(volume - ii) - isro · p&i diagram for water based fire ... installation of fire protection...

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Ref No.: IPRC/S&FS/ISF-RFP/02

REQUEST FOR PROPOSAL (RFP)

FOR

WATER BASED FIRE PROTECTION SYSTEM

OF

ISROSENE STORAGE FACILITY (ISF)

FOR

SEMI CRYOGENIC PROJECT

((VVOOLL UUMM EE -- II II ))

SAFETY & FIRE SERVICES

ISRO PROPULSION COMPLEX

MAHENDRAGIRI - 627133

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Contents

1 INTRODUCTION 5

2 LAYOUT OF WATER BASED FIRE PROTECTION SYSTEM 8

2.1 DELUGE VALVES SHED 8

2.2 FOAM SKID SHED 8

2.3 FIRE HYDRANTS 8

3 DESCRIPITION OF WATER BASED FIRE PROTECTION SYSTEM 9

3.1 MEDIUM VELOCITY WATER SPRAY SYSTEM OPERATED BY DELUGE VALVE 9

3.2 INLINE BALANCED PRESSURE FOAM PROPORTIONING SYSTEM 9

3.3 FIRE HYDRANT SYSTEM 9

4 SCOPE OF WORK BY CONTRACTOR 10

4.1 DESIGN REVIEW 10

4.2 DETAILED ENGINEERING 10

4.3 PURCHASE OF MATERIALS 11

4.4 SUPPLY OF SPARES 11

4.5 FABRICATION 11

4.6 PIPE BENDING 12

4.7 WELDING 12

4.8 TESTING 12

4.9 CLEANING 12

4.10 PAINTING 13

4.11 ERECTION AND INSTALLATION 13

4.12 FASTENERS & GASKETS 13

4.13 STRUCTURAL WORKS 14

4.14 CIVIL WORKS 15

4.15 COATING AND WRAPPING OF UNDERGROUND PIPES 15

4.16 ELECTRICAL WORKS 16

4.17 POWER BODY EARTHING 16

4.18 COMMISSIONING 16

5 SCOPE OF WORK BY DEPARTMENT 17

5.1 PROCESS DESIGN 17

5.2 EQUIPMENT LAYOUT 17

5.3 SERVICES DURING ERECTION AND COMMISSIONING 17

5.4 INSTRUMENTATION SYSTEM 17

5.5 ELECTRICAL SYSTEM 17

5.6 INSPECTION OF WORK AT DEPARTMENT’S SITE 17

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6 SPECIFICATIONS OF THE SYSTEMS 18

6.1 DELUGE VALVE 18

6.2 INLINE BALANCED PRESSURE FOAM PROPORTIONING SYSTEM 20

6.2.1 FOAM CONCENTRATE TANK 20

6.2.2 FOAM CONCENTRATE PUMP 22

6.2.3 INLINE BALANCE PRESSURE FOAM PROPORTIONER 23

6.2.4 FOAM - WATER SPRINKLER 23

6.2.5 LOW LEVEL FOAM-WATER DISCHARGE DEVICE 24

6.2.6 FOAM CONCENTRATE 24

6.3 MANUAL VALVE - TRIPLE OFFSET BUTTERFLY VALVE (TOBV) 25

6.4 MANUAL VALVE - GATE VALVE 28

6.5 MANUAL VALVE - BALL VALVE 30

6.6 MANUAL VALVE – NEEDLE VALVE (3 WAY 2 PORT MANIFOLD VALVE) 32

6.7 PNEUMATICALLY ACTUATED BALL VALVES 33

6.8 LANDING VALVES 35

6.9 FILTER - Y TYPE 37

6.10 WATER SPRAY NOZZLES 39

6.11 SPRINKLERS 40

6.12 PRESSURE GAUGES 41

6.13 PIPES 42

6.14 PIPE FITTINGS AND FLANGES 44

7 SAFETY, QUALITY CONTROL AND INSPECTION 49

7.1 SAFETY 49

7.2 QUALITY CONTROL 49

7.3 SCOPE OF THIRD PARTY INSPECTION 50

8 PHASES OF WORK 51

9 DOCUMENTATION 51

10 INSTRUCTIONS TO BIDDERS 51

11 PRICES AND PAYMENT TERMS 51

12 EXECUTION SCHEDULE 51

13 WARRANTY 51

14 GENERAL CONDITIONS 51

ANNEXURE -1: MEMORANDUM OF UNDERTAKING 52

15 ANNEXURE -2: List of Essential Spares (One Set of Essential Spare Parts for

Individual Units)

53

16 ANNEXURE -3: VENDOR LIST 54

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ANNEXURE -4: DRAWINGS 60

LOCATIONS OF FIRE FIGHTING SYSTEMS FOR ISF 60

P&I DIAGRAM FOR WATER BASED FIRE PROTECTION SYSTEM FOR ISF 61

FIRE HOSE CABIN 62

ANNEXURE -5: QUALITY ASSURANCE PLAN 63

TABLE: 1 - QUALITY ASSURANCE PLAN FOR DELUGE VALVES 63

TABLE: 2 - QUALITY ASSURANCE PLAN FOR FOAM CONCENTRATE TANK 64

TABLE: 3 - QUALITY ASSURANCE PLAN FOR MANUAL TOBV 68

TABLE: 4 - QUALITY ASSURANCE PLAN FOR MANUAL GATE VALVES 69

TABLE: 5 - QUALITY ASSURANCE PLAN FOR MANUAL BALL VALVES & PNEUMATICALLY ACTUATED BALL VALVES

70

TABLE: 6 - QUALITY ASSURANCE PLAN FOR FILTERS 70

TABLE: 7 - QUALITY ASSURANCE PLAN FOR PRESSURE GAUGES 70

TABLE: 8 - QUALITY ASSURANCE PLAN FOR LANDING VALVES 71

TABLE: 9 - QUALITY ASSURANCE PLAN FOR CARBON STEEL PIPES 72

TABLE: 10- QUALITY ASSURANCE PLAN FOR PIPE FITTINGS AND FLANGES 73

TABLE: 11- QUALITY ASSURANCE PLAN FOR STUDS & U-BOLT CLAMPS 74

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1 INTRODUCTION

Isrosene propellant storage facility (ISF) is designed to store and supply Isrosene at

ambient temperature to user facility at ISRO Propulsion Complex(IPRC)for testing the

Semi Cryogenic Engine. The maximum storage capacity is 500 m3considering an ullage

volume of about 15%. Isrosene Storage facility comes under Static and Mobile Pressure

Vessels Rules (SMPVR) of Petroleum and Explosives Safety Organization (PESO).The

civil works, inhabited & intraline distances, PESO approvals, safety systems and other

design requirements are planned for 5 storage tanks (3 present + 2 futures) of total storage

capacity of 500 m3.

Isrosene, refined form of Kerosene is chemically stable and reacts only under strong

oxidising conditions. The density of Isrosene is 800kg/m3 and flash point is 333K. It

comes under petroleum class B and hazard group I of Ammunition and Explosives Safety

Standard (AESS). Isrosene is highly flammable and volatile liquid. The NFPA’s

flammability hazard rating for Kerosene is 2. The major potential hazard involving

Isrosene at storage and its handling is FIRE hazard. To prevent any inadvertent personnel

and property loss, installation of fire protection systems such as deluge system, foam-

water system and hydrant system is essential at Isrosene storage facility.

This Request for Proposal (RFP) describes with requirements for realizing the water

based fire protection systems at Isrosene Storage facility.

The design of the system has been done by the department. The Process and

Instrumentation Diagram (P&ID) along with sizes of the fluid circuits is given in this

document. Brief scope of Engineering, Procurement and Construction (EPC) works to

be carried out by the Contractor comprises the following.

• Review of design work done by the Department.

• Detailed engineering

• Procurement and supply of materials such as equipments, flow components,

gauges/indicators, pipes, pipe fittings, and associated accessories like gasket, ‘U’ bolt

clamps etc including shop fabrication, testing and inspection at manufacturer’s site.

• Transportation and storage of materials at Department’s site.

• Site Fabrication, erection, testing and inspection at Department’s site.

• Commissioning.

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Quotation shall be submitted on two bid basis viz. Technical & Commercial bid and

price bid. Quotations that are satisfying our technical specifications and commercial terms

& conditions only will be eligible for opening the price bid.

A pre bid meeting will be arranged to the interested potential Contractors wherein the

scope of contract and features & criticality of the facility will be described. Also a site

visit will be arranged to enable the bidders to assess the location of proposed facility.

The lead time of the project is 15 months from the date of awarding of contract. As this

project is of national interest and has to be completed within the scheduled period, the

bidders are advised to take utmost care in studying the quantum of works and plan

adequate & suitable resources to complete the project within the stipulated period.

Documents on “Design Report on Safety Systems at Isrosene Bulk Storage Facility”

along with P&ID and equipment layout of the facility will be supplied upon award of

contract. These documents form basis for carrying out Engineering, Procurement and

Construction(EPC) works to be carried out by the Contractor.

Some of the key words used in this document are defined as follows:

• “Department” shall mean and include the President of India acting through the

Director, IPRC and any representative(s) of the Department duly authorized on

his/her behalf.

• “Contractor ” shall mean the individual or firm or company whether incorporated or

not, chosen by the Department among the bidders to this tender enquiry, undertaking

the works and shall include the legal personal representatives of such individuals or

the permitted assignee of such individual or firm(s) or company.

• “Site” shall mean the land or other places at IPRC, Mahendragiri on which work is to

be executed under the Contract, which may be allotted by the Department for the

purpose of carrying out the work.

• “Equipment” shall mean Foam Storage tank, Foam Pump, which are to be erected in

ISF for water based fire protection system.

• “Materials” shall mean all the items required for realizing and forming part of the

ISF including raw materials, semi-finished products & subassemblies, which are

manufactured by the Contractor or their sub- Contractors or bought out from their

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sub-vendors, such as equipments, flow components, pipes, pipe fittings, instruments,

etc.

• “Specifications” shall mean collectively all technical specifications, terms and

conditions contained in this document which shall be considered to realize the

Isrosene Storage Facility.

• “SCP” shall mean Semi Cryogenic Project

• “ ISF” shall mean Isrosene Storage Facility

• “S&FS” shall mean Safety & Fire Service

• “RFP” shall mean Request for Proposal.

� Volume I for Isrosene Storage Facility

� Volume II for Water Based Fire Protection System for ISF

Note:

For location, climatic condition, layout of facility and description of Isrosene storage

facility, refer section 2 and 3 of ‘REQUEST FOR PROPOSAL (RFP) OF ISROSENE

STORAGE FACILITY (ISF) FOR SEMI CRYOGENIC PROJECT (Volume-I)’.

.

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2 LAYOUT OF WATER BASED FIRE PROTECTION SYSTEM

The tentative locations for fire hydrants, sheds for deluge valves and shed for foam skid in

Isrosene Storage Facility are shown in the drawing no

S&FS/PSCFS/ISF/LAYOUT/01/R0.

2.1 Deluge Valves Shed

Two numbers of DN 350 deluge valves shall be positioned in the deluge valves shed

at the tentative location shown in the layout drawing. Contractor shall propose the

area required for positioning the deluge valves, design and construct the deluge valve

shed. In deluge valves shed, in upstream of deluge valves, DN 350 filters, DN 350

TOBV manual valves and in downstream of deluge valves, DN 250 TOBV manual

valves and DN 250 EP valves shall be accommodated. The area shall include space

for access and to carry maintenance work. Suitable structural platforms with

necessary access shall also be planned for operation of deluge valve. Suitable

drainage arrangement shall be made to drain the water from drain point of deluge

valve and storm water.

2.2 Foam Skid Shed

Foam skid, consisting of 5m3 foam Concentrate tank, foam pump, foam

proportionaters and other flow components shall be positioned in the foam skid shed

at the tentative location shown in the layout drawing. Also one number of DN 200

deluge valve with flow components such as filter, manual valve and EP valve shall

be positioned in the foam skid shed. The area shall include space for access and to

carry maintenance work. Suitable structural platforms with necessary access shall

also be planned for operation of foam system and deluge valve. Suitable drainage

arrangement shall be made to drain the water from drain point of foam

propotionating system, deluge valve and storm water.

2.3 Fire Hydrants

Fire hydrants shall be installed in the locations shown in the layout drawing. Fire

hydrant outlet shall be situated 1 meter above the finished ground / floor level. Fire

hydrant stand pipe shall be provided with PCC at the base at least 1000 mm x 1000

mm. Each fire hydrant shall be provided with fire hose cabin at distance of 1500 mm

from hydrant stand pipe. 1000 mm width paved pathways shall be provided to

approach fire hydrants and fire hose cabins.

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3 DESCRIPITION OF WATER BASED FIRE PROTECTION SYSTEM

The Process and Instrumentation Diagram for water based fire protection system of

Isrosene Storage Facility is shown in Drawing no S&FS/PSCFS/ISF/P&ID/02/R0.

The water based fire protection system consists of

• Medium Velocity Water Spray System Operated by Deluge Valve

• Inline Balanced Pressure Foam Proportioning System

• Fire Hydrant System

3.1 Medium Velocity Water Spray System Operated by Deluge Valve

Medium Velocity Water Spray System operated by Deluge Valve is planned for

protecting Isrosene storage tanks and road tankers from any external fire. Two

deluge valves will be protecting storage tanks (3 present and 2 future) and a drain

tank in storage area and one deluge valve for protecting road tankers in transfer bay.

Water spray nozzles shall be provided to protect the surface area of storage tanks and

road tankers. Sprinklers (Quartzoid bulb – Temperature rating 68oC) shall be

provided around the areas to be protected for detecting the fire and actuating the

deluge valve.

3.2 Inline Balanced Pressure Foam Proportioning System

3% Aqueous Film Forming Foam (AFFF) concentrate mixed with 97% water to

make foam solution (Foam-Water) is planned for quenching the fire. For making and

dispensing foam solution at the right ratio for different flow rates, Inline Balanced

Pressure Foam Proportioning System is planned. For quenching fire at the storage

tanks, drain tanks and road tankers, foam-water spray nozzles are planned above the

tanks & tankers. For storage tank dike and transfer bay dike, low level discharge

devices placed at suitable intervals are planned.

3.3 Fire Hydrant System

Single outlet fire hydrants are planned for Isrosene storage facility and command

room. The water supply lines to fire hydrants in storage area shall be connected in a

form of a loop. The water line shall be extended from storage area to tanker parking

area and command room.

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4 SCOPE OF WORK BY CONTRACTOR

The scope of work to be done by the Contractor for the realization of water based fire

protection system at ISF is given in this Section. The bidder shall submit a complete

quotation for the entire works mentioned herein.

4.1 Process Design Review

Process Design Review is similar to that of Volume I of this document.

4.2 Detailed Engineering

Based on the approved design evolved during design review, the Contractor shall

carry out detailed engineering, which shall comprise the following:

a. Preparation of the detailed layout (top view) drawings (indicating skeletal

dimensions and to scale) of the pipelines of the fire protection fluid circuits

shown in the P&IDs for entire storage in a single drawing legibly. The isometric

drawings and other fabrication drawing shall be prepared by using AutoCAD

based software only.

b. Estimation of pressure drop based on the pipeline layout and isometric drawings.

c. Designing of In-line Balanced Pressure Foam Proportioning system for the

designed flow rate. It includes design, fabrication, procurement, installation,

testing and commissioning of foam concentrate storage tank, inter connecting

pipes, flow components, foam pump and terminating electrical/ instrumentation

connections with pump controller.

d. Preparation of sizing calculations of water spray nozzles, foam solution

sprinklers, foam proportionater, foam solution discharge device for dikes and

drawings for spray nozzle coverage details.

e. Preparation of the detailed Quality Assurance Plan (QAP) for the materials such

as pipes, pipe fittings, flow components, instruments, etc, fabrication, erection

and commissioning. The sample format of QAP is given inAnnexure-5.

f. Preparation of detailed procedure and acceptance criteria for fabrication, erection

and commissioning.

g. Preparation of the purchase specification of the materials such as equipments,

flow components, instruments, pipes, pipe fittings, etc.

h. Preparation of the list of spares. The guidelines for selection of spares are given

in Section 4.4

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i. Preparation of static earthing scheme for foam tank and power earthing for foam

pump motor.

j. Preparation ofexecution plan and safety plan to be followed during erection &

commissioning phase.

The detailed engineering documents as per Section 9.3 of volume I shall be

submitted to Department in advance for perusal. The date of Detailed Engineering

Review (DER) meeting shall be mutually agreed upon. Contractor shall organize the

detailed engineering review meeting either at their office/factory or at IPRC, in

which the Department’s representative(s) will participate. Upon review, necessary

modifications/changes, if any required shall be executed by the Contractor.

Modifications/changes shall be dealt as per Section 14.8 of volume I.

4.3 Purchase of Materials

All the materials such as equipments, flow components, instruments, pipes, pipe

fittings, etc are to be purchased by the Contractor. The general specifications of the

systems are given in Section 6. The detailed purchase specifications for the

individual items to be purchased shall be made by the Contractor. The purchase

specifications of such items and the sub-vendors from whom such items are to be

purchased are subject to review and approval by the Department.

4.4 Supply of Spares

a. Spare parts of flow components: For the parts used in the flow components, the

Contractor shall supply one set of essential spare parts for individual units (like

seat insert, body gasket, gland packing, plug stem assembly etc for valves) and

cost shall be included in the individual basic item. The list of essential spares

to be supplied along with flow components shall be provided as per Annexure-2.

b. Spares and consumables for erection and commissioning: Consumables (like

gaskets, lubricants, grease, PTFE tapes, etc) required/ used during erection and

commissioning shall be supplied by the Contractor. It is the responsibility of the

Contractor to account the required quantity till the completion of commissioning.

Cost for these spares shall not be quoted separately.

4.5 Fabrication

Fabrication is similar to that of Volume I of this document.

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4.6 Pipe Bending

Pipe bends is similar to that of Volume I of this document.

4.7 Welding

Carbon Steel (CS) pipelines welding shall be performed by Shielded Metal Arc

Welding (SMAW) with suitable electrodes and welding rods. Any welding of SS

pipelines shall be performed by Gas-purged Tungsten Arc Welding (GTAW) with

Gaseous Argon (99.995 % purity) as the purge medium. The welding processes shall

comply with the requirements of ASME Section IX.

All the welding should be done only by qualified welders for both pipelines and

structural works. The welding procedure qualification and welder’s performance

qualification shall be done as per ASME Section IX.

4.8 Testing

The following tests shall be performed after fabrication of pipelines and wherever

applicable:

a. Dye penetrant test: All the socket weld joints shall be subjected to Dye Penetrant

Test (DPT) at the root and final passes. All the butt and mitre welded joints shall

be subjected to DPT at the root pass. The cost of DPT is to be included with the

cost of respective welding as provided in price format in Section 15.2 of VolumeI.

b. Radiographic test: 10% CS and SS butt welded joints shall be subject to radio-

graphic test (RT) to 2-2T sensitivity. Generally, the RT shall be done with X-rays.

Alternatively, the gamma rays may be used in locations where the joint is

inaccessible to X-ray equipments. All the radiographic films shall be submitted to

the Department for verification along with joint identification numbers marked on

the films. The selection of the joints to be subjected to RT will be done by

Department representatives.

c. Hydro test: All the fabricated pipe-lines shall be subjected to pressure test with

hydraulic medium at 1.5 times the MAWP.

4.9 Cleaning

a. Cleaning shall be done by wire brush in such as way that the slag is fully removed

and the weld seam is clearly visible.

b. All weld spatters shall be finish ground by hand grinding machine without

reduction in thickness to the parent material.

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4.10 Painting

All the pipelines, equipments and flow components shall be painted with two coats

of zinc rich primer. Above the primer coating, two coats of enamel paint shall be

applied. The colour scheme shall be provided by the Department upon award of the

contract. All the pipelines, flow components and instruments shall be provided with

identification numbers/ tag numbers.

All the structural materials shall be painted in grey colour, hand rails in yellow

colour and toe guards in black.

4.11 Erection and Installation

Contractor shall carryout all the erections involving foam tank, foam pump, pipelines

and flow components at Department’s site. The other conditions shall be similar to

that of Volume I of this document.

4.12 Fasteners & Gaskets

a. Studs: Material of full threaded Studs shall conform to ASTM A193 GR.B7and

hexagonal nut shall conform to ASTM A194 GR.2H. The dimension of studs

and nuts shall conform to IS 1367. Flat washers shall suit to corresponding stud

size. One set shall contain a stud, two nuts and two washers.

Sl.No Stud Size Length (mm) No. of Studs (Sets)

1. M 12 70 50

2. M 16 90 300

3. M 20 110 300

4. M 22 115 500

5. M 24 130 200

6. M 32 175 160

b. U-Bolt Clamp: Material for U-bolt clamps and nuts shall be of carbon steel and

conform to IS 1367. It shall be of galvanized finish. Flat washers shall suit to

corresponding U-bolt clamp. One set shall contain a U-Bolt, two nuts and two

washers.

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Sl.No Pipe Size (DN) U-Bolt Clamp Size No. of Clamps (Sets)

1. 15 M8 150

2. 20 M8 150

3. 40 M10 50

4. 65 M12 50

5. 80 M16 50

6. 100 M16 50

7. 150 M20 100

8. 200 M20 50

9. 250 M20 40

10. 350 M24 10

11. 600 M24 5

c. Gaskets: Compressed Asbestos Fiber (CAF) non metallic gaskets shall be used

for flange joints and it shall conform to IS 2712 grade W/3. The gasket shall be

suitable to ASME B16.5, 150 class flanges. Approximate quantity required is

500kg.

4.13 Structural Works

The scope includes design, supply of materials, fabrication, assembly and erection of

all types of structures. The structural works consists of shed for deluge valves and

foam skid at the tentative locations shown in Drawing no.

S&FS/PSCFS/ISF/LAYOUT/01/R0. Contractor shall determine and propose the area

required for positioning the deluge valves and foam skid. The area shall include

space for access and to carryout maintenance work. Suitable structural platforms

with necessary access shall also be planned for operation of deluge valve. Other

structural work involves fabrication of pipeline supports using channels, I-beams,

angles and structural plates. The Contractor shall quote for structural works on per

kg basis in the price bid. Payment will be made for the actual quantity of work

executed. The approximate weight arrived at is 36 tons.

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4.14 Civil Works

Contractor shall perform detailed engineering for the foundations such as foundation

pockets, forces & moments acting on the foundation, etc of foam concentrate storage

tank, foam pump, deluge valves shed, foam skid shed and for any other pipe supports

and structural supports. The equipment layout showing such fine details shall be

made by the Contractor. The scope of civil works includes

a. Breaking of already laid Plain Cement Concrete (PCC)/ Reinforced Cement

Concrete (RCC) pavements and excavation of earth for laying underground

pipes, anchor blocks, pedestals for deluge valve shed, foam skid shed, foam

concentrate tank, foam pump, pipe supports and structural platforms.

b. Filling the earth after laying the underground pipes.

c. Grouting of equipments, pipe supports, structural works by PCC/ RCC, PCC/

RCC pavement of the excavated areas, PCC pavement around hose cabins and

fire hydrants.

d. Construction of hose cabins using brick masonry and RCC slabs as show in

Drawing no. S&FS/PSCFS/ISF/HOSE CABIN/03/R0.

e. Breaking and making holes across walls for laying pipelines.

f. Plastering the wall surfaces of fire hose cabins, applying two coats of white

washing and two coats of cement based paint (Fire red shade).

All the materials such as steel reinforcement rods, binding wires, brick, cement,

sand, gravel, etc shall be arranged by the Contractor. The composition of concrete

shall be as follows:

a. PCC – Cement : Fine aggregate: Coarse aggregate (20mm) = 1:2:4

b. RCC – Cement : Fine aggregate: Coarse aggregate (20mm) = 1:1.5:3

4.15 Coating and Wrapping of Underground Pipes

a. Underground pipes shall be coated with the synthetic primer, type B conforming

to IS 9912.

b. Underground pipes shall be wrapped by 4mm thick coal tar based anticorrosion

tape conforming to IS 15337.

c. Underground pipes coating and wrapping shall be done according to code of

practice IS 10221.

• The pipe surface shall be degreased and the rusts shall be cleaned by wire brush

prior to application of primer. Priming shall be done within 4 hours of

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completion of cleaning.

• The primer shall be applied either by brush or spray and be allowed to become

touch dry prior to wrapping the tape.

• Before wrapping the coal tar based anticorrosion tape to the pipe, the primer-

coated pipe shall be gently heated by a run of LPG torch or suitable heat source.

The tape shall be wrapped either by spiral or circumferential method to the pipe

and there shall be a minimum of 12.5 mm overlap per single wrap.

• Over the weld joints, after necessary inspections, the procedure for coating and

wrapping shall be similar to that of a bare pipe. Overlap on each side of weld

joint shall be a minimum of 50 mm.

• In wrapping application, care shall be taken such that there are no air pockets or

bubbles beneath tape and tape shall be in intimate contact with the primed steel.

4.16 Electrical Works

The electrical works shall be similar to that of Volume I of this document.

4.17 Power Body Earthing

Power body earthing shall be similar to that of Volume I of this document.

4.18 Commissioning

Commissioning activity shall be similar to that of Volume I of this document.

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5 SCOPE OF WORK BY DEPARTMENT

5.1 Process Design

The design of the system has been done by the Department. In this document, the

following drawings along with the sizes of the fluid circuits are given:

� Process and Instrumentation Diagram (P&ID) S&FS/PSCFS/ISF/P&ID/02/R0

The specification of the system, along with the list of flow components &

instruments, are given in detail in Section 6. These details are considered adequate

for price estimation. However, these sizes are subject to changes based on mutual

agreement between the Department and the Contractor during design review and

detailed engineering review. Upon award of the contract, the Department will furnish

the design document along with tentative piping layout for review by the Contractor.

5.2 Equipment Layout

The location of shed for deluge valve shed and foam skid is given in

S&FS/PSCFS/ISF/LAYOUT/01/R0. The details are explained in Section 2.

Based on this location and the P&ID, the Contractor shall prepare the pipeline layout

& isometric drawings and derive the lengths of the pipe-lines and pipe fittings

required to connect between the various inter-faces as per the P&ID.

5.3 Services during Erection and Commissioning

During construction and commissioning, the services provided by the Department

shall be similar to that of Volume I of this document.

5.4 Instrumentation System

The instrumentation systems shall be similar to that of Volume I of this document.

5.5 Electrical System

The electrical system shall be similar to that of Volume I of this document.

5.6 Inspection of work at Department’s site

Inspection shall be similar to that of Volume I of this document.

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6 SPECIFICATIONS OF THE SYSTEMS

6.1 Deluge Valve

General

Nominal size : DN 350 DN 200

Quantity (Nos.) : Two One

Tag numbers : KVD 9121; KVD 9122 KVD 9123

Mounting Type : Horizontal Mounting

Fluid medium : Water

Working temperature range : 300 K to 323 K

MAWP : 1 MPa

Permissible Leakage across Body and Seat

: Bubble tight as per API 598

End connections : Flanged (Raised Face) As per ASME B 16.5

Pressure Rating Class : 150#

Material of Construction:

Body : ASTM A 216 Gr.WCB

Diaphragm & O Ring : BUNA-N/ Neoprene Rubber/ EPDM

Valve Seat : ASTM A 351 Gr.CF 8M

Clapper or Retainer : ASTM A 351 Gr.CF 8/ ASTM A 351 Gr.CF 8M

Bolts & Nuts : A 193 Gr. B7 & A 194 Gr. 2H

Inlet & Outlet Drain Valve : SS 304/304L/316/316L

Gaskets : Asbestos CAF/ Spiral Wound PTFE/ Equivalent

Control Trim

Actuation : Hydraulic, Electric and Manual

Trim Type : Wet pilot trim with test & alarm trim and drain trim.

Accessories to be included per deluge valve

:

a. Pressure Gauges - 1 no.; Dial: 4”;Range: 0 - 20 kg/cm2.

b. Water Motor Gong

c. Release Valve (Manual actuation)

d. Strainer - Y Type

e. Non-Return Valve

f. Flow Control Device

g. 2 Way Solenoid Valve - 1 no.

h. Water Flow Switch - 1 no.

Weather proof IP66 &

Explosion Proof Gr. II B

Essential Spares:

One set of essential spare parts for individual units shall be specified and supplied as per

Annexure – 2.

MOC- SS 304/ 304L/316/316L

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Tests:

I. Material test certificates: The material test certificates, detailing the physical and

chemical properties of the principal pressure–bearing parts shall be provided.

II. Soundness test for castings: All the castings shall be subject to soundness test with radio-

graphic or ultra-sonic technique for flaw detection.

III. Hydraulic shell pressure test: The valve in partially open position shall be subjected to

pressure test with Water (with suitable corrosion inhibitor) at 1.5 times the maximum rated

working pressure of the particular pressure rating class of the valve. The test procedure

and acceptance criteria shall be as per API 598.

IV. Hydraulic seat pressure test: The valve, in closed position, shall be subjected to pressure

test with Water (with suitable corrosion inhibitor) at 1.1 times the maximum rated working

pressure of the particular pressure rating class of the valve. The test procedure and

acceptance criteria shall be as per API 598.

V. Cleaning: All the interior flow surfaces of the valve shall be cleaned and the ends/ ports

shall be blanked off by dust-tight plastic caps.

VI. Marking: All the valves are assigned tag numbers for identification. The tag number for

each valve, nominal size, pressure rating class, material of construction etc. shall be

legibly and indelibly engraved on the body of the valves.

VII. Painting: Two coats of epoxy primer and two coats of fire red shade shall be applied on

the valve body.

VIII. Calibration Certificates: For pressure gauges and water flow switch, calibration

certificates shall be provided.

20

6.2 Inline Balanced Pressure Foam Proportioning System

In-line Balanced Pressure Foam Proportioning system consist of foam skid comprising

5m3 stainless steel foam concentrate tank, positive displacement pump with flame proof

motor and pump controller, foam proportionaters with suitable sizes, interconnecting

pipes, flow components, pressure gauges, foam-water spray sprinklers and low level

discharge device for dikes. All interconnecting pipes between foam concentrate tank, foam

pump and foam proportionaters shall be SS 304L/ 316L. In-line Balanced Pressure Foam

Proportioning system shall be designed and installed according to relevant NFPA

standards.

6.2.1 Foam Concentrate Tank

The scope includes design, procurement of materials, fabrication, testing, cleaning,

inspection and supply of foam concentrate tank as per following specifications.

General

Type : Atmospheric Tank

Volume : 5 m3

Tag numbers : FTK 9001

Mounting Type : Horizontal Mounting

Fluid Medium : Aqueous Film FormingFoam Concentrate

MOC : SS 304L/316L

MAWP : 0.15 MPa

No. of Nozzles : 6 nos.

Nozzles on Top of Tank : Filling, Air Vent, Pressure and Vacuum Vent

Nozzles on Bottom of Tank : Return Line, Suction and Drain

Nozzle Flanges : Flanged (Raised Face) As per ASME B 16.5

Size of Man hole : 600 mm at the top of the tank with Davit Arm arrangement

Accessories to be Included : Level gauge (sight glass) with isolation valves

: Ladder

: Lifting lugs

Codes &Standards

Design : ASME Boiler and Pressure Vessel Code Section VIII Div.1 (Consider only the liquid head elevation for design).

Pipe Flanges And Flanged Fittings

: ASME B16.5

Nozzle pipes : ASME 36.19M

Wind load : IS: 875 (part 3)

Seismic load : IS: 1893

21

1. The contractor shall prepare the design calculation, general arrangement drawing,

fabrication drawings and Quality Assurance Plan (QAP) and it shall be submitted to the

department for approval.

2. Seismic load (zone 3 as per IS: 1893) and wind load (operating wind speed 120 km/hr &

survival wind speed 200 km/hr considering 3 sec gust) shall also be considered during

design of tank.

3. Welding of vessel shall be carried out by GTAW process and shall be performed only by

welders qualified under section IX of the ASME Boiler and Pressure Vessel Code, using

procedures mentioned under Section IX. Welding procedures must be approved and

welder must be qualified by TPI agency.

4. All butt welds shall be full penetration welds and shall be 100% radiographed (X-ray, 2-2T

sensitivity).

5. Saddle supports have to be designed for maximum weight of the tank, i.e., filling test

weight.

6. The vessel shall be offered for inspection to department and Third Party Inspection

Agency. Scope of inspection & test plan by TPI agency shall include approval of the

design calculation and fabrication drawings prepared by the contractor, review of material

test/UT test certificates, witness of DP test, review of radiographic films, witness of filling

test, final dimensional check including check up of internal and external attachments,

Examine final documents and as built drawings and countersigning the same, issuing of all

relevant certificates and final release note.

7. Three numbers of production master file shall be submitted by the fabricator along with

the supply. It shall contain

a. Introduction

b. Approved design calculations

c. Approved drawings

d. Third party inspection certificates (all certificates covers in their scope of inspection)

e. Final release note by third party inspection agency

f. Facsimile of stamping

g. Guarantee certificate

22

6.2.2 Foam Concentrate Pump

Operating Conditions

Fluid Medium : Foam Concentrate

Specific Gravity : 1 to 1.12

Viscosity 0.1 kg/m.s

Flow Rate : 150 lpm

Suction Pressure : 0.1 MPa

Discharge Pressure : 0.9 MPa

Pump

Type : Positive Displacement Pump

MOC : SS 304/304L/316/316L for all metallic parts

Suction Pipe Size : Size shall be based on detailed engineering

Discharge Pipe Size : Size shall be based on detailed engineering

End Connections : Flanged (Raised Face) as per ASME B 16.5

Pump Controller Functions

(Minimum Requirements) : Emergency Start Pushbutton, Remote Start Terminal

Connection, Remote Pump Operating Contact, Pressure/Flow Switch Starting Contact, Low Foam Concentrate Level Alarm, Phase Failure / Phase Reversal Alarm

Drive

Type : Electric

Rated voltage : AC 415V ± 10%, 3 Phase

Frequency : 50 Hz ± 2%

Mounting : Horizontal Floor Mounting

Motor Enclosure : Flame proof suitable for Zone 1 Group IIA/ IIB as per IS2148

Codes & Standards

Selection, Installation and Operation

: NFPA 20

Approvals

Listing : UL

Note: Rated Input, Rated Output, Speed in RPM, Vibration level should be provided by

Pump Supplier.

Essential Spares:


Annexure – 2.

23

6.2.3 Inline Balance Pressure Foam Proportioner

General

Type : Inline Balance Pressure Foam Proportioner with Manual Bypass

Quantity : 5 nos.

MAWP : 1 MPa

MOC : SS 304/304L/316/316L

Flow Rate : 4460 lpm - Storage Dike

1040 lpm - Road Tanker Dike

360 lpm - Storage Tank

160 lpm – Road Tanker

130 lpm – Drain Tank Dike

Type Of Foam Concentrate : AFFF 3%

Approvals

Listing : UL

Essential Spares:


Annexure – 2.

6.2.4 Foam - Water Sprinkler

General

Type : Foam - Water Sprinkler

Quantity : Fifty nos.

(Actual quantity shall vary based on detailed engineering).

Mounting Style : Pendant Type

Discharge Co-efficient, K : Not less than 42 lpm/bar½at 0.2 MPa

(K-Factor shall vary based on detailed engineering).

Fluid Medium : Foam - Water

MAWP : 1 MPa

End Connection : Threaded ½ ” NPT (Male)

Material of Construction

Body, Deflector, Agitator : Bronze/ Brass/ SS

Finish : Natural Bronze/ SS

Approvals

Listing : UL

24

6.2.5 Low Level Foam-Water Discharge Device

General

Type : Type II discharge device - Foam Maker and Pourer

Quantity* : Ten nos. for storage dike

Five nos. for road tanker dike

Flow Rate (lpm)* : 413 per pourer 185 per pourer

Fluid Medium : Foam - Water

MAWP : 1 MPa


Body : SS 304/304L/316/316L

Orifice : SS 304/304L/316/316L

Air inlet Screen : SS 304/304L/316/316L

Approvals

Listing : UL

*Quantity and Flow rate shall vary based on detailed engineering

6.2.6 Foam Concentrate

General

Type : Aqueous Film Forming Foam Concentrate 3%

Quantity : 5000 Liters

Approvals

Listing : UL

25

6.3 Manual Valve - Triple Offset Butterfly Valve (TOBV)

General:

Nominal size :

As mentioned in table 6.3 Quantity (Nos.) :

Tag numbers :

Type : Triple Offset Butterfly Valve- Short type

Actuation : Manual - Gear Operated



MAWP : 1 MPa


: Bubble-tight as per API 598




Body& Disc : ASTM A 216 Gr.WCB

Integral Seat (hard faced) : CoCr alloy Gr.21

Shaft : ASTM A479 Gr.410

Seat Seal : UNS 31803 + Graphite

Bearing : SS 316


Codes & Standards:

Design Standard : API609 Category B, ASME B 16.34

Face to Face Dimension : API609 Category B, ISO 5752

Hydraulic Test - Shell & Seat : API 598

Essential Spares:


Annexure – 2.

26

Tests:













V. Cleaning: All the interior flow surfaces of the valve shall be cleaned and the ends shall be

blanked off by dust-tight plastic caps.





the valve body.

27

Table 6.3 - Triple Offset Butterfly Valve

Sl. No Tag No Size (DN) Quantity (Nos.) Medium

1. KVM 9121 DN 600 01 Water

2. KVM 9123 DN 350 02 Water

3. KVM 9130

4. KVM 9124

DN 250 05 Water

5. KVM 9126

6. KVM 9128

7. KVM 9131

8. KVM 9133

9. KVM 9136

DN 200 04

Water

10. KVM 9146 Foam - Water



13. KVM 9137

DN 150 03

Water

14. KVM 9139 Water

15. KVM 9141 Water

28

6.4 Manual Valve - Gate Valve

General:

Nominal size :


Tag numbers :

Fluid medium :

Type : Gate – Stem Rising

Actuation : Manual


MAWP : 1 MPa







Disc : ASTM A 217 Gr. CA15

Stem : ASTM A182 Gr. F6a

Body Seat Ring : ASTM A 105 + HF

Back Seat : 13% Cr, Balance Steel

Hand Wheel : Steel


Codes & Standards:

Design code : ASME B 16.34/ API 600

Face to Face Dimension : ASME B 16.10

Hydraulic Test - Shell & Seat : API 598

Essential Spares:


Annexure – 2.

29

Tests:













V. Cleaning: All the interior flow surfaces of the valve shall be cleaned and the ends shall be






the valve body.

Table 6.4- Gate Valve

Sl. No Tag No Size (DN) Quantity (Nos.) Medium

1. KVM 9169 DN 100 01 Foam - Water

2. KVM 9135

DN 65 06

Water






8. KVM 9163

DN 40 03

Foam - Water



30

6.5 Manual Valve - Ball Valve

General:

Nominal size :


Tag numbers :

Fluid medium :

Type : Ball

Style of Construction : • With full port (standard bore) and inline end connections

• Single piece construction

Actuation : Manually Operated


MAWP : 1 MPa



Breather Hole : A breather hole shall be provided on any one side of the ball.

End connections : Threaded Ends NPT (F) as per ASME B 1.20.1



Body& End Piece :

Same as Volume I

Ball, Stem, Gland :

Body Seat :

Stem :

Body Primary Seal :

Body Secondary Seal :

Stem Primary Seal :

Stem Secondary Seal :

Lever :

Bolts & Nuts :

Codes & Standards:

Design Standard : API 6D

Testing Code : API 598

Tests: Test shall be performed as mentioned in Volume I

31

Table 6.5 - Ball Valve

Sl. No Tag No Size (DN) Quantity (Nos.) Fluid Medium Port Way Actuation

1. KVM 9142

DN 25 04

Water Two Way Manual

2. KVM 9147 Water Two Way Manual

3. KVM 9150 Foam - Water Two Way Manual


5. KVM 9152

DN 15 09

Foam - Water Two Way Manual









32

6.6 Manual Valve –Needle Valve (3 Way 2 Port Manifold Valve)

General:

Nominal size : DN 15

Quantity (Nos.) : Thirteen

Tag numbers : KVM 9122,KVM 9122(a), KVM 9125, KVM 9127,

KVM 9129, KVM 9132,KVM 9134, KVM 9138,

KVM 9140,KVM 9143,KVM 9144,

KVM 9149, KVM 9149(a)


Port Way : 3 Way 2 Port Manifold Valve

Type : Needle


MAWP : 1 MPa

Pressure Rating Class : 6000 psi

End connections : Threaded Ends NPT (F) as per ASME B 1.20.1

Style of Construction:

Body Pattern :

Same as Volume I

Stem :

Stem seal :

Bonnet :

Plug :

Seat :

Flow direction :

Port opening :


Body :

Same as Volume I Disc, Stem, Seat :

Gland Packing :

Bolts & Nuts :

Codes & Standards:

Design Standard :

Same as Volume I

Inspection and testing code :

Permissible leakage rate across body

:

Permissible leakage rate across seat

:


33

6.7 Pneumatically Actuated Ball Valves

The pneumatic actuated valve shall comprise valve, actuator, status switches and solenoid valve.

(Note: Solenoid valves shall be provided by department)

Valve:

Nominal size :


Tag numbers :

Fluid medium :

Type : Ball

Style of Construction :

• With full port (standard bore) and inline end connections

• Single piece construction for ball valves of size ≤ DN40

• 2-piece construction for ball valves of size ≥ DN50

Actuation : Pneumatically Operated


MAWP : 1 MPa







Other Specifications : Same as Volume I

Codes & Standards:

Design Standard : Same as Volume I

Testing Code :

Actuator:

Response time : Not less than 5 seconds


Status Switch:

Specifications : Same as Volume I

Essential Spares:

One set of essential spare parts for individual units shall be specified and supplied as per Annexure –

2.

34

Note: Testing and other conditions shall be same as mentioned in Volume I

Table 6.7–Pneumatically Actuated Ball Valve

Sl. No Tag No Size (DN) Quantity (Nos.) Fluid Medium Normal Position

1. KVP 9121

DN 250 05

Water Normally Open

2. KVP 9122 Water Normally Open




6. KVP 9129 DN 200 02

Water Normally Closed

7. KVP 9135 Foam - Water Normally Closed

8. KVP 9127 DN 150 02

Water Normally Open


10. KVP 9139 DN 100 01 Foam - Water Normally Closed

11. KVP 9126

DN 65 06

Water Normally Open






17. KVP 9136

DN 40 03

Foam - Water Normally Closed

18. KVM 9137 Foam - Water Normally Closed

19. KVM 9138 Foam - Water Normally Closed

35

6.8 Landing Valves

General:

Type : Type A - Single outlet conforming to IS 5290

Quantity (Nos.) : Ten

Tag numbers : FWH 1 to FWH 10



MAWP : 1 MPa


: Zero Leakage

End connections : Flanged as per ASME B 16.5



Valve Body : Leaded - tin - bronze conforming to Grade LTB-2 of IS 318

Hand Wheel : Mild Steel conforming to IS 1030

Spindle : Brass rod conforming to IS 320

Check Nut : Leaded - tin - bronze conforming to Grade LTB-2 of IS 318

Stop Valve : Leaded - tin - bronze conforming to Grade LTB-2 of IS 318

Spring : Phosphor wire conforming to IS 7608

Washer & Gaskets : Rubber conforming to IS 937 or Leather conforming to IS 518

Gland Packing : Asbestos conforming to IS 4687

Instantaneous Female Outlet : Leaded - tin - bronze conforming to Grade LTB-2 of IS 318

Blank Cap : Leaded - tin - bronze conforming to Grade LTB-2 of IS 318

Codes & Standards:

Design Standard : IS 5290

Testing Code : IS 5290

Essential Spares:


Annexure – 2.

36

Tests:



II. Water tightness test for valve: The stop valve shall be fully closed by screwing down the

spindle. A hydrostatic pressure of 1.4MPa shall then be applied to each valve on its inlet

side. There shall be no leakage through the valve and its seat.

III. Hydraulic shell pressure test: Each assembled unit shall be subjected to a hydrostatic

pressure of 2.1MPa with the valve open and outlet closed for a period of 2½ minutes.

When so tested, it shall not fail or show any leakage either through the valve body or

through the gland of the spindle.

IV. Cleaning: All the interior flow surfaces of the valve shall be cleaned and the ends shall be


V. Finishing: All parts shall be of good finish, clear of burrs and sharp edges. The outside of

instantaneous outlet shall be highly polished.

VI. Marking : All the landing valves are assigned with tag numbers for identification. On the

body of each landing valves, the tag number, BIS certification mark, type of valve,

nominal size, MAWP, manufacturer’s name, year of manufacturer, etc shall be legibly and

indelibly engraved.


the valve top. The hand wheel shall be painted black.

37

6.9 Filter - Y Type

General

Size : DN 350 DN 200

Quantity : Two nos. Two nos.

Tag Numbers : KST 9121 KST 9122 KST 9123 KST 9124

Flow rate (lpm) : 14,540 10,168 4,139 4,358

Fineness of Filtration : ≤ 500 µ (absolute)

Fluid Medium : Water

Working Temperature Range : 300 K to 323 K

MAWP : 1 MPa (g)

Permissible Pressure Drop : 0.05 MPa at clean condition

Permissible leakage rate across the body (external)

: No leakage

Diameter and length of filter element cartridge

: To be specified by the contractor in the GA drawing with the relevant calculations for filtration area and pressure drop.

End connection : Flanged Raised Face as per ANSI B 16.5


Style of Construction

Body : Y - Type with access to replace the filter element cartridge without removing the filter body.

Filter Element : Wire mesh type, supported on perforated cartridge.


Body and Screen Retainer (cover) : ASTM A216 WCB

Filter Element

(mesh & perforated sheet) : Stainless Steel 304/ 316

Retainer gasket : SS 304 spiral wound/Asbestos-graphite filled

Reinforcing perforated sheet : Stainless Steel 304/ 316

Drain Plug : ¾” NPT, A105 N

Stud : A 193 Gr B7

Nut : A 194 Gr 2H

Essential Spares:

One set of essential spare parts for individual units shall be specified and supplied as per Annexure – 2.

38

Tests:





III. Hydraulic shell pressure test: The filter upon final assembly shall be subjected to

pressure test with Water (with suitable corrosion inhibitor) at 1.5 times the maximum

allowable working pressure.

IV. Degree of filtration test: Filter element cartridge shall be subjected to “micron rating” test

by bubble point method as per ARP 901 standard. Sample mesh shall be subjected to

microscopic examination to evaluate minimum and maximum pore size of the filter

element in Govt. approved laboratory.

V. Cleaning: All the interior flow surfaces of the filter shall be cleaned and the ends shall be


VI. Marking : All the filters are assigned tag numbers for identification. The tag number for

each filter, nominal size, MAWP, fineness of filtration (absolute) etc, shall be legibly and

indelibly engraved on the body of the filters.


the filter body.

39

6.10 Water Spray Nozzles

General

Type : Medium Velocity Water Spray Nozzles

Quantity : Four Hundred nos.




(K-Factor shall vary based on detailed engineering).

Spray Angle : 110o

Fluid Medium : Water

MAWP : 1 MPa



Body : Bronze/ Brass/ Copper

Deflector : Bronze/ Brass / Copper

Finish : Chrome Plated

Approvals

Listing : UL

40

6.11 Sprinklers

General

Type : Bulb Type Sprinklers

Quantity : Two Hundred nos.




Coverage : Standard Coverage

Temperature Rating of Bulb : 68oC ± 3 oC

Temperature Response : Standard Response - 5 mm Glass Bulb

Service Medium : Water

MAWP : 1 MPa



Body : Bronze/ Brass/ Copper

Deflector : Bronze/ Brass / Copper

Finish : Chrome Plated

Approvals

Listing : UL

41

6.12 Pressure Gauges

General

Type : Bourdon Type Gauge

Quantity : Eleven nos.

Tag Number : KPL 9122, KPL 9125, KPL 9127, KPL 9129,

KPL 9132,KPL 9134, KPL 9138, KPL 9140,

KPL 9143, KPL 9144, KPL 9149,

Measuring Range : 0 – 2 MPa

Service Medium : Water

Working Temperature Range : 300 K to 323 K



42

6.13 Pipes

Type Seamless pipes Welded Pipes

Material

ASTM A 53 Gr.B/ ASTM A 106 Gr.B/ API 5L Gr.B

ASTM A 53 Gr.B/ ASTM A 135 Gr.B/ ASTM A 139 Gr.B/ API 5L Gr.B

Nominal pipe size & Schedule

DN 15 to DN 200; Schedule 10 for ≥ DN 65 Schedule 40 for ≤ DN 40

DN 250 to DN 600; Schedule 10

As per P&IDs and Table 6.13

Length & Size Based on the equipment layout and P&ID, contractor shall prepare isometric drawings and estimate the actual quantity.

(Approximate length is given in Table 6.14)

Dimensional standard ASME B 36.10M

Table: 6.13 - Pipes

Sl.No Pipe Size Schedule Number Pipe Type Quantity (m)

1. DN 600 10

Welded

25

2. DN 350 10 50

3. DN 250 10 300

4. DN 200 10

Seamless

400

5. DN 150 10 600

6. DN 100 10 200

7. DN 80 10 50

8. DN 65 10 120

9. DN 40 40 100

10. DN 20 40 200

11. DN 15 40 200

43

Tests

1. Visual examination: All pipes shall be visually examined for workmen-like finish against any scratches, dents and surface irregularities, etc.

2. Dimensional check: All the pipes shall be subjected to dimensional check.

3. Chemical analysis: One specimen from each heat lot shall be subject to detailed chemical analysis as per ASTM A 751.

4. Mechanical tests: One specimen from each heat lot shall be subject to tests for mechanical properties as ASTM A 370.

5. Hydraulic pressure test: All pipes shall be hydraulically pressure-tested with Water as per ASTM A 530.

6. Flattening test: For pipes greater than DN 50, pieces of pipes of length 63.5 mm (2.5”) cut from the ends of 5 % of pipe lengths from each heat lot shall be subjected to flattening test as per ASTM A 530 in 2 steps to prove ductility and soundness.

7. Bend test: For pipe DN 50 and under, a sufficient length of pipe shall be bent cold through 90° around a cylindrical mandrel, the diameter of which is twelve times the outside diameter (as shown in ASME B 36.10M) of the pipe, without developing cracks.

8. Cleanliness: The ends shall be blanked off by dust-tight plastic caps.

9. Marking : The pipes shall be marked as per ASTM A 700

10. Inspection : All the pipes should be inspected as per Section 4.7

44

6.14 Pipe Fittings and Flanges

Size & Pressure rating As required based on P&ID. Based on the equipment layout and

P&ID, contractor shall prepare isometric drawings and estimate the

actual quantity.

Type Forged, Seamless, Welded

Quantity Based on the equipment layout and P&ID, contractor shall prepare

isometric drawings and estimate the actual quantity.

(Approximate quantity is given in Table 6.14.1 to 6.14.7 )

Material for fittings � Butt welded fittings: ASTM A 234 WPB

� Socket welded fittings: ASTM A 105

� Flanges: ASTM A 105

Standard for

dimensions

� Butt welded fittings: ASME B 16.9

� Socket welded fittings: ASME B 16.11

� Flanges: ASME B 16.5

Pressure rating class Socket weld fittings: 3000# for pipe schedule ≤ 40

Butt weld fittings: Schedule No. shall be same as that of pipe.

Tests

1. Visual examination: All pipe fittings and flanges shall be visually examined for any scratches, dents, surface irregularities, etc.

2. Dimensional check: All pipe fittings and flanges shall be checked for dimensions as per the standard.

3. Chemical analysis: One specimen from each heat lot shall be subjected to detailed chemical analysis as per ASTM A 751.

4. Mechanical tests: One specimen from each heat lot shall be subjected to mechanical test to verify mechanical properties as per ASTM A 370.

5. Marking: The nominal size, pressure rating class, material, heat number, manufacturer’s name, etc shall be indelibly marked on the pipe fittings and flanges

45

Table: 6.14.1 - Fittings - 90o Elbow

Size (mm) Pressure

Rating Class/ Schedule

Material Dimension Standard

End Connection

Quantity in Nos.

350 10 ASTM A 234 WPB

Welded ASME B16.9

Butt Weld

16

250 10 ASTM A 234 WPB

Welded ASME B16.9 35

200 10 ASTM A 234 WPB

Seamless ASME B16.9 20

150 10 ASTM A 234 WPB


100 10 ASTM A 234 WPB


80 10 ASTM A 234 WPB


65 3000# ASTM A 105 ASME B16.11

Socket Weld

10

40 3000# ASTM A 105 ASME B16.11 5

20 3000# ASTM A 105 ASME B16.11 25

15 3000# ASTM A 105 ASME B16.11 25

Table: 6.14.2 - Fittings - Eccentric Reducers

Size (mm) Pressure


Material Standard End

Connection Quantity in Nos.

350 x 250 10 ASTM A 234 WPB

Welded ASME B16.9

Butt Weld

5

350 x 200 10 ASTM A 234 WPB

Welded ASME B16.9 2

350 x 150 10 ASTM A 234 WPB

Welded ASME B16.9 2

200 x 150 10 ASTM A 234 WPB


200 x 100 10 ASTM A 234 WPB


150 x 100 10 ASTM A 234 WPB


150 x 65 10 ASTM A 234 WPB


100 x 40 10 ASTM A 234 WPB


46

Table: 6.14.3 - Fittings - Equal Tee

Size (mm) Pressure




600 10 ASTM A 234 WPB

Welded ASME B16.9

Butt Weld

1

350 10 ASTM A 234 WPB

Welded ASME B16.9 2

250 10 ASTM A 234 WPB


200 10 ASTM A 234 WPB


150 10 ASTM A 234 WPB


100 10 ASTM A 234 WPB


80 10 ASTM A 234 WPB


65 3000# ASTM A 105 ASME B16.11

Socket Weld

6

40 3000# ASTM A 105 ASME B16.11 8

20 3000# ASTM A 105 ASME B16.11 100

15 3000# ASTM A 105 ASME B16.11 100

Table: 6.14.4 - Fittings - Un-Equal Tee

Size (mm) Pressure




350 x 250 10 ASTM A 234 WPB

Welded ASME B16.9

Butt Weld

4

350 x 200 10 ASTM A 234 WPB

Welded ASME B16.9 3

250 x 100 10 ASTM A 234 WPB


200 x 150 10 ASTM A 234 WPB


200 x 100 10 ASTM A 234 WPB


150 x 80 10 ASTM A 234 WPB


150 x 65 10 ASTM A 234 WPB


100 x 40 10 ASTM A 234 WPB


47

Table: 6.14.5 - Fittings - End Cap

Size (mm) Pressure




350 10 ASTM A 234 WPB

Welded ASME B16.9

Butt Weld

2

200 10 ASTM A 234 WPB


100 10 ASTM A 234 WPB


65 3000# ASTM A 105 ASME B16.11

Socket Weld

10

40 3000# ASTM A 105 ASME B16.11 10

20 3000# ASTM A 105 ASME B16.11 20

15 3000# ASTM A 105 ASME B16.11 20

Table: 6.14.6 - Fittings - Coupling and Half Coupling

Size (mm) Pressure Rating Class

Material Standard End Connection

Quantity in Nos.

Coupling - DN 20 3000 # ASTM A 105 ASME B16.11 Socket Weld

50

Coupling - DN 15 3000 # ASTM A 105 ASME B16.11 50

Coupling - DN 15 3000 # ASTM A 105 ASME B16.11 NPTF 50

Half Coupling - DN 20 3000 # ASTM A 105 ASME B16.11 NPTF

100

Half Coupling - DN 15 3000 # ASTM A 105 ASME B16.11 500

48

Table: 6.14.7 - Flanges - SORF

Size (mm) Pressure Rating Class

Material Standard Flange Type

Quantity in Nos.

600 150# ASTM A 105 ASME B16.5

SORF

8

350 150# ASTM A 105 ASME B16.5 16

250 150# ASTM A 105 ASME B16.5 40

200 150# ASTM A 105 ASME B16.5 20

150 150# ASTM A 105 ASME B16.5 20

100 150# ASTM A 105 ASME B16.5 20

80 150# ASTM A 105 ASME B16.5 30

65 150# ASTM A 105 ASME B16.5 10

40 150# ASTM A 105 ASME B16.5 10

49

7 SAFETY, QUALITY CONTROL AND INSPECTION

7.1 SAFETY

The conditions for safety shall be similar to that of Volume I of this document.

7.2 QUALITY CONTROL

The overall tentative quality assurance plans are given in Annexure-5. The detailed

QAP for individual subsystem is to be prepared by the Contractor during Detailed

Engineering.

Material Selection & Standards

The steel structures shall be fabricated using standard rolled steel sections such as

channels, I-beams, angles, plates and rods. Wherever the structural members are

subjected to heavy loads and dimensional stability is required, the structures shall be

stress-relieved.

The following standards are used for component design, material selection and

fabrication. However, the equivalent standards/ codes in force in the country of the

manufacturer are also acceptable at the discretion of the Department.

50

Sl No. Description Standard/ Code

1. Deluge Valve Manufacturer’s standard& UL/ FM Approval

2. Foam Concentrate Tank ASME Section VIII Division 1

3. Inline Balanced Pressure Foam Proportioning System

NFPA 11/ NFPA 16/ NFPA 20/ UL Listing

4. Triple Offset Butterfly Valve API 609/ ASME B16.34/ API 598

5. Butterfly Valve API 609/ EN 593/ API 598

6. Gate Valve API 600/ ASME B16.34

7. Ball valves API 6D/ API 598

8. Needle Valve ASME B16.34/ API 6D/ API 598/ BS EN ISO 15761/ BS EN 12266

9. EP Valves Manufacturer’s standard

10. Landing Valve IS 5290

11. Filters Manufacturer’s standard

12. Pressure gauges IS 3624

13. Sprinklers Manufacturer’s standard/ UL Listing

14. Water spray nozzles Manufacturer’s standard/ UL Listing

15. CS pipes ASME B36.10/ ASTM A53 Gr.B/ A106 Gr.B/ A135 Gr.B/ A53 Gr.B/ API 5L Gr.B

16. Butt welded fittings ASME B16.9/ ASTM A234 WPB

17. Socket welded/ threaded fittings

ASME B16.11/ ASTM A105

18. Flanges ASME B16.5/ ASTM A105

19. Bolts, Nuts and Washers ASTM A 193 Gr.B7, A 194 Gr.2H

20. CAF Gaskets IS 2712 Gr.W3/ ASME B16.21

21. Coating & Wrapping Material IS 9912/ IS 10221/ IS 15337

22. Hydraulic pressure test of pipelines

ASTM A 530

23. Pickling & passivation ASTM A 380

24. NDT ASME Section V

25. Welding ASME Section IX, AWS

26. Radiography ASTM E 94

7.3 SCOPE OF INSPECTION

Scope of inspection shall be similar to that of Volume I of this document.

51

8 PHASES OF WORK

The overall scope of work is divided into 5 as defined in Volume I of this document.

9 DOCUMENTATION

Scope of documentation requirements is similar to that of Volume I of this document.

10 INSTRUCTIONS TO BIDDERS

Instruction to bidders is similar to that of Volume I of this document.

11 PRICES AND PAYMENT TERMS

Prices and payment terms are similar to that of Volume I of this document.

12 EXECUTION SCHEDULE Execution schedule is similar to that of Volume I of this document.

13 WARRANTY

Warranty terms are similar to that of Volume I of this document.

14 GENERAL CONDITIONS

General conditions are similar to that of Volume I of this document.

52

Annexure-1

MEMORANDUM OF UNDERTAKING

Memorandum of undertaking shall be similar to that of Volume I of this document.

53

Annexure-2

15 List of Essential Spares (One Set of Essential Spare Parts for Individual Units)

Sl. No Name of the Item Size Name of Essential Spares (To be Specified by Contractor)

Quantity

1 Deluge Valve DN 350 2 Sets

DN 200 1 Set

2 Foam Skid Suitable Size

1 Set

3

Triple Offset Butterfly Valve

DN 600 1 Set

DN 350 2 Sets

DN 250 5 Sets

DN 200 4 Sets

DN 150 3 Sets

4

Gate Valve

DN 100 1 Set

DN 65 6 Sets

DN 40 3 Sets

5

Pneumatically Actuated Ball Valves

DN 250 5 Sets

DN 200 2 Sets

DN 150 2 Sets

DN 100 1 Set

DN 65 6 Sets

DN 40 3 Sets

6 Landing Valve DN 80 10 Sets

7 Filters – Y type DN 350 2 Sets

DN 200 2 Sets

54

Annexure-3

16 VENDOR LIST

16.1. Foam Skid

1. Tyco Fire Protection Products Tyco Centre Of Excellence, C-602, RMZ Centennial, Kundalahalli Main Road, Whitefield, Bangalore - 560048 Tel: +91-80-4052 7063, Fax: +91-80-4052 7200

2. Viking Corporation, Bangalore # 2, 1st Floor, 33rd Main Ashtalakshmi Layout, Behind Inchara Hotel,JP Nagar 6th Phase, Bangalore-560078 Phone:+(91)-9886177078 Website: www.vikingcorp.com

3. HD Fire Protect Ltd C-3/6, Nandanvan Industrial Estate, LBS Marg,Thane - 400604, India Phone: +(91) 22 25826958, 25826793, Fax : +(91) 22 25812524, 67969049 Email : [email protected]

4. Fire Safety Devices Pvt. Ltd. B-4, Second Floor, Rama Palace Commercial Complex Sector 20 B, Near Ajronda Modh, Faridabad - 121 007 (Haryana) India Phone: +91-129-2288196/7/8,Fax: +91-129-2288700 E-mail: [email protected], Website: www.fcfsd.com

16.2. Deluge Valve

1. Darling Muesco (India) Pvt. Ltd. Plot No. 97 A, Phase-1 G.I.D.C. Vatva, Ahmedabad - 382 445, Gujarat (India) Phone: +91 79 2583 2578, +91 79 2589 3791 & 92, Fax: +91 79 2583 4392 Email: [email protected]

2. HD Fire Protect Ltd C-3/6, Nandanvan Industrial Estate,LBS Marg, Thane - 400604, India Phone: +(91) 22 25826958, 25826793, Fax : +(91) 22 25812524, 67969049 Email : [email protected]

3. M/s. Tyco Fire Protection Products Tyco Centre Of Excellence, C-602, RMZ Centennial, Kundalahalli Main Road, Whitefield, Bangalore - 560048 Tel: +91-80-4052 7063, Fax: +91-80-4052 7200

4. M/s. Viking Corporation, Bangalore # 2, 1st Floor, 33rd Main Ashtalakshmi Layout, Behind Inchara Hotel,JP Nagar 6th Phase, Bangalore-560078 Phone:+(91)-9886177078 Website: www.vikingcorp.com

55

16.3, 16.4: Ball valves (Manual & EP operated)

Vendor list shall be similar to that of Volume I of this document.

16.5, 16.6: Triple Offset Butterfly Valve

1. Velan Valves India Pvt Ltd, S.F. No. 337/1, Thennampalayam - Annur Road, Naranapuram, Coimbatore-641659, Tamil Nadu State, India. Phone: 0421 2267000; Mobile: 08220746444 Email: [email protected]; Website: www.velan.com

2. L&T Valves Ltd, Mount Poonamallee Road, Post Bag 976, Manappakkam, Chennai-600089, Tamil Nadu State, India. Phone: 044 22498265, 22498268; Fax: 044 22492764 Email: [email protected], [email protected] Website: www.lntvalves.com

3. Virgo Valves and Controls Pvt Ltd, Emerson Process Management, 277, Hinjewadi Phase II, Maan (Mulshi), Pune-411057. Website: www.virgo-valves.com

Virgo Valves and Controls Pvt Ltd, Emerson Process Management, No. 16, Ground Floor, Kambar Street, Alandur, Chennai-600016. Phone: 044 22324119, 22323112 Email: [email protected];

4. Weir BDK Valves, A Unit of Weir India Pvt Ltd, Kaashyap Enclave, First Floor, Block D, 13-A, Velachery Main Road, Velachery, Chennai-600042. Phone: 044-22430995, 22430939 Fax: 044-22433402 Email: [email protected]

Weir BDK Valves, A Unit of Weir India Pvt Ltd, 47/48, Gokul Road, Hubli 580030, Karnataka State, India. Phone: 0836-4248222 Fax: 0836-4248484 Email: [email protected] Website: www.weirgroup.com

5. Xomox Sanmar Ltd - Pacific Valves Division, 89/2, Vadugapatti Village, Viralimalai 621316, Pudukottai District, Tamil Nadu State, India. Phone: 0091 4339 220252, Fax: 0091 4339 220371 Email: [email protected] Website: www.sanmargroup.com

56

16.7: Gate Valve

1. Velan Valves India Pvt Ltd, S.F. No. 337/1, Thennampalayam - Annur Road, Naranapuram, Coimbatore-641659, Tamil Nadu State, India. Phone: 0421 2267000; Mobile: 08220746444 Email: [email protected]; Website: www.velan.com

2. Ampo Valves India Pvt Ltd, S.F. No. 420, 6th Cross, Thaneer Pandal, V.K. Road, Peelamedu, Coimbatore-641004, Tamil Nadu State, India. Phone: 0422-4640900; Mobile: 09003802498, 9003802498, 7708027722 Fax: 0422-4640999; Email: [email protected], [email protected], [email protected]; Website: www.ampo.com

3. L&T Valves Ltd, Mount Poonamallee Road, Post Bag 976, Manappakkam, Chennai-600089, Tamil Nadu State, India. Phone: 044 22498265, 22498268; Fax: 044 22492764 Email: [email protected], [email protected] Website: www.lntvalves.com

4. Virgo Valves and Controls Pvt Ltd, Emerson Process Management, 277, Hinjewadi Phase II, Maan (Mulshi), Pune-411057. Website: www.virgo-valves.com

Virgo Valves and Controls Pvt Ltd, Emerson Process Management, No. 16, Ground Floor, Kambar Street, Alandur, Chennai-600016. Phone: 044 22324119, 22323112 Email: [email protected];

5. Weir BDK Valves, A Unit of Weir India Pvt Ltd, Kaashyap Enclave, First Floor, Block D, 13-A, Velachery Main Road, Velachery, Chennai-600042. Phone: 044-22430995, 22430939 Fax: 044-22433402 Email: [email protected]

Weir BDK Valves, A Unit of Weir India Pvt Ltd, 47/48, Gokul Road, Hubli 580030, Karnataka State, India. Phone: 0836-4248222 Fax: 0836-4248484 Email: [email protected] Website: www.weirgroup.com

6. Xomox Sanmar Ltd - Pacific Valves Division, 89/2, Vadugapatti Village, Viralimalai 621316, Pudukottai District,Tamil Nadu State, India. Phone: 0091 4339 220252,Fax: 0091 4339 220371 Email: [email protected]: www.sanmargroup.com

7. Fouress Engineering (India) Ltd, Plot No. 2, Phase II, Peenya Industrial Area, Bengaluru 560058,Karnataka State, India. Phone: 0091 80 8395734, 8395494, Fax: 0091 80 8395176

8. Intervalve (India) Ltd, 212/2, Hadapsar, Off Soli Poonawala Road, Pune 411028,Maharashtra State, India. Phone: 0091 20 6993900, 6993904, Fax: 0091 20 6993921 Email: [email protected], Website: www.poonawalagroup.com

57

16.8: Needle Valves


16.9:Landing Valves

1. New Age Fire Protection Industries, 4, Champaklal Udyog Bhavan, Sion East, Mumbai-400022. Phone: 022- 2407 7421 / 4351 1500, Fax: 022-24074229 / 2407 Email: [email protected], Website: www.newagefireprotection.com

2. Zenith Fire Services (India) Pvt. Ltd., 15, Vadhani Industrial Estate, Opp. Shreyas Cinema, LBS Marg, Ghatkopar (West), Mumbai 400086. Phone: 022-25000054, 25002591, 25000805, Fax: 25002253 Email: [email protected], Website: www.zenithfire.com Contact person: Dipesh C. Shah

3. Eversafe Protection 234, Blue Rose Ind. Estate, Near C.C.I., W.E. Highway,Borivali (E), Mumbai - 400 066 Phone : +91-22-2854 0715, Fax : +91-22-2854 1863 Email : [email protected]

4. Chandrakant & Co, 89, New Unique Industrial Estate, 2nd Floor, Dr. R.P. Road, Mulund (West), P.O. Box – 7774,Mumbai 400080 Phone: 022-25618502, Fax: 022-25645092 Email: [email protected], Website: www.queenfire.net

5. Rohit Fire & Safety Equipments, 6-6-35/1, Near Petrol Pump, Kavadiguda, Secunderabad – Telangana – 500 080 Phone: 040 27535096, Mobile: 9440894392/9440407747, Fax: 040-27535469 Email: [email protected] Contact person: T.V. Shivakumar

6. Safex Fire Services, No. 17, Ormes Road, Kilpauk, Chennai – 600 010 Phone: 044-26411855, Mobile: 9840070298, Fax: 044-26427580 Email: [email protected], Website: www.safexfire.com Contact person: pradip paul

7. Usha Fire Safety Equipments (P) Ltd, Plot No. 180/10a, Lake Area, Uttangudi Post, Near Meenakshi Hospital, Madurai 625 107 Phone: 0452-4219125, Mobile: 9894367510, Fax: 0452-4219124. Email: [email protected], Website: www.ushafire.com Contact person: A. Padmavathy

8. Ghosh Engineering Industries

46B/1, Reshi Bankim Sarani, P.O. Serampore, DIST. Hooghly,

W.B. - 712201

Mobile: 09433734355

58

16.10: Filters


16.11& 16.12Water Spray Nozzles, Sprinklers

1. HD Fire Protect Ltd C-3/6, Nandanvan Industrial Estate, LBS Marg, Thane - 400604, India Phone: +(91) 22 25826958, 25826793 Fax : +(91) 22 25812524, 67969049 Email : [email protected]

2. Tyco Fire Protection Products Tyco Centre Of Excellence, C-602, RMZ Centennial, Kundalahalli Main Road, Whitefield, Bangalore - 560048 Tel: +91-80-4052 7063 Fax: +91-80-4052 7200

3. Viking Corporation, Bangalore # 2, 1st Floor, 33rd Main Ashtalakshmi Layout, Behind Inchara Hotel, JP Nagar 6th Phase, Bangalore-560078 Phone:+(91)-9886177078 Website: www.vikingcorp.com

4. New Age Fire Protection Industries, 4, Champaklal Udyog Bhavan, Sion East, Mumbai-400022. Phone: 022- 2407 7421 / 4351 1500, Fax: 022-24074229 / 2407 Email: [email protected], Website: www.newagefireprotection.com

5. Vijay Fire Protection Systems Ltd., 23, Kamdar Nagar, Nungambakkam, Chennai-600034

6. Steelage Industries Ltd., (Minimax Division), 15, Moores Road, Chennai-600006

7. Nitin Industries, 89, Vadhani Estate, 2nd Floor, Opp Shreyas, LBS Marg, Ghatkopar (W), Mumbai-400086

59

16.13: Pressure Gauge


16.14: Pipes


16.15: Pipe Fittings


16.16: Studs & U-Bolt Clamps


16.17: Gaskets


63

Annexure –5

Table: 1 - QUALITY ASSURANCE PLAN FOR DELUGE VALVES

Sl.No.

Test

Object

tested

Characteristic

sought for

Sam

ple

size

Test

procedure

Acceptance

criterion

Form of

record

Pre-Delivery Inspection (PDI)

Test

performed

by

Test

witnessed

by

Record

reviewed

by

1.

M

ater

ial t

est

Spe

cim

en

from

raw

m

ater

ials

Che

mic

al

com

posi

tion

and

phys

ical

pr

oper

ties

1 pe

r he

at lo

t R

elev

ant

stan

dard

R

elev

ant

mat

eria

l sp

ecifi

catio

n

Mat

eria

l ce

rtifi

cate

V

endo

r or

T

hird

par

ty

labo

rato

ry

- V

endo

r,

TP

IA,

Pur

chas

er

2.

S

ound

ness

te

st fo

r ca

stin

gs

(whe

reve

r ap

plic

able

)

Cas

tings

A

bsen

ce o

f de

fect

s 10

0 %

R

adio

grap

hic

test

R

elev

ant

stan

dard

T

est

cert

ifica

te

Ven

dor

- T

PIA

, P

urch

aser

3.

D

imen

sion

al

chec

k V

alve

D

imen

sion

s 10

0 %

M

etro

logy

R

elev

ant

stan

dard

/ P

urch

aser

-ap

prov

ed

draw

ing

Tes

t re

port

V

endo

r -

TP

IA,

Pur

chas

er

4.

H

ydra

ulic

sh

ell

pres

sure

te

st

Val

ve in

pa

rtia

lly

open

po

sitio

n

Str

uctu

ral

inte

grity

und

er

stre

ss

100

%

1.5

times

m

axim

um

rate

d w

orki

ng

pres

sure

AP

I 598

T

est

cert

ifica

te

Ven

dor

TP

IA

Pur

chas

er

5.

H

ydra

ulic

se

at

pres

sure

te

st

Val

ve in

cl

osed

po

sitio

n

Str

uctu

ral

inte

grity

of s

eat

unde

r st

ress

100

%

1.1

times

m

axim

um

rate

d w

orki

ng

pres

sure

AP

I 598

T

est

cert

ifica

te

Ven

dor

TP

IA

Pur

chas

er

6.

R

evie

w o

f F

inal

D

ocum

ents

100

%

App

rove

d D

raw

ings

or

spec

she

et o

r D

ata

shee

t

100

%

App

rove

d D

raw

ings

or

spec

she

et o

r D

ata

shee

t

App

rove

d D

raw

ings

or

spec

she

et

or D

ata

shee

t

Tes

t C

ertif

icat

e V

endo

r -

TP

IA,

Pur

chas

er

64

Table: 2 - TENTATIVE QUALITY ASSURANCE PLAN FOR FOAM CONCENTRATE TANK

Sl.

No.

CO

MP

ON

EN

T/

OP

ER

AT

ION

C

HA

RA

CT

ER

IST

ICS

TY

PE

OF

INS

PE

CT

ION

/

CH

EC

K

RE

FE

RE

NC

E

DO

C/

AC

CE

PT

AN

CE

ST

D

RE

CO

RD

INS

PE

CT

ION

AU

TH

OR

ITY

MANUFACTURER

TPI

DEPARTMENT

1 R

evie

w &

App

rova

l of

Des

ign

calc

ulat

ions

and

dr

awin

gs

Des

ign

& D

raw

ings

R

evie

w a

nd a

ppro

val

AS

ME

SE

C.V

III

DIV

.1

Des

ign

calc

ulat

ions

&

Fab

ricat

ion

Dra

win

gs

QA

R

&

A

R &

A

2 R

aw M

ater

ials

In

spec

tion

Mat

eria

l pro

pert

ies

MT

C o

f pla

tes

AS

ME

SE

C.II

Par

t A &

C

Mat

eria

l Tes

t C

ertif

icat

es

QA

R

R

UT

of p

late

s

AS

ME

SE

C.V

U

T, I

GC

Rep

orts

Q

A

R

R

3 M

ater

ial

Iden

tific

atio

n M

ater

ial I

dent

ifica

tion

w.r

.t M

TC

M

ater

ial

Iden

tific

atio

n

App

rove

d D

raw

ings

M

ater

ial

Iden

tific

atio

n R

epor

t Q

A

W

R

4 M

achi

ning

of a

ll th

e co

mpo

nent

s

Mac

hini

ng o

f Com

pone

nts,

su

b as

sem

blie

s, a

nd

asse

mbl

y

Dim

ensi

onal

D

raw

ings

In

spec

tion

Rep

ort

QA

R

R

5 W

PQ

R G

ener

atio

n W

PQ

R

- A

SM

E S

EC

.IX

Rep

ort

QA

R

R

6 W

elde

r Q

ualif

icat

ion

Iden

tific

atio

n of

Wel

ders

-

AS

ME

SE

C.IX

R

epor

t Q

A

W

R

65


Sl.

No.

CO

MP

ON

EN

T/

OP

ER

AT

ION

C

HA

RA

CT

ER

IST

ICS

TY

PE

OF

INS

PE

CT

ION

/

CH

EC

K

RE

FE

RE

NC

E

DO

C/

AC

CE

PT

AN

CE

ST

D

RE

CO

RD

INS

PE

CT

ION

AU

TH

OR

ITY

MANUFACTURER

TPI

DEPARTMENT

7 V

esse

l

Fab

ricat

ion

a. W

eldi

ng o

f d

iffer

ent

size

pla

tes

to g

et

requ

ired

size

● D

imen

sion

al

● W

eld

set

up

● D

P T

est a

fter

root

run

, ba

ck g

ougi

ng a

nd fi

nal

runs

& R

T

Dra

win

g

Dra

win

g

AS

ME

SE

C V

III D

IV.I

Insp

ectio

n R

epor

t

Wel

d se

t up

repo

rt

D P

Tes

t &

X-R

ay

repo

rt

Insp

ectio

n R

epor

t

QA

QA

QA

QA

R

W

R R

R

R

R R

b. S

hell

rolli

ng

Dim

ensi

onal

D

raw

ing

Insp

ectio

n R

epor

t Q

A

R

R

c. L

ong

seam

join

ts

• W

eld

set u

p

• D

P T

est

afte

r ro

ot

run,

bac

k go

ugin

g an

d fin

al r

uns

& R

T

Dra

win

g

AS

ME

SE

C V

III D

IV.I

& A

SM

E S

EC

.V

Wel

d S

et U

p R

epor

t

DP

Tes

t Rep

ort &

X

-Ray

QA

QA

W

R

R

R

d. R

T o

f all

butt

wel

d jo

ints

. D

P T

est

afte

r ro

ot r

un,

back

gou

ging

and

fina

l ru

ns &

RT

AS

ME

SE

C V

III D

IV.I

& A

SM

E S

EC

.V

RT

Tes

t Rep

ort

QA

R

R

66


Sl.

No.

CO

MP

ON

EN

T/

OP

ER

AT

ION

C

HA

RA

CT

ER

IST

ICS

TY

PE

OF

INS

PE

CT

ION

/

CH

EC

K

RE

FE

RE

NC

E

DO

C/

AC

CE

PT

AN

CE

ST

D

RE

CO

RD

INS

PE

CT

ION

AU

TH

OR

ITY

MANUFACTURER

TPI

DEPARTMENT

8

Por

ts o

peni

ng a

nd

Noz

zle

wel

ding

w

ith S

hell

& d

ishe

d en

ds

a. F

lang

e an

d pi

pe

wel

ding

D

imen

sion

al,

R

T &

DP

test

D

raw

ing

AS

ME

SE

C V

III D

IV.I

& A

SM

E S

EC

.V

Insp

ectio

n R

epor

t D

P /X

-Ray

Q

A

R

R

b. M

arki

ng a

nd o

peni

ng

of p

orts

& w

eld

setu

p D

imen

sion

al

Dra

win

g

Insp

ectio

n R

epor

t Q

A

W

R

c. W

eldi

ng o

f all

port

s w

ith v

esse

l D

P T

est s

hall

be c

arrie

d ou

t aft

er r

oot r

un a

nd

afte

r fin

al r

uns

AS

ME

SE

C V

III D

IV.I

& A

SM

E S

EC

.V

Insp

ectio

n R

epor

t

QA

R

R

9

For

mat

ion

of

Dis

hed

End

s D

imen

sion

al/In

case

of

Join

t D

imen

sion

al &

RT

D

raw

ings

AS

ME

SE

C V

III D

IV.I

AS

ME

SE

C.V

Insp

ectio

n R

epor

t

QA

QA

W R

R R

10

Wel

ding

of d

ishe

d en

ds w

ith s

hell

a. F

it-up

b.

Wel

ding

R

T

As

per

the

proc

edur

e In

spec

tion

Rep

ort

QA

R

R

67


Sl.

No.

CO

MP

ON

EN

T/

OP

ER

AT

ION

C

HA

RA

CT

ER

IST

ICS

TY

PE

OF

INS

PE

CT

ION

/

CH

EC

K

RE

FE

RE

NC

E

DO

C/

AC

CE

PT

AN

CE

ST

D

RE

CO

RD

INS

PE

CT

ION

AU

TH

OR

ITY

MANUFACTURER

TPI

DEPARTMENT

11

Sup

port

Str

uctu

re

Fab

ricat

ion

Dim

ensi

onal

DP

tes

ting

Dim

ensi

onal

/ D

P t

est

Dra

win

gs

Insp

ectio

n R

epor

t Q

A

R

R

12

Hyd

rost

atic

pr

essu

re T

est

Hyd

rost

atic

pre

ssur

e T

est

Obs

erva

tion

As

per

stan

dard

H

ydro

stat

ic

pres

sure

Tes

t Q

A

W

W

13

Leak

Tes

t Le

ak T

est

Obs

erva

tion

_ Le

ak T

est

QA

W

R

14

Fin

al In

spec

tion

& S

tam

ping

Vis

ual a

nd D

ocum

enta

tion

Vis

ual,

Ove

r al

l fin

ishi

ng

etc.

D

raw

ings

&.

PO

Q

A/Q

C D

ocum

ents

,

QA

W

W

LEGEND

DP

: DY

E P

EN

ET

RA

NT

TE

ST

R

T: R

AD

IOG

RA

PH

Y T

ES

T

UT

: ULT

RA

SO

NIC

TE

ST

Q

A: Q

UA

LIT

Y A

SS

UR

AN

CE

- by

Con

trac

tor

R &

A: R

EV

IEW

AN

D A

PP

RO

VA

L

W

: WIT

NE

SS

R

: RE

VIE

W

N

DT

: NO

N D

ES

TR

UC

TIV

E T

ES

T.

MT

C: M

AT

ER

IAL

TE

ST

CE

RT

IFIC

AT

E

68

Table: 3 - QUALITY ASSURANCE PLAN FOR MANUAL TOBV

Sl.No.

Test

Object

tested

Characteristic

sought for

Sam

ple

size

Test

procedure

Acceptance

criterion

Form of

record


Test

performed

by

Test

witnessed

by

Record

reviewed

by

1.

M

ater

ial t

est

Spe

cim

en

from

raw

m

ater

ials

Che

mic

al

com

posi

tion

and

phys

ical

pr

oper

ties

1 pe

r he

at lo

t R

elev

ant

stan

dard

R

elev

ant

mat

eria

l sp

ecifi

catio

n

Mat

eria

l ce

rtifi

cate

V

endo

r or

T

hird

par

ty

labo

rato

ry

- V

endo

r,

TP

IA,

Pur

chas

er

2.

S

ound

ness

te

st fo

r ca

stin

gs

(whe

reve

r ap

plic

able

)

Cas

tings

A

bsen

ce o

f de

fect

s 10

0 %

R

adio

grap

hic

test

R

elev

ant

stan

dard

T

est

cert

ifica

te

Ven

dor

- T

PIA

, P

urch

aser

3.

D

imen

sion

al

chec

k V

alve

D

imen

sion

s 10

0 %

M

etro

logy

R

elev

ant

stan

dard

/ P

urch

aser

-ap

prov

ed

draw

ing

Tes

t re

port

V

endo

r -

TP

IA,

Pur

chas

er

4.

H

ydra

ulic

sh

ell

pres

sure

te

st

Val

ve in

pa

rtia

lly

open

po

sitio

n

Str

uctu

ral

inte

grity

und

er

stre

ss

100

%

1.5

times

m

axim

um

rate

d w

orki

ng

pres

sure

BS

675

5 P

art 1

/ A

PI 5

98

Tes

t ce

rtifi

cate

V

endo

r T

PIA

P

urch

aser

5.

H

ydra

ulic

se

at

pres

sure

te

st

Val

ve in

cl

osed

po

sitio

n

Str

uctu

ral

inte

grity

of s

eat

unde

r st

ress

100

%

1.1

times

m

axim

um

rate

d w

orki

ng

pres

sure

BS

675

5 P

art 1

/ A

PI 5

98

Tes

t ce

rtifi

cate

V

endo

r T

PIA

P

urch

aser

6.

R

evie

w o

f F

inal

D

ocum

ents

100

%

App

rove

d D

raw

ings

or

spec

she

et o

r D

ata

shee

t

100

%

App

rove

d D

raw

ings

or

spec

she

et o

r D

ata

shee

t

App

rove

d D

raw

ings

or

spec

she

et

or D

ata

shee

t

Tes

t C

ertif

icat

e V

endo

r -

TP

IA,

Pur

chas

er

69

Table: 4 - QUALITY ASSURANCE PLAN FOR MANUAL GATE VALVES

Sl.No.

Test

Object

tested

Characteristic

sought for

Sam

ple

size

Test

procedure

Acceptance

criterion

Form of

record


Test

performed

by

Test

witnessed

by

Record

reviewed

by

1.

M

ater

ial t

est

Spe

cim

en

from

raw

m

ater

ials

Che

mic

al

com

posi

tion

and

phys

ical

pr

oper

ties

1 pe

r he

at lo

t R

elev

ant

stan

dard

R

elev

ant

mat

eria

l sp

ecifi

catio

n

Mat

eria

l ce

rtifi

cate

V

endo

r or

T

hird

par

ty

labo

rato

ry

- V

endo

r,

TP

IA,

Pur

chas

er

2.

S

ound

ness

te

st fo

r ca

stin

gs

(whe

reve

r ap

plic

able

)

Cas

tings

A

bsen

ce o

f de

fect

s 10

0 %

R

adio

grap

hic

test

R

elev

ant

stan

dard

T

est

cert

ifica

te

Ven

dor

- T

PIA

, P

urch

aser

3.

D

imen

sion

al

chec

k V

alve

D

imen

sion

s 10

0 %

M

etro

logy

R

elev

ant

stan

dard

/ P

urch

aser

-ap

prov

ed

draw

ing

Tes

t re

port

V

endo

r -

TP

IA,

Pur

chas

er

4.

H

ydra

ulic

sh

ell

pres

sure

te

st

Val

ve in

pa

rtia

lly

open

po

sitio

n

Str

uctu

ral

inte

grity

und

er

stre

ss

100

%

1.5

times

m

axim

um

rate

d w

orki

ng

pres

sure

BS

675

5 P

art 1

/ A

PI 5

98

Tes

t ce

rtifi

cate

V

endo

r T

PIA

P

urch

aser

5.

H

ydra

ulic

se

at

pres

sure

te

st

Val

ve in

cl

osed

po

sitio

n

Str

uctu

ral

inte

grity

of s

eat

unde

r st

ress

100

%

1.1

times

m

axim

um

rate

d w

orki

ng

pres

sure

BS

675

5 P

art 1

/ A

PI 5

98

Tes

t ce

rtifi

cate

V

endo

r T

PIA

P

urch

aser

6.

R

evie

w o

f F

inal

D

ocum

ents

100

%

App

rove

d D

raw

ings

or

spec

she

et o

r D

ata

shee

t

100

%

App

rove

d D

raw

ings

or

spec

she

et o

r D

ata

shee

t

App

rove

d D

raw

ings

or

spec

she

et

or D

ata

shee

t

Tes

t C

ertif

icat

e V

endo

r -

TP

IA,

Pur

chas

er

70

Table: 5 - QUALITY ASSURANCE PLAN FOR MANUAL BALL VALVES & PNEUMATICALLY ACTUATED BALL VALVES

QA

P s

hall

be s

imila

r to

that

of V

olum

e I o

f thi

s do

cum

ent.

Table: 6 - QUALITY ASSURANCE PLAN FOR FILTERS

QA

P s

hall

be s

imila

r to

that

of V

olum

e I o

f thi

s do

cum

ent.

Table: 7 - QUALITY ASSURANCE PLAN FOR PRESSURE GAUGES

QA

P s

hall

be s

imila

r to

that

of V

olum

e I o

f thi

s do

cum

ent.

71

Table: 8 - QUALITY ASSURANCE PLAN FOR LANDING VALVES

Sl.No.

Test

Object

tested

Characteristic

sought for

Sam

ple

size

Test

procedure

Acceptance

criterion

Form of

record


Test

performed

by

Test

witnessed

by

Record

reviewed

by

1.

Mat

eria

l tes

t S

peci

men

fr

om r

aw

mat

eria

ls

Che

mic

al

com

posi

tion

and

phys

ical

pr

oper

ties

1 pe

r he

at lo

t R

elev

ant

stan

dard

R

elev

ant

mat

eria

l sp

ecifi

catio

n

Mat

eria

l ce

rtifi

cate

V

endo

r or

T

hird

par

ty

labo

rato

ry

- V

endo

r,

TP

IA,

Pur

chas

er

2.

Sou

ndne

ss

test

for

cast

ings

(w

here

ver

appl

icab

le)

Cas

tings

A

bsen

ce o

f de

fect

s 10

0 %

R

adio

grap

hic

test

R

elev

ant

stan

dard

T

est

cert

ifica

te

Ven

dor

- T

PIA

, P

urch

aser

3.

Dim

ensi

onal

ch

eck

Val

ve

Dim

ensi

ons

100

%

Met

rolo

gy

Rel

evan

t st

anda

rd/

Pur

chas

er-

appr

oved

dr

awin

g

Tes

t re

port

V

endo

r -

TP

IA,

Pur

chas

er

4.

Hyd

raul

ic

shel

l pr

essu

re

test

Val

ve in

pa

rtia

lly

open

po

sitio

n

Str

uctu

ral

inte

grity

und

er

stre

ss

100

%

Rel

evan

t st

anda

rd

IS 5

290

Tes

t ce

rtifi

cate

V

endo

r T

PIA

P

urch

aser

5.

Hyd

raul

ic

seat

pr

essu

re

test

Val

ve in

cl

osed

po

sitio

n

Str

uctu

ral

inte

grity

of s

eat

unde

r st

ress

100

%

Rel

evan

t st

anda

rd

IS 5

290

Tes

t ce

rtifi

cate

V

endo

r T

PIA

P

urch

aser

6.

Rev

iew

of

Fin

al

Doc

umen

ts

100

%

App

rove

d D

raw

ings

or

spec

she

et o

r D

ata

shee

t

100

%

App

rove

d D

raw

ings

or

spec

she

et o

r D

ata

shee

t

App

rove

d D

raw

ings

or

spec

she

et

or D

ata

shee

t

Tes

t C

ertif

icat

e V

endo

r -

TP

IA,

Pur

chas

er

72

Table: 9 - QUALITY ASSURANCE PLAN FOR CARBON STEEL PIPES

Sl.No.

Test

Object

tested

Characteristi

c sought for

Sam

pl

e size

Test

procedure Acceptance

criterion

Form of

record


Test

performed by

Test

witnessed

by

Record

reviewed by

1.

V

isua

l

exam

inat

ion

Pip

es

Sur

face

fini

sh

100%

V

isua

l

exam

inat

io

n

Wor

kmen

shi

p lik

e fin

ish

Insp

ectio

n

repo

rt

Man

ufac

ture

r

Qua

lity

Con

trol

(QC

) T

PIA

TP

I D

epar

tmen

t

2.

C

hem

ical

anal

ysis

Spe

cim

en

from

pip

es

Che

mic

al

com

posi

tion

1 pe

r

heat

AS

TM

A

751

AS

TM

A 3

12

Mat

eria

l

cert

ifica

te

Man

ufac

ture

r or

Thi

rd p

arty

labo

rato

ry

M

anuf

actu

rer,

TP

I,

Dep

artm

ent

3.

M

echa

nica

l

test

Spe

cim

en

from

pip

es

Mec

hani

cal

prop

ertie

s

1 P

er

lot

AS

TM

A

370

AS

TM

A 3

12

Mat

eria

l

cert

ifica

te

Man

ufac

ture

r or

Thi

rd p

arty

labo

rato

ry

M

anuf

actu

rer,

TP

I,

Dep

artm

ent

4.

P

ress

ure

test

Pip

es

Str

uctu

ral

inte

grity

und

er

stre

ss

100%

A

ST

M A

530

AS

TM

A 5

30

Tes

t

cert

ifica

te

Man

ufac

ture

r

TP

I,

Dep

artm

ent

5.

F

latte

ning

test

Spe

cim

en

from

pip

es

Duc

tility

and

soun

dnes

s

5%

AS

TM

A

530

AS

TM

A 5

30

Tes

t

cert

ifica

te

Man

ufac

ture

r V

endo

r,

TP

IA

TP

I,

Dep

artm

ent

6.

B

end

Tes

t S

peci

men

from

pip

es

Duc

tility

and

soun

dnes

s

5%

Rel

evan

t

Sta

ndar

d

Rel

evan

t

Sta

ndar

d

Tes

t

cert

ifica

te

Man

ufac

ture

r V

endo

r,

TP

IA

TP

I,

Dep

artm

ent

73

Table: 10 - QUALITY ASSURANCE PLAN FOR PIPE FITTINGS AND FLANGES

S N

o T

est

Obj

ect

test

ed

Cha

ract

eris

tic

soug

ht fo

r S

ampl

e si

ze

Tes

t pr

oced

ure

Acc

epta

nce

crite

rion

For

m o

f re

cord

P

re-D

eliv

ery

Insp

ectio

n (P

DI)

Tes

t per

form

ed

by

Tes

t w

itnes

sed

by

Rec

ord

revi

ewed

by

1.

Vis

ual

exam

inat

ion

Pip

e fit

tings

S

urfa

ce

prop

ertie

s 10

0 %

V

isua

l ex

amin

atio

n

No

scra

tch,

de

nt, s

urfa

ce

irreg

ular

ity,

etc

Insp

ectio

n re

port

V

endo

r -

TP

IA,

Pur

chas

er

2.

Dim

ensi

onal

ch

eck

Pip

e fit

tings

D

imen

sion

s

100

%

Met

rolo

gy

Rel

evan

t st

anda

rd

Insp

ectio

n re

port

V

endo

r -

TP

IA,

Pur

chas

er

3.

Che

mic

al

anal

ysis

S

peci

men

fr

om p

ipe

fittin

gs

and

flang

es

Che

mic

al

com

posi

tion

1 pe

r he

at

AS

TM

A

751

Rel

evan

t st

anda

rd

Mat

eria

l ce

rtifi

cate

V

endo

r or

Thi

rd

part

y la

bora

tory

-

TP

IA,

Pur

chas

er

4.

Mec

hani

cal

test

S

peci

men

fr

om p

ipe

fittin

gs

and

flang

es

Mec

hani

cal

prop

ertie

s 1

per

lot

AS

TM

A

370

Rel

evan

t st

anda

rd

Mat

eria

l ce

rtifi

cate

V

endo

r or

Thi

rd

part

y la

bora

tory

-

TP

IA,

Pur

chas

er

74

Table: 11 - QUALITY ASSURANCE PLAN FOR STUDS & U-BOLT CLAMPS

Sl N

o T

est

Obj

ect t

este

d C

hara

cter

istic

so

ught

for

Sam

ple

size

T

est p

roce

dure

A

ccep

tanc

e cr

iterio

n F

orm

of r

ecor

d P

re-D

eliv

ery

Insp

ectio

n (P

DI)

Tes

t pe

rfor

med

by

Tes

t w

itnes

sed

by

Rec

ord

revi

ewed

by

1.

Vis

ual

exam

inat

ion

Stu

d B

olts

, U

Bol

ts, N

uts,

W

ashe

rs

Sur

face

F

inis

h 10

0 %

V

isua

l exa

min

atio

n

No

scra

tch,

de

nt, s

urfa

ce

irreg

ular

ity,

etc

Insp

ectio

n re

port

Ven

dor

Ven

dor’s

QC

In

spec

tor

Ven

dor’s

Q

C

Insp

ecto

r P

urch

aser

2.

Dim

ensi

onal

ch

eck

Stu

d B

olts

, U

Bol

ts, N

uts,

W

ashe

rs

Dim

ensi

ons

100

%

Met

rolo

gy

Rel

evan

t st

anda

rd

Insp

ectio

n re

port

Ven

dor

Ven

dor’s

QC

In

spec

tor

Ven

dor’s

Q

C

Insp

ecto

r P

urch

aser

3.

Che

mic

al

anal

ysis

Spe

cim

en fr

om

Stu

d B

olts

, U

Bol

ts, N

uts,

W

ashe

rs

Che

mic

al

com

posi

tion

1 pe

r si

ze

Rel

evan

t sta

ndar

d R

elev

ant

stan

dard

M

ater

ial t

est

cert

ifica

te

Ven

dor

or

Thi

rd p

arty

la

bora

tory

-

Ven

dor’s

Q

C

Insp

ecto

r P

urch

aser

4.

Mec

hani

cal

test

Spe

cim

en fr

om

Stu

d B

olts

, U

Bol

ts

Mec

hani

cal

prop

ertie

s 1

per

size

R

elev

ant s

tand

ard

Rel

evan

t st

anda

rd

Mat

eria

l tes

t ce

rtifi

cate

Ven

dor

or

Thi

rd p

arty

la

bora

tory

-

Ven

dor’s

Q

C

Insp

ecto

r P

urch

aser

5.

Pro

of lo

ad

test

S

peci

men

from

N

uts

Load

ing

capa

city

1

per

size

R

elev

ant s

tand

ard

Rel

evan

t st

anda

rd

Tes

t cer

tific

ate

Ven

dor

or

Thi

rd p

arty

la

bora

tory

-

Ven

dor’s

Q

C

Insp

ecto

r P

urch

aser

6.

Har

dnes

s te

st S

peci

men

from

S

tud

Bol

ts, U

B

olts

, Nut

s.

Har

dnes

s 1

per

size

R

elev

ant s

tand

ard

Rel

evan

t st

anda

rd

Mat

eria

l tes

t ce

rtifi

cate

Ven

dor

or

Thi

rd p

arty

la

bora

tory

-

Ven

dor’s

Q

C

Insp

ecto

r P

urch

aser