Documente Academic
Documente Profesional
Documente Cultură
00 IFP ISSUED FOR ENQUIRY / ORDER 22.02.2019 NMA 22.02.2019 NNG 22.02.2019 NNG -
Barcode
© thyssenkrupp Industrial Solutions (India) Private Limited 2017
Plant Client Contract Code Document ID Contract No.
A. TECHNICAL SPECIFICATION
1. ADAPTOR
Sr No. DESCRIPTION REV.
1.1 TECHNICAL SPECIFICATION FOR ITEM CODE WA0718 00
2. CONDENSATE BOOT
Sr No. DESCRIPTION REV.
2.1 TECHNICAL SPECIFICATION FOR ITEM CODE WX0817N 00
*2.2 TECHNICAL SPECIFICATION FOR ITEM CODE WX11048N 00
*2.3 TECHNICAL SPECIFICATION FOR ITEM CODE WX11049BN 00
3. FUNNEL
Sr No. DESCRIPTION REV.
3.1 TECHNICAL SPECIFICATION FOR ITEM CODE WX0518N 00
3.2 TECHNICAL SPECIFICATION FOR ITEM CODE WX0521N 00
3.3 TECHNICAL SPECIFICATION FOR ITEM CODE WX0522N 00
3.4 TECHNICAL SPECIFICATION FOR ITEM CODE WX0601N 00
3.5 TECHNICAL SPECIFICATION FOR ITEM CODE WX0603N 00
3.6 TECHNICAL SPECIFICATION FOR ITEM CODE WX0604N 00
3.7 TECHNICAL SPECIFICATION FOR ITEM CODE WX0605N 00
3.8 TECHNICAL SPECIFICATION FOR ITEM CODE WX1119N 00
3.9 TECHNICAL SPECIFICATION FOR ITEM CODE WX0533N 00
*3.10 TECHNICAL SPECIFICATION FOR ITEM CODE WX0810N 00
*3.11 TECHNICAL SPECIFICATION FOR ITEM CODE WX2102N 00
*3.12 TECHNICAL SPECIFICATION FOR ITEM CODE WX2201N 00
*3.13 TECHNICAL SPECIFICATION FOR ITEM CODE WX2601N 00
*3.14 TECHNICAL SPECIFICATION FOR ITEM CODE WX2610N 00
*3.15 TECHNICAL SPECIFICATION FOR ITEM CODE WX2613N 00
4. INSERTION NOZZLE
Sr No. DESCRIPTION REV.
4.1 TECHNICAL SPECIFICATION FOR ITEM CODE WX05207N 00
4.2 TECHNICAL SPECIFICATION FOR ITEM CODE WX0617N 00
4.3 TECHNICAL SPECIFICATION FOR ITEM CODE WX0801N 00
4.4 TECHNICAL SPECIFICATION FOR ITEM CODE WX0802N 00
4.5 TECHNICAL SPECIFICATION FOR ITEM CODE WX1115N 00
4.6 TECHNICAL SPECIFICATION FOR ITEM CODE WX3102N 00
5. MIXING POT
Plant Client Contract Code Document ID Contract No.
6. SAMPLE CHAMBER
Sr No. DESCRIPTION REV.
6.1 TECHNICAL SPECIFICATION FOR ITEM CODE WX0003AN 00
6.2 TECHNICAL SPECIFICATION FOR ITEM CODE WX0003BN 00
*6.3 TECHNICAL SPECIFICATION FOR ITEM CODE WX0003DN 00
7. SAMPLE VALVE
Sr No. DESCRIPTION REV.
7.1 TECHNICAL SPECIFICATION FOR ITEM CODE WX1124N 00
7.2 TECHNICAL SPECIFICATION FOR ITEM CODE WX1125N 00
8. SEAL POT
Sr No. DESCRIPTION REV.
8.1 TECHNICAL SPECIFICATION FOR ITEM CODE WX06035N 00
8.2 TECHNICAL SPECIFICATION FOR ITEM CODE WX0607N 00
8.3 TECHNICAL SPECIFICATION FOR ITEM CODE WX3103N 00
*8.4 TECHNICAL SPECIFICATION FOR ITEM CODE WX2615N 00
9. SIGHT GLASS
Sr No. DESCRIPTION REV.
9.1 TECHNICAL SPECIFICATION FOR ITEM CODE WGMG32 00
12. STRAINER
Sr No. DESCRIPTION REV.
12.1 TECHNICAL SPECIFICATION FOR ITEM CODE YH 820 00
15.BIRD CAGE
Sr No. DESCRIPTION REV.
*15.1 TECHNICAL SPECIFICATION FOR ITEM CODE WX26017N 00
16.RAINHOOD
Sr No. DESCRIPTION REV.
*16.1 TECHNICAL SPECIFICATION FOR ITEM CODE WX2612 00
B. ANNEXURES
7. General Engineering Specification fot Start up conical strainer & spacer for Rubber lined, PTFE
lined, FRP, FRP lined Piping, Doc.No :-PIN-LES-PIP-6290 ,Rev.00
9. General Technical Requirements for Special Parts, Doc. no. PIN-LES-PIP-6243 , Rev.00
10. General Engineering Specification dimensional details of Splash Guard for Plastic Piping, Refer
Doc.No.: PIN-lES-PIP-6264, Rev.01.
11. General Engineering Specification dimensional details of Splash Guard for Steel Piping, Refer Doc.
No.: PIN-LES-PIP-6306, Rev.00.
6833)($785( )25*(1(5$/7(&+1,&$/5(48,5(0(176
6833)($785( 5()(5'2&123,1/(63,3
6833)($785( 5()(5(1&/7(&+63(&6)25)533,3,1*
6833)($785( ,7(072%(68,7$%/()25¶¶.JFP
6833)($785( )25*(1(5$/7(&+1,&$/5(48,5(0(176
6833)($785( 5()(5'2&123,1/(63,3
6833)($785( 5()(5(1&/7(&+63(&6)25)533,3,1*
6833)($785( '2&123,1/(63,3
6833)($785( ,7(072%(68,7$%/()25¶¶.JFP
6833)($785( )25*(1(5$/7(&+1,&$/5(48,5(0(176
6833)($785( 5()(5'2&123,1/(63,3
6833)($785( 5()(5(1&/7(&+63(&6)25)5339&&3,3,1*
6833)($785( '2&123,1/(63,3
6833)($785(
6833)($785( )25*(1(5$/7(&+1,&$/5(48,5(0(176
6833)($785( 5()(5'2&123,1/(63,3
6833)($785( 5()(5(1&/7(&+63(&6)25)5339&3,3,1*
6833)($785( '2&123,1/(63,3
6833)($785(
6833)($785( )25*(1(5$/7(&+1,&$/5(48,5(0(176
6833)($785( 5()(5'2&123,1/(63,3
6833)($785( 5()(5(1&/7(&+63(&6)25)5339&3,3,1*
6833)($785( '2&123,1/(63,3
6833)($785(
SUPP. FEATURE-5 :
6833)($785( )25*(1(5$/7(&+1,&$/5(48,5(0(176
6833)($785( 5()(5'2&123,1/(63,3
6833)($785( 5()(5(1&/7(&+63(&6)25)5339&3,3,1*
6833)($785( '2&123,1/(63,3
6833)($785(
6833)($785( )25*(1(5$/7(&+1,&$/5(48,5(0(176
6833)($785( 5()(5'2&123,1/(63,3
6833)($785( 5()(5(1&/7(&+63(&6)25)533,3,1*
6833)($785( '2&123,1/(63,3
6833)($785(
6833)($785( )25*(1(5$/7(&+1,&$/5(48,5(0(176
6833)($785( 5()(5'2&123,1/(63,3
6833)($785( 5()(5(1&/7(&+63(&6)25)533,3,1*
6833)($785( '2&123,1/(63,3
6833)($785(
6833)($785( )25*(1(5$/7(&+1,&$/5(48,5(0(176
6833)($785( 5()(5'2&123,1/(63,3
6833)($785( 5()(5(1&/7(&+63(&6)25)533,3,1*
6833)($785( '2&123,1/(63,3
6833)($785(
SUPP. FEATURE-5 :
SUPP. FEATURE-5 :
SUPP. FEATURE-3 :
SUPP. FEATURE-4 :
SUPP. FEATURE-5 :
SUPP. FEATURE-3 :
SUPP. FEATURE-4 :
SUPP. FEATURE-5 :
6833)($785( )25*(1(5$/7(&+1,&$/5(48,5(0(176
6833)($785( 5()(5'2&123,1/(63,3
6833)($785( 5()(5(1&/7(&+63(&6)25)533,3,1*
6833)($785( '2&123,1/(63,3
6833)($785( ,7(072%(68,7$%/()25¶¶.JFP
SUPP. FEATURE-5 :
Customer Logo
TECHNICAL REQUIREMENTS FOR (if applicable for Contract Specific Document)
Contents:
Barcode
© Copyright 2017 : All rights reserved
ThyssenKrupp Industrial Solutions (India) Private Limited
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6243 (Contract Specific ---
Document ID if adopted document)
SPECIAL PARTS
Rev 01 Page 2 of 5
1 INTENT OF SPECIFICATION
1.1 This specification is intended to cover design, manufacture, assembly, cleaning, inspection, testing,
delivery & proper packing for transportation of special parts.
2 GENERAL REQUIREMENTS
2.2 Size and quantities of special parts covered under this specification are indicated in Bill of Material
enclosed, unless stated otherwise.
2.3.1 The technical part of the offer must consist of tkIS (India) Technical Specification for the particular item in
which the vendor has to mark clearly 'YES' against each line of the specification sheet under the column
"Confirm to spec " if there is no deviation to tkIS (India) Specification.
2.3.2 In case the bidder is taking a deviation from tkIS (India) spec, the bidder should clearly state the
deviation under column “Deviations”. Deviations indicated anywhere else will not be entertained. The
sheet must bear the seal and signature of the bidder in the technical specification sheet.
2.3.3 If the bidder is regretting or has no deviation to state for any specific component code the bidder shall
clearly specify on the applicable component specification sheet as "regret" or "no deviation".
2.3.4 Failure to submit documents as specified in Clauses 2.3.1 to 2.3.3 above, shall lead to rejection of the
offer.
Approval of drawings shall be valid for construction features, dimensions & material
specification. In case the drawing is approved with comments, then the drawing shall not be re-
submitted for final approval. These comments shall be incorporated in final documentation drawings.
2.5.1 The final drawing submitted for documentation shall incorporate the material and dimensional details as
per the order specification with the constructional features remaining unchanged.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6243 (Contract Specific ---
Document ID if adopted document)
SPECIAL PARTS
Rev 01 Page 3 of 5
The following details are required to be confirmed/ provided for the items as listed below.
2.7 HOSES
a) For Class 150 flanged end unlined strainers face to face dimension shall be as per ASME B16.10
(Y-type Globe Valve, Class 150). However, for strainers above Class 150 and ends other than that
stated above, face to face dimension shall be as per manufacturer's standard.
b) Steam traps and lined sight glass shall have face to face dimension as per manufacturer's
standard.
c) Wherever the design manufacturing standard is specified as a specific sketch number in the
technical specification, the face to face dimension shall conform to that sketch unless otherwise
specified.
d) For Class 150 lined strainers, dimension specified in point no.(a) shall be followed, however this
face to face shall be considered before lining.
Rubber lining shall conform to IS 4682 Part 1 or BS 6374 Part 5 or other international standards. 1
Lining hardness shall be maintained to 65 r 5, shore “A” for soft rubber & 80 r 5 Shore “D” for hard
rubber unless otherwise specified.
SPECIAL PARTS
Rev 01 Page 4 of 5
3.1 Material/Heat Treatment Certificate shall be 100% reviewed. The completeness of each piece shall be
verified.Special parts of Alloy Steel, Stainless Steel & Non-Ferrous materials (except carbon steel), shall
be subjected to P.M.I Test as per below listed table.
Note:-
1) tkIS (India) reserves the right to increase the % of Witness based on vendor past performance.
2) In case of failures noticed during witness by tkIS (India), additional sampling shall be in accordance with
API 578.
3.2 Surface, dimension, identification, marking, leakage and functioning shall be inspected/ or witnessed by
inspector for 25% of the pieces, per size, per lot, per code including IBR items. For traps quantity to be
inspected shall be 1 no per size, per code, per visit. Visual inspection will be 100% by tkIS (India) /TPIA
3.3 Non-destructive testing (if specified in the technical specification) shall be witnessed for PT & MPT for
100%. RT films & UT report shall be offered for tkIS (India) review including IBR items.
3.4 The test pressure against each rating/material for strainers & sight glass (without glass) shall be as per
Annexure-I and same shall be indicated on drawing.
3.5 Hydro test for hoses shall be done at a pressure of 1.6 times the design pressure and the bursting
pressure shall be minimum 3.15 times design pressure(Hydro), specified in the technical specification
and it shall be mentioned in drawing. Only certificate for burst test in lieu of actual testing is acceptable.
3.6 Hydro test for sight glass (with glass) shall be done at a pressure of 1.5 times the design pressure
specified in the technical specification.
3.7 Any other test as per vendors regular quality control procedure needs to be carried out by the vendor.
3.8 Spark test shall be carried out for lined items. PTFE lined & Rubber lined items shall be tested 5 KV per
mm of lining thickness, except for butyl rubber which will be tested at 1.5KV per mm of lining thickness.
3.9 Chloride content of water used for hydro testing of stainless steel items shall be < 50 ppm unless more
stringent requirement is specified in project specification.
3.10 The carbon percentage shall be as per individual ASTM material grade.
4 RADIOGRAPHY
4.1 Radiography wherever specified shall be done by X-ray/GAMMA ray to get the sensitivity. The RT shall be
carried out after heat treatment (if heat treatment is applicable).
4.2 Percentage of radiography to be carried out shall be as per individual technical specification.
5 IBR CERTIFICATION
5.1 For items described “IBR”, the same shall be in accordance with the latest IBR (Indian Boiler Regulation)
including the requirements specified in the specification.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6243 (Contract Specific ---
Document ID if adopted document)
SPECIAL PARTS
Rev 01 Page 5 of 5
5.2 For SW/BW end carbon steel items under IBR, the chemical composition shall confirm to the following:
5.3 For items described “IBR”, test certificate in applicable IBR forms shall be furnished, signed by IBR
Inspection Authority or an approved representative. IBR Items will be inspected by tkIS (India) /TPIA in
addition to IBR Inspection Authority.
5.4 For IBR items TC shall indicate all additional requirements (other than IBR) of Order Spec., Project
Spec., tkIS (India) Tag / Item Nos. etc., if not manufacturers Certificate shall be submitted with all details
duly witnessed / or reviewed by tkIS (India) / TPIA as applicable shall be submitted.
6 MARKING
6.1 The marking on each piece shall be done as per Design Manufacturing Standard and the identification
indicated in the Bill of Material attached. Use of hard punch is not allowed for wall thickness less than
3.2mm to avoid notch effect. In such case marking shall be done on stainless/aluminum tag which
should be secured to the special part. Wherever applicable, the direction of flow shall be clearly marked.
7.1 All carbon steel parts shall be painted with two coats of synthetic enamel/aluminum paint/silicon paint or
as per technical specification.
7.2 Galvanizing of the CS parts shall confirm to ASTM A 123/A 123M, unless otherwise specified in technical
specification.
8 GUARANTEE
8.1 Vendor to guarantee usage of all special parts covered under this specification for applicable process
fluids with pressure /temp conditions as specified in the respective technical data sheets. All the special
parts shall be guaranteed for trouble free operation for the period specified in the Commercial part of the
Enquiry document.
9.1 After inspection and testing, the special parts shall be properly packed in wooden boxes. The flanges
shall be closed with plate covers, wooden planks / plastic to avoid transportation damage. Socket
weld/screwed ends shall be closed using plastic caps.
10 MAINTENANCE SPARES
10.1 Bidder should furnish a complete list of maintenance spares required for two years trouble free operation
along with recommended quantities and quote the price for the same.
Technical Requirements for Special Parts Document ID : PIN-LES-PIP-6243-A01,
Annexure - I Rev.1
Test Pressure for Special Parts Page No. 1 of 1
Contents:
1 SUBJECT ...................................................................................................................................2
2 SCOPE.......................................................................................................................................2
3 REQUIREMENTS..........................................................................................................................2
4 TESTS AND CERTIFICATE.............................................................................................................2
5 INSPECTION...............................................................................................................................4
6 MARKING ...................................................................................................................................4
7 PACKING....................................................................................................................................4
8 DOCUMENTATION.......................................................................................................................4
9 PRESSURE TEST AND LEAK TEST AFTER ERECTION .......................................................................5
01 Generally revised and re-issued 12.09.2017 SHK 12.09.2017 NNG 12.09.2017 APK
Previous Doc.No. PI-000-BD-00062,
Rev.0, is revised and reissued as PIN-
00 10.06.2015 SHK 10.06.2015 NNG 10.06.2015 APK -
LES-PIP-6244 due to new document
numbering philosophy.
Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: -
1 SUBJECT
This enquiry enclosure contains uniform recommendations for quality assurance activities during
fabrication and shipment.
2. SCOPE
This enquiry enclosure covers supply and erection of pipes, piping components, pipe connections
and prefabricated pipelines of glass fiber reinforced plastic on the basis of unsaturated polyster
resins, unlined. It shall apply in conjunction with the enquiry letter.
In the event of discrepancies between this enquiry enclosure and the enquiry letter, the latter shall
apply.
3. REQUIREMENTS
The requirements specified in the "Piping Material Summary Form" and the standards indicated
therein, particularly tkIS (PDE) standard UN 3030-16, Part - 1, shall apply.
The following additional requirements shall also be observed:
It is imperative that all requirements specified in AD specification N1, Sec. 2.2 must be fulfilled by the
manufacturer. Vendor shop shall be approved by tkIS (India).
3.2 FABRICATION
3.2.1 The pipes shall have their natural color with UV - absorber.
3.2.2 All flanged fittings and nozzles shall have loose steel flanges.
3.2.3 Branch connection shall be of Stub-in construction and shall preferably be made at shop. Sharp
corner shall be filled up with resin to make a radius at the joint.
3.2.4 All the exposed glass surfaces shall be covered / protected with resin.
3.2.5 Elbow construction shall be according to DIN 16966 Part - 2 without the straight portion.
3.2.6 Laminated joint shall have the same laminate structure of the pipe without the first glass tissue.
3.2.7 Additional one mat shall be laid for branches of NS < 2" for increasing mechanical strength, over and
above the regular laminate structure.
3.2.9 Laminated connections to DIN 16966, parts 7 and 8, shall comply with the PN of the connecting pipe.
Tests shall be performed according to tkIS (PDE) standard UN 3030-16, Part-1, and the codes and
standards indicated therein.
4.1.1 The manufacturer of the materials used such as reinforcing materials, fillers etc. shall certify the
properties of said materials, and assume the related guarantee.
Prior to starting the fabrication, the pipe manufacturer shall take the measures required to make the
materials ready for use. (Furnish the related workshop document).
4.1.2. It is imperative that measures be taken to avoid nonconformity of the materials. This applies
particularly to the different resin types. (Furnish related work-shop document).
4.1.3 The manufacturer shall ensure adequate quality assurance. This includes records showing that the
pipes, piping components and pipe connections correspond to the rules of good workmanship.
2 4.1.4 The material requirement shall comply as per UN 3030-16 Part1, Clause 2.1 and DIN 16964,Clause
2.
2 4.2.1 The manufacturer shall furnish documents corresponding to Sec. 4.8 of this document reflecting that
the short-time hydrostatic pressure tests have been performed as per Clause 3.2 and 4.1 of DIN
16964 & DIN 16966 Part1 and Part7.
4.2.2. At least three pre-fabricated pipes per type of resin or pipe shall be subjected to said hydrostatic
pressure test in accordance with the data indicated by tkIS (India) / Client in technical specification.
4.2.3 This type test is mandatory only in case of new approval of vendor shop.
2 4.3.2 Glass content shall comply DIN 16964,Clause 3.5 and 4.4.
4.3.3 While testing atleast three test specimens per type of laminate or resin required.
4.4.1 Shear strength requirement shall comply UN 3030-16 Part1,Clauses 3 and 4.2. The value of inter
laminar shear strength shall be attained while performing tensile strength as per EN ISO 14130 or by
2 inter laminar shear strength as per BS EN 13121-3.The inter laminar shear strength shall be atleast 8
N/mm2 at all bonding surfaces.
4.4.2 Tensile strength requirement shall comply DIN 16964, Clauses 3.3 and 4.2.
4.4.3 Scope of tests : At least one test specimen per type of resin.
4.5.1 The residual styrene content shall be examined as per DIN 16964, Clauses 3.6 and 4.5 and DIN
16966 Part 1 Clauses 3.5 and 4.4 and Part7 Clauses 3.4 and 4.3 and said examination to be
performed by a qualified laboratory within 7 days from the date of fabrication.
2
4.5.2 Scope of test : 3 test specimens per type of resin to be tested over the whole period of fabrication.
The related workshop records shall be furnished as evidence of said tests.
4.5.3 Styrene content test shall comply ISO 4901: 2011 (since DIN 53394 is withdrawn).
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6244 ---
4.6 HARDNESS
2 For pipe type E ,Hardness of minimum 25 to 35 BHN required by Barcol method as per BS EN 13121-3.
4.7.1 Vendor to comply DIN 16964, Clauses 3.7 , 3.12 , 4.6 and 4.10.
4.7.2 Said check shall be performed on all pipes, piping components and pre-fabricated pipe sections.
4.8 CERTIFICATES
The materials used for fabrication shall be furnished with a works certificate to DIN 50049-2.1
The tests indicated in Section 4.2 to 4.7 of this document shall be recorded in reports and shall be
witnessed by tkIS (India) / Client / Third Party Inspector.
5. INSPECTION
Major inspections will be witnessed by tkIS (India) / Client . The final inspection will be performed by
tkIS (India)/ Client. (Advice of readiness for inspection to be sent to tkIS (India).
6. MARKING
Pipes and piping components shall be marked in accordance with tkIS (PDE) standard UN 3030-16,
Part-1. Pipes and piping component shall have marking of pipe code, Resin used, Date of
manufacture, Manufacturer's name, Maximum allowable pressure and temperature.
6.1 Pre-fabricated pipes shall be marked with the isometric number and a serial number to
fabrication.Shop laminated connections shall be marked with the manufacturer’s symbol.
6.2 Pipes and piping components(incl. Collars and Flanges) shall be marked with tkIS (India) item
numbers.
7. PACKING
The edges of the flange faces and pipe ends shall be protected and loose flanges shall be fixed.
The components shall be packed using adequate fixing materials and soft spacers. For further details
refer to the order letter.
8. DOCUMENTATION
8.1 tkIS (India) preferences are provided as follows. Any deviation from the details furnished shall be
reported to tkIS (India) for approval.
8.2 Manufacturer shall furnish the details of the method to avoid penetration of air in to the outer resin.
Outer resin layer (top coat) shall be made with readymade resin mixed with paraffin.
8.3 Manufacturer shall provide the facility for storing the resin as per recommendation of resin
manufacturer. Shelf life of the resin shall be intimated to tkIS (India) / Client .
8.4 Manufacturer shall furnish the details of the oven for post-curing (heat treatment) of the pre-
assembled pipe components and the site joints if required.
8.5 Following information shall be included in the details of the oven, such as dimensions, heating
method, air revolution, provision of temperature recorder etc.
8.6 Manufacturer shall furnish the details of equipments available for mechanical testing and quality
control and laboratory for testing of resin mixtures / test panels etc. Barcol hardness tester shall be
used for testing.
The line must have been installed according to the laying instructions. Safety valves, rupture disks
and the like may not be installed. All valves in the system to be tested must be open during the test.
It shall be ensured that the test pressure cannot affect the position of the pipeline. In the case of thrust
non-resistant joints or expansion joints without limit stop, the line shall be sufficiently stiffened or
anchored at the ends, elbows, branches and shutoff devices.
9.1.2 Performance of Pressure Test
APPENDIX - I
LAMINATE STRUCTURE - PIPING CLASS PX
Note : The moulder to decide the laminate structure to arrive at the specified thickness as per the above
pressure ratings & wall thickness table and shall submit the same to tkIS (India) for approval.
All pipes, fittings and stub ends are to be produced by "hand lay up".
UV - absorbent in the whole laminate structure.
Heat treatment of pipes, pipe fittings such as Elbows, Stub Ends, Caps, Tees and Reducers and also
Site Joints. Temperature and Hours required for curing shall be communicated to tkIS (India).
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6244 A02 ---
APPENDIX - II
ERECTION OF FRP AND FRP-LINED PIPES AND FITTINGS
Following shall be included in the scope of FRP and FRP-Lined Piping Erection Contractor:
1) Erection of all free issued material like primary / secondary / special supports, in-line / control valves,
instruments, filters, strainers etc.
10) The Bidder to consider site adjustment / cutting / modification / mismatch up to 500 mm in length for
every 10 M Length of the pipeline in the Quoted unit price, without any extra cost to the Owner.
11) All small bore lines (up to 1 ½” NB size) are site routed lines, for which Bidder shall study the actual
site conditions, prior to fabrication of lines. Bidder shall not charge extra claim for any site adjustment
/ cutting / modification / mismatch in the routing & fabrication of the Lines and the Quoted unit price
shall include the same, without any extra cost to the owner.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6245 ---
Contents:
1 SUBJECT ...................................................................................................................................2
2 SCOPE.......................................................................................................................................2
3 REQUIREMENTS..........................................................................................................................2
4 TESTS AND CERTIFICATE.............................................................................................................2
5 INSPECTION ...............................................................................................................................4
6 MARKING ...................................................................................................................................4
7 PACKING....................................................................................................................................4
8 DOCUMENTATION.......................................................................................................................4
9 PRESSURE TEST AND LEAK TEST AFTER ERECTION .......................................................................5
Previous Doc.No.PI-000-BD-00063,
Rev.0, is revised and reissued as
00 10.06.2015 SHK 10.06.2015 NNG 10.06.2015 APK -
PIN-LES-PIP-6245 due to new
document numbering philosophy.
Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: -
1 SUBJECT
This enquiry enclosure contains uniform recommendations for quality assurance activities during
fabrication and shipment.
2 SCOPE
This enquiry enclosure covers supply and erection of pipes, piping components, pipe connections
and prefabricated pipelines of glass fiber reinforced plastic on the basis of unsaturated polyster
resins, unlined. It shall apply in conjunction with the enquiry letter.
In the event of discrepancies between this enquiry enclosure and the enquiry letter, the latter shall
apply.
3 REQUIREMENTS
The requirements specified in the "Piping Material Summary Form" and the standards indicated
therein, particularly tkIS (PDE) standard UN 3030-16, Part - 1, shall apply.
The following additional requirements shall also be observed:
It is imperative that all requirements specified in AD specification N1, Sec. 2.2 must be fulfilled by the
manufacturer. Vendor shop shall be approved by tkIS (India).
3.2 FABRICATION
3.2.1 The pipes shall have their natural color with UV - absorber.
3.2.3 All flanged fittings and nozzles shall have loose steel flanges.
3.2.4 Branch connection shall be of Stub-in construction and shall preferably be made at shop. Sharp
corner shall be filled up with resin to make a radius at the joint.
3.2.5 All the exposed glass surfaces shall be covered / protected with resin.
3.2.6 Elbow construction shall be according to DIN 16966 Part - 2 without the straight portion.
3.2.7 Laminated joint shall have the same laminate structure of the pipe without the first glass tissue.
3.2.8 Additional one mat shall be laid for branches of NS < 2" for increasing mechanical strength, over and
above the regular laminate structure.
3.2.9 Laminated connections to DIN 16966, parts 7 and 8, shall comply with the PN of the connecting pipe.
Tests shall be performed according to tkIS (PDE) standard UN 3030-16, Part-1, and the codes and
standards indicated therein.
PIN-QMC-03-F101 09-2016
4.1.1 The manufacturer of the materials used such as reinforcing materials, fillers etc. shall certify the
properties of said materials, and assume the related guarantee.
Prior to starting the fabrication, the pipe manufacturer shall take the measures required to make the
materials ready for use. (Furnish the related workshop document).
4.1.2. It is imperative that measures be taken to avoid nonconformity of the materials. This applies
particularly to the different resin types. (Furnish related work-shop document).
4.1.3 The manufacturer shall ensure adequate quality assurance. This includes records showing that the
pipes, piping components and pipe connections correspond to the rules of good workmanship.
2 4.1.4 The material requirement shall comply as per UN 3030-16 Part1, Clause 2.1 and DIN 16964, Clause
2.
4.2.1 The manufacturer shall furnish documents corresponding to Sec. 4.8 of this document reflecting that
the short-time hydrostatic pressure tests have been performed to as per Clause 3.2 and 4.1 of DIN
16964 & DIN 16966 Part1 and Part7.
4.2.2. At least three pre-fabricated pipes per type of resin or pipe shall be subjected to said hydrostatic
pressure test in accordance with the data indicated by tkIS (India) / Client in the technical
specification.
4.2.3 This type test is mandatory only in case of new approval of vendor shop.
2 4.3.2 Glass content shall comply DIN 16964,Clause 3.5 and 4.4.
4.3.3 While testing atleast three test specimens per type of laminate or resin required.
4.4.1 Shear strength requirement shall comply UN 3030-16 Part1,Clauses 3 and 4.2. The value of inter
laminar shear strength shall be attained while performing tensile strength as per EN ISO 14130 or by
inter laminar shear strength as per BS EN 13121-3.The inter laminar shear strength shall be atleast 8
N/mm2 at all bonding surfaces.
2
4.4.2 Tensile strength requirement shall comply DIN 16964, Clauses 3.3 and 4.2.
4.4.3 Scope of tests : At least one test specimen per type of resin.
2 4.5.1 The residual styrene content shall be examined as per DIN 16964, Clauses 3.6 and 4.5 and DIN
16966 Part 1 Clauses 3.5 and 4.4 and Part7 Clauses 3.4 and 4.3 and said examination to be
performed by a qualified laboratory within 7 days from the date of fabrication.
4.5.2 Scope of test : 3 test specimens per type of resin to be tested over the whole period of fabrication.
The related workshop records shall be furnished as evidence of said tests.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6245 ---
2 4.5.3 Styrene content test shall comply ISO 4901: 2011 (since DIN 53394 is withdrawn).
4.6 HARDNESS
For pipe type E ,Hardness of minimum 25 to 35 BHN required by Barcol method as per BS EN 13121-3.
2 4.7.1 Vendor to comply DIN 16964, Clauses 3.7 , 3.12 , 4.6 and 4.10.
4.7.2 Said check shall be performed on all pipes, piping components and pre-fabricated pipe sections.
4.8 CERTIFICATES
The materials used for fabrication shall be furnished with a works certificate to DIN 50049-2.1
The tests indicated in Section 4.2 to 4.7 of this document shall be recorded in reports and shall be
witnessed by tkIS (India) / Client / Third Party Inspector.
5 INSPECTION
Major inspections will be witnessed by tkIS (India) / Client. The final inspection will be performed by
tkIS (India) / Client (Advice of readiness for inspection to be sent to tkIS (India)).
6 MARKING
Pipes and piping components shall be marked in accordance with tkIS (PDE) standard UN 3030-16,
Part-1. Pipes and piping component shall have marking of pipe code, Resin used, Date of
manufacture, Manufacturer's name, Maximum allowable pressure and temperature.
6.1 Pre-fabricated pipes shall be marked with the isometric number and a serial number related to
fabrication. Shop laminated connections shall be marked with the manufacturer's symbol.
6.2 Pipes and piping components (incl. Collars and Flanges) shall be marked with tkIS (India) item
numbers.
7 PACKING
The edges of the flange faces and pipe ends shall be protected and loose flanges shall be fixed.
The components shall be packed using adequate fixing materials and soft spacers. For further details
refer to the order letter.
8 DOCUMENTATION
8.1 tkIS (India) preferences are provided as follows. Any deviation from the details furnished
shall be reported to tkIS (India) for approval.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6245 ---
8.2 Manufacturer shall furnish the details of the method to avoid penetration of air in to the outer resin.
Outer resin layer (top coat) shall be made with readymade resin mixed with paraffin.
8.3 Manufacturer shall furnish the total requirement of resin (ALPOLIT / VIAPAL UP797) alongwith detailed
breakup calculations to tkIS (India) / Client, to enable supply of the same as free issue material.
8.4 Manufacturer shall furnish the details of the oven for post-curing (heat treatment) of the pre-
assembled pipe components and the site joints if required.
8.5 Following information shall be included in the details of the oven, such as dimensions, heating
method, air revolution, provision of temperature recorder etc.
8.6 Manufacturer shall furnish the details of equipments available for mechanical testing and quality
control and laboratory for testing of resin mixtures / test panels etc. Barcol hardness tester shall be
used for testing.
The line must have been installed according to the laying instructions. Safety valves, rupture disks
and the like may not be installed. All valves in the system to be tested must be open during the test.
It shall be ensured that the test pressure cannot affect the position of the pipeline. In the case of thrust
non-resistant joints or expansion joints without limit stop, the line shall be sufficiently stiffened or
anchored at the ends, elbows, branches and shutoff devices.
The conditions mentioned hereafter shall apply for the preliminary test, unless agreed otherwise. The
preliminary test shall be carried out at 1.3 times the max. allowable working pressure. The duration of
the test shall be taken from Table 1. The test system shall be de-pressurised prior to the main test.
The main test shall be performed immediately after the preliminary test, the test pressure also being
1.3 times the max. allowable working pressure. According to Table 2 the duration of testing varies.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6245 ---
APPENDIX - I
LAMINATE STRUCTURE - PIPING CLASS PW
Note : The moulder to decide the laminate structure to arrive at the specified thickness as per wall thickness
table and shall submit to TKIS (India) for approval.
All pipes, fittings and stub ends are to be produced by "hand lay up".
UV - absorbent in the whole laminate structure.
Heat treatment of pipes, pipe fittings such as Elbows, Stub Ends, Caps, Tees and Reducers and also
Site Joints. Temperature and Hours required for curing shall be communicated to TKIS (India).
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6245 A02 (Contract ---
Specific Document ID if adopted document)
APPENDIX - II
ERECTION OF FRP AND FRP-LINED PIPES AND FITTINGS
Following shall be included in the scope of FRP AND FRP-Lined Piping Erection Contractor:
1) Erection of all free issued material like primary / secondary / special supports, in-line / control valves,
instruments, filters, strainers etc.
10) The bidder to consider site adjustment / cutting / modification / mismatch upto 500 mm in length for
every 10 M Length of the pipeline in the Quoted unit price, without any extra cost to the Owner.
11) All small bore lines (up to 1 ½” NB size) are site routed Lines, for which Bidder shall study the actual
size conditions, prior to fabrication of lines. Bidder shall not charge extra claim for any site adjustment
/ cutting / modification / mismatch in the routing & fabrication of the Lines and the Quoted unit price
shall include the same, without any extra cost to the Owner.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6246 ---
Contents:
1 SUBJECT ..............................................................................................................................................2
2 SCOPE..................................................................................................................................................2
3 REQUIREMENTS ....................................................................................................................................2
4 TESTS AND CERTIFICATE.......................................................................................................................3
5 INSPECTION..........................................................................................................................................4
6 MARKING..............................................................................................................................................4
7 PACKING ..............................................................................................................................................4
8 DOCUMENTATION .................................................................................................................................5
9 PRESSURE TEST AND LEAK TEST AFTER ERECTION ................................................................................5
01 Generally revised & re-issued 13.09.2017 SHK 13.09.2017 NNG 13.09.2017 APK
Previous Doc.No.PI-000-BD-00064,
Rev.0, is revised and reissued as
00 10.06.2015 SHK 10.06.2015 NNG 02.07.2015 APK -
PIN-LES-PIP-6246 due to new
document numbering philosophy.
Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: -
1 SUBJECT
This enquiry enclosure contains uniform recommendations for quality assurance activities during
fabrication and shipment.
2 SCOPE
This enquiry enclosure covers the supply and erection of pipes, piping components, pipe connections
and prefabricated pipelines of glass fibre reinforced plastic on the basis of unsaturated polyster resins,
with PVC-U liner. It shall apply in conjunction with the enquiry letter.
In the event of discrepancies between this enquiry enclosure and the enquiry letter, the latter shall
apply.
3 REQUIREMENTS
The requirements specified in the "Piping material summary" and the standards indicated therein,
particularly tkIS (PDE) standard UN 3030-16, Part - I, shall apply.
It is imperative that all requirements specified in AD specification N1, section 2.2 must be fulfilled by
the manufacturer. Vendor shop shall be approved by tkIS (India).
3.2 FABRICATION
3.2.1 The pipes shall have their natural color with UV - absorber.
3.2.2 All flanged fittings & nozzles shall have loose steel flanges.
3.2.3 The straight pipe sections and prefabricated components shall be supplied by the same manufacturer
and be of the same quality (proper welds).
3.2.4 All the exposed glass surfaces shall be covered / protected with resin.
3.2.5 Elbow construction shall be according to DIN 16966 Part - 2 without the straight portion.
3.2.6 Additional one mat shall be laid for branches of NS < 2" for increasing mechanical strength, over and
above the regular laminate structure.
3.2.7 Collars for fittings shall be integrally formed or solvent welded type.
3.2.8 Welds shall only be made by welders qualified to recommendation DVS 2212 / BS EN 13121-3. The
welders shall be supervised by qualified foremen.
3.2.9 Laminated connections to DIN 16966, parts 7 and 8, shall comply with the PN of the connecting pipe.
The welds shall be covered with a conductive layer prior to lamination in order to be able to examine
the welds later.
2 3.2.10 Lined pipes and piping components shall be seamless, filament wound, type B as per DIN 16965 Part
2.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6246 ---
The tests shall be performed according to tkIS (PDE) standard UN 3030-16, Part-1, and the codes and
standard indicated therein.
4.1.1 The manufacturer of the materials used such as reinforcing materials, fillers etc. shall certify the
properties of said materials, and assume the related guarantee.
Prior to starting the fabrication, the pipe manufacturer shall take the measures required to make the
materials ready for use. (Furnish the related workshop document).
4.1.2. It is imperative that measures to be taken to avoid nonconformity of the materials. This applies
particularly to the different resin types. (Furnish related work-shop document).
4.1.3 The manufacturer shall perform adequate quality assurance. This includes records showing that the
pipes, piping components and pipe connections correspond to the rules of good workmanship.
2 4.1.4 The material requirement shall comply as per UN 3030-16 Part1, Clause 2.1 and DIN 16964,Clause 2.
4.2.1 The manufacturer shall furnish documents corresponding to Sec. 4.9 reflecting that the short-time
hydrostatic pressure tests have been performed to as per Clause 3.2 and 4.1 of DIN 16964 & DIN
16966 Part1 and Part7.
4.2.2. At least three pre-fabricated pipes per type of resin or pipe shall be subjected to said hydrostatic
pressure test in accordance with the data indicated by tkIS (India) in the technical specification.
4.2.3 This type test is mandatory only in case of new approval of vendor shop.
2 4.3.2 Glass content shall comply DIN 16964,Clause 3.5 and 4.4.
4.3.3 While testing atleast three test specimens per type of laminate or resin required.
4.4.1 Shear strength requirement shall comply UN 3030-16 Part1,Clauses 3 and 4.2. The value of inter
laminar shear strength shall be attained while performing tensile strength as per EN ISO 14130 or by
inter laminar shear strength as per BS EN 13121-3.The inter laminar shear strength shall be atleast 8
N/mm2 at all bonding surfaces. Further adhesion related shearing strength for Pipe type B shall be as
2 per DIN 16964, Clauses 3.9 and 4.8 and DIN 16966 Part 7, Clauses 3.7 and 4.5.
4.4.2 Tensile strength requirement shall comply DIN 16964, Clauses 3.3 and 4.2.
4.5.1 The residual styrene content shall be examined as per DIN 16964, Clauses 3.6 and 4.5 and DIN
16966 Part 1 Clauses 3.5 and 4.4 and Part 7 Clauses 3.4 and 4.3 and, said examination to be
performed by a qualified laboratory within 7 days from the date of fabrication.
2
4.5.2 Scope of test : 3 test specimens per type of resin to be tested over the whole period of fabrication. The
related workshop records shall be furnished as evidence of said tests.
4.5.3 Styrene content test shall comply ISO 4901: 2011 (since DIN 53394 is withdrawn).
4.6 HARDNESS
For pipe type B,Hardness of minimum 25 to 35 BHN required by Barcol method as per BS EN 13121-3.
2 4.7.1 Vendor to comply DIN 16964, Clauses 3.7, 3.12, 4.6 and 4.10.
4.7.2 Said check shall be performed on all pipes, piping components and pre-fabricated pipe sections.
All welds of finished components shall be measured to DVS recommendation 2206 for leakage by
applying a voltage prior to lamination.
4.9 CERTIFICATES
The materials used for fabrication shall be furnished with a works certificate to DIN 50049-2.1
The tests indicated in Section 4.2 to 4.8 shall be recorded in reports and shall be witnessed by tkIS
(India) / Client / Third Party Inspector.
5 INSPECTION
Major inspections will be witnessed by tkIS (India) / Client. The final inspection will be performed by tkIS
(India) / Client. (Advice of readiness for inspection to be sent to tkIS(India))
6 MARKING
Pipes and piping components shall be marked in accordance with tkIS (PDE) standard UN 3030-16,
Part-1. Pipes and piping component shall have marking of pipe code, Resin used, Date of
manufacture, Manufacturer's name, Maximum allowable pressure and temperature.
6.1 Pre-fabricated pipes shall be marked with the isometric number and a serial number to fabrication.
Shop laminated connections shall be marked with the manufacturer’s symbol.
6.2 Pipes and piping components(incl. Collars and flanges) shall be marked with tkIS(India) item numbers.
7 PACKING
The edges of the flange faces and pipe ends shall be protected and loose flanges shall be fixed.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6246 ---
The components shall be packed using adequate fixing materials and soft spacers. For further details
refer to the order letter.
8 DOCUMENTATION
8.1 tkIS (India) preferences are provided as follows. Any deviation from the details furnished shall be
reported to tkIS (India) for approval.
C-Glass Tissue * 26 to 30 g/m^2
Width * 25 and 160mm
Chopped Strand Mat * 450 g/m^2 2
Width required * 25 and 160mm
Woven Roving Mat * 600 to 610 g/m^2
8.2 Manufacturer shall furnish the details of the method to avoid penetration of air in to the outer resin.
Outer resin layer (topcoat) shall be made with readymade Resin mixed with paraffin.
8.3 Manufacturer shall provide the facility for storing the Resin as per recommendation of Resin
manufacturer. Shelf life of the Resin shall be intimated to tkIS (India) / Client.
8.4 Manufacturer shall furnish the details of equipment's available for mechanical testing and quality
control and laboratory for testing of resin mixtures/test panels etc. Barcol Hardness tester shall be used
for testing.
The following shall apply to piping for which a pressure test and / or leak test is required. The type and
scope of the tests as well as the requirements to be met by the respective pipelines shall be
determined in the order.
The line must have been installed according to the laying instructions. Safety valves, rupture disks and
the like may not be installed. All valves in the system to be tested must be open during the test.
It shall be ensured that the test pressure cannot affect the position of the pipeline. In the case of thrust
non-resistant joints or expansion joints without limit stop, the line shall be sufficiently stiffened or
anchored at the ends, elbows, branches and shutoff devices.
A preliminary test must precede the main test. It serves to stop the change in volume, which depends
on the internal pressure and line temperature, to such an extent that the subsequent main test will
allow a definite conclusion to be drawn concerning the tightness of the section tested.
The pressure increase rate should not exceed 10 bar/min. The conditions mentioned hereafter shall
apply for the preliminary test, unless agreed otherwise. The preliminary test shall be carried out at 1.3
times the max. allowable working pressure. The duration of the test shall be taken from Table 1. The
test system shall be depressurised prior to the main test.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6246 ---
The main test shall be performed immediately after the preliminary test, the test pressure also being
1.3 times the max. allowable working pressure. According to Table 2 the duration of testing varies.
APPENDIX - I
ERECTION OF FRP AND FRP-LINED PIPES AND FITTINGS
Following shall be included in the scope of FRP and FRP-Lined Piping Erection Contractor:
1) Erection of all free issued material like primary / secondary / special supports, in-line / control valves,
instruments, filters, strainers etc.
10) The bidder to consider site adjustment / cutting / modification / mismatch upto 500 mm in length for
every 10 M Length of the pipeline in the Quoted unit price, without any extra cost to the Owner.
11) All small bore lines (up to 1 ½” NB size) are site routed Lines, for which Bidder shall study the actual
size conditions, prior to fabrication of lines. Bidder shall not charge extra claim for any site adjustment /
cutting / modification / mismatch in the routing & fabrication of the Lines and the Quoted unit price shall
include the same, without any extra cost to the Owner.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6261 (Contract Specific ---
Document ID if adopted document)
Customer Logo
GENERAL ENGINEERING SPECIFICATION (if applicable for Contract Specific Document)
1 GENERAL
This specification covers the General Assembly sketch and Dimensional Details for Spectacle Blind
Plastic.
PIN-QMC-03-F101 03-2015
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6264 (Contract Specific ---
Document ID if adopted document)
1. GENERAL
This specification covers the dimensional details of Splash Guard for Plastic Piping.
PIN-QMC-03-F101 03-2015
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6289 ---
Contents:
1 SUBJECT...................................................................................................................................................... 2
2 SCOPE ......................................................................................................................................................... 2
3 REQUIREMENTS ............................................................................................................................................2
4 TESTS AND CERTIFICATE ..............................................................................................................................2
5 INSPECTION .................................................................................................................................................4
6 MARKING...................................................................................................................................................... 4
7 PACKING ...................................................................................................................................................... 4
8 DOCUMENTATION .........................................................................................................................................4
9 PRESSURE TEST AND LEAK TEST AFTER ERECTION ........................................................................................5
01 Generally revised & re-issued 13.09.2017 SHK 13.09.2017 NNG 13.09.2017 APK
Previous Doc.No.PI-000-BD-00064,
Rev.0, is revised and reissued as
00 10.06.2015 SHK 10.06.2015 NNG 02.07.2015 APK -
PIN-LES-PIP-6246 due to new
document numbering philosophy.
Rev. Status Description Date Prepared Date Checked Date Approved AC
PIN-QMC-03-F101 09-2016
Based on : PIN-AAA-AAA-NNN
(to be indicated if adopted document)
Category Code: -
1 SUBJECT
This enquiry enclosure contains uniform recommendations for quality assurance activities during
fabrication and shipment.
2 SCOPE
This enquiry enclosure covers supply and erection of pipes, piping components, pipe connections and
prefabricated pipelines of glass fibre reinforced plastic on the basis of unsaturated polyster resins,
unlined. It shall apply in conjunction with the enquiry letter.
In the event of discrepancies between this enquiry enclosure and the enquiry letter, the latter shall
apply.
3 REQUIREMENTS
The requirements specified in the "Piping material summary" and the standards indicated therein,
particularly tkIS (PDE) standard UN 3030-16, Part - I, shall apply.
It is imperative that all requirements specified in AD specification N1, Sec. 2.2 must be fulfilled by the
manufacturer. Vendor shop shall be approved by tkIS (India).
3.2 FABRICATION
3.2.1 The pipes shall have their natural color with UV - absorber.
3.2.2 All flanged fittings & nozzles shall have loose steel flanges.
3.2.3 Branch connection shall be of Stub-in construction and shall preferably be made at shop. Sharp corner
shall be filled up with resin to make a radius at the joint.
3.2.4 All the exposed glass surfaces shall be covered / protected with resin.
3.2.5 Elbow construction shall be according to DIN 16966 Part - 2 without the straight portion.
3.2.6 Laminated joint shall have the same laminate structure of the pipe without the first glass tissue.
3.2.7 Additional one mat shall be laid for branches of NS < 2" for increasing mechanical strength, over and
above the regular laminate structure.
3.2.9 Laminated connections to DIN 16966, parts 7 and 8, shall comply with the PN of the communicating
pipe.
The tests shall be performed according to tkIS (PDE) standard UN 3030-16, Part-1, and the codes and
standard indicated therein.
4.1.1 The manufacturer of the materials used such as reinforcing materials, fillers etc. shall certify the
properties of said materials, and assume the related guarantee.
Prior to starting the fabrication, the pipe manufacturer shall take the measures required to make the
materials ready for use. (Furnish the related workshop document).
4.1.2. It is imperative that measures to be taken to avoid nonconformity of the materials. This applies
particularly to the different resin types. (Furnish related work-shop document).
4.1.3 The manufacturer shall perform adequate quality assurance. This includes records showing that the
pipes, piping components and pipe connections correspond to the rules of good workmanship.
2 4.1.4 The material requirement shall comply as per UN 3030-16 Part1, Clause 2.1 and DIN 16964,Clause 2.
2 4.2.1 The manufacturer shall furnish documents corresponding to Sec. 4.8 of this document reflecting that
the short-time hydrostatic pressure tests have been performed as per Clause 3.2 and 4.1 of DIN
16964 & DIN 16966 Part 1 and Part 7.
4.2.2. At least three pre-fabricated pipes per type of resin or pipe shall be subjected to said hydrostatic
pressure test in accordance with the data indicated by tkIS (India) in the technical specification.
4.2.3 This type test is mandatory only in case of new approval of vendor shop.
4.3.3 While testing atleast three test specimens per type of laminate or resin required.
4.4.1 Shear strength requirement shall comply UN 3030-16 Part1,Clauses 3 and 4.2. The value of inter
2 laminar shear strength shall be attained while performing tensile strength as per EN ISO 14130 or by
inter laminar shear strength as per BS EN 13121-3. The inter laminar shear strength shall be atleast 8
N/mm2 at all bonding surfaces.
4.4.2 Tensile strength requirement shall comply DIN 16964, Clauses 3.3 and 4.2.
4.4.3 Scope of tests : At least one test specimen per type of resin.
4.5.1 The residual styrene content shall be examined as per DIN 16964, Clauses 3.6 and 4.5 and DIN
16966 Part 1 Clauses 3.5 and 4.4 and Part 7 Clauses 3.4 and 4.3 and said examination to be
2 performed by a qualified laboratory within 7 days from the date of fabrication.
4.5.2 Scope of test : 3 test specimens per type of resin to be tested over the whole period of fabrication. The
related workshop records shall be furnished as evidence of said tests.
4.5.3 Styrene content test shall comply ISO 4901:2011 (since DIN 53394 is withdrawn).
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6289 ---
4.6 HARDNESS
2 For pipe type E ,Hardness of minimum 25 to 35 BHN required by Barcol method as per BS EN 13121-
3.
4.7.1 Vendor to comply DIN 16964, Clauses 3.7 , 3.12 , 4.6 and 4.10.
4.7.2 Said check shall be performed on all pipes, piping components and pre-fabricated pipe sections.
4.8 CERTIFICATES
The materials used for fabrication shall be furnished with a works certificate to DIN 50049-2.1
The tests indicated in Sections 4.2 to 4.7 of this document shall be recorded in reports and shall be
witnessed by tkIS (India) / Client / Third Party Inspector.
5 INSPECTION
Major inspections will be witnessed by tkIS (India) / Client. The final inspection will be performed by tkIS
(India) / Client. (Advice of readiness for inspection to be sent to tkIS(India))
6 MARKING
Pipes and piping components shall be marked in accordance with tkIS (PDE) standard UN 3030-16,
Part-1. Pipes and piping component shall have marking of pipe code, Resin used, Date of
manufacture, Manufacturer's name, Maximum allowable pressure and temperature.
6.1 Pre-fabricated pipes shall be marked with the isometric number and a serial number to
fabrication.Shop laminated connections shall be marked with the manufacturer’s symbol.
6.2 Pipes and piping components(incl. Collars and flanges) shall be marked with tkIS(India) item numbers.
7 PACKING
The edges of the flange faces and pipe ends shall be protected and loose flanges shall be fixed.
The components shall be packed using adequate fixing materials and soft spacers. For further details
refer to the order letter.
8 DOCUMENTATION
8.1 tkIS (India) preferences are provided as follows. Any deviation from the details furnished shall be
reported to tkIS (India) for approval.
8.2 Manufacturer shall furnish the details of the method to avoid penetration of air in to the outer resin.
Outer resin layer (topcoat) shall be made with readymade Resin mixed with paraffin.
8.3 Manufacturer shall provide the facility for storing the Resin as per recommendation of Resin
manufacturer. Shelf life of the Resin shall be intimated to tkIS (India) / Client.
8.4 Manufacturer shall furnish the details of the oven for post-curing (heat treatment) of the pre-assembled
pipe components and the site joints if required.
Following information shall be included in the details of the oven, such as dimensions, heating method,
air revolution, provision of temperature recorder etc.
The following shall apply to piping for which a pressure test and / or leak test is required. The type and
scope of the tests as well as the requirements to be met by the respective pipelines shall be
determined in the order.
The line must have been installed according to the laying instructions. Safety valves, rupture disks and
the like may not be installed. All valves in the system to be tested must be open during the test.
It shall be ensured that the test pressure cannot affect the position of the pipeline. In the case of thrust
non-resistant joints or expansion joints without limit stop, the line shall be sufficiently stiffened or
anchored at the ends, elbows, branches and shutoff devices.
A preliminary test must precede the main test. It serves to stop the change in volume, which depends
on the internal pressure and line temperature, to such an extent that the subsequent main test will
allow a definite conclusion to be drawn concerning the tightness of the section tested.
The pressure increase rate should not exceed 10 bar/min. The conditions mentioned hereafter shall
apply for the preliminary test, unless agreed otherwise. The preliminary test shall be carried out at 1.3
times the max. allowable working pressure. The duration of the test shall be taken from Table 1. The
test system shall be depressurised prior to the main test.
The main test shall be performed immediately after the preliminary test, the test pressure also being
1.3 times the max. allowable working pressure. According to Table 2 the duration of testing varies.
APPENDIX - I
LAMINATE STRUCTURE - PIPING CLASS PR
Note :
2 The moulder to decide the laminate structure to arrive at the specified thickness as per the above pressure
ratings & wall thickness table and shall submit the same to tkIS (India) for approval.
All pipes, fittings and stub ends are to be produced by "hand lay up".
Heat treatment of pipes, pipe fittings such as Elbows, Stub Ends, Caps, Tees and Reducers and also Site
Joints. Temperature and Hours required for curing shall be communicated to tkIS (India).
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6289 A02 ---
APPENDIX – II
Following shall be included in the scope of FRP AND FRP-Lined Piping Erection Contractor:
1) Erection of all free issued material like primary / secondary / special supports, in-line / control valves,
instruments, filters, strainers etc.
10) The bidder to consider site adjustment / cutting / modification / mismatch upto 500 mm in length for
every 10 M Length of the pipeline in the Quoted unit price, without any extra cost to the Owner.
11) All small bore lines (up to 1 ½” NB size) are site routed Lines, for which Bidder shall study the actual
size conditions, prior to fabrication of lines. Bidder shall not charge extra claim for any site adjustment /
cutting / modification / mismatch in the routing & fabrication of the Lines and the Quoted unit price shall
include the same, without any extra cost to the Owner.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6302 ---
Contents:
1 SUBJECT...................................................................................................................................................... 2
2 SCOPE ......................................................................................................................................................... 2
3 REQUIREMENTS ............................................................................................................................................2
4 TESTS AND CERTIFICATE ..............................................................................................................................3
5 INSPECTION .................................................................................................................................................4
6 MARKING...................................................................................................................................................... 4
7 PACKING ...................................................................................................................................................... 4
8 DOCUMENTATION .........................................................................................................................................5
9 PRESSURE TEST AND LEAK TEST AFTER ERECTION ........................................................................................5
01 Generally revised & re-issued 18.09.2017 SHK 18.09.2017 NNG 18.09.2017 APK
Previous Doc.No.PI-000-BD-00074,
Rev.0, is revised and reissued as
00 25.06.2015 SHK 25.06.2015 NNG 25.06.2015 APK -
PIN-LES-PIP-6302 due to new
document numbering philosophy.
Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: -
1 SUBJECT
This enquiry enclosure contains uniform recommendations for quality assurance activities during
fabrication and shipment.
2 SCOPE
This enquiry enclosure covers the supply and erection of pipes, piping components, pipe connections
and prefabricated pipelines of glass fibre reinforced plastic on the basis of unsaturated polyster
resins, with PVC-C (Dekadur C) liner. It shall apply in conjunction with the enquiry letter.
In the event of discrepancies between this enquiry enclosure and the enquiry letter, the latter shall
apply.
3 REQUIREMENTS
The requirements specified in the "Piping material summary" and the standards indicated therein,
particularly tkIS (PDE) standard UN 3030-16, Part - I, shall apply.
It is imperative that all requirements specified in AD specification N1, Sec. 2.2 must be fulfilled by the
manufacturer. Vendor shop shall be approved by tkIS (India).
3.2 FABRICATION
3.2.1 The pipes shall have their natural color with UV - absorber.
3.2.2 All flanged fittings & nozzles shall have loose steel flanges.
3.2.3 The straight pipe sections and prefabricated components shall be supplied by the same manufacturer
and be of the same quality (proper welds).
3.2.4 All the exposed glass surfaces shall be covered / protected with resin.
3.2.5 Elbow construction shall be according to DIN 16966 Part - 2 without the straight portion.
3.2.6 Additional one mat shall be laid for branches of NS < 2" for increasing mechanical strength, over and
above the regular laminate structure.
3.2.7 Collars for fittings shall be integrally formed or solvent welded type.
3.2.8 Welds shall only be made by welders qualified to recommendation DVS 2212 / BS EN 13121-3. The
welders shall be supervised by qualified foremen.
3.2.9 Laminated connections to DIN 16966, parts 7 and 8, shall comply with the PN of the connecting pipe.
The welds shall be covered with a conductive layer prior to lamination in order to be able to examine
the welds later.
PIN-QMC-03-F101 03-2015
2 3.2.10 Lined pipes and piping components shall be seamless, filament wound, type B as per DIN 16965 Part
2.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6302 ---
The tests shall be performed according to tkIS (PDE) standard UN 3030-16, Part-1, and the codes
and standard indicated therein.
4.1.1 The manufacturer of the materials used such as reinforcing materials, fillers etc. shall certify the
properties of said materials, and assume the related guarantee.
Prior to starting the fabrication, the pipe manufacturer shall take the measures required to make the
materials ready for use. (Furnish the related workshop document).
4.1.2. It is imperative that measures to be taken to avoid nonconformity of the materials. This applies
particularly to the different resin types. (Furnish related work-shop document).
4.1.3 The manufacturer shall perform adequate quality assurance. This includes records showing that the
pipes, piping components and pipe connections correspond to the rules of good workmanship.
2 4.1.4 The material requirement shall comply as per UN 3030-16 Part1, Clause 2.1 and DIN 16964,Clause
2.
4.2.1 The manufacturer shall furnish documents corresponding to Sec. 4.9 reflecting that the short-time
hydrostatic pressure tests have been performed as per Clause 3.2 and 4.1 of DIN 16964 & DIN
16966 Part 1 and Part 7
4.2.2. At least three pre-fabricated pipes per type of resin or pipe shall be subjected to said hydrostatic
pressure test in accordance with the data indicated by tkIS (India) in the technical specification.
4.2.3 This type test is mandatory only in case of new approval of vendor shop.
2 4.3.2 Glass content shall comply DIN 16964,Clause 3.5 and 4.4.
4.3.3 While testing atleast three test specimens per type of laminate or resin required.
2 4.4.1 Shear strength requirement shall comply UN 3030-16 Part1,Clauses 3 and 4.2. The value of inter
laminar shear strength shall be attained while performing tensile strength as per EN ISO 14130 or by
inter laminar shear strength as per BS EN 13121-3. The inter laminar shear strength shall be atleast 8
N/mm2 at all bonding surfaces. Further adhesion related shearing strength for Pipe type B shall be as
per DIN 16964, Clauses 3.9 and 4.8 and DIN 16966 Part 7, Clauses 3.7 and 4.5.
PIN-QMC-03-F101 03-2015
4.4.2 Tensile strength requirement shall comply DIN 16964, Clauses 3.3 and 4.2.
2 4.5.1 The residual styrene content shall be examined as per DIN 16964, Clauses 3.6 and 4.5 and DIN
16966 Part 1 Clauses 3.5 and 4.4 and Part 7 Clauses 3.4 and 4.3 and said examination to be
performed by a qualified laboratory within 7 days from the date of fabrication.
4.5.2 Scope of test : 3 test specimens per type of resin to be tested over the whole period of fabrication.
The related workshop records shall be furnished as evidence of said tests.
4.5.3 Styrene content test shall comply ISO 4901: 2011 (since DIN 53394 is withdrawn).
4.6 HARDNESS
For pipe type B,Hardness of minimum 25 to 35 BHN required by Barcol method as per BS EN 13121-3.
4.7.1 Vendor to comply DIN 16964, Clauses 3.7 , 3.12 , 4.6 and 4.10.
4.7.2 Said check shall be performed on all pipes, piping components and pre-fabricated pipe sections.
All welds of finished components shall be measured to DVS recommendation 2206 for leakage by
applying a voltage prior to lamination.
4.9 CERTIFICATES
The materials used for fabrication shall be furnished with a works certificate to DIN 50049-2.1
The tests indicated in Section 4.2 to 4.8 shall be recorded in reports and shall be witnessed by tkIS
(India) / Client / Third Party Inspector.
5 INSPECTION
Major inspections will be witnessed by tkIS (India) / Client. The final inspection will be performed by
tkIS (India) / Client. (Advice of readiness for inspection to be sent to tkIS (India))
6 MARKING
Pipes and piping components shall be marked in accordance with tkIS (PDE) standard UN 3030-16,
Part-1. Pipes and piping component shall have marking of pipe code, Resin used, Date of
manufacture, Manufacturer's name, Maximum allowable pressure and temperature.
6.1 Pipes and piping components (incl.Collars and flanges) shall be marked with tkIS(India) item
numbers.
PIN-QMC-03-F101 03-2015
7 PACKING
The edges of the flange faces and pipe ends shall be protected and loose flanges shall be fixed.
The components shall be packed using adequate fixing materials and soft spacers. For further details
refer to the order letter.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6302 ---
8 DOCUMENTATION
8.1 tkIS (India) preferences are provided as follows. Any deviation from the details furnished shall be
reported to tkIS (India) for approval.
C-Glass Tissue * 26 to 30 g/m^2
Width * 25mm to 160mm
Chopped Strand Mat * 450 g/m^2
Width required * 25mm to 160mm
Woven Roving Mat * 600 to 610g/m^2
8.2 Manufacturer shall furnish the details of the method to avoid penetration of air in to the outer resin.
Outer resin layer (topcoat) shall be made with readymade Resin mixed with paraffin.
8.3 Manufacturer shall provide the facility for storing the Resin as per recommendation of Resin
manufacturer. Shelf life of the Resin shall be intimated to tkIS (India) / Client.
8.4 Manufacturer shall furnish the details of equipment's available for mechanical testing and quality
control and laboratory for testing of resin mixtures/test panels etc. Barcol Hardness tester shall be
used for testing.
The line must have been installed according to the laying instructions. Safety valves, rupture disks
and the like may not be installed. All valves in the system to be tested must be open during the test.
It shall be ensured that the test pressure cannot affect the position of the pipeline. In the case of thrust
non-resistant joints or expansion joints without limit stop, the line shall be sufficiently stiffened or
anchored at the ends, elbows, branches and shutoff devices.
9.1.2 Performance of Pressure Test
A preliminary test must precede the main test. It serves to stop the change in volume, which depends
on the internal pressure and line temperature, to such an extent that the subsequent main test will
allow a definite conclusion to be drawn concerning the tightness of the section tested.
The pressure increase rate should not exceed 10 bar/min. The conditions mentioned hereafter shall
apply for the preliminary test, unless agreed otherwise. The preliminary test shall be carried out at 1.3
times the max. allowable working pressure. The duration of the test shall be taken from Table 1. The
test system shall be depressurised prior to the main test.
PIN-QMC-03-F101 03-2015
The main test shall be performed immediately after the preliminary test, the test pressure also being
1.3 times the max. allowable working pressure. According to Table 2 the duration of testing varies.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6302 ---
APPENDIX - I
ERECTION OF FRP AND FRP-LINED PIPES AND FITTINGS
Following shall be included in the scope of FRP and FRP-Lined Piping Erection Contractor:
1) Erection of all free issued material like primary / secondary / special supports, in-line / control
valves, instruments, filters, strainers etc.
10) The bidder to consider site adjustment / cutting / modification / mismatch upto 500 mm in length for
every 10 M Length of the pipeline in the Quoted unit price, without any extra cost to the Owner.
11) All small bore lines (up to 1 ½” NB size) are site routed Lines, for which Bidder shall study the actual
size conditions, prior to fabrication of lines. Bidder shall not charge extra claim for any site adjustment
/ cutting / modification / mismatch in the routing & fabrication of the Lines and the Quoted unit price
shall include the same, without any extra cost to the Owner.
Plant Client Contract Code Document ID Contract No.
--- --- --- PIN-LES-PIP-6306 (Contract Specific ---
Document ID if adopted document)
1 GENERAL
This specification covers the dimensional details of Splash Guard for Steel Piping.
PIN-QMC-03-F101 03-2015
MASTER ABBREVIATIONS LIST 04/12/2015
+ WITH
125 Ra Ra=125-250 m. In
16 Ra Ra=16-32 m. In
250 Ra Ra=250-500 m. In
63 Ra Ra=63-125 m. In
A-20 ALLOY 20
AS ALLOY STEEL
THRD. STD (BOLT) ASME B 1.1 CL2A,
B18.2.2 THRD. STD (NUT) ASME B 1.1 CL2B, UNC
THRD FOR <=1" AND UN8 THRD FOR >1" DIA
BB BOLTED BONNET
BE BEVELED END TO B16.25
BET THREADED BOTH ENDS
BF BLIND FLANGE
BS BELLOW SEALED
BW BUTT WELDING
CA CORROSION ALLOWANCE
CAP PIPE CAP
CI CAST IRON
CON RED CONCENTRIC REDUCER
CORR CORRUGATED
CRS CROSS
CS CARBON STEEL
CVR COVER
DEG DEGREE
DI DUCTILE IRON
DIPH DIAPHRAGM
DN NOMINAL DIA
DPR DESIGN PRESSURE
ECC RED ECCENTRIC REDUCER
EFW ELECTRIC FUSION WELDED
ELB ELBOW
ERW ELECTRIC RESISTANCE WELDED
FBE FLANGED BOTH ENDS
FBE FLG FIXED FLANGE BOTH ENDS
FBP FABRICATED FROM PIPE
FCPL FULL COUPLING
FF FLAT FACE
FLG FLANGE
FNPT SCREWED TO NPT(F) TO B 1.20.1
FOE FLANGED ONE END
GALV GALVANIZED
GASK GASKET
GF GLASS FILLED
GI GALVANIZED IRON
GNLLY GENERALLY
GO GEAR OPERATED
GRF GRAFOIL
GRPH ASB + INC WIRE GRAPHITED ASBESTOS WITH INCONEL WIRE
HCPL HALF COUPLING
HDPE HIGH DENSITY POLYETHYLENE
HF HARD FACED
HO HAND WHEEL OPERATED
HPR HYDROSTATIC PRESSURE
HRL HARD RUBBER LINED