TECHNICAL SPECIFICATIONS - PIPES - 209218.pdf

FORMAT No.: ENGG(MM).PRA.DM.025.F01.Rev. 03

ESSAR STEEL INDIA LIMITED

CAPACITY ENHANCEMENT OF VPSAMOD 6 (DOUBLING)

TECHNICAL SPECIFICATIONFOR PIPES

ESSAR PROJECTS (INDIA) LIMITEDENGINEERING & PROJECT MANAGEMENT

HAZIRA

TS. No.: 2746-H000-F11340-0015-1518-0003 MONTH & YEAR: March 2014

ESSAR STEELINDIA LIMITED

CAPACITY ENHANCEMENT OF VPSAMOD – 6 (DOUBLING)


TS. No.: 2746-H000-F11340-0015-1518-0003ESSAR PROJECTS (INDIA) LIMITED

ENGINEERING & PROJECT MANAGEMENT

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DETAILS OF REVISION:

DATE DETAILS OF REVISION REVISION NO.

16/05/2014 FOR CONCURRENCE A

17/05/2014 FOR APPROVAL P0






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CONTENTS

CHAPTERNo. DESCRIPTION PAGE No.1 GENERAL INFORMATION 42 SCOPE OF WORK 53 TECHNICAL SPECIFICATION 64 INSPECTION & TESTING 85 HSE REQUIREMENT 96 DELIVERY 107 PAINTING 118 WORKMANSHIP & PERFORMANCE GUARANTEE 139 SPECIAL INSTRUCTIONS TO SELLER 14

10 DOCUMENTS TO BE SUPPLIED 15

ANNEXURESI SITE CONDITIONS 16

IIFORMAT FOR DEVIATION FROM SELLERDOCUMENT 17

IIIQUESTIONNAIRE TO BE FILLED IN AND SUBMITTEDWITH OFFER 18

IV OVERALL SUPPLY & IMPLEMENTATION SCHEDULE 19V QUALITY ASSURANCE PLAN 20VI BILL OF QUANTITY






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1. GENERAL INFORMATION

ESSAR Steel (INDIA) Ltd. (EST(I)L) is a fully integrated flat carbon steel

manufacturer — from iron ore to ready-to-market products with a current capacity of

10 million tons per annum (MTPA) at Hazira. The complex has 6 HBI/DRI modules, 2

COREX modules and one blast furnace for making Iron, in six modules module 1 – 5

are HBI/HDRI product, and in module 6 is Cold DRI plant. From this Cold DRI plant

the cold DRI discharged from furnace and transferred to Steel Making Plant through

conveyor system.

M/s EST(I)L contracted to “M/s. ESSAR PROJECT (INDIA) LIMITED - ENGINEERING

& PROJECT MANAGEMENT HAZIRA” to provide engineering service for the

enhancement of VPSA –Mod VI located at Hazira, Surat.

This document covers the minimum technical requirements for valves as mention

below.






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2. SCOPE OF WORK

The scope of work of supplier shall include Manufacture/fabrication, Inspection,

testing and supply of pipes as per attached Bill of Quantity and applicable codes

indicated with this specification.

The scope of supply / work shall comprise of following:

Manufacture, Testing, Inspection, Painting/Protective coating, Marking and Supply ofpipes as per attached BOQ.

Seaworthy packing if applicable

Loading of pipes at works, shipment / transportation and unloading of the same atproject site.

Documentation as per requirement.






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3. TECHNICAL SPECIFICATION

Supplied pipes shall meet the requirement of clauses indicated in the technical

requirement and shall be as per the attached bill of material.

3.1. TECHNICAL REQUIREMENT

Dimensions, tolerances, chemical composition, physical properties, heat treatmentand other testing and marking shall conform to the codes and standards specified inthis specification.

Test reports shall be furnished for all mandatory tests as per the applicable materialspecifications.

Material test certificates (physical property, chemical composition and heat treatmentreport) shall also be furnished for the pipes & pipe fittings.

Pipe shall be supplied in single length of 5 to 6 m.

ERW pipes shall not have any circumferential seam joint in a random length.

Weld repair shall be done on pipe welds upon prior approval from the Buyer/Consultant. Specified heat treatment for carbon steel shall be carried out afterwelding / weld repairs. Number of weld repairs at same spot shall be restricted tomaximum two by approved repair procedure.

3.2. MARKING & DISPATCH

All pipes shall be marked in accordance with the applicable codes, standards andspecifications in addition to the Purchase Order No.

Pipes shall be marked singularly.

Tags shall incorporate the following data: Manufacturer’s identification IS Number LOT identification Nominal pipe size Sch. No. / wall thickness

Pipes shall be dry, clean and free from oil, moisture, dirt and loose foreign materialsof any kind.

Pipes shall be protected from rust, corrosion and mechanical damages during






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transportation, shipment and storage.

Rust preventive used on machined surfaces to be welded shall be easily removablewith a petroleum solvent or shall not be harmful to welding.

Both ends of the pipe shall be protected with the wood / metal.

End protectors to be used shall be securely and tightly attached with belt or wire.

3.3. APPLICABLE CODES AND STANDARDS

Plate work shall conform to IS 2062 (FE 410 WA)

Pipes shall conform to IS 1239 Part – I & IS 3589 (Fe 330 ERW, Bevel end)






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4. INSPECTION AND TESTING

Seller shall furnish a QAP which he proposes to follow at the factory and the tests heproposes to conduct at site within 30 days of email order.

Buyer reserves the right to verify the quality program and entire productcharacteristics during manufacturing to assure the intended and specified quality ofthe product.

Inspection & testing of material shall be witnessed by buyer or an authorized agent ofbuyer at the works of supplier during manufacturing and on final product to ensureconformity with requirement.

The successful bidder shall send the intimation to Buyer for inspection along-with hisinternal inspection certificates at-least three weeks prior to the start of inspection.

The successful Seller shall include and provide for in his offer all facilities, which willenable witnessing inspection by Buyer or his authorized representatives.

Samples of materials shall be furnished by the successful Seller to Buyer freeof cost, if required.

Any material declared defective by Buyer during manufacture/ testing shall bereplaced. However no cost extra commercial implication is acceptable.

All supplied pipes shall be hydrostatically tested at works before dispatch.

Visual and non - destructive examinations of weld preparation and weldedjoints shall conform to the requirements of the stipulated codes for thepurpose.

Non Destructive examination procedures shall be submitted for client approval.

It is mandatory that all welds shall be 100% NDT.






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5. HSE REQUIREMENT

Tenderer shall comply with the entire applicable statutory requirement as minimumnational standards (plant local government’s standard).

In additional to the above Tenderer shall comply with the Client’s internal Standards /Procedures.






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6. DELIVERY

The delivery of all the valves covered under this specification shall be at plant site on doordelivery freight pre paid basis within 03 months from the date of placement of order.

All material shall be packed properly for prevention of damage during transit anddeterioration during storage.






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7. PAINTING

The following specification shall be applicable for all equipment covered under thisdocument unless separate painting specification is elaborated in the respectiveattachments.

Preparation and painting of piping. The term “painting” referred herein covers rustpreventive and decorative coating along with surface protection.

Surfaces made of aluminum, brass; bronze, stainless steel, cast iron and othercorrosion resistant alloys are not required to be painted unless specified except foraesthetic purposes or for identification bands.

All machined mating surfaces (e.g. flanges) shall be properly cleaned, greased andprotected before dispatch. General compatibility between primer and finishing paintsshall be certified by the paint manufacturer supplying the paints.

Areas which become inaccessible after assembly shall be painted before assembly(after painting clearance has been given by the inspecting authority) after requisitesurface cleaning as specified.

The machine finished surfaces shall be coated with white lead and covered beforeshipment or before being put out into the open air.

The Color code to be followed for the final coat shall be intimated to thesuccessful tenderer.

The complete paint system for any item includes the following activities

Proper surface preparation Application of primer coats Application of intermediate coats Application of finished coats

All Sheet metal work shall undergo a process of

Degreasing Pickling in Acid. Cold Rinsing and phosphating. Final coat of painting.

Surfaces which cannot be painted but require protection shall be given a coat of rustinhibitive grease according to standards. The general guideline followed for paintingis follows:






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GENERAL SPECIFICATION FOR SURFACE TREATMENT AND PAINTING

Area or surface Surfacepreparation

Initial Painting Final Painting

Painting Scheme DFT/COAT

Fabricated items(surfacesexposed to gasstream)

SA 2.52 coats of Epoxy polyamideresin based Red-oxide Zincphosphate primer

40 microns NIL NIL

Fabricated items(surfacesexposed toatmosphere)

SA 2.5 2 coats of aluminum paint(normal temp0 25 microns

1 coat ofaluminumpaint (Normaltemp)

25microns






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8. WORKMANSHIP AND PERFORMANCE GUARANTEE

The material used shall be new and best of its kind available and shall conform torelevant latest international standards.

The warrantee shall cover faulty design / material / workmanship. All replacementunder the warrantee shall be done by the supplier free of cost.

The Seller should study the specification and satisfy himself regarding the workabilityof the proposed system and shall take full responsibility for the manufacture, qualityof the material, workmanship, etc. of the entire system

Witness of inspection by Buyer or their authorized representative does not absolve orrelieve the supplier from any of his obligations under this contract.

The supplier is solely responsible and accountable for any defects and subsequentdelays in supply due to manufacture/inspection.






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9. SPECIAL INSTRUCTIONS TO SELLER

The supply items shall meet the requirements stipulated in the technicalspecifications and standard method of manufacture.

The Buyer reserves the right to place order for only one or more items in part or fullquantity on a particular supplier. The Seller shall confirm his agreement to acceptpart order.

Depending on the performance of manufacture, Buyer reserves the right to cancelthe order or increase or decrease the quantity ordered at the same price/rate withoutany financial implications on the Buyer’s part or any compensation to the supplier.

Any deviations proposed by the Seller shall be listed in technical bid. NOADDITIONAL WRITE-UP WILL BE ACCEPTED.

The Seller shall furnish drawings / documents / catalogues as applicable along withthe tender to enable evaluation of his offer. These documents shall be furnished asper clause no. 10

Manufacturing will be taken up only on the basis of material data duly approved andsigned.






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10. DOCUMENTS TO BE FURNISHED

The following sets of document shall be submitted

6 sets of Test and Inspection certificates/ reports (Test Certificate / Report) shallcover material test, destructive test for weld quality.






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Annexure-ISITE CONDITION

Geographical Conditionsi) Site Location : Hazira, Surat, Gujarat, India

ii) Seismic zone

Zone as per IS: 1893(Part-I):2002- Zone – III

Zone factor 0.16

Importance factor 1.50

Meteorological Conditionsi) Ambient air temperature

Maximum dry bulb : 45.6° C

Minimum dry bulb : 4.4° C

Max. daily average Dry bulb : 33.6° C

Design ambient : 50° C

ii) Relative humidity

Maximum (during : 100%

monsoon)

Minimum : 33%

Average Relative Humidity : 71%

iii) Rainfall

Annual average : 1203 mm

Period : June to September

iv) Climatic condition

Tropical sea coast climate with petrochemical complexes within the radius of about 5 km.






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Annexure-IIFORMAT FOR DEVIATIONS FROM TECHNICAL SPECIFICATION

Sr. No. Clause No. Seller’s Deviations Reason for Deviation

The Seller hereby certifies that the above mentioned are the only deviations from thetechnical specification.

Signature :

Name :

Designation :

Company seal






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Annexure-IIITO BE SUBMITTED BY THE SELLER ALONG WITH OFFER

Seller's name and address.

Quotation number and date.

Unit weight of the valves.

Weight and dimension of the heaviest single package.

Special storage requirement, if any.

Available manufacturing facility.

Available spare capacity if required.






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Annexure-IVOVERALL SUPPLY & IMPLEMENTATION SCHEDULE

Sl.No. WORK DESCRIPTIONWEEKS FROM

Start Finish

1.0 Design & Engineering

2.0 Equipment Manufacture

b Mechanical

e Bought out items

i) Ordering on sub sellers

ii)Manufacturing schedule & progress status

iii) Delivery

3.0 Equipment delivery at site






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Annexure-VQUALITY ASSURANCE PLAN (QAP)

Seller shall furnish Quality Assurance Plan (QAP) after completion of detailed

engineering and finalization of billing schedule and prior to start of manufacturing.

QAP shall be prepared and furnished by Seller for all components.

Inspection and test requirements shall be decided with due consideration of factors

like safety, duty cycle, operating conditions, equipment life, environment conditions,

place of installation and statutory regulations, as applicable for a particular

equipment.

QAP shall clearly indicate the followings through use of codes in the appropriate

columns:

Range of inspection & tests to be carried out by Seller and cross checkedduring manufacturing of equipment from raw materials to finishing stage.

Suggestive check/ hold points for Buyer inspection and witnessing of testsduring manufacturing and final product inspection.

Details of test certificates, internal inspection reports and calibration certificatesto be furnished by Seller to Buyer.

Inspection documents to be furnished by Seller to Buyer for reference duringinspection along with acceptable norms as per codes/ regulations.

TECHNICAL SPECIFICATIONS - PIPES - 209218.pdf

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