volume iii-technical specifications-annexure-a mechanical (1)

Doc. No. 0435-JH0902-00-PP-RFQ-0010

ANNEXURE A

TECHNICAL SPECIFICATION – MECHANICAL

of 4

Guru Gobind Singh Refinery Products Evacuation Project (GGSRPEP)

Raman Mandi- Bahadurgarh and Raman Mandi- Bhatinda Multiproduct Pipeline

LIST OF ATTACHMENTS FOR COMPOSITE WORKS TENDER FOR TERMINALS AT RAMANMANDI & BATHINDA (MECHANICAL)

435-JH0902-10-ME-LST-0015

25-Aug-2009

Sanghi Oxygen Compound 1, Mahal Industrial Estate Mahakali Caves Road Andheri (East), Mumbai - 400 093 India Phone: +91-22-67818000 Fax : +91-22-67818080 www.worleyparsons.com

© Copyright 2009 WorleyParsons

of 4

SYNOPSIS

Disclaimer

This report has been prepared on behalf of and for the exclusive use of Hindustan Petroleum

Corporation Limited (HPCL), and is subject to and issued in accordance with the agreement

between Hindustan Petroleum Corporation Limited (HPCL) and WorleyParsons. WorleyParsons

accepts no liability or responsibility whatsoever for it in respect of any use of or HPCL upon this

report by any third party.

Copying this report without the permission of Hindustan Petroleum Corporation Limited (HPCL) or

WorleyParsons is not permitted.

PROJECT 435/JH0902- HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP)

REV DESCRIPTION ORIG REVIEW WORLEY- PARSONS APPROVAL

DATE CLIENT APPROVAL

DATE

A Issued for DIC / SQC

Subramanyam.S

Sameer Ishwad

Jeremy Wallace

08-July-09 N/A

B Issued for Review

Subramanyam.S

Sameer Ishwad

Jeremy Wallace

10-July-09

N/A

C Issued For Tender

Subramanyam.S

Sameer Ishwad

KMN Pillai

25-Aug-09

of 4

Sr.

no.

List of Attachments Document No. Revision No.

1. Basis of Design (Mechanical) 0435-JH0902-00-ME-BOD-0001 Rev-2

2. Scope of Work for Rotating

Equipment & Packages (Part A &

Part B)

435-JH0902-00-ME-SOW-0001 Rev-C

3. Technical Compliance for Rotating

Equipment & Packages 435-JH0902-00-ME-TEN-0001 Rev-C

4. Specifications for Sump Pumps 435-JH0902-10-ME-SPC-0009 Rev-C

5. Equipment Datasheet for

Centrifugal Pumps (VS) at

Bathinda

0435-JH0902-10-ME-DAS-0016 Rev C

6. Equipment Datasheet for

Centrifugal Pumps (VS) at

RamanMandi

0435-JH0902-10-ME-DAS-0012 Rev C

7. Inspection & Test Plan for Sump

Pumps 435-JH0902-00-ME-ITP-0006 Rev-C

8. Experience Record Proforma for

Vertical Submercible Pumps 435-JH0902-10-ME-LST-0014 Rev-C

9. Experience Record Proforma for

VSD’s & Motors 435-JH0902-10-ME-LST-0007 Rev-C

10. Mandatory Spares for Vertical

Submersible (VS4) Pumps 435-JH0902-10-ME-SPL-0003 Rev-C

11. Specification for EOT Crane

435-JH0902-10-ME-SPC-008

Rev C

12. Specification for Corrosion Inhibitor

Package

435-JH0902-10-ME-SPC-0010

Rev C

13 Datasheet For Corrosion Inhibitor

Package For Ramanmandi To

Bahadurgarh Pipeline

435-JH0902-10-ME-DAS-0011

Rev C

of 4

14 Datasheet For Corrosion Inhibitor

Package For Ramanmandi To

Bathinda Pipeline

435-JH0902-10-ME-DAS-0013

Rev C

15 Experience Record Proforma for

Packages

435-JH0902-10-ME-LST-0013 Rev C

16 Inspection & Test Plan for Dosing

Pump

435-JH0902-00-ME-ITP-0007 Rev C

17. Site & Utility Data 435-JH0902-10-ME-SPC-0007 Rev C

18. Scope Of Work And Supply(Static

Equipments Part A & B)

0435-JH0902-00-ME-SOW-002 Rev C

19. General Specification For

Pressure Vessels

0435-JH0902-00-ME-SPC-0015 Rev C

20. ITP For Pressure Vessels 0435-JH0902-00-ME-ITP-008 Rev C

21. Mandatory Spare Parts For Static

Equipments.

0435-JH0902-00-ME-SPL-004 Rev C

22. Specifications for Slop / Interface

Pumps

0435-JH0902-00-ME-SPC-0011 Rev C

23. Mechanical Datasheets for Slop /

Interface Pumps at Bhatinda

0435-JH0902-20-ME-DAS-0022 Rev C

24. Mechanical Datasheets for Slop /

Interface Pumps at Bhatinda

0435-JH0902-20-ME-DAS-0023 Rev C

25. Mandatory Spares for Horizontal

Centrifugal Pumps

0435-JH0902-00-ME-SPL-0005

Rev C

26. Inspection & Test Plan for

Horizontal Centrifugal Pumps

0435-JH0902-00-ME-ITP-0009

Rev C

27 Mechanical Datasheet for Sump

Tank for Ramanmandi

0435-JH0902-10-ME-DAS-0009 Rev C

28 Mechanical Datasheet for Sump

Tank for Bathinda

0435-JH0902-20-ME-DAS-0017 Rev C

Document No.:0435-JH-0902-ME-BOD-0001 Rev.1 Page 1 of 37

Hindustan Petroleum Corporation Ltd. (A Government of India Enterprise)

GGSR Product Evacuation Project

BASIS OF DESIGN MECHANICAL

Document No.:0435-JH0902-00-ME-BOD-0001

2 Reissued for Design SS SVI KMNP 27.08.09

1 Issue for Design SS SVI AK 29/04/09

0 Issue for client comment SS SVI AK 23/04/09

rev Description Originated By Checked By Approved By Date


MECHANICAL DESIGN BASIS

DESIGN PHILOSOPHY FOR

PACKAGED, ROTARY& STATIC EQUIPMENT


CONTENTS

Sl.NO. DESCRIPTION

1. Reference Publications

2 Designed Philosophy / Criteria


1.0 REFFERENCED PUBLICATIONS 1.1 Codes & Standards (latest editions) published by the following bodies, including

their latest addenda, shall be followed unless specified otherwise. ASTM : American Society for Testing and Materials ASHRE : American Society of Heating, Refrigerating and Air Conditioning Engineers. API : American Petroleum Institute ASME : American Society of Mechanical Engineers AGMA : American Gear Manufacturers’ Association NFPA : National Fire Protection Association OCIMF : Oil Companies International Marine Forum TEMA : Students of Tubular Exchanger Manufacturers’ Association OISD : Oil Industries Safety Directorate 1.2 Statutory Provision National laws and statutory provisions, such as, Department of Explosives,

Nagpur, India, together with any local by-laws for the State shall also the complied with. Static and Mobile Pressure Vessels (SMPV) Rules and Petroleum Rules, as applicable, shall be complied with.

2.0 DESIGN PHILOSOPHY / CRITERIA 2.1 SCOPE The Design basis defines the minimum criteria to be followed for the design of

various mechanical Rotary and Static equipments/systems/packages. 2.2 GENERAL DESIGN REQUIREMENTS While specific guidelines pertaining to individual rotary equipment/system/package

are listed in subsequent sections, the following shall be considered for all items while formulating their specifications and also in their procurement engineering activities.


- Reliability in service (assessed from vendor’s relevant track record and ensured by incorporating certain minimum design features or requirements in the specifications).

- Compliance with applicable national or overseas codes and standards as

well as application statutory regulations in existence for a specific item. - Ease of operation and maintenance including any necessary measures for

ensuring safety of personal and equipment as well as a conducive working environment.

- Standardization of components wherever feasible. - Adherence to any limitation of available space for the equipment and for its

operation/maintenance. - Facility for any known future expansion of plant capacity. - Proven Track Record (PTR) of similar unit(s).

2.3 DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS

I) Corrosion allowance for carbon steel and vessels shall be minimum 3mm, unless otherwise specified.

ii) All components/equipment shall meet the requirements of respective area

classification. iii) Insulation shall be provided for personal protection for all surfaces at

temperature higher than 700C. iv) All couplings, gears, and exposed rotating parts shall be provided with

adequate protection guards

001 AIR CONDITIONING SYSTEM 1. Inside Design Conditions DBT,0C % RH ii) Computer Building with all 21 + 1 50 + 5 associated rooms. iii) UPS & Battery charger 24 + 1 50 + 5 Room/Variable Speed Drive panel Room/Operator Room. iv) Operation Staff/ 24 + 1 30 t0 70

Rev. 2


Administrative Building. 2. All the areas as defined in Architectural details are to be air conditioned except

Electric Room, Record Room and Toilets, which shall be force / induced ventilated only.

3. Air conditioning system shall be through local Window and Split AC. 4. For VFD Room, Instrument Calibration room, & HVAC room, Air conditioning shall

be provided as per the Basis of Design HVAC 0435-JH0902-10-HV-BOD-0001 & Specification for HVAC 0435-JH0902-10-HV-SPC-0001 attached elsewhere with the tender

002 BASKET FILTER 1. Basket filters shall normally be used when particles of around 150 microns or

larger size are to be filtered from a fluid stream. 2. Filter shall be designed not to exceed the allowable pressure drop in clean and

dirty conditions. 3. In order to avoid the possibility of frequent basket cleaning the gross and free

areas shall be at least 20 and 16 times respectively of the filter inlet nozzle area. 4. Filter shall be Horizontal type with facility for removal of the basket from the side

after opening the house cover (Quick Opening and Closing Type). 5. Fluid flow shall be from inside to outside of the basket, unless specified otherwise. 6. Fluid housing design shall be as per ASME Section VIII, Division 1. For steam

jacketed housing, applicable IBR requirements shall also be complied with. 7. All the basket Filter shall be provided with Backwashing connection and provision

for back washing of Basket Filter 003 PRESSURISATION FOR SUBSTATIONS / VENTILATION SYSTEM 1. Ventilation air requirement shall be calculated based on 30C temperature rise of

incoming air to room depending upon the suitability of electrical / equipment for the room temperature being maintained.

2. Minimum air changes per hour shall be 12 in the room. 3. Air intakes shall be located in non-hazardous and chemical fume-free areas at

adequate elevation to protect against rains and dust. 4. Pressurized areas shall have over pressure of 5 mm WG. 5. Fire dampers shall be electric motorized type.

Rev. 1

Rev. 1

Rev. 1

Rev. 1

Rev. 2


004 Manual Hoists / Chain Pulley Blocks / EOT and HOT Crane 1. Design and manufacture of chain pulley block with or without trolley shall be

consistent with capacity, lift, head room and other parameters as specified in data sheets.

2. In design of chain pulley blocks, care shall be taken for following features:-

- Minimum effort to lift a specified load

- Self breaking system for holding the load in any position

- Even loading of bearings

- Ease of installation and maintenance

- Compact design

3. For safe area application chain pulley blocks shall be as per IS: 3832 4. For hazardous area application, the materials for non-lubricated rubbing parts shall

be non-sparking type (non-ferrous) 5. EOT / HOT Crane

5.1 These cranes are normally installed in main pump house for the primary purpose of handling equipment and components for maintenance or replacement. Other applications involving use of cranes during plant operation may also exist. 5.2 The bridge structure of overhead traveling crane shall be made from box (double web) type, plate type, or fabricated from rolled sections. The structure can be single girder or double girder type. The use of single girder bridge is limited to lifting capacities up to 5 Ton and span and length upto 10 mtr. In case either of these values is exceeded, the double girder bridge shall be used. 5.3 For cranes which are to operate in areas classified as hazardous besides ensuring that all electrical components are certified for use in specified hazardous areas materials of construction for rubbing non lubricated metallic parts should be specified in such a way that the possibility of sparking during operation is eliminated. This is done by having one part in every such pair made from a suitable non-ferrous material such as phosphor/aluminium or gun metal depending upon the application. 5.4 Maintenance walkway shall be provided on both sides along the travel and minimum 750mm wide platform along traverse travel. 5.5 Minimum capacity of the crane shall be max, weight of the equipment to be lifted plus 10% margin

5.6 EOT CRANES: Unless otherwise stated the following hoisting and travel speeds shall be

used:

Rev. 1

Rev. 1


Hoisting : 2 m/min Cross travel : 10 m/min Long travel : 20 m/min Higher operating speeds may be considered for higher lifts and longer bay

lengths. Suitable inching (creep) speed mechanism shall be provided to facilate accurate spotting of the load

DC electromagnetic or thrustor brake shall be used for the hoisting motion.

Electro hydraulic thrustor-operated brakes are used for the cross and long travel motions.

Auxiliary hoist shall be provided in case of cranes having capacity 15T and above. Capacity of auxiliary hoist shall be 10% of crane capacity with min. 2MT.

EOT crane shall be suitable for hazardous area application


DESIGN BASIS

FOR

ROTATING EQUIPMENT


CONTENTS

Sl.No. Description Page No.

1. REFERENCED PUBLICATIONS………………………………………………………………. 10 2. DESIGN PHILOSOPHY………………………………………………………………… ……. 11

2.1 SCOPE………………………………………………………………………………………….. 11 2.2 CONFLICTING REQUIREMENTS……………………………………………………………… 11 2.3 UNITISATION ………………………………………………………………………………… 11 2.4 APPLICABLE CODES AND STANDARDS…………………………………………… ……. 11 2.5 EQUIPMENT SELECTION AND SIZING CRITERIA……………………………………….. 11 2.6 EQUIPMENT SPARING PHILOSPHY……………………………………………………….. 12 2.7 EQUIPMENT QUALIFICATION

CRITERIA……………………………………………………………………. 12 2.8 EQUIPMENT SUPPLIERS 2.9 ASSOCIATED ACCESSORIES AND AUXILIARY SYSTEMS……………………………. 12 2.10 SEALING SYSTEM SELECTION CRITERIA……………………………………………….. 13 2.11 COUPLINGS & COUPLING GUARDS………………………………………………………. 13 2.12 ALLOWABLE NOISE LEVEL…………………………………………………………………. 13 2.13 EQUIPMENT STORAGE………………………………………………………………………. 13 2.14 INITIAL FILL…………………………………………………………………………………….. 13 2.15 INSTALLATION CRITERIA……………………………………………………………………. 13 2.16 SAFETY………………………………………………………………………………………… 14 2.17 INSPECTION AND TESTING……………………………………………………………….. 14 3. SPECIAL REQUIREMENTS………………………………………………………………… 14

3.1 CENTRIFUGAL PUMPS (OTHER THAN WATER SERVICE)…………………………… 14 3.2 CENTRIFUGAL PUMPS (WATER SERVICE)……………………………………………… 18 4. SPARES & SPECIAL TOOLS……………………………………………………………….. 20 4.1 COMMISSIONING SPARE PARTS…………………………………………………………. 20 4.2 SPECIAL TOOLS/TACKLESS……………………………………………………………….. 21 4.3 MANDATORY SPARES ………………………………………………………………………. 21 4.4 SPARE PARTS FOR T WO YEARS NORMAL OPERATION…………………………….. 21 5. DOCUMENT, DATA & DRAWING…………………………………………………………… 21 5.1 GENERAL………………………………………………………………………………………. 21 5.2 DRAWING AND DOCUMENTS REQUIRED ALONG WITH BID………………………… 21 5.3 DRAWING AND DOCUMENTS REQUIRED DURING DET AILED ENGINEERING….. 21


1. REFERENCED PUBLICATIONS The following codes are referred and applicable for the equipment as enlisted. Table 1: applicable/Referred Codes and Standards

S.No. Description Standard / Codes Remarks

1. PUMPS

1.1 Centrifugal Pumps (Special Purpose Process Service) API Std.610 (10

th edn.)

(1)

1.2 Centrifugal Pumps (General Purpose Process Service)

--- (2)

1.3 Centrifugal Pumps (General Water Service) ISO 5199, ASME B 73.1

(3)

1.4 Centrifugal Pumps (Slurry & Liquor Service) ---

1.5 Positive Displacement Pumps (Reciprocating) API Std. 674 (2

nd edition)

1.6 Positive Displacement Pumps (Controlled Volume) API Std. 675 (2

nd edition)

1.7 Positive Displacement Pumps (Rotary) API Std. 676 (2

nd edition)

2.0 AUXILIARIES

2.1 Lubrication, shaft sealing and control-oil systems and auxiliaries

API Std. 614 (4

th edition)

2.2 Shaft sealing for centrifugal & rotary pumps API Std. 682 (2

nd edition)

2.3 Vibration, Axial Position & Bearing Temp. Monitoring Systems

API Std 670 (4th

edition)

3. MISCELLANEOUS (For reference)

3.1 Gear Units ANSI/AGMA

3.2 Bearings ABMA

3.3 Laboratory Methods of Testing Fans for Rating Purposes

AMCA

3.4 Mechanical Vibrations-Balancing quality requirements of rotating rigid rotors

ISO 1940

Remarks: (1) Centrifugal pumps for special purpose process service are classified as

pumps which are meant for process service (both for on-site & offsite) but excluding the pumps covered either under general-purpose process service or general water service.

(2) Centrifugal pumps for general purpose process service are classified as pumps for applications where maximum pressure by all consideration does not exceed 16.0 kg/cm2g. pumping temperature remains within -290C to 2050C, specific gravity is not less than 0.7 at the specified operating conditions or when dual pressurized / un-pressurized mechanical seals are not required/specified. Typical areas of application are non-process services & utility services such as De-mineralised Water (DMW) plans, /raw Water Treatment Plants (RWTP), Effluent Treatment Plants (ETO), Blow-down services etc.

Rev. 1


(3) Centrifugal pumps for general water service are classified as pumps for applications such as Large Capacity Cooling Water Pumps, Auxiliary Cooling Water Pumps & other centrifugal pumps handling clean & cold water.

(6) General-purpose gear units (conforming to API Std. 677) shall be used in equipment trains that are usually spared, or are in non-critical serviced and up-to a maximum driver rating of 750 KW. all ID fan trains are to be considered as meant for non-critical service.

(7) Special-purpose gear units (conforming to API Std. 613) shall be used in equipment trains that are usually not spared, or are in critical service.

(8) Special-purpose couplings (conforming to API Std. 671) shall be used in equipment trains, as special in the EDB.

2. DESIGN PHILOSOPHY 2.1 SCOPE The specification covers the design criteria for the purpose of carrying out

Engineering for Procurement of various rotating equipment required including requirements with regard to spare parts & special tools. This EDB shall be applied for project of GGSR Product Evacuation Project.

Electrical items, Instrumentation & Controls, Piping, Pressure Vessels, Mechanical

Equipment, etc. associated with rotating equipment shall comply with the design requirements as given in the respective specifications forming part of the bid package / inquiry.

2.2 CONFLICTING REQUIREMENTS In case of conflict between this Engineering Design Basis and other attached and /

or refereed specifications, the following order of precedence shall govern: (a) Process Package approved by HPCL/WP (b) P&ID’s (if any) (c) This Design Basis (d) Other specifications (if any) (e) Other referred codes and standards. 2.3 UNITISATION Unitisation where specified shall be carried out manufacturer’s shop before

dispatch. For other equipment the same may be done at site / shop, as preferred, under direct supervision of driven equipment manufacturer’s representatives.

2.4 APPLICABLE CODES AND STANDARDS Equipment Process Data Sheets, P&IDs, Specification and Standards / Codes (as

per the table 1) along with the requirements specified in this Design Basis shall be the basis of design, selection, manufacture, inspection/testing of the equipment.

For design aspects not specifically covered herein, the design shall be based on good engineering practices.


2.5 EQUIPMENT SELECTION AND SIZING CRITERIA 2.5.1 Selection of Rotating Equipment shall be based upon the following considerations. - Suitability for the specified duty conditions - Standard Models under vendor’s regular range of manufacture

- Proven Track record in similar service as specified under acceptance criteria.

2.5.2 Allowable working pressure & temperature of the rotating equipment shall be

greater than the higher of design pressure & temperature specified in:- - The equipment data sheet (if any) - Engineering specifications, codes & standards. 2.5.3 All rotating equipment & drivers (including gear units and couplings if any) shall be

designed to perform satisfactorily under specified start up conditions, part load operation, maximum differential pressure operation and relief valve set pressure and up to full speed/maximum conditions speed.

2.6 EQUIPMENT SPARING PHILOSOPHY The equipment Sparing philosophy including warehouse spare requirement shall

be as specified in the process package and or bid package. 2.7 EQUIPMENT QUALIFICATION CRITERIA (EQC) All Rotating Equipment shall be field proven and meet the EQC as specified in the

special requirements of the relevant rotating equipment, as applicable. Rotating Equipment Vendor/LSTK Contractor shall complete the Experience Record Performa’s enclosed with the inquiry document to amply prove that the offered Rotating Equipment meet the EQC for technical acceptance. In addition manufacturer’s catalogue and general reference list for Rotating Equipment shall also be furnished during detailed engineering by the Contractor.

2.8 EQUIPMENT SUPPLIERS The equipment supplier shall be one from the approved list of vendors provided

elsewhere in the bid package. 2.9 ASSOCIATED ACCESSORIES AND AUXILIARY SYSTEMS 2.9.1 The Vendor shall furnish all rotating equipment, drivers, auxiliary systems,

instrumentation and control systems, all necessary electrical and safety devices as applicable or required for safe and reliable operation of the unit.

The Vendor/ Contractor in his scope of supply and work shall also include the

hardware required over and above what is specified, for safe and satisfactory operation of the equipment

2.9.2 Motors, electrical/instrument components and electrical/instrument installations

shall be suitable for the area classification specified by the purchaser, and shall


meet the requirements as defined in the electrical/instrument specification attached with the relevant sections of the bid package / order.

2.10 SEALING SYSTEM SELECTION CRITERIA 2.10.1 Centrifugal Pumps 2.10.1.1 All pumps shall be provided with mechanical seals (except. clean cold water

service). 2.10.1.2 Tank/Pit mounted vertical pumps (process service) shall be provided with dry

running vapours seals. In case of handling Hazardous or toxic fluids this vapour seal shall be Nitrogen buffered.

2.11 COUPLINGS & COUPLING GUARDS 2.11.1 Unless otherwise specified, couplings shall be of metallic, non-lubricated, flexible

element type (i.e. either diaphragm or discs) with spacer, for all equipment. All coupling models shall be selected for a minimum service factor of 1.5.

2.11.2 Couplings for the following equipment shall conform to API Standard 671: - Multi-stage (greater than two stages) centrifugal pumps with driver rating

greater than 160 kW. 2.11.4 Universal type coupling (hook joint) shall be used for coupling diesel engine and

the vertical water pumps. 2.11.5 Removable coupling guard shall be provided which shall be fabricated from non-

sparking material, and shall be open at the bottom to permit manual shaft rotation. The guard shall be sufficiently rigid to withstand deflections as a result of body contact of nominally 100 kgs.

2.12 ALLOWABLE NOISE LEVEL 2.12.1 Equipment noise level (Driver + Driven equipment train + auxiliaries) shall not

exceed 85 when measured at One-meter distance from the equipment skid in any direction,

2.13 EQUIPMENT STORAGE All rotating equipment shall be packed for an outside storage period of at least 12

months. 2.14 INITIAL FILL The initial fill of lubricants, sealing fluid & other consumables for start-up &

commissioning shall be included in the scope of supply of the Vendor 2.15 INSTALLATION CRITERIA


2.15.1 Pumps All pumps shall be suitable for outdoor installation. 2.16 SAFETY 2.16.1 Equipment design and engineering shall incorporate adequate safety features (as

per applicable specifications of respective equipment as well as Health. Safety and Environment Codes & Standards applicable for the subject project) to provide protection to operating personnel, equipment and environment

2.16.2 Thermal relief valves shall be provided for components that may be blocked in by

isolation valves (including any cooling water return circuit piping). 2.16.3 All electrical components & installations, instruments shall be suitable for the

electrical area classification and grouping in which the equipment is installed. 2.17. INSPECTION AND TESTING 2.17.1 Inspection and test specified in the bid package shall be carried out by the

Equipment Vendor at his works. The Vendor shall conduct inspection and witness tests of all equipment at vendor’s works and furnish inspection and test reports to the owner.

2.17.2 Owner and/or his consultant/ TPIA may participate along with the vendor’s

inspection personnel in any inspection and tests. The vendor shall notify to owner/ consultant of all inspection and tests at least four weeks before the scheduled date of inspection and test and reconfirm the same at least one week before the date of inspection and testing.

3.0 SPECIAL REQUIREMENTS 3.1 CENTRIFUGAL PUMPS (OTHER THAN WATER SERVICE) 3.1.1 EQUIPMENT QUALIFICATION CRITERIA 3.1.1.1 The vendor shall be an established centrifugal pump manufacturer having

adequate engineering, manufacturing and testing facilities for pumps conforming to API Standard.

3.1.1.2 The pump model offered shall be from the existing regular manufacturing range of

the vendor. The mechanical as well as hydraulic performance (including NPSHR) for the complete range of operation of the offered model shall have been established in the shop test.

The offered pump model shall meet the following minimum service and

manufacturing experience requirements:


Pumps shall be identical or validly similar in terms of Power rating, Hydraulic Performance (including NPSHR), Inlet flow, differential Head, Operating Pressure & Temperature, Pumping Liquid, Speed, Number & Type of Impellers, Mechanical Design, Materials, Bearing span (applicable for between bearing pumps), Column Length (applicable for vertically suspended pumps) etc. and compared to at least TWO UNITS of the proposed model designed, manufactured, tested and supplied from the proposed manufacturing plant in the last seven years and at least ONE of these units shall have successfully operated in the field for at least 8000 hours individually without any major problem as on the date of issue of inquiry.

3.1.1.3 The vendor should have engineered, packaged, tested (performance test, string

test etc.) and supplied at least TWO identical or validly similar pumping units in terms of construction (axially or radically split), size of pumps (flow, head and power), lubrication system, sealing system and type of drive from the proposed shop in the last seven years and at least ONE of these units shall have successfully operated in the field for at least 8000 hours individually without any major problem as on the date of issue of inquiry.

3.1.2 Two stage pumps shall be of in-between bearing types. 3.1.3 Inducers shall not be used except for Sundyne or equivalent type of pumps. 3.1.4 Pumps for high head, low flow duties (falling outside the range of two stage pumps

without continuous bypass) shall be Sundyne or equivalent type. 3.1.5 Pumps where difference between NPSHA and NPSHR is less than 0.6 meter are

not acceptable. The said NPSHR value shall correspond to the maximum value of NPSHR from rated flow down to the recommended minimum continuous stable flow specified by the vendor.

3.1.6 The maximum permissible running clearances shall not be less than twice the

running clearances as specified in API610. 3.1.7 Impeller of multistage pumps shall also be positively locked against axial

movement in the direction opposite to normal hydraulic thrust. 3.1.8 Mechanical Seal for pumps shall conform to API-682. Mechanical Seals shall be

imported either in fully assembled condition OR the critical components shall be imported by Indian seal manufacturers from their respective principals and the seals shall be assembled and tested in the indigenous of these seal manufacturers. Qualification test results of each seal shall be furnished during detail engineering for review.

3.1.9 Pumps shall be provided with single mechanical seals (except for clean cold water

service pumps where gland packing is acceptable). For services involving solid contaminants, hazardous/toxic services, light hydrocarbons such as LPG, NEL, Naphtha, liquid gasses and services involving liquids at or above auto ignition temp., duel mechanical seal shall be used.

3.1.10

Rev.1

Rev.1


(a) Pumps handling non-congealing liquids at temperatures 2000C and above shall be provided with API seal flushing plan 23 or 32 where single mechanical seals are provided Plan 32

(b) Cooler shall not be provided in seal flushing system where seal is flushed by congealing liquid.

(c) For pumps provided with flushing Plan 21 and 23. Temperature Indicator shall be provided in the flushing line.

(d) Seal Plans 52 & 53 (for API-610 Pumps ) shall be as per sketches as per API 682.

3.1.11 In case Multistage pumps require force feed lubrication, the same shall conform to

flg .B.10 of API-610, 10th edition. The instruments shall be suitable for the specified area classification and shall be

from approved vendors (specified elsewhere in the bid package). 3.1.12 The motor nameplate rating for pumps under parallel operation/auto start shall not

be less than the max. BKW indicated on pump data sheet (Power at End of he curve for the rated impeller) and the pump motor shall be suitable for start-up under open discharge valve condition.

3.1.13 The motor nameplate rating for application where the specific gravity of pumped

fluid is less than 1.0 shall not be less than the BKW of pump at minimum continuous stable flow with clean cold water of sp. gravity 1.0.

3.1.14 The coupling service factor shall not be less than 1.5 over the driver rating as a

minimum. 3.1.15 Coupling guard shall be perforated and of non-sparking material. The guard shall

be open at the bottom to permit manual shaft rotation. The guard shall be sufficiently rigid to withstand deflections as a result of bodily contact of nominally 100 kgs. The guard for pumps/motors should have proper and convenient arrangement for vibration readings.

3.1.16 Hydraulic Power Recovery Turbines shall be optimized for best efficiency at

Normal Flow. 3.1.17 INTERCHANGEABLITY: As far as possible pumps & mechanical seals and

couplings shall be of identical make so that minimum levels of inventory can be maintained and maximum interchangeability /standardization can b achieved.

3.1.18 All pumps not open to sky with motor rating equal or higher than 75 kW shall be

provided with monorails. No monorails should normally be provided for pumps outside the rack. Sufficient space below rack shall be available for pump maintenance.

3.1.19 Whenever pumps capacity control is through LIC or LIC/FIC cascade or has a fail

closed control valve on pump discharge or process minimum capacity is less than pump MCF, necessary flow instruments in pump discharge along with pump bypass back to suction vessel with control valve for pump protection shall be


provided. However when continuous Bypass of pump MCF is envisaged bypass from pump discharge back to suction vessel with restriction orifice sized for pump MCF instead of control valve shall be provided.

3.1.20 Equipments along with the drivers shall be procured from the respective driven

equipment manufacturers as skid mounted units with all accessories, auxiliaries along with auxiliary piping.

3.1.21 Magnetic drain plug shall be provided for all centrifugal pumps bearing housings. 3.1.22 For seal flushing plans, piping material shall be of Stainless Steel. For cooling

water plans, piping material shall be carbon steel. 3.1.23 All pumps shall be provided with plugged connection for oil mist lubrication for

future use. 3.1.24 All pumps shall be provided with bearing isolators. 3.1.25 Inspection and Testing (For Each Pump) : 3.1.25.1 Material Certificates for the following are required. 3.1.25.2 The material inspection requirement for pressure containing parts shall be as per the following inspection category. Category A:

This category is applicable for carbon steel and cast iron for services with process design pressure upto 40 bar and design temperature from 0 to 150-0-C. Inspection requirement: As per vendor’s standard Quality/Assurance Plan. Category B: The category is applicable for services within the design pressure range of 0-70 bar and temperature range of -290C to 3000C. Inspection requirement includes visual inspection and magnetic particle or liquid penetrant inspection of following components as a minimum: - Nozzle weld - But t welds on pressure containing components. - Fillet welds on pressure containing components. - Shaft Liquid penetrant inspection shall be performed only when specified magnetic particle inspection is not feasible. Category C: This category is applicable for services with process design pressure above 70 bar or process design temperature below -290C and above 3000C. Inspection includes all the requirements of Category B together with radiographic or ultrasonic inspection of - Nozzle weld - Butt welds on pressure containing components. Ultrasonic inspection shall be carried out when radiography is not feasible.


3.1.25.3 Inspection shall also include dimensional check of pump, drier and auxiliaries (if

any) duly mounted on the base plate, in accordance with certified general assembly drawing. This will include all main pump dimensions, base plate dimensions, location of foundation bolt holes, size /position/rating of flanges, coupling guard arrangement, verification of the required material certificates and their traceability to the respective components. In addition, following checks shall also be carried out:

- A measurement of the actual running clearances throughout the pump. - A check of the hardness of wear rings. - A check for good workmanship and finish throughout. 3.1.25.4 The following tests shall be witnessed by owner’s inspecting agency: - Hydrostatic (For all pressure containing parts including auxiliaries) - Performance

- NPSH (In case difference between NPSHA and NPSHR is less than or equal to 1.0 m or when specified in the job specification)

- Dismantling inspection and reassembly after the running test, which shall included examination of mechanical seals, close clearance parts and measurement of running clearances. In case of multistage pumps having hydrodynamic bearings, the bearing shall be removed inspected and reassembled.

- Sound level Test (During Performance Test) 3.2 CENTRIFUGAL PUMPS (WATER SERVICE) 3.2.1 Equipment qualification criteria 3.2.1.1 The pump vendor shall be an established centrifugal pump manufacturer having

adequate engineering, manufacturing and testing facilities for Centrifugal Pumps (Water Service).

3.2.1.2 The pump model offered shall be from the existing regular manufacturing range of

the pump manufacturer. The mechanical as well as the hydraulic performance (including NPSHR) for the complete range of operation of the offered model shall have been established in the shop test. The offered pump model shall meet the following minimum service and manufacturing experiences requirements.

Pumps shall be identical or validly similar in terms of Power rating, Hydraulic Performance (including NPSHR), Inlet flow, Different Head, Speed, Number & Type of impellers, Mechanical Design, Materials, Bearing span (applicable for between bearing pumps), Column Length (applicable for vertically suspended pumps) etc. as compared to a lest TWO UNIS of the proposed model manufacturer, tested and supplied from the proposed manufacturing plant in the last seven years and at least ONE of these units shall have successfully operated in the field for at least 8000 hours individually without any major overhaul as on the date of issue of invitation to bid.

3.2.2 Pumps with constant speed drivers shall be capable of at least 5 percent head

increase at rated condition and pump rated speed by replacing with a new impeller

Rev. 1


or impellers. Offered impeller shall in no case be less than the minimum diameter impeller.

3.2.3 Horizontal pumps of the close-coupled, the two stage overhung, or the single stage

double suction overhung, type shall not be furnished. 3.2.4 Pumps where difference between NPSHA and NPSHR is 0.6 meter or less are not

acceptable. The said NPSHR value shall correspond to the maximum value of NPSHR from rated flow down to the recommended minimum stable flow specified by the vendor.

3.2.5 Pumps that have stable head/capacity curves (continuous head rise to shut-off) are

preferred for all applications and are required when parallel operation is specified. When parallel operation is specified, the head rise shall be at least 10 percent of the head at rated capacity.

3.2.6 Vertical pumps & motors that could be damaged due to reverse rotation shall be

proved with non-reverse rated or suitable device to prevent reverse rotation. 3.2.7 Impellers shall be cast as one piece. 3.2.8 Shaft shall be provided with sleeves under the packaging/seal. Sleeves shall be

locked to the shaft. The material of sleeve shall be 12 percent chrome steel (hardened). Where the size of pump makes the use of shaft impracticable, the shaft shall be constructed of 12 percent chrome steel (hardened). For vertical pumps, shaft material shall be 12 percent chrome steel.

3.2.9 The following vibration limits shall be applied at rated speed and at flow of +10 percent of rated flow. 3.2.9.1 Horizontal pumps Unfiltered vibration velocity for horizontal pumps upto 3000 rpm with antifriction

bearing or sleeve bearings when measured at the bearing housing in horizontal or vertical direction shall not exceed 7.6 mm/sec (0.3 inch/sec.).

3.2.9.2 Vertical Pumps Unfiltered vibration velocity for vertical pumps with antifriction and or sleeve

bearings when measured at the top bearing housing of pump or top bearing housing of motor or mounting flange for measuring points upto 3 meters above the mounting base shall not exceed the following limit:

Pumps greater than 1500 rpm (Peak to Peak) = 10.1 mm/sec. (0.4 inch/sec) Pumps upto & including 1500 rpm (Peak to Peak) = 8.9 mm/sec. (035 inch/sec.) 3.2.10 Pumps for Fire Water Application shall also meet the following additional

requirements:

Rev. 1


- Pumps shall be direct-coupled except in the case of engine-driven vertical turbine pumps wherein gear drives shall be used.

- Pumps shall be capable of furnishing not less than 150 percent of rated capacity at a head not less than 65 percent of the rated head. Shut off head shall not exceed 120 percent of rated head in horizontal pumps and 140 percent in the case of vertical turbine pumps.

- Difference between NPSHA and NPSHR at 150 percent of the duty point shall not be less than 0.5 meters.

- For Diesel engine drivers, the net continuous site power available after considering the duration due to site condition and power losses, due to other parasitic loads and engine driven auxiliaries shall of the following two values: (a) 20 percent in excess of the maximum BKW (including + 4%

tolerance) required to drive the pump at rated condition. (b) Maximum BKW rated impeller as indicated by the manufacturer in the pump data sheets.

3.2.11 Electrical motor drivers as per (IEC/IS) shall be rated for continuous duty (Duty

type S1) whereas motor as per American Standards shall be designed to operate at a service factor of 1.0 Rating shall not be less than the following unless higher rating is dictated by the Note-1.

Motor Name plate rating Motor MCR (%of Pump Rated BKW inclusive of +4% tolerance)

Less than 22 KW. To suit maximum BKW indicated on pump data sheet or 125% of rated pump BKW, whichever is higher.

22kW – 55 kW 115% of rated pump BKW

Higher than 55kW 110% for rated pump BKW

Note:

1. The motor nameplate rating for pumps under parallel operation shall not be less than the max. BKW indicated on pump data sheet (the power at End of the Curve for the rated impeller) or shall have the specified margin as per this clause whichever is greater. The pump motors shall also be suitable for start-up under open discharge valve condition,

3.2.11.1 INSPECTION AND TESTING Refer Centrifugal Pumps (Other than water service). 4. SPARES & SPECIAL TOOLS 4.1 COMMISSIONING SPARE PARTS Commissioning Spare Parts should be supplied free of cost by the equipment

vendors. Vendor to supply mandatory spares and provide list of recommended spares for two years normal operation.

4.2 SPECIAL TOOLS/TRACKLES

Rev. 1


Special Tools/Tackles shall be procured along with the main equipment as per equipment manufacturer’s recommendations. The list of such recommended shall be provided by vendor

4.3 MANDATORY SPARES Mandatory spares, as specified in the bid package shall be procured along with the

main equipment. Spare rotors where supplied shall be boxed in a metal containers for vertical storage.

4.4 SPARE PARTS FOR TWO YEARS NORMAL OPERATION As per rotating equipment manufacturer’s recommendations, a quotation for spare

parts for two-year normal operation along with unit price shall be furnished with the proposal for customer to order the same separately. Customer shall indicate, in case these spares are required to be order along with the equipment or to be ordered separately.

5. DOCUMENTS, DATA & DRAWINGS 5.1 GENERAL The Consultant shall develop detailed specifications for vendor data requirements

pertaining to each type of Rotating Equipment as applicable in accordance with the owner’s requirements specified in the enquiry document. This specification shall form part of the Consultant’s / Owner’s purchase requisition for the type of Rotating Equipment.

The Consultant shall be responsible for the review & approval of all Vendor Data &

Drawing submitted by the Equipment manufacturer. Owner’s / Consultant’s review / approval shall be limited to the vendor drawing and other documents as specified in the document entitled “Vendor Data, Document & Drawing for Owner / Consultant’s review”

5.2 DRAWING AND DOCUMENTS REQUIRD ALONG WITH BID The Vendor shall furnish the following along with the bid:

(a) Technical Compliance Pro-forma, duly completed. (b) List of deviations if any, to the applicable specifications.

5.3 DRAWING AND DOCUMENTS REQUIRED DURING DETAILED ENGINEERING. The vendor shall submit all the documents and drawings pertaining to design,

engineering and procurement of all Rotating Equipment as specified in Vendor Data.

Requirements for Owner’ review and record. Number of prints to be submitted shall be as specified in the Contract.

Rev. 1


DESIGN BASIS

DESIGN PHILOSOPHY

STATIC EQUIPMENT


CONTENTS

Sl.No. DESCRIPTION 1.0 Referenced Publications 2.0 Design Philosophy/Criteria 2.1 Equipment sizing 2.2 Minimum shell / head thickness 2.3 Equipment end closures 2.4 Design pressure 2.5 Test pressure 2.6 Design temperature 2.7 Corrosion allowance 2.8 Wind consideration 2.9 Earthquake consideration 2.10 Capacity 2.11 Supports 2.12 Manholes 2.13 Floating roof 2.14 Nozzle size 2.15 Flanges 2.16 Internals 2.17 Pipe davit 2.18 Vent/drain/ventilation nozzle connections 2.19 Spares 2.20 MP connections for PG/TI 2.21 Important considerations 2.22 Heat exchangers 2.23 Air coolers 2.24 Bought out suppliers 3.0 Design criteria/requirements – specific applications 3.1 Storage spheres 3.2 Tall columns 3.3 Storage tanks 3.4 Mounted bullet 3.5 Reactors 3.6 Double walled storage tank 4.0 Project specific requirements Table-I Detail & wt. of column attachment Table-II Allowable stress for combined loading Annexure-I Material selection


1.0 REFERENCED PUBLICATIONS

a) The following codes and standards in their latest edition including latest addenda as on the date of first issue of this design basis shall be followed unless otherwise specified in the requisition for the design, fabrication, inspection and testing of Vessels, columns, Reactors, Spheres, Storage Tanks, Steel Silos, Bins, Hoppers, Steel Flare/Vents Stacks & heat exchangers.

ASME SEC. VIII DIV.1 For Pressure Vessels,

API 650/IS:803 For Atmospheric Storage Tanks

API 2000 Venting Atmospheric Storage Tanks

OISD-118 for Oil and Gas Installation

ASME SEC.II For material specification

ASTM/IS For material specification

IS: 875/SITE DATA For wind load consideration

IS: 1893/SITE DATA For seismic design consideration

ASME SEC.IX For welding

ASME B 16.5 For flanges

ASME B 16.20 For gaskets

b) Statutory Provisions:

National laws and statutory provisions such as Indian Boiler Regulation and Department of Explosives, Nagpur, India together with any local by-laws for the state shall be complied with. Static and Mobile Pressure Vessel (SMPV) rules and Petroleum rules as applicable shall also be complied with.

c) Publications

ISO 15156 Containing environments in oil and gas production . WRC Bulletlin#107 Local Stresses in Spherical & Cylindrical Shells due

to External Loadings. WRC Bulletin#297 Local Stresses in Cylindrical Shells due to External

Loadings on Nozzles


2.0 DESIGN PHILOSOPHY / GENERAL CRITERIA

Equipment shall be designed in compliance with the latest design code requirements and applicable standards/specifications. All design calculations shall be performed considering all applicable loads for erection, operating and hydro test conditions.

2.1 Equipment Sizing c) Vessels (Thickness 50mm) Based on inside diameter

d) Tanks Based on API 650

2.2 Minimum Shell/Head Thickness Minimum thickness of equipment wall/components shall be as given below:

a) For carbon and low alloy steel vessels – 6 mm (including corrosion allowance not exceeding 3.0), but not less than that calculated as per following:

For diameters less than 2400 mm Wall thickness = Dia + 1.5 + Corrosion Allowance (if any) 1000 For diameters 2400 mm and above Wall thickness = Dia + 2.5 + Corrosion Allowance (if any) 1000 All dimensions are in mm.

b) For stainless steel vessels and high alloy vessels – 3 mm, but not less than that calculated as per following for diameter n\more than 1500 mm.

Wall thickness (mm)= Dia + 2.5 + Corrosion Allowance (if any) 1000

2.3 Equipment End Closures:

- Unless specified otherwise Deep Torispherical Dished end with 80% crown radius and 15% knuckle radius of alternatively 2:1 semi Ellipsoidal Dished End shall be used for pressure vessels

- Hemispherical Ends shall be considered when the thickness of shell exceeds 70

mm. - Flat Covers may be used for atmospheric vessels. - Flanged Covers (consisting of standard forged WN flanges and blind flange as per

ASME B 16.5 shall be used for Vessels of diameter < 900 mm having internals.

Rev. 1


- All columns 900 mm and below shall be provided with intermediate body flanges. Numbers of intermediate flanges shall be decided based on column height and type of internals.

2.4 Design Pressure Unless specified otherwise elsewhere design pressure shall be calculated as per

the following a) When operating pressure is up to and including 70 Kg/cm2g.

Design pressure shall be equal to operating pressure plus 10% (minimum 2 Kg/cm2g).

b) When operating pressure is over 70 Kg./cm2g.

Design pressure shall be equal to operating pressure plus 10% (minimum 7 Kg/cm2g).

c) Design pressure calculated above or specified in data sheet shall be at the top of

vertical equipment or at the highest point of horizontal equipment. d) The design pressure at any lower point is to be determined by adding the

maximum operating liquid head and any pressure gradient within the equipment (differential pressure as mentioned in Process Data Sheet).

e) Equipment operating under vacuum/Partial vacuum shall be designed for an

external pressure of 1.055 Kg./cm2g. f) Equipment shall be designed for steam out conditions as specified by process data

sheet/piping. 2.5 Test Pressure

a) Equipment shall be hydrostatically tested in the fabricator’s shop as per design code.

b) Equipment open to atmosphere shall be tested by filling with water to the top.

Coils shall be tested separately to code test pressure.

d) Unless others\wise specified in applicable design code allowable stress during

hydro test in tension shall not exceed 90% of yield point. e) Storage tanks shall be tested as per applicable code.

2.6 Design Temperature Unless otherwise specified elsewhere, design temperature shall be as per the following:

a) For vessels operating at 00C and over:

Rev. 1

Rev. 1


Design temperature shall be equal to maximum operating temperature plus 150C subject to a minimum of 650C.

b) Minimum Metal design Temperature (MDMT) shall be lower of minimum

atmospheric temperature and minimum temperature envisaged during operation. 2.7 Corrosion Allowance: Unless otherwise specified elsewhere, minimum corrosion allowance shall be considered

as follows: - Carbon Steel equipment : 3.0 mm* - Stainless steel equipment : Nil - CS Storage Tank bottom most shell : 1.5 mm course and bottom plate - CS Storage Tank shell (other : 1.5 mm course) - Storage tank Fixed roof/floating : Nil Roof - CS Buried Vessels (External) : 1.5 mm Corrosion allowance for nozzles and manholes neck shall be at lest equal to that

specified for the equipment. No corrosion allowance is required for gasket sealing face of flanges. However, for non-standard blind flanges of channel covers the corrosion allowance will be applied.

2.8 Wind consideration Wind load shall be calculated on the basis of IS 875/site data for skirt- supported equipment, storage flanks spheres, flare stacks and air coolers.

a) Drag coefficient for cylindrical vessels shall be 0.7 minimum. b) Drag coefficient for spherical vessels shall be 0.6 minimum. c) Basis wind speed as per zone and area specified in IS 875 part 3. d) Of the factors shall be s below- K1=1.0 K2 shall be based on Category 3 for units and 2 for offsite. K3=1.0 A contingency fact or of 1.1 shall be applied to wind pressure.

2.9 Earthquake Consideration:

Earthquake loads for equipment shall be calculated in accordance with site specific acceleration spectra specified in the project specification.

Rev. 1

Rev. 1


2.10 Capacity 2.10.1 Tank - Nominal capacity for fixed roof tanks shall be volume of cylindrical shell.

- Stored capacity for fixed roof tanks shall be equal to nominal capacity minus free board volume (equivalent to 500mm of shell height)

- Nominal capacity (also stored capacity) for floating roof tanks shall be

volume of cylindrical shell minus free board volume (equivalent to 1500 mm of shell height).

- Nominal capacity (also the stored capacity) for fixed cum floating

roof tanks shall be volume of cylindrical shell free board volume (equivalent to 2500 mm to 3000 mm of shell height for tanks with vent / overflow slot in shell).

2.10.2 Buried vessels shall be suit ably anchored to prevent the uplift due to under ground

water. Anchor bolts shall have corrosion allowance of 6 mm on diameter. Buried vessels shall be rest ed on concrete saddles with anchoring bracket at the bottom of the vessel.

2.11 Manholes:

a) Vessels with diameter greater than 900 mm and up to 1500 mm shall be provided with 500 NB manholes. However, if required, vessels and columns with diameter 1500 mm and above may be provided with 600 NB manholes.

b) High pressure reactor manholes shall be on I.D. basis/. Size shall be as

per licensor drawing. c) For storage tanks minimum number of manholes (Size 600mm) shall be as

follows:- TANK DIAMETER SHELL FLUSH TYPE ROOF* MANHOLE CLEAN OUT DOORS MANHOLES

Diameter. #12m 2 Nil 2 12 m<Diameter # 45m 2 1 2 45 m<Diameter #61 m 3 2 2 Diameter.> 61 m 4 2 2

Rev. 1 Rev. 1


a) Clean out doors shall be provided as per client’s / process requirements and size of clean out doors fittings for tank shall be 36” (900mm) x 48” (1200m),

2.12 Floating roof: 2.12.1 Unless otherwise specified floating roof shall be of following construction

TANK DIAMETER (D) TYPE OF FLOATING ROOF (a) (b) External Internal D # 12 m Double Deck Type Double Deck 12 m < D # 60m Pontoon Type Pontoon Type @ D > 60m Double Deck Type Double Deck 2.13 Nozzle Size: - Minimum Nozzle Size ; 40 NB - Safety Valve Nozzle : Based on I.D. _ Self Reinforced Nozzle neck : Based on I.D.

2.14 Flanges 2.14.1 Nozzle flanges up to 600 NB shall be as per ASME B16.5 and above 600 NB shall

be as per ASME B 16.47 (SERIES’B’) except that for high pressure heat exchanger. Non-standard flanges shall be designed as per ASME Sec. VIII Div.1.

2.14.2 Unless otherwise specified, W.N. Flanges shall be used for all classes. 2.14.3 Unless otherwise specified, all girth flanges and intermediate body flanges shall be

of weld neck type only. 2.14.4 Flanges rating shall be established based on design pressure, design temperature

and considering all external loads (moments and axial force). 2.15 Internals: Unless otherwise specified removable internals shall be bolted type and material of

bolting shall be stainless steel TP 304. For shell & tube heat exchangers, floating


head bolting shall be compatible to shell material and SA 193 Gr. B7M/2HM shall be used as a minimum.

2.16 Pipe Davit:

(i) Vertical Vessels having safety valve size 80 NB and above and or having internals, shall be provided with pipe davit.

2.17 Vent/Drain/Ventilation Nozzle connections:

i) Vessels shall be provided with one number vent/drain connection as per following unless otherwise specified in process data sheet:

Vessel Length of Vent Drain Ventilation Volume (Horizontal Vessel) Nozzle Nozzle Nozzle (V),m3 (L),mm V # 6.0 - 40 NB 40 NB -

6.0 < V # 15 - 50 NB 40 NB - V > 15 - 50 NB 80 NB - - 300mm< L< 4500 mm - 100 NB

- 4500nn< L< 7500mm - 150 NB

- L> 7500 mm - 200 NB

Vertical vessel not having any nozzle on the top shall be provided with 50NB nozzle for conducting hydro test in vertical condition.

2.18 Spares: i) Vessels Gaskets : Two sets for each installed gasket

Fasteners : 10% (Minimum two in each size) of installed fasteners.

Sight/Light Glass : 4 sets for each installed glass. 2.19 Important considerations

- Vessels shall be designed considering maximum operating liquid in addition to design pressure.


- All vessels shall be capable of withstanding water full condition during

system testing.

- In addition, all vertical vessels, and horizontal vessels shall be designed so

as to permit site testing of the equipment with water at the test pressure on the top of the equipment considering 33% of design wind load. The design shall base on fully corroded condition.

- All equipment foundation shall be designed and constructed for water full

condition when equipment is new with 33% of design wind load. - Vessels shall be tested at shop hydrostatically at pressure calculated as per

applicable code

- Seismic design shall be carried out based on site spectra instead of IS:

1893, if furnished. - All nozzle necks, all nozzle flanges and blind flanges shall be of weld

deposit construction for clad equipment. Loose liners are not permitted. - All vertical equipment shall be provided with two lifting lugs. Lifting lugs

shall be designed with impact factor or two.

- Material of various parts of equipment shall be selected as per Table given

in Annexure-I unless otherwise stated on process data sheet.

3.0 DESIGN CRITERIA / REQUIREMENTS – SPECIFIC APPLICATIONS 3.1 Storage Tanks 3.1.1 All storage tanks shall be designed as per code considering liquid height up to top curb-

angle of shell. 3.1.2 Tanks shell thickness calculation shall be carried out by the one (1) – foot method as per

API 650 for tank diameters less than and equal to 60m (200 feet). For tanks greater than 60 m variable design point method shall be used.

3.1.3 Maximum height of unstiffened shell shall be calculated based on the corroded thickness

of shell courses. Section modulus of wind girders shall also base on corroded thickness of shell courses.

3.1.4 Seismic design as per API 650 (Appendix-E) is mandatory for storage tanks.


3.1.5 Annular bottom plates shall be provided for all storage tanks 12 meter diameter and

above. 3.1.6 Anchor bolts shall be provided based on design considering wind/seismic loads, uplift due

to internal pressure etc. However, tanks having diameter # 10 meters shall be provided with anchor bolts and shall be spaced at approximately 1.8M of circumference.

3.2 Loading

Because of critical relationship between the foundation and vessel design, construction of sand-bed/ foundation and settlement shall be strictly monitored during various stages of construction, vessel hydro test etc. Following loading shall be considered for design:

a) Operating Conditions:

Self-weight of vessel (but corroded thickness), mound load, foundation/sand bed reaction, liquid weight, earth quake loading, differential settlement, design pressure, longitudinal frictional load due to thermal and pressure expansion, explosion pressure on mound (if specified).

b) Hydro Test condition:

Self-weight of vessel, mound load (in case of health check-up), foundation/ sand-bed reaction, water weight, differential settlement, test pressure, longitudinal frictional load due to thermal and pressure expansion.

3.3 Cathodic Protection Impressed current cathodic protection system shall be designed and installed as per WP’S

specification. 3.3.1 External Coating

Applied protection shall be fully tested for absence of holidays using high voltage spark tester.

3.4 Location / Spacing of Vessels Minimum spacing of vessels and other safety regulation shall be as per OISD-STD-118. 3.5 Load due to Uneven Settlement

a) To make allowance in the design for effect of tolerances in alignment of shell section. Unevenness in sand-bed, etc. a maximum/minimum reaction may be assumed as given below.

b) Based on soil investigation along with vessel axis, sub grade modules of soil / bed

shall be calculated. Value of Pmax/Pmin may be reduced to 1.30 provided foundation is constructed and differential settlement is ensured by the contractor and demonstrated hydro test.


c) Sand-bed should be properly prepared and compacted to obtain effective angle of support at least 1200 and differential settlement should not be ore than 40 mm between mid-point of vessel and end-point of vessel.

d) During initial hydro test condition sand bed contact angel may be taken as 600

without mound over vessel if such condition arises during construction and hydro testing of vessel.

4.0 PROJECT SPECIFIC REQUIREMENTS GASKETS

- All RTJ gaskets should have proper marketing stamped with metallurgical certificate available.

- Only octagonal section ring should be used in case of RTJ joint. - CAF gasket shall not be used. BOLTING - The length of the studs/bolts should be such that minimum two threads should be

out of the nut on either side. - All studs/bolts should have metallurgical certificates in case of alloy/SS metallurgy

with identified colour marketing at the stud ends/bolt side face. - Torque wrench /hydraulic bolt tensioners to be used for fasteners as specified in

Piping design basis. - All fasteners 2” & above shall be procured with 2 nuts. MISCELLANEOUS REQUIREMENTS - Temperature recorders used in stress relieving should be calibrated and related

certificate should be available for verification. - Calibrated pressure gauges shall be used for hydro testing. Minimum two pressure

gauges to be used – one at the pressurizing point and other at highest / fart hest point.

- Welding of alloy butt joints should be completed in continuation from start to finish. - Electrical resistance coils should be used for preheating/post heating of alloy steel

welding. - Permanent slopping monkey ladder should be provided inside the skirt of the

column and vertical vessels to approach the bottom head for inspection purposes. - Only SS shims shall be used for equipment alignment / leveling. - Shell internal surface of floating roof tanks should be made smooth by grinding

after fabrication so that no protrusion and sharp edges are left over. This is required to avoid damage to the foam seal during the movement o the floating roofs.

- All vessels columns should have utility and instrument connections from the side and not from the bottom except drain point.

- Tanks shell insulation should have continuity in insulation cladding even at stiffener/retainer ring locations on shell.

- Inspection windows in insulation for inspection / thickness survey are to be provided in insulated equipment.


TABLE-I

(ALLOWABLE STRESSES FOR COMBINED LOADING)

CONDITIONS

VESSEL CONDITION/TEMP.TYPE OF STRESSES

ERECTION OPERATING TEST

NEW OR CORRODED NEW CORRODED CORRODED

TEMPERATURE AMBIENT DESIGN AMBIENT

LONGITUDINAL KxSxK KxSxK 0.90 x Y,PxE

LONGITUDINAL COMPRESSIVE STRESS

KxB KxB B

Where S= Basic allowable Tensile Stress as per Clause UG 23(a) of ASME Code Sec.,VIII

Div.1 B= ‘B’ value calculated as per Clause UG-23(b) E= Weld joint efficiency of circumferential weld, depending on extent of radiography. K= Factor for increasing basic allowable value when wind or seismic load is present. Note: Allowable stress in skit to shell joint shall be as per following:

a) 0.45S, if joint is shear type. b) 0.70S, if joint is compression type.


ANNEXURE-I

MATERIAL SELECTION

The following table gives general guidelines for material selection for various Pressure Parts / Non Pressure Parts of the equipment based on design temperature wherever material of construction is not specified by the Owner/WP.

PRESSUR PARTS NON PRESSURE PARTS

DESIGN TEM

0c

PLATE

PIPE (SEE NOTE 8)

TUBES SPACERS (SE NOTE 11)

FORGING (SEE NOTE 12)

BOLTS/ STUDS/ NUTS EXTERNAL (SEE NOTE 13)

STRUCTURAL ATTACHMENT WELDED TO PRESSURE PARTS,BAFFELS, SUPPORTS,TIE RODS,SEALING, SLIDING STRIPS ETC.

INTERNAL PIPES

STUDS BOLTS NUTS INTERNAL

TIE RODS

CRYOGENIC

FROM -254 UPTO-196

SA 240 GR.304L,304 316,316L 347(IMPACT TESTED

SA 312 TYPE-304 304L,316 316L.,347

SA 213 TYPE 304 304L,316 316L,347

SA 182,GR.F 304,304L,316 347,316L.

ABOVE -196 UPTO -80

SA 240 S GR.304L,304, 316,316L, 321, 347 SA 353/553 GR.A

DA 312 TYPE 304 304L,316, 316L.,321 347 SA333 GR.8

SA 312 TYPE 304 304L.,316, 316L.,321 SA 334 GR.8

SA 182,GR.F 304,F304L, F316L,316 321,347 SA 522

SA 320 GR.B8,8C,8T STRAIN HARDENED SA 194 GR.S. 8C,8T

SAMPLE AS PRESSURE PARTS

SS GRADE SAME AS TUBES

LOW TEMPERATURE

ABOVE -80 UPTO -60

SA 203 GR.E IMPACT TESTED (SEE NOTE-1)

SA 333 GE.3

SA 334 GR.3

SA 350 GR. LF3

SA 320 L7 SA 194 GR.4 PR GR.7

SA 203 GR E

SA 333 GR.3

SA 193GR.B8 SA 194 GR.8

CS KILLED

ABOVE -60 UPTO -45

SA 537 CL.1 IMPACT TESTED (SEE BOTE.1)

SA 333 GR.3

SA 334 GR.3

SA 350 GR. LF3

SA 320 L7 SA 194 GR.4 PR GR.7

SA 537 CL.1

SA 333 GR.3

SA 193GR.B8 SA 194 GR.8

CS KILLED

ABOVE -45 UPTO -29

Sa,516(ALL GRADES) IMPACT TESTED NOTE.1)

SA 333 GR.6 OR GR.1

SA 334 GR.6 OR.GR.1

SA 350 GR. LF3

SA 320 GRL.7 SA 194 GR.4 OR GR.7

SA 516 (IN ALL GRADES)

SA 333 GR.6

SA 193 GR.B8 SA 194 GR.8

CS KILLED

ABOVE -29 UPTO 0

SA 516 (ALL GRADES) (SEE NOTE.3(

SA 106 GR.b (SEE NOTE.3)

SA 334 GR.6 OR.1 (SEE NOTE .1)

SA 105/ SA 266 (SEE NOTE.3)

SA 193 (IN ALL GRADES)

SA-516(IN ALL GRADES)

SA 106 G.B

SA-193 GR.B8 SA-194 G.8

CS KILLED

INTERMEDIATE TEMPERALTURE

ABOVE 0 UPTO 343

SA 516(ALL GRADES SA240 TYPE 304L,316,321 (SEE OTE.4)

SA 106 GR.B SA 312 TP.304L 316L,321,SA-376 TP321

SA-179 SA -213 TP 304L 316L,321

SA-105 SA-266 SA 182F 304L,316L.,321

SA-193 B7 SA-194GR.2H SA-193 B7 SA0194GR2H

IS-2062 (PLATES) SAME AS PRESSURE PARTS

SA 106 GR.B SA 106 GR.B

SA-193 GRB8 SA-194 GR.4 SA-193GRB8 SA-194 GR8

IS-2062 (WELDABLE QUALITY) SAME AS GRADE AS PRESSURE PARTS

ABOVE 343 UPTO 427

SA 204 GR.B SA 387 GR.11 CL.1/CL.2 SA 240 TYPE 304L,316L,321 (SEE NOTE 4)

SA 335 GR.P1 SA 335GR GR.P11 SA 312 TYPE 304L,316L 321 SA 376 TYPOE 321

SA 209 GR T1 SA 213 GR.T SA 213 GR.T11 SA213 TYPE 304L,316L,321

SA 182 G.F1 SA 182 GR.F11 SA 182 F 304L,316L 321

SA 193 GR.B7 SA 194 GR.4 SA 193 B7 SA 194 GR.4 SA 193 GR.B7 SA 194, GR.4

SAME AS PRESSURE PARTS SAME AS PRESSURE PARTS SAME AS PRESSURE PARTS

SAME AS PRESSURE PARTS SAME AS PRESSURE PARTS SAME AS PRESSURE PARTS

SA-193 GR.B8 SA-194 GR.8 SA-193 GR.B8 SA-194 GR.8 SA-193 GR.B8 SA-194 GR.8

C-1/2 Mo (COMML.QLTY) 1¼Cl.1/2 mO (comml Qlty) Sa 479 Gr.304l 316,321

LEVATED TEMPERATURE

ABOVE 427 UPTO 38

SA 387 GR.11 CL.1/CL.2 SA 387 GR.12 CL.1/CL.2

SA 335 P11 SA 335 P12

SA 213 T11 SA 213 T12

SA 182 GR F11 SA 182 GR.F12

Sa193 Gr.b16 Sa 194 gr.4

SAME AS PRESSURE PARTS


SA-193 GR.B8 SA 194 G.8

1¼Cl.1/2 mO (comml Qlty)

ABOVE 427 UPTO 500

SA 240 TYPE 304,321 (SEE NOTE.4)sa 312/sa 376 type 304,316,321

sa 312/ sa 376 type 304,316,321

Sa 213 tp 304,316,321

Sa 182f 304 316,321

Sa 193 Gr.b16 Sa 194 gr.4



SA-193 GR.B8 SA 194 G.8

Sa 479 gr.304l,316l.,321

above 538 upto 593

sa 387 gr.22 cl.1/cl.2 sa 387,gr.21 cl.1/cl.2

Sa 335 p22

Sa 213 t22

SA 182 GR F22 SA 336 GR F22

SA 193 GR.B5 SA 194 GE3




2¼c.1 Mo (COMML.QLTY.)


ABOVE 500 UPTO 815

SA 240 G.304H, 316H,321H

SA312/ SA376 TYOE 304H, 316H, 311H

SA213 TYPE 304H, 316H, 321H

SA 182 GRADES 304HM 316H,321H

SA 193 GRB8 SA 194 GR.8 (STRAIN HARDENED)




SA 479 GR.304H, 316H, 321H

Notes:

1. Selection of Carbon Steel and stainless steel material shall be based on process recommendation.

2. This table is not applicable for atmospheric storage tanks. Materials shall be selected

as per API 650 as applicable.

3. Internal bolting shall be selected on the basis of shell side material as follows:

SHELL MATERIAL STUD NUTS Carbon steel & upto 1% Cr. ASTM A 193 Gr B-7M ASTM A-194 Gr 2HM 5% Chrome A 193 Gr B5 A 194 Gr 3 13% Chrome A 193 Gr B6X A 194 Gr 6 Stainless Steel A 193 Gr* A 194 Gr* For low temperatures, min, quality of bolting material shall be as specified for external bolting and shall be improved if shell side materials are better. *Compatible / same grade of SS.

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL)

Page 1 of 7



PART A

SCOPE OF WORK FOR ROTATING EQUIPMENT & PACKAGES (AT RAMANMANDI TERMINAL)

435-JH0902-00-ME-SOW-0001

25-Aug-2009




HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP)

SCOPE OF WORK FOR (ROTATING EQUIPMENT & PACKAGES) – PART A (RAMANMANDI TERMINAL )

.

Page 2 of 7

SYNOPSIS

Disclaimer











DATE


Subramanyam.S

Sameer Ishwad

Jeremy Wallace

08-July-09 N/A

B Issued for Review

Subramanyam.S

Sameer Ishwad

Jeremy Wallace

16-July-09

N/A

C Issued for Tender

Subramanyam.S

Sameer Ishwad

KMN Pillai

25-Aug-09



SCOPE OF WORK FOR (ROTATING EQUIPMENT & PACKAGES (AT RAMANMANDI TERMINAL)

.

Page 3 of 7

1.0 Projects Details in Brief

RamanMandi to Bahadurgarh Pipeline.

As a part of Guru Gobind Singh Refinery (GGSR) Product Evacuation project, Hindustan

Petroleum Co-corporation Ltd (HPCL) Proposes to lay a cross country multiproduct pipeline

from the upcoming Guru Gobind Singh Refinery at Raman Mandi to HPCL’s existing terminal in

Bahadurgarh. The length of the pipeline is approximately 243 Km. The pipeline is planned to

transfer EURO-III MS,EURO-IV MS,EURO III HSD EURO IV HSD,SKO, Naphtha & ATF

products from Raman Mandi to Bahadurgarh. The pipeline throughput shall be as follows:

Pipeline Section Year / Phase Throughput in MMTPA

2011-2012 / Phase-I 3.96 Raman Mandi to

Bahadurgarh 2021-2022 / Phase – II 4.71

The pipeline from Raman Mandi to Bahadurgarh is designed to cater the phase II

throughputs.However to cater to phase-I throughput, the pumps have to run at lower speed

through Variable Frequency Drives (VFD).

Raman Mandi to Bhatinda:

One Multi product Pipeline from GGSR Raman Mandi is proposed to be laid to HPCL’s

existing depot in Bhatinda (approximately 29.6 Km) with a future provision to extend the

pipeline from Bhatinda to Sangrur (approx.86 Km). Products to be transported via Raman

Mandi to Bathinda pipeline are follows:

(1) EURO-III grade of Motor Sprit (MS)

(2) EURO-III grade of High Speed Diesel (HSD)

(3) Superior Kerosene Oil (SKO)

The project requirement for the Raman Mandi to Bathinda pipeline is to transport 0.929 Million

Metric Tones Per Annum (MMTPA) of EURO – III MS, EURO – III HSD and SKO in the Year

2011-12 (Phase-I) and 1.375 MMTPA of the products in the Year 2021-22 (Phase-II) Suitable

tap off facility shall be provided at Bathinda for extension of the pipeline to Sangrur in future.

The pipeline throughput shall be as follows:




.

Page 4 of 7

Pipeline from Raman Mandi to Bathinda and the Stations are designed for the projected throughput of

1.375 MMTPA (Phase - II). However, the pump/driver will be designed such that presently it shall cater

to the requirement of Phase-I throughput of Bathinda alone. Space provision shall be made for

additional pumps to be installed at a later date to cater the requirement of Phase – II throughput for the

volumes upto Sangrur. To cater for more than one flowrate and different densities / viscosities pumps

have to run at lower speed through Variable Frequency Drives (VFD).

2.0 Scope of Work:

Contractor’s scope of work under the Composite works for terminals at RamanMandi shall be as

described under:

2.1 Procurement of Rotating Equipment & Packages (excluding FREE issue materials), refer Table

-1 listed in this scope of work below) from the Approved Vendors attached with the Tender

documents. The scope of supply shall be as per the relevant Specifications, datasheets, process

documents and all other relevant documents attached elsewhere in the Tender.

2.2 To follow the specifications like Engineering Design Basis, relevant specifications, Data Sheets

(wherever attached) and Process package etc. attached with the Bid Document for the purpose

of detail engineering execution for rotating equipments & Packages.

2.3 Contractor’s scope shall include the following:

2.3.1 Preparing enquiry specifications/ documents for each Rotating Equipment & Package item

(Excluding Free issue materials) and materials to be purchased including spare parts for

erection & commissioning, mandatory spare parts, special tools & tackles (as applicable) and

spare parts for two-year normal operation.

2.3.2 Specifications/Datasheets indicating technical requirements are attached in the Tender

document for Rotating Equipments & Packages (Excluding Free issue materials) such as Sump

Pumps, EOT Cranes, and Corrosion Inhibitor Package. Contractor shall use these data sheets

for these equipments for enquiry / purchase and Owner/WP’s approvals. The contractor shall

Pipeline Section Year / Phase Throughput in Million Metric Tons

per Annum (MMTPA)

2011 – 2012 / Phase - I 0.929 Raman Mandi – Bathinda

(incl. Sangrur) 2021 – 2022 / Phase - II 1.375

2011 – 2012 / Phase - I 0.470 Bathinda - Sangur

2021 – 2022 / Phase - II 0.697




.

Page 5 of 7

use the above specifications in conjunction with the process documents, which shall be referred

for Operating Conditions, Material selection, Operational philosophy, instrumentation

requirements and scope of supply etc.

2.3.3 Detailed Purchase Requisition / Specifications for each Rotating Equipments & Packages

(Excluding Free issue materials) and shall obtain the approval/review of Purchase Requisition

by Owner / WP.

2.3.4 Detailed review, checking and approval of equipment engineering and fabrication drawings

and technical data from Vendors for equipment and materials (Excluding Free issue materials), to

ensure adequacy and consistency with the design, safety and operability requirements.

2.3.5 All inspection and tests are conducted for Rotating Equipments & Packages (Excluding Free

issue materials) at Vendor’s shops/site as specified in Tender document, Engineering

Design Basis, Data Sheets, Specifications, Codes and Standards etc. Contractor shall also

submit the schedule of witnessed tests of all rotating equipment well in advance.

2.3.6 Supply spare parts for Two-year normal operation for Rotating Equipments & Packages

(Excluding Free issue materials), if ordered by the Owner, from equipment vendor.

2.3.7 Supply commissioning spares for Rotating Equipments & Packages (Excluding Free issue

materials) as required in the equipment Vendor’s scope. Contractor shall procure the same

from the equipment vendors and make it available well before commissioning of

Plant/Equipment. In case, any additional spares are consumed during commissioning then the

same to be provided by the contractor at no additional cost to the Owner/WP.

2.3.8 Supply all special tools and tackles required for Rotating Equipments & Packages

(Excluding Free issue materials) Assembly/maintenance of the Rotating Equipment in

the scope of supply.




.

Page 6 of 7

2.3.10 Contractor’s scope for Rotating Equipments & Packages (Excluding Free issue

materials) shall include complete Design, Engineering, Procurement of bought out items,

testing supply, transportation from vendor’s shop to site, Receipt of material at site,

Handling at site and arrange for storage at site as per Tender Document.

2.3.11 For Rotating Equipments & Packages (Excluding from Free issue materials) which are

transported by sea shall have sea-worthy packing. The Contractor shall strictly follow the

recommended preservation procedures during the period of storage for all equipment.

2.4 Contractor shall carry out the Erection of all Rotating Equipments and Packages coming

at RamanMandi (including Free issue materials) at the specified location on the properly

designed & cast foundation as per Tender Document.

2.5 Contractor shall carry out the inter-connections piping at all interface points such as

Main Process and all utility connections.

2.6 Contractor shall note that consumables, lubricants etc. required during erection,

commissioning and performance guarantee run for Rotating Equipments & Packages (Excluding

Free issue materials) such as first fill of lubricants etc shall be Contractor’s scope. A

consolidated list for all rotating equipment / package shall be provided indicating type of

lubricant, grease, oil etc. giving specifications, quantities, brand name and their Indian

equivalent. Lubricants for the FREE issue material shall be provided by the purchaser.

2.7 Contractor shall supply & install EOT Cranes for the following Pump houses:

• Mainline Pumps sheds

• Booster Pumps sheds

The cranes shall be sized for handling the heaviest single piece of equipment for maintenance. The maintenance facilities (EOT Cranes) shall be as per Engineering Design Basis – Package Equipment and specifications & datasheets for EOT Crane attached.

2.8 Pre-commissioning and commissioning of all Rotating Equipment & Packages at

RamanMandi is in the scope of the contractor. Representative of Original Equipment

Manufacturer (OEM) of critical rotating equipment such as Mainline & Booster Pumps will

supervise the Pre-commissioning, testing & Commissioning activities. However, the contractor

shall provide all assistance including manpower, tools and tackles in the Pre-commissioning,

testing & Commissioning activities of these critical equipments also.




.

Page 7 of 7

Scope of Work for Free Issue Material & Scope of work for Rotating Equipment & Package, to

be procured by Contractor: Table -1

Sr

no.

FREE ISSUE Rotating

Equipment & Packages

Rotating Equipment & Packages to be supplied by the

Contractor

1. Scope of work shall include

Receipt of material at site,

Handling at site and arrange

for storage at site for Rotating

Equipments & Packages,

Erection, Precommissioning,

testing, and Commissioning

along with interface piping

with other systems / piping.

Scope of work shall include Design, Engineering,

Procurement of materials & bought out items, packaging of

the equipment / Package, inspection & testing at equipment /

package vendor’s works, transportation to site, Receipt of

material at site, Handling at site and arrange for storage at

site, Erection, Precommissioning, testing &

Commissioning along with interface piping with other

systems/ piping.

2. - P-10-11 A/B/C- Booster

Pumps at RamanMandi for


-P-10-12 A/B/C Mainline

Pumps at RamanMandi for


- F-10-14 Filter Water

Separator at RamanMandi

- F-10-11 A/B Basket Filter at

RamanMandi

- P-10-02 A/B Mainline Pumps

at RamanMandi for Bathinda

Pipeline.

- P-10-01 A/B Booster Pumps

at RamanMandi for Bathinda

Pipeline.

- F-10-01 A/B, Basket Filter at

RamanMandi

- P-10-03 / P-10-04 Sump Pumps at RamanMandi

- EOT Crane at RamanMandi for Mainline Pump house

- EOT Crane Booster Pump house

- ZZ-10-0001, Corrosion Inhibitor Package at

RamanMandi.for Bathinda Pipeline,

- ZZ-10-0002, Corrosion Inhibitor Package at RamanMandi

for Bahadurgarh Pipeline

- Supply of 3 Ton chain pulley block.


Page 1 of 7



PART B

SCOPE OF WORK FOR ROTATING EQUIPMENT & PACKAGES (AT BATHINDA TERMINAL)

435-JH0902-00-ME-SOW-0001

25-Aug-2009





SCOPE OF WORK FOR (ROTATING EQUIPMENT & PACKAGES) – PART B (BATHINDA TERMINAL)

.

Page 2 of 7

SYNOPSIS

Disclaimer











DATE


Subramanyam.S

Sameer Ishwad

Jeremy Wallace

08-July-09 N/A

B Issued for Review

Subramanyam.S

Sameer Ishwad

Jeremy Wallace

16-July-09

N/A

C Issued for Tender

Subramanyam.S

Sameer Ishwad

KMN Pillai

25-Aug-09



SCOPE OF WORK FOR (ROTATING EQUIPMENT & PACKAGES (BATHINDA TERMINAL)

.

Page 3 of 7


RamanMandi to Bahadurgarh Pipeline.



from the upcoming Guru Gobind Singh Refinery at Raman Mandi to HPCL’s existing terminal in

Bahadurgarh. The length of the pipeline is approximately 243 Km. The pipeline is planned to

transfer EURO-III MS,EURO-IV MS,EURO III HSD EURO IV HSD,SKO, Naphtha & ATF







through Variable Frequency Drives (VFD).


One Multi product Pipeline from GGSR Raman Mandi is proposed to be laid to HPCL’s







The project requirement for the Raman Mandi to Bathinda pipeline is to transport 0.929 Million

Metric Tones Per Annum (MMTPA) of EURO – III MS, EURO – III HSD and SKO in the Year

2011-12 (Phase-I) and 1.375 MMTPA of the products in the Year 2021-22 (Phase-II) Suitable

tap off facility shall be provided at Bathinda for extension of the pipeline to Sangrur in future.

The pipeline throughput shall be as follows:




.

Page 4 of 7


1.375 MMTPA (Phase - II). However, the pump/driver will be designed such that presently it shall cater

to the requirement of Phase-I throughput of Bathinda alone. Space provision shall be made for

additional pumps to be installed at a later date to cater the requirement of Phase – II throughput for the

volumes upto Sangrur. To cater for more than one flowrate and different densities / viscosities pumps

have to run at lower speed through Variable Frequency Drives (VFD).

2.0 Scope of Work:

Contractor’s scope of work under the Composite works for terminals at Bathinda shall be as

described under:

2.1 Procurement of Rotating Equipment & Packages (excluding FREE issue materials), refer Table

-1 listed in this scope of work below) from the Approved Vendors attached with the Tender

documents. The scope of supply shall be as per the relevant Specifications, datasheets, process

documents and all other relevant documents attached elsewhere in the Tender.

2.2 To follow the specifications like Engineering Design Basis, relevant specifications, Data Sheets

(wherever attached) and Process package etc. attached with the Bid Document for the purpose

of detail engineering execution for rotating equipments & Packages.

2.3 Contractor’s scope shall include the following:

2.3.1 Preparing enquiry specifications/ documents for each Rotating Equipment & Package item

(Excluding Free issue materials) and materials to be purchased including spare parts for

erection & commissioning, mandatory spare parts, special tools & tackles (as applicable) and

spare parts for two-year normal operation.

2.3.2 Specifications/Datasheets indicating technical requirements are attached in the Tender

document for Rotating Equipments & Packages (Excluding Free issue materials) such as Sump

Pumps, Slop/Interface transfer pumps. Contractor shall use these data sheets for these

equipments for enquiry / purchase and Owner/WP’s approvals. The contractor shall use the

Pipeline Section Year / Phase Throughput in Million Metric Tons

per Annum (MMTPA)




2021 – 2022 / Phase - II 0.697




.

Page 5 of 7

above specifications in conjunction with the process documents, which shall be referred for

Operating Conditions, Material selection, Operational philosophy, instrumentation requirements

and scope of supply etc.

2.3.3 Detailed Purchase Requisition / Specifications for each Rotating Equipments & Packages

(Excluding Free issue materials) and shall obtain the approval/review of Purchase Requisition

by Owner / WP.

2.3.4 Detailed review, checking and approval of equipment engineering and fabrication drawings

and technical data from Vendors for equipment and materials (Excluding Free issue materials), to

ensure adequacy and consistency with the design, safety and operability requirements.

2.3.5 All inspection and tests are conducted for Rotating Equipments & Packages (Excluding Free

issue materials) at Vendor’s shops/site as specified in Tender document, Engineering

Design Basis, Data Sheets, Specifications, Codes and Standards etc. Contractor shall also

submit the schedule of witnessed tests of all rotating equipment well in advance.

2.3.6 Supply spare parts for Two-year normal operation for Rotating Equipments & Packages

(Excluding Free issue materials), if ordered by the Owner, from equipment vendor.

2.3.7 Supply commissioning spares for Rotating Equipments & Packages (Excluding Free issue

materials) as required in the equipment Vendor’s scope. Contractor shall procure the same

from the equipment vendors and make it available well before commissioning of

Plant/Equipment. In case, any additional spares are consumed during commissioning then the

same to be provided by the contractor at no additional cost to the Owner/WP.

2.3.8 Supply all special tools and tackles required for Rotating Equipments & Packages

(Excluding Free issue materials) Assembly/maintenance of the Rotating Equipment in

the scope of supply.




.

Page 6 of 7

2.3.9 Contractor’s scope for Rotating Equipments & Packages (Excluding Free issue

materials) shall include complete Design, Engineering, Procurement of bought out items,

testing supply, transportation from vendor’s shop to site, Receipt of material at site,

Handling at site and arrange for storage at site as per Tender Document.

2.4 Contractor shall carry out the Erection of all Rotating Equipments and Packages coming

at Bathinda (including Free issue materials) at the specified location on the properly

designed & cast foundation as per Tender Document.

2.5 Contractor shall carry out the inter-connections piping at all interface points such as

Main Process and all utility connections.

2.6 Contractor shall note that consumables, lubricants etc. required during erection,

commissioning and performance guarantee run for Rotating Equipments & Packages (Excluding

Free issue materials) such as first fill of lubricants etc shall be Contractor’s scope. A

consolidated list for all rotating equipment / package shall be provided indicating type of

lubricant, grease, oil etc. giving specifications, quantities, brand name and their Indian

equivalent. Lubricants for the FREE issue material shall be provided by the purchaser.

2.7 Pre-commissioning and commissioning of all Rotating Equipment & Packages at Bathinda isin

the scope of the contractor.




.

Page 7 of 7

Scope of Work for Free Issue Material & Scope of work for Rotating Equipment & Package, to

be procured by Contractor: Table -1

Sr

no.

FREE ISSUE Rotating

Equipment & Packages

Rotating Equipment & Packages to be supplied by the

Contractor

1. Scope of work shall include

Receipt of material at site,

Handling at site and arrange

for storage at site for Rotating

Equipments & Packages,

Erection, Precommissioning,

testing, and Commissioning

along with interface piping

with other systems / piping.

Scope of work shall include Design, Engineering,

Procurement of materials & bought out items, packaging of

the equipment / Package, inspection & testing at equipment /

package vendor’s works, transportation to site, Receipt of

material at site, Handling at site and arrange for storage at

site, Erection, Precommissioning, testing &

Commissioning along with interface piping with other

systems/ piping.

2. - (ZZ-20-001) Oil Water

Separator Package at

Bathinda

- F-20-01 A/B Basket Filter at

Bathinda

- P-20-01 / P-20-02, Sump Pumps at Bathinda.

- P-20-03 & P-20-04: Slop and interface transfer pumps at

Bathinda

- 3 Ton chain pulley block.



TECHNICAL COMPLIANCE FOR ROTATING & PACKAGES



TECHNICAL COMPLIANCE FOR ROTATING EQUIPMENT & PACKAGES

435-JH0902-00-ME-TEN-0001

16-July-2009






SYNOPSIS

Disclaimer











DATE


Subramanyam.S

Sameer Ishwad

Jeremy Wallace

08-July-09 N/A

B Issued for Tender

Subramanyam.S

Sameer Ishwad

KMN Pillai

16-July-09

N/A




Page 3 of 5

Sr.

No COMPLIANCE STATEMENT / QUERY

BIDDER’S CONFIRMATION / ANSWER

1 BIDDER IS INFORMED THAT THE DETAILED OFFER

FOR ANY ROTATING EQUIPMENT / PACKAGE

EQUIPMENT (EXCLUDED FROM FREE MATERIAL) ,

i.e. FILLED-IN EQUIPMENT DATA SHEETS,

PERFORMANCE CURVES, VENDOR'S SELECTED

EQUIPMENT MODELS ETC. IS NOT REQUIRED AT

THE STAGE OF BIDDING AND SHALL NOT BE

REVIEWED OR TAKEN COGNIZANCE OF AT THIS

STAGE. ACORDINGLY, THE BIDDER SHALL

FURNISH ONLY THE FOLLOWING DOCUMENTS

ALONGWITH THE BID:

a) This Technical Compliance with categorical

Confirmation against each of the clauses

b) Deviations, if any against the equipment data sheets,

Specification shall be duly consolidated at one place

(under exceptions/ deviation list). In case no deviations

are furnished, it shall be construed that bidder’s

Proposal is in total compliance to bid document

requirements.

Bidder shall note that vendor specific deviations to design

codes (ISO/IS/BS/API etc.) shall not be considered at this

stage and shall be subject to review and approval of

Owner/WP during detail engineering. However bidder shall

note that deviations to only those requirements of design

codes, which are technically infeasible to meet, shall be

permitted provided suitable justification for the same is

furnished. Deviations, which can be withdrawn with extra

cost and or time implication, shall not be permitted.




Page 4 of 5

2 Any deviations/deletions/corrections made elsewhere in

the body of the bid (on equipment data sheet, specs etc.)

will not be taken cognizance of and all such deviations

shall be deemed to have been withdrawn by the bidder.

Confirm compliance.

3 Confirm that the equipment supplied shall be from

one of the approved vendors given in the

APPROVED VENDOR LIST attached elsewhere in

4. Confirm that all equipment shall be ordered on the Vendors

only after:

a) Approval/Review of the Purchase Requisition by

HPCL/WP as specified.

b) Ensuring equipment meeting the acceptance criteria

specified in the bid document by furnishing duly filled in

EXPERIENCE RECORD FORMAT attached with the

bid document which shall be subject to HPCL/WP’s

approval/review.

5. Duly filled in equipment data sheets, characteristic

curves for the selected vendor/equipment model shall be

subject to HPCL/WP’s approval/review to ensure

compliance to bid specification during detailed

engineering stage. Confirm compliance

6. Confirm that the Scope of supply and work

considered in the Bid proposal is in total compliance to the

Bid specification requirement including Scope of

Work/Supply, Data Sheet, Job specs. and attatched

specification with respect to all Rotating equipment.

7. Confirm that wherever the Material Of Construction

of equipment components have been specified in the Bid

specification, same or superior MOC shall be offered




Page 5 of 5

8. Confirm that all Inspection & Tests as required for

each equipment, as per the Data sheets, Job specs and

as per specification and Codes attached and referred to

have been included by the bidder in his proposal

9.

Bidder shall obtain and submit a list of Operation and

Maintenance spares required for Two Year Normal

Operation (indicating the price against each spare) as

recommended by the equipment manufacturer / bidder.

This price shall remain valid till six months after the

completion of complete tender work.

10. Confirm that Erection & Commissioning Spares as

required for each equipment have been included by

the bidder in his proposal. Further in case any spare

is consumed over and above the quoted

commissioning spares during startup/commissioning, the

same shall be supplied free of cost.

11. Confirm that Special Tools & Tackles, as required

for each Equipment, have been included by the Bidder in

his proposal.

12. Confirm that all consumables, chemicals, lubricants etc. for

initial charge and for commissioning and site performance

guarantee run have been included in the Bidder’s proposal.

13. Confirm that all Drawings / Data requirements as per

specifications and codes attached and referred to has been

included in the bidder’s proposal.




SPECIFICATION FOR SUMP PUMPS

435-JH0902-10-ME-SPC-0009

31-July-2009






SYNOPSIS

Disclaimer











DATE


Subramanyam.S

Sameer Ishwad

Jeremy Wallace

08-July-09 N/A

B Issued for Review

Subramanyam.S

Sameer Ishwad

Jeremy Wallace

10-July-09

N/A

C Issued for Tender

Subramanyam.S

Sameer Ishwad

KMN Pillai

25-July-09




CONTENTS

1. INTRODUCTION ................................................................................................................6

1.1 Scope of Work ...................................................................................................................6

1.2 Sump Pumps at Raman Mandi & Bhatinda Pump Station ................................................7

1.3 Work Included .........................................................................................................................8

1.3 Design Basis ......................................................................................................................9

1.3.1 Design Life, Availability and Reliability.................................................................................9

1.3.2 Noise Limitation .........................................................................................................9

1.4 Material Certification ..........................................................................................................9

1.5 Reference Documents .....................................................................................................10

1.5.1 British Standards (BS) .........................................................................................10

1.5.2 American Standard Institute (ANSI).....................................................................10

1.5.3 American Society and Mechanical Engineers (ASME)........................................11

1.5.4 American Society for Testing and Materials (ASTM)...........................................11

1.5.5 American Petroleum Institute (API)......................................................................11

1.5.6 The Institute of Petroleum (IP) .............................................................................12

1.5.7 ISO Standards (ISO)............................................................................................13

1.5.8 Manufacturers Standardisation Society (MSS)....................................................13

1.5.9 International Electrotechnical Commission (IEC) ................................................13

1.5.10 National Fire Protection Association (NFPA).......................................................14

1.5.11 Tubular Exchanger Manufacturers Association (TEMA)......................................14

1.5.12 Occupational Safety and Health Administration (OSHA).....................................14

1.5.13 Oil Industries Safety Directorate (OISD)..............................................................14

1.5.14 Petroleum and Explosives Safety Organisation (PESO) .....................................15

1.5.15 Referenced Standard Specifications....................................................................15

1.6 Conflicts, Deviations, and Amendments ..........................................................................15

1.7 Vendor Exceptions...........................................................................................................15




2. TECHNICAL REQUIREMENTS .......................................................................................16

2.1 General ............................................................................................................................16

2.2 Process and Operating Criteria........................................................................................17

2.3 Amendments, Supplements and Choices to API 610......................................................17

2.4 Auxiliary Equipment and Connections .............................................................................23

2.5 Bearings and Bearing Housings ......................................................................................24

2.6 Lubrication........................................................................................................................24

2.7 Electric Motors .................................................................................................................24

2.8 Machinery Protection System ..........................................................................................24

2.9 General..................................................................................................................................25

2.10 Pump Skid Instrument Installation ...................................................................................25

2.11 Civil.....................................................................................................................................25

3. PROTECTIVE COATING .................................................................................................26

4. SPARE PARTS AND SPECIAL TOOLS ..........................................................................27

4.1 Spare Parts ......................................................................................................................27

4.1.1 Spare Parts Required ..........................................................................................27

4.1.2 Information Required ...........................................................................................27

4.1.3 Contents...............................................................................................................27

4.2 Special Tools....................................................................................................................28

5. MARKING .........................................................................................................................29

6. TESTING ..........................................................................................................................30

6.1 General ............................................................................................................................30

6.2 Welds ...............................................................................................................................30

6.3 Castings ...........................................................................................................................30

6.4 Hydrostatic Tests .............................................................................................................31

6.5 Performance Test ............................................................................................................31

6.6 NPSHR Test.....................................................................................................................31

6.7 Unit Test...........................................................................................................................32




6.8 Mechanical Run Test .......................................................................................................32

7. MATERIAL SOURCING TRACEABILITY AND CERTIFICATION ...................................33

8. PACKING, SHIPPING AND HANDLING ..........................................................................34

9. INSPECTION, QUALITY ASSURANCE AND QUALITY CONTROL REQUIREMENTS.35

10. SITE ERECTION, TESTING AND COMMISSIONING ASISTANCE ...............................37

11. PERFORMANCE GUARANTEE ......................................................................................38

13. VENDOR SUPPLIED DOCUMENTS.........................................................................................39

APPENDIX-A: SPECIFICATIONS & DATASHEETS.......................................................................40

APPENDIX-B: VENDOR DATA REQUIREMENT LIST ...................................................................41




6

1. INTRODUCTION

1.1 Scope of Work

The scope of work under this document shall include supply of Sump pumps for Sump tanks

This specification details the general requirements for the pump sets (API 610 10th edition Centrifugal

Pump) and is to be used in conjunction with the data sheets, and specifications enclosed.

The Contractor / Vendor shall be responsible for the design, manufacturing, fabrication, assembly,

painting, inspection and testing, certification (as applicable), preparation for shipment, supply of

documentation for the complete package, and site erection, testing and commissioning as described

in this specification and attachments.

This specification does not dictate the detailed equipment design requirements. It is intended that this

responsibility be retained fully by the Contractor / Vendor so that Contractor’s / Vendor’s warranty

remains fully in force and is not affected by statements herein.

The API 610 Centrifugal Pump Sets shall be complete including all ancillary equipment/items required

to meet the design and environmental conditions as stated herein. Any additional part, equipment,

material, etc., which are not specifically mentioned in this specification, but are required to make the

supplied equipment/item complete in all respect in accordance with the intent of this specification,

statutory requirements, applicable codes/standards, good engineering practices, and for safe and

trouble-free operation, shall be deemed to be covered under the scope of this specification.

If national and/or local regulations exist in which some of the requirements may be more stringent

than in this specification, the Contractor / vendor shall determine by careful scrutiny which of the

requirements are the more stringent and which combination of requirements will be acceptable as

regards to safety, environmental, economic and legal aspects, in all cases the contractor / Vendor

shall inform the Purchaser of any deviation from the requirements of this specification which is

considered to be necessary in order to comply with national and/or local regulations. The Purchaser

may then decide to negotiate with the Authorities concerned with the object of obtaining agreement to

follow this specification as closely as possible.

This specification also includes in the scope of Contractor / Vendor, tagging and preparation for

shipment of all equipment furnished.




7

1.2 Sump Pumps at Raman Mandi & Bhatinda Pump Station

Item Equipment No. Equipment Title Data Sheet No.

1 P-10-03 Sump Pump (at Ramanmandi) 0435-JH0902-10-ME-DAS-0012

2 P-10-04 Sump Pump (at Ramanmandi) 0435-JH0902-10-ME-DAS-0012

3 P-20-01 Sump Pump (at Bhatinda) 0435-JH0902-10-ME-DAS-0016

4 P-20-02 Sump Pump (at Bhatinda) 0435-JH0902-10-ME-DAS-0016




8

1.3 Work Included

The Contractor / Vendor shall furnish all components and ancillary equipment necessary to make the

equipment complete, safe, maintainable and ready for trouble free operation. The equipment scope

shall include but not be limited to:

• Pump assemblies;

• Drive couplings;

• Mechanical seal assemblies and flushing / cooling plans as may be necessary;

• Mounting arrangement for pump assemblies and drives;

• Guarding around exposed rotating surfaces, of non-sparking material;

• Strainer

• Package and equipment lifting lugs;

• Earthing lugs;

• Pump bearing lubrication systems (as applicable)

• Machinery protection system (instruments/controls) as may be necessary safe & trouble free operation, along with necessary cabling. (as applicable)

• Local controls stations (with remote/manual switch).

• Interface with supervisory control systems;

• Inspection and performance testing;

• Disassembly and reassembly of unit test pumps after completion of test work;

• Surface preparation, painting, protective coating and preservation;

• Foundation / holding down bolts with nuts;

• Special tools for installation / operation / maintenance;

• Mandatory Spares as listed in the attachments elsewhere in the bid package

• Spare parts for start up and commissioning (with list);

• Spares for 2 years operation and maintenance (if required – optional), however list with price shall be provided;

• Packing & shipping of equipment to site;

• Unloading & storage at site;

• Erection & commissioning assistance for the package

• Supply of power cabling between switchgears, and between packages and driven motors

• Power supplies as may be required for the package;

• Cabling between panel and pump skid.

• Pressure gauges and pressure transmitters on the pump suction and discharge.




9

• Equipment performance guarantee;

• Operating and maintenance manuals; and

• Information and data as indicated in Vendor Data Requirement List.

1.3 Design Basis

1.3.1 Design Life, Availability and Reliability

The overall availability and reliability of the complete package shall be demonstrated by the

Contractor / Vendor. Unless otherwise stated, the package design life shall be 20 years, with an

uninterrupted period of operation of 3 years.

The Contractor / Vendor shall identify any aspects of its standard components or packages that do

not meet this requirement and submit descriptions to the Purchaser for consideration during the

tendering process.

1.3.2 Noise Limitation

Noise levels of all equipment under normal operation shall not exceed an eight-hour equivalent

continuous A-weighted sound pressure level, LAeq,8h, of 85 dB(A) at 1 metre in all directions. Sound

level tests shall be performed to verify the same. In case noise test certificate shows a sound level

exceeding 85 dB (A), necessary rectification/modification shall be done at Contractor / Vendor ’s own

cost and the pump set shall be re-tested to bring down the sound level to the specified limit.

Predicted noise levels shall be subject to approval by Purchaser.

The specified noise level should be attained without the use of orifices, mufflers, diffusers and/or

credit for thermal or acoustic insulation where practical.

Noise attenuating enclosure is generally not preferred and shall be avoided. However, if used (subject

to approval of Purchaser) shall be designed to provide full access to the equipment for maintenance

and operation.

1.4 Material Certification

Pressure containing parts and shafting shall have material certification in compliance with BS EN

10204 type 3.1 and include original mill certificates or certified copies. Components shall be fully

traceable back to the certificate.

Other parts shall be provided with certification to BS EN 10204 type 2.2.




10

1.5 Reference Documents

The design, fabrication and supply of pump sets shall comply with the applicable sections of the latest

edition of the following codes and standards including their addenda

1.5.1 British Standards (BS)

Standard No. Standard Title

BS 1041 Code for temperature measurement.

BS 2765 Specification for dimensions of temperature detecting elements and

corresponding pockets

BS 3463 Specification for observation and gauge glasses for pressure vessels

BS 3693 Recommendations for design of scales and indexes on analogue

indicating instruments

BS 5308-1 Instrumentation cables. Specification for polyethylene insulated cables

BS EN 10204 Metallic materials. Types of inspection documents

BS EN 13190 Dial thermometers

BS EN 60073 Basic and safety principles for man-machine interface, marking and

identification. Coding principles for indicators and actuators

BS EN 60079 – 0 to 11 Electrical apparatus for potentially explosive atmospheres. General

requirements

BS EN 60584 Thermocouples. Reference tables

BS EN 60751 Industrial platinum resistance thermometer sensors

BS EN 837-1 Pressure gauges. Bourdon tube pressure gauges. Dimensions,

metrology, requirements and testing

PD 5304 Guidance on safe use of machinery

1.5.2 American Standard Institute (ANSI)


ANSI B40.1 Gauges - Pressure Indicating Dial Type - Elastic Element




11

ANSI MC 96.1 Temperature Measurement Thermocouples

1.5.3 American Society and Mechanical Engineers (ASME)


ASME B16.11 Forged Fittings, Socket-Welding and Threaded

ASME B16.34 Valves—Flanged, Threaded, and Welding End

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B18.2.2 Square and Hex Nuts

ASME B31.3 Process Piping

ASME B46.1 Surface Texture (Surface Roughness, Waviness and Lay)

ASME BPVC Section II Materials

ASME BPVC Section V Non-destructive Examination

ASME BPVC Section VIII Rules for Construction of Pressure Vessels - Division 1

ASME BPVC Section IX Welding and Brazing Qualifications

ASME PTC 19.3 Temperature Measurement

1.5.4 American Society for Testing and Materials (ASTM)


ASTM A194 Standard Specification for Carbon and Alloy Steel Nuts for Bolts for

High Pressure or High Temperature Service, or Both

ASTM A36 Standard Specification for Carbon Structural Steel

1.5.5 American Petroleum Institute (API)


API 520 Sizing Selection and Installation of Pressure Relieving Devices in




12


Refineries

API 526 Flanged Steel Pressure Relief valves

API 541 Form-wound Squirrel-Cage Induction Motors - 500 Horsepower and

Larger

API 547 General-purpose Form-wound Squirrel Cage Induction Motors - 250

Horsepower and Larger

API 550 Installation of Refinery Instruments and Control Systems

API 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas

Industries

API 614 Lubrication, Shaft-sealing and Oil-control Systems and Auxiliaries

API 670 Machinery Protection Systems

API 671 Special Purpose Couplings for Petroleum, Chemical and Gas Industry

Services

API 677 General-Purpose Gear Units for Petroleum, Chemical and Gas

Industry Services

API 682 Pumps—Shaft Sealing Systems for Centrifugal and Rotary Pumps

API RP 505 Recommended Practice for Classification of Locations for Electrical

Installations at Petroleum Facilities as Class I, Zone 0, Zone 1 and

Zone 2

API RP 551 Process Measurement Instrumentation

API RP 686 Recommended Practices for Machinery Installation and Installation

Design

1.5.6 The Institute of Petroleum (IP)


IP 205/71 Petroleum Measurement Manual Part V, Automatic Tank Gauging




13

1.5.7 ISO Standards (ISO)


ISO 1940 Mechanical vibration -- Balance quality requirements for rotors in a

constant (rigid) state

ISO 8310 Refrigerated Light Hydrocarbon Fluids – Measurement of Temperature

in Tanks Containing Liquefied Gases – Resistance Thermometers and

Thermocouples.

1.5.8 Manufacturers Standardisation Society (MSS)


MSS SP-55 Quality Standard for Steel Castings for Valves, Flanges and Fittings

and Other Piping Components - Visual Method for Evaluation of

Surface Irregularities

1.5.9 International Electrotechnical Commission (IEC)


IEC 73 Specification for The Colour of Indicator Lights, Push Buttons,

Annunciators and Digital Readouts

IEC 529 Degrees of Protection Provided by Enclosures (IP Code)

IEC 60584-1 Thermocouples – Part 1 : Reference

IEC 60584-3 Thermocouples – Part 3: Extension and Compensating Cables –

Tolerances and Identification system

IEC 60751 Industrial Platinum Resistance Thermometers and Thermometers and

Platinum Temperature Sensors

IEC 60034 Rotating Electrical Machines

IEC 60060 High Voltage Test Techniques

IEC 60072 Dimensions and Output Series for Rotating Electrical Machines

IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres




14

IEC 60085 Thermal Evaluation and Designation of Electrical Insulation

IEC 61972 Method for Determining Losses and Efficiency of Three-phase Cage

Induction Motors

IEC 61986 Rotating Electrical Machines – Equivalent Loading and Super-position

Techniques – Indirect Testing to Determine Temperature Rise

1.5.10 National Fire Protection Association (NFPA)


NFPA 77 Recommended Practice on Static Electricity

1.5.11 Tubular Exchanger Manufacturers Association (TEMA)

1.5.12 Occupational Safety and Health Administration (OSHA)

1.5.13 Oil Industries Safety Directorate (OISD)


OISD-RP-110 Recommended Practices on Static Electricity

OISD-STD-119 Selection, Operation and Maintenance of Pumps

OISD-STD-123 Selection, Operation and Maintenance of Rotary Equipment

Components

OISD-STD-122 Selection, Operation and Maintenance of Fans, Blowers, Gear Boxes,

Agitators & Mixers

OISD-STD-125 Inspection and Maintenance of Mechanical Seals

OISD-RP-126 Specific practices for installations and maintenance of rotating

equipment

OISD-STD-171 Preservation of Idle Static & Rotary Mechanical Equipments




15

1.5.14 Petroleum and Explosives Safety Organisation (PESO)

1.5.15 Referenced Standard Specifications

Document No. Document Title

0435-JH0902-00-PI-SPC-003 Specification for Painting / Coating Requirements

435-JH0902-00-EL-SPC-0002 Specification for Low Voltage Induction Motors

435-JH0902-00-EL-DAS-0085 Datasheet for Low Voltage induction Motors.

1.6 Conflicts, Deviations, and Amendments

Contractor’s / Vendor’s bid shall clearly state and list exceptions to this specification and all

referenced documents. In the event of any conflict arising between this specification and other

documents listed herein, refer comments to Purchaser for clarification before design or fabrication

commences.

The order of precedence that applies is generally as follows:

• Data Sheets

• This Specification

• Referenced Drawings

• Project Specifications

• General Specifications

• Referenced Codes and Standards

1.7 Vendor Exceptions

Contractor’s / Vendor’s Bid shall clearly state and list exceptions/deviations under a separate section

“exceptions/deviations” and all referenced codes and standards and all documents referred in this

specification. Exceptions mentioned elsewhere in the Bid or implied in the Bid shall be invalid.




16

2. TECHNICAL REQUIREMENTS

The pumps including mounting plate, driver and all other ancillary equipment shall be in accordance

with the latest edition (10th

edition) of the API 610 edition / ISO 13079 “Centrifugal Pumps for

Petroleum, Heavy Duty Chemical and Gas Industry Service” plus as amended by the comments on

the subsequent Sections this specification including referenced standards, specifications, datasheets

and drawings enclosed.

The Contractor / Vendor shall comply with applicable Indian Federal, State or Local codes,

regulations, ordinances, and rules.

2.1 General

The pumps shall be of manufacturer’s standard proven design and be suitable for service as

mentioned in the datasheet attached elsewhere in the bid package.

The pumps and their component parts shall be manufactured to controlled tolerances to assure

complete inter-changeability with similar pumps in the station.

The Contractor / Vendor shall offer pumps from an existing manufacturing range which shall be a unit

of the same size and design which has a successful record of proven field service at operating

conditions similar in terms of power rating, hydraulic performance including NPSHR, inlet flow,

differential head, operating pressure and temperature, pumping liquid, speed, number and type of

impellers, mechanical design and materials of construction. At least one pumps similar to those

proposed shall have demonstrated successful continuous operation in the field for at least three years

individually without any major overhaul.

The site environmental conditions for the Sump pump are detailed in the enclosures.

Each pump shall be mounted on a base plate complete with the following ancillary equipment:

• Drive motor;

• API mechanical seal

• Junction boxes for machinery protection;

The lube oil system for each pump unit shall be individual ring oil lubricated and with constant level

oiler.

Materials of construction shall be suitable for the chemical and physical properties of the hydrocarbon

fluids to be pumped. The physical properties of the fluids are detailed in the data sheets.

The pump drive train including shaft shall be adequately sized and shall be designed for a minimum

design factor of 1.5 at maximum load.

Where possible lifting lugs shall be provided to facilitate disassembly of the pumps.




17

Materials for pump parts shall be in accordance with API 610 Table-H and shall be as specified in the

data sheets. For pump parts not designed as full compliance materials in Table-H, Supplier/ Vendors

shall get Purchaser’s prior approval.

The pumps may be subject to dead head conditions (zero flow, maximum head), due to accidental

closure of the discharge valves or any other reason. The Contractor / Vendor shall indicate in the bid

documentation the maximum time period that the pumps can operate under dead head conditions.

2.2 Process and Operating Criteria

The design should be based on the most severe operating condition specified on the Project Data

Sheets.

The pumps shall be selected such that:

• Over the “Normal Operating Flow Range” the duty point is close to the best efficiency point as far as practicable.

• Curves shall rise continuously to shut off from the rated flow duty point. The head rise shall not exceed the percentage specified in API 610

The pumps shall operate such that difference between NPSHA and NPSHR shall be at least 2.0 m

across the entire operating range. The NPSHR shall be lower than the NPSHA over the full operating

range of the pump.

The suction specific speed (Nss), calculated at the best efficiency point (BEP) for the maximum

impeller diameter of the casing, shall not exceed 12800 SI Units (11000 US Units). Pumps offered

with suction specific speed > 12800 SI Units (11000 US Units) may be accepted subject to

Purchaser’s written approval. Pumps with Nss < 10,000 SI Units will be preferred. Pumps fitted with

inducers are not acceptable.

2.3 Amendments, Supplements and Choices to API 610

The amendments, supplements and choices to API 610 / ISO13709 given in this Section are directly

related to equivalent sections and paragraphs in API 610. For clarity, the section and paragraph

numbering of API 610 has been used as far as possible.

Only amendments, supplements and choices have been stated hereafter. All other paragraphs and

clauses which have not been mentioned shall be considered unchanged and shall be applied as

stated in API 610 and references mentioned therein.

API 610 Paragraph no.:

3 Terms and definitions

3.60 (New)




18

‘Supplement' adds the requirement following this term to the referenced API Standard requirement. A

supplement does not change the API Standards requirement.

3.61 (New)

‘Amendment' changes the API Standard requirement to that which follows the term. All parts of the

API Standard requirement, which are not addressed, remain applicable.

3.62 (New)

'Choice' provides direction for choices, which are specified by the API Standard paragraph. Parts of

bulleted paragraphs, which do not require decisions, are fully applicable.

5.1.3 (Amendment)

Contractor / Vendor to note there is no cooling water available in the plant. Contractor / Vendor to

consider air cooling for any cooling requirement.

5.1.10 (Supplement)

The Net Positive Suction Head Available (NPSHA) shall exceed the Net Positive Suction Head

Required (NPSHR) by at least 2 m (6 ft) throughout the range from minimum continuous stable flow

up to and including the rated capacity, and by 0.5 m (2 ft) at 120% of rated flow.

5.1.13 (Choice / Supplement)

Paragraph 5.1.13 shall apply.

Pumps on non-parallel operation shall have stable head/capacity curves, which continuously rise by

at least 5% from rated capacity to shut-off. Pumps in parallel operation shall have a head rise from

the rated point to shut-off not less than 10% and preferably not greater than 20% depending on

system requirements.

5.1.16 (Choice / Supplement)

Paragraph 5.1.16 shall apply.

The maximum sound pressure level shall be as specified under Section ‘Noise Limitation’ elsewhere

in this specification.

5.1.17 (Supplement)

The numbers of vanes in impellers shall be different to the numbers of vanes in diffusers. On pumps

with two or more stages impellers/diffuser configuration shall be staggered to avoid coincidence of

pressure pulses.

5.1.19 (Supplement)

Contractor / Vendor to note there is no cooling water available in the plant. Any cooling system shall

be air cooled.




19

5.1.32 (New)

The Contractor / Vendor shall advise the minimum and maximum allowable safe flows for all

proposed pumps for continuous operation, considering temperature rise, vibration limits and NPSH

limits. Contractor / Vendor shall indicate “preferred operating range” and “allowable operating range”

on the pump characteristic curve for rated speed and lowest operating speed corresponding to the

low flow-low head operating point.

5.1.33 (New)

For balancing axial thrust in multi-stage pumps, only the following arrangements shall be used, either

alone or in combination:

- Individually-balanced impellers or opposed arrangements of impellers;

- A balancing piston (considering the subject service fluid is non-abrasive);

Balance disk or combinations with a balance disk shall not be used.

5.3.6 (Choice)

All parts referred to in the definition of pressure casing (3.42) shall have the same MAWP.

5.4.2.1 (Amendment)

All pumps shall have flanged suction and discharge nozzles of equal ASME pressure/temperature

ratings.

5.4.3.1 (Amendment)

Threaded connections to the pressure casing shall not be used, except that the seal gland connection

may be threaded.

5.4.3.4 (Amendment)

All auxiliary connections to the pressure casing shall be fitted with flanged stubs. Integral flanges may

be used. If the pump nozzles are Class 900 or above, or the pumping temperature is 0°C (32°F) or

below, or if the pump is for hazardous service, or if ISO 15156 or NACE MR0103 is applicable, then

socket welded connections shall not be used. In these cases full penetration butt welded connections

are required.

5.4.3.6 (Supplement)

Valves shall not be welded to the pump.


Openings shall not be furnished unless they are essential, in which case they shall be located away

from high-velocity areas. The provision and location of openings shall be identified in the Contractor /

Contractor’s / Vendor ’s proposal and shall be subject to the approval of the Purchaser. All openings




20

furnished and not connected to piping shall be closed with a flange in accordance with (5.4.3.4).

Balance leak off lines and their connections shall be flanged. Unions shall not be used.


Pumps shall preferably be self-venting. If this is not possible, then external vent connections in

volute(s) and, if necessary, in seal areas shall be provided. Both drain and vent connections shall be

welded and provided with flanged connection and valve. In case of multiple vents/drains, each shall

be manifold to single-flanged and valved connection. Piping shall terminate in ANSI flanges, of the

same rating as the pump discharge nozzle at the baseplate edge.

5.5.1 (Amendment)

Allowable Nozzle loads and moments shall be 2 times of the figures given in API 610 / ISO 13709

Table 4. Supplier shall ensure that base plates are also suitable for withstanding above loads.

5.6.16 (New)

Preferably the pump selection shall be such that their rated impeller diameters not greater than 90%

of the maximum diameter impeller and not less than 110% of the minimum impeller diameter that the

casing will take.

5.7.2 (Amendment / Supplement)

The pump casing wear rings shall be manufactured from material which ideally has a Brinell hardness

preferably 100BHN (but not less than 50BHN) greater than the impeller wear rings in their finished

state. For wear ring materials with higher galling tendencies, if increased running clearances are

considered necessary, efficiencies quoted shall be based on the higher running clearances.

5.7.3 (Amendment / Supplement)

The pump casing and impeller wear rings shall be held in place by setscrews. Tack welding is not

acceptable.

5.8.1 (Supplement)

Pumps shall be equipped with mechanical seals conforming to API 682. Mechanical seals shall be

offered and supplied from one of the following makes viz. Flowserve / Eagle Industries / John

Crane / Burgmann.

The seal manufacturer shall formally approve for each pump the following:

• The seal selection

• The seal flush plans

• The seal metallurgy

• The seal system




21

• The seal installation

• Special features (such as multi point injection)

• The proposed method of operation

The Contractor / pump Vendor shall be responsible for obtaining this approval from the seal

manufacturer and submitting to Purchaser for review.

The Contractor / Vendor shall furnish the seal manufacturer with the pump data sheet and also the

project and pump identification numbers for each pump, in order that the seal manufacturer may

prepare for the Purchaser a complete seal schedule and interchangeability chart.

Compatible buffer / barrier fluid (if applicable) for the intended service and the characteristics shall be

specified by seal manufacturer. Combined heat load (heat soak and seal face generated heat)

calculation shall be furnished by seal manufacturer. Cooling requirements / seal flush rates for

restricting to the maximum allowable rise in temperature of 5°C shall be specified by Contractor /

Vendor based on heat load calculation. Contractor / Vendor shall quote closed loop seal cooling

system with finned coil with air cooling.

Contractor / Vendor to note there is no cooling water available in the plant. Any cooling system shall

be air cooled.

All components of seals and seal systems shall withstand the maximum discharge pressure and the

maximum allowable temperature. The Contractor / Vendor shall advise in his Bid of the maximum

dynamic and static sealing pressure and temperature if these requirements cannot be met.

The pump Vendor shall supply and install all mechanical seal piping and appurtenances to make a

complete operational seal system.


Contractor / Vendor shall perform a transient (as well as steady state) torsional critical speed analysis

for sub-sections (c) and (d) of the clause.

5.9.2.6 (Choice)

Paragraph 5.9.2.6 will apply when specified on the data sheet.

When a torsional analysis is performed the Vendor shall furnish a detailed report.


For vertical, close-coupled, in-line pumps vibration readings shall be taken on both bearings for the

electric motor driver in the horizontal plane at 90° to each other. For vertical pumps with a flexible

coupling additional readings shall be taken at the pump top bearing.





22

When hydrodynamic thrust bearings are proposed, the pump hydraulic design shall be such that the

axial loads are unidirectional under all operating conditions. Contractor / Vendor shall submit with bid,

curves showing the variation of axial load with capacity (zero flow to 120% BEP) for design internal

clearances and two times design internal clearances. For variable speed units, similar curve for

maximum speed and minimum speed shall be submitted.


Contractor / Vendor to note that there is no cooling water available in the plant. In case of any Lube

oil cooling requirement, vendor shall achieve the same using air cooling.

5.12.2.5 (Choice/Supplement)

For casting repairs made in the Contractor’s / vendor's shop, repair procedures including weld maps

shall be submitted for approval to Purchaser. The Purchaser's approval is required before proceeding

with repair. Repairs made at the foundry level shall be controlled by the casting material specification.

6.2.2 (Supplement)

Pump couplings shall be supplied by the pump Vendor. Flexible all-steel couplings shall be provided

for all pumps. Rigid all-steel, axially adjustable, couplings shall be supplied for vertical pumps with

bearings integral with driver. The complete pump coupling shall be supplied fully machined by the

pump Vendor and shipped with the pump. Couplings shall be rated for the maximum transient torque

which can be expected in the case of a short circuit at the motor terminals and rapid automatic

reconnection of the motor with full opposite residual voltage, under full load conditions.

6.2.14 (Supplement)

Coupling guards shall be of non-sparking material and shall conform to BS PD 5304. Aluminium is not

accepted as a non-sparking material.


The datasheet shall specify whether pipe or tubing shall be used for auxiliary systems. Seamless pipe

of ASTM A 312, Type 316L shall be used if maximum pumping temperature is above 260 °C (500 °F)

or if the auxiliary system contains erosive fluid.

If piping is specified on the datasheet, then pipe shall be used for all auxiliary systems, except for

air/water coolers and barrier/buffer gas systems, which may be made using stainless steel seamless

tubing.

If tubing is specified on the data sheet then stainless steel (SS 316L) seamless tubing shall be used

for all auxiliary systems unless higher alloys are required to conform to pump metallurgy.

Insulation or guarding shall be provided as an integral part of the auxiliary piping system to provide

personnel protection if the non-insulated metal temperature exceeds 70 °C (160 °F) and the auxiliary

piping system is in an area where it can be touched during normal operation and maintenance

activities.




23

6.5.1.6 (Choice)

Each piping system shall be manifolded to one purchaser's connection (inlet or outlet); these

connections shall be terminated with proper rated flange at the end of baseplate/skid, and within the

confines of the baseplate/skid.

6.5.2.8 (Amendment)

Flanges shall be used instead of socket-welded unions.


If a spare rotor or complete inner assembly for multistage pumps is supplied with the pump, it shall be

subject to the same running/performance tests in the pump casing as the main rotor.

7.3.3.4b) (Supplement)

Bearing housing temperature shall be measured at all five points of the performance test, except

closed valve. For pump powers greater or equal to 100 kW, pump shall be run until oil temperature

stabilizes at rated condition.


An NPSH test shall be performed in the following cases:

(i) For pumps, if the difference between NPSHA and NPSHR is less than 2 m (6 ft);

(ii) For pumps handling liquids containing dissolved gas;

(iii) For pumps with a suction specific speed above 12800 SI Units (11000 US Units);

(iv) If the NPSHA at 120% of rated flow exceeds the NPSHR by 0.5 m (1.5 ft), or less

2.4 Auxiliary Equipment and Connections

Where required or when specified on the equipment data sheets, lube oil and auxiliary process piping

systems including accessories such as gauges and valves, shall be supplied fully assembled and

installed.

All flushing piping and accessories shall be provided. All parts of the flushing system shall be equal

to or better than the pump casing material, and shall be suitable for maximum discharge pressure and

temperature.

The following connections and auxiliary equipment shall be supplied as a minimum:

• Pump casing drains and piping;

• Pump venting points and piping;

• Bearing temperature connections.




24

All pump vents and drains shall be provided with an isolating valve piped to the base plate edge and

terminated with a blind flange. All terminating flanges shall be in accordance with ASME B16.5 and

shall be of the same rating as the pump discharge nozzle flange.

2.5 Bearings and Bearing Housings

Steel bearing housings shall be provided.

Bearing type and arrangement shall be in accordance with API 610 along with the limitations given in

Table 9 of API 610.

Bearings without pressure lubrication shall be ring oil lubricated and have constant level oilers.

2.6 Lubrication

Where the bearing housing acts as an oil chamber, an oil level sight glass with the recommended

level clearly marked shall be fitted. Topping up of the bearing housing oil chamber shall be possible

without dismantling the pump set assembly or any of it’s auxiliaries.

The Contractor’s / Vendor’s recommendations for lubrication will be submitted in the form of

Lubrication Schedule.

2.7 Electric Motors

Rating of the electric motors shall be sized considering margin required as per API 610 on the

maximum pump duty point. The motor rating shall also be crosschecked to satisfy the maximum

(usually end-of-curve) power requirement of pump with reasonable margin so that the motor is

capable enough to cater to any un-intended run-out case. All the motors shall be flameproof Ex (d)

type, suitable for Zone 2, Gas group IIA, IIB, and temp. class.T3. Type test certificates for explosion

protection class from the recognised testing authority shall be submitted. As per the statutory

requirement in India the approval from the chief controller of explosives (CCOE) for flameproof

motors, Ex (d) must be submitted. CCOE Certificates for the Flameproof motors shall be submitted

along with the final MDR / OMM.

Where sleeve bearing motors are offered, a limited end float type of coupling shall be applied to

prevent damage to the motor due to axial movement of the rotor during start-up or shutdown.

Vertical and horizontal adjustment alignment screws shall be provided for all drivers having a mass of

over 250 kg.

2.8 Machinery Protection System

The instrumentation (as applicable) shall be designed for hazardous area Zone1, Gr. IIA, IIB, T3. The

enclosure protection shall be minimum IP65.




25

The MOC for instrumentation shall be suitable for the process and environment.

The instrumentation process and pneumatic / hydraulic tubing shall be SS316.

All pumps shall be offered with an included primary protection system for safe operation of pump and

driver.

The description of each protective device of the pump shall be in accordance with API 610 and API

682 as required for relevant seal flushing plans

Apart from the protections outlined, the Contractor / vendor may include other protections deemed

necessary for operation of the package as a whole.

2.9 General

Contractor / Vendor to furnish datasheets for total instrumentation employed

Any additional protection devices if recommended by the pump manufacturer shall be considered.

Set points for pressure, temperature, vibration and seal leakage level parameters for the pump and

motor towards alarm and trip conditions shall have to be specified by the Contractor / Vendor.

Pump and drive protection signals shall be interfaced with the Plant Control System.

2.10 Pump Skid Instrument Installation

The installation and wiring of skid-mounted equipment shall be in accordance with the applicable

Standards, Codes and Statutory Regulations.

Pump skid instrument equipment and cabling layout drawings, together with junction box termination

drawings, shall be submitted for approval by the Purchaser.

2.11 Civil

Contractor / Vendor Shall furnish all the relevant information for carrying out foundation designs. As a

minimum following values shall be provided.

- Skid dimensions including General arrangement.

- Loads / Forces acting on top of foundation / Vessel

- Anchor bolts or foundation bolt details




26

3. PROTECTIVE COATING

The equipment base plate and skid structure and support shall be painted as per the project

Specification for Painting / Coating Requirements 0435-JH0902-00-PI-SPC-003. Pump and the

Motors shall be painted as per manufacturer standard. Manufacturer painting standard shall be

furnished with the Bid for review during bid evaluation.




27

4. SPARE PARTS AND SPECIAL TOOLS

4.1 Spare Parts

4.1.1 Spare Parts Required

a) Mandatory Spares: The Check list for Mandatory spares for the pump packages are

attached in bid package. Cost of Mandatory spares shall be included to arrive at the total cost

of package for a particular item.

b) Spares for two years Normal operation: Contractor / Vendor shall furnish an

itemised list of recommended spares with unit prices for two years normal & continuous

operation of the complete pumping unit (including Mechanical, Electrical, Instrumentation

spares) required. These spares shall be over and above the specified mandatory spares.

c) Erection & Commissioning spares : Contractor / Vendor shall include in his

scope of supply for each pump package, the spares required for erection & commissioning of

the pump, motor, Instruments etc .of that package. List for the same (separately for each

pump to be furnished by the bidder along with the bid.

If however, any additional spare is consumed during erection & commissioning over and

above the included erection & commissioning spares, the same shall be provided by the

contractor/ vendor at no extra cost to purchaser at the time of erection & commissioning.

4.1.2 Information Required

The parts list shall specify the source of manufacture and model number of each component part.

4.1.3 Contents

The spare parts list shall also identify the quantity of spare parts held, or the nearest major service

centre, relative to the equipment being offered to the Purchaser.

Should the Purchaser exercise its option to purchase any or all of the spare parts, it shall be the

responsibility of the Contractor / Vendor to provide the following at no extra cost to facilitate

identification and classification of spare parts:

• Every item shall have a tag or legend bearing the drawing and part number reference;

• The shipping advice note shall cross reference to the tag number; and

• A list giving the following information for each spare part:

− Handbook number;

− Handbook drawing number;




28

− Handbook drawing part number;

− Spare parts list and item number description;

− Manufacturing drawing number;

− Manufacturing drawing part number; and

− The Purchaser’s specification number and/or purchase order number under which parts were supplied.

Where the same pump part number is used for a component in differing pumps additional identifiers

must be used.

Spare parts shall be traceable to a pump by size, type and, if unique, pump equipment number.

4.2 Special Tools

The Contractor / Vendor shall supply one (1) set of special tools & tackles required for the erection

and/or maintenance of the package including all ancillary equipment.

Special Tools & Tackles means all such tools / tackles those are specific to the erection and/or

maintenance of the supplied equipment/package, and are normally not expected to be available in a

plant workshop, but without which it would be difficult or time-consuming to do erection and/or

maintenance of the supplied equipment/package.

The Contractor / Vendor shall identify the special tools required with Bid.

Special tools shall be itemised and submitted for review.




29

5. MARKING

Pumps shall have a nameplate made out of 1 mm thick grade 316 stainless steel plate firmly attached

to the pump pedestal by means of stainless steel screws or rivets.

The information stamped on the nameplate shall be as indicated in Clause 5.13.2 of API 610.

Lettering shall be 5 mm high with 3 mm spacing between lines.

Pumps shall have a direction of rotation arrow cast into pump casings or indicated on a stainless steel

plate mounted on the bearing housing or pump pedestal close to the drive end.

Prominent warning signs shall be affixed to the pump for removal of anti-brinelling devices and

lubrication requirements.




30

6. TESTING

6.1 General

As a minimum, inspection, testing and QA shall be conducted according to this specification and the

attached data sheets.

The Contractor / Vendor shall operate a quality management system to ensure the technical

requirements of this project are met. The QA requirements specified herein shall apply to all

materials and equipment in the Contractor’s / Vendor’s scope of supply. Shop inspection by the

purchaser’s nominated inspector will be required and the extent of inspection shall be approved by

the Purchaser.

Test requirements will be as specified here in and as noted on the pump data sheet. Contractor’s /

Vendor’s standard QA/QC procedures are acceptable except if modified herein.

Materials mill test certification (chemical and mechanical data) as noted on the data sheet, for

pressure containing parts, impeller and shaft are required.

The Contractor / Vendor shall supply calculations to show the conversion of data acquired with tests

carried out using water to that applicable for the fluids proposed for operation of the pumps.

The Contractor / Vendor shall include a description of shop pump test set-ups including

instrumentation to be used and specific step by step test program.

6.2 Welds

Testing of welds on the pump sets and associated equipment shall be in accordance with Table-13 of

API 610.

Contractor / Vendor to follow the Basis of Design document: 0435-JH-0902-ME-BOD-0001 for the

extent of inspection & testing criteria.

6.3 Castings

All major weld repairs to pressure containing castings shall be subject to approval by the Purchaser.

Weld procedures and weld maps shall be furnished that show the dimension and locations of these

defects. Material inspection shall be in accordance with Table-13 of API 610.

Major defects are:

• Repairs to leaks that develop during hydrostatic tests;

• Repairs where the depth exceeds 20% of the wall thickness or 25 mm, which ever is less; and

• Repairs where one defect surface area exceed 65 cm².




31

Weld repairs shall be inspected by dye penetrant/magnetic particle examination. Castings shall be

re-hydrotested after repairs have been carried out.

6.4 Hydrostatic Tests

Hydrostatic testing shall be carried out in accordance with API 610.

Gaskets used during hydrostatic test shall be identical to those supplied with the pump for operational

service.

Leaks past any gasketed areas or any joint connections are unacceptable.

6.5 Performance Test

The pumps shall performance tested as per Section 7.3.3 of API 610.

The pumps shall be tested at the following duty points:

• Shutoff wherever practical, otherwise at minimum thermal flow;

• Minimum Continuous Stable Flow;

• Rated flow;

• Guarantee point (if guarantee point is the rated point, then shall normal operating point)

• Best efficiency point (BEP);

• Maximum Allowable Flow (at least 120% of the rated flow or BEP whichever is more); and

• Additional points may be required if more than 30% of the curve is having no measured point.

The following parameters shall be measured during the tests at all test points:

• Pump hydraulic power;

• Flow rate;

• Pump head;

• All bearing vibration amplitudes;

• Bearing temperatures;

When supplied with the pump, the spare rotor and inner casing assemblies shall be performance

tested in the corresponding pressure casing.

6.6 NPSHR Test

NPSHR test if required as per the conditions specified in this specification or if specified in the data

sheet shall be conducted. NPSHR test shall be of the vacuum suppression type. A throttle valve

NPSHR test may be accepted subject to Purchasers approval.




32

NPSHR tests shall be carried out on all pumps in accordance with Section 7.3.4.2 of API 610.

6.7 Unit Test

Each pump set, shall be subject to a complete unit test as per Section 7.3.4.3 of API 610 but with the

flow rates and pump speeds corresponding to the performance tests defined in Section 6.5 of this

specification.

Complete unit test shall be conducted in the same manner as mechanical run test specified under

section 6.8 except that job driver and all job auxiliaries shall be used during this test. Due to use of job

driver, difference in specific gravity between the test liquid and actual pumped liquid may sometimes

not permit running the pump at rated capacity during this test, in such cases, test shall be performed

at the maximum permissible capacity.

6.8 Mechanical Run Test

After the performance test has been completed, the Contractor / Vendor shall operate the pump in a

stable condition for at least 4 hours at rated capacity and for 2 hours at minimum continuous flow,

during which pump mechanical behaviour shall be demonstrated to meet the requirements of this

specification. Counting of test duration shall start after stabilization of bearing temperature. The test

shall be run at maximum continuous speed.

Each pump shall be stripped down after completion of the test and shall undergo a thorough visual

inspection. Special emphasis shall be placed on the following items:

• Pump casing and impeller wear rings; and

• Shaft bearings.

If there is evidence of internal rubbing or sleeve bearing damage on disassembly following the unit

test, the cause of the problem must be corrected and the pump shall be rerun, again dismantled and

re-inspected. This process will be continued until there is no measurable dimensional change or metal

transfer in the bearings or close-clearance parts. Pumps need not be run again if no evidence of

rubbing or other defects is found on disassembly. The cost of subsequent testing plus

disassembly/reassembly (following detection of internal pump damage) shall be at the Contractor’s /

Vendor’s cost.




33

7. MATERIAL SOURCING TRACEABILITY AND CERTIFICATION

The Contractor / Vendor shall submit a Manufacturers Data Report (MDR) which will allow

identification and certification of all pressure retaining parts and key rotational parts of the pumps

which shall include mechanical properties and chemical composition analysis, mill certificates, heat

numbers and certificates of conformance. Each certificate shall be reviewed and signed by the

manufacturer’s authorised personnel as detailed in the Inspection and Test Plan.

Pressure retaining parts shall be clearly marked to ensure that full traceability is maintained.

Pressure-retaining parts shall include body forgings and castings.

Key rotational parts include the impeller and impeller shaft.

Certificates shall be available at final inspection in the manufacturer’s works.

Certificates of compliance shall be provided for bolting used in pressure retaining parts.




34

8. PACKING, SHIPPING AND HANDLING

Preparation for shipment shall be as per Section 7.4 of API 610.

The components of the pump set shall be shop assembled to the maximum extent practical, such that

field assembly is both minimized and simplified, and matching of components is assured. The parts

that cannot be shop assembled prior to shipment shall be shop fitted, identified and match marked.

The equipment items that are shipped in a “knocked down” condition shall be individually tagged with

the assigned tag/part number. Contractor’s / Vendor’s philosophy for the same shall be reviewed and

approved by Purchaser.

Adequate provisions shall be made to prevent damage to the bearings from brinelling during

transport. Rotors on equipment shall be strapped down to wooden blocks for transport, and

appropriate shaft locks shall be provided and fitted. Appropriate high visibility label tags shall be fitted

to all blocked or locked rotor equipment.

All spare parts shall be packed separately from the main pump set assemblies.

All parts and equipment including spares shall be packed suitable for long term storage in a tropical

climate.

The spare rotor shall be crated in a metal container for transportation and storage; the crating method

shall be suitable for at least 4 years storage in both horizontal and vertically suspended position. The

container shall be equipped for nitrogen blanketing.




35

9. INSPECTION, QUALITY ASSURANCE AND QUALITY CONTROL

REQUIREMENTS

The Contractor / Vendor shall conform to the requirements of this specification in the performance of

the work under the Contract.

The Purchaser reserves the right to inspect the manufacture of the pumps at the Contractor / Vendor

or Sub-Vendor’s premises at any time. The Purchaser may also appoint a third party inspector to act

on his behalf.

The Contractor / Vendor shall submit an Inspection and Test Plan (ITP) for approval prior to

commencement of manufacture. The Purchaser will advise the Contractor / Vendor, by marking up

the Inspection and Test Plan, of the specific inspection review, witness and hold points required. The

Contractor / Vendor shall give ten working days prior notice to the Purchaser of such item or hold

point being reached.

Contractor / Vendor shall submit quality plans, test procedures for all tests, for approval of Purchaser,

and testing shall be done only after such documents have been duly approved.

As a minimum the following stages will be subject to witness/

/review by the Purchaser or third party inspector:

• Visual inspection of all parts prior to assembly of pump;

• Visual inspection of the assembled pump with accessories;

• Surface finish and profile verification at each phase of surface preparation and coating;

• Name plate checks;

• Material certification checks;

• Radiography of impeller tip and panoramic shot of impeller;

• Ultrasonic testing of shaft;

• Dynamic balancing of rotor assembly;

• Heat sample of each casing with test results;

• Sound level and vibration tests;

• Review of all documents prior to shipping;

• Full dimensional checks; and

• Pump tests.

The Contractor / Vendor shall obtain Purchaser approval of the following prior to any fabrication

taking place:

• Weld procedures; and




36

• All drawings associated with the pump sets.

The Contractor / Vendor shall afford the Purchaser the use of telephone, facsimile and office facilities

for the purpose of completing reports during inspections.

Where inspection or testing is performed by certified testing laboratories, they shall be registered by

an internationally recognized testing organization.

The appropriate inspection equipment and the Contractor’s / Vendor’s personnel shall be readily

available to complete the inspection at the time agreed.

The appropriate test procedure and acceptance criteria shall be available to the Purchaser for

immediate analysis of the inspection results.

The final inspection, before issue of a release note for the pump sets, shall include material

certificates, test certificates, surface treatment, dimensional conformity, tagging and packing

conformity.

Specimen crating and packaging may also be inspected.




37

10. SITE ERECTION, TESTING AND COMMISSIONING ASISTANCE

The Contractor / Vendor shall provide site erection, pre-commissioning and commissioning

assistance of pump sets. After the completion of the precommissioning activities (including

mechanical, electrical, instrumentation) each pump package shall be subjected to a site trial run /

operation (Duration for the same shall be finalised after award). During this trial run, satisfactory

operation of pump package unit (including pump, driver, contractor / vendor / supplied electrical

equipment and all auxiliary equipment) shall be established. Operating point shall be within pump

operating Flow range. Site trail run shall form the part of commissioning.

The Contractor / Vendor shall be responsible for witnessing and signing off all activities associated

with commissioning and that testing of pumps are carried out in accordance with Pump vendor’s

requirements.

On completion of Site acceptance testing & Commissioning, the Vendor shall submit a report to the

Purchasers detailing all activities associated with precommissioning, commissioning and testing of

pumps.

.




38

11. PERFORMANCE GUARANTEE

The Contractor / Vendor shall guarantee that the pump sets supplied shall the meet the performance

requirements set down in this specification (including referenced documents).

Special emphasis is placed on the following criteria:

• The ability to meet duty point at the normal flow range and rated flow rate;

• Powers draw at normal and rated flow rates;

• NPSH requirements at normal and rated flow rates;

• Drive motor efficiencies at normal and rated flow rates;

• Equipment noise level under all operating conditions.

The Contractor / Vendor will guarantee the pump performance as witnessed in factory tests. The

Contractor / Vendor shall nominate the performance of the pump at the rated test point in terms of

total dynamic head, and power at a nominated flow rate and pump speed. The hydraulic power at the

test point shall be advised by the Contractor / Vendor in the form of a positive and negative

percentage tolerance. No negative tolerance on flow or total dynamic head at the rated speed will be

accepted.




39

13. VENDOR SUPPLIED DOCUMENTS

The Contractor/ Vendor shall supply documentation in accordance with the Vendor Document

Requirements List (VDRL) indicated under Appendix B of this specification.




40

APPENDIX-A: SPECIFICATIONS & DATASHEETS




0435-JH0902-00-EL-DAS-0085 Datasheet for Low Voltage Induction Motors

0435-JH0902-10-ME-DAS-0012 Mechanical Datasheets for Sump Pumps at RamanMandi

0435-JH0902-10-ME-DAS-0016 Mechanical Datasheets for Sump Pumps at Bhatinda




41

APPENDIX-B: VENDOR DATA REQUIREMENT LIST

Sr.

No.

Document / Drawings For Purchaser’s approval For Purchaser’s Information

1. Pump GA Drawings Yes -

2. Pump C/s Drawings Yes

3. Filled in Mechanical

Datasheets

Yes

4. Performance Curves Yes

5. Filled in Motor Datasheets Yes

6. GA Drawings for the Motors

indicating Terminal box

details and cable sizes

Yes

7. Characteristic curves for

Motors

Yes

8.. Instruments Datasheets Yes

9. Quality Procedures:

- Hydro test

procedures

- WPS/PQR

- ITP

- FAT Procedures

- SAT Procedures

Yes

10. MDR / IOM manuals Yes (1 copy) 3 Hard copies & 1 Soft Copy CD.

Equipment Data Sheet for Centrifugal Pump (VS)Tag No. : P-20-01 & P-20-02 Client:

Service: Sump Pumps for Transfer of Drain Oil (Hydrocarbon) Plant Location:

P & ID No. : 435-JH0902-20-PR-PID-2003 Supplier:

Calculation Ref. : Purchase Order No.:

No. of Units:

Service Description: Transfer of Drain Oil (Hydrocarbon)

1 NOTES: INFORMATION BELOW TO BE COMPLETED: BY PURCHASER BY MANUFACTURER BY MANUFACTURER OR PURCHASER

2 DATA SHEETS (6.1.1)

3 NO.

4 PUMP

5 MOTOR

6 GEAR

7 TURBINE

8 APPLICABLE OVERLAY STANDARD(S):

9 OPERATING CONDITIONS (5.1.3) LIQUID (5.1.3)

10 FLOW, NORMAL (m3/h) RATED (m³/h) LIQUID TYPE OR NAME Refer service description & process data (Sheet 2 of 5)

11 OTHER Refer Sheet 2 of 5 HAZARDOUS FLAMMABLE (5.1.5)

12

13 SUCTION PRESSURE MAX./RATED Refer Sheet 2 of 5 / (kg/cm2a) (Refer Sheet 2 of 5)

14 DISCHARGE PRESSURE Refer Sheet 2 of 5 (kg/cm2a) PUMPING TEMP (°C)

15 DIFFERENTIAL PRESSURE (kg/cm2) VAPOR PRESS. (kg/cm

2a)

16 DIFF. HEAD (mlc) NPSHA (m) Remark 1 RELATIVE DENSITY (SG):

17 PROCESS VARIATIONS (5.1.4) VISCOSITY (cP)

18 STARTING CONDITIONS (5.1.4) SPECIFIC HEAT, Cp (kJ/kg °C)

19 SERVICE: CONT. INTERMITTENT (STARTS/DAY) CHLORIDE CONCENTRATION (PPM)

20 PARALLEL OPERATION REQ'D (5.1.13) H2S CONCENTRATION (6.5.2.4) (PPM) WET (5.2.1.12c)

21 SITE DATA (5.1.3) CORROSIVE / EROSIVE AGENT Due to Water (5.12.1.9)

22

23 LOCATION: (5.1.30) MATERIALS (5.12.1.1)

24 INDOOR (covered location) HEATED OUTDOOR UNHEATED ANNEX H CLASS (5.12.1.1) S6

25 ELECTRICAL AREA CLASSIFICATION (5.1.24 / 6.1.4) MIN DESIGN METAL TEMP (5.12.4.1) 0 (°C)

26 CL 1 ZONE 2 GR IIA, IIB DIV T3 REDUCED HARDNESS MATERIALS REQ'D. (5.12.1.11) Yes

27 WINTERIZATION REQ'D TROPICALIZATION REQ'D. BARREL/CASE IMPELLER

28 SITE DATA (5.1.30) CASE/IMPELLER WEAR RINGS

29 ALTITUDE (m) BAROMETER (bara) SHAFT

30 RANGE OF AMBIENT TEMPS: MIN/MAX. / (°C) DIFFUSERS

31 RELATIVE HUMIDITY: MIN / MAX / (%) BOLTING ……………………………………………………………………………………………PTFE coated A193 Gr. B7

32 UNUSUAL CONDITIONS: (5.1.30) DUST FUMES PERFORMANCE:

33 OTHER PROPOSAL CURVE NO. RPM

34 IMPELLER DIA. RATED MAX. MIN. (mm)

35 IMPELLER TYPE

36 DRIVER TYPE RATED POWER (kW) EFFICIENCY (%)

37 INDUCTION MOTOR STEAM TURBINE GEAR MINIMUM CONTINUOUS FLOW:

38 OTHER THERMAL (m3/h) STABLE (m

3/h)

39 Refer motor specification/ Datasheet respectively PREFERRED OPER. REGION TO (m3/h)

40 MOTOR DRIVER (6.1.1 / 6.1.4) ALLOWABLE OPER. REGION TO (m3/h)

41 MANUFACTURER MAX HEAD @ RATED IMPELLER (m)

42 (kW) (RPM) MAX POWER @ RATED IMPELLER (kW)

43 FRAME ENCLOSURE NPSHR AT RATED CAPACITY (m) (5.1.10)

44 HORIZONTAL VERTICAL SERVICE FACTOR MAX SUCTION SPECIFIC SPEED: (5.1.11)

45 VOLTS/PHASE/HERTZ / 3 / MAX. SOUND PRESS. LEVEL REQ'D (dBA) (5.1.16)

46 TYPE EST MAX SOUND PRESS. LEVEL (dBA) (5.1.16)

47 MINIMUM STARTING VOLTAGE (6.1.5) EST MAX SOUND POWER LEVEL (dBA) (5.1.16)

48 INSULATION TEMP. RISE UTILITY CONDITIONS (5.1.3)

49 FULL LOAD AMPS ELECTRICITY

50 LOCKED ROTOR AMPS DRIVERS

51 STARTING METHOD HEATING

52 LUBE SYSTEM VOLTAGE DIP OTHER (6.1.5)

53

54 BEARINGS (TYPE/NUMBER): STEAM MAX. PRESS. MAX. TEMP. MIN. PRESS. MIN. TEMP.

55 RADIAL / DRIVERS

56 THRUST / HEATING

57 VERTICAL THRUST CAPACITY COOLING WATER: (5.1.19) SOURCE NOT APPLICABLE

58 UP (N) DOWN (N) SUPPLY TEMP. (°C) MAX. RETURN TEMP. (°C)

59 NORM. PRESS. (barg) DESIGN PRESS. (barg)

60 REFER MOTOR DATA SHEET MIN. RET. PRESS. (barg) MAX. ALLOW. D.P. (barg)

61 CHLORIDE CONCENTRATION: (PPM)

66

D

C

B

A

Rev.

Hindustan Petroleum Corporation Limited

HPCL Guru Gobind Singh Refinery Products Evacuation Project (GGSRPEP)

Project No: 435/JH0902 SHEET

Datasheet No: 0435-JH0902-10-ME-DAS-0016 1 of 5

Originated Checked Client

07-Jul-09 ISSUED FOR DIC & SQC SS SVI JW

ApprovedDate Issue Description

10-Jul-09 Issued For Review SS SVI

25-Aug-09 Issued for Tender SS SVI

Centrifugal Pump Data Sheet to API 610, 10th Edition

2 Nos. ( 1 per tag no.)


Bhatinda

N/A

80%

N/A

415 V 3 ph 50

KMNP

JW

VOLTAGE PHASE HERTZ

12,800 SI Units

415 50 Max. 85 @ 1.0 m

0 50

5 90

203.5

Refer Sheet 2 of 5 Sht 2/5

Refer Sheet 2 of 5

NORMAL MAX.

1110

MIN.

P-20-01 / P-20-02

M-20-01 / M-P-20-02

REVISIONS

ITEM NO. ATTACHED ITEM NO. ATTACHED ITEM NO. ATTACHED DATE BY

O:\HPCL-GGSR\10-Engineering\8.04-ME-Mechanical\Mechanical docs. for comp. tender\Final Composite Tender\Sump Pumps\435-JH0902-10-ME-DAS-0016 8/26/2009





No. of Units:


1 PROCESS DATA

2 1. The rated and the operating parameters for the pump are as follows :

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17 B.P. Elevation (m)

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62





INTERMITTENT

1 NO PER PUMP TAG NO.

-

YES / DUE TO WATER

YES / DUE TO HYDROCARBON

-' / 10 / 11 m3/h

-

-

Pump casing temperature (Max/Min) oC VTC

Ambient temperature (Norm/Min) oC 25 / 0

5.87

DESIGN CONDITIONS

Pump casing pressure (kPag)

Design differential head (m) 235.0

Hydraulic power Kw

VTC

NPSHA 4.74

Design differential pressure (kPa) 1922

NPSH & DIFF. PRESSURE

Total discharge pressure (kPaa) 1846

Total discharge head (m) 226

Line Losses (kPa) 10

Losses through fittings & eqmt. '- kPa

Total suction head (m) 12

End of Line Pressure (kPaa)

Static Head (kPa) 35

1801

DISCHARGE CONDITIONS

strainer, filter, etc (kPa) -

Total suction pressure (kPaa) 99.00

0.82

Line Losses (piping) (kPa) 3.4

Temperature OC 25

Conc. by Volume %

Conc. by Mass %

Total Flow Rate (Min/Nor./Max.)

Hazardous Service

Corrosive/Erosive

Connected in Series / Parallel

No. of Units

Operation

Vapour Pressure (kPaa) : 9.8 TO 59.8 @ 38 OC

Specific Gravity: Solids/Liquid/Mixture 0.72 TO 0.86

Fluid MIXED HYDROCARBON

Viscosity (cP) 0.52 TO 6.72 @ 20 OC




Bhatinda

Min Submerge Req.

SUCTION CONDITIONS

Source Pressure (kPaa) 101.325

Static Head (kPa)






No. of Units:


1CONSTRUCTION SURFACE PREPARATION AND PAINT

2 ROTATION: (VIEWED FROM CPLG END) CW CCW MANUFACTURER'S STANDARD OTHER (SEE BELOW)

3 PUMP TYPE: (1.3) PUMP: Contractor / Vendor shall furinsh manufacturer painting std

4 VS1 VS2 VS3 VS4 VS5 VS6 VS7 with the bid for review during bid evaluation.

5 CASING MOUNTING: SUMP COVER PLATE PUMP SURFACE PREPARARTION

6 INLINE SEPARATE MOUNTING PLATE (8.3.8.3.1) PRIMER

7 SEPARATE SOLE PLATE (8.3.8.3.3) FINISH COAT

8 CASING SPLIT: BASEPLATE/COLUMN : (6.3.17)

9 AXIAL RADIAL BASEPLATE SURFACE PREPARATION

10 CASING TYPE: PRIMER

11 SINGLE VOLUTE MULTIPLE VOLUTE DIFFUSER FINISH COAT

12 CASE PRESSURE RATING: SHIPMENT: (7.4.1)

13 MAX ALLOWABLE WORKING PRESSURE (MPa) DOMESTIC EXPORT EXPORT BOXING REQUIRED

14 @ (°C) OUTDOOR STORAGE MORE THAN 6 MONTHS

15 HYDROTEST PRESSURE (MPa) SPARE ROTOR ASSEMBLY PACKAGED FOR:

16 SUCTION PRESSURE REGIONS MUST BE DESIGNED HORIZONTAL STORAGE VERTICAL STORAGE

17 FOR MAWP (5.3.6) TYPE OF SHIPPING PREPARATION

18

19 NOZZLE CONNECTIONS: (5.4.2) HEATING AND COOLING

20 SIZE (DN) FLANGE FACING HEATING JACKET REQ'D. (5.8.9) COOLING REQ'D.

21 RATING COOLING WATER PIPING PLAN (6.5.3.1)

22 SUCTION C.W. PIPING:

23 DISCHARGE PIPE TUBING; FITTINGS

24 BALANCE DRUM C.W. PIPING MATERIALS:

25 S. STEEL C. STEEL GALVANIZED

26 PRESSURE CASING AUX. CONNECTIONS: (5.4.3) COOLING WATER REQUIREMENTS:

27 NO. SIZE (DN) BEARING HOUSING (m3/h) @ (MPa)

28 DRAIN HEAT EXCHANGER (m3/h) @ (MPa)

29 VENT STEAM PIPING: TUBING PIPE

30 WARM-UP BEARINGS AND LUBRICATION

31 BALANCE / LEAK-OFF BEARING (TYPE/NUMBER):

32 MACHINED AND STUDDED CONNECTIONS (5.4.3.8) RADIAL

33 CYLINDRICAL THREADS REQUIRED (5.4.3.3) THRUST

34 ROTOR: LUBRICATION (5.11.3, 5.11.4):

35 COMPONENT BALANCE TO ISO 1940 G1.0 (5.9.4.4) GREASE FLOOD PURGE OIL MIST

36 SHRINK FIT - LIMITED MOVEMENT IMPELLERS (8.2.2.3) FLINGER PURE OIL MIST

37 COUPLINGS: CONSTANT LEVEL OILER PREFERENCE (5.10.2.2):

38 MANUFACTURER MODEL OIL VISC. ISO GRADE

39 RATING (kW per 100 r/min) REVIEW AND APPROVE THRUST BEARING SIZE

40 SPACER LENGTH (mm) SERVICE FACT. 1.5 OIL HEATER REQUIRED: STEAM ELECTRIC

41 RIGID

42 THROUGH COUPLINGS: INSTRUMENTATION (6.4.2)

43 MANUFACTURER MODEL ACCELEROMETER (6.4.2.1)

44 RATING (kW per 100 r/min) LUBE PROVISION FOR MOUNTING ONLY (5.10.2.11)

45 SPACER LENGTH (mm) SERVICE FACT. FLAT SURFACE REQUIRED (5.10.2.12)

46 RIGID PRESSURE GAUGE TYPE

47 DRIVER HALF-COUPLING MOUNTED BY:

48 PUMP MFR. DRIVER MFR. PURCHASER

49 COUPLING BALANCED TO ISO 1940-1 G.6.3 (6.2.3) REMARKS: Vendor to recommend instrumentation required for safe and

50 COUPLING PER ISO 14691 (6.2.4) trouble free operation of the pumps in their bid.

51 COUPLING PER ISO 10441 (6.2.4)

52 COUPLING PER API 671 (6.2.4) MASSES (kg)

53 NON SPARK COUPLING GUARD (6.2.14c) PUMP

54 COUPLING GUARD STANDARD PER (6.2.14a) DRIVER

55 MECHANICAL SEAL: REQUIRED (Remark- 3) GEAR

56 SEE ATTACHED ISO 21049/API 682 DATA SHEET SOLE PLATE / MOUNTING FLANGE

57 COUPLING

58 MOTOR STOOL

59 TOTAL

60

61

62

63

64

65

66





300# RF

TYPE



POSITION

300# RF


Bhatinda






No. of Units:


1 SPARE PARTS (TABLE 18) VERTICAL PUMPS (CONT.)

2 START-UP NORMAL MAINTENANCE Supply start-up spares PUMP AND STRUCTURE DYNAMIC ANALYSIS (8.3.5)

3 SPECIFY Two years of operation spares parts DRAIN PIPED TO SURFACE (8.3.13.5)

4

5 OTHER PURCHASER REQUIREMENTS QA INSPECTION AND TESTING

6 COORDINATION MEETING REQUIRED (9.1.3) SHOP INSPECTION (7.1.4) PERF. CURVE APPROVAL

7 MAXIMUM DISCHARGE PRESSURE TO INCLUDE (5.3.2) TEST WITH SUBSTITUTE SEAL (7.3.3.2b)

8 MAX RELATIVE DENSITY TEST NON-WIT WIT OBSERVE

9 MAX DIA. IMPELLERS AND/OR NO OF STAGES HYDROSTATIC TEST OF BOWLS

10 OPERATION TO TRIP SPEED AND COLUMN (8.3.13.2)

11 CONNECTION DESIGN APPROVAL (5.12.3.4) HYDROSTATIC (7.3.2)

12 TORSIONAL ANALYSIS REQUIRED (5.9.2.1) PERFORMANCE (7.3.3)

13 TORSIONAL ANALYSIS REPORT (5.9.2.6) RETEST ON SEAL LKGE (7.3.3.2d)

14 PROGRESS REPORTS (9.3.3) NPSH (7.3.4.2)

15 OUTLINE OF PROCEDURES FOR OPTIONAL TESTS (9.2.5) COMPLETE UNIT TEST (7.3.4.3)

16 ADDITIONAL DATA REQUIRING 20 YEARS RETENTION (7.2.2.1f) SOUND LEVEL TEST (7.3.4.4)

17 MANIFOLD PIPING TO SINGLE CONNECTION (6.5.1.6) CLEANLINESS PRIOR TO

18 DRAIN VENT COOLING WATER FINAL ASSEMBLY (7.2.2.2)

19 MOUNT SEAL RESERVOIR OFF BASEPLATE (6.5.1.4) NOZZLE LOAD TEST (6.3.6)

20 FLANGES REQD IN PLACE OF SOCKET WELD UNIONS (6.5.2.8) 4 h MECH RUN TEST(7.3.4.7.2)

21 CONNECTION BOLTING PTFE COATING SS MECHANICAL RUN UNTIL OIL

22 PAINTED ASTM A153 GALVANISED TEMP. STABLE (7.3.4.7.1)

23 INSTALLATION LIST IN PROPOSAL (9.2.3L) 4 h MECHANICAL RUN AFTER

24 OIL TEMP. STABLE (7.3.4.7.3)

25 PUMP THRUST: (+) UP (-) DOWN TRUE PEAK VELOCITY

26 AT MIN. FLOW (N) (N) DATA (7.3.3.4d)

27 AT RATED FLOW (N) (N) RESONANCE TEST (8.3.9.2)

28 MAX. THRUST (N) (N) AUXILIARY EQUIPMENT TEST

29 SOLEPLATE REQ'D (8.3.8.3.3) (m) X (m) (7.3.4.5)

30 SEPARATE MOUNTING PLATE REQUIRED (8.3.8.3.1) IMPACT TESTING (5.12.4.3)

31 SOLEPLATE THICKNESS (mm) PER EN 13445

32 COLUMN PIPE: FLANGED THREADED PER ASME VIII

33 DIAMETER (mm) LENGTH (m) VENDOR KEEP REPAIR AND HT RECORDS (7.2.1.1c) (copy provided to Purchaser)

34 GUIDE BUSHINGS VENDOR SUBMIT TEST PROCEDURES (7.3.1.2 / 9.2.5)

35 NUMBER VENDOR SUBMIT TEST DATA WITHIN 24 HOURS (7.3.3.3e)

36 LINE SHAFT BEARING SPACING (mm) INCLUDE PLOTTED VIBRATION SPECTRA (5.9.3.3)

37 GUIDE BUSHINGS LUBE: RECORD FINAL ASSEMBLY RUNNING CLEARANCES

38 WATER OIL COMPLETION OF INSPECTION CHECK LIST (7.1..6)

39 GREASE PUMPAGE MATERAIL CERTIFICATION REQUIRED (5.12.1.8)

40 LINESHAFT: OPEN ENCLOSED CASING IMPELLER SHAFT

41 LINE SHAFT DIAMETER: (mm) OTHER Wetted parts

42 TUBE DIAMETER: (mm) CASTING REPAIR PROCEDURE APPROVAL REQ'D (5.12.2.5)

43 LINESHAFT COUPLING: INSPECTION REQUIRED FOR CONNECTION

44 LINE SHAFT DIAMETER: SLEEVE & KEY THREADED WELDS (5.12.3.4)

45 SUCTION CAN THCKNESS (mm) MAG. PARTICLE LIQUID PENETRANT

46 LENGTH (m) RADIOGRAP[HIC ULTRASONIC

47 DIAMETER (m) INSPECTION REQUIRED FOR CASTINGS (7.2.1.3) (5.12.1.5)

48 SUCTION STRAINER TYPE SUITABLE FOR THE PUMP MAG. PARTICLE LIQUID PENETRANT

49 FLOAT & ROD FLOAT SWITCH RADIOGRAP[HIC ULTRASONIC

50 IMPELLER COLLETS ACCEPTABLE (5.6.3) HARDNESS TEST REQUIRED (7.2.2.3)

51 HARDENED SLEEVES UNDER BEARINGS (8.3.10.5) ADDITIONAL SUBSURFACE EXAMINATION (7.2.1.3)

52 FOR

53 METHOD

54

55 Key 3 2 156 1 grade

57 2 low liquid level l 3

58 3 centreline of discharge

59 l 1 sump depth

60 l 2 pump length l 5

61 l 262 l 3 centreline discharge height l 2

63 l 4 height of grade above low liquid level l 1

64 l 5 datum elevation, first-stage impeller

65 l 6 submergence required

66 Ø d sump diameter

67

68 Refer to hydraulic institute standards for definitions

69 l 1 m l 2 m

70 Ø d m l 6 m

71 l 4 m l 3 m VENDOR SHALL FILL-IN THE DIMENSIONS WITH THE TENDER

72 l 5 m

73






Bhatinda


l 6


VERTICAL PUMPS

Pit arrangment

l 4

Ø d






No. of Units:


1 APPLICABLE TO: PROPOSALS PURCHASE AS BUILT

2 FOR HPCL's GURU GOBIND SINGH REFINERY PRODUCT EVACUATION PROJECTUNIT Raman Mandi Pumping Station - Bathinda pipeline

3 SITE RAMAN MANDI PUMPING STATION SERVICE Transfer of Drain Oil

4

5 NOTES: INFORMATION BELOW TO BE COMPLETED: BY PURCHASER BY MANUFACTURER BY MANUFACTURER OR PURCHASER

6

7 PRESSURE VESSEL DESIGN CODE REFERENCES.

8 THESE REFERENCES MUST BE LISTED BY THE MANUFACTURER

9 PRESSURE VESSEL DESIGN STANDARD USED TO DESIGN PRESSURE CASING(5.3.4)

10 CASTING FACTORS USED IN DESIGN( 5.3.2)(TABLE 2)

11 SOURCE OF MATERIAL PROPERTIES

12

13 WELDING AND REPAIRS (5.12.3.1)

14 THESE REFERENCES MUST BE LISTED BY THE PURCHASER. (DEFAULT TO TABLE 10 IF NO PURCHASER PREFERENCE IS STATED)

15 ALTERNATE WELDING CODES AND STANDARDS (5.12.3.1)

16 Welding Requirement (Applicable Code or Standard) Purchaser defined Default per Table 10

17 Welder/operator qualification

18 Welding procedure qualification

19 Non-pressure retaining structural welding such as baseplates or supports

20 Magnetic particle or liquid penetrant examination of the plate edges

21 Postweld heat treatment

22 Postweld heat treatment of casing fabrication welds

23

24 MATERIAL INSPECTION (7.2.2.1)(7.2.1.3)

25 THESE REFERENCES MUST BE LISTED BY THE PURCHASER (DEFAULT TO TABLE 13 IF NO PURCHASER PREFERENCE IS STATED)

26 ALTERNATIVE MATERIAL INSPECTIONS AND ACCEPTANCE CRITERIA (SEE TABLE 13) Vendor shall indicate any alternative codes here

27 Type of inspection Methods For fabrications Castings

28 Radiography

29 Ultrasonic inspection

30 Magnetic particle inspection

31 Liquid penetrant inspection

32

33 1. The Net Positive Suction Head Available (NPSHA) shall exceed the Net Positive Suction Head Required (NPSHR) by at least 2 m (6 ft) throughout the range from minimum

34 continuous stable flow up to and including the rated capacity, and by 0.5 m (2 ft) at 120 % of rated flow.

35 2. Contractor / Vendor to Consider Mechanical Seal (As per API 682) in his scope of supply, Appropriate Seal flushing plan shall be selected for the said service.

36 3 Contractor / Vendor to note that there is no cooling water vailable in the plant. Hence any cooling requirement shall be met by air cooling

37 4 Contractor/ Vendor shall consider instrumentation as may be necessary for the safe and trouble free operation of the pumps. Transmitters are preffered over switches

38 as per Project instrumentation philosophy.

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66






Bhatinda

REMARKS




The drawing, design and details given on this format are the property of WorleyParsons Engineering Pvt. Ltd. They are merely loaned on the borrower’s express agreement

that they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the tender to the borrower for the intended use.

Rev. ITP FOR SUMP PUMP

435-JH0902-00-ME-ITP-0006 C

ITP FOR SUMP PUMP

Page 1 of 5

Sr. No.

Stage Component Characteristics Method of check Quantum of check

Reference documents

Acceptance norms

Record Sub Vendor

Vendor

WP

1. Incoming Material (Castings)

Casing Stuffing Box Impeller Bearing Housing

Surface Quality

Visual

100%

ASME Material specification

ASME Sec-VIII, Div 1, Appendix 7

Inspection report

W

W

- -

2. Incoming Material

Do Dimensions Measurement 100% As per vendors approved drawing

As per vendor approved drawings

Inspection report

W W -


Do Chemical / Physical properties

Review of manufacturers TC

All heats As per relevant material specification

As per relevant material specification

Manufacturers TC

W R R


All castings materials

Heat treatment Review of HT charts



HT chart or TC

W R R

5. Incoming material (Bar stock)

Shaft material Chemical properties / Physical properties

Review of manufacturers TC / Lab check



Manufacturers TC or Lab report

W R R




435-JH0902-00-ME-ITP-0006 C

ITP FOR SUMP PUMP

Page 2 of 5

Sr. No.


Reference documents

Acceptance norms

Record Sub Vendor

Vendor

WP

6. Hard ware items

Gaskets, Fasteners, Gland packings, valves

Suitability Test certificates

Visual review or Test reports or certificates

As per sampling plan

Approved drawings and datasheets & Relevant stds

Approved drawings and datasheets & Relevant stds

Inspection report

W R R

7. Accessories Mechanical seal Leakage test Hydotest Air test Measurement of leakage

Type test As per API 682 API 682 and seal manufacturers drawing

Manufacturers inspection / Test report

W R R

8. Accessories Barrier/Buffer liquid reservoir

1. WPS / PQR/WPQ

2. Leakage check 3. Dimensional

check 4. Materials TC

1. Qualification 2. Hydro test 3. Measurement 4. Review of TC

100% As per approved drawings. ASME Section II / Sec-VIII, div-1 / IX

As per approved drawings. ASME Section II / Sec-VIII, div-1 / IX

As per Manufacturers test record & Inspection record

W W W/R

9. Accessories Barrier/Buffer liquid Coolers

1. WPS /PQR/ WPQ

2. Leakage check 3. Dimensional

check 4. Materials TC

1. Qualification. 2. Hydrotest 3. Measurement 4. Review of TC

100% As per approved drawings. ASMe Section II / Sec-VIII, div-1 / IX


As per Manufacturers test record & Inspection record

W W W/R

10. Accessories Coupling 1. Dimensions 2. Dynamic

balancing

1. Measurement 100% 1. As Per approved drawings

2. ISO 1940& API 610

1. As Per approved drawings

2. ISO 1940& API 610

Manufacturers inspection & test records

W W R

11. In Process Casing Impeller Stuffing Box

Defects open to surface

D.P examination 100% of Machined surfaces

ASTM E 105

ASME Sec VIII Div-1, Appendix -7


- W R

12. In process Butt Weld joint (if Weld defects Radiography On Nozzle ASME Sec V ASME Sec VIII Manufacturers - W R




435-JH0902-00-ME-ITP-0006 C

ITP FOR SUMP PUMP

Page 3 of 5

Sr. No.


Reference documents

Acceptance norms

Record Sub Vendor

Vendor

WP

applicable) to casing joint

Article 2 Div -1 UW 51 inspection & test records

14. In Process Shaft

Internal Defects

Ultrasonic Test

100% 1. ASTM A 388/ Written approved procedure

Approved procedures


- W W/R

15. WPS,PQR,WPQ previous qualifications for overlay

Wear rings Thickness of overlay, Hardness

Visual Hardness Measurement

100% Specifications, WPS,PQR,WPQ

Specifications, WPS,PQR,WPQ

Manufacturers WPS,PQR,WPQ Records

- W R

16. Test before assembly

Rotor Assembly with coupling Half

Dynamic balancing

Measurement Each rotor ISO 1940 ISO 1940 GR.2.5 Manufacturers inspection & test records

- W O

17. Testing Assembled Pump 1. Performance 2. NPSHR 3. Vibration 4. Sound 5. Bearing

temperature rise

6. Mech. Running

Measurement Each pump

API 610 API 610 Manufacturers inspection & test records

- W W

18. Testing Dismantled pump Strip examination Visual check Wear Ring Clearance measurement

Each pump


- W W

19. Testing Unitised Pump, Job Motor, Jack Screws, Base

String test Measurement of sound, temperature rise, Vibrations

Each set Approved GA & API 610

Approved GA & API 610


- W W




435-JH0902-00-ME-ITP-0006 C

ITP FOR SUMP PUMP

Page 4 of 5

Sr. No.


Reference documents

Acceptance norms

Record Sub Vendor

Vendor

WP

plate, instruments

20. Testing Auxiliary piping Leak tightness Hydro test Each set No leakage No Leakage Manufacturers inspection & test records

- W W

21. Testing Base plate Dimensions Measurement Each plate Approved GA drgs.

Approved GA drgs.


- W W

22. Testing Instruments Doc. Review Review Each test report

Approved Datasheet

Approved Datasheet

Manufacturers TC

W W/R R




435-JH0902-00-ME-ITP-0006 C

ITP FOR SUMP PUMP

Page 5 of 5

Legends:

WPS- WELDING PROCEDURE SPECIFICATION

PQR- PROCEDURE QUALIFICATION RECORD

WPQ- WELDER PERFORMANCE QUALIFICATION

W- WITNESS

O- OBSERVED

R- REVIEW

H- HOLD

NOTES:

1. WELD REPAIR IF ANY TO BE DONE AFTER THE APPROVAL OF THE PURCHASER / AUTHORISED REPRESENTATIVE OF PURCHASER AS PER APPLICABLE CODE AND

QUALIFIED WPS AND WELDER.

2. MATERIAL FOR LOW TERMPERATURE SERVICE TO BE IMPACT TESTED AS PER APPLICABLE SPECIFICATION

3. FOR AUSTENITIC STAINLESS STEEL MICRO STRUCTURE AND IGC TESTS TO BE CONDUCTED AS PER APPLICABLE CODE & PURCHASE REQUISITION

4. HARDFACING OF WEARRINGS SHALL BE AS PER APPROVED CROSS SECTIONAL DRAWINGS / DATASHEET.

5. MECHANICAL RUN TEST SHALL BE AS DESCRIBED IN THE SPECIFICATION FOR SUMP PUMPS

6. PUMP DRIVER SHALL BE INSPECTED AT DRIVER MANUFACTURERS SHOP AS PER RELEVANT INSPECTION & TEST PLAN

7. PERFORMANCE TOLERANCES SHALL BE AS PER API 610 10TH

EDITION & SPECIFICATION FOR SUMP PUMPS.

The drawing, design and details given on this format are the property of WorleyParsons Engineering Pvt. Ltd. They are merely loaned on the

borrower’s express agreement that they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written

consent given by the tender to the borrower for the intended use.

EXPERIENCE RECORD PROFORMA NO.

Rev

435-JH0902-10-ME-LST-0014 C

EXPERIENCE RECORD PROFORMA CENTRIFUGAL (VERTICAL SUBMERSIBLE

PUMPS) Page 1 of 6

EXPERIENCE RECORD – CENTRIFUGAL PUMP (VERTICAL)

ITEM : VERTICAL CENTRIFUGAL PUMPS

ITEM NUMBER :

VENDOR :

INSTRUCTIONS TO VENDORS : 1. This proforma duly filled in shall be submitted for each item separately, alongwith the bid.

2. Since the information requested in this proforma will be utilized to assess provenness of offered model, it is in the interest of the

equipment manufacturer to pick up those cases out of total list of references which most closely match with the offered mode. The equipment manufacturer shall also ensure that each & every information asked for is furnished and the same is correct and complete in all respects. Incorrect information furnished in this proforma shall render the bid liable for rejection.

3. While furnishing the materials, where asked for, the equipment manufacturer shall furnish ASTM equivalents also.

4. For the referred installations, the equipment manufacturer shall indicate the name of the person (alongwith his address, telephone no., fax no. / email-id etc.) who may be contacted by the Purchaser/ his representative, if felt necessary.

5. The equipment manufacturer shall also furnish along with the bid his standard reference list for the offered equipment model manufactured and supplied by him.

6. The equipment manufacturer shall clarify the meaning of each letter/ digit used in the model designation below : Description of Model designation system :





Rev

435-JH0902-10-ME-LST-0014 C


PUMPS) Page 2 of 6

INFORMATION ON REFERRED EXISTING INSTALLATIONS SL.

NO. PARAMETER

INFORMATION ON PROPOSED MODEL

Ref – 1 Ref – 2 Ref – 3

REMARKS

1 2 3 4 5 6 7

1 GENERAL

1.1 Cross reference to manufacturer’s Standard Reference list

1.2 Make

1.3 Model Number

1.4 Number of units supplied

1.5 Type of driver (Electric Motor / VSDs)

1.6 Driver rated kW / Speed (rpm)

1.7 Edition of API Std – 610 to which the pump conforms (10th)

1.8 Drive (Fixed Speed / Variable Frequency)

1.9 Shop where pump is designed, manufactured, packaged, tested & supplied with address





Rev

435-JH0902-10-ME-LST-0014 C


PUMPS) Page 3 of 6


NO. PARAMETER


Ref – 1 Ref – 2 Ref – 3

REMARKS

2 OPERATING CONDITIONS

2.1 Fluid handled

2.2 Fluid temperature (Min / Max) °C

2.3 Capacity (m3/hr)

2.4 Maximum Suction pressure (kg/cm2,a)

2.5 Differential Head, Rated (m)

2.6 Differential Pressure, Rated (kg/c m2)

2.7 Minimum Submergence Required (mm)

2.8

Setting depth (mm) (distance between bottom face of the mounting flange and first stage impeller suction eye)

2.9 Efficiency

2.10 BKW, Rated

2.11 Minimum Continuous Stable Flow, (m3/hr)





Rev

435-JH0902-10-ME-LST-0014 C


PUMPS) Page 4 of 6


NO. PARAMETER


Ref – 1 Ref – 2 Ref – 3

REMARKS

2.12 Rated Speed

2.13 MAWP casing (kg/c m2G) @15°C @ pumping temperature

3 CONSTRUCTION

3.1 Type of Pump Discharge (WITH Separate Discharge) : VS4

3.2 Type of line shaft (open / close)

3.3 Line shaft lubrication (pumping medium / separate lubricant)

3.4 Startup prelubrication required (yes / no)

3.5 No. of stages

3.6 Impeller diameter – rated/ Maximum/ Minimum (mm)





Rev

435-JH0902-10-ME-LST-0014 C


PUMPS) Page 5 of 6


NO. PARAMETER


Ref – 1 Ref – 2 Ref – 3

REMARKS

3.7 Whether the proposed model and reference models have identical hydraulic design (for impeller / diffuser / volute)

3.8 Sealing Element ( mechanical seal)

3.9 Type of mechanical seal (Single / Double)

3.10 API Sealing Plan No.

3.11 API Cooling Plan

4 MATERIAL OF CONSTRUCTION

4.1 API – 610 Material Code

4.2 Casing

4.3 Impellers

4.4 Line Shaft

4.5 Column

4.6 Line Shaft bearing





Rev

435-JH0902-10-ME-LST-0014 C


PUMPS) Page 6 of 6


NO. PARAMETER


Ref – 1 Ref – 2 Ref – 3

REMARKS

5 OTHER INFORMATION ON INSTALLATIONS

5.1 Date of supply of entire unit

5.2 Date of commissioning of entire unit

5.3 No. of operating hours completed as on the date of issue of material requisition

5.4 Major problems encountered

5.5 Purchaser’s Name and Address

Name (Company / Organization )

Name of Contract Person

Address

Telephone No.

Fax No.

Email-id





Rev

435-JH0902-10-ME-LST-007 C

EXPERIENCE RECORD PROFORMA MOTORS/VSD’S

Page 1 of 6

EXPERIENCE RECORD – MOTOR / VSDs

ITEM :

ITEM NUMBER :

VENDOR :

INSTRUCTIONS TO VENDORS : 1. This proforma duly filled in shall be submitted for each item separately, alongwith the bid.

2. Since the information requested in this proforma will be utilized to assess provenness of offered model, it is in the interest of the

equipment manufacturer to pick up those cases out of total list of references which most closely match with the offered mode. The equipment manufacturer shall also ensure that each & every information asked for is furnished and the same is correct and complete in all respects. Incorrect information furnished in this proforma shall render the bid liable for rejection.

3. While furnishing the materials, where asked for, the equipment manufacturer shall furnish ASTM equivalents also.

4. For the referred installations, the equipment manufacturer shall indicate the name of the person (alongwith his address, telephone no., fax no. / email-id etc.) who may be contacted by the Purchaser/ his representative, if felt necessary.

5. The equipment manufacturer shall also furnish along with the bid his standard reference list for the offered equipment model manufactured and supplied by him.

6. For pumps with VSD drives, Vendors are cautioned to cite only those pump references where VSDs have been used.

7. The equipment manufacturer shall clarify the meaning of each letter/ digit used in the model designation below : Description of Model designation system :





Rev

435-JH0902-10-ME-LST-007 C


Page 2 of 6


NO. PARAMETER


Ref – 1 Ref – 2 Ref – 3

REMARKS

1 2 3 4 5 6 7

For Electric Motors

1 GENERAL (For design, manufacture, testing and supply of motor)


1.2 Make

1.3 Model Number

1.4 Enclosure Type (Whether Type-n/ Type Ex(e)/ Type Ex(d))

1.5 Rated Kw of motors / No. of poles

1.6 Rated voltage of motor

1.7 Whether Fixed speed/ Variable speed drive

1.8 Speed variation range (through VSDs)

1.9 Model/ Type of driving/ non drive end bearings





Rev

435-JH0902-10-ME-LST-007 C


Page 3 of 6


NO. PARAMETER


Ref – 1 Ref – 2 Ref – 3

REMARKS

1.10 Shop where motor is designed, manufactured, packaged, tested & supplied with address


2.1 Date of supply

2.2 Date of commissioning






Address

Telephone No.

Fax No.





Rev

435-JH0902-10-ME-LST-007 C


Page 4 of 6


NO. PARAMETER


Ref – 1 Ref – 2 Ref – 3

REMARKS

Email-id





Rev

435-JH0902-10-ME-LST-007 C


Page 5 of 6

For Variable Speed Drive Panel

1 GENERAL (For design, manufacture, testing and supply of Variable speed drive (VSD) panels)


1.2 Make

1.3 Model Number

1.4 Power rating

1.5 Voltage rating

1.6 Speed variation range

1.7 Shop where variable speed drive panel is designed, manufactured, packaged, tested & supplied with address

1.8

Experience record for carrying out harmonic analysis (for both harmonic currents & voltages) and calculations of harmonics injected into the AC system

1.9 Experience record for design, engineering and supply of requisite harmonic filters to reduce harmonics within limits recommended in IEC


2.1 Date of supply





Rev

435-JH0902-10-ME-LST-007 C


Page 6 of 6

2.2 Date of commissioning






Address

Telephone No.

Fax No.

Email-id


Page 1 of 31



SPECIFICATION FOR EOT CRANE

435-JH0902-10-ME-SPC-008

16-July-2009






Page 2 of 31

SYNOPSIS

Disclaimer











DATE


Subramanyam.S

Sameer Ishwad

Jeremy Wallace

29-June-09 N/A

B Issued For Review

Subramanyam.S

Sameer Ishwad

Jeremy Wallace

06-July-09

N/A

C Issued For Tender

Subramanyam.S

Sameer Ishwad

Jeremy Wallace

16-July-09




Page 3 of 31

CONTENTS

1. INTRODUCTION ................................................................................................................4

1.1 Scope of Work ....................................................................................................................4

1.2 Extent of Supply..................................................................................................................6

2.0 CODES & STANDARDS ....................................................................................................8

2.2 Order of Precedence: .........................................................................................................9

3.0 QUALITY ASSURANCE, INSPECTION & TESTING.......................................................17

4.0 SURFACE PREPARATION AND FINISH ........................................................................19

5.0 NAMEPLATE DETAILS ....................................................................................................20

6.0 PACKAGING, PRESERVATION AND PREPARATION FOR SHIPMENT ......................20

7.0 SPARE PARTS AND SPECIAL TOOLS ..........................................................................21

7.1 Spares ..............................................................................................................................21

7.2 Special Tools ....................................................................................................................21

8.0 DOCUMENTATION ..........................................................................................................21

8.1 Tender Documentation .....................................................................................................21

8.2 Post Order Documentation ...............................................................................................22

9.0 PERFORMANCE GUARANTEE ......................................................................................23




Page 4 of 31

1. INTRODUCTION

1.1 Scope of Work

The document specifies minimum requirements for the supply of EOT Crane required for HPCL-

GGSRPEP, Project.

This specification along with the relevant Codes & standards describes the minimum requirements for

design, manufacture, testing, supply, supervision of erection and commissioning for EOT Crane. It is

not the intent to completely specify all details of design and construction; nevertheless, the equipment

shall conform to high standards of engineering, design and workmanship in all respects.

The Contractor/ Vendor shall make all possible efforts to comply strictly to the requirements of this

Specifications and other relevant Codes & Standards. In case, any deviations are considered

essential by the Contactor/ Vendor after making all possible efforts, these shall be separately listed in

the Contractor’s /Vendor’s offer under ‘LIST OF DEVIATIONS/ EXCEPTIONS TO THE TENDER

Docs. for the purchaser’s considerations. In the event, of any deviation not listed under the ‘List of

deviations / exceptions to the tender’, even though it is appearing in other part of the offer, shall not

be considered applicable. Deviations accepted by the purchaser are the only exceptions acceptable.

Hence all the requirements shall be binding on the Contractor /Vendor without any cost and schedule

implications to the purchaser.

The Contractor / Vendor shall be responsible for the co-ordination of all Sub-Suppliers and for the

overall guarantee of furnished equipment. It is the specific responsibility of the Supplier to invoke all

applicable referenced specifications to each Sub-Supplier Purchase Order.

The offered equipment shall be sourced from a regular and established manufacturer having requisite

design, manufacturing and testing facilities. The offered model shall be from the regular

manufacturing range of the supplier and the design shall have had a minimum of two years

successful field operation with the same model having the same design and materials of construction.

Relevant information of the offered equipment like catalogues; references, user’s certificates etc. shall

be furnished along with the offer.




Page 5 of 31

The type of handling facilities provided for various buildings/areas are listed in table below

Sr.No. Building / Area Type of Handling Facilities Number of

Crane

1 RamanMandi Mainline Pump

House

EOT Crane (Double Girder) 1

2 RamanMandi Booster Pump

House

EOT Crane (Double Girder) 1

For EOT cranes:

• Load capacity (SWL) in Ton : 20 tonnes (Mainline Pumps) / 10 tonnes (Booster Pumps

• Span in m.: 16 m (Mainline Pumps) / 12 m (Booster Pumps)

• Lifting height in m. : (6.5m from FFL for Mainline Pumps) / (6m above the ground for Booster

pumps)

Description:

• Lifting height: Distance between hook in upper position and lower position.

• Load capacity (SWL): Safe working load; required maximum capacity of crane and hoist.

The equipment shall be complete including all ancillary items required to meet the design and

environmental conditions as stated herein. Any additional part, equipment, material, etc.,

which are not specifically mentioned in this specification, but are required to make the

supplied equipment/item complete in all respect in accordance with the intent of this

specification, statutory requirements, applicable codes/standards, good engineering

practices, and for safe and trouble-free operation, shall be deemed to be covered under the

scope of this specification.

If national and/or local regulations exist in which some of the requirements may be more stringent

than in this specification, the Contractor /Vendor shall determine by careful scrutiny which of the

requirements are the more stringent and which combination of requirements will be acceptable as

regards safety, environmental, economic and legal aspects, in all cases the Contractor /Vendor shall

inform the Purchaser of any deviation from the requirements of this specification which is considered

to be necessary in order to comply with national and/or local regulations. The Purchaser may then

decide to negotiate with the authorities concerned with the object of obtaining agreement to follow this

specification as closely as possible.




Page 6 of 31

1.2 Extent of Supply

The Contractor /Vendor shall furnish all components and ancillary equipment necessary to make the



A) EOT Cranes

Sheet metal casing to protect accessible mechanical parts

Crane and hoist control (joystick type radio remote control pendant type )

Crane long travel rail, rail sections will be fixed by welding to runway beams

Resilient bumpers and rubber buffer where necessary

Inhibition of starting in high speed

Inhibition in reverse at high speed (by additional timers)

Chain guides and rope guides

Hook with safety latch

End stops

Anti-derailment devices

Lubricators

Lube oil and grease supply for the first filling

Fitting and bolts

Flameproof (Exd) Electrical motors and instrumentation necessary for operation

Hoist & Crane Controls

Any other necessary parts/ items required for crane operation

B) General

Metal surface coating and painting in accordance with Project Specification: 0435-JH0902-00-PE-

SPC-003

Special tools for maintenance/ erection and installation (as applicable)

Start-up and commissioning spare parts

Name plate




Page 7 of 31

Supervision of Erection & Commissioning (including supervision of full performance tests) at site.

Inspection and Testing, including load tests at shop along with testing required for Controls &

Electrical equipment.

Packing for transportation to Job sites

Necessary certification

Documentation for approval.




Page 8 of 31

2.0 CODES & STANDARDS

2.1 The Following codes & Standards shall be followed :


IS : 807 Code of Practice for Design, Manufacturing, Erection and testing

(Structural Portion) of cranes & hoists.

IS : 816 Code of Practice for use of Metal Arc Welding for General Construction

in Mild Steel.

IS:1030 Specification for Carbon Steel Castings for General Engineering

Purposes.

IS:1181 Qualifying tests for Metal Arc Welders (Engaged in welding structures

other than pipes

IS: 1570 Schedules for Wrought Steels (Part II- Carbon steel

IS : 1823 Code of Practise for Oxy-acetylene welding for structural work in Mild

Steel

IS : 2048 Parallel Keys & Key ways

IS:2062 Steel for general purposes

IS: 2266 Steel wire ropes for general engineering purposes

IS:3177 Code of Practice for Electric Overhead travelling cranes and Gantry

Cranes other than steel works Cranes

IS:3443 Specification for Crane Rail Sections

IS:3681 General Plan for Spur & Helical Gears

IS:3815 Point Hook with shanks for General Engineering Purpose

IS: 4460 Method of Rating of Machine Cut Spur & Helical Gears

IS: 5749 Forged Ramshorn hooks




Page 9 of 31


IS:8610 Point Hooks with Shank Capacity upto 25 tonnes Trapezoidal section

IS 5572 Classification of Hazardous areas having Flammable gases and

Vapours for Electrical installation.

IEC 60034 Rotating Electrical Machines

ISO 9001 Quality Management Systems – Requirements (2001 Ed.)

EN 10204 / ISO 10474 Type of Inspection Documents (2004Ed.)

Other International standards may be acceptable subject to their being equivalent or superior with

prior approval of purchaser.

All codes & Standards mentioned above and all other relevant codes and standards shall be of latest

issue only.

For Provisions not covered by the above codes & Standards, applicable engineering practices and

norms shall govern.

2.2 Order of Precedence:

The precedence for application of Project Documents, Codes, Standards, Design Engineering

Practices and regulatory requirements shall be as follows:

• Data Sheets (attached as an Annexure to this specification)





• Referenced Codes and Standards




Page 10 of 31

2.3 Design Requirements

2.3.1 General

• The equipment shall meet the type, duty class, required load lifts and load lift height, long/cross

travel requirements as specified in the specifications and/or drawing.

• Each component shall be located in such a manner as to be easy to operate and maintain.

• The Contractor /Vendor shall be fully responsible for the supply, selection and quality of all

materials inclusive of all consumables, welding, testing, protection devices, machinery, tools,

labour and all other necessary materials and services required to complete the supply of

equipment whether or not they are specified in this Specification and datasheet

• The Contractor /Vendor shall be fully responsible for the coordination with all his Sub

Contractor /Vendors for materials and services provided by them. However, Contractor

/Vendor shall be solely responsible to Purchaser for compliance with the specified

requirements. Contractor /Vendor shall submit a list and experience summary of all his Sub

Contractor /Vendors.

• Should the Contractor /Vendor come across any discrepancy, deficiency, or lack of clarity in

any part of this specification or attached documents, he shall notify the same to the Purchaser,

along with his offer, with proposed alternative or additional item and prices for each category

thus included. Any items so identified after Purchase Order award will not constitute a change

and will not be the cause for cost or schedule alteration.

• All equipment within the package shall be suitable for installation for outdoor, undershed.

• Equipment Data Sheet shall be provided by Contractor / Vendor and should be submitted along

with the bid.

2.4 Design Life, Availability and Reliability


Contractor /Vendor. Unless otherwise stated, the package design life shall be 35 years, with an


The Contractor /Vendor shall identify any aspects of its standard components or packages that do not

meet the requirement of this specification, the same shall be listed in a separate section under

Exceptions & Deviations to tender specifications.” Exceptions & Deviations listed elsewhere shall not

be considered and deemed to be accepted by the vendor.




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2.5 Hazardous Area Classification

The hazardous area rating of the equipment shall be specified in the datasheet (Annexure-1 of

this specification).

Building / Area Hazardous Area Classified

RamanMandi Mainline Pump House Ex’d’, Class 1, Zone 2, IIB, T3

RamanMandi Booster Pump House Ex’d’, Class 1, Zone 2, IIB, T3


All load carrying structural girders and main hook shall have material certification in compliance with

BS EN 10204 type 3.1 and include original mill certificates or certified copies. Components shall be

fully traceable back to the certificate.




Page 12 of 31

2.7 TECHNICAL REQUIREMENTS

2.7.1 Mechanical Requirement

2.7.1.1 EOT Crane

General

Overhead travelling bridge cranes shall be designed, manufactured, inspected, and tested

in accordance with this specification, applicable data sheets, and relevant codes &

Standards.

All parts of the individual crane installation shall be designed to be suitable for installation in

outdoor undershed environment as specified on the data sheet. Crane component material

selection and coating for components shall be suitable for site condition, as per the Site &

Utility data.

The long travel rails for all overhead travelling bridge cranes shall be provided by Contractor

/Vendor. These will be welded on the girder. The runway structure (Crane Girder) on which

the long travel rail rest will be part of the building steel works package and will be provided

by Purchaser.

Installation and alignment of long travelling rails will be carried out by the Composite works

contractor under the supervision of the Crane Contractor /Vendor.

All EOT cranes shall be top running double-girder cranes as specified in data sheets with

the crane crab / trolley running on the top of the crane girders.

The design of the crane structure shall be such that no welding is required in the field.

The type of the drives and controls of cranes and hoists shall be as per this specifications

and relevant IS codes.

All lifting equipment shall be clearly stamped and labelled for the Safe Working Load (SWL)

in tonnes.

The crane design and construction shall meet tolerances as per IS codes; particularly for:

• Crane rail joints, wheel running and guidance surfaces

• Tolerance on span

• Crane rail straightness




Page 13 of 31

• Misalignment of crane running surface in vertical plane

Crane Bridges

The crane bridges shall consist of two fabricated box girders and two fabricated box section

type end carriages. Each girder end shall have end carriage bolted to it.

All girders shall be designed to resist both vertical and horizontal stresses.

The maximum deflection of crane girder at test load shall not exceed 1 / 600 of span.

The cranes shall be fitted with facilities for safe and easy access for inspection and

maintenance. Double girder cranes shall have a full-length walkway along one girder so that

all parts are easily accessible. Access to the crane will be through a walkway that forms part

of the building or directly by a caged ladder and provided by the Contractor. Access to the

crane platform will be through a ladder secured with a gate (positive security).

End Carriages

The overhead bridge cranes shall consist of two independent drive units and four long travel

wheels, two of which will be driven. The wheels shall be double flanged with crane rated

hardness suitable for specified maximum wheel loading. The travel wheels shall be fitted

with lifetime lubricated anti-friction bearings.

The end carriages shall be of the welded box section design fabricated from structural steel

and shall be equipped with rigidly mounted high impact resistant bumpers. The construction

of end carriages shall be stable enough to keep the end carriages in alignment to the

runway.

End carriages shall be mounted to the crane girders by high-tensile bolts.

Each end carriage of electrically driven crane shall have one driven travel wheel, so that the

crane is travelling on four wheels with a drive on both crane runways. Each driven wheel

shall be provided with independent electric motor driver. The crane drives shall be low-

maintenance units with gear motor directly driving the travel wheels. The motors shall be

equipped with integrated sliding rotor brakes. Limit switches with all necessary strikers shall

be provided to allow the crane to travel up to the bumper and stop from 80% speed after

reducing from nominal speed without permanently deforming the end carriage or bridge

structures.

The crane long travelling brakes shall be to Contractor /Vendor standards (electro-

mechanical disc type fail-safe circuit brakes are recommended). Brake linings shall be self-




Page 14 of 31

cleaning for long life and reliable operation. Brake coils shall be epoxy impregnated and

bonded to a cast iron body for long life in the roughest environment.

The cranes shall be fitted with a proper safety device to prevent de-railment in the case of

wheel breakage.

The following safety features shall be provided for the cranes:

• Dead man switch

• Fail safe

• Trolley stop

• Rail sweep

• Bridge bumpers

• Travel limit switch

Trolleys and Hoists

The trolley of double girder cranes shall be designed as top running electric driven four-

wheel crab.

The crab assemblies shall be of rigid steel construction.

Travel wheel assembly shall be capable of being removed as a complete assembly with

wheel, axle, bearings and bearing cartridges without disassembly.

Buffers shall be provided at the faces of the crabs.

The trolley brakes should be of electro-mechanical disc type based on the fail-safe circuit

principle. Brake linings shall be self-cleaning for long life and reliable operation. Brake coils

shall be epoxy impregnated and bonded to a cast iron body for long life in the roughest

environment.

The hoist of the electrical cranes shall be electric rope hoist type with sliding rotor self-

braking motor, which safely holds the load even in case of power failure. Limit switches shall

be provided to prevent load hook over travel in lifting and lowering directions. The hoist

make shall be selected from Purchaser’s approved Contractor /Vendor list.

Contractor /Vendor shall incorporate a feature to lower the load in case of power failure.




Page 15 of 31

The hoist brakes shall be magnetic drum brakes, spring set, electrically released, drum type

friction brakes with adequate torque to stop and hold over 125% of the hoist design load.

Additional independent mechanical load brake shall be provided on the hoist drum.

Electrically driven hoists and crabs shall be equipped with squirrel cage motors. An inching

control shall be provided on electrically driven hoists and trolleys.

To prevent over hoisting of the crane, the hook-lifting unit shall be fitted with an over

hoisting-protecting device.

Cranes shall be provided with Ramshorn type hook and shall be provided with ball thrust

bearings for free swiveling. Suitable material shall be offered.

Crane and Hoist Control

Electrical overhead cranes, electrical hoists shall be controlled from the operating floor level

by joystick type radio remote control pendant push button station. When operator cabin is

not specified in data sheet then crane shall be controlled from ground / operating floor level

by means of suspended pendant type push button control box.

The pendant control box shall be fitted with rocker-type or push-button switches for the

crane functions, with a key-operated switch and a mushroom master switch which, when

struck by hand, disconnects the entire power supply to the equipment. All control buttons

shall be recessed to prevent accidental activation.

The pendant control shall be made of "non breakable" (high impact) antistatic plastic with a

galvanised wire rope suspension system to eliminate any strain to the control cable. The

suspension system shall have provision for height adjustment.

The crane pendant control panel shall be movable separately along the girder, independent

of the actual crab or trolley position. All crane operations shall be executed only as long as

the operator is pressing the relevant push button.

The crane control shall be capable of performing any two of three crane motions

simultaneously.

The inching operation shall be provided for electrical overhead bridge cranes to allow

movement of the hook, trolley or bridge in a series of short, discontinuous increments by

momentary operation of an electrical controller.

A precision speed control shall be provided for all crane and lifting gears.




Page 16 of 31

Stepless speed controls for hoisting and travelling providing smooth starts, fast acceleration,

easy positioning and soft stops shall be provided. All motions shall be smoothly controllable

between zero and maximum speed.

Brakes shall be progressively applied so as not to induce shock to the crane system and

shall be fail-safe in operation. Safe load indication shall be provided.

All controls and associated equipment shall be clearly marked with legible and durable signs

and etched to show the functions.

Electrical Equipment / Controls :

Cranes in pump house shall be suitable for outdoor use under shelter.

All electrical equipment shall comply with requirements as indicated in the “Specification for

Low Voltage Induction Motors” Doc. No. 0435-JH-0902-00-EL-SPC-0002, Electric motors

and other electrical items shall be of Purchasers approved make (as per approved

Contractor /Vendor list) for standardization.

Single point power supply shall be available as 415V, 50Hz, 3ph, 4 wires (one feeder). If

any other power is required, Contractor /Vendor shall derive it from this feeder. The

Contractor’s scope limit will be up to cable termination to the main switch furnished by the

crane Contractor /Vendor.

Purchaser will provide Earthing at two points inside Mainline Pump house & Booster Pump

house. Contractor / Vendor shall form an earthing grid for all his equipments and connect it

to Purchaser’s earth grid at two points.

The electrical terminal boxes, junction boxes, pendant control boxes, Electric Motors etc.

shall be with Ingress Protection level of IP-65. and shall be Flameproof Ex’d’ type.

The Control Panel provided by the Contractor / Vendor shall compose of necessary starters,

push buttons and all associated auxiliaries including Flat cable festoon system , cable etc.

All motors starters, control panel, bus bar system, flat cable festoon system and cables etc

shall be supplied by the Vendor/ Contractor for Cranes.

Contractor /Vendor shall provide the details of Power requirements. Considering max.

Possible simultaneous operation of the crane.




Page 17 of 31

3.0 QUALITY ASSURANCE, INSPECTION & TESTING

Inspection, testing and certification of electric overhead traveling cranes shall be in

accordance with the applied codes, and as further defined below. The inspection and test

plan shall be submitted for Purchaser approval. The crane installation completeness

certificate shall include verification of the tolerances meeting relevant IS codes.

All load carrying structural girders and main hook shall be supplied with material certificates

according to EN 10204 "Type 3.1". For other material "Type 2.1" certificate should be

provided.

Material selected for lifting hooks, hook blocks, hoist drums etc. shall be supplied with

material certificates according to EN 10204 Type 2.2.

All welds shall be subjected to 100% visual examination and according to the requirements

of the applied codes and as per Manufacturer's approved Quality Control and Inspection

Plan.

Each crane shall be fully assembled in the factory and subjected to load tests with test loads

125% of SWL (within the allowable deflection of girders) . A test-run covering all functions of

the crane shall also be carried-out before shipment.

The inspection and tests of equipment shall be in accordance with relevant quality

procedure and International Standards. The Contractor /Vendor shall provide type test

certificate and routine test results of all equipment. After final assembly and installation, the

Contractor /Vendor shall undertake necessary inspection and tests to satisfy the

requirements of quality procedure and international standards. The inspection and test plan

shall be submitted to the Purchaser for approval.

3.1 Test at Workshop

All testing shall be carried out at the manufacturing facility. The workshop tests shall include

visual examination, dimensional control, load testing with test load, checking of safety

devices, checking/ verification of crane girder deflection (locating trolley in central position),

performance test of hoists, electrical functional test and review of Contractor /Vendor data

book including all Q/C Test Certificates.

The testing shall be carried out in accordance with relevant IS codes & Standards and this

specification




Page 18 of 31

NDE: - To be per IS Codes. All load bearing fillet welds shall be checked at root runs and

finished welds by 100% MP or DP. Lifting lug shall be designed for 150% of their design

load and with 100% NDE

3.2 Test at Site

On completion of material handling equipment erection the following site tests / performance

tests shall be performed as a minimum requirement:

• Testing without load

• Operation of drive machinery (electrically operated type)

• Working range (clearances, lifting height, etc.)

• Testing with test load, 125% of the SWL load

• Operation testing;

o Correct operation of switches, contactors, power collector, festoons,

indicators, alarm and protection devices etc.

• Brake testing:

o Electrically operated type: during lowering the test load shall be stopped and

shall be reliably held both on nominal operation of the control unit and on

emergency stop device;

• Test with SWL load (Test load will be arranged by Contractor)

o Operation of all gears/wheels;

o Testing of safety equipment;

o Functional operations and tests of all drive units at nominal speed (electrically

operated type) and control devices;

o Inch positioning test where creep units are installed;

• Inspection and tests of electrical items, as a minimum, shall include :

o Verification of completeness of the data on the labels and required degree of

protection of enclosure (including degree of protection with regards to safety).

o Visual examination.




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� Marking of components and terminals and caution / danger / instruction

plates, as applicable.

� Verification of proper mounting of components,

� Interchange ability of similar electrical equipment and components

� Correct wiring of main and auxiliary circuits,

� Suitability of clamping, earthing and terminating arrangement,

� Mechanical operation including correct operation of switches, contactors,

power collectors, festoons etc.

� Correct operation of indications, alarms and protection,

� Insulation tests,

� Tests of each continuity

� Functional tests

� Performance tests for one lot of equipment shall be carried out.

Note: Braking test report and other Test certificates shall be provided for performed tests.

4.0 SURFACE PREPARATION AND FINISH

All exposed steelwork and fabricated items and piping shall be prepared and painted in

accordance with specification Painting and Coating 0435-JH0902-00-PE-SPC-003. Where

operating conditions are not suitable for the specified system, Contractor /Vendor shall

specify a suitable alternative.

The colour of finish coat shall be Golden Yellow unless otherwise specified

All Sub Contractor /Vendor supplied components such as instrumentation, junction boxes

and like equipment shall be protected by the Sub Contractor /Vendors standard protective

coating. Contractor /Vendor shall provide details of the Sub Contractor /Vendor’s protective

coatings with his offer.




Page 20 of 31

5.0 NAMEPLATE DETAILS

All equipments shall be supplied with Tag plates.

Each Crane shall have an easily visible SWL stamped and labelled on crane girder.

All major crane items shall be identified by corrosion resistant tag plates. Stainless steel 316

shall be used. A minimum of 6 mm text and numbering height shall be clearly engraved (not

etched) and paint filled on tag plates. Tag plates shall be secured using stainless steel

screws, stainless steel wire or stainless steel chain.

Each assembly shall be fitted with a stainless steel nameplate providing, as a minimum, the

following information:

• Material handling equipment tag number

• P.O. Number

• Shop order number

• Manufacturer's name

• Manufacture serial number

• Year of manufacture

• Important design parameters crane classification with state of loading / class

of utilization (of each mechanism).

6.0 PACKAGING, PRESERVATION AND PREPARATION FOR

SHIPMENT

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. All assemblies shall be properly

match marked for site erection.

Attachments, spare parts of the equipment and small items shall be packed separately in

wooden boxes. Each item shall be appropriately tagged with identification of main

equipment, item denomination and reference number of the respective assembly drawing.




Page 21 of 31

Detailed Packing list in water proof envelope shall be inserted in the package together with

equipment.

Packaging shall be unless otherwise stated suitable for prolong storage at site to prevent

undue corrosion and damage before erection and commissioning of the crane.

7.0 SPARE PARTS AND SPECIAL TOOLS

7.1 Spares

Contractor /Vendor shall recommend & consider commissioning spares as may be required

for the said package.

7.2 Special Tools

The Contractor /Vendor shall supply one (1) set of tools required for the erection and/or

maintenance of the package including all ancillary equipment.

The Contractor /Vendor shall identify the special tools required with his offer.

Special tools shall be itemised and list shall be furnished along with the bid..

8.0 DOCUMENTATION

The Contractor /Vendor shall be responsible for providing all documentation / drawing as

following.

8.1 Tender Documentation

Tender documentation shall include the following:

• Contractor /Vendor Document List.




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• Production Schedule.

• Product Technical Literature.

• Technical and Performance Data as requested within this Specification.

• General Arrangement Drawing.

• Preliminary Weight Data.

• Schematics Wiring Diagram.

• Paint Procedures.

• Confirmation of material certification.

• Electrical Power requirement.

The Contractor /Vendor shall separately detail each proposed deviation from the

specification or data sheets, and submit to the Purchaser for approval.

8.2 Post Order Documentation

Purchase order documentation shall include the following for approval as a minimum:

• Contractor /Vendor Documentation List

• Production Schedule

• Inspection and Test Plan

• Contractor /Vendor Datasheets including model numbers and materials

• General Arrangement Drawing/ Assembly Drawing (crane weight and

dimension)

• Electrical Wiring Diagram

• Material Certification

• Test Procedures

• Test Results

• Installation, Operations and Maintenance Manual (per equipment type)




Page 23 of 31

9.0 PERFORMANCE GUARANTEE

The offered material handling equipment shall be guaranteed for satisfactory mechanical

performance for the parameters and conditions stated in datasheets & this Specification.




Page 24 of 31

ANNEXURE – 1 Datasheets for EOT Cranes: EOT CRANES: Unless otherwise stated the following hoisting and travel speeds shall be Used: - Hoisting : 2 m/min - Cross travel : 10 m/min - Long travel : 20 m/min




Page 25 of 31

1.0 PURCHASER’S REQUIREMENTS

1.1 Location : RamanMandi Pumping Station

1.2 Quantity : 1 per pump house

1.3 Main/Aux. Hoist Capacity, Metric Tons : 10 tonnes(Booster Pumps) 20 tonnes (Mainline pumps)

1.4 Span, m : 12 m (For Booster) & 16 m (Mainline Pumps)

1.5 Type of crane (Single girder/ Double girder) : Double Girder

1.6 Class of duty (as per IS 807 & 3177) :

1.7 Height of lift (Main/ Aux. hoist), m :

1.8 Operating speeds (loaded) :

a) Main / Aux. hoist (MH) m/min. : 2m/min

b) Bridge travel (LT), m/min. : 20m/min

c) Trolley travel (CT), m/min. : 10m/min.

d) Creep for Main Hoist, m/min. :

1.9 Acceleration cm./sq.sec. :

a) Cross travel :

b) Long travel (main) :

1.10 Bay length (m) : 70 m (Mainline Pumps) / 55 m(Booster Pumps)

1.11 Location (Indoor / Outdoor) : Outdoor under shed

1.12 Max bridge deflection :

1.13 Type of control (cabin / pendant) : Pendant type

1.14 Area classification : Zone 2, Gas Group IIA, IIB, Temp. cl. T3

1.15 Type of power supply system : Single point, 3 phase AC power supply

1.16 Electricity available : 415 V, 3 phase, 4 wire 50Hz, + 10%

1.17 Gantry (Runway) rail size :




Page 26 of 31

2.0 MANUFACTURER’S SPECIFICATIONS (Bidder to fill up completely for each crane

separately & submit after order). 2.1 Crane Performance Data 2.1.1 Name of the Supplier : 2.1.2 Class of Crane : 2.1.3 Main Hoist Capacity, tonne : 2.1.4 Auxiliary hoist capacity, tonne : 2.1.5 Maximum Bridge travel speed, metre/min. : 2.1.6. Maximum trolley travel speed, metre/min. : 2.1.7. Maximum main hoist speed, metre/min. : 2.1.8 Inching Speed (MH / LT) metre / min. : 2.1.9 Maximum auxiliary hoist speed : 2.1.10 Deflection with trolley positioned for : Maximum deflection : 2.1.11 Maximum lift of main hook in meters : 2.1.12 Maximum lift of auxiliary hook above : 2.1.13 Highest position of main hook above : Operating floor level in meters : 2.1.14 Nearest approach of main hook to runway : rails on each side, m 2.1.15 Nearest approach of auxiliary hook to : runway rails on each side, m 2.1.16 Span (m) : 2.1.17 Class of Duty (as per IS : 807 & 3177) : 2.1.18 Camber provided / amount mm : 2.1.19 Factor of safety of ropes : 2.2 Name of Manufacturers 2.2.1 E.O.T. Crane Unit : 2.2.2 Crane Motors : 2.2.3 Control Equipment : 2.2.4 Runway rail : 2.2.5 Runway and cross conductors : 2.2.6 Main hook : 2.2.7 Auxiliary hook : 2.3 Weight of Equipment (kg) : 2.3.1 Bridge assembly (unladen) : 2.3.2 Trolley assembly (unladen) : 2.3.3 Hoisting assembly : 2.3.4 Runway rail with accessories : 2.3.5 Runway conductors with accessories : 2.3.6 Total for equipment : 2.3.7 Each end carriage : 2.3.8 Max. wheel loads :

a) With impact : b) Without impact :




Page 27 of 31

2.4 Crane Design Data 2.4.1 Crane Bridge

i. Girder Particular a) Type of girder construction : b) Size : c) Number : d) Material : e) Weight, each girder, kg :

ii. Platform

a) Type of construction : b) Material : c) Width : d) Length : e) Location : f) Handrail : g) Mattress material :

iii. Rails : trolley bridge

a) Type and size : b) Length : c) Material : d) Buffer frame type : e) Fixing details :

iv. Wheel axles : trolley bridge a) Type : b) Number : c) Material : d) Diameter :

v. Bearings for wheel axles a) Type and make : b) Size : c) Number : d) Material : e) Lubrication : f) Type of dust sealing :

vi. Wheels : trolley bridge

i. Type :

ii. Size :

iii. Number per end carriage :

iv. Hardness No. (BHN) :

v. Material :

vi. Diameter :

vii. Wheel base :




Page 28 of 31

vii. Buffers : trolley bridge a) Type of construction : b) Location : c) Material : d) Number : e) Type of stops to engage the buffers :

viii. Rail Sweep : trolley bridge a) Type of construction : b) Location : c) Material :

ix. End Truck a) Type : b) Size : c) Number : d) Material : e) Weight kg : f) Length :

2.4.2 Operators Cabinet

i. Cab. Particulars a) Type of construction : b) Size : c) Fan type, size and make : d) Illumination :

ii. Operator’s Seat :

a) Type of seat : b) Location :

iii. Warning Gong :

a) Type and make : b) Location :

iv. Ladder from cab to bridge :

a) Fitting :

v. Control Panel : a) Location b) Location of emergency switches :

2.4.3 Pendant Type : Furnish list of Controls / buttons :

2.4.4 Bridge Drive Machinery and Trolley Drive Machinery i. Type of Bridge Drive Unit : ii. Type of Trolley Drive Unit :




Page 29 of 31

iii. Material a) Gear : b) Shafts : c) Other components :

iv. Lubricant Particulars : v. Guards and Enclosures provided as necessary : vi. Bearings :

a) Type and make : b) Size : c) Other components :

2.4.5 Hoisting Mechanism : Main Hoist

i. Materials a) Gear : b) Shaft : c) Drums : d) Sheaves :

ii. Winding Drum Type & Size (dia x length) : iii. Ratio of winding drums (diameter to wire rope) : iv. Bearing :

a) Type : b) Diameter / No. of strands : c) Number of falls : d) Safe capacity tonnes / sq. cm :

2.4.6 Particulars of Hook Block : Main Hoist

a) Type of Hook b) Material of Hook : c) Type and size of bearing at hook support : d) Safety latches provided :

2.4.7 Controls

i. Hoisting : a) Type of control : b) Number of speeds :

ii. Lowering : a) Type of control : b) Number of speeds :

iii. Bridge Travel : iv. Trolley Travel : v. Creep speed :

a) Arrangement during lowering : b) Arrangement during hoisting :

2.4.8 Limit Switch : Long Travel Trolley travel i. Type / Make : ii. Construction : iii. Number : iv. Location : v. Voltage and current rating : vi. Hoist limit switch : a) Over hoist limit switch type / make :




Page 30 of 31

b) Over hoist limit switch construction : c) Over hoist limit switch location : d) Under lowering limit switch type / make : e) Under lowering limit switch construction : f) Under lowering limit switch location : g) Back up limit switch type / make / construction :

2.4.9 Illumination fitting on bridge i. Number : ii. Type : iii. Portable hand lamp with wiring : iv. Supply of transformers and other :

accessories as necessary

2.4.10 i) Runway Rail Type : Material : Size : Manufacturer :

All fittings (including fish plates & bolts) and fixtures ii) Runway Rail End stops :

Type : Number : Material : Construction :

2.4.11 a) Motors : Bridge travel Trolley travel

i. Number : ii. Type : iii. Manufacturer : iv. Voltage, phase, frequency : v. KW : vi. Temp. rise over 50°C ambient : vii. Insulation class : viii. Type of enclosure : ix. Rated speed (rpm) :

b. Hoist Motors : Main Hoist i. Number : ii. Type : iii. Manufacturer : iv. Voltage, phase, frequency : v. KW : vi. Temp, rise over 50°C ambient : vii. Insulation class : viii. Type of enclosure : ix. Degree of protection :

2.4.12 Brakes

i. : Trolley Bridge a) Type and number : b) Make / Size : c) Braking capacity of full load torque : d) Designed distance for complete :

stopping from full speed, mm




Page 31 of 31

ii. Hoist Machinery Brake : Main hoist a) Type, number : b) Make / Size : c) Braking capacity at % of full load :

torque

2.4.13 Gear Boxes Ratio : Type Rating S.F. a) CT : b) LT : c) MH : d) AH :

2.4.14 Load indication sign on Crane Bridge :

2.4.15 Extent and type of Painting on equipment :

Before shipment (as per specs.)

2.4.16 Shop tests conform to requirement of specification :



Raman Mandi- Bahadurgarh and Raman Mandi- Bathinda Multiproduct Pipeline

SPECIFICATION FOR CORROSION INHIBITOR PACKAGE

435-JH0902-10-ME-SPC-0010 27-Aug-09






SYNOPSIS

Disclaimer











DATE


Subramanyam.S

Sameer Ishwad

Jeremy Wallace

06-July-09 N/A

B Issued for Review

Subramanyam.S

Sameer Ishwad

Jeremy Wallace

20-July-09

N/A

C Issued for Tender

Subramanyam.S

Sameer Ishwad

KMN Pillai

27-Aug-09




CONTENTS

1. INTRODUCTION ................................................................................................................5

1.1 Scope of Work...............................................................................................................................5

1.2 Corrosion Inhibitor Package at RamanMandi ...............................................................................6

1.3 Work Included ..............................................................................................................................6

1.3 Design Basis .................................................................................................................................8

1.3.1 Design Life, Availability and Reliability......................................................................................8

1.3.2 Noise Limitation ........................................................................................................................8

1.4 Material Certification .....................................................................................................................8

1.5 Reference Documents ..................................................................................................................9

1.5.1 British Standards (BS) ..............................................................................................................9

1.5.2 American Standard Institute (ANSI) .........................................................................................9

1.5.3 American Society and Mechanical Engineers (ASME) ............................................................9

1.5.4 American Society for Testing and Materials (ASTM) .............................................................10

1.5.5 American Petroleum Institute (API) ........................................................................................10

1.5.6 The Institute of Petroleum (IP) ...............................................................................................11

1.5.7 ISO Standards (ISO) ..............................................................................................................11

1.5.8 Manufacturers Standardisation Society (MSS) ......................................................................11

1.5.9 International Electrotechnical Commission (IEC) ...................................................................11

1.5.10 Petroleum and Explosives Safety Organisation (PESO) ......................................................12

1.5.11 Referenced Standard Specifications.....................................................................................12

1.6 Conflicts, Deviations, and Amendments .....................................................................................12

1.7 Contractor / Vendor Exceptions ..................................................................................................13

2. TECHNICAL REQUIREMENTS ..............................................................................................14

3 DESIGN REQUIREMENTS .....................................................................................................15

4 QUALITY ASSURANCE INSPECTION, & SITE TESTING ......................................................25

4.1 Quality Assurance ......................................................................................................................25




4.2 Factory Inspection and Site Acceptance Testing:.......................................................................25

4.3 Material and Welding Inspection: ...............................................................................................26

4.4 Contractor / Vendor Requirements ............................................................................................27

5 SURFACE PREPARATION AND FINISH .................................................................................27

6 NAMEPLATE DETAILS ............................................................................................................28

7 PACKAGING, PRESERVATION AND PREPARATION FOR SHIPMENT .............................28

8 SPARE PARTS AND SPECIAL TOOLS .................................................................................29

8.1 Spares .........................................................................................................................................29

8.2 Special Tools...............................................................................................................................30

9 DOCUMENTATION ..................................................................................................................30

9.1 Bid Documentation....................................................................................................................30

9.2 Post Order Documentation .......................................................................................................31




5

1. INTRODUCTION

1.1 Scope of Work

This Specification covers the minimum project requirements for the supply of Corrosion

Inhibitor Package suitable for installation on the HPCL-GGSRPEP, Project at Raman

Mandi. There shall be a dedicated Corrosion Inhibitor Package each for RamanMandi to

Bhadurgarh Pipeline & one for RamanMandi to Bathinda Pipeline. The requirements for the

same are as listed and given in this specification.

This specification details the general requirements for the Package and is to be used in

conjunction with the data sheets, drawings and specifications detailed and attached

elsewhere in the bid package.

The Contractor / Vendor shall be responsible for the design, fabrication, assembly, painting,

inspection, erection, testing and commissioning, certification, preparation for shipment and

supply of documentation for the complete package as described in this specification and

attachments in the bid package.

This specification does not dictate the detailed equipment design requirements. It is intended

that this responsibility be retained fully by the Contractor / Vendor so that Contractor’s /

Vendor’s warranty remains fully in force and is not affected by statements herein.

The Corrosion Inhibitor Package shall be complete including all ancillary equipment/items

required to meet the design and environmental conditions as stated herein. Any additional

part, equipment, material, etc., which are not specifically mentioned in this specification, but

are required to make the supplied equipment/item complete in all respect in accordance with

the intent of this specification, statutory requirements, applicable codes/standards, good

engineering practices, and for safe and trouble-free operation, shall be deemed to be covered

under the scope of this specification.

If national and/or local regulations exist in which some of the requirements may be more

stringent than in this specification, the Contractor / Vendor shall determine by careful scrutiny

which of the requirements are the more stringent and which combination of requirements will

be acceptable as regards safety, environmental, economic and legal aspects, in all cases the

contractor / vendor shall inform the purchaser of any deviation from the requirements of this

specification which is considered to be necessary in order to comply with national and/or local




6

regulations. The purchaser may then decide to negotiate with the Authorities concerned with

the object of obtaining agreement to follow this specification as closely as possible.

This specification includes tagging and preparation for shipment of all equipment furnished.

1.2 Corrosion Inhibitor Package at RamanMandi

Item Equipment No. Equipment Title Data Sheet No.

1 ZZ-10-002 Corrosion Inhibitor Package for

RamanMandi to Bhadurgarh Pipeline

435-JH0902-10-ME-DAS-0011

2 ZZ-10-001 Corrosion Inhibitor Package for

RamanMandi to Bathinda Pipeline

435-JH0902-10-ME-DAS-0013

1.3 Work Included

The Contractor / Vendor shall furnish all components and ancillary equipment necessary to make the



• Hydraulically actuated double diaphragm type positive displacement metering pumps

complete with electrical motor and Variable Frequency Drives (For Control of Dosing

Rate)

• Chemical storage tank with access ladder and platforms as required.

• Calibration column

• Strainer

• Pulsation dampener

• Pressure relief valve

• Pressure indicator

• Check valve

• Pressure Transmitter

• Flow transmitter




7

• All necessary instrumentation as shown on P&ID.

• Signals to be carried to PLC (to be provided by Purchaser)

• Local Control Stations for Equipments, with start/stop push buttons And Auto /

Manual Selector Switch.

• All interconnecting pipe work with necessary supports, valves and fittings in SS 316L

• Common skid structure base plate to accommodate the Tank, pump, instrumentation

and connecting piping incorporating integrated skid drip pan.

• Cables, cable gland and cable tray within skid limit

• Earthing lugs

• Supply of power cabling between switchgears, and between package and driven

motors & VFD.

• Power supplies as may be required for the package.

• Name plates for all equipments, instruments, valves, and tanks for the package.

• Foundation / Holding down bolts for the package.

• Inspection of the package at Contractor / vendor / sub vendors shop,

• Complete Erection, Testing and Commissioning of the package.

• Surface preparation and Painting as per Project Painting specifications attached

elsewhere in the bid package.

• First fill of chemicals required for the package.

• First fill of lubricants.

• Packing for Transportation

• Preparation for shipment of the package to site.

• Unloading & storage at site.

• Spares parts for start up & commissioning (with list)

• Spares for 2 years operation and maintenance (if required – optional), however list

with price shall be provided




8

• Documentation for approval.

• Package Performance Guarantees

1.3 Design Basis

1.3.1 Design Life, Availability and Reliability


Contractor / Vendor. Unless otherwise stated, the package design life shall be 35 years, with an


The Contractor / Vendor shall identify any aspects of its standard components or packages that do

not meet this requirement and submit descriptions to the Purchaser for consideration during the

tendering process.

1.3.2 Noise Limitation

Noise levels of all equipment (within the package) under normal operation shall not exceed an eight-

hour equivalent continuous A-weighted sound pressure level, LAeq,8h, of 85 dB(A) at 1 metre in all

directions. Sound level tests shall be performed to verify the same. In case noise test certificate

shows a sound level exceeding 85 dB (A), necessary rectification/modification shall be done at

Contractor’s / Vendor ’s own cost and the equipments shall be re-tested to bring down the sound level

to the specified limit.

Predicted noise levels shall be subject to approval by Purchaser.

The specified noise level should be attained without the use of orifices, mufflers, diffusers and/or

credit for thermal or acoustic insulation where practical.

Noise attenuating enclosure is generally not preferred and shall be avoided. However, if used (subject

to approval of Purchaser) shall be designed to provide full access to the equipment for maintenance

and operation.


Pressure containing parts and shafting shall have material certification in compliance with BS EN

10204 type 3.1 and include original mill certificates or certified copies. Components shall be fully

traceable back to the certificate.

Other parts shall be provided with certification to BS EN 10204 type 2.2.




9

1.5 Reference Documents

The design, fabrication and supply of Corrosion Inhibitor Package shall comply with the applicable

sections of the latest edition of the following codes and standards including their addenda

1.5.1 British Standards (BS)


BS 7244 Specifications for Flame arrestors for General use

1.5.2 American Standard Institute (ANSI)


ANSI B40.1 Gauges - Pressure Indicating Dial Type - Elastic Element

ANSI MC 96.1 Temperature Measurement Thermocouples

1.5.3 American Society and Mechanical Engineers (ASME)


ASME B16.25 Butt welded ends for pipe,valves,flangesand fittings

ASME B16.34 Valves—Flanged, Threaded, and Welding End

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.9 Factory-made Wrought Butt Welding Fittings

ASME B18.2.2 Square and Hex Nuts

ASME B31.3 Process Piping

ASME B46.1 Surface Texture (Surface Roughness, Waviness and Lay)

ASME BPVC Section II Materials (Parts A,B,C,D)

ASME BPVC Section V Non-destructive Examination

ASME BPVC Section VIII Rules for Construction of Pressure Vessels - Division 1

ASME BPVC Section IX Welding and Brazing Qualifications




10

1.5.4 American Society for Testing and Materials (ASTM)


ASTM A194 Standard Specification for Carbon and Alloy Steel Nuts for Bolts for

High Pressure or High Temperature Service, or Both

ASTM A36 Standard Specification for Carbon Structural Steel

AISC American Institute for Steel Construction

AWD D 1.1 American Structural Welding Code

1.5.5 American Petroleum Institute (API)


API 520 Sizing Selection and Installation of Pressure Relieving Devices in

Refineries

API 526 Flanged Steel Pressure Relief valves

API 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas

Industries

API 675 Positive Displacement Pumps- Controlled Volume

API 614 Lubrication, Shaft-sealing and Oil-control Systems and Auxiliaries

API 670 Machinery Protection Systems

API 671 Special Purpose Couplings for Petroleum, Chemical and Gas Industry

Services

API 677 General-Purpose Gear Units for Petroleum, Chemical and Gas

Industry Services

API 682 Pumps—Shaft Sealing Systems for Centrifugal and Rotary Pumps

API 650 Welded Storage Tank

API 12F Specification for Shop weld tank for storage and production liquid.

API RP 505 Recommended Practice for Classification of Locations for Electrical

Installations at Petroleum Facilities as Class I, Zone 0, Zone 1 and

Zone 2




11


API RP 521 Guide for Pressure Relieving & Depressurising systems

1.5.6 The Institute of Petroleum (IP)


IP 205/71 Petroleum Measurement Manual Part V, Automatic Tank Gauging

1.5.7 ISO Standards (ISO)


ISO 9001 Quality Management Systems – Requirements (2001 Ed.)

1.5.8 Manufacturers Standardisation Society (MSS)


MSS SP-55 Quality Standard for Steel Castings for Valves, Flanges and Fittings

and Other Piping Components - Visual Method for Evaluation of

Surface Irregularities

1.5.9 International Electrotechnical Commission (IEC)


IEC 60947-5-1 Specification for The Colour of Indicator Lights, Push Buttons,

Annunciators and Digital Readouts

IEC 60034-1 Rotating Electrical Machines




12

1.5.10 Petroleum and Explosives Safety Organisation (PESO)

1.5.11 Referenced Standard Specifications




435-JH0902-00-EL-SPC-0003 Specification for Variable Frequency Drives

435-JH0902-00-PE-SPC-0001 Piping Material Specifications

435-JH0902-00-PE-SPC-0002 Valve Material Specifications

435-JH0902-00-EL-DAS-0085 Datasheets for Low Voltage Induction Motors

435-JH0902-00-EL-DAS-0086 Datasheets for Low Voltage Variable Frequency Drives

0435-JH0902-00-IN-BOD-001 Basis of Design for Instrumentation

1.6 Conflicts, Deviations, and Amendments

Contractor’s / Vendor’s bid shall clearly state and list exceptions to this specification and all

referenced documents. In the event of any conflict arising between this specification and other

documents listed herein, refer comments to Purchaser for clarification before design or fabrication

commences.

The order of precedence that applies is generally as follows:

• Data Sheets





• Referenced Codes and Standards.




13

1.7 Contractor / Vendor Exceptions

Contractor’s / Vendor’s Bid shall clearly state and list the exceptions/deviations under a separate

section “exceptions/deviations” to Specifications, referenced codes and standards and all documents

referred in this specification. Exceptions mentioned elsewhere in the Bid or implied in the Bid shall be

invalid.




14

2. TECHNICAL REQUIREMENTS

The equipments and all the auxiliaries within the Corrosion Inhibitor Package shall conform to the

minimum requirements mentioned in this specification along with the attached datasheets and

technical requirements furnished elsewhere in the bid package.

All the equipments, piping valves, electrical items, instrumentation and controls shall be properly

mounted completely connected in accordance with the applicable project specifications.

Each component shall be located in such a manner as to be easy to operate and maintain. All

inline/offline instruments and piping valves shall be accessible. The skid layout shall be free from

access obstructions. Layout of piping and cables shall avoid interference and obstructions to any

junction box, instruments or valves.

The design of the individual pieces of equipment forming the packaged unit(s) shall be strictly in

accordance with the mechanical data and process service condition, as noted in this specification and

the data sheets.

The design shall ensure the satisfactory functioning of the complete package, i.e. tanks, chemical

injection pumps, controls and other ancillaries. In cases where the Contractor / Vendor supplies

equipment that he has not manufactured, the Contractor / Vendor shall ensure that the designs of

these are compatible with each other and with his own equipment in all respects. The satisfactory

functioning of the complete package shall form part of the Contractor / Vendor’s guarantee.

The Contractor / Vendor shall be fully responsible for the supply, selection and quality of all materials

inclusive of all consumables, welding, testing, protection devices, machinery, tools, labour and all

other necessary materials and services required to complete the supply of equipment whether or not

they are specified in this Specification and attachments.

The Contractor / Vendor shall be fully responsible for the coordination with all his Sub-Vendors for

materials and services provided by them. However, Contractor / Vendor shall be solely responsible to

Purchaser for compliance with the specified requirements. Contractor / Vendor shall submit to the

purchaser a list of experience for all his sub vendors for the items sub ordered within the package.

Should the Contractor / Vendor come across any discrepancy, deficiency, or lack of clarity in any part

of this specification or attached documents, he shall notify the same to the Purchaser, along with his

offer, with a proposed alternative or additional item and prices for each category thus included. Any

items so identified after Order award will not constitute a change and will not be the cause for cost or

schedule alteration.




15

All equipment within the skid shall be suitable for external outdoor undershed environment, suitable

for the hazardous area classification mentioned in the datasheets.

Contractor / Vendor shall complete all relevant sections of the data sheet, and submit the same with

his bid / offer.

As a minimum, the equipment shall be suitable for service in a Class 1, Zone 2, IIB, T3 hazardous

area as defined by API RP 505.

The Contractor / Vendor shall comply with applicable Indian Federal, State or Local codes,

regulations, ordinances, and rules.

3 DESIGN REQUIREMENTS

The equipment shall be designed to handle chemicals as defined in the relevant datasheets.

Contractor / Vendor shall comply with any requirements or recommendations as stated in the

respective chemical manufacturer’s Material Safety Data Sheets (MSDS).

Contractor / Vendor, shall comply to the requirements furnished below as a minimum, however any

additional item/ equipment / controls, which are not specifically mentioned in this specification

however deemed necessary by the contractor / vendor shall be included in the scope of supply:

Chemical Injection Pump:

a) The chemical injection pumps and accessories shall be designed for 35 years of trouble

free, uninterrupted and safe operation and shall be as per API 675.

b) For Recommended dosing rate please refer Process datasheet 435-JH0902-10-PR-DAS-

0017 & 435-JH0902-10-PR-DAS-0017. Contractor to confirm the dosing rate required for

the pump based on the injection rate required.

c) Each pump shall be capable of 110% of the design capacity.

d) The pump discharge shall be provided with an external relief valve for protection of the

piping against a closed pump discharge.

e) The external relief device shall be in addition to any internal pressure relieving device

which may be supplied as an integral part of the pump.

f) A rupture detection system shall be provided for the detection of the diaphragm failure and

to trip the pump, when either of the diaphragms gets detected as ruptured. Diaphragms

shall be designed in such a way that the stresses developed on the diaphragm during the

deflection are the minimum.




16

g) Contractor / Vendor shall supply fittings/tools for the nitrogen charging of the pulsation

dampeners.

h) All coupling components liable to rub as a result of failure of the flexible elements shall be

of non-sparking materials. Coupling guard shall also be of non-sparking material.

i) All vents and drains shall be terminated with a valve and blind flange. The outlets on valve

vent and drains shall be piped down to the skid.

Chemical Storage :

Corrosion Inhibitor should be stored in a suitably sized tank based on the properties of

inhibitor & dosing rate.The storage tank shall be cylindrical shape with dished end, as may

be necessary for the chemical to be stored in the tank under the required pressure.

If the tank is cylindrical in shape with dished end, it shall meet the following as minimum:

• Design, fabrication, welding, inspection & testing shall be in accordance with ASME Sec

VIII, Div 1.

• It may be installed in vertical or horizontal position.

• Full penetration welds shall be used for all nozzles, manholes etc.

• For proper access & maintenance, adequate platforms and ladders shall be provided if

required.

Following are the recommended Corrosion inhibitor suppliers

Sr.

no.

Suppliers Chemicals *

1. Innospec Ltd DCI-4A

2. Dorf Ketal Chemicals Pvt Ltd Unicor J

3. CIBA Speciality chemicals Ciba ® SARKOSYL ® O

4. Chemtreat India Pvt Ltd Remidol

Note: *Contractor to confirm based on selected Inhibitor. Equivalent or Superior product needs to be

supplied.




17

Interconnecting Piping:

a) All piping shall be designed, fabricated, inspected and test in accordance with ASME

B31.3, this document and other relevant documents attached with the Bid package.

b) Material of construction of all piping, valves shall be as per the Piping Material

specifications & Valve material specifications and The material of tubing and tube fitting (as

applicable for corrosion inhibitor package) shall be SS316L and shall be based on the

projection piping class.

c) The use of asbestos products is prohibited.

d) All piping shall be neatly arranged and shall be terminated at the edge of the skid.

e) Minimum piping / connection size shall be ½” NPT

f) Equipment and valves shall be located to ensure it can be easily accessed, operated and

maintained. Pipe works shall be routed to allow ease of access to valves and

instrumentation.

g) Equipment arrangement shall favour compactness but shall allow ample room for

convenient operation, access and maintenance. The layout shall ensure access is

available without the use of scaffolding or portable ladders. Access routes shall be

provided into the areas of the package for equipment needing inspection, checking or

servicing, of all pumps, valves, instruments etc.

h) All valves and local read-out type instruments shall also be positioned in accessible

locations.

i) All piping systems shall be designed so that the loads and moments applied at the flanges

of equipment shall not exceed the permissible reactions for the equipment as specified by

the manufacturers of the equipment.

j) All piping shall be terminated and anchored at the skid edge with an appropriately rated

flange. Piping connections at the battery limits of package shall be flanged connections.

Piping shall be arranged in such a manner as to avoid tripping or overhead problems.

k) All piping shall be adequately supported for both service & shipment. Thermoplastic pads

shall be installed between all pipes and their supports. Where u-bolts are used, same shall

be of SS 316L.




18

l) Suitably located vents & drains shall be provided for any testing, start-up, operations or

maintenance of the skid. These shall be located on equipment or piping as necessary.

m) As a minimum piping welds shall be subject to 100% DPT and as per clause 4.3 of this

specification , piping shall be hydro tested.

n) Isolation valves are required between the tank and the level instrument and gauges.

Isolation valves are also required between instruments and piping.

Electrical

All Motors & Variable Frequency Drive shall conform to project specifications and data

sheet referred in this specification and in the bid package.

All the motors shall be flameproof Ex(d) type, suitable for Zone 2, Gas group IIA, IIB,

and T3. Type test certificates for explosion protection class from the recognised testing

authority shall be submitted. As per the statutory requirement in India the approval from

the chief controller of explosives (CCOE) for flameproof motors, Ex(d) must be

submitted. This test certificate for flameproof motor, Ex(d) must be tested for having

tested the motor along with Variable Frequency Drive for all the offered type of the

equipment as per the requirement of IEC. Otherwise details of compliance to IEC

requirement for Variable speed flameproof motor shall be submitted. BIS license must

have been possessed by the manufacturer for indigenously manufactured FLP motors;

CCOE Certificates for the Flameproof motors shall be submitted along with the final

MDR / OMM.

Instrumentation:

I) General :

a) All the instrumentation furnished within the package shall meet the requirements

mentioned in the basis of design for Instrumentation for GGSRPEP Project, attached

elsewhere in the bid package. All the instruments furnished within the package shall be

suitable for hazardous area classification of Zone1, Gr. IIA, IIB, and T3. The enclosure

protection shall be suitable minimum IP 65.

b) All materials of pressure housing and all wetted parts shall be compatible with the

process fluid handled. As a minimum, material of construction shall be SS 316L.

c) The cable entry connection to all instrumentations shall be ISO metric (M20).




19

d) Tube fittings shall be of twin-ferrule double compression type. Seamless stainless steel

tubing, fittings and valves shall be in accordance with applicable project specification.

Connection on equipment and piping for instruments and test points shall comply with

piping class specification. All tubes and fittings materials shall be SS 316L as minimum.

The instrument tubing shall be PVC coated (2 mm).

e) All instruments should be readable and easily accessible for maintenance.

f) Transmitters shall have digital communication signal superimposed (HART) on the

standard 4-20 mA DC signal through 600 ohms load.

II) Level Instruments:

a) Storage tank shall be provided with level gauge and level electronic transmitter (for

level shut down low). Both the level instruments shall be mounted on the stand pipe

provided on the tank.

A) Level Gauge:

Level gauges shall be magnetic type with the following features:

• Continuous monitoring of liquid level over measuring length

• Local display/ bar graph style flags in RED and WHITE colours

• Robust, shock proof and completely sealed for safety

• Suitable for high toxic fluids

• Powerful Omni-direction magnet system – guide – free float

• Rotate able display through 360° irrespective of float position

• High pressure capability

• Side or Top mounted options with appropriate flange rating

• SS 316L scale with millimeter marking

• Tank level gauges shall be graduated to indicate the volume of liquid in liters

• Vent and drain connections with isolation valves and caps

• Body material shall be SS 316L as a minimum and rating for level instruments shall

conform to the applicable equipment/ process pipes specification




20

• The protection for the instrument shall be IP65, as a minimum.

B) Level Transmitter:

• Level transmitter shall be external cage side mounted float type

• Transmitter shall have two wire 4-20 mA @24V DC powered from the PLC panel (By

purchaser).

• External level instrument chambers shall be fabricated from seamless process piping.

The chamber shall be self supporting from the primary process connection, without

over stressing the gauge chamber or the vessel nozzles and without the need for

intermediate chamber supports.

• Level transmitter shall be provided with integral digital indicator to read level in

Engineering units

• Level transmitter shall be Intrinsically safe (EEx ‘ia’) certified type

III) Pressure Instruments:

• The pressure gauges shall be provided at upstream and downstream of each pump and

a pressure transmitter shall be provided at the pump common discharge header (for

pressure shut down high).

A) Pressure Gauges

• Pressure gauges shall be 150mm in diameter for general applications.

• Differential Pressure Gauges shall be 150mm in diameter.

• White laminated dials with black numerals shall be standard.

• The dial shall be marked as follows :-

o Manufacturers full name

o Manufacturers model number

o Element material specification and grade

o Other key details, for example NACE MR 01-75

• Casing material shall be 316 Stainless Steel.




21

• For general use gauges shall use a bourdon tube measuring element. The accuracy shall be

0.5% FSD or better. The movement shall be either rotary geared stainless steel or cam and

roller type.

• The element material for process gauges shall be 316 stainless steel as a minimum.

• All gauges shall be full safety pattern fitted with shatterproof safety glass. Gauges below 25

Kg/cm2 range shall have a safety blow-out disc in the back. Gauges for higher than 25

Kg/cm2 service shall have a solid front and blow-out rear.

• Gauges exposed to vibration or process pulsations shall be glycerine filled and shall be fitted

with pulsation dampers to the same material as the element.

• Gauges shall be able to withstand, without zero or calibration shift, over-range pressure of 1.3

x calibrated range as standard.

• Over-range protection such as gauge snubbers or savers shall be provided where the

process pressures may exceed 1.3 x FSD.

• Gauge connection shall be at the bottom (Panel mounted gauges shall have rear process

connections). Standard connections shall be 1/2″NPT male for process gauges.

• Gauges will be supplied with engraved labels stating tag no.

• Gauges for pump service shall have pulsation dampeners where required and gauge savers

in all applications.

B) Pressure Transmitters:

• The pressure transmitter shall be 2-wire, 4-20 mA @ 24 VDC output with ingress protection of

IP65 and shall be intrinsically safe (EEx ‘ia’) certified type. The transmitter shall be provided

with integral digital indicator for pressure (available close to the pump). It shall read in

engineering units for the pressure measurement. The Transmitter shall be powered from PLC

panel (By Purchaser). The accuracy of Pressure Transmitters shall be +/- 0.1% of full scale

reading.

IV) Pressure Relief Valves:

• Pressure relief valve shall be full nozzle, full lift and self seating type and according to API-

RP-520, 521, 526, 527 (with exception to that for low flow items-the dimensions of inlet, outlet

flange and orifice will be smaller than the one specified in API 526 to avoid fluttering).

Body/Bonnet, Nozzle/disc shall be of SS 316L. The spring shall be SS material or Inconel.

• For variable back pressure, balance bellow type valve shall be used with bellow material as

SS 316L. Design/engineering percentage over pressure and blow down shall be considered

to arrive at the selection and calculation.




22

V) Flow Instruments:

• Flow transmitter and indicator shall be provided on pump common discharge.

• The flow transmitter shall be 2-wire, 4-20 mA @ 24 VDC output with ingress protection of

IP65 and shall be intrinsically safe (EEx ‘ia’) certified type. The transmitter shall be provided

with integral digital indicator for flow (available close to the pump). It shall read in engineering

units for the flow measurement. The Transmitter shall be powered from PLC panel (By

Purchaser). The accuracy of flow transmitters shall be +/- 0.1% of full scale reading.

VI) Local Control Stations

The skid shall be provided with a Local Control Stations with the following requirements:

o The panel shall be provided with local Start/Stop push buttons, auto manual

selector switch for each of the chemical injection pumps.

o It shall be suitable for hazardous area of Zone 2, Gas group IIA, IIB, and temp.

Class.T3. The enclosure class shall be IP-65.

o The pumps shall trip on low level in the corrosion inhibitor storage tank.

o The chemical Injection package logic shall be implemented in the PLC panel (By

purchaser).

o Indication lamps shall be provided on the local control stations for pump/motor

running, stopped, tripped, common fault etc.

o The local control stations shall be provided with sunshade. Contractor / Vendor

shall ensure that adequate protection is provided for all the electronic

components mounted inside the panel.

VII) PLC for the Corrosion Inhibitor Package (Provided by the Purchaser)

• All the analogue signals from level transmitter, pressure transmitters etc. shall be wired to the

interface junction box supplied by Contractor / Vendor.

• The multi pair cable from the junction box up to the PLC panel for cable termination shall be

provided Contractor / Vendor. The Corrosion Inhibitor Package Logic shall be implemented in

the PLC Panel. Pumps shall be controlled through VFD for controlling the Dosing into the

main pipeline.




23

VIII) Junction Box on Skid

• All field instrumentation within skid shall be terminated in skid edge mounted Junction Boxes

for further cabling upto PLC. Connections shall be made at terminals in instruments or

junction boxes. Splicing is not acceptable. Junction box terminal strips shall be fabricated of

rail-mounted shoe terminal blocks and associated hardware.

• Instrumentation cables shall be adequately separated from power cables and equipment to

minimize interference. Cables shall be installed in cable trays.

• All junction boxes shall be certified EEx’d’ (Flameproof) as a minimum.

• The junction boxes shall be suitably sized for ease of access, and shall be equipped with

sufficient terminals for termination of cable cores, including all spare cores. An additional 25%

of terminals shall be fitted in excess of the above requirement.

• All cables shall be XLPE/PVC insulated, single galvanized steel wire armour and PVC over

sheathed.

• The terminals in the junction boxes shall be suitably sized for the cable cores,

• Each junction box shall have 20% spare entries for field cables and a spare entry for each

size of multi core cable entering the box. All spare entries shall be fitted with certified sealing

plugs.

• All cable glands shall be certified EEx(d).

Structural Base Plate:

• Corrosion Inhibitor Package Skid shall accommodate the pump, interconnecting piping,

necessary valve, instrumentation and LCS.

• The skid shall be designed and built to ensure that all the equipment along with the

accessories & piping are mounted suitably for convenient operation and maintenance.

• The skid shall be rigid construction that cannot distort during lifting / hoisting and shipment.

Anchor bolts shall be within the Corrosion Inhibitor Package scope of supply.

• The Contractor / Vendor shall provide a common drip pan (with flanged drain outlet

connection) to cover all sources of spillage and extending underneath the entire skid. The drip

pan shall have sufficient strength, thickness to prevent sags, rises and out of level areas that

may cause liquid trapping. The drain from the drip pan shall be terminated at skid edge. The

drip pan shall be sloped towards the flanged drain outlet connection.




24

• All equipment edges shall be within skid structural base plate, no part of equipment or

terminal points shall project beyond the edge of the skid structural base plate.

• Equipment shall be mounted on the skid such that equipment supports bear directly on and

attach to primary structural members of the skid.

• Spreader beam (if required) to facilitate lifting shall be provided by Contractor / Vendor

together with slings and shackles. These lifting devices shall be certified by an approved third

party agency for the required safe working load (SWL).

• Lifting lugs shall be adequately designed and fully welded with 100% NDT and shall be load

tested to minimum 150% of their design load.

• 100% UT & 100% MPI/ DPI will be carried out on parent materials, lifting lugs & lifting aids

material. All welds on lifting lugs & lifting aids shall be subject to a 100% MPI test both before

/ after the load test.




25

4 QUALITY ASSURANCE INSPECTION, & SITE TESTING

4.1 Quality Assurance

The Contractor / Vendor shall demonstrate that he operates a quality system in accordance with

the ISO 9000 series of requirements. The effectiveness of the quality system and the

Contractor’s / Vendor's compliance with it shall be subject to monitoring by Purchaser and in

addition, may be audited following an agreed period of notice.

The Contractor / Vendor shall submit a quality control program for Purchaser review at the time

of offer. The Contractor / Vendor shall provide facilities for and cooperate with Purchaser and

statutory authority inspectors during manufacturing, assembly and testing.

4.2 Factory Inspection and Site Acceptance Testing:

Contractor / Vendor shall submit for review and approval by the Purchaser an Inspection and

Test Plan (ITP) covering all relevant components, completed equipment and systems. The

Extent of witness, review and hold points shall be finalised post award.

Contractor / Vendor shall allow Purchaser access to the fabrication premises for an inspection

prior to order placement.

A detailed test procedure of shop tests shall be submitted at least one (1) month in advance of

any testing and shall be approved by the Purchaser.

The entire unit shall be assembled and tested to functionally check the total system operation

and ensure minimum commissioning and installation time on site. After assembly, Contractor /

Vendor shall perform the following tests:

o Vendor's standard shop tests

o Hydro test of all pressure parts.

o Performance test for all the pumps at pump manufacturer’s shop with job

drivers. The performance test shall include flow repeatability, accuracy, and line

in accordance with API 675.

o Mechanical run test.




26

o Electrical Motor test at manufacturer’s shop.

o Functionality check for VFD at manufacturer’s shop.

o Functional & routine testing of skid and all items / accessories including valves,

cables etc.

o Skid overall dimensions.

o Noise tests.

The complete unit shall be trial assembled and dimensionally checked prior to shipment. This

activity shall be witnessed by the Purchaser and/or his representative.

Site Acceptance Testing :

The Contractor / Vendor shall provide site erection, pre-commissioning and commissioning of

the package. Commissioning shall commence After the completion of the precommissioning

activities (including civil, mechanical, electrical, instrumentation works)

Purchaser's final acceptance of the equipment will be subject to a performance test once the

equipment has been erected, installed and Pre- commissioned. Contractor / Vendor shall

submit to the purchaser a Site acceptance testing procedure after order, SAT shall be

conducted based on the approved Procedure by the purchaser. Such tests shall be held no

later than one (1) year from initial startup.

4.3 Material and Welding Inspection:

Butt welds shall be 10% examined by radiography and pressure retaining fillet welds shall be

100% examined by DP test. Should radiography prove impractical, 100% ultrasonic inspection

shall be permitted with the approval of the Purchaser.

Skid and vessel pad eyes shall require 100% DP test.




27

Pressure retaining parts shall be hydrostatically tested to at least 1.5 times of the design pressure, in

accordance with Section VIII, Division 1 of the ASME Code or ASME B31.3 / 31.4.

Welders/welder operators shall be qualified in accordance with Section IX of the ASME code and

approved by the Purchaser prior to welding on this contract.

Weld procedures shall be qualified in accordance with Section IX of the ASME code and submitted

for approval by the Purchaser before welding can commence

4.4 Contractor / Vendor Requirements

Contractor / Vendor shall provide Purchaser with at least 14 days notice to witness tests run in both

his shop and his Sub-Vendor's shops.

Contractor / Vendor shall provide Purchaser with reasonable access to its and its Sub-Vendor's plant

facilities in order to verify that equipment is manufactured and tested as specified.

Contractor / Vendor shall provide calibration certificates of testing instrumentation for review by the

Purchaser prior to each test.

Contractor / Vendor shall provide weekly reports during procurement and fabrication phases

indicating progress status.

Contractor / Vendor shall provide O&M training for HPCL Operations and Maintenance personnel.

This training shall be provided for the Package supplied including any sub-vendor equipment

included in the package.

5 SURFACE PREPARATION AND FINISH

All exposed steelwork and fabricated items and piping (Other than Stainless Steel) shall be prepared

and painted in accordance with Specification for Painting / Coating Requirements 0435-JH0902-00-

PI-SPC-003. All SS Piping & surfaces shall be pickled & passivated.

All Sub Vendor supplied components such as piping valves, instrumentation, junction boxes and like

equipment shall be protected by the Sub Vendors standard protective coating. Contractor / Vendor

shall provide details of the Sub Vendor’s protective coatings with the bid.




28

6 NAMEPLATE DETAILS

All the Equipment, Tanks, instruments, Speciality items shall be supplied with tag plates.

Tag plates shall be manufactured from 316 stainless steel. Text and numbering shall be clearly

engraved, paint filled and a minimum of 6mm high.

Tag plates for accessories shall be secured using stainless steel screws, stainless steel wire or

stainless steel chain.

All pressure regulators shall have a label identifying operating set pressure.

Each valve and actuator assembly shall be fitted with a stainless steel nameplate providing,

as a minimum, the following information:

• Tag Number

• Manufacturer's Name or Trademark

• Serial Number

• Flange Pressure Rating

• Packing Type

• Maximum Air or Hydraulic supply pressure

7 PACKAGING, PRESERVATION AND PREPARATION FOR

SHIPMENT

The Contractor / Vendor shall prepare the equipment for shipment to RamanMandi site.

Documents, including unloading, unpacking and lifting instructions, a description of the

reassembly steps required for installation and pre-commissioning and start up instructions

shall be included with the package. The number of copies of documents to be provided shall

be as stated in the Bid Package.

Contractor / Vendor shall ensure the equipment is suitably supported and braced for

transport.

Prior to shipment, all instrumentation and other equipment vulnerable to damage shall be

disassembled and boxed separately for shipment.




29

The Contractor / Vendor shall recommend preservation requirements for idle periods of non-

operation up to 1 year protection against rain, moisture, dirt, blasting grit etc.

8 SPARE PARTS AND SPECIAL TOOLS

8.1 Spares

Erection & Commissioning spares

Contractor / Vendor shall provide and include in his scope of supply the recommended spares

parts for the equipments, instruments, valves etc. within his package to cover the

commissioning and start-up for the Corrosion Inhibitor Package.

If however, any additional spare is consumed during erection & commissioning over and

above the included erection & commissioning spares, the same shall be provided by the

Contractor / Vendor at no extra cost to purchaser at the time of erection & commissioning.

Spares for two years Normal operation

Contractor / Vendor shall furnish an itemised list of recommended spares with unit prices for

two years normal & continuous operation of the complete Package (including Mechanical,

Electrical, Instrumentation spares) required.

Equipment manufacturer's recommendations shall be followed by the Contractor / Vendor in

the preparation of recommended spare parts list.

All spare parts furnished by Contractor / Vendor shall be wrapped and packaged to preserve

original as-new condition under normal conditions of storage anticipated in RamanMandi.

The same parts shall be tagged by stainless steel tags and coded so that later identification

as to their intended equipment usage will be facilitated. All items supplied shall be packaged

separately and clearly marked as "Spare Parts" and shipped with the equipment in

accordance with the instructions from Purchaser. Packing lists shall be furnished complete

and in detail so that parts can be handled without uncrating




30

8.2 Special Tools

The Contractor / Vendor shall supply one (1) set of special tools & tackles required for the

erection and/or maintenance of the package including all ancillary equipment.

Special Tools & Tackles means all such tools / tackles those are specific to the erection

and/or maintenance of the supplied equipment/package, and are normally not expected to be

available in a plant workshop, but without which it would be difficult or time-consuming to do

erection and/or maintenance of the supplied equipment/package.

The Contractor / Vendor shall identify the special tools required with Bid. Special tools shall

be itemised and submitted for review. Special tools shall be itemised and submitted for

review.

9 DOCUMENTATION

The Contractor / Vendor shall be responsible for providing all documentation / drawing as

following.

9.1 Bid Documentation

Bid documentation shall include the following:

• Supplier Document List

• Production schedule

• Product technical literature.

• Technical and performance data as requested within this specification.

• General Arrangement Drawing.

• Preliminary weight data

• Schematics wiring diagram.

• Paint procedures.

• Confirmation of Material Certification.




31

• The Contractor / Vendor shall separately detail each proposed deviation from the

specification or data sheets, and submit to the Purchaser for approval.

9.2 Post Order Documentation

Purchase order documentation shall include the following for approval as a minimum:

• Contractor / Vendor documentation list

• Production schedule

• Inspection and test plan

• Control valve sizing calculations (including noise calculations)

• Contractor / Vendor datasheets including model numbers and materials for all the

equipments, Valves, Instruments, Piping specialty items

• Dimensional drawings, including GA drawings for the equipments

• Equipment Layouts

• P&ID for the Package.

• Actuator control system schematics

• Wiring Drawing for the Local Controls Stations.

• Wiring for the PLC Panel (By Purchaser).

• Details of signals to be carried to the PLC panel(By Purchaser)

• Weight data

• Material Certification

• Test Procedures

• Test Results

• Calibration Certificates

• Installation, Operations & Maintenance Manual (Per Equipment Type)




32

Notes:

• MDR & IOM 1 copy shall be submitted for purchaser’s review, after which 3 hard

copies and 1 soft copy shall be submitted to the purchaser.





Rev

435-JH0902-10-ME-LST-0013 C

EXPERIENCE RECORD PROFORMA PACKAGES

Page 1 of 3

Vendor/ Manufacturer’s Experience Record for Fabrication/ Packaging/ Testing of Pump/ Motor/ VSD (as applicable)

Package

ITEM :

ITEM NUMBER :

VENDOR :

(Vendor to clarify the meaning of each letter / digit in the model designation)


NO. PARAMETER


Ref – 1 Ref – 2 Ref – 3

REMARKS

1 2 3 4 5 6 7

1 Size (LxWxH) : Main skid (Pump/ Gear/ Motor/ Instruments, Panels)

2 Weight of main skid

3 No. of support points

4 Pump Data

4.1 Make/ Model





Rev

435-JH0902-10-ME-LST-0013 C


Page 2 of 3


NO. PARAMETER


Ref – 1 Ref – 2 Ref – 3

REMARKS

4.2 Rated Capacity (m3/hr.)

4.3 Suction/ Discharge Pressure (kg/cm2G)

4.4 Differential Head (m)

4.5 Speed (RPM) / Ratted BKW

5 Driver Data

5.1 Type of driver

5.2 Make/ Model

5.3 Driver Rating (kW)/ Speed (RPM)

6 VSD Data

6.1 Type of VSD

6.2 Make/ Model

6.3 Driver Rating (kW)/ Speed Range (RPM)





Rev

435-JH0902-10-ME-LST-0013 C


Page 3 of 3


NO. PARAMETER


Ref – 1 Ref – 2 Ref – 3

REMARKS

7 Control Panel

8 Lube Oil System included (Yes/ No)

9 Engineering for the package done by

10 Project Management by

11

Shop where entire unit is packaged & Tested as per purchaser’s requirements with complete address/ fax & telephone no. and name of the contact person

12 Data of supply & commissioning of unit

13 No. of operating hours completed at specified operating conditions as on bid due date.

14 Name of purchaser with complete address/ fax no./ telephone no. and name of the contact person of the purchaser

15 Location of operating site (complete address/ fax no./ telephone no. and name of contact person)

16 Major problems encountered if any.



Applicable code : API 675

Rev. ITP FOR DOSING PUMP

435-JH0902-00-ME-ITP-0007 C

INSPECTION & TEST PLAN FOR DOSING PUMP

Page 1 of 4

Sr. No.


Reference documents

Acceptance norms

Record Sub Vendor

Vendor

WP

1.a Incoming Material (Castings Plates & Pipes Tubes)

Frame, Cross Head, fluid End Stuffing Box Relief Valve Body

Surface Quality

Visual

100%

ASME Material specification

ASME Sec-VIII, Div 1, Appendix 7

Inspection report

W

W

- -

1.b Incoming Material

Do Dimensions Measurement 100% As per vendors approved drawing

As per vendor approved drawings

Inspection report

W W -

1.c Incoming Material

Do Chemical Properties / Physical properties Hardness

Review of manufacturers TC



Manufacturers TC

W R R

1.d. Incoming Material

All castings materials

Heat treatment Review of HT charts



HT chart or TC

W R R

1.e Incoming material (Bar stock)

Crank Shaft , Connecting & Extn. Rods, Plunger and Gear Blanks

Chemical properties / Physical properties

Review of manufacturers TC / Lab check



Manufacturers TC or Lab report

W R R





435-JH0902-00-ME-ITP-0007 C


Page 2 of 4

Sr. No.


Reference documents

Acceptance norms

Record Sub Vendor

Vendor

WP

1.f Hard ware items

Gaskets, Fasteners, Bearing Gland - Packing

Surface Defects Visual As per sampling plan

Approved drawings / Relevant stds

Approved drawings /Relevant stds

Inspection report

W R R

2.a. Accessories Volume Bottles & Piping l

Fabrication 1) WPS /PQR /WPQ 2) Hydro Test 3) Radiography 4) Dimensional Check 5) Material TC

100% As per approved

drawings. ASME

Section II / Sec-

VIII, div-1 / IX


Manufacturers inspection / Test report

W W W/R

2.b Accessories Coupling 1. Dimensions 2. Dynamic

balancing

1. Measurement 100% 1. As Per approved drawings

2. ISO 1940& API 610

1. As Per approved drawings

2. ISO 1940


W W R

3.a In Process Frame, St. Box Cross Head , Crank Shaft, Connecting Rod, Plunger

Defects open to surface

D.P examination 100% of Machined surfaces

ASTM E 165

ASME Sec VIII Div-1, Appendix -7


- W R

3.b In process Frame Through defects Kerosene Leak Test

100% Oil Sump

Manufacturers Drg

No Leakage / Sweating


- W R

3.c In Process Crank Shaft , Connecting & Extn. Rods , Gear Blanks Plunger, Fluid End & St. Box

Internal Defects

Ultrasonic Test (Pre Machining Stage)

100% ASTM A 388/ Written approved procedure

Approved procedures


- W W/R





435-JH0902-00-ME-ITP-0007 C


Page 3 of 4

Sr. No.


Reference documents

Acceptance norms

Record Sub Vendor

Vendor

WP

4.a Test before assembly

Fluid End. St. Box 1) Inside 2) Jacket Side 3) Volume Bottle 4) Piping

Leak Tightness Hydro test Each set API 675. No leakage Manufacturers inspection & test records

- W W

5.a Testing Assembled Pump 1. Performance 2. NPSHR 3. Vibration 4. Sound 5. Bearing

temperature rise

6. Mech. Running

7. R /V Set. Pr. Function Test

Measurement Each pump


- W W

5.b Testing Dismantled pump Strip examination Visual check of Valve Assembly & Exposed Portion of Plunger

Each pump


- W W

5.c Testing Unitised Pump, Job Driver, Base Frame and Instruments

General Arrangement

Visual & Measurement

Each set Approved GA Drawings

Approved GA Drawings


- W W

5.d Testing Instruments Doc. Review Review Each test report

Approved Datasheet

Approved Datasheet

Manufacturers TC

W W/R R





435-JH0902-00-ME-ITP-0007 C


Page 4 of 4

LEGENDS:




W- WITNESS

O- OBSERVED

R- REVIEW

H- HOLD

NOTES:

1. WELD REPAIR IF ANY TO BE DONE AFTER THE APPROVAL OF THE PURCHASER / AUTHORISED REPRESENTATIVE OF PURCHASER AS PER APPLICABLE CODE AND

QUALIFIED WPS AND WELDER.

2. HARD FACING IF REQUIRED SHALL BE DONE THROUGH QUALIFIED WELDERS USING QUALIFIED WPS./PQR.

3. IF REQUIRED BY PURCHASER FLOW REPEATABILITY AND LINEARITY TESTS SHALL ALSO BE CONDUCTED.



Site & Utility Data

435-JH0902-10-ME-SPC-0007

25 May 2009





GENERAL SITE & UTILITY DATA

Page ii

SYNOPSIS

Disclaimer











DATE

A -

N/A

B Issued for Review

Subramanyam.S

Sameer Ishwad

Anil Kumar

29-Apr-09

N/A

C Issued for Tender

Subramanyam.S

Sameer Ishwad

Jeremy Wallace

16-July-09




Page iii of 8 21 May2009


Ramanmandi to Bahadurgarh Pipeline.



from the upcoming Guru Gobind Singh Refinery at Raman Mandi to HPCL’s existing terminal

in Bahadurgarh. The length of the pipeline is approximately 243 Km. The pipeline is planned

to transfer EURO-III MS,EURO-IV MS,EURO III HSD EURO IV HSD,SKO, Naphtha & ATF







through variable speeds.


One Multi product Pipeline from GGSR Raman Mandi is proposed to be layed to HPCL’s







The project requirement for the Raman Mandi to Bathinda pipeline is to transport 0.929

Million Metric Tones Per Annum (MMTPA) of EURO – III MS, EURO – III HSD and SKO in

the Year 2011-12 (Phase-I) and 1.375 MMTPA of the products in the Year 2021-22 (Phase-II)

Suitable tap off facility shall be provided at Bathinda for extension of the pipeline to Sangrur in

future. The pipeline throughput shall be as follows:




Page iv of 8 21 May2009

Pipeline Section Year / Phase Throughput in Million Metric

Tons per Annum (MMTPA)




2021 – 2022 / Phase - II 0.697


1.375 MMTPA (Phase - II). However, the pump/driver will be designed such that presently it shall

cater to the requirement of Phase-I throughput of Bathinda alone. Space provision shall be made for

additional pumps to be installed at a later date to cater the requirement of Phase – II throughput for

the volumes upto Sangrur. To cater for more than one flowrate and different densities / viscosities

pumps have to run at lower speed through Variable Frequency Drives (VFD).

Table 1. Salient features of the Raman Mandi- Bahadurgarh Pipeline Project

S.No. Feature Details

1 Total Length 250 km long 18’’ Dia

2 Diameter of the pipeline 18”

3 Pump Station 1

4 Line fill 41060 KL

5 Products to be transported Euro III MS, Euro III HSD, Euro IV

MS ,Euro IV HSD, ATF&

, SKO

6 Throughput (MMTPA

2011-12

3.96

2021-22 4.71

7 Location Type

originating Proposed Pumping Station

Raman Mandi

New

Chainage 0.0 Kms.

Latitude 29°-55’-51”

Longitude 74°-57’-22’’




Page v of 8 21 May2009

Elevation 203.53 Mts.MSL

Bahadurgarh Existing

Temperature & Pressure:

Average rainfall maximum shade temperature

Maximum recorded shade temperature

Average annual minimum shade temperature

Minimum recorded shade temperature

Maximum external surface temperature (Direct

exposure to sun)

35 deg. C

41 deg. C

12 deg.C

6 deg.C

45 deg.C

Relative Humidity

Annual average humidity

Absolute maximum humidity

Absolute minimum humidity

Note- The maximum humidity of 90% is

possible in any month throughout the year.

70%

90%

5%

Rainfall

Average annual rainfall

Maximum recorded annual rainfall

Minimum recorded rainfall

350 mm

1250mm

126mm

8 Tap Off Station Raman Mandi No

Existing Receiving Station & delivery to

existing Marketing Terminal at

Bahadurgarh

Yes

Chainage 250 Kms.

Latitude 28°-43’-37’’

Longitude 76°-51’-28’’

Elevation 215.589 Mts. MSL

Features of the Raman Mandi- Bahadurgarh route

9 Canal crossings: Distributaries,

Main/Branch

22

Canals/minors 26




Page vi of 8 21 May2009

10 Forest Length Nil. However, ROU of roads and

canals are protected forests.

11 Drains & Nallahs 03

12 Rail crossings 05( B.G.)

13 River 1

14 Highway / Road crossings

Super Express 1

NH 02

SH 03

MDR /ODR/ other 40

15 Environmentally sensitive areas within project

area

None

16 States Enroute Punjab & Haryana

17 Districts Enroute Bathinda in Punjab; Sirsa, Mansa,

Fatehabad, Jind, Rohtak & Jhajjar

in Haryana

Table 2. Salient features of the Raman Mandi- Bathinda Pipeline Project

S.No. Feature Details

1 Total Length 30 km

2 Diameter of the pipeline 10”

3 Pump Station 1

4 Line fill 1520KL

5 Products to be transported Euro III HSD , Euro IIIMS ,SKO.

, SKO 6 Throughput (MMTPA

2011-12

0.93

2021-22 1.37

7 Location Type :

Originating Proposed Pumping Station &

Storage Terminal at Raman Mandi

New ( Chainage0.0)




Page vii of 8 21 May2009

Proposed Receiving Station& delivery to

existing Marketing Terminal at Bathinda

Existing (Chainage-30.0 Kms.)

Latitude 29°55’51’’

Longitude 74°57’22’’

Elevation 203.53 Mts.MSL

Temperature & Pressure:

Average rainfall maximum shade temperature

Maximum recorded shade temperature

Average annual minimum shade temperature

Minimum recorded shade temperature

Maximum external surface temperature (Direct

exposure to sun)

35 deg. C

41 deg. C

12 deg.C

6 deg.C

45 deg.C

Relative Humidity

Annual average humidity

Absolute maximum humidity

Absolute minimum humidity

Note- The maximum humidity of 90% is

possible in any month throughout the year.

70%

90%

5%

Rainfall

Average annual rainfall

Maximum recorded annual rainfall

Minimum recorded rainfall

350 mm

1250mm

126mm

8 Tap Off Station Raman Mandi No

Bathinda Yes

Latitude 30°09’31’’

Longitude 74°59’04’’

Elevation 206.15 Mts above MSL

Features of the Raman Mandi- Bathinda route

9 Canal crossings 6




Page viii of 8 21 May2009

10 Forest Length Nil. However, ROU of roads and

canals are protected forests.

11 Drains & Nallahs 01

12 Rail crossings 01( B.G.)

13 Highway / Road crossings

NH Nil

SH 01

MDR /ODR/ other Pucca roads 08

14 Environmentally sensitive areas within project None

Table 3. Power Supply Arrangement at Ramanmandi

Station Source Back up DG Set for Emergency Power (KVA)

Ramanmandi 33 KV, 6.6 KV &

415 V

250 KVA AT 415 V

Bathinda 415 V, 3 PH 25 KVA at 415 V

Bhadurgarh 415 V, 3 PH

Sectionalizing

valve station

230 V, 1 PH 25 KVA, 1 PH



MANDATORY SPARE PARTS FOR STATIC EQUIPMENT

0435-JH0902-00-ME-SPL-004 Rev C Page 1 of 3




0435-JH0902-00-ME-SPL-004

25-Aug-09

Sanghi Oxygen Compound

1, Mahal Industrial Estate

Mahakali Caves Road

Andheri (East), Mumbai - 400 093 India

Phone: +91-22-67818000

Fax : +91-22-67818080

www.worleyparsons.com






SYNOPSIS

Disclaimer



between Hindustan Petroleum Corporation Limited (HPCL) and WorleyParsons.

WorleyParsons accepts no liability or responsibility whatsoever for it in respect of any use of or

reliance upon this report by any third party.



PROJECT 435/JH0902 - HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP)

REV DESCRIPTION PREPARED BY

CHECKED BY

APPROVED BY


DATE

A Issued for IDC

Harshal Sasthe

S. Ishwad

J. Wallace 02 July 09

B Issued for Review

Harshal Sasthe

S. Ishwad

J. Wallace 20 July 09

C Issued for Tender

H. Sasthe

S. Ishwad

KMN Pillai 25-Aug-09





1. MANDATORY SPARE PARTS FOR PRESSURE VESSELS

Sr. No. Part Description Quantity Required

1. Bolting for each nozzle with blind/companion flange and for each pad nozzle

10% (Minimum 2 sets)

2 Gasket for each nozzle with blind/companion flange and for each pad nozzle

200%

3. Bolting for Internal Flanges 10% (Minimum 2 sets)

4. Gasket for each Internal Flange 200%

5. Sight/Light glasses assembly complete with bolting and gasket

Four Sets

1 Tag No. : P-20-03 Client: HINDUSTAN PETROLEUM CORPORATION LTD

2 Plant Location: BATHINDA, PUNJAB

3 P & ID No. : 435-JH0902-10-PR-PID-2004 REV D Manufacturer:

4 Calculation Ref.: 435-JH0902-20-PR-CAL-0001 REV A Purchase Order No. :

5 No. of Units: 1 Criticality Rating:

6 Service Description: TRANSFER OF SLOP & INTERFACE Service Category: (3.64)

7

8

9

10 PLEASE REFER THE PROCESS DATA GIVEN ON PAGE 1OF 4

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

c

B

A

Rev. Date Issue Description Originated Checked Approved ClientHindustan Petroleum Corporation Limited


Project Ref: 0435-JH0902 Sheet

2 of 4

Equipment Data Sheet for Centrifugal Pump

25-Aug-09 Issued for Tender SS SVI KMNP

REMARKS

Service: TRANSFER OF SLOP & INTERFACE

13-Aug-09 ISSUED FOR REVIEW

13-Aug-09 ISSUED FOR SQC / DIC

Datasheet No:0435-JH0902-20-ME-DAS-0022

KMN

KMNPSVI

SVI

SS

SS

DRIMS#: 2009558

The drawing, design and details given on this format are the property of WorleyParsons Engineering Pvt. Ltd. They are merely loaned on the borrower’s express agreement that

they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the tender to the borrower for the intended use.

Rev. ITP FOR MAIN PUMP

0435-JH0902 -00- ME-ITP-0009 C

ITP FOR HORIZONTAL CENTRIFUGAL PUMPS

Page 1 of 8

Sr.

No.

Stage Component Characteristics Method of

check

Quantum

of check

Reference

documents

Acceptance

norms

Record Sub

Vendor

Vendor WP

1. Incoming

Material

(Castings)

Casing

Stuffing Box

Impeller

Bearing Housing

Surface Quality

Visual

100%

ASME Material

specification

ASME Sec-

VIII, Div 1,

Appendix 7

Inspectio

n report

W

W

-

2. Incoming

Material

Do Dimensions Measurement 100% As per vendors

approved

drawing

As per

vendor

approved

drawings

Inspectio

n report

W W -

3. Incoming

Material

Do Chemical / Physical

properties

Review of

manufacturers

TC

All heats As per relevant

material

specification

As per

relevant

material

specification

Manufact

urers TC

W R R

3. Incoming

Material

All castings

materials & Forging

materials

Heat treatment Review of HT

charts


material

specification

As per

relevant

material

specification

HT chart

or TC

W R R

4. Incoming

material

(Bar stock)

Shaft material Chemical properties /

Physical properties

Review of

manufacturers

TC / Lab check


material

specification

As per

relevant

material

specification

Manufact

urers TC

or Lab

report

W R R




0435-JH0902 -00- ME-ITP-0009 C


Page 2 of 8

Sr.

No.


check

Quantum

of check

Reference

documents

Acceptance

norms

Record Sub

Vendor

Vendor WP

5. Hard ware

items

Gaskets, Fasteners,

Gland packings,

valves

Suitability Test

certificates

Visual review or

Test reports or

certificates

As per

sampling

plan

Approved

drawings and

datasheets &

Relevant stds

Approved

drawings and

datasheets &

Relevant stds

Inspectio

n report

W R R

6. Accessories Mechanical seal Hydrotest

Leakage test

Air test

Hydotest

Air test

Measurement of

leakage

Type test As per API 682 API 682 and

seal

manufacture

rs drawing

Manufact

urers

inspectio

n / Test

report

W R R

7. Accessories Barrier/Buffer

liquid reservoir (if

applicable)

1. WPS / PQR/WPQ

2. Leakage check

3. Dimensional check

4. Materials TC

1. Qualification

2. Hydro test

3. Measureme

nt

4. Review of TC


drawings. ASME

Section II / Sec-

VIII, div-1 / IX

As per

approved

drawings.

ASME

Section II /

Sec-VIII, div-

1 / IX

As per

Manufact

urers test

record &

Inspectio

n record

W W W/

R

8. Accessories Barrier/Buffer

liquid Coolers (if

applicable)

1. WPS / PQR/WPQ

2. Leakage check

3. Dimensional check

4. Materials TC

1. Qualification

2. Hydro test

3. Measureme

nt

4. Review of TC


drawings. ASMe

Section II / Sec-

VIII, div-1 / IX

As per

approved

drawings.

ASMe

Section II /

Sec-VIII, div-

1 / IX

As per

Manufact

urers test

record &

Inspectio

n record

W W W/

R

9. Accessories Coupling 1. Dimensions

2. Dynamic balancing

1. Measureme

nt

100% 1. As Per

approve

d

1. As Per

approved

drawings

Manufact

urers

inspectio

W W R




0435-JH0902 -00- ME-ITP-0009 C


Page 3 of 8

Sr.

No.


check

Quantum

of check

Reference

documents

Acceptance

norms

Record Sub

Vendor

Vendor WP

drawing

s

2. ISO

1940&

API 610

2. ISO

1940&

API 610

n & test

records

10. Accessories Bearing Lube oil

console (if

applicable)

Suitability 1. Pressure

test

2. Cleanliness

test

3. Operational

test

4. Material TC

5. Review of TC

for Lube oil

Pump &

motor

6. Review of TC

for

instruments

100% As Per approved

drawings

/datasheets &

API 614

As Per

approved

drawings

/datasheets

& API 614

Manufact

urers

inspectio

n & test

records

W W W

11. In Process Casing

Impeller

Stuffing Box

Defects open to surface D.P examination 100% of

Machined

surfaces

ASTM E 105

ASME Sec

VIII Div-1,

Appendix -7

Manufact

urers

inspectio

n & test

records

- W R

12. In process Butt Weld joint (if

applicable)

Internal defects Radiography On Nozzle

to casing

ASME Sec V

Article 2

ASME Sec

VIII Div -1

Manufact

urers

- W R




0435-JH0902 -00- ME-ITP-0009 C


Page 4 of 8

Sr.

No.


check

Quantum

of check

Reference

documents

Acceptance

norms

Record Sub

Vendor

Vendor WP

joint UW 51 inspectio

n & test

records

13. In Process Shaft

Forged outer casing

1.Internal Defects

2. Surface defects

1. Ultrasonic

Test.

2. 2. Magnetic

particle

testing.

3. 3. Liquid

penetrant

testing

100% 1. ASTM A

388/

Written

approved

procedure

2. ASTM E 709

3. ASTM E 165

Approved

procedures

Manufact

urers

inspectio

n & test

records

W W/

R

14. WPS,PQR,

WPQ

previous

qualificatio

ns for

overlay

Wear rings Thickness of overlay,

Hardness

Visual &

Hardness

Measurement

100% Specifications,

WPS,PQR,WPQ

Specification

s,

WPS,PQR,W

PQ

Manufact

urers

WPS,PQR,

WPQ

Records

- W R

15. Test before

assembly

Pump Outer stage

Casing & Stuffing

box

Leak Tightness Hydro test Each set API 610 &

approved drgs.

No leakage Manufact

urers

inspectio

n & test

records

- W W

16. Test before

assembly

Shaft (as

applicable)

Demagnetisation &

Measurement of Mech.

& Elect. Runout

Measurement Each set Approved drgs.

& API 670

API 670 Manufact

urers

inspectio

n & test

- W R




0435-JH0902 -00- ME-ITP-0009 C


Page 5 of 8

Sr.

No.


check

Quantum

of check

Reference

documents

Acceptance

norms

Record Sub

Vendor

Vendor WP

records

17. Test before

assembly

Rotor Assembly

with coupling Half

(as applicable)

Dynamic balancing Measurement Each

rotor

ISO 1940 ISO 1940

GR.2.5

Manufact

urers

inspectio

n & test

records

- W O

18. Testing Assembled Pump 1. Performance

2. NPSHR

3. Vibration

4. Sound

5. Bearing temperature

rise

6. Mech. Running

Measurement Each

pump

API 610 API 610 Manufact

urers

inspectio

n & test

records

- W W

19. Testing Dismantled pump Strip examination Visual check

Wear Ring

Clearance

measurement

Each

pump

API 610 API 610 Manufact

urers

inspectio

n & test

records

- W W

20. Testing Unitised Pump, Job

Motor, Jack

Screws, Base

frames,

instruments along

with lube oil

console

String test Measurement of

sound,

temperature

rise, Vibration

Each set Approved GA &

API 610

Approved GA

& API 610

Manufact

urers

inspectio

n & test

records

- W W




0435-JH0902 -00- ME-ITP-0009 C


Page 6 of 8

Sr.

No.


check

Quantum

of check

Reference

documents

Acceptance

norms

Record Sub

Vendor

Vendor WP

21. Testing Auxiliary piping Leak tightness Hydro test Each set No leakage No Leakage Manufact

urers

inspectio

n & test

records

- W W

22. Testing Base plate Dimensions Measurement Each

plate

Approved GA

drgs.

Approved GA

drgs.

Manufact

urers

inspectio

n & test

records

- W W

23. Testing Instruments Doc. Review Review Each test

report

Approved

Datasheet

Approved

Datasheet

Manufact

urers TC

W W/R R

24. Testing Rotor assembly Torsional Analysis &

Lateral analysis

Computational

analysis

Type test API 610 API 610 Computat

ional

analysis

print outs

- R R




0435-JH0902 -00- ME-ITP-0009 C


Page 7 of 8

Legends:




W- WITNESS

O- OBSERVED

R- REVIEW

H- HOLD

NOTES:

1. WELD REPAIR IF ANY TO BE DONE AFTER THE APPROVAL OF THE PURCHASER / AUTHORISED REPRESENTATIVE OF PURCHASER AS PER APPLICABLE CODE AND QUALIFIED

WPS AND WELDER.

2. MATERIAL FOR LOW TERMPERATURE SERVICE TO BE IMPACT TESTED AS PER APPLICABLE SPECIFICATION

3. FOR AUSTENITIC STAINLESS STEEL MICRO STRUCTURE AND IGC TESTS TO BE CONDUCTED AS PER APPLICABLE CODE & PURCHASE REQUISITION

4. FOR DUPLEX STAINLESS STEEL MICROSTRUCTURE & HARDNESS TO BE EXAMINED AS PER APLICABLE CODE

5. LUBE OIL CONSOLE IS APPLICABLE WHERE PRESSURE LUBRICATION IS REQUIRED FOR BEARINGS

6. STRING TEST OF THE PUMPS ALONG WITH FUNCTIONAL TEST FOR ALL AUXILLIRES SHALL BE CONDUCTED IN THE SHOP USING JOB MOTOR & LUBE OIL CONSOLE &

BASEFRAME

7. OUTER CASING IS APPLICABLE ONLY IN CASE OF DOUBLE CASING BARREL TYPE PUMP.

8. INCASE OF HORIZONTALLY SPLIT CASING MULTISTAGE PUMP. STAGE CASING IS NOT APPLICABLE.




0435-JH0902 -00- ME-ITP-0009 C


Page 8 of 8

9. MECHANICAL RUN TEST SHALL BE AS DESCRIBED IN THE SPECIFICATION FOR SLOP/INTERFACE PUMPS.

10. HARD FACING OF WEAR RINGS SHALL BE AS PER APPROVED CROSS SECTIONAL DRAWING/ DATASHEET

11. PUMP DRIVER SHALL BE INSPECTED AT DRIVER MANUFACTURERS SHOP AS PER RELEVANT INSPECTION & TEST PLAN

12. PERFORMANCE TOLERANCES SHALL BE AS PER API 610 10TH

EDITION & SPECIFICATION FOR SLOP/ INTERFACEPUMPS.

C

B

A

Rev. No DatePrepared By Checked By

07/07/09

HS SVI JJW 01/07/09

HS

PROJECT TITLE:

DOCUMENT TITLE:

GGSR PRODUCT EVACUATION PROJECT(HINDUSTAN PETROLEUM CORPORATION LTD.)

01/09/09SVI KMN P.

DOCUMENT NO. :

0435-JH0902-10-ME-DAS-0009

ISSUED FOR IDC

Description

SVI

Mechanical Datasheet for Sump Tanks-

T-10-01 / T-10-02

TAG NO. - T-10-01 / T-10-02

JJWISSUED FOR REVIEW

App. By

ISSUED FOR TENDER HS

DOC NO. : 0435-JH0902-10-ME-DAS-0009 REV NO. : C Sheet 01 of 03

1 Equipment

2 Equipment tag no.

3 Type / Position

4 Quantity

5 Location

6 Operation

7

8 Fluid

9 Capacity (Working) m3

10 Capacity (Actual) m3

11 Density kg/m3

12 Operating Pressure kg/cm2

13 Operating Temperature °C

14 Viscosity: cP

15

16

17

18

19

20

21 Flash Point ° C

22

23

24

25 SKO Min. 35

26

27

28

29 Design Code Shell

30 Design Pressure (Internal/ Vaccum) Heads

31 Design Temp. Reinforcing Pads

32 Vessel Dia (ID) Nozzle Neck - Pipe

33 Vessel Length (T/T) Forged Flanges

34 Shell Thickness (Nom.) Skirt/Saddle

35 Head Thickness (Min./Nom.) Stiffener Rings

36 Weld Joint Efficiencies: Removable Internals

37 Shell Internal Attachments

38 Head External Attachments

39 Non Destructive Testing: External Bolts

40 Radiography Nuts

41 Corrosion Allowance (Internal /External) Internal Bolts

42 Insulation Nuts

43 Foundation Bolt

44 Gasket (Nozzles / Manhole)

45 Empty

46 Operating Type Of Heads

47 Test Type Of Support

48 Earthing Boss

49 Lifting Lugs / Eyes

50 Nameplate

51 Saddle Support

52

53

54

55

56

57

Yes

0OC / 65 °C

External Painting required

VTS

VTS

1.5 / VTS

None

VTS

2200 mm

13 kg/cm2

6400 mm

VTS

VTS

VTS

VTS

VTS

Yes (Note 7)

Yes

ESTIMATED WEIGHTS

VTS

A 105

Ellipsoidal

No

Yes

-

-

-

Yes

CONSTRUCTION

CONSTRUCTION MATERIAL

Material Specification

A 106 Gr. B / IS 2062 Gr. A/B

PART

IS 2062 Gr. A/B

VTS

VTS

VTS

VTS

VTS

VTS

IS 2062 Gr. A/B

VTS

VTS

OPERATING CASE

GENERAL DATA

DESIGN DATA

IS 2062 Gr. A/B

IS 2062 Gr. A/B

Tag No. T-10-01 / T-10-02

T-10-01 / T-10-02

20

Hydrocarbon (Euro-III MS, Euro-IV MS, Euro-III HSD, Euro-IV HSD, SKO,ATF, Naptha)

ATF Min. 35

SKO 0.75 @ 100 ° C / 1.34 @ 40 ° C

EURO-III MS 0.4 @ 37.8 ° C 0.54 @ 20° C

EURO-III HSD 1.7-4.3 @ 40° C / 7 @ 20° C

EURO-IV HSD 1.7-4.3 @ 40° C / 7 @ 20° C

ATF 1 @ 37.8 ° C / 41.3 @ 20° C

NAPTHA 0.4 @ 37.8 ° C / 0.52 @ 20 ° C

EURO-IV MS <18

EURO-III-HSD Min. 32

EURO-IV-HSD Min. 32

ASME SEC. VIII, DIV. 1,

25

Horizontal Cylindrical

2

Outdoor

Intermittent

24.3

EURO-III MS <18

DOC TITLE: Mechanical Datasheet for Sump Tanks-T-10-01/02

DOC NO. : 0435-JH0902-10-ME-DAS-0009 REV NO. : C Date: 01/09/09

EURO-IV MS 0.4 @ 37.8 ° C 0.54 @ 20° C

650-860

GGSR PRODUCT EVACUATION PROJECT (HINDUSTAN PETROLEUM CORPORATION LTD.)

ATM

Sump Tank


58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

83

84

85

86

87

88

89

90

91

92

93

94

95

96

97

98

99 NOTES:

100 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED.

101 2. ALL NOZZLE FLANGE DIMENSIONS SHALL BE AS PER ANSI B-16.5,150#.

102 3. VENDOR IS FREE TO USED BETTER MATERIAL OPTION.

103 4. VTS - VENDOR TO SPECIFY.

104 5. VENDER SHOULD SUPPLY BOOT DETAILS

105 6. VENT TO BE PROVIDE WITH FLAME ARRESTOR. TO BE VENTED AT MIN 3M ABOVE THE NEAREST OPERATIONAL PLATFORM

106 OR PIPERACK WHICHEVER IS HIGHER

107 7. FOR PAINTING AND COATING SPECIFICATIONS REFER DOC. NO. 0435-JH0902-00-PI-SPC-0003

108

109

110

111

112

113

114

115

116

117

118

119

Flange

TypeRating

DOC NO. : 0435-JH0902-10-ME-DAS-0009 REV NO. : C

Nominal

SizeQTY Remarks

NOZZLESTANDARD

PROJECTION FROM

OUTSIDE OF

SHELL/HEAD PLATE

ServiceNozzle

Number ELEVATION ORIENTATION

VTS

VTS

VTS

VTS

VTS

4"

2"

1

3"

1

1

B6

4"

4"

1

1

1

2"

NOZZLE SCHEDULE

2"

VESSEL SKETCH

150#

150#

150# SO RF

PLATE

B9

24"

2"

B4

B5

M1

S1

B7

B8

B1

B2

VTS

B3

SO RF

6"

1

1

1

1

1

150#

Sampling Connection

150#

150#

150#

150#

To Tank Truck Loading

SO RF

SO RF

150#

150#

150#

SO RF

SO RF

SO RF

SO RF

VTS

VTS

VTS

Closed drain inlet

(From Bahadurgarh Drain

Header)

Closed drain inlet

(From Bathinda Drain Header)

Level Transmitter B 16.5

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTS

VTSVTS

VTS

VTS

B 16.5

B 16.5

VTS

VTS

Pump Motor

B 16.5Spare With B/F

Recirculation

Pressure relief

vent

B 16.5Manhole

B 16.5

B 16.5

B 16.5

B 16.5

B 16.5

B 16.5

SO RF

SO RF

GGSR PRODUCT EVACUATION PROJECT (HINDUSTAN PETROLEUM CORPORATION LTD.)

Tag No. T-10-01 / T-10-02

Date: 01/09/09

DOC TITLE: Mechanical Datasheet for Sump Tanks-T-10-01/02


volume iii-technical specifications-annexure-a mechanical (1)

Documents

rev c page

equipment datasheet

sump pumps

worleyparsons page

ramanmandi bathinda

centrifugal pumps vs

bathinda pipeline

vertical submercible