specification for design, realisation and supply of propellant … · 2018-04-11 · page 1 of 22...
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IPRC/ESPSF/RT/01
Specification for Design, Realisation and Supply of
N2O4 Propellant Road Tanker with prime mover
1.0 General:
1.1 A road tanker is required for transportation of N2O4 propellant between
production plant and ISRO work centers. Tank of 8m3 water capacity
made of AISI 304L is mounted over a semi trailer with telescopic front
and rear supports. The semi trailer shall be of double axle type with 18T
pay load capacity. The scope of the supplier includes procurement &
supply of prime mover, trailer and all materials for fabrication and
realization of the tanker (tanks material and components as given in
clause 12). The following details shall be considered during the design
and fabrication of the tanker.
1.2 The fabricator shall have the approval of Chief Controller of Explosives,
Nagpur for the fabrication of pressure vessels under Static and Mobile
Pressure Vessels (unfired) rules 1981 or latest amendment thereafter.
Copy of the current approval shall be submitted along with the Techno
Commercial bid.
1.3 The fabricator shall design the N2O4 propellant tank and water tank
based on the enclosed preliminary dimensional drawings
IPRC/ESPSF/RT/01, 02 & 03.
1.4 The fabricator shall consider the rules and regulations followed by the
state transport authorities.
1.5 The fabricator should get approval for the following
a) Fabrication drawings, mounting drawings and design calculations for
functional aspects and QAP from IPRC.
b) Fabrication drawings, mounting drawings, design calculations and QAP
from Third Party Inspection (TPI) agency.
c) Fabrication drawings and mounting drawings from Chief Controller of
Explosives, Nagpur for N2O4 road tanker.
1.6 Fabrication works shall be taken up only after final approvals.
1.7 The overall height of the tanker (Prime mover and trailer in hauled
condition) shall meet the State Transport Authorities (STA) requirement.
1.8 The supplier should get clearance from State transport authorities for
overall dimensions and road worthiness of the tanker.
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1.9 The supplier is responsible for temporary registration of the tanker
including prime mover in the name of Director, IPRC. Permanent
registration of the tanker including prime mover with State Transport
Authority is the responsibility of IPRC.
1.10 The supplier should arrange to get CCOE license from Nagpur for N2O4
road tanker in the name of Director, IPRC. Obtaining CCOE license for
N2O4 road tanker is the responsibility of the supplier. The supplier shall
obtain CCOE licence for the tanker within 4 months after permanent
registration of the vehicle by IPRC.
2.0 Prime mover Specification
Specification of Prime Mover (GVW: 35 T) with Sleeper cabin
2.1 Make & Model
Prime mover with Sleeper Cabin
(GVW: 35 T; 4x2 Drive)
Prime mover shall be of reputed make such as
ASHOK LEYLAND / TATA / BHARAT BENZ
2.2
Dimensions (mm)
Wheel Base 3000 to 3600
Overall Length 5400 to 6200
Overall Width 2400 to 2600
King Pin Size (inch) 2 inch
2.3 Capacity
Gross Vehicle weight 35000 kg to 40200 kg
2.4
Engine:
Type Diesel Engine meeting BS-IV norms
Power (hp) 170 hp to 235 hp @ rated rpm
Torque (Nm) 600 Nm to 850 Nm @ rated rpm
Exhaust
Exhaust pipe shall be rerouted to front with
spark arrestor OR
Exhaust pipe may be routed to rear; furnish
necessary exemption certificate from Petroleum
and Explosive Safety Organization (PESO), Govt.
of India 2.5 Gear Box: Synchromesh gearbox
2.6 Brake Pneumatic / Hydraulic
2.7 Tyre Suitable tyre size with 6 Nos. on wheel + 1 Spare
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2.8 Steering Power steering
2.9 Cabin All steel SLEEPER CABIN with berth
2.10 Fuel Tank 250 Litre (minimum)
2.11 Electrical system 12 V or 24 V Electrical system
2.12 Fifth Wheel Coupling Suitable for 2 inch King Pin
2.13 Terms & conditions
(i) Sale documents and relevant papers shall be
drawn in favour of `DIRECTOR, ISRO
PROPULSION COMPLEX, MAHENDRAGIRI,
TIRUNELVELI DIST., TAMIL NADU,
PINCODE: 627 133’.
(ii) The vehicle shall be delivered to IPRC,
Mahendragiri with Temporary registration certificate
(iii) The following vehicle documents shall be
furnished along with chassis
a. Sale invoice
b. Form 21, 22, 22A
c. Temporary Registration certificate
d. CMVR tools kit, First Aid kit and suitable fire
extinguishers
e. Operator’s manual, free service folders,
warrantee certificate etc.
3.0 Tank Specification
Type : Horizontal, Cylindrical with 2:1 ellipsoidal dished ends both sides
Design & : i) ASME Boiler and pressure vessel code Construction Sec. VIII Div.1, latest edition.
ii) During design, wind load for survival wind
speed of 200 km/hr considering 3 sec gust;
operating wind speed of 120 km/hr.
Working pressure : 4 kg/cm2(g)
Design pressure : 7 kg/cm2 (g) (Including 3g)
Allowance : Corrosion allowance – 3 mm.
Surface treatment allowance – 1 mm.
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Suitable allowance for thinning during
forming (rolling/spinning/ pressing) is to be
considered.
Thickness (min) : Shell – 10 mm & Dish end – 12 mm
including all allowances.
4.0 Material of construction
Sl. No. Description Material
1 Shell and Dished ends SA 240 GR 304L
2 Nozzle pipes SA 312 TP 304L (Seamless)
3 Nozzle flanges & blind flanges
SA 182 F 304L
4 Man hole flange & blind flange
SA 182 F 304L
5 Baffle plates, reinforcement & pad/wear plates
SA 240 GR 304L
6 Stud bolts/ nuts/ washers SA 193 GR B8/SA 194 GR 8/ SS
7 Gaskets PTFE & SS 304L spiral wound with SS 304L inner and outer rings
8 Man hole cover flange removal assembly/ Davit arm
SS 304L
9 Lifting lugs, Name plate & bracket
SS 304L
10 Man hole cover (Hood), Handles
SS 304L
11 Ladder & platform supports SS 304L 12 Saddle supports IS 2062
13 Platform Aluminium (chequered)
14 Materials having direct contact with tanks & fluids
SS 304L
5.0 General requirements
5.1 During design, the design stress selected shall include an allowance to
enable the vessel to withstand shocks normally encountered by
movements on road such as sudden acceleration and deceleration for a
minimum of 3g provision as per Static and Mobile Pressure Vessels
(unfired) rules 1981 or latest amendment thereafter shall be made for
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distributing localized stress arising from attachments. Two numbers of
baffle plates with stiffeners shall be provided to minimize the sloshing of
fluid during movements. The baffle plates should have openings of 400
mm radius at bottom to connect liquid phase and 200 mm radius at top
to connect vapour phase of the compartments.
5.2 Mounting of the vessel on the trailer chassis shall be done in such a
manner so as to keep the vibration to a minimum by using pads made of
balata material, and take care of the forward and backward movements
of the vessel due to sudden acceleration and deceleration.
5.3 The king pin mounted on the trailer is under the scope of fabricator. The
size of the king pin shall be 51mmx73mm long (std.). The raw material
for the king pin shall be ultrasonically tested for any internal defects. The
manufacturer’s chemical and mechanical test certificates shall be
provided for materials used for king pin. Only defect free material shall
be used for machining the pin.
5.4 The vessel shall be mounted on the trailer so as to get an inclination of
1O along the length of the vessel towards the drain nozzle at the back.
5.5 The vessel shall be electrically continuous with the chassis.
5.6 Earthing shall be done by providing a chain to touch the road while
running.
5.7 The rear of the vessel shall be protected by a robust steel bumper and
this bumper shall be
a) Attached to the back of the chassis so that the collision stress shall be
transmitted to the frame work of the vehicle.
b) Situated at least 7.5cm away from the rear of the rear most part of the
vessel.
5.8 There shall be clear distance of at least 15cm between the back of the
prime mover cabin and front of the vessel.
5.9 Suitable ladder made of Stainless steel pipe shall be fitted on the left side
of the tanker for operation purpose.
5.10 The trailer should have guard on both sides.
5.11 Platform (1m width x 1.5 m length) made of stainless steel with
Aluminium chequered plates of 5 mm thick on both sides of the manhole
shall be provided with sufficient clearance for tightening and loosening of
manhole flange.
5.12 A height barrier made of 1” Stainless steel pipe shall be fabricated and
fitted at the front side of the trailer chassis with proper support. Height
of the height barrier shall be 25mm above the overall height of the tanker
in hauled condition.
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6.0 Fabrication details
6.1 All the plates to be used for the shell and dish should have the original
heat number of the mill. They shall be inspected by third party
inspection agency and inspector’s stamp shall be marked on the plates.
6.2 Pipes and fittings should be procured directly from the manufacturer.
6.3 Material test certificates for all the parts should be provided.
6.4 IGC (practice-E) test should be carried out for each heat lot of shell &
dish plates in Govt. approved lab.
6.5 All SS plates and nozzle pipes should be 100% ultra sonic tested.
6.6 Dished ends should be stress relieved by solution annealing after forming
(Heat treatment process) as per ASME SEC VIII DIV.1
6.7 All nozzles shall be covered with stainless steel blind flanges, stud bolts
& nuts and gaskets.
6.8 Manhole flange should be SORF and other flanges should be WNRF type.
6.9 All flanges should be as per ANSI B 16.5, RF150 lbs rating.
6.10 WNRF flange ID should match with 160 sch. pipe ID.
6.11 Four numbers of lifting lugs equispaced are to be provided.
6.12 Nozzle below 50mm shall be stiffened with 2 Nos. of gussets at right
angles.
6.13 Name plate with bracket shall be provided.
6.14 Equipment shall be provided with two Nos. of earthing boss.
6.15 A sump of one liter capacity with anti vortex arrangement and 25 NB
drain pipe leading from the bottom of the sump to the drain nozzle flange
shall be provided. The drain line shall be properly clamped with the tank
by providing proper supports and no support is permitted from the
chassis. The drain line and its associated valves shall be fitted well
within the chassis.
6.16 A dip pipe of 50 NB size 160 schedule shall be welded with 50 NB weld
neck flange at the top and slip-on flange to fix it over the man hole cover
flange as shown in drawing shall be provided. There shall be a gap of 100
mm between the bottom of the dip pipe and bottom of tank inside
surface.
6.17 The pressurization nozzle should be extended 100 mm inside the man
hole nozzle with proper supports and terminated with horizontal Φ 5mm
perforated pipe having both ends closed.
6.18 A concave pocket arrangement for fixing temperature gauge as shown in
drawing shall be made for housing the gauge without protruding out of
the tank.
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6.19 A flange of 25 NB size 150 lbs rating as per ANSI B 16.5 welded with ½”
NPT female adapter shall be fabricated to mount the pressure gauge.
6.20 Mounting bolts materials for mounting the tank with the trailer should
be of high tension type (EN8 etc).
6.21 Tell tale holes shall be provided for checking the leakage pneumatically
on weld joints of reinforcement/pad plates.
6.22 All nozzle pipes are of seamless, shall be as per design code and a
minimum schedule of 160 to be provided.
6.23 All the flanges shall have serrated finish and shall conform to ASME B
16.5.
6.24 Inside edges of Manholes shall be smooth and rounded off with a
minimum radius of 3 mm.
6.25 Manhole and all nozzle flanges shall be provided with blind flanges of
same material, size and pressure rating with necessary studs & nuts,
washers and gaskets.
6.26 A davit arm shall be provided near manhole used for removal & assembly
of manhole flange. Provision must be made to remove the arm when it is
not in use.
6.27 All studs shall have ISO threading. Studs shall be threaded to full length
and should have standard SS washers.
6.28 All studs shall be provided with double nuts.
6.29 The fabricator shall supply two sets of gaskets other than those used for
testing and/or during transportation. Service gaskets shall be used
during hydrostatic test.
6.30 Saddle supports shall be designed as per IS: 2825. The included angle of
the saddle support shall be 160 deg. Minimum.
6.31 The saddle supports for the tank shall be designed for the density of
Liquid Di Nitrogen Tetroxide (N2O4) i.e., 1.454 gm/cc.
7 Trailer
7.1 The trailer is a double axle skeletal type flat bed semi trailer with
telescope front and rear supports having two speed landing legs. It shall
have a pay load capacity of 18 T over & above the trailer. Trailer axle
shall have wheel hub suitable for the above prime mover. Trailer shall be
of reputed make such as PL HAULWEL / TATA DLT / SATRAC. The
trailer shall have facilities like fail safe brake system, handbrake, brake
light, parking light post of 1.5m height at both end rear corner with park
light, bonding cable, earthing chain, reflectors of white and red colour,
tool box of size 1000mm X 500mm X 300mm made up of 5mm thick SS
Page 8 of 22
sheet mounted suitably, spare tyre bracket, mud guard, proper electrical
connections for the lighting systems, registration number plates, Fire
extinguisher (10 kg DCP- 2 Nos.) etc. shall be provided. The trailer shall
be painted with two coats of post office red colour synthetic enamel paint
after two coats of red oxide.
7.2 Four numbers of two speed landing gears of suitable capacity (make:
Fuwa/josts/Yoke/BPW) for use in loaded and unloaded condition shall
be provided as described below
- “Two landing legs at front end” of the trailer for mating and de-mating
operations from the prime mover.
- “Two landing legs at rear end” of the trailer platform to relieve the load
on tyres while parked for long duration.
The landing legs consist of two coaxial tubes moving inside the other.
The outer tube is bolted to the trailer through a mounting plate while the
inner tube is free to slide inside the outer tube. The actuation of the
inner tube is through a set of gears (Spur and Bevel gears). Bevel gears
are connected to a shaft with a handle at one end to a threaded rod at
other end. The threaded rod is fitted to a nut. Rotation of the shaft with a
handle causes the inner tube to move relatively. One shaft is directly
connected to the bevel gears and is to be used under no load condition
i.e when the loading leg is relieved of load. This is to be used after the
prime mover and trailers are coupled for lifting the inner tube after it is
lifted off the ground or when the trailer is to be uncoupled from the
prime mover for lowering inner tube before contact with the ground. The
outer shaft is to be used when the landing leg of the trailer is resting on
the ground.
7.3 All the relevant documents for trailer shall be submitted as per the terms
mentioned in clause 2.13.
8 Water tank
A water tank made of SS 304L as per drawing shall be fabricated and it
shall be suitable for mounting on the chassis of each prime mover, back
of the cabin using ‘U’ bolts. Cleaning of the tank shall be done as given in
Para 14 except polishing. Dish end shall be solution annealed.
9. Tank plates
9.1 The number of circular seam weld joints on the cylindrical portion of the
tank shall be minimum.
9.2 Single plate shall be used for longitudinal seam weld joints.
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9.3 Each dome shall be made out of maximum number of two plates only
and shall not be fabricated in petals.
9.4 If the design calls for lower thickness than the minimum thickness
specified in the drawing, the thickness specified in the drawing shall be
provided. But if higher thickness is called for by design than the
minimum thickness specified in the drawing, the higher thickness shall
be provided.
9.5 Welding layout: The welding layout of the tank shell shall be in such way
that either circular seam or Longitudinal seam not to foul with the fillet
weld of R.F pads of saddle supports and Man hole nozzle. A minimum
gap of 100 mm shall be maintained between any two weldments/seams.
9.6 All plates used for the fabrication of tanks shall have traceability with
MIL certificate for Chemical, Mechanical and IGC. All plates used shall
be ultrasonic tested at production MIL itself.
a) All plates shall be procured from a single MIL.
b) The plates should have been rolled within one year of procurement.
c) Plates of age more than one year are not acceptable.
9.7 All butt welds shall be 100% radio graphed (X-ray 2T sensitivity)
10. Welding
10.1 100% by GTAW process shall be followed with high purity (99.99%)
Argon gas purging and shielding, right from root to final passes for all
butt welds (Long seams, ‘C’ seams, nozzles, pipe to flange joints) and all
internal and external welds including fillet welds. Fabricator may also
use Plasma welding.
10.2 Plasma welding in combination with TIG welding is acceptable to reduce
the heat affected zone, weld defects and to improve quality of weld.
SMAW is not acceptable.
10.3 Welding shall be performed only by welders qualified under section IX of
ASME Boiler and Pressure Vessel Code, using procedures mentioned
under Section IX. Welding procedures must be approved and welder
must be qualified by TPI agency.
10.4 Welding consumables (filler wire) shall be used as per AWS classification
/ ER 308L. Filler should be IGC tested.
10.5 All butt welds shall be full penetration welds.
10.6 All butt welds shall be 100% radio graphed (X-ray 2T sensitivity).
10.7 All welds shall be DP tested for root and final welds.
10.8 Hydrostatic test and Pneumatic leak test shall be carried out at 3 bar(g)
before man hole nozzle outside welding with shell plate and welding of
reinforcement plate for checking the inside welding of shell and nozzle.
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10.9 The dye used for Dye-penetrant test shall not have chlorides more than
50 ppm.
10.10 Any re-work / repair have to be carried out as specified in ASME boiler
and Pressure vessel code with the approval of third party/purchaser.
11. Heat treatment
11.1 Solution annealing:
Dished end domes shall be cold formed. After cold forming, solution
annealing shall be done to relieve stresses caused due to cold working as
per code.
Solution annealing shall be as per the following cycle.
a) Loading Temperature : 400 ºC (max.)
b) Rate of heating : 250 ºC/hr (max.)
c) Soaking temperature : 1040 ºC – 1060 ºC
d) Soaking time : 30 minutes (min.)
e) Quenching in water to bring down to temperature 350 ºC within 3
minutes (max.)
The final hardness shall be checked and ensured to be below 201 BHN
11.2 Stress relieving :
The total fabricated tank (full equipment) including saddle to wear plate
welding has to be stress relived at 420 ± 10 ºC as per standard practice
(this operation shall be carried out prior to hydro static test). The
detailed stress relieving cycle is as given below.
Loading Temperature : 300 ºC
Rate of heating : 100 ºC/hr ± 20 ºC
Soaking temperature : 420 ºC ± 10 ºC
Soaking time (min.) : 2 Hrs.
Rate of cooling (min) : 100 ºC/hr
Unloading temperature : 300 ºC (Vessel to be air cooled inside the
furnace by opening furnace doors). Vessel to
be air cooled at atmospheric conditions after
unloading.
11.3 Solution annealing of domes and stress relieving of total tank shall be
carried out in an Electric furnace. Suitable digital photos to be taken in
presence of TPI agency prior & after stress relieving and signed images
shall be sent along with Master Production File.
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11.4 The furnace shall be calibrated prior to taking up stress relieving of the
tanks. The details of the furnace proposed for stress relieving like clear
dimensions, type, number of nozzles, type of fuel used, location and
number of thermocouples proposed for temperature measurement shall
be submitted and approval of TPI agency shall be obtained prior to
performing the stress relieving of entire tanks.
12. Components
12.1 Ball valves: The nozzles for pressurization (25NB), pressure gauge
(25NB), fill line (50NB), and drain line (25NB) shall be provided with one
ball valve each. The specification of the ball valves is given below:
Type : Regular port
Design code : BS EN ISO17292
Construction : Single piece, Antistatic & Fire safe (API 607)
Body material : ASTM A351 Gr. CF8
Ball & stem material : AISI 304
Bolts & Nuts : A 193 Gr.B8 & A 194 Gr.8
Lever material : SS
Body seat : PTFE
Body primary seal : PTFE
Body secondary seal : GFT/Grafoil
Stem primary seal : PTFE
Stem secondary seal : GFT/Grafoil
End connection : Flanged RF with serrated finish as per ANSI B
16.5, 150 lbs Rating
Testing : As per BS EN ISO B 12266
Operation : Lever operated
Heat treatment : Solution annealing of castings as per
ASTM A 351 S 11.1
Radiography : For body castings
Probable suppliers : L&T/ BDK/Micro finish valves/Niton valves
Quantity : 25 NB – 7 Nos. & 50 NB – 1 No.
12.2 Excess flow valves: One number of excess flow valve shall be provided
for each drain line, fill line, pressure gauge line and pressurization line.
The Specification of excess flow valves is given below:
Body material : ASTM A 182 F 304
Bonnet, spindle, seat, spring material : SS 304
End connection : flanged RF as per ANSI B 16.5,
150 lbs rating
Page 12 of 22
Max. flow rate allowed : 6 lit/sec
Probable supplier : Anil Engineering, Mumbai.
Quantity : 1) 25 NB – 3 Nos.
2) 50 NB – 1 No.
The valves shall be designed for arresting the excess flow which may
happen in case of sudden failure of the downstream connections due to
collision or any other reasons.
12.3 Safety Relief valve: One number of safety relief valve each for two 50 NB
nozzles shall be provided. The orientation of safety relief valve nozzle
should be fixed in such a way that the out let of the safety relief valve
should face towards the platform. The specification of safety relief valves
is given below.
Type : Spring loaded with balanced
bellow and closed bonnet
Nozzle type : Full nozzle
Cap : Screwed, closed
Body, bonnet material : ASTM A 351 F 304
Nozzle, disc, Guide & rings, trim
Spring, bellow, cap material : SS 304
Size : 50NB x 80NB flanged RF as per
ANSI B 16.5 150 lbs rating
Set pressure : 4.5 kg/cm2 (g)
Orifice designation : J
Construction code : ASME SEC VIII div. 1
Sizing basis : API RP 520
Valve testing : API 527
Radiography (100%) : Body & bonnet castings
Solution annealing of castings : ASTM A 351 S11.1
Probable supplier : Tyco Sanmar Pvt. Ltd, Chennai
Quantity : 2 Nos.
12.4 Magnetic level Indicator: One number of Magnetic level indicator
should be fixed on 50 NB nozzle provided on the man hole cover flange.
The specification of magnetic level indicator is given below.
Type : Immersible bullet type magnetic level
indicator
Level range : 0-1300 mm
Mounting : 50 NB RF 150 lbs rating
Page 13 of 22
ASTM A 182 F 304 L flange
Guide pipe : 25 NB SCH 40
ASTM A 312 TP
304 L seamless pipe.
Float : SS 304 L
Design pressure : 7 kg/cm2 (g)
Working temperature : 15o C to 40o C
Specific gravity : 1.454 for N2O4
Probable supplier : M/s RK Dutt Concerns, Thane
Quantity : 1 No.
12.5 Temperature gauge: Temperature gauge shall be provided as per the
specification given below.
Dial size : 50 mm
Sensing Element : Bimetallic strip
Stem dia. and Material : 8 to 10 mm, SS 304 or SS 316
Case, Bezel and movement : SS 304 / SS 316
Temperature range : 0 – 600 C
Accuracy : 1.5 % of FSD or better
Thermometer stem length : 400 mm
Thermowell MOC : SS 304 L
Thermo well immersion length : 350 mm
Connection size : ¾” screwed
Weather Protection : IP 65 or better
Mounting : Back / Horizontal
Supplier : M/s Vantage Technologies, Bangalore/
M/s Bangalore fluid System
components pvt. Ltd., Bangalore.
Quantity : 1 No.
12.6 Pressure gauge: Pressure gauges shall be provided as per the
specification given below :
Type : Bourdon type
Range : 0 – 7 kg/cm2 (g)
Accuracy : 1.5 % of FSD or better
Material : SS 304L
Dial size : 100 mm
End connection : ½” NPT (M)
Weather Protection : IP 65 or better
Page 14 of 22
Calibration medium : Air / N2 gas
Make : M/s Odin India pvt Ltd, Chennai/
M/s Kains Instruments India Pvt Ltd,
Bangalore.
Quantity : 2 Nos. (Tanker manhole flange
designation (W) and Water tank
Nozzle, N2)
13. Testing
13.1 Testing of Materials
All materials used shall be tested as per code in the reputed Govt.
approved testing labs before fabrication. All the plates proposed to be
used for fabrication of tank shall be subjected to mechanical, chemical
and IGC tests as per A-262 Practice-E in spite of availability of Mill test
certificates.
The plates used for construction of tank shall also be ensured free from
any lamination and manufacturing defects by 100% Ultrasonic testing as
per Practice A-578 Acceptance criteria Level-B in combination with ASTM
A 577. All nozzle pipes should be 100% ultrasonic tested. The scanning
shall be carried out in four directions during UT test. The test shall be
carried out under TPI at fabrication shop.
Ferrite number in weldment shall be measured by testing and this shall
be within the specified limit of 3% to 12% as per standard code. Test
certificates shall be furnished to purchaser for approval before
fabrication.
13.2 Hydrostatic Test:
13.2.1 Before Hydrostatic test, the inside and outside surfaces of the tanks
shall be mechanically cleaned and buffed.
13.2.2 Hydrostatic test shall be conducted as per code after fabrication and
radiography clearance. The test pressure shall be as per design code
and it shall be done in presence of TPI agency & purchaser.
13.2.3 Clean fresh potable water having chloride content less than 25 ppm
should only be used for Hydrostatic testing.
13.2.4 After Hydrostatic test, the vessel has to be degreased, pickled and
passivated.
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13.3 Pneumatic Leak Test:
After hydro test and pickling & passivation the tank shall be pneumatic
tested at 3 bar (g) by using dry nitrogen gas with dew point of minus 40
ºC or better.
14 Cleaning
14.1 Mechanical Cleaning
All metallic surfaces inside and outside having scales and foreign
materials and all welded surfaces have to be cleaned. This can be done
by scrubbing with metallic brush (Stainless Steel) followed by buffing.
Buffing should be done on the entire inner and outer surface of the total
tank to get a polished surface. The loose scales and powders obtained
from the above process can be cleaned by blowing, sucking or washing
with water. Mechanical cleaning and buffing shall be carried out after
stress relieving, but before hydrostatic test.
14.2 Degreasing
Degreasing has to be done on the inner surface by soaking with hot
detergent solution of Lissapol at 60 ºC to 70 ºC for at least 2 hours till
satisfaction.
14.3 Pickling
Pickling is to be carried out for inner and outer surface with solution
containing Nitric Acid 15% by volume and hydro fluoric acid (HF) 2% by
volume, balance DM water.
Temperature : Ambient
Duration : 1 to 2 hours
Thorough DM water rinsing has to be carried out until all traces of acid
are removed from the surface.
14.4 Passivation
Passivation is to be carried out for inner and outer surface with solution
of Nitric Acid 20-25% by volume, balance DM water.
Temperature : Ambient
Duration : 2 hours
Thorough rinsing with DM water is to be carried out till PH of the final
rinse water is between 6.5 to 7.5 to minimize staining. Surfaces must not
Page 16 of 22
be permitted to dry between successive steps of the acid cleaning or
passivation and rinsing procedures.
The concentration of iron should not exceed 5% by weight in case of
pickling solution and 2% by weight in case of passivation.
15 Swabbing Method
The pickling and passivation of the tank inner & outer surface shall be
carried out by swabbing method using barium sulphate as carrier
(chloride levels 25 ppm) in the form of paste. For each of pickling and
passivation operations, the paste has to be applied on the surface and
has to be kept for atleast two hours. Paste has to be removed with waste
cotton in each operation and finally the surface has to be rinsed with DM
water.
16 Checking
All the relevant tests shall be carried out to ensure proper pickling and
passivation as per ASTM A 380.
17 Drying
The drying is done to remove water and this is done as given below:
Passing dry Nitrogen / Air having dew point less than -40 ºC and free
from oil and grease (< 10 PPM) 60 ºC till the moisture level at the exit
comes to the inlet concentration value.
18 Sealing
After drying, the tank should be sealed so that ambient moisture never
enters inside. The tank is to be pressurized to 0.5 bar (g) with dry
Nitrogen gas at -40 ºC dew point or better.
19 Documentation
19.1 Three copies of master production files shall be supplied by the
fabricator. Each master production file should contain the following.
19.1.1 Introduction.
19.1.2 Approved design calculation & drawings by TPI /CCOE
19.1.3 As built drawing approved by TPI
19.1.4 All test certificates
19.1.5 TPI inspection certificates
19.1.6 All the brought out components catalogue with datasheets
19.1.7 Statutory approvals
Page 17 of 22
19.1.8 Final release note
19.1.9 Facsimile of stamping
19.1.10 Guarantee certificate
20 General Conditions
20.1 Information to be given along with quotation:
20.1.1 Complete technical compliance for the specifications and
detailed technical description with make and model of the
proposed prime mover and trailer with technical data sheet
shall be provided.
20.1.2 Delivery terms.
20.1.3 Validity of the offer.
20.1.4 Warranty.
20.1.5 Delivery period:
• The delivery of tanker shall be within one year from the date
of purchase order which includes fabrication drawing
approval from IPRC for functional details, fabrication
drawing approval from TPI agency and CCOE, Mounting
drawing approval from CCOE, temporary registration of
tanker including prime mover and obtaining clearance from
State Transport Authority for overall dimensions and road
worthiness.
• The supplier shall obtain CCOE licence for the tanker within
4 months after permanent registration of the vehicle by
IPRC.
20.1.6 Payment terms & condition:
Final 10 % of the order value shall be payable only after
submission of the CCOE licence to IPRC for the transportation
of N2O4 propellant in the tanker.
20.1.7 Copy of the current approval of Chief Controller of Explosives,
Nagpur for the fabrication of pressure vessels under SMPV
(Unfired) rules, 1991 or latest amendment thereafter shall be
submitted.
20.1.8 Copy of valid NSIC/MSME registration certificate, if applicable,
shall be submitted.
20.1.9 Previous Experience: The supplier shall furnish the client list
to whom similar type of pressure vessel/tank or tanker
fabricated in Stainless Steel and supplied under reputed TPI
agency viz. M/s Lloyds, BVIS with PESO approval etc. during
last seven years along with copy of purchase orders including
Page 18 of 22
technical specifications and TPI agency release note. This will be
considered as key criteria for evaluation of technical bid and
capability. If these details are not given, the offer may not be
considered.
20.2 The fabricator shall arrange CCOE approved third party inspection
agency like M/s BVIS, Lloyds. The quotation should include third
party inspection charge, charges towards CCOE for approvals /
licences and charges for obtaining temporary registration and road
worthiness certificates from State Transport Authority.
20.3 One set of soft copy of as-built drawings shall be supplied to the
purchaser.
20.4 All radiography films soft copy pertaining to the tanks shall be supplied
to the purchaser.
21 Pre-delivery Inspection:
Inspection shall be carried out by the Purchaser, before dispatch of
tanker at manufacturer’s site.
22 Preparation for Shipment:
Procedures proposed for the preparation of tankers for shipment shall be
intimated to the purchaser and shall generally be in accordance with the
following:
22.1 All shipments shall be protected from damage in transit to site.
22.2 The tankers should be supplied to IPRC, Mahendragiri, Tirunelveli Dist.,
Tamil Nadu State.
23 Form of quotation:
The quotation shall be in two parts tender and shall be submitted in
separate templates:
a. Techno-commercial bid:
Bidders shall comply all the technical and commercial aspects given in
the specification. Techno Commercial bid shall contain all technical
details as well as information and confirmation on all aspects mentioned
in the specification. It shall also contain confirmation on all Commercial
Terms & Conditions, wherever applicable, if any and any additional
Page 19 of 22
information the bidder would like to provide. Under any circumstances,
the Techno Commercial bid’ shall not mention prices of any items.
b. Price quotation:
The bidder shall quote the price with the individual break-up costs as
given in price bid template. The Techno Commercial bid containing the
technical and commercial aspects shall be opened first. The price
quotation shall be opened only after the evaluation of the Techno
Commercial bid.
Sl. No.
Description Amount in Rs.
1.
Basic product cost (N2O4 Propellant road tanker including tank, water tank, components, trailer, prime mover)
2. P&F charges
3. Freight charges
4. Taxes
Page 20 of 22
Annexure-I
Scope of Inspection (as per QAP):
The tankers should be fabricated under the inspection of Third party/
Purchaser representative as per QAP.
QUALITY ASSURANCE PLAN
Sl.
No.
Characteristics / type of
check
Ref.
Document
Method of
check
Quantum of check
Manufa
-cturer
QC
Third
party
Purch
-aser
1.a
Identification of plate
material with Mill test
certificates including
Ultrasonic test reports
As per PO Review 100% H 100% R R
1.b
Sample selection for each
heat lot/heat number &
Witness of Chemical,
Mechanical, IGC Test for
plates
As per PO Visual 100% W 100% W W/R
1.c
Witness of Ultrasonic
Testing of plates and pipes
(*refer in specifications)
As per PO Visual 100% W 100% W W/R
1.d
Sample selection for each
heat lot/heat number &
witness of Chemical,
Mechanical & IGC Test for
pipes, fittings
As per PO Visual 100% H 100% W R
2
Review of fabrication
drawings and design
calculation
As per PO/
drawing
Material as
per design 100% H 100% R R
3 Review of welding
procedure and qualification AWS Review 100% H 100% R R
Page 21 of 22
4
Checking of root run & final
weld by Die penetrant test
(Butt welds)
As per PO Visual 100% W 100% R R
4.1 Measuring of Ferrite
number in all weldments As per PO
Checking
with meter 100% W 100% W R
5 Marking of nozzle
orientation
As per
drawing
Location of
nozzle 100% W 100% W R
6 Dye Penetrant test on all
fillet welds As per PO Visual 100% W
100%
R/W R
7 Visual and dimensional
inspection
As per
approved
drawing
Dimension 100% W 100% W R
8 Shell rolling, long seam &
Cir. Seam fit up As per std Visual 100% W 100% W R
9 Back grinding of long and
Cir. Seam welds As per std Visual 100% W 100% R R
10 Circularity of shells after
rolling As per std Visual 100% W 100% W R
11 Forming of dished ends and
solution annealing As per std Visual 100% W 100% W R
12 Fit up of nozzles, saddle
and supports and welding As per std Visual 100% W 100% W R
13 Evaluation of radiography
films of all butt welds As per PO
Film
evaluation 100% W 100% W R
14 Mechanical cleaning and
buffing As per PO Graph 100% W 100% R R
15 Stress relieving of total
fabricated tank As per PO Visual 100% W 100% W R
16 Hydrostatic test of total
vessel as per design code As per PO Pressure
hold 100% W 100% W W
Page 22 of 22
method
17
Pickling and passivation of
tank internal & external
surfaces
As per PO
Pressure
hold
method
100% W 100% W R
18
Pneumatic leak test at 4.0
bar(g) with nitrogen gas
having dew point of -400C
or better
As per PO Visual 100% W 100% W W/R
19
Pressurizing the tank to 0.5
bar(g) with Nitrogen gas
having dew point of -400C
or better
As per PO Gauge
reading 100% W 100% R R
21 Stamping of name plate
and issue of certificates As per PO Visual 100% R 100% W R
22 Verification of Material test
certificates As per PO Review 100% R 100% R R
23 Production master file As per PO Document 100% R 100% R R
Legend: R- Review, W- Witness, H- Hold
Note: 1. The purchaser has rights to participate in the Inspection at any
stage of fabrication & the bidder shall intimate the work progress
periodically.
2. 100% Evaluation of radiography films shall be carried out by
Third Party Inspection Agency.