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PRODUCT STANDARD TC ENGINEERING
HYDERABAD
TC 65436
Rev No. 01
Page 1 of 10
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HYDERABAD
Instruction to bidders:
1) Bidders are advised to contact BHEL for essential technical queries in writing within one week
of issue of Enquiry. Offers with incomplete information will not be considered for evaluation,
and are likely to be rejected without any further correspondence with the Bidder.
2) Unsolicited requests from bidders for alterations to their already submitted offer will not be
permitted. These would not be taken cognizance, and offers will be evaluated without taking into
account such requests/correspondence.
3) Any technical features over & above BHEL enquiry specification requirements proposed by
Bidder will not be given preference for the purpose of evaluation.
4) Bidders shall comply BHEL specifications in total. Incomplete offers will be rejected. In case
feasible deviations are proposed by the bidder and subsequently withdrawn, no commercial
implications can be claimed by the bidder.
5) The make of Bidder bought out items shall be as per vendor list. In case Bidder proposes
alternate make / model of bought out item due to non-availability of statutory certification etc.,
the same shall not be binding on BHEL. Such changes shall be explicitly listed in deviation list
with applicable price (for removal of the said deviation, if applicable) explicitly indicated (with
specific item no) in the PRICED price schedule.
6) In the event of any conflict between these specifications, data sheets, related standards, codes
etc. the bidder shall refer the matter to the purchaser for clarifications and only after obtaining
the same shall proceed with the manufacture / procurement of the items in question.
7) Bidder shall submit duly filled deviation format enclosed with this specification along with
technical offer, otherwise, it will be presumed that there are no deviations from this
specification. Offer without this deviation list will not be evaluated & shall be rejected. If, there
are no deviations, bidder shall submit signed copy of deviation format, mentioning “No
Deviations”.
8) Changes if any made by BHEL during technical evaluation on the specification requirements or
Bill of material, bidder is requested by the purchase to submit impact price (amount to be
reduced or increased to the original offered price) for those changed items only, other items for
which there are no technical changes, unit rates shall be maintained as it is.
9) In case of any technical query, bidders may contact the following BHEL engineer:
Name: Ramniwas Sangwa
Designation: Manager
Deptt: TC Engineering
Phone: +91 40 2318 3548
Email: [email protected]
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PRODUCT STANDARD TC ENGINEERING
HYDERABAD
TC 65436
Rev No. 01
Page 2 of 10
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HYDERABAD
TECHNICAL ADDENDUM FOR DRY GAS SEAL SKID
Project: HRRL DHDT RG Compressor
1 GENERAL
This specification is applicable for the variants mentioned in the table below and is an addendum to
TC55450-R03 (Specification for Dry Gas Seal Skids for Centrifugal Compressors). Vendor shall
explicitly bring out any conflict between this specification and its attachments with TC55450-R03.
2 VARIANT TABLE
Project Description Material Code Remarks
HRRL DHDT Recycle
Gas Compressor
Seal Gas Filter Skid TC9765436017
1) The Seal Gas system
consists of 01 set Filter
Skid and 02 sets of
Control Skids.
2) The skid rating shall
be 1500# for Primary
lines and 300# for
secondary / barrier lines.
Seal Gas Control
Skid TC9765436025
Seal Gas Skid Mand
Spares (as per price
schedule)
TC9765436033
Seal Gas Skid Loose
Spares (unused items
of Main + Spare
BOM, dispatch to
BHEL)
TC9765436041
3 DESIGN
3.1 The project specific requirements shall as per the following attachments:
Sl.
No. Description Document No.
a Seal Gas P&ID
Annexure-1. For reference only.
Condensate pot with drain On-Off valve is
not indicated, however it is required.
b TC55450-R03 Annexure-2.
c
d EIL specifications, ITP and datasheets Annexure-4.
e Additional Vendor List Annexure-5.
3.2 Vendor shall include automatic change-over arrangement (On-Off valve) from normal to
emergency / start up seal gas supply along with all the necessary instrumentation and
controls required during start-up & emergencies.
3.3 Valve positioner shall be supplied along with valve diagnostic software / valve signature in
USB. This software shall be integrated with customer control system for advance control
valve diagnostics like seat ring condition, gland packing condition, actuator leakage etc.
3.4 The primary seal gas supply lines along with all inline equipment & instruments shall be
min 2”. The gas velocity shall be limited to 30 m/s.
3.5 Vendors to note that the seal gas skid assembly may be changed to a single skid if accepted
by end user, however the same shall be informed only during detail engineering only. No
price or delivery implication will be accepted on account of this.
3.6 Vendor to refer DGS specification for all operating & design parameters.
Rev. No. Revisions Prepared Checked Approved Date
01 Revised RAVI IS RAM 20.03.2020
00 Issued RAVI IS RAM 14.02.2020
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PRODUCT STANDARD TC ENGINEERING
HYDERABAD
TC 65436
Rev No. 01
Page 3 of 10
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HYDERABAD
4 PROJECT SPECIFIC REQUIREMENT
4.1 For all other requirements, formats etc. refer Dry Gas Seal Skid specification TC55450-R03
along with the following project specific requirements.
Clause
No Existing To be replaced with
2.1-a Seal Gas P&I Diagram as per Variant
Table-4 of this specification Annexure-1
2.1-c List of Instruments, make & model as
per Table-1 of this specification As per this addendum.
3.3 NACE NACE MR 0103 is applicable
3.4 Piping material Complete skid piping / tubing material shall
be SS316L.
4.7 Filtration grade
SEAL GAS DUPLEX FILTER:
Filtration efficiency : 99.9 %
Particle efficiency : 1.0 micron
ßx ≥ 1000
SEC/BARR FILTER:
Grade of filtration : 1 μm
5.1
The Pipe sizes and terminal points shall
be as per the Seal Gas P&ID indicated in
variant table-4.
Refer 3.4 above. BHEL shall provide 2”
connection or higher if required for primary
seal gas.
5.4 Flange connection All flanges shall be WN RF / RJ
5.5 PMI & IGC PMI & IGC is applicable for all
instrumentation, piping items.
6.5 All the instruments and quantity shall be
as specified in Table-1. As per this addendum.
7 Instrument installation
The instrument installation shall be piping
standard. Primary inlet / vent / H2S service
shall be provided with double isolation
valves. N2 Lines may be provided with
tubing hookup.
6.6, 8.3 Foundation Fieldbus Applicable for Open and Closed loop DCS
instruments. FF JB by BHEL / Customer.
9 Documentation Vendor to include documents listed in this
specification.
10 Acceptance Criteria
The offered dry gas seal skid and panel shall
be field proven and similar to the specified
operating parameters as compared to at least
FIVE UNITS designed, manufactured,
tested and supplied by the proposed
manufacturer and at least TWO of these
units shall have completed at least ONE
year of satisfactory operation without any
major overhaul as on the bid due date.
Fig-1 to
5 Typical P&ID Annexure-1
Table-1 List of Instruments, make & model As per this addendum.
Table-4 List of variants As per this addendum.
Table-5 Price Schedule As per this addendum.
- Cleanliness Test No discoloration or hard articles found on
20 mesh screen after module blown for 5
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PRODUCT STANDARD TC ENGINEERING
HYDERABAD
TC 65436
Rev No. 01
Page 4 of 10
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HYDERABAD
Clause
No Existing To be replaced with
minutes with 7 kg/cm2g dry filtered gas.
14 Warranty / guarantee
All equipment / instrument supplied shall be
guaranteed upto 31st August 2023 is proved
under normal operating conditions to be of
inadequate design or of defective material or
of poor workmanship. In such event the
guarantee period for the particular
equipment / instrument shall be another 12
months from the date of acceptance by
PURCHASER / OWNER of such replaced /
repaired equipment / instrument. However,
extended guarantee period shall have an
upper limit till 31st August 2024.
15 Special requirement
Sourcing of any raw material or finish good
products, any testing and processing on
product (e.g. assembly) from China is not
allowed except for the following:
Instrumentation items (Field transmitters
like PT, PDT, LT, FT, TT etc. and Control
Valve Positioner) may have some internal
components / parts manufactured in
China, however the instrument supplier
shall not be from China.
5 SEAL GAS SKID DIMENSIONS & PIPING ORIENTATION
5.1 All the seal gas piping nozzles shall be terminated on top of the skids except drains.
5.2 Every effort shall be done to minimize the skid footprint. Efforts shall be made to minimize
the skid size to 2000 mm x 1500 mm (Filter Skid) & 1500 mm x 1000 mm (Control Skid).
5.3 Vendor shall further try to reduce the above indicated dimensions based on its 3-D modeling
of the skids.
5.4 Vendor shall submit seal gas skid 3D model in native file format for integration into BHEL
3D model of RGC Compressor House.
6 DOCUMENTATION
6.1 The following documents as a minimum shall be supplied by the vendor. The number of
hard copies & CD/DVD/USB shall be as per TC55450-R03.
a) As-built GA drawings.
b) As-built Instrument datasheets including instrument vendor datasheets, GA drawings
& sizing calculations.
c) Spares list.
d) Packing list.
e) Material test certificates.
f) Filter degree of filtration test certificate.
g) Explosion protection certificates for all electronic instruments.
h) Terminal wiring details of Junction Box.
i) Skid Photographs.
j) Instruction, Service and Maintenance manual.
k) Guarantee Certificates.
6.2 Three sets hard copies & one number CD/DVD/USB of the above documents shall be
submitted to BHEL prior to dispatch of the skids.
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PRODUCT STANDARD TC ENGINEERING
HYDERABAD
TC 65436
Rev No. 01
Page 5 of 10
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HYDERABAD
7 LIST OF INSTRUMENTS:
SL.
No. Instrument
Qty
Note
(2)
Minimum Specification Vendor Model
1
Differential
Pressure
Gauges
12
Differential Pressure Gauge
Vendor list Switzer 109-V-E-2-6-
0-S or eqv.
IP66; panel mount
Range: as required
Dial Size: 150mm
Pr.Conn. : ¼” NPTF
Static Pr. : 210 kg/cm2(g)
2 Pressure
Gauges 30
Pressure gauge
Vendor list
IP67; panel mount
Accuracy: ±1% of full scale
Range: as required
Dial Size: 150mm
Pr.Conn.: ½” NPTM
Case & Bezel: All SS
Construction
Wetted parts: *
Solid front type for seal gas
line. Liquid filled / with
pulsation damper.
Over range protection: SS316
3
Differential
Pressure
Transmitter
15
Smart-HART / FF
Protocol
Intrinsic safe Ex-ia /
FISCO & flameproof Ex-d
certified for IEC Zone1,
Gas IIA, B, C
Min Load: 600 ohms
All SS construction
Pr.Conn.: ½” NPTF
Accuracy: 0.075% of span
with TD of 1:10
Static Pr.: 210kg/cm2(g)
Integral LCD indicator
In built lightning & surge
protection
SIL certified for ESD /
PLC
Yokogawa / Eqv.
(refer vendor list
for restrictions &
additional vendors)
HART: EJA 110A E
H S4 GU 2 CEB
KU22 A D4 A1 M11
FF: EJA 110A FH
S4 GU 2 CDB A D4
A1 M11 EE FS15
(KS26 / SS25)
4
Pressure
Transmitter
40
Yokogawa / Eqv.
(refer vendor list
for restrictions &
additional vendors)
HART: EJA 430A E
* S4 GU 2 CEB
KU22 A D4 A1
DG6 M11
FF: EJA 430A F *
S4 GU 2 CDB A D4
A1 M11 EE FS15
(KS26 / SS25)
Note : * is as per
range
5 SMART
positioner
For
PDC
V &
On-
Off
valve
partia
l
stroke
test
Positioner with Intrinsic safe
Ex-ia & flameproof Ex-d
certified for IEC Zone1, Gas
IIA, B & C and metallic
housing.
‘Valve operating signature’ in
the form of hard copy and
CD’
Metso, Fisher,
Dresser, Flowserve
& Samson
HART: Metso ND930
* HXT or eqv.
Note : * is as per
requirement
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PRODUCT STANDARD TC ENGINEERING
HYDERABAD
TC 65436
Rev No. 01
Page 6 of 10
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HYDERABAD
SL.
No. Instrument
Qty
Note
(2)
Minimum Specification Vendor Model
6 Flow Meter 10
Internal magnetic float or
Rota meter design or an
integral orifice and
differential-pressure (DP) cell
/ thermal mass flow
Vendor list FF protocol
Range: as required
All other requirements same
as PT / DPT.
Pr.conn: Flanged
7 Junction
Box 8
SS316 / LM6 with SS316
cable glands Vendor list
8
Duplex filter
(Coalescing
type) with
changeover
transfer
valve
1 set /
2 set
With changeover valve
Startup diff. Pr.: *
Max. Pr. For change over: *
Filter vessel: SS316L Change
over valve: SS 316L
BOLL & KIRCH
FILTERBAU
GMBH.,
DONALDSON
INDIA FILTER
SYSTEMS
FLOWSERVE
SANMAR LTD.,
FORAIN SRL
HYDAC (INDIA)
PVT. LTD.,
INDUFIL BV.,
ITALVALV SRL
JOHN CRANE
SEALING
SYSTEMS
PALL INDIA PVT.
LTD.,
Filter sizing shall be as
per API614.
Vendor to provide
TWO separate Primary
seal gas Duplex filters
in case of possibility of
seal gas condensation
in any operating
scenario.
9 Pneumatic DP
control valve
02
nos.
Material of body: SS316 L
Vendor list
Material of Trim: *
ANSI / FCI 70.2 Minimum
class IV.
Noise level shall not exceed
85db. Source treatment for
noise shall be by using
special trims like anti-noise
trims; in case noise exceeds
the allowable level.
Bellow seal for corrosive &
toxic gases like H2S, H2 etc.
Actuator: Pneumatic
diaphragm
10
Secondary
and barrier
seal gas
filters
04
sets
Same as duplex filter, except
it is particulate filter.
Same as duplex
filter
11
Duplex
Pressure
regulator /
04
sets As per system requirement
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PRODUCT STANDARD TC ENGINEERING
HYDERABAD
TC 65436
Rev No. 01
Page 7 of 10
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HYDERABAD
SL.
No. Instrument
Qty
Note
(2)
Minimum Specification Vendor Model
PCV with
SS housing
and
changeover
transfer
valve
12 In line check
valves
As
reqd As per system requirement
Vendor list
13 Needle
valves
As
reqd As per system requirement
Vendor list
14
Instrument
root &
Isolation
valves
As
reqd As per system requirement
Vendor list
15 Tubes, Tube
fittings
As
reqd As per system requirement
Swagelok, Parker
Hannifin corp.
Additional vendor list
not applicable for this
item
16 Cable As
reqd Single pair 1.5 mm2. Vendor list
17
Change over
valve in
startup gas
&
Condensate
Drain valve
2no.
Full bore, On-off ball valve
Vendor list
ANSI / FCI 70.2 Minimum
class VI TSO.
The body as well as the
actuator shall meet the testing
requirements as per API 617
latest revision.
Actuator: Pneumatic cylinder
with spring return
SOV: 24VDC, IS, SIL 3
certified, Universal type,
class H insulation.
Proximity type IS SIL
certified limit switches, P&F
make
18 Temperature
Gauges
05
nos.
Bi-metallic thermometer,
every angle
Vendor list
IP67, direct mount
Accuracy: ±1% of full scale
Range: as per requirement
Dial Size: 150mm
Inst Conn: ½” NPTM bottom.
Case & Bezel: All SS
Construction
Solid front type for gas line
19
Temperature
Gauge
thermowell
05
nos
Instrument connection: ½”
NPTF
Vendor list
Refer EIL drawing
7-52-0035 Pr. Connections: 1-½”
flanged. Rating as per skid
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PRODUCT STANDARD TC ENGINEERING
HYDERABAD
TC 65436
Rev No. 01
Page 8 of 10
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HYDERABAD
SL.
No. Instrument
Qty
Note
(2)
Minimum Specification Vendor Model
rating. Line size shall be
blown to 6” for thermowell
mounting.
All SS316 Construction.
NACE certification
Bore dia: suitable for TG
20
Canopy for
all
transmitters,
positioners
& junction
boxes
As
reqd
Vendor list
21
LT for
condensate
Pot
1 no GWR
Vendor list
22 MIMIC
Panel 1 Set
Notes:-
1. All instrument makes shall be as per this list.
2. Any item not covered in this list shall be from a reputed manufacturer unless otherwise specified
in this specification elsewhere.
3. For the items, which are not covered in the list or vendors not indicated, vendor shall procure the
same from their standard sub-vendors.
4. Since the instrument quantity indicated in the above table is more than the numbers required as
per project specific P&I diagram, the additional quantity shall be supplied loose as LOOSE
SPARES.
5. All the items of the same type of instrument shall be of same make.
6. Additional Vendor List as attached.
7. In case the above listed quantity is less than that required by the vendor as per vendor proposed
P&ID, these additional instruments shall be considered by vendor.
8 DEVIATION FORMAT:
Bidder shall submit duly filled deviation format (as given below) along with technical offer,
otherwise, it will be presumed that there are no deviations from this specification. Offer without
this deviation list will not be evaluated & shall be considered for rejection. If, there are no
deviations, bidder shall submit signed copy of this format, mentioning “No Deviations”.
Sl. No. Clause No.
of Spec Deviation
Reason for
deviation
Deviation category
Product/design
limitation Optimization
1
2
9 CHECKLIST:
(TO BE FILLED BY THE VENDOR AND SUBMITTED ALONG WITH THE OFFER
WITHOUT WHICH OFFER WILL NOT BE CONSIDERED)
Sl.
No. Requirement
Vendor
Confirmation
YES / NO
a. Compliance to BHEL specification and its annexures.
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PRODUCT STANDARD TC ENGINEERING
HYDERABAD
TC 65436
Rev No. 01
Page 9 of 10
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HYDERABAD
Sl.
No. Requirement
Vendor
Confirmation
YES / NO
b. Deviation (if any) included in offer with reason.
c. Price implication for deviation removal is indicated in Priced offer in
case of any deviation.
d. Skid GA & BOM (with make/model) attached with technical offer.
e. Signed and stamped copy of BHEL specification attached with
technical offer.
f. Spares BOM (with make/model) attached with technical offer.
g. Price schedule attached with technical offer with ‘QUOTED’ marked
against each item.
h. PTR attached with technical offer.
10 SPARES PHILOSOPHY:
SL
NO SPARE ITEM DESCRIPTION / SPARE PHILOSOPHY QTY
a Seal gas filter element with gaskets / O-rings (1 set is equal to 100%
duplex filter replacement for complete skids): 6 Set.
1 set
b Local Gauges: DP, Pressure, flow, temperature, level etc.-10% or min 01
no. each type with all accessories
c Transmitters: DP, Pressure, Level, Flow etc.-10% or min.1 no. each
type with all accessories
d
Control valve & On-Off Valve, Pressure Regulating Valve (self-Actuated)
spares: 10 % or minimum 1 no of each type and size.
i. Trim consisting of seat, seat ring/ seal ring, plug with stem, cage
(wherever applicable), packing material.
ii. Positioners (Smart) with links of each type and make.
iii. Actuator Diaphragm.
iv. Solenoid valve (02 nos)
v. Proximity switch.
vi. Air filter regulators of each type and size.
vii. Bonnet Gaskets/ gland packing’s, piston O-rings, bearing & liner.
viii. Any special accessories provided along with the control valve like
boosters, position transmitters (wherever applicable), etc.
e
Instrument valves, manifolds & fittings:
i. Fittings, lugs, nipples, sockets, blinds, unions: 10% or min. 2 no each
type.
ii. ½”, ¾”, 1”, 1-½”, 2” (etc.) valves (Ball, Globe, Gate, Needle, NRV
etc.) : 10% or min. 1 no each type.
iii. 2 valve & 3 valve manifolds, isolation valves, instrument valves, tube
fittings, check valves, filter, regulator, orifice plates etc.: 10% or min.
1 no each type.
`
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PRODUCT STANDARD TC ENGINEERING
HYDERABAD
TC 65436
Rev No. 01
Page 10 of 10
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D.
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.
Ref
.
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c
HYDERABAD
11 PRICE SCHEDULE:
Enquiry ref. no. Date:
Offer ref no. Date:
Sl
no. DESCRIPTION Qty
TOTAL
PRICE
1. Seal Gas Control system consists of the following:
a SEAL GAS FILTER SKID HRRL: TC9765436017 1 set
b SEAL GAS CONTROL SKID HRRL: TC9765436025 2 set
c SEAL GAS SKID MAND SPARE HRRL: TC9765436033 (as per spares
philosophy listed above) 1 set
d
SEAL GAS SKID LOOSE SPARE HRRL: TC9765436041 (unsued
items of Main + Spare BOM, dispatch to BHEL, refer Notes-4 of clause
7)
1 set
2. Additional price to withdraw the deviations to following clauses:
<Vendor To Indicate Clause Nos>
3. Optional offer for addition of each of the following instrument
inclusive of root valves, piping & installation materials etc.
Optional price for
each item
a Filter cartridges / elements with gaskets / O-rings 1 set
b Pressure Transmitter 1 unit
c DP Transmitter 1 unit
d Pressure Gauge 1 unit
e Differential Pressure Gauge 1 unit
f Smart Positioner 1 unit
g Solenoid valve 1 unit
h Flow transmitter 1 unit
i Level transmitter 1 unit
j On-Off Valve 1 unit
k PDCV 1 unit
l PCV 1 unit
4. Pre-Commissioning, Commissioning Supervision
a Per diem for Commissioning activities for seal gas skid at site inclusive
of Travel, boarding, lodging, and local conveyance.
Per
diem
5. Total Price for Evaluation {1+2}
Notes:
i. The word ‘TYPE’ means the Make, Model no., Type, Range, Size/ Length, Rating, Material as
applicable.
ii. The individual prices for the spares and optional items above are valid for one year to order as
and when the requirement arises.
iii. Any additional requirements which are essential for proper functioning of the dry gas seal
system but not indicated in specification are included in the offer.
Vendor’s signature & seal
HRRL DHDT
TC65436-R01 Page 11 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 1 of 32
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SPECIFICATION FOR DRY GAS SEAL SKIDS FOR
CENTRIFUGAL COMPRESSORS
1. Scope
This specification covers the minimum requirements of design, detail engineering, fabrication
and supply of completely assembled Gas Seal Control System (with impulse piping, tubing and
wiring) for a Centrifugal Gas Compressor consisting of (a) Seal Gas Filter Skid & (b) Seal Gas
Control Skid compatible with Dry gas seals. The detail of the different operating cases, Gas
composition, ambient conditions and design parameters of the different lines, etc are furnished
in the project specific DGS specification which is a part of this enquiry.
2. Brief description of Seal Gas Filter Skid and Seal Gas Control Skid for Centrifugal
Compressor:
2.1 The Vendors minimum Scope of Supply and Work shall be as indicated below.
a) Seal Gas P&I Diagram as per Variant Table-4 of this specification.
b) Latest edition of API 614.
c) List of Instruments, make & model as per Table-1 of this specification.
2.2 The scope of supply shall include the following for each compressor:
1) Seal Gas Filter Skid
2) Seal Gas Control Skid
3) Mating flanges with gaskets, bolts and nuts at terminal points
4) Spare filter cartridges – 05 sets (Each set consists of number of cartridges required
for one Filter Bowl).
5) Loose supplied items like:
i. Interconnection pipes and fittings between both assemblies.
ii. Loose cable glands.
iii. Foundation bolts and accessories
iv. Instruments not mounted on the skids, etc.
v. Any other item in Vendor’s scope but not assembled on the skids
2.3 The function of the system is: -
- To supply and monitor process gas/ Nitrogen/ other gas, as applicable for primary
injection to dry gas seals.
- To supply and monitor Nitrogen/ start up gas for purging
- To supply and monitor Inert gas (Nitrogen) for Secondary seals
- To supply and monitor Inert gas (Nitrogen)/ Instrument Air for barrier seals
- To monitor primary gas leakage and initiate Alarms/Shutdown in response to
variation in leakage.
Rev. No. Revisions Prepared Approved Date
03 Refer to record of revisions RAM VVS 17/09/2010
TC65436-R01 Page 12 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 2 of 32
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2.4 The project specific P&I diagram shall be provided after the placement of the order during
the detailed engineering. The availability of the gas for start up in primary injection line and
barrier seal shall be finalized as per P&I diagram.
2.5 The total design and selection of the equipment of Seal gas filter skid and seal gas control
skid is the responsibility of the Vendor. The ranges and set values of the Instruments are to
be furnished by Seal Gas Control Skid & Seal gas filter skid Vendor for BHEL/Customer’s
review during detailed engineering after the placement of the order.
2.6 The primary seal gas line within filter skid shall be steam traced and insulated. All Piping,
Valves and fittings forming a part of steam tracing shall be IBR certified. The steam
parameters shall be provided during detailed engineering.
3. General arrangement of the skid Assemblies
3.1 Gas Seal Control System shall be designed as two Package Units: - a) Seal Gas control skid
and b) Seal Gas filter skid. Each skid shall be stand-alone type and shall be formed out of
suitable structural steel. A common skid shall be supplied in place of individual skids at a)
and b) above, whenever indicated in the enquiry.
3.2 Equipments, Instruments, Regulators, Shut off ball valves, Modulating valves, Isolating
valves, In-line check valves, Piping/Tubing with fittings, etc. shall be mounted and
assembled on the respective skid.
3.3 All the materials in contact with primary seal gas inlet and vent shall be of SS 316L or
Equivalent forging/casting materials and suitable for the gas composition specified in Dry
Gas Seal specification. Also ,they shall comply with NACE-MR-01-75 latest edition
3.4 All the materials in secondary seal inlet and vent lines, barrier seal inlet and vent lines shall
be of SS316 or Equivalent forging/casting materials.
3.5 Vendor to ensure that the Primary seal leakage to flare header lines along with the
instruments shall be designed for the design parameters of seal gas lines up to NRV.
3.6 Vendor to provide the condensing pot as per design code ASME VIII div I as required along
with control system instrumentation for automatic draining as part of scope of supply, for
variants as per Table-4. Also, vendor to check the requirement and indicate in their offer for
other variants in case of the following instances.
a) The gas passes through various elements in the system and shall be mixed with
Hydrocarbons, which may become condensed on cooling. The vendor to provide
suitable arrangement, if required to keep dryness in the gas in all operating
conditions and removal of condensate as required for seals. Vendor to provide DEW
point curve for our review along with the offer.
3.7 Whenever, the condensate pot is provided, the level transmitter shall be provided by
selecting either of the following options which shall be selected after the placement of the
order.
a) Guided wave radar type instrument shall be used for level measurement up to 1219
mm. For all level measurement above 1219 mm diaphragm seal type differential
TC65436-R01 Page 13 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 3 of 32
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nta
l to
the
inte
rest
of
the
co
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pressure transmitter shall be used. The Guided wave radar type level transmitter
shall be with flange size and rating suitable for the design pressure of the system.
b) The level transmitter using remote diaphragm sealed DP transmitter shall be with 3”
flange size and rating suitable for the design pressure of the system. The suitable
flushing rings along with drain & vent valves shall be provided.
3.8 Whenever, the condensate pot is provided, the following shall be provided.
a) A solenoid valve operated drain control valve with proximity type limit switches
designed for the condensate/oil flow envisaged for the project.
b) A level transmitter specified in 3.7 above.
c) A level gauge for local indication.
3.9 The Vendor shall note that the appearance engineering is one of the most important
aspects. The whole Rack shall be very compact and shall give an aesthetically good look as
this equipment is mounted on the operating floor of the compressor.
3.10 The Vendor shall take care of good accessibility for operation and maintenance of all parts.
The Instruments and Components disposition /location on the rack and Piping/Tubing layout
are paramount important aspect.
3.11 External paint shall be with the thickness 80-150 microns and internal paint shall be with the
thickness 40-60 microns. The project specific painting specification, if applicable shall be
provided during detailed engineering; vendor to carry out the same without any commercial
implication.
3.12 The Skids shall be provided with lifting lugs for a 4-point lift.
3.13 Foundation holes shall be oval in shape to help in installation.
4. Seal Gas Duplex Filter (Coalescing)
4.1 The Duplex gas Filter shall be coalescing type as per design code ASME VIII div I,
consisting of two filter bowls mounted in parallel with a change over valve. Each filter bowl is
100 % capacity. Clean Process gas is supplied to primary seal through a Duplex Filter with
required filtration grade for liquids and solids as required for DGS.
4.2 The collapsible pressure for the cartridge is min. 10 kg/cm2 (g) differential.
4.3 The Gas Pressure to Primary Seal is maintained 0.5 kg/cm2 (g) more than Operating Gas by
means of differential pressure controller and control valve.
4.4 While finalising the capacity (Flow) of Duplex Filter assembly, the maximum leakage through
the labyrinth into the compressor and the primary seal leakage indicated in DGS
specification shall be taken into account along with required margins.
4.5 The changeover valve is used for switching over from one filter bowl during operation so that
one filter open to operating gas flow and other closed off for changing filter elements. There
shall not be any reduction of flow during switching over operation. Arrows shall be provided
on filter assembly to indicate the filter in operation. The change over valve shall be of Trans
flow type. Double stage change over valve is preferred.
4.6 The filters shall be provided with drain and vent connections with valves.
TC65436-R01 Page 14 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 4 of 32
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ctly o
r in
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nta
l to
the
inte
rest
of
the
co
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info
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4.7 Filtration grade:
a) Solids: Beta 75(98.7% efficient) on 2 microns or greater.
b) Liquids : Beta 75(98.7% efficient) on 1 microns or greater.
5. Piping
5.1 The Pipe sizes and terminal points shall be as per the Seal Gas P&ID indicated in variant
table-4.
5.2 The exact pipe size and terminal points shall be finalised as per the project specific P&I
diagram provided during detailed Engineering after the placement of order.
5.3 Vendor shall supply the companion flanges, gaskets, O-rings, Stud nuts, etc. for all flanged
end connections.
5.4 All piping and other items shall be as described below
Item For rating upto
#300
For rating upto
#600
For rating #900 &
# 1500
Pipe Schedule Schedule 80 S Schedule 80 S Schedule 160 S
Flanges & 2” Valves # 300 RF # 600 RTJ
#900RTJ &
#1500RTJ as
applicable
Fittings & Valves
upto 1½” SW # 3000 rating SW # 3000 rating BW # Sch 160
Fittings for 2” BW # Sch 80 BW # Sch 80 BW # Sch 160
SS Piping/ Tubing
for instruments and
control valve
½” piping (schedule 80S) / 12.7x2.1 mm thk
Tubing for primary seal inlet and vent lines
( Please refer Table 4 and Material code for
requirement of Piping / Tubing against this
enquiry)
¾” piping (schedule
160S) for primary
seal inlet and vent
lines
12.7mm x 2.1mm thk for Secondary & Barrier seal lines
6mm x 1mm thk for pneumatic line for control valve
5.5 Materials shall be as described below. PMI to be done for all materials, fittings & weld
materials.
Item Seal gas inlet & vent
upto flare
Sec.seal inlet & vent Barrier seal inlet &
vent
Pipes and tubes SS 316L SS 316 SS316
Flanges & Valves SS 316L SS 316 SS316
Fittings SS 316L SS 316 SS316
Manifolds SS 316L SS 316 SS316
Filters SS 316L SS 316 SS316
5.6 The dimension of all fittings shall be as per ASME/ANSI standard.
5.7 In general, the following type of valves shall be provided.
a) For piping root valves Globe valves shall be used.
TC65436-R01 Page 15 of 227
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PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 5 of 32
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nta
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the
inte
rest
of
the
co
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b) For isolation, gate valves shall be used
c) For equalisation and bypass, globe valves shall be used
d) For instrument air, Ball valves shall be used
e) For throttling in secondary and barrier seal lines, needle/globe valves shall be used.
5.8 All Butt-welded joints shall be TIG welded and the welds shall be 100% radio graphed.
5.9 Vent/ Drain/ Any header shall be bigger in size than the individual lines connected to it.
5.10 Supports shall be provided for all items inclusive of pipelines/ tubing/instruments.
5.11 All lines shall be cleaned in order to remove all dust, rust, slag, and all other foreign
particles from internal and external parts.
5.12 All the vent/ drain holes, if any shall be plugged with threaded plugs/caps.
5.13 All the instruments shall be provided with individual root isolating valves. The double valves
shall be provided for all high-pressure (pressures more than 40 ata) isolation, equalization,
vent & drains.
5.14 Design pressure at 170o C of all piping, valves, fittings, instruments, filters shall be as
described below
Item For #300 rating For #600 rating For rating #900 &
# 1500
Primary seal inlet
and vent lines 30 Kg/cm
2(g) 60 Kg/cm
2 (g)
90 Kg/cm2 (g) for
#900 & 152
Kg/cm2(g) for
#1500
Secondary & Barrier
seal lines 20 Kg/cm
2 (g) 20 Kg/cm
2 (g) 20 Kg/sq.cm(g)
5.15 Hydro test pressures for seal gas filter skid and seal gas control skid shall be carried
out with water after the instrument dismounting and isolation of tubing line. After the
test the piping should be blown with air. The hydraulic pressure is as follows:
Item For #300 rating For #600 rating For rating #900 & #
1500
Primary seal inlet
and vent lines 60 Kg/sq.cm(g) 120 Kg/sq.cm(g)
180 Kg/cm2 (g) for
#900& 300 Kg/cm2(g)
for #1500
Secondary &
Barrier seal lines 30 Kg/sq.cm(g) 30 Kg/sq.cm(g) 30 Kg/sq.cm(g)
5.16 The items used for Seal gas inlet & vent upto flare, the following shall be strictly followed
a) All austenitic stainless steel grades shall be solution annealed after welding.
b) Ferrite No. Test: For all austenitic stainless steels, the weld deposit shall be checked
for ferrite content. Ferrite No. (FN) not less than 3% and not more than 10% is
required to avoid sigma phase embrittlement during heat treatment. FN shall be
determined by Ferrite scope prior to post weld heat treatment.
TC65436-R01 Page 16 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 6 of 32
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inte
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the
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c) All girth welded joints (longitudinal and circumferential) shall be 100% radiographed
in accordance with UW-51 of ASME Section VIII, Div-1 and ASME Section V.
d) VALVES:
i. All valve castings shall be of radiographic quality.
ii. All cast valve flanges & bodies with flange rating of Class 1500 shall be
examined in accordance with paragraphs 7.2 through 7.5 of Appendix-7 of
ASME SEC-VIII, DIV.1, regardless of casting quality factor.
iii. Body / bonnet / cover joints & stuffing box of all valves shall have low
emission and shall be helium leak tested as per ASME Sec.V, Subsection A,
Article 10 (Detector Probe Technique), Appendix IV at a minimum of 25% of
the allowable (rated) cold working pressure. Sampling for helium leak Test
shall be one valve selected at random for each item of the material
requisition. The failure of helium leak test shall call for testing of remaining
valves of that item at vendor’s cost. The valve shall show no leakage. No
leakage is defined as a total leakage rate of less than 0.0001 ml/s of helium.
Test Duration shall be 12 Minutes
iv. Casting and test bar shall be heat treated together. Valve casting shall be in
solution heat treated and pickled condition.
v. Critical body and bonnet casing section typically defined by ASME B16.34
shall be radiographed and shall meet ASTM E446 (upto 2" thick) Category
A,B & CA Level 2, Category CB, OC & CD Level 3, Category D,B & F
Level 0. For wall thickness 2" to 4.5" comparable plates of ASTM E186
shall be used. ASTM E94 and ASTM E142 shall be used for recommended
practice & controlling quality of radiography as guide. The entire surface of
all castings shall be dye-penetrant inspected after pickling.
vi. Repair welds shall be 100% radiographed and evaluated in accordance with
paragraph 344.5 of ASME B31.3 with a minimum casting quality factor of
0.95. Dye Penetration test shall be as per ASTM E165 Procedure B-2,
Interpretation as per Appendix-8 of ASME-VIII Div.1.
6. Instrumentation
6.1 The detailed technical specifications of Instruments, Filter Regulators, Valves, Junction
Boxes and other equipment shall be furnished by the vendor.
6.2 All instruments & junction boxes shall be weather proof to IP-65 and shall be certified
suitable for use in intrinsic safe circuit and explosion proof for area classification IEC Zone-1,
Gr. IIA, IIB and IIC, T3 certified by a statutory body.
6.3 All Instruments shall have internal terminal blocks of anti-vibration type for cable termination
suitable for terminating a minimum of 1.5sq.mm size cable conductors. Flying Leads are not
acceptable.
6.4 All the instruments shall have Proven Track Record of 8000 hours of successful
uninterrupted operation.
TC65436-R01 Page 17 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 7 of 32
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nta
l to
the
inte
rest
of
the
co
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6.5 All the instruments and quantity shall be as specified in Table-1.The project specific
requirements shall be finalised after the order placement. All the instruments shall be of
Smart type and compatible to Hart communication until and unless specified otherwise.
6.6 In some specific projects as indicated in variants of table-4, the transmitters connected to
DCS shall be of Foundation field bus type. The instruments and their accessories like field
bus cables, connectors, junction boxes, etc shall be supplied compatible for FF
Bus.(FNICO/FISCO)
6.7 Vendor to confirm compliance for the sub-vendors indicated as per Table-1. For the items,
which are not covered in the list or vendors are not indicated, vendor has to procure from
their standard sub-vendors
6.8 Vendor shall confirm that the bill of material furnished along with offer is only indicative and
the final BOM, which shall be furnished during detailed Engineering (after order placement)
for the approval of BHEL. The additional items, if any required for complying BHEL
specification at later stage or for the satisfactory working of the seals shall be supplied by
vendor without any price/delivery implications.
6.9 The body of the control valves shall be as per Piping Material Specification and as a
minimum trim shall be with stelliting.
6.10 The vendor shall furnish the following test certificates for the instruments
a) Calibration/ test certificates
b) Material test certificates
c) Sub-vendor conformity certificates.
d) Third part statutory certificates
6.11 Vendor shall submit necessary statutory body certificates for the instruments & Junction
Boxes, cable glands, etc from the following statutory authorities.
a) BIS (Bureau of Indian Standards)
b) CIMFR, Dhanbad
c) Petroleum and Explosives Safety Organization (PESO), Nagpur India (earlier CCOE)
Please note that the above are mandatory for all flame proof instruments of Indian origin.
6.12 Vendor shall submit necessary statutory body certificates for the instruments & Junction
Boxes, cable glands, etc from Petroleum and Explosives Safety Organization (PESO),
Nagpur India (earlier CCOE) in addition to the certificates from the country of origin for all
flame proof items of foreign origin.
6.13 All the Device Description (DD) and common file format (CFF) files for all HART and FF
instruments shall be supplied in CD/DVD for configuration.
6.14 The earth connections of all electrical components shall be brought to common bar for
further connection to earth pit at site.
6.15 Electrical Junction Box shall be with LM-6 body, 2Nos of Outlet Connections of 1½” NPT at
bottom and 12nos of Inlets of size ½” NPT. All inlets and outlets shall be complete with
double compression cable glands. Blanking plugs shall be provided for all spare
inlets/outlets. Material of cable gland shall be Nickel plated Brass material with PVC hood.
TC65436-R01 Page 18 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 8 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
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ime
nta
l to
the
inte
rest
of
the
co
mp
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is t
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Fo
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N o.
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. 5 T D
-
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TC
55450.
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Cable glands, JB’s and blanking plug shall be suitable for area Classification IEC Zone 1,
Gas IIA, IIB and IIC “EExd” type Cable OD for outlet gland shall be furnished during detailed
engineering. Telephone sockets and plugs shall be provided in JB. External paint shade
Light Blue Shade 101 as per IS 5.
6.16 Signal cable shall be as follows:
6.16.1. Single pair 7 stranded/ 0.53 mm dia (1.5 mm2) annealed tinned copper conductors of
electrolytic grade copper, PVC insulated.
6.16.2. FRLS type, armoured and of 1100V grade and shall meet insulation resistance,
voltage and spark test requirements as per BS 5308 part-2.
6.16.3. Conductors as per BS6360
6.16.4. Pr. Insulation: Fire retardant (FR) shall be as per standard IEC 60332.Shall have
mica insulation and shall be as per IEC-331 CAT –A type. Primary insulation and inner
jacket of polyethylene with maximum capacitance of 80 pf/m.
6.16.5. Conductor DC resistance at 20° C : ≤ 12.3 ohms / km ; Inductance : ≤ 0.9 μ H /Km
between conductors at 1000 HZ; Capacitance ≤0.06 μ F/ Km between conductors at
1000 Hz; Insulation resistance 100 M ohm / Km.
6.16.6. Color coding: Core insulation: Black & Blue; Inner Jacket: Black; Outer Jacket: Light
blue for intrinsically safe application and black for others.
6.17 Spur cable between FF instruments and FF JB shall be Type A as per IEC61158 part2.
7. Instrument Installation Standards
7.1 The Pressure & DP Gauges shall be grouped as per operational requirement and mounted
on the Gauge Board in the front side of the Skids.
7.2 All the instruments mounted on the skids shall be installed as per hook up diagrams (to be
furnished during the detailed engineering). Based on these, Vendor shall develop & submit a
tag number wise installation Standard (hook up) directory for all the instruments supplied/
mounted in the skids based on the above diagrams for BHEL/Customer approval.
7.3 The tubing for Control valves (from air filter regulator, I/P converter and control valve) shall
be of stainless steel tubing and the same is in vendor’s scope.
7.4 Integral manifolds shall be used if hook up is envisaged as tubing. Integral manifolds
shall be used in piping hook-ups for 300#.
7.5 If hook up is specified as “piping” in the variant table-4, the piping hookup with welded joints
shall be considered for primary seal gas inlet and vent lines. Installation of impulse lines
shall be as per piping class.
7.6 Tubing for impulse line to instruments shall be made of SS 316L (for primary seal gas inlet
and vent) or SS316 (for secondary seal inlet and vent, barrier seal inlet and vent) tube with
double compression fittings of “Swagelok”/”Parker” make and of material SS 316L (for
primary seal gas inlet and vent) or SS316 (for secondary seal inlet and vent, barrier seal
inlet and vent).
7.7 Instead of union; flange to be used in all impulse pipes and tubes irrespective of class.
TC65436-R01 Page 19 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 9 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
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me
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is t
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. 5 T D
-
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TC
55450.
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Ref. D
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. F
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7.8 For pipe class 600# and above, the impulse piping shall be as per pipe class. In these cases
no integral type manifold shall be used. 2-valve or 3-valve manifold shall be fabricated with
gate valve and pipe. Equalization with globe valve only. Closed coupled installation shall be
considered for high viscous services or hydrocarbons containing water for flow/pressure
transmitter. The size (NB) of impulse pipe shall be ¾” for corrosive/congealing and high
pressure services to avoid frequent chocking.
7.9 For pipe class below 600#, the impulse piping shall be as per pipe class. However small
portion of tubing from impulse line to transmitter shall be made of tube with double
compression fittings of “Swagelok”/”Parker” make. In those cases the tube material shall be
suitable for that process fluid condition. In these cases the transmitter with integral manifold
shall be used.
7.10 Bypass line with isolation valves must be provided for inline instruments like Rotameters,
Integral orifice, Control/On-Off valves.
7.11 For impulse line with viscous / congealing services a tee off with blind flange shall be
provided for cleaning purpose near to first isolation valve.
7.12 All the transmitters shall have horizontal impulse entry to have easy interchangeability.
7.13 The double valves (2 valves in series) shall be provided for all high-pressure (pressures
more than 40 ata) isolation, vent & drain application.
7.14 The instruments shall not be mounted directly on its hook-up. The instruments shall
first be mounted on gauge board / 2”pipe and then the hook-up shall be connected.
8. Electrical Installation
8.1 Junction boxes shall be weather proof to IP-65 and shall be certified suitable for use in
intrinsic safe circuit and explosion proof for area classification IEC Zone-1, Gr. IIA, IIB and
IIC, T3 certified by a statutory body, as specified in cause no 6.12.
8.2 Separate Junction box shall be provided for the following signals and grouping of
instruments shall be carried out accordingly.
a) Analog Signals for DCS
b) Analog Signals for PLC
c) Field Bus Signals
d) Proximity signals
e) Digital signals
f) Solenoid valves
g) Intrinsic/Explosion proof signals
8.3 Field bus junction boxes (FNICO/ FISCO/HPT).
a) Junction boxes shall be provided with wiring/ termination blocks.
b) Each Fieldbus junction box shall contain wiring terminal blocks for two Fieldbus
segments. Wiring / termination block for each segment shall have four spur
connections. However vendor shall use only three spur connections and one shall be
kept as spare for future connection.
TC65436-R01 Page 20 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 10 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
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me
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is t
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of
BH
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.
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NFID
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TI
AL
Fo
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N o.
R ev
. 5 T D
-
10 6- 1
TC
55450.
DO
C
Ref. D
oc.
C
CO
MP
. F
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FIL
E N
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c) In each Fieldbus segment, only one close loop can be connected (if applicable),
remaining spur connection in the segment can be used for open loop.
d) Wiring/ termination blocks shall have built-in short circuit protectors.
e) Vendor shall provide field terminator for each segment inside Fieldbus junction box.
f) The junction boxes shall have metallic enclosure.
8.4 Tag plates shall be provided for all the Equipment, instruments & cables. Cable tags shall be
provided for both ends.
8.5 All components (instruments, valves, cable glands, junction box etc.) shall be
identified by means of a plate placed on the structure with stainless material tearing
rivets. All instruments shall have a second stainless steel plate fixed to the
instrument body by means of a steel wire. The junction boxes shall be equipped with
a second plate fixed to its cover by means of an oil-proof adhesive (Loctite or similar).
ALL THE PLATES SHALL BE MANUFACTURED AND ENGRAVED ACCORDING TO
PROJECT SPECIFIC P&ID.
8.6 Identification ferrules and lugs for termination shall be provided at junction box end and
instrument end.
8.7 All the Electrical Instruments shall be neatly concealed wired and terminated in a local
junction box requiring only connection to purchaser’s wiring. The cable connecting the
instrument to junction box shall be armoured.
8.8 Stainless Steel perforated Cable Trays shall be used for cable laying. The edges of cable
trays shall be covered suitably using rubber sleeve.
8.9 The JB grouping and terminal allocation shall be as per BHEL cable schedule (provided
during detailed engineering).
8.10 Junction boxes will be installed on the side plates of the panel; the distance between
the bottom of these junction boxes and the ground must be at least 800 mm and 500
mm in case of adjacent boxes.
8.11 Seal gas gauge board shall be equipped with n°2 earthing bosses.
8.12 Inside each panel a SS bar measuring 16 mm2, rectangular-sectioned shall be
included for the connection of ground cables coming from the instruments or other.
9. The supplier shall furnish the following Documents
9.1 Along with offer:
a) Compliance for BHEL specification and its Annexures
b) Signed and stamped Filled up check-list (Table-2).
c) Price Schedule as per table-5.
d) Proven Track Record as indicated in Clause no 10.0.
e) Dew Point Curve.
9.2 Within 2 weeks of Placement of Order/ LOI:
a) Vendor shall visit BHEL office within one week of receipt of PO / LOI to collect the
project specific information for engineering their drawings / documents.
TC65436-R01 Page 21 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 11 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
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info
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me
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is t
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NFID
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AL
Fo
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N o.
R ev
. 5 T D
-
10 6- 1
TC
55450.
DO
C
Ref. D
oc.
C
CO
MP
. F
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FIL
E N
AM
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NA
ME
b) Vendor shall submit following in 10 sets for approval for the documents as mentioned
below within 2 weeks of Placement of PO /LOI:
i. General Arrangement drawing of Gas Seal Control System Skids giving
overall dimensions. It shall show location /disposition of various
equipments/Instruments on the Rack and location of customer termination
connection.
ii. Bill of Material of all the equipments, instruments, components etc. The Bill
of Material should clearly show the make and model of each component,
which are subjected to BHEL/CUSTOMER approval.
iii. Instruments Data sheets as per ISA format.
iv. Filled in dry gas seal system data sheet as per API format.
v. Quality assurance plan.
vi. Spares list
9.3 Final Documentation: Vendor shall furnish (17 sets of hard copies for a) to c) below + 2
DVD’s for all documents mentioned below)
a) Documents mentioned 9.2 above.
b) Terminal wiring details of Junction Box.
c) Instruction, Service and Maintenance manual
d) Test and Inspection reports : 3 copies
e) Guarantee Certificates : 3 copies
f) Photographs for all views : 2 sets (In DVD, the digital photos shall be provided).
10. Acceptance Criteria
10.1 The offered Dry Gas Seal system skids (Control system and filter) shall be proven and
validly similar to the specified operating parameters, process gas service, pressures and
configuration as compared to at least TWO UNITS designed, manufactured, tested and
supplied from the proposed manufacturing plant and at least one of these units shall have
been successfully operated in the field for at least 8000 hours of continuous operation
without any major overhaul as on the date of issue of enquiry.
10.2 Vendor shall furnish complete reference list / details (Proven track record) along with the
offer. These details shall include Plant name, year of commissioning, number of operating
hours completed and name of contact person(s) etc. for the skids similar to one being
offered.
11. Inspection and Tests
All the equipments shall be subject to inspection and witness tests by
BHEL/CUSTOMER/CONSULTANT. The schedule of quality checks shall be furnished by the
vendor in the quality plan which is subject to the approval of customer/consultant/ BHEL. The
minimum shall be as indicated in clause 12.0 below and Table-3 Quality Plan.
TC65436-R01 Page 22 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 12 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
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The
info
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is t
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Fo
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N o.
R ev
. 5 T D
-
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TC
55450.
DO
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Ref. D
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. F
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12. Material tests for filter and Changeover Valve for Duplex Filter (as a minimum)
Type of Check and
Test
Certificate
Designation
Type of Inspection
12.1 Chemical Analysis Mills Certificates
Verification of test
report certificates
by Lloyds
12.2 Mechanical Tests Certified check
by manufacturer
- do -
12.3
Non destructive Tests (as
per manufacturer’s
standard)
- do - - do -
12.4
Hydrostatic Test
(Filter Housing and valve
body)
Witness Lloyds
12.5 Degree of filtration
(filter element)
Certificate from
manufacturer
Verification of test
report certificates
by Lloyds
13. Marking and Shipping
13.1 Name plates
The Individual components shall be provided with Nameplates giving important details
like make, model etc. Each component shall be provided with stainless steel Tag plates
duly punching Tag Nos. as applicable on it.
13.2 Preparation for Shipment
a) Equipment shall be suitably prepared for shipment. The preparation shall make the
equipment suitable for 6 months of outdoor storage from the date of shipment.
b) Each assembly shall be marked with details like, drawing no, job number, PO No.
etc. at a convenient location.
c) Exterior carbon Steel surfaces shall be given at least two coats of Epoxy paint.
d) Flanges openings shall be provided with metal closures.
e) Pipe union openings shall be suitably closed with Swagelok (or Parker) fittings.
f) Lifting Points and lifting lugs shall be clearly identified.
g) All Loose supplied items like interconnection pipe and fittings between both
assemblies, loose cable glands, spare filter cartridges, foundation bolts, etc., which
are in Vendor’s scope shall be listed out separately in the packing list.
h) Adequate amount of silica gel or equivalent shall be provided in the box before
despatch for the removal of moisture till installation.
i) All safety instructions for storage and handling shall be indicated on external surface
of the box.
TC65436-R01 Page 23 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 13 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
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n o
n t
his
do
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me
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is t
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of
BH
AR
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. 5 T D
-
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TC
55450.
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Ref. D
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. F
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14. Guarantee
The Gas Seal Control System Skids and each component of the unit shall be guaranteed for 18
months of trouble free performance from the date of shipment or 12 months from the date of
commissioning whichever is earlier
15. Bids
Technical bids and Price bids are to be submitted in separate sealed covers. Un-priced copy of
the price bid shall be furnished along with Technical bid.
16. Services:
Vendor shall provide services of their engineers for commissioning of Gas Seal Systems at site
for 7 working days
17. Training:
Vendor shall at no extra cost to the purchaser, undertake to train 4 engineers selected by the
purchaser for a period of 5 working days at BHEL Hyderabad or Vendors works or site
18. SPECIAL NOTES
18.1 Vendor should bring out in his offer clause wise deviations if any, with respect to
proposed supply along with price adder for withdrawing the deviation to comply with
specification. Failure to highlight the same will be construed as acceptance on the
part of the vendor to meet the requirement of this specification totally.
18.2 Vendor shall provide the relevant technical information and supporting documents
whenever asked for by the customer/ consultant.
18.3 Vendor to clearly bring out any additional requirements which are essential for proper
functioning of the dry gas seal system. This shall be included in the offer.
TC65436-R01 Page 24 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 14 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
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tio
n o
n t
his
do
cu
me
nt
is t
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pe
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of
BH
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N o.
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. 5 T D
-
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TC
55450.
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Ref. D
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TC65436-R01 Page 25 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 15 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
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The
info
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n o
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his
do
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me
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is t
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of
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Fo
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N o.
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. 5 T D
-
10 6- 1
TC
55450.
DO
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Ref. D
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. F
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TC65436-R01 Page 26 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 16 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
rma
tio
n o
n t
his
do
cu
me
nt
is t
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pro
pe
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of
BH
AR
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Fo
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N o.
R ev
. 5 T D
-
10 6- 1
TC
55450.
DO
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Ref. D
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MP
. F
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NA
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TC65436-R01 Page 27 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 17 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
rma
tio
n o
n t
his
do
cu
me
nt
is t
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pro
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of
BH
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Fo
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N o.
R ev
. 5 T D
-
10 6- 1
TC
55450.
DO
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Ref. D
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MP
. F
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E
NA
ME
TC65436-R01 Page 28 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 18 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
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The
info
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n o
n t
his
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me
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is t
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of
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.
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AL
Fo
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N o.
R ev
. 5 T D
-
10 6- 1
TC
55450.
DO
C
Ref. D
oc.
C
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MP
. F
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FIL
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AM
E
NA
ME
TC65436-R01 Page 29 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 19 of 32
It m
ust
no
t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
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EN
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Fo
rm
N o.
R ev
. 5 T D
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Table 1: Technical Specifications of Instruments and other components (* Vendor to furnish Information along with offer)
SL. No.
Instrument Qty Note (2)
Minimum Specification Vendor Model
1
Differential Pressure Gauges
6 nos. Differential Pressure Indicator Switzer 109-V-E-2-6-0-S
IP66; panel mount
Range : *
Dial Size : 150mm
Pr.Conn. : 1/4”PT-F
Static Pr. : 210 kg/cm2(g)
2
Pressure Gauges
16 nos Pressure gauge GIC/ WIKA/ WAREE
IP67; panel mount
Accuracy: ± 1% of full scale
Range : *
Dial Size : 150mm
Pr. Connections: 1/2”NPT-M
Case and Bezel : All SS Construction Wetted parts : *
Gold plating for diaphragm seal type in seal gas line
Solid front type for seal gas line
Over range protection: SS316
3 Differential
Pressure Transmitters
6 nos
Smart (Hart Protocol/ FF) Transmitters
Emerson HART model: 3051CD 3A 07A1 J B7 KD L4 M5 Q4 QT T1 DF D1 TR Range : *
intrinsic safe & explosion proof IEC Zone 1,Gas IIA, B & C
FF model: 3051CD 3F 07 A1 J D01 B7 IE(or IA) L4 M6 Q4 T1 DF Min Load: 600 ohms
All SS construction
Pr. Connections: 1/2”NPT-F
Accuracy: 0.075% of span YIL HART model: EJX 110A EH S4 GU 2 CEB/ V1U/A /D4/A1
Min. Static Pr.: 210 kg/cm2(g)
LCD indicator FF model: EJX 110A FH S4 GU 2 CDB/ D4/ A / A1/ FS1(or KS2) / LC1/ D46
In built lightning & surge protection
Integral Manifold: SS 316L 3-way valve for DP and 2-way valve for pressure (Below 600# only. For 600# and above integral manifold not to be used) shall be included in the model number by the vendor
SIL certified( for HART)
4
Pressure Transmitters
21 nos (for fig. 2 & 4) 17 nos (for fig. 1, 3 & 5)
Smart (Hart Protocol/ FF) Transmitters
Emerson HART model: 3051CG X A 07A1 J B7 KD L4 M5 Q4 QT T1 DF D1 TR Note : X is as per range
Range : *
Others same as sl.no. 3 FF(FNICO/FISCO) model: 3051CG X F 07A1 J D01 B7 IE(or IA) L4 M6 Q4 T1 DF Note : X is as per range
TC65436-R01 Page 30 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 20 of 32
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l to
the
inte
rest
of
the
co
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an
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The
info
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tio
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his
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Fo
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N o.
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. 5 T D
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55450.
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YIL HART model: EJX XXX A E X S4 GU 2 CEB/ V1U/A /D4/A1 Note : X is as per range
FF model: EJX XXX A F X S4 GU 2 CDB/ D4/ A / A1/ FS1 (or KS2) / LC1/ D46 Note : XXX is as per range
5
Smart Positioner for DP control valve (sl.no 15)
1 no Smart(Hart Protocol/ FF) Positioner with dual certification (Explosion proof and Intrinsic safe) and metallic housing “Valve’s operating signatures” in the form of hard copy and also CD along with each control valve to be supplied with smart positioner.
Metso HART model: ND 930 X H X1 T Note : X as per requirement
FF model: ND 930 X F X1 T Note : X as per requirement
6
Flow Meters
4 nos Metal Tube Variable Area flow meter (with 2 electrical entries with 1 blind plug), 2 wire
Krohne H250/RR/X/MX/EG/ESK/ EEx Note : X as per requirement
SMART (HART protocol /FF )
Range : *
intrinsic safe & explosion proof IEC Zone 1,Gas IIA, B & C
7
Guided wave radar LT for drain pot
1no. Smart (Hart Protocol/ FF) Transmitters
Emerson or E&H or Magnetrol or Krohne
Pr.conn: Flanged
8
Diaphram seal type LT for drain pot
1 nos
Smart (Hart Protocol/ FF) Transmitters
Emerson HART model: 3051CD 2A 02 A1 J S2 B7 KD L4 M5 Q4 QT T1 DF D1 TR + 1199 WDF XX A FFW 76 DA A 9 H U + 1199 MDF XX A FFW 76 DA A 9 H U Note : XX as per requirement
Range : * FF model: 3051CD 2F 02 A1 J D01 B7 IE(or IA) L4 M6 Q4 T1 DF + 1199 WDF XX A FFW 76 DA A 9 H U + 1199 MDF XX A FFW 76 DA A 9 H U Note : XX as per requirement
Others same as sl.no. 3
Pr. Connections: 3” Flanged YIL Equivalent models for HART and FF
Flush flange with spacer ring minimum SS316 with Flushing / Filling Connection (1/2”size)
9
Magnetic level gauge for drain pot
1no. Body matl.: SS 316L Levcon or Chemtrols or Technomatic or Krohne
Pr.conn: 1” Flanged
The maximum visible range of a single gauge shall not exceed 1470 mm
TC65436-R01 Page 31 of 227
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PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 21 of 32
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l to
the
inte
rest
of
the
co
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an
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The
info
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tio
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his
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is t
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ED
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RIG
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Fo
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N o.
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. 5 T D
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55450.
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Ball check valve (offset design) required.
10
Drain valve for drain pot
1no. Smart/FF positioner as per sl.no 5
Others as per sl.no 15
11
Change over valve in startup gas
1no. On-off ball valve Flowserve or IL, palghat or Koso, palghat or Tyco
ANSI / FCI 70.2 Minimum class VI.
the body as well as the actuator shall meet the testing requirements as per API 617 latest revision.
Actuator: Pneumatic cylinder with spring return scotch yoke type
SS, Universal type, IS or Exp.proof (as per project reqt.), Voltage (as per project reqt.) Solenoid valve : Make: Norgren or ASCO
Proximity type IS SIL certified limit switches
12
---
5 nos Electrical Junction Box with LM-6 body
Baliga lighting or FCG flame proof control gears Or FCG Power Industries Or Flameproof Equipments P Limited
13
2 nos FF JB FF JB Loose supply by BHEL. Vendor to make provision for mounting the same.
14
Duplex filter (Coalescing type) with change over transfer valve
1 nos - Each filter 100% capacity with change over valve - Startup diff. Pr. : * - Max. Pr. For change over : * - Filter vessel : SS 316L - Change over valve : SS 316L
Forain Italy or Indfil Germany or Boll & kirch, Germany; or Hydac, Germany.
15
Pneumatically operated control valve for DP control valve
1 nos Material of body : SS 316 L Fisher- Sanmar or IL, Palghat or Dresser valve India Pvt Ltd.
Material of Trim : *
Suitable for use in IEC Zone 1,Gas IIA, and IIB & IIC area.
ANSI / FCI 70.2 Minimum class IV.
Noise level shall not exceed 85db. Source treatment for noise shall be by using special trims like anti-noise trims, in case noise exceeds the allowable level.
Bellow seal for corrosive & toxic gases like H2S, H2 etc.
Actuator: Pneumatic diaphragm/ cylinder with spring return scotch yoke type
TC65436-R01 Page 32 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 22 of 32
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ust
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e u
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dire
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r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
rma
tio
n o
n t
his
do
cu
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nt
is t
he
pro
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rty
of
BH
AR
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HEA
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CTR
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LS L
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Fo
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N o.
R ev
. 5 T D
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55450.
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16
Duplex Filter, regulator with SS housing and changeover transfer valve
2 nos. As per system requirement Norgren or Parker or or Boll & kirch, or Hydac
17
In line check valves
As per system requirement Audco or BDK or ATIPL
18
Needle valves As per system requirement Audco or BDK or ATIPL
19
Instrument root & Isolation valves
As per system requirement Audco or BDK or ATIPL
20
Tubes, Tube fittings and manifolds
As per system requirement Swagelok / Parker Hannifin corp.
21
Instrument cable
As reqd
Single pair 1.5 mm2.
22
Spur Cable for FF instr.
As reqd
Type A as per IEC 61158-2 Belden
Notes: (1) All instrument makes shall be as per this list. Any item not covered in this list shall be
from a reputed manufacturer unless otherwise specified in this specification elsewhere. For the items, which are not covered in the list or vendors not indicated, vendor has to procure from their standard sub-vendors.
(2) If the quantity indicated above is more than the numbers required as per project specific P&I diagram, the additional quantity with ranges same as used within skid shall be supplied loose.
(3) All the items of the same type of instrument shall be of same make.
TC65436-R01 Page 33 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 23 of 32
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ctly in
an
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etr
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nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
rma
tio
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his
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cu
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is t
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pro
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rty
of
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AR
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CTR
ICA
LS L
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CO
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Fo
rm
N o.
R ev
. 5 T D
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10 6- 1
TC
55450.
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Table 2: Check List (TO BE FILLED BY THE VENDOR AND SUBMITTED ALONG WITH THE OFFER WITH
OUT WHICH OFFER WILL NOT BE CONSIDERED)
Cl.no Description Vendor’s Confirmation
(Yes/No)
9.1(a) Compliance for BHEL specification and its Annexure
2.1 Compliance to clause no 2.1.
3.3,3.4,5.1,5.4 & 5.5
Compliance of materials and sizes to clause no 3.3, 3.4, 5.1, 5.4 & 5.5.
3.6(b) The DEW point curve enclosed along with the offer.
6.7 Compliance for the sub-vendors list indicated as per Table-1. For the items, which are not covered in the list or vendors not indicated, vendor has to procure from their standard sub-vendors. Vendor to confirm compliance for the same.
6.8 Vendor shall confirm that the bill of material furnished along with offer is only indicative and the final BOM, which shall be furnished during detailed Engineering (after order placement) for the approval of BHEL. The additional items, if any required at later stage for complying BHEL specification or for the satisfactory working of the seals shall be supplied by vendor without any price/delivery implications.
9.1(c) Price Schedule as per table-5 enclosed. Also, signed filled copy of Price schedule ( without prices) enclosed with technical offer
9.1(d) Proven Track Record as indicated in Clause no 10.0 enclosed.
18.3 Any additional requirements which are essential for proper functioning of the dry gas seal system included in the offer.
Vendor’s Signature Vendor’s Company seal
TC65436-R01 Page 34 of 227
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PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 24 of 32
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e u
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ctly in
an
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ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
rma
tio
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n t
his
do
cu
me
nt
is t
he
pro
pe
rty
of
BH
AR
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HEA
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ELE
CTR
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LS L
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.
CO
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RIG
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AN
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Fo
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N o.
R ev
. 5 T D
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TC
55450.
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Table – 3: Quality Plan Sl. No.
Description Type of check Quantum of check
100%
Ref. Documents
Type of Inspection
Agency
1
Assembly of Skids
- Location of equipment - Correctness of flow Schematics - Overall dimensions
- Approved GA drg. of Skids
Physical check
BHEL/ CUSTOMER
2 Welding (if applicable)
Type
Manufacturing drawings.
-Review of Radiograph certificate -Welding efficiency of 1
--Do--
3 Duplex Filter
- Material Certification - Hydrostatic test - Degree of filtration-Type Test
-BHEL/ CUSTOMER Specification - Approved drg./docts.
Verification of test report certificate
--Do--
4
Control Valves
- Calibration test certificate -Seat leakage test certificate -100% radiography test certificate (two shall be taken from each area to be tested) -magnetic particle test certificate -hardening test certificate -charpy test -confirmity test certificate -Material Certification - Explosion proof/ Intrinsic safe certification - Hydrostatic test - Control valve functional test
--DO--
- Verification - Review of Certificates
--Do--
5 Valves - Material Certification - Hydrostatic test - Control valve functional test
--DO--
- Verification - Review of Certificates
--Do--
6 Pressure Gauges, Diff. Pr. Gauges,
- Make, Model - Materials Certification
--DO--
--Do--
--Do--
TC65436-R01 Page 35 of 227
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PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 25 of 32
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ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
rma
tio
n o
n t
his
do
cu
me
nt
is t
he
pro
pe
rty
of
BH
AR
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CTR
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LS L
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.
CO
PY
RIG
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AN
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NFID
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Fo
rm
N o.
R ev
. 5 T D
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TC
55450.
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Diff. Pr. Transmitters, I/P converters, DP Switch, Pr. Switches, Junction Box, Flow meters
- Calibration certification - Explosion proof/ Intrinsic safe certification
7 Filter regulators, Valves
- Make, Model
--Do--
--Do--
--Do--
8 Piping/Tubing - Materials Certification
--Do--
- Review of Mills certificates
9 Pipe fittings and swagelok type fittings
- Materials Certification
--Do--
-Verifica- tion - Review of Certificates
--Do--
10 Instrument Hook-ups
- Material Certificate
--Do--
Review of certificates
--Do--
11 Line cleaning Compliance --Do--
Verification --Do--
12 Hydraulic Testing of Piping
- Leakage -Do-- Witness --Do--
13 HP test with Helium or Nitrogen as per API 614
- Leakage --Do-- Witness --Do--
14 Air Leak test for the Hydraulic tested lines
- Leakage --Do-- Witness --Do--
15 Name Plates - Correctness
--Do--
Physical check
--Do--
16 Painting - Pre-Treatment, Chemical Cleaning, Degreasing De-rusting and Phosphating - Two coats of Primer and Two coats of final Paint
- Thoroughness - Thoroughness
No Rust Finish
Physical check Physical check
Supplier
BHEL/CUSTOMER
17 Wiring - Continuity Wiring diagram
Verification --Do--
TC65436-R01 Page 36 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 26 of 32
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e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
rma
tio
n o
n t
his
do
cu
me
nt
is t
he
pro
pe
rty
of
BH
AR
AT
HEA
VY
ELE
CTR
ICA
LS L
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ED
.
CO
PY
RIG
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AN
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NFID
EN
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Fo
rm
N o.
R ev
. 5 T D
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TC
55450.
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Table – 4: Variant Table
VAR NO.
DESCRIPTION MATERIAL
CODE REMARKS
1 FILTER SKID- IOCL BARODA WGC TC9755450017
2 CONTROL SKID- IOCL BARODA WGC
TC9755450025
3 FILTER SKID- BPCL-NET GAS-LP TC9755450033
4 CONTROL SKID- BPCL-NET GAS-LP TC9755450041
5 FILTER SKID- IOCL BARODA VGO TC9755450050
6 CONTROL SKID- IOCL BARODA VGO TC9755450068
7 NOT USED NOT USED
8 CONTROL SKID- BPCL NET GAS-HP TC9755450084
9 FILTER SKID- BPCL-CCR(MOTOR) TC9755450092
10 CONTROL SKID- BPCL-CCR(MOTOR)
TC9755450106
11 FILTER SKID- IOCL VADODARA NHT TC9755450114
12 CONTROL SKID- IOCL VADODARA NHT
TC9755450122
13 FILTER SKID- CPCL DHDT TC9755450130
14 CONTROL SKID- CPCL DHDT TC9755450149
15 FILTER SKID- GGSR-HPCL MITTAL TC9755450157
16 CONTROL SKID- GGSR-HPCL MITTAL
TC9755450165
17 FILTER SKID- HMEL CCR TC9755450173
18 CONTROL SKID- HMEL CCR TC9755450181
19 FILTER SKID- HMEL DHDT TC9755450190
20 CONTROL SKID- HMEL DHDT TC9755450203
21 FILTER SKID- HMEL DCU TC9755450211
22 CONTROL SKID- HMEL DCU TC9755450220
23 FILTER SKID- ONGC TRIPURA TC9755450238
24 CONTROL SKID- ONGC TRIPURA TC9755450246
25 FILTER SKID- BRPL TC9755450254
26 CONTROL SKID- BRPL TC9755450262
27 FILTER SKID- MRPL DCU TC9755450270
28 CONTROL SKID- MRPL DCU TC9755450289
29 FILTER SKID- MRPL DHDT TC9755450297
30 CONTROL SKID- MRPL DHDT TC9755450300
31 FILTER SKID- GSFC-HP-2BCL 507 TC9755450319 As per CCI-MCA-1001-27
32 CONTROL SKID- GSFC-HP-2BCL 507 TC9755450327 As per CCI-MCA-1001-27
33 FILTER SKID- GSFC-BCL 407A TC9755450335 As per CCI-MCA-1001-27
34 CONTROL SKID- GSFC-BCL 407A TC9755450343 As per CCI-MCA-1001-27
35 FILTER SKID- GSFC-LP-2BCL 407A TC9755450351 As per CCI-MCA-1001-27
36 CONTROL SKID- GSFC-LP-2BCL 407A
TC9755450360 As per CCI-MCA-1001-27
TC65436-R01 Page 37 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 27 of 32
It m
ust
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t b
e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
rma
tio
n o
n t
his
do
cu
me
nt
is t
he
pro
pe
rty
of
BH
AR
AT
HEA
VY
ELE
CTR
ICA
LS L
IMIT
ED
.
CO
PY
RIG
HT
AN
D
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NFID
EN
TI
AL
Fo
rm
N o.
R ev
. 5 T D
-
10 6- 1
TC
55450.
DO
C
Ref. D
oc.
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37 FILTER SKID- MRPL CHTU TC9755450378 Item Same as M.code:
TC9755450904
38 CONTROL SKID- MRPL CHTU TC9755450386 Item Same as M.code:
TC9755450912
39 FILTER SKID- MRPL PFCCU TC9755450394 As per CCI-MCN-1001-27
40 CONTROL SKID- MRPL PFCCU TC9755450408 As per CCI-MCN-1001-27
41 SGS SKID- TABRIZ TC9755450416 As per CCI-CA217-27
42 SGS SKID- SPARES- TABRIZ TC9755450424 As per CCI-CA217-27
43 Shifted to Table-4
44 Shifted to Table-4
45 Shifted to Table-4
46
47
48
49
50
TC65436-R01 Page 38 of 227
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PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 28 of 32
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ust
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e u
sed
dire
ctly o
r in
dire
ctly in
an
y w
ay d
etr
ime
nta
l to
the
inte
rest
of
the
co
mp
an
y.
The
info
rma
tio
n o
n t
his
do
cu
me
nt
is t
he
pro
pe
rty
of
BH
AR
AT
HEA
VY
ELE
CTR
ICA
LS L
IMIT
ED
.
CO
PY
RIG
HT
AN
D
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NFID
EN
TI
AL
Fo
rm
N o.
R ev
. 5 T D
-
10 6- 1
TC
55450.
DO
C
Ref. D
oc.
C
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. F
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Table – 4: Variant Table
65 Spares for Seal gas filter skid and control skid
DCS Insts
FF Instruments
TC9755450653 Fig.1
66 Seal gas Filter Skid Rating #300
TC9755450661 Fig.1 Insts Hookup Piping
67 Seal gas Control Skid DCS Insts
FF Instruments TC9755450670 Fig.1
68
Spares for Seal gas filter skid and control skid
TC9755450688 Fig.1
69 Seal gas Filter Skid Rating #300
TC9755450696 Fig.2 Insts Hookup Tubing
70 Seal gas Control Skid DCS Insts FF Instruments
TC9755450700 Fig.2
Var No
Description Requirements Material code Reference P&ID
51 Seal gas Filter Skid Rating: #300
TC9755450513 Fig.1 Insts Hookup:
Tubing
52 Seal gas Control Skid DCS Insts: HART Protocol
TC9755450521 Fig.1
53
Spares for Seal gas filter skid and control skid
TC9755450530 Fig.1
54 Seal gas Filter Skid Rating: #300
TC9755450548 Fig.1 Insts Hookup:
Piping
55 Seal gas Control Skid DCS Insts: HART Protocol
TC9755450556 Fig.1
56
Spares for Seal gas filter skid and control skid
TC9755450564 Fig.1
57 Seal gas Filter Skid Rating: #300
TC9755450572 Fig.2 Insts Hookup: Tubing
58 Seal gas Control Skid DCS Insts:
HART Protocol TC9755450580 Fig.2
Startup Gas: With Changeover valve
59 Spares for Seal gas filter skid and control skid
TC9755450599 Fig.2
60 Seal gas Filter Skid Rating #300
TC9755450602 Fig.2 Insts Hookup Piping
61 Seal gas Control Skid DCS Insts
HART Protocol TC9755450610 Fig.2
Startup Gas: With Changeover valve
62 Spares for Seal gas filter skid and control skid
TC9755450629 Fig.2
63 Seal gas Filter Skid Rating #300 TC9755450637 Fig.1
64 Seal gas Control Skid Insts Hookup Tubing TC9755450645 Fig.1
TC65436-R01 Page 39 of 227
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PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 29 of 32
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Startup Gas With Change over valve 71
Spares for Seal gas filter skid and control skid
TC9755450718 Fig.2
72 Seal gas Filter Skid Rating #300
TC9755450726 Fig.2 Insts Hookup Piping
73 Seal gas Control Skid DCS Insts
FF Instruments TC9755450734 Fig.2
Startup Gas: With Changeover valve 74
Spares for Seal gas filter skid and control skid
TC9755450742 Fig.2
43 Seal gas Filter Skid
Rating #600
TC9755450432 Fig.3 Insts Hookup
Piping/Tubing
44 Seal gas Control Skid DCS Insts HART Protocol
TC9755450440 Fig.3
45 Spares for Seal gas filter skid and control skid
TC9755450459 Fig.3
78 Seal gas Filter Skid Rating #600
TC9755450785 Fig.3 Insts Hookup Piping/Tubing
79 Seal gas Control Skid DCS Insts
FF Instruments TC9755450793 Fig.3
80
Spares for Seal gas filter skid and control skid
TC9755450807 Fig.3
81 Seal gas Filter Skid Rating #600
TC9755450815 Fig.4 Insts Hookup Piping/Tubing
82 Seal gas Control Skid DCS Insts
HART Protocol TC9755450823 Fig.4
Startup Gas: With Changeover valve 83
Spares for Seal gas filter skid and control skid
TC9755450831 Fig.4
84 Seal gas Filter Skid Rating #600
TC9755450840 Fig.4 Insts Hookup Piping/Tubing
85 Seal gas Control Skid DCS Insts FF Instruments
TC9755450858 Fig.4
86 Spares for Seal gas filter skid and control skid
Startup Gas: With Changeover valve
TC9755450866 Fig.4
87 Seal gas Filter Skid Rating #1500
TC9755450874 Fig.3 Insts Hookup Piping
88 Seal gas Control Skid DCS Insts
HART Protocol TC9755450882 Fig.3
89
Spares for Seal gas filter skid and control skid
TC9755450890 Fig.3
TC65436-R01 Page 40 of 227
`
PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 30 of 32
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90 Seal gas Filter Skid Rating
#1500
TC9755450904 Fig.3
91 Seal gas Control Skid Insts Hookup
Piping TC9755450912 Fig.3
92 Spares for Seal gas filter skid and control skid
DCS Insts FF Instruments
TC9755450920 Fig.3
93 Seal gas Filter Skid Rating #1500 TC9755450939 Fig.5
94 Seal gas Control Skid Insts Hookup Piping TC9755450947 Fig.5
95 Spares for Seal gas filter skid and control skid
DCS Insts HART Protocol TC9755450955 Fig.5
Drain pot System
96 Seal gas Filter Skid Rating #1500 TC9755450963 Fig.5
97 Seal gas Control Skid Insts Hookup Piping TC9755450971 Fig.5
98 Spares for Seal gas filter skid and control skid
DCS Insts Drain Pot
FF Instruments system
TC9755450980 Fig.5
Table – 4-A: Variant Table
75 Seal gas Filter Skid Rating #900
TC9755450750 Fig.3 Insts Hookup Piping/Tubing
76 Seal gas Control Skid DCS Insts
HART Protocol TC9755450769 Fig.3
77
Spares for Seal gas filter skid and control skid
TC9755450777 Fig.3
TC65436-R01 Page 41 of 227
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PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 31 of 32
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Table-5 PRICE SCHEDULE
SEAL GAS CONTROL SYSTEM
Enquiry ref. No: Date: Offer ref no. Date:
Sl no. DESCRIPTION Qty PRICE
01 Seal Gas Control system consists of the following
1 set
a) Seal Gas Filter Skid
b) Seal Gas control skid
c) Filter cartridges – 5 sets
d) Matting flanges & accessories for all terminal points– 1 set
e) Loose supplied items
02 Seal Gas Control system Spares as per following
1 set
The word “TYPE”
means the make, model
no, range, size/length,
rating, material as applicable
a) Pressure Gauges, Differential Pressure Gauges, level gauges-10% or min 1 no. each type.
b) Transmitters (both Fieldbus and SMART) for Pressure, Level, Variable area Flow & Differential Pressure-10% or min.1 no each type.
c) Control valve spares-10% or min 1 no. each type of the following: i. Proximity type limit switches. ii. Airfilter Regulator. iii. Solenoid valve. iv. Bonnet Gasket/Special Gasket. v. Gland packing. vi. Stem seal o-rings/Piston o-ring. vii. SMART/Fieldbus positioner. viii. Trim set. ix. Diaphragm, actuator assembly
d) Manifolds- 3.way and 5 way, isolation valves, instrument valves, tube fittings, check valves, filter regulators -10% or min.1 no each type.
03 Optional offer for addition of each of the following instrument inclusive of root valves, piping, & installation materials etc.
a) Pressure Transmitter 1 set
b) DP Transmitter 1 set
c) Pressure Gauge 1 set
d) DP Gauge 1 set
e) Smart Positioner as per sl.no 5 of table-1 1 set
f) Solenoid valve. 1 set
g) Variable area Flow transmitter. 1 set
04 Additional price to with draw the deviations to following clauses:
Note:
(1) The individual prices for the spares and optional items against sl nos 02 and 03 above are valid for one year to order as and when the requirement arises.
(2) Any additional requirements which are essential for proper functioning of the dry gas seal system but not indicated in specification are included in the offer.
Vendor’s signature & seal
TC65436-R01 Page 42 of 227
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PRODUCT STANDARD TC-55450
TURBINES AND COMPRESSORS REV No.: 03
HYDERABAD Page 32 of 32
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Rev. No.
Date Revision Details Revised Approved
00 03.03.2008 New Standard -- AK
01 02.05.2009 Insulation requirement added RAM AK
02 13.12.2009 Generally revised and variants added VJK VVS
03 17.09.2010 Variants 43,44,45 added, Changes Highlighted
RAM VVS
TC65436-R01 Page 43 of 227
TC65436-R01 Page 44 of 227
ENGINEER INDIA LIMI
STED FOR VALVES
(A Govt of India Undertaking)
STANDARD SPECIFICATION No.
6-44-0052 Rev. 7 Page 1 of 12
TECHNICAL NOTES fg0j1 fetWeg
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
01/4 ‘)t.144<-1 MI RN
RN ATD SC DM ND
RN SC DM VC
RN BRB NS MI
AKG NS GRR AS
Prepared by
Checked by
Standards Committee Convenor
Standards Bureau
Chairman
7 13.07.17
6 04.08.10
5 04.07.08
4 15.11.00
3 04.04.94
REVISED AND ISSUED AS STANDARD SPECIFICATION REVISED AND ISSUED AS STANDARD SPECIFICATION REVISED AND ISSUED AS STANDARD SPECIFICATION REVISED AND ISSUED AS STANDARD SPECIFICATION
ISSUED IN LINE WITH GENERAL REVISION
Rev. No
Date Purpose
Approved by
vilcni rduAluiii*
TECHNICAL NOTES FOR VALVES
TC65436-R01 Page 45 of 227
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 2 of 12
TECHNICAL NOTES FOR VALVES
ENGINEERS taleg INDIA LIMITED
ailErf t-recnr11513‘grai (A Govt of India Undertaking)
Abbreviations:
AARH : Arithmetic Average Roughness Height ANSI American National Standards Institute API American Petroleum Institute ASME : American Society of Mechanical Engineers ASTM : American Society for Testing & Materials BGO Bevel Gear Operator BHN Brinnel Hardness Number BIS Bureau of Indian Standards BS • British Standard BVIS ▪ Bureau Veritas Industrial Services BW • Butt Weld CAT • Category CEIL • Certification Engineers International Limited CS Carbon Steel DFT Dry Film Thickness DNV Det Norske Veritas DP Dye-Penetrant eDMS : Electronic Document Management System IBR Indian Boiler Regulations IGC Inter Granular Corrosion IS Indian Standard LT • Low Temperature LTCS • Low Temperature Carbon Steel MOV • Motor Operated Valve MP • Magnetic Particle MR • Material Requisition NDT • Non Destructive Testing PMI • Positive Material Identification PO Purchase Order PR Purchase Requisition RFQ Request for Quotation SCRD : Screwed SS Stainless Steel SW Socket Weld
Piping Standards Committee
Convenor : Mr M. Ismaeel
Members : Mr. Amrendra Kumar Mr. G. Balaji Mr. Udayan Chakravarty Mr. K.J. Harinarayanan (S&ME) Mr. S. Ghoshal (Process-2) Mr. G.K. Iyer (Projects) Mr. Pankaj Kumar Rai (Construction)
Copyright EIL - All rights reserved Format No. 8-00-0001-F1 Rev. 0
TC65436-R01 Page 46 of 227
1f lots ENGINEERS TECHNICAL NOTES Igar 0151-e-G INDIA LIMITED FOR VALVES
tole,r rievore tri.ltrovn)
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 3 of 12
(A Govt of India Undertaking)
CONTENTS
1.0 GENERAL 4
2.0 DOCUMENTATION 4
3.0 DESIGN AND CONSTRUCTION 5
4.0 OPERATION 9
5.0 INSPECTION AND TESTING 9
6.0 RADIOGRAPHY OF CAST VALVES 10
7.0 IBR CERTIFICATION 11
8.0 MARKING 11
9.0 DESPATCH 11
10.0 ATTACHMENTS 12
11.0 REFERENCES 12
Format No. 8-00-0001-F1 Rev. 0
Copyright EIL — All rights reserved
TC65436-R01 Page 47 of 227
LIIdel ENGINEERS TECHNICAL NOTES $1gziT tif4leg INDIA LIMITED FOR VALVES
IA Govt of India Undertaking)
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 4 of 12
MIRFC eleax, 45134115-41)
1.0 GENERAL
1.1
Vendor shall supply valves in accordance with the valve specification sheets along with auxiliaries, if any, such as gear operator, bypasses, drains, locking arrangements etc. wherever specified in the specification sheets, subject notes and other enclosures to the material requisition (MR).
1.2 Vendor shall quote in strict accordance with the valve data / specification sheets, subject technical notes and all other enclosures to the MR. For 'Cat-I valves', no deviations whatsoever shall be accepted. Post Order Waiver/ Deviation format 5-0000-0180-F1 as mentioned in Cl. 5.17 of specification for Quality Management System Requirements from Bidder (6-78-0001) is not applicable for Cat-I valves. For Cat-II Valves, if exceptions/ deviations become absolutely must, the same shall be requested as explained in clause 2.3.6 giving reasons for seeking such exceptions/ deviations.
1.3 All codes and standards for manufacture, testing, inspection etc. shall be of latest editions as on issue date of RFQ.
2.0 DOCUMENTATION
2.1 All document submissions to EIL shall be through EIL eDMS.
2.2 For 'Cat-I' valves, no documents shall be submitted with the offer.
2.3 For 'Cat-IF valves, vendor shall submit the following documents with the offer:
2.3.1 Manufacturer's complete descriptive and illustrative catalogue / literature.
2.3.2 Detailed dimensioned cross section drawing with parts / material lists, weight etc.
2.3.3 Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator, motor, extension bonnet, extended stems with stands, bypass etc. giving major salient dimensions.
2.3.4 One copy of the valve specification sheets signed as "Accepted" by the manufacturer. Deviations, if any shall be marked as applicable on the valve specification sheet.
2.3.5 If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve specification sheets as "Regret" or "No Deviation".
2.3.6 For 'CAT-II' valves, if there is any deviation, the same shall be listed clausewise.
2.3.7 On failure to submit documents as specified in clauses 2.1.1 to 2.1.6 above, the offer is likely to be rejected.
2.4 The following documents shall be submitted through eDMS of EIL after placement of the order:
2.4.1 For Cat-I valves to manufacturers' standard specified in MR/valve specification sheet, detailed dimensioned cross section drawing with parts, materials, weight, etc. shall be submitted for records/information.
Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0
TC65436-R01 Page 48 of 227
laffaad ENGINEERS TECHNICAL NOTES $/fg-ar
kites INDIA LIMITED FOR VALVES (A Govt of India undertaking)
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 5 of 12
(Merl e4tax,...13,63.0
2.4.2 For 'Cat-II' valves, Vendor shall submit for review drawings mentioned in clauses 2.1.2 & 2.1.3 before start of manufacture. No other drawings shall be submitted for review.
2.4.3 Test report shall be supplied for all mandatory tests as per the applicable code. Test reports shall also be furnished for any supplementary tests as specified in clauses 3.13, 3.14 & 3.15.
2.4.4 Material test certificates (physical properties, chemical composition & heat treatment report) of the pressure containing parts shall be furnished for the valves supplied. Material test certificates for the other parts shall also be furnished for verification during inspection.
2.5 In addition to submissions through EIL eDMS, Catalogues/Drawings shall be in submitted in hard copies (6 sets) and soft copies (2 CDs/DVDs) along with delivery for Purchaser's record for all categories/types of valves.
3.0 DESIGN AND CONSTRUCTION
3.1 Valve shall be designed, manufactured, tested, inspected and marked as per the manufacturing standards, design codes and standards indicated in the respective valve specification sheets. Any conflict between the requisition, enclosures, specification sheets and referred standards/ codes shall be brought to the notice of the purchaser for clarifications and resolution, before proceeding with the manufacture. The purchaser's decision shall be final and binding to the vendor. The drawings submitted for review shall not include any deviations except as communicated in writing in Deviation permits. The Drawings shall be reviewed only for design and construction features.
3.2 All flanged valves shall have flanges integral (except forged valves) with the valve body. Flange face finish shall be normally specified in the valve specification sheet as 125 AARH etc. The interpretation for range of face finish shall be as follows:
Stock Finish
: 1000 p. in AARH max. 125 AARH
: Serrations with 125 to 250 p in AARH 63 AARH
: 32 to 63 p. in AARH
33 For all weld end valves with bevel end as per ASME B 16.25, the contour of bevel shall be as follows:
Material Wall Thickness Weld Contour
Carbon Steel (Except Low Temp. Carbon Steel)
Upto 22 mm Figure 2 Type A
> 22 mm Figure 3 Type A
Alloy Steel, Stainless Steel & Low Temp. Carbon Steel
Upto 10 mm Figure 4
> 10 mm & Upto 25 mm Figure 5 Type A
> 25 mm Figure 6 Type A
Valve ends shall match thickness of the connecting pipe. Sloping of inside contour of valves shall be done wherever necessary to achieve this.
Format No. 8-00-0001-F1 Rev. 0
Copyright EIL — All rights reserved
TC65436-R01 Page 49 of 227
ENGINEERS r..11 feitReg INDIA LIMITED
411M eiecnte J ,,RfrA IA Govt or India Undertaking)
TECHNICAL NOTES FOR VALVES
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 6 of 12
3.4 For flanged valves with ring joint flanges the hardness shall be as follows:
Flange Material Min. Hardness of Groove (BHN)
Carbon Steel 140
1% Cr to 5% Cr, 9% Cr 150
Type 304, 316, 321, 347 160
Type 304L, 316L 140
3.5 Following requirements for check valves shall be met over and above the valve specification sheet requirements:
3.5.1 Unless specified otherwise in the data sheet all check valves 3" & above (except in 900#, 1500# & 2500# rating) shall have a drain boss at location "G" (Refer Fig.No.1 of ASME B16.34) where pocket is formed in valve body. A tapped drain hole with plug shall be provided as per ASME B 16.34. Threads shall be as per ASME B 1.20.1 (Taper) NPT.
3.5.2 For heavy check valves, provisions shall be available for lifting by way of lugs, eye bolts and other such standard devices.
3.6 If an overlay weld-deposit is used for the body seat ring seating surface, the corrosion resistance of the seat ring base material shall be at least equal to the corrosion resistance of the material of the shell.
3.7 Following valve bypass requirements shall be met:
3.7.1 By-pass requirement for Gate valves shall be as follows unless otherwise mentioned.
ASME 150 Class ASME 300 Class ASME 600 Class ASME 900 Class ASME 1500 Class ASME 2500 Class
On sizes 26" and above On sizes 16" and above On sizes 6" and above On sizes 4" and above On sizes 4" and above On sizes 3" and above
3.7.2 The by-pass piping arrangement shall be such that clearance between main valve body and by-pass assembly shall be the minimum possible for layout reasons. Vendor shall follow the sketch enclosed in Specification No. 6-44-0052-Al.
3.7.3 By-pass valve shall be a globe valve. The sizes shall be as under:
On main valve 4" 1/2" On main valve 6" to 8" 3/4" On main valve 10" & above 1"
By-pass piping shall be of same metallurgy as main valve. The by-pass piping, fittings and valve tag numbers shall be as specified in Specification No. 6-44-0052-A2. In case details of by-pass arrangement for any Valve tag number is missing, Vendor shall bring the same to notice of EIL and provide by-pass as per details specified.
3.7.4 Vendor shall supply the by-pass valve duly tested and fitted to the main valve. Valves with by-pass shall have the direction of flow marked on the main valve. By-pass attachment to the
Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0
TC65436-R01 Page 50 of 227
,31 Ogell ttfaeg
IA Govt of India Undertaking)
TECHNICAL NOTES FOR VALVES
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 7 of 12
ENGINEERS INDIA LIMITED
main valve body shall not be screwed. All fillet welds for by-pass installation shall be 100% examined by DP/MP test and Butt-weld joints shall be 100% examined by radiography.
3.8 Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of casting but not vice-versa.
3.9 Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However, integral stem of cast material is acceptable for Plug valves.
3.10 Stelliting / hardfacing by deposition, shall be minimum 1.6 mm.
3.11 Renewable seat rings shall be seal welded for valves of size 3" and above to prevent loosening in service.
3.12 For Low Temperature & Cryogenic valve requirements, refer Specification.No.6-44-0052-A3 unless otherwise specified.
3.13 For Hydrogen service valve requirements, refer Specification.No.6-44-0052-A4 unless otherwise specified.
3.14 Valves under `NACE' category shall meet the requirements specified in MR-0103 unless otherwise specified.
3.15 For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall be conducted as per the following:
3.15.1 ASTM A262 Practice 'B' with acceptance criteria of '60 mils/year (max.)' for all materials -forged, rolled, wrought and casting.
Or ASTM A262 Practice `E' with acceptance criteria of 'No cracks as observed from 20X magnification' for all materials other than castings. 'Microscopic structure to be observed from 250X magnification' in addition.
3.15.2 When specifically asked for in MR for high temperature application of some grades of austenitic stainless steel (eg. SS309, 310, 316, 316H etc.) ASTM A262 Practice 'C' with acceptance criteria of ' 15 mils/year (max.)' shall be conducted.
3.15.3 For the IGC test as described in Clauses 3.15.1 & 3.15.2, two sets of samples shall be drawn from each solution annealing lot. One set shall correspond to the highest Carbon content and the other to the highest pressure rating. When testing is conducted as per practice `E', photograph of the microscopic structure shall be submitted for record.
3.16 All types of 321 or 347 stainless steel valves shall be in a stabilised heat treated condition. Stabilising heat treatment shall be carried out subsequent to the normal solution annealing. Soaking temperature and holding time for stabilising heat treatment shall be 900°C and 4 hours respectively.
3.17 Spiral wound bonnet gaskets are to be provided with inner/outer ring except when encapsulated gaskets type body-bonnet joints are employed. Outer ring may be avoided in case of non-circular spiral wound gasket used in 150# valve provided the outermost layer of spiral touches the bolts ascertaining the centering.
3.18 All Stainless Steel Castings shall be solution heat treated.
Format No. 8-00-0001-F1 Rev. 0
Copyright EIL —All rights reserved
TC65436-R01 Page 51 of 227
IrkRer eteakeott3tratTO (A Govt of India Undertaking)
101 tGI J ENGINEERS Ogen EtOleg INDIA LIMITED S TECHNICAL NOTES
FOR VALVES
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 8 of 12
3.19 Only normalized and tempered material shall be used in the following specifications :
Castings A217 Gr.WC1, A217 Gr.WC4, A217 Gr.WC5, A217 Gr.WC6, A217 Gr.WC9, A217 Gr.C5, A217 Gr.C12
Forgings : A182 Gr.F11 C1.2, A182 Gr.F12 C1.2
3.20 Ball / Plug / Butterfly Valves
3.20.1 As a prequalification, fire safe test as per API 607 / API 6FA / BS EN ISO 10497 (Supersedes BS 6755 Part II) shall be carried out on soft seated ball, plug & butterfly valves and also on lubricated plug valves The test shall be witnessed and certified by a third party inspection agency like Lloyds, BVIS, DNV or EIL/ CEIL unless otherwise specified. The vendor has to submit test certificate for the particular design of the valve offered, if fire safe design is required as per the Valve Material Specification sheet..
3.20.2 Each valve shall be supplied with a lever / wrench except for gear operated / motor operated valves.
3.20.3 Soft-seated ball, plug & butterfly valves shall be supplied with antistatic devices.
3.20.4 BW / SW end ball valves shall have a 100 mm long seamless pipe nipple welded to each end of the valve. Nipples are to be welded prior to assembling Teflon seats / seals. Specifications of the nipples shall be as indicated in the MR.
3.20.5 The face-to-face dimensions of all ball valves shall be same as those of gate valves of the corresponding ANSI class (except 10" onwards in Class 150 where the face-to-face dimensions shall be as per API 6D long pattern).
3.20.6 The ball of ball valve shall not protrude outside the end flanges of valve.
3.20.7 Ball valves shall be of floating ball/trunnion mounted type as per following:
150#
8" & below
Floating ball 10" & above
Trunnion mounted
300#
4" & below
Floating ball 6" & above
Trunnion mounted
600# 1.5" & below Floating ball & above 2" & above Trunnion mounted
3.20.8 Unless otherwise specified in the data sheets, bore of all reduced bore ball valves shall be limited to one size lower than the nominal bore.
3.21 The MOVs are to be installed in an open area and the actuators shall be suitable for all weather conditions. The testing of complete assemblies of MOVs along with the actuators shall be done by the supplier at his works.
3.22 Ends of flanged valves of 22" size shall match corresponding flanges to MSS-SP44 unless otherwise specified.
3.23 Yoke material shall be same as bonnet material where maximum temperature specified is more than 427°C.
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TC65436-R01 Page 52 of 227
ENGINEERS TECHNICAL NOTES /gar Ea& INDIA LIMITED FOR VALVES (A Govt. of India undertaking,
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 9 of 12
(ORR MEW MI 3‘17.3)
4.0 OPERATION
4.1 Gear operation shall be provided as under:
Valve Type Class Size Requiring Gear-Operator
Gate Valve, Globe Valve & Diaphragm Valve
150 Class 12" and larger
300 Class 12" and larger
600 Class 10" and larger
900 Class 6" and larger
1500 Class 3" and larger
2500 Class 3" and larger
Ball Valve / Plug Valve (Other than pressure balance plug valves)
150 Class 6" and larger
300 Class 6" and larger
600 Class 4" and larger
900 Class 3" and larger
1500 Class 3" and larger
Butterfly Valve 150, 300 Class 6" and larger
For sizes lower than these ranges, hand wheel / lever / wrench shall be provided. For pressure balance plug valves manufacturer's recommendation shall be acceptable provided the requirements specified in clause 4.6 are met.
4.2 Gear operator shall be provided, with position indicators for open / close positions and with limit stops. (Limit stops are not applicable for gate and globe valves).
4.3 Where gear operator is not called for as per Clause 4.1 but vendor recommends a gear operator, the same shall be highlighted.
4.4 Gear operator shall be so designed as to operate effectively with the differential pressure across the closed valve equal to the cold non-shock pressure rating.
4.5 Ball, plug and butterfly valves, shall have "Open" position indicators with limit stops.
4.6 Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on either side. Effort to operate shall not exceed 35 Kg at handwheel periphery. However, failing to meet the above requirements, vendor shall offer gear operated valve and quote as per clause 4.3.
5.0 INSPECTION AND TESTING
5.1 Every valve shall be subjected to all the mandatory tests and checks called in the respective codes / data sheet by EIL inspection or any third party as approved by the purchaser. For IBR valves refer clause 7.0.
5.2 Every valve, its components and auxiliaries must be subjected to all the mandatory tests and checks called for in the respective codes, data sheets etc. by the manufacturer.
5.3 Though the extent of inspection shall be as under, exact extent with hold points shall be decided by EIL regional inspection office and recorded in the form of inspection plan. In case of third party inspection, the inspection plan shall be approved by the purchaser.
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TC65436-R01 Page 53 of 227
Reie? ENGINEERS Ogelf idaeg INDIA LIMITED
eIreel ,tooe MI OW.) IA Govt of India Undertaking)
(7-A TECHNICAL NOTES FOR VALVES
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 10 of 12
Forged Valves:
1. Visual and dimensional inspection.
2. Review of material test certificates.
3. Any mandatory or supplementary test.
4. Hydrostatic test on 10% valves selected on random basis.
5. Strip check is required for 1% of total ordered quantity of Gate & Globe valves (min. 1 No.) for each Valve sheet no., however, strip check is not required for CS/ Brass/ Bronze material valves with 13% Cr/ Brass/ Bronze trims.
Cast Steel Valves:
1. Visual and dimensional inspection.
2. Review of material test certificates.
3. Review of radiographs/radiographic reports or any other NDT tests wherever applicable as per data sheet.
4. Any mandatory or supplementary test.
5. Hydrostatic test 100% for body, 10% other test.
6. Strip check is required for 1% of total ordered quantity of Gate & Globe valves (min. 1 No.) for each Valve sheet no., however, strip check is not required for CS/ Brass/ Bronze material valves with 13% Cr/ Brass/ Bronze trims.
Samples for strip check shall be selected at random and shall generally be in the highest size in the lot.
5.4 In case of motor operated or actuator operated valves, functional / operational checks as per the requirements of the specifications shall be made on each valve.
6.0 RADIOGRAPHY OF CAST VALVES
6.1 Valve castings shall undergo radiographic examination as specified below.
Material Rating Size Range Radiography
All 150# 24" and below NIL**
26" and above* 100%
300# 16" and below NIL**
18" and above 100%
600# & above All sizes 100%
* No radiography is required for valves of size 26" and above in cooling water service.
**For sizes 24" & below in 150# and 16" & below in 300#, radiography percentage if specifically mentioned in individual valve material spec sheet shall govern.
Radiography specified as random 10% or 20% etc. in the respective valve data sheet implies 10% or 20% etc. of number of valves ordered against each item number with a minimum of one valve against each item.
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rn~rel fEff5teg
ENGINEERS TECHNICAL NOTES INDIA LIMITED (A Govt of India Unclertalcing)
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 11 of 12
FOR VALVES
6.2 Radiography procedure, areas of casting to be radiographed shall be as per ASME B 16.34 and acceptance criteria shall be as per ASME B 16.34 Annexure-B. However for areas of casting to be radiographed for types of valves not covered in ASME B 16.34, vendor shall radiograph castings in line with ASME B 16.34.
6.3 For random radiography wherever specified in individual data sheets, the sampling shall be per size of the quantity ordered for each foundry.
6.4 Radiography wherever specified in the data sheets or as per clause 6.1 shall be done by X-ray / 'y-ray to get the required sensitivity.
7.0 IBR CERTIFICATION
7.1 For valves described "IBR", valves shall be in accordance with the latest IBR (Indian Boiler Regulation) including the requirements specified in the specification.
7.2 For SW / BW end carbon steel valves under IBR, the chemical composition shall conform to the following:
Carbon (Max) Others (S, P, Mn)
0.25% As per IBR
7.3 Valves coming under the purview of "IBR"(Indian Boiler Regulations) shall each be individually accompanied by IBR certificate original in Form III-C duly approved by IBR authority / local authority empowered by the Central Boiler Board of India. Photocopy of original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance.
7.4 All "IBR" valves shall be painted red in body-bonnet / body-cover joint.
8.0 MARKING
8.1 Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the standard referred in specification sheet as applicable. Vendor's name, valve rating, material designation, nominal size, direction of flow (if any) etc. shall be integral on the body.
8.2 Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely attached to the valve body.
8.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead or copper which cause corrosive attack on heating.
8.4 Carbon Steel / Alloy Steel valves shall be painted with one coat of inorganic zinc silicate (minimum DFT 65 to 75 microns).
9.0 DESPATCH
9.1 Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.
9.2 Valves shall be protected from rust, corrosion and any mechanical damage during transportation, shipment and storage.
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,511faeie`i Q41 k1Rs
ENGINEERS TECHNICAL NOTES INDIA LIMITED (A Govt of India Undertaking)
STANDARD SPECIFICATION No.
6-44-0052 Rev.7 Page 12 of 12
Lfth FOR VALVES
9.3 Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum solvent or shall not be harmful to welding.
9.4 Each end of valve shall be protected with the following materials:
Flange Face
Wood or Plastic Cover Bevelled End
Wood or Plastic Cover SW & SCRD. End
Plastic Cap
9.5 End protectors of wood / plastic to be used on flange faces shall be attached by at least three bolts and shall not be smaller than the outside diameter of the flange. However, plastic caps for SW & SCRD end valves shall be press fit type.
9.6 End protectors to be used on bevelled end shall be securely and tightly attached.
9.7 For special service valves additional requirement for despatch shall be as prescribed in data sheet.
10.0 ATTACHMENTS
6-44-0052-A 1 Bypass Piping Arrangement
6-44-0052-A2 Specifications for Bypass Piping, Fittings and Valves
6-44-0052-A3 Special Requirements for Low Temperature and Cryogenic Valves
6-44-0052-A4
11.0 REFERENCES
6-78-0001
6-78-0003
6-81-0001
6-81-0004
Special Requirements for Hydrogen Service Valves
Specification for Quality management system requirements from bidders
Specification for documentation requirements from suppliers
Specification for Positive Material Identification (PMI) at Supplier's Works
Inspection and Test plan for Valves
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L2 Pipe bend
L7 (minimum)
Bevel Gear Operator (BGO)
L6
L5
L4 300 mm (approx.)
for BOO valves Globe valve as per spec. sht. indicated in the MR.
L3
ote-8
150 mm (approx.)
for non-BOO valves
Flow
L1 (minimum possible)
The orientation & location of handwheel of bevel gear operator & the bypass arrangement shall be strictly as per this sketch.
NOTES : 1.
1514-zA ENGINEERS BYPASS PIPING 51guttf54-ag INDIA LIMITED ARRANGEMENT (4.,,,,,N,L15,78..) (A Govt of India Undertaking)
STANDARD SPECIFICATION No.
6-44-0052-Al Rev.7 Page 1 of 1
BYPASS PIPING ARRANGEMENT
2. The bypass connection ends shall be socket welded upto 600# and butt welded for 900# and above rating.
3. The bypass arrangement shall be properly clamped to & supported by the body of the main valve.
4. Basic design of bypass shall be to MSS-SP-45.
5. Material of bypass pipe & 90° elbows shall be same or equivalent to the body material as indicated in Specification No. 6-44-0052-A2.
6. This sketch is applicable for both BGO & NON-BGO Valves.
7. Vendor shall furnish dimensions Ll to L8.
8. Stem shall not be horizontal in the case of CRYO Valves
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ENGINEERS SPECIFICATIONS FOR BYPASS STANDARD SPECIFICATION No.
INDIA LIMITED PIPING, FITTINGS AND VALVES 6-44-0052-A2 Rev.7 (A Govt of India Undertaking)
Page 1 of 3
SPECIFICATIONS FOR BYPASS PIPING, FITTINGS AND VALVES
Class (Main Valve Sht.no.) Pipe Fittings Bypass Valve
Sht.no. A1A(51301), A3A(51321), A9A(51301), A10A(51301), Al 1A(51301), A33A(51301), B1A(51401), B9A(51401), D1A(51501), D9A (51501)
ASTM A106 Gr.B (SMLS) 0.5"-0.75": S160 1.0"-1.5" : XS
ASTM A105 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52001
A6A(51301), B6A(51401) ASTM A106 Gr.B (SMLS) 0.5"-0.5" : XXS 0.75"-1.5": S160
ASTM A105 0.5"-0.5" : SW 9000# 0.75"-1.5": SW 6000#
52001
A13A(51301), B13A(51401) ASTM A106 Gr.B (SMLS) 0.5"-1.5" : XXS
ASTM A105 0.5"-1.5" : SW 9000#
52001
A2A(51302), B2A(51402), D2A (51502)
ASTM A106 Gr.B (SMLS)- IBR 0.5"-0.75": S160 1.0"-1.5" : XS
ASTM A105 - IBR 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52002
A4A (51303), B4A (51403), D4A (51503)
ASTM A333 Gr.6 (SMLS)- LT 0.5"-0.75": S160 1.0"-1.5" : XS
ASTM A350Gr.LF2- LT 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52003
A5A (51304), BSA (51404), D5A (51504)
ASTM A106 Gr.B (SMLS) -H2 0.5"-0.75": S160 1.0"-1.5": XS
ASTM A105 - H2 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52004
A7A (51307) ASTM A106 Gr.B (SMLS) 0.5"-0.75" : S160 1.0"-1.5": XS
ASTM A105 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52007
Al6A (51311), B16A (51411), D16A (51511)
ASTM A106 Gr.B (SMLS) - NACE 0.5"-0.5" : XXS 0.75"-1.5": S160
ASTM A105 - NACE 0.5"-0.5" : SW 9000# 0.75"-1.5": SW 6000#
52011
A19A (51313), B19A (51413), D19A (51513)
ASTM A106 Gr.B (SMLS) 0.5"-0.75" : 5160 1.0"-1.5": XS
ASTM A105 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52013
ElA (51601), FlA (51701) ASTM A106 Gr.B (SMLS) 0.5"-1.5" : S160
ASTM A234 Gr.WPB/ ASTM A105 0.5"-1.5" : BW, S160
52101
E2A (51602), F2A (51702) ASTM A106 Gr.B (SMLS) - IBR
1.5 S160 0.5"-" :
ASTM A234 Gr.WPB/ ASTM A105 - IBR 0.5"-1.5" : BW, S160
52102
E5A (51604), F5A (51704) ASTM A106 Gr.B (SMLS) - H2 0.5"-1.5" : S160
ASTM A234 Gr.WPB/ ASTM A105 - H2 0.5"-1.5" : BW, S160
52104
E9A (51605), F9A (51705)
ASTM A106 Gr.B (SMLS) 0.5"-1.5" : SCH XXS
ASTM A234 Gr.WPB/ ASTM A105 0.5"-1.5" : BW, SCH XXS
52105
E19A (51613), F19A (51713)
ASTM A106 Gr.B (SMLS) 0.5"-1.5" : SCH XXS
ASTM A234 Gr.WPB/ ASTM A105 0.5"-1.5" : BW, SCH XXS
52113
I etecnie ref 34ore)
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STANDARD SPECIFICATION No. 01 el ENGINEERS SPECIFICATIONS FOR BYPASS
INDIA LIMITED PIPING, FITTINGS AND VALVES 6-44-0052-A2 Rev.7 (A Govt of India Undertaking)
Page 2 of 3
Class (Main Valve Sht.no.) Pipe Fittings Bypass Valve
Sht.no.
A5Y (51384), A33Y (51384) ASTM A106 Gr.B ;(SMLS) 0.5"-1.5" : S160 '
4
ASTM A105 0.5"-1.5" : SW 6000# 52085
MD (51330), BM (51430), D1D (51530)
ASTM A335Gr.P11(SMLS) 0.5"-0.75" : S160 1.0"-1.5": XS
ASTM A182 Gr.F11C1.2 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52030
D2D (51531)
ASTM A335Gr.P11 (SMLS) - IBR 0.5"-0.75" : S160 1.0"-1.5": XS
ASTM A182 Gr.F11C1.2 - IBR 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52031
B5D (51432), D5D (51532) ASTM 335Gr.P11(SMLS)- H2 0.5"-0.75" : S160 1.0"-1.5": XS
ASTM A182 Gr.F11C1.2 - H2 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52032
BlE (51433) ASTM A335Gr.P22(SMLS) 0.5"- 0.75" : S160 1.0"-1.5": XS
ASTM A182 Gr.F22C1.3 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52033
D5E (51534) ASTM A335Gr.P22(SMLS) - H2 0.5"-0.75" : S160 1.0"-1.5": XS
ASTM A182 Gr.F22C1.3 - H2 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52034
A4F (51336), B4F (51436) ASTM A335 Gr.P5(SMLS) 0.5"-0.75" : S160 1.0"-1.5": XS
ASTM A182 Gr.F5 0.5"-0.75": SW 6000# 1.0"-1.5" : SW 3000#
52036
B3F (51436) ASTM A335 Gr.P5(SMLS) 0.5"-1.5" : XXS
ASTM A182 Gr.F5 0.5"-1.5" : SW 9000#
52036
A4G (51339), B4G (51439) ASTM A335 Gr.P9(SMLS) 0.5"-0.75" : S160 1.0"-1.5": XS
ASTM A182 Gr.F9 0.5"-0.75: SW 6000# 1.0"-1.5" : SW 3000#
52039
F2D (51731) ASTM A335 Gr.P11 (SMLS) - IBR 0.5"-1.5" : S160
ASTM A234Gr.WP11C1.1/ A182 Gr.F11C1.2 - IBR 0.5"-1.5" : BW, S160
52131
E5E (51634)
ASTM A335 Gr.P22(SMLS) - H2 0.5"-0.75" : S160 1.0"-1.5": XS
ASTM A234Gr.WP22C1.1/ A182 Gr.F22C1.3 - H2 0.5"-0.75" : BW, S160 1.0"-1.5" : BW, XS
52134
A1K (51345), A3K (51345), B1K (51445), D1K (51545)
ASTM A312 TP304(SMLS) 0.5-0.75" : 80S 1.0"-1.5": 40S
ASTM A182 Gr.F304 0.5"-1.5" : SW 3000# 52045
A2K (51346), B2K (51446), D2K (51546)
ASTM A312 TP304(SMLS) - CRY() 0.5"-0.75" : 80S 1.0"-1.5": 40S
ASTM A182 Gr.F304 - CRYO 0.5"-1.5" : SW 3000#
52046
B4K (51448), B5K (51448) ASTM A312 TP304H (SMLS) 0.5"-1.5" : 80S
ASTM A182 Gr.F304H 0.5"-1.5": SW 3000#
52048
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ENGINEERS SPECIFICATIONS FOR BYPASS STANDARD SPECIFICATION No.
INDIA LIMITED PIPING, FITTINGS AND VALVES 6-44-0052-A2 Rev.7 (A Govt of India Undertaking)
Page 3 of 3
Class (Main Valve Sht.no.) Pipe Fittings Bypass Valve
Sht.no.
A6K (51350), B6K (51450) ASTM A312 TP304L (SMLS) 0.5"-0.75" : 80S 1.0"-1.5": 40S
ASTM A182 Gr. Gr.F304L 0.5"-1.5": SW 3000#
52050
AIM (51361), B1M (51461) ASTM A312 TP316(SMLS) 0.5"-0.75" : 80S 1.0"-1.5": 40S
ASTM A182 Gr.F316 0.5"-1.5": SW 3000# 52061
B5M (51462)
ASTM A312 TP316H (SMLS) - H2 0.5"-0.75" : 80S 1.0"-1.5": 40S
ASTM A182 Gr.F316H - H2 0.5"-1.5": SW 3000# 52062
B3M (51463) ASTM A312 TP321(SMLS) 0.5"-0.75" : 80S 1.0"-1.5": 40S
ASTM A182 Gr.F321 0.5"-1.5": SW 3000# 52063
A1N (51366), 131N (51466) ASTM A312 TP 316L (SMLS) 0.5"-0.75" : 80S 1.0"-1.5": 40S
ASTM A182 Gr.F316L Gr. 0.5"-1.5": SW 3000#
52066
B6N (51471) ASTM A312 TP316L (SMLS) 0.5"-0.75" : 80S 1.0"-1.5": 40S
ASTM A182 Gr.F316L 0.5"0.5"-1.5": SW 3000#
52071
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ENGINEERS SPECIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
51g-zufMiH6i
5Veg INDIA LIMITED LOW TEMPERATURE & 6-44-0052-A3 Rev.7 (A Govt of Me Undertaking) CRYOGENIC VALVES Page 1 of 2
own ,limiwre Mn .3P011)
SPECIAL REQUIREMENTS FOR LOW TEMPERATURE & CRYOGENIC VALVES
1.0 SCOPE
All valves of Low Temperature Carbon Steel (LTCS) and all grades of austenitic SS (CRYO) material are categorized as cryogenic valves. All these valves shall have extended bonnet as per BS 6364 except check valves.
Following qualification criteria shall be met by the valve vendors to quote valves for cryogenic services:
2.0 QUALIFICATION CRITERIA
i) Both cryogenic test (clause 2.1) and reference list (clause 2.2) together shall be considered for vendor qualification and vendor shall furnish the same, along with his offer.
ii) Vendors who do not have cryogenic test reports and reference list covering valves of all sizes, materials and ratings required by MR, should confirm / furnish the following for consideration of their offer:
a. Evidence of having conducted successfully at least one cryogenic test as per BS 6364. Test certificate shall be furnished with the offer.
b. Vendor shall confirm to conduct cryogenic test per clauses 2.1 & 2.3 for the remaining valves not later than 12 weeks from the date of purchase order.
c. Vendor shall also furnish reference list for valves supplied for non-cryo service if reference list referred in 2.2.1 does not cover all the sizes of MR.
Offers of vendors who do not comply with above requirements would be rejected.
2.1 Cryogenic Test
Vendors to furnish copies of cryogenic test certificate for tests conducted as per details given below:
2.1.1 Test shall be as per BS 6364.
2.1.2 Test temperature, unless specifically called for otherwise in the individual MR, shall be -45°C for LTCS and -196°C for all grades of austenitic stainless steel.
2.1.3. Tests carried out on a particular size of one type of valve, pressure rating and material shall qualify all sizes equal to and below the test valve size for the same type, pressure rating and material. In case of austenitic SS any one grade would qualify for all other grades of austenitic SS.
2.1.4. Tests should have been witnessed and certified by any one of the following third party inspection agencies; M/s Lloyd, BV, DNV, TUV or EIL/ CEIL.
2.1.5. Cryogenic test need not be conducted for every order. Test conducted previously and witnessed by inspection agencies listed above shall be considered acceptable and need not be repeated.
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Gil eiC1 ENGINEERS SPECIAL REQUIREMENTS FOR STANDARD SPECIFICATION No.
Ogeg tame g INDIA LIMITED LOW TEMPERATURE & 6-44-0052-A3 Rev.7 IA Govt of India Undertaking) CRYOGENIC VALVES Page 2 of 2
eieEDIZ an 3.7.1)
2.2 Reference List
Vendor shall furnish reference list for valves supplied for cryogenic service indicating the name of client, year of supply, size, material, pressure rating, type of valve and quantity.
2.3 Post Order Testing Procedure
2.3.1. Before conducting post order testing, vendor shall submit the following for approval:
a. Test procedure (as per BS 6364). b. Cross-section drawing of the valve with material of construction. c. Schematic of test rig (as per BS 6364) with complete details.
2.3.2. Test has to be conducted irrespective of the service on largest size for each type of valve and for each material and class rating. Vendor shall offer one, two or three valves for selection of test valve by inspector depending upon whether quantity of largest valve in the order is one, two or three and more than three respectively.
In the event of failure of the test valve to meet the specification requirements, the vendor shall conduct test on two more valves. These two valves which pass test successfully, are of lower size, then the qualification will be valid only to sizes upto which test has been conducted successfully.
2.3.3. In case of non-conductance of cryogenic test(s) within 12 weeks or failure in the test(s) conducted after receipt of order, the owner reserves the right to invoke any of the provisions of the purchase order including cancellation of the purchase order at the risk and cost of vendor.
3.0 Bonnet extension, wherever specified in the valve sheet to BS 6364 shall be for "non cold box application" unless otherwise specified in the MR. Even if not called for in valve sheet, valves indicated as "LT" or "CRYO" shall be supplied with bonnet extension.
4.0 Bonnet and Gland extension joints shall be of butt welded/integrally cast construction. I
5.0 Repair welding procedure for austenitic stainless steel valves in "CRYO" service shall have to be qualified for impact test as per ASME B31.3. Minimum acceptable impact energy shall be 20 J or lateral expansion of 0.38 mm at temperature of -196°C.
6.0 Wherever impact test of SS studs / nuts is called for in the data sheet, the impact value shall be 27 J at the intended service temperature specified in the data sheets.
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‘31 Ogelftlf5teg
OMR e9eeR2,1313‘10.1)
STANDARD SPECIFICATION No. ENGINEERS SPECIAL REQUIREMENTS FOR INDIA LIMITED HYDROGEN SERVICE VALVES 6-44-0052-A4 Rev.7 (A Govt of India Undertaking)
Page 1 of 2
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE
1.0 GENERAL
1.1
These requirements are applicable for valves used in Hydrogen service. These are in addition to the requirements described in "Technical Notes for Valves" Spec. No. 6-44-0052, and shall be read in conjunction with this specification.
1.2 All cast valve flanges & bodies with flange rating of Class 900 or greater shall be examined in accordance with paragraphs 7.2 through 7.5 of Appendix-VII of ASME SEC-VIII, DIV.1, regardless of casting quality factor.
1.3 Body / bonnet / cover joints & stuffing box of all valves shall have low emission. One valve per metallurgy, per rating, per size shall be helium leak tested as per ASME Sec.V, Subsection A, Article 10 (Detector Probe Technique), Appendix IV at a minimum of 25% of the allowable (rated) cold working pressure. Selection of valves for helium leak test shall be at random. Test duration shall be as follows:
Test Duration in Minutes
Nominal Size Pressure Class
Upto 300 600 800 & 900 1500 2500
Upto 2" 3 6 9 12 12
3" to 6" 6 9 12 15 18
8" to 16" 9 9 12 15 18
18" to 24" 9 12 15 18 21
The valve shall show no leakage. No leakage is defined as a total leakage rate of less than 0.0001 ml/s of helium.
2.0 Only normalized and tempered material shall be used in the following specifications:
Castings A217 Gr.WC1, A217 Gr.WC4, A217 Gr.WC5, A217 Gr.WC6, A217 Gr.WC9, A217 Gr.C5, A217 Gr.C12
Forgings A182 Gr.F11 C1.2
3.0 CS & AS VALVES
3.1 Bend test and Magnetic Particle inspection of the entire surface of body and bonnet casting shall be in accordance with ASTM A217. Supplementary requirement S3 & S4 evaluation of magnetic particle, inspection shall be in accordance with MSS-SP-53 except that no linear discontinuities shall be allowed.
3.2 The Brinell hardness of heat treated casting shall not exceed 200 BHN for carbon steel & 225 for alloy steel.
3.3 Repair to defective casting shall be outlined in writing to the purchaser before repair starts. Repair method to be approved prior to welding.
3.4 Casting shall be preheated to a minimum of 400°F prior to welding and all Chromium- Molybdenum alloys shall be postweld heat treated after welding is complete. Stress relieving is essential for welds.
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t3t
Oge.il fell5reg (777.1) STANDARD SPECIFICATION No.
ENGINEERS SPECIAL REQUIREMENTS FOR INDIA LIMITED HYDROGEN SERVICE VALVES 6-44-0052-A4 Rev.7 IA Govt of India Undertaking)
Page 2 of 2
3.5 Carbon steel shall be normalised and alloy steels shall be normalised & tempered.
3.6 Dye Penetrant test of welds shall be in accordance with ASTM B165 Procedure B-2. Interpretation as per Appendix-8 of ASME-VIII Div. 1.
3.7 The tensile stress for AS shall be less than 100,000 psi.
3.8 Charpy V-notch impact testing is to be done for valve material (average 20 ft-lb for set of 3 [minimum value 15 ft-lb] at 30°F).
3.9 For radiography and acceptance criteria for valve castings, refer Cl. 4.2.
4.0 SS VALVES
4.1 Valve casting shall be in solution heat treated and pickled condition.
4.2 Critical body and bonnet casing section typically defined by ASME B 16.34 shall be radiographed and shall meet ASTM E446 (upto 2" thick) Category A, B & CA Level 2, Category CB, OC & CD Level 3, Category D, B & F Level 0. For wall thickness 2" to 4.5" comparable plates of ASTM E186 shall be used. ASTM E94 and ASTM E142 shall be used for recommended practice & controlling quality of radiography as guide. The entire surface of all castings shall be dye-penetrant inspected after pickling.
4.3 Welds shall be 100% radiographed and evaluated in accordance with paragraph 344.5 of ASME B31.3 with a minimum casting quality factor of 0.95. Dye Penetration test shall be as per ASTM E165 Procedure B-2, Interpretation as per Appendix-8 of ASME-VIII Div.l.
Copyright EIL — An rights reserved Format No. 8-00-0001-F1 Rev. 0
TC65436-R01 Page 64 of 227
Page 17748 of 18388
TC65436-R01 Page 65 of 227
Format Rev.2 Issue Date-22/10/2014
Format No. 1645-DS-906 Rev. 0 Copyrights EIL – All rights reserved
Document No. B224-109-80-43-DS-1022 REV. A
Page 1 of 1
DRY GAS SEAL SYSTEM
(TYPICAL)
1
GENERAL
2
Project: RAJASTHAN REFINERY PROJECT Job No: B224
3
Owner: M/s HRRL Site: BARMER, RAJASTHAN
4
Purchaser: Unit : Unit No.:
5
Item No.: No. of Units:
6
Applicable to: Proposal Purchase As Built
7
: Scope, Option & Info specified by Purchaser. : Info required from and options left to vendor. Vendor to cross () the selected
option. 8
Gas Seal Module for: Compressor Item No.:
9
Gas Seal Module Supplier: Gas Seal Module Manufacturer:
10
Gas Seal : Mfr.: Model No.: Suppl. By:
11
Separate Modules for each unit/ casing Multiple Package for
12
Dry Gas Seal Details:
13
Dry Gas Seal Type Single (4A-4) Double (4A-1) Tandem (4A-3) Tandem with internal labyrinth (4A-2)
14
Seal Gas Hazardous : Yes No For Seal Gas Composition, refer to: (Remark-3)
15
Unidirectional Bidirectional Rot. Speed,max.,rpm: Dir. of Rotn. comptble with
compr.
Yes No
16
Max. Sealing Pr., kg/cm²g : Seal Max. Design Pr., kg/cm²g : (Rem.-4) Settleout Pr., kg/cm²g:
17
Eqpt.Suc. Pr.(max/min) kg/cm²g : Eqpt. Discharge Temp. C : R.V. Set Pr., kg/cm²g :
18
Vents Leakage : Normal / Static Connected to :
19
Primary Vent / Flare Safe
20
Secondary Vent / Flare Safe
21
Secondary Vent for Internal Labyrinth / Flare Safe
22
Gas Supply: Refer Job spec. Filters :
23
Primary/Buffer Gas Secondary/Barrier
Seal Gas
Separation Gas Primary/Buffer Gas Sec,/Barrier Seal
Gas
Separation Gas
24
Type of Gas Refer Job Spec. Nitrogen Nitrogen Twin Filters Yes Yes Yes
25
Pressure. kg/cm²g Filt.Level-nom. m
26
Temp. C Manufaturer
27
Flow, NM3/hr Model
28
Modules: Design Pr., kg/cm²g
29
Basic Modules: Test Pr., kg/cm²g
30
Seal Gas Filter Module (Fig. No. 4A-5a______) Code Constr./Stamp / / /
31
Separation Gas Filter Module (Fig. No. 4A-5c ___) Matl. Case/ Top SS/ SS SS/ SS SS/ SS
32
Differential Pressure Control (Fig. No. ______) Spare Cartridges
33
Flow Control (Fig. No. ______) Continuous Flow Transfer Valves : Yes No
34
Outlet Modules: Primary/Buffer Gas Sec,/Barrier Seal
Gas
Separation Gas
35
Flow Monitoring - Diff. Pressure (Fig. No. ______) Tight Shut off reqd. Yes Yes
36
Flow Monitoring – Back Pressure (Fig. No. ______) Manufacturer
37
Flow Measuring (Fig. No. ______) Model
38
Separation Gas Modules: 4A-9a 4A-9b 4A-9c Rating, kg/cm²g
39
For Double opposed dry gas seal type: Matl: Body CS CS
40
Differential Pressure Control (Fig. No. 4A-6a_) Matl: Plug or Ball
Ball
SS SS
41
Flow Control (Fig. No. ______) Matl: Trim SS SS
42
Material : Double Blocks & Bleeds
43
Instrument Test Valves Required Piping and Tubing :
44
Special Requirements Tight Shut off Reqd. C.S. slip on flanges
45
Through Studs Reqd. SS Slip-on/Socket Weld/Weldneck Flng
46
Heat Tracing reqd. By Purchaser By Vendor
47
Shop Inspection and Tests : (Remark- 2)
48
Witness Observed
49
Cleanliness
50
Check Controls
51
Changeover Filters
52
Sound level
53
Hydrotest Assembled System
54
Use for Complete Unit System Test
55
Material test Certificates
56
Certified Copies of all Test Logs and Data
57
APPLICABLE CODES: API 617 & API 614,
58
REMARKS: 1) Unless otherwise specified, type of dry gas seal shall be dual tandem with int. labyrinth for each compressor casing.
59
2) Also refer Job Specification & Aneexure-1D of API 617 for typical Dry Gas Seal Testing Considerations.
60 3) Refer PDS, Job Specification and Site & Utility Data for seal gases during normal and transient cases.
61 4) The dry gas seal and seal gas system shall be designed for the supply / return / mechanical design conditions of the proposed seal
gases OR casing MAWP, whichever is greater.
62 5) Dry gas seals shall be bi-directional and interchangeable between Drive end & Non Drive end side of respective compressor casing.
63 6) This is a typical datasheet. Vendor to furnish duly filled in datasheet for each casing of each compressor package during detail engg.
Page 13958 of 18388
TC65436-R01 Page 66 of 227
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE FOR PIPING MATERIALS
JOB SPECIFICATION No.
B224-6-44-0082 Rev. A
Page 1 of 4
A 29.03.2019 ISSUED AS JOB SPECIFICATION MKS PPSW MK
Rev. No
Date Purpose Prepared
by Checked
by Approved
by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE
FOR PIPING MATERIALS
PROJECT : RAJASTHAN REFINERY
OWNER : HPCL RAJASTHAN REFINERY LIMITED
JOB NO. : B224
LOCATION : PACHPADRA ,RAJASTHAN
Page 12873 of 18388
TC65436-R01 Page 67 of 227
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE FOR PIPING MATERIALS
JOB SPECIFICATION No.
B224-6-44-0082 Rev. A
Page 2 of 4
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE
1.0 GENERAL
These requirements are applicable in addition to the requirements specified in the Piping Material Specifications.
2.0 PIPES, FLANGES AND FITTINGS 2.1 Method of Manufacture
All carbon steel pipes, fittings and flanges having wall thickness 9.53 mm and above shall be normalised. Cold drawn pipes and fittings shall be normalised after the final cold draw pass for all thicknesses. In addition, fittings made from forgings shall have Carbon - 0.35% max. and Silicon - 0.35% max. The normalising heat treatment shall be a separate heating operation and not a part of the hot forming operation.
All alloy steel (Cr-Mo) pipes, forgings and fittings shall be normalised and tempered.
The normalising and tempering shall be a separate heating operation and not a part of the hot forming operation. The maximum room temperature tensile strength shall be 100,000 psi.
2.2 Impact Test For all carbon steels and alloy steels pipes, flanges and fittings with thickness over
20 mm, Charpy-V Notch impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section VIII, Div-1 for weld metal and base metal from the thickest item per heat of material and per heat treating batch. Impact test specimen shall be in complete heat treated condition and in accordance with ASTM A370. Impact energies at 0 C shall average greater than 27J (20 ft-lb) per set of 3 specimens, with a minimum of 19J (15 ft-lb).
If welding is used in manufacture, impact test of Heat Affected Zone (HAZ) and weld
metal shall also be carried out.
2.3 Hardness For carbon steel pipes and fittings, hardness of weld and HAZ shall be limited to 200
BHN (max.). For alloy steel pipes and fittings, hardness of weld and HAZ shall be limited to 225
BHN (max.).
3.0 VALVES 3.1 All valve castings shall be of radiographic quality. 3.2 All cast valve flanges & bodies with flange rating of Class 900 or greater shall be
examined in accordance with paragraphs 7.2 through 7.5 of Appendix-VII of ASME SEC-VIII, DIV.1, regardless of casting quality factor.
Page 12874 of 18388
TC65436-R01 Page 68 of 227
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE FOR PIPING MATERIALS
JOB SPECIFICATION No.
B224-6-44-0082 Rev. A
Page 3 of 4
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
3.3 Only Normalized and Tempered material shall be used in the following specifications: Castings: A217 Gr.WC1, A217 Gr.WC4, A217 Gr.WC5,
A217 Gr.WC6, A217 Gr.WC9, A217 Gr.C5, A217 Gr.C12 Forgings: A182 Gr.F11 Cl.2 3.4 Body / bonnet / cover joints & stuffing box of valves shall have low emission. One
valve per metallurgy, per rating, per size shall be helium leak tested as per ASME Sec.V, Subsection A, Article 10 (Detector Probe Technique), Appendix IV at a minimum of 25% of the allowable (rated) cold working pressure. Selection of valves for helium leak test shall be at random. Test duration shall be as follows:
Test Duration in Minutes
Nominal Size Pressure Class
Upto 300 600 800 & 900 1500 2500
Upto 2" 3 6 9 12 12
3" to 6" 6 9 12 15 18
8" to 16" 9 9 12 15 18
18" to 24" 9 12 15 18 21
The valve shall show no leakage. No leakage is defined as a total leakage rate of less than 0.0001 ml/s of helium.
3.5 CS & AS Valves : Bend test and Magnetic Particle inspection of the entire surface of body and bonnet
casting shall be in accordance with ASTM A217. Supplementary requirement S3 & S4 evaluation of magnetic particle, inspection shall be in accordance with MSS-SP-53 except that no linear discontinuities shall be allowed.
The Brinell hardness of heat treated casting shall not exceed 200 BHN for carbon steel & 225 for alloy steel. Repair of defective casting shall be outlined in writing to the purchaser before repair starts. Repair method to be approved prior to welding.
Casting shall be preheated to a minimum of 400ºF prior to welding and all Chromium-Molybdenum alloys shall be postweld heat treated after welding is complete. Stress relieving is essential for welds. Carbon steel shall be normalised and alloy steels shall be normalised & tempered. Dye Penetrant test of welds shall be in accordance with ASTM B165 Procedure B-2. Interpretation as per Appendix-8 of ASME-VIII Div.1. The tensile stress for AS shall be less than 100,000 psi. Charpy V-notch impact testing is to be done for valve material (average 20 ft-lb for set of 3 [minimum value 15 ft-lb] at 30 F). For radiography and acceptance criteria for valve castings, refer para 2 of clause3.6.
Page 12875 of 18388
TC65436-R01 Page 69 of 227
SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE FOR PIPING MATERIALS
JOB SPECIFICATION No.
B224-6-44-0082 Rev. A
Page 4 of 4
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
3.6 SS Valves :
Casting and test bar shall be heat treated together. Valve casting shall be in solution heat treated and pickled condition.
Critical body and bonnet casing section typically defined by ASME B16.34 shall be
radiographed and shall meet ASTM E446 (upto 2" thick) Category A,B & CA Level 2, Category CB, OC & CD Level 3, Category D,B & F Level 0. For wall thickness 2" to 4.5" comparable plates of ASTM E186 shall be used. ASTM E94 and ASTM E142 shall be used for recommended practice & controlling quality of radiography as guide.The entire surface of all castings shall be dye-penetrant inspected after pickling.
Repair welds shall be 100% radiographed and evaluated in accordance with paragraph 344.5 of ASME B31.3 with a minimum casting quality factor of 0.95. Dye Penetration test shall be as per ASTM E165 Procedure B-2, Interpretation as per Appendix-8 of ASME-VIII Div.1.
Page 12876 of 18388
TC65436-R01 Page 70 of 227
t311 eJ ENGINEERS 5fgar failes INDIA LIMITED
IA Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
VARIABLE AREA FLOW METERS
STANDARD SPECIFICATION NO.
6-81- 2007 Rev. 3 Page 1 of 5
.4-Rcrqa- Re4i Lteil t*‹)
ft-4'mm trtaTur
INSPECTION AND TEST PLAN FOR
VARIABLE AREA FLOW METERS
3 20.09.2013 Revised and Reissued RS ( DM
2 22.02.2012 Revised and Reissued MJ GS AKC DM
1 22.01.2008 Revised and Reissued AKG PPM MVKK VC
0 30.04.2002 Issued for implementation RG AKC AK GRR
Standards Committee Standards Bureau Rev. No. Date Purpose Prepared
By Checked
by Convenor Chairman
Approved by
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17164 of 18388
TC65436-R01 Page 71 of 227
ENGINEERS INSPECTION AND TEST PLAN
METERS
STANDARD SPECIFICATION NO.
6-81-2007 Rev. 3 Page 2 of 5
51g-ar tdOtes INDIA LIMITED FOR (A Govt of India Undertaking) VARIABLE AREA FLOW
Abbreviations AS Alloy Steel MRT Mechanical Run Test BASEEFA British Approval Service for Electrical Equipment in Flammable MPT/MT Magnetic Particle Testing
Atmospheres MTC Material Test Certificates BIS Bureau of Indian Standards MOC Material of Construction CCE or CCOE Chief Controller of Explosives NPSH Net Positive Suction Head CELL Certification Engineers International Limited NDT Non Destructive Testing CIMFR Central Institute of Mining & Fuel Research NEMA National Electrical Manufacturers Association CE Carbon Equivalent PO Purchase Order DFT Dry Film Thickness PESO Petroleum Explosive Safety Organization DT Destructive Testing PQR Procedure Qualification Record DP or DPT Dye Penetrate Testing PR Purchase Requisition ERTL Electronics Regional Test Laboratory PMI Positive Material Identification FCRI Fluid Control Research Institute PTB Physikalisch-Technische Bundesanstalt FM Factory Mutual QC Quality Control FLP Flame Proof RT Radiography Testing HART Highway Addressable Remote Transducer SS Stainless Steel HV High Voltage TC Test Certificate ITP Inspection and Test Plan TPI or TPIA Third Party Inspection Agency IP Ingress Protection UT Ultrasonic Testing IC Inspection Certification UL Under writer Laboratories IR Insulation Resistance VDR Vendor Data Requirement IEC International Electro technical Commission WPS Welding Procedure Specification JEC Japanese Electro technical Committee WPQ Welders Performance Qualification LPT Liquid Penetrate Testing XLPE Cross Linked Poly Ethylene
Inspection Standards Committee
Convenor : Mr. S C Gupta
Members: Mr. R.K. Singh
Mr. Rajeev Kumar Mr. Himangshu Pal Mr.Neeraj Mathur
Mr. T Kamalakannan Mr. Deepak Gupta (Project) Mr. Mayank Jain
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17165 of 18388
TC65436-R01 Page 72 of 227
0 --1 ENGINEERS 5fga1 0151-as w INDIA LIMITED
IA Govt of India Undertake g)
INSPECTION AND TEST PLAN FOR
VARIABLE AREA FLOW METERS
STANDARD SPECIFICATION NO.
6-81-2007 Rev. 3
Page 3 of 5 lair,' eirotrettn,,mtv,
1.0 SCOPE
This Inspection and Test Plan covers the minimum inspection and testing requirements for Variable Area Flow Meters.
2.0 REFERENCE DOCUMENTS
PO/PR / Standards referred there in /Job specifications / Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF
CHECK RECORD SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
1.0 Procedures -- -- -- -- -- --
1.1 WPS/PQR/WPQ Welding procedure Qualification for welds as applicable 100%
WPS PQR WPQ -- H
W (New) R (Existing)
2.0 Material Inspection
2.1
Incoming Material like Metal tube, Spool Pipes, Flanges, Float Assembly, Float stoppers, etc.
Chemical & Mechanical Properties, HT
100% Material Test
Certificates / Test Lab Certificates
H H R
3.0 In process Inspection
3.1 Machining of components and assembly
Visual, Dimensions. 100% Supplier's Test
Records - H -
4.0 Final Inspection
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL - All rights reserved
Page 17166 of 18388
TC65436-R01 Page 73 of 227
51gar 215ieg cvecnre .1,157.1)
ENGINEERS INDIA LIMITED IA Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
VARIABLE AREA FLOW METERS
STANDARD SPECIFICATION NO.
6-81-2007 Rev. 3
Page 4 of 5
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF
CHECK RECORD
SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
4.1 NDT , Post Weld Heat Treatment (PWHT) ( If specified)
• Radiography for weld joints • Dye Penetration test. • Post Weld Heat Treatment of welds,
100% NDT reports / PWHT chart
- H R
4.2 Final Inspection
• Visual and dimensional check • Hydrostatic test of complete flow meter
assembly • Calibration test including accuracy and
repeatability • Functional check with Transmitter & flow
switches( if required )
100% by supplier and on random
basis by EIL/TPIA
Supplier's Test Records and Inspection
Witness Record
H R
4.3 Submission of certificates / Documents
• Certificate from testing agency like BASSEFA, FM, PTB, CIMFR, etc. for transmitter/switch enclosure for use in specified hazardous area.
• BIS approval for transmitter enclosure manufactured indigenously.
• Statutory approval certificate for transmitter/switch enclosure from CCOE / PESO for use in specified hazardous area.
• Degree of protection (IP) certificate for transmitter/switch enclosure.
Prototype for each model
Statutory Approval
Certificates / Type Test
Certificates
- H R
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL — All rights reserved
Page 17167 of 18388
TC65436-R01 Page 74 of 227
ll~lei ENGINEERS 5'fgzir 16151eg INDIA LIMITED
IA Go. of Ind. Undendk.9)
INSPECTION AND TEST PLAN FOR
VARIABLE AREA FLOW METERS
STANDARD SPECIFICATION NO.
6-81-2007 Rev. 3
Page 5 of 5 rwant 051 340w1)
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF
CHECK RECORD SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER EIL/TPIA
5.0 Painting
5.1 Painting
• Special cleaning and packing for oxygen and chlorine services
• Pre treatment, primer and final paint, shade, thickness.
100% Test Records - H -
6.0 Documentation and IC
6.1 Documentation and IC
• Review of Internal Test Reports • Manufacturer TC for bought out
components. • IC issuance.
100%
Supplier's Test Records / Inspection Certificate
- H H
6.2 Final Document submission Compilation of Inspection reports ,drawings, etc as per VDR / PR
100% Final data folder /Completeness
certificate - H H
Legends: H- Hold (Do not proceed without approval), R-Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of each type), W- Witness (Give due notice, work may proceed after scheduled date).
NOTES :-
1. This document describes the generic test requirements. Any additional test or inspection scope if specified in contract documents shall also be applicable. (Unless otherwise agreed upon).
2. Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications /Approved documents
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17168 of 18388
TC65436-R01 Page 75 of 227
STANDARD SPECIFICATION NO.
KW, eree172 MI J70,71 6-81- 2013 Rev. 3
Page 1 of 5
INSPECTION AND TEST PLAN FOR
LEVEL INSTRUMENTS
ENGINEERS $1g-al idf5leg INDIA LIMITED
IA Govt or India Undertaking)
Acid 4--Vte
fiturrr a trturrr zhq-9T
INSPECTION AND TEST PLAN FOR
LEVEL INSTRUMENTS
V-1-7\ ,....)9k•s.;-/
3 20.09.13 Revised and Re-issued MJ RS SCG DM
2 22.03.12 Revised and Re-issued MJ GS AKC DM
1 02.01.08 Revised and Re-issued SA CRM MVKK VC
0 29.11.02 Issued for implementation RG AKC AKB GRR
Rev. No. Date Purpose Prepared
by Checked
by
Standards Committee C:nrivannr
Standards Bureau chairman
Approved by
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL - All rights reserved
Page 17179 of 18388
TC65436-R01 Page 76 of 227
ei ENGINEERS INSPECTION AND TEST PLAN STANDARD SPECIFICATION NO.
6-81-2013 Rev. 3
Page 2 of 5
$fgar 0151-'dg etecnre agent)
INDIA LIMITED FOR IA Gov! of India Undertaking) LEVEL INSTRUMENTS
Abbreviations AS Alloy Steel MRT Mechanical Run Test BASEEFA British Approval Service for Electrical Equipment in Flammable MPT/MT Magnetic Particle Testing
Atmospheres MTC Material Test Certificates BIS Bureau of Indian Standards MOC Material of Construction CCE or CCOE Chief Controller of Explosives NPSH Net Positive Suction Head CEIL Certification Engineers International Limited NDT Non Destructive Testing CIMFR Central Institute of Mining & Fuel Research NEMA National Electrical Manufacturers Association CE Carbon Equivalent PO Purchase Order DFT Dry Film Thickness PESO Petroleum Explosive Safety Organization DT Destructive Testing PQR Procedure Qualification Record DP or DPT Dye Penetrate Testing PR Purchase Requisition ERTL Electronics Regional Test Laboratory PMI Positive Material Identification FCRI Fluid Control Research Institute PTB Physikalisch-Technische Bundesanstalt FM Factory Mutual QC Quality Control FLP Flame Proof RT Radiography Testing HART Highway Addressable Remote Transducer SS Stainless Steel HV High Voltage TC Test Certificate ITP Inspection and Test Plan TPI or TPIA Third Party Inspection Agency IP Ingress Protection UT Ultrasonic Testing IC Inspection Certification UL Under writer Laboratories IR Insulation Resistance VDR Vendor Data Requirement IEC International Electro technical Commission WPS Welding Procedure Specification JEC Japanese Electro technical Committee WPQ Welders Performance Qualification LPT Liquid Penetrate Testing XLPE Cross Linked Poly Ethylene
Inspection Standards Committee
Convenor :
Members:
Mr. S C Gupta
Mr. R.K. Singh Mr.Neeraj Mathur Mr. Mayank Jain
Mr. Rajeev Kumar Mr. Himangshu Pal Mr. T Kamalakannan Mr. Deepak Gupta (Project)
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17180 of 18388
TC65436-R01 Page 77 of 227
ENGINEERS INDIA LIMITED IA Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
LEVEL INSTRUMENTS
STANDARD SPECIFICATION NO. nester
-'dg fift RAE, rieantANJAWA,
6-81-2013 Rev. 3
Page 3 of 5
1.0 SCOPE
This Inspection and Test Plan covers the minimum inspection and testing requirements for Float / Displacer Operated Level Instruments.
2.0 REFERENCE DOCUMENTS
PO/PR / Standards referred there in /Job specifications / Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF
CHECK RECORD SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER EIL/TPIA
1.0 Procedures -- -- -- -- -- --
1.1 WPS/PQR/WPQ Welding procedure Qualification for welds as applicable 100%
WPS PQR WPQ
-- H W (New) R (Existing)
2.0 Material Inspection
2.1
Incoming Material like Cage Pipes, Flanges, forgings , gaskets etc.
HT, Chemical & Mechanical Properties, Heat treatment.
100% Material Test Certificates / Test Lab Certificates
H H R
3.0 In process Inspection
3.1 Machining of components and assembly
Visual, Dimensions. 100%
Supplier's Test Records
- H -
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17181 of 18388
TC65436-R01 Page 78 of 227
II Ifgar tlfWes
1.172?,
ENGINEERS INDIA LIMITED IA Govt 01 India Undertaking)
INSPECTION AND TEST PLAN FOR
LEVEL INSTRUMENTS
STANDARD SPECIFICATION NO.
6-81-2013 Rev. 3
Page 4 of 5
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
CHECK OF RECORD SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER EIL/TPIA
4.0 Final Inspection
4.2 NDT , Post Weld Heat Treatment (PWHT) ( If specified)
• Radiography for weld joints • Dye Penetration test. • Post Weld Heat Treatment of welds,
100% NDT reports / PWHT chart
- H R
4.1 Final Inspection
• Visual check for all items • Dimensional checks. • D.P check for all welds • Hydrostatic test on cage and float /
displacer • Calibration check including accuracy and
repeatability. • I.R. test on transmitter • Load driving capability check on
transmitter • Smart /HART transmitter function checks • Functional checks for hand held portable
communicator for smart transmitters • Functional checks for fieldbus transmitter.
100%
Supplier's Test Records and Inspection
Witness Record
- H RW
4.3 Submission of certificates / Documents
• Certificate from testing agency like BASSEFA, FM, PTB, CMRI, etc. for instruments for use in specified hazardous area/ FISCO approval for fieldbus transmitter.
• BIS approval for instruments manufactured indigenously for use in specified hazardous area.
• Statutory approval certificates for
Prototype for each model
Statutory Approval
Certificates / Type Test
Certificates
- H R
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17182 of 18388
TC65436-R01 Page 79 of 227
STANDARD SPECIFICATION NO.
tovaavon,117,01 6-81-2013 Rev. 3
Page 5 of 5
INSPECTION AND TEST PLAN FOR
LEVEL INSTRUMENTS
zi ENGINEERS Og-ar 11t4i-'eg w INDIA LIMITED
(A Govt of India Undertaking)
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
CHECK OF RECORD SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER EIL/TPIA
instruments from CCOE/PESO for use in specified hazardous area.
• Degree of protection certificate for instrument housing.
• Interoperability test certificate for field bus transmitter
• Certificate for electromagnetic compatibility.
5.0 Painting
5.1 Painting
• Special cleaning and packing for oxygen and chlorine services
• Pre treatment, primer and final paint, shade, thickness.
100% Test Records - H
6.0 Documentation and IC
6.1 Documentation and IC • Review of Internal Test Reports & MTC • IC issuance.
100%
Supplier's Test Records / Inspection Certificate
- H H
6.2 Final Document submission Compilation of Inspection reports ,drawings,
etc as per VDR / PR 100%
Final data folder /Completeness
certificate - H H
Legends: H- Hold (Do not proceed without approval), Random 10% , R-Review, RW-Random witness, W- Witness (Give due notice, work may proceed after scheduled date).
NOTES : 1. This document describes the generic test requirements. Any additional test or inspection scope if specified in contract documents shall also be applicable. (Unless
otherwise agreed upon). 2. Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications /Approved documents
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17183 of 18388
TC65436-R01 Page 80 of 227
0 •Aad Ld-1000-00-8 '0N ImuLiod
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panss!-a.0 pue pOSIA3•H
4.) panss! ag pue pas!nal
Copyright EI L — Al l rights reserved
O
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cr
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D
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fP
0
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3 20.09.13 Revised and Reissued MJ RS
2 22.03.12 Revised and Reissued MJ GS
1 09.05.08 Revised and Reissued RB SKD
0 09.12.02 Issued for implementation RG AKC
Rev. No. Date Purpose Prepared
by Checked
by
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AKB GRR
Standards Committee Standards Bureau Convenor Chairman
Approved by
,r..1 ENGINEERS
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are, torOtennundivi/ (A Govt of India Undenakingi
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
STANDARD SPECIFICATION NO.
6-81-2031 Rev. 3 Page 1 of 6
cprOd iViuur atrtaTur z1)79-1
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
Copyright EIL — All rights reserved Format No. 8-00-0001-F7 Rev. 0
Page 17225 of 18388
TC65436-R01 Page 90 of 227
ei INSPECTION AND TEST ENGINEERS PLAN STANDARD SPECIFICATION NO.
6-81-2031 Rev. 3
Page 2 of 6
FOR OgZ1T f615tes iire71 ,ecnre ,ros.)
INDIA LIMITED (A Govt of India Undertaking) CONTROL VALVES
Abbreviations AS Alloy Steel MRT Mechanical Run Test BASEEFA British Approval Service for Electrical Equipment in Flammable MPT/MT Magnetic Particle Testing
Atmospheres MTC Material Test Certificates BIS Bureau of Indian Standards MOC Material of Construction CCE or CCOE Chief Controller of Explosives NPSH Net Positive Suction Head CEIL Certification Engineers International Limited NDT Non Destructive Testing CIMFR Central Institute of Mining & Fuel Research NEMA National Electrical Manufacturers Association CE Carbon Equivalent PO Purchase Order DFT Dry Film Thickness PESO Petroleum Explosive Safety Organization DT Destructive Testing PQR Procedure Qualification Record DP or DPT Dye Penetrate Testing PR Purchase Requisition ERTL Electronics Regional Test Laboratory PMI Positive Material Identification FCRI Fluid Control Research Institute PTB Physikalisch-Technische Bundesanstalt FM Factory Mutual QC Quality Control FLP Flame Proof RT Radiography Testing HART Highway Addressable Remote Transducer SS Stainless Steel HV High Voltage TC Test Certificate ITP Inspection and Test Plan TPI or TPIA Third Party Inspection Agency IP Ingress Protection UT Ultrasonic Testing IC Inspection Certification UL Under writer Laboratories IR Insulation Resistance VDR Vendor Data Requirement IEC International Electro technical Commission WPS Welding Procedure Specification JEC Japanese Electro technical Committee WPQ Welders Performance Qualification LPT Liquid Penetrate Testing XLPE Cross Linked Poly Ethylene
Inspection Standards Committee
Convenor : Mr. S C Gupta
Members: Mr. R.K. Singh
Mr. Rajeev Kumar Mr. Himangshu Pal Mr.Neeraj Mathur
Mr. T Kamalakannan Mr. Deepak Gupta (Project) Mr. Mayank Jain
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17226 of 18388
TC65436-R01 Page 91 of 227
STANDARD SPECIFICATION NO.
2.reaVU 07 6-81-2031 Rev. 3
Page 3 of 6
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
k_111i tel ENGINEERS 1::g-af Of&leg INDIA LIMITED
IA Govt of India UndellakIng)
1.0 SCOPE
This Inspection and Test Plan covers the minimum inspection and testing requirements for Control valve.
2.0 REFERENCE DOCUMENTS
PO/PR / Standards referred there in /Job specifications / Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK RECORD SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER EIL/TPIA
1.0 Procedures -- -- -- -- -- --
1.1 WPS/PQR/WPQ Welding procedure Qualification for welds,
overlays as applicable 100% WPS PQR WPQ
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R (Existing)
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Incoming Material like Forgings & casting for body/ bonnet, wetted parts like plug, Seat, cage, Stem.
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Chemical & Mechanical Properties, HT
Make, model no, functional check.
100% Material Test
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3.0 In process Inspection
3.1 Stellited & Hardened Trim (As specified )
D P Test 100% Supplier's Test
Records H R
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17227 of 18388
TC65436-R01 Page 92 of 227
L31 ENGINEERS
1=g-ar iatit'dg INDIA LIMITED
etrwtrJn :Igo.), (A Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
STANDARD SPECIFICATION NO.
6-81-2031 Rev. 3
Page 4 of 6
SL NO.
STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK
RECORD SCOPE OF INSPECTION
SUB SUPPLIER
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4.1 Final Inspection on assembled Valve
• Visual / Dimensional check • Hydrostatic test. • Helium leak test ( if specified). • Check for valve characteristics like stroke,
Linearity & Hysteresis, etc. • Functional tests including :
i) Seat leakage test, lift characteristics. ii) Test on smart positioners. iii) Control valve dynamic response and response time verification.(If specified) iv) Test on Accessories.
• Interoperability test for Field bus positioners. • Pneumatic test on actuator on representative
samples. • Type test for valves in cryogenic service.(if
specified) • Partial stroke test / valve signature • capability of smart and field bus transmitters
to accept multimeters and check for configuration, calibration, diagnostics through Hand Held terminal.
100% Inspection
Witness Record - H RW
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17228 of 18388
TC65436-R01 Page 93 of 227
STANDARD SPECIFICATION NO.
1.171 21,1Tre 0,1 JVCASO 6-81-2031 Rev. 3
Page 5 of 6
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
ENGINEERS ig- r INDIA LIMITED
(A Govt of India Undertakngi
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK RECORD SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER EIL/TPIA
4.3 Submission of certificates/document
• Certificate from testing agency like BASEEFA, FM, PTB, CIMFR etc. for accessories like solenoid valves, FP converters, Limit switches etc. for use in specified hazardous area.
• BIS approval for explosion proof construction of above accessories manufactured indigenously.
• Statutory approval certificates for instruments from CCOE/PESO for use in specified hazardous area.
• Degree of protection certificate (IP) for instrument housing.
• Fire Safe Certification as applicable.
Prototype for each model
Statutory Approval
Certificates / Type Test
Certificates
- H R
5.0 Painting
5.1 Packing
• Cleaning for oxygen and chlorine services. • Suitable protection to prevent entry of
foreign material. • Lubrication for valves, which require
external lubrication.
100% Test Records - H -
6.0 Documentation and IC
6.1 Documentation and IC • Review of Internal Test Reports, MTC • Issuance of Inspection Certificate 100%
/ Supplier Test Records / IC - H H
6.2 Final Document submission Compilation of Inspection reports ,drawings, etc as per VDR / PR 100%
Final data folder /Completeness
certificate - H H
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17229 of 18388
TC65436-R01 Page 94 of 227
STANDARD SPECIFICATION NO.
IsTrrn riemrc' 131 6-81-2031 Rev. 3
Page 6 of 6
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
raeit-s ENGINEERS
5fgar fai,les INDIA LIMITED IA Govt of Incha Unclettakng)
Legends: H- Hold (Do not proceed without approval, R- Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of each type), W- Witness (Give due notice, work may proceed after scheduled date). NOTES :-
1. This document describes the generic test requirements. Any additional test or inspection scope if specified in contract documents shall also be applicable. (Unless otherwise agreed upon).
2. Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications /Approved documents
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17230 of 18388
TC65436-R01 Page 95 of 227
STANDARD SPECIFICATION NO.
6-81-2032 Rev. 3
o
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Revised and Reissued 22.03.2012
Issued for implementation
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TC65436-R01 Page 96 of 227
Net Positive Suction Head
H
6-81-2032 Rev. 3
STANDARD SPECIFICATION NO. INSPECTION
Abbreviations
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PO/PR / Standards referred there in /Job specifications / Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
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SUPPLIER
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Manufacturer's Test Certificates /
Material Test Certificates
Supplier's Test Records
QUANTUM OF CHECK
CHARACTERISTICS
,
Physical/chemical properties , Heat Treatment as applicable
Dimensions, Insulation resistance, Sensor Characterization, calibration, performance.
STAGE/ ACTIVITY
Procedures
Material Inspection
Incoming Material like sensors, housings, flanges, body castings, studs/nuts .askets • lu:s etc.
In process Inspection
Instrument assembly
Final Inspection
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STANDARD SPECIFICATION NO. INSPECTION
Copyright EIL — All rights reserved Format No. 8-00-0001-F7 Rev. 0
SCOPE OF INSPECTION
EIL/TPIA
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g)
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h)
Display of inbuilt control algorithm (fieldbus transmitter) •
PID operation check for controllers. •
Transmitter power supply check for receiver instruments.
•
Response Time check
•
Protection against short circuit & reverse voltage.
•
Zero elevation /suppression test for level transmitter
•
Bump less transfer check for controllers from manual to auto mode and vice-versa.
•
PID operation check for controllers.
•
Accessories check including air filter regulators, mounting accessories etc.
•
Certificate from testing agency like BASSEFA, FM, PTB, CMIFR, etc. for instruments for use in specified hazardous area/ fisco approval for fieldbus transmitter.
•
BIS approval for instruments manufactured indigenously for use in specified hazardous area.
•
Statutory approval certificates for instruments from /PESO for use in specified hazardous area.
•
De ree of I rotection certificate for
STAGE/ ACTIVITY
Submission of certificates / Documents
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certificate
QUANTUM OF CHECK
. . . .
. .
CHARACTERISTICS
instrument housing.
•
Interoperability test certificate for field bus transmitter
• Certificate for electromagnetic compatibility and transient protection as per IEC 61000-4 • Certified values of failure rates, probability of failure on demand (PFD) and test intervals for safety Inte:ri level (SIL) analysis.
•
Special cleaning and packing for oxygen and chlorine services
•
Review of Internal Test Reports, MTC
•
Device Description files
•
IC issuance.
Compilation of Inspection reports ,drawings, etc as per VDR / PR
STAGE/ ACTIVITY
Painting . _ -5 -g, ,:,.,
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Documentation and IC
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STANDARD SPECIFICATION NO.
REFERENCE DOCUMENTS
This Inspection and Test Plan covers the minimum inspection and testing requirements for Solenoid valves.
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STANDARD SPECIFICATION NO.
Copyright EIL — All rights reserved
2. Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications /Approved documents
Format No. 8-00-0001-F7 Rev. 0
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Statutory approval certificates for instruments from PESO for use in specified hazardous area.
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NDT as applicable
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Visual and Dimensional checks.
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Hydrostatic test on all valve bodies.
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Pneumatic test on actuators.
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Valve stroke Test / functional test
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Manual Valve test
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Partial Stroke Test / Valve Signature
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Seat leakage test
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Open-Close operation time
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STANDARD SPECIFICATION NO.
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This Inspection and Test Plan covers the minimum inspection and testing requirements for Signal Cables.
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Statutory approval certificates for instruments from CCOE/PESO for use in specified hazardous area.
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Internal test report for Performance of smart & field bus transmitter.
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Interoperability test certificate for field bus transmitter
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Load driving capability test for transmitter.
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•
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•
IC issuance.
•
Visual
•
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TC65436-R01 Page 148 of 227
tr(C'M ENGINEERS ligaf fat5teg INDIA LIMITED
,kkE/k
INSPECTION AND TEST PLAN FOR
SELF ACTUATED CONTROL VALVES / REGULATORS
STANDARD SPECIFICATION NO.
6-81-2079 Rev. 4 Page 1 of 5
IA Gov't of India Undertaking)
ciletiI/t0c11
f441-45ur a tr-tuur
INSPECTION AND TEST PLAN FOR
SELF ACTUATED CONTROL VALVES / REGULATORS
4 01.08.16 Revised and Reissued RS c/2),1:' RN
3 21.11.13 Revised and Reissued MJ RS SCG SC
2 22.03.12 Revised and Reissued MJ GS AKC DM
1 10.06.08 Revised and Reissued SA SKD SKP VC
0 09.12.02 Issued for implementation RG AKC AKB GRR
Standards Committee Standards Bureau Rzv. Na. Date Purpose Prepared
by Checked
by Convenor Chairman
Approved by
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 17337 of 18388
TC65436-R01 Page 149 of 227
1 ENGINEERS INSPECTION AND TEST PLAN
10 rat Ifgar fa5teg wr INDIA UMITED FOR
1711
SELF ACTUATED CONTROL VALVES / REGULATORS
STANDARD SPECIFICATION NO.
6-81-2079 Rev. 4
Page 2 of 5 A Govt of India Undertaking)
Abbreviations: AS Alloy Steel LPT Liquid Penetrate Testing BIS Bureau of Indian Standards MRT Mechanical Run Test CEIL Certification Engineers International Limited MPT/MT Magnetic Particle Testing CIMFR Central Institute of Mining & Fuel Research MTC Material Test Certificates CE Carbon Equivalent MOC Material of Construction DFT Dry Film Thickness NPSH Net Positive Suction Head DT Destructive Testing NDT Non Destructive Testing DP or DPT Dye Penetrate Testing NEMA National Electrical Manufacturers Association ERTL Electronics Regional Test Laboratory PO Purchase Order FCRI Fluid Control Research Institute PESO Petroleum Explosive Safety Organization FM Factory Mutual PQR Procedure Qualification Record FLF Flame Proof PR Purchase Requisition HART Highway Addressable Remote Transducer PMI Positive Material Identification HV High Voltage PTB Physikalisch-Technische Bundesanstalt ITP Inspection and Test Plan QC Quality Control IP Ingress Protection RT Radiography Testing IC Inspection Certification SS Stainless Steel IR Insulation Resistance TC Test Certificate IEC International Electro technical Commission TPI or TPIA Third Party Inspection Agency Jr,C Japanese Electro technical Committee VDR Vendor Data Requirement
Inspection Standards Committee
Convenor : Mr. R.K. Singh
Members: Mr. Rajeev Kumar
Mr. Himangshu Pal Mr. Neeraj Mathur
Mr. T Kamalakannan Mr. Deepak Gupta (Project)
Mr. Mahendra Mittal
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL —All rights reserved
Page 17338 of 18388
TC65436-R01 Page 150 of 227
lot eJel
3,eg, ENGINEERS INDIA LIMITED IA Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
SELF ACTUATED CONTROL VALVES / REGULATORS
STANDARD SPECIFICATION NO.
6-81-2079 Rev. 4
Page 3 of 5
1.0 SCOPE
This Inspection and Test Plan covers the minimum inspection and testing requirements for Self Actuated Control Valves / Regulators.
2.0 REFERENCE DOCUMENTS
PO/PR / Standards referred there in /Job specifications / Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL NO.
STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK RECORD
SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER EIL/TPIA
1.0 Procedures -- -- -- -- -- --
2.0 Material Inspection
2.1
Incoming materials like Forgings & Castings for Body / Bonnet, Trim material etc.
Mechanical & Chemical properties, heat treatment as applicable, 100%
Material Test Certificates / Test Lab
Certificates
H H R
3.0 In process Inspection
3.1 Machining of components Visual, Dimensions 100% Supplier's Test
Records - H
4.0 Final Inspection
rriat No. 8-00-0001-F7 Rev. 0
Copyright EIL —All rights reserved
Page 17339 of 18388
TC65436-R01 Page 151 of 227
■_111t kit ENGINEERS err ti5teg'1 INDIA LIMITED
APJ‘117.) IA Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
SELF ACTUATED CONTROL VALVES / REGULATORS
STANDARD SPECIFICATION NO.
6-81-2079 Rev. 4 Page 4 of 5
SL CIO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK RECORD SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
4.1 Final Inspection
• Visual check for all items. • Correctness of model no., Tag plate,
Connection size. • Physical verification of required accessories. • Hydro test (body). • Set pressure test & Functional test. • Seat leakage test. • Helium leak test (if specified)
100 %
Supplier's Internal Test
Records/ Inspection
Witness Record -
H R vv
4.2 NDT • NDT (as specified). 100% ND Report
T s - H R
4.3 Submission of certificates/ Document
• Type test Certificate for droop within 10% or as per data sheet of set point for each type/model.
Sample Type test report - H R
5.0 Painting
5.1 Painting
• Special cleaning and packing for oxygen and chlorine services
• Pre treatment, primer and final paint, shade, thickness
100% Test Records H -
6.0 Documentation and IC
6.1 Documentation and IC • Review of Internal Test Reports & MTCs • IC issuance.
100% Supplier's Test Records / - - II
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL — All rights reserved
Page 17340 of 18388
TC65436-R01 Page 152 of 227
Zlr is cis INIP ei t o%3VTAl
ENGINEERS INDIA LIMITED IA Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
SELF ACTUATED CONTROL VALVES / REGULATORS
STANDARD SPECIFICATION NO.
6-81-2079 Rev. 4
Page 5 of 5
SL NO.
STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK RECORD
SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
Inspection Certificate
6.2 Final Document submission Compilation of Inspection reports ,drawings,
etc as per VDR / PR 100%
Final data folder /Completeness
certificate - H H
Legends: H- Hold (Do not proceed without approval), R-Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of each type), W- Witness (Give due notice, work may proceed after scheduled date).
NOTES :-
1. This document describes the generic test requirements. Any additional test or inspection scope if specified in contract documents shall also be applicable. (Unless otherwise agreed upon).
2. Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications /Approved documents
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL — All rights reserved
Page 17341 of 18388
TC65436-R01 Page 153 of 227
Page 15966 of 18388
TC65436-R01 Page 154 of 227
Page 15967 of 18388
TC65436-R01 Page 155 of 227
Page 15968 of 18388
TC65436-R01 Page 156 of 227
Page 15969 of 18388
TC65436-R01 Page 157 of 227
Page 15970 of 18388
TC65436-R01 Page 158 of 227
$11g-ar tigitg 011,771 eiro,r1 399.3)
ENGINEERS INDIA LIMITED IA Govt of India Undettalong)
INSPECTION AND TEST PLAN FOR
SEAMLESS PIPES
STANDARD SPECIFICATION NO.
6-81-0003 Rev. 5
Page 1 of 6
44\9 fkturir trtuur
INSPECTION AND TEST PLAN FOR
SEAMLESS PIPES
5. 19.09..2016 REVISED AND RE-ISSUED TKK HP
4. 17.06..2013 REVISED AND RE-ISSUED TKK RKS
3 15.07.2011 REVISED AND RE-ISSUED TKK SCG
2 30.06.2010 REVISED AND RE-ISSUED RK VKJ
1 28.09.2007 REVISED AND RE-ISSUED PD RB
Rev. No. Date Purpose
Prepared By
Checked By
(2' 'Ff---- RN
.
SCG DM
AKC DM
SKP ND
MVKK VC
Standards Committee Standards Bureau Convenor Chairman
Approved by
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10172 of 13748
TC65436-R01 Page 159 of 227
al
$1g-ZIT kit154tt WWI MOsIVOIIJOI/Fil)
ENGINEERS INDIA LIMITED IA Goa of Indio Undertaking)
INSPECTION AND TEST PLAN FOR
SEAMLESS PIPES
STANDARD SPECIFICATION No.
6-81-0003 Rev. 5
Page 2 of 6
Abbreviations:
CELL Certification Engineers International Limited MRT Mechanical Run Test CIMFR Central Institute of Mining & Fuel Research NDT Non Destructive Testing CE Carbon Equivalent • NPSH Net Positive Suction Head DFT Dry Film Thickness PO Purchase Order DPT Dye Penetrant Testing PESO Petroleum Explosive Safety Organization DHT De-hydrogen Heat Treatment PQR Procedure Qualification Record ERTL Electronics Regional Test Laboratory PR Purchase Requisition FCRI Fluid Control Research Institute PMI Positive Material Identification HT Heat Treatment RT Radiography Testing HIC Hydrogen Induced Cracking SSCC Sulphide Stress Corrosion Cracking ITP Inspection and Test Plan TC Test Certificate
Ingress Protection TPI or TPIA Third Party Inspection Agency IHT Intermediate Heat Treatment UT Ultrasonic Testing IC Inspection Certificate VDR Vendor Data Requirement IGC Inter Granular Corrosion WPS Welding Procedure Specification MPT/MT Magnetic Particle Testing WPQ Welders Performance Qualification MTC Material Test Certificate
Inspection Standards Committee
Convenor : Mr. R.K. Singh
Members: Mr. Rajeev Kumar Mr. Himangshu Pal Mr. Neeraj Mathur Mr. T Kamalakannan Mr. Mahendra Mittal Mr. Deepak Gupta (Project)
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL — All rights reserved
Page 10173 of 13748
TC65436-R01 Page 160 of 227
INDIA ENGINEERS
LIMITED (WM MOM OANInall IA Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
SEAMLESS PIPES
STANDARD SPECIFICATION No.
6-81-0003 Rev. 5 Page 3 of 6
1.0 SCOPE
This Inspection and Test Plan covers the minimum testing requirements of Seamless Pipes.
2.0 REFERENCE DOCUMENTS
PO/PR/Standards referred therein/ Job specifications /Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL. STAGE/ACTIVITY NO. CHARACTERISTICS QU AN UM
CHECK OF RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER EIL/ TPIA
1.0 Procedure
1.1 Hydrostatic Test, Heat Treatment, NDT and
Other Procedures Documented Procedures 100% Procedure
Documents - H R
2.0 Material Inspection
2.1 Raw Material Inspection Review of MTC for Chemical, Mechanical Properties, size &
steel making process, etc. 100% Test
Certificates - H
3.0 In Process Inspection
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL — All rights reserved
Page 10174 of 13748
TC65436-R01 Page 161 of 227
ENGINEERS INDIA LIMITED IA Govt of India Undedalong)
INSPECTION AND TEST PLAN FOR
SEAMLESS PIPES
STANDARD SPECIFICATION No.
6-81 -0003 Rev. 5
Page 4 of 6
ID1 I
SL. NO. STAGE/ACTIVITY CHARACTERISTICS QUANTUM OF
CHECK RECORD SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER EIL/ TPIA
3.1 Heat Treatment Normalizing, Tempering, Solution Annealing, Stabilization Heat Treatment etc. as applicable
100% HT chart - H R
3.2 NDT
As applicable Surface & Internal Imperfections PR / Purchase Specification NDT Reports - H R
3.3 Identification of Test Samples
Product Chemical, Tensile, Hardness, Impact, IGC and Other
test as applicable
Lot as per specification Test Reports - H H
(Note-1)
3.4 Product Analysis Chemical Composition Lot as per specification Test Reports - H R
3.5 Destructive Testing Tensile, Hardness, Impact, IGC and Other test as applicable
Lot as per specification Test Reports - H H
(Note-1)
3.6 Galvanizing (If Applicable) Integrity Of Galvanised Coating 100%
Inspection Report - H R
4.0 Final Inspection
4.1 Hydrostatic Testing Leak Check 100 % Test Report - H RW
(Note 1)
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10175 of 13748
TC65436-R01 Page 162 of 227
STANDARD SPECIFICATION No.
6-81-0003 Rev. 5
Page 5 of 6
eit4 ENGINEERS Og ern f51 INDIA LIMITED
(A Govt. of India Undettaking)
INSPECTION AND TEST PLAN FOR
SEAMLESS PIPES
SL. NO.
STAGE/ACTIVITY • CHARACTERISTICS
QUANTUM OF CHECK
RECORD SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER EIL/ TPIA
4.2 Visual and Dimensional
Inspection (VDI)
Surface Condition, Straightness, End Finish,
Bevel Angle, Root Face, Outer Dia., Thickness,
Length, End Finish, Marking,
End Caps etc
100% Inspection Report
- H RW
(Note 1)
'
4.3 Weight Checking as
applicable Weight 100% By Supplier H
Inspection
Report - -
4.4 PMI Check Chemical Check As Per EIL, Spec.
6-81-0001 Inseport pection
r - H
RW
4.5 Final Stamping Stamping of Accepted Pipes
Stamping of Pipes which are witnessed by EIL/TPIA..0ther pipes to have suppliers identification
Inspection Report - H H
Copyright EIL — All rights reserved Format No. 8-00-0001-F7 Rev. 0
Page 10176 of 13748
TC65436-R01 Page 163 of 227
ENGINEERS INDIA LIMITED Ogar fa5teg
Wren e,virrke J,77.1) Govt of 1000 Undertaking)
STANDARD SPECIFICATION No.
6-81-0003 Rev. 5
Page 6 of 6
INSPECTION AND TEST PLAN FOR
SEAMLESS PIPES
SL. NO. STAGE/ACTIVITY CHARACTERISTICS QUANTUM OF
CHECK RECORD SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER EIL/ TPIA
5.0 Painting
5.1 Rust Preventive Coating
& Color Coding (As applicable)
Visual & Color Coding as applicable 100% Inspection
Report - W -
6.0 Documentation & IC
6.1 Documentation & Inspection Certificate(IC)
Review of Stage Inspection Reports / Test Reports & Issue of
IC 100% Supplier TC
& IC - H H
Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).
NOTES (As applicable): 1. Carbon Steel Pipes (Other than LTCS & Pipes for special services like NACE, H2, HIC, etc.) up to size 12" will be accepted on review of Supplier Test
Certificates. Supplier Test Certificate to be reviewed by EIL/TPIA. 2. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be
applicable.(Unless otherwise agreed upon) 3. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents. 4. For orders placed on stockist, items shall be accepted based on manufacturer's TC with EN 10204 type 3.2 certification from EIL approved suppliers.
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10177 of 13748
TC65436-R01 Page 164 of 227
INSPECTION AND TEST PLAN FOR
VALVES
REVISED AND RE-ISSUED
TKK RKS SCG DM
TKK SCG AKC DM
RKB VKJ SKP ND
CS SS MVKK VC
Prepared by
Checked by
Standards Committee Convenor
Standards Bureau Chairman
Approved by
6 14 11 2018
5 17 06 2013
4 15 07 2011
3 30 06 2010
2 31 01 2008
Rev No Date
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
Purpose
ratSejege riv,I,tUMITED (A GoN al kIdu UnOxiakmg)
INSPECTION AND TEST PLAN FOR
VALVES
STANDARD SPECIFICATION NO
6-81-0004 Rev. 6 Page 1 of 7
curl * Ml‘crar A trukTur 4 111
Format No 8-00-0001-F7 Rev 0 Copyright EIL — All rights reserved
Page 10178 of 13748
TC65436-R01 Page 165 of 227
MRT NDT NPSH PO PESO PQR PR PM1 RT SSCC TC TPI or TPIA UT VDR WPS WPQ
Mechanical Run Test Non Destructive Testing Net Positive Suction Head Purchase Order Petroleum Explosive Safety Organization Procedure Qualification Record Purchase Requisition Positive Material Identification Radiography Testing Sulphide Stress Corrosion Cracking Test Certificate Third Party Inspection Agency Ultrasonic Testing Vendor Data Requirement Welding Procedure Specification Welders Performance Qualification
?ENGINEERS sLAfafaieg®INDIA LIMITED
Govt of ;ma Undertaking)
INSPECTION AND TEST PLAN FOR
VALVES
STANDARD SPECIFICATION NO.
6-81-0004 Rev. 6
Page 2 of 7
Abbreviations:
CELL CIMFR CE DFT DPT DHT ERTL FCRI HT HIC ITP IP IHT IC IGC MPT/MT MTC
Certification Engineers International Limited Central Institute of Mining & Fuel Research Carbon Equivalent Dry Film Thickness Dye Penetrant Testing De-hydrogen Heat Treatment Electronics Regional Test Laboratory Fluid Control Research Institute
: Heat Treatment : Hydrogen Induced Cracking : Inspection and Test Plan : Ingress Protection
Intermediate Heat Treatment Inspection Certificate Inter Granular Corrosion
: Magnetic Particle Testing : Material Test Certificate
Inspection Standards Committee
Convenor : Mr. R K. Singh
Members: Mr. Rajeev Kumar Mr. T Kamalakannan
Mr. Neeraj Mathur Mr. Himangshu Pal Mr. Mahendra Mittal Mr Deepak Gupta (Projects)
Mr R Muthu Ramalingam (RPO Rep.)
Format No 8-00-0001-F7 Rev 0 Copyright EIL — All rights reserved
Page 10179 of 13748
TC65436-R01 Page 166 of 227
,-*ENGINEERS fittlWregW; INDIA LIMITED
Cori of IMW Undertitrngi
INSPECTION AND TEST PLAN FOR
VALVES
STANDARD SPECIFICATION NO
6-81-0004 Rev. 6
Page 3 of 7
1.0 SCOPE
This Inspection and Test Plan covers the minimum testing requirements of Valves.
2.0 REFERENCE DOCUMENTS
PO/PR/Standards referred therein/ Job specifications /Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL NO / ACTIVITY CHARACTERISTICS
QUANTUM CHECK
RECORD RECORD SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA OF CECK
1.0 Procedure
1.1
Hydrostatic Test, Heat Treatment, NDT,
Helium Leak Test
Other Procedures and
Documented Procedures 100% Procedure
Documents H R
1.2 WPS, PQR & WPQ Welding Parameters & Qualification Record
100% WPS, PQR &WPQ - H W- New
R- Existing
1.3 Pre-Qualification Tests Fire safe,
Cryogenic & Other Test as applicable
As per PR / Purchase
Specification Acceptance Report - H
H (If new)
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10180 of 13748
TC65436-R01 Page 167 of 227
p,"-M; ENGINEERS IgtlitailegW, INDIA LIMITED
INSPECTION AND TEST PLAN FOR
VALVES
STANDARD SPECIFICATION NO.
6-81-0004 Rev. 6
Page 4 of 7
SL NO
STAGE / ACTIVITY CHARACTERISTICS QUANTUM OF CHECK
RECORD SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
2.0 Material Inspection
2.1 Castings & Forgings (Body, Bonnet, Disc, Stem, Body ring)
Chemical, Mechanical, Heat Treatment, NDT,
IGC & Other Properties as applicable
100% Test Certificates H R R
2.2 Castings & Forgings
(Body, Bonnet, Disc, Stem, Body ring) Visual & Dimension 100% Inspection Report H H -
2.3 Body and Bonnet Castings Radiography Examination
As per PR / Purchase
Specification Films and report H R R
2.4 Bars for Trim material Chemical Analysis Each Heat Test Certificates &
Lab Report H R -
2.5 Gaskets, Gear units, Fasteners, Gland,
Packings, etc. Physical / Chemical
Properties 100%
Test Certificates & Lab Report H R
2.6 Actuators as applicable Performance,
Statutory Certificates as applicable
100% Test Certificates, Inspection report
H H R
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10181 of 13748
TC65436-R01 Page 168 of 227
aaLlt4ft- ENGINEERS ar Ig WagW. INDIA LIMITED
eVaile
INSPECTION AND TEST PLAN FOR
VALVES
STANDARD SPECIFICATION NO
6-81-0004 Rev. 6
Page 5 of 7
SL NO STAGE / ACTIVITY QUANTUM
RECORD SCOPE OF INSPECTION
CHARACTERISTICS SUB SUPPLIER SUPPLIER EIL/TPIA OF CHECK
3.0 In Process Inspection
3.1 Welding Welding Parameters as
per WPS / PQR 100% Inspection Reports - H -
3.2 Machining of components Visual / Dimension 100% Inspection Reports - H -
4.0 Final Inspection
4.1 Hydrostatic / Pneumatic Test and
Helium Leak test as applicable Leak Check As per PR /
Purchase Specification
Test Report - H RW
(Note 1)
4.2 Visual / Dimension Surface & Dim ension
Check 100% Test Report - H
RW (Note 1)
4.3 Functional Test for Actuator Operated
Valves Satisfactory Performance
100% Test Report - H RW
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10182 of 13748
TC65436-R01 Page 169 of 227
liSiiftega, ENGINEERS W: INDIA LIMITED
(A GOA of Into Undenalmol
INSPECTION AND TEST PLAN FOR
VALVES
STANDARD SPECIFICATION NO.
6-81-0004 Rev. 6
Page 6 of 7
SL NO STAGE / ACTIVITY CHARACTERISTICS QUANTUM
RECORD SCOPE OF INSPECTION
OF CHECK SUB SUPPLIER SUPPLIER EIL/TPIA
4.4 PMI Check Chemical As per EIL
Spec. 6-81-0001
Inspection Report - H RW
4.5 Strip Check (As applicable) Verify Components & Differential hardness if
applicable
As per PR / Purchase
Specification Inspection Report -
(Note-1) H RW
4.6 Final Stamping Stamping of Accepted Valves
Stamping of Valves which
are witnessed by EIL/TPIA.
Inspection Report - H H (Note-1)
5.0 Painting
5.1 Painting and Color coding as applicable Visual / DFT Check 100% Inspection Report FI
6.0 Documentation & IC
6.1 Documentation & Inspection Certificate (IC)
Review of Stage Inspection Reports /
Test Reports & Issue of IC
100% Supplier TC & IC - H H
Format No 8-00-0001-F7 Rev 0 Copyright EIL — All rights reserved
Page 10183 of 13748
TC65436-R01 Page 170 of 227
ISM ENGINEERS SI-II M
5 ®INDIA INDIA LIMITEDJA,AA IA CAN of Endo Underlatingi
INSPECTION AND TEST PLAN FOR
VALVES
STANDARD SPECIFICATION NO.
6-81-0004 Rev. 6
Page 7 of 7
Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).
NOTES (As applicable):
1. Non NACE & Non Hydrogen service Carbon Steel Cast Valves up to size 12"-300ANSI Class and Carbon Steel Forged Valves up to size 1.5"- 800 ANSI Class will be accepted on review of Supplier Test Certificates. Supplier Test Certificate along with back up reports to be reviewed by EIL/TPIA
2. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable. (Unless otherwise agreed upon)
3. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred therein /Job Specification /Approved Documents.
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10184 of 13748
TC65436-R01 Page 171 of 227
stifte'tjah ENGINEERS azir Et;lesw INDIA LIMITED „,..
INSPECTION AND TEST PLAN FOR
FORGED, SEAMLESS & WELDED FITTINGS
STANDARD SPECIFICATION No
6-81-0005 Rev. 7 Page 1 of 6
to) , itreg ctit ithfrerft
ISM q
INSPECTION AND TEST PLAN FOR
FORGED, SEAMLESS & WELDED FITTINGS
7 14 11 2018
6 19 09 2016
5 17 06 2013
4 15 07 2011
3 30 06 2010
2 31 01 2008
Rev. No. Date
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
Purpos3
TKK HP RKS DM
TKK RKS SCG DM
TKK SCG AKC DM
RKB VKJ SKP ND
CS SS MVKK VC
Prepared by
Checked by
Standards Committee Convenor
Standards Bureau Chairman
Approved by
Format No 8-00-0001-F7 Rev 0 Copyright EIL — All rights reserved
Page 10185 of 13748
TC65436-R01 Page 172 of 227
5df5ille?a ENGINEERS 1s7 laWle...4W INDIA LIMITED
. Govi a/ India Undedakool
INSPECTION AND TEST PLAN FOR
FORGED, SEAMLESS & WELDED FITTINGS
STANDARD SPECIFICATION No
6-81-0005 Rev. 7
Page 2 of 6
Abbreviations:
CELL CIMFR CE DFT DPT DHT ERTL FCRI HT HIC ITP IP IHT IC IGC MPT/MT MTC
Certification Engineers International Limited Central Institute of Mining & Fuel Research Carbon Equivalent Dry Film Thickness Dye Penetrant Testing De-hydrogen Heat Treatment Electronics Regional Test Laboratory Fluid Control Research Institute Heat Treatment Hydrogen Induced Cracking Inspection and Test Plan Ingress Protection Intermediate Heat Treatment Inspection Certificate Inter Granular Corrosion Magnetic Particle Testing Material Test Certificate
M RT NDT NPSH PO PESO PQR PR PMI RT SSCC TC TPI or TPIA UT VDR WPS WPQ
Mechanical Run Test : Non Destructive Testing : Net Positive Suction Head
Purchase Order Petroleum Explosive Safety Organization Procedure Qualification Record Purchase Requisition Positive Material Identification Radiography Testing Sulphide Stress Corrosion Cracking Test Certificate Third Party Inspection Agency Ultrasonic Testing Vendor Data Requirement Welding Procedure Specification Welders Performance Qualification
Inspection Standards Committee
Convenor : Mr. R.K. Singh
Members: Mr. Rajeev Kumar Mr. T Kamalakannan
Mr Neeraj Mathur Mr. Himangshu Pal Mr. Mahendra Mittal Mr Deepak Gupta (Projects)
Mr. R Muthu Ramalingam (RPO Rep.)
Format No 6-00-0001-F7 Rev 0 Copyright EIL — All rights reserved
Page 10186 of 13748
TC65436-R01 Page 173 of 227
ERS IgafeakamiTED Go,n ol in Ow Unden*ingi
INSPECTION AND TEST PLAN FOR
FORGED, SEAMLESS & WELDED FITTINGS
STANDARD SPECIFICATION No.
6-81-0005 Rev. 7 Page 3 of 6
1.0 SCOPE
This Inspection and Test Plan covers the minimum testing requirements of Forged, Seamless & Welded Fittings.
2.0 REFERENCE DOCUMENTS
PO/PR/Standards referred therein/ Job specifications /Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL NO.
STAGE / ACTIVITY CHARACTERISTICS QUANTUM RECORD SCOPE OF INSPECTION
OF CHECK SUB SUPPLIER SUPPLIER EIL/TPIA
1.0 Procedure
1.1 Heat Treatment / NDT Documented Procedures 100% Procedure Documents
H R
1.2 WPS, PQR & WPQ Qualification
Welding Parameters & WPS, 100%
PQR & WPQ
- H W- New
R- Existing
2.0 Material Inspection
2 1
Raw Material Identification (Billets, Rounds, Pipes, Coil, Plates, etc.) (* Special services like NACE, H2,U0P,
AXEN etc)
Chemical and Mechanical Properties, Size & Steel
making practice etc 100%
Mill test certificate, Supplier's
Inspection Report
- H W* /R
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10187 of 13748
TC65436-R01 Page 174 of 227
aR ENGINEERS a-9 s® INDIA LIMITED
, Go. Indo Underhltingi
INSPECTION AND TEST PLAN FOR
FORGED, SEAMLESS & WELDED FITTINGS
STANDARD SPECIFICATION No.
6-81-0005 Rev. 7 Page 4 of 6
SL NO.
STAGE /ACTIVITY QUANTUM
EC OF CHK RECORD
SCOPE OF INSPECTION CHARACTERISTICS
SUB SUPPLIER
SUPPLIER EIL/TPIA
3.0 In Process Inspection
3.1 Forming & Welding Forming & Welding
Parameters 100%
Supplier's records
H
3.2 Ferrite Check Of SS Welds
(If Applicable) % Ferrite Check 100% Inspection Report - H R
3.3 Heat Treatment
Stress Reliving, Normalising, Tempering,
Solution Annealing, Stabilization Heat Treatment etc. as
applicable
100% HT chart / Report - H R
3.4 NDT-RT
As Applicable Surface & Internal
Imperfections
As per PR/Purchase Specification
RT Films & Reports
- H R
(F im Review)
3.5 NDT — UT
(as applicable) Surface & Internal
Imperfections PR/Purchase UT Report
As per
Specification H R
3.6 NDT — DPT/MPT on Bevel Ends
(as applicable) Surface & Internal
Imperfections 100% Test Report - H RW
3.7 Identification of Test Samples Product Chemical,
Mechanical, Impact, IGC and Other test as applicable
As per specifications
Test Reports H H
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10188 of 13748
TC65436-R01 Page 175 of 227
ENGINEERS Zg7tatwegw: INDIA LIMITED
IA Govt of incia UndertaMingl
INSPECTION AND TEST PLAN FOR
FORGED, SEAMLESS & WELDED FITTINGS
STANDARD SPECIFICATION No
6-81-0005 Rev. 7 Page 5 of 6
SL NO.
STAGE / ACTIVITY CHARACTERISTICS QUANTUM OF CHECK
RECORD SCOPE OF INSPECTION
SUB SUPPLIER EIL/TPIA SUPPLIER
3.8 Product Analysis Chemical Composition As per
PR/Purchase Specification
Test Reports H R
3.9 Destructive Testing Mechanical, IGC Impact,
and Other test as applicable 100% Test Reports - H H
3.10 Galvanizing
(If Applicable) Integrity of Galvanised
Coating 100% Inspection Report - H R
4.0 Final Inspection
4.1 Visual and Dimension Size, Thickness / Schedule,
Dimensions, Surface quality, Marking, etc.
100% Inspection Report - H RW (Note-1)
4.2 Hardness testing on Fittings
(*Special services like NACE, H2, HIC, UOP, AXEN etc)
Hardness value of Base metal & Wels/HAZ as
applicable Random 10% Test Report - H
R- For CS/SS &
RW for AS, LTCS,
with special services.
4.3 PMI Check
Chemical Check As Per EIL
Spec. 6-81-0001
Inspection report H RW
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10189 of 13748
TC65436-R01 Page 176 of 227
5iliaZIEge. ENGINEERS EitaregWINDIA LIMITED
fawn eita-421,AianiP re Govi of India lindertakingi
INSPECTION AND TEST PLAN FOR
FORGED, SEAMLESS & WELDED FITTINGS
STANDARD SPECIFICATION No.
641-0005 Rev. 7 Page 6 of 6
SL NO.
STAGE / ACTIVITY QUANTUM
RECORD SCOPE OF INSPECTION
CHARACTERISTICS OF CHECK SUB SUPPLIER
SUPPLIER EIL/TPIA
4.4 Final Stamping Stamping of Accepted
Fittings
Stamping of Fittings which
are witnessed by EIL/TPIA.
Inspection Report H
(Note-1) II
5.0 Painting
5.1 Rust Preventive Coating & Color Coding Visual & Color Coding as
applicable 100% Inspection Report - W
6.0 Documentation & IC
6.1 Documentation & Inspection Certificate
(IC)
Review of Stage Inspection Reports / Test Reports &
Issue of IC 100% Supplier TC & IC - H H
Legend: H- Hold (Do not proceed without approva ), P-Perform, RW - Random Witness (As specified or 10% ( min.l no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date)
NOTES (As applicable):
1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable. (unless otherwise agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred therein /Job Specification /Approved Documents. 3. For orders placed on stockiest, items shall be accepted based on manufacturer's TC with EN10204 type 3.2 certification from EIL approved suppliers. 4. For welded fittings, it is recommended to use low hydrogen consumable for AS, SS410 fittings and HIC resistant consumable for HIC service fittings. 5 EIL/TPIA reserves the right to check raw material consumption and traceability records.
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10190 of 13748
TC65436-R01 Page 177 of 227
TKK RKS SCG DM
TKK SCG AKC DM
RKB VKJ SKP ND
PD RB MVKK VC
Prepared by
Checked by
Standards Committee Convenor
Standards Bureau Chairman
Approved by
5 14 11 2018
4 17 06 2013
3 15 07 2011
2 30 06 2010
1 28 09 2007
Rev. No Date
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
Purpose
faiae5ft ENGINEERS Saga 1612egNilr INDIA LIMITED
GUN d intha undettakm
INSPECTION AND TEST PLAN FOR
FLANGES, SPECTACLE BLINDS & DRIP RINGS
STANDARD SPECIFICATION No
6-81-0006 Rev. 5
Page 1 of 6
tlet-40 mr i fir Riii rfT
fiNTar trukTur
INSPECTION AND TEST PLAN FOR
FLANGES, SPECTACLE BLINDS & DRIP RINGS
Format No 8-00-0001-F7 Rev 0 Copyright EIL — All rights reserved
Page 10191 of 13748
TC65436-R01 Page 178 of 227
ENGINEERS INDIA LIMITED IA GON alines underiakingi
INSPECTION AND TEST PLAN FOR
FLANGES, SPECTACLE BLINDS & DRIP RINGS
STANDARD SPECIFICATION No.
6-81-0006 Rev. 5 Page 2 of 6
141 eltAT'ejeg
Abbreviations:
CELL Certification Engineers International Limited MRT Mechanical Run Test CIMFR Central Institute of Mining & Fuel Research NDT Non Destructive Testing CE Carbon Equivalent NPSH Net Positive Suction Head DFT Dry Film Thickness PO Purchase Order DPT Dye Penetrant Testing PESO Petroleum Explosive Safety Organization DHT De-hydrogen Heat Treatment PQR Procedure Qualification Record ERTL Electronics Regional Test Laboratory PR Purchase Requisition FCRI Fluid Control Research Institute PMI Positive Material Identification HT Heat Treatment RT Radiography Testing HIC Hydrogen Induced Cracking SSCC Sulphide Stress Corrosion Cracking ITP Inspection and Test Plan TC Test Certificate IP Ingress Protection TPI or TPIA Third Party Inspection Agency IHT Intermediate Heat Treatment UT Ultrasonic Testing IC Inspection Certificate VDR Vendor Data Requirement IGC Inter Granular Corrosion WPS Welding Procedure Specification MPT/MT Magnetic Particle Testing WPQ Welders Performance Qualification MTC Material Test Certificate
Inspection Standards Committee
Convenor Mr. R.K. Singh
Members: Mr. Rajeev Kumar
Mr. Neeraj Mathur Mr. Himangshu Pal
Mr R Muthu Ramalingam (RPO Rep ) Mr T Kamalakannan
Mr. Mahendra Mittal Mr Deepak Gupta (Projects)
Format No 6-00-0001-F7 Rev 0 Copyright EIL — All rights reserved
Page 10192 of 13748
TC65436-R01 Page 179 of 227
15iligklega ENGINEERS sLII Elqe.sW INDIA LIMITED
alaa ekaraa minaa IA Gar% al India Undertakingi
INSPECTION AND TEST PLAN FOR
FLANGES, SPECTACLE BLINDS & DRIP RINGS
STANDARD SPECIFICATION No.
6-81-0006 Rev. 5 Page 3 of 6
1.0 SCOPE
This Inspection and Test Plan covers the minimum testing requirements of Flanges, Spectacle Blinds & Drip Rings.
2.0 REFERENCE DOCUMENTS
PO/PR/Standards referred therein/ Job specifications /Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL NO. STAGE / ACTIVITY CHARACTERISTICS QUANTUM OF
RECORD SCOPE OF INSPECTION
CHECK SUB SUPPLIER SUPPLIER EIL/TPIA
1.0 Procedure
1.1 Heat Treatment, NDT and Documented Procedures 100% Procedure
Documents - H R Other Procedures
1.2 WPS, PQR & WPQ Welding Parameters & Qualification Record 100% WPS, PQR & WPQ - H
W- New R- Existing
2.0 Material Inspection
2.1 Raw Material Inspection Chemical & Mechanical Properties 100% Test Certificates - H R
Format No 8-00-0001-F7 Rev 0 Copyright EIL — All rights reserved
Page 10193 of 13748
TC65436-R01 Page 180 of 227
sZ7(® INDIA LIMITED INSPECTION AND TEST PLAN
FOR FLANGES, SPECTACLE BLINDS & DRIP RINGS
STANDARD SPECIFICATION No.
6-81-0006 Rev. 5 Page 4 of 6
SL NO.
STAGE / ACTIVITY QUANTUM OF
CHECK RECORD
SCOPE OF INSPECTION CHARACTERISTICS
SUB SUPPLIER
SUPPLIER EIL/TPIA
3.0 In Process Inspection
3.1 Welding / Forging Forging /Welding
Parameters 100% Inspection Reports - El
3.2 Heat Treatment
Stress Relieving, Normalising, Tempering,
Solution Annealing, Stabilization Heat Treatment etc. as
applicable
100% HT chart - H R
3 3 Identification of Test
Samples
Product Chemical, Mechanical, Impact, IGC
and Other test as applicable 100% Test Reports - H
H (Note-1)
3.4 Product Analysis (As applicable)
Chemical Composition As per
PR/Purchase Specification
Test Reports - H R
3.5 Destructive Testing Mechanical, Impact, IGC
and Other test as applicable 100% Test Reports - H
H (Note-1)
3 6 NDT as applicable Surface & Internal
Imperfections
As per
PR/Purchase Specification
NDT Reports H R
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10194 of 13748
TC65436-R01 Page 181 of 227
laraZida ENGINEERS 1£71 c W INDIA LIMITED
co.. DI India laidenakingl
INSPECTION AND TEST PLAN FOR
FLANGES, SPECTACLE BLINDS & DRIP RINGS
STANDARD SPECIFICATION No
6-81-0006 Rev. 5 Page 5 of 6
SL NO. STAGE / ACTIVITY QUANTUM OF
CHECK RECORD SCOPE OF INSPECTION
CHARACTERISTICS SUB
SUPPLIER SUPPLIER EIL/TPIA
3.7 Galvanizing (If Applicable)
Integrity of Galvanised Coating 100% Inspection Report H R
4.0 Final Inspection
4.1 Final Inspection
1. Visual 2 Dimensions 3. Hardness 4. Marking etc
100% Inspection Report H H (Note-1)
4.2 PMI Check Chemical Check As Per EIL Spec.Inspection 6-81-0001 report - H RW
4.3 Final Stamping Stamping of Accepted Items
Stamping of Items which are
witnessed by EIL/TPIA.
Inspection Report - H H (Note — 1)
5.0 Painting
5.1 Rust Preventive Coating & Color Coding
Visual & Color Coding as applicable 100% Inspection Report H -
Format No 8-00-0001-F7 Rev 0
Copyright EIL—All rights reserved
Page 10195 of 13748
TC65436-R01 Page 182 of 227
aktt4 ENGINEERS LII faWs INDIA LIMITED
A cone India Unaenak
INSPECTION AND TEST PLAN FOR
FLANGES, SPECTACLE BLINDS & DRIP RINGS
STANDARD SPECIFICATION No
6-81-0006 Rev. 5 Page 6 of 6
SL NO.
STAGE / ACTIVITY CHARACTERISTICS QUANTUM
CHECK OF RECORD
SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
6.0 Documentation & IC
6.1 Documentation &
Inspection Certificate (IC)
Review of Stage Inspection Reports / Test Reports &
Issue of IC 100% Supplier TC & IC - H H
Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).
NOTES (As applicable):
I. Non NACE & Non Hydrogen service Carbon Steel Flanges, Spectacle Blinds & Drip Rings up to size 24"-300ANSI Class Will be accepted on review of Supplier Test Certificates. Supplier Test Certificate along with back up reports to be reviewed by EIL/TPIA
2. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable. (unless otherwise agreed upon)
3. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred therein /Job Specification /Approved Documents.
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10196 of 13748
TC65436-R01 Page 183 of 227
4 19.09.2016 REVISED AND RE-ISSUED TKK
3 17.06.2013 REVISED AND RE-ISSUED TKK
2 15.07.2011 REVISED AND RE-ISSUED TKK
1 28.09.2007 REVISED AND RE-ISSUED PD
0 23.04.02 ISSUED FOR IMPLEMENTATION NKN
Rev. No. Date Purpose Prepared
by
HP teRN
RKS SCG DM
SCG AKC DM
RB MVKK VC
SPS AKB SB
Convenor Chairman Standards Committee Standards Bureau Checked
by
ex..?
wen rircntero,
ENGINEERS INDIA LIMITED IA Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
BOLTING MATERIAL
STANDARD SPECIFICATION No.
6-81-0007 Rev. 4
Page 1 of 6
tr"e4r AaRqm fkftut a trftur
INSPECTION AND TEST PLAN FOR
BOLTING MATERIAL
Approved by
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10197 of 13748
TC65436-R01 Page 184 of 227
INDIA LIMITED IA Govt. of Indio Undettaking)
STANDARD SPECIFICATION No.
6-81-0007 Rev.4
Page 2 of 6
■31 el ENGINEERS Ifgzrr Elf51eg
ING71 mtm atiOrAt
INSPECTION AND TEST PLAN FOR
BOLTING MATERIAL
Abbreviations:
CELL Certification Engineers International Limited MRT Mechanical Run Test CIMFR Central Institute of Mining & Fuel Research NDT Non Destructive Testing CE Carbon Equivalent NPSH Net Positive Suction Head DFT Dry Film Thickness PO Purchase Order DPT Dye Penetrant Testing PESO Petroleum Explosive Safety Organization DHT De-hydrogen Heat Treatment PQR Procedure Qualification Record ERTL Electronics Regional Test Laboratory PR Purchase Requisition FCRI Fluid Control Research Institute PMI Positive Material Identification HT Heat Treatment RT Radiography Testing HIC Hydrogen Induced Cracking SSCC Sulphide Stress Corrosion Cracking ITP Inspection and Test Plan TC Test Certificate IP Ingress Protection TPI or TPIA Third Party Inspection Agency IHT Intermediate Heat Treatment UT Ultrasonic Testing IC Inspection Certificate VDR Vendor Data Requirement IGC Inter Granular Corrosion WPS Welding Procedure Specification MPT/MT Magnetic Particle Testing WPQ Welders Performance Qualification MTC Material Test Certificate
Inspection Standards Committee
Convenor : Mr. R.K. Singh
Members: Mr. Rajeev Kumar
Mr. Himangshu Pal Mr. Neeraj Mathur Mr. T Kamalakannan Mr. Mahendra Mittal Mr. Deepak Gupta (Project)
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL — All rights reserved
Page 10198 of 13748
TC65436-R01 Page 185 of 227
STANDARD SPECIFICATION No.
6-81-0007 Rev.4 Page 3 of 6
1,531ReJe1 eh ENGINEERS ftitMes NW INDIA LIMITED
1.11771 ereCIRE
INSPECTION AND TEST PLAN FOR
BOLTING MATERIAL
1.0 SCOPE:
This Inspection and Test Plan covers the minimum testing requirements of Bolting Material.
2.0 REFERENCE DOCUMENTS:
PO/PR/ Standards referred there in/ Job specifications /Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS:
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER EIL/TPIA
1.0 Procedure
1.1 Heat Treatment & NDT Procedures Documented Procedures 100% Procedure
Documents - H R
2.0 Material Inspection
2.1 Raw Material Inspection Chemical, Steel making process, Macro Etch , etc. 100% Test
Certificates H H R
3.0 In Process Inspection
3.1 Thread Rolling,
Hot forging of Nuts/Bolt Heads, Machining
Process Parameters 100% Inspection Report - H -
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10199 of 13748
TC65436-R01 Page 186 of 227
eJel. I.tryn rirowe
ENGINEERS INDIA LIMITED (A Govt of India Undertalongj
INSPECTION AND TEST PLAN FOR
BOLTING MATERIAL
STANDARD SPECIFICATION No.
6 -81 -0007 Rev.4 Page 4 of 6
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER EIL/TPIA
3.2 Heat Treatment
Normalising & Tempering, Quenching & Tempering
Solution Annealing, Stabilization Heat Treatment, Strain
Hardening, Nitriding etc. as applicable
100% Report
Inspection - H R
3.3 NDT (as applicable) Defects detection 100% Test Reports - H R
3.4 Identification of Test Samples
Product Chemical, Proof Load Test, Stress Rupture, Tensile, Hardness, Impact,
and Other test as applicable
Lot as per specification. Test Reports - H W
3.5 Destructive Testing Product Chemical, Proof
Load Test , Stress Rupture, Mechanical, Impact and Other test as applicable
Lot as per specification. Test Reports - H W
3.6 Galvanizing (If Applicable)
Integrity Of Galvanised Coating 100%
. Inspection
Report - H R
4.0 Final Inspection
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL — All rights reserved
Page 10200 of 13748
TC65436-R01 Page 187 of 227
WWI m.o,fecolawanil
STANDARD SPECIFICATION No.
6-81-0007 Rev.4 Page 5 of 6
ENGINEERS aem laaj eg INDIA LIMITED
IA Govt. of Indio Undefteking)
INSPECTION AND TEST PLAN FOR
BOLTING MATERIAL
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER EIL/TPIA
4.1 Visual & Dimension Visual Marking &
Dimensions
100% by supplier &
Random by EIL / TPIA
Inspection Report
- RW
(Note-3)
4.2 Final Stamping Stamping of Accepted
Bolting Material
Stamping of bolting material
which are witnessed by EIL/TPIA.
Others to have suppliers
identification.
Inspection Report
_ H W
4.3 PMI Check
Chemical Check As Per ElL
Spec. 6-81-0001
Inspection repo report
_ - H W
5.0 Painting
5.1 Rust Preventive & Color
Coding (as applicable) Visual & Color Coding as
applicable 100% Inspection
Report - H -
6.0 Documentation & IC
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL —All rights reserved
Page 10201 of 13748
TC65436-R01 Page 188 of 227
(A Gout at India Undedaking)
STANDARD SPECIFICATION No.
6-81-0007 Rev.4
Page 6 of 6
401 ei ENGINEERS 1g -a faiteg INDIA LIMITED
(.112Fr frelAVIRMINA)
INSPECTION AND TEST PLAN FOR
BOLTING MATERIAL
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER EIL/TPIA
6.1 Documentation & Inspection Certificate(IC)
Review of Stage Inspection Reports / Test
Reports & Issue of IC 100%
Supplier TC & IC
H
- H
Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness {As specified or 10% Max. ( min.1 no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).
Notes (as applicable): 1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be
applicable.( unless otherwise agreed upon) 2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.
3. Final visual and dimension shall be checked as per below sampling plan:
Lot Size (Nos.) Sample Size (Minimum)
Upto 100 2% (Min. 2 Nos.)
101 to 500 1% (Min. 3 Nos.)
501 and above 0.5% (Min.5Nos.)
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL — All rights reserved
Page 10202 of 13748
TC65436-R01 Page 189 of 227
TKK RKS SCG DM
TKK SCG AKC DM
AM SS MVKK VC
Prepared By
Checked By
Standards Committee Convenor
Standards Bureau Chairman
Approved by
4 14 11 2018
3 17 06 2013
2 15 07 2011
1 02 01 2008
Rev. No Date
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
REVISED AND RE-ISSUED
Purpose
0151-zieS- ENGINEERS leffalegi NW INDIA LIMITED
INSPECTION AND TEST PLAN FOR
GASKETS
STANDARD SPECIFICATION No.
6-81-0008 Rev. 4 Page 1 of 5
ill et' * fitvur ISTuf I All
INSPECTION AND TEST PLAN FOR
GASKETS
Format No 8-00-0001-F7 Rev 0 Copyright EIL —All rights reserved
Page 10203 of 13748
TC65436-R01 Page 190 of 227
ERS ,gzirsia-AerNN8IiklEIMITED (A GEM al hal undertaking)
INSPECTION AND TEST PLAN FOR
GASKETS
STANDARD SPECIFICATION No.
6-81-0008 Rev. 4 Page 2 of 5
Abbreviations:
MRT NDT NPSH PO PESO PQR PR PMI RT SSCC TC TPI or TPIA UT VDR WPS WPQ
CEIL CIMFR CE DFT DPT DHT ERTL FCRI HT HIC ITP IP IHT IC IGC MPT/MT MTC
: Certification Engineers International Limited Central Institute of Mining & Fuel Research
: Carbon Equivalent Dry Film Thickness Dye Penetrant Testing De-hydrogen Heat Treatment Electronics Regional Test Laboratory Fluid Control Research Institute Heat Treatment Hydrogen Induced Cracking Inspection and Test Plan Ingress Protection Intermediate Heat Treatment Inspection Certificate Inter Granular Corrosion Magnetic Particle Testing Material Test Certificate
Mechanical Run Test Non Destructive Testing Net Positive Suction Head Purchase Order Petroleum Explosive Safety Organization Procedure Qualification Record Purchase Requisition Positive Material Identification Radiography Testing Sulphide Stress Corrosion Cracking Test Certificate Third Party Inspection Agency Ultrasonic Testing Vendor Data Requirement Welding Procedure Specification Welders Performance Qualification
Inspection Standards Committee
Convenor : Mr. R.K. Singh
Members: Mr. Rajeev Kumar Mr. T Kamalakannan
Mr. Neeraj Mathur Mr. Himangshu Pal Mr. Mahendra Mittal Mr Deepak Gupta (Projects)
Mr. R Muthu Ramalingam (RPO Rep.)
Format No 8-00-0001-F7 Rev 0 Copyright EIL — All rights reserved
Page 10204 of 13748
TC65436-R01 Page 191 of 227
aatlEqENGINEERS Ird-efalW ag,g INDIA LIMITED
Goset of India Undertaking)
INSPECTION AND TEST PLAN FOR
GASKETS
STANDARD SPECIFICATION No
6-81-0008 Rev. 4 Page 3 of 5
1.0 SCOPE
This Inspection and Test Plan covers the minimum testing requirements of Gaskets.
2.0 REFERENCE DOCUMENTS
PO/PR/ Standards referred there in/ Job specifications /Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL NO.
STAGE / ACTIVITY CHARACTERISTICS Q UANTUM
RECORD SCOPE OF INSPECTION
OF CHECK SUB SUPPLIER
SUPPLIER EIL/TPIA
1.0 Procedure
1.1 HT & Test Procedure Documented Procedures 100% Procedure Documents
H R
2.0 Material Inspection
2.1 Raw Material Inspection Chemical, Physical and other properties as per applicable
material specification 100% Test Certificates H H -
3.0 In Process Inspection
3.1 Punching & Finishing Finish & Dimension 100% Inspection Report - H -
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10205 of 13748
TC65436-R01 Page 192 of 227
laraZIeTft ENGINEERS lear El5legW INDIA LIMITED
can
INSPECTION AND TEST PLAN FOR
GASKETS
STANDARD SPECIFICATION No.
6-81-0008 Rev. 4 Page 4 of 5
SL NO. STAGE / ACTIVITY CHARACTERISTICS QUANTUM
RECORD SCOPE OF INSPECTION
OF CHECK SUB SUPPLIER SUPPLIER EIL/TPIA
3.2 Heat Treatment for RTJ
Gaskets (As applicable)
Time & Temperature 100% HT Chart H R
4.0 Final Inspection
4 1 Final Visual, Dimension &
Testing
Compressibility, Recovery, Seal ability, Groove Hardness for Ring & Tongue Joint etc as
applicable and Visual / Dimension
100% Inspection Report - H R
4.2 Final Stamping Stamping of Accepted Gaskets 100% Inspection Report - H -
4.3 PMI Check (as applicable) Chemical Check As Spec per EIL
: 6-81-001 Inspection Report - H R
5.0 Painting
5.1 Rust Preventive & Color Coding as applicable
Visual & Color Coding as applicable 100 % Inspection Report H
6.0 Documentation & IC
6.1 Documentation & IC Review of test reports,
Inspection documents & Issue of IC
100% Supplier Records / IC - H H
Format No 8-00-0001-F7 Rev 0 Copyright EIL — All rights reserved
Page 10206 of 13748
TC65436-R01 Page 193 of 227
wIlReleit ENGINEERS lIg7Et (Wleg INDIA LIMITED
(A Govt of inda Undeftakingj
INSPECTION AND TEST PLAN FOR
GASKETS
STANDARD SPECIFICATION No.
6-81-0008 Rev. 4 Page 5 of 5
Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.! no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).
Notes (as applicable):
1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable. (unless otherwise agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred therein /Job Specification /Approved Documents.
Format No 8-00-0001-F7 Rev 0
Copyright EIL — All rights reserved
Page 10207 of 13748
TC65436-R01 Page 194 of 227
eie,Ple41,,g1574)
STANDARD SPECIFICATION No.
6-81-0030 Rev.3
Page 1 of 7
ENGINEERS ffg-a1fal5rdgw INDIA LIMITED
(A Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
CARTRIDGE FILTER
ftfluur a trteTur
INSPECTION AND TEST PLAN FOR
CARTRIDGE FILTER
3 09.09.13 REVISED AND RE-ISSUED TKK RKS
2 15.07.11 REVISED AND RE-ISSUED HP SCG
1 21.01.08 REVISED AND RE-ISSUED CS SS
0 23.07.02 ISSUED FOR IMPLEMENTATION SKT NKN
Rev. No. Date Purpose Prepared
by Checked
by
Approved by
ik,C:---gr 7._.z• Cs=31,-
SCG DM
AKC DM
MVKK VC
AKB GRR
Convener Chairman Standards Committee Standards Bureau
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10373 of 13748
TC65436-R01 Page 195 of 227
f - r laiWteg N17 FREW ASI,g1,11
ENGINEERS INDIA LIMITED (A Govt of India Undettaking)
INSPECTION AND TEST PLAN FOR
CARTRIDGE FILTER
STANDARD SPECIFICATION No.
6-81-0030 Rev.3
Page 2 of 7
Abbreviations:
CEIL Certification Engineers International Limited MRT Mechanical Run Test CIMFR Central Institute of Mining & Fuel Research NDT Non Destructive Testing CE Carbon Equivalent NPSH Net Positive Suction Head DFT Dry Film Thickness PO Purchase Order DPT Dye Penetrant Testing PESO Petroleum Explosive Safety Organization DHT De-hydrogen Heat Treatment PQR Procedure Qualification Record ERTL Electronics Regional Test Laboratory PR Purchase Requisition FCRI Fluid Control Research Institute PMI Positive Material Identification HT Heat Treatment RT Radiography Testing HIC Hydrogen Induced Cracking SSCC Sulphide Stress Corrosion Cracking ITP Inspection and Test Plan TC Test Certificate IP Ingress Protection TPI or TPIA Third Party Inspection Agency IHT Intermediate Heat Treatment UT Ultrasonic Testing IC Inspection Certificate VDR Vendor Data Requirement IGC Inter Granular Corrosion WPS Welding Procedure Specification MPT/MT Magnetic Particle Testing WPQ Welders Performance Qualification MTC Material Test Certificate
Inspection Standards Committee
Convenor : Mr. S C Gupta
Members:
Mr. R.K. Singh
Mr. Rajeev Kumar Mr. Himangshu Pal Mr.Neeraj Mathur
Mr. T Kamalakannan Mr. Deepak Gupta (Project) Mr. Mayank Jain
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10374 of 13748
TC65436-R01 Page 196 of 227
1 a4r, enl ,pasn .1 1
STANDARD SPECIFICATION No.
6-81-0030 Rev.3
Page 3 of 7
fail& ENGINEERS INDIA LIMITED (A Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
CARTRIDGE FILTER
1.0 SCOPE:
This Inspection Test Plan covers the minimum testing requirements of Cartridge Filter
2.0 REFERENCE DOCUMENTS:
PO/PR/ Standards referred there in/ Job specifications /Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS:
SL NO.
STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK
RECORD SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
1.0 Procedures
1.1 Hydro test ,heat treatment, NDT,
hot forming, and other Procedures
Documented procedures. 100% Procedure
Documents - H R
1.2 WPS/ PQR /WPQ Documented procedures. 100% Procedure documents
- H R-Existing
W-New
2.0 Materials inspection
2.1 Plates, pipes, forging,
fittings ,etc
Chemical analysis & mechanical properties as per
PR/data sheet. 100%
Mill test certificates
and TPI reports
H H R
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10375 of 13748
TC65436-R01 Page 197 of 227
ENGINEERS INDIA LIMITED IA Govt or India Undertaking)
INSPECTION AND TEST PLAN FOR
CARTRIDGE FILTER
STANDARD SPECIFICATION No.
6-81-0030 Rev.3
Page 4 of 7
i=g-111Gliai5VeS e1 ore mt.mm. )
SL NO.
STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK
RECORD SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
2.2 Cartridge Cartridge properties 100% Test
Certificate H R -
3.0 In process inspection
3.1 Materials identification for
plates, pipes (pressure parts)
Review of test certificates, markings, visual &
dimensional inspection, identity correlation &
transfer of identity
100% record
Material clearance - H H
3.2 Material identification for
forgings, fittings, fasteners, gaskets (pressure parts)
Review of test certificates, markings identity
correlation . 100%
Material clearance
record - H R
3.3 Non pressure parts (including
internals, supports etc.) Review of test certificates 100 %
Material test
certificate - R R
3.4 Inspection of formed
components
NDT of weld seam as applicable
100% NDT
Reports / RT Films
H H R
DPT on knuckle portion (both inside and out side)
100% Inspection report
H H R
HT chart review as applicable
100% HT Chart H W R
Test coupon as applicable 100% Inspection
report H W W
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10376 of 13748
TC65436-R01 Page 198 of 227
iArr-vo FreL517 en, .N4..11
STANDARD SPECIFICATION No.
6-81-0030 Rev.3
Page 5 of 7
ENGINEERS Li tififieg INDIA LIMITED
(A Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
CARTRIDGE FILTER
SL NO.
STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK
RECORD SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
Visual & dimensional (min.thickness, profile, ovality etc ) inspection
100% report
Inspection H H W
3.5 Weld edge preparation & set up of pressure parts
Visual & dimensional inspection, weld edge, root
gap, offset, alignment, cleanliness etc
100% Inspection check list
- W R
3.6 Welding consumable Chemical , mechanical
properties & IGC as applicable
100% Batch test certificates
H H R
4.0 Final inspection
4.1 Visual and dimensional
inspection (internals & externals) including welds
Visual/ dimensions, completeness of assembly
and weld visual for reinforcement, undercuts,
Surface defects, etc.
100% Inspection
report - H H
4.2 Air test of pads Leak check 100% Test report - W R
4.3 Inspection of completed welds
PWHT as applicable 100% HT chart H R
NDT as applicable 100% NDT rep report / RT films
- H R
Production test coupon testing as applicable
as per specification /
drawing
Inspection report rt
- H H
Hardness for weld /HAZ as applicable
As per spec. Inspection
report H R
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10377 of 13748
TC65436-R01 Page 199 of 227
1.7,1 rircro 451.3IICF711
STANDARD SPECIFICATION No.
6-81-0030 Rev.3
Page 6 of 7
ENGINEERS Ogzu idigt-g INDIA LIMITED
(A Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
CARTRIDGE FILTER
SL NO.
STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK
RECORD SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
4.4 PMI as applicable Chemical check Each component
and weld Inspection
report - H R
4.5 Hydrostatic test Leak check 100% Test report - H H
4.6 Installation Cartridges Visual check 100% Inspection
report - H
4.7 Drying and Nitrogen Filling (as
applicable) Nitrogen Pressure 100%
Inspection report
- W -
5.0 Painting
5.1 Final painting (As applicable)
Visual inspection (after surface preparation and final painting for workmanship,
uniformity) DFT check
100% Inspection
report - H -
6.0 Documentation and IC
6.1 Final stamping, review of
inspection documents and issue of IC
Verifying stamping details and review of inspection
documents 100%
IC / Inspection
reports - H H
6.2 Final documents as per PR Verification & compilation of inspection & test records for submission to customer
100% Final
dossier - H H
Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).
NOTES (as applicable):
Format No. 8-00-0001-F7 Rev. 0
Copyright EIL — All rights reserved
Page 10378 of 13748
TC65436-R01 Page 200 of 227
ei2Zr2 t75I
STANDARD SPECIFICATION No.
6-81-0030 Rev.3
Page 7 of 7
ENGINEERS 51g-aj 25reg w INDIA LIMITED
(A Govt Al Indio Undertaking)
INSPECTION AND TEST PLAN FOR
CARTRIDGE FILTER
1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable.( unless otherwise agreed upon)
2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
Page 10379 of 13748
TC65436-R01 Page 201 of 227
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