8559 Finalresponsetoprebidqueriesftp114720.04.2016 PDF

Pre-Bid Response
for
Tender No - CMM/FTP/75-00-1-1147
Index
S.No.
DESCRIPTION
1.
NPCIL Response on pre-bid queries ( 7 Pages)
2.
Additional information from NPCIL: Following documents are enclosed

with regards to the various technical queries.
1.
2.
3.
4.
5.
A-463-000-16-46-DS-4013 Tank bottom support detail ( 1 Page)

Nozzle end details ( 1 Page)
Painting Specification I301.KK34.0.0.TH.TS.WD122 ( 48 Pages)
Digital seismic response spectra ( 6 pages)
Approved Vendor list ( 3 Pages)
3.
Revised datasheet as additional document ( 19 Pages)
4.
Additional design requirement for document no A-463-000-16-46-DS-4003

( 3 Pages)
Page 1 of 1
Pre bid Queries on Tender No. CMM/FTP/75-00-1-1147 for SS Tanks, Kudankulam

Bidder : M/s Walchandnagar Industries Ltd., Walchandnagar (Dt:02.04.2016)
Sr. No
Query Tender Section/

no. Volume Name
Volume II
Clause No./ Subject
Description of Query
NPCIL's Response
Site visit to see area for site

Mr. S. Jayakrishnan , CCE KKNPP3&4,
Please provide name, contact details & mail id of Concerned officer who
workshop and unloading place of
jayakrishnan@kknpp.com,
can help to give entry in plant for visit & to collect relevant information
Tanks
9443317882
NIT
Submission date of Bid
We have to visit site after pre-bid discussion to see unloading area,

area to set up workshop, approach roads near by site and inside site.
Also design of all majour parts of each Tank has to be completed to
Bid due dates are extended on
arraive at a proper cost estimate. Considerable time is required for
18.04.2016 kindly refer our ecompleting these activities and based on the out come, cost estimation tendering website for details.
to be finalised. Hence request to extend bid submission date by at least
4 weeks after up loading of MOM of pre bid discussion.
Volume II
all datasheets
Process conditions of inflow / outflow of tanks have not been given;

hence, safety / emergency venting requirements have to be clarified in
detail by NPCIL.
all datasheets
It is assumed that design of all tanks is to have frangible roofs (roof

whose welded joint with shell will get detached, before shell joint to
Frangible roof design is for cone roof
bottom plate can rupture and spill the tanks contents). Kindly confirm.
tanks only. To be worked out during
Also NPCIL to clarify on type of conical roof requuired for each tank,
detailed engineering.
whether self supported, or supported, and further, whether frangible or
column and rafter supported, etc...
The structural piers of bottom
support structure are to be welded
to the Embedded Parts provided on
the floor elevation.
Bottom plate of the tank will be
welded to support structure on
periphery.
Wind load consideration not required
as tanks are inside building.
The digital values are provided in the
enclosed attachment.
Volume II
The safety /emergency requirements

are to be provided as mentioned in
Technical specification/datasheet
Volume II
all datasheets
Since bottom plate of Tanks are resting on grid of structural members,

which in turn are resting on multiple structural piers not bolted to
foundations, how do wind forces and moments get taken care of? (It
may be noted that loading due to wind is not explicitly mentioned in
Tender document docs). Kindly clarify. There is no wind load on the
tanks, as all tanks are located in building. Please confirm.
Volume II
all datasheets
Digital values for Seismic response spectra (as per Annexure A) to be

provided by NPCIL within 15 days of release of PO. Please confirm.
Volume II
7.4 (Welding)
We propose to use GMAW and FCAW process particulary for structural

These processes can be used if
joints having requirement of only LPT (Liquid Penetrant test). Please
permitted in ASME STDs.
confirm.
Volume II
7.4 (Welding )
We propose to use common welding consumable ER 347 which is

Not acceptable. Tender condition
compatible with both material grades SS 304 L & SS 321. Please confirm. shall prevail
Volume II
A463-000-16-46-DS-4001
10
10
Volume II
A463-000-16-46-DS-4001
11
11
Volume II
all datasheets
Pl. confirm whether Nozzle -IX can be made from two pieces. The
portion of nozzle outside the tank shal be made from forging & the
inside portion shall be made from hollow bar of quality SA 479 Gr.304L
(Refer data sheet no. 6/9).
OD of Nozzle - VI (towards shell side) is not given in detail drg. (Refer
data sheet No. 6/9). NPCIL to confirm..
OD, thk, end details (BW) are specified in datasheet for nozzles and
mentioned to refer GOST Std. . Please confirm GOST std. to be referred
and for what details?
Ok, Material to be used from SA 479

should be compatible with tank
material.
OD-25 mm and length-50 mm
End connection details provided in
the attachment.
12
12
Volume II
A463-000-16-46-DS-4001
Material to be used from SA 479

Nozzle size is non standard for Nozzle -II, III & VI. Similar case of nozzles
in other tanks. Whether near by std. pipes can be used Or hollow bars
material. End dimensions have to be
made from SA 479?
met.
13
13
Volume II
A463-000-16-46-DS-4001
We Propose to use SA 403 Gr. WP 304L for STD Pipe fittings for ex.
ELBOW of Nozzle -VII. Please confirm.
14
14
Volume II
all datasheets
NPCIL to confirm whether Bottom Support (e.g. parts mentioned in

Yes, Bottom support is in suppliers
BOM of Drg. no. doco. No.4004 sheet 9/10) is insupplier's scope or not. scope
15
15
Volume II
A463-000-16-46-DS-4002 & 4003
Refer detail ~d' given in Sh. 8. Please furnish Qty. of Rods (Dia. 6 & 12).
To be worked out by vender from

sheet no-7
16
16
Volume II
A463-000-16-46-DS-4002 & 4003
NPCIL to furnish height of Cone.
Can be found out by calculation of

volume given in datasheet
Page 1 of 7
Accepted
17
17
Volume II
A463-000-16-46-DS-4002
18
18
Volume II
A463-000-16-46-DS-4002

NPCIL to furnish diatance between tank centre line to end of Nozzle 'XI'.
For elbow of Nozzle XI, WIL proposes to use bend which will be made
material. Nozzle length to be
from hollow bar of quality SA 479 Or can we use standard pipe &
provided as per standard length of
standard elbow of size 50 NB?
nozzles with bends.
Schematic details are given.details to
Connection of Nozzle IX (Hydraulic lock arrangement) is not clear.
be worked out during detailed
Please provide more details.
engineering.
material. Nozzle length to be
provided as per standard length of
nozzles with bends.
engineering.
19
19
Volume II
A463-000-16-46-DS-4003
NPCIL to furnish diatance between tank centre line to end of Nozzle 'I'.
For elbow of Nozzle 'I', WIL proposes to use bend which will be made
from hollow bar of quality SA 479 Or can we use standard pipe &
standard elbow of size 50 NB?
20
20
Volume II
A463-000-16-46-DS-4003
Connection of Nozzle VIII (Hydraulic lock arrangement) is not clear.

21
21
Volume II
A463-000-16-46-DS-4004
22
22
Volume II
A463-000-16-46-DS-4004
23
23
Volume II
A463-000-16-46-DS-4004
24
24
Volume II
A463-000-16-46-DS-4005
Material quality for shell, roof, bottom plate, nozzle flanges, pipe fitting For material refer table in Technical
nozzle necks are under hold by NPCIL. Please confirm the quality.
specification section 2.0 for the tank
25
25
Volume II
A463-000-16-46-DS-4006

Refer detail `H2' given in Sh.6. Please furnish Qty. of Rods (Dia. 6 & 12) sheet no-6 Drawing showing
insulation schematic on tank
26
26
Volume II
A463-000-16-46-DS-4006
Connection of Nozzle IX (Hydraulic lock arrangement) is not clear.


engineering.
27
27
Volume II
A463-000-16-46-DS-4007
Connection of Nozzle-III (Hydraulic lock arrangement) is not clear.


engineering.
28
28
Volume II
A463-000-16-46-DS-4012 & 4013
Detail of bottom Support not given in drg. For other tanks such drg. is
provided for e.g. 4007 sheet 9, 10, 11.
Provided in attachment.
29
29
Volume II
all datasheets
Please confirm type & qty. of staircase required for each tank. Also
confirm the design as per API650 and OSHA 29.
these things are to be worked out in

detailed engineering by supplier.
Type of staircase- monkey ladder
with cage made of carbon steel
30
30
Volume II
all datasheets
31
31
Volume II
all datasheets
32
32
Volume II
OD of Nozzle - VII (towards shell side) is not given in detail drg. NPCIL to
OD-25 mm and length-50 mm
furnish (Refer sh.6/10)
For STD Pipe fitting - ELBOW of Nozzle -IV, We Propose to use SA 403
Acceptable.
Gr.WP 304L.
Refer detail `H2' given in Sh.7. Please furnish Qty. of Rods (Dia. 6 & 12) sheet no-7 Drawing showing
insulation schematic on tank
Please confirm requirement & no. of platform for each tank. Also
please confirm requirement & no. of walkways for each tank. Also
Tender is not clear for stage of insulation ie. prior to despatch or after
receipt of tank at site. Please confirm.
these things are to be worked out in

detailed engineering by supplier
insulation is not in suppliers scope
all datasheets
Painting to be performed as Per

Clarity on Painting whether it is on inside or on outside or on both sides
I301.KK34.0.0.TH.TS.WD122. painting
is to be clarified. Also Paint Sepcification No.
specification
I301.KK43.UKC.AB.DS.WD301 to be profied.
I301.KK34.0.0.TH.TS.WD122 attached.
Please specify type of joints per tank to be inspected by Vacuum box
leak test
33
33
Volume II
all datasheets
34
34
Volume II
all datasheets
35
35
Volume II
UT in retrival digital form
36
36
Volume II
Clause No. 13.5
37
37
Volume I
Payment terms
NPCIL to confirm whether Bottom Support (e.g. parts mentioned in

BOM of Drg. no. doco. No.4004 sheet 9/10) is in insupplier's scope or
not.
UT will be required mainly for corner joint only. Necessity of retrival
digital UT is mentioned for such joint. Is it realy required since cost of
such type of inspection is costly?
Inner fillect / grove of bottom plate to shell shall be leak tested with
penetrating oil prior to welding of out side weld. It difficult to remove
the penetrating oil completely. NPCIL to review the requirement and
confirm.
We propose to have payment terms as (1) 10 % of PO value as advance
against acceptance of PO (2) 10% of PO value against approval design
(3) 10% of PO value against approval of mfg drawings and QAP (4) 20%
of PO Value against receipt of major material (5) 40% against receipt of
Tank at site on Prorata (6) 10 % of PO value against receipt of technical
documents on Prorata basis
Page 2 of 7
Refer to ASME BPVC Section III

Division 1 - Subsection ND Article
5000 Examination for Class 3 & class
4 Components/API 650
Bottom Support is in the suppliers
scope
Retrieval of Digital UT is not
Required.
This clause is deleted.
Kindly submit the bid in line with the

terms & conditions of Tender
document.
38
38
Volume I
39
Right of Recourse under Civil

SSC, Clause No. 3 Liabilty for Nuclear Damage Act
2010 & Rule 2011 thereof
40
40
Volume I
Delivery
41
41
Volume II
Design of components
39
BG for Integrity Pact
Initially Period of BG to be considered as 1 Year. After award of

contract, it can be extended by the supplier executing the order.
Request not acceptable. Tender

Conditions shall prevail.
At present Insurance policy is not available and hence, cost of the same
can not be accessed and built in the bid. It may be made available in
near future and Cost of the same will be known at that time. At that
time it will be informed to NPCIL to consider it additionally.
Tender involves Design. Analysis, Procurement of raw material, lot of
fabrication & transporatation and hence delivery of KKNPP-3 sholud be Request not acceptable. Tender
24 months instead of 13 months and KKNPP should be 30 months
instead of 21 months.
No, complete designing and detail
engineering of the tanks are to be
Are the ASME Sec III, NC / ND Codes to be used only for Nozzle
done as per section III ND
reinforcements and acceptance criteria for stresses, whereas API 650 is
(3300/3200). API 650 to be used only
to be used for the loadings to be considered for calculations of the
for those clauses/calculations not
thicknesses and stresses regarding the parts of the tanks? Kindly clarify.
covered in section III ND or clauses
supeersceeding section ND
Bidder : M/s Fabtech Projects and Engineers ., Pune

Sr. No

no. Volume Name
Clause No./ Subject
NPCIL's Response
42
Delivery
As per Tender: Delivery for Unit III is 13 months and for Unit IV is Request not acceptable. Tender
21 months. Is delivery for both units combined for 21 months is
acceptable.
43
Are Unit 3 & 4 in same location?
44
Civil Liabilty to be removed from the Tender.
45
Is Payment Terms Deviation Acceptable?
Yes
document
Please refer cl. No. 9.0 of ITT.
Accordingly Prices are to be quoted
in Part-II (Price Bid) exclusive of all
taxes and duties. However Bidders
are required to furnish prevailing
rates of taxes and duties applicable in
Annexure-B of Part-I ( Technical and
Commercial except price)bid being
submitted by them.
46
47
48
49
Is there accomodation facilities for contractor's personnels within or

near to the plant?
No accomodation facility is available

within the plant. Nearby the facilities
are available which may be
ascertained by the bidders.
50
Is Hydrotest duration 24 hours or one hour?
As per ASME section III ND subsection 6000
51
10
Painting to be performed as Per

Is there any painting to be done on the SS tanks. If so what type of paint I301.KK34.0.0.TH.TS.WD122. painting
specification
is required?
I301.KK34.0.0.TH.TS.WD122 attached.
Taxes: Should Excise duty to be considered in Price bid?
Power Supply at Plant: What is the rate of Charges for unit power
supply at site?
Water and other resources: What is the rate of Charges for unit power
supply at site?
52
11
Is there any external ladder and platform in our scope?
53
54
12
13
Is Insulation Under our Scope?

Is Breather Valves in our scope?
55
14
Drawings: Details of Hydrolock filling is not complete.
56
15
Seismic Support arrangement:

Is pad for seismic support arrangement required at only four locations
or all around the Tank.
57
16
Kindly confirm. All Nozzles are without Flanges except Manholes.
Page 3 of 7
As per tender document

As per tender document
These things are to be worked out in

detailed engineering by supplier.
Type of staircase- monkey ladder
with cage made of carbon steel
Not in Contractor's scope.
Yes it is in Contractor's scope.
engineering.
Pad for seismic supports to be
provided as per schematic sketch in
datasheet
nozzle ends should be as per
datasheet and schematic sketch.
58
17
Please specify any port near site, incase we transport tanks by sea.
Tuticorin
Name Of Bidder- M/s Lloyds Steel Industries Limited, (Dt:01.04.2016)

Sr. No
59
Query Tender Section

No. /Vollume Name
Clause No./Subject
Description Of Query
NPCIL's Response
Charges for Special Type Tests, Seismic Qualification /Testing shall not
be included in the price of the items and shall be quoted/ claimed
separately.
The Tender doesnot seek seperately

the prices for tests. Please refer
Section E of the Tender.
We request NPCIL to modify following payment terms-10% advance against bank guarantee of equivalent amount .
Against submission of Advance Bank Guarantee (ABG) of equivalent
amount valid till CDD plus three months claim period.
5% of PO Value on approval of Design,drawings, and Analysis part of
equipments.
25 % of PO Value against PO placed for procurement of Major Raw
material , receipt of major raw materials as defined and their approval
& Clearance to start fabrication work .
60
61
Billing Breakup
62
63
a) 50% of Ex-works / FOB price on pro-rata basis along with

Transportation Charges, Transit Insurance charges, Price Adjustment
amount and Taxes & Duties and levies as applicable, in full, on Delivery
document.
& receipt of the Stores at Site Including On submission of original
shipping release, proof of receipt by the consignee against despatch
documents including Invoice (along with copy of LR/GR and IRN)
directly to Owner.
b) Balance 10% Ex-works /FOB price will be released on acceptance of
the Stores at Site after inspection and issue of Site Stores Inspection
Report / Receipt Voucher by the consignee (GCC Sub clause 1.1.1 (a)),
submission of bank guarantee by the Contractor for 10% of Purchase
Order value towards performance of stores as per GCC Sub clause 3.4.5
Payment Terms against required documents after assigned work
execution + Defect liability period + claim Period.
9.2.
Pl confirm that exemption of Terminal exicise duty (TED) will be

available to the vendor. And NPCIL will make available the requsite
documents/certification for the same.
No exemption of Terminal Excise

Duty (TED) is available. However,
kindly note that Refund of TED from
DGFT is one of the benifit under
Foreign Trade Policy(FTP).
KKNPP-3&4 has been notified as
Nuclear Power Project (NPP) vide
Notification No 46/2015 dated
17.09.2015 and hence benefits as per
FTP shall be available. Based on the
Contractor's request, Puchaser will
only issue the necessary documents
as per FTP. Further, Clause No. 9 of
ITT may be referred to.
Taxes and Duties
If the vendor dispatches the SS Tanks from his work shop in sections
after payment of Taxes and duties on the full order value and the
sections are assembled at KKNPP 3&4 site , please confirm that the
purchaser will not deduct any tax at source towards income tax OR
Local VAT.
In a pure Supply Contract, neither

WCT TDS nor IT TDS shall be
applicable.
We propose to add following additional clause in bank guarantees:

This bank guarantee shall come into force on receipt of advance
payment of Rs........ by The Contractor against this guarantee.

Description Of Query
NPCIL's Response
er- M/s Lloyds Steel Industries Limited

Sr. NoQuery No
Tender Section
/Vollume Name
Clause No./Subject
64
Vol II
We understand that equipment design is on the basis of basic

schematic sketch and Data Sheet given by NPC . And detail design in
vendor scope.
Yes
65
3.6 Subcontracting
Vol-I
Please confirm list of recommended suppliers for all type of major

items of supply or services and a list of approved vendors
Vendor list provided in attachment.
66
Vol 1
Request to -provide Section D Format sheet contents in Excell
No additional documents can be

issued and the e-tender is self
sufficient.
Page 4 of 7
67
68
69
70
71
Tech Spec 4.0

LOGICS, INSTRUMENTATION &
CONTROL
Tanks shall be equipped with
suitable level sensors /
Transmitters etc. provided by the
purchaser. However, Compatible
Nozzles shall be provided by the
Vol II section C1
Contractor/Vendor
*Nozzles shall be strictly provided
with either BW (Butt Weld) ends
or shall be flanged (with or
without blind) to the
Specification/Standard,
dimensions as indicated in the
applicable Datasheet.
Instruments mountings on Nozzles we have not considered .References

Nozzles are to be provided by vendor
for compatable Nozzles meant for instrumentation when will be
as per datasheet. Instruments are in
provided by NPCIL.
NPCIL Scope.
Kindly clarify & confirm the scope of work.
6.12 Foundations
Further, the Bottom plate shall be
supplied with necessary
temporary stiffening arrangement
to take care of Handling &
Erection loads till the final
erection.
Kindly clarify the requirements
The bottom support structure
made of carbon steel shall be
supplied loose.The bottom
support structure shall be welded
to the embedded plates provided
in the floor by the erection
agency of the tanks.
The structural piers of bottom

support structure are to be welded
to the Embedded Parts provided on
the floor elevation.Bottom plate of
the tank will be welded to support
structure on periphery.
6.14.
All the Storage Tanks except, KPF
13, KPK 10 & GML 10 shall be
supported on Bottom grillage &
the Bottom plate/Annular plate
shall be continuously welded
from outside either to the
Embedded ring in Foundation or Kindly elaborate & clarify.
to I-beam framework.
The supporting details of the
individual equipments have been
provided in Datasheets.
Contractor/Vendor to ensure the
Bottom plate design based on this
provided information.
As per datasheet
7.2
Evener beams may be required
for handling the tanks during
erection stage. The same shall be
designed and supplied by the
We have not considered design and supply of evener beam however if
bidder. If the bidder feels evener
required we can Design , Testing /Analysis , and supply of evener beam
beam is not required, he should
on the basis of additional cost implication.
provide proper justification
supported with documents
related to load lifting/handling
details with calculations for the
approval of the purchaser.
The design of the tanks inlcuding

evener beam (requirement of evener
beam depends on design) is with the
bidder. Evener beams are with in
scope of this supply and the bid cost
shall be inlcusive.lifting tools and
tackles are in purchasers scope.
Transportation .
taking necessary permits,
licenses, clearances of
obstruction in roads and any
other foreseen /unforeseen
hindrances faced during
transportation shall be resolved
by the contractor himself
Transportation and safe delivery is in

the scope of the Contractor. As such
NPCIL is not obliged to provide
additional documents.
We considered that necessary Administrative support letter from

NPCIL is required and vendor will receipt of the same to handle the
foreseen /unforeseen hindrances, kindly clarify.
Page 5 of 7
72
73
10
74
11
75
76
The unloading of finished tank

from the contractors vehicle
within KKNPP site premises on
delivery is in the scope of the
purchaser.
Vol 1
12
13
We understand unloading with required resources manpower, crane

etc are in the purchaser scope. Kindly confirm.
Yes, unloading of the Tendered items

is in the scope of Purchaser.
7.5
PWHT/Solution annealing
Kindly confirm that PWHT/Solution annealing are not in this scope of

work.
PWHT depends on the design

detailing and as per the codal
requirements. As per spcification
clause no 7.5 "austenitic stainless
stell tanks shall not be heat treated
unless specificaly indicated".
Price Bid format
Request to -provide Section E Format sheet contents in Excell
No additional documents can be

issued and the e-tender is self
sufficient.
Right of Recourse under Civil

Liability for Nuclear Damage Act
2010 & Rule 2011 thereof The
Purchase shall have Right to
Recourse against the Contractor
in accordance with provisions
under Section 17(a) of Civil
Liability for Nuclear Damage Act,
2010, with following limitations,
as stipulated in Rule 24 of the
Civil Liability for Nuclear Damage
Rules, 2011 : The Contractors
liability shall be to the extent of
the Operators iability under subsection 6 of the Act or the value
of the contract, whichever is less,
AND The duration of Contractors
liability shall be limited to
duration of initial license issued
by AERB or the product liability
period, hichever is longer.
We considered As equipment supplied by contractor converts into a

integrated liked safe operating System in various Logics during
operating mode and operating on the basis of design by NPC executed
by others , In this scenerio we can not take the Civil liability.
a) What is Initial license period OR Product liability period for a
replacement item?
Tender conditions shall prevail and
b) As on date, Insurance Policy is not available to take care of the effect bidders are required to adhere to the
of CLND act and hence, we have not taken consideration of the same in same.
our offer. However, the same shall be provided soon after Insurance
policy is made available subject to NPCIL agrees to reimburse the cost of
the same soon after producing the Insurance Policy.NPCIL is requested
to clarify.Moreover initial license issued by AERB , we are not aware in
depth.
Tank Service Life span 30 Years
Since design and Material selection for equipment and their

Instrumentation and control system is not in our scope, hence we
cannot guarantee service life span for 30 years. However, we guarantee
that the material used for the equipments shall be genuinely tested &
certified.
please confirm we do not have to guarantee service life of 30 years?
The tanks shall be designed for

service life as per Technical
Specifications. Guarantee/ Defect
liability shall be as per the General
Conditions of Contract of the Tender.
77
14
Extension of due date of submission of bid Considerable time is

Bid due dates are extended on
required to get offers for Seismic analysis Test , ODC Transportation ,
18.04.2016 kindly refer our eSite Visit and finalization of Resources hence, request to extend the due
tendering website for details.
date of submission of bid by 4 weeks after release of MOM of Pre bid.
78
15
Considering ODC Equipment manufacturing & Safe Transportation up

to the Site --The delivery period should also be extended to 24 months
from 21 months.

conditions shall prevail.
16
Insulation Requirements
Insulation applicability, Material,
& thickness for Tanks shall be as
We consider Insulation fixing will be done by other agency.
per respective Datasheet.
Kindly confirm the same.
Insulation clips/cleats on tanks
shall be provided by the
Contractor/Vendor.
Insulation is not in suppliers scope
80
17
We consider Construction Power (1500 Amp) and water as well as

Construction Power and water as domestic water at one /Two point shall be provided free of cost by
NPCIL. However further power distribution along with Standard spec
well as domestic water at one
Distribution pannel & power cable will be in vendor scope.
/Two point shall be provided .
Kindly confirm,
Tender conditions shall prevail.
81
18
As CISF is the security posted at

Gate
79
Vol II section C1
Elaborate entry procedure issuance of Gate Pass various formalities

mandatory requirements for workmen Technitions/Staff proposed to
be working inside site in both shift.
Page 6 of 7
Detailed procedures are provided in

the tender document.
82
In case, the supplier proposes to

manufacture fully or partly all the
tanks or some of the
tanks at KKNPP site, reasonably
barren and unleveled land, as
available at site, will be
provided by the Purchaser.
19
We considered --Approach/Access Road and Construction shed /Yard (

Tender conditions shall prevail. The
Wide 75 Mtr X125 Mtr Long) or suitably deem fit for fabrication at site
shed for fabrication activities shall be
Inside premises lebelled compacted land shall be provided by NPCIL.
a closed one with concrete flooring.
Kindly confirm
Bidder : M/s Simplex casting limited

Sr. No

no. Volume Name
Clause No./ Subject
83
Volume
II/AnnexureB(page no.1/9
A463-000-16-46DS-4001
84
volume-I
Appendix-X Qualification
Requirements for bidders(point2- Can we outsource design & analysis work
b)
85
volume-II
Clause no.10
86
87
88
89
90
91
92
93
94
95
96
97
NPCILs Response
scope matrix for supplying items along with tanks is to be clarified.

Yes . Erection & commissioning under
Erection & commissioning works are not included in our scope. Only site
Purchasers scope
manufacturing & ODC items are considered.
Section C1
Tender
Clause no.2.8 (special instruction
no.CMM\FTP\75to bidder)
00-11147volume II
Section C1
Tender
no.CMM\FTP\7500-11147volume II
Section C1
Tender
Section C1
Tender
no.CMM\FTP\75- Clause no. 2.9/13.7
00-11147volume II
Section C1
Tender
whether we can purchase bought-out item from the other resoureces.if

List of approved vendor attached
no then provide us your approved vendor list for B/o items
for site activity,please confirm tremporary road length ie. How many
kms to be made for approach at site
Vendor may visit site for these details
The Tender doesnot contain any civil

Quantum of work for civil foundation work apart from tank foundation works to be executed by the
Contractor.
Please confirm total area of site where the tank will be install
Tank erection & commissioning not

under the Contractor's scope .
please confirm availability water sources at site for hydro test
can we hire services of various works\consortium partnership for site

work.
Consortium is not allowed. For

subcontracting please refer General
Conditions of Contract of the Tender.
Additional information from NPCIL: Following documents are enclosed with regards to the various technical queries.
1
A-463-000-16-46-DS-4013 Tank bottom support detail
2 Nozzle end details
3
Painting Specification I301.KK34.0.0.TH.TS.WD122
4 Digital seismic response spectra
5
Approved Vendor list
6 Revised datasheet as additional document
7 Additional design requirement for document no A-463-000-16-46-DS-4003
Page 7 of 7
28.02.2003
506
FSUE
"Atomenergoproekt"
Moscow 2002
NOZZLE END DETAILS
Figure.1 for above OD 57 mm nozzle
Figure.2 for OD 57 mm and below nozzle
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NUCLEAR POWER CORPORATION OF INDIA LIMITED

KUDANKULAM NUCLEAR POWER PROJECT - 3&4 PAGE NO.
REV. NO.
TECHNICAL SPECIFICAITON FOR SHOP & FIELD
DATE
: ii of iii
: R0
: 25-03-2013
PAINTING
NUCLEAR POWER CORPORATION OF INDIA LTD.

(A Government of India Enterprise)
PROJECT
: KUDANKULAM NUCLEAR POWER

PROJECT-3&4
PROCESS SPEC. NO.

: I301.KK34.0.0.TH.TS.WD122
CONSULTANT REF. NO. : A209-323-14-42-PS-0001
REVISION NO.
DATE OF ISSUE
TOTAL NO. OF PAGES

(Including Cover
Sheet+Appendix+Annexures)
R0
25.03.13
48
JOB SPECIFICATION FOR SHOP AND FIELD PAINTING

EIL
PREPARED BY
Dhananjay
25-03-2013
CHECKED BY
Satya Sridhar
25-03-2013
APPROVED BY
R Chaudhury
25-03-2013
Name
Sign
Date
(FOR REVISIONS SEE REVISION CONTROL SHEET)
Issued by
File Name
M/s. Engineers India Limited,

New Delhi
I301.KK34.0.0.TH.TS.WD122=eP2.doc
March 2013
NOT FOR PUBLICATION / PRESENTATION OUTSIDE NPCIL & EIL

KUDANKULAM NUCLEAR POWER PROJECT - 3&4 PAGE NO.
REV. NO.
TECHNICAL SPECIFICAITON FOR SHOP & FIELD
DATE
: iii of iii
: R0
: 25-03-2013
PAINTING
REVISION CONTROL SHEET

DOCUMENT TYPE: PROCESS SPECIFICATION
NO.
I301.KK34.0.0.TH.TS.WD122
TITLE
TECHNICAL SPECIFICATION FOR SHOP & FIELD PAINTING
Rev. No. &

Date
Description of Revision
R0/25.03.13
ISSUED FOR APPROVAL
EIL ( name & signature)

Revised By
DHANANJAY
DEWANGAN
Checked By
Approved By
SATYA SRIDHAR
R CHAUDHURY
March 2013

KUDANKULAM NUCLEAR POWER PROJECT - 3&4
PAGE NO.
: Page 1 of 45
REV. NO.
: R0
CONTENTS
SL.
NO
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
DESCRIPTION
PAGE
NO.
General.
Scope
Reference Codes & Standards....
Equipment
Surface Preparation, Shop Primer, Coating Application & Repair And
Documentation.
Paint Materials..
Shop & Field Painting System For Oil And Water Treatment Plant...............................
Coating System For Indoor Cs Pipes, Equipments & Supports Etc In Areas Other
Than Radio Active Zones.
Coating System For Indoor Metal Structures, Framed Pillers, Hand Rails, Ladders
And Crane Girders Etc In Areas Other Than Radio Active Zones..
Coating System For Indoor Cs Pipes, Equipments, Supports Etc. In Areas Of Radio
Active Zone.....................................................................................................................
Indoor Coating Systems For Metal Structures Of Roof Covering & Wall And Wall
Enclosures
Coating System For Outdoor Cs Pipes, Equipments & Supports Etc..............................
Internal & External Coating System For Embedded CS Ventilation Ducts in Both
Radioactive and Non-Radioactive Zones.........................................................................
Coating System For Roof & Roof Structures Exposed To Outdoor Climate..
External Coating Systems For Cs & Low Alloy Steel Storage Tanks.............................
Internal Coating Systems For Carbon Steel And Low Alloy Steel Storage Tanks..........
External Coating Systems Of Underground Carbon Steel Plant Piping And
Underground Vessels...
External Painting - Under Insulation for both Radioactive And Non-Radio Active
Areas...........................................................................................................
Storage.
Colour Code.
Inspection And Testing
Guarantee.
Qualification Criteria Of Painting Contractor/Sub-Contractor
Vendor Data Requirement
3
3
5
6
Annexure-I Specification For TSAC
36
QC/001
6
16
24
25
25
26
26
26
27
27
28
29
30
31
32
32
32
33
33
34
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ABBREVIATION:
CS
MS
SS
RCC
ETP
FRP
GRP
ASTM
ANSI
ISO
NACE
SSPC
DFT
WFT
DM
TSAC
ASME
BS
AWS
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Carbon Steel
Mild Steel
Stainless Steel
Reinforced Cement Concrete
Effluent Treatment Plant
Fibre Reinforced Plastic
Glass Reinforced Plastic
American Society for Testing and Materials
American National Standard Institution
International Organization for Standardization
National Association of Corrosion Engineers
Society for Protective Coatings

Dry Film Thickness
Wet Film Thickness
De-mineralized
Thermally Sprayed Aluminium Coating
American Society of Mechanical Engineers
British Standard
American Welding Society
March 2013

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1.0
GENERAL
1.1
This technical specifications shall be applicable for the work covered by the contract, and
without prejudice to the provisions of various codes of practice, standard specifications etc.
It is understood that contractor shall carry out the work in all respects with the best quality
of materials and workmanship and in accordance with the best engineering practice and
instructions of Engineer-In-Charge.
1.2
Wherever it is stated in the specification that a specific material is to be supplied or a

specific work is to be done, it shall be deemed that the same shall be supplied or carried out
by the contractor.
Any deviation from this standard without written deviation permit from appropriate
authority will result in rejection of job.
2.0
SCOPE
This specification defines the requirements for surface preparation, selection and
application of primers and paints on external surfaces of equipment, vessels, machinery,
piping, ducts, steel structures, external & internal protection of storage tanks for all services
and chimneys if any. The items listed in the heading of tables of paint systems is indicative
only, however, the contractor is fully responsible for carrying out all the necessary
painting, coating and lining on external and internal surfaces as per the tender and technical
requirement.
2.2
2.2.1
Extent of Work
The following surfaces and materials shall require shop, pre-erection and field painting:
A
All un insulated Carbon Steel, Alloy Steel, Stainless Steel Equipments, vessels,
Columns, Storage Tanks and Exchangers (if any) and parts of boilers etc.
All uninsulated Carbon Steel, Alloy Steel and Stainless Steel plant and related
piping, fittings and valves (including painting of identification marks), furnace
ducts and stacks etc.
All insulated parts of vessels, boilers, chimneys, stacks, piping and steam piping
and if any other insulated items present
All items contained in a package units, desalination plant, chiller package and Oil
& Water treatment package etc as necessary.
All structural steel work, pipe, structural steel supports, walkways, handrails,
ladders, platforms etc.
Flare lines, external surfaces of MS chimney with or without refractory lining and
internal surfaces of MS chimney without refractory lining. (If present)
March 2013

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2.2.2
Identification of colour bands on all piping as required including insulated

aluminium clad, galvanized, SS, plastic or plastic coated and nonferrous piping/
equipments.
H.
Identification lettering/ numbering on all painted surfaces of equipment/piping

insulated aluminium clad, galvanized, SS and non-ferrous piping
Marking / identification signs on painted surfaces of equipment/piping including

hazardous service.
Supply of all primers, paints and all other materials required for painting
Over insulation surface of equipments and pipes wherever required.
Painting under insulation for carbon steel, alloy steel and stainless steel as
specified.
Painting of pre-erection/fabrication and Shop primer
Repair work of damaged pre-erection/ fabrication and shop primer and weld
joints in the field/site before and after erection as required.
All CS Piping, equipments, storage tanks and internal surfaces of RCC tanks in
ETP/ water and oil treatment plants.
The following surfaces and materials shall not require painting in general. However, if
there is any specific requirement by the NPCIL, the same shall be painted as per the
relevant specifications:
A
Plastic and/or Plastic coated materials colour of plastic shall be as per the colour
code. If not matching painting/ tapping may be required for identification.
Non-ferrous materials like aluminium.
FRP/GRP piping and tanks colour shall be as per the applicable colour coding. If not
matching painting/ tapping may be required for identification
2.3
Documents
2.3.1
The contractor shall perform the work in accordance with the following documents
developed by him and accepted by the Purchaser.
a.
Bill of quantities for piping, equipment, machinery and structures etc.
b.
Piping Line List.
c.
Painting specifications including special civil defence requirements.
March 2013

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2.4
Unless otherwise instructed, final painting on pre-erection/ shop primed pipes and
equipments shall be painted in the field, only after the mechanical completion, testing on
systems are completed as well as after completion of steam purging wherever required.
2.5
Changes and deviations required for any specific job due to Purchasers requirement or
otherwise shall be referred to Purchaser for deviation permit.
3.0
REFERENCE CODES & STANDARDS
3.1
Without prejudice to the provision of Clause 1.1 above and the detailed specifications of
the contract, latest editions of the following codes and standards are applicable for the work
covered by this contract.
IS-5
RAL DUTCH
IS-101
IS-2379
ASTM-Vol 6.01 & 6.03
ASA A 13.1-1981
Colour coding.
International Standard for colour shade (Dutch Standard)
Methods of test for ready mixed paints and enamels.
Indian Standard for Pipe line identification-colour code.
American standard test methods for Paints and Coatings.
Scheme for identification of piping systems: American
National Standards Institution.
IO1.KK.0.0.QA.QAD.WD009: NORMs for Piping & equipment identification and colour
coding
3.2
:
:
:
:
:
:
Surface Preparation Standards

The latest editions of any of the following standards shall be followed for surface
preparation:
3.2.1
ISO 8501-1/SIS-05 59 00: ISO standard for Preparation of steel substrates before application
of paints and related products. This standard contains photographs of the various standards
on four different degrees of rusted steel and as such is preferable for inspection purpose by
the Engineer-In-Charge.
3.2.2
Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications (SSPC-SP).
3.2.3
National Association of Corrosion Engineers, U.S.A., (NACE).
3.2.4
Various International Standards equivalent to Swedish Standard for surface preparations are
given in Table-I.
3.3
The contractor shall arrange, at his own cost, to keep a set of latest edition of above
standards and codes at site.
3.4
The paint manufacturer's instructions shall be followed as far as practicable at all times for
best results. Particular attention shall be paid to the following:
a.
Instructions for storage to avoid exposure as well as extremes of temperature.
March 2013

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b.
Surface preparation prior to painting shall be followed as per Table 8.0 to 16.0 of
this standard shall be followed.
c.
Mixing and thinning.
d.
Application of paints and recommended limit on time intervals in between coats.
4.0
EQUIPMENT
4.1
All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning and all
equipments, scaffolding materials, shot & grit blasting equipments & air compressors etc.
required to be used shall be suitable for the work and all in good order and shall be
arranged by the contractor at site and in sufficient quantity. The manufacturers test
certificates / data sheets for all the above items shall be reviewed by Engineer-in-charge at
site before start of work.
4.2
Mechanical mixer shall be used for paint mixing operations in case of two pack systems
except that the Engineer-In-Charge may allow the hand mixing of small quantities at his
discretion in case of specific requirement for touch up work only.
5.0
SURFACE PREPARATION, SHOP PRIMER COATING APPLICATION &

REPAIR AND DOCUMENTATION
5.1
General
5.1.1
In order to achieve the maximum durability, one or more of following methods of surface
preparation shall be followed, depending on condition of surface to be painted and as
instructed by Engineer-In-Charge. Adhesion of the paint film to surface depends largely on
the degree of cleanliness of the metal surface. Proper surface preparation contributes more
to the success of the paint protective system.
5.1.2
a.
Manual or hand tool cleaning.
b.
Mechanical or power tool cleaning.
c.
Blast cleaning.
Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean
and dry surface is obtained. Unless otherwise specified, surface preparation shall be done
as per provisions of relevant tables given elsewhere in this specification. The minimum
acceptable standard in case of manual or hand tool cleaning shall be St. 2 or equivalent, in
case of mechanical or power tool cleaning it shall be St. 3 or equivalent, in case of blast
cleaning it shall be Sa 2-1/2 as per Swedish Standard SIS-055900 (latest edition) or SSPCSP or ISO 8501-01. Blast cleaning shall be Sa 3 as per Swedish Standard in case of highly
corrosive environment.
Remove all other contaminants, oil, grease etc. by use of an aromatic solvent prior to
surface cleaning.
March 2013

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5.1.3
Irrespective of whether external or internal surface to be coated, blast cleaning shall not be
performed where dust can contaminate surfaces undergoing such cleaning or during humid
weather conditions having humidity exceed 85%. Desiccant type de-humidifiers shall be
used to maintain the RH during abrasive blast cleaning and the application of coating
materials. For internal coating of storage tanks the RH shall be maintained less than 60%
and air temperature inside the tank shall be maintained at 25-40 deg C. Dehumidifier
should depress the dew point of air in the enclosed space, sufficient enough so as to
maintain it 3C below the metal substrate temperature during centre period of blasting and
coating application. During the interval time between application of primer coat and
subsequent intermediate and top coats or between blast cleaning completion and start of
application of primer coat, dehumidifier unit should be in continuous operation to ensure
that no condensation occurs on substrate.
Dehumidifier should be able to maintain grain drop (moisture removal) at the rate of 25
grains per pound of air per hour. Dehumidifier should have capacity of at least 2 air
changes per hour of the enclosed space. All necessary psychometric data should be
collected by contractor for the given site conditions before starting operation of
dehumidifier to ensure that desired values of dew point, moisture content in enclosed scope
is achieved.
Dehumidification to be maintained round the clock for surface preparation and painting till
the total coating application is over.
Dehumidifier shall not be stopped under any condition till the entire blasted surface is
primed to the satisfaction of the technical representative of the paint manufacturer
interested with quality assurance for the work. In case the dehumidifier breaks down in
middle of the job, the same shall be replaced at the risk and the cost of the contractor and
the entire unfinished work shall be repeated.
The Engineer in-charge shall have the right to disallow usage of dehumidifier if the
performance is not meeting the specified requirements. Under such circumstances the
contractor shall remove the equipment and replace the same with another equipment to
provide satisfactory results without any additional cost to the owner.
5.1.4
Irrespective of the method of surface preparation, the first coat of primer must be applied
by airless spray/ air assisted conventional spray if recommended by the paint manufacturer
on dry surface. This should be done immediately and in any case within 4 hours of cleaning
of surface. However, at times of unfavourable weather conditions, the Engineer-In-Charge
shall have the liberty to control the time period, at his sole discretion and/or to insist on recleaning, as may be required, before primer application is taken up. In general, during
unfavourable weather conditions, blasting and painting shall be avoided as far as
practicable.
5.1.5
The external surface of R.C.C. chimney to be painted shall be dry and clean. Any loose
particle of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush.
Acid etching with 10-15% HCL solution for about 15 minutes shall be carried and surface
must be thoroughly washed with water to remove acid & loose particles and then dried
completely before application of paint.
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5.2
Procedure for Surface Preparation :
5.2.1
Air Blast Cleaning with abrasives

The surfaces shall be blast cleaned using one of the abrasives like chilled cast iron or
malleable iron and steel at pressure of 7kg/cm2 at a appropriate distance and angle
depending of nozzle size maintaining constant velocity and pressure. Copper slag, A12O3
particles, shall be used only after obtaining clearance of Engineer In charge. Chilled cast
iron, malleable iron and steel shall be in the form of shot or grit of size GP25/GP16 (G42
grade maximum) and S250 grade size of steel shots (maximum) to obtain a desired
surface profile of 35-65 microns trough to peak or specified profile in case of steel and
malleable iron . The combination of steel grits and shots shall be normally in the ratio of
3:1. The quality of abrasives shall be free from contaminants and impurities and shall meet
the requirements of SSPC AB1. Compressed air shall be free from moisture and oil. The
blasting nozzles should be venturi style with tungsten carbide or boron carbide as the
materials for liners. Nozzles orifice may vary from 3/16 to . On completion of
blasting operation, the blasted surface shall be clean and free from any scale or rust and
must show a grey white metallic luster. Primer/first coat of paint shall be applied within 4
hours of surface preparation. Blast cleaning shall not be done outdoors in bad weather
without adequate protection or when there is dew on the metal, which is to be cleaned.
Surface profile shall be uniform to provide good key to the paint adhesion (i.e. 35 to 65
microns). If possible vacuum collector shall be installed for collecting the abrasives and
recycling.
5.2.2
Mechanical or Power Tool Cleaning

Power tool cleaning shall be done by mechanical striking tools, chipping hammers,
grinding wheels or rotating steel wire- brushes. Excessive burnish of surface shall be
avoided as it can reduce paint adhesion. On completion of cleaning, the detached rust mill
scale etc. shall be removed by clean rags and /or washed by water or steam and thoroughly
dried with compressed air jet before application of paint.
5.2.3
Manual or hand tool cleaning

Manual or hand tool cleaning is used only where safety problems limit the application of
other surface preparation procedure and hence does not appear in the tables of paint
systems.
Hand tool cleaning normally consists of the following:
a.
Hand de-scaling and/or hammering
b.
Hand scraping
c.
Hand wire brushing
Rust, mill scale spatters, old coatings and other foreign matter, shall be removed by
hammering, scrapping tools, emery paper cleaning, wire brushing or combination of the
above methods. On completion of cleaning, loose material shall be removed from the
March 2013

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surface by clean rags and the surface shall be bushed, swept, dusted and blow off with
compressed air/steam to remove all loose matter. Finally the surface may be washed with
water and dried for effective cleaning.
5.3
Non-Compatible shop coat primer

For equipments on which application of total protective coating (Primer + Intermediate +
top coat) is carried out at shop, compatibility of finish coat with primer should be checked
with paint manufacturer. If the shop coat is in satisfactory condition showing no major
defect upon arrival at site, the shop coat shall not be removed.
5.4
Shop coated (coated with Primer & finishing coat) equipment should not be repainted
unless paint is damaged. Repair shall be carried out as per Table 7.1 of paint systems
depending upon compatibility of paint.
5.5
Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas by means
of power tool brush cleaning or hand tool cleaning and then spot primed before applying
one coat of field primer unless otherwise specified. If shop primer is not compatible with
field primer then shop coated primer should be completely removed before application of
selected paint system for particular environment.
5.6
For Package units/equipment, shop primer should be as per the paint system given in this
specification. However, manufacturers standard can be followed after review.
5.7
Coating Procedure and Application
5.7.1
Surface shall not be coated in rain, wind or in environment where injurious airborne
elements exists, when the steel surface temperature is less than 5 oF above dew point when
the relative humidity is greater than 85% or when the temperature is below 40oF and when
the ambient/substrate temp is below the paint manufacturers recommended temperature of
application and curing. De-humidifier equipment shall be used to control RH and Dew
point. The paint application shall not be done when the wind speed exceeds 20KM per
hour.
5.7.2
Blast cleaned surface shall be coated with one complete application of primer as soon as
practicable but in no case later than 4 hrs the same day.
5.7.3
To the maximum extent practicable, each coat of material shall be applied as a continuous
film uniform thickness free of probes. Any spots or areas missed in application shall be
recoated and permitted to dry before the next coat is applied. Applied paint should have
the desired wet film thickness.
5.7.4
Each coat shall be in proper state of cure or dryness before the application of succeeding
coat. Material shall be considered dry for recoating when an additional coat can be applied
without the development of any detrimental film irregularities, such as lifting or loss of
adhesion of the under coat. Manufacturer instruction shall be followed for inter coat
interval.
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5.7.5
When the successive coat of the same colour have been specified, alternate coat shall be
tinted, when practical, sufficiently to produce enough contrast to indicate complete
coverage of the surface. The tinting material shall be compatible with the material and not
detrimental to its service life and shall be recommended by the original paint manufacturer.
5.7.6
Air spray application shall be in accordance with the following:

a.
The equipment used shall be suitable for the intended purpose, shall be capable of
properly atomizing the paint to be applied, and shall be equipped with suitable
pressure regulators and gauges. The air caps, nozzles, and needles shall be those
recommended by the manufacturer of the equipment for the material being
sprayed. The equipment shall be kept in satisfactory condition to permit proper
paint application.
b.
Traps or separators shall be provided to remove oil and condensed water from the
air. These traps or separators must be of adequate size and must be drained
periodically during operations. The air from the spray gun impinging against the
surface shall show no condensed water or oil.
c.
Ingredients shall be kept properly mixed in the spray pots or containers during
application by continuous mechanical agitation.
d.
The pressure on the material in the pot and of the air at the gun shall be adjusted
for optimum spraying effectiveness. The pressure on the material in the pot shall
be adjusted when necessary for changes in elevation of the gun above the pot.
The atomizing air pressure at the gun shall be high enough to properly atomize
the paint but not so high as to cause excessive fogging of paint, excessive
evaporation of solvent, or less by over spray
e.
Spray equipment shall be kept sufficiently clean so that dirt, dried paint, and other
foreign materials are not deposited in the paint film.
Any solvents left in the equipment shall be completely removed before applying
paint to the surface being painted.
f.
Paint shall be applied in a uniform layer, with overlapping at the edge of the spray
pattern. The spray patterns shall be adjusted so that the paint is deposited
uniformly. During application, the gun shall be held perpendicular to the surface
and at a distance which will ensure that a wet layer of paint is deposited on the
surface. The trigger of the gun should be released at the end of each stroke.
g.
All runs and sags shall be brushed out immediately or the paint shall be removed
and the surface repainted.
h.
Areas inaccessible to the spray gun shall be painted by brush; if not accessible by
brush, daubers or sheepskins shall be used.
March 2013

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5.7.7
i.
All nameplates, manufacturers identification tags, machined surfaces, instrument

glass, finished flange faces, control valve items and similar items shall be masked
to prohibit coating deposition. If these surfaces are coated, the component shall
be cleaned and resorted to its original condition.
j.
Edges of structural shapes and irregular coated surfaces shall be coated first and
an extra pass made later.
k.
If spray gun shows choking, immediately de-choking procedure shall be

followed.
Airless spray application shall be in accordance with the following procedure: as per steel
structure paint Manual Vol.1 & Vol.2 by SSPC, USA, Air less spray relies on hydraulic
pressure rather than air atomization to produce the desired spray. An air compressor or
electric motor is used to operate a pump to produce pressures of 1000 to 6000 psi. paint is
delivered to the spray gun at this pressure through a single hose within the gun, a single
paint stream is divided into separate streams, which are forced through a small orifice
resulting in automization of paint without the use of air. This results in more rapid
coverage with less over spray. Airless spray usually is faster, cleaner, more economical
and easier to use than conventional air spray.
Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks
paint from any container, including drums. The unit shall have in built agitator that keep
the paint uniformly mixed during the spraying. The unit shall consist of in built strainer.
Usually very small quantity of thinning is required before spray. In case of high build
epoxy coating (two pack). 30:1 pump ratio and 0.020-0.023 tip size will provide a good
spray pattern. Ideally fluid hoses should not be less than 3/8 ID and not longer than 50 ft
to obtain optimum results.
In case of gun choking, de-choking steps shall be followed immediately.
5.7.8
Brush application of paint shall be in accordance with the following:

a.
Brushes shall be of a style and quality that will enable proper application of paint.
b.
Round or oval brushes are most suitable for rivets, bolts, irregular surface, and rough
or pitted steel. Wide flat brushes are suitable for large flat areas, but they shall not
have width over five inches.
c.
Paint shall be applied into all corners.
d.
Any runs or sags shall be brushed out.
e.
There shall be a minimum of brush marks left in the applied paint.
f.
Surfaces not accessible to brushes shall be painted by spray, doubers, or sheepkin.
March 2013

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5.7.9
Manual application by sling (where 6 O clock position of pipe is not approachable)

A canvas strip (alternatively a tinplate strip) about 450 mm wide and 1.5m long is hold
under the pipe by two men holding this sling move it up and down and walk slowly
forward while fresh coating is poured on the pipe and they manipulate the sling so that an
even coating is obtained all round the bottom. This work shall be done very carefully and
by experienced personnel. There shall not be any formation of Whiskers and holes in the
coating. The coating film shall be inspected by mirror.
5.7.10
For each coat the painter should know the WFT corresponding to the specified DFT and
standardize the paint application technique to achieve the desired WFT. This has to be
ensured in the qualification trial.
5.8
Drying of coated surfaces
5.8.1
No coat shall be applied until the preceding coat has dried. The material shall be
considered dry for re-coating when another coat can be applied without the development of
any film irregularities such as lifting or loss of adhesion of undercoats. Drying time of the
applied coat should not exceed maximum specified for it as a first coat; if it exceeds the
paint material has possibly deteriorated or making is faulty.
5.8.2
No paint shall be force dried under conditions which will cause chalking, wrinkling,
blistering formation of pores, or detrimentally affect the conditions of the paint.
5.8.3
No drier shall be added to a paint on the job unless specifically called for in the
manufacturers specification for the paint.
5.8.4
Paint shall be protected from rain, condensation, contamination, snow and freezing until
dry to the fullest extent practicable.
5.9
Repair of damaged paint surface
5.9.1
Where paint has been damaged in handling and in transportation, the repair of damaged
coating of pre-erection / fabrication and Shop primer shall be done as given below and as
per the Table 7.1 of this specification.
5.9.2
Repair of damaged inorganic zinc silicate primer after erection / welding in the design
temperature of -90oC to 550oC.
Surface Preparation: Quickly remove the primer from damaged area by mechanical
scraping and emery paper conforming to SSPC-SP-3 to expose the white metal. Blast clean
the surface, if possible. Feather the primed surface over the intact adjacent surface
surrounding the damaged area by emery paper.
Primer coating: One coat of F-9 shall be applied wherever damaged was observed on preerection pre fabrication / shop primer of inorganic zinc silicate coating (F-9). F-9 shall not
be applied if damaged area is not more than 5x5 cm.
March 2013

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5.10
Paint Application
5.10.1
Shop priming/pre-erection priming with F9 or F12 shall be done only on blasted surface
(SSPC-SP-10)
5.10.2
Shop priming/ pre-erection priming with F9 or F12 shall be done only with airless spray.
5.10.3
For large flat surface field painting shall be done by airless spray otherwise brush can be
used.
5.10.4
Assessment of painting requirement

The paint system to be applied for a specific job shall be arrived at sequentially as given
below
Identify the Design temperature, material of construction and insulated or non insulated
data from the corresponding Technical documents/Data sheets etc
Identify the surface preparation and specific field coating system from the above identified
table and design temperature range.
Identify the shop priming requirement from Table 7.0 based on compatibility of the above
paint system.
Identify the need of repair of shop primer and execute as per Table 7.1.
5.11
Documentation
5.11.1 A written quality plan with procedure for qualification trials and for the actual work.
5.11.2 Daily progress report with details of weather conditions, particular of applications, no of
coats and type of materials applied, anomalies, progress of work versus program.
5.11.3 Results of measurement of temperatures relative humidity, surface profile, film thickness,
holiday detection, adhesion tests with signature of appropriate authority.
5.11.4 Particulars of surface preparation and paint application during trials and during the work.
5.11.5 Details of non-compliance, rejects and repairs.
5.11.6 Type of testing equipments and calibration.
5.11.7 Code and batch numbers of paint materials used.
March 2013

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TABLE-1 (FOR CLAUSE 5.0)

SURFACE PREPARATION STANDARDS
VARIOUS INTERNATIONAL STANDARDS
(EQUIVALENT)
SL.
NO. DESCRIPTION
1
Manual or
cleaning
hand
ISO 8501-1/
SIS-05 59 00
SSPC-SP, USA
REMARKS
NACE, USA
tool
Removal of loose rust, ST.2

loose mill scale and loose
paint, chipping, scrapping,
standing
and
wire
brushing. Surface should
have a faint metallic sheen
Mechanical or power tool
cleaning
SSPC-SP-2
--
Removal of loose rust ST.3

loose mill scale and loose
paint to degree specified
by power tool chipping,
de-scaling, sanding, wire
brushing and grinding,
after removal of dust,
surface should have a
pronounced
metallic
sheen.
Dry
abrasive
Blast
cleaning
SSPC-SP-3
--
This
method
is
applied when the
surface is exposed to
normal atmospheric
conditions
when
other
methods
cannot be adopted
and also for spot
cleaning
during
maintenance
painting.
3.1
There are four common

grades of blast cleaning
White metal
SA 3
SSPC-SP-5
NACE#1
3.2
Blast cleaning to white

metal
cleanliness.
Removal of all visible
rust. Mill scale, paint &
foreign matter 100%
cleanliness with desired
surface profile.
Near white metal
SA 2
Where extremely
clean surface can be
expected for prolong
life of paint system.
SSPC-SP-10
NACE#2
The
minimum
requirement
for
chemically resistant
paint systems such
as epoxy, vinyl,
Blast cleaning to near

white metal cleanliness,
until at least 95% of each
March 2013

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SL.
NO. DESCRIPTION
VARIOUS INTERNATIONAL STANDARDS

(EQUIVALENT)
ISO 8501-1/
SIS-05 59 00
SSPC-SP, USA
REMARKS
NACE, USA
element of surface area is

free of all visible residues
with
desired
surface
profile.
3.3
Commercial Blast
SA 2
SSPC-SP-6
NO.3
3.4
Blast cleaning until at

least two-third of each
element of surface area is
free of all visible residues
with desired surface
profile.
Brush-off Blast
SA 1
SSPC-SP-7
NO.4
polyurethane based
and inorganic zinc
silicate paints, also
for
conventional
paint systems used
under
fairly
corrosive conditions
to obtain desired life
of paint system.
For steel required to
be painted with
conventional paints
for exposure to
mildly corrosive
atmosphere for
longer life of the
paint systems.
Blast cleaning to white

metal cleanliness, removal
of all visible rust, mill
scale, paint & foreign
matter. Surface profile is
not so important
March 2013

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6.0
PAINT MATERIALS
Paint manufacturers shall furnish the characteristics of all paints materials on original printed
literature, along with the test certificate for all specified characteristics given in this
specification. All the paint materials shall be of first quality and suitable for the service life
of about 15 years. They shall conform to the following general characteristics as per the
tables 6.1, 6.2, 6.3, 6.4 and 6.5.
TABLE No. 6.1

Sl.
DESCRIPTION
ZINC ANODE DIMETCOTE
No.
304
6
1
Technical name
Two pack self
Inorganic Zinc
curing solvent
Silicate Coating
based inorganic
zinc silicate
primer
2
Type and composition Ethyl
A heavy duty
silicate/metallic primer
that
zinc
protects
with
just a single
coat, compatible
with
wide
variety
of
intermediate
coats and top
coats
3
Volume Solids %
40 3
(minimum)
4
DFT (Dry Film
65-75
65
thickness) per coat
(minimum)
5
Theoretical covering 8-9.2
10.2
capacity in M2/coat/
litre (minimum)
6
Weight per litre in
2.46
Kg/litre (minimum)
7
Touch dry at 30oC
30 minutes
10 minutes
(minimum)
8
Hard dry at 30oC
overnight
30 minutes
(maximum.)
9
Over coating interval Min.: overnight 24 hrs
Max.: Indefinite
10
Pot life at 30oC for
4-6 Hrs
12 hrs
two component paints
(minimum)
11
Temperature
400 Deg C
(Resistance
(minimum)
CARBOZINC
11 SG
Solvent
base
Inorganic Zinc
Primer
INTERGARD
251
Two Pack Zinc
Phosphate
Primer
An
inorganic
zinc
basecoat
that
protects
steel
galvanically.
This is the first
self
curing
inorganic zinc
primer
Two pack
primers,
anticorrosive
primer/undercoat
pigmented with
Zinc Phosphate
79 2
63 2
50-75
50-75
8.2
8.40
45 minutes
20 minutes
3 hrs.
18 hrs
Min.: 8 hrs
8 hrs
6 hrs
399 Deg C
(Continuous)
427 Deg C
(Intermittent)
March 2013

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TABLE No. 6.2

Sl.
INTERZINCDESCRIPTION
No
72
1
Technical name Two pack Zinc
rich
epoxy
primer
INTERZINC
42
Two
component
metallic zinc
primer
Type and
composition
Two pack Zinc

rich
epoxy
primer
with
fast drying and
rapid handling
properties
A
two
component
metallic zinc
primer,
designed for
use
in
maintenance
situations and
as a primer at
new
construction.
Volume Solids
(minimum.) %
DFT (Dry Film
thickness) per
coat (minimum)
microns
Theoretical
covering
capacity in
M2/coat/litre
(minimum)
Weight per litre
in kg/litre
(minimum)
Touch dry at
30oC
Hard dry at 30oC
(max)
Full cure at 30oC
(for immersion/
high temperature
service)
Over-coating
interval at 30 oC
Pot life (approx.)
at 30oC for two
component
60 2
7
8
9
10
INTERTHANE
-990
Two component
acrylic
polyurethane
INTERTHERM
- 50
High temperature
Silicone
Aluminium Paint
A
two
component
acrylic
polyurethane
finish
giving
excellent
durability and
long
term
recoatability
A
single
component, high
temperature
coating, based on
a moisture curing
silicone
binder
and
pigmented
with aluminium
flake.
55
INTERLINE
850
Two
component
high
build
epoxy
phenolic lining
A
two
component,
chemically
resistant, high
solids,
high
build
epoxy
lining
to
provide
corrosion
protection for
the internals of
steel storage
tanks.
76
57 3
45
50
50-75
100-150
50-75
25
12
7.303
6.1
11.40
18.0
2.0
1.6
1.2
1.1
30 min .
45 minutes
5 hours
90 minutes.
30 minutes
60 minutes
150 minutes
8 hours
6 hrs
2 hours
2 hrs (min.)
8 hrs (min.)
6 hrs
12 hours (min.)
10 hrs.
10 hrs
1 hour
2 hrs
NA
March 2013
11
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paints
(minimum)
Temperature
Resistance
(minimum)
March 2013

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TABLE No. 6.3

Sl.
DESCRIPTION
No
1
Technical name
EPILUX 155
EPILUX 13
HB MIO
Two pack high Two pack high
build epoxy
build
epoxy
resin cured with primer
amine adduct
Type & composition
Two pack high

build catalysed
epoxy resin,
suitably
pigmented
cured with
amine adduct
Volume Solids
(minimum) %
DFT (Dry Film
thickness) per coat
(minimum)
Theoretical covering
capacity in M2/coat/
litre (minimum)
Weight per litre in
kg/litre (minimum)
Touch dry at 30oC
(maximum)
Hard dry at 30oC
(maximum)
Full cure 30oC (for
immersion /high
temperature service)
Over-coating
interval
Pot life at 30oC for
two component
paints (minimum.)
Temperature
Resistance (min)
6
7
8
9
10
11
Two pack high

build
epoxy
primer
with
outstanding
corrosion
resistance
properties,
contains high
level
of
anticorrosive
pigment.
EPILUX 4 CR
Two pack high
performance
epoxy top coat
EPILUX 78
HBTL
Two pack high
build
epoxy
primer
cured
with
amine
adduct
A self priming
high build high
performance
tank
liner
specially
designed
for
sustained
immersion
service.
Two pack high

performance
epoxy top coat
having
good
chemical
resistance
coupled
with
decorative
appeal, possess
good flexibility,
adhesion & oil
resistance.
-
50-60
50-75
25-35
100-150
7.8-9.4
6.7-10
11.7-16.4
3.7-5.5
3-4 hrs
1-2 hrs
2-3 hrs
2-3 hrs
overnight
overnight
Overnight
overnight
Min.: overnight
Max.: 5 days
4-6 Hrs
Min.:Overnight Min.:Overnight
Max.: Indefinite Max.: 5 days
6-8 hrs.
4-6 hrs
Min.: Overnight
Max.: 5 days
6-8 hrs.
93 Deg C
(Continuous)
120 Deg C
(Intermittent)
93 Deg C
(Continuous)
120 Deg C
(Intermittent)
93 Deg C
(Continuous)
120 Deg C
(Intermittent)
93 Deg C
(Continuous)
120 Deg C
(Intermittent)
March 2013

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TABLE No. 6.4

Sl.
DESCRIPTION
No
1
Technical name
Type and composition
Volume Solids
(minimum.) %
DFT (Dry Film
thickness) per coat
(minimum) microns
capacity in m2/coat/litre
(minimum)
Weight per litre in
kg/litre (minimum)
Touch dry at 30oC
Hard dry at 30oC (max)
Full cure at 30oC (for
immersion/ high
Over-coating interval at
30 oC
Pot life (approx.) at 30oC
for two component
paints (minimum)
Temperature Resistance
(minimum)
6
7
8
9
10
11
INTERGARD
475 HS
High
solids,
high build, two
component
epoxy coating
A low VOC,
high solids, high
build, two
component
epoxy coating.
Available with
conventional
pigmentation, or
alternatively can
be pigmented
with micaceous
iron oxide to
provide
enhanced
overcoating
properties.
INTERGARD
740
Two component
epoxy
finish
coat
PROTECTOMASTIC
Two pack high
build
epoxy
resin
EPILUX 4 Z88
High
performance
epoxy primer
A tough twocomponent,
epoxy based
finish with good
abrasion and
chemical
resistance.
Intergard 740 is
suited to interior
surfaces needing
a hard, easily
cleaned surface
High
performance
epoxy
primer
heavily loaded
with
metallic
zinc,
imparts
excellent
cathodic
protection when
applied
over
blast
cleaned
steel.
80
523
A low VOC,
two component,
flexible high
build surface
tolerant coating
with reinforced
with Aluminium
and special
MicaciousIron-Oxide
pigments
for
improved
corrosion
resistance and
extended
temperature
resistance
-
100 - 200
50
100-150
35-50
6.40
10.4
5.7-8.5
9.0-12.8
2.1
1.2-1.5
60 minutes.
5 hrs
2 hrs
8 hrs
2-3 hrs
overnight
15-30 minutes
4-6 hrs
5 hrs
Min.: 16 hrs.
60 minutes.
3 hrs
Min.: Overnight Min.:Overnight

Max.: 7 days
Max.: Indefinite
1-2 hrs
6-8 hrs
120 Deg C
(Continuous)
150 Deg C
(Intermittent)
200 Deg C
(Continuous)
300 Deg C
(Intermittent)
March 2013

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TABLE No. 6.5

Sl.
DESCRIPTION
No
1
Technical name
Type and composition
Volume Solids
(minimum.) %
DFT (Dry Film
thickness) per coat
(minimum) microns
capacity in m2/coat/litre
(minimum)
Weight per litre in
kg/litre (minimum)
Touch dry at 30oC
Hard dry at 30oC (max)
Full cure at 30oC (for
immersion/ high
Over-coating interval at
30 oC
Pot life (approx.) at 30oC
for two component
paints (minimum)
Temperature Resistance
(minimum)
6
7
8
9
10
11
EPILUX 4
AMERCOAT- CARBOLINE CARBOMAST

90 HS
890
IC 15/AL
Two-component Epoxy phenolic Two
Modified
epoxytank lining
component,
Aluminium
polyamide
cross-linked
Epoxy Mastic
epoxy
two-component Epoxy phenolic CARBOLINE Self
priming
epoxytank lining
890 is a high
high
build
polyamide
solids, high
coating
wit
pigmented with
gloss, high build excellent
durable
epoxy topcoat
adhesion
to
pigments giving
that can be
rusted steel and
a glossy finish
applied by
most
aged
spray, brush, or paints
roller
50
64 3
75 2
90 2
-
100-150
100-150
125-150
6.0
7.2
30 minutes
4 hrs
1.5 hrs
4 hrs
4 hrs
6 hrs
24 hrs
Min.: 8hrs.
Max.: 3 days
3 Hrs.
24 hrs
2 hrs.
3 hrs
4 hrs
150oC
Dry service
121 Deg C
(Continuous)
149 Deg C
(Intermittent)
82 Deg C
(Continuous)
121 Deg C
(Intermittent)
5 days
March 2013

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TABLE NO. 6.6: Summary of Painting systems elaborated later in this document:
Sr.
No.
1
Item description
Painting system
SHOP & FIELD PAINTING SYSTEM FOR OIL AND WATER

TREATMENT PLANT:
For External Surfaces of
INTERGARD475 HS @150
C.S./M.S. items
DFT/coat
+ INTERTHANE-990@50
DFT/coat
(Akzo nobel)
For Internal Surfaces of CS/MS
3 coats of EPILUX 155 HB MIO
Items
@125 DFT/coat
All R.C.C./concrete surfaces
Epoxy Screed lining, 3mm
exposed to effluent water / liquid
C.S/M.S Dual media filters
Natural Rubber Lining, 4.5mm
(Internal), Chemical dosing
(As per IS 4682, Part 1)
tanks(internal)
Indoor CS pipes, equipments &
EPILUX 155 HB MIO @125
supports etc in areas other than
DFT/coat
radioactive zones
+ EPILUX 4 @60 DFT/coat
(Berger)
Indoor metal structures, framed
INTERZINC
72
@50-75
pillars, hand rails, ladders and
DFT/coat
crane girders etc in areas other
+ INTERGARD 740 @ 50
than radioactive zones
DFT/coat
(Akzo nobel) (Or)
EPILUX 4 Z 88 @ 40 DFT/coat +
EPILUX 4 @ 20 DFT/coat
(Berger)
Indoor CS pipes, equipments, supports etc. in areas of radioactive zone
PROTECTMASTIC
@125
Up to 80
DFT/coat +
EPILUX 4 CR @75 DFT/coat
(Berger)
81 to 400
INTERZINC 42@
50-75 DFT/coat + 2 coats of
INTERTHERM 50 @ 25
DFT/coat
Indoor coating system for Metal
2 coats of EPILUX 78 HBTL
structures of roof covering &
@100 DFT/coat
wall and wall enclosures
Outdoor CS pipes, equipments & INTERGARD 475 HS @150
supports etc
DFT/coat +
INTERTHANE 990 @ 50
DFT/coat
Internal & external coating High build Epoxy @ 125
system for Embedded CS DFT/coat
Reference
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
March 2013

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Sr.
No.
Item description
Painting system
Reference
ventilation
ducts
in
both Recommended products
radioactive and non-radioactive Protectomastic HB (Berger)
zones
Amercoat-90 (Goodlass Nerolac)
Carbo Line-890 (CDC Carboline )
OR
CARBOMASTIC
CARBOLINE-890
(CDC Carboline)
10
11
12
13
15/AL
Roof & Roof structures exposed INTERGARD 475 HS @125

to outdoor climate
DFT/coat +
Table 14
INTERTHANE 990 @ 50
DFT/coat
External coating systems for CS
2 coats of INTERGARD 475 HS
& low alloy steel storage tanks
@ 100 DFT /coat +
INTERTHANE 990 @ 50 DFT/
Table 15
coat;
(Akzo Nobel)
Internal coating systems for
2 coats of INTERLINE 850@ 75
carbon steel and low alloy steel
DFT /coat
Table 16
storage tanks
(Akzo Nobel)
External coating systems of
1 layer of coal tar tape coating @
underground carbon steel plant
2mm +1 coat of synthetic fast
piping and underground vessels
drying primer 25 @ DFT/ coat
Table 17
+1 layer of coal tar tape coating
@ 2mm /layer
External painting - under 2 coats of INTERLINE-850 @
insulation: For insulated Piping, 75 DFT/coat;
Storage
Tanks/vessels,
Table 18
Equipments etc (Note-1) of (Akzo Nobel)
Carbon Steel, LTCS, Low Alloy
Steel & Stainless Steel
Structural members subjected to
fire (truss, platforms, ladders Primer: Two pack high build
epoxy primer with polyamide.
etc.)
Intermediate
coat:
One
Ref Clause No:
component water based polyvinyl
9.4.11.3.of
acetate emulsion and fillers having
document
no.
high solids intumescent coating
I301.KK34.0.0.TH
basecoat.
TS.WD023
Final coat: Two pack urethane
semi-glossy
with
alphatic
isocyanate.
March 2013

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Table 7.0
Sl.
No.
7.1
7.2
SHOP & FIELD PAINTING

TREATMENT PLANT
SYSTEM
FOR
OIL
AND
WATER
Total
DFT in
Surface Preparation
Remarks
Intermediate/F Microns
Primer
(min.)
inish Coat
For External Surfaces of C.S./M.S. items: Screens, Walk way bridges, Baffles, Dual media filters,
Vertical pumps, piping in treated effluent sump, bio sludge pump, Screw pump and pump house, CS
tanks, sumps and vessels etc.
INTERGARD4
Equivalent
75 HS @150
INTERZINC-42
systems from
DFT/coat
@ 65-75
Berger, CDC
+
-14 to 80
SSPS-SP-10
DFT/coat
Carboline,
INTERTHANE
Good lasss-990@50
(akzo nobel)
Nerolac are
DFT/coat
acceptable
(akzo nobel)
Coating System
Design Temp.
in oC
For Internal Surfaces of CS/MS Items: Bio-sludge sump, Filter feed sump, Process sump, Sanitary
sump, Transfer sump, Sludge, oil tanks, scrapping mechanism in Clarifier etc
-14 to 80
SSPS-SP-10
ZINC ANODE
304 @ 65-75
DFT/coat.
Equivalent
systems from
Berger, CDC
3 coats of
EPILUX 155
Carboline,
HB MIO
365-375 Good lasss@125
Nerolac are
DFT/coat
acceptable
Note:1
7.3
All R.C.C./concrete surfaces exposed to effluent water / liquid such as tanks, structures, drains etc. in
Process sump, TPI separator (Process and Oil), Aeration Tank and Transfer sump etc.
-14 to 80
7.4
Blast
cleaning
to
SSPC-SP guide lines
and Acid etching with
10-15% HCl acid
followed by thorough
water washing.
Epoxy Screed lining
3mm
Epoxy screed
lining shall be
applied as per
manufacturer
and Engineerin-Charge
instructions
4.5mm
Natural
Rubber lining
shall be
applied as per
specific
manufacturer
and Engineerin-Charge
instructions
C.S/M.S Dual media filters (Internal), Chemical dosing tanks(internal)
Up to 60
SSPC-SP-10
Natural Rubber Lining

(As per IS 4682, Part 1)
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Note 1: The paint /coating manufacturers shall provide their Quality control test certificate of coating
materials for immersion service of the exposed effluents
TABLE 8.0
Sl.
No.
8.1
COATING SYSTEM FOR INDOOR CS PIPES, EQUIPMENTS &

SUPPORTS ETC IN AREAS OTHER THAN RADIO ACTIVE ZONES
Design
Temperature.
in oC
Up to 80
TABLE 9.0
Sl.
No.
Surface
Preparation/
Primer
Intermediate + Finish coat
remarks
Total DFT
in Microns
(min.)
SSPC-SP-10
EPILUX 155 HB MIO @125 250

DFT/coat
ZINC
ANODE +
304@65
EPILUX 4 @60 DFT/coat
DFT/coat
(Berger)
(Berger)
Equivalent
systems from
Akzo
nobel,
CDC
Carboline,
Good
lasssNerolac
are
acceptable
COATING SYSTEM FOR INDOOR METAL STRUCTURES, FRAMED

PILLERS, HAND RAILS, LADDERS AND CRANE GIRDERS ETC IN
AREAS OTHER THAN RADIO ACTIVE ZONES
Design
Temperature.
in oC
Surface
preparation
/ Primer
Remarks
Total DFT
in Microns
(min.)
9.1
Alter
nate
Up to 80
SSPC-SP-10
INTERZINC 72 @50-75 150

DFT/coat
INTERGARD
+
251 @ 50-75 INTERGARD 740 @ 50
DFT/coat
DFT/coat
(Akzo nobel)
(Akzo nobel)
EPILUX 13 @ EPILUX 4 Z 88 @ 40 120
60 DFT/coat
DFT/coat +
EPILUX 4 @ 20 DFT/coat
(Berger)
(Berger)
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TABLE 10.0
Sl.
No.
10.1
10.2
Design
Temperature.
in oC
Up to 80
11.1
Sl.
No.
12.1
Up to 80
SSPC-SP-10;
INTERZINC
42@
50-75 DFT/coat
(International)
Surface
Preparation
SSPC-SP-10
Equivalent
systems
from
Akzo nobel, CDC
Carboline, Good
lasss- Nerolac are
acceptable
PROTECTMASTIC @125 265

DFT/coat +
EPILUX 4 CR @75
DFT/coat
(Berger)
2 coats of INTERTHERM
50 @ 25 DFT/coat
2x25=50
100-125
(International)
Primer
Total DFT
in Microns (min.)
ZINC
ANODE 2 coats of EPILUX 78 HBTL 265
304@65
@100 DFT/coat
DFT/coat
COATING SYSTEM FOR OUTDOOR CS PIPES, EQUIPMENTS &

SUPPORTS ETC
Design
Temperature.
in oC
Up to 80
Remarks
Total DFT
in Microns (min.)
INDOOR COATING SYSTEMS FOR METAL STRUCTURES OF ROOF

COVERING & WALL AND WALL ENCLOSURES
Design
Temperature.
in oC
TABLE 12.0
Surface
preparation/
Primer
ZINC
ANODE
304@65
DFT/coat
(Berger)
81 to 400
TABLE 11.0
Sl.
No.
COATING SYSTEM FOR INDOOR CS PIPES, EQUIPMENTS, SUPPORTS

ETC. IN AREAS OF RADIO ACTIVE ZONE
Surface
Preparation
SSPC-SP-10
Primer
Total DFT
in Microns (min.)
INTER ZINC 42 INTERGARD

475
HS 250
@50 DFT/coat
@150 DFT/coat +
INTERTHANE 990 @ 50
DFT/coat
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TABLE 13.0
INTERNAL & EXTERNAL COATING SYSTEM FOR EMBEDDED CS

VENTILATION DUCTS IN BOTH RADIOACTIVE AND NONRADIOACTIVE ZONES
Design
Temperat
ure. in oC
Surface
Preparation
Primer
13.1
Up to 80
SSPC-SP-10
Inorganic
Zinc
Silicate@65-75
DFT/coat
Recommended
Prodcuts
Zinc
Anode304(Berger)
Dimet
coat
-6
(Goodlass Nerolac)
Carbo Zinc -11 SG
(CDC Carboline)
13.2
Up to 80
SSPC-SP-3
CARBOMASTIC
15/AL
(CDC Carboline)
Sl.
No.
Intermediate + Finish
coat
Total
DFT
in
Microns
(min.)
Remark
TABLE 14.0
Sl.
No.
14.1
CARBOLINE-890
(CDC Carboline)
For
wire
brush cleaned
surfaces
COATING SYSTEM FOR ROOF & ROOF STRUCTURES EXPOSED TO

OUTDOOR CLIMATE
Design
Temperature.
in oC
Up to 80
High build Epoxy @ 250

125 DFT/coat
Recommended products
Protectomastic
HB
(Berger)
Amercoat-90 (Goodlass
Nerolac)
Carbo Line-890 (CDC
Carboline )
Surface
Preparation
SSPC-SP-10
Primer
Total DFT
in Microns (min.)
INTER ZINC 42 INTERGARD

475
HS 250
@75 DFT/coat
@125 DFT/coat +
INTERTHANE 990 @ 50
DFT/coat
NOTES:
1.
The list of items given in the heading of the above table is not exhaustive. There may be more
items for a particular contract where these specifications are used. The Contractor is fully
responsible for completing painting including prefabrication primer for all the items supplied
and fabricated through his scope of work as per tender document.
2.
If the Pre-erection/Pre-fabrication & Shop Primer has already been completed, the same shall
not be repeated again in the field. In case the damages of primer are severe and spread over
large areas, the engineer-in-charge may decide & advise re-blasting and priming again.
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3.
In case of shop Primer is not applicable, the same shall be applied as field primer without
altering subsequent coating systems
TABLE 15.0
EXTERNAL COATING SYSTEMS FOR CS & LOW ALLOY STEEL STORAGE

TANKS
Design
Temperature
in deg. C
Sl.
No.
Surface
Preparati
on
Paint system (Field)

Primer
Finish paint
Total Final
DFT
in Microns
(min.)
Remarks
15.1
All external surfaces of shell, wind girders, appurtenances, roof tops of all above ground tanks
including top side of floating roof of open tank as well as covered floating roof tank and associated
structural works of DM water, firewater, raw water, potable water, acids, alkalis, solvents and
chemicals etc.
15.1.1
-14 to 80
SSPC-SP10
INTERZINC-42 @ 6575
DFT/coat
+
INTERGARD
251@
50 DFT/ coat
2 coats of INTERGARD
475 HS @ 100 DFT
/coat + INTERTHANE
990 @ 50 DFT/ coat;
(Akzo Nobel)
(Akzo Nobel)
INTERLINE 850 @
75 DFT/ coat
2 coats of INTERLINE
850 @ 75 DFT/ coat +
INTERTHANE 990 @
50 DFT/ coat;
(Akzo nobel)
(Akzo nobel)
15.1.2
Note 1
280
81 to 100
SSPC-SP10
(Note 2)
15.2
External surfaces of bottom plate (soil side) for all storage tanks.
15.2.1
-14 to 80
15.2.2
345-355
81 to100
SSPC-SP10
SSPC-SP10
(Note 2 )
Note 1
INTERZINC-42 @
65-75 DFT/ coat
3
coats
of 365-375
INTERGARD 475 HS
@ 125 DFT /coat
Note 1
(Akzo nobel)
INTERLINE 850 @ 75
DFT/ coat
(Akzo nobel)
2 coat of INTERLINE
850@75 DFT/coat
Note 1
(Akzo nobel)
(Akzo nobel)
225
NOTES
1. Equivalent coating systems from M/s Berger, M/s CDC Carboline, M/s Goodlass- Nerolac
are acceptable
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TABLE 16.0
Sl.
No.
16.1
INTERNAL COATING SYSTEMS FOR CARBON STEEL AND LOW

ALLOY STEEL STORAGE TANKS
Design
Temperature
in oC
Surface
Preparation

Primer
Finish paint
Total
Final DFT
in Microns
(min.)
Remarks
16.3
Internal surfaces of Diesel oil tanks including underside of floating roof, internal surface of cone roof,
bottom plate, oil side surfaces of deck plates, oil side surfaces of pontoons, roof structures, structural steel,
ladders and supports etc.
-14 to 80
SSPC-SP-10 INTERLINE-850 @ 2 coats of
225-250
Equivalent
75 DFT/coat
INTERLINE 850@
system from
75 DFT /coat
Berger, CDC
carboline,
(Akzo Nobel)
(Akzo Nobel)
goodlassnerolac are
acceptable
Internal surfaces of fixed roof type storage tanks of Potable water
-14 to 80
SSPC-SP-10 EPILUX 13 @50
2 coats of
300-325
Equivalent
DFT/coat;
PROTECTMASTC @
system from
(Berger)
125 DFT/ Coat;
Akzonobel,
(Berger)
CDC
carboline,
Note : test certificate is
goodlassrequired for potable
nerolac are
water application
acceptable
De-mineralized water (DM) Internal shell, bottom plate & all accessories
INTERLINE-850 @ 2 coats of
225-250
Up to 80
SSPC-SP-10 75 DFT/ coat
INTERLINE-850 @
75 DFT/coat
(Akzo Nobel)
(Akzo Nobel)
10 % Hydrochloric acid (HCl) Internal shell, bottom plate & all accessories
16.3.1
-14 to 60
16.4
16.4.1
Aggressive Solvents
16.1.1
16.1
16.1.1
16.2
16.2.2
-14 to 65
SSPC-SP-10
SSPC-SP-10
None
Natural rubber lining
INTERLINE-850 @
75 DFT/ coat
2 coats of
INTERLINE-850 @
75 DFT/coat
(Akzo Nobel)
4.5 mm
225-250
(Akzo Nobel)
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TABLE 17.0
EXTERNAL COATING SYSTEMS OF UNDERGROUND CARBON STEEL

PLANT PIPING AND UNDERGROUND VESSELS
17.1
Total Final
DFT
in Microns
Primer
Finish paint
(min.)
Underground carbon steel plant piping ( Yard/ Over the Ditch Corrosion protection Coating)
17.1.1
25 to 65
17.2
17.2.1
Carbon steel plant piping (underground)

66 to 150
SSPC-SP-10
1 coat of Epoxy
Novalac Primer @
125 DFT/ coat
Sl.
No.
Design
Temperature
in oC
Surface
Preparation
SSPC-SP-10
1 coat of synthetic
fast drying primer
25 @ DFT/ coat
Remarks
1 layer of coal tar tape 4 mm

coating @ 2mm +1 coat
of synthetic fast drying
primer 25 @ DFT/
coat
+1 layer of coal tar
tape coating @ 2mm
/layer as per
EIL Standard Spec. No
6-79-0011 Rev 1
(Standard Specification
for
Tape Coating for
Underground Plant
Piping)
1 coat of Epoxy
Novalac intermediate
coat @ 125 DFT/coat
+ 1 coat of Epoxy
Novalac finish coat
@125 DFT/ coat;
375
Products
form
AkzoNobel
,
Berger,
Jotun are
acceptable
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TABLE 18.0
EXTERNAL PAINTING - UNDER INSULATION

RADIOACTIVE AND NON-RADIO ACTIVE AREAS
FOR
BOTH
For insulated Piping, Storage Tanks/vessels, Equipments etc (Note-1) of Carbon Steel, LTCS, Low
Alloy Steel & Stainless Steel
Sl.
No.
18.1
18.1.1
18.2
18.2.1
18.3
18.3.1
18.3.2
18.4
Surface
Total
design
Preparation & PreFinal DFT
Paint
system
(Field)
Temperature
Remarks
erection/Shop
in Microns
in oC
Primer
Finish
paint
Primer
(min.)
Insulated Carbon steel, LTCS and low allow steel Piping, Stainless Steel Piping, Storage Tanks and
Equipment etc
-45 to 150
SSPC-SP-10
2 coats of
225 - 250
Equivalent
INTERLINE-850
systems
INTERLINE-850
@ 75 DFT/coat;
from Berger
@75 DFT/coat
are
also
(Akzo Nobel )
(Akzo Nobel)
acceptable
Insulated low alloy steel piping, C Steel piping and Stainless Steel Piping with intermittent cyclic service.
Sealer coat ; Refer
TSAC shall be
150 to 4000C SSPC-SP-5
Thermally
flame spray or
ANNEXURE-I
sprayed
arc
spray;
Aluminium
Refer
coating (TSAC)
ANNEXURE; Refer
I)
ANNEXURE-I
Insulated stainless steel including Alloy-20 piping (Note:1)
Below 0oC to
Aluminium sheeting with aluminium foil and Chloride free mineral
If the piping
all minus
sealant coating barium chromate shall be applied.
&
temperature
equipments
are already
400 to 500
SSPC-SP-10
None
TSAC shall be
250
erected than
(15-25 surface
flame spray or arc
surface shall
profile)
spray
be prepared
Refer
by cleaning
ANNEXURE I
with emery
paper
and
wash/flush
Alternate to
SSPC-SP-10
None
1 coat of
240
with chloride
14.3.2
1 coat of
AMERCOAT 738
free
DM
AMERCOAT 738
@ 125 DFT
water
400-600
@ 125 DFT
/coat
followed by
/coat
wiping with
SS
organic
SSPC-SP-1
solvent
With non-chloride
solvent
No painting is required for insulated monel, Incoloy and Nickel lines.
NOTES
1. The blast cleaning abrasives for SS and Alloy steel surfaces shall be SS grits/shots or
Aluminium oxide grits/shots.
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19.0
STORAGE
All paints and painting materials shall be stored only in rooms to be arranged by contractor
and approved by Engineer-in-charge for the purpose. All necessary precautions shall be
taken to prevent fire. The storage building shall preferably be separate from adjacent
building. A signboard bearing the word PAINT STORAGE NO NAKED LIGHT
HIGHLY INFLAMABLE shall be clearly displayed outside. Manufacturers
recommendation shall be followed for storage of paint materials.
20.0
COLOUR CODE
NPCIL norms and guidelines are applicable for colour coding of Piping, Equipments and
vessels etc and for the special requirements like camouflaging
21.0
INSPECTION AND TESTING
21.1
All painting materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufactures as per specifications and shall be
accompanied by manufacturer's test certificates. Paint formulations without certificates are
not acceptable.
21.2
Engineer-In-Charge at his discretion may call for tests for paint formulations. Contractor
shall arrange to have such tests performed including batch-wise test of wet paints for
physical & chemical analysis as per clause 24.4 of relevant ASTM test method. All costs
there shall be borne by the contractor.
The contractor shall produce test reports from manufacturer regarding the quality of the
particular batch of paint supplied. The Engineer-in-Charge shall have the right to test wet
samples of paint at random for quality of same. Batch test reports of the manufacturer's for
each batch of paints supplied shall be made available by the contractor.
21.3
The painting work shall be subject to inspection by Engineer-In-Charge at all times. In

particular, following stage-wise inspection will be performed and contractor shall offer the
work for inspection and approval of every stage before proceeding with the next stage. The
record of inspection shall be maintained in the registers. Stages of inspection are as
follows:
(a)
Surface preparation
(b)
Primer application
(c)
Each coat of paint
In addition to above, record should include type of shop primer already applied on
equipment e.g. Red oxide zinc chromate or zinc chromate or Red lead primer etc.
Any defect/discontinuity / disboanding noticed during the various stages of inspection shall
be rectified by the contractor to the entire satisfaction of Engineer-In-Charge before
proceeding further. Irrespective of the inspection, repair and approval at intermediate stages
of work, contractor shall be responsible for making good any defects found during final
inspection/guarantee period/defect liability period as defined in general condition of
March 2013

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contract. Dry film thickness (DFT) shall be checked and recorded after application of each
coat and extra coat of paint should be applied to make-up the DFT specified without any
extra cost to owner, the extra coat should have prior approval of Engineer-in-charge.
21.4
Primer Application
After surface preparation, the primer should be applied to cover the crevices, corners, sharp
edges etc. in the presence of inspector nominated by Engineer-In-Charge.
21.5
The shades of successive coats should be slightly different in colour in order to ensure
application of individual coats, the thickness of each coat and complete coverage should be
checked as per provision of this specification. This should be approved by Engineer-InCharge before application of successive coats.
21.6
The contractor shall provide standard thickness measurement instrument with appropriate
range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface profile in case
of sand blasting. Holiday detectors and pinhole detector and protector whenever required for
checking in case of immersion conditions.
21.7
Prior to application of paints on surfaces of chimneys, the thickness of the individual coat
shall be checked by application of each coat of same paint on M.S.test panel. The thickness
of paint on test panels shall be determined by using gauge such as 'Elkometer'. The thickness
of each coat shall be checked as per provision of this specification. This shall be approved by
Engineer-In-Charge before application of paints on surface of chimney.
21.8
At the discretion of Engineer-In-Charge, the paint manufacturer must provide the expert
technical service at site as and when required. This service should be free of cost and without
any obligation to the owner, as it would be in the interest of the manufacturer to ensure that
both surface preparation and application are carried out as per their recommendations. The
contractor is responsible to arrange the same.
21.9
Final inspection shall include measurement of paint dry film thickness, Adhesion, Holiday
detection check of finish and workmanship. The thickness should be measured at as many
points/ locations as decided by Engineer-In-Charge and shall be within + 10% of the dry film
thickness, specified in the specifications.
21.10
The contractor shall arrange for spot checking of paint materials for Sp.gr., glow time (ford
cup) and spreading rate.
22.0
GUARANTEE
22.1
The contractor shall guarantee that the chemical and physical properties of paint materials
used are in accordance with the specifications contained herein/to be provided during
execution of work.
23.0
QUALIFICATION
CONTRACTOR
CRITERIA
OF
PAINTING
CONTRACTOR/SUB-
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Painting contractor must have necessary equipments, machinery, tools and tackles for
surface preparation, paint application and inspection. The contractor mush have qualified,
trained and experienced surface preparator, paint applicator, inspector and supervisors. The
contractor supervisor, inspector, surface preparator and paint applicator must be conversant
with the standards referred in this specification.
24.0
VENDOR DATA REQUIREMENT

Following documents/information to be furnished by contractor before procurement of
coating materials:
- Name of the Paint Coating Manufacturer along with past supply records for similar
applications in chemical processing industries & offshore applications.
- Test certificates for the following test items:
Test
Density
Dipping properties
Film characteristics
Drying time
Flexibility
Hardness
Adhesion
Abrasion resistance
DFT/coat
Storage Stability
Resistance to
Humidity for 2000 hrs.
Salt spray 2000 hrs
Accelerated Weathering
% Zn in Dry film for Inorganic Zinc
Silicate primer
24.1
ASTM Test Method

D 1475
D 823
D 1640
D 1737/D 522
D 3363
D 2197
D 968/ D 1044
AS PER SSPC GUIDELINES
D 1849
D 2247
B 117
D 822
G 53
The manufacturer should arrange testing of the coating materials as per the list of tests given
above from one of the following reputed Government laboratories:
IICT, Hyderabad
HBTI, Kanpur
DMSRDE, Kanpur
BIS Laboratories
UICT, Matunga, Mumbai
RITES, Kolkata
PDIL, Sindri
NTH, Kolkata
24.2
Samples of coating materials should be submitted to the Govt. laboratory in sealed

containers with batch no. and test certificate on regular format of manufacturers testing
laboratory. The sampling shall be certified and sealed by a certifying agency.
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24.3
All test panels should be prepared by Govt. testing agency coloured photographs of test
panels should be taken before and after the test and should be enclosed along with test
report.
Sample batch no. and manufacturers test certificate should be enclosed along with the
report. Test report must contain details of observation and rusting if any, as per the testing
code.
24.4
Manufacturers should intimate the company, details of sample submitted for testing, name of
Govt. testing agency, date, contact personnel of the govt. testing agency. At the end of the
test the manufacturer should submit the test reports to the company for approval. The
manufacturer(s) shall be approved based on the results of these tests and other assessment
and the companys decision in this regard shall be final and binding on the manufacturer.
24.4
Coating systems for panel test shall be decided after discussion with NPCIL/EIL
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ANNEXURE-I
SPECIFICATION FOR THERMALLY SPRAYED ALUMINIUM (TSA) COATING
1.0
SCOPE
The following sections outlines the requirement of supply, application and testing of
thermally sprayed Aluminium coatings (TSAC) for corrosion protection of steel structures as
referred elsewhere
2.0
GENERAL
Structures, components thermally sprayed shall not have any uncoated area or shall not be in
mechanically connected by flanges etc to any uncoated bare steel work. Such adjacent areas
to TSA coated areas, if not coated by TSA shall have suitable paint coating system
3.0
TSAC REQUIREMENTS
3.1
Surface Preparation
All the parts to be sprayed shall be degreased according to SSPC-SP 1. The absence of oil
and grease after degreasing shall be tested by method given elsewhere in the specification
(Refer Sec. 6.7). Thereafter the surface to be abrasive blasted to white metal finish as per
NACE 1/SSPC-SP 5 for marine and immersion service. Using SSPC VIS 1, it is to be
visually assessed that the blast cleaned surface meets requirement of SSPC-SP 5. Thereafter
clear cellophane tape test as per ISO 8502-3 shall be used to confirm absence of dust on the
blasted surface. Finally blasted surface shall be tested for presence of soluble salts as per
method ISO 8502-9. Maximum allowable salt content shall be considered 50mg/M2. (5
micrograms/cm2) .In case salt content exceeds specified limit. The contaminated surface
shall be cleaned by method as per Annex C of IS 12944-4 (Water Cleaning). After cleaning
the surface shall be retested for salt content after drying.
The blasting media shall be either chilled iron or angular steel grit as per SSPC-AB-3 of
mesh size G-16 to G-40. Copper or Nickel slag or Garret as abrasive will also be suitable
having mesh size in the range of G16 to G24, conforming to SSPC-AB-1. Mesh size shall be
required as appropriate to the anchor tooth depth profile requirement and blasting equipment
used. The blasted surface should be having angular profile depth not less than 75 microns
with sharp angular shape.
The profile depth shall be measured according to NACE
standard RP 0287 (Replica Tape) or ASTM D 4417 method B (Profile depth gauge).
For manual blasting one profile depth measurement shall be taken every 10-20 m2 of blasted
surface.
Surface preparation shall be completed in one abrasive blast cleaning operation wherever
possible.
If rust bloom (visual appearance of rust) appears on the blast cleaned surface before thermal
spraying, the affected area shall be re blasted to achieve specified degree of cleanliness after
which only thermal spraying shall commence.
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Air blasting pressure at nozzle shall be normally maintained at 100 psi. Air pressure and
media size should be reduced and adjusted to preclude damage/distortion to thin gauge
materials. Blasting time on work piece should be adjusted to only clean the surface and cut
required anchor tooth with minimum loss of metal. Blast angle should be as close to
perpendicular as possible but in no case greater than 30 0 from perpendicular to work
surface. Blasting media must be free of debris, excessive fines, contaminants such as Nacl
and sulphur salts (Ref. SEC 6.0 of this Spec).
3.1.1
Blasting Equipment
The TSAC applicator shall use mechanical (centrifugal wheel) or pressure pot blast cleaning
equipment and procedures. Suction blasting equipment shall not be used. Sec 6.6.2 shall
be used to validate clean and dry air
3.1.2
Feed Stock
The feed stock shall be in the form of wire. The feed stock shall be 99.5% aluminium of
commercial purity grade, its composition shall be in accordance with requirement of BS
1475or ASTM B833 (wrought aluminium and aluminium alloys, wire).
3.1.3
Thickness Requirement
The nominal thickness of finished TSAC shall be 250 microns having minimum value of
225 microns at low thickness areas (valleys) and not more than 275 microns at peak areas.
The finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge
(Magnetic Gauge).
3.1.4
Coating Bond Strength Requirement

The TSAC coating shall have a minimum individual tensile-bond strength value of 1000 psi
for flame sprayed and 1500 psi for arc sprayed coating with an average of 2000 psi for arc
sprayed coatings. Minimum tensile bond strength should be achieved by proper anchor tooth
profile of blasted surface, laying down the TSA thickness in multiple passes and carrying
out TSA application under controlled environment
3.1.5
Porosity
All thermally sprayed metallic coatings will have porosity. For thermally sprayed aluminium
coatings porosity shall not exceed 15% of total surface area for flame sprayed coating and
8% for arc spray coating.
4.0
4.1
4.1.1
THERMAL SPRAY APPLICATION PROCEDURE

Items in the atmospheric zone to be coated by TSA shall be applied by either Flame spray
or Arc spray method only.
Equipment set up
Thermal spray equipment shall be set up calibrated, operated (1) according to manufacturer
instructions/technical manuals and also TSAC applicators refinement thereto and (2) as
validated by Procedure Qualification (Sec 7.0 of this specification).
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4.1.2
Spray parameters
Spray parameters (see 4.1.3 below) and thickness of each crossing pass shall be set and shall
be validated with bend test (See 6.5 of this Spec).
4.1.3
Spray Parameters
Spray Parameters
Arc voltage
Air pressure
Steel surface cleanliness
Method of Application
Arc wire Spray
27 V
80 psi
NACE-1 white metal
Steel surface profile

75 microns (minimum)
Arc current
250-280A
Coating thickness
225 microns (nominal)
Coating adhesion
> 1500 psi (Total coating),see 3.1.4
Coating porosity
Less than 8%
Spray distance (spray Gun 6-8
work piece)
Spray Pass width
40mm
Flame Wire Spray

80 psi
NACE-1 white metal /
or Near white metal
75 microns (min.)
225 microns(Nominal)
>1000 psi
Less than 15%.
5-7
20 mm
The above parameters to be validated with a bend test by the contractor before start of work
(for details of bend test see Sec 6.5 of this Spec).
4.2
Post Blasting Substrate condition and thermal spraying period.
4.2.1
The steel surface temperature shall be at least 50C above dew point of ambient air
temperature.
Steel substrate surface temperature shall be recorded by with a contact pyrometer.
Thermal spraying should commence within 15 minutes from the time of completion of
blasting
4.2.2
Holding Period
Time between the completion of final anchor tooth blasting and completion of thermal
spraying of blasted surface should be no more than four hours. If within this period rust
bloom appears Sec 4.4.1of this specification will apply.
4.3
Pre-Heating
For flame spraying, the initial starting area of 1-2 square feet to be preheated to
approx.1200C to prevent condensation of moisture in the flame on the substrate. For arc
spraying the preheating is not required.
March 2013

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4.4
Thermal spraying
Spraying should commence only after validation of equipment set up by procedure
qualification test
and spray parameter validation tests described in Sec 7.0 and 6.5
respectively. Thermal spraying must commence within 15 minutes from the time of
completion of blast cleaning
The specified coating thickness shall be applied in several crossing passes. The coating bond
strength is greater when the spray passes are kept thin. Laying down an excessively thick
spray pass increases the internal stresses in TSAC and decreases the bond strength of total
TSAC. The suitable thickness for crossing passes shall be determined by procedure
qualification test described in Sec 7.0 of this specification.
For manual spraying, spraying to be done in perpendicular crossing passes to minimize thin
spots in coating. Approx. 75-100 microns of TSAC shall be laid down in each pass.
The surface geometry of the item or area to be sprayed should be inspected before
application. The spraying pass and sequence shall be planned according to following.
-
Maintain Gun as close to perpendicular as possible and within 300 from

perpendicular to the substrate.
Maintain nominal standoff distance and spray pass width as given below:
Spray method
Arc Wire
Flame wire
4.4.1
Standoff (Inches)
6-8
5-7
Spray
pass
width
(Inches)
1 ( 40mm )
( 20mm )
Rust Bloom (Visual appearance of rust or Discoloration)

If Rust bloom appears on the blasted surface before thermal spraying, the affected area shall
be re blasted to achieve the specified level of cleanliness.
If Rust bloom in form of discoloration, or any blistering or a degraded coating appears at
any time during application of TSAC, then spraying shall be stopped and acceptable sprayed
area shall be marked off. The unsatisfactory areas shall be repaired to the required degree of
surface cleanliness and profile.
Blast the edges of the TSAC to provide for 2-3 feathered area overlap of the new work into
existing TSAC.
Then apply TSAC to the newly prepared surfaces and overlap the existing TSAC to the
extent of feathered edge so that overlap is a consistent thickness.
March 2013

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4.4.2
Masking
Masking all those parts and surfaces which are not required to be thermally sprayed as
instructed by purchaser should be inspected by applicator to ensure that they are properly
marked and covered by purchaser.
Complex geometries (flanges, valve manifolds, intersections) shall be masked by applicator
to minimize overspray i.e. TSAC applied outside spray parameters (primarily gun to
substrate distance and spray angle).
4.4.3
TSAC Finish
The deposited TSAC shall be uniform without blisters, cracks, loose particles, or exposed
steel as examined with 10 X magnification.
5.0
SEALER
Sealant shall be applied after satisfactory application of TSAC and completion of all testing
and
measurements of the finished TSAC as per Sec 6.0 of this specification.
For shop work Sealer shall be applied immediately after thermal spraying and for field work
sealer shall be applied within 8 hours. The sealcoat shall be thin enough to penetrate into the
body of TSAC.
The sealant shall be Silicone Alkyd Aluminium paint having DFT not more than 35-40
micron. Typically seal coat shall be applied at a spreading rate resulting in theoretical 38
microns DFT. The seal coat shall be applied in accordance with SSPC-PA 1 and the paint
manufacturer instruction for sealing.
During application of seal coat, complete coverage shall be ensured by visual observation.
6.0
TESTING AND MEASUREMENT SCHEDULE
6.1
Surface Finish
That the blasted cleaned surface meets the required criteria (NACE 1/SSPC-SP 5 ) shall be
visually inspected using SSPC-VIS 1. The clear cellophane-tape test shall be used to
confirm absence of dust or foreign debris on the cleaned surface.
6.2
Blast Profile Measurement: (In-Process testing during actual

application of TSA coating)
production before
The angular profile depth measurement shall be done by profile tape as per method NACE
Standard RP 0287 or ASTM D 4417 method B (Profile depth gauge micrometer). Spot
measurement shall be carried out every 15m2 of blasted surface. At each spot three
measurements shall be taken over an area of 10 cm2 and average of measurements to be
recorded and reported.
March 2013

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If profile is <75 microns blasting shall continue till grater than 75 microns depth profile is
achieved.
6.3
TSAC Thickness (In-Process Testing For finished coating during regular production)
6.3.1
TSAC finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge.
6.3.2
For flat surfaces, measurements shall be taken along a straight measurement line, one
measurement line for every 15 m2 of applied TSAC shall be selected along which 5
measurements to be taken at 25 mm internal and average to be reported.
6.3.3
For curved surface or complex geometry, 5 measurements shall be taken at a spot measuring
10 cm2 in area. One spot to be taken for every 15 m2 of applied TSAC area.
6.3.4
The TSAC thickness in surface changes or contour changes, welds and attachments shall be
also measured and reported.
6.3.5
If TSAC is less than specified minimum thickness, apply additional TSAC until specified
thickness range is achieved.
6.3.6
All locations and values of TSAC thickness measurements shall be recorded in Job Record
(JR).
6.4
Tensile Bond Testing (In-Process testing for finished coating during regular production)
6.5
Tensile Bond strength of the TSAC finish coat shall be determined according to
ASTM D 4541 using a self-aligning adhesion tester.
One measurement shall be made every 50 m2. If tensile bond at any individual spot is
less than 1000 psi for flame sprayed coating and 1500 psi for arc sprayed coating the
degraded TSAC shall completely removed and reapplied.
The tensile bond portable test instrument to be calibrated according to ASTM C 633
Bend Tests
Bend test shall be carried out at beginning of each work shift. Bend tests shall also be
conducted on sample coupons before start of thermal spraying work to qualify the following
as mentioned earlier in this specification.
-
6.5.1
To qualify spray parameters and thickness of each crossing pass.
Test Procedure
a)
Five corrosion control steel coupons each of dimension 50 mm x 150 mm x 1.3 mm

thk. to be prepared.
b)
Surface shall be prepared by dry abrasive blast cleaning as per this specification.
March 2013

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c)
TSAC shall be applied as per specified thickness range. TSAC should be sprayed
in crossing passes laying down approx. 75-100 microns in each pass.
d)
TSAC applied coupons shall be bent 180 0 around a 13 mm diameter mandrel.
e)
Bend test shall be considered passed if on bend radius there is
f)
No cracking or spalling or lifting by a knife blade from the substrate
Only minor cracking that cannot be lifted from substrate with a knife blade.
Bend test fails if coating cracks with lifting from substrate.
6.6
Tests for blasting media, blasting air
6.6.1
Blasting Media (For every fresh batch of media and one random test during blasting)
Blasting Media shall be visually inspected for absence of contamination and debris using 10
X magnification.
a)
6.6.2
Inspection for the absence of oil contamination shall be conducted using following
procedure :
-
Fill a small clean 200 ml bottle half full of abrasive.
Fill the bottle with potable water, cap and shake the bottle.
Inspect water for oil film/slick.If present, the blasting media is not to be used.
b)
Soluble salt contamination if suspected shall be verified by method ASTM D 4940.

If present, media to be replaced.
c)
Clean blasting equipment, especially pot and hoses, then replace blasting media and
retest.
Test for Blasting Air ( Once Daily before start of blasting and once at random during
blasting)
The air for blasting shall be free from moisture and oil. The compressor air shall be checked
for oil and water contamination per ASTM D 4285.
6.7
Test for presence of oil/grease and contamination

The steel substrate after degreasing as per SSPC-SP 1 shall be tested as per following
procedure to validate absence of oil and grease contamination.
a)
Visual inspection - Continue degreasing until all visible signs of contamination are removed.
March 2013

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b)
Conduct a solvent evaporation test by applying several drops or a small splash of residuefree trichloromethane on the suspect area especially pitting, crevice corrosion areas or
depressed
areas. An evaporation ring formation is indicative of oil and grease
contamination.
Continue degreasing and inspection till test is passed.
7.0
TSAC APPLICATOR QUALIFICATION

Following tests to be carried out as part of procedure qualification test for the applicator.
Thickness measurement
Coating bond strength
Porosity test
Bend strength
TSAC applicators surface finishing and application process and equipment set up,
calibration and operation shall be qualified by application of TSA on a reference sample
which shall be used as a comparator to evaluate the suitability of application process. Only
that applicator will be permitted to carry out the work when test specimens coated by the
applicator meets the desired requirements as cited below.
The sample shall be made of a steel plate measuring approx. 18x 18 x thick. If the
actual work is less than thick then the sample to be made from material of representative
thickness.
The surface preparation, TSAC application shall be made with actual field equipments and
process/spray parameters and procedures as per the specification. The depth profile of
blasted surface, TSAC coating thickness for each cross pass and total thickness range shall
be as per
specification.
The surface preparation and thermal spraying shall be carried out in representative
environmental conditions spraying with makeshift enclosure.
7.1
After application of coating, thickness and tensile

following
manner.
bond measurements shall be made in
Divide the sample piece into four quadrants.
Measure thickness along the diagonal line of each quadrant.
Four each quadrant five in-line thickness measurements at 1 interval shall be done
using SSPC-PA 2 type 2 fixed probe gauge. Thus a total of four five in line
thickness measurements to be done for the whole sample.
One tensile bond measurement using ASTM D 4541 type III or IV portable self
aligning test instrument to be done at centre of each quadrant. Total of 4 measurements
for the sample.
March 2013

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7.2
One porosity evaluation test by Metallographic examination shall be conducted to

demonstrate the achievement of porosity within the limits specified. Sample shall be
prepared for Metallographic examination as per ASTME 3.
The procedure shall be considered qualified if thickness and tensile-bond strength and
porosity values meet the specification requirement.
Bend test: Bend test shall be carried out as detailed at sec. 6.5 of this specification.
Applicators thermal spray equipment set-up, operation and procedure of application
including in-process QC checkpoints adopted during procedure qualification as described
above should be always subsequently followed during entire duration of work.
8.0
DOCUMENTATION
The following information shall be provided by TSAC applicator before award of work.
9.0
10.0
TSAC application process consisting of equipment capabilities and their technical

parameters, feed stock material and source of procurement.
Detailed application procedure and in-process quality control check points for (a)
surface preparation (b) thermal spraying (c) seal coats.
Type and specification of instruments to be deployed for measurement of blast

profile depth, TSAC thickness and tensile bond.
Paint manufacturer data sheet for the selected sealing coat to be applied.
RECORDS
-
The TSAC applicator shall maintain a job record to record production and QC
information. All the results of the tests and quality control checks shall be entered
in the record for each component/part thermally sprayed. All the result of tests
(thickness, tensile bond, bend tests) and other validation tests (e.g. procedure
qualification test, test for surface cleanliness after abrasive blasting, test for
cleanliness of abrasives and air) shall also be recorded and duly signed by owner.
All the information mentioned in Sec 8.0 above should also form part of the Job
record.
Any modification affected after procedure qualification in the procedure, QC, spray
parameter, equipment spec to the original information (submitted before award of
the work) must also form part of Job record.
WARRANTY
The TSAC applicator shall warrant the quality of material used by providing the purchaser
with a certificate of materials used to include
March 2013

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11.0
Spray feed stock: Alloy type/designation, Lot Number, wire diameter, chemical
analysis, name of supplier, manufacturer.
Sealant : Name of manufacturer, application data sheet.

SAFETY
The TSAC applicator shall follow all safety procedures required by the purchaser/owner.
Owner shall also give compliance requirement to be followed by applicator. The
applicator shall follow all appropriate regulatory requirements.
12.0
CODES AND STANDARDS

This specification shall apply in case of conflict between specification and following
applicable standards:
AWS C. 2.17
ASTM C 633
Recommended Practice for Electric arc Spray.

Test Method for Adhesive/Cohesive Strength of Flame Sprayed
Coatings.
ASTM D 4285
Method for indicating Oil or Water in Compressed Air.
ASTM D 4417
Test Method for Field Measurement of Surface Profile of Blasted
Steel.
BS 2569
Specification for Sprayed Metal Coating.
NACE Standard RP Field Measurement of Surface Profile of Abrasive Blast Cleaned
0287
Steel Surfaces Using a Replica Tape.
ASTM D 4541
Test method for Pull-Off Strength of Coating Using Portable
Adhesion Testers.
ANSI/AWS C2.18
Guide for the Protection of Steel with Thermal Spray Coatings of
Aluminum, Zinc and Their Alloys and Composites.
NACE No. 12/AWS Specification for the application of thermal spray coatings
C2.23M/SSPC-CS
(Metallizing) of aluminum, zinc, and their alloys and composites
23.00
for the corrosion protection of steel.
SSPC Publication
The inspection of coatings and linings : A Handbook of Basic
practice for Inspectors, Owners , and Specifiers.
SSPC-AB 1
Mineral and Slag Abrasives.
SSPC-AB 3
Ferrous Metallic Abrasives.
SSPC-PA 1
Shop, Field, and Maintenance Painting of Steel.
SSPC-PA 2
Measurement of Dry Coating Thickness with Magnetic Gages.
NACE No. 1/SSPC- White Metal Blast Cleaning.
SP 5
NACE No. 2/SSPC- Near White Metal Blast Cleaning.
SP 10
SSPC-VIS 1
Guide and Reference Photographs for Steel Surfaces Prepared by
Dry Abrasive Blast Cleaning.
March 2013
Z ZPA= 1.17
25
1%
2%
3%
4%
5%
7%
10%
20%
Acceleration,m/s2
20
15
10
0
0
10
15
20
25
30
35
40
45
50
55
Frequency, Hz
60
65
70
75
80
85
90
95
100
Z ZPA= 0.80
9
1%
2%
3%
4%
5%
7%
10%
20%
Acceleration,m/s2
0
0
10
15
20
25
30
35
40
45
50
55
Frequency, Hz
60
65
70
75
80
85
90
95
100
Z ZPA= 0.67
8
1%
2%
3%
4%
5%
7%
10%
20%
Acceleration,m/s2
0
0
10
15
20
25
30
35
40
45
50
55
Frequency, Hz
60
65
70
75
80
85
90
95
100
Z ZPA= 0.68
7
1%
2%
3%
4%
5%
7%
10%
20%
Acceleration,m/s2
0
0
10
15
20
25
30
35
40
45
50
55
Frequency, Hz
60
65
70
75
80
85
90
95
100
Z ZPA= 2.16
25
1%
2%
3%
4%
5%
7%
10%
20%
Acceleration,m/s2
20
15
10
0
0
10
15
20
25
30
35
40
45
50
55
Frequency, Hz
60
65
70
75
80
85
90
95
100
Z ZPA= 2.65
30
1%
2%
3%
4%
5%
7%
10%
20%
25
Acceleration,m/s2
20
15
10
0
0
10
15
20
25
30
35
40
45
50
55
Frequency, Hz
60
65
70
75
80
85
90
95
100
APPROVED VENDOR LIST

SR. ITEM DESCRIPTION
NO.
1.
Seamless
CS Pipe
A106 Gr. B.
2.
SS Tubes
3.
Welded
CS pipes
IS-3589
ERW 410
4.
SS Pipes
A-312 TP 304L
ERW / SML
INDIAN VENDOR
FOREIGN VENDOR
1. M/s. MSL, Raigad

2. M/s. ISMT, Pune
3. M/s. Remi Metals Gujarat Ltd., Mumbai
4. M/s. TISCO
5. M/s. SAIL
6. M/s. Jindal Steel Tubes
7. M/s. Ajanta Tubes
8. M/s. Zenith Steel Tubes
9. M/s. Mann Indus, Indore
10. M/s. Ratnamani, Ahmedabad.
11. M/s. PSL, Daman
12. M/s. Surya Roshini, Delhi
13. M/s. Indus,Delhi
14. M/s. Mukund Pipes
15. M/s. ISMT, Baramati
16. M/s. Lalit Pipes And Pipes Ltd
17. M/s. Madras Steels And Tubes , Chennai
(Trader For Jindal Saw Ltd, Malegaon)
18. M/s. Heavy Metals Tubes (Hmt) Ltd
(Except For Condensate System Pipes)
19. M/s. Anand Tube Pvt Ltd,
Mumbai(Trader)
1. M/s. Choksi, Ahmedabad
2. M/s. NFC, Hyderabad
3. M/s. CST Valinox, Hyderabad
4. M/s. Ratnamani Metals and Tubes Ltd,
Ahmedabad
5. M/s. Praksah Steelage Ltd, Mumbai
6. M/s. Remi, Mumbai
7. M/s. Sandvik, Baroda
1. M/s. S.C. Petrotub,

Romania
2. M/s. Dalmine, Italy
3. M/s. Vallourec and
Mannesmann, France
4. M/s. Productos
Tubulares, Spain
5. M/s. Sumitomo Corp.,
Japan
6. M/s. Tubos Reumidis,
Spain
7. M/s. Commerciale
Tubi Acciaio Spa. Italy
1. M/s. SAIL
2. M/s. Mann Indus., Indore
3. M/s. Deccan Metal Industries, Rajpura,
Punjab
4. M/s. Lalit Profiles, Navi Mumbai
5. M/s. MSL, Raigad
6. M/s. PSL Limited, Chennai
1. M/s. Ratnamani Metals and Tubes Ltd,
Ahmedabad
2. M/s. NFC, Hyderabad
3. M/s. REMI, Mumbai
1. M/s. AB Sandvik,
Sweden
2. M/s. Fine Tubes, UK
3. M/s. Vallourec &
Mannesman,Germany
4. M/s. Dalmine, Italy
5. M/s. Salzgitter
Mannesmann, France
6. M/s. Productos
Tubulares, Spain
-
1. M/s. AB Sandvik,
Sweden
2. M/s. Dalmine
Tenaris, Italy
3. M/s. Salzgitter
Mannesmann,
France
4. M/s. Vallourec &
Mannesman,
5.
Seamless
Elbows, Tees,
Bends,
Reducers, Caps,
Sockolet,
Threadolet,
Couplings,
Flanges, Weldolets
etc.
CS/ASTM-A-105,
A234WPB/P22, SSA182/A403
304L/316L,
6.
Hangers, Supports,
Snubbers and Sway
Braces
7.
Bearing pads /
Lubrite Pads
Fasteners
8.
1. M/s. Dee Development, Fabridabad

2. M/s. Arvind Metal Pipes & Fittings,
Baroda
3. M/s. Steel Samrat, Boisar, Tarapur
4. M/s. Tube Products Incorporate, Baroda
5. M/s. Gujarat Infra Pipes, Baroda
6. M/s. MS Fittings, Kolkata
7. M/s. Alliance Fitting & Forgings Ltd, Navi
Mumbai
8. M/s. Tube Turn, Mumbai
9. M/s. EBY Fasteners, Mumbai
10. M/s. Echjay Industries, Rajkot
11. M/s. EBY Engineers, Mumbai
12. M/s. Commercial Supplying Agency,
Mumbai
13. M/s. Echay Industries, Mumbai (Flanges)
14. M/s. Paramount Forge, Panvel,
Maharashtra (only for flanges)
15. M/s. Hilton Metal Forgings Ltd, Mumbai
16. M/s. Stewards & Lloyds, Calcutta
17. M/s. Swastik Lloyds Engineering Pvt
Ltd, Mumbai
18. M/s. Teekay tubes, Mumbai
19. M/s. True Fab Pvt Ltd, Faridabad
20. M/s. Boney Forge
21. M/s. S&G Engineers Pvt. Ltd., Faridabad
22. M/S. Super Tech, Mumbai
23. M/s. Sawan Engineers Pvt Ltd,
Vadodara
24. M/s. Techno Product Industries(Topsi),
Vadodara
1. M/s. BHEL, Trichy
2. M/s. Pipe Supports India Pvt., Ltd.,
Chennai
3. M/s. SARATHI Engineering, Hyderabad
4. M/s. Myricks, Chennai
5. M/s. Piping and Energy Products, New
Delhi
6. M/s. Shalimar Valves, Mumbai
7. M/s. Spring Supports Manufacturing Co.,
Kolkata
8. M/s. Pipe Supports India Pvt. Ltd., Delhi
1. M/s. Rollon Bearings, Bangalore
1. M/s. ALCO, Hubli
2. M/s. Boltmaster, Vasai
Germany
5. M/s. Productos
Tubulares, Spain
6. M/s. Schoeller
Blackmann
1. M/s. Sungkwang
Bend Co., Korea
2. M/s. Techtube, Italy
3. M/s. Union Piping,
Italy
4. M/s. ERNE, Austria
5. M/s. Petrol
Raccordi, Italy
6. M/s. M.E.G.A, SPA
Italy
7. M/s. Bassi Luigi, Italy
8. M/s. Schultz, Germany
9. M/s. B.K.L. Fittings Ltd,
UK
10. M/s. Raccordi
Forgeati, Italy
11. M/s. Myong
KWANG Metal Co., Korea
12. M/s. TEE Kwang,
Korea
13. M/s. Fino, Germany
1. M/s. Lesiga, Germany

2. M/s. Carpenter and
Pettarson, U.K.
3. M/s. Daman Jarret,
France
4. M/s. NPS Iberica, Spain
5. M/s. Pipe support
systems GmbH
International, Germany
6. M/s. QUIRI, France
9.
Gasket
10.
Structural
Steel(CS&SS)
3. M/s. GKW, Mumbai

4. M/s. Industrial Fasteners, Mumbai
5. M/s. Mega Engineering Pvt. Ltd, RABALE
6. M/s. Laxmi Precision, Mumbai
7. M/s. Precision Engineering Industries,
Baroda
8. M/s. Precision Fasteners, Mumbai
9. M/s. Sundaram Fasteners
10. M/s. TVS, Chennai
11. M/S. Unbrako, Mumbai
12. M/S. Industrial Engineering Corporation
13. M/S. Pioneer Nuts & Bolts Pvt Ltd
14. M/s. Indcon, Delhi
15. M/s. Summits Hygronic, Coimbatore
1. M/s. Starflex,Goa
2. M/s. IGP, Chennai
1. M/s. Lloyd Steel,Mumbai
2. M/s. Rashtriya Ispat Nigam Ltd, Mumbai
3. M/s. SAIL, Mumbai
4. M/s. TISCO, Kolkata
5. M/S. Central Steel Corporation , Mumbai
1. M/s. Flexitallic,UK
Document No. A-463-000-16-46-DS-4001

1.0 Nozzles and connections
Mark
Purpose
Connecting pipeline
size, ODThickness,
mm
Grooving
diameter dgr, mm
Quantity,
psc.
Air vent
322.5
28+0.21
II
Inlet from system
21911
200+0.46
III
Outlet for pumps

intake
27311
255+0.52
IV
Inlet from
recirculation line
1596
150+0.40
Overflow
1596
150+0.40
VI
Level metering
connecting pipe
142
10.5+0.18
VII
Drainage
895
80+0.30
VIII
Manhole
800
VIII
Manhole
800
IX
Protective sheath for

boron measuring
device
122
2.0 Changes made in note 16 of datasheet.

Allowable limiting loads from connected pipelines to nozzles
Load mode and value

Dnom,
mm
NO,
,
kNm
NO,
,
kNm
NO,
F,
kN
NO
F,
kN
NO+DBE
DBE,
kNm
NO+DBE
FDBE,
kN
25
0.175
0.384
1.44
3.16
0.218
1.76
80
2.33
3.45
4.00
5.94
2.87
4.90
150
7.12
10.20
7.16
10.30
8.76
8.74
200
26.80
37.30
9.90
13.70
33.00
12.00
250
37.20
49.30
12.30
16.30
45.70
15.00
Note - , F moment and force by the weight of pipeline. , F range of moment and
force by pipeline temperature compensation. DBE, FDBE - moment and force by joint effect
of pipeline weight and DBE.
3.0 Page 4 & 5 of 9: Tank outline drawing for 3 FAL51BB001, 3 FAL52BB001, 4 FAL51BB001, 4
FAL52BB001
Document No. A-463-000-16-46-DS-4002

Mark
Purpose
ODxThickness, mm
Bore
diameter Db
Number, pcs.
To intake side of montejuses
573
52 +0.3
II
Tank filling
108x5
99 +0.35
III
Tank filling
573
52 +0.3
IV
Blowoff
573
52 +0.3
Recirculation
573
52 +0.3
VI
Compressed air
32x2.5
28 +0.21
VII
Caustic soda
32x2.5
28 +0,21
VIII
Tank filling
1085
99 +0.35
IX
Hydraulic lock sleeve
219x11
200 +0.46
Sleeve for level meter
142
10,5 +0.18
XI
To intake side of pumps
573
52 +0.3
XII
Manhole
820x10
XIII
Hydraulic lock filling
18x2.5
13.5 +0.18
XIV
Hydraulic lock overflow
18x2.5
13.5 +0.18
2.0 Page 4 of 8: Outline drawing and fastening of embedded parts for tanks 3KPF13BB001,
3KPF13BB002, 4KPF13BB001 and 4KPF13BB002.
3.0 Page 5 of 8: Outline drawing and fastening of embedded parts for tank 3KPF13BB003,
4KPF13BB003
4.0 Changes made in Note 13

Mode and load value

Dnom,
mm
NO,
Mw,
kN x m
NO,
Mr,
kN x m
NO,
Fw,
kN
NO
Fr,
kN
NO+DBE
DBE,
kN x m
NO+DBE
FDBE,
kN
10
0.0248
0.0534
0.63
1.35
0.0307
0.77
15
0.0535
0.115
0.81
1.75
0.0661
0.99
25
0.175
0.384
1.44
3.16
0.218
1.76
50
0.727
1.61
2.57
5.68
0.907
3.14
100
2.80
3.98
4.86
6.81
3.44
5.94
Note - w, Fw moment and force from pipeline weight. r, Fr ranges of moment and
force from pipeline temperature compensation. DBE, FDBE moment and force by joint
impact of pipeline weight and DBE.
Document No. A463-000-16-46-DS-4003

OD X Thickness,
mm
573
Bore diameter
Db
52 +0,3
Number,
pcs.
1
573
52 +0.3
573
52 +0.3
32x2.5
28 +0.21
Blowoff
895
80 +0.3
573
52 +0.3
VII
Pump-down with the use of

montejeuse
Manhole
820x10
VIII
219x11
200 +0.46
IX
Boss for thermal sensor
201.5
Flushing water supply
573
52 +0.3
XI
Nitrogen supply
182.5
13.5 +0.18
XII
Supply of sorbents
573
52 +0.3
XIII
Overflow
895
80 +0.3
XIV
Sleeve for level meter
142
10.5 +0.18
XV
18x2.5
13.5 +0.18
XVI
18x2.5
13.5 +0.18
Mark
Purpose
I
II
To intake side of pumps and tank

discharge
Vat residue supply
III
Medium return
IV
Compressed air (bubbling)
V
VI
2.0 Changes made in Note 13

Maximum permissible loads from connected pipelines to nozzles
Dnom,
mm
NO,
Mw,
kN x
m
NO,
Mr,
kN x m
NO,
Fw,
kN

NO
NO+DB NO+DB
Fr,
E
E
kN
DBE,
FDBE,
kNm
kN
NO+SSE
MWE,
kNm
NO+SSE
FWE,
kN
0.0248 0.0534
0.63
1.35
0.0307
0.77
0.0346
0.882
10
0.0535
0.115
0.81
1.75
0.0661
0.99
0.0745
1.13
15
0.175
0.384
1.44
3.16
0.218
1.76
0.247
2.02
25
0.727
1.61
2.57
5.68
0.907
3.14
1.03
3.59
50
2.33
3.45
4.00
5.94
2.87
4.90
3.23
5.61
80
Note - w, Fw moment and force from pipeline weight. r, Fr ranges of moment and force
from pipeline temperature compensation. DBE, FDBE moment and force from joint action of
pipeline weight and DBE. MWE, FWE moment and force from joint action of pipeline weight
and SSE.
3.0 Page No. 4 of 7: Outline drawing of vat residue tanks 3KPK10BB001, 3KPK10BB002,
3KPK10BB003, 4KPK10BB001, 4KPK10BB002, 4KPK10BB003
Document No. A-463-000-16-46-DS-4004

Mark
Purpose
ODThickness, mm
Grooving
diameter
dgr, mm
Quantity,
psc.
Distillate inlet
1085
99+0.35
II
Recirculation
573
52+0.3
III
Outlet for pumps intake
1596
150+0.40
+0.30
IV
Tank unloading
895
80
Overflow
1596
150+0.40
VI
Air vent
322.5
28+0.21
VII
Connecting pipe for level

metering
142
10.5+0.18
VIII
Manhole
800
IX
Connecting pipe for

the tank makeup
by distillate
1085
99+0.35

Load mode and value

Dnom,
mm
NO,
,
kNm
NO,
,
kNm
NO,
F,
kN
NO
F,
kN
NO+DBE
DBE,
kNm
NO+DBE
FDBE,
kN
25
0.175
0.384
1.44
3.16
0.218
1.76
50
0.727
1.61
2.57
5.68
0.907
3.14
80
2.33
3.45
4.00
5.94
2.87
4.90
100
2.80
3.98
4.86
6.81
3.44
5.94
150
7.12
10.20
7.16
10.30
8.76
8.74
Note - , F moment and force by the weight of pipeline. , F range of moment and
force by pipeline temperature compensation. DBE, FDBE - moment and force by joint effect
of pipeline weight and DBE.
3.0 Page No. 4 & 5 of 10: Tank outline drawing for 3 KBC16BB001, 3 KBC17BB001, 4 KBC16BB001, 4
KBC17BB001
Document No. A-463-000-16-46-DS-4005

Mark
Purpose
OD x Thickness,
mm
Bore
diameter Db
Number, pcs.
Medium inlet from systems of

coolant treatment and chemical
agents mixing
573
52 +0.3
II
Boron solution inlet from pumps
89x5
80 +0.3
III
Overflow to boron-containing water

collection system
895
80 +0.3
IV
Medium discharge from to boroncontaining water collection system
573
52 +0.3
Boron acid solution to intake side of

pumps
1085
99 +0.35
VI
Level metering sleeve
14x2
10,5 +0.18
VII
Blowoff
89x5
80 +0.3
VIII
Lower hatch (manhole)
820x10
IX
Upper hatch (manhole)
820x10
Sleeve for concentrate meter
140
Mode and load value

Dnom,
mm
NO,
Mw,
kN x m
NO,
w,
kN x m
NO,
Mw,
kN x m
NO
Fr,
kN
NO,
Mw,
kN x m
NO+DBE
FDBE,
kN
10
0.0248
0.0534
0.63
1.35
0.0307
0.77
50
0.727
1.61
2.57
5.68
0.907
3.14
80
2.33
3.45
4.00
5.94
2.87
4.90
100
2.80
3.98
4.86
6.81
3.44
5.94
3.0 Page no. 4 of 5: Outline drawing of purified boron concentrate tank 3KBC40BB001,
3KBC40BB002,4 KBC40BB001, 4KBC40BB002.
4.0 Changes made to note no. 14: The tank shall withstand loading cycles
Operation
modes
Temperature
variation range,
Temperature
variation
duration, s
Pressure
variation
range, MPa
Pressure
variation
duration, s
Loading
cycles for 30
years
NO modes
20 60
not limited
0 0.067
not limited
3000
Document No. A-463-000-16-46-DS-4006

Mark
I
Purpose
Coolant inlet from Volume and
ODxthickness,
Bore diameter
Number,
mm
Db
pcs.
1596
150 +0.4
chemical control system

II
Coolant outlet to intake of pumps
108x5
99 +0.35
III
219x11
200 +0.46
IV
Inlet of decontaminating solutions
573
52 +0.3
Nitrogen inlet
383
33 +0.25
VI
Blowoff
57x3
52 +0.3
VII
Medium discharge from tank
57x3
52 +0.3
VIII
Level metering sleeves
142
10.5 +0.18
IX
Tank filling sleeve
220x7
209 +0.46
201.5
XI
Upper and lower hatches (manholes)
820x10
XII
18x2.5
13.5 +0.18
XIII
18x2.5
13.5 +0.18
2.0 Changes made in note 15 of datasheet

Maximum permissible loads from connected pipelines on sleeves
Mode and load value

Dnom,
mm
NO,
Mw,
kN x m
NO,
Mr,
kN x m
NO,
Fw,
kN
NO
Fr,
kN
NO+DBE
DBE,
kN x m
NO+DBE
FDBE,
kN
10
0.0248
0.0534
0.63
1.35
0.0307
0.77
15
0.0535
0.115
0.81
1.75
0.0661
0.99
32
0.31
0.68
1.71
3.75
0.386
2.09
50
0.727
1.61
2.57
5.68
0.907
3.14
100
2.80
3.98
4.86
6.81
3.44
5.94
150
7.12
10.20
7.16
10.30
8.76
8.74
200
13.65
18.69
9.90
13.60
16.80
12.10
Note - w, Fw moment and force of pipeline weight. r, Fr ranges of moment and force
from pipeline temperature compensation. DBE, FDBE moment and force by joint impact of
pipeline weight and DBE.
3.0 Page no. 4 of 9: Outline drawing of operational grade coolant storage tank 3KBB10BB001,
3KBB10BB002, 4KBB10BB001, 4KBB10BB002
Document No. A-463-000-16-46-DS-4007

Mark
ODxThickness,
Purpose
Bore diameter Db
mm
Number, pcs.
Coolant inlet
1596
150 +0.4
II
Coolant outlet to intake of pumps
573
52 +0.3
III
219x11
200 +0.46
IV
Distillate inlet
573
52 +0.3
Nitrogen inlet
383
33 +0.25
VI
Blowoff
57x3
52 +0.3
VII
Medium discharge from tank
57x3
52 +0.3
VIII
Level metering sleeves
142
10.5 +0.18
IX
201.5
Manhole
820x10
XI
18x2.5
13.5 +0.18
XII
18x2.5
13.5 +0.18

Permissible loads from connected pipelines on sleeves
Mode and load value

Dnom,
mm
NO,
Mw,
kN x m
NO,
Mr,
kN x m
NO,
Fw,
kN
NO
Fr,
kN
NO+DBE
DBE,
kN x m
NO+DBE
FDBE,
kN
10
0.0248
0.0534
0.63
1.35
0.0307
0.77
15
0.0535
0.115
0.81
1.75
0.0661
0.99
32
0.31
0.68
1.71
3.75
0.386
2.09
50
0.727
1.61
2.57
5.68
0.907
3.14
150
7.12
10.20
7.16
10.30
8.76
8.74
4KBB10BB003
4KBB10BB004
Document No. A-463-000-16-46-DS-4008

Mark
Purpose
ODxThicknes
Bore diameter
s, mm
Db
Number, pcs.
Filling
573
52 +0.3
II
Overflow
573
52 +0.3
III
Draining
573
52 +0.3
IV
Hatch (manhole)
820x10
Pumps recirculation sleeve
383
33 +0.25
VI
Air duct
573
52 +0.3
VII
Intake side of pumps
108x5
99 +0.35
VIII
Level meter sleeve
142
10,5 +0.18

Maximum permissible loads from connected pipelines on nozzles
Mode and load value

DnxS,
mm
NO,
Mw,
kN x m
NO,
Mr,
kN x m
NO,
Fw,
kN
NO
Fr,
kN
NO+DBE
DBE,
kN x m
NO+DBE
FDBE,
kN
10
0.0248
0.0534
0.63
1.35
0.0307
0.77
32
0.31
0.68
1.71
3.75
0.386
2.09
50
0.727
1.61
2.57
5.68
0.907
3.14
100
2.80
3.98
4.86
6.81
3.44
5.94
3.0 Changes made in note 12 of datasheet :The tank shall withstand loading cycles
Operation
modes
Temperature
variation range,
Temperature
variation
duration, s
Pressure
variation
range, MPa
Pressure
variation
duration, s
Loading
cycles for 30
years
NO modes
20 40
not limited
0 0.036
not limited
2800
4.0 Page no. 3 of 8: Outline drawing of auxiliary tanks 3KPF60BB001, 3KPF60BB002,

4KPF60BB001, 4KPF60BB002
Document No. A-463-000-16-46-DS-4013

Connecting pipe
Qty,
Purpose
S, mm
Medium input
573,0
II
Overflow
1085,0
III
Emptying
573,0
IV
Air vent
573,0
Manhole
800
designation
pcs.
2.0 Page no. 4 of 5: Tank outline drawing of 3GML20BB001, 4GML20BB001
Additional design requirement for document no. A-463-000-16-46-DS-4003

(3KPK10BB001, 3KPK10BB002, 3KPK10BB003, 4KPK10BB001, 4KPK10BB002 and
4KPK10BB003)
The vat residue tank shall retain strength and tightness before and after dynamic
impacts as follows: earthquake up to SSE inclusively, Aircraft crash and Air shock wave. Tankto-civil structures fastening members shall be able to withstand dynamic impact from own
weight of equipment unit with medium and insulation, and loads from connected pipelines.
Loads on the tank in case of SSE (OBE) and ASW shall be adopted in line
with response spectra. The response spectra from OBE, SSE levels seismic impacts and spectra
from ASW for the tank installation elevation are given separately. Spectral acceleration
occurred from an aircraft fall which is low spectral accelerations received from seismic impact
of SSE within the total frequency range.
Response spectra from air-shock wave (ASW)
When using response spectra, it shall be mentioned that spectral accelerations from
ASW act simultaneously in three mutually perpendicular directions (horizontal - X and Y,
vertical - Z). Direction X coincides with coordination of literal arrays, direction Y with
coordination of digital axes.
Response spectra occurred from ASW along axes X and Y are directed separately and
act simultaneously. At some elevations, response spectra from ASW for walls and slab have
been differentiated.
Response spectra for intermediate elevations shall be assumed by interpolation.
Response spectra are given for relative damping making 1 % (an upper curve), 2 %, 5 %, 7 %
and 10 %.
For intermediate attenuation values, interpolation shall be used.
Scheme of axes of auxiliary reactor building is adduced in figure .6.
Y
F
X
UC
Figure A.6 - The scheme of axes

Response spectra from ASW for UKC Building, ASW direction along axis X, are
adduced in figure A.7. Response spectra from ASW for UKC building, ASW direction along
axis Y are adduced in figure A.8.
Direction X (ZPA = 1.9 /2)

12
1%
2%
5%
7%
10%
Acceleration, m/s2
, /2
10
8
6
4
2
0
0
50
100
,
Frequency,
150
200
Hz
Direction Y (ZPA = 1.1 /2)

6
1%
2%
7%
Acceleration, m/s2
, /2
5%
10%
3
2
1
0
50
100
150
200
, Hz
Frequency,
Direction Z (ZPA = 5.6 /2)

35
1%
2%
5%
7%
10%
30
Acceleration, m/s
, / 2
25
20
15
10
5
0
0
50
100
150
200
Frequency,
, Hz
Figure .7 - Response spectra from ASW for UKC building along axis X.
Walls and slabs at elevation minus 3.600 m
Direction X (ZPA = 1.2 m/s2)

8
1%
2%
5%
Acceleration, m/s2
7%
10%
4
3
2
1
0
50
100
150
200
,
Frequency,
Hz
Direction Y (ZPA = 2.5 m/s2)

12
1%
2%
10
5%
, /2
Acceleration, m/s2
7%
10%
6
4
2
0
20
40
60
80
100
120
140
160
180
200
, Hz
Frequency,
Direction Z (ZPA = 1.6 m/s2)

7
1%
2%
5%
7%
10%
, /
Acceleration, m/s2
6
5
4
3
2
1
0
0
50
100
150
200
,
Frequency,
Hz
Figure .8 - Response spectra from ASW for UKC building along axis Y.
Walls and slabs at elevation minus 3.600 m

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Pre-Bid Response

NPCIL Response on pre-bid queries ( 7 Pages)

Additional information from NPCIL: Following documents are enclosed

A-463-000-16-46-DS-4013 Tank bottom support detail ( 1 Page)

Revised datasheet as additional document ( 19 Pages)

Additional design requirement for document no A-463-000-16-46-DS-4003

Pre bid Queries on Tender No. CMM/FTP/75-00-1-1147 for SS Tanks, Kudankulam

Query Tender Section/

Clause No./ Subject

Site visit to see area for site

Submission date of Bid

We have to visit site after pre-bid discussion to see unloading area,

Process conditions of inflow / outflow of tanks have not been given;

It is assumed that design of all tanks is to have frangible roofs (roof

The safety /emergency requirements

Since bottom plate of Tanks are resting on grid of structural members,

Digital values for Seismic response spectra (as per Annexure A) to be

We propose to use GMAW and FCAW process particulary for structural

We propose to use common welding consumable ER 347 which is

Ok, Material to be used from SA 479

Material to be used from SA 479

NPCIL to confirm whether Bottom Support (e.g. parts mentioned in

A463-000-16-46-DS-4002 & 4003

To be worked out by vender from

A463-000-16-46-DS-4002 & 4003

NPCIL to furnish height of Cone.

Can be found out by calculation of

Material to be used from SA 479

Connection of Nozzle VIII (Hydraulic lock arrangement) is not clear.

To be worked out by vender from

Connection of Nozzle IX (Hydraulic lock arrangement) is not clear.

Schematic details are given.details to

Connection of Nozzle-III (Hydraulic lock arrangement) is not clear.

Schematic details are given.details to

A463-000-16-46-DS-4012 & 4013

these things are to be worked out in

these things are to be worked out in

Painting to be performed as Per

UT in retrival digital form

Clause No. 13.5

NPCIL to confirm whether Bottom Support (e.g. parts mentioned in

Refer to ASME BPVC Section III

This clause is deleted.

Kindly submit the bid in line with the

Right of Recourse under Civil

BG for Integrity Pact

Initially Period of BG to be considered as 1 Year. After award of

Request not acceptable. Tender

Bidder : M/s Fabtech Projects and Engineers ., Pune

Query Tender Section/

Clause No./ Subject

Are Unit 3 & 4 in same location?

Civil Liabilty to be removed from the Tender.

Is Payment Terms Deviation Acceptable?

Is there accomodation facilities for contractor's personnels within or

No accomodation facility is available

Is Hydrotest duration 24 hours or one hour?

As per ASME section III ND subsection 6000

Painting to be performed as Per

Taxes: Should Excise duty to be considered in Price bid?

Is there any external ladder and platform in our scope?

Is Insulation Under our Scope?

Drawings: Details of Hydrolock filling is not complete.

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