STANDARD SPECIFICATION No.

ENGINEERS TECHNICAL NOTES FOR

lig-a O&
1.11-e,
- .1,.fcrosvi)
INDIA LIMITED
(A Govt of India UndertakIng)
BOLTS AND NUTS 6-44-0057 Rev. 7
Page 2 of 6

Abbreviations:

ASME : The American Society of Mechanical Engineers

ASTM : The American Society for Testing and Materials

GALV : Galvanized

HDG : Hot Dip Galvanized

MR Material Requisition

PMI : Positive Material Identification

SS Stainless Steel

Piping Standards Committee

Convenor: Mr. G. Balaji

Members : Mr. Udayan Chakravarty

Mr. Rameshwar Prasad
Mr. K. Anjaneyulu (SMED)
Mr. Rajesh Chitara (SMMS)
Dr. Sudip Paul (Structural)
Mr. Harsh Vardhan (Projects)
Mr. P.K. Rai (Construction)

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Page 391 of 612

 STANDARD SPECIFICATION No.
ENGINEERS TECHNICAL NOTES FOR
0-41 iaws, INDIA LIMITED BOLTS AND NUTS 6-44-0057 Rev. 7
IA Govt of Intlo UndertakIngt
Page 3 of 6

CONTENTS

1.0 GENERAL 4

2.0 ACCEPTABLE DEVIATIONS 5

3.0 MARKING AND DESPATCH 5 I

4.0 REFERENCES 6

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Page 392 of 612

 STANDARD SPECIFICATION No.
ENGINEERS TECHNICAL NOTES FOR
51gal5leg I NDIA LIMITED BOLTS AND NUTS 6-44-0057 Rev. 7
irett el,c/Ne' is J4inAl IA Govt India Undertaking)
Page 4 of 6

1.0 GENERAL

1.1 The process of manufacture, heat treatment, chemical & mechanical requirements and
marking for all stud bolts, m/c bolts, jack screws & nuts shall be in accordance with the
codes/standards and specifications given in the requisition. Supplier shall strictly comply
with MR stipulations and no deviations shall be permitted. In case of any conflict
amongst documents attached with the MR, the most stringent shall govern and
Owner's/ EIL decision shall be final in this regard.

All codes and standards for manufacture, testing, inspection etc. shall be of latest editions
as on issue date of RFQ.

1.2 Testing

1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications/ MR.

1.2.2 Material test certificate shall also be furnished. (Heat Analysis, Product Analysis,
Mechanical Requirement and any other testing as per MR).

1.2.3 PMI shall be performed as per the scope and procedures defined in the Specification for
PMI at Supplier's Works (6-81-0001).

1.2.4 Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM A453
bolting material irrespective of the temperature.

1.2.5 Refer Specification no 6-81-0007 for 'Inspection & Test Plan for Bolting Material'.

1.3 All bolting shall be as per ASME B 18.2.1 for studs, M/c bolts and jackscrews and ASME
B18.2.2 for nuts.

1.4 Threads shall be unified (UNC for up to 1" dia and 8UN for > 1" dia) as per ASME B1.1
with class 2A fit for studs, M/c bolts and jackscrews and class 2B fit for nuts.

1.5 Stud bolts shall be threaded full length with two heavy hexagonal nuts unless otherwise
specified. Length tolerance shall be in accordance with the requirement of ASME B 16.5.

1.6 The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be
made by the hot forged process and stamped as per respective material specification.

1.7 Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end shall be
rounded.

1.8 All items shall be inspected and approved (stage-wise) by EIL inspector or any other
agency authorized by EIL.

1.9 The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.

1.10 All austenitic stainless steel bolts, nuts, screws shall be supplied in solution annealed
condition unless specified otherwise in the material specification.

1.11 Any additional requirements specified in the requisition shall be fully complied with.

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Page 393 of 612

 STANDARD SPECIFICATION No.
,S1
1 W_Jel ENGINEERS TECHNICAL NOTES FOR
taWs
wren ereasrztnmm,
INDIA LIMITED
(A GoN of India Unclertalongf
BOLTS AND NUTS 6-44-0057 Rev. 7
Page 5 of 6

1.12 Stud bolts, nuts & jackscrews shall be impact tested wherever specified in the material
specification and also where the material specification is indicated as "CRYO". For S.S.
nuts and bolts minimum impact energy absorption shall be 27 Joules and test temperature
shall be -196°C unless mentioned otherwise. For other materials impact energy and test
shall be as per respective code.

1.13 Bolts/nuts of material of construction B7M/2HM shall be 100% Hardness tested as per
supplementary requirement S3 of ASTM A193.

1.14 When specified as "GALV.", the studs, M/C bolts and nuts shall be 'hot dip zinc coated'
in accordance with requirements of 'class C' of `ASTM A 153'. As an alternative, electro-
galvanizing as per IS 1573, 'Service Grade Number 2' is also acceptable. However, for
bolting where "HDG" has been specified, only 'hot dip zinc coating' in accordance with
requirements of 'class C' of `ASTM A 153' is acceptable.

1.15 All Stud Bolts of Bolt diameter size 1" and above shall be provided with three nuts
irrespective of whatever has been specified elsewhere in the MR.

1.16 For stud bolt diameters not covered in ASTM A320, mechanical properties shall match
the values specified for the matching grades and stud bolt diameters in ASTM A193.

1.17 In cases where the lengths of Stud/Machine bolts specified in the MR are not multiples of
0.25", the length supplied shall be equal to the specified length rounded up to the next
higher 0.25".

1.18 All Specialties mentioned in item description like "IBR", "LT", "H2", etc. other than
"CRYO"& "NACE" shall be ignored.

1.19 'Nuts' to ASTM A194Gr.7 to be supplied wherever ASTM A194Gr.4 is specified in the
MR/PR.

2.0 ACCEPTABLE DEVIATIONS

2.1 Stud Bolts to ASTM A453 Gr.660 CI.B are acceptable in lieu of ASTM A453 Gr. 660
CI.A and vice versa.

2.2 In case of ASTM A453 Gr.660, Nuts machined from raw material duly heat treated &
tested (including stress rupture test) as per relevant material specifications are acceptable.
However, all tests required as per MR shall be repeated on finished product.

3.0 MARKING AND DESPATCH

3.1 Bolting shall be protected by non-corrosive oil or grease before dispatch to prevent
rusting.

3.2 The applicable identification symbol in accordance with the material specification shall be
stamped on each bolt and nut.

3.3 Each size of studs & m/c bolts with nuts and jackscrews shall be supplied in assembled
condition in separate containers. Each container shall be clearly marked with the size,
material specification, and item code. `CRY0' shall be marked additionally in case
`CRY0' is specified in the requisition. Packing of studs/bolts and nuts separately are not
acceptable.

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 STANDARD SPECIFICATION No.
ENGINEERS TECHNICAL NOTES FOR
mac'® INDIA LIMITED
,A Go, of indo Undertaking) BOLTS AND NUTS 6-44-0057 Rev. 7
Page 6 of 6

4.0 REFERENCES

6-81-0001 Specification for Positive Material Identification (PMI) at Supplier's

Works

6-81-0007 Inspection & Test Plan for Bolting Material

6-78-0001 Specification for Quality Management System Requirements from

Bidders

6-78-0003: Specification for documentation requirements from suppliers

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Page 395 of 612

 STANDARD SPECIFICATION No.
ENGINEERS TECHNICAL NOTES FOR
ogar"
-
056 INDIA LIMITED
IA Go, of India Undertaking)
GASKETS 6-44-0056 Rev. 7
Page 1 of 5

4litArk*i
Clcbr1 l ch I i dui till'

TECHNICAL NOTES
FOR GASKETS

7 REVISED & ISSUED AS STANDARD 07

15.03.24 PK SH MN
SPECIFICATION
6 REVISED & ISSUED AS STANDARD
11.08.21 PK SH GB SM
SPECIFICATION
5 30.03.18 REVISED & ISSUED AS STANDARD
PK SH MI RN
SPECIFICATION
4 21.03.13 REVISED & ISSUED AS STANDARD
UK SH RN ATD DM
SPECIFICATION
3 23.07.07 REVISED & ISSUED AS STANDARD
SPECIFICATION RN ATD DM VC
Standards Standards
Rev. Prepared Committee Bureau
Date Purpose Checked by Convenor Chairman
No by
Approved by

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Page 396 of 612

 STANDARD SPECIFICATION No.
ENGINEERS TECHNICAL NOTES FOR
51g-ai 056 INDIA LIMITED GASKETS 6-44-0056 Rev. 7
1.1iR PRTefir, [Link] (A G. of Ind. Undeftak, n91
Page 2 of 5

Abbreviations:

AARH : Average Arithmetic Root Height

BHN : Brinnel Hardness Number

CS Carbon Steel

MR : Material Requisition

PMI : Positive Material Identification

RTJ : Ring Type Joint

Piping Standards Committee

Convenor: Mr. G. Balaji

Members : Mr. Udayan Chakravarty

Mr. Rameshwar Prasad
Mr. K. Anjaneyulu (SMED)
Mr. Rajesh Chitara (SMMS)
Dr. Sudip Paul (Structural)
Mr. Harsh Vardhan (Projects)
Mr. P.K. Rai (Construction)

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Page 397 of 612

 STANDARD SPECIFICATION No.
fa.-1e1 ENGINEERS TECHNICAL NOTES FOR
1=
d-ar feligteg INDIA LIMITED GASKETS 6-44-0056 Rev. 7
eic,Pre [A Gam of India UndenakIngi
Page 3 of 5

CONTENTS

1.0 GENERAL 4

2.0 REFERENCES 5

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Page 398 of 612

 STANDARD SPECIFICATION No.
ENGINEERS TECHNICAL NOTES FOR
$1g-eixion
x tiffaleg INDIA LIMITED GASKETS 6-44-0056 Rev. 7
2:12215W JEreFil ,A Gov! of India Undertaking)
Page 4 of 5

1.0 GENERAL

1.1 All gaskets shall conform to the codes/standards and specifications given in the
requisition. In case of any conflict amongst documents attached with the MR, the
most stringent shall govern and Owner's/ EIL decision shall be final in this regard.

Supplier shall strictly comply with MR/PR stipulations and no deviations shall be
permitted.

1.2 Process of manufacture, dimensions and tolerances not specified in requisition shall be in
accordance with the requirements of the manufacturer's standards.

1.3 Testing

1.3.1 Test reports shall be supplied for all mandatory tests for gaskets as per the standards
specified in the requisition.

1.3.2 Chemical composition and hardness of RTJ gaskets shall also be furnished in the form of
test reports on samples.

1.3.3 For Spiral wound material following shall be furnished:

a. Manufacturer's test certificate for filler material and spiral material as per the relevant
material specifications/ MR.

b. Manufacturer's test certificate for raw materials and tests for compressibility/ seal-
ability & recovery as per the relevant material specifications/ MR.

1.3.4 PMI shall be performed as per the scope and procedures defined in the Specification for
PMI at Supplier's Works (6-81-0001) for ring type joint gaskets.

1.3.5 Refer Specification no 6-81-0008 for 'Inspection & Test Plan for Gaskets'.

1.4 Full face gaskets shall have bolt holes punched out.

1.5 Filler material for spiral wound gaskets shall not have any colour or dye.

1.6 All spiral wound gaskets shall be supplied with Outer ring. Material of the outer ring shall
be CS unless otherwise specified in the MR.

1.7 Inner rings shall be provided for all Spiral Wound Gaskets. For spiral wound gaskets,
material of Inner Compression ring shall be same as Spiral Strip material.

1.8 Hardness of metallic RTJ gaskets shall not exceed the values specified below unless
otherwise specified in MR:

Ring Gasket Material Maximum Hardness (BHN)

Soft Iron 90

Carbon steel 120

5 Cr. 'A Mo 130

Type 304, 316, 321, 347 140

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Page 399 of 612

 STANDARD SPECIFICATION No.
ENGINEERS D TECHNICAL NOTES FOR
EtWeg
,Arreer cdecnre =Jere.,
INDIA LIMITE GASKETS 6-44-0056 Rev. 7
(A Gov) of India Undertaking)
Page 5 of 5

Type 304L, 316L 135

Inconel UNS N06625 200

Incoloy UNS N08825 190

Duplex SS UNS S32205, S31803 230

1.9 Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.

1.10 Gaskets of different types and sizes shall be placed in separate shipping containers and
each container clearly marked with the size, rating, material specification and item code.

1.11 All items shall be inspected and approved by EIL Inspector or any other agency
authorized by EIL.

1.12 Any additional requirements specified in the requisition, shall be fully complied with.

1.13 Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B16.5 upto
24" and to ASME B16.47B above 24" unless specified otherwise.

1.14 Spiral wound gasket as per ASME B16.20 shall match flanges to ASME BI6.5 upto 24"
and to ASME B16.47B above 24" unless specifically mentioned otherwise.

1.15 The following abbreviations have been used in the Material Requisition for Spiral Wound
Gaskets :

(I) Inner Ring

(0) Outer Ring
GRAFIL : Grafoil Filler

1.16 Specialties mentioned in item description like "IBR", "LT", "HICI", "H2", "CRYO" etc. I
shall be ignored.

2.0 REFERENCES

6-81-0001 Specification for Positive Material Identification (PMI) at Supplier's

Works

6-81-0008 Inspection & Test Plan for Gaskets

6-78-0001 Specification for Quality Management System Requirements from

Bidders

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Page 400 of 612

 TECHNICAL NOTES FOR STANDARD SPECIFICATION No.
ENGINEERS FLANGES, SPECTACLE BLINDS
INDIA LIMITED 6-44-0053 Rev. 8
IA Govt of ,ndia Underla,ng) AND DRIP RINGS Page 1 of 8

1,01

rk4 d -11 chri uHru I 11.

TECHNICAL NOTES FOR FLANGES,

SPECTACLE BLINDS AND DRIP RINGS

8 15.03.24 REVISED & ISSUED AS STD SPECIFICATION l'‘. .

PK GB MN

7 16.01.20 REVISED & ISSUED AS STD SPECIFICATION PK SH MI RKT

6 25.09.14 REVISED & ISSUED AS STD SPECIFICATION UK SH AK RN SC

5 31 12 13 REVISED & ISSUED AS STD SPECIFICATION UK SH AK RN SC

4 04.07.08 REVISED & ISSUED AS STD SPECIFICATION RN SC DM VC

Standards Standards
Rev. Prepared Committee Bureau
Date Purpose Checked
No by Convenor Chairman
by
Approved by

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Page 401 of 612

 TECHNICAL NOTES FOR STANDARD SPECIFICATION No.
ENGINEERS
LEI Nal
eg
,lecnre M1.1,
215-.0
INDIA LIMITED
IA Govt of India undertak,ogt
FLANGES, SPECTACLE BLINDS
AND DRIP RINGS
6-44-0053 Rev. 8
Page 2 of 8

Abbreviations:

AARH Arithmetic Average Roughness Height

ANSI American National Standards Institute
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing & Materials
AWWA American Water Works Association
BHN Brinell Hardness Number
HIC Hydrogen Induced Cracking
IBR Indian Boiler Regulations
IGC Inter Granular Corrosion
IS Indian Standard
MR Material Requisition
MSS Manufacturer's Standardization Society
NACE MR National Association of Corrosion Engineers : Material Requirement
PMI Positive Material Identification

Piping Standards Committee

Convenor: Mr. G. Balaji

Members : Mr. Udayan Chakravarty

Mr. Rameshwar Prasad
Mr. K. Anjaneyulu (SMED)
Mr. Rajesh Chitara (SMMS)
Dr. Sudip Paul (Structural)
Mr. Harsh Vardhan (Projects)
Mr. P.K. Rai (Construction)

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Page 402 of 612

 514106 ENGINEERS
INDIA LIMITED
TECHNICAL NOTES FOR
FLANGES, SPECTACLE BLINDS
STANDARD SPECIFICATION No.

6-44-0053 Rev. 8
elect, ,51,2154,
t Govt of Ind. Undertalong)
AND DRIP RINGS Page 3 of 8

CONTENTS

1.0 GENERAL 4
2.0 IBR REQUIREMENTS 6
3.0 ACCEPTABLE DEVIATIONS 7
4.0 MARKING AND DESPATCH 7
5.0 REFERENCES 8

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Page 403 of 612

 TECHNICAL NOTES FOR STANDARD SPECIFICATION No.
ENGINEERS
INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 8
IA Gum of India Undertaking)
AND DRIP RINGS Page 4 of 8

1.0 GENERAL

1.1 All items, their dimensions, tolerances, chemical composition, physical properties, heat
treatment and testing etc. shall conform to the latest codes and standards specified in the
requisition. In case of any conflict amongst documents attached with the MR, the most
stringent shall govern and Owner's/ EIL decision shall be final in this regard.

Supplier shall strictly comply with MR/PR stipulations and no deviations shall be permitted.
Post Order Concession/Deviation as mentioned in Cl. 5.17 of Specification for Quality
Management System Requirements from Bidders (6-78-0001) is not applicable.

1.2 Testing

1.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications/ MR. Test reports shall also be furnished for any supplementary tests as
specified in the requisition & Clauses 1.11, 1.12 & 1.15.

1.2.2 Material test certificates (physical property, chemical composition & heat treatment report
including Chart) shall also be furnished for the flanges supplied.

1.2.3 Positive Material Identification (PMI) shall be performed as per the scope and procedures as
defined in the 'Specification for Positive Material Identification (PMI) at Supplier's Works'
(No. 6-81-0001).

1.2.4 Refer to specification no. 6-81-0006 for Inspection and Test plans for flanges, spectacle blinds
& drip rings.

1.3 Ends of weld neck flanges shall be beveled to suit the schedule / thickness of matching pipe,
as specified in the requisition.

1.4 Bevel end details for welding neck flanges shall be as per ASME B16.25. Contour of bevel
end shall be as follows:

Material Wall Thickness Weld Contour

Carbon Steel (Except Upto 22 mm Figure 2 Type A

Low Temp. Carbon Steel)
> 22 mm Figure 3 Type A

Alloy Steel, Upto 10 mm Figure 4

Stainless Steel &
Low Temp. Carbon Steel
> 10 mm & Upto 25 mm Figure 5 Type A

> 25 mm Figure 6 Type A

1.5 Bore of socket weld flanges & reducing blind flanges shall suit the outside diameter and
schedule / thickness of matching pipe.

1.6 Bore of slip on flanges shall suit the outside diameter of matching pipe.

1.7 Flange face finish shall be normally specified in the requisition as serrated finish, 125 AARH
etc. The interpretation for range of face finish shall be as follows:

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Page 404 of 612

 ENGINEERS TECHNICAL NOTES FOR STANDARD SPECIFICATION No.

oge..11 tameg
.117n 2422:512 d51
INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 8
Jtri.
AND DRIP RINGS
IA Govt of India Undertaking)
Page 5 of 8

Stock Finish 1000 [t in AARH max.

Serrated Finish/125 AARH Serrations with 125 to 250[tin AARH
63 AARH 32 TO 63 µ in AARH

1.8 Galvanized flanges shall be coated with zinc by hot dip process conforming to IS 4736 /
ASTM A153.

1.9 Ends of screwed flanges unless otherwise specified shall have taper threads as per
ASME/ANSI B1.20.1.

1.10 For ring joint flanges, blinds and spacers the hardness shall be as follows:

Flange Material Min. Hardness of Groove (BHN)

Carbon Steel 140
1% Cr to 5%, 9% Cr 150
9Cr-lMo-V 190
Type 304, 316, 321, 347 160
Type 304L, 316L 150
Inconel UNS N06625 220
Incoloy UNS N08825 210
Duplex SS UNS S32205, 531803 250

1.11 For ring joint flanges, blinds and spacers, the hardness shall be recorded in the test report.

1.12 NACE/HIC Requirements

1.12.1 Flanges, blinds, drip rings under "NACE" category and those designated as "HIC1" shall meet
the requirements given in NACE MR-0103 unless otherwise specified.

1.12.2 Flanges, blinds, drip rings made from plates and designated as "HICI" shall meet the HIC
requirements of EIL Specification 6-79-0013 unless otherwise specified.

1.13 All austenitic stainless steel flanges shall be supplied in solution annealed condition.

1.14 I.G.C. Test for Stainless Steels:

1.14.1 For all austenitic stainless steel flanges, blinds, drip rings & Fig.8 flanges intergranular
corrosion test shall have to be conducted as per following:

ASTM A262 Practice 'B' with acceptance criteria of "60 mils/year (max.)".
OR
ASTM A262 Practice E : The bent specimen shall be examined under 20X magnification. The
acceptance criteria is that there will be no crack or fissure in the bent specimen. The bent
specimen shall also be subjected to metallographic examination at 250X magnification to
ensure no crack or fissure. The photograph of the bent specimen along with comments shall be
submitted for review.

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 TECHNICAL NOTES FOR STANDARD SPECIFICATION No.
ENGINEERS
INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 8
INfZii [Link]' On .192,441 IA God of India Undertaking)
AND DRIP RINGS Page 6 of 8

1.14.2 When specifically asked for in requisition for high temperature application of some grades of
austenitic stainless steel (like SS309, 310, 316, 316H etc.) ASTM A262 Practice 'C' with
acceptance criteria of "15 mils/year" shall have to be conducted.

1.14.3 For the IGC test as described in 1.14.1 & 1.14.2 two sets of samples shall be drawn from each
solution treatment lot; one set corresponding to highest carbon content and the other
corresponding to the highest rating / thickness.

1.15 All types of 321 or 347 stainless steel flanges shall be in a stabilized heat treated condition.
Stabilizing heat treatment shall be carried out subsequent to the normal solution annealing.
Soaking temperature and holding time for stabilizing heat treatment shall be 900 C and 4
hours respectively.

1.16 For dual grades of SS where specified, chemical composition and mechanical properties of
both grades specified shall be ensured.

1.17 AWWA C207 flanges shall be ring type.

1.18 Dimensions for handle projection for Spacers & Blinds shall be as specified in EIL Std. 7-44-
0166.

1.19 Where ever two sizes have been specified in the MR for flanges, it shall be considered a
reducing flange.

1.20 All 1Cr-Y2Mo and 11/4Cr-V2Mo flanges shall be normalised and tempered.

1.21 Ring Joint Fig-8 Flanges, Spacers & Blinds shall be female type only.

1.22 The handle for spacers & blinds for classes 900# & above shall be designed by the vendor.
The handle may be integral or attached to the line blank / spacer by welding. In case of
attachment by welding heat treatment & welding shall be in accordance with B31.3.

1.23 For Hydrogen service following special requirements shall also be met:

a. All carbon steel flanges having wall thickness 9.53 mm and above shall be normalised.
The normalising heat treatment shall be a separate heat treatment operation and not a part
of the hot forming operation.

b. All alloy steel (Cr-Mo) flanges shall be normalised and tempered. The normalising and
tempering shall be a separate heat treatment operation and not a part of the hot forming
operation.

c. For all carbon steels and alloy steels with wall thickness over 20mm, Charpy-V Notch
impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section
VIII, Div-1 per heat of material and per heat treating batch. Impact test specimen shall be
in accordance with ASTM A370. Impact energies at 0 C shall average greater than 27J (20
ft-lb) per set of 3 specimens, with a minimum of 20J (15ft-lb).

2.0 IBR REQUIREMENTS

2.1 IBR Documentation

2.1.1 Flanges coming under the purview of IBR (Indian Boiler Regulations) shall be accompanied
with IBR Certificate original in Form III G duly approved and countersigned by IBR
authority/ local authority empowered by Central Boiler Board of India. Photocopy of original
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Format No. 8-00-0001-F1 Rev. 0

Page 406 of 612

 ENGINEERS TECHNICAL NOTES FOR STANDARD SPECIFICATION No.
INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 8
lawn vorove d11 JO07.31 Govt of Inda Undeflaimg)
AND DRIP RINGS Page 7 of 8

certificate duly attested by the local boiler inspector where the supplier is located is the
minimum requirement for acceptance.

2.2 For carbon steel flanges under IBR the chemical composition shall conform to the following:
Carbon (max) 0.25%
Others (S, P, Mn) As prescribed in IBR.

The chemical composition as indicated in this clause is not applicable for flanges other than
IBR services.

3.0 ACCEPTABLE DEVIATIONS

3.1 Blind Flanges and Spacers & Blinds if specified as plate materials are acceptable in forging
materials also in the corresponding material grades.

3.2 Flanges/Spectacle Blinds/Drip rings of Grades SS317 of corresponding material are

acceptable in place of Grades SS316 or SS316 (2.5Mo min.).

3.3 Flanges/Spectacle Blinds/Drip rings of Grades SS317L of corresponding material are

acceptable in place of Grades SS316L or SS316L (2.5Mo min.).

3.4 Dual Grade SS304/304L conforming to all chemical composition requirements of SS304L and
mechanical properties of SS304 is acceptable in place of SS304L or SS304 grades. Any
specific additional requirements given in the MR shall also be complied.

3.5 Dual Grade SS316/316L conforming to all chemical composition requirements of SS316L and
mechanical properties of SS316 is acceptable in place of SS316L or SS316 grades. Any
specific additional requirements given in the MR shall also be complied.

4.0 MARKING AND DESPATCH

4.1 All items shall be legibly and conspicuously stamped in accordance with the requirements of
applicable ASME, API and MSS Standards. In addition, EIL item code, purchase order
number & special conditions like "IBR", "CRYO", "NACE" "H2" etc. shall also be stamped.

4.2 All items coming under the purview of "IBR", "CRYO" , "NACE" & "H2" (hydrogen) shall
be painted with one stripe of colour red, light purple brown, canary yellow & white
respectively for easy identification. Width of stripe shall be 25mm and it shall be painted
longitudinally across the complete thickness of flange other than hub.

4.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead
or copper which cause corrosive attack on heating.

4.4 All items shall be dry, clean and free from moisture, dirt and loose foreign materials of any
kind.

4.5 All items shall be protected from rust, corrosion and mechanical damage during
transportation, shipment and storage.

4.6 Rust preventive on machined surfaces to be welded shall be easily removable with a
petroleum solvent and the same shall not be harmful to welding.

4.7 Each end of flange shall be protected with the following materials:

Flange face Wood, metal or plastic cover

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 TECHNICAL NOTES FOR STANDARD SPECIFICATION No.
ENGINEERS
ell EPreg INDIA LIMITED FLANGES, SPECTACLE BLINDS 6-44-0053 Rev. 8
IA Govt of India undertaking)
AND DRIP RINGS Page 8 of 8

Bevelled end Wood, metal or plastic cover

Threaded end Plastic plug
Socket welding end Plastic cover or plug

4.8 Each size of flanges, blinds, etc. shall be supplied in separate packagings marked with the
purchase order number, item code number, material specification, size and rating.

5.0 REFERENCES

6-81-0001 Specification for Positive Material Identification (PMI) at Supplier's

Works.

6-81-0006 Inspection & test plan for flanges, spectacle blinds & drip rings

6-79-0013 Material requirements for carbon steel components used in sour

service for petroleum refinery environments

7-44-0162 Standard for Spacers & Blinds 26" (150CL, 300CL & 600CL FF)

7-44-0164 Standard for Spacers & Blinds 26" (For AWWA Flanges)

7-44-0166 Dimensions for Handle projection for Spacers & Blinds i/2"-24"

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 408 of 612

 STANDARD No.
ENGINEERS TOLERANCES FOR
1ilaW5 INDIA LIMITED
(4.11e
- e=recnre 051 JL.I ) FABRICATION
7-44-0486 Rev. 6
IA Govt of India Unclertakatgi

Page 1 of 1

A ±3mm. MAX: FROM INDICATED DIMENSIONS FOR FACE TO FACE

CENTER TO FACE LOCATION OF ATTACHMENTS ETC. TOLERANCE
CAN NOT BE ADDED.

B ±1.5mm MAX. LATERAL TRANSLATION IN ANY DIRECTION FROM

THE INDICATED POSITION.

C +1.5mm MAX. ROTATION FROM THE INDICATED POSITION MEASURED

AS SHOWN.

D ±1mm MAX. OUT OF ALIGNMENT FROM THE INDICATED POSITION

MEASURED ACROSS ANY DIAMETER AS SHOWN.

E FLATTENING, MEASURED AS DIFFERENCE BETWEEN THE MAX.

AND MIN. OD AT ANY CROSS SECTION.
—3% MAX: FOR PIPE WITH EXTERNAL PRESSURE.
8% MAX: FOR PIPE WITH INTERNAL PRESSURE.

6 22.01.24 REAFFIRMED & ISSUED AS STANDARD K \, SH ,... MN

5 31.12.18 REAFFIRMED & ISSUED AS STANDARD PK SH MI RKT
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 409 of 612

 STANDARD No.
ENGINEERS BUTT WELD DETAILS
/gar 01 51eg INDIA LIMITED ( DIMENSIONS) 7-44-0480 Rev. 6
INWR e,c1,1c'.1.5,
T0+11 (A Goa of India Undertaking)
Page 1 of 1

371/2.+21/2"

OR 30'45'
—0*

0.8-1.6 mm 1.6 mm 1.6 mm

X MAX 0.8-2.4 mm

1.6-3.2 mm

4.8 mm < t < 19.1 mm

X MAX = 1.5 mm FOR PIPES 2" AND BELOW
3.0 mm FOR PIPES ABOVE 2"

rsir SM
6 28.09.23 REAFFIRMED AND ISSUED AS STANDARD ABA SH Sri/
5 10.09.18 REAFFIRMED AND ISSUED AS STANDARD PK SH MI RKT
Prepared Checked Stds. Committee Stds. Bureau
Rev.
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 410 of 612

 STANDARD No.
ENGINEERS WELDING OF PIPE WITH
faVI5 d INDIAIndsLIMITED DIFFERENT THICKNESS
7-44-0476 Rev. 6
aiWR e922617 +I; ,A Govt ofUndertaking)
Page 1 of 1

PERMITTED MISALIGNMENT
OF 1.5mm

30- MAX

THICKER PIPE TAPER BORED TO ALIGN

(AS PER ASME B31.3)

6 28.09.23 REAFFIRMED AND ISSUED AS STANDARD ABA SH

5 10.09.18 REAFFIRMED AND ISSUED AS STANDARD PK SH MI RKT
Rev. Prepared Checked Stds,,Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All tights reserved

Page 411 of 612

 JACK SCREW FOR STANDARD No.
ENGINEERS SPECTACLE BLIND FIG. 8
$ifgar taWegw INDIA LIMITED
IA Goa of incUa Undertaking) AND SPACER & BLIND 7-44-0252 Rev. 6

(150CL , 300CL , 600CL RF) Page 1 of 1

IN OPERATING POSITION IN JACKING POSITION

HEXAGONAL HEAD
NOTE-1 L

150CL RF 300CL RF 600CL RF

NOM.
0
L D L D L D

3" — — — 4 3/4

4" — — — — 4 1/2 3/4

6" 3 1/4 3/4 4 3/4 4 3/4 3/4

8" 3 3/4 3/4 4 1/2 3/4 5 3/4 3/4

10" 3 3/4 3/4 4 3/4 3/4 6 3/4

12" 4 3/4 51/4 3/4 6 1/2 3/4

14" 4 1/2 3/4 5 3/4 3/4 6 3/4 3/4

16" 4 1/2 3/4 6 1/2 3/4 7 1/2 3/4

18" 4 3/4 3/4 6 1/2 3/4 8 3/4

20" 4 3/4 3/4 6 3/4 3/4 8 1/2 3/4

24" 5 3/4 3/4 7 1/4 3/4 9 1/2 3/4

26" 5 3/4 3/4 7 1/4 3/4 10 3/4

28" 5 3/4 3/4 7 1/2 3/4 10 3/ 4

30" 6 1/2 3/4 8 3/4 10 3/4 3/ 4

NOTES

1. DRILLED & TAPPED AT FIELD FOR TWO JACK SCREWS AT 180' APART SUCH THAT SPECTACLE
BLIND CAN BE HANDLED WITHOUT INTERFERENCE WITH OTHER LINES OR EQUIPMENT.
2. THESE JACK SCREW DIMENSIONS ARE FOR RF FLANGES TO ASME B16.5 FOR SIZES UPTO 24"
AND ASME B16.47 A/B FOR SIZES ABOVE 24".
3. JACK SCREW MATERIAL SHALL BE ALLOY STEEL.

6 28.09.23 REAFFIRMED AND ISSUED AS STANDARD ABA SH 4 '17/

5 10.09.18 REAFFIRMED AND ISSUED AS STANDARD PK SH MI RKT

Rev. Ppared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman.
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All rights reserved

Page 412 of 612

 STANDARD No.
. ENGINEERS
5igar 0011-eg
'
, Nr-
eq
INDIA LIMITED
IA Govt of India linden*mg)
GASKET THICKNESS 7-44-0170 Rev. 6
Page 1 of 1

THICKNESS COMPRESSED
TYPICAL
DESCRIPTION
OF GASKET THICKNESS
CROSS SECTION
(NOTE-1)

FLAT RING FOR

I I f RAISED FACE FLANGES
COMPRESSED NON—ASBESTOS
OR SYNTHETIC RUBBER. 2.0 2.0

1 FULL FACE FOR

III! I FLAT FACE FLANGES
I

FLAT RING FOR

L I I RAISED FACE FLANGES
PTFE JACKETED COMPRESSED
NON—ASBESTOS GASKET 3.0 3.0
I
FULL FACE FOR
1 : I I ? FLAT FACE FLANGES
1

SPIRAL WOUND METAL FLAT RING GASKET, NON METALUC

eA (( ( (( i
FILLER , AND A SILEL SOUD RING
DEVICE— FOR RAISED FACE FLANGES
PE CENTERING 4.4 3.0

FLAT METAL JACKETED GASKET , NON METALLIC FILLER

COMPLETELY ENCLOSED WITHIN A FULLY ANNEALED 3.0 2.0
-.C:'-'•7.7-7.7:7--j-7—
''..::.k.:
4
DOUBLE METAL JACKET— FOR RAISED FACE FLANGES

CORRUGATED METAL JACKETED GASKET, NON METALLIC FILLER,

.44.4111011 COMPLETELY ENCLOSED WITHIN A FULLY ANNEALED DOUBLE

METAL CORRUGATED JACKET — FOR RAISED FACE FLANGES
3.2 1.0

CORRUGATED METAL GASKET — FULLY ANNEALED CORRUGATED

'METAL WITH FILLER MATERIAL CEMENTED TO THE CORRUGATIONS 3.2 1.0
ON BOTH FACES—FOR RAISED FACE FLANGES

SOLID METAL FLAT RING FOR SMALL TONGUE AND GROOVE

V////////A FLANGES AS SPECIFIED

SOLID METAL FLAT RING FOR LARGE TONGUE AND GROOVE AS SPECIFIED
V///////////A FLANGES

,
DIMENSIONS SHALL BE AS PER
,/ SOLID METAL OCTAGONAL RING FOR R.T.J FLANGES ASME B 16.20(NOTE-2)

'0,1 SOLID METAL OVAL RING FOR R.T.J FLANGES

DIMENSIONS SHALL BE AS PER
ASME B 16.20(NOTE-2)

FULLY ANNEALED CORRUGATED METAL FOR RAISED FACE 3.2 1.0

FLANGES

NOTES:
1. COMPRESSED GASKET THICKNESS SHALL BE USED AS GAP BETWEEN FLANGES FOR CALCULATING DIMENSIONS.

2. IN CASE OF RTJ FLANGES GAP BETWEEN FLANGES SHALL BE AS PER EIL STD. 7-44-0026.

6 28.09.23 REAFFIRMED AND ISSUED AS STANDARD `ABA SH „y4P- SM

5 10.09.18 REAFFIRMED AND ISSUED AS STANDARD PK SH MI RKT

Prepared Checked Stds. Committee Stds. Bureau,

Rev.
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0 Copyright EIL - All lights reserved

Page 413 of 612

 DIMENSIONS FOR HANDLE STANDARD No.
ENGINEERS PROJECTION FOR SPACERS
INDIA LIMITED AND BLINDS : 1/2"-24"NB 7-44-0166 Rev. 5
2TeWecta.1,1,1,4i, (A Govt of India Undertaking)
(150CL , 300CL , 600CL FF) Page 1 of 1

PIPE 150CL FF 300CL FF 600CL FF

SIZE
INCH E F L E F L E F L

1/2" 25 3 100 25 6 100 25 6 110

3/4" 25 3 100 25 6 100 25 6 110

1" 25 3 100 25 6 100 25 6 110

1 1/2" 25 6 100 25 6 100 25 6 110

2" 25 6 100 25 6 100 25 6 110

2 1/2" 25 6 100 25 6 110 25 6 110

3" 40 6 105 40 6 110 40 8 110

4" 40 6 105 40 6 110 40 8 110

6" 40 6 105 40 6 110 40 8 115

8" 40 6 105 40 8 110 40 10 125

10" 40 8 105 40 10 110 40 10 125

12" 40 8 110 40 10 120 40 15 125

14" 40 10 120 40 15 120 40 15 145

16" 40 10 120 40 15 130 40 20 140

18" 40 10 120 40 20 130 40 20 140

20" 40 14 120 40 20 140 40 25 140

24" 50 16 120 50 20 140 50 25 145

NOTES :
1. ALL DIMENSIONS ARE IN MILLIMETRES.
2. ALL OTHER DIMENSIONS SHALL BE AS PER ASME B16.48.
3. MATERIAL SHALL BE AS PER MR.
4. THE HANDLE MAY BE INTEGRAL OR ATTACHED TO THE LINE BLANK/SPACER BY WELDING.
IN CASE OF ATTACHMENT OF HANDLE BY WELDING, HEAT TREATMENT AND WELDINGHALL
BE IN ACCORDANCE WITH ASME 831.3.

5 28.09.23 REAFFIRMED AND ISSUED AS STANDARD ABA SHP / • Cr

4 10.09.18 REAFFIRMED AND ISSUED AS STANDARD PK SH MI RKT
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - An rights reserved

Page 414 of 612

 STANDARD No.
,d ENGINEERS
5fga fetOlteg INDIA LIMITED ABBREVIATIONS 7-44-0002 Rev. 6
.TV-4 0,0.1 (A Goof of India Undertaking)
Page 1 of 2

API AMERICAN PETROLEUM INSTITUTE FAB. FABRICATED

ANSI AMERICAN NATIONAL STDS. INSTITUTE FF FLAT FACE
ASME AMERICAN SOCIETY OF MECHANICAL ENGINEERS FFL FINISHED FLOOR LEVEL
ASTM AMERICAN SOCIETY FOR TESTING AND MATERIALS FGL FINISHED GRADE LEVEL
AWWA AMERICAN WATER WORKS ASSOCIATION FHY. FIRE HYDRANT

AG ABOVE GROUND FLR FLOOR

ANC. ANCHOR FLGD FLANGED
BBE BEVEL BOTH ENDS FLG. FLANGE
BE BEVEL ENDS FS FORGED STEEL

BF BLIND FLANGE FIG FITTING

B/L BATTERY LIMIT FDN FOUNDATION

BLDG BUILDING FCN FIELD CHANGE NOTE
BLE BEVEL LARGE END FSD FLAT SIDE DOWN
BOM BILL OF MATERIAL FSU FLAT SIDE UP
BOP BOTTOM OF PIPE FW FIELD WELD
B&S BELL & SPIGOT GALV. GALVANIZED
BS EN BRITISH STANDARD EUROPEAN NORM GPM GALLONS PER MINUTE
BSE BEVEL SMALL END GR. GRADE
BTU BRITISH THERMAL UNIT NOR HEADER
BW BUTT WELD HOR. HORIZONTAL
CFM CUBIC FEET PER MINUTE HC HOSE COUPLING

CL CENTRELINE HEX. HEXAGONAL

CAT CATALYST HP HIGH PRESSURE OR HORSE POWER

CI CAST IRON HS HOSE STATION

COL. COLUMN HPP HIGH POINT OF PAVEMENT

CONN. CONNECTION ID INSIDE DIAMETER
CONC. CONCENTRIC INS. INSULATION/INSULATED

CPLG COUPLING INST INSTRUMENT

CS CARBON STEEL OR COLD SPRING INV. INVERT

CSO CAR SEALED OPEN ISBL INSIDE BATTERY LIMIT

CSC CAR SEALED CLOSED IH HOT INSULATION

CR. CHROME IS SAFETY INSULATION

DRAIN CONNECTION IT STEAM TRACED

DC
IE ELECTRICAL TRACED
DCN DESIGN CHANGE NOTE
IC COLD INSULATION
DF DRAIN FUNNEL
DIA. DIAMETER LB POUND

DIM. DIMENSION LC LOCK CLOSED

LF LARGE FEMALE
DISCH. DISCHARGE
DN DIAMETER NOMINAL LJ LAP JOINT
LM LARGE MALE
DWG DRAWING
LO LOCK OPEN
ECC. ECCENTRIC
LR LONG RADIUS
EL. ELEVATION
LT LARGE TONGUE
ELB. ELBOW
LW LAP WELD
EOL. ELBOLET
LWN LONG WELDING NECK
EXH. EXHAUST
EWSS EYE WASH & SAFETY SHOWER

6 28.09.23 REAFFIRMED AND ISSUED AS STANDARD ABA SH

SH' SM
5 10.09.18 REAFFIRMED AND ISSUED AS STANDARD PK SH MI RKT
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 415 of 612

 STANDARD No .
0 el ENGINEERS
$1gar tdMeg INDIA LIMITED ABBREVIATIONS 7-44-0002 Rev. 6
lairenewcra ,.
1.3,
1,5.) IA CioN Of India 'Undertaking)

Page 2 of 2

M&F MALE & FEMALE SO SLIP ON

MI MALLEABLE IRON SOL. SOCKOLET
MOV MOTOR OPERATED VALVE SP. GR SPECIFIC GRAVITY
MOLY OR MO MOLYBDENUM SR SHORT RADIUS
MR MATERIAL REQUISITION SS STAINLESS STEEL
MTO MATERIAL TAKE OFF ST STEAM TRAP
MS MILD STEEL STN STATION
MSS MANUFACTURER'S STANDARD SOCIETY STM STEAM
MH MANHOLE STD STANDARD
NPT NATIONAL PIPE THREAD SW SOCKET WELD
NPS NOMINAL PIPE SIZE SWG SWAGE NIPPLE / STD WIRE GAGE
NPSH NET POSITIVE SUCTION HEAD STA STEAM TRAP ASSEMBLY
NIP. NIPPLE TOG TOP OF GRATING
NTS NOT TO SCALE TEMP. TEMPERATURE
OD OUTSIDE DIAMETER TL TANGENT LINE
P&ID PIPING AND INSTRUMENTATION DIAGRAM TOL. THREADOLET
[Link] PIECE MARK T&C THREADED & COUPLED
PE PLAIN END THRD THREADED
PBE PLAIN BOTH ENDS T&G TONGUE & GROOVE
PL PLATE TBE THREADED BOTH ENDS
PLTF. PLATFORM TLE THREADED LARGE END
PS PIPE SUPPORT TSE THREADED SMALL END
PSE PLAIN SMALL END TOS TOP OF STEEL
PRESS. PRESSURE TOE THREADED ONE END
PSI POUNDS PER SQUARE INCH TYP. TYPICAL
POE PLAIN ONE END UC UTILITY CONNECTION
PSIG POUNDS PER SQUARE INCH GAUGE VC VENT CONNECTION
RAD OR R RADIUS VERT. VERTICAL
RED. REDUCER VF VENDOR FURNISHED
RF RAISED FACE WAFL WAFER LUGGED

R/L RANDOM LENGTH WP WORKING PRESSURE,WORKING POINT

REF. REFERENCE U INVERT LEVEL OF PIPE
RPM REVOLUTIONS PER MINUTE V BOTTOM LEVEL OF THE PIPE
RTJ RING TYPE JOINT V CENTRELINE ELEVATION OF PIPE

SH SPRING HANGER WN WELD NECK

SHT. SHEET WT WEIGHT

SCH. SCHEDULE WOL. WELDOLET
SCRD SCREWED WLD WELD
SC SAMPLE CONNECTION XS EXTRA STRONG
SG SIGHT GLASS XXS DOUBLE EXTRA STRONG

SMLS SEAMLESS

NOTE :

1. FOR ABBREVIATIONS RELATED TO CIVIL ENGINEERING/UNDERGROUND PIPING WORK,

REFER CIVIL ENGINEERING STANDARD 7-65-0001.

6 28.09.23 REAFFIRMED AND ISSUED AS STANDARD ABA SH SM

5 10.09.18 REAFFIRMED AND ISSUED AS STANDARD PK SH MI RKT
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - An rights reserved

Page 416 of 612

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
ENGINEERS INSPECTION, FLUSHING AND
$11gar INDIA LIMITED 6-44-0013 Rev. 6
I ei,cryr, 411,E1S3-1 TESTING OF PIPING SYSTEMS Page 1 of 9

TfEirr f9-*Ti TiqEd7 fltIT

Li'aqtir Hvion f-49-k7

STANDARD SPECIFICATION FOR

INSPECTION, FLUSHING AND
TESTING OF PIPING SYSTEMS

6 28.09.23
REVISED & ISSUED AS STANDARD
w
ABA SH
SPECIFICATION
REAFFIRMED&ISSUED AS STANDARD
5 31.07.18 PK SH MI RKT
SPECIFICATION
REVISED & ISSUED AS STANDARD
4 01.07.13 UK SH RN ATD DM
SPECIFICATION
REVISED & ISSUED AS STANDARD
3 27.08.07 RN ATD DM VC
SPECIFICATION
PMI REQT. INCLUDED AND ISSUED AS
2 05.06.03
STANDARD SPECIFICATION RN DM BN SKG
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved

Page 417 of 612

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
01 el ENGINEERS
gar faiWt- g INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 6
t [Link] Freanu a111,C,:15411
TESTING OF PIPING SYSTEMS Page 2 of 9

Abbreviations:

ASME : The American Society of Mechanical Engineers

IBR : Indian Boiler Regulations

PMI : Positive Material Identification

ppm Parts per million

SS Stainless Steel

Piping Standards Committee

Convenor: Mr. G. Balaji

Members : Mr. Udayan Chakravarty

Mr. Rameshwar Prasad
Mr. K. Anjaneyulu (SMED)
Mr. Rajesh Chitara (SMMS)
Mr. S.C. Maity (Structural)
Mr. Harsh Vardhan (Projects)
Mr. P.K. Rai (Construction)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved

Page 418 of 612

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS
INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 6
Oge41lelaft
I Nr2R etme
TESTING OF PIPING SYSTEMS Page 3 of 9

CONTENTS

1.0 SCOPE 4

2.0 REFERENCES 4

3.0 INSPECTION 4

4.0 FLUSHING 4

5.0 PRESSURE TESTING 5

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 419 of 612

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
0 el ENGINEERS
5fgar laf*leg INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 6
I WA, twant JOirsII IA Govt of India Undertaking)
TESTING OF PIPING SYSTEMS Page 4 of 9

1.0 SCOPE

This specification covers the general requirements for inspection, flushing and testing of
piping systems. However, testing of steam lines falling under IBR shall also be governed by
Indian Boiler Regulations.

Flushing and testing of all piping systems shall be witnessed by the Engineer-In-Charge.

2.0 REFERENCES

ASME B31.3 Process Piping

IBR Indian Boiler Regulations

6-82-0002 Standard Specification for Positive Material Identification

(PMI) at Construction Sites

3.0 INSPECTION

During various stages and after completion of fabrication and erection, the piping system shall
be inspected by the Engineer-In-Charge to ensure that:

Proper piping material has been used.

PMI has been performed as per EIL specification '6-82-0002'.

Piping has been erected as per drawings and instructions of Engineer-In-Charge.

All supports have been installed correctly.

Test preparations mentioned in this specification have been carried out.

4.0 FLUSHING

Flushing of all lines shall be done before pressure testing.

Flushing shall be done by 'fresh potable water' or by 'dry compressed air wherever water
flushing is not desirable to clean the pipe of all dirt, debris or loose foreign material.

Required pressure for water flushing shall meet the fire hydrant pressure or utility water
pressure. For air flushing, the line/system shall be pressurized by compressed air at the
required pressure which shall be 3.5kg/cm2g maximum. The pressure shall then be released by
quick opening of a valve, already in line or installed temporarily for this purpose. This
procedure shall be repeated as many times as required till the inside of the pipe is fully
cleaned.

In line instruments like control valves, orifice plates, rotameters, safety valves and other
instruments like thermowells which may interfere with flushing shall not be included in
flushing circuit.

The screens/meshes shall be removed from all permanent strainers before flushing.
Screens/meshes shall be reinstalled after flushing but before testing.

During flushing temporary strainers shall be retained. These shall be removed, cleaned and
reinstalled after flushing, but, before testing.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved

Page 420 of 612

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS
lef5teg INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 6
ii7Pf 2722117 151.1,101,0 IA Govt of India Undenakingi
TESTING OF PIPING SYSTEMS Page 5 of 9

In case any equipment such as column, vessel, exchanger etc. form part of a piping circuit
during flushing, this shall be done with the approval of Engineer-In-Charge. However,
equipment thus included in the circuit shall be completely drained and dried with compressed
air after flushing is completed.

During flushing discharged water/air shall be drained to the place directed by the Engineer-In-
Charge. If necessary, proper temporary drainage shall be provided by the contractor.

Care shall be taken during flushing so as not to damage/spoil work of other agencies.
Precautions shall also be taken to prevent entry of water/foreign matter into equipment,
electric motors, instruments, electrical installations etc. in the vicinity of lines being flushed.

The contractor shall carry out all the activities required before, during and after the flushing
operation, arising because of flushing requirements, such as but not limited to the following:

Dropping of valves, specials, distance pieces, inline instruments and any other piping part
before flushing. The flanges to be disengaged for this purpose shall be envisaged by the
contractor and approved by the Engineer-In-Charge. These flanges shall be provided with
temporary gaskets at the time of flushing.

After flushing is completed and approved, the valve distance pieces, piping specials etc. shall
be reinstalled by the contractor with permanent gaskets. However, flanges at equipment
nozzles and other places where isolation is required during testing, only temporary gaskets
shall be provided.

Records in triplicate shall be prepared and submitted by the contractor for each piping system
for the flushing done in the proforma provided/approved by the Engineer-in-Charge.

5.0 PRESSURE TESTING

Pressure testing, in general shall be as per clause 345 of ASME B31.3, unless otherwise
specified, herein. Lines carrying highly hazardous/poisonous fluids must have a sensitive leak
test. For IBR lines, 'IBR Regulations' shall also be followed.

5.1 Extent of Testing

With the exclusion of instrumentation, piping systems fabricated or assembled in the field
shall be tested irrespective of whether or not they have been pressure tested prior to site
welding or fabrication.

To facilitate the testing of piping systems, vessels and other equipment may be included in the
system with the prior approval of Engineer-In-Charge if the test pressure specified is equal to
or less than that for the vessels and other equipment.

Pumps, compressors and other rotary equipment shall not be subjected to field test pressure.

Lines which are directly open to atmosphere such as vents, drains, safety valves discharge
need not be tested, but all joints shall be visually inspected. Wherever necessary, such lines
shall be tested by continuous flow of fluid to eliminate the possibility of blockage. However,
such lines if provided with block valve shall be pressure tested up to the last block valve.

Seats of all valves shall not be subjected to a pressure in excess of the maximum cold working
pressure of the valve. Test pressure applied to valves shall not be greater than the
manufacturer's recommendation nor less than that required by the applicable code. Where
allowable seat pressure is less than test pressure, test shall be made through an open valve.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 421 of 612

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS
51gem Ellaleg rff3 INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 6
IA Govt of !tido Undertalongl
TESTING OF PIPING SYSTEMS Page 6 of 9

Instruments in the system to be tested shall be excluded from the test by isolation or removals,
unless approved otherwise by the Engineer-In-Charge.

Restrictions which interfere with filling, venting, draining such as orifice plates etc. shall not
be installed unless testing is complete.

Control valves shall not be included in the test system. Where bypasses are provided test shall
be performed through the bypass and/or necessary spool shall be used in place of the control
valve.

Pressure gauges which are part of the finished system, but cannot withstand test pressure shall
not be installed until the system has been tested. Where piping systems to be tested are
directly connected at the battery limits to piping for which the responsibility rests with other
agencies, the piping to be tested shall be isolated from such piping by physical disconnection
such as valve or blinds.

5.2 General Requirements / Test Preparation for Testing

Testing shall be carried out with permanent gaskets installed unless specified otherwise or
instructed by the Engineer-in-Charge.

No pressure test shall be carried out against closed valve unless approved by the
Engineer-in-Charge

The Engineer-in-Charge shall be notified in advance by the Contractor, of the testing sequence
and programme, to enable him to be present for witnessing the test. The Contractor shall be
fully responsible for making arrangements with the local boiler inspector to witness the tests
for steam lines falling under IBR. IBR certificates for these tests shall be obtained in the
relevant IBR forms and furnished to the Engineer-in-Charge.

Before testing, all piping shall be cleaned by flushing to make it free from dirt, loose scale,
debris and other loose foreign materials.

All piping systems to be hydrostatically tested shall be vented at the high points and the
systems purged of air before the test pressure is applied.

Wherever in the line any void exists due to any reasons, like absence of control valves, safety
valves, check valves etc. it shall be filled with temporary spools.

All joints welded, screwed or flanged shall be left uninsulated and exposed for examination
during the test. Before pressurizing the lines, each weld joint shall be cleaned by wire brush to
free it from rust and any other foreign matter. All joints may be primed and painted prior to
leak testing unless they are subject to sensitive leak test or testing with soap solution (e.g.,
reinforcement pads and lines to be pneumatically tested, etc.).

Where a system is to be isolated at a pair of companion flanges, a blank shall be inserted

between the companion flanges. Minimum thickness of the blank shall be designed in
accordance with applicable design code.

Open ends of piping system where blanks cannot be used, such as pumps, compressors,
turbines or wherever equipment or pipe spools have been recovered or disconnected prior to
hydrostatic testing, shall be blinded off by using standard blind flanges of same rating as the
piping system being tested.

Pressure gauges used in testing shall be installed as close as possible to the lowest point in the
piping system to be tested, to avoid overstressing of any of the lower portions of the system.

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Page 422 of 612

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
4-A ENGINEERS
lgar fdlfires-
taiv-er elecnil MI „Maw.
INDIA LIMITED
in Govt of Inda Undettakong)
INSPECTION, FLUSHING AND
TESTING OF PIPING SYSTEMS
6-44-0013 Rev. 6
Page 7 of 9

For longer lines and vertical lines, two or more pressure gauges shall be installed at locations
decided by the Engineer-in-Charge.

For lines containing check valves any of the following alternatives shall be adopted for
pressure testing:

Whenever possible pressurize up-stream side of valve.

Replace the valve by a temporary spool and reinstall the valve after testing.

Provide blind on valve flanges and test the upstream and downstream of the line
separately and remove the blind after testing. At these flanges, temporary gaskets shall
be provided during testing and shall be replaced by permanent gaskets subsequently.

For check valves in lines 11/2" and below flapper or seat shall be removed during
testing (if possible). After completion of testing the flapper/seat shall be refitted.

Gas lines when hydrostatically tested shall be provided with additional temporary supports
during testing as directed by the Engineer-in-Charge.

Piping which is spring or counter-weight supported shall be temporarily supported, where the
weight of the fluid would overload the support. Retaining pins for spring supports shall be
removed only after testing is completed and test fluid is completely drained.

When testing any piping system, air or steam of approximately 2 kg/ cm2g may be used as
preliminary test to detect missing gaskets etc. as this avoids the necessity of draining the line
to make repairs. However, steam shall not be used for this purpose, if the steam temperature is
more than the design temperature of the line.

For jacketed pipes testing of core pipes shall be done on individual pieces where the pipe is
continuously jacketed, before it is jacketed. The outer jacket shall be tested separately as a
system. For piping with discontinuous jacketing the core pipe and the jacket shall be tested as
separate continuous systems.

5.3 Testing Media, Test Pressure and Test Pressure Gauges

5.3.1 Testing Media

In general all pressure tests shall be hydrostatic using iron free water, which is clean and free
of silt. Test fluid temperature shall be min. 5 °C. Maximum chloride content in water for
hydrostatic testing for SS piping shall be 15- 20 ppm.

Air shall be used for testing only if water would cause corrosion of the system or overloading
of supports etc. in special cases as directed by Engineer-in-Charge.

If operating fluid in the line is much lighter than testing fluid, the additional weight of testing
fluid may render piping supports (as designed) inadequate. This will call for additional
temporary supports. The typical examples are flare and vapor lines. It is preferable that
hydrostatic testing is avoided in such systems and instead pneumatic testing may be specified.

Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene, methanol etc.
shall be used as the testing medium, with due consideration to the hazards involved. These test
fluids shall be specified in the line list given to the contractor.

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Page 423 of 612

 STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.
ENGINEERS
$1?ez idtWieg INDIA LIMITED INSPECTION, FLUSHING AND 6-44-0013 Rev. 6
1.127f vivant,MI JOC15.11 Govt of India Undertaiong
TESTING OF PIPING SYSTEMS Page 8 of 9

5.3.2 Test Pressure

The hydrostatic/ pneumatic test pressure shall be as indicated in the line list or as per the
instruction of Engineer-in-Charge.

The selection of the piping system for one individual test shall be based on the following:

- Test pressure required as per line list.

- Maximum allowable pressure for the material of construction of piping.

Depending upon the above requirements and based on construction progress, maximum length
of piping shall be included in each test.

5.3.3 Test Pressure Gauge

All gauges used for field testing shall have suitable range so that the test pressure of various
systems falls in 35% to 65% of gauge scale range. Pressure gage dial shall be minimum of 150
mm. Size of Bourdon shall not be less than 75% of nominal diameter of dial range. Gauge
shall be of a good quality and in first class working condition.

Prior to the start of any test or periodically during the field test programme, all test gauges
shall be calibrated using a standard dead weight gauge tester or other suitable approved testing
apparatus. Any gauge showing an incorrect zero reading or error of more than ± 2% of full
scale range shall be discarded. The Engineer-in-Charge shall check the accuracy of master
pressure gauge used for calibration. Calibration certificate shall be furnished for the pressure
gages.

5.4 Testing Procedure

5.4.1 Hydrostatic Test

All vents and other connections used as vents shall be left open while filling the line with test
fluid for complete removal of air. In all lines for pressurizing and depressurizing the system,
temporary isolation valves shall be provided if valved vents, drains do not exist in the system.

Pressure shall be applied only after the system / line is ready and approved by the Engineer-in-
charge.

Pressure shall be applied by means of a suitable test pump or other pressure source which shall
be isolated from the system as soon as test pressure is reached and stabilized in the system.

A pressure gauge shall be provided at the pump discharge for guidance in bringing the system
to the required pressure.

The pump shall be attended constantly during the test by an authorized person. The pump shall
be isolated from the system whenever the pump is to be left unattended.

Test pressure shall be maintained for a sufficient length of time not less than 10minutes. Test
pressure shall be released only after physical checking of all the joints and attachments are
completed, to permit thorough inspection of all joints and connections for leakage or signs of
failure. Any joint found leaking during a pressure test shall be retested to the specified
pressure after repair.

The pump and the piping system to be tested are to be provided with separate pressure
indicating test gauges.

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Page 424 of 612