Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
FGRU-
TSLC
Flare Gas Recovery Unit Project
0 14.07.2014 14.07.2014 FIRST ISSUE AS ANR GGR
REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD
Page 1 of 67
TECHNICAL SPECIFICATIONS FOR LIQUID RING COMPRESSOR
PACKAGE (280-LZ-01)
FOR
FLARE GAS RECOVERY UNIT PROJECT
AT
HINDUSTAN PETROLEUM CORPORATION LTD.
VISAKH REFINERY
ENGINEERING CONSULTANT
M/s. PROJECTS & DEVELOPMENT INDIA LIMITED,
VADODARA
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
FGRU-
TSLC
Flare Gas Recovery Unit Project
Page 2 of 67
INTRODUCTION:
For environmental and economic reasons, Visakh Refinery has decided to install a compressor system for
Flare Gas Recovery.
1.0 Vendor’s Scope of Work & Supply; Delivery Schedule:
The Vendor (also referred as “Manufacturer” or “Supplier”) shall be responsible for supply of Liquid
Ring Compressor package as detailed below:
Supply of the complete set of Skid mounted Liquid Ring Compressors (2 Nos.) with electric motor drivers
(2 nos.) along with its auxiliaries as per the relevant API 681 standards (latest edition) and attached
specifications, standards, requirements. The complete package shall be designed for Liquid Ring
Compressors (2 Nos.) with Electric Motor Drivers (2 Nos.) in parallel operation.
The supply shall necessarily include but not be limited to detailed design, procurement, manufacturing,
fabrication, inspection including third party inspection, testing, painting, supply of commissioning spares,
special tools & tackles, Sea worthy export packing for safe transportation including fumigation for safe
inland & ocean transportation. Mechanical, Electrical and Instrumentation Performance Guarantee of the
following equipment in accordance with the requirements of this indent requisition.
Description Q’ty Unit
Liquid Ring Compressors Package complete 1 Lump sum
Accordingly, the Vendor shall be responsible for the supply of the following items:
Liquid Ring Compressors -02 nos.
Electric Driver Motors (2 nos.), push button station(s); Auxiliary Motors (as required) & its push
button station
Seal Water Separator (Common and sized for compressors (2 nos.) working in parallel)
Seal Cooler (Common, type: Shell and tubes and sized for compressors (2 nos.) working in parallel)
Couplings and non-sparking (brass/ brass plated) coupling guards
Mechanical seals and ancillary system
Recycle Valves
Ring Liquid Filters
All instrumentation as required for package operation, monitoring and safeguarding including control
valves, safety valves, emergency valves, PT’s, TG’s, Pressure switches, solenoid valves, temperature
transmitters, PG’s, FT’s etc and compressor seal monitoring. Detailed Instrumentation scope is as per
clause no. 12
All interconnecting wiring within skid (tubing and cables trays with supports)
All auxiliary piping (sealing, lubrication, etc.) - shop fabricated and shop installed
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
FGRU-
TSLC
Flare Gas Recovery Unit Project
Page 3 of 67
All Purchaser’s connections (inlet, outlet, utility, vent, relief and drain, etc.) – flanged, valved and
terminated at skid edge
Steel skid (common) for compressor, driver and all auxiliary equipment
Equipment earthing by externally accessible earthing studs
Bolting and gaskets for all flanges within Vendor’s scope of supply.
Lifting lugs, Anchor bolts/nuts/washers etc. complete requirement.
Special tools and special test equipment (if necessary)
2.0 APPLICABLE CODES, STANDARDS AND SPECIFICATIONS:
Liquid Ring Compressor Packages covered in this indent shall comply with the requirements of the all the
data sheets, drawings, codes, standards, specifications and statutory regulations referred/ listed etc.
Unless specifically designated by date, the latest edition of each publication shall be used, together with
any amendments/supplements/revisions thereto.
2.1 Order of Precedence
In case of conflict between the following documents, the order of precedence shall be as follows. In case
of conflict at same level, more stringent conditions shall be applicable.
Indent Requisition / Mechanical Data Sheets /Attached project drawings / P&ID (if any) (all at same
level)
International standards
3.0 CLARIFICATIONS AND DEVIATIONS
The Vendor shall highlight all clarifications for the ambiguities, conflicts and discrepancies which may be
discovered in the above documents, together with deviations from the requirements therein and propose a
resolution to the Purchaser in separate sheet highlighting the Clarification & Deviation List . The
clarifications and deviations are subject to HPCL Refinery approval. The Vendor shall provide, in
Clarification & Deviation sheet, well explained reasoning or justification as regards the clarifications and
deviations taken for clear understanding by HPCL.
In case the Vendor fails to highlight clarifications prior to PO (Purchase Order) award, the Purchaser’s
interpretation shall be final and the Vendor shall accept such interpretations with no change in delivery
and order amount after PO award. It may please be further noted that during evaluation of bids only the
deviations listed in the list shall be examined and it shall be construed that the bid is in total conformity
with the tender terms – technical as well as commercial, except for the deviations specially listed.
Deviations not listed in “Agreed Technical Terms and Conditions” and listed elsewhere in the bid shall be
ignored and shall not be considered.
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
FGRU-
TSLC
Flare Gas Recovery Unit Project
Page 4 of 67
4.0 INFORMATION REQUIRED
4.1 LIST OF DRAWINGS & DOCUMENTS
The documents and drawings listed below shall be submitted along with supply in bound document
form. The presentation shall be well up to the mark with proper indexing.
SL
DESCRIPTION
With Offer
FOR
APPROVAL OF
OWNER
(AFTER
PLACEMENT
OF PO/FOA,
AND BEFORE
SUPPLY )
WITH FINAL
DOC.
1 Equipment catalogue and experience list
2 Equipment (& accessories) Data / specs sheets 3 General arrangement drawing and foundation plan
4 Cross sectional drawings (typical) of all rotating
equipment
5 Drawing of the couplings and all accessories 6 Compressor performance curve 7 Mechanical seal drawing 8 Recommendation of seal manufacturer
9 Casing drain pipe/ CW arrangement drawing
10 Proposed method for control and protection of the
liquid ring compressor package
11 Clarifications and exceptions to this Requisition
12
PFD (Process Flow Diagram) and P&ID (Piping and
Instrument Diagram) showing major instrument
control points
13 Piping drawing of all the seal plans including
complete sealing system
14 General Arrangement and Fabrication Drawing of
Static Equipment
15 Lube system details (schematics) 16 Estimate of utilities consumption 17 Inspection and test plan 18 Guarantee Certificate 19 Summary sheet of Drg. Nos. 20 Compressor Test Record with performance curves 21 Material Test Certificates
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
FGRU-
TSLC
Flare Gas Recovery Unit Project
Page 5 of 67
4.2 Price Bid Format /Check List (Vendor to indicate Y/N below and the prices to be quoted in Specific
Price Schedule Format Only)
22 Hydrostatic Pressure Test Certificate 23 Dynamic Balancing Certificate 24 Compliance Certificate* 25 Hydro Test Certificate for piping/ equipment 26 Certificate of Non-destructive testing 27 Dimensional reports 28 Motor data sheet and outline drawing 29 Motor Terminal arrangement drawing 30 Motor Thermal withstand characteristics 31 Motor Performance curve and routine test certificate 32 Motor Type Test Certificates 33 Guarantee certificate of Motor 34 Earthing Layout drawing 35 Inspection release note of all equipment /package
36
Equipment /package installation, operation &
maintenance manual with complete spare part list for
the whole package
* Final documents shall be submitted in additional soft form on CD (3 copies) also.
* Certification for testing of all flameproof electrical equipment is to be submitted.
Note :
Five sets of hard bound documents (including inspection and test plan) shall be required as a part
of final documentation. The Final documents shall be submitted in additional soft form on CD
(3 copies) also.
All documents shall be written in the English Language. The standard units for design engineering
shall be based on the SI System, except for pipes, which shall be sized in inches, and flanges,
which shall be rated in pound.
Sr
.
Part description Total
Qty
required
Quoted
(Y/N)
Unit
price (per
set)
Total price
( Rs.)
1. Vendor’s Scope of Work & Supply;
Delivery Schedule:
The Vendor (also referred as “Manufacturer”
or “Supplier”) shall be responsible for
supply of Liquid Ring Compressor package
as detailed below:
Supply of the complete set of Liquid Ring
1
As
indicated
in SP
Forms
As
indicated
in SP
Forms
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
FGRU-
TSLC
Flare Gas Recovery Unit Project
Page 6 of 67
Compressors (2nos.) with electric motor
drivers (2 nos.) along with its auxiliaries as
per the relevant API 681 standards (latest
edition) and attached specifications,
standards, requirements. The complete
package shall be designed for Liquid Ring
Compressors (2 nos.) with Electric Motor
Drivers (2 nos.) in parallel operation.
The supply shall necessarily include but not
be limited to detailed design, procurement,
manufacturing, fabrication, inspection
including third party inspection, testing,
painting, supply of commissioning spares,
special tools & tackles, Sea worthy export
packing for safe transportation including
fumigation for safe inland & ocean
transportation. Mechanical, Electrical and
Instrumentation Performance Guarantee of
the following equipment in accordance with
the requirements of this indent requisition.
Description Q’ty Unit
Liquid Ring Compressors Package complete 1 Lump sum
Accordingly, the Vendor shall be
responsible for the supply of the following
items:
Liquid Ring Compressors -02 nos.
Electric Driver Motors (2 nos.), push
button station(s); Auxiliary Motors (as
required) & its push button station
Seal Water Separator (Common and
sized for compressors (2 nos.) working
in parallel)
Seal Cooler (Common ,type : Shell and
tubes and sized for compressors ( 2 nos.)
working in parallel)
Couplings and non-sparking (brass/ brass
plated ) coupling guards
Mechanical seals and ancillary system
Recycle Valves
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
FGRU-
TSLC
Flare Gas Recovery Unit Project
Page 7 of 67
Ring Liquid Filters
All instrumentation as required for
package operation, monitoring and
safeguarding including control valves,
safety valves, emergency valves, PT’s,
TG’s, Pressure switches, solenoid valves,
temperature transmitters, PG’s, FT’s etc
and compressor seal monitoring.
Detailed Instrumentation scope is as per
clause no. 12
All interconnecting wiring within skid
(tubing and cables trays with supports)
All auxiliary piping (sealing, lubrication,
etc.) - shop fabricated and shop installed
All Purchaser’s connections (inlet,
outlet, utility, vent, relief and drain, etc.)
– flanged, valved and terminated at skid
edge
Steel skid (common) for compressor,
driver and all auxiliary equipment
Equipment earthing by externally
accessible earthing studs
Bolting and gaskets for all flanges within
Vendor’s scope of supply ,
Lifting lugs, Anchor bolts/nuts/washers
etc. complete requirement.
Special tools and special test equipment
(if necessary)
2. Spares
a Double cartridge mechanical seal
1 set As
indicated
in SP
Forms
As
indicated
in SP
Forms
b Complete set of Gaskets for one compressor
(including seal gaskets)
2 set As
indicated
in SP
Forms
As
indicated
in SP
Forms
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
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Page 8 of 67
Note:
The word 'Set' means the quantity required for full replacement of that part in one machine.
The cost of Spares, per diem charges, Fixed Trip and Provision of Shut Down valves shall be added to the
'Total Cost' for commercial evaluation of the offer.
5.0 The Procurement Philosophy / Selection Requirement
It is HPCL’s intention to procure equipment vendor’s successful and proven product. The equipment shall
be designed for an intended operating life of 20 years in line with API 681 requirements. The equipment
shall be suitable for long service life and be suited to local operating conditions, which are hot, humid and
corrosive. Selection criteria shall be:
Low maintenance, with ease of operation (user friendly) and ease of service (maintainability) under
local conditions.
Lowest life cycle cost for all operation and maintenance costs, consistent with safety and
environmental requirements.
Equipment will be amenable to predictive monitoring and shall have vibration, temperature and other
sensors connecting points where ever applicable.
c Complete set of coupling shim packing’s 1 set As
indicated
in SP
Forms
As
indicated
in SP
Forms
d Set of gaskets and ‘O’ rings for PSV 1 set As
indicated
in SP
Forms
As
indicated
in SP
Forms
e Complete set of bearings 1 set As
indicated
in SP
Forms
As
indicated
in SP
Forms
3. Per diem charges for supervision As
indicated
in SP
Forms
As
indicated
in SP
Forms
4. Charges for Fixed Trip As
indicated
in SP
Forms
As
indicated
in SP
Forms
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
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Page 9 of 67
Vendor to commit uninterrupted supply of spares for the system, as and when required by Owner, at least
for 20 years of operation.
6.0 Functional Design Requirements/ Functional Specifications
6.1. Mechanical Requirements:
6.1.1 Skid Layout: The layout of compressor skid shall afford complete and unconstrained access to all
equipment for operation, maintenance and removal.
The compressor skid shall be as per the available site dimensions. The dimensions of site are 13 meters x
15.7 meters (FGRU Layout drawing attached for reference).
6.1.2. Mechanical Equipment requirements
General
The equipment supports shall be generously designed in order to withstand all induced stresses caused
by transportation, wind loading, operating conditions and pressure testing.
All gaskets fitted shall be new after hydro test.
Equipment shall be insulated for personnel protection wherever temperature exceed 70 deg C.
All removable internals shall be designed to provide easy withdrawal from vessel and shall pass
through vessel Man way. Man way to be of 24 inched NB preferably.
Davits for manhole covers shall be provided.
6.1.3 Ring Liquid Compressor:
The Ring liquid Compressor shall be designed and manufactured / constructed in accordance with API
681 latest edition.. Bearing Brackets to be of nodular cast Iron/ Cast steel. Bearing shall be of SKF / FAG
make with machined brass cages.
Material of construction (MOC) of major parts shall be as below:
Casing ASTM 182 Gr F316L or equivalent ASTM /ASME grade
Impeller A351 Gr CF3M or equivalent ASTM/ASME grade
Cone A351 Gr CF3M or equivalent ASTM/ASME grade
Suction Comp.
Cover
A351 Gr CF3M or equivalent ASTM /ASME grade
Shaft ASTM-A 564 TP 630 / or equivalent ASTM /ASME grade
Service Water will be available for liquid ring make up and mechanical seal flushing at a pressure of
2.5 kg/cm2 at FGRU battery limit. Vendor to check the adequacy of the pressure and provide for pumping
requirement (1 Running + 1 stand by), if required.
The gear box, if considered in the offer, shall conform to API-677.
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
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Page 10 of 67
6.1.4 Cooler
Shell and tubes heat exchanger, sized for two compressors, according TEMA R, removable bundle type,
Shell side MOC carbon steel, tube side MOC Cu-Ni 70/30.
6.1.5 Separator
The vessel shell to be provided with demister internals suitable to remove any carry over and level
control to suit operation. Horizontal three-phase gas / liquid separator (sized for two compressors
working) in carbon steel (NACE grade) as per ASME Sect VIII div.1. Provide 24” NB Man-way.
Required instruments shall be provided as per API 681 as a minimum.
Platforms and ladders for separator will be provided by HPCL. Vendor shall provide necessary cleat
arrangement on the vessel. Equipment shall be designed accordingly.
6.1.6 Mechanical Seal:
The Double mechanical seal is to be specifically designed for the compressor. The seals for the
compressor and the ring liquid pump (if applicable) shall be as per API 682. The compressor seal shall
be of cartridge design, C / SiC with Hast Alloy C springs and SS 316 metal parts suitable for HC
applications. Vendor: JOHN CRANE /EAGLE BURGMANN /FLOWSERVE.
1. It is proposed to use API flush plan 32/52 or dry out board seal which is even suitable.
2. Leak detection system.
3. All the “O” rings of the mechanical seal shall be of Kalrez only.
4. For plan 32/52 service water to be used as buffer liquid. Each seal shall preferably be provided with
unpressurized buffer fluid circulation through reservoir and seal leakage detection system. Vendor
may propose alternative seal/sealing system also; accordingly cooling system may also be offered, if
required.
5. a. Duplex filter on the upstream of flushing plan 32 for filter to supply of clean liquid to primary
seal.
b. Duplex filter shall have DP gauge and DP transmitter, upstream and downstream pressure gauges.
c. Duplex filter shall have change over valve for changing of the filter online without affecting the
compressor operation.
It is proposed that vendor shall provide following minimum signals from sealing system.
a. Failure /excessive leakage for individual seals
b. Seal fluid supply pressure indication.
Compressor shutdown or alternative action will be initiated accordingly.
All seal auxiliary system piping shall be of vendor’s standard generous design of SS316 metallurgy.
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
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6.1.7 Piping Requirement
1. The following tie-in points (to the HPCL piping) up to skid limit are envisaged.
a. Gas inlet
b. Gas outlet
c. Relief Valve discharge
d. Vessel connection to closed drain
e. Skid connection to open drain
f. Ring liquid make up
g. Cooler connections (vendor to elaborate)
h. Separator connections (vendor to elaborate)
i. N2 purging
j. Instrument air
Vendor to confirm for any other connection.
1. The skid connecting flanges shall be located at the edge of the skid. Vendor shall supply matching
flanges of all tie-in points.
2. All the package piping shall be designed in accordance with ASME B 31.3. All piping layout shall be
designed to provide access to all equipment. The piping to be designed not to exert greater loads than
those allowed for vessel nozzles or those permitted by original manufacturer.
3. Piping supports at tie in locations shall be suitable to withstand loads per the values given by vendor.
Vendor shall furnish their standard allowable loads at tie-in points to be considered by HPCL for
interconnecting piping outside vendor scope of supply
6.1.8 Structural Requirement:
Materials
All structural steel and weld material used in skid fabrication shall be delivered in accordance with ASTM
A6 or equivalent. The primary structural framing shall be carbon steel. Maximum carbon content of steel
sections shall be 0.23% Structural design shall be designed sturdy enough for type of equipment
considering most severe conditions.
6.1.9 Provision of Shutdown valves:
Shutdown valves along with its associated facilities such as PSV shall be provided by the vendor in the
Liquid Ring compressor Package as per the requirement of HPCL in future. Vendor to quote the price
separately for this facility and shall not be included in the Lump sum price of the Liquid Ring Compressor
package.
Skid Fabrication:
Construction: skid shall be of welded construction. Equipment shall be mounted on adequate supports
either mounted directly or attached through structural member on the skid. Floor grating shall not be used
as a mounting surface for equipment or supports.
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
Doc No:
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All structural welds on the skids shall be 100% Magnetic Particle Inspected and all the fillet welds shall
be continuous.
Unless otherwise mentioned, equipment shall be attached to skid by bolting. All stainless steel/ carbon
steel interfaces shall have insulation gasket sets. The skid (s) to be designed with a Perimeter beam of one
size extending all the way around the skid to allow the deck plate or grating to be attached to the skid
beam.
Vendor to provide 3 mm steel plate drip pan(s) to cover compressors only. The same shall be sloped
towards a flanged low point drain with tie in flange.
Platforms and ladders:
Platform and ladders for separator vessel will be provided by HPCL. Vendor shall provide necessary Cleat
arrangement on the vessel. Equipment shall be designed accordingly.
6.2. Noise Requirements
Noise level shall be limited to 85 dBA at any position not less than one meter from the equipment surface.
6.3. Piping Design Requirements
Equipment and package piping interface connections shall be flanged to ASME B16.5 for nozzles up to
24”, and ASME B16.47 Series B or MSS-SP-44 for nozzles above 24”. Required ratings and face finish
will be detailed on the PIPING SPECIFICATION. Interfaces for utility/auxiliary services shall be
minimized by the use of manifold piping, where necessary, within the Vendor’s package, and shall be
located at the package skid edge.
The minimum allowable forces and moments shall be as follows:
A. Liquid ring compressor & pump
Compressors and pumps with casing constructed of steel and with nozzles smaller than 16 inch shall be in
accordance with NEMA code as per API 681. Allowable loads on compressor shall be as per API 681
(NEMA SM-23).
For flanges larger than 16”vendor shall design the nozzles with generous strength and the values shall be
sent to HPCL for information.
B. Vessels & Exchanger
External Loads for Nozzle of Vessel & Exchanger to be in accordance to ASME VIII div 1 requirements
and WRC Bulletin.
6.4. Foundation
Design & construction of the skid foundation shall be done by HPCL based on the foundation dimension,
anchor bolts location, static & dynamic loads, GA Drawing etc. of the skid which is to be provided by the
bidder. Bidder shall submit foundation plan with relevant information relevant to foundation dimensions,
anchor bolts location, static and dynamic loads to allow M/s HPCL to provide detailed foundation design
and drawing.
Supply of anchor bolts, washers shall be provided along with the loads (Static and Dynamic).
Technical Specifications for Liquid Ring Compressor
Package (280-LZ-01)
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7.0 Hazardous Area Classification
The Liquid Ring Compressor Package will be installed in hazardous area IEC Zone 1, Group IIC & Temp.
Class T3. All electrical equipment shall be in accordance with certification requirements as specified in
the Codes and Standards as per indent.
Equipment Zone-1 Zone-2
Gas Gr II A,
IIB
Gas Gr. IIC Gas Gr.IIA,
IIB
Gas Gr. IIC
MV Motors Ex-d Ex-d Ex-e Ex-e
HV motors Ex-d/Ex-p* Ex-d/Ex-p* Ex-e Ex-e
Push button station Ex-d Ex-d Ex-d Ex-d
Motor starters Ex-d Ex-d Ex-d Ex-d
Plug & socket Ex-d Ex-d Ex-d Ex-d
Welding Receptacle Ex-d Ex-d Ex-d Ex-d
Lighting Fixture Ex-d Ex-d Ex-d Ex-d
i. Lighting fitting
ii. Control Gear Box
Ex-d Ex-d Ex-d Ex-d
Junction Box Ex-d Ex-d Ex-d Ex-d
Hand Lamps
1. Light fitting
2. Transformer
Unit.
3. Plug & Socket
Ex-d Ex-d Ex-d Ex-d
Break Glass Unit (Fire
Alarm Unit)
Ex-d Ex-d Ex-d Ex-d
Lighting panel /Power
panel
Ex-d Ex-d Ex-d Ex-d
*Ex-p motors shall be used only where Ex-d range is not available.
Notes: 1. The electrical equipment for hazardous area shall generally be suitable for gas group IIA/IIB and
temp classification T3 as applicable to the selected type of explosion protection. In case of
hydrogen or hydrogen or hydrocarbon mixtures having more than 30% hydrogen, the gas group to
be considered shall be IIC.
2. As additional safety features, the following requirements for electrical equipment shall be
followed:
A. All electrical motors for agitators / mixtures and metering pumps handling flammable material
shall be flameproof type irrespective of the area being classified as zone-2 or zone-1.
Technical Specifications for Liquid Ring Compressor
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B. All electrics motors for vertical oil sump pumps shall be flameproof type.
C. Irrespective of the area classification (Whether zone-1 or zone-2), all lighting fixtures within
the process /storage areas shall be flame proof type.
D. Irrespective of the area classification (Where zone-1 or zone-2) all motors and lighting fittings
within the pump house (station) associated with storage area and within the loading / unloading
gantries shall be of flameproof type.
E. All emergency /critical lighting fixtures and associated junction boxes in hazardous areas
(whether zone-1 & zone-2) shall be flameproof type.
F. Even though fired heaters in process units are not considered for area classification, all
electrical equipments associated with fired heaters in process units shall as a minimum be
suitable for installation in zone-2 area.
G. Where air conditioning system is designed considering ammonia as refrigerant, the room
housing air conditioning equipment shall be adequately ventilated to classify it as safe area.
For additional safety the following shall be considered.
Location of MCC/ local panels in adjacent separate room
Instrumentation to be flame proof type or hermetically sealed.
AC Plant room motors with min. type ‘e’ protection.
Lighting in AC plant room suitable for zone-I area.
8.0 EQUIPMENT DESIGN REQUIREMENT
8.1 Equipment Reliability, Operability and Maintainability
The Vendor shall provide all information on space requirements for layout, handling and removal of
components, to a point on or beyond the confines of the package/skid, where these can be easily lifted and
handled. The Vendor shall also provide all information on any special laydown or handling procedures,
which may be required, and provide all special tools, support cradles, and lifting frames.
9.0 Combined performance in parallel Operation
Liquid Ring Compressors are to be piped for parallel operation. The vendor shall guarantee the combined
performance at the inlet and outlet manifold of the piping as per attached Process Specification, Doc. No.:
PC00078-280-LZ-01, R2.
Technical Specifications for Liquid Ring Compressor
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10. Seal Water Quality:
Vendor to refer attached Process Data Sheet for seal water quality available at site.
Vendor to consider suitable strainers, Duplex Basket filter to be provided on the Ring liquid inlet to
compressor.
10.1. Compressor Protection
Vendor shall ensure that the compressor start-up logic inhibits starting of compressor until water seal
system has established water seal minimum flow and appropriate level in the compressor.
Vendor shall provide automated start-up logic for compressor package to ensure proper start-up
procedures, sequences and permissives.
Vendor shall advise, in his bid, suction and discharge protection pressure of compressor. 11.0 ELECTRICAL DESIGN REQUIREMENTS
Motor: Motor shall be supplied as per IEC/IS.
Distribution and Utilization Voltage
Utilization Voltage
Motors:
HV motor voltage = 6.6 KV / 3.3 KV +/- 10% , 3 phase, 50 Hz. +/- 3%
MV motor voltage = 415 V +/- 10% , 3 phase, 50 HZ +/- 3%
Frequency variation = 50 Hz +/- 3%
Control --- 50HZ /110V, DC, 2 wire
Voltage grade of HV motor i.e. 6.6 kV or 3.3 kV shall be confirmed later.
Enclosures and Degree of Protection:
Enclosures
Local panels shall have an enclosure of metal, or of an insulating material of sufficient mechanical
strength and shall be self-supporting, suitable for floor or wall mounting in cubicle or box-type
construction. The design shall include measures to avoid condensation as much as possible.
Degree of protection The degree of protection for equipment except electric motors shall be compliant to the following
enclosure classifications, as a minimum environmental protection according to IEC 60529:
IP 66 for outdoor terminal and junction boxes
Technical Specifications for Liquid Ring Compressor
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Accessibility
All components requiring maintenance shall be easily accessible from the front.
The following features for personal and electrical safety shall be incorporated:
- Adequate means shall be provided to ensure the safe removal of fuses, when fitted.
- Adequate insulation or protection shall be provided on all live parts (IP 20) to minimize the risk of
accidental short circuits and to limit their propagation of occurring.
- The insulation shall be capable of providing adequate and lasting protection under specified
normal conditions and recognized over currents and over voltages.
Control Panels, Terminal and Junction Boxes
Control panel power supply shall be 110 V AC 50 Hz, UPS.
Where control devices are grouped in and/or locally mounted control panel, the panel shall be supplied by
the Vendor completely pre-wired to terminal blocks.
Where control devices are grouped in and / or locally mounted control panel, the panel shall be supplied
by the vendor completely pre-wired to terminal blocks.
The local control panel shall be designed for hazardous area classification i.e. Class 1 Division 1 and
temperature classification T3. The panel shall have Z type purge arrangements with + 3 mm or + 5 mm of
WC maintained pressure.
Each Control panel shall be provided with RS 485 (2 wire) Communication port.
Terminal blocks shall be of the locking type construction to prevent wires from vibrating loose. All
terminals shall be tinned plated only accept one wire per terminal and so arranged within the panel to
accommodate all incoming cable cores minimum size 2.5 sq.mm. Removable gland plates shall be
supplied for all incoming cables. Cable Glands of Double Compression Nickel plated Brass, weather
proof to ATEX and Explosion proof to ATEX shall be supplied by the vendor. CMRI test certificate for
cable glands shall be provided.
It is vendor responsibility to hook up all the indication of local panel to DCS control room. Separate
control panels shall be provided with local control panel which shall be plugged with 316 SS plugs.
All terminals shall be numbered. The internal wiring within a panel or box shall be numbered such that
the wire end has the number of the device and / or the terminal, at the other end.
Cable entries to each local control panel should be from bottom only.
Identification of all wires will be achieved by the use of wire markers. Manufacturer’s standard will be
acceptable, however wrap around, adhesive type markers shall not be used.
A minimum of 30% spare terminals shall be provided in each panel.
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A lamp test individual switch shall be provided for all alarm and indicating lights. Power on lamp to be
provided in front of each panel.
A copper earth bar of adequate cross-sectional area and mechanical strength shall be provided in each
panel to allow convenient connection of all earthing conductors.
All motors shall be equipped with main terminal box. A separate auxiliary terminal box for the space
heater shall be provided when applicable. Each cable entry size of motor terminal box shall be spacious
for cable bending.
It is vendor’s responsibility for cable entry size and terminal block size of each junction box and terminal
box during vendor print review & approval stage. After HPCL approval of submitted document from
vendor, vendor shall incorporate the same.
SWITCHES/LAMPS: BCH/L&T/SIEMENS.
Earthing:
All electrical equipment, the unit frame/structure, equipment for electrical signal transmission, including
the enclosures, as well as the armoring, and screening of cables, shall be properly earthed for personal
safety reasons and for obtaining the maximum possible rejection of interference.
All the equipment being supplied by the bidder shall be properly earthed as per IS: 3043 and the extreme
connection shall be brought up to the earth bus provided by the bidder. Further connection from bidder
earth bus to main Earth grid shall be done by purchaser.
Earth bus shall be of length 350 mm made up of GI of size 50x12mm with 8 to 12 holes.
Earthing of equipment rated 240V and below shall be done by 1Cx10 sq mm (Cu) PVC Cable.
Mechanical Equipment like tanks, vessels, steel structure shall be earthed by 50x6 GI strips.
Motor earthing:
Rating Size
i. Up to 22 KW 1Cx10 sq mm (Cu) PVC
ii. Above 22 KW up to 45 KW 1Cx25 sq mm (Cu) PVC
iii. Above 45 KW 50x6 GI strip or
120 sq mm (A1) PVC cable
All equipment rated above 240 V shall have two external earth connection and those rated below shall
have one external earth connection.
Push button station shall have two external earth connections.
All valves, flanges etc. shall be provided continuity Jumper of size 35 x 6 GI earth strip or 1 x 25 sq mm
(Cu).
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Minimum size of earthing cable shall be 1C x 10 sq mm (Cu) PVC.
On package equipment with a number of electrical components to be earthed, parallel earthing shall be
employed and not the series looping of equipment.
Two/adequate number of earth bars to which equipment earthing is connected shall be provided at
opposite ends of the skid.
Earth bars to be provided with two additional holes complete with bolts and washers size M10 to
accommodate Purchasers external earth connection to the main earthing grid. The size of the bar shall be
70 mm minimum.
Metal enclosures of electrical equipment, mechanical equipment and construction parts shall be earthed by
an earthing wire of at least 25 mm2 connected to the common earth bar. In case size is not specified, the
same shall be subjected to approval.
All electrical joints made for earthing shall be accessible and checked for tightness and electrical
continuity.
Earthing wires shall be of the stranded copper PVC covered type; the color of the insulation shall be
yellow/green.
Earthing conductors of cables shall be connected to the earthing terminal bolt inside the terminal box and
to the common earth bar.
Vendor shall submit the earthing layout drawings on package equipment for information only.
As per HPCL, the following shall be applicable.
A. Earth electrode : GI pipe
B. Main earth loop material : GI Strip
C. Substation earth loop : GI strip
D. Lightening Conductor: As per IS 2309.
E. Earthing of motors, small equipment shall be done with Al / Cu conductor PVC insulated green
color cable instead of GI rope.
Interconnecting Cabling:
Interconnecting wiring between equipment on a common skid shall be supplied and installed by the
Vendor.
The minimum size of interconnecting cables shall be:
Power cables – 4 mm2
Control cables – 2.5 mm2
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LV power / control cables used for aboveground wiring shall be stranded copper conductor, XLPE
insulated, galvanized steel wire armored (or braid for sizes up to and including 10 mm2), flame retardant,
PVC over sheathed with FRLS properties.
All power and control cabling to motor remote control stations, heaters, etc. will be connected directly to
the equipment i.e. not via junction boxes, The Vendor shall ensure that the equipment supplied is
completely satisfactory for the termination of Purchaser’s cable(s).
Cabling to controls (not motor control stations), e.g. temperature switches etc, shall be wired to explosion
proof individual junction boxes located on the skid. (Ex-Proof Certificate for junction Boxes and cable
glands from CMRI to be provided).
Where instrument, intrinsically safe and electrical cables are installed on the same skid separate routes
shall be used and due attention shall be given to avoid electromagnetic interference between different
systems.
Conduits, trays, ladders, separators and their supports shall be made of hot-dipped galvanized steel having
galvanizing thickness not less than 100 micron. Cable extensions from cable trays to equipment and other
devices shall be supported and protected from mechanical damage. FRP cable trays minimum 5 mm
thickness shall be used for instrument signal cables and control cables. Nuts & Bolts for FRP cable trays
shall be SS316.
All cable trays, canopies for hazardous area equipment, motors and channels for LCS shall be FRP type.
The thickness of FRP canopy shall be minimum of 3 mm.
All electric devices furnished/installed by the Vendor and requiring external field connections (except
motor power leads) shall be wired by Vendor to terminal blocks in junction boxes located at the edge of
the skid.
Identification of Equipment and Cables
Equipment
All electrical equipment shall be provided with label/tag plates.
A list of labels/tag plates shall be part of Vendor’s drawings for approval before fabrication.
The language to be used on labels/tag plates shall be English.
Cables
The Vendor shall attach cable marker tags to all cables when they are laid. Cable identification shall also
be provided and fixed just below the cable glands at all entries into equipment, junction boxes or through
joints. Markers shall be of 1.5mm thick x 18mm wide lead strip. The circuit identification and cable
schedule numbers shall be stamped on each marker in 6mm high letters and digits.
Alternatively markers in stainless steel or plastic may be used provided that they are attached permanently
to the cable and not subject to deterioration by environment.
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Motor Starting
Motors less than 800 kW will be designed for full voltage starting; motors 800 kW and above will be
designed for autotransformer reduced voltage starting.
Motors designed for autotransformer reduced voltage starting shall be capable of accelerating the load
with 65 percent rated system voltage applied to the motor terminals.
For low voltage motor (415 V), the locked rotor apparent power shall apply with IEC 60034-12. However,
for machines with a rated output in excess of 55 kW the starting current shall not exceed 6.0 times the
rated current of the machine including IEC/IS tolerance.
For high voltage motor (3.3 kV & 6.6 kV), the starting current shall not exceed 5.5 times the rated current
of the machine including IEC/IS tolerance.
12.0 Design basis of Instrumentation
12.1. General
This document details the basic design criteria for the control and instrumentation for Flare Gas
Recovery Unit of HINDUSTAN PETROLEUM CORPORATION LIMITED, Visakhapatnam,
Andhra Pradesh, India.
12.1.1 Scope
a. This specification covers the minimum requirements for the engineering, design and
supply and installation of instrumentation including package units.
b. This specification provides only the qualitative specifications of commonly used
instruments.
c. In the event of any conflict between these specifications, data sheets, related standards,
codes etc., HPCL shall be consulted for clarification before proceeding with manufacturing/
execution.
12.2. Applicable Codes & Standards
Design and terminology shall comply, as a minimum, with the latest edition prior to the date of purchaser's enquiry with following codes, standard practices and publications:-
AGA American Gas association
Report No.3 - Orifice Metering of Natural Gas & other related hydrocarbon fluids
Report No.7 - Measurement of Gas by Turbine Meters.
ANSI/ASME American National Standards Institute/American Society of Mechanical Engineers.
B 1.20.1 Pipe Threads General Purpose (Inch)
B 16.5 Pipe Flanges and Flanged Fittings
B 16.20 Metallic Gaskets for pipe Flanges, Ring Joint, Spiral wound and Jacketed.
B 16.34 Valves, Flanged, Threaded & Welding Ends
ANSI B16.36 (1996)/B16.36a: Steel orifice flanges
ANSI/FCI American National Standards Institute / Fluid Control Institute
70.2 Control valve seat leakage classification
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API American Petroleum Institute
API 520 Sizing, selection and installation of pressure relieving devices in Refineries.
Part-I - Sizing and selection
Part-II - Installation
API 521 Guide for pressure relieving and de-pressurizing systems.
API 526 Flanged steel Pressure Relief Valves.
API 527 Seat tightness of Pressure Relief Valves.
API MPMS Manual of Petroleum measurement standards.
API RP 551 Process Measurement Instrumentation
Part I - Process Control and Instrumentation
API 522 Transmission Systems.
S 1101 Measurement of Petroleum Liquid Hydrocarbon by Positive Displacement meter.
S 2000 Venting Atmospheric and low-pressure storage tank non- refrigerated and
refrigerated.
S 2534 Measurement of liquid hydrocarbons by turbine meter systems
S 670 Vibration, Axial-Position and Bearing-Temperature Monitoring Systems
ASME American Society of Mechanical Engineers
ASME Sec-VIII Boiler and Pressure Vessels Code rules for construction of pressure
vessels
ASME Sec-I Boiler and Pressure Vessels Code. Section-I ‘Power Boilers’
ASTM American Society for Testing and Materials.
BIS Bureau of Indian Standards
BS British Standards
BS-5308 Part-II: Specification for PVC insulated cables.
BS-7244 Flame Arrestors.
DIN German Standards
DIN-43760 Temperature Vs Resistance curves for RTD’s.
DIN-19234 Electrical Distance Sensors; DC interface for Distance Sensor and Signal
Converter.
DIN-50049 Document on Material Testing
IBR Indian Boiler Regulations
IEC International Electro technical Commission
IEC 60079 Electrical Apparatus for Explosive Gas atmosphere
IEC 60085 Thermal Evaluation and Classification of Electrical Insulation.
IEC 60332 Test on bunched wires or cables. Part III Cat. A
IEC 60529 Degree of protection provided by enclosures (IP code)
IEC 60534-2 Industrial Process Control Valves-Flow capacity.
IEC 60584-2 Thermocouple Tolerances
IEC 60751 Industrial Platinum Resistance Thermometer Sensors
IEC 60801 Electromagnetic compatibility for Industrial Process measurement and control
equipment.
IEC 61511 Functional safety: Safety Instrumented system for the process industry
sector
IEC 61508 Functional safety of electrical/electronic/programmable electronic safety-
related
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IS Indian Standards
IS-5 Colours for ready mixed paints and enamels
IS-319 Specification for free cutting Brass bars, rods and sections
IS-1239 Mild steel tubes, tubular and other wrought steel fittings.
IS-1271 Specification of Thermal Evaluation and Classification of Electrical Insulation
IS-1554 PVC insulated (heavy duty) electric cables working Part I -voltage up to and
including 1100 V
IS-2074 Ready mixed paints, air drying, red oxide - zinc chrome
IS-2148 Flame proof enclosures for electrical apparatus for Explosive Gas Atmospheres –
Flameproof Enclosures ‘d’.
IS-3624 Specification for pressure and vacuum gauges
IS-5831 PVC insulation and sheath of electric cables.
IS-7358 Specifications for Thermocouples
IS-8784 Thermocouple compensating cables.
ISA Instrumentation, Systems and Automation Society
S-5.2 Binary logic diagrams for process operations.
S-7.3 Quality standard for instrument air
S-75.01 Flow equations for sizing control valves
ISO 5167 Measurement of fluid flow by means of Pressure differential devices inserted in circular
cross-section conduits running full
S-7.3 Quality standard for instrument air
S-75.01 Flow equations for sizing control valves
NACE National Association of Corrosion Engineers.
NEC National Electric Code.
NEMA National Electrical Manufacturer's Association
ICS-6 Enclosures for Industrial control and systems.
NFPA National Fire Protection Association
NFPA-496 Purged and pressurized enclosures for electrical equipment.
OSHA Occupational Safety and Health Authority.
SAMA Scientific Apparatus Maker’s Association.
12.3 DESIGN PHILOSOPHY
a. Instrumentation shall be complete in all respects and liberal to the extent of providing data on
all operations and variables sufficient for the safe, efficient and easy operation start up and shut
down of the plant.
b. All electronic / electrical Instruments and equipment shall be suitable for area classification as
per IEC codes and shall be certified by any recognized authority like FM, CSA, ATEX
guidelines etc. All electronic / electrical Instruments and equipment shall be finally
approved by statutory authorities in India (Chief Controller of Explosives - NAGPUR).
c. The Design and installation of Instruments shall be generally in accordance with ISA / API
Recommended practices and other applicable standards like BIS, IBR etc. Instrument shall
support availability and reliability of the plant. Material specifications and practices shall, in
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general, conform to appropriate ASTM or equivalent standards. All standards and code of
practices referred to herein shall be of the latest edition.
d. Material selection for various items shall be as per piping material specification unless
otherwise specified in the data sheets and /or “Specification for Instrumentation”. Material
specification and practices shall conform to appropriate ASTM standards.
e. All instruments and equipment shall be suitable for use in a hot, humid, Coastal and tropical
industrial climate in which corrosive gases and / or chemicals may be present. As a minimum,
all instruments and enclosures in field shall be dust proof and weather proof to IP-65 as per
IEC-529 / IS-2147 and secure against the ingress of fumes, dampness, insects and vermin.
All external surfaces shall be suitably treated to provide protection against corrosive plant
atmosphere. Generally all instrument wetted parts in contact with the process fluid shall be
316 stainless steel as minimum, or better material having corrosion resistant against the
service / process fluid. For Instruments in hydrogen service, special attention shall be given to
possible hydrogen permeation e.g. bellows or diaphragms high nickel alloys to be avoided.
Special attention shall also be given in wet H2S service to avoid hydrogen induced cracking.
Certification to NACE MR-0103 shall be specified for sour service. Considering the site
under lightning prone area, all field transmitters shall be provided with surge Protection
devices.
f. Environment Protection: The following conditions shall be considered on the design in order to
ensure the capability of functions for instrument:
i. All equipment shall be tropicalized to eliminate mildew, fungi, and other detrimental
effects of a tropical environment and shall be suitable for operation in a corrosive, salt
laden, marine atmosphere.
ii. Low ambient temperature: 15 Deg C, High ambient temperature: 45 Deg C.
g. Field mount Electronic instruments with integral LCD indicator and/or remote indicators shall
be 2” pipe mounting. FRP canopy shall be provided & installed for the same. Field switches
shall not be used.
h. Weather Protection: IP 65 minimum for all outdoor instruments, junction boxes & Local Panels.
i. Electrical Connection: 1/2” NPT (F).
j. Pneumatic Tubing: ¼” SS 316 tube (minimum) shall be considered.
k. Impulse Tubing: ½” O/D x 0.065” wall thickness, 316 SS Tube shall only be considered.
l. Steam tracing: Typically ¼” bare copper tube shall be used.
m. In general Intrinsic safe instruments philosophy shall be applicable i.e. EEx-ia IIC T4 for
Instrumentation items, Ex D for junction boxes, .Ex-p for Local panel etc. If intrinsic safe
certification is not available, then flameproof instruments (EExd IIC T4) shall be used and same
shall be brought to the notice of PMC / HPCL. The following are the area classification existing
in the Refinery:
Area classification shall be of IEC CENELEC IIA and IIB, T4 for all application except for H2
application which shall be gas group IIC.
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n. Standard 4- 20mA (HART) shall be applied for all Analog Instruments.
o. The design of electronic instruments shall be in compliance with the electromagnetic
compatibility requirements as per IEC 801 ‘Electromagnetic compatibility for Industrial Process
measurement and Control equipment’.
p. All line or equipment mounted instruments like control valves, pressure relief valves, thermo
wells, orifice plates, level instruments etc. installed on pipes & vessels under IBR shall be
certified by IBR.
q. Power Supply: 110VAC (±10%) 50Hz UPS power supply for control and instrumentation to be
considered. The details are as mentioned below:
Equipment Electrical Level
Control Panels supplied with Package Units 110 VAC 50Hz
Two wire transmitters (4-20mA) 24 VDC
Discrete inputs and outputs 24 V DC at PLC. However, interrogation voltage to field shall be 110 V AC.
Solenoid Valves( from UPS) 110 V AC
Equipment/instruments located on field with electrical power required in the field
110 VAC 50 Hz (UPS)
Level gauge Illumination & Lighting in Local Control Panel
230 VAC 50 Hz (non Ups)
r. Units of measurements shall be as under:
Measured Variable Unit of Measurement
Temperature Deg C
Pressure & Diff. Pressure mmWC, kg/cm2g
Vacuum pressure mmHg, mmWC, kg/cm2a
Liquid flow m3/hr
Gas flow Nm3/hr
Steam flow kg/hr, T/hr
Level % level, mm
Density kg/m3
Length mtrs, mm
s. Marking
Each instrument shall have a stainless steel nameplate, permanently attached from the
vendor’s factory containing the following data. Manufacturer’s name, Instrument type and
size, Model and serial numbers, Operating condition, e.g. voltage, pressure, Instrument range &
the specified instrument identification numbers or Tag number.
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t. Connection Details:
INSTRUMENT
SERVICE & / OR RATING
PROCESS TAPPING
SIZE &
TYPE
INSTRUMENT
CONNECTION Flow: D/P Type Pipe Lines 3/4” Welded ½” NPT (F)
Flow: Diaphragm Pipe Lines 3” Flanged 3” Flanged
Level: Guided wave Radar Top mounted
Vessel (300# min.)
4” Flanged
4” Flanged
Level: Guided wave Radar Side mounted
Vessel/Stand Pipe
(300# min.)
2” / 2” Flanged
2” Flanged
Level: D/P TYPE
Vessel/Stand Pipe (300# min.)
3/4”/ 3/4” Flanged
½” NPT (F)
Level: Diaphragm Type D/P
Vessels (300# min.)
3” Flush Flanged
3” Flanged
Level: Magnetic Level Gauge
Vessels/ Stand Pipe (300#min.)
2” / 2”Flanged
2” Flanged
Level: GAUGE GLASS
Vessel/Stand Pipe (300# min.)
3/4” / 3/4” Flanged
3 / 4” Flanged
Pressure: Transmitters Pipe Lines / Vessels 3/4” Welded ½” NPT (F)
Pressure: Diaphragm seal Type Transmitters
Vessels / Pipe Lines
3” Flanged
3” Flanged
Pressure Gauge 3/4” Welded ½” NPT (M)
Diaphragm seal Type gauge
Vessels / Pipe Lines
1 ½” Flanged
1 ½” Flanged
Thermowell
Pipe Lines / Vessels
(300# min.on
vessels)
1 ½” Flanged
½” NPT
Note: These connection sizes will be reconciled with PMS of relevant piping and suitable revisions to
be in consultation with HPCL.
u. Accuracy of Instruments:
Type of Instrument Accuracy
- Differential pressure & Pressure
transmitter - SMART
± 0.075% of span (Note 3)
- Variable area type flow meter with ± 2.0% FS Note (1)
- Vortex flow meter ± 1.0% FS
- Coriolis Mass flow meter ± 0.2 % or ± 0.5 % of Measured value for
liquids depending upon applicability. - Positive Displacement Flow meter
- Raw material and Product
- Others
± 0.2% FS
± 0.5% FS
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- Turbine meter or Mass Flow meter
- Raw material and Product
- Others
± 0.2% FS
± 0.5% FS
- Magnetic type flow meter ± 0.5% FS
- Ultrasonic type flow meter ± 1.5% OR 0.5 % of FS
- Tank gauge ± 1.0% FS OR ± 1 mm as applicable.
- Servo type tank gauge ± 2 mm OR ± 1 mm
- Radar type tank gauge ± 1 mm or better for custody transfer ± 5 mm or better for normal application
- Draft range Pressure transmitter - SMART ± 0.15% of span within TD ratio of 1: 30
- Diaphragm seal transmitter - SMART ± 0.2% of span within TD ratio of 1: 100
- Pressure gauge ± 1.0 % FS
- Temperature Transmitter ± 0.2% of calibrated span for RTD ± 0.5% of calibrated span for Thermo Couple.
- Filled system / Bimetallic ± 1.0% FS
- Small size pressure gauge ± 3.0% FS
- Draft gauge ± 3.0% FS
- Receiver gauge ± 1.5% FS
- Thermocouple & Resistance Bulb Applicable Codes/Standards
Note: 1. Vendor's standard accuracy is applied to local indicator type
Remarks: 1. Accuracy of instrument and special articles except for the above mentioned instrument shall be in accordance with the applicable codes/standards, or Vendor's standards as approved by Purchaser.
2. FS: Full scale.
3. Overall Turn Down of transmitter except for draft range shall be 1: 100. Draft range
transmitter Turn down shall be 1: 30 for the accuracy indicated above.
12.4 FLOW INSTRUMENTS
12.4.1 The choice of primary differential producing devices will depend on service conditions and on the permanent pressure loss, which can be tolerated. A square edged concentric orifice plate
is the usual selection if conditions permit. Quadrant edge or quarter circle orifice plates shall be used for viscous liquids and for pipe Reynolds number below 10,000 Conical entrance type of orifice plates shall preferably be used for very highly viscous liquids up to throat Reynolds number of 250. These shall be fabricated as per ISO 5167. Vent and drain holes shall be provided wherever necessary.
12.4.2 Corilios mass flow meters shall be used where greater accuracy is required like for custody
transfer, blending, feed flow from battery limit, product flow etc and for highly viscous and
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fouling fluids like fuel oil etc. In case of Gas flow Turbine type flow meter shall be used. The mass flow meter must have the capability to periodically check the validation of the last calibration through software without dismantling the meter. Indigenous make, Coriolis Mass Flow Meters shall be calibrated at NABL Accredited Lab like FCRI, Palakkad in India and the calibration of Mass Flow Meters shall be certified by Third Party Agencies like EIL/Lloyds/BV. However imported make Coriolis Mass Flow Meters shall be calibrated at the
respective foreign vendor’s works, duly accredited by the respective country’s well known Accreditation Authority like PTB, SGS etc and the same shall be certified by well-known third party agencies like SGS, LRIS, DNV etc. Procurement and Installation for Custody Transfers / Non Custody Transfers shall be strictly as per approved P&IDs. Wherever Jacketing is shown in the P&ID, the same shall be provided for Mass Flow Meter. For Custody Transfer Applications, one spare Mass Flow Meter for each size shall be procured as shop spare.
In case of High turn down applications: For liquids, Mass Flow meter shall be used & for
Gas, Turbine Flow meter shall be used.
Where Mass flow meter is not applicable, Ultra sonic flow meter/Magnetic flow meter can be used. For the measurement of cooling water flow only magnetic flow meter shall be used including for the pipes below the ground level also.
Venturis and flow nozzles may be selected where system requires low pressure drops.
Pitot tube should be an averaging pressure type, and may be selected for clean fluids, low-pressure loss and large quantity measurement.
Vortex meter may be considered for clean liquids, gases and steam measuring application with higher turndown ratio.
Ultrasonic flow meter may be considered for the flow meter on large bore piping such as flare gas measurement.
Variable area flow meters may be used where measurement with low accuracy is accepted.
Flow nozzles, venturies, target meters, magnetic flow meters, ultrasonic flow meters, self- averaging pitot tube etc may be used wherever specified in the data sheet or as required.
12.4.3 Thin Plate Orifices:
Orifice plate shall be thin plate with square-edge concentric orifice. The plate shall be mounted between a pair of weld-neck flanges with flange taps to form orifice plate assembly.
Design calculation of standard type orifice plates shall be as per ISO 5167.
The flow range shall be selected such that normal flow rates are between 50% and 70% of
the flow upper range value.
Beta ratio limits for orifice plates shall be generally 0.3 to 0.7.
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Material of construction of orifice plate shall be 316 SS except where this material is unsuitable for the service because of corrosion or erosion considerations, in which case an alloy shall be chosen whose corrosion allowance is equal to or better than line material. Orifice plates dimensions, finishing, flatness, tolerances for dimensions and identification information shall be in accordance with ISO standard. Orifice plate shall be provided with tab handle, which is welded on the orifice plate and engraved with following information on the upstream of the tab handle.
- UPSTREAM or UP
- Instrument tag number
- Orifice diameter
- NPS (Nominal Pipe Size) and ANSI flange class
- Material of the orifice plate
- DP range & Meter (Flow) range
12.4.4 Flange taps orifice shall generally be used for line sizes 2” to and including 16”. Above 16” line size, D and D/2 taps shall be used. Integral Orifice assembly with transmitter shall be used for line size 11/2 “or below (as per standard BS-1042).
Orifice assembly shall be provided with two sets of “Flange Taps” located in accordance with latest AGA standards. The orifice assembly shall be provided with jack screw for removal of orifice plate. Instrument tapping connections shall be 1/2”NPT (F).
12.4.5 For multi-transmitter flow installation from a single orifice, separate identical pair of tapping
is to be provided for each Transmitter & no branching from single tapping shall be designed. All tapings emerging from orifices shall be horizontal and shall have sufficient straight length as per standard.
12.4.6 For flow measurements by orifice wherever it is felt difficult to ensure the required upstream & down-stream straight length as per standard, the conditioning orifice plate is to be considered to eliminate the errors due to inadequate straight length.
12.4.7 It is essential that each instrument is having necessary approachable isolation as well as drain valve to check the functionality of the instrument ensuring safety.
12.4.8 Orifice flanges
Orifice flanges shall be in accordance with the ANSI B16.36, ANSI B16.36a and applicable piping specification. The minimum pressure rating of flanges shall be ANSI 300 lbs.
12.4.9 D/P Type Flow Transmitters
Flow transmitters for use with differential producing devices shall be Smart Type. All
transmitters shall be capable of communicating with Hand-Held Communicators. All
Transmitters shall have integral LCD indicator in engineering units and be furnished with test
terminals and bypass diode to facilitate field testing without disconnection of integral
indicator. The transmitters shall have over-range protection. Strain gauge types
Transmitters are not acceptable.
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500 mm H2O 2500 mm H2O
750 mm H2O 5000 mm H2O
1250 mm H2O
Separate transmitters shall be used for shutdown & control loops. Range calibration units for
flow measurement shall be mm H2O.
For Anti-surge loops, all transmitters used shall have faster response & high accuracy &
conventional (4-20 mA) transmitter shall be considered for the same. Wherever SIL (Safety
integrity level) loops are identified, min. SIL 2 certified transmitter shall be offered.
The body pressure rating shall be 100 bar minimum and measuring capsules shall be able to
withstand pressure up to the body rating in either direction without damaging the instrument or
shifting the zero more than 0.5% of the span. The body and other wetted parts material shall be
SS 316 minimum. Also other materials such as hastelloy, Monel or tantalum may be used as
per process requirement.
The transmitter electronics shall be capable of monitoring their performance during normal
operation. The transmitter diagnostics shall be able to detect both an input sensor failure and
transmitter electronics failure. The stability shall be better than +/- 0.5% of upper range limit
for 1 year.
Process connections shall be 1/2” (NPTF) and from the side/horizontal to the transmitter. Cable entry shall be 1/2” (NPTF).
Remote Loop Power indicator shall be provided (with separate DCS repeated output) as per
Licensor’s requirement.
In general Transmitter diaphragm shall have 5.7 micron of Gold plating for Hydrogen service.
Five way valve manifold shall be provided in place of isolation & equalizing valves in the impulse piping of flow transmitters for the service up to 600 # rating. However in case of high pressure service and any special requirement, piping manifold with single / double isolation valves and equalizing valve shall be considered.
12.4.10 As far as possible following standard ranges shall be used:
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12.4.11 Rota meters
Rota meters may be required as indicators or transmitters. Accuracy of measurement shall be within 2% full scale. Rota meters shall be mounted in-line for pipe sizes less than 2 inches. Rotameter Turn Down shall be 10:1. Flow damper shall be provided for pulsating flow. Cooling fins shall be provided for high temperature service (150 deg C & above). Jacket shall be provided for crystallizing fluid at ambient temperature.
Only metal tube Rotameter shall be considered. Glass tube Rotameter shall not be used.
12.4.12 Purge meters
Purge meter units shall consist of a glass / metal tube rotameter with needle valve at the inlet and a built-in check valve at the outlet. A differential pressure regulator shall also be supplied in applications where either the purge supply or process pressures are likely to vary significantly.
The design requirements for Purge meters include: rangeability of 10:1, accuracy
of +/-2% of maximum flow, “O” ring construction, and end connections of 1/4”
N.P.T (F).
12.5 Level Instruments
12.5.1 Selection
Remote diaphragm seal, D/P type level instruments with integral indication
shall be used. For slurries or other difficult services Wafer / flush diaphragm seal
type with extended capillary / Extended Diaphragm seal type shall be considered.
Guided Wave Radar type level instruments shall be used in place of Displacer type
instruments. The guided wave Radar instrument with external cage OR with
internal stilling well shall be considered.
12. 5.2 D/P Type Level Transmitters
Level transmitters for use with differential producing devices shall be Smart type
and be furnished with test terminals and bypass diode to facilitate field testing
without disconnection of integral indicator. The transmitters shall have over-range
protection. Separate transmitters shall be used for shutdown & control loops. Strain
gauge types Transmitters are not acceptable.
Wherever SIL (Safety integrity level) loops are identified, min. SIL 2 certified
transmitter shall be offered.
The body pressure rating shall be 100 bar minimum and measuring capsules shall
be able to withstand pressure up to the body rating in either direction without
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damaging the instrument or shifting the zero more than 0.5% of the span. The body
and other wetted parts material shall be SS 316 minimum. Other materials such
as hastelloy, Monel or tantalum may be used as per process requirement
The transmitter electronics shall be capable of monitoring their performance during
normal operation. The transmitter diagnostics shall be able to detect both an input
sensor failure and transmitter electronics failure. The sensor &/or electronics
failure shall be transmitted to the host system (e.g. DCS / PLC). The stability shall
be better than +/- 0.5% of upper range limit for 1 year.
Process connections shall be 1/2” (NPTF) and from the side/horizontal to the transmitter. Cable entry shall be 1/2” (NPTF).
Remote Loop Power indicator shall be provided (with separate DCS repeated
output) as per Licensor’s requirement.
Three valve manifold and oval flange adaptor shall be provided in place of isolation valves in the impulse piping for the service up to 600 # rating.
The D/P type level instruments are to be wafer seal type. It should preferably be direct mounting on the H.P side and capillary in L.P. side.
The wafer seal instruments must have the integral flange along with the diaphragm suitable to process connection.
Remote seal diaphragm type transmitter shall be used for all clean service except in hydrogen service.
In case, the process temperature is more than 200 degree C and the service is congealing, suitable flashing media is to be used along with the wafer seal type level instruments. In case the process temp. is high but not congealing, the impulse length / wafer location is to selected to reduce the process temp. in contact with wafer to about 150 deg C.
For corrosive, acid and alkali services, top mounted non-contact type
level Transmitters shall be used.
Two nos. Pressure Transmitters shall be used in place of Differential Pressure
Transmitter where long impulse piping / tubing is involved. The DP calculation
shall be done at DCS for PT1-PT2.
Separate and independent tapping shall be provided for level gauges and level
transmitters on the vessels. In case of constraint to provide many nozzles on vessel,
stand pipe may be provided to accommodate installation of field transmitters and
gauge. Stand pipes with isolation valves shall be used for LG/LTs. Maximum length
of single standpipes shall be 1500 mm. Standpipe (if required) shall be used for
Level measurements only. Separate nozzle shall be provided for pressure
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instruments. Stand pipes shall not be used for Transmitters on shutdown
applications.
12. 5.3 Level Gauge Glasses
Liquid level gauges shall be used for local indication. Gauge glasses shall be made of borosilicate armoured / toughened glass. Gauge glass shall be a single piece forged construction.
The reflex/transparent gauge glass shall be used on all clean service application.
The transparent gauge glass shall be provided with protective shield.
In case of service of crystallizing and viscous fluids, need steam tracing at
ambient temperature, level gauge shall be provided with facility of tracing.
Tubular type gauge glass shall not be used.
Gauge cocks shall be provided for all gauges preferably quick operating lever
operated forged offset ball type. All level gauges shall be supplied with ½” Drain
valve with plug & ½” vent plug. All the fittings shall be welded or screwed & seal
weld. All welding shall be TIG welding.
Transparent type glasses shall have integral illuminators operating at 240 V 50 Hz and suitable for the specified electrical area classification.
Transparent type with mica or Kel-F shield shall be used for treated water, boiler and condensate services and corrosive liquids which will attack glass.
The visible range of level gauge shall be selected to cover the operating level or the operating range of level instruments provided for the vessel.
The maximum visibility length of a single gauge shall not exceed 1500 mm. Normally glass of 300 mm (approx.) section length shall be used.
On low temperature services with liquids having very high vapor pressure at ambient temperatures safety valves shall be provided on the vent connection of the gauge glass.
Frost protection shall be considered for minus temperature fluid application. Bi-color
level gauges may also be provided if indicated by Licensor.
Magnetic level indicators shall be used in the place of gauge glasses for corrosive, dangerous or other difficult services. Maximum length for the single gauge shall not be more than 3 mtrs.
Magnetic Level gauges shall be used for high pressure H2 services. For high pressure services no threaded joints shall be used.
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12.5.4 Other level instruments
Other special type of level instruments like ultrasonic type, capacitance type, and nucleonic type shall be used as necessitated by application requirements / process Requirement.
12. 5.5 Steam Drum Level Measurement
For high-pressure steam drum application conductive type (“Hydra step” or equivalent) level instrument shall be preferred.
12.5.6 Solid Level Measurement
For solid level measurement, type of instrument shall be ultrasonic / radio frequency. The actual type selection shall be carried out based on the proven track record of the selected type for the similar type of application.
12.6 Pressure Instruments
12.6.1 General
Gauge Pressure / DP transmitters shall be used for measurement & control of process pressure from DCS. Local indication shall be by means of pressure gauges (bourdon tube, diaphragm or other element) to suit the application.
12.6.2 Pressure Transmitters
Pressure transmitters shall have suitable pressure sensing element and normally be with integral indicator. The pressure transmitters shall have zero and range adjustable, and it shall be specified so that the normal operating pressure is within 40% to 70% of the calibrated range.
Pressure transmitters shall be Smart HART type. All transmitters shall be capable
of communicating with Hand-Held Communicators. All Transmitters shall have
integral LCD indicator in engineering units and be furnished with test terminals and
bypass diode to facilitate field testing without disconnection of integral indicator.
The transmitters shall have over-range protection to 1.3 times the maximum
range of the instrument. Strain gauge types Transmitters are not acceptable.
Separate transmitters shall be used for shutdown & control loops.
For Anti-surge loops, all transmitters used shall have faster response & high accuracy & Conventional (4-20 mA) transmitter shall be considered for the same. Wherever SIL (Safety integrity level) loops are identified, min. SIL 2 certified transmitter shall be offered.
Remote Loop Power indicator shall be provided (with separate DCS repeated output) as per Licensor’s requirement.
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The body pressure rating shall be 100 bar minimum and measuring capsules shall be able to withstand pressure up to the body rating in either direction without damaging the instrument or shifting the zero more than 0.5% of the span. The body and other wetted parts material shall be SS 316 minimum. Other materials such as hastelloy, Monel or tantalum may be used as per process requirement.
The transmitter electronics shall be capable of monitoring their performance during normal operation. The transmitter diagnostics shall be able to detect both an input sensor failure and transmitter electronics failure. The sensor &/or electronics failure shall be transmitted to the host system (e.g. DCS / PLC). The stability shall be better than +/- 0.5% of upper range limit for 1 year.
Process connections shall be 1/2” (NPTF) and from the side/horizontal to the transmitter. Cable entry shall be 1/2” (NPTF).
Transmitters in vacuum service shall be capable of withstanding full vacuum regardless of range, without damage or calibration shift.
Flush type diaphragm seal element with capillary shall be used for congealing, corrosive and highly viscous services. The extended capillary shall be minimum 3 meter long.
The process connection shall be flanged 3” ANSI RF. The flange material and rating shall be as per piping specification / SS-316 minimum.
12.6.3 Pressure Gauges
Local indication shall be by means of pressure gauges utilizing a bourdon tube, diaphragm or other element like capsule to suit the application.
Local pressure gauges shall have 150mm dials and shall be quality gauges designed for the process industry.
Ranges of gauges shall be selected such that the normal operating pressure
indication is approximately at mid-scale. Accuracy of local pressure gauges shall be
+/-1.0% of full scale. Pressure gauges shall be capable of withstanding intermittent
overpressures of 1.3 times the maximum scale reading without damage or
calibration shift of more than 1% of the scale reading. Blow out disc shall be
provided for all ranges & solid front shall be provided for ranges of above 60
Kg/cm2g.
Cases for gauges having ranges between 0-2 and 0-20 Kg/cm2g shall have blowout discs in the back of the case. Cases for gauges having ranges above 0-100 Kg/cm2g shall be of the solid front type having blowout backs.
Gauges connections size shall be 1/2” NPT (M). Connection location shall be bottom for local mounting with wrench flats or back for local panel board with mounting flange.
All the gauges shall be equipped with 2 way valve manifold.
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The standard measuring element shall be a bourdon tube of AISI 316 stainless steel, except where the process fluid requires the use of special material.
Bourdon tubes shall be welded to socket and tip and stress relieved as required.
The Diaphragm Type & Capsule Gauges shall be used for low pressure applications.
Diaphragm seal type Gauges shall be used where necessary to protect gauges
from Corrosive fluid, crystallizing fluid, fluid including solids and high viscous
fluid.
Diaphragm seals shall be of welded diaphragm type close coupled to the instrument, or connected to it with capillary tubing.
The connection size for diaphragm seal type gauge shall be 11/2” flanged. The diaphragm material shall be minimum 316 SS & flange material and rating shall be as per piping specification / minimum SS 316.
In case, the diaphragm seal type instrument with extended capillary is used extended capillary tube shall be armored with stainless steel, and length shall be as determined individually but minimum 3 meters.
Diaphragm seals shall have flush connection 1/4” NPT with plug and filling
connection.
For viscous fluids, the diaphragm seal shall be clean-out type with removable bottom case
Sockets and tips shall be of the same material as the measuring element and shall be welded to the element using the same filler material. Movements shall be SS 304.
Dial face shall be white with black graduations marked. The gauge pointer shall be
adjustable without removing it from its shaft. All pressure gauges shall be
provided with block and bleed valves securely fastened with identification
tags.
Case shall be of stainless steel, solid front type and weather proof to IP-65
minimum.
12.6.4 Auxiliary components for pressure gauge
Over range protector (gauge saver) shall be provided where a pressure gauge cannot withstand design pressure conditions. Over range protector whenever used shall be of SS 316, as a minimum.
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Pulsation dampener shall be provided for all pulsating services e.g. Reciprocating pump discharge piping etc. Pulsation dampeners shall be of minimum SS 316 and have connection 1/2” NPT (F) on both ends. Dampener shall be provided with integral screw head needle valve to adjust aperture externally.
Pigtail type siphon shall be provided for steam service. Siphons shall be made of minimum SS 316 having connections 1/2” NPT (M) Or (F) on both ends as required to suit the PG.
12.7 Temperature Instruments
12.7.1 General For transmission of individual temperature signals, RTD shall be used in conjunction with field mounted temperature transmitters.
Resistance Temperature element (RTD) may be used as temperature primary elements where greater accuracy and better reproducibility are required. RTD shall conform to standard IEC-751.
All temperature elements shall generally be protected by thermo-wells. Class 'A' /
Class ‘1’ tolerance as per IEC 751 / 584-2 shall be specified for RTD /
thermocouple for temperature measurement.
12.7.2 Resistance temperature elements:
In general, Duplex type RTD shall be considered & used up to -200 to 600 Deg C.
- RTD shall conform to be PT-100, 3-wire type.
- RTD shall be spring-loaded, mineral insulated and SS 316 metal sheath type
- The sheath diameter shall be 6.4 mm as a standard unless otherwise
specified.
12.7.3 RTD heads shall be as follows:
- The RTD head shall be connected with thermowell with 3-piece union to
ensure proper contact of RTD junction to thermowell. - Head cover shall be screwed type, with SS retaining Chain fixed to body.
- Head cover shall be weather proof and ex proof suitable to specified hazardous area classification.
- Cable entry shall be 2 nos.1/2” NPT (F) with one entry plugged with SS 304 plug.
- Terminals shall have separate screws for connecting element and extension
cable.
12.7.4 Temperature Transmitters
Temperature transmitters shall be Smart HART type. All transmitters shall be capable of communicating with Hand-Held Communicators. All Transmitters shall have integral LCD indicator in engineering units. Temperature transmitters shall be Remote mounted type (on 2” Pipe), Head mounted transmitters shall not be used.
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Separate transmitters shall be used for shutdown & control loops.
For Anti-surge loops, all transmitters used shall have faster response & high accuracy & conventional (4-20 mA) transmitter shall be considered for the same. Wherever SIL (Safety integrity level) loops are identified, min. SIL 2 certified transmitter shall be offered.
All transmitters shall have universal input for thermocouple / RTD. Transmitter output signal shall be linear and directly proportional to the measured temperature with overall accuracy of +/- 0.1% FS.
Transmitter shall have automatic cold junction compensation for thermocouples. Burnout protection (selectable Up Scale / Down Scale) must be provided for temperature transmitters.
The transmitter Cable entry shall be 1/2” NPT (F).
Temperature transmitters shall be furnished with test terminals and bypass diode to facilitate field testing without disconnection of integral indicator. The transmitters shall have over-range protection to 1.3 times the maximum range of the instrument.
12.7.5 Bimetallic element local gauges
Only Bi-metallic elements shall be used. No liquid filled system to be used.
Bimetallic thermometers shall be bimetallic actuated rigid element and dial every-angle type.
Dial size of the gauge shall be 125 mm diameter. The stem and case material of the gauges shall be 316 SS.
Range shall be selected from manufacturer’s standards such that normal operating temperature indication is approximately at midscale.
In vibrating services bimetallic thermometers shall not be used. Other type of gauges can be used with PMC / HPCL approval.
12.7.6 Thermowells
Thermo well shall generally be provided for protection of the primary measuring
element. Thermowells for all services shall be in SS 316 minimum, and drilled in
a single piece from solid bar stock and tapered.
In general Thermowells process connections shall be flanged. Thermowell
connection on Lines shall be 1 1/2" NB, Thermowell connection shall be 1 1/2" NB
for uncladed vessel & minimum 3" NB for claded vessel. The minimum flange
Rating shall be 300 # or higher depending upon the pipe class for equipment /
vessels, however for the thermowells mounted on the pipe line flange rating shall
be as per pipe class. Thermowell and flange material shall be SS 316 minimum
or better as per piping class. Screwed type thermowells are not acceptable.
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In general, immersion length of thermowells shall be as follows:
Line Size Immersion length (When nozzle height - 200mm *)
4” 280 mm
6’’ to 8’’ 300
From 10” to 14’’ 350
Vessels / columns As per process requirements
For other nozzle heights, immersion length will be adjusted proportionally.
Other sizes and immersion lengths may be considered based on special
condition / actual requirements.
The design of the wells shall be verified by means of stress analysis, resulting from stream velocity condition. The wake frequency shall not exceed 66% of the thermowell natural frequency.
Pipe line below 3” nominal bore shall be blown to 4” NB size to install thermowell.
Only thermowell (test well) when specified, it shall be provided with the element entry plugged with SS plug and SS chain.
All the thermowells shall be offered for hydro testing at site to PMC/OWNER before installation.
12.8 Control Valves
12.8.1 Control valves shall normally be globe type top guided single seated type or eccentric disc rotary shaft type, except where high pressure drops, high capacity or other adverse conditions require for other type of valve.
The butterfly valves may be used for control and on-off applications with size equal or larger than 8”.
Ball valves may be used for on-off applications. Other valve types like diaphragm valves, rotary plug, angle or 3 way etc. shall be selected as per service / Licensor’s requirements.
12.8.2 Control Valve body shall be flange joint type. Valve body material, flange type,
rating and finish shall conform to the piping specification, however, the body & flange rating shall be minimum 300# for globe valves.
The body metallurgy of control valve shall be minimum as per piping specification. Body material WCB / WCC or equivalent is acceptable. If Piping specification calls for WCC or higher grade material then same shall be followed for selecting the control valve body material.
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Trim material shall be SS 316 or better. Trim shall be provided with partial or full stelliting in case of high pressure drops, erosive / slurry / steam / flashing services when recommended by manufacturer.
For all the control/shut down valves in steam / BFW application body metallurgy of the valves shall WCC or equivalent and trim to be properly stellited. All shutdown valves shall have Leakage class VI.
12.8.3 Anti-cavitation trim shall be selected wherever cavitation is expected in the valve.
12.8.4 Sizing of control valves shall be as per ISA-S75-01. Also valve selection to be
made for the manufacturer’s valve “CV” at maximum opening is not less than 160%
of the CV calculated for normal design flow or 110% CV of maximum flow,
whichever is higher.
Valve travel shall be between 20% to 80% for specified minimum & maximum
flow. Minimum body size of the control valve shall be 1”, reduced trim shall be
considered for smaller line size / small flow.
12.8.5 Valve Trim Characteristics
Equal percentage plugs shall normally be used when there are large variations in
valve pressure drop.
Linear characteristic plug shall be selected for
a) Level control
b) Over pressure control in steam or gas service
c) Small variations in valve pressure drop
d) Operation by remote hand controller
e) Split control and parallel control by two valves
f) Small CV and low noise valves as designated by MFR.
Quick opening trim shall be used for ON-OFF and Emergency Shutdown Valves.
For the corrosive & critical services Licensor guidelines shall be followed but in
general Stellite facing / hard facing trim shall be preferred (Plug, Stem, Seat ring).
Licensor’s requirement will take precedence in selecting trim metallurgy. However,
the trim material shall be SS316 with guide bushing of hardened stainless steel like
440C, 17-4PH as a min. up to a pressure drop of 10-12 kg/cm2. For higher pressure
drop, erosive/slurry services hardened surfacing of plug/seat ring etc. are to be
considered. 17-4 PH seat ring, 440C solid plug and other materials like Hastelloy,
Monel etc. should also be considered based on service requirements.
NOTE: Whenever the trim characteristics / material are specified in the Licensor’s data sheets then same shall be followed.
12.8.6 Face to face dimensions of the control valves shall be as per ANSI/ISA-S75.03.
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12.8.7 Noise level measured at 1 meter downstream and 1 m upstream of pipe wall shall
not exceed 85 dB. Source treatment of noise shall be preferred by using special
trims like anti-noise trims.
12.8.8 Copper or copper alloys in valves and accessories shall be avoided.
12.8.9 Seat leakage shall be chosen in accordance with process demands, safe operation of the plant and shall conform to ANSI / FCI 70.2
12.8.10 Bonnet shall be provided with cooling fins or extension when the fluid temperature
is 232 Deg C and more and shall be of extension type for low temperature -29 Deg C
below.
12.8.11 Valve packing shall be Teflon for temperature below 200 deg C and graphite for
steam services and temperatures above 200 deg C.
12.8.12 Generally, control valve actuator shall be of the spring and diaphragm, pneumatically actuated type. Standard air control signal to positioner shall be 0.2 to 1.0 kg/cm2g. Piston type actuators with or without fail-safe capacity tanks shall be considered if actuator force requirements fall beyond the normal range of diaphragm actuators. All actuators shall be adequate to fully stroke the valve under the maximum differential pressure specified by the process requirements.
Actuator colour shall be Red for air failure to close type and shall be green for air failure to open type. The valve actuator should be designed based on 4 kg/cm2
air pressure.
12.8.13 Electro-pneumatic valve positioners shall be provided for all control valves except
for On- Off valves. Air filter Regulator filter to be 5 micron. Miniature type, plastic
body & drain assembly etc .as parts of air filter regulator are not acceptable. Control
valves shall be provided with Smart/ HART type positioners. The Control valve and
its valve positioner shall be from same manufacturer. Proper canopy shall be
provided for E/P positioners and other accessories as required.
Necessary software for valve signature should be a part of the smart positioner
supply.
12.8.14 E/P Positioners, solenoid valves, booster relay, air lock relay, limit switches etc shall be supplied wherever required. I/P converter, when used it shall be Electronic feed back type and the enclosures shall be metallic.
Separate air filter regulator shall be used for each E/P Positioners.
12.8.15 In general, all tubing and fittings for control valve pneumatic signal shall be
SS 316 minimum.
12.8.16 Hand wheel shall be considered where the block and by-pass valves are not provided in the process piping or when required by process. In general no by-pass or hand wheel shall be used for shutdown valves unless otherwise specified by licenser.
12.8.17 Limit switches and any other electrical accessories shall conform to the
electrical area classification and environmental conditions.
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12.8.18 Limit switches shall be of Proximity type and intrinsically safe certified. Limit switches shall be provided both for close and open positions for all shutdown valves & only for Fail position in case of control valves.
12.8.19 Solenoid valves (Direct acting type) shall be used as the pilot valve to trip a
shutdown valve, On/Off valve. Solenoid valves, wherever used, shall be universal
type and shall be continuous rated type with class H coil insulation as per IEC 85/IS
1271. Wherever SOV are used for control valves in modulating services, SOV shall
be installed between positioner output & actuator & de-energising of SOV shall
bring control valve to failure poison by venting the actuator
Solenoid valve shall be of SS body with SS316 trim, three-way type universal operation as a minimum. Positioners with inbuilt SOV’s are NOT acceptable.
The solenoid valve operating voltage shall be 110V AC and suitable for
specified hazardous area classification. For On-Off valves, all Solenoid valves
shall have Auto Reset for ordinary application and field manual reset (FMR) shall
be provided for critical trip application as per Licensor’s Requirement. Integral
Reset with SOV shall not be provided. The ASCO / HERION / Max Seal make
Solenoid Valves shall be considered. Direct line mounted SOV shall not be
considered.
12.8.20 The guideline to identify the tight shutoff control valves is as follows:
1. Compressor spillbacks
2. High pressure shutoff valves (Depressurising valves )
3. Isolation valves
4. Emergency Shutdown valves
12.8.21 Seat leakage class for single ported and double ported valves or cage guided valves shall be minimum class IV type. All tight shut-off valves specified by Licensor shall meet class V seat leakage class requirements for metal seated valves and class VI requirements for soft seated valves as per FCI 70-2.
Class-VI leakage class with soft seat shall be considered for fuel gas service to flare
below 150 deg.C. and / or below 20 kg/cm2 pressure drop, other than this metal to
metal contact with leakage class-V to be used.
12.8.22 The other auxiliary devices such as lock up relay, pilot relay, booster relay volume tank etc. shall be provided as parts of the actuating system in order to achieve the required stroke-speed, fail safe action etc.
12.8.23 All control valves in service for temperature less than –20 deg. C, shall undergo
cryogenic testing in line with BS-6364.
12.8.24 All control valve castings in H2 service shall undergo Helium leak test
(additionally piping specifications also shall be referred for considering basis of helium leak test)
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12.8.25 Tag plates for all Control Valves shall be in SS 316 and necessary information like Tag no, Make, Model no, Service, Cv, Spring Range, Type etc shall be marked in bold font.
12.8.26 On / Off Or shutdown valves (in fire prone Area / As per Licensor’s guidelines) shall have external Fire Proofing Box (K-Mass OR equivalent Type) for actuator & valve assembly. Fire Proofing Box shall be as per API 607 standard. The enclosure material shall be SS304 & it shall withstand Refinery Fire 1100 Deg C for around 15 to 20 minutes. The enclosure shall have adequate openings for entry of Tubes / Cables, which shall be sealed at site after completion of erection.
12.9 Safety Relief Valves
12.9.1 Sizing of safety relief valves shall be in accordance with API RP-520 (latest
edition), Indian Boiler Regulations ASME Section I (Power Boilers) and ASME
code for Pressure Vessels Section VIII’. The code stamps shall be provided for
safety valves in case ASME and Indian Boiler Regulations design.
Safety relief valves shall normally be direct spring loaded types and provided
with full nozzle type. Balanced bellows type safety valves shall be provided when
variable backpressure exceeds 10% of the set pressure or fluid is corrosive. Pilot
operated pressure relief valves shall be used for special services and where set
pressure is closer than 10% of the operating pressure, in general. Thermal relief type
valves shall be used for thermal expansion of liquid or gas. Vacuum relief type
valves shall be used for Storage tank. Steam jacket type safety valves shall be
used for crystallizing fluid at ambient temperature.
12.9.2 ¾ “x 1” threaded (NPT) modified nozzle type valves with typically 0.38 cm2
orifice size shall be specified for thermal relief.
12.9.3 The body material shall, as a minimum, be as per piping specifications. Nozzle and disc material shall be SS316 as a minimum with machined stainless steel guide, and spindle. Whenever semi nozzle designs are unavoidable, body material shall be at least same as nozzle material.
12.9.4 The spring material of pressure relief valves shall be as follows unless
otherwise necessary because of process conditions.
-29ºC to 250ºC : Cadmium / Nickel plated carbon steel
Above 250ºC : Tungsten alloy steel
Below – 29ºC : Stainless steel 316
12.9.5 Flanged connection shall normally be specified for standard sizes 1" or larger with facing and rating in accordance with the piping specification.
12.9.6 Where permissible, screwed connections shall be used on sizes ¾” and below and
for thermal expansion relief valve.
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12.9.7 Conventional type safety valves shall have vented bonnets with screwed caps; balanced bellows type safety valves shall be of the yoke type with screw setted caps.
12.9.8 Plain lifting levers shall be provided for steam and air services. Packed lifting levers
shall be used when protection against leakage is required.
12.9.9 All safety relief valves relieving to flare header shall be balanced bellows type only with trims and bellows in SS 316 L.
12.9.10 Pressure relief valves required for liquid service shall have liquid trim with
discharge coefficient certified by ASME.
12.9.11 Pressure relief valve body casting and nozzle casting with inlet rating of 600 # and above in Hydrogen service shall undergo Helium leak test.
12.10 Gas detection system Hydrocarbon gas detectors shall be IR type. The transmitters shall be intrinsically safe with 4~20 mA output superimposed with HART Protocol. All transmitters shall have local LCD display units.
All the mounting accessories, splash guards, junction box etc. shall be included in the scope of supply. Calibration cylinders for 6 months of operation shall be supplied. Gas detectors shall be weatherproof & IS certified.
12.11 Local control panels & Local Gauge Board
12.11.1 Only indication lamps / alarm panels in flameproof or intrinsically safe enclosure shall be installed in local panels.
Field panels shall be Ex-proof / Pressurized panel with purge system considered depending upon the panel size and other criteria for hazardous areas.
12.11.2 Local control panels, in general, shall be of free standing, totally enclosed construction, fabricated from 3.2 mm thick CRCA steel plate. Maximum dimensions shall be 2100 mm (H) x 1200 mm (W) x 1000 mm (D).
The panels shall be pickled / phosphated and shall undergo a seven-tank process
before primer is applied. The panels shall be provided with 2 coats of red oxide
primer and 2 coats of final stove enameled paint. Paint colour shall be any of the
following (to be confirmed).
Opaline green IS 275
Light admiralty gray IS 697
As approved by the OWNER.
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12.11.3 Panel doors shall cover the total width and height of a panel section. All doors shall have continuous stainless steel plane hinges. Panels over 1200mm wide shall have double rear doors with heavy duty T-bar latches. Panels less than 1200mm wide shall have single rear door with heavy duty T-bar latch.
12.11.4 Panels shall be provided with 4 lifting lugs at the top. The panels shall be well sealed against ingress of dust and moisture. IP 51 as per IEC 529 for indoor applications and IP 55 for outdoor service.
12.11.5 Local control panel for the package units shall be installed within the battery limit of the package considering operational and maintenance requirements and accessibility. In case of skid mounted package; panel shall be located away from the skid.
In case local control panel is housed outdoor i.e. not in a local control room, it shall be designed to meet IP-55 requirements. In addition, panel must be provided with a rain cum sun shade canopy /shed
12.11.6 It shall be possible to switch off incoming power to panel from panel front. All
such power on/off switches shall be flameproof type.
12.11.7 Local control panels shall be either flame-proof Ex.’d’ type or purged type as per
NFPA-496 Type Y purging. An alarm shall be provided on local panel, whenever the
panel pressurization falls below 2.5 mm of H2O. All hinges, screws and other
non-painted metallic parts shall be of stainless steel material.
Local Control Panel shall have Canopy/ Shed Provision at the top for Monsoon/Sun
Protection and also lighting arrangement outside the Local Control Panel shall be
provided at the top of the Panel in addition to the Lighting arrangement inside the
Local Control Panel. 12.11.8 Analogue signals shall be 4~20 mA DC loop powered by intrinsically safe certified
Isolator repeaters in control panel, wherever required. Vendor shall use isolator
repeaters with single input and dual outputs for repeated signals.
All close & open loops signals required at LCP shall be terminated to DCS/PLC
first & the repeated output from DCS/PLC (using 1 in 2 mA output convertors) shall be wired to LCP for local indication / information to the local operator.
12.11.9 LCP shall have LED cluster type intrinsic safe Alarm Annunciator for alarms &
trips. All instruments like push buttons, lamps, selector switches etc on LCP shall be used in Intrinsic Safe Circuit. The switches / push buttons etc. are preferably to be miniature type and the lamps are to be LED type. All stop push buttons shall be guarded type. It is desirable to have only IS type instruments mounted in the local panel in case it is located in hazardous classified.
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12.11.10 Engraved identification plates shall be provided for all instruments on rear of the panel face. Instruments shall have integral nameplate on the panel front. Markers for wires, tubes, terminals, connectors, switches, circuit breakers, panel numbers etc. shall be permanently affixed on them
12.11.11 The panels shall normally be floor mounted on channel base. Channel base and
suitable bolts shall be included in the scope of panel supply.
12.11.12 Cable entry to the panel shall be only from the bottom. Suitable removable cable gland plate with double compression type cable glands shall be supplied along with the panel. All unused cable entries must be plugged.
12.11.13 All panels shall be equipped with an earth bus securely fixed along the inside base
of the panels. Provision shall be made for future extension of the earth bus, if need arises.
12.11.14 The control panel shall be subjected to the following tests and checks:
1. Check of panel alignment and mechanical operation check
2. Verification of degree of protection as per IS 2147.
3. High Voltage Test (2000V for 1 minute)
4. Verification of wiring as per approved drawings
5. Routine tests and checks on all panel accessories
12.11.15 Local Gauge Board : Local gauge board shall be used to install
skid mounted instruments like pressure gauges, temperature gauges and
transmitters. Local gauge boards, when provided shall have easy access at the rear
and front for all instruments and accessories for maintenance and operation.
12.11.16 Gauge board shall be constructed from 3 mm cold rolled cold annealed steel
sheet with other necessary steel supporting structure and shall be painted as per Mfr.
Standard.
12.11.17 Local gauge board shall be supplied with all instruments installed and completely
in tubed/wired condition before shipment.
12.11.18 All pressure gauges shall be provided with block and bleed valves securely
fastened. Identification tags shall be securely fastened for easy identification both at
the front and rear.
12.12 Installation materials
12.12.1 Cables
a) All cables shall have PE insulated primary insulation of 85 Deg C PVC as per IS-
5831 type C and inner and outer jacket shall be 90 Deg C PVC to IS-5831 type
ST-2. Oxygen index of PVC shall be over 30% and temperature index shall be over
250 Deg C.
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b) Cables shall be fire retardant (FRLS) as per standard IEC 332 Part III Cat. A.
c) The insulation grade shall be 600 V/1100 V as a minimum and shall meet insulation
resistance, voltage and spark test requirements as per BS-5308 Part-II.
d) All cables shall be twisted & armoured with galvanised steel wire – round as per IS-
standard.
e) Color coding of thermocouple extension cables shall be as per ANSI standard.
Outer colour shall be light green for intrinsically safe cables.
f) Conductors shall be stranded electrolytic annealed copper except for T/C extension
cables Maximum dc resistance of the conductor of the cable shall be as per IS8130.
g) The drain wire resistance including shield shall not exceed 30 ohms / km.
h) A pair of communication wire shall be provided for multipair cables. Each wire
shall be 0.5 mm2 of plain annealed single or multi-stand copper conductor with
0.4 mm thick 85 Deg C PVC insulation. Insulation shall be green and red color coded.
i) Run length of the cable shall be printed at least at every 5-metre interval.
j) Signal / alarm cables
1) Single pair shielded signal cables shall be used between field instruments
and junction boxes/local control panels.
2) Multipair individually and overall shielded signal/alarm cables shall be
used between junction boxes/local control panels and main control room, in
general.
3) Shield shall be aluminum backed Mylar polyester tape bonded with the
metallic side down helically applied with either side having 25% overlap
and 100% coverage. The minimum shield thickness shall be 0.05 mm
in case of single pair/triad and 0.075 mm in case of multipair/triad cable.
4) Drain wire shall be provided for Multipair cables and overall shield, which
shall be 0.5-mm2 multi, stranded bare tinned annealed copper conductor.
The drain wire shall be in continuous contact with aluminum side of the
shield.
5) All multi pair cables shall have 6 pair/12 pairs only while multitriad cable
shall have 6 triads / 8 triads only.
k) Solenoid valve Cables
1) Single pair cables shall be used between field mounted solenoid valves and junction boxes/local control panels.
2) Multi core control cables shall be used between junction boxes, local control
panel and main control room mounted devices in general. These cables shall have overall shielding apart from individual shielding. Specifications for SOV cables shall be same as signal cables except for the outer sheath color which is ‘Black’.
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l) Power supply cables
1) All power supply cables shall be as per IS-1554 Part I and shall have
copper conductors. Minimum conductor size shall be 2.5 mm2.The cables
shall be PVC insulated and armoured. The higher size conductors shall be
used in case of long distance power cable where voltage drops more than 3
volts than required supply.
2) Any other special cable required for instruments that should also be supplied
as per requirements. CONTRACTOR shall ensure that these cables are armoured type and shall meet all other requirements.
3) The following table shall be followed for selecting cables for specific application:
Type
No of Cores/ Pairs
Brief Specification
Wire Colour
Coding
Colour of Outer Sheath
Remarks
Non -IS
IS
S1 6, 12 Pairs
Main signals runs (Analogue / Digital signals including SOV) between SRR and field junction boxes shall be FRLS as per IEC 332 Part III Cat A, twisted pair (as per IS std.), multi-stranded 1 mm2 (17 AWG) pair electrolytic annealed copper conductors, 85ºC PVC insulated as per IS-5831 type C, an individually shielded with aluminum-mylar/polyster screen, and an overall aluminum-mylar/polysterscreen over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire, 90ºC PVC bedding to IS 5831 type ST-2, galvanised steel wire armoured, 90ºC PVC sheathed overall to IS-5831 type ST-2, an overall shield, 600V/1100 V grade insulation as per BS-5308 Part-II.
Black(-), White(+) (Each pair within a
cable shall be identified
with a unique
number.)
Black Light Blue
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S2 1 pair
Individual analogue/digital signal runs between field junction boxes and instruments, shall be FRLS as per IEC 332 Part III Cat A ,twisted pair (as per IS std.), multi-stranded 1.5 mm2 (15 AWG) pair electrolytic annealed copper conductors, 85ºC PVC insulated as per IS-5831 type C, overall aluminum-mylar/polyster tape over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire, 90ºC PVC bedding to IS 5831 type ST-2,galvanised steel wire armoured, 90ºC PVC sheathed overall to IS-5831 type ST-2,600V/1100 V grade insulation as per BS-5308 Part-II.
Black(-), White(+)
Black Light Blue
Type
No of Cores/ Pairs
Brief Specification
Wire
Colour Codin
g
Colour of Outer Sheath
Remarks
Non -IS
IS
T1
6, 8
Triad (typica
l)
Main runs between SRR and field junction boxes for three wire devices, shall be FRLS as per IEC 332 Part III Cat A ,twisted Triads (Triple) (as per IS std.), multi-stranded 1 mm2 (17 AWG) electrolytic annealed copper conductors, an individually shielded ,85ºC PVC insulated as per IS-5831 type C with aluminum-mylar/polyster screen and one overall aluminium-polyester screen over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire, , 90ºC PVC bedding to IS 5831 type ST-2, galvanized steel wire armoured, 900C PVC sheathed overall to IS-5831 type ST-2, an overall shield, 600V/1100 V grade insulation as per BS-5308 Part-II.
Blue,
Brown, Black
(Each pair within a
cable shall be identified
with a unique
number.)
Black
-
RTD
signal, Vibration measure ment , Axial
Displace ment
measure ment, Gas
Detector
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T2
1 Triad
Three (3) wire devices which have individual signal cable runs to field junction boxes or direct to the SRR, twisted Triads (Triple) (as per IS std.), multi-stranded 1.5 mm2 (15 AWG) copper conductors, 85°C PVC insulated as per IS-5831 aluminium-polyester screen over a 0.5 mm2 (20 AWG) minimum) tinned copper drain wire, type-C 90°C PVC bedding to IS-5831 type-ST2 , galvanized steel wire armoured, 90°C PVC sheathed overall to IS-5831 type-ST2 600/1100 V grade insulation.
Blue,
Brown, Black
Black
-
T3
1 pair
Individual signal runs between elements & transmitters, shall be FRLS as per IEC 332 Part III Cat A 1.3 mm2 (16 AWG) pair solid conductor, provided with overall aluminum-mylar / polyster tape over a 0.5 mm2 (20 AWG) (minimum) tinned copper drain wire. The Thermocouple extension wire shall be in accordance with ISA (ANSI) MC96.1.
Yellow / Red
(K-type)
Black
Type of thermo- couple
extension cable
shall be compatib le with thermo- couple
used. JX type
shall not be used.
P1
3
cores
Power feeder for instruments / Local Panel - 110V AC 50 Hz, shall be FRLS type. The power supplies shall be 2.5mm2 (13 AWG) minimum, copper conductors, PVC insulated, galvanised steel wire armoured, covered by an outer sheath of PVC, 1100V grade min. The power cables shall be designed as per IS-1554 Part-I.
- for 3 core Red (hot),
Black (neutral)
and Green (earth)
Black
-
E1 1 core Earthing, minimum 2.5 mm2 stranded copper conductor
Green with single yellow
strip
m) Cable glands
All cables glands shall be of type 304 SS; double compression type suitable for armoured cables and have PVC shrouds.
Flame proof glands wherever required shall be supplied with applicable
Ex (d) Certification.
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12.12.2 Junction boxes
Separate junction boxes shall be used for IS and non IS signals. Further it shall be segregated based on signal types given below;
a) Analogue input/Analogue output
b) Digital input
c) Digital output & SOV d) Power cable.
e) Vibration signal
f) Gas detectors
NOTE: In general direct cables shall be avoided in general but direct cable shall be considered for pulse signals (If any).
a) Junction boxes shall be of die cast aluminum alloy (LM-6) body minimum 5 mm
thick. All JB’s shall have threaded cover wherever applicable. The JB shall be
flameproof Ex (d) as per IS 2148/81 suitable for Installation in required Hazardous
Locations (Gas Group IIA, IIB OR IIC). Protection shall be IP-65 as per IS
13947/93 Part-1. Junction Box shall be CCOE approved, for specified hazardous
area class based on gas group service.
b) Terminal strips required. – 2 rows of 24 nos of terminals each, 2.5 Sq.mm,
Cage Clamp, SS Spring, Screw less Phoenix / Wago make Connector with Front
Entry and numbering strip shall be clearly visible after wiring. All terminals shall
be DIN rail mounted. Each JB shall be provided with external earthing lugs
suitable for 4 mm2 earthing connection.
c) Cross ferruling philosophy to be followed for wiring. Black letters on yellow/white
sleeve to be followed for normal signals. Red color letters on white/yellow sleeve to
be followed for trip related signals.
d) Telephone sockets and plugs shall be provided in junction boxes.
e) No of Entries: For 12 pair cables - Two bottom entries of size 1½” NPT for multipair cable, 12 Nos Side entries (Six entries in each side) each of ½” NPT for single pair signal cables.
f) In each junction box minimum 2 Nos. of ½” NPT branch cable entries & 1 No. of 1 ½” NPT bottom entry shall be kept as spare. All spare entries shall be provided with SS plugs (Ex d). The multi pair cable entry shall be from bottom & branch cable entries shall be from side only.
g) Graphite based grease should be applied to junction box cover and all screw before shipment. Each junction box shall have SS Tag Plate at the center of cover plate.
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h) JB Colors shall be as described below
For all IS Boxes: Blue (Epoxy shade) – inside Epoxy Yellow
For Non IS & Power Junction Boxes: Gray (Epoxy shade) – inside Epoxy Yellow
12.12.3 Impulse piping/tubing
a) In general transmitters for hydrocarbon service shall be installed close coupled (as
per Licensor requirement) or with minimum length of impulse tubing.
b) Impulse piping / tubing shall be ½ in. NB impulse lines as per piping specification, however final connection to instrument of impulse piping shall be made using 12mm OD X 0.065” thick ASTM A -269 TP 316 stainless seamless tubes and SS 316 compression fittings. SCH 80 seamless pipe with at least 3000 lb rating fittings should be used as minimum for impulse piping.
c) For long impulse lines wherein process line is not accessible and field transmitter
is accessible from a grade level, following guide lines are to be followed.
d) Impulse line entering to the transmitters which are installed at ground/grid levels shall be done by SS-316 tubing and balance impulse line up to the 1
st isolation
valve shall be done by ½” size piping. The joining of these two impulse lines (Pipe & SS Tube) shall be done by flange joints. However, close coupled type impulse line hookups shall be preferred incase both process lines and the transmitters are accessible from same grade level.
e) Steam tracing shall be 1/4” mm OD bare copper tubes of electrolytic grade copper.
f) Proper accessibility to be provided to installed field devices by providing ladder or platforms, for maintenance.
g) Unique colour (post office red) to be painted to the impulse piping for identification
of instrument used for trip applications (near Transmitter end).
h) MOC of tubes and tube fittings shall be of minimum SS-316.
12.12.4 Pipes and tube fittings
a) Pipes and tube fittings shall be SS 316 double compression tube fitting of three-piece construction of Swagelok / Parker make only. The tube fittings shall be of min.3000 # rating.
b) The fitting/ferrule hardness shall be in the range of RB 85-90 so as to ensure
a minimum hardness difference of 5 to 10 between tube and fittings. The ferrule shall be of stainless steel material, in general.
Socket-weld type forged pipe fittings of suitable material and rating shall be supplied for pipe fittings. The minimum rating shall be 800 lbs. Weld neck fittings shall be used where socket weld types are not allowed by piping class.
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c) All threaded fittings shall have NPT threads as per ANSI/ASME B16.11 only. d) All
the pipe fittings shall be of 800 LBS minimum rating. All tubing shall be properly
clamped as per international standard and good engineering practice.
12.12.5 Pneumatic signal tubes
a) Pneumatic signal tubes shall be ¼” OD x 0.028-inch thick SS 3316 tubes as per ASTM A 269 seamless type. Where air supply requirement is more such as large size on/off valves 12 mm OD tube shall be used.
b) Use of intermediate connectors shall be avoided and shall estimate single run
length for each instrument location. Air supply to individual instruments shall be provided with SS 304 full bore ball valves.
12.12.6 Instrument air manifolds, fittings and valves
a) GI Pipe shall be provided from Isolation valve of Air Header up to the Air
manifold. Further distribution will be through the Air manifolds (6 Way Or 10 Way)
b) Instrument air manifolds made out of 2” inch Seamless SS pipe.
c) Double compression type Stainless steel fittings made out of solid bar stock of
3000 lbs rating shall be used.
d) Isolation valves on instrument air service shall be pack less gland type full-bore ball valves and body material shall be SS 316.
e) All isolation and drain valves shall be gate valves. Equalizing valves shall be
globe valves.
f) Body rating and material shall be as per piping class or better and trim material shall
be SS 316. All valves and manifolds shall be forged type only and of minimum
800 LBS rating. g) Superior body and trim material shall be selected if required by process conditions.
Packing material in general shall be of PTFE.
12.12.7 Air filter regulators
a) Instrument air filter regulator of suitable size, range and capacity shall be supplied
for each pneumatic instrument.
b) The body of the filter shall be anodized aluminum.
c) The filter shall have 5 micron sintered bronze/ceramic filter element and shall be provided with manual drain and 2” nominal size pressure gauge.
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12.12.8 Cable trays and Ducts
a) All cables on the main pipe rack shall be laid in cable duct. Cable ducts shall be
of FRP construction with cover.
b) All instrument cables in general will be laid over the ground. All branched field cables in the unit area will be laid on machine molded FRP cable tray. The tray shall be of perforated type FRP material. The same will join the cable duct highway above the pipe rack and proper separation between IS / Non IS cables & Power cables in the duct highway shall be maintained. For road crossing and wherever, above ground laying is not possible, cables will be laid underground through cable trench/ Hume pipe.
Instrument cable duct routing should be designed in such a way, that the same
should not get disturbed or damaged during any underneath running mechanical pipe
line replacement
c) The cable ducting sizing should be done in such a way as to provide at least 50%
extra spare capacity for future additions.
d) The vertical drops on the ducts shall be avoided as a general philosophy. Cables shall be made to drop through inclined (45-60 degree) ducts.
e) All FRP trays shall be made of Glass reinforced Flame retardant Isophthallic polyester (minimum Glass content 45 %). It shall be Corrosion resistant and Fire retardant (Class 1, Fire rating) in accordance with the latest ASTM E-84 / IS - 6746. Painting of cable trays shall be as per HPCL painting specifications (Refer attached document no. DSI-G-1.2)
f) An additive is to be mixed with the matrix polyester to make the material Ultraviolet resistant. The FRP Cable Bearers are to be manufactured using the PULTRUSION process. Both sides of FRP trays shall have machine finish.
g) Up to 150 mm width, FRP trays shall be Channel type and above 150 mm width, FRP
trays shall be Ladder type.
h) All FRP trays shall have minimum thickness as per follows.
Up to 100 mm tray- thickness minimum 4 mm
above 100 mm tray- thickness minimum 5 mm
Only SS 316 nuts & bolts shall be used for FRP trays jointing plates.
i) FRP trays for channel type shall have horizontal array of holes of 4 mm diameter at every 300 mm of tray length for cable clamping purpose. Gaps between holes shall be less than 30 mm.
j) Necessary FRP tray bends, tees etc shall be supplied along with the FRP trays.
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k) Structural supports used for cable ducts / tray etc should be sufficiently strong to take
care of the load of the fully loaded cable duct.
l) All underground cable trenches wherever required shall be loaded up to 50%
capacity in order to meet future additions
m) Separate cable tray will be used for IS / Non IS cables & Power cables. All cables shall be laid in single layer in case of Trays and all cables shall be identified / marked with SS-316 tag plates with SS-316 wires at every 20 metre intervals. Only 316 SS Bolts/Nuts for FRP Cable Trays and Canopies shall be used
12.12.9 Instrument support/structural steel
Instrument stands, stanchions and other structural steel material required for supporting the cable trays, impulse lines and instruments shall be considered. Structural angles used for cable dropping to Junction Box or to field device shall be preferably galvanized. Stanchions shall be made out of A106 Gr. B 2” size pipe as a minimum. In case application calls for higher grade material, the same shall be supplied by contractor” All the structural steel & stanchion shall be epoxy painted.
All field Instruments shall be adequately supported.
12.13 Painting Specification
a) All the outdoor items shall be tropicalized and epoxy painted. All carbon steel
bolting shall be hot dip galvanized or Cadmium plated and bi-chromated.
b) Screws, rivets, brackets and stiffeners shall be stainless steel.
c) Color of the top coat of panels shall be manufacturer standard / to
be confirmed.
d) Painting for field Instruments, Canopies, Instrument lead lines, gas
detectors, cable ducts, trays shall be as per attached Painting
specifications (Document No. DSI-G-1.2)
12.14 Erection of Field Instrumentation
12.14.1 General
a) All the instruments should have approach for maintenance. All instrument location should be accessible /approachable.
b) The JBs are to be Ex proof as a standard to ensure interchangeability. The cable
entry must be from bottom and branch cable entry shall be from the sides. The incoming multi pair cable shall have minimum 1mtr. of spare loop before glanding & termination. All the power supply JBs are to be earthed locally (through electrical earthing system at field).
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c) The power cables are to be laid in different trays and not to be mixed with the signal cables.
d) In general JB’s should not be installed on vibrating body. The location must not have nearby very hot lines, condensate draining arrangement etc. JBs are to be installed in location having approach for maintenance. All the glands are preferably to be double compression type with necessary shrouds
e) The SS tubing for instrument air to control valve, I/P etc. are to be 6 mm O.D
unless otherwise specified. The fittings must be double compression type. Copper tubing should be avoided except for steam tracing.
f) Necessary fire proofing is generally preferred for the complete duct and the venerable
portion of the trays.
g) The supports for the closed couple field instruments are to be taken from the same pipe / equipment (except for wafer seal instruments) only to avoid effect of expansion on account of temperature, pressure etc.
h) The impulse lines are suitably painted if not insulated.
i) Perforated trays are to be used for laying of capillary of wafer seal type instruments.
l) The tapping for level instrument / level stand pipe from vessel / column bottom should be avoided. The impulse for steam / liquid lines must have required slope towards the instruments. However, for gas services the slope must be towards the process i.e. self draining type.
m) It is preferable to use only socket weld (SW) type fittings for impulse piping. Wherever it is difficult (like 150#RF flange etc.), next higher size SW fittings are to be used. The impulse should be sch 80 seamless piping as a minimum.
n) There should be at least one isolation valve & one drain valve in the impulse of each instrument. The remote type impulse piping shall be provided with proper supports.
o) All the impulse fit ups are generally documented with the traceability of
individual fittings / hardware. All the welding joints are subjected to the NDT as per the code/standard as well as hydro tested (Impulse Lines).
p) The Instrument airline after the main header up to Air Manifold is generally made of
GI with heavy schedule of piping, fittings etc. The total instrument air network
is to remain isolated from the header 1st
isolation valve until the same is flushed with water / air etc. and finally charged with instrument air.
q) After completion of the branching of air line pertaining to each tapping, the total branch network is to be flushed. During this period the connection to C/V & other consumers shall be open. The network is to be leak tested and problems rectified. The final connection to the line mounted instruments; C/V etc. are generally made only on final installation after flushing.
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r) Normally the field instruments are installed along with the canopy, if specifically
asked to protect the instrument from damage due other erection activities.
12.14.2 SPECIAL INSTRUCTIONS TO VENDOR:
1. Vendor shall supply compressor along with the complete Instrumentation
& control system for start-up, shutdown and for all specified operating
conditions.
2. Instrumentation & installation shall conform to the API standard 681 as
a minimum.
3. All conduits, armored cables and supports shall be designed and installed
so that it can be easily removed without damage and shall be located so
that it does not hamper removal of bearings, seals, or equipment
internals.
4. A free standing local panel shall be provided which shall include all panel
mounted instruments for the driven equipment and the driver. The
instruments on the panel shall be clearly visible to the operator f r o m the
driver control point. A lamp test shall be provided for all the local panel
lamps. LCP shall be suitable for installation in the specified area
classification.
5. Panel shall be c ompletely assembled, piped and wired, requiring only
connections to the external piping or wiring. When more than one
wiring point is required on a unit for control or instrumentation, the
wiring to each switch or instrument shall be provided from a single
terminal box, with terminal posts. Each box shall be mounted on the
unit or its base if any. All leads and posts on terminal strips, switches
and instruments shall be tagged for identification. Wiring inside panel
shall be neatly run in conduits or supported on cable trays.
6. All the transmitters shall be erected, pre-wired to field ex-proof junction
boxes on the skid. All the cables to and from the field instruments shall be
fully wired up to junction boxes, which shall be mounted on the respective
skids, by the vendor. However, hooking up of these junction boxes to the
control room shall be in the scope of HPCL. All interlock/shutdown related
instruments shall be hooked to Vendor supplied PLC. However, parameters
for monitoring & controlling shall be hooked to existing DCS system.
7. Only transmitters shall be used for trip & alarm sensors. No switches shall be
used.
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8. There shall be no mixing of signal cables, control cables at junction boxes
used for instrumentation. Separate junction boxes shall be provided for signal
cables and control cables.
9. 2 out of 3 voting shall be provided for critical process parameters as required.
Vendor to consider 2oo3 as per the requirements of Vendor's
standards. 3 nos. transmitters need to be considered wherever 2oo3 logic
is used.
10. Vendor to provide machine monitoring & protection system as per
API681/API670 standards. 4 nos. accelerometers on bearing housing (2 nos.
on each bearing), 1 no. axial probe and 2 nos. RTDs for each bearing shall be
considered as a minimum.
a) Monitoring for Vibration and Axial Displacement shall be through Bently
Nevada System (BN 3500) to be located in Control Room with serial
communication to DCS on MODBUS RTU protocol.
b) Vibration and axial displacement monitoring system shall be based on non-
contacting type sensing probe, unless otherwise specified.
c) Vendor shall furnish requirements for monitoring deemed essential by them
with reasons. Two probes at 90 degree apart for each location shall be
provided and connected to same dual channel monitor for vibration
monitoring at each location.
d) The sensing probe shall be accessible for adjustment, repair and replacement
without dismantling the machine. Sensing elements shall be flexible 304 SS
armored with outer PTFE coating / jacketing.
e) Vibration and displacement monitoring system shall be certified intrinsically
safe for use in Hazardous Area zone-I Gr. IIC Temp. class T3 unless
specified otherwise.
f) Key phasor system shall be provided by vendor for performing analysis of
vibration signals to determine machine malfunctions. It shall consist of
proximity probe and transmitter, extension cable etc. and other accessories
to make the system complete. Vendor shall provide necessary reference on
the shaft to determine one-per-turn occurrence
11. Vendor to consider all the required process as well as machine protection
parameters essential to safeguard the equipment.
12. An alarm & shutdown system shall be provided which will initiate an alarm if
any of the specified process parameters reaches alarm point and will initiate
shutdown of the equipment if any one of the specified parameter reaches
the shutdown point.
13. The alarm & shutdown system shall conform to API standard 681.
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14. Alarms & shutdown sequencing is to be achieved using a TUV certified
safety PLC with redundancy at Processor, Power supply, communication &
I/O levels. Vendor scope shall include supply of PLC and its associated
equipment. Vendor to consider dedicated development/engineering system for
PLC for viewing, editing, modifying the logic on-line/off-line. PLC panels
shall be supplied and to be installed in the control room environment.
15. The PLC shall be provided with Serial interface with Modbus RTU protocol.
The serial card shall be configured in ‘Slave’ mode and needs to be connected
to existing DCS system (Yokogawa Centum CS3000 DCS System). Vendor
scope includes co-ordination with DCS vendor during Modbus configuration
& Communication.
16. Vendor to consider PC based ‘Sequence of Events’ Recorder (SOE) for
analysis of events.
17. Vendor to provide the list of documents in the form of DCI (Document
Control Index) for review by client. DCI shall be reviewed by the client for
adding/modifying the documents which are required for the Project.
18. Mandatory Spares: Vendor to provide 10% or minimum 1 for each type of
Instrument, Control valves accessories (like Plug, seat gaskets, O- rings,
diaphragms, capsule, gland packing, AFR ,SOV Limit switches etc.), each type
of PLC card (CPU card, Memory card, Power supply card, I/O cards etc) and
for each type of LCP accessories.
19. Commissioning & Startup spares: vendor to provide commissioning & start-
up spares as required.
20. 2 years O&M Spares: Vendor to provide list of 2 years Operation &
Maintenance spares for all the Instruments, PLC and LCP related equipment.
13.0 SPECIAL REQUIREMENTS
13.1. Paint and Corrosion Protection
The Vendor must ensure that all equipment provided is adequately protected from the
prevailing hot and humid atmosphere at this location, by means of correct material selection,
painting or coating and/or suitable insulation to prevent galvanic corrosion. The Vendor shall
propose and use his standard long life painting/coating system and other protective measures
for approval with provision that final finish colour be agreed with HPCL.
Pre-assembled skids and components shall be supplied with finish paint coat. The Vendor
shall provide necessary paint for field touch-up by the HPCL.
13.2 Equipment Tagging, Labelling And Nameplates
All major items shall be allocated tag numbers. The Vendor must indicate these numbers on
all design documents also.
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All tagged items shall have corrosion resistant nameplates or labels permanently attached
which shall include Vendor’s standard identification and together with HPCL’s tag number (if
made available).
All other control and indication devices that operators will need to access and maintain shall
have identification/duty labels permanently attached.
13.3 PACKING AND PRESERVATION
Packing and Preservation shall be suitable for sea transport worhty and movement over
rugged terrain. Also it shall be suitable for storage at site for up to 6 months in an uncovered
and heated location. The Vendor shall provide information for storage at site prior to
installation and for extended periods post installation prior to start-up.
13.4 Special Tools and Special Test Equipment
Vendor to include in his supply any special tool/ tackles and test equipment etc as required for
the maintenance of the equipment. Vendor to mention the same in the offer.
13.5 MONTHLY REPORTING
The Vendor shall, for the duration of the PO execution, provide monthly reporting covering
project management, engineering, procurement, fabrication and testing activities giving full
details of third party inspection activities done. The Vendor shall develop the form of the
reports. The cut-off date shall be 25th day of each month. Vendor shall send the report through
dispatch and also through e-mails.
The reports shall contain details on all aspects of the Vendor and his Sub-Vendor’s
performance over the reporting period and give an up-to-date and clear picture of the project
progress and the overall status of the PO.
14.0 QUALITY ASSURANCE & CONTROL
14.1 Quality Management System
The Vendor shall provide his standard format Inspection and Test Plan (ITP), relating to the
scope of work, for review with the bid submission. However the same shall be in line with
the ITP guideline as enclosed with this indent requisition, as a minimum. The Plan shall include detail descriptions of all tests and inspections and categorize each test
and inspection as below.
Category R–tested by the Vendor. Reports to be reviewed by TPI or Purchaser
Category W – observed by Purchaser or TPI
Category H – witnessed by Purchaser or TPI
For Category W, the TPIA (third party inspection agency) will attend the test at the test
date notified by the Vendor. If Purchaser or his nominee(s) fail to attend the test by any
reason, the Vendor is entitled to carry out the test as scheduled and Purchaser will accept
the test results. (These are no ‘Hold’ points.)
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For Category H, the Purchaser / TPIA will agree the test date with the Vendor. If TPI fails to
attend the test by any reason, the Vendor shall hold the test until Purchaser / TPIA attend the
test at a new test date agreed by the parties. (These are ‘Hold’ points.)
The Purchaser shall also have free access to the Vendor and Sub-Vendor’s premises during all
stages of manufacturing and testing.
Regular visits by the Purchaser for the purpose of surveillance and documentation review will
not be carried out as a matter of course. However, should it become apparent that the
Vendor’s or Sub-Vendors’ agreed Manufacturing Quality Control Plan is either inadequate or
not being implemented, the Purchaser reserves the right to increase the level or frequency of
his Quality Control activities or request the Vendor to revise his working practices, as
necessary.
14.2 Testing Testing shall be performed in logical sequence. The vendor’s testing procedure shall be
structured in following manner :
Level 1: Factory testing of individual components by the Vendor or his subvendor.
Level 2: Package factory testing of the completely assembled sub systems at the vendor’s
works.
14.3 Factory Tests
The Vendor shall be responsible for the factory testing for all the equipment covered by this
Requisition, as per the data sheets, codes and standards listed.
The Vendor shall submit guarantee along with sound pressure and sound power level spectra
details, in the Noise Level Data Sheet
14.4 Final Acceptance Test
Final acceptance of factory tests will be made by Purchaser/TPIA after the complete test
sequence has been performed, but shall not constitute a waiver of the Vendor obligation to
provide the equipment which meets all specified operating conditions.
15.0 Third Party Inspection Authority / Agency
A third party authority (TPI) shall inspect at all stages including the final test at and his own
inspection to perform all inspection activities on behalf of HPCL. TPI charges shall be borne
by the VENDOR. However, in case that a scheduled shop or field test will fail and it must be
repeated after the remedy of the failed material or equipment, the additional TPIA’s and
Purchaser’s services shall be at Vendor’s care and cost (travelling an accommodation
expenses plus working time of TPIA’s and Purchaser’s inspectors)
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Similarly, Vendor shall bear any additional costs due to delays that may occur, attributable to
the Vendor, e.g., not readiness to perform the test on the agreed date.
The Vendor shall submit in a timely manner to the TPI, all applicable Vendors’
documentation for approval. And the Vendor shall arrange for workshop inspections and tests
witnessing by TPI. Such inspection shall not release the Vendor from performing its own
inspection and quality control programs.
15.1 Scope of Inspection of Third Party agency
Scope of third party inspection agency (TPIA) shall include witness of various tests including
final performance tests, as per QAP.TPIA shall also certify the power consumption of
compressor (refer penalty clause in the specs) during the final performance test.
The scope of TPIA also includes review of procedures/activities, review of tests documents/
inspection test methods/reports/ material identification/ traceability/ QC reports etc required to
ensure strict conformance of material, procedures and testing with specifications, data sheets,
and vendor data requirements etc. as enclosed to the purchase specifications as set out in
enquiry / order, in totality. TPIA shall also endorse the monthly progress report to be prepared
by vendor.
16.0 QA Records
16.1 Inspection and Certification Records
The Vendor shall ensure that all inspection and certification records for equipment and
materials is available on request for a period of 10 years from delivery. The Vendor shall
make such records immediately available to the Purchaser up to completion of his scope of
supply and thereafter within ten days of the Purchaser’s request.
16.2 QA Record Documentation
QA record documentation consisting of collection of original and type test certification,
inspection and test records and final release documentation generated during the approval,
manufacture and testing of the equipment /material shall form part of final documentation to
be submitted to HPCL. All final drawings and manuals including as built documentation must
be supplied prior to the “Release Note”.
16.3 DOCUMENTATION : INFORMATION REQUIREMENTS
Vendor shall submit documentation in accordance with the “List of drawings/ Documents”
(Vendor Data Requirements). In order to reduce the amount of document transmittals, two
types of submission categories will be used;
Category A: Issued to the Purchaser for review/approval. These documents will be
returned to the Vendor with the appropriate action shown on the return label.
Category I: Issued to the Purchaser for information purposes. These documents will only
be returned for subsequent re-submission, if unsatisfactory or incorrect.
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The Vendor shall assume a period of twenty (20) working days from receipt for the Purchaser
to review and dispatch documents back to the Vendor. When required, re-submissions are to
be made no later than ten (10) working days
All final drawings and manuals including as built documentation must be supplied prior to the
“Release Note”.
NOTES:-
Approval of Drawings by HPCL shall not relieve vendor from fulfilling his obligation
under this contract and is, in essence, only an acknowledgment of satisfaction with the
general arrangements and general design. HPCL’s approval shall in no event make HPCL
responsible for errors or omission in vendor’s work. Should Purchaser fail to comment, or
only partially comment, upon any Vendor or Sub-Vendor document, this shall not be
construed as an acceptance of the content of such document. Prior to being submitted to
Purchaser, documents shall be developed to the maximum extent.
LOADING, GUARANTEE AND PENALTIES CRITERIA:
THE LOADING CALCULATIONS SHALL BE DONE CONSIDERING TWO NOS.
OPERATING COMPRESSORS.
1. POWER REQUIREMENT : VENDOR SHALL FURNISH THE GUARANTEED VALUES FOR THE FOLLOWING:
MOTOR EFFICIENCY FOR RATED CASE.
BKW OF COMPRESSOR INCLUDING ALL MECHANICAL/LEAKAGE LOSSES
WITH ZERO PERCENT POSITIVE TOLERANCE INCLUDING INSTRUMENT &
MEASUREMENT TOLERANCES, AT RATED OPERATING CASE (SHALL BE
CONSIDERED FOR LOADING/PENALTY, AS DEFINED BELOW).
POWER CONSUMPTION OF MOTOR WHILE DELIVERING POWER REQUIRED AT
COMPRESSOR INPUT SHAFT FOR RATED COMPRESSOR OPERATING CASE WITH
ZERO PERCENT POSITIVE TOLERANCE INCLUDING INSTRUMENT AND
MEASUREMENT TOLERANCES.
NOTE: IN CASE TESTING CONDITIONS DIFFER FROM ACTUAL OPERATING
CONDITIONS AS SPECIFIED, VENDOR SHALL FURNISH IN HIS BID COMPLETE
CONVERSION FORMULAE, CALCULATIONS, CORRECTION CURVES AS
SPECIFIED AND REQUIRED FOR CONVERTING TEST CONDITION RESULTS TO
OPERATING CONDITION RESULTS, ENSURING COMPLIANCE TO GOVERNING
SPECIFICATION, STANDARDS AND CODES.
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PROCESS CONDITIONS AS PER RATED GAS IS GUARANTEED THOUGH THE TEST
AT VENDOR SHOP IS CARRIED OUT WITH AIR. DETAILED CONVERSION FROM
AIR TO GAS SHALL BE SUBMITTED BY VENDOR.
2. THE ECONOMIC ANALYSIS FOR ARRIVING AT THE TOTAL COST OF
PACKAGE FOR EVALUATION PURPOSE SHALL BE DONE AS UNDER :
CAPITAL COST (SUM TOTAL OF ALL THE COSTS INDICATED IN THE PRICE
SCHEDULE) OF THE EQUIPMENT PACKAGE ALONGWITH DRIVER MOTOR,
ACCESSORIES & AUXILIARIES INCLUDING SPARES COMPLETE AS PER TENDER
DOCUMENT.
FIVE YEARS DIFFERENTIAL COST BASED ON CRITERIA LAID DOWN UNDER
CLAUSE 3 BELOW SHALL BE ADDED TO ABOVE CAPITAL COST.
3. FIVE(5) YEARS DIFFERENTIAL COST SHALL BE WORKED OUT AS UNDER :
LOWEST OFFERED GUARANTEED BKW OF COMPRESSOR = Cref (SAY)
GUARANTEED BKW (AT RATED CONDITION) OF COMPRESSOR VENDOR UNDER
EVALUATION = C (SAY)
DIFFERENCE IN BKW = C – Cref
5 YEARS. DIFFERENTIAL OPERATING COST FOR VENDOR UNDER EVALUATION
IS AS UNDER,
DIFFERENTIAL COST = (C - Cref) X Cf X 8000 X Df X N
WHERE,
Cf = COST OF ELECTRIC POWER IN TERMS OF RUPEES PER KWH & SHALL BE
CONSIDERED AS RS. 12 PER KWH.
N= NO. OF OPERATING EQUIPMENTS AND SHALL BE TWO IN THE PRESENT CASE.
Df = DISCOUNTING FACTOR TO ARRIVE AT NET PRESENT VALUE (NPV) BASED ON
FIVE YEARS OF OPERATING YEARS AND SHALL BE 2.962
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Where
k= Number of operating years for which loading is to be done as specified i.e. 5 years
X=percentage rate of interest = 14.5%.
Df = 2.962
The above formula considers one year time for startup of operation.
THE MAXIMUM DIFFERENTIAL OPERATION COST TO BE LEVIED SHALL NOT
EXCEED 10% OF THE COST OF THE PACKAGE UNDER EVALUATION.
4. DURING THE PERFORMANCE TEST AT VENDOR’S WORKS, IF THE COMPRESSOR
FAILS TO MEET THE GUARANTEED VALUES AS GIVEN BY THE VENDOR, THE
FOLLOWING PENALTIES SHALL BE LEVIED.
FOR EVERY EXTRA KW, CONSUMED OVER AND ABOVE THE GUARANTEED BKW, AS
DESCRIBED IN CLAUSE 1 ABOVE, UPTO A MAX. OF +4% ABOVE THE GUARANTEED
POINT, THE VENDOR SHALL BE PENALISED FOR THE EXTRA POWER CONSUMPTION
FOR A PERIOD OF 5 YEARS AT 8000 HRS. OF OPERATION PER ANNUM AS BELOW:
PENALTY (RS.) = (Ct - Cc) X Cf X 8000 X Df X N
WHERE,
Ct = POWER (COMPRESSOR SHAFT BKW) AS OBTAINED FROM SHOP TEST
VALUES.
Cc = POWER (COMPRESSOR SHAFT BKW) AS GUARANTEED BY VENDOR.
THE MAXIMUM PENALTY TO BE LEVIED SHALL NOT EXCEED 10% OF THE COST
OF THE PACKAGE ON ACCOUNT OF PENALTIES LEVIED ABOVE.
NO ADVANTAGE SHALL BE GIVEN FOR HIGHER PERFORMANCE THAN
GUARANTEED.
5. REJECTION:
HOWEVER, IN CASE DURING SHOP PERFORMANCE TESTS, THE BKW
CONSUMED BY THE COMPRESSOR EXCEEDS THE STIPULATED GUARANTEED
VALUE BY MORE THAN +4% THE ENTIRE PACKAGE STANDS REJECTED.
6. MECHANICAL RUN TEST (MRT): MRT SHALL BE CONDUCTED ON ALL THE LIQUID RING COMPRESSORS.
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7. NO NEGATIVE TOLERANCE SHALL BE ALLOWED FOR DISCHARGE PRESUURE.
HOWEVER DISCHARGE PRESSURE MAY INCREASE UP TO A MAXIMUM OF
1 KG/CM2.
8. FIELD TRIAL:
THE COMPRESSOR UNIT SHALL ALSO BE SUBJECTED TO FIELD TRIAL RUN.
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INSPECTION AND TEST PLAN
FOR LIQUID RING COMPRESSION SYSTEM
Inspect - Activity Inspection - Doc. Type - Remarks -
V Vendor M Manufacturer inspection or activity
CC Conformity certificate
S Supplier W Witness point. The activity cannot proceed without presence of Inspector or his approval to proceed.
MC Mill certificate
P Purchaser H Hold point. The activity cannot proceed without the presence of Inspector
TC Test certificate
IA TPI R Review of document
D Final doc. Dossier
0
Phase
Activity Description
Activity Inspection
Doc. Ref. Documents
Comments
type
V S TPIA
1 LIQUID RING COMPRESSOR
1.1 mill certificates (wetted & pressurized parts + shaft)
R M R -- MC as per code
1.2 mechanical seal R M R -- CC as per code Test report referred to wetted parts material
1.3 visual and dimensional check of M -- -- -- -- detail dwg. -
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components
1.4 hydrostatic test on head M -- H - TC No leakage or deform.
1.5 balancing test of the impeller M -- R - TC ISO 1940 Gr.2,5
1.6 visual and dimensional. check of assembled compressor
M -- R -- TC Outline dwg.-
1.7 performance test (with to be supplied motor)
M -- H -- TC contr. data and curve - both compressor (s)
1.8 vibration measurement M -- H -- TC ISO 10816 part 1; part 3 / VDI 2056 group G
both compressor (s)
1.9 noise level measurement M -- H - TC ISO 3746 / ISO 9614 part 1 or 2
Type Test
1.10 mechanical test (with to be supplied motor)
M -- H -- TC Verify of sealing. Noise / vibration check list
all compressors (1hour at duty point)
1.11 internal cleanliness and drying inspection
M -- -- -- -- STANDARD MANUFACTURER
1.12 painting check M -- -- - TC STANDARD MANUFACTURER
1.13 name plate data check M -- R - copy Relevant dwg.
1.14 final inspection book M -- R - D STANDARD MANUFACTURER
2.0 Electric Motor
2.1 Routine Test R M R -- TC
2.2 Tagging Check R M R -- --
2.3 Painting check R M R -- --
2.4 Conformity Certificates R M R -- CC