STEEL AUTHORITY OF INDIA LIMITED

DURGAPUR STEEL PLANT

RE-BUILDING OF COKE OVEN BATTERY NO. 2

TECHNICAL SPECIFICATION FOR INTERPLANT PIPELINE GAS MAIN & COMPENSATOR

(PACKAGE NO: COB2/EXPN/SM-47)

MECON LIMITED
RANCHI 834002

INDIA

MEC/TS/11/9172/COB2/EXPN/SM-47

December, 2010

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REBUILDING OF COB # 2 TECHNICAL SPECIFICATION FOR INTERPLANT PIPELINE GAS MAIN & COMPENSATOR PACKAGE NO. : COB2/EXPN/SM-47

STEEL AUTHORITY OF INDIA LIMITED

DURGAPUR STEEL PLANT

REBUILDING OF COKE OVEN BATTERY NO. 2

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. NO. MEC/TS/11/9172/COB2/EXPN/SM-47

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REBUILDING OF COB # 2 TECHNICAL SPECIFICATION FOR INTERPLANT PIPELINE GAS MAIN & COMPENSATOR PACKAGE NO. : COB2/EXPN/SM-47

PACKAGE NO. : COB2/EXPN/SM-47

TECHNICAL SPECIFICATION FOR INTERPLANT PIPELINE GAS MAIN & COMPENSATOR

T.S. NO. MEC/TS/11/9172/COB2/EXPN/SM-47

MECON LIMITED RANCHI-834002

02.12.2010
A. Mathur PREPARED BY P.L. SAH CHECKED BY P.L. SAH APPROVED BY DATE

0
REVISION

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. NO. MEC/TS/11/9172/COB2/EXPN/SM-47

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REBUILDING OF COB # 2 TECHNICAL SPECIFICATION FOR INTERPLANT PIPELINE GAS MAIN & COMPENSATOR PACKAGE NO. : COB2/EXPN/SM-47

CONTENTS Chapter 01. 02. 03. Description Revision Status Amendment -Record Sheet Technical Specifications Summary Special Instructions to Tenderer Technical Specification Page No./No. of Sheets 1 Sheet 1 Sheets 4 Sheets 8 Sheets

ANNEXURES: i) ii) iii) iv) ANNEXURE I Format for Quotation (Technical) ANNEXURE II Format For Inspection Call Letter ANNEXURE- III Quality Assurance Plan (Technical) ANNEXURE - IV Price Format 3 Sheets 1 Sheet 1 Sheet 1 Sheet

ENCLOSURES:
1. 2. 3. 4. 5. DRG.No.MEC/TS/9172/COB2/EXPN/SM-47/001 DRG.No.MEC/TS/9172/COB2/EXPN/SM-47/002 DRG.No.MEC/TS/9172/COB2/EXPN/SM-47/003 DRG.No.MEC/TS/9172/COB2/EXPN/SM-47/004 DRG.No.MEC/TS/9172/COB2/EXPN/SM-47/005

2009 MECON LIMITED, ALL RIGHT RESERVED T.S. NO. MEC/TS/9172/COB2/EXPN/SM-47

CONTENT SHEET

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REBUILDING OF COB # 2 TECHNICAL SPECIFICATION FOR INTERPLANT PIPELINE GAS MAIN & COMPENSATOR PACKAGE NO. : COB2/EXPN/SM-47

REVISION STATUS AMENDMENT - RECORD SHEET Rev. No. Date Sheet Amended Description Remarks

2009 MECON LIMITED, ALL RIGHT RESERVED T.S. NO. MEC/TS/9172/COB2/EXPN/SM-47

REVISION SHEET

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01 01.1 01.2 01.3 ,

TECHNICAL SPECIFICATION SUMMARY SHEET Technical specification No. Package No. Item No.s : : : MEC/TS/9172/COB2/EXPN/SM-47 COB2/EXPN/SM-47 1. COB2/EXPN/SM-47/01 2. COB2/EXPN/SM-47/02 3. COB2/EXPN/SM-47/03 4. COB2/EXPN/SM-47/04 5. COB2/EXPN/SM-47/05 6. COB2/EXPN/SM-47/06, 07, 08 7. COB2/EXPN/SM-47/09 8. COB2/EXPN/SM-47/10, 11 9. COB2/EXPN/SM-47/12 10. COB2/EXPN/SM-47/13 01. BF Gas Pipeline 02. Saddle support 03. Roller Support 04. Single Disc Compensator 05. Condensate Seal Pot 06, 07& 08 ERW Pipes 09. Elbow 10&11 Valves 12. Funnel 13. Flexible metallic hose Manufacture / fabrication, inspection, testing and delivery F.O.R., DSP, Durgapur site basis. As per drawings & Annexure-A 52 t : : : (Approx.)

01.4

Item description

01.5

Scope of work

01.6 01.7 01.8 01.9 01.10

Material & Quantity required : Weight of Fabricated Items Weight of Brought Out Items Delivery Schedule Remarks :

0.58 t (Approx.) Delivery of above items shall be completed within 28 weeks from date of LOA i..The weight shown at sl.no 01.7 & 01.8 is indicative only. Actual Weight shall be indicated in the manufacturing drgs ii The supplier shall strictly conform to the requirements given in the Technical Specification. Deviations, if any, shall be clearly highlighted.

SPECIAL INSTRUCTIONS TO TENDERER

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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2.1

General: This chapter shall be read in conjunction with General Conditions of Contract. The supply items shall meet the requirements stipulated in the technical specifications and drawings and standard method of manufacture. Use of inferior materials, which can impair the quality and mechanical properties, is not allowed. Depending on the performance of manufacture, purchaser reserves the right to cancel the order or increase or decrease the quantity ordered at the same price/rate without any financial implications on the purchasers part or any compensation to the supplier. The tenderer shall submit the quotations (technical part) exactly as per the enclosed Format for quotation given in Annexure IA (I) any deviations proposed by the tenderer shall be listed in that format only. NO ADDITIONAL WRITE-UP OR DIFFERENT FORMAT WILL BE ACCEPTED. The tenderer shall furnish 3 sets of drawings/documents/catalogues as applicable along with each copy of the tender to enable evaluation of his offer.

2.1.1

2.1.2

02.01.3

2.1.4

2.1.5
2.1.7

Manufacturing will be taken up only on the basis of drawings duly stamped and signed as Certified for Manufacture by MECON or vendors fabrication /manufacturing drawings approved by MECON. The Purchaser (DSP) reserves the right to place order for only one or more items in part or full quantity on a particular supplier (successful tenderer ). The tenderer shall confirm to accept part order. 02.02 02.02.01 Approval of fabrication/manufacturing drawings: The fabrication/ manufacturing drawings shall be prepared by the supplier based on MECONs design drawings/ general arrangement drawings and shall be submitted to Purchaser/ MECON in 6 sets for approval prior to manufacture/ fabrication. One set of all documents shall be submitted in soft copy also prepared in Auto CAD format. For certain items, MECON/ Purchaser will supply fabrication/ manufacturing drawings stamped Certified for manufacture. The supplier shall go ahead with fabrication/ manufacture of pipeline, fittings & equipment based on vendors fabrication/manufacturing drawings approved by MECON for manufacture as well as MECONS drawings stamped Certified for manufacture.

2.1.8

02.02.02

Documents to be supplied by the Tenderer along with offer

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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The following information / documents are to be submitted by the Tenderer along with the offer: -

Make Type & Standards with Grade Material of construction Nominal sizes with length in metre Weight in kg per running metre OD and thickness in mm Leaflets / catalogues Standards being followed for design, dimensions, material, manufacture & testing of offered items Quality assurance plan as per Annexure-III Exclusions list All technical information / drawings / documents, mentioned in the Technical Specification

02.03 The

Quality Assurance Plan (QAP) relevant preliminary Quality Assurance Plan (QAP) form are duly filled in and enclosed as Annexure III. The tenderer shall confirm adherence of the same during submission of their offer. Inspection: Inspection will be carried out by MECON / DSP/ DSPS authorised representative. The purchaser reserves the right to carryout stage inspection during manufacture and at final stage at the manufacturers works and at site. Inspection for all items will be carried out only as per the appoved QAP. Access to the works: At all times for the authorised representatives of MECON Ltd. & DSP. Assistance for inspection: (To be provided by the supplier). All the labourers required. All tools & tackles, electricity, stores and handling equipment.

02.04 02.04.1

02.04.2
2.4.3

2.4.4

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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2.4.5 Notice period:

All measuring instruments, templates, gauges, jigs & fixtures including special ones to be made by the supplier as per specific requirement of the inspectors. All secretarial assistance for preparation of inspection report & related documents.

Two weeks from the receipt of inspection notice at the purchasers office. 02.04.6 Suppliers obligation: The inspection of materials at manufacturers works and despatch of materials does not relieve the supplier of his obligation to replace/rectify free of cost FOR DSP site basis, those materials which are found defective due to bad workmanship or bad quality of materials at the time of final inspection at plant site or during agreed warrantee/guarantee period. 02.05 Match Marking The sub-assemblies / parts shall be properly match marked before dismantling for packing and despatch. Manufacturer for reference during erection at site shall submit match-marking drawings to the purchaser. 02.06 Painting: As indicated in General Technical Specification / datasheets / drawings 02.07 02.07.01 MARKING & PACKING All pipes, supports, valves etc shall be marked in accordance with the applicable codes, standards and specifications using white weather proof oil paint. In addition, purchase order No., Item No. & special conditions shall also be marked, as applicable. The Marking of despatch should also contain inscription such as recipient, destination and weight of shipment etc. After inspection punching and appropriate seal on the item should make mark of acceptance or rejection. Marking element i.e. paint / ink shall be free from harmful element like zinc, lead or copper. Pipes, supports, equipment & all bought out items shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind. Pipes, supports, valves & equipment shall be protected from rust, corrosion, and mechanical damage during transportation, shipment & storage. Both ends of pipes shall be protected with following materials. Plain ends Bevel ends : : Plastic cap Wire metal or plastic cover

02.07.02 02.07.03 02.07.04

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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End protectors to be used on bevelled ends shall be securely and tightly attached with belt or wire. 02.08 Weights: The tenderer shall study the specification, specification drawings (views, details and bill of quantities therein) to appreciate the full scope of supply involved. In cases, where items like, packing material, asbestos rope, wood, etc. are included in the bill of materials but not included in the total wt. of steel items indicated; tenderer shall include them also in their scope of supply. Additional claims and disputes on this account would not be entertained after placement of order. All fasteners like nuts, bolts, washers, gaskets, etc., shall be supplied 10% extra in addition to the actual quantity required. 02.09 Documents/Drawings to be furnished by the successful tenderer. The list of documents/drawings to be furnished by the successful tenderer is given below: Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Category of Drawing / Documents Manufacturing/General arrangement drawings (for approval) Manufacturing/General arrangement drawings after approval (IBR) Drawings of reference and information category Erection drawings As built drawings List of commissioning and two years operation spare parts and drawings Wearing parts drawings Microfilm of final drawings of approved/ information category/spare parts and wearing part drawing Erection manual Operation and maintenance manuals Storage and re-conservation manuals Safety manuals List of consumables List of lubricants and hydraulic oils List of special tools and tackles Test and Inspection certificates One Polyester film reproducible Soft copy of vendor drawing Status YES / NA YES / NA YES / NA YES / NA YES / NA YES / NA YES / NA YES / NA YES YES YES YES YES YES YES YES YES YES / NA / NA / NA / NA / NA / NA / NA / NA / NA / NA

TECHNICAL SPECIFICATION

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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03.01

Scope of Work and Supply: The Tenderers scope of work and supply shall include, but not limited to, the following.

03.01.1

The scope of work of the Tenderer shall cover manufacture, shop testing, shop painting, packing and supply of pipes for interplant Gas mains. This shall include pipes, supports, valves, equipment & fittings as per Annexure-A of Technical Specification. 3.1.2 The items covered under the Tenderers scope for Inter-Plant Gas Mains are as under:

Fabricated Items: BF Gas Pipeline Saddle support Roller Support Single Disc Compensator Condensate Seal Pot Brought Out Items:

03.01.3

ERW Pipes & Fittings Valves The Tenderer is expected to be familiar with the function of the items covered in this specification and to have had previous experience of supply of similar items. During approval stage, if any additional items like cleats, pads or minor connections are required, the same shall be incorporated without any extra cost.

03.01.4 03.01.5

Source of supply The Tenderer shall furnish list of all bought-out items / components. The makes of various equipment shall be selected from the list of Preferred makes of equipment and supplies of the Purchaser. In case, alternative makes are offered, Tenderer shall give justifications for the same and seek approval for the same from the Purchaser.

03.01.6

All materials required for fabrication, testing and inspection of the item shall be supplied by the vendor, including all consumables / non-consumables, primer, paints etc. No material shall be free issue to vendor. Inspection of the item will be carried out as per approved QAP. Documents to be furnished by the Tenderer along with the bid:

03.01.7 03.01.8

i)

Format for quotation as per Annexure-I (3 sheets)

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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REBUILDING OF COB # 2 TECHNICAL SPECIFICATION FOR INTERPLANT PIPELINE GAS MAIN & COMPENSATOR PACKAGE NO. : COB2/EXPN/SM-47

ii)

Bidders confirmation as per Annexure-II (1 sheet) QAP duly filled in as per Annexure-III (2 sheet). Implementation schedule in form of bar chart to match the delivery schedule.

iii)
iv) 03.01.9

Documents to be furnished by the successful Tenderer: For approval i. Clause 02.02. ii. iii. iv. Detail fabrication drawings in adequate copies as detailed in QAP duly filled in. Test & Warranty certificate for each item offered. Test / Inspection reports, as applicable.

For reference / information i) ii) Catalogues / sketches of brought out items Conservation manuals of bought out items as applicable.

The Tenderers shall also refer to documents listed in clause 02.09 03.02 03.02.01 03.02.01. 1 TECHNICAL REQUIREMENT General The pipes shall conform to the relevant latest revision of Indian Standards or any other agreed International Standards in respect of dimension, tolerance, sizes, material of construction, chemical composition, physical properties, manufacturing, heat treatment, testing, marking and packaging procedures. Deviations, if any, shall be indicated. The pipes shall be supplied in standard length not exceeding 7 metres. The Tenderer shall quote item wise unit weight and price as well as total weight and price of pipes to be supplied under this specification. The Tenderer shall indicate rate of each item separately. The quantities indicated in this specification may undergo changes after completion of engineering of the project. Hence, the unit rates quoted by the Tenderer shall remain unchanged irrespective of the extent of variation. The Tenderer shall include completely new and unused items in the offer. The Tenderer shall not off-load the contract or part thereof to any sub-contractor without written permission of the Purchaser. In case, sub-letting of any part of the work is permitted by the Purchaser, the fact that such permission has been accorded shall not establish any contractual relationship between approved sub-

03.02.01. 2 03.02.01. 3

03.02.01.4

03.02.01. 5 03.02.01. 6

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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contractor and the Purchaser nor shall release the Contractor from any of his obligations and liabilities under the contract. 03.02.01. 7 03.02.01. 8 Metric system shall be followed and English shall be the language of all communication. The Tenderer shall clearly indicate the items, if any, excluded from his scope of work & supply, failing which it will be deemed that the scope of work & supply shall be in conformity with the requirements of this specification. Pipes made of steel produced by acidic Bessemer process shall not be acceptable. Test reports shall be supplied for all mandatory tests as per the applicable material specifications. Test reports shall also be furnished for any supplementary tests as specified by the Purchaser. Material test certificates (Physical properties, chemical composition & heat treatment reports) shall be furnished for pipes. ERW pipes (as applicable) shall not have any circumferential seam joint in a random length. Specified heat treatment for carbon steel pipes shall be carried out after weld repairs. Number of weld repairs at the same spot shall be restricted to maximum 2 (two) by approved repair procedure. Manufacture of Pipelines: Fabrication of elements by machining or gas cutting is allowed. Sheets or shells shall be bent in cold state on rolls and shall have regular circle form and shall be free from cracks, stratification and other defects. Longitudinal butt-welded joints of the adjacent shells shall be staggered by not less than 200 mm relative to each other. Edge preparation for welding shall be done as per stipulated standards. Relative displacement of edges of the shells being joined should not exceed 1/5 th of the wall thickness. It is recommended to weld gas pipeline joints by automatic arc-welding under the layer of flux. With manual welding, it is allowed to use either arc-welding or oxyacetylene welding. In such cases all welding work shall be carried out by skilled welders. Electrodes shall be chosen as per IS: 814. All welds shall be continuous unless otherwise specified. Size for continuous fillet weld shall not be less than the smaller thickness of the members to be welded.

03.02.01. 9 03.02.01.10

03.02.01.11 03.02.01.12 03.02.01.13

03.02.02 03.02.02.1 03.02.02.2 03.02.02.3 03.02.02.4 03.02.02.5 03.02.02.6

03.02.02.7

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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03.02.02.8

When welding gas pipelines additional welding at the root of joint shall be done by any suitable method. Dimensions of Links and tolerances:
Following tolerances are allowed: For the length of links
i. ii.

03.03
03.03.1 A.

+ 3mm for the length upto 1000 mm + 0.5% for the length over 1000 mm but not more than 10 mm for each complete 10 metre. .

B.

For deflection of the cylinder gradient from the straight lines: i. 0.12% of the link length but not more than 15 mm for links with lengths over 10 m when checking by stretched cord.

C.

For difference in diameter of butt-welded ends of links - not more than 2 mm. Tolerance on diameters of shells shall be within + 5 mm and ellipticity shall be within that limit.

03.04 03.04.1 03.04.2 03.04.3 03.04.4 a) b) c) d)

Testing Manufactured items shall be offered for inspection in unpainted state. Test certificates shall be furnished for the quality of material of the pipes. Checking of the dimensions shall be carried out as per relevant standards and specifications. Visual examination of the welding quality shall be carried out with the aim of finding the following possible defects:

Cracks reaching the surface of joints or basic metal and located in the zone of thermal influence of welding. Welding dribbles and cuts in spots where joint passes over the basic metal. Sponginess of the outer surfaces of the joints and porosity on such surfaces. Non-uniform width of joint (fillet) along its circumference and possible deflections from the axis (distortions). 03.04.5 In case any defect is found by visual examination and checking of the dimensions or in case of the absence of required test certificates, the pipeline and the items shall not be allowed for leakage test. Testing for leakage shall be carried out by the following methods.

03.04.6

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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a) b) 03.04.7 03.04.8

Tests by compressed air with application of soap solution over all joints of links of the gas pipes. Checking by chalk-kerosene test of the joints/ links of the gas pipelines.

Tests by the compressed air are carried out under excess pressure. P test = 0.65 Kgf/Cm2 (gauge). For kerosene testing all joints are covered firstly with chalk. When chalk is dried up, the inner surfaces of the joints are abundantly covered with kerosene. Dark greasy spots on the outer surfaces indicate leaks. Examination of joints is carried out 12 hours after applying kerosene.

03.04.9

All defective sections of joints found during above tests shall be cut out and rewelded. Caulking or welding over the defective weld is not allowed. After repairing, such details are to be subjected to repeated tests. Mechanical Testing of welded joints (if applicable) The aim of mechanical testing is the control of the deformability of welded joints. The following tests are obligatory: a) b) Tensile test Bending test strength and

03.05 03.05.1

For this purpose, test joints are made simultaneously with welding, out of which some samples are sent for various types of tests. Welding of a test joint is obligatory for each 50 joints of welded pipe lines but not less than one test joint for the lot under control. Testing shall be carried out as per IS:822-1970. 03.05.2 Dimensions of test joints are chosen so that it would be possible to cut out four normal samples for tensile test and bending test (two samples for each type of test). Results of these tests are considered satisfactory if: a) b) 03.05.4 3.5.5 03.06 Tensile strength of joint's metal is not less than 34 Kgf/Cm2 and elongation is not less than 12%. Angle of bend of the samples is not less than 70 until the first crack appears.

03.05.3

If the tests of given samples are unsatisfactory, repeated tests should be carried out with double the amount of samples. If repeated tests do not show positive results, the item is rejected. Marking, Painting:

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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03.06.1

On the inner surfaces of the link ends of the gas pipelines, the following shall be painted with white weather proof paint: Item number and drawing number according to the manufacturing drawings. Outer surface of the gas pipeline shall be thoroughly cleaned and painted. The painting of all pipelines will be done as per IPSS 1-06 -016 088. Two coats of primer as per IS: 2074 -1992 will be applied on thoroughly cleaned and dry surface. The thickness of dry film coating will not be less than 30 / each coating. Shipment: Gas pipeline links, supports, valves & all bought out items during transportation shall be protected from damage.

03.06.2

03.07

Annexure A

Sheet 1 of 2

Bill of Material A. PIPES & FITTINGS

STANDARD/ QUANTITY WEIGHT IN KG ITEM No. REMARKS 2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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SL. NO.

DRAWING

DESCRIPTION OF PIPE, OD X THK (mm x mm) Fabricated PIPE 1420 x 10 Thk. ERW PIPE 115 x 5.4 Thk. ERW PIPE 89.5 x 4.8 Thk. ERW PIPE 34.2 x 3.2 Thk. 900 ELBOW 34.2 x 3.2 Thk. FUNNEL, DN 260x DN 100 , 5.4 Thk, L=150 Flexible metallic hose DN 25 with female swivel nuts at both the ends, length = 3m

(m)

UNIT WEIGHT (Kg/m)

TOTAL WEIGHT (Kg) To be fabricated from plates conforming to IS:2062 Gr A; ERW Black (BEWEL ENDS) Bought Out Item Bought Out Item Bought Out Item Bought Out Item ---

1.

IS:3589

140

347.86

48700.4

COB2/EXPN/ SM-47/01 COB2/EXPN/ SM-47/06 COB2/EXPN/ SM-47/07 COB2/EXPN/ SM-47/08 COB2/EXPN/ SM-47/09 COB2/EXPN/ SM-47/12

2. 3. 4. 5. 6.

IS:1239,Part 1 IS:1239,Part 1 IS:1239,Part 1 IS:1239,Part 2 ----

8 12 100 10 1

14.5 8.36 2.5 -----

116 100.32 250 -----

7.

DRG.No.MEC/TS/ 9172/COB2/EXPN /SM-47/005

---

---

COB2/EXPN/ SM-47/13

For Nitrogen purging of seal pot & gas mains

Annexure A

Sheet 2 of 2

B.
SL. NO.

SUPPORTS
WEIGHT IN KG STANDARD/ DRAWING DESCRIPTION QUANTITY In (No) UNIT WEIGHT TOTAL WEIGHT ITEM No. REMARKS

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1.

DRG.No.MEC/TS/ 9172/COB2/EXPN /SM-47/001 DRG.No.MEC/TS/ 9172/COB2/EXPN /SM-47/002

DN1400 SADDLE SUPPORT DN1400 ROLLER SUPPORT

100

300

COB2/EXPN/ SM-47/02

100

700

COB2/EXPN/ SM-47/03

FABRICATED FROM PLATES CONFORMING TO IS; 2062, Gr A FABRICATED FROM PLATES CONFORMING TO IS; 2062, Gr A

C.
SL. NO.

VALVES
STANDARD/ DRAWING/ SPECIFICATION DESCRIPTION DN 100 - GATE VALVE For BF Gas Service , Rising Stem, Flanged End Connection with companion flanges, nuts, bolts and gaskets DN 25, CS GLOBE VALVE For Nitrogen Service SW End Connections Class #800 DESCRIPTION QUANTITY In (No) WEIGHT IN KG UNIT TOTAL WEIGHT WEIGHT ITEM No. REMARKS

1.

IS:14846, Body CI Gr. FG 200 SS Trim

50

100

COB2/EXPN/ SM-47/10

Bought Out Item

2.

BS 5352, Body A105; 13% Cr Trim

3.6

18

COB2/EXPN/ SM-47/11

Bought Out Item

D.
SL. NO. 1. 2.

EQUIPMENTS
STANDARD/ DRAWINGS DRG.No.MEC/TS/ 9172/COB2/EXPN /SM-47/003 DRG.No.MEC/TS/ 9172/COB2/EXPN /SM-47/004 QUANTITY In (No) 2 1 WEIGHT IN KG UNIT TOTAL WEIGHT WEIGHT 980 550 1960 550 REMARKS ITEM No.

Single Disc Compensator Condensate Seal Pot

COB2/EXPN/ SM-47/04 COB2/EXPN/ SM-47/05

Fabricated Fabricated

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/9172/COB2/EXPN/SM-47

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Annexure I Sheet 1 of 3

FORMAT FOR QUOTATION Technical Part Only

1. 2. Enquiry No. : Offer No. 1. : dated dated We agree to supply the items indicated hereinafter in sheet-2 of the annexure as per delivery schedule indicated. We agree to all clauses indicated in the technical specification no. ..... and reference drawings listed in the specification including details of inspection excepting those mentioned under deviation/exclusions hereunder. We confirm that commercial part of the tender has been submitted separately.

2. 3. 4.

We confirm that unit price and total prices for each of the items mentioned above has been indicated separately as Price part and submitted under a sealed cover. We confirm to furnish the required documentation.

Signature with company stamp Name: Designation: Companys name: Date:

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/11/9172/COB2/EXPN/SM-47

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REBUILDING OF COB # 2 TECHNICAL SPECIFICATION FOR INTERPLANT PIPELINE GAS MAIN & COMPENSATOR PACKAGE NO. : COB2/EXPN/SM-47

Annexure I Sheet 2 of 3 Scope of Supply and delivery schedule Sl. No Item Descript ion Qty. quoted for Unit Wt. Total Wt. Drg. Nos. Offer Delivery 1st of lot (Qty. to sample be indicated in no. of days from sample approval) 7 8 Monthly Total rate of delivery supply period Remarks

10

11

Annexure I Sheet 3 of 3
2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/11/9172/COB2/EXPN/SM-47

DSP

REBUILDING OF COB # 2 TECHNICAL SPECIFICATION FOR INTERPLANT PIPELINE GAS MAIN & COMPENSATOR PACKAGE NO. : COB2/EXPN/SM-47

Vendor Confirmation Bid / offer without this confirmation sheet duly signed & with company seal shall be treated as incomplete offer and shall not be considered for technical / commercial evaluation. Sl.No (A) 1. 2. 3. 4. 5. 6. 7. 8. Description (B) Dimensions as per certified manufacturing/ approved vendor drawings Material composition as per Annexure- A Inspection as per Cl. No. 02.04 Delivery period as per Cl. No. 01.8 QAP (Quality Assurance Plan) AnnexureIII Part order acceptance as per Cl. No. 02.01.8 Termination of order or change in ordered quantity as per Cl. No. 02.01.3 Tenderer has enclosed Annexure-I duly filled up & signed with company stamp in offer Confirmation (C) Alternative proposal by Vendor (D)

Notes: a) b)

c)

Vendor shall fill up column C with word either Agreed or Not agreed as a mark of their confirmation which shall be implemented during execution period. Tenderer may indicate any alternative proposal in column D, if desire. But it is prerogative of MECON / DSP to accept or reject alternate proposal from vendor without providing any reason to vendor. Once the vendor confirmation sheet is filled up & signed by the tenderer, it will be assumed that clauses in this specification are clearly understood by the tenderer. Signature with company stamp Name: Designation: Companys name: Date:

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/11/9172/COB2/EXPN/SM-47

DSP

REBUILDING OF COB # 2 TECHNICAL SPECIFICATION FOR INTERPLANT PIPELINE GAS MAIN & COMPENSATOR PACKAGE NO. : COB2/EXPN/SM-47

Annexure - II Sheet 1 of 1 FORMAT FOR INSPECTION CALL LETTER PROJECT: REBUILDING OF C.O. BATTERY NO. 2, DURGAPUR STEEL PLANT SL. NO. 1 2 3 4 5 6 7 8 9 10

DESCRIPTION A/T or Purchase Order No. Description of the item/ items with identification mark/ Sl. No. Specification no. of the item/items Drawing No. of the item/ items Type of the inspection:- Stage/Sample/ Final Quantity ordered/offered/balance (Nos. & Weight) Proposed date of Inspection Place of Inspection (with Full address and working days and working hours) Name of Contact Person (s) with Phone No. Documents enclosed (All the following documents must be enclosed with the inspection call letter. "Not Applicable" shall be mentioned, if particular document is not required for the item/ items offered for the inspection) Manufacturers material test certificate for physical & chemical properties as per QAP Supplier's internal inspection report Items Pressure test certificate, if applicable Items Performance test Certificate, if applicable IBR certificate, if applicable Any other certificate for other tests specified in the specification/ Drawing/ Contract

DETAILS

i) ii) iii) iv) v) vi)

SIGNATURE OF THE SUPPLIER WITH STAMP

2010 MECON LIMITED, ALL RIGHT RESERVED T.S. No.: MEC/TS/11/9172/COB2/EXPN/SM-47

Annexure - III FORM NO. 11.20(DQM) F-9 Rev. 0

PURCHASER ORDER No. & DT. MANUFACTURER

--QUALITY ASSURANCE PLAN FOR MECHANICAL EQUIPMENT

PROJECT PACKAGE No. PACKAGE NAME

REBUILDING OF COKE OVEN BATTERY NO. 2 DURGAPUR STEEL PLANT

ORDER No. & DATE

TS No.

COB2/EXPN/SM-47 REPLACEMENT OF LEAN GAS HEADER DN1400 ON COKE SIDE OF COB NO. 2 MEC/TS/11/9172/COB2/EXPN/SM-47

INSTRUCTIONS FOR FILLING UP:

CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS :

1.
2.

QAP shall be submitted for each of the equipment separately with break-up of assembly / sub-assembly & part / component or for group of equipment having the same specification. Use numerical codes as indicated for extent of inspection & tests and submission of test certificates & documents. Additional codes & description for extent of inspection & tests may be added as applicable for the plant & equipment. Separate identification number with quantity for equipment shall be indicated wherever equipment having same specifications belonging to different facilities is grouped together. Weight in tonnes (T) must be indicated under column 5 for each item. Estimated weights may be indicated wherever actual weights are not available.

CODE

DESCRIPTION

CODE DESCRIPTION
17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. Vibration Test Amplitude Test Sponge Test Dust / Water Ingress Test Friction Factor Test Adhesion Test Performance Test / Characteristic curve No Load / Free Running Test Load / Overload Test Measurement of speeds Acoustical Test Geometrical Accuracy Repeatability & Positioning Accuracy Proving Test Surface preparation Hardness Test Spark Test for Lining

CODE DESCRIPTION
34. 35. 36. 37. 38. 39. Calibration Safety Device Test Ease of Maintenance Pouring witness Load/Deflection test of springs Sample

D7. D8. D9. D10. D11. D12. D13. D14. D15.

1.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

3. 4.

ABBREVIATIONS USED : MECON MFR : : MECON LIMITED MANUFACTURER

Visual (Welding, etc.) Dimensional Assembly ,Fitment & Alignment Physical Test (sample) Chemical Test (sample) Ultrasonic Test Magnetic Particle Test Radiography Test Dye Penetration Test Metallographic Exam. Welders Qualification & weld procedure Test Approval of Test and Repair procedure Heat Treatment Pressure Test Leakage Test Balancing

DOCUMENTS
D1. Approved GA drawings D2. Information and other reference drg. / stamped drgs. released for mfg. D3. Relevant catalogues D4. Bill of matl. / Item No D5. Identification Relevant catalogues ,Match mark details D6. Line / Layout diagram

Approved Erection procedures Un priced sub P. O. with specification and amendments, if any. Calibration Certificates of all measuring Instruments and gauges Guarantee Certificate Heat Curve Physical & chemical test certificate IBR / Other Statutory agencies Compliance certificate Manufacturers Test Certificates for bought out items Internal Inspection Report by Contractor

EQUIPMENT DETAILS Description (with equipment heading,place of use & brief specifications) 1 1. 2 Quantity Item No. No./M 3 4 T 5 Expected Schedule of Final Inspn.

I N S P E C T I O N AND T E S T S Raw Material and in process stage inspection MFR 8 DSP 9 MECON 10 Final Inspection / Test by MFR 11 DSP 12 MECON 13 Test Certificates & documents to be submitted to Mecon /DSP Acceptance Criteria Standards/IS/ BS/ ASME/ Norms and Documents Remarks/ sampling plan

Sl. No.

Manufactur ers Name & address 6

14

15

16 1. D.P Test 10% 2. Control Assembly with Match Mark 100 %

Fabricated Pipe

COB2/ EXPN/ SM47/01 COB2/ EXPN/ SM47/02

140 m

As per TS

1, 2, 3, 4, 5, 11

1, 2, 9, 14, 15, 28, 31 1, 2, 3, 9, 28,31

1, 2, 3, 9, 14 , 15 1, 2, 3, 9

1, 2, 9, 14,15, 28, 31 1, 2, 3, 9

D1,D2,D4,D5 ,D9, D10, 4, 5

2. 2

Saddle support

3 No.s

As per TS

1, 2, 3 ,4,5,11

D1, D2, D4, D5, D9, D10, D12, D15

D1,D2 & As per Relevant Standard Codes D1,D2 & As per Relevant Standard Codes

100%

QAP No. MEC/ 9172/ COB2/EXPN/SM-47/01 SHEET 1 OF 2 For MANUFACTURE (Stamp & Signature) For MECON (Stamp & Signature)

REV. - O

3.

Roller Support

COB2/ EXPN/ SM47/03 COB2/ EXPN/ SM47/04 COB2/ EXPN/ SM47/05 COB2/ EXPN/ SM47/13 COB2/ EXPN/ SM47/06, 07,08 COB2/ EXPN/ SM47/09 COB2/ EXPN/ SM47/10, 11 COB2/ EXPN/ SM47/12

7 No.s

As per TS

1, 2, 3, 4, 5, 11

1, 2, 3, 9, 28,31 1, 2, 3,9, 14, 15, 28, 31 1, 2, 3, 9, 14 , 15,28, 31 1, 2, 3, 9, 14 & 15

1, 2, 3, 9 1, 2, 3, 9, 14 , 15,28 1, 2, 3, 9, 14 , 15,28 1, 2, 3,9,1 4, 15 1, 2, 14,15 ,31 1, 2, 14,15 ,31 1, 2, 3, 9, 14, 15,28 ,31 1, 2, 3, 9, 14 & 15

1, 2, 3, 9

D1,D2, D4, D5, D9, D10, D12, D15 D1,D4,D5,D9 , D10, D10, D12, D15 D1,D2, D4, D5, D9, D10, D12, D14, D15 D2, D4, D5, D8,D9, D10, D12, D14, D15 D2, D4, D5, D8,D9, D10, D12, D14, D15 D2, D4, D5, D8,D9, D10, D12, D14, D15 D2, D3,D4, D5,D8, D9, D10, D12, D14, D15 D1,D2,D4,D5 ,D9, D10, 4, 5

As per TS & Certified Mfg. Drg. As per TS Drg. & Relevant Standard Codes As per TS & Certified Mfg. Drg. As per Relevant Standard Codes / D8/D14/D15 As per Relevant Standard Codes / D8/D14/D15 As per Relevant Standard Codes / D8/D14/D15 As per Relevant Standard Codes / D8/D14/D15 As per TS & Certified Mfg. Drg.

100%

4.

Single Disc Compensator

2 No.s

As per TS

1, 2, 3, 4, 5, 11

1, 2, 9, 14,15, 28, 31

100%

5.

Condensate Seal Pot

1 No.s

As per TS

1, 2, 3,11

1, 2, 3, 9, 14 , 15,28, 31 1, 2, 3, 9, 14 & 15 1, 2, 9, 14,15, 31 1, 2, 9, 14,15, 31

100%

6.

FLEXIBLE METALLIC HOSE

1 No.s

As per TS

1, 2, 3

100%

7.

ERW Pipes (Bought Out)

-8m - 12m -100m

As per TS

1, 2, 4, 5, 11 -

1, 2,14, 15

100%

8.

90 Elbow
o

10 No.s

As per TS

1, 2, 4, 5, 11 -

1, 2,14, 15

100%

9.

Valves

6 No.s

As per TS

1, 2, 3

1, 2, 3, 9, 14 , 15,28, 31 1, 2, 3, 9, 14 & 15

1, 2, 3, 9, 14 , 15,28, 31 1, 2, 3, 9, 14 & 15

100%

10.

Funnel

1 No.s

As per TS

1, 2, 3,11

100%

QAP No. MEC/ 9172/ COB2/EXPN/SM-47/01 SHEET 2 OF 2 For MANUFACTURE (Stamp & Signature) For MECON (Stamp & Signature)

REV. - O