SH1.RFP - P4 OTR - Ch13 General Technical Requirements - 140530

Chapter
13
GENERAL TECHNICAL REQUIREMENTS
PVN/Long Phu – Song Hau Project Management Board Song Hau 1 (2x600MW) Power Plant
PECC2/PCC Request for Proposal
CONTENT
13.1. OVERALL REQUIREMENTS .......................................................................................... 5
13.2. PLANT IDENTIFICATION AND LABELING ................................................................ 5
13.2.1. Plant Identification System ............................................................................................ 5
13.2.2. Numbering System, Nameplates and Labels ................................................................. 6
13.3. HAZARDS & OPERABILITY (HAZOP) STUDY ........................................................... 7
13.4. MATERIAL AND WELDING ........................................................................................... 8
13.4.1. General ........................................................................................................................... 8
13.4.2. Materials ......................................................................................................................... 8
13.4.3. Test on Materials .......................................................................................................... 10
13.4.4. Welding and coupling ................................................................................................... 10
13.4.4.1. General ............................................................................................................... 10
13.4.4.2. Welding Procedure Documents ........................................................................... 11
13.4.4.3. Welding Procedure Qualification Tests ............................................................... 11
13.4.4.4. Welders Qualification Tests ................................................................................ 11
13.4.4.5. Storage of Welding Consumables........................................................................ 11
13.4.4.6. Fabrication.......................................................................................................... 12
13.4.4.7. Visual Weld Inspection ....................................................................................... 13
13.4.4.8. Non-Destructive Examination ............................................................................. 14
13.4.4.9. Radiographic Techniques .................................................................................... 14
13.4.4.10. Dye Penetrant Tests ............................................................................................ 14
13.4.4.11. Internal Examination ........................................................................................... 14
13.4.4.12. Weld Repairs ...................................................................................................... 15
13.4.4.13. Quality Requirements for Welds ......................................................................... 15
13.4.4.14. Mandatory Inspections ........................................................................................ 15
13.5. PROTECTIONS, GUARDS AND SUNSHADES ............................................................ 15
13.6. PLATFORMS, WALKWAYS, STAIRS AND LADDERS ............................................. 16
13.6.1. Platforms and Walkways ............................................................................................. 16
13.6.2. Stanchions and Handrails ............................................................................................ 16
13.6.3. Stairs ............................................................................................................................. 17
13.6.4. Steel Ladders for Fixed Access .................................................................................... 17
13.7. FIRE PROTECTION REQUIREMENTS ....................................................................... 18
13.8. LOCKS AND KEY CABINETS....................................................................................... 18
13.9. PIPING, VALVES & FITTINGS ..................................................................................... 18
13.9.1. Code & Standards ........................................................................................................ 18
13.9.2. Valves ............................................................................................................................ 19
13.9.2.1. General ............................................................................................................... 20
13.9.2.2. Valve Position Indicators .................................................................................... 22
13.9.2.3. Manually Operated Valves .................................................................................. 22
13.9.2.4. Motor Operated Valves ....................................................................................... 23
13.9.2.5. General Purpose Valves ...................................................................................... 23
13.9.2.6. Special Purpose Valves ....................................................................................... 24
13.9.2.7. Valve Drives ....................................................................................................... 26
13.9.2.8. Piping Accessories .............................................................................................. 26
Part 4 – Owner’s Technical Requirements – Book 4.1 – Chapter 13: General Technical Requirements
Rev 4 – May, 2014 Page 2 of 54
13.9.3. Piping ............................................................................................................................ 27

13.9.3.1. General............................................................................................................... 28
13.9.3.2. Layout ................................................................................................................ 29
13.9.3.3. Design Velocities ............................................................................................... 30
13.9.3.4. Drain and Vents .................................................................................................. 31
13.9.3.5. Stress and Flexibility Analysis ............................................................................ 31
13.9.3.6. Materials Cleanliness, Packaging and Handling .................................................. 32
13.9.3.7. Hangers and Supports ......................................................................................... 33
13.10. PUMPS.............................................................................................................................. 35
13.10.1. General ......................................................................................................................... 35
13.10.2. General Design and Construction................................................................................ 35
13.10.3. Pump Characteristics ................................................................................................... 36
13.10.4. Fittings .......................................................................................................................... 36
13.10.5. Bearings ........................................................................................................................ 37
13.11. UNFIRED-PRESSURE VESSELS AND STORAGE TANKS ....................................... 37
13.11.1. Unfired-Pressure Vessels ............................................................................................. 37
13.11.2. Storage Tanks............................................................................................................... 37
13.11.3. Tank Connections ........................................................................................................ 38
13.11.4. Accessories.................................................................................................................... 38
13.12. HEAT EXCHANGERS .................................................................................................... 39
13.13. PLATES AND STEEL SECTIONS ................................................................................. 39
13.14. CASTINGS ....................................................................................................................... 39
13.14.1. Steel Castings ............................................................................................................... 40
13.14.2. Cast Iron Castings ........................................................................................................ 41
13.15. FORGINGS ...................................................................................................................... 41
13.16. BOLTS, STUDS AND NUTS ........................................................................................... 42
13.17. CORROSION PROTECTION & PAINTS ..................................................................... 42
13.18. THERMAL INSULATION .............................................................................................. 47
13.19. ELECTRICAL, CONTROL AND INSTRUMENT PANELS/CUBICLES.................... 49
13.19.1. Panel Lighting and Heaters ......................................................................................... 49
13.19.2. Wire and Terminal....................................................................................................... 49
13.19.3. Electromagnetic Interference ...................................................................................... 49
13.19.4. Panel/Cubicle Classification ........................................................................................ 50
13.20. PROHIBITED MATERIALS .......................................................................................... 50
13.21. ENVIRONMENTAL PROTECTION ............................................................................. 50
13.21.1. Environmental Management Plan (EMP) ................................................................... 50
13.21.2. Environmental Training .............................................................................................. 52
13.21.3. Monitoring Requirements for Construction and Commissioning Works .................. 52
13.21.4. Reporting Requirements .............................................................................................. 52
13.21.5. Auditing Requirements ................................................................................................ 52

13.21.6. Environmental Incidents .............................................................................................. 53
13.21.7. General Environmental Responsibilities of Staff Employed by the Contractor ......... 53
13.1. OVERALL REQUIREMENTS

The Bidder must design, install, construct and commission the Units so as to ensure that
the Units is suitable to be run continuously at high availability and reliability.
All Equipment must be good fit for purpose.
Equipment proposed to be used by the Bidder must be new and unused and must be
manufactured by manufacturers with sufficient experience of the particular equipments
proposed for the power station.
Areas with potential flammable atmosphere must be classified in accordance with the
provisions of the internationally recognised standard. Suitably certified Equipment must
be used in the designated hazardous areas. To the maximum extent practicable,
Equipment requiring operator attention and/or electrical equipment must not be installed
in hazardous areas.
For design of all platforms and footpaths, the minimum clearance height is 2.2 m and all
the lifting platforms and walkways must be provided with stop bar.
Dangerous areas for equipment must be designed in conformity to the appropriate safety
regulations by striving to reduce the hazard to the minimum.
Motorised lifting devices, ie. hoists, chain pulleys, jacks, etc. must be provided for
handling and carrying out maintenance of any equipment and / or part having weight in
excess of 500 kg. Suitable beams, hooks etc. for this purpose must be provided in the
buildings.
All Equipment must be protected from ingress and damage by dust and humid
atmosphere and be designed to prevent the entry of vermin, insects or animals which
could result in short circuits or damage. Outdoor Equipment must be weatherproof and
designed so that water cannot collect at any point. The undersides of all tanks must be
ventilated or suitably treated in an approved manner to prevent corrosion.
Rotating or any other moving part of the machinery, hot parts or any part that may cause
accident to the staff must be adequately protected, in accordance with the safest method
known.
A uniform system of padlocks, keys and key cabinets must be supplied for all the Facility
items such as valves, switchgear isolators etc., which have to be locked off for operation
safety and/or prior to the issue of “Permit to Work” for the maintenance. All HV Room
doors should be lockable with a master key. All access ways, platforms stairs, handrails
etc must be in accordance with the relevant international and Vietnamese standards. The
minimum width of access ways must be 900mm and the minimum headroom must be
2200mm. Where the travel distance to the nearest exit from a platform exceeds 23m, a
secondary means of escape from the platform must be provided.
Safety showers and eye washes must be provided in all areas where chemical or
hazardous materials are stored or areas that have higher fugitive dust than normal.
13.2. PLANT IDENTIFICATION AND LABELING

13.2.1. Plant Identification System
The International SI system of units must be used for design, drawings, diagrams,
instruments, etc.
The Bidder must establish a single identification numbering system for items
throughout the Facility. A KKS (Kraftwerk Kennzeichnungs System) comprising of at
least 15 alphanumerical characters must be used to identify all equipment and

components of the Facility. The coding of an item must consist of the following fields:
UU/SSS/SS/EEE/CCC/NN
Where: UU = Unit
SSS = System
SS = Sub-system
EEE = Equipment
CCC = Component
NN = Sub-component or other use (such as small valves, instrument etc).
KKS system must be applicable to all the electrical (including cable) & mechanical
plant & equipments and civil structures/buildings.
The identification numbers must be shown on the manufacturer’s drawings.
The Bidder must prepare and submit comprehensive plant identification schedules to
Owner for review showing the name and identification code of each item of the
Facility. The codes must be shown in the respective drawings of the items.
The proposed identification system must be integrated into the DCS and other
computer management systems to facilitate the searching of items, order replacement
and maintenance planning.
The Bidder must provide detailed training sessions for the use of KKS system.
13.2.2. Numbering System, Nameplates and Labels
The Bidder must supply all labels, nameplates, tags, instruction and warning plates
necessary for the identification and safe operation of the Plant. All nameplates on
equipment must be written in Vietnamese and English. The format must be submitted
to Owner for review during detailed engineering stage.
All labels, nameplates, instruction and warning plates must be securely fixed to items
of Plant and equipment with stainless steel rivets, plated self tapping screws or other
approved means. The use of adhesives will not be permitted. Marks must be
undeletable and clearly visible. Marks made only with paint will not be accepted.
Nameplates and labels must not hinder the normal operation of the Equipment.
The Bidder must submit for Owner’s review a list showing the inscription (in the form
which it will appear on the label), type, size and fixing method proposed to be used for
each label. The inscription must include the plant identification number, plant system
and equipment description and function.
Nameplates for Plant and Equipment identification and record purposes must be
manufactured from stainless steel with a matt or satin finish and engraved with black
lettering of a size which is legible from the working level.
Warning plates must be manufactured from stainless steel with a matt or satin finish,
engraved with red lettering and sited in a position which affords maximum personnel
safety.
All Equipment within panels and desks must be individually identified by satin or matt
finish stainless steel labels, laminated plastic labels or manufacturer’s standard labels
subject to the review of Owner.
Each circuit breaker panel, electrical control panel, relay panel, etc. must have a circuit
designation label engraved with black lettering in accordance with the circuit
designation system. Corridor type panels must additionally have circuit designation
labels within the panels.
Each valve must be fitted with a stainless steel nameplate indicating the valve service
and reference number.
Valve nameplates must be fixed where necessary to a 3mm thick steel backing plate
with steel bracketing and painting agreed by Owner. The mounting must be such that
the label is absolutely clearly associates with the respective valve, and fixed in such a
way that the valve may be maintained or removed and replaced without disturbing the
label. Groups of small instrument valves may be labeled by a single label plate which
shows the valve arrangement and otherwise meets the requirements as listed above.
The pipe identification must include the flow direction arrow in addition to what is
specified.
All unfired pressure vessels and lifting tackle must have permanently attached to it or
stamped on it, in a conspicuous position, a rating plate giving such details as the design
code, design parameter, test parameter, date of test, etc., to the review of Owner.
Labels must be provided on front and rear access doors of all cubicles. Labels must
also be provided inside cubicles to assist the identification of apparatus and terminals.
The description and number of each item of plant must be consistently applied
throughout all drawings, manuals, documents and labels.
Labels/signage for safety, hazardous and dangerous goods including flammable and
toxic gases, acids and alkalis must be in accordance with local works safety
requirements and relevant Vietnamese standards.
All interconnecting pipes including those in trenches and all pipes carrying potentially
hazardous substances must be colour coded and have pipe markings on the outer
surfaces complying fully with relevant Vietnamese standards.
13.3. HAZARDS & OPERABILITY (HAZOP) STUDY

The Bidder must appoint an independent and qualified third party consultant to organize
and run a comprehensive HAZOP study for the whole Plant once the preliminary design
for all systems are complete. With the advice of the consultant, the Bidder must organize
various HAZOP teams consist of personnel of design, operation and maintenance
expertise to review the hazards and operability of various systems. The Bidder must track
and report on progress associated with resolving actions raised during the study and
present the Owner with a complete dossier showing the original minutes and the actions
taken to resolve issues raised. The design must then be modified to incorporate the
recommendations from the HAZOP study.
Wherever possible, the HAZOP study must be carried out before the finalization of the
design to allow the incorporation of the modifications made.
Hazardous Area Classification:
The Bidder must carry out a thorough, comprehensive plant-wide assessment of all areas
that could be deemed hazardous in accordance with IEC 60079/10 and must design the
electrical equipments to meet all the requirements of the relevant codes and standards.
The Bidder must submit a list of potentially hazardous areas as part of the HAZOP Study.
The Owner has identified that the following plant areas or systems may be classified as
hazardous based on industry practice and experience. Such areas include, but not limited
to:
 Fuel oil storage area
 Fuel oil pump house
 Turbine lubrication oil system

 Generator sealing oil system
 Generator hydrogen system
 Diesel generator oil storage Area
 Fire fighting pump (diesel driven) oil storage area
 Chemical storage area
 Hydrogen generation plant and hydrogen pipe routes
 Boiler coal bunker area
 Coal conveyors and transfer towers
 Cover coal yard
 Coal feeders and pulverizer mill system
 Boiler burner operating floors
 Chlorination plant
 Absorbing tower of FGD
 Liquid Ammonia or Urea Storage Area for SCR (optional)
13.4. MATERIAL AND WELDING

13.4.1. General
The Materials used under this Project shall be such as to insure an efficient service life
for each part of the machinery. In particular, material shall not be of inferior quality to
that specified below, or stated in the various sections of these Specifications or
specified in the Standards.
Materials that are injurious to personnel such as asbestos, polyvinyl chlorinated
biphenyl (PCB’s), tar-epoxy paint, etc shall not be used.
13.4.2. Materials
The following ASTM codes or equivalent shall be referenced:
Cast iron ASTM A 48 Class No. 30
Sheet steel for general use ASTM A 284 Grade C
Structural steel and plates ASTM A 36, ASTM A 242
Cast steel ASTM A 27 Grade 65-35
Forged steel (shaft for auxiliary ASTM A 235 Class G
machinery)
Corrosion resistant cast steel ASTM A 296 Grade CA-15
Steel for boiler drums ASTM A 302 Grade B ASTM A 299
Steel pipes for max. design temperature:
 not exceeding 350oC and 100 bar ASTM A53
 not exceeding 425oC ASTM A 106 Grade B, C
 between 425OC and 525oC ASTM A 335 Grade P 12
 between 450OC and 525oC ASTM A 335 Grade P 11
 above 525oC ASTM A 335 Grade P 22, 91

Steel tubes for boiler for max. design
temperature:
 not exceeding 425oC ASTM A 210 Grade A1
ASTM A 213 Grade T12
 between 425oC and 475oC ASTM A 210 Grade T 2, 12
 between 475oC and 525oC ASTM A 213 Grade T 12, T 22
 between 525oC and 600oC ASTM A 213 Grade T 22, 12, 11
Grade TP 321 H
 above 600oC ASTM A 213 Grade T 9
ASTM A 213 Grade TP 304 H
ASTM A213 Grade TP 321 H
Steel tubes for heat exchangers ASTM A 210
Valve body for max. design temperature:
 not exceeding 425oC SCS 13, 14
ASTM A 351 CF 8
ASTM A 217 Grade 69
ASTM A 216 Grade WCB
ASTM A 105 Grade 1
ASTM A 182 Grade F1, F304, F316
 between 425oC and 525oC ASTM A 217 Grade WC 6 or
ASTM A 182 Grade F1, F11,F22, F304,
F316
 above 525oC ASTM A 217 Grade WC 9 or
ASTM A 182 Grade F22, F91, F304, F316
Forged steel for HP and IP turbine rotors ASTM A 293 Class 6
Forged steel for alternator rotor ASTM A 293 Class 2 or 3
Cast steel for turbine HP and IP casings ASTM A 356 Grade 9
Forged steel for gears ASTM A 291 Class 1
Cast bronze ASTM B 143 Alloy 1 B or 2 B
Bronze for bearings, bushes, thrust shoes, ASTM B144 Alloy 3 A
etc
White metal for bearings ASTM B 23 Alloy No.3
Electrolytic copper minimum
purity
99.90%
Silicon steel laminations for generators ASTM A 345
Silicon steel laminations for transformers ASTM A 345
The materials not expressly specified shall conform to the most recently published
ASTM specification regarding the class or type of those materials.
In case materials adopted are classified according to other material specifications, the
Contractor shall submit the equivalence to materials manufactured to ASTM standards.
13.4.3. Test on Materials
Materials used for this Project must be tested in accordance with the Standards. In the
various Sections are described the tests which must be witnessed in order to verify the
correspondence of the material characteristics with those established in this
Specification.
Mill certificates or billets tests shall be provided for materials of major equipments and
forged, structural steel components.
All tests shall be carried out in accordance with relevant ASTM standards, Parts 30-31-
32 or equivalent.
All apparatus, services and costs for such tests will be the responsibility of the
Contractor.
13.4.4. Welding and coupling
13.4.4.1.General
All welding and coupling performed in pursuance of this Contract shall conform to
the approved standards.
In order to obtain the acceptance by the Owner the Contractor shall show that the
proposed welding specification and standards do not conflict with the requirements
of this Specification, and are in agreement and consistent with the design Codes
adopted for the relevant sections of the work.
Where there is conflict between Codes and Standards the Owner shall decide which
shall prevail.
The Contractor shall provide all necessary plant, labour, equipment, appliances,
materials and consumables required to perform all operations in connection with the
welding and coupling outlined in this Contract. All equipment, plant and appliances
shall be of good quality, well maintained and entirely suitable for the intended
purpose.
The Contractor shall be responsible for the compliance of his personnel and
equipment with all applicable regulations and requirements issued by the Socialist
Republic of Vietnam and other International Organizations for cutting and welding
operations and for the use, handling and storage of radioactive sources and isotopes.
All costs for inspection and testing including any additional tests required by the
Owner shall be deemed to be included in the Bid price. When additional inspection
and testing is required by the Owner it shall be performed promptly and no claims
for consequent delay or disruption of the work will be considered.
The Contractor shall co-ordinate his activities so that all inspection work can be
carried out for inspection by the Owner before removal of scaffolding or before the
weld areas are painted. The welding shall be carried out under the supervision of
competent welding supervisors. The welding supervisor appointed to the Site shall
Rev 4 – May, 2014 Page 10 of 54
be well experienced in the supervision of welding on construction sites and shall

have had prior experience of work to the standard indicated in this Specification.
The welding supervisor(s) shall have qualifications and demonstrated ability
satisfactory to the Owner.
13.4.4.2.Welding Procedure Documents
Prior to the commencement of welding the Contractor shall submit to the Owner for
acceptance the welding procedures to be used in the fabrication of the relevant
sections of the work. Welding procedures shall be designed to give a weld
reinforcement height of 1.5 mm minimum to 3 mm maximum. Fabrication and
attendant welding activities shall not commence before the procedures are accepted.
13.4.4.3.Welding Procedure Qualification Tests
Welding procedure qualification test shall be carried out in accordance with the
requirements of the appropriate approved standard for the item of plant under
consideration. Subject to agreement, the Owner will accept the results of welding
procedure qualification test previously carried out under the supervision of any
internationally recognized inspecting authority, providing that the Contractor
confirms that the basic parameters of the procedure have not been changed.
The Contractor shall inform the Owner of any proposed changes to the welding
procedures before such changes are implemented. If in the opinion of the Owner a
further qualification test is required as a result of such changes, then the Contractor
shall perform the required test without additional charge.
The results of all tests shall be made available for examination and copies shall be
retained on Site.
13.4.4.4.Welders Qualification Tests
All welders and welding operators for boiler pressure parts and unfired pressure
vessels shall be qualified for the work and shall hold current welder's qualification
certificates in accordance with the latest edition of the ASME Boiler and Pressure
Vessel Code Section IX, "Qualification Standard for Welding Procedures, Welders
and Welding Operations" or equivalent.
All welder’s tests shall be witnessed and/or approved by the Owner before the
welder or operator is permitted to work. The decision of the Owner regarding the
acceptability of any test or existing qualification shall be final. Evidence of previous
qualification tests shall be accepted solely at the discretion of the Owner.
Records showing the date and results of the qualification tests performed by each
welder and weld operator together with the identification number assigned to him
shall at all times, be available for scrutiny by the Owner.
Each qualified welder and weld operator shall be assigned a unique identifying
number. This number shall be marked in indelible crayon on all work performed by
the welder to whom it is assigned. Any welder or weld operator whose work is
subject to multiple rejections will be required to undergo a re-qualification test on
the appropriate weld procedure. At the discretion of the Owner any welder or weld
operator failing a re-qualification test may be disqualified from any further welding
on the Works.
13.4.4.5.Storage of Welding Consumables
All welding electrodes, wire and fluxes shall be stored in a clean dry place and
protected from all forms of deterioration prior to use.
Rev 4 – May, 2014 Page 11 of 54
All welding consumables shall be properly identified and shall retain their
identification up to the time of use. Each batch of electrodes and wire shall be
identifiable with the respective manufacturer's test certificate and advice note and
shall be used in strict delivery rotation.
Electrodes which have damaged flux coatings, are bent, mis-shapen or have lost
their identification, shall not be issued or used on any work covered by this
Specification.
13.4.4.6.Fabrication
The Owner shall be notified at least two days prior to the commencement of any
assembly or fabrication work.
Welders and welding shall be protected by suitable equipment from wind, air borne
sand, and moisture. Work shall not be performed when weather conditions do not
permit satisfactory workmanship or adequate inspection.
All flame cutting and oxy-acetylene welding at Site shall be controlled to ensure
freedom from fire hazard, and shall only be undertaken with the general knowledge
of the Owner. All welding and cutting operators shall be accompanied by a fire
attendant who shall be equipped with suitable approved fire extinguishing and
alarm equipment. The necessary disciplinary action will be taken against
Contractors contravening these requirements.
Weld preparation profiles may be prepared by machining, shearing, flame cutting
and grinding and shall be performed carefully and accurately both at the factory and
Site. Whenever possible a mechanically guided tool shall be used for flame cutting.
All edges shall be left free of slag, burrs, fins, oxides and foreign matter and the
finished profile shall conform to the designed tolerances for the weld preparation.
Approved line up clamps shall be used and shall not be removed until the root weld
has been completed. Where spacer strips or bridging pieces are utilized due care
shall be taken when the tack welds are removed. All scars and blemishes shall be
ground off prior to submitting the weld for inspection.
Tack welding of weld preparations may be permitted but all tacks must be ground
to a feather edge prior to completing the root pass. Electrodes and pre-heating for
tack welds shall be the same as that required for the completion of the weld. Any
defective tack weld shall be removed prior to welding the root pass.
Where preheating is required it shall whenever practical be carried out by electric
resistance or induction equipment or by specially shaped gas burners. Pre-heat and
interpass temperatures shall be checked by temperature indicating crayons at a
distance of not less than 75 mm from the weld groove. The use of hand weld
torches for pre-heating will not be permitted.
All slag, excess filler metal, and surface irregularities shall be removed between
weld interpass runs. Cleaning may be carried out by hand or power tools. Flame
gouging is prohibited.
Back chipping may be carried out by arc gouging providing that the weld groove is
ground to a smooth profile and all surface irregularities arising from the arc air
process are removed.
Welded on attachments such as lugs, cleats, supports, etc. shall be positioned well
clear of all pressure retaining welds and welds carrying principal stresses. If it is
found essential to bridge or span a principal weld then the attachment shall be so
designed to ensure that no further weld is positioned within 40 mm of the principal
Rev 4 – May, 2014 Page 12 of 54
weld. Attachments bridging principal welds shall be designed to give a minimum

clearance of 25 mm over principal welds.
Attachment welds shall have a contour which is free from notch effects at the weld
junction. Such welds shall be made only by welders qualified for welding under the
requirements of an approved standard.
All transition welds between dissimilar materials will be made under controlled
conditions at manufacturer's works. Site welding of structural high yield steel shall
not be permitted without the prior consent of the Owner.
All tube butt welds shall have 100% penetration with a maximum of 3 mm excess
penetration in the root run.
Unless otherwise specified welds subject to radiographic, ultrasonic or other forms
of non-destructive test shall be dressed to a smooth contour. Care shall be taken to
blend weld and parent metal without underflushing. Branch and attachment welds
shall be finished to a smooth contour and the toes of the weld shall be dressed
smooth. Welds made by submerged arc process or other approved automatic
methods may be left unfinished providing the weld ripple does not interfere with the
assessment of non-destructive test results. All weld dressing shall be carried out
before final heat treatment.
Post weld heat treatment shall be carried out using equipment specifically designed
for the process. Gas burners or hand held torches will not be permitted. For work
which is heat treated in a furnace, the Contractor shall supply copies of the heat
treatment charts. Work which is subject to heat treatment by means of electrically
heated elements shall be monitored by suitable thermocouples connected to a chart
recorder. A minimum of two thermocouples shall be used and copies of heat
treatment charts shall be made available to the Owner.
For pressure vessels 50 mm thick and above, in addition to the considerations
mentioned elsewhere in this Specification in respect of pressure vessels, the
following shall apply:
At the detailed design stage, full consideration must be given to the complex
residual stress systems existing around discontinuities such as nozzle openings. The
toes of all fillet welds, securing attachments and any other internal fittings should
not be allowed to approach nearer than 38 mm to the toes of large fillet welds of
nozzles, or undressed main seam welds.
In no case shall the cleaning of all welds prior to painting be effected by the use of
acidic applications. No weld shall be painted until 72 hours has elapsed after
completion of welding and stress relief.
On completion of fabrication at the Contractor's works, the internal and external
surfaces of pipes, etc., shall be clean, dry and shall be adequately protected from
atmospheric corrosion. Branches and other openings shall be adequately protected
from damage and sealed against ingress of dirt and moisture. Details of the method
of protection shall be submitted to the Owner for approval.
13.4.4.7.Visual Weld Inspection
Each weld shall be subjected to a stringent visual inspection. Welds shall be free
from undercut, excessive spatter, craters, cracks, porosity and other surface
imperfections. Weld reinforcement shall be of regular contour, even weld ripple and
indicative of good workmanship.
Rev 4 – May, 2014 Page 13 of 54
Fillet welds shall be checked for dimensional tolerance and form using an approved
fillet weld gauge. It is preferred that fillet welds shall be slightly concave in form
and each leg of the weld shall have equal length.
13.4.4.8.Non-Destructive Examination
All non-destructive examinations shall be supervised by a fully qualified and
experienced specialist appointed by the Contractor. Individual operators in each of
the respective techniques shall be qualified and trained in the respective subject.
13.4.4.9.Radiographic Techniques
Radiography shall be carried out in accordance with the requirements and
recommendations of ASME or other appropriate International Standard as agreed
by the Owner.
A radiographic report shall be issued for each weld examined. The report shall give
full details of the procedure used for the examination together with the thickness
and type of intensifying screens, film type and specification and source of film
distance. The sensitivity of all radiograph films shall be 2% or less, as indicated by
the image quality indicator.
The Contractor shall supply a minimum of two radiation survey meters to the Site
for use by classified staff and by the Owner as required.
The Contractor shall take all steps possible to protect personnel, visitors, and
classified staff from the effects of Ionising Radiations. The Contractor shall keep an
inventory of all Radioactive sources supplied to the Site and shall be responsible for
ensuring that safe procedures are used for the use, handling, and storage of such
sources. The Contractor shall comply with all Statutory Requirements and any site
instructions in force for the Registration Control and use of Ionising sources. The
storage procedure for radioactive sources shall be to the Owner's approval.
The Contractor's site procedures for storage of unexposed radiographic film and
photographic chemical shall be provided to the Owner upon request.
The Contractor shall provide all necessary equipment and facilities for viewing
radiographs. A suitable dark room shall be provided with air conditioning
equipment as required by the Owner. Viewing equipment to be provided to the site
shall be entirely suitable for the examination of weld radiographs of variable size.
All viewers shall be capable of providing high intensity illumination operated from
a suitable footswitch. At maximum setting all viewers shall have illumination
suitable for radiographs with a standard density reading of 4. A high intensity
illuminator with an adjustable shutter shall be provided to supplement the standard
viewers.
All radiographic films shall be retained on site by the Contractor to be available for
reference by the Owner until the end of the guaranteed maintenance period.
13.4.4.10. Dye Penetrant Tests
Dye penetrants shall be of the water soluble ink type and shall comply with an
agreed Standard.
13.4.4.11. Internal Examination
Wherever possible the internal root bead shall be examined by intrascope or other
suitable optical device.
Rev 4 – May, 2014 Page 14 of 54
13.4.4.12. Weld Repairs

The Owner shall be informed of the necessity for repair or rectification work before
any attempt is made to carry out such repair; approval shall be obtained prior to
commencement of the work.
Weld repairs shall be made to the same procedure as for the original weld. All tests
shall be repeated after the repair has been completed and reports on radiographic
and/or ultrasonic tests shall be marked to indicate that the report refers to a repaired
weld.
13.4.4.13. Quality Requirements for Welds
All welds subjected to non-destructive tests shall be entirely free from cracks or
crack-like defects, lack of root fusion, lack of sidewall fusion, root burn through,
tailed pores. The standard for porosity and slag inclusions will be as indicated in the
agreed standards for design and welding.
13.4.4.14. Mandatory Inspections
Unless otherwise specified, all transition welds and welds on low alloy materials
and high yield steels shall be subjected to 100% ultrasonic examination. In addition,
all butt welds on these materials shall be subjected to radiographic examination and
crack detection. A minimum of 20% of all butt welds of all pressure parts shall be
radio graphically tested (RT) or comply with ASME or equivalent criteria which
approved by the Owner. When one or more defect(s) are found by RT in a lot which
means welding portions welded by a welder or group of welders in one day, an
additional 20% RT shall be required for the inspection of the lot. If more defect(s)
are found after the additional RT, all of the welds in the lot shall be examined by
RT.
13.5. PROTECTIONS, GUARDS AND SUNSHADES

All hot parts with surface temperature exceeding 50oC are to be adequately insulated.
All exposed moving and rotating parts shall be protected by guards to prevent danger to
personnel.
If the pumped product is of a highly inflammable nature or if the pump is to be installed
in a hazardous atmosphere the following additional requirements shall apply for the guard
materials:
a) To be non-sparking and all parts to be electrically bonded to the machine structure
to prevent a static charge build-up.
b) Glass re-inforced or other types of plastics to have trace materials incorporated to
ensure the required anti-static properties.
c) Galvanized steel shall not be used as it is not considered to be spark proof and as,
if installed near to stainless steel pipework or other equipment, it could promote
weakening of the stainless steel due to zinc embrittlement in the event of high
temperatures occurring.
The normal operational areas of outdoor equipment shall be provided with sunshades.
The sunshades shall be adequately sized to protect the areas from direct sun radiation
down to 45o to the horizontal. The sunshades shall give sufficient head clearance to
permit walking and working space for normal maintenance with adequate artificial
lighting as necessary.
Where small items of plant and equipment are concerned the sunshades shall be sized to
shade all the plant.
Rev 4 – May, 2014 Page 15 of 54
The number, position and design of all sunshades shall be as agreed with the Owner. The
sunshades shall be arranged with adequate roof drainage, if required.
13.6. PLATFORMS, WALKWAYS, STAIRS AND LADDERS

13.6.1. Platforms and Walkways
The Contractor shall supply all platforms, walkways and stairs necessary for providing
safe and proper access to the plant for operation and efficient maintenance. Due
allowance shall be made in the design for thermal expansion.
The Contractor shall ensure that the type of flooring stair treads and handrails conform
to a uniform pattern throughout the whole of the Contract Works with the exception of
any ornamental handrailing.
The Contractor shall also provide and erect all necessary interconnecting floors,
platforms and walkways to facilities for convenient operation and access.
All flooring, platforms, walkways and stairs used for access in and around the vicinity
of the plant or where maintenance loads will be applicable shall be designed for an
imposed load of 0.5 t/m2. Where only minor irregular access is required and the
flooring shall not be subjected to maintenance loads, the platforms, walkways and
stairs may be designed for an imposed load of 0.2 t/m2. These loadings shall be
additional to the dead weight of the platforms, walkways or stairs and any additional
load in excess of the loads quoted.
All platforms and walkways shall be constructed using open grid floor panels of the
rectangular pattern. The depth of the floor panel shall not be less than 32 mm.
All platforms and walkways shall be designed with a minimum headroom clearance of
2.2 m. All platforms and walkways floors shall be provided with toe plates having a
minimum height of 100 mm above floor level. Toe plates shall have a minimum
thickness of 6 mm and shall not be fixed to the flooring panels.
Flooring of chequer plate type shall be provided where necessary to the approval of the
Owner. Chequered plates should be of mild steel on the location where they are
required and to the approval of the Owner.
Open grid flooring shall be of mild steel and galvanized.
Any openings cut into any flooring shall be finished off with a welded edging strip in a
manner similar to toe plates.
The minimum width of walkways shall be 700 mm, unless otherwise specified or
agreed with the Owner.
13.6.2. Stanchions and Handrails
All platforms, walkways and stairways shall be provided with stanchions and double
handrails on each side. Handrail heights, measured vertically between the top of
handrails and the floor level or, in the case of a stairway, the pitch line shall not be less
than:
Top Rail Lower Rail
 Platforms 1,070 mm 535 mm
 Stairways 840 mm 420 mm
Steel handrails and stanchions shall be galvanized.
The bases of stanchions shall be of the flat or side palm type for use on platforms and
the flat base type for steel stairways.
Rev 4 – May, 2014 Page 16 of 54
Tubular or solid forged stanchions shall not be spaced at pitches greater than 1.5
meters.
Stanchions shall not be fixed to toe plates.
Handrails shall be of tube having minimum 32 mm outside diameter.
Handrails at the bottom of stairways, where not fixed to a wall or stanchions, shall be
extended to form a loop between the top and bottom rails. There shall be no joints in
these loops.
Connections between the ends of handrails and walls or steel columns shall comprise
flanged connections each having an internal dowel for fitting inside the handrail tube.
The handrail end flange connection shall be drilled for two fixings when fitting to
concrete or brickwork or where drilling of steelwork is permitted, otherwise
connections to steelwork shall be welded.
13.6.3. Stairs
Stairs shall be used wherever necessary. Ladders shall only be used subject to the
approval of the Owner.
Steps of stairs shall be constructed using open grid floor panels. The depth of the floor
panel shall not be less than 32 mm.
Steps of chequered plate type shall be provided where necessary to the approval of the
Owner.
Wherever possible the angle of slope for stairs shall be standardized at 38o or 42o to
the horizontal.
Stairs in frequent use in both directions shall preferably have an angle of slope of 38o.
Stairs giving access to plant and between floors may have an angle of slope of 42o.
The minimum width of stairs shall accommodate stair treads having a length of 700
mm. No flight shall have more than 16 risers with a maximum height of 3.36 m for a
slope of 42o or 3.15 m for a slope of 38o.
Where a stairs height exceeds 16 risers, each flight shall be equal and separated by a
landing. Where a stairs comprises more than two flights, a change of direction shall be
made between adjacent flights and all changes of direction shall be in the same
direction either left hand or right hand.
Stairs landings shall be fitted with toe plates having a minimum height of 100 mm
above landing floor level and a thickness not less than 6 mm. Toe plates shall not be
fixed to the flooring panels.
Minimum headroom shall be 2.2 m. Risers and treads shall be in accordance with the
following:
Riser Tread
Angle of Slope Min. Max. Min. Max.
mm mm mm mm
38o 190 200 240 250
42o 200 210 220 230
Handrailing as specified shall be fitted to both sides of stairs whether the sides are
open or not. Stairs exceeding 2 m in width shall be fitted with a central handrail and a
centre support, for the stair treads.
13.6.4. Steel Ladders for Fixed Access
Ladders shall comply with the requirements of the approved standard.
Rev 4 – May, 2014 Page 17 of 54
Where space allows, ladders should be inclined to the horizontal by not less than 70
degree to the horizontal.
13.7. FIRE PROTECTION REQUIREMENTS

Unless otherwise specified or agreed with the Owner, the following design principles
shall be observed as minimum fire prevention requirements:
a) All the equipment and superstructures shall comply with the Vietnamese fire
fighting law and local regulations of fire protection.
b) All pipeline insulation materials, cable materials and wall sealing materials shall
be of the non-combustible type.
c) All pipelines or vessels which have internal temperatures exceeding 180 0C shall
be properly arranged to avoid contact with flammable liquids if such leakage
should happen.
d) Special care shall be taken to eliminate the risk of soaking hot pipeline insulating
material with liquids that may leak from flammable liquid lines.
e) Cable and pipeline ducts shall be laid at the best possible location to avoid them
from being flooded with flammable liquids.
f) Covered floor ducts must be easily accessible for inspection and cleaning.
g) The plant components and equipment shall be arranged to reduce the formation of
sharp corners or pits which shall be difficult for inspecting and cleaning of
flammable matters or liquid trapped in it.
13.8. LOCKS AND KEY CABINETS

Where padlocks are supplied they shall be of non-ferrous material. Three keys are to be
supplied for each lock, each key and lock being suitably labeled and stamped. All locks
and keys are to be non interchangeable.
Where a set of locks is provided under any particular section of Plant or apparatus a group
master key is to be supplied in addition.
Suitable wall mounting metal cased key cabinets, complete with label and integral barrel
lock in the access doors shall be supplied, one each for the keys supplied with each major
item of Plant. These cabinets shall have labeled hooks. The cabinets shall be wall
mounted, suitably matching in colour and finish.
All necessary features, including locks and keys, for plant and equipment which require
locking in either operation or isolated position for safety, are deemed to be included in
this Contract.
13.9. PIPING, VALVES & FITTINGS

All the piping systems be designed to operate without replacement and with normal
maintenance for a plant service life of 40 years, and must withstand the operating
parameter fluctuations and cycling which can be normally expected during this period.
This section of specification covers all low pressure piping handling fluids like raw water,
clarified water, cooling water, DM water, IDO, condensate, compressed air, hydrogen etc.
13.9.1. Code & Standards
The design, manufacture, shop testing, erection, testing and commissioning of piping
and valves must conform to the latest revisions of the following codes and standards,
Rev 4 – May, 2014 Page 18 of 54
in addition to the other mandatory Vietnamese standards mentioned elsewhere in the

OTR:
BS: 5152 CI globe valve.
ANSI:B 16.5 Steel pipe flanges and flanged fittings.
ANSI:B 31.1 Power Piping code.
ASTM A 106, Gr. C Schedule 80 - Seamless carbon steel pipe
ASTM A 312 Grade TP-316 Schedule 40s - Stainless Steel pipes
ASTM D 3517 / 4024 GRP pipes
Material of construction for pipes carrying various fluids must be as below:
No Service Recommended Material
1. Raw water Carbon Steel /GRP
2. Clarified water/Filtered water HDPE/GRP
3. Potable water HDPE
4. Fire fighting water HDPE
5. Acidic Water Rubber lined Steel/SS
6. Demineralised Water MS Rubber lined /SS
7. Acid (hydrochloric) MS Rubber lined /SS
8. Alkali (Sodium Hydroxide)
a) Strong (5% & above) Stainless Steel
b) Dilute Rubber lined/ Stainless Steel
9. Alum Solution Rubberlined Steel
10. Lime Solution/Suspensions Galvanised Steel
11. Coagulant aid Solution Rubberlined Steel
12. Liquid & Gas Chlorine (Under Seamless Carbon Steel Schedule 80 (Heavy
Pressure) Duty)
13. Chlorinated Water Rubberlined Steel
14. Wet Chlorine gas (Under Polypropylene
Vacuum)
15. Sludge Cast Iron/ Ductile Iron
16. Instrument Air Galvanised Steel
17. Waste effluent from DM HDPE/ MS Rubberlined
13.9.2. Valves
All valves, must be suitable for service conditions i.e. flow, temperature and pressure
under which they are required. The valves must be of standard pressure rating as per
the relevant code/ standard.
Rev 4 – May, 2014 Page 19 of 54
For the pressure above 4 MPa in thermal system, all valves must be butt welded
excepting valves integral with the main plants and instrument valves. Flange
connection valves are not allowed unless they are specifically agreed by the Owner.
Parallel slide or globe valves must be used for all high pressure piping including but
not limiting to steam and HP feedwater.
Manually operated valves must be provided with reduction gear unit for valves of size
250 NB and above. Valve provided with motorised or pneumatic actuator must be
provided with a hand wheel for manual operation.
All the valves must be equipped with adjustable mechanical stop-limiting devices to
prevent over travel of the valve disc in the open and closed positions.
Sluice valve/knife edge type slide valves must be used in the sludge and drain pipe
line.
Valves for acid & alkali services must be proven patented diaphragm type. Diaphragm
must be of reinforced teflon or equivalent for acid services and reinforced
neoprene/hypalon or equivalent for alkali services.
13.9.2.1.General
The Contractor shall select valves, valve drives and accessories which are suitable
for the operating conditions of the systems in which they are to be used, and shall
be responsible for the pressure and temperature ratings of the selected components.
The selected components shall meet the requirements of trouble free and safe
operation under maximum load, part load and transient conditions.
Valves, valve drives and accessories which are of a similar make, size and type
shall be interchangeable with one another. The Contractor shall standardize the
types and the sizes of the valves as far as possible, in order to facilitate maintenance
and limit the stock of spare parts. The manufacturer of valves shall be reputable
company with acknowledged experience in the power industry.
All regularly operated isolation valves and control valves shall be accessible from a
permanent floor or access platform.
All valve bodies shall be of the same nominal size as the adjacent piping, unless
otherwise specified. The internal diameter of valve ends adjacent to the pipe work
shall be the same as the internal diameter of the connecting pipe.
All valves shall be located and designed so that the maintenance and change of
valve internals is possible without removing the valve casing from the pipe.
Valve travel shall have sufficient allowance to compensate for the reconditioning of
disc and seat.
The stems of all valves for outdoor service shall have weatherproof protection
covers of approved construction.
Each valve shall be fitted with nameplate.
Valves other than outside screw and yoke type, in size larger than 50 mm are to be
provided with gate position indicators.
Extension stems are to be provided for normally used valves to permit convenient
operation from adjacent levels.
Valve position locks, where required, shall be non-detachable. Handwheels shall be
of spoked construction, with smooth finished spokes and rims.
The spindles of all valves for use outside shall have weatherproof protection on
spindle bearings and guides.
Rev 4 – May, 2014 Page 20 of 54
All valves shall be arranged to open by counter-clock-wise rotation of the

handwheel and wheels shall be clearly marked with words and arrows to indicate
this. A nameplate shall be attached in a conspicuous location to each valve to
indicate material and designation. Valves shall not be installed with their stems in a
downward position unless approval is granted by the Owner/Engineer.
Stop valves on critical services including, but not limited to, lubricating oil pump
isolators shall be provided with locks to prevent incorrect operation.
All valve components with the exception of the seats, shall be replaceable without
removing the valve from the piping. If the design of the large size valves entails
welding various valve components together during manufacture, the welding is to
be furnace annealed at a controlled temperature and then radiographed. The films
are to be submitted to the Owner/Engineer for his examination and approval.
All valves are to be capable of withstanding a hydraulic pressure test for mechanical
strength and tightness (1.5 times their design pressure).
The minimum design pressure of any valve shall be 10 barg unless otherwise
specified.
All drain and vent valves above 40 bar rating shall be made up of two valves in
series. One isolating and one regulating type valve shall be installed; the isolating
valve shall be on the upstream side with the regulating valve on the downstream for
better interlocking, allowing the isolating valves to be opened first and closed last.
Unless otherwise specified, the bodies of valves of over 50 mm nominal bore not
subjected to temperatures of 218 0C may be of cast iron and of the wedge gate type.
Bronze valves of 50 mm nominal bore and below for service with steam, water or
oil may be used up to a temperature of 218 0C. Where the working temperature
exceeds the above figure or where warranted by pressure conditions, the bodies
shall be forged or cast steel.
Diaphragm type valves when used in the water system shall be of suitable
manufacture with plastic material or zinc free bronze bodies for valves up to 50 mm
nominal bore and of cast iron with neoprene linings for sizes above 50 mm nominal
bore.
The internal diameter of all valves at the ends adjacent to the pipes shall be the
same as the internal diameter of the pipe to which they are joined.
In the case of all welded valves, the stub ends of the valves must project from the
valve body a sufficient length to ensure that the welding process will not affect the
valve seats. Valves for lubricating oil services shall be flanged.
Steel-body valves of higher classes shall have either pressure seal or integral type
bonnet joints.
Bonnet joints for 300 kg valves shall be flanged. Gate and globe valves shall have
outside screw and yoke construction.
All valves except 300 kg gate valves shall have a seat of the integral type.
Class 750 and 1,250 kg globe for strainer blow-off piping and equipment drain
connections shall be of the Y-pattern blow-off type.
Valve discs and valve stems shall be stainless steel. Valve seats shall be stellite
faced except 300 kg valves that may have hardened stainless steel.
Bronze body valves shall have union type bonnet joints and renewable seats.
Valves subject to vacuum operation shall be furnished with lantern type glands with
a connection on the gland housing for sealing water application. For small valves
Rev 4 – May, 2014 Page 21 of 54
where gland sealing application is not practical, valves with extra deep stuffing box
glands shall be provided.
Electric valve motor actuators shall be "Limitorque" or approved equivalent for all
plant.
The valves which are operated at unit start-up and shut-down shall be remotely
operated.
To avoid the need for any temporary lifting device, permanent lifting devices shall
be provided where regular maintenance necessitate the removal of equipment.
13.9.2.2.Valve Position Indicators
Valves shall be fitted with indicators such that it may be readily seen whether the
valves are open or shut, and the extent of opening. In the case of valves fitted with
extended stems, indicators shall be provided both on the valve and at the extended
stem handwheel. Where remote indication is required, the valves shall be equipped
with limit switches mounted on the valves for electrical signal of valve positions
"open" and "shut".
13.9.2.3.Manually Operated Valves
All hand operated valves shall be easily operated by one man. Special attention
shall be given to the operating mechanism for large size valves with a view to
ensuring that a minimum of maintenance is required and quick and easy operation is
achieved.
Unless otherwise specified, manually operated gate, globe, or butterfly valves shall
be handwheel operated and plug valves or ball valves shall be wrench-operated.
Manually operated valves, whose handwheel centerline elevations are more than 2.0
m above the operator's access elevation, shall be provided with access platform or
valve floor stand.
Valve extensions stems, where required, shall be sturdily constructed and guided to
provide satisfactory service. Valve floor stands, where required, shall have the
height 1 m below the handwheels.
For valves with hot handwheels which are dangerous to be touched by naked hand,
operation shall be by remote handwheel.
Where necessary, ball bearings shall be provided in the extension gear to take the
thrust or weight of the extended stem. Forces being transmitted to the valve due to
pipe work expansion shall be prevented.
Grease gun lubrication shall be provided where necessary and the grease nipple
shall be of an approved standard to ensure uniformity throughout the power plant.
Manual gear operation shall be provided, as required, depending on the size and
pressure rating of the valve.
All gear operators shall be of the totally enclosed type, self-locking, with position
indicators.
All manually operated valves shall be arranged for closing with a clockwise rotation
of the handwheel. The words "open" and "shut", with adjacent arrows, shall be cast
on the rims of all handwheels in order to indicate the direction of rotation.
Where necessary, valves shall be equipped with a locking device which permits
locking in the open or closed position.
Rev 4 – May, 2014 Page 22 of 54
13.9.2.4.Motor Operated Valves

Preference will be given to motor operated valves to achieve a high level of process
automation. The Offer shall include a preliminary list of motor operated valves in
each of the plant areas.
Motor operated valves shall be supplied with electric actuators incorporating an
overload protection device in the form of a centrifugal clutch or other device which
ensures that the driving motor does not engage the drive until the motor has reached
full speed. A torque switch arrangement shall be included to prevent overtravel of
the valve in either direction.
Motor operated valves shall be provided with both motor and hand operating gear.
Electrically operated valves are preferred, however, should the Contractor consider
that an electric motor element would not satisfy the requirements he may offer
alternative methods which shall be approved by the Owner/Engineer.
The hand operating gear shall automatically disengage when the valve is power
operated. Unless otherwise specified valves shall lock in position on failure of the
operating medium.
Where a bypass valve is provided this shall also have both hand and power
operating gear and interlocked to ensure that the bypass valve is opened before the
main valve operates.
A handwheel and position indicator shall be provided for manual operation of the
valve. Provision shall be made for manual engagement of the handwheel at any
time except when the motor is energized during which time the handwheel shall be
automatically disengaged.
Motor operated valves shall be suitable for installation in any position without
lubricant leakage or other operating difficulties.
13.9.2.5.General Purpose Valves
(a) Gate and Globe Valves
All gate and globe valves, except bronze body valves, shall be of the outside screw
and yoke design with rising stems. Bronze body valves shall have union type
bonnets and rising stems.
Globe valves shall be used generally for regulating purposes.
Valves, DN 150 mm nominal size and larger, for service pressures above 40 bar and
2000C, shall be provided with bypass valves for balance upstream and downstream
pressure and for system warm-up. The bypass shall be integral with the main valve,
unless otherwise approved.
Gate valves shall be of the parallel slide or wedge gate design. Globe valves shall
have plug type discs. All valves shall have replaceable seat rings.
The maximum force required to open or close the valves under maximum operating
conditions shall be less than 30 kgf applied to the handwheel.
(b) Check Valves
Check valves shall be designed for mounting in horizontal or vertical piping runs.
Check valves shall be of a swing disc, power assisted or spring loaded quick closing
type.
Check valves shall be placed in line with a gate valve or a globe valve where
guaranteed tightness is required.
Rev 4 – May, 2014 Page 23 of 54
(c) Butterfly Valves

Butterfly valves may be used instead of gate or globe valves for low pressure liquid
or gas service.
All valves shall be bubble tight, rubber or synthetic seated, (except as otherwise
noted) with flanged ends.
The valve seating materials shall be entirely satisfactory for the service conditions
under which the valve is to operate and the Contractor shall submit evidence to
show that similar valves have been successfully employed for a period of not less
than five years. The valve design shall be such as to reduce leakage to insignificant
proportions.
Valves shall be designed for minimum pressure loss when open and be capable of
withstanding the full pressure of the line when closed and cause minimum vibration
when used for throttling of flow.
All manually operated valves shall be of the gear type with totally enclosed gearing.
Valves shall be subject to approval by the Owner/Engineer.
(d) Plug Valves
Eccentric plug valves may be used for low pressure liquid or gas service. Valves
shall have bolted bonnets and plugs of the conical type. Valves shall be synthetic
seated and are subject to approval by the Owner/Engineer.
Manual valves up to DN 150 mm nominal size shall be lever-operated. Larger size
valves shall be provided with worm-geared handwheels.
All lubricant fittings and injectors required for introduction of plug lubricant shall
be supplied with each valve.
(e) Ball Valves
Ball valves may be used for low pressure liquid or gas service in nominal sizes up
to DN 70 mm.
Each ball valve shall be provided with an operating lever.
(f) Sluice Valves
Sluice valves shall only be used on low duty water systems. Large bore valves are
to be provided with easing screws and a suitable flushing connection with the valve
to facilitate removal of any dirt preventing complete closure.
(g) Instrument Valves
Instrument air-shut-off valves shall be bronze and instrument shut-off valves shall
be needle valves of stainless steel construction (ASTM A182, Gr. F6), no bonnet,
outside screw, rising stem, with socket weld ends.
(h) Float Valves
Float valves shall be of the equilibrium ball front type fitted with floats of tinned
copper or other approved material. They shall comply with the approved standard
and be complete with float rods and guides together with covers and brackets where
required.
13.9.2.6.Special Purpose Valves
(a) Control Valves
Rev 4 – May, 2014 Page 24 of 54
Control valves shall be provided in accordance with their purpose and operating
conditions. A gate valve shall be placed upstream and downstream of the control
valve and a globe valve shall be provided as a bypass so that repair work can be
done on the control valve without reducing plant load.
Special attention shall be paid to valves which handle flashing condensate to avoid
erosion, excessive noise and vibration.
The valves shall have "straight away" globe pattern bodies and high lift top and
bottom guided inner valves for heavy duty service.
Direct acting and self-contained pilot-type valves may have low lift inner valves.
Valves which are too small for top and bottom guiding shall be provided with top
cylinder guides designed for heavy-duty service. Bonnet joints, preferably of the
flanged and bolted type shall be designed for easy disassembly and for assurance of
correct valve stem alignment.
Plugs shall be of one-piece construction, either cast, forged or machined from solid
bar stock. Plugs shall be screwed and pinned to valve stems or shall be integral with
the valve stems. All valves shall be arranged such that the inner valves may be
removed from the valve bodies from the bonnet side.
Unless otherwise specified, all control valves shall have stainless steel stems, guide
bushings, inner valves, seat rings, stem lock pins and stuffing box parts and stellited
seating surfaces.
Flow control valves shall be especially designed for high pressure drop application.
They shall have stainless steel stems, stellited seats and discs. They shall be capable
of regulating the flow through the valve from zero flow to flow with the valve fully
open.
Control valves shall be fitted with approved indicators, showing the accurate
amount of valve opening, and shall have electric position transmitters with 4 - 20
mA output equivalent to 0 - 100% opening. The valves shall be of the outside screw
type. All valve seats and faces shall be readily renewable and be made from
materials that are corrosion and wear resistant. Valves shall be supplied with
handwheels.
(b) Safety and Relief Valves
All relief valves shall be direct spring loaded, angle body types of a design unless
otherwise specified suitable for the respective operating conditions. Relief valves
for steam or compressed air service shall be of the "safety" type. These valves shall
be provided with adjustments for blowdown range. Relief valves for water or oil
shall be of the liquid relief type having a slow opening and closing action. All relief
valves shall be arranged for field adjustments of the set pressure and shall be
provided with lifting levers.
All steel body relief valves shall have seats and spindle constructed from stainless
steel.
Tungsten alloy steel springs shall be used in all relief valves for application with
steam temperatures greater than 232OC on enclosed spring valves. Tungsten alloy,
stainless steel, or carbon steel springs shall be used in all other valves.
All bronze body relief valves shall have enclosed carbon steel springs, integral
bronze seats and carbon steel or brass spindles.
Discs shall have metal seat facings unless otherwise specified for composition
facings.
Rev 4 – May, 2014 Page 25 of 54
(c) Vacuum Relief Valves

Vacuum relief valves shall be automatically sealed with water and provided with
any necessary water tank and pipework arranged to maintain the water seal.
(d) Pressure Reducing Valves
Pressure reducing valves shall be perfectly stable, quiet and non-vibratory over the
full range of operation and shall be suitable for continuous use at the operating
temperature.
Where an electrical or hydraulic valve operator is provided, on failure of the
operating mechanism, the valve shall not close automatically and the valve opening
shall be readily adjustable by hand. A pressure relief valve shall be provided at the
discharge of each reducing valve, capable of discharging the maximum flow of the
reducing valve without undue build-up of pressure. The discharge from the relief
valve shall be led to a safe location approved by the Owner/Engineer.
Pressure gauges and thermometers shall be provided upstream and downstream of
each reducing valve.
13.9.2.7.Valve Drives
(a) General
Valve actuators and stems shall be adequate to handle the unbalanced forces
occurring under the respective flow conditions and maximum differential pressure
and shall be adequate to assure tight seating of the valve.
(b) Float Operated Valves
The valves shall be of an approved design and manufacture. Floats shall be made
from suitable corrosion resistant material, the float rod shall preferably be of
stainless steel or bronze.
Where the float rods pass through the top of a tank, they shall have a suitable dust-
tight guide of corrosion resisting material.
13.9.2.8.Piping Accessories
(a) Steam Traps
Trap bodies shall be adequate for maximum inlet pressure conditions. Capacities
shall be sufficient for maximum and minimum inlet pressure conditions. Inverted
bucket-type traps, with bottom inlet connections, are preferred and shall be
employed unless conditions of the installation make the use of other types
necessary. As far as possible, all trap shall be of the same manufacture and basic
design. Moving or wearing parts, including orifice plugs, shall be conveniently
renewable.
All traps shall be protected by suitable inlet strainers, either integral or separate
having removable baskets and valve blow-off connections. Traps are to be installed
in the locations permitting convenient access for operation and maintenance. Each
trap shall be provided with isolation and bypass valves, as well as test and free-blow
valves and, where necessary, discharge check valves.
(b) Drain Valves
High pressure drain valves and drain valves for wet steam service shall be provided
with erosion and corrosion resistant seats and discs. The valves shall permit
extended drain operation without any loss of tightness.
Rev 4 – May, 2014 Page 26 of 54
13.9.3. Piping
Piping runs must be arranged aboveground as far as practicable. When the Site
conditions dictate other arrangement, the following criteria must be observed.
 Underground: Living, fire-fighting, storm drains and waste water
pipes;
 Overhead: Hydrogen, fuel gas, fuel oil and heating pipes;
 Overhead or inside trench: Compressed air, oxygen, acid and alkaline
pipes;
Racks must be used for cabling and piping which crosses roads. Where piping, valves
and fittings are installed below ground (either in trenches, pits or buried in ground),
they must be made of suitable material to withstand corrosion due to accidental
flooding or chemical attack. Where piping are installed in trenches or underground, the
design must allow for free and ready access to reach all parts of the pipe run and, in
particular, valves for repair and maintenance. The underground pipe must be wrapped
by appropriate wrapping materials for corrosion protection. In addition, there must be
sufficient clearance between adjacent pipe runs for maintenance.
No pipework must be run in trenches carrying electrical cables. Centralized piping
support racks, and piping trenches must be used as far as practicable.
The piping layout and arrangement must be clearly shown on flow diagrams, pipe
routing and erection drawings. Pipe dimensions, materials, operating conditions,
insulation thickness and piping and equipment identification numbers must be shown
on the relevant drawings.
The Bidder must design all piping systems with the piping arranged in orderly pipe
runs giving due consideration to pipe expansion, valve locations, practical pipe
supporting and access to all piping accessories for operation and maintenance
purposes.
All saturated steam and compressed air pipeworks must be arranged with a slope of not
less than 1:100.
Piping arrangements must be provided for the removal and/or maintenance of
equipment and equipment internals without removing the piping. A minimum of 2.2 m
headroom must be maintained to the bottom of all piping components or insulation in
walking areas.
A minimum passageway of 1.0 m must be provided for access between and around all
equipment and a 50 mm minimum clearance must be provided between piping,
including insulation, and any point of adjacent equipment or piping.
Additional clearance must be provided, where required, for pipe movement due to
thermal expansion.
Control valves, strainers, orifices, valve motor drives and all other piping accessories
must be provided with adequate space for instrument piping manifolding and/or
removal of parts for maintenance. Valve handwheels, bracket supports and other
protruding attachments which constitute a hazard to operating personnel must be
elevated to a minimum of 2.2 m from the operator's access elevation. All horizontal
runs of outdoor piping must be supported by pipe racks with a maximum distance
between supports of 6.0 m. Pipe accessory handles, stems, linkages, instruments,
brackets, etc., must not project into passageways. All instruments must be positioned
to allow easy observation.
Rev 4 – May, 2014 Page 27 of 54
A 230 mm minimum clear space must be provided from the bottom surface of pipe to
trench bottom or finished grade.
All piping must be grouped where practicable and must be routed to present a neat
appearance while making maximum use of the plant, steel and concrete structures for
hanging and support.
13.9.3.1.General
The Contractor shall supply all the piping system required to provide a complete
and acceptable installation for the safe, proper and efficient operation of each
equipment. The piping systems shall conform to the standards and codes specified
in the various sections of this specification. The standards and codes shall be of the
latest edition including all revisions, supplements and addenda which are in effect
as of the date of specification issue and shall be considered to be part of this
specification. The use of other internationally recognized standards and codes are
subject to the Owner/Engineer’s approval.
The design and erection of the pipework is to be executed in such a manner that it
shall be possible to test and commission the first unit before completion of the
whole installation covered by this Contract. In this respect, all necessary
interconnections, i.e. terminal points, valves, etc., required to be interconnected
with the other units and any future extension without interruption to the running
unit is deemed to be included in this Contract.
The pipes and tubes less than 400 mm nominal diameter shall be of solid drawn
steel except where otherwise approved by the Owner/Engineer and shall be
specially selected to withstand the temperature, stresses and strains involved in the
operation of the plant.
The design of piping systems shall be submitted to the Owner/Engineer for review
and approval.
Such approval shall not relieve the Contractor of his responsibilities. Items installed
and found to be contrary to the specification requirements, including inconvenient
operation and difficult maintenance shall be rectified without charge to the
Owner/Engineer.
Deviations from Specification or approved drawings will be permitted only with
prior written consent of the Owner/Engineer.
Drawings covering arrangement of piping 100 mm diameter or smaller shall be
submitted only in schematic form showing conformity with Contract drawings,
Specification, and principles of operation.
Actual layout and route shall be the Contractor's responsibility. Any required
modifications to suit the actual site conditions shall be subject to approval of the
Owner/Engineer.
The piping system shall include all pipework, couplings and accessories, complete
in every respect, and suitable for satisfactory continuous operation. The Mechanical
coupling should be installed to save the area and convenient for maintenance at the
place where installed area is limited.
All pipework shall be fabricated with appropriate connections for pressure gauges,
thermometers and any other initiating device required by the plant design or
requested by the appropriate sections of this Specification. Appropriate connections
for Performance and Efficiency Tests instrumentation shall also be provided.
Rev 4 – May, 2014 Page 28 of 54
All instrument piping from the T-joint at the pipe (between the root valve and the
blowdown valve) to the instrument isolation valve shall be of stainless steel. Pipe
connection after the isolation valves may be by means of compression type
couplings to the approval of the Owner/Engineer. All instrument piping from the
root valve or the detecting connector shall be of stainless steel for the furnace, flue
gas and water system. All instrument piping material shall be subject to the
Owner/Engineer’s approval. The necessary purge set shall be also provided.
Lubricating oil piping is to be of solid drawn steel throughout. All bends are to be
of large radius, and right angle branches are to be made with 4-way cross pieces or
other approved provision for cleaning in both directions. The return oil pipes are to
be of sufficient size to avoid running full bore and the return flow from all bearings
are to be provided with visual flow indicators.
General service piping for fresh water shall be in galvanized mild steel or its
material will be designed in accordance with the approved standard. As an
alternative the Contractor shall submit prices for running fresh water piping in solid
drawn copper.
Adequate provision for filling, venting and draining the system for hydrostatic tests,
flushing, etc. of these systems of any one unit without causing any interruption to
the running unit, must be provided under this Contract.
The Contractor shall design all piping systems in accordance with applicable system
performance and operating data and shall be responsible for all dimensions, wall
thickness, pressure losses, stress calculations and reliability of the systems.
The piping systems shall be designed to meet the requirements of trouble-free and
safe operation under maximum load, part load and transient conditions.
The piping design shall result in an installation which will be neat in appearance
and convenient to operate. Items requiring periodic attention shall be readily
accessible from floors or platforms. Pipes shall neither obstruct passageways of any
kind nor interfere with access to other valves or equipment.
Piping to be installed in outdoor locations shall be designed for flooded weights and
for wind design criteria as given elsewhere in this Specification.
Pipe sleeves shall be provided for pipe and tubing which penetrates platforms,
floors, roofs and partitions. Proper flashing shall be provided to ensure tightness
and water proofing, where required.
Each fabricated pipe component shall be properly identified with its piece mark
number painted on each end.
All drain, vent and instrument root valves above 40 barg rating shall be made up of
two valves in series.
13.9.3.2.Layout
The piping layout and arrangement shall be clearly shown on flow diagrams, pipe
routing and erection drawings. Pipe dimensions, materials, operating conditions,
insulation thickness and piping and equipment identification numbers shall be
shown on the relevant drawings.
The Contractor shall design all piping systems with the piping arranged in orderly
pipe runs giving due consideration to pipe expansion, valve locations, practical pipe
supporting and access to all piping accessories for operation and maintenance
purposes.
Rev 4 – May, 2014 Page 29 of 54
All saturated steam and compressed air pipeworks shall be arranged with a slope of
not less than 1:100 unless otherwise specified or according to the approved
standard. Where this requirement cannot be attained the Contractor shall obtain the
Owner/Engineer's approval of any alternative arrangements.
Piping arrangements shall be provided for the removal and/or maintenance of
equipment and equipment internals without removing the piping. A minimum of 2.2
m headroom shall be maintained to the bottom of all piping components or
insulation in walking areas.
A minimum passageway of 1.0 m shall be provided for access between and around
all equipment and a 50 mm minimum clearance shall be provided between piping,
including insulation, and any point of adjacent equipment or piping.
Additional clearance shall be provided, where required, for pipe movement due to
thermal expansion.
Control valves, strainers, orifices, valve motor drives and all other piping
accessories shall be provided with adequate space for instrument piping
manifolding and/or removal of parts for maintenance. Valve handwheels, bracket
supports and other protruding attachments which constitute a hazard to operating
personnel shall be elevated to a minimum of 2.2 m from the operator's access
elevation. All horizontal runs of outdoor piping shall be supported by pipe racks
with a maximum distance between supports of 6.0 m. Pipe accessory handles,
stems, linkages, instruments, brackets, etc., shall not project into passageways. All
instruments shall be positioned to allow easy observation.
A 230 mm minimum clear space shall be provided from the bottom surface of pipe
to trench bottom or finished grade.
All piping shall be grouped where practicable and shall be routed to present a neat
appearance while making maximum use of the plant, steel and concrete structures
for hanging and support. Piping shall generally be routed above ground but where
necessary to facilitate access, pipework may be arranged in trenches or buried
depending on the service and to the approval of the Owner/Engineer. However, no
pipework shall be run in trenches carrying electrical cables.
13.9.3.3.Design Velocities
Pipeline fluid velocities shall be designed in consideration of the pressure drop, the
pipeline vibration, erosion, corrosion and other factors.
As for the typical pipelines, fluid velocities shall not exceed the following values
under rated operating conditions or according to approved standard.
Type of Pipework Max. Velocity
Steam lines:
Main steam, hot reheat, cold reheat lines 50 m/s
H.P turbine bypass lines 200 m/s
Low-pressure steam lines above 5 barg 40 m/s
Low-pressure steam lines 1 barg up to 5 barg 45 m/s
Exhaust steam/Drain lines from turbines to atmosphere/Blowdown Tank 20 m/s
Vacuum lines 60 m/s
Saturated steam lines 20 m/s
Rev 4 – May, 2014 Page 30 of 54
Water lines:
Feedwater discharge lines 4 m/s
Auxiliary cooling water suction 1.5 m/s
Auxiliary cooling water delivery lines 3.0 m/s
Main cooling water lines 2.6 m/s
Drinking, fire fighting, raw and demineralized water lines 1.5 m/s
Pump suction lines, in general 1.0 m/s
Condensate delivery lines 2.0 m/s
Air lines:
Suction line for reciprocating compressors 18 m/s
Delivery line for reciprocating compressors 30 m/s
Suction and delivery lines for rotary compressors 25 m/s
Compressed air lines 15 m/s
Oil lines:
Lubricating oil lines and fuel oil suction lines (depending on viscosity)0.5 - 1.0
m/s
Fuel oil supply lines (preheated) 1.5 m/s
13.9.3.4.Drain and Vents
All pipelines shall be provided with vent and drain connections at all high and low
points, respectively, and as required for suitable operation.
Where practicable, all steam lines shall be sloped in the direction of steam flow and
shall be adequately trapped at low points and vented at high points in the pipe runs.
Drain chambers shall be provided on steam lines at the drainage points to avoid
blockage of drain pipes. Each trap and strainer arrangement shall have suitable
block valves, bypass valve, strainer, and blow-off valve.
The minimum valve size for vents and drains shall be DN 20 mm. In general, the
piping for drain and vents from vessels shall be manufactured from the same
material as the vessel.
All piping shall be arranged to permit complete drainage when a particular unit is
shutdown.
All vent lines which are normally operated shall be terminated 3.0 m or higher
above the highest service platform.
Weatherhoods and/or silencers as necessary are to be provided at the open ends of
all upward facing atmospheric exhaust or vent pipes.
All drain lines which run to waste shall be routed to a suitable drain trench, floor
drain or waste line, etc.
13.9.3.5.Stress and Flexibility Analysis
Piping systems shall be designed in such a way that no excessive stresses, forces,
moments or deflections can take place. The forces and moments transmitted by the
pipelines to the connected equipment shall not exceed the maximum permissible
values allowed by the supplier of these components.
Rev 4 – May, 2014 Page 31 of 54
Design calculations and stress analyses for required piping systems shall be
performed by the Contractor and the appropriate documents shall be presented to
the Owner/Engineer for approval.
The calculations shall be based on maximum operating pressures, temperatures and
weights. The calculations shall determine the maximum combined pipe stresses and
the forces, moments, and deflections at all points of support, anchors and restraints.
The pipe stress and flexibility analyses shall be performed on the proposed layout of
power piping systems in accordance with ANSI Code B 31.1 and the ASME Boiler
and Pressure Vessel Codes or International Equivalent.
In all calculations the manufacturing tolerance shall be taken into account. In
addition, the water weight for hydrostatic testing and the insulation weight shall be
taken into account.
From the calculated results, the positions of supports or hangers and springs used in
the piping systems shall be established. Loads and deflections at the proposed
hanger positions shall be given, together with the type of hanger support, or
restraint, i.e. constant spring hanger, variable spring hanger, etc. Hanger locations
shall be chosen to suit the building steelwork, but where this is not practical,
additional steelwork shall be provided by the Contractor.
The Contractor's design shall take into account possible maximum values, e.g. head
of the pumps in the system as well as exceptional operating conditions, such as
over-pressures, actuation of safety valves and vibrations.
There shall be sufficient allowance for thermal expansion and displacement without
excessive stresses. The thermal expansion of the pipework shall be carefully
analyzed and appropriate pipe routing and location of the supporting equipment
shall prevent the piping from causing excessive forces and moments to the
anchoring points (pressure vessels, turbine, pumps, boiler, header, etc.). The shape
of branch sections shall be such that the stresses caused by transient conditions will
be acceptable.
13.9.3.6.Materials Cleanliness, Packaging and Handling
The Contractor shall submit a detailed cleaning procedure to the Owner/Engineer
for approval prior to its use.
Exterior and interior surfaces of piping system components shall be free of
particulate contaminants such as sand, metal chips, weld slag, etc. Thin uniform rust
films are acceptable on internal carbon steel surfaces. The outside surface shall have
a coat of mill varnish.
Internal and external surfaces of stainless steel materials shall be "metal clean"
when visually examined without magnification, and shall be free of organic films
and contaminants such as oils, paints and preservatives.
Packing shall provide protection against corrosion, contamination, physical damage
or any effect which would lower the quality or cause the item to deteriorate during
the time it is shipped, handled and stored.
All bevels, threads, flange faces and other sealing surfaces shall be suitably
protected with wood, plastic or soft metal to prevent damage to these surfaces
during shipping and handling.
All pipes shall be capped using plastic or soft metal caps or plugs. All caps shall be
taped.
Rev 4 – May, 2014 Page 32 of 54
All packaging or crating shall be suitable for long term outdoor storage on or off the
ground.
Each fabricated pipe section as well as fittings, flanges, etc., shall be properly
identified by a piece mark number printed on each end and on opposite sides. Code
symbols and inspection stamps shall be applied to each fabricated pipe section
where required. Markings shall indicate type of material, size and thickness and
shall conform to the relevant drawings. If cleaning is performed on the material and
the markings are removed, the material shall be remarked.
Main Steam, Hot Reheat, Cold Reheat and Main Boiler feed piping should be
internally cleaned by high pressure water blasting after erection but before final
weld closure. Procedures for this operation shall be submitted to the
Owner/Engineer for approval 3 months prior to carrying out this cleaning.
13.9.3.7.Hangers and Supports
(a) General
The terms "hangers and supports" shall mean all types of piping support assemblies
such as hangers, anchors, guides, brackets, vibration dampers and include the
miscellaneous steel quantities required to support the piping.
All piping supports and hangers shall be designed and spaced as per ANSI Code B
31.1. "Power Piping" or where applicable, the ASME Boiler and Pressure Vessel
Code or International Equivalent.
Hangers for main pipes shall be supplied by the Contractor as finished construction
elements, whereas small hangers may be fabricated on site.
The Contractor shall submit to the Owner/Engineer for approval or comment,
without relieving the Contractor of any responsibility, drawings of complete
supporting systems with typical examples in detail of each support to be installed.
All supports shall be furnished and installed in conformance with relevant approved
standards.
Plates and any other appliance, in connection with the support work, to be
imbedded in the building concrete structure, shall be included in the supply.
Wherever it is practical, all hot pipe lines shall be supported with flexible
connections, such as constant support spring hangers and variable spring hangers, to
permit axial and lateral movements without restraint or bending of any piping or
piping support. However, in no case shall the angular deflection of the hanger rod
exceed 4 0C as measured from the vertical axis.
Hangers and supporting elements shall be fabricated and assembled to permit the
free movement of piping caused by thermal expansion and contraction. The design
of elements for supporting or restraining piping systems, or components thereof,
shall be based on all the concurrently acting loads transmitted into the supporting
elements. Where resonance with imposed vibration and shocks occur during
operation, suitable dampers, restraints, anchors, etc., shall be added to remove these
effects.
All piping shall be installed with supporting devices selected and located to insure
that the finished system will provide uniform continuous slope for draining, that
expansion will be so directed as to minimize stresses in the piping material, and that
all elements will be suitably and substantially supported, guided and anchored.
Supports at floor or wall sleeves will not be permitted. Numbers and positions of
supports may be influenced by the location and adequacy of available building
Rev 4 – May, 2014 Page 33 of 54
work, but additional or independent structural steel work shall be furnished and
erected by Contractor, if necessary, to secure a proper installation. Loads imposed
on the building structure shall, in all instances, be subject to the approval of the
Owner/Engineer. Support design shall be such that the loading will not be
significantly affected in going from shutdown to operating condition. Principal
supports shall be provided with convenient means for adjusting and then securely
locking rod lengths or spring tensions.
Temporary construction supports shall not be welded to the pipe except with
approval of the Owner/Engineer and shall be attached in a manner that will not
damage the pipe. These supports shall be completely removed upon completion of
construction.
Equipment connections shall not be used to support piping either for temporary or
permanent support.
Supports and maximum support spacing of all piping shall be in strict accordance
with the manufacturer's recommendations.
All outdoor installation supports and spring hangers shall be suitably coated to
withstand the local environmental conditions. Springs shall be Neoprene-coated and
all other parts shall be hot dipped galvanized. Sliding type supports for indoor
service shall have lubricated surfaces. Sliding supports for outdoor services shall
have a self-lubricating surface.
Riser pipes shall be individually supported. To reduce riser loads, the riser supports
may be supplemented by the nearest support on a horizontal pipe. The horizontal
length of pipe between the nearest support and risers shall be not longer than the
length of the riser supplemented by the nearest support. Bends shall have the
supports no further away from the riser than the radius. Where two rods are used in
a solid rod riser hanger, each rod shall be capable of taking the entire load.
When riser clamps are used, the Contractor shall not rely solely on the friction of
the pipe clamp to support the pipe; instead he shall provide stops or lugs and attach
same to the pipe. All lugs or attachments welded to the pipe shall be of the same
material as the pipe. All temporary or permanent attachments shall be welded to
alloy piping material using the required preheat and stress-relief.
The Contractor shall ensure that the piping is properly supported with particular
attention to:
 The setting of spring hangers
 The avoidance of cold springing, unless considered absolutely necessary, in
agreement with the Owner/Engineer
 The introduction of the correct pitch to allow for drainage
The Contractor shall submit guidelines for the proper readjustment of the hangers
after the system has reached its service temperature and if fully insulated. However,
the readjustment shall be undertaken by the Contractor during commissioning.
All spring hangers shall be equipped with a device to enable locking during
hydrostatic testing and flushing of the system. Temporary supports, if required,
shall be supplied by the Contractor.
Hanger rods shall be designed with a minimum factor of safety of 5 based on the
ultimate strength of the material but shall not be less than 12 mm in diameter or
shall be designed according to approved standard.
Rev 4 – May, 2014 Page 34 of 54
Design shall be such that, during the installation of the pipe hanger supports,
drilling of holes in building or equipment structural steel shall be avoided.
Overheating of building structures by welding operations shall be avoided by
suitable design of the pipe hanger supports.
13.10. PUMPS
13.10.1.General
All pumps shall be designed, manufactured and erected in accordance with the latest
valid issues of codes, standards, accident prevention regulations and legal regulations.
They shall be designed for continuous operation unless otherwise specified.
Pumps shall be installed in positions convenient for operation and servicing. Where
multiple pump installations are required, each pump and its associated equipment shall
be arranged in such a manner as to permit easy access for operation, maintenance and
pump removal without disrupting plant operation.
If several pumps are used for the same pumping process, they shall be similar in
design, i.e. interchangeable.
Lifting lugs and eyes and other special tackle shall be provided as necessary to permit
easy handling of the pump and its components.
Standard production pumps with suitable characteristics shall be used wherever
practical. Only proven makes and models are to be supplied. All accessories and the
overall design of the pump sets shall be suitable for automation as planned for the
relevant systems.
13.10.2.General Design and Construction
Centrifugal pumps shall be used wherever possible. All pumps shall be designed to
withstand 1.5 times the pump zero flow pressure under maximum suction pressure
conditions.
All pumps shall be of ample size to transmit the maximum possible output from the
driving machine. The pump shaft and coupling are to be so dimensioned that the
maximum permissible torque of the shaft is higher than the maximum transmissible
torque of the coupling.
Renewable wear rings shall be fitted to the casing and impeller where economically
justified.
All pumps shall be constructed of materials specifically designed for the conditions
and nature of the pumped fluid, and be resistant to cavitation, erosion and corrosion.
The pump glands or mechanical seals shall be so arranged that repacking or fitting of
replacement seals can be carried out with the minimum of disturbance to plant
operation. Except for the boiler feed pumps mechanical seals shall be provided for all
pumps but the seal housings shall be suitable for conversion to packed glands if found
necessary later. Spare gland flanges shall be provided for each pump to facilitate
conversion. For this purpose the shafts shall be fitted with renewable bronze gland
sleeves.
Where material specifications are given in the various pump specifications, these are to
be considered as minimum requirements. They do not relieve the Contractor of the
responsibility for selecting the correct materials.
In all cases where pumps are fitted with stuffing boxes, the shafts are to be provided
with protective sleeves in a suitable material. In accordance with the individual
Rev 4 – May, 2014 Page 35 of 54
requirements, devices for cooling, heating, flushing or locking the shaft seals are to be
provided.
Centrifugal pumps shall preferably be of the horizontal shaft type unless specified
otherwise. The pump casing shall be split type for ease of maintenance such that the
impeller and shaft are capable of being withdrawn without disturbing any of the main
pipework and valves carrying the pumped fluid.
Each horizontal pump shall be mounted with its driving motor on a common bed plate
of rigid construction, except the special case which submitted to the Owner’s approval.
The bed plate shall be complete with drip tray fitted with a conveniently located drain
plug.
Vertical pumps are to be provided with foundation frames, and if necessary positioned
by suitable means in a pump sump. It shall however be possible to remove these
pumps without entering the sump.
Pumps must be carefully sited to ensure that the net positive suction head available
under all operating conditions will be adequate for the type of pump employed. The
NPSH values are to be referred to the least favourable operating conditions - lowest
atmospheric pressure, lowest level of water on the suction side of the pump, and
highest temperature of the pumped fluid.
Pumps shall operate smoothly throughout the speed range up to their operating speeds.
The first coupled critical speed must be at least 10% higher than the maximum
operating speed. The determination of the shaft diameter and the distance between two
consecutive bearings must include a sufficient large safety margin to satisfy this
condition. The entire rotor assembly shall be statically balanced and dynamic
balancing of the impeller is required if either of the following applies:
 Pump speed exceeds 1,800 r.p.m., capacity exceeds 56 m3/h and impeller
diameter exceeds 150 mm.
 Pump speed exceeds 1,800 r.p.m. for pumps of 2 or more stages.
Where necessary the pumps are to be fitted with devices to ensure a minimum
throughflow.
13.10.3.Pump Characteristics
Where duplicate pumps are installed for the same service, they shall be suitable for
parallel operation.
The pump head characteristic shall be such that the head will continuously increase
with decreasing flow quantity with a maximum head reached at zero flow. Generally a
head increase of 15% above the duty point to no flow will be acceptable.
Full pump characteristic curves giving head/capacity, efficiency/capacity, power
absorbed/ capacity, net positive suction head required/capacity shall be provided for all
pumps.
Unless specified otherwise all pumps shall be sized so that under normal operation,
their total running rated capacity is 110% of process flow requirement if the suction
level is controlled, and 115% of process flow if the suction level is uncontrolled (i.e.
free suction pump).
13.10.4.Fittings
All pumps shall be installed with isolating valves, a discharge non-return valve and
suction and discharge pressure gauges unless otherwise stated.
Rev 4 – May, 2014 Page 36 of 54
All couplings and any intermediate shafting shall be supplied with removable type
guards.
Coupling halves shall be machine matched to ensure accurate alignment. Horizontal
shaft pumps shall be driven by the motor through an approved type of flexible
coupling. Pin-type flexible couplings shall not be used. Vertical shaft and in-line
pumps may be driven directly by the motor through a solid coupling.
All pumps other than submersible pumps and vertical wet pit pumps shall have
temporary strainers fitted in the suction pipework during initial start-up and
commissioning. Permanent strainers shall be provided where specified, together with
differential pressure gauges and alarm facilities.
Air release valves shall be fitted to all pumps at suitable points on the pump casing
unless the pump is self-venting due to the arrangement of the suction and discharge
nozzles. Drainage facilities shall be provided on the pump casing or adjacent pipework
to facilitate the dismantling of pumps.
All positive displacement pumps shall be fitted with a discharge relief valve.
Water discharged from air cocks, drains and glands shall be piped via tundish to the
nearest convenient drain trench.
13.10.5.Bearings
All bearings shall be of ample surface area and for large pumps shall be of the
automatic oil lubricated sleeve type. Bearings on vertical shaft pumps shall be spaced
to prevent shaft whipping or vibration under any mode of operation.
Bearing housings on horizontal shaft pumps shall be designed to enable the bearings to
be replaced without removing the pump or motor from its mounting. Bearing housings
on horizontal shaft pumps shall be effectively protected against the ingress of water,
pumped fluid and dust by suitable non-ferrous deflectors.
All bearing oil wells shall be fitted with visual oil level indicators. Non-pressure oil
lubricated bearings shall be equipped with constant level oilers. Means of draining
bearing housings shall be provided.
13.11. UNFIRED-PRESSURE VESSELS AND STORAGE TANKS

13.11.1.Unfired-Pressure Vessels
Pressure vessels unless otherwise specified shall be designed with a joint factor not
exceeding 0.95 and manufactured and tested in accordance with the requirements of
the approved standards. The flanged connections shall not be less than the
requirements of the approved standards.
Connections are to be provided for all pipework, whether indicated on the
Specification drawings or not, together with connections and tapping points for
instrumentation. Manholes, drains and relief valves required shall be provided for the
vessels.
13.11.2.Storage Tanks
The design, fabrication, erection and testing of storage tanks shall conform to the
approved standards, as appropriate for horizontal and vertical mild steel welded
storage tanks.
On completion of erection, tanks shall be shot blasted internally and painted with
approved quality paint to withstand the service and temperature condition anticipated.
Rev 4 – May, 2014 Page 37 of 54
On all tanks the necessary nozzles are to be provided for connections to all pipework,
whether as indicated on the Specification drawings or not; connections and tapping
points for instrumentation, manholes, vents, drains, access stairways and handrails, etc.
shall be provided.
13.11.3.Tank Connections
a) Bidder shall furnish all piping material required for the tank connections.
b) Unless otherwise specified, for all flanged connections Tenderer shall furnish
suitable counter flanges and the necessary nuts, bolts, gasket.
c) Flange faces of all nozzles shall be machined and square with the vessel centrelines.
d) Unless otherwise stated bolts and nuts shall be of hexagonal head.
e) The material and thickness of gaskets shall be suitable for the specified service. On
completion of hydraulic test, contractor shall replace the gaskets used during testing at
his own cost.
f) All tanks shall be provided with connections for drains, vent and overflow.
Condensate storage tank shall be provided with pump recirculation connections. Blank
flanged spare inlet and outlet- 2 (two) each shall be provided for condensate storage
tank and one (1) each for others. Each of the above spare connections shall be provided
with isolating valves.
Internal access stairways or ladders should include inspection and maintenance of
storage tanks. The storage tank shall have a covered top and the whole suitably braced
and stiffened externally only.
Each tank shall be provided with two hinged and jointed manhole doors secured by
bolts and winged nuts.
External access to the manholes should be via the tank top level walkway whose
handrails are to be extended to surround the area of the manhole.
All tank overflows shall be of the syphonic vermin proof type. Where two similar large
storage tanks are adjacent to each other, they shall be connected at roof level with a
walkway.
Instrumentation and alarms shall be provided to the Owner's approval for each tank.
13.11.4.Accessories
The tanks shall be provided with accessories as indicated in the Specification.
All the accessories shall conform to relevant Indian Standard. The following broad
guidelines are given for some of the accessories.
a) Conservation Vent Valve/Breather
Where continuous venting to atmosphere directly is not permitted for the stored liquid,
a conservation vent valve or a breather of approved make & design shall be provided
on each of the vent/overflow connection of the condensate storage tank. The
conservation vent valves where provided, shall be designed to relieve the pressure or
vacuum corresponding to plus or minus 55mm water gauge in the space above liquid
in the tank. Detail cross-sectional drawing indicating materials of construction shall be
submitted along with the proposal.
b) Level Indicator
Float operated or tubular gauge glass type indicator of high-grade workmanship shall
be provided on each tank. Tank of height not exceeding 3m shall have tubular gauge
glass and others float operated level Indicator. For tubular gauge glass, isolating valves
and
Rev 4 – May, 2014 Page 38 of 54
protective guards against mechanical shock shall be provided.

c) Level Switch
Where specified level switch of approved make & type shall be furnished along with
instrument root valves. Repeat accuracy of operation shall be +_ 1% of the full range.
At least two level switches one for High-level actuation and other for Low Level
actuation shall be provided for each tank to motor operated gate valves at inlet lines of
specified tank.
d) Dip Hatch
Each large dia cylindrical tank shall be fitted with one dip hatch. Dip hatch shall have
screwed end and shall be fitted with brass cap and chain.
e) All tanks shall be provided with vertical rung ladder. In addition to this, internal
vertical ladder is to be provided in all tanks where the tank height exceeds 3M, vertical
ladder is to be provided with cage.
f) Top Manhole shall be provided in all tanks. Besides it, manhole at the side of tank
shall be provided in case of condensate storage. Manhole size shall be 600mm NB
(min.).
13.12. HEAT EXCHANGERS

Where tubular heat exchangers are used the design shall be in accordance with Standards
of Tubular Exchanger Manufacturers' Association or equivalent and shall incorporate
facilities for easy removal of the tube nest or individual tubes. Where a corrosive fluid is
being handled welded tube joints shall be incorporated wherever possible provided
residual weld stresses likely to be sensitive to the corrosive conditions prevailing in the
plant item can be adequately relieved.
The tube nest shall be designed so that up to five (5) percent of the available tubes can be
plugged without effecting the efficiency of the heat exchanger.
13.13. PLATES AND STEEL SECTIONS

Plates and steel sections must be perfectly straight with smooth surfaces. If straightening
is necessary, hammering must be avoided if possible. After the cutting of sheets and steel
sections, the edges must be left sharp, clean and without burrs.
Heavy parts may be cut with a flame provided that the material is not damaged and that
the edges of the cut are ground clean or machined.
Plates may be cold rolled but without heavy blows to effect the final curvature
13.14. CASTINGS
The Contractor should advise the Owner of the schedule for the casting of heavy pieces.
These items must be inspected immediately after casting before the commencement of
any machining. The Owner will advise the Contractor of the items which will be
inspected, after receipt of the casting schedule.
The repair by welds and the inspection shall be performed in accordance with the
applicable ASTM standard.
If the Owner deems it necessary to radiograph the castings, the tests and interpretation of
results will be in accordance with ASTM Standards E71, E94 and E186.
Rev 4 – May, 2014 Page 39 of 54
13.14.1.Steel Castings
The Contractor shall prepare material purchasing specifications for all important
castings. Each document shall indicate fully the quality and inspection requirements
for the component casting covered. Copies of the Specifications shall be issued to The
Owner for his use. Wherever possible castings shall be selected from the range of
materials covered in the approved standard and the inspection and quality
requirements, together with the other provisions of this Specification, shall be regarded
as the minimum acceptable standard.
Castings shall be properly fettled and dressed. All surfaces shall be satisfactorily
prepared for inspection purposes. Gates, risers, headers and feeders, shall be removed
after annealing and before normalizing and the scars carefully blended by grinding.
On medium and large size castings the test blocks for mechanical test shall be cast
integrally with the casting and shall not be removed until all heat treatment has been
completed or otherwise authorized by the Owner.
Magnetic particle inspection shall be applied to all castings after acid cleaning and shot
blasting. All defect cut outs shall be inspected by magnetic particle inspection after
grinding and before repairs are commenced.
Castings may be repaired by welding provided that the approval of the Owner is first
obtained. The Contractor shall submit drawings, sketches or photographs showing the
location and principle dimensions of the defect together with the proposed weld repair
procedure.
The Owner's approval in writing must be obtained prior to the repair of defects which
penetrate more than 50% of the wall thickness or extend more than 12,000 mm2.
Only welders who have passed an appropriate qualification test for first class welders
shall be employed on the repair of castings. All repairs shall be carried out by the
metal arc process.
Selected areas for future butt welds shall be subjected to radiographic examination.
The defects revealed by this examination shall be compared with the acceptance
criteria given within the agreed standard. Wherever possible the acceptance criteria
shall be related to an agreed set of reference radiographs. The reference radiographs to
be used for this purpose together with the selection of the standard films for shrinkage,
subsurface linear discontinuities, porosity, voids, sand and slag shall be to the Owner's
approval.
Ultrasonic inspection shall be applied to all important castings to locate the extent of
sub surface defects and to check the wall thickness of castings. Records of the results
of such tests together with full details of the procedure used shall be forwarded to the
Owner.
On completion of repair, welded areas shall be ground smooth and carefully blended
into the parent material. After final heat treatment the total internal and external
surface shall be subjected to magnetic particle inspection.
All records and test certificates covering chemical analysis, mechanical properties,
heat treatment history, location and size of defects reported, radiographic report,
ultrasonic report, dimensional inspection, shall be forwarded to the Owner.
All castings shall be identified by hard stamped, or cast on reference marks which shall
be entered on all relevant documents and test certificates.
Rev 4 – May, 2014 Page 40 of 54
13.14.2.Cast Iron Castings

Cast iron is not to be used for any part of equipment which is in tension or which is
subjected to impact, or to a working temperature exceeding 200oC unless specifically
approved by the Owner.
Materials for iron castings shall comply with the approved standards and in all cases
shall be close grained quality.
Castings for parts in contact with water shall be of corrosion-resistant quality.
No weld interlocking, plugging or filling of defective part is to be performed without
the prior approval of the Owner in writing. Full details of the proposed method of
repair shall be submitted for approval.
Test blocks are to be integrally cast on all medium and large castings.
13.15. FORGINGS
The Contractor shall draw up material purchase specifications for all important forgings,
and supply copies of these specifications to the Owner for his use. Specifications shall be
produced for, but not be limited to, turbine shafts, diaphragm discs, generator rotors, rotor
end covers or end bells, exciter shafts, large motor shafts and precision forged turbine
blades, etc. In each case the quality and inspection requirements shall be clearly stated.
Wherever possible steel forgings shall comply with the approved standards.
All forgings are to be manufactured from basic electric steel or fully killed acid open
hearth steel. Consideration shall be given to use of vacuum degassed steels in appropriate
cases.
Sulphur prints shall be taken from all large forgings and other forgings as directed by the
Owner, the prints shall indicate the absence of significant segregation.
Test blocks from which the mechanical test pieces will be machined shall be cut from the
forgings at positions to be agreed by the Owner. On large and important forgings several
test pieces shall be taken from radial and longitudinal directions.
Solid shaft forgings will be acceptable provided that ultrasonic examination confirms the
absence of centre line defects. The Owner will reserve the right to insist that shaft or rotor
forgings with centre line defects be bored to remove such defects.
Shaft and rotor bores where provided, shall be smooth machined to a standard suitable for
intrascope examination. Trepanned sections of the cores shall be subjected to mechanical
test for information purposes only. Local chambering or remachining of bores to a larger
diameter shall only be carried out with the approval of the Owner.
Bores, where provided, shall be inspected visually and with magnetic particle inspection.
Magnetization shall be in accordance with the approved standard. The inspection shall be
made with a suitable intrascope having an acceptable level of illumination and
magnification.
Forgings shall be subjected to ultrasonic examination at the forge-masters works. The
equipment and probe system shall be to the approval of the relevant standard and probe
scans shall be performed in a radial and axial direction. Probes shall be of a maximum
diameter of 25 mm with a frequency of 2 or 2.5 MHz.
Forgings shall be free from cracks externally or internally, extensive non-metallic
inclusions and surface defects which cannot be removed by subsequent machining.
Bearing journals of large shafts and rotors shall be subjected to dye penetrant examination
on completion of final machining.
Rev 4 – May, 2014 Page 41 of 54
Repairs by welding or other means shall not be undertaken on forgings at any state of the
production cycle.
Test certificates shall be provided to the Owner including the following records, chemical
analyses, mechanical properties, electrical properties (when supplied), heat treatment
records, ultrasonic reports, top and bottom percentage ingot discards, dimensional and
concentricity records.
Each forging shall be suitably branded with an identification number which shall be
transferred throughout all final machining stages. The identification number shall be
marked on all documents and test certificates relative to the forging.
Copies of thermal stability tests conducted on turbine rotors shall be forwarded to the
Owner.
13.16. BOLTS, STUDS AND NUTS

All bolts, studs and nuts shall conform dimensionally and be threaded in accordance with
the approved standards.
The material of all bolts, studs and nuts shall conform to the requirements of the approved
standards.
Where there is a risk of corrosion studs and bolts are to be finished flush with the surface
of the nuts otherwise a maximum of 1½ complete threads shall protrude.
The use of slotted screws shall be avoided, hexagon socket screws of recess type heads
being preferred.
When connecting pipework to fittings, studs shall not be used except with the Owner's
approval.
Where fitted bolts are used they shall be adequately marked to ensure correct assembly
and the fitted portion shall be not less than 4 mm in diameter larger than the threaded
diameter. They shall be a driving fit in the reamed holes they occupy.
All washers shall be included under this Contract, including locking devices and
antivibration arrangements, which shall be subject to the relevant standard. Taper washers
shall be fitted where necessary.
13.17. CORROSION PROTECTION & PAINTS

Due attention must be paid to the environmental conditions prevailing at Site subject to
seawater corrosion. All painting systems including the proposed surface preparation,
application of primer and topcoat materials must be reviewed and agreed by the Owner.
All metallic surfaces of the Facility that are subject to corrosion must be properly cleaned
(e.g. sand-blasted) and prepared prior to the application of suitable anti-corrosion primers
and top coats in the factory shops. All paints must be products of renowned paint
suppliers and painting standards must be provided.
Where dissimilar metals are in contact or close proximity and corrosion may occur
through electrolytic action or differences in electric potential, protection must be afforded
by electroplating, suitable gaskets, cathodic protection or other means.
All surfaces must be adequately protected in transit and any damage must be renovated
immediately on off-loading and on completion of erection.
Materials subject to corrosion, including all exterior equipment surfaces and structural
steelwork, must be protected with suitable coatings systems in relevant International or
Vietnamese Standards.
Rev 4 – May, 2014 Page 42 of 54
Surfaces that will be inaccessible after shop assembly must be finish coated/painted for
lifetime protection. All access ladders, security fencing and hand railing etc. must be hot-
dip galvanized. Galvanized coating must also be applied to structural steel members,
where deemed necessary. Bitumen painting must protect walkways.
Colour strip indication system must be used for pipes. These strips must be painted on the
joint of pipes, entrance, valves of pipe. This pipe without outside protection layer must be
marked by some colour in whole length. RAL code for piping must be submitted for
Owner’s review during detailed engineering stage.
The principal colour of field equipment is outlined as follows:
Equipment Colour RAL Color
Code
Major building
1 Sandwiched corrugated metal sheet Main colour: navy blue 5002
wallboard
Auxiliary colour: grey white 9002
2 Sandwiched corrugated metal sheet Light grey 7035
wallboard
3 Architectural external wall painting Main colour: grey white 9002
Auxiliary colour: Navy blue 5002
4 Indoor steel handrail Light grey 7035
5 Outdoor steel handrail and stair Light grey 7035
6 Steel door Light grey 7035
7 Wood door Light grey 7035
8 Steel window Light grey 7035
9 Steel door Light grey 7035
10 Crane beam Navy blue 5002
11 Steel column and beam Agate grey 7038
12 Steel coal bunker Light grey 7035
13 Crane Signal yellow 1003
14 Boiler coping Navy blue 5002
Boiler
1 Boiler top Navy blue 5002
2 Boiler coating Agate Grey 7038
3 Flue gas duct from FGD Silver grey 7001
4 Boiler steel supporting 7000
5 Air heater White aluminium 9006
6 FD Fan Light grey 7035
Rev 4 – May, 2014 Page 43 of 54

Code
7 PA Fan Light grey 7035
8 ID Fan Light grey 7035
9 Coal mill Light grey 7035
10 Coal feeder Light grey 7035
11 Seal air fan Light grey 7035
12 Core air fan Light grey 7035
13 Air compressor Sky blue 5015
14 Equipment in oil system Traffic yellow 1023
15 Ash handling system Light grey 7035
16 Coal handling system Light grey 7035
17 Stacker cum Reclaimer Navy blue 5002
18 Coal crusher Navy blue 5002
Turbine
1 Overhead cranes Signal yellow 1003
2 Main steam turbine Light blue 5012
3 Gland steam condenser Pale green 6021
4 Gland steam condenser fans Pigeon blue 5014
5 Main oil pump Sulfur yellow 1016
6 AC lub oil pump Sulfur yellow 1016
7 DC lub oil pump Sulfur yellow 1016
8 Jackling oil pump Sulfur yellow 1016
9 Oil tank fans Sulfur yellow 1016
10 Oil cooler Sulfur yellow 1016
11 Main oil tank Sulfur yellow 1016
12 Generator Light blue 5012
13 Hydrogen cooler Light blue 5012
14 DM Water cooler Pale green 6021
15 Hydrogen water cooling pump Pale green 6021
16 DM water cooling tank Pale green 6021
17 Condenser Silver grey 7001
18 HP heater White aluminium 9006
Rev 4 – May, 2014 Page 44 of 54

Code
19 LP heater White aluminium 9006
20 Deaerator White aluminium 9006
21 Deaerator tank Pale green 6021
22 Vacuum pump Pigeon blue 5014
23 Condensate pump Pale green 6021
24 Boiler feed pump White aluminium 9006
25 Dirty oil storage tank Clay brown 8003
26 Oil storage tank Sulfur yellow 1016
Turbine pipework
1 Main steam and reheat steam pipes
2 Extraction steam pipes
3 Other steam pipes
4 Condensate pipes（insulated）
5 Condensate pipes（non-insulated) Pale green 6021
6 Feed water pipes
7 DM water and Chemical dosing Pale green 6021
pipes
8 Drain pipes
9 CW water and Industrial Water Signal black 9004
pipes
10 Oil pipes Sulfur yellow 1016
11 CO2 and N2 pipes Pearl light grey 9022
12 Air pipes Distant blue 5023
13 Underground pipes Signal black 9004
14 Support Silver grey 7001
15 N2 pipes Silver grey 7001
Electrical
1 Generator excitation panel Gray 7004
2 11kV panel Grass green 6019
3 415V panel Gray 7004
4 Generator Transformer Olive grey 7002
Rev 4 – May, 2014 Page 45 of 54

Code
5 Unit Auxiliary Transformer & Olive grey 7002
Station Transformer
6 22kV generator IPB Pastel Turquoise Indoor: 034
Outdoor:
7002
7 11kV NPB Grass green Indoor:
6034
Outdoor:
7003
8 Generator excitator casing Olive grey 7002
9 Electric panel in control room White ivory 1015
10 415V AC LV motor Gray 7002
11 11kV AC HV motor Grass green 6019
12 220V DC motor Orange 2007
13 Electric local control panel Grey 7004
C&I
1 DCS panel Light ivory 1015
2 FGD DCS panel Light ivory 1015
3 BOP PLC control panel & console Light ivory 1015
4 CCR panel Light ivory 1015
5 CCR console Light ivory 1015
6 Electronic room panel Light ivory 1015
7 Air preheater local panel Agate grey 7038
8 Local panel, cubicle junction box Agate grey 7038
and termination box
Chemical
1 Acid storage trough Red orange 2001
2 Alkali storage trough Signal yellow 1003
3 Acid pump Red orange 2001
4 Alkali pump Signal yellow 1003
5 Acid spray Red orange 2001
6 Alkali spray Signal yellow 1003
7 Anion exchangers Leaf green 6002
Rev 4 – May, 2014 Page 46 of 54

Code
8 Cation exchangers Leaf green 6002
9 Mixed beds Leaf green 6002
10 Resin trap Grass greet 6010
11 DM water pump Pale green 6021
12 DM water tank Pale green 6021
13 Washing pump Grass greet 6010
14 Back-washing pump Leaf green 6002
15 Resin transport Trolly Grass greet 6010
16 Water pump Grass greet 6010
17 Acid metering tank Red orange 2001
18 Alkali metering tank Signal yellow 1003
19 Acid metering pump Red orange 2001
20 Alkali metering pump Signal yellow 1003
Water supply
1 Circulating water pump Pigeon blue 5014
2 Washing pump Pigeon blue 5014
3 Rotating type screen Pigeon blue 5014
4 Service water/Potable Pigeon blue 5014
water/Wastewater system
5 Potable water pump Pigeon blue 5014
6 Service water pump Pigeon blue 5014
7 Mechanical filtration equipment Grass greet 6010
8 Sanitary sewage wastewater Grass greet 6010
equipment
13.18. THERMAL INSULATION

The Contractor shall furnish and install insulation for all piping, ducting, vessels and
equipment which could have a surface temperature of 50oC or higher. As much as
possible all insulating materials shall be procured in Vietnam.
The material shall comply with the following standard specifications or equivalent for
mineral fiber:
 Pipesections ASTM C547-77 class 3
 Wired mats ASTM C592-80 class 2
 Block and board ASTM C612-83 class 4
 Density (general) ASTM C612-83 annex
Rev 4 – May, 2014 Page 47 of 54
The design value of radiated heat for insulation material shall be as follows:
 Radiated heat Not more than 200 kcal/m2h
 Difference between surface temperature of insulation material and ambient
temperature:
Equipment and Pipe Temperature Temperature Difference
 300oC min. 20oC max.
 200oC min. 15oC max.
 Under 200oC 10oC max.
(Ambient temperature: air temperature at place 500 mm distant perpendicularly from heat
radiating surface)
Thermal insulation shall refer to the supply and application of all heat insulation materials
together with all necessary associated materials such as fastenings, vapour barriers,
jacketing cements, adhesives, etc., which are used as insulating materials for piping,
vessels, ductwork and equipment for the purpose of reducing heat loss, prevention of
condensation and for personnel protection.
All insulation materials for hot application shall be of nonflammable insulation materials,
compatible with the surface being covered and shall not cause corrosion of the covered
material. All insulation material shall be chemically inert and remain so in the event of
being saturated with water. Asbestos insulation material is not acceptable.
Insulation for condensation prevention shall be applied to equipment, plant, piping, etc.
operating at temperatures below the maximum dew-point where condensation could form
to the detriment of plant structures or equipment or cause discomfort to operating
personnel.
Insulation immediately adjacent to hot surfaces shall be capable of withstanding the full
temperature conditions without deterioration or breakdown of the material and due
allowance shall be made for expansion.
The type and thickness of insulation materials used shall be entirely suitable for the
particular application and shall be subjected to approval by the Owner. Calcium silicate
shall be used for insulation of hot surfaces of indoor pipes and Perlite (water repellent
type) for insulation of surfaces of outdoor pipes unless otherwise approved by the Owner.
Sprayed on "asbestos free" insulation shall be provided on irregularly shaped items of
equipment. The type of jacketing to be used shall be capable of withstanding the site
atmospheric conditions without surface deterioration. All insulation shall be covered with
more than 0.6 mm aluminum sheets jacket for piping and vessels.
Where regular inspection of the equipment is required, the insulation and/or protection
must be readily removable. Where access across pipework or insulation is required, the
insulation must be protected by checker plating or other suitable protection.
Access doors to the boiler casings and the exhaust stacks must be insulated to a similar
degree as the casings. Insulation of doors must be removable and replaceable so that
access can be gained without causing damage to nearby insulation.
Cladding must be made of aluminium and not less than 0.7mm. (22 SWG) in thickness
and must be adequately supported to prevent sagging or excessive deflection. All
aluminium cladding must be coated to prevent the appearance of oxidation. In the case of
exterior surfaces, it must be designed to resist wind loadings. Due allowance must be
made in the design and fixing of the cladding for thermal expansion of the lagged surface.
Rev 4 – May, 2014 Page 48 of 54
Where necessary, expansion joints must be provided in insulating materials. All joints in
cladding must be waterproof.
Thermal insulation of valves, strainers and fittings must be of modular design structure to
allow efficient dismantling and installation and “cladding and insulation” together.
Ceramic insulation blankets must be used to insulate turbine cylinders, steam chests and
loop pipes.
Cladding and insulation over all flanges and valves must be easily removable and
replaceable without disturbing the surrounding insulation. The separate portion of the
cladding and insulation must extend sufficiently far along the pipe to allow the joint bolts
and nuts to be withdrawn without disturbing the cladding and insulation on the pipe. The
casing over flanges must have a drain hole to indicate the presence of a leak.
13.19. ELECTRICAL, CONTROL AND INSTRUMENT PANELS/CUBICLES

13.19.1.Panel Lighting and Heaters
Panels containing apparatus that requires regular routine testing and maintenance must
be fitted with a lamp (or lamps) to adequately illuminate all wires and apparatus as
evenly as possible without glare.
Electrical equipment including switchgear, panels and cubicles must be provided with
totally enclosed, metal clad type anti-condensation heaters with thermostat control.
The surface temperature of the heater with which accidental contact may be made must
not exceed 60oC.
13.19.2.Wire and Terminal
Internal wiring must be of copper conductor. All wiring must be protected from
abrasion and the location and routing must minimize the risk of damage from heat,
steam, oil and hydraulic fluids.
To prevent accidental contact, shrouds or covers must be provided over terminals that
are energized above 50V. Low voltage 3 phase AC circuits must be separately bunched
and segregated with appropriate warning labels. They must not be run in common
wiring troughs or through flexible trunking with circuits at other voltages unless the
higher voltage wiring has double insulation.
Adequate segregation of circuits susceptible to alternating current “pick-up” from
cables carrying AC must be provided.
Terminal block for outgoing connections must provide 20% spare ways, in excess of
those required for active cores. Not more than two connections may be made to a
terminal on one side of a terminal block. Internal and external connections of a cubicle
etc. must not be on the same side of a terminal.
Terminals must be numbered systematically and all wires must have an identification
marker at each end numbered. Terminal numbers and wire marker must be shown and
matched in relevant drawing.
13.19.3.Electromagnetic Interference
Equipment must not generate electrical or electromagnetic interference at a level
which could be detrimental to the performance of other equipment or which could
cause annoyance or discomfort to personnel.
Particular attention must be paid to minimize the effects of radio frequency
interference which could emanate from a 3 Watt ERP mobile radio telephone operating
at VHF or UHF. In this connection, undue reliance must not be placed upon the fact
that the equipment is earthed, as at radio frequencies the earth impedance may be
Rev 4 – May, 2014 Page 49 of 54
significant. As a minimum, the operation of 3 Watt ERP radio (walkie-talkie) must

pose no detrimental effect to the control and distributed control systems, in particular,
the keyboard, mouse and trackball of these systems.
13.19.4.Panel/Cubicle Classification
Equipment housings must normally be made of appropriately coated steel sheet.
Adequate framework must be constructed internally to support the housing and the
equipment mounted on it. Panels / cubicles placed outdoor must be made by stainless
steel.
Instrumentation must perform sensing, indicating, transmitting functions as required
for safe, efficient, reliable operation of the unit and station plant.
Where required, shock absorbing mountings must be supplied for instrumentation
equipment. Instrumentation must be protected from the weather and also accidental
tampering.
13.20. PROHIBITED MATERIALS

The Facility must not incorporate:
 Asbestos or asbestos-containing materials
 Cast iron for any oil service;
 PCBs
 Askerals
 CFC’s or other ozone depleting substances
 Carcinogenic materials;
 Any other materials generally known in the construction industry at the time of
use to be harmful to health.
13.21. ENVIRONMENTAL PROTECTION

The Site construction, erection, commissioning and initial plant operation works shall be
carried out by the Contractor under careful consideration to negative impacts on the local
environment such as air pollution, water pollution, noise, vibration etc.
Mitigation measures shall be provided by the Contractor but not be limited to the
following:
 Control of air pollution and dust;
 Prevention of water pollution by preventing oil, chemicals, waste, silt and dust,
coal dust, ash, etc being discharged into water sources;
 Control of erosion;
 Restoration of soil, rock and gravel borrow pits;
 Control of noise and vibration;
 Safe disposal of solid and liquid wastes;
 Responding to emergency situations;
13.21.1.Environmental Management Plan (EMP)
An Environmental Management Plan (EMP) shall be developed by the Contractor and
submitted for the acceptance of the Owner before the commencement of Work on Site
and not later than one (1) month after Effective Date of the Contract. The Contractor
Rev 4 – May, 2014 Page 50 of 54
shall assign the specific responsibility for application of the EMP to the Contractor’s
Site Manager or Safety Manager.
a. Objectives
The Environmental Management Plan shall address the following objectives:
 Encourage good management practices by planning, commitment and continuous
improvement of environmental practices;
 Define day-to-day roles and environmental responsibilities for Site personnel;
 Define how the management of the environment is reported and performance
evaluated;
 Identify and control possible environmental hazards associated with the power
station’s operation and associated activities to ensure information is up-to-date and in
compliance;
 Describe work practices, procedures and controls established to ensure compliance,
best practice and prevent impacts and minimize risks related to environmental issues;
 Describe all monitoring procedures required to identify impacts on the environment
of the Station’s operation and activities; and
 Establish procedures for response to actual or potential environmental problems,
community complaints and ensure corrective action is taken.
b. Scope
The Environmental Management Plan shall cover the following:
 Air Quality control
 Fugitive emissions
 Noise control
 Chemicals
 Storm water
 Solid waste
 Liquid waste
 Receiving water quality
 Complaints
 Emergency Response.
c. Management Plan Elements
Environmental Management Plans shall comprise the following elements:
 Policy
 Performance Objective
 Implementation Strategy/Mitigation Measures
 Monitoring
Rev 4 – May, 2014 Page 51 of 54
 Reporting
 Identification of Incident or Failure to Comply
 Corrective Action.
13.21.2.Environmental Training
The Contractor shall be responsible for ensuring environmental training and awareness
programs are provided to construction staff. Specific attention should be made to
incident management and reporting, use of plant and equipment, noise control, water
quality control, Site access/no-go areas. All construction staff is required to participate
in an induction program so that a minimum level of environmental awareness is
achieved. This induction program shall be directed to assist in minimizing any Site
environmental problems including noise, air and water quality, solid waste and
contamination. The Contractor shall maintain a record of all training undertaken for all
employees, detailing the type and purpose of the training.
13.21.3.Monitoring Requirements for Construction and Commissioning
Works
All determinations of the quality of contaminants released to the environment as air
quality, waste water quality, solid waste and all measurement and reporting of noise
and vibration levels that are required must be undertaken by a person or body
possessing appropriate experience and qualifications to perform the required
determination and the required measurements.
All instruments and devices used for the measurement or monitoring of any parameter
under any condition of the EMP must be calibrated, and appropriately operated and
maintained.
The Contractor shall be responsible to install the Continuous Environmental
Monitoring system (CEMS) to measure concentration of CO, SO2, NOx, TSP and
temperature in flue gas flow at stacks.
The Contractor shall be responsible to implement periodical environmental monitoring
report complying with environmental impact assessment report approved by
Vietnamese Ministry of Natural Resources and Environment.
13.21.4.Reporting Requirements
The Contractor shall submit to the Owner with a written report at the end of every
month during the construction period to report on compliance with the elements of the
Environmental Management Plan.
In respect of each of the elements of the EMP, the Contractor shall detail the progress
of works during the period since the last report. The report shall also detail the results
of any construction phase inspections or monitoring of environmental safeguards
undertaken. This shall include details such as who undertook the monitoring, where the
monitoring was done, when the monitoring was done and as necessary, how this
monitoring was carried out and the results of monitoring.
The report shall detail any corrective actions taken by the Contractor during the period
since the previous monthly report.
Each element of the EMP shall be addressed in the report notwithstanding that no
action has occurred during the period since the last report.
13.21.5.Auditing Requirements
The Contractor shall undertake and report on all auditing requirements of the EMP.
Rev 4 – May, 2014 Page 52 of 54
13.21.6.Environmental Incidents
As soon as reasonably practicable after becoming aware of any emergency or incident
which results in the release of contaminants not in accordance, or reasonably expected
to be not in accordance with the conditions the EMP or otherwise having potential to
cause environmental harm, the Contractor must notify the Owner and the responsible
authorities of the release by telephone or facsimile.
A record of events shall be maintained by the Contractor and this shall include, but not
be limited to the following:
 The location of the emergency or incident;
 The details (i.e., name and telephone number) of the person reporting the emergency
or incident;
 The estimated time of the release;
 The time at which the Contractor was made aware of the emergency or incident;
 The suspected cause of the emergency or incident;
 The environmental harm and or environmental nuisance caused, threatened, or to be
caused by the emergency or incident; and
 Actions already taken to prevent further any release and mitigate any environmental
harm and or environmental nuisance caused by the emergency or incident.
Not more than 14 days following the initial notification of an emergency or incident,
the Contractor must provide written advice of the above in addition to:
 proposed actions to prevent a recurrence of the emergency or incident (i.e.
amendments to the EMP);
 outcomes of actions taken at the time to prevent or minimize environmental harm and
or environmental nuisance; and
 The results of any environmental monitoring performed.
13.21.7.General Environmental Responsibilities of Staff Employed by the
Contractor
If any person while performing their work notices that serious or material
environmental harm is being caused or threatened by their actions or the actions of
someone else, they should then report the matter.
The Contractor will have a responsibility to:
 Comply with all Vietnamese environmental regulations and standards;
 Conform to the requirements of the Owner;
 Comply with the requirements of the EMP;
 Undertake any training required to effectively perform its environmental
responsibilities and procedures;
 Ensure its servants or agents report environmental accidents and incidents and
participate in their investigation and implementation of corrective action; and
Rev 4 – May, 2014 Page 53 of 54
 Ensure its servants or agents promptly notify any cases of environmental harm, either
actual or threatened by their actions, or by the actions of another person, to the
Owner/Engineer.
 Immediately notify and provide copies to the Owner/Engineer of any notices,
directions or orders under an Environmental Regulations.
 Consult with the Owner on the conditions, including draft conditions, of any
proposed permit, authority, acceptance required under any Environmental
Regulations in respect of the work under the Contract or occupation of the Site.
Rev 4 – May, 2014 Page 54 of 54

SH1.RFP - P4 OTR - Ch13 General Technical Requirements - 140530

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Chapter

13.9.3. Piping ............................................................................................................................ 27

13.21.5. Auditing Requirements ................................................................................................ 52

13.1. OVERALL REQUIREMENTS

13.2. PLANT IDENTIFICATION AND LABELING

least 15 alphanumerical characters must be used to identify all equipment and

13.3. HAZARDS & OPERABILITY (HAZOP) STUDY

 Turbine lubrication oil system

13.4. MATERIAL AND WELDING

 above 525oC ASTM A 335 Grade P 22, 91

be well experienced in the supervision of welding on construction sites and shall

weld. Attachments bridging principal welds shall be designed to give a minimum

13.4.4.12. Weld Repairs

13.5. PROTECTIONS, GUARDS AND SUNSHADES

13.6. PLATFORMS, WALKWAYS, STAIRS AND LADDERS

13.7. FIRE PROTECTION REQUIREMENTS

13.8. LOCKS AND KEY CABINETS

13.9. PIPING, VALVES & FITTINGS

in addition to the other mandatory Vietnamese standards mentioned elsewhere in the

All valves shall be arranged to open by counter-clock-wise rotation of the

13.9.2.4.Motor Operated Valves

(c) Butterfly Valves

(c) Vacuum Relief Valves

13.11. UNFIRED-PRESSURE VESSELS AND STORAGE TANKS

protective guards against mechanical shock shall be provided.

13.12. HEAT EXCHANGERS

13.13. PLATES AND STEEL SECTIONS

13.14.2.Cast Iron Castings

13.16. BOLTS, STUDS AND NUTS

13.17. CORROSION PROTECTION & PAINTS

Equipment Colour RAL Color

Equipment Colour RAL Color

Equipment Colour RAL Color

Equipment Colour RAL Color

13.18. THERMAL INSULATION

13.19. ELECTRICAL, CONTROL AND INSTRUMENT PANELS/CUBICLES

significant. As a minimum, the operation of 3 Watt ERP radio (walkie-talkie) must

13.20. PROHIBITED MATERIALS

13.21. ENVIRONMENTAL PROTECTION

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