tech specs

February 2015

Indian Oil Corporation Limited, Refineries Division, New Delhi

Knowledge Consolidation An Initiative by Projects

“Delivering Excellence”

Technical Specifications (Volume 1 of 2)

Author : Project Engineering Cell

Index

Discipline Page No.

Volume ‐ 1

1. Mechanical : 003

2. Instrumentation : 413

Volume ‐ 2

3. Electrical : 002

MECHANICAL

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Index

SL. NO. ITEM DESCRIPTION DOCUMENT NO. PAGE NO.

1 AIR COOLED HEAT EXCHANGERS RHQ-EC-ML-SP-0001 006

2 CENTRIFUGAL PUMPS RHQ-EC-ML-SP-0002 035

3 HEAT EXCHANGERS RHQ-EC-ML-SP-0003 058

4 SAFETY RELIEF VALVES RHQ-EC-ML-SP-0004 087

5 TRAYS AND TOWER INTERNALS RHQ-EC-ML-SP-0005 096

6 PRESSURE VESSELS RHQ-EC-ML-SP-0006 125

7 AGITATORS RHQ-EC-ML-SP-0007 155

8 RECIPROCATING PUMP CONTROL VOLUME RHQ-EC-ML-SP-0008 169

9 STEAM TRAPS RHQ-EC-ML-SP-0009 180

10 DEMISTER RHQ-EC-ML-SP-0010 188

11 STRAINERS RHQ-EC-ML-SP-0011 194

12 CLAD PLATES RHQ-EC-ML-SP-0012 205

13 SPRING SUPPORTS RHQ-EC-ML-SP-0013 213

14 FILTER SEPARATOR AND COALESCER RHQ-EC-ML-SP-0014 223

15 CARTRIDGE FILTER RHQ-EC-ML-SP-0015 232

16 AXIAL AND COMPRESSOR CENTRIFUGAL RHQ-EC-ML-SP-0016 242

17 COLUMNS RHQ-EC-ML-SP-0017 269

18 BURNERS RHQ-EC-ML-SP-0018 289

19 RECIPROCATING COMPRESSORS RHQ-EC-ML-SP-0019 303

20 ANCHOR BOLT/ TEMPLATE RHQ-EC-ML-SP-0020 339

21 STATIC MIXER RHQ-EC-ML-SP-0021 349

22 SUPPORT RING AND BOLTING BAR FOR TRAYS AND TOWER INTERNALS RHQ-EC-ML-SP-0022 356

23 GUARD FOR MACHINERY RHQ-EC-ML-SP-0023 363

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24 ALLOWABLE NOZZLE LOADS RHQ-EC-ML-SP-0024 372

25 EJECTORS RHQ-EC-ML-SP-0025 380

26 PRESSURE VESSELS FOR PACKAGED EQUIPMENT RHQ-EC-ML-SP-0026 393

27 BASKET FILTERS RHQ-EC-ML-SP-0027 402

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ENGINEERING CELL PROJECT DEPARTMENT- RHQ

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PAGE 1 OF 29 TECHNICAL SPECIFICATIONS

FOR AIR COOLED HEAT EXCHANGER

AIR COOLED HEAT EXCHANGERS

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Abbreviations: ACHE Air Cooled Heat Exchanger BIS Bureau of Indian Standards BS British Standards BHN Brinell Hardness Number DP Dye Penetration STAAD Structural analysis and design computer program MDMT Minimum Design Metal Temperature TPlA Third Party Inspection Agency ASME American Society of Mechanical Engineers AWS American Welding Society CS Carbon Steel GAD General Arrangement Drawings ID Internal Diameter LSTK Lumpsum Turnkey MOC Material of Construction MR Material Requisition OD Outside Diameter PQT Procedure qualification test PQR Procedure qualification record PL Process Licensor PMC Project Management Consultant SS Stainless Steel TIG Tungsten Inert Gas WPS Welding Procedure specification

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CONTENTS

SL. NO. DESCRIPTION PAGE NO.

1.0 GENERAL 4 2.0 SPECIFIC REQUIREMENTS 5 3.0 PROPOSAL 5 4.0 DOCUMENTATION 5 5.0 DESIGN 6 6.0 MATERIAL 17 7.0 FABRICATION 22 8.0 QUALITY CONTROL 24 9.0 PREPARATION FOR SHIPMENT 26

10.0 SUPPLEMENTAL REQUIREMENTS 27 11.0 SPARES 29

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1.0 GENERAL

This specification covers the general requirements for the thermal and mechanical design, materials. Fabrication, workmanship, inspection, testing and supply of air cooled heat exchangers (ACHE) and is intended to supplement the minimum requirements of the applicable codes. In case thermal design is furnished by Purchaser, Clause-6.0 under Section-6 of this specification on thermal design is not to be considered. In case thermal and mechanical design are done and engineering drawings furnished by Purchaser, then details given in these engineering drawings take precedence over this specification. This specification shall not be considered limiting and it shall be Vendor's responsibility to comply with all requirements of Material/ Purchase Requisition/Bid Documents to which this specification is attached. Any conflicting requirements shall be referred to IOCL for clarification before proceeding with the design and/or fabrication of the affected part. In addition to the contents of this Engineering Standard, exchangers shall comply with the following as applicable. The applicable revision, issue, and addenda of all Codes and Standards will be stated on the Material Requisition. American Society of Mechanical Engineers Codes ASME, Section II Part D Materials Properties ASME, Section VIII DIV.1 Boiler and Pressure Vessel Code - Unfired Pressure Vessels ASME, Section VIII DIV.2 Boiler and Pressure Vessel Code - Alternative Rules ASME, Section IX Boiler and Pressure Vessel Code - Welding Qualifications ASME, B16.47 Large Diameter Steel Flanges ASME B16.5 Pipe Flanges and Flanged Fittings TEMA 8th Edition TEMA 8th Edition Table 12B – 4.5.2 (Only) American Petroleum Institute API 661/ISO 13706 Air cooled Exchangers for General Refinery Service.

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E.E.M.U.A. Publications Publication 132 Electric Motors. Publication 140 Noise Procedure Specification. Publication 141 Guide to Use of Specification 140. Publication 143 Recommendations for Tube End Welding.

2.0 SPECIFIC REQUIREMENTS

The Code applicable for ACHEs shall be API 661, latest edition except to the extent modified hereunder. The section, paragraph and figure numbers refer to those used in the API standard. "New" applies to entirely new paragraph presently not included and to be inserted in the numbering order of API-661. "Addition" applies to an addition to the original para while ·"Modified" applies to modification of the applicable portion of the API - 661 para.

3.0 PROPOSALS The proposal shall include the certified noise data sheet. The proposal shall include power consumed by the motor and required motor Horse Power (HP).

4.0 DOCUMENTATION Documents shall be furnished by vendor as per Vendor Data requirements as specified in the requisition.

5.0 DESIGN

5.1 Thermal Design

5.1.1 Thermal rating when specified shall be done by the Vendor. Thermal design proposed by the Vendor will have to be in order as per either HTRI or HTFS software. This

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includes adequacy of heat transfer area and tube and air side pressure drops. If any modifications are required to be carried out by the Vendor in order to make the thermal design acceptable as per either HTRI or HTFS software; the same will be done without any cost and delivery implications.

5.1.2 If an ACHE has to satisfy more than one process condition, separate “Equipment Data Sheet” shall be furnished for each condition. The relevant process condition number shall be given in the heading of each sheet.

5.1.3 ACHE design shall take into account operation at part load. This is particularly important for viscous materials (5 cP and greater) and those with high pour points. The following shall be considered by Vendor:

5.1.4 The varying air temperature across the rows of a single pass condenser results in unequal performance. This should be eliminated by employing variable fins per inch in the individual rows with the lowest in the bottom row and highest in the top row.

5.2 Tube Bundle Design

5.2.1 Vendor shall strictly follow the design information issued by the Purchaser. Any comment and/or reservations shall be resolved with the Purchaser at the bidding stage. Reservations or deviations not accepted during bidding stage shall not be reopened during job execution.

5.2.2 There shall be practically no air gaps in bolted joints (plenum to beam, in between parts of plenum etc.). However these gaps shall be limited to 0.5 mm (maximum).

5.2.3 The bundle side frame shall have minimum 5 mm thickness for tube lengths less than 6 m and bundle width up to 2 m and shall have 8 mm thickness (minimum) for greater tube lengths or bundle widths. Only one joint is permitted in the frame. The weld, if any, shall be full penetration weld, shall be ground flush from inside and dye penetrant (D.P.) examined.

5.2.4 Tube to tube sheet joints shall be expanded type except that the tube to tube sheet joint shall be welded for the following cases:

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i) Critical service requirements such as lethal, hydrogen service with hydrogen partial pressure > 7 kg/cm2 (g), etc.

ii) For duplex and super duplex materials where reliable expanded joints are difficult

to achieve. iii) When specified in Process Licensor's requirements or datasheet. iv) Tube hardness or yield strength exceeds that of tube sheet. v) When design pressure > 50 kg/cm2 (g) and design temperature is > 4000C. vi) When design pressure > 70 kg/cm2 (g) and design temperature is > 3000C. vii) For sour service with stainless steel (SS) tubes and tube sheet.

5.3 Tube Bundle Design Temperature

5.3.1 The ACHE minimum design metal temperature (MDMT) shall be taken lower of 0 0C or the design temperature specified in the equipment drawing or Design Basis.

5.3.2 Extruded fins may be used for design temperature up to 280 0C (maximum). Embedded „G‟ fins may be used for design temperature up to 400 0C (maximum). Beyond 400 0C, only welded fins shall be used.

5.4 Headers

5.4.1 If the design temperature exceeds 180 °C, a split header shall be provided after first tube pass of multi pass bundle.

5.4.2 Header shall be designed so that the inter pass cross-sectional flow area is at least 130 % of the flow area in the previous tube pass.

5.4.3 The minimum tube sheet thickness for expanded tube to tube sheet joint shall be 25 mm for Carbon Steel (CS) and Low Alloy Steel (LAS) materials with 3 mm Corrosion Allowance (CA), and 22 mm for SS material with no CA, to ensure two grooves for expansion.

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5.4.4 For higher CA, minimum thicknesses shall be increased by the additional CA (e.g. CA in

excess of 3 mm for CS or LAS, etc.).

5.4.5 Even numbers of passes are preferred for simplicity in piping layout. Nozzles between tube bundles shall be at the fixed header end to minimize thermal expansion stresses.

5.4.6 The type of header as specified by Purchaser shall be adopted. In general cover plate type headers shall be used when fouling resistance is greater than 0.0004 hr m2 0C/kcal. Plug headers shall be provided for services such as hydrogen, lethal, sour, amine, design pressure greater than 50 kg/cm2 (g).

5.4.7 Pass partition plates shall be provided with one 6 mm diameter drain hole. 5.4.8 Low friction pads, suitable for design conditions, shall be provided under moving

headers. For up to 200°C: PTFE on PTFE or PTFE on stainless steel is considered acceptable. If PTFE or a loaded PTFE is used for Pad material, Pad must be bonded to C.S. backing plate and be of a suitable size to allow for header movements and reduced ‘bearing areas’ thus caused. Pads to be sized so as to avoid deformation from compressive loading.

5.4.9 Steam Coil headers shall be fabricated from SA-106 Grade B. Nozzle size and rating for all coil connections shall be 75 mm - 150 lb raised face, as a minimum.Steam coils shall be from 25.4mm dia., 12 BWG, SA-214 tube.Fins for steam coil tubes shall be embedded aluminium with a diameter of 57.2 mm and a maximum density of 433 fins per metre.

5.5 Removable-Cover-Plate and Removable-Bonnet Headers

5.5.1 Removable bonnet headers shall not be used.

5.5.2 Bolted joints shall be designed with confirmed gasket only.

5.5.3 Use stud bolts for header flange and cover plate joint. 5.6 Plug Headers

5.6.1 For strength welded tube to tube sheet joints, if clearance between the top/ bottom/ side/

partition plate and tube is less than 18 nun or the plug size is less than tube Outside

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Diameter (OD) plus 9 mm, then Vendor shall demonstrate his experience by giving past references and by performing mock up to prove his capability in this regard. The mockup shall be done before the submission of design or drawings.

5.6.2 Plug type headers shall be designed in accordance with ASME VIII Div 1, App. 13 and transition type nozzles in accordance with App. 13.12. Nozzle reinforcement should be by area replacement in accordance with para UG-37. Other means of calculating nozzle reinforcement must be approved by IOCL

5.7 Tube Access Plugs

5.7.1 Plug shall not project into the header box. In case of sour and lethal service, double gasket type plug shall be used.

5.8 Gasket

5.8.1 Gaskets shall be in one piece. This shall however not mean exclusion of gaskets made by welding, provided the weld area is not harder than the adjoining material and has the same corrosion resistance. The pass ribs of metal jacketed gaskets may be tack welded to the inside of peripheral section.

5.8.2 The selection of gaskets in header flanges depends on the temperature, pressure and corrositivity conditions of the fluid to be sealed. For cover type header, the gasket shall be Compressed Asbestos Fibre (CAF) or metal jacketed type with the metal compatible with cover and flange material. CAF may be used only for water, air, steam (up to 1500C) with ANSI 150 Class. CAF shall be 2 mm thick only. For plug headers, only solid soft metal gaskets are to be used.

5.8.3 Metal Jacketed (3 mm thick) gaskets shall be 13 mm (minimum) wide all around. CAF (2 mm thick) gaskets shall be 19 mm (minimum) wide all round. Width of the gasket at pass partition shall be equal to the pass partition plate thickness.

5.9 Nozzles and other connections

5.9.1 Maximum nozzle size shall be limited to 12" NB and where possible shall be restricted to 8" NB by splitting large flows into multi nozzles, if necessary. Header boxes having length more than 1800 nun shall have minimum two nozzles for process inlet and outlet.

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5.9.2 All connections shall be flanged irrespective of flange rating.

5.9.3 Bolt holes shall straddle principal centerlines.

5.9.4 Fabricated transition pieces wherever indicated in this clause shall not be permitted. Swaged CS nozzles shall be normalized if the thickness exceeds 16 mm or if they are not formed in the normalizing range. Hot formed SS nozzles to be solution annealed.

5.9.5 Slip-on flanges shall not be used.

5.9.6 Threaded connections shall not be used. Multi Purpose (MP) connections shall be as per Design Basis.

5.9.7 If specified by Purchaser, additional chemical cleaning connection shall he minimum 2" NB. The type and location shall be as specified.

5.10 Maximum allowable moments and forces for nozzles and headers

5.10.1 Nozzle loads in excess of API limits shall be considered if specified by Purchaser. 5.11 Tubes 5.11.1 For extruded fins (integral type) the minimum tube thickness applies to the inner tube.

5.11.2 Fins serrated on the outside edge may be used only tor CS fins.

5.11.3 L-fins shall not be used.

5.11.4 The mechanical bond between tube and embedded fins shall be tested as follows:

i. Cut fin to obtain a sector with a chord of approximately 12 mm at the root of the fin.

ii. Pull out the fin sector by hanging weights or any other appropriate method. Acceptance criteria shall be a force of at least 3.0 kg.

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iii. 1% of the total number of tubes per size, fin diameter, fin pitch shall be tested at two locations along the tube length. Tubes which pass the test may be used after stitching of fin portions across the cut.

iv. In the event of any tube failing to comply with pull out test requirements, a further

two tubes shall be re-tested and, if the results are satisfactory, the tubes can be accepted. If, however, the further test results are unsatisfactory, the entire lot of tubes shall be rejected.

v. The pulling test shall not be carried out within 25 mm from each fin connection point. Two cross-section cutaways shall be made for inspection of tube grooving and fin bonding per each machine setting (i.e. one tube for each type of tube and fin detail and minimum one test per order).

5.11.5 The number of fins shall not exceed 433 per meter (11 per inch). 5.12 Air side Design 5.12.1 If the control of airflow is to be achieved by use of auto variable fans at least 50% of the

fans are to be made auto variable, unless specified otherwise. Auto variable fans, if used, shall be located towards that end of the bundle where inlet nozzle (s) is I are located.

5.12.2 Drivers, gear boxes, transmission components, instrumentation, louver actuator and positioner etc. shall not be installed in the hot air stream.

5.13 Noise Control 5.13.1 Permissible noise level of the air cooled heat exchanger measured shall not exceed 85

dB (A) (weighted sound level reading when measured on the A scale of a general purpose sound level meter set at slow response) with all fans running at full load. Measurement shall be taken one meter from bundle on the header access walkways and 1 m from the bay limits on the motor maintenance platform. The permissible noise levels at the points defined in Appendix-F shall be 90 Db (A) maximum. These noise level limits shall be demonstrated by vendor during run-in tests.

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5.14 Fans and Fans Hubs 5.14.1 Two or more fans aligned in the direction of tube length shall be provided for each bay.

All fans in a bay shall be arranged for independent operation. Common fans cooling more than one process duty shall be used only on approval from Purchaser.

5.14.2 Fans shall be designed for max 85 dB (A) noise level, keeping in mind the overall limits as per 6.2.2.1. Fan tip speed shall be suitably selected. Fan manufacturer shall furnish noise level datasheet for fans.

5.14.3 Pneumatic actuator shall be equipped with a positioner. Each actuator shall have an integral positioner mechanism and mechanical maximum and minimum stops, adjustable over the full range. Exposed actuator shafts shall be protected with canvas gaiters. Each actuator shall be provided with flexible hose (s), terminating in a ¼" NPT screwed female connection. The actuators shall be suitable for an air supply pressure of 9.5 kg/cm2(g) design, 7 kg/cm2(g) normal and 2.5 kg/cm2(g) minimum. The exact air supply pressure will be specified by Purchaser. Any pressure reduction system on the supply air shall be in Vendor's scope.

5.14.4 In case of loss of supply air pressure or control signal, the blades shall lock at maximum air flow position unless specified otherwise. In the event that the fan fails to respond in this manner, means shall be included by the Vendor to physically lock the blades in high pitch position. Auto variable fans to be shop adjusted for variation between zero performance and max pitch required. Positioner to be supplied and set for full signal pressure range. Signal pressure for auto variable fan shall be 0.2 to 1.0 kg/cm2(g) for zero flow to design flow unless specified otherwise. HP of motor to be selected based on the air flow at design pitch. Provide one IP converter per item, unless specified otherwise. One volume booster shall be provided for each auto-variable fan.

5.14.5 Approved suppliers for fans are MOORE (UK. or USA), COFIMCO (Italy) and HUDSON (USA).

5.15 Fan Shafts and Bearings 5.15.1 Fans shall be provided with QD bushes (minimum 10 mm thickness) for attachment to

fan shaft. Fan assemblies shall be fitted with their own thrust bearing situated at the drive end and a steady bearing at the outer end. The thrust bearing shall be capable of

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carrying any thrust loads transmitted by the driver. The thrust bearing inner race shall be mechanically locked by means of split rings to prevent accidental downward movement of shaft.

5.15.2 Fan hubs shall be examined for hairline cracks using magnetic particle or dye penetrant according to hub materials.

5.15.3 Fan shaft and bearings shall be a one-piece assembly incorporating top and bottom bearings for forced and induced draft arrangements.

5.16 Fan Guards 5.16.1 Removable galvanized steel fan guards shall be furnished on forced draft as well as on

induced drafts units. A door shall be provided on the fan guard of each fan, of diameter greater than 2 m, to attend to minor problems without removing entire fan guard.

5.16.2 For forced draft exchangers the top of finned tube bundles shall be protected by an 8 BWG (Min.) steel wire mesh 50 mm x 50 mm. For induced draft exchangers the top of the finned tube bundles shall be similarly protected immediately beneath the removable fan guards extending to the fan shaft to provide access to the fan hubs and bearings.

5.16.3 The design of the fan ring shall comply with the fan manufacturer’s requirements. Where an inlet cone or bell is used the fan ring and cone, or bell, shall be one piece or welded. No flanged joint between ring and cone, or bell, is permissible. Where the fan ring itself is fabricated in sections (e.g. two half circles) then the above shall apply to each section.

5.17 Electric Motor Drivers 5.17.1 All electrical equipments shall be selected to suit the specified hazardous area

classification, and the environment in which these have to operate. Area classification shall be as specified elsewhere.

5.17.2 As a minimum motors shall be rated to provide 120% of the summer design fan power, including drive losses. The rating shall be exclusive of the Motor Service Factor.

5.17.3 Electric motors (shaft up) shall be fitted with a brass slinger plate or equivalent device to prevent access of rain to shaft bearing. Where flange mounted motors are used, precautions must be taken to avoid the build up of water within the flange area. This area should be provided with a drain and/or a suitable shroud fitted the motor.

5.17.4 Requirements for ‘E’ motors

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All motors are to be able to re-accelerate immediately upon voltage recovery following a voltage dip. The worst case, which all equipment must withstand, may be an instantaneous recovery to full voltage with 30% residual, out of phase voltage on switchgear bus. Motor termination boxes shall be metric 1.5 ISO pitch for cable glands(by others). Cable entries to motor terminal boxes shall be from below or side of the terminal boxes. Minimum protection standard for motors shall be IP66 to IEC 529. Motors shall be provided with grounding lug connections on the motor frames as well as in the terminal boxes.

5.18 Couplings and Power Transmissions 5.18.1 Belt Drives

a) Belt drives shall be high torque type, positive drive belts and shall be either HTD of

Gates. USA or Fenner, UK; PG-GT of Gates, USA; or TORQUE DRIVE PLUS of Fenner, UK unless specified otherwise by the Purchaser.

b) Belt drive tensioning means shall be adjustable without the need to remove the

guard and without losing the alignment of the pulleys. c) Pulley wheel shall be of cast iron or steel. All pulleys shall be dynamically

balanced. Pulleys shall be thoroughly cleaned of rust, grease, dirt and shall be shop coated. Belt drive pulleys shall be supplied by Vendors approved by belt supplier indicated in para a) above and shall be certified accordingly.

d) Belts shall be heavy duty, oil resistant, antistatic and have neutral twist and shall

be selected to suit the specified hazardous area classification. e) Belt drives shall have a minimum service factor based on the belt manufacturers

recommendation for the service. In any case the minimum service factor shall be not less than 1.4 based on the driver rated power.

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5.19 Structural Design 5.19.1 General

a) For ACHE to be installed in India, the Codes for structural design shall be Indian

Standard unless otherwise specified. b) For induced draft units, tube bundles shall be removable without requiring removal

of the platforms. For forced draft units, the bundles shall be removable without separately supporting or dismantling of the fan, plenum, or platforms and without requiring disturbance of the structure or adjacent bays.

c) The structural design shall be done on a reputed software package based on

stiffness method of analysis e.g. STAAD. Spliced joint is not permitted in columns and bracings. Beams of length 6 m and below shall not have a splice joint, however for length above 6 m one splice joint may be permitted subject to the following conditions:

i) The spliced joint is not located at the point of maximum bending moment or

shear.

ii) Weld joint in the member shall be full penetration weld duly D.P tested.

iii) Suitable size of connecting plate shall be welded on both sides of the web and preferably inside of flange.

5.19.2 In order to meet the vibration requirements it is preferred that the drive assembly shall

not be suspended from plenum but supported on the main column. 5.19.3 The structural assembly shall be done by bolting only so that the same can be easily

dismantled. However, structural modules like platforms and brackets may be pre-welded and bolted to columns at site.

5.19.4 Piping support loads on structure, if specified by Purchaser, during detailed engineering shall be considered by Vendor.

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5.19.5 Vendor shall provide holding down bolts and galvanized shims at base plates. Shim packs shall consist of the following thicknesses for each column: 1 x 25,1 x 12, 2 x 6, 2 x 3, 4x2.5(mm).Holding down bolts is to be Grade 8.8 or equivalent. For rack or structure mounted items. Structural bolting to be Grade 8.8 or equivalent.

5.19.6 All main structural connections shall be double nutted for secondary connections. Metalic star or spring washer shall be used. Where earth bonding is required, star washers shall be additionally employed.

5.20 Vibration Testing 5.20.1 Vibration check shall be made on each motor (both driving and non-driving ends). Motor

base plate, fan or motor supporting beams, main structure columns with all machines running individually and also with all machines running together at their full load. The velocity of vibration shall not exceed 6 to 8 mm/s (RMS velocity). Motor and bearing blocks for any abnormal heating shall also be checked by running all the machines for sufficient time. Vendor to provide necessary instrumentation as well as carry out the vibration check and subsequent modifications, if required.

5.21 Structural Design Loads and Forces 5.21.1 Thermal force reaction shall be based upon an effective coefficient of friction equal to

0.3.

5.21.2 Wind load shall be in accordance with IS-875 unless stated otherwise in design basis.

5.21.3 Earthquake forces shall be in accordance with IS-1893 unless stated otherwise in design basis.

5.22 Plenums 5.22.1 Minimum thickness of steel sheet material used in construction of plenums shall be 2.8

mm (12 gauge) minimum, if the construction is transition type or straight box type. If it is inclined panel type as in case of induced draft then the minimum thickness shall be 3 mm for fan diameter up to 1.2 m (i.e. 4 feet) and 4 mm for larger size of fans.

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5.23 Mechanical Access Facilities 5.23.1 Access platforms shall be provided on all four sides of a continuous bank of bundles.

Stairs shall be provided on one side and ladders on the other side. 5.23.2 Maintenance platforms shall be provided, unless specified otherwise, beneath each drive

assembly to provide access for removal and replacement of all drive components. An unobstructed platform area extending at least 900 mm in any plan dimension on all sides of the driver and drive components shall be provided. However such platforms shall not extend beyond the bay plan limits. Ladders shall be provided for access to induced fan for maintenance.

5.23.3 Platform for header access shall have minimum clear width of 900 mm.

5.23.4 Grating shall be provided. These shall be anti-skid type, removable with maximum length of 1.5 m.

5.24 Lifting Devices

Positioning of lifting lugs shall be such that horizontal balance of bundles is obtained. 5.25 Roofing

Roofing shall be provided if specified by Purchaser and covering shall be of asbestos sheet unless specified otherwise.

6.0 MATERIALS 6.0.1 Material of construction may be specified in the requisition or data sheets in the general

terms. Materials shall conform to relevant ASME specifications, or equivalent thereof.

6.0.2 Cast iron including nodular ductile iron shall not be used for pressure components in any service.

6.0.3 All steel sections, plates and other miscellaneous structural steel materials shall be free from loose mill scales, rust as well as oil, mud, paint or other coatings. The materials, construction specifications such as dimensions, shape, weight, tolerances, testing etc.

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for all structural materials shall conform to IS 2062 Grade A or equivalent, unless specified otherwise.

6.0.4 All structural parts of tube bundle frame, plenum chamber, motor suspension assembly, shaft housing, gratings for stairs and platform, all guards etc. shall be hot dip galvanized. Bolting shall be electro galvanized.

6.0.5 Pressure part plates having thickness 16 mm to 50 mm (both inclusive) shall be Ultrasonically Tested (UST) as per ASTM A-435. Pressure part plates having thickness above 50 nun and all plates to be used for tube sheet and plug sheet shall be UST as per ASTM A-578 Level B. No laminations or inclusions shall be permitted.

6.0.6 All the tubes shall be seamless and cold drawn. Product analysis of tubes shall be carried out and reported. CS tubes shall be in annealed condition. SS tubes shall be in solution annealed condition. It is preferable while procuring tubes to check that actual yield strength and maximum hardness of tubes are lower than those of tube sheet, in order to achieve a sound expanded tube to tube sheet joint, complying with the requirements.

6.0.7 All pipes shall be seamless and hot finished. Dimensions and tolerances shall be in accordance with ANSI 36.10 or ANSI 36.19 as applicable per material specification.

6.0.8 CS or LOW TEMPERATURE CS (LTCS) MATERIALS (Pressure Parts or Non-pressure parts welded to pressure parts or parts wetted by the fluid in tube side) a) Carbon content shall not exceed 0.23 %. b) Plates shall be in normalized condition. Pipes shall be SA 106 Gr. B or higher

grade. LTCS pipes shall be SA 336 Gr. 1 or higher grade. c) Use of SA 515 Gr 70 is not permitted. d) CS plates above 50 nun thickness shall also meet the following additional

requirements of SA-20:

i) Vacuum treatment as per the supplementary requirement S1. If vacuum degassing is not reported in the test certificates then through thickness test

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as per SA 770 shall be conducted and minimum reduction in area of 35% shall be ensured.

ii) Charpy V-notch test as per supplementary requirement S5 with:

Test temperature : Minus 29 0C. For SA-515 Gr 60, use 00C.

Acceptance criteria : Impact test values as per applicable material Specification. For SA 515, values indicated for SA 516 to be used.

Orientation of test bar : Transverse to the direction of rolling.

iii) Bend test as per supplementary requirement S 14 of SA-20.

e) Unless specified otherwise in Enquiry document, all CS materials specified as HIC

tested shall meet the following requirements.

i) Carbon equivalent shall be restricted to 0.40% maximum. Nickel content shall b0.2 % maximum.

ii) Sulphur content shall be 0.002% max for plates and 0.01% for tubes, pipes

and forgings.

iii) Hardness of plates and pipes shall not exceed 200 BHN, and that of forgings shall be 187 BHN maximum.

iv) Plates shall be to SA 516 Gr 60 only (Higher grades like SA 516 Gr. 70 are

not acceptable). The plates shall contain calcium or other rare earth materials to create spherical inclusions instead of stringers. The plates shall be tested in accordance with NACE TM-02-84 using the test solution of NACE-TM-01-77. The acceptance criteria shall be crack length ratio 10% maximum.

f) For all materials with MDMT less than 00C, charpy V notch impact testing shall be

carried out. The test temperature shall be lower of MDMT or the test temperature specified in the applicable material specification. Unless specified otherwise, impact energy values shall be more stringent of the values specified in para UG 84 of ASME Sec. VIII, Div. l or the applicable material specification.

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6.0.9 LAS MATERIALS (Pressure Parts or Non-pressure parts welded to pressure parts or

parts wetted by the fluid in tube side)

a) All LAS plates, pipes and forgings except C-½ Mo materials shall be in normalized and tempered conditions.

b) For 1¼ Cr- ½ Mo materials the maximum room temperature tensile strength of all

pressure containing components, materials and welds shall be 100000 psi. c) For LAS tubes (SA-199, 209 and 213) hardness test shall be performed on outside

of the tubes as per ASTM A-450. d) For LAS plates above 50 mm thickness, following supplementary requirements of

SA-20 shall also apply.

i) Vacuum treatment as per supplementary requirement Sl. If vacuum degassing is not reported in the test certificates then through thickness test as per SA 770 shall be conducted and minimum reduction in area of 35% shall be ensured.

ii) Charpy V-notch impact test as per supplementary requirement S5 with:

Test temperature : Minus 18 0C or MDMT. For 5 Cr ½ Mo materials, the test

temperature shall be 00C.

Acceptance criteria : As per ASME Sec. VIII Div. 1

Orientation of test bar : Transverse to the direction of rolling.

iii) Bend test as per supplementary requirement S14. 6.0.10 SS MATERIAL (Pressure Parts or Non-pressure parts welded to pressure parts or parts

wetted by the fluid in tube side)

a) All SS material (300 series) shall be in the solution annealed and pickled condition. All stabilized grades of SS (i.e. SS 321, SS 347 etc.) shall be given stabilization treatment in addition to solution annealing.

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b) All SS (300 series) plates shall be hot finished and shall have No. 1 finish on both

sides. c) SS (300 series) materials shall be procured with the IGC test as per ASTM-A 262

(test shall be carried out, after the specified heat treatment and sensitization per specification) with acceptable corrosion rate and practices as under :

i) All services except nitric acid service - Practice E

Specimen after exposure shall be bent as per mentioned in A 262 Practice E and shall be examined at a magnification of 200 X. The bent specimen shall be free of any cracks or grain droppings. The microscopic examination result shall be submitted to Authorized Inspector for approval.

ii) Nitric acid service - Practice C corrosion rate < 635 micro-m per annum 6.0.11 All forgings except nozzle flanges less than 10” NB shall be 100% UST as per ASTM A-

388. Acceptance standard shall be as per AM 203.2 of ASME Sec. VIII Div.2. 6.1.1 Louvers

Louver blades shall be made of corrosion resistant material like aluminum.

6.2 Other Components 6.2.1 Aluminum fin material shall not be less than 99.% pure (grade 1060).

6.2.2 Fan blades shall be of aluminum alloy. Aluminum alloys for fan blades shall be selected

to be resistant to stress corrosion cracking. Fan hub and blade material shall be non sparking type. Copper content in aluminum blade should not exceed 0.4%.

6.2.3 If specifically indicated by Purchaser, Fiber Reinforced Plastics (FRP) blades may be used. FRP blades shall be used only for forced draft units. In order to prevent the generation of static charge, the FRP blades shall have a surface resistivity of less than 1x10s ohms, determined in accordance with BS 2782: Part 2 method 231 A. The blades shall be provided with antistatic coating.

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6.2.4 Solid metal gaskets for shoulder plugs shall be dead soft annealed. It is recommended that Soft Iron and Soft SS gaskets for plugs shall have hardness of minimum 15 BHN less than the material of plug and plug sheet. Hardness of Soft Iron gaskets shall not 90 BHN and that of Soft SS gaskets shall not exceed 140 BHN.

6.2.5 Fan shaft shall be to either SA 105 or EN 24 (hardened and tempered and UST). CS pipes may be used for shaft housing. Bearing housing shall be to SA lOS.

6.2.6 Material for instrumentation valves and tubings shall be SS. All instrumentation shall be suitable for the hazardous area classification for electrical safety.

7.0 FABRICATION 7.0.1 All welding procedures shall be submitted to the Authorized Inspector for approval. All

welding shall be done with electrodes, fillers and fluxes of reputed make with proven reproducibility of results. Brand names shall be specifically approved by Authorized Inspector. Only low hydrogen electrodes shall be used for all CS pressure parts welds.

7.0.2 All connections to header welds shall be full penetration.

7.0.3 Backing strips if used shall be removable type only.

7.0.4 Repairs to base material and welds shall not be made without the approval of the Purchaser or Inspection Authority.

7.0.5 Non-pressure attachments, such as lugs or structural steel supports, shall be attached to the pressure parts with a continuous weld. All double fillet welds in contact with hydrogen stream shall be vented. All LAS weld attachment to pressure retaining component shall be full penetration weld and ground to a smooth concave contour.

7.1 Plug Headers 7.1.1 Partition plates to abutting plates welding shall be full penetration welds. 7.2 Removable cover plate and removable bonnet headers

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7.2.1 Stiffener plates 6 nun thickness shall be provided to stiffen the flanges of all flanged headers at a spacing of approximately 250 mm. These shall be spaced as not to interfere with the bolts and nozzles.

7.3 Post Weld Heat Treatment

For hydrogen, sour, amine and caustic service, the minimum stress relieving temperature for CS or LAS materials shall be 6200C. For P5 materials, the temperature shall be as per ASME Sec. VIlI Div. 1.

7.4 Tube-to-tube sheet joints

7.4.1 Expanded tube-to-tube sheet joints

Expanded tube-to-tube sheet joints shall be in accordance with code and standards.

7.4.2 Welded tube-to-tube sheet joints

Welded tube-to-tube sheet joints shall be in accordance with code and standards.

7.5 Alignment and tolerances

7.5.1 Gasket flange faces on stacked units shall not be out of parallel by more than 0.8mm (1/32 inches).

7.5.2 The face of each gasket contact surface shall lie between two parallel planes 0.8mm (1/32 inches) apart.

7.6 Finishing

7.6.1 All welds in the area 250 mm from the ends in the bottom of header (where the header is resting on frame channel) shall be ground flush. In a split header all welds in bottom plate of top header and top plate of bottom header shall be ground flush. Inside comers of openings for nozzles to be rounded off to 3 mm radius.

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8.0 INSPECTION, EXAMINATION AND TESTING 8.1.1 All materials for pressure parts and non-pressure parts welded to pressure parts shall be

accompanied by mill test certificates duly certified by reputed third party agency or by the representative of the Purchaser. In absence of mill test certificates the material shall be got tested and certified from a reputed third party agency like ElL, Lloyds, BV, DNV, etc. and the test results shall be submitted in lieu of mill test certificates. All cost towards such testing and inspection shall be borne by Vendor. All material shall be inspected at Vendor's or sub vendor's shop for verification prior to use on the job. The decision of the Authorized Inspector to accept or reject materials on the basis of such testing shall be final. All structural material shall be accompanied by quality certificates. In case the certificates are not available, or are incomplete or when the material quality differs from standard specification, such materials shall not be used. However, Vendor shall get all appropriate tests conducted in approved test houses for such materials as directed by the Authorized Inspector without claim to extra cost and submit the same to the Inspector for his approval. The Authorized Inspector may approve the use of such materials entirely at his discretion. All flame proof electrical equipment manufactured in the country shall have CCE approval certificates along with a valid BIS license. Electrical equipment with area classification as Type 'e' or Type 'n' shall have CCE approval. All imported electrical equipment shall have a similar certificate from the country of origin.

8.2 Quality Control

8.2.1 Minimum Radiography shall be spot. Radiography shall be full (100%) if the thickness of

weld exceeds 30 mm for CS and for all thickness of LAS plates. For hydrogen, lethal, sour, amine and caustic service 100% radiography shall be done irrespective of thickness.

8.2.2 When spot radiography is indicated, it shall mean 10% of weld length (minimum one shot) for each weld configuration to be radio graphed with a minimum of six radiographs of at least 250 mm length each in one header box as detailed below: a) One shot each of the four long seams between top/ bottom plate and tube sheet/

plug sheet.

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b) One shot for any one of the welds of side plate to top and bottom plates. c) One shot for any of the welds of side plate to tube sheets and plug sheet.

8.2.3 MP or DP test of finished welds shall apply also to all header materials greater than 38 mm thickness.

8.2.4 When set-on connections are used, the header plates shall be ultrasonically inspected in the area of attachment for a radial distance equal to twice the thickness of plate and no laminations shall be permitted.

8.2.5 Additionally hardness limitations for materials wherever specified on drawings or datasheets or specifications and for LAS materials shall be as per 6-15-0091. Hardness limitation for tube to tube sheet welding shall be established on a mock up.

8.2.6 Tubes shall be manufactured full length without circumferential welds.

8.2.7 Tubes shall be eddy current tested in addition to hydro test at the mill. For eddy current testing entire metal column of the tube shall be used. The hydraulic test pressure shall be higher of actual exchanger pressure than or as required as per ASME Sec. II.

8.2.8 Radiography can be substituted by 100 % UST provided either a print out is submitted or the examination is witnessed by the Authorized Inspector. However when the supplementary requirements as per para 11 (below) are applicable or if required by Code, substitution is not permitted and full (100%) radiography only shall be done.

8.2.9 All nozzle attachment welds and pass partition plate to header plate attachment welds shall be examined by magnetic particle or liquid penetrant for crack detection. Examination shall apply to root pass after back chipping or flame gauging (where applicable) and to the complete weld.

8.2.10 When impact tests are required on material as per Code or specification the welds shall also be qualified for impact test. In such case following special requirements shall apply to the welding procedure qualification:

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i) Qualification tests shall be made on plates of the ASME specification as specified for the ACHE using welding electrodes of AWS/SFA specification and wire & flux of the specification and brand as are to be used on the job.

ii) Welding current and travel speed shall be considered essential variables in order

to ensure that production welding is substantially equivalent to the procedure qualification.

iii) Welded test plates shall be subjected to a total thermal history expected of the

finished ACHE. Additionally one extra stress relieving cycle shall be considered for site repair.

iv) Charpy V-notch impact tests shall be made on the weld and heat affected zone

of the test plate for each welding procedure to be qualified. Test procedure shall be in accordance with UG 84 of ASME Sec. VIII Div.1. Test temperature shall be MDMT. Impact energy requirements shall be as per Table 2.15 of SA 20 of ASME Sec. II Part A or UG 84 of ASME Sec. Vlll. Div. 1 whichever is more stringent.

8.3 Pressure Test

Potable water with chlorides less than 25 ppm by weight shall be used in hydrostatic testing of units with stainless steel or monel materials exposed to the test medium.

8.4 Shop Run-In

Vibration test, noise level test, etc. that are necessary to ensure smooth running of ACHEs shall be conducted by Vendor at shop or site. If the site erection is not in Vendor's scope, Vendor shall provide site supervision and supply all necessary material and instrumentation.

9.0 PREPARATION FOR SHIPMENT 9.1.1 All units shall be dry, thoroughly cleaned and free from loose scale and other foreign

matters before shipment.

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9.1.2 Tube bundles s hall be completely dried by passing hot air for sufficient time until no

increase in relative humidity of outgoing air is observed. After drying all CS and LAS bundles shall be purged with dry nitrogen at 0.25 kg/cm2. The bundle shall be provided with pressure gage to monitor nitrogen pressure and ½" non- return valve.

9.1.3 All connections not provided with blind shall be provided with gasketed steel covers

fastened by four bolts or fifty percent of the required flange bolting whichever is greater. 9.1.4 Fin tubes shall be protected with permanent heavy duty wire mesh duly stiffened to

prevent damage by personnel walking on top during shipping, handling, erection etc. During transport and storage a maximum of two bundles - may be stacked provided sufficient precaution is taken to prevent damage.

9.1.5 The primer coat shall be inorganic zinc silicate. The header shall also be given final coat

of paint as specified by Purchaser. The airside face of tubesheet shall be painted after stress relieving (in case of CS or LAS) and before drilling of tube-holes. The paint shall be suitable for corrosive industrial and coastal environment as applicable.

9.1.6 All structural steel not galvanized shall be prepared to near white sandblast finish to SA-

2.5 (see SSPC Volume 2, chapter 2, SP 10) and then given an inorganic zinc silicate primer coat of 0.075 mm DFT.

10.0 SUPPLEMENTAL REQUIREMENTS 10.1 General 10.1.1 The supplemental requirements given in this section shall apply if the design pressure

exceeds 70 kg/cm2(g) or when the plate thickness of a box type header exceeds 50 mm or when the exchanger is in lethal or critical service. Whether the service is lethal or critical shall be defined by Purchaser.

10.2 Design 10.2.1 Top/ bottom plate to tube-sheet/ plug sheet joints shall be made butt welds with tube-

sheet/ plug sheet having a hub meeting the requirements of Fig. UW 13.3 (a) or (b) of ASME Sec. VIII, Div.1.

10.2.2 All tubes shall be strength welded to tube-sheet. Seal welding is not permitted.

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10.2.3 Production test coupons (PTC) are required for all butt welds if the weld thickness exceeds 50 mm for CS and 25 mm for LAS, or when required by the specifications or ASME Sec. VIII Div.1. The following shall apply:-

a) Two PTCs representative of the weld between top/ bottom plate and tube-sheet/

plug sheet shall be provided for each procedure, position and thickness. One of the test plates shall be provided for the closing joint of the plug type header.

b) PTC shall be from material of the same heat and thickness as of parent metal.

During and after welding PTC shall be subjected to same heat treatment as and together with the course they represent, extra PTC shall be preserved to take care of eventuality of retests.

c) The tests mentioned below shall be carried out as per methods of testing given in

ASME Sec. VIII Div.1:

i) One transverse tension test. (Ultimate Tensile Strength, Yield Strength and percentage elongation shall not be less than those specified for base material).

ii) Two sides bend tests with weld located in the center of bend.

iii) One hardness test on PTC weld and HAZ (Heat Affected Zone).

iv) Micro and micro examination of welds.

v) For CS material charpy V notch tests on weld and HAZ shall be carried out as

follows:

a) For low temperature service (MDMT below 00C) impact test temperature shall be MDMT.

b) For service with MDMT greater than 0.0C, the test temperature shall be 00C.

c) The acceptance criteria for energy absorption shall be as per table A 2.15 of SA 20

of ASME Sec.II Part A or UG-84 of ASME Sec. VIII Div.1 whichever is more stringent.

vi) For LAS material charpy V notch tests on weld and HAZ shall be carried out.

Test temperature and acceptance criteria shall be as indicated in para 7.1.15 (d)(ii) above.

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11.0 SPARES

Mandatory and 2 years Maintenance spares including spares for electrical and instrumentation parts shall be as mentioned elsewhere. Vendor shall include the mandatory spares in his item rate and indicate unit rate for 2 years maintenance spares, unless specified otherwise.

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PAGE 1 OF 23

TECHNICAL SPECIFICATIONS FOR

CENTRIFUGAL PUMPS

CENTRIFUGAL PUMPS

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Abbreviations: BIS Bureau of Indian Standards BS British Standards BHN Brinell Hardness Number DP Dye Penetration STAAD Structural analysis and design computer program MDMT Minimum Design Metal Temperature TPlA Third Party Inspection Agency ASME American Society of Mechanical Engineers AWS American Welding Society CS Carbon Steel GAD General Arrangement Drawings ID Internal Diameter LSTK Lumpsum Turnkey MOC Material of Construction MR Material Requisition OD Outside Diameter PQT Procedure qualification test PQR Procedure qualification record PL Process Licensor PMC Project Management Consultant SS Stainless Steel

TIG Tungsten Inert Gas WPS Welding Procedure specification

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CONTENTS


1.0 SCIOPE 4 2.0 CODES & STANDARDS 5 3.0 TECHNICAL REQUIREMENTS 5 4.0 INSPECTION & TESTING 12 5.0 INSPECTION & TESTING WITNESSING / CERTIFICATION 15 6.0 DOCUMENTATION 16 7.0 LOADING CRITERIA & PENALTY CLAUSE 17 8.0 SPARES 20

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1.0 SCOPE

This specification along with the attached Data Sheets and other specifications/attachments defines the minimum requirements for vertical and horizontal centrifugal pumps and their accessories / auxiliaries.

1.1 The scope of supply shall include followings as a minimum:

1.1.1 Pump, base frame, coupling, non-sparking coupling guard, anchor

bolts, gland packing unless specified otherwise, auxiliary piping, etc., strictly as per the enquiry requirements.

1.1.2 Rubber Expansion Joint (Suction) with clamping rings, nuts &

bolts, etc., Vent Cock, Priming Funnel with Cock, Drain Cock, Motor & Pump alignment cleats with jack bolts.

1.1.3 Matching squirrel cage induction motor (as per IOCL Technical

Specification), unless specified otherwise, strictly as per the enquiry requirements, and its GI Canopy.

1.2 VENDOR RESPONSIBILITIES

1.2.1 Vendor shall make all possible efforts to comply strictly to the

requirements of this specification and other specifications/attachments to inquiry/order.

1.2.2 In case deviations are considered essential by the vendor (after

exhausting all possible efforts) these shall be separately listed in the vendor’s proposal under separate section titled as “LIST OF TECHNICAL DEVIATIONS/EXCEPTIONS TO THE SPECIFICATION”. Deviation shall be listed separately for each document with cross-reference to Page No/Section/Clause No/Para etc. of the respective documents supported with proper reasons for the deviation for purchaser’s consideration. Any deviation not listed under the above section; even it reflected in any other portion of the proposal shall not be considered applicable.

1.2.3 No deviation or exception shall be permitted without the written

approval of the purchaser. Compliance with this specification shall not relieve the vendor of the responsibility of furnishing equipment and accessories/auxiliaries essential for safe and satisfactory operation of the equipment; he shall recommend the same along

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with reasons in separate sections along with his proposal and include the same in his scope of supply.

2.0 CODES & STANDARDS

2.1 API 610 : Latest edition or as per data sheet 2.2 ASME B 16.1 : Cast Iron Pipe flanges and flanged fittings2.3 ASME B 16.5 : Pipe flanges and Flange fittings (Steel) 2.4 ASME B 16.11 : Forged steel fittings, Socket-welding and Threaded2.5 IS:5120 : Technical Requirements for Rotodynamic Special

Purpose Pumps 2.6 HI : The Codes, standards, and specifications of the

Hydraulic Institute (Centrifugal Pump section) 2.7 ISO:1940 : Mechanical Vibration – Balance Quality requirements

of Rigid Rotors \ Part-1 : Determinations of Permissible Residual Unbalance Part-2 : Balance Errors

2.8 OISD-STD-119, OISD-RP-126

: Latest editions

3.0 TECHNICAL REQUIREMENTS

3.1 GENERAL

3.1.1 Pump with constant speed driver shall be capable of at least

a 5% head increase at rated conditions and pump speed specified on the performance curve by installing new impeller. Similarly it shall also be possible to achieve a 5% head decrease by installing a new impeller, which shall be in no case less than the minimum diameter for the pump casing. The pump shall be preferable of back- pull out design type.

3.1.2 The capacity head curve for the pump shall be continuously

rising type up to shut-off with a minimum shut-off head of 110% but not exceeding 120% of the head at the rated capacity.

3.1.3 a) For overhung and between bearing centerline supported

pumps dismantling of rotor assembly shall be possible without disturbing casing piping. b) Pumps shall be centerline mounted.

3.1.4 The pressure casing shall be designed to 600 PSIG (42.2 Kg/cm 2

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G) & have a corrosion allowance of 3 mm.

3.1.5 The party should comply pump nozzle loading as per API-610 10th editions. It shall be confirmed that the nozzle loading for piping is as mentioned in API 610 latest Edition.

3.1.6 a) If the pumping temperature of the fluid is above 150 degC

provision for cooling water jackets are to be made for bearing housing, stuffing box and

pump pedestal. The same is applicable for pumps offered with cooling water plan.

b) All cooling water piping header size for hot water pumps

shall be 25 mm NB (min). Instead of series connection separate connection for all circuits shall be provided. For cleaning purpose flange with blind is to be provided at the dead end.

3.1.7 Party should indicate the minimum flow required for the

pump in the characteristic curve.

3.1.8 The pump RPM should be 3000 RPM unless specified otherwise.

3.1.9 The vendor must consider while offering their model that the velocity of fluid in the suction nozzle is limited to 4.5 M/Sec.

3.1.10 Best efficiency point of any offered pump should preferably lie

between the rated point and the normal point. However, in no case the rated point shall be beyond 110% of the BEP of the rated impeller. And, in no case shall the normal operating flow be less than 70% of BEP of the rated impeller, unless otherwise mentioned specifically in the pump data sheet.

3.1.11 Irrespective of pump operating parameters and rated impeller, all

pump components shall be designed for operation with maximum impeller diameter, except for coupling, impeller and motor. It means in order to achieve higher operating parameters in future, with a higher impeller, only coupling and motor are to be replaced and nothing else. Therefore, the maximum allowable working pressure at pumping temperature has to be more than the maximum discharge pressure, corresponding to shutoff head at maximum impeller diameter and maximum

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suction pressure as indicated in the data sheet. And hydrostatic pressure has to be 1.5 times the maximum allowable working pressure at pumping temperature.

3.1.12 Pump model with suction specific speed greater than 11000 (U.

S. Units) shall not be offered. Suction Specific Speed to be calculated based on the figures corresponding to BEP at maximum impeller diameter of the quoted model.

3.1.13 Offered model where difference between NPSHA and NPSHR,

from quoted minimum flow to rated flow, is less than 0.6 meter will not be acceptable. The quoted NPSHR figure shall correspond to the maximum value of NPSHR from rated flow down to the recommended minimum continuous flow specified by the vendor.

3.1.14 NPSH test shall be performed if NPSH margin(water) is less than 1.0 M. 3.1.15 Pumps fitted with inducers for reducing NPSHR are not

acceptable unless is permitted by the Purchaser

3.1.16 No attempt shall be made for moderating the pump characteristic curve by installing any restriction orifice at discharge nozzle or by effecting any modification to the discharge nozzle.

3.1.17 Viscosity correction to be carried out as per Hydraulic Institute charts.

However, bidder/vendor has to confirm that all viscosity correction factors as mentioned against each model are firm and are guaranteed figures.

3.1.18 Maximum impeller diameter for single stage overhung design

pump, operating at 2800 rpm and higher, shall be limited to 380 mm.

3.1.19 Fabricated Impellers are not acceptable.

3.1.20 Individual components like impeller, balancing drum, and

similar rotating components shall be dynamically balanced to grade G 1.0 of ISO 1940. However, the complete assembly to be balanced to grade G 2.5 of ISO 1940.

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3.1.21 Pump Type-Horizontal, Centrifugal, Radially split, Single Stage/ Two Stage, Overhung Back pull out/ In-between bearing, Single Suction/Double Suction; unless anything is specially mentioned elsewhere.

3.1.22 Two stage pumps and double-suction single stage pumps

shall have in- between bearing type of construction only. Overhung design shall not be used for such pumps.

3.1.23 Minimum continuous stable flow requirement for each

pump has been indicated in concerned pump spec. sheet and the same shall be satisfied by vendor. Meeting minimum flow requirements with orifice arrangement will not be preferred unless mentioned otherwise.

3.1.24 Vertical pumps taking suction from sump/ vessel shall be

furnished with corrosion resistant suction strainer. Perforation / mesh size shall be suitable for proper operation of pump. Free flow area of the strainer shall be minimum 2.5 times the area of equivalent suction nozzle area.

3.1.25 In case of vertical pumps, column & bowl assembly joints shall be flanged.

3.1.26 For vertical pumps the specified head shall be measured at

the discharge flange, at pump mounting level. Pumps shall be suitable to develop specified discharge head in addition to the column losses and vertical distance, between minimum level in the sump tank & centre line of discharge flange. Pump

vendor shall indicate total head to be developed by the pump in the offer.

3.1.27 Power calculations shall be with maximum specific gravity.

3.1.28 Bidder has to specify the Guaranteed Power for Loading /Penalty.

3.1.29 Stuffing box dimensions shall be as per Table-1 of API-682.

Otherwise it has to conform to Table-2 of API-682 as minimum.

3.1.30 Gauge Glasses with Ball type Flow Indicator are to be provided in the auxiliary piping of Cooling Plan.

3.1.31 Coupling shall be Metal Laminate, Non-Sparking type with Spacer as per

IOCL technical specification IOC/M&I/MECH/E/R/07 (Revision-00);

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3.1.32 Service factors of coupling shall be as given below:

TYPE OF DRIVER SERVICE FACTOR MOTOR 1.5 STEAM TURBINE 1.25 DIESEL ENGINE 3.0

3.1.33 Mechanical Seals : Pump will be generally provided with single mechanical seals except for dirty service or environmentally hazardous service for which dual seals shall be provided or specifically mentioned in the data sheet.

3.1.34 Mechanical Seals shall be designed strictly per the

requirements of API-682 latest edition & IOCL Technical specification IOC/M&I/MECH/E/R/06 (Revision- 00) and shall be complete with all of the following features that are applicable for the offered models:

3.1.35 Bearings and bearing housings shall be arranged for

hydrocarbon oil lubrication. Grease lubricated bearing is not acceptable.

3.1.36 Coupling Guard shall be non-sparking type fabricated from 18

SWG (MIN), Aluminum sheet and shall be open at the bottom to permit manual shaft rotation.

3.1.37 The base plate shall be of rigid construction and fabricated out

of standard steel sections:

The minimum height of the section shall be as under:

Pump With Motor Rating up to Min Section Height 7.5 KW ISMC 10045 KW ISMC 15075 KW ISMC 200 Above75 KW ISMC 250

3.1.38 Alignment screws are to be provided for motors weighing over

500 KGS. In addition jackscrews are to be provided for motors weighing over 650 Kgs.

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3.1.39 Motor side of the base frame shall be capable of accommodating next higher frame size of the proposed motor.

3.1.40 The casing wear ring should be harder by minimum difference of 50 BHN.

3.1.41 Coupling shall be non-lubricated flexible metallic type with spacer.

3.1.42 Pump shall be operated at the shop at the rated speed and

capacity. At least five data points shall be taken at shut-off, minimum continuous stable flow, minimum flow, rated flow and 110% of rated flow for complete test data including head, capacity, NPSHR and power.

3.1.43 Magnetic drain plug shall be provided in the bearing oil chamber.

3.1.44 Bearing isolator as per IOCL technical specification shall be

provided to avoid lube oil contamination.

3.1.45 Pump bearing housing shall include sump indicator with sight glass.

3.1.46 Pump bearing housing shall include sump bottle at the bottom for visual monitoring of lube oil of the operating pump which shall be provided with isolation valve to facilitate removal in running pump.

3.1.47 The Vendor's offers shall include following Data:

• Make and type of mechanical seal selected and literature/catalogue for type of seal selected alongwith Seal vendor's recommendation, Seal plan , type of sealing system and utilities consumption data i.e. steam, cooling water etc in a tabulated form (refer Table A) shall be furnished.

• Mechanical Seal plan API 54 is not acceptable. • EBIPL/FLOWSERVE/JOHN CRANE/AES SEAL make

Mechanical Seal are only acceptable. • Make & type of coupling along with literature/catalogue shall

be given. • Data sheet with complete vendor's information entered thereon. • Performance curves, which include differential head,

efficiency, water NPSHR and brake horsepower, expressed as function of capacity. In addition, the head curves for maximum and minimum impeller diameters shall also be shown.

• Typical cross-sectional drawings indicating material of

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construction as per ASTM/AISI of each component and literature to describe fully details of offerings.

• Any other information which vendor wants to furnish for offering.

Table A

SL Vendor / Tag No

Model Seal Plan Offered

Cooling water Required in LPM

Steam Required in LPM

Bearing Cooling Water required in LPM

1.0

2.0

3.1.48 The Vendor shall furnish G.A drawings & pump Cross Section

Drawing, Mech Seal Drg; Cooling Plan & Quenching plan Drgs. (3 sets) for approval by purchaser.

3.1.49 The loading criteria shall be applied during the evaluation of

the vendors’ quotation. The price loading shall be in terms of the excess cost of electrical power consumption for motor driven equipment over the competing bidders. The same shall be calculated as per the procedure given in this specification.

3.1.50 The Penalty shall be applied upon the performance test of

the supplied equipment, if it found that the power is in excess than the vendors’ guaranteed value. The same shall be calculated as per the procedure given in this specification.

3.1.51 The quotation for the motor should conform to Technical

Specification attached.

3.1.52 Vendor shall indicate the Max BKW at the end of the curve of rated Impeller.

3.1.53 Party has to submit KW rating calculation for motor. The motor KW at operating point plus API 610 margin should not be lower than the KW required at the end of H.Q curve. It means motor should be selected at operating point plus API margin or

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power requirement at the end of the curve whichever is higher.

4.0 INSPECTION AND TESTS

4.1 GENERAL

4.1.1 Unless otherwise specified, all pumps shall be inspected and all tests shall be witnessed by the purchaser or by the Purchaser’s authorized representative.

4.1.2 Purchaser’s or their authorized representative shall have access

to the plant including sub vendors plants where work on or testing of equipment is being performed.

4.1.3 No surfaces of parts of pumps are to be painted until the

inspection is completed.

4.1.4 Vendor shall give to the purchaser at least 15 days notice prior to commencement of testing. Vendor shall carry out all running test and mechanical checks and staisfy himself prior to purchaser’s arrival for inspection and shall maintain desired log of tests.

4.1.5 Acceptance of shop test shall not constitute a waiver of

requirement to supply equipment as per specification and/or meet field test under operating condition, nor does inspection relieve the manufacturer of his responsibility in any way whatsoever.

4.2 TESTS

Following tests shall be performed, as a minimum. The basic reference standard shall be the latest edition of API 610 and other referenced standards in this specification.

4.2 Hydrostatic Test

4.2.1 Pressure casings including column pipe and discharge head (if

any) shall be hydrostatically tested with water at ambient temperature at 1 ½ time the maximum allowable working pressure specified in the data sheet.

4.2.2 Jackets for bearing, stuffing box, coolers, etc, shall be tested at 8Kg/cm2g or 1 ½

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times the maximum allowable jacket working pressure whichever is higher.

4.2.3 Hydrostatic test shall be maintained for minimum period of 30 minutes.

4.3 Performance Test

4.3.1 Unless specifically agreed upon, each pump shall be tested at the

rated speed specified in the data sheet with calibrated motors, atleast for four hours. During the four hour run test, complete data including pressure, capacity, power, vibration levels, bearing temperatures and noise levels shall be recorded and guaranteed parameters verified.

4.3.2 The pump shall be tested with water at ambient temperature.

4.3.3 The tolerance of the guaranteed parameters shall be as follows:

Rated head : Zero negative tolerance. Shut-off head : Zero negative tolerance. Positive

tolerance permitted as long as shut-off head does not exceed 120 percent of rated head for horizontal pumps and 140 percent for vertical pumps.

Min. Submergence required/ NPSH(R) : Zero Positive Tolerance. Rated BKW : Zero positive tolerance

(However pumps may be accepted upto 104 percent of Guaranteed BKW subject to Penalties as defined elsewhere).

At least four to six values between duty point and shut off and two values on the right of duty point including one point with discharge valve fully open, shall be measured and recorded during tests. All the instruments used for conducting the tests shall be calibrated before tests and calibration certificates furnished from a recognized testing institution to the Inspector.

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4.3.4 Engine driven horizontal and vertical pumps shall be subjected to a 4 hour complete unit string test at the pump vendor’s works during which mechanical performance of the train shall be verified, in terms of vibration, bearing/oil temperature, engine parameters and controls.

4.3.5 During the performance test, rise in temperature of bearing oil shall

be measured and results recorded on the test log. Values shall not exceed those given in this specification.

4.3.6 During the performance test, the equipment shall be checked for its sound Level & valves shall not exceed those specified in this specification.

4.3.7 NPSH Test / Min. Submergence Test

Unless otherwise specified NPSH test shall be carried out where difference between NPSH available and NPSH required is 1 meters or less. In case of vertical pumps all pumps shall be subjected to minimum submergence test.

4.3.8 Vibration Measurement

During performance test vibration shall be measured on the bearing housing for the capacity range from pump MCF to 110% of rated capacity.

4.3.9 Dismantling Inspection

After the performance test, 4 hours running test and NPSH test (if any) the pump shall be dismantled, to check for wear. Parts having close clearance and mechanical seal faces shall be checked for any abnormal rubbing and wear. Wearing ring clearance shall be measured and recorded.

4.3.10 Final Inspection

After the performance/dismantle test the pump and the job driver shall be unitized on the job base plate, aligned and coupled to make a complete unit. The pump will then be checked for visual inspection to confirm compliance to the GA drawings, nozzle dimension and facing, elevations, anchor bolts position, direction of rotation etc.

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4.3.11 Prior to start of tests, vendor shall furnish the following:

1. Certificate of calibration of driver. 2. Certificate of calibration of measuring instruments,

which should be recalibrated after a period of every one year. Pressure gauges shall be calibrated prior to start test and after completion of test.

3. Record of all running test and mechanical checks (including test curves and data) completed prior to purchaser’s inspection.

Unless otherwise specified, the following tests shall also be performed: 1. Dynamic balancing of impellers for Overhung pumps (Observed). 2. Other test (if any) as specified elsewhere.

4.3.12 If it is necessary to dismantle a pump after the performance test

for the sole purpose of machining impellers to meet the tolerances for differential head, no re-test will be required unless the reduction in diameter exceeds 5 percent of the original diameter. The diameter of the impeller at the time of shop test, as well as the final diameter of the impeller, shall be recorded on a certified shop test curve that shows the operating characteristics after the diameter of the impeller has been reduced.

4.3.13 If it is necessary to dismantle a pump for some other correction,

such as improvement of power, NPSH, or mechanical operation, the initial test will not be acceptable, and the final performance test shall be run after the correction is made.

5.0 INSPECTION & TESTING WITNESSING / CERTIFICATION

5.1 Tests to be witnessed and/ or reviewed by third party Inspector along with IOC

representative:

• Performance Test shall be carried out at minimum 5 points namely

a) Shut off b) Minimum Continuous stable flow c) Midway between Minimum & Rated flow d) Rated Flow e) Maximum Allowable Flow

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5.2 Tests to be witnessed and/ or reviewed by third party Inspector independently:

• Hydrostatic Test • NPSH Test:

For NPSH(A)-NPSH(R) < 0.5 MLC - Pump is not acceptable. From 0.5 to 1 MLC - Testing is required. > 1 MLC - Testing not called for.

• Ultrasonic test of Shaft • Radiographic Test for Casing • Dynamic Balancing of Rotating Elements (As per quality grade G2.5 of ISO

1940). • Dimensional Checking • Strip-check after performance test for visual checking of any

rubbing etc. with rotating element • Any Other Test Required by the Purchaser/TPIA

6.0 DOCUMENTATION

6.1 The vendor shall submit six sets of hardcopy and 2 sets of softcopy in

CD format of the following: • Performance Test Certificate • NPSH Test Certificate • Hydrostatic Test Certificate • Dynamic Balancing Test Certificate • Material Test Certificate • The vendor has to furnish actual ,i.e, measured, vis-a

-vis design diametrical clearance minimum & maximum for wear rings,throat bush & intermediate sleeves.

• Coupling details • Total axial play of rotor • Operating and Maintenance Manual • Cross-Sectional Drawings of pump showing various parts

identified by numbers and Material of Construction as per ASTM/AISI.

• Party shall submit their offered model's family curves .They should also indicate the suction specific speed in US/SI units.

• General Arrangement Drawings & Foundation Drgs(Ref Note :1) • Lubrication Chart • Guarantee Certificate • Complete Pump Data Sheet Duly filled up

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• Motor Certificate from CMRS & CCE Authority • Routine Test Certificate for Motor • Type Test Certificate for Motor • Speed-Torque Characteristics curve for motor • Inspection Release Note from Inspecting Authority • Any other motor document as per IOCL’s standard

specification for electric motors.

6.2 The general arrangement drawing must have the following information:

• Complete overall dimensions with 3 views & sectional views separately. • Pump & motor make and model with driver HP/KW • Coupling make, model & rating with its supplementary drg. • Mechanical Seal make model and its supplementary drg. With

flushing / quenching plan. • Pump and motor shaft dimensions at coupling ends with tolerances. • Allowable forces & moments at nozzles with sketches. • GD² of pump, motor and coupling. • Weight of assembly with individual weight of pump, motor & coupling. • Bearing make, Model, Sr No.

7.0 LOADING CRITERIA & PENALTY CLAUSE

7.1 GENERAL

7.1.1 Power loading and penalty criteria shall be based on guaranteed

performance of the pumping unit. The parameters for loading shall be guaranteed shaft power consumed (BKW) at the rated operating point specified in the Pump data sheet.

7.1.2 Loading shall be done individually for each pump item number.

Loading shall be applied to the number of operating units only.

7.2 PERFORMANCE GUARANTEES

Vendor shall furnish the guaranteed values for the following:

7.2.1 PUMP:

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BKW of pump with zero per cent positive tolerance including any allowances for errors in instruments and measurement at the rated point specified in the data sheets.

7.3 Loading Criteria

The total cost of pumping unit for evaluation purposes shall be computed as under.

Total cost = A + B + C, Where A = Capital cost of the total number of pumping units (both operating as well as Standby) and auxiliaries including commissioning spares, if any. B = Differential operating cost as defined here under, C = Cost of mandatory spares.

Differential operating cost Differential operating cost (B) is defined as under: B (in Rupees) = Nop X (Fe – Fr) X Cp X 8000 X Df

Where, Fe = Guaranteed shaft power requirement in KW at rated operating condition as quoted by the vendor Fr = Lowest guaranteed shaft power requirement in KW at rated operating condition amongst the vendor. Nop = Number of operating units Cp = Cost of electrical energy per KWH (prevailing rate to be taken) Df = Discount factor at 16% annum interest rate, (present value discount) factor, Df = Discount factor (at 16% annum interest rate - present value discount - factor, Df works out to 2.8227 for 05 years of operating life of pumps). Discount factor shall vary and shall be as mentioned separately elsewhere or else to be calculated based on prevailing annual interest rate i.e. borrowing rate +1%. 8000 = Number of operating hours for one year,

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n = k+1

DF = ∑ [ 1÷ 1 + (R/100)n] n=2

where k = Number of operating years for which loading is to be done as

specified i.e. 5 years R = Percentage rate of interest (e.g.12%) DF = e.g. 3.2186

Note:

• In case of Fe – Fr is 0.5 KW or less, No loading

shall be adopted. • The maximum loading to be applied however shall not

exceed 10% of the total capital cost i.e. (A + C) as defined earlier.

Penalty Criteria

During shop performance tests, if the BKW consumed by the pump exceeds the stipulated guaranteed value, for every extra KW consumed over and above the guaranteed BKW, the vendor shall be penalized for extra power consumption as per following formula.

Penalty Computation

The penalty shall be worked out on the basis of differential operating cost (B) as under: P1t (in Rs.) = (Ft – Fg) X Cp X 8000 X Df

Where, Ft = Shaft at rated operating condition (corrected to pumping fluid) during test run. Fg = Guaranteed shaft power at rated operating condition as indicated in the purchase requisition Df = Discount factor (at 16% annum interest rate - present value discount - factor, Df works out to 2.8227 for 05 years of operating life of pumps). Discount factor shall vary and shall be as mentioned separately elsewhere or else to be calculated based on prevailing annual interest rate i.e. borrowing rate +1%.

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Note: • In case (Ft – Fg) is 0.5 or less, no penalty shall be applied. • During performance tests, if the BKW consumed by a pump

exceeds the stipulated guaranteed value at rated operating condition by more than 4%, the pump gets rejected.

• The maximum penalty to be charged for non-conformance to guaranteed values during the shop performance test of all pumps of an item number put together (i.e. all working & standby units) shall not exceed 10% of the total capital cost i.e. (A + C) as defined earlier.

8.0 SPARES

8.1 As a minimum vendor shall quote for all the spare parts as defined in

the attached list, as applicable to the proposed design of equipment, indicating their unit prices.

8.2 The cost of these mandatory spare parts shall be added to the

total cost for bid evaluation purposes.

8.3 The quantity of mandatory spare parts to be quoted shall be as defined in the attached list based on required quantity of equipment against each item (Tag No).

8.4 The offers not including the quote for these mandatory spare

parts shall be considered as incomplete offers, and shall be liable for rejection.

8.5 Vendor shall (apart from the mandatory spare parts) quote for

any additional spares (mechanical, electrical and instrument spares), which by his experience may be required for normal maintenance of proposed equipment, indicating the quantity used per machine, quantity recommended and unit price against each item. The list of such recommended spares shall be furnished separately along with the offer.

8.6 Wherever the word “SET” has been used under Part Description it means quantity sufficient for full replacement of that part in one machine.

8.7 Minor parts like fastening screws for wear rings, springs,

washers etc. for impeller nut, retaining rings, lock washers etc. for bearings, and similar other parts shall be considered to be included along with the main part and hence not listed separately.

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8.8 Spare parts shall be identical in all respects to the parts fitted

on the main equipment including dimensions, materials of construction and heat treatments.

8.9 Spare parts quotation shall list all the spares in the same manner

and order as indicated in the attached list with applicable quantity, and parts not applicable to the proposed design of equipment shall be clearly highlighted.

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MANDATORY SPARE PARTS FOR COMMISSIONING AND TWO YEARS OPERATION

SL. NO. PART DESCRIPTION

QTY. REQUIRED BASED ON TOTAL NO. OF PUMPS PER ITEM

1 2 3 4

5 6 A .

SPARE PARTS FOR PUMPS 1. Set of impellers (Full dia)

with wear rings fitted. 1 1 1 1 1 1

2. Shaft with keys

1 1 1 1 2 2

3. Set of shaft sleeves

1 1 1 1 2 2

4. Set of case wear rings

2 3 3 3 4 4

5. Set of impeller wear 2 3 3 3 4 46.

Set of throat bushing 1 1 1 1 2 2

7. Set of throttle bushing

1 1 2 2 2 2

8. Set of gaskets

3 4 6 6 8 8

9. Set of labyrinths – as applicable

1 1 1 1 2 2

10. Set of oil seals- as applicable

2 2 2 2 4 4

11. Set of constant level

il

1 1 1 1 2 2

12. Set of deflectors

1 1 1 1 2 2

13. Impeller nut

1 2 2 2 2 2

14. Set of mechanical seals (Complete assembly)

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a. With sleeve andgland plate (for cartridge

1 1 1 1 1 1

b. Without sleeve andgland plate for (non- cartridge

1 1 1 1 1 1

15. Set of mechanical seal parts :

a. Seal faces (stationary + rotary) *

2 3 3 3 5 5

b. Secondary seal 2 3 4 5 7 8 c. Gaskets/O-Rings &

Packings 2 4 5 5 8 8

d. Springs and pins, screws

2 2 2 2 3 3

• For bellows type seal, set of faces shall mean face along with

16. Set of gland packings

2 3 3 4 4 4

17. Set of bearing pads (if bearings are tilting pad type)

a. Radial bearing pads 1 1 1 1 1 1

b. Thrust bearing pads 1 1 1 1 1 118. Set of balance drum

and balance sleeve insert (if provided)

1 1 1 1 1 1

19. Set of interstage bushes 1 1 1 1 1 1

20. Complete coupling (balanced) (only for multi- stage pumps- pumps with more than

1 1 1 1 2 2

21. Flushing oil cooler

in case of Plan-23

1 1 1 1 1 1

22 Motor Spare- One Set of Bearings for each pump tag. i.e One Set for two identical motors.

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Abbreviations: BIS Bureau of Indian Standards BS British Standards BHN Brinell Hardness Number DP Dye Penetration STAAD Structural analysis and design computer program MDMT Minimum Design Metal Temperature TPlA Third Party Inspection Agency ASME American Society of Mechanical Engineers AWS American Welding Society CS Carbon Steel GAD General Arrangement Drawings ID Internal Diameter LSTK Lumpsum Turnkey MOC Material of Construction MR Material Requisition OD Outside Diameter PQT Procedure qualification test PQR Procedure qualification record PL Process Licensor PMC Project Management Consultant SS Stainless Steel TIG Tungsten Inert Gas

WPS Welding Procedure specification

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CONTENTS


1.0 GENERAL 4 2.0 MATERIAL SPECIFICATION 6 3.0 SUPPLY 12 4.0 FABRICAION 14 5.0 NON DESTRUCTIVE TESTS 23 6.0 HEAT TREATMENT 24 7.0 INSPECTION AND TESTING 25 8.0 STAMPING, NAME PLATES AND WARNING PLATES 28 9.0 PROTECTION AND DESPATCH 28

10.0 SUPPLIER’S GUARANTEES 29

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1.0 GENERAL

1.1 Scope

This specification covers the requirements for residual design, engineering, materials, fabrication, workmanship, inspection and testing of shell and tube heat exchangers and is intended to supplement the requirements of the applicable Codes. Specifications and standards wherever indicated in the requisition shall be followed unless stated otherwise.

This specification shall not be considered limiting and it shall be Supplier’s responsibility to comply with all requirements of requisition or bid documents to which it is annexed.

1.2 References

1.2.1 CODES AND REGULATIONS

The following codes in their edition referenced in drawings or data sheets or design basis along with the other specifications enclosed with the requisition shall form the basis for design, materials, fabrication, inspection, testing and acceptance of the equipment:

(a) ASME Boiler and pressure Vessel Code Section VIII Division 1 (Code), ASME Section II Part A, B, C and D, ASME Section V, ASME Section IX. (b) TEMA (Class as specified on the drawings or data sheets or design basis) (c) IBR, if applicable (latest edition with amendments up to date). (d) National and local laws or regulations, as applicable.

1.2.2 FOR HEAT EXCHANGER UNDER THE PURVIEW OF IBR:

(a) Supplier shall carry out design calculations as per IBR and only in case of any Doubt refer the same to Purchaser for clarifications. All materials fabrication, welding, testing etc. shall meet the requirements of IBR.

(b) In case the equipment is manufactured in India, the design calculations and fabrication drawings after preliminary review of Purchaser shall be got approved by Supplier from CIB of the State where Supplier’s shop is located, prior to start of fabrication. Supplier shall also provide the necessary assistance to Purchaser for obtaining approval from CIB of State of installation, such as

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providing additional copies of calculations and drawings etc. as required by CIB of that State.

(c) In case the equipment is manufactured outside India, the design calculations and fabrication drawings after preliminary review by Purchaser shall be got approved by Supplier from the agency authorized by IBR in the country of fabrication and the CIB of the State where the equipment is to be installed, before the start of fabrication.

(d) It shall be the responsibility of Supplier to incorporate modifications or additions required by CIB or its authorized agency and obtain the final approval. Purchaser shall be kept informed about these. All costs towards approval from CIB shall be borne by supplier. All IBR approved design calculations and drawings shall be furnished to Purchaser for final review of fabrication drawings and in equipment dossier.

1.3 Deviations

In general no deviations from datasheets, drawings, standards specifications and requisition shall be permitted. This does not preclude possible innovations or improvements by the Supplier based on available facilities. Such deviations must be clearly listed in the format “SCHEDULE OF DEVIATIONS” in the Supplier’s offer, so as to avoid any confusion and ambiguity and to facilitate analysis of offer in minimum possible time. It shall be taken for granted that except for the deviations listed under the “SCHEDULE OF DEVIATIONS” in the supplier’s offer, all other technical requirements shall be adhered to by the supplier.

Generally no deviations shall be entertained after the supplier has accepted the order unless it is to comply with statutory or Code requirements. Delay in supply of the equipment because of such deviations being not entertained or approved by Purchaser or any delay in processing the same by Purchaser shall be to Supplier’s account. Any additional design work in support of such a deviation shall be performed by the Supplier and submitted along with the deviation.

1.4 Contradictory requirements

In case of any contradiction between the requirements of the requisition, drawings and other documents forming part of the requisition, Supplier shall resolve the matter in consultation with Purchaser. Decision of Purchaser shall be binding and without any implication of cost and time, if not resolved at bidding stage.

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2.0 MATERIAL SPECIFICATION

2.1 General

2.1.1 All materials used for fabrication shall be new and of first quality. All materials and accessories required for the fabrication, inspection, testing etc. of the heat exchanger shall be supplied by the supplier unless otherwise stated. Whenever some material is to be supplied by the Purchaser, this shall be so indicated as Free Issue Material and the supplementary specifications in this regard shall be complied with.

2.1.2 In addition to the requirements of materials as per material specifications, materials shall also meet the requirements mentioned in this specification and other specification enclosed with the requisition. All materials shall be certified for compliance with IBR requirements for the item(s) so specified. While procuring materials, Supplier shall stipulate additional requirements such as limits on hardness, UTS yield strength, and chemical composition, heat treatment and any other specific requirements to ensure that final requirement as per specification and Code are met with.

All materials for pressure parts and parts welded to pressure parts including materials in the scope of sub-suppliers shall be accompanied with mill test certificates duly certified by a reputed third party inspection agency. In the absence of mill test certificate the material shall be got tested from IOCL approved third party inspection agency(TPIA) and test results shall be submitted in lieu of mill test certificate. All cost towards such testing and inspection shall be borne by the Supplier. All materials shall be inspected at Supplier and sub-supplier’s shop for verification prior to use on the job. The decisions of Purchaser / TPIA accept or reject materials on the basis of such testing shall be final.

2.1.3 Wherever simulated heat treatment of test specimens is required as per Code or specification, the simulation cycle shall include one extra cycle of stress relieving for any eventuality of repair at site by Purchaser during the life of the equipment.

2.1.4 MDMT shall be taken as 0ºC or the design temperature specified in drawing or datasheet whichever is lower, unless specified otherwise in design basis or datasheets or drawings. For low temperature service, all CS and LTCS materials for pressure parts and attachments to pressure parts shall be charpy V- notch impact tested. All LAS materials for pressure parts and attachments to pressure parts shall be charpy V-notch impact tested irrespective of the design temperature. Impact test temperature

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shall be lowest of minimum ambient temperature, design temperature and MDMT. Low temperature service shall be specified in datasheets.

2.1.5 PLATES

2.1.5.1 Pressure parts having thickness 16 to 50 mm (both inclusive) shall be Ultrasonically Tested (UT) as per SA-435.

2.1.5.2 Pressure parts having thickness > 50 mm shall be UT as per ASME SA-578 Level B.

2.1.6 TUBES

2.1.6.1 All the tubes shall be seamless and cold drawn.

2.1.6.2 Product analysis of tubes shall be carried out and reported in the material test certificates.

2.1.6.3 Tubes shall be in fully heat-treated condition as received from the mill. CS tubes shall be in annealed condition and copper alloy tubes shall be in annealed temper condition. LAS tubes shall be supplied in normalized and tempered condition.

2.1.6.4 All unstabilized SS tubes shall be supplied in the solution annealed condition and all stabilized grades of SS such as SS 321 and SS 347 shall be supplied in stabilized heat-treated condition, in addition to solution annealing.

2.1.6.5 It is preferable while ordering tubes, the maximum yield strength and hardness of tubes are specified such as to be lower than those of tube sheet, in order to achieve a sound expanded tube to tube sheet joint, complying with Code requirements.

2.1.6.6 “Air under water” testing shall be carried out for all tubes except non-ferrous tubes. As an alternative, tubes can be hydro tested. In case the tubes are hydro tested, hydro test pressure of tubes shall be higher of tube side test pressure or as required by code. Water quality shall be as per Para 7.2.1 of this specification.

2.1.6.7 FORGINGS

Forgings manufactured to SA-105 and SA-266 above 75 mm thickness (thickness as defined in para AM 200.2 of ASME Sec. VIII Division 2), all tube sheet forgings and all forgings of other materials, except for the standard nozzle flanges up to 8” NB and small forgings (of couplings, plugs and eye bolts) shall be 100% UT as per SA-388. Acceptance criteria shall be as per para AM 203.2 of ASME Section VIII Division 2.

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2.1.8 PIPES

Pipes shall be seamless and sizes above 1½” NB shall be hot finished. Dimensions and tolerances shall be in accordance with ASME 36.10 or ASME 36.19, as applicable, as per material specification.

2.2 Specific material requirements (Pressure parts and parts welded to pressure parts)

2.2.1 CS AND LTCS MATERIALS

(a) Carbon content shall not exceed 0.23%

(b) All plates shall be in normalized condition.

(c) Plates>50mm thickness shall meet following additional requirements of SA-20:

(i) Vacuum treatment as per the supplementary requirement S1. If vacuum degassing is not reported in the test certificates, then through thickness tests as per SA 770 shall be conducted and minimum reduction in area of 35% shall be ensured.

(ii) Charpy V-notch test as per supplementary requirement S5. Test temperature shall be lowest of minimum ambient temperature, design temperature, MDMT and minus 29o C for MDMT> or equal to 0o C. For MDMT less than 0o C refers clause 2.1.5. Impact energy values shall be as per Para UG-84 of code or applicable material specification, whichever is higher. Orientation of test bar shall be transverse to rolling direction.

(iii) Bend test as per supplementary requirement S14.

(d) Unless specified otherwise in requisition or bid document, all CS materials specified, as HIC tested shall meet the following requirements.

(i) Carbon equivalent shall be<0.40%. Nickel content shall be<0.2%.

(ii) Sulphur content shall be<0.002% for plates and<0.01% for tubes, pipes and forgings.

(iii) Hardness of plates and pipes shall not exceed 200 BHN, and that of forgings shall not exceed 187 BHN.

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(iv) Plates shall conform to SA 516 Gr 60/70 only .The plates shall be treated with calcium or other rare earth elements to create spherical inclusions instead of stringers.

(e) All LTCS and CS charpy plate material shall be made to fine grain practice and the primary austenitic grain size shall be measured and reported in mill test certificates. (f) CS pipes shall be SA-106 Gr.B. LTCS pipes shall be SA 333 Gr. 1 or 6. (g) Non-standard forgings (SA 266, SA 350 etc.) shall be normalised and tempered.

2.2.2 LAS MATERIALS

(a) All LAS plates, pipes, forgings and fittings shall be in normalised and tempered condition. Use of C-½ Mo material is prohibited. LAS materials shall be charpy V- notch impact tested. Test temperatures shall be lowest of minimum ambient temperature, design temperature, MDMT and -18ºC (0oC instead of –18oC for 5Cr-1/2 Mo materials). Impact energy values as per UG-84 or applicable specification, which ever is higher.

(b) In the case of 1 41 Cr-½ Mo materials and weldments, the maximum room

temperature tensile strength for all pressure containing components, materials and welds shall be 100000 psi.

(c) For LAS tubes (SA-199, 209 and 213) hardness test shall be performed on outside of the tubes as per SA-450.

(d) For LAS plates>50mm thickness, following supplementary requirements of SA- 20 shall also apply.

(i) Vacuum treatment as per supplementary requirement S1. If vacuum degassing is not reported in the test certificates, then through thickness tests as per SA 770 shall be conducted and minimum reduction in area of 35% shall be ensured.

(ii) Bend test as per supplementary requirement S14.

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2.2.3 SS AND OTHER HIGH ALLOY MATERIAL

(a) All SS material (300 series) shall be in the solution heat-treated (fully annealed) and prickled condition. All stabilized grades of SS (SS 321, SS347 etc.) shall be given stabilization heat treatment, in addition to solution annealing.

(b) SS (300 series) plates shall be hot rolled and shall have No. 1 finish on both sides.

(c) SS (300 series) materials for all components including non-pressure parts like baffles, tie rods, etc. shall be procured with the IGC test as per ASTM A-262 (test shall be carried out, after the specified heat treatment and sensitization per specification) with acceptable corrosion rate and practices as under:

i) For all services except nitric acid service, Practice E shall be followed. Specimen after exposure shall be bent as per requirements mentioned in A262 practice E and shall be inspected under magnification of 200X. The bent specimen shall be free of any cracks or grain dropping. The microstructure shall be submitted to TPIA for approval.

ii) Nitric acid service: Practice C with corrosion rate not > 25 mils per year.

(d) For straight chrome (13% Cr.) material, maximum carbon content shall be <0.06%. Hardness of UNS no. S41000 and S40500 shall be <85 RB.

2.2.4 NON-FERROUS MATERIALS

(a) All copper based non-ferrous plates shall be procured in annealed condition.

(b) Plates for pressure parts shall be 100% UT. Supplier shall submit the procedure for UT to TPIA for approval.

(c) In addition to hydro test, all tubes shall be eddying current tested in their final annealed condition.

(d) All pipe bends shall be stress relief annealed after bending.

(e) The paragraphs NF7 and NF14 in part UNF of Code are mandatory. This applies to non-ferrous cladding and weld overlay also.

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2.2.5 CLAD MATERIALS

(a) Cladding shall be integrally and continuously bonded to the base metal. All clad plates shall be rolled-on or explosion bonded type.

(b) Clad plates shall be UT from the cladding surface as per SA-578. Scanning shall be 100% of the plate surface. Acceptance standard shall be level B. Clad plates shall meet the supplementary requirements of S7 of SA-578. All UT shall be undertaken after specified heat treatment of clad plates.

(c) Both base material and clad material shall meet the specification of the respective materials as stipulated in this specification.

(d) Alloy clad steel plates shall be as per SA 263 or SA 264 or SA 265. Bond between cladding and the base metal shall be checked for a minimum strength of 14 kg/mm2 in shear for alloy clad steel plates, by conducting shear test as per applicable material specification.

(e) For copper alloy clad pates, the bond between cladding and base metal shall be checked for a minimum strength of 10kg/mm2 in shear by conducting shear test.

(f) During tension test of clad plates the cladding shall be removed and the tensile properties of the base material shall meet the code material requirements.

(g) For austenitic SS clad plates the SS surface shall be acid pickled as per ASTM A-380. For chromium steel clad surfaces the pickling shall be as per Supplier’s established procedure. The same shall be submitted to Purchaser / TPIA for approval.

(h) For clad components, Supplier to ensure that plate thickness after bonding and machining shall not be less than the thickness specified in drawings. Supplier to consider sufficient margin on clad and base material so that thickness after machining and complete fabrication shall be as per the drawings. For nozzles necks with weld deposit, sufficient margin on ID shall be taken to allow for shrinkage.

2.3 Non pressure parts

2.3.1 CS plates shall be minimum IS-2062 or SA 283 Gr. C or equivalent. Pipes shall be to IS 1239 or SA 53 or equivalent.

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2.3.2 Saddle material shall be same as that of shell for shell design temperature >350 °C.

2.4 Equivalent materials

The materials for various components in a heat exchanger shall be as per Purchaser’s requirements. This does not preclude use of equivalent or better materials. However, these deviations should be clearly indicated in the prescribed format. If an equivalent material sought by the supplier is to a specification, other than IS or ASTM or ASME, it is necessary for the Supplier to submit the specifications of the equivalent material with complete details in English for approval.

3.0 SUPPLY

Supply shall be in accordance with requisition or bid document to which this specification is attached. It shall however, include the following also:

3.1 Test ring assembly, dummy shell and test flange

a. Test ring assemblies, dummy shells and test flanges wherever required shall be designed and supplied by the supplier. The stresses shall not exceed 90% of the minimum yield stress of the material as stipulated in material specification. Material used for fabrication of these shall be of tested quality.

b. Test ring assembly construction shall be stuffing box type as per fig.E-4.13.2 of TEMA. It is preferred that the test ring flange thickness not exceed the shell cover flange thickness, otherwise, supplier to provide separate bolting for assembling test ring flange to shell. Similarly, supplier to check that the studs for stationary tube sheet bolting can be used with test flange. Else separate bolting shall be provided for assembling test flange.

c. For “I” type of floating head exchanger necessary washers, bolts and nuts for sealing of bolt holes in tube sheet to be provided during hydro test.

3.2 Accessories for testing

All necessary accessories such as supports, blind flanges, test gaskets, bolts, nuts etc. shall be provided and supplied by the supplier for testing of heat exchangers, in supplier’s shop and for subsequent testing by purchaser at site, whenever required.

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3.3 Other accessories

3.3.1 Supplier shall also supply tie bolts, leveling shims or intermediate supports for stacked units. Gaskets, nuts and bolts for interconnecting nozzles (both tube and shell side) along with spares shall be supplied by supplier. All these components shall be dispatched separately with due care having been taken regarding identification of these for ease of installation.

3.3.2 Earthing lugs shall be provided on each heat exchanger and shall be located in such a way as to avoid any fouling with the exchanger foundation bolts at site.

3.3.3 Supplier to supply one set of torque wrenches for bolt size M45 (1¾”) to M56 (2¼”) and one Bolt tensioner for bolt sizes greater than M56 (2¼”), in case these bolt sizes are being used in exchangers covered in the requisition. Bolt tensioner capacity shall be 40% more than the maximum load required for hydro test condition. Bolt tensioner pump shall be pneumatically and manually driven. Supplier shall supply one pump unit, required load cells and 4 heads of each size Torque values for tightening the bolts shall be mentioned in the fabrication drawings.

3.3.4 Davits, if required as per design basis or drawings, shall be provided.

3.3.5 Additions like cleats for piping, ladder, platform, insulation etc. that may be required at a later stage shall be provided.

3.4 Cathodic protection

Whenever cathodic protection is specified both sacrificial anodes and internal painting shall be provided.

3.5 Spares to be supplied by Supplier

3.5.1 BOLTING: 20% studs and nuts but not less than 4 studs with 8 nuts for each size.

3.5.2 GASKET: 400% gaskets other than those used for hydro testing and dispatch for each joint.

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4.0 FABRICAION

4.1 Edge preparation 4.1.1 For CS, the edges for welding shall be made by machining, chipping, cold shearing,

oxy-acetylene flame cutting or a combination of these. Chipping or cold shearing shall be followed by grinding to a smooth and regular surface. Oxy-acetylene flame cutting shall be followed by machining or grinding to eliminate any discoloration of material affected.

4.1.2 For LAS, the edges for welding shall be made by oxy-acetylene flame cutting or by machining. Cold shearing may be used for cutting thickness up to 10 mm. Oxy-acetylene flame cutting shall be used with preheat and shall be followed by machining or grinding to eliminate any discoloration of material affected.

4.1.3 For austenitic SS, the edges for welding shall be made by plasma arc, however, cold

shearing may be adopted for thickness up to 15 mm. In all cases the cut edges shall be ground back or machined back by 2 to 3 mm.

4.1.4 All welding edges after cutting shall be DP or MP examined for laminations, cracks or

segregation. Additionally UT shall be carried out within five times the material thickness of edge for LAS materials or when the service is low temperature or hydrogen or HIC.

4.2 Rolling and dishing of plates 4.2.1 ROLLING Rolling for bending and forming of plates shall be in the longitudinal direction of the

plates. This direction shall be clearly marked on the plates.

Re rolling after welding is not normally recommended. However, if for large diameter shells, rerolling of welded shell course is inevitable, procedure for re-rolling along with extent of NDT shall be submitted for approval of the TPIA. All welds on the section to be re-rolled must be ground flush. After re-rolling all the welds on the re-rolled section must be DP checked. Such welds shall then be subjected to radiography as required by drawings and Code.

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4.2.2 DISHING:

All dished heads shall preferably be of single piece construction. However dished ends with one chordal seam are acceptable for shells with diameter greater than 1 m. In such cases, the chordal seam shall preferably be in the middle one-third of the blank. Dished ends shall be torispherical (knuckle radius 15% of outside diameter and crown radius 80% of outside diameter) or 2:1 ellipsoidal. Dished heads shall be subjected to DP test on knuckle portions (both inside and outside) and weld edges after heat treatment. Supplier to ensure adequacy of indicated thinning allowance for dished head. If nominal thickness indicated is not adequate then the nominal thickness should be increased accordingly, keeping minimum thickness as per item drawing. A straight face of 38 mm or 3 times the nominal thickness of dished head, whichever is more, shall be provided, but maximum straight face shall be limited to 50 mm.

4.3 Welding 4.3.1 All welding and weld overlays shall be done with electrodes, fillers and fluxes of

reputed make with proven reproducibility of results. TPIA shall specifically approve brand names. For CS pressure parts, the electrodes shall be of low hydrogen type. IGC test as per ASTM A262 Practice E shall be done for austenitic SS consumables, which are to be used in application involving solution annealing. Austenitic SS consumables of low carbon and stabilized grade shall also be IGC tested as per ASTM A262 Practice E. straight chrome materials shall be welded with electrode that produces an austenitic chromium nickel weld deposit or a non air hardening nickel- chromium-iron weld deposit.

4.3.2 All welding procedures shall be submitted for approval by TPIA giving all relevant

details. Welding qualification records shall indicate hardness values of weld metal, HAZ and parent metal and also results of impact tests when design temperature are below 0o C or when specifically indicated for materials being welded. No welding shall be undertaken until TPIA has approved the welding procedure and welder’s qualification. All welding procedures and welders shall be qualified for the particular type of welding and material in accordance with the ASME Section IX. Supplier shall be responsible for the quality of the welds performed.

4.3.3 Pressure holding joints shall be Full Penetration Welded (FPW).Root pass of single

side welded joints shall be done with GTAW process. Backing strip for single side welded joints is not permitted. For LTCS materials, both inside and outside of welds shall be ground flush and dressed smooth. All internal welds in the shell shall be ground flush in order to insert and remove tube bundle. Also all internal welds shall be ground flush to the extent of facilitating draining of complete equipment. All other weld may be left in the de-scaled condition only.

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4.3.4 Longitudinal seams shall be staggered with the circumferential distance between the

centers of welds being at least 5 times the thickness of the thicker-plate. Weld seams shall be located so as to avoid interference with weld seam of nozzles and external attachments.

4.3.5 Attachment to pressure part shall be of same quality as the pressure part. All LAS weld attachments to pressure retaining component shall be FPW and ground to a smooth concave contour. External attachments like lugs, supports etc. of CS shall not be welded directly to high alloy or austenitic SS heat exchanger components. These attachments should be of the same material as the heat exchanger component. If this is not so, intermediate pad plate of the same material type as the heat exchanger component may be used. These pads shall be at least 100mm wider and longer than the attachment and shall be at least 5mm thick. Welding of CS or LAS to austenitic SS shall be done with austenitic SS electrodes or filler wire (AWS-ASTM-E 309L or E-309 Mo L only).

Wrapper plates, reinforcing pads, saddle plates or stiffeners of higher thickness than

specified can be used provided there is no change in basic dimensions and with the approval from TPIA. No separate deviation permit is required for the same.

4.3.6 Partition plates of CS and 300 series SS except for low temperature service, shall be welded to channels etc. by continuous fillet welds with minimum size of 6 mm on both sides. For all other materials and for hydrogen and low temperature services, all welds involving partition plates shall be FPW. However all pass partition plates shall be FPW up to a distance of 2” (50mm) from the gasket contact surface. Partition plates thicker than 10 mm shall be tapered to 10 mm at partition groove end except when mentioned otherwise on drawings. One weep hole of 6 mm diameter shall be provided at the center of each horizontal pass partition plate and a 5 mm radius notch on top and bottom point of each vertical pass partition plate for all multiphase exchangers for effective venting and draining.

4.3.7 Welding of shell to uncurbed tube sheet shall meet the requirements of Code

considering that the tube sheet is unsupported. 4.3.8 When impact tests are required on material as per Code or specification the welds

shall also be qualified for impact test. In such case following special requirement shall apply to the welding procedure qualification:

i) Qualification tests shall be made on plates of the ASME specification as specified for

the exchanger using welding electrodes of AWS of SFA specification and wire & flux of the specification and brand as are to be used on the job.

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ii) Welding current and travel speed shall be considered essential variables in order to ensure that production welding is substantially equivalent to the procedure qualification.

iii) Welded test plates shall be subjected to a total thermal cycle sequence similar to the

finished equipment. Specifically, test plates shall be held at intermediate and final stress relief temperatures for approximately the same length of time as the finished exchanger. Final cooling rate shall be approximate to that expected for the finished exchanger.

iv) Charpy V-notch impact tests shall be made on the weld and HAZ of the test plate for each welding procedure to be qualified. Test procedure shall be as per UG 84 of Code. Test temperature shall not be higher than MDMT. Impact energy requirements shall be as per Table 2.15 of SA 20 of ASME Section H Part A or UG 84 of Code whichever is higher.

4.3.9 WELD OVERLAY 4.3.9.1 Wherever cladding is specified in datasheets or drawings, weld overlays are not

acceptable. 4.3.9.2 Weld deposit overlay shall be done by a qualified a welding procedure and surface

shall be properly machined or ground flush after overlay. Minimum thickness of finished weld deposit shall be as indicated in the drawings or specifications. In case a higher deposition thickness and multiple weld layers are required to achieve the minimum specified undiluted deposit metal, the same shall be done only after taking prior approval from purchaser. Minimum thickness of undiluted finished weld overlay from top shall be 2 mm or as specified in the drawings. For non-ferrous weld deposit, the iron dilution should be restricted to 2.5% (maximum) in the finished undiluted layer (thickness defined above).

4.3.9.3 The weld overlay procedure shall be qualified on base metal of the same composition

as the exchanger component and meeting the requirements of ASME Section IX. 4.3.9.4 The weld overlay shall be relatively smooth with no notches and undercuts that would

act as stress raisers. All cracks, fissures and circular defects greater than 1/16 inch diameter shall be removed. Repaired areas shall be DP checked. Weld overlay shall be applied to base metal, which has been grit blasted and is smooth and clean so as to ensure full bonding. Welding overlay cladding shall be applied after any normalizing but before PWHT. The weld overlay shall consist of at least 2 layers.

4.3.9.5 The alloy cladding shall be cut back at all seams to permit back welding of the base

metal. Weld metal shall be ground flush and fully covered with the applicable weld deposit. The weld joint in base plate shall be 100% DP tested for detection of cracks

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and flaws before welding from clad side. The weld deposit shall be at least as thick as the cladding.

4.3.9.6 Shells, cones, dished heads and nozzles formed from clad plates shall be subject to

UT after forming, for a minimum of 10% of the clad surface, but no less than one square feet in each 10 square feet or fraction there of. Unbounded areas that cannot be encompassed by a 3-inch diameter circle shall be repaired by weld overlay. When repairs in excess of 5% of the total examined area are required, the complete component shall be subject to 100% UT. Repaired areas and weld deposit overlay at weld seams shall be DP examined. UT shall be repeated for dished heads after heat treatment. UT procedures shall be in accordance with SA 578 S6 for spot examination and SA 578 S7 for 100% examination.

4.3.9.7 All weld overlays shall be 100% DP examined in accordance with the method described in ASTM-E-165. The barrier layer shall be 100% examined. When the overlay involves multiple passes (layers) and the procedure uses an intermediate heat treatment with cooling to room temperature prior to applying the subsequent layer, each layer shall be examined by DP. Where overlay is to be machined such as for flange facing, machined surface shall be 100% examined after final PWHT. If overlay is examined prior to the final PWHT, overlay shall be spot examined (not less than 10% of the surface) after heat treatment.

4.3.9.8 Samples of the weld overlay shall be taken to perform chemical analysis to the

specified depth. The number and location of samples and method of taking samples shall be approved by TPIA. However, they shall be representative of each exchanger component for each type of welding process. Report of chemical analysis shall be submitted to TPIA for approval.

4.3.9.9 For all weld overlays used in hydrogen or H2S service with design temperature greater

than 350°C, Hydrogen disbanding test shall be carried out. The test condition shall be representative of the actual design conditions and the procedure shall be submitted to TPIA for approval. Rate of cooling shall be 100°C/hr (min.) unless specified otherwise in datasheets. Holding time shall be 48 hours unless specified otherwise in datasheets.

4.3.9.10 Product Test Coupons(PTC) are required for CS welds above 50 mm thickness and for

LAS welds above 25 mm or when required by the Code or when specified in the requisition. The following shall apply: -

a) Two PTCs representative of one longitudinal and another circumferential seam

shall be provided for each procedure, position and thickness.

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b) PTC shall be from material of the same heat and thickness as that of parent metal. During and after production welding PTC shall be subjected to same heat treatment as and together with the course they represent. Extra PTC shall be preserved to take care of eventuality of retests.

c) The tests mentioned below shall be carried out as per methods of testing in

Code:

i) One transverse tension test. ii) Two sides bend tests with weld located in the center of bend.

iii) One hardness test on PTC weld and HAZ. The acceptable limits

are 200 BHN for CS, 225 BHN for P3 and P4 materials and 235 BHN for P5.

iv) Micro and macro structural examination of welds.

v) For CS, charpy V notch tests on weld and HAZ shall be carried out. For MDMT<0°C, impact test temperature shall be MDMT. For MDMT> or equal to 0°C, the test temperature shall be 0°C. The acceptance criteria for impact energy shall be as per table a 2.15 of SA 20 of ASME Sec-II Part A or UG-84 of Code whichever is higher.

vi) For LAS, charpy V notch test on weld and HAZ shall be carried

out. Test temperature and acceptance criteria shall be as per clause 2.2.2 (d) (ii).

4.6 Nozzle flanges, nozzles and reinforcing pads

4.6.1 FLANGES

Unless otherwise indicated, dimensions, drilling, facing and tolerances for nozzle flanges (and blind covers if required) shall be as per ASME B 16.5 (for size up to 24” NB) and ASME B 16.47 series B (for sizes above 24” NB) for the respective class. Weld overlays, wherever specified or required, shall be in addition to the thickness as per these standards. Bolt holes on these nozzle flanges shall straddle principal vertical and horizontal centerlines or equipment. If the component to which nozzles are attached is subsequently stress relieve, it shall be Supplier’s responsibility to maintain true gasket faces by machining or otherwise. If distortion is expected, final machining

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operation should be done after stress relieving; Sufficient-machining allowance for this purpose should be available. Gaskets for flanges to ASME B16.5 and B16.47 shall be as per ASME B16.20.

4.6.2 NOZZLES 4.6.2.1 Nozzle pipes shall be attached to the heat exchanger components by FPW.

Attachment welds using only inner and outer fillet welds are not permitted. Unless otherwise indicated on the datasheets or drawings, necks of all nozzles shall be flush with the inside of the heat exchanger component. Inside corners of nozzle pipes at shell and channel inside diameter shall be flushed. All nozzles 2” NB and below, except long weld neck, shall have two stiffeners (30mm* 6mm) at right angles.

4.6.2.2 Whenever nozzle inside is required to be overlaid, these shall be done by weld overlay or cladding. Minimum nozzle ID before weld depositing to be 50 mm in such cases. Liners are not acceptable

4.6.3 REINFORCING PADS AND TESTING

Reinforcing pads whenever required as per drawings or Code shall be of the same material or equivalent as the heat exchanger component to which it is welded. All reinforcing pads shall be provided with two 1/8” (3 mm) NPT tapped holes located 180º apart for air soap solution test with a pressure of 1.25 kg/cm2 (g). This test shall also be required to be carried out for slip on flanges. Higher test pressures are not recommended because of accompanying risks and also because the soap bubbles have a chance to blow off. Tell-tale holes in the reinforcing pads shall be plugged with hard grease unless otherwise indicated after the hydro test of the exchanger.

4.7 Bolts, studs etc. and tapped holes

4.7.1 All fasteners shall have metric threads and shall conform to ISO-R261 except for size M24 and above, where it shall have 3 mm pitch.

4.7.2 Studs shall extend beyond the nut by about 10mm and shall be threaded full length

except when square ends are required for use with BTD, in which case the extension shall be as per BTD manufacturer’s recommendation. The studs for extended tube sheets and the studs for use with connecting piece shall also have square ends.

4.7.3 All nuts shall be of heavy series only and nut-seating faces shall be machined or spot

faced.

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4.7.4 Threads on external bolting, plugs etc. shall be lubricated with graphite grease for working temperature up to 200°C and with Molybdenum Disulphide for higher temperatures.

4.7.5 Tapped holes on the channel side face of clad tube sheet for removable bundles shall

be fitted with plugs of a material similar to channel side material in contact with tube side fluid.

4.7.6 For extended tube sheets, tapped holes shall be provided for girth bolting. 4.7.7 All floating head bolting to have 2 mm wide and 0.5 mm deep groove at both ends to

prevent mix up with other blots. 4.7.8 In addition to stamping, the specifications and manufacturers symbol as specified in

ASME material specifications, on one of the ends the size of the studs shall be clearly punch marked. Similarly the nuts shall give the size punch marked on one of the faces. In case of tapped hole the size shall be punch marked near the hole without disturbing the gasket seating area. Further for all alloy/SS metallurgy bolts & nuts shall also be identified by distinct colour marking at the stud end/bolt side face.

4.8 Assembly and handling 4.8.1 Supplier shall be responsible for taking adequate preventive measures to ensure the

quality and finish of materials and to avoid any rusting. 4.8.2 Suitable method of alignment like dowels etc. shall be provided for proper assembly of

channel, channel covers, stationary tube sheet etc. 4.8.3 Stacked exchangers shall be assembled in the shop for a trial fit. Special care shall be

exercised in truing up connecting nozzle flanges. 4.8.4 ‘T’ wherever indicated on drawings, denotes match mark for assembly and shall be

punched on all mating parts. 4.8.5 Lifting lugs shall be provided as per standard for lifting of channels, channel covers,

floating heads, shell covers, test rings, test flanges etc. 4.8.6 In case of removable bundles the following are required:-

(a) Stationary tube sheets shall be drilled and tapped at vertical (0°) position for attaching eyebolts; or a lifting lug of adequate thickness shall be welded with 25 mm (minimum) diameter hole.

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(b) Drilling and tapping as above shall be carried out on floating tube sheet.

(c) Last support plate shall be drilled (25 mm diameter hole) for lifting the assembled bundle. Local stiffening may be necessary to withstand the bundle load, which shall be designed by the Supplier.

4.8.7 Pulling eyebolts made from forged CS shall be provided for all removable bundles.

These shall be sent loose along with the spares. Insert piece shall be provided for all clad tube sheets. Material of insert piece shall be same as that of cladding material.

4.8.8 Stationary tube sheet shall be drilled and tapped for tie rods. Care should be taken to

ensure that holes are not drilled through.

4.8.9 Interchangeable and 180° rotatable bundles shall have common pass-partition groove arrangement in the respective tube sheet. For exchangers where bundles are specified to be interchangeable, the same shall be ensured at the supplier’s shop by actually inserting the bundles or using a template consisting of 4 full diameter baffles, each spaced at a distance equal to the baffle pitch.

4.8.10 Jackscrews shall be provided on all girth flanges. 4.9 Descaling, pickling and passivation shall be done for all SS parts in accordance with

ASTM A-380. The Supplier shall furnish details of the procedure for approval to TPIA. 4.10 No distortion whatsoever shall be permitted on the gasket seating surfaces due to

tube-to-tube sheet welding, shell to tube sheet wilding, PWHT etc. If distorted, the same shall be machined subsequently.

4.11 Fabrication tolerances and finish 4.11.1 The dimensional tolerances shall be within the limits indicated on drawings and

standards. Where tolerances are not specified, these shall be in accordance with the requirements of TEMA and Code.

4.11.2 All edges and corners including baffle holes shall be deburred (or rounded, if shown). 4.11.3 Finish of all machined components shall be minimum 12 microns (500 RMS) unless

otherwise indicated. Parts subjected to UT shall have minimum finish of 6 microns. 4.11.4 Tube sheet face shall be flat within +/- 1.5 mm (camber).

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5.0 NON DESTRUCTIVE TESTS 5.1 All the NDT procedures shall be submitted to TPIA for approval. For all NDT activities,

only qualified NDT technician shall be deployed with the approval of TPIA. 5.2 The extent of radiography shall be as specified in datasheets or drawings or job

specification. Radiography shall be performed after PWHT. In case radiography is carried out before PWHT, then UT shall be carried out on the welds after PWHT.

5.3 Minimum extent of radiography shall be spot, unless full radiography is specified in the

drawings or required as per specification or Code. Spot radiography shall mean that at least 5% of the total welded length must be radiographed. Further, all ‘T’ joints must be radiographed and at least one shot must be taken on each longitudinal and circumferential seam. This requirement shall supplement the ones specified in Code. TPIA shall be consulted in marking the areas to be radiographed.

5.4 Full radiography when specified shall imply 100% radiography of all butt welds including nozzle flange to nozzle neck, pipe to pipe and pipe to fitting.

5.5 All welds of nozzle necks fabricated from plate, irrespective of diameter, thickness of

plate and radiography specified, shall be 100% radiographed. 5.6 Weld seams of formed heads shall be 100% radio graphed after forming and heat

treatment. 5.7 All nozzles to shell welds and unhubbed tube sheet to shell welds shall be DP or MP

checked at the root run and final weld. 5.8 All welds, which cannot be fully radiographed such as nozzle to shell, shell to

unhubbed tube sheet, unhubbed floating head to cover etc., shall be 100% UT after final PWHT. Fillet welds and welds which cannot be radiographed or UT (i.e. pass partition plate to channel and floating head etc.), the root run shall be DP checked and the welds shall be finally MP checked after PWHT.

5.9 All attachment welds shall be either DP or MP tested. 5.10 If radiography is being substituted by UT for the final closing seam as permitted by

Code, MP shall be carried out in addition to UT.

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6.0 HEAT TREATMENT 6.1 PWHT shall be done if required by datasheets, drawings, and specifications, Code etc.

PWHT when mentioned on the drawings shall be over and above the requirements of specifications or Code. No. Welding or heating is permitted after PWHT. All machining operations shall preferably be carried out after PWHT (also refer clause 4.6.1). It shall be the responsibility of the supplier to leave sufficient allowance for this purpose. Supplier shall submit all the procedures for PWHT to TPIA for review.

6.2 During PWHT of assemblies of fixed tube sheet exchanger, care shall be taken to

ensure that differential stresses are not caused between tubes, shell and tube sheet. The temperature differential between shell and tubes during PWHT to be minimized (not to exceed 25°C) and the rate of heating and cooling shall not exceed 25-30°C per hour. For this purpose, thermocouples shall be installed on various components and compliance assured.

6.3 Heat treatment of SS clad assemblies shall be at reducing temperature to avoid

sensitization of SS materials. The soaking time shall be increased accordingly as per Code.

6.4 Heat treatment of non-ferrous clad assemblies, if required, shall be performed with

extra care, at reduced temperatures to avoid differential thermal expansion. The soaking time in such a case shall be increased accordingly as per Code.

6.5 Heat treatment of CS and LAS dished heads shall be as follows:

a) Stress Relieving for:

(i) Cold formed dish heads up to 16 mm thick. (ii) Cold formed floating head cover up to 16 mm thick if fiber stretch

exceeds 5%.

b) Normalizing for CS and normalizing and tempering for LAS:

(i) Hot formed dish head and floating head dish if not formed in normalizing range.

(ii) Cold formed dish heads for thickness greater than 16 mm.

(iii) Cold formed floating head dish above 16 mm thick.

This heat treatment need not be given if same heat treatment is given subsequently on

sub-assembly. Thicknesses specified above are nominal.

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6.6 SS components shall be solution annealed in the following cases.

i) Cold formed dished heads with nominal thickness of 16 mm or above. ii) Hardness value of dished heads after cold forming exceeds 235 BHN.

iii) Hot formed shells, cones, dished heads.

After any heat treatment on austenitic SS, IGC test shall be carried out as per clause 2.2.3 (c)

6.7 All LAS welds shall be PWHT.

6.8 If stress relieving is indicated on shell side or tube side and the service on either side is the welded tube-to-tube sheet joints of CS or LTVS material shall be stress relieved, lethal or low temperature or if specifically indicated in the datasheet or drawings, the welded tube to tube sheet joint of CS or LTCS material shall be stress relieved.

6.9 For LAS materials, pre-heating procedure shall be established in the welding procedure and got approved by TPIA. Pre-heating by resistance or induction heating method is preferred. Preheating shall extend uniformly to at least three times the thickness of joint but not less than 50 mm on both sides of the weld. Temperature indicating crayons shall be used for assessment of correct pre heat temperature.

7.0 INSPECTION AND TESTING 7.1 Inspection

7.1.1 The inspection shall be carried out by TPIA. The materials, fabrication and testing of exchangers shall be open to inspection by TPIA in addition to any inspection required by the specified Code or local authorities having jurisdiction over the installation.

7.1.2 Inspection shall be carried out both during fabrication and before delivery and also for

sub ordered materials. In addition to final inspection and certification by TPIA during the course of manufacture, TPIA’s written approval shall be obtained by the supplier at various stages of fabrication. For this purpose, supplier shall prepare his QAP, defining the stages of fabrication, hold points for his own inspection and that by the TPIA or Code or statutory authorities etc. the QAP shall be discussed with TPIA before start of

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job and mutually agreed. The various stages of fabrications to be inspected (either by Supplier or TPIA or both) shall include but not limited to the following:

(a) Raw material identification and verification of mill test certificate. (b) Edge preparation for welding, including visual check for laminations.

(c) Alignment of longitudinal and circumferential seams.

(d) Rolling tolerances on individual section.

(e) Alignment and fit up of sections and components.

(f) Root passes clearance before further welding and cleaning.

(g) Profile and thinning of dished ends and toriconical pieces after forming.

(h) Checking of tube sheet after drilling including checking of tube layout

patterns, tube holes, pass partition locations, visual check for laminations.

(i) Tube sheet to shell set up for fixed tube sheet exchangers, prior to welding.

(j) Tube to tube sheet joint expansion or welding.

(k) Visual check of shell inside and tube bundle insertion.

(l) Welding of expansion bellows or joints, if required.

(m) Review of NDT reports and heat treatment charts.

(n) Final visual and dimensional inspection.

(o) Witnessing of hydro test. 7.1.3 The presence of TPIA shall not modify or reduce the obligation of the supplier to carry

out his own tests and control. If any material and/or equipment are not found in compliance with the specified requirements, TPIA or his delegate shall be entitled to irrevocably reject them even if such non-compliance has not been evidenced in the course of inspection and/or tests.

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7.1.4 TPIA will, at the time of his initial visit, set up with the supplier actual details of inspection stages to be witnessed or carried out; the schedule of future visits and subsequent inspection notices can be arranged between TPIA and the supplier.

7.1.5 The supplier shall notify TPIA sufficiently in advance of any fabrication operations to permit arrival at the supplier’s shop in time to witness these.

7.1.6 The supplier shall provide to TPIA, free access to his shops at all times. He shall also

supply all tools and tackles to TPIA for carrying out the inspection. The supplier shall also arrange for similar facilities at his sub-contractor’s shops.

7.1.7 The supplier must satisfy TPIA that the welding procedures, welders, electrodes,

fluxes, welding wires etc. are in accordance with the requirements of the Code and specifications. Further the welder’s qualification test must be carried out in the presence of TPIA.

7.1.8 Prior to final inspection, all slag, weld spatter loose scale, dirt, grit, paint, grease, oil

and other foreign matter shall be removed in order to facilitate inspection. All reinforcing pads and slip on type flange welds shall be pressure tested with air and soap solution before and after heat treatment (if any) and before final hydrostatic test.

7.1.9 A dimensional check of equipment shall be carried out taking into account the

tolerances shown on drawings, standards, specifications or code, the more stringent valued shall govern. Dimensional checks are to be taken of the internal measurements of equipment together with external ones and these are to be recorded on the drawings as being the “As Built” dimensions.

7.2 Hydrostatic tests 7.2.1 Hydrostatic tests shall be witnessed by TPIA. When hydrostatic tests are performed

the indicating gauge shall be connected to the upper most part of the equipment. Testing water shall be clean potable water. Seawater shall not be used. For SS equipment, water used for these tests shall not contain more than 25-ppm chlorides. Minimum metal temperature during hydrostatic test shall be 20 C. Test pressures shall be maintained for at least one hour. Shell and tube sides shall be tested separately, unless otherwise mentioned on the drawing. For tube sheets designed for differential pressure, special care shall be taken during testing. Equipment drawings shall clearly indicate if tube sheets have been designed for differential pressure. Drying out as per clause 9.1 shall be carried out immediately after hydro test.

7.2.2 All vertical exchangers shall be tested in vertical position. Alternatively, exchanger may

be tested in horizontal position with test pressure modified with prior approval of designer.

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7.2.3 Stacked exchangers with nozzles interconnected shall be hydro tested in stacked

condition except when the hydro test pressure of the individual exchanger is different. 8.0 STAMPING, NAME PLATES AND WARNING PLATES 8.1 Each exchanger shall be fitted with an SS nameplate. 8.2 Warning plates, if required, shall be provided. 8.3 The following exchanger parts shall have the item number stamped except for heat

exchangers in low temperature service in which case the item number shall be marked with non-removable ink:

Shell girth flanges, shell cover flange, channel girth flanges, flat channel cover,

stationary and floating tube sheets, floating head cover flange, floating head backing ring, connecting pieces, test rings, test flanges and other main removable parts.

9.0 PROTECTION AND DESPATCH 9.1 After completion of all testing and inspection, the inside of complete equipment shall

be thoroughly drained and dried out. Equipment shall be completely dried by passing hot air for sufficient time until no further increase in relative humidity of outgoing air is observed. Dry out shall be done simultaneously on both shell and tube sides. After drying, the equipment shall be purged and filled with dry N2 at 0.25 kg/cm2. The equipment shall be provided with pressure gauge to monitor N2 pressure, and ½” non-return valve. All threaded holes; other than tell tale holes for testing, shall be suitably protected with steel bar plugs. All nozzles not provided with blind flange shall be provided with steel covers, temporary gaskets and bolts.

9.2 Shop painting

All CS and LAS external surfaces, except gasket faces and machined surfaces shall be primer painted. Surfaces to be painted shall be prepared for painting by removing loose mill scale, rust, oil, grease and other films or substances harmful to the adhesion of paint by an approved method such as shot blast cleaning. The surface shall be prepared to near white finish as per SA 2 ½.The primer shall be inorganic zinc silicate (65-75 microns dry film thickness), unless stated otherwise. Two coats (min. DFT 70 microns) of Aluminium paint to be provided as finished paint.

9.3 The equipment item number, PO number and Purchaser name and address shall be painted in bold white paint letters written with stencil, on the heat exchanger. Sliding

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end of exchangers shall be painted as “CAUTION-SLIDING END” in black on the primer coating in the shop.

9.4 Dispatch of equipment

No heat exchanger shall be released for shipment until it has been approved by TPIA. Heat exchangers shall be dispatched after the operations as required by clauses 9.1, 9.2 and 9.3 have been carried out and shall be dispatched in as-tested condition. In case stacked exchanger shells are dispatched separately the supplier shall provide additional set of gaskets for interconnected nozzles other than the gaskets included in spares. Heat exchangers shall be securely anchored for dispatch in order to prevent any shifting and damage during transportation. Expansion joints and bellows shall be suitably protected against any possible damage by providing tie bars before boxing up. Packaging shall be suitable for rail or road transport and also sea worthy if transported by sea. Spares shall be dispatched separately in a box and marked with PO number, item number and Purchaser’s name and address.

Supplier shall provide sling mark identification on all heat exchangers with respect to center of gravity of the equipment.

No equipment shall be dispatched until a written clearance is obtained from Purchaser regarding piping clips and structural cleats on individual equipment.

10.0 SUPPLIER’S GUARANTEES

The supplier shall be completely responsible for the compliance to code requirements, residual design, detailing, fabrication, materials and workmanship of the exchangers as per the stipulations of the requisition and its attachments. In this regard, it may be noted that review by Purchaser or authorized representative shall not relieve the supplier of his responsibility of meeting all requirements and ensuring satisfactory performance of the equipment. Guarantee period shall be as per GPC of Purchase

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SAFETY RELIEF VALVES

SAFETY RELIEF VALVE

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Abbreviations: BIS Bureau of Indian Standards BS British Standards BHN Brinell Hardness Number DP Dye Penetration STAAD Structural analysis and design computer program MDMT Minimum Design Metal Temperature TPlA Third Party Inspection Agency ASME American Society of Mechanical Engineers AWS American Welding Society CS Carbon Steel GAD General Arrangement Drawings ID Internal Diameter LSTK Lumpsum Turnkey MOC Material of Construction MR Material Requisition OD Outside Diameter PQT Procedure qualification test PQR Procedure qualification record PL Process Licensor PMC Project Management Consultant SS Stainless Steel TIG Tungsten Inert Gas WPS Welding Procedure specification

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CONTENT


1.0 GENERAL 4 2.0 VENDOR'S RESPONSIBILITIES 4 3.0 CODES & STANDARDS 5 4.0 DESIGN BASIS 5 5.0 VALVE CONSTRUCTION 6 6.0 NAME PLATES 7 7.0 INSPECTION 8 8.0 PACKING AND SHIPPING 9 9.0 DOCUMENTATION 9

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1.0 GENERAL

1.1 This specification together with the data sheets enclosed herewith covers the basic requirements for design, construction, testing and performance of safety relief valves.

1.2 Deviations from these specifications and respective valve data sheets are not allowed unless prior approval from IOCL has been taken.

1.3 Items shall be provided with proper anticorrosion protection. For offshore applications, the equipment shall also be suitable for the humid and saline atmosphere.

2.0 VENDOR'S RESPONSIBILITIES Vendor shall be responsible for supplying right size and type of safety relief valves to suit the process conditions specified in the respective data sheets.

2.2 Along with offer: 2.2.1 Vendor shall furnish signed and stamped copy of this technical specification as a token

of acceptance along with their techno-commercial offer failing which their offer shall be rejected Deviation, if any shall be clearly spelt out on separate sheet.

2.2.2 Along with the quotation, the bidder shall submit 2 sets of drawings, furnishing the cross-

sectional details of the valves and the material list. 2.2.3 The bidder shall furnish documentary proof of capacity certification for PSV (in

combination with Rupture Disc wherever applicable), issued by ASME certified body, along with the offer.

2.2.4 The bidder shall furnish the cross-sectional drawings of the offered PSVs and Rupture

Discs (wherever applicable) along with the offer. 2.2.5 Bidder shall furnish the orifice sizing calculations for every individual PSV, including the

calculated discharge area, selected area, orifice designation, inlet and outlet calculations, actual relieving capacity and cold bench test pressure as minimum, along with the offer.

2.3 Approval of Design / Drawings:

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The PSV/ TSV data sheet and drawings shall be submitted to IOCL for approval. However, IOCL approval does not absolve the party from the design responsibilities.

2.4 Deviations, if any, shall be listed /highlighted in a separate sheet.

3.0 CODES & STANDARDS Vendor shall follow the latest editions of the following codes & standards as applicable:

a) API RP - 520, 521, 526, 527 b) ASME Section I and VIII c) API Standard 2000 d) ANSI B 16.5 e) ANSI B 16.20 f) ANSI B 1.20.1

4.0 DESIGN BASIS

4.1 The basis of design and selection of safety relief valves shall be in accordance with

latest edition of API RP520 - sizing, selection and installation of pressure relieving devices in refineries, the latest revisions of ASME boilers and pressure vessels code and Indian Boiler Regulations.

4.2 Wherever it is specified in the data sheets, safety relief valves shall be marked and certified in accordance with the ASME boiler and pressure vessels code / IBR code.

4.3 The calculated orifice areas, if given, in respective data sheets are indicative only. Vendor shall calculate the orifice areas as per the process data furnished and select the safety relief valves accordingly. Vendor shall furnish sizing calculations to IOCL for approval.

4.4 For two phase liquid / vapour relief application, the total orifice area shall be the sum of

the orifice areas calculated individually for liquid and vapour. 4.5 Percentage of over pressures used in calculating the sizes area as under :

a) Steam boilers (ASME code) 3%

b) Steam boilers (IBR code) 5%

c) Gas or vapour service and liquid 10%

except as noted below in (d)

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d) Fire exposure on unfired pressure 21%

vessels with vapour

4.6 Body drain with a plug shall be provided as a standard feature on every pressure relief valve.

4.7 Wherever stelliting of disc and nozzle has been specified, it stands for stelliting of the seat joint and the entire disc contour, unless otherwise specified.

4.8 Lifting levers shall b provided for valves used for steam service.

4.9 Bonnet shall be of the enclosed type in general. Open bonnet shall be used only for steam service.

4.10 Whenever the specified set pressure exceeds 70 kg /cm2g, vendor shall submit the

leakage rate of valves for approval of purchaser. 4.11 Where bubble tightness is specified, there shall be no leakage or bubbles of air at the

specified percentages of set pressure. 5.0 VALVE CONSTRUCTION

5.1 In general the material of construction shall be cast carbon steel (ASTM A216 Gr WCB)

for body, SS316 (forged) for trim and cadmium plated CS for spring, unless otherwise specified on the datasheets. Tungsten alloy steel springs shall be used for temperature above 230 deg. C.

5.2 For safety relief valves in sour service a) Carbon steel/Duplex SS /Incoloy 825 shall meet the requirements of NACE MR-

01-75 latest edition and other job specific requirements as mentioned in datasheets.

b) Materials other than CS/Duplex SS / Incoloy 825 shall meet the requirements of

NACE MR-01-75 latest edition and all the castings and welding shall be 100% radio graphed.

5.3 Normally full nozzle, full lift type valves shall be supplied for sizes 1" and larger./ the

nozzle bushing shall extend through and beyond the inlet flange base and shall form the gasket bearing surface for the inlet flange.

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5.4 Flanged safety relief valves shall have enclosed spring bolted bonnet, screwed cap with a tapped and plugged vent for easy conversion to balanced bellows type valves.

5.5 Bellows safety valves shall be considered wherever back pressure exceeds 10% of the set pressure. Bellows material shall be same as trim material as a minimum.

5.6 Open bonnet type safety valves along with lifting lever shall be used for water above 60 degC, air and steam services.

5.7 Flanged connections shall be as per ANSI B16.5 and the rating shall be as per the piping specifications as indicated in the data sheets. However, vendor shall confirm the flange ratings as per his sizing calculations.

5.8 Centre to centre dimensions shall be as per the latest edition of API Std 526. 5.9 Testing for seat tightness shall be accordance with the latest edition of API Std.527. Soft

seating (coring) shall be provided wherever tight shutoff is called for. 5.10 Safety relief valves for set pressure of 17.5 kg/sq.cm. (250 psig) or less shall have

springs suitable for a range of adjustment of plus or minus 10% of the set pressure. 5.11 Safety relief valves set at pressures higher than 17. 5 Kg/Sq.cm.g(250 psig) shall have

springs suitable for range of adjustment of plus or minus 5% of the set pressure. Range identification shall be provided on the spring.

5.12 The allowable tolerance in set pressures are as below :

a) + 0.14 kg/cm2g for set pressure upto and including 5 kg/cm2g. b) + 3% for set pressure above 5 kg/cm2g.

5.13 Safety relief valves shall be provided with tamper proof seals after factory set calibration.

6.0 NAME PLATES

Each valve shall have SS name plate (Tag details) permanently fastened to the body and shall include the following :

a) Manufacturer's Name and trade mark b) IOCL material SAP code . c) Valve Tag No. d) Serial number and type

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e) Orifice designation f) Valve inlet and outlet connection sizes and ratings g) Valve body, spring and nozzle materials h) Set pressure i) Back pressure j) Relieving temperature k) Cold differential test pressure l) Test Medium m) ASME Code stamp shall be furnished with the safety relief valve (Type test only)

: If specified in datasheet.

7.0 INSPECTION

7.1 Vendor shall provide all facilities free of cost to IOCL or their authorized representative to conduct following tests at vendor's works:

a) Material Body, trim etc.

b) Physical Visual and dimensional as per

API/ASME/ASTM stds.

c) Hydraulic Leakage test at 1.5 times the maximum

Working pressure for inlet flange and nozzle

d) Seat tightness test e) Set pressure test.

The valve shall be tested for opening at specified set pressure and also for seat tightness.

Third party inspection shall be done by IOCL approved third party inspection agencies and scope of inspection as per the attached Annexure – I (Quality Assurance plan for safety relief valve /Thermal relief valve.)

8.0 PACKING AND SHIPPING

8.1 All threaded and flanged openings shall be suitably protected to prevent entry of foreign material during shipment.

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8.2 Valves shall be supplied as a whole, complete with all accessories like cap, lifting lever, test gauge etc.

9.0 DOCUMENTATION

9.1 Along with offer :

Vendor shall furnish signed and stamped copy of this technical specification as a token of acceptance along with their techno-commercial offer failing which their offer shall be rejected [Deviation, if any shall be clearly spelt out on separate sheet].

9.2 Approval of Design /Drawings:

The PSV/TSV data sheet and drawings shall be submitted to IOCL for approval. However, IOCL approval will not absolve the party from the design responsibilities.

9.3 Final documentation. Vendor shall supply three (3) bound copies and 1(one) soft copy of data folder containing the following information:

a) Approved PSV/TSV data sheet b) GA drawing c) Test reports of set pressure, back pressure test, seat tightness pressure test etc. d) Hydrostatic test reports. e) Third party inspection certificates along with release note in original on their letter

head.

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TRAYS AND TOWER INTERNALS

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CONTENTS


1.0 INTRODUCTION 4 2.0

DEFINITIONS

4

3.0 SCOPE OF WORK 4 4.0

DESIGN

6

5.0

FABRICATION AND SUPPLY

18

6.0

INSPECTION AND TESTING

22

7.0

SITE INSTALLATION AND SUPERVISION

25

8.0

VENDOR DATA REQUIREMENT 27

9.0

SHIPPING

27

10.0

SUBMISSION OF BIDS

28

11.0

GUARANTEE REQUIREMENT

29

12.0

AS BUILT DOCUMENTATION

29

13.0

DATA FOLDER

30

14.0

LIST OF ATTACHMENTS

30

ANNEXURE - I VENDOR DATA REQUIREMENTS

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1.0 INTRODUCTION

This specification covers the general requirements for hydraulic and mechanical design, engineering, procurement of material, fabrication, inspection/testing, packing, supply and installation (in the columns at site) of Trays, Packed Column Internals and Structured Packing separately and collectively known as "Internals". The requirements laid down in this specification are the minimum requirements. Supplementary specifications indicating special or specific requirements, wherever applicable, shall form addenda to this specification and shall govern whenever in conflict with the provisions contained herein. Addenda, when made part of this specification, shall be referenced in the Material Requisition and/or the Purchase Order.

2.0 Definitions : 2.1 Definitions:

• OWNER - shall mean IOCL

3.0 SCOPE OF WORK 3.1 The illustrative scope of work and major responsibilities of Internals vendor are given in

clauses 3.1 to 3 . 13. All other activities required to ensure the proper design and operation of the Internals over the entire range of loadings, whether explicitly stated or not, are implied.

3.2 Vendor shall carry out the hydraulic design of trays, associated Internals like collector

trays, internal piping, feed arrangement, demisters, de-entrainment baffles etc. In case of packed beds, the design shall include packings selection, pressure drop calculations, capacity check, heat transfer adequacy check and design of associated support plates, bed limiters, liquid distributors, pipe headers, vapour distributors, collector trays, spray nozzles etc.

3.3 Vendor shall Review process nozzles size and elevations given in the Column Drawing

by OWNER and suggest necessary changes based on the column internal design. The orientation of the nozzles shall be given by the vendor for review to the OWNER.

3.4 Vendor shall submit the hydraulic design in the form of the data sheets for trays and

packed columns respectively to the OWNER for approval. These data sheets along with back-up calculations/computer outputs shall be submitted for review prior to proceeding for mechanical design of Internals.

3.5 Vendor shall carry out the mechanical design of Internals including packing, distributor,

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tray support rings, bolting bars, other supports etc. for the type and quantum of design loadings covered elsewhere in this specification. The Mechanical design calculations shall be submitted to OWNER for approval.

For Tray supporting ring and bolting bar, refer Engineering spec RHQ-EC-ML-SP-0022.

3.6 Vendor shall prepare the t ray support rings/support cleats, and bolting bars drawings for fabrication. The details shall be submitted to OWNER. OWNER shall co-ordinate with pressure vessel vendor for nozzles orientations and welding of the support rings/support cleats and bolting bars etc. Any changes required by Pressure Vessel Vendor shall be communicated by OWNER. The same shall be reviewed by the Internal Vendor and implemented accordingly. The set of drawings for support rings/support cleats shall include the following as a minimum: • Column sketch indicating location and orientation of Tray support ring. • Support Ring plan with location of bolting bars, slot centres and applicable tolerances. • Sectional details with applicable tolerances. • Material of construction. • Extent and details of welding requirement for support rings/bolting bars/support cleats. • Inlet feed pipe arrangement details. • Nozzle orientation. • Feed/Distributor pipe support details required to be welded by Pressure vessel

vendor.

3.7 Vendor shall prepare the detailed General Arrangement Drawings (GAD's) of all the Internals along with part detail/ fabrication drawings and Bill of Material. These drawings shall be submitted for approval to OWNER, prior to start of the fabrication, as per Vendor Data Requirements. The GAD's for Internals shall include the following as a minimum:

• Column sketch indicating Tray/tower internal elevation. • Fully dimensioned PLAN v i e w clearly showing t h e layout of Tray panel,

down-comers, weirs, valves, bubble caps, orifices, risers or as the case may be. (Part Plans are NOT ACCEPTABLE)

• Sectional views illustrating the installation of internals. • Mechanical design parameters such as beam depths, thickness etc. • Material of construction. • Part numbers of individual segments that should also tally with the bill of material

prepared by the vendor and shall be marked on plan and sectional views. • Bill of material indicating item number, number of various components, thickness,

weight of individual components and total weight.

3.8 Vendor shall submit detailed Inspection test plan for fabrication and submit the same to OWNER for approval.

3.9 Stage-wise inspection of Internals shall be arranged by vendor through TPIA. The TPIA

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inspection release note shall form part of the dispatch documents. 3.10 Arrange for packing, dispatch, transportation insurance etc. and receipt of all internals at

site.

3.11 Vendor shall arrange for mock assembly of column internals for each column for viewing by TPIA.

3.12 Arrange for installation supervision of Internals by experts in mass transfer along with

leak testing wherever required and certify the column as good for boxing and operation. All installed internals shall also be finally checked and cleared for box-up by Owner.

3.13 As part of documentation vendor shall submit bound sets of all data/drawings (As built)

in requisite number as per contract document along with specifications, material test reports for all components, TPIA inspection release note, tolerance standards, installation instructions, inspection procedures and reports of leak testing at site, for each column along with one set of electronic files in CD of all documents for records and future reference.

4.0 DESIGN 4.1 Materials 4.1.1 All materials shall conform to those specified in the respective process drawings or

data sheets.

No substitution of material will be permitted without the written consent of Owner. In case substitution of material is proposed, vendor shall clearly indicate the reasons for requiring such change and give chemical and physical properties of the proposed alternate material with their standard specification number.

All the material supplied by vendor shall be new and of first quality supported with mill test certificates.

Unless specified in data sheets, Material shall be as per clause from 4.1.2 to 4.1.7.

4.1.2 13 Cr Stainless Steel Internals

All sheet and plate material shall be in accordance with SA 240 Type 41OS or 405 having No.1 finish only for thickness more than 4mm. For thickness up to and including 4 mm, No. 2B/20 finish is also acceptable.

All bolting material shall be 13 Cr - SA 193 Gr B6X or B6 for bolts and SA 194 Grade 6 for nuts and lock-nuts.

4.1.3 18 Cr - 8 Ni Stainless Steel Internals

All sheet and plate material shall be in accordance with SA 240 Type 304 having No.1 finish only for thickness more than 4mm. For thickness up to and including 4 mm, No.

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2B/20 finish is also acceptable.

All bolting material shall be SA 193 B8 for bolts and SA 194 Gr.8 for nuts and lock-nuts. 4. I .4 Monel Internals

All sheet and plate material shall be in accordance with SB 127 in hot rolled, annealed and pickled condition. For plate thickness up to 5.0 mm, cold rolled plates in annealed and de- scaled condition are also acceptable.

All bolting material shall be Monel, made from rod or bar stock, SB164.

4.1.5 Carbon Steel Internals

Unless otherwise specified, sheets and plates shall be procured in hot rolled conditions and shall be free of mill scale. Material shall be suitable for bending. The bend test specimens shall stand being bent cold through 180 degree without cracking on outside of the bent portion, to an inside diameter equal to or less than twice the thickness of the specimen or as per relevant material specification, whichever is severe. All sheet, plate material shall conform to SA515, SA516 or better unless specified otherwise on the data sheets/drawings.

All fasteners including clamps, material shall be as per clause 4.1.2 above, unless specified otherwise.

4.1.6 Gaskets

Trays gasketing material shall be woven tape, fabricated from Asbestos Free Material such as Woven Fibre-glass Tape (Amatex-G36-P752 or equal), Woven Teflon Tape, Woven Expanded flexible graphite tape, soft graphite or Ceramic Fibre Tape etc. and shall be suitable for process fluid and column design temperature, unless specified otherwise in the Data Sheets/Purchase Specifications. The thickness of the woven tape shall be 1.5 mm minimum. The use of Woven Asbestos Tape or Wire shall be subject to Owner's prior approval only.

4.1.7 Support Rings /Bolting Bars/Support C l e a t s

Support rings, down-comer or up-comer bars and other parts welded to vessel shall be of same metallurgy as of vessel. Minimum thickness excluding corrosion allowance of welded parts shall be 6 mm for vessel diameter up to 3000 mm and 10 mm for higher diameter. Corrosion allowance as specified in vessel data sheets shall be added on both sides of Support Ring, Bolting Bar and other welded parts.

4.2 Thickness of Internals 4.2.1 Minimum Thickness of Internals:

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Corrosion allowance, wherever specified in the data sheets for Internals in excess of corrosion allowance as indicated in clause 4.2.2 shall be added to the minimum thickness specified below:

Alloy Steel(mm) Carbon steel(mm) i) Deck plates, seal pans, draw-off 2.0 3.5* Pans,

weirs/seal plates, other removable Components

ii) Welded deck plates, down-comer 3.0 3.5* aprons and other welded components iii) Downcomer/lnternal pipes 2.0 3.5* iv) Bubble Caps 1.6 2.0 Risers (fixed) 2.0 3.5* Risers (removable) 1.6 2.0 v) Valves 1.6 (will not be used)

vi) Structured Packings 0.15 (will not be used)

vii) Support Grid for Structured Packings 5.0 8.0

viii) Locating Grid/Retaining 5.0 8.0 Grid/Bed Limiter

ix) Grid Packings

(a) Bottom-most layer/support grid

(b) Balance Layers

5.0 1.6

8.0

(As per vendor's standard)

x) Random Packings (As per vendor's standard, **)

xi) Loose Beams To suit load To suit load xii) Lattice Girders

(a) Primary Members 5.0 6.0 (b) Secondary Members 3.0 4.0(c) Gusset Plates 10.0 10.0 (d) Downcomer bolting bars 5.0 10.0

* 10 USSG is also acceptable in lieu of 3.5 mm. ** Random packing thickness shall be suitable for test load comprising of

dead weight of the packed bed + 10 % liquid load. Maximum compression shall be limited to 5% of the bed height without damaging the bottom packing.

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All bolting shall be minimum M10 for Internals and M16 for Lattice Girders. All nuts shall be hexagonal.

Minimum corroded thickness of the internals for the loading condition as per Clause 4.3.3 (i) and (ii) below, shall be 3.0 mm.

4.2.2 Corrosion Allowance

The following corrosion allowance shall be added to calculate thickness of Internals unless otherwise specified on data sheets or bid specification.

i) No corrosion allowance is required for Monel or Stainless steel alloy assemblies. ii) The corrosion allowance for all surfaces of floor of carbon steel assembly shall

be 1.5 mm (total). 4.2.3 Unless specified on the data sheets or bid specifications, corrosion allowance

shall be higher of 1.5 mm (total) or one quarter of the vessel corrosion allowance on each surface of trays and its components.

4.2.4 Beams, trusses and other support members shall have total corrosion allowance equal

to vessel corrosion allowance for removable (through vessel manhole) type construction and twice the vessel corrosion allowance for non-removable type construction.

4.2.5 All tray components and structured packing shall be so designed, so that each is

easily removable from the manhole of column. The size of the column manhole shall be referred in the data sheet.

4.3 Design Loadings 4.3.1 Design loads for tray assemblies shall be based on a liquid height of 50 mm liquid

above weirs plus self weight of deck plates and beams or live load of 150 kg/m2 whichever is severe. In case liquid density is less than water, 1000 kg/m3 shall be considered for purpose of calculating liquid load.

4.3.2 Under-down-flow plates and seal pans shall be designed to withstand a weight of

liquid equal to half the tray spacing or 300 kg/m2, whichever is severe. In case liquid density is less than water, 1000 kg/m2 shall be considered for purpose of calculating liquid load.

4.3.3 Five trays above/below 2-phase feed inlets and five trays in bottom zone of

column wherever process steam or two-phase feed is admitted shall be provided with lock nuts. Trays shall be capable of sustaining a net thrust of i) 1464 kg/m2 and with shear clips for Vacuum Columns (Stripping + Wash + HVGO

sections) ii) 1000 kg/m2 and with shear clips for Crude Column / Main Fractionator Columns.

iii) 450 kg/m2 for all other services

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4.3.4 One tray above and below the intermediate vapour/liquid feeds shall be

provided with lock nuts. Additionally, all lattice girders and major beam boltings shall be provided with lock nuts.

4.3.5 The packing support plate shall be designed to support the maximum

expected load of tower packings, liquid hold-up (min 10 percent). In case of liquid density is less than water, 1000 kg/m3 shall be considered for purpose of calculating load due to liquid hold-up.

4.3.6 Bed limiters frame shall be strong enough to take care of surges/uniformly

distributed load of 100 kg/m2 and 135 Kgs concentrated load at any point. 4.3.7 Hold down plate shall exert sufficient static load on the bed to restrict

movement of the packing. The hold down plate shall be designed for exerting a load of 100 kg/m2 minimum on the packed bed.

4.3.8 Liquid distributors/ Re-distributors shall be designed for self weight plus

maximum expected liquid load. 4.3.9 All Internals assemblies except cartridge tray assemblies, shall be able to

withstand the self weight plus the following number of 135 Kgs concentrated loads (maintenance loads) at ambient temperature.

Vessel Diameter Number of 135 kg loads Up to 1200 mm 1 (at center of diameter) Up to 3600 mm 2 (at center and 1/4 point of diameter) Over 3600 mm 3 (at center and 1/4 points of diameter) 4.4 Allowable Stress and Deflection 4.4.1 Allowable stresses for all Internals shall be as per ASME Sec. II. Part D, latest

edition. 4.4.2 The maximum deflection of tray/tower internal assembly shall not exceed 1

mm per meter of column diameter or 7.5 mm, whichever is lower for the design loadings given in clause 3.3.1 and 3.3.2 above. Deflection for distributor assembly shall be limited so that overall liquid mal-distribution does not exceed the limit. Deflection for support plate and seal pans shall be limited to L/400, where L is the length of individual component.

4.4.3 Deflection as per clause 3.4.2 may be ignored for trays designed based

on design loadings as per clause 3.3.3 and 3.3.9.

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4.4.4 For large diameter vessels, initial camber may be made in the principal support

members of the assemblies so as to limit the deflection as specified in clause 4.4.2 above.

4.5 Arrangement/Details of Internals 4.5.1 All assemblies except one piece cartridge type trays for column ID <750mm shall

be of removable type unless otherwise indicated. The general design, number, type and spacing shall be established on the individual vessel drawing/data sheets. Cartridge type trays shall be designed to rest on four support cleats.

4.5.2 Each removable section shall be so dimensioned/sized to permit passage

through vessel manhole and shall be suitable for assembly/ dismantling from upper side in so far as structural contingencies permit. Maximum diagonal dimension of the components shall be restricted to vessel manhole ID - 12mm clearance.

4.5.3 Internals support trusses supporting more than one Internal, as are

commonly used in large diameter columns and which cannot be installed through manholes, shall be split into sections for access through manhole and minimising welding work inside the column.

4.5.4 Internals decks shall have a maximum length of 3000 mm. To achieve this

maximum distance between main support beams or girders shall be limited to 3000 mm. However, the main support beams or girders having length more than 3000 mm shall be provided with one butt joint with splice plates of the same thickness as the main member upto 6000 mm length and two butt joints with splice plates of the same thickness as the main member for more than 6000 mm length and so on. The butt joint shall be provided inclined at 45 degrees,

4.5.5 Manways

i) One(1) manway in single cross flow decks, two(2) manway in double flow decks and so on shall be provided. These manway shall be freely removable from top and bottom. Manway shall be in the same vertical line for a set of trays. These shall be at such a location and of a shape and size to permit easy access to every area of the tray. Manway of different set of trays (about 20 trays) shall be staggered to each other. Minimum clear opening on tray shall be 380mm x 450mm.

ii) Where manway cannot be provided, decks shall be split (turn-up -

turndown) to provide suitable access for Inspection and assembly from

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top as well as bottom. 4.5.6 Unless specified otherwise, support rings, bolting bars, support

bracket/cleats when required shall be designed for welding to the vessel. All other parts shall be designed for bolting or clamping in place. Clamping shall be used on Tray floor and all downcomerl/ upcomer shall be through bolted. Spacing of bolting or clamping shall be close enough to ensure optimum liquid tight construction but shall not exceed 120 mm on deck portion in downcomer area/liquid holding area/downcomer apron bolting etc. For active area, bolting/clamp spacing shall be limited to maximum 120 mm in general. However, in case some fouling occurs with valves or other components, maximum 150 mm spacing may be adopted. All joints and seams of trays specified to be liquid tight without gasketted joints shall be seal welded at site. Maximum spacing for clamps/bolting for gasketted construction shall be restricted to 100 mm.

4.5.7 Drawings and instructions for installation and fabrication of support ring,

bolting bar and support bracket/cleats welded to vessel shall be furnished by Internals supplier. They shall show clearly the type, size and extent of welding. All support rings and bolting bars shall be continuously welded on both sides. All support brackets shall be welded all around.

Support stool shall be provided for downcomer (first piece) or loose beams in excess of 1500 mm length.

4.5.8 When locations of bed support, retainer and distributor are not indicated on

data sheets, Tower Internal/Packing supplier shall determine and indicate dimensional requirement.

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4. 5.9 Gasketing need not be used in the design or installation of Internals except

for bubble cap trays, all liquid holding portions (e.g. seal pans, draw-offs), collector trays, distributors and redistributors. Fabrication shall provide tight metal to metal joints. Metal seal plates shall be used to close construction joints where necessary.

4.5.10 All stiffeners and support members shall be located on the underside of

the tray floor with the exception of open type trusses supporting two trays. Stiffeners and support members in bubbling areas shall not exceed 75 mm in width and shall be designed so as not to impede or channel the liquid flow on the tray. Depth of stiffeners and support members transverse and parallel to the liquid flow shall not exceed 20 and 30 percent respectively of tray spacing.

4.5.11 A minimum o f 20 mm overlap sha l l be provided b e t w e e n tray floor section

and support members. 4.5.12 Trays and seal pans not specified to be liquid tight, and of a design which

would not easily drain shall be provided with one or more 12mm diameter/square drain holes/slots located in the outlet weir directly above the tray flow. Size and number of drain hole/slot may be reduced depending upon liquid rate. Draw off sumps shall be located flush with the invert side of draw off nozzles to allow complete draining of sumps.

4.5.13 All the three (3) and four (4) pass trays shall have pressure equalising pipes

(vent tubes) across the downcomers. 4.5.14 Bubble Cap Trays, Risers Fixed Risers

Fixed risers shall be used unless otherwise specified in the data sheets. For deck plates less than 3 mm in thickness, riser shall be expanded into upward flanged opening in the deck plates and then stitch welded to upturned edges of the opening.

For deck plate 3 mm thickness and more, the riser shall be continuously welded to the deck plates with the holes in the deck plate being plane, not upturned. Caps shall be attached to the attachments welded to the top of risers.

Removable risers shall be used only where specified on the drawings. These shall be flanged at the bottom to fit over upturned flanged/venturi openings in the deck plates. Each cap and riser shall be held rigidly in place by a special snap-on bar to which is welded either a bolt or a bar with a wedge. Caps, risers and snap-on bars shall be removable from top.

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Bubble Cap

Bubble caps are to be furnished in Full Annealed and scale free bright condition.

4.5.15 Valve Trays Valve assemblies of proprietary trays shall be provided with following features.

i) A means of preventing the orifice covers from adhering to tray floor.

ii) A means of preventing the orifice covers with integral guide legs and lift stops from popping out of place during operation.

4.5.16 Sieve Trays

All perforations shall be punched and made from top side and burr side on tray decks must be downwards when installed, unless specified otherwise. In case of liquid-liquid extractor column trays, punching direction shall depend on the direction of liquid flow of continuous phase.

4.5.17 Burrs shall be removed from all perforated areas and edge of internal sections. 4.5.18 Distributors/Redistributors

Distributors of liquid feed to packed beds, unless otherwise specified in data sheets, shall be gravity flow type (e.g. orifice drip trays, tubed drip trays, trough type, orifice header laterals) in accordance with following requirements:

i) Distributors shall preferably be provided with side elevated orifices. For

such elevated orifices, anti fouling covers are not required. ii) In case deck type distributors are provided/ specified, orifices shall preferably

be minimum 6.0 mm diameter and shall be arranged on an approximate equal spacing throughout the distributor. Distributor supports shall be designed and arranged so as not to interfere with flow from orifices.

In case orifice diameter calculated is less than 6.0 mm, then anti-fouling covers shall be provided on each orifice.

iii) Vapour risers shall have a total cross sectional area as per Vendor's design but

not less than 15 percent of vessel cross sectional area. Number, size and arrangement of vapour risers shall be such so as not to affect the orifice spacing and liquid distribution to the packings.

iv) Distributor joints shall be gasketted to be liquid tight. Gasket material used shall

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be suitable for service and soft enough for leak tight joint. v) Distributor shall be capable of performing satisfactorily for the range of loadings

specified to cover entire range of plant operation. vi) Flow variation from orifice to orifice shall not be more than 10 percent at turndown

condition.

vii) Feed pipe shall form part of Distributor supply.

4.5.19 Packing Support Plate

Packed bed support plate shall be vapour-injection type, providing separate passage for liquid and vapour flow. The support plate shall have at least 90 percent free area based on cross sectional area of vessel. Slot size shall be so selected to avoid any sneak through of packings from slots.

4.5.20 Bed Limiters/Bed Retainers

Bed Limiters/Bed Retainers shall be located just above top of packings to avoid fluidising of bed and shall be fixed in position so as not to be moved by the packings and shall be designed so as not to affect distribution from the liquid distributor to the packings. Bed Limiters/Bed Retainers for use with spray nozzle distributor shall be designed with major structural support on the underside of the retainer so as not to affect the spray distribution on the packings. Expanded metal of 2 mm thickness and equivalent open area is also acceptable in place of wire mesh.

4.5.21 Hold Down Plates

Hold down plates shall be provided on the top of ceramic or carbon tower packings. The hold-down plate shall directly rest on the bed without any support cleats. Hold-down plate shall exert sufficient static pressure on the bed to restrict movement of the bed. Care shall be taken not to use hold-down grid with metallic or plastic tower packings. Expanded metal of 2 mm thickness and equivalent open area is also acceptable in place of wire mesh.

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4.5.22 Flash Feed Distributor

Flash feed distributor for flashing or mixed phase, vapour and liquid feeds to packed bed shall be designed to separate the two phases and distribute the liquid phase on distributor/ re-distributor. If flashing feed gallery is used, riser area shall be 50% of vessel cross sectional area.

4.5.23 Tower Packing

If type of packings is not specified in the process data sheets, following shall be taken as guidelines:

i) For wash zone of vacuum column, Grid Packings shall be used.

ii) For all other applications preferably Pall Rings shall be used. If pall rings

are not expected to perform to desired performance, proprietary random packings may be used. Alternatively, Vendor may also adopt/recommend use of Structured Packings.

4.5.24 The maximum allowable pressure drop for a packed bed shall include packed

bed support, bed limiter and distributor. 5.0 FABRICATION AND SUPPLY 5.1 Tolerances

5.1.1 Tolerances and tray ring sizes shall be in accordance with the following:

NOMINAL VESSEL INSIDE DIAMETER mm

WIDTH OF TRAY SUPPORT RING mm

NOMINAL TRAY DIAMETER mm

TRAY DIAMETER TOLERANCES mm

Under 915 40 ID minus 25 Plus 0

915 to under 1830 50 ID minus 25 Minus 3

1830 to under 3960 65 ID minus 50 Plus 0

3960 to under 5490 75 ID minus 65 Plus 0

5490 and over 90 ID minus 65 Plus 0

5.1.2 The tolerances from the top of the first tray support ring to the reference plane shall be ±6mm. Tolerance top of support ring to top of support ring of adjacent trays shall be ±3mm.

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5.1.3 Trays shall be level so that when fully assembled, in a vertical erected position, they shall not exceed the following tolerances in millimetres taken over the full tray diameter:-

Less than 1800 diameter ±2.0mm From 1800 to 3500 diameter ±2.5mm From 3500 to 6000 diameter ±3.0mm From 6000 to 9150 diameter, inclusive ±5.0mm Over 9150 diameter ±7.0mm

5.1.4 The tolerances on all like parts shall be such as to make the parts completely interchangeable.

5.1.5 Length of downcomers shall be within ±3mm. Clearance between bottom of downcomer and tray/seal pan shall be ±6mm.

5.1.6 The tops of all risers, downflows, and weirs shall be true and square with the tray. Additionally, regardless of tower diameter, weirs must not exceed 1.5mm out of level (this may be accomplished by using adjustable weirs).

5.1.7 Tolerances for bubble caps shall be as follows:-

hs = Height of slot above top of tray floor ±1.5mm hc = Height of bubble cap chimney above top of tray floor ±1.0mm hw = Height of weir above top of tray support ring ±3.0mm

The above tolerances apply when hw – hs > 12mm. When hw – hs < 12mm the tolerances on dimensions hw – hs shall be ±1.5mm.

5.1.8 Downcomer horizontal clearances measured at the bottom edge to seal pan on inlet weir shall be ±3mm.

Tolerance on width of downcomer horizontal dimension between downcomer weir, and vessel wall or weir dimension in multi pass through shall be ±3mm for vessels under 2000mm dia. and ±6mm for vessels over 2000mm dia.

5.1.9 All tolerances not shown on drawing e.g. the location of parts bolted to clip on brackets welded to the tower by others shall be ±3mm.

5.2 Welding 5.2.1 All welding shall be done by metal arc welding. For welding on thinner gauge sheets

TIG welding is preferred. 5.2.2 Gas or Carbon arc welding shall not be used. 5.2.3 Welding electrodes of composition similar to Internals material shall be used

except austenitic electrodes of higher chromium and nickel content such as AWS A5.4, ASME SFA 5.4 class E309 and E310 may be used for 12 Cr stainless steel. For dissimilar material welding, electrode composition shall be similar to nobler material being welded. Following electrodes shall be used unless specified otherwise:

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E 7018 for all CS materials E308 for all SS 304 to SS 304 E308L for all SS 304L to SS 304L E 309MoL for SS 410S to SS 410S, SS to CS, SS 410S to SS 304304L,316,316L E 316 for all SS 316 E 316L for all SS 316L E Ni Cu7 for Monel to Monel and Monel to CS/SS.

5.2.4 Welding wherever specified, is to be done by qualified and approved welders using

the suitable fillers and fluxes recommended for the materials in the fabrication drawings. For welding the stud on tray decks and support beams, use of stud welding gun with suitable flux is acceptable. In manually welding the studs, care should be taken to minimise the weld spatter and the outside diameter of the weld so that it should not foul with tray deck or washer. For stud welding, proper welding procedure shall be established. Torque required for welding failure shall be higher than the torque required for failure of the stud.

5.2.5 A proposed Welding Procedure Specification (WPS) shall be submitted to TPIA

for his approval. On approval, a Procedure Qualification Test (PQT) shall be conducted which shall be witnessed by TPIA . On acceptance of all tests as per ASME Section IX, a final WPS along with Procedure Qualification Record (PQR) shall be submitted. Production welding shall start only after approval of final WPS/PQR and qualification of welders as

per ASME Section IX. T P I A may accept previously qualified WPS/PQR at his sole discretion.

5.3 Miscellaneous 5.3.1 All parts fabricated shall be smooth, true, clean and free from burrs, grease and

dents. Openings for passage of workman must have exposed edges rounded. 5.3.2 All support rings, bolting bars, beams support brackets and other components which

are integral and therefore welded to the column shell inside, shall be supplied and installed by column fabricator.

5.3.3 Total draw-off trays shall be designed for zero leakage construction and may be

seal welded (if required) at site to attain zero leakage. 5.3.4 Seal welds shall have a throat thickness at least equal to the specified

corrosion allowance. 5.3.5 All stainless steel tray assemblies/internals and their components (e.g. Bubble

caps, valves etc.) shall be pickled and passivated. Pickling and Passivation shall be as per ASME 380. However, vendor shall prepare procedure for Pickling and Passivation and obtain approval from Owner.

5.3.6 All parts shall be fabricated in accordance with good shop practice and in uniformity

so that all corresponding parts will be inter-changeable.

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5.4 Spares Following spares shall be included as part of the supply: 5.4.1 Constructional Spares

The supply shall include the following as constructional spares:

Bolts Nuts 10% of total for each size (minimum 10 nos. of each size)

Clamp assemblies 10% of total for each size (minimum 10 nos.

of each size) Valves for trays 5% of each size

Bubble caps 5% of each type and size

Gasketing or tapes 100% of each type and size

Sealing foils for cartridge trays 200% of each type

Ll-clamps 10% of each type and size or 10 nos.

whichever is minimum

Tower Pac kings 1 0% for Metallic and Plastic Packings 15% for Carbon and Ceramic Packings

Spray Nozzles Up to 25 Nos. (of each type) - 100%

More than 25 (or each type) – 2 5 % (subject to minimum of 25 Nos.)

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5.4.2 Vendor shall submit list of spares recommended for two years of satisfactory

operation. However, following operational spares as a minimum shall be supplied as Mandatory Spares:

i) ii)

Valves for Trays Bolts &Nuts

10% of each type 10% of total for each type/size (minimum 10 nos. of each size)

iii) Clamp Assemblies - do - iv) Gaskets or Tapes 100% of each type and size

v) Sealing foils for 200% of each size Cartridge Trays vi) Spray Nozzles 25% subject to minimum 5 Nos. of each type and size. vii) Tower Packings 5% of each type and size.

If desired by owner, item wise price for above spares shall be furnished after award of the job.

6.0 INSPECTION AND TESTING 6.1 General 6.1.1 The materials, f a b r i c a t i o n , testing and trial assemblies are subject to

inspection by TP IA , at shop floor before shipment and during installation. 6.1.2 Any rejection made by inspector shall be final. Approval/ Inspection by Owner and /or

their designated representative shall in no way relieve the vendor of his responsibility to meet all requirement of the purchase order.

6.1.3 TPIA/Owner shall have free entry to the Vendor's shop at all times where and while

the work is being performed. The Vendor shall offer the inspectors all reasonable facilities to satisfy them that the materials are being furnished in accordance with the specifications.

6.1.4 Vendor shall notify the TPIA/Owner sufficiently in advance of any fabricating

operations to permit the TPIA to arrive at the Vendor's shop. 6.2 Stage Inspection during Fabrication: 6.2.1 Dimensions

The inspector will check that the thickness and the dimensions of all parts for the

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Decks, Weirs, Seal and Draw off pans, Down-comers, Draw off pipes, Supports, Beams, Valves, Bubble caps, Clamps, Studs, Bolts, Nuts, Risers, Washers and Gaskets etc. are as per the approved drawings.

6.2.2 Fabrication

The inspector shall check each individual part of the equipment fabricated as per approved drawings and specifications. For instance, for the Bubble cap dimensions, height, width and number of slots, heights, OD and ID or riser and cap, shroud ring height, exit and inlet weirs height etc. shall be measured. The inspector will check that all identical parts shall be interchangeable.

Inspector shall check that the sharp edges on the Internal components, man way covers, weirs, down comers etc. are properly removed. Also that all burrs from punched holes and loose weld slags and materials are removed from all components. Stage-wise inspection during fabrication will be thoroughly carried out. Before starting welding, welders' qualification test will be carried out, if required, as per ASME Sec. IX. Where number of similar items are to be made, inspector shall give the clearance for the fabrication of the lot only after checking and approving the first sample piece.

6.3 Trial Assembly

One tray of each type and size with its accessories shall be assembled as floor mock-up, inside the fabricators’ shop. The components for such an assembly will be taken at random from each lot of identical items.

The assembled tray will be carefully checked for its dimensions, tolerances, number and arrangement of perforation, the working of the valves in case of valve trays, V-notch or Blocked Weir, adjustability of weir, vent tube details, downcomer clearance, weir heights, downcomer length and width, number of clamps, gaps and potential leakage points etc.

The assembly shall also be checked for each type and size of packed tower internals. Inspector will also check the flatness and deflection of the trays, internals, beams, tray edges and beam ends clearance.

6.4 Leak Testing

Bubble cap, Collector trays, Liquid holding portion of other trays such as Seal pans, Recessed seal pans, Draw off pans shall be subjected to leakage test at shop floor as well as in the field by filling water up to weir level or up to normal liquid level as the case may be. Appropriate ring fixture or a portion of column shell with supports for seal pan/recessed seal pans/draw off box etc. shall be made by Internals Vendor to facilitate leak testing in the shop.

Leak testing shall be carried out with service gaskets and drain holes temporarily plugged. Leakage rate shall not exceed 0.5 percent of design liquid flow rate unless otherwise specified.

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For collector trays/other internals, if seal welding is carried out at site inside the column, leak testing at shop floor is not required.

6.5 Distributor Testing

All Liquid distributors/redistributors shall be water tested in the vendor's shop by the following procedure at 50%, 100% and 110% of the design liquid volumetric flow rate. The vendor shall certify to the purchaser at the time of bidding that they believe their equipment can meet the testing requirements listed below:

(i) If the distributor contains a pre-distributor, it shall be tested first to ensure that it has

a CV of 5 or less at the design flow rate. Each orifice in the predistributor shall be tested. The CV is defined as the ratio of the standard deviation to the sample mean, expressed as a percent.

(ii) The distributor/re-distributor itself shall be tested and the CV determined.

To determine the CV, at least 30 pour points or at least 10% of the pour points (whichever is higher) shall be randomly selected and tested. If the CV specified below cannot be met, the vendor will correct the problem at its expense.

(a) For orifice pans, tubed drip pans and other similar devices, a CV of 10 or less

must be achieved at the design liquid volumetric flow rate. (b) Four orifice parts, tubed drip pans or trough distributors that employ a

modular (sectional) design, (wherein many pieces are geometrically identical) all pieces of the same geometry shall be treated as one group or strata. One piece from each strata shall then be tested by the procedure outlined above.

(c) The average flow rate per pour point for any grouping of 10 of the tested pour

points from a single area should differ by no more than 5% from the average for the group or strata being tested. (d) Spray nozzle distributors shall not be tested in the vendor's shop but must be

tested in the tower prior to start-up to ensure that all nozzles are operable and develop the desired spray pattern. This test shall be carried out as close to design rates as possible.

(e) The test results shall be furnished to TPIA in a written report. This report shall

also contain a drawing of the distributor in plan view. This drawing shall be broken down into 3 radial zones of equal area and the location of pour points sampled in each zone.

All distributors/redistributors shall be leak tested at shop floor as well as at site. For distributors/redistributors, if performance testing is carried out at shop floor, leak testing at shop floor is not required.

6.6 SPRA Y NOZZLES

Apart from the usual material quality tests (chemical analysis and mechanical

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properties) and manufacturing quality control tests, vendor shall include for & carry out the testing of the spray nozzles with respect to the flow rates for specific L\P, spray angle, spray coverage and distribution for the tip distance given in the data sheet. The testing medium shall be water. These results shall be submitted to Owner for review. Tests and acceptance criteria is as below:

Flow rates ± 10 % for specific ∆P Spray angle ± 50 Flow variation As per vendor's Standard.

(Data to be reported for Information) No. of nozzles to be tested - 10% of each size and type. (Min. 2

nos. of each type & size) 7.0 SITE INSTALLATION AND SUPERVISION 7.1 Installation of trays, tower internals, tower packings and associated components

shall be as per the Vendor's Installation Procedure and the approved General Arrangement Drawings for each column. All requirements of the drawing shall be complied in totality. Installation records in vendor's installation formats giving following parameters (Dimension as per drawing Vs actual readings) of trays and internals shall be furnished:

• Distance between tray support rings (Tray Spacings). • Location of downcomer bolting bars • Tray support ring levelness (Minimum 4 diametrically opposite locations). • Height of Exit Weir (From top of tray deck) • Under Down Flow Clearance (At tray and seal pan locations). • Horizontal clearance between down comer apron and seal/recessed seal

pan. • Drop in water level during leak testing of seal pans, recessed seal pans,

chimney trays, liquid distributors/redistributors and other liquid holding portions.

Vendor shall also furnish a certificate stating that all installed trays and internals have been inspected and the column is good for boxing up the manways. The above mentioned installation records and the certificate shall be furnished by vendor prior to offering the trays and internals for TPIA/Owner inspection.

7.2 Safety, Health and Environment

Vendor shall arrange for installation of an exhaust fan for exhaling welding!

cutting fumes etc. and to maintain adequate oxygen level, before any work is started inside confined spaces (i.e. columns). Adequate ventilation shall be maintained at all times. Gas/LPG cylinders shall not be taken inside confined space. When a worker/supervisor enters a confined space, it shall be mandatory to have a second man as stand by. Safety belts shall be worn

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while entering column if there is a danger of falling. All ladders/stair cases shall be in place before any item is offered for inspection. Rope ladders/scaffolding shall be provided inside the column in case trays are not easily approachable from column manhole. Low voltage (24V) lamps equipped with guards shall be used to prevent accidental contact with bulb. All electrical connections shall be through ELCB's and proper earthing shall be ensured. Acids and other materials used for pickling shall be disposed off to a designated place. All statutory Regulations and owner's safety, health and environment requirements shall be complied with. Inspection aids for carrying

out the inspection of internals shall also be provided. 7.3 It shall be the responsibility of vendor to provide trained engineers to supervise

the erection of trays, packings and internals to ensure that these are assembled properly and meet the expected leakage rates and tolerances. Final clearance shall be obtained from designer of Internals. Vendor's engineer shall satisfy himself that the column before it is boxed-up, is having all Internals duly and correctly fitted, clean and without leakage (as required per drawings) and bolts are tight with lock-nuts (wherever specified). A certificate shall be issued by the vendor that the column is good for boxing up the manways. The leakage test data and levelness of each tray shall be recorded and submitted in data folders. Vendor's offer shall include for this service and charges indicated separately.

7.4 The Internals shall be offered by vendor for final clearance by Process Licensor

(if applicable) and Owner after vendor has satisfied themselves with the quality of installation.

7.5 Vendor shall follow safety & environmental policy of IOCL for site installation work. The

same is attached as Annexure. 8.0 VENDOR DATA REQUIREMENT 8.1 Vendor shall furnish design, drawings and documents as per Vendor Data Requirements given in Annexure-I, unless indicated otherwise in the Purchase

Order/Contract Documents. 8.2 It is emphasized that review of documents shall be done for each column only after receipt of complete information such as vendor's designs / specifications,

column fabrication drawings including feed arrangement GAD's etc. Part submission of data shall not be entertained and Owner shall not be held responsible for holding the work or schedule slippages.

9.0 SHIPPING 9.1 Preparation 9.1.1 All metal parts shall be free of all foreign matter, except that any oil coating

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inherent with the manufacturing process need not be removed. 9.1.2 All Carbon Steel Internals shall be given two coats of rust preventive coating

preferably double boiled linseed oil. All stainless steel internals shall be supplied duly pickled and passivated. Internals supplier shall also indicate procedure for removal of rust preventive coating (if applied) in the instructions for Installation of Internals.

9.2 Packing

9.2.1 All Internal components shall be properly packed, crated and boxed in a manner such

as to protect all parts from damage or loss during transit. It will be Internals Supplier's responsibility to pack to ensure damage free transit for the mode of transportation finally adopted and adequate for storage at site for a minimum period of 6 months. All packings shall be done in polythene lined wooden cases. Maximum weight of each case shall preferably be limited to 250 kgs.

9.2.2 All Internal components are to be provided with match and identification marks and shall

also bear the column number. All identical elements shall have the same markings. Markings shall be done with indelible paint or ink which contains non-metallic pigments.

9.2.3 Materials for different columns shall not be intermixed. 9.2.4 Material test certificates, test reports, Inspector's approval certificates, release notes

etc. and two sets of assembly and fabrication drawings are to be enclosed along with shipment of Internals.

9.2.5 All support rings, bolting bars and other attachments of the vessel, if made by

Internals supplier shall be shipped directly to vessel fabricator unless otherwise designated. This shipment shall include two sets of drawing and instructions for Installation, Welding etc.

9.3 Constructional Spares 9.3.1 All shipments shall include extra fasteners, gaskets and valves/bubble caps, packings

etc. to cover loss waste and shrinkage as specified in clause 4.4 in a separate container.

9.3.2 All spares shall be packaged and supplied separately so as to preserve them in new

condition, tagged properly so as to identify them as and when needed and shall be clearly marked "Spares".

10.0 SUBMISSION OF BIDS Vendor shall submit the bids containing following information:

a) Column sketch showing all Internals and nozzles. b) Completed data sheet (as per Annexure I) for trays with computer outputs

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normal and minimum cases. c) Completed data sheet (as per Annexure II) for each packed bed.

d) Data for spray nozzles, if used.e) Data on distributors - type and salient features. f) Details of other Internals.

g) List of Deviations from this specification and/or MR requirements. h) Reference list for the type of Internals offered in this enquiry supplied earlier

for similar service. This shall cover at least client's name, type of Internal, plant, service, column diameter and year of commissioning.

i) Quality plan j) Vendor's catalogues

Bidder's offer shall be liable to rejection in absence of data as requested vide (a) to J)

above. 11.0 GUARANTEE REQUIREMENT 11.1 Mechanical Guarantee/Warranty Vendor shall guarantee all items supplied by him against defective material; poor

workmanship, improper design and failure from normal usage for a period as per Client's commercial terms and conditions.

11.2 Hydraulic Performance Guarantee Vendor will, in addition to mechanical guarantee/warranty explained in clause 11.1

above, guarantee hydraulic performance specified in specification sheets for all the Internals for which Vendor is required to carry out functional process design also.

11.3 In case of mal-operation or failure of the trays and internals, vendor shall be responsible

to carry out re-engineering and modify/replace the hardware without any cost to the Client and without delay. In case modifications are required due to inadequate performance, the guarantee period shall be extended for 12 months from the date the column is put back into operation.

12.0 AS BUILT DOCUMENTATION Shop changes made by Vendor after approval of drawings under Code-l by owner and

deviations granted in deviation permits, if any, shall be marked in hard copy of drawings which shall then be stamped' As-built' by the vendor. These' As-built' drawings shall be reviewed and stamped by Authorised Inspector also. Vendor shall prepare scanned image files of all marked-up 'As-built' drawings. Vendor shall also incorporate the above changes in the native soft files of the drawings.

Authorised Inspector shall ensure/certify completeness of Vendor's Final/As-built

documents before equipment dispatch.

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"

In addition, vendor shall also incorporate site changes, if any, based on mismatch

observed at site and resubmit the' As-built' documents. 13.0 DATA FOLDER Vendor shall complete requisite copies of data folders along with one set of electronic

copies, of the drawings in "pdf'/"native" format in CD. These folders shall contain the following documents.

(a) Hydraulic and mechanical design calculations along with computer print out. (b) Final hydraulic data sheets for trays and tower internals as per Annexure-I and II

respectively (c) Support Rings, Support Cleats and Bolting Bar drawings. (d) As built General Arrangement drawings with Bill of Material for Internals. (e) Part detail/shop fabrication drawings. (f) Material Certificates (g) Shop testing procedure and installation procedure.

(h) Inspection reports and leak test records. (i) Vendor's certificate stating that Internals have been designed, fabricated,

supplied and installed as per Vendor practices so as to meet design conditions. U) Welding Procedure Specifications (WPS) and Procedure Qualification

Records(PQR). (k) Site Installation Records. 14.0 LIST OF ATTACHMENTS

ANNEXURE : I. Vendor Data Requirements

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Annexure-1VENDOR DATA REQUIREMENTS

Sl N DESCRIPTION

Along with Bids

AFTER ORDER PLACE

FOR R/I AS BUILT IN DATA FOLDER

No. of Prints

Duration in Weeks

Purpose No. of

PrintsNo. of CDs

1 Deviation List 03 NA - - NA - 2.

Hydraulic Data Sheets, Calculations, Computer output

03 04 04 R

04 -

3. Mechanical Design Calculations - 04 04 I 04 02

4. Support Rings, Support Cleats andBolting Bar Drawings

NA 04 04 I 04 02

5.

GA Drawings, Column Sketch withInternals and Nozzle details/ Elevation, including MOC Details.

NA 04

04

R

04 02

6. Bill of Material NA 04 08 I 04 02

7. Material Test Certificates NA 04 With Inspection

R 04 -

8.

Weld Procedures, InspectionRecords/Data NA NA

-- 04 -

9.

Site Installation Procedure/Check Lists

NA 04 16 I 04 -

10.

List of Spares - Installation - Operations

04

04

08

1

04 -

11. Fabrication Schedule - 04 04 I - -

12. Vendor Drawing Index - 04 Note 5 I 04 -

13. Vendor's Quality Assurance Practices

04 - - - - -

14. Reference ListlVendor' s Catalogue

04 NA NA NA NA NA

15 Technical Questionnaire duly filled,signed and stamped 04 NA NA NA NA NA

16 Pickling and Passivation Procedure

NA 04 08 R - -

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LEGEND

NA Not Applicable R Shall be reviewed by Owner, comments, if any, to be taken care by vendor A Shall be Approved by Owner before fabrication. I Shall be submitted to Owner for Information.

NOTES:

1. Fold all prints to 210 mm x 297 mm size. 2. Vendor shall be held accountable for furnishing all data/drawings required in

proper form and quantity in accordance with these requirements. The vendor shall also be accountable for documentation required from his Sub-Vendor.

3. Each vendor data item must be identified by purchase order number and

equipment tag no. located on the cover sheet of first page of said item and in case of engineering drawing on each and every drawing.

4. All drawings and literature shall be in English language and in metric system.

All drawings in electronic form shall be editable. 5. Vendor's drawing index to be submitted with each submission of documents. 6. An As-Built drawings shall be duly certified by authorised Inspection Authority.

7. All drawings/documents/data folders shall be submitted to Owner as per

instructions given separately.

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PAGE 1 OF 30

TECHNICAL SPECIFICATIONS

FOR PRESSURE VESSELS

PRESSURE VESSELS

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Abbreviations: BIS Bureau of Indian Standards BS British Standards BHN Brinell Hardness Number DP Dye Penetration STAAD Structural analysis and design computer program MDMT Minimum Design Metal Temperature TPlA Third Party Inspection Agency ASME American Society of Mechanical Engineers AWS American Welding Society CS Carbon Steel GAD General Arrangement Drawings ID Internal Diameter LSTK Lumpsum Turnkey MOC Material of Construction MR Material Requisition OD Outside Diameter PQT Procedure qualification test PQR Procedure qualification record PL Process Licensor PMC Project Management Consultant SS Stainless Steel TIG Tungsten Inert Gas

WPS Welding Procedure specification

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C O N T E N T S


1.0 SCOPE 4 2.0 TECHNICAL REQUIREMENTS 4 3.0 SCOPE OF SUPPLY AND SERVICES 21 4.0 VENDOR DATA SHEET 21 5.0 INSPECTION AND TESTING 21 6.0 NAME PLATE 24 7.0 PAINTING AND PROTECTION 24 8.0 PACKING & SHIPMENT 26 9.0 GUARANTEE 27

10.0 SITE FABRICATION & ERECTION 27 11.0 DIMENSIONAL TOLERANCES FOR PRESSURE VESSELS 28 12.0 DATA FOLDER 29

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1.0 SCOPE

This specification covers the general requirements for the design, fabrication, workmanship, erection, inspection, testing and supply of unfired pressure vessels and is intended to supplement the minimum requirements of the applicable codes.

Exception/ variation shown in the enclosed Data Sheet(s) and “Special Requirements” shall prevail over those shown here. Bidder shall quote for the pressure vessels based on the requirements given in this specification and the attached data sheets. Any items not listed in this specification but considered necessary by Bidder shall also be included in the offer.


2.1 Design

2.1.1 The Pressure Vessels shall be built by Bidder in accordance with ASME Boiler

and Pressure Vessel Code, Section VIII, Division-I and the requirements given below and in the attached vessel data sheets including engineering drawings. The design/engineering work related to preparation of fabrication drawings, weld joint and weld details, etc. shall be in Bidder's scope of work.

Applicable standards:

(a) ASME Section- II (b) ASME, Section VIII, Div-1- Boiler and pressure vessel code- Alternative

rules (c) ASME, Section VIII, Div-2- Boiler and pressure vessel code- Welding

qualifications (d) ASME, Section IX- Boiler and pressure vessel code- Welding

qualifications (e) ASME B16.47- Large diameter steel flanges (f) ASME B16.5- Pipe flanges and flanged fittings (g) WRC Bulletin 107- Local stresses in spherical and cylindrical shell due to

external loadings (h) WRC Bulletin 297- Local stresses in spherical and cylindrical shells due

to external loadings- Supplement to WRC Bulletin- 107 (i) Indian Boiler regulations 1950 (j) The static and mobile pressure vessel (Unfired) Rules- 1981 (k) British Standards PD 5500 Fusion Welding Unfired Pressure Vessels

2.1.2 The thickness of all major components like shell, head, nozzle etc., if specified in mechanical data sheets, are to be followed strictly by Bidder. Otherwise, vessel manufacturer shall submit designs for approval when Purchaser does not furnish a design or does not specify the required plate thickness for different parts. The following shall be the basis for design calculation

a) Pressure Vessel shall be designed to withstand the loadings exerted by

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internal or external pressure, weight of the vessel, wind, earthquake, reaction of supports, impact, and temperature. The maximum allowable working pressure shall be limited by the shell or head, not by minor parts.

b) For all vessels, pressures shall be specified by following terms and values

i) Service / Operating Pressure ii) Design Pressure / Maximum Service Pressure will be equal to :

- Service pressure + 1 Kg/Sq.Cm for maximum pressure below or

equal to 10 Kg/Sq.Cm. - Service pressure increased by 10% for maximum pressures

above 10 Kg/Sq.Cm

iii) Vesels operating under vacuum shall be designed for an external pressure of 1.055 Kg/Sq.Cm.

iv) First-test pressure will be applied before the vessel is put in

operation and shall be, unless otherwise indicated in the drawing, atleast equal to 1.3 times the maximum allowable pressure of vessel in cold and new condition (corrosion allowance not excluded while calculating the maximum allowable pressure) so that it does not exceed 90% of the yield point of the material.

c) For all vessels, design temperature shall be atleast equal to :

i) Service temperature +15 Deg C for vessels whose temperature is

above zero Deg C.

ii) Minimum operating temperature for vessels whose temperature is below zero Deg C.

d) All vessels shall be designed to be free standing. It will be assumed that

wind and earthquake loads do not occur simultaneously, thus the vessel should be designed for either wind or earth-quake loading, whichever is greater.

Wind pressure shall be considered as per the following for the purpose of wind load calculation (necessary changes as per specific site requirement may be considered during design) :

0 - 30 m - 200 Kg/Sq.m 30 - 35 m - 208 Kg/Sq.m 35 - 40 m - 210 Kg/Sq.m 40 - 45 m - 217 Kg/Sq.m 45 - 50 m - 222 Kg/Sq.m

(e) Earth-quake loading shall be calculated as per IS-1893, latest edition.

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f) Horizontal vessels supported by saddles shall be designed according to the method of L.P. zick.

2.1.3 In no case the shell or head thickness be less than 6 mm exclusive of corrosion allowance.

2.1.4 Corrosion Allowance

a) Corrosion allowance to be used for carbon or low alloy steel vessels

shall be indicated on outline drawing. It shall be included in the speicified thickness, but shall not be included in the strength calculations.

b) For fixed internal parts, corrosion allowance shall be applied to one face only.

c) For vessels having internal separation heads or water tight partitions

corrosion allowance shall be applied on both faces.

d) For vessels or parts or vessels whose content require an important corrosion allowance, an internal protective lining should be considered for shells and dished heads, by means of :

- Corrosion resisting lining.

- Cladding or lining of the basic steel plate with stainless metal at

least 1/8" (3 mm) thick, unless indicated to the contrary on the drawing.

In the case of cladding or lining, nozzle necks, manholes, flange faces, covers, etc... shall have an internal lining of same metal as used for shells and heads.

Unless otherwise indicated on the drawing, cladding or lining thickness shall not be included in the strength calculations.

2.2 Vessel Supports

2.2.1 Vertical vessels shall be provided with skirt which shall have an outside diameter

equal to the outside diameter of the supported vessel. The minimum thickness of the skirt shall be 6 mm exclusive of 1.5 mm corrosion allowance.

2.2.2 Skirts 1200 mm in diameter and less shall have one access opening; larger than

1200 mm diameter skirts shall have two 450 NB access opening reinforced with sleeves.

2.2.3 Skirt openings for piping shall have a 1/2 inch (13 mm) maximum clearance

between the pipe OD and the skirt. Minimum of two 2 inch Vent holes shall be provided in the skirt at highest possible location 180 degrees apart.

2.2.4 Skirt base ring shall be designed for an allowable bearing pressure on concrete

of 625 psi. Anchor bolt chairs or lug rings shall be used where required and in all cases

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where vessel height exceeds 18 meters. The number of anchor bolts shall be in multiples of 4; a minimum of 8 is preferred.

2.2.5 All horizontal vessels shall be supported by saddle supports fabricated to fit

the outside surface of the vessel within the tolerances required by the design to prevent excessive localized stresses in the shell. Saddles should not be placed over vessel girth welds and are to be continuously seal welded to the shell.

2.3 Nozzles and Manways

2.3.1 When the inside diameters of nozzles are specified, they shall be maintained.

When the inside diameters of manways are specified, they shall be considered as minimum.

2.3.2 Nozzles, manways and their reinforcements shall be attached to the vessel with

complete penetration welds.

2.3.3 Nozzles up to and including 50 mm NB in size shall be stiffened by 2 Nos. 40 X 6 mm thick flats welded at 90 Deg. apart.

2.3.4 Nozzles flanges shall be as per ANSI B 16.5, type and rating as specified in

drawings. Substitution of Weld Neck type flanges with Slip-on type will not be permitted.

2.3.5 All manhole covers shall be hinged or provided with a davit along with suitable

lifting handle.

2.3.6 External reinforcing pads shall have a minimum of one vent hole except that pads for nozzles greater than 16 inch NPS shall have a minimum of 2 vents and nozzles in excess of 36 inch (914 mm) NPS shall have 4 vents. Pads installed by sections shall have at least one vent per section, for future plugging with a maximum 1/4 (6 mm) inch NPS hole.

2.3.7 Class 150 flanges are not permitted for design temperatures over 700 Deg.F or

for pressure relief valve connections; Class-300 flanges shall be used as a minimum instead.

2.3.8 Integrally reinforced necks are preferred, although long welding neck flanges

and built-up construction are permissible. Caution shall be exercised for connection which must receive equipment to insure that the inside diameter is large enough and the flanges match.

2.3.9 Where 125 Ra is specified for flange surface finish, the range for acceptance

shall be 63 Ra minimum to 250 Ra maximum. Finishes shall be judged by visual comparison with surface finish roughness standards conforming to ANSI B 46.1. It is the Contractor's/Purchaser's responsibility both to comply with the above finish requirements and to assure that such flange finishes be protected from damage during shipping, storage and installation. Where flange surface finish is not specified, it will be the responsibility of the

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manufacturer for furnishing the gasket specification.

2.3.10 Lap joint flanges are not permitted in severe cyclic service. An example of severe cyclic service is defined in paragraph 300.2 of ANSI / ASME B 31.3 Piping Code.

2.3.11 All flanges intended for use with spiral wound metal gaskets shall be

designed using the manufacturer’s minimum gasket seating stress or the ASME Code value, whichever is greater.

2.3.12 The manufacturer shall give special consideration for the prevention of

overstressing the flange or bolts during gasket seating, when Class 300 and lower flanges are used with spiral wound metal gaskets.

2.3.13 Nozzles and man-ways shall not be located in tray down comers.

2.3.14 Manways and hand-holes shall be cut off flush with the inside of shell and the

inside edge shall be rounded. Unless internal projections are specified, nozzles are to be cut off flush with the inside of the shell and the inside edge shall be rounded to a radius of 3 mm. However, for mortar lined vessels, the nozzles falling in the lined zone will be internally projected to the extent of 5mm in excess of mortar thickness.

2.3.15 Threaded fittings of tapped holes are not permitted.

2.3.16 Flanges for nozzles and manways including blind flanges, upto 600mm

nominal size shall have ratings and dimension in accordance with ASME B-16.5 2.3.17 Flanges over 600mm nominal size and connected to piping shall be in

accordance with ASME B16.47 Series B and cheked for suitability for design condition plus any piping load.

2.3.18 Flanged manways and nozzles shall be of forged long weld neck or built-up

construction using weld neck flanges.

2.3.19 Non standard flanges should be avoided but if necessary shall be designed to code rules and shall take into account external loads, flange deflection, intial bolt load and hydrotest conditions.

2.4 Materials

2.4.1 General

a. Pressure vessel materials shall be in accordance with ASME Section II, Part A. Non- pressure parts may be in accordance with American Society for Testing and Materials (ASTM) Specification. ASME Specification numbers are prefixed by SA and the corresponding ASTM Specification numbers are prefixed by A.

b. Low temperature services as per the applicable Minimum Design Metal Temperature (MDMT) materials pretested and certified for low temperature

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applications. These materials are listed in ASME Section VIII, Division 1, Table UG-84.3.

c. All material used in the vessel(s) shall be new. d. Each plate, forging, and other product form shall be legibly stamped or

stenciled showing specification number, grade and class. When metal stamping is used it shall be on the long edge of each component as it leaves the mill. Metal stamping on rolled surface shall be done with a “low stress” stamp. Marking shall be protected from erosion, wear, or other events that may render them unreadable.

e. When the room temperature tensile strength of pressure containing components and welds is not limited to a lower value by the applicable product specification, it shall not exceed 100,000 psi (7030 kg/cm2).

f. Accelerated cooling from the austenitizing temperature is acceptable where permitted by the applicable product specification.

g. The tempering temperature for tempered material shall be at least 500 F (280 C) greater than the maximum intermediate or post weld heat treatment temperature.

h. The affect of heat treatment on tensile strength shall be determined by testing specimens from each heat of plate, pipe, and forgings [small forgings may be tested on a “lot” basis as defined in ASME Section VIII, Division 1, Section UG-84 (e) (2) ] and weldments representing each batch of welding consumables, covered electrodes and wire-flux combinations used for each production welding process. The specimens shall be subjected to the maximum heat treatment as defined in Paragraph 2.5.1i. The results shall comply with the requirements of the subject material specification.

i. When Charpy V –notch impact testing is required for a component or weld that will be heat treated, test specimens shall be provided in both the minimum and maximum heat-treated condition. Testing of welds shall include samples from each procedure, welder/welding operator and welding position. The minimum heat treated condition means subjected to the fewest heat treatment cycles and /or time-at-temperature anticipated for the component. The maximum heat treated condition means subjected to the maximum number of heat treatment cycles and / or time at temperature anticipated during fabrication (including intermediate stress relief and multiple heat treatment exposures) plus one additional heat treatment to simulate a future requirement.

j. Plates and forgings over 4 inches ( 100 mm) thick or used for pressure containment in HF acid or hydrogen service shall be:

1. Ultrasonically examined with 100% scanning in accordance with the following:

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a. Plates shall be examined before forming in accordance with ASME SA-435 including supplementary requirements SI.

b. Forgings shall be examined in accordance with ASME SA-388 and

ASME Section VIII, Division 2, AM-203.2.

2. Examined by either liquid penetrant (PT) or magnetic particle (MT) in accordance with the following:

a. The entire surface of all forgings, after finish machining.

b. Formed plate surfaces to be welded i.e. the weld bevel area and a minimum of 2

inches (50 mm) of neighboring surfaces.

c. Formed plate surfaces where weld overlay will be applied.

2.4.2 Shells, Heads and Other Pressure Containing components a. Shells may be fabricated from rolled plate, forgings or pipe. Layered construction is

prohibited.

b. Carbon steel plate shall be ASME SA - 285 Grade C. Other product forms shall be the equivalent grade of carbon steel.

c. Killed carbon steel plate shall be ASME SA - 516. Other product forms shall be the equivalent grade of killed carbon steel.

Item

Carbon Steel Vessels

Killed Carbon Steel Vessels

Pipe Plate for nozzle necks

SA - 53 type S, Grade B SA - 285 Grade C

SA - 106 Grade B SA - 516

Flanges Plate for Flanges ( Where permitted by ASME B16.5 or ASME B 16.47) Fittings

SA - 105 SA - 516 SA-234 Grade WPB Seamless

SA - 105 SA - 516 SA-234 Grade WPB- Seamless

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d. When the shell or head is internally lined or the thickness exceeds 2 inches (50 mm) a calibration block for ultrasonic examination shall be provided. The block shall be in accordance with ASME Section V, Article 5 and shall include a lining identical with the vessel lining.

2.4.3 Nozzles and Man ways

a. Flanges shall be forged.

b. Material requirements:

c. Solid alloy nozzles are not recommended for any service and shall not be used at design temperature above 4500 F (2300 C).

d. Austenitic stainless steel nozzles are not permitted.

e. Reinforcing pads shall be the same material as the shell.

f. Corrosion allowance for nozzles and man ways shall be at least equal to the specified for

the vessel shell.

g. Bolting materials shall be as required by the Pipe Class specified on the Piping and Instrumentation Diagram (P&ID). The applicable Pipe Class is that specified for the connected piping. When there is no connected piping ( e.g. a man way), use the miscellaneous connection Pipe Class specified for the vessel on the P&ID.

2.4.4 Vessel Support and Exterior Attachments

a. Material for rings, lugs, saddles, wear / corrosion plates, legs supporting vessels and the upper three feet of support skirts welded directly to the vessel or to reinforcing rings welded to the vessel shall be the same material as the shell when the design temperature is greater than 6500 F (3400 C). Otherwise, the material shall be ASTM A 285 or A 516.

b. External vacuum stiffening rings shall be the same material as the shell when the design temperature is greater than 6500 F (3400 C). When the design temperature is 6500 F (3400 C) or less the material shall be ASTM A 36, A 283, A 285, A 516, A913 or A992. Internal vacuum stiffening rings shall be the same material as the shell.

c. Base rings, reinforcement for skirt openings, saddle base plates, external lugs for platforms, ladders, insulation supports, pipe supports and other non-pressure parts welded to the vessel shall be ASTM A 36, A 283, A 285, A 516, A 913, or A 992. Angles and rods shall be ASTM A 36, A 913,

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or A 992.

d. External supports and attachments may be exposed to low ambient temperatures. The effects of this exposure upon material selection, stress analysis, fabrication details, etc shall be addressed.

2.4.5 Internals, Internal Bolting and Internal Supports

a. Carbon steel is specified, pipe shall be ASTM A106 or A 53 type S and plate, bars and shapes shall be ASTM A 36, A 283, A 516, A 913 or A 992.

b. Internal support rings, lugs, brackets and other items welded to the shell shall be the same material as the shell base metal in killed steel vessels and ASTM A 285 or A 516 in carbon steel vessels. In lined portions of the vessel they shall be covered with alloy lining. When welded directly to the lining, they shall be an alloy corresponding to the lining.

c. Bolting for distributors, baffles, or other miscellaneous items, not furnished by the tray supplier, shall be the same or similar alloy as the internals.

d. Drawings and instructions for fabrication and installation of tray and mesh blanket supports attached to the vessel shall be furnished by the supplier of the vessel internals. The vessel manufacturer shall fabricate and install the vessel attachments in accordance with those instruction and the Project and Standard Specification and Drawings.

e. As an alternative to welding rings, lugs and brackets to the shell, they may be formed from weld build- up (using the same weld materials used for the vessel strength welds) or integrally forged with the shell and covered with alloy lining where required. The transition to the shell shall be machined to a smooth and generous concave contour prior to the application of alloy lining (if required). The top surface of the completed support rings (i.e. after the application of alloy lining, if required) shall be machined to provide a smooth flat surface. The welding procedure, inspection and examination of weld build-ups shall be the same as required for the vessel strength welds.

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2.4.6 Gaskets

a. Gaskets shall conform to the requirements of the Piping Class Specified on the Piping and Instrument Diagram (P&ID). The applicable Piping Class is that specified for the connected piping. When there is no connected piping (e.g. a man way), use the miscellaneous connection Pipe Class specified for the vessel on the P&ID.

b. Gaskets for use with raised face flanges shall be spiral wound as per ASME

B16.20 with a non- asbestos filler material. In lined portions of the vessel, the winding material shall be the same as the vessel lining. In unlined portions of the vessel, the winding material shall be a minimum of ASTM A 240 Type 304. Gasket shall include an outer retainer ring. The outer ring may be carbon steel, protected against corrosion. Gaskets for Class 900 and greater flanges, flanges over 24 inch NPS and gasket in vacuum service shall have an inner retainer ring of the same material as the windings. Gaskets with an inner retainer ring shall also be used between flanges of different metallurgies with different coefficient of thermal expansion when they operate at an elevated temperature. The contractor shall verify the adequacy of all gaskets considering potential buckling of the outer or inner retaining ring (s ) and the windings.

c. The use of corrugated, double jacketed gaskets as per ASME B16.20 may be considered for large diameter openings (over NPS 24 inch), especially when the sealing surface is vertical or when the surface to be sealed is not round (e.g., multi-pass exchanger channel to shell closure gaskets).

d. Ring joint gaskets shall be as per ASME B16.20.

2.5 Fabrication

2.5.1 Plates shall be bent along the direction of plate rolling for forming the shell. Plates shall have only positive tolerances on thickness.

2.5.2 For vessels diameters 500 mm NB and below, pipes conforming to a code

listed equivalent material specification may be used for the shell.

2.5.3 Vessels heads may be deep hemispherical, tori spherical or 2:1 semi-ellipsoidal. The head type proposed shall be specified by Bidder in the offer, if the same is not indicated on the attached data sheet. Plate thickness selected for vessel heads shall include due allowance for thinning during the forming operations.

2.5.4 When a formed head is made from more than two plates it shall have a

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crown plate having diameter greater than that of the reinforcing pad of any nozzle located at the centre of the head. The inside and outside surfaces shall be MP/DP examined for detection of cracks.

2.5.5 Skirt and other attachment welds shall have complete fusion for the full length

of the weld, and shall be free from undercut, overlap, or abrupt bridges or valleys. All internal attachment welds shall be continuous.

2.5.6 Edges shall be prepared after cutting, machining or grinding to eliminate

defective material or discolouration. All welding edges of above 25 mm thickness and the welding edges of dish ends of all thickness shall be checked by MP/DP examination for detection of cracks, laminations or segregations.

2.5.7 All pressure bearing butt welds shall be full penetration, double welded joints.

When the second side welding is not possible due to inaccessibility, single welded butt joints with root run by Tungsten Inert Gas Process (TIG) may be used to ensure full penetration. Backing strip shall not be used.

2.5.8 Shell assembly and head assembly welds shall be spaced as far as possible and at a minimum distance of 2" (50 mm) from taps, gussets, nozzles, reinforcing pads, or other items welded to shell.

2.5.9 Depending upon shipping conditions and possibilities, vessels shall be delivered

either completely assembled, or in pre-fabricated sections. When a vessel has to be delivered in pre-fabricated sections, a provisional assembly shall be carried out in manufacturer's shop in order to check alignments and stamp the necessary markings for field assembly.

2.5.10 All vertical vessels shall be provided with lifting lugs or side trunions, as

desired by the Purchaser.

2.5.11 Reinforcing pads for internal or external structural attachments to vessel shells shall be provided with a 1/4 in (6 mm) diameter vent hole for the enclosed space between welds. External vent holes shall be plugged with a plastic sealant after the vessel has been tested.

2.6 Welding

2.6.1 a) All welding shall be done by a metal arc process.

b) Covered welding electrodes for non-alloy welding shall be in accordance with Specification AWS A5.1, ASME SFA-5.1.

c) Bare electrodes shall be in accordance with the following :

WELDING PROCESS ELECTRODE

Submerged Arc Welding AWS A-5.17, ASME SFA-5.17

Inert Gas Welding AWS A-5.18, ASME SFA-5.18

Flux-Cored Arc Welding AWS A-5.20, ASME SFA-5.20

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2.6.2 Deposited weld metal mechanical properties shall conform to the ASTM

requirements for the base metal. Low-alloy, high strength weld materials shall not be used unless the vessel is required to be post-weld heat treated (PWHT) at a temperature of 1150 Deg. F minimum.

2.6.3 Drawings and instructions for fabrication and installation of tray and mesh

blanket supports attached to the vessel shall be furnished by the appropriate supplier of the vessel internals. The vessel attachments shall be installed in accordance with the instructions, and specifications, by the vessel manufacturer. It is the responsibility of the vessel manufacturer to supply, or cause to be supplied, all material required for the fabrication of the vessel attachments for the support of internals.

2.6.4 All pressure vessels weld joints of categories A or B shall be Type No. 1 full

penetration butt welds in accordance with UW-3 and table UW-12 of the ASME Code.

2.6.5 Nozzles and manways and their reinforcement shall be attached to the

vessel with full penetration welds.

2.6.6 Circumferential welds shall be so located that visual inspection can be made with all internal equipment in place.

2.6.7 Seams in supporting skirts shall be made with full penetration butt welds.

Connections between skirts and vessel heads shall be made with a smooth flat faced weld, unless otherwise shown. The width of the weld shall be atleast equal to the skirt thickness, and its height shall be twice its width.

2.6.8 All welding directly to the base metal shall be completed prior to final heat treatment.

2.6.9 Each pressure retaining strength weld shall be spot radiographed, as

a minimum requirement. Each spot radiograph shall be a minimum of six inches (152mm) in length and in accordance with the ASME code. All welds to be covered by nozzle reinforcing pads and at least one weld intersection shall be included. Non-radiographable welds shall be examined by magnetic particle or dye penetrant as an acceptable alternate.

2.6.10 Welds in vessel shells shall be examined by 100% radiography as govened by UCS-57 of ASME Section-VIII, Division-I wherever required. In addition, 100% ultrasonic examination in accordance with the ASME Code is required after final post weld heat treatment.

2.6.11 Floating rings for insulation support shall be furnished with the vessel when specified.

2.7 Heat Treatment

2.7.1 For carbon steel formed components, including dished ends, stress

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relieving shall be performed as per ASME Section VIII Div.1, (UCS-79).

2.7.2 In addition cold formed carbon steel heads and knuckles shall be stress relieved when their thickness is 16 mm or greater. Hot formed heads shall also be normalized in case they are formed at temperatures below the normalizing range. Hot formed dished ends or similar parts, which have not been uniformly heated in the normalising range in the final stages of manufacture, shall be normalized.

2.7.3 Vessels in caustic service, amine or sour gas service shall be stress relieved.

2.7.4 Flange facings must be protected against oxidation during heat treatment.

2.7.5 When postweld heat treatment is required, one Brinell hardness reading shall

be taken on the inside (except in alloy lined portions of vessels) of each shell section, head, longitudinal weld, and nozzle, and each longitudinal, girth and nozzle weld after final post-weld heat treatment; and no reading shall exceed a value of 200.

2.8 Alloy lining

a. General

1 The term “Alloy Lining” is a general term that does not imply a specific fabrication or manufacturing process.

2 Alloy lining for shells and heads shall be integrally bonded cladding or weld

deposit overlay. The required alloy and thickness are specified in the project specifications.

3 Strip lining is not permitted.

4 Rings, lugs, brackets and other attachments in the lined portion of the vessel shall

be weld deposit overlayed unless they are fabricated from an alloy corresponding to the lining.

5 Tubular liners are not acceptable in nozzles greater than 1 ½ inch NPS or nozzles of

any size in HF acid service. Tubular liners may be used for smaller nozzles. The liner shall be welded to the alloy facing at the flange end. Attachment of the liner at the inside surface of the vessel shall be by an expansion /contraction collar. When differential thermal expansion/contraction between the liner and the nozzle is not a concern, the liner may be welded flush with the vessel's inside surface. The final details shall account for the sustained, transient, thermal (expansion/ contraction), and cyclic stresses due to the operation of the vessel.

6 In hydrogen service, nozzles with tubular liners welded on both ends shall be vented

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with a 1/8 inch NPS hole, drilled from the outside of the nozzle to the OD of the liner. The vent hole shall be tapped for future plugging with a material adequate for the operating temperature but incapable of retaining the operating pressure.

b. Cladding

1. Integrally bonded clad plate shall be fabricated in accordance with SA-263 for corrosion

resistant chromium stainless steel cladding, SA – 264 for chromium nickel stainless steel cladding, or SA- 265 for nickel based cladding.

2. The bond between the cladding and the base metal shall be tested by and comply with

the requirement of the “shear strength” test as described in the applicable cladding specification.

3. When integrally bonded clad plate is used, the lining shall be cut back at all seams a minimum of ¾ inch (19 mm) from the edge of the weld bevel to permit welding of the base metal. Complete removal of the cladding shall be verified before proceeding with welding of the base metal. The weld metal shall be ground flush and fully covered with the applicable weld deposit overlay per Paragraph 2.8 b.(4) of this Standard Specification. The weld deposit overlay shall be at least as thick as the cladding but no greater than twice its thickness.

4. Welding in conjunction with a clad lining shall be done with covered electrodes in

accordance with

ASME Specification Electrodes

Cladding Applied Lining Alloy to Carbon orKilled Carbon Steel

Alloy to Alloy

SA-263 SA-264

SA-240,Types 405 or 410S SA-240, Type 304

SFA-5.4 E309L SFA-5.4 E309

SFA-5.4 E309L SFA-5.4 E308

SA-264 SA -264 SA-264

SA-240, Type

304L SA-240,

Type 316

SFA-5.4 E309L

SFA-5.4

E309Mo SFA-

SFA-5.4

E308L SFA-

5.4 E316

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SA-264 SA-265

SA-240, Type 321 or 347 SB-127

SFA-5.4 E309Cb SFA-5.11 ENiCu-7

SFA-5.4 E347 SFA-5.11ENiCu-7

ASME Section II, Part C and the following electrode specification:

Note: When inert gas shielded or submerged arc processes are used, stainless steel welding shall be in accordance with ASME Section II, Part C, SFA – 5.9, with composition similar to those listed above. Nickel- Copper alloy (Monel) welding shall be in accordance with ASME Section II, Part C, SFA – 5.14 with a composition similar to that noted above. 5. ASME Section VIII, Division1, Part UNF, Appendix NF, Paragraphs NF-7 and NF-14 are

mandatory for non-ferrous types of cladding or weld overlay.

6. Internals may be attached directly to the cladding if the stress at the attachment under the design loads is less than one quarter of the allowable stress for the lug, ring, or bracket material. Otherwise, the cladding shall be cut back at least 3/4 inch (19mm) beyond the toe of the attachment weld and the lug, ring, or bracket shall be attached directly to the base metal. After the attachment is complete, the expose area shall be completely covered with weld overlay as described in paragraph 2.8 b.(4) of this standard specification. The weld deposit overlay shall be at least as thick as the cladding, but no greater than twice its thickness.

7. Large nozzles and manways utilizing built-up construction may use integrally bonded

cladding for the nozzle neck if the nozzle neck is fabricated from rolled plate

c. Weld deposit overlay 1. Weld deposit overlay may be applied by a single or multi-pass procedure and shall

comply with the requirements of API RP 582 except as modified or amended. The first pass of multipass austenitic stainless steel weld overlays shall be applied prior to post weld heat treatment when it is required and shall be made with an electrode complying with the requirements of paragraph 2.8 b.(4). The remaining passes shall be made with an electrode of the required lining alloy. Where internals will be attached to the lining, the second layer shall be applied after completion of the final post weld heat treatment. When the second layer is applied after post weld heat treatment, the thickness of the first layer and the heat input of the second pass welding procedure shall be such that the base metal is not affected by the heat and additional heat treatment of the base metal after the second layer is not required.

2. The ferrite content of austenitic stainless steel weld deposit shall be controlled to a

WRC (Welding research Council) Ferrite Number (FN) of 3 (5 for type 347) minimum to

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8 maximum. FN control shall be by reference to the DeLong constitution diagram for stainless steel weld metals. The limit defined above shall be confirmed by thoroughly checking the final deposits prior to post weld heat treatment with a magnetic instrument calibrated in accordance with the standards procedure defined in AWS A4.2. Reading shall be taken from at least ten randomly selected location on each shell course and head, and at least one location from each nozzle girth weld, vessel seam overlayed separately (e.g., between clad sections), overlayed support ring, bracket, or lug and strength weld. At least 6 readings shall be taken at each location.

3. Weld deposit overlay shall be applied circumferentially to the vessel and shall be

smooth with no notches or undercuts that would act as stress intensifiers. If necessary, longitudinal application in nozzles up to 8 inch NPS is acceptable. Flaws on the surface of the base metal that would interface with bonding of the overlay shall be removed by grinding.

4. The weld deposit overlay procedure shall be qualified on base metal of the same

composition as the vessel and thickness of at least one-half of the vessel thickness or 2 inches (50mm), whichever is less.

5. Nozzles and manways in alloy lined portion of vessels shall be alloy lined and

faced. The nozzles facing shall be made with a minimum of a two layer weld deposit in accordance with paragraph 2.8 b.(4). The surface layer shall be weld deposit of the same alloy as vessel lining and shall be at least as thick as the vessel lining when properly machined. The first pass shall be applied before post weld heat treatment (PWHT) when it is required. When nozzles are lined with ferritic Type 405 or 410S stainless steel, the facing weld deposit shall be made with Type 309L welding electrode. For ring joint flanges with an austenitic stainless steel overlay, the second pass shall be applied after completion of PWHT. The thickness of the first pass and the heat input of the second pass welding procedure shall be such that the base metal is not affected by the heat and additional PWHT of the base metal is not required after the second pass.

6. When austenitic stainless steel weld deposit overlay is used in an solvated operating

temperature over 7000F (3700C) hydrogen service the fabricator shall demonstrate that their procedure and materials provide immunity to lining disbonding. Testing shall be per ASTM G 146. As a minimum, the test shall representative of the actual operating conditions (e.g., hydrogen partial pressure, materials and materials thicknesses, temperatures, and heating / cooling rates).

7. Weld deposit overlay cracks and fissures and volumetric defects that penetrate through

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the overlay or are greater than 1/16 inch (1.6mm) diameter shall be removed. Repaired areas shall be 100% re- inspected by liquid penetrant.

8. The weld deposit overlay of each overlayed shell section and head shall be examined

in at least two separate, randomly selected, location to confirm the required chemical analysis of the specified overlay material. Each manual weld overlay, such as those on girth seams, nozzles and flanges facing, shall also be examined in the same manner. After machining, analysis at a depth equal to the specified overlay thickness from the surface exposed to the process environment shall conform to the chemistry requirements (e.g., C, Cr, Ni, Nb (Cb), Mo, V, Ti, and Cu as applicable) for the alloy specified in the Specifications . Where weld deposit overlay is applied by more than one welder / welding operator and / or procedure, examination shall include at least 2 samples of deposits made by each welder / welding operator for each procedure.

2.10 Tolerances

a. Vertical vessels shall be checked for plumbness. The outside surface of the cylinder

shall not vary from a straight vertical line by more than 1/4 inch (6mm) in any 20 feet (600mm), nor more than 3/4 inch (19mm) between any two points in the total length of the vessel. The vertical reference line shall be perpendicular to the vessel’s cross section. When the shell thickness is 4 inches (100mm) or more the variation from a straight line shall not exceed 1-1/4 inches (30mm) between any two points in the total length of the vessel.

b. Horizontal vessels shall comply with the criteria of paragraph 5.5a. of this Standard

specification except that the reference line shall be horizontal and perpendicular to the vessel’s cross section.

c. The maximum offset (misalignment) for longitudinal joints shall be 1/4 inch

(6mm) and for circumference joints, 1/2 inch (13mm).

d. Vessels with internal trays or grids shall not vary more than plus or minus 1/2 percent from the nominal diameter specified in the specifications, with a maximum variation in diameter from nominal of 1/2 inch (13mm). Vessels without trays or grids shall not vary more than plus or minus 1 percent from the nominal diameter specification in the specifications, with a maximum variation from nominal diameter of 1 inch 925mm).

e. The overall length of the vessel, not including the skirt, shall be within plus or minus

the greater of 1/2 inch (13mm) or 1/64 inch (0.4mm) per foot (300 mm) of length specified in the specifications, up to a maximum of plus or minus 3/4 inch (19mm).

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f. The length of skirt shall be within plus or minus 1/4 inch (6mm) of the specified length. g. Nozzle elevations shall be within plus or minus 3/8 inch (10mm) and orientation shall

be within plus or minus 1/4 inch (6mm) of the specified location. The nozzle projection shall be within plus or minus 1/8 inch (3mm) of the specified value.

h. The maximum horizontal or vertical deflection of the machined faces of nozzles from the design plane shall be 1/2 degree or 1/32 inch (0.8mm), whichever is greater.

i. Man way elevation, orientation and projection shall be within plus or minus 1/2 inch

(13mm) from the specified values. Tilt shall be within plus or minus 1/4 inch (6mm) of perpendicular nozzle axis.

j. The maximum deviation of internal tray supports from a level (horizontal) reference

plane shall be plus or minus 3/8 inch (10mm).

k. The maximum variation in spacing between supports for adjacent tray shall not exceed 1/16 inch (1.6mm) per foot (300mm), with a maximum of 1/8-inch (3mm).

l. The maximum variance (distance between high and low points) in individual tray

supports with respect to the level plan shall be 0.3 percent of the nominal inside diameter of the vessel, with a maximum of 1/4 inch (6mm).

m. The tray supports plane shall not vary more than 1 degree from normal to the vessel centerline.

3.0 SCOPE OF SUPPLY AND SERVICES

3.1 Scope of Supply

Bidder's scope of supply shall include the pressure vessels as specified in the attached data sheets, complete with all internals and appertunances as applicable.

4.0 VENDOR DATA SHEET

Bidder shall comply with the enclosed "Vendor Data Requirements" list for drawing and documents to be submitted to Purchaser with the bid and after placement of order.

5.0 INSPECTION AND TESTING

5.1 The pressure vessels shall be subject to stagewise and final inspection at Bidder's

shop by Purchaser. The same shall be offered prior to any primer coating.

5.2 Inspection shall be carried out based on IOCL’s quality assurance plan after agrement between purchaser and the vendor.

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5.3 Prior to the final inspection of vessels, all slag, loose scale, dirt, grit, weld spatter, paint, oil and other foreign matter are to be removed in order that the inspection can be conducted in a thorough manner.

5.4 The approval of the work by the purchaser's inspector and his release of the

vessels for shipment shall in no way release the manufacturer from, or relieve the manufacturer of, any responsibility for carrying out all of the provisions of this specification and the fulfilment of the guarantee; nor does the purchaser by such approval and release, assume any responsibility whatever for such provisions and guarantee.

5.5 Manway and hand hole cover hinges and hinge bolts shall be in place before

the vessel is tested. The hinge bolts shall fit so they can be turned freely by hand. Covers shall be swung open to insure that no binding occurs.

5.6 Welded attachments provided with vent holes shall be tested by pneumatic or

hydrostatic pressure prior to post weld head treatment and final hydrostatic test.

5.7 Vessels shall be shop hydrostatically tested in the horizontal position and shall be supported adequately to prevent local stresses in the shell from exceeding 90% the yield strength of the material.

5.8 For vessels or sections of vessels where butt welded seams are 100% radiographed, all other pressure containing welds and all attachment welds to pressure containing parts shall be examined as follows -

a) Welded joints covered by reinforcing pads shall be 100%

radiographed prior to installation of the reinforcing pad.

b) Support skirt and lifting lug welds, and pressure containing welds other than butt joint, shall be examined by the ultrasonic method using either the straight beam or shear wave mode. Alternative inspection methods such as in-process magnetic particle examination, may be substituted if approved by the Purchaser.

c) All attachment welds to pressure containing parts on materials other than

P1, Groups 1 and 2, shall be examined by the magnetic particle method. If the material is non- magnetic, the liquid penetrant inspection method shall be used in place of the magnetic particle method.

Accessible welds subject to PWHT shall be inspected after PWHT. All locations of temporary attachment welds on materials other than P1, Group 1 and 2, shall be similarly inspected.

5.9 Hardness of hot formed sections, base metal, weld metal and the related heat

affected zone (HAZ) of all welds shall not exceed 225 Brinell for P-1, P-3, P-4 and P-10 materials, before PWHT.

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The vessels fabricator shall check the weld hardness of the initial production weld for each welding process, filler metal, and technique used. If the clearances are such that it is not possible to check the production weld, a mock-up with identical conditions shall be used.

5.10 For vertical vessel supports skirts, the finished skirt-to-shell weld shall be

examined by the magnetic particle method after any required postweld heat treatment (PWHT). For field welded skirts, the top skirt course of alloy material shall be "safe-ended" with a carbon steel extension prior to any required PWHT, Skirt butt welds shall be inspected by spot radiography. Atleast one radiograph shall be made for every two girth seams, and one for every two vertical seams.

5.11 Charpy impact tests shall be carried out for deposited weld metal from

electroslag, electrogas, and other single pass butt welds through the full thickness of the material. Tests shall be made on weld production impact test plates (run-off tabs). Required impact values shall be as given below -

Reference Charpy V impact value for full size Thickness specimen at minimum design metal temp. (mm) (Min. Av. of 3 specimens/Min. of 1 Specimen)

SA-515/516,Gr.55 & 60 SA-515/516,Gr.65&70

<= 17/13 20/16 10 to 25 20/16 27/22 25 to 50 20/16 34/27 > 50 34/27 47/38

5.12 For stainless steel vessels, the quality of water to be used for hydrotesting

shall have a maximum value of 25 ppm chloride. For C.S. Vessels, the testing medium (water) shall be at a temperature of more than 20 Deg C. Sea water shall not be used for testing.

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5.13 Bidder shall give minimum 15 days clear notice of shop inspection and testing to

Purchaser.

6.0 NAME PLATE

Each vessel shall be provided with a name plate of stainless material, bearing the trade name of the manufacturer. This plate shall be permanently fixed and carry all the relevant process informations, capacity and empty weight of the vessel.

Name plates shall be permanently visible. On hot insulated vessels this plate shall be fashioned on a small support so as to protrude beyond vessel insulation.

7.0 PAINTING AND PROTECTION

7.1 Surface cleaning and painting

7.1.1 All completed equipment shall be cleaned internally and externally to remove

scale, dirt, sand, water and foreign matter

7.1.2 The surface preparation of outside surface of vessels / columns shall be done by blast cleaning only.

On completion of operation, the blasted surface shall be clean, dry and free from any mill cale, rust, rust scale and foreign matter. Primer or first coat of paint shall be applied with spray / brush as per the manufacturer’s recommendations and preferably within 4 hours of surface prepraration. Blast cleaning shall not be done outdooe in bad weather without adequate protection or when there is dew on the metal surface which is to be cleaned or when humidity exceeds 85 %.

The finish of surface preparation of steel surface requiring painting shall conform to SA 2.5 of Swedish Standard SIS-05-5900. The anchor profile shall be in general 15 to 50 microns. However, for F-12 system of painting, anchor profile shall be 10 to 15 microns.

The two types of blast cleaning methods are as given below :

7.1.2.1 Air Blast Cleaning

The surface shall be blast cleaned using one of the abrasives : sand chilled cast iron or malleable iron and steel at pressure of 7 Kg / Sq.cm at appropriate distance and angle depending on nozzle size; maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel shall be in the form of shot or grit of size not greater than 0.055“ maximum in case of steel and malleable iron and 0.04 “ maximum in case of chilled iron. Compressed air shall be free from moisture and oil. The blasting nozzles shall be venturi style with Tungsten Carbide or Boron Carbide as the materials for liners. Nozzle orifice from 3/16” to 3/4”.

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7.1.2.2 Water Blast Cleaning

Environmental, health and safety problems associated with abrasive blast cleaning limit the application of air blasting in many installations. In such cases, water blasting shall be resorted to.

Water blast cleaning can be applied with or without abrasive and high pressure water blasting. The water used shall be inhibited with sodium chromate / phosphate. the blast cleaned surface shall be washed thoroughly with detergents and wiped with solvent and dried with compressed air. For effective cleaning, sand is used as an abrasive. The operation shall be carried out as per SSPC guidelines for water blast cleaning.

7.1.3 Austenitic stainless steel, high alloy steel and non-ferrous materials shall be kept

free of paints 7.1.4 All flanged faces and other machined surfaces shall be greased or

protected with rust preventive coating.

7.1.5 The shades of successive coats shall be kept different in order to ensure visual inspection of application of each coat.

7.2 Painting

Except for machined surfaces, all exterior surfaces of the vessels and columns, including skirts and integral supports shall be painted as given below to prevent rust, corrosion or damage during transit and storage before erection and final painting. This paint system mentioned hereunder shall be applicable for all environments after satisfactory surface preparation. System Description Operating Paint System Temp Range ( Deg C)

Uninsulated Carbon and Low Alloy Steel Columns & Vessels - above ground & underground

(-) 25 to 400 One coat of Inorganic Zinc Silicate coating Total DFT : 65 to 75 microns

Insulated carbon and low alloy (-) 15 to 100 One coat of Epoxy Phenolic coating steel columns & vessels Total DFT : 10 microns

DM Water Service

101 to 400 2 coats of heat resistant silicon paint suitable upto 400 Deg C of 20 microns per coat Total DFT : 40 microns

a) External Surface

b) Internal Surface

All Temp All temp

As per applicable system above 2 coats of Epoxy Zinc phosphate primer (35 microns / coat) plus 2 coats of Epoxy high built coating (100 microns / coat) Total DFT : 270 microns

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7.3 After the vessels are shop tested, all exposed machined surfaces shall be suitably

protected by an approved type of protective compound. All nozzle openings shall be covered by wooden or metal closures prior to despatch.

7.4 Marking

In addition to General Purchase Conditions, the following requirements shall also be complied with.

7.4.1 All loose components such as studs, nuts, washers, gaskets, etc., shall be

packed in crates and shall be marked for the project, consignee, consigner, job no., item no., order no., gross & net weight, dimensions, etc.

7.4.2 Additional indications such as North / East / South / West along with the centre of

gravity shall be clearly marked with white paint.

7.4.3 Vessels which have been post weld heat teated or have an applied lining, eg. lead, glass, rubber, etc., shall have a suitable warning printed on the visible portion on the outside on the outside of the vessel.

7.4.4 Specific marking with white paint for slinging shall be provided for all heavy lifts

weighing 5 tonnes and above.

7.4.5 A copy of the packing list shall accompany the material enclosed in a water tight envelope fastened inside a shell connection with an identifying arrow sign “Documents” applied with indelible paint.

7.4.6 If it is necessary to separate the unit into different parts for transportation all

components and sub-assemblies shall be carefully identified and match marked to prevent aby error in assembly.

8.0 PACKING & SHIPMENT

8.1 Pre-fabricated sections shall be protected by temporary stiffeners at each non-

supported end. Edges of plates or sections to be welded shall also be protected. Flange faces on all nozzles and couplings shall be protected by blanks. Tapped orifices shall have threaded plugs.

8.2 Equipment shall be carefully packed so as not to be damaged in any way during

transport. Fragile or machined parts in particular, shall be especially protected, not only against rust but also against shocks of any nature.

8.3 All parts shall be carefully cleaned. Unless otherwise indicated vessels shall be

delivered unpainted.

8.4 If it is necessary to separate a unit into different parts for transport reasons, all parts shall be carefully identified or match marked to prevent any error in assembly.

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8.5 Large diameter vessels of small thickness shall be provided with an adequate

number of struts, positioned inside the vessel to prevent ovalization effect while being handled. These struts shall not be removed until after vessel is placed in postion at jobsite.

8.6 Vessels, unless provided with their own steel saddles for entire protection, shall

be provided with suitable wooden saddles with steel saddles with steel ties and tension rods. The minimum height of the saddle shall correspond to the maximum projected length of the connected attachments, plus an additional clearance of 45 mm. Saddle spacing shall depend on the length of the equipment.

8.7 After removal of plugs and checking of flange faces, vessels shall be shipped to

the field with gaskets used for shop hydraulic tests. Final gaskets shall be shipped properly protected in a separate container.

Solid metal joints used for shipment, together with the corresponding flange faces, shall be specially covered with a coat of grease or varnish.

9.0 GUARANTEE

Bidder shall guarantee the pressure vessels supplied in respect of design, materials and fabrication in accordance with the terms of General Purchase Conditions.

10.0 SITE FABRICATION & ERECTION 10.1 Where the shape or size of the vessel makes it impossible to ship it in one

piece, the fabricator shall ship minimum number of shop fabricated sections suitable for shipment. Assembly and testing shall be completed by the vessel fabricator at site in horizontal position (for erection by others) in strict accordance with the provisions of the applicable order / specification.

10.2 Where the size or shape of vessel makes it impossible to erect it in single piece, the

fabricator shall ship minimum number of shop fabricated sections suitable for erection.Erection, assembly and testing shall be completed by vessel fabricator at site in vertical position in strict accordance with the provisions of the applicable order / specification.

10.3 In either of the above two cases, the following additional requirements shall apply :

10.3.1 All pieces shall be shop fit up into sections and each section fit to the adjacent

one by the fabricator and all pieces match marked thereafter.

10.3.2 The width of the permissible gap furing fitup shall be in accordance with the approved shop drawings and welding procedures.

10.3.3 Suitable erection lugs and locating pins shall be provided by the fabricator to

ensure proper fitup of the equipment.

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10.3.4 All radiographic requirements for welds completed in the shop shall be made by the fabricator before the part of the section leaves the shop.

11.0 DIMENSIONAL TOLERANCES FOR PRESSURE VESSELS

Dimensional tolerances for pressure vessels shall be as listed below except when specified otherwise in the vessel data sheet :

11.1 Outside surface of shell cylinder may be out of alignment/straightness not more

than 6 mm in any 6 metre of cylinder length, subject to a maximum of 20 mm in the total length.

11.2 The maximum permissible offset for longitudinal joints shall be 6 mm and for

circumferential joints 12 mm.

11.3 Out-of-roundness (ovality) of vessel shell shall be as per ASME Code, with the additional limitation that for vessels with internal trays any diameter may not vary more than +/- 0.5 percent from the nominal diameter, with a maximum variation in diameter from nominal of 12 mm.

11.4 Outside circumference of shell shall be within the following limits :

+/- 10 mm for noimnal diameter 1200 mm and under. +/- 12 mm for noimnal diameter 1200 mm through 2400 mm. +/- 20 mm for noimnal diameter above 2400 mm.

11.5 Tolerance for overall length of vessel, not including the skirt, shall be +/-5 mm

per 3 metre subject to a maximum of 15 mm.

11.6 The skirt length for vertical vessels shall be held within a tolerance of +/- 6 mm.

11.7 The tolerance for nozzle location shall be +/- 10 mm for elevation, +/- 6 mm for orientation, and +/- 3 mm for projection.

11.8 The tolerance for manways shall be +/- 12 mm for elevation, orientation and

projection, and 6 mm for tilt.

11.9 Elevations from reference plane may vary to the extent of +/- 12 mm for manholes, +/- 6 mm for nozzles, and +/- 5 mm for internal supports except that locations or manholes and nozzles near trays shall not vary more than +/- 5 mm from the tray.

11.10 Tolerance for centre to centre distance between any pair of instrument connections

shall be+/- 1mm.

11.11 The maximum horizontal or vertical perfection of the machined surfaces of the gaskets contact faces of nozzles shall be +/- 2 Degree or 0.6 mm whichever is greater.

11.12 The tolerance for the maximum variance (distance between high and low

points) in individual tray supports with respect to the level plane shall be within +/- 5 mm of the specified elevation from datum. Variation in spacing between adjacent internal trays/supports be within 0.30 percent of the nominal inside

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diameter, with a maximum of 6 mm.

11.13 The maximum tolerance from a true base for internal tray supports shall be +/- 10 mm.

11.14 The tolerance for maximum variation of tray supports with respect to the vessel shell shall not exceed 1 Deg. from normal.

11.15 Tolerance for distance between horizontal vessel centre line and bottom of

saddle supports shall be +/- 3 mm.

11.16 Centre to centre distance between saddle supports and saddle bolt holes may vary +/- 3 mm.

11.17 Skirt base ring out of squareness shall be within +/-3 mm for 2500 mm OD and under,

and +/-6 mm for larger diameters.

11.18 The base ring bolt circle diameter and the distance between two consecutive anchor bolt holes may vary +/- 5 mm.

11.19 Tolerance for distance between any pair of adjacement structural attachments

shall be +/- 3 mm.

12.0 DATA FOLDER

The manufacturer shall prepare six copies of data folders and two copies in soft form (CD form) as required in the purchase order. The folder shall contain the following information, duly certified by the Inspector :

a) Manufacturer’s code certificate b) Sketches of the vessel showing as-built dimensions and the plates used with

their cast and test numbers. c) Material test and analysis certificates. d) Welding procedure qualification reports.. e) Welder qualification reports. f) Radiograhic results g) Ultrasonic, Magnetic particle, dye-penetrant test results (if applicable) h) Hardness, corrosion and leak test record (if applicable) i) Record charts showing complete heat treatment cycle (if applicable) j) Production test coupon results (if applicable) k) Charpy V notch test results (if applicable) l) Record chart of pressure test (hydrostatic and / or pneumatic) m) Rubbing of name plate n) Any other documentation as required in the purchase requisition / order.

13.0 Following should be attached as Annexure (as per tender specific requirement):

1. Supplementary Specification for Handling/Cleaning of Stainless Steel and Nickel

alloys (IOCL/M&I/MECH/E/S/13). 2. Supplementary Specification for Carbon Steel Vessels (IOCL/M&I/MECH/E/S/04). 3. Supplementary Specification for Structural Quality Plates for Tanks &

Vessels (IOCL/M&I/MECH/E/S/12). 4. Technical specification for Boiler Quality Carbon Steel Plates

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((IOCL/M&I/MECH/P/14). 5. Technical specification for Stainless Steel Plates (IOCL/M&I/MECH/P/16).

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Abbreviations: BIS Bureau of Indian Standards BS British Standards BHN Brinell Hardness Number DP Dye Penetration STAAD Structural analysis and design computer program MDMT Minimum Design Metal Temperature TPlA Third Party Inspection Agency ASME American Society of Mechanical Engineers AWS American Welding Society CS Carbon Steel GAD General Arrangement Drawings ID Internal Diameter LSTK Lumpsum Turnkey MOC Material of Construction MR Material Requisition OD Outside Diameter PQT Procedure qualification test PQR Procedure qualification

record PL Process Licensor PMC Project Management Consultant SS Stainless Steel TIG Tungsten Inert Gas WPS Welding Procedure specification

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CONTENTS

SL. NO. DESCRIPTION PAGE NO. 1.0 SCOPE 4 2.0 VENDOR'S QUALIFICATION 4 3.0 APPLICABLE DOCUMENTS 4 4.0 DESIGN CRITERIA 4 5.0 INSPECTION 11 6.0 TESTING 11 7.0 PREPARATION FOR SHIPMENT 12 8.0 HANDLING 12 9.0 DOCUMENTATION 12

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1.0 SCOPE 1.1 This specification covers the minimum requirements for rotating agitators designed

and manufactured to Vendor’s standard design. 1.2 Compliance with this specification does not relieve the Vendor or his sub-

Vendors of their responsibility to provide equipment of correct design, construction and materials entirely suitable for continuous, safe and reliable operation under the specified process and environmental operating conditions.

2.0 VENDOR'S QUALIFICATION Equipment offered by Vendor shall satisfy the following minimum service and

manufacturing experience requirements: 2.1 Equipment shall be identical or validly similar in power rating, speed, capacity,

service and application, mechanical design, materials and rotor dynamics as compared with at least two units produced by the Vendor at the proposed manufacturing plant one of which must have had at least one year's satisfactory operation at the time of enquiry issue.

2.2 Equipment manufactured under license, in addition to satisfying the above

requirements shall also have the licensor's written guarantee. Relevant reference list shall be submitted with Vendor’s quotation detailing the

application, power rating, rotational speed, year of installation, client contact person details, mechanical configuration and materials of construction etc.

3.0 APPLICABLE DOCUMENTS 3.1 Statutory Requirements: The Vendor shall ensure that all equipment in his scope of

supply complies with all applicable statutory requirements, standards, codes, local rules and regulations.

4.0 DESIGN CRITERIA 4.1 General 4.1.1The equipment ( including auxiliaries ) covered by this specification shall be

designed and constructed for a minimum service life of 20 years and at least 3 years of uninterrupted operation. Vendor shall recognize that this is a design criterion.

4.1.2 The Vendor shall assume unit responsibility for all equipment and all auxiliary

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systems included in the scope of the order. He shall assure that all sub-Vendors comply with the requirements of this specification and all reference documents.

4.1.3 The Vendor shall select impeller for axial flow or radial flow, on the basis of required

(a) Physical duty i.e. suspension/homogenization/heat transfer or Dispersion and (b) Chemical duty i.e liquid /liquid & liq-gas sol reaction/dissolution/ blending or liquid gas reaction/emulsification/dispersion respectively.

4.1.4 All electrical components, enclosures and installations shall be in accordance with

“Electrical Requirements for Package Supply Equipment Units’’ and suitable for the area classification and environmental conditions specified in the material requisition.

4.1.5 The Vendor shall provide all the information necessary for the correct design of

allelectrical, instrumentation, civil and mechanical interfaces. Agitator components shall be designed to fit the vessel opening specified in the Material Requisition.

4.1.6 All special tools and fixtures required to dismantle, re-assemble and maintain the

agitator and its components shall be provided by the Vendor with the equipment. 4.1.7 The motor, transmission system and shaft shall be rated adequately to cover the

most arduous of the following operating conditions: a. In water b. With solids in suspension (particularly if suspension is not homogenous). c. In the process liquid specified. d. Operation in multi-phase layers and in the transition between liquid and vapour

phases. e. In air (outside the liquid). f. During speed changes. g. For the vessel design, e.g. whether baffles, heaters etc are fitted. h. During vessel filling and emptying, including passing through the liquid surface. 4.1.8 The agitator, including drive and seal unit, shall be designed for 3 years of

continuous operation. 4.2 Pressure Conta inment : Pressure con ta in ing components including

mount ing f langesshall be suitable for the design pressure and temperature, of the mixing vessel, specified in the Material Requisition.

4.3 Agitator Shafts 4.3.1 Solid constant diameter, one piece shafts of cantilever design are preferred. 4.3.2 The shaft’s first critical speed shall not be less than 30% above the maximum

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shaft speed under all operating conditions, including operation in air and when partially submerged in the process liquid.

4.3.3 When specified the Vendor shall conduct a lateral/torsional analysis of the

rotating system and submit the calculated critical speeds to the IOCL for review declaring the allowances made for support stiffness and damping.

4.3.4 Torsional modes of the complete drive systems shall be at least 10% away from

any operating speed under all operating conditions. 4.3.5 If mechanical seal is not specified, packed glands may be offered. The shaft, in

the region of packed glands shall be surface hardened with a hardness in the range of 360/465 Brinell unless otherwise specified.

4.3.6 Impeller hubs shall be keyed and located with set screws to the shaft. Hubs shall

be fabricated with full penetration welds. 4.3.7 Impeller vanes shall be bolted to hubs by at least four (4) bolts, located by two (2) dowels at two bolts and two close fitted bolts. 4.3.8 The shaft shall be designed for an operating life of 200,000 hours minimum 4.3.9 All changes in shaft section shall be radiused, polished and shot peened. 4.4 Balancing Impellers, hubs and couplings shall be individually statically balanced

and complete shaft assemblies shall be check balanced. High speed agitator assemblies, running at over 200 RPM, shall be dynamically balanced.

Vendor shall submit full details of the balance procedure for IOCL’s review. 4.5 Shaft Seals 4.5.1 Shaft seals shall be provided to prevent leakage from or into the mixing vessel

over the range of specified operating conditions and during periods of idleness. Shaft seals shall be designed for safety and suitability for the intended service taking into account all normal, abnormal and emergency conditions as specified, including start-up and shutdown.

4.5.2 Where mechanical seals are used, the same shall comply with technical

specification for Mechanical Seals and the following:

a. The shaft mechanical seal assembly shall be of the cartridge type, designed for ease of maintenance and shall be positioned close to a bearing. The shaft and shaft support system shall be designed to minimize shaft deflections in the seal area. Maintenance and replacement of the seal shall be possible without draining the vessel, removing the agitator from the vessel or, for large agitator units, removing the drive unit. The agitators shall have provision for the support of the agitator shaft

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during servicing of the mechanical seals. b. Mechanical seals of the single type are preferred. When leakage cannot be

tolerated, double seals, tandem seals or auxiliary shaft sealing devices shall be provided. The Vendor shall furnish all mechanical seal piping and appurtenances. Seal pots, when required, shall be designed to ASME VIII, fully tested and code stamped.

c. A fully detailed mechanical seal schedule shall be submitted. d. Mechanical seals shall be designed for continuous operation of at least 120% of the

maximum pressure expected. e. Vendor shall submit seal details with his quotation. f. All parts of seal housing in contact with the process fluid shall be constructed

in a material providing similar or better mechanical and chemical properties to the vessel material.

4.5.3 Where gland packing is used: a. Stuffing boxes for packing’s shall include a seal cage with connections for introducing

cooling medium or lubricant directly into the packing. b. A spare set of gland packing shall be supplied with each agitator. 4.6 Bearings and Lubrication 4.6.1 The use of steady bearings is discouraged, however where they are used, they

shall comply with the following: a. Unless otherwise specified, bearings shall be of the replaceable design and

lubricated by the liquid in the vessel. b. Bearings shall be capable of running 'dry', for short periods during tank filling and

emptying, and while totally immersed in the tank fluids. The Vendor shall consider carefully the selection of shaft, bush materials and running clearances.

c. The Vendor shall be responsible for the design of the fixing of any proposed steady

bearing. The Vendor shall state in his quotation the proposed method of securing the steady bearing support to the vessel.

d. Bearing inserts shall be readily replaceable without removing the agitator or the

impeller. e. Provision shall be made to permit steady bearing alignment in the field.

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f. The shaft shall be engaged in the steady bearing at all times including when the mechanical seal unit is removed or serviced.

g. All locating points on steady bearings shall have at least two (2) dowels or fitted bolts

per plane of location. h. Fixed joints on steady bearing supports shall have two (2) dowels or fitted bolts. 4.6.2 Vendor shall state the L-10 rating of the proposed bearings. 4.6.3 The lubrication system shall be Vendor's standard unless otherwise specified in

the material requisition. Bearing housings for oil bath lubrication shall be equipped with constant level oilers or an oil level indicating gauge, a fill connection with a plug, a drain connection with a plug, a breather-type vent with a dust filter and a means of locking constant oil level oilers in the correct position.

4.6.4 Main bearings shall be rated to take loads 50% greater than those predicted for

the equipment. The effect of reverse thrust shall be taken into consideration. 4.7 Agitator Mounting Flanges 4.7.1 Mounting flanges shall be in accordance with ANSI B16.5 unless otherwise

specified and shall be designed as a pressure part of the vessel in accordance with the vessel design code.

4.7.2 Agitator Vendor shall include the gasket, nuts and bolts for the vessel mounting

flange in his scope of supply. Gasket type to be as specified in the material requisition.

4.7.3 The Vendor shall advise the magnitude of the static and dynamic loads imposed on

the vessel nozzle by the agitator. The Vendor shall also advise the details of the required mounting flange flatness required to which the nozzle should be machined.

4.8 Auxiliary Piping 4.8.1 All auxiliary piping including all accessories such as gauges and valves, shall be

furnished by the agitator Vendor, fully assembled and installed. 4.8.2 Flanged connections shall conform to ANSI B16.5. 4.8.3 Pipe nipples shall be seamless Schedule 160 and shall be 20mm (3/4") minimum

size. 4.9 Materials 4.9.1 Materials for agitator parts shall be suitable for the service specified. Materials

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shall be identified in the proposal with the applicable International Standard numbers, including material grade listed on requisition data sheet. Where International standards are not available, internationally recognized national or other equivalent standards may be used.

4.9.2 Asbestos shall not be used in any form. 4.9.3 The Vendor shall furnish bolt torque values with his installation instructions. 4.10 Drivers 4.10.1 Electric motor drivers shall be in accordance with the material requisition and

shall have the nameplate power rating at least equal to the following percentage of the maximum absorbed power (including transmission losses), required for any of the specified operating conditions.

Motor Nameplate Power Percentage of Max Abs Power 18.5 kw and less 125% 22 kw - 74 kw 115% 75 kw and more 110% 4.10.2 Electric motors to be supplied to Specification ‘’Induction Motors’’. Vendor to

complete and return the relevant motor data sheets. 4.11 Gears 4.11.1 All gear ratings and service factors shall preferably conform to AGMA 420 or

AGMA 421. Gear service factor should not be less than 2.0 based on motor installed power.

4.11.2 Gears shall be designed for direct-on-line starting of electric motor and starting

torque of agitator. 4.11.3 A positive lubrication system shall be used to ensure a continuous supply of oil to

the meshed surfaces of the gears and to the bearings (pumped or splash lubrication). Pumped systems shall be fitted with strainer and/or filter, a pressure gauge and low pressure trip to safeguard against pump failure. The oil reservoir shall be positioned such that the oil level can be adjusted while the agitator is running. An oil cooler shall be included where necessary.

4.11.4 The Vendor shall provide full details of the lubrication system in his proposal. 4.11.5 A ready means of checking the gear box oil level shall be provided.

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4.11.6 Gear box design shall be such that oil will not leak down the shaft in the event of a failure of the gear box rotary oil seal. 4.12 V-Belt Direct or gearbox drives are preferred, however V-belt drives may be acceptable for agitators with a power rating of 75kW or less. V-belts shall be furnished by the agitator Vendor.

4.12 V-belt drives shall be selected with a minimum service factor of 1.4. All belts shall

be oil resistant. Belt guards shall be supplied along with the equipment. 4.13 Couplings and Guards 4.13.1 Agitator to gearbox coupling shall be of the rigid spacer type. For motor to

gearbox connection a flexible coupling, belt drive or geared motor unit is acceptable. Gear type couplings are not acceptable. Flexible couplings shall be adequately rated for all operating and transient conditions.

4.13.2 The flexible coupling between the driver and gear shall be supplied and installed

by the agitator Vendor. Unless otherwise specified, installation and alignment of the driver and gear box shall be the responsibility of the agitator Vendor.

4.13.3 Couplings shall be keyed in place. Cylindrical interference fits shall be light to

permit removal in the field without heat. 4.13.4 A spacer type coupling shall be provided for units using solid shaft drive units

equipped with mechanical seals. Sufficient length of spacer shall be allowed to permit replacement of the seal assembly without removing the driver.

4.13.5 Limited end float couplings shall be used with sleeve bearing motors to prevent

the motor rotor from rubbing the ends of either bearing. The maximum rotor thrust that can be developed shall be stated by the motor Vendor and must be taken care of by the gear unit, if used or by the agitator if a gear unit is not used.

4.13.6 The agitator Vendor shall be responsible for the finished boring of the motor half

coupling. 4.13.7 Coupling guards shall be provided along with equipment. 4.14 Instrumentation and Control In addition to any instrumentation specified in the

Material Requisition, the Vendor shall specify all the necessary instrumentation, control, alarms and shut-down devices to ensure safe and reliable operation.

4.15 Jacking screws shall be provided to assist in parting joints. 4.16 Parting surfaces shall be spigotted or provided with fitted bolts or dowels to

ensure correct alignment (spigots are preferred). 4.16.1 Means for removal of seal cartridges and supporting the shaft during this

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operation shall be provided. 5.0 INSPECTION 5.1 Inspection shall be carried out in accordance with the material requisition. 5.2 The Vendor shall provide a quality control plan showing the proposed

programme of inspection and testing and which items are to be witnessed or observed. This plan will be reviewed by IOCL who will advise any required amendments. When requested, the Vendor shall provide a copy of his quality control procedures for IOCL's review.

5.3 The scope of IOCL’s inspection shall include as a minimum, suborders,

materials, welding, heat treatment, non-destructive testing of materials and welds, repairs, rotor balancing, dimensional checks, hydrostatic and running tests, internal check after testing and final inspection prior to shipment.

5.4 IOCL's inspector shall be informed of any defects noticed during manufacture. Vendor shall also inform IOCL and obtain his permission before proceeding with any

repairs which may affect equipment operation, integrity or interchangeability. Repair procedures shall beapproved by IOCL before rectification. Rejections made by IOCL shall be final.

6.0 TESTING 6.1 The number of working days for advance notice shall be as specified in the

Purchase order. 6.2 IOCL or his representatives shall observe all testing, dismantling, inspection and re-

assembly of equipment, as specified in the data sheet. 6.3 Mechanical Seals Tests All mechanical seal assemblies shall be hydrostatically works tested to a

minimum test pressure of 1.5 times the normal seal lubricant pressure. A works running test of the seal at this pressure is also required.

6.4 Mechanical Running Test The Vendor shall conduct a standard running test on all agitators to ensure

satisfactory operation at the specified operating speed. Such tests should consist of the following:

- Operation of the assembled mixer under "no load". - Running test of shaft seal with the seal under pressure.

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- Actuation of the tank shut-off device with the test tank at maximum operating pressure. 6.5 Test Procedures Vendor shall issue test procedures for the mechanical seal and running tests for

IOCL’s approval. 6.6 Certified copies of test data shall be submitted to IOCL immediately following the test. 7.0 PREPARATION FOR SHIPMENT 7.1 The preparation for shipment, storage type and period, and the type and mode of

shipment shall be in accordance with the purchase order. 7.2 The paint for all exterior surfaces shall be suitable for the environment specified. The paint, preparation and painting procedures shall be approved by IOCL.

7.3 Unless otherwise stated in the purchase order, all on package pipe-work shall be fully

fitted and assembled prior to dispatch. Pipe-work between main packages and off-package auxiliaries, if supplied by Vendor, shall have sufficient spare lengths for final field welding.

7.4 All openings, disconnected for shipping purposes, shall be closed. These shall be

identified with a securely attached tag indicating the type of connection, the instrument or the line description of the connecting piping.

8.0 HANDLING 8.1 The equipment shall have sufficient rigidity and strength to permit normal

handling. 8.2 The equipment shall be provided with sufficient bracing and lifting lugs to permit

handling at the construction site with conventional slings or hooks without damage to the equipment.

9.0 VENDOR'S DATA 9.1 Proposals The Vendor's proposals shall include the information listed below: 1. Completed copies of the material requisition data sheet(s) with all required

information entered thereon. 2. Certified outline arrangement drawing and weights.

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3. Typical c r o s s -sectional drawings, schematic drawings and literature to describe fully all details of the offer including specific drawings of the gear and variable speed system (if applicable).

4. Power absorbed by the agitator assembly. 5. The diameter, type and position of the impeller, together with its speed and direction

of rotation. 6. The size, type and location of any baffles that may be considered necessary to

ensure adequate mixing. 7. The critical speeds. 8. Type of shaft seal where necessary. Seals and glands shall be readily renewable

without dismantling other components of the mixer. A seal change procedure shall be provided.

9. Flange thickness calculations, agitator calculations and all loadings imposed on the vessels by the agitator.

10. A Specific statement that the system and all components are in strict

accordance with the material requisition and specifications. If they are not in strict accordance, the Vendor shall include a definitive list detailing every deviation and exception.

11. Evidence of manufacturing and service experience, stating the name of the user,

plant, location, service and date of commissioning. 12 The Vendor shall quote in his proposal separate itemized prices for spare parts. a. For commissioning b. for 2 year operation 13 Vendor to provide a statement of guaranteed noise emission data and confirm

compliance to material requisition requirements. 14 Contract Data 1. After receipt of the purchase order, the Vendor shall supply certified dimensional

drawings as agreed prior to the purchase order. The Vendor’s certified drawings shall show identification data, rotation, weight, applied loads and adequate dimension data to permit the design of supporting vessel or structure, piping and wiring connections. All auxiliary piping connections shall be identified with terminations located and sizes indicated. The drawings shall show the disassembly clearances required.

2. Vendor's drawings shall be reviewed by IOCL; such review shall not constitute permission to deviate from any requirements in the order unless specifically agreed upon in writing. After the drawings have been reviewed, the Vendor shall furnish certified copies in the quantity specified in the purchase order.

3. In addition the information listed below shall be submitted at dates agreed prior to order placement.

I. Major repair procedures (if applicable). II. Test schedule.

III. Quality control plan.

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IV. Surface preparation and painting procedure. V. A drawing showing mechanical seal installation and setting dimensions.

VI. Certified test data. VII. Installation, operation and maintenance manuals.

VIII. Production data book with all required material and electrical certification data.

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(CONTROLLED VOLUME)

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Content


1.0 GENERAL 4 2.0 TECHNICAL 4 3.0 INSPECTION 8 4.0 DOCUMENTS TO BE FURNISHED BY VENDOR 10 5.0 DOCUMENTS TO BE FURNISHED AS PART OF

DESPATCH DOCUMENT 10

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1.0 GENERAL

1.1 SCOPE OF SUPPLY

Pump, single speed electric drive, base frame, coupling, non sparking coupling guard, anchor bolts, in-built / line mounted relief valve, suction and discharge dampener, Y-type suction strainer, suction piping hardware, discharge volume bottle, suction volume bottle, if any, etc.

1.2 Measuring pot / calibration pot shall be supplied by the pump

supplier along with pump.

1.3 All documents listed in Sl no. 5 shall be accompanied in good hard bound folders and shall be furnished in six sets and two soft copies of the same.

2.0 TECHNICAL

2.1 Basic design shall be as per API – 675, latest edition or as indicated

in the data sheet.

2.2 PUMP TYPE: Plunger type/Double diaphragm type of PTFE make (both Process & Hydraulic diaphragm), self calibrated, Flanged suction & discharge nozzles.

2.3 Pump Diaphragm shall be made of PTFE / SS. Diaphragm

material shall be compatible to the fluid coming in contact with diaphragm. Diaphragm shall not be of Viton.

2.4 Coupling: Flexible metallic coupling (as per IOCL Technical

Specification IOC/M&I/MECH/E/R/07 Revision-00).

2.5 Coupling Guard : Non Sparking Type

2.6 Suction & Discharge flanges of 300# rating shall be drilled & dimensioned as per ANSI B 16.5.

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2.7 Accuracy of flow Control shall be +/-2% for the pump.

2.8 The mechanical as well as the hydraulic performance of the model shall have been established in the shop test.

2.9 Pumps shall have positive return stroke mechanism and not the

spring return motion mechanism.

2.10 The vendor may offer at his option, alternatively new / modified design of model.

2.11 Unless otherwise specified, the pump flow rate shall be

adjustable over the range of 10% to 100% of rated capacity while the pump is running.

2.12 Pump rated capacity shall be equal to the maximum capacity

specified by the purchaser. The liquid cylinder design shall be based on volumetric efficiency of 90% or less.

2.13 In order to ensure proper & accurate pumping, The pump speed

shall not exceed 100 strokes per minute. Due consideration shall be given for the viscosity of pumping liquid, while selecting the pump speed.

2.14 The flow repeatability shall be within ± 1% over the turn down ratio

of 10:1.

2.15 Vendor shall consider, in his design, double check valves at both ends. i.e. suction and discharge

2.16 Pulsation suppression shall be provided at the discharge of all

metering pumps. When necessary pulsation dampener shall be provided at suction to maintain adequate margin between NPSHA and NPSHR.

2.17 To meet the required rated capacity, vendor may offer, at his

option, two or three cylinder arrangement (Duplex or Triplex ) with a common drive, in place of simplex arrangement when specified. However, in such a case suction and discharge manifolds to connect such suction and discharge nozzles, fabricated out of SS 316 material shall be supplied by the vendor. Manifolds shall be complete with forged flange of equivalent rating, gasket, nuts

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and bolts. Relief valve shall be designed to pass rated capacity when fully open and limiting the accumulation pressure to 110% of rated discharge pressure.

2.18 Inlet and Outlet connections shall be flanged for nozzle sizes

½” and above, and shall be suitable for maximum allowable working pressure. Threaded pipe nipples shall be provided for sizes below ½”. The flanges shall be forged and conform to ANSI B16.5 rating.

2.19 Unless otherwise specified elsewhere, pulsation suppression

device, when specified, shall be designed in such a way as to give amplitude of pulsation within the limit of ± 3% of mean.

2.20 Selection of material of pulsation damper and bladder shall be suitable for the liquid being handled.

2.21 When bladder type suppression device is specified, gas

charging assembly (kit) shall be supplied by the vendor alongwith necessary instruction for use.

2.22 Unless otherwise specified relief valve, for packed plunger pump

shall be furnished by the vendor and shall be mounted on pump discharge flange or on purchaser’s piping. The relief valve setting pressure shall be 105 over the rated discharge pressure or 1 kg/cm2 over the rated discharge pressure whichever is lower. Relief valve shall be single coil type and shall be procured from a reputed manufacture. Material of construction of relief valve shall be equal or better than that of main pump wetted parts, however, shall not be less than AISI 304. end connections of relief valve shall be flanged type and shall be connected to suction source by the purchaser. Relief valve shall be selected to pass 100% rated capacity of pump when fully open to limit accumulation pressure to 110% of rated discharge pressure.

2.23 Pumps with drivers rated above 100 HP (75 KW) shall have

pressurized Crankshaft lubrication.

2.24 For motor driven units, the motor nameplate rating excluding service factor shall be minimum of 110% of the greatest horsepower (including gear and coupling losses) required for rated capacity of

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pump. Motor nameplate rating including service factor shall include operation at the relief valve set pressure, including 10% accumulation.

2.25 Anchor bolts will be furnished by the vendor.

2.26 Each Pump will be provided with the following :

a. Adequately sized in-built / line mounted Relief valve with

threaded end. The PSV shall be line mounted.

b. One number Y-type strainer of corresponding suction line size, flanged end.

c. Companion flanges of 300# rating.

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POSITIVE DISPLACEMENT PUMPS (CONTROLLED VOLUME)

d. Suction piping hardware comprising one meter of suction

pipe and one number 90 degree elbow. Size of suction line of pump has been given in the data sheet.

e. Intermediate fluid chamber of the diaphragms shall have a

probe connection. This probe shall give an electrical signal in the range of 4- 20 mA in case of rupture of primary diaphragm. A local pressure gauge is also to be also provided to detect leak. I.e. one pressure transmitter and one local pressure gauge to be provided.

Note : Thread in all fittings shall conform to ANSI B 1.20.1

2.27 Material of

Construction :

(a) Liquid

End : SS 316 (b) Valve, valve seat, Valve guide, Valve body : SS 316 (c) Plunger : Case – hardened CS (d) Process & Hydraulic Diaphram : PTFE (e) Power End : CI Body, Ph. Bronze worm wheel , EN 24 Worm

Shaft. (f) Suction strainer : SS 304 body, SS-316 Strainer element. (g) Suction piping hardware : SS 316

3.0 INSPECTION

3.1 Pump

3.1.1 Test to be carried out in front of Purchaser’s Inspector : (

IOCL ): Performance Test (a) Hydrostatic Pressure Test ( Test pressure shall be 1.5 times the

Pump design Pressure ) (b) Linearity and Repeatability (c) Dismantling and Inspection after Test (d) Relief Valve Test (e) Diaphragm rupture detection (as applicable).

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3.1.2 Certificates to be furnished to Purchaser’s Inspector for review :

a. Material Test certificates of the main components

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3.2 Motor

Manufacturer’s routine test certificates and guarantee certificates to be furnished to Purchaser’s Inspector for review.

4.0 DOCUMENTS TO BE FURNISHED BY VENDOR WITHIN 30

DAYS OF RECEIPT OF P.O. FOR PURCHASER’S APPROVAL :

4.1 General arrangement Drawing indicating Overall dimensions,

foundation details, weight of pump assembly, etc.

4.2 Details of motor

4.3 Details of relief valve & Y-strainer

4.4 Sectional drawing of Pump & accessories with complete parts- list indicating part number & metallurgy of each part.

4.5 Specification of the lubricants to be used in the pump in SERVO

Grade marketed by IOCL.

5.0 DOCUMENTS TO BE FURNISHED AS PART OF DESPATCH DOCUMENT ( IN SIX SETS ) IN HARD BOUND FOLDER AND (2 SETS) AS SOFT COPIES :

5.1 Operation Maintenance Manual for Pump & Motor

5.2 Performance Guarantee for 12 months from the date of

commissioning of the pump in accordance with the terms of Purchaser.

5.3 Final Test Certificates duly signed by Purchaser’s inspector.

5.4 Materials Test Certificates

5.5 Final Data Sheet

5.6 All approved documents listed under Sr. No.4.0

5.7 Routine Test Certificates of Motor.

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LIST OF MANDATORY SPARES FOR RECIPROCATING PUMPS (CONTROLLED VOLUME)

SL.N O.

MATERIAL DESCRIPTION

Quantity as per installation Units

REMARKS

MECHANICAL UNIT 1 2 3 4 5 6 7 8 PU

1 Suction valve assembly SET 3 3 5 5 5 5 5 5 2 Discharge valve assembly SET 3 3 5 5 5 5 5 5 3 Bearings SET 2 2 3 3 3 3 3 3 4 Gaskets `O`- rings/packing SET 3 4 6 8 8 8 8 8

5

Stroke adjustments mechanism complete

SET

1

1

1

1

1

1

1

1

6

Additional Spares for Plunger Pumps

6.1 Plungers SET 1 1 1 1 1 2 2 2 6.2 Plunger packing SET 3 4 6 8 8 8 8 8 6.3 Relief valve NOS. 1 1 2 2 3 3 3 3

7 Additional Spares for Diaphragm

7.1 Diaphragm SET 2 2 4 6 6 6 6 6 7.2 Hydraulic piston packing/rings SET 2 2 4 6 6 6 6 6

NOTE:

1 The word `SET` in unit column means the quantity required for full replacement of that part in one machine. The word `NOS.` in unit column means number.

2 The Bidder shall quote for all the mandatory spares as defined above and as application to the proposed design of the equipment .In case, any spare which is listed in the checklist but not applicable due to specific construction/design of the equipment ,the same shall be highlighted as `Not Applicable` against that spares supported with proper technical explanation.

3 Spares part shall be identical in all respects to the parts fitted on the main equipment, including dimensions, material of construction and heat treatment.

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PAGE 1 OF 8


STEAM TRAPS

STEAM TRAPS

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STEAM TRAPS

Abbreviations: BIS Bureau of Indian Standards BS British Standards BHN Brinell Hardness Number DP Dye Penetration STAAD Structural analysis and design computer program MDMT Minimum Design Metal Temperature TPlA Third Party Inspection Agency ASME American Society of Mechanical Engineers AWS American Welding Society CS Carbon Steel GAD General Arrangement Drawings ID Internal Diameter LSTK Lumpsum Turnkey MOC Material of Construction MR Material Requisition OD Outside Diameter PQT Procedure qualificationtest PQR Procedure qualification record PL Process Licensor PMC Project Management Consultant SS Stainless Steel TIG Tungsten Inert Gas WPS Welding Procedure specification

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STEAM TRAPS

CONTENT


1.0 SCOPE 4 2.0 DESIGN AND CONSTRUCTION 4 3.0 IBR REQUIREMENTS 6 4.0 DOCUMENTATION 7 5.0 TESTS AND INSPECTION 7 6.0 MARKING AND DESPATCH 8

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STEAM TRAPS

1.0 SCOPE

1.1 This specification covers the design and construction, IBR requirements, documentation, testing, inspection, marking and dispatch requirements for Traps. Vendor shall supply Traps in accordance with the technical notes and details specified in the data sheet for steam/ air traps.

2.0 DESIGN AND CONSTRUCTION

2.1 All Codes and Standards for manufacture, testing and inspection etc. shall

be of latest editions.

2.2 The material of construction shall be as per the data sheet; for parts not mentioned in the datasheet, vendor shall guarantee the material used for the service conditions specified. Following alternative body materials are acceptable:

• AISI 420/ AISI 410/ A743 Gr. CA40/ A743 Gr. CA15 in lieu of

ASTM A105. • A 182 F22 in lieu of Al82Fl1. • AISI420/ A 182 F11 in lieu of A 182 F1.

For flanged traps, MOC of end flanges shall correspond to the material specified in the data sheet.

For welding of dissimilar materials required for trap assembly, welder qualification procedure shall be done prior to welding.

2.3 The material composition, physical properties, heat treatment &

mandatory test reports, dimensions and tolerances shall conform to the applicable codes/standards/specifications as specified in the requisition.

2.4 All traps shall be designed with back pressure upto 80% of upstream

pressure unless otherwise specified in the datasheet.

2.5 All Thermodynamic and Thermostatic traps shall have an integral strainer and its material shall be SS304/SS316. However, Ball Float and Inverted Bucket traps shall be supplied with separate strainer, but vendor should quote composite price for the same. Trap and strainer

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STEAM TRAPS

shall be supplied in assembled condition having strainer in the upstream. This strainer shall be of Y-type having 40mesh size and material of construction for body and internals shall be same as that of trap.

2.6 Thermodynamic traps shall have seat integral or seal-welded to the body & central entry with respect to the disc. The seat and disc shall be differentially hardened to Rc 45-50 and Rc 40-45 respectively maintaining a minimum difference of Rc 5 to ensure wear on the disc.

2.7 Thermostatic traps shall be designed with subcool temperature setting

as per data sheet. If nothing is specified in data sheet, subcooling of 10 Deg C should be considered by default.

2.8 Upto 300# rating, Composite Impulse cum Thermodynamic type steam

trap with two integral strainers in place of Thermodynamic and Thermostatic trap is also acceptable.

2.9 Inverted bucket steam trap shall be of horizontal entry & exit type.

2.10 For flanged end traps, weld-on flanges are also acceptable. However, the type of flange shall be SW/ WN as specified in data sheet.

2.11 Ends shall be as specified in the data sheet. The applicable

dimension standards are:

Flanged ends : ASMEB16.5 SW ends : ASMEB16.11 SCRD ends : ASMEB16.11 BW ends : ASME B16.25

2.12 Bevel end details for BW steam traps shall be as per ASME B16.25.

Contour of bevel end shall be as follows:

Material Wall Thickness Weld Contour Carbon steel (except low temperature carbon steel)

Upto 22 mm Figure 2 Type A

> 22 mm Figure 3 Type A Alloy steel, stainless steel & low temperature carbon steel

Upto 10 mm Figure 4 > 10 mm & upto 25 mm Figure 5 Type A

> 25 mm Figure 6 Type A

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STEAM TRAPS

2.13 Flanged end face finish shall be normally specified in the data sheet.

The interpretation for range of face finish shall be as follows:

Stock Finish : 1000 in AARH max. Serrated/ Smooth Finish/125 AARH : Serrations with 125 to 250 µ in AARH Extra Smooth/ 63 AARH : 32 to 63 µ in AARH

2.14 For traps with ring joint type flanged ends the hardness shall be as follows :

Flange Material Min. Hardness of Flange Groove (BHN)

Max. Gasket Hardness (BHN)

Carbon steel 140 90 1% Cr. To 5% Cr. 150 130 Type304, 316, 321, 347 160 140 Type 304L, 316L 140 120

2.15 For traps with flanged ring type joint ends, the hardness shall be recorded in the test report.

3.0 IBR REQUIREMENTS

3.1 IBR Documentation:

3.1.1 Traps coming under the purview of IBR (Indian Boiler Regulations) shall

be accompanied with IBR Certificate original in Form 111 C duly approved and countersigned by IBR authority / local authority empowered by Central Boiler Board of India. Photocopy of original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance.

3.2 For carbon steel traps described as "IBR", chemical composition for all

carbon steel components shall conform to the following:

Carbon (max.) : 0.25% (C=0.30% for A182 Gr. F1) Others (S, P, Mn) : As prescribed in IBR Regulation

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STEAM TRAPS

4.0 DOCUMENTATION

4.1 Vendor shall submit the following along with the offer :

4.1.1 Catalogues/ detailed dimensional drawings of all steam/ air traps, giving

details of trap performance, construction and material specifications for all parts.

4.1.2 Applicable capacity charts for each quoted model.

4.1.3 Material specifications for parts not covered in the data sheet.

4.1.4 Signed & stamped copy of Technical Notes for Traps.

5.0 TESTS AND INSPECTION

5.1 IBR steam traps shall be hydrostatically tested as per LBR

regulations (1aest edition). Other steam traps shall be hydrostatically tested to twice the design pressure for which the traps are suitable. For air traps test pressure shall be 1.5 times the design pressure.

5.2 Radiography of BW joints shall be as follows:

a) For all ratings in alloy steel and 900# ratings and above in carbon steel/ stainless steel, B W joints shall be 100% radiographed.

b) For carbon steel and stainless steel upto 600# rating, 20% of joints shall be radiographed with a minimum of 1 number against each type, size, rating and material. Joints for weld-on flanges shall be 100% radiographed.

5.3 Test reports shall be supplied for all mandatory tests as per the

relevant material specifications/ requisition. Test reports shall also be furnished for hydrotest and any other supplementary tests as specified in the requisition.

5.4 Material test certificates (physical properties, chemical composition & heat

treatment report) of the pressure containing parts shall be furnished for the steam traps supplied. Material test certificates for the other parts shall also be furnished for verification during inspection.

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STEAM TRAPS

5.5 Third Party Inspection Agency reserve full right to witness stage wise

inspection of all mandatory/ applicable supplementary tests. However, for IBR items, the tests/ inspection shall be by IBR authority.

6.0 MARKING AND DESPATCH

6.1 Vendor shall securely attach on the body a metal tag stamped with item

code, Tag no. (If mentioned in requisition), size, rating and special conditions like 'IBR'. Wherever nameplate is provided, marking can be done on the same.

6.2 Paint or ink for marking shall not contain any harmful metal or metallic salts

such as zinc, lead or copper which cause corrosive attack on heating. IBR traps shall be painted with red stripes (25mrn width).

6.3 All traps shall be dry, clean and free from moisture, dirt and loose foreign

material of any kind.

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

6.5 Rust preventive on machined surfaces to be welded shall be easily removable

with a petroleum solvent and shall not be harmful to welding.

6.6 Each end of trap shall be protected with the following materials :

Flange Face : Wood or Plastic Cover

Bevelled End : Wood or Plastic Cover SW & SCRD End : Plastic Cap

6.7 End protectors of wood / plastic to be used on flange faces shall be

attached by at least three bolts and shall not be smaller than the outside diameter of the flange. However plastic caps for SW & SCRD end steam traps shall be press fit type. End protectors to be used on beveled end shall be securely and tightly attached.

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FOR WIRE MESH DEMISTER

WIRE MESH DEMISTERS

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CONTENTS


1.0 SCOPE 4 2.0 MATERIAL 4 3.0 DESIGN & F ABRICATION 5 4.0 SPARES 5 5.0 INSPECTION AND TESTING 5 6.0 PACKING & FORWARDING 6 7.0 GUARANTEE 6 8.0 DOCUMENTATION 6

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1.0 SCOPE

This specification covers the general requirements for design, fabrication, inspection and supply of knitted wire mesh assemblies (Demisters) in duly packed condition. The demister assembly(ies) shall consist of wire mesh pad, top/ bottom holding grids, major beams (if specified / required), bolting/ clamps/ tiewires / tierods /J-bolts/spacer pipes and any other components which are essential to complete the demister assembly to be installed on supports welded inside the vessel.

2.0 MATERIAL

All the material used for fabrication & supply of Demister shall be new & of first quality and shall be duly supported with material test certificates.

3.0 DESIGN & FABRICATION 3.1 Applicable Codes & Standards

ASME Sec. II : Material Specifications Sec. VIII Div. 1 : Boiler and Pressure Vessel Code Sec. IX : Welding Qualifications AISI : Material specification for wires, spacer rods etc. as per

drawings attached along with enquiry.

The diameter of the demister pad(s) shown in the drawings/specification shall be equal to the inside diameter of the column/vessel or demister housing or the nozzle. Demister pad shall be over sized to ensure the snug fitment. In case demisters are required for the complete cross- section of the vessel/column, the out of roundness of the vessel/column should be considered as per applicable Code and standard.

3.2 Demister assembly shall be designed for a net upward thrust of 100 kg/m2 (uniform)

due to the vapour loadings. The assembly should also be able to withstand a concentrated live load of 60 kg at midpoint of any of the demister sub-assembly/component.

In addition to the above loading, demister shall be designed to withstand the additional pressure surges, if specified.

3.3 All demister sub-assemblies shall be sized to facilitate installation inside the

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column/vessel through the manhole. These shall rest on support ring/cleats welded inside vessel/column by others.

3.4 Tentative details of the support rings/cleats, mid span beams (wherever required)

grid details & fixing arrangements shall be as given in the referenced standards/ sketches. Vendor is advised to follow the same for the design/fabrication in their scope of work. Vendor may, however, suggest any improvement in the design. Such suggestions will however be reviewed /approved by IOCL and can be followed by the vendor only on written acceptance by IOCL.

3.4 All internal bolting shall be minimum M1 0 size and shall be

compatible with Demister material. All bolting shall be provided with locknuts.

3.5 Welding

All welding shall be done by metal arc welding. For welding on thinner gauge sheets TIG welding is preferred. Welding wherever required, is to be done by qualified and approved welders using the suitable fillers and fluxes recommended for materials used for fabrication.

4.0 SPARES 4.1 Constructional spares @ 10% (minimum 4 Nos. of each type/size)

fasteners - bolts, nuts, clamps, spacer pipes, I-bolts etc. & 20% of tie-wires shall be supplied.

4.2 Operational Spares In addition to Constructional spares as indicated above, vendor shall also

supply operational spares @ 10% (minimum 4 Nos. of each type/size) fasteners - bolts, nuts, clamps, spacer pipes, J-bolts etc. & 20% of tie-wires.


5.1 The material, fabrication and trial assembly is subject to Inspection by the

IOCL and/or their authorised representative. 5.2 The individual demister assembly along with grids, beams etc. shall be

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assembled on shop floor in a manner comparable with actual installation & shall be offered for final inspection. Assembly shall be checked for dimensions as per approved drawing

6.0 PACKING & FORWARDING

The individual components shall be marked with proper item/part number as given in the drawings to facilitate identification at site. Demister shall be packed and supplied in polythene lined wooden cases for damage free transportation

7.0 GUARANTEE

Vendor shall guarantee the design, performance (i.e. separation efficiency, and pressure drop), material, fabrication and workmanship for the demisters for the period as outlined in General Purchase Conditions.

8.0 DOCUMENTATION

Documents/drawings shall b e furnished as per the 'Vendor Data Requirement'. All the drawings prepared by the vendor shall be on AUTOCAD latest version. Hand drawn drawings are not acceptable.

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FOR STRAINERS

STRAINERS

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FOR STRAINERS


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FOR STRAINERS

CONTENTS

CLAUSE NO DESCRIPTION PAGE NO.

1.0 SCOPE 4

2.0 GENERAL 4

3.0 DOCUMENTATION 5

4.0 DESIGN AND CONSTRUCTION 6

5.0 DESIGN BASIS FOR STRAINER 8

6.0 TESTING 8

7.0 IBR REQUIREMENTS 9

8.0 SPECIAL REQUIREMENT FOR NACE SERVICE

10

9.0 SPECIAL REQUIREMENT FOR HYDROGEN SERVICE

10

10.0 MARKING, PAINTING AND DESPATCH

10

11.0 POSITIVE MATERIAL IDENTIFICATION (PMI)

11

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FOR STRAINERS

1.0 SCOPE

This specification lists the mandatory technical and associated requirements for purchase of various piping items. These requirements are in tandem with requirements of Piping Material Specification (PMS). 2.0 GENERAL

2.1 Vendor shall supply strainer in accordance with the DATA SHEET FOR STRAINER.

2.2 Vendor shall quote in strict accordance with the Strainer data / specification sheets,

subject -technical notes and all other enclosures to the MR. Deviations to the specification /datasheets, subject technical notes and other enclosures of the MR, if any, shall he asked as explained in clause 2.0.

2.2 Orientation of the strainer element relative to process flow shall ensure that collected

solid or foreign material shall not fallback into the line.

2.4 The design and location of permanent strainers shall permit cleaning without removing the strainer body.

2.5 Inline Y-type and T- type strainers shall have a flanged clean out connection. 2.6 Maximum carbon content for any carbon steel shall not exceed 0.25%. 2.7 Basket type strainer:

Basket type strainer shall meet the following requirements. (a) IOCL specs for Basket Filters

(b) Strainer body shall be provided with bolted top covers for easy of strainer elements. (c) Strainer body shall be provided with tapped NTP blow –off connection. (d) Large capacity fabricated strainer shall be provided with their own floor mounting stands.

2.8 In case of temporary strainers the effective area of screen assembly shall not be less than 150 percent of cross sectional area of the pipe. Temporary strainer shall be removed after flushing and start up of the line.

2.9 Strainers shall be designed to accommodate an acceptable level of clogging. 2.10 Screen specified for strainers shall be in accordance with ASTM E 674 or equivalent.

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FOR STRAINERS

2.11 Mesh specified for strainers shall be in accordance with ASTM E 2016 or equivalent. 2.12 Y – Type strainer :

Y - Type strainer shall meet the following requirements.

(a) The effective area of the screen assembly shall not less than 150 percent of the line crosssectional area.

(b) Strainer shall be furnished with a plugged blow –off connection. (c) Strainer body shall be provided with bolted top covers for easy of strainer elements. 2.13 T – Type strainer :

T - Type strainer shall meet the following requirements;

(a) The effective area of the screen assembly shall not less than 150 percent of the line crosssectional

area.

3.0 DOCUMENTATION

3.1 Vendor shall submit the following with the offer. 3.1.1 Manufacturer’s complete descriptive and illustrative catalogue / literature. 3.1.2 Drawings for strainers with all the accessories, giving all the major salient dimensions. 3.1.3 One copy of the strainer data sheets signed as “Accepted” by the manufacturer with all

deviations marked clearly. 3.1.4 If the strainer is regretted or has no deviation, the manufacturer shall write clearly on

Strainer data sheets as “Regret” or “No Deviation”. 3.1.5 For subject notes, if there is any deviation, the same shall be listed clause wise. Even

clauses, which are acceptable, shall be categorically confirmed as “Accepted”. 3.1.6 On failure to submit documents as specified in clauses 3.1.1 to 3.1.5 above, the offer is likely

to be rejected. 3.2 The following documents shall be submitted after placement of the order.

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3.2.1 Vendor shall submit for approval drawings mentioned in clauses 3.1.2 & 3.1.3 before start of manufacture. No other drawing shall be submitted for approval.

3.2.2 Test report shall be supplied for all mandatory tests as per the applicable code. Test reports

shall also be furnished for any supplementary tests as specified in the MR and clauses. 3.2.3 Material test certificates (physical properties, chemical composition & heat treatment report)

of the pressure containing parts shall be furnished for the valves supplied. Material test certificates for the other parts shall also be furnished for verification during inspection.

4.0 DESIGN AND CONSTRUCTION 4.1 The Strainer shall be designed on the basis of DATA SHEET FOR STRAINER. Strainer shall

be designed, manufactured, tested, inspected and marked as per the manufacturing standards, design codes and standards indicated in the respective DATA SHEET FOR STRAINER. Any conflict between the requisition, enclosures, specification sheets and referred standard codes shall be brought to the notice of the purchaser for clarifications. But generally, specification sheets and enclosures of the requisition including subject notes shall govern. After issue of the Purchase Requisition (PR). no deviation to specification / standards shall be permitted through vendor drawing approval. Approval of drawings shall be valid only for design/constructional features.

4.2 Strainer shall be designed, fabricated and inspected in accordance with ASME section VIII,

division 1. 4.3 End connection shall be in accordance with the following standard.

SCRD (Screwed) : NPT, ASME B1.20.1 SW (Socket weld) : ASME B16.11 FLGD (Flanged End) : ASME B16.5 for NPS 24 and smaller

ASME B16.47 Sr. B for NPS 26 and Larger BW (Butt weld) : ASME B16.25

4.4 Flange face finish shall be normally specified in the strainer data sheet as serrated finish,

125 AARH etc. The interpretation for range of face finish shall be as follows:

Serrated / Smooth Finish 125 -250μ in AARH Extra Smooth Finish 32-63 μ in AARH (For RTJ groove) Serration shall be concentric type for hydrogen or any toxic/flammable service.

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4.5 For all weld end strainers with bevel end as per ASME B 16.25. The contour of bevel shall be as follows.

Material Wall Thickness Weld contour C.S up to 22 mm Fig.2 type A A.S/S.S. Up to 10 mm Fig.4 A.S/S.S. 10 mm to 25mm Fig.5 type A

4.6 Strainer installed in IBR piping, design shall meet IBR requirements and ASME B 31.3. 4.7 Unless otherwise specified following philosophy shall be applied:

NPS 1½ “and below = Y- Type strainer NPS 2” and over = T- Type strainer

4.8 Strainer element shall be designed, fabricated and suitably fixed with the body so as not to

be damaged due to vibration, differential pressure (MIN. 1.0 kg/cm2 g) or impact of the fluid in the element. Pulsating flow screens of mesh size 20 or finer shall be reinforced with perforated plate or heavier screen with steel bar.

4.9 The Strainer element shall always be reinforced using suitable backup like punched plates to

withstand the process conditions. Material of Reinforcement and all other internals shall be same as the filter element material.

4.10 Unless otherwise specified Strainer mesh shall be of Austenitic Stainless steel. All Strainers

shall be supplied with a spare mesh. The spare mesh shall be finer than the actual requirement (Minimum 1 commercially available mesh number). This shall be installed during commissioning in order to protect the internals like mechanical seals of the associated equipments. This mesh shall be removed after commissioning and the actual mesh shall be installed.

4.11 For fabricated strainers, all BW joints shall be fully radio graphed and fillet welds shall be

100% DP/MP checked. 4.12 Flow direction shall be marked (cast or embossed) on the body. 4.13 Specified Heat Treatment for Carbon Steel and Alloy Steels and solution annealing for all

Austenitic Stainless Steels shall be carried out again after weld repairs. 4.14 No copper or copper alloy shall be used in any part that comes into contact with process fluid.

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4.15 All branch attachment welds such as couplings, welding outlet, nozzles, etc. shall be full penetration groove welds.

4.16 No openings such as branches shall be located to pass through a weld. Such openings shall

have their boundaries at least one Outside Diameter away from the adjacent welds. 4.17 No welds shall be covered / concealed by external attachments like pads. 4.18 Welds of pressure retaining parts shall be made by qualified welders, welding operators and

welding procedure qualified in accordance with ASME Sec IX. 4.19 All the welds for pressure retaining parts shall be so identified as to be traceable to the

welding condition, welders and the inspection results. 4.20 As minimum strainer internals shall be stainless steel. 5.0 DESIGN BASIS FOR STRAINER 5.1 Net free area shall be min TWO times of pipes cross section area after taking the 50%

clogged condition. 5.2 Pressure drop calculation shall be submitted by vendor for approval. 5.3 If the type of strainer selected does not meet Pressure Drop requirement, then type of the

strainer shall be changed to basket type to meet the Pr. Drop requirement. 5.4 Multiple basket strainers shall not be used. 5.5 Installation of the strainer shall be above ground & installation of the same in the pit is not

acceptable. 5.6 All strainers shall be provided with NPS ¾“Drain connections with valves and Threaded

capsat the lowest point. 6.0 TESTING 6.1 Every strainer shall be subjected to all the mandatory tests and checks called in the

respective codes / data sheet by IOCL inspection or any third party as approved by the purchaser.

6.2 All the strainers shall be hydrostatically tested at 2 TIMES the design pressure. 6.3 Strainer installed in IBR piping, design shall meet IBR requirements and ASME B 31.3 (2008

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edition). 6.4 The examining personnel shall have the requisite qualification and experience. 6.5 Client and its authorized representative reserve the right to vet and suggest changes in vendor procedures. 6.6 Vendor’s works and facilities shall be accessible to the client/ representative at all reasonable times. 6.7 Test reports for all mandatory (as well as supplementary, wherever specified) tests shall be furnished. 6.8 All items of alloy steel & higher alloy piping material shall be subjected to ‘Positive material

identification (PMI) test before dispatch. 6.9 Water for pressure tests shall not contain chlorides more than 25 PPM. 7.0 IBR REQUIREMENTS 7.1 Strainer under the purview of “IBR” (Indian Boiler Regulations) shall be accompanied with

original IBR certificate in Form Ill-C duly approved and countersigned by IBR authority / local authority empowered by Central Boiler Board of India. Photocopy of the original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance.

7.2 For materials 1 1/4Cr - ½Mo (ASTM A 234Gr.WP11 & ASTM A234 Gr.WP11W) & 2 ¼ Cr –

1 Mo (ASTM A 234 Gr.WP22 & ASTM A234 Gr. WP22W), where fittings are manufactured from pipe, Form III-C approved by IBR shall include the tabulation of Et, Sc ,& Sr. values for the entire temperature range given below. Et, Sc ,& Sr.values shall be such that throughout the temperature range.=

Et/1.5 > = Sr/1.5 > = SA Sc >=

Where, SA : Allowable stress at the working metal temperature. Et : Yield point (0.2% proof stress at the working metal temperature) Sc : The average stress to produce elongation of 1 % (creep) in 100000 hrs at the

working metal temperature.

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Sr : The average stress to produce rupture in 100000 hrs at the working metal temperature and in no case more than 1.33 times the lowest stress to produce rupture at this temperature

Note: SA values given above are from ASME B31.3-(1999 edition). Values shall be as per

the latest edition prevailing.

8.0 SPECIAL REQUIRMENTS FOR NACE SERVICE 8.1 All items under this category shall be as par NACE MR-0103 and / or any other applicable

standards shall also be followed. Hardness shall be below BHN 200 for C.S. material. Carbon equivalent (CE) shall be limited to 0.43.

CE = C% + Mn% / 6 + (CR% + Mo% + V%) / 5 + (Ni% + Cu%) / 15.

8.2 Strainers as required HIC & NACE, to be complied with latest Edition including S & P % shall

be within 0.010 & 0.020 wt % respectively. Ni shall be less than 1%. 9.0 SPECIAL REQUIRMENTS FOR HYDROGEN SERVICE

Refer attached Annexure –I for special requirement of hydrogen service

10.0 MARKING, PAINTING AND DESPATCH 10.1 Marking may be in accordance with manufacturer's standard. However, following items shall

be inevitably marked on the nameplate, end pipe or flange.

Name or trade mark of the manufacturer Strainer item number/tag no or special commodity number Connection Size Flow direction on the body Like “IBR”,”CRYO”,”NACE” etc. shall also be marked.

10.2 For all strainers MOC shall be punched on the body. 10.3 All material shall be MARKED / PAINTED properly with following:

PJ: SAP PO NO/DATE: SAP ITEM CODE: MATERIAL SPECIFICATION/ RATING/ TAG NO:

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10.4 Paint or ink for marking shall not contain any harmful metal or metallic salts such as zinc, Lead or copper which cause corrosive attack on heating

10.5 Strainer shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind. 10.6 Strainers shall be protected from rust, corrosion and mechanical damage during

Transportation Shipment and storage. 10.7 Rust preventive used on machined surfaces to be welded shall be easily removable with the

petroleum solvent and the same shall not be harmful to welding. 10.8 All strainers shall be properly covered by suitable protective means to avoid any damage

during transportation. Butt-welding ends of valves shall be capped or properly protected. Machined surface (Flanges, Threads, Bevel end, etc.) shall be coated with a corrosion inhibitor. Un-machined exterior surfaces of the shell are painted Aluminium. Rust protection for inside of valves shall be performed according to the manufacturer's standard.

10.9 Ends shall be suitably protected, and the protectors shall be securely and tightly attached.

Flange face : Wood, metal or plastic cover Beveled end : Wood, metal or plastic cover Plain end : Plastic cap SW & Screwed end : Plastic cap

10.10 Machined surface (Threads, Bevel end, etc.) shall be coated with a corrosion inhibitor. 10.11 End protectors to be used on beveled ends shall be securely and tightly attached with belt or wire. 10.12 Steel end protectors for galvanized items shall be galvanized. 10.13 All the strainers shall be cleaned at shop and cleaning procedure may be in accordance with

manufacturer's standard. The extent of cleaning shall include the cleaning of shop dirt, filings, loose weld spatter, chips, fluxes, welding flux deposits, etc.

10.14 PROGRESS: Vendor shall furnish weekly Manufacturing progress report to PMC/ Owner. 11.0 POSITIVE MATERIAL IDENTIFICATION (PMI)

Positive Material Identification (PMI) shall be performed as per the scope and procedures defined in Procedure for Positive Material Identification at vendor’s works (PMI).

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CONTENTS

CLAUSE NO DESCRIPTION PAGE NO 1.0 SCOPE 4 2.0 GENERAL 4 3.0 SUPPLEMENTARY TECHNICAL

REQUIREMENTS 5

4.0 CERTIFIED DOCUMENTS 8 5.0 PAINTING AND COATING 8 6.0 INSPECTION AUTHORITY 8

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1.0 SCOPE

This specification covers clad plates of a carbon steel or low alloy steel base integrally and continuously bonded on one side with a layer of chromium steel or chromium nickel steel & monel. The base as well as the alloy cladding metal shall meet the requirements of ASME Boiler and Pressure Vessel Code Section II. This is intended to supplement the minimum applicable requirements of material specification indicated in the material requisition.

2.0 GENERAL

2.1 Plates supplied to this specification shall conform to the latest issue of

applicable specification SA-263, SA-264, SA 265, SA-20 and SA- 578 with additional requirements mentioned herein.

2.2 The tolerance on thickness of base metal as well as cladding metal shall

be positive only.

2.3 Final rolling shall be lengthwise.

2.4 Outside surface of base metal shall meet requirements of EN 101 63 class- A sub clause 3.

2.5 Unless otherwise specified in the requisition the surface of alloy

cladding shall have No.1 finish for hot rolled and 2B finish for cold rolled.

2.6 Acid pickling shall be done for chromium nickel stainless steel

cladding as per ASTM A-380. Manufacturer's standard practice for pickling shall be followed for chromium steel cladding.

2.7 Repair of cladding surface by welding shall not exceed 3% of surface area of

individual plate.

2.8 The integral & continuous cladding shall be produced by roll bonding or by explosion bonding procedure with bond integrity Class I.

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3.0 SUPPLEMENTARY TECHNICAL REQUIREMNTS

3.1 Chemical composition of clad metal shall meet the requirement of applicable material specification but in case of straight chrome (13% Cr) cladding material, carbon content shall be less than 0.06%.

3.2 Unless otherwise specified in the requisition, heat treatment of the clad steel plate shall be as per applicable clad plate material specification. All stabilized grades of austenitic stainless steel (SS 321, SS 347 etc.) clad plate shall be in stabilization heat treated condition in addition to solution annealing.

3.3 Alloy cladding representative of each heat shall be subjected to inter-

granular corrosion test as per ASTM A-262, Practice E for all 300 series material. IGC test shall be carried out after cladding process.

3.4 During mill tension test of all clad steel plates the cladding shall be removed

and the tensile properties shall meet the requirements of the base material. Test specimen shall be taken transverse to rolling direction.

3.5 For all clad steel plates, shear test shall be conducted. Strength of bond

shall be minimum 20,000 psi in shear.

3.6 All clad steel plates shall be ultrasonically examined in accordance with SA-578 with acceptance standard level-C and shall meet supplementary requirements of S 1 and S7.

3.7 The ultrasonic examination shall be conducted after the specified heat

treatment of clad steel plates.

3.8 Requirements for Base Metal

3.8.1 One product analysis of each heat shall be carried out and reported. Chemical analysis shall be as applicable specification.

3.8.2 If specified in material requisition, plate shall meet the requirement of

Indian Boiler Regulation (IBR).

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3.9 Specific Requirements for Carbon Steel Base Metal

3.9.1 The carbon content for plate shall not exceed 0.23%. Additionally, one of the following requirements for carbon equivalent based on heat analysis, shall also be satisfied:

Ceq = C + Mn/6 ≤ 0.42 … (Eqn-1) Ceq = C + Mn/6 + (Cr + Mo + V)/5 + (Cu +Ni)/15 ≤ 0.43 … (Eqn-2)

Equation-1 shall be used when applicable material specification specifies C and Mn only. Equation-2 shall be used when applicable material specification specifies the above elements or restricted chemical requirements are specified or supplementary requirements S19 and S21 of SA-20 are specified in material requisition.

3.9.2 If specified in the material requisition Charpy V-notch impact test as per

supplementary requirement S5 of specification SA-20 at temperature indicated in the material requisition shall be conducted, for low temperature service.

3.9.3 The hardness of base plate shall not exceed 180 BHN.

3.9.4 Simulated heat treatment of base plate test coupon

The following heat treatment shall be conducted on the base plate test coupons representative of heat treated clad plates before the specified mechanical testing like tensile, bend, impact test etc. these details shall also be recorded on the test certificates.

All plates above 16 mm thick : One stress relieving as per UCS-

56 of ASME Sec. VIII Div. 1

Note: Any other special requirement shall be specified in Material Requisition.

3.10 Specific Requirements for Cr-Mo low alloy steel base metal

3.10.1 Base plate shall be impact tested at (-) 180C. The acceptance criteria

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(energy absorption values), unless otherwise specified, shall be as per UG-84 of ASME Sec. VIII Div.1.

3.10.2 The hardness of base plate shall not exceed 200 BHN.

3.10.3 Simulation heat treatment of base plate test coupon.

The following heat treatment shall be conducted on test coupons representative of heat treated clad plates before the specified mechanical tests like tensile, bend, impact tests etc. These details shall also be recorded on test certificate.

All plates : Two stress relieving cycle as per Mill's

recommendations. (However, Soaking temperature of 680 ± 200C and holding time as 1 hour per 25mm of thickness but not less than half an hours is recommended).

3.11 Additional Requirements for Base Metals Exceeding 50 mm thick

Base metal of thickness 50 mm and above shall meet the following additional requirements:

3.11.1 Vacuum degassing treatment as per supplementary requirement S1 of

specification SA 20.

3.11.2 Charpy V-notch impact tests for carbon steel base metal as per supplementary requirement S5 of specification SA-20.

Material meant to be used for design temperature warmer than 00C, impact test shall be carried out at (-) 29°C and acceptance criteria for

energy absorption shall be as per table A2.15 of SA-20. Acceptance criteria for impact testing of non listed material in Table A2.15 of SA20 shall be as per UG-84 unless otherwise specified in material requisition.

3.11.3 Bend test as per supplementary requirement S14 of specification

SA20.

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4.0 CERTIFIED DOCUMENTS

The supplier shall furnish 6 copies of the following certificates/ documents inclusive of all tests required as per specification, duly certified by the inspecting Authority before shipment of plates. The actual values obtained shall be recorded in the test certificates/documents. Purchaser's technical requirements shall be clearly shown in the test certificates. The actual values obtained shall be recorded in the test certificates / documents. Material certificate shall conform to EN1024 Type 3.2.

4.1 Chemical Analysis for both cladding metal and base metal. 4.2 Mechanical test for base metal and shear strength for clad plate. 4.3 Data of heat treatment of clad plate i.e. initial temperature, heating rate, soaking temperature/ time, cooling rate etc. For simulation heat

treatment of base plate test coupon, chart of heat treatment is to be attached to Mill's Certificate.

4.4 Ultrasonic examination. 4.5 Inter-granular corrosion test. 4.6 Finish for a cladding & base metal. 4.7 Method of cladding. 4.8 Certification as per IBR (if specified in material requisition) 4.9 Date of manufacture. 4.10 Pickling procedure.

5.0 PAINTING AND COATING

Plates are not to be painted/ coated but shall be covered with plastic foils or paper or by other means for careful protection and shall be packed against any damage during transit and sea weather conditions.

6.0 INSPECTION AUTHORITY

6.1 EIL / Lloyds Register of Shipping/ Third party approved by IOCL as

indicated in the requisition.

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CONTENTS

CLAUSE NO DESCRIPTION PAGE NO

1.0 SCOPE 4

2.0 TECHNICAL REQUIREMENTS 4

3.0 PAINTING AND GALVANIZING 7

4.0 DOCUMENTATION 8

5.0 TESTING AND INSPECTION 8

6.0 MARKING AND DESPATCH 9

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1.0 SCOPE

This document covers supply, material, fabrication, testing and inspection requirements for 'Spring Support Assemblies' with helical, hot coiled & heat treated compression type springs. Detailed design of spring assemblies is Vendor's responsibility. Vendor shall guarantee proper functioning of the Spring Assemblies under specified load & travel conditions. Items not indicated clearly in Vendor's offer but required as per this requisition shall be considered in Vendor's scope of supply.


2.1 Material Requirements

Unless otherwise specified, the material of construction shall be as follows:

Clamp (CS) IS 2062 Gr. A/B

Clamp (AS) -Note 1 ASTM A 387 Gr. 11/22 or SS 316 / 321.

Clamp (SS) SS 316/321Lugs (CS) - Note 2 IS 2062 Gr. A/BLugs (AS) - Note 3 ASTM A 387 Gr. 11/22Lugs (SS) - Note 3 SS 316/321Eye rod (CS Forged / Rolled Bar)

IS 1875 Cl-II/IIA / ASTM A 105 / IS 2062 Gr. A/B

Hanger Rod (CS) IS 1875 Cl-II/IIA / ASTM A 105 / IS 2062 Gr. A/B

Turn Buckle IS 1875 CI-II/IIA, ASTM A 105 for sizes ≤ M30. For sizes > M30 these may be fabricated type of equivalent material (refer clause 2.8)

Plates 5, 10, 12,20,25 mm etc. IS 2062 Gr. A/B.Stud / Bolt for CS Clamps ASTM A 193 Gr.B7Stud / Bolt for AS Clamps ASTM A 193 Gr. B 16Stud /Bolt for SS Clamps ASTM A 193 Gr.B8Nuts for CS Clamps ASTM A 194 Gr.2HNuts for AS Clamps ASTM A 194 Gr.4/ Gr.7Nuts for SS Clamps ASTM A 194 Gr.8

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Spring Coil BS 970 EN 42, 45-45A, 47, 50 Cr.V4, 51Cr. MoV4, IS-4454-Part 1 (for springs up to 40 mm coil dia. only)

Casing IS 1239-1 (Medium) / IS 2062 Gr. A, 5.00 mm thk (min.) / API 5L Gr. A/B ERW, 5.00 mm (min.) / IS 3589 Gr. 330 ERW, 5.00 mm (min.)

Name Plate SS / Aluminum

Load Indicator SS / AluminumWelding Electrode IS 814Other Bolts I Nuts IS 1367 CI. 4.6 /IS 1367 Cl. 4.0 Roller / Ball arrangement (Note - 4)

SS 304/316/SAE52100

Notes:

1. In case of Alloy Steel Clamps vendor can alternately supply SS Clamps.

2. Lug material for both pipe side & structure side attachments 3. Lug material for pipe side attachment. 4. Balls shall be provided in a semi encapsulated type enclosure with

separators for each ball. The bal ls shall be protruding above the enclosure so that the pipe support plate rests on the balls & the balls remain at the same location and move on their axis in case of movement of pipe. Sliding of balls in case of pipe movement is not acceptable.

2.2 Design & Manufacturing Requirements.

2.2.1 Design & manufacture of Hot coiled helical compression spring shall be to

BS 1726, Part 1 / MSS-SP-58 & ASTM A 125. All requirements of the specification must be met.

2.2.2 Unless otherwise stated all joints shall be of welded construction and shall

be in accordance with IS 816 / ASME Sec. IX.

2.2.3 All weld sizes shall be 6 mm or 0.8 times the thickness of metal (whichever is more) to be connected.

2.2.4 All bolt holes shall be minimum 2 mm larger than the bolt dia.

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2.2.5 All threads shall be metric type to IS 4218 - Standard Coarse Pitch, alternatively IS0 Metric threads may be employed.

2.3 The springs shall be coiled, ensuring that the coils are uniformly

spaced and are parallel to the axis of the spring.

2.4 The springs shall have their ends ground flat and smooth at right angles to the axes of the springs over the full circumference so that they stand perpendicular when placed on a horizontal plane.

2.5 All springs shall be enclosed in a robust casing of specified material with

two 6 mm dia. holes or equivalent at lowest point 180 deg apart for drainage.

2.6 The entire spring assembly including attachments & preset locking device shall

be designed for 2 times the service load or the hydro test load whichever is higher and shall be of the nut-bolt type for variable spring assemblies and pin type for constant spring assemblies. The springs shall also have suitable features so that they can be locked in any position within the range of load capacity of the hangers.

2.7 Each spring shall be factory preset to the load given in the spring

schedule.

2.8 All springs shall be supplied with lengths as specified in the MR. Deviation in lengths is not acceptable. Each spring shall also be provided with a means of adjusting the installed length by a minimum of 25 mm. Rod and turnbuckle assembly shall be designed for +/- 50 mm adjustment over the specified length of spring support assembly. Turnbuckles shall be made from forged material for sizes up to M30 and for sizes above M30 they can be forged type or machined from rolled bar or fabricated type.

2.9 All springs shall have an affixed load and travel plate on which hot and

cold positions are clearly marked. The load on the spring at any instant shall be indicated by an integral pointer on a load position plate.

2.10 All hanger type spring assemblies shall allow minimum 4 Deg.

Horizontal movement of pipe in any direction. Variable springs shall have max 15% load variation on operating load unless otherwise specified. However for constant springs load variation shall not exceed 5%. Vendor may offer springs with lesser % load variation than specified above. The value of spring constant if specified is the maximum value spring can have, Vendor may offer springs with up to

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6% lesser spring constant but not vice versa. For springs with preset load & spring constant, max % variation is not restricted to 15%.

2.11 All springs shall be provided with a means of positively and firmly

locking the piston plate for hydrostatic testing of the pipe.

2.12 Teflon / Graphite pads for reducing lateral frictional force shall be provided when specified in the requisition. Wherever temperature is greater than 2040C, only graphite pad shall be used. Thickness of Teflon / Graphite pads shall be minimum 10 mm / 12.7 mm respectively. Retainer plate of 8 mm / 10 mm thickness respectively shall be welded around the pads so that the pads are projected minimum 2 mm above the retainer plates. It must be ensured that the low friction material is bonded with the steel base plate and remains in place at the specified load conditions by using suitable adhesives. Adhesives used for pads should be capable of withstanding the line temperatures. Additionally two or more countersunk screws shall also be installed to avoid dislocation in case of Graphite pads.

2.13 The hanger support, except for the spring shall be designed with a safety

factor of 5. 2.14 All Constant & Variable spring supports weighing more than 45 Kg.

shall be provided with lifting lugs.

2.15 All spring coils shall be neoprene coated to prevent corrosion. Alternatively, polyurethane coating of spring coil is also acceptable. However, corrosion protection of spring coil through electroplating is not acceptable.

2.16 All Alloy Steel Springs shall be shot-peened.

2.17 Springs with free height to mean diameter ratio of more than 4 shall not

be used without external guiding arrangements.

2.18 Drawing showing arrangement of spring hangers shall be considered for overall guidance. The individual components shall be designed by the Vendor to meet the requirements of the requisition.

3.0 PAINTING & GALVANIZING

The spring support shall be thoroughly scrapped and Wire brushed on all

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surfaces to remove dust, mill scales etc. All external & internal surfaces shall be given two coats of Zinc Chromate Red Oxide Primer to IS-2074. All threaded parts I components shall be galvanized to ASTM A153 / A123 / IS-1573 / IS-1367, Part XI11 and spring coils shall be neoprene / polyurethane coated.

4.0 DOCUMENTATION

4.1 After placement of order and before commencement of

manufacturing, vendor shall obtain approval on detailed dimension drawings complete with material for different parts only if specified in the material requisition.

4.2 Material test certificates (physical properties) report, Heat treatment report

(wherever specified or required as per code) and chemical composition shall be furnished for all materials other than coil. For coil material, chemical composition load deflection, cramp test certificate shall also be furnished.

4.3 Test reports for each spring for all mandatory tests and other supplementary

tests as specified in the requisition shall be submitted.

4.4 Final documents to be submitted along with delivery of the springs.

• 6 copies of as built drawings of spring assemblies. • 6 copies of catalogues, operation manual & installation

procedure.

5.0 TESTING & INSPECTION

5.1 Testing of springs shall be as per BS-1726 Part 1.

5.2 A compression test shall be made by pressing the spring solid at least three times in succession. The spring should thereafter conform to dimensional requirements.

5.3 A cramp test shall be made by holding the spring compressed to the

minimum working compressed length for a period of not less than 12 hours with full load. The spring shall show a reduction of not more than 5% in its free length.

5.4 The manufacturer shall conduct tests to establish the spring rate, and the

measurement shall be carried out within 30% to 70% of the maximum

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deflection of the spring (free height minus solid height). The actual load test shall be conducted on the spring supports in the final assembled condition and shall be witnessed by the purchaser's representative.

5.5 The IOCL representative or TPIA shall have free access to inspect stage

wise fabrication at fabricators shop. All inspection shall be made in accordance with the relevant codes and specifications.

5.6 All alloy steel springs shall be examined by magnetic particle method.

6.0 MARKING AND DESPATCH

6.1 In addition to standard marking, each spring support shall be marked with

MR number and Spring Number / Tag Number with white weather proof paint on the casing or punched on a SS / Aluminum tag attached securely to the support with a rust proof wire.

6.2 Paint or ink used for marking shall not contain any harmful metal or

metallic salts.

6.3 All items shall be dry, clean and free from moisture, dirt & loose foreign material of any kind.

6.4 All items shall be properly packed in wooden boxes / crates and shall be

protected from rust, corrosion and mechanical damage during transportation, shipment & storage.

SPRING SCHEDULE

Sl. N

Sprin SpringNumb

Qty. (No

Spring

SuppFigu

re N

Dimensions(m Nominal

Pipe

Deflection Operating Load

%Load

Var. Line Numb

Line Pipe Materi

Line Design

Insulation

ThickneRemarks

Sch. L C(Max

)Up

Down

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

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24. 25.

Notes: 1. Variable spring shall have max. load variation on operating load as stated above.

Vendor may offer spring with lesser % load variation. 2. The deflections specified are the actual deflections. 3. Hydrotest load for spring shall be three times of operating load, vendor shall design

the present locking device, low friction pad and spring assembly components accordingly.

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SEPARATOR/COALESCER

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CONTENTS

CLAUSE NO DESCRIPTION PAGE NO 1.0 GENERAL 4 2.0 CODES AND STANDARDS 4 3.0 TECHNICAL REQUIREMENTS 4 4.0 INSPECTION AND TESTING 7 5.0 PROTECTION AND PAINTING 7 6.0 PACKAGING AND IDENTIFICATION 8 7.0 SPARE PARTS 9

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1.0 GENERAL

This standard specification specifies the minimum requirements under which the manufacturer shall design, manufacture, test and supply Filter Separator (for separating liquid and solid contaminants from gas stream)/ Coalescer (for separating liquid & solid contaminants from liquid stream).

2.0 CODES & STANDARDS

2.1 The following latest edition of codes, standards and recommended practices shall

be applicable:

ASME Sec. VIII. Div. I : Boiler and Pressure Vessel Code. ASME Sec. IX : Welding and Brazing Qualifications. ANSI Sec. II & ASTM : Material specifications. ANSI B 16.5 : Pipe flanges & pipe fittings. ANSI B 16.11 : Forged steel fittings socket welded &

threaded. ANSI B 36.10 : Welded & seamless wrought steel pipe.

Other International Standards may also be acceptable subject to their being equivalent or superior with prior approval of IOCL.

2.2 For provisions not covered by the above codes and standards, applicable

engineering practices and norms shall govern.


3.1 Acceptance Criteria

3.1.1 The vendor or his collaborators (for process / equipment design) should have supplied at least 10 nos. Filter Separator / Coalescer, of which at least 4 nos. must have completed minimum 16000 hours (approx. 2 years) of continuous service for similar capacity, performance and design conditions, without major breakdown.

3.1.2 Vendor shall submit along with his bid proposal, Vendor's / Collaborator's

Reference List for Filter Separator / Coalescer, giving the following minimum information:

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• Name & address of the client. • Equipment type / mode no. • Operating data (fluid / contaminant, flow rate, design temperature &

pressure). • Performance data. • Year of commissioning.

3.1.3 In case, the vendor has collaborative/back-up arrangement with a foreign

manufacturer of repute, the vendor shall clearly indicate in his bid, the extent of back-up assistance provided by the collaborators for the vendor's scope of work.

3.2 The equipment shall be of the type as mentioned in the data sheets and shall

meet the duty requirements and performance parameters as mentioned therein.

3.3 Vendor shall submit process design calculations for sizing of the equipment

together with all supporting documents /catalogues / nomographs etc. with the bid. It shall be clearly indicated as to how the number of cartridges has been arrived at for each equipment.

3.4 The material of construction of various parts of the equipment shall be as

mentioned in the data sheets.

3.5 The Coalescer vessel shall conform to IOCL specification given along with the enquiry.

3.6 In case the vendor's fabrication shop is not approved for the thickness of

vessel involved, the vendor shall either (i) get the vessel fabricated by any other vendor who is IOCL approved or (ii) get the vessel rolled by one of the IOCL approved vendor and the fabrication done at his own shop, subject to welding procedure qualification by IOCL / TPIA.

3.7 Suitable baffle plates shall be provided in the vessels for proper fluid flow

distribution.

3.8 Corrosion allowance of 3mm shall be considered for all carbon steel parts, unless otherwise mentioned in the data sheets.

3.9 Dished ends shall be of seamless construction, torispherical or 2:1 ellipsoidal type and shall be heat treated after forming as per ASME Sec. VIII Div. 1.

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3.10 All nozzles less than or equal to 2" NB size shall be provided with 2 nos.

6mm thick stiffeners at 90 degree to each other.

3.11 All nozzles above 3" NB size shall be provided with reinforcement pads. Calculations for reinforcement pads as per ASME shall be submitted for IOCL's approval.

3.12 All flanges upto 150 # rating shall be of weld neck type (for sizes upto 100

NB) or slip-on type forged steel to ANSI (for sizes above 100 NB). All flanges above 150 # rating shall be weld neck type only, irrespective of the nozzle size.

3.13 Quick opening closure for vessels, if specified in the data sheet, shall be of PEERLESS / GRINELL / PECO / SIIRTEC / HUBER YALE / GD ENGG make o n l y c o n f o r m i n g to A S M E r e q u i r e m e n t s . The c l o s u r e s h a l l b e equipped with locking device which can be opened only when the vessel is completely depressurized. Alternatively, swing bolts with pin arrangement shall be provided for the closure, if specified in the data sheet. The swing bolts shall be of one piece construction, without welding. Hinge pins shall be forged and of the same material as the swing bolts.

A davit / hinged arrangement shall be provided for the closure for convenient handling. The closure shall have perfect sealing arrangement to prevent leakage.

3.14 The filtering / coalescing elements shall be able to withstand without

damage the pressure differential created by choked conditions. The maximum allowable differential pressure (bursting pressure) shall be indicated in the bid proposal.

3.15 The material of the cartridge elements shall be chosen by the vendor based on

his past experience with similar service to suit the duty requirements. Bidder shall submit a list of past installations of the offered cartridge element for similar service.

3.16 The cartridges / pack elements shall be of PALL / PECO / FILTAN / FACET /

VELCON/ACS / SIIRTEC NIGI / make only. The type, model and number of elements shall be selected based on the supplier's recommendation.

3.17 Safety valves and Level instruments, if included in vendor's scope, shall be

designed as per instrument specification. Complete design and sizing calculations for instruments, as applicable, along with filled-in data sheet from the supplier

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shall be submitted with the bid. The make of instruments shall be as per IOCL approved list only (to be given by IOCL).

3.18 Insulation / fireproofing cleats of specified width shall be provided on the

vessels, if indicated in the data sheets.


4.1 Equipment shall be subjected to stage wise inspection and testing at vendor's / sub-vendor's works by IOCL / its authorized inspection agency. Vendor shall submit Quality Assurance (QA) plan before commencement of fabrication. Approved QA procedures shall form the basis for equipment inspection.

4.2 Testing at vendor's works shall include but not limited to the following :

• Non destructive tests such as radiography, dye penetration tests. • Hydrostatic test at 150% of design pressure for the vessel. • Any other test as per data sheet / standards / codes.

4.3 Any or all the tests shall be witnessed by IOCL / its authorized inspection

agency. However, such inspection shall be regarded as check up and in no way absolve the vendor of his responsibility.

5.0 PROTECTION AND PAINTING

5.1 All exposed carbon steel parts to be painted shall be thoroughly cleaned from

inside and outside to remove scale, rust, dirt and other foreign materials by wire brushing and sand blasting as applicable. Minimum acceptable standard in case of power tool cleaning shall be St. 3 and in case of blast cleaning shall be Sa 2% as per Swedish standard SIS 055900- 1967.

5.2 Non-ferrous materials, austenitic stainless steels, plastic or plastic coated

materials, insulated surfaces of equipment and pre-painted items shall not be painted.

5.3 Stainless steel surface, both inside and outside, shall be pickled and

passivated.

5.4 Machined and bearing surface shall be protected with varnish or thick coat of grease.

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5.5 Depending on the environment, following primer and finish coats shall be

applied:

S.No Environmental Description 1 Normal Industrial Primer 2 coats of red oxide

zinc chromate each 25 microns (min.) thick.

Finish coat 2 coats of synthetic enamel each 25 microns (min.) thick.

2 Corrosion industrial Primer 2 coats of Epoxy zinc chromate each 35 microns (min.) thick.

Finish coat 2 coats of Epoxy high built paint each 100 microns (min.) thick.

3 Coastal and Marine

Primer 2 coats of high build chlorinated rubber zinc phosphate each 50 microns (min.) thick.

Finish coat 2 coats of chlorinated rubber paint, each 50 microns (min.) thick.

4 All environments (temperature 80-4000C

Finish coat 2 coats of heat resistant aluminum paint suitable for specified temperature each 20 microns (min.) thick.

All values of paint thickness refer to DFT (Dry Film Thickness).

5.6 The colour of finish coat shall be intimated to vendor after placement of order.

6.0 PACKAGING AND IDENTIFICATION

6.1 All packaging shall be done in such a manner as to reduce the volume. The

equipment shall be dismantled into major components, suitable for shipment and shall be properly packed to provide adequate protection during shipment. All assemblies shall be properly match marked for site erection.

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6.2 Attachments, spare parts of the equipment and small items shall be packed

separately in wooden-cases. Each item shall be appropriately tagged with identification of main equipment, item denomination and reference number of the respective assembly drawing.

6.3 Detailed packing list in water-proof envelope shall be inserted in the

package together with equipment.

6.4 Each equipment shall have an identification plate giving salient equipment data, make, year of manufacture, equipment number, name of manufacturer etc.

7.0 SPARE PARTS

7.1 Vendor shall submit his recommended list of spare parts with recommended

quantities and itemized prices for first two years of operation of the equipment. Proper coding and referencing of spare parts shall be done so that later identification with appropriate equipment will be facilitated.

7.2 Recommended spares and their quantities shall take into account related

factors of equipment reliability, effect of equipment downtime upon production or safety, cost of parts and availability of vendor's service facilities around proposed location of equipment.

7.3 Vendor shall also submit a list of recommended commissioning spares with

quantities and the itemized prices.

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FOR CARTRIDGE FILTER

CARTRIDGE FILTER

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CONTENTS


1.0 GENERAL 4

2.0 CODES AND STANDARDS 4

3.0 TECHNICAL REQUIREMENTS 4

4.0 INSPECTION AND TESTING 7

5.0 PROTECTION AND PAINTING 8

6.0 PACKAGING AND IDENTIFICATION

10

7.0 SPARE PARTS 10

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1.0 GENERAL

1.1 This specification outlines the minimum requirements under which the manufacturer

shall design, manufacture, test and supply the Cartridge Filter for separating solid

contaminants from the liquid/gas stream. 2.0 CODES AND STANDARDS 2.1 Following codes & standards (latest edition) shall be followed for design,

manufacture, testing etc. of the equipment.

ASME SEC.VIII DIV. 1 Boiler and Pressure Vessel Code.

ASME SEC. IX Welding and Brazing Qualifications.

ASME SEC. II & ASTM Material specifications.

ANSI B 16.5 Pipe flanges & pipe fittings.

ANSI B 16.11 Forged steel fittings socket welded &

threaded.

ASME B 16.47 Large diameter Steel Flanges.

ANSI B 36.10 Welding & seamless pipe wrought steel pipe

For purposes of material selection, national code of the country of origin shall also be

acceptable provided the vendor specifically establishes, to the satisfaction of the purchaser, the equivalence or superiority of the proposed material with respect to those specified.


The equipment shall be of the type as mentioned in the data sheets and shall meet the duty requirements and performance parameters as mentioned therein. Vendor shall submit back up documents for selection/sizing of cartridge elements duly signed and stamped by element manufacturer along with the bid. The type, model, number of cartridges and filter vessel OD shall be selected based on allowable pressure drop and cartridge element manufacturer's recommendation and all the above required information shall be clearly reflected in back up document furnished

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by vendor.

The total internal cross sectional area of mounted cartridges shall not be less than inlet nozzle area.

The filter cartridges shall be of single piece construction, with no joints. The cartridges shall be of make as specified below:

The non metallic filter Cartridge shall be of PECO-FACET/PALL/BURGRESS/MANNINGNELCON make.

Additionally elements of M/s Dahlman may also be acceptable subject to their having Proven Track Record (PTR) of at least one year of satisfactory operation as on bid due date for similar service condition. PTR shall be submitted with the bid containing the following information: Name of Client Name of Project Year of Supply & commissioning Process and operating conditions Filtration efficiency Particle retention rating Type / Model / MOC of Filter element. For Porous metal filter cartridge, FUJUMOTT/PORAL are acceptable makes Vendor to ensure proper flow distribution to utilise the full cartridge area available for filtration Under no circumstances, the inlet fluid shall be allowed to directly impinge on the cartridge elements.

Vessel diameter shall be minimum twice the diameter of inlet nozzle. All internal nuts and bolts shall be of stainless steel irrespective of material of construction of filter vessel. Corrosion allowance of minimum 3mm shall be considered for all carbon steel parts unless otherwise specified in job specification/data sheet. Nozzles/davit/leg orientation shall be as per orientation drawing to be released to successful vendor at post order stage. Filter vessel support length shall be decided during detailed engineering based on actual layout requirement.

Equipment shall be designed and built to ensure that all equipment along with the accessories are mounted suitably for convenient and safe operation. Adequate

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access within the equipment shall be provided for removal and fixing of cartridge element. For filter cartridge maintenance & replacement, the inlet and outlet pipe connection shall not be disturbed. A blind flange at shell top shall facilitate the removal, maintenance and/or replacement of filter cartridges without disturbing the inlet and outlet pipe connections. The filter cartridges shall be of single piece construction, with no joints. Filter-Vessel Filter Vessel shall conform to EIL Standard. Specification 6-12-0030. Vessels of diameters 300 NB and below shall be made from seamless pipe only. For bigger diameters, the shell shall be fabricated by rolling the plates and welding with specified radiography and applicable welding procedures shall be followed. The rolling for making shell shall be lengthwise. In case the vendor's fabrication shop is not EIL approved for the thickness of vessel involved, the vendor shall either (i) get the vessel fabricated by any other EIL approve vendor or (ii) get the vessel rolled by one of the EIL approved vendor and get the fabrication done at his own shop, subject to welding procedure qualification by EIL. Dished ends shall be preferably of seamless construction, deep tori-spherical or 2:1 ellipsoidal type and shall be heat treated after forming as per Specification 6-12-0030. Full vessel dia size shell flange shall be provided for removal of cartridges. The matching cover shall be a forged blind flange. Suitable number of dowel pins shall be provided for proper location of the cover. The standard stud bolt and nut arrangement shall be provided for the cover unless specified otherwise. The cover and blind flanges weighing more than 15 kg shall be provided with lifting davit as per Standard Vessel supports shall be as per standards corresponding to the type of supports provided. Calculations for vessel supports as per ASME shall be submitted for purchaser's approval. Filter vessel shall be provided with suitable lifting lugs and earthling lugs All internal nuts, bolts and washers shall be of stainless steel irrespective of material of construction. Drain and vent connections shall be provided with matching blind cover flanges along with necessary gaskets, nuts and bolts.

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The nozzles shall be provided with reinforcement pads when required by the applicable code/standard. The calculations for reinforcement pads as per ASME shall be submitted for purchaser's approval. Alternatively, EIL Standard 7-12-0013 shall be followed. All nozzles shall be self-reinforced forged nozzle with integral flange in case vessel thickness is more than 50 mm. The vessel shall be designed for wind load and seismic load as per IS 875 and IS 1893 unless and otherwise specified in job specification. Nozzles shall be designed as per nozzle load furnished in Job Specification/ Datasheet. 0 For vessel in stainless steel construction, lower allowable stress values mentioned in ASME code shall be considered.

4.0 INSPECTION AND TESTING 4.1 Equipment shall be subjected to stage wise expediting, inspection and testing at

vendor's/sub-vendor's works by purchaser/its authorised inspection agency. Vendor shall submit Quality Assurance (QA) procedures before commencement of fabrication. Approved QA procedures shall form the basis for equipment inspection.

4.2 Testing at vendor's works shall include but not limited to the following:

- Non destructive tests such as radiography, dye penetration tests.

- Hydrostatic test at 150% of design pressure for the vessel. - Any other tests as per data sheets/standards/codes

4.3 Any or all the tests, at purchaser's option, shall be witnessed by purchaser/its authorised inspection agency. However, such inspection shall be regarded as check-up and in no way absolve the vendor of his responsibility.


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5.1 All exposed carbon steel parts to be painted shall be thoroughly cleaned from inside

and outside to remove scale, rust, dirt and other foreign materials by wire

brushing and sand blasting as applicable. Minimum acceptable standard in

case of power tool cleaning shall be St.3 and in case of blast cleaning shall be

Sa 2 112 as per Swedish standard SIS 0055900. 5.2 Non-ferrous materials, austenitic stainless steels, plastic or plastic coated materials, insulated surfaces of equipment and pre-painted items shall not be painted. 5.3 Stainless steel surfaces both inside and outside shall be pickled and passivated

5.4 Machined and bearing surfaces shall be protected with varnish grease. or thick coat of

5.5 Depending on the environment, following primer and finish coats shall be applied:

Sl. Environment Description

i) Normal Industrial Primer 2coats of Red oxide Zinc Chromate each 25 micron (min) thick.

Finish coat 2coats of synthetic enamel, each 25 micron (min) thick.

ii) Corrosive Industrial Primer 2coats of Epoxy zinc chromate, each 35 micron (min) thick.

Finish coat 2coats of Epoxy high build paint each 100 micron (min) thick.

iii) Coastal and marine Primer 2coats of high build chlorinated rubber zinc phosphate, each 50 micron (min) thick.

Finish coat 2coats of Chlorinated rubber paint each 35 micron (min) thick.

iv) All environment (Temp 80-400C)

Finish 2coats of heat resistant aluminium paint, suitable for specified temp. each 20 micron(min) thick.

Note: All values refer to dry film thickness 5.6 The colour of finish coat shall be intimated to vendor after placement of order

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5.7 Quick Opening Closure (QOC) 5.7.1 The filter shall be provided with Quick Opening Closure (QOC), if specified in job

Specification/data sheet for easy removal & replacement of filter element during maintenance. The diameter of QOC shall be same as that of filter vessel diameter unless otherwise specified in job specification/data sheet. The QOC shall be of the makes as specified in job specification, conforming to ASME code requirements and will carry ASME code stamp.

5.7.2 The Closure shall be equipped with locking device, which can be opened only when

the Vessel is completely depressurized. Quick opening closure shall be of double yoke / Band Lock design only. Swing bolt type, threaded type and other designs are not acceptable as a QOC. A davit/hinge arrangement shall be provided for the closure for convenient Handling. The closure shall have perfect sealing arrangement to prevent leakage.

5.7.3 Approved Vendor List for QOC is as mentioned below:-

a) GD Engineering b) PECO-FACET c) Multitex (In case of Band lock type, upto 42" size and 900# is acceptable.)

Additionally QOC of following makes may also be accepted subject to their Proven Track larger size and same or higher design pressure:

I. Huber Yale II. CYPRIS Technologies

III. Grinell IV. Peerless V. Pipeline Engineering, UK

VI. Piping Technologies, France (Genoyer Group)

5.7.4 Vendor to submit Proven Track Record (PTR) of at least one year of satisfactory operation as on bid due date clearly indicating the following information: 1. Make and model of QOC 2. Name of Plant 3. Purchaser name and address 4. Contact details (Telephone no. and Email ID) 5. Date of commissioning of filter 6. Design parameters ( Service, Size, Design Temp & Pr.)

6.0 PACKAGING AND IDENTIFICATION 6.1 All packaging shall be done in such a manner as to reduce the volume. The

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equipment shall be dismantled into major components suitable for shipment and shall be properly packed to provide adequate protection during shipment. All assemblies shall be properly match marked for site erection.

6.2 Attachments, spare parts of the equipment and small items shall be packed

separately in wooden-cases. Each item shall be appropriately tagged with identification of main equipment, its denomination and reference number of the respective assembly drawing.

6.3 Detailed packing list in water-proof envelope shall be inserted in the package

together with equipment. 6.4 Each equipment shall have an identification plate giving salient equipment data,

make, year of manufacture, equipment number, name of manufacturer etc. 7.0 SPARE PARTS 7.1 Vendor shall submit his recommended list of spare parts with recommended

quantities and itemised prices for first two years of operation of the equipment. Proper coding and referencing of spare parts shall be done so that later identification with appropriate equipment will be facilitated.

7.2 Recommended spares and their quantities should take into account related



quantities and the itemised prices.

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AXIAL AND CENTRIFUGAL COMPRESSORS


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CONTENTS

SR NO DESCRIPTION PAGE NO

1 INTRODUCTION 4

2 CHAPTER 1- GENERAL REQUIREMENTS 4

3 CHAPTER 2- CENTRIFUGAL AND AXIAL COMPRESSORS 22

4 CHAPTER 3- INTEGRALLY GEARED COMPRESSORS 26

5 CHAPTER 4- EXPANDER-COMPRESSORS 27

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INTRODUCTION

The API Std. 617 seventh edition July 2002, "Axial and Centrifugal Compressors and Expander-compressors for Petroleum, Chemical and Gas Industry Services, is an integral part of this Specification . The numbering of sections and paragraphs is the same as in API 617. The type of change e.g. addition, deletion, modification, substitution or new, is noted in parenthesis for each item.

CHAPTER 1 GENERAL REQUIREMENTS

1. GENERAL

1.1 Scope

(mod) This Specification is intended to cover the minimum requirements for axial and centrifugal compressors and expander compressors, for all types of plants. It is not restricted to petroleum, chemical and gas industry service.

1.1.2 (new) Compliance with this Specification does not relieve the manufacturer or the Vendor of the responsibility for supplying equipment of proper design and construction and fully suitable for all specified operating conditions.

1.1.3 (new) Equipment offered by Vendor shall satisfy the following minimum service and manufacturing experience requirements:

1. Compressors and expander compressors shall be identical or validly similar in power rating, speed, discharge pressure, suction capacity, process gas, mechanical design, materials and rotor dynamics as compared with at least two units produced by the Vendor at the proposed manufacturing plant of which one must have had at least one year's satisfactory operation at the time of enquiry issue.

2. Equipment manufactured under licence, in addition to satisfying the above requirement shall also have the licensor's written guarantee.

3. Corresponding requirements of items 1 and 2 above, shall also apply to the driver, gear and auxiliary equipment.

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1.6 Normative References

(mod) The latest revisions of the Engineering Specification provided in the MR shall form part of this Specification and take precedence over those listed in API 617 Annex 1A.

1.6.5 (mod) The Specifications as stated in the enquiry or purchase order documentation shall apply.

1.7 (sub) Statutory Requirements

The Vendor shall ensure that all equipment in his scope of supply complies with all applicable statutory requirements, standards, codes, local rules and regulations.

2. BASIC DESIGN

2.1 General

2.1.1.5 (new) Any gas properties used in compressor design that are not stated on IOCL’s datasheets shall be advised by Vendor.

2.1.8 (add.) Ambient and environment conditions are as per MR specification

For installations in tropical climates, all instrumentation, motor insulation and similar equipment, which may be subject to attack by moisture, fungus or insects, shall be suitably treated with polyurethane or equivalent coating to inhibit such attack.

2.1.9 (mod) The noise level for the pump set shall not exceed the values specified in Datasheet. Where lagging of pipe-work is necessary for noise attenuation, the Vendor shall indicate this in his quotation. The lagging will be carried out by others at site.

2.1.14 (add.) All electrical components and installations shall also be suitable for the environmental conditions specified.

2.1.17 (new) Unless specified otherwise, the Vendor shall supply with each compressor and/or expander-compressor a complete spare rotor assembly including couplings. For two or more identical compressors and/or expander only one common spare rotor assembly including couplings shall be supplied.

2.1.18 (new) The Vendor shall use the specified values of gas analysis and weight flow to verify the specified molecular weight, specific heat ratio, inlet capacity and compressibility factors. Where discrepancies occur, the Vendor shall resolve these with IOCL prior to order placement.

2.1.19 (new) Installed standby compressors shall be suitable for running with equal load in parallel operation.

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2.2 Materials

2.2.1 General

2.2.1.14 (mod) Copper or copper alloys shall not be used in contact with process fluid unless specifically approved in writing by IOCL.

2.2.1.15.2 (mod) All components of the machinery train shall be evaluated for the prevention of brittle fracture.

2.2.1.16 (add) Vendor shall advise in his proposal any coatings that are recommended by him to be used and the associated sequence of balance.

2.2.1.17 (new) Asbestos shall not be used in any form.

2.2.1.18 (new) Where materials of major components, including such items as coolers and intercoolers are not specified by IOCL, Vendor shall propose the most appropriate materials, based on his experience, for IOCL review.

2.3.1 Pressure Containing Casings

2.3.1.9 (add) Weld procedures, including joint details and non-destructive test requirements, shall be submitted for IOCL's approval for all connections and attachments welded to pressure casings.

2.3.1.9 (add) All piping welds shall have full penetration.

2.3.1.11.2 (add) Vendor shall provide, drawings showing locations of all welds inaccessible for NDT, in particular stressed welds on hydrocarbon containing components of the compressor.

2.3.1.12.2 (add) All pressure welds shall be 100% radiographed. If radiography is not feasible, magnetic - particle inspection shall be performed instead.

2.3.2 Pressure Casing Connections

2.3.2.1.1 (mod) All connections shall be flanged unless otherwise approved by IOCL.

2.3.2.1.7 (mod) For all compressors and compressor-expanders, each casing drain shall be piped by Vendor to a valve located and properly supported

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at the edge of the baseplate. All casing drains shall be connected to a common header requiring only a single IOCL connection.

2.3.2.1.7 (add) When closed drains are installed, valved "check vent" connections shall be provided on each drain to provide a visual check of complete drainage.

2.3.2.2.2 (mod) When connections of 24 inch diameter and larger are to be piped-up by IOCL, the Vendor shall furnish a welding-neck mating flange together with nut bolts and gasket. The weld neck shall be prepared suitable for the thickness of the connecting pipe.

2.3.2.3.3 (mod) All auxiliary connections shall be flanged unless otherwise approved by IOCL.

2.5 Rotating Elements

2.5.4 (add) The maximum stress in the impellers in any direction at maximum continuous speed, shall not exceed 70% of the impeller material yield strength.

2.5.10 Impellers

2.5.10.1 (mod) Cast impellers may be furnished only when specifically approved by IOCL.

2.6 Dynamics

2.6.2.6 (add) A train lateral analysis is required where one or more rigid couplings are employed. An analysis from an identical train from a previous project may be offered.

2.6.2.14 (add) This additional information shall be provided if vibration levels and critical speed characteristics are determined to be unacceptable during factory acceptance testing or initial running after installation at site.

2.6.7 Torsional Analysis

2.6.7.1 (mod) Unless otherwise specified, for motor-driven units and for units including gears, the Vendor having unit responsibility shall perform a

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torsional-vibration analysis of the complete compressor - driver unit and shall be responsible for the unit's satisfactory performance.

2.6.7.1 (add) The torsional vibration analysis shall be checked and approved by the driver Vendor or in the case of units driven via a gear, by the gear Vendor before submitting to IOCL for approval.

2.6.7.4 (mod) Torsional modes within 5 percent of twice any shaft speed, up to the trip speed, are not acceptable.

2.6.7.6 (mod) For units with motor drivers of 10 MW and larger and for units with synchronous motors, the Vendor having unit responsibility shall also perform a transient torsional analysis using the time-step method simulating system response to the oscillatory torques at time increments. Vendor shall submit to IOCL a report of the analysis, for approval.

2.6.7.6 (add) The analysis shall consider but not be limited to the following transient load cases:

a) 2 and 3 phase terminal short circuit

b) Malsynchronous run up of synchronous motors

c) Pulse operation of variable frequency motors

2.6.8 Vibration and Balancing

2.6.8.2.1.1 (mod) Delete ‘’When specified.‘’

2.6.8.3 (mod) Delete ‘’when specified’’

2.6.8.6 (mod) All balancing at operating speed shall be preceded by a low speed balance.

2.6.8.7 (mod) A low speed residual unbalance check is required for rotors that are balanced at operating speed,

2.7 Bearings and Bearing Housings

2.7.2 Hydrodynamic Radial Bearings

(add) Each radial bearing shall be fitted with two bearing metal temperature sensors in accordance with API 670

2.7.3 Hydrodynamic Thrust Bearings

2.7.3.5 (new) Two bearing metal temperature sensors shall be to fitted on the active side and two on the inactive side in accordance with API 670.

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2.7.4 Bearing Housings

2.7.4.6 (mod) The number of cable connections shall be minimised to facilitate ease of assembly and disassembly.

2.7.4.7 (new) If the process gas is liable to cause deterioration of the lube oil, the bearings shall be isolated from the shaft seal by a ventilated space and labyrinths or other seals to prevent contamination or interchange of the seal oil, process gas and lube oil. The space shall have provision for external air or inert gas purge.

2.7.4.8 (new) Bearing housings shall be provided with Vendor's standard breather or venting connection for piping-up by IOCL as specified. The breathers shall be designed such that there is no visible oil emanating from them.

2.8 Shaft End Seals

2.8.1.1 (add) Clearance seals shall not be used for flammable or toxic gas service.

2.8.1.1 (add) The shaft seals and sealing system shall be suitable for rapid depressurisation.

2.8.1.3 (mod) Clearance seals shall be used for air or inert gas service, self-acting dry gas seals for flammable and or toxic service subject to the experience criteria of para. 1.1.3

2.8.3 Oil Seals

2.8.3.4 (add) Seals shall incorporate a supplementary sealing device to prevent process gas leakage when the compressor is not running and the seal system is shut down.

2.8.3.5 (add) 1. A positive internal gas pressure shall be maintained at the seals under all start-up and operating conditions including partial vacuum during air run-in operation. The Vendor shall specify in his quotation any seal characteristics which may affect air run-in operation.

2. Vendor's proposal shall state the expected and the guaranteed maximum inner seal fluid leakage per seal for both normal operating conditions and also with the compressor at rest.

3. For low temperature service, seal oil temperature at the inner seal drain shall be maintained above its pour point to ensure satisfactory draining.

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2.8.3.7 (new) For seals supplied with sealing oil, when compressing air during run-in or during process operation, buffer gas injection shall be provided if air discharge temperature is likely to exceed 177°C (350°F).

2.8.3.8 (new) For continuous buffer gas injection, Vendor shall supply an automatic differential pressure controller, a dual gas strainer (150 micron), low pressure alarm and pressure gauge. Piping downstream of the strainer shall be stainless steel.

2.8.3.9 (new) When buffer gas injection is used only during compressor start-up and shutdown, the overall seal system design shall ensure effective sealing during change over between normal seal operation and buffer gas injection. If necessary to meet this requirement, initiation of buffer gas injection shall be automatic on shut-down of the compressor.

2.8.3.10 (new) When buffer gas injection is used only during compressor run-in operation, the buffer gas system may be hand-valve controlled and be without a low pressure alarm.

2.8.3.11 (new) Vendor shall state the expected buffer gas injection rate for seals at both design and double design (i.e. worn) clearances.

2.8.4 Self Acting Dry Gas Seals

2.8.4.1 (mod) In toxic or flammable gas applications tandem seals with intermediate labyrinth are required, unless otherwise agreed with IOCL.

2.8.4.1 (add) (a) The design shall prevent process gas leakage into the lube oil system or oil leakage into the seal face area. If a separation gas purge (e.g. Nitrogen) is required the maximum flow rate per seal shall be stated and guaranteed by the Vendor.

(b) The compressor or compressor expander Vendor shall be responsible for ensuring that all possible operating conditions for the seals are given to the seal Vendor. These shall include all machine and seal operating conditions including minimum speed (e.g. slow roll, barring etc) and time to depressurise the casing after shutdown. If reverse rotation is a possibility after shutdown, bi-directional seal shall be provided.

2.8.4.3 (mod) Seal support systems for self acting dry gas seals shall be in accordance with Engineering Spec. ‘Lubrication, Shaft Sealing and Control Oil Systems and Auxiliaries.’, if provided in the MR.

2.10 Lubrication and Sealing Systems

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2.10.3 (mod) Pressurized oil systems shall comply with Engineering Spec ‘Lubrication, Shaft Sealing and Control Oil Systems and Auxiliaries, if provided in the MR.

3. ACCESSORIES

3.1 Drivers

3.1.4 (sub) Unless otherwise specified, steam turbines for main drivers shall be in accordance with Engineering Spec of ‘Special Purpose Steam Turbines.’, if provided with MR. Their rated power output at rated steam conditions shall be not less than 110% of the power required by the compressor (including gear and transmission losses) at all specified operating points and their corresponding speeds.

Unless otherwise specified, steam turbine drivers for auxiliary equipment shall be in accordance with Engineering Spec. ‘General Purpose Steam Turbines.’(if provided in MR) Their rated power output at rated steam conditions shall be not less than 110% of the greatest horsepower (including gear and coupling losses) required by the auxiliary machine.

3.1.5 (add) 1. Unless otherwise specified, electric motors for main drivers shall be in accordance with Engineering Spec of ‘Induction Motors.’

2. Compressor unit rotor system shall be suitable to withstand without any detriment, transient torques associated with any interruption in supply voltage.

3. For compressors driven by synchronous motors, the compressor unit rotor system shall be suitable to withstand without any detriment the peak oscillatory transient torque associated with the motor start-up.

3.1.5 (mod) Motor nameplate rating excluding service factor shall be at least 110% of the greatest power including transmission losses for any of the specified operating conditions.

3.1.8 (mod) Main speed increasers and reducers shall be in accordance with Engineering Spec. ‘Special Purpose Gears.’, if provided in MR.

3.1.9 (new) Motors for auxiliary equipment shall be in accordance with Engineering Spec. of ‘Induction Motors.’

3.2 Couplings

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3.2.2 (sub.) Couplings shall conform to Engineering Spec. ‘Special Purpose Couplings.’

(add) Flexible multiple parallel discs (disc pack) fail-safe type couplings are preferred. Gear type couplings, continuously lubricated, are acceptable only if approved by IOCL.

(add) Coupling guards shall comply with Engineering Spec. ‘Guards for Machinery.’

3.2.5 (mod) The Vendor shall provide a plug and ring gauges as required for manufacturer and assembly. All hubs shall be fitted to the finish machined shaft ends before factory testing, and before delivery.

3.2.7 (del) This paragraph is deleted.

3.2.8 (new) Coupling flexible discs shall be stainless steel.

3.2.9 (new) When hydraulically fitted hubs are supplied, the Vendor shall supply all necessary equipment for installation and removal purposes.

3.3 Mounting Plates

3.3.2 Baseplates

3.3.2.1 (mod) Steam turbine driven compressors shall have a common baseplate for the compressor(s) and turbine.

Gas turbine driven compressors shall have separate baseplates, one for the turbine and one for the compressor(s) and gear.

Motor driven compressors may have a common baseplate for the compressor(s), motor and gear. Alternatively, the motor may be mounted separately on a soleplate, with the compressor(s) and gear mounted on a common baseplate.

3.3.2.4 (mod) Unless otherwise specified, grating shall be provided for all areas where personnel access may be required.

3.3.2.4.1 (mod) Unless otherwise specified, all solid decked surfaces shall be sloped to prevent collection of water.

3.3.2.6 (mod) Vendor shall provide his standard method for levelling unless otherwise specified.

3.3.2.9 (mod) Baseplates shall be supplied with machined mounting pads unless otherwise specified.

3.4 Controls and Instrumentation

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3.4.1 General

3.4.1.1 (add) The instrument and control system shall permit local start-up of the equipment and subsequent transfer of control to the remote control room panel. The equipment shall then normally be operated from the remote control room panel. Instrumentation shall be designed for minimum manning and operator attention. Alarms for equipment and process functions, equipment and process initiated shutdown annunciation and all critical operating information shall be displayed on the remote control room panel and be provided with suitable signals to repeat this information on the local panel as specified in the material requisition.

3.4.1.1 (add) Starting of compressors shall be possible from either the local or remote control panels where these are provided.

3.4.1.1 (add) The compressor and driver shall be suitable for automatic unattended start up.

3.4.1.2 (mod) Instrumentation and installation shall conform to Engineering Spec...

3.4.1.3 (add) Compressor and driver control panels shall be mounted in the control room unless otherwise specified.

3.4.1.4 (add) All controls and instrumentation shall be suitable for the electrical supply, area classification and environment specified.

3.4.2 Control Systems 3.4.2.6 (sub) Unless otherwise specified, the anti-surge control system shall be

designed by the Vendor and the equipment shall be provided by IOCL

3.4.3 Instrumentation and Control Panels 3.4.4 (del) This paragraph is deleted. 3.4.5 Instrumentation 3.4.6 (del) The reference to API Std’s is deleted. 3.4.4.1 (new) Alarms and interlock/shutdown circuits shall be generally “fail safe”

i.e. normally energised, contacts closed in the healthy state. 3.4.5 Alarms and Shutdowns

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3.4.5.1 (new) When a redundant voting shutdown system is specified the following

shall apply. Three switches shall be furnished on each of the specified shut-down services. The switches shall be monitored by a solid state logic system. If one switch operates, an alarm shall be given. When two switches in any one service operate, a shut-down shall be actuated. A logic power supply fault alarm shall be furnished.

3.4.5.2 (new) Electrical switches shall comply with the requirements of Engineering ‘Electrical Requirements for Package Supply Equipment Units’

3.4.8 (new) As a minimum and unless otherwise specified, the following instrumentation shall be provided.

1. All thrust bearing temperatures (Two pads on active side and two pads on inactive side) shall be monitored as follows:

a) Each temperature sensing point high temperature alarm. b) If specified, a temperature recorder shall be provided for

temperature sensing points. 2. Permissive start facility shall be provided for lube oil, seal oil

and control oil, so that the driver cannot be started unless the oil system is functioning correctly.

3. A permissive start is required to prevent the starting of the lube oil system until the separation gas pressure is established to prevent oil contamination of the main dry gas seals. However low separation gas pressure to be alarm only.

4 Compressor discharge high gas temperature alarm shall be provided; shutdown shall be provided if there is a possibility of compressor discharge temperature exceeding maximum case design temperature. IOCL shall provide and install alarm and shutdown switches in the compressor discharge pipe adjacent to the compressor flange.

5. Shaft seal injector or educator system seal chamber low and high pressure alarm (when applicable).

6. Diaphragm cooling water system, low water pressure alarm and stand-by water pump cut-in alarm (when applicable).

3.5 Piping and Appurtenances 3.5.1 General 3.5.1.5 (new) All piping welds shall have full penetration.

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4. INSPECTION, TESTING, AND PREPARATION FOR SHIPMENT 4.1 General 4.1.6 (mod) Acceptance of equipment shall be performed in accordance with the

requirements of the purchase order. 4.1.8 (new) Unless otherwise specified, all mechanical running and complete

unit tests shall continue for a minimum of 4 hours from the time bearing and other significant temperatures have stabilised.

4.2 Inspection 4.2.1.6 (new) The Vendor shall provide a quality control plan showing the

proposed programme of inspection and testing and which items are to be witnessed or observed. This plan will be reviewed by IOCL who will advise any required amendments. When requested, the Vendor shall provide a copy of his quality control procedures for IOCL's review.

4.2.1.7 (new) The scope of IOCL's inspection shall include as a minimum, sub-orders, materials, welding, heat treatment, non-destructive testing of materials and welds, repairs, rotor balancing, dimensional checks, hydrostatic and running tests, internal check after testing and final inspection prior to shipment.

4.2.1.8 (new) IOCL's inspector shall be informed of any defects noticed during manufacture. Vendor shall also inform IOCL and obtain his permission before proceeding with any repairs which may affect equipment operation, integrity or interchangeability. Repair procedures shall be approved by IOCL before rectification. Rejections made by IOCL shall be final.

4.2.1.9 (new) All welded piping shall be inspected as follows: as a minimum, 10% of all circumferential buttwelds, selected at

random, shall be radiographed in accordance with ANSI B31.3 4.2.1.10 (new) All accessible surfaces of welds, including welded external

attachments, shall be inspected by magnetic particle method. 4.2.2.7 (new) Cast steel casings shall be examined by the magnetic particle

method. Casing pressure welds shall be 100 per cent radiographed.

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4.3 Testing 4.3.1 General 4.3.1.4 (new) IOCL or his representatives shall observe all testing, dismantling,

inspection and re-assembly of equipment, as specified in the data sheet.

4.3.5 (sub) Details of the seal manufacturers shop test per Annex 1F shall be included in the proposal.

4.3.6 Mechanical Running Test 4.3.6.1.3 (add) The recordings of vibration amplitude versus frequency shall be

made at maximum continuous speed and minimum operating speed. 4.3.8 Optional Tests 4.3.8.2 (add) Casings for compressors handling gas containing 30 mol-percent or

higher of hydrogen, shall be subject to a helium leakage test, at not less than the casing maximum allowable working pressure.

4.3.8.4 (add) Auxiliary Equipment Test Dry gas seals shall be tested by the seal manufacturer, in

accordance with Annex 1D. 4.3.8.4 (add) Vendor shall submit all auxiliary equipment test procedures for IOCL

acceptance. 4.3.8.5 (mod) Post-test Inspection: The gas leak test shall be performed following the reassembly after

the post test inspection, unless otherwise specified. 4.3.8.6 (add) Vendor shall submit the test procedure for IOCL acceptance. 4.3.8.8 (mod) Unless otherwise stated in the purchase order, only spare rotor

assemblies and dry gas seals shall be tested. 4.4 Preparation for Shipment 4.4.1 (add) The preparation for shipment and the type and mode of shipment

shall be in accordance with the purchase order. 4.4.3.1 (mod) The paint for all exterior surfaces shall be suitable for the

environment specified. The paint, preparation and painting procedures shall be approved by IOCL.

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4.4.3.11 (mod) Unless otherwise stated in the purchase order, all on package pipe-work shall be fully fitted and assembled prior to dispatch. Pipe-work between main packages and off-package auxiliaries, if supplied by Vendor, shall have sufficient spare lengths for final field welding.

5. VENDOR'S DATA 5.1.3 r. (new) Details of the thrust and radial bearings, rated and actual loads with

respect to volume flow over the full speed range including start up. 5.1.5 (new) All data and information provided during the proposal stage shall

also be confirmed for the contract and as-built stages of the contract.

5.1.6 (new) Number and quantity of drawings required shall be as specified in the enquiry or purchase order, together with a mutually agreed schedule for obtaining submission and approval.

5.2.3 Technical data 5.2.3.b (mod) A statement of guaranteed noise emission data shall be provided. 5.2.3.w (new.) Performance curves for each specified operating case at the

corresponding operating speed shall be supplied. 5.2.3.x (new) The Vendor shall identify in his quotation all materials which contain

asbestos in any form. 5.2.3 y (new) A list of reference installations to verify compliance with the

requirements of proven design as specified in para. 1.1.3 5.3 Contract Data 5.3.1 General 5.3.1.1 (sub.) The following paragraphs specify the information to be furnished by

the Vendor. This information and that covered by the material requisition and purchase order shall be provided within the time mutually agreed upon by IOCL and the Vendor.

5.3.1.5 (new) Certified copies of test data shall be submitted to IOCL prior to shipment.

5.3.1.5 (new) Unless otherwise specified in the enquiry or purchase order, manufacturing shall not be held pending approval of drawings except for welding procedures. All weld procedures must be approved prior to manufacture.

5.3.1.6 (new) Weld procedures, weld penetration details and non-destructive examination procedures shall be provided by Vendor.

5.3.1.7 (new) Completed “as built” IOCL’s data sheets and performance curves shall be provided by Vendor.

5.3.2.1 Curves

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5.3.2.1.7 (new) Extrapolated performance curves, based on test results, shall be provided for variable speed units or units fitted with inlet guide vanes, showing the performance for each specified operating point when operating at the required speed or required inlet guide vane setting. The curves shall show the following parameters versus actual inlet capacity.

1. Discharge Pressure. 2. Polytrophic head. 3. Shaft power. 4. Required operating speed. 5. Required inlet guide vane setting. In the case of multi-section compressors, the performance curves

specified above, shall be furnished for the overall compressor and in addition for each compression section.

5.3.5.1.2 (mod) Draft manuals shall be provided, unless otherwise specified. 5.3.5.4 (mod) The technical data manual shall be provided. Format and content

shall comply with the requirements of the purchase order.

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ANNEXE 1F (new) Witness Test Procedure - for a Dry Gas Seal (including barrier seal) at Seal Manufacturers Works a) The following tests are deemed to duplicate the worst conditions the seals will

be subjected to in the field. b) All test pressures, temperatures, etc., referred to in this procedure are based

upon anticipated operating conditions of the machine stated in the material requisition. The seals shall be tested to the maximum design conditions of temperature, pressure and speed, including overspeed specified for the machine. The gas used in the test should have a similar molecular weight to that of the working seal gas where possible.

c) The seal shall be subjected to a static leakage test with pressures ranging

from atmospheric to the maximum operating pressure of the compressor. The pressure increments shall be 0, 1/4, 1/2, 3/4 and one times the maximum operating pressure. These readings shall be taken at ambient temperature and the breakaway torque at each pressure increment shall be recorded.

Note: Maximum static pressure may occur at settle out condition. d) The dynamic seal leakage test then shall be run at the maximum continuous

speed of the compressor, while maintaining a pressure equal to 1.2 times the maximum operating pressure of the seal provided that this is within the design limit of the seal. This condition shall be maintained until the seal temperature is stabilized and held for a minimum of 1 hour.

e) After step d) above is reached, the seal cavity shall be rapidly depressurized

to atmospheric pressure at a maximum rate of 20 bar per minute and the driver tripped off the line.

f) The driver shall then be re-started and run at the lowest possible speed for 10

minutes with atmospheric pressure on the seal; the driver will then be tripped off the line.

g) The driver will be restarted and run at the maximum continuous speed and

the seal pressure set to 1.2 times the operating pressure. After the temperatures have stabilized in the seal area, the driver speed will be increased to the overspeed value of the compressor and the motor tripped with the pressure remaining on the seal. After the speed of the driver has reached 0 rpm, the seal will be rapidly depressurized to atmospheric pressure at a maximum rate of 20 bar per minute.

h) In the case of tandem seals the back-up seal also shall be tested at 1.2 times

the operating pressure. The driver shall be run up to the maximum

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continuous speed and run there until all critical temperatures are stabilised at maximum anticipated temperature in the seal area. After reaching stabilization, the seal cavities shall be simultaneously blown down to atmospheric pressure at a maximum rate of 20 bar per minute, while the driver is still at maximum continuous speed. With atmospheric pressure on the seals, the driver shall be tripped off line.

j) After completion of the running tests, the static leakage measurement shall be

repeated as per para c) while the seals are still hot. k) Step j) above shall be repeated after the seals have reached room

temperature. l) If the static leakage before and after tests c), j) and k) above are not

comparable within ± 30% then the seal shall be dismantled for visual inspection of the seal faces. Signs of contact shall be the cause for rejection. The tests shall be repeated upon reassembly after rectification. If static leakage is comparable then the seal should not be dismantled.

m) The following items shall be recorded during the testing:

(1) Seal identification or serial number (2) Name of operator (3) Time and date of each set of readings (4) Shaft speed (5) Inlet gas temperature (6) Drive load (7) Seal cavity pressure (8) Seal cavity temperature (9) Seal leakage rate (10) Static leakage rate and torque at ambient temperature (11) Static leakage rate and torque at temperature of the hot seal (12) All critical temperatures related to the seal

n) After completion of the test programme, the manufacturer shall present IOCL's representative a copy of all test results. A graphical representation of the above is shown on the following page.

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CHAPTER 2 CENTRIFUGAL AND AXIAL COMPRESSORS

2.0 BASIC DESIGN

2.1 General 2.1.1 Performance 2.1.1.2 (new) The rise in discharge pressure from normal operating point to surge

point shall be not less than that shown below:

Number of impellers 1 2 3 4 and above Minimum % increase in

discharge pressure(abs) 4.0 4.5 5.0 6.0 from normal operating point to surge point

2.1.1.3 (new) The head developed at 115% of normal capacity and normal speed,

shall be not less than approximately 85% of the head at the normal operating point.

2.1.1.4 (new) The turndown or stability range of any compressor or compressor

section, at normal speed and normal unthrottled suction pressure, shall be not less than that specified in the purchase order.

2.1.1.5 (new) Compressors shall be suitable for "running-in" on air, with suction at

atmospheric pressure. Vendor shall advise of any special features required for that purpose in his quotation.

2.1.1.6 (new) Vendor to select an efficient compressor train to minimise a penalty

loading as specified in ‘Loading and Penalty Criteria for Rotating Equipment.’

2.3 Casings 2.3.2 Pressure Casing Connections 2.3.2.4 (mod) Vendor shall advise in his proposal all possible locations for

borescope inspection points and the advantages any such inspection points would have.

2.4 Guide Vanes, Stators and Stationary Internals 2.4.2 (mod) Vendor shall advise his proposal whether such a feature is required

or of benefit.

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2.4.3 (mod) Where AIGVs are supplied, Vendor shall also provide a valve

positioner with local position indicator, unless otherwise specified. 2.4.4 (add) The fixing method of the variable guide vanes and/or stator blades

shall be designed to positively prevent loosening in operation. E.g. Lock nuts to be fitted with split pins to prevent loosening.

2.4.11 (new) AIGVs shall only be supplied of a type where the identical design

has been demonstrated to operate in a validly similar duty, for a period of 3 years without any operational problems. In particular, no blade, linkage or bearing wear or failure has been observed due to high frequency or resonant vibration. The full operating range of the compressor performance map and all blade angles shall be available to be used by IOCL, unless agreed otherwise between Vendor and IOCL.

2.4.12 (new) Design of diaphragms in horizontally split casings shall be such that

they can be removed without disassembly of the rotating element. 2.5 Rotating Elements 2.5.3 Thrust Balancing 2.5.4.3 (mod) Unless otherwise stated, the pressure tapping shall be provided. 2.7 Bearings and Bearing Housings 2.7.2 Hydrodynamic Radial Bearings 2.7.2.2 (mod) Unless otherwise specified, Vendor shall offer his standard, well

proven materials and design for tilting pad bearings. 2.8 Shaft End Seals 2.8.2 (mod) The type of shaft end seal shall be as required by Chapter 1. 2.8.3 (mod) Unless otherwise specified, the requirements of this paragraph shall

apply. 2.10 Lubrication and Sealing 2.10.1 (add) Pressurised lube oil systems shall comply with Engineering .

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2.11 Nameplates and Rotation Arrows 2.11.2 (mod) Unless otherwise specified, the SI system of units shall be used. 3. ACCESSORIES 3.1 Drivers 3.1.1 (new) For compressors driven by electric motor or steam turbine, the

compressor Vendor shall have the overall responsibility for the entire unit, comprising compressor, driver, power transmission, controls, instrumentation and all associated auxiliary equipment. Unless otherwise specified, for compressors driven by gas turbines, the turbine Vendor shall have the overall responsibility.

3.1.2 (new) The Vendor having the overall responsibility, shall co-ordinate and

resolve any engineering or contractual problems for the complete unit.

3.1.3 (new) When compressor flushing is specified its effect on power

requirements shall be considered in sizing the driver. 3.1.4 (new) For air compressors, the effect of minimum design ambient

temperature on compressor power requirements shall be considered in sizing the driver.

3.4 Controls And Instrumentation 3.4.2 Control Systems 3.4.2.3 (mod) Where adjustable inlet guide vanes and/or adjustable stator vanes

are furnished then compliance with this paragraph is required. 3.5 Piping And Appurtenances 3.5.1 General 3.5.2 Process Piping (mod) Process piping shall be as per the requirements of the purchase

order. 4. INSPECTION, TESTING AND PREPARATION FOR SHIPMENT 4.3.1 Mechanical Running Test

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4.3.1.1.10 (mod) Vendor shall furnish all vibration equipment used for testing unless otherwise specified.

4.3.1.2 (mod) Procedures shall be submitted at the time specified in the purchase

order. 4.3.3 Optional Tests 4.3.3.1 Performance Test: 4.3.3.1.1 (add) Air shall not be used for closed loop testing. 4.3.3.1.3 (add) add "and is within ± 2% of the originally quoted speed". 4.3.3.1.7 (new) Performance test report shall be submitted in accordance with

ASME PTC 10 Section 6. Vendor shall provide a hand calculation for one of the test points to verify the computer generated results. The test report shall include a statement by the Vendor to the validity and acceptability of the test results.

4.3.3.1.8 (new) The penalty due for as tested power above zero percent shall be as

specified in ‘Loading and Penalty Criteria for Rotating Equipment.’ 5.1 General 5.1.1 (mod) Vendor data shall be submitted in accordance with the requirements

of the enquiry and purchase order.

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CHAPTER 3 INTEGRALLY GEARED COMPRESSORS

2 BASIC DESIGN 2.1.1 Performance 21.1.2 (new) Vendor to select an efficient compressor train to minimise a penalty

loading as specified in ‘Loading and Penalty Criteria for Rotating Equipment.’

2.7 Bearings 2.7.2 Hydrodynamic Radial Bearings 2.7.2.2 (add) IOCL’s requirements are as stated in Chapter 1 Para’s 2.7.2. and

2.7..3.5 2.11 Nameplates and Rotation Arrows 2.11.2 (mod) Unless otherwise specified, the SI system of units shall be used. 3.4 Controls and Instrumentation 3.4.2 Control Systems 3.4.2.1 (mod) Vendor shall propose an adjustable inlet geometry device to permit

efficient operation at all of the specified operating points. The associated positioner shall have a local manual override.

4 INSPECTION, TESTING, AND PREPARATION FOR SHIPMENT 4.3.1 Mechanical Running Test 4.3.1.3.7 (mod) Unless otherwise specified, Vendor shall provide all necessary

vibration monitoring equipment for shop testing. 4.3.3 Optional Tests 4.3.3.1.1 (add) The requirements of Chapter 1 Para 4.3.8 shall apply. 4.3.3.1.6 (new) The penalty due for as tested power above zero percent shall be as

specified in ‘Loading and Penalty Criteria for Rotating Equipment.’

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1.0 CHAPTER 4 EXPANDER-COMPRESSORS

3. ACCESSORIES 3.4.3 Over-speed Shutdown System 3.4.3.1.2 (mod) Unless otherwise specified, the 2 out of 3 voting over-speed

shutdown system shall be provided by the Vendor. 3.4.3.5 (mod) Unless otherwise specified, the Vendor shall provide the trip

mechanism. 4. INSPECTION AND TESTING 4.3.3 Mechanical Running Test 4.3.3.5 (add) The requirements of Chapter 1 shall apply. 4.3.5 Optional Tests 4.3.5.2 (mod) Unless otherwise specified, the gas leak test shall be performed

after the post test inspection. 4.3.5.3 (mod) Delete ‘’ as specified’’

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COLUMNS

COLUMNS

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CONTENTS

CLAUSE NO DESCRIPTION PAGE NO 1.0 SCOPE 4 2.0 REFERENCE CODES, STANDARDS,

SPECIFICATIONS & PUBLICATIONS 4

3.0 BASIS OF DESIGN 5 3.1 GENERAL REQUIREMENTS 5 3.2 DESIGN PRESSURE 5 3.3 DESIGN TEMPERATURE 6 3.4 CORROSION ALLOWANCE 6 3.5 DESIGN LOADS 7 3.6 MINIMUM THICKNESS 8 3.7 STRESS LIMITS AND CALCULATIONS 9 3.8 SHELL AND HEADS 9 3.9 NOZZLE CONNECTIONS & MANWAYS 10 3.10 BRANCH REINFORCEMENT 12 3.11 INTERNALS 12 3.12 SUPPORTS 13 3.13 BOLTS AND NUTS 13 3.14 GASKETS 14 4.0 MATERIAL SELECTION 14 4.1 GENERAL 15 5.0 FABRICATION 15 5.1 PLATE LAYOUT 15 5.2 FORMING 15 5.3 WELDING 16 5.4 POST WELD HEAT TREATMENT 16 5.5 ATTACHMENT 17 6.0 PRESSURE TEST 17 7.0 INSPECTION 18 8.0 PAINTING AND TRANSPORTATION 18

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1.0 SCOPE: 1.1 This standard specification covers the requirements for the design, fabrication,

inspection and testing of unfired pressure vessels for IOCL plants under the provisions of the ASME code section VIII, division 1 or division 2, plus the additional requirements of this specification.

1.2 These specification shall also include vessels falling within the scope of static & Mobile

pressure vessels (unfired) rules 1981. 1.3 Any vessels falling within the scope of the Indian Boiler Regulations shall comply with

the Indian Boiler Regulations over and above the applicable codes & standards. 2.0 REFERENCE CODES, STANDARDS, SPECIFICATIONS & PUBLICATIONS:

CODES, STANDARDS, SPECIFICATIONS AND PUBLICATIONS ASME Codes Sec II Part D Materials Sec VIII division 1 Boiler and Pressure vessel codes Sec VIII division 2 Boiler and Pressure vessel codes Sec IX Welding & Brazing qualification ASME Publications Pressure vessel Stresses in large horizontal pressure vessels and piping. Design and Piping analysis ASME Standards B16.5 Pipe flanges and flanged fittings B16.47 Large diameter steel flanges (NPS 26 through NPS 60) B16.20 Metallic Gaskets for pipe flanges. B31.3 Pressure Piping ASTM Standards A193/A193 M Alloy steel & stainless steel bolting materials for high temperature service A194/A194 M Carbon & alloy steel nuts for bolts for high pressure & Temperature service. A320/A320 M Alloy steel bolting materials for low-temperature service A453/A453M Specification for bolting materials for high temperature

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ANSI/AWS Specifications A5.1 Carbon steel arc welding electrodes A5.17 Carbon steel electrodes and fluxes for submerged arc welding A5.18 Carbon steel filler metals for gas shielded arc welding NACE Standards MR 0175 Material for use in H 2 S Containing Environments in Oil &

Gas Production MR 0103 – 2007 Material resistant to Sulfide Stress Cracking in Corrosive

Petroleum Refining Environment Welding Research Council (WRC) Bulletins 107 Local stresses in spherical and cylindrical shells due to External loadings. 297 Local stresses in cylindrical shells due to external loadings on nozzles-supplement to WRC bulleting no.107 INDIAN Standards IS 875 part 3(1987) Codes and practice for design loads other than earthquake IS 1893 (2002) Criteria for design of the earthquake resistant structure IBR 1950 Indian Boiler Regulations SMPV rules 1981 Static and Mobile Pressure vessels (unfired) rules 1981

3.0 BASIS OF DESIGN 3.1 General Requirements: 3.1.1 The design, materials, fabrication, inspection and testing of pressure vessels shall

comply with requirements of ASME section VIII division 1 or 2. 3.1.2 The design calculation shall be carried out on standard computer programme. Vendor

shall be prepared to justify the same to IOCL. The drawing shall be on AutoCAD platform.

3.1.3 Allowable stresses for materials shall be in accordance with ASME Section II, part D. 3.1.4 The vessel manufacturer shall determine the need for performing any special analyses

above the minimum calculations required by the ASME code. 3.2 Design Pressure: 3.2.1 Design Pressure shall be taken as specified in the data sheet. The internal static head

(up to normal liquid level) shall be added to the design pressure to determine the thickness of any specific part of the vessel.

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3.2.2 Operating pressure is defined as maximum operating pressure at top of vessel.

3.2.3 The vessel designer shall make allowances for pressure drop across internals and static head due to normal liquid level that must be added to the operating pressure to arrive at the design pressure for the lower sections of the vessel. (Basic information shall be provided by IOCL engineer.)

3.2.4 It is experienced that majority of pressure vessels in Refinery operate under positive pressure have to go for steam-out conditions during start-up and shutdown. Hence such vessels have to be checked for steam-out conditions or consider conditions of full vacuum unless otherwise mentioned elsewhere in the document or data sheet.

3.2.5 Steam-out conditions are to be 175º C@ 3.0 kg/cm² g and full vacuum 175º C @1.055 kg/cm²g unless otherwise specified in data sheet. However vessels operating under vacuum (or partial) shall be designed for differential external pressure of 1.055 kg/cm2.

3.2.6 Parts of Vessels subject to different internal pressure on both sides shall be designed to withstand the most severe combination of the pressures.

3.2.7 Maximum allowable working pressure (MAWP) is the maximum gauge pressure at the top of vessel, which shall be obtained from the calculation based on the thickness under corroded condition.

3.3 Design Temperature:

3.3.1 Design temperature shall be as specified in data sheet. Two kinds of design temperature, one for maximum design temperature (called as “Design temperature”) and the other for minimum design temperature (called as “Minimum design metal temperature= MDMT) are specified. Minimum Design metal Temperature (MDMT) shall be lower of minimum atmospheric temperature and lowest operating temperature.

3.3.2 When different temperatures are predicted for different zones of vessel, these

temperatures are indicated for respective zones of the vessel.

3.3.3 When vessels parts are in contact with two fluids having two different temperatures, then the vessel shall be designed for both higher and lower design temperatures.

3.4 Corrosion Allowance:

3.4.1 Corrosion allowance shall be included as follows:

3.4.2 On the inside of shells, heads, nozzles and covers add the full corrosion allowance.

3.4.3 On internal parts either welded to the inside of the vessel or non-removable add the full corrosion allowance to each face in contact with the vessel contents.

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3.4.4 On bolted removable parts add one half the corrosion allowances to each face in contact

with the vessel contents 3.4.5 For clad vessels no corrosion allowance shall be taken. 3.4.6 Non-mandatory Appendix E (E-6) of section VIII div1 shall also be followed.

3.4.7 Wherever strip or sleeve liners are used in clad designs, 1.5 mm corrosion allowance minimum shall be applied to the backing material below the liner.

3.4.8 However suitable/higher corrosion allowances shall be considered depending on

process considerations and only after agreement with Process licensor/IOCL PDEC department.

3.5 Design Loads:

3.5.1 Loading to be considered in designing a vessel shall be as per the ASME code Section VIII. However the following shall be mandatory for consideration for strength calculation, supports and anchor bolts for self supporting tall column and its anchorage block.

• Internal and/or external design pressure specified in data sheet. • Self weight of column inclusive of piping, platforms, ladders, manholes, nozzles,

trays, welded and removable attachments , insulation and operating liquids. Loading shall be as per UG-22 of ASME code sec VIII div.1 wherever applicable.

• Seismic forces and moments shall be computed in accordance with IS 1893(latest edition). Unless otherwise specified importance factor and damping coefficient shall be considered as 2 and 2% respectively.

• Basic wind pressure and wind velocity(for short duration) for the computation of forces/moments and dynamic analysis respectively shall be in accordance with IS 875 part -3.

• Loadings resulting in stresses due to mounting of reflux/reboiler etc.

3.5.1.1 Operating condition (column in corroded condition) The loading shall include those from:

(a) Internal & external design pressure (b) Weight of vessels and contents at operating condition (including static

head of liquids) (c) Weight of insulation and fire proofing (d) Weight of piping, platform and other attachments. (e) Weight of combined equipment. (f) Reactions from piping systems. (g) Cyclic or dynamic reactions from combined equipment (h) Wind or seismic load (Not to consider simultaneously refer IS875 part 5)

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3.5.1.2 Erection Load (column in un-corroded condition)

The loading shall include those from: (a) Weight of vessels and contents at erection. (b) Weight of piping, platforms and other attachments if any. (c) Weight of combined equipment. (d) Wind or seismic load, which ever is greater.

3.5.1.3 Testing Load (in the installed position and corroded condition) The loading shall include those from:

(a) Test pressure (b) Weight of vessels and contents at testing condition (including static head of

liquids) (c) Weight of insulation and fireproofing. (d) Weight of piping, platform and other attachment. (e) Weight of combined equipment. (f) 1/3rd of design wind load.

3.5.2 Wind load shall be determined in accordance with IS 875-1987 part 3.Consider wind

velocity defined as per metrological survey data available in IS875. 3.5.3 Vortex shedding analysis shall be carried out for tall vessels were height to diameter

exceeds 12.0. If vortex shedding analysis results indicate that unacceptable levels of vibrations can occur, then helical strakes, dynamic vibration absorbers or other means shall be adopted provided prior approval from owner is obtained.

3.5.3 Seismic load shall be determined in accordance with IS 1893-2002. Seismic zone shall

depend from place to place and shall be defined as per metrological survey data available in IS1893

3.5.4 Seismic loads are not to be considered coincident with wind loads. 3.5.5 Vessels and their supports shall be capable of supporting the vessel filled with water in

the erected position. The corroded (i.e., nominal thickness minus the corrosion allowance) vessel shall be adequate for hydro testing in the erected position.

3.5.6 The maximum deflection of trayed columns, other than under earthquake loading shall

be no greater than the vessel height/200(h/200), with a maximum deflection of one foot(300 mm)

3.6 Minimum Thickness: 3.6.1 Vessel pressure components and supports shall have minimum thicknesses after

forming and not less than the requirements of the code and this standard.

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3.6.2 However the minimum nominal thickness before forming of carbon and alloy steel

vessels, shells, heads and support skits shall not be less than the larger of the following:

(a) Inside diameter in mm + 2540 + C.A. (mm) 1000 (b) 4.5 mm + C.A. (c) 10 mm + clad thickness for clad vessels

3.6.3 Nozzle necks shall not be less than as per ASME VIII div 1.UG-45.

3.6.4 Minimum thickness of vessel skirt shall be 6 mm.

3.7 Stress Limits and Calculations:

3.7.1 Vessels shell and attachments, vessel supports and internals shall be designed to code allowable stresses.

3.7.2 The allowable stress values shall be taken for each selected material with respect to

temperature from the values given in ASME sec II part D or relevant ASTM standards.

3.7.3 Internal removable parts like pipes, flanges may be designed to code or ASME B31.3 allowable stresses.

3.7.4 Total tensile stress under hydro test conditions shall not exceed 90% of yield stress. 3.7.5 Stress in vessels due to saddle supports shall be checked in accordance with British

Standard PD5500 appendix G. Allowable stresses shall be code allowable stress multiplied by the factors defined in PD 5500.

3.7.6 Stress due to external load on nozzles or brackets shall be evaluated using welding

research council bulletins 107 & 297 or L.P.Zick’s method (ASME publications: Pressure Vessels & Piping: Design & Analysis vol II 1972)

3.7.7 Nozzle falling outside the applicable range of WRC bulletins 107 & 297 shall be

evaluated using Finite element analysis. 3.8 Shells and Heads: 3.8.1 The shape of the formed head shall be specified on the data sheet. 2:1(ratio of major

axis to minor axis) ellipsoidal or hemispherical head are used, in general. 3.8.2 The nominal thickness of 2:1 ellipsoidal or dished head shall be selected such that

minimum thickness after forming shall not be less than the minimum required thickness

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of head. Also the nominal thickness shall not be less than the minimum required thickness of connecting cylindrical shell.

3.8.3 When a dished end is made of more than two plates, it must have a crown plate.

Whenever a nozzle or a manhole is positioned at the centre of the dished end the crown plate should be larger than the nozzle/manhole-reinforcing pad

3.8.4 Girth Flange Design in shell will be for through-bolting. Flanges for girth joints shall

conform the following:

(a) Flanges shall be as per ASME B16.5, ASME B16.47 series B, or designed per ASME code, section VIII div 1 with allowable stresses determined as per code.

(b) Welding neck flanges shall be used where the pressure-temperature design conditions require an ASME class 300 or greater flange.

(c) Slip-on flanges shall not be used if the following conditions are exceeded: • Pressure/temp design conditions require an ASME class 300 or greater

flange • Design temperature exceeds 750º F(400º C) • Specified corrosion allowance for the vessel is greater than 3 mm. • The vessel is in hydrogen service.

(d) Girth flange larger than NB 24 inch that are not in accordance with ASME B

16.47 Series B, shall be designed to meet the flange rigidity recommendations as per ASME code Sec VIII Div 1, Appendix S, Para S-2.

3.8.5 Stiffening rings shall be installed on the exterior surface of the vessel. 3.9 Nozzle Connections and Manways:

3.9.1 All vessels connections shall be flanged unless butt-welded connections are indicated on the data sheets. Minimum nominal size of flange shall be 40 mm NB.

3.9.2 Threaded or socket weld connections are not permitted. 3.9.3 Flanges for nozzles and manways, including blind flanges up to 600 mm nominal size

shall have ratings and dimensions in accordance with ASME B 16.5. 3.9.4 Flanges over 600mm nominal size and connected to piping shall be in accordance with

ANSI B 16.47 series B and checked for suitability for design conditions plus any piping loads.

3.9.5 Non-standard flanges should not be used. However, if it is necessary, same shall be

designed to code rules.

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3.9.6 Gasket factors shall be taken from codes only. 3.9.7 Weld neck flanges shall have the same bore as the nozzle neck. 3.9.8 Slip-on flanges shall not be used. 3.9.9 Man way shall have a minimum clear inside diameter of 20-inch nominal diameter.

Manway cover shall be hinged or provided with handling davits (over 20kg). 3.9.10 Manholes shall be provided for all pressure vessels over 900 mm dia. smaller vessels

shall have hand holes or flanged heads or both, as specified. 3.9.11 Nozzles and man ways necks shall finish flush with the internal contour of the vessel.

The inside edge shall be radiused to 6 mm minimum. 3.9.12 Gasket seating surface finish shall be in accordance with Annexure E unless otherwise

specified. 3.9.13 Unless otherwise specified, all instrument connections except thermo wells shall be a

minimum of 2” NB (50 mm) flanged and thermo wells shall be 1 21 inch NB (40 mm)

flanged. Nozzles of 2 inch shall be braced. 3.9.14 Nozzles in portions of vessels with gunite/internal lining shall have internal projections

such that the nozzle end is flush with the lining. 3.9.15 The nozzle neck thickness shall be selected in accordance with standard. The pipe

material for nozzle neck shall be seamless, unless otherwise specified. 3.9.16 A vent of 6 inch min. diameter to facilitate ventilation during vessel entry must be

provided at or near top of the vessels with manholes. Alternately there shall be a flanged nozzle at top whose piping can be removed.

3.9.17 Nozzle outstands shall keep flange bolting or butt-weld clear of the vessel wall,

insulation, platforms or other obstructions. 3.9.18 Nozzle and man ways shall not be located in tray down comers. 3.9.19 Flanges shall not be located inside of vessel support skirts or other confined

areas. 3.9.20 Skirt manholes shall be provided with light weight manhole covers. 3.9.21 Separate nozzle shall be provided for wash water facility for structured packing if

required.

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3.10 Branch Reinforcement: 3.10.1 Reinforcement pads shall be made from the same material as the shell and shall be

within code limits and shall be preferably of the same thickness as the shell. 3.10.2 Except as indicated below all branch connections shall have a 2 times diameter-

reinforcing pads that provides 100% replacement of all material removed (i.e. corroded nozzle bore x new shell thickness excluding all cladding thickness.

(1) Small bore connections for which code requires no added reinforcement. (2) Heavily loaded nozzles requiring special consideration.

3.10.3 Nozzle reinforcement and other external pads shall be provided with a vent hole

threaded 6 mm. After pressure testing of pad, holes shall be plugged. 3.10.4 Integral reinforcement employing butt welds (like weldolets, sockolets etc) that can be

examined by radiography (per ASME VIII div.1 Fig UW-16.1 sketch f) shall be used if any of the following apply:

(1) Wall thickness of shell or head exceeds 50 mm (2) Size 1-1/2 inch & below. (3) Material of construction is NACE/HIC (4) Vessel is in cyclic thermal shock service.

3.11 Internals:

3.11.1 Unless otherwise specified, removable internal parts shall be designed in units as large as can be put in and out from the vessel through the nearest upper manhole. Demister pads may be, however, put in and out through the nearest lower manhole or opening.

3.11.2 Trays, distributors, baffles and support beams shall be so designed not to restrict

deformation of the shell due to operating pressure and thermal expansion.

3.11.3 Demisters pads shall be properly fastened to the support ring by bolting or clamping. 3.11.4 Internal bolts subject to vibration, load, and impact load shall be protected against

loosening. Double nuts, Washers, Tack welding, shall be used. 3.11.5 All removable internals shall be checked to ensure their insertability and removability

through the manhole. 3.11.6 For Design and construction requirements for trays please refer Annex 1 (RHQ -EC-ML-

SP-0005)

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3.12 Supports: 3.12.1 Skirt shall be so designed (exclusive of allowance for corrosion) to withstand the most

severe combination of live and dead loads anticipated during the normal life of the vessel/column.

3.12.2 The joint of the skirts to head/shell shall be designed and welded so as to prevent

excessive stress concentration. Both ends to be continuously welded to the head/ shell and the base ring respectively.

3.12.3 Skirt shall be provided with vents and access holes as indicated in drawing. Opening in

supports skirts shall be reinforced. 3.12.4 Saddles, lugs or legs for pressure vessel shall be as per the table attached. 3.12.5 Vertical vessel subject to vibration for example reciprocating compressor suction drums

(that are not machine mounted), shall be skirts supported on a solid or continuous concrete base.

3.12.6 A single skirt access man way of 20-inch (500 mm) diameter shall be provided for

access for inspection purpose. 3.12.7 Fire proofing of skirt shall be provided as per datasheet (at site).The same shall be in the

scope of IOCL. However required lugs/cleats to be provided by vendor. 3.12.8 Vessel to be analyzed for buckling, bending. Analysis may be performed in accordance

with WRC bulletin 107 and 297 as applicable. 3.12.9 The top section of the skirt shall be fabricated from the same material as the shell to

which it is attached for maximum distance of ‘L’ as follows: ( )t.R5L ×= Or 1000 mm, whichever is greater.

Where, R = inside radius of skirt in mm t = skirt plate thickness at top in mm.

3.12.10 Skirt opening for piping shall have ½ inch maximum clearance between the pipe OD

including insulation and the skirt when inside of the skirt is not to be fire-proofed. 3.13 Bolts & Nuts: 3.13.1 Unless otherwise specified, all bolting threads to be used for pressure vessel shall be

ISO metric system.

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3.13.2 Girth flange bolting shall be of stud bolt type, threaded full length, and at least M16 for flange of 600 mm and smaller inside diameter and at least M20 for over 600 mm inside diameter flange.

3.13.3 Gasket contact surface of girth flange shall have a finish equivalent to Ra (roughness

average) the following in μm.

(1) For asbestos sheet gasket: Ra 3.2 ( 125 μ inch) (2) For spiral wound gasket: from Ra 1.6 to Ra 3.2 (63- 125 μ inch) (3) For metal jacket, solid metal gasket: Ra 1.6(63 μ inch) and finer.

3.14 Gaskets 3.14.1 Gaskets for use with raised face flanges shall be spiral wound as per ASME B16.20

with non-asbestos filler material. Gaskets shall have an outer retainer ring. The outer ring may be carbon steel, protected against corrosion.

3.14.2 Asbestos in any form shall NOT be used. 4.0 Material Selection: 4.1 General: 4.1.1 All materials to be used shall be new and shall meet the requirements of the code and

the applicable fabrication standard. Material shall be as stated on the datasheet. 4.1.2 Carbon-0.5Mo material shall not be used. 4.1.3 Materials shall be selected from those listed in ASTM/ASME standards considering the

fluid characteristics, design condition and applicable codes and standards. However, considering the availability in the market, equivalent material may be selected with approval of purchaser.

4.1.4 Unless otherwise specified girth flanges and flat covers shall be forged steel. 4.1.5 Carbon, Carbon Manganese and Low Alloy Steels Carbon and Carbon-Manganese steels that are to be welded shall comply with the

following requirements: • Carbon content shall not exceed 0.23%, except for forgings

which shall be limited to 0.25% maximum. • Carbon equivalent (CE) shall not exceed 0.45 where CE=%C + %Mn + (%Cr + %Mo + %V) + (%Cu + % Ni) 6 5 15

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• Where a full analysis is not available, carbon equivalent shall

not exceed 0.42 where CE = %C + %Mn/6

The following limitations shall apply to low alloy (Cr-Mo) steels:

C = 0.20% max (forgings only, up to 2% Cr) C = 0.17% max (all other forms, up to 2% Cr) C = 0.15% max (all forms, over 2% Cr)

Carbon and C-Mn steels shall be supplied in the as rolled, normalized, normalized and tempered or, when specifically approved, quenched and tempered conditions.

5.0 Fabrication: 5.1 Plate Layout 5.1.1 Plate layout shall be arranged so that circumferential seams are clear of Internals, tray

support, stiffening rings, insulation rings, saddles and Skirts Longitudinal seam shall not be covered by down comer bars, Baffles of other longitudinal attachment. (A plate layout drawing is required)

5.1.2 Visual Inspection Visual inspection of seams inside and outside must be possible with

the vessel complete including internals. All main seams shall miss nozzles, manholes and reinforcing pads.

5.1.3 Nozzles, Man ways and Their Reinforcement Nozzles, man ways and their

reinforcement shall be attached to the vessel with full penetration welds and the nozzles set through the vessel wall.

5.1.4 Knuckle Radii of Heads or Cones, Nozzles and their reinforcement shall not encroach

over the knuckle radii of heads or cones, except as agreed in writing by IOCL for any specific case

5.2 Forming 5.2.1 Selection of hot or cold forming of materials may be done by the fabricator. But heat

treatment after forming shall conform to the requirement of materials specification. 5.2.2 Heads shall be preferably of one-piece construction. For heads which are not one-piece

construction, all head welds shall be subject to 100% Radiography.

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5.2.3 Weld separation for attachments like man way, nozzle Reinforcement pad shall not be located within 50 mm or twice the shell thickness which ever is greater.

5.2.4 Weld separation main longitudinal seams shall be offset at least five times plate

thickness or 150 mm which ever is greater. 5.3 Welding: 5.3.1 Welding procedure and welders shall be qualified in accordance with the specified code

or standard. 5.3.2 Welding electrodes shall be in accordance with ASME section II part C. However

welding processes, materials, and procedures shall comply with the requirements of API RP 582 and this specification. Welding electrodes and wires shall have chemical composition and mechanical properties equal to or of higher grade than the base material.

5.3.3 Preheating shall be carried out for carbon and low alloy steel welding where required.

Preheating temperature shall be kept uniform from the start to the end of welding. 5.3.4 Weld attachment of internals to austenitic weld overlay, when approved by the owner’s

engineer, shall be made after heat treatment. 5.4 Post weld heat treatment 5.4.1 Unless otherwise stated, post weld heat treatment shall be carried out in accordance

with the applicable codes or standards. 5.4.2 No welding shall be performed on vessels after the final post weld heat treatment. 5.4.3 When post weld heat treatment is required, the entire vessel shall preferably be heat

treated as a single piece in an enclosed furnace. 5.4.4 Vessels, which are too large to be post, weld heat treated as a single piece in an

enclosed furnace, may be, subject to post weld heat treatment in sections. 5.4.5 The local PWHT arrangement (including the provision of adequate insulation) shall

ensure that the temperature gradient (from the section at PWHT temperature to the section at ambient temperature) shall be low enough to avoid the development of harmful residual stresses. (As a general rule the insulated section shall extend a

minimum distance of 2.5 R t from the edge of the heated band, where R is the radius of the vessel and t the vessel thickness).

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5.4.6 Thermocouples shall be located on the inside and outside of the vessel surface to ensure that all portions of the vessel are properly and uniformly heat treated, without the effect of detrimental thermal gradients.

5.4.7 Reading shall be taken with a calibrated hardness tester. 5.5 Attachments: 5.5.1 Cleats for insulation or platforms/structural shall be designed and provided as per

prevailing practices. 5.5.2 The location of cleats shall be such that platforms can be provided to approach all the

column nozzles/manholes. 5.5.3 Insulation support ring shall not retain rain water. 6.0 Pressure Test: 6.1 Hydrostatic test method shall be used for pressure testing. Pneumatic testing may

be used only when hydrostatic testing is not feasible and owner & fabricator agree. For pneumatic tests all necessary safety precautions shall be taken.

6.2 All vessels shall be hydrostatically tested in accordance with code minimum

requirement. The test pressure shall be determined and shall not be less than the as specified in UG 99(b), ASME sec VIII div 1.

6.3 Vertical vessels tested horizontally shall be supported on properly designed saddles on

a suitable firm foundation, which is adequate for the test load. Additional hydrostatic pressure due to vertical height of the column shall be taken into consideration i.e.

6.4 Hydro test temperature shall be at least 15 0C above the minimum design metal

temperature. 6.5 The test pressure shall be held for at least one hour. 6.6 When carbon and low alloy steel material are exposed to test water, chloride content

shall be less then 100 ppm. 6.7 When austenitic stainless steel (SS 300 series) material is exposed to test water,

chloride content shall be less then 30 ppm. 6.8 All reinforcement pads and loose liners shall be tested with air at 1.0 bar after PWHT but

before hydro test of the vessel.

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6.9 No preliminary hydro test, regardless of pressure, shall be made on any vessel prior to any required post weld heat treating operation.

6.10 Vessel with linings (except cladding or weld overlay) shall be tested prior to installation

of such lining. 7.0 INSPECTION 7.1 All Examinations

All examinations shall be made by the Vendor as required by the order, Vendor's practices for quality control, IOCL and project specifications. For all vessels the Vendor shall produce a Quality Plan covering Design, manufacture, examination and testing.

7.2 High Surface Loading Regions of high surface loading such as lifting lugs shall be examined by Ultrasonic after welding to check for lamellar tearing and weld defects. 7.3 Tolerances Tolerances shall be to as per Annexure and the applicable Code. 8.0 PAINTING AND TRANSPORTATION 8.1 Painting

Surface preparation, priming and coating shall be carried out. The surface preparation shall be to SA 21/2 and two coats of Zinc chromate primer shall be provided. Vessel under hot insulation shall be provided with 2 coats of heat resistant aluminum paint.

8.2 Rust Prevention

All unpainted machined metal surfaces, both external and internal shall be coated with a rust preventative which will maintain a protective coating for a minimum of Twenty-four (24) months so long as the coating is not burned, dissolved or mechanically rubbed off. For surfaces, which are external, the rust preventative should be a heavy application of grease or liquid film, which dries, to a tough coating. For machined surfaces, which are internal of an assembled unit, the rust Preventative should be of a type, which does not require removal before operation of the equipment.

8.3 Protection for Transport

Flanged openings shall be protected with bolted-on wooden outdoor plywood (min.12mm thickness) or metal covers, using at least three bolts. Wiring-on covers is not acceptable. A mastic sealer shall be used between the flanges and the cover. After

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openings have been covered, the joint shall be wrapped with waterproof adhesive tape. For ocean shipment flanged openings shall be covered with securely taped heavy Plastic sheet. All butt weld connections shall be sealed with heavy plastic sheet taped to the nozzle. All vessels shall be suitably protected against salt water for ocean transport. Stainless Steel vessels shall not be carried as deck cargo. All loose items shall be suitably packaged and marked with identification. All vessel appurtenances susceptible to damage shall be suitably protected.

8.4 Shipping Saddles

Attachments and tackle for securing vessel to transport shall be suitable to prevent any horizontal and rotational movement of the vessel. Shipping saddles shall be located approximately symmetrical each side of the vessel’s centre of Gravity. Shipping saddles and vessel shall be designed for the following forces acting simultaneously during transit, as a minimum:

Longitudinal 0.6g Transverse 0.7g Vertical upward 0.2g Vertical downward 1.5g

Shipping saddles strength shall be suitable for being supported at each end of the saddle on 1 – square meter supports during shipment and storing for up to 6 months, without causing deflection of the saddle base and locally stressing the vessel above the design limits. The shipping base shall be suitable for securing to the transporter by clamping or bolting.

Sizes of shipping saddles are dependent on method of transportation and method of lifting on to transport vehicle. Dimensions shall be agreed during design

Engineering Typical lengths of saddle base supports are: 4.9 m long for 3.0 m width bogie 5.5 m long for 3.65 m width bogie 6.3 m long for 4.8 m width bogie 7.8 m long for 6.2 m width bogie

Saddle height to be a minimum to reduce overturning forces, but sufficient for vessel attachments projecting downwards to clear surfaces on which it is to be placed. Vessel is to be attached securely to the shipping saddles. Shear stops are to be fitted to prevent rotation about the shipping saddle during lifting and unloading.

8.5 Warning Markings

The Vessel item number, its purchase order number and suitable warnings about Lifting limitations shall be clearly marked on the Vessel.

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Vessels which have been stress relieved shall have warnings printed on the outside of shell in letters at least 100mm high saying:

HEAT TREATED VESSEL

NO WELDING PERMITTED

Similar precautions shall be taken for vessels with an applied lining e.g. lead rubber, glass, epoxy etc.

Vertical vessels shall have "0 DEGREES" clearly marked by a vertical yellow line 50mm minimum wide. "Plant north" shall also be indicated in a similar way.

8.6 For anchor bolt and template design refer Annex. 2 RHQ-EC-ML-SP-0020

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FOR BURNERS

BURNERS

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CONTENTS

CLAUSE NO DESCRIPTION PAGE NO 1.0 SCOPE 4 2.0 BIDDER’S QUALIFICATIONS AND

REQUIREMENTS 4

3.0 APPLICABLE CODES 5 4.0 DESIGN CRITERIA 5 5.0 TEST AND INSPECTION 9 6.0 DRAWINGS AND DATA SUBMISSION 9 7.0 MANUALS 11 8.0 GAURANTEE 11 9.0 SPARES 12 10.0 PAINTING 12 11.0 PACKAGING AND SHIPPING 13 12.0 REJECTION 13

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FOR BURNERS

1.0 SCOPE 1.1 This specification covers the requirements of up-fired burners, which are to be

installed in the radiant sections of process heaters. 1.2 A `burner’ in this specification is defined as the complete device for mixing the

combustion air and fuel and for stabilizing the flame. It includes gas distributor pipes, fuel oil gun, gas nozzles, air register, air directors, air control linkages, refractory lining including refractory burner block sections in the furnace floor, ignitor, pilot and where specified flame failure equipment. It also includes the means of mounting the burner to the furnace and such sections of the windbox, which are required to guide and distribute the combustion air correctly to the burner.

1.3 This specification does not cover burner instrumentation or burner piping other than

flexible hoses. Instrumentation and piping will be separately specified by IOCL, if required.

1.4 Burner designs offered shall be commercially proven in comparable services taking

into account fuel fired, orientation and heat release. 1.5 Unless otherwise specified, burner shall meet all the requirements of ISO 13705 / API

RP 535. 2.0 BIDDER’S QUALIFICATION AND EXPERIENCE 2.1 Qualifications 2.1.1 Bidders shall be a reputed and regular vendor for design, engineering and supply of

offered model burners for similar fuel with respect to viscosity, metal content, ash content, and emission of NOx, etc. and currently continuing the same.

2.1.2 Documented Quality Assurance System 2.2 Experience 2.2.1 Bidder should have supplied the offered model designed for similar fuel to at least 2

users in last 5 years and in successful operation for at least 2 years. In case the burner model is an outcome of recent development, the burner should have been tested and approved by an independent third party.

2.2.2 Reference list for the offered model burner including type, heat liberation capacity, fuel characteristics (viscosity/ash content/metal content/ NOx), clients/plant name and year of supply & operation shall be submitted.

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3.0 APPLICABLE CODES 3.1 The burners shall be designed, constructed, inspected and tested in accordance with

this specification and the requirements of the following codes and standards.

ASTM and IS - For Material designation ASME B1.20.1 - Pipe Threads General Purpose ASME Sec. IX - Welding ANSI B 16.5 - Flanges API RP 531 M - Measurement of Noise from Fired Process Heaters API RP 535 - Burners for Fired Heaters in general refinery services API 560 - Fired Heaters for General Refinery Services. ISO 13705 - Petroleum & Natural Gas Industries – Fired Heaters for

General Refinery Services. 3.2 The above referred codes and standards shall be in their latest editions. 4.0 DESIGN CRITERIA 4.1 General 4.1.1 Burners shall be designed for the design heat liberation for the fuels, excess air and

allowable pressure drop/draft specified in the burner data sheet. 4.1.2 Burner shall be suitable for outdoor operation in a refinery, petrochemical or fertilizer

complex environment under the specified ambient conditions.

4.1.3 Burner Design to take care of following:

a. No flame impingement of Tubes at Maximum Heat Release b. Flame shall have uniform pattern1 c. No coke formation at burner throat d. No fuel dripping due to improper atomization

4.2 Process Requirements

For process requirements refer “Process data sheets for Burners”. 4.3 Mechanical Requirements 4.3.1 Burner design shall take into account the burner spacing and clearances from furnace

tubes and refractory walls needed to prevent flame impingement on tubes walls and adjacent burners.

4.3.2 In a multiple burner system, burners shall be so designed that their performance does

not get affected due to the operation of the adjacent burner.

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4.3.3 The burners shall be so designed that the oil gun(s) and the gas nozzle(s)/pipe(s) can

be readily removed for cleaning without dismantling other parts of the burner as defined. Oil guns shall be removable by plant operators while the other adjoining burners are in operation.

4.3.4 A minimum tip drilling (excluding ignition ports) shall be 2.38mm. 4.3.5 Where firing on combination fuels is specified, the burner shall be capable of firing on

one fuel with the oil gun or gas nozzles removed. 4.3.6 When preheated combustion air is specified and its pressure is such as to cause

hazard to personnel when oil or gas gun(s) are removed, special arrangement must be provided to prevent its escape.

4.3.7 When any liquid fuels above 25o API are specified to be burnt, an interlocking

mechanism must be provided to ensure :-

a) That the gun cannot be withdrawn until the liquid fuel supply has been cut off, purge steam applied and then cut off.

b) That the fuel and steam cannot be turned on with the gun withdrawn. This interlock mechanism must be of such design and materials that the interlock cannot be overridden.

b) That the liquid fuel cannot be turned on before atomising steam and atomising

steam cannot be turned off before liquid fuel. 4.3.8 For oil fired burners, burner windbox shall be designed to permit drainage of any oil

accumulation. 4.3.9 The burner shall be provided with a fixed, self inspiriting continuous burning gas pilot

operating on the specified gas supply at the fuel gas pressure specified in the process data sheet.

4.3.10 Each pilot burner shall have its own lighting port independent of any viewing ports.

The lighting ports shall be freely accessible and suitable for portable electric igniters. 4.3.11 The Pilot burner shall remain stable over the full firing range of the main burner. It shall

also remain stable upon loss of main burner fuel, minimum draft, all combustion air rates and for all operating conditions.

4.3.12 Burner block installation shall be designed to expand and contract as a unit,

independent of heater refractory.

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4.3.13 A damper shall be fitted to the burner housing at the air entrance. The damper should be provided with a scale, enabling the air supply to be throttled during startup or shut down. The damper shall be lockable at all positions from open to close.

4.4 Materials 4.4.1 Burner components located in combustion zone (except consumable items) shall be

capable of at least 25000 hours of continuous operation with specified fuels and at the design conditions, without significant deterioration. For all other components design life shall be 1,00,000 hours.

4.4.2 Following materials shall be used for various critical components of the burners. Component Material Fuel gas manifold Type 316L metallurgy with a min. thickness of 2.76mm Fuel gas risers Type 316L metallurgy with a min. thickness of 2.76mm Fuel gas tip and stabilizer cone 25Cr-20Ni (ASTM A 297 Gr. HK) Oil gun tip 400 series stainless steel Atomiser and orifice spud 300 series stainless steel Flame retention head 25Cr-20Ni 4.4.3 Where fuel oil has erosive, properties oil tips shall be hardened to Rockwell C46 upto

0.08” depth.

4.4.4 Due to the possibility of failure in the event of fire, the use of brittle materials e.g. cast iron, SG iron, malleable iron and low melting point materials e.g. copper, aluminum and their alloys, plastics etc are not acceptable for any burner pressure parts and associated supports, bolts, nuts, springs etc.

4.4.5 Burner blocks (tiles) shall have a minimum of 90% alumina content and 30000F

services(continuous use) temperature. Burner blocks based on silica and/or calcium cement bonders shall be pre dried up to 5000F(2600C). chemically bonded tiles do not required drying.

4.4.6 Burner blocks shall be furnished with a tile alignment device to insure proper tile

installation. For horizontal firing, burner block shall be furnished as an integral tile assembly (define as burner tile pieces mounted on the burner casing and not on the heater wall). Vendor shall provide procedures and tolerances for burner and burner block installation.

4.4.7 Tips should be designed and adequately protected to prevent coking, at any operating

condition. Tips should be able to withstand normal furnace operating conditions while not in operation.

4.4.8 Materials not specified by IOCL shall be of manufacturer’s selection, suitable for the

design temperature and operating conditions.

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4.5 Connections 4.5.1 Where required for burner adjustment, the liquid fuel and atomising steam

connections shall be of flexible metallic construction. 4.5.2 Each burner shall be supplied with a pressure tap (NPT ½” NB coupling with stainless

steel extension and plug) located in the plenum chamber down stream of the burner damper.

4.5.3 A minimum of one 1” NB snuffing steam connection shall be provided for each burner

plenum chamber with flanged connection. 4.5.4 For multiple gas tip burner, the gas manifold shall be in burner supplier’s scope. Fuel

gas supply to the main burner will be provided by the purchaser at a single point. Burner supplier has to provide a flanged connection of suitable rating, good for mechanical design conditions as specified in the burner data sheet.

4.5.5 Provide firm seal, pivoting slide plate type sighting and lighting ports (pyrex glass

sighting and capped lighting ports for forced draft burners ) on each burner. Providea minimum of one sighting and one lighting port for the pilot. Provide one sightingport for the main gas tip for fuel gas only burners. Provide two sighting ports for the oil tip for fuel oil/combination burners.

4.6 Ignition System 4.6.1 Each set of burners as specified in the burner data sheet shall be provided with

burner ignition system comprising of minimum 2 numbers (or as specified in scope sheet) permanently installed ignition transformer and push button suitable for 230V+/-6%, 50 Hz (+/-3%). AC supply unless otherwise mentioned and area classification as specified in the data sheet along with specified length of HT cable and ignitor. Each ignitor shall be suitable to light up multiple burners. Main supply on-off lamp along with an isolation switch shall be provided on the ignition transformer housing.Transformer housing shall be suitable to EEXd IIB/C T5. Lighting port of the burner shall have provision for fixing the ignitor temporarily during light up. A mounting bracket along with a protector for the ignitor tip shall be provided for idle condition Igniter.

4.6.2 Ignitors shall be a capacitive discharge type and fixed in appropriate flameproof

enclosure suitable to EEXd IIC T5. Ignitor rod should not be permanently fixed inside the heater. Incase of multiple burners, change over switch to different ignitor rods from main two ignitor supply unit to be designed. Ignitor assembly to be permanently fixed near the heater.

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4.7 Noise and Thermal Insulation 4.7.1 It is desired that burner will not produce noise causing hearing impairment, speech

interference or a public nuisance. Furnace noise at any location 1.0M from the furnace with all burners firing at design heat release rate shall not exceed 85 dBA.

4.7.2 Materials for thermal and acoustic insulation shall be approved by IOCL. When block

insulation, fibre glass or mineral wool is used as internal lining for burner plenum or wind box it shall be suitably anchored by studs and have exposed face protected from shredding by expanded metal sheets, so that no insulation material can get airborne in the combustion air flow. Insulation should be protected from damage due to any spillage of oil.

4.8 Burner Operation 4.8.1 All burner components required for operation such as connections, sight and lighting

ports and operating handles should be suitably arranged and oriented for easy operation by plant operators.

4.8.2 On burners that are to be fitted to an upshot fired heater, the burner controls, valves,

interlocking devices, oil guns and other items which have to be manually operated from grade shall be so arranged that they are not more than 2340 mm from grade and bottom of wind box or register of the burner is not nearer to grade than 2460 mm.

5.0 TEST AND INSPECTION

Refer to Test and Inspection Plan, defining the minimum requirements to be adhered to by the vendor.

5.1 Performance Testing 5.1.1 Burner vendor shall provide the proven performance record of similar model with

specified heat release. 6.0 DRAWINGS AND DATA SUBMISSION 6.1 INFORMATION REQUIRED WITH OFFER 6.1.1 The following drawings and data shall be provided by the burner vendor when

responding to purchase enquiry. 6.1.2 Drawings a. Dimensional general arrangements of the burner and showing the air register, guard,

air swirlers (if any) with position of gas nozzles, oil gun(s), pilot gas nozzle, burner block, viewing and ignition ports, integral piping, valves, interlocks, etc. and space required for extracting the liquid fuel gun and gas guns.

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b. Ignition equipment and transformer details alongwith their mounting details. 6.1.3 Data

a. Filled up burner data sheet furnishing all data as required. b. Data Sheet for Pilot burner c. Data Sheet for Ignitor d. Material of Construction of all components of the burner as defined in para1.2.

Operating Temperature of components to be specified. e. Capacity curve of the burner showing heat liberation versus fuel oil, and

atomising steam or fuel gas Pressure. f. Guaranteed design parameters. g. Oil filtration requirements (mesh size), steam filtration requirements (mesh

size),Fuel gas and pilot gas filtration requirements (mesh size) h. An estimation of CO, Nox, Sox and Hydrocarbon particulates in products of

combustion for the specified range of fuels. i. Weight of the burner assembly. j. Burner block specification & data sheet. k. Over all dimensions of flame for all fuels being fired both singly and in

combination. 6.2 DOCUMENTS REQUIRED AFTER PLACEMENT OF ORDER

The vendor shall follow the instructions mentioned in the “Documents Requirements Form”, part of the Requisition and extended by the following requirements: Each general arrangement drawing shall bear as a minimum the following information:

• Complete Bill of Material with item numbers, description, material designation,reference drawing number etc.

• Burner Data Sheet • Heat release max., normal, min. • All process parameters • Dimensional sectional drawings of the gas nozzles, oil guns, pilot gas burner and the

interlock showing sequencing required. • Dimensional drawing burner block in relationship to heater refractory lining showing

recommended expansion joining, where necessary • Ignition equipment and transformer details along with their mounting details. • Gas tip drillings, including orientation • Painting requirements • Windbox insulation and fixing method • Fabrication tolerances • Burner tile material designation and pre-firing requirements

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• Number of burners • Purchase order number • Noise level • Weight of tile and burner housing • NOx level • Mounting detail • Gas gun (tips) easy removal and free space required for removal • Fuel gas flanges size and location • Flame holder material • Damper handle location and handle extension (outside insulation) to be sized to

prevent interference/obstruction • Location of ignition port and sight port • Capacity curves for heat release versus fuel gas / fuel oil pressure of pilot burner

under all operating conditions. • Register draft loss curve showing combustion air pressure drop (both for hot air cold

air) versus heat liberation for fuel oil / fuel gas firing.. • Heat release curves / table for combination firing (Dual firing) with minimum oil

requirement. Note :

1. The vendor shall mark revision on documents properly by “clouds” and revision number.

2. Each burner type shall have a separate general arrangement drawing 3. Vendor shall indicate to which pre-assembled extent the burner will be supplied.

7.0 MANUALS

The installation, maintenance and operating instructions shall include the following: a. Installation procedure. b. Operating and maintenance instructions. c. Burner data sheets and capacity curves d. Ignition equipments e. General arrangement drawings f. Complete parts list and bought out equipment data and manuals. g. Recommended spare parts list for two years operation and commissioning

8.0 GUARANTEE 8.1 Performance Guarantee 8.1.1 Vendor shall guarantee the following design parameters based on the operating

conditions specified in the data sheets.

a) Heat release, maximum / normal / minimum

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b) Turndown ratio c) Atomising steam consumption rate & Steam consumption ratio d) Fuel oil & Fuel gas consumption e) Flame dimensions at maximum / normal / minimum heat liberation. f) Excess air under all operating condition g) Noise level 85 dBA at 1.0M distance from burner h) Nox, CO and particular emission rate i) Flame stability j) No flame impingement on tubes or refractories

8.1.2 No negative tolerance on guaranteed figure for liberation and turndown is acceptable.

However, for other guaranteed parameters +/-5% variation is acceptable. 8.1.3 In case any problem is faced by the client or his representative during burner start-up

and commissioning, vendor shall depute his engineer to the plant site and shall demonstrate the above guaranteed parameters. In case any changes, modification or replacement is required of any part or complete assembly, the same shall be made by the vendor at his own cost without any delay.

8.1.4 Any demonstration to show the performance of the burner by the supplier shall be

carried out for at least 72 hours continuous operation, at specified site condition. 8.2 Workmanship Guarantee 8.2.1 All the burners and their components shall be guaranteed for a period as specified in

the commercial section of the purchase requisition. Any part found of poor workmanship, defective, improper design should be replaced by the vendor at his own cost and without any delay.

9 SPARES 9.1 Spares shall be considered in three categories:

a. Commissioning spares: vendor to recommend b. Spares required for two years normal operation: vendor to recommend. c. Mandatory Spares: as per SR.

10 PAINTING 10.1 Burner components shall be painted with heat resistant paint as per vendor’s standard

practice. 10.2 Paintings not required for Stainless and other corrosion resistant high alloy steels.

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10.3 The vendor must ensure that the paint applied is fully cured before the goods are further handled / transported.

11 PACKING AND SHIPPING 11.1 The supplier shall be responsible for suitability packaging the burner and its auxiliary

equipment to protect them from damage or loss during handling and shipment and anyspecial requirements or storage conditions specified in the enquiry.

11.2 All equipment shall be clear of debris, thoroughly clean inside and outside, and free of

any dirt and foreign matter before preparation for shipment. 11.3 Each shipping package shall be durably marked with the receiver’s address,

purchaser equipment item number, purchase order number, requisition number and project name.

11.4 Package markings shall be in English. 11.5 Bolts, nuts and washers shall be shipped, assembled, packed in boxes or kegs with

threads protected by a light coat of oil. Loose clips and other small structural parts shall be either boxed or wired together then wired to larger parts.

11.6 Equipment likely to be damaged by water or humidity shall receive additional

protection as required including desiccant for electrical components. Components with no drainable crevices or chambers shall be covered and protected at all times from entrance of water and debris.

11.7 Special tools if any shall be separately boxed, shipped, identified with the equipment

on which they are to be used, and marked as special tools. 11.8 Spare parts shall be shipped in separate packages clearly marked “Spares” and

properly identified with the equipment on which they will be installed. 11.9 The supplier shall provide any special protection or packaging and details of any

storage, shelf life or maintenance instructions which are not within the scope of the order and pertain to the supplier’s guarantee or are otherwise necessary for protection of the equipment.

11.10 All pressure parts are to be identified marked with alkyd based paint. Lead based

paint or hard stamping is for bidders. 12 REJECTION 12.1 Burner or parts thereof and material entering therein indicating irremediable or

injurious defects, improper fabrication, excessive repairs or which are not in accordance with this specification shall be subject to rejection. They shall also be

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subject to rejection if such conditions are discovered after acceptance at the supplier’s work.

12.2 Completed burner, parts of burner or materials containing defects originating with the

supplier’s design, materials or workmanship or which are not in complete compliance with either the requirements of the order and/or suitable for the intended service will be rejected.

12.3 Discovery of conditions warranting rejection, after inspection and acceptance of the

equipment by the purchaser does not relieve the supplier of responsibility to comply with the order.

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RECIPROCATING COMPRESSORS


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Abbreviations: DA Design Approach EQC Equipment Qualification Criteria GA General Arrangement MA WP Maximum Allowable Working Pressure OD Outside Diameter PEEK Poly Ether Ether Ketone P&ID Piping & Instrumentation Diagram PSV Pressure Safety Valve PTR Proven Track Record SWG Standard Wire Gauge TFE Tetrafluoroethylene VDR Vendor Data Requirement

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CONTENTS

CLAUSE NO DESCRIPTION PAGE NO1 SCOPE 5

1.1 GENERAL 5 1.2 EQUIPMENT QUALIFICATION CRITERIA 6 3 DEFINITION OF TERMS 9 5 REQUIREMENTS 9

5.1 DIMENSIONS 9 5.3 CONFLICTING REQUIREMENTS 10 6 BASIC DESIGN 10

6.1 GENERAL 10 6.4 ALLOWABLE SPEEDS 12 6.5 ALLOWABLE DISCHARGE TEMPERATURE 12 6.6 ROD AND GAS LOADS 12 6.7 CRITICAL SPEEDS 13 6.8 COMPRESSOR CYLINDERS 14 6.9 VALVE AND UNLOADERS 15 6.10 PISTONS,PISTON RODS AND PISTON

RINGS 15

6.11 CRANK CASES,CRANK SHAFT,CONNECTING RODS,BEARINGS AND CROSSHEADS

16

6.12 DISTANCE PIECES 16 6.13 PACKING CASES AND PRESSURE

PACKING 17

6.14 LUBRICATION 17 7 ACCESSORIES 17

7.1 DRIVERS 17 7.3 REDUCTION GEARS 17 7.5 MOUNTING PLATES 18 7.6 CONTROLS AND INTRUMENTATION 19 7.7 PIPING AND APPURTENANCES 20 7.8 INTERCOOLERS,AFTER COOLERS AND

SEPARATORS 22

7.9 PULSATION AND VIBRATION CONTROL 23

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7.11 SPECIAL TOOLS 24 8 INSPECTION AND TESTING 24

8.1 GENERAL 24 8.2 INSPECTION 25 8.3 TESTING 26 8.4 PREPARATION FOR SHIPMENT 27 9 VENDOR’S DATA 28

9.1 GENERAL 28 9.2 PROPOSAL 28 9.3 CONTRACT DATA 28

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SCOPE (Substitution)

1.1 General

(i) This specification together with attendant data sheets and other specifications/attachments to the inquiry/order covers the minimum requirements for reciprocating compressors and their drivers for use in petroleum, chemical, and gas industry services for handling process air or gas with either lubricated or non-lubricated cylinders. Compressors covered b y this specification are of moderate to low speed and in critical services. Also covered are related lubricating systems, controls, instrumentation, intercoolers, after-coolers, pulsation suppression devices and other auxiliary equipment.

Compressors not covered are: a) Integral Gas-engine Driven Compressors, b) Packaged H igh Speed Separable Engine-driven Reciprocating Gas

Compressors, c) Compressors with Single Acting Trunk-type (automotive-type) pistons that

also serve as crossheads d) Utility or Instrument A i r Compressors that discharge at 10.0 Kg/cm2 g or below.

Gas engine and steam engine drivers are excluded from the scope of this specification.

(ii) Vendor shall make all possible efforts to comply strictly with the

requirements of this specification and other specifications/attachments to inquiry/order.

In case deviations are considered essential by the vendor (after exhausting all possible efforts) these shall be separately listed in the vendor's proposal under separate section titled as ''List of deviations/exceptions to the inquiry document". Deviation shall be listed separately for each document with cross reference to Page No./Section/Clause No./Para etc. of the respective document supported with proper reasons for the deviation for purchaser's consideration . Any deviation not listed under the above section, even if reflected in any other portion of the proposal shall not be considered applicable.

No deviations or exceptions shall be permitted without the written approval of t h e Purchaser.

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(iii) Compliance with this Specification shall not relieve the vendor of the

responsibility of furnishing equipment and accessories /auxiliaries of proper design, materials and workmanship to meet the specified start up and operating conditions.

In case the vendor considers requirement of additional instrumentation, controls, safety devices and any other accessories/auxiliaries essential for safe and satisfactory operation of the equipment, he shall recommend the same along with reasons in a separate section along with his proposal and include the same in his scope of supply.

(iv) Except as modified herein, the reciprocating compressors and their

auxiliaries shall be designed, fabricated , tested and supplied strictly in accordance with the API Standard -618; Fifth Edition, December 2007; "Reciprocating Compressors for Petroleum, Chemical and Gas Industry Services". All requirements specified in the following paragraphs are additions, modifications or substitution (as noted in parenthesis) to above standard and appear in the alphabetical or numerical order as followed in the above Standard.

(v) Except for new paragraph , the number and title of the paragraphs in this

Specification correspond to the respective sections and paragraphs of the above standard . Paragraphs not addressed in this specification shall be strictly in accordance to API Standard 618, Fifth Edition, December 2007.

The word in parenthesis following the number or title of a paragraph indicates the

following:

1.2 Equipment Qualification Criteria (New)

(Addition) An addition to a part, section or paragraph referred to

(Modification) An amplification or rewording has been made to a part of the corresponding section or paragraph but not a substitution replacing the entire section or paragraph.

(Substitution) A substitution has been made for the corresponding section or paragraph of the standard in its totality.

(New) A new section or paragraph having no corresponding section or paragraph in the Standard.

(Delete) This paragraph is deleted.

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1.2.1 Unless otherwise specified elsewhere, the Equipment Qualification Criteria (EQC) specified vide para 1.3.2 to 1.3.5 of this specification shall be applied for acceptance of the offered compressor model and its manufacturer.

1.2.2 The vendor for the complete unit shall be an established manufacturer of

the Reciprocating Compressors (As per API Std. 618) and shall also be the manufacturer of the proposed compressors having adequate engineering, manufacturing & testing facilities for the same.

1.2.3 The vendor shall have engineered, designed, packaged, tested and

supplied, in the last TEN (I 0) years, from the proposed manufacturing plant, at least ONE (I) reciprocating gas compressor package (as per API Std. 618), which is from the same model series and having same type of driver having similar driver power, as offered. As a minimum, this package shall have completed ONE (1) year of satisfactory operation at site, as on bid due date.

In case offered compressors are equipped with step-less capacity control system, vendor shall have past packaging experience of having supplied, in the last TEN (10) years, at least ONE (I) reciprocating gas compressor package (as per API Std. 618), having similar driver power, number of cylinder valves, cylinder sizes & pressures, with similar step-less capacity control system.

1.2.4 The vendor besides satisfying the requirements of clause 1.2.2 & 1.2.3

above shall also be the packager of the complete system proposed and shall have the single point responsibility for the entire package.

1.2.5 The compressor model frame offered shall be from regular

manufacturing range of the vendor and shall meet the following qualification requirements:

Compressors shall be identical in model I frame size, frame rating & maximum allowable continuous rod loadings and similar in terms of Driver rating, Rod loadings, Stroke length, Rotational speed, Piston linear speed, Inlet & Discharge pressures and temperatures, Service (i.e. type of gas handled such as N2, H2, bone dry, saturated etc.), Cylinder assemblies, Number of throws I cylinders, Mechanical design, Materials etc. as compared to at least ONE (1) UNIT designed, manufactured, tested and supplied from the proposed manufacturing plant in the last TEN (10) years and the same unit shall have completed ONE (1) year of satisfactory operation at site, as on bid due date.

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In case all the above parameters are not available from single past reference, more than one reference may be cited to satisfy the above qualification requirement.

As an alternative, vendor may show to the satisfaction of purchaser, that the equipment offered is comprised of modules such as frame (crankcase), cylinder assemblies etc. Each of which individually satisfies the requirements specified above.

1.2.6 In case the vendor is a licensee I member of a group company (As defined in

I .2.6.6 below) and does not possess the manufacturing experience of the proposed Compressor Frame at his own manufacturing plant, the vendor may propose to supply the complete package with duly mechanical run tested bare compressor (together with cylinder assemblies etc.) sourced from the vendor 's licensor I another member of the group company, who shall also be a regular manufacturer of the proposed Compressor Frame, provided the vendor meets the following criteria:

1.2.6.1 The vendor shall be a regular & established manufacturer of reciprocating

gas compressors (as per API Std. 618) and shall be a licensee I member of group company (As defined inI .2.6.6 below) and shall meet the requirements of Cl. 1.2.3 above on his own.

1.2.6.2 Vendor's licensor I member of Group Company meets the equipment

qualification criteria as per 1.2.5 above with respect to the proposed compressors.

1.2.6.3 a) The vendor's license agreement is valid and continues to remain valid

till, at least TWO years after the delivery of the compressors. Necessary documents to establish that vendor has requisite facilities and has been authorized to package the proposed compressor model/frame shall be furnished in the proposal.

b) In case of member of Group Company, vendor to furnish requisite documents from Group Company to establish that vendor has requisite facilities and has been authorised to package the proposed compressor model.

1.2.6.4 The vendor shall source the duly mechanical run tested bare

compressor (together with cylinder assemblies etc.) from the licensor I another member of the group company.

1.2.6.5 The Licensor I member of Group Company, furnishes a back-up

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guarantee regarding design, mechanical integrity and performance of the machine equivalent to as if the machines were manufactured & supplied by them .

1.2.6.6 Group Company shall mean one of the following:

a) Wholly owned subsidiary of the bidder. b) Principal of whom the bidder is a wholly owned subsidiary. c) Another wholly owned subsidiary of the Principal of whom the

bidder is a wholly owned subsidiary.

1.2.6.7 The vendor shall indicate details of such arrangement in the proposal. 1.2.7

Documentation for Proven Track Record The vendor shall complete the Experience Record Proforma as enclosed in the inquiry specification to amply prove that the equipment offered meet the EQC for technical acceptance.

Vendor may furnish additional information to justify that the EQC is being met. In addition, manufacturer's catalogue and general reference list for all the above equipments shall also be furnished along-with the proposal.

3 DEFINITIONS OF TERMS

3.6.3 ( NEW)

Shaft speed irregularity: Shaft Speed Irregularity is a dimension-less number and is equal to the difference between the maximum and minimum instantaneous shaft speeds during cycle divided by the arithmetic mean of these two speeds.

3.6.4 ( NEW)

Bone dry gas: If the gas dew point (either at atmospheric conditions or at the inlet conditions) is below -40°C, the gas is supposed to be considered as "bone dry". Compressor vendor is expected to calculate & furnish the value of gas dew point based on the specified gas composition & the specified operating conditions.

5 REQUIREMENTS

5.1 Dimensions (Modification)

Delete 'either' and 'or US customary'

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5.3 Conflicting Requirements (Substitution) In c a s e of conflict between this specification and the attendant data sheets, job specifications ( if any) and other attached specification the following order of precedence shall govern: I. Equipment Data Sheets. 2. Job Specifications (if any) 3. P&IDs (if any) 4. This Specification 5. Other Specifications 6. Other referred codes and standards

6 BASIC DESIGN

6.1 General

6.1.3 Delete ‘Unless otherwise specified' and read 'rated' in place of 'normal'.

6.1.5 The pressure design code as a minimum shall be ASME Sec VIII Div 1 or

equivalent. 6.1.6 (Modification)

Unless otherwise specified, the maximum sound pressure level of the compressor driver train shall not exceed 88 dBA measured at 1 meter from equipment surface for the recommended range of operation.

6.1.7 (Substitution)

(a) For once through cooling system fed from purchaser's cooling water network, unless otherwise specified, the cooling Water system shall be designed for the following condition: For Heat Exchangers: Velocity over heat exchanger surface 1.5 - 2.5 m/sec. Maximum Allowable Working Pressure (MAWP) 8.0 kg/cm2g Test Pressure = 1.5 x MA WP Maximum Pressure Drop 1.0 kg/cm2 g Maximum Inlet Temperature 33°C Maximum Outlet Temperature 45°C Maximum Temperature Rise 12°C Fouling Factor on Water Side 0.0004 m2hr°C/kcal Shell Side Corrosion allowance 3.2 mm

For Cylinder Jackets and Packing Cases:

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Maximum Allowable Working Pressure (MA WP): 8.0 kg/cm2g Test Pressure: = 1.5 X MAWP

Provision shall be made for complete venting and draining of the system.

(b) If a closed circuit cooling water system is being utilized , MA WP & Test

pressure of cooling water circuit shall be based on vendor standard design practises. However, MA WP shall not be less than the shut-off pressure of closed circuit cooling water pump.

6. 1.12 (Substitution)

All e l e c t r i c a l components and installations shall be s u i t a b l e for the hazardous area classification and gas group specified in the inquiry I order documents.

6. 1.17 Delete 'When specified ‘.

6. 1.18 Substitute ' rated’ in place of ' normal '.

6.1 .25 (Addition)

Compressors and drivers (including gear units and couplings, if any) shall be designed to perform satisfactorily under the specified statt up conditions, patt load /full load operation, maximum differential pressure operation and cylinder relief valve setting pressure and upto trip speed.

Unless otherwise specified , the compressor vendor shall assume full responsibility to undertake:

i) Torsional analysis of the complete compressor train including the

driver and gear unit (except V-Belt driven units). ii) Selection, sizing and rating of the power transmission components as

also the base plates, sole plates and slide rails. iii) Checking the conformity of the motor coupling flange with

compressor coupling flange and supplying to the motor manufacturer in due course of time, the drilling jig for the motor coupling flange, in case of rigid coupling drive.

iv) Stress analysis of the piping and appurtenances from the intake filter I suction strainer up to the outlet flange of the final compression stage pulsation suppression devices I separators I after coolers I air receivers as the case may be.

v) Furnishing equipment layout. vi) Furnishing t h e design, type and location of the supports f o r

the piping and appurtenances as defined above under (iv).

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vii) Acoustical evaluation and Mechanical evaluation of the Compressor cylinders. Pulsation suppression devices, piping and equipment system between the first major vessel upstream of the compressor and first major vessel downstream of the Compressor (if specified), as per the specified design approach of API 618.

6.4 Allowable Speeds (Addition)

Unless otherwise specified, except for vertical and/or labyrinth type reciprocating compressors, the average piston speed shall not exceed 4 m /sec for lubricated cylinders and shall not exceed 3.5 m/sec for non-lubricated cylinders, except for the following specific cases:

i) For 'Boil-off gas' service (i.e. Ethylene, Propylene) with non-lubricated

cylinders, the piston speed shall be limited to 3.0 m /sec. ii) For ' Bone Dry Nitrogen ' gas service or any other service having gas

dew point value less than (-)40°C, the piston speed shall be limited to 2.5 m /sec.

In addition to the above, the rotational speed shall be limited as under:

i) Compressors handling gas containing H2S in any concentration, together with water in any form, shaH be limited to a maximum of 500 rpm.

ii) Compressors handling hydrogen, speed ofthe compressor shall be limited to 350 rpm. iii) Compressors of labyrinth type (vertical construction), speed shall be limited to 420 rpm.

iv) Unless otherwise specified, the maximum speed for reciprocating compressors (for all other gases, not mentioned above) shall not exceed 600 rpm.

6.5 Allowable Discharge Temperature

6.5.1 (Addition)

For high pressure air compressors (meant for air injection services for oilfields), requiring lubricated or mini-lubricated cylinders, to prevent auto-ignition, predicted maximum actual discharge temperature limit shall be 130°C and the same shall be subject to purchaser's approval.

The vendor shall ensure that the recommended cylinder lubricating oil is suitable from the point of view of auto-ignition that can occur with applications handling air at high pressures such as above.

Synthetic oil, if offered to be used, shall require purchaser's specific approval.

6.6 Rod and Gas Loads

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6.6.I (Addition)

The actual combined (gas + inertia) rod loading, calculated considering the cylinder gas relieving pressures, maximum differential pressure possible during operation under all specified operating conditions, and inertial forces of reciprocating masses, shall not exceed 90% of the maximum allowable rod load.

Also the actual rod loading due to inertial forces of reciprocating masses alone, shall not exceed the maximum allowable continuous rod load.

6.7 Critical Speeds

6.7.5 Shaft Speed Irregularity (New)

The compressor speed irregularity shall not exceed the values specified below under any required operating conditions including part load operation: V-Belt D r i v e 1/80 Direct drive by electric motor 1/100 Drive through gear unit 1 /100 For compressors direct driven by reciprocating engine, the shaft speed irregularity of the complete compressor-driver train shall be agreed between the vendor and the engine manufacturer. The inertia of the motor rotor shall not be considered f o r computing the shaft speed irregularity, except in case where torsionally rigid couplings are used.

6.7.6 Vibrations (New)

In the proposal, the compressor vendor shall indicate the permissible values of vibration [either in displacement (microns) or in velocity (mm/sec)] at foundation, frame & cylinders, which are to be measured during shop testing and under installed condition in field. Compressor vendor shall provide all the requisite data to enable the foundation designer to meet their recommended requirements.

Note: The determination of the compressor vibration levels shall be based on the maximum vibration levels occurring over the entire speed range (if applicable), for all operating conditions.

(e.g. different pressures), specified alternative gases (e.g. N2 for start-up), unloading conditions, single and multiple compressors in service, etc.

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6.8 Compressor Cylinders

6.8.1 General

6.8.1.1 (Modification) The maximum allowable working pressure of the cylinder shall be at least equal to the specified relief valve set pressure plus the required over-pressure (i.e. Accumulation pressure which is normally 10% above the specified relief valve set pressure).

6.8.1.2 (Addition)

Delete ‘Un less otherwise specified'. (Addition) Horizontal balanced opposed machines shall have e v e n number of throws & with even number of cylinder on each side. The arrangement of valves and ports in horizontal cylinders shall be such which ensures complete drainage of cylinders. When vertical cylinders are specifically allowed (e.g. only for dry gases) or specified , these shall be designed so that complete drainage of the cylinder is possible.

6.8.1.4 (Substitution)

Tandem cylinder arrangements, if offered, shall require purchaser's specific approval.

In case of tandem cylinder arrangements, the compressor vendor shall furnish along with the bid, a line schematic of the cylinder assemblies indicating location of cylinder packing, piston/piston rod diameters and operating pressures.

6.8.2 Cylinder Appurtenances

6.8.2.4 (Modification)

The words 'If specified' stand deleted. 6. 8. 2.8 (Substitution)

Valve chambers and clearance pockets shall be designed to prevent trapping of liquid.

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6.8.2.1 0 (New) Plugs for core holes and /or repairs shall not be used on the gas pressure side containing wall sections of cylinder heads or cylinders including the bore under the liner.

6.8.3 Cooling

6.8.3.5 .6 (New)

Pressure & flow measurement devices (i .e. Pressure & flow transmitter) shall be provided in the common outlet header of closed circuit cooling water pumps.

6.8.4 Cylinder Connections 6.8.4.1.2 (Addition)

For flammable and toxic services, screwed or screwed and seal welded fittings are not permitted. For corrosive and sour services socket welded fittings are not permitted.

6.9 Valves and Unloaders 6.9.1 Valves

6.9.1.2 (Addition)

Any limitation on operation of valve with different gases shall be clearly brought out in the proposal.

In case of any sort of limitations in operation of valve with different gases, separate set of valves & valve unloaders for each gas service must be provided by the vendor.


Unless otherwise specified, plug type unloaders shall not be used. Unloaders shall be pneumatically o p e r a t e d u n l e s s otherwise specified on the data/requisition sheet. Vendor shall provide the capacity control system with properly sequenced unloader operation.

6.10 Pistons, Piston Rods and Piston Rings 6.10.3.2 (Addition)

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In case of single piece wear bands on non-segmented p is tons, vendor shall also provide suitable wear band installation mandrel(s) as standard tools.

6.10.3.3 (New)

For bone dry gas applications, the material of construction o f piston rings, seal rings & rider rings shall be selected by the vendor based on established proven track record of the same, under the intended duty conditions.

Vendor (or the ring supplier) shall indicate the predicted guaranteed l i f e of such piston rings, seal rings & rider rings, when operated upon under the intended duty conditions.

As a minimum, purchaser desires 8000 hours of predicted guaranteed life.

Note: The selection of materials for piston and rider rings in non-lubricated s e r v i c e , particularly where gases do not contain water vapour or are termed as bone dry, shall be based upon references in identical or more severe services.

6.11 Crankcases, Crankshafts, Connecting Rods, Bearings and Crossheads

6.11.5 Delete 'If specified'

6.12 Distance Pieces

6.12.1 Distance Piece Types

Unless otherwise specified, long/long, two compartment distance pieces (Type C) shall be provided for compressors on flammable or toxic service.

For applications where space constraints exist (e.g. Sometimes offshore), use of a long/short, double compartment distance piece (Type D) may be considered.

Single compartment t y p e (Type A or B) distance pieces shall not be used for any of the process gas applications.

In cases of air or pure nitrogen, long single compartment ( Type B) type distance piece shall only be used.

6.12.2 Distance Piece Requirements


For flammable or toxic services, distance pieces (or compartments) shall be equipped with gasketed solid metal covers.

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6.12.2.4 (Addition)

Unless otherwise specified, Figure 1-2 of Annex-1 shall be used to minimize the leakage of process gas.

6.13 Packing Cases and Pressure Packing

6.13.1 General


When specified or for applications where process gas is hydrogen rich (molar mass less than or equal to 12) or process gas contains H2 S in concentration level of 0.5 mole % or greater or when process gas is toxic and in lethal service, cylinder pressure-packing case shall be purged with nitrogen.

6.14 Lubrication

6.14.2.2 Auxiliary Pump (Addition)

For compressors having a nominal frame rating below 150 kW equipped with a pressurized lubrication system, a hand driven lube oil pump shall be provided for start-up lubrication.

7 ACCESSORIES

7.1 Drivers

7.1 .2 Motor Drivers

7.1.2.2 (Substitution) For motor-driven units, the motor rating (with unity service factor), shall be at-least 110% of the guaranteed power (with 0% positive tolerance, including power transmission losses) or 105% of the power required (including power transmission losses) for the PSV set pressure conditions, whichever is higher.

7.1.2.13 (Addition)

Whenever single bearing motors are used, the motor shaft shall be rigidly connected to the compressor crank shaft and Compressor Crank Shaft bearing system shall be suitable to take into account additional loads imposed due to motor rotor.

7.3 Reduction Gears

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7.3.1 (Substitution)

Gear units for the compressors having rated BK W upto 1500 k W shall comply with API Standard 677 and for rated BKW above 1500 kW, gear units shall comply with API Standard 613.

7.5 Mounting Plates

7.5.3 Levelling, Alignment and Lift ing


The words ‘If specified ' stand deleted.

7.5.3.6 (Substitution) Anchor bolts shall be furnished by the vendor.


The vendor shall indicate the type of grout (i.e. cementatious or epoxy) and its estimated quantity (in m3)& its details(i.e. recommended make, recommended grade, desired strength etc.), which is to be used for the equipment along with the proposal. In case, vendor recommends use of epoxy grout, vendor shall comply with the requirements of this clause regarding surface preparation.

7.5.4 Base plate and Skids

7.5.4.1 (Addition)

Unless otherwise specified, s k i d mounted reciprocating compressor p a c k a g e s are permitted only up-to the driver rating of 160 kW.


Non-skid decking covering all walk and work areas shal l b e provided o n the top of the baseplate.

7.5.5 Soleplates and Rails


Sub-soleplates shall be provided with the soleplates by the vendor. Soleplates, rails, base plates, or compressor parts to be grouted (such as crankcase or a crosshead frame) shall be drilled and tapped for

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levelling screws. Screws for levelling, bolts for attaching the frame to the soleplates, or rails, chock blocks, and 300 series stainless steel shims shall be provided by the vendor.

7.6 Controls and Instrumentation

7.6.1 General


All instrumentation, c o n t r o l s , control panels etc shall conform to the requirements specified in the data sheets and specifications for instrumentation attached and/or referred to in the inquiry document.

7.6.2 Control Systems

7.6.2.4 (Addition)

The solenoid valves i n the unloading scheme capacity control scheme shall be of "Auto" reset type without requiring any sort of field intervention.

7.6.5 Relief Valves

(Modification) Relief valves shall be set to operate at the specified re l i e f valve set pressure, which shall be within the maximum allowable cylinder working pressure. If the relief valve set pressure is not specified, the recommended values ofTable-4 of API Std. 618 shall govern.

(Addition) Unless otherwise specified, all relief valves required e i t h e r on equipment or in the piping within the vendor's battery limits, shall be supplied b y the vendor.

7.6.6 Alarm and Shutdowns


All protective devices as well as an alarm and shutdown system shall be provided by the compressor vendor. When both alarm and shutdown is specified for the same function, the

Alarm actuation shall precede the shutdown actuation, and the shutdowns shall b e with simultaneous alarms.

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The words "If specified" shall be replaced with "lf specified or as recommended by vendor".

7.6.6.8 (New) Where automatic start feature of auxiliary oil pump is provided in case of failure

of main oil pump, an audio visual alarm shall be actuated simultaneously. 7.6.7 Vibration and Position Detectors 7.6.7.4 (Modification)

Unless otherwise specified , for horizontal cylinders, non-contact type piston rod drop detectors (i.e. Mechanical roller or fuse- metal plug (eutectic) type) shall be provided for all machines having non metallic wear bands & piston rings, when the compressor rated BKW 750 kW or when Differential pressure (between I st stage suction and final stage discharge) 70 kg/cm2 .

7.7 Piping and Appurtenances 7.7.1 General

All piping for utilities (cooling water, steam, exhausts gas, purge gas, buffer gas etc.) shall be furnished by the vendor and terminated at the vendor's battery limit (unless otherwise specified, the vendor’s battery limit shall be treated as the compressor house battery limit) with single inlet and single outlet flanged connections per service for purchaser's interface.


Interconnecting piping between equipment groupings and off-base facilities shall also be supplied by the vendor. These pre-fabricated interconnecting piping shall be provided with spool pieces to accommodate actual locational requirements of the Site. Complete connection of this piping shall be done at site by the field contractor. The piping, flanges, bolts, gaskets etc. required for this purpose by the Equipment Erection Contractor at site shall be supplied by the vendor. The vendor shall be responsible for any modification required at site, during assembly of pre-fabricated interconnecting piping by other agency. All vent pipes shall be supplied by the vendor and terminated outside the compressor shelter above the shelter roof level.

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To the extent possible all drains shall be manifolded and terminated at the grade level for purchaser's interface. Where man i fo ld ing is not feasible/advisable, the individual d r a i n s shall be terminated a t the grade level. All drains shall be terminated with a flanged valve. All flare lines required for the package shall be piped by the vendor u p t o the purchaser's. For all the process and utility piping included in the vendor's scope of supply (as defined by the vendor's battery limits), vendor shall be responsible for furnishing the following: - Compressor House layout drawing / Equipment Layout drawing -Piping general arrangement drawings with complete Bill of material & Part number. - Piping isometrics along with correspondence to piping G.A. drawings. - Location and type of Supports including supply of piping support and fabricated support structures along with support design data.


The compressor vendor shall be responsible for reviewing the Purchasers design and layout of the piping and appurtenances from the intake filter/suction knock-out drum upto the outlet flange of the final compression stage pulsation suppression devices/separators/after coolers/air receivers/discharge knock-out drums, as the case may be, for smooth and trouble free operation of compressor and aux. equipment, based on his experience and good engineering practice. The compressor vendor shall advice the purchaser of any modifications necessary for trouble free operation.

7.7.4 Coolant Piping 7.7.4.3 (Modification)

Coolant piping system for the compressor and its auxiliaries shall be provided by the compressor vendor. Thermal relief valves shall be provided with each independent cooling water loop.

7.7.6 Process Piping 7.7.6.2 (Modification)

Suction Strainers along with piping spool pieces will be installed in compressor suction lines of each stage and shall be supplied by the vendor. These strainers will be positioned as close as possible to the cylinder inlets but in no event shall they be located downstream of the inlet pulsation suppression equipment. The vendor furnished piping systems which will incorporate such strainers, shall include flanged spool pieces,

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or approved substitute to afford easy removal and reinsertion of the strainers without the necessity of pipe springing or equipment removal. The type of suction strainers (i.e. permanent / temporary / permanent & temporary) shall be as specified in the inquiry / contract.


The words `If specified' stand deleted.

7.7.6.5 (New)

In case of non-lubricated air compressors or if specified for other services all piping and appurtenances on the gas side shall be hot dip galvanized upto suction flange of the final stage cylinders.

7.8 Intercoolers, After coolers and Separators 7.8.1 Intercoolers and After coolers 7.8.1.3 (Addition)

Tubes shall not be smaller than 16 mm (5/8 inch) outside diameter (OD). The minimum allowable tube wall thickness is 18 SWG in case of copper/copper alloys tubes and 16SWG in case of carbon steel tubes.

7.8.2 Separators 7.8.2.1 (Modification)

The words `If specified' stand deleted.

7.8.2.2 (Modification) The type of liquid separation device shall be as recommended by the vendor.

7.8.2.5 (Modification) The sump or boot of an integral separator, or lower pat1 of the separate separation vessel shall be sized to provide minimum holding capacity for two hours.


The words ‘If specified' stand deleted.

7.8.2.8 (Modification) The words ‘If specified' stand deleted.

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7.8.2.9 (New)

For Hydrogen gas service, no threaded connections shall be used on Inter & after Coolers.

7.9 Pulsation and Vibrat ion Control

7.9.4 Design and Documentation

7.9.4.1.2 (Substitution)

Compressor vendor shall get the evaluation c a r r i e d out by an agency which has sufficient experience in carrying out similar studies. The vendor shall furnish sufficient data/reference in his bid to prove the capability o f the proposed a g e n c y . The compressor vendor shall be responsible for all coordination with the agency carrying out the study. In case of any malfunctioning in the compressor installation, if the same is caused by any errors in the acoustical and mechanical evaluation, the compressor vendor shall carry out a field survey to identify the cause of the problem and rectify the same. If any modifications are required to be made in the compressor installation, the same shall be made by the compressor vendor at his own cost.

7.9.5 Pulsation Suppression Devices

7.9.5.1 General

7.9.5.1.15 (Modification)

Pulsation s u p p r e s s o r connections other than those covered by 7.9.5.1.13 and 7.9.5.1.14 shall be flanged unless threaded connections are specified. For Hydrogen service ,no t h r e a d e d connections s h a l l be used on Pulsation suppression devices

7.9.5.1.17 (Substitution)

Unless specified otherwise, provision shall be made for attaching insulations for all cryogenic service applications viz. refrigeration compressors etc. and also for personnel protection where operating temperature exceeds 60 °C.

7.9.5.1.24 (New)

A vent connection with blind flange of minimum I inch size shall be provided for each pulsation suppressor.

7.9.6 Supports for Pulsation Suppression Devices (Modification)

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Adequate suppor t s for the pulsation suppression devices and piping shall be furnished b y the compressor vendor. Consideration shall a lso b e given t o thermal expansion of the components while designing the supports.

7.11 Special Tools

7.11.2(e) (Modification)

The words 'If specified' to be substituted with ‘where required’.

7.11.2 (Addition) (f) Bearing Extractor* (g) Piston Extractor* (h) Valve Extractor* (i) Sleeve to fit piston assembly into cylinder bore (if necessary based on

shape of the liner)* (j) Piston rod thread cover* (k) Hydraulic pump & hose for hydraulic tightening of piston rod to crosshead,

piston rod to piston, connecting rod head bolts, frame spacer bars bolting, foundation bolts etc.*

Note: * Items are not mandatory but are "as applicable to vendor specific

compressor design".

8 INSPECTION AND TESTING 8.1 General 8.1.1 (Modification)

The extent of shop inspection and test and purchaser's participation in the same shall be as specified in the equipment data sheets , specifications and Inspection test plan (if any) enclosed with the inquiry / order.

8.1.6 (Modification)

Whenever the data sheets or specifications call for certain shop inspections and tests to be witnessed, observed, or performed in presence of purchaser's representative, the vendor shall provide a written notice of at least 30 days in advance to the Purchaser prior to each inspection or test. The vendor shall reconfirm the date seven days prior to the test date.

8.1.11 (New)

The material certification and shop test data shall be furnished to the purchaser's inspector in requisite number of sets for his review and comments prior to the commencement of the tests to be witnessed by Inspector.

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8.2 Inspection 8.2.2 Material Inspection 8.2.2.6 Material Certificates (New)

I. The vendor shall furnish material test certificates showing the chemical

composition and the mechanical properties of the materials of construction employed. The vendor shall also carry out and furnish the results of any material test specified in the applicable codes.

ii) When so required, material, tests shall be carried out in presence of the

purchaser's inspector.

iii) Material test certificates shall be furnished to the Purchaser's inspector for his review and approval prior to his witnessing any specified non-destructive testing.

8.2.2.7 Component Inspection (New)

1) All pressure containing castings (such as cylinders, liners, cylinder heads, headers etc.) shall be tested by the vendor in accordance with the following table. The requirements of vendor's certificates and of witnessing by the purchasers inspector shall be as stated in this table.

S.No Tests Certificate Required from Vendors

Test Witness by Purchasers Inspector

1 Chemical Analysis Yes No 2 Physical test for tensile

strength, elongation and Hardness.

Yes No

3 Visual Inspection Yes Yes 4 Hydrostatic test Yes Yes

2) Critical components (such as fabricated steel pistons, crank-shafts, crossheads,

connecting rods, piston rods, big-end bolts, main-bearing studs etc.) shall be tested by the vendor in accordance with the following table. The requirements of vendor's certificates and witnessing bv the purchaser's inspector shall be as stated in this table.

S.No Tests Certificate Required from Vendors

Test Witness by Purchasers Inspector

1 Chemical Analysis Yes No 2 Physical test for tensile Yes No

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strength, elongation and Hardness.

3 Microstructure report (for Nodular/Spheroidal cast iron only. Certificate shall be accompanied by photograph).

Yes No

4 Visual Inspection No Yes 5 Ultrasonic testing of

crank shaft, piston rods, connecting rods & big end bolts (as applicable).

Yes Yes

6 Magnaflux testing / Magnetic particle test of crankshaft, connecting rods, piston rods & big end bolts (asapplicable). OR

Yes Yes

7 Dye-penetration testing for crankshaft, connecting rods, piston rods & big end bolts (as applicable).

Yes Yes

8.3 Testing 8.3.1.2 (Modification)

During detail engineering vendor shall furnish detailed shop inspection and test procedures for all standards and specified inspection and testing requirements for purchaser's review, but not later than twelve weeks prior to the test. The test shall also include complete description of the test set up, instrumentation, test procedure, test conditions, an outline of proposed report, report forms, acceptance criteria, method of calculation, sample calculations etc.

8.3.2 Hydrostatic and Gas Leakage Tests 8.3.2.8 (New)

The frame and the distance piece shall be tested for leaks using kerosene or a suitable testfluid for a minimum period of 24 hours. Water shall not be used for testing.

8.3.3 Mechanical Running Tests 8.3.3.1 (Modification)

Unless otherwise specified, all compressors, drivers and gear units shall be shop tested in their respective manufacturing works as per manufacturer's standard test procedure(s), duly approved by the purchaser.

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8.3.3.2 (Addition)

Mechanical Running Test at rated speed shall be conducted for a minimum period of 4 hours. The Mechanical Running Test shall be started only after all the parameters to be measured have stabilised. Shop test readings shall be recorded at an interval of 30 minutes during the duration of test.


The words "If specified, packaged units" shall be replaced with the words "Skid mounted packaged reciprocating gas compressor units".


A11 auxiliary equipment not integral with the unit such as auxiliary lube oil consoles, cooling fluid consoles, lube oil pumps etc. shall be subjected to 4 hours running tests at their respective sub-vendor's works.


After the Mechanical Running Test, the compressor shall be dismantled and visual inspection for the following shall be done:

(a) Main bearing - drive end side (Not applicable for non-split type journal bearings). (b) Connecting rod big end bearing (at least one number) (c) Piston assembly including piston, piston rings, piston rod and packings (at least one number) (d) Cylinder bore effective surface - all cylinders.

8.3.4 Other Tests 8.3.4.2 (Substitution)

Machine mounted equipment such as valves, unloaders, lubricators etc. and pulsation suppression devices (where these are common to more than one cylinder), shall be fitted and assembled in the vendor's shop. The vendor shall demonstrate proper fitting and ensure that assembled equipment is free from any sort of harmful stress / strain.

Note: In case, all the above mentioned items are not available at the time of testing, only the components available shall be used for the test. However, vendor, at his own cost, shall carry out the test with all the components, at site.

8.4 Preparation for Shipment 8.4.1 (Modification)

The preparation shall make the equipment suitable for 12 months of outdoor storage from the time of shipment. If any extra precaution is to be taken by the Purchaser for

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storage beyond 12 months the same shall be explicitly indicated in the operation and maintenance manuals.

8.4.14 (Modification) In case the country of origin for the equipment being supplied is different than the country where the project site is located, the equipment shall be packed for export shipment.

9 VENDOR'S DATA 9.1 General (Substitution)

The information to be furnished by the vendor is specified in 9.2, 9.3 and purchaser's Vendor Data Requirements as included in the inquiry document. Vendor shall complete and forward the document `Vendor Data Index & Schedule Document Control Index (DCI)' to the purchaser. (Destination & Contact persons as per order).

9.2 Proposals (Substitution)

The vendor's proposals shall as a minimum include the following: a) All data sheets drawings and documents listed under `PRINTS WITH QUOTE 'in then closed Vendor Data Requirement Form. b) List of recommended commissioning spares included in the offer. c) List of mandatory spares (where specified by the purchaser) included in the offer. d) List of Vendor's Standard Spare Parts for Two Years Normal Operation This list shall be made separately for each item including auxiliaries and drivers in the form of a table & shall show i) Part name, description and number. ii) Quantity installed in one unit. iii) Quantity recommended per unit for 2 years normal operation. iv) Quantity recommended for number of units of an item as specified in the inquiry. v) Quantity recommended as insurance for the units of an item as specified in the inquiry.

e) An itemised list of special tools included in the offer. f) Any start-up, shutdown or operating restrictions required to protect the integrity of the equipment. g) Any limitations of vendor's test-facility to carryout the specified tests. h) A specific compliance statement that the scope of supply, the offered equipment/systems and all its components are in strict accordance with the data sheets, job specifications, this specifications and all other attachments, except for specific deviations as listed in the proposal.

9.3 Contract Data (Substitution) 9.3.1 General

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9.3.1.1Drawings and data as required after purchase order has been specified in the Vendor Data Requirement. Vendor to note that the drawing/document description/titles as given in the Vendor Data Requirement are generic in nature. It is possible that against one drawing/document specified there are several drawings to be furnished by the vendor or vice versa. Vendor shall complete & forward a document `Vendor Data Index & Schedule/ Document Control Index (DCI)' to the purchaser (Destination & contract person as per order). This document shall list out in consolidated form all drawings and documents required by purchaser (as specified in the Data Sheets, Specifications and Vendor Data Requirement forms enclosed with the order). Against each drawing/document vendor shall indicate the Vendor's drawing numbers, titles, rev. no., and category (whether for information or approval) and schedule of submission. This shall be the first document to be submitted by vendor within two weeks of order. This shall be the first document to be submitted by vendor within two weeks of order. No drawing shall be taken up for review till DCI for the inquiry/order is finalized by vendor.

9.3.1.2 All transmittal Letters (cover), drawings and data shall have a title block (in addition to vendors standard title block) which shall as a minimum contain the following contract information. (i) Purchaser's/ Consultant' s corporate name. (ii) Project Name (iii) Equipment Name and Item Number. (iv) Purchase Order No. (v) Purchase requisition no.

Title block on drawings shall be placed on the lower right hand corner. 9.3.1.3 All Vendor data/ Drawings/ Documents shall be in English Language and in Metric

System. 9.3.1.4 Data specified in the VDR is the minimum requirement of the purchaser. Any additional

document / data required or requested by purchaser for engineering or construction shall also be made available by the vendor.

9.3.2 Co-ordination Meeting When specified, a co-ordination meeting shall be held at

Purchaser's office, preferably within 4 weeks of order. An agenda shall be prepared for this meeting and would include the following points related to technical aspects.

a. Any clarifications required by the vendor on purchaser's order. b. Vendor Data Index & Schedule. c. Vendor Data Review/approval modalities. d. Sub-vendor lists proposed by vendor. e. Utility requirements. f. Preliminary General Arrangement & layout drawings & purchaser's interface drawings.

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9.3.3 Drawings

The number of prints required and the times within which these are to be submitted by vendor are specified in Purchaser's inquiry/order. Drawing review shall be through EDMSNDOCS in soft, as per the details provided elsewhere in inquiry document.

9.3.3.1 The purchaser's review of the vendor's drawings shall not constitute permission to

deviate from any requirements in the purchase order/specifications unless specifically agreed upon in writing. After the drawings have been reviewed, the vendor shall furnish certified copies in the quantity specified. All the drawings / documents shall be provided either in A4 or A3 paper size. All drawings must be clearly legible and shall be folded to 216 mm x 279 mm size.

9.3.3.2 Drawings/documents with following titles shall contain as a minimum the following information:

a) General Arrangement Drawing A general arrangement drawing shall indicate: i) Outline dimensions (minimum three views) (All principal dimensions). ii) Allowable forces and moments on suction and discharge nozzles. iii) Location (in all three planes), size, type, rating and identification of all purchaser's

interface connections including those of vents, drains lubricating oil, sealing fluid, cooling water, steam & Electrical/Instrumentation.

iv) Direction of rotation viewing from the driving end. v) Weight of each assembly/component. vi) The weight & location of center of gravity of the heaviest assembly/components

that must be handled for erection. vii) Identification and weight, dimensions of the heaviest assembly /subassembly/

component required to be handled for maintenance. viii) Maintenance clearances and dismantling clearances. ix) Speeds of Driven Equipment and driver and driver rating. Location of driver

terminal box (in case of Electric Driver) x) Layout of auxiliary equipment and operating platform. xi) Make, Type and Size of couplings and the location of guards and their

coverage. xii) A list of reference drawings if any. xiii) A list of any special weather-protection and climatic features.

b) Foundation Drawing

A foundation drawing shall indicate complete information required for foundation design by purchaser including the following:

a) Foundation bolt sizes & pipe sleeve details and pocket sizes & locations. b) Recommended grouting material (i.e. cementatious or epoxy), make of grout,

specifications, quantity, grouting thickness and other necessary technical details.

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c) Static weight of each independently grouted item (such as compressor, gear box, driver, control panel etc.) and location of center of gravity of each of such items in all three planes.

d) Weight distribution for each bolt/subsole-plate location and total static weight. e) Dynamic loads, if any, caused due to various items grouted independently. (The

cause of generation of such loads shall also be indicated). f) The direction and magnitude of unbalance forces and moments (with their phase

angles) generated by the out of balance of the rotating / moving parts of the machine at the relevant operating conditions. [These loads and their locations are to be given in all three planes. These shall be utilised for computing the amplitudes of vibration of the foundation].

g) GD2 value of each item resolved to motor speed. h) Maximum permissible amplitude of vibration on the foundation at the base level.

(The location of the points on the foundation base where such amplitudes are not to be exceeded shall be given in all three planes). The reference of relevant code, if any, shall also be indicated.

i) Total mass of rotating parts. j) Total mass of reciprocating parts. k) Suggested dynamic factor and ratio of weight of foundation to weight of machine. I) Short circuit loads caused in motor drivers. m) Operating speed of the machine and the driving motor. n) Scope of Supply of the Foundation Bolts (unless otherwise specified, by vendor). o) Maximum permissible magnitude of the unbalance forces and moments

generated by the out of balance of the rotating / moving parts of the machine as allowed by the relevant codes, if any. (The reference of such code, if any, shall also be indicated).

p) Recommended separation margin (if any), between the machine operating speeds and the natural frequencies of the machine foundation system along with the basis of such recommended separation margins.

[Note: Unless otherwise indicated by vendor, the dynamic forces as given in e) & l) above are considered as additional static loads for designing the foundations statically. Such dynamic forces are not unbalance forces and therefore, these shall not be utilised for computing the amplitudes of vibration.]

c) Layout Drawing (For multi-skid packages)

This drawing shall include atleast the following: i) Layout of all skid/equipment and their auxiliaries, vessels, control panels,

exchangers etc. Vendor shall furnish an optimised layout (considering the space allocated, site wind conditions, area classification, the type of equipment located in the vicinity etc.) indicating elevation and dimension of skids/equipment.

ii) Minimum spacing required between the various skids/equipment and between the skids and the walls/columns/roof for an easy accessibility and maintenance.

iii) Layout for water piping, trenches for water piping, cable tray/trenches layout. iv) Piping arrangement and piping support arrangement/location for piping in

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vendor's scope. v) Layout for auxiliary equipment and operating platform details. vi) Specification for crane/mono rail (including suggested mono rail layout)

recommended for maintenance and height of the lifting hook from the centreline of equipment.

d) Field Alignment Diagram.

The diagram shall indicate the relative displacements to be kept between the Centrelines of various equipments at the time of installation so that under normal Running conditions the equipment gets fully aligned. This relative displacement should be decided on the basic of driver, gearbox, crankshaft & piston centreline temp. Rise data.

e) Heat Exchanger Drawings

Heat exchanger drawing and data shall include heat and mass balance data, details of provisions for separating and withdrawing the condensate, construction details, cross sections & general arrangement drawings of heat exchangers, vendors recommendations regarding provision for support and piping expansion.

9.3.3.3 P & I Drawing (with Bill of Material)

P & I Drawing shall indicate the system details, location of various auxiliaries, instruments, controls and safety devices, as required, vendor's scope shall be clearly demarcated, line sizes piping class, valve sizes and class shall be clearly marked on the P&ID. Each item shall have an item number which shall correspond to the item number shown on the bill of materials. The bill of material, shall include item number, name of the item, function, normal value set value, range, quantity per unit, make and other specifications as applicable. Legends adopted shall be furnished at the bottom of each drawing. The legends shall be as per ISA.

9.3.3.4 Cross Sectional Drawing (With Bill of Material)

The vendor shall supply cross-sectional or assembly type drawings for all equipment furnished showing all parts, design assembly and running clearances, and balancing data required for erection and maintenance. Each part shall be numbered which shall correspond to the part number on the bill of materials. The bill of materials shall include the part no., name of component, materials quantity installed per unit & sizes where applicable (say for bolts, nuts, rings, gaskets etc.). All boughtout items shall also be indicated with make and brief specifications. A separate cross-sectional drawing showing installation and setting dimensions for the seals shall be furnished.

9.3.4 Performance Data 9.3.4.1 Data Sheet

The Vendor shall provide completely filled in data sheets, first for "As Purchased" and then for "As Built". This shall be done by the vendor correcting and filling out the data sheets and submitting copies to the purchaser.

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9.3.4.2The vendor shall submit performance curves or tables of power and capacity versus

suction pressure with parameters of discharge pressure, showing the effects of unloading devices and showing any operating limitation and with calculation input and output data identified, all as mutually agreed between the vendor and the purchaser.

9.3.4.3Rod load and gas load charts for each load step, complete in accordance with 6.6,

including inertial forces and rod reversal magnitude and duration shall be furnished. 9.3.4.4The vendor shall furnish the data required for independent rod load, gas load, and

reversal calculations. 9.3.4.5The effect of valve failure on rod loads and reversal shall be calculated and furnished.

The required specifics of this study shall be mutually agreed upon by the purchaser and vendor.

9.3.4.6Curves of starting torque vs. speed shall be furnished for the compressor, for the motor at

rated voltage and for the motor at the specified voltage reduction. The curve sheet shall also state separately the (moment of inertia of the motor alone and the resultant moment of inertia of the driven equipment referred to the motor shaft speed plus the calculated time for acceleration to full speed at the specified voltages (as per Clause 7.1.2 of API 618) and specified operating conditions (refer clause 7.1.1.6 and 7.1.2.1 of API 618). All curves shall be scaled in finite values. Values expressed in percentage terms alone shall not be provided.

9.3.5 Contents of Pulsation and Vibration Control Study

Compressor vendor shall submit a Pulsation and vibration control evaluation report to purchaser. The report shall contain as a minimum the following data:

i) Methodology of conducting the study. ii) Hardware/Software used to conduct the study. iii) Basis used for conducting the study, i.e. information provided by purchaser and

that provided by compressor vendor. Compressor vendor shall also indicate the allowable vibration limits for the compressor at cylinder head and at suction and discharge flange of cylinders.

iv) Amplitude vs. frequency plot of pressure waves for compressor valves and various points in piping.

v) Actual PV card of compressor cylinders superimposed graphically on ideal card indicating percentage under-load or overload in both capacity and horsepower.

vi) Values of pressure drop through pulsation suppression devices and significant piping element.

vii) Mechanical natural frequencies, mode shapes amplitudes of vibration & stresses in compressor manifold system.

viii) Mechanical natural frequencies of piping system. ix) In case of insufficient margin of separation mode shapes, amplitudes of vibration

and stress levels in piping both steady state as well as cyclic.

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x) A confirmation from the agency conducting the study that the defined system is safe under all the specified operating conditions, considering all aspects as indicated in this specification.

9.3.6 Technical Data Manual/Mechanical Catalogue 9.3.6.1 Technical Data Manual/Mechanical Catalogue is a compilation of `As built' drawings and

data, manufacturing and test records, installation, operating and maintenance instructions.

9.3.6.2Not later than 2 weeks after successful completion of all specified tests, the vendor shall

furnish the required no. of Technical Data Manual/Mechanical Catalogues for equipment. The catalogue shall include the following documents as a minimum: i) All drawings and data as listed in the vendor data requirement form. (For

drawings where purchaser's approval is required, the final certified drawings should be attached). Sections shall be organised in a manner that data & drawings related to one subject is grouped together such as Mechanical, Electrical, and Instrumentation etc.

ii) All manufacturing, inspection and test data records. iii) Installation Manual

The vendor shall provide sufficient written instructions, including a cross-reference list of all drawings, to enable the purchaser to correctly install the equipment and prepare the equipment for start-up. It shall include any special information required for proper installation that is not on the drawings, special alignment or grouting procedures, utility specifications (including quantity) and all installation data. It shall also contain the following information:

(a) Instructions for erecting, piping, aligning (including the expected thermally induced shaft centre line shift between normal site ambient temperature position and that at normal equipment operating temperature).

(b) A description of rigging procedures, including the lifting of the assembled equipment, and methods of disassembly, repair, adjustment, inspection and reassembly of the equipment and auxiliaries.

(c) Pre-commissioning/commissioning/functional test procedures and acceptance criterion.

iv) Operation and Maintenance Manual

This manual shall provide sufficient written instructions and data to enable purchaser to correctly operate and maintain the equipment ordered. It shall include a section to cover special instructions for operation at extreme environmental and/or extreme operating conditions. The following shall be included in this manual:

(a) Instructions covering start-up, normal shutdown, emergency shutdown, operating limits and routine operational procedures.

(b) A description of equipment construction features and the functioning of component parts or systems (such as control, lubrication, sealing systems etc.).

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(c) Outline and sectional drawings, schematics and illustrative sketches in sufficient details to identify all parts and clearly show the operation of all equipment and components and the methods of inspection and repair. Standardised sectional drawings are acceptable only if they represent the actual construction of the equipment.

(d) The following maintenance information:

i. Maximum and minimum bearing, labyrinth and seal clearances including any other clearance between moving and stationary parts of the equipment affecting proper running and maintenance of the equipment.

ii. Instructions for measuring and adjusting cold clearances, shaft runout, concentricity etc.

iii. Rotor/Crankshaft float allowance. iv. Interference fits on parts that are required to be removed or replaced for

maintenance of normally consumable spares. v. Balancing tolerances. vi. Lubricating schedules indicating recommended grades of oil, their

properties, replacement period etc. vii. Normal maintenance procedure. viii. Preventive maintenance schedules and criterion for replacement of parts. ix. Trouble - shooting procedures.

(e) The following reassembly information:

i. Bolting sequence and torque values for all bolts affecting equipment performance/integrity/safety.

ii. Reassembly sequences together with required inspection checks. iii. Adjustment procedures to achieve required positions, clearances, float

and so forth. iv. Detailed procedures for pre-operational checks, including settings and

adjustments. v. Seals and coupling installation procedures. vi. Parts list indicating cross-sectional drawings of various assemblies and

subassemblies, part numbers, materials of construction etc. to facilitate identification of parts and for procurement of spares.

v) Following information shall also be included in the Technical Data Manual/Mechanical Catalogue:

1. Storage instructions for storing and preserving the equipment (including

driver and all the auxiliary units) at the plant site before installation of the same.

2. Instructions for preserving the equipment after it has been installed. This is particularly required in cases where a long time gap is expected between equipment installation and commissioning.

3. Field performance test procedures and acceptance criterion. 9.3.6.3 Technical Data Manual shall be in Hard board folder(s) of size 265 mm x

315 mm and shall not be more than 90 mm thick; it may be of several

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volumes and each volume shall have a volume number, index of volumes & index of contents of that particular volume.

9.3.6.4 Title sheet (Top sheet) of each volume of Technical Data Manual shall

contain the contract information as defined under clause 9.3.1.2 besides the volume number.

9.3.6.5 In case order contains more than one item, separate dedicated Technical

Data Manuals shall be submitted for each item. 9.3.4.6 Two (2) sets of Final / "As-Built" drawings / documents shall also be

submitted as electronic files on secondary storage media (Pen drives / CD ROMs).

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PAGE 1 OF 10


ANCHOR BOLT/ TEMPLATE


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CONTENTS CLAUSE NO DESCRIPTION PAGE NO

1.0 SCOPE 4 2.0 GENERAL 4 3.0 FABRICATION 6 4.0 INSPECTION 7

ATTACHMENTS- ANCHOR BOLT TEMPLATE DETAILS FIGURES 1,2&3

9

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1.0 SCOPE

1.1 This Specification covers the requirements for the fabrication of anchor bolt templates to be used for the setting out of anchor bolts for the foundations of skirted vertical vessels having more than four anchor bolts.

1.2 The anchor bolt template shall have a companion gauge plate to be used for drilling anchor bolt holes in the base plate of the vessel skirt.

2.0 GENERAL

2.1 Types of Anchor Bolt Templates The following two types of anchor bolt templates shall be used and they shall be selected based on the shape and size of the pressure vessels.

2.1.1 Plate Type

Plate type anchor bolt templates shall be made from a single steel plate shown in figure 1. This type shall be used for vessels with skirts having single ring type base plates.

2.1.2 Stiffener Type

Stiffener type anchor bolt template shall consist of upper and bottom plates with stiffeners and pipe spacers fabricated as shown in figure 2. This type shall be used for skirts having double ring type base plates with compression rings.

Stiffener type anchor bolt templates shall be constructed in one piece for base plates having a 3000 mm or smaller anchor bolt circle diameter, and two or three pieces for larger anchor bolt circles, for ease of transportation.

Preparation

The anchor bolt template shall be delivered to site in advance of the shipment of the vessel and prior to the commencement of the foundation installation. Delivery date will be as stated in the vessel purchase order.

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The preferred fabrication method is to machine the holes in the vessel base plates and anchor bolt template together in a single operation thus minimising the risk of accumulated manufacturing errors. For this method a gauge plate will not be required.

If the anchor bolt template has to be fabricated prior to the fabrication of the vessel skirt base ring, for scheduled delivery reasons, then a gauge plate shall be manufactured.

The gauge plate shall be made at the same time as the anchor bolt template and the holes machined in both components in a single operation.

2.2 Gauge Plate

The gauge plate shall be made from carbon steel plate having a minimum thickness of 6 mm.

Gauge plate dimensions shall be the same as those of the anchor bolt template and divided construction shall not be permitted.

Gauge plate markings shall be in accordance with section 4.4.

The gauge plate shall be kept with care at the fabricator’s shop until completion of vessel inspections.

Gauge plates shall be reinforced with flat bars to prevent deformation if necessary.

DIMENSIONS OF ANCHOR BOLT TEMPLATES

2.3 Plate Type

The dimensions of plate type anchor bolt templates shall conform to Table 1.

TABLE 1 - DIMENSIONS OF PLATE TYPE

(Units mm)

Nominal Size of Anchor Bolt

Width of Jig Plate

Diameter of Bolt Holes

Minimum Thickness of Plate

B (mm) d (mm) T (mm)

M24 120 25.5 10

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2.4 Stiffener Type

The dimensions of stiffener type anchor bolt templates shall conform to Table 2.The height (H) of the anchor bolt template shall be the same as the height of the skirt bolt chair Tower Base Support Lugs for Anchor Bolts plus 40mm grout.

TABLE 2 - DIMENSIONS OF STIFFENER TYPE

Nominal Size of Anchor

Bolt

Width of Jig Plate

Diameter of Bolt Holes

Minimum Thickness of Plate

Distance Pieces (Std

Pipe) B (mm) d (mm) T (mm) Inch

M30 130 32 10 1½

M36 150 38 10 2

M42 160 44 10 2½

M48 180 50 10 2½

M56 180 58 10 3 M64 200 66 10 3

3.0 FABRICATION

3.1 Material Material of the anchor bolt template and gauge plate shall be ASTM A283, A36 or equal.

3.2 Reinforcement Anchor bolt templates shall be reinforced with steel angles, flat bars or other steel members to prevent deformation, as shown in Figure 3.

3.3 Form Correction Should any strains / distortions be caused in anchor bolt templates, they shall be corrected to exact specified form.

3.4 Marking

The top surface only of the anchor bolt templates and gauge plate shall be painted black then the following shall be marked on the top surface of the anchor bolt template and gauge plate:

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a) Equipment number.

b) Orientation in degrees at 0, 90, 180, and 270 degrees.

c) Match marks at connection points of divided construction type.

Equipment number shall be marked with both die stamp and white paint.

Orientation and match markings shall be made with both die stamp and white paint.

Orientation notches cut perpendicularly, as shown in Figures 1 & 2.

3.5 Bolt Holes

The holes of anchor bolts on both anchor bolt template and skirt base plate shall be drilled exactly by tracing of the holes from the gauge plate.

For divided construction type of anchor bolt template, the holes shall be made in the fully assembled condition after sectioning.

3.6 Assembly

Anchor bolt template assembly joints shall be made with the use of reamer bolts or cotter pins to ensure accurate assembly.

4.0 INSPECTION

4.1 General All anchor bolt templates and gauge plates shall be inspected at the fabricator’s shop in accordance with the following requirements:

a) Dimensional inspection.

b) Visual inspection, including match markings and clarity.

c) Deviation check of bolt holes by placing gauge plate on the anchor bolt template (max. deviation 1mm).

4.2 Dimensional Check Dimensional check shall cover the following dimensions:

a) Bolt circle diameter (±2 mm for BCD of 2100 and under, ±4 mm for over

2100 mm).

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b) Bolt circle pitch (±3 mm).

c) Bolt hole diameter (+1/-0 mm).

d) Orientation notches (±1.5 mm).

e) Height of jig “H” as shown in Figure 2 (±4 mm).

f) Alignment of bolt holes between upper and bottom plate from stiffener

type jig plates (±2 mm in any plane).

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90°

90°

90°

20

20

50

90°

90°

90°

20

50

TEMPLATE ON THE FOUNDATION

FIG. 1 PLATE TYPE TEMPLATE

TB

TT

FIG. 2 STIFFENER TYPE TEMPLATE

PIPE DISTANCEPIECES

FULL WIDTHGUSSETS

'H' TO BE AS PER ANCHORBOLT CHAIR PLUS 40mm GROUT.

H

VESSEL 0^

B

t

d BOLT HOLE d BOLT HOLE

EQUIPMENTITEM NO.

20

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ANGLE MEMBERFLAT BAR

PLATE TYPE

A

A

VIEW "A-A"

B

B

VIEW "B-B"DIVIDED CONSTRUCTION TYPE

FIG. 3

STIFFENER TYPE

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FOR STATIC MIXER

STATIC MIXERS

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FOR STATIC MIXER


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CONTENTS

CLAUSE NO DESCRIPTION PAGE NO 1.0 GENERAL 4 2.0 SCOPE OF SUPPLY AND SERVICES 4 3.0 EXCLUSIONS 5 4.0 TECHNICAL REQUIREMENTS 5 5.0 DEVIATION SCHEDULE 6 6.0 INSPECTION AND TESTING 6 7.0 PACKAGING AND IDENTIFICATION 6 8.0 TRANSPORTATION 6 9.0 GUARANTEED WARRANTY 7

10.0 DOCUMENTS REQUIRED WITH BID 7

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FOR STATIC MIXER

1.0 GENERAL

This specification gives the minimum requirements for the engineering, procurement of materials, manufacture / fabrication, inspection & testing at vendor's/ sub vendor's works/site, surface preparation & painting, packing and supply of Static Mixer required for IOCL.

2.0 SCOPE OF SUPPLY AND SERVICES

Vendor shall design, fabricate & supply the Static mixer in accordance with the enclosed Data Sheets:

Vendor’s scope of work and supply shall include but not limited to the following.

2.1 Complete Process design and Sizing of the equipment. 2.2 Complete Mechanical design of the equipment. 2.3 Material procurement, fabrication, testing & inspection. 2.4 Supply of all materials, meeting all specifications mentioned in the requisition. 2.5 Preparation of design report, detailed fabrication drawing and submission of the same as per

scope of supply document. 2.6 Complete mixer housing with necessary mixing elements. 2.7 Necessary End Connecting flanges at inlet and Outlet. 2.8 Lifting Lugs and Mixer supporting arrangement including support bolting if required. 2.10 Dimensional check as per relevant Codes & Standards. 2.11 Recommended spares for installation and commissioning. 2.12 Conducting all NDT examinations, radiography, PWHT, etc. as per codes and standards. 2.12 Hydro test as per code.

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2.13 Mechanical guarantee for the design, material and workmanship along with performance

guarantee. 2.14 Painting, Packing and Transportation to site. 3.0 EXCLUSIONS 3.1 Civil works. 3.2 Fire proofing 3.3 Insulation. 4.0 TECHNICAL REQUIREMENTS 4.1 Mixer shall be designed to meet the duty requirements & performance parameters as

mentioned in the process datasheet. 4.2 Vendor shall explain the principle utilized in the offered design of mixing and how the

specified mixing shall be established at shop/ site. Vendor shall submit reference list of similar past installations (Indicating duty performance specified/ achieved) operating with similar duty/Capacity.

4.3 Vendor shall submit design calculations indicating clearly the basic design parameter

considered for sizing of the equipment together with all supporting literature, catalogues etc.

4.4 The shell thickness selection shall be based on design calculations considering all loads

for erection/ operating/ hydro test conditions. 4.5 Vendor to ensure maximum allowable pressure drop as required in Data Sheet. 4.6 All KCS parts to be post weld heat treated. The hardness in KCS welds not to be exceed

200BHN. KCS material shall be HIC tested. 4.7 All mixer are subjected to steam out condition as required in Data Sheet. 4.8 MOC of bolting for attachment of internals shall be same as MOC of internals. 4.9 Inlet & outlet end connections connecting to mixers are as per Data Sheet.

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FOR STATIC MIXER

5.0 DEVIATION SCHEDULE

Bidder to note that no deviation from this specification is acceptable. However in case it becomes unavoidable, bidder shall furnish the clause wise deviations in enclosed format. No cognizance shall be taken of any deviations other than those furnished in deviation schedule.

6.0 INSPECTION AND TESTING 6.1 Stage wise inspection and Final inspection. Stage wise inspection can be done in house

by the vendor approved quality plan. However Final inspection shall be done by third party inspection agency.

6.2 Vendor shall engage third party inspection agency and Name of the proposed third party

inspection agency shall be furnished in the bid proposal. 6.3 Any or all the tests, at TPKTI/Purchaser’s option may be witnessed by TPKTI /

Purchaser. However, such inspection shall be regarded as check up and in no way absolve the bidder of his responsibility.

7.0 PACKAGING AND IDENTIFICATION 7.1 All the materials shall be thoroughly packed and dispatched. Static Mixer shall be purged

& filled with dry N2. All requisite blind flanges, gaskets, fasteners, pressure gauge shall be supplied by vendor.

7.2 Attachments, spare parts of the equipment and small items shall be packed separately in wooden cases. Each item shall be appropriately tagged with identification of main equipment, item denomination and reference number of the respective assembly drawing.

7.3 Detailed packing list in waterproof envelope shall be inserted in the package together with equipment. 7.4 Any damage during shipment shall be taken care by the vendor with fresh material at his own cost. 8.0 TRANSPORTATION

After inspection & testing at vendor’s shop, Mixer shall be packed in seaworthy & transported to site as per clause 7.0 above. Proper care shall be taken during transportation as required.

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FOR STATIC MIXER

9.0 GUARANTEED WARRANTY Vendor shall provide the Performance and Mechanical guarantee of the Mixer in respect of design, performance, material and workmanship.

10.0 DOCUMENTS REQUIRED WITH BID

• Deviation schedule technical, duly filled in, stamped and signed. • Process and Mechanical Datasheet. • Vendor catalogue. • Itemized list of special tools, tackles, jigs and Fixtures required, if any. • List of recommended spares for installation & commissioning. • Priced List of two years operational spares.

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FOR SUPPORT RING AND BOLTING BARS TRAYS

AND TOWER INTERNALS

SUPPORT RINGS AND BOLTING BARS


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OF SUPPORT RING AND BOLTING BARS FOR TRAYS AND TOWER INTERNALS


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CONTENTS


1.0 SCOPE 4

2.0

REFERENCES 4

3.0

MATERIALS

4

4.0

DIMENSIONS 4

5.0

GENERAL CONSTRUCTION FEATURES 4

6.0

INSPECTION AND ACCEPTANCE

7

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1.0 SCOPE

This specification covers the fabrication and inspection requirements emphasizing the important parameters, which shall be taken into consideration while welding tray supports and bolting bars to the column. The requirements as specified in tray support drawings take precedence over those specified in this specification.

2.0 REFERENCES

Following shall form the reference documents for carrying out the work:

i) Tray Support Ring (TSR) and Bolting Bar (B/Bar) drawings.

ii) Construction Tolerances for Welded Supports for Trays/Tower Internals 3.0 MATERIALS

Unless otherwise specified the materials of TSR and B/Bars, Support Cleats etc. shall be same as that of the column shell (cladding if any). All the materials shall be new, of first quality and of the type & grade as specified on the column drawing and shall meet all the requirements such as NACE, HIC etc. if specified on the column drawings.

4.0 DIMENSIONS

The dimensions as shown on the engineering drawings are final and shall be maintained (in as welded condition) within the tolerances furnished either on the TSR & B/Bar drawings itself or as covered in this specification and General Construction Tolerances Standard No. 7-14-0001. For any deviation, written acceptance shall be obtained from IOCL.

5.0 GENERAL CONSTRUCTION FEATURES 5.1 All support rings, bolting bars, beam support brackets and other components which

are welded to the column shell inside, will be supplied and installed by column fabricator in accordance with details supplied by IOCL.

In case of revamp jobs, the supply and installation shall be as covered in the relevant Project Specification.

5.2 All parts shall be fabricated smooth, true, clean & free from burrs, creases and dents. 5.3 Welding shall be done by qualified and approved welders using suitable fillers and

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fluxes. 5.4 Welding of Support Ring 5.4.1 Carbon Steel Material

Support Rings shall be continuously welded with column shell on top as well as bottom side or as specified in Job Specifications.

5.4.2 Other Nobler Material

In case of SS columns or in case of shell cladding with nobler metallurgy with no CA on column internals (i.e. Incoloy, Monel etc.) support rings shall be provided with continuous welding on top side and stitch weld (25mm @50mm pitch) or continuous welded on bottom side.

5.4.3 No gap shall be left at the joint of bolting bar and the support ring. Refer Figure 5.4.3.1 and Figure 5.4.3.2 below:

FIGURE 5.4.3..1

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FIGURE 5.4.3.2

5.4.4 No welding to be done at the top and edge of support ring and bolting bar joint.

Refer Figure 5.4.4.1 and Figure 5.4.4.2 below:

FIGURE 5.4.4.1 FIGURE 5.4.4.2 5.4.5 Provide seal run weld on top and bottom of support ring at locations wherever support

ring is crossing longitudinal weld on the vessel. No gaps shall be allowed between vessel wall and support ring.

5.4.6 In case the support ring is fabricated out of various pieces, butt weld provided on

support ring shall be ground flushed on top and bottom faces of the ring. 5.4.7 Support Ring Width (W) and minimum Thicknesses (T) shall be as per respective

TSR & B/Bar Drawings furnished by IOCL or the Tray Vendors duly approved by IOCL.

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5.5 Welding of Bolting Bar 5.5.1 Size of the B/Bars shall be as specified in the drawings. These can, however,

be varied/adjusted to achieve the dimensions of various parts within the tolerances as specified in the drawings.

5.5.2 B/Bars wherever crossing circumferential seam of the vessel, shall be provided with

seal run weld. No gap is permitted between vessel wall and bolting bar edge. . 5.5.3 The weld joint between straight and sloping downcomer shall be ground flushed.

Alternately, bolting bar may be bent by making a groove on one side and tack welding on the groove thereafter. Refer Figure 5.5.3.1 below: FIGURE 5.5.3.1

5.5.4 Bolting Bar Width (W) and Thicknesses (T) shall be as per respective TSR & B/Bar

Drawings furnished by IOCL or the Tray Vendors duly approved by IOCL 6.0 INSPECTION AND ACCEPTANCE 6.1 Correct location and fixing of tray support rings/bolting bars and the

support cleats are extremely important for smooth installation of the trays and internals at the site. It is absolutely necessary that careful inspection of the supports welded to the shell is done in the shop floor in order to avoid unnecessary delays and inconvenience during the installation of trays and internals inside the column at site.

It is the responsibility of the vessel fabricator to ensure that all the supports are welded as per drawing/standards/specification and 100 percent checked by the fabricator's inspection department before offering the same for inspection by Owner's representative/nominated inspection authority. Records of fabrication and quality check shall be maintained by the vessel fabricator duly counter checked by Owner's representative/authorized inspection authority.

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PAGE 1 OF 9


GUARD FOR MACHINERY

GUARD FOR MACHINERY

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GUARD FOR MACHINERY



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GUARD FOR MACHINERY

CONTENTS

CLAUSE NO DESCRIPTION PAGE NO 1 SCOPE 4 2 PURPOSE OF THE GAURD 4 3 BASIC DESIGN 4 4 FORMS OF GAURDS 7 5 TYPICAL FORMS OF

GAURDS 8

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GUARD FOR MACHINERY

1. SCOPE

This Specification covers the minimum requirements for the methods of safeguarding of dangerous i.e. exposed moving parts of machinery and indicates the criteria to be observed in the design, construction and application of such safeguards.

2. PURPOSE OF THE GUARD

The guard shall provide an adequate enclosure for the coupling, flywheel, shafting, belt drive, piston rod or any other exposed moving parts, to ensure the safety of all personnel whilst at work around the machinery.

3. BASIC DESIGN

3.1 Construction

The guard(s) shall comply with the following:-

3.1.1 Securely fixed in position when the machinery is operable and removable, only with the aid of a tool. The guard shall be readily removable for inspection and maintenance without disturbing the machine(s).

3.1.2 Rigid to withstand a 100 Kg static point load or force in any direction

without permanent deflection and a maximum elastic deflection of less than 0.25 of the minimum design clearance between stationary and moving parts.

3.1.3 For outdoor installation, guards shall provide weather protection for the

moving parts.

3.1.4 Weatherproof V-belt drive guards shall be ventilated and provided with weatherproof access door(s) to allow inspection of the belts.

3.1.5 A guard covering a component such as a shaft seal from which a

dangerous spray could occur shall not be made from perforated material. 3.1.6 Each coupling shall have a coupling guard that sufficiently encloses the

coupling and shafts to prevent any personnel from accessing the danger zone during operation of the equipment train.

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GUARD FOR MACHINERY

3.1.7 Guards for couplings at intermediate and high speed for centrifugal compressors, turbines, gears and so forth, shall be of the complete enclosure type (Fig. 2), axially split, with provision at each end for connection to the coupled equipment. If a slip joint is required for thermal expansion purposes, the joint shall be provided with two O-rings. Alternatively expansion may be accommodated by using a flexible diaphragm. The guards shall be oil-tight (maintaining oil-tight integrity for at least a 5-year period of operation), and essentially air-tight at the radial and axial flanged joints and at the slip joint. Sealing compounds shall not be used at the slip joint. A baffled vent connection 2 inch (51mm) or larger, complete with a threaded filter-breather shall be supplied. The guards shall also be fitted with a 1 inch (25mm) or larger connection, complete with a steel plug, for purging with dry air or an inert gas. (This is necessary when unusual corrosive conditions exist). Each guard shall also be provided with a flanged oil drain connection 2 inch (51mm) or larger, piped up to the drain manifold.

Guards for flexible-disc couplings shall be designed to minimise the potential heating caused by windage. For couplings with electronic devices, the temperature inside the guard shall not exceed the permissible level for the electronic device or electric wiring. An example of this case is a coupling guard containing instrumentation such as torque-meter.

3.1.8 Guards for flexible-disc couplings shall be designed to minimise the potential heating caused by windage.

3.1.9 Guards shall be electrically bonded to the machine structure to prevent

static charge build up. 3.1.10 The guard shall contain anti-swirl baffles to reduce the effects of windage oil swirl, as required.

3.1.11 Unless otherwise specified, the contract guard shall be used when the contract coupling is factory tested with the driver and driven equipment. 3.1.12 Coupling guard drawings shall be reviewed by both the driver and driven equipment Vendors before submitted to IOCL.

3.2 Support

The guard shall be securely attached to the baseplate, a fixed support or adjacent fixed parts of the machinery.

If adapting flanges are required to mate the guard to the associated components of the equipment train, the prime Vendor shall include them.

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GUARD FOR MACHINERY

3.3 Materials

3.3.1 Guard material shall be suitable for general application or for spark-

resisting service, as specified.

3.3.2 For general applications, the guard shall be constructed from one of the following:

1. Carbon steel

2. Stainless steel

3. Non-ferrous metallic materials.

3.3.3 For spark-resisting service, the guard shall be constructed from either

copper or copper based alloys (e.g. brass, bronze) or aluminium with a maximum magnesium content of 2%. Alternatively steel guards with brass linings/rubbing strips at close clearances are acceptable subject to IOCL’s approval.

Notes

1. Surface coating (e.g. galvanised or plastic) does not render the

guard spark-resisting.

2. Other spark-resisting materials shall not be used without the prior approval by IOCL.

3. Copper or copper bearing alloys shall not be used in an ammonia

polluted atmosphere.

3.3.4 Asbestos shall not be used in any form as a material of construction. 3.3.5 Machinery Guards of woven wire are not acceptable.

3.4 Thickness

The thickness of metal guards shall be not less than 18 BWG (1.24 mm). The thickness of lining material shall be not less than 18 BWG (1.24 mm). Requirements of Para. 5.1.2 Shall be satisfied.

3.5 Clearance

1. The radial clearance between the guards and couplings or shafting

shall be not less than 1 inch (25 mm) (See Fig. 1). (See also Para. 5.1.7).

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GUARD FOR MACHINERY

2. The clearance between the guards and stationary parts shall be not

more than ¼” (6 mm) (See Fig. 1).

3.6 Size of Mesh

On guards of perforated metal, metal lattice, or similar materials the size of opening shall not exceed the following:

Size of Perforation ( mm )

Minimum Distance From Moving part ( mm )

Square or Round Hole Dimension of slotted, Rectangular or Diamond Hole

Less than 6 Less than 6 30 Between 6 and 9 Between 6 and 8 100

Note: The size of the opening shall be small enough to prevent entry by foreign objects that are 10 mm (3/8 inch) or larger in diameter.

3.7 Finish

1. All carbon steel guards shall have protective surface finish all over,

suitable for the environment specified.

2. Guards may be galvanised or painted if such finish is suitable for the environment specified.

4. FORMS OF GUARDS

4.1 The guards shown in Fig. 1, 2 and 3 are illustrations of typical methods of

guarding shafting, couplings and rods and are not intended to depict actual designs.

4.2 In cases where the nearest stationary parts, (such as bearing housings) do

not offer adequate protection, a complete enclosure type of guard shall be provided (Fig. 2).

4.3 In cases of shafting, couplings or rods exposed through openings in

casings, metallic lattice type of guard over the opening shall be provided (Fig. 3).

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GUARD FOR MACHINERY

5. TYPICAL FORMS OF GUARDS

Fig. 1. General form of coupling guard applied to a machine where the bearing housings are near the coupling.

Fig. 2. Coupling guard affording in itself complete protection.

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GUARD FOR MACHINERY

Fig. 3. Guard over shafting or a rod exposed through an opening in casing.

Metallic lattice type guard

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PAGE 1 OF 8 TECHNICAL SPECIFICATIONS FOR

ALLOWABLE NOZZLE LOADS


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CLAUSE NO DESCRIPTION PAGE NO 1 SCOPE 4 2 ALLOWABLE LOADS ON NOZZLES 4

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1.0 SCOPE

This document covers allowable loads on nozzles for Pressure Vessels, Columns and Silencers. These loading are minimum acceptable, EPCC contractor to check the loadings on each process nozzle and necessary calculations shall be made in this regard.

2.0 ALLOWABLE LOADS ON NOZZLES

2.1 Each process nozzle of vessels shall be analyzed for the loads provided in this specification.

2.2 All load combinations given in this standard including internal/external pressure

shall be considered for analysis. Stress categories and limits of stress intensity shall be as per ASME Section VIII Div.2. Allowable stress shall be as per ASME Section VIII Div.1.

2.3 In addition, analysis shall be carried out considering 50% of load combinations

given in this standard without internal/external pressure. But stress shall be limited to one and a half times the allowable stress at temperature. Allowable stress shall be as per ASME Section VIII Div.1.

2.4 Stress calculations shall be carried out as per WRC Bulletin No. 107/297. WRC

107 shall be used for Nozzles on Dished ends and WRC 297 shall be used for

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Nozzles on Cylindrical Shell.

2.5 In case of failure due to WRC, FEM analysis/PD 5500 analysis can be carried out to establish the adequacy of provided configuration.

CARBON STEEL

EQUIPMENTS

CLASS 150 AND CLASS 300

NOZZLE SIZE (NB)

(IN INCHES)

FA (Kgf)

FL (Kgf) FC (Kgf) MT (Kgf-m) ML (Kgf-m)

MC (Kgf-m)

2 13

200 200 50

40

303 2

0300 300 1

190

674 2

7400 400 2

016

1206 4 600 600 4 3 2708 5

4800 800 8

064

48010 6 1000 1000 12

010

75012 8

11200 1200 18

0014

108014 9

41400 1400 24

019

147016 1

01600 1600 32

002 1920

18 12

1800 1800 4050

32

243020 1

32000 2000 50

0040

300024 1

62400 2400 72

005 4320

26 1 2600 2600 840

6 507028 1

82800 2800 98

0078

588030 2

03000 3000 112

090

675032 2

13200 3200 128

001024

768034 2

23400 3400 144

501156

867036 2

43600 3600 162

001296

972038 2 3800 3800 180

01444

1083040 2

74000 4000 200

001600

1200042 2

84200 4200 220

501764

1323044 2

94400 4400 242

001936

1452046 3 4600 4600 264 21 1587048 3

24800 4800 288

002304

1728050 3

35000 5000 312

02500

18750

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52 3 5200 5200 33800

2704

2028054 3

65400 5400 364

02916

2187056 3 5600 5600 392

003136

2352058 3

95800 5800 420

03364

2523060 4 6000 6000 450 36 27000

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CARBON STEEL

EQUIPMENTS

CLASS 600 AND ABOVE

NOZZLE SIZE (NB)

(IN INCHES)

FA (Kgf)

FL (Kgf) FC (Kgf) MT (Kgf-m) ML (Kgf-m)

MC (Kgf-m)

2 16

250 250 62

50

373 2

5375 375 14

011

844 3

3500 500 25

020

1506 5

0750 750 56

245

3378 6

71000 1000 100

080

60010 8

41250 1250 156

212

93712 1

01500 1500 225

018

135014 1

11750 1750 306

224

183716 1

32000 2000 400

032

240018 1

52250 2250 506

240

303720 1

62500 2500 625

050

375024 2

03000 3000 900

072

540026 2

13250 3250 1056

284

633728 2

33500 3500 1225

098

735030 2

53750 3750 1406

21125

843732 2

74000 4000 1600

01280

960034 2

84250 4250 1806

21445

1083736 3

04500 4500 2025

01620

1215038 3

24750 4750 2256

21805

1353740 3

35000 5000 2500

02000

1500042 3

55250 5250 2756

22205

1653744 3

75500 5500 3025

02420

1815046 3

85750 5750 3306

22645

1983748 4

06000 6000 3600

02880

2160050 4

26250 6250 3906

23125

2343752 4

36500 6500 4225

03380

2535054 4

56750 6750 4556

23645

2733756 4 7000 7000 4900

03920

2940058 4

87250 7250 5256

24205

3153760 5 7500 7500 5625 45 33750

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STAINLESS STEEL EQUIPMENTS

ALL CLASSES

NOZZLE SIZE (NB) (IN INCHES)

FA (Kgf) FL (Kgf) FC (Kgf) MT (Kgf-m) ML (Kgf-m) MC (Kgf-m)

2 13

200 200 50

40

203 2

0300 300 1

190

454 2

7400 400 2

0160

806 4

0600 600 4

5360

1808 5

4800 800 8

0640

32010 6 1000 1000 12

0100

0500

12 81

1200 1200 1800

1440

72014 9

41400 1400 24

50196

0980

16 10

1600 1600 3200

2560

128018 1

21800 1800 40

50324

01620

20 13

2000 2000 5000

4000

200024 1

62400 2400 72

00576

02880

26 17

2600 2600 8450

6760

338028 1

82800 2800 98

00784

03920

30 20

3000 3000 11250

9000

450032 2

13200 3200 128

001024

05120

34 22

3400 3400 14450

11560

578036 2

43600 3600 162

001296

06480

38 25

3800 3800 18050

14440

722040 2

74000 4000 200

001600

08000

42 28

4200 4200 2200

17640

882044 2

94400 4400 242

001936

09680

46 31

4600 4600 26450

21160

1058048 3

24800 4800 288

002304

011520

50 33

5000 5000 31250

25000

1250052 3

55200 5200 338

002704

013520

54 36

5400 5400 36450

29160

1458056 3 5600 5600 392

003136

015680

58 39

5800 5800 42050

33640

1682060 4 6000 6000 450 3600 18000

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FOR EJECTOR

EJECTORS

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FOR EJECTOR

CONTENT


1.0 SCOPE 4

2.0 REFERENCES 4

3.0 DESIGN 4

4.0 DRAWING/DOCUMENTS FOR

APPROVAL

5

5.0 CONTRADICTORY REQUIREMENTS 6

6.0 DEVIATIONS 6

7.0 MATERLAL SPECIFICATION & SUPPLY 7

8.0 MANDATORY SPARES 8

9.0 FABRICATION 8

10.0 TOLERANCES/FINISH 10

11.0 GENERAL NOTES FOR DRAWINGS 10

12.0 RADIOGRAPHY AND OTHER NDT

REQUIREMENTS

11

13.0 HEAT TREATMENT 11

14.0 INSPECTION AND TESTING 11

15.0 DATA FOLDER 12

16.0 PROTECTION AND DESPATCH 12

17.0 GUARANTEES 13

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1.0 SCOPE

This specification covers the general requirements for Thermal and Mechanical design, fabrication, materials, workmanship, inspection, testing and supply of Ejectors. In case of conflict between general requirements, standards and codes, which is stricter shall govern and shall be referred to IOCL/TPIA for clarification before job execution.

2.0 REFERENCES

2.1 The following codes in their latest edition shall form the basis of design, materials selection, manufacture, testing and acceptance of equipment and all their requirements shall be complied with.

a. HEI standards for Steam Jet Ejectors

b. ASME B31.3 Petroleum Refinery Piping

c. ASME Sec VIII Div. I

d. ASME Sec-II

e. Any other code/specification as listed in the requisition. 3.0 DESIGN 3.1 The ejectors shall be designed and detailed out based on the following documents included in the requisition.

a. Process data sheet of Ejector system.

b. Piping material specifications (PMS)

3.2 The design and detail engineering shall include but not be limited to:

a. Thermal design of Ejectors.

b. Mechanical design of Ejectors.

3.3 The design motive steam pressure at the ejector motive inlet shall be 90% of the minimum steam pressure available at Ejector B/L.

3.4 Noise level shall not exceed 85 DBA at a distance of 1 m from ejector.

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3.5 The ejector shall be designed for corrosion allowance of 3 mm on C.S. parts and no corrosion allowance shall be considered for SS parts unless specified otherwise.

3.6 All data / documents furnished for approval after placement of order shall be reviewed by IOCL/TPIA. If any discrepancy is found in the design data/design basis, the same shall be corrected and modified by vendor without any price & schedule implication.

4.0 DRAWINGS / DOCUMENTS FOR APPROVAL

4.1 The following shall be submitted by vendor for approval:

a. Ejector datasheet.

b. Ejector drawing showing over all dimension and process and motive fluid nozzle sizes and flange ratings.

c. Mechanical Design calculations,

d. Ejector name plate information showing operating and design data.

4.2 All the documents and drawings submitted by vendor shall have been checked by vendor's qualified engineers and marked and signed to that effect without which THESE DOCUMENTS WILL NOT BE REVIEWED/APPROVED. No fabrication shall start prior to approval of these documents and drawings. IOCL/TPIA 's approval of vendor's documents will not relieve vendor of his responsibility in any manner to meet the requirement of purchase order, including process performance.

4.3 Engineering / Fabrication drawings prepared by Vendor shall be drawn to scale in metric system and shall at least cover the following information as detailed below. These shall be submitted in 6 sets for approval.

4.3.1 ASSEMBLY DRAWING

i. Drawing showing exact arrangement of ejector including steam chest, steam nozzle, suction chamber, diffuser and flow direction etc.

ii. Overall outside dimensions of Ejector including nozzle to nozzle distances, projections, flange details, various pressure parts thickness, part no. and side view showing nozzle orientation.

iii. Internal flange /Screw detail of steam nozzle connection.

iv. Tolerances on dimensions.

v. Name plate location and details.

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vi. Operating and Design data covering the followings: a. Applicable codes b. Design pressure and temperatures c. Hydro test pressures ( Suction chamber / diffuser and Motive fluid side) d. Corrosion allowances, heat treatment and radiography e. Operating pressures - suction, motive, discharge f. Operating temperature - suction, motive, discharge g. Suction fluid details with mol. wt. and flow in kg/hr. h. Motive fluid and its flow in kg/hr. i. Pressure/temperature at which motive steam is supplied (min./nor/max) k. Insulation (if any) with thickness and total area covered. i. Weights - empty and full of water m. Inspection.

vi. Nozzle Schedule Data showing list of nozzles, their size, ANSI class, pipe schedule, type of finish, reinforcement pad details, piping class, etc.( odd sizes like 2 1/2", 3 1/2", 5" shall not be used unless specifically asked for)

vii. Bill of material, listing exact material specification for flanges, nozzle pipes, steam nozzles, suction chamber, diffuser etc. The material specification for studs/nuts and gaskets shall also indicate size and quantity with spares.

viii The title of drawing shall include clients Tag/Item No., PR No., quantity, client's name and address, consultant's name, order no., plant name, place of fabrication.

ix. General notes as per Cl. 11.0

x. Reference drawings/standards/specification

xi. All weld details.

5.0 CONTRADICTORY REQUIREMENTS

In case of any contradiction between the various requirements of the requisition, the one which is stricter shall govern and shall be referred to IOCL/TPIA for clarification. IOCL/TPIA decision in such cases shall be binding for vendor.

6.0 DEVIATIONS

If there is any deviations from the requisition, these should be brought out specifically under heading "DEVIATIONS" at the time of quotation. Any deviation not covered in this heading and mentioned elsewhere in the offer shall not be considered. If nothing is mentioned in the offer it shall be presumed that vendor confirms to comply with the

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requirements without any deviation. After placement of order no such request for deviation shall be entertained.

7.0 MATERIAL SPECIFICATION & SUPPLY

7.1 All the materials and accessories required for the fabrication and testing shall be supplied by the Vendor. The materials shall conform to ASME Sec. II and in addition shall meet the requirements listed/enclosed with the requisition. The materials shall be new, of first quality and of the type and grade specified on individual equipment drawing/data sheets. All materials shall be accompanied by Mill test certificates, certified by reputed Inspection Agency.

7.2 Carbon content in plates, pipes, forgings etc. shall not exceed 0.23%. All carbon steel material shall be killed CS.

7.3.1 C.S. materials for ejector in general shall mean, if not specified in the data sheet, the following: -

Plates SA 516 Gr 70 (in normalized condition)

Pipes SA106GrB

Forgings SA 105

Non std. Forgings SA 266 Gr 4

Castings S A 216 Gr WCB (for Ejector parts only)

Studs/ nuts SA 193 Gr B7 / Gr. 2H

Gaskets IJA. (for Ejector internals and others as per piping

material specifications )

Fittings SA234GrWPB

Steam nozzles SS316Ti

Studs/nuts SA 193 GrB8 / SA194 Gr8 (for Ejector Internal flange)

7.3.2 Where the service dictates, on account of corrosion requirements, the use of other materials, may be required. This may be clearly reflected in the offer.

7.4 All non pressure parts welded to pressure parts shall be of boiler quality, if specified in the data sheet.

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7.5 FLANGES

All nozzle flanges shall be forged weld neck as per ASME B 16.5 upto 24" NB size and as per ASME B 16.47 series B above 24" size. The ASME class and finish shall be as per piping material specification for piping classes as listed on P & ID or in datasheet.

7.7 NAME PLATE

A suitable S.S. name plate shall be supplied by Vendor for each ejector. These shall be welded/riveted to name plate bracket.

8.0 MANDATORY SPARES

Following mandatory spares shall be supplied by Vendor in addition to commissioning / /testing gaskets:

FOR EJECTORS :

a. Steam nozzle for ejectors 100% for Each Ejector

b. Gaskets 400% for each flanged Joint

c. Bolting 20% but not less than 4 studs with 8 nuts for each flanged joint

FOR CONDENSERS

a. Gaskets 400% for each flanged Joint

b. Bolting 20% but not less than 4 studs with 8 nuts for each flanged joint

9.0 FABRICATION

9.1 Rolling of plates shall be only in longitudinal direction of the plates. This shall be clearly marked on the plate.

9.2 Rerolling after welding is not recommended except when allowed by Inspector in writing, in which case all welds on the rerolled sections shall be ground flush. After rerolling all welds must be dye checked.

9.3 WELDING

All welding procedures shall be submitted to Purchaser and/or its authorized Inspection

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Agency for approval giving all relevant details. Welding qualification records shall indicate hardness values of weld metal, HAZ and parent metal and also results of impact tests when design temperatures are 0 deg C or lower or when specifically asked. No welding shall be undertaken unless welding procedure and welder's qualification have been approved by IOCL/TPIA. All welding procedures and welders shall be qualified for the particular type of welding and material in accordance with ASME Section IX. Fabricator shall be responsible for the quality of welds performed. All welding shall be done by TIG / electric fusion shielded arc or submerged arc welding.

9.4 Pressure holding seams, nozzle attachments and similar joints shall be full penetration, double side welded butt joints. Roots of single side welds shall be done with TIG welding and with Argon gas purge.

All internal welds on the ejectors shall be ground flush from inside to desired finish. 9.5 Longitudinal seams shall be staggered with a minimum circumferential distance

between centers of welds of 5 times the thickness of thicker plate. Weld seams shall be so located as to avoid connections and external attachments.

9.6 All welding shall be done with electrodes, fillers and fluxes of reputed make with reproducibility of results. Brand names shall be specifically approved by IOCL/TPIA's authorized agency. For carbon steel pressure parts, the electrodes shall be of low hydrogen type.

9.7 Nozzle reinforcement pads shall be provided with two 1/8" NPT tapped holes located 180 deg apart for air- soap solution test. This test shall also be carried out on ring type flanges at pressure of 1.25 kg/cm2g, These holes shall be plugged with heavy grease only.

9.8 All inch bolting and threading shall conform to ANSI B.1.1 except for size 1” and above it shall be 8 threads per inch. Metric bolting/threading shall conform to ISO- R261 except for sizes M24 and above, where it shall have pitch of 3 mm. Studs shall extend beyond the nut by 6 to 10 mm and shall be threaded full length. Threads on external bolting, plugs etc. shall be lubricated with graphite grease for temperatures upto 200 deg C and with molybdenum disulphide for higher temperatures. All nut seating faces shall be machined or spot faced.

9.9 Jack screws shall be provided to break flanged joints. 9.10 Descaling, pickling and passivation shall be done for all stainless steel parts. Fabricator shall supply details of the procedure for approval.

9.11 Gasket shall confirm to ASME B16.20 & ASME B 16.21.

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10.0 TOLERANCES/FINISH

10.1 The dimensional tolerances shall be as per HEI standard.

10.2 Finish in ejectors shall be as under:

As per DIN 314 Microns

Steam nozzle throat/divergent/convergent section 4

Diffuser throat/divergent/ convergent section 10

Others 45

11.0 GENERAL NOTES FOR DRAWINGS

Following notes shall be marked on vendor drawings:

i. All dimensions are finished dimensions and in mm unless otherwise indicated.

ii. Bolt holes on nozzle flanges shall straddle to principal centre lines of equipment.

iii. ‘T’ denotes match mark for assembly and shall be punched on all removable joints for ease of reassembly.

iv. All welds shall be full penetration welds. Single sided welds shall have root run done by TIG with argon purging. All welds accessible from second side shall be chipped / gauged back to sound metal before welding from second side.

v. All fillet and other welds which, are not being radiographed shall be checked by DP/MP test.

vi. All fillet welds shall be continuous unless specified otherwise.

vii. All internal welds shall be ground flush.

viii All edges and corners shall be deburred and inside corners of nozzle pipes shall be rounded off.

ix All weld neck flanges shall be bored to suit pipe ID.

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12.0 RADIOGRAPHY AND OTHER NOT REQUIREMENTS

12.1 Minimum extent of radiography shall be spot. Spot radiography shall mean that at least 10% of total welded length shall be radiographed. Length of each radiograph shall be 250 mm. Further all "TEE" joints shall be radiographed and at least one sheet shall be taken on each longitudinal and circumferential seam. Inspector shall mark the areas to be radiographed. Acceptance standard for radiography shall be as per ASME Sec VIII Div. I.

12.2 All fillet or other welds shall be continuous. The welds which are not being radiographed shall be tested by dye penetrate/magnetic particle method.

13.0 HEAT TREATMENT

Heat treatment as specified shall be done when required by relevant specifications/drawings/codes etc. No welding or heating is permitted after heat treatment. All machining operations shall be carried out after heat treatment. It shall be the responsibility of Vendor to leave sufficient allowance for this purpose.


14.1 INSPECTION

The inspection shall be carried out by owner's authorized representative, here-in-after referred to as authorized inspector. Stage wise inspection shall be carried out as under:

i) Identification of materials and verification of test certificates.

ii) Overall dimensional checks as per approved fabrication drawings.

iii) Performance testing.

iv) Certification and issue of release note.

Ejector item number shall be punched on suction and discharge nozzle flanges and on steam chest flange through which steam chest is bolted with ejector body.

The ejectors shall be open to inspection by authorized inspector. The presence of inspector, however, shall not modify or reduce the obligation of Vendor/ sub-vendor to carry out his own tests, inspection and quality control.

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14.2 TESTING

The motive chest, diffuser, suction nozzle etc shall be hydrotested as per code at vendor's shop. All shop tests, and performance tests shall be carried out in presence of client/Client's representative.

During hydrotest, the indicating gauge shall be connected to the uppermost part of the equipment. Testing water shall be clean portable water. Sea water shall not be used. For SS equipment water used for this test shall not contain more than 25 ppm chloride. Final hydrotest shall be carried out using service gaskets and ejectors shall be dispatched in as tested condition. Test pressure shall be maintained for at least one hour.

14.3 PERFORMANCE TEST

Design/performance and testing of ejectors shall confirm to HEI standard for steam Jet Ejectors.

Performance test shall be conducted at site by vendor. All necessary test nozzles, instruments, gaskets, tools and tackles etc. required for conducting the above test are to be arranged by vendor.

All testing accessories such as Gauges, valves, fittings orifices, supports, blind flanges, gaskets, pumps, seals etc. shall be provided by Vendor for hydrotest and performance test of the ejector at vendor's shop.

15.0 DATA FOLDER

Vendor shall supply six (06) bound copies of data folders containing following information: a) Manufacturer's data report b) As built drawing of ejector showing overall dimensions sizes and part list. c) Material test reports d) Hydrotest / performance test report and record of radiographic examination. d) Copy (rubbing) of name plate

f) Any other documentation as required 16.0 PROTECTION AND DESPATCH

After completion of all testing and inspection, the inside of complete ejectors shall be thoroughly drained out. Ejector shall be completely dried by passing hot air for sufficient time until no further increase in relative humidity of outgoing air is observed. After drying, the equipment shall be purged and filled with dry N2 at 0.25 Kg/cm2. The equipment shall be provided with pressure gauge to monitor N2 pressure, and ½”

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NRV. Flange faces shall be covered by a suitable rust preventing easily removable oil grease and protected by temporary steel covers. Threaded holes shall be suitably protected with bar plugs.

Carbon steel external surfaces other than flange faces and other machined surfaces shall be given one coat of Inorganic zinc silicate primer. The surfaces, before paint, shall be prepared to near white finish as per SA21/2. The shop primer shall be Inorganic zinc silicate @65-75 microns DFT, unless stated otherwise. The finish paint shall be 2 coats of heat resistant synthetic medium based aluminium paint @ 20 microns DFT/Coat

Ejector number, P.O. number and owner's name / address shall be painted in bold white paint letters written with stencil on the ejector body.

No ejector shall be released for shipment unless it has been approved by client's authorized inspector. These shall be suitably protected and packed to avoid any damage in transportation.

17.0 GUARANTEE

The supplier shall be completely responsible and shall guarantee that equipment furnished is free from fault in design, material, workmanship, and is in conformity with process requirement to fulfill satisfactorily the conditions and to give the performance as specified. Should any defect in design, material and workmanship develop before or during the guarantee period, the vendor shall make all necessary alterations, repairs or replacement of defective equipment without any cost and time implication. If the defect or failure to function cannot be corrected, the supplier shall promptly replace free of charge, said equipment.

IOCL/TPIA inspection or approval of suppliers design/ drawings at any stage will in no way absolve vendor or lessen his responsibility.

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PRESSURE VESSELS

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CONTENTS

SL. NO. DESCRIPTION PAGE NO. 1.0 SCOPE 4 2.0 CODES, SPECIFICATIONS AND REGULATIONS 4 3.0 DESIGN BASIS 5 4.0 MATERIALS 7

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1.0 SCOPE 1.1 This specification covers g e n e r a l r e q u i r e m e n t s for material, design,

f a b r i c a t i o n , erection a n d testing of pressure vessels.

1.2 Vessel S i z i n g /Design shall b e in vendor’s scope u n l e s s o t h e r w i s e specified. Vendor s h a l l submit all design parameters of vessels as per Annexure-H.

2.0 CODES, SPECIFICATIONS AND REGULATIONS

2.1 Design Codes

a) Vessels with design pressure 1.0 Kg/Cm2 (g) and less than 210

Kg/cm2 (g) shall be designed, fabricated, inspected and tested as per ASME Code Sec. VIII Div.1. (Latest)

b) All v e s s e l s with design pressure 210 K g /cm2 (g) shall be designed,

fabricated, inspected and tested as per ASME Code Sec. VIII Div.2. (latest)

c) Vessels full of liquid and/or with design pressure < 1.0 Kg/cm2(g) shall

be designed, fabricated, inspected and tested as per ASME Code Sec. VIII Div.1 - Practice.

d) Mechanical design of self-supporting tall column shall be carried out as per

guidelines given in Annexure-IV.

2.2 Material Specifications,

Materials to be used shall conform to

a) ASME Section II.

b) Indian Standard Specification of equivalent grade.

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2.3 Statutory Regulations

a) National laws & regulations together with local bye-laws for the country or state where vessel(s) is (are) to be erected must be complied with. Approval of design and drawings from statutory authorities shall be Vendor's responsibility.

b) Wind and earthquake loads shall be calculated in accordance with

relevant Indian Standards unless otherwise specified. 3.0 DESIGN BASIS

3.1 Minimum Wall Thickness

Vessel shell and heads shall have minimum wall thicknesses calculated with design pressure and temperature, in accordance with codes, but in no case, shall the thickness be less than that determined by following formulas:

a) For carbon and low alloy steel vessels - 6mm (Including corrosion

allowance not exceeding 3.0 mm), but not less than that calculated as per following:

FOR DIAMETERS LESS THAN 2400 mm

Wall thickness= Dia./1000 + 1.5 + Corrosion Allowance

FOR DIAMETERS 2400 mm AND ABOVE

Wall thickness= Dia./ 1000 + 2.5 +Corrosion Allowance

All dimensions are in mm.

b) For stainless steel vessels and high alloy steel vessels - 3 mm, but not

less than that calculated as per following for diameter more than 1500mm.

Wall thickness (mm) = Dia./ 1000+ 2.5 Corrosion allowance, if any, shall be added to minimum thickness.

c) If the vessel height (H) from base of skirt to top tangent line is greater

than 5 times diameter (D) then vessel shall be considered as column

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and shall be designed accordingly.

d) For carbon and low alloy steel columns/towers- 8mm (including corrosion allowance not exceeding 3.0 mm)

e) For stainless steel and high alloy steel

columns/towers- 5 mm.

Corrosion allowance, if any, shall be added to minimum thickness. "

3.2 Design Pressure

Design pressure shall be calculated as per the following unless otherwise specified elsewhere in the package:

a) When operating pressure is upto 70 Kg/cm2 (g) the design pressure shall

be equal to maximum operating pressure at top of vessel or highest point in vessel plus 10% (minimum of 1.0 Kg/cm2) more than operating pressure.

When operating pressure is over 70 Kg/cm2

(g), the design pressure shall

be equal to operating pressure plus 5% (minimum 7 Kg/cm2).

b) Design pressure at any lower point is to be determined by adding the maximum operating liquid head and any gradient within the vessel.

c) Vessel operating under vacuum (or partial vacuum) shall be designed for

differential external pressure of 1.055 Kg/cm2•

3.3 Design Temperature

Design temperature shall be calculated as per the following unless otherwise specified elsewhere in the package:

a) For vessels operating at 0° C and over, the design temperature shall

be operating temperature plus 15° C. However design temperature shall not be less than 65° C.

b) For vessel operating below 0° C, design temperature shall be

lowest operating temperature.

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c) Minimum Design Metal Temperature (MDMT) shall be lower of minimum atmospheric temperature and minimum temperature envisaged during operation.

3.4 Corrosion Allowance

Minimum corrosion allowance for carbon steel vessels shall be 3.0 mm unless otherwise specified elsewhere in the package.

3.5 Allowable Stresses

3.5.1 Basic allowable stresses for s h e l l , heads a n d o t h e r components etc.

Shall be the v a l u e s specified in the design code.

3.5.2 The allowable stresses for structural members and anchor bo l ts shall be as specified in Indian Standard IS:800.

3.6 Wind and Seismic Loads

3.6.1 Wind load shall be calculated as per Indian Standard IS 875 site specific wind

data if attached with the bid package. ·

3.6.2 Earthquake forces shall be calculated in accordance with Indian Standard I S : 1893 or it shall be based on meteorological and seismic data of the site, if attached with the bid package.

4.0 MATERIALS

Materials of various parts of equipment shall be selected a s per Table given in Annexure – III for general industrial condition/services.

4.1 Specifications of Carbon Steel Plates

4.1.1 Chemical Analysis

Plates used shall conform t o latest issue of specification SA-20 w i th additional requirements mentioned herein.

a) Only normal ized plates free from injurious defects w i t h workman like

finish shall be used. Reconditioning/repair of plates by welding shall not

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be permitted.

b) One product analysis of each heat shall be carried out and reported. Chemical analysis shall be as per applicable specifications with carbon content not exceeding 0.23%.

I

Additionally, one o f following requirements for carbon equivalents (Ceq) based on heat analysis shall be satisfied.

Ceq = C + Mn/6 0.42 ...(1)

Ceq = C + Mn/6+ (Cr + Mo + V)/5+(Cu+Ni)/15 0.43 ...(2)

Equation -(1) shall be used when applicable material specify C and Mn only.

Equation-(2) is applicable f o r restricted chemistry r e q u i r e m e n t s or for supplementary requirements of S19 & S21 of specification SA-20.

4.1.2 Ultrasonic Examinations of Plates

a) Plates having thickness 16 mm to 50 mm (both inclusive) shall be examined ultrasonically as per specification SA-435.

b) For thickness above 50 mm, ultrasonic examinations shall be carried

out as per specification SA-578 and shall have acceptance standard of level-B.

c) For quenched and tempered steel plates, ultrasonic examination shall be

carried out after the specified heat treatment.

4.1.4 Charpy V-notch impact testing as per S5 of specification SA-20 to be carried out at design temperature for low temperature services.

4.1.5 Plates needed for IBR vessels shall meet the requirements of IBR(Indian Boiler Regulations).

4.1.6 Plates above 50 mm in thickness shall meet following additional requirements.

a) Vacuum treatment as per supplementary requirement S1 of specification SA-20.

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b) Charpy V-notch test as per the supplementary requirement S5 of

specification SA-20. c) Material meant to be used for design temperature

warmer than 0° C.

Test temperature minus 29° C.

Acceptance Criteria - As per Table A 2.15 of specification SA-20. Orientation

of test bar Transverse to the direction of rolling.

d) Simulated heat treatment of mechanical test coupon as per clause 4.1.3 of this specification.

4.2 Specification of Stainless Steel Plates/Pipe/Forging

Plates used shall conform to latest issue of specification SA-480 with additional requirements mentioned herein.

a) All plates shall be hot rolled, annealed, pickled and shall have No.1 finish

on both sides with reference to specification SA-480. In addition, all stabilized grade of SS (SS 321, SS 347 etc.) shall be given stabilization heat treatment.

b) Unless otherwise specified plates, pipes, forgings and fittings representative

of each heat shall be subjected to inter granular corrosion tests as per ASTM A 262 practice E.

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BASKET FILTERS

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CONTENTS

SL. NO. DESCRIPTION PAGE NO. 1.0 GENERAL 4 2.0 CODES AND STANDARDS 4 3.0 TECHNICAL REQUIREMENTS 5 4.0 INSPECTION AND TESTING 8 5.0 PROTECTION AND PAINTING 9 6.0 PACKAGING AND IDENTIFICATION 10 7.0 SPARE PARTS 11

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1.0 GENERAL This specification outlines the minimum requirements for the design,

manufacture, testing and supply of Basket Filters. 2.0 CODES AND STANDARDS 2.1 Latest editions of following codes & standards shall be followed.

ASME SEC.VIII DIV. 1 Boiler and Pressure Vessel

Code. ASME SEC. IX Welding and Brazing

Qualifications. ASME SEC. II & ASTM Material Specifications.

ANSI B 16.5 Pipe Flanges & Pipe Fittings.

ANSI B 16.11 Forged Steel Fittings Socket Welded&Threaded

ANSI B 36.10 Welding & Seamless

Wrought Steel Pipe. ANSI B 16.47 Large Diameter Steel

Flanges

Standards on Vessel Tolerance ; Skirt Base Details; Angle Leg Support; Pipe leg

support; Nozzle Reinforcement & Projection; Fire-Proofing & Insulation supports

Earthing Lug

Other international standards may be acceptable subject to their being equivalent or superior with prior approval of purchaser.

2.2 For provision not covered by the above codes and standards, applicable engineering

practices and norms shall govern.

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3.0 TECHNICAL REQUIREMENTS 3.1 The mesh size selected shall meet the particle retention/removal specifications. The

pressure drop across the filter shall not exceed the value specified. 3.2 Free area of basket shall be minimum 8 times of the inlet nozzle area. Gross area

shall be calculated based on the required free area and the % free area, and it shall not be less than 20 times of the inlet nozzle area. Bidder shall furnish calculations for the actual gross/free area of basket. Basket shall be of straight cylindrical shape. Both concentric and pleated type baskets shall not be accepted

3.3 Vessel diameter shall be minimum twice the diameter of inlet nozzle. 3.4 Minimum corrosion allowance for carbon steel parts shall be 3.0mm unless

otherwise specified. 3.5 For vessel in stainless steel construction, lower allowable stress values mentioned in ASME code shall be considered. 3.6 Vessel shell and heads shall have minimum wall thicknesses calculated with design

pressure and temperature, in accordance with codes, but is no case, shall the thickness be less than that determined by following formulas:

a) For carbon and low alloy steel vessels-6mm (Including corrosion allowance not exceeding 3.0mm), but not less than that calculated as per following:

For diameter less than 2400mm Wall thickness = Dia. 1000 + 1.5 + Corrosion Allowance

For diameters 2400mm and above Wall thickness = Dia.1000 + 2.5 + Corrosion Allowance

All dimensions are in mm.

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b) For stainless steel vessels and high alloy vessels - 3mm, but not less than that calculated as per following for diameter more than 1500 mm

Wall thickness (mm) = Dia. 1000+ 2.5 Corrosion allowance, if any, shall be added to minimum thickness

c) If the vessel height (H) from base of skirt to top tangent line is greater than 5 times diameter(D) then vessel shall be considered as column and shall be designed accordingly.

3.7 Fabrication tolerances shall be as per IOCL standard or equivalent shall be adhered to.

3.8 Filter-Vessel 3.8.1 Vessels of diameters 300 NB and below shall be made from seamless pipe only. For

bigger diameters, the shell shall be fabricated by rolling the plates and specified radiography and applicable welding procedures shall be followed. The rolling direction for making shell shall be lengthwise.

3.8.2 In case the vendor's fabrication shop is not approved for the thickness of vessel involved, the vendor shall either (i) get the vessel fabricated by any other IOCL/PMC approved vendor or (ii) get the vessel rolled by one of the IOCL/PMC approved vendor and get the fabrication done at his own shop, subject to welding procedure qualification.

3.8.3 Dished ends shall be of seamless construction, torispherical or 2:1 ellipsoidal type and

shall be heat treated after forming as per ASME Sec. VIII Div .1. 3.8.4 Full vessel dia size shell flange shall be provided for removal of basket. The

matching cover shall be a forged blind flange. Suitable number of dowel pins shall be provided for proper location of the cover. The standard stud bolt and nut arrangement shall be provided for the cover unless specified otherwise. The cover weighing more than 15 kg shall be provided with lifting davit .

3.8.5 The calculations for vessel supports as per ASME shall be submitted for purchaser's

approval. Alternatively, IOCL/PMC standards may be followed corresponding to the type of supports provided.

3.8.6 Suitable baffle plates shall be provided in the vessel for proper fluid flow

distribution. 3.8.7 Filter vessel shall be provided with suitable lifting lugs and earthing lugs.

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3.8.8 All internal nuts and bolts shall be of stainless steel irrespective of material of

construction. 3.8.9 Drain and vent connections shall be provided with matching blind cover flanges

alongwith necessary gaskets, nuts and bolts.

3.9 Nozzles 3.9.1 All nozzles/pipes on the vessel shall be of seamless construction. 3.9.2 All nozzles upto 50 NB size shall be provided with 2 number of 40mm wide x 6mm

thick stiffeners at 900 to each other. 3.9.3 The nozzles shall be provided with reinforcement pads when required by the

applicable code/standard. The calculations for reinforcement pads as per ASME shall be submitted for purchaser's approval.

3.10 Flanges 3.10.1 All flanges shall be as per ANSI B 16.5. Larger flanges not covered by ANSI

B 16.5 shall be as per ANSI B 16.47 (Series B). 3.10.2 The flanges shall be of following types unless specified otherwise:

a) For nozzles 100 NB and below, only weld neck flanges to be used. Slip on flanges may be used for nozzles above 100 NB for class 150 Lbs flange only.

b) All flanges above class 150 Lbs shall be weld neck type.

c) All flanges of class 900 and above shall have gasket surfaces for RTJ.

3.11 Welding Full penetration weld shall be employed for joining pressure parts. Where both sides

are not accessible for welding, root run by tungsten inert gas process or backing strip shall be used to ensure full penetration. Backing strip, if used, shall be

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removed after welding, wherever possible. 3.12 Post Weld Heat Treatment

Vessels shall be post weld heat treated whenever it is required due to service requirement or due to code requirements. Vessels shall be post weld heat treated as a complete unit and no welding shall be permitted once the post weld heat treatment is performed.

3.13 Fire proofing and insulation

Vessels requiring insulation and/or fire proofing shall be provided with supports.


4.1 Equipment shall be subjected to stagewise inspection and testing

at vendor's/subvendor's works by purchaser/its authorised inspection agency. Vendor shall submit Quality Assurance (QA) procedures before commencement of fabrication. Approved QA procedures shall form the basis for equipment inspection.

4.2 Testing at vendor's works shall include the following:

Non destructive tests such as radiography, dye penetration tests. Pressure tests. Any other tests as per data sheets/standards/codes.

4.3 Pressure Testing

All vessels shall be hydrostatically or pneumatically tested as per the code. Necessary precaution shall be taken to guard against the risk of brittle fracture during hydrostatic test. Test water temperature shall not be lower than 15°C plus minimum design metal temperature.

4.4 Radiography/Non-destructive testing 4.4.1 The extent of radiography shall be as specified in the data sheet. In no case shall

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the radiographic examination be less than that specified in the code. However, spot radiography is the minimum requirement for all vessels.

4.4.2 When spot radiography is specified, the following requirements shall supplement the

requirements specified in ASME Section VIII Division I:

i) All T joints shall be radio graphed. ii) Minimum 5% of total weld length excluding T joints shall be radio graphed.

4.4.3 All nozzles fabricated from plate irrespective of thickness of plate shall be 100% radio graphed. 4.4.4 The technique employed and the weld quality achieved shall meet the requirement

of the code. 4.4.5 All nozzle to shell welds (Root and Final run) shall be examined by magnetic

particle/Dye penetrate test.

4.5 Any or all the tests, at purchaser's option, shall be witnessed by purchaser/ authorised inspection agency. However, such inspection shall be regarded as check-up and in no way absolve the vendor of his responsibility


5.1 All exposed carbon steel parts to be painted shall be thoroughly cleaned from inside

and outside to remove scale, rust, dirt and other foreign materials by wire brushing and sand blasting as applicable. Minimum acceptable standard in case of power tool cleaning shall be St.3 and in case of blast cleaning shall be Sa 2 112 as per Swedish standard SIS 0055900.

5.2 Non-ferrous materials, austenitic stainless steels, plastic or plastic coated materials,

insulated surfaces of equipment and pre-painted items shall not be painted. 5.3 Stainless steel surfaces both inside and outside shall be pickled and passivated

5.4 Machined and bearing surfaces shall be protected properly. 5.5 Depending on the environment, following primer and finish coats shall be applied.

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Sl. Environment Description

i) Normal Industrial Primer 2coats of Redoxide Zinc Chromate each 25 micron(min) thick.

Finish coat 2coats of synthec enamel, each 25 micron(min) thick.

ii) Corrosive Industrial Primer 2coats of Epoxy zinc chromate, each 35 micron(min) thick.

Finish coat 2coats of Epoxy high build paint , each 100 micron(min) thick.

iii) Coastal and marine 2coats of high buildchlorinated rubber zinc phosphate, each 50 micron(min) thick.

Finish coat 2coats of Chlorinated rubber paint, each 35 micron(min) thick.

iv) All environment (Temp 80-400C)

Finish 2coats of heat resistant aluminium paint, suitable for specified temp. each 20 micron(min) thick.

Note: All values refer to dry film thickness 5.6 The colour of finish coat shall be intimated to vendor after placement of order

6.0 PACKAGING AND IDENTIFICATION 6.1 All packaging shall be done in such a manner as to reduce the volume. The

equipment shall be dismantled into major components suitable for shipment and shall be properly packed to provide adequate protection during shipment. All assemblies shall be properly match marked for site erection.

6.2 Attachments, spare parts of the equipment and small items shall be packed separately in wooden-cases. Each item shall be appropriately tagged with identification of main equipment, its denomination and reference number of the respective assembly drawing.

6.3 Detailed packing list in water-proof envelope shall be inserted in the package

together with equipment. 6.4 Each equipment shall have an identification plate giving salient equipment data,

make, year of manufacture, equipment number, name of manufacturer etc.

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7.0 SPARE PARTS 7.1 Vendor shall submit his recommended list of spare parts with recommended

quantities and itemised prices for first two years of operation of the equipment. Proper coding and referencing of spare parts shall be done so that later identification with appropriate equipment will be facilitated.

7.2 Recommended spares and their quantities should take into account related



quantities and the itemised prices. The list shall include following commissioning spares as minimum:

i) Gasket Two sets for each installed gasket. ii) Fasteners 10% (minimum two in each size) of installed fasteners.

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Index

SL. NO. ITEM DESCRIPTION DOCUMENT NO. PAGE NO.

1 ORIFICE PLATES RHQ-EC-IN-SP-0001 415

2 VENTURI METERS & NOZZLES RHQ-EC-IN-SP-0002 423

3 ANNUBARS RHQ-EC-IN-SP-0003 432

4 PRESSSURE GAUGES RHQ-EC-IN-SP-0004 440

5 JUNCTION BOXES RHQ-EC-IN-SP-0005 448

6 LEVEL GAUGES RHQ-EC-IN-SP-0006 455

7 TEMPERATURE GAUGES RHQ-EC-IN-SP-0007 463

8 THERMOCOUPLES AND RTDS RHQ-EC-IN-SP-0008 471

9 THERMOWELLS RHQ-EC-IN-SP-0009 479

10 TRANSMITTERS (PT, FT, LT AND TT) RHQ-EC-IN-SP-0010 486

11 CONTROL VALVES RHQ-EC-IN-SP-0011 500

12 ON-OFF VALVES RHQ-EC-IN-SP-0012 523

13 INSTRUMENT VALVE AND ACCESSORIES RHQ-EC-IN-SP-0013 546

14 LEVEL INSTRUMENTS RHQ-EC-IN-SP-0014 555

15 SIGNAL AND CONTROL CABLE RHQ-EC-IN-SP-0015 567

16 THERMOCOUPLE EXTENSION CABLES RHQ-EC-IN-SP-0016 579

17 MASS FLOW METER RHQ-EC-IN-SP-0017 587

18 HEATER TUBE SKIN THERMOCOUPLE RHQ-EC-IN-SP-0018 598

19 ELECTROMAGNETIC FLOWMETER RHQ-EC-IN-SP-0019 606

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ORIFICE PLATES & FLANGES

Orifice Plates and

Flanges

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Contents

Clause No. Description Page No.

1.0 General 3

2.0 Codes & Standards and Abbreviations 4

3.0 Design Requirements 5

4.0 Documentation 6

5.0 Name Plate 7

6.0 Shipping 8

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.

1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of orifice plates and flanges.

1.2 Orifice Plate and Flange assembly shall be supplied in fully assembled condition

1.3 In the event of any conflict between this standard specification, data sheets, statutory regulations, related standards, codes etc., the following order of priority shall govern:

a) Statutory Regulations b) Licensor Requirements (if specified in MR) c) Data Sheets d) Standard Specification e) Codes and Standards

1.4 Enclosed data sheets specify the material for orifice plate and flanges. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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2.0 CODES & STANDARDS AND ABBREVIATIONS

2.1 ASME American Society of Mechanical Engineers.

B 1.20.1 Pipe Threads General purpose (Inch) B 16.5 Pipe Flanges and Flanged Fittings B 16.20 Metallic gaskets for Pipe flanges‐ Ring joint, Spiral wound and jacketed. B 16.36 Orifice Flanges MFC 14M Measurement of Fluid Flow using Small Bore Precision Orifice Meters

2.2 AGA American Gas Association

Report No 3 Orifice metering of natural gas and other related hydrocarbon fluids. Part 1 : General equations and uncertainty guidelines

2.3 EN European Standards

10204 Inspection Documents For Metallic Products

2.4 IBR Indian Boiler Regulation

2.5 ISO International Organisation For Standardisation

5167 (All Parts) Measurement of fluid flows by means of orifice plates, nozzles and venturi tubes inserted in circular cross‐section conduits running full.

5168 Measurement of fluid flow‐estimation of uncertainty of a flow rate

measurement.

2.6 Flow Measurements Engineering Handbook by R.W. Miller

2.7 Principles and Practice of Flow Meter Engineering by L.K.Spink

2.8 Abbreviations:

AARH Arithmetic Average Roughness Height ASTM American Society for Testing and Materials NPT National Pipe Thread

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3.0 DESIGN REQUIREMENTS 3.1 Standardization

The reference conditions for standardized flows shall be: Liquids : 15°C and 760mm Hg Gas/ Vapours: 0°C and 760mm Hg

3.2 Orifice Plates

3.2.1 Orifice Plate shall be of SS316 material as a minimum.

3.2.2 Flow measurement shall generally be by orifice plates, sized and installed in accordance with ISO 5167‐2. The values of 'beta' shall be between 0.3 and 0.7. For high accuracy measurement a Beta ratio of 0.56 is preferred.

3.2.3 The thickness of orifice plates shall be as specified in purchaser's data sheets, as a minimum. However wherever Quadrant edge type of orifice plate is specified, the thickness of the orifice shall be equal to the radius of curvature of the orifice, as a minimum.

3.2.4 The fluid outlet surface of the plate should be flat and smooth and shall not have roughness and scores that can be ascertained by touch or sight.

3.2.5 Orifice plates in oxygen and chlorine service shall be thoroughly degreased using reagents like trichloro‐ethylene or carbon tetrachloride and all connections shall be plugged after degreasing process in order to avoid entrance of grease or oil particles.

3.2.6 General Orifice assemblies having ring‐type joint flanges (RTJ) shall be supplied with a plate‐carrying holder. Even when only the orifice plate has been ordered, vendor shall supply the plate with the holder for use with ring type joint flanges. Plate holder hardness shall meet the requirements specified in the data sheet.

3.3 Orifice Flanges

3.3.1 Orifice flanges shall be to ANSI/ASME B16.36.

3.3.2 Flange bore diameter shall be the same as pipe's internal diameter.

3.3.3 They shall be supplied with two pair of flange taps complete with plugs as a minimum. The tap design shall be in accordance with ISO 5167. The minimum rating shall be 300lb. For pressure classes ≥ 900lb the flange facing shall be RTJ and the orifice plate shall be installed on API carrier ring.

3.3.4 For line sizes < 2” (50 mm) NB: prefabricated meter runs shall be used. The associated orifice shall be installed in a carrier ring utilizing corner taps. The meter run, plate and carrier ring shall be manufactured from 316 stainless steel unless compatibility with the

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flowing medium requires a higher alloy and purchased as an entity. For extremely small flows, integral orifice transmitters shall be used.

3.3.5 Unless otherwise specified, the following shall govern: ‐

a) Threaded end connections shall conform to NPT as per ASME B 1.20.1. b) Flanged end connections shall be as per ASME B 16.5. c) Grooves of the ring type joint flanges shall be octagonal as per ASME B16.20. d) Flange face finish shall be as per ASME B 16.5. The face finish as specified in the

data shall be as follows: 125 AARH : 125 to 250 micro inch AARH 63 AARH : 32 to 63 micro inch AARH

3.3.6 Where flange taps have been specified, the centre lines of the tap‐holes shall be at a distance of 25.4 millimetres from the nearest face of the orifice plate, taking into account the gasket thickness mentioned in the specification sheets.

3.3.7 Where conical entrance type of orifice plates have been specified in purchaser's datasheet, only corner taps shall be offered. Flange taps shall not be permitted.

4.0 DOCUMENTATION

4.1 Post Order Documents to be submitted by the bidder for review/ approval.

DOCUMENTATION REQUIREMENTS

Review/ Approval QUALITY ASSURANCE PLAN (QAP) For Approval PRODUCTION PROGRAMME For Review SIZING CALCULATION For Review INSTRUMENT DATA SHEETS For Approval INST GA / INSTALLATION DRAWINGS For Approval BILL OF MATERIALS INCLUDING SPARES For Review

Note: Schedule of submission of the above documents shall be aligned to meet the delivery requirements.

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4.2 Final documentation consisting of design data, installation manual, operation and maintenance manual etc., submitted by the vendor after placement of purchase order shall include the following, as a minimum;

a) Specification sheet/ Data sheet/ Sizing Sheet for each orifice plate and its accessories.

b) As built drawings for each orifice plate and flanges, providing dimensional details, constructional details and material of construction.

c) Copy of test certificates for all the tests as per MR and Documents along with TPI IRN.

d) Installation procedure for each orifice plate and flanges. e) BOM including spares (if applicable) f) Product Catalogs of Main equipment and accessories/ boughtouts.

Three hard copies in bound format and one soft copy in CD/ DVD of the above shall be submitted as final document.

5.0 NAME PLATE

5.1 Orifice Plates shall be complete with tab handles which shall be marked with the tag number, bore size and Upstream/ downstream side, clearly stamped on the tab handle. Other details as per MR shall also be suitably indicated on the Tab handle

5.2 Each flange shall have following information stamped on it at a visible place:

a) Tag number as per purchaser's data sheets. b) Nominal flange size in inches and rating in pounds. c) Flange material to ASTM specifications.

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6.0 SHIPPING

6.1 All threaded and flanged openings shall be suitably protected to prevent entry of foreign material.

6.2 Pairs of flanges shall be packed separately. Each pair of flanges shall be assembled, inserting a disc of suitable soft material between them, for the protection of gasket bearing surfaces during transport with the stud bolts and nuts slightly tightened. Internal pipe threads shall be fitted and protected by plastic plugs before dispatch.

6.3 Orifice plate holders, ring spacers, and flanges shall be protected with a rust preventer removable by trichloroethylene or petrol.

6.4 Orifice plate shall be packed inside thick polythene bags with suitable protective packing outside. Each plate shall be packed separately.

6.5 All orifice plates in oxygen and chlorine service shall be separately packed along with a certificate indicating 'SUITABLE FOR OXYGEN/CHLORINE SERVICE', as applicable.

6.6 The consignment shall be packed and suitably labelled clearly indicating the following as minimum:

a) Project Name and Location b) PO Number c) Packing List inside consignment (indicating Main equipment Tag nos, Accessories and

Spares as applicable) d) Vendor Name and location of dispatch

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VENTURIS & FLOW NOZZLES

Venturis and

Flow Nozzles

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Contents


1.0 General 3



4.0 Documentation 7

5.0 Name Plate 8

6.0 Shipping 9

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Flow elements (Venturi / Flow Nozzles) along with their accessories.

1.2 Flow elements (Venturi / Flow Nozzles) along with their accessories shall be supplied in fully assembled condition

1.3 In the event of any conflict between this standard specifications, data sheets, statutory regulations, related standards, codes etc., the following order of priority shall govern:


1.4 Enclosed data sheets specify the material for Flow elements (Venturi / Flow Nozzles) along with their accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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B 1.20.1 Pipe Threads General purpose (Inch) B 16.5 Pipe Flanges and Flanged Fittings B 16.20 Metallic gaskets for Pipe flanges‐ Ring joint, Spiral wound and jacketed. B 16.47‐B Large Diameter Steel Flanges




2.4 ISO International Organisation For Standardisation

5167 (All Parts) Measurement of fluid flows by means of orifice plates, nozzles and venturi tubes inserted in circular cross‐section conduits running full.



2.7 Abbreviations:

AARH Arithmetic Average Roughness Height ASTM American Society for Testing and Materials NPT National Pipe Thread DP Differential Pressure

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The reference conditions for standardized flows shall be: Liquids: 15°C and 760mm Hg Gas/ Vapours: 0°C and 760mm Hg

3.2 General Requirements for Flow Elements (Venturis/ Nozzles)

3.2.1 Flow elements shall be designed and fabricated as specified in IS0 5 167 latest edition.

3.2.2 The flow elements shall be sized so that the maximum pressure drop after full recovery shall not exceed the maximum allowable pressure drop indicated in purchaser's data sheet.

3.2.3 Vendor shall follow the proper welding procedures for welding of dissimilar materials.

3.2.4 The flow element shall be suitable for horizontal & vertical mounting and flow direction shall be clearly stamped or cast on the body.

3.2.5 All weld joints shall undergo 100% radiography.

3.2.6 All welding projections inside the pipe shall be flush grinded.

3.2.7 For all flow elements, minimum two pairs of pressure taps shall be provided for purchaser's impulse piping. Orientation of these taps shall be at least 45 degrees from vertical. One set of pressure taps shall be provided with blind flanged plugs for each Flow element.

3.2.8 Flow elements (Venturi/Flow Nozzles) shall have flanged end connections; unless otherwise specified. Weld joints, if any, shall be of radiographic quality. End connection for flanges shall be as per ASME B-16.5 up to 24" size and as per ASME B-16.47-B for sizes greater than or equal to 26".

3.2.9 All flanges shall be weld neck type unless otherwise specified.

3.2.10 Unless otherwise mentioned, end connection details shall be as below: a) Threaded end connections shall be to NPT as per ASME B 1.20.1. b) Flanged end connections shall be as per ASME B 16.5. c) Grooves of ring type joint flanges shall be octagonal as per ASME B 16.20 and

groove finish shall be 63 AARH : 32 to 63 micro inch AARH d) When Flanges are Raised Face (RF) type, the face finish shall be as per ASME

B16.5 and shall be 125 AARH : 125 to 250 micro inch AARH

3.2.11 The material of construction of flow element shall be provided as specified in the respective data sheets.

3.2.12 Meter Sizing: All calculations and units of measurement shall be in metric standard only. Sizing calculations indicating the sizing differential pressure and max pressure loss at all operating flow conditions specified in the purchaser's data sheet as well as at meter maximum shall be submitted.

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3.2.13 The flow elements shall be designed to have minimum measurable DP of 25 mmWC. Accordingly the DP at meter maximum shall be selected and calculated based on the allowable DP indicated in the purchaser's data sheet. The DP below 25 mmWC shall not be considered at operating flow conditions.

3.2.14 Vendor data sheet for each Flow elements (Venturi/ Flow Nozzles), shall also indicate the following:

a) Calculated differential pressure at specified maximum, normal, minimum flow rates. b) Maximum pressure loss through the flow element at maximum flow rate c) Upstream and downstream straight pipe length requirement for installation.

3.2.15 Each flow meter and accessories shall be subjected to successful hydrostatic testing. The hydrostatic test pressure shall be 1.5 times the design pressure.

3.3 Venturi Flow Element

3.3.1 The design, sizing and construction of Venturi Flow element shall conform to IS05167 standard (latest version) and shall be classical, machined, non truncated type unless otherwise specified.

3.3.2 Impulse piping connection for venturi tubes shall be provided with 1/2" NPTF connection, unless otherwise specified in the data sheet.

3.3.3 Venturi tube shall be forged/ cast construction in general. However fabricated construction shall also be acceptable, wherever allowed as per ISO-5167.

3.3.4 Venturi tube shall be provided with Annular chamber/ Piezo-metric Ring. Material of construction of Annular chamber/ Piezo-metric Ring shall be same as material of Venturi tube.

3.3.5 Material of construction of Venturi tube shall be SS316 as a minimum. Material of construction for Throat, Divergent section and Convergent section shall also be SS316 as a minimum. Flanges shall be provided as per the material specified in the datasheet.

3.4 Flow Nozzle

3.4.1 The design, sizing and construction of Flow nozzle shall conform to IS05167 standard (latest version) and shall be ISA 1932 type, unless otherwise specified.

3.4.2 Flow nozzle shall be supplied in spool piece construction with flanged end construction. Nozzle itself shall also be mounted within flanges with similar specification. The spool piece length shall be 5D upstream and 5D downstream.

3.4.3 Material of construction of nozzle shall be SS316 as a minimum. The material of Spool piece and flange shall be considered as per the material indicated in the datasheet.

3.4.4 Impulse piping connection for flow nozzle shall be with 1/2" flanged end connection, unless otherwise specified in the datasheet.

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4.0 DOCUMENTATION






a) Specification sheet/ Data sheet/ Sizing Sheet for each Flow elements (Venturi / Flow Nozzles) along with their accessories.

b) As built drawings for each Flow elements (Venturi / Flow Nozzles) along with their accessories, providing dimensional details, constructional details, tapping orientation, marking for flow direction and material of construction.


d) Installation procedure for each Flow elements (Venturi / Flow Nozzles) along with their accessories.

e) BOM including spares (if applicable) f) Product Catalogs of Main equipment and accessories/ bought‐outs.


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5.0 NAME PLATE

5.1 Flow Nozzle: a) Tag No. as per purchaser's datasheet. b) Flow Nozzle type (ISA 1932), Size & Rating. c) Flow Nozzle material specification. d) Spool piece material as per specification. e) Spool piece inner diameter and outer diameter in millimeter. f) Flow Nozzle throat diameter (Bore diameter) in millimeter. g) Manufacturer's name. h) Manufacturers serial no. and model no.

5.2 Venturi Tube:

a) Tag No. as per purchaser's datasheet. b) Venturi Tube type (Classical Venturi), Size & Rating c) Venturi Tube material specification. d) Venturi throat diameter (Bore diameter) in millimeter. e) Manufacturer's name f) Manufacturers serial no. and model no.

5.3 Other details as per MR shall also be suitably indicated on the Flow Meter.

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6.0 SHIPPING





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AVERAGING PITOT TUBES/ ANNUBARS

Averaging Pitot Tubes and

Annubars

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Contents


1.0 General 3



4.0 Documentation 7

5.0 Name Plate 8

6.0 Shipping 8

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of averaging pitot tube and its accessories

1.2 Averaging pitot tube and its accessories shall be supplied in fully assembled condition



1.4 Enclosed data sheets specify the material for averaging pitot tube and its accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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B 1.20.1 Pipe Threads General purpose (Inch) B 16.5 Pipe Flanges and Flanged Fittings B 16.20 Metallic gaskets for Pipe flanges‐ Ring joint, Spiral wound and jacketed. B 16.34 Valves ‐ flanged, Threaded and Welding End. PTC 1 9.3 TW 2010 Performance Test code‐Temperature measurement






2.6 Abbreviations:

AARH Arithmetic Average Roughness Height NPT National Pipe Thread DP Differential Pressure

PTFE Poly Tetra Fluoro Ethylene

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The reference conditions for standardized flows shall be: Liquids: 15°C and 760mm Hg Gas/ Vapours: 0°C and 760mm Hg

3.2 General Requirements for Averaging Pitot Tubes/ Annubars

3.2.1 The flow sensor shall be a continuous averaging velocity head producing type of pitot tube with four or more equal annubar sensing ports or continuous slots to suit line velocity profile. The sensor shall also incorporate a rear port for the measurement of line static pressure.

3.2.2 The sensor shall be designed to provide a non‐clog design and shall be able to provide a uniform flow pattern around the sensor to ensure accurate differential pressure consistently.

3.2.3 Unless otherwise specified, averaging pitot tube shall be of flanged construction. The process flange connection shall be of 3" size with material and rating as specified in the datasheet.

3.2.4 Vendor shall also supply a special weldolet along with weld neck flange with inner diameter to suit the outer diameter of averaging pitot tube. The material and rating of weldolet and flange shall be as specified in purchaser's data sheet.

3.2.5 High pressure and low‐pressure connections for differential pressure transmitter connection shall be 1/2" NPTF. The isolation valves with 316 Stainless Steel construction shall be provided for each pressure tap.

3.2.6 Clean out plugs shall be provided as standard with all averaging pitot tubes.

3.2.7 Vendor shall perform vibration analysis for each averaging pitot tube element for the indicated flow conditions as per ASME PTC 19.3 TW 2010 to ensure that the quoted averaging pitot tube is of sufficient thickness and strength to withstand the vibration effects created due to karman vortex shedding in the fluid stream.

3.2.8 Unless second support is specifically recommended by vendor, based on vibration analysis, the free end of the averaging pitot tube shall be pressure supported at the pipe wall

3.2.9 Unless otherwise specified, the offered averaging pitot tubes shall meet the following performance requirements:

a) Accuracy inclusive of repeatability and hysteresis shall be +1% of actual value. b) Repeatability of averaging pitot tube shall be + 0.1 % of actual value.

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3.2.10 Averaging pitot tubes in oxygen and chlorine service shall be thoroughly degreased using reagents like trichloro‐ethylene or carbon tetrachloride and end connections shall be plugged after degreasing process in order to avoid entrance of grease or oil particles.

3.2.11 Vendor shall follow the proper welding procedures for welding of dissimilar materials.

3.2.12 Unless otherwise mentioned, end connection details shall be as below: a) Threaded end connections shall be to NPT as per ASME B 1.20.1. b) Flanged end connections shall be as per ASME B 16.5. c) Grooves of ring type joint flanges shall be octagonal as per ASME B 16.20 d) When Flanges are Raised Face (RF) type, the face finish shall be as per ASME

B16.5 and shall be 125 AARH : 125 to 250 micro inch AARH 63 AARH : 32 to 63 micro inch AARH

3.2.13 Vendor data sheet for each Averaging Pitot tube/ Annubar, shall also indicate the following:

a) Calculated differential pressure at specified maximum, normal, minimum flow rates.

b) Maximum pressure loss through the flow element at maximum flow rate c) Upstream and downstream straight pipe length requirement for installation. d) Expected accuracy at minimum, normal and maximum flow. e) Permanent pressure loss that will be created by the averaging Pitot tube. f) Material of Construction g) Calculations of vibration analvsis and its recommendation h) Minimum clearance requirement for removal of pitot tube.

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4.0 DOCUMENTATION






a) Specification sheet/ Data sheet/ Sizing Sheet for each Flow elements (Averaging Pitot Tube/ Annubar) along with their accessories.

b) As built drawings for each Flow elements (Averaging Pitot Tube/ Annubar) along with their accessories, providing dimensional details, end connection details, constructional details, tapping orientation, marking for flow direction and material of construction.


d) Copy of calibration report, calibration curve for each averaging pitot tube/ Annubar.

e) Installation procedure for each Flow elements (Averaging Pitot Tube/ Annubar) along with their accessories.

f) BOM including spares (if applicable) g) Product Catalogs of Main equipment and accessories/ bought‐outs. h) Calibration and maintenance procedures including replacement of internal

parts, wherever applicable.


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5.0 NAME PLATE

a) Tag No. as per purchaser's datasheet. b) Material specification. c) Nominal Pipe size in which flow element is to be installed. d) Max value of DP (in mmWC) at Meter maximum (as per datasheet) e) Manufacturer's name. f) Manufacturers serial no. and model no.

Other details as per MR shall also be suitably indicated on the Flow Meter.

6.0 SHIPPING


6.2 Each averaging pitot tube flow element and its accessories shall be packed separately for shipment.

6.3 All averaging pitot tubes in oxygen and chlorine service shall be separately packed along witha certificate indicating 'SUITABLE FOR OXYGEN/CHLORINE SERVICE', as applicable.




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PRESSURE, DIFFERENTIAL PRESSURE & VACUUM GAUGES

Pressure, Differential Pressure

and Vacuum Gauges

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Contents


1.0 General 3



4.0 Documentation 7

5.0 Name Plate 8

6.0 Shipping 8

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of pressure, differential pressure and vacuum gauges with accessories.



1.3 Enclosed data sheets specify the material for pressure, differential pressure and vacuum gauges along with their accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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B 1.20.1 Pipe Threads General purpose (Inch) B 16.5 Pipe Flanges and Flanged Fittings B 16.20 Metallic gaskets for Pipe flanges‐ Ring joint, Spiral wound and jacketed. B 40.100 Pressure Gauges & Gauge Attachments




2.4 IS/IEC Indian Standard/International Electro‐technical Commission

IS/IEC 60529 Degree of Protection Provided by Enclosures (IP Code) IS 3624 Specification for Pressure and Vacuum Gauges

2.5 Abbreviations:

AARH Arithmetic Average Roughness Height ASTM American Society for Testing and Materials NPT National Pipe Thread MAWP Maximum Allowable Working Pressure

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3.0 DESIGN REQUIREMENTS

Unless otherwise specified, the accuracy which is inclusive of repeatability and hysteresis of pressure gauges/ differential pressure gauges shall meet the following performance requirements:

Direct pressure gauge : +l% of full scale Chemical seal type pressure gauge : +2% of full scale Differential pressure gauges : +2% of full scale

3.1 Design Requirements for Pressure Elements 3.1.1 The pressure element shall be an elastic element like bourdon tube, bellow, diaphragm etc

with material as specified in the data sheet.

3.1.2 In case of bourdon type of gauges, the size of the bourdon tube shall not be less than 75% of the nominal diameter of the dial size.

3.1.3 The gauge socket shall be in one piece and shall also serve as element anchorage in case of bourdon tube type element, which shall be directly connected to the socket, without any capillary or tube in between. For other types of elements, the anchorage may be integral with the socket or connected with the socket using capillary tube with minimum bore of 3 millimetres.

3.1.4 Any joint in the process wetted system including joint between the element and the anchorage/socket shall be welded type only.

3.1.5 Unless specified otherwise, the pressure gauges shall have an over‐range protection of at least 130% of maximum working pressure, as a minimum. Data sheet indicates the minimum requirement of material of construction.

3.1.6 The gauge movement material shall be of stainless steel unless specified otherwise in the data sheet. It shall be adjustable for calibration without dismantling the sensor unit.

3.1.7 Pressure gauges with range as 0 to 100kg/cm2g and above shall have safety type solid front case.

3.1.8 All gauges in oxygen and chlorine service shall be thoroughly degreased using reagents like trichloro‐ethylene or carbon tetrachloride. All connections shall be plugged after degreasing process in order to avoid entrance of grease or oil particles.

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3.2 Design Requirements for Casings and Dials

3.2.1 The gauges shall be weather proof to IP 55 as per IS/IEC 60529.

3.2.2 In general, dial markings and dial colour shall be as per IS 3624. Dials of gauges in oxygen service shall additionally have the word 'OXYGEN' or 'CHLORINE’ written in black and 'USE NO OIL’ written in red.

3.2.3 The pointer stops shall be provided at both ends of the scale to restrict the pointer motion beyond 5% above the maximum of scale and less than 5% below the minimum of the scale.

3.2.4 The dial cover shall be made out of shatter proof glass sheet of thickness 1.5 to 3mm for gauges with dial size less than 100 mm while minimum 3.0mm for gauges with dial size 100 mm or greater.

3.2.5 All gauges shall be provided with a blow out device i.e. blow out disc of aperture not less than 25mm for gauges with dial size 100 mm and above, while 20mm for gauges with dial size less than 100mm.

3.2.6 When safety type solid front type of gauges is required, they shall consist of a solid partition isolating the pressure element from the dial. In such gauges the total solid partition disc area shall not be less than 75% of the cross sectional area of the inside of the case surrounding the pressure element.

3.2.7 The bezel ring shall be Screwed or Bayonet type.

3.2.8 The dials shall be colour coded in circular arc along with the pressure marking with clear visibility. The details of colour coding shall be as below:

a) 0‐30% of Range : Yellow

b) 30‐75% of Range : Green

c) 75‐100% of Range : Red 3.3 Design Requirements for Diaphragms

3.3.1 Unless otherwise indicated in purchaser's data sheets, gauges specified with diaphragm seals shall have their diaphragms integral with the gauges.

3.3.2 Whenever diaphragm seal gauges are specified with capillary, the size of the capillary shall be selected to ensure response time of the gauge better than 5 seconds.

3.3.3 The sealing liquid for diaphragm seal gauges shall be an inert liquid, compatible with the process fluid and its temperature. For gauges in oxygen and chlorine service, the sealing liquid shall be fluro lube or equivalent compatible with the specified service.

3.3.4 For diaphragm seal pressure gauges with flanged ends, the diaphragm shall be rated for the maximum allowable pressure of the associated flange.

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3.4 End Connections

3.4.1 Unless otherwise mentioned, end connection details shall be as below: a) Threaded end connections shall be to NPT as per ASME B 1.20.1. b) Flanged end connections shall be as per ASME B 16.5. c) RTJ flanges shall be with octagonal Grooves as per ASME B 16.20 d) When Flanges are Raised Face (RF) type, the face finish shall be as per ASME

B16.5 and shall be 125 AARH : 125 to 250 micro inch AARH 63 AARH : 32 to 63 micro inch AARH

4.0 DOCUMENTATION



Review/ Approval QUALITY ASSURANCE PLAN (QAP) For Approval PRODUCTION PROGRAMME For Review INSTRUMENT DATA SHEETS For Approval INST GA / INSTALLATION DRAWINGS For Approval BILL OF MATERIALS INCLUDING SPARES For Review



a) Specification sheet/ Data sheet/ Sizing Sheet for each pressure, differential pressure and vacuum gauges with accessories.

b) As built drawings for each pressure, differential pressure and vacuum gauges with accessories, providing dimensional details, constructional details, tapping orientation, end connection details and material of construction.


d) Installation procedure for each gauge along with their accessories.

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e) BOM including spares (if applicable) f) Product Catalogs of Main equipment and accessories/ bought‐outs.


5.0 NAME PLATE

a) Tag No. as per purchaser's datasheet (shall be mentioned on the casing only and not on the dial)

b) Manufacturer's name. c) Manufacturers serial no. and model no. d) MAWP and maximum vacuum rating of the element.

Other details as per MR shall also be suitably indicated on the Gauge.

6.0 SHIPPING


6.2 Proper care shall be taken in shipping gauges with diaphragm seals to ensure safety of the diaphragm seals, extensions, capillaries, where specified, shall also be suitably protected.




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JUNCTION BOXES & ACCESSORIES

Junction Boxes and

Accessories

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Contents


1.0 General 3



4.0 Documentation 6

5.0 Name Plate 7

6.0 Shipping 7

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Junction Boxes & accessories including Cable Glands.


a) Statutory Regulations b) Data Sheets c) Standard Specification d) Codes and Standards

1.3 Enclosed data sheets specify the material for Junction Boxes with their accessories including Cable Glands. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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B 1.20.1 Pipe Threads General purpose (Inch)




IS/IEC 60529 Degree of Protection Provided by Enclosures (IP Code) IS/IEC‐60079 Electrical Apparatus for Explosive Gas Atmosphere. IS‐5 Colours for ready mixed paints and enamels.

2.4 Abbreviations:

NPT National Pipe Thread Sq.mm Square millimeter (mm2)

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3.1 Design Requirements for Junction Boxes 3.1.1 Junction boxes, Cable Glands and Plugs shall be of the following type:

a) Weather proof and flameproof

3.1.2 Unless otherwise specified, the Junction Box, Cable Glands and Plugs shall conform to the following standards:

a) Weatherproof housing: IP 65 to IS/IEC‐60529 and

b) Flameproof housing: Flameproof/Ex (d) (to Zone‐1 IIA/B as minimum) as per IS/IEC‐60079.

3.1.3 Number of entries and their location shall be as per data sheets. Junction boxes with top entries shall not be offered. The size of cable entries shall be as per the cable sizes / Cable gland sizes indicated in the data sheet.

3.1.4 Junction boxes shall be provided with telephone sockets and plugs for connection of hand‐powered telephone set.

3.1.5 The material of construction of junction boxes shall be cast light metal alloy preferably die‐cast aluminium (LM6).

3.1.6 Flameproof junction box shall have detachable cover, which shall be fixed to the box by means of cadmium plated triangular head/ hexagonal head screws.

3.1.7 Terminals shall be spring loaded, vibration proof, screw type, mounted on nickel plated steel rails complete with end cover and clamps for each row.

3.1.8 All terminals used in the junction boxes shall be suitable for accepting cable sizes between 0.5 mm2 and minimum 6mm2.

3.1.9 Junction Boxes shall have 2 entries for Multi pair/ triad cables and 12 entries for single pair/ triad cables. The junction boxes shall be supplied with cable glands with PVC sleeves/ shrouds and plugs for all the entries.

3.1.10 All Cable glands shall be double compression type for use with armoured cables. The cable glands shall be of nickel plated brass, as a minimum.

3.1.11 Unless higher number of terminals are specified in the purchaser's data sheet, the number of terminals in the junction boxes shall be 48 Nos in two rows duly numbered. The colour of the terminals shall be Blue/ Grey.

3.1.12 Junction boxes shall be provided with external earthing lugs.

3.1.13 Sizing shall be done with due consideration for accessibility and maintenance in accordance with the following guidelines:

a) 50 mm (minimum) gap shall be maintained between terminals/ terminal strip and sides/ top/ bottom of the Junction box.

b) 100 mm (minimum) gap shall be maintained between the terminal strips

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3.1.14 Surface shall be prepared for painting. It shall be smooth and devoid of rust and scale. Two coats of lead‐free base primer and two final coats of lead free epoxy based paint shall be applied both for interior and exterior surfaces. The colour shall be Light Blue/ Light Gray as per datasheet.

4.0 DOCUMENTATION



Review/ Approval QUALITY ASSURANCE PLAN (QAP) For Approval PRODUCTION PROGRAMME For Review DATA SHEETS For Approval INST GA / INSTALLATION DRAWINGS For Approval BILL OF MATERIALS INCLUDING SPARES For Review



a) Specification sheet/ Data sheet/ Sizing Sheet for each Junction Box and Accessories.

b) As built drawings for each Junction Box and Accessories, providing dimensional details, constructional details, cable entry details and material of construction.


d) Installation procedure for each Junction Boxwith their accessories. e) BOM including spares (if applicable) f) Product Catalogs of Main equipment and accessories/ bought‐outs.


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5.0 NAME PLATE

a) Tag No. as per purchaser's datasheet b) Manufacturer's name. c) Manufacturers serial no. and model no. d) Type of protection for use in hazardous area (This should be stamped on

individual cable glands and plugs also)

Other details as per MR shall also be suitably indicated on the Junction Box.

6.0 SHIPPING

6.1 All threaded openings shall be suitably protected to prevent entry of foreign material and avoid damage to threads.




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LEVEL GAUGES

Level Gauges

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LEVEL GAUGES

Contents


1.0 General 3



4.0 Documentation 7

5.0 Name Plate 8

6.0 Shipping 8

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LEVEL GAUGES

1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Level Gauges with accessories.

1.2 Level Gauges inclusive of excess flow check valves, drain/ vent valves, flanges etc. shall be supplied in fully assembled condition



1.4 Enclosed data sheets specify the material for Level Gauges with their accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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LEVEL GAUGES



B 1.20.1 Pipe Threads General purpose (Inch) B 16.5 Pipe Flanges and Flanged Fittings B 16.20 Metallic gaskets for Pipe flanges‐ Ring joint, Spiral wound and jacketed.



2.3 BS British Standards

3463 Observation and Gauge Glasses for Pressure Vessels.



IS/IEC 60529 Degree of Protection Provided by Enclosures (IP Code) IS/IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere. IS 5428 Part‐1 Tubular glasses for Level Gauges Part‐2 Protector glasses for Tubular Gauge glasses. Part‐3 Through‐vision and Reflex Glasses.

2.6 Abbreviations:

AARH Arithmetic Average Roughness Height ASTM American Society for Testing and Materials NPT National Pipe Thread PTFE Poly Tetra Fluoro Ethylene

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LEVEL GAUGES


a) Gauge glasses and cocks shall be suitable for the designed pressure and temperature related to the corresponding ASME rating specified for each item.

b) Unless specified otherwise, the following shall govern:

• Threaded end connections shall be to NPT as per ASME B 1.20.1

• Flanged end connections shall be as per ASME B 16.5

• Grooves of ring‐type joint flanges shall be octagonal as per ASME B 16.20

• Flange face shall be as per ASME B 16.5. The flange face finish as specified in data sheets shall be as follows:

125 AARH: 125 to 250 micro inch AARH 63 AARH: 32 to 63 micro inch AARH

3.1 Design Requirements for Tubular Type Gauge Glasses

3.1.1 Tubular type gauge glasses shall have a minimum of 3/4 "(19mrn) tempered glass tube with steel guard rods.

3.1.2 All gauge glasses shall have SS graduated scale along the length of gauge glass fixed external to the glass tube.

3.1.3 Tubular type gauge glasses shall have side‐side connections (as per datasheet) with ½” threaded vent and drain connections. Vent and drain connection shall be plugged.

3.1.4 The length of individual tubular gauge glass shall not exceed 1000 mm.

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LEVEL GAUGES

3.2 Design Requirements for Armoured Type Level Gauge

3.2.1 Gauge glasses shall be of the mechanical and thermal shock resistant type. Glass material shall be toughened borosilicate, for all types of gauges.

3.2.2 The gauge glasses shall be of heavy armour design and shall meet the following test pressures as a minimum:

Type of Chamber

Model Type Test Pressure (Kg/ cm2 g)

Standard Reflex 1 (upto 300 Class flange rating) 165

2 (upto 600 Class flange rating) 210

Transparent 3 (upto 300 Class flange rating) 84

4 (upto 600 Class flange rating) 210

Large Reflex 5 (upto 300 Class flange rating) 50

Transparent 6 (upto 150 Class flange rating) 40

3.2.3 Cover bolts and nuts shall correspond to ASTM A‐193 Gr. B7/A‐194 Gr. 2H, unless otherwise specified.

3.2.4 Where side‐side connections are specified, the gauge shall have two entries, 180 degrees apart at each end with one side plugged.

3.2.5 Unless otherwise specified, vent and drain connections shall be ½ " threaded which shall be suitably plugged.

3.2.6 Gauge glasses in corrosive service shall be supplied with glass protective shield/liners of minimum 1/16" (1.5 mm) thickness suitable for the process fluid being handled. Mica shield shall be provided for all steam and / or condensate services.

3.2.7 All Level gauges shall be provided with excess flow check valves. Excess Flow Check valves shall be of the quick‐closing type. Unless otherwise specified, all moving and wetted internals shall be 316 Stainless Steel, as a minimum. The stem packing shall be of PTFE or better suited for process conditions.

3.2.8 Illuminator wherever specified, shall be supplied complete with mounting brackets and lighting fixtures. Unless otherwise specified, illuminator lamps shall operate on 240 V, 50 Hz single phase supply. The illuminator housing shall be constructed to the following standards:

a) Weather proof housing ‐ to IP 65 as per IS/IEC 60529 and

b) Flame proof housing ‐ flame proof Ex (d) (to minimum Zone-1 IIA/B) as per IS/IEC 60079.

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LEVEL GAUGES

c) Multiple illuminators in gauge shall be wired internally using armoured cables and suitable glands. The incoming power terminals shall be suitable for cable connection up to 4.0 mm2 size.

4.0 DOCUMENTATION






a) Specification sheet/ Data sheet for each Level Gauge with accessories. b) As built drawings for each Level gauge with accessories, providing dimensional

details, constructional details, tapping orientation, end connection details and material of construction.


d) Installation procedure for each Level gauge along with their accessories. e) BOM including spares (if applicable) f) Product Catalogs of Main equipment and accessories/ bought‐outs.


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LEVEL GAUGES

5.0 NAME PLATE

a) Tag No. as per purchaser's datasheet b) Manufacturer's name. c) Manufacturers serial no. and model no. d) Pressure-temperature rating.

Other details as per MR shall also be suitably indicated on the Level Gauge.

6.0 SHIPPING





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TEMPERATURE GAUGES

Temperature Gauges

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TEMPERATURE GAUGES

Contents


1.0 General 3



4.0 Documentation 7

5.0 Name Plate 8

6.0 Shipping 8

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TEMPERATURE GAUGES

1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Temperature Gauges with accessories.



1.3 Enclosed data sheets specify the material for Temperature gauges along with their accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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TEMPERATURE GAUGES




B 40.200 Thermometers ‐ Direct Reading and Remote Reading PTC 19.3 Performance Test Code‐Temperature measurement




IS/IEC 60529 Degree of Protection Provided by Enclosures (IP Code) SAMA Scientific Apparatus Maker's Association.

2.4 Abbreviations:

AARH Arithmetic Average Roughness Height NPT National Pipe Thread

PTC Performance Test Code

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TEMPERATURE GAUGES


Unless otherwise specified, the accuracy of temperature gauge shall be +/‐ 1 % of set range, which is inclusive of repeatability and hysteresis .

3.1 Design Requirements for Temperature Gauges

3.1.1 Temperature gauges shall be of the separate socket type suitable for well installation. Upon assembly of components, the temperature gauge element shall firmly contact the bottom of the well. The gauge stem shall fit the well so that maximum heat‐transfer rate results.

3.1.2 Unless otherwise specified, the temperature gauges shall be of bimetallic type.

3.1.3 Whenever filled system type temperature gauges are specified, the following SAMA Classifications shall be referred:

SAMA Class Filling Fluid

I LiquidII VapourIII Gas

Mercury filled type of temperature gauges shall not be offered.

3.1.4 Vendor shall ensure that the operating temperature falls in 30% to 60% of the offered range.

3.1.5 Unless otherwise specified, the temperature gauges shall have an over range protection of at least 130% of specified range or maximum working temperature, whichever is higher.

3.1.1 Whenever temperature gauges are specified with capillary extension for remote installation, the capillary shall be of 304 Stainless Steel protected by stainless steel flexible armour. Preferred lengths are 3m (minimum) to 10m (maximum).

3.1.2 The Gauge movement material shall be of stainless steel, as a minimum, unless specified otherwise in the data sheet. It shall be adjustable for calibration without dismantling the sensor unit.

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TEMPERATURE GAUGES

3.2 Design Requirements for Casings and Dials

3.2.1 Unless specified otherwise, the case of bimetallic type of gauges shall be all angles rotatable type, 130 mm diameter.

3.2.2 Unless specified otherwise, the gauges shall be weatherproof to IP55 as per IS/IEC 60529 as a minimum.

3.2.3 The gauge dial shall be made of a suitable metallic material so that the finished dial shall be capable of withstanding a dry heat of 85°C for 10 hours and immersion in water at 85°C for1 hour without cracking, blistering, warping or discolouration of the dial or paint on the dial.

3.2.4 The pointer stops shall be provided at both ends of the scale to restrict the pointer motion beyond 5% above the maximum scale and less than 5% below the minimum of the scale.

3.2.5 The dial cover shall be made out of shatter proof glass sheet of thickness of minimum 3 mm.

3.2.6 In general, dial markings and dial colour shall be as per IS 3624.

3.2.7 The dials shall be colour coded in circular arc along with the temperature marking with clear visibility. The details of colour coding shall be as below:

a) 0‐30% of Range : Yellow

b) 30‐75% of Range : Green

c) 75‐100% of Range : Red

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TEMPERATURE GAUGES

4.0 DOCUMENTATION






a) Specification sheet/ Data sheet/ Sizing Sheet for each Temperature Gauge with accessories.

b) As built drawings for each Temperature gauge with accessories, providing dimensional details, constructional details, end connection details and material of construction.

c) Copy of test certificates for all the tests as per MR and Documents along with TPI /IRN.

d) Installation procedure for each gauge along with their accessories. e) BOM including spares (if applicable) f) Product Catalogs of Main equipment and accessories/ bought‐outs.


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TEMPERATURE GAUGES

5.0 NAME PLATE


b) Manufacturer's name. c) Manufacturers serial no. and model no. d) Range of the instrument


6.0 SHIPPING


6.2 Proper care shall be taken in shipping gauges to ensure safety of the Case Glass, extension capillaries (where specified). All items shall be adequately packed to withstand shipping conditions, without damage.




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THERMOCOUPLES & RTDS

Thermocouple and RTDs

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Contents


1.0 General 3



4.0 Documentation 7

5.0 Name Plate 8

6.0 Shipping 8

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Thermocouple and RTDs with accessories.



1.3 Enclosed data sheets specify the material for Thermocouple and RTDs with accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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PTC 19.3 Performance Test Code‐Temperature measurement





IS/IEC 60529 Degree of Protection Provided by Enclosures (IP Code) IS/IEC‐60079 Electrical Apparatus for Explosive Gas Atmosphere IEC‐60751 Industrial Platinum Resistance Thermometer Sensor. IEC‐60584‐2 Thermocouple Tolerances. IS7358 Specifications for Thermocouples.

2.5 API American Petroleum Institute

RP 551 Process Measurement Instrumentation.

2.6 Abbreviations:

AARH Arithmetic Average Roughness Height ASTM American Society for Testing and Materials NPT National Pipe Thread PTC Performance Test Code RTD Resistance Temperature Detector SS Stainless Steel

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Unless otherwise specified, the accuracy of Thermocouples and RTDs shall be as per IEC 60584‐2 and IEC 60751 respectively. Colour of wires shall be as per IEC standard.

3.1 Design Requirements for Thermocouple

3.1.1 The type of thermocouple shall be ISA‐ K Type, unless otherwise mentioned in datasheets. The thermocouple element shall be 18 AWG for all thermocouples, unless otherwise specified in purchaser's data sheet.

3.1.2 Thermocouple assemblies shall be furnished with threaded heads.

3.1.3 Unless otherwise specified, the assembly shall confirm to the following standards;

a) The heads shall be weatherproof to IP 65 as per IS/IEC‐60529. b) In case of flameproof construction, heads shall be flame proof as per IS/IEC‐60079 and

weather proof to IP 65 as per IS/IEC‐60529.

3.1.4 The heads shall consist of a case, screwed on cover and terminal block. The thermocouple shall be screwed to the terminal block. Separate screw shall be provided on the terminal block for terminating the extension / compensating cables. There shall be an extra terminal in the terminal block connected to the head for grounding the shield.

3.1.5 The case shall be suitable for mounting terminal blocks for single or duplex type thermocouple element assemblies. Duplex element sensors, if used, shall have two separate cable entries and shall be plugged with SS plugs only.

3.1.6 A heat resistant and moisture proof gasket shall be fitted between the case and cover. Head support chain (between case and cover) material shall be stainless steel.

3.1.7 The terminals shall be permanently and legibly identified for their polarity. The terminal block shall be permanently and legibly marked with the IEC letter code to designate the type of thermocouple. There shall be an extra terminal connected to the head for grounding.

3.1.8 The thermocouple assemblies shall be spring loaded.

3.1.9 The thermocouple properties and limits of error shall be as per IEC‐60584‐2.

3.1.10 Thermocouple shall be 316 Stainless Steel sheathed magnesium oxide insulated, ungrounded type, unless otherwise specified.

3.1.11 The design of thermocouple assemblies shall be such that on line replacement is possible.

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3.2 Design Requirements for Resistance Temperature Detectors(RTDs) 3.2.1 The type of RTD shall be 3 wire type with platinum element having 100 ohms resistance at

O°C, unless otherwise mentioned in Data sheet.

3.2.2 RTD shall be The element shall be of highly refined material of reference grade and shall have been stress relieved. RTD calibration shall be as per IEC‐60751.

3.2.3 The wire shall be wound on a ceramic core and immobilised against strain or damage. The winding shall be of bifilar type. The leads shall be copper up to terminal block.

3.2.4 The element shall be within a metal sheath, in a manner which provides good thermal transfer and protection against moisture. The sheath material shall be 316 Stainless Steel, unless otherwise specified.

3.2.5 The RTD assemblies shall be furnished with threaded heads. The heads shall consist of a case, screwed on cover and terminal block. The RTD shall be screwed to the terminal block. Separate screw shall be provided on the terminal block for terminating the incoming cable. There shall be an extra terminal in the terminal block connected to the head for grounding the shield.

3.2.6 The case shall be suitable for mounting terminal blocks for single or duplex type RTD element assemblies. The connecting terminals shall be properly numbered and shall be permanently and legibly identified.

3.2.7 The RTD assemblies shall be spring loaded.

3.2.8 A heat resistant and moisture proof gasket shall be fitted between the case and cover. The head support chain (between case and cover) shall be of stainless steel.

3.2.9 Unless otherwise specified, the assembly shall confirm to the following standards: a) The heads shall be weather proof to IP 65 as per IS/IEC-60529. b) In case of flame proof construction, heads shall be flame proof as per IS/IEC-60079

and weather proof to IP 65 as per ISIIEC-60529.

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4.0 DOCUMENTATION






a) Specification sheet/ Data sheet/ Sizing Sheet for each Thermocouple and RTDs with accessories.

b) As built drawings for each Thermocouple and RTDs with accessories, providing dimensional details, constructional details, end connection details and material of construction.

c) Copy of test certificates for all the tests as per MR and Documents along with TPI/ IRN.

d) Installation procedure for each thermocouple / RTD with their accessories. e) BOM including spares (if applicable) f) Product Catalogs of Main equipment and accessories/ bought‐outs.


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5.0 NAME PLATE


b) Manufacturer's name. c) Manufacturers serial no. and model no. d) Thermocouple type/RTD element type. e) Grounded or Ungrounded

Other details as per MR shall also be suitably indicated on the Instrument

6.0 SHIPPING


6.2 Proper care shall be taken to withstand the shipping conditions.




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THERMOWELLS

Thermowells

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THERMOWELLS

Contents


1.0 General 3



4.0 Documentation 6

5.0 Name Plate 7

6.0 Shipping 7

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THERMOWELLS

1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Thermowell.



1.3 Enclosed data sheets specify the material for Thermowells. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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THERMOWELLS







2.4 Abbreviations:

AARH Arithmetic Average Roughness Height ASTM American Society for Testing and Materials NPT National Pipe Thread MAWP Maximum Allowable Working Pressure

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THERMOWELLS


Vendor shall carryout the vibration analysis of the thermo‐wells as per ASME PTC 19.3 TW2010 standard .The thermowell shall be supplied with collars wherever required as per wake frequency calculations. The wake frequency calculations shall be reviewed as a part of vendor document review & actual requirement of collar shall be indicated on vendor drawing.

3.1 Design Requirements for Thermowells

3.1.1 Unless otherwise specified, the thermowell material shall be 316 Stainless Steel, as a minimum.

3.1.2 Thermowells with immersion length up to 500mm shall be mechanised out of forged barstock.

3.1.3 Built‐up thermowell with welded well construction shall be considered for immersion length of greater than 500mm, unless specified otherwise in the datasheet.

3.1.4 All thermowell weld joints shall be full penetration weld type only.

3.1.5 Thermowell immersion length shall be as specified in data sheets. Where immersion length is not specified in the purchaser's data sheet, following shall govern;

Line Size Immersion Length Upto 6" 280mm 8" and above 320mm Equipments 400mm

3.2 End Connections

3.2.1 Unless otherwise mentioned, end connection details shall be as below:

a) Threaded end connections shall be to NPT as per ASME B 1.20.1. b) Flanged end connections shall be as per ASME B 16.5. c) RTJ flanges shall be with octagonal Grooves as per ASME B 16.20 d) When Flanges are Raised Face (RF) type, the face finish shall be as per ASME

B16.5 and shall be 125 AARH: 125 to 250 micro inch AARH 63 AARH: 32 to 63 micro inch AARH

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THERMOWELLS

4.0 DOCUMENTATION






a) Specification sheet/ Data sheet/ Sizing Sheet for each Thermowell b) As built drawings for each Thermowell, providing dimensional details,

constructional details, tapping orientation, end connection details and material of construction.


d) Installation procedure for each Thermowell. e) BOM including spares (if applicable) f) Product Catalogs of Main equipment and accessories/ bought‐outs.


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THERMOWELLS

5.0 NAME PLATE

a) Tag No. as per purchaser's datasheet

b) Thermowell and Flange material

c) Thermowell immersion length 'U'

d) Nominal flange size in inches and rating in pounds.

e) Manufacturer's name.

f) Manufacturers serial no. and model no.

g) MAWP and maximum vacuum rating of the element.

Other details as per MR shall also be suitably indicated on the Thermowell.

6.0 SHIPPING


6.2 All thermowells in oxygen and chlorine service shall be thoroughly degreased using reagents like trichloro‐ethylene or carbon tetrachloride. All connections shall be plugged after degreasing process in order to avoid entrance of grease or oil particles.




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TRANSMITTERS

Electronic Transmitters

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TRANSMITTERS

Contents


1.0 General 3



4.0 Documentation 12

5.0 Name Plate 14

6.0 Shipping 14

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TRANSMITTERS

1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Electronic Transmitters with accessories.



1.3 Enclosed data sheets specify the material for Electronic Transmitters along with their accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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TRANSMITTERS








IS/IEC 60529 Degree of Protection Provided by Enclosures (IP Code) ISIIEC 60079 Electrical Apparatus for Explosive Gas Atmospheres IEC 61000‐4 Electromagnetic Compatibility (EMC) for Industrial Process

Measurement and Control Equipment IEC 61 158 Fieldbus Standard for use in Industrial Control System IEC 61158‐2 Physical Layer Specification and service definition for Fieldbus IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic

Safety related Systems. IEC 61511 Functional safety instrumented system for the process industry sector IEC 61804 Function blocks (FB) for process control ‐ Electronic Device Description IEC 61518 Mating dimensions between differential pressure (type) measuring

instruments and flanged‐on shut‐off devices up to413 bar(41,3 MPa)

2.5 ISA International Society of Automation

S 7.3 Quality Standard for Instrument Air S 50.1 Compatibility of Analog Signals for Electronic Industrial Process

Instruments.

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TRANSMITTERS

2.6 ITK Interoperability Test Kit (latest version)

2.7 Abbreviations:


EDDL Electronics Device Description Language FISCO Fieldbus Intrinsic Safety Concept FDT/DTM Field Device Tool/ Device Type Manager FF Fieldbus Foundation HART Highway Addressable Remote Transducer LAS Link Active Scheduler LCD Liquid Crystal Display NPS Nominal Pipe Size RAM Random Access Memory WC Water Column

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TRANSMITTERS


3.1 General Requirements for Electronic Transmitters

3.1.1 The range of instruments shall be selected by vendor based on the set range indicated in the data sheet. Where no set range is indicated, vendor to select the same as per the following guidelines:

a) The set range shall be 1.1 times the maximum process value or 1.4 times the operating process value whichever is higher rounded to the nearest ten.

b) The set range shall preferably be in the middle third of the selected instrument range.

3.1.2 Measuring element in vacuum service shall have under range protection down to full vacuum, without undergoing a change in calibration or permanent set.

3.1.3 Unless otherwise specified, diaphragm seal instrument shall meet the following requirements;

a) Instruments shall have its diaphragm seal (flanged type) integral with the instrument. In case wafer type diaphragm seal is provided, it shall be supplied with companion flange.

b) When Data sheets specify wafer seal type of instrument, vendor shall include supply of studs, nuts and gasket as per the materials specified in the Data sheet.

c) The sealant shall be an inert liquid, compatible with the process fluid and process temperature indicated in the Data sheets. In general, sealant shall be:

I. DC 704 or equivalent for all diaphragm seal instruments except for oxygen and chlorine.

II. Flouro‐lube or equivalent for all diaphragm seal instruments in oxygen and chlorine.

d) The requirement of spacer ring shall be as specified in Data sheet. The material of construction of spacer ring shall be 316 Stainless Steel, as a minimum unless otherwise specified in the Data sheets.

e) The span of the offered model shall be selected to ensure zero elevation/zero suppression equal to the head created by the fill fluid for the specified capillary length in the data sheet.

3.1.4 Wherever Data sheet specifies integral flow transmitter, vendor shall supply complete assembly consisting of integral orifice, upstream and downstream meter runs with end flanges. Unless otherwise specified, material of construction shall be 316 Stainless Steel for integral orifice and meter run with flanges.

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TRANSMITTERS

3.1.5 The instrument enclosure shall be suitable for the area classification indicated in the Data sheets. Unless otherwise specified, the enclosure shall be Weatherproof housing IP‐65 to IS/IEC‐60529 as well as Flameproof/ Ex (d) as per IS/IEC‐60079. Unless otherwise specified, the finish shall be as per manufacturer’s standard and shall be suitable for sulphurous, salt laden environmental conditions.

3.1.6 Unless otherwise specified, the electronic transmitters shall be certified intrinsically safe.

3.1.7 Electrical cable entries shall have ½” NPT threaded connection. Process connections on instruments other than analysers shall be 1/2" NPT female. Mounting accessories and brackets shall be supplied along with transmitters.

3.1.8 All electronic instruments in oxygen and chlorine service shall be thoroughly degreased using reagents like trichloro‐ethylene or carbon tetrachloride. End connection shall be blinded / plugged after the degreasing process in order to avoid entrance of grease or oil particles.

3.1.9 Measurement linearization shall be accomplished in the transmitter, e.g.: square root extraction of differential pressure flow measurement.

3.1.10 Unless otherwise specified, Accuracy/ Rangeability of transmitters, smart as well as field bus

Based, shall be as follows:

Type of Transmitter Accuracy/Rangeability

Direct Standard Transmitters

Static Pressure : 100 kg/cm2 minimum

Overall rangeability : 1:100

Accuracy :

Equal to or better than ± 0.075% of span within a turndown ratio of 1:10

Diaphragm seal Static Pressure : As per flange rating


Accuracy :


Draft range transmitters

Static Pressure : As required


Accuracy :


The accuracy is defined as the combined effect of repeatability, linearity and hysteresis

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3.2 Design Requirements for Electronic Transmitters

3.2.1 All instruments shall be of state‐of‐the‐art technology and shall be in compliance with the electromagnetic compatibility requirements specified in IEC‐61000‐4 standard.

3.2.2 Plug‐in circuit boards shall be designed and manufactured such that reverse insertion or insertion of the wrong card is prevented.

3.2.3 Electronic instruments shall generally operate on nominal voltage of 24 VDC and shall be protected against short circuit and reverse voltage. Transmission and output signal shall generally be 4 to 20 mA DC for Analog and Smart transmitters.

3.2.4 The display of integral output meter shall be in engineering units for pressure, differential pressure, flow & Temperature and 100% linear for level.

3.2.5 Electronic transmitters with two‐wire system shall be suitable for delivering rated current to an external loop resistance of at least 600ohm when powered with 24 V DC.

3.2.6 Terminals for electrical connections shall be clearly identified, and polarity shall be permanently marked.

3.3 Design Requirements for Smart and Fieldbus based Transmitters

3.3.1 Smart and field bus based transmitters shall be two wire microprocessor based type. These shall have a non‐volatile memory, storing, complete sensor characterisation and configuration data of the transmitter. All necessary signal conversions and output generation with the required protocol shall be carried out in the transmitter electronics. Integral output meter with LCD display shall be provided for all transmitters.

3.3.2 Transmitter shall also run complete diagnostic subroutines and shall provide diagnostic alarm messages for sensor as well as transmitter healthiness. Field bus based transmitter in addition shall have facility to detect plugged impulse lines, whenever specifically indicated in purchaser's data sheets. In the event of detection failure, the output shall be driven to a predefined value, which shall be field configurable.

3.3.3 The transmitters with field bus connectivity shall have built in control algorithm like proportional, proportional‐integral and proportional‐integral‐differential.

3.3.4 The meter electronics shall be provided with in‐built lightning and power supply surges. The transient protection shall meet the requirements specified in IEC‐61000‐4.

3.3.5 The configuration data of the instruments shall be stored in a non‐volatile memory such that this remains unchanged because of power fluctuations or power off condition.

3.3.6 The stability of the transmitters shall be equal to or better than +0.1% of span for a period of minimum 6 months, as a minimum.

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3.3.7 In the transmitter, the 'WRITE' option shall be protected through password.

3.3.8 Following features must be ensured for Smart HART transmitters;

a) It shall allow multi masters (two for example, primary and secondary) for configuration, calibration, diagnostics and maintenance. The primary could be the control system or host computer and the secondary could be the hand‐held communicator.

b) It shall be capable of implementing universal commands from either of these locations. 3.4 Exclusive Design Requirements for Field bus transmitters

In addition to the requirements mentioned elsewhere in the specification, field bus based transmitter shall meet the following requirements;

3.4.1 All instruments must satisfy the requirements of the field bus registration laboratory with applicable checkmark like foundation field bus, profibus NutZer organisation e.v (PNO), or as specified in the Data sheets.

3.4.2 All instruments shall be polarity insensitive. Also transmitter shall be LAS capable and provided with line plugging detection, whenever specified in data sheet.

3.4.3 All instruments shall have one no. of Analog Input (AI) block and One no. of Proportional, Integration and Differential (PID) control block, as a minimum. All function blocks supplied with the device shall be instantiated by the device manufacturer. AI block execution time shall be better than 45ms and PID block execution time shall be better than 60msec.

3.4.4 All instruments must be interoperable including maximising of the associated advanced diagnostic features coupled to asset management capabilities within DCS System and shall have valid interoperability test clearance like ITK latest version for foundation field bus .

3.4.5 The field bus instruments shall support peer to peer communication.

3.4.6 The field bus instruments in hazardous area shall be certified as per entity concept or shall be FISCO approved as per the requirements specified in the purchaser's specification.

3.4.7 All instruments shall support EDDL or FDT/DTM requirements, as specified in data sheets.

3.4.8 Internal Software shall be configured by the vendor including the following information.

‐ Serial Number

‐ Device Tag (Tag No.)

‐ Process Description

3.4.9 All instruments shall be capable of supporting incremental Device Descriptor (DD) for extra functionality and/or software revisions in Device Memory.

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3.5 Exclusive Design Requirements for Temperature transmitters In addition to the requirements mentioned elsewhere in the specification, Temperature transmitter shall meet the following requirements;

3.5.1 Temperature transmitter shall be universal type and shall be able to accept input from resistance temperature detector (RTD) or thermocouple (T/C) of any type and range.

3.5.2 Temperature transmitters shall be freely programmable i.e. element type and range shall be programmable without any change in hardware / software.

3.5.3 Temperature transmitter shall be remote mounted type, in general. Head mounted transmitters shall be supplied when specifically indicated in Data sheets.

3.5.4 The accuracy of the temperature transmitter with RTD element shall be as follows:

a) For temperature range above 350 deg C, the accuracy shall be equal to or better than +/‐0.075% of range.

b) For temperature range with ranges between 350 deg C to 150 deg C, the accuracy shall be equal to or better than +/‐0.15% of range.

c) For temperature range below 150 deg C, the accuracy shall be equal to or better than +0.25% of range.

3.5.5 The accuracy of temperature transmitter with cold junction compensation for Thermocouple element shall be as follows;

a) For temperature above 350 deg C, accuracy shall be +/‐0.25% of range.

b) For temperature between 150 deg C to 350 deg C. accuracy shall be +/‐0.5% of range

c) For temperature below 150 deg C, accuracy shall be +/‐0.75% of range.

3.6 Design Requirements for transmitter Accessories 3.6.1 Field universal Communicator

Hand held communicator for field bus and HART transmitters shall have minimum following features:‐

a) It shall be possible to perform routine configuration / calibration, display process variable, diagnostics etc. from Hand Held Communicator, which can be connected at any location in the transmitter loop. It shall be possible to perform all the above functions on line and the loop function shall remain unaffected.

b) There should be no interruption on the output while communicating with the transmitter.

c) Hand held communicator shall be universal type and shall be compatible with all make and models of HART transmitters and smart Positioners with all engineering capability like calibration , diagnostics, configuration, inhibition of HART signal etc. Similarly Fieldbus Hand

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Held communicator shall also be universal type and shall be suitable for all make and models of FF transmitters and positioners.

d) It shall be possible to connect the communicator at any location at the following locations for the purpose of digital communication:

i. Marshalling cabinet serving the transmitter , in safe area ii. Junction box serving the transmitter in hazardous area iii. Directly at the transmitter in hazardous area

Plug in type connections shall be provided with field communicator. Necessary interconnection accessories shall be supplied by the vendor.

e) Offered communicator shall be dustproof, certified intrinsically safe and suitable for outdoor location. Carrying case shall be supplied with each communicator. The software shall also be capable of configuring the other makes of transmitters

f) They shall be powered with replaceable and rechargeable battery suitable for recharging with 240 V AC 50 HZ. In case vendor standard doesn't permit rechargeable battery , vendor shall supply two sets of additional batteries.

3.6.2 Remote output meter

a) Remote output meter shall be electronics with LCD display. b) The display shall be in actual engineering units c) The indicator electronics shall be able to perform square root extraction for flow measurement d) Offered output meter shall be suitable for Intrinsically safe/FISCO when used in Hazardous as

specified in datasheet. e) The field bus based field indicator shall be 2 wire segment powered and shall be able to indicate

minimum of 8 signals available in the field bus segment selectively f) Yoke mounted instruments shall be supplied with universal mounting brakets, U bolt and nuts

suitable for mounting the instrument on 50 mm ( nominal bore) pipe stancion(horizontal or vertical)

3.6.3 Battery charger

Battery charger shall be supliedwith all the necessary accessories and shall be suitbal for 240 VAC+/‐ 10% 50HZ+/‐ 3 Hz unless otherwise specified.

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3.7 End Connections


a) Threaded end connections shall be to NPT as per ASME B 1.20.1. b) Flanged end connections shall be as per ASME B 16.5. c) RTJ flanges shall be with octagonal Grooves as per ASME B 16.20 d) When Flanges are Raised Face (RF) type, the face finish shall be as per ASME B16.5 and shall be

125 AARH : 125 to 250 micro inch AARH 63 AARH: 32 to 63 micro inch AARH

4.0 DOCUMENTATION



Review/ Approval QUALITY ASSURANCE PLAN (QAP) For Approval PRODUCTION PROGRAMME For Review INSTRUMENT DATA SHEETS For Approval INST GA / INSTALLATION DRAWINGS For Approval certified values of failure rates, probability of failure on demand (PFD) and test intervals for offered items for Safety Integrity Level (SIL) analysis

BILL OF MATERIALS INCLUDING SPARES For Review


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a) Specification sheet/ Data sheet/ Sizing Sheet for each Electronic transmitter with accessories. b) As built drawings for each Electronic transmitter with accessories, providing dimensional

details, constructional details, connection details and material of construction. c) Copy of test certificates for all the tests as per MR and Documents along with TPI/ IRN. d) Installation procedure for each Electronic transmitter along with their accessories. e) Calibration, Configuration and Maintenance procedures f) Device Descriptor (DD) Files/EDDL file/DTM files for configuring the device parameters (Soft

Copy) g) Common File Format (CFF) files for integrating the device into the system (Soft COPY). h) DD/ITK/CFF Revision number i) Calculations for integral orifice j) BOM including spares (if applicable) k) SIL data l) Product Catalogs of Main equipment and accessories/ bought‐outs.


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5.0 NAME PLATE a) Tag No. as per purchaser's datasheet b) Manufacturer's name. c) Manufacturers serial no. and model no. d) Range of Measurement e) Area Classification of the Instrument

Other details as per MR shall also be suitably indicated on the Instrument.

6.0 SHIPPING


6.2 Instrument shall be supplied individually, in suitably sealed packing.

6.3 Proper care shall be taken in shipping gauges with diaphragm seals to ensure safety of the diaphragm seals, extensions, capillaries, where specified.




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CONTROL VALVES

Control Valves

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Contents


1.0 General 3




5.0 Name Plate 22

6.0 Shipping 23

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Control valves with accessories.



1.3 Enclosed data sheets specify the material for Control Valves along with their accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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B 1.20.1 Pipe Threads General purpose (Inch) B 16.5 Pipe Flanges and Flanged Fittings B 16.20 Metallic gaskets for Pipe flanges‐ Ring joint, Spiral wound and jacketed. B 16.34 Valves ‐ flanged, Threaded and Welding End. B 16.47‐B Large Diameter Steel Flanges

2.2 ANSI/FCI American National Standard Institute/Fluid Control Institute

FCI 70‐2 Control Valve Seat Leakage


6D Pipelines valves (Gate valve, Plug, Ball and Check valves) 598 Inspection Requirements 609 Lug and wafer type, Butterfly valves

2.4 AWWA American Water Works Association ‐ Steel Pipe Flanges for Water C207 CL.D Works Services


6364 Valves in cryogenic service European Standards


10204 Inspection Documents For Metallic Products 61056‐1 Specification for performance, design and construction of

valve, regulated sealed type.




Measurement and Control Equipment

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IEC 61158 Fieldbus Standard for use in Industrial Control System IEC 61158‐2 Physical Layer Specification and service definition for Fieldbus IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic

Safety related Systems. IEC 61511 Functional safety instrumented system for the process industry sector IEC 61804 Function blocks (FB) for process control ‐ Electronic Device Description IEC 60534‐3‐2 Face to Face dimension of rotary valves except butterfly valves. IEC 60534‐4 Seat leakage IEC 60534‐8.3 Industrial process control valves, noise consideration, control valve

aerodynamic noise prediction method IEC 60534‐8.4 Industrial process control valves, noise consideration, prediction of

noise generated by hydrodynamic flow FF 890 Function Block Application Process Part 1 FF 891 Function Block Application Process Part 2 FF 892 Function Block Application Process Part 3 FF 893 Function Block Application Process Part 4 FF 894 Function Block Application Process Part 5


75.01.01 Flow equation for sizing control valves. 75.02 Control valve capacity test procedure. TR75.04 Control Valve positioner stability 75.05.01 Control Valve terminology 75.07 Laboratory measurement of aerodynamic noise generated by control valves 75.08.01 Face to face dimensions for integral flanged Globe‐style control valve bodies (ASME Class 125,150,300 and 600) 75.08.02 Face to face dimensions for flangeless control valve (ASME Class 150,300 and 600) 75.08.04 Face to face dimensions for Buttweld‐end globe style control valve (ASME Class 4500) 75.08.05 Face to face dimensions for Buttweld‐end globe style control valve (ASME Class l5O,3OO,6OO,9OO, 1500 and 2500) 75.08.06 Face to face dimensions for flanged Globe‐style control valve bodies (ASME Class 900,1500 and 2500) 75.11.01 Inherent flow characteristic and Rangeability of control valves. 75.19.01 Hydrostatic testing of control valves.

75.22 Face to centre‐line dimensions for flanged Globe‐style Angle control valve bodies (ASME Class 150,300 and 600)

75.25.01 Test Procedure for Control valve response measurement for step inputs

TR75.25.02 Control valve response measurement for step inputs 75.13 Method of evaluating the performance of positioners with analog

input signals and pneumatic output. 75.17 Control valve aerodynamic noise prediction.

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RP75.23 Considerations for evaluating control valve Cavitation


2.11 MSS Manufacturer's Standardisation Society

SP25 Standard Markings System for Valves, Fittings, Flanges and Unions

2.12 NACE National Association of Common Engineers

MR0103 Materials Resistant to Sulphide stress cracking in Corrosive Petroleum Refinery Environments

2.13 OSHA Occupational Safety and Health Authority

2.14 Abbreviations:


EDDL Electronics Device Description Language FISCO Fieldbus Intrinsic Safety Concept FDT/DTM Field Device Tool/ Device Type Manager FF Fieldbus Foundation HART Highway Addressable Remote Transducer LAS Link Active Scheduler LCD Liquid Crystal Display NPS Nominal Pipe Size RAM Random Access Memory WC Water Column

CIMFR Central Institute of Mining and Fuel Research ERTL Electronics Regional Testing Laboratory HHT Hand Held Terminal NACE National Association of Corrosion Engineers PID Proportional, Integral and Derivative PTFE Poly Tetra Fluoro Ethylene SS Stainless Steel TSO Tight Shutoff

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3.1 General Requirements for Control Valves

3.1.1 Vendor shall be responsible for selecting their standard valve flow coefficient suitable for the specified service and process conditions specified in the Data sheets.

3.1.2 Vendor shall be responsible for checking for cavitation, flashing and noise generated and to provide suitable trim and treatment to limit these within appropriate limits.

3.1.3 Vendor must furnish certified values of failure rates, probability of failure on demand (PFD) and test intervals for the safety integrity level (SIL) analysis wherever specified.

3.1.4 Vendor shall furnish sizing calculation for each tag number clearly highlighting the standard used for calculation, noise level, Cavitation or flashing, Cv selected, percentage opening at minimum, normal and maximum flow, inlet and outlet velocity etc.

3.1.5 Catalogues giving detailed technical specifications, model decoding details and other information for each type of control valve and accessories covered in the bid. For fieldbus positioners, information shall include, but not limited to, product certification, power supply, current drawn, Standard/Advanced/Enhanced function blocks available and the execution time for each block, device type, number of link objects, Virtual Communication Relationships, Basic and advanced diagnostic features, failure mode etc.

3.1.6 For valves in cryogenic service, vendor shall meet the following acceptance criteria:

a) Vendor shall furnish, along with the offer, type test certificate, duly witnessed by Third Party Inspection agency like MIS LRIS, DNV BV, TUV, CEIL etc. of having successfully conducted the cryogenic test as per BS 6364 on the offered valves (same model, size, rating and material) in cryogenic service. Further vendor to note the following:

i. Test temperature shall be ‐45 Deg C for LTCS and ‐196 Deg C for all grades of austenitic Stainless Steel.

ii. Test carried out on a particular size of one type of valve, pressure rating and material shall qualify all sizes equal to and below the test valve size for the same type, pressure rating and material. In case of austenitic Stainless Steel any one grade would qualify for other grades of austenitic Stainless Steel.

b) In case vendor does not have cryogenic type test certificate for the offered valves as mentioned above, vendor shall confirm to conduct the cryogenic test on the offered valves and furnish type test report meeting requirements specified above.

3.2 Design Requirements for Control Valve Body

3.2.1 Control valves shall have flanged end connections integral to the valve body. Split body type valve design shall not be offered unless specifically indicated in the Data sheets. Whenever flangeless control valve body design is specified in the Data sheet, following shall apply:

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a) Wafer type or lug type body design for control valves body size up to 6 inches.

b) Lug type body design for butterfly type of control valve body size more than 6 inches.

3.2.2 The valve body rating should be equal to or higher than the flange rating specified in the data sheets. As a minimum, control valve body shall be rated for ASME Class 300. However, end connection shall be as specified in Data sheet.

3.2.3 The control valves shall be suitable for installation in horizontal as well as in vertical lines. For all applications, where full port valves are specified, following shall apply:

a) Port size shall be equal to line size for rating up to ASME Class 1500.

b) Port size shall not be smaller than one size lower than that of the line size for body rating ASME Class 1500 and above.

3.2.4 Flow Direction:

3.2.4.1 In general, flow direction shall be as below:

a) Flow tending to open for single seated unbalanced valve design.

b) Flow entering between the seats for double seated valves.

c) Flow entering at the side and leaving at the bottom for angle valves.

For valves design other than those specified above, flow direction shall be as per manufacturer standard.

3.2.4.2 Flow direction shall be clearly marked on the control valve body.

3.2.4.3 For 3‐way control valves, service like mixing or diverting, shall be clearly identified with inlet and outlet end connection clearly marked on the control valve body.

3.2.5 Material of Construction

a) The material of construction of control valves shall be as specified in the data sheet.

b) Control valve body, bonnet, flanges and other pressure containing assemblies shall be of the same material of construction as specified for valve body in the data sheets.

c) The bonnet flange and bottom flange shall have metallic spiral wound gaskets suitable for the specified service.

d) Vendor shall be responsible for selecting proper material for the internal parts of control valve. All such materials shall have the same or better specification than specified in the data sheets.

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e) The material of construction of silencers, diffuser plates, diffuser plate assembly etc shall be as per the body material specified in the data sheets, as a minimum.

3.3 Design Requirements for Control Valve: Trim

3.3.1 The term 'trim' covers those parts of valve assembly (excluding the body, bonnet and bottom flange) which are exposed to and are in contact with the line medium consisting of but not limited to the seat ring, valve stem, valve plug, valve plug guide, guide bushing and cage. In case of rotary type of control valves like butterfly, ball, segmental ball, rotary plug, eccentric disc and rotary disc, the term trim covers disc/ball, seat ring, shaft and bearing.

3.3.2 Guiding

a) Single seated globe (unbalanced) and angle type control valves shall have heavy top plug guiding. Stem guided control valve design shall not be acceptable unless specifically indicated in datasheets.

b) Single seated globe (balanced) control valves shall be of cage guided design. The cage shall provide a continuous plug guiding.

c) Double seated valves shall have top and bottom or cage guiding and shall be of the pressure balanced type.

d) Whenever cage type control valves are specified, top guided or top and bottom guided control valves can be offered provided it meets all other process and functional requirements. But whenever top or top and bottom type of guiding is specified, cage type control valves shall not be offered.

e) 3‐way control valves of either diverting or mixing type shall have top guiding.

f) Rotary control valves like butterfly, segmental ball, eccentric rotary plug etc shall have blowout proof shaft guiding design.

g) Guide bushings shall be of a sufficiently hard material to resist side thrust on the plug.

3.3.3 Trim Design

3.3.3.1 Control valve manufacturer/vendor shall be responsible for trim selection and trim design of the control valve. However it must meet the following minimum requirements:

a) Control valve trim design shall suit the type of guiding specified in the data sheet.

b) The trim design and material of construction shall be selected to minimize the risk of galling particularly in case of cage guided valves. Vendor shall select proper material

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pairs, surface finish, hardness and clearances wherever possibility of galling exist.

c) Under extreme temperature conditions, vendor shall consider increased clearances at room temperature and seal welding of threaded seat rings etc. Hard facing of trim shall be used in high temperatures. For very low temperature application, material used shall have adequate cold impact strength.

d) For Globe/Angle/3‐way type of control valves, Stem and Plug shall be detachable and shall be attached together by suitable threaded design secured with a pin to avoid plug rotation during operation.

e) For top and bottom guided control valves with sizes above 8", post and guide bushing design shall be used to prevent rotation of plug and stem.

f) Whenever Cavitation conditions are expected, vendor shall select a special anti‐Cavitation trim design and shall use trim material of sufficiently high hardness.

g) Whenever the possibility of aerodynamic noise in a control valve exists under any operating condition specified in data sheet, vendor shall select a special low noise trim for that application.

3.3.3.2 The plug inherent characteristics shall be as indicated in the Data sheet. However, following shall be followed unless otherwise specified:

a) Control valves with low noise and anti‐cavitation trim design shall have modified equal percentage or linear characteristics.

b) Rotary type control valves shall have modified equal percentage or equal percentage characteristics.

c) Control valves with flow co‐efficient less than 0.4 shall have equal percentage or linear characteristics.

d) All other control valves shall have equal percentage characteristics. Whenever linear or modified equal percentage characteristics are specified, equal percentage characteristics shall also be acceptable. Characterized positioner cam design to meet specified inherent control valve characteristics shall not be offered.

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3.3.4 Trim Material

Whenever stellited trim is specified in the data sheets following material of construction for the trim parts shall be acceptable.

a) Plug and seat: Stellite sheathing/hard alloy coating or solid stellite

b) Cage: Nitrided or stellite sheathing/hard alloy coating or solid

stellite.

c) Guide bushing: Stellite coating/sheathing or solid stellite

d) Valve stem : Hardened SS /Inconel X‐760

Special material requirements, if specified in the datasheets, shall supercede the above mentioned requirements.

Whenever hardened SS trim is specified in the Data sheet, following material of construction for the trim parts shall be acceptable provided same are compatible with the specified process conditions;

a) Plug and seat: Stellite sheath/hard alloy coating or 17‐4PH SS or 440C

b) Cage: Nitrided or stellite sheathing/coating, solid stellite, ENC

coating, 17‐4 PH SS

c) Guide bushing: 440C, 3 16SS stellited, 17‐4 PH SS or solid stellite

d) Valve stem: 17‐4 PH SS

3.3.5 Leakage class

a) Leakage class shall be as per ANSI FCI 70.2 and shall be as per Data sheet for each control valve. Where no leakage class is specified, the same shall be considered as Class IV.

b) For control valves specified with Class VI leakage class, vendor shall select the soft seat (elastomer) material suitable for the process conditions i.e., shut off pressure, maximum temperature and process fluid.

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3.3.6 In case vendor's calculation show occurrence of cavitation , flashing or noise under any of the specified process condition, vendor shall select proper type of valve trim to suit such process conditions.

3.4 Design Requirements for Control Valve Sizing

3.4.1 Data sheet indicates calculated flow co‐efficient values at minimum, normal and maximum operating conditions. Vendor shall calculate this co‐efficient as per the offered control valve and select the size considering valve openings as under:

At maximum flow: Less than 90% open

At normal flow: Typically 75% open

At minimum flow: More than 10% open

3.4.2 Conventional Butterfly valves shall be sized assuming a 600 opening at maximum flow. Wherever high performance butterfly valves are specified, these shall be sized considering maximum opening of 900 at maximum flow.

3.5 Design Requirements for Control Valve Noise

3.5.1 Vendor shall examine each control valve for noise generation possibilities. The noise level shall be calculated as per ISA 75.17.

3.5.2 Noise generated by control valve during operation shall be limited to OSHA specified levels i.e. the maximum allowable noise shall be less than 85 dBA, when measured at a distance governed by ISA 75.17.

3.5.3 If the predicted noise level is found to exceed 85 dBA SPL, control valve shall be treated for noise. Source treatment for noise shall be resorted to. When source treatment for noise is not sufficient to reduce the noise level below 85 dBA, vendor shall provide path treatment like diffuser plate/silencer etc in addition to source treatment so as to reduce the level below 85dBA. Whenever additional path treatment is recommended, the maximum differential pressure across the silencer/diffuser plate shall not exceed 40% of the specified differential pressure.

3.5.4 Vendor shall also furnish noise calculations with and without the use of these devices and the noise abatement achieved in individual components.

3.5.5 Diffuser plate shall be inserted between control valve body and pipe flanges. In cases where the diffuser plate size is higher than the valve body size or there is a need of multiple diffuser plates, vendor shall supply the complete diffuser assembly with flanged end connections.

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3.5.6 The silencer whenever offered for noise abatement shall always be supplied with flanged end connections.

3.6 Design Requirements for Control Valve Actuator

3.6.1 Pneumatic Actuator

a) Actuator shall be sized for the shut‐off differential pressure indicated in Data sheets. However, for 3‐way type control valve, the actuator shall be sized for maximum differential pressure, unless specifically indicated otherwise.

b) The actuator shall be designed to move the valve to the failure position specified in the Data sheet. For failure position specified as 'fail‐locked', vendor shall provide fail‐lock relays to meet the requirement.

c) Actuator casing shall be made of pressed steel or anodised aluminium. Non‐metallic actuator casings shall not be offered.

d) Springs shall be corrosion‐resistant and shall be cadmium or nickel‐plated. Alternately vendor standard coating shall also be acceptable. These shall be of the enclosed type. The compression of the springs shall be adjustable.

e) In general, an actuator operating range of 0.2‐to 1.0 kg/cm2g is preferred. However when vendor standard actuator model is not able to meet the specified shutoff pressure, higher actuator operating range may be offered.

f) In general, spring opposed diaphragms type actuators shall be used. Only when this type of actuator becomes extremely unwieldy, based on the data specified in the Datasheet, should a piston and cylinder type of actuator be considered.

g) Whenever piston and cylinder actuator is considered, single acting spring return type shall be used.

h) Whenever double acting springless type of actuator is unavoidable, all accessories like pilot valves, booster relays, non‐return valve, pressure gauge, volume tank etc. shall be provided to ensure desired action on air failure. The volume tank shall be sized considering full stroking of the valve for two complete cycles. The volume tank shall be of carbon steel construction and sized as per ASME Section VIII with design pressure of 10kg/cm2 g as a minimum. Accessories like pressure relief valves and tubing shall be of 316 Stainless steel construction. Other accessories can be of Cast Aluminium.

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i) The actuator casings and diaphragms shall be designed for minimum twice the

maximum pneumatic operating pressure of the control valve.

j) Valve stem position indicator shall be provided for every control valve. The position indicator scale shall be marked from 0 to 100% in steps of 10%.

k) In general, side‐mounted handwheels will be used. Hand wheels shall provide manual control in both opening and closing directions independent of spring action. Hand‐wheels shall be of non‐rising type suitable for accurate valve positioning .The hand‐wheel actuator shall be sized to provide the required thrust for valve positioning with 178N force applied to the hand‐wheel.

l) Actuator orientation shall be as per purchaser's requirements, in general. When, no requirements are indicated by purchaser, vendor shall provide recommended actuator orientation. It shall be possible to change this orientation at site for the offered valve‐actuator combination in case it is found necessary.

3.6.2 Actuator Sizing

3.6.2.1 Vendor shall be fully responsible for the sizing and selection of the correct actuator for the specified control valve. While sizing the actuator, vendor shall ensure that the actuator is able to develop sufficient thrust to properly seat the control valve plug/disc at the actuator air pressure (lowest specified pressure) and shut‐off conditions specified in the purchaser's data sheets.

3.6.2.2 While sizing the actuator, vendor must ensure that the sizing factor indicated below is fully complied. Higher sizing factor may be considered if found necessary by vendor.

a) For control valves with leakage class IV and below, the actuator shall be sized considering actuator thrust more than 1.3 times the total force induced by shut‐off conditions specified in the data sheet and the force required to overcome packing friction. Vendor shall utilize this factor as 1.5 in case the control valve is operating between 80% to 90% or 10% to 20% in any of the specified conditions

b) For control valves with leakage class V and above, the actuator shall be sized considering actual thrust more than 1.7 times the total force induced by specified shut‐off conditions in the Data sheet and the force required to overcome packing friction

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3.7 Design Requirements for Control Valve Packing Box, Bonnet and Stem

3.7.1 Packing Box

a) The packing box shall be flanged bolted to the bonnet and shall meet the requirements specified in Data sheet.

b) Generally low friction type packing like braided teflon will be used wherever operating conditions permit. For high temperature application (>200°C), Grafoil or equivalent gasket suitable for the specified service shall be selected.

c) Where specifically indicated, control valve shall have its packing box drilled and tapped to 1/4" NPT (F) for connecting external lubricator. When external lubricator is not provided, this hole shall be plugged.

d) An isolating valve shall be provided with all valves having external lubrication provision. Vendor shall specify the lubricator stick material used in each case.

e) For application in vacuum service, vendor to provide inverted packing design suitable for vacuum service. For pressure‐cum‐vacuum service, the control valve shall have dual packing design suitable for the application. Dual packing design shall also be provided for control valves in toxic service.

f) Wherever environmental packing design is specified vendor shall supply special packing design suitable to minimize fugitive emission.

3.7.2 Bonnet

a) The bonnet shall be flanged bolted to the body. Threaded bonnets are not permitted.

b) Wherever the operating temperature of the fluid is above 200°C, extension or radiation finned bonnet shall be provided. Vendor standard bonnet design shall also be acceptable if these are suitable for higher temperatures.

c) For temperature below O°C, vendor shall provide extended bonnet design. For valves in cryogenic application bonnet extension shall be as per BS‐6364 as a minimum.

3.7.3 Stem

a) The stem surface finish shall be fine. Extra fine surface finish shall be provided wherever the packing material is PTFE.

b) The stem/shaft shall be designed for the maximum thrust of the actuator without any measurable deflection.

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c) The valve stem/shaft shall be connected to the actuator stem/shaft by suitable arrangement to avoid backlash problem.

3.8 Design Requirements for Control Valve Accessories

3.8.1 Positioners

a) Positioners shall be of force‐balance type or smart digital type or field bus type as specified in the Datasheet. They shall be direct acting, with an adjustable gain unless otherwise specified.

b) The Positioner shall be provided with an integral by‐pass switch whenever the operating range of the actuator is the same as that of the control signal.

c) Every positioner shall have two pressure gauges mounted on it, one each for air supply and for positioner output to actuator.

d) In addition , pneumatic positioner shall have third pressure gauge for control signal.

e) Pneumatic connections shall be 1/4" NPT (F) and cable entry shall be 1/2 " NPTF . If connection for cable entry is different than that specified, suitable adapters shall be provided.

f) Positioners shall be side‐mounted on the control valve and shall have corrosion resistant linkages and rugged brackets.

3.8.2 Smart type and field bus type positioners

Digital smart positioners or field bus type of positioners with diagnostic capabilities shall be supplied whenever specified in the purchaser's data sheets. These shall meet the following minimum requirements:

a) The positioner sensor and sensing mechanism shall be rugged and shall not be affected by the line/valve vibration. The performance of the positioners shall be immune to above vibration.

b) The positioner's output and input range shall be field adjustable without any hardware modification. The output from the positioners shall be available for both single acting as well as double acting actuator.

c) Each positioner shall be operable, configurable and accessible through HART compatible hand held configurator/field bus configurator as applicable.

d) Unless otherwise specified, vendor shall offer smart positioner for control valves in critical applications such as split range, high pressure drop (>50kg/cm2) high temperature (>250°C), low temperature (<‐29°C), tight shut off leakage (leakage class ANSI class V and VI) and where vendor's calculations indicate phenomenon like

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cavitation, flashing and high noise level (>85 dBA) irrespective of requirements specified in Data sheet for such control valves.

e) The positioner shall be a two‐wire device, which shall operate on two‐way digital communication mode. All engineering, configuration, diagnostic and maintenance related data shall be provided by the positioner.

f) The smart positioner shall provide HART protocol of latest version and shall be capable of implementing commands from Instrument Asset Management System / hand‐held HART configurator.

g) Positioners with field bus output shall meet the following requirements:

i. All positioners must satisfy the requirements of the field bus registration laboratory with applicable checkmark like FieldBus foundation , Profibus Nutzerorganisation e.v (PNO) or as specified in the Data sheets.

ii. All positioners shall have analog output (AO) and controller blocks (PID).

iii. All positioners must be interoperable and shall have valid interoperability test clearance like ITK latest version for foundation field bus or equivalent for profibus PA, as applicable.

iv. The field bus positioners shall support peer‐to‐peer communication with two wire communicator and bus powered supply.

v. Field bus positioners as offered shall not be polarity sensitive. The field bus positioners shall be certified as per entity concept or shall be FISCO approved.

vi. Internal software shall be configured by the vendor including the following information:

‐Serial Number

‐Device tag(Tag No.)

‐Process Description/service

vii. Positioners shall be capable of supporting incremental Device Description (DD) for extra functionality and/or software revisions in Device memory.

h) The positioners shall be suitable to operate with commercially available asset management software and shall support the following features, as a minimum:

• It shall allow multimaster for configuration, calibration, diagnosis and maintenance. The primary could be a host computer and secondary could be a hand held communicator.

• It shall be .capable of implementing universal commands. It shall be possible to communicate all commands of commercially available asset management system to/ from smart positioner.

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i) The offered positioners shall meet the following performance characteristics:

• Overall control accuracy shall be better that +/‐0.5% of span.

• Repeatability shall be less than +/‐ 0.25% of span.

• Hysteresis shall be less than +/‐ 0.5% of span.

• Vendor shall supply the valve's operating signatures in the form of hard copy and soft copy for each control valve supplied with smart positioners.

j) All positioners shall have metallic casing and cover either of stainless steel or of anodized aluminium.

k) Fieldbus positioners shall support EDDL requirements as per IEC 61804/FDT/DTM requirements.

3.8.3 Electro‐Pneumatic Converter

a) Electro‐pneumatic converter shall be of electronic feedback type unless specified otherwise and shall be yoke mounted.

b) It shall have an integral terminal housing. Electro pneumatic converter with flying leads shall not be acceptable.

c) Unless otherwise mentioned, it shall be intrinsically safe.

d) Pneumatic connections shall be 1/4" NPT (F). The electrical connections shall be 1/2" NPT (F). If they are different, suitable adapters shall be provided.

e) The overall accuracy of the electro‐pneumatic converter shall be better than +/‐0.3%.

3.8.4 Air Filter Regulator

a) Vendor shall supply air filter regulator with each positioner complete with an integral output gauge

b) Air filter Regulator shall be sized considering the air supply pressure and flow required to meet the requirement mentioned in datasheet.

c) Filter material shall be sintered bronze. Filter size shall be maximum 5 micron. However, lower filter mesh size shall be considered to suit the eletropneumatic converter vendor's requirement.

3.8.5 Valve Jacketing

a) Jacketed valves shall have inlet/outlet steam connection shall be flanged. b) Valve end connection shall be one size higher than the normal valve connection for

jacketed valve.

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3.8.6 Hand held communicator/configurator

a) It shall be possible to perform routine configuration / calibration, display process variable, diagnostics etc. from Hand Held Communicator, which can be connected at any location in the loop. It shall be possible to perform all the above functions on line and the loop function shall remain unaffected.

b) There should be no interruption on the output while communicating with the positioner.

c) Hand held communicator shall be universal type and shall be compatible with all make and models of HART transmitters and smart Positioners with all engineering capability like calibration , diagnostics, configuration, inhibition of HART signal etc. Similarly Fieldbus Hand Held communicator shall also be universal type and shall be suitable for all make and models of FF transmitters and positioners.


• Marshalling cabinet serving the transmitter , in safe area

• Junction box serving the transmitter in hazardous area

• Directly at the transmitter/positioner in hazardous area


e) Offered communicator shall be dustproof, certified intrinsically safe and suitable for outdoor location. Carrying case shall be supplied with each communicator. The software shall also be capable of configuring the other makes of transmitters/positioners.

f) They shall be powered with replaceable and rechargeable battery suitable for recharging with 240 V AC 50 HZ. Replaceable battery and battery charger shall be supplied with each Hand held communicator. In case vendor standard doesn't permit rechargeable battery , vendor shall supply two sets of additional batteries.

3.9 Valve finish Valve body shall be painted as below:‐

a) Carbon steel body Light grey

b) Alloy steel body Canary yellow

c) Stainless steel body Natural

d) Above 150 Deg C Aluminium paint(White colour)

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Items like silencers, diffuser plate assemblies etc. shall be painted as per respective control valve body requirement

3.9.1 Actuator shall be painted as below:‐

a) Direct Action Valve(Open on air failure)‐ Green b) Reverse Action Valve(Close on air failure)‐ Yellow c) Actuators for shutdown valves‐ Red

Items like air volume tanks etc. shall be painted as per corresponding Actuator

3.10 End Connections


a) Threaded end connections shall be to NPT as per ASME B 1.20.1. b) Flanged end connections shall be as per ASME B 16.5/ B 16.47B/ AWWAA C207 CL.D. c) RTJ flanges shall be with octagonal Grooves as per ASME B 16.20 d) Flange face finish shall be as per ASME B16.5 and shall be


3.10.2 Face‐to‐face dimensions of globe type control valves shall be in accordance with ISA 75.08.

3.10.3 Where provided, control valve bottom drains shall be plugged off or blind flanged. Where a plug is used, threads shall correspond to ASME B 1.20.1 (NPT). Where a flange is used, its dimensions and rating shall correspond to ASME B 16.5.

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4.0 DOCUMENTATION



Review/ Approval QUALITY ASSURANCE PLAN (QAP) For Approval PRODUCTION PROGRAMME For Review INSTRUMENT DATA SHEETS For Approval INST GA / INSTALLATION DRAWINGS For Approval certified values of failure rates, probability of failure on demand (PFD) and test intervals for offered items for Safety Integrity Level (SIL) analysis

SIL data

DTM/EDDL file etc.




a) Specification sheet/ Data sheet/ Sizing Sheet for each Control valve with accessories. b) As built drawings for each Control valve with accessories, providing dimensional

details(face‐to‐face and height of completely assembled valve), Dimensions of clearance space for maintenance work, weight of completely assembled valve , constructional details, connection details, orientation with respect to flow direction marked on the body and material of construction.

c) Copy of the type test certificates. d) Copy of test certificates for all the tests as per MR and Documents along with TPI/ IRN. e) Installation procedure for each control valve along with their accessories. f) Calibration, configuration and maintenance procedures including replacement of its

parts/ internals wherever applicable

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g) Control valve operating signatures whenever smart positioners or field bus based positioners are specified.

h) Device Descriptor (DD) Files for configuring the device parameters (Smart positioner /Fieldbus parameters)

i) Common File Format (CFF) files for integrating the device into the system (Soft COPY). j) BOM including spares (if applicable) k) Product Catalogs of Main equipment and accessories/ bought‐outs.


5.0 NAME PLATE

a) Tag No. as per purchaser's datasheet b) Body Size and port size in inches c) Valve flow coefficient(Cv) d) Stem travel in millimetres e) Action on Air failure f) Spring range g) Air supply pressure h) Manufacturer's name. i) Manufacturers serial no. and model no. for Valve body, Actuator and

positioner.


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6.0 SHIPPING


6.2 Control valve and its accessories shall be supplied preassembled and pretubed

6.3 Control valves with external lubricators shall be lubricated before shipment





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On‐Off Valves

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Contents


1.0 General 3




5.0 Name Plate 22

6.0 Shipping 23

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of On‐off valves with accessories.



1.3 Enclosed data sheets specify the material for On‐off Valves along with their accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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B 1.20.1 Pipe Threads General purpose (Inch) B 16.5 Pipe Flanges and Flanged Fittings B 16.10 Face to face dimension and grooves B 16.20 Metallic gaskets for Pipe flanges‐ Ring joint, Spiral wound and

jacketed. B 16.34 Valves ‐ flanged, Threaded and Welding End. B 16.47 Large Diameter Steel Flanges

2.2 ANSI/FCI American National Standard Institute/Fluid Control Institute

FCI 70‐2 Leakage class classification


6D Pipelines valves (Gate valve, Plug, Ball and Check valves) 598 Inspection Requirements 609 Lug and wafer type, Butterfly valves 6 FA Specification for Fire Test of Valves API 607-4 Fire test for soft seated valves. API 608 Metal Ball Valves - Flanged, Threaded and welding end

2.4 AWWA American Water Works Association ‐ Steel Pipe Flanges For C207 CL.D Water Works Services


6364 Valves in cryogenic service European Standards 6755 Part 2 Testing of Valves ‐ Specification For Fire type ‐ testing

requirements


10204 Inspection Documents For Metallic Products 61056‐1 Specification for performance, design and construction of

valve, regulated sealed type.

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Measurement and Control Equipment IEC 61 158 Fieldbus Standard for use in Industrial Control System IEC 61158‐2 Physical Layer Specification and service definition for Fieldbus IEC 61508 Functional Safety of Electrical/Electronic/Programmable

Electronic Safety related Systems. IEC 61511 Functional safety instrumented system for the process industry

sector IEC 61804 Function blocks (FB) for process control ‐ Electronic Device Description

IEC 60534‐3‐2 Face to Face dimension of rotary valves except butterfly valves. IEC 60534‐4 Seat leakage IEC 60534‐8.3 Industrial process control valves, noise consideration, control

valve aerodynamic noise prediction method


75.01.01 Flow equation for sizing control valves. 75.02 Control valve capacity test procedure. TR75.04 Control Valve positioner stability 75.05.01 Control Valve terminology

75.08.01 Face to face dimensions for integral flanged Globe‐style control valve bodies (ASME Class 125,150,300 and 600)

75.08.02 Face to face dimensions for flangeless control valve (ASME Class 150,300 and 600)

75.08.04 Face to face dimensions for Buttweld‐end globe style control valve (ASME Class 4500)

75.08.05 Face to face dimensions for Buttweld‐end globe style control valve (ASME Class l5O,3OO,6OO,9OO, 1500 and 2500)

75.08.06 Face to face dimensions for flanged Globe‐style control valve bodies (ASME Class 900,1500 and 2500)

75.11.01 Inherent flow characteristic and Rangeability of control valves. 75.19.01 Hydrostatic testing of control valves.

75.22 Face to centre‐line dimensions for flanged Globe‐style Angle control valve bodies (ASME Class 150,300 and 600)

75.25.01 Test Procedure for Control valve response measurement for step inputs

TR75.25.02 Control valve response measurement for step inputs 75.25.13 Method of evaluating the performance of positioners with

analog input signals and pneumatic output.

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2.11 MSS Manufacturer's Standardisation Society

SP25 Standard Markings System for Valves, Fittings, Flanges and Unions

2.12 NACE National Association of Common Engineers

MR0103 Materials Resistant to Sulphide stress cracking in Corrosive Petroleum Refinery Environments

2.13 OSHA Occupational Safety and Health Authority

2.14 Abbreviations:


EDDL Electronics Device Description Language FISCO Fieldbus Intrinsic Safety Concept FDT/DTM Field Device Tool/ Device Type Manager FF Fieldbus Foundation HART Highway Addressable Remote Transducer LAS Link Active Scheduler LCD Liquid Crystal Display NPS Nominal Pipe Size RAM Random Access Memory WC Water Column CIMFR Central Institute of Mining and Fuel Research ERTL Electronics Regional Testing Laboratory HHT Hand Held Terminal NACE National Association of Corrosion Engineers PID Proportional, Integral and Derivative PTFE Poly Tetra Fluoro Ethylene SS Stainless Steel TSO Tight Shutoff CIMFR Central Institute of Mining and Fuel Research DD Device Description DPDT Double Pole Double Throw MVT Manual Valve Testing PFD Probability of Failure on Demand PST Partial Stroke Testing

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3.1 General Requirements for On off Valves

3.1.1 For valves in cryogenic service, vendor shall meet the following acceptance criteria:

a) Vendor shall furnish, along with the offer, type test certificate, duly witnessed by Third Party Inspection agency like MIS LRIS, DNV BV, TUV, CEIL etc. of having successfully conducted the cryogenic test as per BS 6364 on the offered valves (same model, size, rating and material) in cryogenic service. Further vendor to note the following:

i. Test temperature shall be ‐45 Deg C for LTCS and ‐196 Deg C for all grades of austenitic Stainless Steel.

ii. Test carried out on a particular size of one type of valve, pressure rating and material shall qualify all sizes equal to and below the test valve size for the same type, pressure rating and material. In case of austenitic Stainless Steel any one grade would qualify for other grades of austenitic Stainless Steel.

b) In case vendor does not have cryogenic type test certificate for the offered valves as mentioned above, vendor shall confirm to conduct the cryogenic test on the offered valves and furnish type test report meeting requirements specified above.

3.2 Design Requirements for On-off Valve Body

3.2.1 On‐off valves shall have flanged end connections integral to the valve body. Top entry valve design shall not be offered unless specifically indicated in the Data sheets.

3.2.2 Whenever flangeless on off valve body design is specified in the Data sheet, following shall apply:

a) Wafer type or lug type body design for on‐ff valves body size up to 6 inches.

b) Lug type body design for butterfly type of on‐ff valve body size more than 6 inches.

3.2.3 The valve body rating should be equal to or higher than the flange rating specified in the data sheets. As a minimum, on‐ff valve body shall be rated for ASME Class 300. However, end connection shall be as specified in Data sheet.

3.2.4 The on‐off valves shall be suitable for installation in horizontal as well as in vertical lines. For all applications, where full port valves are specified, following shall apply:

a) Port size shall be equal to line size for rating up to ASME Class 1500.

b) Port size shall not be smaller than one size lower than that of the line size for body rating ASME Class 1500 and above.

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3.2.5 For steam jacketed valves, the body and port size shall be one size lower than the on‐off valve end connection.

3.2.6 Flow Direction

3.2.6.1 Flow direction shall be clearly marked on the on‐off valve body.

3.2.6.2 For 3‐way on‐off valves, service like mixing or diverting, shall be clearly identified with inlet and outlet end connection clearly marked on the on‐off valve body.

3.2.7 Material of Construction

a) The material of construction of on‐off valves shall be as specified in the data sheet.

b) On‐off valve body, bonnet, flanges and other pressure containing assemblies shall be of the same material of construction as specified for valve body in the data sheets.

c) The bonnet flange and bottom flange shall have metallic spiral wound gaskets suitable for the specified service.

d) Vendor shall be responsible for selecting proper material for the internal parts of on‐off valve. All such materials shall have the same or better specification than specified in the data sheets.

3.3 Design Requirements: Trim

3.3.1 The term 'trim' covers those parts of valve assembly (excluding the body, bonnet and bottom flange) which are exposed to and are in contact with the line medium consisting of but not limited to the seat ring, valve stem, valve plug/disc/ball, valve plug guide, guide bushing and cage etc.

3.3.2 In case of ball‐type of on‐off valves:

• The valve design shall ensure valve seat and body protection against thermal expansion of the entrapped fluid when the on‐off valve is fully close.

• In case of ball‐type of on‐off valves for size up to 4" and rating up to ASME Class 300, the on‐off valve shall have floating ball design. For ratings ASME Class 600

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and above, floating ball is acceptable for sizes less than 2". For higher sizes trunion mounted ball design shall be provided.

3.3.3 Guiding

a) Single seated globe (unbalanced) and angle type on‐off valves shall have heavy top plug guiding. Stem guided on‐off valve design shall not be acceptable.

b) Rotary type on‐off valves like Ball valves, butterfly valves etc. shall have blow out proof shaft guiding design.

c) Guide bushing shall be of a sufficiently hard material to resist side thrust on the plug or shaft.

3.3.4 Trim Design

3.3.4.1 Valve manufacturer/vendor shall be responsible for trim selection and trim design of the on‐off valve. However it must meet the following minimum requirements:

a) Valve characteristics shall be quick opening (on‐off) type unless otherwise specifically mentioned in datasheet.

b) The trim design and material of construction shall be selected to minimize the risk of galling . Vendor shall select proper material pairs, surface finish, hardness and clearances wherever possibility of galling exist.

c) Under extreme temperature conditions, vendor shall consider increased clearances at room temperature and seal welding of threaded seat rings etc. Hard facing of trim shall be used in high temperatures(above 200 deg C). For very low temperature application, material used shall have adequate cold impact strength.

d) For all on off valve including 3‐way type of valves, Stem and Plug shall be detachable and shall be attached together by suitable threaded design secured with a pin to avoid plug rotation during operation.

3.3.4.2 Trim Material

Whenever stellited trim or hardened SS trim is specified in the data sheets following material of construction for the trim parts shall be acceptable provided same are compatible with the specified process conditions;

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. a) Ball/Disc/Plug and seat : Stellite sheathing/hard alloy coating or solid stellite

17‐4PH SS or SS 440C

b) Guide : Stellite sheath/hard alloy coating or solid

stellite,17‐4PH SS or SS 440C.

c) Stem: 17‐4PH SS,Hastelloy

Special material requirements, if specified in the datasheets, shall supersede the above mentioned requirements.

3.3.4.3 In case of rotary valves, vendor shall select the stem bearing type and material as per the process conditions. Material of construction shall be as per the wetted part material specified in Datasheet, as a minimum.

3.3.4.4 Leakage class

a) Leakage class shall be as per ANSI FCI 70.2 and shall be as per Data sheet for each valve. Where no leakage class is specified, the same shall be considered as Class IV.

b) For valves specified with Class VI leakage class, vendor shall select the soft seat (elastomer) material suitable for the process conditions i.e., shut off pressure, maximum temperature and process fluid. Metal seated on‐off valves meeting the leakage class shall also be acceptable.

3.4 Design Requirements for On-off Valve Sizing

3.4.1 Body size of on‐off valve shall be same as the line size. Valve sizing shall be carried out only for those on‐off valves where Datasheet specify the same.

3.5 Design Requirements for Valve Actuator

3.5.1 Pneumatic Actuator a) Actuator shall be sized for the shut‐off differential pressure indicated in Data

sheets. However, for 3‐way valve, the actuator shall be sized for maximum differential pressure, unless specifically indicated otherwise.

b) The actuator shall be designed to move the valve to the failure position specified in the Data sheet. For failure position specified as 'fail‐locked', vendor

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shall provide Air reservoir with all the accessories to meet the requirement. Air reservoir shall be designed considering full stroking of the valve for one complete cycle. Air reservoir shall be carbon construction and sized as per ASME section VIII with design pressure 10Kg/Cm2g as a minimum. All accessories and tubing shall be SS316

c) Actuator casing shall be made of pressed steel or anodised aluminium. Non‐metallic actuator casings shall not be offered.

d) Springs shall be corrosion‐resistant and shall be cadmium or nickel‐plated. These shall be of the enclosed type. The compression of the springs shall be adjustable.

e) The actuators shall be sized for maximum air pressure of 3.5 Kg/ cm2, unless otherwise specified in the datasheet.

f) In general, spring opposed diaphragms type actuators shall be used. Only when this type of actuator becomes extremely unwieldy, based on the data specified in the Datasheet, should a piston and cylinder type of actuator be considered.

g) Whenever piston and cylinder actuator is considered, single acting spring return type shall be used.

h) Whenever double acting springless type of actuator is unavoidable, all accessories like pilot valves, booster relays, non‐return valve, pressure gauge, volume tank etc. shall be provided to ensure desired action on air failure. The volume tank shall be sized considering full stroking of the valve for three complete cycles. The volume tank shall be of carbon steel construction and sized as per ASME Section VIII with design pressure of 10kg/cm2 g as a minimum. Accessories like pressure relief valves and tubing shall be of 316 Stainless steel construction. Other accessories can be of Cast Aluminium.

i) The actuator casings and diaphragms shall be designed for minimum twice the maximum pneumatic operating pressure of the valve.

j) Valve stem position indicator shall be provided for each valve. The position indicator scale shall be marked from 0 to 100% in steps of 10%.

k) In general, side‐mounted handwheels will be used. Hand wheels shall provide manual on‐off in both opening and closing directions independent of spring

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action. Hand‐wheels shall be of non‐rising type suitable for accurate valve positioning .The hand‐wheel actuator shall be sized to provide the required thrust for valve positioning with 178N force applied to the hand‐wheel.

l) Actuator orientation shall be as per purchaser's requirements, in general. When, no requirements are indicated by purchaser, vendor shall provide recommended actuator orientation. It shall be possible to change this orientation at site for the offered valve‐actuator combination in case it is found necessary.

m) For the on off valve where operating time is specified in Datasheet/MR , vendor shall design the actuator and its accessories to meet these requirements.

3.5.2 Actuator Sizing

3.5.2.1 Vendor shall be fully responsible for the sizing and selection of the correct actuator for the specified valve. While sizing the actuator, vendor shall ensure that the actuator is able to develop sufficient thrust to properly seat the on off valve at the actuator air pressure (lowest specified pressure) and shut‐off conditions specified in the data sheets.

3.5.2.2 While sizing the actuator, vendor shall consider actuator thrust equal to two times the total force induced by shut off condition specified in the Datasheet and the force required to overcome packing friction.

3.6 Design Requirements for Packing Box, Bonnet and Stem

3.6.1 Packing Box

a) The packing box shall be flanged bolted to the bonnet and shall meet the requirements specified in Data sheet.

b) Generally low friction type packing like braided teflon will be used wherever operating conditions permit. For high temperature application (>200°C), Grafoil or equivalent gasket suitable for the specified service shall be selected.

c) Wherever on off valve is offered with external lubricator, it shall have its packing box drilled and tapped to 1/4" NPT (F) as per ASME B 1.20.1 for connecting external lubricator.

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d) An isolating valve shall be provided with all valves having external lubrication provision. Vendor shall supply the lubricator stick in each case.

e) For application in vacuum service, vendor to provide inverted packing design suitable for vacuum service. For pressure‐cum‐vacuum service, the valve shall have dual packing design suitable for the application. Dual packing design shall also be provided for valves in toxic service with facility to connect inert fluid between packings.

f) Wherever environmental packing design is specified vendor shall supply special packing design suitable to minimize fugitive emission.

g) 3 way on off valve of either diverting or mixing type shall have PTFE box rings.

3.6.2 Bonnet

a) The bonnet shall be flanged bolted to the body. Threaded bonnets are not permitted.

b) Wherever the operating temperature of the fluid is above 200°C, extension or radiation finned bonnet shall be provided. Vendor standard bonnet design shall also be acceptable if these are suitable for higher temperatures.

c) For temperature below 0°C, vendor shall provide extended bonnet design. For valves in cryogenic application bonnet extension shall be as per BS‐6364 as a minimum.

3.6.3 Stem

a) The stem surface finish shall be fine. Extra fine surface finish shall be provided wherever the packing material is PTFE.

b) The stem/shaft shall be designed for the maximum thrust of the actuator without any measurable deflection.

c) The valve stem/shaft shall be connected to the actuator stem/shaft by suitable arrangement to avoid backlash problem..

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3.7 Design Requirements for Valve Accessories

3.7.1 Positioners

a) Positioners shall be of force‐balance type or smart digital type or field bus type as specified in the Datasheet. They shall be direct acting, with an adjustable gain unless otherwise specified.

b) The Positioner shall be provided with an integral by‐pass switch whenever the operating range of the actuator is the same as that of the control signal.

c) Every positioner shall have two pressure gauges mounted on it, one each for air supply and for positioner output to actuator.

d) Cable entry shall be 1/2 " NPTF. If connection for cable entry is different than that specified, suitable adapters shall be provided.

e) Positioners shall be side‐mounted on the on‐off valve and shall have corrosion resistant linkages and rugged brackets.

3.7.2 Smart type and field bus type positioners

Digital smart positioners with diagnostic capabilities shall be supplied whenever specified in the purchaser's data sheets. These shall meet the following minimum requirements:

a) The positioner sensor and sensing mechanism shall be rugged and shall not be affected by the line/valve vibration. The performance of the positioners shall be immune to above vibration.

b) The positioner's output and input range shall be field adjustable without any hardware modification. The output from the positioners shall be available for both single acting as well as double acting actuator.

c) Each positioner shall be operable, configurable and accessible through HART compatible hand held configurator/field bus configurator as applicable.

d) The positioner shall be a two‐wire device, which shall operate on two‐way digital communication mode. All engineering, configuration, diagnostic and maintenance related data shall be provided by the positioner.

e) The smart positioner shall provide HART protocol of latest version and shall be capable of implementing commands from Instrument Asset Management System / hand‐held HART configurator.

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f) The positioners shall be suitable to operate with commercially available asset management software and shall support the following features, as a minimum:

• It shall allow multimaster for configuration, calibration, diagnosis and maintenance. The primary could be a host computer and secondary could be a hand held communicator.

• It shall be .capable of implementing universal commands. It shall be possible to communicate all commands of commercially available asset management system to/ from smart positioner.

g) The offered positioners shall meet the following performance characteristics:

i) Overall control accuracy shall be better that +/‐0.5% of span.

ii) Repeatability shall be less than +/‐ 0.25% of span.

iii) Hysteresis shall be less than +/‐ 0.5% of span.

iv) Vendor shall supply the valve's operating signatures in the form of hard copy and soft copy for each on‐off valve supplied with smart positioners.

h) All positioners shall have metallic casing and cover either of stainless steel or of anodized aluminium.

3.7.3 Air Filter Regulator

a) Vendor shall supply air filter regulator with each positioner complete with an integral output gauge

b) Air filter Regulator shall be sized considering the air supply pressure and flow required to meet the requirement mentioned in datasheet.

c) Filter material shall be sintered bronze. Filter size shall be maximum 5 micron.

3.7.4 Valve Jacketing

a) Jacketed valves shall have inlet/outlet steam connection shall be flanged. b) Valve end connection shall be one size higher than the normal valve connection

for jacketed valve.

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3.7.5 Limit Switches

Limit switches shall be provided for open and close positions suitably mounted in a Limit Switch Box. The limit switches shall be proximity type switches unless otherwise specified.

3.7.6 Hand held communicator/configurator

a) It shall be possible to perform routine configuration / calibration, display process variable, diagnostics etc. from Hand Held Communicator, which can be connected at any location in the loop. It shall be possible to perform all the above functions on line and the loop function shall remain unaffected.

b) There should be no interruption on the output while communicating with the positioner.

c) Hand held communicator shall be universal type and shall be compatible with all make and models of HART transmitters and smart Positioners with all engineering capability like calibration , diagnostics, configuration, inhibition of HART signal etc. Similarly Fieldbus Hand Held communicator shall also be universal type and shall be suitable for all make and models of FF transmitters and positioners.


• Marshalling cabinet serving the transmitter , in safe area

• Junction box serving the transmitter in hazardous area

• Directly at the transmitter/positioner in hazardous area


e) Offered communicator shall be dustproof, certified intrinsically safe and suitable for outdoor location. Carrying case shall be supplied with each communicator. The software shall also be capable of configuring the other makes of transmitters/positioners.

f) They shall be powered with replaceable and rechargeable battery suitable for recharging with 240 V AC 50 HZ. Replaceable battery and battery charger shall be supplied with each Hand held communicator. In case vendor standard doesn't permit rechargeable battery , vendor shall supply two sets of additional batteries.

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3.8 Valve finish

Valve body shall be painted as below:‐

a) Carbon steel body‐ Light grey

b) Alloy steel body‐ Canary yellow

c) Stainless steel body‐ Natural

d) Above 150 Deg C‐ Aluminium paint(White colour)

Items like silencers, diffuser plate assemblies etc. shall be painted as per respective on‐off valve body requirement

3.8.1 Actuator shall be painted as below:‐

a) Direct Action Valve(Open on air failure)‐ Green b) Reverse Action Valve(Close on air failure)‐ Yellow c) Actuators for shutdown valves‐ Red

Items like air volume tanks etc. shall be painted as per corresponding Actuator

3.9 End Connections


a) Threaded end connections shall be to NPT as per ASME B 1.20.1. b) Flanged end connections shall be as per ASME B 16.5 c) RTJ flanges shall be with octagonal Grooves as per ASME B 16.20 d) Flange face finish shall be as per ASME B16.5 and shall be


3.9.2 Face‐to‐face dimensions of globe type on‐off valves shall be in accordance with standards specified in this specification.

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3.9.3 Where provided, on‐off valve bottom drains shall be plugged off or blind flanged. Where a plug is used, threads shall correspond to ASME B 1.20.1 (NPT). Where a flange is used, its dimensions and rating shall correspond to ASME B 16.5.

3.10 Special Requirements:

3.10.1 On‐Off Valve stroke testing:

Whenever specified in the data sheet / specifications, the operational integrity of the on‐off valves shall be verified at regular intervals by performing physical testing without upsetting the process / operation. The methodology of testing adopted shall also be indicated in the data sheets. The testing scheme shall be designed by the vendor to meet specified operational functional and safety requirements specified below;

3.10.1.1 Manual Valve Testing (MVT)

Manual valve testing scheme shall be designed by the vendor to ensure operational integrity of actuating components i.e. solenoid valves etc without stroking the on‐off valve. The test hardware shall meet the following requirements; The manual valve testing scheme shall be designed and supplied complete with minimum two solenoid valves, a two position (normal test) manual switch (with lock) and a pressure gauge (50mm dial). The scheme shall meet the following functional requirements;

a) There shall be no upset or disturbance in the process while carrying out MVT. The solenoid valves, therefore shall be pneumatically tubed in 2 out of 2 configuration. b) While in test mode, the switch shall supply air supply to actuator bypassing the accessories. The solenoid valves are manually actuated one by one with their operational status indicated by pressure gauge. c) No software for MVT is in vendor's scope, however, an electrical contact rated for 11OV, 0.5 A DC shall be provided to purchaser for audit trail when in test position.

. 3.10.1.2 Partial Stroke Testing (PST)

Partial stroke testing shall be performed to ensure satisfactory operation of on‐off valve including all accessories on demand. The test shall be performed automatically by partially (around 10%) stroking the valve while these valves are in service. The

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test hardware and software shall meet the following minimum requirements;

a. Partial stroke test scheme shall be complete with all hardware and softwares which shall include solenoid valves, valve positioner and logic solver. All components used in PST shall be fail safe and shall not affect the on‐off valve performance under any circumstances.

b) The PST design shall ensure;

• The testing shall be carried out automatically at pre‐defined intervals which shall be adjustable.

The shutdown demand shall always over‐ride if PST is in operation at that time.

The valve shall not operate beyond a predefined maximum allowable stroke valve under any condition or failure. When valve positioner is used to realise PST, the positioner output shall be limited beyond the allowable value in case of valve struck condition.

Audit trail shall be available to indicate time and date of PST, test results (OK 1 fail), reason of failure, changes made etc as a minimum.

Upward connectivity to purchaser's Host system.

Vendor shall supply the complete testing assembly duly tubed / piped / wired

on a SS mounting plate of thickness 3.2mm suitable for 2" pipe stanchion mounting. Standard pre designed rigidly mounted components shall also be acceptable for PST assembly.

3.10.2 Fire Safe Design Requirements

3.10.2.1 Wherever the valves are indicated as fire safe on the data sheets they shall be

tested for fire safe as per BS 6755 (Part‐2) when the valves are supplied with metal‐to‐metal seats and shall be tested as per API 607 latest edition when the valves are provided with soft seats. In case soft‐seated valves with fire safe design are offered, vendor's design shall be such that soft seat is not damaged while closing/opening of the valve.

3.10.2.2 Wherever fire safe actuator and controls have been asked for, actuators and all

accessories such as solenoid valves, air volume bottles etc. shall meet the fire proof requirement to ensure normal valve operation even during and after exposure to fire. Vendor shall clearly define the schemes they propose to achieve the above requirements and ensure that the proposed schemes shall meet the requirement in terms of type of exposure and exposure time of the

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testing procedure given in BS 6755/ API 607. Vendor must note that all items i.e. actuators, its accessories and interconnecting tubing including Volume bottles is required to be protected under fire exposure conditions. The fire protection methodologies like fully enclosed fireboxes or special material coverage are acceptable provided fire safe certification is provided for complete assembly as indicated above.

3.10.2.3 Vendor shall furnish type test certificate duly witnessed by third party inspection agency like MIS LRIS,BV,DNV,TUV etc. for fire safe testing of valve, actuator and controls for the offered models along with the offer. Vendor to note that fire safe box upto maximum twice the surface area of fire box already satisfactorily fire safe type tested is acceptable provided the clearance inside the fire box with all accessories duly mounted are maintained equal to or greater than those maintained in fire safe box successfully type tested. In case, earlier fire safe test carried out by vendor is not applicable for quoted size hating of the valve, fire safe box, then vendor shall carry out the test for fire safe design for the offered valves / actuators & controls.

3.10.2.4 Backup volume bottles for the valve operation shall be designed in line with ASME Sec. VIII requirement. Each volume bottle shall be sized for a minimum of 3 valve strokes. Backup bottles shall also meet the requirement of fireproofing in case fireproof actuators and controls have been asked for.

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4.0 DOCUMENTATION



Review/ Approval QUALITY ASSURANCE PLAN (QAP) For Approval PRODUCTION PROGRAMME For Review INSTRUMENT DATA SHEETS For Approval INST GA / INSTALLATION DRAWINGS For Approval Certified values of failure rates, probability of failure on demand (PFD) and test intervals for offered items for Safety Integrity Level (SIL) analysis SIL data DTM/EDDL file etc. BILL OF MATERIALS INCLUDING SPARES For Review



a) Specification sheet/ Data sheet/ Sizing Sheet for each ON‐OFF valve with accessories. b) As built drawings for each on-off valve with accessories, providing dimensional

details(face‐to‐face and height of completely assembled valve), Dimensions of clearance space for maintenance work, weight of completely assembled valve , constructional details, connection details, actuator orientation with respect to flow direction marked on the body and material of construction.

c) Copy of test certificates for all the tests as per MR and Documents along with TPI/ IRN. d) Installation procedure for each on‐off valve along with their accessories. e) Calibration, configuration and maintenance procedures including replacement of its

parts/ internals wherever applicable

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f) Valve operating signatures whenever smart positioners or field bus based positioners are specified with on‐off valve.

g) Device Descriptor (DD) Files for configuring the device parameters (Smart positioner /Fieldbus parameters)

h) Common File Format (CFF) files for integrating the device into the system (Soft COPY). i) BOM including spares (if applicable) j) Product Catalogs of Main equipment and accessories/ bought‐outs.


5.0 NAME PLATE

a) Tag No. as per purchaser's datasheet b) Body Size and port size in inches c) Stem travel in millimetres d) Action on Air failure e) Spring range f) Air supply pressure g) Manufacturer's name. h) Manufacturers serial no. and model no. for Valve body, Actuator and

positioner.

Other details as per MR shall also be suitably indicated on the Valve/ Actuator

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6.0 SHIPPING


6.2 On off Valve and its accessories shall be supplied preassembled and pre tubed.

6.3 On off valves with external lubricators shall be lubricated before shipment





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INSTRUMENT VALVES & ACCESSORIES

Instrument Valves and

Accessories

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Contents


1.0 General 3



4.0 Documentation 8

5.0 Name Plate 9

6.0 Shipping 9

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of :‐

a) Miniature Instrument Valve

b) Instrument Valve Manifolds

c) Instrument Air Valves



1.3 Enclosed data sheets specify the material for Instrument valves and Manifolds and its accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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B 1.20.1 Pipe Threads General purpose (Inch) B 16.11 Forged steel fittings‐socket welding and threaded B 16.9 Factory made wrought steel Butt welding fitting B 16.34 Valves ‐ flanged, Threaded and Welding End.




598 Valve Inspection and Testing


2.5 MSS Manufacturers Standardisation Society of the valve and Fitting Industry

SP99 Instrument Valves

2.6 Abbreviations:


PTFE Poly Tetra Fluoro Ethylene

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3.0 DESIGN REQUIREMENTS 3.1 General Requirements

3.1.1 Qualification test(Hydrostatic proof and burst test) as per MSS SP‐99 shall be conducted by vendor for each design and size of the valve to establish the cold working pressure(CWP) rating.

3.1.2 For all valves and manifolds with body material of Carbon steel/Stainless steel, the valve trim material shall be 316SS or superior. Whenever body material is other, trim material shall be same as body material or superior.

3.1.3 Unless otherwise specified, valve packing material for all valves and manifolds shall be PTFE only. O ring material whenever used shall also be of PTFE.

3.1.4 Finishing and tolerance of parts like stem, piston, stem threading etc. of the offered valves and manifolds shall be properly machined to avoid problems like galling.

3.1.5 Hand wheel material for all valves and manifolds shall be Zinc/nickel plated carbon steel. Any other material, if provided as per standard vendor design shall also be acceptable.

3.1.6 Minimum cold working pressure (CWP) rating of manifolds shall be as per the table below.

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3.2 Instrument Valve (Miniature)

3.2.1 The instrument valve shall be of globe pattern needle valve forged/bar stock with inside screwed bonnet with back seated blow out proof system.

3.2.2 Body Material shall be SS 316 ,unless specified otherwise.

3.2.3 End connection shall be 1/2"NPTF to ASME B 1.20.1, unless specified otherwise.

3.2.4 Flow direction shall be marked on the body.

3.2.5 Valve dimension shall be as follows:‐

a) End to End dimension: 76 mm approx.

b) Height in fully open condition‐135 mm max.

These dimensions are indicative only.

3.3 Valve Manifolds

3.3.1 General requirement for Valve Manifolds

a) The flanges shall be integral part of manifold block.

b) Material of construction shall be SS 316 unless specified otherwise.

c) Process connection shall be 1/2"NPTF to ASME B 1.20.1, unless specified otherwise.

d) Wherever the manifolds are specified for stanchion mounting, these shall be supplied along with mounting accessories. The bolds and nuts shall be alloy steel as per ASTM A 193 Gr B7 and ASTM A194 Gr. 2H (Hot dip galvanised or Zinc plated) respectively. Other accessories shall be Zinc plated.

3.3.2 3 way valve manifold

a) 3 way valve manifold shall be designed for direct coupling to differential pressure transmitters having 2 bolt flanges with 54mm(2‐1/8 ") centre to centre connections and 41.3 mm(1‐5/8")bolt to bold distance.

b) 3 way valve manifold shall contain two main line block valves and equalising bypass valve . The valves shall be needle type. They shall use self aligning 316 SS ball seats, unless specified otherwise.

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3.3.3 5 way valve manifold

a) 5 way valve manifold shall be designed for direct coupling to differential pressure transmitters having 2 bolt flanges with 54mm(2‐1/8 ") centre to centre connections and 41.3 mm(1‐5/8")bolt to bold distance.

b) 5 way valve manifold shall contain two main line block valves and a combination of double block and bleed for the bypass line. The vales shall be needle type or special ball with bleed hole.

3.3.4 3 way 2 way valve manifold for pressure gauges

a) Manifold shall be designed for use with Pressure gauge with block and bleed valves. The manifold body shall be either straight or angle type as specified in the datasheet.

b) The valve shall be a needle type. c) Material of construction shall be SS 316 unless specified otherwise. d) Manifold shall have the following connections:

i. The inlet connection shall be 3/4"plain ends with a minimum of 100mm nipple

extension suitable for socket weld or butt or butt weld as per B16.11/B16.9. ii. The gauge connection shall be with union nut and tail piece threaded to 1/2" NPTF iii. The drain connection shall be 1/2"NPTF

3.4 Instrument Air valves

3.4.1 Instrument Air Isolation valves (Miniature)

i. The valves shall be full bore ball type with forged body ii. Material of construction shall be SS 316 . iii. End connection shall be 1/2"NPTF to ASME B 1.20.1, unless specified otherwise. iv. End to end dimension shall be 70mm(approx.)

3.4.2 Instrument Air needle valve (Miniature)

a) The instrument valves shall be globe pattern needle valve forged/bar stock with inside screwed bonnet.

b) Material of construction shall be SS 316 . c) End connection shall be 1/2"NPTF to ASME B 1.20.1, unless specified otherwise. d) Flow direction shall be marked on the body

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e) Valve dimension shall be as follows:‐ i. End to end dimension shall be 54mm(approx.) ii. Height in fully open condition‐49mm(approx)

These dimensions are indicative only.

3.5 All valves and manifolds tubes in oxygen and chlorine service shall be thoroughly degreased using reagents like trichloro‐ethylene or carbon tetrachloride and end connections shall be plugged after degreasing process in order to avoid entrance of grease or oil particles.

4.0 DOCUMENTATION






a) Specification sheet/ Data sheet for each type of instrument Valve and Manifold b) As built drawings, providing dimensional details, constructional details and material

of construction. c) Copy of test certificates for all the tests as per MR and Documents along with TPI/

IRN. d) Installation and maintenance procedure . e) BOM including spares (if applicable) f) Product Catalogs of Main equipment and accessories/ bought‐outs.


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5.0 NAME PLATE

a) Material of construction b) Cold working pressure of each item c) Manufacturer's name. d) Manufacturers serial no. and model no. e) Flow direction(if applicable)

Other details as per MR shall also be suitably indicated on the valve/manifold

6.0 SHIPPING





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Level Instruments

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Contents


1.0 General 3




5.0 Name Plate 12

6.0 Shipping 12

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Level Instruments with accessories.

1.2 Level instruments along with their accessories shall be supplied in fully assembled condition



1.4 Enclosed data sheets specify the material for Level instruments along with their accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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B 1.20.1 Pipe Threads General purpose (Inch) B 16.5 Pipe Flanges and Flanged Fittings B 16.20 Metallic gaskets for Pipe flanges‐ Ring joint, Spiral wound and

jacketed.





IS/IEC 60529 Degree of Protection Provided by Enclosures (IP Code) IS/IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres IEC 61000‐4 Electromagnetic Compatibility (EMC) for Industrial Process

Measurement and Control Equipment IEC 61158 Fieldbus Standard for use in Industrial Control System IEC 61158‐2 Physical Layer Specification and service definition for Fieldbus IEC 60587 Electrical Insulating Materials under severe ambient conditions‐ Test methods for evaluating resistance to tracking and erosion IEC/ TS 60079 FISCO Technical Specification


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2.6 Abbreviations:


EDDL Electronics Device Description Language FISCO Fieldbus Intrinsic Safety Concept FDT/DTM Field Device Tool/ Device Type Manager FF Fieldbus Foundation HART Highway Addressable Remote Transducer LCD Liquid Crystal Display NPS Nominal Pipe Size RAM Random Access Memory WC Water Column AC Alternating Current DC Direct Current SPDT Single Pole Double Throw DPDT Double Pole Double Throw TDR Time Domain Reflectometery PESO Petroleum and Explosive Safety Organization DGMS Director General of Mine Safety CCE Chief Controller of Explosives CIMFR Central Institute of Mining and Fuel Research ERTL Electronics Regional Testing Laboratory

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3.1 Sensor / Probe

3.1.1 Vendor shall select the probe length and diameter based on the application and process parameters. The type and material of construction of level instrument shall be as specified in the datasheet.

3.1.2 Probe shall be of flanged construction with material of construction of flange as specified in data sheet. In case of welded flanged connection design, the weld joint shall be of radiography quality.

3.1.3 Probe shall be of rugged construction without any mechanical moving part and shall not be affected by abrasion because of fluid turbulence. The probe design shall ensure that the deposits, dust, noise, foam or turbulence in the fluid shall not affect the performance of the level instruments.

3.1.4 Unless otherwise specified, the following shall govern:

a) Threaded end connections shall be to NPT as per ASME B1.20.1. b) Flanged end connections shall be as per ASME B 16.5. c) Flange face finish shall be as per ASME B16.5. The face finish shall be as follows:


d) Grooves of ring type joint flanges shall be octagonal as per ASME B 16.20.

3.1.5 Sensor/Probes installed in oxygen and chlorine service shall be thoroughly degreased using reagents like tri‐chloro‐ethylene or carbon tetrachloride. End connection shall be blinded/plugged after the degreasing process, in order to avoid entrance of grease or oil particles.

3.2 Instrument Electronics

3.2.1 Level Instrument electronics shall be compatible with the associated level probe and shall comprise of pre‐amplifier, converter, transmitter, switching amplifier etc. as applicable for the specified application. Vendor shall ensure that the input/output signals and performance characteristics of individual item supplied as a part of each level instrument are compatible with each other.

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3.2.2 The instrument electronics shall be integral with the probe. Where remote mounted converter/transmitter is offered in place of integral electronics a minimum of 10 meters of interconnecting cable shall be included.

3.2.3 Instrument electronics shall be of microprocessor based state‐of‐the‐art technology, which shall be capable of being configured locally and through a universal hand held configurator.

3.2.4 The meter electronics shall be provided with in‐built lightning and power supply surge protectors. The transient protection shall meet the requirements specified in IEC 60587.

3.2.5 Power Supply a) Transmitters shall generally be two wire transmitters. However, in case of four wire

transmitters, Instrument shall be suitable for use in voltage ranges of 110V AC and 220VAC, 50 Hz.

b) Supply voltage fluctuation of ±10 percent and supply frequency fluctuation of ±3 Hz shall not affect the instrument performance.

3.2.6 Terminals and Enclosure

3.2.6.1 Proper terminal blocks shall be provided in the transmitter unit for the termination of cables. Flying leads shall not be provided. Separate terminal blocks shall be provided for power and signal connections.

3.2.6.2 All terminals shall be clearly identified and polarity shall be permanently marked.

3.2.6.3 Separate cable entries shall be provided for signal and power cables. The cable entry sizes shall be 1/2" NPT (F) for signal and 3/4" NPT (F) for power.

3.2.6.4 The instrument enclosure, housing the electrical parts shall be certified for the area classification indicated in the data sheets. Unless otherwise specified, the enclosure shall conform to the following standards, as a minimum;

Weather‐proof housing to IP 65 as per IS/IEC‐60529. Flameproof housing Flameproof/ Ex(d) as per IS/IEC‐60079 suitable for Zone‐1 IIA/ IIB. Flameproof housing shall also be made weatherproof.

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3.2.7 Converter/Transmitter 3.2.7.1 Electronic transmitter shall generally operate at nominal voltage of 24V DC and shall be

protected against short circuit and reverse voltage. 3.2.7.2 Electronic transmitters with two‐wire system shall be suitable for delivering rated current

to an external loop resistance of at least 600ohm when powered with 24 V DC. 3.2.7.3 The span of the transmitter shall be field adjustable. 3.2.7.4 Field mounted converters/transmitters shall have an integral output meter. Local indication

of the output meter must be digital and in engineering units. 3.2.7.5 Smart and Field‐bus based Transmitters.

a) Smart and field‐bus based transmitters shall be two wire microprocessor based type. All necessary signal conversions and output generation with the required protocol shall be carried out in the transmitter electronics. Integral output meter with LCD display shall be provided for all transmitters.

b) The configurational data of the instruments and complete sensor characterization which is stored in a non‐volatile memory shall remain unaffected because of power fluctuations or power‐off condition.

c) Transmitter shall also run complete diagnostic subroutines and shall provide

diagnostic alarm messages for sensor as well as transmitter healthiness.

d) Transmitter protocol shall ensure the following features: i. It shall allow multi masters (two for example, primary and secondary) for

configuration, calibration, diagnostics and maintenance. The primary could be the control system or host computer and the secondary could be the hand‐held communicator or integral facia.

ii. It shall be capable of implementing universal commands from either of these locations.

e) In addition to the requirements specified above, field‐bus based transmitter shall meet the following requirements:

i. All instruments must satisfy the requirements of the field‐bus registration laboratory with applicable checkmark like foundation field‐bus, or as specified in the data sheets.

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ii. All instruments shall have two analog input blocks and PID controller block as a

minimum.

iii. All instruments must be interoperable and shall have valid interoperability test clearance like ITK latest version for foundation field‐bus.

iv. The field‐bus instrument shall support peer‐to‐peer communication.

v. Field‐bus instruments shall be polarity in‐sensitive.

vi. The intrinsically safe field‐bus instruments in hazardous area shall be certified as per entity concept or shall be FISCO approved as per the requirements specified in the purchaser's specification.

3.3 Guided Wave Radar type Level Instrument

3.3.1 The instrument shall work on TDR principle and shall be capable of measuring level of process fluid of dielectric constant as low as 1.9.

3.3.2 The type of wave guide i.e. coaxial/twin rod/single rod shall be selected by the vendor based on the specified application.

3.3.3 The instrument probe length shall be selected based on the minimum and maximum levels indicated in the data sheet.

3.3.4 External type guided wave radar instrument shall have external chamber/cage with 2" flanged end connections. The chamber/cage shall also have 3/4" NPT vent and drain connection. Internal type guided wave radar instrument shall have 4” flanged end connection.

3.3.5 The instrument shall meet the following performance requirement:

a) Accuracy inclusive of linearity, repeatability and hysteresis shall be better than ± 3mm.

b) Repeatability of level instrument shall be better than ±3.0 mm. c) Response time (i.e. 63.2% response) shall be better than 1 second.

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LEVEL INSTRUMENTS

3.4 Ultrasonic Type Level Instrument

3.4.1 Ultrasonic probe shall be selected based on the level measurement range specified in the data sheet.

3.4.2 The instrument probe shall have 2" flanged end connection.

3.4.3 The instrument shall have an accuracy (inclusive of linearity, repeatability and hysteresis) better than ±0.25% of measuring range.

3.5 Radio‐Frequency Type Level Instruments

3.5.1 The type of probe i.e. rod or rope type shall be selected by vendor based on the specified application.

3.5.2 The instrument probe length shall be selected by vendor based on the specified level measurement range.

3.5.3 The instrument probe shall have 2" flanged and connection.


3.6 Capacitive Type Level Instrument

3.6.1 The type of instrument probe rod or rope shall be selected by vendor based on the specified level range.

3.6.2 The material of construction of the probe shall be stainless steel 316/ 316L with insulation of PTFE.

3.6.3 For non‐metallic equipments or equipments lined internally with insulation material, probe having suitable ground reference shall be provided.

3.6.4 The instrument probe shall have 2" flanged end connection.


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LEVEL INSTRUMENTS

4.0 DOCUMENTATION


DOCUMENTATION REQUIREMENTS REVIEW/ APPROVAL

QUALITY ASSURANCE PLAN (QAP) For Approval PRODUCTION PROGRAMME For Review INSTRUMENT DATA SHEETS For Approval INST GA / INSTALLATION DRAWINGS For Approval CERTIFIED VALUES OF FAILURE RATES, PROBABILITY OF FAILURE ON DEMAND (PFD) AND TEST INTERVALS FOR OFFERED ITEMS FOR SAFETY INTEGRITY LEVEL (SIL) ANALYSIS




a) Specification sheet/ Data sheet/ Sizing Sheet for each Level Instrument with accessories. b) As built drawings for each Level Instrument with accessories, providing dimensional details,

constructional details, connection details and material of construction. c) Copy of test certificates for all the tests as per MR and Documents along with TPI/ IRN. d) Installation procedure for each Level Instrument along with their accessories. e) Calibration, Configuration and Maintenance procedures f) Device Descriptor (DD) Files/EDDL file/DTM files for configuring the device parameters (Soft Copy) g) Common File Format (CFF) files for integrating the device into the system (Soft Copy). h) DD/ITK/CFF Revision number i) BOM including spares (if applicable) j) SIL data k) Product Catalogs of Main equipment and accessories/ bought‐outs.

Three hard copies in bound format and one soft copy in CD/ DVD of the above shall be submitted as

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LEVEL INSTRUMENTS

final document.

5.0 NAME PLATE a) Tag No. as per purchaser's datasheet b) Manufacturer's name. c) Manufacturers serial no. and model no. d) Range of Measurement e) Area Classification of the Instrument f) End Connection: Size and Rating g) Body Material

Other details as per MR shall also be suitably indicated on the Instrument.

6.0 SHIPPING



6.3 Proper care shall be taken in shipping the instruments to avoid damage.


a) Project Name and Location

b) PO Number

c) Packing List inside consignment (indicating Main equipment Tag nos, Accessories and Spares as applicable)

d) Vendor Name and location of dispatch

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SIGNAL & CONTROL CABLES

Signal and

Control Cables

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Contents


1.0 General 3


3.0 Design And Construction 6


5.0 Name Plate 11

6.0 Shipping 12

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Signal and Control Cables.



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2.1 ASTM American Society for Testing and Materials

D 2843 Standard Test Method for Density of Smoke from the

Burning or Decomposition of Plastics. D 2863 Test method for measuring the minimum oxygen

concentration to support candle like combustion of plastics (oxygen index).


5308 Part 1 Specification for Polyethylene insulated cables. 5308 Part 2 Specification for PVC insulated cables.

2.3 IEC International Electro technical Commission

540 & 540A Test methods for insulation and sheaths of electric Cables 60331 Testing of Fire Resistant cables. 60332 Tests on bunched wires and cables. 60092 Electrical Installations of Cables 60754 Test on Gases EvoIved during Combustion of materials from Cables ‐ Part 1,2.

2.4 IS Indian Standards

1554 Part 1 PVC insulated (heavy duty) electric cables‐working voltage up to and including 1100V. 3975 Mild steel wires, formed wires and tapes for armouring of cables. 5831 PVC insulation and sheath of electric cables. 6380 Elastomeric insulation and sheath of electric cables 6474 Polyethelene Insulation and sheath of electric cables 10810 Method of test for cables. Part 40 Method for testing uniformity of coating on zinc coated articles. Part 41 Mass of zinc coating on steel armour Part 58 Oxygen Index test Part 59 Determination of halogen acid gas evolved during combustion of polymeric material taken from cables

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Part 61 Flame Retardant test Part 62 Flame Retardance test for bunched cables Part 63 Smoke density of electric cables under fire conditions

2.5 Abbreviations:

DC Direct Current EPR Ethylene Propylene Rubber FR Flame Retardant PE Poly Ethylene PETP Poly Ethylene Terepthalate PVC Poly Vinyl Chloride

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2.7 Constructional Requirements

2.7.1 Primary insulation for PVC insulated cables, shall be 85°C polyvinyl chloride Type C as per IS5831. Thickness of primary insulation shall be 0.5 mm as a minimum. For PE insulated cables, primary insulation shall be of 70 deg C Polyethylene.

2.7.2 Inner sheath colour of signal cables shall be black. Outer sheath colour shall also be black except for cables used in intrinsically safe systems. The outer sheath colour for all such cables used in intrinsically safe application shall be light blue. The thickness of the sheath shall be as per IS 1554 part 1.

2.7.3 Inner and outer sheath of cable shall be flame retardant made of extruded PVC Type ST2 (90°C)as per IS 583 1 and shall meet the following requirements:

a) Minimum Oxygen index of PVC shall be 30 at 27 deg C +/‐ 2 deg C. b) Temperature index shall be over 250 deg C. c) Inner and Outer sheath shall meet flame retardant requirements for bunched cables as per

IS 108 10 (Part 62) category AF or IEC 60332 category A. d) A rip cord shall be provided for inner sheath. e) Outer sheath shall be suitable for protecting the cable against rodent and termite attack.

2.7.4 Armour over inner sheath shall be of galvanised steel wire/flat. The dimensions of armour shall be as per IS 1554 (Part 1). Requirement and methods of tests for amour material and uniformity of galvanisation shall be as per IS 3975 and IS 10810 (Part 40) respectively.

2.7.5 Each pair/triad shall be shielded. Shield shall be of aluminium backed by mylar / polyester tape bonded together helically applied with metallic side down having 25% overlap on either side and 100% coverage. Minimum shield thickness shall be 0.05 mm. Drain wire shall be 0.5 mm2 multi‐strand bare tinned annealed copper conductor. The drain wire shall be in continuous contact with aluminium side of the shield.

2.7.6 Overall shield shall be of aluminium backed up by mylar /polyester tape helically applied with the metallic side down with either side having 25% overlap and 100% coverage. Minimum shield thickness shall be 0.075 mm. Drain wire shall be similar to individual

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pair/triad drain wire and shall be over the overall shield.

2.7.7 The cores of a pair triad shall be twisted with a minimum of 10 twists per metre of cable.

2.7.8 Sequential marking of the length of the cable in meters shall be provided on the outer sheath at every one meter. The embossing /engraving shall be legible and indelible.

2.7.9 Tolerance in overall diameter of cable shall be within +/‐ 2 mm over offered value.

2.7.10 The cables used in installations under the jurisdiction of Director General of Mines and Safety (DGMS) shall meet all requirements of DGMS. The word "Mining Cable" shall be embossed on the cable outer sheath as per IS 1554 (Part 1).

2.7.11 Drum length and length tolerance

2.7.11.1 The length of the cables in each drum (drum length) shall be as specified in the purchaser data sheets. Where no drum length is indicated in the data sheet /material requisition, the following shall be apply:

• Drum length for single pair/ single triad cable : 500 metres

• Drum length for multi‐pair/ multi‐ triad cable : 1000 metres

2.7.11.2 Actual produced drum length shall not vary by more than +/‐ 5% from drum length .

2.7.12 Tolerance over the total ordered length for a type of cable shall be as follows;

a) +/‐ 5% for total length less than 5 km. b) +/‐ 2% for total length more than 5 km.

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2.7.13 Specific Requirements for Fire Resistant cable

2.7.13.1 The cables shall have circuit integrity as per IEC 60331.

2.7.13.2 Primary insulation shall be heat resisting elastomeric which can withstand temperature up to 90°C such as silicon rubber/mica glass tape/EPR (medium grade) as per IS 6380. Insulation thickness shall be 1.0 mm minimum and shall confirm to IEC 60092.

2.7.13.3 A wrapping of tape made of PETP (polyethylene terepthalate)/woven glass shall be provided over core insulation.

2.7.13.4 Individual pair triad shall be shielded. The shield shall be aluminium backed by glass mica/PETP tape with the metallic side down helically applied with 25% overlap on either side and 100% coverage. Minimum shield thickness shall be as per IEC 60092. Drain wire shall be 0.5mm2 (7/0.3mm dia) multi‐stranded bare tinned annealed copper conductor. Drain wire shall be in continuous contact with aluminium side of the shield.

2.7.13.5 Inner and outer sheath shall be made of low smoke, heat resistant, oil resistant and flame retardant material with oxygen index over 30, temperature index shall be over 250°C. Acid generation shall be maximum 20% by weight as per IEC 60754. Smoke density rating not to exceed 60% as per ASTM D 2843.

2.7.13.6 The thickness of the sheath shall be as per IEC 60092. Inner and outer sheath colour shall be orange. A rip cord shall be provided for inner sheath.

2.7.13.7 Armour bedding over inner sheath shall be of special high oxygen index, low smoke halogen free fire resisting compound.

2.8 Electrical Characteristics

2.8.1 Maximum DC resistance of the conductor of the finished cable shall not exceed 12.3 Q / km at 20°C for cables with 1.5 mm2 conductors and 39.7 Q / km at 20°C for cables with 0.5 mm2 conductors.

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2.8.2 Capacitance

2.8.2.1 Mutual Capacitance for PVC Insulated cables: The mutual capacitance of between pairs/triads or adjacent cores shall not exceed of 250 pF / metre at a frequency of 1 KHz.

2.8.2.2 Mutual Capacitance for PE Insulated cables: The mutual capacitance between the pairs/triads shall not exceed of 100 pF / metre at a frequency of 1 KHz.

2.8.2.3 Capacitance between any core or screen: The capacitance between any core and screen shall not exceed a maximum of 400 pF / metre at a frequency of 1 KHz.

2.8.2.4 L/R ratio of adjacent core shall not ex5eed 40 µH/Ω for cables with 1.5 mm2 conductors and 25 µH/Ω for cables with 0.5 mm conductors.

2.8.2.5 The drain Wire resistance including shield shall not exceed 30 Ω/ km.

2.8.2.6 Electrostatic noise rejection ratio of the finished cable shall be over 76 dB.

2.9 Type I (Single pair/Triad shielded). 2.9.1.1 Each core shall be 1.5 mm2 made of 7 stranded annealed electrolytic copper conductor.

Each strand shall be 0.53mm diameter.

2.9.1.2 Colour of core insulation shall be black and blue in pair and black, blue and brown in a triad. Other requirements of this specifications shall be complied.

2.10 Type-II (Multi-pair/ Multi-triad cable with individual pair/triad shield and overall

shield)

2.10.1.1 Conductor sizes shall be 0..5mm2 made up of 7 strands of annealed electrolytic copper conductor. Each strand shall be of 0.3 mm diameter.

2.10.1.2 Overall twist of all pair/triads shall be as per vendor's standard. 2.10.1.3 A pair of communication wire shall be provided for multipair/ multitriad cables. Each wire

shall be 0.5 mm2 of plain annealed single or multistrand copper conductor with 0.4 mm thick 85°C PVC insulation. Insulation shall be green and red colour coded.

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2.10.1.4 A pair identification shall be with numbers at interval of not more than 250 mm. Other requirements of this specifications shall be complied.

2.11 Type-III (Multi-pair / Multi-triad cable with only overall shield)

2.11.1.1 The cable shall be same as type‐II cable, except that the individual pair/triad shall not have shielding.

2.12 Type-IV (Multi-pair /Multi-triad cable with individual pair shield and overall

shield)

2.12.1.1 The cable shall be same as Type II, except conductor size shall be 1.5 mm2 made of 7 stranded annealed electrolytic copper conductor. Each strand shall be of 0.53 mm dia.

2.13 Type-V (Multi-pair / Multi-triad cable with overall shield only)

2.13.1.1 The cable shall be same as type IV except that the individual pair/triad shall not have the shielding.

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3.0 DOCUMENTATION



QUALITY ASSURANCE PLAN (QAP) For Approval PRODUCTION PROGRAMME For Review DATA SHEETS For Approval DRUM SCHEDULE For Approval


3.2 Final documentation consisting of design data etc. submitted by the vendor after placement of purchase order shall include the following, as a minimum;

a) Specification sheet/ Data sheet for each type of cable. b) Cable details giving electrical characteristics, overall diameter, diameter under amour and diameter

over amour.

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4.0 NAME PLATE a) Manufacturer's name. b) Type and size of the cable with cable indicated in material requisition. c) Length of the cable in meters contained in the drum. d) Gross weight e) Drum number f) Direction of rotation of drum for unwinding by means of an arrow Purchase order number.

Above details shall be marked on each drum. Other details as per MR shall also be suitably indicated.

5.0 SHIPPING

5.1 Cables shall be dispatched in wooden drums securely battened, with takeoff end fully protected against damage. Minimum number of eight PVC rubber end caps shall be shipped with each drum.

5.2 Each drum of the consignment shall be suitably labelled clearly indicating the following as minimum:


b) PO Number

c) Vendor Name and location of dispatch

d) Other details as per Nameplate details

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PAGE 1 OF 8


THERMOCOUPLE EXTENSION CABLES

Thermocouple Extension Cables

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Contents


1.0 General 3



4.0 Documentation 7

5.0 Name Plate 8

6.0 Shipping 8

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Thermocouple Extension Cable.



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2.1 ASTM American Society for Testing and Materials

D 2863 Test method for measuring the minimum oxygen

concentration to support candle like combustion of plastics (oxygen index).


5308 Part 2 Specification for PVC insulated cables.

2.3 IEC International Electro technical Commission

60332 Tests on bunched wires and cables. 60584‐3 Extension and compensating cables ‐ Tolerances and identification system

2.4 IS Indian Standards

1554 Part 1 PVC insulated (heavy duty) electric cables‐working voltage up to and including 1100V. 3975 Mild steel wires, formed wires and tapes for armouring of cables. 5831 PVC insulation and sheath of electric cables. 10810 Method of test for cables. 8784 Thermocouple Extension and compensating cables. Part 40 Method for testing uniformity of coating on zinc coated articles. Part 41 Mass of zinc coating on steel armour Part 58 Oxygen Index test Part 61 Flame Retardant test Part 62 Flame Retardance test for bunched cables

2.5 Abbreviations:

FR Flame Retardant PVC Poly Vinyl Chloride

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3.0 DESIGN AND CONSTRUCTION 3.1 Constructional Requirements 3.1.1 Type and material of extension cable core shall be as per IS 8784 and IEC 60584‐3 as applicable.

3.1.2 Primary insulation for PVC insulated cables, shall be 85°C polyvinyl chloride Type C as per IS583 1. Thickness of primary insulation shall be 0.5 mm as a minimum.

3.1.3 Unless specified otherwise, insulation, inner sheath and outer sheath colour shall be as per IEC60584. However it is vendor’s responsibility to re‐confirm insulation and sheath colour with purchaser prior to manufacturing. The thickness of the sheath shall be as per IS 1554 part 1.

3.1.4 Inner and outer sheath of cable shall be flame retardant made of extruded PVC Type ST2 (90°C)as per IS 583 1 and shall meet the following requirements:

a) Minimum Oxygen index of PVC shall be 30 at 27 deg C +/‐ 2 deg C. b) Temperature index shall be over 250 deg C. c) Inner and Outer sheath shall meet flame retardant requirements for bunched cables as per IS 108

10 (Part 62) category AF or IEC 60332 category A. d) A rip cord shall be provided for inner sheath. e) Outer sheath shall be suitable for protecting the cable against rodent and termite attack.

3.1.5 Armour over inner sheath shall be of galvanised steel wire/flat. The dimensions of armour shall be as per IS 1554 (Part 1). Requirement and methods of tests for amour material and uniformity of galvanisation shall be as per IS 3975 and IS 10810 (Part 40) respectively.

3.1.6 Each pair shall be shielded. Shield shall be of aluminium backed by mylar / polyester tape bonded together helically applied with metallic side down having 25% overlap on either side and 100% coverage. Minimum shield thickness shall be 0.05 mm. Drain wire shall be 0.5 mm2 multi‐strand bare tinned annealed copper conductor. The drain wire shall be in continuous contact with aluminium side of the shield.

3.1.7 The cores of a pair shall be twisted with a minimum of 10 twists per metre of cable.

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3.1.8 Sequential marking of the length of the cable in meters shall be provided on the outer sheath at every one meter. The embossing /engraving shall be legible and indelible.

3.1.9 Tolerance in overall diameter of cable shall be within +/‐ 2 mm over offered value.

3.1.10 Drum length and length tolerance

3.1.10.1 The length of the cables in each drum (drum length) shall be as specified in the purchaser data sheets. Where no drum length is indicated in the data sheet /material requisition, the following shall be apply:

• Drum length for single pair cable : 500 metres

• Drum length for multi‐pair cable : 1000 metres

• 3.1.10.2 Actual produced drum length shall not vary by more than +/‐ 5% from drum length.

3.1.11 Tolerance over the total ordered length for a type of cable shall be as follows;

a) +/‐ 5% for total length less than 5 km. b) +/‐ 2% for total length more than 5 km.

3.2 Electrical Characteristics 3.2.1 Thermoelectric specifications and limits of error shall be as per IEC 60584‐3.

3.2.2 Mutual capacitance of the pairs or adjacent cores shall not exceed 250 pF / m at a frequency of 1 KHz.

3.2.3 Capacitance shall not exceed 400 pF / m between any core and screen at a frequency of 1 KHz.

3.2.4 Core inductance shall not exceed 4 mH / km.

3.2.5 The drain wire resistance including shield shall not exceed 30 ohm / km.

3.2.6 Electrostatic noise rejection ratio shall be over 76 dB.

3.3 Type I (Single pair/Triad shielded).

3.3.1 Each core shall be made of 16 AWG solid conductor.

Other requirements of this specification shall be complied.

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3.4 Type-II (Multi-pair/ Multi-triad cable with individual pair/triad shield and overall shield)

3.4.1 Each core shall be made of 20 AWG solid conductor.

3.4.2 Overall twist of all pair shall be as per vendor's standard.

3.4.3 In addition to individual pair shield overall shield shall be provided. Overall shield shall be of aluminium backed up by mylar/polyester tape helically applied with metallic side down either side 25% overlap and 100% coverage. Minimum shield thickness shall be 0.075 mm. Drain wire shall be similar to individual pair drain wire and shall be in continuous contact with the aluminium side of the overall shield.

3.4.4 A pair of communication wire shall be provided for multipair cables. Each wire shall be 0.5 mm2 of plain annealed single or multistrand copper conductor with 0.4 mm thick 85°C PVC insulation. Insulation shall be green and red colour coded.

3.4.5 A pair identification shall be with numbers at interval of not more than 250 mm. Other requirements of this specification shall be complied.

3.5 Type-III (Multi-pair/ Multi-triad cable with individual pair/triad shield and overall

shield)

The cable shall be same as type‐II cable, except conductor size shall be 16 AWG.

4.0 DOCUMENTATION



QUALITY ASSURANCE PLAN (QAP) For Approval PRODUCTION PROGRAMME For Review DATA SHEETS For Approval DRUM SCHEDULE For Approval


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4.2 Final documentation consisting of design data etc. submitted by the vendor after placement of purchase order shall include the following, as a minimum;

a) Specification sheet/ Data sheet for each type of cable. b) Cable details giving electrical characteristics, overall diameter, diameter under amour and diameter

over amour.

5.0 NAME PLATE

a) Manufacturer's name. b) Type and size of the cable with cable indicated in material requisition. c) Length of the cable in meters contained in the drum. d) Gross weight e) Drum number f) Direction of rotation of drum for unwinding by means of an arrow Purchase order number. g) Purchase Order Number

Above details shall be marked on each drum. Other details as per MR shall also be suitably indicated.

6.0 SHIPPING

6.1 Cables shall be dispatched in wooden drums securely battened, with takeoff end fully protected against damage.

6.2 Each drum of the consignment shall be suitably labelled clearly indicating the following as minimum:


b) PO Number

c) Vendor Name and location of dispatch

d) Other details as per Nameplate details

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MASS FLOW METER

Mass Flow Meter

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MASS FLOW METER

Contents


1.0 General 3



4.0 Documentation 9

5.0 Name Plate 10

6.0 Shipping 11

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MASS FLOW METER

1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Mass Flow Meter.

1.2 Mass Flow Meter shall be supplied in fully assembled condition



1.4 Enclosed data sheets specify the material for Mass Flow Meter. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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MASS FLOW METER



B 1.20.1 Pipe Threads General purpose (Inch) B 16.5 Pipe Flanges and Flanged Fittings B 16.20 Metallic gaskets for Pipe flanges‐ Ring joint, Spiral wound and jacketed. B16.34 Valves‐ Flanged, Threaded and Welding End



2.3 IS/IEC Indian Standards/ International Electro‐technical Commission

IS/IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere. IS/IEC 60529 Degree of Protection Provided by Enclosures (IP code). IEC 60068 Environmental Testing IEC 60587 Test method for evaluating resistance to tracking and erosion of electrical insulating materials used under severe ambient conditions. IEC 6 1000‐4 Electromagnetic Compatibility for Industrial Process Measurement and Control Equipment IEC 61158 Field Bus Standard for use in Industrial Control System. IEC 61158‐2 Physical Layer Specification and service definition for field bus. IEC 61508 Functional Safety of Electrical / Electronic /Programmable Electronic

safety related system.

2.4 Abbreviations:

AARH Arithmetic Average Roughness Height NPT National Pipe Thread FISCO Fieldbus Intrinsic Safety Concept HART Highway Addressable Remote Transducer RAM Random Access Memory PID Proportional, Integral and Derivative EMI Electromagnetic Interference RFI Radio Frequency Interference

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3.1 Flow Meter

3.1.1 Flow meter shall be of in‐line mounting design with flow direction clearly marked on the flow meter body to ensure correct installation.

3.1.2 Flow meter design shall ensure that the location and / or orientation of installation of mass flow meter in the line shall not affect the calibration, accuracy and performance of the meter.

3.1.3 The material of construction of mass flow internals and body shall be as specified in the respective data sheets, as a minimum.

3.1.4 The mass flow meter shall be provided with the external flow tube housing wherever specifically indicated in the data sheet. In all such cases, the flow tube housing shall have provision to monitor housing pressure continuously.

3.1.5 The mass flow meter shall have high vibration immunity. The meter output shall not be affected by the pipeline vibration where the meter is installed.

3.1.6 End Connection

3.1.6.1 Flow meter shall be of flanged body construction with material of construction as specified in data sheet. In case of meter design where end flanges are welded to the meter body all weld joints shall be of radiography quality.

3.1.6.2 Unless otherwise specified, the following shall govern: ‐

a) Threaded end connections shall conform to NPT as per ASME B 1.20.1. b) Flanged end connections shall be as per ASME B 16.5. c) Flange face finish shall be as per ASME B 16.5. The face finish as specified in the data shall

be as follows: 125 AARH: 125 to 250 micro inch AARH 63 AARH: 32 to 63 micro inch AARH

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MASS FLOW METER

3.1.7 Terminal Housing

3.1.7.1 Following shall apply for both integral as well as for remote meter electronics:

a) All connections shall be terminated on the terminals brought out in the terminal housing located on the flow meter body. Flying leads shall not be provided.

b) All intrinsically safe terminals shall be properly identified and shall be separate from the non intrinsically safe terminals.

c) Separate cable entry shall be provided in the terminal housing for power and intrinsically safe signals.

d) The flow meter enclosure, housing the electrical parts shall be suitable for the area classification indicated in the data sheets. Unless otherwise specified, the enclosure shall conform to the following standards, as a minimum:

• Weatherproof housing ‐ IP 65 to IS/IEC‐60529

• Flameproof housing ‐ Flame proof / Ex (d) as per IS/IEC‐60079

Flameproof housing shall also be made weatherproof.

3.2 Meter Electronics

3.2.1 Flow meter electronics shall be microprocessor based and shall include pre‐amplifier, converter, transmitter electronics and integral output meter. The indication on the output meter shall be digital with engineering units.

3.2.2 The mass flow meter transmitter shall be smart type and shall provide 4‐20rnA analog output superimposed with digital signal for meter diagnostics (HART Output). When specified, flow meter shall provide field‐bus output conforming to the standard specified in the specification sheets.

3.2.3 The mass flow meter shall be capable of computing field density and shall incorporate temperature sensor flow fluid temperature measurement. Whenever specified in the data sheets, the flow meter electronics shall have capability to compute volumetric flow rates.

3.2.4 The meter electronics shall be protected against transients induced by lightning and power supply surges. Transient protection electronics shall preferably be provided in the terminal block. The transient protection shall meet the requirements specified in IEC‐60587.

3.2.5 The configurational data of the instrument shall be stored in a non‐volatile memory such that this remains unchanged because of power fluctuations or power off condition. In case, vendor standard instrument has battery backed RAM vendor to ensure that battery drain alarm is provided as diagnostic maintenance message.

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MASS FLOW METER

3.2.6 For smart transmitters or for field bus based transmitter the following features must be ensured;

a) It shall allow multi master (primary and secondary) for configuration, calibration, diagnosis and maintenance. The primary could be the control system or host computer, and the secondary could be the hand held communicator.

b) It should be capable of implementing universal command.

3.2.7 In addition to the requirements specified above, field bus based transmitter shall meet the requirements;

a) All instruments must satisfy the requirements of the field bus registration laboratory with applicable checkmark like foundation field bus or as specified in the data sheets.

b) All instruments shall have two analog input blocks and a PID controller block, as a minimum.

c) All instruments must be interoperable and shall have valid interoperability test clearance like ITK 4.6 for foundation field bus or as applicable.

d) The field bus instruments shall support peer‐to‐peer communication.

e) Field bus instruments as offered shall not be polarity sensitive.

f) The field bus instruments in hazardous area shall be certified as per entity concept or shall be FISCO approved as per the requirements specified in the Material requisition/datasheet.

3.2.8 Meter electronics shall also be provided with security lockout feature to disable access to configuration modification features.

3.2.9 Flow meter electronics shall be either integral to flow meter or shall be remote mounted type. Where remote mounted electronics is offered a minimum of 10 metres of interconnecting cable shall be included.

3.2.10 Flow meter electronics shall have enclosures suitable for the hazardous area classification indicated in data sheets. When area classification is specified as electrically hazardous flow meter shall have flameproof enclosure with intrinsically safe circuitry for sensor connectivity. Safety barrier if required for the sensors shall be supplied by vendor and shall be part of transmitter enclosure.

3.2.11 The meter electronics along with flow meter shall be pre‐calibrated at vendor's works with calibration factor duly established for the flow meter.

3.2.12 The meter electronics shall be immune to RFI and EMI radiation and shall be in compliance with the electromagnetic compatibility requirement as per IEC 61 000‐4.

3.2.13 Following shall be applicable for power supply to instrument:

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MASS FLOW METER

a) Transmitters shall generally be two wire transmitters. However, in case of four wire

transmitters, Instrument shall be suitable for use in voltage ranges of 110V AC and 220VAC, 50 Hz.

b) Supply voltage fluctuation of ±10 percent and supply frequency fluctuation of ±3 Hz shall not affect the instrument performance.

3.3 Meter Sizing The meter shall be sized considering the following guidelines; a) Minimum flow, maximum flow and meter maximum as specified in the data sheet.

b) Flow accuracy between the minimum and maximum flow specified in the data sheet.

Where only normal flow is specified, the maximum and minimum flows considered for the purpose of sizing shall be; • Maximum flow = 1.4 times the normal flow • Minimum flow = 0.4 times the normal flow

When only maximum flow is specified, minimum flow shall be considered as 0.2 times the maximum flow for sizing the meter.

c) The maximum pressure drop at meter maximum shall not exceed the allowable pressure drop across the meter specified in the data sheet.

d) The meter shall be selected such that both accuracy and allowable pressure differential across the meter are complied.

3.4 Performance Requirements Unless specified otherwise in the data sheets, the performance requirements for the mass flow meter shall be as follows;

a) Flow meter accuracy: +/‐ 0.2% of mass flow rate for liquid service. +/‐ 0.5% of mass flow rate for gas / vapour service

b) Flow meter repeatability: +/‐ 0.1% of mass flow rate for liquid service +/‐ 0.25% of mass flow rate for gas / vapour service

The performance requirements specified above excludes the effect of zero stability of the flow meter on these parameters.

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MASS FLOW METER

3.5 Accessories

3.5.1 Hand held configurator for Smart Instruments: Hand Held configurator shall be universal type and shall be able to communicate with all make and models of smart instruments with HART output like transmitters, smart positioners etc., and shall be capable of carrying out all engineering like calibration, configuration and diagnostics. The hand held configurator shall be certified intrinsically safe. Carrying case shall be supplied with each configurator.

3.5.2 Field bus hand held tester: The field bus hand held tester shall be able to communicate with the specified field bus instrument and shall be capable of calibrating and configuring field bus devices. The field bus hand held tester shall be certified intrinsically safe. Carrying case shall be supplied with each tester.

3.5.3 Battery charger: Both field bus hand held tester and hand held configurator for smart instruments with HART output shall be supplied with battery charger for battery charging of hand held configurator / field bus tester. Unless otherwise specified, battery charger shall operate at 240V 50Hz supply.

4.0 DOCUMENTATION






a) Specification sheet/ Data sheet/ Sizing Sheet for each Mass Flow Meter.

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MASS FLOW METER

b) As built drawings for each Mass Flow Meter, providing dimensional details, constructional details, Weight and material of construction.

c) Copy of test certificates for all the tests as per MR and Documents along with TPI IRN. d) BOM including spares (if applicable) e) Product Catalogues of Main equipment (inclusive of Installation procedure) and

accessories/ bought outs. f) Curves for flow measurement vs. accuracy and rangeability. g) Maximum and minimum supply voltage required for the instrument to function within the

stated performance characteristics. h) Clearance required for maintenance work i) Calibration procedures for mass flow meter


5.0 NAME PLATE

5.1 Each mass flow meter and its accessories shall have a stainless steel nameplate attached firmly to it at a visible place, furnishing the following details as applicable.

a) Tag number b) Manufacturer's model number and serial number. c) Manufacturer's name. d) Nominal end connection size in inches and rating in ASME B16.5 class. e) Body and trim material. f) Area classification in which the equipment can be used. g) Standard for body/trim materials (eg. ASTM) h) Enclosure type i) Calibrated range and unit of measurement of flow.

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MASS FLOW METER

6.0 SHIPPING


6.2 The mass flow meter remote electronics and its accessories shall be packed separately.




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HEATER TUBE SKIN THERMOCOUPLES

Heater Tube Skin Thermocouples

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Contents


1.0 General 3



4.0 Documentation 7

5.0 Name Plate 8

6.0 Shipping 8

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of heater tube skin thermocouples and its accessories.



1.3 Enclosed data sheets specify the material for heater tube skin thermocouples and its accessories.. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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IS/IEC 60529 Degree of Protection Provided by Enclosures (IP Code) IS/IEC‐60079 Electrical Apparatus for Explosive Gas Atmosphere IEC‐60584‐2 Thermocouple Tolerances. IS7358 Specifications for Thermocouples.


2.5 Abbreviations:


MAWP Maximum Allowable Working Pressure AWS American Welding Society

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3.1 The type of heater tube skin thermocouple assembly shall be either welded type or extraction type. The type of assembly shall be offered as specified in Material requisition/datasheet.

3.2 Each heater tube skin thermocouple shall be supplied as a complete assembly consisting of:

a. Magnesium oxide insulated sheathed thermocouple element with stainless steel compression fitting and terminal head. The total length of the thermocouple shall be determined by the vendor based on data sheets and Material requisition.

b. Retaining clips required for each assembly as per the quantity indicated in the datasheets or as recommended in installation drawings.

c. Welding rods of suitable material required for welding of offered skin thermocouple sheath to the heater tube.

d. Any other item, not specifically indicated, but required to make installation of heater tube skin thermocouples complete.

3.3 Element

3.3.1 Unless specified otherwise, the thermocouple element shall meet the following requirements:

a. The thermocouple element shall be type "K' as per ISA/IS‐7358 or IEC 60584. The thermocouple properties and limits of error shall be as per IEC 60584‐2.

b. The element wire diameter shall correspond to 16 AWG as a minimum.

3.4 Sheath

3.4.1 Unless specified otherwise, the thermocouple sheath shall meet the following requirements;

a. The sheath material shall be AISI type 446 Stainless Steel.

b. The outside diameter of the sheath shall be 6mm and 9.5mm (minimum) and the sheath

wall thickness shall be minimum 1.0mm and 2.2mm for pad type Simplex and Duplex

thermocouples respectively. The outside diameter of the sheath shall be 12.7 mm and the

sheath wall thickness shall be minimum 3.18 mm for knife edge type.

3.5 Sensing Section

3.5.1 The sensing section shall be either pad type or knife‐edge type. Vendor shall supply the type of element as specified in the purchaser's data sheet.

3.5.2 The extreme end of the sheath (in the direction opposite to the terminal head) shall be formed to achieve a 'Wedge' shape/pad shape in the lower half section. This formed section shall extend to a length of 50mm.

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3.5.3 The thermocouple junction shall be grounded and shall be in the middle of this formed section. The junction shall be located at the tip of the wedge/pad.

3.5.4 The formed section shall be straight or curved to suit the heater tube outer diameter as per the data sheets.

3.5.5 The formed section shall be welded to the heater tube on the circumferential periphery for obtaining the skin temperature of the tube, as per manufacturer's recommendation.

3.5.6 Protection shield shall be provided to cover the thermocouple at heater tube side.

3.5.7 The weld pad and the protective shield shall have a minimum thickness of 5mm and shall be of AISI type 446 Stainless Steel.

3.5.8 When specified design requires extraction of temperature element, it shall meet the following requirements:

a. The sensing element is designed to fit into a pad, which is welded to the heater tube.

b. The element, if required, can be pulled out of welded pad and can be reinserted.

c. The protection shield shall be welded from three sides.

3.6 Retaining Clips

3.6.1 Unless otherwise specified, retaining clips shall meet the following requirements:

a. Retaining clips shall be 63 mm long, 12 mm wide and 3 mm thick. These shall be used

for holding thermocouple sheath to the heater tube.

b. The material of retaining clips shall be AISI type 446 Stainless Steel.

3.7 Terminal Head

3.7.1 The terminal head shall consist of a cast aluminium case, screwed on cover and terminal block. The terminals shall be clearly identified for their polarity.

3.7.2 The terminal block shall be clearly marked with the IS/IEC calibration letters to designate the type of thermocouple. An extra terminal shall be provided and connected to the head for grounding the shield.

3.7.3 The thermocouple sheath shall be fixed to the terminal head by a stainless steel compression fitting. The cover shall be fastened to the case by a stainless steel chain with a swivel. It shall be provided with a screwdriver slot. A heat resistant and moisture proof gasket shall be placed between the case and the cover.

3.7.4 Unless otherwise specified, the assembly shall confirm to the following standards:

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a. The heads shall be weatherproof to IP65 as per IS/IEC60529.

b. In case of flameproof construction, heads shall be flameproof to the specified area

classification as per IS/IEC 60079 and weatherproof to IP 65 as per IS/IEC 60529

4.0 DOCUMENTATION






a) Specification sheet/ Data sheet/ Sizing Sheet for heater tube skin thermocouple and its accessories

b) As built drawings for each heater tube skin thermocouple and its accessories, providing dimensional details, constructional details, end connection details and material of construction.

c) Installation details, showing location of holding clips, expansion loop orientation etc. d) Copy of test certificates for all the tests as per MR and Documents along with TPI/ IRN. e) Installation and welding procedure for each heater tube skin thermocouple and its

accessories which shall also include ASME or AWS specification for the welding rod required for welding for offered skin thermocouple sheath to the heater tube as per the material specification given in the data sheets.

f) Calibration and maintenance procedures including replacement of its internal parts wherever applicable.

g) BOM including spares (if applicable) h) Product Catalogs of Main equipment and accessories/ bought‐outs.

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5.0 NAME PLATE a) Tag No. as per purchaser's datasheet (shall be mentioned on the casing only and not on the

dial) b) Manufacturer's name. c) Manufacturers serial no. and model no. d) Thermocouple type e) Grounded or Ungrounded f) Type of Protection for thermocouple head.

Other details as per MR shall also be suitably indicated on the Instrument

6.0 SHIPPING


6.2 Proper care shall be taken to withstand the shipping conditions.




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ELECTROMAGNETIC FLOW METER

Electromagnetic Flow Meter

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Contents


1.0 General 3



4.0 Documentation 9

5.0 Name Plate 10

6.0 Shipping 10

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1.0 GENERAL

1.1 This specification, together with the data sheets, MR and Special Requirements (if any) covers the requirements for the design, materials, nameplate marking, inspection, testing and shipping of Electromagnetic Flow meter and its accessories.

1.2 Electromagnetic Flow meter and its accessories shall be supplied in fully assembled condition



1.4 Enclosed data sheets specify the material for Electromagnetic Flow meter and its accessories. Unless specifically indicated otherwise, alternate superior material of construction shall also be acceptable provided vendor assumes complete responsibility for the selected materials for their compatibility with the specified fluid and its operating conditions.

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2.3 IS/IEC Indian Standards/ International Electrotechnical Commission

IS/IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere. IS/IEC 60529 Degree of Protection Provided by Enclosures (IP code). IEC 6 1000‐4 Electromagnetic Compatibility for Industrial Process Measurement and Control Equipment IEC 61158 Field Bus Standard for use in Industrial Control System. IEC 61158‐2 Physical Layer Specification and service definition for field bus. IEC 61508 Functional Safety of Electrical / Electronic /Programmable Electronic

safety related system. IS 1271 Specification for Thermal Evaluation and Classification of Electrical

Insulation

2.4 ISO International Organisation for Standardisation

6817 Measurement of Conductive liquid flow in closed Conduit ‐ Method using electromagnetic flow meters

9104 Measurement of fluid flow in closed conduits ‐Methods of evaluating

the performance of electromagnetic flow meters for liquids.

2.5 Abbreviations:

NPT National Pipe Thread FISCO Fieldbus Intrinsic Safety Concept HART Highway Addressable Remote Transducer PID Proportional, Integral and Derivative LCD Liquid Crystal Display PTFE Poly tetra fluoro Ethelene

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3.1 Flow Meter 3.1.1 Unless otherwise specified, flow meter shall be of in‐line mounting design. Insertion type of

magnetic flow meter shall not be offered.

3.1.2 Flow direction should be clearly marked on the magnetic tube to ensure correct installation of the flow meter.

3.1.3 Vendor to note, that the location and orientation of installation of electromagnetic flow meter in the line, shall not affect the calibration, accuracy and performance of the meter.

3.1.4 End Connection

3.1.4.1 Flow meter shall be of flanged body construction with material of construction as specified in data sheet. In case of welded end connection design, the weld joints shall be of radiography quality.

3.1.4.2 Unless otherwise specified, the following shall govern: ‐

a) Threaded end connections shall conform to NPT as per ASME B 1.20.1. b) Flanged end connections shall be as per ASME B 16.5. c) Grooves of ring‐type joint flanges shall be octagonal as per ASME B16.20. d) Flange face finish shall be as per ASME B 16.5. The face finish as specified in the data shall

be as follows: 125 AARH: 125 to 250 micro inch AARH 63 AARH: 32 to 63 micro inch AARH

3.1.5 Unless specified otherwise, the flow meter tube shall have PTFE liner. The liner shall hold tightly and rigidly against the flow meter tube without any air gap.

3.1.6 Magnetic Coils

3.1.6.1 The field coils shall operate on an alternating supply voltage as indicated in the data sheets. The performance of the flow meter shall not be affected by the following variations in the supply voltage;

a) Voltage variation of +/‐ 10% of nominal value. b) Frequency variation of +/‐ 3% of nominal value.

3.1.6.2 Coil insulation should be class F suitable for high temperature as per IEC 60085/IS 1271.

3.1.6.3 Unless otherwise specified, the coil housing shall be of carbon steel construction fully welded to the meter body to avoid ingress of moisture, dust and corrosive gases.

3.1.6.4 Coil excitation technique shall be pulsed DC type or dual frequency type. In case of slurry

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applications, the meters shall have high coil current and high frequency excitation.In case of slurry applications, grounding ring shall act as lining protector.

3.1.7 Electrodes

3.1.7.1 Electrodes shall have good corrosion resistance and shall be welded to meter body. Field replaceable electrode construction shall be offered only when specifically indicated in the data sheet.

3.1.7.2 Vendor shall offer on line removable electrodes where cleaning of electrodes, is necessary due to coating characteristics of the process fluid.

3.1.7.3 The vendor shall ensure that for potential equalisation between sensor and liquid, the flow meter shall be provided with integral earthing reference electrode when installed in non lined pipe and an earthing plate / ring when installed in lined pipe. Vendor's scope of supply shall also include earthing cables and cable accessories like earthing lugs for interconnection with meter electronics. Unless specifically indicated, earthing electrode shall not be acceptable in place of earthing ring.

3.1.7.4 The electrodes including earthing ring shall be connected in the intrinsically safe circuit for flow meter handling electrically hazardous fluids.

3.1.8 Sizing Considerations

3.1.8.1 Meter shall be capable of measuring process fluid of conductivity 5 micromhos /microsiemens per centimetre unless specified otherwise in the data sheet.

3.1.8.2 Following velocity limits shall be considered for meter sizing, unless otherwise specified.

a) For slurries and viscous flow: 4 to 5 m/s. b) For all other services: 2 to 3 m/s.

Velocity beyond these limits shall not be considered for sizing.

3.1.9 Terminal Housing

3.1.9.1 Following shall apply for both integral as well as for remote meter electronics:

a) All connections shall be terminated on the terminals brought out in the terminal housing located on the flow meter body. Flying leads shall not be provided.

b) All intrinsically safe terminals shall be properly identified and shall be separate from the non‐intrinsically safe terminals.

c) Separate cable entry shall be provided in the terminal housing for power and intrinsically safe signals.

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d) The flow meter enclosure, housing the electrical parts shall be suitable for the area classification indicated in the data sheets. Unless otherwise specified, the enclosure shall conform to the following standards:

• Weatherproof housing ‐ IP 65 to ISIIEC‐60529.

• Flameproof housing ‐ Flame proof 1 Ex (d) as per ISIIEC‐60079.

• Flameproof housing shall also be made weatherproof.

3.1.9.2 Proper terminal blocks shall be provided in the transmitter unit for the termination of cables. Separate terminal blocks shall be provided for power and signal connections.

3.2 Meter Electronics

3.2.1 Meter electronics includes all the associated electronics like pre‐amplifiers, transmitter/ converters etc. Where the vendor is supplying the complete meter electronics, vendor shall ensure that the input/output signals and performance characteristics of individual item are compatible with each other.

3.2.2 When meter electronics is specified for installation in electrically classified area, the transmitter shall be flameproof with intrinsically safe sensor. Safety barrier as required for the sensor shall be provided by the vendor and shall be part of transmitter enclosure.

3.2.3 The electronic transmitter shall be two (2) wire micro‐process based and shall be capable of providing 4 to 20mA analog output superimposed with diagnostic data in digital mode (i.e.HART output). When specified, flow meter shall provide field‐bus output conforming to the standard specified in the Material specification/Datasheet.

3.2.4 For smart transmitters with HART output or for field bus based transmitter the following features must be ensured;

a) It shall allow multi‐master (primary and secondary) for configuration, calibration, diagnosis and maintenance. The primary could be the control system or host computer, and the secondary could be the hand held communicator.

b) It should be capable of implementing universal commands.

3.2.5 In addition to the requirements specified above, field bus based transmitter shall meet the following requirements;

a) All instruments must satisfy the requirements of the field bus registration laboratory with applicable checkmark like foundation field bus or as specified in the data sheets.

b) All instruments shall have two analog input blocks and a PID controller block, as a minimum.

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c) All instruments must be interoperable and shall have valid interoperability test clearance for foundation field bus, as applicable.

d) The field bus instruments shall support peer‐to‐peer communication. e) Field bus instruments as offered shall not be polarity sensitive. The field bus instruments in hazardous area shall be certified as per entity concept or shall be FISCO approved as per the requirements specified in the specification Datasheet.

3.2.6 Field mounted converters/transmitters shall have an integral output LCD meter. Local indication of the output meter shall be digital with engineering units.

3.2.7 The span of the transmitter shall be field adjustable. In case separate device is required, to make such a change, the same shall be included.

3.2.8 The configurational data for the instrument shall be stored in a non‐ volatile memory such that the data remains unchanged because of power fluctuations or power off condition.

3.2.9 When data sheets indicate the presence of permeable solids in the stream (e.g. slurries containing magnetic materials like iron) vendor shall offer a flow meter system whose circuitry compensates for signal changes induced by the presence of permeable solids.

3.2.10 When specified, the meter electronics shall be protected against transients induced by lighting and power supply surges. Transient protection electronics shall preferably be provided in the terminal block.

3.2.11 Where remote mounted converter/ transmitter is offered a minimum of 10 metre of interconnecting cable shall be included for both, measuring electrode and earthing electrode /plate, unless specified otherwise.

3.3 Performance Requirements Unless specified otherwise in the data sheets, the performance requirements for the flow meter shall be as follows;

a) Flow meter accuracy , inclusive of linearity, repeatability and hysteresis shall be better than +/‐ 0.5% of flow rate.

b) Flow meter repeatability: shall be better than +/‐0.1 % of flow rate

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4.0 DOCUMENTATION






a) Specification sheet/ Data sheet/ Sizing Sheet for each Mass Flow Meter. b) As built drawings for each Mass Flow Meter, providing dimensional details, constructional

details, Weight and material of construction. c) Copy of test certificates for all the tests as per MR and Documents along with TPI IRN. d) Installation procedure for each orifice plate and flanges. e) BOM including spares (if applicable) f) Product Catalogs of Main equipment and accessories/ bought outs. g) Curves for flow measurement vs. accuracy and rangeability. h) Maximum and minimum supply voltage required for the instrument to function within the

stated performance characteristics. i) Clearance required for maintenance work j) Calibration procedures for mass flow meter


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5.0 NAME PLATE

5.1 Each electromagnetic flow meter and its accessories shall have a stainless steel nameplate attached firmly to it at a visible place, furnishing the following information:

a) Tag number as per data sheet. b) Manufacturers serial number and model number. c) Manufacturer's name/ trademark. d) Nominal end connection size and rating. e) Tube, tube liner and electrode materials. f) Calibrated range of flow. g) Area classification for which the equipment is certified for installation. h) Hazardous area certification number and marking i) Operating power supply voltage and frequency. j) Specified range and units of measurement for flow.

6.0 SHIPPING


6.2 The flow transmitter and its accessories shall be packed separately.




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