HPCL Cement Lined Spec PDF

Page 1 of 7
STANDARD SPECIFICATION FOR

CEMENT LINED PIPING
DOCUMENT NO: 44LK-5100/L.02/001/A4
Rev Issue Date Pages Rev Description Prepared Checked Approved

No. By By By
0 02-01-2009 7 Issued for Feed ASJ PUP RMP / PVS
JACOBS
HPCL, Mumbai STANDARD SPECIFICATION Doc. No:- 44LK-5100/L.02/001/A4
Refinery FOR
DHT Project CEMENT LINED PIPING Rev. 0
Date of Issue: 02/01/09 Sheet 2 of 7
TABLE OF CONTENTS
1.0 SCOPE
2.0 COADES & STANDARDS
3.0 MATERIALS
4.0 LINING APPLICATION
5.0 CURING
6.0 PROCEDURE QUALIFICATION
7.0 INSPECTION
8.0 REPAIRS OF LINING
9.0 PIPE JOINTS
10.0 FITTINGS & FLANGES
11.0 BRANCH CONNECTIONS
12.0 HANDLING & TRANSPORTATION
13.0 REFERENCE DOCUMENTS
JACOBS
Doc.No:- 44LK-5100/L.02/001/A4 STANDARD SPECIFICATION HPCL, Mumbai Refinery
FOR
Rev. 0 CEMENT LINED PIPING DHT Project
Sheet 3 of 7 Date of Issue: 02/01/09
1.0 SCOPE
1 This specification shall be followed in connection with ANSI / AWWA C-205-95 for cement
lining or piping at shop/field by the contractor. This covers the minimum requirements of
materials, mixing, application of cement lining, curing, inspection, repair, handling &
transportation of piping system carrying sea-water, brackish water up to 70 0C and 10.55
Kg/cm2 g (65 0C and 16.0 Kg/cm2 g for fire water) pressure for piping system 3” and above. The
provisions of this specification shall govern over and above AWWA C205 and relevant piping
material classes gives in job Piping Material Specification.
2.0 CODES AND STANDARDS
i) ANSI/ AWWA C205-95 Cement mortar protective lining and coating for steel water
pipe-shop applied
ii) AWWA C602-83 Cement mortar lining of water pipelines in place
iii) ASME B31.3 ASME code for Pressure piping –chemicals Plant & Petroleum
refinery piping
iv) IS: 12330 Specification for sulphate resisting Portland cement
v) IS: 383 Coarse & fine aggregates from natural sources for concrete
vi) IS: 456 Code of practice for plain & reinforced concrete
vii) ASTM A-82 Standard specification for steel wire, plain, for concrete
reinforcement
viii) ASTM A-185 Standard specification for steel welded wire fabric, plain, for
concrete reinforced
3.0 MATERIALS
3.1 Pipes & piping materials
Basic pipe fittings, flanges etc. shall be carbon steel or cast iron and designed as per ASME B-
31.3 as per the relevant piping material specifications (A5Y) given in job
PMS (Refer document no.44LK-5100-00/L.02/0101/A4 ) for the project.
3.2 Cements
Cement used in mortar lining shall be sulphate resistant as per ASTM C150 type-II or Portland
cement conforming to IS: 12330. Cement shall be free of lumps.
3.3 Sand
Sand shall consist of inert granular material and the grain shall be strong, durable and
uncoated. Sand shall be clean and free from injurious amount of dust, clay, flaky particles, oil,
alkali, mica and other deleterious substances. Sand shall conform to IS: 383 grading zone III.
3.4 Water
Water used for cement mortar mixing and curing shall be clean and free from injurious
ingredients or organic matter, alkali, oil, acid, salt, sugar or other impurities and shall confirm to
IS: 456. Salt water shall not be used for mixing under any circumstances.
3.5 Reinforcement
Reinforcement shall consist of welding steel wire fabric. Wires shall conform to ASTM A-82.
Steel wires shall be galvanised at finished size. Wire fabric manufactured in flat sheets to
ASTM A-185 shall be 2”x 4” maximum steel wire mesh, with wire 12 SAG (2.6 mm minimum)
JACOBS
Refinery FOR
each way.
4.0 APPLICATION
4.1 Cement mortar mixing
Cement lining shall be done in the field shop, which may be outside the refinery boundary.
Suitable mechanical equipment capable of mixing mortar and doing the lining work to a
reasonable degree of uniformity w.r.t. thickness, density and strength shall be employed.
Mortar shall be mixed in batches.
Mortar shall be composed of cement, sand and water and mixed well in proper consistency to
obtain a dense, homologous lining that shall adhere firmly to the pipe surface. Cement mortar
for lining shall consist of one part cement to not more than three parts sand by weight.
Water-cement shall be between 0.3 to 0.4 by volume.
Trial mixes shall be made to arrive at mix to achieve the requirements specified in procedure
qualification clause 6.0 below.
4.2 Surface preparation & primer application
Pipes shall be welded in suitable length and immediately prior to lining, the surface shall be
thoroughly cleaned removing all grease, scale, rust etc. by power tool to St.3 as per ISO 8501-
1/ SIS 05 5900/ BS 4232. Surface cleaning shall be followed by spray application of welding
grade of inorganic zinc silicate prefabrication primer from approved paint manufacturers with a
dry film thickness of 25 microns at both the pipes ends up to 100 mm pipe length. The cement
lining shall be done at least after 10 hours drying of the prefabrication primer to avoid damage
of the primer. Suitable products are such as inter plate-11 from M/s AKZO NOBEL coatings
(India) ltd., Banglore, Carboweld-11 from M/s Carboline product Chennai.
4.3 Application of reinforcement
Pipes & fittings in sizes 26” and above shall be cement lined with reinforcement. Wire fabric
reinforcement shall be applied to the interior pipes and fittings.
Reinforcement shall be placed in pipe in such a way as to cover the whole pipe length or
section to be lined. The reinforcement shall terminate at a distance of approx. 50 mm from the
ends. The reinforcement then shall be suitably tack welded. There shall be an overlap of
minimum 25 mm at the longitudinal joint of the reinforcement.
For the pipe butt joints, reinforcement in the form of strip approx. 150 mm wide shall be placed
and tack welded.
There shall be an overlap of minimum 25 mm between two reinforcement sections.
4.4 Lining application
The lining shall be applied in one course for the pipe section. No unfinished surface shall
remain exposed for more than 20 minutes. Mortar shall be handled so as to avoid any kind of
segregation and excessive moisture loss. During mortar application pipes should be ambient
temperature. If pipe is hot due to such reasons as lying in the hot sun, then the pipe must be
cooled with the help of wet gunny bags prior to application of mortar. Lining shall be free of any
sharp corners and edges and must be suitably contoured/rounded prior to curing.
For the lining at the joints of two pipes, reinforcement shall be applied as per 4.3 above. Old
lining shall be suitably hacked to make it rough before filling mortar. Prior to mortar filling
cement slurry may be applied on the surface.
JACOBS
FOR
Straight section of pipe shall be lined by using spinning method or a method known to provide
equivalent results such as by a machine travelling through the pipe and distributing the freshly
mixed mortar uniformly along the full section and long radius bends of the pipe. The lining
machine shall be provided with attachment for mechanically trowelling the mortar. Both the
application and trowelling of the mortar shall take place at the rear of the machine so that the
freshly placed and trowelled mortar will not be damaged. The trowel attachment, the rate of
travel of machine and the rate of discharge of mortar shall be such that the pressure applied to
the lining will be uniform and produce a lining of uniform thickness with a smooth finished
surface.
Hand patching of the end of the bore of the pipe, for length not more than 100 mm length, shall
be permitted to rectify the thinning of linings.
Fittings and specials shall be centrifugally spray lined to the same standard as straight pipes
or, if this is precluded by their shape, be hand patched so as to achieve comparable results.
The thickness of lining shall be as per figure-01. However to accommodate the disc
movement of butterfly valve the cement lining of the mating flanged spool shall be
suitably tapered keeping minimum 3mm lining thickness.
5.0 CURING
After lining, the pipe shall be marked with the date of lining and shall be cured either by misting
curing as per AWWA C-205.
Moist curing shall starts after 24 hours of completion of cement lining and shall be done by
continuous wetting or ponding. Under no circumstances the lining shall be allowed to dry
during curing period. Curing shall be carried out for minimum period of 7 days.
6.0 PROCEDURE QUALIFICATION
Prior to the application of the shop cement lining the manufacturer shall perform procedure
tests and qualify a working procedure to demonstrate that he is able to produce a lining system
in accordance with design requirements. The constituents, mortar & finished pipe shall be
tested. To establish the correct combination of sand & water, minimum of five samples shall be
prepared. For each mix following shall be accurately checked and recorded:
For individual constituents
Cement / admixture
Sand
Water
Proportions & weight of respective materials.
For cement mortar test specimen
Density
Compressive Strength
Water absorption
JACOBS
Refinery FOR
Test blocks of this material when subjected to testing as per IS 6441/IS 4031. shall exhibit
compressive strength of not less than 200 Kg/sq. cm. After 28 days of curing and the density of
cured lining shall be less than 2300 kg/cu.m. Water absorption as per ASTM C642 shall not
exceed 10 % for the test specimen
Based on the test results a procedure shall be standardised for mixing of the materials.
Inspection personnel shall witness the mixing of materials and sample preparations for
procedure qualification. Test result shall be correlated with sample no. and a stand red
procedure shall be evolved.
7.0 INSPECTION DURING PRODUCTION
The entire procedure of applying cement-mortar lining shall be subjected to continuous
inspection by owner or their authorised representative. However, such inspection shall not
relieve the contractor of the responsibility of meeting the specifications. The job shall be
subjected to inspection at the following stages:
i. After surface preparation and prior to application of lining.
ii. After the application of reinforcement if any
iii. After application and curing
Any lining not applied in accordance with this standard or as per required thickness shall be
subjected to rejection and replaced / repaired at the expense of the contractor.
The inspector shall have free access to all areas and facilities concerned, and contractor shall
furnish all reasonable assistance.
The inspection of lining in pipe up to 24” dia. shall be made from both ends of the lined pipe
segment by using strong lights and / or mirrors. The inspection shall be done before the lining
has attained its initial set. For pipes 24” & above, a manual, visual inspection of the lined pipe
interior shall be made.
Defects in cement-mortar lining include, but are not limited to, sand pockets, voids, over
sanded areas, honey comb, excessively cracked, drummy areas, areas of lining thinner than
specified, and areas of unsatisfactory surface finish.
The surface of lining shall be smooth and free from irregularities; cracks up to 0.8 mm wide and
not over 300 mm in length are acceptable. Trough to crest height shall not exceed 1.0 mm.
8.0 REPAIR OF LINING
For pipes up to 24” dia, the defective lining shall be removed in total from the pipe segment
before the initial setting. The pipe segment shall then be relined in full compliance with the
specifications.
For pipes above 24”, small defective areas shall be repaired by manual removal of the
defective lining and by hand reapplication of mortar lining. Defective areas encompassing the
full dia of the pipe shall be replaced by machine wherever practical.
9.0 PIPE JOINTING
Refer Drg. no :44LK-5100/L.02/8401/A4 (1 OF 6) - figure-01 for joints details (Attached.)
10.0 FITTINGS & FLANGES
All fittings up to 24” size shall be flanged ends. Flanges may be welded in field shop prior to
lining. For details refer Drg. no :44LK-5100/L.02/8401/A4 ( 2 of 6) fig-02(attached). Flanges
faces shall be free of cement lining.
11.0 BRANCH CONNECTION
a. Branches in cement-lined pipes shall be of minimum of 3” size. Stub in branch
connections of size 3” onwards shall be flanged as per figure-03.
JACOBS
FOR
b. Branches connections of sizes less than 3” shall be with 3” flanged stub as per figure-
03 instruments branches for temperature and pressure instruments shall e as per
figure-04 & 05. The 3” blind flanges shall be drilled to suit inst. / vent / drain size. The
blind flanges used for instruments connections shall be as per instrumental standards.
Other blind flanges used shall be internally FRE lined (refer figure-06).
c. Vents and drains on cement-lined piping shall be by 3” flanged stub with blind flange,
which is internally epoxy (FRE) lined. The blind flange shall be provided 3/4” tapped
hole and 3/4” vent/drain with valve and blind. Refer figure –06 for details of vents and
drains
12.0 HANDLING AND STORAGE:

Care shall be exercised during loading, hauling, unloading and storage to prevent damage to
any of the parts of lined pipes/fittings. Pipes and specials shall be suitably braced, supported to
provide suitable bearing area to prevent damage to the coating and tied to prevent shifting or
distortion of the pipes during transportation.
Plastic end caps shall be securely fastened to pipe ends of completed pipes for protection of
the cement mortar lining. End caps shall be maintained in place until time of installation.
13.0 REFERENCE DOCUMENTS (attached) :

Cement lined Drg.No. 44LK-5100/L.02/8401/A4 (fig 1 to 6)
Page 1 OF 15
HINDUSTAN PETROLEUM CORPORATION LIMITED

MUMBAI REFINERY
DHT PROJECT
TITLE : JOB SPECIFICATION FOR WELDING CHARTS
DOCUMENT NO : 44LK-5100-00/L.02/0103/A4
Prepared By Approved By
Rev No. Issue Date Total Pages Rev Description Checked By
(PIPING) (PIPING)
0 13.07.2010 15 Issued for OSBL Mechanical Tender YSP DRP/PUP PVS/RMP

Page 2 OF 15
PROJECT NO. : 44LK-5100

INDEX - WELDING SPECIFICATION CHART
TITLE : DHT
CLIENT : HPCL DOC. NO. : 44LK-5100-00/L.02/0103/A4
ABBREVIATION:
GTAW: Gas Tungusten Arc Welding
SMAW: Shielded Metal Arc Welding
WPS: Welding Procedure Specification
PQR: Procedure Qualification Record
CS: Carbon Steel
LAS: Low Alloy Steel
SS: Stainless Steel
SHEET REV. NO. 0

DATE 13/7/2010
Page 3 OF 15

TITLE : DHT
1.0 GENERAL NOTES
1.1 SCOPE :
This document covers the Welding Specification for the piping classes covered in Piping
Material Specification ( 44LK-5100-00/L.02/0101/A4 ). WPS & PQR for the field fabrication
& erection of piping system shall be made in conformity with this document
Contractor to develop welding charts, if required for any additional Piping Specifications.
Practice to be followed as per existing Welding Charts and updated welding charts shall be
submitted for review / comments.
1.2 REFERENCE STANDARDS :

This document shall have to be read in conjunction with the latest revision of the following
documents :
a) Job Specification for Non-Destructive Examination Requirements of Piping, 44LK-5100-
00/L.02/0102/A4.
b) Piping Material Specification, 44LK-5100-00/L.02/0101/A4.
c) ASME Boiler & Pressure Vessel Codes Section V, VIII (Div-1), IX, II-C
d) ASME B 31.3
e) ASTM E 10
f) Standard specification for Fabrication & erection piping, 44LK-5100/L.02/0105
g) Standard Specification for Fabrication on Piping, 44LK-5100/L.02/0104
h) Indian Boiler Regulation (IBR)
1.3 GTAW process can be applied in place & SMAW process with a corresponding suitable filler
metal for the application.
2.0 HISTORY OF REVISION
2.1 Revision 0
Issued for OSBL Mechanical Tender
SHEET REV. NO. 0

DATE 13/7/2010
TITLE : DHT
REVISION
WELDING CHART INDEX

SR.NO DESCRIPTION
1 WELDING CHART FOR PIPING CLASSES A1A, A9A, A10A, B1A 0
2 WELDING CHART FOR PIPING CLASSES A11A 0
3 WELDING CHART FOR PIPING CLASSES A14A, A16A, A35A,B16A 0
5 WELDING CHART FOR PIPING CLASSES B2A, D2A 0
7 WELDING CHART FOR PIPING CLASSES A5Y, J2A, J3A 0
8 WELDING CHART FOR PIPING CLASSES A5A, B5A 0
9 WELDING CHART FOR PIPING CLASSES A52A, B52A 0
10 WELDING CHART FOR PIPING CLASSES A3K 0
11 WELDING CHART FOR PIPING CLASSES J1M 0
SHEET REV. NO. 0

DATE 13/7/2010
PROJECT NO. : 44LK-5100 CLASS
WELDING SPECIFICATION CHART
REVISION
TITLE : DHT
SEE BELOW
CLIENT : HPCL SPEC NO. : 44LK-5100-00/L.02/0103/A4
REV NO. : 0 ISSUE DATE : 13/7/2010

PIPING CLASS A1A, A9A, A10A, B1A.
PIPES ASTM A 106 GR.B, A 672 GR B 60 CL 12, API 5L GR B PSL1.
MATERIAL FITTINGS ASTM A 105, ASTM A 234 GR WPB, ASTM A 234 GR WPBW.
SPECIFICATIONS FLANGES ASTM A 105, ASTM A 516 GR. 70.
OTHERS -
BASE METAL 'P' NO 1
GROOVE JOINT
BUTT OTHER THAN BUTT
ROOT PASS FILLER PASS ROOT PASS FILLER PASS
WELDING SMAW SMAW SMAW SMAW
PROCESS
GTAW
(NOTE-4)
FILLET JOINTS / SOCKET JOINTS SMAW
GROOVE JOINT
E7016 / E7018 E6010 / E6013 E7016 / E7018
E6010 / E6013
(NOTE-2)
(NOTE-2)
WELDING ER70 SG/
MATERIALS ER70S-2
(NOTE-4)
FILLET JOINTS / SOCKET JOINTS E7016 / E7018
BACKING RING CONSUMABLE INSERT

- -
JOINT PREPARATION ASME B 31.3
GASES PURGING - SHIELDING ARGON
GAS COMPOSITION PURGING - SHIELDING 99.995%
PREHEATING PREHEAT TEMP 10°C MIN /

100°C(FOR THK>=25.4 MM)
POST HEATING -
(NOTE 3)
CONTINUITY OF WELDING AND PREHEAT -
HOLDING TEMPERATURE HOLDING TIME
- -
POST WELD HEAT
RATE OF HEATING MIN. HOLDING TIME
TREATMENT
- -
(NOTE 1)
METHOD OF COOLING RATE OF COOLING
- -
MECHANICAL PROPERTY REQUIREMENTS CHARPY 'V' NOTCH IMPACT TEST VALUE
MINIMUM - AVERAGE -
AT TEMPERATURE -
HARDNESS -
CODE OF FABRICATION ASME B 31.3
TECHNICAL NOTES
1. HEAT TREATMENT SHALL BE DONE AS PER ASME B 31.3 FOR WALL THICKNESS EXCEEDING 19 MM.
2. E6013 MAY BE USED FOR ROOT PASS PROVIDED UNIFORM ROOT PENETRATION IS OBTAINABLE AND IS
DEMONSTRATED THROUGH PROCEDURE QUALIFICATION.
3. PRE-HEAT TEMPERATURE OF ATLEAST 50°C SHALL BE PROVIDED FOR THE FIRST TWO PASSES FOR
THK>=12.7MM & <25.4MM.
4. GTAW SHALL BE EMPLOYED FOR THE ROOT PASS WELDING FOR SMALL BORE PIPING OF DIAMETER 2" &
SMALLER.
SMAW: SHIELDED METAL ARC WELDING, GTAW: GAS TUNGSTEN ARC WELDING
REVISION
TITLE : DHT
SEE BELOW

PIPING CLASS A11A
PIPES ASTM A 106 GR.B, ASTM A 672 GR B 60 CL 12
SPECIFICATIONS FLANGES ASTM A 105, ASTM A 516 GR. 70.
OTHERS -
BASE METAL 'P' NO 1
GROOVE JOINT
WELDING SMAW SMAW SMAW
SMAW
PROCESS
GTAW
(NOTE-4)

GROOVE JOINT
ER7016/ E6010 / E6013 ER7016/
E6010 / E6013
E7018 (NOTE-2) E7018
(NOTE-2)
WELDING ER70 SG/

MATERIALS ER70S-2
(NOTE-4)
FILLET JOINTS / SOCKET JOINTS ER7016 / E7018

- -
PREHEATING 10°C MIN /

PREHEAT TEMP
100°C(FOR THK >=25.4 MM)
POST HEATING -
(NOTE-3)
- -
POST WELD HEAT
TREATMENT
- -
(NOTE-1)
- -
MINIMUM - AVERAGE -
AT TEMPERATURE -
HARDNESS 200 BHN MAX.
TECHNICAL NOTES
1. HEAT TREATMENT SHALL BE DONE AS PER ASME B 31.3 FOR WALL THICKNESS EXCEEDING 19 MM.
2. E6013 MAY BE USED FOR ROOT PASS PROVIDED UNIFORM ROOT PENETRATION IS OBTAINABLE AND
IS DEMONSTRATED THROUGH PROCEDURE QUALIFICATION.
3. PRE-HEAT TEMPERATURE OF ATLEAST 500C SHALL BE PROVIDED FOR THE FIRST TWO PASSES FOR THK.>=12.7 MM
& <25.4 MM.
4. GTAW SHALL BE EMPLOYED FOR THE ROOT PASS WELDING FOR SMALL BORE PIPING OF DIAMETER 2"
AND SMALLER.
REVISION
TITLE : DHT
SEE BELOW

PIPING CLASS A14A, A16A, A35A, B16A.
PIPES ASTM A 106 GR.B, ASTM A 672 GR B 60 CL 12
SPECIFICATIONS FLANGES ASTM A 105
OTHERS -
BASE METAL 'P' NO 1
GROOVE JOINT
WELDING GTAW/ GTAW GTAW/
GTAW
PROCESS SMAW SMAW
FILLET JOINTS / SOCKET JOINTS GTAW / SMAW

GROOVE JOINT
ER70S-2 ER70S-2/ ER70S-2 ER70S-2/
E7018 E7018
WELDING
MATERIALS
FILLET JOINTS / SOCKET JOINTS ER70S-2 / E7018

- -

PREHEAT TEMP
100°C(FOR THK >=25.4 MM)
POST HEATING -
(NOTE-2)
595-650°C 1 HR PER INCH THICKNESS
POST WELD HEAT
TREATMENT
200°C/HR MAX 1 HR
(NOTE-1)
CONTROLLED 200°C/HR MAX
MINIMUM - AVERAGE -
AT TEMPERATURE -
TECHNICAL NOTES
1. POST WELD HEAT TREATMENT SHALL BE DONE FOR ALL WALL THICKNESS
2. PRE-HEAT TEMPERATURE OF ATLEAST 500C SHALL BE PROVIDED FOR THE FIRST TWO PASSES FOR THK.>=12.7 MM
& <25.4 MM.
REVISION
TITLE : DHT
SEE BELOW

PIPING CLASS A19A
PIPES ASTM A 106 GR.B, ASTM A 672 GR.B60 CL.22
FITTINGS ASTM A 105, ASTM A234 GR.WPB, ASTM A234 GR.WPB-W
MATERIAL SPECIFICATIONS
FLANGES ASTM A105, ASTM A 516 GR. 70
OTHERS
BASE METAL 'P' NO 1
GROOVE JOINT
WELDING PROCESS ROOT PASS FILLER PASS ROOT PASS FILLER PASS
GTAW SMAW GTAW SMAW
GROOVE JOINT
ER 70-S2 E7016 / E7018 ER 70-S2 E7016 / E7018
WELDING MATERIALS

- -

PREHEAT TEMP 100°C(FOR THK >= 25.4 MM)
POST HEATING -
(NOTE 2)
595°C-650°C 1 HR PER INCH THK
POST WELD HEAT
TREATMENT
200°C/HR MAX. 1 HOUR
(NOTE 1)
CONTROLLED 200°C/HR MAX.
MINIMUM - AVERAGE -
AT TEMPERATURE -
HARDNESS

TECHNICAL NOTES
1. POST WELD HEAT TREATMENT SHALL BE DONE FOR ALL WALL THICKNESSES.
THK.>=12.7 MM & <25.4 MM.
REVISION
TITLE : DHT
SEE BELOW

PIPING CLASS B2A,D2A
PIPES ASTM A106 GR. B, ASTM A 672 GR. B60 CL. 12.
MATERIAL FITTINGS ASTM A 105, ASTM A234 GR WPB, ASTM A234 GR WPBW.
SPECIFICATIONS FLANGES ASTM A 105.
OTHERS -
BASE METAL 'P' NO 1
GROOVE JOINT
WELDING SMAW SMAW SMAW SMAW
PROCESS
GTAW
(NOTE-4)
GROOVE JOINT
E7016 / E7018 E6010 / E6013 E7016 / E7018
E6010 / E6013
(NOTE-2)
(NOTE-2)
WELDING ER70 SG/

MATERIALS ER70S-2
(NOTE-4)

- -
JOINT PREPARATION ASME B 31.3 & IBR

PREHEAT TEMP 100°C(FOR THK >=25.4 MM)
POST HEATING -
(NOTE- 3)

600+20°C 1 HR PER INCH THK
POST WELD HEAT
TREATMENT
(NOTE- 1)
CONTROLLED 200°C/HR MAX
MINIMUM - AVERAGE -
AT TEMPERATURE -
HARDNESS -
CODE OF FABRICATION ASME B 31.3 & IBR
TECHNICAL NOTES
1. HEAT TREATMENT SHALL BE DONE AS PER IBR FOR WALL THICKNESS EXCEEDING 19 MM.
THK.>=12.7 MM & < 25.4 MM.
4. GTAW SHALL BE EMPLOYED FOR THE ROOT PASS WELDING FOR SMALL BORE PIPING OF DIAMETER 2" AND
SMALLER.
REVISION
TITLE : DHT
SEE BELOW

PIPING CLASS A22A
FITTINGS ASTM A 105, ASTM A234 GR.WPB, ASTM A234 GR.WPBW
FLANGES ASTM A105, ASTM A 516 GR. 70.
OTHERS
BASE METAL 'P' NO 1
GROOVE JOINT
WELDING PROCESS
SMAW / SMAW / SMAW
SMAW
GTAW (NOTE-4,5) GTAW (NOTE-5)
GROOVE JOINT
E6010 / E6013 E6010 / E6013
(NOTE-2) (NOTE-2)
E7016 / E7018 E7016 / E7018
WELDING MATERIALS ER70SG / ER 70S-2 ER70SG / ER 70S-2
(NOTE-4,5) (NOTE- 5)
FILLET JOINTS / SOCKET JOINTS E7016/ E7018

- -
JOINT PREPARATION ASME B 31.3 & IBR
PREHEAT TEMP 100°C(FOR THK >= 25.4 MM) POST HEATING -
(NOTE- 3)
600+/-20 °C 1 HR PER INCH THK
POST WELD HEAT
TREATMENT
(NOTE 1)
CONTROLLED 200°C/HR MAX.
MINIMUM - AVERAGE -
AT TEMPERATURE -
HARDNESS -
CODE OF FABRICATION ASME B 31.3 & IBR

TECHNICAL NOTES
1. HEAT TREATMENT SHALL BE DONE AS PER IBR FOR WALL THICKNESSES EXCEEDING 19 MM.
THK>=12.7MM & <25.4MM.
4. GTAW SHALL BE EMPLOYED FOR THE ROOT PASS WELDING FOR SMALL BORE PIPING OF DIAMETER 2" &
SMALLER.
5. GTAW SHALL BE EMPLOYED FOR THE ROOT PASS FOR ALL THE SIZES FOR PIPING CLASSES WITH 100%
RADIOGRAPHY.
REVISION
TITLE : DHT
SEE BELOW

PIPING CLASS J2A, J3A, A5Y
PIPES ASTM A 106 GR.B, IS 1239, IS 3589 GR.330.
FITTINGS ASTM A 105 , ASTM A234 GR.WPB, ASTM A234 GR.WPB-W,
MATERIAL SPECIFICATIONS IS 1239 PART-II, IS 3589 GR.330
FLANGES ASTM A105, ASTM A 285 GR.C
OTHERS
BASE METAL 'P' NO 1
GROOVE JOINT
SMAW SMAW SMAW SMAW
GROOVE JOINT
E6010 / E6013 E6013 / E7016 / E7018 E6010 / E6013 E6013 / E7016 / E7018
WELDING MATERIALS
FILLET JOINTS / SOCKET JOINTS E6013 / E7016 / E7018

- -
GASES PURGING - SHIELDING -
GAS COMPOSITION PURGING - SHIELDING -
PREHEATING PREHEAT TEMP 10°C MIN POST HEATING -

- -
POST WELD HEAT RATE OF HEATING MIN. HOLDING TIME
TREATMENT - -
- -
MINIMUM - AVERAGE -
AT TEMPERATURE -
HARDNESS -

TECHNICAL NOTES
REVISION
TITLE : DHT
SEE BELOW

PIPING CLASS A5A, B5A
FITTINGS ASTM A 105, ASTM A234 GR.WPB, ASTM A234 GR.WPB-W
FLANGES ASTM A105
OTHERS
BASE METAL 'P' NO 1
GROOVE JOINT
GTAW GTAW / SMAW GTAW GTAW / SMAW
GROOVE JOINT
ER 70S-2 ER 70S-2 / E7018 ER 70S-2 ER 70S-2 / E7018
WELDING MATERIALS
FILLET JOINTS / SOCKET JOINTS E7018

- -
10°C MIN /
PREHEATING PREHEAT TEMP 100°C(FOR THK >= 25.4 MM)
POST HEATING -

- -
POST WELD HEAT
TREATMENT
- -
(NOTE 1)
- -
MINIMUM - AVERAGE -
AT TEMPERATURE -

TECHNICAL NOTES
1. HEAT TREATMENT SHALL BE DONE AS PER ASME 31.3 FOR WALL THICKNESSES 3/8 INCH AND ABOVE.
2. REFER JOB SPECIFICATION FOR SPECIAL REQUIREMENT OF HYDROGEN SERVICE.
REVISION
TITLE : DHT
SEE BELOW

PIPING CLASS A52A, B52A
FITTINGS ASTM A 105, ASTM A234 GR.WPB, ASTM A234 GR.WPBW
FLANGES ASTM A105
OTHERS
BASE METAL 'P' NO 1
GROOVE JOINT
GTAW GTAW / SMAW GTAW GTAW / SMAW
GROOVE JOINT
ER 70S-2 ER 70S-2 / E7018 ER 70S-2 ER 70S-2 / E7018
WELDING MATERIALS
FILLET JOINTS / SOCKET JOINTS E7018

- -
10°C MIN /
PREHEATING PREHEAT TEMP 100°C(FOR THK >= 25.4 MM)
POST HEATING -

- -
POST WELD HEAT
TREATMENT
- -
(NOTE 1)
- -
MINIMUM - AVERAGE -
AT TEMPERATURE -

TECHNICAL NOTES
1. HEAT TREATMENT SHALL BE DONE AS PER ASME 31.3 FOR ALL WALL THICKNESSES.
2. REFER JOB SPECIFICATION FOR SPECIAL REQUIREMENT OF HYDROGEN SERVICE.
REVISION
TITLE : DHT
SEE BELOW

PIPING CLASS A3K
PIPES ASTM A 312 TP.304, ASTM A 358 TP.304 CL.1
MATERIAL FITTINGS ASTM A 182 GR F304, A 403 GR WP 304-S, A 403 GR WP304-WX
SPECIFICATIONS FLANGES ASTM A 182 GR F304
OTHERS -
BASE METAL 'P' NO 8
GROOVE JOINT
WELDING
PROCESS
GTAW GTAW / SMAW GTAW / SMAW GTAW / SMAW
GROOVE JOINT
ER 308/ ER 308/ ER 308/ ER 308/
ER 308L ER 308L ER 308L ER 308L
WELDING
MATERIALS E 308-15/16 / E 308-15/16 / E 308-15/16
E 308L-15/16 E 308L-15/16 E 308L-15/16
FILLET JOINTS / SOCKET JOINTS E 308-15/16 / E 308L-15/16

- -
GASES PURGING ARGON SHIELDING ARGON
GAS COMPOSITION PURGING 99.995% SHIELDING 99.995%
PREHEATING PREHEAT TEMP 10°C POST HEATING -
- -
TREATMENT - -
- -
MINIMUM - AVERAGE -
AT TEMPERATURE -
HARDNESS -

TECHNICAL NOTES
REVISION
TITLE : DHT
SEE BELOW

PIPING CLASS J1M
PIPES ASTM A 312 TP 316.
FITTINGS ASTM A 182 GR. F316, ASTM A 403 GR WP316-S.
FLANGES ASTM A 182 GR F316.
OTHERS -
BASE METAL 'P' NO 8
GROOVE JOINT
GTAW GTAW / SMAW GTAW / SMAW GTAW / SMAW
GROOVE JOINT
ER316 / ER316/ ER316 / ER 316 /
ER316L ER316L ER316L ER316L
WELDING MATERIALS
E316-15/16 / E316-15/16 / E316-15/16
E316L-15/16 E316L-15/16 E316L-15/16
FILLET JOINTS / SOCKET JOINTS E 316-15/16 / E 316L-15/16

- -
GASES PURGING ARGON SHIELDING ARGON
GAS COMPOSITION PURGING 99.995% SHIELDING 99.995%
PREHEATING PREHEAT TEMP 10°C POST HEATING -
- -
TREATMENT - -
- -
MINIMUM - AVERAGE -
AT TEMPERATURE -
HARDNESS -

TECHNICAL NOTES
Page 1 OF 12
HINDUSTAN PETROLEUM CORPORATION LIMITED

MUMBAI REFINERY
DHT PROJECT
TITLE : JOBS SPECIFICATION FOR NON DESTRUCTIVE EXAMINATION

REQUIREMENT OF PIPING
DOCUMENT NO : 44LK-5100-00/L.02/0102/A4
Prepared By Approved By
Rev No. Issue Date Total Pages Rev Description Checked By
(PIPING) (PIPING)
0 13.07.2010 12 Issued for OSBL Mechanical Tender YSP DRP/PUP PVS/RMP

Page 2 OF 12
Client : HINDUSTAN PETROLEUM CORPORATION LTD Dept. / Sect. :

Project : 44LK-5100 Doc. No. : 44LK-5100-00/L.02/0102/A4
Location : DHT, MUMBAI
ABBREVIATIONS:
DP / LP : Dye / Liquid Penetrants
MP : Magnetic Particle
CS : Carbon Steel
AS : Alloy Steel
SS : Stainless Steel
ASTM : American Society of Testing & Materials
ASME : American Society of Mechanical Engineers
IBR : Indian Boiler Regulations
PMS : Piping Material Specification
SHEET REV. NO. 0

DATE 13/7/2010
Page 3 OF 12

SR. NO. TITLE PAGE NOS.
1.0 GENERAL 04 OF 12
2.0 VISUAL EXAMINATION 04 OF 12
3.0 NON DESTRUCTIVE EXAMINATION 05 OF 12
4.0 TABLE – 1 06 - 9 OF 12
(APPICABLE NOTES TO TABLE - 1) 10 - 12 OF 12
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Page 4 OF 12

1.0 GENERAL
1.1 SCOPE
General requirements for the non-destructive examination of shop & field fabricated piping are covered under
this specification.
1.2 RELATED CODES & ENGINEERING STANDARDS

Referred codes/ standards are as follows. Latest Editions of the codes / standards referred shall be followed.
A. ASME Boiler & Pressure Vessel Codes, Section V & VIII (Div.1) including addenda.
B. ASME B 31.3
C. ASME B16.5
D. ASME B16.34
E. Piping Material Specification, 44LK-5100-00/L.02/0101/A4
F. Welding Specification Charts for Piping Classes, 44LK-5100-00/L.02/0103/A4
G. Standard Specification for Fabrication & Erection Piping, 44LK-5100/L.02/0105
H. ASTM E10
I. Standard Specification for Fabrication on Piping, 44LK-5100/L.02/0104
2.0 VISUAL EXAMINATION

2.1 Weld shall be visually inspected wherever accessible in accordance with the following requirements:
A. Internal misalignment 1.5 mm or less
B. Cracks or lack of fusion Not permitted
C. Incomplete penetration (for other than 100% Depth shall not exceed the lesser of 0.8 mm or 0.2
radiography butt-weld) times thickness of thinner component joined by
butt-weld. The total length of such imperfections
shall not exceed 38 mm in any 150 mm of weld length.
D. Surface porosity and exposed slag inclusions Not permitted

(For nominal wall thickness 4.7 mm and less).
E. Concave root surface (suck up) For single sided welded joints, concavity of the root
surface shall not reduce the total thickness of joint,
including reinforcement, to less than the thickness
of the thinner of the components being joined.
F. Weld Ripples irregularities 2.5 mm or less
G. Lack of uniformity in bead width 2.5 mm or less
H. Lack of uniformity of leg length 2.5 mm or less
I. Unevenness of bead 2.0 mm or less
J. Weld undercutting 0.8 mm or ¼ thickness of thinner components joined by

butt weld, whichever is less (shall be smooth finished).
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DATE 13/7/2010
Page 5 OF 12

K. Overlap 1.5 mm or less
L. Bead deflection 2.5 mm or less
M. External weld reinforcement and internal weld protrusion (when backing rings are not used) shall be fused
with and shall merge smoothly into the component surfaces. The height of the lesser projection of external
weld reinforcement or internal weld protrusion from the adjacent base material surface shall not exceed the
following limits:
Wall thickness of thinner component joined Weld reinforcement or internal weld protrusion
by butt weld (mm) (mm) max.
6.4 and under 1.6
Over 6.4 – 12.7 3.2
Over 12.7 – 25.4 4.0
Over 25.4 4.8
N. Throat thickness of fillet welds: Nominal thickness of the thinner component X

0.7 or more.
O. Flattening Flattening of a bend, as measured by difference

between the nominal outside diameter and minimum
or maximum diameter at any cross section shall not
exceed 5% of the nominal outside diameter of pipe.
P. Reduction of wall thickness Reduction of wall thickness of a bend, as measured

by difference between the nominal thickness and
minimum thickness shall not exceed 10% of the nominal
wall thickness of pipe
2.2 Welds having any of imperfections which exceed the limitations specified in various clauses of 2.1 shall be repaired by
welding, grinding or overlaying etc. number of times of repair welding for the same weld, however shall conform to
applicable notes to table 1 - 6.0(B.)B.5.
3.0 NON DESTRUCTIVE EXAMINATION

3.1 The type and extent of weld examination shall be in accordance with Table - I. All visual and supplementary methods of
girth weld examination shall be in accordance with ASME B31.3 and the requirements of this standard specification.
3.2 Welds between dissimilar materials shall be examined by method and to the extent required for the material having
the more stringent examination.
3.3 Certain categories of critical piping are classified under inspection class IV (100 % radiography) as follows:
A. High Pressure : Classes 900# and above.
B. Severe cyclic : As defined by ASME B 31.3
C. Low temperature : Below temperature of -45°C.
D. Critical service : Hydrogen, Oxygen, NACE, Caustic, Chlorine

& such other critical services.
E. High alloys : 5% Cr. & above for all pressure classes.
F. High Temperature : Above 500°C
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Page 6 OF 12

4. TABLE - I (WITH APPICABLE NOTES)
TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION

INSPECTION CLASS : I
INSPN. SERVICE MATERIAL P. NO. TEMP. (°°C.) PRESS. CLASS APPICABLE TYPE OF TYPE OF WELD EXAMINED
CLASS (NOTE 3) B16.5 / B16.34 PIPING CLASS EXAMINATION
GIRTH BUTT SOCKET WELD ATTACHMENT FABRICATED FABRICATED
WELD (NOTE - 2) WELD BRANCH WELD WELDS OF
(NOTE - 1) MITRES / REDUC.
1 2 3 4 5 6 7 8 9 10 11 12 13
J2A, J3A
I CATEGORY "D" CARBON STEEL 1 0 TO 186 150# UPTO
FLUID SERVICE 10.55 KG/CM2
A3K, J1M
AUSTENIC SS 8 -29 TO 186
A. VISUAL 100% 100% 100% 100% 100%
---
HDPE --- -20 TO 50
B. LP --- --- --- 10% 10%
(NOTE 4, 6, 9)
---
CUPRO NICKEL 34 -29 TO 60
REMARKS FOR ABOVE TABLE :-

1. LP TEST NOT APPICABLE TO NON - METALLIC CLASSES.
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DATE 13/7/2010
Page 7 OF 12

TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTI..)

INSPECTION CLASS : II
1 2 3 4 5 6 7 8 9 10 11 12 13
A1A, A9A, A10A, A11A,
II A. ALL SERVICES COVERED CARBON STEEL 1 -29 TO 400 150#
A5Y A. VISUAL 100% 100% 100% 100% 100%
UNDER INSPECTION
CLASS - I BUT EXCEEDING
CATEGORY 'D' PR. / T
LIMITATIONS.
B. RADIOGRAPHY 10% --- --- --- 50%

(NOTE 5, 6)
B. ALL SERVICES OTHER A22A

THAN THOSE COVERED CARBON STEEL
UNDER INSPECTION C. MP* / LP --- 10% --- 10% 50%
(IBR)
CLASS - I BUT NON - (NOTE 4, 6,
TOXIC NOT SUBJECTED
10, 11)
TO SEVERE CYCLIC
CONDITIONS.
D. HARDNESS NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7

1. FOR A22A IBR SERVICE NOTE 8 IS ALSO APPLICABLE.
2. FOR A5Y FIRE WATER SERVICE NOTE 12 IS ALSO APPLICABLE.
3. EXTENT OF HARDNESS TEST FOR A11A IS 100%.
4. * - FILLET WELDS SHALL BE MP TESTED ONLY.
SHEET REV. NO. 0

DATE 13/7/2010
Page 8 OF 12


INSPECTION CLASS : III
GIRTH BUTT SOCKET WELD ATTACHMEN FABRICATED FABRICATED
WELD (NOTE - 2) T WELD BRANCH WELD WELDS OF
1 2 3 4 5 6 7 8 9 10 11 12 13
III A. TOXIC , NON-LETHAL CARBON STEEL 1 ABOVE -29 150# ---

A. VISUAL 100% 100% 100% 100% 100%
& FLAMMABLE
B. FLAMMABLE/ NON
FLAMMABLE & TOXIC / KILLED CARBON -45 TO 200 150# TO 600# ---
NON-TOXIC, NOT B. RADIOGRAPHY 20% --- --- --- 100%
STEEL
SUBJECT TO SEVERE (NOTE 5, 6)
CYCLIC CONDITION
B1A
ALL GENERAL SERVICES CARBON STEEL 1 -29 TO 425 300# TO 600#
C. MP* / LP --- 20% --- 20% ---
EXCEPT THOSE
SUBJECTED TO SEVERE (NOTE 4, 6, 11)
CYCLIC CONDITION
B2A, D2A
CARBON STEEL
D. HARDNESS NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7
(IBR)

1. FOR IBR SERVICE B2A AND D2A NOTE 8 IS ALSO APPLICABLE
2. * - FILLET WELDS SHALL BE MP TESTED ONLY.
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DATE 13/7/2010
Page 9 OF 12


INSPECTION CLASS : IV (CONTI..)
1 2 3 4 5 6 7 8 9 10 11 12 13
IV SERVICES SUBJECT TO CARBON STEEL 1, 3, --- A. VISUAL 100% 100% 100% 100% 100%
(CONTI.) SEVERE CYCLIC CONDITIONS & 0.5 TO 9 Cr. 4, 5 ALL ALL
Mo. STEEL
A5A, A16A, A19A, A35A, A52A,

SPECIAL SERVICES (NACE, O, B5A, B16A, B52A,
H, AMINE, CAUSTIC), VACUUM
B. RADIOGRAPHY 100% --- --- --- 100%

(NOTE 5, 6)
SERVICES SUBJECT TO 12 Cr. STEEL 6 ---

SEVERE CYCLIC CONDITIONS (TYPE 410 SS)
C. LP / MP* --- 100% 10% 100% ---
(NOTE 4, 6, 10,
SERVICES SUBJECT TO 3.5 Ni. STEEL 9 --- 11,13)
SEVERE CYCLIC CONDITIONS
SPECIAL SERVICES (NACE, O, ---

H, CAUSTIC)
41,
SPECIAL SERVICES (NACE, O, Ni. ALLOYS 42, --- D. HARDNESS NOTE 7 NOTE 7 NOTE 7 NOTE 7 NOTE 7
H, CAUSTIC) 43
---
ALL SERVICES 45

1. EXTENT OF HARDNESS TEST FOR CLASSES A5A, A52A, B5A, B52A IS 10% AND
FOR CLASSES A16A, A19A, A35A, B16A IT IS 100%.
2 * - FILLET WELDS IN CS/AS CLASSES SHALL BE MP TESTED ONLY.
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DATE 13/7/2010
Page 10 OF 12

APPLICABLE NOTE TO TABLE - 1

1.0 Branch welds shall consist of the welds between the pipe & reinforcing element (if any), nozzles & reinforcing element
and the pipe & nozzle under the reinforcing element. Reinforcing element to be interpreted as Pads, saddles, Weldolets,
sockolets etc.
2.0 Seal welds of threaded joints shall be given the same examination as socket welds.
3.0 Unless specifically stated, all materials shall be for “Non IBR” service.
4.0 Magnetic Particle & the Liquid Penetrant method of examination shall be in accordance with Section V of the ASME
Boiler and Pressure Vessel Code, Article VII and VI respectively. The entire area of the accessible finished weld surface
shall be examined. Selected root runs, subject to a maximum of 10%, before finished weld, may also be examined, at
the discretion of the engineer-in-charge.
A. Wherever MP / LP testing is specified, either MP or LP test may be used. But wherever only MP test is specified,
LP method of examination may be used only if MP examination is impracticable in the field as concurred by
site-in charge.
B. “Random 10%” of Liquid Penetrant / Magnetic Particle test shall mean testing, by applicable test, one weld for each
ten welds or less made by the same welding procedure or operator or both. Similarly “random 20 %” shall mean
testing, by applicable test, one weld for each five welds or less made by the same welding procedure or operator or both.
C. When Liquid Penetrant examination is specified, the surface shall be free of peened discontinuities. Abrasive blast
cleaning shall be followed by light surface grinding prior to Liquid Penetrant examination.
D. Inspection shall be performed in the welds excluding those for which radiography has been done.
E. Girth weld, branch weld, attachment weld & socket weld of 3-1/2% Ni steel shall be Liquid Penetrant tested only when
welded with austenitic material, where MP test has been specified.
5.0 RADIOGRAPHY
A. “Random 10% or 20% radiography” shall mean examining not less than one from each 10 welds or less in case of “Random
10% Radiography” or one from each five welds or less in case of “Random 20% Radiography” made by the same welding
procedure or welder or both. Irrespective of percentage, no. of welds to be radiographed shall be minimum 1. However first
two welds made by each welder shall also be radiographed in case of “Random Radiography”. Welds selected for examination
shall not include flange welds and shall be radiographed for their entire length. However, where it is impossible or impracticable
to examine the entire weld length of field welds for either random or 100% radiography, and if the same impossibility is
agreeable to site-in charge, then a single 120 deg. exposure of the weld length may be given a Magnetic Particle test or Liquid
Penetrant test. However in such cases for ferro-magnetic materials, only MP test shall be acceptable for classes higher
than 600#.
B. In process examination shall not be substituted for any required radiographic examination.
C. Number of radiograph per one circumferential weld shall be as per ASME Sec.V Article 2 and 22.
6.0 REPAIRS OR DEFECTS/ ACCEPTANCE CRITERIA

Wherever radiography or other non destructive inspection is specified, the acceptance criteria for repair or defects shall
be as follows:
A. In case of 100% examination, any unacceptable weld shall be repaired and re-inspected.
B. If required random examination reveals a defect requiring repair, then

B.1. Two additional examinations of same type shall be made of the same kind of item (if welded joint, then by the
same welding procedure or operator or both).
SHEET REV. NO. 0

DATE 13/7/2010
Page 11 OF 12

B.2. If the group of items examined as required by B.1. above is acceptable, the items requiring repair shall be repaired
or replaced and re-examined as required and all items represented by this additional examination shall be accepted.
B.3. If any of the items examined as required by B.1. above reveals a defect requiring repair, two further comparable
items shall be examined for each defective item found by examination.
B.4. If all the items examined as required by B.3. are acceptable, the items requiring repair shall be repaired or replaced
and re-examined as required, and all items represented by this further examination shall be accepted.
B.5. Number of times repair welding could be done for the same weld before acceptance shall be as follows:
MATERIAL NO. OF TIMES REPAIR WELDING IS ALLOWED

C.S. UPTO 300 # 3 OR LESS
C.S. ABOVE 300 # 2 OR LESS
KILLED STEEL 2 OR LESS
LOW ALLOY STEEL 2 OR LESS
AUSTENITIC S.S. 2 OR LESS
3.5 Ni STEEL 2 OR LESS
Al & Al BASE ALLOY 2 OR LESS
Cu & Cu BASE ALLOY 2 OR LESS
OTHERS 2 OR LESS
B.6. Welds not found acceptable for allowed number of times of repair as per B.5. above shall be replaced and re-examined.
B.7. If any of the items examined (as required by B.4.) above reveals a defect requiring repair, all items represented by
these examinations shall be either:

i. Repaired or replaced and re-examined as required.
ii. Fully examined and repaired or replaced as necessary, and re-examined as necessary.
7.0 HARDNESS TEST

A. Hardness test shall be in accordance with ASTM specification E10. Hardness tests of the heat affected zone
shall be made at the point as near as practicable to the edge of the weld. One test per weld shall be performed.
B. Hardness test where specifically called out in Table - 1 of this specification or in PMS, shall be carried out irrespective
of thickness and to the extent (% age) as mentioned therin.
C. All weld which are given heat treatment shall be hardness tested. Hardness test shall be performed after heat
treatment.
D. A minimum of 10% of welds of hot formed and hot bent material in each heat treatment batch which are furnace
heat treated and 100% of those which are locally heat treated, shall be hardness tested.
E. For C - 0.5 Mo. Steels, a minimum of 10% of welds shall be hardness tested.
F. Hardness test requirement not covered in B. & E. above shall be as per ASME B31.3.
G. The hardness limit applies to the weld and heat affected zone. Following hardness values shall be maintained:
BASE METAL GROUP MAXIMUM BRINELL HARDNESS (BHN/RC)

CS 238BHN / RC22
CS (NACE) 200BHN
Cr 0.5% OR LESS 225BHN
Cr > 0.5% & UPTO 2% 225BHN
Cr.2.25% - 10% 241BHN
18/8 SS (NACE) RC22
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DATE 13/7/2010
Page 12 OF 12

H. In case hardness values are mentioned in both Welding Specification Charts for Piping Classes, 44LK-5100-00/L.02/0103/A4
table given in Note - 7.G. the lower of the two values shall be applicable.
8.0 IBR SERVICE LINES

In addition to the Clauses 4, 5, 6, 7, 12 and Table - I, following IBR requirements shall apply. In case of conflict
between above notes and these requirements, the more stringent ones shall apply. IBR piping shall be erected of IBR
inspector approved material and the construction procedure. Erected piping shall be hydrotested, inspected and
approved by IBR inspector.
A. Piping over 4” NB:

10% of welds made by each welder on a pipeline with a minimum of two welds per welder, selected at random,
shall be subjected to radiography.
B. Piping 4” NB and under, but not less than 1½” NB:

Two percent of welds made by each welder on a pipeline with a minimum of one weld per welder, selected at
random, shall be subjected to radiography or may be cut for visual examination and tests.
C. Piping less than 1½” NB:

Special tests are not normally required but 2% of welds by each welder on a pipeline may be cut out from the
pipeline for the visual examination and bend tests.
D. Retest
If any test specimen is unsatisfactory, two further weld specimens for retests shall be selected from the
production welds and subjected to tests. In the event of failure of any retest specimens, the production welds
carried out by this welder subsequent to the previous test shall be given special consideration.
9.0 FABRICATED FITTINGS

LP test shall be done on the final pass of welding only, in addition to visual examination, root LP test & other
specified NDT.
10.0 MITRES AND FABRICATED REDUCERS

LP / MP Test shall be done on root pass in addition to radiography applicable to circumferential joint of respective piping class.
11.0 BRANCH CONNECTIONS

LP / MP test shall be done on root pass and final pass.
12.0 As per TAC requirements, 10% of the butt welded joints shall be radiographed, however, 50% of these butt weld joints
shall be field weld joints.
13.0 In addition to 100% radiography, butt weld joints for A16A, B16A & A35A classes shall be wet fluorescent magnetic
particle tested.
14.0 For lined specs, testing (MP / LP / Radiography etc.) shall be performed before lining.
SHEET REV. NO. 0

DATE 13/7/2010
Page 1 of 17
HINDUSTAN PETROLEUM CORPORATION LTD.
MUMBAI
DIESEL HYDROTREATER PROJECT
TITLE PAINTING SPECIFICATIONS
DOCUMENT NO. 44LK-S100-00-V.02-0002-04
REV ISSUE PAGES REV DESCRIPTION PREPARED CHECKED APPROVED

NO. DATE
BY BY BY
A 30.07.2008 17 Issued for Client's approval MVS CR HSC
o
05.12.2008 17 Issued for FEED f!'o, SNK CR .. HSC
1
22.09.2010 17 Issued for FEED MVS~ HSC@P
JACOBS
HPCL-MUMBAI PAINTING SPECIFICATIONS Page2of17
44LK-5100 Rev. 1
DOC.NO. 44LK-51 00-00-V.02-0002-A4 Date: 22.09.2010
TABLE OF CONTENTS
ANNEXURE - I PAINTING SPECIFICATION
ANNEXURE - II PAINTING SYSTEM FOR UNIT EQUIPMENT & PIPELINES
ANNEXURE -II HPCL SPECIFICATIONS FOR PAINTS TO BE USED IN PAINTING OF UNITS
ANNEXURE - IV COLOUR CODE FOR PAINTING
44LK-5100-00-V.02-0002-M- Rev. 1 - Painting spec.doc

JACOBS
HPCL-MUMBAI PAINTING SPECIFICATIONS Page 3 of 17

44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
ANNEXURE -I
PAINTING SPECIFICATION
1.0 PAINTING SYSTEM & PAINT SPECIFICATIONS:
The painting system for equipment and piping in units shall be as follows:
Painting System: It shall be as per Annexure - II (3 Pages)
Specifications of the paints: It shall be as per Annexure - III (5 Pages).
Color Code for painting - Annexure IV (1 page)
2.0 GUARANTEE:
The paint manufacturer shall specify the following guarantee period of the system.
"Four years for all surfaces"
The paint manufacturer! authorized painting contractor shall furnish a performance bank guarantee to this
effect. All mechanical damage to painting (after completion of painting) will be excluded from this
guarantee. Client shall have the sole discretion to invoke the bank guarantee in full or part in case of paint
failure.
After completion of the job a report shall be generated every three months by Client about the paint
condition and the manufacturer shall make good all areas with paint failures within 30 days of reporting of
defects.
In case the agency is an approved manufacturer, it should give the guarantee for the paint supplied as
well as for defects in the paint application. Any defect in the guarantee period (as per Client report)
should be rectified free of cost immediately.
If the painting company is not able to take the job directly for some reason, it can authorize any reputed
painting contractor to paint on its behalf. In this case as the agency is not an approved manufacturer but
is a painting contractor authorized by the paint manufacturer to paint on its behalf, it shall give a joint
performance guarantee with the approved paint manufacturer and any defect in the paint application
during the guarantee period (as per Client report) will be rectified by the agency free of cost immediately.
It shall be the responsibility of the paint company to supervise the painting work and make sure that good
quality painting work is carried out. However, if the authorized painting contractor fails to make good the
defects reported by Client within stipulated time frame, it will become the responsibility of the paint
manufacture to repair all defects reported by Client. Non-rejection by the paint manufacturing company
does not in any way constitute acceptance of any defective work.
3.0 APPROVAL OF PAINTS:

Vendor shall indicate his offered paint system in line with applicable paint system along with vendor's
product catalogue & painting instructions. Vendor shall submit the paint (each and every tin of all types of
paint) along with the test certificates for Client approval at least 15 days prior to its proposed date of
application in field. The test certificate from the manufacturer shall clearly state type of paint, base of
paint, Batch No., Date of manufacture, Color, finish, shelf life, Temperature resistance, mixing ratio,
spreading rate, Density, Viscosity, Volume solids, Recommended DFT & Corresponding WFT, Touch dry
time, Hard dry time! Overcoat interval, % of metallic Zinc by weight in dry film for Inorganic Zn silicate
and Zn rich epoxy primers, % of epoxy resin by weight in mixed resin coal tar blend for coal tar epoxies
and other details specified by Client. Paints with test certificates without these details shall be rejected.
Client reserves the right to check the paint quality independently at any laboratory. The complete lot of
paint shall be accepted or rejected on this basis.
44LK-5100-00-V.02-0002-A4- Rev. 1 - Painting spec.doc

JACOBS

44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
4.0 SURFACE PREPARATION:

Shot blasting/girt blasting is the most preferred method of surface preparation. Power tool cleaning and
Hand tool-cleaning operation could be allowed in area where shot blasting is impractical due to approach
problem or height.
Three types of surface preparations have been specified by Client.
a) Shot Blasting:
It shall be as per Sa 2 1/2 (Near White Metal) of Swedish Standard SIS-05-5900 1967 / ISO 8501-1
1988. Contractor shall use Client approved equipment, shots for blasting, and moisture & oil free air. It
shall be the responsibility of the contractor to provide suitable protection for the nearby equipment and
insulation while carrying out shot blasting to avoid damage to them.
b) Mechanical or Power Tool Cleaning:

It shall be as per ST 3 of Swedish standard SIS -05-59001967/ ISO- 8501-1-1988. Depending upon the
locality, the contractor may be advised to use Client approved non sparking type brass mechanical
striking tools, brass chipping hammers, grinding wheels or rotating brass wire brushes.
c) Manual or Hand tool cleaning:

It shall be as per St 2 of Swedish Standard SIS -05-5900 1967/ ISO -8501-1-1988. Depending upon the
locality, the contractor may be advised to use Client approved only non sparking type (brass) - Hand de
scaling / hammering tools, hand scrapers and wire brushes.
It may be noted that in case of power tool cleaning or shot blasting, manual cleaning may be allowed
solely at HPCL discretion for the pockets/ areas where shot blasting or power tool cleaning is not
possible.
5.0 WASHING WITH FRESH WATER:

All bare lines/ vessels/ equipment shall be fully cleaned by fresh water before cleaning / shot blasting to
remove all possibilities of salt deposits. The subject surface shall be also cleaned before application of
next coat if area is subject to salt water sprays. Suitable arrangement for covering shall also be made
to avoid salt water sprays for complete duration of cleaning and painting till final coat cures
completely).
6.0 PAINTING AFTER CLEANING:

The primer coat shall be applied within 4 hours of cleaning. However, if rust spots appear even during this
interval, the same shall be re-c1eaned and re offered for inspection before applying the paint.
7.0 OVERCOAT DURATION:

The contractor shall strictly adhere to the minimum and maximum overcoat intervals for any painting
system as per paint manufacturer's recommendations. In case the contractor is not able to apply the
subsequent coats within the specified time frame, he will have to clean the surface to bare metal again as
per original specifications and reapply the total paint.
8.0 COLOR CODE:

.The contractor shall follow Client Color code. The contractor shall provide the finish coat such that it
meets the color code of the refinery. Contractor shall verify the RAL shade with the engineer in charge
before application. In rare circumstances, if the manufacturer cannot supply the requisite color of the
finish coat, the vendor shall apply approved color bands (epoxy or enamel) at Client approved locations
free of cost.
44LK-51 OO-OO-V.02-0002-A4- Rev. 1 - Painting spec.doc

JACOBS
44LK-5100 Rev. 1
DOC.NO. 44LK-5100-00-V,02-0002-A4 Date: 22,09.2010
9.0 SINGLE SOURCE OF SUPPLY FOR PAINTS:

All the coats of a painting system shall be from the same manufacturer. No waiver regarding this aspect
shall be considered.
10.0 DOCUMENTATION:
The contractor shall maintain the following documentation:
a) Quality Plan - It is advisable to divide the location in various zones and maintain zone-wise details.
b) Daily Progress Report with clear details of job done in the form of daily logbook. (Both approved and
rejected jobs).
c) Results of approval of surface preparation, water washing, and measurement of paint OFT
d) Colors and batch nos. of paint material used.
It shall be the responsibility of the contractor to obtain written approvals of the inspector at each stage of
painting before proceeding for the next stage of painting.
11.0 RESTRICTIONS:
Surfaces shall not be coated in rain., wind or in environment where injurious airborne elements exists,
when the steel surface temp is less than -15°C above dew point, when the relative humidity is greater
than 85%,or when temp is below 4.4 OC & when temp is above 50 OC.
12.0 MEASUREMENT OF SURFACE PROFILE & PAINT OFT:

The contractor shall bring his own gadgets/ devices for checking the surface preparation and OFT (at
each stage from bare metal to every coat), These equipment shall be duly approved/ calibrated by Client.
Client shall check the OFT and any shortfall in OFT (max +/- 5%) shall be rectified. The contractor shall
check and record the OFT readings. Client will cross check these readings at any number of spots
randomly. The contractor shall provide proper scaffolding for checking of painting at stage.
13.0 QUALITY OF PAINTING:

Good quality shall be maintained at every stage of painting. The painting shall have an aesthetic
appearance in addition to quality. Any defect noticed during the various stages of inspection shall be
rectified to the entire satisfaction of Client inspectors before proceeding further. Final inspection shall
include OFT measurement, Adhesion, Holiday detection check and workmanship. Irrespective of the
inspection, repair and approval at the intermediate stages of work, contractor shall be responsible for
making good any defects found during final inspection or agreed guarantee period. It would be prudent if
the application contractor and paint supplier from recommended list come together to share the gurantee
requirements by application supervision provided by the paint supplying company.
14.0 STENCILING OF EQUIPMENT / LINE NUMBER:

The scope of work of the contractor shall include stenciling of equipment number, line number, product's
name and flow direction by contrasting black or white colors at the existing locations. The style and size
of letters of the stenciling shall be approved by Client.
15.0 QUALITY OF MANPOWER:

The contractor shall use only skilled manpower who have at least three years of experience. Painting
contractor shall use only qualified painters and supervisors who shall be conversant with paint material
characteristics, surface preparation grades, Paint application techniques, measurements of OFT.
precautions to be observed during painting/surface preparation and safety precautions in painting. All the
painters shall have to undergo a painter qualification test.

JACOBS

44LK-5100 Rev. 1
DOC.NO. 44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
16.0 FIRE -PROOFED STRUCTURES:

All fireproofed structures shall be cleaned and coated with two Coats of Client approved weatherproof
cement paints from reputed manufacturers.
17.0 PAINTING FOR R.C.C SUPER STRUCTURE.

All R.C.C shall be painted with two coat of anti-fungal, anti-flaking and water proof paint approved by
client / consultant
18.0 PRECAUTIONS:
All nameplates, manufacturer's identification tags, machined surfaces, instrument glass, finished flange
faces, control valve stems and similar items shall be masked to prohibit coating deposition. If these
surfaces are coated, the component shall be cleaned and restored to original condition.
19.0 DETAILS OF EXPERIENCE:

The contractor shall supply documentary evidence of similar jobs (similar system of painting) carried out
in the past with location of site, type of painting and value of work executed.
20.0 PAINTING FOR PLATFORM AND LADDER

Ladder and platform has to be galvanized and painted for colour coding as per required system for
galvanized structure. Gratings shall be galvanized but No further painting is required.
21.0 SYSTEM OF PAINTING:

It is recommended that for any particular location / unit! area the contractor shall quote as following:
System "a" BARE VESSELS/ EXCHANGERS

System" b" STRUCTURES
This has been divided into two parts.
Part 1 Structures & platforms till 15mts height or till the topmost O/H
Condenser level whichever is higher.
Part 2 All structures higher than sections covered under first part
System "c" BARE PIPING (including piping in O/H Pipe-racks etc.)
System "d" ROTARY EQUIPMENT, VALVES, PSV, INSTRUMENT Etc.
System "e" WALKWAYS, MONKEY LADDERS, and CHECKERED PLATES ETC.
PRONE TO FOOT TRAFFIC:
Two optional systems are provided. Anyone of the options can be chosen by
the vendor/contractor. Further, under each option two categories have been
defined.
Part 1 Walkways, platforms etc. till 15mts height or till the topmost O/H
Condenser lever whichever is higher.

Part 2 All platforms, walkways etc higher than sections covered under first
part.
System "f' CLADDED EQUIPMENT & PIPING (on top of cladding)
System "g" HOT SURFACES (100-300 deg C)
System "h" EQUIPMENT YET TO BE INSUALTED

JACOBS

44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
System "i" STRUCTRE AND EQUIPMENT YET TO BE FIREPROOFED

System "j" FIRE PROOFED STRUCTURE (CEMENT PAINT):
To be quoted as LUMPSUM for manual tool cleaning and painting.
System "k" GALVANIZED STRUCTURAL SURFACES
It should be noted that system g, h or i mayor may not be required to be carried out. Hence it is required
to be quoted as unit rate (Rs.l sq. mts.). For similar reasons unit rates for sand blasting also have to be
quoted.
If sea transportation is involved SS surfaces shall be suitably protected using Epoxy Coating materials,
which have minimum leachable chlorides or Cello film.
22.0 CLAUSE FOR EXCLUSION OR EXTRA PAINTING:

For every system of painting for which rates have been quoted as lump sum, the vendor should specify
rate of per square meter of painting. This shall be used to either carry out extra painting in that unit or to
deduct a proportionate amount from the lump sum amount for the areas, which could not be painted due
to unforeseen circumstances. It shall be solely HPCL's prerogative to invoke this clause. Under no
circumstances shall this rate be used to make claims for payments for areas which the vendor
has inadvertently missed while quoting or for making part payments for the areas in which the
vendor has failed to carry out painting.
23.0 RATE FOR SHOT BLASTING:

The vendor shall quote unit rate for shot blasting on per square meter basis. This shall be used solely at
HPCL discretion for areas where painting permission cannot be given after shot blasting due to
unforeseen circumstances.
24.0 TIMING SCHEDULE OF PAINTING SYSTEM

Timing schedule of painting system have to be followed as per Paint manufacturer's specification. Final
coat shall be before Rainy season, giving due consideration to shelf life and lead-time required for primer
and intermediate coat.
25.0 PREFERRED PAINT MANUFACTURE
BERGER PAINTS
ASIAN PAINTS
SIGMA COA TlNGS
SHALIMAR PAINTS
CLEAN COATS PVT. LTD.
CHUGOKU JENSON & NICHOLSON LTD

GOODLASS NEROLAC PAINTS LTD.
KIRLOSKAR BROTHERS
GRAND POL YCOA TS COMPANY PVT. LTD.
* For very high performance coatings.

JACOBS
44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
Annexure-II
PAINTING SYSTEM FOR UNIT EQUIPMENT & PIPELINES
I) SYSTEM - "a": BARE VESSELS/ EXCHANGER~ (Maximum Design Temp = 100 deg C): - To be
quoted as Lumpsum for each vessel/Exch. ill
OPTION -1: WITH SHOT BLASTING:
Specification No of Application Thickness

Coats Method (DFT in microns)
Surface Preparation: ShotlGrit Blast to Sa 21/2
Primer - Inorganic Zinc Silicate
ONE Airless spray 1 X 75 = 75
Stripe Coat - Epoxy HB MID
Tie Coat - HB MID Epoxy

Stripe Coat - HB Epoxy I HB MID Epoxy
Inter - High Build 2 pack epoxy

Or, HB MID Epoxy
Stripe Coat: Acrylic Aliphatic PU
Finish - Acrylic Modified 2 pack Polyurethane ONE Airless spray 1X 50 = 50

(Recoatable)
TOTAL: OFT = 325 microns
(OPTION-2): WITH POWER TOOL CLEANING: (Recommending if shot blasting becomes practically
impossible because of approach or height.)

Coats Method (OFT in microns)
Surface Preparation: Power tool cleaning ST 3
Stripe Coat- Self priming Epoxy -
Primer - Self Priming Epoxy Aluminum ONE Airless spray 1X 125 =125
Stripe Coat- MID 2 Pack Epoxy
Mid coat - MID 2 Pack Epoxy

ONE Airless spray 1 X 100 =100
Inter - High Build 2 pack epoxy ONE Airless spray 1 X 100 =100
Or, HB MID Epoxy
Finish - Acrylic Modified 2 pack Polyurethane

ONE Airless spray 1X 50 = 50
(Recoatable)
TOTAL: OFT = 375 microns

JACOBS

44LK-5100 Rev. 1
DOC.NO. 44LK-51 OO-OO-V. 02-0002-A4 Date: 22.09.2010
II) SYSTEM -"b" : STRUCTURES: (To be Quoted as Lumpsum)
PART l : Structures & Platforms upto the height of topmost overhead condenser or upto a height of
15 metres whichever is higher.
Specification Noof Application Thickness

Surface Preparation: Shot Blast to Sa 2 1/2
Primer - Zn Rich Epoxy ONE Brush I Spray 1 X 50 = 50
Stripe Coat- Epoxy HB MIO
Mid coat - MIO 2 Pack Epoxy ONE Brush 1 X 100 =100
Stripe Coat- HB Epoxy
Inter - High Build 2 pack epoxy ONE Brush 1 X 100 =100
Or, HB MIO Epoxy
Stripe Coat - Acrylic Aliphatic PU
Finish - Acrylic Modified 2 pack PU (Recoatable) ONE Brush 1X 50 = 50
Total OFT = 300 microns
PART 1\: All structures and platform above the height mentioned in "PART l" earlier (ie above 15 m
height or topmost condenser height whichever is more) - Lumpsum

~rface Preparation: Power tool cleaning ST 3
I Stripe Coat - Self priming epoxy -- ---- -----
Primer - Self Priming Epoxy Aluminum ONE Airless spray 1 X 125 =125
Stripe Coat- MIO 2 Pack Epoxy ---- ------ -------
Mid coat - MIO 2 Pack Epoxy ONE Airless spray 1 X 100 =100
Or, HB MIO Epoxy
Finish - Acrylic Modified 2 pack Polyurethane ONE Airless spray 1X 50 = 50
(Recoatable)
Total OFT= 375 microns

JACOBS

44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
III) System "c" : BARE PIPING (including lines in olh pipe rack) (Maximum design temp= 100 deg C) :
To be quoted as Lumpsum 6
Stripe Coat - Self Priming Epoxy

---- ----- ------
Primer - Self Priming Epoxy Aluminum
ONE Airless spray 1 X 125 :: 125
Stripe Coat- MIO 2 Pack Epoxy
----- -------- -----------
Mid coat - MIO 2 Pack Epoxy ONE Airless spray 1 X 100 :: 100 I
Inter - High Build 2 pack epoxy ONE Airless spray 1 X 100 = 100
I Or, HB MIO Epoxy
Finish - Acrylic Modified 2 pack Polyurethane ONE Airless spray 1X 50 :: 50
(Recoatable)
Total OFT= 375 microns
IV) System "d": PSV, MOTORS, PUMPS, COMPRE~ORS, INSTRUMENTS, Valves etc.: Maximum
design Temperature: 100 deg C - LUMP SUM ~

Surface Preparation: Manual Cleaning to ST 2
Stripe Coat- Self Priming Epoxy --- --- ----
Primer - Self Priming Epoxy Aluminum ONE Brush 1 X 125 = 125
Stripe Coat- MIO 2 Pack Epoxy ------ ----- -------
Mid coat - MIO 2 Pack Epoxy ONE Brush 1 X 100 = 100
Inter - High Build 2 pack epoxy ONE Brush 1 X 100 = 100
Or, HB MIO Epoxy
I Finish - Acrylic Modified 2 pack Polyurethane ONE Brush 1X 50 = 50
(Recoatable) I I

JACOBS

44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
V) System "e" : Carbon Steel Checkered Platel Walkwayl Rungs of Monkey Ladder etc. areas which are
prone to foot traffic and consequent abrasion.
OPTION I (Upto 15 m height or till the level of topmost o/h condenser whichever is higher)
Lumpsum

Surface Preparation - Shot Blast to Sa 2 1/2
Primer - Zn Rich Epoxy ONE Airless spray 1 X 50 = 50
Stripe Coat- Epoxy HB MIO
Stripe Coat - HB Epoxy
Or Epoxy HB MIO
Stripe coat- Coal Tar Epoxy
Finish - Coal Tar Epoxy (Recoatable) ONE Airless spray 1 X 150 = 150
OPTION I (Above 15 m height or above the level of topmost o/h condenser whichever is higher)
Lumpsum
Surface Preparation: Manual Cleaning to ST 2
Stripe Coat- Self Priming Epoxy --- --- ----
Primer - Self Priming Epoxy Aluminum ONE Airless spray 1 X 125 =125
Stripe Coat- MIO 2 Pack Epoxy ----- ------ --------
Or Epoxy HB MIO
Stripe coat- Coal Tar Epoxy
Finish - Coal Tar Epoxy (Recoatable) ONE Airless spray 1 X 150 = 150
44LK-5100-00-V.02-0002-A4- Rev. 1 - Painting spec. doc

JACOBS

44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
OPTION \I (Upto 15 m height or till the level of topmost olh condenser whichever is higher)
Lumpsum
Coats Method (OFT in microns) I
Surface Preparation: Shot Blast to Sa 21/2
Primer - Zn Rich Epoxy One Airless spray 1X 50 =50
Stripe Coat - Epoxy HB abrasion Resistant
II Intermediate- Epoxy HB abrasion Resistant One Airless spray 1 X 75 =75
Stripe Coat - Epoxy HB abrasion Resistant.

I
Mid Coat- Epoxy HB abrasion Resistant One Airless spray 1 X 75 =75
Finish - Epoxy HB abrasion Res. (Recoatable)

ONE Airless spray 1 X 75 =75
Total OFT= 275 Microns
OPTION II (Above 15 m height or above the level of topmost olh condenser whichever is higher)
Lumpsum

Stripe Coat- Self priming epoxy
II ~-~~---- ------------ ---------
Primer - Self priming epoxy Airless spray 1X 125 = 125
I Stripe Coat - Epoxy HB abrasion Resistant ONE Airless spray 1 X 75 = 75
Intermediate- Epoxy HB abrasion Resistant ----- ------- ----------
Mid Coat- Epoxy HB abrasion Resistant ONE Airless spray 1 X 75 = 75
Finish - Epoxy HB abrasion Resistant ONE Airless spray 1 X 75 = 75
Total OFT= 350 Microns
VI) System "f" Cladded Equipment and Piping (To be applied on top of GllAlum clad sheets)
LUMPSUM

Surface Preparation: Manual by wire brush and degreasing if oil spill is there.
Primer - Wash Etch Primer ONE Brush 1 X 10 =10
Finish - HR Alum Paint ONE Brush 1 X 20 =20
44LK-5100-00-V.02-0002-A4- Rev. 1 - Painting spec. doc

JACOBS

44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
VII) System "g" :ALL OTHER BARE EQUIPMENT, LINES ~ SURFACES For WHICH Design
Temperature is between: 100 to 300 Deg C - UNIT RATE ~

Surface Preparation: Shot Blast to Sa 2 %
Primer - Heat Resistant AI-Silicone Paint ONE Brush 1 X 20 = 20
Finish - Heat Resistant AI-Silicone Paint ONE Brush 1 X 20 = 20 I
Note: No temperature curing is allowed for the Heat Resistant paint of this system.
VIII) System "h" Structure, Lines and Equipment which are to yet to be insulated and (UNIT RATE) .&
PART 1: Whose design temp is less than 100 deg C

Surface Preparation: Shot Blasting to Sa 2 %
Finish - MIO 2 pack epoxy TWO Airless spray 2 X 100 = 200
PART 2: Metal surfaces, hines to be insulated (CS/LAS only and before insulation) - hot insulation
between 100 to 400°C. 0
OPERATION OPERATING DESCRIPTION
A) Surface Preparation Blast cleaning to Swedish Specification SIS-05-5900 with
grade SA2%-3
B) Priming Inorganic Zinc Silicate DFT of 75 Microns (Ethyl Silicate based)
Note:
Where surface preparation by blast cleaning is impracticable mechanical cleaning is to be
carried out followed by two coats of silicon based heat resisting aluminum paint of 40-50 OFT
total microns instead of inorganic zinc silicate primer of 75 microns OFT.

JACOBS

44LK-5100 Rev. 1
DOC.NO. 44LK-51 00-00-V.02-0002-A4 Date: 22.09.2010
IX) System "i" : Structure and Equipment which are to yet to be fire-proofed: (UNIT RATE)

Coats Method (DFT in microns)
Surface Preparation: Shot blasting to Sa 2 %
Finish - Epoxy tie Coat ONE Airless spray 1 X 25 = 25
Total DFT = 75 microns
X) System "j" : FIRE PROOFED Structure and Equipment : (LUMPSUM)

Surface Preparation: Manual Cleaning
Primer - Weather Resitant Cement Paint ONE Brush/ Spray
Finish - Weather Resistant Cement Paint ONE Brush /Spray
XI) System "k" : Galvanized Structural surfaces

Coats Method (OFT in microns) I
~Urface Preparation: Manual by wire brush and degreasing if oil spill is there.
Primer - Wash Etch Primer ONE Brush 1X 5 =5
Mid Coat - High Build Polyamide cured Epoxy (2- Pack ONE Brush 1 X 125 =125
I
System)
Finish - Aliphatic Acrylic modified (Iso-Cyanate) ONE
--tI Brush 1 X 50 = 50
,
I cured 2-Pack Polyurethane (Re-coatable)

NOTE:
1. After application, every coat of paint should be of average minimum OFT as indicated in the above
mentioned respective painting systems.
2. Stripe Coat: Stripe coat should be applied using half to one inch brush to only weld joints, nut bolts
etc. and confined areas before application of full coat. This is to provide additional protection to
these areas, as these are usually the starting points of corrosion.
& 3. Wrapping and coating system for underground C.S. pipes has been included in Engineering Design
Basis - Piping (Doc. no. 44LK-5100-00/L.02/002/A4).

JACOBS
HPCL-MUMBAI PAINTING SPECIFICATIONS Page 150f17

44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
Annexure-III
Specifications for Paints to be used in Painting of Units
Required Specifications
1 Inorganic
Zn Silicate
2 Zn Rich
Epoxy
3 Self Priming
Epoxy
4 Epoxy Tie
Coat
5 MIO 2 Pack
Epoxy
6. Two Pack
Epoxy
(High
Build)
7. Two Pack
Epoxy
Abrasion
Resistant

JACOBS

44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
Required Specifications
8. Aliphatic Brand Name

Acrylic DFT (Microns) fCoat 50 =
Modified =
Continuous Service Temp (Deg C) 0-125
(Isocynate) Volume soilds (minimum) 55% =
Cured Two It should be a two pack PU.
Pack It Should be Re-Coatable after Completion of guarantee
Polyurethane period subject to sound condition of total system.
Finish
9. Heat
Resistant
AI. Paint C
(Acrylic!
Silicone
Based)
10. High Build

Amine Cured
Epoxy
12 Epoxy
Coal Tar
ments
13 Wash etch Brand Name

Primer To be used as primer for painting of AI sheets! GI sheets of
insulation c1adding.(2 component based on Poly Vinyl
Butyral)
DFT(microns) f Coat 10; =
=
Color Yellow
Volume Solids
14 HR Aluminum
Paint (Alkyd
Based)

JACOBS

44LK-5100 Rev. 1
DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010
ANNEXURE-IV
COLOUR CODE FOR PAINTING
SI. No. SERVICE COLOUR BAND

1. PROCESS LINES:
1a. All Lines below 120 dec C Grey -

1b. All lines above 120 deg C Aluminum -
2. UTILITY LINES: -
2a. All Lines except cooling & Fire Water Lines < 120C Grey -
2b. All Lines except coolinq & Fire Water Lines> 120C Aluminum -
2c Cooling water Lines Opaline Green
3. CHEMICALS
3a Acid, Alkali, and all other corrosive contents i.e. Grey Yellow
corrosive to the person except toxic lines
3b. Toxic Lines Grey Tangerine
4. FIRE WATER LINES & FIRE FIGHTING EQUIPMENT Red Gloss -

5a. Fired Heaters, Heat Exchangers, Storage Tanks, < 120 C - Grey
Vessels (Except Chemicals) > 120 C - Aluminum
5b. Fired Heaters, Heat Exchangers, Storage Tanks, < 120 C - Grey Yellow/
Vessels (Chemicals) > 120 C - Aluminum Tangerine
6. INSULATED LINE! EQUIPMENT Aluminum. -
7. CHLORINE STORAGE White
8. MOVING EQUIPMENT
8a. Pumps, Comp, Turbines, stirrers, Blowers, Rotary air Mushroom gloss
locks etc.
8b. Motors & their field mounted switch qear Tangerine Gloss
9. AIRLINE & OUTSIDE INSTRUMENT SYSTEMS Black

Page 1 of 7
JACOBS H&G
PIPING STANDARD SPECIFICATION
PROCUREMENT OF STEEL PIPES
DOCUMENT NO : L SS 001
PREVIOUS DOC. NO. : BSS-12-161/1
Rev No. Issue Date Pages Rev Description Prepared Checked Approved
By By By
0 20 Aug. 2002 7 Issue for Use SST BSD RVM
X:\std\leveliv\L_SS_001.doc 10-11-10 12:25 PM

JACOBS H&G LTD
PIPING STANDARD SPECIFICATIONS L SS 001 DATE : 20 Aug. 2002

PROCUREMENT OF STEEL PIPES PAGE: 2 OF 7
REVISION NO: 0
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITIONS
4.0 GENERAL
5.0 RELATED DOCUMENTATION (REFERENCES)
6.0 RECORDS
7.0 ATTACHMENTS / APPENDICES

JACOBS H&G LTD

REVISION NO: 0
1.0 PURPOSE
The purpose of this Standard Specification is to establish the requirements for procurement of Steel
pipes.
2.0 SCOPE
The scope of the Standard Specification is to define the requirements of various pipes that the
suppliers have to comply with. This Specification doesn’t cover high yield materials such as
API 5L X_.
3.0 DEFINITIONS
ANSI: American National Standards institute

ASME: American Society of Mechanical Engineers
ASTM: American Society for Testing materials
API: American Petroleum Institute
MSS-SP Manufacturer’s Standard Society-Standard Practice
BSI: British Standards Institution
BIS: Bureau of Indian Standards
IBR: Indian Boiler Regulations
4.0 GENERAL
This specification, together with the Purchase requisition / Order, all documents referenced in
the Requisition/ Order and the Company’s / Client’s conditions of order covers the
requirements of the supply of steel pipes listed below
a) Carbon Steel
b) Alloy Steel
c) Austenitic Stainless Steel
d) Galvanised Iron (G.I)
4.1 Conflicting Requirements
4.1.1 Any conflict between requirement of this specification, Purchase Data sheets and related Documents
shall be referred back to the Company for Approval, at the Bid stage.
4.2 Supplier’s Alternatives
4.2.1 Supplier’s shall submit the specification of the alternative for approval at the bid stage, in case the
supplier wishes to supply equivalent / suitable alternative. Alternatives will not be accepted during
supply stage.
4.3 Materials and Manufacture
4.3.1 Materials, dimensions and Manufacturing process of the Pipes shall be in accordance with the
Codes / Standards mentioned in the purchase requisition/ Order.
4.3.2 Pipes shall be supplied in Single / Double random lengths unless otherwise specified in the Data sheets.

JACOBS H&G LTD

REVISION NO: 0
4.4 Specific Requirements
4.4.1 Austenitic Stainless Steel items shall be furnished in the heat –treated condition.
4.4.2 All H grades shall be furnished in solution- treated conditions.
4.4.3 Double Long Seam is allowed for sizes 36” and larger.
4.4.4 Unless specifically exempted, welded pipes shall be acceptable only with longitudinal weld made
employing automatic welding.
4.5 Intergranular Corrosion Test (IGC Test)
4.5.1 Where IGC test is specified it shall be in accordance with ASTM A262, Practice E.
4.6 Special Requirements
4.6.1 NACE-MR-01-75 shall be followed for Pipes falling under NACE category.
4.6.2 For Hydrogen and other demanding services, Vendor shall include all special quality checks
and inspection in the quality Plans.
4.6.3 Special Tests would be applicable for items falling under cryogenic conditions.
4.7 End Finish
4.7.1 Unless otherwise specified end preparation of pipes shall be as follows
a) ½” to 1 ½” : Plain ends
b) 2” and above : Bevelled ends
c) Galvanized Pipes : Threaded and coupled Ends (T&C)
4.7.2 Wherever bevelled ends are specified it shall confirm to ASME B16.25. Threaded ends shall be as per
ASME B1.20.1
4.8 Pipes falling under the purview of IBR
4.8.1 Spirally welded Pipes shall not be supplied for Steam service falling under the purview of IBR. All
Pipes falling under the purview of IBR shall be shall bear the inspection punch of IBR Inspector and
shall be supplied with Form III A.
4.8.2 Pipes supplied to API 5L Specification shall not be cold expanded.
4.9 Workmanship, Finish and Appearance
4.9.1 All pipes shall be cleanly finished and when visually inspected shall be free from defects /
imperfections such as cracks, surface flaws, laminations etc.
4.9.2 The repair of defects shall be carried out as per the codes/ standards specified in the data
sheets.
4.9.3 All pipes shall be clean of rust, foreign materials, scales, oil and grease. Pipes shall be
provided with a suitable protective coating. Where Pipes are to be galvanized the zinc coating
shall be as per codes/ standards.
4.9.4 Pipes supplied for Oxygen / Chlorine services, shall be chemically cleaned.

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REVISION NO: 0
4.10 Tests
4.10.1 The following tests shall be carried out on the materials / Finished Items as prescribed in
applicable codes / standards.
a) Visual Examination
b) Chemical composition/ Product analysis
c) Mechanical Tests
i) Tensile Test
ii) Flattening Tests
iii) Bend Tests
d) Hydrostatic test
e) Other NDT tests
4.11 Product Marking
4.11.1 Product marking shall include Heat Number and all other information as per Codes/
Standards.
4.11.2 For identification of materials at site, the following colour marking schedule given in 4.11.4
shall be used.
4.11.3 Colour / Ink used for marking shall not contain harmful metal or metal salts that causes
corrosive attack either ordinarily or in service.
4.11.4 Stainless Steel Pipes and Galvanised pipes do not require colour coding.
4.11.5 Colour Marking Schedule
Material Specification Colour Code
IS 1239 White One Strip
IS 3589 Black One Strip
ASTM A 53 Gr. A/ B Orange One Strip
ASTM A 106 Gr. A/ B/ C Green One Strip
ASTM A 333 Gr.1/ 6 Brown One Strip
API 5L Gr. A/ B Yellow One Strip
ASTM A 335 Gr. P1 Black & Green One Strip each
ASTM A 335 Gr. P5 Black & Red One Strip each
ASTM A 335 Gr. P11 Black & Black One Strip each
ASTM A 335 Gr. P22 Black & White One Strip each
4.11.6 Colour Code Strip shall be as follows
1 ½” and Smaller Colour code rings every 1.5 metres. apart
2” and Larger broad line (s) (min. ½” width painted along the
length of the pipe).

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REVISION NO: 0
4.12 Inspection
4.12.1 Unless otherwise specified in the purchase order, it is the responsibility of the producer/
supplier to perform all inspection requirements specified in the Codes/ standards/ Data
sheets. The Company / client shall have the right to perform any inspection and tests set forth
in the specification.
4.12.2 Inspection and Test necessary to confirm that the products meet the requirements of the
standards, Specifications and of the Purchase Order shall be carried out in the Vendors Plant
by the Vendors specially trained Personnel.
4.12.3 Products that are to the specifications shall be guaranteed by inspection certificate,
conformity certificate, Material certificate, test certificates etc.
4.12.4 All inspection activities shall be listed in the quality plan. This quality plan shall be submitted
for approval.
4.12.5 PMI (Positive Material Identification) by alloy analyser to be carried out where specified.
4.13 Extent of inspection and witnessing by Client/ Consultant/ Third Party
4.13.1 Extent of witness inspection shall be minimum 20% of the lot. However, extent of witness
inspection shall be increased where Vendor’s performance is not satisfactory. Inspection and
witnessing rate for all the points listed in the quality plan shall be as follows :
Pipe Sizes Sampling
1½” and smaller 10%
2” to 10” 25%
12” and above 100%
4.14 Documentation
4.14.1 Certificate of Conformity: The Vendor shall submit a certificate of conformity with the
standards specified in the Purchase order.
4.14.2 Materials Certificate: The Vendor shall submit all material certificates pertaining to the results
of chemical analysis, mechanical tests, Non destructive tests and Acceptance certificates,
carried out in accordance with the requirements of the codes/ standards, specified in the
purchase order.
4.15 Acceptance
4.15.1 Inspection department shall not release the materials unless all the required certificates are
submitted and approved.
4.16 Preparation, Packing and Forwarding
4.16.1 All pipes shall be dry, clean and free of moisture, dirt, and loose foreign materials.
4.16.2 All pipes shall be protected from rust, corrosion and any mechanical damage during
transportation, shipment and storage.
4.16.3 Rust preventive coats shall be applied on machined surfaces, which is not harmful to the
material, welding etc. Coating shall be easily removable with a petroleum solvent.
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REVISION NO: 0
4.16.4 Suitable End protectors shall be provided and they shall be properly secured and tightly
attached.
5.0 RELATED DOCUMENTATION (REFERENCES )
5.1 ASME B 16.25 : Butt welding Ends
5.2 ASME B 36.10 : Welded and Seamless Wrought Steel Pipe
5.3 ASME B 36.19 : Stainless Steel Pipe
5.4 ASME B1.20.1 : Pipe Threads- General Purpose (Inch)
5.5 API : American Petroleum Institute
5.6 IBR : Indian Boiler Regulations.
6.0 RECORDS
6.1 Supplier shall compile a Test report manual, comprising of all Test reports, Inspection reports,
Acceptance report, inspection release certificate and shall submit along with the supplies.
Refer ‘Table of Contents’

Page 1 of 7
JACOBS H&G
PROCUREMENT OF STEEL PIPE FITTINGS
DOCUMENT NO: L SS 002
By By By
0 4 Sept. 2002 7 Issue for Use SST BSD RVM
X:\std\leveliv\LSS002.doc 10-11-10 12:26 PM

JACOBS H&G LTD
PIPING STANDARD SPECIFICATION L SS 002 DATE : 4 Sept. 2002

PROCUREMENT OF STEEL PIPE FITTINGS PAGE: 2 OF 7
REVISION NO: 0
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITIONS
4.0 GENERAL
4.1 CONFLICTING REQUIREMENTS

4.2 SUPPLIER’S ALTERNATIVES
4.3 MATERIALS AND MANUFACTURE
4.4 SPECIFIC REQUIREMENTS
4.5 INTERGRANULAR CORROSION TEST (IGC TEST)
4.6 SPECIAL REQUIREMENTS
4.7 END FINISH
4.8 FITTINGS FALLING UNDER THE PURVIEW OF IBR
4.9 WORKMANSHIP, FINISH AND APPEARANCE
4.10 TESTS
4.11 PRODUCT MARKING
4.12 INSPECTION
4.13 EXTENT OF INSPECTION AND WITNESSING BY CLIENT / CONSULTANT/ THIRD
PARTY
4.14 DOCUMENTATION
4.15 ACCEPTANCE
4.16 PREPARATION, PACKING AND FORWARDING
5.0 RELATED DOCUMENTATION ( REFERENCES )
6.0 RECORDS

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REVISION NO: 0
1.0 PURPOSE
The purpose of this Standard Specification is to establish the methods for procurement of
Steel butt welding, socket welding and screwed fittings.
2.0 SCOPE
The scope of the Standard Specification is to define the methods and requirements for
procurement of Steel butt welding, socket welding and screwed fittings.
3.0 DEFINITIONS

MSS-SP Manufacturer’s Standard Society-Standard Specification
4.0 GENERAL
the Requisition/ Order and the Company’s / Client’s conditions of order cover the
requirements of the supply of steel butt welding, socket welding and screwed fittings listed
below:
a) Carbon Steel
b) Alloy Steel
4.1.1 Any conflict between requirement of this specification and Purchase Data sheets and related
Documents shall be referred back to the Company for Approval, at the Bid stage.
supply stage.
4.3.1 Materials, dimensions and Manufacturing process of the Fittings shall be in accordance with the Codes
/ Standards mentioned in the purchase requisition/ Order.

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REVISION NO: 0
4.4.1 Austenitic Stainless Steel items shall be furnished in the heat-treated condition.
4.6.1 NACE-MR-01-75 shall be followed for Fittings falling under NACE category.
4.6.2 For Hydrogen and other demanding services Vendor shall include all special quality checks
4.7 END FINISH
4.7.1 Unless otherwise specified end preparation of Fittings shall be as follows
a) ½” to 1 ½” : Socket welding Ends

b) 2” and above : Bevelled ends
c) Galvanized fittings : Threaded (Male)
ASME B1.20.1. Wherever Socket weld, Screwed ends are specified, it shall confirm to ASME B 16.11
4.8 FITTINGS FALLING UNDER THE PURVIEW OF IBR
4.8.1 All Steel fittings, falling under the purview of IBR shall be shall bear the inspection punch of IBR
Inspector and shall be supplied with Form III C.
4.9.1 All fittings shall be cleanly finished and when visually inspected shall be free from defects /
sheets.
4.9.3 All fittings shall be clean of rust, foreign materials, scales, oil and grease. Fittings shall be
provided with a suitable protective coating. Where fittings are to be galvanized the zinc
coating shall be as per codes/ standards.
4.9.4 Fittings supplied for Oxygen / Chlorine services, shall be chemically cleaned.
4.10 TESTS
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REVISION NO: 0
b) Chemical composition / Product analysis
c) Mechanical Tests
i) Tensile Test
iii) Bend Tests
d) Hydrostatic Tests
e) NDT tests
Standards.
4.11.2 For identification of materials at site the following colour marking schedule given in 4.11.4
shall be used.
4.11.4 Stainless Steel and Galvanised items do not require colour coding
4.11.5 Colour Marking Schedule
Material Specification Colour Code
IS 1239 (Part II) White One Strip
ASTM A 234 Gr. WPB/ WPC Orange One Strip
ASTM A 234 Gr. WP1 Green One Strip
ASTM A 234 Gr. WP11/12 Cl.2 Black & Red One Strip each
ASTM A 234 Gr. WP5/WP9/11/12 Cl.1 Black & White One Strip each
ASTM A 420 Gr. WPL6/9/3/8 Yellow One Strip
4.12 INSPECTION
4.12.1 Unless otherwise specified in the purchase order, it is the responsibility of the producer /

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REVISION NO: 0
for approval.
4.13 EXTENT OF INSPECTION AND WITNESSING BY CLIENT/ CONSULTANT/ THIRD PARTY
4.13.1 Inspection and witnessing rate for the all points listed in the quality plan shall be as follows
Pipe Sizes Sampling
2” to 10” 25%
4.14 DOCUMENTATION
purchase order.
4.15 ACCEPTANCE
4.16.1 All items shall be dry, clean and free of moisture, dirt, and loose foreign materials.
4.16.2 All items shall be protected from rust, corrosion and any mechanical damage during
4.16.4 Suitable end protectors shall be provided and they shall be properly secured and tightly
attached.
5.2 ASME B 36.10 : Welded and Seamless Wrought Pipe

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REVISION NO: 0
5.4 ASME B1.20.1 : Pipe Threads-General purpose (Inch)
5.5 ASME B 16.9 : Factory-made Wrought Steel Butt welding Fittings
5.6 ASME B 16.11 : Forged Fittings Socket Welding and Threaded
5.7 MSS-SP-43 : Wrought Stainless Steel Butt -welding Fittings
6.0 RECORDS
Supplier shall compile a Test report manual comprising of all test reports, Inspection reports,
Acceptance reports and submit the same along with the supplies.

Page 1 of 6
JACOBS H&G
PROCUREMENT OF STEEL FLANGES,

SPADES AND SPACERS
PREVIOUS DOC. NO. :
By By By

JACOBS H&G LTD

PROCUREMENT OF STEEL FLANGES, SPADES AND SPACERS PAGE: 2 OF 6
REVISION NO: 0
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITIONS
4.0 GENERAL

4.7 FLANGES, SPADES AND SPACERS FALLING UNDER THE PURVIEW OF IBR
4.8 FACE FINISH
4.10 TESTS
4.12 INSPECTION
4.13 EXTENT OF INSPECTION AND WITNESSING BY CLIENT / CONSULTANT/ THIRD
PARTY
4.14 DOCUMENTATION
4.15 ACCEPTANCE
6.0 RECORDS

JACOBS H&G LTD

REVISION NO: 0
1.0 PURPOSE
The purpose of this Standard Specification is to establish the requirements for procurement of
Steel flanges, spades and spacers.
2.0 SCOPE
The scope of the Standard Specification is to define the requirements of various flanges,
spades and spacers, that the suppliers have to comply with.
3.0 DEFINITIONS

AWWA: American Water Works Association
MSS-SP: Manufacturer’s Standard Society- Standard Specification
4.0 GENERAL
This specification, together with the Purchase requisition / Order, all documents referenced in the
Requisition/ Order and the Company’s / Client’s conditions of order covers the requirements of the
supply of steel flanges, spades and spacers listed below
a) Carbon Steel
b) Alloy Steel
supply stage.
4.3.1 Materials, dimensions and Manufacturing process of the flanges, spades and spacers shall be in
accordance with the Codes / Standards mentioned in the purchase requisition/ Order.
4.4.1 Austenitic Stainless Steel items shall be furnished in the heat treated condition.
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REVISION NO: 0
4.6.1 NACE-MR-01-75 shall be followed for flanges, spades and spacers falling under NACE
category.
4.7 FLANGES, SPADES AND SPACERS FALLING UNDER THE PURVIEW OF IBR
4.7.1 All flanges, spades and spacers falling under the purview of IBR shall be shall bear the inspection
punch of IBR Inspector and shall be supplied with Form III C.
4.8 FACE FINISH
4.8.1 Unless otherwise specified in the data sheets the face finishing shall be as follows
a) Stock Finish : (250- 1000 AARH) 6.3- 25.4 Ra

b) Serrated Finish : (250- 500 AARH) 6.3- 12.7 Ra
c) Smooth Finish : (125- 250 AARH) 3.2- 6.3 Ra
d) Extra Smooth Finish: ( 32- 63 AARH) 0.8- 1.6 Ra
4.9.1 All flanges, spades and spacers shall be cleanly finished and when visually inspected shall be
free from defects / imperfections such as cracks, surface flaws, laminations etc.
sheets.
4.9.3 All flanges, spades and spacers shall be clean of rust, foreign materials, scales, oil and
grease. flanges, spades and spacers shall be provided with a suitable protective coating.
Where Pipes are to be galvanized the zinc coating shall be as per codes/ standards.
4.9.4 Flanges, spades and spacers supplied for Oxygen / Chlorine services, shall be chemically
cleaned.
4.10 TESTS
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REVISION NO: 0

c) Other NDT tests
Standards.
4.12 INSPECTION
for approval.
4.13.1 Inspection and witnessing rate for the all points listed in the quality plan shall be as follows:
Flange Sizes Sampling
2” to 10” 25%
4.14 DOCUMENTATION
purchase order.

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REVISION NO: 0
4.15 ACCEPTANCE
4.16.4 Suitable end protectors shall be provided and they shall be properly secured and tightly
attached.
5.1 ASME B 16.5 : Steel Pipe Flanges and Flanged fittings
5.2 ASME B 16.47 : Large diameter Steel Flanges (NPS 26” Through NPS 60”)
5.3 API 605 : Large Diameter Carbon Steel Flanges
5.4 MSS-SP-44 : Steel Pipe Line Flanges
5.5 AWWA C-207 : Steel Pip[e Flanges for Water Works 4”-144”
5.6 BS 1560 : Circular flanges for Pipes, valves and fittings
5.7 BS 3293 : Carbon steel flanges (Over 24” Nominal size) for Petroleum Industry
5.8 BS 4504 Section 3.1: Circular flanges for Pipes, valves and fittings
5.9 ASME B1.20.1 : Pipe Threads, General Purpose (Inch)
6.0 RECORDS
Supplier shall compile a Test report manual, comprising of all Test reports, Inspection reports,
Acceptance report and shall submit along with the supplies.

Page 1 of 6
JACOBS H&G
PROCUREMENT FOR STEEL FLANGES,

GASKETS
PREVIOUS DOC. NO. :
By By By

JACOBS H&G LTD

PROCUREMENT FOR STEEL FLANGES, GASKETS PAGE: 2 OF 6
REVISION NO: 0
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITIONS
4.0 GENERAL
4.1 GENERAL
4.2 DEFINITION OF “GASKET”
4.8 TESTS
4.9 PRODUCT MARKING
4.10 INSPECTION
4.11 EXTEND OF INSPECTION AND WITNESSING BY CLIENT / CONSULTANT / THIRD
PARTY
4.12 DOCUMENTATION
4.13 ACCEPTANCE
6.0 RECORDS

JACOBS H&G LTD

REVISION NO: 0
1.0 PURPOSE
gaskets for Steel flanges, spades and spacers, Valves and fittings.
2.0 SCOPE
The scope of the Standard Specification is to define the requirements of gaskets for flanges,
spades and spacers, Valves and fittings that the suppliers have to comply with.
3.0 DEFINITIONS

AWWA: American Water Works Association
MSS-SP Manufacturer’s Standard Society- Standard Specification
4.0 GENERAL
4.1 This specification, together with the Purchase requisition / Order, all documents referenced in
requirements of the supply of Gaskets for steel flanges, spades and spacers, Valves and
fittings.
4.2 The term “Gasket” includes compressed fibre Gaskets, Spiral wound Gaskets, Octagonal ring
Gaskets, double -jacketed and non-metallic Gaskets. Use of Asbestos material in any form is
unacceptable as per company’s HSE guidelines.
supply stage.
4.5.1 Materials, dimensions and Manufacturing process of the flanges, spades and spacers shall be in
accordance with the Codes / Standards mentioned in the purchase requisition/ Order.

JACOBS H&G LTD

REVISION NO: 0
4.6.1 NACE-MR-01-75 shall be followed items falling under NACE category.
4.7.1 All gaskets shall be cleanly finished and when visually inspected shall be free from defects /
sheets.
4.7.3 All gaskets shall be clean of rust, foreign materials, scales, oil and grease. flanges, spades
and spacers shall be provided with a suitable protective coating. Where Pipes are to be
galvanized the zinc coating shall be as per codes/ standards.
4.8 TESTS
c) Other NDT tests
4.9 PRODUCT MARKING
Standards.
4.10 INSPECTION
for approval.

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REVISION NO: 0
4.11 EXTEND OF INSPECTION AND WITNESSING BY CLIENT/ CONSULTANT/ THIRD PARTY
4.11.1 Inspection and witnessing rate for the all points listed in the quality plan shall be as follows
Gasket Sizes Sampling
1 ½” and smaller 10%
2” to 10” 25%
4.12 DOCUMENTATION
purchase order.
4.13 ACCEPTANCE
5.5 AWWA C-207 : Steel Pip[e Flanges for Water Works 4”-144”

JACOBS H&G LTD

REVISION NO: 0
5.7 BS 3293 : Carbon steel flanges (Over 24” Nominal size) for Petroleum Industry
5.9 ASME B1.20.1 : Pipe Threads, General Purpose (Inch)

.
6.0 RECORDS

Page 1 of 6
JACOBS H&G
PROCUREMENT OF STEEL FLANGE,

BOLTING MATERIALS
PREVIOUS DOC. NO. :
By By By
0 7 Oct. 2002 6 Issue for Use SST BSD RVM

JACOBS H&G LTD
PIPING STANDARD SPECIFICATION L SS 005 DATE : 5 Oct. 2002

PROCUREMENT OF STEEL FLANGE, BOLTING MATERIALS PAGE: 2 OF 6
REVISION NO: 0
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITIONS
4.0 GENERAL
4.1 GENERAL
4.2 DEFINITION OF “BOLTING MATERIAL”
4.4 SUPPLER’S ALTERNATIVES
4.5 MATERIALS AND MANUFACTURER
4.7 ORKMANSHIP, FINISH AND APPEARANCE
4.8 TESTS
4.9 PRODUCT MARKING
4.10 INSPECTION
4.11 EXTEND OF INSPECTION AND WITNESSING BY CLIENT / CONSULTANT / THIRD
PARTY
4.12 DOCUMENTATION
4.13 ACCEPTANCE
6.0 RECORDS

JACOBS H&G LTD

REVISION NO: 0
1.0 PURPOSE
Bolting materials for Steel flanges, Valves and fittings.
2.0 SCOPE
The scope of the Standard Specification is to define the requirements of Bolting materials for
flanges, valves and fittings, that the suppliers have to comply with.
3.0 DEFINITIONS

AWWA: American water works Association
MSS-SP Manufacturer’s Standard Specification
4.0 GENERAL
4.1 This specification, together with the Purchase requisition / Order, all documents referenced in
requirements of the supply of Bolting material for steel flanges, Valves and fittings.
a) Carbon Steel
b) Alloy Steel
4.2 The term “Bolting material” includes Hexagonal headed full threaded/ partly threaded machined bolts
with washers and nut, Full length threaded studs with washers and two nuts and hexagonal headed full
length threaded jack screws.
supply stage.
4.5.1 Materials, dimensions and Manufacturing process of the bolting materials shall be in accordance with
the Codes / Standards mentioned in the purchase requisition/ Order.

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REVISION NO: 0
4.6.1 NACE-MR-01-75 shall be followed items falling under NACE category.
4.7.1 All bolting materials shall be cleanly finished and when visually inspected shall be free from
defects / imperfections such as cracks, surface flaws, laminations etc.
sheets.
4.7.3 All bolting materials shall be clean of rust, foreign materials, scales, oil and grease. flanges,
spades and spacers shall be provided with a suitable protective coating. Where bolts are to
be galvanized the zinc coating / cadmium coated, it shall be as per codes/ standards.
4.8 TESTS
c) Other NDT tests
4.9 PRODUCT MARKING
Standards.
4.10 INSPECTION
for approval.

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REVISION NO: 0
4.11 EXTEND OF INSPECTION AND WITNESSING BY CLIENT/ CONSULTANT/ THIRD PARTY
4.11.1 Inspection and witnessing rate for the all points listed in the quality plan shall be decided at
the time of placement of firm purchase order.
4.12 DOCUMENTATION
purchase order.
4.13 ACCEPTANCE
5.5 AWWA C-207 : Steel Pipe Flanges for Water Works 4”-144”
5.7 BS 3293 : Carbon steel flanges (Over 24” Nominal size) for
Petroleum Industry
5.9 ASME B1.1 : Unified Inch Screw Threads

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REVISION NO: 0
5.10 ASME B 18.2.1 &

B 18.2.2 : Square or Hexagonal headed Bolts & Nuts
6.0 RECORDS

Page 1 of 8
JACOBS H&G
PROCUREMENT OF METALLIC EXPANSION JOINTS
PREVIOUS DOC. NO. : None
By By By

JACOBS H&G LTD
PIPING STANDARD SPECIFICATION L SS 006 DATE : 7 Octt. 2002

PROCUREMENT OF PAGE: 2 OF 8
METALLIC EXPANSION JOINTS REVISION NO: 0
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITIONS
4.0 METHODS
4.1 DESIGN
4.2 FABRICATION
4.3 TESTING AND INSPECTION
4.4
4.5
4.6 VACCUM TEST
4.7 SPRING RATE TEST
4.8 MATERIAL TEST
4.9 LIFE CYCLE TEST
4.10 SUPPLEMENTARY WORL EXAMINATION
4.11 WITNESSING OF TEST
4.12 MARKING – COMPANY’S IDENTIFICATION
4.13 PROTECTION, PACKING AND TRANSPORTATION
6.0 RECORDS
7.1 DATASHEET FORMAT FOR BELLOWS
7.2 CHECK SHEET FOR BELLOWS

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1.0 PURPOSE
The purpose of this Standard Specification is to establish methods for procurement of metallic
expansion joints used in piping systems.
2.0 SCOPE
This Standard Specification defines the methods for the intended purpose of procurement,
design, supply of metallic expansion joints. Expansion joints used in Equipments, Vessel
shells, Heat Exchanger shells are not included in the scope of this Standard Specification.
3.0 DEFINITIONS
Vendor / Supplier / Manufacturer: Successful Bidder
Company : Jacobs H&G Pvt. Ltd.
EJMA : Expansion Joints Manufacturer’s Associate Inc.
ASME : American Society for Mechanical Engineers.
4.0 GENERAL
4.1 DESIGN
4.1.1 Design of expansion joints shall be as per EJMA and ASME Standards and Codes.
4.1.2 Any conflicting requirements between this Standard Specification and related specification data sheets,
shall be immediately referred to the company for classification, prior to design, supply / procurement of
materials.
4.1.3 Where a Vendor / Supplier finds a suitable alternative to that specified, without comprising on the
working conditions, quality and other requirements specified in the data sheets, shall submit the
alternative in writing to the company for approval at the Bid stage.
4.1.4 When straight 18/8 stainless steels are used titanium stabilised is preferred for operating temperatures
of 7000C (13000F) and above. Unstabilised steels are acceptable if the carbon content is restricted to
0.04% max.
4.1.5 External sleeves or shrouds shall be removable to allow internal inspection.
4.1.6 Steam out connections will be required for same services, this will be noted on the data sheets. Such
connections shall be provided at suitable locations except on convolutions of the thin expansion joints.
4.1.7 Internal sleeves or liners shall not be designed to function as internal axial guides in axial movement
expansion joints.
4.1.8 When internal sleeves are required the supplier shall mark permanently on the unit, the direction of
flow.
4.1.9 Presettling of expansion joints is not acceptable unless, otherwise specified in the data sheets.
4.1.10 Spring rate indicated in the data sheets are maximum values. Vendors shall keep the values below the
specified values. In case it is not possible, the same shall be referred to the Company for approval.
4.1.11 Expansion joints that are working under vacuum conditions, shall be designed as per EJMA clause C.4
Bellows design – Circular expansion joints; considering the effects of “external pressure”. For such
JACOBS H&G LTD

expansion joints pressure thrust absorbing member (Tie-rods /Limit rods / Hinges / Gimbals) shall be
evaluated for an internally pressurised system. However the effects of compression loading on slender
member (viz. Long tie rods / limit rods) must be considered.
4.1.12 Number of tie-rods, lugs, their sizes shall be decided by the Manufacturer / Supplier / Vendor taking
into consideration all aspects of adequacy from the point of strength of the expansion joint for its
proper working during operating conditions.
4.1.13 Wherever limit rods / tie rods are specified for the expansion joints, due consideration in Design /
Manufacturing shall be given for the pressure thrust and pipe loads.
4.1.14 Wherever Butt welded ends for expansion joints are specified along with limiting tie-rods,
manufacturer shall design the thickness of the pipe piece, so as to withstand forces and moments
transferred to the pipe. The pipe schedule / thickness specified in the data sheet is for the main piping.
The same thickness shall not be used before proper design checks. Pipe Butt weld ends shall be as per
ASME B 16.25.
4.1.15 Wherever flanged end connections are specified, the manufacturer shall provide flanges to ASME B
16.5 unless otherwise specified.
4.2 FABRICATION
4.2.1 Welding of dissimilar material directly on end pipe piece or intermediate spool price of the
expansion joint shall be carried out only after providing a proper pad plate.
4.3 TESTING & INSPECTION
4.3.1 Vendor shall submit his quality assurance plan for approval. Vendor shall proceed for
fabrication only after getting approval of the same.
4.3.2 Vendor shall submit all heat treatment procedures when asked for.
4.3.3 Following tests shall be carried out as per the requirements laid down by EJMA and ASME
a. Visual Dimensional Test

b. Leak Test (optional), if leakage rate is specified.
4.3.4 Non-Destructive Testing
a. Radiographic Examination ( spot examination, min.)

b. Liquid Penetration Examination
4.3.5 Pressure Test
The test pressure shall be as per the value mentioned in the Technical Data Sheets, giving
due consideration to temperature connection factor as per EJMA.
4.3.6 The following guidelines shall be followed for pressure testing of various types of expansion
joints.
a. Axial expansion joints (without limit rod) : Axial expansion joints shall be tested
hydrostatically, with ends fixed (restrained) properly by means of rigid fixtures, so that
the pressure thrust during testing can be absorbed by the restraints, without causing
any deformation at the constructions of the expansion joints.

JACOBS H&G LTD

b. Axial Expansion Joints (with limit rods) / Lateral Expansion Joints (with tie rods) /
Expansion Joints (with Hinges / Gimbals) : During the pressure testing of the above
type of expansion joints, the ends shall be blanked, but shall not be held between fixed
restraint. If required expansion joints can be suitably guided for maintaining its
alignment during testing.
4.4 Expansion joints shall be tested in such a way that the tie rods, limit rods, Hinges / Gimbals
are also subjected to the internal loading due to pressure thrust. This method of hydrostatic
testing will indicate the presence of leakage, if any. This will also verify structural integrity of
the item being tested as well as the stability of the expansion joints.
4.5 Large expansion joints shall be provided with additional supports to take care of water load
during hydrostatic testing.
4.6 VACUUM TEST
4.6.1 When full vacuum test is asked for, the expansion joint, shall be subjected to test at 730 mm
of flange vacuum. All testing arrangement shall be same as mentioned in clauses 4.3.
4.7 SPRING RATE TEST
4.7.1 Spring rate mentioned in the data sheet is the maximum. Vendor shall consider this in the
design. In case if not possible to provide the required spring rate, Vendor shall submit the
calculation.
4.7.2 Axial spring rate test shall be performed on all types of expansion joints.
4.8 MATERIAL TEST
4.8.1 Mechanical tests, chemical analysis test on materials, which become a permanent part of the
expansion bellow shall be carried out.
4.9 LIFE CYCLE TEST
4.9.1 Vendor shall guarantee the working of the expansion joints for 7000 life cycles.
4.10 SUPPLEMENTARY WELD EXAMINATIONS
4.10.1 Any supplementary weld inspection and test, will be specified in the data sheet.
4.11 WITNESSING OF TEST
4.11.1 This activity shall be clearly identified in the Vendor’s quality plan and the same shall be
submitted for approval.
4.11.2 All test identified for witnessing in the quality plan shall be witnessed by the Company’s
inspector / Client’s inspector / Third party inspector.
4.12 MARKING – COMPANY’S IDENTIFICATION

JACOBS H&G LTD

4.12.1 The Company’s identification shall be the project no., the item tag no. / S.M. no. given in the
datasheet.
4.12.2 Each expansion joint shall be provided with a non-corrosive metal tag by embossing the
Company’s identification.
4.12.3 Each expansion joint must be permanently marked with the flow direction wherever
appropriate.
4.13 PROTECTION, PACKING AND TRANSPORTATION
4.13.1 Generally, high alloy or stainless steel portion of the expansion joint shall be free of paint of
any kind.
4.13.2 All assemblies shall be protected against corrosion and mechanical damage.
4.13.3 All joints shall be clearly labelled with picture and notes for proper handling.
4.13.4 Should any expansion joint contain defects which are revealed during shop fabrication,
installation or whilst under normal test conditions, they will be rejected and a detailed report
submitted to the supplier, who shall immediately replace them with bellows complying with the
specification.
4.13.5 Should any expansion joint or delivery be found damaged or in any way not in compliance
with the terms of this specification, they will be rejected and a derailed report submitted to the
Vendor who shall immediately replace them with sand bellows complying with the
specification.
EJMA Std. : Expansion Joint Manufacturer’s Association Inc.
ASME Sec. VIII Div. : American Society Mechanical Engineers.
6.0 RECORDS
Vendor shall compile all stage wise test certificates, certified approvals, from design stage
upto delivery. The same shall be submitted in a file item wise. Vendor shall update all his
engineering documents to “As-Built” stage for submission.

JACOBS H&G LTD

ATTACHMENT 7.1
DATA SHEET FOR METALLIC EXPANSION JOINTS
JACOBS H&G
Rev. No. Prpd. By Date Chkd.by Date Appd. By Date
Project Data Sheet for Metallic Expansion Joints
Client Data Sheet No. UU-VVVV-XX/ L.YY/ZZZZ/A_ Sheet 1 of __
Project No. BC-VVVV S.M. No. Qty
1 Nominal Size/I.D/ O.D (In./ mm)
Single Expn.
2 Expansion Joint Type
3a Medium Gas/ Liquid
3b Fluid Information Velocity (m/ sec)
Joint
3c Flow Direction
2
4 Design Pressure (Kg/cm g)
Single Expn.
Joint W/ Tie
5 Test Pressure (kg/cm2g)
6a Design (0C)
Max./ Min. (0C)
Rods
6b Temperature
6c Installation (0C)
7a Axial Compression (mm)
Double Expn.
7b Maximum Installation Axial Extension (mm)
intermediate
7c Movement Lateral (mm)
Joint w/
Anchor
7d Angular (deg.)
8b Axial Extension (mm)
Universal Expn. Universal Expn.

Maximum Design
balanced Expn. Joint w/short tie Joint w/overall

8c Lateral (mm)
Movements
8d Angular (deg.)
tie rod
8e No. of Cycles
9b Axial Extension (mm)
9c Operating Fluctuations Lateral (mm)
9d Angular (deg.)
9e No. of Cycles
rod
10a Bellows
10b Liners
10c Materials of Construction Cover
10d Pipe Specification
Pressure
10e Flange Specification

Joint
11 Rods (Tie/ Limit/ Control)

12 Pantographic Linkage
balanced Expn.
13 Anchor Base (Main/ Intermediate)

Universal
14a overall (mm)

Pressure
14b Dimensional Limitations Outside Dia. (In.)

Joint
14c Inside Dia. (In.)

15a Axial (kg/mm)
balanced Expn.
Inline Pressure
15b Spring Rate Limitations lateral (kg/mm)

15c Angular ( kg/mm/deg.)
16 Installation Position: Horizontal / Vertical
Joint
17a Bellows Long Seam

17b Weld NDE Attach.
Hinged Expn.
17c Pipe NDE

Quality Assurance
17d Design Code Requirements
Requirements
17e Partial Data Requirements
Joint
17f
17g
Gimbal Expn.
19 Vibration Amplitude/ Frequency

20
21 Flange Standard : ASTM B16.5/ BS_____/ Din______
Joint
21a Facing
21b O.D (In.)
Special Flange
Pentographic
21c I.D (In.)

Expn. Joint
Design
Universal
21d Thickness (In.)

21e B.C.Diameter(In.)
21f No. Of Holes
21g Size of Holes
21h Hole Orientation
Form No. f1-L006.xls Applicable Work Instruction L SD 006
f1-L006.xls, Rev. 0
Note : Please double click on icon to display document

JACOBS H&G LTD

ATTACHMENT 7.2
CHECK SHEET FOR BELLOWS
DOC. No.
PIPING SHEET
JACOBS H&G CHECKLIST FOR BELLOWS DRG. No.
APPD. BY
Project No. CHKD. BY
Project Location PRPD. BY
Project Title DATE
Client REV. A 0 1
YES NO Not Acceptable Remarks
G Tag No. Checked
E Data Sheet completed by vendor
N
Deviations from data sheet Identified
E and informed vendor
R
A Unit weight shown
L Line No. shown
Convolution details shown
D
R Welding Details shown
A Flange Deails shown
W
Tie rods/ Limit rods/ lugs/ brackets/
I Hinges/ gimbals Details shown
N
G Internal sleeve details shown
S Protective cover details shown
Overall and individual Dimensions of

the bellow and other parts shown
D
E Material of Construction as per Data
S sheet, if not alternate acceptable
I
Design Pressure +ve and/ or vac.
G
Test Pressure +ve and/ or vac.
N
Design Temperature
Axial/ lateral movements
C
Axial/ lateral / angular sprinf rates
A
Design Life cycles
L
Membrane Stress due to internal
C pressure
U
Membrane/ Bending Stress due to
L deflection
A
Fatigue Life
T
Column instability
I
Axial Spring rate
O
Lateral Spring rate
N
Angular spring rate
S
Tie rods and Lug design
External pressure (Vacuum) design
Isometric checked
S Supports (Anchors/ guides etc)
T checked from isometrics
R
Stress outputs checked for bellows
E
S
S
f2-L006.xls, Rev. 0
Note : Please double click on icon to display document

Page 1 of 4
JACOBS H&G
TEST CERTIFICATE REQUIREMENTS FOR

PIPING ITEMS AND COMPONENTS
PREVIOUS DOC. NO. :
By By By

JACOBS H&G LTD

TEST CERTIFICATE REQUIREMENTS FOR PAGE: 2 OF 4
PIPING ITEMS AND COMPONENTS REVISION NO: 0
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITIONS
4.0 GENERAL

4.2 CERTIFICATES
4.3 SUPPLY OF CERTIFICATES
4.4 DOCUMENTATION
4.5 ACCEPTANCE
6.0 RECORDS

JACOBS H&G LTD

1.0 PURPOSE
The purpose of this Standard Specification is to establish the type of certificates that
Manufacturers/Vendors/ Suppliers have to submit for Piping items and components
2.0 SCOPE
The scope of the Standard Specification is to define the requirements of various types of Test
certificates and guarantee certificates that are to be submitted for Piping items and
components generally designed in accordance to various National and International
Standards.
3.0 DEFINITIONS

MSS-SP Manufacturer’s Standard Specification
4.0 GENERAL
requirements of various certificates that are to be submitted for the Piping items and
components listed below:
a) Pipes
b) Fittings
c) Flanges
d) Valves
e) Bolting
f) Gaskets
g) Special Piping Components
4.2 CERTIFICATES
4.2.1 Type ‘A’ - (General Compliance): A formal Manufacturers / Suppliers guarantee certificate,
certifying that components and items forming components all fully comply with the
specifications and requirements stated in the purchase order and that, where applicable,
radiographic and other non-destructive examinations have been satisfactorily applied.

JACOBS H&G LTD

4.2.2 Type ‘B’ – (Certified Chemical Analysis, Mechanical & Heat Treatment): A certified
statement from Manufacturers / Suppliers giving the results of chemical analysis tests,
mechanical tests and heat treatment carried out in compliance with specifications and
requirements of the purchase order. Also, where applicable, confirmation that radiographic
and other non-destructive examinations have been satisfactorily applied.
4.2.3 Type ‘C’ – (Certified pressure Tests): A certified statement from Manufacturers / Suppliers
giving the results of Pressure test ( e.g. Hydrostatic tests, Pneumatic tests etc.,) carried out in
compliance with specifications and requirements of the purchase order.
4.3 SUPPLY OF CERTIFICATES
4.3.1 The type and quantities of certificates required shall be as mentioned in the Vendor
Document Requirements. (Refer to Attachment 7.5 of SOP 108)
4.4 DOCUMENTATION
4.4.2 Materials Certificate: The Vendor shall submit all material certificates pertaining to the
results of chemical analysis, mechanical tests, Non destructive tests and Acceptance
certificates, carried out in accordance with the requirements of the codes/ standards,
specified in the purchase order.
4.5 ACCEPTANCE
LSS 001: Procurement of Steel Pipes

LSS 002: Procurement of Steel Pipe Fittings
LSS 003: Procurement of Steel Flanges, Spades and Spacers
LSS 004: Procurement of Steel Flange, Gaskets
LSS 005: Procurement of Steel Flange, Bolting Material
LSS 006: Procurement of Metallic Expansion Joints
6.0 RECORDS

Page 1 of 6
JACOBS H&G
PROCUREMENT OF SUPPORTS
By By By
0 24 Sep, 2002 6 Issue for Use SST BSD RVM

JACOBS H&G LTD
PIPING STANDARD SPECIFICATIONS L SS 009 DATE : 24 SEP, 2002

PROCUREMENT OF PIPE SUPPORTS PAGE: 2 OF 6
REVISION NO: 0
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITIONS
4.0 GENERAL
6.0 RECORDS
INDEX AND ATTACHMENTS OF PIPING SUPPORT STANDARDS

JACOBS H&G LTD

REVISION NO: 0
1.0 PURPOSE
The purpose of this Standard Specification is to establish the requirements for procurement of Pipe
Supports, which are of mainly bought items.
2.0 SCOPE
The scope of the Standard Specification is to define the requirements of fabrication and
supply of Pipe supports (Bought Items only), which suppliers have to comply with.
3.0 DEFINITIONS

MSS-SP Manufacturer’s Standard Society-Standard Practice
4.0 GENERAL
requirements of the supply of Pipe Supports listed below:
a) Carbon Steel
b) Alloy Steel
supply stage.
4.3.1 Materials, dimensions and Manufacturing process of the Pipes shall be in accordance with the
Codes / Standards mentioned in the purchase requisition/ Order.

JACOBS H&G LTD

REVISION NO: 0
ASME B1.20.1
4.6.1 All supports shall be cleanly finished and when visually inspected shall be free from defects /
sheets.
4.6.3 All supports shall be clean of rust, foreign materials, scales, oil and grease. Supports shall be
provided with a suitable protective coating. Where supports are to be galvanized the zinc
coating shall be as per codes/ standards.
4.6.4 Fabrication of Support hanger rods, eye bolts and clamps shall not by welding.
4.7 TESTS
c) Mechanical Tests
i) Tensile Test
iii) Bend Tests
d) Other NDT tests
4.8 TESTING & SETTING OF SPRING SUPPORT UNITS
4.8.1 Spring Units shall be tested by loading each unit with the installed load and then by either
decreasing to the operating load. The actual spring extension or compression shall be
checked against the net deflection given on the spring data sheet.
4.8.2 After testing, the unit shall be pre-set at installed load as given in the spring data sheet.
4.8.3 Any deviation to the spring ’K’ value mentioned in the data sheet shall be intimated
accordingly for approval. Spring units have different ‘K” values shall not be despatched till
approval is availed.
4.8.4 Spring units shall be marked with instructions regarding installation, operation and protection
of the spring during Hydrostatic testing.

JACOBS H&G LTD

REVISION NO: 0
4.9 PRODUCT MARKING
Standards.
4.10 INSPECTION
for approval.
4.11.1 Inspection and witnessing rate for all the points shall be listed in the quality plan.
4.12 DOCUMENTATION
purchase order.
4.13 ACCEPTANCE
JACOBS H&G LTD

REVISION NO: 0
4.14.4 Suitable End protectors shall be provided and they shall be properly secured and tightly
attached.
5.2 ASME B 36.10 : Welded and Seamless Wrought Steel Pipe
5.4 ASME B1.20.1 : Pipe Threads- General Purpose (Inch)
5.5 API : American Petroleum Institute
5.7 MSS-SP : Manufacturer’s Standard Society Standard Specification
6.0 RECORDS
6.1 Supplier shall compile a Test report manual, comprising of all Test reports, Inspection reports,

Page 1 of 13
STANDARD SPECIFICATIONS FOR
EQUIPMENT ERECTION
DOCUMENT NO : Z SS 003
Rev.No. Issue Date Pages Rev Description Prepared Checked Approved

By By By
0 02.11.2001 13 Issue for use. MRAK CLS AGG
1 2 August 2004 13 Cover page revised ALB SGR AGG
\\nmumfil01\construction\44 mm 2800 mrpl\mechanical works\tender\section no. 3 technical documentation\zss003.doc 08/17/2009 15:23

JACOBS
DATE: 2 August 2004 SPECIFICATION NUMBER: Z SS 003

PAGE: 2 OF 13 STANDARD SPECIFICATION FOR EQUIPMENT ERECTION
REVISION NO: 1
TABLE OF CONTENTS
1.0 PURPOSE (INTRODUCTION)
2.0 SCOPE
3.0 ERECTION OF STATIC EQUIPMENT
4.0 ERECTION OF ROTARY EQUIPMENT AND MACHINERIES
5.0 SPECIAL INSTRUCTIONS TO CONTRACTOR
6.0 DELIVERY STORAGE AND CUSTODY OF EQUIPMENTS / MACHINERIES
7.0 HANDLING, TRANSPORTING AND ERECTION
8.0 GROUTING
9.0 FINAL CHECKING AND FINISHING
10.0 TRIAL RUNS OF EQUIPMENT AND MACHINERY
11.0 OWNERS / CONSULTANTS SCOPE OF SUPPLY
12.0 CONTRACTORS SCOPE OF SUPPLY
13.0 SYSTEM TEST / START-UP (PRECOMMISSIONING)
ZSS003 08/17/09 15:23

JACOBS
SPECIFICATION NUMBER: Z SS 003 DATE: 2 August 2004

STANDARD SPECIFICATION FOR EQUIPMENT ERECTION PAGE: 3 OF 13
REVISION NO: 1
1.0 PURPOSE (INTRODUCTION)
The purpose of this specification is to define the Construction requirements of equipment

erection.
2.0 SCOPE
2.1 This specification supplements the applicable code requirements / data sheets / drawings and
specifications for fabrication, erection, inspection, testing, commissioning of equipments.
2.2 Engineering drawings/ specifications data sheets shall take precedence over this specification
if there are any conflicting clauses.
3.0 ERECTION OF STATIC EQUIPMENTS
3.1 SCOPE OF WORK
3.1.1 The work under this specification covers transportation of vessels, exchangers, heaters,
drums, condensers, tanks filters, etc., from Owners stores / storage point, erection on
foundation furnished by Owner, leveling, aligning and grouting including assembly and fixing of
other internal / external fittings and completing the vessels, exchangers, filters, drums etc., in
all respects for commissioning the plant all as per drawings, documents and specifications
and as per instructions of the Owner.
The Contractor shall study related equipment layout, steel structural drawing, piping layout,
foundation drawing, underground piping and equipment drawing before starting any
installation work. Grouting of equipment and machineries shall be carried out by the
Contractor.
3.1.2 Approximate total weights are given in the schedule of rates. Approximate empty weight,
elevation at which the vessels, columns etc., are to be erected are given in the equipment list
to the extent possible. Rigging procedures / installation schemes for all major lifts and all
other equipment maximum crane capacity shall be submitted by the Contractor to the Owner
for approval prior to installation of equipment. However, approval to rigging procedure
proposed by the Contractor shall not relieve the Contractor from his responsibility.
3.1.3 For details of equipments refer relevant project equipment list.
3.2 ERECTION
3.2.1 Before taking up the equipment for erection, the Contractor shall check the orientation of the
nozzles, centre lines, elevations, length and position of anchor bolts spacing and size of bolt
pockets on foundation, the diameter of anchor bolting and diameter of bolt hole in the
equipment base plate with respect to piping and other applicable drawings and also with
physical measurement of the equipment wherever required, and discrepancies if any shall be
brought to the notice of Owner. Providing enlarging of the holes on the brackets and / or skirts
of the equipment during installation shall be carried out by the Contractor at no extra cost to
the Owner. Prior to installation of equipment on foundations that top of concrete foundation
shall be thoroughly cleaned with air, water and dried.
3.2.2 Normally all concrete pedestals shall have bolt holes pockets as required. However, where
opening for introduction of grouting materials has not been provided by Owner, the Contractor
shall drill the required holes at approved rates before installation of equipment. Location and
dimensions of foundations shall be checked with respect to general layout plans, civil floor
layouts and other drawings well in advance before starting of actual erection work. The size,
number and locations of foundation bolt pocket or holding down bolt holes shall be checked in
advance by the Contractor and discrepancy if any, shall be brought to the notice of the Owner.
Foreign matter if any, in the foundation bolt pocket, shall be completely removed by the
Contractor. The rough foundation surface shall be chipped 5-6mm or more and the packers
ZSS003 08/17/09 15:23

JACOBS

REVISION NO: 1
which need to lay in advance shall be levelled at the same level. Blue matching will be carried
out wherever required at no extra cost by the Contractor.
3.2.3 When the Contractor intends to carry out installation work by using truck crane, chain block, or
by any other lifting devices the following to be checked thoroughly before erection.
i. Rated load, working radius. Hoisting from height and safety factor of truck crane.
ii. Conditions of ground for safe planning work.
iii. Chain block used for installation shall withstand overloading and slant slinging to a
certain degree.
iv. Strength of beams and girders on which chain block is hung.
When the equipment to be installed on the steel structure, necessary arrangements shall be
made with frame builders so that beams, floors, railings, etc., are built in a removable way if
so required or built after the installation of the equipment. It shall be recommended that the
beams for swing stoppers of long equipment are installed to match setting holes of the
equipment after installation and centering.
3.3 LEVELING, CENTERING AND ALIGNMENTS
3.3.1 The Contractor shall select and provide size and number of packets / shims and insert them
on both sides of each foundation bolt and at such places where load is expected. More than
three layers of packers shall not be used. For line adjustment, shims shall be used. Packers
shall be black steel plate free from surface scales, unevenness, injurious burrs etc. Wherever
possible flat packers shall be used. The leveling and centering should be done by using two
taper packers which shall be ultimately fastened together by tack welding. Shims and packers
shall be spaced to enable mortar filling in the bolt hole without trouble. All equipment shall be
properly levelled and plumbed where manufacturer has provided levelling pads or marks the
same shall be used as a guide.
3.3.2 Centering / alignment of al vertical equipment like towers, vessels, heat exchangers (vertical
type) which are taller than 6M in height shall be done with the help of theodolite. Centers shall
be measured at more than two points on the top and bottom with transits at two positions
0
forming 90 approximately. The center line shall be 10mm wide and shall be marked by the
equipment manufacturer.
Alignment / centering of small equipment shall be done with the help of bob weights.
Accuracy for centering shall be as under.
i. For towers containing trays - within + 0.5mm per 1M.

ii. For vessels and heat exchangers - within + 1mm per 1M.
However, in case of special / critical equipment’s, manufacturers / owners recommendations

should be followed.
Horizontal equipment like vessels, heat exchangers (horizontal type) etc., leveling shall be
measured with water level on the datum point (punched) at both ends of the equipments.
Where no datum points are available, leveling shall be measured by placing of 1/10 accuracy
on the nozzle (largest diameter preferable) of the equipment. All horizontal vessels shall be
checked for level across machined face of nozzle flange with precision level.
In case where nozzle is of small diameter of inclined and cannot be used for measuring the
level by use of a level, the canter line of equipment shall be measured with theodolite.
Alignment / leveling of equipment with agitators shall be done with great care. Unless
otherwise specified the accuracy shall be 5/100 to 10/100 on the rotary shaft.
ZSS003 08/17/09 15:23

JACOBS

REVISION NO: 1
It will be Contractors responsibility for marking arrangements for all measuring instruments to
be used for centering and leveling purpose shall be as but not limited to transit, Y level, level
gauge (accuracy 1/10 - 1/100) bob, scale etc.
The Contractor shall also carry out the assembly, erection, leveling and alignment of all types
of trays, downcomers, and seal pans, wieplates, baffles, demisters, and other internal fittings.
Work shall be carried out as per manufacturers standard / specification which shall be made
available to the contractor at the time of erection.
Tolerances on assembly of internals like demisters, and other parts shall be specified by
manufacturers / Owner.
All proprietary equipment shall be installed as per equipment layout and nozzle orientation
issued by the Owner and considering manufacturers manuals, installation instruction,
catalogues / drawings and as per any specific directions of the Owner. Some of the
equipment and machineries may be supplied in dismantled condition.
The Contractor shall :
a) Check contents with packing list.

b) Check for any damage.
c) Check for any abnormality
d) Check for rusting or corrosion
e) Check for protectors, reinforcing material etc., which must beretained till end of erection.
Should there be any damage or discrepancy the Contractor shall immediately inform the
Owner for taking necessary action.
Exchanger shall be set at level and square so that pipe connections can be made without
strain. While setting on foundation bolts, bolts of one end shall be kept loose to allow free
expansion of shell. Slotted holes are provided in supports to achieve this.
All items of equipment shall be properly oriented and the fabricated parts and connections
should be installed as indicated on the drawings. Equipment to be installed on steel structural
frame shall be levelled by use of shims, packers and wedges.
Equipment to be installed on concrete foundations shall be placed on the foundations together

with the base plate and the bolts connecting the equipment to the base plate slackened.
The base plate shall be leveled on concrete foundations by putting wedges between the base
plate and concrete foundations initially and subsequently replacing the wedges with concrete
grout. All the wedges shall be removed after the concrete grout is set. Equipments shall be
placed level on the base plate and bolts connecting the equipment and base plate tightened. If
necessary inserting shims in between. Setting of anchor bolts shall be checked with the latest
revision of manufacturers drawings / or other applicable drawings.
ZSS003 08/17/09 15:23

JACOBS

REVISION NO: 1
4.0 ERECTION OF ROTARY EQUIPMENT AND MACHINERIES
4.1 SCOPE OF WORK
The work under this specification covers transportation of machinery / equipment etc., from
Owners stores / storage point to worksite, assembling of sub-assemblies / parts, erection on
foundation furnished by Owner, leveling, aligning and grouting, of equipment for trial runs,
carrying out no load trial runs as per instructions of Owner and handover in fit condition for the
start up of the plant.
Defects due to Contractors fault noticed ruing trail runs shall be rectified by him. Schedule of
quantities given at the end of this chapter indicate approximate number dimensions and
weights of the equipments.
The work shall in all respect be carried out in accordance with good present day engineering
practice and to the satisfaction of Owner. The Contractor shall study the respective
specification given in this document for the work which he is required to carry out in this plant.
The Contractor shall also study the related equipment layout, steel structure, piping layout
foundation drawing, underground piping and equipment drawing before starting installation
work.
4.2 ERECTION AND ALIGNMENT
4.2.1 Erection / alignment of all machineries shall be carried out by experienced fitters and
technicians. Contractor shall employ experienced erection supervisors and crews who have
done similar type of jobs.
4.2.2 Proper sequence for assembly erection / installation and trial runs shall be adhered to in
accordance with drawings, catalogue and manufacturers instruction.
4.2.3 Couplings of machinery received with drive in assembled condition, shall be removed by the
Contractor, if required and alignment shall be checked. Realignment if required shall be done
before recoupling. In case where the drive unit and driven unit arrive separately, they are to
be assembled at site, wherever necessary the Contractor shall mark and drill holes including
tapping the box plate for fixing motors, fixing of coupling on shaft, if necessary file / scrap the
keys and key ways for fixing coupling on shafts, dowelling including providing dowel pins for
retaining the alignment of machineries. All operations mentioned in this para shall be carried
out by the Contractor within the unit rates quoted by him. However, Owner shall provide the
machining facility if required.
4.2.4 Cooling water flushing and other piping connections connected with equipment / machineries
and its ancillaries shall be installed by the Contractor as per drawing, specification and
instruction of Owner.
4.2.5 Items such as sight glasses, level gauges, etc., shall be installed by the Contractor as part of
equipment erection work and no separate payment will be made for the same.
4.2.6 After initial alignment the equipment shall be properly grouted. Grouting shall be carried out
as per the specification and insurrection of Owner. Shims shall be taken out and cavity
formed shall be grouted wherever grout holes are provided in the base plates, grout shall be
filled through them also.
4.2.7 To ensure that piping connections do not induce any undue stresses on the equipment, the
alignment shall be checked by the Contractor again, after the piping has been connected.
After making necessary corrections on the piping, if any, realignment shall be done by the
Contractor and he will ensure that no undue stresses are induced in the equipment.
ZSS003 08/17/09 15:23

JACOBS

REVISION NO: 1
5.0 SPECIAL INSTRUCTIONS TO CONTRACTOR
Contractor in addition to general specifications for erection as outlined in 3.0 & 4.0 shall follow
the following special instructions.
5.1 PUMPS, BLOWERS ETC.
5.1.1 Pumps shall be supplied to the Contractor for erection either completely assembled, coupled
to the drive and both mounted on a common based plate or in three individual parts as pump
assembly, motor and base plate, or as pump assembly and motor mounted on separate base
plate. The pumps shall be erected on foundation given by Owner and levelled with shims and
wedges with the help of precision levels and other instruments. The pump and the driver and
reducing gear, if any, shall be then coupled and centering / alignment.
Initially centering shall be done and centering shall be made by placing a level of 1/10
accuracy on the pump base or nozzle.
Grouting of foundation bolts to be done after temporary centering.
5.1.2 First Centering
First centering shall be done after the anchor is fixed. Shaft center deflection and inclination
shall be measured at four point on the top, bottom. Left and right side by way of turning, the
coupling in single or both with dial gauge or clearance gauge etc.
After the first centering is over the space between the base and foundation shall be grouted.
5.1.3 Second Centering
Second centering / final alignment shall be done after all piping connections are done. The
alignment and tolerance for alignment shall be maintained as specified in the manufacturers
instruction manual. Shims and wedges where required will be arranged by Contractor.
The Contractor has to rectify, if any misalignment which might be observed after trial run of
pump with water.
5.1.4 All auxiliaries like lube oil system, filters, cooling water systems, and other piping connections
shall be supplied alongwith the pump in fabricated condition. If the piping are not received in
fabricated condition then the Contractor shall have to fabricate the same form material issued
by Owner and finally to be installed by the Contractor as per manufacturers instruction and
instructions of Owner. The payment will be made as per piping schedule of rates.
5.2 EJECTORS
Ejectors shall be delivered in assembled or sub-assembled condition and shall be installed in

accordance with manufacturers drawing, specification and instruction of Owner. The nozzles
and diffusers shall be fixed on the associated piping as per arrangement drawings and shall
be properly aligned.
5.3 COMPRESSORS
Compressors shall be delivered to the Contractor in sub-assembled condition. The

compressor and the whole equipment shall be grouted after obtaining approval from Owner. If
the compressor is received in knock down condition, the Contractor has to assemble and fit
various parts of the compressor as per instruction of Owner and manufacturers instruction.
ZSS003 08/17/09 15:23

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REVISION NO: 1
The Contractor shall carry out the following as part of his work without any extra cost :
a) Placing the compressor on foundation after assembly with the motor.
b) Leveling the entire unit.
c) Rough alignment of motor.
d) Grouting after the leveling and alignments are checked by Manufacturers

representative and Owner.
e) Rechecking of alignment after the grout is set.
f) If, necessary, Contractor has to open compressor cover and cleaning of Rotor,
Impellers, Seals and Bearings to be carried out.
g) After cleaning and checking the compressor to be closed up.
h) Gear box to be cleaned and alignment of gear box to compressor to be carried out.
i) The manufacturer shall supply after coolers, prefilters, after filters separately. The
Contractor has to carry out erection, alignment and grouting of these equipment.
j) Piping connection such as water, steam, cooling water, other inlet and outlet
connections, connections to coolers are made. Tolerance for alignment shall be
maintained as specified in the manufacturers instruction manual. To ensure that
piping connections do not induce any undue stresses on the equipment, the alignment
shall be checked by the Contractor again after, the piping has been connected. Any
rectification / correction necessary for proper alignment shall be done by the
Contractor.
k) All auxiliaries and other piping will be supplied with the compressor in prefabricated
condition and shall be installed by the Contractor. If the piping are not supplied in
fabricated condition, then the Contractor has to fabricate the piping as required with
the material issued by Owner. Installation of piping will be paid as per Piping
schedule of rates.
l) After pipings are connected, the Contractor shall check the alignment finally after
coupling the entire train i.e. motor, gear box and compressor. After this, trial run to be
carried out and bearing temperature etc., to be noted and after this again alignment to
be checked. If any defects are there, Contractor has to rectify the defects
immediately.
The contractor shall study the layout drawings for compressors and other such machineries
with their auxiliaries, controls, defining scope of supply and shall connect the gas steam and
utility piping instruments and oil pipings as per manufacturers manual drawing specification
and instruction of owner and manufacturers representative.
5.4 PACKAGE UNITS
Units shall be supplied by the manufacturers as a package unit. The Contractor shall have to
erect the unit on the foundation prepared by Owner. In general all accessories connected with
the unit will be installed by the manufacturer in the package unit. In case if the Contractor is
required to carry out installation of any items as part of the package unit the same shall have
to be carried out by the Contractor and will be paid on weight basis alongwith the units. The
Contractor shall have to make all necessary facilities and fulfill the requirements for erection of
the unit on the foundation.
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REVISION NO: 1
5.5 AGITATORS/ CONVEYORS/ ELEVATORS
These items may be supplied in sub-assembled condition. However, if it is received in

assembled condition, it has to be dismantled to the extent it is required and shall be erected at
no extra cost. Erection of motor, gear box, etc., to be carried out separately. Contractor shall
align Motor, Gear box etc., separately then couple with each other. This again final alignment
to be carried out including assembly of structure, belts etc.
6.0 DELIVERY STORAGE AND CUSTODY OF EQUIPMENTS / MACHINERIES
The Contractor shall unpack, inspect, check the quantity extent of damage and rust if any of
the equipment and accessories supplied to him at the time of taking delivery in presence of
Owner.
The Owner shall not be liable for any claims or complaints whatsoever in respect of quality
and quantity or condition of said materials once the Contractor has taken delivery thereof.
However, Owner shall keep the accessories which are not directly necessary for installation.
7.0 HANDLING, TRANSPORTING AND ERECTION
The Contractor shall be responsible for handling and transporting the items of equipment/
machineries from wherever stored at site by Owner, to the point of installation. The Contractor
shall be responsible for organizing the lifting of the equipment / machineries in the proper
sequence, so that orderly progress of the work is ensured and access routes for erecting the
vessels, columns, heat exchangers, and other machineries etc., care should be taken not to
damage nozzles, instruments, connections, structurals, clips etc.
Lifting tackles, slings and shackles before use at site must be tested by an approved agency,
and a certificate to that effect shall be produced by the Contractor. These certificates shall be
maintained at site. Lifting tackle shall be visually inspected before use and shall be sent for
re-testing by the Contractor if any doubt is expressed by the Owner, about its worthiness.
Under no circumstances the Contractor shall use a defective or doubtful appliance.
The following shall be followed by the Contractor during transport, handling and lifting of the
equipment / machinery.
i. Use suitable capacity crane / truck lifting tackle, lifting beam / hoist.
ii. Obtain prior permission of the Owner for using building or structure for slinging.
iii. Use wire rope as per IS 1835 or stronger for thimbles.
iv. Apply thimbles to lifting lugs taking into account center of gravity of the equipment.
Never use other parts of the equipment except the lifting lugs.
v. When no lifting lugs are provided, take measures to be prevent slippage in

consultation with the Owner. In case slip preventing device is not available, attach a
wire to prevent slippage.
vi. Avoid swinging motion of the equipment while lifting.
vii. Use stay wire to prevent over turning.
ZSS003 08/17/09 15:23

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REVISION NO: 1
8.0 GROUTING
For equipment installed on concrete foundations, the Contractor shall fill mortar / concrete
under the base plate as soon as possible after final tightening foundation bolts. Mortar shall
be used for smaller equipment and concrete shall be used for bigger equipment.
The surface of the concrete shall be thoroughly scraped, all waste material and dirt shall be
removed, also all oil, grease, paint from the surfaces of the base plates (supports, lugs etc.)
which are to be in contact with grout shall be cleaned.
The top surface of the foundation shall be chipped if necessary to maintain the required
elevations of equipment as per drawings at no extra cost. The concrete foundation shall be
thoroughly wetted and kept wet for 24 hours before grouting. Cement slurry shall be brushed
into the concrete surface immediately before placing the grout.
8.1 GROUTING OF POCKETS
The grouting shall be done with cement water in proportion of one part of Portland cement
plus one part of sand and one part of grit (maximum size 6mm). Adequate quantity of water
shall be added. In case where anchor bolts with sleeves are provided it shall be the
responsibility of the Contractor to keep them clean particularly threaded portion of bolts shall
be greased to protect them from damage. Grout shall be gradually poured in the pockets
without disturbing the holding down bolts, and shall be tamped with a steel rod for proper
compactions. For initial grouting all foundation bolt holes shall be filled to a height of 75mm to
100mm below top. After initial set has taken place cure with water by filling the holes to the
top for seven days. After 7 to 10 days of initial grouting all foundation bolts shall be pulled up
tight and if necessary checked with Capstan gauge reading.
8.2 GROUTING UNDER BASE PLATES AND MACHINE BASES
Before final grouting of base plates and machine bases all water should be removed from
pockets.
Grouting shall be done as per specification and instruction of Owner and manufacturers
representative. The following mortar mixing ratio to be followed at the time of preparation of
grout.
MIXING RATIO BY WEIGHT
01. Mortar Mix A Mix B

Cement - 1 1
Non Shrink grout - 1 0
Sand - 1 1
Gravel - 0 0
Water - (0.4 - 0.5)
02. Concrete
Cement - 1 1
Non Shrink grout - 1 0
Sand - 1 1
Gravel - 1.5 1.5
Water - (0.4 - 0.5)
Note : Mix A - Mix with Non-Shrink Grout

Mix B - Mix without Non-Shrink Grout
To be adjusted at site for workability as per local conditions.
ZSS003 08/17/09 15:23

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REVISION NO: 1
It shall be worked in and compacted so that the inside space under the base plate and around
the anchor bolts is thoroughly filled with the dense grout. Care should be taken that no air
bubbles are left inside the grout.
The grout shall be cured for a minimum of 7 days wetting the exposed areas.
The shim plates and pockets under the base should be left undisturbed while grouting is
undertaken. Thickness of grout shall be as per the drawings but in no case the thickness of
grout shall be less than 25mm.
Ordinary “SHRINKOMP” developed by the Research & Development Division of M/s. A.C.C.
Ltd., or other equivalent Non-shrinking grout, approved by the Owner shall be used for
grouting purpose in case of critical equipment like towers, compressors, turbines, centrifuges,
D.G. sets and other such like items and ordinary grout shall be used for grouting purpose in
case of non-critical equipment. All required precautions as per prevalent procedures not
standard engineering practices will be followed while carrying out the grouting.
The grouting shall be done exactly as per manufacturers specification.
9.0 FINAL CHECKING AND FINISHING
Equipment such as thermowells, trays, demister pads, grills etc., shall be properly installed by
the Contractor after proper installation of the equipment.
In case structural steel cleats are required to be welded and / or modified on the equipment,
the same will be carried out by the Contractor at no extra cost to the Owner.
Minor access ladder and platforms when supplied by the vessel fabricator shall also be fixed
by the Contractor. Packing materials which shall be supplied by the Owner, shall be properly
loaded in the equipment buy the Contractor wherever required.
Final alignment for machinery, shall be done after piping connections are made. Tolerances
for alignment shall be as specified by the vendors / suppliers, specification and Owner.
Contractors should ensure that they do not induce any stress on the machinery. Care shall be
taken to avoid undue strains or distortion of equipment caused by uneven bearing on
foundations or equipment under operating condition, units such as pumps, fans, compressors,
etc., shall be checked for proper alignment of driver.
All shafts shall be checked for freeness, alignment and freedom of rotation, cooling water,
flushing exhaust air and other piping connections with the main equipment and auxiliaries
shall be installed as per the drawings specifications and manufacturers instructions.
All accessories and fittings either shipped lose or removed from main equipment during
erection shall be kept tagged separately and installed after completion of erection / installation
of the main equipment. All flanged connections and openings shall be kept blank with plugs /
covers to prevent entry of foreign matter and shall be removed while making connections to
the respective piping or other associated components.
All the instruments like pressure gauges, temperature indicators etc., forming part of
equipment supplied by a vendor shall be installed after the main equipment is installed as a
part of the main equipment.
Safety valves with manifolds / distant piece, if any, shall be installed by the Contractor. Setting
of safety valves will, however be carried out by the other agency. But the Contractor shall
remove the safety valves for calibration as and when instructed by Owner and reinstall the
same after calibration including to and fro transportation within plant premises at no extra cost
to the Owner.
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REVISION NO: 1
All equipment shall be thoroughly cleaned, oiled and greased and presented for inspection to
the Owner before placing in for operation. A list of all oils and lubricants to be used as
stipulated in the manufacturers instruction manuals shall be supplied to the contractor by the
Owner.
While filling lubricants and oils, care shall be taken that they conform to manufacturers
recommendations. The required quantities of oils and lubricants shall be supplied by the
Owner.
10.0 TRIAL RUNS OF EQUIPMENT AND MACHINERY
10.1 Any construction defects shall be intimated to Owner before startup. Before trial runs all
protection devices and guards shall be installed and equipment shall be checked for free
movement by hand rotation. All foundation bolts and alignment shall be checked before
starting the trial run.
10.2 Unless indicated to the contrary all the machinery will be subjected to trial runs for a period of
72 hours continuous. Contractor has to decouple and turn over to other agencies doing
electrical work for testing and no load running of motors. After satisfactory completion of test
the Contractor shall recouple the motors to the machinery and recheck the alignment. The
trial shall start only after this is completed. In all, Contractor has to carry out coupling and
decoupling twice. If it is required to do more than twice then Contractor shall be paid on
manday rate basis.
10.3 During the trial run period the Contractor shall provide necessary skilled personnel round the
clock as required. Any defect noticed during the run and after the trial run shall be made good
by the Contractor at his own cost if that part of the work is done by the Contractor and if it is
otherwise then the Contractor shall be paid extra. Skilled personnel and worker required for
this purpose shall be supplied by the Contractor.
10.4 Where the initial running of items of equipment is carried out with gland packings wherever
necessary the gland packing shall be replaced by mechanical seal. During the trial runs,
reading of bearing temperature, cooling water inlet and outlet temperature, lube oil
temperature, output pressure etc., shall be recorded by the Contractor.
11.0 OWNERS / CONSULTANTS SCOPE OF SUPPLY
11.1 Owner shall supply the equipment in assembled, package unit, or in condition received from
the supplier.
11.2 Owner shall provide necessary foundations for the equipment.
11.3 Owner shall provide necessary foundations bolts and nuts for erection of equipment.
However, please refer qualifications of this item under item 12.5 under Contractors scope of
supply.
11.4 Owner/ Consultant shall provide drawings and necessary instructions required for installation
of equipment machinery. Besides above information, instruction manual and other literature
wherever furnished by manufacturer will be made available only for consultation of the
Contractor. The Contractor shall on completion of job return all the documents and drawings
supplied to him.
11.5 Owner/ Consultant shall provide assistance from manufacturers representative wherever
applicable.
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REVISION NO: 1
11.6 Owner shall supply ordinary Portland cement for grouting, if available on special request from
Contractor cost recoverable basis. Wherever cement is supplied to the contractor, the Owner
/ Consultant shall deduct the value of cement thus taken form the Owner from Contractors
bills, at the prevalent rate.
11.7 Oil charges required for pump sumps, compressor crank, cases, bearing housings, gear
boxes, cylinder lubricators, flushing oil shall be provided by the Owner. However, please refer
qualifications of this under 12.4 under Contractors scope of supply.
11.8 Owner shall provide free of cost at their direction and for duration of contract reasonable open
space common for equipment, piping, structural and other works given in this tender
document.
12.0 CONTRACTORS SCOPE OF SUPPLY
12.1 Contractor shall arrange necessary skilled and unskilled labour, supervising staff, engineers,
stores personnel. The Contractor shall increase the strength of any of the above category of
personnel as advised by Owner / Consultant.
12.2 The Contractor shall make his own arrangement of necessary erection and handling
equipment tools and tackles such as but not limited to cranes, winches, slings, shackles, test
equipment, pressure gauges, dial gauges and other measuring tools welding sets, electric
tools, oxyacetylene gas torches, electrical cables, drilling tapping machines, hydraulic test
pumps, scaffolding materials etc., required for expeditious completion of work.
12.3 In cases wherein oil required for pump sumps, compressor crank cases, bearing housings,
gear boxes etc. are not available the contractor shall procure the same as per instructions and
specifications of owner/ consultants. Non availability of lubricating/ cooling oil shall not be
considered as a reason for delay in job completion. .
12.4 The Contractor shall arrange all consumable required for the purpose of erection. This will
include but not limited to straight and tapper packers, SS, CS, and brass shims (SS & CS)
wedges, cement, sand, gravel, drill bits, tapping sets, hacksaw blades, fixes, scrappers,
chisels, cotton waste, rags kerosene oil, grease, anti rust compound, wooden blocks, emery
paper, grinding wheels, bolts & nuts required for supporting structures for equipment,
platforms, walkways, ladders, etc.
12.5 All foundation bolts and H.D. bolts shall be supplied by the Owner free of cost. The Special
Conditions of Contract, Schedule of items will however superseded. This clause if the two are
in variance.
13.0 SYSTEM TEST / START-UP (PRE-COMMISSIONING)
During the phase of work the Contractor shall provide as part of his work any necessary
skilled personnel as required by Owner. Any defects noticed in the equipment shall be made
good by the Contractor at his cost, if such defects are attributable to the Contractor.
ZSS003 08/17/09 15:23

Page 1 of 24
FABRICATION AND ERECTION OF PIPING
DOCUMENT NO: Z SS 004
PREVIOUS DOC. NO.: BSS-26-02/1
By By By
0 02.11.2001 14 Issue for use MRAK CLS AGG
1 25.07.2003 14 Issue for use RNK SGR AGG
2 30.09.2003 23 Design requirements BK AGG AGG

added
ZSS004 Std Spec for Fabrication Erection of piping

JACOBS
DATE: 30 September 2004 SPECIFICATION NUMBER: Z SS 004

PAGE: 2 OF 24 STANDARD SPECIFICATION FOR
REVISION NO: 2 FABRICATION AND ERECTION OF PIPING
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITIONS
4.0 GENERAL
4.1 TECHNICAL REQUIREMENTS

4.2 SCOPE OF WORK
4.3 APPLICABLE STANDARDS, CODES AND SPECIFICATIONS
4.4 PIPING MATERIAL CLASSIFICATION
4.5 DRAWING & SPECIFICATION
4.6 METHOD OF WORK
4.7 ALIGNMENT
4.8 FABRICATION
4.9 PREPARATION
4.10 FLANGE CONNECTIONS
4.11 BENDING, FORGING AND FORMING
4.12 THREADING
4.13 MITRE BENDS & FABRICATED REDUCERS
4.14 TOLERANCES
4.15 PREPARATION OF PIPE AND OTHER FITTINGS
4.16 INSPECTION OF FABRICATED PIPING
4.17 CLEANING OF PIPES
4.18 HEAT TREATMENT
4.19 WELDING
4.20 ERECTION
4.21 FLANGES
4.22 FITTING
4.23 VALVES AND ON-LINE FITTINGS
4.24 SUPPORTS, GUIDES AND ANCHORS
4.25 INSTRUMENTS
4.26 BOLTS & NUTS
4.27 STRAINERS
4.28 ASSEMBLY
4.29 FLANGE JOINTS WITH A GASKET
4.30 STRUCTURAL ATTACHMENTS
4.31 TREATMENT AFTER FABRICATION
4.32 FABRICATION PRIORITIES AND MATERIAL
4.33 INSPECTION
4.34 PROTECTION
4.35 PIECE MARKING
5.0 RELATED DOCUMENTATION (REFRENCES)
6.0 RECORDS
7.1 TOLERANCES
7.2 BRANCH REINFORCEMENT
7.3 HEAT TREATMENT REQUIREMENTS

JACOBS
SPECIFICATION NUMBER: Z SS 004 DATE: 30 September 2004

STANDARD SPECIFICATION FOR PAGE: 3 OF 24
FABRICATION AND ERECTION OF PIPING REVISION NO: 2
1.0 PURPOSE
The purpose of this specification is to define the pre-fabrication, Heat treatment, Inspection,
Erection, construction and protection requirements of Carbon steel, Chromium Molybdenum,
Carbon ½ MO. Pipe Work based generally on American National Standard Code for Pressure
Piping.
2.0 SCOPE
2.1 This Specification does not apply to Low Pressure Ducting.
2.2 This specification supplements the applicable code requirements / data sheets / drawings and
specifications for fabrication, erection, inspection, testing of pipelines.
3.0 DEFINITIONS
Client/ Owner: The Company, which intends to put up the Plant/ It’s
nominated representative
Consultant: The Company nominated by the Client/ Owner to carry out
Detailed Engineering / Construction Supervision.
Contractor/ Fabricator: The successful bidder for Piping construction works.
IBR Indian Boiler Regulations
4.0 GENERAL
4.1 TECHNICAL REQUIREMENTS
4.1.1 All Conflicts between the requirements of this specification, related Engineering documents/
Drawings/ Codes shall be immediately brought to the notice of the Construction Manager/
Engineer-in -charge or the Site Representative nominated by the company.
4.1.2 This specification is intended to cover the technical requirements for the execution of piping
fabrication and erection of entire piping work defined hereinafter. The work will include
installation of inline instruments such as Control Valves, Orifice Flanges, Rotameter etc., and
Impulse Piping up to 1st block valve.
4.1.3 The quantities of piping material listed in the Schedule of Rates are approximate and are
subject to variations.
4.2 SCOPE OF WORK
4.2.1 Contractor’s Scope of Work
a) Installation of piping system which shall include but not limited to pipes, pipe fittings,
flanges, bolts, nuts, gaskets, inline fittings such as valves, strainers, traps, filters,
thermo wells, orifice plates, safety valves, control valves, relief valves, pressure
reducers, flame arrestors, sight glasses, rain hoods etc., and pipe supports at all
elevations.
b) Testing and flushing / cleaning of all piping systems as per specification.
c) Fabrication and erection of all support elements such as shoes, rollers, wooden
saddles, guides, stop / anchors, U-bolts, clamps, cradles, hangers, turn buckles, etc.,.
d) Fabrication and erection of supporting fixtures, brackets, cantilever struts etc.,.

JACOBS

e) Fabrication, excavation, laying, inspection, testing, flushing / cleaning, coating and

wrapping and backfilling of underground piping, with all specials and fittings.
f) Fabrication and erection of pipe supports like shoe, saddle, guides, stops, Anchors,
clips, cradles, hangers, turn buckles, supporting fixtures, Bracket cantilevers, struts,
Tee Posts, sway braces.
g) Erection of prefabricated spring supports to be supplied by the Owner, wherever

specified.
h) Prefabrication of threaded and unthreaded nipples and Swage Nipples made from
pipes.
i) Construction of 60 degrees and 30 degrees or other angle elbow by cutting 90

degrees and 45 degrees elbow supplied by Owner.
j) Modification of piping that has been completed and / or is being fabricated.
k) Fabrication of 90 degrees, 60 degrees, and 45 degrees mitre bends from pipes

supplied by Owner.
l) Fabrication of Stub-in / Stub-on connections with or without reinforcement.
m) Pickling and passivation of S.S. Pipes, if required, after fabrication and before erection
or after erection as per specifications.
n) Fabrication and installation of spool pieces with scrap pipes and plate flanges, in
place of valves and other on-line fittings wherever required, to continue erection of
piping.
o) Any other items as required in the drawings / specifications to be fabricated from the
pipe material.
p) Additional cleats for pipe supports to be welded with vessels and columns not stress
relieved.
q) Radiography and / or heat treatment of weld wherever applicable.
4.3 APPLICABLE STANDARDS, CODES AND SPECIFICATIONS.
Code of Petroleum Refinery Piping : ASME B31.3
Code of Procedure for Manual metal Arc Welding of mild steel : IS 823
Welding procedure specification, welders procedure, qualification

tests and performance qualification tests. : ASME-Sec.IX
Standard for welding pipe and related facilities : API Code 1104
Indian Boiler Regulations : IBR
All codes referred to shall be the latest editions. The contractor shall bear the cost of repairs,
changes, replacement etc., due to non-compliance with the standards, codes and this contract
or due to disregard of the instructions given by the Owner / Consultant.

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4.3.1 All piping systems shall be fabricated, installed, tested, flushed in accordance with this
specification, piping specifications, general arrangements and other applicable drawings /
standards and good engineering practice.
4.4 PIPING MATERIAL CLASSIFICATION
4.4.1 The complete piping system is broadly divided into various piping classes based on design
pressure, temperature and medium conveyed and the material of construction used in the
piping. All the components used in a given pipeline shall be in conformity with the piping
specifications assigned to it.
4.5 DRAWING & SPECIFICATION
4.5.1 Piping specifications, Engineering Line Diagrams, Piping General arrangement drawings,
Piping Isometrics, Equipment layout drawings, Supporting standards and other relevant
drawings shall be furnished to the Contractor during the execution of the work.
4.5.2 The following drawings shall be supplied to the contractor.
i) FOR CARBON STEEL (NON IBR LINES):The contractor shall be supplied with
construction drawing, General Arrangement drawings, P&IDs, Isometric Drawings,
support standards, etc., for Carbon Steel Pipe 2”NB and Above. Preferred Routings
for 1½”NB and below in General Arrangement Drawings.
ii) The contractor shall be supplied with isometric drawings for all sizes of stainless steel,
alloy steel and Composite isometric for IBR carbon steel pipe work.
iii) The Owner / Consultant shall provide the Contractor standard pipe support and steam
trap assembly sketches and location. Further detailing / routing of the lines are
contractors responsibility.
4.5.3 If any details specifically required for fabrication and erection are missing from the drawing
supplied by the Owner / Consultant, the contractor shall develop the same and submit to the
Owner / Consultant for approval.
4.5.4 The Contractor shall bear the cost of repair, changes, replacements, etc., due to non-
compliance with the standards, codes, of this tender of due to disregard of instruction of
Owner / Consultant.
4.5.5 Contractor shall prepare Sketches / Isometrics for field routed lines.
4.6 METHOD OF WORK
4.6.1 PREFABRICATION
4.6.2 The contractor shall fabricate all pipe work in conformity with the requirements of pertinent
general arrangement drawings, isometrics, piping specification and other specifications /
documents. The piping layouts, isometric drawings and other documents specify the
conditions of design, viz. Pressure ratings, clarifications, shape dimensions of pipe and piping
components sufficient for fabrication. However, if necessary, the contractor shall prepare
SHOP FABRICATION drawings, based on piping drawings and actual field measurements.
4.6.3 All Carbon steel piping 1½”NB and below are called as Field runs, unless otherwise
specifically Isometrics are issued, shall be fabricated, erected, supported and tested by the
contractor in consultation with the Owner / Consultant.

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4.6.4 Where specific details of fabrication are not indicated on the drawings or not specified herein
fabrication and erection shall be done in accordance with the code of Petroleum Refinery
Piping ANSI B31.3 latest edition and INDIAN BOILER REGULATION of latest edition, as
applicable.
4.6.5 Steam piping falling under jurisdiction of INDIAN BOILER REGULATIONS shall be fabricated
in accordance with the requirements of the applicable drawings, the latest edition of INDIAN
BOILER REGULATIONS and to the entire satisfaction of local Boiler Inspector. Documents
certifying the fabrication and testing of fabricated components of the piping system shall be
obtained from the local Boiler Inspector in Form IIIA and IIIB of IBR by the contractor.
4.6.6 The contractor shall be responsible for working to the exact dimensions as shown on the
drawings irrespective of individual tolerance permissible. Where errors are / or omissions
occur on the drawing with respect to site conditions, it shall be the contractors responsibility to
notify the Owner/ Consultant prior to fabrication or erection.
4.7 ALIGNMENT
4.7.1 The pipes to be joined by welding shall be aligned correctly with the existing tolerance on
diameters, wall thickness and out of roundness. The same alignment shall be preserved
during welding. Pipes with the higher wall thickness shall be internally machined / ground so
that the adjoining surfaces are approximately flushed. No extra payment will be made for this
purpose.
4.8 FABRICATION
4.8.1 GENERAL
4.8.2 Pipes shall be supplied with plain or beveled ends of random lengths (6.0 Mtrs) or double
random lengths (12.0 Mtrs) depending on the availability in the market. Wherever beveling is
required as per welding procedure, contractor shall do the beveling at his own cost.
4.8.3 Longitudinal seam in seam-welded pipe shall be located so as to clear the pipe opening and
external attachments wherever possible. Longitudinal seems in adjoining courses shall be
preferably at 180 degrees but a minimum distance of 150mm between seams, measured
around pipe circumference shall be provided, where pipe size permits and external
attachments wherever possible.
4.8.4 Sections of Pipes shall not be welded together for lengths below 3m(10ft.) and the number of
welds shall be kept minimum for longer lengths.
4.8.5 Materials found to be damaged or found to have defects shall not be used in fabrication
except that minor surface marks may be dressed up provided that the nominal wall or
minimum wall thickness is not encroached upon after considering the manufacturing
tolerances defined in the appropriate material or purchase specifications.
4.8.6 All pipe branches shall be 90 degrees unless otherwise indicated in the drawings. All changes
in direction of piping shall be 90 degrees / 45 degrees unless otherwise specified. The
dimensions indicated in the drawings are true and contain no allowance for weld gaps.
Gaskets less than 1/16” (1.5mm) are ignored in dimensional computations.
4.8.7 For laying out headers, tees, laterals, and other irregular details cutting templates shall be
used to ensure accurate cutting and proper fit-up. All cuttings shall follow the outline of the
template.

JACOBS

4.8.8 Branch connections shall be made by fabricated intersections, welded or screwed fittings,
forged branch attachments, couplings or manifold extrusions as specified in the Piping
material specifications/ Company’s drawings.
4.8.9 Fabrication details of special items; jacketed pipelines; multi-nozzle headers, extrusions, etc.,
will be specified on the purchase order, the contract Piping or in an addendum to this
specification.
4.8.10 The contractor shall be responsible for working to the dimensions shown on drawings,
Isometrics and standards. The dimensions shown on the drawings/ Isometrics and those
actually existing may not be matching for unknown reasons. To take care of these variations
“FIELD WELDS” shall be provided in X, Y, Z directions during prefabrication stage. Extra
length of 200 mm shall be provided at the field weld point over and above the dimension
shown in the drawings/ Isometrics. During erection the pipe with extra length shall be suitable
cut to obtain the actual dimension. Provision of field welds and cutting the extra length of pipe
to achieve the actual length will not entertained as extra claim for the contractor.
4.8.11 Installation and protection of proprietary items, during fabrication shall be as per
Manufacturer’s instructions.
4.9 PREPARATION
4.9.1 PIPE JOINTS
4.9.2 Piping Material Specification specifies the type of Pipe joint for each piping class to be
adopted. In general, for Pipe sizes 2” NB and above, erection joints are Butt-Welded and
maintenance joints are flanged. For Pipe sizes 1 ½” NB and below erection Joints are socket
welded/ threaded, maintenance joints are flanged / with Unions.
4.9.3 Machined out bevels to form the welding groove are preferred in carbon steel pipe. However,
smooth, clean, slag-free, flames cut bevels are acceptable. In cases of alloy steel, S.S. Pipes
weld bevels shall be generated with file or a grinder. Arc cutting in stainless steel pipe and
alloy steel pipes is prohibited. “C” Cleats buttered on the edges with electrodes compatible
with parent pipe is also acceptable.
4.9.4 Tack welds with full penetration shall be used and shall become the part of the finished weld.
Neither defective welds nor tack welds with lack of penetration are acceptable and shall be
chipped / ground out.
4.9.5 If thermal cutting is used, at least 1.6mm thickness of the flame cut edge material shall be
dressed back to clean material.
4.9.6 Prior to welding, all fusion surfaces shall be free from foreign substances such as rust, loose
scale, slag, swarf, oil and grease etc., including any protective coating, for a distance of at
least 25mm internally and externally back from the welding edges.
4.9.7 No joint within the distance of 20 pipe diameters upstream and 8 pipe diameters down stream
of orifice flange shall be allowed in straight running pipes. For other configurations of piping
orifice flanges shall be located strictly as per drawings. In all cases, weld inside orifice flange
shall be ground flush.
4.9.8 BRANCH CONNECTIONS
• All the branch connections, except where forged tees are required as per the
specifications, shall be accomplished by pipe to pipe connections as per relevant code
requirements and piping specification. Payment will be made for this as per the rates
quoted in the respective table.

JACOBS

• Fabricated intersections shall be of the “Set-On” type with the branch pipe prepared to suit
a full penetration weld of a quality comparable to the girth welds.
• Branch reinforcement shall be of the type specified in the “BRANCH TABLE” of the Piping
material specification.
• For reinforcement and non-reinforcement branch connections, the pipe longitudinal, girth
and attachment welds be clear of the branch reinforcement perimeter, by a minimum of six
times the header wall thickness.
• Forged branch attachments shall be of the type specified in the Piping material
specification/ Isometrics and fitted accurately to the contours of the Pipes.
• Couplings and Half-couplings shall be accurately shaped and “SET-ON” to suit the contour
of the run pipe. Those for”pressure taps” shall header drilled after welding.
• Reinforcement of branch connections of all piping systems if required shall be done in

accordance with the requirements of the ANSI code for Petroleum Refinery, Piping B31.3
and the Indian Boiler Regulations wherever applicable. Payments will be made for this work
based on unit rates quoted.
4.10 FLANGE CONNECTIONS
4.10.1 All flange facing shall be true and perpendicular to the axis of the pipe to which they are
attached. Flanges bolt holes shall be straddle to the normal centre lines unless different
orientation shall be shown in the drawing to match the equipment connection etc., Tolerance
in fabrication shall be as per relevant standards / execution drawings.
4.10.2 Flanged connections shall be used at connections to vessels and equipment and where
required for ease of erection and maintenance unless otherwise stated.
4.10.3 Wherever spectacle blinds are to be provided as per drawings, drilling and tappings in the
flanges will be done by the contractor before welding of the flanges with the pipe to facilitate
installation and operation of the jackscrews.
4.11 BENDING, FORGING AND FORMING
4.11.1 Bends shall be used up to and including 40mm dia, pipe sizes where essentially required as
indicated in piping specifications. Carbon steel, alloy steel, stainless steel bends shall be cold
bent to a radius of 5 times the nominal pipe diameter using formers or shoes which fit the
desired contour of the pipe. The completed bend shall lie in one plane, have a smooth
surface and shall be free from defects such as cracks, buckles, wrinkles, bulges, flat spot etc.
They shall be true to dimensions. The flattering of a bend as measured by the difference
between maximum and minimum diameters at any cross sections shall not exceed 5% and
3% of the nominal outside diameter for internal and external pressure respectively, wherever
specified piping components shall be fabricated by hot or cold forming, rolling, forging,
hammering etc., in any case, wall thickness after bending shall not be less than 87 ½ % of
nominal wall thickness.
4.11.2 Proper account of spring back during bending shall be taken. Tolerance of angle of bend shall
be + 1/2 degrees.
4.11.3 Hot forming shall be adopted with a temperature range consistent with material characteristics
and post heat treatment shall be done wherever necessary as indicated in piping
specifications. The rates quoted by the contractor for carbon steel, alloy steel and stainless
steel piping of 40mm NB and below shall be inclusive of fabrication and erection of piping
components as specified in drawings / specifications and or as required by the Owner /
Consultant at site. Material for such fabrication shall be supplied by the Owner.
4.12 THREADING

JACOBS

4.12.1 Threading of pipes shall be preferably done after bending, forging or heat treatment
operations. When this is impossible or very difficult to perform the threading may be done
prior to such operations but precautions shall be taken to properly protect the threads from
damage. Thread joints that are to be seal welded shall be made up dry (without using thread
compound or tape). Unless otherwise stated, the threads shall be to IS 554 in case of G.I.
Pipes and fittings. However, in other cases, it shall be NPT tapped and smooth to ANSI B2.1
unless otherwise mentioned in the material specification.
4.12.2 The threads shall be full length and free from defects. The threads on each joint of pipe shall
be carefully inspected and examined prior to installation. All threaded pipe joints (except
those to be seal welded) shall be lubricated or tapped on the male and with thread joining
component or P.T.F.E. tape acceptable to the Owner / Consultant. The contractor shall
connect all joints of pipe into a screwed line sufficiently tight to withstand the test pressure
specified.
4.12.3 On all threaded connections like vents, drains, couplings, etc., the threads shall be protected
from rusting by applying grease / oil when in open conditions.
4.12.4 While fixing the plugs / caps for pressure testing or otherwise the tightness of the joints shall
be ensure by using proper thread seal and suitable to the service temperature. Oil, grease
and other sealing and protecting materials / consumables shall be supplied by the contractor
at his cost. The rates quoted by the contractor shall be inclusive of threading and seal welding
as required. Threaded connections wherever specified in drawings / documents or if required
by the Owner / Consultant shall be seal welded by the contractor. Such thread joints shall be
made up dry (without using thread compound or tape).
4.13 MITRE BENDS & FABRICATED REDUCERS
4.13.1 The specific application of welded mitre bends and fabricated reducers shall be governed by
the piping specification furnished to the Contractor. The radiographic requirements shall be
as per the piping material specification for process and utility systems with the exception of
steam piping falling under INDIAN BOILER REGULATIONS where radiographic requirement
of IBR should be complied with.
4.13.2 The piping rates shall be inclusive of erection of mitre bends and fabricated reducers.
However, the contractor shall be paid separately for fabrication of mitre bends as per the rates
quoted.
4.14 TOLERANCES
4.14.1 In addition to tolerances contained within the specified codes or standards, the following shall
also apply.
• For bending of pipes subjected to internal pressure, the difference between maximum and
minimum outside diameters, at any cross section along the axis of bent portions of the
pipe, shall NOT exceed 5% of the nominal outside diameter. The wall thickness of pipes
after bending shall be not less than (Nominal wall thickness) x 87 ½ % (Minimum wall
thickness).
4.14.2 All linear dimensions involved in relative position of branches, bases, flanges end, instrument
tappings and changed in directions, each to each other shall be maintained within + 3mm
(1/8”).
4.14.3 In case of long lines this tolerance in linear dimension cannot be added that is the overall
dimension should be within + 3mm.

JACOBS

4.14.4 All angular dimension of bends and branches shall be maintained within + 3mm. All angular
dimension of bends and branches shall be maintained within + 1/4 degree.
4.14.5 Flange joint contact surfaces shall be flat and true as machined. Should warping take place
due to fabrication processes, the joint contact surfaces may be restored to their original
accuracy, provided that the flange thickness dimensions are not reduced below the minimum
required by the relevant ASME/ API/ MSS flange specification.
4.14.6 The rotation of flanges away from their axis shall be measured as indicated in Attachment
7.1. Tithe misalignment shall not exceed 1.5mm between diametrically opposed boltholes.
4.14.7 Alignment of flanges and branch welding ends measured as shown in Attachment 7.1. across
any diameter shall not deviate from the true position more than 1/32” per foot (2.5mm per
metre) of diameter.
4.15 PREPARATION OF PIPE AND OTHER FITTINGS
4.15.1 Prior to aligning pipe for welding the ends of the pipe shall be machine bevelled. Bevel
dimensions shall be as per applicable codes / standards and piping specifications given to the
contractor.
4.15.2 The bevelled ends of each joint of the pipe shall be thoroughly cleaned of paint, rust, mill
scale, dirt or other foreign materials to avoid defects in the completed welds. This shall be
done by use of power driven wire brushing wheels or other methods approved by the
consultants.
4.15.3 Any foreign matter or obstruction remaining inside the pipe shall be removed by appropriate
means.
4.15.4 Couplings and half couplings shall be accurately shaped and set on to suit the contour of the
run pipe, weldolets shall be fitted accurately to the contour of the run pipe. Pipe shall be
properly supported and aligned by jigs or clamps as required in order to preclude extraneous
loads and minimise strains during tacking.
4.15.5 Small tack weld i.e. between 1/2” (12.5mm) and 3/4” (18mm) in length penetrating to the
bottom of the groove may be used in fitting up.
Tacks should be equally spaced as follows :
For 2 1/2” pipe and smaller - 2 tacks

For 3” to 12” pipe - 4 tacks
For 14” and large pipe - 6 tacks
Unless otherwise specified, all pipe to pipe joints shall be butt welds.
4.15.6 Pipe with a wall thickness of 1.4” (6mm) and greater shall not have internal mis-alignment of
pipe wall exceeding 1/16" (1.5mm).
4.15.7 Pipes with a wall thickness less than 1.4” (6mm) shall not have internal mis-alignment of pipe
wall exceeding 25% of pipe wall thickness. When mis-alignment is greater than the above
component shall be aligned by drifting, rolling or machining in accordance with the code,
ensuring that the nominal wall of minimum wall thickness is not encroached upon after
considering the manufacturing tolerances defined in the appropriate material specifications.

JACOBS

4.16 INSPECTION OF FABRICATED PIPING
4.16.1 Pipe work that has been done shall be checked with the isometric drawings and other related
documents to verify that it is fabricated, complies with the dimensions and specifications.
4.16.2 Fabrication shall have dimensions falling within the tolerances defined earlier.
4.16.3 All welds shall be visually examined and shall also be subjected to radiographic inspection as
provided for in para Radiographic inspection thereof. Joints shall have proper weld
penetration without undercuts, overlaps, or abrupt ridges or valleys. Visual defects such as
cracks, pin holes incomplete fusion, etc., shall be removed and joints rewelded at contractors
cost and particular case should be exercised in built welding of small diameter pipes and
stainless steel pipes so as to prevent reduction of internal diameter at the joint beyond the
limits specified below. The root pass of butt joints, regardless of techniques use shall be such
that the projection of weld metal into the pipe bare shall not exceed specified limits indicated in
standard codes and piping specifications.
4.17 CLEANING OF PIPES
4.17.1 On completion of fabrication, all pipes and fittings shall be cleaned inside and outside by a
suitable means (mechanically driven rotary cleaning tool, wire brush, compressed air,
detergent etc.). Before erection to ensure that assembly is free from all loose foreign material
such as scale, sand, weld spatter particles, cuttings chips etc.
4.17.2 All field fabricated piping shall also be cleaned at the completion of the fabrication. All burrs
welding icicles and weld spatter shall be removed by any suitable means (mechanical tools,
wire brush etc.). The pipe interior shall be water flushed to eliminate cement mortar, sand,
heavy oil films and loose scale etc., and ends shall be capped.
4.17.3 Both shop and field fabricated piping shall be blown with compressed air at the termination of
cleaning. The ends of complete section of pipe line shall be closed with suitable plugs, caps
or other approved methods. All fabricated piping shall be protected against rust and corrosion
pending erection, by the contractor at his own cost.
4.17.4 Cleaning requirements for special services, if any, shall be followed by the contractor as
specified in the piping specifications.
4.17.5 Pickling and passivation of S.S. pipes if required shall be carried out as specified in the
attached specifications.
4.18 HEAT TREATMENT
4.18.1 PRE-HEATING
Piping joints shall be preheated before welding to the extent required for different types of
materials as per the requirement of standards / codes and specifications and also refer to
Attachment 7.3
4.18.2 POSTWELD HEAT
Welded joints shall be heat treated for the various types of steel as specified in the piping
specifications and also refer to Attachment 7.3
4.18.3 Flange seal surfaces must be protected against oxidation during Heat –Treatment.
4.18.4 All bends and other parts worked either cold or hot shall be heat treated as indicated in
Attachment 7.3

JACOBS

4.18.5 In all cases maximum Brinell hardness values given in Attachment 7.3 shall not be exceeded.
4.19 WELDING
4.19.1 All welding shall be in accordance with the code and with any amendments or additional
requirements noted on drawings or within this specification.
4.19.2 All welding procedures and supporting qualifications to be used by the contractor shall be
presented to the company for written approval.
4.19.3 Welder qualification shall be in accordance with section IX of the ASME Boiler and Pressure
vessel code and shall be witnessed by the client/ company’s representative. In case of IBR
piping welders & welding, procedure shall be subject to approval from IBR inspectorate.
4.19.4 Backing rings shall not be used without the approval of the company.
4.19.5 During welding, sections of pipe shall be adequately supported so that the joints are relieved
of any strain.
4.19.6 All welding shall be supervised and records maintained, identified with the individual welder
concerned.
4.19.7 Electrodes shall be stored , dried and utilized as per manufacturer’s recommendations.
4.20 ERECTION
4.20.1 For erection of piping, use of davits, welding of temporary supports on adjacent equipment /
structure, use of existing foundation or steel structure shall be allowed only after approval of
Owner / Consultant. In each case maximum load and erection procedure shall be as direct by
the Owner / Consultant.
4.20.2 The intent of prefabrication at the shop is to accelerate progress of pipe work and to minimize
work in the field. Such prefabrication should be based on approved isometrics and piping
layouts furnished to the contractor. Field weld means position weld of prefabricated piece at
site or near the plant. However, the contractor shall bear in mind that there can be variations
in dimensions between those appearing in the isometrics and those actually occurring at the
site due to minor variations in the location of equipments, inserts etc. Therefore field welds
shall be decided by the contractor permitting preassembly to be installed without any
modifications. The shop fabricated pieces shall be largest practicable size limited for easing
transportation to site. In any case, no extra claims will be entertained on this score. After
prefabrication, during intermediate storage pipe ends shall be sealed off. Before, sealing the
ends, piping shall be cleaned inside to remove welding spatter and foreign debris (brush
clean).
4.20.3 All piping shall be routed and located as shown in piping drawing keeping in view the piping
specifications. No deviations from the arrangement shown shall be permitted without the
express consent of the Owner / Consultant.
4.20.4 All piping shall be straight and direct with requisite slopes provided to headers and jacketed
lines as indicated on drawings. Piping shall generally be routed parallel to or at right angles to
the plant columns and beams and shall be neatly and evenly spaced as shown in drawings
4.20.5 Pipes shall be installed at elevations and dimensions indicated on piping drawings and the
contractor shall be fully responsible for accurately laying out the pipe work. Should changes
be necessary at site in order to avoid interference, this shall be carried out by the contractor in
consultation with the Owner / consultant at no extra cost.

JACOBS

4.20.6 Steam lines shall be provided with steam traps at low points in general. Drains and vents shall
be provided on all pipe lines at low and high points respectively as well as at locations
necessary for pressure testing, even though the same may not have been shown in the piping
drawings.
4.20.7 Installation of jack screws will be done by the Contractor. Jack screws will be issued by the
Owner
4.20.8 Lines requiring steam tracing shall be laid by the contractor in strict compliance to the
specification drawings and details provided. Payment for tracer lines will be made at the
corresponding unit rates quoted separately.
4.20.9 Location and design of pipe supports shown in Construction drawing, general arrangement
drawings, support manuals should be strictly adhered to. Pipe supports have been designed
and located to effectively sustain the piping system for weight and thermal effects. Erection
and fabrication of supports i.e. restraints, such as guides steps, anchors must be made in
such manner that they will not contribute to the over stressing of a line, while protecting a
weaker or more sensitive sections of a line, while protecting a weaker or more sensitive
component e.g. turbine, pump, compressor of approved nozzles. Supports other than these
specified above shall be designed fabricated and erected by the contractor.
4.21 FLANGES
4.21.1 While fitting up mating flanges, care shall be exercised to properly align the pipes and to
check the flanges for stress, so that faces of the flanges can be pulled up together without
inducing any stresses at the pipes and equipment nozzles. The bolt holes of the flanges in the
vertical plane shall straddle the vertical centre line of the pipe in the erected position and for
flanges in the horizontal plane the bolt holes shall straddle the plant north south axis unless
otherwise indicated on the drawings.
4.21.2 Flanged connections at the pumps, turbines, compressors shall be made in such a way so as
not to induce any stresses due to misalignment excessive gaps etc. The final tightening shall
be redone when the machines are aligned completely and specifically authorized by the
Owner / Consultant. Temporary protective covers shall be provided at all flanged connections
of pumps, compressors, turbines and other similar equipments until the piping is finally
connected.
4.22 FITTING
4.22.1 Wherever cold spring is specified, the contractor shall maintain the necessary gap provided
for cold spring as indicated in the drawings. Before cold pulling two sections, Consultant /
Owner must check the gap and confirmation in writing is to be obtained in this respect that
gap provided is in accordance with the drawings.
4.22.2 Expansion loops shall be fabricated from pipe and prefabricated bends and installed by the
contractor from material supplied by Owner / Consultant.
4.22.3 Slopes specified for various lines in the drawings shall be maintained by the contractor. In
case the contractor unable to maintain the indicated slope, he shall check the sagging of pipe
with a precision spirit level. Vents and drains are shown in the isometrics of each line and
these are intended, during hydraulic test, for releasing the trapped air and draining out the test
fluid after testing. Valved vents and drains are also shown wherever required. The contractor
shall provide vents and drains connections even these are not shown in the drawings and are
found necessary by the Consultant/ Owner. The details of the type of connections to be
adopted shall be given to the contractor at the time of work.

JACOBS

4.22.4 Avoid any metal to metal pressure contact between stainless or acid resistant steel and
unalloyed steel, as such contact can cause corrosion damage.
4.22.5 When applying wire-rope slings, keep these chaffing against the item being handled by
interposing cushioning material. Take care during field assembly that structural members of
unalloyed steel do not rub against stainless steel and acid resisting steel components.
If any piping components have to be held in vices, or similar clamping devices, cover the vice
jaws or holding surfaces with work protectors of the same stainless steel or of lead or copper
sheet.
4.22.6 After the piping is erected in final position, it shall be cleaned, tested for tightness and kept dry
wherever instructed as described in this specification.
4.23 VALVES AND ON-LINE FITTINGS
4.23.1 All on-line fittings such as valves, strainers, traps, filters, thermowells, safety valves, control
valves, pressure reducers, ejectors, flame arrestors, sight glasses, rainhoods etc., shall be
installed as specified in the drawings. Valves should preferably be with stem pointing upwards
or horizontal as directed. They shall be installed in such a manner that hand wheels, stem
and motors will not obstruct platforms and walkways. Temporary spool pieces in place of any
of the on-line fittings shall be provided. Should such items be not available at the time of
erection / testing the spool pieces shall be replace with the appropriate fittings when the same
is available.
4.23.2 In case of control valves spool pieces shall be provided in their place on pipelines at the time
of testing and flushing. The spool pieces, shall be removed and control valves shall be
installed in their place before trial running and pre-commissioning. Fabrication installation and
removal of spool pieces is in the contractors scope of work and no extra payment shall be
made for the same.
4.23.3 All globe valves shall be installed with the fluid pressure acting on the bottom of the discs.
Globe valves, check valves, control valves shall be installed in the correct sequence and
direction as shown in line diagrams and piping drawings. In case the direction of flow is not
given in the valve body, the contractor shall check then and mark the correct direction on the
valves prior to their installation.
4.24 SUPPORTS, GUIDES AND ANCHORS
4.24.1 Pipe supports shall be provided generally as per the standard piping support details shown in
drawings / pipe support manual, location and design of main pipe racks only are given in
drawings. But, for certain critical piping, location and design of pipe supports are also given in
piping drawing. The contractor shall strictly adhere to these details and provide proper pipe
supports.
4.24.2 For the field run piping, the contractor shall locate suitable and adequate supports consistent
with the design and type supports used in the rest of the plant.
4.24.3 Additional supports may have to be provided at site where necessary to avoid sagging and / or
transmitting undue loads to interconnecting equipment. Discretion for providing all such
additional support lies with the Owner / Consultant.
4.24.4 If temporary pipe supports are required during installation, the contractor shall provide the
same at no extra cost and remove the same on fixing of permanent supports.

JACOBS

4.24.5 Welding on any piping, machinery or equipment for the purpose of pipe / valve support shall
not be done unless otherwise indicated on drawings or written permission is obtained from the
Owner/ Consultant.
4.24.6 Correct installation of supports at pumps and compressors is a must. The following points are
to be checked after installation with Owner / Consultant and necessary confirmation in writing
is to be obtained in this respect.
i. Restraints installed properly.
ii. Clearance as per support drawings.
iii. Restraints strength adequate (visual)
iv. Insulation (does not restrict thermal growth)
v. Spring supports located as per support drawings, spring removed and cold load
setting checked. Interference and travel from cold to hot to be checked.
4.24.7 Lines shown with the pipe hangers shall be installed with hanger rods set at a slope in the
direction opposite to the pipe movement from the operation. No supports shoe/ cradle shall
be offset unless shown specifically in the drawing. Spring supports shall be checked for the
range of movement and adjusted if necessary to obtain correct positioning in the cold
condition.
4.24.8 Fabrication and erection of supporting elements and structural fixtures wherever required and
as pointed out by the Owner / Consultant shall be carried out by the Contractor.
4.24.9 For fabrication of pipe supports, payment will be made separately as per unit rates quoted.
4.24.10 However, for spring hangers supplied by the owner, piping rates shall be inclusive of these
supports.
4.25 INSTRUMENTS
4.25.1 In case of instruments the limits of piping contractor are clearly shown in the drawings
provided (such as up to first block valve, nozzle and flanges taps, etc.). In addition to this, the
contractor shall install all on-line instruments such as restriction orifices / orifice assemblies
with first block valves venturies, control valves, flow integrators, positive displacement meters,
with strainers, pressure relief / safety valve, rotameters, rots transmitters, etc. Though exact
location is indicated on drawing for take off for temperature pressure flow level, sample
connections etc. The contractor shall ensure correct orientations site in consultation with the
Owner/ Consultant before starting final welding. Care shall be used a control valves, flow
meters, etc., to avoid contamination with dust and foreign matters.
4.26 BOLTS & NUTS
4.26.1 During erection of the piping, the contractor shall use proper number and size of bolts and
nuts as per drawings and specifications. The contractor shall clean all bolts and nuts if
required with rust removing compound and provide approved quality of grease mixed with
graphite powder thoroughly on all the bolts and nuts to prevent rusting during storage of his
stores, immediately after erection and when the flanged joints are opened and remade for any
purpose including flushing, testing and alignment of equipment etc. The grease and graphite
powder shall be supplied by the contractor within the rates for piping work.

JACOBS

4.27 STRAINERS
4.27.1 The installation of the conical strainers between two flanges shall be part of piping erection
work and no separate payment will made for this work.
4.28 ASSEMBLY
4.28.1 The assembly of various piping components shall be done so that the completely erected
piping conforms to the requirements of the specification as wells as the arrangements and
details shown in construction drawings.
4.28.2 All flanged pipe sections and flanged appurtenances shall be accurately lined up before
making up flanges in order to prevent any stresses from slinging or forcing the piping in to
place by means of flange bolts. Flange facings shall be true and perpendicular to the axis of
the pipe.
All bolts shall extend completely through their nuts but not more than 1/2”.
All flange bolts connections shall be off - centre lines unless otherwise required.
4.29 FLANGE JOINTS WITH A GASKET
4.29.1 The following procedure shall be adopted when assembling

a) Brush off the flange surfaces.
b) Align the flanges.
c) Insert two or three aligning pins.
d) Remove the gasket from the package, drop into its place.
e) Cleaning bolts and nuts if required with rust removing compounds and grease with
graphite powder.
f) Insert bolts into free holes and tighten.
g) Replace aligning pins with bolts and nuts.
h) Tighten all bolts evenly first on the quarter and then gradually in symmetrical pattern to
ensure equal torque on the bolts.
4.29.2 Full face drilled gaskets shall be used on all flat faced flanges unless specified otherwise.
During erection / installation of the piping, proper number and size of the nuts and bolts shall
be fitted as per drawings and specifications. All flanged joints shall be so fitted that the gasket
contacts faces bear uniformly on the gasket and then made up with relatively uniform bolt
stress.
4.29.3 In case of Tie-in-joints the joint fit up will be checked and approved by Owner/ Consultant.
Root run will be checked by dye penetration testing. The joint will be fully radiographed and
defects, if any will be rectified and re-radiographed. All these will be carried out at contractors
cost. The tie-in-joints will not be tested hydrostatically.
4.30 STRUCTURAL ATTACHMENTS
4.30.1 Reinforcement pads for structural attachment shall be provided with an untapped hole of 6mm
diameter for venting, drilled prior to welding to header. Attachment welds shall be in
accordance with 4.18 & 4.19
4.31 TREATMENT AFTER FABRICATION
4.31.1 Where pipe work is required to be lined, coated or given treatment of any kind after
fabrication, these operations will be subject of separate specification.

JACOBS

4.32 FABRICATION PRIORITIES AND MATERIAL
4.32.1 Where contract requirements demand, the company will inform the contractor/ Fabricator of
the fabrication priorities, which are subject to periodic revision and updating. The contractor/
fabricator shall provide a fabrication control system that is flexible enough to accommodate
reasonable change in priority.
4.32.2 Optimisation on weight or work content shall not be factors of fabrication priority.
4.32.3 The company reserves the right to request the production of pipe spools where minor items of
the materials are not available in time, e.g half couplings, full couplings, bosses, sockolets etc.
4.32.4 The contractor/ Fabricator shall be able to maintain production with these variations and
absorb any double handling necessary.
4.33 INSPECTION
4.33.1 Pipe work shall be checked against the Engineering Drawings issued for construction and
other related documents to verify that it complies with the company’s requirements, as
fabricated.
4.33.2 Fabrication shall have dimensions falling within the tolerances defined elsewhere in this
document.
4.33.3 All completed welds shall be visually examined for visible defects.
4.33.4 For non-destructive test requirements, reference should be made to the Annexure in piping
material specification.
4.34 PROTECTION
4.34.1 The contractor/ fabricator shall ensure that all fabricated pipe work is protected against
corrosion and mechanical damage during storage, transportation and erection.
4.35 PIECE MARKING
4.35.1 All spool pieces shall be marked with proper identification for ease of assembly. Each spool
shall be marked with the following, starting from the direction of flow arrow shown in the
Isometrics/ drawings.
• Piece identification mark e.g. MK-1, MK-2 etc.,
• Line Number
• Isometric number
4.35.2 Hard stamping shall not be used as a method for marking pipe work.
Z SS 005 : Specification for Piping-Welding
Z SS 006 : Specifications for piping –flushing, testing and inspection
6.0 RECORDS
None
7.0 ATTACHMENTS/ APPENDICES
Refer to “Table of Contents”

JACOBS

ATTACHMENT: 7.1

JACOBS

ATTACHMENT: 7.2

JACOBS

ATTACHMENT 7.3
1. THERMAL CUTTING
TABLE 1
PREHEAT TEMPERATURES FOR THERMAL CUTTING

MATERIAL Preheat Minimum o C
Carbon Steel See Notes below
1 Cr ½ Mo. 100, See Notes below
1 ¼ Cr ½ Mo. 100, See Notes below
2 ¼ Cr 1Mo. 150, See Notes below
Carbon ½ Mo. 100, See Notes below
Notes:
• Where carbon content is greater than 0.25% or wall thickness is greater than 19mm (¾
in.) a preheat of 80 degree C minimum shall be applied.
• Preheat shall be applied uniformly around pipe circumference prior to cutting.
• Treatment after thermal cutting
1. Remove all slag.
2. Oxide skin on weld preparation to be dressed back to clean metal by grinding,

machining or filing.
2. COLD BENDING OR FORMING
TABLE 2
0 Heat treatment
Materials Max bending Temp C
after Bending
Carbon steel 620 Note-1
1 ¼ Cr. ½ Mo. 650 None
2 ¼ Cr. 1Mo. 680 None
5 Cr. ½ Mo. 720 None
Carbon ½ Mo. 650 None
Austenitic Cr. Ni. 425 Note-2
Notes:
1. Cold bent carbon and low alloy steel pipes in all thicknesses shall be stress
relieved when impact tested. All pipes intended for caustic, or any other service,
likely to induce stress corrosion cracking, shall also be stress relieved (Table 5).
This information will be defined in the contract specification.
2. Under certain circumstances e.g. when the fabrication is to be exposed to

conditions which promote stress- corrosion cracking, solution annealing at 1050-
0
1100 C should be considered.

JACOBS

Definitions:
1. For ferritic steels, cold bending involves operations at temperatures below the
lower critical point; the temperature limitations of Table 2 make allowances for
safe margin below this temperature.
3. HOT BENDING OR FORMING
TABLE 3
Materials Hot bending Temp 0C Heat treatment after Bending

Carbon steel 850- 10500 C (N) 900 - 9500C, Note 1
0 0
1 – 9 Cr. Mo. 900- 1100 C (N) 900 - 950 C and (T), Note 2
0 0
Carbon ½ Mo. 900- 1100 C (N) 900 - 950 C, Note 3
0 0
Austenitic Cr. Ni. 950- 1100 C Solution Annealing at 1050- 1100 C, Note 4
Notes:
1. Heat treatment may not be necessary. Precise requirements are defined in the
contract piping specification.
2. Normalise (N) and Temper (T) as defined in contract piping specification.
3. Normalise (N) as defined in the contract piping specification.
4. The complete item shall be normally be heat-treated. Local heating shall not be
used except under special circumstances with Company approval.

JACOBS

4. PREHEATING REQUIREMENTS FOR WELDING
TABLE 4
PRE-HEATING REQUIREMENTS FOR WELDING

Material Low Hydrogen Metal (Note 2) Non Low Hydrogen Metal (Note 2)
Thickness (mm) Note 1 Minimum Pre-heat Thickness (mm) Note 1 Minimum Pre-heat
C.S Less than or equal Greater than 30 800 C Greater than 20 800 C
to 0.25% of Carbon Less than or equal to 30 100 C Less than or equal to 20 100 C
C.S greater than 0.25% Greater than 12.5 1000 C Greater than 12.5 1000 C
of Carbon Less than or equal to 12.5 100 C Less than or equal to 12.5 100 C
0
Greater than 12.5 100 C Note 3
Carbon ½ Mo. 0
Less than or equal to 12.5 10 C Less than or equal to 12.5 1000 C
1 Cr. ½ Mo. Greater than 12.5 1500 C Note 3
1 ¼ Cr. ½ Mo Less than or equal to 12.5 1000 C Note 3
2 ¼ Cr. 1Mo. Greater than 12.5 2000 C Note 3
3 Cr. 1Mo. Less than or equal to 12.5 1500 C Note 3
5 Cr. ½ Mo.
7 Cr. ½ Mo. ALL 2000 C Note 3
9 Cr. 1 Mo
3 ½ Ni.
5 Ni. Consult Company Construction department
9 Ni.
Notes:
1. Greater component thickness at weld joint.
2. Low hydrogen weld metal shall contain not more than 10 ml of diffusible
hydrogen, per 100g of deposited weld metal (BS 639).
3. Only Low hydrogen weld metal shall be used.
5. POST WELD HEAT TREAMENT REQUIREMENTS
TABLE 5
Minutes of Soak
Material Thickness Temperature Maximum Hardness (Note 1)
Time
0 Per
(mm) C Minimum Vickers Brinell
mm
Less than or equal to 20
Carbon Nil (Notes 2 & 3) Nil Nil 237 225
(Note 2)
Steel
Greater than 20 580- 620 (Note 3) 2.5 30 237 225
1 Cr. ½ Mo.
1 ¼ Cr. ½ All (Note 5) 705- 740 (Notes3, 4 & 6) 5 120 237 225
Mo
2 ¼ Cr.
1Mo. All 710- 750 (Notes3, 4 & 7) 5 120 253 241
3 Cr. 1Mo.
5 Cr. ½ Mo.
7 Cr. ½ Mo. All 720- 760 (Note 3, 4) 5 120 253 241
9 Cr. 1 Mo
3 ½ Ni.
5 Ni. Consult Company Construction Department
9 Ni.
Carbon ½
All (Note 6) 650- 680 (Notes 3, 4 & 5) 2.5 60 237 225
Mo.

JACOBS

Notes:
1. The method employed for hardness testing shall be of identifying peak hardness
values, which occur in the heat-affected zone. Acceptable methods are the
Vickers test preferably with a load of 10 Kg for laboratory evaluation of weld test
pieces and portable dynamic tests for assessment of production welds.
2. Post weld treatment may be required on carbon steel and low temperature
carbon steel for process reasons, e.g. caustic or chloride service, regardless of
wall thickness. Such requirements will be defined in the Piping specification.
3. i) Where a static furnace is used, the furnace temperature shall not exceed
4000 C when inserting the weldment.
ii) The heating rate shall not exceed the following

0
For pipes of thickness up to and including 25mm- 220 C per hour; for pipes
of thickness over 25mm- 2200 C x (250 C /t) per hour, or 550 C whichever is
greater.
0
iii) For pipes thickness t up to and including 25mm - 275 x (25 C /t) per hour or
550 C per hour, whichever is greater.
0
4. The cooling rate down to 400 C shall not exceed the following:-
For Pipes of thickness t up to and including 25mm – 2750 C per hour.
For pipes thickness t over 25mm - 275 x (250 C /t) per hour or 550 C per hour,
whichever is greater.
5. Post weld heat treatment is not required for thicknesses up to and including 12.5
mm providing the hardness in the weld and heat affected zone does not exceed
237 Vickers (225 Brinell).
0 0
6. Post weld heat treatment shall be carried out at 630 C - 670 C, when optimum
creep properties are required.
0 0
7. Post weld heat treatment shall be carried out at 680 C - 720 C, when optimum
creep properties are required. In this case the minimum soaking time shall be
180 minutes regardless of thickness.

JACOBS

8. DISSIMILAR METAL WELDS
TABLE 6
ST nd
1 Base Metal 2 Base Metal Filler Material Pre-Heat Post Heat Notes
nd nd nd
C. ½ Mo. As for 2 Base As for 2 Base As for 2 Base
Carbon Steel Note 1
1-3 Cr. Mo. metal metal metal
nd nd
As for 2 Base As for 2 Base
Carbon Steel 5- 9 Cr. Mo. 2 ¼ Cr. Mo. Note 1 & 2
metal metal
E309 st
As for 1 Base Consult the
Carbon Steel Austenitic S.S Inconel82/182 or -
Equiv. metal company
nd
As for 2 Base As for 2nd Base As for 2nd Base
Cr. Mo. Higher Cr. Mo. Notes 1 & 2
metal metal metal
E309 st nd
Cr. Mo. As for 1 Base As for 2 Base
Austenitic S.S Inconel82/182 or
Carbon.½ Mo. Equiv. metal metal
As for 2nd Base As for 2nd Base As for 2nd Base
1-3 Cr. Mo. Note 1
metal metal metal
Carbon.½ Mo.
As for 2nd Base As for 2nd Base
5- 9Cr. Mo. 2 ¼ Cr. Mo. Note 1 & 2
metal metal
C.S, E309 nd Consult the Company
As for 2 Base
Austenitic S.S C.½ Mo., Inconel82/182 or Piping Group (piping
Cr. Mo. Equiv. metal shall consult FEG)
nd
Another As for 2 Base
Austenitic S.S None None
Austenitic S.S metal
Notes:
1. When welding any of the Cr. Mo. Steels in situations where P.W.H.T is
impractical and higher hardness values are likely occur, consideration shall be
given to welding with INCONEL 82/ INCONEL 182.
2. When joining of steels widely variable compositions, such as:
Carbon steel/ 1Cr. ½ Mo./ 1 ¼ Cr. ½ Mo. Welding to 5Cr. ½ Mo./ 7Cr. ½ Mo./
9Cr. 1Mo. Consideration shall be given to use of mutually compatible
intermediate transition piece. Where such changes occur, the company
construction Department shall be consulted.

Page 1 of 1
PIPING - WELDING
By By By
0 02.11.2001 14 Issue for use MRAK CLS AGG
1 02.08.2004 14 Cover page revised ALB SGR AGG
ZSS005 Std Spec for Piping Welding

JACOBS

PAGE 2 OF 14 STANDARD SPECIFICATION FOR PIPING – WELDING
REVISION NO: 1
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 INTRODUCTION
4.0 WELDING EQUIPMENT AND ACCESSORIES
5.0 WELDING PROCESS
6.0 WELDER'S QUALIFICATION AND PROCEDURE TESTS
7.0 WELDER'S SYMBOL
8.0 WELDING PROCEDURE
9.0 CLEANING OF WELD JOINTS
10.0 INSPECTION AND TESTING GENERAL
11.0 EXAMINATION METHODS AND REQUIREMENT
12.0 DEFECTS
13.0 WELDING CONSUMABLES
14.0 APPENDICES
14.1 APPENDIX I - WELDING SPECIFICATION CHART

JACOBS

STANDARD SPECIFICATION FOR PIPING – WELDING PAGE 3 OF 14
REVISION NO: 1
1.0 PUPOSE
This purpose of this specifications is to define the construction requirements of welding for
pipelines.
2.0 SCOPE
2.1 This specifications supplements the applicable code requirements / specifications / drawings
for fabrication, erection, inspection, testing of pipelines.
2.2 Engineering drawings/ codes/ standards shall take precedence over this specifications if there
are any conflicting clauses.
3.0 INTRODUCTION
The specification shall be adopted to all welded pipe joints of Carbon Steel and Stainless Steel
piping system coming under the Plant.
The welded pipe joints are defined as under:-
a) All line joints of the longitudinal and circumferential butt welded and socket welded
type.
b) Split sleeve joints on certain S. S. Pipes.
c) Attachments of castings, forging, flanges and other supporting attachments to pipes.
d) Welded manifold headers and other sub-assemblies.
e) Welded branch connections with or without reinforcing pads.
f) Manufacture of welded / fabricated piping components.
g) The attachment of smaller connections for vents, drains, drips and other instrument
tappings.
All welding, heat treatment, other ancillary welding equipment and the welding personnel shall
be in accordance with the following accepted standards, codes and procedures, latest editions
as applicable.
a) Code for Petroleum Refinery Piping - ANSI B31.3

b) Standard for Welding Pipes and other Related Facilities - API 1104
c) Welding Qualifications - ASME Sec. IX
d) Code of Procedure for Metal and Welding of C.Steel - IS-823
e) The Indian Boiler Regulations - IBR
In the event of any variation due to additional requirements over and above those that are
obligatory as per codes, this specification shall be binding.
4.0 WELDING EQUIPMENT AND ACCESSORIES
All welding machines, line up clamps, levelling machines and other equipment’s used in
connection with the welding work must be satisfactory and must be kept in good mechanical
condition so as to produce sound welds. Only D.C. Motor generator welding sets or Rectifier
Welding sets shall be used for welding on pipes.

JACOBS

REVISION NO: 1
For TIG welding on stainless steel pipes high frequency units shall be used in conjunction with
D.C. Motor generator welding sets or Rectifier Welding Sets.
5.0 WELDING PROCESS
5.1 No welding process or procedure shall be adopted without prior approval of the Owner /
Consultant.
5.2 All piping shall be welded using either the Shielded Metal Arc Welding (SMAW). Process or
the Gas Tungsten Arc Welding (GTAW) process or a combination of the two.
5.3 Oxy-acetylene brazing shall be used for brazing copper and copper alloys where used. Oxy-
acetylene soldering process shall be used for soldering bronze to C.S. and Cast Bronze to
copper.
5.4 For welding of all grades of Steel and Nickel alloys by the GTAW process, a 2% Thoriated
Tungsten Electrode confirming to AWS a5, 12-69 EW TH - 2 classification shall be used.
5.5 Any other welding process, if proposed by the Contractor, shall require specific approval of
Owner / Consultant..
5.6 A combination of different welding processes or a combination of electrodes of different

classes / makes could be employed for a particular joint only after duly qualifying the welding
procedure to be adopted and obtaining the approval of Owner / Consultant.
6.0 WELDER'S QUALIFICATION AND PROCEDURE TESTS
6.1 WELDER'S QUALIFICATION
Any Welder who is entrusted with the performance of welding work shall passed the pipe
Welder Test to ASME Section IX. Prior to his assignment in the field, the Welder shall weld a
test specimen in a horizontal and vertical position or as directed by Owner / Consultant as per
the requirement of ASME Section IX. API 1104 or other equivalent / applicable code as may
be required and get himself qualified for welding on the job.
Depending on the pipe welding shall be done on one or several pipes.
For all welding coming under IBR, Welders shall be qualified by Boiler Inspectorate
possessing IBR.
Certificate in addition to above shall only be employed.
The Owner / Consultant shall witness the test and certify the qualifications of each welder
separately.
IBR Welders shall be approved by the Boiler Inspector before deployment on the Job.
The test specimen shall be 100% radiographed.
The test specimen 2.5 cm in width, shall be out from the pipe piece at right angles to weld.
The test specimens shall be subjected to root bend, face bend, tests. These tests shall be
arranged by the Contractor at his own cost but shall be witnessed by the Owner / Consultant.
The manner of performing the test and the results required shall be in accordance with ASME
Section IX, API - 1104 and ASME Boiler and Pressure Vessel Code as may be applicable.

JACOBS

REVISION NO: 1
The contractor shall submit the Welders qualification test report in the standard format as
required by Owner / Consultant.
The Welder shall not be entrusted with any work until the test specimen has been fully
evaluated and approved.
If a Welder is found to perform a type of welding or in a position for which he is not qualified,
he shall be debarred from doing further work. All such welds performed by an unqualified
Welder shall be out and redone by a qualified welder at the expense of the Contractor.
6.2 Welding procedure qualification tests shall be carried out in accordance with job requirements
and the relevant requirements laid down in Section IX of ASME Boiler and Pressure Vessel
code or other applicable codes and the job requirement. The Contractor shall submit the
welding procedure to the Owner / Consultant who will check and approve the welding
procedure and shall release the procedure for procedure qualification tests. Standard tests
shall be performed in all cases. In addition to these standard tests. Tests like micro-
examination, hardness tests, dye-penetration examination, charpy V notch and U notch impact
tests, etc., shall be carried out on specimens depending on the type of base, materials,
operating conditions and requirements laid down in specification. It shall be the responsibility
of the Contractor to carry out all such tests free of charge. The procedure qualification test
shall be carried out by the Contractor at his expenses.
It shall be the responsibility of the Contractor to carry out all the tests required to the
satisfaction of the Owner / Consultant.
7.0 WELDER'S SYMBOL
After qualification, the Welder's symbol shall be confirmed and recorded in a list. This symbol
(die stamp) shall be used for identifying all welds made by that welder.
For thin-walled and alloy steel pipes, the welding superintendent may decide that the Symbol
will be applied to the work piece by painting.
8.0 WELDING PROCEDURE
8.1 EDGE PREPARATION
The edges to be welded shall be prepared to meet the joint design requirement by any of the
following methods given below:
a) Carbon Steel
Gas cutting, machining or grinding methods shall be used. After gas cutting oxides
shall be removed by chipping or grinding.
b) Low Alloy Steel Containing up to 2.5% Chromium
Gas cutting, machining or grinding methods shall be used. After gas cutting machining
or grinding shall be carried out on the cut surfaces.
c) Stainless Steel
Plasma cutting, hacksaw cutting, machining or grinding methods shall be used.

Plasma cutting out shall be machined or ground smooth.

JACOBS

REVISION NO: 1
8.2 CLEANING
The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides,
sand, earth and other foreign matters. The ends shall be completely dry before the welding
commences.
8.3 ALIGNMENT
The pipe shall be aligned so that the longitudinal mill weld in the pipe is on the top 90 degrees
of the pipe lines (except on vertical bends) and in such a way that the longitudinal Mill welds
are staggered not less than 45 degrees.
Elements to be joined by welding shall be aligned with the aid of internal or external centering
facilities. Root opening and root gap shall depend on the root welding procedure and as per
code specified.
The welding butts as well as the surroundings must have a bright finish and be free of grease.
For pipes of wall thickness 5 mm and above the ends to be welded shall be secured in
position with the aid of couplers, yokes, and 'c' Clamps to maintain perfect alignment. Yokes
shall be welded to the pipes with the electrodes suitable for welding the parent pipe material
and shall be detached after the completion of weld, without causing any surface irregularities.
Any irregularity caused on the pipe surface must be suitably repaired to the satisfaction of the
Owner / Consultant.
Tank welds, for maintaining the alignment, of pipe joints shall be made only by qualified
welders. Since the tack welds become part of the final weldment they shall be executed
carefully and shall be free from defects. Defective tack welds must be removed prior to the
actual welding of the joints. Tack welds should be equally spaced - Minimum number of tacks
shall be:
2 tacks - for 2 ½" dia, and smaller

4 tacks - for 3" to 12" pipe dia.
6 tacks - for 14" pipe dia, and larger
8.4 WEATHER CONDITIONS
The parts being welded and the welding personnel should be adequately protected from the
rain and strong winds. In the absence of such a protection no welding shall be carried out.
During field welding using CTAW process, particular care shall be exercised to prevent any air
current affecting the welding process.
General Welding Requirements
a) Surfaces to be welded shall be free from paint, rust, oil, grease, dust or any other
contamination.
b) Root passes shall be made with electrodes / filler wires recommended in the welding
specification chart and as approved in procedure test. The preferable size of the
electrodes is 2.5 mm diameter (12 SWG) but in any case not greater than 3.15 mm
(10 SWG).
c) Upward technique shall be adopted for welding pipes held fixed with its axis
horizontal.

JACOBS

REVISION NO: 1
d) The root pass of butt joints should be executed properly so as to achieve full
penetration with complete fusion of the root edge without under cutting along the sides
of the weld.
e) Welds shall be cleaned between passes to remove all traces of slag and flux before
successive beads or layers are deposited. The craters at the starting and stopping
points of each individual bead shall be carefully examined and any defects shall be
removed by grinding. Wire brushed used for cleaning stainless steel joints shall have
stainless steel wires and the grinding wheels used for grinding stainless steel shall be
of a suitable type. Separate grinding wheels and wire brushes should be used for
Carbon steel and stainless steel.
f) Welding shall be continuous and uninterrupted during a pass.
g) While the welding is in progress care should be taken to avoid any kind of movement
of the components.
h) Fillet weld shall be made by shielded metal arc / CTAW welding process irrespective
of the thickness and class of piping. Fillet welds shall preferably be slightly convex and
shall be free from undercutting and overlap at the tee of the weld.
i) Peening shall not be permitted.
j) Dams used for conserving inert gas during purging, shall be removed after completion
of the welding and shall be accounted for.
k) Joint shall be completed using the class of electrodes recommended in the welding
specification chart.
l) Two weld beads shall not be started at the same point in different layer.
m) Butt joints shall be completed with a cover layer that would effect good fusion at the
joint edges and a gradual notch free surface.
n) The welding shall be free from under cuts and other defects.
9.0 CLEANING OF WELD JOINTS
All weld joints shall be free from adherent weld spatters, slag, swarp, dirt or foreign matter.
This can be achieved by brushing. For stainless steel, brushes with only stainless steel bristles
shall be used.
10.0 INSPECTION AND TESTING GENERAL
a) Owner / Consultant shall have free access to all concerned areas, where the actual
work is being performed.
b) Owner / Consultant shall be entitled to inspect at shop or field where prefabrication

and erection of pipe lines are being done with the following objectives:
i) To supervise the welding procedure qualification.
ii) To supervise the welder performance qualification.
iii) To check the conformance to relevant standards and suitability of various

welding equipment’s and the welding performance.

JACOBS

REVISION NO: 1
iv) Any other checking / inspection work connected with Construction work.
v) For welding of all grades of steel and nickel alloys by the GTAW process, a
2% Thoriated Tungsten electrode confirming to AWS AS 12-69 EWTH - 2
classification shall be used.
vi) Argon Gas Cylinder (Min. purity 99.95%) with regulator and flow meters.
vii) Nitrogen Gas Cylinder (Min. purity 99.95%) with regulator and flow meter.
viii) The power source shall consist of a meter generator welding set connected
with a high frequency unit or rectifier welding set connected with a high
frequency set.
ix) Inspection of all welds shall be carried out as per ANSI and other relevant
applicable codes, latest edition. All finished welds shall be visually inspected
for parallel and axial misalignment of the work, excessive reinforcement,
concavity of welds shrinkage, cracks, inadequate penetration, un-repaired
burn through under cuts, dimensions, of the weld, surface porosity and other
surface defects.
INTERNAL WELD PROTRUSION ( INCLUDING PENETRATION BEAD )
Normal Pipe Size All Protrusion in mm
Upto 1" NB 1.0 mm or 3% of pipe outside dia.

whichever is less.
Over 1" NB upto 2 ½" NB 1.5mm or less
Over 2 ½" NB upto 10" NB 2.0mm or less
Over 10" NB upto 18" NB 2.5mm or less
Normal Pipe Size All Protrusion in mm
i) Over 18" NB 3.0mm or less
ii) Weld ripple irregularities 2.5mm or less
iii) Lack of uniformity in Bead 2.5mm or less
iv) Lack of uniformity of leg length 2.5mm or less
v) Unevenness of Bead 2.5mm or less
vi) Weld undercutting (Weld undercutting 2.5mm or less

of 0.5mm or less shall be smoothly finished)
vii) Overlaps 1.5mm or less
viii) Bead Deflection 2.5mm or less
ix) Thickness of weld reinforcement

JACOBS

REVISION NO: 1
Nominal Wall Thickness
Upto 12mm 2.5mm or less
Upto 12mm upto 25mm 3.0mm or less
Upto 25mm upto 50mm 3.5mm or less
Upto 50mm 4.0mm or less
10.1 SHIELDING AND PURGING
Purging at a flow of approx. 0.28. m³ / hr subjected to maximum of 1.4m³ / hr depending on

diameter of pipe until 6 times the volume of the Section of piping between the dams has been
replaced is usually adequate. In no case should the initial purge be for less than 10 Minutes.
10.2 After the initial purging is completed the flow of Backing gas during welding should be reduced
to a point where only a slight positive pressure prevails. For systems which have a small
volume (up to 14 liters) to be purged during welding a gas flow rate of 0.14 m³ / hr is usually
adequate. Systems of larger volume may require higher flow rates and these should be
established at the procedure test. Purging is not required on socket type welded joints,
provided it is ensured that oxidation does not take place in case of stainless steel material.
Argon Gas shall be used for shielding purpose.
The rate of flow for shielding purposes shall be established in the procedure qualification.
10.3 The filler wire shall be of approved quality and test certificates for the batch production of filler
wire from the manufacturer shall be furnished by the Contractor to the Owner / Consultant for
approval.
TIG Welding shall be done in stringer runs.
11.0 EXAMINATION METHODS AND REQUIREMENTS
The type and extent of weld examination shall be as per the piping specification attached.
11.1 VISUAL EXAMINATION
As a matter of principle the exterior of all weld joints must be examined visually and as far as
possible the interior also before starting any other examination.
11.2 RADIOGRAPHY EXAMINATION
11.2.1 The radiography examination shall be carried out in accordance with the piping specification.
11.2.2 The procedure and quality of radiography examination limits of acceptability, repair and
removal of defects etc., shall be as per API Standard 1104, ANSI 1331.3 and other applicable
codes.
11.2.3 Where 10% radiography is called for, this shall be spread uniformly over all pipe diameters in
a particular system as follows:
In diameter up to and including 500mm shall mean 10% of the joints in each pipe diameter
encountered.

JACOBS

REVISION NO: 1
11.2.4 The radiographers employed shall be qualified as stipulated in the said codes and must be
fully familiar with radiographic equipments and methods including safety procedure and
thoroughly experienced in the field of radiographic work.
11.3 DYE PENETRATION TEST
Liquid penetrant examination is a method of non destructive examination which for the
detection of discontinuities open to the surface in ferrous and non ferrous material which are
non porous. Typical discontinuities detectable by this method are cracks, seams, laps, cold
shuts and laminations.
11.3.1 Surface Preparation
a) In general satisfactory results may be obtained when the surface is in the as-welded,
as-rolled, as-cast, or as-forged condition. When the surface irregularities mask the
indication of defects, grinding or machining of the surface will be required.
b) Prior to liquid penetrant examination, the surface to be tested and any adjacent area
within atleast 25mm of the surface to be tested shall be dry and free of any dirt,
grease, lint, scale, welding flux, spatters, oil or any extraneous matter that would
obscure surface openings or otherwise interfere with the test.
11.3.2 Drying
Drying of the surface to be tested, after steaming can be accomplished by normal

evaporation.
11.3.3 Penetrant Application
a) The penetrant solution confirming to the code IS 3658 / 1966 shall be applied by
dipping, brushing or spraying.
b) Penetration time is critical. In general, the finer and tighter the discontinuity, the longer
the penetration time should be. At temperature between, 16°C and 52°C, the
penetration time shall be atleast 10 minutes, but this minimum time may have to be
extended under certain conditions.
c) Penetrant shall not be allowed to become "tacky". If a long penetration is required,

fresh penetrant shall regularly be applied to the surface to ensure that the surface is
wet at all times.
d) After the penetration time specified in the procedure has elapsed, any penetrant
remaining on the surface shall be removed.
11.3.4 Developing
a) The developer shall be applied as soon as possible after the penetrant removal
operation and the interval shall not exceed the time as specified in standard document
and codes.
b) The developer is a suspension of powder in water or a volatile solvent and shall be

applied by dipping or spraying.

JACOBS

REVISION NO: 1
11.3.5 Examination
a) It is a good practice to observe the surface during the application of the developer in
order to detect the nature of certain indications, which might tend to bleed out
profusely. Final interpretation however, shall be made after allowing the penetrant to
bleed out for a minimum of seven (7) minutes to a maximum of thirty (30).
b) The developer should form a more or less uniform coating. Surface defects are
indicated by bleeding out of the penetrant, which is normally of a deep red colour.
11.4 ULTRASONIC TEST
The ultrasonic test may be performed, provided that the work pieces are of suitable material
and wall thickness and that qualified personnel is available.
12.0 DEFECTS
Defects revealed by visual inspection as well as radiographic inspection and / or dye penetrant
check of welds shall be repaired / rectified by the Contractor at his cost to the satisfaction of
the Owner / Consultant. The repaired portion shall be re-examined by dye check and / or
radiographically at no extra cost to the Owner. The repairs carried out shall meet the approval
of the Owner / Consultant. For Weld Joints other than 10% radiography, 2 additional checks
shall be carried out for each weld joint judged "Not applicable" and these shall be made on
welds done by the welder who is responsible for defective workmanship at no extra cost to the
Owner.
A register of welding checks shall be maintained and continually updated by the Contractor,
said register shall indicate the opinions expressed by the Owner on examining welding joints,
welding to be repaired and the reference of welder who has performed the work. A register
revised to the date of their last entry shall be consigned to the Owner at the end of work.
All radiographic films submitted by the Contractor or the independent Agency carrying out the
radiographic inspection of welds shall be the property of the Owner / Consultant. All cost and
expenses involved in radiographic inspection including but not limited to the cost of labour,
materials, equipment, tools and payments to the independent agency by the relevant item of
the Schedule of Rates. Repeat radiography due to defective unclear and unsharp films or in
repaired joints due to contractor's fault shall be carried out at Contractor's cost.
13.0 WELDING CONSUMABLES
The welding consumables used shall meet requirements of the relevant codes and shall
produce a deposit with, which is compatible in chemical analysis and similar in mechanical
properties to the parent material.
Only consumables which have received the prior approval of the Owner / Consultant shall be
used.
SS Consumables
max. Ferrite contents 6% permissible

max. Copper 0.2% permissible
Before proceeding with welding, Contractor shall submit for approval to the Owner /
Consultant type, brand and size for each batch of consumables for use in each class of piping.

JACOBS

REVISION NO: 1
Different grades of electrodes shall be completely separated. The Contractor shall have
facilities available for storing electrodes at recommended temperatures where specified. The
consumables shall be stored and handled at all times during construction so as to avoid
damage to them and to the containers in which they are transported. Those in open containers
shall be protected from excessive moisture changes. Electrodes, filler wires and fluxes that
show signs of damage or deterioration shall not be used. Electrodes shall be stored in
electrode storage ovens at 250°C - 300°F or as otherwise, recommended by manufacturer.

JACOBS
DATE: 2 August 2004 SPECIFICATION NUMBER : Z SS 005

REVISION NO.: 1
14.1 APPENDIX 1 WELDING SPECIFICATION CHART
Sr. Material P. MOC Specification Pipe size and Welding process Material Type of Purging Shielding Remarks
No. No. thickness Root Filler Root Pass Filler Pass Joints
Pass Pass
1 Carbon P1 A 53 Gr. ‘B’ Pipe Size 2” & SMAW SMAW E 6010 E6013 BUTT
Steel API 5L Gr.‘B’ above with wall WELD
A 285 Gr.‘C’ thickness upto NA NA
IS 1239 19mm
IS 2062
2 Carbon P1 A 106 Gr.‘B’ Pipe Size 2” & SMAW SMAW E6010 / E7016 / BUTT
Steel A 105 above with wall E7016 / E7018 WELD
A 216 Gr. WCB thickness above E7018 NA NA
A 181 19mm
3 Carbon P1 A 53 Gr. ‘B’ Pipe size 1½” SMAW SMAW E7018 E7018 FILLET
Steel API 5L Gr.‘B’, and below WELD
IS 1239, irrespective of NA NA
A 106 Gr. ‘B’, thickness
A 105
4 Carbon P1 As in Sr. No. 1&2 Pipe Size 2” & GTAW SMAW ER70S2 E7018 / BUTT Argon
Steel above with wall E7016 WELD
thickness upto NA
19mm
5 Stainless P8 A 312 TP 304 Pipe Size 2” & GTAW SMAW/ ER308/ E308L BUTT Nitrogen Argon
Steel A 312 TP 304L above with wall GTAW ER308 L E308 WELD
thickness upto
12mm
6 Stainless P8 A 312 TP 304 All sizes GTAW SMAW ER308/ E308-15/ BUTT
Steel A 312 TP 304L thickness > ER308 L E308-16 WELD -Do- -Do-
12mm
7 Stainless P8 A 312 TP 321 All size, GTAW SMAW ER347 E347-15/ BUTT Nitrogen Argon
Steel All thickness E347-16 WELD

JACOBS

REVISION NO: 1
14.1 APPENDIX 1 WELDING SPECIFICATION CHART
Sr. Material P. MOC Specification Pipe size and Welding process Material Type of Purging Shielding Remarks
No. No. thickness Root Filler Root Pass Filler Pass Joints
Pass Pass
8 Stainless P8 A 312 TP 316 All sizes, All GTAW GTAW/ ER316L ER316 - L/ BUTT Nitrogen Argon
Steel A 312 TP 316L thickness SMAW ER316 E316 - L WELD
9 Low Alloy P1 A 333 Gr. 6 All sizes, All GTAW SMAW ER70 S 2 E7018-Al BUTT Argon
Steel thickness E8018-Cl WELD NA
10 Low Alloy P9 A 333 Gr. 3 All sizes, All GTAW SMAW ER80SNi 3 E8016-C2 / BUTT Argon
Steel B thickness E8018-C2 WELD NA
11 Low Alloy P3 A 335 P1 All sizes GTAW SMAW ER80S D2 E7010A1 BUTT Argon
Steel E7018A1 WELD NA
12 Low Alloy P4 A 335 P 11 All sizes, All GTAW SMAW ER80S B2 E8018 B2 BUTT Argon
Steel thickness E8015 B2 WELD NA
E8016 B2
E8018 B2 L
13 Low Alloy P5 A 335 P 22 All sizes, All GTAW SMAW ER90S B3 E8018 B2 BUTT Argon
Steel thickness E8015 B2 WELD NA
E8016 B2
E8016 B2L
NA - Not Applicable.
NOTE : This is for guidance only and actual site requirement shall be decided as per applicable codes.

Page 1 of 9
PIPING – FLUSHING, TESTING AND INSPECTION
By By By
0 02.11.2001 9 Issue for use. MRAK CLS AGG
1 02.08.2004 9 Cover page revised ALB SGR AGG
ZSS006 Std Spec for Piping Flushing Testing Inspection

JACOBS
SPECIFICATION NUMBER : Z SS 006 DATE: 2 August 2004

STANDARD SPECIFICATION FOR PIPING – PAGE 2 OF 9
FLUSHING, TESTING AND INSPECTION REVISION NO: 1
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 FLUSHING
4.0 GENERAL REQUIREMENTS OF TESTING
5.0 TEST FLUID
6.0 TEST PREPARATION
7.0 PROCEDURE FOR PRESSURE TESTING
8.0 TEST RECORD

JACOBS

PAGE 3 OF 9 STANDARD SPECIFICATION FOR PIPING –
REVISION NO: 1 FLUSHING, TESTING AND INSPECTION
1.0 PUPOSE
The purpose of this specification is to define the construction requirements of flushing, testing
and inspection of pipelines.
2.0 SCOPE
2.1 This specifications supplements the applicable code requirements/ specifications/ standards
for fabrication, erection, inspection, testing of pipelines.
2.2 Engineering drawings/ codes/ standards shall take precedence over this specification if there
are any conflicting clauses.
3.0 FLUSHING
3.1 Flushing of all lines shall be done before pressure testing.
3.2 Flushing of all lines including IBR lines etc. shall be done in the presence and as per the
approval of the Owner / Consultant.
3.3 Flushing of pipe lines will be done by fresh potable water or dry compressed air wherever
water flushing is not desirable to clean the pipe of all dirt, debris or loose foreign materials.
3.4 The supply of compressed air for flushing will be Contractor's responsibility and it will be done
at his cost.
3.5 It will be Contractor's responsibility to provide pumping equipment, compressors, water / air
hoses with accessories etc., Wherever required, instruments such as pumps, pressure
gauges, safety valves etc. spool pieces, temporary gaskets, tools and tackles and all other
arrangements, equipment, materials and consumables etc. required as aids for completing the
flushing as per the directions of the Owner / Consultant.
3.6 During flushing, care shall be taken for on line instruments as per clause of this specification.
3.7 The Contractor shall carry out all the activities required before, during and after the flushing
operation arising from the flushing requirement such as but not limited to the following :
3.7.1 Removing of valves, specials, distance pieces, on line instruments and any piping part before
flushing. The flanges to be broken for this purpose should be envisaged by the Contractor,
approved by the Owner / Consultant and should be provided with temporary gaskets at the
time of initial erection.
3.7.2 After flushing is completed and approved, the valves, distance pieces, piping specials etc.
shall be re-installed by the Contractor with permanent gaskets. However, flanges at equipment
nozzles and other places where isolation is required during testing, only temporary gaskets will
be provided.
3.7.3 Flushing will be continued till the inside of the pipe is fully cleaned to the satisfaction of the
Owner / Consultant.
3.7.4 For air flushing the line / system will be pressurised by the compressed air at the required
pressure. Then pressure will be released by quick opening of a valve already in line or
installed temporarily for this purpose.
This procedure will be repeated as many times as required till inside of the pipe is fully
cleaned. The arrangement for raising and releasing the air pressure will be made by the
Contractor as per the approval of the Owner / Consultant.

JACOBS

3.7.5 During the flushing, discharged water / air shall be drained to the place directed by the Owner/
Consultant. Care shall be taken during flushing so as not to damage / spoil other agencies
work. As desired by the Owner / Consultant, proper temporary drainage for flushing of water
shall be provided by the Contractor. Precautions shall also be taken to prevent entry of water /
foreign particles in to equipment, electrics, motors, instruments, electrical installations etc. in
the vicinity of lines being flushed.
3.7.6 In case where fluid inlet in to the pipe lines through connected equipment such as columns,
vessels, exchangers etc. is unavoidable this shall be done after having approval of the Owner
/ Consultant. However, equipment thus included in the circuit for the flushing shall be
completely drained and dried with compressed air after flushing is completed.
3.7.7 Wherever required as per specification lines will be dried with air after flushing.
4.0 GENERAL REQUIREMENTS OF TESTING
The intent of this specification is to provide a basis and guide for carrying out field testing of
piping to ensure leak tightness.
This covers the general requirements for testing of piping after erection as specified by the
code of Petroleum Refinery Piping ANSI B.31.3. Chapter VI Inspection and Test - Latest
Edition.
Upon completion of installation the piping system shall be inspected to ascertain that each of
the following points have been adhered to :
i) Proper use of material.

ii) Correct erection of line (in accordance with drawings).
iii) Correct installation of (temporary) blind discs to be employed during testing.
iv) The correct application of pre-established pressure.
v) Sectioning of the line in correspondence with these materials and / or equipment,
which are not a part of the test.
With the exclusion of instrumentation, piping systems fabricated or assembled in the field shall
be test in the field, irrespective of whether or not that have been pressure tested prior to site
welding or fabrication (Process and Utility piping system).
For the steam piping falling under Indian Boiler Regulation, testing shall be done as per latest
Indian Boiler Regulation. The test shall be performed in accordance with the requirements of
local Boiler Inspector, prior to testing all lines shall be flushed as per procedure in clause
thereof. All tests shall be completed to the satisfaction of the Owner / Consultant. On
completion of the test the system shall be dried with compressed air at the pressure decided
by the Owner / Consultant and made ready for operation. From all permanent strainers the
screens mesh shall be removed before flushing is done.
After completion of flushing and testing, draining and drying of lines, the permanent strainers
screens shall be cleaned and re-installed. During flushing temporary strainers shall be
retained. After flushing temporary strainers shall be removed, cleaned and re-installed before
testing. All joints remaining untested during hydro-testing such as nozzles in columns, vessels,
heat exchangers etc. shall be tested pneumatically after the hydrogenating is over. Pneumatic
test pressure will be indicated by the Owner / Consultant and Contractor shall ensure that this
test pressure is not exceeded any time during this test.

JACOBS

All tests shall be conducted as per the procedure outlined in this specification. Lines repaired
by welding subsequent to the pressure test shall be retested after the repair at the same test
pressure originally applied. However, the Owner / Consultant may waive such retest in case of
minor addition or alteration by taking some precautionary measure to assure sound
construction.
Following basis for preparation of process / utility loops shall be followed by the Contractor.
The selection of piping systems for individual test will be based on the following :
1) Test Pressure required.

2) Maximum allowable pressure for the MOC of piping.
Depending on the above requirement and based on Construction completed / on construction

progress, maximum length of piping shall be included for each test. Piping checks
incorporating various lines to be tested at the same process shall be marked on the P&I
diagram.
4.1 Systems / lines may be tested in sections to facilitate completion of work in that area or areas,
however, such sections so tested shall be capped out, tagged suitably and subsequently
tested as a complete system prior to final acceptance. Such weld joints (untested) may be
exempted from hydraulic testing by the Owner / Consultant subject to radiography approval of
these joints.
4.2 Lines, which are directly, open to atmosphere such as vents, drains, safety valves, discharge
shall not be tested but all joints shall be visually inspected. Wherever necessary, as decided
by the Owner / Consultant, such lines shall be tested by continuous flow of fluid to eliminate
the possibility of blockage.
4.3 Instrumentation pressure impulse piping shall start beyond the first block valve located in the
process line. During the pressure test this isolation valve must be kept closed to prevent dirt or
any foreign matter entering in to the instrument piping. Temperature impulse connections shall
be blocked off by a blind flange or threaded plug to be provided by the Contractor.
4.4 Locally mounted indicating pressure gauge may be tested with the piping if the test pressure
does not exceed the scale range. However, the gauge shall be blocked off from the piping
during cleaning and flushing. Where lines to which they are connected will receive a higher
test pressure the gauge shall be isolated by closing the gauge isolation valve.
The Owner / Consultant shall be notified in advance by the Contractor of the testing sequence
/ programme to enable him to be present for witnessing the test. The Contractor shall be fully
responsible for making all necessary arrangements with the local Boiler Inspector to witness
the necessary tests applicable to steam lines falling under purview of Indian Boiler
Regulations.
Required number of copies of test certificates in this respect shall be obtained in the relevant
forms of IBR and shall be furnished to the Owner / Consultant.
5.0 TEST FLUID
Fresh potable water shall be used as the testing medium for the hydrostatic testing of piping
unless specified otherwise. Air shall be used as alternate medium wherever specified in the
line list / specification and for drying the lines. In testing of stainless steel equipment and
piping water containing more than 50 ppm of chloride shall not be used.
In case chloride content of water is less than 50 ppm. water used for hydrostatic testing of
S.S. equipment and / or piping should be drained completely as soon as test is approved.

JACOBS

Salty water shall never be used for hydrostatic testing under any circumstances. Pressure
testing for certain specific lines will have to be carried out as per piping specifications.
6.0 TEST PREPARATION
All equipment, materials, consumables, and services mentioned below but not limited to them,
required for carrying out pressure testing of piping shall be provided by the Contractor at his
cost.
- Pump sets for pressurisation, air compressor etc.
- Hoses for water and other test fluid if any, with accessories and adaptor flanges.
- Supply, fabrication and erection of temporary carbon steel piping valves, fittings
specials etc.
- Pressure gauges, safety valves and all such instruments with necessary connections.
- Temporary gaskets wherever required as per specifications and instructions of the

Owner.
- Soap solution, grease, graphite, white lead, paints etc. all consumables.
- Tools, Tackles, pipe wrenches, spanners etc.
- All aids not specified here but required for carrying out pressure test of piping.
6.1 Before testing all piping shall be cleaned by fresh potable water or blown with compressed air
where water flushing is not desirable to make it free from dirt, loose scale, debris and other
loose foreign material as per the details given in clause thereof. This should be completed
wherever required prior to completion of final weld in order that visual inspection of interior is
possible.
6.2 INSTRUMENTATION
6.2.1 Any restrictions which interfere with filling of draining such as orifice plates etc., shall not be
installed until flushing is completed. Till such time that orifice plate is installed orifice flanges
shall be provided with temporary gaskets.
6.2.2 Control valves shall be first installed with temporary gaskets. Before flushing is started control
valves shall be removed and reinstalled after completion of flushing and testing with
permanent gaskets. If for any reason control valve is retained in the line during tests, it shall
be isolated by blinking off.
6.2.3 All safety valves and rotameters shall be installed only after flushing and testing is completed
successfully.
6.3 Wherever in the line any void is existing, due to any reasons, for absence of control valves,
safety valves, check valves etc.. it will be filled with temporary spools.
6.4 All joints welded, screwed or flanged shall be left exposed for the examination during the test.
Before pressurising the lines each weld joint shall be cleaned by wire brush to make it free
from rust and any other foreign matter.
6.5 The test will be carried out with permanent gaskets installed unless otherwise specified herein
or instructed by the Owner.

JACOBS

6.6 Vents and drains at the highest and the lowest points in the piping systems shall be provided.
6.7 Pumps, blowers, compressors, in line instruments other equipment and piping specialities
shall be isolated during flushing and pressure testing by metallic blinds, blanks caps or plugs.
6.8 No pressure test shall be carried out against closed valve unless approved by the Owner /
Consultant.
6.9 Piping which is spring or counter weight supported shall be temporarily supported where the
weight of the test fluid would overload the supports.
Retaining pins or spring supports shall be removed only after testing is completed and test
fluid is fully drained.
6.10 Piping systems subject to extended hydrostatic test period shall be provided with protective
device to relieve excess pressure due to the thermal expansion of the test fluid.
6.11 TEST PRESSURE GAUGES
6.11.1 All gauges used for field testing should be of the Bourdon type having a suitable range and
dial scale not less than 4 ½ diameter. Test pressure indication should fall between 40% to
80% of gauge scale range. Gauge shall be of good quality and shall be in first class working
condition.
6.11.2 Prior to the start of test and periodically during the field test programme all test gauges shall
be calibrated using a standard Dead Weight gauge tester or other suitable approved testing
apparatus. Any gauge showing incorrect zero reading, or error of more than + 2% of full scale
range shall be discarded. The Owner / Consultant shall check the accuracy of water pressure
gauge used for calibration. The Contractor shall furnish documentary proof of having
calibrated each gauge / instrument to the satisfaction of the Owner / Consultant and shall
maintain such records until completion of the project.
6.11.3 The pressure gauge shall be installed as close as possible to the lowest point of piping system
to be rested to avoid over stressing of any of the lower portion of the system. For longer lines
and vertical lines two or more pressure gauges shall be installed at the locations decided by
the Owner / Consultant. Over and above the pressure gauges installed in the system being
tested, a pressure gauge will be installed on discharge of pumps or other pressurising source.
For lines containing check valves any of the following alternatives will be adopted for pressure
testing :
i) Wherever possible pressurise up stream of valve.
ii) Replace the valve by a temporary spool and reinstall the valve after testing.
iii) Provide blind on valve flanges and test the up streams and down streams of the line
separately and remove the blind after testing, (in all the above mentioned cases
wherever valves, flanges are required to make and break for testing, the Contractor
shall provide temporary gaskets at the time of initial installation of check valves. Final
gaskets will be provided only after completion of testing.)
7.0 PROCEDURE FOR PRESSURE TESTING
7.1 All pipe lines to be tested are shown in the piping specifications. The medium to be used and
test pressure to be applied is also indicated in the piping specifications provided to the
Contractor for the performance of work.

JACOBS

7.2 TEST PRESSURE
7.2.1 The minimum hydrostatic / pneumatic test pressure shall be indicated in the piping
specifications or as per instructions of the Owner / Consultant.
7.2.2 The selection of the piping system for one individual test will be based on the following :
- Test pressure required as per line list.
- Maximum allowable pressure for the material of Construction of piping.
Depending upon the above requirements and based on construction progress maximum
length of piping shall be included in each test.
7.3 PRESSURISING, INSPECTION APPROVAL
7.3.1 All vents and other connections used as vents shall be left open while filling the line with test
fluid for complete removal of air, in the lines for pressurising and depressurising the system
temporary isolating valves shall be provided in valve vents, drains do not exist in the systems.
7.3.2 Pressure shall be applied only after the system / line is ready and approved by the Owner /
Consultant.
7.3.3 Pressure shall be applied by means of a suitable test pump of other pressure source which
shall be isolated from the system as soon as test pressure is reached and established the
system.
7.3.4 The test pressure shall be retained long enough to facilitate inspection of the complete
system. Duration of the test in each case shall be fixed up by the Owner / Consultant but in no
case it will be less than 2 hours. No leakage of any kind will be permissible. The glands of the
valves in the system being tested shall be tightened by the Contractor, so as to stop /
minimise the leakage, if any. In case leakage is not stopped after adequate tightening of the
glands, the handwheel of such valves shall be painted red only on the rim to identify these
valves for subsequent repair. The gland packing for replacement shall be supplied by the
Owner.
The Contractor shall replace the gland packing on the valve and tighten it to make it leak
proof. Valve gland tightening and handwheel painting shall be done by the Contractor.
7.3.5 Care shall be taken to avoid increase in pressure due to temperature variation during the test.
7.3.6 After completion of hydrotest, the pressure shall be released gradually. All vents and drains
shall be kept open till the lines are fully drained. After draining, lines / systems shall be dried
by air.
7.3.7 Pressure test shall be considered, complete only after approval by the Owner / Consultant.
Defects, if any noticed during testing shall be rectified immediately and retesting immediately
and retesting of the system / line shall be done by the Contractor at his cost.

JACOBS

8.0 TEST RECORDS
Records in triplicate shall be prepared and submitted by the Contractor for each system
(linewise) for the flushing and the pressure test done giving following details in the proforma
approved by the Owner / Consultant.
- Date of flushing.
- Date of test.
- Identification of piping tested, i.e. line no., line diagram no., plant area etc.
- Flushing medium used.
- Test fluid used.
- Minimum test pressure required and actual test pressure obtained.
- Signature of the Contractor's representative.
- Approval signature of the Consultant.
- Approval signature of the Owner.

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Page 1 of 7

STANDARD SPECIFICATION FOR

DOCUMENT NO: 44LK-5100/L.02/001/A4

Rev Issue Date Pages Rev Description Prepared Checked Approved

12.0 HANDLING AND STORAGE:

13.0 REFERENCE DOCUMENTS (attached) :

HINDUSTAN PETROLEUM CORPORATION LIMITED

TITLE : JOB SPECIFICATION FOR WELDING CHARTS

0 13.07.2010 15 Issued for OSBL Mechanical Tender YSP DRP/PUP PVS/RMP

PROJECT NO. : 44LK-5100

CLIENT : HPCL DOC. NO. : 44LK-5100-00/L.02/0103/A4

GTAW: Gas Tungusten Arc Welding

SMAW: Shielded Metal Arc Welding

WPS: Welding Procedure Specification

PQR: Procedure Qualification Record

CS: Carbon Steel

LAS: Low Alloy Steel

SS: Stainless Steel

SHEET REV. NO. 0

PROJECT NO. : 44LK-5100

CLIENT : HPCL DOC. NO. : 44LK-5100-00/L.02/0103/A4

1.0 GENERAL NOTES

1.2 REFERENCE STANDARDS :

2.0 HISTORY OF REVISION

SHEET REV. NO. 0

WELDING CHART INDEX

SHEET REV. NO. 0

REV NO. : 0 ISSUE DATE : 13/7/2010

FILLET JOINTS / SOCKET JOINTS E7016 / E7018

BACKING RING CONSUMABLE INSERT

PREHEATING PREHEAT TEMP 10°C MIN /

REV NO. : 0 ISSUE DATE : 13/7/2010

FILLET JOINTS / SOCKET JOINTS SMAW

WELDING ER70 SG/

FILLET JOINTS / SOCKET JOINTS ER7016 / E7018

BACKING RING CONSUMABLE INSERT

PREHEATING 10°C MIN /

REV NO. : 0 ISSUE DATE : 13/7/2010

FILLET JOINTS / SOCKET JOINTS GTAW / SMAW

FILLET JOINTS / SOCKET JOINTS ER70S-2 / E7018

BACKING RING CONSUMABLE INSERT

PREHEATING 10°C MIN /

REV NO. : 0 ISSUE DATE : 13/7/2010

BACKING RING CONSUMABLE INSERT

PREHEATING 10°C MIN /

CODE OF FABRICATION ASME B 31.3

REV NO. : 0 ISSUE DATE : 13/7/2010

WELDING ER70 SG/

FILLET JOINTS / SOCKET JOINTS E7016 / E7018

BACKING RING CONSUMABLE INSERT

PREHEATING 10°C MIN /

CONTINUITY OF WELDING AND PREHEAT -

REV NO. : 0 ISSUE DATE : 13/7/2010

BACKING RING CONSUMABLE INSERT

CODE OF FABRICATION ASME B 31.3 & IBR

REV NO. : 0 ISSUE DATE : 13/7/2010

BACKING RING CONSUMABLE INSERT

PREHEATING PREHEAT TEMP 10°C MIN POST HEATING -

CONTINUITY OF WELDING AND PREHEAT -

CODE OF FABRICATION ASME B 31.3

REV NO. : 0 ISSUE DATE : 13/7/2010

BACKING RING CONSUMABLE INSERT

CONTINUITY OF WELDING AND PREHEAT -