns:

- 5% on approval of drawings, manufacturing schedule & QAP by TPIA.
- 15% after receipt of identified raw materials at fabrication yard and against certification by TPIA
against Hypothecation Bond.
- 50% on completion of fabrication in all respect, Third party inspection and making completed
column ready for hydro-testing.
- 10% after hydro-testing of completed column and against submission of Performance Bank
Guarantee for 10% of total order value valid for the guarantee period plus 3 (Three) Months
claim period.
- 20% after receipt of tax invoice along with taxes & duties and after submission of final technical
documentation and drawings as per Purchase Requisition and on transportation of completed
column from fabrication yard/ assembly yard to erection site, delivery of column up to equipment
foundation and handing over to Engineer-in-charge at site.
Terms of Delivery shall be delivery of column up to equipment foundation and handing over to
Engineer-in-charge at site.
1.1.2 For supply of Mandatory Spares:
- 90% on dispatch of spares against direct delivery of dispatch documents to PURCHASER.
- 10% on receipt and acceptance of materials at site and on submission of EI/E2 FORM (wherever
applicable).
1.1.3 Site Work:
- 90% against monthly progressive bills (based on agreed billing schedule) duly certified by
Engineer-in-charge.
- 10% on successful completion of site work and handing over of goods/equipment at site.
1.1.4 Supervision of Erection, Testing & Commissioning
- 100% prorate against monthly bills to be submitted by seller duly certified by Engineer-in-
Charge.
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Document No.
1.1.5 Training
- 100 % on successful completion of Training duly certified by PURCHASER, as per Purchase
Requisition.
1.1.6 Annual Maintenance Contract (AMC):
- 100% payment shall be paid at the end of each half year of the contractual year against quarterly
progressive bills to be submitted by seller duly certified by Site-in-Charge.
1.2 FOR FOREIGN BIDDERS
1.2.1 Supply:
(i) Where the MR is for supply of materials and there is no Vendor Data requirement (VDR)
specified in the MR (Without Site Work):
- 100% against shipping documents through irrevocable Letter of Credit
(ii) Where the MR is for supply of materials and calls for Vendor Data requirement: (Without
site work)
- 5% against approval of Drawings, wherever required (identified in Purchase Requisition) in at
least in Code-2 & manufacturing schedule through Wire Transfer.
- 90% (95% in cases where drawing approval is not required) against shipping documents through
irrevocable Letter of Credit.
- 5% on receipt of Final/ As built Drawings/Documents/Data/Manual in requisite number of
copies/sets/CDs as per VDR specified in Purchase Requisition through wire transfer.
(iii) Where the MR is for supply of materials and calls for Vendor Data requirement: (With site
work)
- 5% against approval of Drawings, wherever required (identified in Purchase Requisition) at least
in Code-2 & manufacturing schedule through Wire Transfer.
- 80% against shipping documents through irrevocable Letter of Credit .
- 10% on successful completion of Site Work through wire transfer.
(iv) Where the MR is for Packages (with significant Boughtout item) and calls for Vendor Data
Requirement: (Without site work)
- 10% against placement of sub orders for specified major raw materials, against submission of
equivalent bank guarantee through wire transfer.
- 80% against shipping documents through irrevocable Letter of Credit.
(v) Where the MR is for supply Packages (with significant Boughtout item) and calls for
Vendor Data Requirement: (With site work)
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Document No.

- 10% against placement of sub orders for specified major raw materials, against submission of
equivalent bank guarantee through wire transfer.
- 70% against shipping documents through irrevocable Letter of Credit.
(vi) For Pumps, Compressors, Heat Exchangers, Columns and Vessels: (Without site work)
- 15% against receipt and identification of specified major raw materials against submission of
equivalent BG through wire transfer.
Pumps : Castings
(vii) For Pumps, Compressors, Heat Exchangers, Columns and Vessels: (With site work)
- 15% against receipt and identification of specified major raw materials against submission of
equivalent BG through wire transfer.
Pumps : Castings
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Document No.
1.2.2 For supply of Mandatory Spares:

- 100% against shipping documents through Bank through irrevocable Letter of Credit.
1.2.3 Site Work:
- 90% against monthly progressive bills (based on agreed billing schedule) duly certified by
Engineer-in-charge.
- 10% on successful completion and handing over of goods/equipment at site.
1.2.4 Supervision of Erection, Testing & Commissioning:
- 100% prorate against monthly bills to be submitted by seller duly certified by Engineer-in-
Charge.
1.2.5 Training:
- 100% through Wire Transfer on successful completion of Training duly certified by
PURCHASER, as per Purchase Requisition (PR).
1.2.6 Annual Maintenance Contract (AMC):
- 100% payment shall be paid at the end of each half year of the contractual year against quarterly
progressive bills to be submitted by seller duly certified by Site-in-Charge.
NOTES :
(i) Total Order value shall be as indicated in the Purchase Order.
(ii) All bidders are required to submit their acknowledgement of FOA and/or PO.
(iii) PRS, if applicable, shall be deducted from payment milestone subsequent to dispatch of
material. In case of clause no. 1.1.1 (viii), i.e., Fabricated column at site , PRS , if applicable,
shall be deducted from milestone payment of 20%.
(iv) All foreign vendors having service components in their purchase order are required to submit
PAN (Indian I. Tax) and to provide TRC (Tax Residency Certificate) from the Govt. of vendor’s
country in order to claim the benefit of DTAA, wherever applicable.
(v) In case of indigenous SUPPLIERs, wherever taxes/duties are separately indicated, the order
value shall be exclusive of taxes/duties. 100% payment of taxes/duties shall be paid alongwith
the payment released against dispatch documents on receipt of Cenvatable (Duplicate Copy of
Excise Invoice)/vattable documents (wherever applicable).
Payment to indigenous SUPPLIERs shall be released through Electronic Clearing System (ECS).
In view of this, necessary details, such as name of bank, bank account no. etc., duly attested by
BIDDER’s bank must be submitted along with the offer.
(vi) Status of bills after submission can be viewed on our website http://www.engineersindia.com.
(vii) Foreign bidders are required to submit contract cum Performance Bank Guarantee within 30
days of FOA/PO.
(viii) Irrevocable Letter of Credit for payment to Foreign SUPPLIERs shall be established in favour of
the supplier in a bank in his country, for an appropriate amount (in line with Payment Terms). L/C
shall be opened within 45 days of receipt of acknowledgement of FOA/PO along with PBG
(wherever applicable). In case confirmed L/C is insisted by supplier, L/C confirmation charges
shall be to supplier’s account.
(ix) Payment to foreign SUPPLIERs against Site Work and Supervision/Training shall be through
wire transfer.
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Document No.
(x) All payments (other than through L/C) shall be released within 30 days of receipt of invoice and
all requisite documents, complete in all respects.
(xi) All bank charges of respective bankers shall be to respective account.
(xii) Seller shall submit Billing Schedule within three weeks after placement of FOA/PO (whichever is
issued earlier). For PURCHASER’s approval (wherever applicable).
(xiii) Sellers requiring multiple despatches will restrict the number of despatches to maximum three,
unless agreed otherwise by Project Manager.
(xiv) All progressive advances to foreign as well as Indian bidders (except the milestone payment
against drawing approval) shall be against equivalent bank guarantees. The progressive
advances shall be paid through wire transfer to foreign bidder.
(xv) Other than the payment terms given above, no other advance payments shall generally be
payable. However, if any Seller insists on advance payments, such advance payment (other
than the payment terms given in RFQ) shall be interest bearing @ SBI PLR + 2% per annum
(simple interest) on reducing balance, up to delivery period and shall be released only against
equivalent Bank Guarantee, which shall be valid up to contractual delivery date plus three
months. Interest shall be adjusted while releasing the payment against despatch documents.
2 TERMS OF DELIVERY
2.1 INDIGENIOUS ENQUIRIES:

Terms of delivery are FOT Project site on freight prepaid & door delivery basis. The date of
receipt of material at site shall be considered as the date of delivery.
2.2 FOREIGN ENQUIRIES:
Terms of delivery are FOB international sea port of exit basis. The Date of On Board Bill of
Lading shall be considered as date of Delivery.
2.3 GLOBAL ENQUIRIES:
2.3.1 For Indigenous Suppliers:
Terms of delivery are FOT Despatch point on freight to pay basis. The date of LR/GR shall be
considered as the date of delivery.
2.3.2 For Foreign Suppliers:
Terms of delivery are FOB international sea port of exit basis. The Date of On Board Bill of
Lading shall be considered as date of Delivery.
3 TRANSPORTATION
3.1 INDIGENOUS SUPPLIERS

Indigenous SUPPLIERs are required to dispatch the goods on door delivery basis through any
of the bank approved Transporters. Any deviation shall be subject to prior approval of Project
Manager.
3.2 FOREIGN SUPPLIERS
In case order is placed on FOB International port of exit basis, ocean transportation from FOB
Port of Exit to the designated Indian Port (CHENNAI) shall be arranged through PURCHASER
nominated freight forwarder. BIDDER shall arrange handing over the material to nominated
freight forwarder at the designated Port of Exit. The BIDDER will be required to furnish firm
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Document No.
cargo details containing weight, dimensions, no. of packages, no. & type of containers required
& Port of shipment. In case the actual cargo dispatched exceeds the cargo details furnished,
the extra freight incurred by PURCHASER will be to SUPPLIER’s account.The marine freight
quoted should be kept valid for a period one month lesser to delivery period. However, Vendor
shall furnish the shipping details viz. Net/ Gross weight, Volume of consignment, number of
packages with dimensions at least two month before the expiry of validity of Ocean Freight. In
the event of any delay by Vendor, the quoted Ocean Freight charges shall remain valid further
for one month from the date of furnishing the above details. EIL reserves the option to ask the
bidder to arrange shipment at the quoted freight rates.
4 CURRENCY OF QUOTE
4.1 FOREIGN SUPPLIERS

Foreign SUPPLIERs are required to submit prices only in USD. In case a foreign SUPPLIER is
sourcing part of equipment/ services from India, prices of such equipment/ services shall be
quoted in Indian Rupees only and terms & conditions applicable to Indian portion shall be same
as applicable to Indian Bidders.
4.2 INDIGENOUS SUPPLIERS
Indigenous SUPPLIERs are required to submit price in Indian Rupees.
5 ANNUAL MAINTENANCE CONTRCT (AMC)
The prices shall be asked for AMC, if required as per Material Requisition.
6 SINGLE POINT RESPONSIBILITY OF THE SUPPLIER
In case of MRs containing supplies as well site work, a single order, covering the supply part as well
site work, shall be placed. Split ordering will not be permitted.
In case, a foreign SUPPLIER requests for a separate order on his Indian sub-SUPPLIER, the same
shall not be accepted. However, payment to Indian sub-SUPPLIER shall be released directly in Indian
Rupees against invoices duly certified by the Foreign SUPPLIER.
For this purpose, the Indian sub-SUPPLIER’s name, material and corresponding price in Indian
Rupees, shall be clearly spelt out in the purchase order on foreign SUPPLIER.. In case a Foreign
supplier sources supplies/ services within India, the applicable terms & conditions shall be modified to
the extent as per Annexure-1 enclosed.
7 GUARANTEE PERIOD
GUARANTEE PERIOD:
For all items having CDD up to Dec 2014 :
18 Months from the date of successful Commissioning or 36 Months from the date of shipment,
whichever is earlier.
For all items having CDD beyond Dec 2014 :
18 Months from the date of successful Commissioning or 30 Months from the date of Shipment,
whichever is earlier.
8 PERFORMANCE BANK GUARANTEE (PBG)/(CPBG)
8.1 PBG shall be required @ 10% of total order value. However, PBG shall not be required for
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Document No.
orders upto Rs. Twenty Five (25) Lakhs (equivalent Foreign currency in case of Foreign
SUPPLIERs) in case of Pipes, Fittings, Flanges, Gaskets and Fasteners in Limited enquiries.
For all other cases, PBG shall not be required for Orders upto Rs. Five (5) lakh (equivalent
Foreign currency in case of Foreign SUPPLIERs).
8.2 PURCHASER shall get all bank guarantees verified for authenticity from the regional /
controlling / branch office of the issuing bank before the same are accepted.
8.3 In limited enquiries for purchasing, Indigenous suppliers shall be required to submit the PBG
while claiming the dispatch payment.
8.4 In all other cases, the PBG shall be required to be submitted within four weeks of issue of FOA.
8.5 Performance Bank Guarantees shall be valid till expiry of guarantee period plus 3 (Three)
Months claim period after which the PBG shall be released.
8.6 Bank Guarantee(s) shall be issued through Indian Nationalised Bank/ Indian Scheduled bank
(other than Co-operative Banks) / Indian branches of foreign banks registered with Reserve
Bank of India as a scheduled foreign bank. Bank Guarantee from Foreign banks will only be
accepted if same is counter signed by their Indian branch or by any scheduled Indian bank.
8.7 Bank Guarantee shall have a claim period of 3 (Three) Months after its expiry.
9 INDIAN TAXES/DUTIES
9.1 The prices shall be exclusive of all Indian taxes/duties applicable on finished goods/services
supplied directly to PURCHASER. The excluded taxes/duties shall be payable extra at actuals
against documentary evidence. Where Purchase Order includes supply and site work, Purchase
Order will be divided into supply and service portion separately , no VAT on work contracts is
envisaged, however VAT on work contract on site work portion if applicable shall be included in
the bidder’s quoted price & no statuary variation is payable on the same.
9.2 Entry Tax and Terminal taxes are presently not applicable. If applicable at a later date, same
shall be payable extra at actual on production of necessary Documentary evidence. Road permit
shall be issued to supplier by CPCL for material consigned to CPCL.
9.3 All payments on account of Excise Duty, Service Tax, TNVAT on finished goods shall be
released on receipt of CENVATABLE ( Duplicate Copy of Excise Invoice) /VATTABLE copy of
corresponding invoice and documents valid for availing CENVAT / VAT credit.
9.4 PURCHASER shall be able to avail 100% credit against TNVAT(i.e. VAT on sale of finished
goods). PURCHASER will not issue any concessional form for TNVAT.
TN VAT on sale of goods shall not be loaded for evaluation.
9.5 EIL shall issue concessional form-C for central sales tax.
CST against inter state sale shall be loaded during evaluation at the applicable rates.
9.6 Since Cenvat Credit shall be available against Excise Duty and Service Tax (excluding service
tax on freight) & the same shall not be considered for comparison purpose.
9.7 Indigenous SUPPLIER’s shall issue E1/E2 form on quarterly basis within 60 days after
completion of each quarter based on “C” form no. provided by PURCHASER. PURCHASER will
provide original “C” form in exchange of original E1/E2 form.
Statutory Variations are eligible only on Service Tax, cenvatable excise duty, and VAT amount
for which input tax credit is available to the OWNER under TNVAT Act subject to SUPPLIER
producing documentary evidence for the above . Statutory Variations are eligible on CST also.
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Document No.
Statutory variations on non-cenvatable excise duty and VAT amount for which input tax credit is
not available to the OWNER/PURCHASER under TN VAT Act shall be to SUPPLIER’s account.
9.8 All non-cenvatable /non-vattable taxes/duties shall be considered for evaluation.
9.9 All new taxes/duties/cess/levies notified after the last date of submission of final price bid/price
implication, but within contractual delivery /completion period, shall be to EIL’s account. These
shall be reimbursed against documentary evidence.
However, in case of delay on account of supplier, any new or additional taxes and duties
imposed after contractual delivery shall be to supplier’s account.
9.10 Labour cess, if applicable to supplier at project site shall be reimbursed at actuals upon
submission of documentary evidence for remittance to the statutory authorities.
10 CUSTOMS DUTY/EPCG LICENSE
10.1 OWNER is obtaining an EPCG license for this project. In view of this concessional rate of
Custom Duty shall be applicable to imports from foreign BIDDER’s for the goods directly
consigned to CPCL.
10.2 Indigenous BIDDER’s will be required to quote price considering only merit rate of duty, for their
built in import content, in their bid and evaluation shall be done accordingly. No
PAC/EC/INVALIDATION LETTER shall be issued to Indigenous BIDDER’s.
11 FIRM PRICES
11.1 The prices shall be firm and fixed and not subject to any variation, whatsoever. In case of Cables,
variation in prices shall be admissible as per IEEMA Price Variation Clause.
11.2 For 2 years O&M spares, prices shall be kept valid for a period of 2 years from the date of order
of main equipment along with annual % escalation ( to be indicated by the bidder) for subsequent
two years.
12 PRICE REDUCTION SCHEDULE
12.1 In case of MRs other than packages, Price Reduction Schedule shall be @1/2% of value of
delayed equipment/ item per week of delay or part thereof subject to a maximum of 5% of total
order value.
12.2 For packages and critical items, with or without site work, the Price Reduction Schedule shall be
@1/2% of total order value per week of delay or part thereof subject to a maximum of 7.5% of
total order value.
12.3 Wherever the supply period and site work are indicated as two separate periods and notice of
site readiness is required for site work, intervening period, if any, shall be excluded, while
calculating the price reduction for delay.
Note: it shall be endeavor to split the period, i.e., a separate period for supply and site work.
12.4 Price reduction shall be effected in the Invoice value before presenting for payment. The
Purchaser reserves the right to cancel the Purchase Order for any delay exceeding the period of
maximum reduction and the Seller shall be liable to all consequences thereof.
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Document No.
13 INSPECTION
All items shall be inspected by a Third Party Inspection agency as follows:

13.1 INDIGENOUS BIDDER’s: CEIL shall be appointed as Third Party Inspection for the indigenous
materials & accordingly the charges for the same shall be borne by EIL. The quoted price of
Bidder shall be exclusive of TPI charges.
13.2 FOREIGN BIDDERs: The quoted price shall be inclusive of TPI charges (out of M/s.Lloyds
Register (Country of origin), M/s.Bureau Veritas(BV) and M/s.TUV Nord)
Suppliers will be informed the following:
a) QAP will be approved by Third Party Inspection agency incorporating requirements of ITP, Technical
specifications and approved documents. Approval of QAP will not be carried out by EIL.
b) The Inspection release note issued by the Third party inspection agency shall clearly stipulate that
materials/equipment have been inspected as per Code-1 approved drawings, wherever applicable
and approved QAP.
c) Certification of final documents, wherever applicable, for release of final payment, shall be carried
out by Third Party Inspection Authority issuing the final inspection certificate.
14 GENERAL PURCHASE CONDITIONS
General Purchase Conditions including formats for advance bank guarantee and Performance Bank
Guarantee shall be as approved earlier by ED Committee for LSTK Projects with modification based on
these terms and conditions.
15 COMPREHENSIVE MARINE-CUM-ERECTION INSURANCE
Comprehensive Insurance (Transit/Marine cum storage, erection, till handing over of equipment) shall
be arranged by PURCHASER.
16 BASIS OF EVALUATION
16.1 WHERE ONLY INDIAN BIDS ARE UNDER COMPARISON

16.1.0 Bids shall be evaluated on the basis of landed cost at Site, including site work, if any, all duties,
taxes, transportation charges less Cenvatable Excise duty, Cenvatable Service tax, Cenvatable
Educational cess & Vattable TNVAT (100% of TNVAT).
16.1.1 Cost of mandatory spares, if identified in the Material Requisition, commissioning spares and
special tools & tackles will be included for price evaluation of bids, but cost of Spares for two
years operation shall be excluded.
16.1.2 AMC charges shall be considered for evaluation wherever AMC is required.
16.1.3 Supervision and Training charges shall be considered for evaluation wherever supervision and
training are required.
16.1.4 Commercial loading shall be considered for evaluation of bids.
16.1.5 Technical loading, if any, shall be considered for evaluation of bids.
NOTE :
- Site Work, wherever applicable, shall be considered for evaluation.
- In case freight charges are not quoted, estimated freight shall be taken from EIL shipping dept.
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Document No.
and loading shall be done with the same. In case of ordering , bidder shall be asked to absorb
the freight first. In case bidder does not agree to absorb then negotiation shall be done with the
bidder to agree upto maximum of the freight with which loading has been done. If bidder does
not agree with this also, then refloating of MR shall be done.
16.2 WHERE ONLY FOREIGN BIDS ARE UNDER COMPARISON

16.2.1 Bids shall be evaluated on the basis of CFR (CHENNAI) prices including third party inspection
charges, stowage charges wherever applicable (as quoted by BIDDERs), and considering sea
freight as under:
(i) Packages/equipments/pipes & plates : Firm freight as quoted by BIDDER’s
(ii) Bulk items – piping (other than pipes) / instruments : Firm freight as quoted by BIDDER’s.
In case, firm freight is not quoted by BIDDER ( For Bulk Items as well as
Packages/equipments/pipes & plates), freight shall be taken from Transchart through shipping
Dept. and loading shall be done with the same. In case of ordering, transportation shall be done
by the Transchart only.
16.2.2 Cost of mandatory spares identified in the Material Requisition, Commissioning Spares and
special tools & tackles will be included for evaluation of bids, but costs of Spares for two years
operation shall be excluded.
16.2.3 AMC charges shall be considered for evaluation wherever AMC is required.
16.2.4 Supervision (man days as indicated in MR as well as TBA ) and Training charges shall be
considered for evaluation, wherever, supervision and training are required.
16.2.4 (i) Service tax on Reverse charge and withholding tax ( in case it is not included in bidder’s price)
basis, wherever applicable shall be added for bid evaluation purpose only.
16.2.5 Commercial loading shall be considered for evaluation of bids.
16.2.6 Technical loading, if any, shall be considered for evaluation of bids.
16.2.7 For global enquiries, evaluation of offer shall be done considering foreign exchange rate, i.e., 1
USD = Rs. 56.13 *(for procurement of foreign component on global basis up to USD 8312771).
For balance items, evaluation shall be carried out on equivalent Indian Rupees basis
considering Bills Selling rates of Foreign Exchange as available from State Bank of India on the
day of priced opening. In case the same is not available, the exchange rate from Economic
Times, New Delhi edition, published on the day of priced opening, shall be considered. *
Payment shall be made based on the Foreign Exchange Rate prevailing on the date of making
payment.
NOTE :Site Work, wherever applicable, shall be considered for evaluation.
16.3 WHERE INDIAN AS WELL AS FOREIGN BIDS ARE UNDER COMPARISON

16.3.1 INDIGENOUS BIDDERS:
(i) The evaluated price of indigenous BIDDERs shall be carried out on the basis of landed cost
at Site, as per clause 16.1 above.
(ii) Notional Loading of 1% for TPI charges shall be considered for evaluation.
16.3.2 FOREIGN BIDDERS :
The evaluated price of foreign BIDDERs shall be on the basis of landed cost at Site, including
the following:
(i) Evaluation shall be done as per clause 16.2 above plus marine insurance @ 1% of FOB
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Document No.
Price.
(ii) L/C charges @ 1% of FOB price.
(iii) Landing Charges @ 1% of CIF Value i.e S.No. (i).
(iv) Custom clearance, Port Handling and Inland Freight (from Port of Entry (CHENNAI) to
CPCL project site) charges @ 3% of CIF value including L/C Charges, i.e., S. No. (i) plus
(ii).
(v) Landed Cost = S.No. (i) to (iv).
NOTE :
- Site Work, wherever applicable, shall be considered for evaluation.
- Transit insurance for Indigenous and Foreign BIDDERs, will not be loaded..
16.4 GENERAL
16.4.1 Taxes and duties will be cost loaded as quoted by the bidder. However, if a SUPPLIER states
that taxes/duties are not applicable at present and will be charged as applicable at the time of
delivery then his bid shall be loaded by the maximum rate of taxes/duties applicable at the time
of evaluation of Bids.
16.4.2 In case of pipes, if a foreign BIDDER has not quoted or not included stowage charges, the
same shall be loaded @ 10% of BIDDER’s quoted Ocean Freight.
17 LOADING/REJECTION CRITERIA
Cost loading on account of deviations to commercial terms & conditions shall be calculated on FOT
Despatch Point price/ FOB price as under :
17.1 PERFORMANCE BANK GUARANTEE (PBG)

In case, Foreign SUPPLIER takes any deviation with respect to the amount or period or validity of the
performance bank guarantee, the offer shall be rejected.
Any other type of bond (e.g. indemnity bond ) is not acceptable in lieu of Performance Bank
Guarantee (PBG).
In case foreign bidder submit stand by Letter of Credit in lieu of CPBG, same shall be accepted.
Confirmation charges for the stand by Letter of Credit shall be to seller’s account.
In case, Indian Supplier takes any deviation with respect to the amount or period or
validity of the performance bank guarantee, loading shall be done for the differential amount and /or the
differential period.
For differential period/amount loading, the following example will amplify the methodology :
For differential period:
10% for differential period : 10% * differential period /total period ,i.e, (guarantee period + claim period)
In case of Differential Amount:
Amount offered by the Bidder : Loading
a) 10% : Nil
b) Less than 10% : Differential between the offered percentage and 10%
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Document No.
17.2 PRICE REDUCTION SCHEDULE (PRS)

17.2.1 PRICE REDUCTION SCHEDULE (APPLICABLE AS 1/2% DOV ~ 5% TOV) FOR DELAYED
DELIVERY:
(i) 1/2% of DOV up to maximum of 5% of TOV No loading
(ii) 1/2% of DOV up to maximum of 5% of DOV 2.5%
(iii) Other than the above 5%
17.2.2 PRICE REDUCTION SCHEDULE ( APPLICABLE AS 1/2% TOV ~ 7.5% TOV FOR
PACKAGES & CRITICAL ITEMS ONLY )
(i) 1/2% of TOV up to maximum of 7.5% of TOV No loading
(ii) 1/2% of TOV to x% of TOV (7.5-x)%
(iii) Other than the above 7.5%
NOTE: TOV – Total Order Value (FOT Despatch Pt. Price); DOV – Delayed Order Value (FOT
Despatch Pt. Price).
17.4 PRICE VARIATION

(i) Firm Prices : No Loading
(ii) In case of Price Variation Formula with : Loading by ceiling %age offered
ceiling
(iii) No formula and no ceiling specified by the : Offer shall be rejected
BIDDER
Note : In case the enquiry itself provides for price variation on account of certain variables, offers
seeking such variation shall not be loaded.
17.5 PAYMENT TERMS

Payment terms at variance with RFQ (which are not interest bearing), will not be permitted. However, if
a BIDDER insists on the same, these shall be loaded @ SBI PLR+ 2% per annum (simple interest) for
the relevant period as under:
(i) Advance against FOA / PO : 100% of the delivery period
(ii) Drawing approval : 80% of the delivery period
(iii) Order on sub Vendors : 75% of the delivery period
(iv) Receipt of raw material at Vendor’s works : 50% of the delivery period
(v) %age payment against dispatch : Interest for three month
Documents instead receipt & acceptance
at Site (Specified in RFQ)
(vi) % age payment against dispatch : Interest for one month
document instead of Final document
as per Purchase Requisition
(Specified in RFQ)
(vii) %age payment against receipt of : Interest for three month
material at site instead
acceptance of material at site
(Specified in RFQ)
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Document No.
Notes to S. No. (vii) :

- Shall be applicable to indigenous bidders.
- Shall be against Additional BG of equivalent amount valid initially for 3 months plus claim
period.
PBG shall be required along with the Dispatch documents, in cases where there is no further milestone
payment of 10% or more left.
17.6 DELIVERY
17.6.1 FOR IDENTIFIED CRITICAL EQUIPMENTS (TO BE IDENTIFIED BY THE PROJECT):
Delivery/Completion period longer than required in enquiry shall be liable for rejection..
17.6.2 FOR BALANCE ITEMS/EQUIPMENTS (OTHER THAN CRITICAL EQUIPMENTS) :
(i) FOR ENQUIRIES WITH DELIVERY/COMPLETION PERIOD UPTO 6 MONTHS
Delivery/Completion period longer than required in enquiry shall be loaded @ 1/2% per week up
to a maximum of four (4) weeks. In case, a SUPPLIER quotes delivery longer than four (4)
weeks from required, the bid shall be rejected. One (1) month shall be construed as equal to
four (4) weeks for the purpose of such evaluation.
(ii) FOR ENQUIRIES WITH DELIVERY /COMPLETION PERIOD BEYOND 6 MONTHS
Delivery/Completion period longer than required in enquiry shall be loaded @ 1/2% per week
upto a maximum of six (6) weeks. In case, a SUPPLIER quotes delivery longer than six (6)
weeks from required, the bid shall be rejected. One (1) month shall be construed as equal to
four (4) weeks for the purpose of such evaluation.
NOTE: In case under clause no. 2.1, indigenous bidder offers a deviation against the terms of
delivery basis, their bid shall be rejected.
*Wherever source of supply will get changed from indigenous to foreign or foreign to
indigenous, project will provide approval for the same.*
17.7 OFFER VALIDITY:

In case a SUPPLIER offers shorter validity of the bid against RFQ requirement, the bid shall be
rejected.
18 INVOICING INSTRUCTIONS
For imported goods, The Invoices shall be billed to CPCL a/c EIL. Consignee on the invoices and bill of
lading issued by the foreign supplier shall be in the name of CPCL, COKER BLOCK OF RESID
UPGRADATION PROJECT, MANALI REFINERY, CHENNAI. For Indigenous Goods, the invoices shall
be billed to EIL a/c CPCL. However, the consignee in the tax invoices shall be CPCL A/C EIL, COKER
BLOCK OF RESID UPGRADATION PROJECT, MANALI REFINERY, CHENNAI to avail input credit of
Excise duty by CPCL.
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Document No.
Annexure I
TERMS & CONDITIONS FOR INDIAN SOURCED COMPONENTS / SERVICES BY FOREIGN BIDDER
Foreign bidder may source components / sub-supplies and services from India, if allowed as per Material
Requisition. For such sub-supplies / services ,Commercial Terms & Conditions of the RFQ shall stand
modified to the following extent:
1. PRICING:
1.1 Unit and total price on FOT Despatch Point basis including packing and forwarding charges.
1.2 Details of Taxes and duties (rates) payable extra on the finished goods, applicable on Indian sub-
suppliers. Purchaser shall issue ‘C’ form for Concessional rate of Central sales tax.
1.3 Separate and clear break-up of charges for inland transportation excluding Entry Tax & Terminal
Tax. Entry Tax and Terminal Tax, if applicable, shall be reimbursed at actuals by EIL on
submission of documentary evidence.
1.4 Materials if ordered against the RFQ/Bidding Document are required to be dispatched on door
delivery basis through a reliable bank approved Road Transport Company.
1.5 Transit insurance of Indian sub supplies shall be borne and arranged by the EIL.
2. CURRENCY OF QUOTE:
The quoted price of sub-supplies / services shall be in Indian Rupees only.
3. AWARD OF ORDER:
Foreign Principal shall be the single point responsible Vendor and separate order on Foreign
supplier and Indian sub-supplier / sub-contractor is not acceptable. Single Purchase order shall be
issued on the Foreign principal clearly indicating the sub-supplier’s / sub-contractor’s name,
material and corresponding price in Indian Rupees.
4. DELIVERY:
The delivery period for sub-supplies shall be on FOT site basis within specified delivery period for
Foreign bidder as per Terms of RFQ/Bidding document.
5. PRICE REDUCTION SCHEDULE:

PRS shall be applicable in totality on Foreign scope + Indian sourced component / Service for
delay in supply of goods/services either by Foreign principals or Indian counterpart.
6. PAYMENT TERMS:
6.1 Indian sub-supplies:
 90% through E-Payment with taxes and duties will be paid against receipt of Indian sourced
goods/material at project site.
 10% against receipt & Acceptance on delivery of main equipments by Foreign principal and
as well as Indian supplies at site as per Terms of bidding document.
Payment of Indian sub supplies/Services shall be released directly to Indian counterpart against
Invoices raised by Indian counterpart duly certified by Foreign principal.
6.2 Foreign principals: Payment terms of Foreign bidder shall be modified and 5% payment out of
payment against shipping documents through L/c shall be released after receipt on delivery of
main equipments by Foreign principal as well as Indian supplies at site as per Terms of bidding
document through wire transfer.
6.3 The payments shall be made after Adjustment of Price Reduction Schedule.
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Document No.
7. PERFORMANCE BANK GUARANTEE:

Foreign principal shall submit the performance bank guarantee for 10% of total order value
including value of Foreign portion and Indian sourced components / services
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Terms and conditions for Reverse Auction

1 Owner / Purchaser reserves the right to go in for reverse auction among the
technically and commercially acceptable bidders. The decision to conduct reverse
auction or not, will be conveyed to short listed bidders prior to opening of price bid.
In view of this, the bidders must quote most competitive prices in the first instance
itself.

2 Once the decision to conduct Reverse Auction is conveyed to the bidders, it will be
mandatory for the bidders to participate in Reverse Auction, failing which, the
bidder shall be liable for punitive action including but not limited to rejection of
offer, encashment of bid security, wherever applicable, etc. For this purpose, even
log‐in to the system shall be construed as participation.

3 Schedule for Reverse Auction

The Reverse Auction shall be scheduled for a duration of two hours. If a bidder
places a Bid in the last 5 minutes of scheduled closing time of the Auction, the
Auction time shall get extended automatically for another 5 minutes from the time
of the last Bid placed. In case, there is no Bid in the last 5 minutes of closing of the
Auction, the Auction shall be closed automatically without any extension.

The above provision shall apply to the bids in extended time also.
4 Auction process

- Each Bidder shall be assigned a Unique User Name & Password. The Bidders are
requested to change the Password and edit the information in the Registration
Page after the receipt of initial Password. All bids using the Login ID given to
the bidder will be deemed to have been submitted by the bidders. During the
auction, bidders will be referred by proxy names as B1, B2, B3, etc. and identity
will not be disclosed.
- The Reverse Auction shall be conducted based on the lowest evaluated price
out of all the techno‐commercially acceptable bidders, based on the prices
submitted along with the bid, as the opening price. The Bidder shall be able to
bid lower than the opening price in multiples of the decrement, but a Bidder
must always bid lower than the Lowest Bid.
- Only one bidder shall be at a particular position / rank, which means only one
L1.
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- The Bidder shall be able to view the following on his screen along with the
necessary fields:

i) Opening Price.
ii) Leading Bid in the Auction, i.e., the lowest bid.
iii) Bid placed by him.
At no point of time will any bidder see the names of other bidders, or the
prices of bidders other than the lowest bid.

- A bidder can continue to revise his bid till the auction ends. However, the
Bidder cannot quote / Bid equal to the Leading / Lowest Bid. He must always
quote lower than the Leading / Lowest Bid.
- The evaluation criteria is based on Price alone. The Bidder who quotes the
lowest evaluated Price is determined as the lowest bidder.
- However, if Reverse Auction does not lead to any bid, EIL shall reserve the right
to award the job based on the lowest prices quoted in sealed envelope.
- Apart from the participating bidders, the Reverse Auction shall be visible, while
in progress to authorized officials of Owner / Purchaser, who are monitoring
the process.

5 Bid Price

The price shall be based on the scope, technical specifications and commercial
terms & conditions and other part of Bidding document agreed upto the date of
reverse auction.

The Opening Price and the Bid Decrement shall be displayed on the auction site at
the start of the auction. However, the bidders shall be able to view the auction
details, generally, 15 to 30 minutes before the start of actual auction.

6 Bid Decrement

Shall be 0.1% of the Opening Price. The bidder to lower the bid in multiples of the
bid decrement.

7 Bidding Currency

Bidding will be conducted in Indian Rupees (INR).

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8 Bid Validity

The Bid Price submitted in the reverse auction shall be firm and valid for
acceptance for a period of 15 days from the date of reverse auction and shall not be
subject to any change whatsoever.

9 Bids once placed, binding on the Bidder

The bid of the bidder will be taken to be an offer to sell. Bids once submitted by
the bidder cannot be cancelled. The bidder is bound to sell the material/services at
the price that they bid. Should any bidder back out and not accept the order as per
the rates quoted, Owner / Purchaser reserves the right to take action as considered
appropriate, including encashment of bid security and placement on Holiday /
Negative list etc.

10 Lowest bid of a Bidder

During the process of reverse auction, the bidder may submit several bids. In case
the bidder submits such multiple bids, the lowest bid will be considered as the
bidder’s final offer to sell.

11 Submission of final prices by successful bidder
Successful bidder shall be required to submit the final prices, quoted during the
Reverse Auction in an appropriate format within two days of the completion of
Auction to EIL, duly signed and stamped as token of acceptance without any new
condition. However, in case the reverse auction is for a package, within 2 working
days after completion of the online event of Reverse Auction, the successful bidder
would submit their cost break down as per the price format for the final price
arrived at after reverse auction.

12 General

- The bidders may quote from their own offices/ place of their choice. Internet
connectivity shall have to be ensured by each agency on its own. In extreme
case of failure of internet connectivity, (due to unforeseen circumstances other
than power failure), communication shall have to be sent by fax/E‐mail/ phone
immediately. Owner / Purchaser shall extend the bidding time, in such a case,
appropriately (generally by half an hour) but not more than once per bidder.
- The Bidder, himself or any of his representatives, shall not involve in Price
manipulation of any kind directly or indirectly by communicating with other
bidder.

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- The Bidder shall not divulge either his Bids or any other exclusive details of
Owner / Purchaser to any other party.

- Bidders agree to non‐disclosure of trade information regarding the purchase,
identity of EIL, bid process, bid technology, bid documentation and bid details.

- Owner / Purchaser can decide to extend, reschedule or cancel any Auction. No
bidder can claim any kind of compensation on account of the same.

- Owner / Purchaser shall not have any liability to Bidders for any interruption or
delay in access to the site irrespective of the cause.

- Owner / Purchaser shall not be responsible for any direct / indirect /
consequential losses / damages, on account of systems problems, inability to
use the system, loss of electronic information etc.

- Owner / Purchaser shall be at liberty to cancel the reverse auction process /
tender at any time, before ordering, without assigning any reason.

- Owner / Purchaser’s decision on award of Contract shall be final and binding on
all the Bidders.

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Instructions to Bidders for e-Tendering
Instructions for Online Bid Submission:
The bidders are required to submit soft copies of their bids electronically on the CPP Portal (URL:
http://eprocure.gov.in) only, using valid Digital Signature Certificates. The instructions given below are
meant to assist the bidders in registering on the CPP Portal, prepare their bids in accordance with the
requirements and submitting their bids online on the CPP Portal.
More detailed information useful for submitting online bids on the CPP Portal may be obtained at:
https://eprocure.gov.in/eprocure/app .
REGISTRATION
1) Bidders are required to enroll on the e-Procurement module of the Central Public
Procurement Portal (URL: https://eprocure.gov.in/eprocure/app) by clicking on the link “Click
here to Enroll” on the CPP Portal is free of charge.
2) As part of the enrolment process, the bidders will be required to choose a unique username
and assign a password for their accounts.
3) Bidders are advised to register their valid email address and mobile numbers as part of the
registration process and submit in EIL tender portal for updation of records
(http://tenders.eil.co.in) . These details would be used for any communication from the CPP
Portal.
4) Upon enrolment, the bidders will be required to register their valid Digital Signature
Certificate (DSC) (Class II or Class III Certificates with signing key usage) issued by any
Certifying Authority recognized by CCA India (e.g. Sify / TCS / nCode / eMudhra etc.), with
their profile.
5) Foreign Bidders have to refer “DSC details for foreign Bidders” for Digital signature
Certificates requirements which comes under Download Tab at
https://eprocure.gov.in/eprocure/app and the remaining part is same as above and below.
6) Only one valid DSC should be registered by a bidder. Please note that the bidders are
responsible to ensure that they do not lend their DSC’s to others which may lead to misuse.
7) Bidder then logs in to the site through the secured log-in by entering their user ID / password
and the password of the DSC / e-Token.
SEARCHING FOR TENDER DOCUMENTS
1) There are various search options built in the CPP Portal, to facilitate bidders to search active
tenders by several parameters. These parameters could include Tender ID, organization
name, location, date, value, etc. There is also an option of advanced search for tenders,
wherein the bidders may combine a number of search parameters such as organization
name, form of contract, location, date, other keywords etc. to search for a tender published
on the CPP Portal.
2) Once the bidders have selected the tenders they are interested in, the same can be moved
to the respective ‘My Tenders’ folder. This would enable the CPP Portal to intimate the
bidders through SMS / e-mail in case there is any corrigendum issued to the tender
document.
3) The bidder should make a note of the unique Tender ID assigned to each tender, in case
they want to obtain any clarification / help from the Helpdesk.
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PREPARATION OF BIDS
1) Bidder should take into account any corrigendum published on the tender document before
submitting their bids.
2) Please go through the tender advertisement and the tender document carefully to
understand the documents required to be submitted as part of the bid. Please note the
number of covers in which the bid documents have to be submitted, the number of
documents - including the names and content of each of the document that need to be
submitted. Any deviations from these may lead to rejection of the bid.
3) Bidder, in advance, should get ready the bid documents to be submitted as indicated in the
tender document and generally, they can be in PDF / XLS / RAR / DWF formats. Bid
documents may be scanned with 100 dpi with black and white option. However, Price
Schedule / SOR shall be strictly in RAR format without altering any contents of the
formats uploaded by EIL in their Bidding Document.
4) To avoid the time and effort required in uploading the same set of standard documents which
are required to be submitted as a part of every bid, a provision of uploading such standard
documents (e.g. PAN card copy, annual reports, auditor certificates etc.) has been provided
to the bidders. Bidders can use “My Space” area available to them to upload such
documents. These documents may be directly submitted from the “My Space” area while
submitting a bid, and need not be uploaded again and again. This will lead to a reduction in
the time required for bid submission process.
SUBMISSION OF BIDS
1) Bidder should log into the site well in advance for bid submission so that he/she upload the
bid in time i.e. on or before the bid submission time. Bidder will be responsible for any delay
due to other issues.
2) The bidder has to digitally sign and upload the required bid documents one by one as
indicated in the tender document.
3) Bidder has to select the payment option as “offline” to pay the tender fee / EMD as
applicable and enter details of the instrument.
4) Bidder should prepare the EMD as per the instructions specified in the tender document. The
original should be posted/couriered/given in person to the Tender Processing Section, with
in 7 calendar days of the date of Unpriced bid opening. The details of the DD/any other
accepted instrument, physically sent, should tally with the details available in the scanned
copy and the data entered during bid submission time. Otherwise the uploaded bid will be
rejected.
5) A Price Bid format has been provided with the tender document to be filled by all the bidders.
Bidders are requested to note that they should necessarily submit their financial bids in the
format provided and no other format is acceptable. Bidders are required to download the
Price Bid file, open it and complete the cells with their respective financial quotes and other
details (such as name of the bidder). No other cells should be changed. Once the details
have been completed, the bidder should save it and submit it online, without changing the
filename. If the Price Bid file is found to be modified by the bidder, the bid will be rejected.
6) The server time (which is displayed on the bidders’ dashboard) will be considered as the
standard time for referencing the deadlines for submission of the bids by the bidders,
opening of bids etc. The bidders should follow this time during bid submission.
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7) All the documents being submitted by the bidders would be encrypted using PKI encryption
techniques to ensure the secrecy of the data. The data entered cannot be viewed by
unauthorized persons until the time of bid opening. The confidentiality of the bids is
maintained using the secured Socket Layer 128 bit encryption technology. Data storage
encryption of sensitive fields is done.
8) The uploaded tender documents become readable only after the tender opening by the
authorized bid openers.
9) Upon the successful and timely submission of bids, the portal will give a successful bid
submission message & a bid summary will be displayed with the bid no. and the date & time
of submission of the bid with all other relevant details.
10) The bid summary has to be printed and kept as an acknowledgement of the submission of
the bid. This acknowledgement may be used as an entry pass for any bid opening meetings.
RETENDER
1) Please note that if Tender has been retendered, than it is mandatory for the bidder to
submit their offer again on CPP Portal.
ASSISTANCE TO BIDDERS
1) Any queries relating to the tender document and the terms and conditions contained therein
should be addressed to the Tender Inviting Authority for a tender or the relevant contact
person indicated in the tender.
2) Any queries relating to the process of online bid submission or queries relating to CPP Portal
in general may be directed to the 24x7 CPP Portal Helpdesk. The contact number for the
helpdesk is 1800 233 7315.
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ENGINEERS INDIA LIMITED
COKER BLOCK OF RESID UPGRADATION PROJECT
GENERAL PURCHASE CONDITIONS

(INDIGENOUS)
INDEX
PART – A: GENERAL PURCHASE CONDITIONS (INDIGENOUS)
1. DEFINITIONS 18. RECOVERY OF SUMS DUE

2. REFERENCE FOR DOCUMENTATION 19. CHANGES
3. CONFIRMATION OF ORDER 20. CANCELLATION
4. SALES CONDITIONS 21. PATENTS AND ROYALTY
5. COMPLETE AGREEMENT 22. CONTROL REGULATION
6. INSPECTION - CHECKING - TESTING 23. PERFORMANCE GUARANTEE
7. OFFICIAL INSTITUTIONAL TESTING 24. NON-WAIVER
8. OILS & LUBRICANTS 25. NON-ASSIGNMENT
9. SPARE PARTS 26. PART ORDER/REPEAT ORDER
10. TRANSIT RISK INSURANCE 27. SELLER’S DRAWINGS AND DATA REQUIREMENT
11.RESPECT FOR DELIVERY DATES 28. TECHNICAL INFORMATION
12. DELAYED DELIVERY 29 PROGRESS CHART AND EXPEDITING
13. DELAYS DUE TO FORCE MAJEURE 30. SERVICES OF SELLER’S PERSONNEL
14. REJECTION, REMOVAL OF REJECTED GOODS AND 31. SELLER’S LIABILITIES
REPLACEMENT 32. PURCHASER’S MATERIAL
15. TRANSFER OF PROPERTY FROM THE 33. HEADINGS
SELLER TO THE PURCHASER 34. ARBITRATION
16. PRICE 35. JURISDICTION
17. TERMS OF PAYMENT
PART – B: PACKING, MARKING, SHIPPING AND

DOCUMENTATION SPECIFICATION FOR INDIGENOUS
MATERIAL (Document No. 8-1843-0002 Rev. No. 0)
PART–C: PROFORMA OF BANK GUARANTEE

(PERFORMANCE)
PART–D: PROFORMA OF BANK GUARANTEE

ADVANCE (INDIGENOUS)
A133-01-GPC (Ind.)-R0
Page 43 of 441 Page 1 of 7
PART – A: GENERAL PURCHASE CONDITIONS (INDIGENOUS)
1. DEFINITIONS: Purchase Order / Purchase Requisition number must

appear on order confirmation, correspondence,
The following expressions used in these General drawings, invoices, shipping notes, packing and/ or any
Purchase Conditions (GPC) and the Purchase shall documents or paper connected with the Order.
have the meaning indicated against each of these:
3. CONFIRMATION OF ORDER:
The PURCHASER / OWNER means Engineers India
Limited, a company incorporated in India having its The Seller shall acknowledge the receipt of the Fax of
registered office at Engineers India Bhawan, 1, Bhikaiji Acceptance (FOA) / Purchase Order (PO) within seven
Cama Place, RK Puram, New Delhi-110066 and shall days following the date of the FOA / Purchase Order
include its successors and assignees. and shall thereby confirm his acceptance of the FOA /
Purchase Order without any exceptions. This
“GOODS/MATERIALS”: Goods and/or materials shall acknowledgment will bear on both FOA / Purchase
mean any of the Articles, Materials, Machinery, Order and General Purchase Conditions
Equipment, Supplies, Drawings, Data and other
property and all services including but not limited to 4. SALES CONDITIONS:
design, delivery, installation, inspection, testing and
commissioning specified to complete the order. With Seller’s acceptance of provision of the Purchase
Order, he waives and considers as cancelled any of his
“SELLER”: Seller shall mean the Person, Firm or general sales conditions.
Corporation to whom the Fax of Acceptance / Purchase
Order is issued. 5. COMPLETE AGREEMENT:
“Contractual Delivery Date”: Contractual Delivery The terms and conditions of the Purchase Order shall
Date is the date on which goods shall be delivered constitute the entire Agreement between the parties
F.O.T dispatching point/destination in accordance with hereto. Changes will be binding only if the amendments
the terms of the Purchase Order. The contractual are made in writing and signed by an authorized
delivery date/period is inclusive of all the lead time for representative of the Purchaser.
engineering, procurement of raw materials,
manufacturing, inspection, testing packing and any 6. INSPECTION-CHECKING-TESTING:
other activities whatsoever required to be accomplished
for effecting the delivery at the agreed delivery point. The equipment, materials and workmanship covered by
the Purchase Order are subject to inspection and
“Procurement co-coordinators /Managers”: testing at any time prior to shipment and/or despatch
Purchaser’s authorized representative appointed as and to final inspection within a reasonable time after
procurement co-ordinators/ manager. arrival at the place of delivery. Inspectors shall have the
right to carry out the inspection and testing which will
“INSPECTORS”: Inspectors Inspectors deputed / include the raw materials at manufacturer’s shop, at
authorized by Purchaser including Third Party fabricator’s shop and at the time of actual despatch
Inspection Agency. before and after completion of packing.
CLIENT: client means Chennai Petroleum Corporation All tests, mechanical and others as specified in the
Limited. Purchase Requisition and particularly those required by
codes will be performed at Seller’s expenses and in
PROJECT: Resid Upgradation Project- Coker Block accordance with Inspector’s instructions. The Seller will
at Manali Refinery of Chennai Petroleum Corporation also bear the expenses concerning preparation and
Limited. rendering of tests required by Boiler Inspectorate or
such other statutory testing agencies or by Lloyds
PROJECT MANAGEMENT CONSULTANT” or Register of Shipping and Industrial Services as may be
“PMC” or “CONSULTANT” shall mean any person(s) required.
nominated by the OWNER as the Project
Management Consultant for the Project. The words The salaries and fees of Inspectors and their travelling,
“PROJECT MANAGEMENT CONSULTANT”, “PMC”& lodging and boarding expenses will not be borne by the
“CONSULTANT” are synonymous. M/s Jacobs Seller unless inspection becomes anfractuous due to
Engineering India Private Limited is the PMC for this any omission or commission on the part of the Seller.
Project. Before shipping or despatch, the equipment and/or
materials will have to be checked and stamped by
2. REFERENCE FOR DOCUMENTATION: Inspectors who are authorized also to forbid the use
A133-01-GPC (Ind.)-R0
and despatch of any equipment and/or materials which Inspectors to maintain Schedule and delay, if any, in
during tests and inspection fail to comply with the this process will not be taken into consideration as a
specification, codes and testing requirements. cause of Force Majeure.
The Seller shall: 8. OILS & LUBRICANTS:
- Inform Procurement Coordinator/Managers at The first filling of oils and lubricants, if any, required for
least eight days in advance of the exact place, every equipment shall be supplied inline with MR. The
date and time of rendering the equipment or Seller shall also recommend the quality / quantity of oils
materials for required inspection. and lubricants required for one-year continuous
operation.
- Provide free access as required to Inspectors
during normal and / or extended working hours 9. SPARE PARTS:
to Seller’s or his/its sub-Supplier’s works and
place at their disposal all useful means of The Seller must furnish item wise and priced list of
performing, checking, marking, testing, spare parts required for two years normal operation and
inspection and final stamping. maintenance of the equipment and prime movers also.
Even if the Inspections and tests are fully carried out, The Seller shall provide the necessary cross - sectional
Seller would not be absolved to any degree from his drawing to identify the spare parts numbers and their
responsibilities to ensure that all equipment and location as well as an inter-changeability chart.
material supplied comply strictly with requirements as
per agreement both during manufacturing, at the time of 10. TRANSIT RISK INSURANCE:
delivery, inspection, on arrival at site and after its
erection or start-up and guarantee period as stipulated The Purchaser against its/ Client’s Open General Policy
in Clause 23 herein. (The name of the Insurance Co. will be conveyed
subsequently) shall cover transit Risk Insurance. The
The Seller’s responsibility will not be lessened to any Seller shall advise the dispatch particulars to the
degree due to any comments made by Procurement Insurance Company under advice to the Procurement
Coordinators/Managers and Inspectors on the Seller’s Coordinators / Managers before shipment.
drawings or specifications or by inspectors witnessing
any chemical or physical tests. In any case, the 11. RESPECT FOR DELIVERY DATES:
equipment must be in strict accordance with the
Purchase Order and/or its attachments failing which the Time of delivery as mentioned in the Purchase Order
Purchaser shall have the right to reject the goods and shall be the essence of the agreement and no variation
hold the Seller liable for non-performance of contract. shall be permitted except with prior authorization in
writing from the Purchaser. Goods should be delivered
7. OFFICIAL INSTITUTIONAL TESTING: securely packed and in good order and condition at the
place and within the time specified in the Purchase
In addition to testing and inspection by Inspectors Order for their delivery. The Purchaser reserves the
mentioned above, Lloyds register Industrial services or right to defer the period of delivery in writing.
similar institutional agencies like Boiler-Inspectorate
may be assigned for official testing of all coded 12. DELAYED DELIVERY:
equipment. The Seller shall ensure that all Procedures
for preparation and Performance of test prescribed by The time and date of delivery of materials / equipment
such institution shall be complied scrupulously. as stipulated in the Order shall be deemed to be the
essence of the contract. In case of delay in execution
The Seller is required to send to such institutions as of the order beyond the date of delivery stipulated in the
may be designed by the Purchaser at least three sets of order or any extensions sanctioned, the Purchaser may
fabricated / manufactured drawings for each equipment at his option either:
and calculations. All manufacturer’s mill test certificates
and analytical reports from material laboratories in (i) Accept delayed delivery at prices reduced by as per
respect of all raw material and components employed Price Reduction Schedule Clause of RFQ.
shall have to be presented to such Institution’s
Inspectors in the number of copies required. Seller (ii) Cancel the order in part or full and purchase such
shall be responsible for any delay in submission of cancelled quantities from elsewhere on account and at
necessary certificates. The Seller shall maintain close risk and cost of the Seller, without prejudice to its right
liaison with Procurement Co-ordinators and Institution’s under (i) above in respect to goods delivered.
A133-01-GPC (Ind.)-R0
13. DELAYS DUE TO FORCE MAJEURE: The transfer of property shall be deemed to have taken
place as follows subject to the provisions herein
In the event of causes of Force Majeure occurring within contained:
the agreed delivery terms, the delivery dates can be
15.1 F.O.T. despatch point: On handing over the
extended by the Purchaser on receipt of application
equipment to the carrier against receipt and
from the Seller without imposition of penalty. Only
such receipt having been passed over to the
those causes which depend on natural calamities, wars
Purchaser.
and national strikes which have duration of more than
seven consecutive calendar days and Government Acts 15.2 Equipment sent freight/ carriage paid to the
and other direct legislative enforcement are considered
Refinery site: On receipt of goods at site.
the causes of Force Majeure.
15.3 Equipment erected by the Seller; on
The Seller must advise the Purchaser by a registered acceptance at job site.
letter duly certified by a local Chamber of Commerce or
15.4 Equipment commissioned by the Seller: On
statutory authorities, the beginning and the end of such
taking over by the Purchaser for regular
causes of delay immediately, but in no case later than
operation after test run at maximum capacity
10 days from the beginning and end of each cause of
for specified period satisfactorily performed.
such Force Majeure condition defined above.
16. PRICE:
The extension of time for completion of the work or any
part of the work or any operation(s) involved therein Unless otherwise agreed to in the terms of the
shall be the sole remedy of the Seller for any cause or Purchase Order, the price shall be:
event of delay and the Seller shall not be entitled in
addition to or in lieu of such extension to claim any a) Firm and not subject to escalation for any reasons
damages or compensation for extended stay or whatsoever till the execution of entire order even though
otherwise whether under the law governing contracts or it might be necessary for the order execution to take
quasi-Seller or any other relationship, and the Seller longer than the delivery period specified in the order.
hereby waives and disclaims any and all contrary rights.
b) Inclusive of adequate road worthy packing and
14. REJECTION, REMOVAL OF REJECTED forwarding charges upto effecting delivery at F.O.T.
GOODS AND REPLACEMENT: despatch point in all cases whenever F.O.T destination
delivery terms are agreed to but exclusive of transit
In case the testing and inspection at any stage by insurance.
Inspectors reveal that the equipment, material and
workmanship do not comply with the specification and c) Exclusive of Central/State Sales Tax, Excise Duty
requirements, the Seller at his/its own expense and risk and or such imposts which are leviable by law on sales
shall remove the same within the time allowed by the of finished goods to Purchaser and/or Octroi duty, if
Purchaser. The Purchaser shall be at liberty to dispose any, leviable at destination/ project site. The nature and
of such rejected goods in such a manner, as he may extent of such levies shall be shown separately.
think appropriate. In the event the Seller fails to remove
the rejected goods within the period as aforesaid, all 17. TERMS OF PAYMENT:
expenses incurred by the Purchaser for such disposal
shall be to the account of the Seller. The freight paid by Payment terms shall be as specified in the Inquiry /
the Purchaser, if any, on the inward journey of the Purchase Order.
rejected materials shall be reimbursed by the Seller to
the Purchaser before the rejected materials are Seller shall claim their invoice excluding Excise Duty.
removed by the Seller. The Excise Duty shall be released separately on receipt
of documents including Transporters copy of Invoice,
The Seller shall have to proceed with the replacement valid for availing CENVAT. In the event CPCL is not
of that equipment or part of the equipment at able to claim CENVAT, the amount of Excise Duty to
Purchaser’s stores / site, if so required by the that extent shall be recovered from the Seller.
Purchaser, without claiming any extra payment. The
time taken for replacement in such event will not be Seller shall ensure submission of proper documents for
added to the contractual delivery period. availing CENVAT/ VAT benefits of Service Tax/ VAT. In
case the documents are not found to be in order,
15. TRANSFER OF PROPERTY FROM THE amount of Service Tax/ VAT will be recovered from the
SELLER TO THE PURCHASER. Seller.
A133-01-GPC (Ind.)-R0
The Seller shall furnish to the Purchaser bank owned by the Seller.
guarantee / Cash Security. Bank Guarantee shall be
from a Scheduled/ Nationalized Bank in a form Upon receipt of the cancellation notice the Seller shall
approved by the Purchaser for an amount of 10% of the discontinue all work on the Purchase Order and matters
contract value as security for the due performance of all connected with it.
the Seller’s liability in terms of and/or in connection with
the contract. This security will be released after the The Purchaser in that event will be entitled to procure
expiry of the period of performance guarantee. the requirement in the open market and recover the
excess payment over the Vender’s agreed price, if any,
The financial settlement of Seller’s Invoice is liable to be from the Seller, reserving to itself the right to forfeit the
withheld in the event the Seller has not complied with security deposit, if any, made by the Seller against the
submission of drawing, data and such documentation contract. The Seller is aware that the said goods are
as called for in Purchase Order and/or as required required by the Purchaser for the ultimate purpose of
otherwise. material production and that non delivery may cause
loss of production and consequently loss or profit to the
18. RECOVERY OF SUMS DUE: Purchaser. In this event of the Purchaser exercising the
option to claim damages for non-delivery other than by
Whenever any claim against the Seller for payment of way of difference between the market price and the
sum of money arises out of or under the contract, the contract price, the Seller shall pay to the Purchaser, the
Purchaser shall be entitled to recover such sums from fair compensation to be agreed upon between the
any sum then due or which at any time thereafter may Purchaser and the Seller.
become due from the Seller under this or any other
contract with the Purchaser including right to encash the The provision of this clause shall not prejudice the right
PBG. In the event of encashment of PBG, the same of the Purchaser from invoking the provisions of clause
shall be re-stored to its original amount by the Seller “Delayed Delivery” as aforesaid.
and should this sum be not sufficient to cover the
recoverable amount, the Seller shall pay to the 21. PATENTS AND ROYALTIES:
Purchaser on demand the balance remaining due.
On acceptance of this order, the Seller will be deemed
19. CHANGES to have entirely indemnified the Purchaser and
Procurement Coordinators/Managers from any legal
The Purchaser has the option at any time to make action or claims regarding compensation for breach of
changes in quantities ordered or in specifications and patent rights which the Seller deems necessary to apply
drawings. If such changes cause an increase or for manufacturing the ordered equipment and/or
decrease in the price or in the time required for supply, materials or which can in any way be connected in the
an equitable, adjustment under this provision must be manufacture.
finalized within 10 days from the date when the change
is ordered. 22. CONTROL REGUALTIONS:
20. CANCELLATION: The supply, despatch and delivery of goods shall be

arranged by the Seller in strict conformity with the
The Purchaser reserves the right to cancel the statutory regulations including provision of Industries
Purchase Order or any part thereof and shall be entitled (Development and Regulation) Act, 1951 and any
to rescind the contract wholly or in part in a written amendment thereof as applicable from time to time.
notice to the Seller if: The Purchaser disowns any responsibility for any
irregularity or contravention of any of the statutory
i) The Seller fails to comply with the terms of this regulations in manufacture or supply of his stores
Purchase Order. covered by this order.
ii) The Seller fails to deliver the goods on time

23. PERFORMANCE GUARANTEE:
and/or replace the rejected goods promptly.
iii) The Seller becomes bankrupt or goes into The Seller shall guarantee that any and all materials
liquidation. used in execution of the Purchase Order shall be in
strict compliance with characteristics, requirements and
iv) The Seller makes a general assignment for specifications agreed upon and that the same shall be
the benefit of creditors. free from any defects. Checking of the Seller’s drawings
by Procurement Co-coordinators/ Managers and their
v) A receiver is appointed for any of the property approval and permission to ship or despatch the
A133-01-GPC (Ind.)-R0
equipment and materials guaranteed by Inspectors 27. SELLER’S DRAWING AND DATA
shall not relieve the Seller from any part of his/its REQUIREMENT:
responsibilities of proper fulfillment of the requirement.
The Seller will guarantee that all materials and The Seller shall submit drawings, data and
equipment shall be repaired or replaced as the case documentation in accordance with but not limited to
may be, at his own expense in case the same have what is specified in the requisition and/or in the Seller
been found to be defective in respect of materials, drawings and data form attached to the Purchase
workmanship or smooth and rated operation within Requisition and as called for in Clause 8, viz. Expediting
Guarantee Period as stipulated in the RFQ document. above. Types, quantities and time limits of submitting
this must be respected in its entirety failing which the
The guarantee period for the replaced parts shall be 18 Purchase Order shall not be deemed to have been
months starting from the date on which the executed for all purposes including settlement of
replacements are put in service or period as specified payment since the said submission is an integral part of
above in case of critical items, whichever is later. Purchase Order execution.
Acceptance by the Purchaser or Inspectors of any
equipment and materials or their replacement will not 28. TECHNICAL INFORMATION:
relieve the Seller of his/its responsibility concerning the
above guarantee. Drawings, specifications and details shall be the
property of the Purchaser and shall be returned by the
The Seller shall furnish a Bank Guarantee for 10% of Seller on demand. The Seller shall not make use of
total of total order value (as per proforma hereunder) to drawings and specifications for any purpose at any time
support Seller’s performance. This bank guarantee save and except for the purpose of the Purchaser.
shall remain in force for the entire period covered in
Performance Guarantee plus three months. The Seller shall not disclose the technical information
furnished to or gained by the Seller under or by virtue of
24. NON-WAIVER: or as a result of the implementation of the Purchase
Order to any person, firm or body or Corporate authority
Failure of the Purchaser / Procurement Coordinators/ and shall make all endeavours to ensure that the
Managers to insist upon any of the terms or conditions technical information is kept CONFIDENTIAL. The
incorporated in the Purchase Order or failure or delay to technical information imparted and supplied to the
exercise any rights or remedies herein or by law or Seller by the Purchaser shall at all times remain the
failure to properly notify Seller in the event of breach, or absolute property of the Purchaser.
the acceptance of or payment of any goods hereunder
or approval of design shall not release the Seller and 29. PROGRESS CHART AND EXPEDITING:
shall not be deemed a waiver of any right of the
Purchaser / Procurement Coordinators/Managers to The Seller shall submit to EIL within four (4) weeks from
insist upon the strict performance thereof or any of his the date of Fax Of Acceptance a BAR CHART showing
or their rights or remedies as to any such goods start and finish dates for various activities forming part
regardless of when goods are shipped received or of the execution of the order and identifying the delivery
accepted nor shall any purported oral modification or dates to this activity schedule. Seller shall update this
revisions of the order by Purchaser/ Procurement bar chart every fortnight showing the actual
Coordinators/Managers act as waiver of the terms performance of the activities and if and how the delivery
hereof. date has been affected thereby. Copies of the updated
bar chart will also be submitted for review of the
25. NON ASSIGNMENT: progress of the order.
The Seller without obtaining prior written consent of the Procurement Coordinator/Managers have been
Purchaser shall not assign the Purchase Order to any assigned to expedite both manufacture and shipment of
other agency. equipment and materials covered by the Purchase
Order. The Procurement Co-coordinator/ Managers
26. PART ORDER/ REPEAT ORDER shall have free access to Seller’s shop and/or sub-
Supplier’s shop at any time and they shall be provided
Seller hereby agrees to accept part order at Purchasers all the necessary assistance and information to help
option without any limitation whatsoever and also them perform their job.
accept repeat order(s) during a period of 6 months from
the date of original purchase order on same unit prices, In order to facilitate over-all execution of the order within
terms and conditions. the contractual delivery date, Seller shall furnish to
Procurement Coordinator / Manager within 4 weeks of
A133-01-GPC (Ind.)-R0
receipt of Purchase Order in required number of copies c) The Seller shall give a firm and binding list of
of documents / detailed drawings such as but not Purchasers issue of materials which shall be duly
limited to schedule/PERT chart, unpriced copies of sub reviewed & approved by EIL and the desired schedule
orders/sub contracts, phased program of itemize of its delivery to shop floor strictly in accordance with
manufacturing, testing and delivery and any other the sequence of fabrication vis-a-vis the contractual
information/documentation as may be called for by the delivery period.
Procurement Coordinators/Managers. All post order
correspondence shall be addressed to the DGM d) Unused materials or scrap from material supplied by
(Inspection), with a copy to the Project Manager, the Purchaser to the Seller shall be returned by the
Engineers India Ltd., New Delhi. Seller to the Purchaser or if the Purchaser so directs the
Seller may dispose of the same by sale or otherwise on
30. SERVICES OF SELLER’S PERSONNEL: such terms and conditions as the Purchaser may
stipulate and the Seller shall pay to the Purchaser the
Upon three week advance notice, the Seller shall sale proceeds of the material so disposed off by sale
depute the necessary personnel along with required deducting there from expenses incurred by the Seller on
Tools & Tackles to site for supervision of erection and such sale, the quantum of such deduction to be
start up of the equipment and train a few of the IOCL/ mutually agreed upon in advance between the
EIL’s personnel for the operation and maintenance of Purchaser and the Seller.
the equipment, if required by the Purchaser. The terms
and conditions for the services of the Seller shall be 33. HEADINGS:
mutually settled.
The headings of the conditions hereof shall not affect
31. SELLER’S LIABILITIES construction thereof.
The Seller’s workmen or employees shall under no 34. ARBITRATION:

circumstances be deemed to be in Purchaser’s
employment and the Seller shall hold himself Any dispute or difference between the parties hereof
responsible for any claims which they or their heirs, arising out of any notified claim of the SELLER included
dependents or personal representatives may have or in his final bill and /or arising out of any amount claimed
make for damages or compensation for anything done by the OWNER (whether or not the amount claimed by
or committed to be done in the course of carrying out of the OWNER or any part thereof shall have been
the work covered by this Purchase Order, whether deducted from the Final bill of the supplier or any
arising on Purchaser’s premises or elsewhere and amount paid by the OWNER to the SELLER in respect
agrees to Indemnify the Purchaser against any such of the work) shall be referred to arbitration in
claim or claims if made against the Purchaser and all accordance with the UNCITRAL Rules as adopted in
cost (as between attorney and client) of proceedings, India by the Arbitration & Conciliation Act, 1996.
suits or action which the Purchaser may incur or sustain
in respect of the same. The Seller shall also procure The venue of the arbitration shall be New Delhi.
and keep in force at his own cost comprehensive
automobile Liability insurance for adequate coverage in Notwithstanding the existence of any dispute or
respect of all his vehicle/s visiting or plying in project arbitration in terms hereof or otherwise, the Seller shall
premises. The Seller shall also be responsible for continue and be bound to continue and perform the
compliance of existing laws in respect of their workmen works to completion in all respects according to the
and employees.
Contract (unless the Contract or works be determined
32. PURCHASER’S MATERIAL by the Owner or by the Seller under the provisions of
the Contract), and the Seller shall remain liable and
a) Purchaser’s materials shall be delivered to the Seller bound in all respects under the Contract.
after the Seller submits the Bank Guarantee for
Indemnifying the full value thereof strictly in the manner 35. JURISDICTION
and as per Performa of Bank Guarantee approved by
the Purchaser. The Seller hereby agrees that the Court situated at New
Delhi alone shall have the jurisdiction to hear and
b) Wherever possible, the material shall be consigned determine all action and proceedings arising out of this
to goods depot to be specifically confirmed by Seller. contract.
The Seller at his responsibility and cost shall arrange
Loading/Unloading and any handling from the
destination.
A133-01-GPC (Ind.)-R0
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PROFORMA OF BANK GUARANTEE
(PERFORMANCE)
(On non-judicial stamp paper of appropriate value)
(For Indigenous Suppliers)
To
Engineers India Bhawan
1 Bhikaiji Cama Place
R.K. Puram
Kind Att.: Head (LSTK-Finance)
RFQ NO.: _______________________
Dear Sirs,
In consideration of the Engineers India Limited, 1 Bhikaiji Cama Place, R.K. Puram, New Delhi-110066 (hereinafter
called – “the Purchaser” which expression shall include its successors and assigns having awarded
________________________________ work to M/s (Name) _______________________________________
(Constitution) ___________________________ (Address) _____________________________ (hereinafter referred
to as “the Supplier” which expression shall wherever the subject or context so permits include its successors and
assigns) a supply contract in terms inter-alia, of the Purchaser’s Letter No. ______________________ dated
__________ hereinafter referred to as the “Contract” and the general purchase conditions of the purchaser and upon
the condition of Supplier’s furnishing security for the Performance of the Supplier’s obligations and/or discharge of the
Supplier’s liabilities under and/or in connection with the said supply contract for a sum of Rs.
_______________________ only amounting to 10% (ten percent) of the total contract value.
We _______________________________________ (name) a body / corporate registered/constituted under the laws

of ___________________________ and having a Branch at ______________________ (Indian Branch Address)
(hereinafter called “the Bank” which expression shall include its successors and assigns) with the intent to bind the
Bank and its successors and assigns, hereby undertake to pay the Purchaser at __________________ (place) on
first demand in writing without protest or demur or proof or satisfaction or condition and without reference to supplier
any and all amounts from time to time demanded by the Purchaser from the Bank with reference to this
Guarantee/Undertaking upto an aggregate limit of Rs. _________________ (Rupees
___________________________ only).
AND THE BANK DOTH HEREBY FURTHER AGREE AS FOLLOWS:-
1. This Guarantee/Undertaking shall be a continuing Guarantee/Undertaking and shall remain valid and
irrevocable for all claims of the Purchaser and liabilities of the Supplier arising upto and until ___________
plus claim period of 3 months.
2. This Guarantee/Undertaking shall be in addition to any other guarantee or security whatsoever that the
Purchaser may now or at any time have in relation to the Supplier’s obligations liabilities under and/or in
connection with the said supply contract and the Purchaser shall have full authority to take recourse to or
reinforce this security in preference to the other security(ies) at its sole discretion, and no failure on the part
of the Purchaser in enforcing or requiring enforcement of any other security shall have the effect of releasing
the Bank from its full liability hereunder.
3. The Purchaser shall be at liberty without reference to the Bank and without affecting the full liability of the
Bank hereunder to take an other security in respect of the Supplier’s obligation and/or liabilities under or in
connection with the said supply contract and to vary the terms vis-à-vis the Supplier of the said supply
contract or to grant time and/or indulgence to the Supplier or to reduce or to increase or otherwise vary the
prices of the total contract value or to release or to forebear from enforcement of all or any of the obligations
of the Supplier under the said supply contract and/or the remedies of the Purchaser under any other
Guarantee(s) or Security(ies) now or hereafter held by the Purchaser and no such dealing(s), variation(s),
reduction(s) or other indulgence(s) or arrangement(s) with the Supplier or release or forbearance whatsoever
shall have the effect of releasing the Bank from its full liability to the Purchaser hereunder or of prejudicing
rights of the Purchaser against the Bank.
4. This Guarantee/Undertaking shall not be determined or affected by the liquidation or winding up, dissolution,
or change of constitution or insolvency of the Supplier or any change in the legal constitution of the Bank or
of the Purchaser.
A133-01-GPC (Ind.)-R0 Page 1 of 2
Page 57 of 441
5. Bank hereby waives all rights at any time inconsistent with the terms of this Guarantee/Undertaking and the
obligations of the Bank in terms hereof shall not be anywise affected or suspended by reasons of any dispute
or disputes having been raised by the Supplier (whether or not pending before any Arbitrator, Officer,
Tribunal or Court) or any denial of liability by the Supplier or any other order for Communication whatsoever
by the Supplier stopping or preventing or purporting to stop or prevent any payment by the Bank to the
Purchaser in terms hereof.
6. Notwithstanding anything contained herein:
(a) The Bank’s liability under this Guarantee/Undertaking shall not exceed Rs._____________ (In
figures) ______________________ (In words) ____________________________ only).
(b) This Guarantee/Undertaking shall remain in force upto _____________ and any extension(s)
thereof, if any; and
(c) The Bank shall be released and discharged from all liability under this Guarantee/Undertaking
unless a written claim or demand is issued to the Bank on or before _____________ plus 3 months
period or the date of expiry of any extension(s) thereof if this guarantee/undertaking has been
extended.
7. The Bank doth hereby declares that Shri ______________________ (name & designation of the person
authorized to sign on behalf of the Bank) is authorized to sign this Guarantee/Undertaking on behalf of the
Bank and to bind the Bank thereby.
Yours faithfully,
(Signature)
NAME & DESIGNATION

NAME OF THE BANK
NOTE
1. This Guarantee is required to be stamped as an agreement according to the Stamp Duty Act.
2. The Performance Bank Guarantee shall be strictly as per above proforma and shall be through Indian or
Foreign Branches of Indian Scheduled Banks (other than Cooperative Bank)/Nationalized Bank or Indian
Branches of Foreign Banks.
3. The bank shall provide details viz contact person, telephone number, fax number, e-mail address and
address of the Controlling/Regional Office of issuing bank for verification of authenticity of Bank Guarantee.
4. This Guarantee is required to be sent by Seller’s Bankers directly to the Head (LSTK-Finance), Engineers
rd
India Limited, EI Bhawan, 3 Floor, 1, Bhikaiji Cama Place, New Delhi-110066.
Page 58 of 441
PROFORMA OF BANK GUARANTEE
ADVANCE (INDIGENOUS)
(On non-judicial stamp paper of appropriate value)
To
1 Bhikaiji Cama Place
Attn.: Head (LSTK-Finance)
Project ______________________
RFQ No. _____________________
Dear Sirs,
Engineers India Limited, 1, Bhikaiji Cama Place, New Delhi-110066 (hereinafter called – “the Purchaser” which
expression shall include its successors and assigns) has awarded M/s ____________________________________
(hereinafter called “The Supplier” which expression shall include its successors and assigns) the work of designing,
manufacturing, fabricating and supply of ______________________ in terms of a contract as constituted by Purchase
Order No. ____________________ dated _________________ issued by the Purchaser to the Supplier (hereinafter
called “The Contract” which expression include all the amendments and/or modifications of the Purchase Oder).
AND WHEREAS the Purchaser has agreed to advance the Supplier a sum of Rs._________________ (Rupees
_________________________________________________) hereinafter called “The Advance” as financial
assistance to the Supplier under the Contract on the condition, inter alia, that the advance shall be secured by a Bank
Guarantee as hereinafter appearing:
We ______________________________ Bank _____________________ a Bank incorporated/ constituted under the

laws of _____________________ and having it registered/principal office at _________________________________
(hereinafter called “The Bank” which expression shall include our successors and assigns) in consideration of the
aforesaid promises and at the request of the Supplier DO HEREBY bind ourselves and our successors and assigns,
and irrevocable undertake to pay the Purchaser on first demand in writing without protest or demur or proof or
condition and without reference to the Supplier any and all amounts at any time and from time to time claimed by you,
as due to you under or in respect of the said advance, and demanded by you from us, with reference to this
undertaking for an aggregate limit of Rs. _____________ (Rupees
___________________________________________).
AND, we, the Bank DO HEREBY further agree as follows:
(i) The Purchaser shall have the fullest liberty without reference to the Bank and without affecting in any way the
liability of the Bank under this Guarantee/Undertaking, at any time and/or from time to time to anywise vary
the Contract and/or any of terms and conditions thereof or of or relative to the advance and to extend time for
the performance of the Contract and/or repayment of the advance or to postpone for any time or from time to
time the obligations of the Supplier and to waive or postpone exercise of any of the rights available to the
Purchaser against the Supplier or to forebear from enforcing any of the terms or conditions of the Contract
and/or the advance or any security(ies) available to the Purchaser, AND the liability of the Bank shall remain
in full force and effect notwithstanding any exercise by the Purchaser of the liberty with reference to any or all
the matters aforesaid or by reason of time being given to the Supplier or any forbearance, waiver, act or
omission on the part of the Purchaser or any indulgence by the Purchaser to the Supplier or any other act,
matter or thing whatsoever which under the law relating to sureties would have the effect of releasing the
Bank from its liability hereunder or any part thereof, AND the BANK DOTH HEREBY waive all rights at any
time inconsistent with the terms of this Guarantee/Undertaking.
(ii) It shall not be necessary for the Purchaser to proceed against the Supplier before proceeding against the
Bank and this guarantee/undertaking shall be enforceable against the Bank as principal debtor
notwithstanding the existence of any other security for any indebtedness of the Supplier to the Purchaser
(including relative to the advance) and notwithstanding that any such security shall at the time when claim is
made against the Bank or proceedings taken against the Bank be outstanding or unrealized.
(iii) As between the Bank and the Purchaser for the purpose of this guarantee/undertaking the amount claimed
by the Purchaser from the Bank with reference to this guarantee/ undertaking shall be final and binding upon
the bank as to the amount payable by the Bank to the Purchaser hereunder.
Page 59 of 441
(iv) The liability of the Bank to the Purchaser under this guarantee/undertaking shall remain in full force and
effect notwithstanding the existence of any difference or dispute between the Supplier and the Purchaser,
the Supplier and the Bank and/or the Bank and the Purchaser, or otherwise howsoever touching or affecting
these presents or the liability of the Supplier to the Purchaser, and notwithstanding the existence of any
instructions or purported instructions of the Supplier or any other person(s) to the Bank not to pay or for any
cause withhold or defer payment to the Purchaser under these presents with the intent that notwithstanding
the existence of such difference, dispute or instruction, the Bank shall be and remain liable to make payment
to the Purchaser.
(v) This guarantee/undertaking shall not be affected by any change in the constitution of the Bank or that of the
Supplier or the Purchaser, or any irregularity in the exercise of borrowing powers by or on behalf of the
Supplier.
(vi) This guarantee/undertaking shall be valid for all claims/demands made by the Purchaser to or upon us upto
____________________ provided always that if for any reasons, the Supplier is unable to complete supplies
under the Contract, the Bank shall at the request of the Purchaser and without recourse to the Supplier
extend the validity of this guarantee/undertaking for a further period of six months. For the purpose of this
clause, the Purchaser’s statement that the Supplier is unable to complete supplies under the contract shall
be conclusive and final binding on us.
(vii) Notwithstanding anything contained herein:
(a) The Bank’s liability under this Guarantee/Undertaking shall not exceed Rs. _______ (Rupees
__________________________________only).
(b) This Guarantee/Undertaking shall remain in force upto ______________ and any extension(s)
thereof; and
(c) The Bank shall be released and discharged from all liability under this Guarantee/ Undertaking
unless a written claim or demand is issued to the Bank on or before ________ plus 3 months claim
period, or the date of expiry of any extension(s) thereof if this guarantee/undertaking has been
extended.
(viii) The Bank DOTH HEREBY declare that Mr. ______________ (name of the person signing on behalf of the
Bank) who is _____________ (his designation), is authorized to sign this guarantee/undertaking on behalf of
the Bank and to bind the Bank thereby.
Dated this ________________________ day of ______________
Yours faithfully,
For _____________________________________________
Signature ________________________________________
Name & Designation ________________________________
Name of the Branch ________________________________
NOTE
1. This Guarantee is required to be stamped as an agreement according to the Stamp Duty Act.
2. The Performance Bank Guarantee shall be strictly as per above proforma and shall be through Indian or
Foreign Branches of Indian Scheduled Banks (other than Cooperative Bank)/Nationalized Bank or Indian
Branches of Foreign Banks.
3. The bank shall provide details viz contact person, telephone number, fax number, e-mail address and
address of the Controlling/Regional Office of issuing bank for verification of authenticity of Bank Guarantee.
4. This Guarantee is required to be sent by Seller’s Bankers directly to the Head (LSTK-Finance), Engineers
rd
India Limited, EI Bhawan, 3 Floor, 1, Bhikaiji Cama Place, New Delhi-110066.
Page 60 of 441
Page 61 of 441
Page 62 of 441
Page 63 of 441
Page 64 of 441
Page 65 of 441
JOB NO. A133
RESID UPGRADATION PROJECT – COKER BLOCK OF CPCL, CHENNAI
PRE-FILLED AGREED TERMS & CONDITIONS (FOR INDIGENOUS SUPPIERS)
BIDDER’s NAME : M/s._____________________________________________________________________________
RFQ No.: ________________________________________________________________________________________
Bidder’s Offer Ref. No. :____________________________________________________________________________
Tel No. : ____________________________________ Fax No.:_____________________________________________
Contact Person :________________________E-Mail:______________________Mobile No:_____________________
S. No. DESCRIPTION BIDDER’S CONFIRMATION

Quoted prices are on FOT despatch point basis inclusive of Packing &
a) Confirmed
Forwarding (P&F) charges.
Indicated
b) Specify Despatch Point in the enclosed Annexure – I
(Refer ANNEXURE – I)
Confirm that firm freight charges for transportation by road upto the
c) Project site including Service Tax & Education Cess, have been quoted in Confirmed
the price bid.
1 Confirm the freight charges for Recommended Spares for two years
d) normal operation & maintenance, if any, have been quoted extra in the Confirmed
Price Schedule separately.
Confirm the freight for all other supplies like mandatory spares
e) commissioning spares, tools and tackles etc., are included in freight for Confirmed
main equipment.
Marine-cum-erection insurance (MCE policy) shall be arranged by EIL and
f) Confirmed
therefore, the same shall not be included in the quoted prices.
Excise Duty + Education Cess: Indicated
a)
Tarrif sub heading no. (Refer ANNEXURE – I)
Present rate of Excise Duty + Education Cess payable extra against Indicated
b)
documentary evidence on finished products (including spares). (Refer ANNEXURE – I
Indicated
c) Maximum rate applicable (If present rate is nil or concessional)
2 (Refer ANNEXURE – I)
Clarify whether Excise Duty + Education Cess will be applicable on freight Indicated
d)
charges also. (Refer ANNEXURE – I)
Please indicate following break-up
Indicated
e) I) Cenvatable [Excise Duty + Educational Cess]
II) Non Cenvatable
Sales Tax:
Indicated
a) Sales tax payable extra Specify CST/ Tamilnadu VAT (TN VAT) on sale of
goods.
3 *In case of CST, C form shall be provided.
b)
In case of TN VAT, no concessional form shall be provided. TN VAT shall be Confirmed
reimbursed to bidder subject to submission of requisite documents
enabling owner to avail “INPUT CREDIT’ for the same.
A133 ATC (IND)-REV 0 AUG13 PAGE 1 OF 7
Page 66 of 441
EIL/CPCL shall avail credit of 100% of TN VAT on sale of goods. However,
for price evaluation TN VAT on sale of goods shall not be loaded. TN VAT
c) Confirmed
shall be reimbursed to bidder subject to submission of requisite
documents enabling EIL/IOCL to avail ‘INPUT CREDIT’ for the same.
Clarify whether CST / TN VAT on sale of goods will be applicable on freight Indicated
d)
charges also. (Refer ANNEXURE – I)
Indigenous suppliers shall issue E1/E2 form on quarterly basis within 60
days after completion of each quarter based on “C” form no. provided by
e) Confirmed
PURCHASER. PURCHASER will provide original “C” form in exchange of
original E1/E2 form.
In case Excise Duty / CST / TN VAT are stated as not applicable on freight
charges presently, and if they are applicable at the time of delivery due to
4 Confirmed
any reasons other than statutory, the same will be borne by the Bidder.
Confirm compliance.
Only statutory variations, if any, in the present rate of Service Tax,
cenvatable excise duty, Central Sales Tax and VAT amount for which input
a) Confirmed
tax credit is available to the EIL under TN VAT Act etc. shall be to EIL’s
account subject to documentary evidence to be furnished by the bidder.
5 Statutory variations on non-cenvatable excise duty shall be to SUPPLIER’s
b) Confirmed
account.
However, any variation in Excise duty + Ed. Cess at the time of supplies for
c) any reasons, other than statutory, including variations due to turnover, Confirmed
shall be borne by bidder.
VAT on Works Contract:
Confirmed
a) Wherever site job is involved, bidders to quote their prices inclusive of TN
VAT on work contracts (if applicable).
Only single order covering complete scope of supply & services will be
6 b) issued (indicating supply and services portion separately). Order for supply Confirmed
and services shall not be split.
Any statutory variation on TN VAT on work contracts or change in rate of
c) TN VAT due to wrong assessment by supplier shall be to supplier’s Confirmed
account.
Service Tax:
a) Service Tax on freight charges shall be included in the quoted Freight Confirmed
Charges.
Percentage of Cenvatable Service Tax applicable extra on Site Work Indicated (Refer Annexure I)
Charges, , if applicable as per MR.
b)
Service tax shall be paid only against a cenvatable invoice issued in Confirmed
accordance with Service Tax rules.
7 Percentage of Cenvatable Service Tax applicable extra on Supervision Indicated (Refer Annexure I)
Charges, if applicable as per MR.
c)
Percentage of Cenvatable Service Tax applicable extra on AMC Charges, if Indicated (Refer Annexure I)
applicable as per MR.
d)
Page 67 of 441
Percentage of Cenvatable Service Tax applicable extra on Training Indicated (Refer Annexure I)
Charges, if applicable as per MR.
Entry Tax and Octroi:
Entry Tax / Octroi and Terminal Taxes are presently not applicable. If
8 a) applicable at a later date, same shall be payable extra at actual on Confirmed
production of necessary Documents/Invoices and information. Confirm
Compliance.
All new taxes/duties/cess/levies notified after the last date of submission
of final price bid/price implication, but within contractual delivery
/completion period, shall be to EIL’s account. These shall be reimbursed
a) against documentary evidence. Confirmed
9 However, in case of delay on account of supplier, any new or additional
taxes and duties imposed after contractual delivery shall be to supplier’s
account. Confirm compliance.
Any errors of interpretation of applicability of taxes/duties by bidders shall
b) Confirmed
be to bidders’ account.
Price Reduction Schedule:
a) Acceptance of applicable Price Reduction Schedule for delayed delivery as Confirmed
10 specified in RFQ/SIB.
In case of delay in delivery, bills shall be submitted after deducting price
b) Confirmed
reduction for delay.
Delivery Period / Completion Period:
11 Please confirm delivery/completion period as specified in RFQ Covering Confirmed
Letter.
Payment Terms:
a) Confirmed
Acceptance of applicable Payment terms as specified in RFQ /SIB.
Payment shall be released through Electronic Clearing System (ECS).
12 Furnished
In view of this, confirm that necessary details such as name of bank, bank
b) account no. etc. as per Mandate Form enclosed with RFQ, has been
furnished duly attested by your bank alongwith a cancel cheque, along (Refer ANNEXURE – II)
with your offer (as per Annexure-II to ATC) .
Part Order:
a) Confirmed
Acceptance of Part Order as per GPC (Indigenous).
13
Any charges quoted extra as lumpsum shall be applicable prorata on value
b) Confirmed
basis in the event of part order.
Repeat Order:
14 Confirmed
Acceptance of repeat order as per the clause specified in GPC (Indigenous).
Performance Bank Guarantee:
a) Submission of Performance Bank Guarantee for 10% of total order value as Confirmed
15 per General Purchase Conditions (GPC)/ Instructions to Bidders.
Indemnity Bond/Corporate Guarantee in lieu of PBG shall not be
b) Confirmed
considered.
Page 68 of 441
Guarantee :
16 Confirm acceptance of Guarantee period & terms as per referred Clause of Confirmed
Instruction to Bidders/General Purchase Conditions (Indigenous) in RFQ
Covering Letter.
Firmness of prices:
17 The prices shall be firm and fixed and not subject to any variation, Confirmed
whatsoever. However, in case of Cables, variation in prices shall be
admissible as per IEEMA Price Variation Clause.
CIF Value of Built in Import Content and Import Duties:
a) In case of any Built-in import content considered in your offer, details of Confirmed
items to be furnished in Annexure-I.
Confirm that quoted prices are based on Merit rate of Customs duty, CVD,
b) Confirmed
Educational Cess and SAD as applicable.
18
Quoted prices shall remain firm and fixed on account of FE variation and
c) Confirmed
Custom Duty Variation, till complete execution of the order.
d) EIL shall not provide any import license. Noted
Quoted prices are after considering the benefit of CENVAT on CVD
e) Confirmed
including Edu. Cess.
Testing charges:
19 Confirm that quoted prices are inclusive of all testing including IBR/ IGC/ Confirmed
Radiography/ NACE charges (if applicable) as per Material Requisition
attached.
Third Party Inspection charges:
a) Goods and services shall be subject to stagewise and final inspection by Confirmed
CEIL.
The TPI charges for Certification Engineers India Ltd. (CEIL) as TPI agency
20 b) Confirmed
shall be borne by EIL.
All built in import content shall be subject to inspection by TPI (out of M/s.
Lloyds Register (Country of origin), M/s.Bureau Veritas(BV) and M/s.TUV
c) Confirmed
Nord) for which charges are included in quoted price and no additional
charges shall be paid by EIL.
Validity:
a) Confirm that the Offer is valid for period as mentioned in RFQ covering Confirmed
letter from the bid due date/ extended due date.
21 For 2 years O&M spares, prices shall be kept valid for a period of 2 years
b) Confirmed
from the date of order of main equipment.
Confirm that Annual % escalation for subsequent two years beyod the
c) validity of 2 years for O&M spares have been quoted in format for prices Confirmed
for O&M spares.
Page 69 of 441
Confirm acceptance in totality to the following :
General Purchase Conditions (GPC) indigenous Confirmed
Instructions to Bidders / SIB Confirmed
Terms & Conditions for supervision of Erection, Testing & Confirmed
22
Commissioning (if applicable).
Terms & Conditions for site work (if applicable). Confirmed
Terms & Conditions for Annual Maintenance Contract (if applicable). Confirmed
All other terms & conditions of RFQ covering letter. Confirmed
Confirm that you have furnished the following documents in the offer:
a) Original Integrity Pact Furnished
23
b) Solvency Certificate Furnished
c) Concurrent / Present Commitment Furnished
Confirm the list, wherever required as per MR, has been submitted for
following :
a) Mandatory Spares (if specified in MR) Confirmed
b) Commissioning Spares (as included in main item) Confirmed
24
c) Special tools & tackles (if required) Confirmed
d) Recommended Spares for two years normal operation & maintenance (if Confirmed
required)
e) First fill of consumables, lubricant, etc Confirmed
Confirm that you have quoted strictly for items based on your registration
25 Confirmed
/ approval with EIL on the date of issue of RFQ.
Furnish Annual Report containing Balance Sheet & Profit & Loss Statement
26 Enclosed
for last one (01) years along with your unpriced offer.
Confirm that net worth of your company (bidder) during the last financial
27 Confirmed
year is positive.
Whether any of the Directors of Bidder is a relative of any Director of EIL
or the Bidder is a firm in which any Director of EIL or his relative is a
28 No
partner of the Bidder or a private company in which any Director of EIL is a
Director.
Please confirm you have not been banned or delisted by any Government
29 or Quasi Government agencies or PSUs. If you have been banned, then this Confirmed
fact must be clearly stated.
Deviations to Terms & Conditions shall lead to loading of prices or
30 Confirmed
rejection of offer as per Instructions to Bidders. Please confirm.
Printed terms and conditions, if any, appearing in quotation, shall not be
applicable in the event of order. In case of contradiction between the
31 Confirmed
confirmations given above and terms & conditions mentioned elsewhere
in the offer, the confirmation given herein above shall prevail.
BIDDER’S SIGNATURE & DATE : _______________________________

SEAL/ STAMP
Page 70 of 441
ANNEXURE – I TO PRE-FILLED AGREED TERMS & CONDITIONS (FOR INDIGENOUS SUPPIERS)
NAME OF BIDDER : _______________________________________________________________________
OFFER REFERANCE: ________________________________________________ DATED ________________
RFQ NO.: _______________________________________________________________________________
ITEM : ________________________________________________________________________________
PROJECT : RESID UPGRADATION PROJECT – COKER BLOCK OF CPCL, CHENNAI
1. Bidder confirms the following :DESPATCH POINT ________________________________

2. Service Tax & Education Cess on Supervision Charges, if applicable. _________________________% EXTRA
3. Service Tax & Education Cess on Site Work Charges, if applicable. _________________________% EXTRA
4. Service Tax & Education Cess on AMC, if applicable.
5. Service Tax & Education Cess on Training, if applicable.

6. Rate of Excise Duty : Tariff Sub Heading No. ________________________________
7. Excise Duty + Education Cess _________________________% EXTRA
8. Maximum rate of Excise Duty applicable (If present rate is nil or
concessional) _________________________% EXTRA
9. Please indicate following break-up
a) Cenvatable [Excise Duty + Educational Cess] a) Cenvatable [ED+ Edu. Cess]________%
b) Non Cenvatable b) Non Cenvatable [ED+ Edu. Cess]____%
10. Excise Duty on freight charges (Tick one whichever is applicable). APPLICABLE
(In case no option is selected, ED on Freight Charges shall be
NOT APPLICABLE
considered to be not applicable)
11. Central Sales Tax against form ‘C’
_________________________% EXTRA
12. Tamilnadu VAT without concessional form.
(Applicable for supplies from TN State) _________________________% EXTRA
13. CST/TN VAT on freight charges (Tick one whichever is applicable). APPLICABLE
(In case no option is selected, CST/TN VAT on Freight Charges shall be
NOT APPLICABLE
considered to be not applicable)
14. Built-in import content in the offer (Tick one whichever is applicable).
APPLICABLE
(In case no option is selected, Buit-in import content shall be
considered to be not applicable) NOT APPLICABLE
15. Item detail of CIF Content
16.
(a) The bidder is a Micro or Small Enterprise under the Micro, Small & YES NO
Medium Enterprises Development Act, 2006.
(b) Documentary evidence required as per RFQ to avail preference to FURNISHED
MSEs.
(c) The MSEs is owned by SC/ST Entrepreneurs. YES NO

\
(d) Supporting documentary evidence with respect to MSEs is owned FURNISHED

by SC/ST Entrepreneurs as per RFQ to avail preference to MSEs
owned by SC/ST.
BIDDER’S SIGNATURE & DATE : _______________________________WITH SEAL/STAMP
Page 71 of 441
ANNEXURE - II TO AGREED TERMS & CONDITONS (INDIGINEOUS)
MANDATE FORM
1. Bidder Name :
2. Bidder Code: :
3. Address of the Bidder :

4. Particulars of Bank Account of Bidder :
a. Name of the Bank :

b. Name of the Branch and Address of the Branch :
c. Branch Code :
d. 9 – Digit MICR code Number of the Bank & Branch :

(As appearing in the MICR Cheque issued by the bank)
(Please do not give multicity cheque book code Number)
e. Type of account (Saving Bank, Current or Cash Credit) :

f. Account Number :
g. RGTS/ IFSC Code (11 digit) :

h. NEFT Code No. :
5. E-mail address of the Bidder :

6. Contact Person(s) of the Bidder :
I/ we declare that the particulars given above are correct and complete and I/ we accord our consent for
receiving all our payments through Electronic Mechanism.
____________________________________________________
(Signature and designation of the Authorised person(s) of Bidder)
Official seal of the Bidder

Place :
Date :
BANK CERTIFICATION
Certified that the particulars furnished above are correct as per our records.
Place :
Date :
______________________________________
Signature of the Authorised Official of the Bank
Bank’s Stamp
Page 72 of 441
Page 73 of 441
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, exhibited
TAG NO/
SR. NO. ITEM CODE/ [ ID. NO. ] DESCRIPTION QUANTITY
01.00 Complete mechanical design, Design as per

IBR as applicable, detail engineering,
procurement of all materials and bought
out components, fabrication,
assembly/sub-assembly at shop,
inspection, testing at manufacturer's
works, hydrotesting, surface preparation
& application of primer, IBR approval of
drawings, documents, stage wise
inspection and final certification by CIB
as applicable, packing & forwarding (sea-
worthy packing in case imported),
delivery from vendor's work to site for
the following Heat Exchangers complete
in all respects, including supply of all
commissioning spares & hydrotesting
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.
accessories like test rings & test

flanges and documentation as per the
enclosed Jacob standard specifications,
instructions to vendors, EIL job
specification, data sheets etc. and other
codes and standards attached or referred
to:
01.01 086-E-25 LEAN AMINE HEATER (IBR) 1 Nos
01.02 086-E-26 BLOW DOWN COOLER 1 Nos
02.00 << DELETED >>
03.00 Transportation from Vendors work/ shop to
site for the following as per the
enclosed Licensor / EIL standard
specifications, instructions to vendors,
job specification, data sheets etc
03.01 {03}086-E-25 For Sr. No. 01.01 1 Nos
03.02 {03}086-E-26 For Sr. No. 01.02 1 Nos
04.00 Supply of Mandatory Spares as per Doc.
No. A133-16-46-SS-6142
04.01 {04}086-E-25 For Sr. No. 01.01 1 Lot
04.02 {04}086-E-26 For Sr. No. 01.02 1 Lot
05.00 << DELETED >>
06.00 Unit Rates
06.01 Unit Rates of items for addition/ 1
deletion purpose, as per Doc. No. A133-
16-46-SS-6142
07.00 << DELETED >>
08.00 << DELETED >>
09.00 Drawings and documents as per attached Lot
Vendor Data requirement for all supplies
and services covered above in Sr.Nos.1.00
to Sr.No.8.00
Vendors shall quote prices in EIL Price Schedule except for Sr.No.9.00. Price for
documentation is implied to be included in the prices quoted against Sr.No.1.00 to
Sr.No.8.00
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.
Project: RESID UPGRADATION PROJECT-COKER BLOCK

ENGINEERS INDIA LIMITED REQUISITION NO. REV.
16 Client: CPCL A133-086-EE-MR-6142 A
Page 74 of 441
Sheet 2 of 6
File Name: D:/6142.pdf
SR. NO.

16
Page 75 of 441
TAG NO/
Client:
ITEM CODE/ [ ID. NO. ]
CPCL
DESCRIPTION
Sheet
A133-086-EE-MR-6142
REQUISITION NO.
3 of 6
A
QUANTITY
REV.
LIST OF ATTACHMENTS
REVISION
SL. REV. REV. REV. REV.
DOCUMENT TITLE DOCUMENT NO.
No.
DATE DATE DATE DATE
DRAWINGS
1 Sketch for lipped floating A133-000-16-46-SK- 0
head flange 14 27/09/2013
2 Setting plan/ section drawing A133-086-16-46-DS- B
for Heat exchanger Item tag 4023 05/02/2014
no-086-E-25
3 Tube layout for Heat exchanger A133-086-05-45- 1
Item tag no-086-E-25 4025
4 Setting plan/ section drawing A133-086-16-46-DS- A
for Heat exchanger Item tag 4024 20/12/2013
no-086-E-26
5 Tube layout for for Heat A133-086-05-45- 0
exchanger Item tag no-086-E-26 4026
6 Detail of weld deposit on A133-000-16-46-SK- 0
flaoting head flange and 13 27/09/2013
partition plate
7 Detail of insertion piece for A133-000-16-46-SK- 0
pulling eye bolt (1 sheet) 011 27/09/2013
8 Detail of weld deposit on A133-000-16-46-SK- 0
flange 4 and partition plate 12 27/09/2013
STANDARD SPECIFICATIONS
9 General Specification For 44NC-4600-0000- 0
Pressure Vessel ( no of sheets V.02-0101-A4 09/03/2010
33)
10 General Specification For Heat 44NC-4600-0000- 0
Exchangers ( no of sheets 21) V.02-0102-A4 09/03/2010
Welded Tube To Tubesheet V.02-0104-A4 09/03/2010
joints (No. of Sheets 8)
12 General Specification For Shop 44NC-4600-0000- 1
And Field Painting (No. of V.02-0111-A4 08/07/2013
sheets 45)
Hardness Requirements (No. of V.02-0113-A4 09/03/2010
Sheets 3)
14 Standard Specification For BQ 44NC-4600-0000- 0
Carbon Steel Plates (No. of V.02-0117-A4 09/03/2010
Sheets 5)
15 Scope of work for Fabricated 44NC-4600-0000- 1
equipment - Coker Block V.02-0172-A4 19/07/2010
16 General Specification- 44NC-4600-0000- 0
Material Specification V.02-0114-A4 09/03/2010
17 Supplementary specification 44NC-4600-0000- 0
for Carbon steel CS Vessels V.02-0120-A4 09/03/2010
18 Standard specification for 6-15-0021 4
vender-designed shell and tube
heat exchangers.
19 Quality management system 44NC-4600-0000-
N.02-0040-A4
20 Quality management system 44NC-4600-0000-
(Annexure I to V) N.02-0040-A4
Annexure

Page 76 of 441
Sheet 4 of 6
LIST OF ATTACHMENTS
REVISION
No.
DATE DATE DATE DATE
STANDARD SPECIFICATIONS
21 Sliding/deflector strips to 7-15-0007 (No. of 3
tubesheet welding details Sheet 1)
22 General notes for SS clad 44NC-4600-0000- 1
exchanger (2 sheets) V.02-0167-A3 20/07/2010
23 Specification for duplex 6-79-0015 1
stainless steel and super
duplex stainless steel
24 Specification for welding of 6-79-0016 1
duplex stainless steel and
super duplex stainless steel

25 General notes for KCS 44NC-4600-0000- 1
exchanger V.02-0166-A3 20/07/2010
JOB SPECIFICATION
26 Job Specification for Shell & A133-16-46-SP-6142 A
Tube Exchangers 21/03/2014
27 Guide line to Vendor regarding A133-16-46-TL-6142 A
Tube Layout Preparation 21/03/2014
SCOPE OF WORK
28 Scope of Work and Supply A133-16-46-SS-6142 A
21/03/2014
INSTRUCTIONS TO VENDORS
29 Instructions to vendor for A133-16-46-TR-6137 A
submission of offer for Shell 21/03/2014
& Tube Heat Exchangers
VENDOR DATA REQUIREMENTS
30 Vendor Data Requirements A307-086-16-46- A
VDR-6142 21/03/2014
DESIGN BASIS
31 Site Specific Spectra for 44NC- D
Seismic (Sheets 42 to 45) 4600/C.02/0001/A4 12/07/2010
32 Engineering Design Basis 44NC-46 00-0000- 1
Static Equipment (No. of V.02-0001-A4 21/07/2010
Sheets 49)
INSPECTION & TEST STANDARDS
33 Indicative Inspection and test A133-00-000-ITP- 0
plan for shell & tube heat 0009
exchangers
STANDARDS
34 Earthing Lug (1 sheets) IND VSD 080 0
01/10/2009
35 General Tolerances for Heat IND VSD 101 0
Exchangers (3 sheets) 01/10/2009
36 Standard Name Plate for Heat IND VSD 102 0
Exchanger (1 sheets) 01/10/2009
37 Heat Exchanger Part Details (3 IND VSD 103 0
sheets) 01/10/2009
38 Types of Non Standard Gaskets IND VSD 104 0
(3 sheets) 01/10/2009
39 Saddle Support for Horizontal IND VSD 106 0
40 Davit for Heat Exchangers (3 IND VSD 108 0
sheets) 28/08/2009
Page 77 of 441
Sheet 5 of 6
LIST OF ATTACHMENTS
REVISION
No.
DATE DATE DATE DATE
STANDARDS
41 Welded Tube to Tube Sheet IND VSD 110 0
Joints (2 sheets) 01/10/2009
42 Pulling Eye Bolt Detail (1 IND VSD 111 0
sheets) 01/10/2009
43 Jack Screws, Tapping and IND VSD 112 0
Location (1 sheets) 01/10/2009
44 Fixing detail of Dowel Pins IND VSD 113 0
(1 sheets) 01/10/2009
45 Lifting Lugs for Heat IND VSD 114 0

46 Method of Fastening Nuts to IND VSD 115 0
Tie Rods (1 sheets) 01/10/2009
47 Detail of Sealing Strip IND VSD 117 0
Assembly for Two Pass Shell 01/10/2009
(1 sheets)
48 Drawing Title Standard
Annexure-III (1 Sheet)
49 Compliance Sheet (1 Sheet)
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:

Page 78 of 441
Sheet 6 of 6
Format No.: EIL-1641-1923 Rev.1
Engineers India Limited Status

Vendor Drawing/ Document Submission Schedule Date
Client: CPCL Project: RESID UPGRADATION PROJECT-COKER BLOCK Vendor Name:
Item Description: HEAT EXCHANGER SS- PR No.: Address:

DUPLEX, HEAT EXCHANGER CARBON STEEL.
Date of LOI:
PO No.:
Date of PO: City:
Page 79 of 441
EIL Originating Department: PRESSURE VESSELS Contact Person(EIL): Contact Person: Fax:
Phone: Email:
Drg./ Doc. Nomenclature Category Scheduled Form

S.No. Equipment Number as per EIL Vendor Data Vendor Drg. / Doc. Numbe Vendor Drg./ Doc. Title Electronic Remarks
Review (R) / date of 1st
Requirement Records (I) Submission (E)/ Print (P)
Page 1 of 45
CHENNAI PETROLEUM CORPORATION LIMITED

CHENNAI, INDIA
CPCL REFINERY - RESID UPGRADATION PROJECT
PART : III
SECTION : B.12
TITLE: GENERAL SPECIFICATION FOR SHOP AND FIELD PAINTING
DOCUMENT NO. : 44NC-4600-0000-V.02-0111-A4
REV ISSUE DATE PAGES REV DESCRIPTION PREPARED CHECKED APPROVED

NO. BY BY BY
0 09.03.2010 48 Issued as general specification MS CR CR

Revised as marked and issued
1 08.07.2010 45 SNK MS HSC
for FEED
Page 80 of 441
CPCL, Chennai GENERAL SPECIFICATION FOR Part III Section B.12
44NC-4600 SHOP AND FIELD PAINTING Page 2 of 45
LSTK Doc. No. 44NC-4600-0000-V.02-0111-A4 Rev. 1
TABLE OF CONTENTS
1.0 General
2.0 Scope
3.0 Codes & Standards
4.0 Equipment
5.0 Surface Preparation
6.0 Paint Materials
7.0 Paint Systems
7.1 Pre-erection / Pre-fabrication and shop priming for carbon steel, low temperature carbon
steel & low alloy steel, un-insulated and insulated steel structures, piping and equipment,
etc.,
7.2 Repair of pre-erection /fabrication and shop priming after erection / welding for carbon steel,
low temperature carbon steel & low alloy steel uninsulated and insulated items in all
environments.
7.3 Repair of all weld joints and damages of galvanized steel, carbon steel and alloy steel
structures, piping and equipment after erection on above ground / overhead areas at site.
8.0 Field paint system for normal corrosive environment (for carbon steel, low temperature
carbon steel and low alloy steel)
9.0 Field paint system for corrosive areas in plant (for carbon steel, low temperature carbon
steel and low alloy steel)
10.0 Field paint system for highly corrosive areas in plant (for carbon steel, low temperature
carbon steel and low alloy steel)external surfaces of piping & equipment
11.0 Field paint system for carbon steel storage tanks (internal & external) for all environment
and areas
12.0 Coating system for external side of underground carbon steel plant piping and tanks
13.0 Painting under insulation for (hot, cold & safety) Carbon Steel plant piping and tanks
14.0 Internal protection of Carbon Steel water boxes and tube sheets of cooler condensers
15.0 Field painting system for GI towers / Non-Ferrous tueb sheet
16.0 Shop & Field painting system for Effluent treatment plant
17.0 Storage
18.0 Color code for piping as per CPCL
19.0 Identification of vessels, piping, etc.,
20.0 Painting for civil defence requirements
21.0 Inspection and testing
22.0 Guarantee
23.0 Qualification criteria of painting contractor
Annexure-1 List of Recommended manufacturers

Annexure-2 Paint colour code for Piping & Equipment as given by CPCL
44NC-4600-0000-V.02-0111-A4 General Specification for Painting.doc
Page 81 of 441
1.0 GENERAL
1.1 These technical specifications shall be applicable for the work covered by the contract and
without prejudice to the various codes of practice, standard specifications, etc. It is understood
that Contractor shall carry out the work in all respects with the best quality of materials and
workmanship and in accordance with the best engineering practice and instructions of Engineer-
in-Charge.
1.2 1 Wherever it is stated in the specification that a specific material is to be supplied or a specific
work is to be done, it shall be deemed that the same shall be supplied or carried out by the
contractor. Any deviation from this standard without written deviation permit from appropriate
authority will result in rejection of job.
2.0 SCOPE
2.1 Scope of work covered in the specification shall include, without being limited to the following
2.1.1 This specification defines the requirements for surface preparation, selection and application of
paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures,
external & internal protection of storage tanks for all services. MS chimney without refractory
lining and flare lines etc. The items listed in the heading of tables of paint systems is indicative
only, however the contractor is fully responsible for carrying out all the necessary painting,
coating and lining on external and internal surfaces as per the tender requirement.
2.2 Extent of Work
2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting :
a. All un-insulated C.S & A.S equipment like columns, vessels, drums, storage tanks, heat
exchangers, pumps, compressors, electrical panels and motors etc., and tanks and
equipment in ETP plant.
b. All un-insulated carbon and low alloy piping fittings and valves (including painting of
identification marks), furnace, ducts and stacks.
c. All items contained in a package unit as necessary.
d. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders,
platforms, etc.
e. External surfaces of MS chimneys without refractory lining & flare lines.
f. Identification color bands on all piping as required including insulated aluminum clad,
galvanized, SS and nonferrous piping.
g. Identification lettering / numbering on all painted surfaces of equipment / piping insulated

aluminum clad, galvanized, SS and non-ferrous piping.
h. Marking / identification signs on painted surfaces of equipment / piping hazardous service.
i. Supply of all primers, paints and all other materials required for painting other than Owner’s
supply.
j. Over insulation surface of equipments and pipes wherever required.
k. Painting under insulation for carbon steel, alloy steel and stainless steel as specified. 1
Page 82 of 441
l. Repair work of damaged / pre-erection / fabrication shop primer and weld joints at field.
m. Internal surfaces of RCC tanks and structures in Effluent Treatment Plant.
2.2.2 The following surfaces and materials shall not require painting in general. However, if there are
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, galvanized “piping”, “gratings” and “Handrails” etc.
except G.I. Tower.
2.3 Unless otherwise instructed final painting on pre-erection / shop primed pipes and equipments
shall be painted in the field, only after the mechanical completion, testing on systems are
completed as well as after completion of steam purging wherever required.
2.4 Changes and deviations required for any specific job due to clients requirements or otherwise
shall be referred to Jacobs for deviation permit.
3.0 CODES & STANDARDS
3.1 Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the
contract, the following codes and standards shall be followed for the work covered by the
contract.
Color coding Color coding inspection manual for piping issued by CPCL (Ref.
Annexure-2) 1
IS-101 Methods of test for ready mixed paints and enamels.
ASTM American standard test methods for paints and coatings.
ASA A 13.1-1981 Scheme for identification of piping systems: American National Standards
Institution.
3.2 Surface Preparation Standards
Following standards shall be followed for surface preparations
3.2.1 Swedish Standard – SIS-05 5900-1967 (surface preparation standards for painting steel surfaces)
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 British Standards (Surface Finish of Blast-Cleaned for Painting) BS-4232.
3.2.4 National Association of Corrosion Engineers, U.S.A (NACE).
3.2.5 Various International Standards equivalent to Swedish Standard for surface preparations are
given in Table-I.
3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of above standards
and codes at site.
Page 83 of 441
3.4 The paint manufacturer’s instructions shall be followed as far as practicable at all times.
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.
c. Mixing and thinning.
d. Application of paints and recommended limit on time intervals between coats.
e. Suggested Quality assurance procedures.
4.0 EQUIPMENT
4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning, inspection
instruments, e.g. surface profile gauges, holiday detectors, pin hole detectors, dry film thickness
gauges, etc. and all equipments, scaffolding materials, shot blasting equipments like hooper, grit
etc & air compressors, etc., required to be used shall be suitable for the work and all in good
order and shall be arranged by the Contractor at site and in sufficient quantity. 1
4.2 Mechanical mixing shall be used for paint mixing operations in case of two pack systems except
that the Engineer-in-Charge may allow the hand mixing of small quantities at his discretion.
5.0 SURFACE PREPARATION, SHOP, COATING APPLICATION & REPAIR AND

DOCUMENTATION
5.1 General
5.1.1 In order to achieve the maximum durability, blast cleaning is considered the most desirable
method to achieve required profile however one or more of following methods of surface
preparation shall be followed, depending on conditions of steel surface and as instructed by
Engineer-in-Charge. Adhesion of the paint film to surface depends largely on the degree of
cleanliness and surface profile of the metal surface. Proper surface preparation contributes more
to the success of the paint protective system.
a) Manual or hand tool cleaning

b) Mechanical or power tool cleaning.
c) Blast cleaning. NO sand shall be used. Only grit blasting shall be allowed. 1
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. The minimum acceptable standard in case of manual or hand tool cleaning
shall be St. 2 or equivalent, in case of mechanical or power tool cleaning it shall be St. 3 or
equivalent in case of blast cleaning it shall be Sa 2-1/2 OR equivalent as per Swedish Standard
SIS-055900-1967 or equivalent. Where highly corrosive conditions exist, then blast cleaning shall
be Sa 3 as per Swedish Standard.
Remove all other contaminants, oil, grease, etc. by use of an aromatic solvent prior to surface
cleaning.
5.1.3 Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such
cleaning or during humid weather conditions having humidity exceed 85%.
Page 84 of 441
5.1.4 Irrespective of the method of surface preparation, the first coat of primer must be applied by
airless spray gun on dry surface No brush shall be used except for touchup. This should be done
immediately and in any case within 4 hours of cleaning of 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, as may be required, before primer
application is taken up. In general, during unfavorable weather conditions, blasting and painting
shall be avoided as far as practicable. 1
5.1.5 The external surface of RCC 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 if necessary
acid etching with 10-15% HCl solution for about 15 minutes shall be carried and surface must be
thoroughly washed with water to remove acid & loose particles then dry completely before
application of paint.
5.2 Procedure of Surface Preparation :
5.2.1 Blast Cleaning
5.2.1.1 Air Blast Cleaning
The surfaces shall be blast cleaned using one of the abrasives Al2O3 particles chilled cast iron or
malleable iron and steel at pressure of 7 Kg /cm2 at appropriate distance and angle depending of
nozzle size maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel
shall be in the form of shot or grit of size not greater than 0.055” maximum in case of steel and
malleable iron and 0.04” maximum in case of chilled iron. Compressed air shall be free from
moisture and oil. The blasting nozzles should be venturi style with tungsten carbide or boron
carbide as the materials for liners. Nozzles orifice may vary from 3/16” to ¾”. 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 or when there is dew on the metal, which is to be cleaned. Surface profile shall be
uniform to provide good key to the paint adhesion (i.e. 35 to 50 microns). If possible vacuum
collector shall be installed for collecting the abrasives and recycling.
5.2.1.2 Water Blast cleaning
Environmental, health and safety problems associated with abrasive blast cleaning limit the
application of Air Blast Cleaning in many installations. In such case water blast cleaning is
resorted to.
Water Blast Cleaning can be applied with or without abrasive and high pressure water blasting.
The water used shall be inhibited with sodium chromate / phosphate. The blast-cleaned surface
shall be washed thoroughly with detergents and wiped with solvent and dried with compressed
air. For effective cleaning abrasives are used. The most commonly used pressure for high
pressure water blast cleaning for maintenance surface preparation is 3000 to 6000 psi at 35-45
lit/minute water volume and pressures upto 1000 psi and water volume at 45 lit/minute provide
maximum cleaning.
The water blast cleaned surface shall be comparable to SSPC-SP-12/nace No. 5. The operation
shall be carried out as per SSPC guidelines for water blast cleaning. The indicative values for
sand injection is :
Air : 300 to 400 Cu. Ft. / min

Water : 5-10 lit/min. with corrosion inhibitor
Sand : 200-400 lbs/hr.
Nozzle : 0.5 to 1” dia.
Page 85 of 441
Special equipments for water blast cleaning with abrasives, now available, shall be used.
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 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 or stream and thoroughly dried with compressed
air jet before application of paint.
5.2.3 Manual or hand tool cleaning
Manual or hand tool cleaning is used only where safety problems limit the application of other
surface preparation procedure and there is approach problem in certain areas and hence does
not appear in the tables of paint systems.
Hand tool cleaning normally consists of the following :
a. Hand descaling and / or hammering

b. Hand scraping
c. hand wire brushing
Rust, mill scale spatters, old coatings and other foreign matter, shall be removed by hammering,
scrapping tools, emery paper cleaning, wire brushing or combination of the above methods. On
completion of cleaning, loose material shall be removed from the surface by clean rags and the
surface shall be bushed, swept, dusted and blow off with compressed air/steam to remove all
loose matter. Finally the surface may be washed with water and dried for effective cleaning.
5.3 Non-compatible shop coat primer
The compatibility of finishing coat should be confirmed from the paint manufacturer. In the event
of use of primer such as zinc rich epoxy, inorganic zinc silicate etc., as shop coat, the paint
system shall depend on condition of shop coat. If the shop coat is in satisfactory condition
showing no major defect, the shop coat shall not be removed. However a non-compatible primer
shall have to be removed before application of compatible paint system for the environment. The
touch up primer and finishing coat(s) shall be identified for application by Engineer-in-Charge.
5.4 Shop coated (coated with primer & finishing coat) equipment should not be repainted unless paint
is damaged.
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
particular environment.
5.6 For Package units / equipment, shop primer should be as per the paint system given in this
specification. However, manufacturer’s standard can be followed after review.
5.7 Coating Procedure and Application
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious airborne elements
0
exists, when the steel surface temperature is less than 5 F above dew point when the relative
0
humidity is greater than 85% or when the temperature is below 40 F.
5.7.2 Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hrs. the same day.
Page 86 of 441
5.7.3 To the maximum extent practicable, each coat of material shall be applied as a continuous film
uniform thickness free of probes. Any spots or areas missed in application shall be recoated 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 recoating 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 instruction shall be followed for inter-coat interval.
5.7.5 When the successive coat of the same color have been specified, alternate coat shall be tinted,
when practical, sufficiently to produce enough contrast to indicate complete coverage of the
surface. The tinting material shall be compatible with the material and not detrimental to its
service life.
5.7.6 Deleted 1
5.7.7 Airless spray application shall be in accordance with the following procedure : as per steel
structure paint Manual Vol. 1 & Vol. 2 by SSPC, USA. Air less spray relies on hydraulic pressure
rather than air atomization to produce the desired spray. An air compressor or electric motor is
used 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 inbuilt agitator that keep the paint
uniformly mixed during the spraying. The unit shall consist of inbuilt strainer. Usually very small
quantity of thinning is required before spray. In case of high build epoxy coating (two pack), 30:1
pump ratio and 0.020-0.023” tip size will provide a good spray pattern. Ideally fluid hoses should
not be less than 3/8” ID and not longer than 50 ft. to obtain optimum results.
In case of gun choking, de-choking steps shall be followed immediately.

5.7.8 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.
b. Round or oval brushes are most suitable for rivets, bolts, irregular surface and rough or pitted
steel. Wide flat brushes are suitable for large flat areas, but they shall not have width over
five 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, doubaers or sheepskin.
5.7.9 Manual application by sling (where 6 o’ clock position of pipe is not approachable)
A canvas strip (alternatively a tinplate strip) about 450mm wide and 1.5m long is held under the
pipe by two men holding this sling move it up and down and walk slowly forward while fresh
coating is poured on the pipe and they manipulate the sling so that an even coating is obtained all
round the bottom. This work shall be done very carefully and by experienced personnel. There
shall not be any formation of “Whiskers” and holes in the coating. The coating film shall be
inspected by mirror.
Page 87 of 441
5.7.10 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 it 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 checking, 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 manufacturer’s
specification for the paint.
5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dry to
the fullest extent practicable.
5.9 Repair of damaged paint surface
5.9.1 Where paint has been damaged in handling and in transportation, the repair of damaged coating
of pre-erection / fabrication shall be as given below.
5.9.2 Repair of damaged inorganic zinc silicate primer after erection / welding.
Quickly remove the primer from damaged area by mechanical scrapping and emery paper to
expose the white metal. Blast clean the surface if possible. Feather the primer over the intact
adjacent surface surrounding the damaged area by emery paper.
0 0
5.9.3 Repair of damaged pre-erection and shop priming in the design temperature of –90 C to 400 C
• Surface preparation shall be done as per procedure 5.9.2
• One coat of F-9 shall be applied wherever damage was observed on pre-erection / pre-
fabrication / shop primer of inorganic zinc silicate coating (F-9).
5.10 Paint Application
5.10.1 Shop priming / pre-erection priming with F9 or F12 shall be done only on blasted surface.
5.10.2 Shop priming / pre-erection priming with F9 shall be done only with airless spray.
5.10.3 For large flat surface field painting shall be done by airless spray otherwise brush can be used.
5.11 Documentation
5.11.1 A written quality plan with procedure for qualification trials and for the actual 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.
Page 88 of 441
5.11.5 Details of non-compliance, rejects and repairs.
5.11.6 Type of testing equipments and calibration.
5.11.7 Code and batch numbers of paint materials used.
Page 89 of 441
TABLE-1 (FOR CLAUSE 5.0)
SURFACE PREPARATION STANDARDS
VARIOUS INTERNATIONAL STANDARDS

(EQUIVALENT)
SR.
DESCRIPTION BRITISH REMARKS
NO. Swedish SSPC-
NACE STANDAR
Standard SP
USA D
SIS-05- USA
BS-4232
5900
1. Manual or hand tool ST.2 SSPC- -- -- This method is applied
cleaning. SP-2 when the surface is
exposed to normal
Removal of loose rust, atmospheric conditions
loose mill scale and loose when other methods
paint, chipping, scrapping, cannot be adopted and
standing and wire brushing. also for spot cleaning
Surface should have a faint during maintenance
metallic sheen. painting.
2. Mechanical or power tool ST. 3 SSPC- -- --
cleaning. SP-3
Removal of loose rust,
loose mill scale and loose
paint to degree specified by
power tool chipping,
descaling, sanding, wire
brushing and grinding, after
removal of dust, surface
should have a pronounced
metallic sheen.
3. Blast cleaning (air & water)
There are four common
grades of blast cleaning
3.1 White metal SA.3 SSPC- NACE First Where extremely clean
Blast cleaning to white SP-5 #1 Quality surface can be
metal cleanliness. expected for prolong
Removal of all visible rust. life of paint system.
Mill sale, paint & foreign
matter 100% cleanliness
with desired surface profile.
Page 90 of 441
3.2 Near white metal SA 2 ½ SSPC- NACE Second The minimum

SP-10 #2 Quality requirement for
chemically resistant
paint systems such as
epoxy, vinyl,
polyurethane based
and inorganic zinc
silicate paints, also for
conventional paint
systems used under
fairly corrosive
conditions to obtain
desired life of paint
system.
3.3 Commercial Blast SA 2 SSPC- No. 3 Third For steel required
Blast cleaning until at least SP-6 Quality to be painted with
two-third pf each element of conventional paints for
surface are is free of all exposure to mildly
visible residues with corrosive atmosphere
desired surface profile for longer life of the
paint systems.
3.4 Brush-off Blast SA 1 SSPC- No. 4
Blast cleaning to white SP-7
metal cleanliness, removal
of all visible rust, mill scale,
paint & foreign matter.
Surface profile is not so
important.
Page 91 of 441
6.0 PAINT MATERIALS
Paint manufacturers shall furnish the characteristics of all paints materials on printed literature
along with the test certificate for all specified characteristics given in this specification. All the paint
materials shall be on first quality and conform to the following general characteristics. As per the
tables 6.1, 6.2 and 6.3.
TABLE No. 6.1 PRIMERS
Sr.
Description P-2 P-4 P-6
No.
1. Technical Name Chlorinated rubber Etch primer / Epoxy zinc phosphate

Zinc Phosphate primer wash primer primer
2. Type and Single pack, air drying Two pack Two component polyamide
composition chlorinated rubber based polyvinyl butyral cured epoxy resin medium-
medium plasticised with resin medium pigmented with zinc
unsaponifiable plasticizer, cured with phosphate.
pigmented with zinc phosphoric acid
phosphate solution
pigmented with
zinc tetroxy
chromate
3. Volume Solids 40% 7-8% 40%

(approx.)
4. DFT (Dry Film 40-45µ 8-10µ 40-50µ

thickness) per
coat (approx.)
5. Theoretical 8-10 8-10 8-10

covering capacity
2
in M /coat/litre
(approx.)
6. Weight per liter in 1.3 1.2 1.4

kgs/liter (approx)
7. Touch dry at 30 minutes 2 hrs. After 30 min.

0
30 C (approx.)
0
8. Hard dry at 30 C 24 hrs. 24 hrs. 24 hrs.
(approx.)
9. Over coating Min: 8 hrs. Min: 4-6 hrs. Min.: 8 hrs.

interval (approx.) Max. : No limitations Max. : 24 hrs. Max. : 3-6 months
10. Pot life (approx) Not applicable Not applicable 8 hrs.

0
at 30 C for two
component paints
(approx.)
Page 92 of 441
TABLE No. 6.2 FINISH PAINTS
Sr. Description F-2 F-3 F-6A/F-6B F-7

No.
1. Technical Acrylic Chlorinated rubber Epoxy high High build coaltar

Name polyurethane based finish paint build finish paint epoxy coating.
finish paint
2. Type and Two-pack Single pack Two pack Two pack polyamide
composition aliphatic plasticized polyamine (F- cured epoxy resin
isocynate cured chlorinated rubber 6A) / polyamide blended with coaltar
acrylic finish based medium (F-6B) cured medium, suitably
paint with chemical and epoxy resin pigmented.
weather resistant medium suitably
pigments pigmented
3. Volume Solids 40% 40% 62% 65%

(approx.)
4. DFT (Dry Film 30-40µ 40-45µ 100-125µ 100-125µ

thickness) per
coat (approx.)
5. Theoretical 10-13 8-10 5-6 5.2-6.5

covering
capacity in
2
M /coat/litre
(approx.)
6. Weight per liter 1.3 1.2 1.4 1.5

in kg/liter
(approx)
7. Touch dry at 1 hr. 30 minutes 3 hrs. 4 hrs.

0
30 C (approx.)
8. Hard dry at Overnight 8 hrs. Overnight 48 hrs.

0
30 C (approx.)
9. Over coating Min : Overnight Min : Overnight Min : Overnight Min. : 24 hrs.
interval (12 hrs.) Max. : Unlimited Max : 5 days Max. : 5 days
(approx.) Max. : Unlimited
10. Pot life 6-8 hrs. Not applicable 4-6 hrs. 4-6 hrs.
(approx) at
0
30 C for two
component
paints (approx.)
Page 93 of 441
Sr. Description F-8 F-9 F-11 F-12

No.
1. Technical Name Self priming type Inorganic zinc Heat resistant Heat resistant silicone
surface tolerant silicate coating synthetic medium aluminum paint suitable
0 0
high build epoxy based on two pack upto 500 C / 550 C dry
coating (complete Aluminum paint temp.
rust control suitable upto
0
coating) 250 C dry temp.
2. Type and Two-pack epoxy A two pack air Heat resistant Single pack silicone resin
composition resin based drying self curing synthetic medium based medium with
suitable solvent based based two pack Aluminum flakes.
pigmented and inorganic zinc Aluminum paint
capable of silicate coating suitable upto
0
adhering to 250 C
manually
prepared surface
and old coating.
3. Volume Solids 72% 60% 25% 20%

(approx.)
4. DFT (Dry Film 100-125µ 65-75µ 20-25µ 20-25µ

thickness) per coat
(approx.)
5. Theoretical covering 6.0-7.2 8-9 10-12 8-10

capacity in
2
M /coat/litre
(approx.)
6. Weight per liter in 1.4 2.3 1.2 1.1

kg/liter (approx)
0
7. Touch dry at 30 C 3 hrs 30 minutes 3 hrs. 30 min
(approx.)
0
8. Hard dry at 30 C 24 hrs 12 hrs. 12 hrs. 24 hrs
(approx.)
9. Over coating interval Min : 10 hrs Min : 8 hrs at Min : 16 hrs Min. : 16 hrs
0
(approx.) Max. : 6 months 20 C & 50% RH Max : Unlimited Max. : Unlimited
Max. : Unlimited
10. Pot life (approx) at 90 min 4-6 hrs Not applicable Not applicable
0
30 C for two
component paints
(approx.)
0 0
11. Temperature - - 250 C 500 C
Resistance
Page 94 of 441
Sl. DESCRIPTION F-14 F-15 F-16

No
1 Technical name Polyamine cured Epoxy phenolic Ambient temperature curing Poly
coal tar epoxy coating Siloxane/ inorganic copolymer
based aluminium coating suitable
for under insulation coating of CS
and SS piping for high
temperature service
2 Type and Specially formulated Two pack ambient Amercoat 738 from Ameron
composition polyamine cured temperature curing Products, USA/ Berger 938 from
coal tar epoxy epoxy phenolic coating Berger Paints Ltd., Kolkata or
suitable for suitable for application Intertherm 751 CSA from Akzo
application under under insulation Nobel coating, Bangalore.
insulation
3 Volume Solids 70% 65% 60%

(approx.)
4 DFT (Dry Film 125 urn 75-100 urn 75-100 urn

thickness) per coat
(approx.)
5 Theoretical covering 5.5 6.5-8.5 6.0- 8.0

capacity in M2/ coat/
litre (approx.)
6 Weight per liter in 1.5 1.7 1.3
kg/ litre (approx.)
7 Touch dry at 30°C 4hrs 2 hrs 1hr
(approx.)
8 Hard dry at 30°C 168hrs(7days) 168 hrs (7 days) 12 hrs

(approx.)
9 Over coating Min. 6 hrs Min. 36 hrs Max. Min. 16 hrs Max. Not applicable
interval (approx.) Max.5 days 21 days
10 Pot life (approx.) at 4 hrs 1.5 hrs 1hr
30°C for two
component paints
(approx.)
11 Temperature -45°Cto150°C under -45°C to 150°C under Up to 400 deg. C for CS & SS
Resistance insulation insulation surfaces under insulation
0 0
F-14 Specially formulated polyamide cured Coal-tar epoxy suitable for –45 C to 125 C for application
under insulation.
0 0
F-15 Two pack ambient temperature curing epoxy phenolic coating suitable for –45 C to 125 C for
application under insulation.
F-16A Engineered polysiloxane coating : Amercoat 738 from Ameron Products, USA
F-16B Engineered poly siloxane coating : Berger 938 from Berger Paints Ltd., Kolkatta
Page 95 of 441
NOTES
1 Covering capacity and DFT depends on method of application. Covering capacity specified above
are theoretical. Allowing the losses during application, min. specified DFT should be maintained.
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.
4. Technical data sheets for all paints shall be supplied at the time of submission of quotations.
6.4 List of recommended Manufacturers
The paints shall conform to the specifications given above and best quality in their products range of
manufacturers listed in Annexure-I.
Page 96 of 441
7.0 PAINT SYSTEMS
The paint system should vary with type of environment envisaged in and around the plants. Three
types of environment as given below are considered for selection of paint system. The paint system
is also given for specific requirements.
PRIMERS & FINISH COATS COVERED IN TABLE NOS. 7.0 TO 15.0
PRIMERS
P-2 : Chlorinated rubber zinc phosphate primer
P-4 : Etch primer / wash primer
P-6 : Epoxy zinc phosphate primer
Finish Coats / Paints
F-1 : First quality corrosion resistant synthetic enamel
F-2 : Acrylic – Polyurethane finish paint
F-3 : Chlorinated rubber finish paint
F-6A : High build epoxy finish coating cured with polyamine hardner
F-6B : High Build epoxy finish coating cured with polyamide hardner
F-7 : High build coal tar epoxy coating
F-8 : Self priming surface tolerant high build epoxy coating
F-9 : Inorganic zinc silicate coating
F-11 : Heat resistant synthetic medium based aluminium paint
F-12 : Heat resistant silicone aluminium paint

0
F-14 : Specially formulated polyamine cured coal for epoxy coating suitable upto 150 C
F-15 : Epoxy phenolic coating
F-16A : Epoxy siloxane coating : Amercoat 738
F-16B : Epoxy siloxane coating Berger 938
Page 97 of 441
TABLE 7.1 : SHOP PRIMING, PRE-ERECTION / PRE-FABRICATION FOR STRUCTURES,

PIPING & EQUIPMENT ETC.
Materials : CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL,
STEEL
TYPE : UNINSULATED AND INSULATED
Sr. Design Surface Paint System Total DFT Remarks

0
No. Temperature in C Preparation in Microns
(min.)
7.1.1 -90 to 400 SSPC-SP-10 1 coat of F-9 65-75 No over coating is to be done
7.1.2 401 to 500 SSPC-SP-10 1 coat of F-12 40-50 Finish coat at site
TABLE 7.2 : REPAIR OF SHOP PRIMING, PRE-ERECTION / PRE-FABRICATION AFTER

ERECTION / WELDING FOR ITEMS IN ALL ENVIRONMENTS
Materials : CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL
Sr. Design Surface Preparation Paint System Total DFT in Remarks

No. Temperature Microns (min.)
0
in C
7.2.1 -90 to 400 SSPC-SP-3 (for repair only) 1 coat of F-9 65-75
SSPC-SP-10
7.2.2 401 to 500 SSPC-SP-3 (for repair only) 2 coats of F-12 40-50
SSPC-SP-10
TABLE 7.3 : REPAIR OF ALL WELD JOINTS AND DAMAGES FOR STRUCTURES, PIPING
AND EQUIPMENT AFTER ERECTION ON ABOVE GROUND OVERHEAD AREAS
AT SITE
Materials : GALVANIZED STEEL, CARBON STEEL AND ALLOY STEEL
Sr. Design Surface Preparation Paint System Total DFT in Remarks

No. Temperature Microns (min.)
0
in C
7.3.1 -14 to 80 SSPC-SP-3 1 coat of F-8 100
7.3.2 81 to 500 SSPC-SP-3 1 coat of F-12 20
Page 98 of 441
TABLE 8 : FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT IN OFFSITE

AREAS FOR STRUCTURES, PIPING, EQUIPMENT, FLARE LINES ETC. -
UNINSULATED
TYPE : UNINSULATED
Sr. Design Surface Paint System Total DFT Remarks

No Temperat Preparation in Microns
. ure in 0C (min.)
Field Primer Finish paint
-90 to -15 SSPC-SP-10 Repair of None 65-75 No over coating to be

8.1 done. Follow repair
pre-fabrication
primer 1 coat of procedure only on
F-9 @ 65-75 µ damaged areas of
DFT/coat pre-erection / pre-
fabrication primer /
-14 to 60 SSPC-SP-10 Repair of 2 coats of F-3 225 Coating F-9 / F-12 shall
8.2
pre-fabrication @ 40 µ DFT/ be ambient
primer 1 coat of Coat 2x40=80 temperature curing
F-9 @ 65-75 µ type till operating
DFT/coat + 2 temperature is attained
coats of P-2 @ for full curing.
40 µ DFT/Coat
2x40=80
61 to 80 SSPC-SP-10 Repair of 1 coat of F- 245
8.3
pre-fabrication 6B@ 100 µ
primer 1 coat of DFT/Coat
F-9 @ 65-75 µ
DFT/coat + 2
coats of P-6 @
40 µ DFT/Coat
2x40=80
81 to 250 SSPC-SP-10 Repair of 3 coats of F-12 125
8.4
pre-fabrication @ 20 µ DFT/
primer 1 coat of Coat 3x20=60
F-9 @ 65-75 µ
DFT/coat
8.5 251 to SSPC-SP-10 Repair of 2 coats of F-12 105
400 pre-fabrication @ 20 µ DFT/
primer 1 coat of Coat 2x20=40
F-9 @ 65-75 µ
DFT/coat
8.6 401 to SSPC-SP-10 Repair as per 2 coats of F-12 80
500 7.2.2. @ 20 µ DFT /
Coat 2x20=40
NOTE 1 : For external surfaces of MS chimney with or without refractory lining 8.3, 8.4 and 8.5 shall
be followed.
NOTE 2 : For external surfaces of RCC chimney: 2 coats of F-6B @ 100µ DFT/Coat to obtain
2x100=200 µ DFT shall be applied after making surface preparation as per guidelines in
5.1.5. The DFT on concrete surfaces can be checked by Tool Gauge or by applying the
same coating system simultaneously on a carbon steel panel of 12"x12" size and measure
the DFT by normal Magnetic gauges/digital electronic gauges for ferrous surfaces.
Page 99 of 441
NOTE 3 : Wherever required S.No.8.3 shall be used for -14°C to 80°C and S.No.8.2 will be deleted.
TABLE 8 A : FIELD PAINT SYSTEM FOR CORROSIVE ENVIRONMENT IN PLANT AREA

Surface : Un-insulated
Note :
For all corrosive areas above ground where H2S, SO2 fumes or spillages of
acid/Alkali/Salt are likely to come in contact with surfaces such as external surfaces of
un-insulated columns, vessels, heat exchangers, blowers, piping, pumps, towers,
compressors, and structural steel etc.
Sl. Design Surface Paint System Total Remarks
No. Temperature Preparation DFT in
in °C Microns
(min.)
Field Primer Finish Paint
9.1 -90 to -15 SSPC-SP-10 Repair of pre- None 65-75 Repair of pre-erection /
fabrication primer pre-fabrication primer shall
1 coat of F-9 @ be done wherever damage
65-75µ DFT/coat is observed.
9.2 -14 to 80 SSPC-SP-10 Repair of pre- 1 coat of F- 245
fabrication primer 6A@ 100 µ
1 coat of F-9 @ DFT/coat +
65-75 µ DFT/coat 1 coatofF-2
+ 1 coats of P-6 @40u
@ 40 µ DFT/coat DFT/coat.
9.3 81 to 400 SSPC-SP-10 Repair of pre- 2 coats of 105

fabrication primer F-12@20
1 coat of F-9 @ µ DFT/coat
65-75 µ DFT/coat 2x20=40
9.4 401 to 500 SSPC-SP-10 Repair as per 2 coats of 80
7.2.2. F-12@20
µ DFT/coat
2x20=40
Page 100 of 441

TABLE 9 : FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE AREAS IN PLANT AREA
EXTERNAL SURFACES OF UNINSULATED COLUMNS, VESSELS, HEAT
EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS,
STRUCTURAL STEEL ETC.
Surface : Un-insulated
Note : Exposed to spillage or fumes of HCL, H2SO4, salty water, water impingement,
chloride etc
Sl. Design Surface Paint System Total DFT Remarks
No. Temperature Preparation In
in°C Microns
(min.)
10.1 -90 to -15 SSPC-SP-10 Repair of pre- None 65-75 Repair procedure of
fabrication primer pre-erection/fabri
1c o at of F- 9 @ cation primer shall be
65-75u DFT/coat followed. No
overcoating is
allowed.
Surface preparation is
required only for
repairing of damaged
pre-erection/
fabrication primer.
10.2 -14 to 80 SSPC-SP-10 Repair of pre- 2 coats of F- 345

fabrication primer 6A @ lOOu
1c o at of F- 9 @ 65-DFT/Coat =
75u DFT/coat + 1 2x100=200 +
coats of P-6@ 40u 1coatofF-2
DFT/Coat @40u
DFT/coat.
10.3 81 to 400 SSPC-SP-10 Repair of pre- 2 coats of F- 105
fabrication primer 12@20u
1c o at of F- 9 @ DFT/Coat
65-75u DFT/coat 2x20=40
10.4 401 to 500 SSPC-SP-10 Repair as per 7.2.2. 2 coats of F- 80
12@20u
DFT/Coat
2x20=40
Page 101 of 441

TABLE 10 : PAINTING UNDER INSULATION FOR INSULATED (HOT, COLD & SAFETY) PIPING,
STORAGE TANKS AND EQUIPMENTS IN ALL ENVIRONMENT
Materials : CARBON STEEL, LOW ALLOY STEEL, LOW TEMPERATURE CARBON STEEL &
STAINLESS STEEL
Surface : Insulated
Paint System
Sr. Design Surface Field Primer Finish paint Total Remarks
No. Temperatur Preparation DFT in
0
e in C Microns
(min.)
9.1 Insulated carbon steel, low alloy steel and LTCS piping and equipment and tanks
9.1.1 -45 to 125 SSPC-SP-10 Repair of pre- 2 coats of F-14 315

fabrication primer @ 125 µ For other temperature
F-9 @ 65-75 µ DFT/coat = ranges no painting is
DFT. 2x125=250 OR 3 required under insulation
coats of F-15 =
3x80=240
9.1.2 Operating SSPC-SP-10 Repair of pre- 2 coats of F-12 105-115

temperature fabrication primer @ 20 µ DFT /
–45 to F-9 @ 65-75µ coat = 3x20 = 60
0
125 C but DFT.
design
temperature
0
126-400 C
9.2 Insulated stainless steel including Alloy-20 piping
9.2.1 Below 00C Aluminium sheeting with aluminium foil and “Chloride free mineral If the piping &
to all minus sealant coating barium chromate” shall be applied. equipments are already
temperature erected then surface
shall be prepared by
cleaning with emery
9.2.2 0 to 120 SSPC-SP-10 None 2 coats of F-14 @ 250 or
paper and wash / flush
(15-25µ surface 125 µ DFT / coat 240
with chloride free DM
profile) = 2x125 = 250 or 3
water followed by wiping
coats of F-15 =
with organic solvent.
3x80=240
All the coating materials
9.2.3 121 to 400 SSPC-SP-10 None 3 coats of F-12 60 for SS shall be free from
@20µ DFT /Coat = leachable chlorides.
3x20=60 or 1 coat
of Poly siloxane or
coating (F-16 A/B)
@ 75 microns
DFT/coat
9.2.4 401 to 600 SSPC-SP-10 None 2 coats of heat 40

resistant silicone
aluminium paint @
20 microns DFT /
coat = 2x20=40
9.3 No painting is required for insulated Monel, Incoloy and Nickel lines
Page 102 of 441

Page 103 of 441

Page 104 of 441

Page 105 of 441

TABLE 12.0 COATING SYSTEM FOR EXTERNAL SIDE OF UNDERGROUND CARBON STEEL
PLANT PIPING AND TANKS
Sl. Design Surface Paint System Total Remarks

No. Temp. °C Preparation DFT in µ
(min.)
12.1 Carbon steel plant piping (underground)

12.1.1 Yard coating
12.1.1.1 25 to 60 SSPC-SP-10 1 coat of 4 mm thick 4 mm CTE coating shall confirm
synthetic fast coaltar to 120/5 as per BS:4164
drying primer coating
type-B as per wrapping as
AWWA-C-203 per AWWA-
(1991) C-203 in 2
layers of
each 2 mm
thickness.
12.1.2 Over the Ditch Coating
12.1.2.1 25 to 60 SSPC-SP-10 1 coat of 2 layers of 4 mm
synthetic fast coal tar
drying primer based tape
type-B as per coating
AWWA-C-203
(1991)
12.2 Carbon plant piping (underground).

12.2.1 61 to 225 SSPC-SP-10 1CoatofF-15@ 75 2 Coat of F- 225 Cold and hot insulation
µ DFT/coat 15 @ 75 µ shall be provided
DFT/coat
12.2.2 221 to 400 SSPC-SP-10 1CoatofF-16@ 75 1 Coat of F- 175 Cold and hot insulation
µ DFT/coat 16@ 100µ shall be provided
DFT/coat
12.3 External side of un-insulated underground storage tanks:

12.3.1 -40 to 80 SSPC-SP-10 1CoatofF-9@ 65- 3 coats of 365
75 µ DFT/coat F-7 @100 µ
DFT/coat
3x100=300
12.3.2 81 to 180 SSPC-SP-10 1CoatofF-15@ 75 2 Coat of F- 225
µ DFT/coat 15 @ 75u
DFT/coat
12.3.3. 181 to 400 SSPC-SP-10 1CoatofF-9@ 65- 2 Coat of F- 215-225
75 µ DFT/coat 16 @ 75 µ
DFT/coat
2x75=150
Note: No Coating and Wrapping systems are available for underground high temperature services
Page 106 of 441

TABLE 13.0 PAINTING UNDER INSULATION FOR INSULATED (HOT, COLD & SAFETY) CARBON
STEEL, LOW ALLOY STEEL, LOW TEMPERTURE CARBON STEEL & STAINLESS STEEL
PIPING, STORAGE TANKS AND EQUIPMENTS IN ALL ENVIRONMENT.
Sl. Design Surface Paint system Total

No. Temp. °C Preparation DFT in µ
(min.)
Primer Finish Paint
13.1 Insulated carbon steel, low alloy steel and LTCS piping and equipment & tanks
13.1.1 -45 to 125 SSPC-SP-10 Repair of 2 coats of F- 315 For other temperature ranges no
pre- 14 @125 µ painting is required under
fabricatio DFT/coat = insulation F-12 shall be ambient
n primer 2x125=250 temperature curing type till
F-9 @ 65- OR 3 coats of operating temperature is attained
75 µ DFT. F-15= for full curing. F-16 is completely
3x80=240 ambient temperature curing.
13.1.2 Operating SSPC-SP-10 Repair of 2 Coats of 125-135
temperature pre- F-12 @20 µ
-45 to 125°C fabricatio DFT/coat
but design n primer 3x20=60 (or)
temperature F-9 one coat of
126-400°C @65-75 µ Poly-siloxane
DFT coating @ 75
µ DFT/coat
13.2 Insulated stainless steel including Alloy-20 piping

13.2.1 Below 0°C to Aluminum sheeting with aluminum foil and If the piping & equipments are
all minus "Chloride free mineral sealant coating barium already erected than surface
temp. chromate" shall be applied. shall be prepared by cleaning with
emery paper and wash/flush with
chloride free DM water followed
by wiping with organic solvent. No
pre-erection primer to be applied.
F-12 shall be ambient temp
curing type till final curing is
obtained during operating temp.
F-16 is completely ambient temp
curing type.
13.2.2 0 to 120 SSPC-SP-10 None 2 coats of F- 250

(15-25 14@125 µ or
surface DFT/COAT 240
profile) 2x125=250 or
3 coats of F-15
= 3x80=240
Page 107 of 441

13.2.3 121 to 400 SSPC-SP-10 None 3 coats of F- 60-75

12@20 µ
DFT/COAT
3x20=60 or 1
coat of F-16 Poly
Siloxane coating
@ 75 microns
DFT/coat
13.2.4 401 to 600 SSPC-SP-10 3coatsofF-12@ 60
20 µ DFT/coat 60
13.2.5 Cyclic SSPC-SP-10 None 2 coats of DFT/coat 150

service-196 F-16 Poly
to 480 Siloxane coating
excepting - @ 75 µ DFT/coat
45 to 120 = 2x75=150
13.3 No painting is required for insulated Monel, Incoloy and Nickel lines.
Page 108 of 441

TABLE 14.0 INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF
COOLERS / CONDENSERS
Water boxes, channels, partition plates, end covers and tube sheets etc.
Sl. Design Surface Paint system Total DFT Remarks

No. Temperature Preparation in Microns
in°C (min.)
Primer Finish paint
14.1 Upto 80 SSPC-SP-10 1 coat of P-6 @ 2 coats of F-7 290 For C.S.
40 µ DFT/coat @125 µ
DFT/coat
2x125=250
14.2 Upto 80 Non SSPC-SP-3 1coatofP-4@ 8-1 2 coats of F-7 300 For non ferrous
ferrous and On DFT/coat. @125 µ surfaces
brass tube 1coat of P-6 @ DFT/coat
sheets 40 µ DFT/coat. 2x125=250
TABLE 15.0 FIELD PAINTING SYSTEM FOR GI TOWERS/NON-FERROUS TUBE SHEET
Sl. Design Surface Paint System Total DFT Remarks

No. Temperature Preparation in Microns
in°C (min.)
Primer Finish Paint
15.1 Upto 80 SSPS-SP-3 1 coat of P-4 @ 2 coats of F-2 130 Shade as per
8-10 µ DFT/coat @40 µ defence
+ 1 coat of P-6 @ DFT/coat Requirements.
40u DFT/coat 2x40=80
15.2 Upto 80 Non SSPS-SP-3 lcoatofP-4@8u 2 coats of F-7 300

ferrous and DFT/coat @125 µ
brass tube 1coat of P-6 @ DFT/coat
sheets 40u DFT/coat 2x125=250
Page 109 of 441

TABLE 16.0 SHOP & FIELD PAINTING SYSTEM FOR EFFLUENT TREATMENT PLANT
Sl. Design Temp. °C Surface Paint System Total DFT Remarks

No. Preparation in Microns
(min.)
Primer Finish Paint
16.1 -14 to 80(for SSPS-SP-10 1 3 coats of F- 365
C.S./M.S. items): coatofF-9 6A @100u
Screens, Walk way @ 65-75u DFT/coat
bridges, Baffles, Dual DFT/coat 3x100=300
media filters
(external) Vertical
pumps, piping in
treated effluent sump
and pump house,
external side lining of
Slop oil MS tank
16.2 -14 to 80(CS/MS SSPS-SP-10 1 2 coats of F- 265

Items) for Vertical coatofF-9 6A @100u
pump and piping in, @ 65-75u DFT/coat
Bio-sludge sump and DFT/coat.
pump, Filter feed
sump and pump,
Process sump,
Sanitary sump;
Transfer sump,
Sludge, MS Slop oil
tank internal,
scrapping
mechanism in
Clarifier, Screw pump
16.3 -14 to 80 deg.C :All Blast cleaning Epoxy Epoxy 3mm Epoxy screed lining
R.C.C. surfaces such t o SSPC- SP screed screed shall be used as per
as tanks, structures, guide lines and lining lining specific instructions
drains etc.) in Acid etching from Engineer-in-
Process sump, TPI with 10-15% Charge at site.
HCl acid
separator (Process
followed by
and Oil), Aeration thorough water
Tank, Transfer sump washing.
etc.
16.4 U p t o 6 0 d e g . C SSPC-SP-10 Rubber 4.5mm
C.S/M.S Dual media Lining
filters (Internal),
Chemical dosing
tanks(internal such
as DAP, Urea)
Page 110 of 441

17.0 STORAGE
1 All paints and painting materials shall be stored only in rooms 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
INFLAMABLE" shall be clearly displayed outside.
18.0 PIPING COLOR CODE
The color code shall be followed as given in Annexure-II.
19.0 IDENTIFICATION OF VESSELS, PIPING ETC.: As per color coding given in

Annexure-II
20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS
20.1 Following items shall be painted for camouflaging if required by the client.
a. All columns
b. All tanks in off sites
c. Large Vessels
d. Spheres
20.2 Two coats of selected finishing paint as per defence requirement shall be applied in a
particular pattern as per 20.3 and as per the instructions of Engineer-In-Charge.
20.3 Method of Camouflaging
20.3.1 Disruptive painting for camouflaging shall be done in three colors in the ratio
of
5:3:2 (all matt finish).
Dark Green Light Green Dark Medium Brown

5: 3: 2
20.3.2 The patches should be asymetrical and irregular.
20.3.3 The patches should be inclined at 30 Deg.. to 60 Deg. to the horizontal.

20.3.4 The patches should be continuous where two surfaces meet at an angle.
20.3.5 The patches should not coincide with corners.
20.3.6 Slits and holes shall be painted in dark shades.
20.3.7 Width of patches should be 1 to 2 meters.
21.0 INSPECTION AND TESTING
21.1 All painting materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufactures as per specifications and
shall be accompanied by manufacturer's test certificates. Paint formulations without
certificates are not acceptable.
21.2 Engineer-In-Charge at his discretion may call for tests for paint formulations. Contractor
shall arrange to have such tests performed including batch-wise test of wet paints for
physical & chemical analysis. All costs there shall be borne by the contractor.
Page 111 of 441

21.3 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
In addition to above, record should include type of shop primer already applied on equipment
e.g. Red oxide zinc chromate or zinc chromate or Red lead primer etc.
Any defect noticed during the various stages of inspection shall be rectified by the contractor
to the entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, contractor shall be
responsible for making good any defects found during final inspection/guarantee
period/defect liability period as defined in general condition of contract. Dry film thickness (D
F T)) 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
cost should have prior approval of Engineer-in-charge.
21.4 Primer Application
After surface preparation, the primer should be applied to cover the crevices, corners, sharp
edges etc. in the presence of inspector nominated by Engineer-In-Charge.
21.4.1 The shades of successive coats should be slightly different in color in order to ensure
application of individual coats, the thickness of each coat and complete coverage should
be checked as per provision of this specification. This should be approved by
Engineer-In-Charge before application of successive coats.
21.4.2 The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface profile in case
of sand blasting. Holiday detectors and pinhole detector and protector whenever required
for checking in case of immersion conditions.
21.4.2 Prior to application of paints on surfaces of chimneys, the thickness of the individual coat
shall be checked by application of each coat of same paint on M.S.test panel. The
thickness of paint on test panels shall be determined by using gauge such as
'Elkometer'. The thickness of each coat shall be checked as per provision of this
specification. This shall be approved by Engineer-In-Charge before application of paints on
surface of chimney.
21.4.3 At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert
technical service at site as and when required. This service should be free of cost and
without any obligation to the owner, as it would be in the interest of the manufacturer to
ensure that both surface preparation and application are carried out as per their
recommendations.
21.4.4 Final inspection shall include measurement of paint dry film thickness, Adhesion, Holiday
detection check of finish and workmanship. The thickness should be measured at as
many points/ locations as decided by Engineer-In-Charge and shall be within + 10% of the
dry film thickness, specified in the specifications.
Page 112 of 441

21.4.5 The contractor shall arrange for spot checking of paint materials for Sp.gr., glow time (ford
cup) and spreading rate.
22.0 GUARANTEE
22.1 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.
22.2 The contractor shall produce test reports from manufacturer regarding the quality of the
particular batch of paint supplied. The Engineer-in-Charge shall have the right to test wet
samples of paint at random for quality of same, as per the paint materials specification.
Batch test reports of the manufacturer's for each batch of paints supplied shall be
made available by the contractor. The contractor shall stand guarantee for carrying
out the rectification/repair/re-painting of the defects/ failures of painting found during the
execution of painting job and till the expiry of the defect liability period of total project as
per the directions of the Engineer-in-Charge of CPCL/JE
23.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR
Painting contractor who is awarded the job under this standard must have necessary
equipments, machinery, tools and tackles for surface preparation, paint application and
inspection. The contractor mush have qualified, trained and experienced surface
preparator, paint applicator, inspector and supervisors. The contractor's supervisor,
inspector, surface preparator and paint applicator must be conversant with the
standards referred in this specification. The painting job shall be carried out by the approved
agencies of paint manufacturers and supervised by the approved paint manufacturers own
representative or paint manufacturer their scheme( supply and apply basis).
Page 113 of 441

ANNEXURE-I
LIST OF RECOMMENDED MANUFACTURERS
Indian Vendors
1. Asian Paints (I) Ltd., Mumbai

2. Berger Paints Ltd., Kolkata
3. Goodlass Nerolac Paints Ltd., Mumbai
4. Chemguard Coatings, Mumbai(For Ameron, USA Products only)
5. Chokugu Marine paints Pte. Ltd., Mumbai/Singapore
6. Shalimar Paints Ltd., Kolkata
7. Sigma Coatings, Mumbai.
8. CDC Carboline Ltd., Chennai
9. Premier products Ltd., Mumbai
10. Coromandel Paints & Chemicals Ltd., Visakhapatnam
11. Anupam Enterprises, Kolkata
12. Grand Polycoats, Vadodata
13. Bombay Paints Ltd., Mumbai
14. Akzo Nobel Coatings and Sealants Pvt. Ltd., Bangalore
15. Cipy Polyurethanes Pvt. Ltd., Pune
16. Gunjan Paints Ltd., Ahmedabad
17. Advance Paints Ltd., Mumbai
18. VCM Polyurethane Paints (for polyurethane paints only)
19. Jotun Paints, Chennai(Singapore)
20. Chembond Chemicals Ltd., Navi Mumbai
Foreign Vendors
1. Sigma Coatings, Singapore

2. Ameron, USA
3. Kansai Paints, Japan
4. Hempel Paints, USA
5. Valspar Corporation, USA
6. Akzo Nobel/International Coatings, UK
7. Jotun Paints, Singapore
For De-humidification equipment (on Rental Basis)
1. Technical Drying Equipment (Asia) Pvt. Limited, Gurgaon, Haryana
The following are approved vendors for speciality items (phosphating chemical) only.
1. Mark-chem Incorporated, Mumbai.
2. Chemtreat India Ltd., Navi Mumbai
Page 114 of 441

Annexure-II
Paint Color Code for Piping & Equipment given by CPCL Document No. 00-ES-100-004, Rev. 5
dated 24/12/2006 to Specification No.6782-0642-PT-L06 Rev.2
This section of the standard deals with the color coding to he given to in service piping for easy
identification bused on the liqui d contained in the line.
1. Where ever paint is required for piping external surfaces, the finish coat color shall be as follows
except for paragraph 2, Type of paint, surface preparation. DFT etc. shall he as per the
painting specification.
a) 1 lent resistant paint - Alum inn in

b) Other grades of paint - White or Al. in Color
Insulated and austenitic stainless steel lines will he having only color coding for fluid
discrimination as given in 3 below.
2. Fire water lines shall he painted " Red '" as per IS 536 through out the line.
3. All lines, in general, shall he provided with discrimination color coding mark over the final coat or
on the cladding / jacketing surface of insulated piping as mentioned in 1 above . as
well as on the surfaces on which any paint is not provided. The color coding shall be as per the
attachment to this standard and in the following manner. Color codes on Austenitic SS lines should
he done only wit chloride free paint suitable for application on stainless steel surfaces.
As far as possible, paint used for color bands should he of the same specification as the finish
coat. If for some reason a deviation is required for this, then enamel paint can be used over finish
coat after taking approval from the ‘engineer In - Charge'
3.1 The system of color coding shall consist o f a primary identification color band and other color
hand (s) superimposed on the primary band. All the bands shall be painted circumferential!;
around the line.
The primary color hand identifies the basic nature of the fluid carried in the line. The second and
the third color hands will identify the exact fluid carried in the line. The various primary color
bands included in t h i s standard are explained below:
Basic fluid Color of primary band
Water Sea Green

Steam Signal Red
Air Sky Blue
Gases Canary Yellow
Acids and acid producing, gases Dark Violet
Hydrocarbons Dark Grey
Alkalies Light Brown
Chemicals Light Orange
No identification required Black
Page 115 of 441

3.2 Painting of color bands
3.2.1 Primary colorblind / color band ( s ) (see Fig I) arc required to be located at
- battery limit points

- intersection points in the piping system
- start and terminal points
- at spec i lied intervals as given below
- specific points on the l i n e as directed by the "Engineer - In - Charge "
3.2.2 Primary color band shall he intermittently coated along respective lines with primary color
bands of 2V1 length with the following maximum center to center distance between two
adjacent color bands.
− 15 M for lines with in battery limits of respective units

− 50 M for lines on interconnecting pipe rack and in lower plateau
Center to center distances at lesser intervals may be given. if" so desired by unit head.
3.2.3 Sizing of II &. Ill color bund (s)
Size II color band I I I Color band

3" and below 100 mm 50 mm
> 3" upto ft" 200 mm 100 mm

> 6" upto 12" 300 mm 150 mm
> 12" 400 mm 200 mm
Page 116 of 441

SR CONTENTS Primary II Color Band 111 Color

NO Color Band Band
1 ALL KINDS OF WATER

Drinking water Sea green French Blue Signal rod
De-mineralized water Sea green Light Orange
Cooling water Sea green French blue
Boiler feed water Sea green Gulf Red
Condensate Sea green Light Brown
Quench water Sea green Dark grey Signal rod
Wash water Sea green Canary Yellow
Process water Sea green Light grey
Raw water ( from river } Sea green
Page 117 of 441

Fire water ( Full color, not band ) Fire red

2 STEAM
Very high pressure steam Signal Red Silver Grey
High pros sure steam Signal Red French Blue
Medium Pressure steam Signal Red Gulf Red
Low Pressure steam Signal Red Canary Yellow
Dilution steam/ Purge steam Signal Red Silver Grey Canary Yellow
3 AIR
Plant Air Sky Blue Silver Grey
Instrument Air Sky Blue French Blue
Process air ( ex: bitumen, Sky Blue Signal Red
Mereox)
Combustion air Sky Blue Canary Yellow

4 GASES
Hydrogen Canary Yellow Signal red French Blue
Nitrogen Canary Yellow Black
Flare gas Canary Yellow
Hydrogen sulfide/ Acid gas Canary Yellow Gulf Red
Fuel gas Canary Yellow Light Brown While
Regeneration gas Canary Yellow While Dark Violet
LPG (as gas) Canary Yellow Brilliant Green While
Propane ( as gas ) Canary Yellow Signal Red Black
Sulfur Dioxide Dark Violet Brilliant Green
Ammonia Dark Violet
Chlorine Dark Violet Signal Red
HCN Dark Violet Trench Blue
5 AC IDS
Sulfuric Acid Dark Violet Brilliant Green Light Orange

Nitric Acid Dark Violet French Blue Light Orange
1 Hydrochloric Acid Dark Violet Signal Red Light Orange
Acetic acid Dark Violet Silver Grey
6 LIQUID HYDROCARBONS
LPG ( as liquid ) Dark Grey Brilliant Green While

Naphtha. Dark Grey Brilliant Green
MS Dark Grey Sky Blue
Reformate Dark Grey While
SKO Dark Grey Light Brown
ATF Dark Grey Light Brown Sky Blue
USD Dark Grey Light Orange
FO Dark Grey Signal Red
LSHS / Low Sulfur fuel Dark Grey Signal Red Black
Bitumen Dark Grey Black
Page 118 of 441

Other Hydrocarbons not defined Dark Grey

Above
Crude Dark Grey Canary Yellow
7 ALKALIES Light Brown

8 CHEMICALS-GENERAL Light Orange
Sulfur Light Orange Black
9 All other items which do no Black

require individual identification
Surface Part Color Remarks

Tanks A.C. Grey
Spheres White
Vessels, drums, heat exchangers D.A. Grey
etc.
Furnace casing Silver
Machinery - Pumps. Silver
Compressors, blowers etc)
Steam Turbine Silver
Generator' Mfr. Std.
Motor Light grey ISC 631
Packaged dosing system Mfrs. Std
DG Set Mfrs. Std
Cable duct Silver
Instrument Panel
Instrument Panel including DCS Indoor
Cabinet Front Opaque Beige With leather lone
Other Neutral Grey With leather lone
sides Neutral Grey
Inside
Control Valve
C:S Body Light grey ISC 631
SS Body No paint
Low alloy body Canary Yellow ISC 309
Control Valve Actuators
Normally Brilliant Green ISC 221
Closed
Normally Open Signal Red \SC 537
Instruments. Transmitters Mfrs Sid
Page 119 of 441

Sr. No. Content Final Color ISC

No:
1 Gantry girder and monorail Brilliant Green 221
2 Stopper for gantry girder and monorail Signal Red 537
3 Pipe rack structural steel and trestle including that Dark Admiralty Grey 632
for equipment and platform
4 Chequered Plates Dark Admiralty Grey 632
Ladder rungs, verticals and cage Canary Yellow 309
6 Hand railing. middle rail, toe pi ale and Canary Yellow 309
vertical post
7 Platforms : Structural sled parts other Dark Admiralty Grey 632
than grating and hand railing
8 Staircase : Structural steel parts other Dark Admiralty Grey 632
than hand railing and steps using galvanized
9 Safety Gate Signal Red 537

10 Miscellaneous Structural Part Dark Admiralty Grey 632
Notes : 1) Wherever Dark Admiralty Grey is not available due to the nature of the final coat of
paint ( eg: Coal Tar epoxy in high H2S environments ) . Black can be used.
2) Canary Yellow for ladders etc. has been selected for visibility.
1. Equipment number shall be stenciled in black (after initial painting if any) on each vessel,
column, equipment, machinery till a visible location as directed by the "Engineer - in -
charge "'
Size of letters is as below:
− Column, vessel. exchanger, other stationary equipment : 150 mm height
− Pump. Compressor and other machinery including : 50 mm height HT

motors
Rotating equipment shall have tin arrow showing the direction of rotation painted on the
equipment.
In case of small auxiliary equipment in packaged unit, separate identification by stenciling is

not required as long as name plate or tag bearing item number is duly attached to the aux.
equipment.
2. Line number, service, source and destination shall be stenciled in black on respective
pipe lines at
− start and terminating points of line next to the color code
− battery limit points next to the color code,
Page 120 of 441

Additional stenciling of line numbers and service will be required and shall be provided on
the lines at the direction of “Engineer- In - Charge"
Sizing of letters shall be :
OD of pipe Height of letters
80- 150 mm 40 mm
150-250 mm 60 mm
> 250 mm 90 mm
Auxiliary piping in packaged units or on base plates of pumps / compressors wilh in the
scope of vendors do not need numbering at site.
However, an auxiliary line with operational significance (where it is referenced specifically in

the operation manual by a line number) shall he provided with a number by stenciling hi-
other suitable means.
3. The following details are to he painted on the Lank shell in black color, letter size 50 mm
high, at the entrance point of the staircase.
• Tank number
• Reference height
• Stile filling height
• Critical /one ( in ease of floating roof tanks only )
• Dale of commissioning
• Date of last cleaning
4. The following details are to be painted on the tank shell near the top landing platform of the
staircase, in letter size 50 mm high, black color.
• Reference height
• Sale filling height
• Critical zone ( in case of floating roof tanks only )
5. The following details shall he painted on the kink at 2!3 the height of the tank at a
location facing the road, from where normal approach lo the Tank is provided. In addition,
the same details shall be provided on two additional points in the lank 120 degrees apart.
Tank number
• Capacity
• Service.
The size of the above lettering shall be 500 mm for 20 M high tanks and 300 mm for
smaller tanks.
DGCA requirements for a l l shall be followed in addition to the above.
Page 121 of 441

1.0 The part of the standard covers the method of identification of STORED piping material by
color coding. This standard is applicable to storage during project Stage as well.
2.0 General guide lines of identification by color coding:
a) Piping shall be painted with one color or a combination of two color as
enclosed.
b) Color identification is not required on galvanized material and mm ferrous
material such as Copper. Aluminum etc. because of their peculiar color and
Page 122 of 441

Jacobs
character
e) Special items l i k e bellow, strainers, steam Imps etc. should be lagged and hence do
mil require color identification.
d) Color identification of Austenitic Stainless Steel is not desirable due to r i s k
of contamination from paint material.
e) Ends of piping to be welded shall not be painted. The color band shall start
2" from the pipe ends.
f) Width of color strips shall be 25 mm for .V nominal pipe dia and above. Secondary
color strip where required, shall be half the size of primary strips. For less than 3" size
color strip shall be 12 mm < 1/2") or maximum practical.
Carbon Steels
API 5L Gr B Pink Seamless

API 5L Gr B Pink / White Welded
A 106 Gr B Red [BR
A 106 Gr B Yellow Non IBR
Welded and seamless fittings Red IBR
Welded and seamless fittings Yellow Non IBR
Welded fittings Yellow / White Normalized
Miters Silver
Class 22 fittings Silver / Pink Stress relieved at s h o p
IS 3589- IS 12239 No Paint Non critical
Alloy Steels
P1, F1. WP1, WP1W etc. Green / Red
P12, F12, W12 etc Green / Yellow
P22, F22, WP22. etc Green / Silver
P11, F11, WP11 etc. Green / Orange
P5, F5, WP5 etc. Green / Blue
P9, F9, WR9 etc. Green / Pink
Page 123 of 441

Jacobs
Color ( In alphabetical order ) ISC No:

Black
Brilliant Green 221

Canary Yellow 309
Dark Grey 632
Dark Violet 796
Fire Red 536
French Blue 166
Golden Yellow 356
Gulf Red 473
Jasmine Yellow 397
Light Brown 410
Light Grey 631
Light Orange 557
Sea Green 217
Signal Red 537
Silver 110
Silver Grey 628
Sky Blue 101
White -
Page 124 of 441

Page 1 of 8

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: GENERAL SPECIFICATION FOR WELDED TUBE TO

TUBESHEET JOINTS
DOCUMENT NO. 44NC-4600-0000-V.02-0104-A4
Rev Issue Pages Rev Description Prepared Checked Approved

No. Date By By By
Page 125 of 441

CPCL, Chennai GENERAL SPECIFICATION FOR Part V Section 3.4
44NC-4600 WELDED TUBE TO TUBESHEET JOINTS Page 2 of 8
LSTK Doc. No. 44NC-4600-0000-V-02-0104-A4 Rev. 0
TABLE OF CONTENTS
1.0 PURPOSE
2.0 APPLICABLE CODES
3.0 WELDING PROCESS AND JOINT DETAIL
4.0 WELDING PROCEDURE QUALIFICATION
5.0 WELDERS QUALIFICATION
6.0 PREPARATION OF TUBES AND TUBESHEET
7.0 WELDING
8.0 EXAMINATION OF JOINTS
9.0 TUBE EXPANDING
10.0 REPAIRS
11.0 TEST AND REPAIR REPORTS
APPENDIX-1 : JOINT DETAILS
APPENDIX-2 : DETAILS OF TEST SPECIMENS
44NC-4600-0000-V.02-0104-A4 General Spec for welded tube to tubesheet joints.doc

Page 126 of 441
1.0 PURPOSE
This specification covers minimum requirements for the welding and testing of tube to tubesheet
joints of shell and tube heat exchangers and air coolers. It is the vendor’s responsibility to furnish
sound, leak free joints. For the purpose of this specification, the terms “joints” shall be construed to
mean “tube-to-tube sheet joints”.
2.0 APPLICABLE CODES
Following codes and standards shall be complied with:
a. ASME Sec. VIII Div. 1, Edition 2007 Addenda 2008
b. ASME Section V, Edition
c. ASME Section IX, Edition
d. TEMA for tubular exchangers, Edition
e. API 661 for air coolers, Edition
f. AWS, Edition
3.0 WELDING PROCESS AND JOINT DETAIL
3.1 Manual or automatic Tungsten Inert Gas shielded Arc (TIG) welding shall be used. All joints shall
be made by using minimum two weld passes. The first pass should be preferably made without
filler wire to ensure root fusion. The second or final pass shall be with filler wire. Any other welding
process can be used only after obtaining written approval from Jacobs.
3.2 Joint detail shall be as indicated on the Purchaser drawings by giving reference to figure numbers in
Appendix-1 of this specification. In absence of any Purchaser drawings or indication regarding type
of joint Figure-2 or Figure-3 shall be used depending upon whether tube thickness is ≥ 2.0 mm or <
2.0 mm respectively.
4.0 WELDING PROCEDURE QUALIFICATION
4.1 Welding Procedure Specification shall be complied by the vendor and submitted to the Authorised
Inspector for approval before the qualification tests are performed. Mock up test shall commence
only after approval is obtained from the Authorised Inspector.
4.2 Welding procedure qualification test is required to be carried out if: -
a) Authorised Inspector requires the test to be carried out.
b) There exists no previous qualification tests within last three years for the proposed
combination of tube and tubesheet P number and group number (as per ASME section IX),
tube outside diameter (OD), tube thickness, tubesheet thickness, tube pitch, tube pitch
pattern, welding procedure and joint detail.
All other factors remaining same, the procedure test need not be repeated if the job tube
sheet thickness exceeds 40mm and qualification exists for 40mm or higher tube sheet
thickness.
For plug type air coolers additional procedure qualification test is required to be performed for
any of the following conditions: -

Page 127 of 441
i) The job has lower clearances between tube and any of the header plates like
top/bottom/end/stiffener/pass partition plate compared to earlier tests.
ii) The job has lower plug size for the same tube size compared to earlier tests.
iii) The job has higher plugsheet thickness compared to earlier tests.
c. Code or requisition or enquiry document requires the test to be carried out.
4.3 If required as per 4.2 above, the vendor shall perform a procedure qualification test, at least two
weeks before the scheduled beginning of production. Procedure shall be qualified for the same
hand position as is being proposed for production.
Procedure test shall consist of the welding of nine tubes for square pitch and eight tubes, (three, two
and three tubes per row arrangement) if on a triangular pitch. This shall be done for each set of
combination of tube and tube sheet P number and group number, welding procedure, joint detail,
tube OD, tube thickness, tube pitch, tube pitch pattern, tube sheet thickness.
Additionally for air cooler, tests shall be done for each tube size with lowest plug size, lowest
clearance between tube and any of the header plates, and the lowest plug sheet thickness to be
used on the job.
Thickness of the tube sheet used for procedure testing shall be same as used for job, except that
for carbon steel and austenitic stainless steel materials, it need not exceed 40mm, unless otherwise
indicated. Refer Appendix-2 of this specification for test specimen details.
4.4 The following data report (six copies) shall be furnished for review to Authorised Inspector with the
weld samples as outlined below: -
a. Complete details of welding procedure employed indicating various machine settings, welding
rods, inert gas composition & purities, flow rate, weld sequence, etc.
b. Mechanical properties and chemical composition of tubesheet, tubes and filler metal
c. The hardness of the weld, the tube, the tubesheet heat affected zone and the tubesheet base
metal after each pass.
d. The complete test sample shall be cut (by sawing) as per Appendix 2 of this specification.
These shall then be subjected to various tests etc. as outlined below: -
i. Section 1 shall be polished, etched and micro photographed for examination of depth of
weld, penetration and definition of boundaries. The minimum leak path of each weld
shall be not less than the nominal thickness of the tube. The weld leg shall also be
measured and shall be minimum 1.4 times the nominal thickness of the tube.
ii. Section 2 (two specimens) shall be subjected to tear test. These specimens shall be
tongue bent to show the extent of weld penetration. The underside of the weld shall
show evidence of adequate & uniform weld penetration.
iii. A section 10mm thick containing the tube end welds shall be sawed from section 3 and
radiographed for weld quality. The radiograph shall be submitted to Authorised Inspector.
No cracks or crack like or visual defects are acceptable.
Acceptance shall be as per Appendix 4 of ASME Section VIII Division-1. In case the
radiograph is not acceptable, welding procedures shall be suitably modified so that
proper weld and acceptable radiographs are obtained. These shall be proved by retests.
iv. Section 4 shall be etched and polished and given to Authorised Inspector.
e. A tension strength test shall be carried out as per ASME Sec. VIII Div.-1 Appendix A. This

Page 128 of 441
strength test shall be performed at room temperature for each combination set of tube and
tubesheet P number and group number, tube OD, tube thickness and joint detail.
The breaking loads shall be at least equal to the load required for breaking the tube using the
minimum specified ultimate tensile strength of tube as indicated in certificates issued by the
tube supplier.
When tube material is to a specification which does not call for mechanical tests to be
performed, ultimate tensile strength of the tube material shall be considered as four times the
allowable stress at room temperature as indicated by the ASME Section II Part D, or other
relevant code.
Failure of the test piece at the weld shall not be a cause for rejection in case the minimum
strength is attained, but the fracture should be examined for any evidence of faulty
workmanship.
4.5 Vendor is advised to satisfy himself that the procedures employed are the best for the job and would
enable him to give workmanship guarantee for the equipment. Authorised Inspector’s approval
shall in no way relieve the vendor of his responsibility and guarantee to supply the equipment as per
the conditions of the purchase order.
5.0 WELDERS QUALIFICATION
The purpose of this operator qualification test is to demonstrate that both the welding operator and
the welding machines are capable of producing satisfactory joints. Once welding procedures have
been qualified as above, welding operators employed on welding shall be required to prove their
ability by making test samples similar to that prescribed above for welding procedure qualification.
Welding operators may be qualified based on para 4.4.d (i), 4.4.d (ii) and 4.4.d (iii) above only,
provided same welding machines & welding procedures are used. This welding operator
qualification test should also be carried out if the welding operator has not executed similar welding
six months prior to production. Repeat tests may be called for in the course of manufacture to
determine the consistency of operator or machine to produce sound welds.
6.0 PREPARATION OF TUBES AND TUBESHEET
6.1 Tube holes shall be to special close fit tolerance as per TEMA for shell and tube exchangers and as
per API 661 for air coolers. Tube holes shall be free from any burrs and the bundle side edge of
tube holes shall be chamfered or radiused. Tube holes shall have smooth finish to 63 AARH.
6.2 Prior to assembly, the tubesheet and tube ends (inside and outside for a distance equal to the
tubesheet thickness + 30mm) shall be cleaned and degreased to free from dirt, grease etc. It is
essential that the solvent used for degreasing be chloride free and sulfide free and non-residue
forming. The solvent should not lead to any possible fire hazard.
0
6.3 The tubes shall be positioned in the tubesheet by 30 tapered drift pin.
6.4 Before welding tube to tubesheet, the tubesheet shall be heated to a temperature as required to
remove any last traces of moisture or solvent, which may remain after the cleaning operation. Any
specific requirement for applications of preheat shall be established as a part of the welding
procedure qualification test and should account for increased restraint offered by the larger
assembly during production.
7.0 WELDING
Tubes shall be individually welded, using the procedure approved by the Authorised Inspector.
Systematic welding procedure shall be adopted so as to result in minimum tubesheet distortion.
All tubes are to have initial pass completely cleaned as necessary, visually examined and tested as
per para 8.1 below, if required, before subsequent layers are applied. Welds shall be suitably

Page 129 of 441
finished and any spillage or spatter on tubesheet removed. Spillage of weld metal into the bores of
tube is not permitted.
8.0 EXAMINATION OF JOINTS

2
8.1 Joints shall be subjected to air-soap solution test after first weld pass with air at 1.25 kg/cm (g).
Procedures outlined in ASME Section V Article 10 shall be followed.
8.2 After completion of welding, the tubesheet face, the welds and internal tube surfaces to a distance
of 25mm beyond the fusion line must be cleaned thoroughly by wire brushing and examined
carefully for surface defects. Defects such as cracks, surface breaking porosity, slag inclusions and
lack of fusion are not acceptable.
8.3 After the visual inspection, a liquid penetrant examination in accordance with ASME Section VIII
Division 1, Appendix –8 & Section V Article 6 shall be done. Before conducting this test, the faces
of the carbon steel tubesheet shall be cleaned thoroughly by wire brush and solvents to remove all
weld slag, rust and scale.
8.4 When specified on the drawings or requisition, a halide test shall be performed after the tests as per
para 8.1, 8.2 and 8.3 above have been successfully completed. Procedures for halide test shall be
as per ASME Section V, Article 10, Appendix – III Halogen diode detector probe test.
8.5 After the final tube expanding (refer para 9.0) has been completed, the liquid penetrant examination
as outlined in para 8.3 above shall be repeated.
8.6 Whenever a halide test has been specified, an envelope test shall also be done as a further test for
leaks after final tube expanding. For this test, tubesheet shall be securely wrapped in plastic sheets
and the shell shall be allowed to remain under test pressure with halogen tracer, for a period of 10
to 12 hours.
Then with the detection set at a maximum sensitivity, the probe shall be inserted through the plastic
cover at the bottom of the tubes sheet and readings taken to observe if any leakage has occurred.
8.7 Final acceptance hydraulic pressure test shall be conducted after tube expansion at hydrotest
pressure for at least one hour.
9.0 TUBE EXPANDING
After the tests outlined in 8.1, 8.2, 8.3 and 8.4 have been successfully completed and all leaking
welds repaired, the tubes shall be ‘contact expanded’ with a PARALLEL type expander. Contact
expanding is intended to bring the tube OD into contact with the tube hole. Contact expanding shall
begin 12mm from the tubesheet face and extend to 3mm from the back face. The contact
expansion shall have thinning of 3-5% which shall be ensured by measuring the inside diameter of
tubes.
10.0 REPAIRS
If leaks are found during any of the above testing procedures these shall be reported to Jacobs and
after obtaining written approval from Jacobs, repairs shall be made by removing the defects down to
sound parent metal and repeating the qualified weld procedures. All weld repairs shall be retested
in accordance with procedures outlined in para 8.0 above.
11.0 TEST AND REPAIR REPORTS
Test and repair reports shall be included in final documentation folder. These reports shall also
indicate the number of leaks discovered on each test and the extent of the repair done.

Page 130 of 441
APPINDEX-1
JOINT DETAILS

Page 131 of 441
APPINDEX-2
DETAILS OF TEST SPECIMEN

Page 132 of 441
Page 1 of 49

CHENNAI, INDIA
SPECIFICATION NO: 44NC-46 00-0000-V.02-0001-A4 1
TITLE: ENGINEERING DESIGN BASIS

STATIC EQUIPMENT
PROJECT REFERENCE:
- Project No: 44NC 4600
- Project Location: Manali, Chennai
- Project Title: Resid Upgradation project
- Client: Chennai Petroleum Corporation Limited

(WHERE APPLICABLE)
- Project Manager Authorisation: R. P. Gaikwad Date:
- Client Authorisation: Date:
REV ISSUE PAGES REV DESCRIPTION PREPARED CHECKED APPROVED

NO. DATE BY BY BY
A 02.03.2010 49 Issued for Client’s comments MS CR CR

Client’s comments incorporated
0 09.04.2010 49 & issued MS CR CR
Revised as marked & issued for
1 21.07.2010 49 feed SNK MS HSC
Page 134 of 441

CPCL, Chennai Engineering Design basis for Page 2 of 49
44NC-4600 Static Equipments Rev. 1
Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
CONTENTS
DESCRIPTION PAGE NO.
FOREWORD 3
SECTION-A (COLUMNS, VESSELS, TANKS & HEAT EXCHANGERS) 4
PART - 1 (OWNER'S REQUIREMENTS) 5
PART - 2 (DESIGN PHILOSOPHY) 11
SECTION B (TRAYS AND TOWER INTERNALS) 37
SECTION C (MECHANICAL EQUIPMENT) 56
ADDENDUM TO ENGINEERING DESIGN BASIS 63
FOREWORD
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
This document, titled ENGINEERING DESIGN BASIS, is intended to be a communication link between JE
and the owner to firm up the Engineering Design Parameters for a particular project, before the actual
start of engineering activities. Whereas the design basis shall provide for JE, requisite technical information
to complete the engineering design / specification on a once through basis with a minimum of revisions, for
the owner, this would present a general idea of standard design criteria/ philosophy followed in engineering by
JE.
This document is divided into three Sections.
SECTION - A (Columns, Vessels, Tanks & Heat Exchangers) : This Section is divided into two parts.
PART-1 : Comprising of a Questionnaire in which owners preferences and site

dependent details on certain technical parameters as requested had
been furnished by the owner. Incase of conflict, same takes
precedence over the standard design criteria/ philosophy covered in
part 2.
PART - 2 Describes the standard design criteria / philosophy intended to be

followed in engineering by JE for owner’s information.
SECTION - B (Trays and Tower Internals): This Section describes the design criteria / philosophy
intended to be followed by JE for engineering of Trays, Packings & Tower Internals.
In case the owner has any specific instructions on this design criteria / philosophy he is requested to furnish
these instructions in writing separately with cross reference to section and clause in question as an
'Addendum' to design philosophy in the format available at the end of this document.
This complete Engineering Design Basis document consisting of Section-A (Including both PART - 1 and
PART - 2) and Section-B along with addendum if any shall be duly signed and returned by the owner before
the start of Engineering by JE. Major/ significant changes to this document received after the start of the
project may result in the change of schedule and/ or additional engineering effort.
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
SECTION-A
(COLUMNS, VESSELS, TANKS & HEAT EXCHANGERS)
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
PART -1
(OWNER'S REQUIREMENTS)
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
VESSELS, STORAGE TANKS AND HEAT EXCHANGERS
A) Storage Tanks
1. Tank Bottom √ Cone up □ Cone down
2. External Painting √ Jacobs □ Owner's
Specifications Specifications
(Modified)
3. Painting of Internal √ Jacobs Specifications □ Owner's
Surfaces Modified) Specifications
4. Internal Floating Roof □ SS √ CS

Material
5. Type of Floating Roof √ Aluminum □ SS □ CS
(for conversion of
existing cone roof to
covered floating roof
6. Requirement of primary √ Yes □ No
drain for internal floating
roof tanks
7. Platform/Steps √ Grating (Electro forged □ Chequered plate

and bolted Type)
8. Gratings for Steps / □ Painted √ Hot dip galvanized incl. Bolting

Platforms
9. Hand Railing on Tanks □ GI Pipe bolted to √ CS with Painting

stairways, bolting also 0
hot dip galvanized.
10. Clean out Doors □ For tanks of all product √ For tanks of specific product, like
0
Crude, Slop & heavy products
11. Minimum size of

i) Shell manholes □ 20" √ 24" □ 30"
ii) Roof manholes □ 20" √ 24" □ 30"
12. Supporting Arrangement □ Self Supported √ Structurally guided by super imposed
for Cylindrical Column structure
< 1000mmdia.
13. Cathodic Protection For □ Required √ Not Required

Tank's bottom
(Unless tanks are
placed directly on
concrete foundations/
pile caps with no
intervening earth
Filling)
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
14. Camouflage painting □ Required √ Not Required

requirement meeting
Defense / Strategic
Location for Storage
Tanks
15. Under tank leak Required for H2SO4, √ Not Required
detection and subgrade □ Acetic acid service,
protection Caustic service.
B) Vessels/ Reactors
1. High Pressure □ Forged √ Plate

Reactors and Construction Construction.
Vessels
(Limited to 150
mm thickness)*
√ Clad plate
Weld deposit construction
For SS Lined construction
(Limited to 100
Reactors & Vessels
mm thickness)*
Buried Vessel √ Option -1 □ Option - 2 √ Option - 3

Installation, Painting
and Cathodic (Client's Requirements)
Protection
(Refer Annexure-1
to Engineering
Design Basis (EDB)
Questionnaire
C) Air Cooler
i) Air Cooler fan √ Aluminum □ FRP
blade material (Hollow Blades)
ii) Roof on air cooler □ Required

√ Not Required
tube bundle
D) Any other specific requirements of Owner (*)

i) For Vessels _______________________________________________
ii) For Tanks ________________________________________________
iii) For Reactors ___________________________________
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
ANNEXURE -1 TO ENGINEERING DESIGN BASIS (EDB) QUESTIONNAIRE OPTION-1
• The vessel should be located in a RCC pit and sand packed with vibro- compression, with100 mm
thickness of lean concrete on top. The pit shall have a minimum clearance of 2 meter all around the
vessel or as decided during detail engineering.
• Surface preparation and paint systems for different temperature ranges shall be as per the
recommendations given below.
• Cathodic protection shall be provided.
OPTION - 2
The vessel should be located in a RCC pit and sand packed with vibro compression, with 100 mm
thickness of lean concrete on top. The pit shall have a minimum clearance of 500 mm all around the
vessel or as decided during detail engineering.
• Surface preparation and paint systems for different temperature ranges shall be as per the
recommendations given below.
• No Cathodic protection shall be provided.
SURFACE PREPARATION AND PAINT SYSTEM FOR OPTION-1, 2
10 SURFACE PREPARATION
Blast cleaning to Sa 2½ finish of ISO 8501-1 or SSPC-SP-10 or SIS-05-5900 with a surface profile of 35-
50 microns of trough to peak.
20 PAINT SYSTEM
2.1 As per painting specifications
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
PART - 2
(DESIGN PHILOSOPHY)
Page 142 of 441

Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
CONTENTS:
10 REFERENCED PUBLICATIONS
a) Codes and Standards

b) Statutory Provisions
c) Publications
2.0 DESIGN PHILOSOPHY / GENERAL CRITERIA
2.1 Equipment Sizing

2.2 Minimum Shell/Head Thickness
2.3. Equipment End Closures
2.4 Design Pressure
2.5 Test Pressure
2.6 Design Temperature
2.7 Corrosion Allowance
2.8 Wind Consideration
2.9 Earthquake Consideration
2.10 Capacity
2.11 Supports
2.12 Nozzles and Manholes
2.13 Floating Roof
2.15 Flanges
2.16 Internals
2.17 Pipe Davit
2.18 Vent/Drain/Ventilation Nozzle Connections
2.19 Spares
2.20 MP Connection for PG/TI
2.21 Important Considerations
2.22 Heat Exchangers
2.23 Air Coolers
2.24 Bought Out Item Suppliers
30 DESIGN CRITERIA / REQUIREMENTS - SPECIFIC APPLICATIONS
3.1 Tall Columns

3.2 Storage Tanks
3.3 Mounded Bullet
3.4 Reactors
3.5 Heat Exchangers
3.6 Air Coolers
3.7 Usage of Existing Equipment
3.8 Transportation (Columns and Vessels)
TABLE-I : DETAILS AND WEIGHT OF COLUMN ATTACHMENT

TABLE-II : (ALLOWABLE STRESSES FOR COMBINED LOADING)
ANNEXURE -I : MATERIAL SELECTION
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
1.0 REFERENCED PUBLICATIONS
a) Codes And Standards 0
The following codes and standards with their edition including addenda shown here shall be followed unless
otherwise specified in the requisition for the design, fabrication, inspection and testing of Vessels,
Columns, Reactors, Spheres, Storage Tanks, Steel Silos, Bins, Hoppers, Steel Flare/Vents Stacks &
heat exchangers:
ASME SEC. VIII DIV. 1 Ed 2007, Ad 2009 For Pressure Vessels, Heat Exchangers
IS 2825 Ed 1969 (RA 2007) For Pressure Vessels
ASME SEC. VIII DIV. 2 Ed 2007, Ad 2009 For Pressure vessels and heat
exchangers (Selectively for high
pressure/high thickness)
ASME SEC VIII DIV 3 Ed 2007, Ad 2009 For very high pressure Vessel
ASME SEC. VIII DIV.2 Ed 2007, Ad 2009 For Storage Spheres
th
API650 11 Ed. Add Nov 2009 For Atmospheric Storage Tanks
th
API 620 11 Ed. Add 1, 2009 For Low Pressure Storage Tanks
IS : 6533 Part 1: Ed 1989 (RA 2005), For Steel Chimneys
Part 2: Ed 1989 (RA 2008)
ASME SEC. VIII Div. 1 Ed 2007, Ad 2009 For workmanship of Vessels not
categorized under any other code
BS : 4994/ASME SEC. X Ed 1987 / Ed 2007 Ad 2009 FRP vessels and Tanks
th
ISO16528 / IBR Ed 2007 / 11 Ed. 2010 For Steam producing equipment, steam
storage, catch water vessels, condensate
flash drums and similar vessels and BFW
OISD-STD 150/ PD Ed 2008 / Ed 2009 / Ed 2007 For Mounded Vessel
5500/ASME SEC. VIII DIV.2 Ad 2009
ASME B 96.1 Ed 1999 Welded Aluminum alloy storage tank
ASME SEC II / IS (As Ed 2007, Ad 2009 For material specification
applicable)
IS:875 - PART 3 Ed 1987 (RA 2008) For wind load consideration
IS: 1893 - PART 1 Ed 2002 (RA 2005) For seismic design consideration of new
equipments on totally new foundation
IS:1893 - PART 4 Ed 2005 For seismic design
ASME Sec. IX Ed 2007, Ad 2009 For welding
ASME B 16.5 Ed 2009 For flanges
ASME B 16.47 Ed 2006 For large diameter flanges
ASME B 16.20 Ed 2007 For gaskets
th th
TEMA CLASS-R / API 661 6 Ed / 9 Ed For shell and tube Exchanger / Air cooled
exchangers
ASME SEC.V Ed 2007, Ad 2009 For non-destructive testing
IS 800 Ed 2007 For Air cooled exchangers structural
design
IS 9178: PART 1 / PART 2 / Ed 1979 (RA 2005) / Ed For Steel Bins
PART 3 1979 (RA 2001) / Ed 1980
(RA 2001)
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
b) STATUTORY REQUIREMENTS
National laws and statutory provisions such as Indian Boiler Regulation and Chief Controller of
Explosives, Nagpur, India together with any local by-laws for the state shall be complied with.
Static and Mobile Pressure Vessel (SMPV) rules (CCOE), Petroleum rules, Factory Acts and
Rules, Environmental Protection Act & Rules etc. as applicable shall also be complied with. 1
INTERNATIONAL PUBLICATIONS
NACE MR 0103 2007 Materials Resistant to Sulfide Stress Cracking in

Corrosive Petroleum Refinery Environments
NACE TM 0296 2002 Evaluating Elastomeric materials in sour liquid
environment
NACE TM 0284 2003 Evaluation of Pipeline and Pressure Vessel Steel for
Resistance to Hydrogen Induced Cracking.
NACE TM 0177 2005 Laboratory Testing of Metals for Resistance to Sulfide
Stress Cracking in Hydrogen Sulfide Environment
NACE RP 0472 2008 Methods & controls to prevent in service cracking of
CS welds in P1 materials in corrosive petroleum
refining environments
WRC Bulletin # 107 2002 Local Stresses in Spherical & Cylindrical Shells due
to External Loadings
WRC Bulletin # 297 1987 Local Stresses in Cylindrical Shells due to External
Loadings on Nozzles
WRC Bulletin # 368 1991 Stresses in intersecting Cylindrical Shells subject to
pressure
API-RP-945 2003 Avoiding environmental cracking in Amine Units
(R2008)
2.0 DESIGN PHILOSOPHY / GENERAL CRITERIA
All design calculations shall be performed considering all applicable loads for Erection, Operating
and Hydro test conditions.
Equipment Sizing
a) All Columns Based on inside diameter
b) All Clad/Lined Vessels Based on inside diameter
c) Vessels (Thickness 50mm) Based on inside diameter
d) Tanks & Spheres Based on inside diameter
e) Reactors Based on inside diameter
g) Air Cooled Heat Exchangers Based on nozzle size and no. of tube rows
Minimum Shell/Head Thickness
Minimum thickness of equipment wall/components shall be as given below :
a) For carbon and low alloy steel vessels - 6mm (Including corrosion allowance not
exceeding 3.0 mm), but not less than that calculated as per following
FOR DIAMETERS LESS THAN 2400 mm
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Wall thickness = Dia. + 1.5 + Corrosion Allowance (if any)

1000
FOR DIAMETERS 2400 mm AND ABOVE
Wall thickness = Dia. + 2.5 + Corrosion Allowance (if any)

1000
All dimensions are in mm.
b) For stainless steel vessels and high alloy vessels - 3 mm, but not less than that calculated
as per following for diameter more than 1500mm.
Wall thickness (mm) = Dia. + 2.5 + Corrosion Allowance (if any)

1000
c) Vertical vessel with Height (TL to TL) / Diameter ratio greater than 5 shall be
considered as tall column and shall be designed accordingly. (Refer Clause 3.2)
d) For carbon steel, stainless steel, low alloy steel columns/towers & high alloy steel
columns/tower - 5mm (excluding corrosion allowance)
e) For shell & tube heat exchangers, minimum thickness shall be as per TEMA.
f) For Air Cooled heat exchangers, minimum thickness shall be as per API 661, however
minimum tube sheet thickness shall be 22mm (excluding corrosion allowance).
2.3. Equipment End Closures:
− Unless otherwise specified 2:1 semi Ellipsoidal Dished End shall be used for pressure vessels & heat
exchangers. Seamless dished end shall be used for specific services whenever specified by process
licensor.
− Hemispherical Ends shall be considered when the thickness of shell exceeds 70 mm.
− Flat Covers may be used for atmospheric Vessels
− Pipe Caps may be used for vessels diameter <= 600mm having no internals.
− Flanged Covers shall be used for Vessels/Columns of Diameter <= 900mm having internals.
− All columns below 900 mm shall be provided with intermediate body flanges. Numbers of intermediate
flanges shall be decided based on column height and type of internals.
Design Pressure
Unless otherwise specified elsewhere design pressure shall be calculated as per the following.
2
a) When operating pressure is up to and including 70 Kg/cm g.
2
Design pressure shall be equal to operating pressure plus 10% (minimum 2 kg/cm g)
2
b) When operating pressure is over 70 Kg/cm g.
2
Design pressure shall be equal to operating pressure plus 5% (minimum 7 Kg./cm g).
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
c) Design pressure calculated above shall be at the top of vertical equipment or at the
highest point of horizontal equipment.
d) The design pressure at any lower point is to be determined by adding the maximum
operating liquid head and any pressure gradient within the equipment (differential
pressure as mentioned in Process Data Sheet and catalyst loadings).
e) Equipment operating under vacuum/Partial Vacuum shall be designed for an external

2
pressure of 1.055 kg./cm g.
f) Equipment shall be designed for steam out conditions as specified by process data
sheet/piping. Equipment shall not be designed for Full vacuum if steam out conditions are
specified in process data sheet.
g) Minimum design pressure shall be 3.5 kg/cm2g for any equipment working above
atmospheric pressure 1
h) For vessels operating at ATM pressure minimum design pressure shall be ATM
h) Pressure chambers of combination units including heat exchanger shall be designed

for testing independently without pressure in the adjacent chamber in corroded
condition
2.5 Test Pressure
a) Equipment shall be hydrostatically tested in the fabricator's shop as per design code.
b) Equipment open to atmosphere shall be tested by filling with water to the top.
c) 1. Pressure Chambers of combination units that have been designed to operate

independently shall be hydrostatically tested to code test pressure as separate equipment
i.e. each chamber shall be tested without pressure in the adjacent chamber unless
otherwise specified in equipment data sheet.
2. When pressure chambers of combination units have their common elements

designed for maximum differential pressure, the common elements shall be
subjected to test pressure equivalent to the differential pressure multiplied by a
factor as per applicable design code.
3. Coils shall be tested separately to code test pressure.
d) Unless otherwise specified in applicable design code allowable stress during hydrotest
in tension shall not exceed 90% of yield point.
e) Storage tanks shall be tested as per applicable code.
2.6 Design Temperature
Unless otherwise specified elsewhere, design temperature shall be as per the following.
a) For vessels operating at 0 °C and over:-
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
Design temperature shall be equal to maximum operating temperature plus 15 °C subject

to a minimum of 65 °C.
b) For Vessels operating below 0 °C.
Design temperature shall be equal to lowest operating temperature.
c) Minimum Metal Design Temperature (MDMT) shall be lower of minimum

atmospheric temperature and minimum temperature envisaged during operation. MDMT shall
be as specified in Process Data Sheet.
2.7 Corrosion Allowance :
Unless otherwise specified elsewhere, minimum corrosion allowance shall be considered as follows:
Carbon Steel equipment : 3.0 mm*
Low alloy steel equipment : 1.5 (* 3 mm for shell & tube exchangers)
Stainless steel equipment : NIL

:
Clad equipment NIL (3 mm cladding minimum)
Lined equipment : 3.0 mm (plus lining)

:
CS Storage Tank bottom most shell 3.0 mm
course and bottom plate
CS Storage Tank shell (other courses) : 1.5 mm
Storage tank Fixed roof/ Floating Roof : As specified in process data sheet / Nil 0
CS Burried Vessels (External) : 1.5 mm
CS Spheres : 1.5 mm
* Except for tubes
For alloy lined or clad equipment, no corrosion allowance is required on the base metal. The cladding
or lining material shall be in no case less than 3.0 mm thickness and the same shall be considered as
corrosion allowance for the purpose of stress analysis.
Corrosion allowance for nozzles and manhole neck shall be at least equal to that specified for the
equipment. No Corrosion allowance is required for gasket seating face of girth flanges. However, for
non standard blind flanges of channel covers the corrosion allowance will be applied.
Wind Consideration
Wind load for equipment including anchor chair shall be calculated on the basis of IS 875 / site
data for skirt supported equipments, storage tanks, spheres, flare stacks and air coolers.
a) Drag coefficient for cylindrical vessels shall be 0.7 minimum.
b) Drag coefficient for spherical vessel shall be 0.6 minimum considering:
K1 = Risk factor 1.0 (for 50 years life)
K2 = Terrain category Factor based on category 3 (for units) and factor based on
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
category 2 (for off sites)
K3 = Topography Factor based on site topography =1.0
Contingency factor of 1.1 shall be used on wind pressure
2.9 Earthquake Consideration:
For seismic design consideration of new equipments which are replaced on the existing old
foundation, Earthquake loads shall be calculated in accordance with IS:1893- 1984/Site data.
For seismic design consideration of new equipments on totally new foundations (i.e. skirt
supported equipments, storage tanks, spheres and air coolers) Earthquake loads shall be
calculated in accordance with IS:1893 (Latest), if site specific acceleration spectra is not
specified in the project specification.
2.10 Capacity
2.10.1 Tank
Capacity shall be specified as Nominal capacity and stored capacity. Nominal capacity for fixed
roof tanks shall be volume of cylindrical shell.
Stored capacity for fixed roof tanks shall be equal to nominal capacity minus free board volume
(equivalent to 500mm of shell height).
Nominal capacity (also the stored capacity) for floating roof tanks shall be volume of cylindrical
shell minus free board volume (equivalent to 1500mm of shell height).
Nominal capacity (also the stored capacity) for fixed cum floating roof tanks shall be volume of
cylindrical shell minus free board volume (equivalent to 2500mm to 3000mm of shell height for
tanks with vent / overflow slot in shell.).
2.11 Supports
2.11.1 Skirt supports shall be provided for all tall columns {Refer Cl. 2.2 (c)} and reactors. However,
small vertical equipment may be supported on legs (pipe or structural section) or brackets. All
horizontal vessels and exchangers shall be supported on two or more saddles depending on Weight &
Length of the equipment. 1
2.11.2 All Cr-Mo steel reactors shall be supported on skirts.

Welding of external clips on Cr-Mo steel Reactors shall be avoided wherever possible.
2.11.3 Skirt Thickness
The thickness for the skirts inclusive of corrosion allowance shall be the maximum of following:
a) 6 mm.
b) Thickness required by analysis.
c) 30 mm or 1/3 of the vessel wall thickness whichever is lower.
Corrosion allowance of total 1mm minimum shall be considered for skirt unless otherwise specified
in the project specifications to achieve final thickness of skirt shell.
2.11.4 All columns with diameter 1000 mm and more shall be self supporting.
2.11.5 All columns with diameter < 1000 mm shall be supported by superimposed structure
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
around the column covering the entire height. Guy wires are not permitted to be used for
supporting any equipment.
2.11.6 In specific cases, columns having diameter < 1000 mm and total L/D ratio not
exceeding 10 may be self supported.
2.11.7 Flare and Vent stacks shall be supported structurally by super imposed structure all around for the
entire height.
2.11.8 Buried vessels shall be suitably anchored to prevent the uplift due to under ground water.
Anchor bolts shall have corrosion allowance of 6 mm on diameter. Buried vessels shall be
rested on concrete saddles with anchoring bracket at the center line of the vessel.
2.11.9 All skirt supported columns/equipments with height 20 m and above (irrespective of weight) and
weight 50 MT and above (irrespective of height) are to be provided with tailing lug.
2.11.10 All round platform for operation & maintenance on the top of columns and vertical vessels with davit
for all tall columns as per Jacobs standard 0 1
2.12 Nozzles and Manholes:
2.12.1 Nozzles:
a) Nozzle rating for all the pressure containing equipment (Vessels, Reactors, heat
exchangers, Air Coolers etc.) shall be as per PDS. However for all instrument nozzles
flange rating shall be min #300 0
b) Minimum nozzle sizes shall be as below:
• Process & Instrument Nozzles on Unclad Vessel : 40 NB

• Process & Instrument Nozzles on Cladded Vessels : 80 NB
• Draw off sumps shall be provided for all storage tanks.
2.12.2 Manholes:
a) Vessels and columns with diameter up to 1000 mm shall be provided with 500 NB manhole.
Vessels and columns with diameter greater than 1000 mm and up to 1500
mm shall be provided with 500 NB manhole. However, if required, vessels and
columns with diameter above 1500 mm shall be provided with 600 NB manhole.
b) High pressure reactor manholes i.e. DHDS/ DHDT/ OHCU/ Isomerization Reactor/
CCR shall be on I.D. basis. Size shall be as per Licensor drawing.
c) For storage tanks minimum number of manholes (size 600mm) shall be as follows:
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Tank diameter Shell manhole Flush type clean out Roof manhole
fittings
(if specified)
Dia. ≤ 12 m. 2 1 2
> 12m <Dia. ≤ 45m dia 2 1 2
45m < Dia. ≤ 61m. 3 2 2
Dia. > 61m 4 2 2
Notes: 1) In the deck of floating roof tank one number additional 30" NB manhole with internal
ladder shall be provided on floating roof as per fabricator's standard.
2) Tank Manholes including bolting and gaskets shall be as per API 650.
d) Clean out doors shall be provided as per client's / process requirements and Size of clean
out doors fittings for tanks shall be 36" (900 mm) x 48" (1200mm).
e) Vessels should have minimum 2 man-way nozzles.
2.13 FLOATING ROOF
2.13.1 Floating roof shall be of following construction unless specified otherwise.
Tank diameter Type of floating roof

External Internal
≤ 12 m Double deck type Double deck
≥ 12 m < 60 m Pontoon type Pontoon type
≥ 60 m Double deck type Double deck
2.14 Minimum Nozzle Size For Vessels And Their Basis:
Minimum Nozzle Size : 40 NB
Minimum Nozzle Size for Clad Equipment : 80 NB*
Safety Valve Nozzle : Based on I.D.

:
Self Reinforced Nozzle neck Based on I.D.
* Except for MP connection on heat exchanger nozzle where it will be 50 NB
2.15 Flanges
2.15.1 Nozzle flanges up to 600 NB shall be as per ASME/ANSI B16.5 and above 600 NB shall be
as per ASME/ANSI B 16.47 (SERIES 'B') except that for high pressure heat exchanger. Non
standard flanges shall be designed as per ASME Sec. VIII Div. 1
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2.15.2 Unless otherwise specified, W.N. Flanges shall be used for all classes.
2.15.3 Unless otherwise specified, all girth flanges and intermediate body flanges shall be of weld
neck type only.
2.15.4 Flange rating shall be established based on design pressure, design temperature and
considering all external loads (moments and axial force).
2.15.5 For high pressure (> 60 bar) and high temperature service, flange bolting shall be through the
use of torqued or tensioned bolts. No manual bolting is envisaged.
2.16 Internals :
Unless otherwise specified removable internals shall be bolted type and material of bolting shall
be stainless steel TP 304. For shell & tube heat exchangers, floating head bolting shall be
compatible to shell material. Bolting SA 193 Gr. B7M/2HM shall be used as a minimum.
2.17 Pipe Davit:
i) Vertical Vessel/Column having safety valve size >= 80 NB and or having

internals shall be provided with pipe davit as per Jacobs standard 1
ii) Deleted 0
2.18 Vent/Drain/Ventilation Nozzle connections:
i) Vessel shall be provided with one number vent/drain connection as per following
unless otherwise specified in process data sheet:
Vessel Volume (V), Length of Vent Drain Ventilation

3 Nozzle
m (Horizontal Nozzle Nozzle
Vessel) (L),mm
V<6. 0 - 40 NB 40 NB -
6.0<V< 15 - 50 NB 40 NB -
V>15 - 50 NB 80 NB -
- 3000mm<L<4500 mm - 100 NB
- 4500mm<L< 7500 mm - 150 NB

L>7500mm 200 NB
i) Vertical vessel not having any nozzle on the top shall be provided with 50 NB nozzle for
conducting hydro test in vertical conditions.
ii) Exchanger shall be provided with vent and drain connection as per P&ID or 40 NB vent /
drain nozzle connection with blind flange etc. if not shown in P&ID (Separate vent and drain
will not be provided if vented / drained by other nozzle
For clad exchangers, minimum size of vent and drain nozzle connection shall be 50 mm
NB LWN
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
2.19 Spares
2.19.1 Mandatory Spares

i) Vessels & Columns
Gaskets Two sets for each installed gasket.
Fastener 10% (Minimum two in each size) of installed
fasteners
Sight/Light Glass 4 sets for each installed glass
ii) Shell & tube Exchangers
Gaskets 400%
Bolting 20% (Min. 4 studs and 8 nuts per joint)
iii) Air coolers
a) 400% for gaskets (for headers & blinded flanges)
b) 200% gaskets for plugs
c) 20% plug
d) 100% belts
e) 20% (minimum 4) studs and nuts for each pair of cover header and nozzles
with blinded flange
f) 100% Bearings
g) One blade for each size / type of fan
h) 1 set of Diaphragm Actuator with positioner for each type of auto variable
pitch fan (for Moore fans) (Alternatively vendor recommended spares for his
type of auto variable pitch fans for make other than Moore).
Variable Speed Drives (If applicable)

(One set of spares for each rating of VSD)
Rectifier Control Module 1 Set

Thyristor module 1 Set
Inverter control unit 1 Set
IGBT driver card 1 Set
IGBT 10% with min. 1 No. for each rating of IGBT
PCB of each type 1 No.
All fuses (Power & Control) 20% or 1 Min for each rating of fuse.
Control cards One set
Power supply card One set / 1 No. of each type and rating
Relays 10% with min. 1 No. for each type of relay
Contactors 10% with min 1 No. for each rating of contactor
Man machine interface One set
CT / PT One No. for each type & rating
Cooling fans One set / 1 no. of each rating
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
Limiters & protection devices One set

Indicating lamps 20% with Min. 3 Nos
Induction Motors (If applicable)-37kW and above
Bearing set (DE & NDE) 1 no. for each type
Terminal studs / bushing assembly 1 no. for each type
External cooling fans 1 no. for each type
DE / NDE end shields 1 no. for each type
2.19.2 Commissioning Spares:
i) Reactors and Columns :
Gaskets 100% (For Manways, Interconnecting
Nozzles, and nozzles with blind
Flange).
Fasteners 10% (Minimum two in each size) of installed
fasteners.
ii) Shell & tube Exchangers 200% Gaskets
iii) Air Coolers
Plug/ Header Gaskets 30 % (Min 1 no) of Installed quantity)
Plugs 10%
Belts 50%
2.19.3 MP Connection for PG/TI

i) Shell & Tube heat exchangers For Clad Exchangers
1 no. 50mm NB LWN nozzle with BF on each
inlet/outlet nozzle. If it is not possible to provide
on inlet/outlet nozzle, then it shall be provided
on main shell/channel close to main nozzles.
Rating shall be as per PDS with min #300 0
Others (Non Clad)
One no. 40NB nozzle with blind on each
inlet / outlet.
ii) Air Cooler: One on one of the inlet & one on one of the
outlets of each header, size 40NB nozzle with
BF etc. If it is not possible to provide on process
nozzle then it shall be provided on header.
Page 154 of 441

Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
2.21 Important Considerations
Vessels and columns shall be designed considering maximum operating liquid head in addition to
design pressure.
All columns and vessels shall be capable of withstanding water full condition during system testing.
In addition, all vertical vessels, columns and Horizontal vessels shall be designed so as to permit site
testing of the equipment with water at the test pressure on the top of the equipment considering 33%
of design wind load. The design shall be based on fully corroded condition.
All equipment foundation shall be designed and constructed for water full condition when equipment
is new with 33% of design wind load.
Vessels and columns shall be tested at shop hydrostatically at pressure calculated as per applicable
code in new and cold condition.
Seismic design shall be carried out based on site spectra of IS 1893, if furnished..
Design of components not covered in IBR (Indian Boiler Regulations) shall be in accordance with
ASME SEC VIIIDIV I.
All stress analysis, local load analysis etc. shall be carried out for critical equipments only.
All nozzle necks, all nozzle flanges and blind flanges shall be of weld deposit construction for clad
equipments. Loose liners are not permitted.
All vertical equipment shall be provided with two lifting lugs. Lifting lugs shall be designed with impact
factor of two.
Mechanical design of self supporting Tall Columns /Tower shall be carried out for various load
combinations as per Clause 3.2
Material of various parts of equipment shall be selected as per Table given in Annexure-I unless
otherwise stated on process data sheet.
Stress analysis shall be carried out for nozzle to shell junction using maximum shear stress theory for
vessels and columns. Allowable stress intensity shall be as per ASME SEC VIII Div 2.
Stress analysis of shell to skirt junction shall be carried out using maximum shear stress theory for
vessels and columns designed as per ASME SEC VIII DIV 2. In case skirt shell joint is of butt welded
construction, the same shall be 100 % radiographed.
Projection of vacuum stiffening rings, on insulated vessel shall be less than insulation thickness
wherever possible. Alternatively, the stiffening rings shall be covered with insulation & cladding.
Page 155 of 441

Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
2.22 Heat Exchanger
1. Tube Sheet type for floating head and Non-extended for floating head.
U tube heat exchanger Extended for Stab in bundles only of 'B' type
stationary head of U tube exchangers
2. Testing accessories for shell and tube 1) Testing rings shall be provided on all floating 'S'
Heat Exchanger & 'T' head type exchangers.
2) Dummy shell shall be provided for fixing test
ring for exchangers such as kettle type or floating
head without shell covers (TEMA 'AHT' or
'AKT') or stab in bundle where shell design
pressure is higher than tube side pressure
3) Test flanges shall be provided
(i) For exchangers with removable bundle
and bonnet type channel
(ii) For exchanger with removable bundle
and channel with flat cover if tube side
pressure is greater than shell side pressure.
4) Minimum number of test rings/ test
flanges/dummy shells shall be at least one
per set of three bundles.
5) For shell side interconnected and stacked
exchangers the minimum number of test rings
shall be equal to the number of exchangers in one
stack.
6) For 'U' tube & removable bundle exchanger,
number of test flanges shall be equal to number
of exchangers in one stack.
3. Cathodic Protection Anodes and painting shall be provided wherever

specified in thermal data sheets/ process data sheet.
4. Maximum Tube-bundle Weight and

diameter Weight – 14000 kg 0
Diameter – 1500 mm
5. Preferred Tube Dimensions Tube OD – 25 mm
Minimum wall thickness – 2.5mm for KCS / CS
2.1mm for KCS / CS
(IBR)
2.0mm for SS
Tube Length – 6.0 m
6. Gaskets Spiral Wound or Cam Profile only
7. Clear distance between edge of 300 mm

foundation and back of girth flange
Page 156 of 441

Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
2.23 Air Coolers
1. Noise level The noise level shall be limited to 85 dB(A) max.

measured at a distance of one meter from the bundle
at the header access platform walkways and one
meter from the bay limit on motor maintenance
platform. The noise level within the air cooler bay
shall be 90 dB(A) maximum, at locations defined as
per API.
2. Type of Drives ( Speed HTD/PGGT of GATES or Torque Drive plu belts of
reducers) FENNER, UK up to 40KW. Gear drive above 40 KW.
3. Access Platform Shall be provided wherever possible on all the four

sides, (width - 900 mm) with stairs on one
side and ladder on other side.
4. Maintenance Platform Full steel platform duly inter-connected along

full length and width of both air coolers for
fan/motors etc
5. Protective Covering (for finned By heavy duty wire mesh
tubes) on bundle top
6. Hot dip galvanizing of air cooler
structurals As per structural design basis
7. Final Painting of header box All header boxes shall be finally painted at vendor’s
shop.
8. Headroom below motor 2.2 m

9. Vibration Measurement Accelerometer of 100 mV/G shall be mounted on the
fan bearing housing and cabled to a junction box at
a accessible location and provided with MIL-C-5015
2 pin connector
2.24 Bought Out Item Suppliers:
1. Fans from Cofimco or Hudson or Moore.
2. Belts from Gates or Fenner
3. Vibration Switches from First Inertia Switches or Metrix USA
Page 157 of 441

Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
30 DESIGN CRITERIA / REQUIREMENTS - SPECIFIC APPLICATIONS
3.1 Tall Columns
Vertical vessel with Height (TL to TL) / Diameter ratio greater than 5 shall be considered as tall
column.
Mechanical design of self supporting tall column and its anchorage block shall be carried out
considering combination of various loads.
3.1.1 Loadings
The loadings to be considered in designing a self supporting tall column/tower shall include:
(i) Internal and or external design pressure specified on process data sheets.
(ii) Self weight of column inclusive of piping, platforms, ladders, manholes, nozzles,
trays, welded and removable attachments, insulation and operating liquid etc. The
weight of attachments to be considered shall be as per Table-I enclosed.
(iii) Other loadings as specified in UG-22 of ASME Code Sec. VIII Div. 1, wherever
applicable.
(iv) Seismic forces and moments shall be computed in accordance with IS 1893 (latest
edition) unless otherwise specified in project specification. Unless otherwise
specified importance factor and damping coefficient shall be considered as 2 and 2%
respectively. Soil / foundation factor shall be considered based on soil/foundation of the
equipment.
(v) Basic wind pressure and wind velocity (including that due to winds of short duration
as in squalls) for the computation of forces/moments and dynamic analysis
respectively shall be in accordance with IS 875 (latest edition). Additional wind loading
on column due to external attachments like platforms, ladders, piping and attached
equipment should be given due consideration.
(vi) Loadings resulting in localized and gross stresses due to attachment or mounting of
reflux / reboiler, condenser, etc.
3.1.2 Loading Condition
Analysis shall be carried out for following conditions :
(i) Erection Condition Column (un-corroded) erected on foundation, without insulation,

platforms, trays etc. but with welded attachments plus full wind on
column and thermal load
(ii) Operating Condition Column (in corroded condition) under design pressure, including
welded items, trays, removable internals, piping, platforms,
ladder, reboiler mounted on column, insulation and operating
liquid etc. plus full wind on insulated column with all other
projections open to wind, or earthquake forces.
(iii) Test Condition Column (in corroded condition) under test pressure, filled with
water plus 33% of specified wind load on un-insulated column
including all attachments shall be considered.
(iv) Earth quake And Wind Shall Be Considered Not Acting Concurrently.
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
3.1.3 Deflection of Column
Maximum allowable deflection at top of column shall be equal to height of the column divided
by 200 up to a maximum of 300 mm.
(i) If the deflection of column exceeds the above allowable limit, the thickness of skirt shall
be increased as first trial upto a maximum value equal to the column thickness and this
exercise shall be stopped if the deflection falls within allowable limit.
(ii) If the above step is inadequate, skirt shall be gradually flared to reduce the deflection.
Flaring of skirt shall be stopped if the deflection falls within limits or half angle of cone
reaches maximum limit of 9.
(iii) If the above two steps prove inadequate in limiting the deflection within allowable limits,
the thickness of shell courses shall be increased one by one starting from bottom course
above skirt and proceeding upwards till the deflection falls within allowable limits.
3.1.4 Stress Limits
The stresses due to pressure, thermal load /weight, wind/seismic loads shall be combined using
maximum principal stress theory for ASME Section VIII Div. I. Thicknesses are accordingly
chosen to keep the stresses within limits as per Table-2.
3.1.5 Skirt Support Base
Base supporting including base plate, anchor chairs, compression ring, foundation bolting etc.
shall be designed based on over-turning moment (greater of seismic or wind). A minimum
number of 8 foundation bolts shall be provided. Nos. of foundation bolts shall be in multiple of
four. Foundation bolts with sleeve may be considered.
3.1.6 Minimum Hydro test Pressure
Minimum Hydro test Pressure (in Horizontal position) shall be equal to Q x design pressure x
temperature correction factor, as specified in ASME Code Section VIII Div.I /Div.2, at top of
column unless specified otherwise, where Q is a factor depending on code of construction.
3.1.6 Dynamic Analysis of Column/Tower
Dynamic analysis of each column shall be carried out for stability under transverse wind
induced vibrations as per standard design practice.
3.2 Storage Tanks
3.2.1 All storage tanks shall be designed as per code considering liquid height upto top curb-angle
of shell.
3.2.2 Tanks shell thickness calculation shall be carried out by the one (1) - foot method as per API
650 for tank diameters less than and equal to 60m (200 feet).
3.2.3 Maximum height of un-stiffened shell shall be calculated based on the corroded thicknesses of
shell courses. Section modulus of wind girders shall also based on corroded thickness of shell
courses.
3.2.4 Seismic design as per API 650 (Appendix-E) is mandatory for storage tanks.
3.2.5 Annular bottom plates shall be provided for all storage tanks of 12 meter diameter and above.
3.2.6 Anchor bolts shall be provided based on design considering wind/seismic loads, uplift due to
Page 159 of 441

Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
internal pressure etc. However, tanks having diameter <=1 0 meter shall be provided with
anchor bolts and shall be spaced at approximately 1.8M of circumference.
3.2.7 Tanks having design temperature more than 100 °C shall have thermal isolation barrier
(suitable fire bricks) between tank bottom and foundation.
3.2.8 All platform gratings and stairway grating steps (anti skid type) shall be hot dip galvanized and
the same shall be bolted to the frame / stringer. No welding is permitted on grating. All hand
railing shall be of CS pipe welded to stairway. 0
3.2.9 Pipe davit for cone roof / dome roof as well as floating roof tanks near stairway to platform shall
be provided for loading and unloading roof appurtenances. Pipe davit shall be preferably located
at the roof main truss location with provision of suitable size of stiffening member inside the cone
roof tank. If davit is located at some other location suitable stiffening member shall be provided.
Minimum capacity of pipe davit shall be 500 kg.
3.2.10 Stairway for all tanks shall be provided on upstream of predominant wind direction for safety of
fire fighting personnel.
3.2.11 All instruments shall be located near the platform for easy maintenance.
3.2.12 Cone roof, dome roof tanks shall have approach to the centre with roof treads (removable
gratings) along with hand railings.
3.2.13 If applicable, Amine (DEA & MEA) tanks, Caustic tanks (irrespective of concentration), Sour
water tanks shall be fabricated from Sa 516 Gr. 60 materials for all components (Shell, bottom,
roof and reinforcing pads). Roof and bottom shall be of butt welded construction. All shell joints
shall be 100% radiographed and all flanges shall be WNRF flanges. These tanks shall be post
weld heat treated and hardness measurement shall be made on HAZ and weld metal at the
interval of 300 mm for each ring and value shall not exceed 200 BHN.
3.2.14 Top of pontoon surfaces between foam dam and outer rim for floating roof tanks shall be
provided with anti-skid arrangement.
3.2.15 Erection of tanks by hydraulic jacking method is preferred.
3.2.16 Bottom slope (apex down) of 1:100 (in general) or bottom slope (apex up) of 1:100 (in general)
shall be provided for tanks as indicated in process data sheet
3.2.17 Top landing platform shall be visible from main road 0
3.3 Reactors
a) The design shall be done based on Process Licensor's Specifications.
b) Material selection shall be strictly be as per Licensor's Specification.
Minimum thickness as per Licensor's Specification shall be adhered to.
c) MDR & UDS as per ASME Code shall be obtained by the Fabricator for Reactors
designed and stamped as per ASME SEC. VIII Div. II.
d) FEM Analysis shall be done for all Process nozzles, shell to head junction Y shaped
skirt, welded/weld over-layed support rings and any other stressed point as defined in
Licensor's specification.
e) All internals shall have minimum thickness as given in Process Licensor's Specification
and shall be designed for loads defined in Licensor's drawings.
f) Thermal analysis for HOT box shall be conducted.
g) Reactors as well internals shall be fabricated by Process Licensor's approved Vendors.
h) Lifting arrangement shall be as defined by Process Licensor's drawings
i) Floating type insulation supports shall generally be provided wherever feasible.
Page 160 of 441

Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
j) Reactors shall be ASME code stamped if required as per process data sheet.
3.4 Heat Exchangers
Mechanical design of heat exchangers shall preferably be done by internationally wetted

accredited and certified software.
For Vendor designed equipment, mechanical design of heat exchangers shall preferably be
done by internationally wetted accredited and certified software.
3.5 Air Coolers
Mechanical design of heat exchangers shall preferably be done by internationally wetted

accredited and certified software.
For Vendor designed equipment, mechanical design of heat exchangers shall preferably be
done by internationally wetted accredited and certified software.
3.6 Usage of Existing Equipment
3.6.1 Shell & Tube and Air Cooled Heat Exchangers
a) Adequacy checking of the existing exchangers w.r.t. the revised process/ design
conditions, shall be carried out based on the following:
i) Dimensions available in the As-Built drawings, if As-Built drawings are

available.
ii) Dimensions available in the thermal design data sheets, if As-Built drawings are
not available.
If both As-Built drawings and thermal design data sheets are not available &
mechanical design pressure and / or temperature, due to revised process
condition, exceeds the original design parameters, then new exchangers shall
be provided to replace the existing exchangers.
b) Client shall furnish As-Built drawings for existing exchangers (which are to be
checked for adequacy) and As-Built isometrics of thermo-syphon re-boilers.
c) Health check of the existing exchangers shall be carried out by Client. Mechanical
adequacy checking shall be done on the basis of available thickness of components.
In absence of Health check report, adequacy checking shall be carried out based on
thickness of components indicated in the As-Built drawings, considering no reduction in
thickness of components over the years during operation.
d) Client shall indicate if any of the existing exchangers have already undergone any
modification from the As-Built drawings. Otherwise, adequacy checking shall be
carried out based on As-Built drawings, considering no modification over the years
during operation.
e) Client shall check and inform plugging of tubes & damages to the existing
exchangers, if any.
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
f) Mechanical adequacy checking of existing equipment shall be carried out as per the
design code for which equipment is designed. 0
3..6.2 Columns and Vessels
a) Adequacy checking of the existing columns & vessels w.r.t. the revised process/
design conditions, shall be carried out based on the dimensions available in the As-
Built drawings, if As-Built drawings are available.
If As-Built drawings are not available & mechanical design pressure and / or
temperature, due to revised process condition, exceeds the original design parameters,
then new columns & vessels shall be provided to replace the existing columns &
vessels.
b) Client shall furnish As-Built drawings for existing columns & vessels (which are to be
checked for adequacy).
c) Health check of the existing columns & vessels shall be carried out by Client.
Mechanical adequacy checking shall be done on the basis of available thickness of
components.
In absence of Health check report, adequacy checking shall be carried out based on
thickness of components indicated in the As-Built drawings, considering no reduction in
thickness of components over the years during operation.
d) Client shall indicate if any of the existing columns & vessels have already undergone
any modification from the As-Built drawings. Otherwise, adequacy checking shall be
carried out based on As-Built drawings, considering no modification over the years
during operation.
e) Mechanical adequacy checking of existing equipment shall be carried out as per latest
ASME codes.
3.7 Transportation (Columns and Vessels)
Columns and Vessels shall be transported in single piece.
For large vessel/ column which can not be transported in single piece from the shop, following
methodology shall be adopted:
• The vessel /column shall be fully fabricated with additional length and fully hydro
tested at shop.
• The vessel/ column shall be cut into number pieces as approved with exact dimensions
(Max 2 site welds)
• Transported to site, fit up, fabrication welding carried out, 100% radiography of the weld
joints taken apart from other QC activity. Limpet coil hydro testing carried out.
• Limpet coil is cut and removed later on.
• Additional cleats to be welded on the equipment for erecting temporary platforms
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
TABLE-I
DETAILS AND WEIGHT OF COLUMN ATTACHMENT
1. SHAPE FACTOR FOR SHELL (FOR WIND 0.7

FORCE CALCULATION)
2
2. WEIGHT OF TRAYS (WITH LIQUID) TO BE 120 KG./M
CONSIDERED.
3. WEIGHT OF PLAIN LADDER 15 KG./M
4. WEIGHT OF CAGED LADDER 37 KG./M
5. EQUIVALENT PROJECTION TO BE 300 MM

CONSIDERED FOR WIND LOAD ON CAGED
LADDER
6. DISTANCE OF PLATFORM BELOW EACH APPROX. 1000 MM

MANHOLE
( REFER PIPING DESIGN BASIS)
7. MAXIMUM DISTANCE BETWEEN CONSECUTIVE 5000 MM

PLATFORMS
8. PROJECTION OF PLATFORM ( REFER PIPING 900 MM UPTO 1 METER DIA.

DESIGN BASIS) COLUMN AND 1200 MM FOR
COLUMN DIA. >1 METER, FROM
COLUMN INSULATION SURFACE
9. EQUIVALENT HEIGHT OF PLATFORM (FOR

WIND LOAD COMPUTATION) 1000 MM
1.0
SHAPE FACTOR FOR PLATFORM
2
10. 170 KG/M
WEIGHT OF PLATFORMS
11. FOR TOP & BOTTOM, PLATFORM SHALL BE CONSIDERED AS ALL AROUND
PLATFORMS. ALL INTERMEDIATE PLATFORMS SHALL BE TAKEN AS SEGMENTAL.
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
TABLE-II
(ALLOWABLE STRESSES FOR COMBINED LOADING)
VESSEL CONDITION/TEMP. TYPE OF CONDITIONS

STRESSES
ERECTION OPERATING TEST
NEW OR CORRODED NEW CORRODED CORRODED
TEMPERATURE AMBIENT DESIGN AMBIENT
LONGITUDINAL KxSxE KxSxE 0.90xY.PxE
LONGITUDINAL COMPRESSIVE KxB KxB B

STRESS
Where
S = Basic allowable Tensile Stress as per Clause UG 23(a) of ASME Code Sec. VIII Div.1.
B = 'B'value calculated as per Clause UG-23(b).
E = Weld joint efficiency of circumferential weld, depending on extent of radiography.
K = Factor for increasing basic allowable value when wind or seismic load is present.
The following table gives general guidelines for material selection for various Pressure Parts/Non
Pressure Parts of the equipment based on design temperature wherever material of construction is
not specified by the process licensor.
Note : Allowable stresses in skirt to shell joint shall be as per following :
a) 0.49S, if joint is shear type.
b) 0.70S, if joint is compression type
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
MATERIAL SELECTION ANNEXURE-I

The following table gives general guidelines for material selection for various Pressure Parts/Non Pressure Parts of the
equipment based on design temperature wherever material of construction is not specified by the process licensor.
PRESSURE PARTS NON PRESSURE PARTS
DESIGN PLATE PIPE TUBES, FORGING BOLTS/ STRUCTURAL INTERNAL STUDS TIE RODS
TEMP.°C
(SEE NOTE SPACERS (SEE NOTE STUDS/ ATTACHMENT PIPES BOLTS
8) (SEE NOTE- 12) NUTS WELDED TO NUTS
EXTERNAL PRESSURE INTERNAL
11) (SEE NOTE PARTS, BAFFELS,
13) SUPPORTS, TIE
RODS, SEALING,
SLIDING STRIPS
ETC.
CRYOGENIC
FROM-254 SA240 SA312 SA213 SA 182,GR F SA320
UPTO-196 GR.304L,304, TYPE 304 TYPE 304 304,304L,316 GR B8,8C,8T

316,316L 304L,316, 304L,316, 347,316L STRAIN
347 (IMPACT 316L,347 316L,347 HARDENED
TESTED)
SAME AS PRESSURE PARTS
ABOVE-196 SA240 SA312 SA213 SA 182,GR F SS GRADE
UPTO -80 GR.304L,304, TYPE 304 TYPE 304 304,F304L, SA194GR.S, SAME AS
316,316L 304L,316, 304L,316, F316L,316 8C,8T TUBES
321,347 316L,321, 316L,321, 321,347,
347 347
SA 353/553 SA333GR.8 SA334 SA522
GR.A GR.8
LOW TEMPERATURE
ABOVE -80 SA 203 GR E SA333GR.3 SA334GR.3 SA350 SA 320 L7 SA 203 GR E SA333GR.3 SA193GR.B8 CS KILLED
UPTO -60 IMPACT GR.LF3 SA194GR.4

TESTED (SEE ORGR7 SA 194 GR.8
NOTE-1)
ABOVE -60 SA537CL.1 SA333GR.3 SA334GR.3 SA350 SA 320 L7 SA 537 CL.I SA333GR.3 SA193GR.B8 CS KILLED
UPTO -45 IMPACT GR.LF3 SA194GR.4

TESTED(SEE ORGR7 SA 194 GR.8
NOTE-1)
ABOVE -45 SA 516 (ALL SA333GR.6 SA334GR.6 SA350 SA 320 GRL7 SA-516(INALL SA333GR.6 SA193GR.B8 CS KILLED
UPTO -29 GRADES) ORGRI ORGRI GRLF2 SA194GR.4 GRADES)

IMPACT ORGR7 SA 194 GR.8
TESTED (SEE
NOTE-I)
ABOVE -29 SA 516 (ALL SA 106 GR.B SA334GR.6 SA105/ SA-193GRB7 SA-516(INALL SA 106 GR.B SA-193GR.B8 CS KILLED
UPTO 0 GRADES) (SEE NOTE OR1 SA266 SA-194GR2H GRADES)

(SEE 3) (SEE NOTE 3) (SEE NOTE 3) SA-194GR.8
NOTE-3)
INTERMEDIATE TEMPERATURE
ABOVE 0 SA 516 (ALL SA 106 GR.B SA179 SA-105 SA-193B7 IS-2062 SA 106 GR.B SA-193GR.B8 IS- 2062
UPTO 343 GRADES) SA-266 SA-194GR2H (PLATES) (WELDABLE

SA-194GR.4 QUALITY)
SA 240 TYPE SA-312 SA-213 SA182F SA-193B7 SAME AS SA 106 GR.B SA-193GR.B8 SAME
304L,316, 321 TP 304L TP 304L 304L,316L, SA-194GR2H PRESSURE PARTS GRADE AS

(SEE NOTE 4) 316L,321 316L,321 321 SA-194GR.8 PRESSURE
SA-376
TP321 PARTS
ABOVE 343 SA-204 GR.B SA 335 GR SA 209 GR SA182GR.F1 SA193GR.B7 SAME AS SAME AS SA-193GR.B8 C-1/2 Mo
UPTO 427 P1 T1 SA194GR.4 PRESSURE PARTS PRESSURE (COMML.

PARTS SA 194 GR.8 QLTY)
SA387GR.11 SA335 SA213 SA182 SA193GR.B7 SAME AS SAME AS SA-193GR.B8 1%Cr.1/2Mo

CL.1/CL.2 GR.P11 GR.T11 GR.F11 SA194GR.4 PRESSURE PARTS PRESSURE (COMML.
PARTS SA 194 GR.8 QLTY)
SA 240 TYPE SA312 SA 213 TYPE SA182F SA193GR.B7 SAME AS SAME AS SA-193GR.B8 SA4 79
304L,316L, TYPE 304L, 304L, 316L, 304L, 316L, SA194GR.4 PRESSURE PARTS PRESSURE Gr.304L,
321(SEE 316L, 321 321 321 PARTS SA 194 GR.8 316L, 321
NOTE 4) SA376
TYPE 321
ELEVATED TEMPERATURE
ABOVE 427 SA387GR.11 SA335P11 SA213T11 SA182GR SA193 SAME AS SAME AS SA-193GR.B8 1%Cr-1/2Mo
UPTO 538 CL.1/CL.2 SA335P12 SA213T12 F11 GR.B16 PRESSURE PARTS PRESSURE (COMML.
SA387GR.12 SA182 SA194GR.4 PARTS SA 194 GR.8 QTLY)
CL.I/CL.2 GR.F12
ABOVE 427 SA 240 TYPE SA312/ SA213TP SA182F304, SA193 SAME AS SAME AS SA-193GR.B8 SA4 79Gr.
UPTO 500 304,316,321 SA376 304,316,321 316,321 GR.B16 PRESSURE PARTS PRESSURE 304L,316L,
(SEE NOTE 4) TYPE SA194GR.4 PARTS SA 194 GR.8 321
304,316,321
SAME AS SAME AS 2%Cr.1 Mo
ABOVE 538 SA387GR.22 SA 335 P22 SA213T22 SA182GR SA193GRB5 SAME AS PRESSURE PRESSURE (COMML.
PRESSURE PARTS
UPTO 593 CL.1/CL.2 F22 SA194GR.3 PARTS PARTS QLTY)
SA387GR.21 SA 336 GR
CL.1/CL.2 F22
SAME AS SAME AS SA4 79Gr.
ABOVE 500 SA240 SA312/ SA213 SA182 SA193GRB8 SAME AS PRESSURE PRESSURE 304H,
UPTO 815 GR.304H, SA376 TYPE 304H, GRADES SA 194 GR.8 PRESSURE PARTS PARTS PARTS 316 H, 321 H.
316H TYPE 304H, 316H,321H 304H, (STRAIN
321H, 316H, 321H 316H,321H HARDENED)
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Notes:
1. Plates are purchased to the requirement of the standard ASME SA-20, which requires testing of
individual plates for low temperature service. Carbon steel material is ordered to meet the impact
requirements of supplement S5, of standard ASME SA-20, typical material specification is
as follows. SA 516 Gr.60. Normalised, to meet impact requirements per supplement S5 of SA 20
at minus 50°F.
2. All permanent attachments welded directly to 9% nickel steel should be of the same material or of an
austentic stainless steel type, which cannot be hardened by heat treatment.
3. Check for impact testing requirement as per UCS-66, for coincident temperature and part
thickness.
4. Selection of stainless steel material shall be based on process recommendation / process

licensor.
5. This table is not applicable for atmospheric/low pressure storage tanks. Materials shall be
selected as per API 650/API 620 as applicable.
6. Materials for caustic service, sour service or sour service + HIC shall be selected based on
specific recommendation of process licensor.
7. Material for pressure vessels designed according to ASME Section VIII Division 2 shall be given
special consideration as per code.
8. All pipes shall be of seamless construction.
9. Non-ferrous material and super alloys are not covered above and shall be selected based on
specific recommendation.
10. Material for vessel / column skirt shall be the same material as of vessel / column shell for the upper
part with a minimum of 1000mm.
11. All tubes shall be of seamless construction.
12. SA 336 shall be used for non-standard LAS forgings and SA 965 shall be used for non-standard SS
forgings.
13. Internal bolting shall be selected on the basis of shell side material solid or clad as follows:
SHELL MATERIAL STUD NUTS
Carbon steel &up to 1 % Cr. ASTM A 193 Gr B-7M ASTM A-194 Gr 2HM
5% Chrome A 193 Gr B5 A 194 Gr 3
13% Chrome A 193 Gr B6X A 194 Gr 6
Stainless Steel A 193 Gr* A 194 Gr*
For low temperatures, min. quality of bolting material shall be as specified for external bolting and
shall be improved if shell side materials are better.
* Compatible / same grade of SS.
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
SECTION-B
(TRAYS & TOWER INTERNALS)
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
CONTENTS:
1. INTENT
2. PROCESS PARAMETERS, DESIGN CONDITIONS & SELECTION OF INTERNALS
3. USAGE OF EXISTING INTERNALS
4. DESIGN
4.1 Materials
4.2 Thickness of Internals
4.3 Design Loadings
4.4 Allowable Stress and Deflection
4.5 Arrangement/Details of Internals
5. FABRICATION AND SUPPLY
5.1 Tolerances
5.2 Welding
5.3 Miscellaneous
5.4 Spares
6. INSPECTION AND TESTING
6.1 General
6.2 Stage Inspection During Fabrication
6.3 Trial Assembly
6.4 Leak Testing
6.5 Distributor Testing
7. SITE INSTALLATION AND SUPERVISION
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1.0 INTENT
1.1 The intent of this specification is to define basis to be followed for Mechanical Design,
engineering, fabrication, inspection/testing, supply and installation (inside the columns at site)
of Trays, Packed Column Internals and Tower Packings separately and collectively known as
"Internals". For licensed units, in case the requirements specified here are in conflict with
licensor's specifications, licensor's requirements shall govern.
1.2 In case of any conflict between various documents, resolution shall be in accordance with the
following:
• Data Sheets/P&IDs
• Job Specifications
• Design Basis
• Standard Specifications/Engineering Standards.
2.0 PROCESS PARAMETERS, DESIGN CONDITIONS & SELECTION OF
INTERNALS
As per Process Datasheets
3.0 USAGE OF EXISTING INTERNALS
All As-Built drawings of Columns, Tray/Internals as well as Tower Attachments shall be

provided by Client, which shall be the basis of revamp to be carried out by JE. However in case
drawings provided by Client are not As-Built, same shall be treated as base document for
proceeding further with engineering. Wherever drawings of existing internals are not
available, new internals will be considered including replacement of existing support
ring/bolting bars to suit the new configurations.
All existing internals found adequate with/without any modifications will be retained presuming:
(a) All such internals are in good physical conditions and can be retained.
(b) All the existing internals are in good physical condition to permit partial
modifications as necessary to make it suitable for revised conditions.
(c) No mechanical design checks of existing internals being retained will be carried out
unless explicitly asked/required by Client based on operating feed back.
4.0 DESIGN
4.1 Materials
4.1.1 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/JE 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.
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Unless specified in data sheets, Material shall be as per clause from 4.1.2 to 4.1.7.
4.1.2 13 Cr Stainless Internals
All sheet and plate material shall be in accordance with SA 240 Type 41 0S or 405 having No.1
finish only for thickness more than 4mm. For thickness up to and including 4 mm, No. 2B/2D
finish is also acceptable.
All bolting material shall be 13 Cr - SA 193 Gr B6X or B6 for bolts and SA 194 Grade 6 for nuts
and lock-nuts.
4.1.3 18 Cr - 8 Ni Stainless Internals
All sheet and plate material shall be in accordance with SA 240 Type 304 having No.1 finish
only for thickness more than 4mm. For thickness up to and including 4 mm, No. 2B/2D finish
is also acceptable.
All bolting material shall be SA 193 B8 for bolts and SA 194 Gr.8 for nuts and lock-nuts.
4.1.4 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, SB 164.
4.1.5 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
SA285, SA283 or better unless specified otherwise on the data sheets/drawings.
All fasteners including clamps, material shall be as per clause 4.1.2 above, unless
specified otherwise.
4.1.6 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 Graphite Tape 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. The use of
Woven Asbestos Tape or Wire shall be subject to JE/Owner's prior approval only.
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
4.1.7 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 diameter up to 3000 mm and 10 mm for higher diameter.
Corrosion allowance as specified in vessel data sheets shall be added on both sides of
Support Ring, Bolting Bar and other welded parts.
4.2 Thickness of Internals
4.2.1 Minimum thickness of Internals:
Corrosion allowance, wherever specified in the data sheets for Internals in excess of
corrosion allowance as indicated in clause 4.2.2 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, other removable
Components
ii) Welded deck plates, downcomer aprons and other 3.0 3.5*
welded components
iii) Downcomer/Internal pipes 2.0 3.5*
iv) Bubble Caps 1.6 2.0
Risers (fixed) 2.0 3.5*
Risers (removable) 1.6 2.0
v) Valves 1.6 (will not be used)
vi) Structured Packings 0.15 (will not be used)
vii) Support Grid for Structured Packings 5.0 8.0
viii) Locating Grid/Retaining Grid/Bed Limiter 5.0 8.0
ix) Grid Packings
(a) Bottom-most layer 5.0 8.0
(b) Next Five Layers 2.0 (As per vendor’s standard)
(c) Balance Layers 1.6 (As per vendor’s standard)
x) Random Packings (As per vendor’s standard, **)
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
To suit
xi) Loose Beams To suit Load
Load
xii) Lattice Girders
(a) Primary Members 5.0 6.0
(b) Secondary Members 3.0 4.0
(c) Gusset Plates 10.0 10.0
(d) Downcomer bolting bars 5.0 10.0
xiii) Z-Bars 5.0 8.0
xii) Lattice Girders
(a) Primary Members 5.0 6.0

(b) Secondary Members 3.0 4.0
(c) Gusset Plates 10.0 10.0
(d) Downcomer bolting bars 5.0 10.0
* (10 USSG is also acceptable in lieu of 3.5 mm)
** (Random packing thickness shall be suitable for test load comprising of dead weight of the
packed bed + 10% liquid load. Maximum compression shall be limited to 5% of the bed height
without damaging the bottom packing.)
All bolting shall be minimum M10 for Internals and M16 for Lattice Girders. All bolt
head/nuts shall be hexagonal.
Minimum corroded thickness of the internals for the loading condition as per Clause
4.3.3. (i) and (ii) below, shall be 3.0 mm.
4.2.2 Corrosion Allowance
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
1.5 mm (total).
4.2.3 Unless specified on the data sheets or bid specifications, corrosion allowance shall be
higher of 1.5 mm (total) or one quarter of the vessel corrosion allowance on each surface of
trays and its components.
4.2.4 Beams, trusses and other support members shall have total corrosion allowance equal to
vessel corrosion allowance for removable type construction and twice the vessel corrosion
allowance for non-removable type construction through vessel man-hole.
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4.3 Design Loadings
4.3.1 Design loads for tray assemblies shall be based on a liquid height of 50 mm liquid above
2
weirs plus self weight of deck plates and beams or live load of 150 kg/m whichever is
3
severe. In case liquid density is less than water, 1000 kg/m shall be considered for
purpose of calculating liquid load.
4.3.2 Under-down-flow plates and seal pans shall be designed to withstand a weight of liquid
2
equal to half the tray spacing or 300 kg/m , whichever is severe. In case liquid density is less
3
than water, 1000 kg/m shall be considered for purpose of calculating liquid load.
4.3.3 Five trays above/below 2-phase feed inlets and in bottom zone of column wherever
process steam or two-phase feed is admitted, shall be provided with lock nuts. Trays shall be
capable of sustaining a net thrust of
2
i) 1464 kg/m and with shear clips for Vacuum Columns (Stripping + Wash + HVGO
sections)
2
ii) 1000 kg/m and with shear clips for Crude Column/Main Fractionator Columns,
2
iii) 450 kg/m for all other services
4.3.4 One tray above and below the intermediate vapour/liquid feeds shall also be provided with
locknuts.
4.3.5 The packing support plate shall be designed to support the maximum expected load of
tower packings, liquid hold-up (min 10 percent). In case of liquid density is less than
3
water, 1000 kg/m shall be considered for purpose of calculating load due to liquid hold-
up.
4.3.6 Bed limiters frame shall be strong enough to take care of surges/uniformly distributed load
2
of 100 kg/m and 135 kg concentrated load at any point.
4.3.7 Hold down plate shall exert sufficient static load on the bed to restrict movement of the
2
packing. The hold down plate shall be designed for exerting a load of 100 kg/m
minimum on the packed bed.
4.3.8 Liquid distributors/Re-distributor shall be designed for self weight plus maximum
expected liquid load.
4.3.9 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)
Up to 3600 mm 2 (at center and % point of diameter)
Over 3600 mm 3 (at center and % points of diameter)
4.4 Allowable Stress and Deflection
4.4.1 Allowable stresses for all Internals shall be as per ASME Sec. II. Part D, latest edition.
4.4.2 The maximum deflection of tray/tower internal assembly shall not exceed 1 mm per
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
meter of column diameter or 7.5 mm, whichever is lower for the design loadings given in
clause 4.3.1 and 4.3.2 above. Deflection for distributor assembly shall be limited so that
overall liquid mal-distribution does not exceed the limit as per clause 4.5.18(v).
Deflection for support plate and seal pans shall be limited to L/400, where L is the length
of individual component.
4.4.3 Deflection as per clause 4.4.2 may be ignored for trays designed based on design
loadings as per clause 4.3.3 and 4.3.9.
4.4.4 For large diameter vessels, initial camber may be made in the principal support members of
the assemblies so as to limit the deflection as specified in clause 4.4.2 above.
4.5 Arrangement/Details of Internals
4.5.1 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.
4.5.2 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.
4.5.3 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 minimizing welding work inside the
column.
4.5.4 Internals decks shall have a maximum length of 3000 mm. To achieve this maximum
distance between main support beams or girders shall be limited to 3000 mm. However, the
main support beams or girders having length more than 3000 mm shall be provided with
one butt joint with splice plates of the same thickness as the main member up to 6000
mm length and two butt joints with splice plates of the same thickness as the main member
for more than 6000 mm length and so on. The butt joint shall be provided inclined at 45
degrees.
4.5.5 Man ways
i) One(1) man way in single cross flow decks, two(2) man way in double flow decks
and so on shall be provided. These man way shall be freely removable from top and
bottom. Man way 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.
Man way of different set of trays (about 20 trays) shall be staggered to each other.
Minimum clear opening on tray shall be 380mmx450mm.
ii) Where man way cannot be provided, decks shall be split (turn-up - turndown) to
provide suitable access for Inspection and assembly from top as well as bottom.
4.5.6 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 /up
comer shall be through bolted. Spacing of bolting or clamping shall be close enough to
ensure optimum liquid tight construction but shall not exceed 125 mm on deck portion in
downcomer area/liquid holding area/downcomer apron bolting etc. and 150 mm in active area.
All joints and seams of trays specified to be liquid tight without gasketted joints shall be
seal welded at site. Maximum spacing for clamps/bolting for gasketted construction
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
shall be restricted to 100 mm.
4.5.7 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 continuously welded on both sides. All support brackets shall be welded all
around.
4.5.8 When locations of bed support, retainer and distributor are not indicated on data sheets,
Tower Internal/Packing supplier shall determine and indicate dimensional requirement.
4.5.9 Gasketting need not be used in the design or installation of Internals except for bubble cap
trays, all liquid holding portions (e.g. 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.
4.5.10 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. A minimum of 20 mm overlap shall be provided between tray
floor section and support members.
4.5.11 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 12mm 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.
4.5.12 All the three (3) and four (4) pass trays shall have pressure equalizing pipes (vent tubes)
across the down-comers.
4.5.13 Bubble Cap Trays 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.
Bubble Cap
Bubble caps are to be furnished in Full Annealed and scale free bright condition.
4.5.15 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.
4.5.16 Sieve Trays
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
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.
4.5.17 Burrs shall be removed from all perforated areas and edge of Internal sections.
4.5.18 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) Orifice for liquid distributor shall preferably be minimum 8.4 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 8.4 mm, then antifouling covers
shall be provided on each orifice. Orifice below 6mm diameter shall be preferably
provided at an elevation in drip tube or in side of trough with guide tubes.
ii) 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.
iii) Distributor joints shall be gasketted to be liquid tight. Gasket material used shall be
suitable for service and soft enough for leak tight joint.
iv) Distributor shall be capable of performing satisfactorily for the range of loadings
specified to cover entire range of plant operation.
v) Flow variation from orifice to orifice shall not be more than 10 percent at turndown
condition.
vi) Feed pipe shall form part of Distributor supply.
4.5.19 Packing Support Plate
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.
4.5.20 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.
4.5.21 Hold Down Plates
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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.
4.5.22 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.
4.5.23 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.
4.5.24 Maximum allowable pressure drop for a packed bed shall include packed bed support,
bed limiter and distributor.
50 FABRICATION AND SUPPLY
5.1 Tolerances
All sections shall be truly flat within 2 mm and shall be free from burrs and welds spatters
Tolerances wherever unspecified shall be taken as ±1 mm and not to be accumulative,

except on thickness and assembly diameter (D). Tolerances on thickness shall be as per
applicable specification and tolerances on assembly diameter shall be as below:
Cartridge Trays : +0
D -3
+0
Other Assemblies : D =< 1500, D- 6
+0
1500 <D=<4500, D- 10
+0
D>>4500,
D- 20
5.2 Welding
5.2.1 All welding shall be done by metal arc welding. For welding on thinner gauge sheets TIG
welding is preferred.
5.2.2 Gas or Carbon arc welding shall not be used.
5.2.3 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
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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 forallSS304LtoSS304L
E 309MoL for SS 410S to SS 410S, SS to
CS
304L, 316, 316L SS410StoSS304,
E 316 forallSS316
E 316L forallSS316L
E NiCu7 for Monel to Monel and Monel to CS/SS.
5.2.4 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 stablished. Torque
required for welding failure shall be higher than the torque required for failure of the
stud.
5.2.5 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 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.
5.3 Miscellaneous
5.3.1 All parts fabricated shall be smooth, true, clean and free from burrs, grease and dents.
Openings for passage of workman must have exposed edges rounded.
5.3.2 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.
5.3.3 Total draw-off trays shall be designed for zero leakage construction and may be seal
welded (if required) at site to attain zero leakage.
5.3.4 Seal welds shall have a throat thickness at least equal to the specified corrosion
allowance.
5.3.5 All stainless steel tray assemblies/internals and their components (e.g. Bubble caps,
valves etc.) shall be pickled and passivated. Pickling and Passivation shall be as per
ASTM 380. However, vendor shall prepare procedure for Pickling and Passivation and
obtain approval from Owner/PMC.
5.3.6 All parts shall be fabricated in accordance with good shop practice and in uniformity so
that all corresponding parts will be inter-changeable.
5.4 Spares
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Following spares shall be included as part of the supply:
5.4.1 Constructional Spares
The supply shall include the following as 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 200% of each size

cartridge trays
U-clamps 10% of each type and size or 10 nos. whichever is minimum.
Tower Packings 10% for Metallic and Plastic Packings

(Only Random Packings) 15% for Carbon and Ceramic Packings
Spray Nozzles Up to 25 Nos. (of each type) - 100%

More than 25 (or each type) - 25% (subject
to minimum of 25 Nos.)
5.4.2 Vendor shall submit list of spares recommended for two years of satisfactory operation.
However, following operational spares as a minimum shall be supplied as Mandatory
Spares:
i) Valves for Trays 10% of each type

ii) Bolts/Nuts nos. of each size 10% of total for each type/size (minimum 10)
iii) Clamp Assemblies - do -

iv) Gaskets or Tapes 100% of each type and size
v) Sealing foils for Cartridge
200% of each size 0
Trays
vi) Spray Nozzles and size 25% subject to minimum 5 Nos. of each type and size 0
vii) Tower Packings If desired by owner, item wise price for above spares shall
(Only Random Packings) be furnished after award of the job.
60 INSPECTION AND TESTING
6.1 General
6.1.1 The materials, fabrication, testing and trial assemblies are subject to inspection by
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Doc. No. 44NC-4600-0000-V.02-0001-A4 Date: 21.07.2010
Owner/JE, at shop floor before shipment and during installation.
6.1.2 Any rejection made by Inspector shall be final. Approval/Inspection by JE/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.
6.1.3 Owner/JE/Authorized Inspector 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.
6.1.4 Vendor shall notify the Owner/JE sufficiently in advance of any fabricating operations
to permit the Inspector to arrive at the Vendor's shop.
6.2 Stage Inspection during Fabrication
6.2.1 Dimensions
The inspector will check that the thickness and the dimensions of all parts for the Decks,
Weirs, Seal and Draw off pans, Down comers, Draw off pipes, Supports, Beams, Valves,
Bubble caps, Clamps, Studs, Bolts, Nuts, Risers, Washers and Gaskets etc. are as per the
approved drawings.
6.2.2 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
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, man way
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
numbers 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.
6.3 Trial Assembly

One tray of each type and size 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 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.
Trays/ Internals shall be assembled at site on ground prior to fixing inside the column.
6.4 Leak Testing
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Bubble cap, Collector trays, Liquid holding portion of other trays such as Seal pans,
Recessed seal pans, Draw off pans, Distributors/Redistributors shall be subjected to
leakage test at shop floor as well as in the field by filling water up to weir level or up to
normal liquid level as the case may be. 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
Internals Vendor to facilitate leak testing in the shop.
Leak testing shall be carried out with service gaskets and drain holes temporarily
plugged.
All distributors/redistributors shall be leak tested with all holes 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.
For collector trays / other internals if seal welding is carried out at site inside the column
leak testing at shop floor is not required
6.5 Distributor Testing

6.5.1 All vendor's Proprietary Liquid distributors/redistributors shall be water tested in the
vendor's shop only 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 pre-distributor, 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 pre-distributor 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/re-distributor 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.
(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) 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 / re-distributors shall be leak tested at shop floor as well as at site. For
distributors / re-distributors, if performance testing is carried out at shop floor, same is not
required at site.
6.5.2 Spray Nozzle Distributors
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Spray header with Spray nozzles duly installed, shall be mock assembled & tested at site on
ground on a fixture resembling the height above the bed, before installation. Nozzle height etc
shall be modified, if required, to get proper wetting, after such a mock test. Test shall be
carried out as close to design rates as possible.
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/JE for review. Tests and acceptance criteria is as
below:
Flow rates - ± 10% for specific AP
Spray angle - ±5°
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)
7.0 SITE INSTALLATION AND SUPERVISION
7.1 For revamp jobs, cutting & removal of existing attachments, welding of new attachments
inside the existing columns and installation of new internals shall preferably be done by
column internals supplier to have single point responsibility for complete supply.
Alternatively, all these activities can also be included in the scope of Mechanical
Contractor (covered in separate mechanical tender) to minimize the agencies involved at the
site. In such a case, all such modifications, installation shall be carried out under the
supervision of Internals supplier so as to ensure guarantee of performance of column
internals by supplier.
7.2 For new columns, installation of internals shall be done by column internals supplier
only.
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Page 1 of 3

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: GENERAL SPECIFICATION FOR HARDNESS REQUIREMENTS
DOCUMENT NO : 44NC-2600-0000-V.02-0113-A4
Rev Issue Date Pages Rev Description Prepared Checked Approved

No.
By By By
Page 183 of 441

44NC-4600 HARDNESS REQUIREMENT Page 2 of 3
CONTENTS
1.0 PURPOSE
2.0 HARDNESS REQUIREMENTS
3.0 WELDING QUALIFICATION TEST
4.0 PRODUCTION TEST
5.0 APPROVAL
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44NC-4600 HARDNESS REQUIREMENT Page 3 of 3
1.0 PURPOSE
This specification covers general requirement of hardness of base metal, weld and heat
affected zone (HAZ) and is applicable to all C-1/2Mo, Cr-Mo steels and other materials
whenever asked for in drawings / specifications / standards. All testing shall be done in
accordance with ASTM A 450 after PWHT.
2.0 HARDNESS REQUIREMENTS
Hardness in base metals, weld and heat affected zone as per ASTM E10 shall not exceed
the following:-
For P1 materials - 200 BHN
For P3& P4 materials - 225 BHN
For P5 & P6 materials - 235 BHN
3.0 WELDING QUALIFICATION TEST
3.1 For each welding procedure qualification six tests shall be made, three in weld metal and
three in HAZ. Hardness requirements shall be as per clause 2.0 above.
3.2 In addition to the requirement of 3.1 above, Vickers Micro hardness test shall be made on
a full cross-section at 25 mm intervals beginning at 3 mm from the top surface with 5 kg
load or with a load approved by the authorised inspector. Tests shall be made at each
level for each of the following locations as per ASTM E 92:
Three tests shall be made in the weld metals, two tests in HAZ and one test in the base
metal in accordance with Fig. 1 and the hardness shall not exceed the following in base
metal, weld metal and HAZ.
For P1 materials - 210 VHN
For P3 & P4 materials - 237 VHN
For P5 & P6 materials - 247 VHN
4.0 PRODUCTION TEST
4.1 All pressure containing weld metals are to be checked for hardness of weld and HAZ after
PWHT but before hydrotest. The hardness shall not exceed the values stipulated.
4.2 Each longitudinal seam shall be checked both internally and externally near the centre
and at one end.
4.3 Each circumferential weld shall be checked at four locations approximately 90º apart, both
internally and externally.
4.4 Each nozzle weldments shall be checked at two locations, 180º apart, both internally and
externally.
5.0 APPROVAL
In case the hardness as obtained on production test is more than the limit specified in 2.0
above, the vendor shall submit the corrective procedure to lower the hardness in writing to
Jacobs and / or authorised inspection agency for review / approval.
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Page 1 of 45
SPECIFICATION NO: 44NC-4600/C.02/0001/A4

CIVIL / STRUCTURAL
PROJECT REFERENCE:
- Project No: 44NC-4600
- Project Location: Manali, Chennai
- Project Title: RESID UPGRADATION PROJECT
- Client: Chennai Petroleum Corporation Limited

(WHERE APPLICABLE)
- Project Manager Authorization: R.P.GAIKWAD Date:
- Client Authorization: Date:
APPROVALS
Rev. Issue Pages Revision Description By Check Approve
No. Date
D 12.07.2010 45 Owner’s comments incorporated and issued for PN BPS DPC

Engineering
C 19.04.2010 44 Owner’s comments incorporated and issued for PN BPS DPC

Engineering
B 03.03.2010 43 Issued for Owner’s comments PN DPC MBR
A 16.02.2010 40 Preliminary - Issued for Owner’s approval PN DPC MBR
Entire Specification SPECIFICATION ISSUED FOR:

Issued this Revision In-house Review Purchase
Revised Pages Only Client Approval Construction
Issued this Revision Enquiry Engineering
Page 186 of 441

PROJECT NO.: 44 NC-4600
SPEC. NO. 44NC-4600/C.02/0001/A4
REV. NO./ISSUE DATE - D / 12-JULY-10
CIVIL / STRUCTURAL
Page 2 of 45
CONTENTS
1.0 GENERAL
1.1 Scope
1.2 Units of measurement
1.3 Codes & Standards
2.0 SITE CONDITIONS
2.1 Location
2.2 Rainfall
2.3 Temperature
2.4 Levels
2.5 Soil parameters
3.0 MATERIALS OF CONSTRUCTION
3.1 Reinforced/plain concrete grade

3.2 Reinforcement
3.3 Structural steel
3.4 Cement
3.5 Bricks
3.6 Admixtures
3.7 Cladding
3.8 Water Stops
3.9 Grout
3.10 Fire Proofing
4.0 STRENGTH AND ALLOWABLE STRESSES
4.1 Soil
4.2 Characteristic Compressive Strength of Structural Concrete
4.3 Tensile Strength of Reinforcing Bars
4.4 Structural Steel
4.5 Common Bolt
4.6 Allowable Stresses for Combined Load
5.0 STRUCTURAL DESIGN CRITERIA
5.1 General
5.2 Loads
5.2.1 Dead loads
5.2.2 Live load
5.2.3 Equipment loads / Piping loads
5.2.4 Wind load
5.2.5 Seismic load
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5.2.6 Thermal Load

5.2.7 Impact & Vibratory Loads
5.2.8 Erection / Construction Loads
5.2.9 Blast forces
5.2.10 Other loads
5.2.11 Load combinations
5.3 Deflections
5.4 Foundation
5.4.1 Type of foundation
5.4.2 Minimum height of plinths / pedestals
5.4.3 Grouting
5.4.4 Lean Concrete
5.4.5 Uplift on Foundations
5.4.6 Soil and Hydrostatic Pressure on Walls below Grade
5.4.7 Bearing capacity of soil
5.4.8 Tank foundation
5.4.9 Stability
5.4.10 Vibration
5.4.11 Settlement
5.5 Minimum Cover to main reinforcement
5.6 Minimum Thickness
5.6.1 Min. thickness of structural concrete
5.6.2 Min. thickness of structural steel components
5.7 Painting
5.8 Minimum Cover to foundation bolts
5.9 Non-suspended ground floor slab
5.10 Liquid retaining/storage RCC structure & basement
5.11 Equipment foundations
5.12 Staircase / Ladders
5.13 Grating floors
5.14 Plinth protection
5.15 Damp proof course
5.16 Masonry wall
5.17 Ramps
5.18 Plant area: Site Grading and Roads
5.19 Pavement & Dyke Walls
5.20 Cable Trenches
5.21 Drinking / Sanitary / Fire Water Distribution
6.0 PLANT AREA DRAINAGE AND SEWAGE SYSTEM

6.1 Storm drainage
6.2 Process drainage
6.3 Sanitary sewers
6.4 Acid / Alkali proof paved areas
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CIVIL / STRUCTURAL
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7.0 DESIGN CRITERIA

7.1 Pipe-rack
7.2 RCC & Steel Chimneys
7.3 Flare Stack & Vent Support Structures
7.4 Machine Foundation
. 7.5 Blast Resistant Structures
7.6 Platforms
7.7 Vessel & Tank foundations and supporting structures
7.8 Special Detailing of Structures for Cyclone Resistance
8.0 ANNEXURE -1
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1.0 GENERAL
1.1 SCOPE
This design basis covers the general requirement and conditions of Civil/Structural works for RESID
Upgradation project for Chennai Petroleum Corporation Limited, Manali, Chennai.
This engineering design basis defines the minimum design criteria that shall form the basis for
D
carrying out detailed structural design and engineering of all plant and non plant structures and
buildings included in the bid document. All data required with regards to working a proper field project
shall be taken into consideration for acceptable, satisfactory and trouble free engineering of the
structures.
Compliance with this design basis and/or review of any of the contractor documents shall in no case
relieve the contractor of the contractual obligations. All structures shall be designed for the
satisfactory performance of the functions for which they are being constructed.
D 1.2 UNITS OF MEASUREMENT
Units of measurement in design shall be in Metric System (eg: kN, kN/m2, N/mm2 Load
m, cm, mm Length)
The design shall be in accordance with latest established codes, sound engineering practices and
shall conform to the statutory regulations applicable to the country.
The main codes, standard and statutory regulations, publications considered as minimum
requirement are as follows.
1.3.1 CONCRETE STRUCTURES
• General purpose : IS: 456 - 2000, SP16: 1980, SP23: 1982,

SP24: 1983
D • Code of practice for design and construction IS: 2911 (Part 1 – Sec 1, 2 , 3 & 4) – 1979 &
:
of Pile foundation Part 4
• Code of practice for design and construction
: IS: 2950 (Part 1) - 1981
of raft foundations
• Code of practice for concrete structure for : IS: 3370 (Part 1) – 1965, IS : 3370 (Part 2) –
storage of liquid 1965, IS : 3370 (Part 3) – 1967, IS : 3370
• Code of practice for design and construction (Part 4) – 1967
of foundation for transmission line tower and : IS : 4091 -1979
poles

: IS: 2974 – 1982,
of machine foundations
• Criteria for design of RCC chimney : IS: 4998 – 1992
of foundation in soils :General requirement : IS :1904 - 1986
• Code of practice for earthquake resistant
design and construction of buildings : IS:4326 - 1993
D
• Code of practice for Non Destructive Integrity : IS: 14893 – 2001
Testing of Piles (NDT)
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1.3.2 STEEL STRUCTURES
• Code of practice for general construction in : IS: 800 – 2007

steel
• Code of practice for use of cold formed light IS :801 -1975
gauge steel structural member in general
building construction.
• Code of practice for use of structural steel in IS :802
overhead transmission towers
• Code of practice for use of steel tubes in : IS: 806 – 1968
general building construction
• Indian Standard on Dimensions of Hot Rolled : IS :808 -1989
Steel Beams ,columns, channels and Angles
• Covered electrodes for manual metal arc IS : 814 -2004
Code of practice for use of metal arc welding
for general construction.
• Indian standard on Hot Rolled Parallel : IS :816 -1969
Flanged Steel sections for Beams ,Columns
Bearing Piles.
: IS: 12778
• Recommendation for metal arc welding of
carbon and carbon manganese steel.
• Recommendation practice for hot dipped
galvanizing on iron and steel : IS :9595 -1996
• Methods of testing uniformity of coating of zinc
coated articles : IS : 2629
Code of practice for design & construction of
steel chimney welding of carbon and carbon : IS: 2633
manganese steel : IS: 6533 - 1989
• Structural steel : IS: 2062 – 2006
1.3.3 • DESIGN LOADS : IS: 875 –1987

1.3.4 • EARTHQUAKE LOADS : IS: 1893 – 2002
(Part 1 to 4)
1.3.5 • ROADS : IRC: 37 – 2001
1.3.6 • DUCTILE DETAILING OF R.C. : IS: 13920 -1993
STRUCTURES SUBJECT TO SEISMIC
FORCES
1.3.7 • OTHER CODES AND REFERENCE
PUBLICATIONS
• Method of determinations of mass of zinc

coating. : IS : 6745
• Chlorpyrifos emulsifiable concentrares : IS :8944
• Two parts polysulphide based sealants : IS 12118
• Code of practice for calculation of settlements
of foundation : IS :8009 (PART I, II )
• Code of practice for determination of bearing
:
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capacity of shallow foundations IS : 6403

:
• Determination of dynamic properties of soil IS : 5249
IS:1597
• Code of practice for construction of stone
masonry
• Code of practice for structural use of un :
reinforced masonry
IS:1905
• Fillers for expansion joints :
IS :1838
• Circular hollow sections/pipe : IS :1161-1998
• RHS & SHS sections : IS : 4923
:
• Control Room Safety (a publication of Oil
Industry Safety Directorate) OISD-STD-163
• Fire Proofing in Oil and Gas Industry (a
:
OISD-STD-164
publication of Oil Industry Safety Directorate)
• Fire Protection System for electrical
:
OISD –STD-173
Installations
• Process design &operating philosophies on
Blow Down & Sewer system : OISD-STD-109
• Recommended Practice on Oil Storage &
Handling : OISD-STD-108
• Fire Protection Facilities for Petroleum
Refineries and Oil/Gas Processing Plant :
OISD-STD-116
• National Building Code
• OISD Standard 118,2004 Edition layout for Oil
and Gas Installation
• Petroleum Rules,2002
• Gas Cylinder Rules2004
• Director General of Civil Aviation Rules
• The Static and Mobile Pressure Vessels
(unfined) rules-1981
• Building Bye Laws3
• Factory Rules
• Process Licencers requirement, if any
• SMMS Specification
• BIS Codes for Fire Fighting Equipments
• NFPA Codes for Clean Agent ,CO2 System
and Foam system.
• Rules of TAC for
i) Sprinkler system ii) water spray system
Note : The above list is suggestive and not exhaustive. Apart from these basic codes any other related codes
shall be also followed wherever required.
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1.3.8 In case of any conflict /deviations amongst various documents, the order of precedence shall be as
as follows
- Statutory Regulations
- Job specifications
- Engineering Design Basis
- Standard Specifications
2.0 SITE CONDITIONS:
2.1 LOCATION : Manali, Chennai
2.2 RAINFALL
• Maximum rainfall intensity per hr : 100 mm

• Maximum rainfall intensity per day : 450 mm
• Average annual rainfall : 1378 mm
• Design rainfall intensity for Storm Water
: 50 mm per hour
Drain
2.3 TEMPERATURE
0
• Maximum design temperature : 40.0 c
0
• Minimum design temperature : 17 c
2.4 LEVELS
• Finished grade level : To be finalized as per existing unit , Plot plan and
D
soil investigation report.
2.5 SOIL PARAMETERS
Type of soil : Reference soil reports attached.

Ground water table : Actual to be ascertained after final soil
investigation by LSTK contractor.
3.0 MATERIALS OF CONSTRUCTION
3.1 REINFORCED/PLAIN CONCRETE GRADE
• M 7.5 : Blinding concrete (P.C.C.) (1:4:8)

• M20 : Plinth protection and PCC for water retaining structure (1:1.5:3)
• M35 : Grade slab in non plant area U.N.O. (Design Mix) & foundation for all masonry wall.
• M35 : Grade slab in plant area, Paved area & Storm water drainage etc. U.N.O.(Design Mix)
• M35 : Concrete below F.G.L (including pile), pile caps and in substructure (design mix)
D • M30 : Concrete above F.G.L. and in superstructure (design mix)
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The minimum grade of reinforced cement concrete shall be used for superstructures M30 and for
substructure shall be M35. From durability considerations the minimum cement content and
maximum water-cement ratio shall be as under. However, the maximum cement shall not exceed
450 kg/m3.
Plain Concrete Reinforced Concrete Exposure
Grade of Minimum Maximum free Grade of Minimum Maximum Condition
concrete cement water-cement concrete cement free water-
D content ratio content cement ratio
3 3
(kg/m ) (kg/m )
M20 275 0.5 M35 400 0.45 Severe
M30 330 0.45 Severe
Concrete in contact with earth shall be given 2 coats of cold applied bituminous paint.
3.2 REINFORCEMENT
High strength deformed steel bars of grade Fe 500 (TMT) conforming to IS:1786 shall be used for all
structures. 18 Gauge SWG GI wire shall be used for binding reinforced bars.
3.3 STRUCTURAL STEEL
• All structural steel work of Grade A/B and anchor bolt of Grade B, shall conform to IS: 2062-2006
/ IS 432: 1982 except tubular sections which shall conform to IS: 1161 – 1998 and IS: 1239 (Part
1) – 2004, IS : 1239 (Part 2) - 1992. Wide Flange Sections shall be as per IS : 12778. Use of
Structural steel of Grade B shall be taken appropriately into design consideration specifically in
line with stipulations of IS: 800-2007.
• High Strength bolts shall conform to IS: 3757-1985
• Chequered plate shall conform to IS: 3502 – 1994.
• Welding electrodes shall conform to IS: 814 – 2004
• Welding shall conform to IS: 816 – 1969 & IS: 9595 – 1996
• Welding symbols shall be as per IS: 813 - 1986
• Rectangular/Square hollow section as per IS: 4923
3.4 CEMENT
Ordinary Portland cement conforming to IS : 12269 – 1987 for Grade 53. Sulphate Resistant Cement
(SRC) conforming to IS: 12330-1988 shall be used (if required as per soil recommendation) for all
substructure concrete or the surface in contact with soil. Alternatively Portland Slag Cement
conforming to IS : 455 – 1989 shall be used for all sub-structures.
Ordinary Portland cement of Grade 53 shall be used for all super structure concrete work.
Portland Pozzolana Cement (Fly Ash based) conforming to IS : 1489 (Part – 1) – 1991 shall be used
for all mortars for Block masonry and plastering works.
3.5 BRICKS
Bricks shall comply with the requirements of IS: 1077 – 1992.
3.6 ADMIXTURES
Admixtures shall conform to IS: 9103 - 1999 and to be mixed with concrete (if required) strictly as per
manufacturer’s recommendations.
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3.7 CLADDING
The roof and wall cladding for all structures shall be Pre-coated Galvalume Sheets (base metal
thickness = 0.6mm). Rainwater gutters of RCC or Pre-coated Galvalume and Sand Cast Iron /PVC
rain water down take pipes shall be provided for proper roof drainage, wherever specified.
3.8 WATER STOPS
Hydrophilic water bar shall be used at construction joints laid as per manufacturer specification.
3.9 GROUT
3.9.1 All anchor bolt sleeves / pockets and spaces under column bases, shoe plates etc. shall be grouted
with free flow non-shrink cementious grout of premix type with a minimum compressive strength (28
days) of 400 kg/cm2 and shall be used strictly as per manufacturer’s recommendations.
3.9.2 Grouting for machines / equipments shall be with free flow non-shrink cementious grout as above or
epoxy (if suggested by equipment supplier), as per manufacture’s requirements.
3.9.3 Ordinary grout shall consist of 1 part of O.P.C and 2 parts of clean, dry well graded sand mixed with
water and non shrink admixture to obtain the required consistency.
3.10 FIRE PROOFING
Pipe-racks and technological structures shall be fire proofed as per OISD–STD–164. Steel structures
shall be fire proofed by minimum 50mm thick vermiculite based fire proofing. (minimum 2 hrs rating
D hydrocarbon fire)
For structures supporting fire-potential equipment, vertical and horizontal steel support members from
grade up to the highest level at which equipment is supported shall be fireproofed.
For structures supporting non-fire potential equipment, vertical and horizontal steel support members
from grade up to the level nearest to 10 m elevation shall be fireproofed.
Knee and diagonal bracing shall be fireproofed if these contribute to the support of vertical loads or to
the horizontal stability of columns. Those provided for wind, earthquake or surge loading need not be
fireproofed.
Skirts / legs of vessels / towers / drums etc., and saddle supports of horizontal heat exchangers shall
be fireproofed.
For pipe-racks, all vertical and horizontal supports up to and including the first levels shall be
fireproofed. If the pipe-rack carries piping of dia greater than 6” at levels above the first level or if large
hydrocarbon pumps are installed beneath the rack, fireproofing shall be done up to and including the
level nearest to 10 m elevation. Wind or earthquake bracing and non-load bearing stringer beams
that run parallel to piping need not be fireproofed.
If air fin-fan coolers are installed on top of pipe-rack, fire proofing shall be done for all support
members irrespective of their elevation above grade.
Fire proofing shall be done for auxiliary pipe supports carrying pipes of dia greater than 6”.
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4.0 STRENGTH AND ALLOWABLE STRESSES
4.1 SOIL
4.1.1 Safe bearing capacity shall be determined as per recommendation of soil investigation report.
4.1.2 PILE
Pile specification – IS : 2911 (Part – 1, Sect – 1 & 2) – 1979. Driven / Bored Cast-in-Situ piles shall
be used as per recommendation of soil investigation report and site condition.
Pile capacities shall be determined as per recommendation of final report of soil investigation .
4.2 CHARACTERSTIC COMPRESSIVE STRENGTH OF STRUCTURAL CONCRETE

2
• M20 : 20 N/mm
2
• M30 : 30 N/mm
• M35 : 35 N/mm2
4.3 TENSILE STRENGTH OF REINFORCING BARS
2
• TMT Fe 500 : 500 N/mm
4.4 STRUCTURAL STEEL
• Grade IS: 2062 – 2006 : 250 N/mm2

• Allowable stress for tension Ft : 150 N/mm2 on the net effective area
2
• Allowable average stress for shear Fv : 100 N/mm
2
• Allowable stress for bearing for Base plates : 185 N/mm
4.5 COMMON BOLT

D
IS: 1363 – 2002 / IS: 1364 – 2002 / IS: 1367 –
2002 (Property class 4.6)
Bolts in clearance holes
• Allowable stress for Axial Tension : 120 N/mm2

2
• Allowable stress for Shear : 80 N/mm
IS: 3757-1985/ IS : 4000-1992( Property class 8.8)
2
• Allowable stress for Axial Tension 360 N/mm
• Allowable stress for Axial Shear 200 N/mm2
4.6 ALLOWABLE STRESS INCREASES FOR COMBINED LOAD
Increase as per Codal procedures for combinations involving Wind, Earthquake etc., when using the
working stress method is allowed.
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5.0 STRUCTURAL DESIGN CRITERIA
5.1 GENERAL
Structural design shall be designed for steel and concrete structure as specified in IS: 800 - 2007and
IS : 456 - 2000 respectively.
5.1.1 RCC Design:

All buildings, structures, foundations, machine / equipment foundations, liquid retaining / storage
structures, trenches, pits etc., shall be of RCC and designed based on the following IS Codes (latest
revision with all amendments issued there to) in general and other relevant IS Codes applicable :
IS:456, 875, 1893, 1904, 2911, 2950, 2974, 3370, 4091, 4326, 4991, 4995, 4998, 5249, 6403, 8009,
13920.
Only limit state method as per IS:456 shall be followed in the design unless otherwise specified
elsewhere in this document for special structures.
All structures shall be of frame-type construction. Wherever required detailing shall be as per
provision of IS : 13920.
Where the specified design depth of groundwater table so warrants all underground pits, tunnels,
basements etc., (excluding appurtenances of storm water / effluent collection system, cable trench,
pipe trench) shall be of leak-proof RCC construction using waterproofing compounds .Where ever
required at construction joints hydrophilic water bar is to be used as per manufacturer specification.
Top of all Foundations / Pile caps / Plinth Beams shall be at a Minimum depth of 1.2m below FGL so
as to avoid fouling with cable trench / underground services. Tie beams under Pipe racks if provided
shall not foul with cable trench.
Minimum embedment of Pile in Pile caps shall be 100mm.
The minimum diameter of reinforcement bars for slabs, beam stirrups and column ties shall be 8mm
and for footing slabs & vertical walls shall be 10mm. The maximum spacing of these bars shall not
be more than 300mm c/c.
Intermixing of different grades of concrete or different grades of main reinforcement within structures /
structural element is not permitted.
Mild steel sliding plate 10mm thick (min.) with top surface machined shall be provided in RCC
pedestals at sliding end of Horizontal vessels and Exchangers.
Ductile Detailing of RCC structures shall be done in accordance with IS: 13920 – 1993.
5.1.2 Structural Steel Design:
Design fabrication and erection of the above work shall be carried out in accordance with the following
IS Codes as applicable to the specific structures viz, IS : 800, 801, 802, 806, 814, 816, 875, 1893,
9178, 9595, 6533 etc. Basic consideration of structural frame work shall primarily be stability, ease of
fabrication / erection and overall economy satisfying relevant Indian standard codes of practice.
Simple and fully rigid design as per IS:800 shall be used. Where fully rigid joints are adopted they
shall generally be confined to the major axis of the column member.
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Structural elements continuously exposed to temperatures above 2000 C shall be designed for
reduced stress as per Table 4 of IS:6533 (Part 2). The expected temperature of steel components
shall not be allowed to exceed 4000 C.
RC slab at higher elevation over structural steel structures shall be done using decking panel sheets
conforming to IS : 513, IS : 277, IS:14246, AS - 1397, ASTM A 607, BS-EN-10147 or equivalent in
place of conventional centering and shuttering.
Wherever required by OISD-STD-164 norms structural steel members shall be fire proofed by
vermiculite based fireproofing.( hydrocarbon fire of 2hr fire rating).
Crane gantry girders shall generally be of welded construction and of single span length. Galvanised
chequered plate shall be used for gantry girder walkway flooring.
Welded connections shall be adopted as far as practicable except for the removable members where
bolted connections are required, viz (Galvanized) electrical switchyard structures and transmission
towers. Structural connections shall have minimum two bolts of 16mm dia unless otherwise limited
by the size of members.
Wide flange beams as per IS-12778 wherever applicable shall be used.

All connections for steel shall be of full strength and welded construction except switchyard structures
and transmission towers.
For all sheds, roofs shall have 1:3 slopes. MS wind ties (40mm X 6mm) shall be provided over roof
sheeting on the last purlin at eaves and first purlin at the ridge on each slope of the roof. Purlins shall
not be more than 1.4m apart.
For steel sheds, horizontal wind bracing connecting the last two trusses at either end shall be done.
The number of successive unbraced bays shall be limited to four. If number of bays is less than four,
one bay at each end alone is to be braced. In case of gable frame, in plane bracing along building
envelope shall be provided. Suitable bracing system shall be provided in roofing system both in
horizontal and diagonal directions.
Special requirements of cyclone resistant design as stated in Section 7.8 shall be taken into account.
For compressor sheds and other plant sheds, cladding shall be provided from 3.0m heights with
respect to FFL. Each compressor shed shall have an EOT crane of adequate capacity.
Air circulation shall be ensured by providing Monitor at top and louvers on sides, wherever required.
All structural columns shall be fixed in concrete pedestals with min. 16mm dia. Anchor bolts.
Minimum 2 nuts shall be used for all anchor bolts.
900mm walkways shall be provided around each air fin-fan cooler, wherever possible, with stairs on
one side and ladder on the other side.
Pipe racks wider than 10m shall have 2 bays, i.e. three lines of columns.
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Clearance below pipe-rack shall be as follows:

- 3m in general areas
- 5m at secondary roads
- 7m at main roads
- Min. headroom of 2.2m shall be provided in building and structures.
- Arrangements for earthing for all steel structures, tanks, vessels, columns, fences, lighting posts
and masts shall be made
5.1.3 Limiting permissible Stresses
Permissible stresses in structural members shall be as specified in:

IS : 800 : Hot rolled sections (excluding transmission towers and switchyard structures)
IS : 801 : Cold formed light gauge sections
IS : 802 : Transmission towers & switchyard structures.
IS : 806 : Tubular structures.
Permissible stresses in bolts shall be as specified in:

IS : 800 : Hot rolled sections
IS : 802 : Transmission towers & switchyard structures.
Permissible stresses in welds shall be as specified in:

IS : 816 : Metal Arc welding
5.2 LOADS
The design loads for buildings and other structures shall be as specified in IS: 875 – 1987 Part 1
except as specified herein.
5.2.1 DEAD LOADS:

The weight of all permanent construction including walls, fire proofing , floors, roofs, partitions,
D stairways and fixed service and other equipments excluding their content.
3
• Reinforced Concrete : 25.0 kN/m
3
• Plain Concrete : 24.0 kN/m
• Structural Steel : 78.50 kN/m3
• Brick Masonry : 19.20 kN/m3
• Backfill Soil : 18.00 kN/m3
• Operating floor with grating : 1.00 kN/m2
• Staircase (steel) : 1.40 kN/m2
• Ladder : 0.40 kN/m
2
• False ceiling : 0.60 kN/m
2
• Heavy duty tar felting : 0.30 kN/m
5.2.2 LIVE LOADS:

Live loads shall be in general ,as per IS:875 Part 2. However, the following minimum live loads shall
be considered in the design of structures to account for maintenance and erection as well.
Process Building/Technological Structures (open / enclosed type)
2
• Operational areas on upper floors : 5.0 kN/m
2
• Maintenance areas : As mentioned in equipment layout, else 7.5 kN/m
2
• Ground floor (including Forklift area) : As mentioned in equipment layout, else 5.0 kN/m
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Substation
• Roof load : 1.5 kN/m2
2
• 1st Floor : 15.0 kN/m (including wt. of panels) for HT switchgear
2
: 10.0 kN/m (including wt. of panels) for LT switchgear
• Ground floor : As mentioned in electrical layout, else 5.0 kN/m2
2
MCC/Control Room : As mentioned in electrical layout, else 10.0 kN/m
(including wt. of panels)
D
• Partitions : 2.0 kN/m2
Cooling Tower
2
• Operating Platforms / Hot water : 3.0 kN/m
Basin Cover Slab
Service platforms
2
• Vessel / Tower : 3.0 kN/m
• Isolated platform (for valve operation) : 2.5 kN/m2
• Access way : 2.5 kN/m2
• Cross over : 2.0 kN/m2
Staircases
2
• For Plant Building / office : 5.0 kN/m
D 2
• Substation / Control Room : 5.0 kN/m
• Laboratory : 3.0 kN/m2
• For Service Platforms : 2.5 kN/m2
Administrative building
2
• Office area : 3.0 kN/m
2
• Lobby : 5.0 kN/m
2
• Exit way : 5.0 kN/m
• Partitions : 2.0 kN/m2
Walkway
2
• Gantry girder : 3.0 kN/m
Live loads on various types of roofs shall be as per the requirements given in IS : 875 Part -2
5.2.3 EQUIPMENT LOADS / PIPING LOADS:
The empty weight of process equipment including all fixtures, platforms, ladders and attached piping
but excluding contents shall be considered. If piping weight is not indicated separately or included in
the weight of the equipment, the same shall be taken as 10% of the weight of the equipment.
• Ee : Empty Weight of Equipment including all fixtures, platforms and attached piping
• Eo : Operating Weight of Equipment
• Et : Hydrostatic Test Load
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For pipe rack loading, please refer to Section – 7.1
5.2.4 WIND LOAD

Wind load shall be as per IS: 875 Part - 3 except for switchyard structures & transmission towers for
which IS: 802 shall be applicable. The basic wind speed of the site is taken as 50m/s.
Values of coefficients k1, k2 & k3 shall be as:
K1(probability factor, risk coefficient) = 1.00 for permanent structures and

=0.90 for temporary structures
:
= 0.71 for barricading structures
K2(Terrain ,height & structure size factor) :

= Shall be established from Terrain Category 2
: of Table 2 of IS 875: Part 3
:
K3(Topography factor) =1.00
The design life span of all structures (units& offsite) shall be taken as 50 years. Temporary structures
shall be designed for a design life span of 25 years. Design life span for boundary wall shall be as
provided in IS: 875 Part - 3.
To account for surface of piping, platform and other attachments fixed to the equipment the surface
area of the equipment (vessel/column) exposed to wind shall be increased by 20% or as specified in
the mechanical data sheet of the equipment.
5.2.5 SEISMIC LOAD
Seismic forces for new structures shall be based on IS 1893-latest (Part -1, Part – 4) and for the
modification of structures on the existing structures shall be done as per IS 1893-1975. The
foundation and superstructures shall conform to the requirement of IS:1893 (Part-4) and permissible
increase in allowable bearing pressure / pile capacities shall be as per provisions laid down in IS:1893
(Part-1 & 4) for the new structures. Site specific seismic spectra for CPCL Chennai is attached as
annexure 1.
Based on IS:1893(Part 4)-2005, sections 7.5.1 and 7.5.2, structures in Category 1 shall be designed
for MCE(Maximum considered Earthquake) and structures in Category 2,3, and 4 shall be designed
for DBE( Design basis Earthquake).
Response reduction factor R shall be as given in Table 3, IS:1893(Part 4)-2005.
Importance factor I shall be as given in Table 2, IS:1893(Part 4)-2005.

Damping ratios:
D For DBE : Steel 2%, Concrete 5%
For MCE :Steel 4% , Concrete 7%
Structure category shall be as given in Table 5, IS:1893(Part 4)-2005. However, these can be
grouped as follows:
Category 1 : CCR (Blast resistant) ,vertical columns/vessels/reactors. These will require detailed
analysis.
Category 2 : All process plant /equipment /structures,process building ,emergency/essential utilities
plant and structures. These will require detailed analysis
Category 3: Utilities plant and structures, non emergency/essential infrastructure. These will require
simplified analysis.
Category 4 : Non process , non industrial building, non plant utility structures , non emergency
infrastructures. These will require simplified analysis.
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5.2.6 THERMAL LOADS
The thermal loads due to equipment or piping acting on the fixed or sliding points thereof shall be
considered in the structural design taking into account its actual situation.
5.2.7 IMPACT & VIBRATORY LOADS
Structures subjected to impact or vibratory loads shall be designed as per the provisions of IS: 875
(Part 2) -1987 & IS: 2974 – 1982.
Wherever specifically not mentioned either in above codes or in equipment drawings, the loads which
involve impact forces shall be increased as follows:
• Supports of elevators : 100% of live load

• Shaft or motor driven machinery : 20% of machinery weight
• Reciprocating machinery : 50% of machinery weight
• Hangers for floors or balconies : 33% of live load
• Overhead Traveling crane
• Vertical force : 25% of max. wheel load for crab operated
crane. 10% of max. wheel load for pendant
operated crane.
• Lateral force : 20% of the weight of trolley and lifted load
applied one half at the top of each rail.
• Longitudinal force : 10% of max. wheel load
• Hoist ((Lateral force) : 20% of lifted load
• Bundle Pull Force
Bundle Pull force for different types of Exchangers shall be as follows:
• Fixed Type : Nil
• Kettle Type : 0.3 X Bundle weight
• All other types : 0.86 X Bundle weight or 30 N/mm of dia.
whichever is greater
Total Bundle pull shall be considered on fixed pedestal alone.
When the manufacturer of equipment specifies the loads, then such loads shall be considered in
the design instead of the above.
5.2.8 ERECTION / CONSTRUCTION LOADS
Erection / Construction loads furnished by equipment manufacturer shall be used for designing
technological structure, hardstands etc., wherever applicable.
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5.2.9 BLAST FORCE
Blast resistant control room or any other specified structures subjected to blast forces generated due
to accidental blasts from hydrocarbon ignitions shall be designed to withstand all such forces. Design
blast loads, and Blast resistant construction, shall conform to OISD-STD-163. Blast Resistant
Structures shall be designed to withstand blast force of minimum 3 psi as per OISD – STD – 163.
5.2.10. OTHER LOADS
Apart from the specified live loads, any other equipment load or possible overloading during
construction/hydro-test/maintenance/erection shall also be considered in the design. Under
hydro test condition the wind force shall be taken as 25% of normal loading. Design of all
structures shall also consider any other relevant and consequential load/stress imparted to the
structure.
All building /structures shall be designed to resist the worst combination of the above loads.
However wind loads shall not be considered in combination with loads due to maintenance
cranes in workshop, comp. House etc.
5.2.11 LOAD COMBINATIONS:
5.2.11. Stacks, Towers, Vertical Vessels, Exchangers and Horizontal Vessels, Open Technological
1 Structures supporting equipment
Load elements shall be as set out below:
a = Self weight of equipment and foundation (incl. fire proofing, piping, internals, insulation,
platforms supported from equipment)
b = Operating weight of equipment (as above, including weight of operating fluid)
c = Test wt. of equipment (as per ‘b’ except full of water instead of operating fluid)
d = Live load on platforms
e = Wind load
f = 25% of wind load
g = Earthquake load
h = Erection load
i = Dynamic loads
j = Thermal loads
k = Pipe stress loading
The above load elements shall be combined to form load combinations as shown in the following
Load Element Combination Table.
Load element combination table for stacks, towers vertical vessels

OPERATING ERECTION TEST
STABILITY
W/O WIND WITH WIND WITH EQ. WITH WIND WITH WIND
COMBINATION NO 1 2 3 4 5 6
Dead Load a -- -- -- X -- X
Operating Load b X X X -- -- --
Test c -- -- -- -- X --
Live Load d X X X1 -- X --
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Wind Load e -- X -- X -- X
25% Wind Load f -- -- -- -- X --
Earthquake Load g -- -- X -- -- --
Erection h -- -- -- X -- --
Dynamic i X X X -- -- --
Thermal j X X X -- -- --
Pipe Stress k X X X -- -- --
NOTE:
X= Indicates applicable load case
X1 = Live Load as appropriate to seismic
Selection of Load combinations to be considered in analysis and design shall be decided based on the type of
structure under consideration.
Combinations 1, 2 and 4 shall always be considered and combinations 3 and 5 when applicable.
The overall stability of the structure and foundations may need to be reviewed against a more critical load
combination than combinations 1 to 6 depending upon configuration of structure.
5.2.11.2 Horizontal Vessels/ Exchangers
a = Self-weight of equipment and foundation

b = Operating weight of exchanger
c = Live load on platform (if any)
d = Wind load (longitudinal)
e = Wind load (transverse)
f = Earthquake load
g = Thermal load
h = Pipe stress load
i = Bundle pull
The load element combination table shall be as follows:

OPERATING MAINTENANCE STABILITY
COMBINATION NO
1 2 3 4 5 6
Dead Load a -- -- -- X X --
Operating Load b X X X -- -- X
Live Load c X X X -- -- --
Wind Load d/e -- X -- -- X --
Earthquake f -- -- X -- -- X
Thermal g X X X -- -- --
Pipe Stress h X X X -- -- --
Bundle pull i -- -- -- X -- --
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5.2.11.3 Open Technological Structures Supporting Equipment
a = Self weight of structure, equipment, piping, insulation, fireproofing

b = Operating weight (as ‘a’ but including weight of operating fluid)
c = Test weight (as per ‘b’ except full of water instead of operating fluid)
d = Live load
e = Wind load - 100%
f = Wind load - 25%
g = Earthquake load
h = Dynamic load
i = Thermal load
j = Pipe stress load
The load element combination table shall be as follows:

OPERATING ERECTION TEST STABILITY
COMBINATION NO
1 2 3 4 5 6 7
Dead Load a -- -- -- X -- X X
Operating Load b X X X -- -- -- --
Test Load c -- -- -- -- X -- --
Live Load d X X X -- X -- --
Wind Load - 100% e -- X -- X -- X --
Wind Load - 25% f -- -- -- -- X -- --
Seismic g -- -- X -- -- -- X
Dynamic h X X X -- -- -- --
Thermal i X X X -- -- -- --
Pipe stress j X X X -- -- -- --
5.2.11.4 Shed type buildings with crane loads:
a. For design of roof trusses

• DL + LL on roof
• DL + WL
b. For design of roof for portals

• DL + LL on roof + crane load + Surge
• DL + WL
c. For design of roof leg

• DL + LL + Surge
• DL + LL + Surge + WL (50%)
• DL + LL (50%) + Surge (50%) + WL
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d. For design column and foundation

• DL + LL + Surge
• DL + LL + Surge + WL (50%)
• DL + WL (100%)
5.3 DEFLECTIONS
5.3.1 Deflections in concrete structures shall in general be limited by adherence to the limits on span by
depth ratio for beams and slabs and length to lateral dimension ratios for columns as prescribed in
IS: 456. Where special functional/serviceability requirements or large spans demand actual
deflections and/or crack widths shall be calculated and the following limits adhered to:
Total deflection due to all loads including the effects of : Span / 250
temperature creep and shrinkage
Crack width (for non-liquid retaining structure) : 0.3 mm
5.3.2 Deflections in steel structures shall be limited to the following values: -

DEFLECTION
TYPE OF MEMBERS SIMPLE OR CANTILEVER LOADING
CONTINUOUS BEAM BEAM
Girders, beams supporting floors, SPAN / 325 SPAN / 400 Dead + Live
walkways
Girders, beams, supporting floors, SPAN / 325 SPAN / 250 Dead + Live +
walkways Wind/Seismic
SPAN / 325 SPAN / 400 Dead +Live
Purlins Dead + Live +
SPAN / 200 SPAN / 200
Wind/Seismic
D Beams subject to dynamic loads SPAN / 450 SPAN / 500 Dead + Live +
Wind/Seismic
Crane Girders
• Carrying manually operated cranes SPAN / 500 SPAN / 1000 Dead + Live +
Wind
• Carrying EOT cranes up to 50T capacity SPAN / 750 SPAN / 1500
• Carrying EOT cranes more than 50T SPAN / 1000 SPAN / 2500
capacity
Wall stanchions, side runners, wall beams SPAN / 325 ---- Wind/Seismic
Grating/Chequered plate SPAN / 200 or 6mm ---- Dead + Live
whichever is minimum
5.3.3 The permissible horizontal deflection for multi-storied steel structure/building including flare stack
shall be storey height / 325 unless otherwise specified. For other structures / structural components
limiting deflection shall be as specified in relevant IS codes.
The limiting horizontal deflection for structures supporting two-phase fluid flow pipe shall be limited to
25mm or H / 300 (H is height of support above the pedestal top) whichever is lower.
5.4 FOUNDATIONS
5.4.1 Type of foundations - To be decided as per final Soil investigation report..
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5.4.2 Minimum heights of plinth/pedestals above H.P. of paving / Finished Ground Level (FGL) / Finished
Floor Level (FFL) shall be:
• Building plinth : 300 mm (min) above high point of pavement (HPP)

• Pedestals for structural : 300mm (min) above finished floor level.
columns
• Open paved area : 150mm (min.) above HPP or as indicated in equipment
layout drawing.
• Open unpaved area Same as HPP level.
• Covered area (building etc.) : 200mm (min.) above HPP or as indicated in drawing
• Storage tank foundation : As per equipment layout
All equipment supporting foundations/pedestals
• Open area : As required but not less than 300mm from HPP
• Covered area : As required but not less than 150mm from FFL
• Stair Pedestals : 150mm (min.) from FFL or as indicated in equipment layout
drawing.
• Ladder pedestals : 150mm from FFL
5.4.3 Grouting
The minimum thickness of grout shall be 25mm and not more than 50mm.
All anchor bolt sleeves / pockets and spaces under column bases, shoe plates etc., shall be grouted
with free flow, non shrink (premix type) grout with 28 day minimum cube crushing strength of
40N/mm2. Ordinary cement sand (1:2) grout (with non shrink cement admixture) shall only be used
under the base plates of crossovers, short pipe supports (not exceeding 1.5m height) and small
operating platforms (not exceeding 2m height) not supporting any equipment.
Grouting requirement for machines and equipments are not covered here. The same shall be
governed by vendors requirement.(See clause no 3.9.2)
5.4.4 Lean Concrete
• Lean concrete blinding layer of mix 1:4:8 (M 7.5) shall be provided under pile caps, floor slabs
and other foundations.
• Minimum thickness of blinding concrete layer shall be 50mm and minimum extent beyond the
foundation edge is 50mm. However, for water retaining structures thickness shall be 75mm and
extent shall be 75mm beyond the foundation edge with mix 1:1.5:3.
• Lean concrete of mix 1:4:8 (M 7.5) shall be used to compensate for difference in founding levels,
weak soil etc.
• Lean concrete of grade M20 of thickness 150mm shall be provided under all masonry footings.
5.4.5 Uplift on foundations
In the design of horizontal elements below Grade, the upward pressure of water, where applicable
shall be taken as the full hydrostatic pressure applied over the whole area. The hydrostatic head
shall be measured from the underside of construction. Any other upward load shall also be included
in the design. Factor of safety against Uplift shall be 1.2.
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5.4.6 Soil and Hydrostatic pressure on walls below grade
In the design of Walls below Grade, provision shall be made for the lateral pressure of adjacent soil.
Due allowance shall be made for possible surcharge from fixed or moving loads. When a portion or
whole of the adjacent soil is below a free water surface, computations shall be based on the weight
of the soil diminished by buoyancy, plus full Hydrostatic Pressure. The Walls below Grade shall also
be designed to withstand lateral soil loads.
The lateral pressure from surcharge loads shall be taken in addition to the lateral earth pressure
loads. A minimum surcharge of 2 t/m2 shall be considered for all working areas.
5.4.7 Bearing capacity of soil
Permissible increase in SBC / Pile capacities (for compressive, shear and uplift / tension) shall be as
per final soil investigation report..
Under blast (due to hydrocarbon explosion) load combinations the design bearing pressure of soil
shall not exceed twice the allowable static bearing pressure of soil. Pile capacity shall be similarly
increased in blast condition to 1.5 times the permissible capacity under compression, tension and
shear modes.
5.4.8 Tank foundation
For tank foundation design refer standard specification no 44NC-4600-000/C-02/0027/A4 &

recommendation as per final soil investigation report.
5.4.9 STABILITY
Minimum factor of safety for foundations for different structures shall be as given below:
MINIMUM FACTOR OF
MINIMUM FACTOR OF
SAFETY AGAINST % WEIGHT OF
SAFETY AGAINST SLIDING
OVERTURNING OVERBURDEN OVER
TYPE OF STRUCTURE
PROJECTED PLAN
WITH WIND WITHOUT WIND WITH WIND WITHOUT WIND
AREA OF FOOTING
OR SEISMIC OR SEISMIC OR SEISMIC OR SEISMIC
All buildings / structures / 1.5 2.0 1.5 1.5 100

equipments in units.
$
Pipe-rack (Offsite) 1.5 2.0 1.5 1.75 50
Flood light mast 1.5 - 1.5 - 50$
Retaining wall 1.5 2.0 1.5 1.75 100
Overhead water tank 1.5* / 2.0 - 1.5 - 50$

$
Flare supporting structure 1.5 - 1.5 - 50
Blast resistant structures 1.5 2.0 / 1.2# 1.5 1.5 / 1.5# 100
* Empty condition
# With blast pressure
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$ In case area is paved, overburden shall be based on NGL (for area under filling) or 600mm
below HPP whichever is lower. In case of unpaved area, it shall be w.r.t. FGL.
Minimum factory of safety against UPLIFT shall be 1.2 for all structures. (Note : In case of sumps,
lining weight shall not be included)
5.4.10 VIBRATION
Foundations and structures for machines subject to vibrations shall be so proportioned that the
amplitude and frequency of foundation/structure are within the permissible limits.
5.4.11 SETTLEMENT
The settlement of foundation by the dead plus imposed load criteria shall not exceed the following
values, unless otherwise specified:
• Foundation in Unit areas, Utility areas and Plant building : 25 mm

foundations (housing process equipment and piping)
• Non-plant buildings (not housing process equipment and piping) : 40 mm
• Raft foundations : 40 mm
5.5 MINIMUM COVER TO MAIN REINFORCEMENT
The following minimum clear cover shall be provided for RCC work unless otherwise specified:
D
Pile ( All sides ) : 75mm
Pile cap
• Bottom face : 100 mm
• Top face, sides : 50 mm
Foundation / Superstructure
• Bottom : 100 mm
• Side and top : 50 mm
• Base slab, plinth beam : 50 mm
• Slab (roof and floor), waist slab : 50 mm or dia of bar whichever is greater
D • Canopy, chajja, louver, fin 30 mm or dia of bar whichever is greater
• Beam (roof, floor, tie), lintel : 50 mm or dia of bar whichever is greater.
• Column, Pedestal : 50 mm
Retaining wall, Basement

• Face in contact with earth : 50 mm
• Free face : 50 mm or dia. of bar whichever is greater
Liquid Retaining structure

• Face in contact with liquid : 50 mm or dia. of bar whichever is greater
• Face away from liquid but in contact with earth : 50 mm
• Free face : 50 mm or dia. of bar whichever is greater
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Trenches : 50 mm
5.6 MINIMUM THICKNESS
5.6.1 Minimum thickness of structural concrete elements shall be:
• Footings (all types including raft foundations)

(Note : Tapered footings shall not have thickness less than 150 mm at : 300 mm
the edges. Minimum average thickness shall not be less than 300mm)
• Pile cap : 500 mm
• Basement walls : 150 mm
• Base slab with beams : 200 mm
• Base slab without beams : 300 mm
• Slab thickness in raft foundations with beam & slab constructions. : 150 mm
• Floor / Roof slab, walkway, canopy slab : 150 mm
• Cable pipe trench walls and base slab : 125 mm
• Parapet / Chajja : 100 mm
• Louver / Fin : 100 mm
• Precast trench cover/floor slab : 125 mm
• Precast floor slab/Louver (in contact with liquid) : 125 mm
• Liquid retaining/leak proof structure walls : 150 mm
• Liquid retaining / leak proof structure, base slab with beams : 200 mm
• Liquid retaining / leak proof structure, base slab without beams : 300 mm
• Silo/Bin walls : 150 mm
• U/G pit/Reservoir (below ground water table) walls & base slab : 200 mm
• Underground pit (above ground water table) walls and Base slab : 200 mm
• Ground floor slab (non-suspended) : 150 mm
D • Minimum dimension of column : 300 mm
• Minimum width of beam : 300 mm
• Underground Pit Base slab without beams : 300 mm
5.6.2 Minimum thickness of various structural steel components (hot rolled Sections) shall be:
General Construction
• Trusses, purlins, side runners and bracings : 6 mm

• Columns, beams : 7 mm
• Gussets in Trusses and Girders
• Up to and including 12m span : 8 mm
• Above 12m span : 10 mm
• Stiffeners : 8 mm
• Base plates : 10 mm
• Galvanized Chequered plate : 6 mm (on plane)
• Flats for Electro Forged Galvanized grating : 3 mm
• Insert Plate : 10 mm
• Sliding plate under horizontal vessels and Exchanger base : 10 mm
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However, the minimum thickness of structural steel components (except grating and Chequered
plates) which are directly exposed to weather and inaccessible for repainting shall be 8 mm
Hand railings
Minimum thickness of tubes shall be as specified in IS: 806 – 1968.
Hand rails, 1050mm high, shall be provided to all walkways, platforms, staircases, Toe plate (100mm
x 6mm) shall be provided for all hand-railing (except for staircases). Spacing of upright shall be
1500mm (maximum). Two types of hand railing shall be provided.
- For Tech. structures, walkways, platforms (except platform around / on circular / horizontal
vessels), staircases : Top rail and upright shall be 40mm dia, midrail shall be 25mm dia (NB) MS
tubes.
- For platforms around circular vessels : Top rail shall be 32mm dia (NB) MS tubes but mid rail and
upright shall be of structural steel.
Structural members exposed to marked corrosive action shall be increased to thickness or otherwise
shall be protected suitably.
5.7 PAINTING
Painting including shop primer to structural steel shall be as per the painting specification. For RCC
structure it will be as per Architectural design basis & specification and job specification.
5.8 MINIMUM COVER TO FOUNDATION BOLTS
Minimum distance from the center line of foundation/ anchor bolt to edge of pedestal shall be the
maximum of the following:
• Clear distance from the edge of the base plate/base frame to the outer edge of the pedestal shall
be minimum 50mm
• Clear distance from the face of the pocket to the outer edge of pedestal shall be 75mm.
• Clear distance from the edge of the sleeve or anchor plate to the edge of pedestal shall be 75mm
• Minimum gap of 30mm between edges of anchor plates of adjoining anchor bolts.
5.9 NON SUSPENDED GROUND FLOOR SLAB
For non suspended ground floor /Grade slab details refer Architectural design basis.
5.10 LIQUID RETAINING/STORAGE R.C.C STRUCTURE AND BASEMENT

All liquid retaining/storage R.C.C structures shall be leak proof and designed as uncracked section in
working stress method as per IS: 3370 – 1965 or in limit state method having a maximum allowable
crack width of 0.1mm under normal loading conditions. However, the parts of such structures not
coming in contact with the liquid shall be designed according to IS: 456 – 2000 except ribs of beams
of suspended floor slabs and counterforts of walls (located on the side remote from liquid) and roof of
liquid retaining structures which shall be designed as uncracked section or cracked section having
crack width within the limit as mentioned above.
All liquid retaining/storage structures shall be designed assuming liquid up to the full height of wall
irrespective of provision of any overflow arrangement.
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For cooling tower, hot/cold water basin and other primary-framing members, which remain constantly
in contact with water, shall be designed as uncracked section/cracked section having crack within the
permissible limit.
Following conditions shall be considered for design of liquid retaining structures, basement, trenches
and other underground structure: -
• Only water pressure from inside and no earth pressure, groundwater pressure or surcharge from
outside (application only to structures which are to be filled up with water/liquid)
• Earth pressure, surcharge pressure or ground water pressure from outside and no water pressure
from inside
• Base slab shall also be designed for the empty condition during construction and maintenance
stages with maximum ground water table.
Intermediate dividing walls of pump sumps shall be designed considering water in one pump sump
only and the other sump being empty for maintenance.
Exterior faces of underground structures in contact with earth shall be painted with two coats of cold
applied bitumen paint of approved made, laid as per manufacturer’s specification.
5.11 EQUIPMENT FOUNDATIONS

Foundations and structures supporting rotating machinery shall be so proportioned that their natural
frequency shall not fall within the range of 0.9 to 1.1 of normal operating speed of the equipment.
Further for major rotating machinery such as main compressor, the amplitude of foundation or
structure during normal operation shall not exceed the allowable amplitude specified by the
equipment manufacturer. The above consideration may be omitted for centrifugal pumps and fans
and other minor rotating equipment weighing less than one ton or if the mass of the rotating parts are
less than 1/100th of the mass of foundation installed directly on concrete foundation provided that the
weight of foundation is not less than 3.0 times of the equipment weight. In such cases, dynamic
analysis is not necessary.
5.12 STAIRCASE / LADDERS
5.12.1 For details of Staircase refer Architecture design basis.

o
5.12.2 All steel staircases shall have channel (minimum MC150) provided as stringer with a slope of 37 . ``.
5.12.3 For series of tall columns, stairs shall be provided up to top platform with interconnected platforms in
between.
5.12.4 For isolated columns, ladders shall be provided.
Ladders shall be provided to platforms, which do not require frequent access. Safety cages shall be
provided when height is more than 4.5m.
5.13 GRATING FLOORS
For grating floors on steel beams, the beams shall be suitably braced to ensure the integrity of the
floor for horizontal diaphragm action. Electro-forged Hot Dipped Galvanised Gratings of Mild Steel
shall be provided. Minimum depth of grating shall be 25mm and maximum size of voids shall be
30mm X 55mm. The minimum thickness of galvanizing shall be 120 microns.
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5.14 PLINTH PROTECTION
Each building shall be provided with 1.0 m wide concrete M20, 100mm thick laid on 50thk. M7.5 (PCC
1:4:8) concrete all round as plinth protection. Paving shall be sloped for a rapid run off of rainwater
away from the building.
5.15 DAMP PROOF COURSE (D.P.C)
P.C.C of grade 1:1.5:3 with water repelling admixture of minimum 50mm thickness (D.P.C) shall be
provided as DPC at plinth level for all masonry walls.
5.16 MASONRY WALL
For details refer Architectural design basis.
5.17 RAMPS
Ramps for building entrance shall be cast in situ R.C.C designed, as a grade slab and the slope of
ramps shall not be less than 1 in 10. Minimum thickness of the slab shall be 150mm.
5.18 PLANT AREA ROADS & PAVING INCLUDING APPROACH ROAD
5.18.1 All road widths shall be as indicated in plot plan/equipment layout. Contractor shall design cross
section of roads ,including roads for access wherever applicable as per IRC 37. All main road in ISBL
unit area shall be of rigid/concrete type and all other roads between buildings /approach road shall
be flexible /asphalt type .In case contractor proposes to use existing roads for erection purpose ,the
same should be strengthened to cater the erection loads. The contractor shall ensure that use of
existing roads does not hinder normal activities in existing plants. The contractor shall repair any
damage to existing roads or other facilities , at the earliest at no extra cost.
Note: Width of all types of roads ,shoulders/ berm road elevation of all new roads shall be in line
with existing refinery roads. Thickness of new roads sections should not be less than that of existing
as followed refinery for different uses.
5.18.2 Crown level of the road shall be 150mm above FGL.
5.18.3 All roads shall be designed as per IRC: 37 – 2001 (using 2 msa & design CBR as per final soil
investigation report)
Minimum requirements
• Camber : 1 in 35
• Berm slope : 1 in 100
• Embankment fill side slope : 1 in 1.5
• At road intersections minimum radius of turn : 12m for 7.5m, 9m wide road
15m for 12.5m wide road
8m for 6.0m road
6m for 4.0m wide road
• Head Room Clearance : 6.5 m above crown unless specified
CBR curve to be followed for designing roads subjected to heavy crane movement.
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Minimum cross section (Final after compaction)
I. Sub base: The sub base shall be of 200 mm layer of crushed /broken stone over 75 mm
D thick layer of murum/sand on well compacted earth.

II. Base course : The base course shall be of 250 mm thick wet bound macadam consisting of 3
layers of 100,75,75 mm.
III. Bituminous Wearing course: The wearing course shall be 75 mm thick for roads, the grade of
bitumen shall be 60/70..
The above thickness are minimum requirement actual will depend on CBR value & IRC requirement
5.19 PAVEMENT & DYKE WALLS
Pavements where required shall be of following types:
5.19.1 HARDSTAND : For pavements : To be designed based on envisaged loads

required for erection of
heavy equipments
TYPE I : For pavements : 200mm thick concrete M-35 with double layers
subjected to vehicular reinforcement 8mm dia. @ 150 c/c both ways
traffic, Tube bundle placed over 50mm thick PCC 1:4:8 over 200mm
pulling areas thick sand/boulder in two layers
TYPE II : For pavements not : 150mm thick concrete M-35 with single layer
subjected to vehicular reinforcement 8mm dia. @ 200 c/c both ways
movement placed centrally over 50mm thick PCC 1:4:8 on
150mm compacted sand or soling.
TYPE III : Non operating areas : 125mm thick concrete M-35 with single layer
reinforcement 8mm dia. @ 300 c/c both ways
placed centrally over 50mm thick PCC 1:4:8 on
150mm compacted sand or soling.
5.19.2 Pavements shall be properly sloped (min. 1 in 100) and provided with 12mm joints around equipment
foundations/pedestals/columns. The joints shall be filled with sand except for the top 25mm, which
shall be filled with polysulphide/bitumen sealant.
5.19.3 Expansion joints shall be provided at a maximum spacing of 25m. The 12mm joints shall be filled with
premoulded filler boards or approved equivalent with the top 25mm filled with polysulphide/bitumen
sealing compound.
5.19.4 Type I paving shall be provided with 20mm M.S.dowel bars @ 300mm c/c at expansion joints.
5.19.5 Paving adjacent to unpaved areas shall have down stand edge beams 450mm deep.
5.19.6 Dyke walls shall be of Leak proof RC construction conforming to OISD-STD-118.
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5.20 CABLE TRENCHES
5.20.1 RCC cable trenches are to be provided in the plant area and shall be designed to withstand load of
cranes, whenever required.
5.20.2 ISA 50X50X6 is to be embedded throughout the length of the trench.
5.20.3 Cable crossings at Roads & pipe way shall be with RCC pipes NP-3 class as per IS: 458 – 2003.
5.21 DRINKING / SANITARY / FIRE WATER DISTRIBUTION
5.21.1 Drinking water pipes shall be laid underground or routed on pipe rack.
5.21.2 Minimum size of drinking water header shall be 2”.
5.21.3 Drinking water posts shall be provided at suitable locations.
5.21.4 Drinking water line laid above shall be insulated.
5.21.5 Flushing tank shall be provided for each building.
5.21.6 Fire water lines shall be provided through trenches.
6.0 PLANT AREA DRAINAGE AND SEWAGE SYSTEM
In principle, drainage system shall be of open ditch, underground piping system or combination
thereof. Drainage system shall be separated to the following three categories:
1. Storm Water
2. Process Water
3. Sanitary Water
6.1 STORM DRAINAGE:
6.1.1 Surface drainage shall be designed as two separate systems, carrying contaminated and
uncontaminated surface water with clear demarcation between the two.
The storm water drains shall cover uncontaminated surface water run-off. The drains shall generally
be rectangular RCC (M35) with Electro-forged hot dipped galvanized grating.
Heavy duty galvanized grating in accordance with IS: 12592 shall be provided in vehicular movement
area to suit 10 ton axle load.
Storm water drains are to be provided on both sides of the road.
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6.1.2 All storm water drains shall be designed for the maximum hourly rainfall intensity. Also the designed
discharge of a particular drain shall be checked for fire water requirement as well as for design rainfall
run off and the higher of the two will prevail.
The design run-off shall be calculated using the formula.
Q = KxIxA
360
Where Q = Discharge in cum/sec

K = Run-off co-efficient
I = Intensity of rainfall in mm/hr
A = Influence are being drained in hectares (10,000 sq.m)
The run-off co-efficient for areas may be taken as follows:
Paved area-concrete : 1.0

Bituminous : 0.9
Compacted area such as tank farm / offsite areas / expansion area : 0.7
Unusable open area / green belt area : 0.4
The following parameters are to be followed for sizing of ditches:
Minimum velocity in ditch : 0.6 m/sec

Maximum velocity in ditch : 2.4 m/sec
Minimum depth : 300mm
Min. Rectangular ditch width : 300mm
Main rectangular ditch width : 500mm
Slopes:
Rectangular drains : 1 : 500 min.
Sizing of ditches shall be done as per Manning’s formula:

2/3 1/2
V = R S
N
Where
V = Velocity of flow (m/sec)
R = Hydraulic radius = A/P (m)
A = Area of cross section of drain (m)
P = Wetted perimeter of drain (m)
S = Slope (dimensionless)
N = Co-efficient of roughness
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The co-efficient roughness shall be taken as follows:

- Plastered concrete : 0.013
- Cast-in-situ concrete : 0.015
- Brick lined : 0.017
6.1.3 The storm drains shall be provided with baffle type of oil catchers at final outlet at boundary of plant.
6.1.4 Ditches
a) Type : Rectangular type in and around units. Other areas,

ditches shall be rectangular and / or trapezoidal type.
b) Construction.
- Rectangular ditches : RCC in units
- Trapezoidal ditches : Stone pitching with raised pointing, PCC (M20) bedding
at bottom where erosion is expected.
6.1.5 Storm water drains shall cross the roads by suitable pipe culverts or box culverts. Material of
construction of culverts shall be as below:
Pipe culverts Roads : RCC pipe class NP3 as per IS:458 (minimum size 350mm)
Box culverts : RCC construction (M35 grade)
Culverts for crane movement roads shall be separately designed.
6.2 PROCESS DRAINAGE
6.2.1 Underground sewer system in the plant are divided into following categories:
I) Contaminated water sewers (CRWS)

II) Oily water sewers (OWS)
III) Closed blow down sewer (CBD)
IV) Amine blow down sewer (ABD)
V) Chemical sewer / sour water sewer
6.2.2 Surface drainage from contaminated areas due to floor washings, drains etc., are collected in
separate catch basins and led through CRWS. CRWS shall consist of carbon steel sewer with
corrosion protection, funnel points, clean outs, vent pipe, flame arrester etc.
6.2.3 Discharge from regular oil contamination areas are collected in separate catch basins and are joined
by OWS. Oily water from pumps, equipment, drains etc., are collected through separate headers with
OWS funnels. OWS shall consist of carbon steel sewer with corrosion protection, funnel points, clean
outs, vent pipe, flame arrester etc.
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2
6.2.4 The maximum influence area per catch basin shall be 150m with 12m x 12m or 15m x 10m size. The
catch basin shall be located so that high point ride line is in middle of pipe-rack. Paved areas shall be
slopped towards catch basis with a slope of 1 : 100. The maximum surface drainage travel extent
shall be limited to 15m. No catch basin is located in heater area.
6.2.5 The sewer from the first catch pit shall have a minimum size of 200mm based on fire water flow of
144 Cu.m/hr. Sewers from subsequent catch pits shall have minimum size of 300mm based on a fire
water requirement of 216 Cu.m/hr. The main sewer linking two or more units shall be designed for
firewater requirements of 600 Cu.m/hr.
The slopes shall be provided so as to have the following velocities with sewers running full.
Min. velocity 0.6 m/sec
Max. velocity 2.4 m/sec.
6.2.6 The minimum cover over pipes shall be as follows:
I) Sewer size 6” from equipment drain points to nearest main header / manhole = 300mm.
II) For main headers having size 6” and above, without possibility of truck / crane movement =
450mm.
III) For headers in open paved areas with possibility of truck / crane movement = 750mm (pipes
should also be encased with 150mm thk. Concrete in this case)
6.2.7 Material of construction
CRWS : CS pipes as per piping specification

OWS : CS pipe as per piping specification with corrosion protection and tape coating.
Manhole : RCC M35
Vent pipe : MS pipe
6.2.8 Manholes shall be provided as shown:
Spacing:
Sewers upto 12” dia : 30m max.
Sewers upto 12” – 20” dia : 45m max.
Sewers above 36” : Depends on local condition but not more than 60m.
Location:
Junction of sewers
Dead end of mains
Change of grade or size of mains.
6.2.9 Sealed manholes shall be provided at following locations:
At Unit Battery Limit (B/L) so that unit area is cut off from any fire in offsite area.
At manhole where branch sewers connect with main sewers.
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On oily main sewers, provide fire barriers at suitable points for isolating vital installations from
hazardous ones.
One sealed manhole for every 30m length of main sewer in the unit shall be provided.
Sealed manholes with bent pipes seal type shall be used for CS pipes upto 16” dia. For pipes above
16” dia, CS pipes and all dia RCC pipes, double compartment type manholes shall be used.
6.2.10 Clean outs shall be provided at following locations:
Dead ends of sewers

Where a sewer is in horizontal plane and makes at 90 degree turn.
Where a sewer is in horizontal plane and makes a 45 degree turn in direction and u/s length of line
exceeds 15m.
6.2.11 The sump for holding CRWS / OWS pumps shall be covered with adequate number of manhole
access ladders and air vents. Hand rail shall be provided over sump of horizontal centrifugal pumps
with RCC stairs to reach the top. Covered pump house shall be provided with monorail. RCC flooring
shall be provided in the pump house area. Drains covered with GI gratings shall be provided for
drainage of area.
6.2.12 Closed blow down and amine blow down sewers shall be provided as per P&IDs. These shall be
collected in close funnels connected to U/G system and protected as per specification.
6.2.13 Chemical sewer from battery rooms etc., shall be discharged to storm sewers after passing through
neutralization pits.
Corrosion chemicals like acid, caustic and other chemicals shall be collected through separate
sewers and taken to neutralization pit.
HDPE sewer, funnel points, RCC manholes with chemical resistant epoxy coating etc are required.
6.3 SANITARY SEWERS
6.3.1 The system shall be designed on two pipe system i.e. soil pipe (SP – for waste water from water
closets) and waste pipe (WP – for waste water from wash basin, sink, cooler etc.). Ventilating pipe
with cowl at top is to be provided.
6.3.2 Sanitary sewers shall be designed for minimum 120 liters/capita/day and shall be designed for 3
times the average daily flow. It shall be designed to run half-full upto 400mm dia.
Sewers shall be designed for a minimum self cleansing velocity of 0.75m/sec and the maximum
velocity shall not exceed 2.4 m/sec.
Normal slopes shall not be less than as follows:
100 dia - 1 in 57
150 dia - 1 in 100
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200 dia - 1 in 145

250 dia - 1 in 195
300 dia - 1 in 250
Mannings formula shall be used for sizing of sewers.
The minimum size of sewer shall be 150mm stone ware pipe.
6.3.3 Minimum cover over sewers shall be 600mm. Under road, the sewers shall have minimum cover of
1200mm, if not, it shall be enclosed in concrete.
6.3.4 Manholes shall be provided as follows:
Spacing:
Sewers upto 300mm dia = 30m max.
Sewers upto 500 mm dia = 45m max.
Location:
Junction of sewers
Dead end of mains.
Change of grade or size of mains.
6.3.5 Sewers upto first manhole shall be UPVC pipe conforming to IS : 13592 - 1992. Sewer from first
manhole onwards shall be stone ware pipe conforming to IS : 3006-1979.
6.3.6 Manhole shall be of RCC M-35 grade.
6.4 ACID / ALKALI PROOF PAVED AREAS
6.4.1 Acid / Alkali proof floor tile lining shall be provided within and around the caustic treatment / handling /
wash areas and on associated equipment foundation. The entire area shall be curbed by a 300mm
high kerb wall. Normally 25mm thick tile shall be used except for traffic areas where 65mm brick
shall be used.
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7.0 DESIGN CRITERIA
7.1 PIPE RACK
For designing Pipe rack superstructure and foundation the following loads shall be considered.
• Vertical Loading:
Actual weights of pipes coming at each tier shall be calculated. In calculating the actual weight
of pipe, the class of pipe, material content and insulation, if any, shall be taken into
3
consideration. Insulation density shall be taken as 2600 N/m minimum. In case of gas / steam
carrying pipes, the material content shall be taken as one-third volume of pipe filled with water.
The total actual weight thus calculated shall then be divided by the actual extent of the span
covered by the pipes to get the uniformly distributed load per unit length of the span. To obtain
the design uniformly distributed load over the entire span, the u.d.l. obtained as above shall be
increase by 20% to account for fittings and accessories and shall be assumed to be spread over
2
the entire span. However, minimum loading for any pipe rack shall not be less than 1.25 kN/m .
2
In case, the calculated loading is higher than 1.25 kN/m , this shall be rounded off to the nearest
2
multiple of 0.25 (i.e. 1.50, 1.75, 2.0 kN/m ).
Dynamic analysis shall be done for Pipe racks / trestles if supporting pipes with two-phase fluid
flow / transfer line. The minimum natural frequency of the supporting structure shall be 8 hertz.
For calculation of natural frequency of structure, the weight of the pipes shall be ignored.
Vertical loads of Flare pipes shall be taken as one third full of water for piping within units and
one sixth full for outside unit battery limit. All flare line independent support shall be of four
legged braced open tower type construction.
• Friction Force (Longitudinal & Transverse):

The friction force at each tier on every portal both in longitudinal direction shall be 10% of the
design vertical loading of the pipes for four or more pipes supported on a tier. Longitudinal
friction force shall be considered as uniformly distributed over the entire span of the beam at
each tier. Friction force on T-supports and trestles shall be as taken as 30% of the vertical
loading. Both longitudinal and transverse forces shall be considered to be action simultaneously.
For two-phase fluid flow / transfer lines frictional force shall be minimum 50% of the weight of the
pipe including contents & insulation, acting simultaneously in transverse & longitudinal direction.
• Anchor and Guide Force (Thermal load):
These are to be considered as per piping inputs.
• Wind Force:
Transverse wind loading shall be calculated depending on the width of the Pipe rack as per the
following table. This force shall be considered irrespective of the height between two tiers.
Width of Pipe Rack Wind Force at each tier level (N)

Up to 4.0m : 1.25 x p x s
Above 4.0m but up to 6.0m : 1.5 x p x s
Above 6.0m : 2.0 x p x s
2
Where p = Horizontal wind pressure as per IS: 875 (N/m )
s = Spacing of portals (m)
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• Loading on Intermediate Beam at Tier Level

Intermediate beam at tier level shall be designed for 25% of load on main portal beams in
transverse direction. A reduction of 10% in vertical loading may be considered for main portal
beams if intermediate beams are provided.
• Loading on Longitudinal Beams
Longitudinal beams connection portal columns shall be sufficiently strong to sustain 25% of the
load on the transverse beams. This load shall be assumed as two equal concentrated loads
acting at 1/3rd span. Other longitudinal axial forces coming on it from the design of the
supporting system shall also be simultaneously taken into account in the design of the
longitudinal beam. Friction & Anchor forces, if specifically given by piping specialist shall also be
catered for in the design. Loads from monorails, when supported from these beams, shall also
be considered to be acting simultaneously along with all other loads mentioned above.
• Cable tray and Walkway Loads
The estimated actual load from electrical, instrumentation trays shall be considered at the
specified locations, together with walkways, if provided.
• Seismic Loads
For seismic loads, refer clause no. 5.2.5
7.2 RCC AND STEEL CHIMNEYS
RCC and steel chimney shall be designed as per IS:4998 - 1992 and IS:6533 – 1989 respectively.
7.3 FLARE STACK AND VENT SUPPORT STRUCTURES
If the stack is not self supporting a four legged guide structure of structural steel shall be provided.
Operating platforms with chequered plate / grating flooring with ladder approach shall be suitably be
provided to the top. Vent stack pipe shall be supported or guided at various elevations as per the
specifications enclosed elsewhere. Also refer Clause no. 7.7.
7.4 MACHINE FOUNDATIONS
Machine foundations shall satisfy the following requirements:
• Grade of concrete to be used as M35.

• Minimum reinforcement as per requirements of IS:2974 shall be provided with symmetric
reinforcement on opposite faces, even if not required by design considerations.
• The soil stress below foundations under dead loads shall not exceed 80% of the allowable soil
bearing capacity, or safe load on pile, for static loading.
• The combined center of gravity of the machine and foundation system shall as far as possible
pass through the center of area of the foundation raft or centroid of the pile group. Where
unavoidable, eccentricity shall be less than 5% of block foundations and 3% for frame
foundations. However, in highly compressible soils, no eccentricity shall be permitted.
• Foundations shall be so designed that natural frequency of the foundation system shall not
resonate with the following:
a) Operating speed of the motor
b) Operating speed of the machine
c) 2 x operating speed of the machines
d) Critical speed of the machine (for centrifugal machines)
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• Natural frequency of the foundation shall preferably + 20% away from the above mentioned
frequencies. However, amplitudes of vibration of the foundation block shall always be checked to
be within permissible limits.
• Amplitudes of the vibration shall be less than values specified by the machine manufacturer or
provisions of IS : 2974 whichever is stringent.
• The foundation and its superstructure shall be separated from adjacent foundations and
platforms. Clear air gap shall be provided in superstructure to avoid transmission of vibration to
adjacent structures. Special notes shall be given on the drawing in this respect and suitable
details shall be shown as required.
• Foundation resting partly on rock and partly on soil shall preferably be avoided. However, if
unavoidable, the soil area shall be replaced by lean concrete (1:4:8). However, PMC
concurrence shall be obtained for such cases.
• Foundations shall not rest on previously backfilled on sensitive soils. In case it is unavoidable
PMC concurrence shall be obtained for any soil treatment.
• For frame foundations, base raft shall be cast in a single concreting operation. A properly
designed construction joint shall be provided between the base slab and columns. The entire
superstructure of columns and upper deck shall be cast in a continuous concreting operation.
• If height of the frame columns above raft level exceeds 8.0m, an additional construction joint at
the junction of columns / top-deck may be provided.
• Block foundations shall be cast in single concreting operation. Foundations consisting of various
blocks seated on a common foundation raft may be provided with a single, properly designed
construction joint at the top of base raft. However, a special note shall always be given on the
drawing the recommended procedure of construction.
• When several foundations for similar machines need to be seated on a common raft, the
computation of vibration shall proceed assuming that each foundation is independent of other s
by breaking up the raft into sections corresponding to separate foundations. The design value
for the permissible amplitude of vibrations may be increased by 30%. However, PMC
concurrence shall be obtained for such combinations.
7.5 BLAST RESISTANT STRUCTURES
The structure shall be designed on shear wall concept with roof acting as a diaphragm that transfers
the transverse loads to the side shear wall and columns in proportion to their stiffness. Internal
partitions and divisions wall shall not be designed as shear wall.
The structure shall be designed for actual blast pressure or 3 psi whichever is more.
Minimum thickness of reinforced concrete blast walls shall be 230mm to meet the criteria of TAC
(Tariff Advisory Committee) and minimum thickness of roof slab shall be 150mm.
RC blast wall shall be taken upto 1.5m below FGL or upto top of footing whichever is shallower
maintaining the wall thickness & Reinforcement (R/F) same as in superstructure.
All superstructure members shall be designed for reversal of stresses.
Minimum R/F in wall in each face shall be 1% (as total % in both direction) of gross cross sectional
area as calculated from structural design considerations. The maximum R/F in each face however
shall not exceed 2%.
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Roof slab shall be doubly reinforced, minimum R/F on top & bottom shall be 1% of gross cross
sectional area (as total % in both direction).
Maximum spacing of bars in walls and roof slabs shall not exceed 150mm c/c.
Design bearing pressure of soil shall not exceed twice the allowable static bearing pressure of soil for
blast load combination only.
Allowable pile capacity on compression, uplift and shear may be increased by 50% under blast load
combination.
7.6 PLATFORMS
All platforms on grade and on equipment (horizontal, vertical vessels and process columns etc.) shall
be provided with handrail and stair / ladder access.. The platforms shall also be suitably
interconnected wherever required. Platform floors shall be of grating and designed for specified
loads.
7.6.1 PLATFORMS FOR TOWERS VERTICAL & HORIZONTAL VESSELS
• Distance of platform below centerline of manhole flange side platform : 900 – 1050mm
• Width of manhole platform from manhole cover to outside edge of platform : 1000mm
• Platform extension beyond centre line of manhole – side platform : 1000mm
• Distance of platform below under side of flange – head platform : 175mm
• Width of platform from three sides of manhole – head platform : 750mm
Complete platform all around shall be provided in case of columns at all manhole locations.
Maximum height of platform ladders shall be restricted to 5-6 meters.
For upto two number safety valves on column top platforms davit is adequate. For more than two
number safety valves, monorails with chain pulley block shall be provided. Load capacity for davit &
monorail shall be minimum 0.5T.
Access platforms / ladders shall to be provided along the column for valves and instruments.
Minimum width of platform shall be 750mm clear.
For ease of operation and maintenance, column and vessels which are grouped together shall have
their platforms at the same elevation should be interconnected by walkways.
Platforms with stair access shall also be provided for:

• Location at which normal monitoring once a day or more is required or where samples are taken.
• Locations where vessels or equipment items have operator attention such as compressors,
boilers etc.
Platforms with ladder access shall be provided for:

• Points which require occasional operating access including valves, spectacle blind and motor
operated valves, heater stack sampling points.
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• Man-ways above grade on equipment.

• Platform shall be provided all along the transfer lines.
Ladder location
• Wherever practicable, ladder shall be so arranged that users face equipment or platform rather
than facing open space.
• Landings shall be staggered. No ladder shall be more than 6M in one flight.
7.7 VESSEL & TANK FOUNDATIONS AND SUPPORTING STRUCTURES
All columns with diameter more than 800mm shall be self supporting.
All columns with dia upto 800mm shall be supported by superimposed structure around the column
covering the entire height. Guy wires are not permitted to be used for supporting any equipment.
In specific cases, columns have dia upto 800mm and total height not exceeding 20m can be made
self supporting and heights exceeding 20m shall be supported by superimposed structure around the
column covering the entire height.
Flare and vent stacks shall be supported structurally by super imposed structure around for the entire
height.
Following are the details and weight of column:
• Shape factor for shell (for wind force calculation) : 0.7

• Weight of trays (with liquid) to be considered : 12 N/m
• Weight of plain ladder : 1.5 N/m
• Weight of caged ladder : 3.7 N/m
• Equivalent projection to be considered for wind load on the
: 300 mm
ladder.
• Distance of platform below each manhole : Approx 1000mm
• Projection of platform : 900 mm upto 1 meter dia
Column and 1200mm for
column dia > 1 meter from
column installation.
• Equivalent heights of platforms for wind load comparison. : 1000 mm
• Weight of platforms : 17 N/m2
• Platform shall be considered all around.
All reactors, columns, vertical vessels shall be designed so as to permit site testing of the equipment
in vertical condition (horizontal condition for horizontal vessels) with test pressure as per code at the
top with the equipment completely filled with water. A value of 33% of maximum wind load shall be
considered for designing the equipment for hydrotest condition. The design shall be based on fully
corroded condition. Equipment foundation shall be designed and constructed for hydrotest condition
as well as operating condition with seismic / wind loads whichever is governing with equipment in new
condition.
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7.8 SPECIAL DETAILING OF STRUCTURES FOR CYCLONE RESISTANCE

Following measures are to be taken in the detailing and construction of buildings / structures:
For fixing of roof sheeting

• Specially in the corners of each sheet, sufficient number of bolts shall be used.
• Extra fittings shall be used in regions subjected to high suction forces.
• Unsupported / overhung portion of the sheeting shall be properly detailed.
• Hook bolts shall be used to fix the centre of the sheeting.
• Metal washers shall be designed properly.
• Lapping of sheets shall not be left unsupported.
Trusses shall be anchored only suitably designed RCC columns, RCC bond beams, or steel
stanchions. Brick pilasters shall not be considered. A minimum of four anchor bolts shall be used at
each support.
Brick in filled walls shall include adequate reinforcing bands to transfer the wind loads acting on them.
An unreinforced brick panel is to be considered as simply supported along its edge and checked for
its adequacy.
In the structural steel sheds horizontal wind bracing connecting the last two trusses at either end shall
be done for enhancing the cyclonic resistance of the structural assemblage. Wherever applicable,
the number of successive un-braced bays shall be limited to four. If the number of bays is less than
four, one bay at each end along are to be braced. In case of gable frame, in plane bracing along the
building envelope shall be provided. Suitable bracing system shall be provided in the roofing system
both horizontal and diagonal directions.
Ductile detailing for RCC structures shall be done in accordance with IS-13920.
rd
Splicing shall be restricted to 1/3 of the total number of bars at section.
For structural steel sheds following measures shall be adopted:

• Roof pitch shall not be less than 10 degrees.
• Purlin shall not be spaced more than 1.0m apart.
• Galvanized 6mm dia U hook bolts shall be used with diamond shaped curved metal washers and
bituminous or rubber under washers in case of non asbestos cement sheets only for cooling
tower and other spillage of process water roofing. The non asbestos cement sheets will have
other accessories i.e gutters ,ridges & flashings, curve sheets of non asbestos cement material.
• Stainless steel self drilling self tapping screws with cyclone plate for galvalume sheets for all area
u.n.o.
• The detailing of corners where roofing sheets meet shall be detailed properly.
• The structures connected to column / heater / vessels working at high temperature shall not be
rigidly connected with the structures of staircase or technological structure etc., which are the
ambient temperature.
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8.0
ANNEXURE – 1
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Page 1 of 41

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: GENERAL SPECIFICATION FOR PRESSURE VESSELS
DOCUMENT NO. 44NC-4600-0000-V.02-0101-A4

No.
By By By
1 11.02.2014 41 Revised as marked 1 & Issued TD MS HSC

as general specification
Page 231 of 441

44NC-4600 PRESSURE VESSELS Page 2 of 41
TABLE OF CONTENTS
1.1 CODES
1.2 STATUTORY REQUIREMENTS
1.3 INTERNATIONAL REQUIREMENTS
2.0 DESIGN BASIS – GENERAL
3.0 DESIGN REQUIREMENTS – SPECIFIC APPLICATIONS
4.0 MATERIAL SPECIFICATION
5.0 SUPPLY
6.0 FABRICATION
7.0 NON DESTRUCTIVE TESTS
8.0 HEAT TREATMENT
10.0 PROTECTION AND DESPATCH
11.0 VENDOR’S GUARANTEES
TABLE – 1 DETAIL & WEIGHT OF COLUMN ATTACHMENTS
TABLE – 2 ALLOWABLE STRESS FOR COMBINED LOADING
TABLE – 3 MATERIAL SELECTION CHART
TABLE – 4 NOZZLE LOCAL LOADS
Page 232 of 441

1.1 CODES 1
The following applicable codes and laws of India shall be followed unless otherwise
specified for the design, fabrication, inspection and testing of Vessels, Columns, Reactors,
Storage Tanks, Steel Flare/ Vent Stacks :
ASME SEC. VIII DIV. 1 Ed 2013 For Pressure Vessels
ASME SEC. VIII DIV. 2 Ed 2013 For Pressure Vessels (as specified in
bid package for high shell wall
thickness of equipment)
ASME SEC.V Ed 2013 For non-destructive testing
ASME SEC. II Part A, Ed 2013 For material specification & allowable

B, C, D stresses
ASTM/ IS Ed 2013 For material specification for Tanks
ASME Sec. IX Ed 2013 For welding
ASME B 16.5 Ed 2013 For flanges
ASME B 16.47 Ed 2011 For large diameter flanges
ASME B 16.20 / Ed 2007 For gaskets
ASME B1.1 2003 For bolting specification
ASME B 16.28 1994 For elbows & return bends
ASME SEC. VIII Div. 1 Ed 2013 For workmanship of Vessels not

categorised under any other code
th
API 650 12 Ed. Mar 2013 For Storage Tanks
API 620 11th Ed. Nov 2008 For Low Pressure Storage Tanks
IS: 6533 Part 1: Ed 2.1,1989 For steel vent stacks etc

(RA 2010)
Part 2: Ed 2.1,1989
(RA 2006)
IS: 875/ Site Data Ed 1987 (RA 2008) For wind load consideration
IS: 1893/ Site Data Ed 2005 (RA 2010) For seismic design consideration
44NC-4600-0000-V.02-0101-A4_R1 General Spec for Pressure vessels.doc
Page 233 of 441

IBR 1950 / 13th Ed. 2012 For steam producing, steam storage, catch
water vessels, condensate flash drums and
similar vessels
SMPV Edition 1981 Static and mobile pressure vessel (unfired)

rules, 1981
1.2 STATUTORY REQUIREMENTS
National laws and statutory requirements such as of Indian Boiler Regulations and
requirements of Department of Explosives, Nagpur, India together with any local by-laws for
the state shall be complied with. Static and Mobile Pressure Vessel (SMPV) rules and
Petroleum rules, Directorate (OISD) etc. as applicable shall also be complied with.
1.3 INTERNATIONAL PUBLICATIONS 1
NACE MR 0103 2012 Sulphide Stress Cracking Resistant Metallic

Materials for Oil Field Equipment
NACE MR 0284 2011 Evaluation of Pipeline and Pressure Vessel

Steel for Resistance to Hydrogen Induced
Cracking
NACE TM 0177 2005 Laboratory Testing of Metals for Resistance

to Sulphide Stress Cracking in Hydrogen
Sulphide Environment
NACE RP 0472 2010 Methods & controls to prevent in service

cracking of CS welds in P1 materials in
corrosive petroleum refining environments
WRC Bulletin # 537 2010 Local Stresses in Spherical & Cylindrical

(WRC 107 replaced Shells due to External Loadings
by WRC 537)
WRC Bulletin # 297 1987 Local Stresses in Cylindrical Shells due to
External Loadings on Nozzles
WRC Bulletin # 368 1991 Stresses in intersecting Cylindrical Shells

subject to pressure
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2.0 DESIGN BASIS – GENERAL
All equipment shall be designed in accordance with the design codes, and applicable
standards/ specifications. Design calculations shall be made considering all loads for
Erection, Operating and Hydrotest conditions (ref. Para.3.1.2)
2.1 SIZING OF EQUIPMENT
All equipment columns, clad/lined vessels, vessels (including thickness ≥ 50 mm), tanks,
bullets & all others vessels shall be sized on the basis of internal diameter only.
2.2 SHELL/HEAD THICKNESS
2.2.1 For columns of carbon and low alloy steel, minimum thickness shall be 8mm (including
corrosion allowance up to 3mm).
The minimum thickness of carbon and low alloy steel vessels shall be 6.0 mm (including
corrosion allowance not exceeding 3.0 mm) but shall not be less than calculated as per
following formula:
Wall thickness = Dia / 1000 + 1.5 + Corrosion Allowance, for Dia. less than 2400 mm.
Wall thickness = Dia / 1000 + 2.5 + Corrosion Allowance, for Dia. 2400 mm and more.
All dimensions are in mm. Above formula is applicable for both columns & vessels.
2.2.2 For columns of stainless steel and high alloy steel, minimum thickness shall be 5mm.
Corrosion allowance shall be added in this minimum thickness as specified in process
data sheet.
The minimum thickness of stainless steels & high alloy vessels shall be 3.0 mm but shall
not be less than calculated as per following formula:
Wall thickness = Dia / 1000 + 2.5 + Corrosion Allowance, for Dia. more than 1500 mm.
Corrosion allowance shall be added to minimum thickness as specified. Above formula is

applicable for both columns & vessels.
2.2.3 Tangent to tangent height (H) to diameter (D) ratio (H/D) greater than 5 shall be
considered as column and designed accordingly.
2.3 VESSEL END CLOSURES
2.3.1 2:1 semi-ellipsoidal dished end shall be used for pressure vessels unless otherwise
specified. Seamless dished ends shall be used for specific services as per process
licensor requirement.
2.3.2 Unless specified otherwise, hemispherical ends shall be used when the thickness of shell
exceeds 70 mm.
2.3.3 For atmospheric vessels, flat covers may be used.
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2.3.4 For vessels diameter < 600 mm, without any internals, pipe caps may be used.
2.3.5 Dished ends, after forming, shall be heat treated as per following applicable details:
a) For thickness ≤ 16mm

Dished ends with nominal thickness ≤ 16mm shall be stress relieved
b) For thickness > 16mm
Dished ends with nominal thickness > 16mm shall be normalized. Recommended
normalizing cycle:
0 0
• Soaking temperature: 900 C to 1000 C
• Holding time one 2.4 min per mm thickness but shall not less than half an
hour
• Cooling in still air
2.3.5 Vessels and columns with diameter up to 1000 mm shall be provided with 500 NB
manhole. Vessels and columns with diameter greater than 1000 mm and up to 1500
mm shall be provided with 500 NB manhole. However, if required, vessels and
columns with diameter above 1500 mm shall be provided with 600 NB manhole.
Trays and other column internals installation shall be given consideration in deciding the
size and location of manholes, hand holes or body flanges as the requirements may be at
the initial design itself.
High pressure reactor manholes i.e. HCGO/OHCU Reactor etc. shall be on I.D. basis.
Size shall be as per Licensor drawing.
2.3.6 All process vessels that have a manhole will also be specified to have a vessel vent to
provide ventilation for maintenance. This vessel vent will be located at the top, or a
minimum distance from top of vessel. Size of this vent shall be as follows.
Vessel capacity Length of (Horizontal Vent Nozzle Drain Ventilation

Vessel) (L) mm Nozzle Nozzle
V<6. 0 - 40 NB 40 NB -
6.0<V< 15 - 50 NB 40 NB -
V>15 - 50 NB 50 NB -
- 3000mm<L<4500 mm - 100 NB
- 4500mm<L< 7500 mm - 150NB
L>7500mm 200NB
Vertical vessel not having any nozzle on the top shall be provided with 50 NB nozzle for
conducting hydro test in vertical conditions.
All vent and drain lines of light Hydrocarbons like MS, naphtha, LPG, propylene, and H2
shall be provided with double isolation valves with end flanges as per OISD. Dia11/2 in
NB (40 NB) and above drain lines shall be provided with end flanges.

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2.3.7 If the equipment process data sheet indicates sour service (alkaline or wet H2S service),
the equipment materials, their testing, their post weld heat treatment and any other
recommendations of the NACE materials recommended by the licensor and pertinent
publications like NACE MR 175 shall be complied without exception.
2.4 DESIGN PRESSURE
Design pressure shall be calculated as per the following unless otherwise specified
elsewhere.
2.4.1 Design pressure = As per PDS
2.4.2 Design pressure shall be at the top of vertical vessel or at the highest point of horizontal
vessel.
2.4.3 The design pressure at any lower point shall be calculated by adding the highest operating
liquid head and any pressure drop within the vessel.
2.4.4 Equipment with steam out condition shall be designed for full vacuum condition.
2.4.5 Equipment operating under vacuum / partial vacuum shall be designed for an external
2
pressure of 1.055 kg/cm g (15 psi g)
2.4.6 Vessels shall be designed for steam out conditions if specified on process data sheet. For
steam out conditions equipment shall not be designed for Full vacuum.
2.4.7 Minimum design pressure shall be 3.5 kg/cm2 g for any equipment except API storage
tanks.
For vessels operating at ATM pressure minimum design pressure shall be ATM
2.4.8 All storage tanks shall be designed as per code considering full height & using specific
gravity 1.0 if not specified.
2.4.9 Pressure chambers of combination units in equipment shall be designed for testing
independently without pressure in the adjacent chamber in corroded condition.
2.5 DESIGN TEMPERATURE
2.5.1 Design temperature = As per PDS
2.5.2 Minimum Design Metal Temperature (MDMT) shall be lower of minimum atmospheric
temperature and minimum operating temperature encountered during operation.
Un-insulated vessels containing LPG and similar fluids shall be designed for maximum &
minimum temperature as recommended by SMPV rules.

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2.6 HYDRO TEST PRESSURE
2.6.1 Equipment shall be hydro tested in the fabricator’s shop as per applicable design code &
specification requirements. However care shall be taken that hydrostatic temperature shall
be at least 6 degree centigrade higher than critical exposure temperature (CET) for vessel
thickness up to 50 mm and minimum 17 degree centigrade higher than the CET where CET
id minimum design metal temperature (MDMT). However, if code requirement is found to be
stringent, than the same shall be followed.
2.6.2 All vertical vessels, columns and horizontal vessels (in full corroded condition) shall also be
designed for site testing of the equipment with water at the test pressure on the top of the
equipment considering 33% wind load.
2.6.3 All equipment foundation shall be designed and constructed for water full condition when
equipment is new with 33% wind load.
2.6.4 Open atmospheric vessels shall be tested by filling water up to the top curb angle.
2.6.5 Pressure chambers of combination units that have been designed to operate independently
shall be hydro tested to code test pressure as separate vessels i.e., each chamber shall be
tested without pressure in the adjacent chamber.
When pressure chambers of combination units have their common elements designed for
maximum differential pressure, the common elements shall be subjected to test pressure
equivalent to the differential pressure multiplied by a factor as per applicable design code.
Hydro test pressure shall be equal to 1.3 x design pressure x temperature correction factor
as specified in ASME SEC. VIII DIV.1 (Clause UG-99) at top of column unless specified
otherwise. If column is tested in horizontal position, hydro test pressure shall be increased
in order to take the effect of water head.
After taking precautions as suggested in para 2.21.5, an IBR equipment may be tested to
meet IBR’s hydrostatic test requirements.
2.6.6 Coils shall be hydro tested to code test pressure separately.
2.6.7 Unless otherwise specified in applicable design code allowable stress during hydro test in
tension shall not exceed 90% of yield stress point.
2.6.8 Storage tanks shall be tested as per applicable code.
2.7 CORROSION ALLOWANCE
2.7.1 Corrosion allowance shall be as per Process data sheet
2.7.2 No corrosion allowance for stainless steel columns & vessels shall be used unless
otherwise specified.
2.7.3 If it is agreed to develop the cladding by weld overlay method, then it shall be ensured to
have undiluted chemistry of the cladding upto specified thickness of cladding. Surface
texture requirement if applicable shall also be ensured.

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Cladding or lining thickness shall not be included in strength calculations.
2.7.4 For storage tanks, minimum corrosion allowance shall be as follows unless otherwise
specified:
Bottom plate : 1.5 mm,
First shell course : 3 mm,
Subsequent shell courses : 1.5 mm
Floating roof/fixed roof : 1.0 mm.
2.7.5 Corrosion allowance for nozzles including manholes shall be equal to that specified for the
vessel. No corrosion allowance is required for standard flange face.
2.7.6 Corrosion allowance for girth/ body flange faces shall be used equal to that specified for
vessel.
2.7.7 Corrosion allowance for support skirts of columns & vertical vessels shall be 1.5 mm
(minimum) unless specified otherwise.
2.8 Earthquake & Wind Considerations
2.8.1 Wind Consideration
Wind load for equipment including anchor chair shall be calculated on the basis of IS 875 / site
data for skirt supported equipments, storage tanks, spheres, flare stacks and air coolers.
a) Drag coefficient for cylindrical vessels shall be 0.7 minimum.
b) Drag coefficient for spherical vessel shall be 0.6 minimum considering:
K1 = Risk factor 1.0 (for 50 years life)

K2 = Terrain category Factor based on category 3 (for units) and factor based
on category 2 (for off sites)
K3 = Topography Factor based on site topography =1.0
Contingency factor of 1.1 shall be used on wind pressure
2.8.2 Earthquake Consideration:
For seismic design consideration of new equipments which are replaced on the existing old
foundation, Earthquake loads shall be calculated in accordance with IS: 1893- 1984/Site data.
For seismic design consideration of new equipments on totally new foundations (i.e. skirt
supported equipments, storage tanks, spheres and air coolers) Earthquake loads shall be
calculated in accordance with IS:1893 (Latest), if site specific acceleration spectra is not
specified in the project specification.

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2.9 TANK CAPACITY
Capacity shall be specified as Nominal capacity and stored capacity. Nominal capacity for
fixed roof tanks shall be volume of cylindrical shell.
Stored capacity for fixed roof tanks shall be equal to nominal capacity minus free board
volume (equivalent to 500mm of shell height) or location of fixing of lowest roof structure
member
Nominal capacity (also the stored capacity) for floating roof tanks shall be volume of cylindrical
shell minus free board volume. (Equivalent to minimum 1500mm of shell height)
Nominal capacity (also the stored capacity) for fixed cum floating roof tanks shall be volume of
cylindrical shell minus free board volume. (Equivalent to minimum 2500 mm of shell height).
2.10 SUPPORTS
2.10.1 Skirt supports shall be provided for all vertical vessels, columns and reactors. Small vertical
vessels may be supported on legs or brackets.
2.10.2 All Cr-Mo steel reactors shall be supported on skirts. Welding of external cleats on Cr-Mo steel
reactors shall be avoided wherever possible.
2.10.3 Skirt thickness
The minimum thickness for the skirts shall be greater of:
a. The thickness required by stress analysis with a minimum of 6 mm.
b. 30 mm or 1/3 of the vessel wall thickness whichever is lower.
Corrosion allowance of total 1mm minimum shall be considered for skirt unless otherwise
specified in the project specifications to achieve final thickness of skirt shell.
2.10.4 Columns with diameter 1000 mm & larger shall be self supported unless the process data
sheet indicates a guide supported design.
2.10.5 Columns with diameter less than 1000mm shall be supported by superimposed structure
around the column covering the entire height. Guy wires shall not be used to support any
equipment. Supporting of columns by superstructure require prior approval from Jacobs
2.10.6 In special cases, columns with diameter up to 1000mm and height not exceeding 10m
(including skirt height) can be self-supported and heights exceeding 10m shall be supported
by super imposed structure around the column covering the entire height.
2.10.7 Flare and vent stacks shall be supported structurally by superimposed structure around for
complete height.
2.10.8 Buried vessels shall be suitably anchored to prevent the uplift due to water table. Anchor bolts
shall have corrosion allowance of 6mm. Buried vessels shall be supported on concrete
saddles with bracket support at the centerline of the vessel.
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2.11 NOZZLE SIZE
Minimum nozzle size = 40 NB
Minimum nozzle size for clad vessels / columns = 80 NB
Safety valve nozzle = Based on I.D.
Self reinforced nozzle neck = Based on I.D.
2.12 Nozzles and manholes including self-reinforced type shall be “set in” type attached to vessel
with full penetration welds unless otherwise specified.
2.13 FLANGES
2.13.1 Nozzle flanges up to 600 NB shall be as be ASME / ANSI B16.5 and above 600 NB shall be
as per ASME / ANSI B 16.47 (SERIES ‘B’).
2.15.2 Nozzle flanges shall be welding neck flanges unless specified otherwise.
2.15.3 Slip on flanges shall not be used in Lethal, Hydrogen, Amine, Caustic, severe cyclic service,
sour service, HIC (Hydrogen induced cracking) service and corrosive service where corrosion
allowance is more than 3 mm.
2.14 INTERNALS
All removable internals shall be bolted type and bolting shall be SS type 304 unless specified
otherwise.
2.15 GASKETS
Service gaskets supplied shall not be used for hydro testing purpose. Gasket used for hydro
testing of equipment shall be of same specification as that of service gaskets for all nozzles,
manholes and body/girth flanges. Gasket seating face of flanges shall have finish as per
gasket specified.
2.16 COLUMN DAVIT
All columns and Vertical vessels with internals & safety valve shall be provided with pipe davit
as per Jacobs’s standard. Weight of the valve or item to be handled shall be advised for
selection of configuration.
2.17 Spares
2.17.1 Mandatory Spares
i) Vessels & Columns
Gaskets Two sets for each installed gasket.

Fastener 10% (Minimum two in each size) of installed fasteners
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Sight/Light Glass 4 sets for each installed glass

ii) Shell & tube Exchangers
Gaskets 400%
Bolting 20% (Min. 4 studs and 8 nuts per joint)
iii) Air coolers
a) 400% for gaskets (for headers & blinded flanges)
b) 200% gaskets for plugs
c) 20% plug
d) 100% belts
e) 20% (minimum 4) studs and nuts for each pair of cover header and nozzles
with blinded flange
f) 100% Bearings
g) One blade for each size / type of fan
h) 1 set of Diaphragm Actuator with positioner for each type of auto variable pitch
fan (for Moore fans) (Alternatively vendor recommended spares for his type of
auto variable pitch fans for make other than Moore).
Variable Speed Drives (If applicable)

(One set of spares for each rating of VSD)
Rectifier Control Module 1 Set

Thyristor module 1 Set
Inverter control unit 1 Set
IGBT driver card 1 Set
IGBT 10% with min. 1 No. for each rating of IGBT
PCB of each type 1 No.
All fuses (Power & Control) 20% or 1 Min for each rating of fuse.
Control cards One set
Power supply card One set / 1 No. of each type and rating
Relays 10% with min. 1 No. for each type of relay
Contactors 10% with min 1 No. for each rating of contactor
Man machine interface One set
CT / PT One No. for each type & rating
Cooling fans One set / 1 no. of each rating
Limiters & protection devices One set
Indicating lamps 20% with Min. 3 Nos
Induction Motors (If applicable)-37kW and above
Bearing set (DE & NDE) 1 no. for each type
Terminal studs / bushing assembly 1 no. for each type
External cooling fans 1 no. for each type
DE / NDE end shields 1 no. for each type
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2.17.2 Commissioning Spares:

i) Reactors and Columns :
Gaskets 100% (For Manways, Interconnecting Nozzles,
and nozzles with blind Flange).
Fasteners 10% (Minimum two in each size) of installed
fasteners.
ii) Shell & tube Exchangers 200% Gaskets
iii) Air Coolers
Plug/ Header Gaskets 30 % (Min 1 no) of Installed quantity)
Plugs 10%
Belts 50%
MP Connection for PG/TI
i) Shell & Tube : For Clad Exchangers

vessels
1 no. 50mm NB LWN nozzle with BF on each inlet/outlet nozzle.
If it is not possible to provide on inlet/outlet nozzle, then it shall
be provided on main shell/channel close to main nozzles
Others (Non Clad)

One no. 40NB nozzle with blind on each inlet / outlet. Rating
shall be same as process nozzle
ii) Air Cooler One on one of the inlet & one on one of the outlets of each
header, size 40NB nozzle with BF etc. If it is not possible to
provide on process nozzle then it shall be provided on header.
Rating shall be same as process nozzle.
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2.18 IMPORTANT CONSIDERATIONS
2.18.1 All vessels and columns shall be designed considering design pressure; maximum
operating liquid head and any pressure drop within the vessels/columns.
2.18.2 All columns and vessels shall be capable of withstanding water full condition during system
testing.
2.18.3 Vessels and columns shall be hydro tested at shop at pressure calculated as per applicable
code in new and cold condition.
2.18.4 Seismic design shall be carried out based on design requirement for earthquake.
2.18.5 Equipment covered under the purview of IBR (Indian Boiler Regulations) shall be designed
as per IBR regulations. However, design of components not covered in IBR Regulations
shall be designed in accordance with ASME SEC. VIII Div-1 by multiplying the allowable
stress at design temperature by 0.8667 (1.3/1.5 which is the ratio of minimum multiplying
factor for hydro test for ASME sec VIII div-1 and IBR). This way the equipment can be safely
tested to meet ASME as well as IBR requirements.
2.18.6 Detail stress analysis, local load analysis for loads due to piping and supported equipment
etc. shall be carried out for all equipment. Critical equipment shall be analysed by using
finite element analysis methods (FEM) as defined in job specifications & reports shall be
submitted for Jacobs review. For allowable nozzle loads refer Jacobs’s standard
specification attached with Bid package.
2.18.7 All nozzle necks, all nozzle flanges and blind flanges shall be of weld overlay construction
for clad equipment. Loose liners on nozzle necks and blind flanges are not permitted.
2.18.8 All vertical vessels and columns shall be provided with 2 lifting lugs/Lifting trunions. Lifting
lugs shall be designed with impact factor of two.
2.18.9 Mechanical design of self supporting Tall columns / tower shall be carried out for various
load combinations as per Clause 3.1
2.18.10 Material of various parts of equipment shall be selected as per table given in TABLE– 3
unless otherwise stated on process data sheets. In case the suggested basic material
system for equipment does not meet the temperature applicability requirement, it shall be
brought to the notice of Jacobs and clarification obtained at enquiry stage itself.
2.18.11 Local Stress analysis shall be carried out for nozzle to shell junction using maximum shear
stress theory for vessels and columns. Allowable stress intensity shall be as per ASME
SEC. VIII Div. 2 and non-destructive examinations shall be carried out for shell to nozzle
junction as per ASME SEC. VIII Div. 2.
2.18.12 Stress analysis of shell to skirt junction shall be carried out using maximum shear stress
theory for vessels and columns designed as per ASME Sec. VIII Div. 2. In case skirt shell
joint is of butt-welded construction, the same shall be 100% radiographed.
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2.18.13 All vessel, columns and tanks shall be provided with earthing bosses as per Jacobs’s
standard. Body flanges of equipment shall have provision to provide jumpers for earthing.
2.18.14 Permanent fixed ladders shall be provided inside the skirt of columns/vertical vessels for
inspection of dome / dished end.
2.18.15 ODC / Very heavy equipment shall require special considerations for handling,
transportation and erection by Contractor.
2.18.16 All equipment shall be painted as per Jacobs painting specification.
2.18.17 All equipment requiring insulation shall be provided with insulation support rings /cleats as
per Jacobs’s specifications.
3.0 DESIGN REQUIREMENTS-SPECIFIC APPLICATIONS
3.1 TALL COLUMNS
Mechanical design of self-supporting column and its anchorage block shall be carried out
considering combination of various loads.
3.1.1 Loadings:
The loadings to be considered in designing a self supporting column / tower shall include:
a. Internal and or external design pressure specified on process data sheets.
b. Self weight of column inclusive of piping, platforms, ladders, manholes, nozzles, trays,
welded and removable attachments, insulation and operating liquid etc. The weight of
attachments to be considered shall be as per Table–1
c. Other loadings as specified in UG-22 of ASME SEC. VIII Div. 1 wherever applicable
d. Seismic forces and moments shall be computed in accordance with design

requirement for earthquake. Unless otherwise specified importance factor and
damping coefficient shall be considered as 2 and 2% respectively.
e. Basic wind pressure and wind velocity (including that due to winds of short duration as
in squalls) for the computation of forces / moments and dynamic analysis respectively
shall be in accordance with site data for the project (Refer Clause 2.8 above).
Additional wind loading on column due to external attachments like platforms, ladders,
piping and attached equipment should be given due consideration.
f. Loadings resulting in localized and gross stresses due to attachment or mounting of

reflux / reboiler, condenser etc
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3.1.2. Loading condition
Analysis shall be carried out for following conditions:
(a) Erection condition: Column (uncorroded) erected on foundation without insulation,

platforms, trays, removable internals etc., but with welded
attachments plus full wind on column.
(b) Operating condition: Column in (corroded condition) under design pressure, including
welded items, trays, removable internals, piping, platforms,
ladder, reboiler mounted on column, insulation and operating
liquid etc., plus full wind on insulated column with all other
projections open to wind or earthquake forces.
(c) Test conditions Column (in corroded condition) under test pressure, filled with
water plus 50% of specified wind load on uninsulated column
including all attachments shall be considered.
Earthquake and wind shall be considered not acting concurrently.
3.1.3 Deflection of column:
Maximum allowable deflection at top of column shall be equal to total height (including skirt
height) of the column divided by 200 but shall not exceed 300 mm in any case.
3.1.3.1 If the deflection of column exceeds the above allowable limit, the thickness of skirt shall be
increased as first trial upto a maximum value equal to the column thickness and this exercise
shall be stopped if the deflection falls within allowable limit.
3.1.3.1 If the above step is inadequate, skirt shall be gradually flared to reduce the deflection. Flaring of
skirt shall be stopped if the deflection falls within limits or half angle of cone reaches maximum
limit of 9°.
3.1.3.3 If the above two steps prove inadequate in limiting the deflection within allowable limits, the
thickness of shell courses shall be increased one by one starting from bottom course above skirt
and proceeding upwards till the deflection falls within allowable limits.
3.1.3.4 For tall equipment fabricated from stainless steels and other exotic materials, it shall be
examined if an external guide will be helpful in controlling the required thickness such that the
equipment along with its guide structure cost is economical than a free standing design
3.1.4 Stress Limits
The stresses due to design pressure, weights, wind/seismic loads shall be combined using
maximum principal stress theory for ASME SECTION VIII Div.1. Thickness is accordingly
chosen to keep the stresses within limits as per Table-2.
3.1.5 Skirt support base
Base supporting including base plate, anchor chairs, compression ring, foundation bolting etc.,
shall be designed based on over-turning moment (greater of seismic or wind). Minimum size of
anchor bolts shall be M24.
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A minimum number of 8 foundation bolts shall be provided. Numbers of foundation bolts shall be
in multiple of four. Skirt thickness shall also be checked to anchor chair reaction forces.
Anchor bolts shall be so spaced that there is no interference between fixing arrangement, Anchor
bolt sleeves and trailing lug etc.
3.1.6 Dynamic analysis of column / Tower
Dynamic analysis of each column shall be carried out for stability under transverse wind induced
vibrations as per standard design practice and calculations for each column shall be submitted to
Jacobs for approval.
The recommended magnification factor for unlined towers / column shall be taken as 70 and
allowable dynamic amplitude shall be limited to tower diameter divided by 5.
4.1 General
4.1.1 All materials and accessories required for the fabrication, inspection, testing etc. of the vessel
shall be supplied by the Vendor unless otherwise stated. Whenever some material is to be
supplied by the Owner, this shall be so indicated as Free Issue Material and the supplementary
specifications in this regard shall be complied with.
4.1.2 In addition to the requirements of materials as per material specifications, material shall also
meet the requirements mentioned in this specification and other specifications enclosed with the
requisition. All materials shall be certified for compliance with IBR requirements for the term(s)
so specified.
While procuring materials, Vendor shall stipulate additional requirements such as limits on
hardness, ultimate tensile strength (UTS), yield strength, chemical composition, heat treatment
and any other specific requirements to ensure that final requirement as per specification and
Code are met with.
4.1.3 All materials for pressure parts and parts welded to pressure parts including materials in the
scope of sub-vendors shall be accompanied with mill test certificates duly certified by a reputed
third party inspection agency. In the absence of mill test certificate the material shall get tested
from a reputed third party inspection agency like Jacobs, Lloyds, BV, DNV etc. and test results
shall be submitted in lieu of mill test certificate.
All cost towards such testing and inspection shall be borne by the Vendor. All materials shall be
inspected at Vendor’s and sub-vendor’s shop for verification prior to use on the job. The decision
of Authorized Inspector to accept or reject materials on the basis of such testing shall be final.
4.1.4 Wherever simulated heat treatment of test specimens is required as per code or specification,
the simulation cycle shall include one extra cycle of stress relieving for any eventuality of repair
at site by Owner during the life of the equipment.
0
4.1.5 The exchanger’s minimum design metal temperature (MDMT) shall be taken as 0 C or the
design temperature specified in drawing or datasheet whichever is lower, unless specified
otherwise in design basis or datasheets or drawings.
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All Carbon steel (CS), low temperature carbon steel (LTCS) and low alloy steel (LAS) materials for
0
pressure parts and attachments to pressure parts having MDMT below 0 C shall be impact tested.
The test temperature shall be minimum of MDMT and impact test temperature as specified in
applicable materials specification or as given in job specification whichever is lower. Unless
specified otherwise, impact values shall be more stringent of the values as per UG 84 or applicable
material specification
In addition to the tests done at the mill, one impact test (three specimens) per heat shall be repeated
after receipt of materials at vendor shop, with the test temperature same as given above.
If the test results do not meet the impact energy requirements given above, the material shall be
rejected.
4.1.6 PLATES
4.1.6.1 Pressure parts having thickness 16 mm to 50 mm (both inclusive) shall be ultrasonically tested as
per SA – 435.
4.1.6.2 Pressure parts having thickness greater than 50 mm shall be ultrasonically tested as per SA-578
Level B.
4.1.7 FORGINGS
Forgings to SA-105 and SA - 266 above 75 mm thickness, all tube sheet forgings and all forgings of
other materials except standard nozzle flanges up to 8” NB and small forgings shall be 100%
ultrasonically tested as per SA-388. Acceptance standard shall be as per para AM 203.2 of ASME
Section VIII Division 4.
4.1.8 PIPES
Pipes shall be seamless and sizes above 1 ½ “ NB shall be hot finished. Dimensions and
tolerances shall be in accordance with ANSI 36.10 or ANSI 36.19 applicable as per material
specification.
4.2 Specific material requirements (Pressure parts and parts welded to pressure parts)
4.2.1 CS AND LTCS MATERIALS
a) Carbon content shall not exceed 0.23%.
b) All plates shall be in normalized condition
c) Use of SA 515 of any grade is not permitted.
d) Plates above 50 mm thickness shall meet following additional requirements of SA- 20.
i) Vacuum treatment shall be as per the supplementary requirement S1. If vacuum degassing
is not reported in the test certificate, then through thickness tests as per SA 770 shall be
conducted and minimum reduction in area of 35% shall be ensured.
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ii) Charpy V-notch test shall be as per supplementary requirement S5. Test temperature shall
0 0 0
be minus 29 C for MDMT greater than or equal to 0 C. For MDMT less than 0 C refers
clause 4.1.5 above. Impact energy values shall be as per Para UG-84 of Code, or as per
applicable material specification, whichever is higher. Orientation of test bar shall be
transverse to rolling direction.
iii) Bend test as per supplementary requirements S14 of SA-20.
e) Unless specified otherwise in requisition or bid document. All CS materials specified, as HIC
tested shall meet the following requirements.
i) Carbon equivalent shall be restricted to 0.43% max. Nickel content shall be 0.2% max.
ii) Sulphur content shall be 0.002% max for plates and 0.01% for pipes and forgings.
iii) Hardness of plates and pipes shall not exceed 200 BHN, and that of forgings shall not
exceed 187 BHN.
iv) Plates shall be to SA 516 Gr. 60/70 only. The plates shall contain calcium or other rare
earth elements to create spherical inclusions instead of stringers. The plates shall be
tested in accordance with NACE TM-02-84 using the test solution of NACE TM-01-77.
The acceptance criteria shall be crack length ratio 10% maximum.
f) All LTCS and CS charpy plate material shall be to fine grain practice and the austenitic grain
size shall be measured and reported in the mill test certificate.
g) CS pipes shall be SA-106 Gr.B. LTCS pipes shall be seamless conforming to SA 333 Gr. 1 or 6
h) Non-standard forgings (SA 266, SA 350 etc.) shall be in normalized and tempered condition.
4.2.2 LAS MATERIALS
a) All LAS plates, pipes, forgings and fittings shall be in normalized and tempered condition. Use
of C-½ Mo materials is prohibited.
b) For 1-¼ Cr- ½ Mo materials the maximum room temperature tensile strength of all pressure
containing components, materials and welds shall be 100000 psi.
c) For LAS tubes (SA-199, 209 and 213) hardness test shall be performed on outside of the tubes
as per SA-450.
d) For LAS plates above 50 mm thickness, following supplementary requirements of SA-20 shall
also apply:
i) Vacuum treatment shall be as per supplementary requirement S1. 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.
ii) Charpy V-notch impact test as per supplementary requirement S5 with impact values as
0 0
per UG 84 of Code. Test temperature shall be lower of MDMT or -18 C (0 C for 5Cr- ½
Mo) whichever is lower. Orientation of test bar shall be transverse to the direction of
rolling.
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iii) Bend Test as per supplementary requirement S14.
4.2.3 SS AND OTHER HIGH ALLOY MATERIAL
a) All SS material (300 series) shall be in the solution heat treated (fully annealed) and pickled
condition. All stabilized grades of SS (SS 321, SS 347 etc.) shall be given stabilization heat
treatment, in addition to solution annealing.
b) All SS (300 series) plates shall be hot rolled and shall have No.1 finish on both sides.
c) SS (300 series) materials for all components shall be procured with the IGC test as per ASTM
A-262 (test shall be carried out, after the specified heat treatment and sensitization per
specification) with acceptable corrosion rate and practices as under.
i) For all services except nitric acid service, Practice E shall be followed Specimen after
exposure shall be bent as per requirements mentioned in A262 Practice E and shall be
inspected under magnification of 200X. The bent specimen shall be free of any cracks or
grain dropping. The microstructure shall be submitted to the Authorized Inspector for
approval.
ii) For Nitric acid service: Practice C with corrosion rate not greater than 25 mils per year.
iii) For straight chrome (13% Cr.) material, maximum carbon content shall not exceed
0.08%. Hardness of UNS No.S41000 and S41008 shall not exceed 75 RB and that of
S40500 shall not exceed 80 RB.
4.2.4 CLAD MATERIALS
a) Cladding shall be integrally and continuously metallurgically bonded to the base metal. All
clad plates shall be rolled-on or explosion bonded type.
b) Clad plates shall be ultrasonically examined from the cladding surface in accordance with SA-
578. Scanning shall be 100% of the plate surface. Acceptance standard shall be level B.
Clad plates shall meet the supplementary requirements of S7 of SA-578. All ultrasonic
testing shall be undertaken after specified heat treatment of clad plates.
c) Both base material and clad material shall meet the specification of the respective materials
as stipulated in this specification.
d) Alloy clad steel plates shall be as per SA 263 or SA 264 or SA 265. Bond between cladding
and the base metal shall be checked for a minimum strength of 14 kg/mm2 in shear for alloy
clad steel plates, by conducting shear test as per applicable material specification.
e) For copper alloy clad plates, the bond between cladding and base metal shall be checked for
a minimum strength of 10 kg/mm2 in shear by conducting shear test.
f) During tension test of clad plates the cladding shall be removed and the tensile properties of
the base material shall meet the Code material requirements.
g) For austenitic SS clad plates the SS surface shall be acid pickled as per ASTM A-380. For
Chromium steel clad surfaces the pickling shall be as per Vendor’s established procedure.
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The same shall be submitted to Owner /Jacobs for approval.
h) For all clad plates used in Hydrogen or H2S service with design temperature greater than 350
0
C, Hydrogen dis-bonding test shall be carried out. The test condition shall be representative
of the actual design conditions and the procedure shall be submitted to Authorized Inspector
for approval.
4.3 Non Pressure Parts
4.3.1 CS plates shall be minimum IS-2062 Gr. B/C or SA 283 Gr. C or equivalent. Pipes shall be to IS
1239 or SA 53 or equivalent.
0
4.3.2 Saddle material shall be same as that of shell for design temperature greater than 350 C.
4.4 Equivalent materials
The materials for various components in a vessel shall be as per Owner or Jacobs’s requirement.
This does not preclude use of equivalent or better materials. However, these deviations should be
clearly indicated in the prescribed format. If an equivalent material sought by the Vendor is to a
specification, other than IS or ASTM or ASME, it is necessary for the Vendor to submit the
specifications of the equivalent material with complete details in English for approval.
5.0 SUPPLY
Supply shall be in accordance with requisition or bid documents to which this specification is
attached. It shall, however, include the following:
5.3 Other accessories
5.3.2 Earthing lugs shall be provided on each vessel and shall be located in such a way as to avoid any
fouling with the exchanger foundation bolts at site.
5.3.3 Vendor to supply one set of torque wrenches for bolt size M45 (1¾“) to M56 (2¼”) and a set of bolt
tensioner device for bolt sizes greater than M56 (2¼”) in case these bolt sizes are being used in
exchangers covered in the requisition. BTD capacity shall be 40% more than the maximum load
required for hydro test condition. BTD pump shall be pneumatically and manually driven. Vendor
shall supply one pump unit, required load cells and 4 heads of each size. Torque values for
tightening the bolts shall be mentioned in the fabrication drawings.
5.3.4 Davits, if required, as per design basis or drawings, shall be provided.
5.3.5 Additions like cleats for piping, ladder, platform, insulation cleats etc. which may be required shall be
provided.
6.0 FABRICATION
6.1 Edge preparation
6.1.1 For CS, the preparation of edges for welding shall be done using machining, chipping, cold
shearing, oxy-acetylene flame cutting or a combination of these. Chipping or cold shearing shall be
followed by grinding to a smooth and regular surface. Oxy-acetylene flame cutting shall be followed
by machining or grinding to eliminate any discoloration of material affected.
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6.1.2 For LAS, the edges for welding shall be made by oxy-acetylene flame cutting or by machining. Cold
shearing may be used for cutting thickness up to 10 mm. Oxy-acetylene flame cutting shall be used
with preheat and shall be followed by machining or grinding to eliminate any discoloration of material
affected.
6.1.3 For austenitic SS, the edges shall be prepared using plasma arc; however, cold shearing may be
adopted for thickness up to 15 mm. In all cases the cut edges shall be ground back or machined
back by 2 to 3 mm.
6.1.4 All welding edges after cutting shall be Dye Penetrant (DP) or Magnetic Particle (MP) examined for
laminations, cracks or segregation. Additionally UST shall be carried out within twice the material
thickness of edge for LAS materials or when the service is low temperature or hydrogen or HIC.
6.1.5 The paragraphs NF7 and NF14 in part UNF of Code are mandatory. This applies to non-ferrous
cladding and weld overlay.
6.2 Rolling and dishing of plates
6.2.1 Rolling
Rolling for bending and forming of plates shall be in the longitudinal direction of the plates. This
direction shall be clearly marked on the plates.
Re-rolling after welding is not normally recommended. However, if for large diameter shells, re-
rolling of welded shell course is inevitable, procedure for re-rolling along with extent of non-
destructive tests (NDT) shall be submitted for approval of the Authorized Inspector.
All welds on the section to be re-rolled must be ground flush. After re-rolling all the welds on the re-
rolled section must be DP checked. Such welds shall then be subjected to radiography as required
by drawings and Code.
6.2.2 Dishing
All dished heads shall preferably be of single piece construction. However dished ends with one
chordal seam are acceptable for shells with diameter greater than 1 m. In such cases, the chordal
seam shall preferably be in the middle one-third of the blank.
Dished ends shall preferably be 2:1 ellipsoidal or tori-spherical (knuckle radius 15 % of the outside
diameter and crown radius 80% of outside diameter).
Dished heads shall be subjected to DP test on knuckle portions (both inside and outside) and weld
edges after heat treatment. Vendor to ensure adequacy of indicated thinning allowance for dished
head. If nominal thickness indicated is not adequate then the nominal thickness should be increased
accordingly, keeping minimum thickness as per equipment drawing.
A straight face of 38 mm or 3 times the nominal thickness of dished end, whichever is less shall be
provided. However, if larger straight face is specified, it shall be ensured.
6.3 Welding
6.3.1 All welding and weld overlays shall be done with electrodes, fillers and fluxes of reputed make with
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proven reproducibility of results. Brand names shall be specifically approved by Authorized

Inspector. For CS pressure parts, the electrodes shall be of low hydrogen type, IGC test as per
ASTM A262 Practice E shall be done for austenitic SS consumables, which are to be used in
application involving solution annealing.
Austenitic SS consumables of low carbon and stabilized grade shall also be IGC tested as per
ASTM A262 Practice E. Straight chrome materials shall be welded with electrode that produces an
austenitic chromium nickel weld deposit or a non-air hardening nickel –chromium-iron weld deposit.
6.3.2 All welding procedures shall be submitted for approval by Authorized Inspector giving all relevant
details. Welding qualification records shall indicate hardness values of weld metal. HAZ and parent
0
metal and also results of impact tests when design temperature are below 0 C or when specifically
indicated for materials being welded. No welding shall be undertaken until the welding procedure
and welder’s qualification have been approved by the Authorized Inspector.
All welding procedures and welders shall be qualified for the particular type of welding and material
in accordance with the ASME Section IX. Vendor shall be responsible for the quality of the welds
performed.
6.3.3 Pressure holding joints shall be full penetration welds. Root pass of single side welded joints shall
be done with GTAW process. Backing strip for single side welded joints is not permitted.
For LTCS materials both inside and outside of welds shall be ground flush or dressed smooth. All
internal welds in the shell shall be ground flush in order to insert and remove tube bundle. Also all
internal welds shall be ground flush to the extent of facilitating draining of complete equipment.
6.3.4 Longitudinal seams shall be staggered with the circumferential distance between the centers of
welds being at least 5 times the thickness of the thicker-plate. Weld seams shall be located so as to
avoid interference with weld seam of nozzles and external attachments.
6.3.5 Attachment to pressure part shall be of same quality as the pressure part. All LAS weld
attachments to pressure retaining component shall be with full penetration weld and ground to a
smooth concave contour.
External attachments like lugs, supports, etc. of CS shall not be welded directly to high alloy or
austenitic SS vessel components. These attachments should be of the same material as the vessel
components.
If this is not so, intermediate pad plates of the same material type as the vessel component may be
used. These pads shall be at least 100 mm wider and longer than the attachment and shall be at
least 5 mm thick. Welding of CS or LAS to austenitic SS shall be done with austenitic SS electrodes
or filler wire (AWS – ASTM – E 309L or E-309 Mo.L only).
Wrapper plates, reinforcing pads or stiffeners of higher thickness than specified can be used
provided there is no change in basic dimensions and with the approval from Jacobs.
6.3.6 When impact tests are required on material as per Code or specification the welds shall also be
qualified for impact test. In such case following special requirement shall apply to the welding
procedure qualification:
i) Qualification tests shall be made on plates of the ASME specification as specified for the
exchanger using welding electrodes of AWS or SFA specification and wire & flux of the
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specification and brand as are to be used on the job.
ii) Welding current and travel speed shall be considered essential variables in order to ensure
that production welding is substantially equivalent to the procedure qualification.
iii) Welded test plates shall be subjected to a total thermal cycle sequence similar to the finished
equipment. Specifically, test plates shall be held at intermediate and final stress relief
temperatures for approximately the same length of time as the finished exchanger. Final
cooling rate shall be approximate to that expected for the finished exchanger.
iv) Charpy V-notch impact tests shall be made on the weld and HAZ of the test plate for each
welding procedure to be qualified. Test procedure shall be as per UG 84 of Code. Test
temperature shall not be higher than MDMT. Impact energy requirements shall be as per
Table 2.15 of SA 20 of ASME Section II Part A or UG 84 of Code whichever is higher.
6.3.7 WELD OVERLAY
6.3.7.1 Weld deposit overlay shall be done by a qualified welding procedure and surface shall be properly
machined or ground flush after overlay. Minimum thickness of finished weld deposit shall be as
indicated in the drawings or specifications.
In case a higher deposition thickness and multiple weld layers are required to achieve the minimum
specified undiluted deposit metal, the same shall be done only after taking prior approval from
Jacobs.
Minimum thickness of undiluted finished weld overlay from top shall be 3 mm or as specified in the
drawings. For non-ferrous weld deposit, the iron dilution should be restricted to 2.5% (maximum) in
the finished undiluted layer (thickness defined above).
6.3.7.2 The weld overlay procedure shall be qualified on base metal of the same composition as the
exchanger component and meeting the requirements of ASME Section IX.
6.3.7.3 The weld overlay shall be relatively smooth with no notches and undercuts that would act as stress
raisers. All cracks, fissures and circular defects greater than 1/16” diameter shall be removed.
Repaired areas shall be DP checked.
Weld overlay shall be applied to base metal, which has been grit blasted and is smooth and clean
so as to ensure full bonding. Welding overlay cladding shall be applied after any normalizing but
before the post weld heat treatment (PWHT). The weld overlay shall consist of at least 2 layers.
6.3.9.4 The alloy cladding shall be cut back at all seams to permit back welding of the base metal. Weld
metal shall be ground flush and fully covered with the applicable weld deposit.
The weld joint in base plate shall be 100% DP tested for detection of cracks and flaws before
welding from clad side. The weld deposit shall be at least as thick as the cladding.
6.3.7.5 Shells, cones and dished heads formed from clad plates shall be UST after forming for a minimum
of 10% of the clad surface, including no less than one square feet in each 10 square feet or fraction
thereof.
Unbonded areas that cannot be encompassed by a 3“ diameter circle shall be repaired by weld
overlay. When repairs in excess of 5% of the total examined area are required, the complete
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exchanger shall be 100% UST.
Repaired areas and weld deposit overlay at weld seams shall be DP examined. UST shall be
repeated for dished heads after heat treatment. All UST shall be in accordance with SA 578 S6 for
spot examination and SA 578 S7 for 100% examination
6.3.7.6 All weld overlays shall be 100% DP examined in accordance with the method described in ASTM-E-
165. The barrier layer shall be 100% examined.
When the overlay involves multiple passes (layers) and the procedure uses an intermediate heat
treatment with cooling to room temperature prior to applying the subsequent layer, each layer shall
be examined.
Where overlay is to be machined such as for flange facing, machined surface shall be 100%
examined after PWHT. If 100% of overlay is examined prior to the final PWHT, overlay shall be spot
examined (not less than 10% of the surface) after heat treatment.
6.3.7.7 Samples of the weld overlay shall be taken to perform chemical analysis to the required depth as
specified. The number and location of samples shall be at the discretion of Authorized Inspector.
However, they shall be representative of each exchanger component for each type of welding
process. Report of this chemical analysis shall be submitted to Authorized Inspector for approval.
0
6.3.7.8 For all weld overlays used in hydrogen or H2S service with design temperature greater than 350 C.
Hydrogen disbonding test shall be carried out. The test condition shall be representative of the
actual design conditions and the procedure shall be submitted to Authorized Inspector for approval.
6.4 Production test coupons (PTC) are required for CS welds above 50 mm thickness, for LAS welds
above 25 mm or when required by the Code. For PTC the following shall apply:
a) Two PTCs representative of one longitudinal and another circumferential seam shall be
provided for each procedure, position and thickness.
b) PTC shall be from material of the same heat and thickness as of parent metal. During and
after welding PTC shall be subjected to same heat treatment as and together with the course
they represent, extra PTC shall be preserved to take care of eventuality of retests.
c) The tests mentioned below shall be carried out as per methods of testing in Code:
i) One transverse tension test
ii) Two side bend tests with weld located in the center of bend
iii) One hardness test on PTC weld and HAZ. The acceptable limits are 200 BHN for CS, 225
BHN for P3 and P4 materials and 235 BHN for P5
iv) Micro and macro examination of welds

0
v) For CS, charpy V notch tests on weld and HAZ shall be carried out. For MDMT below 0 C,
0
impact test temperature shall be MDMT. For MDMT greater than or equal to 0 C, the test
0
temperature shall be 0 C. The acceptance criteria for impact energy shall be as per table a
2.15 of SA 20 of ASME Section II part A or UG – 84 of Code whichever is higher.
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vi) For LAS, charpy V notch tests on weld and HAZ shall be carried out for 25 mm thickness
and above or when specified in requisition. Test temperature and acceptance criteria shall
be as per clause 2.2.2 (d) (ii) above.
6.5 Hardness limitations
Hardness limitation for materials wherever specified on drawings or datasheets and LAS materials
shall be as per Jacobs Spec. 44NC-4600-0000-V.02-0110-A4-General Spec for hardness
requirements. Hardness limitation for tube to tubesheet welding shall be established on a mock-up
with simulation heat treatment. Hardness of straight chrome materials in the cold-formed state, HAZ
and welds shall not exceed 88 RB.
6.6 Nozzle flanges, nozzles and reinforcing pads
6.6.1 Flanges
Unless otherwise indicated, dimensions, drilling, facing and tolerance for nozzle flanges (and blind
covers if required) shall be as per ASME B 16.5 (for size up to 24” NB) and ASME B 16.47 series B
(for sizes above 24” NB) for the respective class. Weld overlays, wherever specified or required,
shall be in addition to the thickness as per these standards. Bolt holes on these nozzle flanges shall
straddle principal vertical and horizontal centerlines of equipment. If the component to which
nozzles are attached is subsequently stress relieved, it shall be Vendor’s responsibility to maintain
true gasket faces by machining or otherwise. If distortion expected is considerable, final machining
operation should be done after stress relieving; sufficient machining allowance for this purpose
should be available. Gaskets for flanges to ASME B16.5 and B16.47 shall be as per ANSI B16.20.
6.6.2 Nozzles
6.6.2.1 Nozzle pipes shall be attached to the vessel components by full penetration welds. Attachment
welds using only inner and outer fillet welds are not permitted. Unless otherwise indicated on the
datasheets or drawings, necks of all nozzles shall be flush with the inside of vessel component.
Inside corners of nozzle pipes at shell and channel inside diameter shall be radiused. All nozzles 2”
NB and below except long weld neck, shall have two stiffeners (40 mm x 6 mm) at right angles.
6.6.2.2 Whenever nozzle inside is required to be over-layed, these shall be done by weld overlay or
cladding. Minimum nozzle ID before weld depositing shall be 50 mm in such cases. Loose liners
are not acceptable.
6.6.3 Reinforcing pads and testing
Reinforcing pads whenever required as per drawings or Code shall be of the same material as the
vessel component to which it is welded. All reinforcing pads shall be provided with two 1/8” (3 mm)
0 2
NPT tapped holes located 180 apart for air soap solution test with a pressure of 1.25 kg/cm (g).
This test shall also be required to be carried out for slip on flanges.
Higher test pressure are not recommended because of accompanying risks and also because the
soap bubbles have a chance to blow off. Tell-tale holes in reinforcing pads shall be plugged with
hard grease unless otherwise indicated after the hydro test of the exchanger.
6.7 Bolts, studs etc. and tapped holes
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6.7.1 All inch bolting and threading shall conform to ANSI B 1.1 except for size 1” and above where it shall
be 8 threads per inch. Metric bolting and threading shall conform to ISO – R261 except for size
M24 and above, where it shall have 3 mm pitch.
6.7.2 Studs shall extend beyond the nut by about 10 mm and shall be threaded full length except when
square ends are required for use with bolt tensioner, in which case the extension shall be as per bolt
tensioner manufacturer’s recommendation. The studs for extended tubesheet and the studs for use
with connecting piece shall also have square ends. The extended portion of the stud shall be
provided with a suitable protection cap to avoid clogging / rusting of stud threads.
6.7.3 All nuts shall be of heavy series only and nut-seating faces shall be machined or spot faced.
6.7.4 Threads on external bolting, plugs etc. shall be lubricated with graphite grease for working
0
temperature unto 200 C and with Molybdenum Disulphide for higher temperatures.
6.8 Assembly and handling
6.8.1 Vendor shall be responsible for taking adequate preventive measures to ensure the quality and
finish of materials and to avoid any rusting.
6.8.4 ‘T’ wherever indicated on drawings, denotes match mark for assembly and shall be punched on all
mating parts.
6.8.5 Lifting lugs shall be provided as per standard for lifting of channels, channel covers, shell covers,
test rings, test flanges etc.
6.9 De-scaling, pickling and passivation shall be done for all SS parts of vessels in accordance with
ASTM A-380. The Vendor shall supply details of the procedure for approval to the Authorized
Inspector.
6.10 Fabrication tolerances and finish
6.10.1 The dimensional tolerances shall be within the limits indicated on Jacobs’s drawings and standards.
Where tolerances are not specified, these shall be in accordance with the requirements of TEMA
and Code.
6.10.3 Finish of all machined components shall be minimum 12 microns (500 RMS) unless otherwise
indicated. Parts subjected to UT shall have minimum finish of 6 microns.
7.1 All the NDT procedures shall be submitted to the Authorized Inspector for approval. For all NDT
activities, only qualified NDT technicians shall be deployed with the approval of Authorized
Inspector.
7.2 The extent of radiography shall be as specified on the datasheets or drawings or job specifications.
In no case it shall be less than that required in the Code.
7.3 Minimum extent of radiography shall be spot, unless full radiography is specified in the drawings or it
is required as per specification or Code. Spot radiography shall mean that at least 10% of the total
welded length must be radiographed. Further, all “T” joints must be radiographed and at least one
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shot must be taken on each longitudinal and circumferential seam. This requirement shall
supplement the ones specified in Code. The Authorized Inspector shall be consulted in marking the
area to be radiographed.
7.4 Full radiography when specified shall imply 100% radiography of all butt welds.
7.5 All nozzles fabricated from plate, irrespective of thickness of plate and radiography specified, shall
be 100% radiographed.
7.6 Weld seams of formed heads shall be 100% radiographed after forming and heat treatment, if any.
7.7 All nozzles to shell welds shall be DP or MP checked at the root run and final weld.
7.8 For LAS welds, radiography shall be done after final PWHT. All welds which cannot be fully
radiographed such as nozzle to shell weld etc. shall be 100% ultrasonically tested after final PWHT.
Regarding fillet welds and welds which can not be radiographed or ultrasonically tested (i.e. pass
partition plate to channel and floating head joint etc.), the root run shall be DP checked and the
welds should finally be MP checked after stress relieving.
7.9 All attachment welds shall be either DP or MP tested.
7.10 Acceptance standards for radiography shall be as per Code unless stated otherwise.
8.0 HEAT TREATMENT
8.1 PWHT shall, in general, be done as required by datasheets, drawings, specifications, Code etc.
PWHT when mentioned on the drawings shall be over and above the requirements of specifications
or Code. No welding or heating is permitted after PWHT operation.
All matching operations shall preferably be carried out after heat treatment (Also refer clause 4.6.1.
above). It shall be the responsibility of the Vendor to leave sufficient allowance for this purpose.
Vendor shall submit all the procedures for PWHT to Authorized Inspector for review.
8.3 Heat treatment of SS clad assemblies shall be at reduced temperature to avoid sensitization of SS
materials. The soaking time shall be increased accordingly as per Code.
8.4 Heat treatment of non-ferrous clad assemblies, if required, shall be performed with extra care, if
required at reduced temperatures to avoid differential thermal expansion. The soaking time in such
a case shall be increased accordingly as per Code.
8.5 Heat treatment of CS and LAS dished heads shall be as follows.
a) Stress Relieving for:
i) Cold formed dish heads unto 16 mm thick.
ii) Cold formed floating head cover up to 16 mm thick if fiber stretch exceeds 5%.
b) Normalizing for CS and normalizing and tempering for LAS:
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i) Hot formed dish head and floating head dish if not formed in normalizing range.
ii) Cold formed dish heads for thickness greater than 16 mm.
iii) Cold formed floating head dish above 16 mm thick.
This heat treatment need not be given if same heat treatment is given subsequently on sub-
assembly.
8.6 SS component shall be solution annealed in the following cases.
i) Cold formed dished heads with nominal thickness of 16 mm or above.
ii) Hardness value of dished heads after cold forming exceeds 235 BHN.
iii) Hot formed shells, cones, dished heads.
After any heat treatment on austenitic SS, IGC test shall be carried out as per clause 2.2.3 (c)
above.
8.8 For LAS materials, preheating procedure shall be established in the welding procedure and got
approved by the Authorized Inspector. Preheating by resistance or induction heating method is
preferred. Preheating shall extend uniformly to at least three times the thickness of joint but not less
than 50 mm on both sides of the weld. Temperature indicating crayons shall be used for
assessment of correct pre-heat temperature.
8.9 All Low Alloy Steel pressure containing welds shall be PWHT.
9.1 Inspection
9.1.1 The inspection shall be carried out by Authorized Inspector. The materials, fabrication and testing of
exchangers shall be open to inspection by the Authorized Inspector in addition to any inspection
required by the specified Code or by local authorities having jurisdiction over the installation.
9.1.2 Inspection shall be carried out both during fabrication and before delivery and also for sub-ordered
materials. If any, in addition to final inspection and certification by Authorized Inspector during the
course of manufacture, Authorized Inspector’s written approval shall be obtained by the Vendor at
various stages of fabrication. For this purpose, Vendor shall prepare his Quality Assurance Plan,
defining the stages of fabrication, hold points for his own inspection and that by the Authorized
Inspection or Code or statutory Authorities Inspection etc.
The Quality Assurance Plan shall be discussed with Authorized Inspector before start of job and
mutually agreed. The various stages of fabrication to be inspected (by Vendor or the Authorized
Inspector) shall include but not limited to the following.
a) Raw material identification and verification of mill test certificate.
b) Edge preparation for welding, including visual check for laminations
c) Alignment of longitudinal and circumferential seams
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d) Rolling tolerances on individual section
e) Alignment and fit up of section, nozzle setting and components.
f) Root pass clearance before welding and cleaning
g) Profile and thinning of dished ends and toriconical pieces after forming
h) Review of NDT reports and any other specified test such as for leak, corrosion and hardness.
i) Review of heat treatment charts.
j) Calibration records of measuring instruments.
k) Final visual and dimensional inspection
l) Witnessing of hydro test
m) Surface preparation, primer painting
9.1.3 The presence of the Authorized Inspector shall not modify or reduce the obligation of the Vendor to
carry out his own tests and control. Should any material and / or equipment be found not in
compliance with the requirements specified, the Authorized Inspector or his delegate shall be
entitled to irrevocably reject them, even if such non-compliance has not been evidenced in the
course of inspections and/or tests.
9.1.4 The Authorized Inspector will, at the time of initial visit, set up with the Vendor actual details of
inspection stages to be witnessed or carried out: the schedule of future visits and subsequent
inspection notices can be arranged between the Authorized Inspector and the Vendor.
9.1.5 The Vendor shall notify the Authorized Inspector sufficiently in advance of any fabrication operations
to permit him to arrive at the Vendor’s shop in time to witness the operations.
9.1.6 The Vendor shall provide to the Authorized Inspector, free access to his shops at all times. He shall
also supply all tools and tackles to the Authorized Inspector for carrying out the inspection. The
Vendor shall also arrange for similar facilities at this sub-contractor’s shops.
9.1.7 The Vendor must satisfy the Authorized Inspector that the welding procedures, welders, electrodes,
fluxes, welding wires etc. are in accordance with the requirements of the Code and specifications.
Further the welder’s qualification test must be carried out in the presence of the Authorized
Inspector.
9.1.8 Prior to final inspection, all slag, weld spatters, loose scale, dirt, grit, paint, grease, oil and other
foreign matter shall be removed in order to facilitate inspection. All reinforcing pads and slip on type
flange welds shall be pressure tested with air and soap solution before and after heat treatment (if
any) and before final hydro test.
9.1.9 A dimensional checking of equipment shall be carried out taking into account the tolerances shown
on job drawings and standards, design specification or Code; the more stringent values shall
govern. Dimensional checks are to be taken of the internal measurements of equipment together
with external ones and these are to be recorded on a copy of the drawings as being the “As Built”
dimensions.
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9.2 Hydrostatic tests
9.2.1 Hydrostatic tests shall be witnessed by the Authorized Inspector. When hydrostatic tests are
performed the indicating gauge shall be connected to the upper most parts of the equipment.
Testing water shall be clean potable water. Seawater shall not be used.
For SS equipment water used for these tests shall not contain more than 25 ppm chlorides.
0
Minimum metal temperature during hydrostatic tests shall be 20 C.
Test pressures shall be maintained for at least one hour. Shell and tube sides shall be tested
separately, unless otherwise mentioned on the drawing.
10.1 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.
Dry out shall be done simultaneously on both shell and tube sides. After drying, the equipment shall
2
be purged and filled with dry N2 at 0.25 kg/cm . The equipment shall be provided with pressure
gauge to monitor N2 pressure, and a ½” non-return valve.
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 and temporary
gaskets and bolts adequate to maintain nitrogen pressure as above.
10.2 Shop painting
All CS and LAS external surfaces other than gasket faces and other machined surfaces shall be
given one coat of primer paint. Surfaces to be painted shall be prepared for painting by removing
loose mill scale, loose rust, oil, grease and other films or substances harmful to the adhesion of
paint by an approved method such as shot blast cleaning.
The surface shall be prepared to near white finish as per SSPC-SP-10 [SA 2 ½ Swedish standard
(SIS-05-5900)]. The shop primer shall be inorganic zinc silicate with 65-75 microns dry film
thickness, unless stated otherwise.
10.3 The equipment item number, Purchase Order (PO) number and Owner name and address shall be
painted in bold white paint letters written with stencil, on the vessel.
10.4 Dispatch of equipment
Vessels shall be securely anchored for dispatch in order to prevent any shifting and damage during
transportation. Expansion joints and bellows, wherever used shall be suitably protected against any
possible damage by providing tie bars before boxing up.
Packaging shall be suitable for rail or road transport and also sea worthy if transported by sea.
Spares shall be dispatched separately in a box and marked with PO number, item number and
Owner’s name and address.
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Sling mark identification shall be provided by Vendor on all vessels with respect to center of gravity
of the equipment.
No equipment shall be dispatched until a written clearance is obtained from Owner or Jacobs
regarding Piping Clips and Structural Cleats on individual equipment.
The Vendor shall be completely responsible for the compliance to Code requirements, residual
design, detailing, fabrication, materials and workmanship of the exchangers as per the stipulations
of the requisition and its attachments. In this regard, it may be noted that review by Owner or
Jacobs shall not relieve the Vendor of his responsibility of meeting all requirements and ensuring
satisfactory performance of the equipment. Guarantee period shall be as per Purchase Condition of
Owner.
Page 262 of 441

TABLE – 1
DETAILS AND WEIGHT OF COLUMN ATTACHMENTS
1. Minimum Shape factor for shell (for wind load : 0.7

calculations) (Also refer para 2.8.1.1 for
column design)
2
2. Weight of trays (with liquid) to be considered : 120 kg / m
3. Weight of plain ladder : 15 kg / m
4. Weight of caged ladder : 37 kg / m
5. Equivalent projection to be considered for wind : 300 mm

load on caged ladder.
6. Distance of platform below each manhole : Approx. 1000 mm
7. Maximum distance between consecutive : 5000 mm

platforms
8. Projection of platform : 900 mm up to 1.0 m dia. Column and

1.2 m for column dia.>1m from column
insulation surface
9. Equivalent height of platform (for wind load : 1000 mm

computation)
2
10. Weight of platforms : 170 kg/m
Page 263 of 441

TABLE-2
ALLOWABLE STRESS FOR COMBINED LOADING
Vessel condition / temperature –type of Conditions

stresses
Erection Operating Test
New or corroded New Corroded Corroded
Temperature Ambient Design Ambient
Longitudinal KxSxE KxSxE 0.90 x Y.P. x E
Longitudinal compressive stress KxB KxB B
Where
S = Basic allowable tensile stress as per Clause UG 23(a) of ASME SEC.VIII Div.1
B = ‘B’ value calculated as per clause UG-23 (b)
E = Weld joint efficiency of circumferential weld, depending on extent of radiography
K = Factor for increasing basic allowable value when wind or seismic load is present
Y.P. = Yield point stress
Note: Allowable stresses in skirt to shell joint shall be as per following:
0.49S, if joint is shear type.
0.70S, if joint is compression type.
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TABLE- 3
MATERIAL SELECTION CHART
The following table gives general guidelines for material selection chart for various pressure parts / non
pressure parts of the equipment:
Design Plate Pipe (See Forging Bolts / Structural Interna Studs /
0
Temp. C note 8) Studs / attachment l pipes Bolts /
Nuts welded to Nuts
External pressure parts Internal
CRYOGENIC
From – SA240 SA312 SA182, Gr. F SA320, Gr.B8, 8C, 8T strain
254 up to Gr.304L, Type 304 304, 304L hardened
–195 304, 316, 304L, 316, 316, 347, SA 194 Gr.8, 8C, 8T
316L, 347 316L, 347 316L
(impact
tested)
Same as pressure parts
Above SA240, SA312, SA182 Gr.F SA320, Gr.B8, 8C, 8T strain
–195 up Gr.304L, Type 304, 304 F304L, hardened
to –80 304, 316, 304L, 316, F316L SA194 Gr.8, 8C, 8T
316L, 316L, 321,
321, 347. 347.
SA 353, SA333, SA522

553, Gr.A Gr.8
LOW TEMPERATURE
Above – SA203 SA 333 SA 350 SA 320 L7 SA 203 Gr.E SA333 SA193 Gr.B8
80 Gr.E Gr.3, 4 Gr. LF3 SA 194 Gr.3, 4 SA194 Gr.8
Up to – impact Gr.4 or Gr.7
60 tested
(see note-
1)
Above – SA537 SA333 SA350 SA320 L7 SA537 Cl.1 SA333 SA193, Gr.B8,
60 Cl.1 Gr.3 Gr.LF3 SA194 Gr.4 Gr.3 SA194 Gr.8
Up to – impact Or GR 7
45 tested
(see note-
1)
Above-45 SA516 SA333 SA350 SA320 Gr.L7 SA516 (in all SA333 SA193, Gr.B8,
upto –29 (All Gr.6 or Gr.LF2 SA194 Gr.4 grades) Gr.6 , SA194 Gr.8
grades) Gr.1 or Gr.7 1
impact
tested
(see note-
1)
Above SA516 SA106, SA105 / SA193 SA516 (in all SA106, SA-193, Gr.B8,
-29 upto (all Gr.B (see SA266 (see Gr.B7 grades) Gr.B SA194, Gr.8
0 grades) note 3) note 3) SA194
(See note Gr.2H
3)
Page 265 of 441

Design Plate Pipe (See Forging Bolts / Structural Internal Studs /

Temp. note 8) Studs / attachment pipes Bolts /
0
C Nuts welded to Nuts
External pressure parts Internal
INTERMEDIATE TEMPERATURE
Above 0 SA516 SA106 Gr.B SA105 SA193 B7 IS2062 (plates) SA106 Gr.B SA193
Upto (all grades) SA266 SA194 Gr.2H Gr.B8
343 SA194,Gr.
SA193 B7 Same as Same as 4
SA240 SA312 SA182 F SA194 Gr.2H Pressure parts Pressure
type 304L, TP304L, 304L, 316L, parts SA193,
316L, 321 316L, 321, 321 Gr.B8,
(see note A376 SA194
4) TP321 Gr.8
Above SA387 SA335, SA182 SA193 Gr.B7 Same as Same as SA193
343 Gr.11 Cl.1 / Gr.P11 Gr.F11 SA194 Gr.4 Pressure parts Pressure Gr.B8
upto Cl.2. parts SA194
427 SA-193, B7 Gr.8
SA240 SA312 type SA182F SA194 Gr.4 Same as
type 304L, 304L, 316L, 304L, 316L Pressure parts Same as
316L, 321 321,SA 376 321 Pressure SA193
(see note Type 321 parts Gr.B8
4) SA-194
Gr.8
ELEVATED TEMPERATURE
Above SA387 SA335 P11 SA182 SA193 Gr.B16 Same as Same as SA193
427 Up Gr.11, Cl.1/ SA335 P12 Gr.F11, SA194 Gr.4 Pressure parts Pressure Gr.B8.
to 538 Cl.2, SA182 parts SA194
SA387 Gr.F12 Gr.8
Gr.12, Cl.1/
Cl.2
Above SA240 SA312, SA182 F SA193 Same as Same as SA193

427 type 304, SA376 type 304, 316, 321 Gr.B16 Pressure parts Pressure Gr.B8.
Upto 316, 321, 304, 316, SA194 Gr.4 parts SA194
500 (See note 321 Gr.8
4).
Above SA387 SA335 P22 SA182 SA193 Gr.B5,

538 Gr.22 Cl.1/ Gr.F22, SA194 Gr.3
Upto Cl.2 SA387 SA336 Same as pressure parts
593 Gr.21, Cl.1/ Gr.F22
Cl.2
Above SA240, SA312/ SA182 Gr. SA193, Gr.B8

500 Gr.304H, SA376 304H, 316H, SA194, Gr.8
Upto 316H, Type 304H, 321H. (strain Same as pressure parts
815 321H 316H, hardened)
321H
Page 266 of 441

NOTES
1. Pressure vessel steel plates are purchased to the requirement of the standard ASME SA-20
which requires testing of individual plates for low temperature service. Carbon steel material is
ordered to meet the impact requirements of supplement S5, of standard ASME SA 20. Typical
material specification is as follows. SA516 Gr.60 normalised to meet impact requirements per
o
supplement S5 of SA 20 AT -50 F.
2. All permanent attachments welded directly to 9% nickel steel should be of the same material or
of an austentic stainless steel type which can not be hardened by heat treatment.
3. Check for impact testing requirement as per UCS-66 for coincident temperature and part
thickness.
4. Selection of stainless steel material shall be based on process recommendation / process

licensor.
5. This table is not applicable for atmospheric / low pressure storage tanks. Materials shall be
selected as per API 650 / API 620 as applicable.
6. Materials for caustic service, sour service, or sour service + HIC shall be selected based on
specific recommendation of process licensor & considering chemical composition, hardness,
Vacuum degassing requirements & heat treatment requirements.
7. Material for pressure vessels designed according to ASME SEC VIII DIV. 2 shall be given special
consideration as per code.
8. All pipes shall be of seamless construction.
9. Non-ferrous material and super alloys are not covered above and shall be selected based on
specific recommendation.
10. Material for vessel / column skirt shall be the same material as of vessel / column shell for upper
part with a minimum of 1000mm.
11. Materials used for IBR equipment shall meet all requirements of Indian Boiler Regulations.
Page 267 of 441

TABLE 4:
NOZZLE LOADING DATA FOR NOZZLES ON CYLINDRICAL SHELLS
2
(Not applicable for High Pressures > 75 kg/cm )
NOZZLE FORCES FLANGE RATING

SIZE AND
NB MOMENTS 150# 300# 600# 900# 1500# 2500#
1” FA (kg) 120 140 160 180 200 220
FL (kg) 120 140 160 180 200 220
FT (kg) 90 10.5 120 135 150 165
ML (kg.m) 7.8 9.1 10.5 11.7 13 14.5
MT (kg.m) 9 10.5 12 13.5 15 16.5
MC (kg.m) 6 7.5 8 9 10 10
1½” FA (kg) 180 210 240 270 300 330

FL (kg) 180 210 240 270 300 330
FT (kg) 135 158 180 203 225 248
ML (kg.m) 17.5 20.5 23 26 29 32
MT (kg.m) 20 24 27 30 34 37
MC (kg.m) 13.5 16 18 20 23 25
2” FA (kg) 240 280 320 360 400 440

FL (kg) 240 280 320 360 400 440
FT (kg) 180 210 240 270 300 330
ML (kg.m) 31 37 42 47 52 57
MT (kg.m) 36 42 48 54 60 66
MC (kg.m) 24 28 32 36 40 44
3” FA (kg) 360 420 480 540 600 660

FL (kg) 360 420 480 540 600 660
FT (kg) 270 315 360 405 450 495
ML (kg.m) 70 82 94 106 117 129
MT (kg.m) 81 95 108 122 135 148
MC (kg.m) 54 63 72 81 90 99
4” FA (kg) 480 560 640 720 800 880

FL (kg) 480 560 640 720 800 880
FT (kg) 360 420 480 540 600 660
ML (kg.m) 125 146 167 187 208 229
MT (kg.m) 144 168 192 216 240 264
MC (kg.m) 96 112 128 144 160 176
6” FA (kg) 720 840 960 1080 1200 1320

FL (kg) 720 840 960 1080 1200 1320
FT (kg) 540 630 720 810 900 990
ML (kg.m) 281 328 375 421 468 515
MT (kg.m) 324 378 432 486 540 594
MC (kg.m) 216 252 288 324 360 396
Page 268 of 441

8” FA (kg) 960 1120 1280 1440 1600 1760

FL (kg) 960 1120 1280 1440 1600 1760
FT (kg) 720 840 960 1080 1200 1320
ML (kg.m) 499 583 665 749 832 915
MT (kg.m) 576 672 768 864 960 1056
MC (kg.m) 384 448 512 576 640 704
10” FA (kg) 1200 1400 1600 1800 2000 2200

FL (kg) 1200 1400 1600 1800 2000 2200
FT (kg) 900 1050 1200 1350 1500 1650
ML (kg.m) 780 910 1040 1170 1300 1430
MT (kg.m) 900 1050 1200 1350 1500 1650
MC (kg.m) 600 700 800 900 1000 1100
12” FA (kg) 1440 1680 1920 2160 2400 2640

FL (kg) 1440 1680 1920 2160 2400 2640
FT (kg) 1080 1260 1440 1620 1800 1980
ML (kg.m) 1123 1310 1498 1685 1872 2060
MT (kg.m) 1296 1512 1728 1944 2160 2376
MC (kg.m) 864 1008 1152 1296 1440 1584
14” FA (kg) 1680 1960 2240 2520 2800 3080

FL (kg) 1680 1960 2240 2520 2800 3080
FT (kg) 1260 1470 1680 1890 2100 2310
ML (kg.m) 1530 1784 2038 2293 2548 2803
MT (kg.m) 1764 2058 2352 2646 2940 3235
MC (kg.m) 1176 1372 1568 1764 1960 2156
16” FA (kg) 1920 2240 2560 2880 3200 3520

FL (kg) 1920 2240 2560 2880 3200 3520
FT (kg) 1440 1680 1920 2160 2400 2640
ML (kg.m) 1997 2330 2663 2995 3328 3660
MT (kg.m) 2304 2688 3072 3456 3840 4224
MC (kg.m) 1536 1792 2048 2304 2560 2816
18” FA (kg) 2160 2520 2880 3240 3600 3960

FL (kg) 2160 2520 2880 3240 3600 3960
FT (kg) 1620 1890 2160 2430 2700 2970
ML (kg.m) 2527 2949 3370 3791 4212 4633
MT (kg.m) 2916 3402 3888 4374 4860 5346
MC (kg.m) 1944 2268 2592 2196 3240 3564
Page 269 of 441

20” FA (kg) 2400 2800 3200 3600 4000 4400

FL (kg) 2400 2800 3200 3600 4000 4400
FT (kg) 1800 2100 2400 2700 3000 3300
ML (kg.m) 3120 3640 4160 4680 5200 5720
MT (kg.m) 3600 4200 4800 5400 6000 6600
MC (kg.m) 2400 2800 3200 3600 4000 4400
22” FA (kg) 2640 3080 3520 3960 4400 4840

FL (kg) 2640 3080 3520 3960 4400 4840
FT (kg) 1980 2310 2640 2970 3300 3630
ML (kg.m) 3775 4405 5034 5663 6292 6921
MT (kg.m) 4356 5082 5808 6534 7260 7986
MC (kg.m) 2904 3388 3872 4356 4840 5324
24” FA (kg) 2880 3360 3840 4320 4800 5280

FL (kg) 2800 3360 3840 4320 4800 5280
FT (kg) 2160 2520 2880 3240 3600 3960
ML (kg.m) 4493 5242 5991 6739 7488 8237
MT (kg.m) 5184 6048 6912 7776 8640 9504
MC (kg.m) 3546 4032 4608 5184 5760 6336
26” FA (kg) 3120 3640 4160 4680 5200 5720

FL (kg) 3120 3640 4160 4680 5200 5720
FT (kg) 2340 2730 3120 3510 3900 4290
ML (kg.m) 5273 6152 7031 7909 8788 9667
MT (kg.m) 6084 7098 8112 9126 10140 11154
MC (kg.m) 4056 4732 5408 6084 6760 7436
28” FA (kg) 3360 3920 4480 5040 5600 6160

FL (kg) 3360 3920 4480 5040 5600 6160
FT (kg) 2520 2940 3360 3780 4200 4620
ML (kg.m) 6115 7135 8154 9173 10192 11211
MT (kg.m) 7056 8232 9408 10584 11760 12936
MC (kg.m) 4704 5488 6272 7056 7840 8624
30” FA (kg) 3600 4200 4800 5400 6000 6600

FL (kg) 3600 4200 4800 5400 6000 6600
FT (kg) 2700 3150 3600 4050 4500 4950
ML (kg.m) 7020 8190 9360 10530 11700 12870
MT (kg.m) 8100 9450 10800 12150 13500 14850
MC (kg.m) 5400 6300 7200 8100 9000 9900
Page 270 of 441

NOZZLE LOADING OF CYLINDRICAL, DISHED / FORMED END
Y
FA
FY=FA
MT
Z X
ML MC
FZ=FT FX=FL
FT FL
C Y L IN D R IC A L E N D S
FA
MB
Y MT
Z X
FR = R ESU LTAN T
D IS H E D / F O R M E D E N D S
(NOTE: LOADS INDICATED IN THE TABLES TO BE CHECKED FOR BOTH POSITIVE AND NEGATIVE
CONDITIONS)
Page 271 of 441

SPECIFICATION FOR WELDING STANDARD SPECIFICATION No.
- 7
4.5iIlatie4ifft ENGINEERS
a' itirds W INDIA UMITED
OF DUPLEX STAINLESS STEEL
AND SUPER DUPLEX STAINLESS
6-79-0016 Rev. 1
Page 1 of 11
STEEL
TATE chi ck tfil t'1Ic1

.n1W-fi 43141 tril Will V.
feTbr
SPECIFICATION FOR
WELDING OF
DUPLEX STAINLESS STEEL
AND
SUPER DUPLEX STAINLESS STEEL
3 14.-3G41
07.10.11 REVISED & REISSUED AS STANDARD
1 SPECIFICATION PC SG PPL DM
0 28.12.04 ISSUED AS STANDARD SPECIFICATION SG VRK KKM SKG
Standards Standards
Prepared Checked Committee Bureau
Rev. Date Purpose Convenor Chairman
No by by
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 273 of 441
aleat ENGINEERS OF DUPLEX STAINLESS STEEL
5,gar fa5legilitiO INDIA LIMITED AND SUPER DUPLEX STAINLESS
6 - 79 - 0016 Rev. 1
,..,,wri,..mny ,A Gort of India Undetta NI
STEEL Page 2 of 11
Abbreviations:
ABS : American Bureau of Shipping

ASME : American Society of Mechanical Engineers
ASTM : American Society for Testing and Materials
BV : Bureau Veritas
CEIL : Certification Engineers International Limited
CPI : Chemical Process Industry
CSC : Chloride Stress Cracking
DNV : Det Norske Veritas
DSS : Duplex Stainless Steel
HAZ : Heat Affected Zone
ISO : International Organization for Standardization
NACE : National Association of Corrosion Engineers
PQT : Procedure Qualification Tests
PREN : Pitting Resistance Equivalent Number
PWHT : Post Weld Heat Treatment
SDSS : Super Duplex Stainless Steel
SSC : Sulphide Stress Cracking
SMMS Standards Committee:
Convener: Mr. PP Lahiri
Members: Mr. A Amin

Mr. GS Hegde
Mr. R Chaudhury
Mr. S Ghosal
Mr. P Saha
Mr. R Nanda (Piping)
Mr. AK Gupta (HMTD)
Mr. S Mukherjee (Construction)
Mr. R Muthulingam (Inspection)
Mr. Raj Kishore (Pipeline)
Mr. AR Purushottam (POSD)
Mr. MP Jain (Projects)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved
Page 274 of 441

SPECIFICATION FOR WELDING
oaraelei oft ENGINEERS
STANDARD SPECIFICATION No.
slg-ar fameg w INDIA LIMITED
,A GOA
of (nth
undertaking)
OF DUPLEX STAINLESS STEEL
AND SUPER DUPLEX STAINLESS
6-79-0016 Rev. 1
(Inne'airs'-"""
STEEL Page 3 of 11
CONTENTS
1.0 SCOPE 4
2.0 CODES AND STANDARDS 4
3.0 WELDING PROCESSES 4
4.0 WELDING CONSUMABLES 5
5.0 APPLICABLE REQUIREMENTS FOR DSS AND SDSS WELDING CONSUMABLES 5
6.0 CLEANING 6
7.0 QUALIFICATION CRITERIA 6
8.0 CORROSION TESTS FOR QUALIFICATION 9
9.0 FABRICATION 11
10.0 QUALITY SURVEILLANCE AND INSPECTION 11
11.0 DOCUMENTS TO BE SUBMITTED 11
Page 275 of 441

Sti12-a-e7 ENGINEERS OF DUPLEX STAINLESS STEEL
INDIA LIMITED 6-79-0016 Rev. 1
5ta■LT IA Go./ Inda Undertaking' AND SUPER DUPLEX STAINLESS
STEEL Page 4 of 11
1.0 SCOPE
1.1 This specification covers the requirements for the welding processes, the quality of the
welding consumables, the welding consumable qualification, the welding procedure
qualification, the welder qualification and the quality assurance testing during fabrication of
DSS and SDSS components. DSS and SDSS welding consumables shall be considered
acceptable when they meet the qualification criteria mentioned in this specification. This
specification shall be applicable for both shop fabricated and field/site fabricated components.
1.2 This specification shall be read together with the corresponding product specifications,
mentioned in the relevant piping material specifications, and/or the equipment data
sheets/design drawings, intended to be used in sour and/or chloride containing environments,
as applicable.
1.3 In case of conflict between this specification and the referred material codes/standard
specifications, the requirement of this specification shall govern.
2.0 CODES AND STANDARDS
The manufacture, inspection, testing, marking and supply of the item covered by this
specification shall follow the latest editions of the following codes and standard specifications:
ASTM A 370 Standard methods and definitions for mechanical testing of steel
ASTM A 923 Standard test methods for detecting detrimental intermetallic phase in
wrought duplex austenitic/ferritic stainless steels
ASTM E 18 Rockwell hardness testing of metallic materials
ASTM E 562 Determining volume fraction by systematic manual point count
ASTM G 36 Performing stress corrosion cracking tests in a boiling magnesium
chloride
ASTM G 48 Standard test methods for pitting and crevice corrosion resistance of
stainless steels and related alloys by use of ferric chloride solution
ASME Section II- Material specifications — Welding rods, Electrodes and Filler metals
Part C
ASME Section V Non-destructive examination
ASME Sec.VIII- Rules for construction of pressure vessels
Division 1
ASME Section IX Welding and Brazing qualifications
NACE MR0175/ Petroleum and natural gas industries-Materials for use in
ISO 15156- H2S-containing environments in oil and gas production:
Part 1: General principles for selection of cracking-resistant materials
Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other alloys
NACE MR0103 Material resistant to Sulfide Stress Cracking in corrosive petroleum
NACE TM0177 Laboratory testing of metals for resistance to sulfide stress cracking and
stress corrosion cracking in H2S environments
SNT-TC-1A Personnel qualification and certification of nondestructive testing
personnel, American Society for Nondestructive Testing (ASNT)
3.0 WELDING PROCESSES
Shielded metal arc welding (SMAW), Gas tungsten arc welding (GTAW), Gas metal arc
welding (GMAW), Submerged arc welding (SAW) and Plasma arc welding (PAW) processes
are suitable for duplex and super duplex stainless steel. All necessary operational precautions
such as cleanliness, protective inert gas shielding applicable for DSS and SDSS shall be
adopted while employing these welding processes.
Page 276 of 441

PRzIe?ifit ENGINEERS OF DUPLEX STAINLESS STEEL
5.1g:a telfalesS' INDIA LIMITED
(A Gort cola unactakingi AND SUPER DUPLEX STAINLESS
6-79-0016 Rev. 1
STEEL Page 5 of 11
4.0 WELDING CONSUMABLES
The welding consumables for welding duplex stainless steels of UNS No.(s) S 31803, S 32205
or equivalent and for welding super duplex stainless steel of UNS No.(s) S 32760,S 32750,S
39274, S 32550, J 93380 or equivalent shall conform to the recommendations made by the
DSS and SDSS base metal manufacturers. The welding consumables shall be used only after
conducting the requisite consumable qualifications tests as given in Clause No. 7.0.
5.0 APPLICABLE REQUIREMENTS FOR DSS AND SDSS WELDING CONSUMABLES
5.1 Chemical Composition
The chemical composition of the DSS and SDSS welding consumables shall be adjusted with
respect to austenite formers such as nickel and ferrite formers such as molybdenum, in order
to obtain the requisite ferrite-austenite balance and the corrosion resistance properties in the
as-welded condition of the weldment. The specific chemical composition of as-welded deposit
shall be as recommended by the DSS and SDSS base metal manufacturers.
5.2 Pitting Resistance Equivalent Number (PREN)
5.2.1 PREN shall be calculated by the following formula:
PREN = % Cr + 3.3 x (%Mo) + 16x (% N)
5.2.2 PREN for DSS
The pitting resistance equivalent number of the DSS welding consumables shall be greater
than 35, when calculated as mentioned in Clause No.5.2.1.
5.2.3 PREN for SDSS
The pitting resistance equivalent number of the SDSS welding consumables shall be greater
than 40, when calculated as mentioned in Clause No. 5.2.1.
5.3 Microstructure
The ferrite content of the weld metal estimated through metallography examination should be
between 30 to 55% to obtain weld joints with the best ductility and corrosion resistance
properties. The welding consumables composition and the welding heat input should be so
selected as to give the ferrite content of the weld metal between 30 and 55%. Ferrite content
measurement shall be carried out by the metallography method in accordance with ASTM E
562.
5.4 Mechanical Properties
5.4.1 DSS
Tensile Strength 680-880 N/mm2
Yield Strength (0.2% Offset) 450 N/mm2 (Min.)
Elongation 25% (Min)
Impact Energy (Charpy V-notch)
at 20° C 100 J Average/ 75 J Minimum

at -30° C 60 J Average/ 40 J Minimum
Page 277 of 441

15raireg e ENGINEERS OF DUPLEX STAINLESS STEEL
511g-ien titgleg IS INDIA UMITED 6-79-0016 Rev. 1
Goa of Irdia Underlalong) AND SUPER DUPLEX STAINLESS
STEEL Page 6 of 11
5.4.2 SDSS
Tensile Strength 800-1050 N/mm2
Yield Strength (0.2% Offset) 550 N/mm2
Yield Strength (1% Offset) 650 N/mm2
Elongation 25% minimum
Impact Energy (Charpy V-notch)
at 20° C 100 J Average/ 75 J Minimum

at -30° C 60 J Average/ 40 J Minimum
6.0 CLEANING
6.1 Cleaning of weld joints before and after the welding shall follow the good engineering
practices applicable for stainless steels. All accessible weld surfaces shall be cleaned after
welding by using pickling paste or pickling agent recommended by the welding consumable
suppliers, for a minimum period of 20 minutes, followed by water washing. This process shall
remove all oxide, tarnish, heat tint and surface contamination.
In the case of tube-to-tube sheet joints of the exchanger, extra care shall be taken to
completely remove the traces of the pickling paste or agent to maintain weld quality.
Wherever completely removal of pickling paste or agent cannot be ensured, such as air cooler
with plug type headers, pickling shall not be carried out.
Where access for cleanings not practicable, such as pipe butt welds, reliance must be placed
on good purging practice to minimize contamination of the backing gas by air. The purge gas
must contain below 10-ppm oxygen or moisture to achieve maximum corrosion resistance of
welds.
6.2 The area where DSS and SDSS fabrications are carried out shall be separated from carbon and
low-alloy steel fabrication area.
7.0 QUALIFICATION CRITERIA
7.1 Welding Consumable Qualification (One-Time Qualification)
Each classification of the DSS and SDSS welding consumables, used for welding procedure
qualification, welder qualification as well as for production welds, shall be procured from
qualified welding consumable manufacturers.
7.1.1 Qualification Criteria for Vendors/Manufacturers with Prior Experience Track Record
Vendors/manufacturers who have proven track record of supplying DSS and SDSS welding
consumables for sour service and chloride containing environments in chemical process
industries (CPI) to any of the reputed operating companies/Engineering Consultants or
Process Licensors such as UOP, IFP, EXXON, BP, CHEVRON, IOCL, HPCL, BPCL, and
EIL shall be considered as qualified vendors/manufacturers', on production of the relevant
purchase orders and test certificates, certified by a witnessing third party inspection agency
such as DNV, Lloyds, BV, ABS, TUV, SGS, CELL, and EIL for the conformance of the
materials to the respective materials specification of the mentioned operators/engineering
consultants. For qualified vendors / manufacturers, Clause No.7.1.2 is not applicable.
Page 278 of 441

a
l t ENGINEF_RS
ISIIRZRY:
f OF DUPLEX STAINLESS STEEL
2-ar EVe
g W INDIA UMITED 6-79-0016 Rev. 1
Gorl of India undensiong) AND SUPER DUPLEX STAINLESS
STEEL Page 7 of 11
7.1.2 Qualification Criteria for New Vendors/Manufacturers without Track Record
A vendor/manufacturer who has no track record of supplying DSS and SDSS welding
consumables for sour service and chloride containing environments in chemical process
industries (CPI) to any of the reputed engineering consultants/operators, as mentioned above
in Clause No.7.1.1, shall be considered as a new vendor/manufacturer. The chemical, the
mechanical and all the corrosion tests shall be carried out as mentioned in Clause Nos. 5.0, 8.0
for qualification by any one of the reputed third party inspection agencies like Lloyds, BV,
CEIL, DNV, TUV, and EIL.
Sulphide Stress Cracking (SSC) test as per Clause No. 8.1, Chloride Stress Cracking (CSC)
test as per Clause No. 8.2, Pitting Corrosion test as per Clause No. 8.3 and Crevice Corrosion
test as per Clause No.8.4, are mandatory for DSS and SDSS welding consumables.
In case the vendors/manufacture(s) had already conducted all the corrosion tests in the past,
and has an approved quality assurance system in place, and the test results are certified by a
witnessing a third party inspection agency such as DNV, Lloyds, BV, ABS, TUV, SGS, CEIL,
and EIL, the test results shall be furnished by the bidder, along with his bid, for Company's
review.
The vendors/manufacturers shall be qualified based on the satisfactory review of the submitted
test results. The Company's decision in this regard shall be final and binding on the bidder.
7.2 Welding Procedure Qualification
7.2.1 General
7.2.1.1 Each particular welding procedure shall be specially qualified. Previous test reports shall not
be recognized as a qualification record for the work to be performed on a new job.
7.2.1.2 Welding consumable qualification tests and welding procedure qualification tests shall be
conducted before the start of fabrication, by employing an approved welding procedure in
presence of the Company third party inspection agency such as DNV, Lloyds, BV, ABS,
TUV, SGS, CEIL, and EIL.
7.2.1.3 All the mills supplying the raw material/pipes etc. shall be required to pass the tests required
for the procedure qualification testing. Approved procedure shall be common to all the mills.
7.2.1.4 In case a combination of different UNS No. has to be used, due to unavoidable reasons, each
combination shall be specifically subjected to welding procedure qualification testing
including all the corrosion tests.
7.2.1.5 Laboratory tests shall be performed at an acceptable reputed laboratory.
7.2.2 Test Samples
Procedure qualification tests shall be performed on welded test pieces that include the parent
metal, heat affected zone and the weld metal.
7.2.3 Procedure Qualification Tests (PQT)
PQT shall be carried out as given below:
Page 279 of 441

46111Retit et ENGINEERS OF DUPLEX STAINLESS STEEL
51g9- Raleg r e INDIA UMITED 6-79-0016 Rev. 1
eli-i-n-11 a coN al Oda unaciaingl AND SUPER DUPLEX STAINLESS
STEEL Page 8 of 11
7.2.3.1 Chemical Composition and Microstructure Examination
The chemical composition analyzed shall conform to the claimed composition mentioned in
the technical brochures of the welding consumable manufacturers approved by the Company
prior to qualification.
The ferrite content measurement of test pieces shall be carried out by both of the following
method:
Metallography examination
Magna-gage method/Ferrite Scope
The procedure of ferrite measurement and the calibration of measuring instruments shall bear
the approval of the Company before being employed. Ferrite content measurement shall be
carried out by the metallography method in accordance with ASTM E 562. Acceptance level
shall be as per Clause No.5.3.
The weld metal of DSS and SDSS shall be checked by the method in accordance with ASTM
A 923, for the presence of intermetallic phases that are detrimental to the weld metal. The
intermetallic phases shall not be more than 1%.
7.2.3.2 Mechanical Properties
These tests shall include tensile testing, impact testing and bend testing, in accordance with
ASTM A 370. Bend tests shall be performed with a plunger diameter equal to 4 times the
thickness. The acceptance values for tensile and impact testing shall be as per Clause Nos.
5.4.1 and 5.4.2. In case of bend testing, the specimen shall not reveal any crack or fissure.
7.2.3.3 Hardness Tests
Each qualification test shall include a cross-sectional hardness survey. The test method shall
be in accordance with ASTM E 18. The distance between indentations shall be a maximum of
1.0 mm. The hardness values shall not exceed RC 28 for DSS and RC 32 for SDSS.
If any other methods including portable hardness tester are to be deployed for checking
production welds, then the correlation between the qualification method and the production
method shall be established and the calibration graph shall be generated for use at the
field/shop. The acceptance criteria shall be as per Rockwell 'C' scale.
7.2.3.4 Corrosion Tests for weldments
Sulphide Stress Cracking (SSC) test as per Clause No. 8.1, Chloride Stress Cracking (CSC)
test as per Clause No. 8.2, Pitting Corrosion test as per Clause No. 8.3, Crevice Corrosion test
as per Clause No.8.4, are mandatory when DSS and SDSS weldments are intended to be used
for sour service and chloride containing environments.
If DSS and SDSS weldments are intended to be used only for chloride containing
environments, the SSC test as per Clause No.8.1 shall be waived off. The remaining corrosion
tests specified in this section shall be carried out for DSS and SDSS weldments meant for use
in the chloride containing environments.
7.2.3.5 Radiography
All welds shall be 100% radiographed. The radiography procedure shall be followed as per
ASME Section V. Acceptance standard shall be as per ASME. Section-VIII, Division-1, UW-
51. The operator's certification to SNT-TC-1A or equivalent is required.
Format No. 8-00-0001-F1 Rev. 0 Copyright Ell — All rights reserved
Page 280 of 441

IsirEzrda ENGINEERS OF DUPLEX STAINLESS STEEL 6-79-0016 Rev. 1
5@zir lalaregWINDIA LIMITED
IA Govt of India Undertaking) AND SUPER DUPLEX STAINLESS
STEEL Page 9 of 11
7.2.3.6 Penetrant Test (PT) And Magnetic Particle Test (MPT)
All fillet and groove welds other than those to be examined by radiography shall be tested by
fluorescent penetrant test or by fluorescent magnetic particle test. No defect indication shall
be accepted. The procedures for penetrant tests and magnetic particle tests shall be followed as
per ASME Section V. The operator's certification to SNT-TC-IA or equivalent shall be
ensured.
7.2.3.7 Post Weld Heat Treatment (If Required)
For DSS and SDSS, no post weld heat treatment is envisaged or recommended. In case,
autogenous welding is adopted or if the process licensor or the client recommends a PWHT,
then the only PWHT shall be solution annealing. The solution annealing heat treatment
procedures shall be established for ensuring retention of the properties of the welded joints for
DSS and SDSS materials. The heat treatment procedures shall be approved by the Company's
representative before their implementation.
7.3 Welder Qualification
Welders shall be qualified at the fabrication yard/barge employing the qualified welding
procedure. The qualification test pieces of each welder shall be subjected to microstructure
examination, mechanical tests, cross sectional hardness survey, radiography examination,
fluorescent penetrant and fluorescent magnetic particle tests, and with the same test procedure
and acceptance criteria as mentioned above in Clause Nos. 7.2.3.1, 7.2.3.2, 7.2.3.3, 7.2.3.5,
7.2.3.6 respectively.
8.0 CORROSION TESTS FOR QUALIFICATION
8.1 Sulphide Stress Cracking (SSC) Test
DSS
SSC test on duplex stainless steel shall be carried out by using the following test solutions and
test conditions:
i) a) Test solution : NACE TM0177

Test temperature : 24°C
Stress value : 350 N/mm2
d) Acceptance criteria : test sample failure at or after 720 hours.
ii) a) Test solution : NACE TM0177

Test temperature : 90° C
Partial pressure of H2S : 16 bars
Acceptance criteria : test sample failure at or after 720 hours.
SDSS
The Sulphide Stress Corrosion Cracking tests on super duplex stainless steel shall be carried
out by using the following solutions and test conditions:


Page 281 of 441
ISIMZIel ENGINEERS OF DUPLEX STAINLESS STEEL
5fg:ar INDIA LIMITED 6-79-0016 Rev. 1
Go. aI kid. Und.na.nal AND SUPER DUPLEX STAINLESS
STEEL Page 10 of 11
ii) a) Test solution : NACE TM0177

Partial pressure of H 2S : 16 bars
Acceptance criteria : test sample failure at or after 720 hours.
8.2 Chloride Stress Cracking (CSC) Test
DSS and SDSS
The CSC tests shall be conducted on representative specimens of DSS and SDSS, in
accordance with the testing procedure mentioned in ASTM G-36, in aerated, boiling 40%
calcium chloride (CaCl 2 ) solution at 100° C with the pH of the solution maintained
around 6.5.
Acceptance criteria: Stress to cause rupture in 500 hours shall exceed 0.85 times the
actual ultimate tensile strength values of duplex stainless steel and super duplex stainless
steel material individually.
8.3 Pitting Corrosion Test
DSS
The pitting corrosion test shall be conducted on the representative DSS specimen, in
accordance with ASTM G-48 method A, using 6% ferric chloride (FeCI 3 .6 H20) solution
by weight at 30°C, as well as at 50°C, for duration of 24 hours.
Acceptance criteria: No pitting shall occur on the surface of the test sample at 30°C. For
the testing at 50°C, the weight loss shall be reported to company for review.
SDSS
The pitting corrosion test shall be conducted on the representative SDSS specimen, in
accordance with ASTM G-48 method A, using 6% ferric chloride (FeCI 3 .6 I-1 2 0) solution
Acceptance criteria: No pitting shall occur on the surface of the test sample at 40°C. For
8.4 Crevice Corrosion Test
DSS
The crevice corrosion test shall be performed on the representative DSS specimen, in
accordance with ASTM G-48 method B, using 6% ferric chloride (FeCI 3 .6 H 2 0) solution
by weight, at 25°C for duration of 24 hours.
Acceptance criteria: No crevice shall form on the surface of the test sample at 25°C.
SDSS
The crevice corrosion test shall be performed on the representative SDSS specimen, in
accordance with ASTM G-48 method B, using 6% ferric chloride (FeCI 3 .6 H 2 0) solution
Acceptance criteria: No crevice shall form on the surface of the test sample at 30°C.
Page 282 of 441

ENGINEERS OF DUPLEX STAINLESS STEEL 6-79-0016 Rev. 1
INDIA LIMITED
151:e7
5'1411E1. IA Gov? of Inch, Undertaking) AND SUPER DUPLEX STAINLESS
STEEL Page 11 of 11
9.0 FABRICATION
9.1 No fabrication shall start until the Company approves the results of the welding consumable
qualification, the welding procedure qualification tests and the welder qualification tests as per
the approved procedure.
9.2 Quality Assurance Tests on Production Welds
As a part of quality assurance, field/shop fabricated weldments shall be subjected to the

following tests, as per the applicable Clauses mentioned in this specification:
Hardness test as per Clause No. 7.2.3.3

Radiography as per Clause No. 7.2.3.5
PT /MPT tests as per Clause no. 7.2.3.6
Ferrite Measurement as per Clause No. 7.2.3.1.
9.3 The weld joints not conforming to the specification requirements with respect to the results of
above tests, shall be cut out to make fresh joints. The reasons for such a breakdown in quality
assurance system shall be investigated and the report shall be submitted to the Company for
review.
10.0 QUALITY SURVEILLANCE AND INSPECTION
The vendors/suppliers shall perform all the tests and inspection procedures mentioned above
to ensure that the welding consumables, the procedure and the fabrication conform to the
requirements of this specification. Company, or the representative duly approved by the
Company, shall have unhindered access for inspection and/or witnessing the selection of test
samples, the preparation of test specimens, and the performance of tests. The company or its
representative shall have the right to indicate the pieces from which the specimens are to be
drawn for various tests. In case of any reasonable doubts regarding the quality of the product,
Company shall have the option to ask for a re-qualification, at the vendor's/contractor's cost.
Inspection by the Company or its authorized representative shall not relieve the supplier of his
responsibility for ensuring the compliance of the materials supplied to this specification.
11.0 DOCUMENTS TO BE SUBMITTED
The vendors/suppliers shall submit the following records of the tests and inspection conducted
on the materials, as per the applicable Clauses mentioned in this specification, to the company
in quadruplicate:
Chemical composition analysis report

- Heat treatment records and charts
Micro-structure examination and ferrite measurement reports
Mechanical properties evaluation reports
Corrosion testing results (qualification records)
Radiography examination report
Penetrant test report
Magnetic Particle test report.
Page 283 of 441

Page 284 of 441
MANALI REFINERY
EPCC-1 : COKER BLOCK : DELAYED COKER UNIT & LPG CFC TREATING UNIT
PART : I
SECTION : 9
TITLE: QUALITY MANAGEMENT SYSTEM
DOCUMENT NO.: 44NC-4600-0000/N.02/0040/A4
A 03-May-10 7 Issued for FEED RB RPG BBD

Prepared Checked Approved
Rev No. Issue Date Pages Rev Description
By By By
Page 285 of 441

Jacobs
CPCL, Chennai QUALITY MANAGEMENT SYSTEM Part-I
LSTK – 1 : Coker Block Section-9.0
44NC-4600 Doc.no.: 44NC-4600-0000/N.02/0040/A4 Page 2 of 7
TABLE OF CONTENTS
1.0 INTRODUCTION 3
2.0 DEFINITIONS 3
3.0 SCOPE OF WORK BY CONTRACTOR 3
4.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS 4
5.0 CONFLICT 7
6.0 CONTRACTOR’S MANAGEMENT REVIEW 7
ANNEXURES
ANNEXURE – I : QUALITY PLAN FORMAT – DESIGN FUNCTIONS
ANNEXURE – II : QUALITY PLAN FORMAT – PROJECT SERVICES
ANNEXURE – III : QUALITY PLAN FORMAT – PROCUREMENT
FUNCTIONS
ANNEXURE – IV : QUALITY PLAN FORMAT – CONSTRUCTION
ACTIVITIES
ANNEXURE – V : QUALITY PLAN FORMAT – WAIVER / DEVIATION
REQUEST
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Jacobs
1.0 INTRODUCTION
This Quality Management System requirements are to be met by the LSTK Contractor during
execution of contracted Scope of Work.
It is preferred by Owner / PMC, that Contractor has a fully documented and certified (by a third
party, internationally accredited certification agency) quality system such as ISO 9001:2000.
2.0 DEFINITION
2.1 Owner – shall mean Chennai Petroleum Corporation Limited.
2.2 PMC – shall mean Project Management Consultant i.e. Jacobs.
2.3 Contractor
For the purpose of this specification, the work “Contractor” means the person(s), firm, company
or organisation who is either under the process of being contracted or contracted by Owner /
PMC for delivery of some products (Including service). The work is considered synonymous to
supplier, bidder or tenderer.
2.4 Quality Manager – Shall mean quality assurance manager dedicated to this project.
2.5 Third Party - Shall mean an independent organisation carrying out assessment on behalf of
Owner / PMC to assess Contractor’s compliance with quality system.
3.0 SCOPE OF WORK BY CONTRACTOR
3.1 Prior to the award of contract
The LSTK contractor shall provide a detail of plan for his total scope of work along with the Bid.
This is required to assure Owner / PMC that he has understood the work and has required
capabilities to carry out the work. Following documents are required to be submitted along with
the bid to enable assessment of above stated requirements,
3.1.1 Brief description of the quality system used by the contractor for carrying out the following
activities:
¾ Project management
¾ Licensor / Technology Slection
¾ Engineering
¾ Procurement including inspection and expediting
¾ Planning and controls
¾ Construction
¾ Commissioning
¾ Subcontracting
¾ Training
¾ Quality Management
3.1.2 Details indicating the plan for all activities, required to be done by the contractor, to accomplish
offered scope of work. These quality plans must be made on enclosed forms, complete in all
respects. The quality plans shall be assumed to be detailing contractors understanding and
planning for the contract / offered scope of work. It is the responsibility of the contractor to
ensure complete harmony between deliverables covered under quality plan(s) and other
documents of the contract.
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Jacobs
Applicable forms for quality planning are enclosed as Annexure-I to IV.
3.2 During / After the award of the Contract
3.2.1 Various documents submitted by the Contractor during the pre-award stage shall be finalised in
consultation with PMC / Owner. It shall be presumed that once an offer is made, the contractor
has understood the requirements given in this specification and agrees to comply with them in
totality unless otherwise categorically so indicated during pre-award stage by Owner / PMC.
3.2.2 Owner / PMC will review all the quality documents including quality manual and contractor is
obliged to incorporate all comments as per this specification.
3.2.3 It is obligatory on the contractor to obtain approval on every quality document (documents
demanded by this specification and / or in the quality plans) before using a particular document
for delivery of contracted scope of work.
3.3 During Job Execution
3.3.1 The LSTK contractor is expected to fully comply with all quality documents submitted and
finalised / agreed against the requirements of this specification. Approval of PMC / Owner on all
these documents shall be sought before start of work.
3.3.2 The LSTK contractor shall be producing sufficient quality records on controlled forms such that
requirements given in this specification can be objectively demonstrated..
3.3.3 The LSTK contractor shall facilitate PMC / Owner during quality audits / surveillance at his office
works / sites to demonstrate compliance to any / all requirements of this specification. PMC /
Owner may institute audits at its sole discretion.
3.3.4 The LSTK contractor shall discharge all responsibilities towards enforcement of this
specification on all the sub-contractors for any part of the work that is sub-contracted by the
contractor.
4.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS

4.1 The contractor shall nominate an overall in charge of the quality titled as “Quality Manager” for
the scope of work of agreed contract. The name of this person shall be duly intimated to PMC /
Owner and all subsequent changes in this shall also be duly intimated to PMC / Owner.
4.2 The LSTK contractor shall clearly establish the responsibilities and authorities of senior
functionaries such that PMC / Owner has total clarity about the concerned person depending
upon nature of the issue. The contractor shall provide adequate manpower and material
resources as per the agreed quality plans.
4.3 The contractor is required to review the contract at all appropriate stages to evaluate its
capability vis-à-vis contract scope of work. All major / critical aspects must be evaluated before
acceptance of the contract. It is expected that the contractor completely plans the contract scope
of work on quality plan formats such that no major variation is expected during delivery of
contract scope of work. Contractor shall plan the type of resources, including various work
methodology and strategies that are to be utilised for delivery of contract scope of work and form
the basis for the costing. The resources shall be planned and deployed based on good industry
practices and as per the job need.
4.4 The scope of the audit shall cover but not limited to the following areas of the project:
4.4.1 Engineering and design
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Jacobs
- Project specific procedures

- Requisitions for equipment and bulk materials .
- Requisitions for Construction sub-contracts.
- Drawings
- Documentation
- Calculations
- Design Verification & Reviews
- Vendor data and vendor calculations
- Constructability review
- Design Safety review
- Document Control
- Softwares to be used.
4.4.2 Procurement
- Enquiry documents for equipment / materials etc.

- Bids for equipment / materials and sub-contract selection, qualification of vendors and sub-
contractors.
- Approval of purchase requisitions of critical equipment as stated in the Contract by Owner /
PMC.
- Purchase Orders
- Inspection and test requirements.
- Contents of inspection reports
- ODC consignments and transportation.
- Packing requirements
- Completeness of manufacturer’s data, documentation requirements,
- Review of installation, pre-commissioning & commissioning documents including vendor
assistance whenever required.
- Documents and Data Control.
4.4.3 Construction / Pre-commissioning / Commissioning / Guarantee Run.
- QA / QC plans for all disciplines including PMI

- Fabrication, erection & Commissioning procedures
- Requirements for mechanical completion
- Handing over procedures and documentation.
- HSE requirements.
4.4.4 The quality requirements shall address the activities / procedures associated but not limited to
following personnel / disciplines.
- Home office activities
- Project team consisting of managers from various disciplines such as process, mechanical,
electrical, civil, instrument, procurement etc.
- All functional disciplines
- Site Construction etc.
4.5 All design activities, if any, performed during delivery of contract scope of work shall be so
controlled that the output is efficient and reliable. It is expected that during development of
design, the contractor shall take recourse to detailed checking, inter departmental reviews and
documented verification methods. Demonstrable objectives evidence for these measures shall
be retained. For all design activities (including verification and review), the contractor shall use
duly qualified personnel as per good industry practices
4.6 A system which assures that latest / required version(s) of the documents(s) are available at all
locations / point of use.
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Jacobs
4.7 In case the contractor decides to sub-contract any part of the contract scope of work (with in the
frame-work of main contract), the contractor shall ;
4.7.1 Evaluate the sub-contractor(s) before awarding them with any work.
4.7.2 Requirements of this specifications shall be enforced on sub-contracted agency also. No

relaxation shall be granted (after finalisation of main contract) on the requirements of this
specification. The contractor shall choose sub-contractor based on their capability to meet
requirements of this specification also.
In case, a sub-contractor may not have a system meeting requirements of this specification, the
contractor may lend his system to sub-contractor for the contract such that sub-contractor
effectively meets the requirements of this specifications.
4.8 All outputs delivered against the contract scope of work shall be suitably identified in such a
manner that either through identification or some other means, sufficient traceability is
maintained which permits effective resolution of any problem reported in the outputs. By this, the
intention is that when some problems are found in the outputs, the root cause can be traced
back through available marking on the output such that effective preventive action is feasible.
4.9 For all critical activities, contractor is expected to have documented methodologies that are to be
utilized for delivery of contract scope of work. Wherever it is difficult to fully inspect or verify the
output (special process), contractor shall pre-qualify the performers and methodologies.
4.10 All inspections carried out by the contractor’s surveillance / inspection staff shall be in conformity
to quality plans and / or inspection and test plans. All inspections results shall be duly
documented on controlled forms such that results are traceable to specific product, that was
inspected / tested. All inspections shall be carried out by duly qualified personnel as per industry
norms or applicable standards.
4.11 All Inspection, Measuring & Test Equipment (IMTE) shall be duly calibrated as per national,
international standards / codes and only duly calibrated and so certified IMTEs shall be utilised
for inspection / testing of contract scope of work.
4.12 All outputs / products delivered against contract scope of work shall be duly marked such that
their inspection / control status is clearly evident during all stages / period of the contract.
4.13 All non-conformities found by contractor’s inspection / surveillance staff shall be duly recorded
including their disposal action. Effective corrective and preventive action shall be implemented
by the contractor for all repetitive non-conformities.
4.14 All non-conformities found by PMC / Owner representative shall be duly recorded on a controlled
form. Such non-conformities shall be analyzed by the contractor and effective and appropriate
correction, corrective and preventive actions shall be implemented. Contractor shall intimate
PMC / Owner of all such corrective and preventive actions implemented by him. Effectiveness of
implemented corrective and preventive action shall be monitored till next two audits.
4.15 Contractor shall establish appropriate methodologies for safe and effective handling, storage,
preservation of various materials / inputs encountered during delivery of contract scope of work.
4.16 Contractor shall prepare sufficient records for various processes carried out by him for delivery
of contract scope of work such that requirement of this specification can be objectively
demonstrated. Various records produced during performance of any activity shall be specified in
the quality plans. In case PMC / Owner finds that enough objective / recording is not available for
any particular process, contractor shall be obliged to make additional records so as to provide
sufficient objective evidence. The decision of PMC / Owner shall be final and binding on such
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Jacobs
issues.
4.17 The contractor shall carry-out internal quality audit for the contract scope of work including this
specification after every three months. Audits shall be scehduled such that each element of
contractor’s quality system applicable to each major activity areas viz., design / engineering,
project management, procurement, construction and commissioning is audited. An independent
team having appropriate qualification shall be appointed for this purpose. The findings of such
assessment shall be duly recorded and appropriate corrective and preventive actions
established and acted upon, the complete report / copy of these shall be sent to PMC / Owner
for information / review.
4.18 The contractor shall institute second part audits on all subcontractors after every three months to
establish compliance to this specification. PMC / Owner reserves the right to nominate their
representatives during such audits. Records of findings and actions shall be maintained.
4.19. For all special, verification and critical processes, contractor shall deploy only qualified
performers. Wherever PMC / Owner find any deficiency, the contractor shall be obliged to impart
necessary training / qualifications to the performer(s) before any further delivery of work.
5.0 CONFLICT
In case of any conflict between the main contract and requirements given in this specification or
any document finalised based on this specification, the requirements / provisions of the main
contract shall prevail.
6.0 CONTRACTOR’S MANAGEMENT REVIEW
6.1 Management Review Meetings shall be carried out scheduled quarterly or on as needed basis at
sufficient intervals.
6.2 The Management shall address in these meetings the feed back received from audit findings,
non-conformities and the feed back from Owner / PMC.
6.3 There shall be total involvement and commitment by the Management to enhance Owner’s
satisfaction through continual improvement of the system and assurance of conformity to
Owner’s and applicable regulatory requirements.
Page 291 of 441

ANNEXURE - I
QUALITY PLAN (Design Function) Document Number
Organisation DIVISION / Document Number
DEPARTMENT : Revision Number Sheet of
Reviewed by : (Signature, Name & Date)

Page 292 of 441
Approved by : (Signature, Name & Date)

GENERAL BASIC PROCESS DESIGN MATURITY Final All
Procedure / Verification Verification Reviewed Validated Validation Approval Records Generated
Activity module / Deliverable Work Ins. Performer By Method By By Method By
ANNEXURE - II
QUALITY PLAN (Project Services) Document Number

Page 293 of 441

GENERAL BASIC PROCESS SERVICE PERFORMANCE ANALYSIS All
Activity Description Procedure / Performer Reports / Outputs Sampling Acceptance Criteria By Records Generated
Work Ins. Basis
ANNEXURE - III
QUALITY PLAN (Procurement Function) Document Number

Page 294 of 441

GENERAL BASIC PROCESS FINAL APPROVAL All
Activity Module / Deliverable Procedure / Performer Reviewer (if any) Sampling Acceptance By Records Generated
Work Ins. Basis Criteria
ANNEXURE - IV
QUALITY PLAN (Construction Activities) Document Number

Page 295 of 441

GENERAL BASIC PROCESS FINAL APPROVAL All
Activity Module / Deliverable Procedure / Performer Records Maintained Sampling Acceptance Criteria Inspected Records Generated
Work Ins. Basis By
ANNEXURE V
QUALITY PLAN (Design Function)
(STRIKE WHICH EVER IS NOT APPLICABLE)
PROJECT _______________________ ORIGINATOR REF. __________________
JOB NO. ________________________ ORDER / CONTRACT NO. _______________

TO BE FILLED BY ORIGINATOR
ORIGINATOR : VENDOR / CONTRACTOR / JACOBS DEPARTMENT ______________________________________________
REQUIREMENT AS PER SPECIFICATION DESCRIPTION OF WAIVER / DEVIATION SOUGHT
Why the Waiver / Deviation is required ?
Contractual Implication if waiver / deviation is granted :

* Time taken shall be More / Less / No change
* Cost of item shall be More / Less / No change
* Performance requirement shall be Satisfied / Not Satisfied
Under present constraints, requested waiver / deviation is most optimum for the project and does not involve any security and
safety hazard
Date Signature
Contractor / Vendor(With Seal) / Jacobs
Decision on waiver / deviation with remarks, if any, on time / cost implications
(To be filled by the department / division in Jacobs responsible for conveying to the originator)
Signature : _________________________
Date : _____________
Name : _____________________________
WAIVER / DEVIATION REQUEST NUMBER
Page 296 of 441

OPINION FROM PMC
Date : __________ Signature : _________________

Name : ____________________
Department : ________________
FORWARDED TO ________________________ BY PROJECT DIRECTOR OF PMC

(PROJECT MANAGER)
Date : __________ Signature : _________________

Name : ____________________
FORWARDED TO __________________
(Target Resolution Div / Dept./Group)
Date : __________ Signature : ___________________

(PROJECT MANAGER)
Name : ____________________
DISPOSITION BY TARGET RESOLUTION DIV / DEPT / GROUP
Date : __________ Signature : _________________

Name : ____________________
FINAL DECISION OF PROJECT MANAGER ALONG WITH OVERALL REVIEW

(Client's decision required / not required)
Date : __________ Signature : _________________

Name : ____________________
OWNER'S DECISION, IF REQUIRED
Date : __________ Signature : _________________

Name : ____________________
WAIVER / DEVIATION REQUEST NUMBER
Page 297 of 441

APPENDIX - A
INDICATIVE INSPECTION & TEST PLAN** SHEET 1 OF 3

PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID UPGRADATION
PROJECT
DOC. NO: A133-00-000-ITP09A VENDO
EQUIPMENT / ITEM DESCRIPTION : SHELL & TUBE HEAT R : P.O.
EXCHANGER NO. :
EQUIPMENT / ITEM TAG NO. :
PR/PS
TEST & INSPECTION AS PER :
(CODES & SPECIFICATIONS) : EQUIPMENT
NO.
INSPECTION CODE : A DRG.
NO.
A 1 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / PMC
C
T 2 WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY THIRD PARTY
I INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY
V 3 WITNESS INSPECTION BY SUB VENDOR,VENDOR Rev.1
I
4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR /
T VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC
1Y H H X PRE-INSPECTION MEETING TO BE CONDUCTED AFTER ISSUE OF PO /
PR / PS. AGENDA TO BE PREPARED BY LSTK CONTRACTOR
2 A A R X DETAILED INSPECTION & TEST PLAN AFTER ISSUE OF PO/PR/PS
(INCLUDING FOR BOUGHT – OUT ITEMS)
3 A R X INSPECTION & TEST PROCEDURES INCLUDING NDT / PWHT / WELD
REPAIR / HYDRO TEST / PAINTING / PICKLING & PASSIVATION
PROCEDURES, ETC.
4 A X PACKING PROCEDURE . Rev.1
5 R R X Rev.1
6 A W X WELDING PROCEDURE SPECIFICATIONS AND PROCEDURE
QUALIFICATION RECORD INCLUDING WELD REPAIR.
7 H/ W X TUBE TO TUBE SHEET JOINT MOCK-UP PROCEDURE
R QUALIFICATION AND REVIEW OF RECORDS.H FOR NEW MOCK UP AND R
FOR EXISTING MOCK UP Rev.1
8 A W X WELDERS’ QUALIFICATION / WELDERS PERFORMANCE RECORDS
9 H W X NEW WELDING PROCEDURES AND WELDERS QUALIFICATION
10 R R X WELDING CONSUMABLES BATCH CERTIFICATE
11 H W X RAW MATERIAL INSPECTION / IDENTIFICATION FOR ALL PRESSURE
PARTS / COMPONENTS W.R.T MILL / MANUFACTURER’S TCs.
12 R W X RAW MATERIAL IDENTIFICATION FOR NON-PRESSURE PARTS/
STRUCTURAL MATERIALS
13 R R X SUB-ORDER VERIFICATION FOR BOUGHT-OUT ITEMS VIZ FLANGES /
FORGINGS, FORGE TUBE SHEET, GIRTH FLANGES FITTINGS,
TUBES, DISHED ENDS, BELLOWS, FASTENERS ETC.
14 H W X INSPECTION OF BOUGHT-OUT ITEMS AT MANUFACTURES, WORKS FOR
* FORGINGS, TUBES SHEETS, GIRTH FLANGES, TUBES, FITTINGS,
FASTENERS, DISHED ENDS, EXPANSION BELLOWS ETC.
15 R W X LONG-SEAM, CIRC-SEAM SET-UP CHECK FOR SHELLS, CHANNELS,
BONNETS, NOZZLES ETC Rev.1
16 H W X IDENTIFICATIONS OF ALL BOUGHT OUT ITEMS AT FABRICATION SHOP
17 H W X TUBE SHEET INSPECTION AFTER MACHINING / DRILLING / REAMING.

18 R W X NOZZLES ATTACHMENTS & INTERNALS FIT-UP CHECK ON SHELLS /
DISHED ENDS. Rev.1
Page 298 of 441

PROJECT
VENDOR :
DOC. NO: A133-00-000-ITP09A P.O. NO. :
EQUIPMENT / ITEM DESCRIPTION : SHELL & TUBE HEAT
EXCHANGER PR/PS NO.
EQUIPMENT / ITEM TAG NO. : DRG. NO.
TEST & INSPECTION AS PER :
(CODES & SPECIFICATIONS) :
EQUIPMENT INSPECTION CODE : A

C
V 3 WITNESS INSPECTION BY SUB VENDOR,VENDOR Rev.1
I
T 4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR /
Y VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC
19 W W X SHELL & TUBE BUNDLE INSPECTION BEFORE INSERTION /

ASSEMBLY IN SHELL. Rev.1
20 W/ W X TUBE SHEET TO SHELL AND GIRTH FLANGES TO SHELL / BONNET /
R CHANNEL SET-UP CHECK. Rev.1
21 R W X ROOT RUN DP CHECK Rev.1
22 R W X ROOT RUN DP CHECK FOR TUBE TO TUBE SHEET JOINTS Rev.1
23 R W X DP CHECK AFTER BACK GOUGING OF WELD JOINTS Rev.1
24 H W X EXPANSION CHECK OF TUBE TO TUBE SHEET JOINTS
AIR TEST OF REINFORCING PADS & TUBE TO TUBE SHEET JOINTS
25 W W X
Rev.1
26 H/ W X NDT (RT, UT, MT, PT, HALOGEN / HELIUM LEAK TESTING ETC, AS
R APPLICABLE.) EXAMINATION / NDT CLEARANCE OF WELD JOINTS
BEFORE PWHT/HYDROTEST Rev.1 R for UT,MT,PT
27 H W X VISUAL (INTERNALS & EXTERNAL) & DIMENSIONAL CHECK BEFORE
RELEASE FOR PWHT (IF APPLICABLE)
28 H W X PWHT CHART / RECORDS (IF APPLICABLE)
29 H W X MECHANICAL TESTS OF COUPONS FOR TENSILE, HARDNESS,
IMPACT AS APPLICABLE
30 W W X HARDNESS CHECK OF BASE METAL, HAZ & WELD AFTER PWHT AND
ANY OTHER SUPPLIMENTATRY REQUIREMENT CHECK LIKE IGC,
FERRITE ETC. Rev.1
31 W W X VISUAL (INTERNAL & EXTERNAL) & DIMENSIONAL CHECK BEFORE
RELEASE FOR HYDROTEST Rev.1
32 H W X HYDROSTATIC TEST (SHELL SIDE & TUBE SIDE ASSEMBLY)
(WATER CHLORIDE PPM TO BE CHECKED FOR SS EQUIPMENTS)
33 H W X FINAL INSPECTION INCLUDING NAME PLATE AND MARKING CHECK
34 R W X SURFACE PREPARATION, PAINTING / PICKLING AND PASSIVATION
CHECK Rev.1
35 H R X FINAL DOCUMENTATION INCLUDING CERTIFICATION OF AS-BUILT
DRAWINGS AND STAMPING OF EQUIPMENT
36 W H X SPARES AND PACKING LIST CHECK. PACKING & LOADING OF
EQUIPMENT AS PER SHIPPING DRAWING. Rev.1
Page 299 of 441

PROJECT
DOC. NO: A133-00-000-ITP09A VENDOR :
EQUIPMENT / ITEM DESCRIPTION : SHELL & TUBE HEAT P.O. NO. :
EXCHANGER
EQUIPMENT / ITEM TAG NO. : PR/PS NO.
TEST & INSPECTION AS PER : DRG. NO.
(CODES & SPECIFICATIONS) :
EQUIPMENT INSPECTION CODE : A
C
V 3 WITNESS INSPECTION BY SUB VENDOR,VENDOR & LSTK CONTRACTOR
I
T 4 CERTIFICATES / DATA TO BE SUBMITTED BY LSTK CONTRACTOR /
Y VENDOR FOR APPROVAL / REVIEW BY TPI A / OWNER / PMC
37 H H INSPECTION RELEASE CERTIFICATE
LEGENDS : H – HOLD, W - WITNESS, R – REVIEW, A - APPROVAL, I - INFORMATION, X – SUBMIT

PO – PURCHASE ORDER, PR – PURCHASE REQUISITION, PS – PURCHASE SPECIFICATION
** NOTE : THIS IS AN INDICATIVE INSPECTION AND TEST PLAN IDENTIFYING SCOPE OF INSPECTION
/REVIEW OF DOCUMENTS AS A MINIMUM REQUIREMENT, DETAILED INSPECTION AND TEST PLAN
INDICATING ALL SPECIFIED REQUIREMENTS AFTER ISSUE OF PO / PR TO BE GENERATED BY
VENDOR AND SAME DULY APPROVED BY TPI A TO BE SUBMITTED TO OWNER / PMC FOR APPROVAL.
* TPI A TO CARRY OUT INSPECTION AT SUB-VENDORS’ WORKS.
OWNER / PMC RESERVES RIGHT TO WITNESS INSPECTION OF ANY ITEM AT ANY STAGE WHICH SHALL BE INDICATED ON QAP /
INSPECTION & TEST PLAN AT THE TIME OF APPROVAL AND SAME TO BE COVERED AS PART OF PURCHASE ORDER
CONDITION ISSUED BY CONTRACTOR.
Note : Following modification has been made from the original ITP attached with Bid Document.
1. In activity :scope of Inspection LSTK contractor has been deleted

2. Activity 4: Shipping drawings of completed equipments has been deleted
3. Activity 5: Summary of all supplimentary requirements as specified in the order/PS/PR deleted
4. Activity 7: TTP joint Mock up procedure has been modified as H/R for TPI
5. Activity 15: Long seam and Circ. Seam set up check has been modified as R for TPI
6. Activity 18: Nozzle attachment and internal fit up check has been modified as R for TPI
7. Activity 19: Shell and Tube bundle inspection before insertion has been modified as W for TPI
8. Activity 20: Tube sheet to shell and girth flange to shell /Bonnet has been modified as W/R for TPI
9. Activity 21: Root run DP check has been modified as R for TPI
10. Activity 22: Root run DP check for tube to tube sheet joints has been modified as R for TPI
11. Activity 23: DP check after back gouging has been modified as R for TPI
12. Activity 25: Air test of RF pad and TTP joints has been modified as R for TPI
13. Activity 26: NDT Examination/Clearance has been as H/R for UT,MT,PT for TPI
14. Activity 30:Hardness check after PWHT and other supplementary requirement has been modified as R for TPI
15. Activity 31: Visual and Dimensional check before release for Hydro test has been modified as W for TPI
16. Activity 34:Surface preparation painting /pickling etc has been modified as R for TPI
17. Activity 36:Spares and packing list check has been modified as W for TPI
18. Activities in respect of QAP / ITP and IRN /IC for categories will be as below:
For PMC category A : QAP/ITP approval by EPC , TPIA & PMC.
IRN/IC issued by TPIA and to be endorsed by PMC
Page 300 of 441

Page 301 of 441
Page 1 of 5

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: SUPPLEMENTARY SPECIFICATION FOR CARBON STEEL

VESSELS
DOCUMENT NO. : 44NC-4600-0000-V-02-0120-A4
Rev No. Issue Date Pages Rev Description Prepared Checked Approved
By By By
0 09.03.2010 5 Issued as Standard specification MS CR CR
Page 302 of 441

CPCL, Chennai SUPPLEMENTARY SPECIFICATION FOR Part V Section 3.4
44NC-4600 CARBON STEEL VESSELS Page 2 of 5
TABLE OF CONTENTS
1.0 PURPOSE
2.0 DESIGN
3.0 ELECTRODES
4.0 FABRICATION
44NC-4600-0000-V.02-0120-A4 Supp spec for CS vessels.doc

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1.0 PURPOSE
This supplementary specification indicating additional requirements for fusion welded carbon steel
vessels shall form addenda to General Specification for Pressure Vessels No. 44MM-2800-00-
V.02-0101-A4
2.0 DESIGN
2.1 Reinforcement for nozzle openings shall be integral type when required by the applicable
codes/standards or when the nominal thickness of vessel part exceeds 50mm. Self-reinforcing
type nozzles of size 3” NB and above shall be `set in’ type.
2.2 Design calculations for self reinforced nozzles/self reinforced weld ends shall be submitted by
Vendor.
3.0 ELECTRODES
3.1 Electrodes conforming to following specification shall be used. In case of any deviation, prior
approval from Jacobs shall be obtained.
Sr. 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 upto 70,000 psi : ASME IIC SFA 5.1 E7016/ E7018
b. Steels with UTS upto 80,000 psi : ASME IIC SFA 5.5 E8016-X/
E8018-XX depending upon the alloy
element
c. Low temperature service

0 0
Below minus 0 C and upto minus 46 C : ASME IIC SFA 5.1 E7016-1/
Steels to A-516, A-537, A-333 Gr.6 and A-350 E-7018-1
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. All weld metal shall have equal
or better mechanical properties than the parent metal.
3.2.2 Only dry flux shall be used.
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.

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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 discoloration 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.
0
4.2.5 No welding shall be carried out when ambient temperature is less than 10 Celsius unless
preheating is carried out.
4.3 Heat Treatment
4.3.1 Heat treatment of formed parts shall be carried out as per following:
(a) Cold formed dished ends or knuckles up to 16 mm nominal thickness shall be stressed
relieved.
(b) Cold formed dished ends or knuckles above 16 mm nominal thickness shall be
normalised
(c) Hot formed dished ends or similar parts, which have not been uniformly heated in the
normalising range in the final stages of manufacturing shall be normalised.
(d) When the completed vessel involves post weld heat treatment, heat treatment
recommended in (a) above shall not be applicable.
4.3.2 Vessels in caustic service, amine or sour service shall be stress relieved.
4.4 Production Weld Tests
Production weld tests shall be applicable for vessels above 50 mm nominal thickness or when
required by the applicable code. The following 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.

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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 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
0
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 or the Design Code whichever is more stringent.
4.5 For vessels required to meet stress corrosive conditions (such as caustic service, H2S service,
amine, etc.), 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.

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Document No.
VENDOR DATA REQUIREMENTS A133-086-16-46-VDR-6142
FOR Rev. A
ISSUED FOR BIDS Page 1 of 3

FOR
ISSUED FOR BIDS
A 21-MAR-2014 ISSUED FOR BIDS RK KRK BBC

Rev. Date Purpose Prepared by Checked by Approved by
No.
Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved
Page 307 of 441

Document No.
FOR Rev. A
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 Full size plus 11" x 17"
EQUIPMENT WEIGHT, GENERAL NOTES, scale down of each.
NOZZLE SCHEDULE, DETAIL OF SHELL, DURATION OF
HEADS, SUPPORTING ARRANGEMENT, SUBMISSION : 4
WEEKS AFTER LOI
MAIN WELD SEAMS, NOZZLE ORIENTATION
PLAN, CUTTING LAYOUT ETC.
2. WELDING PROCEDURES AND
QUALIFICATION TEST REPORTS @
3. DESTRUCTIVE AND NON-DESTRUCTIVE
TEST REPORTS @
4. MATERIAL TEST CERTIFICATES @
5. RADIOGRAPHIC EXAMINATION REPORTS
WITH FILMS @
6. HEAT TREATMENT PROCEDURE AND TIME
TEMPERATURE CHARTS @
7. CODE CERTIFICATES (INCLUDING
INSPECTION CERTIFICATE, HYDROSTATIC
TEST CERTIFICATE, LOCAL CODE
REQUIREMENTS, RUBBING OF CODE
STAMP AND NAME PLATE ETC.) @
8. PACKING AND FORWARDING
INSTRUCTIONS @
9. LIST OF SPARE PARTS WITH DETAILS
10. MANUFACTURER'S DATA REPORT
11. TUBE BUNDLE DETAILS Full size plus 11" x 17"
scale down of each.
DURATION OF
SUBMISSION : 4
WEEKS AFTER LOI
12. DETAIL OF NOZZLES AND EXCHANGER Full size plus 11" x 17"
scale down of each.
SUPPORT DURATION OF
SUBMISSION : 4
WEEKS AFTER LOI
13. DETAILS OF GASKETS Full size plus 11" x 17"
scale down of each.
DURATION OF
SUBMISSION : 4
WEEKS AFTER LOI
14. HEAT EXCHANGER DETAILED DRAWINGS Full size plus 11" x 17"
scale down of each.
AND PARTS LIST DURATION OF
SUBMISSION : 4
WEEKS AFTER LOI
15. (AS BUILT) S. NO. : 1-5
16. INSPECTION AND TESTING PLAN @
17. Mechanical design calculation DURATION OF
SUBMISSION: 4
WEEKS AFTER LOI.
Page 308 of 441

Document No.
FOR Rev. A
POST ORDER
S. WITH WITH
N DESCRIPTION FOR FOR DATA REMARKS
BID
O. REVIEW RECORD BOOK
(FINAL)
1. IBR DESIGN CALCULATION FOR ITEM NOS 086-
E-25. IBR
CALCULATION &
EXCHANGER
DRAWINGS SHALL
BE APPROVED BY
CIB.
DURATION OF
SUBMISSION: 4
WEEKS AFTER LOI.
Notes :
1. "TICK" denotes applicability
2. Quality requirements as mentioned in specification 44NC-4600-0000/N.02/0040/A4.
3. Refer 44NC-4600-0000/N.02/0040/A4/A4+Annexure- I to V for quality management system
4. Bidder to submit 6 nos. hard copy of each drawing and 3 hard copy of each calculations at drawing review
stage along with soft copy in eDMS. Final documentation shall be submitted in hard copy (15 prints) and soft (4
CDs/ DVDs) in addition to submission through EIL eDMS.
5. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).
6. All post order documents shall be submitted / approved through EIL eDMS portal
7. 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).
8. "@" indicates submission of documents to Inspection Agency.
9. Bill of Material shall form part of the respective drawing.
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Page 1 of 5

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: STANDARD SPECIFICATION FOR BQ CARBON STEEL PLATES
DOCUMENT NO. 44NC-4600-0000-V.02-0117-A4
Rev No. Issue Date Pages Rev Description Prepared Checked Approved
By By By
0 09.03.2010 5 Issued as Standard specification MS CR CR
Page 314 of 441

CPCL, Chennai STANDARD SPECIFICATION FOR Part V Section 3.4
44NC-4600 BOILER QUALITY CARBON STEEL PLATES Page 2 of 5
CONTENTS
1.0 PURPOSE
2.0 GENERAL
3.0 TECHNICAL REQUIREMENTS
4.0 FINAL DOCUMENTS
5.0 PAINTING AND COATING
6.0 INSPECTION AUTHORITY
44NC-4600-0000-V.02-0117-A4 Standard Specification for BQ plates.doc

Page 315 of 441
1.0 PURPOSE
This specification covers requirements for carbon steel plates intended primarily for pressure
vessels / heat exchangers. The steel plates shall meet the requirements of ASME Section II
(latest). This is intended to supplement the minimum applicable requirements of the material
specification indicated in the purchase requisition.
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. Final Rolling shall be
lengthwise.
2.3 The plates shall be free from injurious defects and shall have workman like 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 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 also be satisfied.
Ceq = C + Mn/6 ≤ 0.42 (Eqn. – 1)
Ceq = C + Mn/6 + ( Cr+Mo+V)/5 + ( Cu+Ni)/15≤ 0.45 (Eqn. – 2)
Equation – 1 shall be used when applicable material specification specified 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 S19 and
S21 of SA-20 are specified in purchase requisition.
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 thickness above 50 mm 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.

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These details shall also be recorded on the test certificates.
3.5 Heat Treatment Cycle for components as well as test coupons
For plates above 16 mm thickness : One normalising * + One stress relieving as per
intended for hot rolling / hot forming UCS-56 of ASME Sec. VIII Div. 1
Note: Any other special requirement shall be specified in purchase requisition.
* Recommended normalising cycle :
0 0
(I) Soaking temperature: 900 C to 1000 C
(ii) Holding time one hour per 25 mm thickness but shall not less than half an hour
(iii) Cooling in still air
3.6 If specified in the purchase requisition, charpy V-notch impact test as per supplementary
requirement S5 of specification SA-20 at temperature indicated in the purchase requisition shall
be conducted, for low temperature service.
3.7 If specified in the purchase requisition, plates shall meet the requirements of Indian Boiler
Regulations (IBR).
3.8 Additional requirements for high thickness plates
Plates of thickness 50 mm and above shall meet following additional requirements: -
a. Vacuum Degasing treatment as per the supplementary requirement S1 of specification

SA-20
b. Charpy V – notch impact test as per the supplementary requirement S5 of specification

SA 20.
0
i) Material meant to be used for design temperature warmer than 0 C, impact test
0
shall be carried out at minus 29 C and acceptance criteria for energy absorption
shall be as per Table A2.15 of SA-20.
ii) Acceptance criteria and test temperature for impact testing of non listed material of
Table A2.15 of SA-20 shall be as specified in purchase requisition.
c. Bend test as per the supplementary requirement S14 of specification SA-20.
d. Simulated heat treatment of test coupons for all plates as per Clause 3.4 mentioned
above.
4.0 FINAL DOCUMENTS
The supplier shall furnish 7 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 DIN 50049 Type 3.1 B/EN 10204 Type 3.1 B.
a. Chemical Analysis
b. Mechanical Tests

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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. Bend test (S14 of SA 20 if specified in the requisition or whenever applicable)
h. Certification as per IBR (if specified in the requisition)
i. Date of manufacture (final rolling)
j. SSC and / or HIC tests (if specified in purchase requisition)
5.0 PAINTING AND COATING
No painting / coating of any kind is permitted on the steel plates, except stencil marking.
6.0 INSPECTION AUTHORITY
6.1 Material test certificate duly certified by Mill’s quality assurance / quality control department is
acceptable. However, if third party inspection is specified in requisition, all test certificates and
documents shall be duly certified by the third party.

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SPECIFICATION FOR DOCUMENT No.
SHELL &TUBE A133-16-46-SP-6142
HEAT EXCHANGERS Rev. A
DCU, CPCL Page 1 of 6
JOB SPECIFICATION
FOR SHELL AND TUBE
HEAT EXCHANGERS
PROJECT : COKER BLOCK (EPCC-1)

RESID UPGRADTAION PROJECT, CPCL, CHENNAI
OWNER : CHENNAI PETROLEUM CORPORATION LIMITED
PMC : JACOBS ENGINEERING INDIA PRIVATE LIMITED
CONTRACTOR : ENGINEERS INDIA LIMITED
JOB NO. : A133
A 21.03.2014 ISSUED FOR BIDS RK KRK BBC
Rev. No Date Purpose Prepared by Checked by Approved by
Template No 5-0000-0001-T1 Rev1 Copyright EIL – All rights reserved
Page 324 of 441

1. The drawings issued for bids are strictly for quotation purpose. The drawing with
revision if required shall be issued along with Purchase Requisition for drawing
preparation and fabrication etc. On placement of order the successful vendor shall
immediately furnish design calculations & outline sketch as per TEMA, ASME Sec. VIII
div.I for EIL/JACOBS approval. Based on approved calculation & outline sketch,
vendor can proceed with the procurement of major material for ordered items.
Requirements specified in attached specification shall be complied with.
2. Vendor to quote group wise price. Basis of pricing shall be strictly as per Scope of
Work and Supply.
3. All materials required for fabrication, testing and inspection shall be supplied by
vendor. No material shall be supplied as "FREE ISSUE" by owner.
4. It shall be entirely the vendor's responsibility to ensure compliance to codes specified

for design, fabrication, testing etc. and to all requirements of Requisition including its
specifications / drawings after the order is placed. In view of this, the fabrication
drawings prepared by vendor will be reviewed by EIL/JACOBS to the following extent
only:
i) Nozzle data, orientation and location, saddle location, dimensions for
interfacing.
ii) Pass partitions arrangement, tube layout and bundle detail.
iii) Design data and materials of construction.
iv) Critical details like tube to tubesheet joint detail.
Other details of fabrication drawings submitted shall only be for information/records of

EIL/JACOBS and vendor to fabricate, supply equipment based on his responsibility of
ensuring compliance to EIL/JACOBS PR requirements including drawings,
specifications etc. Vendor to note that approval of documents does not mean
approvals of any deviations contained therein. Such deviations if noticed at anytime,
even after delivery, same to be rectified as per requisition by vendor.
5. Vendor must ensure that all the vendor documents are thoroughly checked and
approved at vendor's end by vendor's competent engineer and responsible
engineering office in charge before the same are submitted to EIL/JACOBS for review.
6. The tube bundles for the following items are interchangeable among themselves, and
the same shall be checked at the vendor shop prior to despatch:
Set /Sl. No. Item Nos.
NIL
7. Test ring assembly shall be stuffing box type in accordance with Fig. E-4.13.2 of
TEMA. Drawing for test rings/test flanges shall be furnished by the vendor separately.
Vendor to design and supply test rings/test flanges including all testing accessories
separately in accordance with following instructions:
Page 325 of 441

Individual test rings/test flanges as listed against the items (refer sht 2 of spec. no.
A133-086-16-46-SS-6142).
o Common test rings/test flanges for following items:
Set /Sl. No. Item Nos.
All testing materials /accessories to be provided by vendor, even if not specified in the
equipment datasheet.
8. Cathodic protection as per spec. no. 44NC-4600-0000-V.02-0125 shall be provided for

all items with painting and sacrificial anodes on channel and floating head cover to
minimize waterside corrosion.
Vendor must submit anode test reports as required in the anodes specification for
EIL/JACOBS-SMMS’s approval before start of the anodes manufacture. This shall be
“HOLD” point for Inspection.
9. While preparing fabrication drawing it shall be endeavored to cover all fabrication

details in minimum number of drawings, not exceeding 5 in any case. There shall be a
separate drawing for gaskets. Preparation of fabrication drawing will also include
developing tube layouts as under.
o Based on enclosed tube layouts.
Based on indicative tube layouts and Guide lines issued with this requisition.
The indicative tube layouts for the items covered in this requisition are issued to the
vendor for developing detailed tube layouts in line with the Guide lines issued. The
detailing will call for providing tie rods, spacers, sealing strip/sliding strips, seal rods,
eye bolts, plugs for eye bolts, inserts for eye bolts in case of clad tube sheets etc.
Vendor is expected to consider the aspects and base his quotation accordingly. No
extra cost shall be admissible on this account.
10. Vendor is expected to quote strictly in accordance with the requirement of the
requisition. Subcontracting of the entire / main equipment is not acceptable.
Subcontracting of the boughtouts / components should be done to approved vendors
only. When no list exists for sub vendors consider only reputed vendors after
EIL/JACOBS approval.
11. ACCEPTABLE ALTERNATIVES:
(I) SA 516 Gr 70 is also acceptable in place of SA 516 Gr 60.

(II) Forgings can be used in place of plates or pipes wherever the stress values are
same or higher.
(II) Higher thickness for reinforcement pad, stiffeners and non-pressure parts shall be
acceptable.
Page 326 of 441

12. Vendor shall comply with clause 1.2.2 of 44NC-4600-0000-V.02-0102-A4 in respect of

following items falling under the purview of IBR.
Sl. No. Item Nos.
1 086-E-25
13. Hardness limits of various material for nozzle flange & RTJ gaskets are as follows:
FLANGES GASKET
MATERIAL HARDNESS (BHN) MATERIAL HARDNESS

(BHN)
C.S 140 (Min) SOFT IRON 90 (Max.)
1 Cr TO 5 Cr 150 (Min) 5 Cr- ½ Mo 130 (Max.)
9 Cr 160 (Min) 5 Cr-½ Mo, 9 Cr-1 Mo 140 (Max)
SS 304, 316 150 (Min) SS 304L, SS 316L 160 (Max)
SS304L,316L 140 (Min) SS 304L, SS 316L 160 (Max)
SS321,SS347 170 (Min) SS 321L, SS 347 160 (Max)
14. Positive material identification (PMI), vendor shall ensure that all alloy steel and
stainless steel materials are properly identified and finally check tested by a PMI
analyser before dispatch of equipment as per 44NC-4600-0000-V.02-0100-A4.
15. Metric threads shall be used for all non-standard flanges. However ASME flanges may
have threads as per American standards.
16. Interchangeable / 180 rotatable bundles shall have common pass partition grooving
arrangements in respective tubesheets. The interchangeability shall be ensured in
shop by physical insertion of bundle in shell. For the items where tube bundles are
interchangeable, it is vendor’s responsibility to ensure all the materials, dimensions of
the tube bundle are same. In case of any discepancy, vendor shall bring the same to
EIL/JACOBS notice and EIL/JACOBS decision shall be final and binding on the
vendor.
17. During welding of nozzles in exchanger, if back gouging is required, gouging

electrodes should be used instead of grinding to avoid / minimize the reduction in the
thickness of nozzle pipe.
18. All the reinforcement pad tell-tale holes should be tapped properly and plugged with
hard grease. No grub screws to be provided.
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19. Vendor shall ensure that all data folder documents including the “AS BUILT
DRAWING” are updated & complete in all respect & incorporate all
suggestions/correction informed by EIL/JACOBS-Inspection while obtaining certificate
of completeness from Inspection.
20. Vendor shall furnish list of drawings/ documents with schedule of submission of
drawings for approval by EIL/JACOBS. The same shall be submitted to EIL/JACOBS
immediately after placement of order. Drawing index duly updated to be
submitted with each submission of documents.
21. Refer VDR document no A133-086-16-46-VDR-6142 for list and submission schedule
of drawing & document. Final documentation shall be submitted in soft copy in CD form
in 2 sets in addition to the specified requirements of documentation.
22. All mandatory spares shall be listed separately along with description, item no.,
detailed specifications, name of supplier etc.
23. All commissioning spares shall be listed separately along with description, item no.,
detailed specifications, name of supplier etc.
24. Vendor must ensure minimum thickness of undiluted finished weld overlay as per the
clause 4.3.9.1 of specification 44NC-4600-0000-V.02-0102-A4 and shall take special
precautions to ensure the same. Vendor to take suitable allowance on machining in
this regard so that minimum undiluted thickness is guaranteed after machining. Vendor
to qualify WPS/PQR and submit documents to the inspecting authority for approvals
before proceeding with the fabrication.
Also refer clause 4.3.9 of specification 44NC-4600-0000-V.02-0102-A4. The following

additional requirements shall also be complied. “All weld overlays shall be tested for
iron pick-up after each pass during welding in addition to other tests stipulated. In case
of weld overlay failure due to poor workmanship while in service during the warranty
period, the affected component shall be replaced by vendor without any cost and
delivery implication
25. Note-1 on exchanger setting plan drawing is not relevant to vendor.
26. The heat exchangers should have free movement at sliding end on the supports to
avoid any restriction during thermal expansion. The saddle of the exchanger
should be at centre of the foundation bolt slot during erection. Sliding end of
Exchangers shall be painted as “CAUTION-SLIDING END” in black on the primer
coating in the shop. Only SS shims shall be used for equipment alignment.
27. Wherever radiography is indicated as FULL or 100% all long and circ. Seams including
flange to neck, pipe to pipe and pipe to fitting shall be 100% radiographed.
28. Torque values required for tightening of bolts shall be specified in vendor documents.
29. Wherever stress relieving is mentioned in mechanical datasheet, same shall be
considered as PWHT.
30. Clause 1.5 of Specification 44NC-4600-0000-V.02-0102 stands deleted.
31. INSPECTION
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Inspection requirements are as mentioned here under:
Inspection of all imported raw materials by third party inspection agency.

Stage wise and final inspection by TPIA.
Inspection of all indigenous raw materials by TPIA.
All other inspection details shall be as per commercial documents
IBR items to be inspected by IBR or Agency approved by IBR. All cost towards
IBR inspection shall be borne by the vendor.
32 Wherever EIL is specified in the MR document, it shall be read as Jacobs/EIL.
33 Refer CL 1.1 of 44NC-4600-0000-V.02-0114-A4, Rev 0. This Clause is modified to

the extent as given below:
“Carbon content <=0.2%, Carbon equivalent (Ceq)<=0.43%”
34. TECHNICAL DOCUMENTATION REQUIRED WITH BID.
The technical part of the bid document shall contain the following:
o Duly filled-in, signed and stamped comment/query sheet.
Deviation Schedule Technical, duly filled-in, stamped and signed.

o Any other documents as required in the MR.
Completely filled-in Scope of work & supply Spec- A133-16-46-SS-6142 for the
items quoted
INDICATES APPLICABILITY.
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Page 1 of 9

CHENNAI, INDIA
PART : III
SECTION : B.5.1
TITLE: SCOPE OF WORK FOR FABRICATED EQUIPMENT – COKER

BLOCK
DOCUMENT NO : 44NC-4600-0000-V.02-0172-A4
Rev Issue Date Pages Rev Description Prepared By Checked Approved

No. By By
0 26.04.2010 9 Issued for FEED MS CR CR

1 19.07.2010 9 Revised as marked and issued for SNK MS HSC
FEED
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CPCL, Chennai SCOPE OF WORK FOR Part III Section B.5.1
44NC-4600 FABRICATED EQUIPMENT – COKER BLOCK Page 2 of 9
LSTK - 1 Doc. no. 44NC-4600-0000-V.02-0172-A4 Rev. 1
CONTENTS
1.0 GENERAL
2.0 ENGINEERING AND SUPPLY
3.0 EQUIPMENT INSTALLATION
44NC-4600-0000-V.02-0172-A4 Scope of work for Fab equipment - COKER BLOCK.doc
Page 332 of 441

MECHANICAL- FABRICATED EQUIPMENT: PRESSURE VESSELS, COLUMNS, HEAT

EXCHANGERS, AIR COOLERS, AND OTHER AUXILLARY UNITS
1.0 GENERAL
1.1 Contractor shall develop the Licensor’s Basic process package into AFC status, taking into
account the detailed requirements of the various requirements of Engineering Design basis,
Job specifications, Standard specifications, standards and other documents with respect to
all equipment.
1.2 The scope of work shall include but not be limited to process/thermal design, mechanical
design including stress analysis, detailed engineering, procurement, supply, material testing
and inspection, shop/site fabrication, assembly, stage inspection, shop testing, transportation
to site, storage, preservation, construction, erection, installation, field testing, pre-
commissioning, commissioning and Performance guarantee tests, and documentation
activities relating to:
- Fabricated Equipment
- Packaged items
- Site fabricated / Worksite built equipment
- All other equipment required for the facilities and further described / referred within this
overall scope of work.
- Mechanical Completion
- Obtaining approvals from Owner/PMC on QAP, Drawings and Documentation
- Supply ‘As built” documentation and QC dossiers.
- Obtaining statutory approvals from authorities for equipment falling under purview of
Indian Boiler Regulation and Static and Mobile Pressure Vessel Rules, 1981 viz; Chief
Inspectorate of Boilers and CCE (Chief Controller of Explosives), respectively.
1.3 The scope of work as defined herein, shall be read in conjunction with various Design Basis,
job specifications, standard specifications and process related issues
1.4 Detailed Engineering by Contractor
1.5 The section defines the requirements for the detailed engineering of equipment (including all
mountings and accessories) viz. Heat Exchangers, Air Coolers, Vessels, Reactors, Columns,
flare stacks, storage tanks, equipment packages, trays and tower internals, etc., by
Contractor. Contractor shall develop the Licensor’s Basic process package to Approved for
Construction (AFC) status for the equipment. Vendor shall provide the equipment list. The
Contractor shall, during Detailed Engineering, make any additions necessary to fully define all
equipment items required for the units subject to approval by Owner/PMC, without any
commercial or cost implication.
During detailed engineering stage, if any additional equipment are required as per Licensor /
Client / PMC requirements, same shall be provided without any cost implication
Page 333 of 441

2.0 ENGINEERING AND SUPPLY:
Contractor shall provide:
- Detailed design including Stress Analysis and specification for all equipment in
accordance with the applicable Design Basis, and international or national codes, job
specifications / standard specifications, standard drawings and data sheets.
- Detailed design for all equipment complying with design requirements specified in the
Engineering sheets as a minimum.
- A comprehensive equipment list produced on a Data Base showing all items by Process
unit. Equipment list shall also identify equipment requiring approval from statutory
authority e.g.C.I.B. (Chief Inspectorate of Boilers), C.C.E. (Chief Controller of
Explosives) and equipment requiring ASME Code Stamping and those requiring
compliance to Petroleum rules. Equipment list shall include against each item the
following: Equipment item number, description, drawing number, P&ID number, Vendor,
data sheet number, design pressure and temperature, special features (etc.).
- Equipment data sheets suitable for equipment purchases for all equipment of all units.
These data sheets shall be formatted in accordance with the latest edition API format
and other relevant code for tanks, RVs etc., where applicable
- All data sheets shall include vendor specific data, through the procurement cycle to an
às built’ status for inclusion in the mechanical catalogues.
- For Pressure Vessels, heat exchangers and air coolers approved mechanical
Engineering Data sheets of Contractor shall be the basis for generation of fabrication
drawing and after incorporation of all comments from Contractor / Owner/ Jacobs, these
drawings shall obtain the status of “AFC”. After equipment fabrication, these shall be
revised to “As Built” status. Native Soft copies of “AS BUILT” fabrication drawings of
all equipment shall be furnished along with “COMPLETION DOCUMENTS” in
CD 1
- Work out thermal design and sizing of equipment as per the requirements defined in
Design Basis, Job Specifications, Standard Specifications, applicable Codes, Standards
and other process related tender documents. Enquiry Requisitions and Purchase Order
document for all equipment and materials to be purchased including spare parts for
commissioning, Mandatory spare parts and operational spares for two years and
subsequent period of operation.
- Requisitioning activities shall include full Technical Bid Analyses (TBA’s) and
recommendations for each requisition. TBA for major and critical equipment shall be
reviewed by Owner /PMC.
- Preparation of Detailed Purchase Requisition for all equipment - the equipment shall be
ordered only after approval of Purchase Requisition by Owner / PMC.
- Analysis and compilation of generic equipment group standardisation lists for all
equipment.
To this end Contractor shall carry out a review of all equipment to maximise commonality
and inter-changeability. Equipment vendors shall be consulted on this exercise to help
define opportunities for maximising commonality and inter-changeability.
Page 334 of 441

- Typically this shall include a review of heat exchangers where the duties,
pressure/temperature ranges and metallurgy would allow exchange of items if they were
specified to be identical. The objective is to reduce the spares holding of items which
are similar, if not identical.
- The Contractor will develop a corrosion monitoring programme for each unit, which will
identify the following :
- Number, location, type and frequency of inspection of corrosion coupons
- Stage wise inspection programmes to ensure the integrity of all equipment and piping.
This programme should include inspection and testing as per process package, data
sheets, design basis, job specs, standard specifications/ standards and codes etc., but is
not limited to the following :
− Identification of Raw Material
− UT inspection / Extent / location / frequency
− RT inspection / Extent / location / frequency
− DP inspection / location / frequency
− MP / Eddy current inspection / location / frequency
− IR camera inspection / location / frequency
- Location, number, frequency of inspection of corrosion meters
- Location, number, type and frequency of inspection of instrumentation directly related to

corrosion monitoring of the units.
- Detailed review, checking and approval of equipment engineering and fabrication

drawing and technical data from vendors for equipment and materials, to ensure
adequacy and consistency with the design, safety and operability requirements
- Ensure all inspection and tests are conducted for all equipment at vendor’s shops / site
as specified in Bid Document, Job Specifications, Codes and Standards
- A co-ordination role in design, procurement, inspection, testing and commissioning of

packaged equipment
- Technical advisory control on all Mechanical matters, thorughout all phases of project
execution i.e. from design through procurement, construction and commissioning /
problem resolution
- Spare parts interchangeability records
- Preparation of mechanical handling studies, resulting data sheets and supply all
specialised installed mechanical handling equipment such as heat exchanger bundle
pulling and insertion facilities, runway beams or the like and provide procedures for
maintenance activities involving these items
- Specific maintenance instructions where relevant which will minimise the removal of
obstacle for routine maintenance
Page 335 of 441

- Contractor shall supply and install all maintenance facilities like EOT/HOT Cranes, Chain
Pulley Blocks and Monorails for assembly and maintenance for all static equipment
including Reactors, Columns, Vessels, exchangers, trays and tower internals as per
Engineering Design Basis.
2.1 For Pressure Vessels, Heat Exchangers, air coolers trays and tower internals: Contractor’s
scope shall include but not be limited to :
- Design for all equipment, detailed engineering, vibration free design of shell and tube
heat exchangers, air coolers, procurement of materials, fabrication, PWHT / Stress
relieving, inspection, testing, fitting of other attachments, insulation, refractory, fire
proofing, internal packings, chemical cleaning, calibration, surface preparation and
painting, any additional cleaning required by licensor, supply and erection of equipment
as per Design Basis. Equipment list, Process data sheets, engineering sheets, etc
- Procurement and supply of all materials (Metallic and non-metallic), consumables for all
process equipment and tanks required to complete the job as per bid document.
- Supply of mixers as per Mixer Process data sheet / Licensors/ PMC’s specification
- Supply of demisters, refractory, packings, ceramic / alumina balls etc
- Supply of insulating material, primer and paints, fire proofing materials wherever required
- Supply of materials / equipment required for blast cleaning / chemical cleaning
- Supply of all tools & tackles, equipment, consumable / non-consumable materials

required for inspection and testing (NDT, hydro-testing, performance testing, etc)
- All material required for completion of storage tanks including all accessories as
specified
- All approach ladders, platforms (independent and interconnecting) for different

accessories, instruments, operating valves, etc. shall be included and all layout and
design shall be as per requirements of Bid Document
- All material / equipment required for hydro-testing of field erected equipment
- Supply of slot dipping device for pressurised tanks where gauge hatch has been
specified, when the tank is gas blanketed
- Supply of all other materials whether specifically mentioned or not but required for
completion of the job in all respect as per bid package
2.2 Equipment noise limits and vendor equipment noise details shall be as per specified on the
relevant data sheets and/or Design Basis.
2.3 Contractor shall ensure that work area and plot fence line noise levels meet specification.
Where necessary Contractor shall provide acoustic attenuation measures (e.g.enclosures,
acoustic insulation) within Contractor’s scope of supply to comply with noise level
requirements
2.4 Contractor shall ensure that the following are provided:
Page 336 of 441

- Where necessary analyse any possible problems associated with surge pressures,
settle out pressures and blow down etc., and take the appropriate steps to ensure
protection of facilities and equipment.
- Where necessary to ensure protection of equipment during closed valve operation or

part load operation by suitable provision of spill back line, Auto Recirculaiton Valves,
etc.
- Equipment is supplied in accordance with pertinent regulations, codes, standards

required by the Indian authorities.
- For imported items- Certificate issued by an authority empowered by Central Boiler

Board (as per IBR) or under the law in force in a foreign country in respect of boilers
manufactured in that country may be accepted. In case of imported boiler IBR items,
prior advice of Director of Boiler, Maharashtra State shall be obtained.
- The materials of construction, corrosion allowances and corrosion protection are

provided as per Basic Engineering Design Package and engineering specifications.
- Adequate access for the safe construction, operation and maintenance of the
equipment
- Calculations for wind load, internal / external pressure, seismic loads, stress analysis
(for vertical equipment), local load analysis, transportation and erection loads shall be
carried out for PMC’s review as required.
- Loadings data for Technological structures foundations and buildings.
- Submission of all Engineering Drawings, fabrication drawings, vendor drawings, and

documents for review of Owner /PMC and for process licensor (as applicable) in
accordance with the list enclosed in the Bid Document
- Provide Process P&ID’s for all equipment including “As built” documents
- Specifications for equipment covering forming, welding, heat treatment, preservation

during storage period, together with any other specification relevant to optimisation of
equipment
- All packings, proprietary internals, chemicals, lubricants and desiccants and all
consumables required for equipment during erection, commissioning and performance
guarantee test runs and their correct filling into the equipment, including provision of all
necessary equipment and detailed procedures for filling (hoppers, sleeves, etc.)
erection, storage etc.
- Check lists for all types of equipment to ensure their correct installation, alignments,
assembly, levelling, grouting in and completion and specification and provision of any
specialist equipment to achieve same.
- Ensure presence of equipment manufacturer (vendor) at WORKSITE for supervision of

erection and during commissioning for all equipment.
- Ensure that commissioning spares for all equipment as recommended by the

Equipment manufacturers are procured in time and are available before commissioning
of the Plant / equipment.
Page 337 of 441

- Ensure that Mandatory Spares for all equipment as specified in the Bid document are
procured and handed over to the Owner together with the main equipment prior to
commissioning.
- Ensure that besides Mandatory Spares which are to be supplied by Contractor.

Commissioning spares which are required up to guarantee run are to be procured by
the contractor for all equipment.
- Ensure that special tools and tackles for all equipment as required for equipment
assembly / maintenance are handed over to the Owner with the main equipment.
- Ensure that Proprietary Equipment and proprietary internals of equipment shall be

procured strictly from the manufacturer / supplier mentioned in process data sheet /
process package and no equivalent alternate design from other manufacturers /
suppliers shall be considered.
- LLI items will be supplied to site by LLI vendors. For all LLI items, for balance work
required at site, please refer Doc No. 44NC-4600-00-V.02-0170-A4-Scope of work for
LLI.
- For LLI items, all platforms and ladders required shall be supplied and erected by
contractor. This includes engineering and preparation of required drawings.
- Installation, supply of instruments (those which are not included in LLI vendor’s scope),
civil, piping, Final painting, insulation, fir-proofing of LLI items are included in
contractor’s scope
- For Coke drums and other LLI items, contractor shall provide the anchor bolt length so
that LLI vendors will supply the anchors.
3.0 EQUIPMENT INSTALLATION BY CONTRACTOR
3.1 This section defines the requirements for the installation of equipment. Manufacturer’s
instruction shall be considered as pertinent to these requirements. It is the responsibility of
Contractor to carry out the work in a workmanlike manner consistent with the best practices
for process facilities installations and subject to approval of Jacobs. Installation shall
include preparation of foundation, installation of base plate, levelling, aligning, grouting, etc.
After installation of equipment internals, installation shall be reviewed with respect to

performance first by the Contractor / Vendor and then followed by PMC/Owner and Process
Licensor.
3.2 Contractor shall be responsible for personnel and facilities safety. Safe movement of
equipment/personnel shall be ensured at all stages of work.
3.3 Contractor shall assure all permits including Hot Work Permits where required are in place
to commencement of applicable work. This includes Contractor’s permits as applicable and
Owner permits.
3.4 Contractor shall be responsible for the transportation of all equipment to the erection
location. Equipment which are transported by sea shall have sea-worthy packing.
Recommended preservation procedures shall be strictly followed by the Contractor during
the period of storage for all equipment.
Page 338 of 441

3.5 Contractor shall be responsible throughout the duration of the Contract for any loss or
damage to equipment. Any such loss or damage shall be brought to the immediate
attention of PMC and arrangements made for repair or replacement of item.
3.6 Prior to the commencement of the installation work, Contractor shall provide current non-
destructive test certificates and carry out load test as per statutory requirements for all items
of rigging equipment.
3.7 Contractor shall at all times perform his work in a completely safe manner in strict
accordance with both industry and WORKSITE safety practices.
3.8 No nozzles or other vital attachments on the equipment being lifted shall be used as
supporting or lifting points other than those which have been specifically designed and
designated.
3.9 Contractor shall be responsible for surveying all bases and ensuring that such bases
comply with the appropriate drawings and specifications. Holding down bolts shall be
checked for condition, cleaned, lubricated and nuts checked for running down bolts.
3.10 Contractor shall be responsible for the maintenance and protection of all equipment for the
duration of the work, in accordance with manufacturer’s Preservation Check List.
3.11 Contractor is responsible for completing all work in accordance with the work time schedule.
3.12 Contractor shall provide specifications for the installation of all equipment which include
special requirements advised by Vendor’s and shall fully detail all the requirements for the
accurate, safe and technically correct installation of the equipment.
3.13 Contractor shall fill catalysts, and provide all packings, proprietary internals, chemicals,
lubricants, oils, greases, etc.
A consolidated list for all equipment shall be provided indicating type of lubricants, grease,
oil etc., giving the specification, quantities brand name and their equivalent Indian oil
specification wherever feasible.
3.14 On all stress relieved equipment, it shall be stencilled that “equipment is stress-relieved and
no welding shall be permitted after PWHT”.
3.15 Contractor shall comply with the requirements of Mechanical Completion as described in the
bid document.
Page 339 of 441

Page 340 of 441
Page 341 of 441
SPECIFICATION FOR STANDARD SPECIFICATION No.
01'4216a ENGINEERS DUPLEX STAINLESS STEEL AND 6-79-0015 Rev. 1
Sig2:11€01-du Ni101 INDIA LIMITED SUPER DUPLEX STAINLESS
eo,gezill,A1911 IA Gov't of India uneenatng)
STEEL Page 1 of 12
1 4 €€ 141 1 4 I I KOR
-1 -
TAM€ ch I 1 tzi 4(11d

Th g reibi m
SPECIFICATION
FOR
DUPLEX STAINLESS STEEL AND
SUPER DUPLEX STAINLESS STEEL
414 44 #6daAr_
07.10.11 REVISED & REISSUED AS STANDARD
1 SPECIFICATION SKM SG PPL DM
0 28.12.04 ISSUED AS STANDARD SPECIFICATION SG VRK KKM SKG
Standards Standards
Prepared Checked Committee Bureau
Rev. Date Purpose Convenor Chairman
No by by
Approved by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved

Page 342 of 441
ILi1Prire? ENGINEERS DUPLEX STAINLESS STEEL AND
5g-elkreg) IP Govt of India Underlakingi SUPER DUPLEX STAINLESS
Page 2 of 12
STEEL
Abbreviations:
ABS : American Bureau of Shipping

ASME : American Society of Mechanical Engineers
ASTM : American Society for Testing and Materials
BV : Bureau Veritas
CEIL : Certification Engineers International Limited
CPI : Chemical Process Industry
CSC : Chloride Stress Cracking
DNV : Det Norske Veritas
DSS : Duplex Stainless Steel
HAZ : Heat Affected Zone
ISO : International Organization for Standardization
MSS : Manufacturers Standardization Society
NACE : National Association of Corrosion Engineers
PREN : Pitting Resistance Equivalent Number
SDSS : Super Duplex Stainless Steel
SSC : Sulphide Stress Cracking
SMMS Standards Committee:
Convener: Mr. PP Lahiri
Members: Mr. A Amin

Mr. GS Hegde
Mr. R Chaudhury
Mr. S Ghosal
Mr. P Saha
Mr. R Nanda (Piping)
Mr. AK Gupta (HMTD)
Mr. S Mukherjee (Construction)
Mr. R Muthulingam (Inspection)
Mr. Raj Kishore (Pipeline)
Mr. AR Purushottam (POSD)
Mr. MP Jain (Projects)
Page 343 of 441

lalfaeldia ENGINEERS DUPLEX STAINLESS STEEL AND
bfba-fir OIRes NW INDIA LIMITED
Govl of India lffideftlion9) SUPER DUPLEX STAINLESS
6-79-0015 Rev. 1
STEEL Page 3 of 12
CONTENTS
1.0 SCOPE 4
2.0 CODES AND STANDARDS 4
3.0 STEEL MANUFACTURE 5
4.0 HEAT TREATMENT 5
5.0 APPLICABLE REQUIREMENTS FOR DSS AND SDSS 5
6.0 PRE-QUALIFICATION CRITERIA FOR MILL / MANUFACTURER 8
7.0 CORROSION TESTS FOR PRE-QUALIFICATION 9
8.0 REQUIREMENTS FOR PRODUCTION TESTING 11
9.0 QUALITY SURVEILLANCE AND INSPECTION 12
10.0 DOCUMENTS TO BE SUBMITTED 12
Page 344 of 441

ENGINEERS DUPLEX STAINLESS STEEL AND
s'g7galeg W INDIA UMITED 6-79-0015 Rev. 1
(A Gave DI i,tea UndellakON SUPER DUPLEX STAINLESS
STEEL Page 4 of 12
1.0 SCOPE
1.1 This specification covers the specific requirements for manufacture, inspection, testing and
supply of duplex stainless steels conforming to UNS No.(s) S 31803, S 32205 or equivalent
and super duplex stainless steel conforming to UNS No.(s) S 32760, S 32750, S 39274, S
32550, J 93380 or equivalent. DSS and SDSS material shall be considered acceptable when
they meet the pre-qualification criteria mentioned in this specification.
1.2 This specification shall be read together with the corresponding product specifications
mentioned in the relevant piping material specifications or the equipment data sheets/design
drawings intended to be used in sour and/or chloride containing environments, as applicable.
1.3 In case of conflict between this specification and the referred material codes/standard
specifications, the requirement of this specification shall govern.
2.0 CODES AND STANDARDS
The manufacture, inspection, testing, marking and supply of the item covered by this
specification shall follow the latest editions of the following codes and standard specifications:
ASTM A 182 Forged or rolled alloy steel pipe, flanges, forged fittings and valves and
parts for high temperature service
ASTM A 240 Heat resisting chromium and chromium - nickel stainless steel plate, sheet
and strip for pressure vessels
ASTM A 276 Stainless steel bars and shapes
ASTM A 351 Casting - austenitic, austenitic-ferritic (duplex) for pressure containing
parts
ASTM A 370 Standard methods and definitions for mechanical testing of steel
ASTM A 743 Castings - iron-chromium-nickel-base corrosion resistant, for general
application
ASTM A 744 Casting - iron-chromium-nickel-base corrosion resistant, for severe
application
ASTM A 789 Seamless and welded ferritic/austenitic stainless steel tubing for general
service
ASTM A 790 Seamless and welded ferritic- austenitic stainless steel pipe
ASTM A 799 Steel castings-stainless instrument calibration for estimating ferrite
content
ASTM A 815 Wrought ferritic, ferritic-austenitic and martensitic stainless steel pipe
fittings
ASTM A 923 Standard test methods for detecting detrimental intermetallic phase in
wrought duplex austenitic/ferritic stainless steels
ASTM A 928 Specification for ferritic/austenitic (duplex) stainless steel pipe electric
fusion welded with addition of filler metal
ASTM E 18 Rockwell hardness testing of metallic materials
ASTM E 562 Determining volume fraction by systematic manual point count
ASTM G 36 Performing stress corrosion cracking tests in a boiling magnesium
chloride
ASTM G 48 Standard test methods for pitting and crevice corrosion resistance of
stainless steels and related alloys by use of ferric chloride solution
ASME B 16.34 Valves- flanged, threaded, and welding end
ASME Sec.V Non-destructive examination
MSS-SP-55 Manufacturers Standardization Society of the Valve and Fitting Industry
Standard — Quality Standard for Steel Castings for valves, flanges, and
fittings and other components (visual method)
Page 345 of 441

51. Et2eGlit
1510 zi ah ENGINEERS DUPLEX STAINLESS STEEL AND
(A Govt ol moa unaeoakingi SUPER DUPLEX STAINLESS
STEEL Page 5 of 12
NACE MR0175/ Petroleum and natural gas industries-Materials for use in H2S-containing
ISO 15156 environments in oil and gas production:
Part 1: General principles for selection of cracking-resistant materials
Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other alloys
NACE MR0103 Material resistant to Sulfide Stress Cracking in corrosive petroleum
NACE TM0177 Laboratory testing of metals for resistance to sulfide stress cracking and
stress corrosion cracking in H2 S environments
SNT-TC-1A Personnel qualification and certification of nondestructive testing
personnel, American Society for Nondestructive Testing (ASNT)
3.0 STEEL MANUFACTURE
3.1 The steel shall be manufactured / produced by the following or as specified in the applicable
material specification:
3.1.1 The steel shall be made by one of the following primary steel making processes:
- electric arc furnace,

- electric induction furnace.
3.1.2 The steel shall be subjected to tertiary steel refining treatments such as vacuum oxygen
decarburization (VOD)/ argon oxygen decarburization (ACID), and vacuum arc degassing
(VAD) to minimize dissolved gas contents, inclusions content and to meet the chemical
composition with close tolerances.
4.0 HEAT TREATMENT
4.1 Duplex Stainless Steel (DSS)
All the finished product forms shall be solution annealed by holding it at 1020-1100°C
followed by a fast cooling procedure. The duration of homogenizing treatment is dependent on
the product forms and thickness, but shall be not less than 20 minutes per 25 mm of thickness.
For product thickness is less than or equal to 10 mm, forced air cooling shall be carried out
while for thickness greater than 10 mm, water quenching shall be carried out. All hot
working/forging operations shall be carried out within a temperature range of 1020-1100°C.
No hot working/forging operations shall take place at temperature less than 1020°C.
4.2 Super Duplex Stainless Steel (SDSS)
All the finished product forms shall be supplied in solution annealed condition. The product
shall be homogenized at 1050-1120°C followed by a fast cooling procedure. The duration of
homogenizing treatment is dependent on the product forms and thickness, but shall be not less
than 20 minutes per 25 mm of thickness. For product thickness is less than or equal to 10 mm,
forced air cooling shall be carried out while for thickness greater than 10 mm, water
quenching shall be carried out. All hot working/forging operations shall be carried out within
a temperature range of 1050-1120°C. No hot working/forging operations shall take place at
temperature less than 1050°C.
5.0 APPLICABLE REQUIREMENTS FOR DSS AND SDSS
5.1 Chemical Composition
Chemical composition of DSS and SDSS shall be as per Clause Nos. 5.1.1 and 5.1.2
respectively.
Page 346 of 441

ENGINEERS DUPLEX STAINLESS STEEL AND
5g:zrr W.aG
, IA Govt of India Undettaongl SUPER DUPLEX STAINLESS
STEEL Page 6 of 12
5.1.1 DSS
Element Wt%
Carbon (C) 0.03 (max.)

Manganese (Mn) 2.0 (max.)
Silicon (Si) 1.0 (max.)
Sulphur (S) 0.02 (max.)
Phosphorus (P) 0.03 (max.)
Chromium (Cr) 21.00 - 23.00
Nickel (Ni) 4.50 - 6.50
Molybdenum (Mo) 2.5 - 3.50
Nitrogen (N) 0.15 - 0.20
Copper (Cu) 0.50 (max.)
Tungsten (W) 0.50 (max.)
5.1.2 SDSS
Element Wt%
Carbon (C) 0.03 (max.)

Manganese (Mn) 1.0 (max.)
Silicon (Si) 1.0 (max.)
Sulphur (S) 0.2 (max.)
Phosphorus (P) 0.3 (max.)
Chromium (Cr) 24.0 - 27.0
Nickel (Ni) 6.0 - 8.0
Molybdenum (Mo) 3.5 - 4.5
Nitrogen (N) 0.20 - 0.35
Copper (Cu) 0.75 (max.)
Tungsten (W) 1.00 (max.)
5.1.3 If any other elements are proposed to be added, such proposals shall be submitted to Company
for specific written approval. Copper (Cu) and Tungsten (W) additions exceeding the limits as
specified above shall be acceptable, provided the weldability and freedom from undesirable
metallurgical constituents are ensured.
5.2 Pitting Resistance Equivalent Number (PREN)
5.2.1 PREN shall be calculated by the following formula:
PREN = % Cr + 3.3 x (%Mo) + 16x (% N)
5.2.2 PREN for DSS
The pitting resistance equivalent number of the duplex stainless steel materials shall be greater
than 35, when calculated as mentioned in Clause No.5.2.1.
5.2.3 PREN for SDSS
The pitting resistance equivalent number of the super duplex stainless steel materials shall be
greater than 40, when calculated as mentioned in Clause No. 5.2.1.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL -All rights reserved
Page 347 of 441

15irdzIellft ENGINEERS DUPLEX STAINLESS STEEL AND
Sg-Lit la2egiiiVINDIA LIMITED 6-79-0015 Rev. 1
EA Got of India Undertaking) SUPER DUPLEX STAINLESS
STEEL Page 7 of 12
5.3 Microstructure
5.3.1 DSS
The duplex stainless steel shall have approximately equal proportions of austenite and ferrite
phases and the ferrite content shall be in the range of 40-55% in the austenite-ferrite matrix.
5.3.2 SDSS
For super duplex stainless steel, the ferrite content shall be in the range of 35-55% in the
austenite-ferrite matrix.
5.3.3 Ferrite content measurement for DSS and SDSS material shall be carried out for each heat by
metallography method in accordance with ASTM E 562.
In case ferrite-scope is expected to be used during fabrication/erection for the ferrite

measurement, then the testing at shop shall be carried out by the ferrite-scope also, and the
correlation between the results from the two methods shall be established for future use.
5.3.4 For DSS and SDSS products, either in the as-supplied condition, solution annealed condition,
or in the as welded condition, the microstructure shall not reveal the presence of any carbide
or any intermetallic phases to the extent that are detrimental to the toughness and corrosion
resistance of the material. The detection of the detrimental intermetallic phases in the wrought
products shall be carried out in accordance with ASTM A 923. The intermetallic phases shall
not be more than 1%.
S4 Mechanical Properties
5.4.1 DSS and SDSS
The material in the solution-annealed condition shall conform to the mechanical properties
such as ultimate tensile strength, 0.2% & 1% offset yield strength, % elongation, hardness
applicable for the respective UNS No. of the material. The tensile test shall be carried out as
per ASTM A 370.
The hardness test method shall be in accordance with ASTM E 18. If any other methods
including portable hardness tester are to be deployed for checking production welds, then the
correlation between the qualification method and the production method shall be established
and the calibration graph shall be generated for use at the field/shop.
5.4.2 Impact energy (Charpy V-notch) for DSS and SDSS
The impact test shall be carried out as per ASTM A 370.
Wrought materials
at 20°C 120 J (Average)/ 90 J (Minimum)
at -30°C 100 J (Average)/ 75 J (Minimum)
Cast materials
at 20°C 75 J (Average)/ 55 J (Minimum)
at -30°C 60 J (Average)/ 40 J (Minimum)
Page 348 of 441

ti at ENGINEERS SPECIFICATION FOR
DUPLEX STAINLESS STEEL AND
STANDARD SPECIFICATION No.
azzlErAeglIVINDIA UMFIED 6-79-0015 Rev. 1

SUPER DUPLEX STAINLESS
STEEL Page 8 of 12
6.0 PRE-QUALIFICATION CRITERIA FOR MILL / MANUFACTURER
6.1 The DSS and SDSS material components shall be procured from a pre-qualified supplier. The
supplier shall be qualified for specific TINS No. for which the mill was pre-qualified. Any
change in UNS No. shall require a fresh pre-qualification.
6.1.1 Pre-Qualification Criteria for Vendors with Prior Experience Track Record
Vendors/manufacturers who have proven track record of supplying DSS and SDSS materials
for sour service and chloride containing environments in chemical process industries (CPI) to
any of the reputed operating companies/Engineering Consultants or Process Licensors such as
UOP, IFP, EXXON, BP, CHEVRON, IOCL, HPCL, BPCL, and EIL shall be considered as
`pre-qualified vendors/manufacturers', on production of the relevant Purchase Orders and test
certificates, certified by a witnessing third party inspection agency such as DNV, Lloyds, BV,
ABS, TUV, SGS, CEIL, and EIL for the conformance of the materials to the respective
materials specification of the mentioned operators / engineering consultants. For pre-qualified
vendors, Clause No.6.1.2 is not applicable.
6.1.2 Pre-Qualification Criteria for New Vendors without Track Record
A vendor who has no track record of supplying DSS and SDSS materials for sour service and
chloride containing environments in chemical process industries (CPI) to any of the reputed
engineering consultants/operators, as mentioned above in Clause No.6.1.1, shall be considered
as a new vendor. The chemical, the mechanical and all the corrosion tests shall be carried out
as mentioned in Clause Nos. 5.0, 7.0 for pre-qualification by any one of the reputed third party
inspection agencies like Lloyds, BV, CEIL, DNV, TUV, and EIL.
6.2 The corrosion tests for DSS and SDSS in accordance with the Clause No. 7.0 shall be
conducted for the pre-qualification of the manufacturers/mills.
6.3 All the tests reports including the corrosion tests shall be based upon the tests conducted on
the product specimen drawn from a single heat, and shall bear the same heat number.
6.4 In case the manufacture(s) had already conducted all the corrosion above tests on a product of
the same material in the past, and has an approved quality assurance system in place, and the
test results are certified by a witnessing a third party inspection agency approved by the
Company, the test results shall be furnished by the bidder, along with his bid, for Company's
review.
The manufacturer(s) shall be qualified based on the satisfactory review of the submitted test
results. The Company's decision in this regard shall be final and binding on the bidder.
While selecting and procuring the duplex stainless steel and super duplex stainless steel
materials for a specific project, care shall be taken to use the same UNS No. for the entire
system. Bidder shall note that, subsequent to qualification, a change in combination of
mill/manufacturer and UNS No. shall call for a fresh qualification exercise to be conducted.
6.5 Examination for DSS and SDSS Castings
6.5.1 Visual
All castings for valves, flanges, fittings and other components of DSS and SDSS shall be
visually examined in accordance with the quality levels mentioned in MSS-SP-55. The
procedure for visual examination and the acceptance criteria shall be as per MSS-SP-55.
Format No. 8-00-0001-Fl Rev. 0 Copyright EIL — All rights reserved
Page 349 of 441

151fraegifa ENGINEERS DUPLEX STAINLESS STEEL AND
@.ti Ciir INDIA LIMITED 6-79-0015 Rev. 1
IA Gov't of India uneenatmg) SUPER DUPLEX STAINLESS
STEEL Page 9 of 12
6.5.2 Radiography
Radiography examination shall be performed on all DSS and SDSS valve castings (in
accordance with ASME B16.34 with the acceptance criteria mentioned therein) and flanges,
fittings and other components of DSS and SDSS in accordance with Article 2 of ASME
Section V. The operator's certification to SNT-TC-1A or equivalent is required.
6.5.3 Penetrant Test
Wet fluorescent penetrant examination shall be performed on the exterior and accessible
interior surfaces of all DSS and SDSS valve castings (in accordance with ASME B16.34 with
the acceptance criteria mentioned therein) and flanges, fittings and other components of DSS
and SDSS in accordance with Article 6 of ASME Section V. The operator's certification to
SNT-TC-1A or equivalent is required.
7.0 CORROSION TESTS FOR PRE-QUALIFICATION
7.1 Sulphide Stress Cracking (SSC) test as per Clause No. 7.2, Chloride Stress Cracking (CSC)
test as per Clause No. 7.3, Pitting Corrosion test as per Clause No. 7.4, Crevice Corrosion test
as per Clause No.7.5, are mandatory when DSS and SDSS steel materials are intended to be
used for sour service and chloride containing environments.
If DSS and SDSS materials are intended to be used for chloride containing environments only,
the SSC test as per Clause No.7.2 shall be waived off. The remaining corrosion tests specified
in this section shall be carried out for DSS and SDSS materials meant for use in the chloride
containing environments.
The corrosion tests applicable for DSS and SDSS materials shall be as furnished in the
following paragraphs:
7.2 Sulphide Stress Cracking (SSC) Test

7.2.1 DSS
SSC test on duplex stainless steel shall be carried out by using the following test solutions and
test conditions:
i) a) Test solution NACE TM0177

Test temperature 24° C
Stress value 350 N/mm 2
d) Acceptance criteria test sample failure at or after 720 hours.
ii) a) Test solution NACE TM0177

Test temperature 90° C
Stress value 325 N/mm2
Partial pressure of H2S 16 bars
Acceptance criteria test sample failure at or after 720 hours.
7.2.2 SDSS
The Sulphide Stress Corrosion Cracking tests on super duplex stainless steel shall be carried
out by using the following solutions and test conditions:

Page 350 of 441

el ENGINEERS DUPLEX STAINLESS STEEL AND
S INDIA LIMITED
s'Ig7 Wes We' 6-79-0015 Rev. 1
(A Gait of India Untie/10mM SUPER DUPLEX STAINLESS
STEEL Page 10 of 12
Test solution : NACE TM0177

Partial pressure of II2S : 16 bars
e) Acceptance criteria : test sample failure at or after 720 hours.
7.3 Chloride Stress Cracking (CSC) Test
7.3.1 DSS and SDSS
The CSC tests shall be conducted on representative specimens of DSS and SDSS, in
accordance with the testing procedure mentioned in ASTM G-36, in aerated, boiling
40% calcium chloride (CaCl 2) solution at 100°C with the pH of the solution
maintained around 6.5.
Acceptance criteria: stress to cause rupture in 500 hours shall exceed 0.85 times the
actual ultimate tensile strength values of duplex stainless steel and super duplex
stainless steel material individually.
7.4 Pitting Corrosion Test
7.4.1 DSS
The pitting corrosion test shall be conducted on the representative DSS specimen, in
accordance with ASTM G-48 method A, using 6% ferric chloride (FeCI 3 .6 H 2 0) solution
Acceptance criteria: no pitting shall occur on the surface of the test sample at 30°C. For
7.4.2 SDSS
The pitting corrosion test shall be conducted on the representative SDSS specimen, in
accordance with ASTM G-48 method A, using 6% ferric chloride (FeCI 3 .6 1420) solution
Acceptance criteria: no pitting shall occur on the surface of the test sample at 40°C. For
7.5 Crevice Corrosion Test
7.5.1 DSS
The crevice corrosion test shall be performed on the representative DSS specimen, in
accordance with ASTM G-48 method B, using 6% ferric chloride (FeCI3 .6 H 2 0) solution
Acceptance criteria: no crevice shall form on the surface of the test sample at 25°C.
7.5.2 SDSS
a) The crevice corrosion test shall be performed on the representative SDSS specimen, in
accordance with ASTM G-48 method B, using 6% ferric chloride (FeCI3.6 F120) solution
Page 351 of 441

0223E4a ENGINEERS DUPLEX STAINLESS STEEL AND
a-9( laras W INDIA LIMITED 6-79-0015 Rev. 1
(A Govt of India Undetlaxingl SUPER DUPLEX STAINLESS
STEEL Page 11 of 12
b) Acceptance criteria: no crevice shall form on the surface of the test sample at 30°C.
8.0 REQUIREMENTS FOR PRODUCTION TESTING
8.1 Test Samples
Separate test blanks shall be required for each process of manufacture of the finished products.
Each test sample shall receive the same working / heat treatment as the finished products it
represents.
If the test specimen cannot be taken from a finished product, then a representative test
specimen shall be taken from the same heat, heat treated in the same batch, and be subjected to
the same extent of working as the most worked section of the finished product. In case the
finished product is of welded type, then the test piece shall be so chosen as to include the
parent metal, the weld metal and the heat affected zone.
8.2 Testing Frequency
The product analysis and the mechanical properties evaluation shall be conducted strictly as
per requirements of the relevant material product specifications. Micro-structural examination,
ferrite measurement and hardness testing on the finished product, shall be carried out for one
sample per heat per method of manufacturer.
The test results shall be submitted to the Company as a part of the product documentation.
8.3 Mandatory Production Tests (First Heat)
On placement of order, a vendor who has met the pre-qualification criteria, shall carry out the
following production tests, to meet the acceptance criteria mentioned in the respective clauses.
All the following tests shall be witnessed and certified by a reputed the third party Inspection
Agency duly approved by the Company, on the first heat:
Chemical composition analysis as per Clause No.5.1

Pitting Resistance Equivalent Number as per Clause No.5.2
Microstructure examination and ferrite measurement as per Clause No.5.3
Mechanical properties evaluation as per Clause No.5.4
Visual examination on casting as per Clause No. 6.5.1
Radiography examination for casting as per Clause No.6.5.2
Wet fluorescent penetrant examination for casting as per Clause No.6.5.3.
8.4 Routine Tests
The routine testing of product of each heat shall be carried out on a regular basis, in house.
The chemical composition, the pitting resistance equivalent number, the mechanical
properties, the micro-structural examination and for casting, the visual examination, the
radiography and the wet fluorescent penetrant examinations shall conform to the requirements
specified in the respective Clauses of this specification.
Page 352 of 441

StilizaZleTa ENGINEERS DUPLEX STAINLESS STEEL AND
strantEgItaiev INDIA LIMITED 6-79-0015 Rev. 1
A GA1 of incha Aviel410.01 SUPER DUPLEX STAINLESS
STEEL Page 12 of 12
9.0 QUALITY SURVEILLANCE AND INSPECTION
The supplier shall perform all the tests and inspection procedures mentioned above to ensure
that the materials conform to the requirements of this specification. Company, or the
representative duly approved by the Company, shall have unhindered access to the material
being manufactured for inspection and/or witnessing the selection of test samples, the
preparation of test specimens, and the performance of tests. The company or its representative
shall have the right to indicate the pieces from which the specimens are to be drawn for
various tests. In case of any reasonable doubts regarding the quality of the product, Company
shall have the option to ask for the re-qualification of the mill at the vendor's/contractor's cost.
Inspection by the Company or its authorized representative shall not relieve the supplier of his
responsibility for ensuring the compliance of the materials supplied to this specification.
10.0 DOCUMENTS TO BE SUBMITTED
The vendors/suppliers shall submit the following records of the tests and inspection conducted
on the materials, as per the applicable Clauses mentioned in this specification, to the company
in quadruplicate:
Chemical composition analysis report

Heat treatment records and charts
Micro-structure examination and ferrite measurement reports
Mechanical properties evaluation reports
Corrosion testing results (Pre-qualification records)
Visual examination report for castings
Radiography examination report for castings
Penetrant test report for castings.
Page 353 of 441

Page 354 of 441
Page 355 of 441
Page 356 of 441
Page 357 of 441
Page 358 of 441
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
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.
DCU
CPCL
NEW DELHI
0
REV.

DATE
18.11.2013
FOR
REVISION
TUBE LAYOUT
ITEM NO: 86-E-26

ISSUED FOR ENGINEERING
BY
KMB
JSK
CHECKED
DRAWING NO.
SS
APPD.
A133-86-05-45-4026
0
APPD.
REV.
1-1641-0504 REV.0 A4-210x297
Page 359 of 441

Page 360 of 441
DOCUMENT No.
GUIDE LINE TO VENDOR REGARDING
TUBE LAYOUT PREPARATION
A133-16-46-TL-6142
DCU, CPCL Rev. A
Page 1 of 3
GUIDELINE TO VENDOR
REGARDING

JOB NO. : A133
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved
Page 361 of 441

DOCUMENT No.
A133-16-46-TL-6142
DCU, CPCL Rev. A
Page 2 of 3
SCOPE
Vendor shall develop detailed tube layout drawings based on the guidelines given below and other
attachments of the specification. Contractor can proceed with drilling of tubesheets, baffles, support plates
only after the detailed tube layout drawings have been reviewed by EIL in writing. Any conflict between the
guidelines/other requirements of the requisition shall be brought to EIL's notice and EIL's decision on the
same shall be final and binding on the vendor without any cost/time implication after the order.
GUIDELINES
1. Sealing strips shall be as indicated on the drawings. Sealing strips minimum width to be 25mm,
however minimum clearance between tube OD to sealing/sliding strip to be 5 mm. The actual width
of the sealing strips to be calculated based on a minimum clearance of 5mm between tube OD and
the baffle OD. The sealing strips shall extend from first to last baffle unless when they are required to
hold the bundle (i.e. there is no tie rod placed within 50 mm distance of the sealing strip), in which
case they shall extend from stationary tubesheet to last support plate. Ensure that sealing strips/tie
rods do not obstruct nozzle opening. Sealing strip thickness shall be 8 mm (min). However the
sealing strip thickness shall not be less than twice corrosion allowance. Sealing strips shall extend
up to baffle OD and shall not be extended up to shell ID.
2. Impingement plate shall be held by tie rods/sealing strips/sliding strips. Extra tie rods shall be
provided if necessary to hold the impingement plate. Impingement plate may be welded to shell in
fixed tubesheet exchangers only. In such case impingement plate in material shall be same as that
of shell. Width of impingement plate shall be as indicated in the tube layout. Length of impingement
plate along the shell, if not specified in the Setting Plan drawing shall be taken as nozzle ID + 50mm.
o o
3. In case of 45 & 90 tube patterns, through clear lanes shall be provided for cleaning outside of tubes
and no tie rod, seal strip/seal rod/sliding strip shall interface with these lanes.
4. The notches in baffle for sealing strips/sliding strips shall be the strip thickness + 0.5mm.
5. Width of sliding strips to be maximum keeping a gap of 5 mm between the tube and sliding strip.
However, minimum thickness & width of sliding strip shall be as given in Table-1. Any change in
minimum width and thickness shall be brought to EIL's notice and EIL's decision shall be final. The
sliding strip shall extend from last support plate to stationary tubesheet. To facilitate bundle
insertion/withdrawal a maximum of 0.8mm clearance between the shell ID and sliding strip to be
provided.
6. For removable bundles, eye bolts shall be provided on the channel side face of stationary tubesheet
and located approximately diametrically opposite. In case of four eye bolts, these shall be spaced
along the circumference of tubesheet at approximately diametrically opposite ends. For cladded
tubesheets on channel side, alloy base plugs as per standard drawings shall be used. Eye bolt size
shall be selected based on a bundle pulling force of 1.5 times bundle weight. Eye bolt holes shall not
be drilled through the tubesheet thickness. Location to be such as to distribute loads on tube sheet
evenly.
7. The ligament between eye bolt hole edge and tubesheet edge/tube hole shall be minimum 6 mm.
8. For Ù' tube exchangers, the support plate, if required near Ù' bend, shall be located on the straight
length portion, 50 mm from tangent line of Ù' tubes.
9. Pass lane width given in the tube layout are from tube centre to tube centre across the pass partition
lane.
10. The dome height specified in the tube layouts is the minimum distance to be maintained from shell
ID to the top of impingement plate (or top of tube if there is no impingement plate).
0
11. Baffles/support plates shall be provided with 90 top and bottom notches with width given below:
Shell ID (mm) Notch width (mm)
Less than 300 : 6
300 to 600 : 10
Greater than 600 : 12
Page 362 of 441

DOCUMENT No.
A133-16-46-TL-6142
DCU, CPCL Rev. A
Page 3 of 3
12. Where tie-rods have been considered without spacers, then tie-rods shall be welded to
baffles/support plate.
13. For LAS tubesheets, do not weld any attachment like sealing strips, dowel lugs/jack screw lugs to
tube sheet. These shall be attached by screw connections.
TABLE - 1
MINIMUM SIZE OF SLIDING STRIPS
Shell ID (mm) Width (mm) Thickness (mm)

Less than 432 -- --
433 to 812 50 16
813 to 1092 60 18
1093 to 1524 70 20
1525 & above 100 25
Page 363 of 441

Page 364 of 441
Page 1 of 17

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: GENERAL SPECIFICATION – MATERIAL SPECIFICATIONS

(Vessels, Heat exchangers, Tanks, Air Cooled Exchangers, Reactors, Columns)
DOCUMENT NO. 44NC-4600-0000-V.02-0114-A4
Rev Issue Pages Rev Description Prepared Checked Approved

No. Date By By By
Page 365 of 441

Jacobs
CPCL, Chennai Job specification Part V Section 3.4
44NC-4600 Material specifications Page 2 of 17
LSTK Doc. no.: 44NC-4600-0000-V.02-0114-A4 Rev. 0
TABLE OF CONTENTS
1.0 MATERIAL REQUIREMENTS FOR SOUR SERVICE
2.0 MATERIAL SPECIFICATION FOR PARTS OF C.S. EQUIPMENT
3.0 MATERIAL SPECIFICATION FOR PARTS OF C.S.(NACE/HIC) EQUIPMENT
4.0 MATERIAL SPECIFICATION FOR PARTS OF SS316L CLAD EQUIPMENT
5.0 MATERIAL SPECIFICATION FOR PARTS OF S.S. EQUIPMENT
6.0 MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (1¼Cr-1/2Mo) EQUIPMENT
7.0 MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (2 ¼ Cr-1 Mo) EQUIPMENT
8.0 MATERIAL SPECIFICATION FOR PARTS OF TANKAGES
9.0 MATERIAL SPECIFICATION FOR PARTS OF MONEL 400 CLAD EQUIPMENT
10.0 PICKLING & PASSIVATION PROCEDURE FOR SURFACE CLEANING ON MONELCLAD

SURFACE
11.0 MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL ( 1 ¼ Cr-1/2 Mo)
EQUIPMENT WITH SS 347 CLAD
12.0 MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL ( 2 ¼ Cr-1 Mo) EQUIPMENT
WITH SS 347 CLAD
13.0 MATERIAL SPECIFICATION FOR PARTS OF HIGH THICK (>50 MM) C.S. EQUIPMENT
44NC-4600-0000-V.02-0114-A4 General Spec for Materials.doc
Page 366 of 441

1. Introduction
Intention of this specification is to state minimum requirements for various materials to be used
for plant equipment.
In case of conflict with any of Licensor documents, requirements specified in Licensor documents
will govern.
In case of conflict with any of code requirements, stringent of the requirements specified herein
and code will govern.
1.1 SOUR SERVICE REQUIREMENTS (NACE MR 0103)
PLATES
− Carbon steel plates conforming to SA-516 Gr. 60 shall be supplied in normalised condition
− Carbon content ≤ 0.18%, Carbon equivalent (Ceq) ≤ 0.43%
− Hardness of plates shall be less than 200 BHN
− Cold deformation during forming / rolling shall be less than 5%
FORGINGS
− Carbon steel forging shall conform to SA-105 or equivalent
− Hardness of forging shall be less than 187 BHN
PIPES
− Seamless carbon steel pipes shall conform to SA-106 Gr. B and hardness shall not exceed
190 BHN.
− Cold deformation during forming / rolling shall be less than 5%
BOLTINGS
− Internal bolting and bolting exposed to H2S environment shall conform to SA 193 B7M/SA-
194 Gr. 2HM
1.2 SOUR SERVICE + HIC RESISTANT REQUIREMENTS
PLATES
− Carbon steel plates conforming to SA-516 Gr. 60 shall be supplied in normalised condition.
The steel shall be killed and shall conform to fine austenitic grain size as per SA-20.
− Carbon content ≤ 0.2%. Carbon equivalent (Ceq) ≤ 0.42% for t < 2” and 0.45% for t ≥ 2”
− Manganese content shall be less than 1.2%

Page 367 of 441

− Nickel content shall be less than or equal to 0.5 %
− Sulphur content shall be less than or equal to 0.002%
− Phosphorus content shall be less than or equal to 0.01%
Materials shall pass the NACE standard TM 0284 but using the acidified test solution specified
in NACE TM 0177 with:
Crack Length Ratio (CLR) ≤ 10%
− Hardness of plates shall be less than 200 BHN (22HRC)
− Through thickness tension testing of plates 25mm thick and above shall be carried out as per
SA-770, S-3 and minimum reduction area shall be 35%.
− Ultrasonic inspection of plates shall be carried out as follows :
a. Plates having thickness 16mm to 50mm (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 – 1
c. For quenched and tempered steel plates, ultrasonic examination shall be done after the
heat treatment of plates
− Cold deformation during forming/rolling shall be less than 5%
The steel shall be specially produced as HIC resistant steel at the specified HIC resistant
level, tested originally by the Steel Producer.
PIPES
− Seamless carbon steel pipes conforming to SA-106 Gr. B shall have following chemistry
requirement on product
− Hardness of pipes shall be limited to 190 BHN. Cold deformation < 5%
FORGINGS
− Carbon steel forging shall conform to SA-105 or equivalent
− Hardness of forging shall be limited to less than 187 BHN
WELD METAL : Welding consumables shall conform to ASME Section II Part C
BOLTINGS
Internal bolting and bolting exposed to H2S environment shall conform to SA 193 B7M/SA-194
Gr. 2HM

Page 368 of 441
1.3 HIC RESISTANT HIGH THICK FORGED CARBON STEEL
Carbon steel forging shall conform to SA-266 Gr.2 with the following requirements:
− Nickel content shall be less than or equal to 0.5 %
− Sulphur content shall be less than or equal to 0.01%
− Hardness of forging shall be limited to less than 187 BHN
The HIC resistance of these forgings shall be verified in the HIC test in accordance with NACE
TM-0284 but using the acidified test solution specified in NACE TM 0177. The acceptance
criteria of the material shall be as follows:
Crack Length Ratio (CLR) ≤ 10%
All licensor requirements shall be complied with. However in case of any contradiction
same to be resolved in consultation with the Owner/Jacobs/Licensor

Page 369 of 441
2. MATERIAL SPECIFICATION FOR PARTS OF CS EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 516 GR. 60/70
Reinforcement Pad/Pad for external Same as shell material
attachment
Nozzles & Pipes SA 106 Gr. B (Seamless) < 12” NB
“Same as shell material” for 12” NB and above

(with full radiography of weld joints)
Flanges SA 105
Fittings SA 234 WPB
Couplings SA 105
Gaskets As per Piping Material Specification

0
External Bolts & Nuts SA 193 Gr. B7/SA 194 Gr. 2H upto 343 C
0
*SA 193 Gr. B16/SA 194 Gr. 4 for temp. > 343 C
Internal Bolts & Nuts SS 304 / as specified in Process Data Sheet
Wrapper Plate Same as shell material
Skirt support for min. top 1m (Top 2m in case Same as shell material
0
of design temp. ≥ 400 C)
Skirt / Base Plate SA 283 Gr. C

0
Angle leg support / Pipe leg support / Bracket SA 283 Gr. C / SA 53 upto 343 C
0
Support / Saddle support Same as shell material for temp > 343 C
Welded internal parts Same as shell material
Removable Internal parts As specified in Process Data Sheet
External cleats (Directly welded to vessel) Same as shell material

0
External cleats with pad (same as shell/head SA 283 Gr. C upto 343 C
0
Material) Same as shell material for temp > 343 C
Internal Gaskets Non-asbestos
Tray support ring Same as shell material
Demister support Same as shell material
* MDS shall be referred for material of external bolts / nuts and in case of discrepancy between this
material specification and PMS, the same shall be referred to OWNER/Jacobs for clarification.
Page 370 of 441

3. MATERIAL SPECIFICATION FOR PARTS OF CS (NACE/HIC) EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 516 GR. 60 WITH
NACE/HIC REQUIREMENTS (See Note 1)
Reinforcement Pad / Pad for external Same as shell material / use self reinforced nozzles if
attachment required as per design
Nozzles & Pipes SA 106 Gr. B (Seamless) < 12” NB

“Same as shell material” for 12” NB and above (with full
radiography of weld joints)
Flanges SA 105
Fittings SA 234 WPB
Couplings SA 105

0
External Bolts & Nuts SA 193 Gr. B7M/SA 194 Gr. 2HM upto 343 C
0
Wrapper Plate SA 516 Gr. 60
Skirt support for min. top 1m (top 2m in case Same as shell material
0

0
Angle leg support / Pipe leg support / SA 283 Gr. C / SA 53 upto 343 C
0
Bracket Support / Saddle support Same as shell material for temp > 343 C

0
External cleats with pad (same as shell/head SA 283 Gr. C upto 343 C
0
Material) Same as shell material for temp > 343 C
material specification and PMS, the same shall be referred to OWNER/Jacobs for clarification
Note 1 : All materials shall comply with the requirement of Clause 1
Page 371 of 441

4. MATERIAL SPECIFICATION FOR PARTS OF SS316L CLAD EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 516 GR. 70 + SA 240 Gr.
316L CLAD (In case of a different SS cladding, the same shall be applicable )
Reinforcement Pad/Pad for external SA 516 Gr. 70
attachment
Nozzles & Pipes ** SA 106 Gr. B (Seamless) + SS 316L Weld overlay <
8” NB

Flanges SA 105 + SS 316L Weld overlay
Fittings SA 234 WPB + SS 316L Weld overlay
Couplings SA 105 + SS 316L Weld overlay

0
0
*SA 193 GR. B16/SA 194 Gr. 4 for temp. > 343 C
Skirt support for min. top 1m (top 2m in case SA 516 Gr. 70

0
design temp. ≥ 400 C)

0
0
support / Saddle support Same as shell material for temp > 343 C
Internal parts (Removable & welded both) Same as cladding alloy
External cleats (Directly welded to vessel) SA 516 Gr. 70
Tray support ring Same as cladding alloy material
Demister support Same as cladding alloy material
Vacuum Stiffeners SA 516 Gr. 70

** For smaller size if weld overlay is not possible in seamless pipe (3” NB & below) it shall be cut in
two pieces and after weld overlay & proper finish these two pieces shall be welded and weld
Seams shall be fully radiographed.
Page 372 of 441

5. MATERIAL SPECIFICATION FOR PARTS OF SS EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 240Gr.

304/304L/316L
Reinforcement Pad/Pad for external Same as shell material
attachment
Nozzles & Pipes SA 312 Type 304/304L/316L (seamless) upto 6”

NB
“Same as shell material” for above 6” NB
Flanges SA 182 F 304/304L/316L
Fittings SA 403 WP 304/304L/316L (Seamless)
Couplings SA 182 F 304/304L/316L

0
0
Internal Bolts & Nuts SS 304
Wrapper Plate Same as shell material
0

0
0
Support / Saddle support Same as shell material for temp > 343 C
Internal parts Same as shell material / As specified in Process

Data Sheet

0
External cleats (welded over pad ) SA 283 Gr. C for temp. <343 C
0
same as shell material for temp. ≥ 343 C
* MDS shall be referred for material of external bolts / nuts and in case of discrepancy between
this material specification and PMS, the same shall be referred to OWNER/Jacobs for
clarification.
Page 373 of 441

6. MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (1¼ Cr-1/2 Mo) EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 387GR. 11 Cl. 1

Reinforcement Pad/Pad for external attachment SA 387 Gr. 11 Cl. 2
Nozzles & Pipes SA 335 P 11 (seamless) < 16” NB

Flanges SA 182 F 11 Cl. 2
Fittings SA 234 WP 11 Cl. 2
Couplings SA 182 F 11 Cl. 2
0
0
Internal Bolts & Nuts SS 304 / As per Process data sheet
Skirt support for min. top 1m (top 2m in case of Same as shell material
0
design temp. ≥ 400 C)
Saddle support Same as shell material
Welded Internal parts Same as shell material
Removable Internals As specified in process data sheet
Vacuum Stiffeners Same as shell material
Page 374 of 441

7. MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (2 ¼ Cr-1 Mo) EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 387 Gr. 22 Cl. 2
Reinforcement Pad / Pad for external SA 387 Gr. 22 Cl. 2
attachment
Nozzles & pipes SA 335 P 22 (seamless) <12” NB.

Flanges SA 182 F 22
Fittings SA 234 WP 22
Couplings SA 182 F 22
External Bolts & Nuts *SA 193 Gr.B7 / SA 194 Gr. 2H upto 343°C
* SA 193 GR. B16/ SA 194 Gr.4 for temp. >343°C
Internal Bolts & Nuts SS 304 / as per Process Data Sheet
Skirt support for min. top 1m (top 2m in Same as shell material

case design temp. ≥400°C)
External cleats (Directly welded to Vessel) Same as shell material
Removable internals As specified in Process Data Sheet
Internal Gaskets Non-Asbestos.
Tray Support Rings Same as shell material
Demister Support Same as shell material
Page 375 of 441

8. MATERIAL SPECIFICATION FOR PARTS OF TANKAGES
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/BOTTOM AND ROOF PLATE IS SA 36 / IS

2062 Gr. B / SA 516 Gr.70 / SA 516 Gr. 60
Reinforcement Pad / Pad for external attachment Same as shell material
Nozzles Pipes upto 10” NB SA 106 Gr. B
Nozzle ≥ 12” NB and Man way necks Same as shell material
Nozzle Flanges SA 105
Man way Flanges Same as shell and roof material
Fittings SA 234 WPB
External Bolts & Nuts * SA 193 GR B7/SA 194 GR 2H
Internal Bolts & Nuts SS 304
Bolting for structures IS 1363/IS 1367
Structures IS 2062 Gr. B
Internal Same as shell material or as specified in Process

Data Sheet
Hand railing, Stairway, Platform IS 1239 Cl.1 as per standard / SA 53/IS2062 Gr.A/B
External cleats Same as shell material for temperature>343deg.C
Heating coil SA 106 Gr A/.B / As per Process Data Sheet
Wind girder Same as shell material
Page 376 of 441

9. MATERIAL SPECIFICATION FOR PARTS OF MONEL400 CLAD EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 516 Gr. 70 +

MONEL 400 CLADDING / WELD OVERLAY
Reinforcement Pad / Pad for external SA 516 Gr. 70
attachment
Nozzles & pipes ** SA 106 Gr. B + Monel 400 Weld overlay <8” NB.
Flanges SA 105 + Monel 400 Weld overlay
Fittings SA 234 WPB + Monel 400 Weld overlay
Couplings SA 105 + Monel 400 Weld overlay

0
0
Internal Bolts & Nuts MONEL 400
Skirt support for min. top 1m (top 2m in SA 516 Gr. 70

case of design temp. ≥400°C)
Saddle support SA 516 Gr. 70
External cleats SA 516 Gr. 70
Internal parts Monel 400 / As specified in Process Data Sheet.
Internal Gaskets Non-Asbestos.
Tray Support Rings Monel 400
Demister Support Monel 400
Vacuum Stiffeners SA 516 Gr. 70
** For small size if weld overlay is not possible in seamless pipe (3” NB & below) it shall be cut in two
pieces and after weld overlay and proper finish these two pieces shall be welded and weld seams
shall be fully radiographed.
Note : In case of Monel weld overlay ferrite content shall be checked and the same shall be limited
to 2.5% at the depth of 3 mm cladding.

Page 377 of 441
10. PICKLING & PASSIVATION PROCEDURE FOR SURFACE CLEANING ON MONEL CLAD
SURFACE
SURFACE CLEANING OF MONEL (SB 127) 400 CLAD SURFACE

1.0 The following pickling procedure shall be adopted for cleaning the internal surfaces of the
Monel cladding / weld overlay.
1.1 Swab with a solution made of
Water : 1 gal.
Nitric acid (42 D Be) : 1 gal.
Common Salt : 2 lb.
Temperature : 70-100°F (ambient)
Time : 5 Sec.
1.2 Rinse clean repeatedly with hot water (180°F)
1.3 Second swab with a solution with
Water : 1 gal.
Nitric acid (42 D Be) : 1 gal.
Temperature : 70-100°F (ambient)
Time : 5 Sec.
1.4 Neutralisation by swabbing 1-2% soda ash followed by hot water rinse.
1.5 Cleaning with saw dust or dry cloth cleaning
The procedure shall be pre-qualified before being employed on the vessel.
Page 378 of 441

11. MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (1¼ Cr-1/2Mo) EQUIPMENT
WITH SS347 CLAD
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 387 GR. 11 CL.1 + SS
347 CLAD
Reinforcement Pad/Pad for external SA 387 Gr. 11 Cl. 1
attachment
Nozzles & Pipes ** SA 335 P 11 (seamless) + SS347 Weld overlay <12” NB

Flanges SA 182 F 11 Cl. 2 + SS 347 Weld overlay
Fittings SA 234 WP 11 Cl. 1 + SS 347 Weld overlay
Couplings SA 182 F 11 Cl. 2 + SS 347 Weld overlay

0
0
Internal Bolts & Nuts SS 304 / as per Process Data Sheet
Skirt support for min. top 1m (top 2m in Same as shell material

0
case of design temp. ≥ 400 C)
Internal Gaskets As specified in Process Data Sheet
Vacuum Stiffners Same as shell material
* For smaller size if weld overlay is not possible in seamless pipe (3” NB & below) it shall be cut in two
* pieces and after weld overlay and proper finish these two pieces shall be welded and weld seams
shall be fully radiographed .

Page 379 of 441
12. MATERIAL SPECIFICATION FOR PARTS OF LOW ALLOY STEEL (2¼ Cr-1 Mo) EQUIPMENT
WITH SS347 CLAD
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 387 GR. 22 CL.2 + SS
347 CLAD
Reinforcement Pad / Pad for external SA 387 Gr. 22 Cl. 2
attachment
Nozzles & Pies ** SA 335 P 22 + SS 347 Weld Overlay (seamless) <

12” NB.,“Same as shell material” for 12” NB and above
Flanges SA 182 F 22 + SS 347 Weld Overlay
Fittings SA 234 WP 22+ SS 347 Weld Overlay

0
0
0
Saddle Support Same as shell material
Internal Gaskets Non-Asbestos
Tray supporting Same as shell material
Demister Support Same as shell material
** For smaller size if welded overlay is not possible in seamless pipe (3” NB & below) it shall be cut in
two pieces and after weld overlay and proper finish these two pieces shall be welded and weld
seams shall be fully radiographed.
Page 380 of 441

13. MATERIAL SPECIFICATION FOR PARTS OF HIGH THICK (>50 MM) C.S. EQUIPMENT
MATERIAL SPECIFICATION FOR PARTS WHEN SHELL/DISHED HEAD IS SA 516 Gr. 60 / 70 / SA
266 Gr.2
Pad for external attachment Same as shell material / SA516 Gr. 70
Pipes (Except for nozzles directly welded to SA 106 Gr. B (Seamless) < 12” NB.
vessels “Same as shell material” for 12” NB and above (with full
Flanges & SR Nozzles including integral type SA 350 GR. LF2

flanges
Fittings SA 234 WPB
External Bolts & Nuts * SA 193 GR. B7/SA 194 Gr. 2H upto 343°C
* SA 193 GR. B7/SA 194 Gr. 4 Temp. > 343°C
Wrapper Plate Same as Shell Material / SA516 Gr. 70
0
Saddle Support SA 283 Gr. C upto 343°C

Same as shell material for temp > 343°C
Welded internal parts ** Same as shell material / SA516 Gr. 70
External cleats with pad (same as shell / SA 283 Gr. C upto 343°C
head material Same as shell material / SA516 Gr.70 for temp > 343°C
Internal Gaskets Non-Asbestos
Tray support ring Same as shell material / SA516 Gr. 70
Demister Support Same as shell material / SA516 Gr. 70

material specification and MDS, the same shall be referred to OWNER/Jacobs for clarification.
* For welded internal parts of clad portions of equipment, refer to respective material specifications /
Mechanical Data sheet.
Page 381 of 441

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Page 1 of 21

CHENNAI, INDIA
PART : V
SECTION : 3.4
TITLE: GENERAL SPECIFICATION FOR HEAT EXCHANGERS
DOCUMENT NO. 44NC-4600-0000-V.02-0102-A4

No.
By By By
Page 402 of 441

44NC-4600 HEAT EXCHANGERS Page 2 of 21
LSTK Doc. no. : 44NC-4600-0000-V-02-0102-A4 Rev. 0
CONTENTS
1.0 GENERAL
3.0 SUPPLY
4.0 FABRICATION
6.0 HEAT TREATMENT
8.0 STAMPING, NAME PLATES AND WARNING PLATES
Page 403 of 441

44NC-4600-0000-V.02-0102-A4 General spec for Heat Exchangers.doc
1.0 GENERAL
1.1 Purpose
This specification covers the general requirements for residual design, detailing, materials,
fabrication, workmanship, inspection and testing of shell and tube heat exchangers and is
intended to supplement the minimum requirements of the applicable codes & Jacobs standards
wherever indicated in the requisition shall be followed unless indicated otherwise.
This specification shall not be considered limiting and it shall be Vendor’s responsibility to
comply with all requirements of Material or Purchase Requisition or Bid documents to which this
specification is annexed.
1.2 References
1.2.1 CODES AND REGULATIONS
The following codes in their edition referenced in drawings or data sheets or design basis shall
form the basis for design, materials, fabrication, inspection, testing and acceptance of the
equipment.
a) ASME Sec. VIII Div. 1, Edition 2007, Addenda 2008
b) ASME Sec. II Part A, B, C and D
c) ASME Sec. V,
d) ASME Sec. IX.
e) TEMA (Class as specified on the drawings or data sheets or design basis).
f) Indian Boiler Regulation (IBR), if applicable (latest edition with amendments upto date)
g) National and local laws or regulations, as applicable
1.2.2 FOR HEAT EXCHANGERS UNDER THE PURVIEW OF IBR
a. Vendor shall carry out design calculations as per IBR and only in case of any doubt;
refer the same to Jacobs/Owner for clarifications.
b. In case the equipment is manufactured in India, the design calculations and fabrication
drawings after preliminary review of Owner and Jacobs shall be got approved by
Vendor from Chief Inspector of Boilers (CIB) of the state where Vendor’s shop is
located, before start of fabrication. Vendor shall also provide necessary assistance to
Owner for obtaining approval from CIB of state of installation such as providing
additional copies of calculations and drawings as required by CIB, etc.
c. In case the equipment is manufactured outside India, the design calculations and
fabrication drawings after preliminary review by Owner and Jacobs shall be got
approved by Vendor from the agency authorised by IBR in the country of fabrication and
CIB of the state where the equipment is to be installed, before the start of fabrication.
d. It shall be the responsibility of the Vendor to incorporate modifications or additions if

required by CIB or its authorised agency in (b) and (c) above and obtain the final
approval.
e. Owner and Jacobs shall be kept informed of all changes or modifications desired by
CIB. All costs towards approval from CIB shall be borne by Vendor.
Page 404 of 441

f. All materials, fabrication, welding, inspection, testing etc. shall meet the requirements of
IBR.
1.3 Deviations
In general, no deviations from datasheets, drawings, standards, specifications and requisition

shall be permitted. This does not preclude possible innovations or improvements on the part of
the Vendor based on available facilities. Such deviations must be clearly pointed out in the
format “SCHEDULE OF DEVIATIONS” in the Vendor’s quotation, so as to avoid any confusion
and ambiguity and to facilitate analysis of quotation in minimum time. It shall be taken for
granted that except for the deviations pointed out under the “SCHEDULE OF DEVIATIONS” in
the vendor‘s quotation, all other technical requirements shall be adhered to by the Vendor.
Generally, no deviations shall be entertained after the order has been accepted by the Vendor
unless it is to comply with statutory or code requirements. All waivers and deviations after order
shall be routed through the Inspection officer-in-charge in the prescribed format. Delay in
supply of the equipment because of such deviations being not entertained or approved by
Owner or Jacobs or any delay in processing the same by Owner or Jacobs shall be to Vendor’s
account. Any additional design work in support of such a deviation shall be performed by the
vendor and submitted along with the deviation.
1.4 Contradictory requirements
In case of any contradiction between the requirements of the requisition, drawings and other
documents forming part of the requisition, the matter shall be resolved by Vendor in
consultation with Jacobs/Owner. Decision of Owner or Jacobs shall be binding and without any
implication of cost and time, if not resolved at bidding stage.
1.5 Designed flanges
Design stress values used for calculating body flanges, floating head flanges, channel covers
and bolted tube sheets shall be 88% of the code allowable stress in ASME BPVC, Section II,
Part D, Table A.
An additional thickness of 3.2mm minimum shall be added to the final flange thickness to
facilitate machining of the flange and gasket surface
− This extra thickness shall not be included in any of the flange stress calculations
− This extra thickness shall be clearly indicated as machining allowance on the part drawing
2.1 General
2.1.1 All materials and accessories required for the fabrication, inspection, testing etc. of the heat
exchanger shall be supplied by the Vendor unless otherwise stated. Whenever some material
is to be supplied by the Owner, this shall be so indicated as Free Issue Material and the
supplementary specifications in this regard shall be complied with.
2.1.2 In addition to the requirements of materials as per material specifications, material shall also
meet the requirements mentioned in this specification and other specifications enclosed with
the requisition. All materials shall be certified for compliance with IBR requirements for the
term(s) so specified.
While procuring materials, Vendor shall stipulate additional requirements such as limits on
hardness, ultimate tensile strength (UTS), yield strength, chemical composition, heat treatment
and any other specific requirements to ensure that final requirement as per specification and
Code are met with.
Page 405 of 441

2.1.3 All materials for pressure parts and parts welded to pressure parts including materials in the
scope of sub-vendors, shall be accompanied with mill test certificates duly certified by a reputed
third party inspection agency. In the absence of mill test certificate the material shall be got
tested from a reputed third party inspection agency like Jacobs, Lloyds, BV, DNV etc. and test
results shall be submitted in lieu of mill test certificate.
All cost towards such testing and inspection shall be borne by the Vendor. All materials shall
be inspected at Vendor’s and sub-vendor’s shop for verification prior to use on the job. The
decision of Authorised Inspector to accept or reject materials on the basis of such testing shall
be final.
2.1.4 Wherever simulated heat treatment of test specimens is required as per code or specification,
the simulation cycle shall include one extra cycle of stress relieving for any eventuality of repair
at site by Owner during the life of the equipment.
0
2.1.5 The exchanger’s minimum design metal temperature (MDMT) shall be taken as 0 C or the
design temperature specified in drawing or datasheet whichever is lower, unless specified
otherwise in design basis or datasheets or drawings.
All Carbon steel (CS), low temperature carbon steel (LTCS) and low alloy steel (LAS) materials
0
for pressure parts and attachments to pressure parts having MDMT below 0 C shall be impact
tested.
The test temperature shall be minimum of MDMT and impact test temperature as specified in
applicable materials specification or as given in job specification whichever is lower. Unless
specified otherwise, impact values shall be more stringent of the values as per UG 84 or
applicable material specification
In addition to the tests done at the mill, one impact test (three specimens) per heat shall be
repeated after receipt of materials at vendor shop, with the test temperature same as given
above.
If the test results do not meet the impact energy requirements given above, the material shall
be rejected.
2.1.6 PLATES
2.1.6.1 Pressure parts having thickness 16 mm to 50 mm (both inclusive) shall be ultrasonically tested
as per SA – 435.
2.1.6.2 Pressure parts having thickness greater than 50 mm shall be ultrasonically tested as per SA-
578 Level B.
2.1.7 TUBES
2.1.7.1 All the tubes shall be seamless and cold drawn.
2.1.7.2 Product analysis of tubes shall be carried out and reported.
2.1.7.3 Tubes shall be in fully heat-treated condition as received from the mill. CS tubes shall be in
annealed condition and copper alloy tubes shall be in annealed temper condition. LAS tubes
shall be supplied in normalised and tempered condition.
All un-stabilized stainless steel tubes shall be supplied in solution annealed condition and all
stabilised grades of stainless steel such as SS321 and SS347 shall be supplied in stabilisation
heat-treated condition, in addition to solution annealing.
Page 406 of 441

2.1.7.4 All tubes shall be hydro tested. Hydro test pressure of tubes shall be higher of actual exchanger
tube side pressure or as required by ASME Section II.
2.1.7.5 It is preferable while ordering tubes the maximum Yield strength and hardness of tubes are
specified such as to be lower than those of tubesheet. In order to achieve a sound expanded
tube-to-tube sheet joint, complying with Code requirements.
2.1.8 FORGINGS
Forgings to SA-105 and SA - 266 above 75 mm thickness (thickness as defined in para. AM

200.2 of ASME Sec.II Div- 2), all tube sheet forgings and all forgings of other materials except
standard nozzle flanges up to 8” NB and small forgings (of couplings, plugs and eye bolts) shall
be 100% ultrasonically tested as per SA-388. Acceptance standard shall be as per para AM
203.2 of ASME Section VIII Division 2.
2.1.9 PIPES
Pipes shall be seamless and sizes above 1 ½ “ NB shall be hot finished. Dimensions and
tolerances shall be in accordance with ANSI 36.10 or ANSI 36.19 applicable as per material
specification.
2.2 Specific material requirements (Pressure parts and parts welded to pressure parts)
2.2.1 CS AND LTCS MATERIALS
a) Carbon content shall not exceed 0.23%.
b) All plates shall be in normalised condition
c) Use of SA 515 of any grade is not permitted.
d) Plates above 50 mm thickness shall meet following additional requirements of SA- 20.
i) Vacuum treatment shall be as per the supplementary requirement S1. If vacuum

degassing is not reported in the test certificate, then through thickness tests as per SA
770 shall be conducted and minimum reduction in area of 35% shall be ensured.
ii) Charpy V-notch test shall be as per supplementary requirement S5. Test temperature
0 0
shall be minus 29 C for MDMT greater than or equal to 0 C. For MDMT less than 0
0
C refers clause 2.1.5 above. Impact energy values shall be as per para UG-84 of
Code, or as per applicable material specification, whichever is higher. Orientation of
test bar shall be transverse to rolling direction.
iii) Bend test as per supplementary requirements S14 of SA-20.
e) Unless specified otherwise in requisition or bid document. All CS materials specified, as

HIC tested shall meet the following requirements.
i) Carbon equivalent shall be restricted to 0.43% max. Nickel content shall be 0.2%
max.
ii) Sulphur content shall be 0.002% max for plates and 0.01% for tubes, pipes and
forgings.
iii) Hardness of plates and pipes shall not exceed 200 BHN, and that of forgings shall
not exceed 187 BHN.
iv) Plates shall be to SA 516 Gr. 60/70 only. The plates shall contain calcium or other
rare earth elements to create spherical inclusions instead of stringers. The plates
Page 407 of 441

shall be tested in accordance with NACE TM-02-84 using the test solution of NACE
TM-01-77. The acceptance criteria shall be crack length ratio 10% maximum.
f) All LTCS and CS charpy plate material shall be to fine grain practice and the austenitic
grain size shall be measured and reported in the mill test certificate.
g) CS pipes shall be SA-106 Gr.B. LTCS pipes shall be seamless conforming to SA 333 Gr. 1
or 6
h) Non-standard forgings (SA 266, SA 350 etc.) shall be in normalised and tempered
condition.
2.2.2 LAS MATERIALS
a) All LAS plates, pipes, forgings and fittings shall be in normalised and tempered condition.
Use of C-½ Mo materials is prohibited.
b) For 1-¼ Cr- ½ Mo materials the maximum room temperature tensile strength of all
pressure containing components, materials and welds shall be 100000 psi.
c) For LAS tubes (SA-199, 209 and 213) hardness test shall be performed on outside of the
tubes as per SA-450.
d) For LAS plates above 50 mm thickness, following supplementary requirements of SA-20

shall also apply:
i) Vacuum treatment shall be as per supplementary requirement S1. 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.
ii) Charpy V-notch impact test as per supplementary requirement S5 with impact values
0 0
as per UG 84 of Code. Test temperature shall be lower of MDMT or -18 C (0 C for
5Cr- ½ Mo) whichever is lower. Orientation of test bar shall be transverse to the
direction of rolling.
iii) Bend Test as per supplementary requirement S14.
2.2.3 SS AND OTHER HIGH ALLOY MATERIAL
a) All SS material (300 series) shall be in the solution heat treated (fully annealed) and
pickled condition. All stabilised grades of SS (SS 321, SS 347 etc.) shall be given
stabilisation heat treatment, in addition to solution annealing.
b) All SS (300 series) plates shall be hot rolled and shall have No.1 finish on both sides.
c) SS (300 series) materials for all components shall be procured with the IGC test as per
ASTM A-262 (test shall be carried out, after the specified heat treatment and sensitisation
per specification) with acceptable corrosion rate and practices as under.
i) For all services except nitric acid service, Practice E shall be followed Specimen
after exposure shall be bent as per requirements mentioned in A262 Practice E and
shall be inspected under magnification of 200X. The bent specimen shall be free of
any cracks or grain dropping. The microstructure shall be submitted to the
Authorised Inspector for approval.
ii) For Nitric acid service: Practice C with corrosion rate not greater than 25 mils per
year.
Page 408 of 441

iii) For straight chrome (13% Cr.) material, maximum carbon content shall not exceed
0.08%. Hardness of UNS No.S41000 and S41008 shall not exceed 75 RB and that
of S40500 shall not exceed 80 RB.
2.2.4 NON-FERROUS MATERIALS
a) All copper based non-ferrous plates shall be procured in annealed condition.
b) Plates for pressure parts shall be 100% ultrasonically examined. Vendor shall submit
the procedure for UST to Authorised Inspector for approval.
c) In addition to hydro test, all tubes shall be Eddy current tested in their final annealed
condition.
d) All pipe bends shall be stress relief annealed after bending.
e) The paragraphs NF7 and NF14 in part UNF of Code are mandatory. This applies to
non-ferrous cladding and weld overlay.
2.2.5 CLAD MATERIALS
a) Cladding shall be integrally and continuously metallurgically bonded to the base metal.
All clad plates shall be rolled-on or explosion bonded type.
b) Clad plates shall be ultrasonically examined from the cladding surface in accordance
with SA-578. Scanning shall be 100% of the plate surface. Acceptance standard shall
be level B. Clad plates shall meet the supplementary requirements of S7 of SA-578. All
ultrasonic testing shall be undertaken after specified heat treatment of clad plates.
c) Both base material and clad material shall meet the specification of the respective
materials as stipulated in this specification.
d) Alloy clad steel plates shall be as per SA 263 or SA 264 or SA 265. Bond between
cladding and the base metal shall be checked for a minimum strength of 14 kg/mm2 in
shear for alloy clad steel plates, by conducting shear test as per applicable material
specification.
e) For copper alloy clad plates, the bond between cladding and base metal shall be
checked for a minimum strength of 10 kg/mm2 in shear by conducting shear test.
f) During tension test of clad plates the cladding shall be removed and the tensile
properties of the base material shall meet the Code material requirements.
g) For austenitic SS clad plates the SS surface shall be acid pickled as per ASTM A-380.
For Chromium steel clad surfaces the pickling shall be as per Vendor’s established
procedure. The same shall be submitted to Owner /Jacobs for approval.
h) For all clad plates used in Hydrogen or H2S service with design temperature greater than
0
350 C, Hydrogen disbonding test shall be carried out. The test condition shall be
representative of the actual design conditions and the procedure shall be submitted to
2.3 Non Pressure Parts
2.3.1 CS plates shall be minimum IS-2062 Gr. B/C or SA 283 Gr. C or equivalent. Pipes shall be to
IS 1239 or SA 53 or equivalent.
0
2.3.2 Saddle material shall be same as that of shell for design temperature greater than 350 C.
Page 409 of 441

2.4 Equivalent materials
The materials for various components in a heat exchanger shall be as per Owner or Jacobs
requirement. This does not preclude use of equivalent or better materials. However, these
deviations should be clearly indicated in the prescribed format. If an equivalent material sought
by the Vendor is to a specification, other than IS or ASTM or ASME, it is necessary for the
Vendor to submit the specifications of the equivalent material with complete details in English
for approval.
3.0 SUPPLY
Supply shall be in accordance with requisition or bid documents to which this specification is
attached.
It shall, however, include the following:
3.1 Test ring assembly, dummy shell and test flange
Test rings assemblies, dummy shells and test flanges wherever required shall be designed and
supplied by the Vendor. The stresses shall not exceed 90% of the minimum yield stress of the
material as stipulated in material specification. Material used for fabricating these shall be of
tested quality.
For removable bundle with the tube side test pressure higher than shell side, the bundle shall
be tested outside the shell, with tube side pressurised for tube side test pressure to check tube
to tubesheet joint leakage from the back of tubesheet. Test flange shall be designed
accordingly.
Test ring assembly construction shall be stuffing box type as per fig.E-4.13-2 of TEMA. It is
preferred that the test ring flange thickness not exceed the shell cover flange thickness,
otherwise Vendor to provide separate bolting for assembling test ring flange to shell.
Similarly, for test flange Vendor to check that the studs for stationery tubesheet bolting can be
used with test flange. Otherwise separate bolting shall be provided for assembling test flange.
3.2 Accessories for testing
All necessary accessories such as supports, blind flanges, test gaskets, bolts, nuts etc. shall be
provided and supplied by the Vendor for testing of heat exchanger, in his shop and for
subsequent testing by Owner at site, whenever required.
3.3 Other accessories
3.3.1 Vendor shall also supply the bolts, levelling shims or intermediate supports for stacked units.
Gaskets, nuts and bolts relating to interconnecting nozzles (tube and shell side) including
spares shall be supplied by Vendor. All these components shall be despatched separately with
due care having been taken regarding identification of these for ease of installation.
3.3.2 Earthing lugs shall be provided on each heat exchanger and shall be located in such a way as
to avoid any fouling with the exchanger foundation bolts at site.
3.3.3 Vendor to supply one set of torque wrenches for bolt size M45 (1¾“) to M56 (2¼”) and a set of
bolt tensioner device for bolt sizes greater than M56 (2¼”) in case these bolt sizes are being
used in exchangers covered in the requisition. BTD capacity shall be 40% more than the
maximum load required for hydro test condition. BTD pump shall be pneumatically and
manually driven. Vendor shall supply one pump unit, required load cells and 4 heads of each
size. Torque values for tightening the bolts shall be mentioned in the fabrication drawings.
3.3.4 Additions like cleats for piping, ladder, platform, insulation cleats etc. which may be required
Page 410 of 441

shall be provided.
3.4 Cathodic protection
Whenever cathodic protection is specified both sacrificial anodes and internal painting shall be
provided as per Jacobs Specification unless specified otherwise.
3.5 Spares to be supplied by vendor:
3.5.1 BOLTING : 20% (Min. 4 studs & 8 nuts for each joint)
3.5.2 GASKETS : 400% gaskets other than those used for hydro testing and despatch for
each joint
3.5.3 Spare bolting and gaskets shall be provided for all joints of girth flanges, floating head, channel
cover, tubesheet, interconnecting nozzles, nozzles with blind flange or companion flange etc.
4.0 FABRICATION
4.1 Edge preparation
4.1.1 For CS, the preparation of edges for welding shall be done using machining, chipping, cold
shearing, oxy-acetylene flame cutting or a combination of these. Chipping or cold shearing
shall be followed by grinding to a smooth and regular surface. Oxy-acetylene flame cutting shall
be followed by machining or grinding to eliminate any discoloration of material affected.
4.1.2 For LAS, the edges for welding shall be made by oxy-acetylene flame cutting or by machining.
Cold shearing may be used for cutting thickness up to 10 mm. Oxy-acetylene flame cutting
shall be used with preheat and shall be followed by machining or grinding to eliminate any
discoloration of material affected.
4.1.3 For austenitic SS, the edges shall be prepared using plasma arc, however, cold shearing may
be adopted for thickness up to 15 mm. In all cases the cut edges shall be ground back or
machined back by 2 to 3 mm.
4.1.4 All welding edges after cutting shall be Dye Penetrant (DP) or Magnetic Particle (MP) examined
for laminations, cracks or segregation. Additionally UST shall be carried out within twice the
material thickness of edge for LAS materials or when the service is low temperature or
hydrogen or HIC.
4.1.5 The paragraphs NF7 and NF14 in part UNF of Code are mandatory. This applies to non-
ferrous cladding and weld overlay.
4.2 Rolling and dishing of plates
4.2.1 Rolling
Rolling for bending and forming of plates shall be in the longitudinal direction of the plates. This
direction shall be clearly marked on the plates.
Re-rolling after welding is not normally recommended. However, if for large diameter shells, re-
rolling of welded shell course is inevitable, procedure for re-rolling along with extent of non-
destructive tests (NDT) shall be submitted for approval of the Authorised Inspector.
All welds on the section to be re-rolled must be ground flush. After re-rolling all the welds on the
re-rolled section must be DP checked. Such welds shall then be subjected to radiography as
required by drawings and Code.
Page 411 of 441

4.2.2 Dishing
All dished heads shall preferably be of single piece construction. However dished ends with
one chordal seam are acceptable for shells with diameter greater than 1 m. In such cases, the
chordal seam shall preferably be in the middle one-third of the blank.
Dished ends shall preferably be 2:1 ellipsoidal
Dished heads shall be subjected to DP test on knuckle portions (both inside and outside) and
weld edges after heat treatment. Vendor to ensure adequacy of indicated thinning allowance for
dished head. If nominal thickness indicated is not adequate then the nominal thickness should
be increased accordingly, keeping minimum thickness as per equipment drawing.
A straight face of 38 mm or 3 times the nominal thickness of dished end, whichever is less shall
be provided. However, if larger straight face is specified, it shall be ensured.
4.3 Welding
4.3.1 All welding and weld overlays shall be done with electrodes, fillers and fluxes of reputed make
with proven reproducibility of results. Brand names shall be specifically approved by Authorised
Inspector. For CS pressure parts, the electrodes shall be of low hydrogen type, IGC test as per
ASTM A262 Practice E shall be done for austenitic SS consumables, which are to be used in
application involving solution annealing.
Austenitic SS consumables of low carbon and stabilised grade shall also be IGC tested as per
ASTM A262 Practice E. Straight chrome materials shall be welded with electrode that
produces an austenitic chromium nickel weld deposit or a non-air hardening nickel –chromium-
iron weld deposit.
4.3.2 All welding procedures shall be submitted for approval by Authorised Inspector giving all
relevant details. Welding qualification records shall indicate hardness values of weld metal.
0
HAZ and parent metal and also results of impact tests when design temperature are below 0 C
or when specifically indicated for materials being welded. No welding shall be undertaken until
the welding procedure and welder’s qualification have been approved by the Authorised
Inspector.
All welding procedures and welders shall be qualified for the particular type of welding and
material in accordance with the ASME Section IX. Vendor shall be responsible for the quality of
the welds performed.
4.3.3 Pressure holding joints shall be full penetration welds. Root pass of single side welded joints
shall be done with GTAW process. Backing strip for single side welded joints is not permitted.
For LTCS materials both inside and outside of welds shall be ground flush or dressed smooth.
All internal welds in the shell shall be ground flush in order to insert and remove tube bundle.
Also all internal welds shall be ground flush to the extent of facilitating draining of complete
equipment.
4.3.4 Longitudinal seams shall be staggered with the circumferential distance between the centres of
welds being at least 5 times the thickness of the thicker-plate. Weld seams shall be located so
as to avoid interference with weld seam of nozzles and external attachments.
4.3.5 Attachment to pressure part shall be of same quality as the pressure part. All LAS weld
attachments to pressure retaining component shall be with full penetration weld and ground to a
smooth concave contour.
External attachments like lugs, supports, etc. of CS shall not be welded directly to high alloy or
austenitic SS heat exchanger components. These attachments should be of the same material
as the heat exchanger components.
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If this is not so, intermediate pad plates of the same material type as the heat exchanger
component may be used. These pads shall be at least 100 mm wider and longer than the
attachment and shall be at least 5 mm thick. Welding of CS or LAS to austenitic SS shall be
done with austenitic SS electrodes or filler wire (AWS – ASTM – E 309L or E-309 MoL only).
Wrapper plates, reinforcing pads or stiffeners of higher thickness than specified can be used
provided there is no change in basic dimensions and with the approval from Jacobs.
4.3.6 Partition plate of CS and 300 series SS except for low temperature service, shall be welded to
channels etc. by continuous fillet welds with minimum size of 6 mm on both sides. For all other
materials and for hydrogen and low temperature services, all welds involving partition plates
shall be full penetration weld.
Partition plates thicker than 10 mm shall be tapered to 10 mm at partition groove end except
when mentioned otherwise on drawings. One weep hole of 6 mm diameter shall be provided at
the centre of each horizontal pass partition plate and a 5 mm radius notch on top and bottom
point of each vertical pass partition plate for all multi -pass exchangers for effective venting and
draining.
4.3.7 Welding of shell to unhubbed tubesheet shall meet the requirements of Code considering that
the tubesheet is unsupported.
4.3.8 When impact tests are required on material as per Code or specification the welds shall also be
qualified for impact test. In such case following special requirement shall apply to the welding
procedure qualification:
i) Qualification tests shall be made on plates of the ASME specification as specified for the
exchanger using welding electrodes of AWS or SFA specification and wire & flux of the
specification and brand as are to be used on the job.
ii) Welding current and travel speed shall be considered essential variables in order to
ensure that production welding is substantially equivalent to the procedure qualification.
iii) Welded test plates shall be subjected to a total thermal cycle sequence similar to the
finished equipment. Specifically, test plates shall be held at intermediate and final stress
relief temperatures for approximately the same length of time as the finished exchanger.
Final cooling rate shall be approximate to that expected for the finished exchanger.
iv) Charpy V-notch impact tests shall be made on the weld and HAZ of the test plate for
each welding procedure to be qualified. Test procedure shall be as per UG 84 of Code.
Test temperature shall not be higher than MDMT. Impact energy requirements shall be
as per Table 2.15 of SA 20 of ASME Section II Part A or UG 84 of Code whichever is
higher.
4.3.9 WELD OVERLAY
4.3.9.1 Weld deposit overlay shall be done by a qualified welding procedure and surface shall be
properly machined or ground flush after overlay. Minimum thickness of finished weld deposit
shall be as indicated in the drawings or specifications.
In case a higher deposition thickness and multiple weld layers are required to achieve the
minimum specified undiluted deposit metal, the same shall be done only after taking prior
approval from Jacobs.
Minimum thickness of undiluted finished weld overlay from top shall be 3 mm or as specified in
the drawings. For non-ferrous weld deposit, the iron dilution should be restricted to 2.5%
(maximum) in the finished undiluted layer (thickness defined above).
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4.3.9.2 The weld overlay procedure shall be qualified on base metal of the same composition as the
exchanger component and meeting the requirements of ASME Section IX.
4.3.9.3 The weld overlay shall be relatively smooth with no notches and undercuts that would act as
stress raisers. All cracks, fissures and circular defects greater than 1/16” diameter shall be
removed. Repaired areas shall be DP checked.
Weld overlay shall be applied to base metal, which has been grit blasted and is smooth and
clean so as to ensure full bonding. Welding overlay cladding shall be applied after any
normalising but before the post weld heat treatment (PWHT). The weld overlay shall consist of
at least 2 layers.
4.3.9.4 The alloy cladding shall be cut back at all seams to permit back welding of the base metal.
Weld metal shall be ground flush and fully covered with the applicable weld deposit.
The weld joint in base plate shall be 100% DP tested for detection of cracks and flaws before
welding from clad side. The weld deposit shall be at least as thick as the cladding.
4.3.9.5 Shells, cones and dished heads formed from clad plates shall be UST after forming for a
minimum of 10% of the clad surface, including no less than one square feet in each 10 square
feet or fraction thereof.
Un-bonded areas that cannot be encompassed by a 3“ diameter circle shall be repaired by weld
overlay. When repairs in excess of 5% of the total examined area are required, the complete
exchanger shall be 100% UST. .
Repaired areas and weld deposit overlay at weld seams shall be DP examined. UST shall be
repeated for dished heads after heat treatment. All UST shall be in accordance with SA 578 S6
for spot examination and SA 578 S7 for 100% examination
4.3.9.6 All weld overlays shall be 100% DP examined in accordance with the method described in
ASTM-E-165. The barrier layer shall be 100% examined.
When the overlay involves multiple passes (layers) and the procedure uses an intermediate
heat treatment with cooling to room temperature prior to applying the subsequent layer, each
layer shall be examined.
Where overlay is to be machined such as for flange facing, machined surface shall be 100%
examined after PWHT. If 100% of overlay is examined prior to the final PWHT, overlay shall be
spot examined (not less than 10% of the surface) after heat treatment.
4.3.9.7 Samples of the weld overlay shall be taken to perform chemical analysis to the required depth
as specified. The number and location of samples shall be at the discretion of Authorised
Inspector.
However, they shall be representative of each exchanger component for each type of welding
process. Report of this chemical analysis shall be submitted to Authorised Inspector for
approval.
4.3.9.8 For all weld overlays used in hydrogen or H2S service with design temperature greater than
0
350 C. Hydrogen dis-bonding test shall be carried out. The test condition shall be
representative of the actual design conditions and the procedure shall be submitted to
4.3.10 Production test coupons (PTC) are required for CS welds above 50 mm thickness. For LAS
welds above 25 mm or when required by the Code. The following shall apply:
a) Two PTCs representative of one longitudinal and another circumferential seam shall be
provided for each procedure, position and thickness.
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b) PTC shall be from material of the same heat and thickness as of parent metal. During
and after welding PTC shall be subjected to same heat treatment as and together with
the course they represent, extra PTC shall be preserved to take care of eventuality of
retests.
c) The tests mentioned below shall be carried out as per methods of testing in Code:
i) One transverse tension test
ii) Two side bend tests with weld located in the center of bend
iii) One hardness test on PTC weld and HAZ. The acceptable limits are 200 BHN for CS,
225 BHN for P3 and P4 materials and 235 BHN for P5
iv) Micro and macro examination of welds
v) For CS, charpy V notch tests on weld and HAZ shall be carried out. For MDMT below
0
0 C, impact test temperature shall be MDMT. For MDMT greater than or equal to 0
0 0
C, the test temperature shall be 0 C. The acceptance criteria for impact energy shall
be as per table a 2.15 of SA 20 of ASME Section II part A or UG – 84 of Code
whichever is higher.
vi) For LAS, charpy V notch tests on weld and HAZ shall be carried out for 25 mm
thickness and above or when specified in requisition. Test temperature and
acceptance criteria shall be as per clause 2.2.2 (d) (ii) above.
4.4 Tube to tubesheet joints
Refer respective Jacob standards
4.5 Hardness limitations
Hardness limitation for materials wherever specified on drawings or datasheets and LAS
materials shall be as per Jacobs General Spec for hardness requirements. Hardness limitation
for tube to tubesheet welding shall be established on a mock-up with simulation heat treatment.
Hardness of straight chrome materials in the cold-formed state, HAZ and welds shall not
exceed 88 RB.
4.6 Nozzle flanges, nozzles and reinforcing pads
4.6.1 Flanges
Unless otherwise indicated, dimensions, drilling, facing and tolerance for nozzle flanges (and
blind covers if required) shall be as per ASME B 16.5 (for size upto 24” NB) and ASME B 16.47
series B (for sizes above 24” NB) for the respective class. Weld overlays, wherever specified
or required, shall be in addition to the thickness as per these standards. Boltholes on these
nozzle flanges shall straddle principal vertical and horizontal centerlines of equipment. If the
component to which nozzles are attached is subsequently stress relieved, it shall be Vendor’s
responsibility to maintain true gasket faces by machining or otherwise. If distortion expected is
considerable, final machining operation should be done after stress relieving; sufficient
machining allowance for this purpose should be available. Gaskets for flanges to ASME B16.5
and B16.47 shall be as per ANSI B16.20.
4.6.2 Nozzles
4.6.2.1 Nozzle pipes shall be attached to the heat exchanger components by full penetration welds.
Attachment welds using only inner and outer fillet welds are not permitted. Unless otherwise
indicated on the datasheets or drawings, necks of all nozzles shall be flush with the inside of
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heat exchanger component. Inside corners of nozzle pipes at shell and channel inside
diameter shall be radiused. All nozzles 2” NB and below except long weld neck, shall have two
stiffeners (40 mm x 6 mm) at right angles.
4.6.2.2 Whenever nozzle inside is required to be overlayed, these shall be done by weld overlay or
cladding. Minimum nozzle ID before weld depositing shall be 50 mm in such cases. Loose
liners are not acceptable.
4.6.3 Reinforcing pads and testing
Reinforcing pads whenever required as per drawings or Code shall be of the same material as
the heat exchanger component to which it is welded. All reinforcing pads shall be provided with
0
two 1/8” (3 mm) NPT tapped holes located 180 apart for air soap solution test with a pressure
2
of 1.25 kg/cm (g). This test shall also be required to be carried out for slip on flanges.
Higher test pressure are not recommended because of accompanying risks and also because
the soap bubbles have a chance to blow off. Tell-tale holes in reinforcing pads shall be plugged
with hard grease unless otherwise indicated after the hydro test of the exchanger.
4.7 Bolts, studs etc. and tapped holes
4.7.1 All inch bolting and threading shall conform to ANSI B 1.1 except for size 1” and above where it
shall be 8 threads per inch. Metric bolting and threading shall conform to ISO – R261 except
for size M24 and above, where it shall have 3 mm pitch.
4.7.2 Studs shall extend beyond the nut by about 10 mm and shall be threaded full length except
when square ends are required for use with bolt tensioner, in which case the extension shall be
as per bolt tensioner manufacturer’s recommendation. The studs for extended tubesheet and
the studs for use with connecting piece shall also have square ends. The extended portion of
the stud shall be provided with a suitable protection cap to avoid clogging / rusting of
stud threads.
4.7.3 All nuts shall be of heavy series only and nut-seating faces shall be machined or spot faced.
4.7.4 Threads on external bolting, plugs etc. shall be lubricated with graphite grease for working
0
temperature upto 200 C and with Molybdenum Disulphide for higher temperatures.
4.7.5 Tapped holes drilled on the channel side face of clad tube sheets for removable bundles shall
be fitted with plugs of a material similar to channel side material in contact with tube side fluid.
For extended tubesheet, tapped holes shall be provided for girth bolting.
4.7.6 All floating head bolting shall have 2 mm wide and 0.5 mm deep groove at both ends to prevent
mix up with other bolts.
4.8 Assembly and handling
4.8.1 Vendor shall be responsible for taking adequate preventive measures to ensure the quality and
finish of materials and to avoid any rusting.
4.8.2 Suitable method of alignment like dowels etc. shall be provided for proper assembly of channel,
channel covers, stationary tubesheet etc.
4.8.3 Stacked exchangers shall be assembled in the workshop for a trial fit. Special care shall be
exercised in truing up connecting nozzle flanges.
4.8.4 ‘T’ wherever indicated on drawings, denotes match mark for assembly and shall be punched on
all mating parts.
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4.8.5 Lifting lugs shall be provided as per standard for lifting of channels, channel covers, shell
covers, test rings, test flanges etc.
4.8.6 In case of removable bundles the following are required.

0
(a) Stationery tube sheets shall be drilled and tapped at vertical (0 ) position for attaching
eyebolts, or a lifting lug of adequate thickness shall be welded with 25 mm (minimum)
diameter hole.
(b) Drilling and tapping as above shall be carried out on floating tubesheet.
(c) Last support plate shall be drilled (25 mm diameter hole) for lifting, local stiffening may be
necessary to adequately support the bundle.
4.8.7 Pulling eyebolts made from forged CS shall be provided for all removable bundles. These shall
be provided loose.
4.8.8 Stationery tubesheet shall be drilled and tapped for the rods. Care should be taken to ensure
that holes are not drilled through.
0
4.8.9 Interchangeable and 180 rotatable bundles shall have common pass-partition groove
arrangement in the respective tubesheet. For exchangers where bundles are specified to be
interchangeable the same shall be ensured at the Vendor’s shop by actually inserting the
bundles or using a template consisting 4 full diameter baffles, each spaced at a distance equal
to the baffle pitch.
4.8.10 Jackscrews shall be provided on all girth flanges.
4.9 Descaling, pickling and passivation shall be done for all SS parts of heat exchangers in
accordance with ASTM A-380. The Vendor shall supply details of the procedure for approval to
the Authorised Inspector.
4.10 No distortion whatsoever shall be permitted on the gasket seating surfaces due to tube to
tubesheet welding, shell to tubesheet welding, PWHT etc. If distorted, the same shall be
machined subsequently.
4.11 Fabrication tolerances and finish
4.11.1 The dimensional tolerances shall be within the limits indicated on Jacobs drawings and
standards. Where tolerances are not specified, these shall be in accordance with the
requirements of TEMA and Code.
4.11.2 All edges and corners shall be deburred (or rounded, if shown). Baffles holes shall be
deburred.
4.11.3 Finish of all machined components shall be minimum 12 microns (500 RMS) unless otherwise
indicated. Parts subjected to UT shall have minimum finish of 6 microns.
4.11.4 Tubesheet face shall be flat within +/- 1.5 mm (camber)
5.1 All the NDT procedures shall be submitted to the Authorised Inspector for approval. For all
NDT activities, only qualified NDT technicians shall be deployed with the approval of Authorised
Inspector.
5.2 The extent of radiography shall be as specified on the datasheets or drawings or job
specifications. In no case it shall be less than that required in the Code.
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5.3 Minimum extent of radiography shall be spot, unless full radiography is specified in the
drawings or it is required as per specification or Code. Spot radiography shall mean that at
least 10% of the total welded length must be radiographed. Further, all “T” joints must be
radiographed and at least one shot must be taken on each longitudinal and circumferential
seam. This requirement shall supplement the ones specified in Code. The Authorised
Inspector shall be consulted in marking the area to be radiographed.
5.4 Full radiography when specified shall imply 100% radiography of all butt welds.
5.5 All nozzles fabricated from plate, irrespective of thickness of plate and radiography specified,
shall be 100% radiographed.
5.6 Weld seams of formed heads shall be 100% radiographed after forming and heat treatment, if
any.
5.7 All nozzles to shell welds and unhubbed tubesheet to shell welds shall be DP or MP checked at
the root run and final weld.
5.8 100% UT shall be carried out for un-hubbed floating head to cover welds.
5.9 For LAS welds, radiography shall be done after final PWHT. All welds which cannot be fully
radiographed such as nozzle to shell weld, shell to unhubbed tube sheet etc. shall be 100%
ultrasonically tested after final PWHT.
Regarding fillet welds and welds which can not be radiographed or ultrasonically tested (i.e.
pass partition plate to channel and floating head joint etc.), the root run shall be DP checked
and the welds should finally be MP checked after stress relieving.
5.10 All attachment welds shall be either DP or MP tested.
5.11 Acceptance standards for radiography shall be as per Code unless stated otherwise.
6.0 HEAT TREATMENT
6.1 PWHT shall, in general, be done as required by datasheets, drawings, specifications, Code etc.
PWHT when mentioned on the drawings shall be over and above the requirements of
specifications or Code. No welding or heating is permitted after PWHT operation.
All matching operations shall preferably be carried out after heat treatment (Also refer clause
4.6.1. above). It shall be the responsibility of the Vendor to leave sufficient allowance for this
purpose. Vendor shall submit all the procedures for PWHT to Authorised Inspector for review.
6.2 During PWHT of assemblies of fixed tubesheet exchangers, care shall be taken to ensure that
differential stresses are not caused between tubes, shell and tubesheet. The temperature
0
differential between shell and tubes during PWHT to be minimised (not to exceed 25 C) and
0
the rate of heating and cooling shall not exceed 25 – 30 C per hr. For this purpose,
thermocouples shall be installed on various components and compliance assured.
6.3 Heat treatment of SS clad assemblies shall be at reduced temperature to avoid sensitisation of
SS materials. The soaking time shall be increased accordingly as per Code.
6.4 Heat treatment of non-ferrous clad assemblies, if required, shall be performed with extra care, if
required at reduced temperatures to avoid differential thermal expansion. The soaking time in
such a case shall be increased accordingly as per Code.
6.5 Heat treatment of CS and LAS dished heads shall be as follows.
a) Stress Relieving for:
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i) Cold formed dish heads upto 16 mm thick.
ii) Cold formed floating head cover upto 16 mm thick if fibre stretch exceeds 5%.
b) Normalising for CS and normalising and tempering for LAS:
i) Hot formed dish head and floating head dish if not formed in normalising range.
ii) Cold formed dish heads for thickness greater than 16 mm.
iii) Cold formed floating head dish above 16 mm thick.
This heat treatment need not be given if same heat treatment is given subsequently on sub-
assembly.
6.6 SS component shall be solution annealed in the following cases.
i) Cold formed dished heads with nominal thickness of 16 mm or above.
ii) Hardness value of dished heads after cold forming exceeds 235 BHN.
iii) Hot formed shells, cones, dished heads.
After any heat treatment on austenitic SS, IGC test shall be carried out as per clause 2.2.3 (c)
above.
6.7 If stress relieving is indicated on shell side or tube side and the service on either side is lethal or
low temperature, the welded tube to tubesheet joint of CS or LTCS material shall be stress
relieved or if specifically indicated in the datasheet or drawings.
6.8 For LAS materials, preheating procedure shall be established in the welding procedure and got
approved by the Authorised Inspector. Preheating by resistance or induction heating method is
preferred. Preheating shall extend uniformly to at least three times the thickness of joint but not
less than 50 mm on both sides of the weld. Temperature indicating crayons shall be used for
assessment of correct pre-heat temperature.
6.9 All Low Alloy Steel pressure containing welds shall be PWHT.
7.1 Inspection
7.1.1 The inspection shall be carried out by Authorised Inspector. The materials, fabrication and
testing of exchangers shall be open to inspection by the Authorised Inspector in addition to any
inspection required by the specified Code or by local authorities having jurisdiction over the
installation.
7.1.2 Inspection shall be carried out both during fabrication and before delivery and also for sub-
ordered materials. If any, in addition to final inspection and certification by Authorised Inspector
during the course of manufacture, Authorised Inspector’s written approval shall be obtained by
the Vendor at various stages of fabrication. For this purpose, Vendor shall prepare his Quality
Assurance Plan, defining the stages of fabrication, hold points for his own inspection and that
by the Authorised Inspection or Code or statutory Authorities Inspection etc.
The Quality Assurance Plan shall be discussed with Authorised Inspector before start of job
and mutually agreed. The various stages of fabrication to be inspected (by Vendor or the
Authorised Inspector) shall include but not limited to the following.
a) Raw material identification and verification of mill test certificate.
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b) Edge preparation for welding, including visual check for laminations
c) Alignment of longitudinal and circumferential seams
d) Rolling tolerances on individual section
e) Alignment and fit up of section, nozzle setting and components.
f) Root pass clearance before welding and cleaning
g) Profile and thinning of dished ends and toriconical pieces after forming
h) Checking of tubesheet after drilling including visual check for laminations
i) Tubesheet to shell set up for fixed tubesheet exchangers, prior to welding operation.
j) Tube to tubesheet joint expansion or welding
k) Visual check of shell inside and tube bundle insertion.
l) Welding of expansion bellows or joints, if required
m) Review of NDT reports and any other specified test such as for leak, corrosion and
hardness.
n) Review of heat treatment charts.
o) Complete fitment of stacked heat exchangers
p) Calibration records of measuring instruments.
q) Final visual and dimensional inspection
r) Witnessing of hydro test
s) Surface preparation, primer painting
7.1.3 The presence of the Authorised Inspector shall not modify or reduce the obligation of the
Vendor to carry out his own tests and control. Should any material and / or equipment be found
not in compliance with the requirements specified, the Authorised Inspector or his delegate
shall be entitled to irrevocably reject them, even if such non-compliance has not been
evidenced in the course of inspections and/or tests.
7.1.4 The Authorised Inspector will, at the time of initial visit, set up with the Vendor actual details of
inspection stages to be witnessed or carried out: the schedule of future visits and subsequent
inspection notices can be arranged between the Authorised Inspector and the Vendor.
7.1.5 The Vendor shall notify the Authorised Inspector sufficiently in advance of any fabrication
operations to permit him to arrive at the Vendor’s shop in time to witness the operations.
7.1.6 The Vendor shall provide to the Authorised Inspector, free access to his shops at all times. He
shall also supply all tools and tackles to the Authorised Inspector for carrying out the inspection.
The Vendor shall also arrange for similar facilities at this sub-contractor’s shops.
7.1.7 The Vendor must satisfy the Authorised Inspector that the welding procedures, welders,
electrodes, fluxes, welding wires etc. are in accordance with the requirements of the Code and
specifications. Further the welder’s qualification test must be carried out in the presence of the
Authorised Inspector.
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7.1.8 Prior to final inspection, all slag, weld spatters, loose scale, dirt, grit, paint, grease, oil and other
foreign matter shall be removed in order to facilitate inspection. All reinforcing pads and slip on
type flange welds shall be pressure tested with air and soap solution before and after heat
treatment (if any) and before final hydrotest.
7.1.9 A dimensional checking of equipment shall be carried out taking into account the tolerances
shown on job drawings and standards, design specification or Code, the more stringent values
shall govern. Dimensional checks are to be taken of the internal measurements of equipment
together with external ones and these are to be recorded on a copy of the drawings as being
the “As Built” dimensions.
7.2 Hydrostatic tests
7.2.1 Hydrostatic tests shall be witnessed by the Authorised Inspector. When hydrostatic tests are
performed the indicating gauge shall be connected to the upper most parts of the equipment.
Testing water shall be clean potable water. Seawater shall not be used.
For SS equipment water used for these tests shall not contain more than 25 ppm chlorides.
0
Minimum metal temperature during hydrostatic tests shall be 20 C.
Test pressures shall be maintained for at least one hour. Shell and tube sides shall be tested
separately, unless otherwise mentioned on the drawing.
For tubesheet designed for differential pressure, special care shall be taken during testing.
Equipment drawings shall clearly indicate by a note, if tubesheet have been designed for
differential pressure. Drying out as per clause 9.1 below shall be carried out immediately after
hydro test.
7.2.2 All vertical exchangers shall be tested in vertical position. Alternately, exchanger may be tested
in horizontal position with test pressure modified with prior approval of Designer.
7.2.3 Stacked exchangers with nozzles interconnected shall be hydrotested in stacked

condition except when the hydrotest pressure of the individual exchanger is different.
8.0 STAMPING, NAME PLATES AND WARNING PLATES
8.1 Each exchanger shell shall be fitted with an SS nameplate.
8.2 Warning plates, if required, shall be provided.
8.3 The following exchanger parts shall have the item number stamped except for heat exchangers
in low temperatures service in which case the item number shall be marked with non-
removable ink:
Shell girth flanges, shell cover flange, channel girth flanges, flat channel cover, stationary and
floating tubesheet, floating head cover flange, floating head backing ring, connecting pieces,
test rings, test flanges and other main removable parts.
9.1 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.
Dry out shall be done simultaneously on both shell and tube sides. After drying, the equipment
2
shall be purged and filled with dry N2 at 0.25 kg/cm . The equipment shall be provided with
pressure gauge to monitor N2 pressure, and a ½” non-return valve.
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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 and
temporary gaskets and bolts adequate to maintain nitrogen pressure as above.
9.2 Shop painting
All CS and LAS external surfaces other than gasket faces and other machined surfaces shall
be given one coat of primer paint. Surfaces to be painted shall be prepared for painting by
removing loose mill scale, loose rust, oil, grease and other films or substances harmful to the
adhesion of paint by an approved method such as shot blast cleaning.
The surface shall be prepared to near white finish as per SSPC-SP-10 [SA 2 ½ Swedish
standard (SIS-05-5900)]. The shop primer shall be inorganic zinc silicate with 65-75 microns
dry film thickness, unless stated otherwise.
9.3 The equipment item number, Purchase Order (PO) number and Owner name and address
shall be painted in bold white paint letters written with stencil, on the heat exchanger.
9.4 Despatch of equipment
No heat exchanger shall be released for shipment until it has been approved by the Authorised
Inspector. Heat exchangers shall be despatched after the operations as required by clauses
9.1, 9.2 and 9.3 have been carried out and shall be despatched in as tested condition.
In case stacked exchanger shells are despatched separately the Vendor shall provide
additional set of gaskets for interconnected nozzles other than the gaskets included in spares.
SS shim plate sets shall also form part of supply for proper fixing of stacked units at
site.
Heat exchangers shall be securely anchored for despatch in order to prevent any shifting and
damage during transportation. Expansion joints and bellows, wherever used shall be suitably
protected against any possible damage by providing tie bars before boxing up.
Packaging shall be suitable for rail or road transport and also sea worthy if transported by sea.
Spares shall be despatched separately in a box and marked with PO number, item number and
Owner’s name and address.
Sling mark identification shall be provided by Vendor on all heat exchangers with respect to
center of gravity of the equipment.
No equipment shall be despatched until a written clearance is obtained from Owner or Jacobs
regarding Piping Clips and Structural Cleats on individual equipment.
The Vendor shall be completely responsible for the compliance to Code requirements, residual
design, detailing, fabrication, materials and workmanship of the exchangers as per the
stipulations of the requisition and its attachments. In this regard, it may be noted that review by
Owner or Jacobs shall not relieve the Vendor of his responsibility of meeting all requirements
and ensuring satisfactory performance of the equipment. Guarantee period shall be as per
Purchase Condition of Owner.
Page 422 of 441

INSTRUCTION FOR SUBMITTING DOCUMENT No.
OFFERS FOR SHELL AND TUBE HEAT A133-16-46-TR-6142
EXCHANGER Rev. A
INSTRUCTIONS FOR SUBMITTING

OFFERS FOR
SHELL & TUBE EXCHANGERS

JOB NO. : A133
Page 423 of 441

EXCHANGER Rev. A
GUIDE LINES TO VENDOR FOR SUBMITTING OFFER
BIDDING INSTRUCTION (CATEGORY - II)
1. BIDDERS TO NOTE THAT NO CORRESPONDENCE WHATSOEVER SHALL BE ENTERED INTO OR

ENTERTAINED AFTER THE BID SUBMISSION.
2. BIDDERS TO NOTE THAT A PREBID MEETING SHALL BE HELD IN WHICH BIDDERS CAN SEEK ANY
CLARIFICATIONS/CONFIRMATION IF REQUIRED, BIDDER TO ENSURE THAT THIS CONFERENCE IS
ATTENDED BY BOTH TECHNICAL AND COMMERCIAL PERSONNEL OF THE VENDOR WHO SHOULD
HAVE THOROUGHLY SCRUTINISED THE MR BEFORE HAND SO THAT ALL ISSUES ARE FINALY
RESOLVED IN THIS MEETING.
3. BIDDER SHALL FURNISH QUOTATIONS ONLY FOR THOSE ITEMS, WHICH HE CAN SUPPLY STRICTLY AS
PER MR SPECIFICATIONS.
4. IF THE OFFER CONTAINS ANY TECHNICAL DEVIATIONS AND/OR IF THE BID DOES NOT INCLUDE
COMPLETE SCOPE AND TECHNICAL/ PERFORMANCE DATA REQUIRED TO BE SUBMITTED WITH THE
BID, THE OFFER SHALL BE SUMMARILY REJECTED.
5. DEVIATIONS ARE NOT ACCEPTABLE IN GENERAL. HOWEVER, IF IT IS ABSOLUTELY NECESSARY,
BIDDER TO LIST THE DEVIATIONS IN DEVIATION SCHEDULE TECHNICAL FORMAT ONLY, DULY SIGNED
AND STAMPED, AND SUBMIT THE SAME ALONG WITH OFFER. DEVIATION SCHEDULE - TECHNICAL
FORMAT SHALL BE SUBMITTED DULY REPLIED WHETHER “DEVIATIONS” OR “NO DEVIATIONS”.
6. INSPECTIONS REQUIREMENTS SHALL BE AS PER CLAUSE 31.0 OF SPECIFICATION A133-16-46-SP-6142.
7. ANY DOCUMENT NOT RECEIVED BY BIDDER SHOULD BE OBTAINED PRIOR TO BID SUBMISSION.
8. BIDDERS SHALL NOT CONSIDER ANY EXCLUSIONS IN BID e.g. VALVES & INSTRUMENTS REQUIRED
FOR NITROGEN FILLING ELSE BID SHALL BE LIABLE FOR REJECTION.
9. ALL REQUIREMENTS AS PER MR DRAWINGS, STANDARDS, SPECIFICATIONS, CODES ETC. ATTACHED/
INDICATED WITH MR SHALL BE MET WITH.
10. SUBCONTRACTING OF THE ENTIRE / MAIN EQUIPMENT IS NOT ACCEPTABLE. SUBCONTRACTING OF
THE BOUGHTOUTS / COMPONENTS SHOULD BE DONE TO JACOBS APPROVED VENDORS ONLY. WHEN
NO LIST EXISTS FOR SUBVENDORS CONSIDER ONLY REPUTED VENDORS AFTER EIL/JACOBS
APPROVAL.
11. BIDDER SHALL SUBMIT SCOPE OF WORK AND SUPPLY (DOCUMENT NO: A133-16-46-SS-6142) DULY
SIGNED AND STAMPED ALONG WITH OFFER. BIDDER SHALL SUBMIT DULY FILLED-IN, SIGNED &
STAMPED UNIT RATES AS PER SHEET- 3 TO 4 OF SCOPE OF WORK & SYPPLY.
12. ALL DOCUMENTATION AS PER CLAUSE 34.0 OF SPECIFICATION: A133-16-46-SP-6142 SHALL BE
SUBMITTED ALONGWITH BID. BIDS WITHOUT THESE DOCUMENTS SHALL BE LIABLE FOR REJECTION.
Page 424 of 441

EXCHANGER Rev. A
2.0 DEVIATION SCHEDULE - TECHNICAL (SHELL & TUBE HEAT EXCHANGERS)
BIDDERs are requested to mark  thus as applicable

NO DEVIATION IS REQUIRED
DEVIATION IS REQUIRED
List of deviations (exceptions and/or additions requested by BIDDER) from specification, standards and/or drawings etc.
DEVIATION
SL.NO. DOCUMENT(S)/DRAWING(S)
PROPOSED
PARA GRAPH / CLAUSE / REASON
No. AND TITLE
DETAIL
NOTE: DEVIATIONS SHALL BE LISTED IN THIS FORMAT ONLY. DEVIATIONS APPEARING ELSEWHERE IN
THE OFFER SHALL NOT BE CONSIDERED
BIDDER'S NAME : :
BIDDER'S SIGNATURE :
WITH SEAL/STAMP
DATE :
Page 425 of 441

Page 426 of 441
Page 427 of 441
Page 428 of 441
Page 429 of 441
Page 430 of 441
SCOPE OF WORK & SUPPLY DOCUMENT No.
FOR SHELL & TUBE A133-16-46-SS-6142
DCU, CPCL PROJECT Page 1 of 4
SCOPE OF WORK & SUPPLY

FOR SHELL & TUBE HEAT EXCHANGERS

JOB NO. : A133
Page 431 of 441

SCOPE OF WORK AND SUPPLY
Bidder’s scope of work and supply shall be as follows: Bidder’s quotation shall consider
the same.
1. Complete mechanical design as per TEMA, ASME Sec. VIII Div.I & IBR and detail
engineering. Please note that IBR is applicable only for Item Tag- 086-E-25.
2. Complete equipment supply (total shells as specified) as per requirements of MR.
3. Supply of test ring & test flange
4. Supply of following commissioning spares:
Gaskets: 200% for each girth joint, nozzle with blind flange, interconnected nozzle and
companion flange
5. The weights indicated on EIL drawings do not form the basis for offer, since these are
approximations only.
6. Complete documentation including submission of design calculations, As-Built dossier,
QAP etc.
7. Inspection as per General Purchase conditions
8. Any other requirements specified in requisition.
Bidder to provide separate quote for following mandatory spares against Cl.4.00 of MR
(A133-086-EE-MR-6142):
Gaskets 400% gaskets (each type) for nozzles with BF, companion flanges, tube
sheet / girth joints of each size/type.
Bolting 20% (Minimum 4 Studs and 8 Nuts per joint) for nozzles with BF,
companion flanges, tube sheet / girth joints of each size/type.
QUATITY OF TEST RING AND TEST FLANGES:

SL.
ITEM NO. QUANTITY
NO.
NO. OF
NO. OF SHELLS NO. OF TEST
TEST
UNITS PER UNIT FLANGES
RINGS
1 086-E-25 ONE ONE ONE ONE
2 086-E-26 ONE ONE ONE ONE
NOTES:
1. The submission of prices by vendor shall be construed to mean that he has confirmed compliance with all
technical specification:
Vendor’s Name :
Vendor’s Signature :
With Seal/ Stamp
Date :
Page 432 of 441

PRICES FOR FUTURE ADDITIONS / DELETIONS OF CLEATS ETC.
DESCRIPTION PRICE LIST
1. Indicate charges for the following for future

addition/deletion of cleats etc. with material:
External support clips per Kg. Basis :
IS: 2062 GR B
SA 516 Gr. 60
SA 516 Gr. 70
2. Indicate charges for the following for future

addition/deletion of pipe davits etc with material
Pipe Davits for exchangers
SA 53
SA 106 Gr B
3. Addition/deletion of forging per kg. basis :
SA 266 Cl. 2
SA 266 Cl. 2+ S 31803 Clad
SA 266 Cl. 2+ S 32750 Clad
4. Addition/deletion of tubes per kg. basis :
SA-789 (UNS S32750)

SA-210 Gr.A1
The schedule of rates for addition / deletion of nozzles shall also be submitted as per sht. 4 of 5.
Vendor’s Name :
With Seal/ Stamp
Date :
Page 433 of 441

SCHEDULE OF RATES FOR ADDITION/DELETION OF NOZZLES

MATERIAL : KCS (As per respective datasheets)
CLASS 150 CLASS 300 CLASS 600
(WN RF FLANGE) (WN RF FLANGE) (WN RF FLANGE)
Nominal Without With Without With Without With
Size Blind Flange Blind Flange Blind Flange Blind Flange Blind Flange Blind Flange
1 ½"
2"
3"
4"
6"
8"
10"
12"
NOTES:
1. MATERIAL SPECIFICATION FOR NOZZLE COMPONENTS SUCH AS NOZZLE NECK, FLANGE.
REINFORCEMENT PAD, NOZZLE STIFFENERS, STUDS, NUTS AND GASKETS SHALL BE IN ACCORDANCE
WITH ENGINEERING DRAWINGS. NOZZLE REINFORCEMENT AND PROJECTION DETAIL CAN BE
WORKED OUT BASED ON DATA AVAILABLE IN EXCHANGER DRAWINGS IN THIS REQUISITION.
2. SCOPE OF SUPPLY OF NOZZLE COMPONENTS SHALL BE AS PER MATERIAL REQUISITION.
3. THE RATES QUOTED SHALL INCLUDE SUPPLY OF NOZZLE NECK, FLANGE STIFFENER, STUDS, NUTS
AND GASKETS (WHEN SUPPLIED WITH BLIND FLANGE) AND ASSOCIATED FABRICATION AND TESTING.
4. PRICES, IF VARYING, FOR VARIOUS NOZZLE NECK WALL THICKNESSES SHALL BE INDICATED
CLEARLY.
5. VENDOR MUST FILL-IN ALL THE COLUMNS MENTIONED ABOVE..
Vendor’s Name :
With Seal/ Stamp
Date :
Page 434 of 441

Page 435 of 441
Page 436 of 441
Page 438 of 441
Page 439 of 441
Page 440 of 441
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
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.
DCU
CPCL, MANALI
NEW DELHI
1
0
REV.

DATE
21.01.2014
01.10.2013
FOR
REVISION
TUBE LAYOUT
ITEM NO: 086-E-25

REISSUED FOR ENGG
ISSUED FOR ENGINEERING
BY
HG
HG
JSK
JSK
CHECKED
DRAWING NO.
SS
SS
APPD.
A133-086-05-45-4025
1
APPD.
REV.
1-1641-0504 REV.0 A4-210x297
Page 441 of 441

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M/s Client Chennai Petrochemical Corporation Limited

PRICED BID OPENING : DATE & TIME SHALL BE INTIMATED LATER

Bids should be submitted separately in two parts as follows:

Part-I : The techno-commercial Part consisting of following:

i) Offer Covering letter (in bidder’s letter head)

ii) Techno-commercial compliance to the RFQ terms & Conditions.

ix) Latest Complete Audited Balance Sheet.

xi) Integrity Pact (Clause # 22 of Special Commercial Notes to RFQ).

xii) Concurrent Commitment, in the format enclosed with RFQ

xiii) Technical Compliance/ datasheets/ documents, required as per Material Requisition.

Part-II : PRICED BID

Ms. Rekha Choudhary–AGM (C&P) ; Phone:011-26762071 ; E-mail: r.choudhary@eil.co.in

* Please specify Ref. No. (i.e. RFQ No.) in all correspondence

THIS IS NOT AN ORDER Very truly yours,

 Forms & Formats

Client : Chennai Petrochemical Corporation Limited

(To be pasted on the envelope containing Integrity Pact)

FAX Nos. : 00-91-11-26191714, 26167664

Engineers India Limited

Attn. : Ms. Rekha Choudhary – Asst. General Manager (C&P)

Further, our response is as under:- (Bidders to put a tick , as applicable).

1. We will submit the bid within due date.

2. We regret to submit our offer/quote because of the following reasons:

Very truly yours,

We……………………………………..hereby authorise following representatives (s) to attend the Pre-Bid

1. Name & Designation ………………………………Signature …………………………..

2. Name & Designation ……………………………… Signature …………………………

Name & Designation ……………….

For & on behalf of ………………….

RFQ No. : RC/A133-086-EE-MR-6142/0052

SIGNATURE OF BIDDER : _______________________

NAME OF BIDDER : _______________________

COMPANY SEAL : _______________________

RFQ No. : RC/A133-086-EE-MR-6142/0052

SL. REFERENCE OF RFQ DOCUMENT BIDDER'S QUERY EIL'S REPLY

SIGNATURE OF BIDDER : ___________________________

NAME OF BIDDER : ___________________________

RFQ No. : RC/A133-086-EE-MR-6142/0052

SL.NO REF. OF RFQ DOCUMENT SUBJECT DEVIATIONS

SIGNATURE OF BIDDER : _______________________

COMPANY SEAL : _______________________

RFQ No. : RC/A133-086-EE-MR-6142/0052

FULL POSTAL DATE OF

SIGNATURE OF BIDDER : _______________________

NAME OF BIDDER : _______________________

COMPANY SEAL : _______________________

23. INSTRUCTION FOR ENROLMENT OF BIDDER TO CPP PORTAL:

1.1 FOR INDIGENOUS BIDDERS:

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL- All rights reserved

T&C FOR ED COMMITTEE APPL- LSTK-A133

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL- All rights reserved

(viii) For all Site Fabricated Columns:

T&C FOR ED COMMITTEE APPL- LSTK-A133

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL- All rights reserved

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL- All rights reserved

least in Code-2 & manufacturing schedule through Wire Transfer.

T&C FOR ED COMMITTEE APPL- LSTK-A133

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL- All rights reserved

1.2.2 For supply of Mandatory Spares:

T&C FOR ED COMMITTEE APPL- LSTK-A133

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL- All rights reserved

2.1 INDIGENIOUS ENQUIRIES:

We __________ Bank _ a Bank incorporated/ constituted under the