INDIAN OIL

TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER

JOB SPECIFICATION – PIPING WORKS

Document Number : D10-PMC-JSF-015

INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
FARIDABAD (HARYANA)

JOB SPECIFICATION – PIPING WORKS

Doc No. : D10-PMC-JSF-015

R.0 10-Jun-20 Issued for approval KK BB SB

Submission
Rev. No. Description Prepared By Reviewed By Approved By
Date

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 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
JOB SPECIFICATION – PIPING WORKS

Document Number : D10-PMC-JSF-015

Table of Contents

1. FABRICATION & ERECTION ..............................................................................................................................3

2. PRESSURE TESTING........................................................................................................................................11

3. FLEXIBILITY ANALYSIS AND SUPPORTING..................................................................................................18

4. WELDING AND NON DESTRUCTIVE TESTING ..............................................................................................28

5. PAINTING ...........................................................................................................................................................34

6. INSULATION ......................................................................................................................................................49

7. 3D MODELLING .................................................................................................................................................69

8. PROCUREMENT OF PIPING MATERIALS.......................................................................................................73

9. PIPING MATERIAL SPECIFICATION ...............................................................................................................80

10. VALVE MATERIAL SPECIFICATION................................................................................................................83

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 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
JOB SPECIFICATION – PIPING WORKS

Document Number : D10-PMC-JSF-015

1. FABRICATION & ERECTION

1.1 Scope
This specification covers general requirements of fabrication and erection of above ground and trench piping
systems to be followed by the EPC Contractor at site.

The purpose of this specification is to provide the methods and procedures for the fabrication, handling and
installation of Process and Utility Piping. The specification covers the scope of work of Contractor, basis of work
to be carried out by Contractor and standards, specifications and normal practice to be followed during fabrication
and erection by the Contractor.

1.2 Scope of Work of EPC Contractor

Generally the scope of work of Contractor shall include the following -

1.2.1 Transportation
Transportation of required piping materials, pipe supports and all other necessary piping materials from the
designated Storage point to work site/shop.

Piping materials include the following but not limited to the same -
 Pipes (All sizes and schedule), Flanges (All sizes, types & Pressure ratings), Fittings (All sizes, types and
schedule), Valves (All sizes, types and Ratings), Gaskets (All sizes, types & Ratings), Bolts, Nuts or M/C
Bolts (All types), Expansion Joint/Bellows (All types), Specialty items like online filters, ejectors, sample
coolers, traps, strainers, air traps, springs, silencers, snubbers, injection nozzles, MOVs, sight glass,
spray nozzles, integrated traps, hoses, hose couplings, etc.

 All piping items to be butt welded shall be supplied with end bevel edges. The dimensional tolerances of
all the bought out piping items shall be as per the relevant codes and standards.

 Online instruments like control valve, all types of flow instruments, like orifice flanges, rotameter,
restriction orifices, annubar, magnetic flow meter, ultrasonic flow meter, Coriolis mass flow meters, venturi
PG/PT/ Flow transmitter, safety valves, rupture disc, de-super heaters, corrosion probes, , ejectors, static
mixers, flame arrestors, thermal flow switches, pre-fabricated hook-ups, Shut Down Valves with and
without fire box etc.

1.2.2 Material Receiving and Storage

All material purchased for the project, shall be stored in an area specifically assigned to the project where
exposure to heat, dirt, and contamination are avoided. EPC contractor shall provide the procedure for handling
and storing materials at the job site. Bulk materials, pipe and fittings shall be segregated by material type and
schedule within the storage area.

Stainless steel and Aluminum piping shall be stored under cover and clear of the ground. Contact with ferritic
steel is not permitted. Contamination from ferritic sources is not acceptable. Stainless steel material shall not
come into contact with zinc coating such as galvanized materials. All slings and hooks shall be protected by a
plastic insulation or nylon. Storage banding for pipe shall be of a non-contaminating and compatible material.

EPC CONTRACTOR shall visually inspect every pipe and component and reject items that contain an injurious
defect. Injurious defects are internal or external surface gouges, scars, scratches, blisters, or discontinuities that
produce a notch effect or reduce the specified wall thickness by 5 percent or more.
The end caps shall be kept in place during transport and storage in order to prevent dust, dirt, foreign matter
etc., from entering the pipe.

For loading and unloading of very heavy pipes, it is recommended to use slings with cushion pads or a suitable
fork-arrangement placed at the center of the joints. Hooks or other devices which insert into the ends of the pipe
shall not be used. A flat-bed trailer provides the best support for the lined pipes during transport. During loading
or unloading lined pipes shall not be dropped on to or off of the transporting vehicle.

To prevent bending of the pipes which can cause damage to the lining, supports shall be used during storage
and shipping.

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TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
JOB SPECIFICATION – PIPING WORKS

Document Number : D10-PMC-JSF-015

1.2.3 Prefabrication Cleaning

All piping and fittings shall be cleaned free from debris, grease, oil, and loose foreign material prior to fabrication
or installation.

Each weld lane shall be cleaned before the weld is started. The weld cleaning shall be accomplished by wire
brushing or grinding. The cleaned area shall be free from rust, scale, or mill coating. Stainless steel piping shall
be fabricated within a separate area free from ferric contamination. Tools, such as flapper wheels, grinders,
saws, and other abrasives that have been previously used on carbon steel shall not be used on stainless steel.

Welds of branch connections shall be completed and the fabricated piping shall be cleaned of all foreign
materials before it is flanged or welded into, the main line.

1.2.4 Site Fabrication of Piping Items

Site fabrication of any type of piping items is not to be done and only bought out piping items are to be used in
the job.

1.2.5 Fabrication/ Handling/ Installation

The EPC CONTRACTOR shall shape or bevel the ends of piping to be field welded in accordance with ASME
B16.25.

Adjacent sections of longitudinally welded pipe that are joined by butt welding shall have the longitudinal weld
seams positioned so that they are at least 30 degrees apart from the horizontal centreline.

The EPC CONTRACTOR shall not position the longitudinal weld seam on the top or bottom of the line so that
branch connections are not located on the seam.

The area of header welds where subsequent branch connections will be made shall be examined by
Radiography (RT). In addition, the weld edges of the branch weld shall be examined by Magnetic Particle (MT)
[or Liquid Penetrant (PT) for nonmagnetic steels]. Unacceptable defects shall be removed and repaired. This
inspection supplements the existing requirements for final inspection performed on each weld.

The scope of work of the EPC contractor shall involve all types of fabrication and erection including the
fabrication and erection of all types of pipe supports like shoe, saddle, guide, stops, anchors, clips, cradles,
hangers, turn-buckles, supporting fixtures, bracket cantilevers, struts, tee-posts including erection of spring
supports, sway braces, dummy pipes, corrosion pads/protection shields, low friction pads, clamps, special
support, expansion bellows, etc. and all other types of miscellaneous supports.

 Internal Misalignment
Misalignment criteria shall be governed by ASME B31.3 if the deviation factors are exceeded, one of the
following procedures shall be used -
a. Rotate the pipe or fittings to reduce misalignment to the acceptable tolerances (before attempting
any of the following methods).

b. Use spreaders or internal or external line-up clamps to correct moderate out-of-round condition.

c. The end with the larger internal diameter may be built up internally by depositing weld metal to
improve alignment.

d. Taper the wall of the component internally after obtaining approval from OWNER for the proposed
method and ensure wall thickness is not reduced below the minimum required by the ASME B31.3
code.

e. If allowable deviations are exceeded beyond repair methods, the fabrication shall be redone.

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TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
JOB SPECIFICATION – PIPING WORKS

Document Number : D10-PMC-JSF-015

 Flanges
Flange bolt holes are to be oriented as follows, unless otherwise indicated in the electronic files -
a. Flange face vertical - bolt holes to straddle vertical centreline.
b. Flange face horizontal - bolt holes to straddle north-south centreline.
c. Where line taps are called for, the hole shall be drilled square to the axial centreline, clean, sharp,
free from burrs, wire edges, or other irregularities. The hole shall be drilled after first attaching the
connection fitting.

Where slip-on flanges are called for, they shall be welded inside and outside (See Figure 328.5.2B of
ASME B31.3). The weld shall be applied so that the flange face shall be free of weld spatter and does not
require facing.

Orifice flanges shall be installed with the taps in the exact orientation shown in the Isometric. The sections
of pipe to which the orifice flanges are attached may be standard mill run pipe, but shall be choice
selected pieces and shall be round, smooth and free from blisters and scale. The interior of the pipe, at
welds, shall be ground smooth. Welds to be performed on site shall be kept at a maximum distance back
from the face of the orifice flange.

 Reinforcement Pads
Each pad shall have 1/8 NPS weep hole drilled and tapped NPT (American National Taper Pipe Thread)
prior to installation (at the side and not at the crotch) of the pad. Branch connection weld shall be 100%
complete and subjected to the required examination (including visual) prior to installation of reinforcing
pads.

Reinforcing pad to be air tested at 1 kg/cm2 by the EPC CONTRACTOR. After test, the vent shall be seal
welded.

 Bending
Bending of pipes shall only be done where indicated in the isometric and only with OWNER’S approval,
otherwise welding elbows shall be used. Bending shall be as per ASME B31.3 except that corrugated or
creased bends shall not be used. Prior to bending, EPC CONTRACTOR shall submit their hot and cold
bending procedures to the CONTRACTOR for approval.

If the pipe contains a longitudinal weld, this weld shall be located in the neutral zone.

Cold bends for lines 1-1/2” and below, with a bend radius of 5 times the nominal diameter shall be used
as required in place of elbows wherever allowed by piping specifications.

Pipe bending, normally up to 4 NPS shall be done in pipe bending machines or presses using formers.
No wrinkling, excessive thinning or flattening is allowed. Excessive scratches, gouges or die marks will be
grounds for rejection.

The completed bend shall have a smooth surface, free from cracks, buckles, wrinkles, bulges, flat spots
and other serious defects. They shall be true to dimensions. The flattening of a bend, as measured by the
difference between the maximum and minimum diameters at any cross-section, shall not exceed 8% and
3% of the nominal outside diameter, for internal and external pressure respectively.

 Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In general, joining of lines 2"
and above in process and utility piping shall be accomplished by butt-welds. Joining of lines 1-1/2" and
below shall be by socket welding/butt welding/threaded joints as specified in "Piping Material
Specifications". However, in piping 1-1/2" and below where socket welding/ threaded joints are specified
butt - welds may be used with the approval of Owner/PMC for pipe to pipe joining in long runs of piping.
This is only applicable for non-galvanized piping without lining.

Flange joints shall be used at connections to Vessels, Equipment’s, Valves and where required for ease
of erection and maintenance as indicated in drawings.

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 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
JOB SPECIFICATION – PIPING WORKS

Document Number : D10-PMC-JSF-015

1.2.6 Installation
Except where shown otherwise, piping shall -
a. Be run level and plumb
b. Be run on the North-South and East-West axis
c. All piping shall be fabricated and installed to the configurations as shown in the isometric. Spool piece
identification mark numbers or field welds are not indicated for field fabricated small bore piping systems.
The INSTALLATION CONTRACTOR shall sectionalize as required for fabrication, handling, and
installation, and shall supply spool piece installation mark numbers as required. No changes shall be
made without prior approval of the OWNER.
d. Pipe work shall be erected on permanent supports designated for the line. Temporary supports shall be
kept to an absolute minimum, but to an extent sufficient to protect nozzles and adjacent piping from
excessive loads during the erection.
e. Straight sections of pipe should contain the minimum number of welds. The use of off-cuts in straight
piping runs shall be avoided.

Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and outside by suitable
means. The cleaning process shall include removal of all foreign matter such as scale, sand, weld spatter chips
etc. by wire brushes, cleaning tools etc. and blowing with compressed air/or flushing out with water. Special
cleaning requirements for some services, if any, shall be as specified in the piping material specification or
isometric or line list.

Pipe to pipe, pipe to structure / equipments distances / clearances as shown in the drawings or as per the
relevant standard, codes and specifications shall be strictly followed as these clearances may be required for
the free expansion of piping / equipment. No deviations from these clearances shall be permissible without the
approval of Owner/PMC.

Safety belt and all other kinds of safety equipments/ harnesses are to be strictly used while working at height
more than 2 metres.

1.2.7 Flange Bolting

a. Use a logical sequence of bolt tightening to ensure even gasket compression, as indicated in ASME
B16.5.
b. Bolt tensioning shall be in done wherever required.
c. Prior to bolt up, inspect flange faces. Flange faces shall be in “as-new” condition and shall be wiped clean
of any debris, excess oil or grease and dirt. Restore damaged flange faces. Do not perform weld repairs
on flange faces or flanges.
d. Do not use washers or spacers to make up bolt length. Bolt lengths are specified to prevent oversizing.
e. Apply lubricant to bolts.
f. Stud bolts shall be installed so as to leave approximately an equal number of threads exposed from the
nuts on each side of the flange assembly. In all cases the nut threads shall be fully engaged with the stud.

While fitting up mating flanges, care shall be exercised to properly align the pipes and to check the flanges for
trueness, so that faces of the flanges can be pulled together, without inducing any stresses in the pipes and the
equipment nozzles. Extra care shall be taken for flange connections to pumps, turbines, compressors, etc. The
flange connections to these equipments shall be checked for misalignment, excessive gap etc. after the final
alignment of the equipment is over. The joint shall be made up after obtaining approval of Owner/PMC.

Temporary protective covers shall be retained on all flange connections of pumps, turbines, compressors and
other similar equipments, until the piping is finally connected, so as to avoid any foreign material from entering
these equipments.

The assembly of a flange joint shall be done in such a way that the gasket between these flange faces is
uniformly compressed. To achieve this, the bolts shall be tightened in a proper sequence. All bolts shall extend
completely through their nuts but not more than 1/4"

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 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
JOB SPECIFICATION – PIPING WORKS

Document Number : D10-PMC-JSF-015

1.2.8 Pipe Supports

a. Piping shall be supported, guided and anchored as specified on the relevant piping drawings.
b. Install pipe supports exactly as per the corresponding support standard.
c. Welding of supports shall be indicated in the support standard.
d. No temporary supports shall be used for hydrotest loads. Permanent supports shall be installed to sustain
hydro test loads.

Preset pins of all spring supports shall be removed only after hydrostatic testing and insulation is over. Springs
shall be checked for the range of movement and adjusted if necessary to obtain the correct positioning in cold
condition. These shall be subsequently adjusted to hot setting in operating condition.

1.2.9 Cleanliness of Piping

a. Open end and flange protection shall be used throughout installation. Protect open pipes at all times
when work on them is not actually taking place.
b. Inspect individual pipe section, prefabricated spools and pipeline items internally during installation and
remove any foreign matter before final welding or bolting.
c. The internal cleaning of piping after fabrication or installation.
d. Piping contiguous with special equipment or piping within a packaged, VENDOR provided “skid”, which
requires cleaning in accordance with the equipment MANUFACTURER‟s procedures, shall be inspected
by, and have cleaning supervised by the MANUFACTURER‟s representative.

1.2.10 Valve and Equipment Flange Connections

Flange covers shall be retained on all flange connections to valves or equipment, until ready to connect the
mating piping flanges.

Flanges connecting to strain sensitive mechanical equipment, e.g., pumps, compressors, turbines, etc. shall be
fitted-up in close parallel and lateral alignment prior to tightening the bolting.

In general, flange connections to equipment shall be the last connection made on completion of a line or
interconnecting system of lines. With the piping flange fitted and prior to bolting up the joint, the following
tolerances shall be maintained -
 Bolting shall move freely through accompanying bolt holes at right angle to the flange faces.
 There shall be a clear gap between two flange faces before gasket installation. There shall be sufficient
flexibility to install and replace gaskets.

1.2.11Dimensional Tolerances
Dimensional tolerances for piping fabrication shall be as per the relevant codes and standards. EPC Contractor
shall be responsible for working to the dimensions shown on the drawings. However, the EPC Contractor shall
bear in mind that there may be variations between the dimensions shown in the drawing and those actually
existing at site due to minor variations in the location of equipments, inserts, structures etc. To take care of
these variations "Field Welds" shall be provided during piping fabrication. An extra pipe length of 100 mm over
and above the dimensions indicated in the drawing may be left on one side of the pipe at each of the field welds.
During erection, the pipe end with extra length at each field weld, shall be cut to obtain the actual dimension
occurring at site.

In addition to the tolerances specified in the applicable codes or standards, the dimensional tolerances for
finished piping shall conform to the following -
 All linear dimensions involved in the relative positions of branch connections, flanges, ends and changes
in direction shall be maintained within ± 3.0 mm (± 1/8 in.)
 The ovality of a pipe bend as a measured difference between the maximum and the minimum diameters
at any cross-sectional area of a bend shall not exceed 8 % of the nominal outside diameter of the straight
portion of the pipe.
 Lateral transition of branches or connections shall be within ± 3.0 mm (±1/8 in.).
 Rotation of flanges from the indicated position measured as shown shall be within ± 1.5 mm (± 1/16 in.).
 Alignment of flanges and branch-welded ends measured across any diameter shall not deviate from the
indicated position more than 0.75 mm (1/32 in.).

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TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
JOB SPECIFICATION – PIPING WORKS

Document Number : D10-PMC-JSF-015

1.2.12Screwed Piping
a. Galvanized piping shall have threads as per ANSI B2.l NPT as required to match threads on fittings,
valves etc. All other piping shall have threads as per ANSI B2.l, tapered unless specified otherwise.

b. Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed. Threading of
pipes shall be done preferably after bending, forging or heat treating operations. If this is not possible,
threads shall be gauge checked and chased after welding heat treatment etc.

c. During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly cleaned of
cuttings, dirt, oil or any other foreign matter. The male threads shall be coated with thread sealant and
the joint tightened sufficiently for the threads to seize and give a leakproof joint. Threaded joints to be
seal-welded shall be cleaned of all foreign matter, including sealant and made up to full thread
engagement before seal welding.

1.2.13Miscellaneous Works
 Radiography/Ultrasonic Testing, stress relieving, dye penetration, magnetic particle test etc. as required
in specification.
 Performing PMI using alloy analyzers for carrying out Positive Material Identification at site.
 Casting of concrete pedestals and Fabrication and erection of small structures/ platforms for pipe
supports and valve operation / attending some instruments, spectacle blinds etc., providing brackets,
modification / extension of platforms, providing additional platforms / ladders for improving / providing
accessibility.
 Providing insert plates with anchor fasteners in concrete structures / paved floors and repair of platform
gratings around pipe openings and providing suitable members for support under the platform grating.
 Making material reconciliation statement and return of Owner's supply left over materials to Owner's
storage if any free issue material is issued by OWNER to the EPC Contractor.
 Flushing and testing of all piping systems as per the relevant specification for inspection, flushing and
testing of piping systems. The accessories required for blinding the line like flange, blind flange, gasket
(all sizes, type and rating), stud-bolts, flexible hoses etc. are to be arranged by the EPC Contractor.
During flushing the discharged water / air shall be drained / routed as directed by the Engineer – In
Charge.
 EPC Contractor shall prepare welding specifications for all weld joints and obtain approval from OWNER/
PMC.
 Chemical passivation treatment for stainless steel piping as per ASTM A 380-99.
 Galvanized carbon steel piping shall be completely cold worked, so as not to damage galvanized
surfaces. This piping involves only threaded joints and additional external threading on pipes may be
required to be done as per requirement.

1.3 Deviations
Where a deviation from the drawings, specifications and approved job procedure described above is required or
where the basis of work does not cover a particular situation, the matter shall be brought to the notice of
Owner/PMC and the work carried out only after obtaining written approval from him in each case.

1.4 Shop Fabrication / Prefabrication

The purpose of shop fabrication or pre-fabrication is to minimize work during erection to the extent possible.
Piping spool, after fabrication, shall be stacked with proper identification marks, so as facilitate their withdrawal at
any time during erection. During this period all flange (gasket contact faces) and threads shall be adequately
fabricated by coating with removable rust preventive. Care shall also be taken to avoid any physical damage to
flange faces and threads.

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JOB SPECIFICATION – PIPING WORKS

Document Number : D10-PMC-JSF-015

1.5 Miscellaneous
The pipe to pipe, pipe to structure / equipments distances / clearances shall be as per the relevant codes and
standards.

Slopes specified for various lines in the drawings / P&ID/ Process packages shall be maintained by the EPC
Contractor. Corrective action shall be taken by the EPC Contractor in consultation with Owner/PMC wherever the
EPC Contractor is not able to maintain the specified slope.

Stage inspection like Visual inspection/Radiography/DPT/MPT/Heat treatment/hydro-test or other tests as

required during fabrication/piping welding work at site as per the relevant codes and standards shall be followed.

1.5.1 Vents and Drains

High point vents and low point drains shall be provided even if these are not shown in the drawings. The details
of vents and drains shall be as per piping material specifications / job standards.

1.5.2 Valves
Valves shall be installed with spindle / actuator orientation / position as shown in the layout drawings. Care shall
be exercised to ensure that globe valves, check valves, and other uni-directional valves are installed with the
"Flow direction arrow "on the valve body pointing in the correct direction.

1.5.3 Instruments
Installation of in-line instruments such as control valve, orifice flange, rotameter, safety valves, restriction orifice,
rupture disc, de-super heaters, corrosion probes, annubar, magnetic flow meter, ultrasonic flow meter, Coriolis
mass flow meters, venturi PG/PT/ Flow transmitter, ejectors, etc. and Shut Down Valves with fireboxes shall
form a part of piping erection work.

Fabrication and erection of piping upto first block valve / nozzle / flange for installation of offline Instruments for
measurement of level, pressure, temperature, flow etc. shall also form part of piping construction work. The
limits of piping and instrumentation work will be shown in drawings / standards / specifications. Orientations /
locations of take-offs for temperature, pressure, flow, level connections etc. shown in drawings shall be
maintained.

Care shall be exercised and adequate precautions taken to avoid damage and entry foreign matter into
instruments during transportation, installation, testing etc.

1.5.4 Line Mounted Equipment / Items

Installation of line mounted items like filters, strainers, air traps, de-super heaters, ejectors, samples coolers,
mixers, flame arrestors, sight glasses etc. including their supporting arrangements shall form part of piping
erection work.

1.5.5 Bolts and Nuts

The Contractor shall apply moly coat grease mixed with graphite powder (unless otherwise specified in piping
classes) all bolts and nuts during storage, after erection and wherever flange connections are broken and made-
up for any purpose whatsoever. The grease and graphite powder shall be supplied.
1.5.6 Material Traceability
 Shop Traceability Control
Correct material identification throughout fabrication activities shall be maintained and monitored by the
EPC CONTRACTOR. At the completion of an individual fabrication, the EPC CONTRACTOR shall verify
and document that correct material identification was made on the drawings and that the physical
material identification is legible. Any discrepancies encountered shall be resolved. Confirming
documentation, as necessary, shall be included in the Traceability Package for the work involved.

 Field Traceability Control

Correct material identification throughout field fabrication, assembly and installation activities shall be
maintained and monitored by the EPC CONTRACTOR conducting the work.

At the completion of an individual field fabrication, assembly or installation, the EPC CONTRACTOOR
shall verify and document that correct material identification has been made on the drawings and that the
physical material identification is legible. Any discrepancies encountered shall be resolved through

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Document Number : D10-PMC-JSF-015

consultation with the concerned authority. Confirming documentation, as necessary, shall be included in
the Traceability Package for the work involved.

Non-conforming material shall be identified and clearly segregated.

EPC CONTRACTOR shall maintain records of all approved drawings/documents for all completed field
fabrication. Subsequent field assembly and installation activities shall include the implementation of a
procedure for recording and maintaining documented traceable continuity through the completion of final
field installation.

1.6 Scope of Inspection by Third Party Inspection Agency

Scope of inspection by third party inspection agency for piping items procured from suppliers / manufacturer -

Tests to be witnessed
i. Testing for physical properties.
ii. Visual Inspection & Dimensional check
 10% random basis for each heat. Minimum one length in case of pipe is procured from
manufacture.
 100% in case the pipe is procured from stockiest/ traders.
iii. Hydrostatic test
 10% random basis for each heat. Minimum one length in case the pipe is procured from
manufacture.
 100% in case the pipe is procured from stockiest / traders.

Review of documents
i. Mill test certificate of raw materials.
ii. Material identification reports.
iii. Radiographs (if required).
iv. Heat treatments (if required).
v. Material composition as per NACE (if required).
vi. Manufacturer’s test certificate.
vii. Hydro-test 100%
viii. Supplementary test as required.
ix. Manufacturer’s test certificates for 100% visual & dimension check in case of Manufacturer

Third party inspection release note shall contain the information on test witnessed, documents reviewed,
observations/ remarks, identifications, order status and date(s) of inspection. The original certificate shall be
furnished with supply of material.

Third party inspector shall stamp each length of pipe based on the same performed by the manufacturer and shall
mention the same in the inspection release note. For small bore i.e. 1½” and below, stamping on the bundle of
pipes instead of each length may be considered.

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TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
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Document Number : D10-PMC-JSF-015

2. PRESSURE TESTING
2.1 Scope
This specification gives minimum requirements and procedures for Field/Shop Pressure Testing of the pressure
piping systems, connected equipment and integral components to assure tightness, integrity and safe operation.

This specification also covers the general requirements for inspection and flushing of piping systems.

The purpose of this specification is to provide minimum requirements deemed necessary for the post-fabrication
testing of process and utility pressure piping systems, in order to ensure piping system integrity and reliability, as
well as to attain consistency in the pressure testing process.

Flushing and testing of all piping systems shall be witnessed by the Owner/PMC.

2.2 References
ASME B31.3 : Process Piping

2.3 Inspection of Installed Piping System

During various stages and after completion of fabrication and erection and prior to the pressure testing of the
subject piping system, the piping system shall be inspected by the Owner/PMC to ensure the mechanical
completion of the piping system. During inspection for the mechanical completion of piping system, the following
broad points shall be checked and ensured.
 Piping material as per the drawings and piping material specification has been used.
 Positive Material Identification has been performed.
 Piping has been erected as per drawings.
 All supports have been installed correctly.
 Test preparations mentioned in this specification have been carried out.

2.4 Flushing of Installed Piping System

a. The installed piping system may contain debris, dirt and foreign unwanted particles which are necessary to
be removed prior to pressure testing of the piping system. Therefore, flushing of all lines in a piping system
shall be done before pressure testing.

b. Flushing shall be done by ‘fresh potable water’ or by ‘dry compressed air wherever water flushing is not
desirable to clean the pipe of all dirt, debris or loose foreign material.

c. Required pressure for water flushing shall meet the fire hydrant pressure or utility water pressure. For air
flushing, the line/system shall be pressurized by compressed air at the required pressure which shall be 3.5
kg/cm2g maximum. The pressure shall then be released by quick opening of a valve, already in line or
installed temporarily for this purpose. This procedure shall be repeated as many times as required till the
inside of the pipe is fully cleaned.

d. In line instruments like safety valves, control valves, orifice plates, flow instruments like rotameters, vortex
flowmeters, venturimetres and other instruments like temperature elements which may interfere with
flushing shall not be included in flushing circuit.

e. The screens/meshes shall be removed from all permanent strainers before flushing. Screens/meshes shall
be reinstalled after flushing but before testing.

f. During flushing temporary strainers shall be retained. These shall be removed, cleaned and reinstalled
after flushing, but, before testing.

g. In case any equipment forms part of a piping circuit during flushing, this shall be done with the approval of
Owner/PMC. However, equipments thus included in the circuit shall be completely drained and dried with
compressed air after flushing is completed.

h. During flushing discharged water/air shall be drained to the place directed by the Owner/PMC. If
necessary, proper temporary drainage shall be provided by the contractor.

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i. Care shall be taken during flushing so as not to damage/spoil work of other agencies. Precautions shall
also be taken to prevent entry of water/foreign matter into equipments, electric motors, instruments,
electrical installations etc. in the vicinity of lines being flushed.

j. The EPC Contractor shall carry out all the activities required before, during and after the flushing operation,
arising because of flushing requirements, such as but not limited to the following:

k. Dropping of valves, specials, distance pieces, inline instruments and any other piping part before flushing.
The flanges to be disengaged for this purpose shall be envisaged by the contractor and approved by the
Owner/PMC. These flanges shall be provided with temporary gaskets at the time of flushing.

l. After flushing is completed and approved, the valve distance pieces, piping specials etc. shall be reinstalled
by the contractor with permanent gaskets. However, flanges at equipment nozzles and other places where
isolation is required during testing, only temporary gaskets shall be provided.

m. Records of the flushing activity shall be prepared and submitted by the EPC Contractor for each piping
system in the approved format.

2.5 Pressure Testing

Prior to initial operation, all installed piping shall be pressure tested, except where otherwise stated in this
Specification. Process and utility tubing and tie-in connection with existing system shall also be tested by the
requirements of this specification.

The calculated test pressure for each line shall be specified in the Piping Line List Pressure testing, in general
shall be as per clause 345 of ASME B31.3, unless otherwise specified, herein. Lines carrying highly
hazardous/poisonous fluids must have a sensitive leak test. For IBR lines, 'IBR Regulations' shall also be
followed.

Testing Range
a. With the exclusion of instrumentation, piping systems fabricated or assembled in the field shall be
tested irrespective of whether or not they have been pressure tested prior to site welding or fabrication.

b. For carrying out the testing of piping systems if it is necessary then vessels and other equipment’s may be
included in the system but with the prior approval of Owner/PMC if the test pressure specified is equal to or
less than that for the vessels and other equipment’s.

c. Pumps, compressors and other rotary equipments shall not be subjected to field test pressure.

d. Lines which are directly open to atmosphere such as vents, drains, safety valves discharge need not be
tested, but all joints shall be visually inspected. Wherever necessary, such lines shall be tested by
continuous flow of fluid to eliminate the possibility of blockage. However, such lines if provided with block
valve shall be pressure tested up to the last block valve.

e. Seats of all valves shall not be subjected to a pressure in excess of the maximum cold working pressure of
the valve. Test pressure applied to valves shall not be greater than the manufacturer's recommendation nor
less than that required by the applicable code. Where allowable seat pressure is less than test pressure,
test shall be made through an open valve.

f. Instruments in the system to be tested shall be excluded from the test by isolation or removals, unless
approved otherwise by the Owner/PMC.

g. Restrictions which interfere with filling, venting, draining such as orifice plates etc. shall not be installed
unless testing is complete.

h. Control valves shall not be included in the test system. Where bypasses are provided test shall be
performed through the bypass and/or necessary spool shall be used in place of the control valve.

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i. Pressure gauges which are part of the finished system, but cannot withstand test pressure shall not be
installed until the system has been tested. Where piping systems to be tested are directly connected at the
battery limits to piping for which the responsibility rests with other agencies, the piping to be tested shall be
isolated from such piping by physical disconnection such as valve or blinds.

2.6 Field Procedures

2.6.1 Test Preparation
a. All joints, including welds shall be left unpainted, uninsulated and exposed for examination during the
test, except that joints previously tested in accordance with this Specification may be insulated or
covered. If a Sensitive Leak test is required, joints will also be left unprimed and unpainted.

b. Underground portions of pressure piping systems if any shall be tested prior to backfilling.

c. Piping designed for vapour or gas will be provided with permanent supports to support the weight of the
test liquid.

d. Spring hangers which have been provided with stops for carrying the test load normally do not require
additional temporary supports; if this is not the case, temporary support must be provided before filling
the system

e. Testing shall be carried out with permanent gaskets installed unless specified otherwise or instructed by
the Owner/PMC.

f. No pressure test shall be carried out against closed valve unless approved by the Owner/PMC.

g. The Owner/PMC shall be notified in advance by the Contractor, of the testing sequence and
programme, to enable him to be present for witnessing the test.

h. Before testing, all piping shall be cleaned by flushing to make it free from dirt, loose scale, debris and
other loose foreign materials.

i. Prior to testing, the following needs to be verified -

 Piping systems shall be completely checked.
 All lines shall be checked to ensure the entire system can be completely drained after testing.
 Vents or other high point connections shall be opened to eliminate air from lines which are to
receive a hydrostatic test.
 System shall be purged of air before hydrostatic test pressure is applied.

j. Short pieces of piping which have been removed to permit installation of a blind or blank shall be tested
separately.

k. Lines containing check valves shall have the source of pressure located in the piping upstream of the
check valve so that the pressure is applied under the seat. If this is not possible, jack open the check
valve closure mechanism or remove check valve completely and provide necessary filler piece or blinds
as per the requirement. At these flanges, temporary gaskets shall be provided during testing and shall
be replaced by permanent gaskets subsequently. For check valves in lines 1½” and below flapper or
seat shall be removed during testing (if possible). After completion of testing the flapper/seat shall be
refitted.

l. Wherever in the line any void exists due to any reasons, like absence of control valves, safety valves,
check valves etc. It shall be filled with temporary spools.

m. Systems that include expansion joints shall be investigated to verify that any testing will not damage
expansion joints and that required temporary restraints, anchors, guides, etc., are installed prior to test.
Preparation for testing of expansion joints shall be in accordance with ASME B31.3, paragraph 345.3.3.

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n. All joints welded, screwed or flanged shall be left exposed for examination during the test. Before
pressurizing the lines, each weld joint shall be cleaned by wire brush to free it from rust and any other
foreign matter.

o. When dismantling of piping is necessary to perform testing, less costly gaskets suitable for the test
pressure may be substituted. After completion of the test, the test gaskets shall be replaced by the
gasket listed in the piping specifications

p. Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted between the
companion flanges. Minimum thickness of the blank shall be designed in accordance with applicable
design code.

q. Open ends of piping system where blanks cannot be used, such as pumps, compressors, turbines or
wherever equipment or pipe spools have been recovered or disconnected prior to hydrostatic testing,
shall be blinded off by using standard blind flanges of same rating as the piping system being tested.

r. Pressure gauges used in testing shall be installed as close as possible to the lowest point in the piping
system to be tested, to avoid overstressing of any of the lower portions of the system. For longer lines
and vertical lines, two or more pressure gauges shall be installed at suitable locations.

s. Piping which is spring or counter-weight supported shall be temporarily supported, where the weight of
the fluid would overload the support. Retaining pins for spring supports shall be removed only after
testing is completed and test fluid is completely drained.

t. When testing any piping system, air or any other media of approximately 2 kg/ cm2g may be used as
preliminary test to detect missing gaskets etc. as this avoids the necessity of draining the line to make
repairs.

2.6.2 Testing Resources

 Testing Medium
In general all pressure tests shall be hydrostatic using iron free water, which is clean. Maximum chloride
content in water for hydrostatic testing for SS piping shall be 20 ppm and carbon steel systems shall
have chloride content not exceeding 250ppm. The water used for the hydrostatic test, apart from the
requirements as to chloride content, shall be free from sediment or undissolved solids of any type.
Air shall be used for testing only if water would cause corrosion of the system or overloading of supports
etc. in special cases as directed by Owner/PMC.

If operating fluid in the line is much lighter than testing fluid, the additional weight of testing fluid may
render piping supports (as designed) inadequate. This will call for additional temporary supports. The
typical examples are flare and vapor lines. It is preferable that hydrostatic testing is avoided in such
systems and instead pneumatic testing may be specified.

Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene, methanol etc. shall be
used as the testing medium, with due consideration to the hazards involved.

 Test Pressure
The hydrostatic test pressure at any point in the system to be as follows -
i. Not less than 1-1/2 times the design pressure, except as provided in point “c” bellow.
ii. For a design temperature above the test temperature, the minimum test pressure shall be
calculated by the following equation, except that the ratio of ST/S shall not exceed 6.5.
PT = 1.5 P*ST/ S
Where -
PT = Minimum Hydrostatic Gauge Pressure (Barg )
P = Internal Design Gauge Pressure (Barg)
ST = Allowable Stress at Test Temperature (MPa)
S = Allowable Stress at Design Temperature (MPa)
(See Table I, Appendix A, ASME B31.3)

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Where the test pressure as defined above would produce a stress in excess of 90 percent of the yield
strength at test temperature, the test pressure will be reduced to the maximum pressure at which the
stress will not exceed 90 percent of the yield strength at the test temperature. The maximum test
pressure at which the stress produced will not exceed 90 percent of the yield strength will be calculated
by the ASME B31.3 Piping Code, para 304.1.2.

Depending upon the above requirements and based on construction progress, maximum length of piping
shall be included in each test.

 Test Pressure Gauge

All gauges used for field testing shall have suitable range so that the test pressure of various systems
falls in 35% to 65% of gauge scale range.

Prior to the start of any test or periodically during the field test programme, all test gauges shall be
calibrated. Any gauge showing an incorrect zero reading or error of more than ± 2% of full scale range
shall be discarded. Calibration certificate shall be furnished for the pressure gages.

2.6.3 Testing Procedure

 Hydrostatic Test
a. In order to hydrostatic test as much piping as possible at one time, a systems test may be
employed. This test may include one or more lines.

b. The minimum test pressure for a system test shall be such that each line in the system is
subjected to a common test pressure. System may consist of lines which belong generally to one
service.

c. The maximum system test pressure shall not exceed the pressure test rating of any piping
component included in the test system. (Maximum test pressures for flanges and valves
conforming to ASME B16.5 are to be considered.

d. 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 all lines for pressurizing and depressurizing the system, temporary
isolation valves shall be provided if valved vents, drains do not exist in the system.

e. Pressure shall be applied only after the system / line is ready. Pressure shall be applied by
means of a suitable test pump or other pressure source which shall be isolated from the system
as soon as test pressure is reached and stabilized in the system. The pump shall be attended
constantly during the test by an authorized person so that there is no over pressurization of the
piping system due to any reasons whatsoever. Care shall be taken to avoid increase in the
pressure due to temperature variation during the test.

f. Valves included in a pressure test shall be open 90%. Valves shall not be included in a pressure
test fully open or fully closed.

g. Systems or sections of piping to be isolated from equipment or vessels not included in the test
shall be either disconnected or isolated by blinds or other means during the test.

h. The normal location for the pressure test gauge is at grade near the pressure test pump.
Readings may be made at higher points providing the gauge pressure reading plus the static
head (0.1 bar per Meter) between low point in the system and the point of measurement does not
exceed the maximum test pressure. Pressure test gauges shall be numbered and calibrated a
minimum of once a week, using a dead weight tester. The gauge shall be tagged with the date
last calibrated. Gauges with outdated calibration tags shall be recalibrated before use.

i. Hydrostatic test pressure shall not be applied when the test liquid and/or metal temperature is
below 4°C.

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j. Hydrostatic test pressure to be maintained for a sufficient length of time to check all joints
(including welds) to determine if there are any leaks, but in no situation shall it be less than ten
minutes. Test pressure shall be released only after physical checking of all the joints and
attachments are completed. Any joint found leaking during a pressure test shall be retested to the
specified pressure after repair.

k. For underground buried pipeline within the plant premises hydrostatic test pressure to be
maintained for at least 24 hours to determine if there are any leaks. The test pressure gauge shall
include a chart pressure recorder to monitor the pressure continuously.

 Pneumatic Test Procedure

a. At time of testing, the minimum pipe metal temperature should be as listed below -
NOM. WALL THICKNESS MIN. TEMP.
Carbon Steel 38 mm and less 15 Deg C
Post-Heat Treated Ferric Alloy Steels 25mm and Less 15 Deg C
Austenitic Stainless Steels 25 mm and Less 12 Deg C

Clear test area while bringing line up to test pressure. It may be desirable to conduct test during
weekend when minimum personnel are present. Piping within the test shall be either tied down or
secured to minimize pipe movement in the event of rupture or sudden loss of pressure.

During pneumatic testing, care shall be exercised not to exceed the specified test pressure.

b. The maximum test pressure for pneumatic testing shall not exceed 75 percent of the stated
pressures in APPENDIX 1 (110% of design pressure).

c. Pneumatic tests shall include a preliminary check at 0.70 bar to locate major leaks. The pressure
shall be increased gradually in steps to full test pressure, holding the test pressure at each step
long enough to equalize piping strains, and shall be maintained for 30 minutes. All weld and
flange joints shall be examined using a leak detection fluid at 0.70 bar pressure and at test
pressure to determine whether leaks are present.

d. Prior to soaping the joints, the entire line shall be “Walked” to determine if there is any audible
evidence of leakage. Any leaks found at this time shall be marked, and repaired after
depressuring the line.

e. When the system has been brought up to the stipulated test pressure, all joints and welds shall
be covered with a bubble forming solution in order to detect any leakage. The solution shall be a
commercial preparation made specifically for leak detection.

f. Bolting shall not be tightened while systems being tested are pressured above 2 bar.

g. Pneumatic test pressures shall be maintained for a sufficient length of time to permit thorough
visual inspection of all joint and weld seams but not less than ten minutes. Pressure shall be
reduced gradually when de-pressuring.

h. When testing with air, pressure shall be supplied by means of a compressor. The compressor
shall be portable type with a receiver, after cooler and oil separator.

i. All other details shall be same as per hydro testing procedure (specified above).

2.6.4 Test Completion

a. After the hydrostatic test has been completed.

b. After completion of testing, pressure shall be released by opening the vents, in a manner and at a rate so
as not to endanger personnel or damage equipments.

c. All vents shall be opened before the system is to be drained and shall remain open till all draining is
complete, so as to prevent formation of vacuum in the system. After draining, lines / systems shall be
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dried by air. In services like dry air, ethylene etc., small traces of water can cause problem. For such lines
hot air drying is to be done after hydro-test.

d. All temporary blanks and blinds will be removed, all operating blinds returned to proper position and all
lines and piping components (except those tested pneumatically) will be completely drained. Valves,
orifice plates, expansion joints and short pieces of piping which have been removed shall be reinstalled
with proper gaskets in place. Lines being drained after testing will have all vents open. Care shall be
exercised in controlling the rate of drainage from vessels with respect to the inflow of air through the vent
to insure that the vessel is not subjected to vacuum. After vessels are completely drained, vents, cyclones
and other internal closures which were opened prior to testing will be closed.

e. Piping systems downstream of check valves should be inspected to insure complete drainage. The
connections shall be checked for tightness in subsequent pneumatic tests to be carried out by the EPC
Contractor for complete loop / circuit including equipment (except rotary equipment).

f. After lines have been drained, temporary supports shall be removed and insulation and painting
completed. Spring hangers provided with stops to carry the test load will have these stops removed in
accordance with the “Field Instructions” provided on the Project Drawings for Constant and Variable
Support Spring Hangers (to be developed during detailed design)in accordance with project
specifications.

g. Flanged joints at which test blinds have been removed will not be retested. Special length bolting and test
gaskets shall be removed and replaced with line class bolts and gaskets.

h. Instruments which were removed or blinded for test shall be reinstalled and blinds placed in the normal
operating position

i. Defects, if any, noticed during testing shall be rectified immediately and retesting of the system / line shall
be done by the contractor at his cost.

2.6.5 Test Records

Records shall be prepared and submitted by the EPC contractor for each piping system, for the pressure test
done in the format provided/approved by the Owner/PMC.

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3. FLEXIBILITY ANALYSIS AND SUPPORTING

3.1 Scope
This specification gives minimum requirements and procedures for the design of piping systems and components
for thermal flexibility, support, pressure, vibration and carry out the complete flexibility analysis of piping system
as per ASME B 31.3. It also includes wind load analysis and flange leak test.

The purpose of this specification is to ensure the practices outlined herein and to establish the minimum
requirements of design considerations for the flexibility analysis for the piping systems, and keep the following
parameters within acceptable limits of design -
 Stresses in Piping
 Deflection / movements of pipes
 Forces / moments on equipment and restraints

3.2 Codes and Standards

The following codes and standards, to the extent specified herein, form a part of this specification. When an
edition date is not indicated for a code or standard, the latest edition in force at the time of contract award shall
apply.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME SECTION VIII Pressure Vessels, Division 1 & 2

ASME B31.1 Power Piping

ASME B31.3 Process Piping

ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 through
NPS 24

AMERICAN PETROLEUM INSTITUTE (API)

API STD 610 Centrifugal Pumps for Petroleum, Petrochemical and

Natural Gas Industries (ISO13709)

API STD 617 Axial and Centrifugal Compressors and Expander-

compressors for Petroleum, Chemical and Gas Industry
Services

API STD 618 Reciprocating Compressors for Petroleum, Chemical and

Gas Industry Services

API STD 650 Welded Tanks for Oil Storage

API STD 660 Shell-and-Tube Heat Exchangers

API STD 661 Air-Cooled Heat Exchangers for General Refinery

Services

API STD 662 Plate Heat Exchangers for General Refinery Services

BRITISH STANDARDS INSTITUTE (BSI)

PD 5500 Specification for Unfired fusion welded pressure vessels

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INTERNATION STANDARDS ORGANIZATION (ISO)

BS EN ISO 9001 Quality Management Systems - Requirements.

BS EN ISO 9004 Quality Management Systems – Guidelines for

Performance Improvements

ISO 14692 Petroleum and natural gas industries Glass-reinforced

plastics (GRP) Piping

Part 1 - Vocabulary, symbols, applications and materials

Part 2 - Qualification and manufacture
Part 3 - System design
Part 4 - Fabrication, installation and operation

TEMA “R” Tubular Exchanger Manufacturers Association Standards

IBC International Building Code

ASCE 7 Minimum Design Loads for Building & other Structures

WELDING RESEARCH COUNCIL (WRC)

WRC 107 Local Stresses in Spherical and Cylindrical Shells Due to

External Loadings Supplement WRC 297

3.3 Reference Documents

The following documents shall be used for stress analysis -
 Piping GAD / Isometrics
 Piping clip drawings, if required
 Engineering Design Basis- Piping
 Pipe Support Standards
 P&ID, Process Package & Line list
 Equipment Drawing
 Piping Material Specification
 Allowable Nozzle loads for the Equipments.
 Structure Drawings

3.4 Design
The flexibility analysis shall be carried out in accordance with ASME B31.3 and shall consider the most severe
temperature condition sustained during start-up, normal operation, shutdown or regeneration.
The ambient temperature used in the flexibility analysis for hot lines shall be 5 Deg C. The ambient temperature
to be considered while flexibility analysis of cold lines shall be 45 Deg C.

 The flexibility analysis shall be carried out as per ASME B31.3 & ASME B 31.1. Values of thermal
displacements to be used in determining total displacement strains for computing the stress range shall be
determined from ASME B31.3/B31.1 as applicable. Similarly to compute the values for reactions, relevant
section of ASME B31.3/B31.1 shall be used.
 Piping systems shall have sufficient flexibility to prevent the thermal expansion / contraction or the externally
imposed displacements from causing:-
o Failure of piping material due to excessive plastic strains.
o Leakage of flanged or clamped joints.
o Fatigue failure of the piping material due to overstress.
o Overloading of the in-line components which would impair their operation.
o Detrimental distortion of connected equipment, resulting from excessive thrust and moments in
piping.
o Failure of supporting structure due to excessive loads.

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 The minimum criteria for defining the minimum acceptable flexibility are”
o Stress in piping system
o Deflection/ movement of piping
o Resultant forces & moments on the connected equipment
o Loads on supporting structure
o Natural frequency of piping
o Fouling between adjacent lines due to thermal movement
o Sagging in free draining lines

3.5 Piping Flexibility Analysis

When connecting to existing systems it is the EPC CONTRACTOR‟S responsibility to collect all the relevant data
of existing lines related to stress analysis at site. EPC CONTRACTOR shall ensure that the existing piping
system is safe, with stress point of view, where new lines are to be hooked up.

The flexibility analysis shall be based upon the following design conditions as shown on the Line List -
 Design pressure shall be used for defining allowable stresses, pipe wall thickness and the dead weight
(pressure + weight) piping code requirement.
 Design temperature shall be used for defining allowable stresses.

The Design temperature shall be used to determine the stress/strain range. Also, the supports shall be based on
the design temperature. In case of significant difference between design and operating temperatures, additional
check for spring supports shall be made using operating temperature. The maximum operating temperature,
rather than the design temperature shall be used when calculating loadings in-line items such as flanges.

Upset operating temperature, if applicable, shall be used for abnormal conditions, and the allowable stresses
shall be adjusted to an “occasional load” as defined in the piping code according to the duration of the abnormal
condition. If the duration of the abnormal condition is longer than the limits and frequency stated in the piping
code, then the upset operating temperature will become the normal operating temperature and the piping system
shall be analyzed at the higher temperature for the piping code requirement.

The following practices outlined herein, establishes the type of piping systems where the analysis to be
performed. Stress Critical Line List shall be generated to include all critical lines based on criteria mentioned in
clause 5.1. As a minimum, type of analysis considered such as static (wind, flange leakage) or dynamic (PSV
force analysis / Model analysis / Spectrum analysis etc.) shall be indicated against each line.

The standard load cases to be taken in to account in a formal computer analysis should be -

1. Operational – Max. design condition

OPE1 = W+P1+T1+D1+F

2. Operational – Operating condition

OPE2 = W+P2+T2+D2+F

3. Operational – Min. design condition

OPE3 = W+P1+T3+D3+F

4. Sustained – SUS1 = W+P1+F

5. Sustained – SUS2 = W+P2+F
6. Expansion - EXP1 = OPE1-SUS1
7. Expansion - EXP2 = OPE2-SUS2
8. Expansion - EXP3 = OPE3-SUS1

Where:
W : Weight of pipe and content.
P1 : Design Pressure
P2 : Operating Pressure
T1 : Thermal expansion between installation (ambient) temperature and the maximum
design temperature.
D1 : Nozzle/anchor displacements related to the maximum design temperature.

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D2 : Nozzle/anchor displacements related to the normal operating temperature.

D3 : Nozzle/anchor displacements related to the minimum design temperature
F : Loads due to concentrate forces or spring hangers.

T2 : Thermal expansion between installation (ambient) temperature and the normal

operating temperature.
T3 : Thermal expansion between installation (ambient) temperature and the minimum
design temperature

In addition to standard cases, possible occasional load cases due to wind, seismic or PSV reaction force shall
be considered. Occasional loads on equipment or supports are to be added to case 2 given above.

3.5.1 Formal computer analysis shall be performed on the following piping systems -
a. Process lines to and from compressors and blowers.
b. Lines to and from turbines.
c. Lines with design temperature differences from base temperatures of greater than or equal to 180 DegC
for piping NPS 6 and larger and greater than or equal to 260 DegC for piping NPS 4 and smaller.
d. Lines connected to rotating machinery (Pumps & Compressors) NPS 2 and above.
e. Other process lines in Toxic or category „M‟ services, per ASME B31.3, para 300.2.
f. GRE/GRP piping for water hammer and elevated temperatures as determined by the manufacturer.
g. Two phase flow piping such as blow-down piping.
h. Lines to and from reciprocating compressors using the results from analogue study carried out as per API
618.
i. Other process lines in critical services such as -
i. multi-phase flow lines
ii. lines subject to slug flow
iii. lines subject to pressure surges for which a transient pressure surge analysis is required
j. Lines NPS 4 and larger to air coolers.
k. Lines NPS 16 and larger and differential temperature (Design Temp. minus Base Temp) greater than or
equal to 85 degree C.
l. Non-metallic Piping
m. Vacuum lines
n. Relief systems whether closed or relieving to atmosphere with consideration for attached or detached
discharge pipes.
o. All Jacketed lines.

3.5.2 As a minimum, engineering analysis, by visual inspection and short cut manual calculations,
shall be performed on the following systems -
a. Lines with design temperature differences from base temperatures greater than or equal to 80 DegC
and less than 180 DegC for piping sizes 6” and larger.
b. Those piping systems that are selected by the EPC CONTRACTOR which do not require formal
computer analysis.

3.5.3 Special consideration shall be given to piping systems in the following categories
a. Lines subject to excessive deflection resulting from differential settlement, structural and/or equipment
displacement.
b. Lines subjected to mixed phase flow (liquid and vapor).
c. Lines subject to external pressure by reason of vacuum or jacketing.

3.5.4 Piping Systems

Piping flexibility shall be obtained through pipe routing or expansion loops unless process conditions, limitations
of space or economics dictate the use of flexible connectors. The use of expansion joint requires OWNER’s
approval. Expansion loops, when installed in a horizontal plane, shall be offset vertically to clear adjacent piping
unless process considerations (e.g. flare lines) dictate otherwise. Expansion loops shall be avoided on pipe
bridges over roadways.

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Lines will not be disconnected during purging, if purging is specified in the process package; therefore, they
shall be designed with sufficient flexibility to accommodate the thermal displacement of the vessel.

3.5.5 External Load on Equipment

The flexibility analysis shall resemble the operation of the equipment. When equipment is redundant for back-up
or sparing, the flexibility analysis shall represent at least two cases for the operation of equipment. The first case
is for all equipment operating and is called the “Hot-Hot” case. The next case is for normal operation of the
equipment which considers at least one piece of equipment idle. This case is called the “Hot-Cold” case. The
EPC CONTRACTOR shall decide which equipment will be idle during the “Hot-Cold” case to produce the most
severe loads on the equipment. The equipment loads from both the “Hot-Hot” and “Hot-Cold” flexibility cases
shall be compared to the allowable loads on the equipment.

3.5.6 Flange Leakage

Flange leakage analysis shall be carried out as per the relevant codes and standards for flanges having
following criteria -
 Flanges NPS 4 & above and 900# & above for Hydrocarbon lines
 Flanges NPS 8 & above and 900# & above for all other lines
 Flanges NPS 26 & above and 600# & above for all other lines except air and water lines.

3.5.7 SUPPORTING
Pipe supports shall be able to withstand the loads determined by the piping analysis. Standard supports shall be
used for the supporting. If standard supports are not meeting requirements then job specific support shall be
used.

Pipe guides should be used to prevent buckling of long-run piping. They are also to be used on both sides of the
loops to avoid shifting of line sideways. Due care to be taken to divert the thermal/ other deflection away so as
to avoid interference with the other piping or structures.

Maximum deflection between supports shall be limited to 15 mm.

3.5.8 Seismic Analysis

Design for seismic loads shall be in accordance with ASCE 7 or equivalent British Standard.

3.5.9 Wind Analysis

All lines should have a sufficient number of horizontal restraints/guides to resist the wind load. Additional
horizontal supports may be required to reduce excessive horizontal deflection of pipe due to wind load.

3.5.10Specific Equipment Requirements

 Pumps
The allowable loads at Pump nozzles shall be as per the relevant codes and standards.

For one pump operating and another at stand-by. The following three different cases shall be
considered -
o Both pumps operating.
o Pump A operating, Pump B stand-by
o Pump B operating, Pump A stand-by

For two pumps operating and another at stand-by. The following three different cases shall be
considered -
o Pumps A & B operating, Pump C stand-by
o Pumps A & C operating, Pump B stand-by
o Pumps B & C operating, Pump A stand-by

 Centrifugal Compressor
Allowable nozzle loads shall be as per the relevant codes and standards.

Calculated loads wherever exceeding shall be sent to Vendor for approval, if piping design changes are
not possible.

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 Pressure Vessels
Nozzle loads shall be within the Nozzle Allowable loads mentioned in the respective equipment
datasheets.
Nozzle loading shall be analyzed using nozzle flexibilities derived from WRC-107 / 297 or finite
element analysis.

3.5.11Vibrations
Dynamic analysis shall include natural frequency calculations, harmonic analysis, and response spectrum
analysis for all modes of operation up to and including the fourth harmonic.

Supports and anchors on lines to and from reciprocating compressors and pumps shall be designed so that the
natural frequencies of the piping system do not respond to the natural frequencies of the equipment. Lines
subject to impact forces due to rapid valve closures shall be designed to avoid vibration.

Vibration that is caused by fluid flowing around or through objects is referred to as vortex shedding or flow-
induced vibration. Vortex shedding shall be a part of the dynamic analysis. Lines with two-phase flow shall be
designed to avoid vibration.

3.6 Software Used

CAESAR II software shall be used for the formal piping stress analysis.

3.7 Piping Support Design

3.7.1 General
1. Each support assembly, including a spring support, shall be designed to sustain the hydrostatic load.

2. Small bore lines should not be supported from larger lines. Where unavoidable, only un-insulated lines
can be applied as supporting lines.

3. Hanger type supports shall be used only where it is not practical to install resting type supports.

4. Spring type supports shall be used only where the following purposes is achieved -
 To allow the lines subject to thermal expansion or contraction to move vertically and remain
supported.
 To reduce reaction force and moment from supports on equipment nozzles or other portions to
be protected from excessive external load.

5. Variable spring type support shall be selected on condition that the maximum allowable variation in
supporting load is within 25 percent for the total travel between hot and cold position. Above 25 percent,
constant type spring support shall be used.

6. Where expansion joints are applied, anchor and guide supports shall be provided and designed in
accordance with the requirements of the manufacturer and the standard of EJMA.

7. The type and location of supports for two phase flow lines which may cause vibration shall be selected
properly. Especially for large flexible piping systems with spring and hanger supports on account of the
absorption of thermal expansion or contraction, low frequency vibration shall be prevented by provision
of guides, directional stop or vibration proof devices such as snubbers.

8. Piping shall be arranged in grouping, and common support or supporting structure shall be provided so
that the number of supports, especially special supports are minimized.

9. Trunnion and stanchion type supports installed on grating directly are not allowed for piping of NPS2
and over. The supports shall be installed on structural beam directly. For piping of NPS1.1/2 and under,
supports may be installed on grating directly.

10. For supports of cantilever type, reinforcements such as rib plate and/or additional beam shall be
provided on the structural where the supports are connected if the local bending of the structural beams
is expected.

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3.7.2 Maintenance Consideration

Permanent supports should be provided around piping parts or components requiring frequent dismantling for
maintenance so that the maintenance work can be performed without adding any temporary supports. The
followings are the potential location where the above consideration is required -
 Spacers & Blanks
 Pipe spool pieces near heat exchangers
 Auxiliary and process piping around rotating equipment
 Piping around control valves

3.7.3 Support Span

1. Support span shall generally be determined so that the stress and deflection of piping caused by the
weight of piping components, fluid, and insulation do not exceed one –half (1/2) of the allowable stress
at service temperature and 20mm respectively. Additionally, local stress at supporting points shall be
confirmed to decide their spans.

2. Maximum standard guide span shall be as follows in general -

 For vertical piping
Run Pipe Size (NPS) Max. Standard Guide Span (m)
8 & under 6
10 & over 10

 For horizontal piping

Run Pipe Size (NPS) Max. Standard Guide Span (m)
2 & under 6
3-8 12
10 & over 18

3. For lined and plastic piping, the support span specified by the manufacturer shall be applied.

4. Special consideration shall be given for support locations near which heavy weight component such as
valves, strainers, in-line instruments and equipments etc. are installed. In such cases, the supports shall
be located as close as possible to these components to prevent the excessive stress on piping systems.

5. Where necessary to avoid liquid contamination in lines due to process reason (i.e. free draining lines),
support span shall be optimized to reduce pipe deflection.

3.7.4 Pipe Support Definitions

1. Anchor a device which restrains the pipe from movement and rotation in all directions.

2. Rotating support an anchor which allows the line to rotate around the longitudinal axis of that support
but prevents vertical and lateral movement

3. Base support or a dummy pipe with base plate welded to the pipe. Stanchion pipe dummy will rest on
the supporting structure and so support the pipe.

4. Dummy leg a dummy pipe welded to the pipe. The pipe dummy will rest on the supporting structure
and so support the pipe

5. Pivot an element similar to a base support, but which allows the pipe to rotate around and to move
along the longitudinal axis of that pivot. These supports are usually used as a sort of base support but
they allow vertical movement and rotation while preventing lateral movement. Downward movement can
be restricted with this type of support

6. Guide a device controlling the direction of movement of piping/supports Guided support a support
allowed to move along a predetermined axis, controlled by guides

7. Pipe stop a device preventing the pipe from displacement in one direction may be applied in
combination with a guide and other direction
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8. Rest support Location where a pipe is resting with or without the application of a pipe shoe on the
supporting structure

9. Clamp or clip a device bolted around a pipe or, for cold insulation and around the insulation. Clamps
form an integral part of standard hangers and clamped cradles or pipe shoes.

10. Constant load a spring loaded support assembly or device designed support such that the
supporting effort is constant over the total travel of the support. Constant load supports are mainly used
in pipes connected to strain sensitive equipment or for critical systems with large movements.

11. Goal post support frame type support for situations where heavy loads may be expected.

12. Hanger a support suspended from concrete floors, beams etc.

13. Pipe shoe or cradle a pipe support welded or clamped to a pipe.

14. Reinforcing pad or saddle a plate welded to the pipe in order to reinforce thin-walled pipe to prevent
the pipe from being damaged

15. Shear lug a welded attachment to the pipe at one or both sides of a clamped cradle or pipe shoe,
preventing the pipe from slipping through the pipe support.

16. Snubber a shock absorbing device, allowing the pipe to freely and slowly move whilst absorbing
sudden shocks (e.g. seismic). It may be of the hydraulic, spring loaded or verge and verge wheel type.

17. Sway brace an adjustable spring or friction loaded device, usually applied for controlling vibration,
absorbing shock loading, guiding or restraining the movement of the pipe and bracing against sway

18. Sway strut an adjustable device, usually applied for restraining movement of piping in one direction
while providing for movement in another direction.

19. Spring hanger a suspended spring loaded support

20. Spring support a spring loaded assembly or device, supporting the pipe from underneath

21. Trunnion a tubular supporting device, branching-off horizontally from a vertical line, and resting on, or
suspended from, the supporting structure

22. U-bolt a light-duty fixture, U-shaped, with both ends threaded and provided with nuts. These supports
can be used as guiding points

3.7.5 Additional Design requirements

1. Supports must be designed to meet all static as well as dynamic operational conditions to which the
piping may be subjected. All piping shall be adequately supported, guided or anchored so as to prevent
undue vibration, deflection/ expansion or loads on connected equipment and piping and leakage at
joints.

2. Piping at valves and equipments such as heat exchangers and pumps, requiring periodic maintenance,
shall be supported in such a way so that the valves and Equipments can be removed with a minimum
necessity of installing temporary pipe supports.

3. The first solid support for pump suction and discharge lines shall be adjustable type to facilitate pump
alignment. Pedestal for pipe supports for outdoor installation shall be 150 mm above HPP. In case of
unpaved area, the pedestal height shall be 300mm.

4. For insulated lines on pipe rack shoe support shall be provided. Shoe height shall be based on insulation
thickness. Minimum shoe length shall be 300mm and shall be suitably increased to suit thermal
movement of line.

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5. Shoe shall be sufficient height such that temperature of the contact point on pipe rack/ support location
shall not exceed a temperature of 120 deg.C on concrete or 350 deg.C on structural steel.

6. Spring supports shall have Teflon pad on top slide plate of spring for temperature upto 200C and
graphite pad or roller bearing for higher temperatures. Spring supports should be unlocked and cold set
prior to commissioning of the system by the EPC Contractor as per the instructions of the spring
manufacturer. A complete list of all spring supports to be compiled along with relevant details (i.e. Make,
spring rate, loads, travel & location) & submitted to Owner as final documentation.

7. Supporting of safety valve piping from the equipment platforms shall be avoided. Support cleats shall be
provided in the equipments for these lines. In case it is necessary to support these lines on the platform,
the members of the platform shall be designed considering the imposed loads due to piping. Also
supporting of other vibration prone lines from platform or structural members not designed for supporting
of pipes, shall be avoided.

8. For high pressure piping separate pipe support with load bearing capacity, shall be developed for
supports of vents, drain and pressure connection, orifice tapping etc. Suitable support may be provided
below high pressure flange joints and below valve body if the valve is butt welded.

9. Pipe support, its type, location shall be indicated on piping isometrics and shall be in line with piping
flexibility analysis.

3.7.6 Installation of Supports

1. Piping shall be properly anchored and guided before pressure testing.

2. Tie rods shall be locked in their proper position before testing, and re-adjusted as necessary after testing
in accordance with the installation instructions.

3. Pipe supports shall be able to sustain the hydrostatic test load of the piping they support, if applicable.

4. Spring assemblies shall be shipped to the job site with the springs compressed in the installed position
as indicated on the pipe support detail drawing and/or requisition. They shall have caution tags attached
which warn that the spring locks must be removed before the line is put in service. Additionally, the
spring supports shall have the marks "C" or "H" on the casing load indication scale:
 Mark "C" indicates the cold position of the spring when the line is at ambient temperature but filled
with its actual service fluid. For tank pipes filled with the actual service fluid, it indicates the
position when the tank is empty and has zero settlement.
 Mark "H" indicates the operation positions of the spring.

Spring supports shall be installed with the spring locks in place. These spring locking plates or pins shall
not be removed until hydrostatic testing and insulation of the piping system has been completed.

Note: In order to ensure the locking pins are available when next needed (e.g. during a shutdown), it
should be considered to attach the pin with a plastic tie near the support.

5. Normally, all construction aids such as spring locks, temporary supports, welding tacks, etc. shall be
removed prior to commissioning. However, if the spring force on the empty line will cause possible
damage to connected strain sensitive equipment, the spring locks shall remain in position until the line is
filled with the actual service fluid.

6. The length of pipe shoes shall be sufficient to prevent pipes moving off their supports when subjected to
thermal expansion or contraction.

7. Adjustable supports shall be used where differential settlement between equipment and piping may
occur.

8. Field-welded supports shall be set correctly in place and adjusted to the final position before welding to
the pipe. Base supports shall have welded end plates.

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9. Dummy legs shall have a limit on the maximum length and be provided with a 12 mm (½ in) drain hole
located at a short distance from the weld to the run pipe. Dummy legs shall not be installed at pipes
operating below ambient temperature to prevent condensation to the run pipe.

10. Hanger rods for pipes subject to expansion or contraction of more than 75 mm (3 in) shall be set equal to
half of the calculated travel of the pipe at the point of support, in the opposite direction to the travel as
indicated on the support detail drawing, the piping arrangement drawing and/or the isometric drawing.
For sliding supports, bearing surfaces shall be sufficiently clean to ensure unrestricted movement.

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4. WELDING AND NON DESTRUCTIVE TESTING

4.1 Scope
This specification shall be followed for the fabrication of all types of welded joints of piping and supporting.

There shall be many types of welded pipe joints which shall be as below -
 All pipe joints, longitudinal butt welds, circumferential butt welds and socket welds.
 Attachments of forgings, flanges and other supports to pipes.
 Welded branch connections with or without reinforcing pads.
 The attachments of smaller connections for vents, drain drips and other instrument tappings.

Any approval granted by the OWNER/PMC, shall not relieve the EPC CONTRACTOR of his responsibilities and
guarantee for the quality of weld.

4.2 References
Unless otherwise stated, the following Codes, Standards and Project Documents shall be of the latest issue
(including revisions, addenda and supplements) and are considered part of this specification.
ASME B31.3 - Chemical Plant and Petroleum Refinery Piping
ASME B31.1 - Power Piping
ASME Section II, Part C - Welding Rods, Electrodes and Filler Materials
ASME Section V - Non-Destructive Examination
ASME Section IX - Welding and Brazing Qualifications
NACE RP-0472-95 - Methods and Controls to Prevent In- Service Cracking of
Carbon Steel Welds in P-1 Materials in Corrosive Petroleum
Refinery Environments
ASME Section VIII - Rules for construction of Pressure Vessels

4.3 Welding Procedures

 Welding Procedure Specifications and Procedure Qualification Test records for welding covered by this
specification shall be submitted to Owner for review and acceptance prior to start of any welding. No
welding shall commence until welding procedure specifications and qualification records have been
accepted.

 Welding Performance Qualification test records shall be made available to Owner personnel for review
upon request. Welding Performance tests shall be in accordance with ASME Section IX, under conditions
of restraint and accessibility as demanding as those to be experienced in production by the welder.
Welding Performance test records shall conform to ASME Section IX form QW-484 or equivalent.
Structural steel welding performance qualification records may comply with AWS recommended format.

 When impact testing is required by the code or technical specifications, impact test results for weld and
heat affected zone shall be reported with the welding procedure qualifications.

 When maximum Brinell hardness is required by code, the technical specifications, or this specification,
they shall be reported with the Welding Procedure Qualification Record and they shall not exceed the
maximum specified.

 Welders to be used shall be qualified for each welding procedure they will use in the position they will use
it. EPC Contractor shall make available to the Owner’s inspector a copy of each welder’s qualification
certificate, with name and stencil I.D. Welds made with uncertified welders shall be removed and
replaced by a certified welder at the EPC Contractor’s expense. The EPC Contractor shall bear all costs
for qualifying welders.

 EPC Contractor’s QA/QC Supervisor shall maintain all Welder Qualification Records and make available
to Owner Representative when requested.

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4.4 Welding Process

 Welding of various materials under this specification shall be carried out using one or more of the
following processes with the approval of the OWNER/PMC.
o Shielded Metal Arc Welding Process (SMAW)
o Gas Tungsten Arc Welding Process (GTAW)

 Automatic and semi-automatic welding processes shall be employed only with the express approval of
the OWNER/PMC. The welding procedure adopted and consumables used shall be specifically
approved.

 A combination of different welding processes could be employed for a particular joint only after duly
qualifying the welding procedure to be adopted and obtaining the approval of OWNER/PMC.

4.5 Weld Joint Preparation & Cleaning

 Weld joint design shall confirm to the allocable design code, project specification or approved drawings.

 Weld joint shall be prepared by machining, grinding or thermal cutting.

 Alloy materials shall be edge prepared by PLASMA cutting, machining or grinding.

 When thermal cutting is employed all slag and heat affected areas shall be dressed by mechanical
means.

 Weld joint tolerances for root and alignment shall meet the requirements of applicable code, specification,
approved drawing and the sketch details included in the approved WPS.

 When poor fitted joints occur with excessive joint gap or offset or any other discrepancies, a repair
procedure shall be prepared and submitted for OWNER review and approval. Welding shall not perform
on poorly fitted joints.

 Grinding and cleaning of austenitic stainless steel or higher nickel and nonferrous alloy shall be done only
with tools that have not been previously used on nonferrous materials, copper alloys, aluminum or zinc
coatings (paint or galvanized).

 All tack welds shall be made by the qualified welders. The required preheat temperature shall be
maintained prior to any tack welding. Tack welds which are to be incorporated into the final weld shall be
thoroughly cleaned, prepared at each end and inspected for cracks any cracked tacks shall be removed
before welding starts. Minimum 3 no. of tack welds shall be used for pipe sizes up to 2” and 4 tacks for
sizes 3” and above.

 The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides, sand, earth
and other foreign matter. The ends shall be completely dry before the welding commences.

 On completion of each run, craters, welding irregularities, slag etc., shall be removed by grinding and
chiseling. Wire brushes 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 steels and stainless steels.

4.6 Welding Consumables

 Filler materials and fluxes shall be as specified in ASME, Section II, part C. Filler materials and fluxes
other than those specified in the above code and which meet other requirements of this specification shall
not be assumed to be acceptable.

 All welding electrodes and consumables shall be subjected to OWNER Approval as part of Welding
Procedure Specification.

 All welding consumables shall be supplied along with original manufacturer test certificates.

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 The electrode/filler wire chemistry shall meet the requirements of the base material, and shall be selected
such that the deposited weld metal exhibits mechanical properties equal or excess of the base metal.

 For any dissimilar metal weld applications welding consumables and procedure shall be subjected to
OWNER approval.

 All welding electrode/consumables shall as a minimum, be stored and used in accordance with the
manufacturer’s recommendations.

 Carbon, Low alloy, Stainless steel and special electrode shall be stored separately.

 The electrodes, filler wires and flux used shall be free from rust, oil, grease, earth and foreign matter
which affect the quality of welding.

 The preferred size of the electrodes is 2.5 mm diameter (12 SWG) but in any case not greater than 3.25
mm (10 SWG) for the root pass.

4.7 Shielding Gases

 Argon gas used in Gas Tungsten Arc welding for shielding and purging purposes shall be 99.995% pure.
The purity of the gas shall be certified by the manufacturer.

 When GTAW process alone or a combination of GTAW and SMAW processes is recommended for the
production of a particular joint, the purging shall be maintained during the root pass and for the first filling
pass to minimize oxidation on the inner side of the pipe.

 Initial purging shall be maintained for sufficient period of time so that at least 4-5 times the volume
between the dams is displaced, in order to completely remove the entrapped air. In no case should the
initial purging period be less than 10 minutes. High gas pressure should be avoided. After initial purging,
the flow of the backing gas should be reduced to a point where only a slight positive pressure prevails.
The flow rates required should be established during welding procedure qualification.

 Gas purging is not required for socket type of welded joints.

4.8 Welding Equipment

The EPC CONTRACTOR must have the sufficient number of welding machine and other miscellaneous other
equipment as per requirement to meet the project schedule.

All the radiographic equipment and the equipment for performing the heat treatment and provided by the EPC
CONTRACTOR must be approved of the OWNER/PMC.

4.9 Welding Technique

 Upward technique shall be adopted for welding pipe held fixed with its axis horizontal and welding shall
be uninterrupted. Single pass welding procedures are not acceptable.

 The root pass of butt joints should be executed so as to achieve full penetration with complete fusion of
the root edges. Weld projection inside the pipe shall be as per applicable code. However, it shall not be
more than 3mm in any case.

 Peening shall not be used.

 All piping butt-weld shall be full penetration welds.

 If a welding joint is wet or has surface moisture or condensation it shall be dried by heating.

 Each weld joint shall have a workmanship like finish. Weld identification work shall be stamped clearly at
each joint, just adjacent to the weld. Metal stamping shall not be used on thin pipe having wall thickness
less than 3.5mm. Suitable paint shall be used on thin wall pipes for identification.

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 All welds shall be cleaned of foreign materials (slag etc.) down to clean metal both on completion of each
pass and when the weld is finished.

 For dissimilar welding between carbon steel / alloy steel to stainless steel, filler wire/electrodes E/ER-309/
E-310/ E NiCr Fe-3 shall be used.

4.10 Preheat, Inter-Pass Temperature and Post Weld Heat Treatments

 Preheat temperature shall be in accordance with that specified by the applicable code. However, no
welding shall be performed without preheating the joint to minimum 10 Deg C when the ambient
temperature is below 10 deg C.

 The minimum preheat temperature shall be maintained throughout the welding cycle.

 Minimum preheat requirements shall apply to all types of welding, including tack welds, temperature
attachments, repair welds, seal welds of threaded joints and thermal cutting.

 Maximum inter pass temperature for austenitic stainless steel shall not exceed 175°C. This includes
dissimilar welds between stainless steel and carbon steel.

 Post weld heat treatment (PWHT) shall be performed in accordance with the requirements of the ASME
code as applicable. PWHT by direct impingement by torch or burner is not acceptable. Post weld heat
treatment shall be done in a furnace or by using an electric resistance or induction-heating equipment, as
decided by the OWNER/PMC. While carrying out local post weld heat treatment, technique of application
of heat must ensure uniform temperature attainment at all points of the portion being heat-treated. It is to
be to ensure that width of heated band over which specified PWHT temperature attained is at least that
specified in the relevant applicable standards/codes. Control of temperature shall be done using
microprocessor/computer controlled system. Throughout the cycle of heat treatment, the portion outside
the heated band shall be suitably wrapped under insulation so as to avoid any harmful temperature
gradient at the exposed surface of pipe. The temperature attained by the portion under heat treatment
shall be recorded by means of thermocouple pyrometers. Adequate number of thermocouples should be
attached to the pipe directly at equally spaced location along the periphery of the pipe joint.

4.11 Qualification Procedures

Welding procedure qualification shall be carried out in accordance with the applicable requirements of ASME
Sec. IX latest edition and/or other applicable codes and the job requirements. The EPC CONTRACTOR shall
submit the welding procedure specification (ASME Section IX Form QW-482 or equivalent) for OWNER/
OWNER REPRESENTATIVE’S review and approval for further welding procedure qualification tests. Tests as
specified in the relevant code shall be carried out. It shall be the responsibility of the EPC CONTRACTOR to
carry out all the tests required to the satisfaction of the OWNER’s inspector. Procedure Qualification Records
(ASME Form QW-483 or equivalent) shall be submitted to OWNER by the EPC Contractor. Welding shall not
proceed until these documents are returned to the EPC Contractor with authorization to proceed.

Each Welding Procedure Qualification Records (PQR) referenced with its subsequent WPS shall be witnessed
and certified by OWNER/OWNER REPRESENTATIVE and shall include -
a. Welding process or processes when more than one is used in marking a complete joint;
b. Parent metal specification thickness and for pipe, the outside diameter or dimension;
c. Whether shop or site welding;
d. Edge preparation (sketch);
e. Cleaning, degreasing etc;
f. Fit-up (sketch)
g. Jigging or tacking, backing etc.;
h. Welding position (including direction for vertical position);
i. Make, brand and type of welding consumables; (AWS number (ASME)) - a and f number
j. Filler material composition and size (diameter);
k. Pre-heating and interpass temperature, including method and control;
l. Travel speed (mechanized welding);
m. Approximate number and arrangement of runs and weld dimensions (sketch);
n. Welding sequence;
o. Back gouging;

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p. Post-weld heat treatment, including method and control;

q. When applied, the temperature and time adopted for drying/baking of welding consumables before use;
r. Any special features, including heat input control requirements, e.g. Run-out length (R.O.L.).
s. Gases/shielding/backing to include composition and flow rate.

Welders shall be qualified in accordance with the ASME Section-IX or other applicable codes. The OWNER’s
inspector reserves the right to witness the test and certify/approve the qualification of each welder separately.
Only those welders who have been approved by the OWNER’s Inspector shall be employed for welding. 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 any further work. All welds performed by an unqualified welder shall be cut and redone by a qualified
welder at the expense of the EPC CONTRACTOR.

4.12 Non-destructive Examination (NDE), Testing and Inspection

The minimum extent of NDE shall be in accordance with ASME B31.3. The percentage NDT stated applies to all
piping weld joints and applicable fillet welds for each NDT technique.

All NDE shall be performed by personnel certified to ASNT level II as a minimum in accordance with ASNT
Recommended Practice SNT-TC-1A or equivalent. Interpretation of the RT films shall be performed by
personnel certified to ASNT Level II or III and the OWNER assigned Inspector for final review and acceptance.

4.12.1Visual Examination
 Visual examination procedures shall be in accordance with ASME Section V, Article 9.
 Visual examinations shall be performed on accessible surfaces of all completed welds.

The evaluation of indications and the acceptance criteria for visual inspection shall be in accordance with ASME
B31.3. The visual acceptance of each weld shall be recorded by the contractor.

4.12.2Magnetic Particle Examination (MT)

 Magnetic particle examination procedures shall be in accordance with the requirements and methods
specified in ASME Section V, Article 7.
 Magnetic particle examination of welds shall include a band of base metal at least 25 mm wide on each
side of the weld.
 The sensitivity of the method employed shall be demonstrated, prior to acceptance of the MPI
procedure by means of a calibrated Burmah-Castrol strip type 1, and/or suitable sample welds.

4.12.3Liquid Penetration Weld

 Liquid penetrant examination procedures shall be in accordance with ASME Section V, Article 6.
 Liquid penetrant examination of welds shall include a band of base metal at least 25 mm wide on each
side of the weld.

4.12.4Ultrasonic Examination (UT)

 Ultrasonic examination procedures shall be in accordance with the requirements and methods specified
in ASME Section V, Article 5, or ASME B31.3, whichever is applicable.
 The evaluation of indications and the acceptance criteria shall be in accordance with ASME B31.3
OWNER approved engineering design acceptance criteria. The sensitivity/calibration shall be set to
meet minimum radiographic acceptance standards and as such a calibration block should be prepared
to ensure all non-allowable defects e.g. lack of fusion/lack of penetration can be detected.
 For P N° 1 and P N° 4 piping of thickness 40 mm and above 100% ultrasonic examination shall be
required on butt welds in addition to the specified radiography examination. Where a joint configuration
involves tapering either internally or externally inside the scanning area, or there is limited access (e.g.
fittings/valves). The UT procedure shall clearly demonstrate that full inspection of the weld can be
performed and any limitations stated.
 Ultrasonic examination shall be regarded as a complementary examination to the radiography for the
detection of ―Planar Flaws.

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4.12.5Radiographic Examination
Radiographic examination procedures shall be in accordance with the requirements and methods specified in
ASME Section V, Article 2.

The final non-destructive testing of welds for acceptance purposes shall be carried out after completion of any
PWHT.

4.12.6Hardness Testing
Hardness test shall be in accordance with ASTM specification E10. Hardness tests of the heat affected zone
shall be made at a point as near as practicable to the edge of the weld. One test per weld shall be performed.
All welds which are given heat treatment shall be hardness tested. Hardness test shall be performed after final
heat treatment.

The hardness limit applies to the weld and heat affected zone. Following hardness values shall be maintained,
or shall be as per ASME B 31.3 whichever is stricter.

Base Metal Group Maximum Hardness (BHN/RC)

CS 238BHN/RC22
CS (NACE), Caustic, 200BHN

Amine, H2
Cr Upto 2% 225BHN
Cr 2.25%-10% 241BHN
18/8 SS (NACE) RC22

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Document Number : D10-PMC-JSF-015

5. PAINTING
5.1 Scope
This specification covers requirements and recommendations for the surface preparation and the new external
painting and coating of piping, vessels, structural steel and other equipments. To achieve a long term service life
of the protective coating system, full attention shall be given to the quality of surface preparation and application
of the coating system.

5.2 Codes and Standards

External painting and protective coating shall meet or exceed the requirements of the latest edition of the
following codes, regulations and standards, except as superseded herein. In cases where more than one code,
regulation or standard apply to the same condition, the most stringent shall be followed.

RAL DUTCH : International Standard for colour shade

SSPC SP1 : Solvent Cleaning
SSPC SP2 : Hand Tool Cleaning
SSPC SP3 : Power Tool Cleaning
SSPC SP5 : White Metal Blast Cleaning
SSPC SP6 : Commercial Blast Cleaning
SSPC SP7 : Brush-Off Blast Cleaning
SSPC SP10 : Near White Blast Cleaning
SSPC SP11 : Power Tool Cleaning to Bare Metal
SSPC PA 1 : Shop, Field and Maintenance Painting
SSPC PA 2 : Measurement of Dry Coating Thickness with Magnetic Gages
SSPC PA Guide 3 : Guide to Safety in Paint Application
SSPC PA Guide 8 : Guide to Top Coating Zinc Rich Primers
SSPC AB 1 : Mineral and Slag Abrasives
SSPC AB 2 : Cleanliness of Recycled Ferrous Metallic Abrasives
SSPC VIS 1 : Visual Standard for Abrasives Blast Cleaned Steel
SSPC VIS 3 : Visual Standard for Power and Hand Cleaned Steel
SSPC, Volume 1 : Good Painting Practice
SSPC, Volume 2 : Systems and Specification
IS-101 : Methods of test for ready mixed paints and enamels
IS-2379 : Indian Standard for Pipe line identification-colour code
ISO-12944 : Corrosion Protection of steel Structures by Protective Paint
ASTM D4541 : Standard Test Method for Pull-Off Strength of Coating Using Portable
Adhesion Testers
ASTM D4417 : Standard Test Methods for field Measurement of Surface Profile of
Blast Cleaned Steel
ASTM D5162 : Standard Practice for Discontinuity (Holiday) Testing
ISO 2808 : Paint and Vanishes – Determination of Film Thickness
ISO 4624 : Paint and Vanishes – Pull-off Tests for Adhesion
ISO 8501-1 : Preparation of Steel Substrates before Application of Paint and Related
Products-Visual Assessment of Surface Cleanliness
ISO 8502 : Preparation of Steel Substrates before Application of Paint and
Related Products- Tests for the Assessment of Surface Cleanliness
ISO 8504-2 : Preparation of Steel Substrates before Application of Paint and Related
Products –Surface Preparation Methods

5.3 Extent of Painting

All surfaces subject to weathering, rushing or corrosion by exposure to the elements of corrosion like all un-
insulated Carbon Steel & Alloy Steel equipment like vessels, storage Tanks, Exchangers, piping including all of its
components like flanges, fittings, valves and other miscellaneous inline components, all insulated parts of the
equipment and piping as per the technical requirements specified in the codes and in this specification, all
structural steel components etc.

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The following are not to be painted and must be protected from painting -
 Un-insulated austenitic stainless steel
 Porcelain, Gauge Glasses, Meter Faces
 Insulation
 Valve Stems and Threads
 Equipment/ Instruments Name Plates/ tags
 Nonferrous piping like Aluminium, Cu-Ni or monel.
 Fireproofing
 Galvanized surface
 Factory Finished Control Panels, Finished Instrument Cases and Meters
 Polished and machined surfaces e.g. flange facings

5.4 Responsibilities of the Paint Applicator

The EPC CONTRACTOR shall be responsible for the following activities -
a. Supply and application of all paint materials, labour, supervision, coating equipment, inspection tools and
each and every item of expense necessary for complete application of the paint system.

b. Supply, erection and removal of scaffolding to perform the painting work.

c. Removal of identification marks on bare or unfinished equipment, piping and structural steel and
reapplication of the identification marks on the finished surfaces.

d. Full protection from abrasives and paints to items, which shall not be painted.

e. Cleaning and application of painting systems on welded and damaged surfaces.

f. Collection and disposal of all toxic waste materials from the work site as directed by the OWNER.

g. Preparation of appropriate work planning and taking all precautions to avoid interference with the execution
of work of other EPC CONTRACTORS.

h. Obtaining the OWNER’S releases that the equipment is certified safe and available and that all appropriate
tests are completed before starting any painting work.

i. Earthing of abrasive blast cleaning / painting equipment and paint containers.

j. Application of the paint systems to the extent stated in the procurement documents in accordance with this
Specification and all other relevant documents such as site regulations, safety rules, referenced standards
and codes, etc.

k. Maintenance of the paint work until completion of the contract. This shall include the repair of any damage
caused by third parties responsible to the EPC CONTRACTOR.

l. Repair work of damaged pre-erection/ fabrication and shop primer and weld joints in the field/site before
and after erection as required

m. Quality control, testing and inspection during all stages of work (surface preparation, application of coating
and testing of furnished coating)

5.5 Materials
 All paints used shall be obtained from Manufacturers approved by the OWNER.

 All paints and painting materials shall be stored only in rooms to be arranged by EPC Contractor and
approved by Owner/PMC for the purpose. All necessary precautions shall be taken to prevent fire. The
storage building shall preferably be separate from adjacent building. A signboard bearing the word "Paint
Storage –No Naked Light- Highly Inflammable" shall be clearly displayed outside. Manufacturer's
recommendation shall be followed for storage of paint materials.

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 All material shall be supplied in the Manufacturer's original containers, durably and legibly marked with the
description of the contents. This shall include the specification number, the colour reference number, the
method of application for which it is intended, the batch number, date of manufacture, the shelf-life expiry
date and the Manufacturer's name or recognised trade mark.

 Different brands or types of paints shall not be inter-mixed.

 The storage and preparation of paints and other coating materials shall be in accordance with the
Manufacturer's instructions.

 Samples for testing the paint being used may be taken by the OWNER at any time. Should a sample fail to
meet the required specification, the EPC Contractor shall remove this paint from areas already covered and
recoat them with paint that meets the specification.

 Test methods for above tests shall be as per relevant ASTM or ISO Standard.

5.6 Tools & Accessories

All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning and all equipments,
scaffolding materials, shot & grit blasting equipments & air compressors etc. required to be used shall be suitable
for the work and all in good order and shall be arranged by the contractor at site and in sufficient quantity. The
manufacturer’s test certificates / data sheets for all the above items shall be reviewed by Owner/PMC at site
before start of work.

5.7 Surface Preparation

The type of surface preparation shall be in accordance with Annexure 1 of painting specification.

5.7.1 Abrasive blasting

 Basic Cleaning
Dust, dirt and debris shall be removed from the substrate surfaces by high pressure fresh water washing.
Stubborn deposits shall be removed by scrubbing with stiff plastic brushes. The water wash shall continue
until all water soluble salts are removed from the surfaces. All oils and grease contamination shall be
removed from the surface in accordance with SSPC-SP-1, ‘Solvent Cleaning’ and using bio-degradable
water soluble cleaner prior to blasting. The degreased surfaces shall be further washed with fresh water to
remove all traces of the cleaner chemicals. The surfaces shall be allowed to thoroughly dry before
proceeding with any further coating work.

 Weather Conditions
No surface preparation or application paint shall take place under the following conditions -
i. Air temperature is below 10 °C or the surface temperature is below 5 °C
ii. Relative humidity is 85% or above
iii. Rain, mist or fog is present
iv. Wind speed above 25 kmph
v. Atmosphere contaminated by dirt, dust, oil, product or any other pollutant.
vi. In case of internal coating of storage tanks, dehumidifier shall be used, to control humidity level
below 60%.

 Abrasive blast cleaning

i. The Steel surface shall be cleaned by abrasive blast cleaning.
ii. All rough welds, burrs, silvers, laminates, porosity, weld splatter and surface projections shall be
ground smooth or filled prior to and after blasting operations prior to coating.
iii. Sand blasting or other material producing silica shall not be used. Abrasive to be used for blast
cleaning carbon steel and low alloy steel surfaces are listed below as specified in ISO-8504-2.
o Chilled Iron Grit or Shot
o Non & metallic Iron Grit or Shot
o Non Metallic Abrasive (Aluminum, Oxide, Copper Slag Garnet)
o Grit Spec-Particles that are predominately angular have fractured faces and sharp
edges and are less than half round in shape.

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o The quality of abrasives shall be free from contaminants and impurities.

o Vendor shall follow SSPC AB 1 and SSPC AB 2, as applicable.
o On completion of blasting operation, the blasted surface shall be clean and free from
any scale or rust and must show a grey white metallic luster. Primer/first coat of paint
shall be applied within 4 hours of surface preparation. Surface profile shall be uniform to
provide good key to the paint adhesion (i.e. 35 to 50 microns).

The compressed air for blasting and coating shall be free of water, oil and other contaminants. Air
compressor shall not be allowed to deliver air at a temperature above 110 °C. Equipment such as air dryer,
filters, coolers, and other equipment necessary for clean dry air shall be the responsibility of the EPC
Contractor. Owner will not provide plant, utility or instruments air for blasting and coating purposes.

All abrasive shall be removed by brush, air blast or vacuum type cleaner prior to applying primer. Care shall
be exercised to assure that the cleaned surface is not contaminated with any foreign material or fingerprints
prior to applying primer.

Blast cleaned surfaces shall meet the requirements of the surface preparation standard specified for the
particular situation.

Surface preparation shall be subject to inspection before the prime coat is applied to ensure all traces of
dust and foreign matter including soluble salts have been removed by brushing, blowing with clean
compressed air, or vacuum cleaning. The surface profile, of a blast cleaned surface, shall also be subject
to inspection prior to application of the prime coat.

Use of De-humidifier
o Blast cleaning shall not be performed for internal or external surface, where dust can contaminate
surfaces undergoing such cleaning or during humid weather conditions having humidity exceed
85%. In case of internal coating of storage tanks, dehumidifier shall be used, to control humidity
level below 60%. Dehumidifier should depress the dew point of air in the enclosed space, sufficient
enough so as to maintain it 3°C below the metal substrate temperature during entire period
of blasting and coating application. During the interval time between application of primer coat and
subsequent intermediate and top coats or between blast cleaning completion and start of
application of primer coat, dehumidifier unit should be in continuous operation to ensure that no
condensation occurs on substrate.

o Dehumidifier should be able to maintain grain drop (moisture removal) at the rate of 25 grains per
pound of air per hour. Dehumidifier should have capacity of at least 2 air changes per hour of the
enclosed space. All necessary psychometric data should be collected by contractor for the given
site conditions before starting operation of dehumidifier to ensure that desired values of dew point,
moisture content in enclosed scope is achieved.

o Dehumidification shall be maintained round the clock for surface preparation and painting till the
total coating application is over.

o Dehumidifier shall not be stopped under any condition till the entire blasted surface is primed to the
satisfaction of the technical representative of the paint manufacturer interested with quality
assurance for the work. In case the dehumidifier breaks down in middle of the job, the same shall
be replaced at the risk and the cost of the contractor and the entire unfinished work shall be
repeated.

o The Owner/PMC shall have the right to disallow usage of dehumidifier if the performance is not
meeting the specified requirements. Under such circumstances the contractor shall remove the
equipment and replace the same with another equipment to provide satisfactory results without any
additional cost to the owner.

o Irrespective of the method of surface preparation, the first coat of primer must be applied by airless
spray / air assisted conventional spray if recommended by the paint manufacturer on dry surface.
This should be done immediately and in any case within 4 hours of cleaning of surface. However,

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at times of unfavorable weather conditions, the Owner/PMC shall have the liberty to control the
time period, at his sole discretion and/or to insist on re cleaning, as may be required, before
primer application is taken up. In general, during un-favourable weather conditions, blasting and
painting shall be avoided as far as practicable.

5.7.2 Power Tool Cleaning

Power tool cleaning if required shall be done by mechanical striking tools, chipping hammers, grinding wheels or
rotating steel wire- brushes. Excessive burnish of surface shall be avoided as it can reduce paint adhesion. On
completion of cleaning, the detached rust mill scale etc. shall be removed by clean rags and /or washed by
water and thoroughly dried with compressed air jet before application of paint. Generally the power tool cleaning
is required for the maintenance painting or the repair of already done painted surface which is damaged during
the erection stage.

5.8 Painting Application

5.8.1 Preparation for painting
 Storing, thinning, mixing and handling, of paint materials shall be in accordance with the manufacturer’s
recommendations. All containers shall remain closed in factory sealed containers until required for use.
Each container must have full identification information including manufacturer’s name, product
identification, and batch number, date of manufacture, shelf life, basic instructions.

 All aspects of safety relating to the use of coatings and associated thinners shall be in complete
accordance with the MANUFACTURER’S stated requirements.

 Mixing of different brands or generic types of coating materials is not allowed. On-site mixing of
approximate proportions is not permitted. All mixing shall be done using factory proportioned containers
only.

 Ends of pipe and related components, weld joints, structural steel, and like areas of other items that will
require subsequent welding at site, shall be masked off after blast cleaning and left uncoated.

5.8.2 Paint Application Procedure

 Surfaces shall be painted with paint systems specified in Annexure-1.

 Paint shall be applied to dry, clean, prepared surfaces under favourable conditions.

 Pigmented and catalyzed materials shall be thoroughly mixed using power mixers before being applied.
Sticks shall not be used.

 Extra coats of paint shall be applied on areas where shape and/or plane of application results in thinly
applied coating; e.g., at edges, welds, corners, etc. To compensate for these effects, a stripe coat of
paint shall be brush applied before applying the full coat.

 All coatings shall be uniformly applied without runs, sags, solvent blisters, dry spray or other blemishes.
All blemishes and other irregularities shall be repaired or completely removed and recoated. Special
attention shall be paid to crevices, corners, edges, weld lines, bolt heads, nuts, and small brackets, to
apply the specified minimum dry film thickness by brush application if spray will not completely cover all
surfaces.

 Surfaces that will be inaccessible after assembly shall receive the complete painting system before
being assembled.

 Inter-coat contamination shall be minimized by maintaining proper cleanliness and by applying

intermediate and finish coats within the time period recommended by the manufacturer.

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 The preferred method of coating application shall be conventional or airless spray. Pneumatic spray
coating shall not be carried out when temperature is less than 4 °C or more than 40 °C. Traps or
separators shall be provided to remove oil and water from the air. The air from the spray gun impinging
on the steel substrate shall show no condensed water or oil. Compressed air for blasting and coating
shall be free of all moisture, oil and other contaminants. Brush or roller application may be used for
touch up and repair or when area cannot be coated with spray.

a. Spray Application
Hose and containers shall be thoroughly cleaned before addition of new materials. The spray
gun shall be held no closer than 200 mm or more than 600 mm from the surface to be coated.
During application the spray gun shall always be held at a right angle to the substrate. Each
pass shall overlap the previous one by 50 percent. In order to achieve a uniform application,
when large surface areas are being coated, spray application shall be made in two directions so
that the passes are at right angles to each other. Pressures and spray fan shall be adjusted so
that the optimum spray pattern is utilized for the surface being coated.

Spraying should be continuous until all material is used up avoiding long periods of pause.
Each coat shall be in proper state of cure or dryness before the application of succeeding coat.
Manufacturer instruction shall be followed for inter-coat interval. Wet film thickness gauges shall
be used during application to ensure proper film build. Wet film thickness gauges shall be used
during application to ensure proper film build.

b. Brush Application
Application with brush is only acceptable under the following conditions -
 When areas cannot be properly coated by spray for any reason or when spray
application is difficult due to location of work and wind conditions.
 For touch-up or repair of localized damaged paint or to areas of incorrectly applied
paint.
 For painting of stripe coat.
 When applying the initial coat of paint to corners, edges, crevices, holes, welds or other
irregular surfaces prior to spray application.

The number of coats shall be adjusted to comply with the dry film thickness requirements. Paint
brushes used shall be of a style and quality that will permit appropriate application of the
material being applied. Material applied by brush shall be smooth, uniform in thickness, without
any apparent surfaces defects such as brush marks, runs, sags, or curtains.

5.8.3 Drying
No coat shall be applied until the preceding coat has dried. The material shall be considered dry for re-coating
when another coat can be applied without the development of any film irregularities such as lifting or loss of
adhesion of undercoats.

No paint shall be force dried as it may cause deterioration in the painted surface quality like wrinkling, blister
formation at the surface etc.

Paint shall be protected from rain, condensation, contamination, snow and freezing until dry to the fullest extent
practicable.

5.8.4 Repairs
Before application of any further coat of material, all damage to previous coats shall be repaired to specification
requirements.
Surface preparation shall wherever possible be carried out by dry blast cleaning. If dry blast cleaning is not
feasible then manual cleaning shall be performed. Manual cleaning shall be performed using hand wire brushes,
or mechanically operated tools (grinders, chippers, wire brush etc.) in accordance with ISO 8504-3. The surface
shall be left roughly abraded, but a burnished surface is not acceptable.

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If the surface being prepared lies adjacent to a sound coated surface, which is not to be repaired, the surface
preparation shall overlap the coated surface by at least 25 mm. Inorganic zinc primer shall not overlap adjacent
intermediate and finish coats.

Areas with inadequate coating thickness shall be thoroughly cleaned and, if necessary, abraded, and additional
compatible coats applied until they meet this specification. Colour match shall be achieved.

Non-Compatible Shop Coat Primer

 For equipment on which application of total protective coating (Primer+ Intermediate + top coat) is carried
out at shop, compatibility of finish coat with primer should be checked with paint manufacturer. If the shop
coat is in satisfactory condition showing no major defect upon arrival at site, the shop coat shall not be
removed.
 Shop coated equipment {coated with Primer & finishing coat) should not be repainted unless paint is
damaged.
 Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas by means of power
tool brush cleaning or hand tool cleaning and then spot primed before applying one coat of field primer
unless otherwise specified. If shop primer is not compatible with field primer then shop coated primer
should be completely removed before application of selected paint system for particular environment.
 For Package units/equipment, shop primer should be as per the paint system given in this specification.
However, manufacturer's standard can be followed after review.
 Coating application at field (field primer, intermediate and top coat) on equipment, structures, piping, etc.
shall be carried out only after its erection and all welding, testing, purging (wherever carried out) have
been completed.

5.9 Inspection and Testing

 All painting materials including primers and thinners brought to site by contractor for application shall be
procured directly from manufactures as per specifications and shall be accompanied by manufacturer's test
certificates.

 The painting work shall be subject to inspection by Owner/PMC at all times. Stage-wise inspection will be
performed for the surface preparation, primer application and finish paint application. EPC Contractor shall
offer the work for inspection and approval of every stage before proceeding with the next stage.

 All prepared surfaces shall be subject to inspection by OWNER/ OWNER’S REPRESENTATIVE and
approval before primer is applied. Acceptance of the blast cleaned surface will be made by OWNER’S
REPRESENTATIVE based on visual comparison with ‘Anchor Pattern Standards’ or ‘Surface Profile
Comparator’. EPC Contractor shall maintain surface preparation cleanliness per SSPC VIS 1 or SSPC VIS
3 (Visual Standards). Measurement of surface profile shall be per ASTM D 4417 and ISO 8502.

 Measurement of paint dry film thickness shall be made with an Elkometer or similar approved gauge for
each coat of the total system. The dry film thickness measurement shall be per ISO 2808. Measured DFT
shall be within + 10% of the dry film thickness, specified in the specifications.

 Adhesion of the primer to the steel substrate and inter-coat adhesion of the subsequent coats after curing
for at least a week after application of the topcoat shall be examined by a knife test in accordance with
ASTM D 6677. The adhesion test is destructive and tested areas shall be repaired afterwards.

 The painted surfaces will be subject to a random holiday test to verify painting is holiday free in accordance
with ASTM D5162.

 The EPC Contractor’s QA/QC representative shall ensure 100% of the painted area is devoid of any bare
metal and is free of holiday. The EPC Contractor’s QA/QC representative shall also ensure that the DFT
requirements and colour codes have been achieved as per the requirements of this specification.

 All pipes shall have the proper colour code bands per the process fluid service for ease of identification.

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 Acceptable finish work must be free of abrasions and must be uniform in color and appearance.

 Further following requirements are to be met with respect to inspection and testing -
a. The EPC Contractor must produce Test Certificate from Paint Manufacturer for various tests
as specified in this document, for each batch and for each category of product. The Owner/PMC
shall have the right to test wet samples of paint from each batch at random for verifying quality of
paint supplied. EPC Contractor shall arrange to have such tests, when called for by Owner/PMC,
performed at his cost any one of the independent laboratories listed in this document. Samples for
the test will be drawn at random in presence of Owner/PMC or his representations. Following tests
to be carried out if called for by Owner/PMC -
 Specific Gravity
 % solids by weight (% zinc content in case of inorganic or organic zinc primer)
 Drying time (touch dry & full curing)
 Adhesion
 Flexibility
 Hardness
 Storage stability (pot life)

Test methods for above tests shall be as per relevant ASTM or ISO Standard.

b. During surface preparation, following tests are to be carried out -

 Test for absence of oil and grease after degreasing before blasting.
 Tests for surface finish of blasted surface shall be done by visual inspection using SSPC-
VISl. Clear cellophane tape test as per ISO 8502-9 shall be used to confirm absence of
dust on blasted surface. Checks shall be done on each component at least once per 200
m2 of blasted surface and minimum of 3 checks per shift.
 Test for presence of soluble salt as per method ISO 8502-9. Maximum allowable salt
content shall be considered 20 mg /m2 (2 mg /cm2). Checks shall be done on each
component at least once per 200 m2 of blasted surface and minimum of 3 checks per
shift. In case salt exceeds specified limit, the contaminated surface shall be cleaned by
method as per Annexure-C of IS: 12944-4 (water cleaning). After cleaning surface shall
be retested for salt after drying.
 Blast profile measurement.
Test for blasting Media and Blasting air- In addition to above, record should include type
of shop primer already applied on equipment e.g. zinc silicate, or zinc rich epoxy, or zinc
phosphate. Any defect noticed during the various stages of inspection shall be rectified by
the contractor to the entire satisfaction of Owner/PMC before proceeding further.
Irrespective of the inspection, repair and approval at intermediate stages of work,
contractor shall be responsible for making good any defects found during final
inspection/guarantee period/defect liability period as defined in general condition of
contract. Dry film thickness (DFT) shall be checked and recorded after application of each
coat and extra coat of paint should be applied to make- up the DFT specified without any
extra cost to owner, the extra coat should have prior approval of Owner/PMC.

c. Primer Application: After surface preparation, the primer should be applied to cover the crevices,
comers, sharp edges etc. in the presence of inspector nominated by Owner/PMC.

d. The shades of successive coats should be slightly different in colour in order to ensure application
of individual coats, the thickness of each coat and complete coverage should be checked as per
provision of this specification. This should be approved by Engineer-In- Charge before application of
successive coats.

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e. The contractor shall provide standard thickness measurement instrument with appropriate range(s)
for measuring.
 Dry film thickness of each coat,
 Surface profile gauge for checking of surface profile in case of sand blasting.
 Holiday detectors and pinhole detector and protector whenever required for checking in
case of immersion conditions.

f. Prior to application of paints on surfaces, the thickness of the individual coat shall be checked by
application of each coat of same paint on M.S. test panel. The thickness of Paint on test panels
shall be determined by using gauge such as 'Elkometer'. The thickness of each coat shall be
checked as per provision of this specification. This shall be approved by Owner/PMC before
application of paints on surface.

g. At the discretion of Owner/PMC, the paint manufacturer must provide the expert technical service at
site as and when required. This service should be free of cost and without any obligation to the
owner, as it would be in the interest of the manufacturer to ensure that both surface preparation and
application are carried out as per their recommendations. The contractor is responsible to arrange
the same.

h. Final inspection of finished coating shall consist of measurement of -

 Paint dry film thickness (DFT),
 Adhesion, and,
 Holiday detection check as well as for finish and workmanship.

Coating DFT measurement shall be as per ISO: 2808. Type II electromagnetic gauges should be
used for ferrous substrates. DFT gauge calibration, number of measurement shall be as per SSPC-
DA 2. Measured DFT shall be within + 10% of the dry film thickness, specified in the specifications.

i. Adhesion of the primer to the steel substrate and intercoat adhesion of the subsequent coat(s) after
curing for at least a week after application of the topcoat shall be examined by a knife-test in
accordance with ASTM D 6677. For the knife test, if the rating is better than 8, the adhesion is
considered acceptable. The adhesion is detective and:-tested areas shall be repaired afterward
using the spot repair procedure. Alternatively, the applicator may perform the adhesion test on a
steel coupon coated using the same surface preparation and coating application procedure as the
work piece. Adhesion testing shall be carried out for each component at least once per 200 m2
(2000 ft2) of coated surface.

j. Holiday testing shall be conducted in accordance with NACE SP Oi88. For immersion services,
100% of coated area shall be inspected for holidays. For atmospheric exposure, 10% of coated
area which must include weld seams, comers and edges to be holiday tested. Voltage at which test
is to be carried out will depend upon DFT of coating being tested and shall be as per NACE SP
0188. Any holiday is unacceptable and should be marked and repaired immediately.

k. The contractor shall arrange for spot checking of paint materials for Specific gravity, glow time (ford
cup) and spreading rate.

l. Final Inspection of coating system

A final inspection shall be conducted prior to the acceptance of the work. The Contractor and the
Owner / Owner/PMC shall both be present and they shall sign an agreed inspection report. Such
reports shall include -
 General
Names of the painting Contractor and the responsible personnel - Dates when work was
performed

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 Painting Materials
Information on painting materials being applied - Condition of painting materials received

 Environmental Conditions
Weather and ambient conditions - Painting periods

 Surface Preparation
o Condition of surface before preparation
o Tools and methods used to prepare surface
o Condition of surface after preparation

 Painting Application
Equipment used - Mixing procedure prior to application - Coating application techniques
used.

 Testing
Type and calibration of inspection instruments used - Type of quality control tests
performed, and results

m. Method of sampling & dispatch for laboratory testing (Pre-Qualification tests, Batch testing and
Inspection testing)
 Samples of coating materials should be submitted to the Govt. laboratory in sealed
containers with batch no. and test certificate on regular format of manufacturer's testing
laboratory. The sampling shall be certified and sealed by a certifying agency.
 All test panels should be prepared by Govt. testing agency coloured photographs of test
panels should be taken before and after the test and should be enclosed along with test
report.
 Sample batch no. and manufacturer’s test certificate should be enclosed along with the
report. Test report must contain details of observation and rusting if any, as per the
testing code.
 Manufacturers should intimate the company, details of sample submitted for testing,
name of Govt. testing agency, date, and contact personnel of the govt. testing agency. At
the end of the test the manufacturer should submit the test reports to the company for
approval.
 Coating systems for panel test shall be decided after discussion with Owner
 Test shall be carried out at any one of the following laboratories and tests to be witnessed
& certified by third party inspection agency (TUV, BY, DNV)
o IICT, Hyderabad
o HBTI, Kanpur
o DMSRDE, Kanpur
o BIS Laboratories
o UICT, Matunga, Mumbai
o RITES, Kolkata
o PDIL,-Sindri
o NTH, Kolkata

5.10 Conflicts, Deviations and Clarifications

 Any conflicts between this specification and other applicable Engineering Standards, Material
Specifications, Standard Drawings, Engineering Procedures, Company Forms or Industry standards,
specifications, Codes and forms shall be brought to the attention of Owner’s Authorized Representative
by the EPC Contractor for resolution.

Until the resolution is officially made by the Owner’s Authorized Representative, the most stringent
requirement shall govern.

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 Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it
shall be brought to attention of Owner’s Authorized Representative by EPC Contractor for resolution.

 Direct all requests for deviations or clarifications in writing to the Owner’s Authorized Representative for
final resolution.

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Document Number : D10-PMC-JSF-015

5.11 Annexure-1 (Painting Systems)

Design Surface Primer Interm. Finish

System Service Temp Prep. (DFT in Coat (DFT Coat (DFT Remarks
(Deg C) SSPC µm) in µm) in µm)
Acrylic–
Inorganic High Build
Structural Steel, Un-insulated Piping, Equipment’s Except Storage

Polyuretha
Zinc Polyamide
≤ 80 Deg SSPC-SP- ne
System 1 Silicate Epoxy
C 10 DFT: 60-
DFT: 60- DFT: 90-
75 µm
75 µm 110 µm
Inorganic
Silicone Silicone
81 Deg Zinc
SSPC-SP- Acrylic Acrylic
System 2 C to 200 Silicate
Tanks (For CS, LTCS & AS

10 DFT 30 DFT 30
Deg C DFT: 60-
µm µm
75 µm
Heat Heat
resistant resistant
Inorganic
Silicone Silicone
201 Deg Zinc
SSPC-SP- Aluminium Aluminium
System 3 C to 400 Silicate
10 paint paint
Deg C DFT: 60-
DFT 25 DFT 25
75 µm
µm µm

Heat Heat
resistant resistant
Silicone Silicone
401 Deg
SSPC-SP- Aluminium Aluminium
System 4 C to 538 NIL
10 paint paint
Deg C
DFT 25 DFT 25
µm µm

1 coat of
synthetic fast
1 layer of
External painting of Under-ground carbon steel piping

Synthetic drying primer

coal tar
fast drying Coaltar 25 @μ DFT/
tape
Up to 65 SSPC-SP- primer 25 tape coat is to be
System 5 coating @
Deg C 10 @μ DFT/ coating @ applied
2mm
coat 2mm between
/layer
intermediate
and final
coats

Epoxy Epoxy Epoxy

phenolic/ phenolic/ phenolic/
novalac novalac novalac
66 Deg epoxy epoxy epoxy
SSPC-SP-
System 6 C to 150 phenolic phenolic phenolic
10
Deg C coating coating coating
DFT: 120 DFT: 120 DFT: 120
µm µm µm

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Document Number : D10-PMC-JSF-015

Design Surface Primer Interm. Finish

System Service Temp Prep. (DFT in Coat (DFT Coat (DFT Remarks
(Deg C) SSPC µm) in µm) in µm)
Carbon steel, LTCS and low Alloy Epoxy Epoxy
steel Piping Under Insulation phenolic phenolic
Up to
SSPC-SP-
System 7 125 Deg NIL
10 DFT: 125 DFT: 125
C
µm µm

Heat Heat Heat

resistant resistant resistant
126 Deg Silicone Silicone Silicone
SSPC-SP-
System 8 C to 540 Aluminium Aluminium Aluminium
10
Deg C DFT 25 DFT 25 DFT 25
µm µm µm

Inert Inert Inert

SSPC SP-
polymeric polymeric polymeric
1 with
matrix matrix matrix
Up to 0 non-
System 9 coating coating coating
Deg C chloride
Stainless Steel Piping Under Insulation

DFT: 125 DFT: 125 DFT: 125

solvent
μm μm μm

SSPC-SP-
10
Epoxy Epoxy Epoxy
(15-25μ
0 Deg C phenolic phenolic phenolic
surface
System 10 to 125 coating coating coating
profile) by
Deg C DFT: 75 DFT: 75 DFT: 75
Aluminium
μm μm μm
oxide grits

SSPC-SP-
Epoxy Epoxy Epoxy
10
poly poly poly
(15-25μ
126 Deg Siloxane Siloxane Siloxane
surface
System 11 C to 400 Coating Coating Coating
profile) by
Deg C DFT: 75 DFT: 75 DFT: 75
Aluminium
μm μm μm
oxide grits

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Document Number : D10-PMC-JSF-015

5.12 Annexure-2 (Colour Coding)

5.12.1Scope
This annexure defines the color coding requirement of piping to identify the contents of piping carrying different
fluids at site.

5.12.2Identification
The system of colour coding consists of a ground colour or 1 metre band and secondary colour bands
superimposed over the ground colour/ band colour. The ground colour identifies the basic nature of the service
and secondary colour band over the ground colour distinguishes the particular service. The ground colour shall
be applied over the entire length of the un-insulated pipes. For insulated lines ground colour shall be provided
as per specified length of 1 metre and at specified intervals to identify the basic nature of service and secondary
colour bands to be painted on these specified length to identify the particular service.

The following ground colour designation for identification of basic classification of various important services
shall be followed -
Post Office Red : Fire Protection Material
Canary Yellow : Chemicals and dangerous materials
Dark Admiral grey : Crude Lube oil
Orange : Volatile petroleum products (Motor spirit & Lighter)
Oxide Red : Non-volatile petroleum products (Kerosene & Heavier)
Sky Blue : Water
Sea Green : Air & its Components and Freon

5.12.3Colour Bands & Identification Lettering

Color bands and size of lettering for piping shall be as below -

Outside Diameter of pipe Width of color bands Size of legend

or covering in mm in mm letters in mm
19 to 32 200 13
38 to 51 200 19
64 to 150 300 32
200 to 250 600 64
Over 250 800 89

Either white or black letters are selected to o maximum contrast to the band color. Bands usually are 50 mm
wide and regardless of band width are placed 25 mm apart when two bands are employed.

Size of the letters stenciled for the equipment shall be as below -

o Vessels - 150 mm height
o Pumps, Compressors and other machines - 50 mm height

In addition the direction of flow in a line is to be indicated with the help of arrows and legend.

Color bands: The location, size of bands shall be as below -

o On both sides of the valves, tees and other important fittings
o Where the pipe emerges or enters in to wall, emerges from walkways/ bridges, overpasses, battery
limit.
o At uniform intervals along long sections of pipes
o Adjacent to tanks, vessels and pumps.

Color band specification -

o Bands at intervals of 6 metres.
o Each pipe segment irrespective of length shall have band identification.
o For stainless steel pipes/ fittings/ flanges valves etc. the color band (min. 0.5 inch wide) should be
applied along the length of the items.

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The following table shall be followed for the color coding -

RAL NUMBER RAL NUMBER

ITEM COLOUR FOR BASE FOR BAND
COLOR COLOR
AIR LINES
PLANT AIR/ SERVICE Sea green with 1 signal red
6018 3001
AIR/ COMPRESSED AIR strip
INSTRUMENT AIR Sea green with 1 black strip 6018 9005
NITROGEN Milky White 9016 -
GAS LINES
Orange with 1 light green
HYDROGEN 2011 6021
strip
OXYGEN Sea Gren with 1 blue strip 6018 5013
Orange with 3 oxide red
NATURAL GAS 2011 3009
strips
CHLORINE Canary yellow with 1 oxide 1012 3009
red strip
ZERO AIR Sea Green with 1 white band 6018 9010
Sea Green with 2 white
ARGON 6018 9010
bands
CARBON MONO-OXIDE Sea Green with 1 black band 6018 9005
Sea Green with 2 black
CARBON DIOXIDE 6018 9005
bands
Sea Green with 1 Aluminium
HELIUM 6018 9006
Band
WATER LINES
POTABLE WATER Sky blue with 1 green strip 5015 6010
Sky Blue with 3 Signal Red
FLUSHING WATER 5015 3001
Strips
COOLING WATER Sky Blue with 1 Brown Biege
5015 1011
SUPPLY/ RETURN Strip
CHILLED WATER Sky Blue with 2 Viloet Blue
5015 5000
SUPPLY/ RETURN Strips
FIRE WATER Post Office Red 3002 -
DOMESTIC COLD
Sky Blue with 2 red signal red
WATER/ DOMESTIC HOT 5015 3001
strips
WATER
RAW WATER Sky blue with 1 black Strip 5015 9005
CONDENSATE Sky blue with 1 white strip 5015 9010
Sky Blue with 2 Brown Biege
HOT WATER- HVAC 5015 1011
Strips
Sky Blue with 1 red signal red
SERVICE WATER 5015 3001
strip
TEMPERED WATER Sky blue with 2 green strips 5015 6010
INDUSTRIAL WATER Sky blue with 2 signal red 5015 3001
strip
TREATED WATER Sky blue with 1 oxide red 5015 3009
strip
ETP TREATED WATER Sky blue with 2 oxide red 5015 3009
strips
HYDROCARBON/ MISCELLANEOUS
HIGH SPEED DIESEL Oxide red with 1 white strip 3009 9010
SLOP Black with 1 orange band 9005 2011

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6. INSULATION
6.1 Scope
This Specification stipulates the design, supply and methods for application of external insulation for piping for
operation in hot service or cold service and personnel protection.

Insulation is required to conserve heat of piping and equipment, to control process temperatures (avoid
condensation, solidification, or excessive viscosity of fluids and materials) and to provide personnel protection.

6.2 Reference Codes and Standards

EPC Contractor shall meet or exceed the requirements of the latest edition of the following codes, regulations and
standards as applicable.

ASTM B209 M Aluminum and Aluminum–Alloy sheet and plate (Metric)

A 167 Stainless and Heat Resistant Chromium Nickel Steel Plate, Sheet and Strip

ASTM C195 Mineral fibre thermal insulating cement

OISD 177 Inspection and Maintenance of Thermal Insulation

NFPA 274 Standard test method to evaluate Fire performance characteristics of Pipe Insulation

ASTM C547 Mineral Fibre pipe insulation

ASTM C612 Specification for Mineral Fiber Block and board thermal insulation

ASTM C795 Thermal insulation for use in contact with austenitic stainless steel

ASTM C892 High - Temperature Fibre Blanket Thermal Insulation

ASTM C592 Mineral Fibre Blanket Insulation and Blanket-Type Pipe Insulation
(Metal-Mesh Covered) (Industrial Type)

ASTM C 871 Chemical Analysis of Insulation Materials

BS 874 Part 2 Methods for determining thermal insulating properties

ISO 8497 Thermal Insulation- Determination of steady state thermal

transmission properties of thermal insulation for circular pipes

BS 476 Part 6 Method of test for Fire propagation for Products

BS 476 Part 7 Method for classification of the surface spread of flame of products

DIN EN 12667 Thermal performance of building materials and products

DIN 53122 Determination of water vapour transmission (density of moisture flow rate) of plastic
films, paper, board and other sheet materials- Electrolysis Method

DIN 52615 Testing of Thermal Insulating Materials

DIN EN 12086 Thermal insulating products for building applications – Determination

of water vapour transmission properties

DIN EN 13469 Thermal insulating products for building equipment and industrial installations -
Determination of water vapour transmission properties of preformed pipe insulation

ISO 5659 Determination of optical density by a single-chamber test

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BS 6853 Fire Test to wire or Cable

DIN 52616 Testing of thermal insulation materials; determination of thermal conductivity by means
of a heat-flow meter

6.3 General Design

Insulation is required on the piping for any of the following purposes, as indicated in the Process/ Utility P&IDs,
line lists, Instrument lists -
 Heat conservation (H)
 Electric tracing (E)
 Personnel Protection (PP)
 Fire Protection
 Conservation of Cold temperature (IC)

Insulation for personnel protection shall be provided as follows on all piping and equipment adjacent to work
platforms or other operating areas where the maximum operating bare metal temperature exceeds 60 C or the
temperature is below -10 Deg C.. The actual extent of insulation shall be determined by Field Construction
Personnel and/or operating personnel using the criteria that the exposed surfaces located within 750mm
horizontally or 2200mm vertically of a normal access, walkway or work area are to be insulated.

Extent of Insulation
 All components of a piping system shall be hot insulated including the pipes, fittings, flanges except valves
and flanges which shall be insulated in lines where the operating temperature is more than 300 Deg C.
 The insulation shall be done as shown on PIDs. Lines in which the heat loss is desired shall not be
insulated except for the personal protection reasons to the extent required.
 Heat traced instrumentation when specified shall be insulated.
 Insulation is not required on the expansion joints.
 Supports of piping shall not be insulated in case of hot insulation.
 When cold insulation is required, the entire system shall be fully insulated to such an extent that all piping
components, piping/tubing of instruments, drains, equipment nozzles and supports are properly included.

6.4 Materials
6.4.1 General
 All materials must be non-corrosive, compatible with other material and used in accordance with the
manufacture’s recommendations. All materials supplied shall be new and undamaged. All insulation
material shall be properly stored and protected from humidity, moisture, rain, dust, dirt, sand, mud etc.

 Insulation materials shall be of high quality and good appearance. Insulation materials shall be of low
chloride content and chemically inert. It must be non-injurious to health and must not contain asbestos in
any form.

 All insulation shall be rigid and self-supporting. When installed the insulation shall fit snugly and shall
have a tight joint.

 All insulation materials selected shall conform to the regulations of the latest edition of the occupational
health and & safety act and all other applicable standards.

 Insulation materials to be used over austenitic stainless steel surfaces shall not have zinc and shall be
inhibited with sodium silicate as per ASTM C-795. The amount of leachable chloride in the insulation
material shall not exceed l0 ppm. For the chemical analysis of insulation materials ASTM C-871 shall be
referred.

 All insulation materials shall be stored in moisture-proof containers.

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 An important requirement of a cold insulation system is to prevent water ingress into the insulation. The
presence of water as vapour, liquid or ice in the insulation will decrease its insulating value and may
eventually lead to corrosion of the insulated metal surfaces. In order to prevent water ingress and
corrosion, the vapour barriers and metallic jacketing should be properly selected and applied and all
insulated metal surfaces shall be suitably painted.

6.4.2 Hot Insulation Material

 The hot insulation material shall be in the form of preformed insulation and shall be fibred rock material
processed from a molten state into fibrous form bonded with a binder. The hot insulation material shall
be suitable for the intended operational temperature range from ambient to 550 °C. The insulation
material shall not be made up of Slagwool. Glasswool shall also be acceptable for operating
temperatures up to 350 °C.

 The rockwool preformed pipe sections shall conform to ASTM C547 Type II or III. Whereas the mineral
wool fibre blanket shall conform to ASTM C592 CLASS II. The density shall be 140 kg/m3 for the pipe
sections and 130 kg/m3 for blankets. The thermal conductivity for preformed pipe sections shall be 0.061
W/mK at 200°C and for the mineral wool blanket, the same shall be 0.057 W/mK at 200°C.

 Blankets shall be faced on one side with 25mm GI/Stainless Steel (SS 304/SS 316) 22 SWG wire-mesh
stitched through with 22 SWG GI/SS lacing wire. SS wire mesh to be used in insulation over stainless
steel lines.

 Rigid Polyisocyanurate / Polyurethane foam block, pipe and fitting insulation shall be manufactured with
polyester or polyether resins, flammability retarding agents, special catalysts and a blowing agent with
density as per ASTM C303, compressive strength as per ASTM C165 and thermal conductivity as per
ASTM C177.

 For instrument lines/ tubings of material Stainless Steel, insulation material shall be sodium silicate
inhibited Ceramic fibre rope insulation of min density 225 Kg/m 3.

6.4.3 Cold Insulation Material

 Where required cold insulation prevents condensation or icing on the outside surface of the insulating
system, conserve low temperatures or controls heat input into the contained fluid within a temperature
range of ambient and below.

 Polyurethane foam shall be used as an insulating material over piping for cold applications (Operating
temperature -180 Deg to +100 Deg C). Preformed pipe sections shall be used for the cold insulation
material whose dimensions shall be as per outside diameter of pipe and the insulation thickness. The
insulation material shall be rigid preformed cellular polyurethane foam of self-extinguishing type in
accordance with ASTM C 591, Type II, Grade 2. The insulation material shall have the following
properties -
o Thermal conductivity at 20 °C mean temperature per ASTM C-177 measured on 25 mm thick
foam, cut on both sides and aged at 21 °C for 180 days shall be no greater than 0.023 /m.K.
o The thermal conductivity for freshly blown foam shall be no greater than 0.020 W/m.K.
o Minimum percentage of closed insulation cells 90% (percent) per ASTM D-2856.
o Maximum water vapor permeance at 38 °C and 100% RH shall be 4.38 x 10-3 μg/Ns (ASTM
E-96).
o Linear coefficient of thermal expansion/contraction 70 x 10-6 per °C (BS 4370).
o Maximum leachable halides content 90 ppm.
o A minimum density of 45 kg/m3, measured per ASTM D-1622.
o Compressive strengths of at least 200 kPa and 250 kPa at 10% deformation and at 20 °C,
perpendicular and parallel to foam rise respectively, as per ASTM D-1621.
o Where supplied in two halves, pipe sections shall be oversized to accommodate contractions.
o For all sizes up to and including 10" NPS, the PUF/PIR shall be applied in two half sections.
o For sizes over 10" NPS and equipment between 250 mm and 3600 mm diameters, the
PUF/PIR shall be supplied in radiuses and beveled segments having a width on the outside
radius of minimum 450 mm.

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 Pre-formed Spacers shall be of PUF/PIR with the following minimum properties -

o The spacers shall consist of fully monolithic molded (180°) half pipe sections with a minimum
density of 50 kg/m3, designed to form compartments for the in-situ molding operation.
o The foam shall have a fire-resistive property as defined in ISO 3582 (10/10 SE): self-
extinguishing.
o Minimum percentage of closed cells 90% per ASTM D-2856.
o Compressive strength -
i. 240 kPa minimum perpendicular to foam rise.
ii. 290 kPa minimum parallel to foam rise.
o Thermal conductivity at 20 °C mean temperature per ASTM C-177, measured on 25 mm thick
foam cut on both sides and aged at 21 °C for 180 days shall be no greater than 0.025 W/m.K.

 PUF material for pipe supports shall be the following -

o For pipe sizes 6" and under, foam shall be 160 kg/m3 high density polyurethane with a
minimum ultimate compressive strength of 2 MPa at 20 °C and a design stress of 735 kPa.
o For pipe sizes 8" through 24", foam shall be 224 kg/m3 high density polyurethane with a
minimum ultimate compressive strength of 4 MPa at 20 °C and a design stress of 1.15 MPa.
o When tested at cryogenic temperature of -160°C, the maximum apparent thermal conductivity
shall be as follows -
i. 160 kg/m3 : 0.022 W/m.K
ii. 224 kg/m3 : 0.025 W/m.K

 The vapor barrier shall be of a corrugated aluminum sheet, alloy 3003 or 5005 in accordance with ASTM
B-209. Material to have a factory applied moisture barrier of a laminate of chemically inert polyethylene
and a layer of Kraft paper (without adhesives), to ensure the highest adhesion with the foam. Thickness
of the vapor barrier shall be at least 0.2 mm minimum. Primary metal vapor barrier shall only be applied
on PUR.

 The joint sealant used to seal all cellular glass insulation for dual temperatures and those parts in the
insulation system that shall be readily removable shall have the following minimum properties –
Material: Butyl Sealant
Property Unit Value
Consistency Soft paste
Color Grey
Service temperature °C -56.6 to +82
Water vapor transmission (at 3 mm Perm 0.03
dry-film thickness) ASTM E-96
Solids Vol. % 84
Flame spread ASTM E-84 5
Smoke development 5

 The fabrication adhesive used for bonding together pieces of prefabricated PUF/PIR insulation for
removable fittings/flange covers and valves, shall be a fire resistive two-part component material with the
following minimum properties -
Property Unit Value
Color Grey
Consistency Soft paste
Specific gravity kg/l 1.3-1.8
Flammability: - Non-flammable
Service temperature °C -70 to +90

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Document Number : D10-PMC-JSF-015

 The adhesive used to bond insulation and/or supports to piping/equipment in cold insulation shall be a
virtually 100% solids free, three component cryogenic adhesive, enabling bonding between nonporous
surfaces without problems of evaporation and having the following minimum properties -
Property Unit Value
Color Black
Consistency Thixotropic
Specific gravity kg/l 1.8
Service temperature range °C -196 to +121

 Stainless Steel rivets shall be grade 304 SS blind rivet pop-type, 4mm dia x 8mm long.

 The reinforcing membrane for embedding between the coats of the vapor barrier mastic in preformed
PUF shall be a high strength resilient synthetic fabric, having minimum 20 x 10 threads per 25 mm and
a weight of 33 g/m2, or an open weave glass cloth, with a weave lock finish and having minimum 18 x 12
threads per 25 mm.

 The tape used to secure the inner layers of PUF/PIR and cellular glass to the pipework shall be a
pressure sensitive glass fibre reinforced tape of minimum 19 mm wide.

 The vapor barrier cover for contraction joints in the outer layer of insulation shall be a corrugated butyl
rubber sheet with 1.2 mm minimum thickness.

 The adhesive for the secondary foil vapor barrier, shall be an adhesive suitable for adhering the
polyester and stay flexible within the service temperature range from -60°C up to ambient.

 The glued overlaps of the secondary foil vapor barrier shall be sealed off with a 50 mm wide adhesive
tape of similar material (adhesive on one face) capable of sealing the foil within the temperature range
from -60°C up to ambient.

 The tape to seal all longitudinal/circumferential joints of primary metal vapor barrier shall be a composite
type aluminium foil, reinforced and with a self-bonding layer made of butyl rubber on the back face.
Minimum width of 75 mm will allow for sufficient cover of the joints.

 A secondary vapor barrier of 3 mm thickness shall be applied between the outermost layer and the next
inner layer of the insulation. Whilst this coat is still wet, glass cloth shall be laid over the surface and
embedded in the mastic with 75 mm overlap at the junctions. The insulation shall then be finished with a
primary vapor barrier on the outside and surrounded with a metallic jacket.

6.4.4 Acoustic Insulation

This section defines the special requirements of acoustical insulation for pipes, valves, and flanges with the aim
of reducing the noise emitted by these items. In many respects, acoustical insulation resembles thermal
insulation However, some aspects of acoustical insulation are different.

The control of noise in a plant is required for the following reasons -

 to conserve the hearing of personnel
 to reduce speech and work interference
 to ensure that warning signals are audible
 to allow adequate speech, telephone, and radio communication
 to maintain working efficiency
 to provide quiet accommodation for personnel
 to prevent annoyance to the neighbouring community.

The noise radiated by the wall of a pipe is usually generated by equipment connected to the pipe, such as
compressors, pumps, valves, or ejectors. The noise sources may cause long sections of pipe to radiate noise
because noise will travel in the pipe with little reduction. The noise radiation may be reduced by acoustical
insulation.

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Although materials used for thermal insulation may also be suitable for acoustical insulation, there are some
additional application requirements. Special attention shall be paid to the prevention of noise leakage through
gaps and to isolation of vibrations in order to prevent their transmission to the cladding or adjacent structures,
such as supports.

The acoustic insulation consists of the following -

a. Porous Layer
The porous layer serves the following purposes -
 This layer represents a vibration-isolating support for the cladding.
 This layer converts acoustical and vibrational energy into heat and should therefore have an
optimum flow resistivity for the oscillatory flows which occur in sound waves.

The porous layer shall be in the form of blankets, mattresses, or semi-rigid sections, within the density
range of 100 to 150 kg/m3.

The flow resistivity of the porous layer shall be in the range of 25,000 to 75,000 N-s/m4. (Suppliers of
porous layer materials will usually be able to state the flow resistivity of their products).

The material of mineral wool shall conform to BS 3958. Part 3 or Part 4.

b. Cladding
The cladding serves the following purposes -
 The cladding is a barrier to the noise radiated by the pipe and shall, therefore, be completely
sealed.
 The cladding protects the porous layer from mechanical damage and provides a weather protection
for the porous layer and the pipe surface underneath. It shall, therefore, have sufficient strength
and durability for these purposes.
Cladding material shall be stainless steel. Aluminized or galvanized steel are not acceptable as they are
prone to rusting due to damage coating.

c. Anti-Vibration Seals
The following materials are suitable for use in anti-vibration seals -
 synthetic and natural rubber
 Non-flammable felt.

Where these materials are incompatible with the operating temperature, such seals shall be made of
compressed porous layer material.

d. Cladding Support
Where the porous layer is composed of semi-rigid sections and the pipe is horizontal, it will not normally
be necessary to support the cladding. However, where blankets are used, it may be necessary to support
the cladding separately. Short, semi-rigid sections, installed at regular intervals, may be found suitable for
this, provided they are compatible with the operating temperature and the chemical environment.

Rigid spacers, as used in distance rings for thermal insulation, shall not be used in acoustical insulation.
Spacers shall contain resilient elements. The spring stiffness, k, in N/m of a single element and in
directions normal to the pipe axis, should be of the order

k ≤ Dcd rM/n = xC (N / m)

Where -
M = mass per unit area of the cladding, kg/m2
n = number of resistant elements in one distance ring
dr = distance between distance rings, m
Dc = diameter of cladding, m
C = defection factor, 1/s2
The resilient elements shall have a built-in mechanical stop, in the direction normal to the pipe axis, in
order to limit its maximum defection

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Document Number : D10-PMC-JSF-015

Support rings which carry the weight of vertical stretches of acoustical insulation shall contain resilient
elements. Spring stiffness in lateral directions should be in the range as given for distance rings, where
possible. Resilient elements for support rings have both axial and lateral mechanical stops, to limit
movements of the insulation, (even) when the resilient element fails.

Commercially-available anti-vibration mountings should be used wherever possible. Where the operating
temperatures prohibit the use of natural or synthetic rubber as resilient material, other materials should be
used instead. For example, steel springs in the form of a folded band or knitted metal can be substituted
for rubber materials.

Installation of Acoustic Insulation -

 An essential feature of acoustical insulation is that the cladding shall not be in direct or indirect
metal-to-metal contact with the pipe. Any such contact will allow a transmission of vibrations to the
cladding which will reduce or nullify the noise reduction of the insulation. It may even enhance the
noise radiation because of the greater surface area of the cladding.

 Resilient elements shall not be pre-stressed or pre-tensioned to the extent that their operational
range of deflections is exceeded.

 The pipe on which the acoustical insulation is to be mounted is not necessarily hot. Thus, attention
shall be paid to corrosion prevention by painting the pipe as well as the prevention of both rainwater
ingress and condensation of water vapour within and upon the insulation.

 At positions where metal-to-metal contact would normally occur, anti-vibration seals shall be applied.

 When insulation is required for thermal as well as for acoustical reasons, the same material may be
used for both purposes, provided the acoustical requirements are met.

 The thickness of the porous layer shall be determined by the more stringent of the two requirements.

 The cold insulation system as described in the relevant section shall be applied first to the pipe and
the acoustical insulation shall be applied on top. The density of the porous layer should be about 150
kg/m3 for this application. To prevent condensation at the interface between the two layers, a
second vapor seal shall be applied outside the porous layer. Care should be taken to avoid damage
when applying the cladding directly over the vapor seal; rivets or selftapping screws shall not be
used.

 Vapour barrier with wet application shall not be used in acoustical insulation.

6.4.5 Piping Insulation

All piping requiring insulation like chilled water, hot water piping and all other lines requiring insulation as per the
relevant PID and line list shall be insulated in the manner specified herein and as per the relevant code. Before
applying insulation, all pipes shall be brushed and cleaned. All pipes (Carbon steel and stainless steel) shall be
painted as per the painting specification prior to insulation. Thermal insulation shall be applied as per the table
provide in Annexure-1 to the specification. The insulation over the equipment shall be as per the thickness and
material shown in the equipment drawing.

6.4.6 Insulation Supports

Insulation supports for vertical piping shall be of a bolted or clamp-on type. The width of the support shall be
one-half of the thickness of the insulation for single layer insulation. Support width for multiple layers of
insulation shall be 15 mm less than the total insulation thickness. Insulation supports for vertical piping shall be
provided and installed by the EPC Contractor at the following locations -
 300 mm above the uppermost weld of an elbow or tee in a vertical run of piping.
 Bolt length plus 25 mm above vertical oriented flanges.
 Every 3.5 meters of vertical carbon steel pipe elevation and every 2.75 meters of vertical stainless steel
pipe elevation.

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Document Number : D10-PMC-JSF-015

Insulation supports for vertical equipment shells shall be welded rings. Support rings shall be spaced on 3.5
meter centres for carbon steel vessels and on 2.5 meter centres for stainless steel vessels. The width of the
insulation support rings shall be equal to the total insulation thickness.

6.4.7 Weather Protection Jacket

The cladding of material SS 304 shall be provided over the insulation. For the stainless-steel cladding, the
materials shall be in accordance with ASTM A167 or A240, type 304.
Thickness of the cladding shall be 0.56 mm (24 SWG) flat.

6.4.8 Ancillary Materials

 24 SWG thick x 15 mm wide stainless-steel SS 304 Bands shall be used to for securing the insulation
over the pipe.
 24 SWG thick x 15 mm wide stainless-steel SS 304 Bands shall be used to for securing the cladding over
the insulation.
 Stainless steel rivets and screws shall be used to secure the cladding over the insulation.
 S & J clips shall be formed by 25 mm wide SS banding.
 To ensure perfect water proofing, all the cladding joints shall be packed with sealing materials which shall
be an elastomeric sealing compound. The sealing so achieved should be anti-vibration and shall
withstand the vibration caused to lines by the rotating equipment.
 The glass cloth to be used for vapour barrier reinforcement, shall be open weave 10 mesh Glass Cloth
having glass fibre thickness of 5 mils.
 Materials for Adhesives, Cements, Coatings and Sealers shall be as below -
Adhesive Pittcote 88 or approved equivalent
Thermocote 1-GP/FF, Thermocote 1-FW or approved
Insulating Cement
equivalent.
Joint Sealant Pittseal 444 or approved equivalent.
Vapor Barrier Bakelite 110-14, Pittcote 300 or approved equivalent.
Vapor Seal Mastic Foster Fire Retardant Mastic 60-30

6.5 Application
6.5.1 Hot Insulation
 The EPC Contractor shall perform all work with the highest quality workmanship throughout to provide a
neat, uniform appearance with no sharp edges exposed.

 Insulation shall not be applied until all testing such as hydrostatic, radiography, painting has been
completed on all piping and equipment involved and all leaks have been required or made tight.

 All surfaces to be insulated shall be thoroughly cleaned of all dirt, grease, rust, scale etc. and shall be
perfectly dry before insulation is applied.

 Insulation shall not be installed during weather which might cause the pipe or insulation to become wet.

 Insulation to be installed over an extended period must be protected to ensure it remains dry until it has
been properly sealed. Insulation shall be installed such that shrinkage is held to a minimum. Any cracks
or openings that occur in the insulation or weatherproofing are to be filled in with additional insulation or
weatherproofing to provide a smooth sealed surface.

 Insulation shall not cover the face of gauge glasses, equipment name or data paltes or tags, nor be
applied so as to interfere with dynamic parts of instruments or equipment.

 Valves and flanges operating above 300°C, or in a service, at any temperature where the product may
solidify, shall be provided with removable insulation covers.

 At all flanges, unions and pipe termination, the pipe insulation shall be bevelled at a 45 Deg angle to
facilitate removal of flange bolts and union collars without damage to the main pipe insulation and metal
jacketing. A screwed and sealed metal cover shall be installed.

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Document Number : D10-PMC-JSF-015

 Where specified by Owner/ PMC, the removable inspection windows for corrosion monitoring of the base
metal to be provided.

 The insulation shall be carried out with the least number of material pieces as possible and all
unavoidable gaps, cavities, and voids shall be suitably filled with compatible loose fill material.

 Straight pipe shall have metal cladding cut and machine rolled (approx. 1 metre long) wrapped around,
with 50mm minimum overlaps on both longitudinal and circumferential overlaps. All laps shall be arranged
to shed water.

 The metal cladding shall be secured tightly around the insulated pipe and held in place with stainless
steel bands on a maximum of 300mm centres. One band shall be located on each circumferential lap and
the distance between laps divided at equal band spacing. The band securing seals shall be kept neatly in
line and positioned away from viewing angles as much as is possible.

 The thickness of basic insulation on pipe fittings shall be the same as the thickness of insulation on
adjoining pipe.

 Insulation shall be covered with metal jacketing lapped a minimum of 50 mm on all seams and secured
with screws and bands. Locating one band at each lap joint and spaced maximum 450 mm on centre.
Vertical jacketing shall be secured with “S” clips. The minimum number of S-clips shall be two for pipe
sizes up to and including 6 inches NPS, and four for pipe sizes over 6 inches NPS.

 Insulation to be protected from any kind of damage e.g, mechanical, oil, welding spots etc.

 Wet or damaged insulation should not be used in any circumstances. The insulation material if not
protected during rain and water from other means, shall be replaced without any extra time and cost
implication.

 The minimum clearance of the finished insulation surface from the nearby structure or any other facility
shall be 50 mm to avoid any kind of interference.

 Hot insulation Application over the Equipment

i. Insulation on vessels and tubular equipment shall be applied in a staggered joint arrangement
and to fit the contour so that no gaps are evident. The insulation shall be secured in place with
bands spaced on 450 mm centres.

ii. Banding of insulation over the heads of horizontal equipment and top heads of vertical equipment
shall be as follows -
A floating ring, large enough to clear the centre nozzle flange, if one exists, shall be made from 6
mm diameter stainless steel rod. The ring shall be placed in the centre of the head. A girth ring,
made from two bands shall be installed on the shell at approximately 150 mm below the tangent
line of the head. Bands shall be run radially from the floating ring to the girth ring. The radial
bands shall be spaced at 300 mm maximum centres on the girth ring.

iii. Unexposed bottom heads and cones on vertical vessels and tubular equipment shall have the
blanket insulation shaped so that all sections are tight and secured with wire to slotted weld pins
or blank nuts. Vessel and tubular equipment transitions shall have the insulation applied with all
edges securely laced together with wire.

iv. Vessels and tubular equipment stiffener rings shall be insulated. The insulation shall be applied
with all edges securely laced together with wire. The insulation shall also be secured in place with
a band in the centre of each stiffener ring.

v. Vessel and tubular equipment shells shall be weatherproofed with SS jacketing, (0.56 mm thick
corrugated).

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Document Number : D10-PMC-JSF-015

vi. Vertical overlaps of corrugated metal jacket sections shall be a minimum of one and one half
corrugations but not less than 75 mm. Vertical overlaps of non-corrugated metal jacket sections
shall be a minimum of 75 mm.

vii. Circumferential overlaps at the top tangent lines, transitions, and stiffeners shall be a minimum of
150 mm. All other circumferential overlaps shall be a minimum of 75 mm.

viii. Metal jacketing overlaps and seams shall be arranged to shed water. Seams shall be water and
weather tight.

ix. Insulation on the heads and transitions shall be weatherproofed with metal jacketing fabricated
from gores shaped to fit and lapped a minimum of 75 mm to ensure a weather tight construction.
The gores shall be secured with screws spaced on 75 mm maximum centres. All overlaps on the
top head shall have sealant.

x. On vertical vessels and equipment, S-clips shall be used to keep the jacket sheets from sliding
down. S-clips shall be fabricated from 25 mm wide bands. The length of the S-clip shall equal the
overlap. They shall be spaced on 300 mm maximum centres but not less than three per each
metal sheet.

6.5.2 Cold Insulation

 Application of Pre-Formed PUF Sections Over Piping -
i. Insulation shall be performed to fit the diameter of the pipe, fitting or underneath layer of
insulation, and shall be applied in staggered positions with all joints tightly fitted together. Gaps
resulting from poor fit or damaged material are not permitted to be filled with joint sealer or mastic
but shall be refitted.

ii. Preformed PUF insulation materials shall be supplied as curved cylindrical sections/segments
and in half-pipe sections in either 915 or 1000 mm length with or without a shop-applied
secondary foil vapor barrier.

iii. For two-piece pipe sections of PUF/PIR, a clearance between the pipe surface and the inner
layer of insulation shall be provided. Therefore, the pipe sections must be fabricated oversized to
suit. This shall ensure that during operation, the preformed PIR will be snug-fit into the pipe with
no gap between the pipe surface and the preformed PIR. No clearance is required on the inner
layer where radiuses and bevelled segments are employed.

iv. PUF sections shall be supplied with circumferential and longitudinal joints ship lapped for
thickness above 50 mm.

v. Prior to application of the PUF sections a joint sealer/adhesive shall be applied to the outside half
of all the circumferential and longitudinal ship lapped joints and over the full height of butt joints,
to a wet film thickness of approximately 1.5 mm. Application shall be to only one of the mating
surfaces for the full depth of the outside half of the ship lapped joints, before bringing the surface
together. No sealant or adhesive shall be applied to any other insulation contact/bore faces.

vi. PUF inner layer, where applied in two halves, shall be secured with 19 mm wide pressure
sensitive filament tape bands spaced at 450 mm centres and applied with a 50% overlap. Where
applied in radiuses and bevelled segments, securement shall be by 12 mm wide x 0.5 mm thick
stainless steel bands at 450 mm centres, machine-tensioned and sealed.

vii. The secondary foil vapor barrier shall be applied between the outer most layer and the next inner
layer of the insulation and shall be arranged with 50 mm overlaps. These overlaps shall be glued
with an adhesive. All joints shall then be sealed with tape.

viii. Primary vapor barrier mastic shall then be applied on the outside surface of the insulation.

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Document Number : D10-PMC-JSF-015

 Application of Cold Insulation on Equipment -

i. Insulation for equipment up to 750 mm outside diameter shall be applied as described for straight
pipework.

ii. For diameters of equipment above 750 mm, the insulation shall be performed sections to fit the
diameter of the equipment or underneath layer of insulation, and shall be applied in staggered
positions with all joints tightly fitted together. Gaps resulting from poor fit or damaged materials
are not permitted to be filled with joint sealer or mastic and shall be refitted.

iii. All parts extending beyond the surface to be insulated, shall be insulated first with preformed
sections and a vapor stop.

iv. Insulation for heads and skirts shall be executed as follows -

o The heads of both vertical and horizontal equipment shall be insulated with metered
block insulation trimmed to fit the contour of the head.
o The equipment with diameters less than 750 mm shall have flat board insulation at both
ends.
o The insulation on the bottom heads of the vertical equipment shall be secured by 19
mm wide x 0.5 mm thick stainless steel bands with maximum 300 mm centres
measured around the equipment's circumference on vessels that are skirt-supported.
The bands on the bottom head shall be attached to the inside skirt support angle.
o For top head of vertical equipment, and both heads of horizontal equipment, the
insulation shall be secured by using a welded floating ring fabricated from 6.0 mm
diameter type 304 stainless steel rod.
o The floating ring shall be laid over the insulation and positioned in the centre of the
head.
o 19 mm wide x 0.5 mm thick stainless steel bands shall be installed and spaced on 300
mm centres measured around the circumference of the equipment. One end of the
band shall be fastened to the floating ring, and the other end shall be anchored to a
band or ring welded around the cylindrical section of the equipment close to the head.

v. For two-piece sections, a clearance between equipment surface and inner layer shall be
provided.

vi. PUF segments shall be supplied with circumferential/longitudinal joints either ship lapped keyed
or butted. All butt joints shall be installed without a gap. In multilayer constructions, the first layer
will be applied without sealant.

vii. A secondary foil vapor barrier shall be introduced between the outermost layer and the next inner
layer of the PUF/PIR insulation. This laminate foil shall be arranged with 50 mm overlaps,
completely sealed with the specified adhesive/tape.

6.6 Insulation for HVAC Piping and Ducts

This section shall be used for the insulation of piping, ducts and other facilities related to HVAC.

6.6.1 Thermal / Acoustic / Piping Insulation

a. General
It comprises of supplying, installing, testing and commissioning of insulation on duct, pumps, hilled/hot
water piping, chillers, expansion tank, AHU room and duct acoustic lining.

Providing insulation and covering in strict accordance with authorities governing combustibility and
fireproofing of materials and in accordance with manufacturer’s recommendations.

Providing non-combustible insulation, jackets and finishes having a Flame Spread/Smoke Developed
rating meeting authorities’ requirements.
 All materials must be non-corrosive, compatible with other material and used in accordance with the
manufacture’s recommendations. All materials supplied shall be new and undamaged. All insulation
material shall be properly stored and protected from humidity, moisture, rain, dust, dirt, sand, mud
etc.

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Document Number : D10-PMC-JSF-015

 Insulation materials shall be of high quality and good appearance. Insulation materials shall be of
low chloride content and chemically inert. It must be non-injurious to health and must not contain
asbestos in any form.

 All insulation shall be rigid and self-supporting. When installed the insulation shall fit snugly and
shall have a tight joint.

 All insulation materials selected shall conform to the regulations of the latest edition of the
occupational health and & safety act and all other applicable standards.

 Insulation materials to be used over austenitic stainless steel surfaces shall not have zinc and shall
be inhibited with sodium silicate as per ASTM C-795. The amount of leachable chloride in the
insulation material shall not exceed l0 ppm. For the chemical analysis of insulation materials ASTM
C-871 shall be referred.

 All insulation materials shall be stored in moisture-proof containers.

 Reference Codes and Standards –

EPC Contractor shall meet or exceed the requirements of the latest edition of the following codes,
regulations and standards as applicable.
S.no Parameters Testing Methods
1 Bulk Density IS 3144
2 Recovery after compression IS 3144
3 Shot Content IS 3144
4 Vibration & Jolting IS 3144
5 Corrosive attack IS 3144
6 Thermal Conductivity IS 3346
7 Moisture Absorption IS 3144
8 Mould Growth IS 3144
9 Non Combustibility BS 476 Part 4
10 Fire Propagation Index BS 476 Part 6
11 Surface Spread of Flame BS 476 Part 7
12 Toxicity Index BS 6853
13 Flame Development Index (FDI) ASTM E 84
14 Surface Development Index (SDI) ASTM E 84
15 Alkalinity (PH) IS 3144
16 Chloride & Sulphur Content IS 3144
17 Odour test IS 3144
Inspection and Maintenance of
18 OISD 177
Thermal Insulation

b. Insulation
 Scope
The scope of this section comprises the supply and application of insulation conforming to these
specifications.

 Material
o Glass wool for duct External insulation & For acoustic lining of the ducts

o Thickness of the insulation shall be as specified for the individual application. Insulation
material delivered at site shall be accompanied with manufacturer’s test certificate for
thermal conductivity values, density, water vapour permeability and fire properties.
Samples of insulation material from each lot delivered at site may be selected by Owner’s
site representative and gotten tested for thermal conductivity and density at Contractor’s

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Document Number : D10-PMC-JSF-015

cost. Adhesive used for sealing insulation shall be fibre glass insulation based on poly-
chloroprene with special rosin and tacky fire. The adhesive shall be non-flammable in dry
form and minimum solid 18 to 24% with heat, water & chemical resistance. The adhesive
application method shall strictly be as per adhesive manufacturer’s technical data sheet.

o Thickness of the insulation shall be as specified for the individual application. Each lot of
insulation material delivered at site shall be accompanied with manufacturer’s test
certificate for thermal conductivity values, density, water vapor resistance factor, and fire
properties. Samples of insulation material from each lot delivered at site may be selected
by Owner/PMC and gotten tested for thermal conductivity and density at Contractor’s cost.
Adhesive used for sealing the insulation shall be modified neoprene contact adhesive with
minimum bond strength of 1.25 kg/m2. It should have high water vapor resistance, good
weathering properties and self-extinguishing once dried strictly as per manufacturer’s
recommendations.

c. Duct Insulation
 Duct Location – Inside the Building
External thermal insulation shall be provided as follows -
o Supply, Installation & Testing of thermal insulation on Air Conditioning ducts with Non-
combustible Glass wool Insulation duly mechanically protected with factory laminated
Aluminium Foil, having density 32 kg/cum. The Thermal conductivity of the insulation
material shall not exceed 0.034 W/m K at 25 deg C mean temperature. The thickness of
insulation shall be so selected as to prevent any condensation and should be able to meet
R-Value requirements. Temperature range -195 to 230deg C.

o The materials shall comply with following standards.

BS 476: Part 4 – Non Combustible (As per National Building Code – 2016)
BS 476: Part 6 – Fire propagation Index (I<12)
BS 476: Part 7 - Surface spread of flame (Class 1)

o The minimum thermal resistance (R-Values) for insulation of ducts (as per ASHRAE 90.1-
2004 and ECBC 2017) shall be as described below -
i. Supply & Exposed Air Ducts R= 1.4 m2 deg. /W (Thickness requirement of Glass wool
50MM)
ii. Return Air Ducts R= 0.6 m2 deg. /W (Thickness requirement for Glass wool 25MM)

Note: Insulation shall meet ECBC, GRIHA and NBC criteria.

o Duct surfaces shall be cleaned to remove all grease, oil, dirt, etc. prior to carrying out
insulation work. Measurement of surface dimensions shall be taken properly to cut special
composite insulation sheets to size with sufficient allowance in dimension. Cutting of faced
insulation sheets shall be done in a manner for each face of the duct surface separately with
adjustable blade to make 900 cut in thickness of insulation sheet.

o Material shall be fitted under compression and no stretching of material shall be permitted. A
thin film of a compatible adhesive or Poly-chloroprene insulation adhesive shall be applied
on the back of the insulating material sheet. When adhesive is tack dry, insulating material
sheet shall be placed in position and pressed firmly to achieve a good bond. All longitudinal
and transverse joints shall be sealed by providing 6 mm thick 75 mm wide polyethylene foam
tape. The adhesive shall be strictly as recommended by the manufacturer. All longitudinal
and transverse joints shall be sealed by self-adhesive Al foil tape 75 mm wide and the
insulated ducts strapped with PVC straps at each 750 mm C/C. The adhesive shall be non-
flammable vapor proof, odourless type.

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Document Number : D10-PMC-JSF-015

o The installation guideline for Glass wool duct-wrap -

i. The duct surface should be cleaned with suitable solvents and rendered free from all
physical and chemical impurities.
ii. The duct should be inspected and all joints should be sealed against leakages.
iii. For ducts having width greater than 0.6m, heavy duty self-adhesive pins are to be
applied to the duct at appropriate intervals (max 300mm) as per manufacturer‘s
Installation Manual.
iv. The insulation of specific R-value and thickness should then be cut to appropriate length
and stuck to the duct while the adhesive is still wet. For proper laying technique, refer to
manufacturer’s Installation Manual.
v. All longitudinal joints and circular overlaps should be sealed with aluminium foil tape
(50mm width) to make the installation leak proof. For large ducts, where adhesive pins
have been used, speed washers/clips should be covered completely with Aluminium
foil-tape to have an air-tight finish.
vi. The insulation should then be secured over the duct using mechanically fastened
nylon/steel straps (12mm/50mm) at appropriate intervals (max 1.2m).
vii. After the installation the vapour retarding foil should be inspected and all tears should
be sealed with Aluminium foil-tape to prevent air leakage.

o Duct Adhesive Specification

The adhesive shall be specially formulated for the Duct insulation application and supplied
by insulation manufacturer. Adhesive should be a solvent based low voc, poly chloroprene
rubber contact adhesive, used for strong and flexible, full surface bonding of elastomeric
rubber to elastomeric rubber and elastomeric rubber to various galvanized and non-
galvanized metal. It should be manufactured by safe and low VOC solvent and does not
contain restricted material. The adhesive can easily apply by brush or pressure feeding
equipment, designed for contact adhesive.

The adhesive shall be non-flammable in dry form and minimum solid 18 to 24% with heat,
water & chemical resistance. The adhesive application method shall strictly be as per
adhesive manufacturer’s technical data sheet.

 Duct/pipe Location – Outside the Building

o Supply, Installation & Testing of thermal insulation on Air Conditioning ducts with Non-
combustible Glasswool Insulation duly mechanically protected with factory laminated
Aluminium Foil, having density 32 kg/cum. The Thermal conductivity of the insulation
material shall not exceed 0.034 W/m K at 25 deg C mean temperature. The thickness of
insulation shall be so selected as to prevent any condensation and should be able to meet
R-Value requirements. Temperature range -195 to 230deg C. The thickness of insulation
shall be 50 mm for Supply and Return Duct.

o All insulation shall be provided with the protective coating as per BS 476 Part-7, Class-‘1’,
IS101(Part-2/Sec-2)/1986 and IS 101 (Part-2/Sec-1)/1988 with three coat with the
reinforcement as per IS 11871 glass fibre cloth . Each coat should be dry before another
coat. The coverage of each coat not less than 1 kg per 43.04 sq. ft. (4m²/coat).

o The installation guideline for Glass wool duct-wrap in exposed area -

i. Duct shall be thoroughly cleaned with wire brush and rendered free from all foreign
matter and grease.
ii. The Duct joint should be sealed against leakages
iii. Fiberglass wool insulation shall be fixed tightly to the surface. All joints to be sealed
properly. Fixing and sealing adhesive shall be CR base duct liner insulation adhesive.
All joints of Aluminium foil shall be sealed properly by means of 75 mm wide self-
adhesive aluminium tape of approved make.
iv. Apply tack coat over the insulation and embed immediately non-combustible (Glass
Fibre Cloth) 7 Mil only fabric for reinforcement.
v. Apply 1st coat of fire retardant coating evenly.
vi. Apply 2nd coat of fire retardant coating curing the 1st coat as per supplier
recommendation.

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d. Acoustic Lining of Ducts

For acoustic lining ducts the material shall be resin bonded Glass wool Insulation of density 48 kg/m3 with
factory laminated Fibre Glass Tissue on one side. All duct up to a distance of 5m from AHU outlet or as
shown in the drawing shall be acoustically lined from inside. The Thermal conductivity of the insulation
material shall not exceed 0.032 W/m K at 25 deg C mean temperature. The Noise Reduction coefficient
shall be more/equal than 0.85. Temperature range -195 to 230deg C.

Application
 Clean the inner surface of duct which is to be lined with wire brush to remove the dirt.
 Fixing 25 mm x 25 mm/50 mm GI frame work of 24 gauge 600mm distance screwed with the duct
and making size as per requirement.
 Apply a cold setting adhesive compound over duct surface.
 The adhesive shall be non-flammable vapor proof odourless type.
 Fix insulation material of 25 mm thickness overlapped as specified below and fixed with GI screws.
 Finally cover the insulation with 0.5 mm thick perforated Aluminium sheet having minimum 23 %
perforation with joints overlapped and screwed to the frame by means of brass metal screws, to
produce an even surface.

e. Glass wool Acoustic Board for AHU Room, Utility Spaces & HVAC Plant Room
Supply, Installation & Testing of acoustic lining on wall and ceiling of AHU/TFA rooms with 25mm thick
Rigid Board of Glass wool Board having one side aluminium faced and other side Black Glass Cloth
lamination, density of the insulation shall be 70 to 80 kg/cum. Thermal conductivity shall not be more than
0.032 w/m deg C at 25 deg C. The Noise Reduction Coefficient shall be more/equal than 0.65.
Temperature range -195 to 230 deg C.

Application
 The surface shall be cleaned and friction fixed in 610mm X 610 mm frame of 25X25X18 mm made
out of 22 G thick GI sheet U shaped channel or else it can installed on the wall with screw bit.
 If wall surface is smooth it is prefer to install acoustic board with screw bit.
 The Acoustic board should be placed in such a way that black glass cloth is visible from inside the
AHU room. Complete as required and as per specifications.

6.6.2 Chilled Water Pipes Insulation

All piping requiring insulation like chilled water, hot water, process water and condensate drain piping and all
other lines requiring insulation as per the relevant PID and line list shall be insulated in the manner specified
herein and as per the relevant code. Before applying insulation, all pipes shall be brushed and cleaned. All
pipes (Mild steel and stainless steel) shall be painted as per the painting specification.

Preformed Pipe of Glass wool having density 64-80 kg/m3 mechanical protected with factory pre-laminated
Aluminium foil on the outside. The Aluminium foil shall extend by a minimum 50 mm on one side of the pipe
section along the length to seal all longitudinal joints. Bonding of insulation material shall be with a cold setting
compound. All joints shall be sealed with minimum 50mm wide fire rated aluminium tape.

 Temperature Range : -195 deg C to +230 deg C

 Thickness of insulation shall be as follows -

Pipe Size in mm Thickness of Insulation in mm
Chilled water pipes
25 to 100 : 25
125 to 300 : 50
300 above : 75

 The insulation for drain piping shall be Glass wool of density 64-80 kg/m3 and thermal conductivity shall
not be more than 0.033 W/mK at 25º C mean temperature. All joints shall be sealed with minimum
50mm wide fire rated aluminium tape.

 Pre-moulded pipe section shall be used for pipes up to and including 250 mm dia.

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 Thickness of insulation shall be as follows -

Pipe Size in mm Thickness of Insulation in mm
Drain pipe : As per Drawing/Design basis

 Application
All chilled water and drain pipe shall be insulated after pressure tested as follows -
o Brush and clean all piping and fittings to remove all dust, rust, dirt, mortar and oil. Then provide
2 coats of zinc chromate primer of ASIAN Paints or approved equal.
o Apply 2 coats of cold setting CPRX adhesive.

Manufacturer’s installation manual shall be submitted and followed for full compliance. All insulation
work shall be carried out by skilled workmen specially trained in this kind of work. All insulated pipes
shall be labelled (S.R. or R.R.) and provided with 300 mm wide band of paint along circumference at
every 1200 mm for colour coding. Direction of fluid shall also be marked. Un-insulated MS pipes shall
be painted throughout and direction of fluid marked. All painting shall be as per relevant BIS/NBC
codes.

 Pipe Adhesive Specification

o The adhesive shall be specially formulated for the Pipe insulation application and supplied by
insulation manufacturer. Adhesive should be a low Viscosity, high solid poly-chloroprene based
rubber contact adhesive. The adhesive is specially designed to bond different types of
elastomeric tubing & piping insulation and its butt joints. It is also recommended where multi
layers and thick insulation sheet to be installed. It should have very good performance with
most of thick curved surfaces, where mainly normal adhesive does not perform.
o The adhesive shall be non-flammable in dry form and minimum solid 18 to 24% with heat, water
& chemical resistance. The adhesive application method shall strictly be as per adhesive
manufacturer’s technical data sheet.

a. Kitchen Duct Insulation

All kitchen exhaust ducts connected to kitchen hoods shall be insulated with 50 mm / 75 mm thick 48
kg/m3 density pre-laminated Glass wool. PVC strap of 25 mm width shall be fixed at 300 mm interval to
secure the insulation in position.

Kitchen duct exposed to outside shall be further treated as under -

 Wrapping of “scrim glass fabric” and thereafter applying first coat of resin system formulated with
activators and inert fillers. This coat is allowed to cure to a non-stick state.
 Second coat of activated resin with suitable pigment is applied over the first coat and finished to
give a though smooth surface.
 Duct Insulation VOC limit shall not exceed to 850 (g/L less water)

b. Pre Insulated Chilled Water buried piping

 Piping material
Prefabricated MS class `C' pipes confirming to IS 1239 Part ‘II’ for pipe size upto 150 mm dia and
IS 3589 for 200 mm dia pipes and above, minimum thickness of pipes 200 mm dia and above
shall be 6.0 mm, complete with all necessary Grooved fittings such as bends, tees, reducers,
flanges etc and supports such as clamps, anti-vibration hangers etc. and also note that field joints
and end seals shall be designed and factory fabricated to prevent the ingress of moisture into the
system. The service pipe shall be hydrostatically tested to 150 psig or 1.5 times the design
pressure whichever is greater

 First layer of primer on MS pipe

Painting of exposed pipes with two or more coats eh of primer and synthetic enamel paint colour
code as per IS 2379.1990.

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 Insulation material
The pipe insulation shall be polyurethane foam (PUF) covered with HDPE jacket, Metal diffusion
barrier shall be applied between the outer surface of the insulation and the jacketing material so
as to eliminate the effect of reduced insulation properties to aging detail as given below –

Detail of polyurethane foam (PUF)

S. No. Property Detail
1 Density (Kg/m3) 42+2
Thermal conductivity at an average
2. 0.023
temperature of 10oC
3. Fire Resistance Class 1
50 mm up to 250mm
4. Thickness
dia. Beyond that 75 mm

Detail of HDPE
S. No. Property Detail
1 Density (Kg/m3) 940-960
2. Thickness 2-5 mm
3. Tensile Strength 19.0 Mpa minimum

c. Underdeck Insulation of Exposed Roof

For Underdeck insulation of exposed roof with Resin Bonded Rockloyd Rockwool conforming to IS: 8183
ONE SIDE ALUMINIUM FOIL and density 48 kg/ m3,50 mm thick, fixed to ceiling with metallic cleats
(50x50x3 mm) @ 60 cm and wire mesh of 12.5mm x 24gauge wire mesh. Thermal conductivity value
0.029 W/mK at 10° C. mean temp and conforms to IS : 8183 , BS :3958 Pt.5. also confirm the BS 476
part 4 standard

Application
 Clean the surface thoroughly with wire brush to free it from dust and chippings.
 Providing and fixing M.S. cleats of size 50mm x 50mm x 3mm to the ceiling @ 500mm c/c with help
of dash fasteners.
 Providing & fixing 50mm thick Rockwool slab of 48kg/m3 density laminated on one side Al foil. And
hold it with the help of criss-cross GI wire.
 All joints to be sealed with adhesive tape and held tightly in position with the help of criss-cross GI
lacing wire and further installing the same in 24 G x 3/4” hexagonal wire netting.
 The joints of the wire netting shall be butted and stitched with GI lacing wire.

Note: EPC contractor to ensure that Insulation should be provided on all exhaust ducts including
purge exhaust and even supply also.

6.7 Refrigerant & Drain Pipes Insulation

a. The insulation for Refrigerant piping shall be Class 'O' Closed Cell elastomeric Nitrile Rubber of density
40-60 kg/m3 mechanical protected with factory pre-laminated glass cloth having 7 mil minimum thickness
(Colour as per Owner/PMC recommendation). All joints shall be sealed with minimum 50mm wide fire
rated aluminium tape.
Temperature Range : -40 deg C to +105 deg C

 Entire liquid and suction refrigerant pipe lines including all fittings, valves and strainer bodies, etc.
shall be insulated with 13mm thick nitrile rubber upto pipe size of 15.9mm dia and above that with
19mm thick nitrile rubber
 All suction pipes and low temperature / pressure liquid pipes of the refrigerant pipe work shall be
insulated with slip on closed cell nitrile rubber fire retardant pipe insulation having a wall thickness
of not less than 13 mm for soft pipe / 19mm for hard pipe.
 The thermal conductivity of the insulation material shall not exceed 0.035 W/m K at 0 deg C mean
temperature. The density of the insulation material shall be 40-60 Kg/ cum.

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 Insulation duly mechanically protected with factory laminated glass cloth

 All joints of the insulation shall be sealed with 100 mm width x 3 mm thick self-adhesive tapes of the
same material as insulation and shall be of the same make as the basis insulation material.

b. The insulation for drain piping shall be Class 'O' Closed Cell elastomeric Nitrile Rubber of density 40-60
kg/m3. All joints shall be sealed with minimum 50mm wide fire rated aluminium tape.

Pre-moulded pipe section shall be used for pipes upto and including 250 mm dia.

Thickness of insulation shall be as follows –

Pipe Size in mm Thickness of Insulation in mm
Drain pipe : As per BOQ

c. Pipe Adhesive Specification

The adhesive shall be specially formulated for the Pipe insulation application and supplied by insulation
manufacturer. Adhesive should be a low Viscosity, high solid poly-chloroprene based rubber contact
adhesive. The adhesive is specially designed to bond different types of elastomeric tubing & piping
insulation and its butt joints. It is also recommended where multi layers and thick insulation sheet to be
installed. It should have very good performance with most of thick curved surfaces, where mainly normal
adhesive does not perform.

The adhesive shall be non-flammable in dry form and minimum solid 18 to 24% with heat, water &
chemical resistance. The adhesive application method shall strictly be as per adhesive manufacturer’s
technical data sheet.

Application
All Refrigerant and drain pipe shall be insulated after pressure tested as follows -
 Brush and clean all piping and fittings to remove all dust, rust, dirt, mortar and oil. Then provide 2
coats of zinc chromate primer.
 Apply 2 coats of cold setting CPRX adhesive.

6.8 Inspection
a. The insulation system shall be inspected during the following stages
 At the time of material receipt
 Before applying the insulation
 During insulation application

b. Before and during application of weatherproofing Quality control activities shall include at least the
following activities at the time of receipt of the materials:
 Appropriate checks shall be made to verify materials received at the site are the same as the
specified or approved materials. Such checks shall include verification of labels, material safety
data sheets, delivery receipts, and thickness. Damaged, unspecified, or, unapproved, insulation and
related materials shall be removed from the site.
 Ensure that storage of materials will protect them from being damaged by moisture, temperature,
wind or any other atmospheric factors.

c. Quality control activities shall include at least the following prior to insulation application:
 If the pipe or equipment to be insulated is heat treated, inform the Insulation carrying Agency that
welding of insulation supports is prohibited.
 Verify that pressure tests have been completed.
 Verify that surfaces to be insulated are clean, dry, and coated as per the Specification for Painting.
 Verify that painting at protrusions through insulation has been done.
 Ensure that protective coatings, over stainless steel surfaces to prevent external stress corrosion
cracking, have been applied.

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d. Quality control activities shall include at least the following during insulation application:
 Make sufficient checks to verify that the materials applied are the same as the specified or
approved materials.
 Verify the insulated item, and insulation code is the same as given on the P&IDs and related
drawings.
 Inspect the insulation supports for correct location, type, width, and length.
 Verify that the insulation surface is uniform without gaps and voids.
 Inspect for tightness of joints and fasteners.
 Verify the location, width, and installation of expansion joints.

e. Quality control activities shall include at least the following prior to and during weatherproofing:
 Ensure that the insulation is clean, dry, and fit for its intended purpose before weatherproofing is
applied.
 Inspect for proper overlaps of metal and flashing.
 Verify that the location of bands, screws, S-clips, J-clips, and breather springs is as specified.
 Ensure that moisture protection and weatherproofing at cut-outs, protrusions, and locations where
moisture could enter the insulation has been appropriately installed.

f. Samples of insulation material from each lot delivered at site may be selected by Owner’s site
representative and gotten tested for the required properties at EPC Contractor’s cost.

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6.9 Annexure

TABLES FOR INSULATION THICKNESSES

1. HEAT CONSERVATION (H & T)

Material: Rockwool/ Glass wool

OPERATING TEMPERATURE (DEG. C)

Nominal Dia
(Inches), NB Up to 100 101-150 151-200 201-250 251-300 301-350
Up to 1.5 30 30 45 50 60 70
2 to 3 30 30 45 60 70 80
4 to 6 30 45 45 70 70 90
8 to 18 30 45 60 70 80 90
20 to 24 30 45 60 70 80 90

2. PERSONAL PROTECTION (S)

Material: Rockwool/ Glass wool

OPERATING TEMPERATURE (DEG. C)

Nominal Dia
Up to 101-
(Inches), NB 151-200 201-250 251-300 301-350
100 150
Up to 1.5 30 30 30 30 45 50
2 to 3 30 30 30 50 45 60
4 to 6 30 30 30 50 60 70
8 to 18 30 30 45 50 70 80
20 to 24 30 30 45 50 70 80

3. COLD INSULATION (IC)

Material: Polyurethane/ Poly-isocyanurate

OPERATING TEMPERATURE (DEG. C)

Nominal Dia
-5 to - -15 to -30 to -50 to -160 to
(Inches), NB Up to 5 5 to -5
15 -30 -50 -70 -180
Up to 1.5 25 25 40 40 50 60 100
2 to 3 25 30 40 50 60 70 120
4 to 6 30 35 40 60 70 80 140
8 to 10 40 45 50 60 80 95 160
12 40 45 50 60 80 105 170
14 to 18 40 45 50 70 85 110 180
20 to 24 40 45 50 70 90 110 190
>24 & Vessels 40 45 50 70 100 130 220

Cold Insulation with thickness up to 50 mm shall be applied in single layer, thickness up to 110 mm shall
be applied in double layer, and more than 110mm shall be applied in three layers.

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7. 3D MODELLING
7.1 Scope
This specification covers requirements and guidelines for the 3D modelling of piping, equipment and structure on
PDS/ PDMS/ E3D platform.

All engineering activities especially for the piping, equipment and structure are to be carried out using 3D
modelling applications on any of the latest platform of either PDS, PDMS or E3D. The modelling has to be
comprehensive and is also to be used in the extraction of drawings, MTO etc. also so that the final deliverables
are always accurate and as per the 3D Model. The various databases for the required 3D modelling to be
developed by the EPC Contractor and the same to be handed over to OWNER/PMC at the time of job completion
along with the As Built 3D Model.

7.2 Codes and Standards

All the codes, specifications, standards and good engineering practices of piping, structure, instrumentation,
electrical and equipments are to be adhered to while carrying out the 3D modelling

7.3 3d Modelling
The engineering activities and output of all the disciplines shall be based on the 3D modelling whose extent and
scope shall be as per below -
a. Equipment 3D Modelling
 All equipment to be modelled with exact dimensions.
 Manholes with davits in Equipment to be modelled.
 The Equipment davits with arm length to be shown.
 All nozzles to be modelled as per the nozzle size and rating.
 Lifting lugs to be shown.
 Piping clips for supporting the piping from the equipment shell/ dome to be shown by exact
modelling so that the fouling with other adjacent line can be avoided.
 Pumps shall be modelled along with their motors.
 Compressors shall be modelled along with their auxiliary skids, motors, LO Coolers, coolers etc.
 Maintenance areas around equipment shall be modelled as soft envelopes.
 Drop out areas for the monorails/ davits shall be modelled as soft envelopes.
 Swing volume of the pipe davits shall be modelled as soft envelopes.
 Equipment supports (saddles/ skirts/ legs/ lugs) shall be modelled.
 Insulation over the equipment shall be modelled.
 Any stiffener ring over the equipment shall be modelled.
 Equipment numbering shall be done in the 3D model as per the PID.

b. Piping Modelling
Piping shall be modelled to the extent as below -
 All above and underground piping of all sizes shall be modelled.
 The modelling shall include all piping components such as pipes, fittings, flanges, valves,
strainers, drip legs, connections for instruments like pressure instruments, thermowells, flow
instruments etc.
 All inline instruments like pressure gauges, pressure and temperature transmitters, control valves,
PSVs, various types flow instruments like orifice, vortex, venture, rotameter as applicable shall be
modelled.
 Vessel trims with level gauges, level switches, level transmitters etc. shall be modelled.
 Piping shall be modelled with the type of insulation indicated on the PID.
 Piping supports shall be modelled.
 Tagging of all Line nos., Instruments nos., special items, and Equipment nos. shall be as per
P&IDs.
 It is to be ensured that the piping is modelled taking care of the Engineering design Basis-Piping
and with good engineering practice without any clash and taking care of good layout and meeting
the maintenance and operational requirements.

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c. Civil and Structural Modelling

 Complete underground facilities including various underground piping like drain lines etc. and
manholes, catch-pits shall be modelled.
 Soft envelopes to be modelled for the underground facilities so that any kind of interference
between the underground and above ground facilities can be avoided.
 All types of roads to be modelled.
 Any kind of dykes/ curb walls if applicable to be modelled.
 Water reservoirs to be modelled.
 Pipe rack shall be modelled along with all constituents like concrete, structural columns, beams,
stiffener plates, moment connections, bracings, gusset plates etc.
 Operating platforms to be modelled.
 The walkways to be modelled.
 Access ways, isles, escape routes to be modelled as a soft envelope.
 Handrails, gratings to be modelled.
 Buildings if in the scope of EPC Contractor to be modelled along with doors, windows, ducts.
 Staircases and ladders to be modelled.

d. Instrumentation Modelling
 Instrument cable ducts to be modelled.
 Analyser shelter/ cabinets to be modelled.
 Instrument junction boxes to be modelled.
 CCTV to be modelled.
 Local Control panels to be modelled.
 Impulse piping to be modelled.
 Detectors to be modelled.
 Instruments like gauges, transmitters, switches, etc. to be modelled.
 Level gauges, level transmitters to be modelled.

e. Electrical Modelling
 Electrical cable trays to be modelled.
 Local control stations to be modelled.
 Plant communication system equipment including field call stations, loudspeakers and telephones
in the field to be modelled.
 Lighting poles and other fixtures to be modelled.
 Sleeves containing cables to be modelled.
 Fire alarm system with all accessories to be modelled.
 Motors to be modelled.
 Junction boxes to be modelled.
 Transformers to be modelled.
 All other miscellaneous electrical equipment shall be modelled not limited to above.

f. Miscellaneous
Any package unit if in the scope of the EPC Contractor shall be modelled.

7.4 Discipline Interface Management

All the disciplines must carry out modelling concurrently on real times basis so that the interface issues do not
creep in while modelling. All modellers must attach / display the models of all disciplines for that particular zone
so as to minimize clashes between them.

However, regularly interface/ clash check is to be conducted among various disciplines to resolve any kind of
interference between them. Clash check has to be conducted before release of any deliverable. The records of
such coordination shall be maintained by the EPC Contractor.

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7.5 Design Review

In order to have a good quality 3D model maintaining good engineering practices and taking view of others as a
feedback to improve upon the modelling, it is imperative to have various model reviews at regular time intervals.
The following are minimum model reviews which are to be conducted by the EPC Contractor in order to improve
upon the quality of 3D model.

a. Internal Model Review

3D Model Review shall be conducted internally by EPC Contractor to check the model for completeness
of inputs, hold identification, progress review, identification &resolution of model queries and interface
among various disciplines. The model reviews shall be conducted on the Autodesk Navis-work
software.

The internal model review shall be carried out by EPC Contractor every month and record shall be
maintained for the same for review by OWNER/PMC any time as desired. The punch points so
observed must be attended by the EPC Contractor at the earliest after the completion of model review.
Clash check shall also be conducted at each stage of the internal model review session and the clashes
observed shall be resolved.

b. Model reviews
Comprehensive 3D model reviews with Owner/PMC shall be conducted as per below –

1. Stage-1 Model review

The purpose of this model review is to reflect upon the equipment placements, pipe rack design
and route, platform layouts, maintenance and constructability aspects of major equipment.

The minimum extent of modelling completeness required as a prerequisite to Stage-1 model

review is as below -
 All equipment modelling to be completed. The equipment’s whose drawings are not
available at the stage must be modelled as dummy with some prior data.
 All big bore lines modelling must be complete.
 Maintenance areas must be modelled as a soft envelope.
 Access ways and escape routes must be modelled as soft envelopes.
 Main pipe rack along with its branches must be modelled.
 Roads must be modelled.
 Bridges over the roads must be modelled.
 Firefighting equipment must be modelled.
 Underground main lines must be modelled along with manholes.

2. Stage-2 Model Review

The purpose of this model review is to ensure and emphasize upon the operability, accessibility,
and process design review and maintenance aspects of the facilities. The punch points of the
stage-1 model review shall first be closed before the start of the stage-2 model review.

The minimum extent of modelling completeness required as a prerequisite to Stage-1 model

review is as below -
 All the balance piping
 All equipment trims with their operating platforms.
 All platforms, stairs and ladders
 All structural detail members
 All piping supports
 Sprinkler piping if applicable.
 Cable trays and ducts
 Junction boxes, local control panels and local control stations
 All remaining underground facilities
 Package units if applicable
 All disciplines modelling complete in all respects.

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3. Stage-3 Model review (Final Model review)

The purpose of this model review is to review the modelling of any component whose data was
not available in the previous reviews like any instrument data, package vendor items like filter,
pumps, compressors etc. and to review the completeness/ resolution of tag points of earlier
model reviews. This model review shall be conducted after the availability of all data required to
complete the modelling of engineering works in all aspects.

The tag points/ observations of this stage of model review shall be resolved by the EPC
Contractor within 7 days of the completion of the review and the final 3D Model along with the tag
point’s resolution snapshots and xml file shall be furnished to the Owner/PMC for review at their
end.

Schedule for each stage of Model Review shall be prepared by the EPC Contractor and shall be
submitted to the Owner/ Consultant for review at their end. The comments on the schedule shall
be taken care by the EPC Contractor and the 3D Model reviews shall be conducted as per the
agreed schedule.

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8. PROCUREMENT OF PIPING MATERIALS

8.1 Scope
This specification covers the minimum requirements and recommendations to be followed in addition to the
respective codes and standards for the procurement of piping materials. In case of any conflict in the requirement
arisen from this specification and the codes/ standards, the more stringent requirement shall be followed.

8.2 Codes and Standards

The following codes and standards, to the extent specified herein, form a part of this specification –

ASME B 1.1 Unified inch screw threads

ASME B 1.20.1 Pipe threads-general purpose(inch)

ASME B 16.5 Pipe flanges and flanged fittings NPS ½ through NPS24

ASME B 16.9 Factory made wrought butt welding fittings

ASME B 16.11 Forged fittings, socket welding and threaded

Metallic gaskets for pipe flanges-Ring-joint, spiral-wound, and

ASME B 16.20
jacketed

ASME B 16.21 Non-metallic flat gaskets for pipe flanges

ASME B 16.25 Butt welding ends

ASME B 16.47 Large diameter steel flanges NPS 26 through NPS 60

ASME B16.48 Line Blanks

ASME B 31.3 Process piping

ASME B 36.10M Welded and seamless wrought steel pipe

ASME B 36.19M Stainless steel pipe

Integrally reinforced forged branch outlet fittings - socket

MSS SP 97
welding, threaded and butt welding ends

8.3 General Technical Requirements

a. Materials
i. Carbon Steel/ Alloy Steel
 Materials shall conform to the applicable specification.
 All forged carbon steel material shall be in normalized condition.

ii. Austenitic Stainless Steel

 Materials shall be furnished in the solution heat treated condition.
 In order to use austenitic stainless steel at lower temperature, base metal, weld deposits,
and heat affected zone shall be qualified as required by ASME B31.3 para. 323.2.2.
 For all austenitic stainless steel products inter-granular corrosion test shall have to be
conducted as per ASTM A262 Practice “B” with acceptance criteria of “60 mils/year (max.)”.

b. Impact Testing
All welded pipes/ fittings indicated as ‘CRYO’ & ‘LT’ in MR shall be impact tested per requirement &
acceptance criteria of ASME B31.3. The impact test procedure and the temperature range shall be as per
the relevant codes and standards.

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Document Number : D10-PMC-JSF-015

c. Galvanization
Galvanized piping items shall be coated with zinc by hot dip process conforming to ASTM A153.

Piping items where bevel end is specified, its configuration shall be in accordance with ASME B16.25

8.4 Item Specific Technical Requirements

a. Pipes
 Wall thickness shall conform to ASME B36.10M for carbon and alloy steels and to ASME
B36.10M/ASME B36.19M for stainless steels.

 Pipes with a positive quality tolerance of maximum one random length shall be acceptable (no
tolerance on negative side). Pipes shall be supplied in single or double random lengths of 4 to 7 and
7 to 14 meters respectively.

 Welded pipes up to sizes 36” shall be supplied with maximum one longitudinal joint. Pipes shall not
have any circumferential seam joint in a random length.

 Pipes made up of steel by acid Bessemer process shall not be acceptable.

 All longitudinally welded pipes should employ only automatic welding.

 Pipe with screwed ends shall have NPT external taper pipe threads conforming to ASME B1.20.1.

 Pipes under “NACE” category shall meet the requirements given in NACE MR-0103 unless
mentioned otherwise.

 All pipes shall be hydrostatically pressure tested as per the applicable code.

b. Fittings
 Welded Fittings
i. Design shall be in accordance with the requirements of ASME B31.3.
ii. Dimensions and tolerances shall conform to ASME B16.9.
iii. All welded fittings shall be double welded.
iv. For fittings made out of welded pipe, the welded pipe shall be double welded type & shall be
manufactured with the addition of filler metal.
v. All welds including welds in tubular products from which fittings are made shall be
radiographically examined throughout the entire length of each weld.
vi. Welded tees shall not be of fabricated (stub-in) type.
vii. For manufacturing of elbows from pipes, same size of pipe as that of elbow shall be used and
the nominal wall thickness of the starting pipes shall have positive tolerance only so that the
finished product does not have lower than the required thickness on any section.

 Wall Thickness of Tees

The type of tee required as “welding tee per ASME B16.9 with rx ≥ 1/8 Db and Tc ≥ 1.5 nominal
wall thickness” according to Appendix D of ASME B31.3, where -
Db : Outside Diameter of the Branch
Tc : Crotch thickness of branch connections measured at the center of the crotch
Rx : Radius of curvature

 Forged fittings (socket welding or screwed)

Dimensions and tolerances shall conform to ASME B16.11.

 Branch Outlet Fittings (“OLET” fittings)

Branch connections shall be designated to replace the use of tee pieces or set on branches and
provide reinforcement to replace material removed from pipe all in accordance with ASME B31.3.
Dimensions and tolerances shall meet the requirements of MSS SP 97 as applicable.

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c. Flanges
 Flange Dimensions
24” and smaller ASME B16.5
26” and larger ASME B16.47 series B

 Flange facing finish

Flange facing shall be in accordance with ASME B16.5 or ASME B16.47, as applicable. However,
raised face Flanges, the finish shall be normally specified in the requisition as serrated finish, i.e.,
125-250 AARH.

 Hardness
For Ring Joint Flanges, Blinds and Spacers, the hardness shall be as be as per the relevant codes
and standards.

For RTJ flanges, blinds & spacers, the hardness of the groove shall be specified on the test report.
For RTJ flanges, only octagonal section ring joint flanges shall be used.

Bore of weld neck flange shall correspond to the inside diameter of pipe for specified
schedule/thickness. Ends shall be bevelled to suit the specified schedule / thickness.

d. Valves
 General
i. Valves of Class 900 & above shall be pressure-seal type. Threaded and seal welded or
welded bonnet may be employed upto sizes 11/2".
ii. All flanged valves (except forged) shall have flanges integral with the valve body. Weld-on
flanges, if unavoidable, shall be made by full penetration joints and 100% radiographed.
iii. Yoke material shall be at least equal to body material.
iv. Forgings are acceptable in place of Castings but not vice-versa.

 Dimensions
Face-to-Face/End-to-End dimension shall be as per ANSI B16.10.

 Operation
Generally the valves are hand wheel or lever operated. However, suitable gear operator in enclosed
gear box shall be provided for valves as follows –

Valve Type Class for Sizes ≥

Gate/Globe 150 14"

300 12"
600 10"

Ball/Plug (other than 150 6"

Pressure balanced Plug) 300 6"

600 4"

Butterfly 150 6"

300 6"

Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500 mm on each
side. Effort to operate shall not exceed 35 kgf at hand wheel periphery. However, failing to meet the
above requirement, vendor shall offer gear operation.
Quarter-turn valves shall have "open" position indicators with limit stops.

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 By Pass
i. A globe type by-pass valve and drain connections shall be furnished in accordance with
MSS SP 45. Valves to be drilled and tapped for drain connections, body cavity vents etc.
shall be supplied with the tapped holes fitted with solid, square head pipe plugs of the
same material as the valve body, in accordance with ASME B16.34.
ii. By-pass Piping, Fitting and Valves shall be of compatible material and design. Complete
fillet welds for by-pass installation shall be DP/MP tested.

 Ball/Plug/Butterfly Valves
i. Each valve shall be supplied with a lever/wrench except for gear operated/ motor operated
valves.
ii. Soft seated ball, butterfly and plug valves shall be equipped with an anti-static
feature/device to ensure electrical continuity between balls, stem and body of valve.
iii. The ball of Ball valves shall not protrude outside the end flanges.
iv. Ball valves shall be floating ball type/trunion mounted type as per following –

Class Floating Ball Trunion Mounted

150 6" & below 8" & above
300 4" & below 6" & above
600 11/2" & below 2" & above

v. Use of soft seated ball/plug/butterfly valves shall be suitably selected based on

temperatures handled.
vi. For trunnion mounted ball valves, use of antifriction type of bearings is not allowed. Use of
bronze or any low strength material is not permitted. The trunnion shall be integral with the
ball.
vii. Butterfly valves shall be suitable for throttling application.
viii. Fire safe valves shall be used for all Hydrocarbon services.
ix. For Process (Hydrocarbon) services, butterfly valve shall be triple offset, high performance
type.

e. Strainer
 Allowable pressure drop when specified shall be certified along with the offer. If asked specifically,
pressure drop calculations shall be furnished.

 Mesh size for strainers used in the suction line of pumps shall be selected on the basis of the
pumped fluid Characteristics.

 In the Gas Suction service, the mesh in the strainer shall be reinforced with perforated plate or
heavier mesh and steel bars.

 All 2" & higher sized Y or T type strainers shall be provided with 3/4" threaded tap and solid threaded
plug as drain connection on the blind flange. For less than 2", this shall be 1/2" size.

 Bottom flange of Y-type strainer shall not have tapped hole. Full length standard size studs shall be
used for joining blind flange.

 Material for temporary strainer elements shall be suitable for the process fluid being handled.

 Conical strainer with mesh shall be used for the temporary strainer.

 Dimension Standards for various components are as follows -

Body ASME B16.9/B16.11
Flanges/ Blind Flange ASME B16.5/B16.47 Series B
Gaskets ASME B16.20/B16.21
Bolts & Nuts ASME B18.2.1 & B 18.2.2 respectively

 For fabricated strainers, all BW joints shall be fully radiographed and fillet welds shall be 100%
DP/MP checked.
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 All the strainers shall be hydrostatically tested as per ASME B 31.3 but minimum the twice of design
pressure of the line in which the strainer is installed.

 All 2" and higher size strainers shall be provided with 3/4" screwed plug for drain connection. For
less than 2" this shall be 1/2" size.

f. Hoses
 Suitability of hoses shall be guaranteed for the service and working conditions specified.

 All hoses shall be clearly marked with service and working pressure at both ends.

 Hoses shall be resistant to ageing, abrasion and suitable for outdoor installations.

 Complete Hose assembly shall be tested as per ASME B 31.3 but minimum at two times the design
pressure of the line in which the hose is to be installed.

 Electrical continuity test shall be conducted on all hoses which are made up of non-metallic materials
such as rubber etc.

g. Gaskets
 All gaskets, whatever the type, shall be asbestos free.

 Full face gaskets shall have bolt holes punched out.

 Non-metallic ring gaskets as per ASME/ANSI B16.21 and Spiral wound gaskets as per ASME
B16.20 shall match flanges to ASME/ANSI B16.5 up to 24", and ASME/ANSI B16.47 for sizes > 24".

 Inner and outer rings requirement for spiral wound gaskets shall be as per ASME B 16.20.

 Inner ring shall be provided for the following -

o As per code (B 16.20) requirement
o For sizes 26" & above in all classes
o For Vacuum, Cryogenic and Hydrogen service

 In case of RTJ gaskets, only octagonal section ring gaskets shall be used & shall have proper
marking stamped.

 Unless otherwise specified, the types of gaskets to be used shall be -

1. Flat gaskets
o Dimensions in accordance with ASME B16.21.
o Thickness 1.6mm, all diameters limited to maximum NPS 24
o Treated anti-stick both sides for the full range of temperature as specified.

2. Spiral wound gaskets

o All spiral wound gasket shall be supplied with centering ring whatever is the filler
material.
o All spiral wound gaskets rating 150# shall be of the low stress type.
o All spiral wound gaskets shall conform to ASME B16.20
o Spiral wound gaskets shall have a compressed thickness of 3.2mm from an
uncompressed thickness of 4.5mm.
o Diameters above NPS 24 shall conform to ASME B16.47 series B

3. Ring joint (RTJ)

o Ring joint gaskets shall be oval in cross section.
o Ring joint shall conform to ASME B16.20
o Hardness shall be in accordance with ASME B16.20 except for austenitic stainless
steels where Brinell hardness shall be less than 130.

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h. Studs/ Bolts and Nuts

 All bolting shall be as per ASME/ANSI B18.2.1 for Studs, M/C Bolts and Jack screws.
 Threads shall be unified (UNC for ≤ 1" dia and 8UN for > 1" dia) as per ANSI B1.1 with class 2A fit
for Studs, M/C Bolts and jack screws, and class 2B fit for nuts.
 Stud bolts shall be threaded full length with two heavy hex nuts. Length tolerance shall be in
accordance with the requirement of table F2 of Annexure F of ASME B16.5
 The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made by the
hot forged process.
 Nuts shall conform to ASME B18.2.2.
 Machine Bolts shall be supplied with 1 Heavy Hex nut
 The length of the studs/ bolts should be such that minimum two threads should be out of the nut on
either side.
 All the stud/ bolt should have metallurgical certificates in case of alloy/ SS metallurgy with identified
colour marking at the stud ends/ bolt side face.
 Heads of jack screws and M/C bolts shall be heavy hexagonal type. Jack screw end shall be
rounded.

i. Polypropylene Piping Items

 For Purified water, Homogenous polypropylene (PP-H-100) as per EN ISO 15494 shall be used.
 Dimensional standard for the PP-H-100 pipes, fittings and flanges shall be DIN 8077.
 For homogenous polypropylene, the material shall meet all the quality requirements as per DIN
8078.
 Non asbestos, EPDM gasket conforming to EN 681 shall be used for the flanges made up of
homogenous polypropylene.
 For laboratory waste vent system shall use Flame retardant polypropylene as per ASTM D 4101.
Mechanical joint fittings shall be used for all waste piping outdoors at accessible locations and
electrofusion welded fittings shall be used at inaccessible locations and behind the walls.

8.5 Marking and Transportation

a. Marking and Stamping
 All piping items shall be marked in accordance with the applicable codes, standards and
specifications. In addition the piping item code & special conditions if any shall also be marked.
 Components that cannot be hard stamped or electro-etched shall have the required markings
stamped on metal tags securely wired to each piece.
 Galvanized components shall not be electro-etched.
 Stainless steel components shall not be electro-etched prior to solution annealing and/or pickling.
 Marking can be omitted for components of nominal size of NPS 1 ½ and smaller provided marking
are transferred on the packing box.
 The marking requirements specified herein are in addition to the color coding requirements and shall
be positioned so as not to interfere with color coding.
 Immediately following the electro-etching of any ferrous component, the markings are to be painted
over with a durable, clear, hard finish varnish that will protect the markings from corrosive
obliteration.
 Paint or ink to be used shall not contain any harmful metal, or metal salts, such as zinc, lead,
Sulphur or copper which could cause corrosive attack on heating.
 Where specified to be on attached metal tags, metal dies shall be used to make a permanently
readable depression without cutting through the tag

b. Dispatch and Transportation

 All piping shall be ensured dry, clean and free from moisture, dirt and loose foreign materials of any
kind prior to transportation. Items shall be protected from rust & corrosion. Both ends of the pipes,
fittings, flanges and valves shall be protected with suitable means.
 Test reports shall be supplied for all mandatory tests as per the applicable material specifications.
Material test certificates for the physical property, chemical composition & special treatments carried
out on the piping items during manufacturing shall also be furnished.

8.6 Inspection
Scope of inspection by third party inspection agency for piping items procured from suppliers / manufacturer -
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Tests to be witnessed
i. Testing for physical properties.
ii. Visual Inspection & Dimensional check
 10% random basis for each heat. Minimum one length in case of pipe is procured from
manufacture.
 100% in case the pipe is procured from stockiest/ traders.
iii. Hydrostatic test
 10% random basis for each heat. Minimum one length in case the pipe is procured from
manufacture.
 100% in case the pipe is procured from stockiest / traders.

Review of documents
i. Mill test certificate of raw materials.
ii. Material identification reports.
iii. Radiographs (if required).
iv. Heat treatments (if required).
v. Material composition as per NACE (if required).
vi. Manufacturer’s test certificate.
vii. Hydro-test 100%
viii. Supplementary test as required.
ix. Manufacturer’s test certificates for 100% visual & dimension check in case of Manufacturer

Third party inspection release note shall contain the information on test witnessed, documents reviewed,
observations/ remarks, identifications, order status and date(s) of inspection. The original certificate shall be
furnished with supply of material.

Third party inspector shall stamp each length of pipe based on the same performed by the manufacturer and shall
mention the same in the inspection release note. For small bore i.e. 1½” and below, stamping on the bundle of
pipes instead of each length may be considered.

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Document Number : D10-PMC-JSF-015

9. PIPING MATERIAL SPECIFICATION

9.1 General
This specification covers the details of various piping classes for the utility and process service piping systems for
Indian Oil Technology Development & Deployment Centre planned by Indian Oil at Sector-13, Faridabad. These
shall be adhered to by EPC Contractor or his subcontractor(s) during the course of engineering, procurement,
construction and successful commissioning of the piping systems. All piping shall meet the requirements of ASME
B 31.3.

9.2 Reference Codes & Specifications

ASME B1.20.1 Pipe Threads General Purpose (Inch)
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME B16.9 Factory Made Wrought Steel Butt Welding Fittings
ASME B16.10 Face-To-Face & End-To-End Dimensions of Valves
ASME B16.11 Forged Steel Fittings (Socket Welded and Threaded)
ASME B16.20 Metallic Gasket for Pipe Flanges- Ring Joint, Spiral Wound & Jacketed
ASME B16.21 Non Metallic Flat Gaskets for Pipe Flanges
ASME B16.25 Butt Welding Ends
ASME B16.34 Valves - Flanged, Threaded & Welded Ends
ASME B16.47 Large Dia. Line Flanges: NPS 26 Thru NPS 60
ASME B18.2.1 Square and Hex. Bolts and Screws (Inch Series)
ASME B18.2.2 Square and Hex. Nuts (Inch Series)
ASME B31.3 Process Piping
ASME B36.10 Welded and Seamless Wrought Steel Pipe
ASME B36.19 Stainless Steel Pipe
ASME BPV SEC. IX Welding & Brazing Qualification
ASME BPV SEC. V Non Destructive Examination
ASME BPV SEC II Pt.C Welding Rods, Electrodes & Filler Materials
EJMA Standards Expansion Joint Manufacturer’s Association
API 6FA Specification for Fire Test for Valves
API 594 Check Valves: Wafer, Wafer Lug and Double Flanged Type
API 598 Valve Inspection & Testing
API 600 Bolted Bonnet Steel Gate Valves for Petroleum and Natural gas Industries
API 602 Steel Gate, Globe and Check Valves for Sizes DN 100 and Smaller for the
Petroleum and Natural gas Industries.
API 607 Fire Test for Soft Seated Quarter-Turn Valves
API 609 Butterfly Valves: Double Flanged, Lug and Wafer Type
BS 1868 Specification for Steel Check Valves (Flanged & Butt Welding Ends) For
The Petroleum, Petrochemical & Allied Industries.
BS 1873 Specification For Steel Globe And Globe Stop And Check Valves (Flanged
& Butt Welding Ends) For The Petroleum, Petrochemical & Allied
Industries.
BS 5155 Specification for Butterfly Valves.
BS 5351 Specification for Steel Ball Valve for the Petroleum, Petrochemical & Allied
Industries.
BS 5352 Specification For Steel Wedge, Gate, and Globe & Check Valves For
50mm And Smaller For Petroleum, Petrochemical & Allied Industries.
BS 6755 PT I Testing Of Valves: Specification For Production Pressure Testing
Requirements.
BS 6755 PT II Testing Of Valves: Specification for Fire Type-Testing Requirements
MSS-SP-97 Integrally Reinforced Forged Branch Outlet Fittings- Socket Welding,
Threaded & Butt Welding Ends
All other statutory requirements of governing authority or its sub divisions, where piping is to be installed shall be
followed.

Indian Government / Haryana State Government Rules and Regulations/ bye-laws, applicable Indian Standards
and Codes shall be complied.

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9.3 Design Requirements

Individual piping Class has been generally designed to cover a set of services operating within pressure-
temperature combination as per ASME B16.5 / B16.34 or part of it.

9.4 Piping Class Designation

The class designation shall consist of three components made up of a letter, number & letter.

 The first component designates the rating if the piping class as per ASME B-16.5. The rating designations
shall be as per below -
01- 150#
02- 300#
03- 600#
04- 900#
05- 1500#
06- 2500#

 The second component consists of a letter which designates the metallurgy of the piping class. The
metallurgy designations shall be as per below -
C - Carbon Steel
G - Carbon Steel- Galvanized
X - Carbon Steel- IBR
K - Stainless Steel SS 304
L - Stainless Steel SS 304L
M - Stainless Steel SS 316
N - Stainless Steel SS 316L
P - Polyproylene
Q - Copper
V - CPVC

 The third component designates the service of the fluid in the piping. The service designations are as per
below -
01- Utility water like Raw Water, Tempered water, Hot water-HVAC, Domestic Cold water
02- Specialty gases of high purity (N2, CO2, He, Oxygen, Argon etc.), Nitrogen, Lab Vacuum
03- Laboratory Natural Gas, Flammable gases like H2, CH4, C2H2
04- Potable water, Softened (Demineralised) water, Industrial hot & cold water
05- Specialty gases of high purity (N2, CO2, He, Oxygen, Argon etc.)- Certified for Oxygen Service
06- Laboratory Compressed Air, Laboratory Air- Certified for Oxygen Service
07- Tepid Water and Industrial soft water
08- Deleted
09- Domestic and Flushing Water, Potable water outside the process area
10- Laboratory Waste and Vent
11- Purified Water
12- Process chilled water (PCWS/ PCWR), chilled water (CHWS/ CHWR), Industrial hot water
(IHW), Industrial cold water (ICW)
13- Liquid Nitrogen

9.5 Piping Items Specific Notes

9.5.1 Pipes
 NPS 3/8, 1¼, 2½, 3½, and NPS 5 shall not be used. However, in cases where the use of these sizes
cannot be avoided, the required piping material, fittings, flanges, valves and gaskets shall be the same
material as next larger sizes in the applicable piping class.
 Pipe dimension shall be in accordance with ASME B36.10, for wrought steel and wrought iron pipe; to
B36.10 / B36.19 for stainless steel pipe and respective ASTM standard.

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9.5.2 Flanges
 Flanges not conforming to ASME B16.5, ASME B16.1, or ASME B16.47 shall be specified on piping
drawings.
 Sizes for reducing or blind flanges are indicated by nominal pipe sizes.
 Cross reference of Press. /Temp. rating for Metric PN Class vs. ASME Class -
PN Class 20 50 64 100 150 250 420
ASME Class 150 300 400 600 900 1500 2500

 Piping flanges not shown in the piping classes but that are required to mate to control valves, spec breaks at
valves, equipment, or vessel nozzles, are permitted. For example: Higher rating flanges are permitted in
lesser rating piping system or ASME B16.47 series B flanges are allowed to match equipment/vessel
nozzles). All mating flanges with applicable line class bolting and gasket materials shall be provided by
piping BOM.
 Fl and SPCR & BLN shall be as per B16.48 upto 24" (150-1500#) & upto 12" for 2500#.

9.5.3 Fittings
 Reducing Fittings
o Reducing fittings shall only be utilized as indicated in the individual Piping Class Branch
Connection Chart, unless otherwise indicated on the P&ID.
o Reducers (concentric or eccentric) are the preferred fittings for all butt weld end reductions.
o Swage Nipples shall be used for reductions between buttweld end and socketweld or threaded
end pipe and piping components. The maximum size of any swage shall be NPS 4.
o Reducing couplings shall be used for line reductions NPS 2 and smaller where the centerline of
pipe elevations are to be maintained. Reducing couplings are preferred in lieu of swages for
sizes NPS 2 and less.
 Threaded joints shall conform to American Standard taper per ASME B1.20.1.
 Forged steel threaded and socket weld fittings shall be per ASME B16.11.
 Butt-weld fittings shall be in accordance with ASME B16.9.

9.5.4 Gaskets
 Unless otherwise noted non-metallic gaskets shall be 1.6 mm (1/16”) thick after compression.
 Unless otherwise noted spiral wound gaskets shall be 3.0 mm (1/8”) thick after compression.

9.5.5 Bolting
 Stud bolt lengths shall be purchased to the next higher increment of 13 mm (1/2”). Upon installation,
standard bolt thread shall be exposed only on one side with the thread exposure of the extra bolt length to
the other side of the flange.
 Cap screws shall only be used when mating valves with threaded taps. These cap screws shall have the
same material designation and grade as the stud bolts in the corresponding pipe classes. The valve
manufacturer’s stated tap depth and thread data shall be used as the basis for the final selection of cap
screws.

9.5.6 Vents and Drains

Valved and un-valved pipe vent and drain connections shall be NPS ¾.

9.5.7 Threads
 Threads for threaded Pipes, Fittings, Flanges and Valves shall be in accordance with B1.20.1 taper threads
unless otherwise mentioned.
 Upto 204 deg.C, threaded joints shall be made with 1" width PTFE joining tape.
 Above 204 deg.C, threaded joints shall be seal welded with a full strength fillet weld.
 All threaded joints irrespective of pressure and temperature on lines carrying toxic fluid shall be seal welded
with a full strength fillet weld.

For Piping Material Specification Classes, kindly refer Attachement-1.

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Document Number : D10-PMC-JSF-015

10. VALVE MATERIAL SPECIFICATION

10.1 Gate Valves

GAV01C01F GATE VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: FULL
DISC: FLEXIBLE ONE-PIECE WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST CARBON STEEL, ASTM A216 GR. WCB
TRIM: API-600 NO. 8
SERVICE: NORMAL FLUID
DESIGN: API-600
DIMENSIONS: ASME B16.10
TEST: API-598

GAV01L02F/ GATE VALVE

GAV01L03F RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: FULL
DISC: FLEXIBLE ONE-PIECE WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 GR. CF3M
TRIM: SS 316L
STEM PACKING: TFE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34
DIMENSIONS: ASME B16.10
TEST: API-598

GAV01L05F/ GATE VALVE

GAV01L06F RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: FULL
DISC: FLEXIBLE ONE-PIECE WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 GR. CF3M
TRIM: SS 316L
STEM PACKING: TFE
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: ASME B16.34
DIMENSIONS: ASME B16.10
TEST: API-598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

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Document Number : D10-PMC-JSF-015

GAV05L02F/ GATE VALVE

GAV05L03F RATING: CLASS 1500, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: FULL
DISC: FLEXIBLE ONE-PIECE WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 GR. CF3M
TRIM: SS 316L
STEM PACKING: FLEXIBLE GRAPHITE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34
DIMENSIONS: ASME B16.10
TEST: API-598

GAV05L05F GATE VALVE

RATING: CLASS 1500, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: FULL
DISC: FLEXIBLE ONE-PIECE WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 GR. CF3M
TRIM: SS 316L
STEM PACKING: FLEXIBLE GRAPHITE
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: ASME B16.34
DIMENSIONS: ASME B16.10
TEST: API-598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1
GAV01K04F GATE VALVE
RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: FULL
DISC: FLEXIBLE ONE-PIECE WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 GR. CF8
TRIM: SS 304
STEM PACKING: TFE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34
DIMENSIONS: ASME B16.10
TEST: API-598

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Document Number : D10-PMC-JSF-015

GAV01K13F GATE VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: FULL
DISC: FLEXIBLE ONE PIECE WEDGE,WITH 1/8”DIAMETER BLEED HOLE
BONNET & STEM: BOLTED BONNET, RISING STEM, EXTENDED BONNET REQUIRED
MATERIAL: CAST STAINLESS STEEL, ASTM A351 GR. CF8M
TRIM: API-600 NO. 10
SERVICE: CRYOGENIC TO –196 ºC
DESIGN: ASME B16.34, BS-6364
DIMENSIONS: ASME B16.10
TEST: API-598, BS-6364

GAV01M12F GATE VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: FULL
DISC: FLEXIBLE ONE-PIECE WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 GR. CF8M
TRIM: SS 316
STEM PACKING: TFE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34
DIMENSIONS: ASME B16.10
TEST: API-598

GAV02C03F GATE VALVE

RATING: CLASS 300, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: FULL
DISC: FLEXIBLE ONE-PIECE WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST CARBON STEEL, ASTM A216 GR. WCB
TRIM: API-600 NO. 8
SERVICE: NORMAL FLUID
DESIGN: API-600
DIMENSIONS: ASME B16.10
TEST: API-598

GAV01G09S GATE VALVE

RATING: CLASS 150, MSS-SP-80
ENDS: SCREWED FEMALE 3000 PER ASME B-1.20.1
PORT: REGULAR
DISC: SOLID WEDGE, BRONZE
MATERIAL: ASTM B62,GRADE 83600
TRIM: BRONZE
SERVICE: NORMAL FLUID
DESIGN: MSS-SP80
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598

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Document Number : D10-PMC-JSF-015

GAV01G09F GATE VALVE

RATING: CLASS 150, MSS-SP128
ENDS: FLGD PER ASME B16.5
STEM TYPE: BRONZE
PORT: REGULAR
DISC: SOLID WEDGE, BRONZE
BONNET & STEM: BOLTED BONNET, NON RISING STEM
MATERIAL: ASTM A 395
TRIM: BRONZE, C83600
SERVICE: NORMAL FLUID
DESIGN: MSS-SP128
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598

GAV01L02W/ GATE VALVE

GAV01L03W RATING: CLASS 800, API-602
ENDS: BUTTWELD PER ASME B16.25
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: REDUCED
DISC: SOLID WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 GR. F316L
TRIM: STELLITED
STEM PACKING: TFE
SERVICE: NORMAL FLUID
DESIGN: API-602
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598

GAV01L05W/ GATE VALVE

GAV01L06W RATING: CLASS 800, API-602
ENDS: BUTTWELD PER ASME B16.25
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: REDUCED
DISC: SOLID WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 GR. F316L
TRIM: STELLITED
STEM PACKING: TFE
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: API-602
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

GAV01K04W GATE VALVE

RATING: CLASS 800, API-602
ENDS: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: REDUCED
DISC: SOLID WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 GR. F304
TRIM: STELLITED
STEM PACKING: TFE
SERVICE: NORMAL FLUID
DESIGN: API-602
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598

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Document Number : D10-PMC-JSF-015

GAV01K13W GATE VALVE

RATING: CLASS 800, API-602
ENDS: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: REDUCED
DISC: SOLID WEDGE, WITH 1/8” DIAMETER BLEED HOLE
BONNET & STEM: BOLTED BONNET, RISING STEM, EXTENDED BONNET REQUIRED
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 GR. F316
TRIM: API-602 NO. 10
SERVICE: CRYOGENIC TO –196 ºC
DESIGN: API-602, BS-6364
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598, BS-6364
OPERATOR: HANDWHEEL

GAV01M12W GATE VALVE

RATING: CLASS 800, API-602
ENDS: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: REDUCED
DISC: SOLID WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 GR. F316
TRIM: STELLITED
STEM PACKING: TFE
SERVICE: NORMAL FLUID
DESIGN: API-602
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598

GAV05L02W/ GATE VALVE

GAV05L03W RATING: CLASS 1500, API-602
ENDS: BUTTWELD PER ASME B16.25
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: REDUCED
DISC: SOLID WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 GR. F316L
TRIM: STELLITED
STEM PACKING: FLEXIBLE GRAPHITE
SERVICE: NORMAL FLUID
DESIGN: API-602
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598

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Document Number : D10-PMC-JSF-015

GAV05L05W GATE VALVE

RATING: CLASS 1500, API-602
ENDS: BUTTWELD PER ASME B16.25
STEM TYPE: OUTSIDE SCREW AND YOKE
PORT: REDUCED
DISC: SOLID WEDGE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 GR. F316L
TRIM: STELLITED
STEM PACKING: FLEXIBLE GRAPHITE
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: API-602
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

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Document Number : D10-PMC-JSF-015

10.2 Ball Valves

BV01C01F BALL VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
PORT: REGULAR
TYPE: FLOATING BALL
MATERIAL: CAST CARBON STEEL, ASTM A216 WCB
BALL & STEM: 316 STAINLESS STEEL
TRIM: 316 STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE / GRAPHITE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34 / API 608
DIMENSIONS: SHORT PATTERN TO ASME B16.10
TEST: API 598

BV01L02F BALL VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
PORT: REGULAR
TYPE: FLOATING BALL
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF3M
BALL & STEM: 316L STAINLESS STEEL
TRIM: 316L STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE / GRAPHITE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34 / API 608
DIMENSIONS: SHORT PATTERN TO ASME B16.10
TEST: API 598

BV01L03F BALL VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
PORT: REGULAR
TYPE: FLOATING BALL
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF3M
BALL & STEM: 316L STAINLESS STEEL
TRIM: 316L STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE / GRAPHITE
SERVICE: HYDROCARBON
DESIGN: ASME B16.34 / API 608/ FIRE SAFE TO API 607
DIMENSIONS: SHORT PATTERN TO ASME B16.10
TEST: API 598/ FIRE SAFE TEST TO API 607

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Document Number : D10-PMC-JSF-015

BV01L05F/ BALL VALVE

BV01L06F RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
PORT: REGULAR
TYPE: FLOATING BALL
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF3M
BALL & STEM: 316L STAINLESS STEEL
TRIM: 316L STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE / GRAPHITE
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: ASME B16.34 / API 608
DIMENSIONS: SHORT PATTERN TO ASME B16.10
TEST: API 598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

BV01K04F BALL VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
PORT: REGULAR
TYPE: FLOATING BALL
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF8
BALL & STEM: 304 STAINLESS STEEL
TRIM: 304 STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE / GRAPHITE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34 / API 608
DIMENSIONS: SHORT PATTERN TO ASME B16.10
TEST: API 598

BV01K13F BALL VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
PORT: REGULAR
TYPE: FLOATING BALL
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF8M
BALL & STEM: 304 STAINLESS STEEL
TRIM: 304 STAINLESS STEEL
SEATS/SEALS: CPTFE / GRAPHITE
SERVICE: CRYOGENIC TO -196 DEG C
DESIGN: ASME B16.34 / API 608, BS-6364
DIMENSIONS: SHORT PATTERN TO ASME B16.10
TEST: API 598, BS-6364
OTHER REQ.: 1. EXTENDED BONNET/ GLAND AS PER BS-6364
2. PRESSURE RELIEVING DEVICE IN THE FORM OF A HOLE IN
. BALL FOR RELIEVING CAVITY PRESSURE ON UPSTREAM SIDE.

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Document Number : D10-PMC-JSF-015

BV01M12F BALL VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
PORT: REGULAR
TYPE: FLOATING BALL
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF8M
BALL & STEM: 316 STAINLESS STEEL
TRIM: 316 STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE / GRAPHITE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34 / API 608
DIMENSIONS: SHORT PATTERN TO ASME B16.10
TEST: API 598

BV02C03F BALL VALVE

RATING: CLASS 300, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
PORT: REGULAR
TYPE: FLOATING BALL
MATERIAL: CAST CARBON STEEL, ASTM A216 WCB
BALL & STEM: 316 STAINLESS STEEL
TRIM: 316 STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE / GRAPHITE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34 / API 608/ FIRE SAFE DESIGN TO API 607
DIMENSIONS: SHORT PATTERN TO ASME B16.10
TEST: API 598/ FIRE SAFE TEST TO API 607

BV01C01W BALL VALVE

RATING: CLASS 600 / API-608
ENDS: SOCKETWELD PER ASME B16.11 W/PE NIPPLES
PORT: REGULAR
BODY DESIGN: THREE PIECE OR TOP ENTRY
TYPE: FLOATING BALL
MATERIAL: FORGED CARBON STEEL, ASTM A105
TRIM: 316 STAINLESS STEEL
BALL & STEM: 316 STAINLESS STEEL
SEATS/SEALS: REINFORCED PTFE / GRAPHITE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34 / API-608
TEST: API-598

BV02C03W BALL VALVE

RATING: CLASS 600 / API-608
ENDS: SOCKETWELD PER ASME B16.11 W/PE NIPPLES
PORT: REGULAR
BODY DESIGN: THREE PIECE OR TOP ENTRY
TYPE: FLOATING BALL
MATERIAL: FORGED CARBON STEEL, ASTM A105
TRIM: 316 STAINLESS STEEL
BALL & STEM: 316 STAINLESS STEEL
SEATS/SEALS: REINFORCED PTFE / GRAPHITE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34 / API-608/ FIRE SAFE TO API 607
TEST: API-598, FIRE SAFE TEST TO API 607

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Document Number : D10-PMC-JSF-015

BV01G09S BALL VALVE

RATING: CLASS 150
ENDS: SCRF TO B-16.11
PORT: REGULAR
TYPE: FLOATING BALL
MATERIAL: ASTM B62,GRADE 83600
TRIM: BRONZE
BALL & STEM: BRONZE
SEATS/SEALS: REINFORCED PTFE / GRAPHITE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34
TEST: API-598

BV01L02W BALL VALVE

RATING: CLASS 600 / API 608
ENDS: BUTTWELD PER ASME B16.25 W/PE NIPPLES
PORT: REGULAR
BODY DESIGN: THREE-PIECE BODY OR TOP ENTRY
TYPE: FLOATING BALL
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP.316L
BALL & STEM: 316L STAINLESS STEEL
TRIM: 316L STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34 / API 608
TEST: API-598

BV01L03W BALL VALVE

RATING: CLASS 600 / API 608
ENDS: BUTTWELD PER ASME B16.25 W/PE NIPPLES
PORT: REGULAR
BODY DESIGN: THREE-PIECE BODY OR TOP ENTRY
TYPE: FLOATING BALL
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP.316L
BALL & STEM: 316L STAINLESS STEEL
TRIM: 316L STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE
SERVICE: HYDROCARBON
DESIGN: ASME B16.34 / API 608/ FIREE SAFE TO API 607
TEST: API-598, FIRE SAFE TEST TO API 607

BV01L05W/ BALL VALVE

BV01L06W RATING: CLASS 600 / API 608
ENDS: BUTTWELD PER ASME B16.25 W/PE NIPPLES
PORT: REGULAR
BODY DESIGN: THREE-PIECE BODY OR TOP ENTRY
TYPE: FLOATING BALL
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP.316L
BALL & STEM: 316L STAINLESS STEEL
TRIM: 316L STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: ASME B16.34 / API 608
TEST: API-598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

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Document Number : D10-PMC-JSF-015

BV01K04W BALL VALVE

RATING: CLASS 600 / API 608
ENDS: SOCKETWELD PER ASME B16.11 W/PE NIPPLES
PORT: REGULAR
BODY DESIGN: THREE-PIECE BODY OR TOP ENTRY
TYPE: FLOATING BALL
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP.304
BALL & STEM: 304 STAINLESS STEEL
TRIM: 304 STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34 / API 608
TEST: API-598

BV01M12W BALL VALVE

RATING: CLASS 600 / API 608
ENDS: SOCKETWELD PER ASME B16.11 W/PE NIPPLES
PORT: REGULAR
BODY DESIGN: THREE-PIECE BODY OR TOP ENTRY
TYPE: FLOATING BALL
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP.316
BALL & STEM: 316 STAINLESS STEEL
TRIM: 316 STAINLESS STEEL
SEATS/SEALS: REINFORCED TFE
SERVICE: NORMAL FLUID
DESIGN: ASME B16.34 / API 608
TEST: API-598

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Document Number : D10-PMC-JSF-015

10.3 Check Valves

CV01C01F CHECK VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
TYPE: SWING
COVER: BOLTED
MATERIAL: CARBON STEEL, A216 GR. WCB
TRIM: API 600 NO. 1
SERVICE: WATER
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

CV01L02F/ CHECK VALVE

CV01L03F RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
TYPE: SWING
COVER: BOLTED
MATERIAL: STAINLESS STEEL, A351 CF3M
TRIM: SS316L
SERVICE: LAB GASES
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

CV01L05F/ CHECK VALVE

CV01L06F RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
TYPE: SWING
COVER: BOLTED
MATERIAL: STAINLESS STEEL, A351 CF3M
TRIM: SS316L
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

CV01K04F CHECK VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
TYPE: SWING
COVER: BOLTED
MATERIAL: STAINLESS STEEL, A351 CF8
TRIM: SS304
SERVICE: WATER
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

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Document Number : D10-PMC-JSF-015

CV01K13F CHECK VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
TYPE: SWING
COVER: BOLTED COVER
MATERIAL: CAST 316 STAINLESS STEEL, ASTM A351 GR CF8M
TRIM: API 600 NO. 10
SERVICE: CRYOGENIC TO –196 C
DESIGN: ASME B16.34, BS-6364
DIMENSIONS: ASME B16.10
TEST: API 598, BS-6364

CV01M12F CHECK VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
TYPE: SWING
COVER: BOLTED
MATERIAL: STAINLESS STEEL,A351 CF8M
TRIM: SS316
SERVICE: WATER
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

CV02C03F CHECK VALVE

RATING: CLASS 300, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
TYPE: SWING
COVER: BOLTED
MATERIAL: CARBON STEEL, A216 GR. WCB
TRIM: API 600 NO. 1
SERVICE: WATER
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

CV05L02F/ CHECK VALVE

CV05L03F RATING: CLASS 1500, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
TYPE: SWING
COVER: BOLTED
MATERIAL: STAINLESS STEEL, A351 CF3M
TRIM: SS316L
SERVICE: LAB GASES
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

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Document Number : D10-PMC-JSF-015

CV05L05F CHECK VALVE

RATING: CLASS 1500, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
TYPE: SWING
COVER: BOLTED
MATERIAL: STAINLESS STEEL, A351 CF3M
TRIM: SS316L
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

CV01C01W/ CHECK VALVE, API 602

CV02C03W RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
TYPE: LIFT CHECK TYPE
COVER: BOLTED
MATERIAL: FORGED CARBON STEEL, ASTM A105
TRIM: API 602 NO. 1, WITH STAINLESS STEEL SPRING
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

CV01G09S CHECK VALVE, MSS-SP80

RATING: CLASS 150, MSS-SP80
ENDS: SCRF AS PER ASME B-1.20.1
TYPE: LIFT CHECK TYPE
MATERIAL: ASTM B 62, UNS C83600
TRIM: BRONZE, C83600
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

CV01L02W/ CHECK VALVE, API 602

CV01L03W RATING: CLASS 800, API 602
ENDS: BUTTWELD PER ASME B16.25
TYPE: LIFT CHECK TYPE
COVER: BOLTED
MATERIAL: FORGED STAINLESS STEEL, ASTM A182, GR F316L
TRIM: TRIM SS 316L STELLITED, STAINLESS STEEL SPRING
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

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Document Number : D10-PMC-JSF-015

CV01L05W/ CHECK VALVE, API 602

CV01L06W RATING: CLASS 800, API 602
ENDS: BUTTWELD PER ASME B16.25
TYPE: LIFT CHECK TYPE
COVER: BOLTED
MATERIAL: FORGED STAINLESS STEEL, ASTM A182, GR F316L
TRIM: TRIM SS 316L STELLITED, STAINLESS STEEL SPRING
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598
CLEANING:CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1
CV05L02W/ CHECK VALVE, API 602
CV05L03W RATING: CLASS 1500, API 602
ENDS: BUTTWELD PER ASME B16.25
TYPE: PISTON TYPE LIFT CHECK
COVER: BOLTED
MATERIAL: FORGED STAINLESS STEEL, ASTM A182, GR F316L
TRIM: TRIM SS 316L STELLITED, STAINLESS STEEL SPRING
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

CV05L05W CHECK VALVE, API 602

RATING: CLASS 1500, API 602
ENDS: BUTTWELD PER ASME B16.25
TYPE: PISTON TYPE LIFT CHECK
COVER: BOLTED
MATERIAL: FORGED STAINLESS STEEL, ASTM A182, GR F316L
TRIM: TRIM SS 316L STELLITED, STAINLESS STEEL SPRING
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

CV01K04W CHECK VALVE, API 602

RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
TYPE: LIFT CHECK TYPE
COVER: BOLTED
MATERIAL: FORGED STAINLESS STEEL, ASTM A182, GR F304
TRIM: TRIM SS 304 STELLITED, STAINLESS STEEL SPRING
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

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Document Number : D10-PMC-JSF-015

CV01K13W CHECK VALVE, API 602

RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
TYPE: LIFT CHECK TYPE
COVER: BOLTED
MATERIAL: FORGED STAINLESS STEEL, ASTM A182, GR F316
TRIM: TRIM NO. 10, STAINLESS STEEL SPRING
SERVICE: CRYOGENIC TO –196 C
DESIGN: API 602, BS-6364
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598, BS-6364

CV01M12W CHECK VALVE, API 602

RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
TYPE: LIFT CHECK TYPE
COVER: BOLTED
MATERIAL: FORGED STAINLESS STEEL, ASTM A182, GR F316
TRIM: TRIM SS 316 STELLITED, STAINLESS STEEL SPRING
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

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Document Number : D10-PMC-JSF-015

10.4 Globe Valves

GV01C01F GLOBE VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST CARBON STEEL, ASTM A216 GRADE WCB
TRIM: API 600 NO. 1
SERVICE: NORMAL FLUID
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

GV01G09F GLOBE VALVE

RATING: CLASS 150, MSS-SP85
ENDS: FLGD PER ASME B16.5, FF/125AARH
STEM TYPE: BRONZE
PORT: REGULAR
DISC: PLUG TYPE, BRONZE
BONNET & STEM: BOLTED BONNET, NON RISING STEM
MATERIAL: ASTM A 395
TRIM: BRONZE, C83600
SERVICE: NORMAL FLUID
DESIGN: MSS-SP128
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598

GV01L02F/ GLOBE VALVE

GV01L03F RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF3M
TRIM: SS 316L
SERVICE: NORMAL FLUID
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

GV01L05F/ GLOBE VALVE

GV01L06F RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF3M
TRIM: SS 316L
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

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GV01K04F GLOBE VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF8
TRIM: SS 304
SERVICE: NORMAL FLUID
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

GV01K13F GLOBE VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM, EXTENDED BONNET REQUIRED
MATERIAL: CAST 316 STAINLESS STEEL, ASTM A351 GR. CF8M
TRIM: API 600 NO. 10
SERVICE: CRYOGENIC TO –196 C
DESIGN: ASME B16.34, BS-6364
DIMENSIONS: ASME B16.10
TEST: API-598, BS-6364

GV01M12F GLOBE VALVE

RATING: CLASS 150, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF8M
TRIM: SS 316
SERVICE: NORMAL FLUID
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

GV02C03F GLOBE VALVE

RATING: CLASS 300, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST CARBON STEEL, ASTM A216 GRADE WCB
TRIM: API 600 NO. 1
SERVICE: NORMAL FLUID
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

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Document Number : D10-PMC-JSF-015

GV05L02F/ GLOBE VALVE

GV05L03F RATING: CLASS 1500, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF3M
TRIM: SS 316L
SERVICE: NORMAL FLUID
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598

GV05L05F GLOBE VALVE

RATING: CLASS 1500, ASME B16.34
ENDS: RF FLANGED, ASME B16.5
FACING: 1/16 INCH RAISED FACE, SERRATED FINISH PER ASME B16.5
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: CAST STAINLESS STEEL, ASTM A351 CF3M
TRIM: SS 316L
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: API 600
DIMENSIONS: ASME B16.10
TEST: API 598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

GV01C01W/ GLOBE VALVE

GV02C03W RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED CARBON STEEL, ASTM A105
TRIM: API 602 NO. 1
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

GV01G09S GLOBE VALVE

RATING: CLASS 150, MSS-SP-80
ENDS: SCREWED FEMALE 3000 PER ASME B-1.20.1
DISC: PLUG TYPE, BRONZE
MATERIAL: ASTM B62,GRADE 83600
TRIM: BRONZE, C83600
SERVICE: NORMAL FLUID
DESIGN: MSS-SP80
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598

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Document Number : D10-PMC-JSF-015

GV01L02W/ GLOBE VALVE

GV01L03W RATING: CLASS 800, API 602
ENDS: BUTTWELD PER ASME B16.25
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP 316L
TRIM: STELLITED
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

GV01L05W/ GLOBE VALVE

GV01L06W RATING: CLASS 800, API 602
ENDS: BUTTWELD PER ASME B16.25
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP 316L
TRIM: STELLITED
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1
GV01K04W GLOBE VALVE
RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP 304
TRIM: STELLITED
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

GV01K13W GLOBE VALVE

RATING: CLASS 800, API 602
END: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM, EXTENDED BONNET REQUIRED
MATERIAL: FORGED 316 STAINLESS STEEL, ASTM A182 GR F316
TRIM: API 602 NO. 10
SERVICE: CRYOGENIC TO –196 C
DESIGN: API 602, BS-6364
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API 598, BS-6364
OPERATOR: HANDWHEEL

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GV01M12W GLOBE VALVE

RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP 316
TRIM: STELLITED
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

GV05L02W/ GLOBE VALVE

GV05L03W RATING: CLASS 1500, API 602
ENDS: BUTTWELD PER ASME B16.25
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP 316L
TRIM: STELLITED
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

GV05L05W GLOBE VALVE

RATING: CLASS 1500, API 602
ENDS: BUTTWELD PER ASME B16.25
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: PLUG TYPE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP 316L
TRIM: STELLITED
SERVICE: CERTIFIED FOR OXYGEN SERVICE
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598
CLEANING: CLEANING FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA,G-4.1

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Document Number : D10-PMC-JSF-015

10.5 Butterfly Valves

BFV01C01F BUTTERFLY VALVE

RATING: CLASS 150, ASME B16.34
ENDS: WAFL TO ASME B-16.5 WAF/125 AARH
FACING: RAISED FACE, SERRATED FINSH PER ASME B16.5
MATERIAL: CAST CARBON STEEL, ASTM A216 GR. WCB
STEM: 17-4 PH SHAFT
DISC MATERIAL: ASTM A 216 GR. WCB
DISC LINER : RPTFE/ EPDM
SEAT & SEAL: 13% CR STEEL/ SS 316, GRAPHITE SEAL
SERVICE: NORMAL FLUID
DESIGN: API 609
TEST: API 598

BFV02C03F BUTTERFLY VALVE

RATING: CLASS 300, ASME B16.34
ENDS: WAFL. TO ASME B-16.5 WAF/125 AARH
FACING: RAISED FACE, SERRATED FINSH PER ASME B16.5
MATERIAL: CAST CARBON STEEL, ASTM A216 GR. WCB
STEM: 17-4 PH SHAFT
DISC MATERIAL: ASTM A 216 GR. WCB, TRIPLE OFFSET
DISC LINER : SS 316 + GRAPHITE
SEAT & SEAL: 13% CR STEEL/ SS 316, GRAPHITE SEAL
SERVICE: HRDROCARBON
DESIGN: API 609, FIRE SAFE TO API 607
TEST: API 598, FIRE SAFE TEST AS PER API 607
OTHER REQ.: HIGH PERFORMANCE TYPE, TIGHT SHUT-OFF

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10.6 Needle Valve

NV01C01W NEEDLE VALVE

RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: NEEDLE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED CARBON STEEL, ASTM A105
TRIM: API 602 NO. 1
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

NV01G09S NEEDLE VALVE

RATING: CLASS 150, MSS-SP-80
ENDS: SCREWED FEMALE 3000 PER ASME B-1.20.1
DISC: NEEDLE, BRONZE
MATERIAL: ASTM B62,GRADE 83600
TRIM: BRONZE, C83600
SERVICE: NORMAL FLUID
DESIGN: MSS-SP80
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API-598
NV01K04W NEEDLE VALVE
RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: NEEDLE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP 304
TRIM: STELLITED
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

NV01K13W NEEDLE VALVE

RATING: CLASS 800, API 602
END: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: NEEDLE
BONNET & STEM: BOLTED BONNET, RISING STEM, EXTENDED BONNET REQUIRED
MATERIAL: FORGED 316 STAINLESS STEEL, ASTM A182 GR F316
TRIM: API 602 NO. 10
SERVICE: CRYOGENIC TO –196 C
DESIGN: API 602, BS-6364
DIMENSIONS: MANUFACTURER’S STANDARD
TEST: API 598, BS-6364
OPERATOR: HANDWHEEL

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NV01M12W NEEDLE VALVE

RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: NEEDLE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED STAINLESS STEEL, ASTM A182 TP 316
TRIM: STELLITED
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

NV02C03W NEEDLE VALVE

RATING: CLASS 800, API 602
ENDS: SOCKETWELD PER ASME B16.11
STEM TYPE: OUTSIDE SCREW AND YOKE
DISC: NEEDLE
BONNET & STEM: BOLTED BONNET, RISING STEM
MATERIAL: FORGED CARBON STEEL, ASTM A105
TRIM: API 602 NO. 1
SERVICE: NORMAL FLUID
DESIGN: API 602
DIMENSIONS: MANUFACTURER'S STANDARD
TEST: API 598

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ANNEXURE - SHEET FOR LISTING DEVIATIONS

Although deviations are generally not acceptable, but in case it becomes pertinent
as per Vendor, then they are requested to specifically give the details of
deviations, if any, on this sheet and continuation thereof in the below mentioned
format only.

Deviation mentioned at any other place shall not be considered.

Item Description As per

S. no. Deviation by Tenderer/Bidder Approved By
Tender

10

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PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01C01"

Class Conditions
Pressure Temperature
SERVICE TEMPERED WATER Kg/ cm2 °C
20.04 -29
20.04 38
PIPING CLASS: # 150 18.28 93
PIPING CODE ASME B 31.3 16.17 149
COROSSION ALLOWANCE: 1.6 MM 14.06 204
DSG. PR. 15 kg/cm2 at 45 Deg C
NORE-1 NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.
NOTE- 2 ALL SMALL BORE SOFT SEATED WELDED VALVES SHALL HAVE 100mm SPOOL PIECE
Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
PIPES
DN 15-DN 40 XS ASME B-36.10 ASTM A106 GR.B PE,SEAMLESS
DN-50 XS ASME B-36.10 ASTM A106 GR.B BE,SEAMLESS
PIPES
DN 80-DN 150 STD ASME B-36.10 ASTM A106 GR.B BE,SEAMLESS
DN 200-DN 600 STD ASME B-36.10 ASTM A53 GR.B BE,ERW
DN 15-DN 40 160 ASME B-36.10 ASTM A106 GR.B TOE, SEAMLESS
NIPPLE
DN 15-DN 40 XS ASME B-36.10 ASTM A106 GR.B PBE, SEAMLESS
FLANGES

WN FLANGE DN 50-DN 600 M ASME B-16.5 ASTM A 105 150,RF/125 AARH

SW FLANGE DN 15-DN 40 ASME B-16.5 ASTM A 105 150,RF/125AARH

BLIND
DN 15 – DN 600 ASME B-16.5 ASTM A 105 150,RF/125 AARH
FLANGE
FLNG.FIG.8 DN 15-DN 300 ASME B-16.48 ASTM A 105 150,FF/125AARH

SPCR & BLIND DN 350-DN 600 ASME B-16.48 ASTM A 105 150,FF/125AARH
FITTINGS
DN 15-DN 40 ASME B-16.11 ASTM 105 SW,3000
ELBOW 90 DN 50-DN 150 M ASME B-16.9 ASTM A234 GR.WPB-SEAMLESS BW, R=1.5D
DN 200 - DN 600 M ASME B-16.9 ASTM A234 GR.WPB-WELDED BW, R=1.5D
DN 15-DN 40 ASME B-16.11 ASTM 105 SW,3000
ELBOW 45 DN 50-DN 150 M ASME B-16.9 ASTM A234 GR.WPB-SEAMLESS BW, R=1.5D
DN 200 - DN 600 M ASME B-16.9 ASTM A234 GR.WPB-WELDED BW, R=1.5D
DN 15 – DN 40 ASME B-16.11 ASTM A105 SW,3000
TEE DN 50-DN 150 M ASME B-16.9 ASTM A234 GR.WPB-SEAMLESS BW
DN 200 - DN 600 M ASME B-16.9 ASTM A234 GR.WPB-WELDED BW
DN 50 – DN 150 M ASME B-16.9 ASTM A234GR.WPB,SEAMLESS BW
REDUC. ECC.
DN 200 – DN 600 M ASME B-16.9 ASTM A234GR.WPB,WELDED BW

DN 50 – DN 150 M ASME B-16.9 ASTM A234GR.WPB,SEAMLESS BW

REDUC. CON.
DN 200 – DN 600 M ASME B-16.9 ASTM A234GR.WPB,WELDED BW

RED. CPLNG.
DN 15 – DN 40 ASME B-16.11 ASTM A 105 SW,3000
COUPLING

FULL CPLNG. DN 15 – DN 40 ASME B-16.11 ASTM A 105 SW,3000

DN15 – DN 40 ASME B-16.11 ASTM A 105 SW,3000

CAP DN 50 – DN 150 M ASME B-16.9 A234 GR.WPB,SEAMLESS BW

DN 200 – DN 600 M ASME B-16.9 A234 GR.WPB,WELDED BW

SWAGE ECC. DN 15 – DN 80 M BS-3799 ASTM A 105 PBE

SWAGE CONC. DN 15 – DN 80 M BS-3799 ASTM A 105 PBE

HEX. PLUG DN 15 – DN 40 ASME B16.11 ASTM A 105 3000, THREADED

GASKETS
ASME B16.21- NON ASBESTOS, ARAMID FIBRES
GASKETS DN 15 – DN 600 RING ,150#, 3MM
ASME B16.5 BOUND WITH PTFE
BOLT S/ NUTS

BOLT STUD DN 15 – DN 600 ASME B-18.2 BOLT: A193 GR.B7,NUT: A194 GR.2H
 PIPING MATERIAL SPECIFICATION "01C01"
VALVES PIPING MATERIAL SPECIFICATION "01C01" Class Conditions
BODY-ASTM A105,TRIM BODY SEAT
DN 15-DN 40 SERVICE TEMPERED
API 608 WATER SW, 600# BV01C01W
RPTFE, TRIM-SS316
BALL VALVE
ASME B-16.34/ BODY-ASTM A105/A216GR.WCB, BODY FLGD, 150#, ASME B-16.5, RF/
DN 15-DN 600 BV01C01F
API 608 SEAT RPTFE, TRIM-SS316 125AARH
DN 10-DN 40 API-602 ASTM A105,TRIM NO. 8 SW, 800#, 3000, B-16.11 GAV01C01W
GATE VALVE FLGD, 150#, ASME B-16.5,
DN 50-DN 600 API-600 BODY-ASTM A216 GR.WCB,TRIM NO. 8 GAV01C01F
RF/125AARH
DN 15 – DN 40 API 602 ASTM A105,TRIM-NO. 1 SW, 800#, 3000, B-16.11 CV01C01W
CHECK VALVE API 600 /
DN 50 – DN 600 BODY-ASTM A216 GR.WCB,TRIM-NO.1 FLGD, 150#, B-16.5, RF/125AARH CV01C01F
B-16.34
DN 15 – DN 40 API 602 ASTM A105,TRIM-NO. 1 SW, 800#, CL.3000, B-16.11 GV01C01W
GLOBE VALVE API 600 /
DN 50 – DN 400 BODY-ASTM A216 GR.WCB,TRIM-NO. 1 FLGD 150#, B-16.5, RF/125 AARH GV01C01F
B-16.34
NEEDLE VALVE DN 10 - DN 40 API 602 ASTM A105,TRIM-NO. 1 SW, 800#, CL.3000, B-16.11 NV01C01W
BODY-ASTM A216 GR.WCB,TRIM-13%
BUTERFLY VALVE DN 80– DN 600 API-609 WAFL, 150#, B-16.5, 125AARH BFV01C01F
CR STEEL
STRAINERS
DN 15 – DN 40 MNF STD A105 ; INT SS304 SW,Y-TYPE,800
DN 50 – DN 150 M MNF STD BODY A234 GR.WPB; INT SS304 BW,T-TYPE
STRAINER
BODY A234 GR.WPB WELDED ; INT
DN 200- DN 600 M MNF STD BE,T-TYPE
SS304
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01C4"

Class Conditions
Pressure Temperature
SERVICE HOT WATER - HVAC Kg/ cm2 °C
10.55 0
10.55 38
PIPING CLASS: # 150 10.55 50
PIPING CODE ASME B 31.3 10.55 65
COROSSION ALLOWANCE: 1.6 MM 10.55 100
DSG. PR. 15 kg/cm2 at 45 Deg C 10.55 150
NORE-1 NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.
NOTE- 2 ALL SMALL BORE SOFT SEATED WELDED VALVES SHALL HAVE 100mm SPOOL PIECE
Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
PIPES
DN 15-DN 50 SCH. HVY IS-1239-PART I IS-1239- BLACK SCRM, WELDED
PIPES DN-65- DN150 SCH. HVY IS-1239-PART I IS-1239- BLACK SCRM, WELDED
UL & FM APPROVED DI GROOVED
DN150-DN300 6.0 MM IS-3589 IS-3589 GR. 330
FITTING END
NIPPLE DN 15-DN 40 SCH. HVY IS-1239-PART I IS-1239- BLACK SCRM, WELDED
FLANGES

S.O. FLANGE DN 50-DN 300 M ASME B-16.5 ASTM A 105 150,RF/125 AARH

SW FLANGE DN 15-DN 40 ASME B-16.5 ASTM A 105 150,RF/125AARH

BLIND
DN 15 – DN 300 ASME B-16.5 ASTM A 105 150,RF/125 AARH
FLANGE

FLNG.FIG.8 DN 15-DN 300 ASME B-16.48 ASTM A 105 150,FF/125AARH

FITTINGS
IS- 1239-PART
DN 15-DN 50 IS-1239-PART II SCRF
II
MADE FROM HVY GRADE IS-1239-
ELBOW 90 DN 65-DN 150 M UL & FM APPROVED DI GROOVED GROOVED END
PART- I PIPE
MADE FROM HVY GRADE IS-3589,
DN 200 - DN 600 M UL & FM APPROVED DI GROOVED GROOVED END
6.0 MM THK PIPE
DN 15-DN 50 IS-1239-PART II IS-1239-PART II SCRF
MADE FROM HVY GRADE IS-1239-
ELBOW 45 DN 65-DN 150 M UL & FM APPROVED DI GROOVED GROOVED END
PART- I PIPE
MADE FROM HVY GRADE IS-3589,
DN 200 - DN 600 M UL & FM APPROVED DI GROOVED GROOVED END
6.0 MM THK PIPE
DN 15-DN 50 IS-1239-PART II IS-1239-PART II SCRF
MADE FROM HVY GRADE IS-1239-
TEE DN 65-DN 150 M UL & FM APPROVED DI GROOVED GROOVED END
PART- I PIPE
MADE FROM HVY GRADE IS-3589,
DN 200 - DN 600 M UL & FM APPROVED DI GROOVED GROOVED END
6.0 MM THK PIPE
DN 15-DN 50 IS-1239-PART II IS-1239-PART II SCRF
MADE FROM HVY GRADE IS-1239-
REDUC. ECC. DN 65-DN 150 M UL & FM APPROVED DI GROOVED GROOVED END
PART- I PIPE
MADE FROM HVY GRADE IS-3589,
DN 200 - DN 600 M UL & FM APPROVED DI GROOVED GROOVED END
6.0 MM THK PIPE
DN 15-DN 50 IS-1239-PART II IS-1239-PART II SCRF
MADE FROM HVY GRADE IS-1239-
REDUC. CON. DN 65-DN 150 M UL & FM APPROVED DI GROOVED GROOVED END
PART- I PIPE
MADE FROM HVY GRADE IS-3589,
DN 200 - DN 600 M UL & FM APPROVED DI GROOVED GROOVED END
6.0 MM THK PIPE

RED. CPLNG.
DN 15 – DN 40 ASME B-16.11 ASTM A 105 SW,3000
COUPLING

FULL CPLNG. DN 15 – DN 40 ASME B-16.11 ASTM A 105 SW,3000

DN 15-DN 50 IS-1239-PART II IS-1239-PART II SCRF

MADE FROM HVY GRADE IS-1239-
CAP DN 65-DN 150 M UL & FM APPROVED DI GROOVED GROOVED END
PART- I PIPE
MADE FROM HVY GRADE IS-3589,
DN 200 - DN 600 M UL & FM APPROVED DI GROOVED GROOVED END
6.0 MM THK PIPE
GASKETS
ASME B16.21- NON ASBESTOS, ARAMID FIBRES
GASKETS DN 15 – DN 600 RING ,150#, 3MM
ASME B16.5 BOUND WITH PTFE
BOLT S/ NUTS
BOLT: A193 GR.B7 (GALV.),NUT: A194
BOLT STUD DN 15 – DN 600 ASME B-18.2
GR.2H (GALV.)
VALVES
BODY-ASTM A105,TRIM BODY SEAT
DN 15-DN 40 API 608 SW, 600# BV01C01W
RPTFE, TRIM-SS316
BALL VALVE
ASME B-16.34/ BODY-ASTM A105/A216GR.WCB, FLGD, 150#, ASME B-16.5, RF/
DN 15-DN 600 BV01C01F
API 608 BODY SEAT RPTFE, TRIM-SS316 125AARH
DN 10-DN 40 API-602 ASTM A105,TRIM NO. 8 SW, 800#, 3000, B-16.11 GAV01C01W
GATE VALVE FLGD, 150#, ASME B-16.5,
DN 50-DN 600 API-600 BODY-ASTM A216 GR.WCB,TRIM NO. 8 GAV01C01F
RF/125AARH
DN 15 – DN 40 API 602 ASTM A105,TRIM-NO. 1 SW, 800#, 3000, B-16.11 CV01C01W
CHECK VALVE API 600 /
DN 50 – DN 600 BODY-ASTM A216 GR.WCB,TRIM-NO.1 FLGD, 150#, B-16.5, RF/125AARH CV01C01F
B-16.34
DN 15 – DN 40 API 602 ASTM A105,TRIM-NO. 1 SW, 800#, CL.3000, B-16.11 GV01C01W
GLOBE VALVE API 600 /
DN 50 – DN 400 BODY-ASTM A216 GR.WCB,TRIM-NO. 1 FLGD 150#, B-16.5, RF/125 AARH GV01C01F
B-16.34
NEEDLE VALVE DN 10 - DN 40 API 602 ASTM A105,TRIM-NO. 1 SW, 800#, CL.3000, B-16.11 NV01C01W
BODY-ASTM A216 GR.WCB,TRIM-13%
BUTERFLY VALVE DN 80– DN 600 API-609 WAFL, 150#, B-16.5, 125AARH BFV01C01F
CR STEEL
STRAINERS
DN 15 – DN 40 MNF STD A105 ; INT SS304 SW,Y-TYPE,800
DN 50 – DN 150 M MNF STD BODY A234 GR.WPB; INT SS304 BW,T-TYPE
STRAINER
BODY A234 GR.WPB WELDED ; INT
DN 200- DN 600 M MNF STD BE,T-TYPE
SS304
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01K13"

Class Conditions
Pressure Temperature
SERVICE LIQUID NITROGEN Kg/ cm2 °C
19.33 -196
19.33 38
PIPING CLASS: # 150 16.17 93
PIPING CODE ASME B 31.3 14.41 149
COROSSION ALLOWANCE: 0 MM 13.35 204
DSG. PR. 15 kg/cm2 at -110 Deg C
NOTE-1 THIS PIPING CLASS IS FOR CRYOGENIC SERVICE.
NORE-2 NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.

Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
PIPES
DN 15-D 40 40S ASME B-36.10 ASTM A312GR TP 304 PE,SEAMLESS
PIPE DN 50 -DN 50 40S ASME B-36.10 ASTM A312GR TP 304 BE,SEAMLESS
DN 80-DN 600 10S ASME B-36.10 ASTM A312GR TP 304 BE,EFSW
DN 15-DN 40 80S ASME B-36.10 ASTM A312GR TP 304 TOE SEAMLESS
NIPPLE
DN 15-DN 40 40S ASME B-36.10 ASTM A312GR TP 304 PBE SEAMLESS
FLANGES
WN FLANGE DN 15-DN 40 ASME B-16.5 ASTM A 182 GR F 304 150,RF/125 AARH
LJ FLANGE DN 50-DN 600 ASME B-16.5 ASTM A 105 150, STK
BLIND FLANGE DN 15 – DN600 ASME B-16.5 ASTM A 182 GR F 304 150,RF/125 AARH
SPCR & BLND DN 15-DN 600 ASME B-16.48 ASTM A 182 GR F 304 150,FF/125 AARH
FITTINGS
DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 304 SW,3000
ELBOW 90 DN 50-DN 50 M ASME B-16.9 ASTM A403 GR WP304 SEAMLESS BW,1.5D
DN 80-DN 600 M ASME B-16.9 ASTM A403 GR WP304 -WX WELDED BW,1.5D
DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 304 SW,3000
ELBOW 45 DN 50-DN 50 M ASME B-16.9 ASTM A403 GR WP304 SEAMLESS BW,1.5D
DN 80-DN 600 M ASME B-16.9 ASTM A403 GR WP304 -WX WELDED BW,1.5D
DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 304 SW,3000
TEE DN 50-DN 50 M ASME B-16.9 ASTM A403 GR WP304 SEAMLESS BW
DN 80-DN 600 M ASME B-16.9 ASTM A403 GR WP304 -WX WELDED BW
REDUC. ECC. DN 50 – DN 600 M ASME B-16.9 ASTM A403 GR WP304-WX WELDED BW

REDUC. CON. DN 50 – DN 600 M ASME B-16.9 ASTM A403 GR WP304-WX WELDED BW

RED. COUPLING DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 304 SW,3000

FULL COUPLING DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 304 SW,3000

DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 304 SW,3000

CAP DN 50-DN 50 M ASME B-16.9 ASTM A403 GR WP304 SEAMLESS BW

DN 80-DN 600 M ASME B-16.9 ASTM A403 GR WP304 -WX WELDED BW

SWAGE ECC. DN 15 – DN 80 M BS-3799 ASTM A 182 GR F 304 PBE

SWAGE CONC. DN 15 – DN 80 M BS-3799 ASTM A403 GR WP304 PBE

STUB END DN 50-DN 50 M ASME B-16.9 ASTM A403 GR WP304 SEAMLESS BW, 125 AARH
STUB END DN 50-DN 600 M ASME B-16.9 ASTM A403 GR WP304 -WX WELDED BW, 125 AARH
HEX. PLUG DN 15-DN 40 ASME B16.11 ASTM A 182 GR F 304 SCRD, 3000
GASKETS

ASME B16.20-ASME SPIRAL WOUND, 304 SS W/GRAPHITE

GASKETS DN 15 – DN 600 300#, 3MM, SPIRAL
B16.5 FILLER, SS 304 CENTERING RING
BOLTS
BOLT: A320 GR.B8 CL. 2,NUT: A194 GR.8
BOLT STUD DN 15 – DN 600 ASME B-18.2.1/18.2.2
HEAVY HEX. NUTS
VALVES
ASME B-16.34/ API BODY-ASTM A351 CF8M, TRIM- SS 316,
BALL VALVE DN 15-DN 40 FLGD,150,B-16.5,RF/125AARH BV01K13F
608 BODY SEAT PCTFE
DN 15 – DN 40 API-602 ASTM A182 F316,TRIM NO. 10 SW,800,3000,B-16.11 GAV01K13W
GATE VALVE
DN 50 – DN 600 API-600 ASTM A 351 CF8M, TRIM NO. 10 FLGD,150,B-16.5,RF/125 AARH GAV01K13F
DN 15 – DN 40 API 602 ASTM A 182 GR. F316, TRIM NO. 10 SW,800,3000,B-16.11 CV01K13W
CHECK VALVE API 600 /
DN 50 – DN 600 ASTM A 351 CF8, TRIM NO. 10 FLGD,150,B-16.5,RF/125 AARH CV01K13F
B-16.34
NEDDLE VALVE DN 15 – DN 40 API 602 ASTM A182 F316 TRIM NO. 10 SW,800,3000,B-16.11 NV01K13W
DN 15 – DN 40 API 602 ASTM A182 F316,TRIM NO. 10 SW,800,3000,B-16.11 GV01K13W
GLOBE VALVE API 600 /
DN 50 – DN 600 ASTM A 351 CF8, TRIM NO. 10 FLGD,150,B-16.5,RF/125 AARH GV01K13F
B-16.34
STRAINERS
ASTM A 403 GR WP 316 SEAMLESS; INT
DN 50 – DN 50 SS316 BW,T-TYPE
M MNF
STRAINER ASTM A 403 GR WP 316 -WX WELDED;
DN 80 – DN 600 INT SS316 BW,T-TYPE
M MNF
DN 15 – DN 40 MNF A 182 RG. F 316 INT 316 SW,Y-TYPE,800
NOTES PERTAINING TO CRYOGENIC SERVICE:

1. Impact testing is required for all welded piping items.

2. In shop and/or field fabrication welds (girth, branch and fillet), all weld metal deposits and heat affected zone (HAZ) shall meet the impact test requirements for low temperature service (at -196°C for semi-
cryogenic S.S. "K" specs and for cryogenic S.S. "L" specs) per Paragraph 323 of ASME B31.3
3. A 1/8 in. diameter bleed hole shall be provided in the disc from the cavity of the gate valve to the “vent” side of the valve only. An arrow with “vent” shall be stamped on the outside of the valve body indicating
the direction of venting.
4. Extended bonnet valves shall have the minimum extended bonnet lengths from the centerline of the valve bore to the bottom of the packing (stuffing box) as stated in BS-6364.
5. Blind and spacer shall be used instead of Figure 8 in cryogenic services.
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01M12"

Class Conditions
Pressure Temperature
PROCESS CHILLED WATER (PCWS/ PCWR), CHILLED WATER (CHWS/ CHWR), INDUSTRIAL
SERVICE Kg/ cm2 °C
HOT WATER (IHW), INDUSTRIAL COLD WATER (ICW)
19.33 -29
19.33 38
PIPING CLASS: # 150 16.52 93
PIPING CODE ASME B 31.3 15.11 149
COROSSION ALLOWANCE: 0 MM 13.71 204
DSG. PR. 15 kg/cm2 at 45 Deg C
NORE-1 NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.
NOTE-2 THE WELDING OF JOINTS SHALL BE DONE WITH ORBITAL WELDING ONLY.
NOTE- 3 ALL SMALL BORE SOFT SEATED WELDED VALVES SHALL HAVE 100mm SPOOL PIECE.
Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
PIPES
DN 15-D 40 40S ASME B-36.10 ASTM A312GR TP 316 PE,SEAMLESS
PIPE DN 50 -DN 50 40S ASME B-36.10 ASTM A312GR TP 316 BE,SEAMLESS
DN 80-DN 300 10S ASME B-36.10 ASTM A312GR TP 316 BE,SEAMLESS
DN 15-DN 40 80S ASME B-36.10 ASTM A312GR TP 316 TOE SEAMLESS
NIPPLE
DN 15-DN 40 40S ASME B-36.10 ASTM A312GR TP 316 PBE SEAMLESS
FLANGES

WN FLANGE DN 15-DN 300 ASME B-16.5 ASTM A 182 GR F 316 150,RF/125 AARH

BLIND FLANGE DN 15 – DN300 ASME B-16.5 ASTM A 182 GR F 316 150,RF/125 AARH

FLNG.FIG.8 DN 15-DN 300 ASME B-16.48 ASTM A 182 GR F 316 150,FF/125 AARH

FITTINGS
DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 316 SW,3000
ELBOW 90
DN 50-DN 300 M ASME B-16.9 ASTM A403 GR WP316 SEAMLESS BW,1.5D
DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 316 SW,3000
ELBOW 45
DN 50-DN 300 M ASME B-16.9 ASTM A403 GR WP316 SEAMLESS BW,1.5D
DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 316 SW,3000
TEE
DN 50-DN 300 M ASME B-16.9 ASTM A403 GR WP316 SEAMLESS BW

REDUC. ECC. DN 50 – DN 300 M ASME B-16.9 ASTM A403 GR WP316 SEAMLESS BW

REDUC. CON. DN 50 – DN 300 M ASME B-16.9 ASTM A403 GR WP316 SEAMLESS BW

RED. COUPLING DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 316 SW,3000

FULL COUPLING DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 316 SW,3000

DN 15-DN 40 ASME B-16.11 ASTM A 182 GR F 316 SW,3000
CAP
DN 50-DN 300 M ASME B-16.9 ASTM A403 GR WP316 SEAMLESS BW
SWAGE ECC. DN 15 – DN 80 M BS-3799 ASTM A 182 GR F 316 PBE

SWAGE CONC. DN 15 – DN 80 M BS-3799 ASTM A403 GR WP316 PBE

HEX. PLUG DN 15-DN 40 ASME B16.11 ASTM A 182 GR F 316 SCRD, 3000
GASKETS
NON ASBESTOS, GASKET WITH
ASME B16.21-
GASKETS DN 15 – DN 300 SYNTHETIC FIBRES BONDED WITH RING ,150#, 3MM
ASME B16.5
NBR.
BOLTS
ASME B-
BOLT STUD DN 15 – DN 600 BOLT: A193 GR.B8,NUT: A194 GR.8
18.2.1/18.2.2
VALVES
BODY-ASTM A182 F316 ,TRIM-SS 316,
DN 15-DN 40 API 608 SW,600#, 3000, B 16.11 BV01M12W
BODY SEAT RPTFE
BALL VALVE
ASME B-16.34/ BODY-ASTM A351 CF8M,TRIM- SS 316,
DN 15-DN 300 FLGD,150,B-16.5,RF/125AARH BV01M12F
API 608 BODY SEAT RPTFE
DN 15 – DN 40 API-602 ASTM A182 F316,TRIM STELLITED SW,800,3000,B-16.11 GAV01M12W
GATE VALVE
DN 50 – DN 300 API-600 ASTM A 351 CF8M, TRIM 316 FLGD,150,B-16.5,RF/125 AARH GAV01M12F
ASTM A 182 GR. F316, TRIM 316
DN 15 – DN 40 API 602 SW,800,3000,B-16.11 CV01M12W
STELLITED
CHECK VALVE
API 600 /
DN 50 – DN 300 ASTM A 351 CF8M, TRIM 316 FLGD,150,B-16.5,RF/125 AARH CV01M12F
B-16.34
NEDDLE VALVE DN 15 – DN 40 API 602 ASTM A182 F316,TRIM STELLITED SW,800,3000,B-16.11 NV01M12W
DN 15 – DN 40 API 602 ASTM A182 F316,TRIM STELLITED SW,800,3000,B-16.11 GV01M12W
GLOBE VALVE API 600 /
DN 50 – DN 300 ASTM A 351 CF8M, TRIM 316 FLGD,150,B-16.5,RF/125 AARH GV01M12F
B-16.34
STRAINERS
ASTM A 403 GR WP 316 SEAMLESS;
DN 50 – DN 300 BW,T-TYPE
STRAINER M MNF INT SS316
DN 15 – DN 40 MNF A 182 RG. F 316 INT 316 SW,Y-TYPE,800
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01L02"

Class Conditions
Pressure Temperature
SPECIALTY GASES OF HIGH PURITY (N2, CO2, HE, OXYGEN, ARGON ETC.), NITROGEN, LABORATORY
SERVICE Kg/ cm2 °C
VACUUM
16.17 -29
16.17 38
PIPING CLASS: # 150 13.71 93
PIPING CODE ASME B 31.3
COROSSION ALLOWANCE: 0 MM
DSG. PR. 10 kg/cm2 at 55 Deg C
NOTE1: FOR WELD JOINTS, ONLY ORBITAL WELDING SHALL BE DONE.
NOTE2: NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.
NOTE3:

Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
TUBES
O.D. 0.50 INCH 0.89 ASTM A 269 ASTM A269, TP-316L
O.D. 0.75 INCH 1.25 ASTM A 269 ASTM A269, TP-316L
O.D. 01.0 NCH 1.65 ASTM A 269 ASTM A269, TP-316L
O.D. 1.50 INCH 1.65 ASTM A 269 ASTM A269, TP-316L
TUBES
O.D.02.0 INCH 2.6 ASTM A 269 ASTM A269, TP-316L
O.D.03.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
O.D.04.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
O.D.06.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
FLANGES
O.D. 0.50 INCH TO FLANGE BORE TO MATCH TUBE
FLANGE WN M ASME B-16.5 ASTM A 182 GR F 316L 150,RF/125 AARH
O.D. 06.0 INCH BORE
FITTINGS
O.D. 0.50 INCH TO
TUBE BEND 90 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH
O.D. 0.50 INCH TO
TUBE BEND 45 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH
O.D. 0.50 INCH TO
TEE ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED TEE
O.D. 06.0 INCH
O.D. 0.50 INCH TO
REDUC. CON. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH
O.D. 0.50 INCH TO
REDUC. ECC. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH
O.D. 0.50 INCH TO
WELDOLET MSS-SP97 ASTM A 182 GR F 316L BE, BORE TO MATCH TUBE BORE
O.D. 02.0 INCH
GASKETS

O.D. 0.50 INCH TO ASME B16.20- SPIRAL WOUND, SS 316L+ GRAFOIL + I

GASKETS SPIRAL GASKET, 150#
O.D. 06.0 INCH ASME B16.5 RING
BOLTS/ NUTS

O.D. 0.50 INCH TO

BOLT STUD ASME B-18.2 ASTM A 453, GR. 660 CLASS A
O.D. 06.0 INCH
VALVES
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,800,3000,B-16.11 GAV01L02W
1.50 INCH
GATE VALVE
O.D. 02.0 INCH TO
API-600 ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH GAV01L02F
06.0 INCH
O.D. 0.50 INCH TO ASTM A 182 GR. F316L, TRIM 316L
API 602 BW,800,3000,B-16.11 CV01L02W
1.50 INCH STELLITED
CHECK VALVE
O.D. 02.0 INCH TO API 600 /
ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH CV01L02F
06.0 INCH B-16.34
O.D. 0.50 INCH TO
API 602 ASTM A182 F316L,TRIM STELLITED SW,800,3000,B-16.11 GV01L02W
1.50 INCH
GLOBE VALVE
O.D. 02.0 INCH TO API 600 /
ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH GV01L02F
06.0 INCH B-16.34
BODY-ASTM A182 F316L ,TRIM-SS 316L,
DN 15-DN 40 API 608 SW,600#, 3000, B 16.11 BV01L02W
BODY SEAT RPTFE
BALL VALVE
ASME B-16.34/ BODY-ASTM A351 CF3M, TRIM- SS
DN 15-DN 600 FLGD,150,B-16.5,RF/125AARH BV01L02F
API 608 316L, BODY SEAT RPTFE
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01L03"

Class Conditions
Pressure Temperature
SERVICE LABORATORY NATURAL GAS, FLAMMABLE GASES LIKE H2, CH4, C2H2 Kg/ cm2 °C
16.17 -29
16.17 38
PIPING CLASS: # 150 13.71 93
PIPING CODE ASME B 31.3
COROSSION ALLOWANCE: 0 MM
DSG. PR. 10 kg/cm2 at 55 Deg C
NOTE1: FOR WELD JOINTS, ONLY ORBITAL WELDING SHALL BE DONE.
NOTE2: NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.
NOTE3: BALL VALVES SHALL BE FIRE SAFE DESIGN

Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
TUBES
O.D. 0.50 INCH 0.89 ASTM A 269 ASTM A269, TP-316L
O.D. 0.75 INCH 1.25 ASTM A 269 ASTM A269, TP-316L
O.D. 01.0 NCH 1.65 ASTM A 269 ASTM A269, TP-316L
O.D. 1.50 INCH 1.65 ASTM A 269 ASTM A269, TP-316L
TUBES
O.D.02.0 INCH 2.6 ASTM A 269 ASTM A269, TP-316L
O.D.03.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
O.D.04.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
O.D.06.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
FLANGES
O.D. 0.50 INCH TO FLANGE BORE TO MATCH TUBE
FLANGE WN M ASME B-16.5 ASTM A 182 GR F 316L 150,RF/125 AARH
O.D. 06.0 INCH BORE
FITTINGS
O.D. 0.50 INCH TO
TUBE BEND 90 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH
O.D. 0.50 INCH TO
TUBE BEND 45 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH
O.D. 0.50 INCH TO
TEE ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED TEE
O.D. 06.0 INCH
O.D. 0.50 INCH TO
REDUC. CON. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH
O.D. 0.50 INCH TO
REDUC. ECC. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH
O.D. 0.50 INCH TO
WELDOLET MSS-SP97 ASTM A 182 GR F 316L BE, BORE TO MATCH TUBE BORE
O.D. 02.0 INCH
GASKETS
O.D. 0.50 INCH TO ASME B16.20- SPIRAL WOUND, SS 316L+ GRAFOIL + I
GASKETS SPIRAL GASKET, 150#
O.D. 06.0 INCH ASME B16.5 RING
BOLTS/ NUTS
O.D. 0.50 INCH TO
BOLT STUD ASME B-18.2 ASTM A 453, GR. 660 CLASS A
O.D. 06.0 INCH
VALVES
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,800,3000,B-16.11 GAV01L03W
1.50 INCH
GATE VALVE
O.D. 02.0 INCH TO
API-600 ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH GAV01L03F
06.0 INCH
O.D. 0.50 INCH TO ASTM A 182 GR. F316L, TRIM 316L
API 602 BW,800,3000,B-16.11 CV01L03W
1.50 INCH STELLITED
CHECK VALVE
O.D. 02.0 INCH TO API 600 /
ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH CV01L03F
06.0 INCH B-16.34
O.D. 0.50 INCH TO
API 602 ASTM A182 F316L,TRIM STELLITED SW,800,3000,B-16.11 GV01L03W
1.50 INCH
GLOBE VALVE
O.D. 02.0 INCH TO API 600 /
ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH GV01L03F
06.0 INCH B-16.34
BODY-ASTM A182 F316L ,TRIM-SS
DN 15-DN 40 API 608 SW,600#, 3000, B 16.11 BV01L03W
316L, BODY SEAT RPTFE
BALL VALVE
ASME B-16.34/ BODY-ASTM A351 CF3M, TRIM- SS
DN 15-DN 600 FLGD,150,B-16.5,RF/125AARH BV01L03F
API 608 316L, BODY SEAT RPTFE
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01L05"

Class Conditions
Pressure Temperature
SPECIALTY GASES OF HIGH PURITY (N2, CO2, HE, OXYGEN, ARGON ETC.) CERTIFIED FOR OXYGEN
SERVICE Kg/ cm2 °C
SERVICE
16.17 -29
16.17 38
PIPING CLASS: # 150 13.71 93
PIPING CODE ASME B 31.3
COROSSION ALLOWANCE: 0 MM
DSG. PR. 10 kg/cm2 at 55 Deg C
NOTE1: FOR WELD JOINTS, ONLY ORBITAL WELDING SHALL BE DONE.
NOTE2: NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.
NOTE3: TUBING SHALL BE CERTIFIED FOR OXYGEN SERVICE.
Note 4: THE TUBING SHALL BE INSTALLED IN ACCORDANCE WITH NFPA 99 AND NFPA 99C.
Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
TUBES
O.D. 0.50 INCH 0.89 ASTM A 269 ASTM A269, TP-316L
O.D. 0.75 INCH 1.25 ASTM A 269 ASTM A269, TP-316L
O.D. 01.0 NCH 1.65 ASTM A 269 ASTM A269, TP-316L
O.D. 1.50 INCH 1.65 ASTM A 269 ASTM A269, TP-316L
TUBES
O.D.02.0 INCH 2.6 ASTM A 269 ASTM A269, TP-316L
O.D.03.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
O.D.04.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
O.D.06.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
FLANGES
O.D. 0.50 INCH TO FLANGE BORE TO MATCH TUBE
FLANGE WN M ASME B-16.5 ASTM A 182 GR F 316L 150,RF/125 AARH
O.D. 06.0 INCH BORE
FITTINGS
O.D. 0.50 INCH TO
TUBE BEND 90 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH
O.D. 0.50 INCH TO
TUBE BEND 45 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH
O.D. 0.50 INCH TO
TEE ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED TEE
O.D. 06.0 INCH
O.D. 0.50 INCH TO
REDUC. CON. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH
O.D. 0.50 INCH TO
REDUC. ECC. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH
O.D. 0.50 INCH TO
WELDOLET MSS-SP97 ASTM A 182 GR F 316L BE, BORE TO MATCH TUBE BORE
O.D. 02.0 INCH
GASKETS

O.D. 0.50 INCH TO ASME B16.20- SPIRAL WOUND, SS 316L+ GRAFOIL + I

GASKETS SPIRAL GASKET, 150#
O.D. 06.0 INCH ASME B16.5 RING
BOLTS/ NUTS

O.D. 0.50 INCH TO

BOLT STUD ASME B-18.2 ASTM A 453, GR. 660 CLASS A
O.D. 06.0 INCH
VALVES
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,800,3000,B-16.11 GAV01L05W
1.50 INCH
GATE VALVE
O.D. 02.0 INCH TO
API-600 ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH GAV01L05F
06.0 INCH
O.D. 0.50 INCH TO ASTM A 182 GR. F316L, TRIM 316L
API 602 BW,800,3000,B-16.11 CV01L05W
1.50 INCH STELLITED
CHECK VALVE
O.D. 02.0 INCH TO API 600 /
ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH CV01L05F
06.0 INCH B-16.34
O.D. 0.50 INCH TO
API 602 ASTM A182 F316L,TRIM STELLITED SW,800,3000,B-16.11 GV01L05W
1.50 INCH
GLOBE VALVE
O.D. 02.0 INCH TO API 600 /
ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH GV01L05F
06.0 INCH B-16.34
BODY-ASTM A182 F316L ,TRIM-SS 316L,
DN 15-DN 40 API 608 SW,600#, 3000, B 16.11 BV01L05W
BODY SEAT RPTFE
BALL VALVE
ASME B-16.34/ BODY-ASTM A351 CF3M, TRIM- SS
DN 15-DN 600 FLGD,150,B-16.5,RF/125AARH BV01L05F
API 608 316L, BODY SEAT RPTFE

CLEANING REQUIREMENTS

1 FITTINGS, TUBE, VALVES, AND PIPING SYSTEM COMPONENTS SHALL BE CLEANED FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA, G-4.1. CLEANING SHALL BE
PERFORMED BY THE MANUFACTURER OR A FACILITY EQUIPPED TO CLEAN, RINSE, AND PURGE THE MATERIAL IN ACCORDANCE WITH CGA, G-4.1.

2 IMMEDIATELY BEFORE FINAL ASSEMBLY, FITTINGS, TUBE, VALVES, AND PIPING SYSTEM COMPONENTS SHALL BE VISUALLY EXAMINED INTERNALLY FOR
CONTAMINATION. MATERIAL THAT HAS BECOME CONTAMINATED SHALL NOT BE INSTALLED.
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01L06"

Class Conditions
Pressure Temperature
SERVICE COMPRESSED AIR, LABORATORY AIR CERTIFIED FOR OXYGEN SERVICE Kg/ cm2 °C
16.17 -29
16.17 38
PIPING CLASS: # 150 13.71 93
PIPING CODE ASME B 31.3
COROSSION ALLOWANCE: 0 MM
DSG. PR. 10 kg/cm2 at 55 Deg C
NOTE1: FOR WELD JOINTS, ONLY ORBITAL WELDING SHALL BE DONE.
NOTE2: NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.
NOTE3: PIPING SHALL BE CERTIFIED FOR OXYGEN SERVICE.
NOTE 4: THE TUBING SHALL BE INSTALLED IN ACCORDANCE WITH NFPA 99 AND NFPA 99C
Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
TUBES
O.D. 0.50 INCH 0.89 ASTM A 269 ASTM A269, TP-316L
O.D. 0.75 INCH 1.25 ASTM A 269 ASTM A269, TP-316L
O.D. 01.0 NCH 1.65 ASTM A 269 ASTM A269, TP-316L
O.D. 1.50 INCH 1.65 ASTM A 269 ASTM A269, TP-316L
TUBES
O.D.02.0 INCH 2.6 ASTM A 269 ASTM A269, TP-316L
O.D.03.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
O.D.04.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
O.D.06.0 INCH 3.2 ASTM A 269 ASTM A269, TP-316L
FLANGES
O.D. 0.50 INCH TO FLANGE BORE TO MATCH TUBE
FLANGE WN M ASME B-16.5 ASTM A 182 GR F 316L 150,RF/125 AARH
O.D. 06.0 INCH BORE
FITTINGS
O.D. 0.50 INCH TO
TUBE BEND 90 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH
O.D. 0.50 INCH TO
TUBE BEND 45 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH
O.D. 0.50 INCH TO
TEE ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED TEE
O.D. 06.0 INCH
O.D. 0.50 INCH TO
REDUC. CON. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH
O.D. 0.50 INCH TO
REDUC. ECC. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH
O.D. 0.50 INCH TO
WELDOLET MSS-SP97 ASTM A 182 GR F 316L BE, BORE TO MATCH TUBE BORE
O.D. 02.0 INCH
GASKETS

O.D. 0.50 INCH TO ASME B16.20- SPIRAL WOUND, SS 316L+ GRAFOIL + I

GASKETS SPIRAL GASKET, 150#
O.D. 06.0 INCH ASME B16.5 RING
BOLTS/ NUTS

O.D. 0.50 INCH TO

BOLT STUD ASME B-18.2 ASTM A 453, GR. 660 CLASS A
O.D. 06.0 INCH
VALVES
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,800,3000,B-16.11 GAV01L06W
1.50 INCH
GATE VALVE
O.D. 02.0 INCH TO
API-600 ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH GAV01L06F
06.0 INCH
O.D. 0.50 INCH TO ASTM A 182 GR. F316L, TRIM 316L
API 602 BW,800,3000,B-16.11 CV01L06W
1.50 INCH STELLITED
CHECK VALVE
O.D. 02.0 INCH TO API 600 /
ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH CV01L06F
06.0 INCH B-16.34
O.D. 0.50 INCH TO
API 602 ASTM A182 F316L,TRIM STELLITED SW,800,3000,B-16.11 GV01L06W
1.50 INCH
GLOBE VALVE
O.D. 02.0 INCH TO API 600 /
ASTM A 351 CF3M, TRIM 316L FLGD,150,B-16.5,RF/125 AARH GV01L06F
06.0 INCH B-16.34
BODY-ASTM A182 F316L ,TRIM-SS
DN 15-DN 40 API 608 SW,600#, 3000, B 16.11 BV01L06W
316L, BODY SEAT RPTFE
BALL VALVE
ASME B-16.34/ BODY-ASTM A351 CF3M, TRIM- SS
DN 15-DN 600 FLGD,150,B-16.5,RF/125AARH BV01L06F
API 608 316L, BODY SEAT RPTFE

CLEANING REQUIREMENTS

1 FITTINGS, TUBE, VALVES, AND PIPING SYSTEM COMPONENTS SHALL BE CLEANED FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA, G-4.1. CLEANING SHALL
BE PERFORMED BY THE MANUFACTURER OR A FACILITY EQUIPPED TO CLEAN, RINSE, AND PURGE THE MATERIAL IN ACCORDANCE WITH CGA, G-4.1.
IMMEDIATELY BEFORE FINAL ASSEMBLY, FITTINGS, TUBE, VALVES, AND PIPING SYSTEM COMPONENTS SHALL BE VISUALLY EXAMINED INTERNALLY FOR
2
CONTAMINATION. MATERIAL THAT HAS BECOME CONTAMINATED SHALL NOT BE INSTALLED.
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "05L03"

Class Conditions
Pressure Temperature
SERVICE LABORATORY NATURAL GAS, FLAMMABLE GASES LIKE H2, CH4, C2H2 Kg/ cm2 °C
210.92 38
177.87 93
PIPING CLASS: # 1500
PIPING CODE ASME B 31.3
COROSSION ALLOWANCE: 0 MM
DSG. PR. 150 kg/cm2 at 55 Deg C
NOTE1: FOR WELD JOINTS, ONLY ORBITAL WELDING SHALL BE DONE.
NOTE2: NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.
NOTE3:

Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
TUBES
O.D. 0.50 INCH 1.25 ASTM A 269 ASTM A269, TP-316L
O.D. 0.75 INCH 1.651 ASTM A 269 ASTM A269, TP-316L
O.D. 01.0 NCH 2.11 ASTM A 269 ASTM A269, TP-316L
O.D. 1.50 INCH 3.41 ASTM A 269 ASTM A269, TP-316L
TUBES
O.D.02.0 INCH 4.78 ASTM A 269 ASTM A269, TP-316L
O.D.03.0 INCH 7.17 ASTM A 269 ASTM A269, TP-316L
O.D.04.0 INCH 10.1 ASTM A 269 ASTM A269, TP-316L
O.D.06.0 INCH 15.15 ASTM A 269 ASTM A269, TP-316L
FLANGES
O.D. 0.50 INCH TO FLANGE BORE TO MATCH TUBE
FLANGE WN M ASME B-16.5 ASTM A 182 GR F 316L 1500,RF/125 AARH
O.D. 06.0 INCH BORE
FITTINGS
O.D. 0.50 INCH TO
TUBE BEND 90 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH

O.D. 0.50 INCH TO

TUBE BEND 45 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH

O.D. 0.50 INCH TO

TEE ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED TEE
O.D. 06.0 INCH

O.D. 0.50 INCH TO

REDUC. CON. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH

O.D. 0.50 INCH TO

REDUC. ECC. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH

O.D. 0.50 INCH TO

WELDOLET MSS-SP97 ASTM A 182 GR F 316L BE, BORE TO MATCH TUBE BORE
O.D. 02.0 INCH
GASKETS
O.D. 0.50 INCH TO ASME B16.20- SPIRAL WOUND, SS 316L+ GRAFOIL + I
GASKETS SPIRAL GASKET, 1500#
O.D. 06.0 INCH ASME B16.5 RING
BOLTS/ NUTS
O.D. 0.50 INCH TO
BOLT STUD ASME B-18.2 ASTM A 453, GR. 660 CLASS A
O.D. 06.0 INCH
VALVES
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,1500#, ASME B-16.25 GAV05L03W
1.50 INCH
GATE VALVE
O.D. 02.0 INCH TO
ASME B-16.34 ASTM A 351 CF3M, TRIM 316L BW, 1500#, ASME B-16.25 GAV05L03F
06.0 INCH
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,1500#, ASME B-16.25 CV05L03W
1.50 INCH
CHECK VALVE
O.D. 02.0 INCH TO
ASME B-16.34 ASTM A 351 CF3M, TRIM 316L BW, 1500#, ASME B-16.25 CV05L03F
06.0 INCH
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,1500#, ASME B-16.25 GV05L03W
1.50 INCH
GLOBE VALVE
O.D. 02.0 INCH TO
ASME B-16.34 ASTM A 351 CF3M, TRIM 316L BW, 1500#, ASME B-16.25 GV05L03F
06.0 INCH
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "05L02"

Class Conditions
Pressure Temperature
SPECIALTY GASES OF HIGH PURITY (N2, CO2, HE, OXYGEN, ARGON ETC.), NITROGEN,
SERVICE Kg/ cm2 °C
LABORATORY VACUUM
210.92 38
177.87 93
PIPING CLASS: # 1500
PIPING CODE ASME B 31.3
COROSSION ALLOWANCE: 0 MM
DSG. PR. 150 kg/cm2 at 55 Deg C
NOTE1: FOR WELD JOINTS, ONLY ORBITAL WELDING SHALL BE DONE.
NOTE2: NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.
NOTE3:

Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
TUBES
O.D. 0.50 INCH 1.25 ASTM A 269 ASTM A269, TP-316L
O.D. 0.75 INCH 1.651 ASTM A 269 ASTM A269, TP-316L
O.D. 01.0 NCH 2.11 ASTM A 269 ASTM A269, TP-316L
O.D. 1.50 INCH 3.41 ASTM A 269 ASTM A269, TP-316L
TUBES
O.D.02.0 INCH 4.78 ASTM A 269 ASTM A269, TP-316L
O.D.03.0 INCH 7.17 ASTM A 269 ASTM A269, TP-316L
O.D.04.0 INCH 10.1 ASTM A 269 ASTM A269, TP-316L
O.D.06.0 INCH 15.15 ASTM A 269 ASTM A269, TP-316L
FLANGES

O.D. 0.50 INCH TO FLANGE BORE TO MATCH TUBE

FLANGE WN M ASME B-16.5 ASTM A 182 GR F 316L 1500,RF/125 AARH
O.D. 06.0 INCH BORE
FITTINGS
O.D. 0.50 INCH TO
TUBE BEND 90 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH

O.D. 0.50 INCH TO

TUBE BEND 45 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH

O.D. 0.50 INCH TO

TEE ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED TEE
O.D. 06.0 INCH

O.D. 0.50 INCH TO

REDUC. CON. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH

O.D. 0.50 INCH TO

REDUC. ECC. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH

O.D. 0.50 INCH TO

WELDOLET MSS-SP97 ASTM A 182 GR F 316L BE, BORE TO MATCH TUBE BORE
O.D. 02.0 INCH
GASKETS

O.D. 0.50 INCH TO ASME B16.20- SPIRAL WOUND, SS 316L+ GRAFOIL + I

GASKETS SPIRAL GASKET, 1500#
O.D. 06.0 INCH ASME B16.5 RING
BOLTS/ NUTS

O.D. 0.50 INCH TO

BOLT STUD ASME B-18.2 ASTM A 453, GR. 660 CLASS A
O.D. 06.0 INCH
VALVES
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,1500#, ASME B-16.25 GAV05L02W
1.50 INCH
GATE VALVE
O.D. 02.0 INCH TO
ASME B-16.34 ASTM A 351 CF3M, TRIM 316L BW, 1500#, ASME B-16.25 GAV05L02F
06.0 INCH
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,1500#, ASME B-16.25 CV05L02W
1.50 INCH
CHECK VALVE
O.D. 02.0 INCH TO
ASME B-16.34 ASTM A 351 CF3M, TRIM 316L BW, 1500#, ASME B-16.25 CV05L02F
06.0 INCH
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,1500#, ASME B-16.25 GV05L02W
1.50 INCH
GLOBE VALVE
O.D. 02.0 INCH TO
ASME B-16.34 ASTM A 351 CF3M, TRIM 316L BW, 1500#, ASME B-16.25 GV05L02F
06.0 INCH
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "05L05"

Class Conditions
Pressure Temperature
SPECIALTY GASES OF HIGH PURITY (N2, CO2, HE, OXYGEN, ARGON ETC.) CERTIFIED FOR
SERVICE Kg/ cm2 °C
OXYGEN SERVICE
210.92 38
177.87 93
PIPING CLASS: # 1500
PIPING CODE ASME B 31.3
COROSSION ALLOWANCE: 0 MM
DSG. PR. 150 kg/cm2 at 55 Deg C
NOTE1: FOR WELD JOINTS, ONLY ORBITAL WELDING SHALL BE DONE.
NOTE2: NDT REQUIREMENTS SHALL BE AS PER THE JOB SPECIFICATION FOR WELDING & NON
DESTRUCTIVE TESTING OF PIPING.
NOTE3: TUBING SHALL BE CERTIFIED FOR OXYGEN SERVICE.
NOTE 4: THE TUBING SHALL BE INSTALLED IN ACCORDANCE WITH NFPA 99 AND NFPA 99C
Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
TUBES
O.D. 0.50 INCH 1.25 ASTM A 269 ASTM A269, TP-316L
O.D. 0.75 INCH 1.651 ASTM A 269 ASTM A269, TP-316L
O.D. 01.0 NCH 2.11 ASTM A 269 ASTM A269, TP-316L
O.D. 1.50 INCH 3.41 ASTM A 269 ASTM A269, TP-316L
TUBES
O.D.02.0 INCH 4.78 ASTM A 269 ASTM A269, TP-316L
O.D.03.0 INCH 7.17 ASTM A 269 ASTM A269, TP-316L
O.D.04.0 INCH 10.1 ASTM A 269 ASTM A269, TP-316L
O.D.06.0 INCH 15.15 ASTM A 269 ASTM A269, TP-316L
FLANGES

O.D. 0.50 INCH TO FLANGE BORE TO MATCH TUBE

FLANGE WN M ASME B-16.5 ASTM A 182 GR F 316L 1500,RF/125 AARH
O.D. 06.0 INCH BORE
FITTINGS
O.D. 0.50 INCH TO
TUBE BEND 90 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH

O.D. 0.50 INCH TO

TUBE BEND 45 ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED BENDS
O.D. 06.0 INCH

O.D. 0.50 INCH TO

TEE ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED TEE
O.D. 06.0 INCH

O.D. 0.50 INCH TO

REDUC. CON. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH

O.D. 0.50 INCH TO

REDUC. ECC. ASTM A269, TP-316L BE, BORE TO MATCH TUBE BORE PULLED REDUCER
O.D. 06.0 INCH

O.D. 0.50 INCH TO

WELDOLET MSS-SP97 ASTM A 182 GR F 316L BE, BORE TO MATCH TUBE BORE
O.D. 02.0 INCH
GASKETS

O.D. 0.50 INCH TO ASME B16.20- SPIRAL WOUND, SS 316L+ GRAFOIL + I

GASKETS SPIRAL GASKET, 1500#
O.D. 06.0 INCH ASME B16.5 RING
BOLTS/ NUTS

O.D. 0.50 INCH TO

BOLT STUD ASME B-18.2 ASTM A 453, GR. 660 CLASS A
O.D. 06.0 INCH
VALVES
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,1500#, ASME B-16.25 GAV05L05W
1.50 INCH
GATE VALVE
O.D. 02.0 INCH TO
ASME B-16.34 ASTM A 351 CF3M, TRIM 316L BW, 1500#, ASME B-16.25 GAV05L05F
06.0 INCH
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,1500#, ASME B-16.25 CV05L05W
1.50 INCH
CHECK VALVE
O.D. 02.0 INCH TO
ASME B-16.34 ASTM A 351 CF3M, TRIM 316L BW, 1500#, ASME B-16.25 CV05L05F
06.0 INCH
O.D. 0.50 INCH TO
API-602 ASTM A182 F316L,TRIM STELLITED BW,1500#, ASME B-16.25 GV05L05W
1.50 INCH
GLOBE VALVE
O.D. 02.0 INCH TO
ASME B-16.34 ASTM A 351 CF3M, TRIM 316L BW, 1500#, ASME B-16.25 GV05L05F
06.0 INCH

CLEANING REQUIREMENTS

FITTINGS, TUBE, VALVES, AND PIPING SYSTEM COMPONENTS SHALL BE CLEANED FOR OXYGEN SERVICE IN ACCORDANCE WITH CGA, G-4.1. CLEANING SHALL BE
1
PERFORMED BY THE MANUFACTURER OR A FACILITY EQUIPPED TO CLEAN, RINSE, AND PURGE THE MATERIAL IN ACCORDANCE WITH CGA, G-4.1.
IMMEDIATELY BEFORE FINAL ASSEMBLY, FITTINGS, TUBE, VALVES, AND PIPING SYSTEM COMPONENTS SHALL BE VISUALLY EXAMINED INTERNALLY FOR
2
CONTAMINATION. MATERIAL THAT HAS BECOME CONTAMINATED SHALL NOT BE INSTALLED.
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01P10"

Class Conditions
Pressure Temperature
SERVICE LABORATORY WASTE VENT Psi °C
50 65

PIPING CLASS: # PN 10
PIPING CODE ASME B 31.3
COROSSION ALLOWANCE: 0 MM
DSG. PR.TO
NOTE-1 30BE
PSIUSED
at 65 UNDERGROUND
Deg C AND BEHIND THE WALLS OR OUTDOOR AT INACCESSIBLE
LOCATIONS.
NOTE 2: TO BE USED OUTDOORS AT ACCESSIBLE LOCATIONS

Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
PIPES
FLAME RETARDANT AS PER ASTM D
PIPES DN 15-DN 300 SCH 80 ASTM F1412 POLYPROPYLENE
4101
FITTINGS
POLYPROPYLENE FLAME RETARDANT
FITTINGS DN 15-DN 300 ASTM F1412 ELECTROFUSION WELDED NOTE-1
AS PER ASTM D 4101
POLYPROPYLENE FLAME RETARDANT
FITTINGS DN 15-DN 300 ASTM F1412 MECHANICAL JOINT FITTINGS NOTE-2
AS PER ASTM D 4101
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01V07"

Class Conditions
INDUSTRIAL SOFT COLD WATER, POTABLE WATER, SOFTENED (DEMINERALIZED) WATER, Pressure Temperature
SERVICE
INDUSTRIAL (LABORATORY) HOT WATER (IHW) & INDUSTRIAL COLD WATER (ICW) Kg/ cm2 °C
26 23
PIPING CLASS: # 150 23.66 32
PIPING CODE ASME B 31.3 21.32 38
COROSSION ALLOWANCE: 0 MM 16.9 49
DSG. PR.PIPES
NORE-1 11.83 SHALL
kg/cm2 BE
at 65 Deg CAS REQUIRED BY USING SOLVENT CEMENT MADE OF CPVC MATERIAL
JOINED 13 60
CONFIRMING
NOTE-2 TO ASTM F493.
UV RESISTANCE SHALL BE AS PER D 6360-39 AND SHOULD PASS MINIMUM 500 HOURS 11.83 65
EXPOSURE.
NOTE- 3 NDT REQUIREMENT -- ONLY VISUAL

Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
PIPES
PIPE DN 15-DN 80 80 ASTM F441 ASTM D-1784, CLASS 24448 PE
FLANGES
SW FLANGE DN 15-DN 80 M ASTM F1970 ASTM D-1784, CLASS 23447 ENDS, 150#
BLIND FLANGE DN 15 – DN 80 ASTM F1970 ASTM D-1784, CLASS 23447 ENDS, 150#
FITTINGS
ELBOW 90 DN 15-DN 80 80 ASTM F439 ASTM D-1784, CLASS 23447 SOCKET END

ELBOW 45 DN 15 -DN 80 80 ASTM F439 ASTM D-1784, CLASS 23447 SOCKET END

EQUAL TEE DN 15 -DN 80 80 ASTM F439 ASTM D-1784, CLASS 23447 SOCKET END

RED. TEE DN 15 -DN 80 80 ASTM F439 ASTM D-1784, CLASS 23447 SOCKET END

RED. COUPLING DN 15 -DN 80 80 ASTM F439 ASTM D-1784, CLASS 23447 SOCKET END

FULL COUPLNG DN 15 -DN 80 80 ASTM F439 ASTM D-1784, CLASS 23447 SOCKET END

GASKETS
ASME B16.21-
GASKETS DN 15 – DN 80 BUTYL RUBBER RING, 150#, 3mm THICK
ASME B16.5
BOLTS

BOLT STUD DN 15 – DN 80 ASME B-18.2 BOLT: A193 GR.B7 / NUT: A194 GR.2H
VALVES
BALL VALVE DN 15-DN 80 MNF STD CPVC (BODY AND BALL) SOCKET END

CHECK VALVE DN 15-DN 80 MNF STD CPVC SOCKET END

STRAINERS
STRAINER DN 50 – DN 80 MNF STD CPVC Y TYPE, SOCKET END

Temperature Pressure Derating factor

Operating Temp (°C) 23 32 38 49 60 65
Derating factor 1 0.91 0.82 0.65 0.5 0.455
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01H09"

Class Conditions
DOMESTIC WATER, FLUSHING WATER, R.O. (POTABLE) WATER OUTSIDE THE PROCESS Pressure Temperature
SERVICE
AREA Kg/ cm2 °C
10.2 30
PIPING CLASS: # 150 6.2 45
PIPING CODE ASME B 31.3
COROSSION ALLOWANCE: 0 MM
DSG. PR. 6.2 kg/cm2 at 45 Deg C
NOTE- 1 THE
NOTE-2: NDT GRADE
REQUIREMENT -- ONLY
OF MATERIAL VISUAL
AND PRESSURE RATING OF FITTINGS SHALL BE SAME AS
CORRESPONDING SIZE OF PIPE.
NOTE-3: PRESSURE DERATING TO BE DONE AS PER IS-4984 AT INTERMEDIATE TEMPERATURES.
Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
PIPES
1.9 mm- 2.3
DN 16 IS-4984 PE100, PN 16, HDPE PIPE PE
mm
1.9 mm- 2.3
DN 20 IS-4984 PE100, PN 12.5, HDPE PIPE PE
mm
1.9 mm- 2.3
DN 25 IS-4984 PE100, PN 10, HDPE PIPE PE
mm
3.0 mm -
DN 40 IS-4984 PE100, PN 10, HDPE PIPE PE
3.5 mm
3.7 mm -
DN 50 IS-4984 PE100, PN 10, HDPE PIPE PE
4.3 mm
5.6 mm -
DN 75 IS-4984 PE100, PN 10, HDPE PIPE PE
6.3 mm
6.7 mm -
DN 90 IS-4984 PE100, PN 10, HDPE PIPE PE
7.5 mm
8.1 mm -
PIPE DN- 110 IS-4984 PE100, PN 10, HDPE PIPE PE
9.1 mm
9.2 mm -
DN- 125 IS-4984 PE100, PN 10, HDPE PIPE PE
10.4 mm
10.3 mm -
DN- 140 IS-4984 PE100, PN 10, HDPE PIPE PE
11.6 mm
11.8 mm -
DN- 160 IS-4984 PE100, PN 10, HDPE PIPE PE
13.2 mm
13.3 mm -
DN- 180 IS-4984 PE100, PN 10, HDPE PIPE PE
14.8 mm
14.8 mm -
DN- 200 IS-4984 PE100, PN 10, HDPE PIPE PE
16.4 mm
16.6 mm -
DN- 225 IS-4984 PE100, PN 10, HDPE PIPE PE
18.4 mm
18.4 mm -
DN- 250 IS-4984 PE100, PN 10, HDPE PIPE PE
20.5 mm
FLANGES
FLANGE DN 25-DN 250 M IS: 8008 SLIP ON FLANGE, HDPE ENDS, 150#
BLIND FLANGE DN 25 – DN 250 IS: 8008 BLIND FLANGE, HDPE ENDS, 150#
FITTINGS
ELBOW 90 DN 16-DN 250 80 IS-4984 HDPE ELECTROFUSION FITTING WELDING END

ELBOW 45 DN 16-DN 250 80 IS-4984 HDPE ELECTROFUSION FITTING WELDING END

EQUAL TEE DN 16-DN 250 80 IS-4984 HDPE ELECTROFUSION FITTING WELDING END

RED. TEE DN 16-DN 250 80 IS-4984 HDPE ELECTROFUSION FITTING WELDING END

RED. COUPLING DN 16-DN 250 80 IS-4984 HDPE ELECTROFUSION FITTING WELDING END

FULL COUPLING DN 16-DN 250 80 IS-4984 HDPE ELECTROFUSION FITTING WELDING END

GASKETS
ASME B16.21-
GASKETS DN 16 – DN 250 BUTYL RUBBER RING, 150#, 3mm THICK
ASME B16.5
BOLTS

BOLT STUD DN 16 – DN 250 ASME B-18.2 BOLT: A193 GR.B7 / NUT: A194 GR.2H
VALVES
BALL VALVE DN 16 – DN 250 MNF STD HDPE (BODY AND BALL), PTFE SEAT SOCKET END

CHECK VALVE DN 15-DN 75 MNF STD HDPE SOCKET END

STRAINERS
STRAINER DN 16 – DN 75 MNF STD HDPE Y TYPE, SOCKET END
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

PIPING MATERIAL SPECIFICATION "01U14"

Class Conditions
Pressure Temperature
SERVICE RAW WATER, DOMESTIC COLD WATER
Kg/ cm2 °C
16.16 23
PIPING CLASS: # 150 10.02 38
PIPING CODE ASME B 31.3 8.08 43
COROSSION ALLOWANCE: 0 MM 6.46 49
DSG. PR.PIPES
NORE-1 6.46 kg/cm2
SHALLat 49JOINED
BE Deg C AS REQUIRED BY USING SOLVENT CEMENT 4.85 54
MADE OF
NOTE-2 FOR UPVC
PRIMERS MATERIAL
MUST BE USEDCONFIRMING
IN SOLVENTTO ASTM DJOINTS
CEMENT 2564. OF PIPES
AND FITTINGS SIZES ABOVE 2".
NOTE- 3 NDT REQUIREMENT -- ONLY VISUAL
NOTE-4: THE PIPES PRESSURE RATING SHALL BE AS PER THE ASTM D-1785 FOR S80 THICKNESS.
NOTE-4: FLANGES HAVE A PRESSURE RATING OF 150 PSI @ 23 DEG C.

Dmn.STD/
Item Type Size Range Sch/Thk Material Description REMARKS
Dsn. STD
PIPES
UPVC
PIPE DN 15-DN 80 40 CONFORMING TO PE
ASTM D-1785
UPVC
PIPE DN 100- DN300 80 CONFORMING TO PE
ASTM D-1785
FLANGES
ASTM D-1784,
UPVC CELL ANSI B-16.5,
SW FLANGE DN 15-DN 300 M ASTM F1498 SOCKET & SPIGOT ASTM D 2467 (UPVC)
CLASSIFICATION ENDS, 150#
12454-B
ASTM D-1784,
UPVC CELL ANSI B-16.5,
BLIND FLANGE DN 15 – DN 80 M ASTM F1498 SOCKET & SPIGOT ASTM D 2467 (UPVC)
CLASSIFICATION ENDS, 150#
12454-B
FITTINGS
UPVC
DN 15-DN 80 40 CONFORMING TO SOCKET END
ELBOW 90 ASTM D-2466
UPVC
DN 100- DN300 80 CONFORMING TO SOCKET END
ASTM D-2467
UPVC
DN 15 -DN 80 40 CONFORMING TO SOCKET END
ELBOW 45 ASTM D-2466
UPVC
DN 100- DN300 80 CONFORMING TO SOCKET END
ASTM D-2467
UPVC
DN 15 -DN 80 40 CONFORMING TO SOCKET END
EQUAL TEE ASTM D-2466
UPVC
DN 100- DN300 80 CONFORMING TO SOCKET END
ASTM D-2467
UPVC
DN 15 -DN 80 40 CONFORMING TO SOCKET END
RED. TEE ASTM D-2466
UPVC
DN 100- DN300 80 CONFORMING TO SOCKET END
ASTM D-2467
UPVC
DN 15 -DN 80 40 CONFORMING TO SOCKET END
RED. COUPLING ASTM D-2466
UPVC
DN 100- DN300 80 CONFORMING TO SOCKET END
ASTM D-2467
UPVC
DN 15 -DN 80 40 CONFORMING TO SOCKET END
FULL COUPLING ASTM D-2466
UPVC
DN 100- DN300 80 CONFORMING TO SOCKET END
ASTM D-2467
GASKETS
1/8” (3 mm) THK.
FULL FACE VITON
ASME B16.21- (ASME B16.21), RING, 150#, 3mm
GASKETS DN 15 – DN 300 SHORE
ASME B16.5 THICK
HARDNESS 50 TO
70 DUROMETER
BOLTS
BOLT: A193 GR.B7
BOLT STUD DN 15 – DN 300 ASME B-18.2
/ NUT: A194 GR.2H
VALVES
UPVC BODY,
BALL VALVE DN 15-DN 100 MNF STD STEAM AND BALL, SOCKET END
PTFE SEAT
UPVC BODY,
SPRING CHECK
CHECK VALVE DN 15-DN 100 MNF STD SOCKET END
VALVE, SS 316
SPRING

STRAINERS
STRAINER DN 50 – DN 300 MNF STD UPVC Y TYPE, SOCKET END

Temperature Pressure Derating factor

Operating Temp (°C) 23 27 32 38 43 49 54
Derating factor 1 0.9 0.75 0.62 0.5 0.4 0.3
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

Branch Connection Table

Piping Classes 01K04, 01M12, 01K13

HEADER SIZE
600 500 450 400 350 300 250 200 150 100 80 50 40 25 20 15

15 3 3 3 3 3 3 3 3 3 3 3 3 2 2 2 1
20 3 3 3 3 3 3 3 3 3 3 3 3 2 2 1
25 3 3 3 3 3 3 3 3 3 3 3 3 2 1
40 3 3 3 3 3 3 3 3 3 3 3 3 1
B 50 8 8 8 8 8 8 7 7 7 7 5 4
R 80 8 8 8 8 8 8 7 7 7 5 4
A 100 8 8 8 8 8 8 8 8 5 4
N 150 8 8 8 8 8 8 8 5 4

C 200 8 8 8 8 8 8 5 4 BRANCH CONNECTION

H 250 8 8 8 8 8 5 4 1-Socketweld Tee

300 8 8 8 8 5 4 2-Socketweld Reducing Tee
S 350 8 8 8 5 4 3-Half Coupling
I 400 8 8 5 4 4-Buttweld Tee
Z 450 8 5 4 5-Buttweld Reducing Tee
E 500 5 4 6-Weldolet
600 4 7-Pipe To Pipe
8-Pipe To Pipe With Reinforcement.
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

Branch Connection Table

Piping Material Class: 01C01, 01C04

(Carbon Steel)
HEADER SIZE
600 500 450 400 350 300 250 200 150 100 80 50 40 25 20 15

15 3 3 3 3 3 3 3 3 3 3 3 3 2 2 2 1
20 3 3 3 3 3 3 3 3 3 3 3 3 2 2 1
25 3 3 3 3 3 3 3 3 3 3 3 3 2 1
40 3 3 3 3 3 3 3 3 3 3 3 5 1
B 50 8 7 7 7 7 7 7 7 7 7 5 4
R 80 8 7 7 7 7 7 7 7 7 5 4
A 100 8 7 7 7 7 7 7 7 5 4
N 150 8 7 7 7 7 7 7 5 4
BRANCH CONNECTION
C 200 8 7 7 7 7 5 5 4
LEGEND
H 250 8 7 7 7 7 5 4 1-Socket weld Tee
300 8 7 7 7 5 4 2-Socket weld Reducing Tee
S 350 8 7 7 5 4 3-Half Coupling
I 400 8 7 5 4 4-Buttweld Tee
Z 450 8 5 4 5-Buttweld Reducing Tee
E 500 5 4 6-Weldolet
600 4 7-Pipe to pipe
8-Pipe to pipe with Reinforcement.
 INDIAN OIL
TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER
PIPING MATERIAL SPECIFICATION
Document No. - D10-PMC-JSF-015

Table : Branch Connection Table

Piping Material Class- 01V07
CPVC
HEADER SIZE
80 50 40 25 20 15
15 9 9 2 2 2 1
20 9 9 2 2 1
25 9 2 2 1
B 40 2 2 1
R 50 2 1
A 65 2
N 80 1
C
H BRANCH CONNECTION
LEGEND
S 1-Socket Tee
I 2-Socket Reducing Tee
Z 3-Socket weldolet
E 4-Buttweld Tee
5-Buttweld Reducing Tee
6-Weldolet
7-Pipe to pipe
8-Pipe to pipe with Reinforcement.
9-Clamp On Saddle x Socket Joint
 INDIAN OIL

TECHNOLOGY DEVELOPMENT & DEPLOYMENT CENTER

PIPING MATERIAL SPECIFICATION

Document No. - D10-PMC-JSF-015

INDEX FOR THE PIPING MATERIAL SPECIFICATION CLASSES

Piping Design Basic SPECIAL

S. No C.A. mm Rating / Facing Services
Class Code Material REQUIREMENTS

1 01C01 B31.3 1.6 CS 150LB/RF NONE TEMPERED WATER

2 01C04 B31.3 1.6 CS 150LB/RF NONE HOT WATER- HVAC

3 01K13 B31.3 0 SS 304 150LB/RF CRYO LIQUID NITROGEN

SPECIALTY GASES OF HIGH PURITY (N2,

SS TUBING WITH
4 01L02 B31.3 0 SS 316L 150LB/RF CO2, HE, OXYGEN, ARGON ETC.),
ORBITAL WELDING
NITROGEN, LABORATORY VACUUM

SS TUBING WITH LABORATORY NATURAL GAS,

5 01L03 B31.3 0 SS 316L 150LB/RF
ORBITAL WELDING FLAMMABLE GASES LIKE H2, CH4, C2H2

SS TUBING FOR
SPECIALTY GASES OF HIGH PURITY (N2,
OXYGEN
6 01L05 B31.3 0 SS 316L 150LB/RF CO2, HE, OXYGEN, ARGON ETC.)
SERVICEWITH
CERTIFIED FOR OXYGEN SERVICE
ORBITAL WELDING
SS TUBING FOR
OXYGEN COMPRESSED AIR, LABORATORY AIR
7 01L06 B31.3 0 SS 316L 150LB/RF
SERVICEWITH CERTIFIED FOR OXYGEN SERVICE
ORBITAL WELDING

PROCESS CHILLED WATER (PCWS/

8 01M12 B31.3 0 SS 316 150LB/RF NONE
PCWR), CHILLED WATER (CHWS/ CHWR)

SPECIALTY GASES OF HIGH PURITY (N2,

SS TUBING WITH
9 05L02 B31.3 0 SS 316L 1500 LB/ RF CO2, HE, OXYGEN, ARGON ETC.),
ORBITAL WELDING
NITROGEN, LABORATORY VACUUM

SS TUBING WITH LABORATORY NATURAL GAS,

10 05L03 B31.3 0 SS 316L 1500 LB/ RF
ORBITAL WELDING FLAMMABLE GASES LIKE H2, CH4, C2H2

SS TUBING FOR
SPECIALTY GASES OF HIGH PURITY (N2,
OXYGEN
11 05L05 B31.3 0 SS 316L 1500 LB/ RF CO2, HE, OXYGEN, ARGON ETC.)
SERVICEWITH
CERTIFIED FOR OXYGEN SERVICE
ORBITAL WELDING

12 01P10 B31.3 0 PP 50 PSI NONE LABORATORY WASTE VENT

INDUSTRIAL SOFT COLD WATER,

POTABLE WATER, INDUSTRIAL
13 01V07 B31.3 0 CPVC 100 PSI NONE
(LABORATORY) HOT WATER (IHW) &
INDUSTRIAL COLD WATER (ICW)

14 01U14 B31.3 0 Upvc 100 PSI NONE RAW WATER, DOMESTIC COLD WATER

DOMESTIC WATER, FLUSHING WATER,

15 01H09 B31.3 0 HDPE 100 PSI NONE POTABLE WATER OUTSIDE THE
PROCESS AREA